Today I finally got around to tearing my 041AVS down and rebuilding it onto a "better" case. Still not perfect but the best AV case I've seen so far.
Here's what I started out with:
Here I already have the cylinder mounting studs inserted into the case with blue threadlocker for added security. Regular 61cc 041 cylinders use regular mounting bolts which only go through the base flange instead of the entire cylinder.
You can see this case's only two defects - the broken bolt eye at the very top of the photo that I repaired, and a crack in the thin metal on the bottom of the case below the flywheel area, at the very lower right in the photo. I haven't tackled this one yet because I'm not quite sure how to do it right. Not sure if some mesh and a thin layer of JB on the backside would help it or if it's worth the effort. This is a major weak spot with this case design. I also installed a brand new plug wire in this unit, which must pass through the rubber grommet to the right of the bottom-right cylinder stud. The kill wire passes through a smaller grommet in the top of the case, visible at the very bottom edge of the photo.
Got the points ignition installed and hooked up to the new plugwire. I tried an electronic setup that I had but couldn't get it to produce a hot enough spark to start the saw, so back to good ol' reliable points it is. The points are located under the black housing at 6:00 in the photo, and the round grey cover tab can be pulled out to inspect and service the points themselves. There are three wires going to the condenser - the bottom one is the timing wire from the points, the top one is the kill wire going out through the case, and the one on the left is the incoming high-voltage wire from the coil.
This is what the SEM electronic ignition coil looks like. The high-tension coil is missing in this photo but looks similar to the points coil, just without the metal "ears" sticking out the ends.
These are the different flywheels - the one on the left is for the SEM electronic ignition, and the one on the right is for a points ignition. You can barely see the timing lobe on the inner shaft of the flywheel - it goes from about 9:00 to 12:00 on the shaft. Notice the windows in the flywheel for checking the point gap as well.