PIPER SENECAII SERVICEMANUAL

8-35. INSPECTIONOF MAGNETOS.

a. After the first 25 hour and 50 hour periods, and periodically thereafter, the contact assemblies
should be checked. Examine the points for excessive wear or burning. Points which have deep pits or
excessively burned areas should be discarded. Examine the cam follower felt for proper lubrication. If
necessary, points can be cleaned by using any hard finished paper. Clean breaker compartment with dry
cloth.
b. If engine operating troubles develop which appear to be caused by the ignition system, it is
advisable to check the spark plugs and wiringfirst before working on the magnetos.
c. Should the trouble appear definitely associated with the magneto, the most effectivemeasure is
to install a replacement magneto which is known to be in satisfactory condition and send the suspectedunit
to the overhaul shop for test and repair.
d. Should this not be possible, a visual inspection may disclose the source of trouble. Remove the
harness outlet plate from the magneto. Inspect for the presence of moisture and foreign matter on the
rubber grommet and high tension outlet side of the distributor block. Check height of block contact
springs. The top of the spring must not be more than 0.422 of an inch below the top of the tower as shown
in Figure 8-9. If the springsare broken or corroded, replacethem.
e. Inspect the distributor block for cracks or burned areas. The wax coating on the block should not
be removed. Do not use solvents.
f. Check for excess oil in the breaker compartment. If present, it may mean a bad oil seal or oil seal
bushing at the drive end. Check the magneto manufacturer's overhaul procedure.
g. Remove the breaker cover and harness securingscrewsand nuts and separate coverfrom magneto
housing. Check contact assemblies to see that cam follower is securely riveted to its spring. Examine the
contact points for excessive wear or burning. Figure 8-10 shows how the average contact point will look
when surfaces are separated for inspection. Desired contact surfaces have a dull gray, sandblasted (almos
rough) or frosted appearance over the area where electrical contact is made. This means that points are
worn in and mated to each other, thereby providing the best possible electrical contact and highest
efficiency of performance.
h. Minor irregularities or roughness of point surfaces are not harmful (refer to Figure 8-10, center),
neither are small pits or mounds, if not too pronounced. If there is a possibility of pit becoming deep
enough to penetrate pad, Figure 8-10, right, reject contact assembly.
NOTE

No attempt should be made to stone or dress contact points.

Should contact assembly have bad points or show excessivewear,
the complete contact assemblyshould be replaced.

i. Check the condition of the cam follower felt. Squeeze felt tightly between thumb and forefinger.
If fingers are not moistened with oil, re-oil using 2 or 3 drops of Bendix 10-86527 lubricant. Allow
approximately 30 minutes for felt to absorb the oil. Blot off the excess with a clean cloth. Too much oil
may foul contact points and cause excessive burning.
j. Inspect the felt washer in the distributor block for oil content. If the felt is dry, inspect the bronze
bushing for wear. (Refer to the latest revisionof the manufacturer'soverhaul instruction.) Oil felt washerwith
BendixDistributorBlock LubricantPart No. 10-391200.Blot excess oil from washeruntil flat surfacestake on
a "frosted" appearance and seat washer in its recess in block.
k. Check the capacitor mounting bracket for cracks or looseness. Using the Bendix 11-1767-1, -2
or -3 Condenser Tester or equivalent, check capacitor for capacitance, series resistance and leakage.
Capacitance shall be at least 0.30 microfarads. Series resistance should not be over 1ohm at 500 kc.

Revised: 3/16/81 POWERPLANT

2R8
Island Enterprises
 PIPER SENECA II SERVICE MANUAL

A280

19

12

14

1. SCREW 14. IGNITION CABLE FERRULE

2. LOCK WASHER 15. DISTRIBUTOR CABLE PLATE
3. NUT 16. GROUND TERMINAL KIT
4. LOCK WASHER 17. WASHER
5. HOLD DOWN WASHER 11. INSULATING SLEEVE
6. MAGNETO 19. INNER FERRULE
7. GASKET 20. OUTER FERRULE
8. COTTER PIN 21. COUPLING NUT
9. NUT 22. COUPLING BUSHINGS
10. GEAR SUPPORT SHAFT 23. RETAINER
11. PIN 24. NEEDLE BEARING
12. IGNITION CABLE EYELET 25. WASHER
13. DISTRIBUTOR CABLE GROMMET 26. PILOT SLEEVE BUSHING
27. MAGNETO DRIVE GEAR

