DATE 

ALERT SERVICE BULLETIN 

REVISION NOTICE 

AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOGBOOK UPON ACCOMPLISHMENT 

IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER

Dec 08, 2008 

TO: All Owners/Operators of Bell 205A & 205A-1 Helicopters

SUBJECT: REVISION “A” TO ALERT SERVICE BULLETIN 205-07-94: 

 (STARTER/GENERATOR POWER CABLE UPGRADE) 

Revision “A” to this bulletin is to incorporate minor changes into the text for better 

comprehension, also to make a correction to the kit part list by adding a missing nut 

and two missing washers . Please note that the intent of the bulletin did not change. 

Consequently, no action is required on aircraft already modified per the original 

release of this bulletin. 
NO. 

 

DATE 

PAGE 

 DATE 

 REV 

ALERT SERVICE BULLETIN 

AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOGBOOK UPON ACCOMPLISHMENT 

IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER

205-07-94 

 Dec 08, 08 June 01, 2007 

 A 1 of 7 

MODEL AFFECTED: 205A & 205A-1

SUBJECT: STARTER/GENERATOR POWER CABLE, 

UPGRADE. 

HELICOPTERS AFFECTED: Model 205A & 205A-1 helicopters serial number 

30001 through 30332. 

 

COMPLIANCE: 1 year from release date of this bulletin.

DESCRIPTION: 

 

Bell Helicopter has been made aware of a possibility of fire hazard caused by the 

starter/generator power cable shorting out at connector P81 (J81) pins. This ASB 

addresses this issue by replacing the affected cable assemblies. 

 

APPROVAL: 

The engineering design aspects of this bulletin are FAA/DER approved. 

MANPOWER: 

Approximately 10.0 man-hours are required to complete this bulletin. Man-hours are 

based on hands-on time, and may vary with personnel and facilities available. 

WARRANTY: 

Owners / Operators of Bell 205A-205A1 Helicopters who comply with the instructions 

in this Bulletin will be eligible to receive a 100% credit for the replacement parts Kit 

CT205-07-94-1 outlined under the required material section. 
ASB 205-07-94 

Page 2 of 7 

To receive this credit: 

• Purchase the required kit CT205-07-94-1 from a BHT supply 

source. 

• Comply with the instructions contained in this Bulletin no later 

than the applicable hours or date listed in the “compliance 

section” of this ASB. 

• Submit an MMIR to the Bell Warranty Department for the 

replacement parts. 

-NOTECustomers who fail to comply with the instructions in this 

Bulletin after one year from date of release of this Bulletin 

are not eligible for the special warranty credit provisions 

listed above. No labor cost will be covered under this 

bulletin. 

MATERIAL: 

Required Material: 

The following material is required for the accomplishment of this bulletin and may be 

obtained through your Bell Helicopter Textron Supply Center. 

Part Number Nomenclature Quantity 

CT205-07-94-1 Starter/generator cable kit 1 

 

Note: The Starter/generator cable kit consists of the following parts: 

205-075-265-103 Cable Assembly 1 

205-075-265-105S Cable Assembly 1 

MS27212-5-2 Terminal Board 1 

MS18029-5S2 Cover 1 

MS3373-A3 Insulating strip 1 

MS3373-C3 Insulating strip 1 

31-034-1-150 Tape 1 

80-011-P7F0-0 Plug 3 

80-011-S7D08-0 Sleeve 3 

MS21042L6 Nut 1 

AN960D616L Washer 2 A 
ASB 205-07-94 

Page 3 of 7 

Consumable Material: 

The following material is required to accomplish this bulletin, but may not require 

ordering, depending on the operator’s consumable material stock levels. This material 

may be obtained through your Bell Helicopter Textron Supply Center. 

Part Number Nomenclature Quantity Reference

 

299-947-100, type II, class 2 Adhesive A/R C-317 

MIL-S-81733 type 2 Sealant A/R C-251 

SPECIAL TOOLS: 

Part Number Nomenclature Quantity 

 

MS 25441 (or equivalent) Crimper 1 

MS 23002-1 (or equivalent) Die 1 

ELECTRICAL LOAD DATA: 

Not affected 

REFERENCES: 

BHT-205-IPB Illustrated Parts Breakdown 

BHT-205-MM Maintenance Manual 

BHT-MED-SRM-1 Structural Repair Manual 

BHT-ELECT-SPM Electrical Standard Practice Manual 

PUBLICATIONS AFFECTED: 

BHT-205-IPB Illustrated Parts Breakdown 

BHT-205-MM Maintenance Manual 

ACCOMPLISHMENT INSTRUCTIONS:

1) Prepare helicopter for maintenance. 

