John Deere Snowmobile Operators Manual

SPITFIRE®

Snowmobile

(Serial No. 155,001-

1'10,~

~

JOHN

DEERE

)

RLE

MARK

THIS

IT

FOR

REVISED

KEEP

MACHINES

SERIAL

OM-

MANUAL.

OM-M68421

BELOW

NO.

Horicon Works

68928

155,001

Issue

lmtO

AND

FO

IN

USA.

To The Operator

This

safety

tant

safety

you

see

this

bility

of

personal

the

message

This operator's manual contains Sl Metric equivalents which follow immediately after the U.S. customary units of measure.

When in need of major parts or service, be prepared to provide your John Deere dealer with both the machine and engine serial numbers. Record these serial numbers in the space below.

This operator's manual is prepared for: John Deere SPITFIRE Snowmobiles (Serial No. J34AK 155001

).

alert

symbol

messages

symbol,

injury

that

follows.

in be

this

alert

and

identifies

impor-

manual. When

to

the

possi-

carefully

read

M-

Snowmobile Serial Number

Engine Serial Number

JOHN DEERE SPITFIRE SNOWMOBILE

Machine Serial No.

Engine Serial No.

Date

of

Purchase

(To be filled

_______

________

in

by

_

purchaser)

(

UNPACK COMPONENTS

1.

Skis.

2. Windshield.

3. Operator's manual.

4. Bag of parts.

ASSEMBLE COMPONENTS

Install Skis

1.

Remove ski bolts, washers, lock nuts and cotter pins from bag of parts.

2. Insert bushing into spindle. Use Never-Seez on

w

ffi

I

~

(.)

bushing.

3. Position ski under ski saddle.

4. Install ski bolt with head of bolt facing out.

Assembly

5. Install washer and lock nut. Torque nut to 39 ft-lbs

(52 Nm).

6.

Install cotter pin through ski bolt.

Install Windshield

1.

Remove washers, screws, J-clip and retaining nuts from bag of parts.

2.

Use screws and washers to secure windshield to hood.

NOTE: Install J-clip behind screw "A". Place headlight

in

wiring harness behind screw "8".

J-clip. Install hood lanyard

PREDELIVERY CHECK LIST

CAUTION: When starting snowmobile, support machine so track ground. Check throttle for proper operation.

1. Align skis and check steering linkage.

2.

Check track tension and align.

3.

Check brakes. Adjust if necessary.

4.

Check operation of choke and throttle. Adjust if necessary.

5. Fill fuel tank with 40:1 mix.

6. Start engine and check idle speed.

7. Check emergency stop and key switch.

8. Check operation of all lights.

9. Aim and adjust headlight.

10. Test drive or dynamometer test snowmobile.

11. Install accessories desired by customer.

is

clear of

DELIVERY CHECK LIST

1. Explain operator 's manual to customer.

2. Instruct customer about snowmobile operat i

NOTE: BREAK-IN PERIOD:

Do

not

25

miles (40 km), throttle in deep snow. An occasional burst power on hard-packed snow will ful.

3. Explain fuel-oil mixture. Use regular leaded or nonleaded gasoline with an anti-knock index of 88 or higher. Use a 40:1 ratio for first tank of fuel and a 50:1

ratio thereafter.

NOTE: Regular (leaded) gasoline is preferred

non-leaded gasoline is acceptable .

4. Tell customer about 10-hour or 200 mile check up.

on

.

exceed 30 mph (48 kml h) for the first

or

force the machine

not

at

full

of

be harm-

but

PERFORM THESE 10 HOUR OR 200 MILE CHECKS

3

c

The following inspection must be performed on your new John Deere snowmobile. This should be done at approximately the first 10 hours or 200 miles of operation . It will help assure you of top performance and avoid premature faiiure of critical components . Your John Deere dealer

Contact your dealer to arrange for an appointment. You are obligated to deliver the snowmobile to the dealer. Any normal maintenance or repair work required, not covered by warranty, will be charged to you should you decide to have the work done.

The inspection check list is as follows:

NEEDS

OKAY

REPAIR

1.

Track tension.

2. Drive belt, drive, and driven sheaves.

3. Carburetor adjustment.

4. Carburetor mounting hardware.

5. Operation and adjustment of brake, throttle, and choke lever controls.

6. Condition of ski wear rods.

7.

Suspension hardware.

is

qualified to perform this inspection.

c

DEALER COMMENTS:

Dealer Name

Town

Date

8. Suspension slide wear bars.

9. Ski

10. Operation of headlight, stop-taillight, dimmer switch, and emergency stop

11

12. Steering component hardware.

al

ignment.

switch.

. Engine head bolts and exhaust manifold nuts.

)

c

Contents

Page

Safety Identification

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Service

Trouble Shooting . .... . . . .

Specifications . . .

Accessories

..........

.......

Mix Fuel Fill Fuel Tank

Before Operating . . . . . . . . . . . . . . . . . . . . . . . 7

Start Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Stop Engine. . . . . . . . . . . . . . . . . . . . . . . . . . .

Li

ghts Clearing Track Towing . Dressing For The Weather

Service Interval Chart

Spark Plugs . . . .

Carburetor

Choke System Adjusting Choke Adjusting Carbu retor .

Checking Float L Main In

-Line Fuel Filter ........

