SERVICE
STC-7010
JOHN
DEERE
TRAINING
1980
SNOWMOBILES
COURSE
This
Instructor
designed for the
Guide
new
isapart
1980John
package and will provide
tions, adjustments
This
for both the
the
student
When
li
IG
is designed with the Technical
instructor
's
instr
sted
below:
instructor
textbook, be sure
ucting
1. In preparation
and
are highlighted in the
this
course,
for
objectives of the course
so
that
d
irected
these
of the Technical
what poin
Gu
ide and add any
it
f
the
class
so
that
objectives,
ts
are to be
your needs.
will achieve these objectives
these objectives
read the ent
Manuals
specific
INSTRUCTOR
DIRECTIONSTOTHE
training
trouble shooting for the
GUIDE
1 -
1980
SNOWMOBILES
INSTRUCTOR
of the Service Training
Deere
Snowmobiles.It
CourseSTC-701
is a
completeinstructi
material necessary to cover predel ivery, opera-
1980
Snowmobiles.
Manualsas t he
prime
source of
and the student. Specif ic teaching points
IG.
Since the Technical Manual s are t he
the
that
class,
emphas
each student receives copies.
we
recommend
stated
we
on
suggest
page
that
that
4.
you
follow the s
you
ThisInstructo r Guide is
and
are
achieved. After
ire
In
and
project
ized
notes
structor
sl ides.
on
each sl ide. T
that
youwill
Guide
Make
need
become
your
famil iar with the
instruct
you
and
approp
sure
hen
that
reread the In
to
modi
0, a course
on
information
and
notes to
ugges
ted guide
wr
itten
ion should be
are fam
riate
ili
ar
wit h
section(s)
you know exactly
stru
ctor
fy the lesson to
lin
es
Give
2.
and
so
We
3.
60
4. After
the student a
state
that
the student will
recommend
%spent in the
you
review the
5. After a
ll
students a
discuss
6. Please
report
1.
Stress
it
have
to us so
the use of Operator's
to emphasize proper
delivery procedures.
2. This course
experience.
your students.
brief
what
he should
that
approximately 40%of the time be spent in the classroom and
shop
have
completed the lesson,
main
points to the lesson.
student questions
few
minutes to complete it . If t i
introduction to the course. Include the ob
know
at
the
know
where
or
field.
have
been
with the students.
the student
that
we
fill
can
out the course evaluation.
make
any necessary
NOTESTOTHE
Manuals
fuels,
is
designed for the
Modify
the course as required to
lubricants,
advanced
ject
ives
end
of the
he
is
going
you
should conduct a
answered, pass out the test and al
class.
and
what
Then
outl ine the c
is expected of him.
brief
me
al lows, grade testin c
Sendthe
improvements
in the course.
summar
traini
y to
low
lass
ng
INSTRUCTOR
to students. Use the Operator's Manual s
operat ion, predel ivery, adjustments and
student
hav
match
ing substant ia l s
nowmobi
the experience level of
lass
and
le
I
NDE
X
S
TC-
Page 2
70l 0
IG
-l
Page
Accessories
............•..
Carburetion Charts
Clutc hing Charts
Co
urse Objectives 4
Fu
el andLubricants
Mac
hine Specif ications 5
at
eri
M
al s Required 4
11
15
13
10
Service Tool s 17
Torque
Spec
ifications
Liquifire
A
djust
Adju
ing C
sti
ng Oi l Pump
Cab
le .......
hoke
.•.•...•
.....
•..
30
30
Chaincase Tensioner•...20
Checking
C
hecking
Limiter . . .
Oil Pump Flo
w.
32
28
RPM
ChokeCable Synchroni-
z
at
ion . . .••.•. .. . . . . 30 44
C
lutc
h Alignment . . . .
Cooling
System . .
CoolingSystem
Pressure Test
Coo
lingSys
tem
Pressure T
Cran
kcase Torque
Sequence
Crankshaft
Gear
Bearing Insta l
Cra
nks
haft
Bearing
Cyl
inder Head
Sequence
Deep
Dra
SnowSuspension
Kit
ining andFi
Cooling
DriveSha
Engine
Gear
Remova
.• ..
•.
