Pioneer 1200 Maintenance Service Manual page 192

12
ELECTRICAL COMPONENTS: FE400 ENGINE
Ignition Coil Removal, Continued:
7. Remove the pan head bolts (5) securing the fan shroud (8) to the fan housing (9) (Figure 12-26,
Page 12-25).
8. Loosen, but do not remove, the three bolts (6) attaching the fan housing as shown.
9. Remove the remaining four bolts (10) attaching the fan housing (Figure 12-26, Page 12-25), then while
opening the housing, detach the spark plug wire grommet (4) from the housing (Figure 12-28,
Page 12-25).
10. Disconnect the 18-gauge black wire (12) from the spade terminal (13) on the ignition coil (11) and remove
the coil by removing two bolts (10) (Figure 12-27, Page 12-25).
Ignition Coil Installation
NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must
be removed from the old coil and installed on the new coil. See steps 1 through 8 for procedures
to remove and install these existing parts.
If the existing ignition coil will be remounted, proceed to step 9.
1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire.
2. Remove the cap (2) from the wire by turning the cap counterclockwise three or four revolutions while gen-
tly pulling it off the wire (Figure 12-28, Page 12-25).
3. Remove the gasket (1) and protector tube (3) from the old coil. See following NOTE.
NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier.
4. Remove the grommet (4) from the old spark plug wire. Clean the grommet and place it on the new spark
plug wire (5).
5. Install the protector tube (3) onto the new wire.
6. Slide the gasket (1) onto the end of the new spark plug wire.
7. Install the cap (2) on the new coil spark plug wire by rotating it clockwise three or four revolutions while
applying light pressure on the cap.
8. Install the gasket (1) on the cap (2).
9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two
mounting bolts (6) finger-tight.
10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012 inch
(0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet.
Tighten the two mounting bolts (6) to 30 in-lb (3.4 N·m) (Figure 12-29, Page 12-25).
11. Connect the 18-gauge black wire (12) to the spade terminal (13) on the coil (Figure 12-27, Page 12-25).
12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch
on the housing.
13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder
shroud. The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in
the housing with the flanged bolts (6) loosened earlier (Figure 12-26, Page 12-25).
14. Install the four flange bolts (10) that secure the fan housing to the engine crankcase. Tighten all mounting
bolts (6) and (10) to 90 in-lb (10.2 N·m).
15. Install the fan shroud with four pan-head bolts (5) and tighten to 50 in-lb (5.7 N·m).
16. Place the engine onto the engine mounting plate and slide the two washers (3) onto the two engine body
bolts, then slide the bolts through the mounting plate and transaxle housing. Loosely attach the two nuts
(6) finger-tight. See Figure 13-5, Section 13, Page 13-6.
Page 12-24 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Ignition Coil