TM 5-4240-501-14P
IGNITION
Flywheel Type - External Breaker
REPLACING BREAKER PLUNGER
AND BUSHING
Model Series 19D, 23D, 193000, 200000, 230000,
243000, 300000, 320000
Two styles of plunger bushing have been used.
Removal and installation is as follows.
Fig. 37
Remove breaker box cover, condenser and breaker
assembly, Fig. 38, Illus. 1. Place a thick 3/8" inside
diameter washer, such as P/N 22238, over the end of
bushing and screw on a 3/8-24 nut, as shown in Fig. 38,
Illus. 2. Tighten the nut to pull the bushing. After the
bushing has moved about 1/8", remove the nut and put
on a second thick washer, as shown in Fig. 38, Illus. 3.
A total stack of 3/8" of washers (2-22238) will be required
to completely remove the bushing. Be sure the plunger
does not fall out of the bushing as it is removed.
Fig. 38 - Removing Plunger and Threaded Bushing
Installing Threaded Bushing and Plunger
Place the new plunger in the bushing with the large end
of the plunger opposite the threads on the bushing.
Screw the 3/8-24 nut onto the threads to protect them.
See Fig. 39.
Fig. 39 - Plunger and Bushing
Fig. 40 - Inserting Bushing
Insert bushing into cylinder. Place a piece of tubing such
as P/N 295840 piston pin against the nut, as shown in
Fig. 40. Use a hammer to drive the bushing into the
cylinder until the square shoulder on the bushing is flush
with the face of the cylinder. Check to be sure plunger
operates freely.
Alternate Design
Fig. 41 - To Remove Bushing and Plunger
Pull plunger outward as far as possible. Use a pliers to
break plunger off as close to bushing as possible. See
Illus. A, Fig. 42. Use a 1/4-20 tap ora 93029 self-
threading screw to thread the hole in the bushing to a
depth of approximately 1/2 to 5/8" deep, as shown in
Illus. B. Use 1/4-20 x 1/2" hex head screw and two
spacer washers as shown in Illus. C, to pull the bushing
out of the cylinder. The bushing will be free when it has
been extracted 5/16". CAREFULLY remove the bushing
and the remainder of the broken plunger. Do not allow
the plunger or chips to drop into the crankcase.
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