• 0 • • • • • • • • • • •
System
ft
Cap
est
and
and
Torque
•...
lling
.•.
.....•
lation
l .
....
....
••.
•..
21
. 21 14
22
21
24
23
23
25
••
18 4
22
20
23
EngineHardware
Torque L
Engine
Torque R.H.
EngineTim
Filling
Inject
FuelPump
Gea
rcase
Gearcase
Replacement
.H
Hardware
ing
and
Bleed
ion
System
....
••.
Cover
..
......•
........
ing Oil
........
Bearing
......
..••
.• .
..
26
26
32
28
31
23
24
Slide
Gearcase
General Fe
Instrum
Lubri
Oi
l 27
atur
es 18
entati
on
cating Throttle
Cable
Lubri
OilInj
8
OilPump
OilPump
PowerJet
43
46
PowerJet Carbur
Pow
10
50
38
Prim
Replac ing
cating
Pump
Dri ve
ection
Wat
System
er
••. . .... .
Instal lation .
Carburetor
etor
Fun
ction 29
er JetCarburetor
Jet Locati
ons...•••
ary Clutch . •. .
Pow
er Jet
and
Main Jet •... . . .
Secondary Clutch •. . . . .
13
16
Shi
mm
ing
Crankshaft
End
Play . . . ••.
Shimming Oi l
Dr
ive G
ear
Pump
. •.....
(Cont i nued)
15
(Continued) . •......
Suspension 18
23
Synchron
izing
Carburetors
22
21
Th
erm
ostat
Tra
ck
TrackAdjus
tme
nt
Track Stud Kit. . ....•. 19
30
18
9
19
Track We
Replac
Sportfire
Center Distance
Offset...•..•.... . .
Center Pan Section
ar
Cl ip
em
ent
and Tra
ilfi
re
and
Clutches . . ••. •. . . .
32
33
51
Engi
ne Bases
Engine Sn
atur
atur
es - Sp
es -
Fe
Fe
ubber
...•.
ortfir
340Trailfire
37
48
20
Features -
440 Trailf ire 33
Front
Sus
pens
ion
Springs
25
Rear
Suspe
Spri
ng
nsion
s
Page
18
31
26
..
25
.....27
25
..
29
29
....20
29
21
.....24
. .
24
25
25
30
22
19
19
19
35
..
..
34
..
•. 35
34
..•
35
e . . 33
33
36
36
S
lide
34
47
31
29
36
29
39
40
41
11
42
12
23
26
27
28
45
17
63
56
61
57
60
52
53
54
64
65
1
2
3
5
6
8
7
Li Lh i n IJSA
IN
DEX
- Co
nti
nued
STC
Pag
-7010
IG
-l
e 3
Spo
rtf i re
and
- Continued econ
dary C
S
Speedometer
Sportf ire Engine .
Steerin g S
St
ud
yste
Installat
Track
Tr
ailfire
Eng
Trailfi
lutc
re
h
..•
m 34
ion 37
ine... •..35
36
37
. • 35
37
Slid
62
65
58
55
67
66
69
e
S
pitfir
e
erfl
Butt
Features
y Carburetor
•••••
• •••c • • •
Fireburst Engine . .
Intake Block Washer..
IgnitionSyst
Su
spensi
on
Testing Ign
Systern.
Track . . . . . . . . .
Wiring
Harness
em
• • • • C>
iti
....
. . . ...39
••
on
...
......
.......
Page
...
ill ., • •
. . . .
.
Slide
38
38
38
71
69
70
38 72
76
39
73
40
39
39
74
75
ST
C-7
Pa
010
I
G-1
ge 4
Upon
1. Explain the
2. Explain the
3. Perform the
1. Slide
2. Slide
3. Technical
completion of
features
new
new
set
for
projector
Manuals
this
features
service procedures and adjustments
STC-7010.
and screen.
TM-1197-Trailfires
TM-1191-Sp
TM-
1217
- Liqu
TM-1222-Sportfire
4. Operator'sManuals
COURSE
OBJECTIVES
course the student should be able to:
of the
Liquifire
on
Trailfire
MATERIALS
and
Sportfire.
and
Spitfire.
REQUIRED
itfire
ifire
on
1980
Snowmobiles
.
