why not cut the wire about 1/4in from coil and solder the new wire to the old stub? just asking.

tinkerman wrote:

Ok I’ve rewired the mag with new plug wires and secondary wires. Got the carb cleaned up pretty good. Haven’t doped the coils yet. On the carb, there was a black plastic piece with a hexagon lip to accept a nut from the linkage. This was broke. I somewhat rebuilt it with epoxy, we will see if it holds up. So far so good on bonding strength as there is quite a bit of resistance to turn the baffle but it engages properly

It’s common to find broken, or break the end of the bakelite throttle spool,
where the hex drive engages. There’s a tricky procedure to remove the throttle
spool, to rotate it as it comes out so it will clear the fuel jet inside.
There’s a “cartoon” like service manual on the Zephyr carbs. The Lightfour
carbs are very similar.
I recently removed the throttle spool on mine, with much trouble, as it hadn’t been
out in decades, was all junked up with corrosion, dirt, etc. It went in much easier
after it was all cleaned!

I found the cartoon maintenance manual, but it was too large to upload.
Here’s the procedure to remove the throttle spool.

• This reply was modified 1 year, 9 months ago by Buccaneer.
• This reply was modified 1 year, 9 months ago by Buccaneer.