Figure 8-8a. Magneto Assembly

Reissued: 10/11/79 POWER PLANT

2B9

Island Enterprises
 PIPER SENECA II SERVICE MANUAL

1. Inspect coil leads for damagedinsulations and terminals for tightnessand solderedconnection.
m. Inspect impulse coupling parts for excessivewear. Particularlycheck clearancebetween cam and
flyweights of the cam assembly. Measure the clearance between the cam flyweights using the shank of a
new No. 18 drill (0.169 inch diameter). If the drill will fit between cam and flyweight as shown in Figure
8-11, the cam assembly must be replaced. Check clearance between both flyweights and the cam of each
cam assembly.
n. Check the clearance between each flyweight and each stop pin as follows:
1. Bend the end of a stiff piece of wire into a right angle 0.125 inch long (maximum).
2. Hold magneto as shown in Figure 8-12. Pull heel of flyweightoutward with the hooked wire
and make certain that feeler gauge of 0.010 inch minimum thickness will pass between stop pin and the
highest point of the flyweight.
NOTE
A true and accurate check of the clearance between flyweight and
stop pin can only be obtained by pulling the flyweight outward as
described above. Do not attempt the check by pushing in on
flyweight at point "A."
o. Check internal timing and reinstall and time magneto to engine.

8-36. REMOVALOF MAGNETO.

a. Remove the side accesspanel from the engine nacelle.
b. Disconnect the "P" lead from the magneto.
c. Remove the harness outlet plate from the magneto by removingthe four attaching screws.
d. Remove the two nuts and washers securingthe magneto to the engine accessoryhousing.
e. Pull the magneto from the engine.
8-37. MAGNETOTIMING PROCEDURE (INTERNAL TIMING). When installing or adjusting breaker
points and before timing the magneto to the engine, it is important that the internal timing of the magneto
be correct. The recommended method of checking the internal timing of the magneto is to use the Bendix
11-8150 Timing Kit using the procedure described in sub-paragraph a. However if a timing kit is not
available,the cast in timing marks in the breaker housingand a fabricated pointer may be used as described
in sub-paragraphb.
a. Check the internal timing with the Bendix 11-8150Timing Kit using the followingprocedure:
1. Remove the magneto from the engineand remove the contact point cover.
2. Loosen the nut securing the drive plate to the magneto shaft sufficiently in order to install
the Bendix 11-8465Rotor HoldingTool under the nut and flat washer as shown in Figure 8-13. Tighten the
nut enough to hold the tool securely.
3. Install the Bendix 11-8147 Plate Assembly to the breaker compartment of the magneto as
shown in Figure 8-14.
4. Remove the timing inspection plug from the top of the magneto and turn the rotating
magnet in the direction of normal rotation until the painted chamfered tooth on the distributor gear is
approximately in the center of the inspection window.Then turn it back until rotating magnet locates in its
neutral position. Tighten adjustment knob of 11-8465 Rotor HoldingTool, holding the rotating magnet in
the neutral position.

Reissued:10/11/79 POWERPLANT

2B10
Island Enterprises
 PIPER SENECA II SERVICE MANUAL

MAX

Figure 8-9. Contact Spring Inspection

CAUTION

Tighten adjusting knob of rotor holding tool only enough to hold

magnet shaft firmly. Do not overtighten.