OM-M68421-Spitfire
OM-M67978-Liquifire
OM-M68674-Sportfire
OM-M68491-340
5. Tools (a
Handtools
Essential Tools (See page 19)
Convenience Tools (See page 19)
set
for
each
and
work
440
Trailfires
station)
(ALi, iJst -7
"?
)
Lt tho in HSA
MA
CHINE
SPECIFICATIONS
STC
Page
-7010
-l
IG
5
Li
guifi re
Engine
Manufa
Model
Bore
Stroke
Displacement
Compression
Compression
ctur
er
TC44
Ratio 6.9:1
(PSI) 120to
KHI
0A-C
68
60
436
202 T
rran
mm
cc
140
FuelSystem
Capacity 7.75 7.
(U.S. Ga
Fuel
Pump
11
ons)
(29.3L)
Di
aphragm
with
Shut-Off
FuelFi1ter
Carburetor
Typ
e
In-lin
Mikuni
e
PowerJet
Sp
ortfire
KHI
A440B-C202
68
mm
60
mm
436
cc
340
Trai
lfire
KHI
TA340A-D202 TA440A-D202
60
mm
60
mm
339
cc
Tr
440
ailf
KHI
68
60
436
ire
TB340A-A202
nm
rran
cc
7.3:1 6.9:1 6.5:1 6.9:1
130
to
155
75
(29.3L)
Diaphragm
In-lin
Mikuni
Power
Jet
125
7.75 7.75 5.
(29.3L) (29.
Di
aphr
e In-
Mikuni
S
lide
to
lin
140
agm
Valve
130
to 155
3L)
Diaphragm
e In-
line
Mi
kuni Mi
Sl ide Val ve Butterfly
110
Spitf
ire
KHI
60
mm
60
mm
339
to
50
(20.8L)
D
iaphragm
In-line
kun
cc
130
i
on
untity
Syst
Two
em
Carburetor Qa
and
Size
Oil
Injecti
Capacity 3.5 Pints
Pump
Mikuni
Plunger
Co
olingSystem
Typ
e Liquid
4
Capa
city
qts
(2.8
19
Pump
Output
.56
(74L)
(7000
Th
ermostat
Pressure
Cap
108°F
12
13
(0.8 to
0.9 Bar)
36
,
L)
gpm
rpm)
to
PSI
mm
@
One
34
rran
N/A
N/A
Fa
n
N
/A
N/A N/A
N/A N/A
N/A
One34
N/A
N/A
Fan
N/A
N/A
mm
One
34
mm
N/A N/A
N/A
Fan
N/A
N/A
N/
A
N/
A N/A
One32
N/
A
Free Air
N/
A
N/
A
N/A
mm
elt
B
(Al
Tension N
l.
U t )
/A
3/8 inch 3/8 inch 3
(9.52
mm)
(9.52
mm
) (9.52
/8
inch
mm
/A
N
)
oj t ho in U
SA
S
TC-
Page 6
7010
IG- l
Electr
Type
Lighting
Ignit
Spark
Plug
RPM
ical
S
Co
Capac
ity
ion Timi ng
Plug
Gap
Limiter
ystem
il
MACHINE
Li
guifi re
Capacitor
Discharge
120
Watts
16° B
@
(0.058
C
hamp
TDC
6500
11
ion C
RPM@6000
)
QN-2
0.025
(0.635
11
mm)
Yes
SPECIFICATIONS
Sportf
Capaci
Discha
120
ire
tor
rge
Watts
18°BTDC
RP~l
(0.073
hamp
11
ion
)
QN-2 Q
0.025"
(0.635
mm
)
No
- Continued
44
340
Tra
ilfi
re Trailfire Spitf i re
Capacitor Capaci tor Capa
Di
scharge
120Watts
22°
BTDC
@
6000
Di
120Watt s 120W
@
RPM
0
scharge
22°BTDC
6000
RPM@65
Di
scharge
22° BT
cit
00 R
(0.108") (0.108") (0.108
C
hampion
N-3
0.
