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Universal EasyCap for Bosch Flywheel Magneto

The picture on the right shows a Bosch flywheel magneto/generator taken from a Fichtel & Sachs 98 cc two-stroke engine.

The back plate is stamped with the part number 327/36Z, but the principles described below no doubt apply to many other models of Bosch magnetos and other makes too.

The original condenser is not shown in the photo, but was fitted in a recess between the ignition coil and the right-hand generator coil.

The live wire of the LT winding in the ignition coil is connected to the static point plate, which is therefore live. The moving point is earthed, and its spring is attached to an anchor post which passes through, but is isolated from, the live static point plate.

Read through all of these notes  before you start cutting and drilling your EasyCap, and make sure that it appears that the EasyCap will fit. For example check that there is enough space between the static point plate and the moving point arm.  
With the moving point and its spring removed, the spring anchor post and another clamping screw for the static point plate can be seen more clearly.
   
With the anchor post, clamping screw and upper insulating plate removed, this picture shows a second lower insulating plate between the live static point plate and the back-plate. Also, there are insulating sleeves in the holes through the static point plate.

The upper insulating plate will be replaced by the Universal EasyCap, after the EasyCap had been shaped and drilled.

   
If you click on the picture to the right, it will open a template in Adobe Acrobat .pdf format. Print it out, making sure that you use the print dialogue box and that the page scaling is set to "no scaling" or "100%" so that it comes out the correct size.

   
Check that the template seems to be correct for your particular flywheel magneto, and if so shape and drill the Universal EasyCap accordingly.

If the template doesn't seem to be correct, you will need to design your own.

It is important that the anchor post and clamping screw (earthed) do not make contact with the bottom copper layer (live) of the EasyCap. You therefore need to countersink the holes on the underside.


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Bottom

   
This photo shows the EasyCap fitted ...
   
... and this photo shows the moving point replaced.

 

Job done.

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