Air Intake Silencer

Drive

Replacing Drive Belt . . . .

Adjusting Brake Slide Suspension

Replacing Wear Bars ......

Adjusting Track Ten sion .

Adjusting Suspension Springs Skis .

Replace Ski Wear Rods .

Replace Ski Wear Plates . .

Aligning Skis . . .

Eliminating Loose Steering . . . .

Lighting System

Adjusting Headlight.

Replacing Headlight

Replacing Stop-Taillight . .

Tightening Hardware and Components . .

Storage . . .

..

.......

......

..

. .

......

........

Jet

Chart

System . . . . . . . . . . . . . . . . . . . . . . . . . . 14

...

. .

......

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......

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...

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..

......

. ...............

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...

..

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.....

evel ..

...

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..

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..

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..... ..

...

.....

......

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.

......

.

...

.

.....

...

. .........

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......

.

....

......

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......

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...

..

........

. . ........

....

. .

..

. . . .... ......

...

. ....

...

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. . .

........

..

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......

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...

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. ...

.... . ·

.......

......

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...

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...

.....

...

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. . . . .

.........

...

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......

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. 6

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. ·

...

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. 9

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. . . .

......

...

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..

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. .... . 26

. 10

.....

1 0

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11

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...

12

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12 13

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. 13

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. 14

14

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15

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16

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16

. 16

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17

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17

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19

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24

1

2

6

8

8 8

9

c

OOA

a

Safety

M23365

CAUTION: DO

A

proper use or maintenance by the operator can result in injury. Follow these safety suggestions.

NOT

carry a passenger.

Im-

Preparation

Before starting the engine, read your operator's ual from cover to cover. Knowledge can prevent accidents.

Always operate

times before you start th e engine. Stuck or frozen controls could cause serious injury or damage.

Know

your

gency.

Know

your

pertaining to snowmobiling. Respect property of others. Don't spoil this fine winter sport by creating a bad

im

age.

Never ning

clean fuel of the proper mixture. See page 6.

frostbite . Never wear scarves, loose belts, or clothes that could catch on moving parts

Always wear

against injury.

add

. Use a safe gasoline container. Always use fresh,

Wear clothing designed for snowmobiling .

your

throttle

controls. Learn how to stop in

state, provincial, federal

fuel when smoking

eye

and

brake controls several )

and

or

while engine is

or

tree limbs.

headgear protection to guard

man-

an

emer-

local laws

run-

..

avoid

Prolonged exposure to loud noise can cause impairment

or

loss

of

hearing. Wear earplugs

hearing protective device that is comfortable when wearing a snowmobile helmet to protect against jectionable an approved helmet to guard against head injury.

Avoid sun blindness. Wear properly tinted goggles or face shield. Never wear yellow eye protection in the bright sun .

Do

not

proper instructions. Take proper precautions before allowing young operators to drive.

Always use the "buddy " system. Remember you can drive farther in 30 minutes than you can walk in a day.

Carry adequate tools and repair items for emergency ) field repairs.

Don 't overload

provisions.

or

uncomfortable loud noises. Always wear

allow anyone to operate snowmobile witho

your

snowmobile .

or

any suitable

..

use sleds to carry

ob-

ut

Always carry emergency survival supplies when going on long trips. Let friends and relatives know your destination and expected arrival time.

Operation

Safety

3

Give complete

snowmobile .

Do

not

operate snowmobile in crowded areas or

steer the machine toward persons.

Do

not

operate snowmobile too close to avalanche

or

areas, occur.

Observe

lations, especially those with regard to operating on

stre ets and highways.

When cross ing highways (where permitted

a

lw

degree angle. Post guards when crossing in groups.

Do

tr

acks. Trains cannot always be heard above sound of

snowm obile engine .

tw

een tracks.

Skiers

hillsides. Avoid ski slopes.

Never operate snowmobile

first checking thickness don't panic. Conserve energy.

on other unsafe terrain where spills could

all

ays stop, look both directions, and cross at a

not

operate snowmobiles

and

undivided attention to

..

don't be a show-off.

state, provincial, federal

on

..

it is difficult to escape from be-

snowmobi

les

don't

on

rivers

of

ice. If you go through the ice,

and

local regu-

or

near

mix

on the same

or

lakes without

your

by

law)

90-

railroad

c

Never operate snowmobile

Keep headlight and taillight areas free of snow.

Keep

all

shields in place . . . all guards and protective

hoods.

Never open

trails. Unseen barbed wire serious injury

Always use both hands for steering. Avo

id

Always be aware of terrain.

If

thrott

switch on the right-hand handlebar. See page 8.

ys

Alwa

ground cover conditions. Remember, ice requires a greater stopping distance. apply brakes rapidly on ice.

Ice

or

ity as snow. Drive slower on these surfaces. Do not

accelerate rapidly.

new

trails

or

death.

operating snowmobile

le

sticks, don't panic. Turn emergency stop

allow adequate stopping distance based on

hard

surfaces

do

at

night without lights.

at

night. Follow established

or

guy

wires can cause

at

excessive

To

avoid skidding, don't

not

provide the

speed

same

stabil-

M23364

.

M23366

4 Safety

box

Be sure tool

could cause interference with steering or possible co

ntact with the throttle lever producing un expected

acceleration.