02
5" 0.02
(0.635
No
mm)
Champion
QN
-3
5"
(0.635
No
Cham
mm
) (0.635
pion
ON-3
0.02
No
att
11
5"
or
s
DG
PM
)
rrm)
Powe
r Train
Primary
(Comet)
Secondary
Final Drive Ratio
Sprockets (upper/
lower) 22/35
Chain
Drive
Bra
Brake
ke
Type
Be
lt
Pad
Material
Suspension
Type
JD
102C
John
44°
Deere
Cam
1.
59
:1 1.86:1 2.06:1 1.86:1 Direct D
66Pitch
M68
715
Mecha
nical
Disk
Sintered
Metal
A
lum
inum
Slide
JD
John
Comp
102C
Deere
ound
Cam
JD
John
38°
102C
DeereJohn
Cam
21/39 17/ 35 21/39
62
66
Pi tch
M66345
Mechanical
Pitch
M66345
Mechanical Mechanical
Disk Disk
Sintered Sintered
Sint
Metal Metal
Aluminum
Sl ide
A
luminum
Sli
de Slide Slide
JD
102C
JD
DeereJohn
44°
66Pit
M66345
Cam
ch
44°Ca
M6841
Mechanical
Disk
er
ed
Di
Sintered
Metal Metal
Alumin
um
Aluminum
94C
Deere
N/A
N/
A
6
sk
m
riv
e
Track Type
Track
Width
Rubber,
Mo
lded
15.38 in• .
(39.1cm)
Rubber,
Rive
ted
15 in.
(38.2
cm
) (38.1
Rubber,
Riveted
15
in.
cm
) (38.1
Rubber,
Riv
et ed
Rubber,
Riv
15 in. 15 in.
cm)
(38.1 em)
eted
STC-7010
IG-
Pa
ge 7
1
unne
and
l
Chassis
T
Pan
Hood
Winds
hield
Seat
Ski Stance
OverallWidth
Body
MACHINE
SPEC
IFICATIONS
-
Cont
inued
340
L
iguifire
Aluminum
Sportfire
Aluminum
Tr
ailfi
Alumin
re Tr
um
ail
Alu
Steel Steel Steel Steel
&TPR &
SMC SMC
Spo
rt
Sport
32
.0 in.
(81 e
m)
39
in.
(99.1
em)
TPR
Sport
Sport
30
.0 in. 30.0 in. 30.0 in .
(76
em)
37
in.
(94
em)
&T
PR
SMC
Trai
1 Tr
Standard St
with
Seat Strap
(76 em)
37
in.
(94 e
m)
&
S
and
wi
Seat Strap
(76 em)
37
(94em) (84 em)
440
fir
e
Spit
minum
TP
R
MC
ail
Alumi
Al
uminum
S
Standard
ard Standard
th
30
.0 in .
(76 em)
in.
33.25 in.
fi
num
MC
re
Overa
ll
Length
Overall Height
Dry
Weight
102
(259
37
(94 em)
404
(183.3
in.
em)
in.
lbs.
kg)
102
(259
37
(94
385
(175
in.
em)
in.
em)
1bs,
kg)
102
in.
(259
em)
40
in. 40 in .
(102
em)
375
1bs.
102
in.
(259 em)
(102
em) (104
37
0 lbs.
98.6 in.
(250.4 em)
41
in.
em)
285
lbs.
(170 kg) (168kg) (129.27 kg)
(
Al~
usi - 79)
L
it,
,0 " US
!"
TO
RQUE
SPECIFICATION
STC-70
IG-
Page
lO
1
8
S
Engine
Crankcase 16 ft
Cylinder Head
Intake
Exh
Fan
Carbure
Manifo
aust
Manifo
PulleyNut
tor
ld
ld
Flange
(Rubber ) 3.5
Oil Pump
Gear
Nut
340
Liguifire Sportfire Trailfi re
.lbs.
(22Nm)
16
ft.
lbs. 16 ft .lbs. 16 f
(22
Nm)
N/A
11
ft .1bs• 13 ft
(16
Nm
N/A
ft
.lbs.
(4.7 Nm)
11.6ft.lb
(17
Nm)
16ft.
(22Nm) (22Nm)
(22 Nm) (22 N
4.3
ft.lbs. 4.3 f t .lbs.
