* PRE-TEST THE MAGNETO, LOOKING FOR ANY PROBLEMS WITH MAGNETO SYSTEM.

* COMPLETE TEAR DOWN OF MAGNETO GENERATOR AND LOWER HOUSING. SONIC CLEAN ALL PARTS. RUST AND CORROSION REMOVED FROM INTERNAL AND EXTERNAL PARTS.

* MEASURE RUN-OUT PLAY ON BOTH UPPER AND LOWER MAGNET ASSEMBLIES. IF TOO LOOSE AND OF SPEC, OUR STEEL SHAFT CONVERSION WILL HAVE TO BE INSTALLED TO CORRECT THE PROBLEM.

* MACHINE STATOR AND MAGNET ASSY. WHEN REASSEMBLED THE AIR GAPS WILL BE THE SAME 360° ACROSS THE SURFACES. THE STATOR AND MAGNET ASSEMBLIES WILL BE SEALED TO HELP PREVENT CORROSION.

* THE LOWER HOUSING WILL BE REASSEMBLED. THE BUSHING, BEARING AND SEAL WILL BE REPLACED IF NEEDED. THE GEAR IS INSPECTED FOR WEAR AND CAM ENGAGEMENT. THE PROPER END PLAY IS SET AND NEW A ROLL PIN IS INSTALLED ALONG WITH A NEW SYSTEM 1 FLEX COUPLER.

* THE MAGNETO GENERATOR IS REASSEMBLED. IF THE MAGNETO NEEDED BEARINGS, WE WOULD REPLACE THE OLD ONES WITH OUR PRECISION, SEALED BEARINGS. THE MAGNET ASSEMBLIES ARE INSTALLED AND THE AIR GAP BETWEEN THE STATOR AND MAGNETS ARE SET TO A PRECISE SETTING. BOTH SETS OF TOP AND BOTTOM MAGNET ASSEMBLIES MUST BE PARALLEL TO EACH OTHER. THE GENERATOR IS PLACED IN OUR ALIGNMENT FIXTURE AND TORQUED TO 20 FT LBS.

* THE MAGNETIC PICK-UP IS TESTED FOR AIR GAP, OUTPUT AND TIMING STABILITY. THE 2 AND 4 WIRE HARNESSES ARE CLEANED AND TESTED. A GROUND WIRE FROM THE NEGATIVE POST IN THE STATOR IS INSTALLED. THIS WIRE GROUNDS THE MAGNETO TO THE CYLINDER HEAD. SILICON HEAT RESISTANT SLEEVING IS INSTALLED TO PROTECT HARNESSES FROM DEBRIS AND HEAT.

* THE MAGNETO IS TESTED FOR PHASING (E-GAP), 45° CYLINDER FIRING AND AMPERAGE OUTPUT. ALL MAGNETOS ARE TESTED USING AN OSCILLOSCOPE, LOAD BANK, AMP PROBE AND PRESSURE CHAMBER.

* IF SENT WITH THE POINTS BOX AND/OR CAP AND WIRES THEY WILL BE CLEANED AND TESTED. IF FOUND DEFECTIVE THEY CAN BE REPAIRED OR REPLACED.

* RED MSD 7908 MAGNETO CAN BE RE-ANODIZED BLACK IF SPECIFIED.

* AFTER WE HAVE BLUEPRINTED YOUR MAGNETO THERE IS NO NEED TO MACHINE YOUR STATOR OR MAGNET ASSEMBLY AGAIN.

* PRE-TEST MAGNETO (POINTS BOX AND/OR CAP AND WIRES IF SENT IN WITH MAG).

* COMPLETE TEAR DOWN MAGNETO AND LOWER HOUSING. SONIC CLEAN ALL PARTS AND REMOVE RUST AND CORROSION.

* ASSEMBLE LOWER HOUSING REPLACE BEARING, BUSHING AND SEAL IF NEEDED. INSPECT BRONZE GEAR FOR WEAR AND CAM ENGAGEMENT. SET END PLAY AND INSTALL NEW ROLL PIN AND A NEW SYSTEM 1 FLEX COUPLER.

* REASSEMBLE GENERATOR. INSTALL NEW BEARINGS IF NEEDED AND SET MAGNET ASSEMBLY AIR GAPS, MAGNET ALIGNMENT AND TORQUE ASSEMBLY TO SPEC.

* THE MAGNETIC PICK-UP IS TESTED FOR AIR GAP, OUTPUT AND TIMING STABILITY, THE HARNESSES ARE INSPECTED, AND NEW SLEEVING IS INSTALLED TO PROTECT THE DIRT AND HEAT.

* THE SAME TESTING PROCEDURE AS THE BLUEPRINT IS FOLLOWED AFTER ASSEMBLY.

* RED MSD 7908 MAGNETO HOUSINGS CAN BE RE-ANODIZED BLACK UPON REQUEST.