Do

not

speed through wooded areas. Hidden obstruc- )

tions, hanging limbs, unseen ditches, and even wild animals can cause accidents.

lid is closed

at

all times. An open lid

Do not tailgate when riding trails. Rear end collisions

can cause injury and machine damage.

Don't mix alcoholic beverages with snowmobiling.

Keep feet on footrests

to hang over sides. Do not attempt to stabilize machine with feet when making turns Broken limbs could result.

Select a riding position

you'

re

operating. Do not stand on seat, stunt, or

show-off.

Do

not jump snowmobile. Operator injury or machine

damage could result.

Keep

hands and

cially careful when freeing your snowmobile from deep snow.

feet

at

all times. Do not permit them

or

in near-spill situations.

sui

ted to the terrain upon which )

out

of

the track area .

..

be espe-

When towing a sled, use a solid towbar. Do not use

ropes or other flexible tow straps. See page 9.

Observe fuel supply regularly. Do not travel farther

than your fuel will permit you to return.

Remove

machine unattended.

Never drive

Winch it on.

Always secure snowmobile firmly to trail

trail

key

from switch whenever you leave your

your

snowmobile onto a tilt-bed trailer.

er

lights are operative.

er

. Be sure

Maintenance and Storage

Check

vent many problems from occurring.

Do

while engine is running.

Keep matches

fuel tank. Avoid possible explosions.

Check skis

they are in good condition. Keep all hardware tight.

Never lift the rear

Chunks machine on one footrest when clearing track keep all persons clear clear of track.

over

your

snowmobile regularly. This will pre-

not

attempt to make repairs to your snowmobi le

away

and

do

not

smoke while filling the

and

steering components frequently to see

of

the snowmobile to clear the track.

of

ice or rocks may be thrown rearward. Tilt

of

area. Keep hands and feet

...

and

c

5

Identification

c

A-Shock B-Skis C-Front D-Hood E-Headlight F

-Winds

G-Brake

H-Seat

I

-Rear

J-Track

K-Pan

L-Ski

A-Snow B-Rear C-StopD-Seat E-Fuel FG-Hood H-Ski 1-Ski J

K-Serial l-Track

Bumper

hield

Bumper

Spring

Bumper Taillight

Tank

Throttle

Handle

-Recoil

Absorbers

Control

M26719

Flap

Control

Start

Number

c

a

Preparation

)

MIX FUEL

IMPORT ANT: Use

NOTE: Regular (leaded) gasoline is preferred

non-leaded gasoline is acceptable.

Use John Deere 2-cycle oil or an equivalent BIA approved 2-cycle oil. Mixing is improv room temperature.

The correct fuel-oil mixture is 40:1 ratio for the first tank of fuel and

1.

Pour half the gasoline into container.

2.

Pour in all the oil.

3.

Shake mixture vigorously.

4.

Pour in remaining gasoline.

5. Shake mixture vigorously.

50:1

CAUTION: Use safe

- Use and

-

Mix

-Do

not

-Do

not

regular gasoline 88

or

higher,

in

the

proper

line

that

time.

ratio thereafter. See page 25.

an

approved

refueling.

fuel

outdoors. smoke. spill

with

has

fuel.

leaded

an

anti-knock

mixed

ratio.

been

container

with 2-cycle

Never

stored

ed

mixing

or

if the oil is at

procedures.

non-leaded

index

of

oil

use

gaso-

for a long

but

for

stora

ge

\

J

NOTE: Mix gasoline

never stored mixtures thoroughly before using.

FILL FUEL TANK

CAUTION: Use safe

-Fuel

-Do

-Avoid

- Clean

Fill tank to bottom of. filler neck. Fuel tank holds 5.5 U.S. gallons (20.8

and

oil

in a separate container -

mix

in the snowmobile fuel tank. Agitate

snowmobile

not

smoke.

sp

illing

fuel

tank

refueling

outdoors.

fuel. Do

of

any

procedures.

not

overfill.

spilled

L)

fuel.

.

7

c

a

Operatio n

BEFORE OPERATING

1. Wipe windshield with a clean damp cloth. Do not use gasoline, solvents or abrasive cleaners.

2. Check skis , wear rods, and all steering components. Check steering for a full right and left-hand turn.

3.

Check track for proper tension.

4. Check fuel level.

5.

Check throttle and brake for proper operation.

START ENGINE

Engine Break-In

Do not exceed 30 mph (48 (40 km), or force the machine at full throttle in deep snow.

A CAUTION: Be sure area in front of machine

..

is

clear. Be prepared to apply brake

prevent snowmobile movement.

km/h)

for the first 25 miles

to

c

1.

With no choke and handle to turn engine over two

2.

Pull out on choke knob.

3. Emergency stop switch must be in center position.

4. Insert key and turn key switch " throttle lever.

5. Pull recoil start rope.

6.

When engine starts, allow it to run briefly before pushing choke knob in.

NOTE: Choke knob can

smooth engine performance during warm-up.

If engine becomes Hold the throttle in wide open position. Pull start rope until engine rope until engine starts.

NOTE: Remove

IMPORTANT: DO NOT permit engine

Warm Starting

"pops".

and

tremely flooded.

long intervals. Shut engine off whenever you stop.

no

throttle, pull recoil start

or

three times.

ON."