(5.8 N
.lb
) (16 N
47
ft.lbs
(64Nm)
N/A
s.
N/A
lbs. 16
m)
s.
13
m)
.
47ft.l bs.
3.5
ft.
t.
(5.8 N
ft.
(16 N
Nm)
(64
ft.
(4.7
N/A
Trailfir
lbs.
16
(22
1bs. 16 f
m)
(22Nm)
4.3
m)
1bs.
m)
(5.8Nm)
13
(16Nm) (16 N
47ft.lbs.
(64
lbs . 3.5
Nm
) (4. 7 N
440
ft.
Nm
t.l
ft.
ft.
Nm)
ft
N/A
e
lbs.
)
bs.
lbs. 4.3
lbs.
.lbs.
m)
Spitfire
16
ft.lbs.
(22
Nm
)
16ft.lbs.
Nm)
(22
ft.
1bs.
Nm
(5.8
13
ft.
lbs.
m)
N/A
N/A
N/A
)
Flywheel
Eng
ine Bracket
L.H.(Cap
Eng
ineBrack
L.H.(S
et
ocket
Screw)
Eng
ine
Brack
et
R.H.Nut
Rubber Mount
Engine to Base
late
P
Scr
R.H.
ew)
60
ft
.lb
(81Nm)
8 ft
.lbs.
(11
Nm
12
ft.
lbs. N
(17Nm)
12
ft .lbs.
(17Nm)
31ft.lb
(44
Nm)
N/
A
s.
)
s.
60ft.lbs
.
60ft.l
(81Nm) (81Nm)
N/A
/A
N
/A
N/
A
50 ft .lbs.
Nm
(68
)
N
/A
N/A
N/
A
N/
A
50ft.lbs .
(68 N
m)
bs.
60ft.lbs.
60
ft.lb
(81 Nm) (81Nm)
N/A
N/A
N/A
N/A
50
ft.
(68Nm)
lbs.
50
(68
N
/A
N/A
N
/A
N
/A
ft
.lbs.
Nm
)
s.
(
uu
st
-?
)
i u-o in
IJ
SA
STC-7010
I
G-1
Page
9
Power
Trai n
ma
Pri
Seco
ndary Bolt
ry Bolt
ChassisandBody
SkiBo
Drag
Tie
lts
LinkHardware
Rod
Jam
Nuts
TORQUE
Li quif i re
50ft.lb
(68
20ft.lbs.
(27
39
(52
32 to 38
ft . lbs.
43
(
51 Nm) 51 N
8 to 12
ft
SPEC
IFICAT
IONS
- Continued
Sportfire Tra
50
ft.
s.
Nm)
Nm
)
ft .lbs .
Nm
) (52 N
to
(68Nm) (68 N
20
(27
39
32 to
ft
(43 to
lbs.
ft . lbs.
Nm
)
ft .lbs.
m)
38
.lbs.
m)
8 to 12
.lbs. ft .lbs . ft . lbs.
(11 to (11 to
16Nm)
16 Nm)
34
0 4
40
ilfire Trailfi re Spitf ire
50
ft.
20 ft
(27
39ft.
lbs.
m)
.l
Nm
lbs.
50ft.
(68 N
bs.
20ft.lbs. 20
lbs.
m)
50ft.lbs.
(68
) (27Nm) (27
39
ft .lbs.
39ft.
Nm)
ft.
Nm)
(52 Nm) (52Nm) (52Nm)
32 to
ft
.lbs .
38
32 to 38
ft . lbs.
32
ft.
to 38
lbs .
(43 to (43 t o (43 to
51Nm) (51 N
m)
51 Nm)
8 to 12 8 t o 12 8 to 12
ft.lb
s.
ft.lbs.
(11 to (11 to (11 to
(16
16
Nm)
Nm)
(16 N
lbs.
lbs.
m)
Spindle
Spindle Bolt
Arm
to
22
22
to
to
28
t.
lbs.
f
22
to
ft.lbs.
28
ft.lbs.
28
22 to
28 22
to 28
ft .l bs. ft .lbs.
STC-/Ul U
I
G-1
Pa
ge 10
Liguifire*
Fuel
Oil
Engine
Tank
Tank
Gear
Case
Fuel/OilRatio
I
MPORTANT:
Sp
ortf
ire,
M.i.
