joecb wrote:

Another thought / caution on Zephers in general.  The close proximity of fuel and high voltage within the close confines of the front shroud have all the makings for FIRE.  Be sure that there no fuel leaks. as for the potential of a stray spark… consider using short body spark plugs… why?  The original style champion plugs had slightly shorter bodies than the modern equivalents. The longer bodies put the terminals closer to the aluminum front shroud.,, potential for a stray spark.  Short body plugs of the correct heat range are available from both Champion and NGK. I like the NGK – BM7A… they seem to have the right heat range and also have screw-on terminal nuts.

Joe B

Good advice for sure. Regarding the screw-on terminals, this 1949 Zephyr has rubber spark plug boots and rubber coated wires like a 1950’s classic would have. I’m gathering that earlier models had open terminals like other motors from that time, but maybe someone can verify that.  Did the pre-war 1941-1942 models also have cloth insulated wires? Regarding the fire danger from fuel leaks, that is a serious consideration with the sparkplugs and wires right up front with the carburetor and fuel lines. No amount of fuel leakage is acceptable here.

After disassembling and cleaning the fuel tank, it was noted that there was no tank filter. I thought it was missing, but the parts diagram I have does not show one. Is this correct? Do they rely on a filter internal to the carburetor and nothing more?