2) Remove and discard cable assembly 205-075-902-017 using following steps: 

a) Gain access to connector P81 located on the left hand side engine deck. 

A 

A 
ASB 205-07-94 

Page 4 of 7 

b) Disconnect connector P81 from J81 and disconnect wires at starter/generator 

terminals E, B, and C. Retain hardware for re-installation. 

3) Remove and discard cable assembly 205-075-911-007 using following steps: 

-NOTENote cable routing and clamping when removing cables, and 

use similar routing and clamping when installing the new 

cables. 

a) Gain access to connector J81 located underneath the left hand side engine 

deck. 

b) Remove connector J81 from lower engine deck panel. Retain attaching 

hardware for re-installation. 

4) Remove wires as per Table 1. Retain hardware for re-installation. 

5) Install plugs and sleeves as follow: 

a) Locate qty 3 holes in accordance with Figure 1. 

b) Drill qty 3 holes 0.296 to 0.289 inch through panel assembly as shown on 

figure 1. 

c) Install qty 3 sleeves P/N 80-011-S7D08-0 far side and plug P/N 80-011-P7F0-0 

using adhesive C-317 as detailed in Structural Repair Manual (SRM). 

d) Allow adhesive to cure. 

6) Install terminal board P/N MS27212-5-2, TB 150, on inboard side of main beam at 

STA 205.10 using qty 3 screws MS35206-233, qty 3 washers AN960PD6L, and qty 

3 nuts NAS679A06. 

7) Install identification tape P/N 31-034-1-150 beside terminal board and apply 

sealant C-251 over tape. 

8) Install cable assembly P/N 205-075-265-105 connector J81 on lower side of engine 

deck using retained hardware. 

-NOTEReference to Figure 2 for the following steps. 

9) Prepare ground pad for electrical bonding per BHT-ELECT-SPM. Connect wire 

P73B1N to ground pad using retained hardware. 
ASB 205-07-94 

Page 5 of 7 

10) Connect wire P95B1 to K57 (starter relay) terminal A2 using retained hardware. 

11) Connect wire P72B1 and P72C1 to TB 150, terminal 1 using strip P/N MS3373-A3, 

strip P/N MS3373-C3, qty 2 washer P/N AN960D616L and nut P/N MS21042L6. 

12) Install cover assembly P/N MS18029-5S-2 on TB 150. 

13) Connect the other end of wire P72C1 to R1 (Generator Shunt) on the + side as 

follows: 

a) Route wire P72C1 to R1 (Generator Shunt). 

b) Cut wire P72C1 and install terminal lug P/N MS25036-130 using crimper p/n 

MS 25441 with die p/n MS23002-1. 

c) Connect wire P72C1 to RI (generator Shunt) on + side using retained 

hardware. 

14) Install cable assembly P/N 205-075-265-103 by connecting P81 to J81 and safety 

with lockwire. 

15) Perform continuity check using multimeter as follow: 

a) Check continuity between end of wire P73A1 and ground. Reading should be 

approximately 0 ohms. 

b) Check continuity between end of wire P72A1 and R1, + side (generator shunt). 

Reading should be approximately 0 ohms. 

c) Check continuity between end of wire P95A1 and K57 terminal A2 (starter 

relay). Reading should be approximately 0 ohms. 

16) Connect wires to G6 (starter generator) 

a) Connect wire P73A1 to G6 (starter generator) terminal E using retained 

hardware. 

b) Connect wire P72A1 to G6, terminal B using retained hardware. 

c) Connect wire P95A1 to G6, terminal C using retained hardware. 

17) Make helicopter safe for flight. 

18) Make an entry in helicopter historical record indicating compliance with this Alert 

Service Bulletin. 
ASB 205-07-94 

Page 6 of 7 

Wire number From connection Pin 

K5B0N GROUND PAD N/A 

K5D4N GROUND PAD N/A 

P37D4 GENERATOR SHUNT R1 + SIDE 

P37B0 GENERATOR SHUNT R1 + SIDE 

K6C4 STARTER RELAY AFT K57 A2 

K6A4 STARTER RELAY AFT K57 A2 

Table 1 

Remove wires 

80-011-S7D08-0 3.00 IN 

(76.2 mm) 

Figure 1 

Structural Modification

1.50 IN 

(38.1 mm) 
ASB 205-07-94 

Page 7 of 7 

Figure 2 

Wiring diagram