Harley Davidson Sportster (1959 to 1969). Service manual - page 13

Insert rotor shaft into gearcase. Install magneto on adapter plate and attach with bolts (44) and nuts (45). On magnetos having manual retard, install magneto control arm (63) before replacing mounting bolt nuts.

Adjust ignition timing. See "Timing Ignition.”

On manual retard magneto install control wire (21) through swivel blocks (22) when handlebar grip control and magneto are in fully advanced position. Turn handlebar grip control to full retard then to advance position and check to see that magneto has returned to fully advanced position against screw stop. Readjust control wire in swivel block if necessary.

INSPECTION AND REPLACEMENT OF PARTS (Fig. 5F-6)

Inspect circuit breaker points (4). Normally, point contact surfaces should appear clean, dull gray, and slightly rough. If contact points are dirty, they may be cleaned with a strip of hard surface paper saturated with clean white gasoline. If points are pitted, burned or worn badly, they should be replaced.

Point faces must seat squarely against each other. If bent, square up by bending contact plate.

To replace a set of circuit breaker points remove screw (20). Remove fulcrum pin snap ring and lift circuit breaker lever from pivot stud. Remove screws (10 and 11), cam wick holder and circuit breaker stationary contact.

Install new points in reverse order of disassembly. Be sure point faces seat squarely against each other. Adjust point gap as previously described in "Adjust-ing Circuit Breaker Points.”

Lubricate breaker cam with a trace of grease when points are replaced or every 5000 miles. Be extremely careful to avoid excessive lubrication. If too much grease is used, the excess is apt to get on the contact points and cause them to burn. The cam oiler felt (13), if dry or hard, should be replaced by a new factory-impregnated wick.

The condenser (3) is a relatively long life part and will not require frequent replacement. However, if the condenser is suspected of being defective simply replace with a proven new condenser and note whether engine performance is improved. A condenser that is defective will have either an open or short circuit. An open circuit will be evident by excessive arcing at breaker contact points and a shorted circuit will have no noticeable spark at the contact points.

If the coil (1) is suspected of being defective replace with a proven new coil and note whether engine performance has improved.

DISASSEMBLING MAGNETO (Fig. 5F-8)

Remove four end cap screws (1), end cap (2) and end cap gasket (3). Pull the two spark plug cables (4)

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