* WHEN TROUBLE SHOOTING AN IGNITION PROBLEM, WE PREFER THAT THE CUSTOMER SENDS THE MAGNETO WITH CAP AND WIRES AS WELL AS THE POINTS BOX SO THIS WAY THE COMPLETE SYSTEM CAN BE TESTED. THE MAGNETO IS TESTED THE SAME  WAY AS THE BLUEPRINT AND SERVICE. WE DO REMOVE THE HOUSINGS SO WE CAN CHECK THE MAGNET ALIGNMENT AND INSPECT THE FLEX COUPLER.

* WE PRETEST THE POINTS BOX TO DETERMINE IF THERE IS AN ISSUE. IF THERE IS PROBLEM WE DETERMINE IF IT IS THE CIRCUIT BOARD OR COIL. THE TEST PROCEDURE INVOLVES SCOPE TESTING THROUGH A LOAD BANK AND PRESSURE CHAMBER. IF THERE IS NO PROBLEM, THE POINTS BOX IS CLEANED, WIRE HARNESS INSPECTED AND TAGGED WHEN TESTED.

* TO SERVICE A BOX THAT HAS TESTED GOOD, ALL COMPONENTS ARE REMOVED, SONIC CLEANED A REASSEMBLED. NEW SLEEVING IS INSTALLED AND FINALLY TESTED BEFORE SHIPPING.

* IF THE POINTS BOX CIRCUIT BOARD TESTED BAD, WE CAN REPAIR THE BOARD. IF A COIL TESTS BAD, WE REPLACE THE COIL WITH A NEW ONE. THEN FINAL TESTING.

* IF YOU HAVE AND OLDER MSD 8105 POINTS BOX WITH A BAD 8105 COIL, WE CAN UPGRADE THE HOUSING AND COIL TO NEW 8106 STYLE SET UP. (NOTE! THE 4 SCREW 8105-POINT BOX IS NOT REPAIRABLE NOR CAN BE UPGRADED TO THE 8106 COIL).

* RED MSD POINTS BOXES CAN TOO BE POWDER COATED BLACK UPON REQUEST.

* PRE-TEST COMPLETE SYSTEM CHECK AMPERAGE AND MAGNETO FUNCTION.

* TEAR DOWN MAGNETO, CHECK ALL PARTS AND SETTINGS. SONIC CLEAN ALL PARTS AND REMOVE ANY CORROSION.

* MACHINE GENERATOR STATOR AND BOTH TOP AND BOTTOM MAGNET ASSEMBLIES. AFTER THE MACHINE PROCESS, WE GLASS BEAD AND SEAL BOTH THE STATOR AND MAGNET ASSEMBLIES.

* THE GENERATOR STATOR IS REASSEMBLED REPLACING KEYS AND INSTALLING PRECISION HEAVY DUTY SEALED BEARINGS IF NEEDED. THE AIR GAPS PRECISELY SET PER TOP AND BOTTOM MAGNETS. GENERATOR ASSEMBLY IS PLACED IN A FIXTURE AND THE TWO MAGNET ASSEMBLIES ARE SET PARALLEL TO EACH OTHER. ONCE SET, THE MAGNETS ARE TORQUED TO 24 FT. LBS.

* THE MAGNETIC PICKUP IS INSPECTED OR REPLACED IF NEEDED. THE TWO HARNESSES ARE TESTED AND REINSTALLED USING A HIGH HEAT SILICON SLEEVING TO PROTECT FROM HEAT AND CHAFFING.

* THE LOWER HOUSING IS REASSEMBLED WITH NEW BEARINGS, IF NEEDED THE KEYS ARE REPLACED ON THE LOWER SHAFT. THE SHAFT SPACING IS SET AND INSTALLED WITH THE LOWER DRIVE SET UP AND TORQUED. A NEW SYSTEM 1™ HEAVY DUTY FLEX COUPLER IS PLACED IN LOWER SHAFT. BOTH TOP AND BOTTOM HOUSINGS ARE SECURED THE STATOR. NOW THE GENERATOR IS READY FOR TESTING.

* ONCE IN THE MAGNETO, WE TEST STROBE THE ROTOR DRIVE AND THE CAP ADAPTER IS INSTALLED. THE MAGNETO IS HOOKED UP TO THE OSCILLOSCOPE, LOAD BANK AND AMP PROBE. THE MAG IS TESTED FOR PROPER INTERNAL PHASING (E-GAP), ROTOR ALIGNMENT AND AMPERAGE OUTPUT. THE FINAL TEST IS IN A PRESSURE CHAMBER TO MAKE SURE ALL EIGHT CYLINDERS ARE FIRING. WE WILL ALSO PRESSURE TEST THE CUSTOMER’S SPARK PLUGS IF SUPPLIED. (NOTE ROTOR PHASING IS SET BY APPLICATION AND AMOUNT OF RETARD USED).