DO

NOT

open

be

pushed

"floo~ed",

Release throttle . Pull recoil start

dry

push in on choke knob.

spark plugs

in gradually for

if

engine is

to

idle for

ex-

Choke Knob

c

With emergency stop switch in center position and key switch

NO

TE:

"ON,"

DO

pull recoil start rope.

NOT

use choke

and

open throttle slightly.

8 Operation

Emergency Starting

1.

Raise hood and use tool kit provided with snowmobile to remove recoil starter.

2.

Knot one end starter.

3. Wind opposite end of rope around spark plug wrench from tool kit.

4. Pull on rope to start engine.

Carry

an

STOP ENGINE

1 . Release throttle lever.

2.

Apply brake. )

3.

Turn emergency stop switch up or down.

4. Before restarting, stop switch must be turned to the center position. Always check stop switch before attempting to start engine.

5.

Turn key switch "OFF." Remove key when leaving machine unattended.

of

rope and wind rope around recoil

extra rope for emergency starting.

LIGHTS

NOTE: The lights are automatically "ON" whenever

the engine is running.

1 . Stoplight comes on when brake is applied.

2.

Turn dimmer switch once for low beam.

3.

Turn dimmer sw itch again for high beam.

NOTE:

If one filament

still be used. See page

light

CLEARING TRACK

1.

Clear track after operating in slushy snow.

2. Tip machine on its side until track clears the ground.

3.

Spin track at moderate speed until snow and ice are thrown clear.

A CAUTION:

chine when clearing track. Injury could result from ice

of

and

changing bulbs.

Be

or

bulb fails, the other beam can

19

for adjusting head-

sure no one

rocks thrown from track.

is

behind

ma-

IMPORTANT: If track freezes, free the track

ually. Do not use the engine to break track loose because it will burn and damage the drive belt.

man-

CAUTION: Always use a solid tow bar when possible. Flexible ropes or pull straps do not allow for control on turns or when stopping.

1. Remove drive belt.

2.

Connect only one ski of disabled machine to the tow

machine.

3.

DO NOT use rear bumper for towing.

4.

When towing with a rope or strap, tie to only one ski. Do

not loop rope or strap through both skis, as this

may damage the steering tie rod.

Operation 9

TOWING

M26770

c

DRESSING FOR THE WEATHER

1. To be safe from frostbit weather.

2.

Wear protective clothing and accessories.

3.

The chart provid danger zones.

CAUTION: Always wear a snowmobile

A

helmet with face shield or goggles. The helmet provides both warmth and protec-

tion against head injury.

e,

dress for the wind and

es

a guide a

ESTIMATED WIND SPEED IN MPH

calm

5 10 15 20 25 30

35

40 26

(Wind spee greater 40 littl tiona I

mph ea

than

have ddi effect

ds

.)

nd

ACTUAL THERMOMETER READING (°F.)

50

EQUIVALENT TEMPERATURE (°F.)

50 48

40 36 22 9 32 30 28 13 27

LITTLE INCREASING DANGER DANGER DANGER

(for

properly

p

erso

illustrates the

WIND CHILL CHART

40

30 20 10

40

30 20

37 27 16

16 4 -58

28

18 4 -10 -25 -39 -53 -67 -82 16

0

-2

-4

11 10 -6 -

clothed

n) Da

~-30

-5 -72

-15 -29 -44 -59

-1

8

-33

-20 -3

5 -49 -67 -82 -98

21

-37

nger

-1

0 -20 -30

0

-48

-63

-69 -85 -100

-5

3

from

freezing

-36

-74

-88

-79

-94

GREAT

of

exposed flesh

-40

-47

-70

-85

-96

-104

-109

-113

-116

-50

-60

-50 -60

-57 -68

-83 -95

-99 -

11

-11

0 -124

-1

18 -133

-125 -140

-129

-1

45

-132

-148

2

c

M10123

Service

SERVICE INTERVAL CHART

Item

Clean Windshield Check Condition of Skis and St Check Track Condition and Tension Check Throttle Control Operation Check Operation of Brakes Check Emergency Stop and Key Switches Check Lighting System Check In-Line Fuel Filter Check Drive Belt Condition Check Carburetor Adjustments Check Choke Adjustments Check Ski Alignment Check Headlight Adjustment Check Ski Wear Rods and Wear Plates Check Slide Suspension Wear Bars

Use Never-Seez on Throttle Cable End

Check All Components for

Condition and Tightness Check Drive and Driven Sheaves Store Snowmobile Properly

ee

ring

As

Needed

Dai

ly

Every

150

Miles Miles

Every

300

Annually

X 7

X 17-18 X 16 X 12 X X 7-8 X 8 X

X

X X X 12 X X X

X

X X X 19 X X

X X

X

X 20 X 14-15 . X

Page

15

14

12 18

17

16

12

21

SPARK PLUGS

NOTE: Spark

Removing Spark

CAUTION: can

ing on

1.

Stop engine.

2. Pull connectors from plugs. IMPORT

3. Remove plugs.

plugs

are Champion

(John Deere Part No. AM55045).

