Mallory Ignition 257005, 257038, 257040, 257041, 186836P User Manual

PRO 25 UNIVERSAL
WIRE SET INSTALLATION
INSTRUCTIONS

READ CAREFULLY BEFORE
STARTING INSTALLATION

1. Remove only one wire at a time. Replace it with
a new wire before removing a second wire.

2. Begin with the longest wire. Then replace the
next longest wire, and so forth, ending with the
shortest wire.

3. Select new wire from universal set, using the
longest wire in the package first.

4. Snap spark plug boot onto spark plug and route
new wire back through brackets to distributor cap.

5. Cut off excess spark plug wire length at
distributor cap. (See illustration5.)

6. Slide distributor boot onto spark plug wire
(See illustration 6.)

7. Strip 7/8” of insulation away from spark plug
wire conductor core. Be very careful not to cut
or nick the conductor core when stripping
away the insulation. (See illustration 7.)

8. Fold conductor core back along wire.
(See illustration 8.)

9. Put distributor terminal over conductor and
crimp into place. (See illustration9.) We
recommend the use of ACCEL crimping
jaws part no. 170042 on 7mm and 8mm wire
sets or ACCEL part no. 170036 or 170037
ignition wire crimping tool. The ACCEL
crimping jaws are much less expensive
than the crimping tool, but requires the use
of a vise to hold in place.

10. Push distributor terminal firmly into distributor

cap and slide distributor boot onto distributor cap.

11. Return to step 2 (above) and repeat process

for each wire, ending with the coil wire.

(SEE REVERSE SIDE FOR
H.E.I. INSTRUCTIONS)

ACCEL www.accel-ignition.com

1

CUT

BOOT

FOLD

TERMINATE

SUPPRESSION OR SPIRAL CORE

COPPER CORE

DO NOT SLIT CORE

WRONG

WRONG

RIGHT

WRONG

WRONG

RIGHT

DO NOT SHRED OR STRIP AWAY CORE

DO NOT CUT OFF SINGLE STRANDS

DO NOT LEAVE STRANDS SEPARATED AFTER STRIPPING

9

8

7

6

5

2 www.accel-ignition.com

ACCEL IS A DIVISION OF PRESTOLITE PERFORMANCE
10601 MEMPHIS AVE. #12, CLEVELAND, OH 44144

216.688.8300 FAX [phone]

FORM 186836P

© 5/08

Made in China

INSTALLING H.E.I. DISTRIBUTOR CAP BOOTS

Follow Steps 1-5 and 7-9 first.

1. Lightly lubricate the terminal with silicone dielectric grease and slide the
wire into the H.E.I. boot.

2. Small amounts of grease may also be applied inside of boots on both spark plug
and distributor cap ends. This silicone dielectric grease will prevent corona and
arching conditions.

3. Be sure you have made a good connection in the distributor cap and coil. You
should recheck these connections periodically. If connector in distributor cap or coils
is gray-green, or appear corroded you may have a poor connection. Poor connections

at either the distributor or spark plug ends will cause an arching condition

.