-6omeoil
Trai
x.
6ud
lfires
a.nd
has
and
7.75 U.S.
oil
at
been
U-6ed
Spitfire
FUELAND
Capacity
Ga
6.
50
Imper
55
ounces
1.35 oz.
Idle - 1
50: 1
Jr..a.;t{.o60Jt
6Jtom
oil
*
LUBRICANTS
l . (29.3
ial
Ga
l.
40
cc
20
:1
the
:tanka.6teJt
L)
6
J.JL6t:tank
6J.JL6t
06
:tank.
Typ
RegularLead
BIA
-TCW
SAE
10W40
W.O.T.
6ud
. Check..tha.:t
06
6ud
,i.¢ used,
e
2-Cycle
-
25
:1
ed*
Ratio Oil
40
:1 1 Pt. (0.473 L) 5 Gal. (18.9 L)
50:1 1 Pt. (0.473
I
MPORTANT:
*
Regu
lar
but
non
U-6e
(leaded) gasoline with
-leaded gasoline can
U.S.
L)
40: 1 m-tx.twte -in
6 Gal. (22.7
be
Canada
Fuel
Oil
1 U.S. Pint 4
(0.473
1 Imp
eri
L)
al Pt.
Imperi
(18.2
5
Imp
Fuel
eri
(0. 568 L) (22.7
L)
the
6J.JL6t
an
anti-knock index of 88 or higher is perferred
used
:ta
nk.
on
occasion if necessary.
1 U.S. Pint
(0.
473
L)
1 Imperial Pt.
(0. 568 L)
and 50: 1
th
eJt
ea.
5
(22.7 L)
6 Imperial
(27.2 L)
6teJt.
Imperi
L)
L)
al
al
al
Ga
Ga
Ga
Ga
l.
l.
l.
l.
Litho.
in J A
S
TC-70lO
IG~l
Page
11
Speed
ometer
Tachometer
Electric
Start
Battery Charger
ACCESSORI
Liguifire
Standard
Standard
*
N
N/
/A
A
Sportf
Standard
AM52346
BM2
1167
AM36
786
ire
ES
Tr
AM54916
AM52346
BM
AM36786
Cross Country
Windshiel d
AM55084
AM55
084
AM
Sport Windshiel d Standard Standard A
Trai l
Tow
Backrest Kit
Hi
Win
tch
dshiel d
AM55050
AM54858
BM2I023**
AM55050
A
M54858
BM2I023**
Standard
AM54858
BM2
340
ail
fire
211
66
55084
M55051
I023
440
Tra
il
fir
Standard
AM
52346
BM21167
AM
3678
AM55084
AM
55051
Spitfi
e
AM
54656
AM
52346
N
/A
6
N/A
N/A
N
/A
Standard Standard
Standard
BM
2102
3
A~154 858
N/A
re
Sport Seat Standard Standard
Handlebar Heater
Partial
Wear
Carbide
Rods
Full Carbide
Wear
Tunnel
Rods
Wear
Bars
Five Star Studs
Steel Penetrater
Steel
Pen
etrater
Carbide Tip
Spring Helper Kit
AM54918
AM549
18
AM54964+ AM54964+
AM54701+
AM55182
+
AM54921
AM551
77
AM55178
AM54971
AM54701
AM55180+AM55180+
AM5492
1 A
N/A
N/
A
AM549
71
AM
54987
A
M54918
AM5496
4+
+ AM54701+
M5492
1
N/A
N/
A
AM54971
AM
54987
AM5491
AM54
8
964+
AM54701+
AM
55180+
AM54921
N/A
N/
A
AM54971
N/A
AM
551
42
AM
54964+
AM
547
01+
AM55181#
AM
549
21
N/A
N/
A
N/A
Primer Kit N
C
hrome
Ski
Shock
AM55130
Absorber
Li
ght
Duty
Spring (R.H.)
(bl"'i"C:
? ~
Rear
N/A
1
)
/A
N/
A
Standard
M679
50
N/A N/A
AM
551
30
AM55130
M67950 M67950
AM
54923
AM551
30
N/A
Lith.' in
U~·,fi