ON-3

Plugs

Stop

ANT:

High-en produce engine

ignition

Do

not

and

nectors. Pull on connectors only.

ergy

ignition

injurious electrical

remove

.

pull

on

wire

key

to

before

remove

systems

shock.

work-

con-

(

Service

11

.

c

Checking

1. Reconnect spark plug wire to plug.

2. Lay plug on the engine fins.

3. Pull the recoil start rope and check for spark.

New plugs are gapped at 0.025 inch (0.635 mm). The gap will widen in proportion to the hours and miles of use . When plug gap reaches 0.045 inch (1.143 mm) or

if plug malfunctions, replace it.

IMPORTANT:

Plug Appearance

Tan or Cocoa Brown

Black or Sooty

White

Spark

CAUTION: wire

in

your High-energy injurious

or

Light Tan

electrical shock.

Do place

Plug

Do

not

hold

the

hand

when

checking

ignition

not

it!

systems

regap

the

plug,

Possible

Proper fuel mixture, good combustion.

Fuel mixture too rich, poor combustion .

Fuel mixture too lean, hot combustion.

Cause

plug

can

always

or

plug

for

spark.

produce

re-

c

NOTE: Replace

gine starts

Installing

1. Clean plug seating surface on cylinder head.

2.

Install plugs and torque

Nm).

3.

Install spark plug wires.

plug

Spark

if

appearance is abnormal,

hard

or

malfunctions.

Plug

to

10 to 12 ft-lbs (14

to

en-

16

CARBURETOR

IMPORT

The The in the bowl. adjustments. Altitude and temperature variations may require carburetor changes

ANT:

carburetor is a float-type, fixed main jet carbureto float in

Do

not

run

engine

carburetor.

the

fuel bowl maintains a constant fuel level

The

fixed main jet eliminates high-speed

and

when

adjustments.

adjusting

r.

c

Continued

on

page

12

Service

Choke System

A separate metered choke system is used. The system is opened and closed by a choke plunger. Do not open the throttle when starting the engine, otherwise the

fuel-air mixture will be too lean for starting.

A-Jam

Nut

B--Adjusting Sleeve

Adjusting

1.

Remove air intake silencer.

Choke

2. Push choke knob in (closed).

3. Look in the choke plunger hole in the carburetor throat. Plunger should be all the way down in the bore.

4.

To adjust plunge adjusting sleeve (

IMPORTANT:

5. Pull out on choke knob and look hole. Plunger shou

r,

loosen jam nut (A) and turn

B)

clockwise. Tighten jam nut.

Plunger must bore

or

carburetor

This

will

affect

ld

raise and be a

be

down

engine

tight

in

will

run "rich".

performanc

in

choke plunger

ll

the way up

the

e.

in

the bore.

Adjusting

Carburetor

Idle S

peed

Adjusting Screw

1. Remove air intake silencer.

2. Back idle speed adjusting screw out until it no longer contacts

3. Look

in

carburetor throat to make sure butterfly

th

e carburetor throttle lever.

valve is completely closed.

4.

Loosen jam nut (A) on throttle cable. Turn adjusting s

le

eve

(B)

until cable is just snug and the butterfly is closed. Tighten jam nut. Use Never-Seez on throttle cable end

A-Jam B-Adjusting

Nut

in

the throttle lever.

Sleeve

c

5. Look in carburetor throat and compress the handgrip throttle lever until it contacts handgrip. Butterfly valve should be in full open position and parallel

with carburetor bore. Repeat Steps 2 through 4 if

necessary. Release throttle lever.

6.

Turn idle speed adjusting screw in until it contacts throttle lever. Turn in one additi onal turn for preliminary idle speed adjustment.

7. Lightly seat idle mixture screw and then open one to two turns for initial mixture adjustment.

8. Install air intake silencer and warm up engine.

9.

Turn idle mixture screw in (lean) or out (rich) to obtain an even engine idle.

10. Readjust idle speed adjusting screw to obain an engine idle speed of 2000 rpm.

Service

13

c

Checking Float Level

NOTE: The fuel/eve/ in the float chamber is regulated

by

the float.

1. Remove air intake silencer, fuel lines and carburetor.

2.

Remove float chamber body.

3. Turn carbureto r on its side. Touch float (A) lightly

with finger until it ju st contacts needle valve (B). Float should be parallel with edge of float chamber

(C).

4.

If adjustment is necessary, bend the float arm.

5.

After adjustment, tap the float lightly. If it is adjusted correctly , it will bounce from spring resistance of the needle valve.

MAIN JET CHART

Carburetor and clutch changes, adjustments or modifi

cations may be necessary for operation at altitudes above 3,000 feet (914 m). See your John Deere dealer for these changes.

112335

?Y

A-Float B-Needle

Below - 30°F - 30° Below - 35°C - 35°

Main

Valve

Jet

195

TEMPERATURE

to

+30°F

to

- 1°C

Main

Jet

180*

C-Fioat

+30°

to

+60°F

to

+ 16°C Above 16°C

- 1°

Main

Jet

1

70

Chamber

Above

Main

155

60

Jet

°F

ALTITUDE

Sea Level

3,000

ft.

(914

m)

c

*Factory Installed.

14

Service

IN-LINE FUEL FILTER

Change the filter annually or when contamination builds up in the cone.

)

AIR INTAKE SILENCER

The

first indication power and performance. The engine will run because adequate air will not be mixing with the fuel.

1. Remove silencer screen.

2. Shake

3. Install silencer screen.

DRIVE SYSTEM

Replacing Drive Belt

of

trash in the silencer will be loss

or

blow out the screen to remove any trash.

of

"rich"

)

The drive belt should be replaced if its width is reduced

1/8

by mobile top speed. Correct width is mm).

