95235 Mercury PISTON PIN

1. Put identification on each wire and screw on the magneto (2).2. Disconnect the wires (1) from the magneto (2). 3. Remove mounting bolts (3) and washers.4. Remove the magneto and gasket.Install Magneto
1. See TIMING MAGNETO TO ENGINE in TESTING AND ADJUSTING. 2. Put magneto (1) and gasket in position on drive housing.3. Install mounting bolts and washers. 4. Connect wires (2) to the magneto (1). Each wire must be connected to the same terminal from which it was removed.Disassemble Magneto
start by:a) remove magneto
Care must be taken when cover (2) is removed, because grounding wire is fastened to the cover.
1. Remove screws (1) and lockwashers that hold cover (2) in place. Turn cover (2) over to show the grounding wire connection. 2. Remove screw (3) and disconnect the grounding wire from block assembly (4). 3. Remove screws (5), washers and lockwashers. Remove block assembly (4) from the cover. 4. Remove brushes (6) and springs from the block assembly. 5. Remove four screws (8) and lockwashers. Pull end cap (7) away from the housing far enough to disconnect the grounding wire from the contact points. 6. Disconnect grounding wire (9) from the contact points. 7. Disconnect grounding wires (9) from end cap (7).8. Remove vent cover (10) and screens from each side of the end cap. 9. Remove screw (11), lockwasher and distributor disc (12). 10. Remove contact points (13) and condenser (14). Put a mark on cam (15) for the correct keyslot to be used at assembly.11. Remove nut (16), cam (15) and key from the shaft.12. Remove two screws, washers, lockwashers and plate (17) from the bearing support. 13. Remove three screws (18) and lockwashers that hold bearing support (19) in position. 14. Install a 1/4"-20 NC forcing screw (20) 1 1/2" long as shown and remove bearing support (19) from the housing. 15. Use tool (A) to remove snap ring (21).16. Use a press to remove distributor gear and shaft assembly (22) from the bearing support. 17. Loosen screws (24) and wedges (23) and turn rotor shaft assembly (25) until flux lock (magnetic field) is broken. Remove screws, wedges and coil (26) from the housing. 18. Turn the housing over and remove nut (27) and washer from the impulse coupling.
Care must be taken when coupling shell (28) and spring are removed. The coupling shell is under spring force.
19. Use pliers on one of the drive lugs of coupling shell (28). Turn and pull the coupling shell at the same time until the spring releases. To make a separation of the coupling shell from the hub, the spring end must be removed from the (slot) groove in the hub. The coil of spring (30) must be in correct direction for magneto rotation. For counterclockwise rotation the coil of the spring must be in a clockwise direction from end (29).20. Remove spring (30) from coupling shell (28). 21. Remove hub (31) from the shaft. 22. Remove key (33) and seal (32). Seal must be destroyed to remove. 23. Use tool (B) to remove snap ring (35). Remove coupling pawl stop pin (34). 24. Use a press to remove rotor shaft assembly (25) from housing (36). 25. Remove snap ring (37) that holds bearing (38) in position with tool (B). 26. Use a press to remove bearing (38) from housing (36).27. Remove vent cover (39) and screens from each side of housing (36).Assemble Magneto
1. Thoroughly clean and inspect all parts for wear and damage. 2. If a replacement of the bearings in bearing support (2) is needed, they must be made as a unit.3. Use a press to install distributor gear and shaft assembly (1) in bearing support (2). 4. Use tool (A) to install snap ring (3) that holds distributor gear and shaft assembly (1) in position. 5. Put an identification mark on the tooth by mark (4) on rotor shaft assembly (5) pinion. 6. Make an alignment of mark (6) on rotor shaft assembly (5) pinion with the letter "A" for counterclockwise (anti-clockwise) rotation on the distributor gear and shaft assembly (1). 7. Use a press to install rotor shaft assembly (5) in bearing support (2). Vent cap (7) opening is to be installed in a "down" position with the magneto installed on the engine.8. Install two vent screens and vent cap (7) on each side of housing (8).9. Use tool (B) to install the bearing in housing (8). 10. Install snap ring (9) that holds the bearing in position with tool (C). 11. Put coil (12) in position in the housing with the shorter wire (11) to the left as shown. Install wedges (10). Fasten short wire (11) under left coil wedge (10) screw. 12. Put bearing support (2) and rotor shaft assembly in position in housing (8). Use a press and a 3/16" diameter rod (13) 1 3/4" long to install the rotor shaft assembly in the bearing in housing (8).13. Install the three screws that hold bearing support (2) and clip (14) in position. 14. Use tool (A) to install snap ring (15) that holds the rotor shaft assembly in position. 15. Install seal (16) with the lip of the seal away from the housing.16. Install coupling pawl stop pin (17). Use the left hole as shown for counterclockwise rotation. 17. Install plate (18) on bearing support (2). 18. Install key (19) on the distributor shaft. Cam (20) has two keyslots, one for each direction of magneto rotation. Each keyslot has an arrow for each direction of rotation.19. Make an alignment of the key in the distributor shaft and the keyslot by the counterclockwise direction arrow on cam (20). Put cam (20) in position on the shaft. 20. Install nut (22) that holds the cam in position.21. Install condenser (23) and contact points