Fig.
42
Before inserting pulley,
slick.
di
sc
(3,
Fig.
41]
0.8
mm
thick
(0
.
032
in.)
wilh a little
grease
into recess of
pulley.
Fit
pulley on to bearing bo
lt
and
insert end
of
spring (4,
Fig
. 41]
01
stud
(1].
Tension pulley/coil spring
in
di-
rection
of
cord exil until slop is
encountered.
Release coil spring
opp
rox. 'II
... 1 turn until the recess for the
FOH
Q
lI
'"
soldering nipple
in
the pulley
resls
near
the cord duct of Ihe
f i
g.
42
housing.
Again hold the pulley firmly with home-made retaining clip
(1,
Fig.
43].
Pull
the starler cord through a
rag
soaked wilh
SAE
1 0 oil before assembl ing.
fig.
43
Fi
g.
44
fjg.43
Note:
When
converting starting dlrec-
lion, reposition cord gUide
(2)
olso.
Fit
starter
handle
with stop
and
clamping ring on to cord.
lay
starter cord
around
clamp-
ing
toper
and
pull
it
into clamp-
ing ring.
Pull
clamping ring inio starter
handle
and
let starter cord run
bock.
Fi
ll.
44
Screw labyrinth ring
(2)
tight.
lubrica
te storler powl
bed
and
start
er
pawls lightly with
SAE
10
oil.
Fi
t starter p
aw
ls
(1
and
4).
The
open
side
of
the starter
pawl seating
and
the l
ong
side
of
the starler pawl
face
in starl-
ing direction.
Fit
washer 0
.1
mm
(0.0039
in.)
thi
ck,
friction plate
(3),
spring
ring
and
shims as reqUired.
Insert
broke spring
(5].
After mounting Ihe broke spring, Ihe friction pla te should have on axial play of
0.
1 ... 0.2
mm
(0.0039
... 0.0079 in.).
Correct this ploy by putting shims under Ihe broke spring.
26
Flywheel
dynamo
ma
gneto
c
ente
r
ing
tool
Replacing
the
ignition
or
lighting
ormatur
e
f i
f!o
45
I.
Pass the l
eads
th
rough a hole
in
the centering pl
ale
and
in
position in centering plat
e.
2.
Place centering unit
in
posi-
tion
and
tighten hexagon
head
screw by hand.
3.
Remove foully armatures a nd
r
eplace
by new ones .
4.
Pl
ace
centering ring
in
posi-
tion, press newly fitted
arma-
lure
against
Ihis ring
and
ligh-
ten both screws. After removal
of
the centering ring the
gop
between
armature
core
and
magne
to flywheel w
il
l
be
of
the correct width.
Note:
--
,
..
. *,.
The F & S centering tool will not
be
supplied
any
more when the
present stock
is
exhausted. F
ig
.
45
New ignition
or
lighting
armatures
have to be fitted according to the installation
instructions wh i
ch
are
attached
to BOSCH
spore
parts.
In
order
to
ob
tain the maximum ignition
and
lighting power
it
is
recommended to
maintain the
gop
of
0.25 ... 0.35
mm
(0.0098
... 0.0138
in.
) between the
armature
poles
and
the flywheel
under
any
circumstances.
Replacing the contact breaker
The contact
breake
r should
be
changed
when the contacls, the slider
or
the pivot
pin
are
badly
worn; also when the
bearing
bush
is
warn
or
if
the
contact
arm or the spring
is
damaged.
1.
Unscrew cutout l
ead,
and,
if
fitted, noting correct
sequence
of
insulating washers
for connector
angle
brocket
in
cont
act
carrier.
2.
Remove r
etainer
and
contact
arm from pivot pin (take
care
of
shimming washers
].
3.
Unscrew fillister
head
screw
and
remove contact
car
rier.
4.
Unscrew pivot pin from
armature
bose plate.
New ports should be fitted
in
reverse
order,
proceeding as follows:
Caulk
the pivot pin
after
screwing
in.
Use only the contact
breaker
assembly specified for this engine.
When
fitted
in
position, the contacts on the contact
arm
must not be displ
aced
or
ti
lted.
Apply
BOSCH Ft1 v 8
grease
to
bearing
before
fitting.
Smear
BOSC
H
Ft
1 v 4
grease
on the felt lubricating pod
and
greaser
wedge
in
the
slider.
(BOSCH
grease
is
obtainable
in
tubes from all BOSCH suppliers.]
Do
not allow
any
grease
or
oil to reach the contacts.
Replocing the condenser
I. Unsolder both leads.
2.
Push the
de
fective
condenser
out of the
arma
ture bose plate with 0 wooden dowel.
3.
Re
move the sealing caulk from the hole with a triangular scraper.
4. Insert new conde nser
and
ca
ref
ull
y caulk
again.
5. Solder both cables to their terminals.
27
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