If drive belt wears rapidly, drive and driven sheaves may be

inch (3.18 mm). A narrow belt reduces snow-

1-1/4

inches

out

of alignment. See your John Deere dealer.

(31.75

)

Service 15

c

A belt worn narrow in free a frozen track with manually before starting engine.

CAUTION: Keep fingers out of area be-

A

tween driven sheave halves. If driven sheave sticks, use care in opening it to prevent hand from being pinched.

1.

Push in on cen ter and

over

sheave

2. Remove belt from drive

IMPORTANT: Never pry belt over sheaves.

3. Install belt in reverse sequence . Always install belt so that from left-hand side

N

OTE: As

number

belt remove "anti-creep " shims (A) from behind retaining washer (8). When new belt is inst

alled, replace shims. Torque cap screw to

ft-lbs

(27 Nm). After installing a

snowmobile has a tendency to creep speed, add

one

area is caused

the

engine. Free a frozen track

of

driven sheave and lift belt

half.

sheave

on belt can

of

snowmobile.

wear increases

a shim .

by

.

be read when

or

if

belt

stretches,

new

trying to

up

view

ed

20

belt, at

idle

if

A-"Anti-Creep"

Shims

B-Retaining

Washer

c

Adjusting Brake

1. Apply the brake control lever and measure the the

lever

to

distance from

to

1-1/2

1

2. Adjust brake ing adjusting screw (B). Tighten jam nut.

/).

..

3. Check brake tension.

4. Rea djust if necessary.

NOTE: Be certain dowel on

inches (25

by

loosening jam nut (A) and tighten-

CAUTION: DO brake cable.

seated properly in recess lever.

the handgrip. It should be

to

38

mm).

NOT

adjust jam nuts on

end

of

brake cable is

of

brake control

5. After brake switch. If stop light does not work, fective switch.

adjustment,

check

operation

check

of

stoplight

for a

de-

A-Jam

Nut

B-Adjusting

Screw

16

Service

SLIDE SUSPENSION

Replacing Wear Bars

When running bars daily.

1.

Tip snowmobile on its side.

2.

Check wear bars areas and sand

NOTE: Sand

3.

If any of these conditions exist, see your John

Deere dealer for wear bar replacement.

in

marginal snow conditions, check wear

in

several places for cracks, thin

or

gravel imbedded

or

gravel imbedded in the wear

as

an

abrasive

grouser bars in the track.

and

will destroy the steel

in

the bar.

bar

s acts

Adjusting Track Tension

Check track tension and alignment frequently. A loose track causes excessive slap and cou track, tunnel additionaL-power to operate.

or

slide assembly. A tight track requires

ld

damage the

)

M2467?Y

A-Jam

Nut

8-Adjusting

Screw

1. Suspend or support snowmobile so track is clear of ground.

2. Loosen jam nuts (A) on track adjusting screws (B).

3.

Turn adjusting screws (B) to tension track.

4.

Measure below the lower shock absorber mount for

clearance of flush to track and slide wear bar. Both sides should equal. Tighten jam nuts.

1/4

inch (6.35 mm) between

be

After Adjustment

1.

Start engine and allow the track to rotate slowly

several times. Shut off engine and allow track to coast to a stop. DO NOT APPLY BRAKE TO STOP TRACK.

2.

Check alignment. Rear idler wheels should run in

center of drive lugs.

3.

Slide rail wear bar should be rail opening of track.

4.

If either Step 2 repeat the procedure.

NOTE: Track will run to the loose side.

far to the left, tighten the left adjusting screw to )

move the track to the right.

or

3 indicates a need for adjustment,

in

middle of each slide

If

track is too

c

Adjusting Suspension Springs

Ride the snowmobile. If the suspension bottoms fre-

quently, increase the rear spring preload. To increas e the preload, move the springs from the

bottom position (A) to the top position (8).

SKIS

M24678.Y

A- Bottom

Pos

ition

Service

B- Top Position

17

c

Replace Ski Wear Rods

Wear rods should be rep laced when they are worn to one-half their original size.

1.

Remove lock nuts securing wear rod to ski.

2. Pry rod down to free studs from holes.

3. Slide rod forward to remove rod from rear hole.

4. Install new rod

Replace Ski Wear Plates

Replace wear plates when excessively worn.

1. Raise front of snowmobile.

2. Remove cotter pin (D) and drilled pin (A).

3. Lift spring (C) and remove wea r plate (B).

4. Install new wear plate

5. Lower spring (C) and install drilled pin (A) and cotter pin (D).

in

opposite sequence.

(8

).

c

N26722

A-Drilled B-Wear

Plate

C-Spring D-Cotter

Continued on page 18

18

Service

M26723

Aligning

When properly aligned, skis are parallel and handlebars are position ed straight ahead .

1. Loosen jam nuts (D). Gold-colored tie rod ends (C) have left-hand threads. Loosen opposite normal rotation.

2. Turn tie rods to align skis. Measure from straight edges of skis; not tapered ends.

IMPORTANT:

3. Tighten jam nuts (D). Hold tie rod

when tightening jam nuts. This prevents stripping the threads in the ball joint.

