Evinrude & Johnson 1975 E265RC, 1975 J265RC Service Manual
©
OUTBOARD
SN
MOBILE DIVISION/OUTBOARD
OUTBOARD
MARINE
MARINE
45
MARINE
CORPORATION,
CORPORA-TION
CORPORATION
HP
OF
CANADA
MODELS:
1974
ALL
RIGHTS
3031
NORTH 114th STREET, MILWAUKEE , WISCONSIN 53222
LTD., PETERBOROUGH,
E265RC,
RESER
VED
CANADA.
j265RC
.
INTRODUCTION
SPECIFICATIONS
SAFETY
THE
ATTRACT
DANGERS.
PLANATtONS
CAREFUL
ING.
SELVES,
STRUCTIONS
NOT
PREVENTION
SYMBOL
L..lWARNING
PURPOSE
SAFETY
ELIMINATE
SUBSTITUTES
A
SAFETY
YOUR
ATTENTION
INTRODUCTION
SYMBOLS
OF
SAFETY
ATTENTION
THE
SYMBOLS, AND
WITH
WARNINGS
OR
WARNINGS
FOR
MEASURES.
MEANING
FAILURE
SAFETY
RESULT
YOU
THEM,
AND
DO
ANY
DANGER.
PROPER
OR
SECTION
SYMBOLS IS
TO
POSSIBLE
THE
DESERVE
UNDERSTAND-
NOT,
THEY
TO
WARNING MAY
IN
INJURY
TO
OTHERS.
YOUR
BYTHEM-
THE
GIVE
ACCIDENT
OBEY
1
TO
EX-
IN-
ARE
A
TO
GEN
ERAL
SNOWMOBI
TROUBLE
TUNE-UP
FUEL
IGNITION
ELECTRICAL
.
MANUAL
SHOOTING
PROCEDURES
SYSTEM
AND
SYSTEM
STARTER
LE
IN
FORMATION
o
DNOTE
Before
ments
WARNINGS
5-5, 5-7,
8-2,
12-5,
PROHIBITED
proceeding
on
this
on
inside
6-7, 6-9,
9-2,
12-6
9-3,
and
12-8.
WARNS YOU AGAINST AN
ACTIVITY
MAY
YOUR
ADVISES YOU
MATION
TIONS
OPERATION
NANCE
MENT.
with
snowmobile,
AREA.
any
front
7-4,
10-2,
10-3,
WHICH IS,
BE,
cover
OF
VIT
AL
OR
YOUR
repaiXr
see
7-13,
ILLEGAL
OF
INFOR-
INSTRUC-
TO
OR
MAINTE-
EQUIP-
adjust-
SAFETY
and
on
page/:?:
7-18,
THE
7-20,
10-4, 11-3, 11-4,
OR
IN
ENGINE
~
__
D_R_IV
_E
__ T_RA_I_N ____________
STEERING,
LUBRICATION
TRACK
AND
AND
SUSPENSION
STORAGE
~
__
~~
1-2
/
The
formance.
ceive
is
service
Parts
to
manual
perienced
the
for
sequence
reference
desired
which
ment
Section 2 lists
information,
up
snowmobile
skilled
important
which
This
manual,
Catalogs;
service
that
guidance
The
Parts
replacement.
of
during
The
Section
section.
gives
simplifies
procedures,
It
this
serViceman,
the page
of
has
is
important
and
thorough
to
the
service
will
maintaIn
together
provide
snowmobile.
will
not
the
less
Catalogs
In
all
parts.
disassembly
Index on
At
the
number
locating
complete
including
are
given
been
designed -and
to
every
service
dealer
the
customer's
with
the
the
serviceman
only
serve
but
will
experienced
contain
addition,
page
R.C.
the
This
catalog
and
1-1
beginning
on which
the
desired
specifications
engine
in
Sections 3 through
snowmobile
for
to
be
regularly
An
also
complete
enables
with
effort
as a ready
provide
man.
exploded
can
reassembly.
of
each
each
information
on
theory,
built
for
his
vehicle
able
to
satisfaction.
issued
all
has
reference
more
lfstings
views
be
of
the
reader
Section
topic
the
snowmobile.
trouble
5 of
dependable,
owner
offer
the
been
begins.
to
when
the
service
literature
made
book
basic
of
the
illustrate
considerable
to
locate
is a Table
within
shooting,
this
manual.
high
be
able
to
necessary.
type
of
skilled
bulletins
necessary
to
produce
for
the
information
parts
required
the
correct
help
quickly
of
Contents
This
arrange-
this
manual.
All
general
and
per-
re-
and
ex-
for
as
any
tune
)
It
a
a
\
37323
Figure
1-1
I
1- 3
C
sections 6 through
disassembly
Section
the
texts
intermixed.
man
to
formation.
reading
illustration
Read
procedures
for
use
to
give
maintain a reputation
This
however,
does
not
to
the
complete
number.
All
information,
literature
publication.
notice.
and
reassembly
12
provides
treat
reread
of
this
as a reference.
better
service
new
appear
Service
information,
are
each
This
discussions
Illustrations
explanatory
and
text.
manual
described,
service
manual
service
to
Department
based
The
right
11
provide
lubrication
topic
makes
be
it
placed' in
text,
carefully
then
keep
If
prope'rly
to
the
for
reliable
covers
situations
answered
for
including
illustrations,
on
the
product
is
reserved
fully
instructions
separately;
unnecessary
of
snowmobile
illustrated,
and
storage
theory
the
and
permit
to
become
it
readily
used,
service.
all
phases
sometimes
in
this
additional
model
and
specifications
information
to
make
detailed,
and
adjustment
information.
theory
for
the
along
with
margins
close
thoroughly
available
it
will
enable
owner,
of
servicing
arise
manual,
.
you
help. Always
number
available
changes
step-by-step
procedures.
In
and
practice
experienced
specific
provide
relationship
familiar
in
the
service shop
the
serviceman
and
thereby
the
snowmobile,
If
a
service
are
invited
be
sure
and
vehicle
contained
at
at
any
time
this
way,
are
not
service-
service
unimpeded
the
in-
between
with
the
build
and
question
to
write
to
give
serial
in
this
time
without
of
1.
Hand
Brake
2.
Hi-Lo
3.
Tachometer
4.
Speedometer/Odometer
5.
Safety
Throttle
6.
7.
Primer
and
Parking
Beam
Headlight
Stop Switch
Switch
Lock
Figure
9.
10.
11. Hood
12. Choke
13.
14.
1- 2
8.
Ignition/Lights
Manual
Instrument
Latches
Neutral
Reverse
Starter
Panel
Control
Control
Switch
Handle
Door
I '
c
2-1
TABLE
SPECIFICATIONS
TORQUE
PART
SPECIFICATIONS
Snowmobile
NO.
OF
.......•...........
Special
Service
CONTENTS
......•••...
Tools
- 45
DESCRIPTION
SECTION
SPECIFICATIONS
2- 2
2-3
H.P.
2
378103
318501
318502
319990
383966
291030
114146
162282
263308
318665
385996
*
Refer
*
*
to
the
Flywheel
Center
Three
Wrench -Flywheel
Truarc
Spring
Reli-Coil
Spark
Splined
Drive
Disassembly
Sensor
Static
Tool
Guide
Screws
Pliers
Winder
Plug
(11/16")
Wrench
Alignment
(Clamp)
Adjustment
Air
Catalogue
Puller
for
Flywheel
for
Flywheel
Nut
Installers & Inserts
Wrench -12mm
Hex.
Gauge
Tool
(Primary
Leak
Gauge
Gauge
Puller
Puller
Drive)
2-2
SPECIFICATION
o
the
legally
Length
Width
Height
Starter
Variable
Final
Reverse
Muffler.
Brake
Throttle
Track
Skis
Seating
Hood
Headlight
Taillight/stoplight
Tach
Fuel
Lubrication.
Gasoline
Carburetor
PROHIBITED:
manufacturer
required
speed
Overall
drive
Sprocket
transmission
.
Width.
...
capacity
.....
...
and
speedometer
tank
. .
..
does
for
drive.
ratio.
...
ratio
.
.
. .
Snow
not
such
represent
use.
light
Evinrude,
........................
S
Vehicles
.
Polyurethane -Specially
. . . . . . . . . . . . . . . . . . .
Johnson
are
that
Centrifugal
Single,
. . . . . . . .
. . . . . . . . . . . . .
Formed
steel,
.f-. Two
Capacity 5 Imperial
.
or
not
manufactured
they
are
tuned
equipped
springs
OMC
50:1
equipped
.
. . . . . . .
44.9
37
. . . . .
operated
Dog
muffler
with
and
replaceable
adults.
molded
rotary
Regular
........
inches
Disc
designed-fully
for
highway
with
all
the
107
inches
sheave
clutch
urethane
·
gallons,
..
with
without
Electric
for
type,
shock-absorbing
Vinyl
· .
Sealed
·
......
....
combustion
leaded
windshield
windshield
and
engages V-belt
. . . .
..
Silent
drive
. . . . . 17
and
bevel
quiet
hand
Thumb
..
20.4
wear
coated
foam
Molded
beam
OMC 262779
6 U.S.
or
OMC
use
and
devices
inches
37
inches
manual
5 to 1
chain
to
39
gears
operation
operated
operated
adjustable
inches
leaf
runners
cover,
cushion
fiberglass
GE
4002
GE 1157
gallons
lubricant
unleaded
float
type
)
RPM
Ratings
Idle .....
Transmission
Maximum
Ignition
Breakerless
Spark
Spark
Ignition
Magneto
Ignition
Lighting
Battery
Engine
Rating
Displacement
Type
Compression
Ro
tor
Apex
Rotor
Side
Specifications
oblig~tion
RPM
plug
plug
sensor
charge
coil
coil
......
....
...
.....
housing
seal
height -normal.
housing
seal
nominal
towards
·
wide
wet
21.4
1.265.
OMC
charge
without
·
· . . .
UP-77V
PrestoliteNo.
Dimensions
and
cubic
belt
engaging
at
which
magneto
. . . . . . . . . . .
gap.
. . . . . . . . . . . .
coil
resistance
coil
secondary
resistance
12
volt
32
are
of
terminals).
to
fill
.
.
ratio
width
-
minimum.
width
height
and
features
vehicles
speed
neutral
C.D.
(Capacitor
resistance
resistance
(See
Section
Canada
ampere
approximately 7-3/4
0.44
. . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . 32
Single
inlet
. . .
may
previously
. . . . . . . . . .
control
(2
coils)
. . . . . . . .
7)
Prestolite
hour
rating,
Weight
U.S.
gallons.
rotor,
air
port,
be
changed
manufactured.
will
operate.
Discharge)
total
. . . . . . . .
dry
Specific
cooled
peripheral
ignition
Champion
of
. 860 ± 75
No. 2920, U.S.A.
manifold
long,
at
5-1/8
17
lbs.,
gravity
housing,
high
any
time
vented.
performance
gressive
....
Approx.
Approx.
(Surface
.
1700-2400
0.38
7-1/4
lbs.-
Rotary
HP
@ 6500
inches
cooled
port
carburetor
notice
1100- 1400
2900-3300
2000
Gap)
Fixed
26-30
ohms
ohms
ohms
ohms
± 10%
9955X,
in
inches
high
(to
(528cc)
with
linkage
8.5
3.058"
0.354"
0.315"
3.062"
0.092"
without
top
RPM
side
pro-
to
Electrolyte
Combustion
rotor,
and
1
2-3
c
TORQUE
PART
* Nut
Nut
Nuts
Screw
Screw
*Nuts
Screw
*Nuts
*Screw
##Nut
* Nut
*Screw
Nuts
#
Screw
Setscrew
*
Bolt
*Screw
Nut
Bolt
and
Nut
Setscrew
Nut
* Nut
*Screw
#
Screw
*Screw
*
+
Nut
*Screw
*Screw
*Nut
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
SPECIFICATIONS
Ball
Joint
to
Cable
Carburetor
Drive
Engine
Engine
Engine
Exhaust
Flangettes
Flywheel
Front
Idler
Axle
Insulator
Intake
Locking
Primary
Primary
Ratchet
Rear
Axle
Rear
Idler
Rear
Suspension
Runner
Secondary
Sensor
Shifter
Spark
Throttle Cable
Truck
Truck
U
Bolt
.J
Steering
to
Solenoid
Sprocket -Chain
Frame
thru
to
and
Passage
to
Shield
Clevis
Plug
to
to
to
to
Main
Bolts
Engine
Flange
(See
Rear
to
Block
Collar
End Cap
Sliding
Tube
Pivot
Ski 5/
End
Frame
Frame
Saddle
General
Torque
Requirements
to
Frame
Primary
Frame
Cover
Front
Wheel
Cap
to
to
Cold
Adjusting
Frame
Truck
•
to
Sheave
to
Flywheel
Pinion
APPLICATION
Arm
and Rod
Frame
Assembly
Drive -Reassembly)
Axles
to
Fan
End
Axle
Main Shaft
to
Hub 5/
Frame
to
Shaft
End
Shaft
Screw
Housing
Housing
End
to
Steering
Column
SIZE
3/
8-24
5/16-24
3/ 8- 16
1/
4-28
3/
8-16
5/
16-18
3/ 8- 16
1-3/8-12
5/
8-18
3/ 8- 16
5/
16-18
#10-
24
5/ 16 - 18
4-16
3/
16-18
1"
- 16
16-24
5/
3/ 8- 16
5/
16-24
16-18
3/
8-16
#10-
24
1/
4-28
12mm
5/ 16-18
3/
8-16
7/ 16- 14
#6
#8
#10
#12
1/ 4
5/ 16
3/ 8
7/ 16
TORQUE
IN.
!
LBS.
36-60
110-120
75-85
60-84
75-85
25
- 35
350-375
90-100
25-35
160-180
150-180
60-80
7-10
15-22
25-35
35-40
60-80
120-140
220-240
340-360
FT
./
LBS.
18-20
10-12
15-17
18-20
18-20
5-7
20-25
90-110
35-45
20-25
6-7
10-12
90-100
29-31
40-45
12-15
18- 20
12-15
22-25
2-3
12-15
25-30
25-30
10-12
2-3
3-4
5-7
10-12
18-20
28-30
Specifications
vehicles
*Use
Torque
##Apply
# Apply
+Exercise
may
Loctite
result.
and
previously
Wrench
Loctite
Compound TL242
care
features
manufactured.
Retaining
to
avoid
may
Compound
over torqueing
be
changed
#40
Flywheel
(especially
at
any
time
Nut
(OMC
in a hot
without
Part
engine)
notice
and without
No. 386951)
or
damage
obligation
to
the
rotor
towards
housing
[[
i
I
~
)
--
-.
c
GENERAL
TABLE
ROTARY COMBUSTION ENGINE
SNOWMOBILE
OF
CONTENTS
THEORY.
..
SECTION
INFORMATION
3-2
3
Ell
RC
ENGINE
AND
COMPRESSION.
CARBURETION
COOLING . . . . . . . . . . . . . . . . . . . . . . .
IGNITION.
LIGHTING
POWER
PRIMARY
NEUTRAL
SECONDARY
REVERSE
PARTS
FUNCTION.
. . . . . . . . . . . . . . . . . . . . . .
SYSTEM
FLOW.
NOMENCLATURE
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . • . . . . . . . .
. . . . . . . . . . . . . . . . . .
DRIVE
CONTROL
TRANSMISSION. . . . . . . . . .
DRIVE
.................
. . . . . . . . . . . . .
...............
..
..
..
..
..
..
..
..
..
3-3
3-5
3-5
3-6
3-7
3-8
3-8
3-8
3-9
3-9
3-10
3-2
ROTARY
The
rotary
working
force a three-lobed
the
output
The
ignition/ expansion
engine
rotor
clockwise
that a vacuum
the
port
of
bustion
the
and
of
rotor
complete
a
RC
at
carburetor
CD
the
rotor
the
this
at
The
rotor,
shaft.
COMBUSTION
combustion
on
the
Otto
shaft.
engine
is
unique
the
same
direction
is
is
. In
positions
fuel/air
of
as
exhaust
process
the
revolution
(See
mixture
the. compressed
shown
is
are,
same
while
Figure
cycle
rotor
runs
on
and
exhaust
in
that
time.
around
created
thus
induced
5-7
in
8, 9 and
squished
of
time.
of
the
riding
3-2.) A set
ENGINE
(RC) engine
whereby
inside a chamber
the
same
principal
all
four
(See
the
at
positions
the
takes
place.
fuel/air
10.
out
as
course,
Steps
rotor.
in
its
is
the
expanding
induction
phases are
Figure
stationary
into
the
intake
mixture.
The
shown
taking
one
thru
orbital
of
needle
1-4
port
Then
in
an
internal
to
(fuel
as
four
3-1.)
gear
and a
engine
is
we
The
exhaust
11, 12
place
twelve
path,
bearings
THEORY
gases
rotate.
intake),
cycle
taking
As
the
in
the
fuel/air
through
closed,
have
expanding
port
and
1.
at
all
three
above
pushes
separate
combustion
from
combustion
The
rotor
compression,
engines.
place
around
rotor
moves
center,
mixture
the
open
and
compression
ignition
®
occur
and
gases
then
Various
flanks
during
an
eccentric
the
engine
turns
The
in
we
from
intake
com-
push
opens,
phases
of
rotor
)
RC
one
a
see
the
one
on
FIXED
-
@EXHAUST
(GINTAKE
1- 4
-
INDUCTION
COMPRESSION
EEJ
5-7
COMBUSTION
Figure
3- 1
D ·
8-10
EXPANSION
'I
III
11-1
EXHAUST
37135
c
3-3
and
eccentric.
notice
clockwise.
shaft
the
receives
R.C.
&
A.
B. ROTOR: The
that
in
each
One-third
one
full
6000
rotation,
shaft
power
eccentric
ENGINE
FUNCTION
ROTOR HOUSING:
Inner
surface
peripheral
the
spark
high
mount
the
intake,
The
combustion
rotor
within
which
intake
plug
performance
in
the
compression,
rotor
contains
pressure
turns
at
the
rotor
meshes
Following
diagram
rotation
three
strokes,
PARTS
(See
Center
is
trochoid
and
hole
inlet
rotor
housing
rotating
1/ 3
eccentric
housing
with
the
the
the
of
and one
times.
Figure
in
exhaust
and
fuel
port
base.
piston
expansion
the
apex,
to
the
by a
internal
2
rotor
through
eccentric' shaft
the
rotor,
complete
An
RC
but
the
rotor
diagrams
therefore,
revolution
engine
is
turning
NOMENCLATURE
3- 3)
member
shape,
ports
pump
passage
eccentric
shaft
in
the
button,
fixed
gear
of
the
three
has
cooling
through
pulse
RC engine. The
and
speed,
gear
in
pressure
and
throttle
exhaust
and
side
shaft
kept
on
the
rotor.
the
to
the
3
Figure
has
3-2
1-2-3-4-5,
advanced
turns
of
the
running
only 2000 RPM.
part
engine
fins
on
trochoid
port.
valve
seals
proper
output
rotor
and
phases
produce
in
1/4
the
eccentric
rotor
at
6000 RPM
"case."
the
outside,
surface
It
has
and
controls
of
the
engine.
transmits
power.
orientation
side
housing
we
turn
turns
and
the
motor
The
4
5
37t36
SIDE
HOUSING
ROTOR
HOUS
ING
ECCENTRIC
Figure
3-3
SHAFT
ROTOR
37333
3-4
.,.
C.
ECCENTRIC SHAFT: The
bearings.
is
separated
the
first
bustion
on the output end and
D.
SIDE HOUSINGS:
bustion
and
seals,
side
silicone
outside
E.
SEALS:
apex
adjacent
behind
which
two
piece
Side
function
caVity. A wave
side
:
'.
'"
.
'.
junction point
combustion
shaft
button
The
eccentric
by a
power
pressure,
chambers.
inlet
aluminum
for
Three
seals
chambers
it
all
seal.
seal
is
seal
cavity. Button
against
producing
carburetor
port
in
cooling.
types
fit
in
to
exert a light
three
seals
- The
to
seal
against
spring
where
chambers
side
set
and
The
They
fan
for
groove
from
side
side
housing.
eccentric
shaft
is
pushed
of
needle
member.
carries
the
fan
side
contain
intake
end housing. Side
good
of
seals
at
apex
each
pressure
are
always
seals
combustion
behind
housing. Button
apex
and
seal
seals
bearings.
the
flywheel and
and
hOUSings
the
manifold
wear
characteristics,
are
used
of
other.
in
contact
fit
in
chambers
Side
seal
and
side
combustion
have
part
shaft
turns
by the
The
It
supports
primary
manual
rotor.
grooves
starter
form
main
against
the
eccentric
in
flywheel
housings
on
rotor:
Their
Each
seal
with. The
in
from
provides a light
seal
- Button
seals
meet.
gases
of one
in
side
rotor
eccentric
full
on
sides
side
are
and
Apex
function
has a leaf
the
trochoid
side
of
the
coil
of
housing
from
force
drive
the
other
of
the
shaft
bearings
housing
made
have
seal
is
surface,
apex
seal
rotor.
eccentric
pressure
seals
They
separate
from
eccentric
spring
main
which
shaft
of
com-
sheaves
end.
com-
and
of high
fins
on
- The
to
seal
spring
is
Their
shaft
seal
the
to
load
it
is
a
of
)
I ·
SEE
TROCHOID
BELOW
F. BEARINGS: All
cated
G. F AN:
1000 cubic
housing.
H.
SIDE INLET PORT: In fan
mix
to engine
inlet
port
and
throttle
I.
PERIPHERAL
progressive
RPM. Good high
J.
TROCHOID - Shape of
K.
MINOR
L. MAJOR
1
by
OMC
A two
AXIS
AXIS
RC
piece
feet
gives
response.
OR
linkage on
- Axis
- Axis
MINOR
AXIS
roller
Lubricant
high
of
air
at
idle
easy
starting,
HIGH
speed
thru
thru
and
ball
type
mixed
performance,
per
minute to
end
and low RPM below 3000 RPM.
smooth
PERFORMANCE
carburetor,
characteristics,
the
inner
the
narrow
longer
anti-friction
with
gasoline
centrifugal
cool
Side
hOUSing,
idle
starts
surface
dimension
of
dimension
1-----
in
the
side
supplies
and good low
INLET
to open
maximum
the
OMC
of
of
the
trochoid.
MAJOR
AXIS
hOUSings
PORT: Opened by
power.
trochoid.
bearings.
a 50:1
ratio.
blower
all
Use
speed
at
3000-4000
RC
engine.
--------;~
Lubri-
supplying
and
rotor
fuel/air
of
side
torque
37137
3-5
c
M. MINIMUM CHAMBER VOLUME - (Intake
of
rotor
when
center
on
exhaust
N. MAXIMUM CHAMBER VOLUME - (Intake
when
maximum
in
3/4
O. MINIMUM CHAMBER VOLUME - (Spark
Top
Dead
formed
Rotor
past
position
P.
MAXIMUM CHAMBER VOLUME when
maximum
is
2-1/4
and
chamber
volume.
revolution
Center
by
rotor
is
1800 past
I. (SEE POSITION III)
chamber
volume.
revolutions
of
intake
formed
past
flank
formed
side
Rotor
position
on flywheel.)
A-C
position
by
Rotor
past
position
rotor
by
is
and
I and
is
flank (A-C)
of
rotor
housing.
rotor
flank
900 past
I.
rotor
2700 past
position I and
(SEE POSITION II)
Position
housing
eccentric
(Exhaust
flank
position
I.
(SEE POSITION IV)
COMPRESSION
Compression
sary
for
the
rocating
of
the
intake
Chamber
plug
side) -See
seals,
with
side
housing
They
compress
force
of
combustion
the
rotor
tion,
and
and
rotor
combustion
efficient
carbon
to
of
the
proper
engine.
Volume
proper
surfaces.
seals
carbon
gears
gases
performance.
allow
gases
the
is
and
seals
operation
Proper
(Intake
Theory
spring
referred
in
past
fuel/air
compression
in
the
above.
tension
The
fuel/air
after
ignition.
the
area
internal
poor
Grooves
to
shift
mixture
of
the
rotating
side)
seals
mixture
to
as
''blow
of the
surfaces
seals
within
in
RC engine,
is
chamber
to
Minimum
This
is
behind
and
rotor
before
Escape
by"
rotor
of
will
for
rotor
them.
the
the
accomplished
them,
flanks
of
and
rotor.
result
and
exhaust
is
side).
A-C
plug
of
is
at
shaft
side).
A-C
rotating
just
result
from
Chamber
and a
ignition
the
is
Sides,
Loss
in
seals
side).
closest
and
side).
rotor
its
and
I and
as
the
perform
combustion
indicated
eccentric
loss
must
to
(SEE POSITION
Position
housing
eccentric
(Marked
when
minimum
is
1-1/2
Position
housing
eccentric
chamber
it
is
in
of
maximum
time
of
Volume
thru
smooth
trochoid
two
and
by
of
compression
of
power
be
Position
minor
axis
of
rotor
is
at
its
shaft
TDC-
chamber
volume.
revolutions
of
rotor
is
at
its
shaft
is
neces-
the
recip-
sealing
Maximum
(spark
good
rotor
and
functions.
receive
gases
discolora-
shaft,
free
fixed
and
from
the
past
or
in-
I)
POSITION
INTAKE
POSITION
II
SPARK
PLUG
CARBURETION
GaSOline,
However,
ture
becomes
results,
mixed.
into
an
The
intake
chamber
Gasoline
12:1
to
for
different
leaner
conditions;
buretor
to
the
in
when gasOline
the
fuel
This
mixture
air
stream.
atomized
manifold
surface.
vapor
18:1
by
purposes.
mixture
avoid
is
designed
engine
for
its
liquid
highly
and
mixture
and
will
weight.
is
desirable
lean
these
state,
is
flammable
air
must
is
then
This
is
is
rotary
burn
Mixtures
Idling
mixtures
to
deliver
various
combined
the
later
chamber,
when
for
burns
relatively
with
and
burns
be
correctly
atomized
function
requires a relatively
conditions.
by
of
vaporized
with a few
mixed
of
different
maximum
for
high
the
correct
slow
air
to
very
proportioned
spraying
the
carburetor.
in
particles
with
air
proportions
economy
speed
proportion
with
an
even
form a vapor,
fast.
To
and
through
the
in a proportion
under
operation.
fine
carburetor
clinging
are
rich
normal
of
fuel
flame.
the
mix-
obtain
mixture;
best
thoroughly
nozzles
barrel,
to
the
from
required
load
The
car-
and
air
POSITION
a
37137
POSITION
III
EXHAUST
IV
3-6
INDUCED
PRESSURE
$
FUEL
FORCED
BY
ATMOSPHERIC
LOW
~
Figure
/
VENTURI
UPWARDS
PRESSURE
3-4
17136
The
valves
A
in
ticular
The
creating a partial
it
air
the
fuel
During
engine
the
peripheral
engine
power
air
the
drawn
shutter,
to
gaSOline
fuel/
choke
flo'w
carburetor
permit a precise
small
chamber
the
carburetor
point· the
venturi
is
rushed
stream
Movement of the
fuel/air
mixture
carburetor
at
A
throttle
drawn
throttle
into
richer
A
restrict
air
is
from
has
along to
and
vaporized.
mixture
is
start-up
thru
the
side
admits
port
performance
high engine
or
through the
opens
the
engine.
fuel
mixture
called
<l;nd
mixture.
opened and the
a choke,
the flow. of
less
the
carburetor.
is
essentially a simple
amount of .fuel
holds the
throat
throat
the
vacuum
rotor
admitted
and low RPM (below 3000 RPM),
throttle.
at
butterfly
or
air
When
fuel
extend down into
is
re~ricted
effect
of
which
the
firing
in
the
thru
the
carburetor
' to
the
inlet
port.
the
fuel/air
Use of the
low
speeds,
speeds.
valve
carburetor.
closes,
is
regulating
is
required
is
placed
air.
When the choke
allowed into
normal
standard
as
it
is
consumed
reducing
draws
chamber,
housing
rotor
housing
At high
mixture
andperipheralportinggives
in
the
To
for
starting a cold
into
the
operating
ratio
metering
to
flow to
the
fuel
by a
venturi
air
pressure
fuel
from
the fuel
creates a suction
barrel
air
of
and
thru
speeds,
to the engine by opening the
side
inlet
throat
vary
the amount of
the
regulates
the
throat
shutter
stream
temperature
gasoline
device. Needle
the
carburetor
by the engine.
chamber.
(see
Figure
in
the
air
the
jet
nozzles.
is
swirled
into
two
fuel
progressive
port
speed
forward
resulting
and
about
which
the
engine.
different
is
drawn
provides
the
of
the
fuel/air
engine. A
of
is
closed,
in a richer
is
reached,
air
is
allowed
throat.
Nozzles
At a
par3-4).
stream,
As
in
the
draws
The
ports.
into
the
linkage
good
maximum
amount
engine,
mixture
second
the
jets,
more
the
)
on
of
to
)
--~
•
INDUCTION
COOLING
I\IR
AIR
COOLING
The
engine
and fuel
,
the
outside
is
mixture
of
the
TOP
cooled
from
thru
the
engine. See
engine
"
--
two
Figures
-
different
itself;
3-5
t
I
0
I
t
I
'I
../
,
I
(
I
!
sources,
and 2.)
and
3-6.
MUFFLER
J
air
1.)
forced
the
induction
FUEL
TANK
thru
fins
air
on
Figure
37227
3-5
c
3-7
c
--_I
- - -
The
The
air/fuel
thru
openings
bustion
Cooling
panel,
trifugal
then
pushed
the
exhaust
escapes
mobile.
THE
OPERATING
ENGINE.
INDUCTION
COOLING
induction
mixture
chamber.
and
in
air
is
thru
openings
blower
thru a slot 'behind
.
HOOD
at
thru
pipe
MUST
IGNITION
The
voltage
chamber
chamber.
voltage
and
ignition
in
magneto
This
system
1.
Flywheel
2.
Stator
3.
Ignition
4.
Power
5.
Ignition
The
following
The
flywheel
(See
Figure
generate a voltage.
Here
it
is
the
sensor
is
triggers
the
voltage
coil.
the
secondary
electric
and
assembly
and
sensor
Pack
coil
3 -7.)
changed
magnet
generated.
an
stored
The
capaCitor
thus
is
charge
sequence
rotates
electronic
AIR
air
the
drawn
the
the
and
FOR
current
ignites
made
assembly.
RB
assembly
The
This
to
rotates
in
ignition
firing
AIR
Figure
and
fuel
thru
the
engine
enters
rotor,
side
the
flywheel
cooling
. .
thru
louvers
under
rate
of
and
muffler.
the
the
the
manual· starter
1000
rotor
housing
Air
under
muffler
in
cubic
and
end
rotor
the
feet-per
the
is
side
before
right
fins
hood
out
called
side
and
the
charge
housing
entering
of
by
a two
minute.
then
is
pressurized
bottom
3-6
and
the
instrument
piece
The
ducted
of
the
cooling.
is
ported
the
around
1. 1 NOTE
BE
CLOSED
PROPER
discharge
which
the
up
of
the
coil
assembly
of
events
around
magnets
voltage
DC
and
by
This
smaller
switch
the
capacitor
coil
across
ON
THE SNOWMOBILE WHEN ·
COOLING
(CD)
jumps
compressed
following
will
the
in
the
(AC)
stored
the
ignition
in
being a transformer,
the
OF
ignition
the
major
illustrate
stator
voltage
Power
to
spark
and
flywheel
flows
in a capacitor
sensor
flows
Pack
discharge
plug
THE
syt>temgenerates
spark
fueVair· mixture
components:
how
and
into
gap.
MUFFLER
plug
this
charge
the
two
the
Power
. . At
coil
and a smaller
into
RB
to
turn
into
the
steps
If
the
gap
system
coil
charge
the
same
Power
on
primary
up
the
engine
AND
within
works.
assembly.
Pack
Pack
allowing
voltage
com-
cen-
air
is
and
snow-
a high
the
in
the
coils
RB.
time
AC
RB
of
the
speed
REFERENCE
S -
SOUTH
F -
FLYWHEEL
C -
LAMINATED
POLE
Figure
PICTURE
-
SHOE
COIL
3-7
CORE
11
137
I
•
3-8
should
in
Power
reach
Pack
approximately
LIGHTING
The
This
the
electric
The
lights
alternator
and
alternating
bridge
alternator
rectifier
battery
starter
are
voltage
frequency
diode
from
the
when
POWER
The
transmission
front
sheave
ary
diameter
a
mission
the
transmission
primary
sembly
movable
axle
which
assembly
sheave
transmission
PRIMARY DRIVE
The
engine
assembly
than
primary
belt
is
sheave
halves
sheave
the
when
belt
RB
will
SYSTEM
coils
in
current
is
then
motor.
output
turned
FLOW
assembly
propels
is
attached
primary
belt.
sheave
the
rotating
rides
assembly
are
separated
half.
7300
cut
out
produce
proportion
output
and
used
used
is
automatically
on.
the
directly
has
its
sheave
is
centrifugally
engine
at
idle
on a
(see
RPM,
the
the
ignition.
alternating
to
is
to
charge
to
power
transmits
vehicle
to
own
mounting
assembly.
speed
speed
ball
Figure
by a compression
built
the
engine
converted
the
headlights
increased
power
along
the
eccentric
operated
reaches
or
below
bearing
3-8).
the
pedestal
in
overspeed
current
speed.
to
direct
battery.
to
from
the
track.
The
two
and
2800
to
2800
between
The
primary
spring
protection
which
changes
current
Direct
and
taillights,
maximum
the
engine
The
shaft.
The
and
is
are
connected
engages
3200 RPM. When
to
3200 RPM,
the
halves
sheave
in
the
current
charge
to
primary
second-
larger
the
trans-
of
hub of
by
and
as-
in
the
in
by
the
the
the
)
a
)
Neutral
A.
B.
Emergency
Sheave
Garter
C.
Spring
End
D.
Movable
E.
F.
Trahsmission
Fixed
G.
Eccentric
H.
Ball
I.
J.
Spring
K.
Compression
L.
Neutral
Flywheel
M.
Bolt,
N.
Shaft
o.
Spring
Neutral
P.
Spring
R.
Lockout
(Activating)
Cap
Half
Sheave/Flywheel
Shaft
Bearing
Cup
Lockout
Nut
End
Cap
Lockout
Plunger
Starting
of
Sheave
Belt
Spring
Balls
to
Rod
As
spring
axially
the
in
against
A
engine
the
end
speed
the
TRANSMISSION
increases,
cap
outward
movable
against
sheave
LOCKED
Figure
centrifugal
the
half.
As
IN
NEUTRAL
3-8
effect
contour
the
sheaves
forces a garter
of
the
end
cap
are
brought
G
H
and
)
37138
c
NUT
TRANSMISSION
POSITION -BELT
HIGH
ENGAGED
SPEED
3-9
3
713
9
TIONING
BECAUSE
RPM
TOO
HIGH
37140
-
together,
diameter
Figure
sheave
eter.
presenting
the
NEUTRAL
A
ing
plunger
through
able
control
apprOximately 2000
When the engine
spring
spring
sheave
covered
(P-Figure
3-8)
lockout
shown
RPM,
sheave
the
through
the
SECONDARY DRIVE
the
of
3-9). Since
halves
In
this
the
speed
at
which
CONTROL
neutral
during
sheave
cannot move
plunger
neutral
starting,
is
the
is
spring
will
will
toward
the
3-8)
balls.
in
Figure
the
garter
to
move away
the
position.
actuated,
expand
control
splines
then
holes
inward. The
eccentric
transmission
the
primary
spread
way,
engine with a
it
half,
actuated
ride
the
is
Spring
3-10.
Figure
sheave
the
belt
apart,
the
engine
is
operating.
mechanism
warm-up
a cone on
of
the
eccentric
preventing
and will engage only when
RPM.
is
running above
by
centrifugal
up
the
fixed
sheave.
in
the
eccentric
not
pushed
in
because
(R-Figure
If
the
spring
from
shaft.
See
will
neutral
Figure
3-9
belt
is
assembly,
length
allowing
transmits
mechanical
is
used
period,
the
it
from
approximatley
effect.
ramp
In
in, the
the
movable
3-8)
engine
close
the
fixed
lockout
The
movable
3-8.
forced
the
and idle. When
end of
of
doing thiS,
shaft.
speed
outward
increasing
remains
belt
to
power
advantage
to
prevent
the
shaft
and
engaging
See
the
end
When
spring
sheave
will
therefore
is
now
and allow
sheave.
balls
sheave
constant,
ride
through a variable
plunger
into
Figure
cap
the
loaded
Spring
will
to
ride
belt
on a
most
the
drive
the
neutral
raises
the
path
the
belt.
the
engine
2000 RPM,
3-10. The
and
push
movable
the
neutral
plunger
now
covers
be
compressed
reduced
the
movable
(R)
then
will now
on a
speed
the
secondary
smaller
favorable
from
lockout
two
of
the
The
neutral
is
the
the
movable
sheave
lockout
(A-Figure
the
neutral
to
below 2,000
half
will
then
move
outward,
be
locked
larger
(see
diam-
ratio,
for
engag-
balls
mov-
below
garter
garter
has
rod
as
of
the
push
in
Figure
3-10
The
secondary
that
detects
the
drive
need
mechanism
for
more
incorporates a torque
power
for
steep
inclines
senSing
or
deep snow.
device
3-10
The
mechanism
gether
the
yields
mitted
the
17:39.
REVERSE TRANSMISSION
"Forward"
means
released
to
drive
chain
The
drive
an
overall
from
front
axle.
The
ratio
The
reverse
of a "dog" type clutch. IN
while a
Shifting
lower
and
ratio
the
between
gear
gear,
must
immediately
the
transmission
track.
varies
drive
secondary
the
secondary
is
the
input
gear
set
be
done with
forces
from
range
of
sheave
designed
shaft
engages
the
the
secondary
ratio
and
provide a higher
3.3
to 1 in
approximately 5 to
assembly
sheave
as
drives
to
low to .67
assembly
part
of the
the output
"reverse"
reverse
I_ I NOTE
engine
at
idle
sheaves
to 1 in
1.
through a drive
and
secondary
gear,
rotation
and
machine
Power
the
front
shaft
directly
the
dog
of output
at
closer
high which
torque
is
trans-
chain
axle
drive.
clutch
shaft.
rest.
to-
by
)
to
to
is
In
is
)
TROUBLE
SECTION
SHOOTING
4
t
till·
(
TABLE
DESCRIPTION.
TROUBLE
STARTING.
STARTING -MANUAL
STARTING -ELECTRIC
RUNNING - LOW
RUNNING - HIGH
RUNNING - HIGH AND LOW
SHOOTING
OF
• • • • . . . . . . . • • • . • • . .
PROCEDURES.
. • • . . • • • • • • • • • • • • • • • •
SPEED
SPEED
CONTENTS
STARTER.
STARTER.
...••
..........••
SPEED.
• • • •
...
• • •
• • •
. .
• •
.•
•.
••
••
••
••
4-2
4-3
4-3
4-3
4-4
4-4
4-4
4-5
4-2
DESCRIPTION
This
section
Steps
to
ance
are
Being
snowmobile
systematic
be
located
Any
service
1. Identifying
2.
Determining
3.
Correcting
Familiarity
performance
tors
which
fuel
mixtures,
ment.
are
outlined
tion
formance
experience
Engine
discussed
12.
provides
be
followed
outlined.
able
to
is
approach
and
identified
operation
with
is
affect
compression,
theory,
in
on
the
inside
Familiarity
of an engine
is a great
in
locate
as
important
to
the
problem
the
cause
the
problem.
the
important
engine
compression,
Section
front
with
asset
trouble
determining
the
trouble
in
can
factors
3.
are
shooting
cause
as
shooting
minimum
be
broken
of
the
which
in
making a correct
performance
ignition,
Correct
cover,
factors
Similarly
here.
procedures
causes
of
trouble
being
problem,
able
is
time.
down into
affect
include
and
carburetion,
fuel
mixture
and
fuel
which
helpful.
of
unsatisfactory
in
an
to
correct
important
three
and
rotary
service
the
proper
blending
contribute
quality
ignition
for
The
for
the
improperly
the
if
the
steps:
combustion
diagnosis.
this
is
discussed
to
skilled
of
system
and
snowmobile
abnormal
drive
snowmobile.
perform-
operating
trouble.
trouble
the
power
mechanic's
is
engine
Fac-
fuel
adjust-
flow
in
Secper-
A
to
and
is
)
)
c
TROUBLE
PROCEDURES
Trouble
operating
lowing
a.
b.
c.
performance.
An
for
trouble
provide
clue
to
Preliminary
1.
2.
3.
shooting
problem
steps:
Obtaining
Preliminary
Use
of
Trouble
accurate
shooting.
valuable
the
cause
Inspection
Engine
Spark
Carburetor
turns
at
spark
an
description
SHOOTING
to
determine
may
be
broken
accurate
inspection.
information
of
the
over
plug
adjusted
Check
The
problem.
freely
properly
description
Chart
of
the
down
to
the
trouble
owner's
which will
cause
into
the
of
the
trouble
analyze
is
essential
comments
serve
of any
fol-
engine
may
as
4-3
k.
Faulty
1.
Weak
2.
Engine
a.
Low
.
a
3.
4.
b.
Spark
c.
Cracked
Engine
a.
Fuel
b.
Carburetor
of
c.
Fuel
d.
Choke
Engine
a.
External
terference
or
missing
battery
turns
over
static
air
plug
loose
or
starts,
pump
not
adjustment
filter
clogged
not
working
won't
turn
parts
or
faulty
extremely
leak
broken
but
stops
working
low
speed
over
assembled
gaskets
electric
easy
check
engine
properly
castings
immediately
system
on
intake
starter
blocked
wrong
systems
or
causing
out
in-
(
4.
Power
5.
Air
cleaner
6.
Air
intake
7.
Cooling
under
8.
Proper
9.
Static
STARTING
1.
Hard
a.
Low
b.
Old
passages
c.
Choke
d.
Primer
e.
Carburetor
correctly
port
fan
muffler
fuel
air
leak
to
start
static
fuel,
not
butterfly
clean
clean
intake
not
and
check
or
air
water
working
not
working
and
and
not
not
restricted
oil
in
within
won't
leak
in
low
speed
closed
properly
restricted
restricted
tank
limits
start
check
(see
fuel,
properly
properly
needle
completely
installed
and
fan
(see
Section
or
restricted
not
at
idle
air
exit
Section
5)
fuel
adjusted
5)
5.
b.
Rotor
meShing
c.
"J"
type
d. No
e.
Bearings
f.
Rotor
g.
Engine
Weak
a.
Faulty
b.
Faulty
c.
Faulty
d.
Grounded
e.
Flywheel
f.
Faulty
g.
Ignition
assembled
gap
(wrong
gasket
cracked
castings
spark
charge
sensor
Power
ignition
plug
type).
under
seized
or
no
ignition
not
switch
upside
installed
surface
or
broken
cracked
spark
coil
coil
Pack
switch
magnetized
coil
or
leads
not
working
down,
instead
gap
or
broken
or
wire
of
plug
gears
surface
not
gap
f.
Bad
spark
plug
g.
No
spark
h.
Air
cleaner
i.
Clogged
j.
Engine
or
fuel
line
flooded
intake
or
filter
blocked
or
restricted
h.
Sensor
STARTING - MANUAL
1.
Manual
engage
a.
Friction
gap
starter
flywheel
spring
adjustment
(see
STARTER
pulls out, but
bent
or
burred
Section
starter
7).
does not
4-4
2.
b.
Excess
spring
c.
Pawls
d.
Pawls
Starter
bent
frozen
rope
or
or
does
incorrect
burred
(water)
not
return
in
grease
place
on
pawls
or
3.
i.
Starter
drive
Starter
a.
Drive
be
b.
Lubricate
does
gear
is
will
not
gear
removed).
helix.
not
engage
not
free
disengage
is
not
free
with
on
helix.
flywheel
on
helix
engine
ring
(debris
because
gear.
must
J
a.
Recoil
b.
Starter
c.
Loose
3.
Clattering
a.
Friction
b.
Starter
c.
Excess
spring
d.
Dry
STARTING -
1.
Starter
a.
Weak
b.
Loose
connection
c.
Faulty
spring
housing
or
missing
manual
spring
housing
or
incorrect
starter
ELECTRIC
cranks
spindle
too
battery
or
corroded
starter
broken
bent
parts
starter
bent
bent
STARTER
slowly
solenoid
or
binding
or
burred
grease
connections
or
solenoid
on
pawls
or
ground
wiring
or
RUNNING - LOW
1.
Low
speed
a.
Incorrect
b.
Incorrect
c.
Loose
d.
Spark
e.
Weak
f.
Loose
g.
Power
h.
Bad
fold
i.
Choke
j.
Low
RUNNING - HIGH
or
plug
coil
port
or
not
static
SPEED
miss
gas -lubricant
idle
adjustment
broken
electrical
missing
SPEED
ignition
terminal
butterfly
gaskets
operating
air
leak
ratio
coil
loose
connections
not
closed
around
correctly
check
(see
wires
completely
intake
Section
-I
mani-
5)
2.
d.
Worn
e.
Faulty
windings)
Starter
a.
Weak
b.
Loose
c.
Broken
d.
Faulty
e.
Faulty
f.
Moisture
g.
Broken
spring
h.
Faulty
windings)
armature
field
will
not
battery
or
corroded
wire
ignition
starter
in
or
field
or
crank
in
starter
worn
or
brushes
armature
engine
connections
harness
key
switch
solenoid
brushes
armature
or
or
motor
or
or
spring
(shorted
or
ground
connector
solenoid
broken
(shorted
or
wiring
brush
or
open
open
1.
2.
High
a.
b.
c.
d.
e.
f.
Poor
a.
b.
c.
d.
e.
speed
miss
Water
in
Weak
spark
ArCing
Bad
Low
Carburetor
Incorrect
Old fuel
Fuel
Fuel
Bad fuel
around
spark
static
acceleration,
hose
filter
pump
fuel
ignition
plug
air
leak
cheCk
inlet
needle
top
rpm
gas -lubricant
pluged
or
restricted
kinked
coil
or
(see
sticking
is
low
ratio
leads
Section
5)
4-5
r
f.
Pulse
g.
Loose
h.
Weak
i.
Bad
j.
Carburetor
k.
Power
1.
Overheating
m.
Low
n.
Fuel
RUNNING -
1.
Engine
a.
Incorrect
b.
Improper
line
to
or
broken
coil
Power
port
static
air
tank
vent
mGH
AND
overheats
gas -lubricant
engine
fuel
pump
high
tension
Pack
passageways
butterfly
leak
restricted
LOW
not
check
SPEED
assembly
restricted
lead
restricted
opening
or
blocked
ratio
completely
2.
c.
Cooling
d.
Cooling
e.
Cooling
f.
Dirty
g.
Air
h.
Intake
hood.
Engine
a.
No
b.
Seized
c.
Broken
d.
Cracked
air
intake
seizes
oil
in
fins
fan
air
filter
air
gas
rotor
rotor
or
blocked
intake
exit
restricted
restricted
box
leaking,
(stops
or
main
or
stationary
broken
by
restricted
getting
suddenly)
bearin
engine
foreign
air
g
gear
castings
material
from
under
)
)
•
c
TABLE
DESCRIPTION.
TUNE-UP
OF
. . . . . • • . . . • • . • . • • . •
CONTENTS
.•
SECTION
PROCEDURES
5-2
5
c
FACTORS
FUEL
IGNITION
COMPRESSION.
NEW
TUNE-
STATIC
CARBURETOR
LOW
IDLE
SPARK
AFFECTING
SYSTEM
VEffiCLE
UP
PROCEDURES
AIR
LEAK
SPEED
ADJUSTMENT
PLUG
PERFORMANCE.
.•..•....••.•.....
SYSTEM.
DELIVERY.
ADJUSTMENTS.
NEEDLE
•.••••.••••••
. . • • • . • • • . . . • • • •
. . . . • • • • • • • • • . • •
CHECK.
VALVE
SCREW.
• . • • • . . • • .
. . • . . • • . . . • •
• • • • • . • • • •
. . . . . . .
AND
. . . . . . . .
! • • • • • •
• • .
••
.•
••
••
..
..
••
5-2
,
5-2
5-2
5-2
5-3
5-3
'-
5-5
5-7
5-7
5-7
5-2
DESCRIPTION
The
have
the
an
and a
complete
ation,
procedures
purpose
been
lost
snowmobile.
understanding
familiarity
tune-up
and
to
Section 4 for
and
FACTORS
In
the
normal
aware
long
assured
preferably
ing one
obtained
by
FUEL
is
emptied
at
ture
fuel
affect
may
or
starting,
discussion
of
period
if
It
is
seldom
or
by following a
correcting
SYSTEM
A
fresh
necessary
of old fuel,
the
beginning
may
delivery,
high-speed
cause
incorrect
the
decrease
of
a
complete
at
the
advisable
two
items
all
fuel
for
cause
as
operating
use
rough
on
carburetion.
of a tune-up
through
of
with
procedures.
instructions
wear
The
successful
principles
factors
AFFECTING
operation
in
performance
time.
mixture,
peak
hard
running,
Economical,
tune-up
start
of
the
to
only.
items
of
definite
affecting
with
engine
rinsed
the
season
starting,
the
result
performance.
difficulties
of
the
manual
or
is
to
restore
or
deterioration
completion
of
rotary
affecting
Refer
trouble
for
of
an
season.
attempt
Time
the
performance.
out,
installed
and
stalling,
of a faulty fuel
poor
performance.
to
shooting
storage
engine,
trouble-free
is
performed
to
improve
will
be
and
thorough
power
and
correct
at
every
Incorrect
at
idle
choke by
fuel
and
power
combustion
Section 3 for
and
of
of a
procedures.
are
included
performance
one
or
tune-up
engine
This
principles
PERFORMANCE
the
operator
which
takes
at
performance
saved
and
procedure
performance.
ratio
of
lubricant
The
tank
and
refilled
tune-up. A stale
faulty
pump
carburetor
speed.
the
operator
economy.
may
place
operation
least
once
more
should
with a
operation.
or
clogged
needle
Faulty
choke
may
See
more
section
in
slowly
lasting
of
analysis
and
be
fresh
Section 3 for
which
parts
depends
operation,
gives
of
oper-
Lubrication
Section
not
be
fully
over
can
best
each
year,
by
correct-
results
and
gasoline,
removed,
supply
fuel
mixInadequate
filter,
adjustment
cause
will
operation
hard
)
of
on
12.
a
be
a
IGNITION SYSTEM
A good
formance.
system
speed
are
to
the
theory,
COMPRESSION
Compression
ber
checked
compression
compression
It
is
with
ignition
A weak
components,
performance.
frequently
operation
and
Section 7 for
to
realize
by
using
essential
an
engine
checked
of
must
maximum
check
cannot
that
tune-up.
system
spark,
will
The
first
the
engine. See
complete
be
well
the
static
is
important
be
tuned
the
static
is
of pr-ime
which
cause
spark
in a tune-up
sealed
power
air
successfully
air
importance
may
be
the
hard
starting, ~ misfiring,
plug and
Section 3 for a discussion
ignition
by
and
performance.
leak
because
leak
the
check
an
check
ignition
because
system
rotor
described
result
and
engine
to
give
be
made
for
system
of
analysiS.
Compression
with low
peak
of
faulty
or
their
seals
in
on
Page
peak
performance.
before
engine
components
per-
ignition
poor
high-
importance
on
ignition
the
chamcan
be
5-5.
or
uneven
proceeding
A
)
5-3
NEW
Complete
are
included
with
each
understands
of
important
eration.
a.
Be
sure
lbs.
b.
Be
sure
minal.
c.
Be
sure
mixture
d.
Caution
power
time,
tomer
Manual.
e.
Be
sure
correctly,
electric
VEHICLE
instructions
in
the
snowmobile.
the
instructions
things
spark
Cold) with
spark
the
correct
into
tank
the
customer
until
at
short
periods
to
follow
that
the
espeCially
starting,
Owner's
Be
to
plug
spark
plug
through
least
the
customer
and
check
DELIVERY
for
putting
Manual
sure
the
given
in
when
is
installed
plug
gasket
lead
is
securely
gasoline
not
one
of
break-in
such
reverse
a fine
to
operate
tankful
full
power
understands
things
and
procedure
shift
a new
and
assembly
customer
it.
The
putting
and
tightened
in
place.
lubricant
mesh
strainer.
a new
of
fuel
may
as
lever.
snowmobile
instruction
receives
following
a new
snowmobile
securely
attached
mixture
engine
has
been
used.
to
neutral
used.
operate
be
described
how
the
into
this
manual
list
is a reminder
to
spark
is
used.
at
continuous
During
Instruct
in
the
control,
operation
packed
and
into
op-
(12-15
plug
ter-
Pour
full
this
the
cus-
Owner's
the
engine
choke,
ft.
TUNE-UP
Components
into
three
1.
items
2.
items
3.
items
Any
tune-up
Correction
all
items
factorily.
ciencies
performance
those
ing
tion
shooting,
a.
by
parts
for
performance.
4.
Repair
is
Test
1.
Neutral
Can
and engine
PROCEDURES
which
affect
groups,
affecting
affecting
affecting
of
affecting
Attempts
run
namely:
compression,
ignition,
carburetion.
procedure
items
altering
or
of a
covered
vehicle, checking
transmission
affecting
compression
to
increased
tune-up
and
replacement
in
control
at
idle
engine
should
overcome
carburetor
fuel
which involve
Trouble
Sections 6 through
be
speed?
power
cover
carburetion
and
ignition
compression
settings
consumption.
shooting
of
parts,
particularly
locked
in
adjustments,
and
performance
these
groups
should
have
or
will
This
procedures
as
determined
11.
the
following:
neutral
when
in
not
been
ignition
result
section
cleaning,
are
machine
can
the
order
be
attempted
corrected
system
in
poor
covered
through
be
divided
overall
covers
and
checkin
trouble
is
at
given.
until
satis
defi-
only
Sec-
rest
-
5- 4
-
p
n=rrsr_
..
-
2.
3.
4.
5.
b.
Perform
c.
If
starter
and
Check
tolerance
If
inspect
it
and
bowed
must
Function
Engine
Ski
After
neutral
celerate
control
mately
engine
excessive
is bowed
alignment
and
listen
for
the
a new
then
be
replaced.
performam!
running
is
2000
static
knocks,
for
is
of
brake
control
engine
spring
rpm.
air
fan
knocks.
end
play
.011
play
roller
outward
retaining
the
ball
and
handling
snowmobile,
knob out
to
see
actuated,
leak
test,
check
housing
to
for
by
pushing
.023.
is
detected
bearing
then
ring
type
(see
thrust
reduce
to
lock
if
transmission
and
cannot
see
page
loose
fan
Section
and
between
retaining
the
roller
installed.
bearing
engine
transmission
5-5.
or
8).
pulling
ring
bearing
speed
is
in
be
engaged
flywheel.
Rock
on flywheel.
flywheel
in
the
If
the
in
the
....
to
in
neutral.
neutral.
above
Remove
fan
back
and
fan
end
should
retaining
fan
end
---
idle
and
approxi
and
End
side
housing,
housing.
be
re-seated
ring
side
-
pull
Ac-
Neutral
manual
forth
play
is
not
housing
)
-
If
d.
If
quired
e.
Test
high
f.
Check
plug
g.
Remove
tion
primer
h.
Inspect
ment
i.
Thoroughly
j.
Tighten
plug
k.
Check
1.
Start
Section
m.
Repeat
adjustment.
static
ignition
tension
or
6).
and
to
engine
air
leak
(see
Section
system
lead.
spark
replace
and
drain
Install
operation.
fuel
pump
gasket.
lubricate
all
external
specified
track
tension
11).
test
run
check
9).
See
plug
to
as
necessary.
fuel
tank,
and
torque.
and
allow
on vehi.cle.
is
not
using
spark
Section
be
sure
tank,
refill
hoses.
snowmobile
bolts,
and
ski
alignment
to
warm
nuts,
satisfactory,
checker
7.
it
is
the
flush, -and
with
fresh
Clean
filter,
(see
Section
and
screws,
(see
up.
Check
carburetor
and
correct
clean
fuel
Section
Check
engine
or
overhaul
neon
Tester.
type.
thoroughly
mixture
replace
12).
and
11).
track
low
Clean
(see
and
filter
retorque
alignment
speed
is
re-
Inspect
spark
Sec-
check
ele-
spark
(see
needle
n.
o.
After
stop
speeds.
Clean
tomer.
engine
and
Check
and
Fog
has
restart
acceleration
dry
snowmobile
motor
run
sufficiently
it
several
for
from
thoroughly,
storage
to
times.
low
using
indicate
Operate
to
high
before
OMC-RC
satisfactory
it
at
speed.
returning
oil
(see
condition,
high
and
it
to
Section
low
cus-
12).
5-5
STATIC
The
objective
seals,
combustion
ings,
of
pressure
the
leakage,
the
Figure
60
pressure,
sure
sure
apparatus
at
ber,
of
TEST
rotor
This
is
and
each
combustion
engine. The
past
reference
5-1.
The
test
psi.
is
throttled,
read
(G)
threaded
from
the
chamber
PROCEDURE
1.
Screw
place
AIR
LEAK
of
this
housing
accomplished
chambers
rotor
to
an
apparatus
The
read
on
is
piped
which
12
on
adapter.
and
housing,
orifice
amount
the
rotor
pressure,
pressure
on
the
as
the
test
thru
into
the
it
escapes
being
tested.
m.m.
chamber.
it
CHECK
test
side
by
pressurizing,
formed
and
of
known
of
air
seals
across
is
connected
is
regulated
reference
passes
pressure
the
swivel
spark
by
adapter
is
to
determine
housings.
by
the
then
may
leaking
three
measuring
Air
is
diameter,
flow
thru
be
judged by
the
orifice,
at
(A)
pressure
thru
the
gage
at
at
plug hole and
(G)
(F) and
past
into
one
at a time,
rotor
supplied
the
to
at
(B)
gage
orifice
(E).
into
the
spark
the
condition of
each
flanks,
the
amount
at
a known
and then
test
to
an
to
at
The
thru
side
plug hole with
apparatus,
the
pressure
the
test
air
supply
60
psi,
at
(C). The
(D),
air
the
the
combustion
seals
to a test
to
flow
12
the
of
the
the
side
of
leakage
reference
gage and
and
drop
pressure.
greater
the
reference
air
the
test
thru
the
m.m.
adapter
and
apex
O-ring
rotor
three
hous-
out
hence
from
See
than
pres-
pres-
test
cham-
seals
in
--
2.
Turn
flywheel
on
the
rotor
now
at a minimum
so
flywheel TDC
housing
volume
minor
~
Set
this
rotor
position
motor
3.
Attach
until
within ±
from
air
the
fitting
reference
position
gage
carefully
1/8"
of
pressure
(A)
(C)
to
A SAFETY WARNING
Avoid moving
minor
wrench
Get
Never
(CONNECTION
TO
axis
on
a good
use
FITTIN~
AIR SUPPLY)
the
flywheel index
bolt
center
the
primary
hold
hands
to
J
REFERE~
REGULATING ORIFICE
VALVE
on
hold
GAUGE
line
wrench
mark
is
axis
as
shown
position.
SAFETY WARNING
with
the
bolt
and
air
reads
or
end
cap
when
flywheel
(.070"1.0.)
the
center
injure
supply and open
about
the
)
the
60
psi.
mark
beyond ±
engine
bolt, flywheel
performing
rim,
or
1J
TEST
GAUGE
lined
up with the
in
Figure
flywheel index
line
or
careless
may
an
injury
SWIVEL
5-2.
the
engine
regulating
1/8"
motor.
nut
or
this
operation.
may
THREADS WI
J
thru
bolt
Rotor
is
mark
in
may
operator.
valve
(B)
from
the
Use
a
fan
nut.
result.
AOAP~
(12
M.M.
"O"RING)
37141
Figure
5-1
Figure
5-2
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