Ignition Cap Replacement

Ignition Cap Replacement - DA50, 60, 70, 85, 100, 120, 150, 170, 200, 215

Your Desert Aircraft Ignition Spark Plug Cap can be replaced in a few minutes using a pair of cutters and pliers- you can also use a pair of ear clamp pliers for the ear clamp, but regular pliers will work fine. This is not compatible with the DA-35 ignition. 

1. Disconnect all power to the ignition. Remove the old damaged ignition cap using a pair of cutters to cut the wire. Do not cut an excess amount of wire off as you may not have enough to reach your spark plug! 

2. Slide the red heat shrink tubing and the ear clamp onto the ignition wire. Pull back the ignition wire shielding to give you room to work. 

3. Insert the ignition wire into the end of the silicone cap with the diode. Push the wire in so that it is fully and firmly seated to the diode inside of the silicone cap. This step is critical as if the wire is not firmly inserted into the diode end of the silicone cap you may not get spark!

4. Locate the metal cap with the 4 tabs protruding out. Place it on the outside of the silicone cap. 

5. Place the opposite side metal cap on top of the assembly. 

6. Using a pair of pliers, crimp down the metal tabs to firmly secure the 2 sides of the metal cap over the silicone cap. 

7. Slide the wire shielding completely over the end of the metal cap ensuring to take out the excess slack along the length of the wire.  

8. With the slack in the shielding removed, slide the ear clamp firmly over the end of the cap. Use a pair of pliers (or ear clamp pliers) to crimp down on the outside edges of the ear clamp to firmly secure it to the end of the ignition cap assembly. This step is critical to ensure the shielding is able to complete the ignition ground correctly. 

9. Install the metal spring clip onto the end of the ignition cap. 

10. Slide the red heat shrink tubing over the finished assembly and use a heat gun to shrink the tubing in place.