* IF POINTS BOX AND COIL ARE SENT WITH THE MAGNETO, THEY ARE CLEANED AND TESTED WITH THE SYSTEM.

* IF REQUESTED, WE CAN BLACK ANODIZE THE CURRENT RED MAGNETO HOUSINGS.

* THE MAGNETO CAN BE UPGRADED TO 58 AMPS UPON REQUEST.

* IF THE MSD 44 AMP MAGNETO HAS ALREADY BEEN BLUEPRINTED BY SYSTEM 1, THERE WILL BE NO NEED TO MACHINE THE STATOR OR MAGNET ASSEMBLIES.

* PRE-TEST COMPLETE SYSTEM CHECK AMPERAGE AND MAGNETO FUNCTION.

* DISASSEMBLE MAGNETO, CHECK ALL PARTS AND SETTINGS. SONIC CLEAN ALL INTERNAL AND EXTERNAL PARTS.

* GLASS BEAD PARTS IF NEEDED, TO REMOVE CORROSION.

* REASSEMBLE GENERATOR, REPLACING BEARINGS IF NEEDED USING OUR HEAVY-DUTY SEALED BEARING. THE MAGNET ASSEMBLIES AND INSTALLED ON THE CENTER MAGNET SHAFT. THE OLD KEYS ARE PLACED WITH NEW AND AIR GAPS ARE PRECISELY SET TOP AND BOTTOM. THE GENERATOR ASSEMBLY IS PLACED IN A FIXTURE AND THE TWO MAGNET ASSEMBLIES ARE SET PARALLEL TO EACH OTHER. ONCE SET, THE ASSEMBLE IS TORQUED TO 24 FT. LBS.

* THE MAGNETIC PICKUP IS INSPECTED OR REPLACED IF NEEDED. THE 2-WIRE AND 4-WIRE HARNESSES ARE TESTED AND REINSTALLED USING A HIGH HEAT SILICON SLEEVING TO PROTECT FROM HEAT AND CHAFFING.

* THE LOWER HOUSING IS REASSEMBLED WITH NEW BEARINGS IF NEEDED AND THE KEY REPLACED ON THE LOWER SHAFT. THE LOWER SHAFT SPACING IS SET AND ONE OF THE CORRECT SHIMS ARE IN PUT IN PLACE. THE LOWER DRIVE IS INSTALLED AND PROPERLY TORQUED. A NEW SYSTEM 1™ HEAVY DUTY FLEX COUPLER WILL BE INSTALLED ONTO THE LOWER SHAFT AND BOTH TOP AND BOTTOM HOUSINGS ARE ATTACHED TO THE STATOR ASSEMBLY. THE MAGNETO IS READY TO BE SET UP AND TESTED.

* THE MAGNETO IS PLACED INTO THE TEST STROBE AND THE CAP ADAPTOR AND ROTOR ARE INSTALLED. THE MAGNETO IS CONNECTED TO THE OSCILLOSCOPE, LOAD BANK AND AMP PROBE. THE MAGNETO IS TESTED FOR PHASING, ROTOR PHASING AND AMPERAGE OUTPUT. FINAL TEST IS WITH CAP AND WIRES CONNECTED TO THE CYLINDER PRESSURE CHAMBER. ALL 8-SPARK PLUG WIRES AND SYSTEM ARE TESTED UNDER PRESSURE. IF SUPPLIED THE CUSTOMERS POINTS BOX, COIL AND SPARK PLUG WIRES ARE TESTED UNDER PRESSURE. (NOTE: ROTOR PHASING IS ADJUSTED AND SET BY APPLICATION AND HOW MUCH TIMING RETARD IS USED)

* IF THE POINTS BOX AND COIL ARE SENT WITH THE MAGNETO, THEY ARE CLEANED AND TESTED WITH THE MAGNETO.

* UPON REQUEST, THE MAGNETO CAN BE UPGRADED TO 58 AMPS AND THE HOUSINGS CAN BE ANODIZED BLACK.

* WHEN SENDING YOUR MAGNETO SYSTEM IN FOR TESTING, IT IS ADVISABLE TO YOU SEND THE COMPLETE SYSTEM. THIS WAY THE COMPLETE SYSTEM CAN BE TESTED AS A COMPLETE UNIT. THE SYSTEM IS TESTED AS THE SAME AS THE BLUEPRINT AND SERVICE PROCEDURE. THE TEST DOES INCLUDE REMOVING HOUSINGS, CHECKING MAGNET ALIGNMENT AND TO SEE IF THE FLEX COUPLER IS WORN. AFTER THE TEST, THE CUSTOMER IS CALLED AND GIVEN THE RESULTS OF THE TEST. FROM THAT POINT, THE SYSTEM CAN BE EITHER SENT BACK OR REPAIRED.