PIPER AIRCRAFT, INC.
PA-28-161, WARRIOR III
MAINTENANCE MANUAL
PAGE 1
Nov 30/06
5D3
74-20-00
DISTRIBUTION
1. Ignition Harness
A. Inspection
(1) Check lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other
evidence of physical damage. Inspect spark plug sleeves for chafing or tears, and damage or
stripped threads on coupling nuts. Check compression spring is not broken or distorted.
Inspect grommet for tears. Check all mounting brackets and clamps to see that they are secure
and not cracked.
(2) Use an ohmmeter, buzzer, or other suitable low voltage device, and check each lead for
continuity. If continuity does not exist, wire is broken and must be replaced.
(3) For electrical test of harness assembly, use high voltage, direct current tester such as TAKK
model 86 or 86A or equivalent direct current high voltage tester capable of delivering test
potential of 10,000 volts. Connect ground lead to high voltage tester to outer shielding braid of
a single lead. Connect plug terminal. Turn tester ON and apply 10,000 volts. Insulation
resistance should be 100 megohms minimum. Check all other harness leads in same manner.
(4) Minor repair to harness assembly, such as replacement of contact springs, spring retainer
assemblies, insulating sleeves, or of one lead assembly, is done with harness assembly
mounted on engine. To replace more than one lead assembly or cable outlet plate, harness
should be removed from engine and sent to an overhaul shop.
B. Removal
(1) Disconnect clamps holding wires to engine and accessories.
(2) Loosen coupling nuts at spark plugs and remove insulators from spark plug barrel well. Do not
damage insulator spring when withdrawing insulator.
(3) Place a guard over harness insulators.
(4) Remove harness assembly terminal plate from magneto.
(5) Remove harness from airplane.
C. Disassembly
(1) To remove spring, Slick M-2929, from damaged lead, turn spring counterclockwise while
pulling gently. This will remove spring and M-1498 electrode screw from end of coiled
conductor.
(2) To separate spring and screw, hold electrode screw with pliers and turn spring clockwise until it
is through the threaded portion.
(3) Remove insulator sleeve from end of wire.
(4) To remove lead from M-1569 harness cap, use diagonals or cutting pliers and cut lead off
close to cap. Use drift or punch to tap ferrule loose from harness cap.
NOTE: Further service on Slick harnesses will require the use of Slick T-200 or M-1495
Service Tool Kit, obtained from:
Slick Aircraft Products
(See Introduction - Supplementary Publications)
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