5. Install the Bendix 11-8149 Pointer Assembly on the cam screw and align pointer with the
zero degree mark on the timing plate.
6. Loosen adjusting knob of rotor holding tool and turn rotating magnet in normal direction of
rotation until pointer indexes with the respective 10 ° mark ("E" gap). Tighten adjustment knob of rotor
holding tool.
7. With the Bendix 11-9110 Timing Light or equivalent, adjust main breaker contacts to just
open at this position. Loosen holding tool and turn rotating magnet until breaker cam follower is on the
high point of the cam lobe. Tighten holding tool and measure contact clearance. It must be 0.018 ± 0.006.
If not, readjust breaker and recheck to be sure that contacts will open within "E" gap tolerance ± 4° .
Replace breaker assembly if "E" gap tolerances and contact clearance cannot be obtained.
8. After timing is complete, tighten breaker securing screws to 20 to 25 inch-pounds and
recheck settings. Remove timing kit parts.
b. The internal timing can be checked without a timing kit using the cast in marks in the breaker
compartment. These marks indicate "E" gap and limits (refer to Figure 8-15). The point in the center of
the "E" gap boss indicates the exact "E" gap position. The width of the boss on either side of the point is
the allowable tolerance of ± 4. In addition to these marks, the cam has an indented line across its end.
When the indented line is aligned with the mark at the top of the breaker housing, the rotating magnet is in
its "E" gap position. Check the timing using the following procedure:
1. Install the Rotor Holding Tool 11-8465 under the drive shaft nut and washer as shown in
Figure 8-13.

Reissued: 10/11/79 POWER PLANT

2B11

Island Enterprises
PIPER SENECA II SERVICE MANUAL

NORMAL POINT IS SMOOTH MINOR IRREGULARITIES WELL DEFINED MOUND

AND FLAT. SURFACE HAS SMOOTH ROLLING HILLS
DULL GRAY "SANDBLASTED" AND DALES WITHOUT ANY
APPEARANCE. DEEP PITS OR HIGH PEAKS.
THIS IS A NORMAL CON-
DITION OF POINT WEAR.
EXTENDING NOTICEABLY
ABOVE SURROUNDING
SURFACE. REJECT POINTS.

Figure 8-10. Contact Points

Figure 8-11. Impulse Coupling

Reissued: 10/11/79 POWER PLANT

2B12
Island Enterprises
 PIPERSENECA II SERVICEMANUAL

Figure 8-12. Flyweight Clearance of Impulse Coupling

NOTE

The rotor holding tool facilitates the timing procedure. However,

it is possible to manually hold the shaft at the specified angle
when setting the-breakers.

2. Turn rotating magnet in direction of rotation until painted chamfered tooth of distributor
gear is just becoming visible in timing window. Continue turning rotating magnet until line on end of cam is
aligned with mark at top of breaker housing. (Refer to Figure 8-15.) Tighten adjusting knob of the holding
tool to hold rotating magnet.
3. Fabricate a pointer as shown in Figure 8-16 and install the pointer under the cam screw so
the pointer indexes in the center of "E" gap position.
4. Connect the 11-9110 Timing Light or equivalent across breaker assembly. Adjust breaker
contacts to just open at this position.
5. Loosen holding tool and turn rotating magnet until cam follower is on high point of cam
lobe. Tighten holding tool and measure contact clearance. It must be 0.018 ± 0.006. If necessary, readjust
breaker. Check to be sure contacts open within "E" gap tolerance. Replace breaker assembly if "E" gap
tolerance and contact clearance-cannot be obtained. Tighten breaker screws to 20 to 25 inch-pounds and
recheck breaker settings.

Reissued: 10/11/79 POWER PLANT

2B13

Island Enterprises
 PIPER SENECA II SERVICE MANUAL

Figure 8-13. Rotor Holding Tool Installed Figure 8-14. Timing Kit Installed

8-38. MAGNETO INSTALLATION AND TIMING PROCEDURE (MAGNETO TO ENGINE) (LTSIO IS

COUNTER-ROTATING). (Refer to Figure 8-17.)
a. TSIO timing marks are on the outer edge of the crankshaft counterweight blade between No. 2
and No. 4 cylinders. The inspection plug between No. 2 and No. 4 cylinders on the left top side of the
crankcase must be removed to view the marks on the crankshaft. (Refer to Sketch A.)
1. Plug one spark plug hole of the No. 1 cylinder and place a thumb over the other plug hole.
Have a second person stand in front of the engine and turn the crankshaft in a counterclockwise direction
until pressure is felt on the thumb. No. 1 piston is coming up on the compression stroke.
2. Remove the inspection hole plug and turn the crankshaft counterclockwise until the 20 degree
BTC mark appears in the center of the inspection hole. A timing device as described in the latest revision of
Service Bulletin M68-2, may also be used.
3. Remove the inspection hole plug from the magneto. Turn the magneto coupling until the
painted chamfered tooth on the distributor gear is approximately centered in the inspection hole. Hold the
magneto in its approximate installed position. Note carefully the position of the coupling drive lugs.
4. Lubricate the gear support shaft with clean lubricating oil and install the drive gear assembly
so the slots of the coupling bushings will be in the approximate position for aligning with the drive coupling
lugs on the magneto.
5. Insert the retainer into the gear hub slot. Apply a film of Lubriplate grease to each of the
new rubber bushings and insert the bushings into the retainers, rounded long edges first.
6. Place a new gasket on the magneto flange. Install the magneto carefully, so the drive
coupling lugs mate with the slots of the drive bushings. Install and snug down the two sets of attaching
screws. Do not tighten at this time.

Revised: 3/16/81 POWER PLANT

2B14
Island Enterprises
 PIPER SENECA II SERVICE MANUAL

Figure 8-15. Cast-in Timing Marks Figure 8-16. Fabricated Pointer

7. Breaker point opening may be checked by use of a suitable timing light. Tap the magneto
case with a non-marring hammer, counterclockwise (from the rear) to make certain the points are closed.
After the timing light indicates that the points are closed, tap the magneto lightly clockwise until the points
are open. Tighten the magneto attaching nuts.
8. Check timing by backing up crankshaft approximately 5 degrees and tapping gently forward
until the timing light indicates opening of breaker points. If timing is correct, the 20 degree mark (midway
between the 16 and 24 stamped on the crankshaft) will appear in the center of the inspection hole. The
crankshaft has punch marks in 2 degree increments with 16 and 24 at each end. Tighten the magneto
attachment nuts and replace the plug in the inspection hole on top of the engine.
b. LTSIO timing marks are on the outer edge of the crankshaft propeller flange. (Refer to Sketch
B.)
1. Plug one spark plug hole of the No. 1 cylinder and place a thumb over the other plug hole.
Have a second person stand in front of the engine and turn the crankshaft in a clockwise direction until
pressure is felt on the thumb. No. 1 piston is coming up on the compression stroke.
2. Hold a machinist square so its base is along the crankcase vertical parting line above the
crankshaft and the arm of the square is pointing outward past the crankshaft propeller flange.
3. Turn the crankshaft clockwise until the 20 degree Before Top Center mark on the engine is
now in the advanced ignition firing position.
4. Remove the inspection hole plug from the magneto. Turn the magneto coupling unit. The
painted chamfered tooth on the distributor gear is approximately centered in the inspection hole. Hold the
magneto in its approximate installed position. Note carefully the position of the coupling drive lugs.
5. Lubricate the gear support shaft with clean lubricating oil and install the drive gear assembly
so the slots of the coupling bushings will be in the approximate position for aligning with the drive coupling
lugs on the magneto.

Reissued: 10/11/79 POWER PLANT

2B15

Island Enterprises
 PIPER SENECA II SERVICE MANUAL

6. Insert the retainer into the gear hub slot. Apply a film of Lubriplate grease to each of the
new rubber bushings and insert the bushings into the retainers, rounded log edges first.
7. Place a new gasket on the magneto flange. Install the magneto carefully so the drive
coupling lugs mate with the slots of the drive bushings. Install and snug down the two sets of attaching
screws. Do not tighten at this time.
.8. Breaker point opening may be checked by the use of a suitable timing light. Tap the
magneto case with a non-marring hammer counterclockwise from the rear to make certain the points are
closed. After the timing light indicates that the points are closed, tap the magneto lightly counterclockwise
until the points are open. Tighten the magneto attachment nuts.

POWER PLANT
Reissued: 10/11/79
2B16
Island Enterprises