Skis

When from should

(33.6 em).

adjusting

center

not

exceed

tie

rods

hole-to

(B)

(B),

length

-center

13-1/4

with vice grips

hole

inches

)

A-

Tie

Rod End

B-Tie

Rod C-Gold-Colored D-Jam

Nuts

Tie Rod End

IMPORTANT:

Eliminating

A CAUTION:

..

and tightness.

The two major causes of loose steering are:

1.

Excessively worn tie rod ends (A).

2. Excessively worn spindle bushings.

3. Replace or tighten parts as required.

After

jam

rod

ends

Loose

Check

hardware

nuts

are

(A)

still

Steering

steering

frequently

tight,

swivel

components

for

condition

be freely.

sure

tie

and

)

LIGHTING SYSTEM

Service

19

c

1-+------------,--25

Adjusting Headlight

1. Position snowmobile on a flat surface with the headlight 25 feet (7.6 meters) from a vertical sur-

face.

2. Have operator on seat and headlight on beam. Light beam centerline should be straight ahead and level.

3. Loosen or tighten the two left-hand adjusting screws to raise or lower the light beam.

4. Loosen or tighten the right-hand adjusting screw to move the light beam right or left.

24-3/4

inches (628 mm) above ground

HI

GH

(7. 6

''---:------

m)

-

---

-

--

-

------.;

24

-3/4"

(628

mml

c

Replacing Headlight

1.

Disconnect wiring from light.

2. Unhook wire end from slot.

3. Remove wire clamp and headlight.

4.

In

stall new headlight in opposite sequence.

Replacing Stop-Taillight

1. Remove lens.

2.

Pu

sh and turn bulb counterclockwise to remove i

3. Install new bulb in opposite sequence.

IMPORT ANT: Be sure bulb locking tabs match

slots.

t.

c

20

Se

rvi

ce

TIGHTENING HARDWARE AND COMPONENTS

)

Check hardware and components for tightness, wear and damage on a yearly basis. Replace any parts that are questionable.

/).

CAUTION: Worn, bent or damaged ski a

nd

A steering components are unsafe.

1.

Wear rod nuts.

2. Ski bolts.

3.

Steering arm bolts.

4.

Tie rod end bolts.

5.

Drive shaft bearing cap screws.

6. Driven sheave cap screw.

7. Muffler clamp.

8. Throttle and choke cables.

9. Intake manifold nuts.

1

0.

Carburetor attachment.

11. Engine mounting bolts.

12. Drive sheave cap screw.

13. Suspension cap screws.

14. Shock absorber screws.

c

21

Storage

c

PLACE SNOWMOBILE

1 .

Thoroughly clean snowmobile.

Polish hood, pan and tunnel with automotive-type

2.

wax. Use upholstery cleaner on seat. Touch up all

bare metal parts with paint. Check cap screws and components for tightness.

3.

Order any new parts required . Siphon fuel from tank. Start and run engine out of

4.

'

fuel at IDLE SPEED .

Replace in-line fuel filte

5.

6.

Remove spark plugs and add one teaspoon of 2-cycle oil in each cylinder. Pull recoil start rope six or seven times to lubricate cylinder walls. Replace plugs.

7. Remove drive belt and coat drive and driven sheaves with light grease.

8. Support snowmobile so track is clear of ground.

Loosen track adjusting screws.

9.

Place cover on snowmobile and store inside.

r.

REMOVE SNOWMOBILE FROM STORAGE

IN

STORAGE

c

1. Wipe grease from drive and driven sheaves. Install drive belt.

2. Fill fuel tank with properly mixed fuel.

3. Check throttle and brake controls for proper adjust-

ment and operation.

4. Adjust track tension.

5. Review operating and safety suggestions.

6. Start engine and test operation of all switches and

lights.

7. Ride snowmobile

is operating properly.

at

slow speed until you are sure it

Trouble Shooting

ENGINE

Engine Starts Hard or Will Not Start

Fuel tank empty. Emergency stop switch in "STOP" position.

in

Plugged Fuel pump malfunctioning. Faulty ignition system. Ignition timing incorrec Idle set too high.

Engine Lacks Power or Acceleration

Running on one cylinder.

Throttle cable improperly adjusted.

Improper fuel mixture.

Carburetor out of adjustment.

Restricted Ignition timing incorrect.

Center distance between drive and driven sheaves too

short for belt.

-line fuel filter.

in

-line fuel filter.

)

t.

Engine Backfires and Runs Unevenly

Ignition timing incorrect.

Engine Overheats

Carburetor too "lean". Intake manifold

LIGHTS

Stoplight Not Working

Bulb burned out. Stoplight switch defective. Stoplight switch "frozen ".

Lights Won't Light

Bulbs burned out. Loose electrical connections. Faulty lighting coil.

or

carburetor leaking .

)

c

POWER TRAIN AND CHASSIS

Clutch Does Not Disengage

Engine idles too fast. Faulty clutch. Short drive belt.

Clutch engages slowly

Faulty clutch.

Stretched

Excessive Drive Belt Wear

Freeing frozen track with engine. Drive and driven sheaves misaligned. Driving long distances

or

worn drive belt.

at

clutch engagement speed.

Trouble Shooting 23

c

Rapid Track Wear

Operating on bare ground. Track improperly tensioned.

