IMPORTANT KV85

FITTING INSTRUCTIONS

Magnecor KV85 8.5mm Competition Ignition Cables (unlike conventional resistive carbon conductor ignition wires) use a 2.5mm Metallic Inductance Suppressed conductor and are specifically designed to conduct the total output of the ignition coil (which, with some racing ignition systems can be considerable) and provide RFI (radio frequency interference', and EMI (electro magnetic interference) suppression. Therefore, to get the best results, care should be taken when fiffing Magnecor Cables. Magnecor KV85 Competition Ignition Cables are made entirely of a silicone rubber that is extremely strong and flexible - so it is possible to fit them into both 7mm and 8mm separators and retainers - despite their 8.5mm size.

The most Important thing to remember Is that all sorts of problems can occur If the metal terminals Inside the wires' protective boots are not fully engaged with spark plug tops and distributor and ignition coil connectors.

If you are replacing burnt out resistive carbon conductor ignition wires, it would be worthwhile to check spark plugs rotor and distributor cap for defects such as cracks an~ excessively burnt metal arcing points, as well as for a badly worn or broken carbon contact (rubs on center of rotor) inside cap. Also, check coil tower for cracks and corrosion.

FITTING CABLE SPARK PLUG ENDS:

To properly fit a spark plug boot/terminal assembly (including those with plastic extensions) onto a spark plug, take care to ensure that the assembly is lined up to follow the angle at which the spark plug is fitted into the cylinder head. Push assembly over spark plug until a click is felt (or heard) as terminal engages the spark plug top.

On some engines it is almost physically impossible to comfortably get both your hand and the spark plug boot/terminal assembly near the spark plug. The best approach in this situation is to get the spark plug boot/terminal assembly onto the spark plug as best you can and to ensure the metal terminal is engaged over the spark plug top - push and gently rock on the top half of the rubber boot (or top cover on plastic connector). There will be a loose spongy feel, and boot or connector will lift off easily if terminal is not engaging, whereas there will be a more solid feel, and more effort will be needed to pull off boot or connector when terminal is engaging the spark plug top.

FITTING DISTRIBUTOR AND COIL ENDS:

Carefully fit distributor and coil boot/terminal assemblies into (or over) the distributor cap (and coil) connectors. Make sure that the metal terminals inside the boots are in full contact (engaged) with the metal connecting surfaces of both the distributor cap and coil tower connectors. On older GM distributor caps it is important to ensure that each and every distributor boot/terminal assembly is pushed down until click is heard or felt. Do not just place distributor boot/terminal assemblies in position and rely on the retaining ring (if used)

to push them down to properly engage onto distributor cap towers.

Some aftermarket push-in style distributor caps have brass Inserts-withgut a top taper to allow terminal to be easily pushed into the insert. Care should be taken to ensure that terminal (particularly the 900 style) is pushed into cap insert straight and centered. If a resistance is felt (edge of terminal is hung up against un-tapered lip of insert) - don't apply too much force to terminal as it could be distorted and become too loose inside the cap insert. The terminal can be bent back into shape by expanding the section that pushes into the cap insert to its original size.

A worthwhile practice is to again check Wire bootherminal assemblies for proper engagement after the vehicle has run a few miles. The vibration of the vehicle traveling will quickly loosen up any bootifterminal assembly not properly engaged.

REMOVING CABLES FROM SPARK PLUGS:

After twisting boot fitted to spark plug (to break seal between boot and spark plug insulator), try to pull boot (or extension) off spark plug at the same angle the spark plug is fitted into the engine. With an extension type spark plug connector, if connector is not pulled up parallel to the spark plug, Magnecor's heavy duty terminal could hook onto some spark plug tops, and with the extra force needed to drag connector off plug top, the bottom seal could be jolted off and/or the floating terminal needed for some connectors could be pulled out of position inside plastic extension tube.

Although Magnecor KV85 Competition Ignition Cables are able to withstand a service heat of 6000F, and 1,OOOOF for short burst race conditions, their jackets and boots could lose their effectiveness if allowed to rest for prolonged periods against headers and turbocharger plumbing that reach temperatures in excess of 1200*F. We recommend that cables are routed so that a gap of at least 20mm is left between these cables and any 1,200OF plus heat source. Severe heat destruction of spark plug boots too close to headers can rarely be cured by shielding boots. Header heat wraps and coatings, etc. can be very effective.

NOTE:

It is possible that the boottlerminal assemblies fitted to the wires enclosed do not resemble the original or replacement ignition wires you are about to replace. The reason is that we have found (after 20 years experience) that the design and construction used for some original and replacement Ignition wires, a well as some original engine designs, cause wire assemblies to become inherently unreliable (the reason you are replacing them), and wherever possible we try not to imitate a design that we know will inevitably fail - particularty with our name on it'

*EVERY PART OF ANY MAGNECOR IGNITION CABLE IS AVAILABLE AS A SEPARATE SPARE PART.

LIMITED WARRANTY

Magnecor Ignition Wires will be replaced or repaired free of charge if the product should fail for any reason other than abuse, accident, negligence, improW installation, alteration or failure attributed to original engine design, engine maintenance (or lack thereof) or engine modification. Warranty applies on~ to the original purchaser and Is lirniled to replacement or repair of the suspected failed vAre and does not Include labor charges for rernoval or replacement Wire shoWd be returned together with proof of purchase to any autinorized MagneoDr distrbutDr or dealer or Magnecor Itself for aulhaization for replacernent or repair.

Manufactured exclusively by Magnecor Australia Limited

Walled Lake, Michigan, USA. Made in USA Rev.031298