Installing mag cup on single coil 951???

[JonRusso89]

So i swapped in a 99+ 951 into my 98 xpl. I'm in the process of swapping the mag cup since the new motor was from a dual coil ski and my 98 xpl is single coi (different mag cups discussed in my other thread). After some investigation it appears that the flywheel is also different.. still usable, but the hole used for aligning the mag cup is in a different place, so its pretty much useless. So how do I align the mag cup without using the alignment mark for a 98 (single coil) application??

 

[Dr Honda]

PM Chester, and ask. Let him know Dr Honda sent you.

Then... once he tells you... let us know. (I've never tried that one)

 

[JonRusso89]

Thanks I will... I know it can be done because people have used a pre 99 motor in post 99 skis just by changing the mag cup, without changing the flywheel. And I've found threads on how to line up the newer mag cup on an older flywheel without using the alignment hole.. Just not the other way around. Apparently with the newer mag cup you set mag cylinder at tdc and set the the 1 long protrusion on the mag cup just after the pickup.. I have a feeling the procedure would be the same with the older style with the 2 long protrusions.. Not positive though and don't really want to take this thing apart a second time.. Also the cup looks to be symetrical.. so I don't think i can accidently set it 180 degrees off.. In other words.. i dont think it matters which protrusion I use for alignment.. Hopefully someone has done this.. Any input is welcome!

 

[JonRusso89]

Anyone else have any ideas..? haven't heard from chester, was hoping to get this thing together tomorrow morning..

 

[Chester]

Once the flywheel is off, the engine doesn't care which ignition you have. Your 98 XPL has a single coil so you just use the original single coil flywheel and cup for it. And yes, you can put the cup on it either way.

Chester

 

[JonRusso89]

Yeah I know.. But i'm using the flywheel from a dual coil set up, and a cup from a single coil.. The alignment hole on the single coil flywheel is in a different spot then on the dual coil flywheel. So how do I set the mag cup without the use of the alignment hole? I guess I'm just gonna try to figure it out and see what happens.

 

[Chester]

Why do you want to use that flywheel?

Chester

 

[SabrToothSqrl]

... so that he doesn't have to swap them....

the 2 large hole marks should still line up, can you see any circles on the front of the fly wheel? you can also hold the magneto in place with 2-4 bolts, then bolt on the cover with 2-4 bolts, and see if it will idle... mine, with the wrong magneto wouldn't start. EVER. with the right one, it started right up, then I bolted everything up solid.

If you have the metal air duct clips from the 99+ engine, I'd be willing to buy them. I have a set from a '98 and they are different as well...

My guess is the alignment is the same as the newer one, like your description. either that.. or swap the flywheels.

I thought I posted that the MAG should be bottom, while the long strip was top? or is it the other way? I should have written that down or taken a pic, I'll look up my post on it, then print it for reference as I have an engine going out to be rebuilt this week.


The 951 difference list, that I know of.

98-99 oil pump bracket is now in the magneto housing (99+)
99+ Dual coil igntion means new magneto/flywheel cup
01+ new exhaust manifold gasket design
(00?) metal clips for air ducts have 2 tabs each vs. 1 for rubber flaps.

 

[JonRusso89]

Yes the big circles in the cup line up the same for the different cups.. I was surprised so I double checked piston position and it was good.. started right up.. now just dealing with carb stuff..

 

[JonRusso89]

And I have the clips but i think my brother wants them.. I'll let you know if they don't go to good use..