SKIS AND STEERING

Loose Steering

Worn tie rod ends. Worn spindle bushings.

Poor Maneuverability

Worn ski wear rods. Loose steering linkage.

c

Specifications

SNOWMOBILE SPECIFICATIONS

Component

Engine

Fuel System

Chassis and Tunnel

Track and Suspension Suspension Type

Item

Manufacturer Model Number of Cylinders Bore Stroke Displacement

Carburetor Mfgr. Carburetor Number Tank Capacity Fuel Mixing Ratio

Material:

Tunnel and Pan

Hood

Windshield Overall Length Overall Width Overall Height Weight (Approx.)

Track Material Track Width

Specification

John Deere "Fireburst"* TB340A Two 60 mm 60 mm 339

cc

Mikuni

AM54886

5.5 U.S. gal. (20.8 L) 50:1

See page 6.

Aluminum Sheet Molded Compound

Polycarbonate

98 in. (2489.2 mm)

33.25 in. (844.6 mm)

38.0 in. (965.2 mm) 275 lbs.

Slide Suspension Rubber 15 in. (38.1 em)

(1

25 kg)

)

Power Train

Electrical System Spark Plug (Champion)

*Manufactured for John Deere

**

Manufactured for John Deere

by by

Transmission:

Type Manufacturer

Primary Secondary

Final Drive Ratio:

Secondary Clutch Brake Drive Belt

Spark Plug Gap

Timing

Lighting Coil Capacity Light Bulbs :

Headlight

Stop-Taillight

Kawasaki Heavy Industries, Japan Comet Industries, Richmond, Indiana.

2-Sheave Variable

John Deere (94C Comet) John Deere

·Low - 4.5:1, High - 1.23:1 ca

Mechani M68416

ON-3 (AM55045)

0.025 in. (0.635 mm) See page 11. 22° BTDC with engine running

at 6500 rpm (0.1 09 in. BTDC) (2.76 mm BTDC )

120 Watts

AM52959 AM52619

l Disk

**

)

FUEL AND OIL MIXTURES

Specifications

25

c

UNITED STATES

Ratio

40:1

50:1 1 pt. 6 gal.

NOTE: United States gallon contains

Oil

1 pt. 5 gal. 40:1 1 U.S. pt. 4 Imperial gal. (0.473 L) (18.9 L)

473

(0.

L) (22.7 L)

(Specifications

leaded

3.

and

CANADA

Fuel

785 liters

design subject to change without notice.)

Ratio

50:1 1 U.S. pt. 5 Imperial gal.

and

the Canadian Imperial gallon contains 4.543 liters.

Oil

(0.473 L) (18. 2 L) 1 Imperial pt. 5 Imperial gal.

(0.568 L) (22.7 L)

(0.473 L) (22.7 L) 1 Imperial pt. 6 Imperial gal.

(0.568 L) (27.3 L)

leaded

Fuel

c.

c

Accessories

1. Speedometer.

2. Tachometer.

3.

Protective Cove

4. Hitch.

5.

Track Stud Kit.

r.

)

c

__

c

JOHN DEERE SERVICE LITE RATURE AVAILABLE ...

To

order these publications, fill out the form below and mail payment to the address given. Make checks payable to Deere Service Publications. Please allow three weeks for delivery. Prices include handling, taxes and postage to anywhere Canada.

__j_

- - -

! I

: 1

1

~

------

John Deere Distribution Service Center

Department 1400 3rd Ave.

Moline, Ill. 61265 I

Please send to . .

Name

SIP

__________________

- - -

-----

____________

in

the U.S.

________

it

with

& Co.

A.

and

-

---

____

PARTS CATALOG

-

A parts catalog containing exploded view illustrations and lists of

1

all parts the correct parts. Useful

I

OPERATOR~

I

_

I

is

useful when purchasing service parts. Helps identify

in

assembling and disassembling.

MANUAL

c

Address

Town

I

State---

I

lw

I

a:

I

~

h-

Title No.

l

i3

I

Pa

I

SPITFIRE Snowmobile

I

I I

Operat

I

S

I

Service or SPITFIRE Snowmobile

NOTE: If this list, list the model number, seri equipment below.

______________________________________

__________________________________________

-

----

rts Catalog

or"

s Manual

PI

TFIRE Snowmobile

Te

chnical Manual -

you want manuals or catalogs for equipment not shown on

- - - - -

__

--

Zip _

__

Order Price

PC-1623

M68928

TM-1191 $14.00

al

number a

Qty.

nd

name of the

Each

$

1.

1.00

$

50

_

I

An

_

I

_

I

extra copy of the

nu

operator's ma be important if the copy furnished with your machine is misplaced.

al may

I

SERVICE OR TECHNICAL MANUAL

I I

I

The service or technical manual is a service guide for your machine. Included

I

adjustments, illustrations of special assembly and disass

I

procedures, and wiring diagrams.

in

the manual are specifications, diagnosis and

em

bly

I

c

lllio

o;,

S"te

Re<;deot< add 5%

Check or money order (Do

not se

nd

cash or stamps)

Pr

ice

s s

SP-317 Litho in U.S.A. MAR-

in U.S.

ubject

78

foe

dollars enclosed

to change

without

ROT

not

...

ice

.

. . ..... ..

...

Total

. D

I

~

I

)

John Deere Snowmobile Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual