John Deere SNOWMOBILES 1980 Instruction Manual

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

STC-7010

IG-l

Pa

ge 12

Li ght

Duty

SpringL.H.

Chrome

Deep

Hand

Snow

Rear
le

Ki t

* Requires

**

Requ

ires

+ P

ackage

#

Package

Rear

Grab

Suspension

AM52050
AM54717

of 2

of 3

ACCESSORIES

- Continued

Liguifire Sportfire Trai

N/A

M6865

1 Standard

BM21169

M67951

N/A N/A

Battery
Seat

340

lfire

44

0

Trai lfire

M67951 M67951

M68651

M686

51

N/A

Spitfire

N/

A

N

/A

N/

A

l.t t ho tn SA

C

LUTC

HING

CHAR

TS

S

TC-

7010
IG- 1

Page 13

Engag

~

1titude

lSea

Level

to

~OOO

14000

Ft.

Ft.

to
6000
6000

Ft.

Ft.

to

4400-4600 8000-8200

4400

5200-5400

Above

Engagement

AH i tude

Sea Level

to 3800-4000

3000
300

6000
6000

0 Ft .
to

to

Above

Ft.

4300-4500
Ft.
Ft.

4300-4500 6

ement

RPM

-4600

RPM

Liquifir

Pr

-ima

rv

L I

Governed

RPM

Spacers

Sprinq

2 Sil ver

8000

-8200 2

8200-8400 2

Si

lver

Red

Sportfire

Primarv Cl tch Secondar

Governed

RPM

6700-

7200

6700-7200

700

-7200 2 SilverAM54287

Spacers

2

2

Spring
Silv

er

S

ilverAM5

e

rtc

n

ArmKit
AM55

AM55

AM55174

Arm
AM55158

428

Spri ng

Positi

172

172 2

Spring

Ki t Po

siti

7

C] tJ t r h

on

2

Cam
44°

44°

2 44°

( 1utch

or

2

1

1

C

am

Co

mpound

Compoun

Com

pound

rha;n

Gearings

22/35 66

22

/39

22

/39

Ch

ain :ase

Gearings

21/ 39

d

21/39

21/39 66

:asp

Cha

68

68

Chain

66

66

in

Engagement

A

ltitude

rsea

Level

to 3600-3800

~OOO

3000

Ft.
Ft.

to 4300-4500

6000
6000

to

Ft.
Ft.

4300-4500

Above

RPM

Gov

erned

RPM

6200-6700

6200-6700

6200-6700

340 Trailfir

.o r v ( 1

Spacers

Spri

2 Sil ver AM55

Si

2

2

lver

Silver

e

Itc

ng

ArmKit

AM5

AM54287

-

h

159

428

Secondarv

Spri

Po

sit

7 2

ng

ion C

2

2

Clutch

am

38°

Compound

Compound

Chain Case

Ge

arin

gs

17

/ 35

17/35

17/35

Cha

62

62

62

in

(Aug\,',t-79)

Lit ho in U

SA

A

ltitude

Level

Sea

to
3000
3000

Ft.
Ft.

to
6000Ft.

6000

Ft.

to

Above

Eng

agement

RPM RPM

3600

-3800

3700-3900

3700-3900

CLU

Governed

6200-6700

6200-6700

6200

-6700 2

TCHING

440

Primary

Spac

ers

2

2

CHARTS-

Trailfire

Cl

Sprinq
Si

lver

S

ilver

Silver

Spitfire

Cont

utch

ArmKit
AM542

AM5492

AM5492

inued

81

0

0

Seconda

Spring

Positio

2

2

2

ry Clutch

Cam

n

44°

44°

44°

ST

C-

7010

G-

1

I

Page

Ch

Gearinq

ain

14

Case

Ch

21/39

21/39 66

21/ 39

ain

66

66

Altitude

Sea

Level

to to
3000
3000

Ft .
Ft .

to to

600

0 Ft .

6000

Ft.

to

9000
9000

Ft .

Ft .

And

Above

Engagement

RPM RPM
32

00

3600

3200
3600

3200

to
3600
3200

to

3600

Governed

56

00

to
6100
5600

to
6

100
5600

to
6

100
5600

to
6

100

Primary Clutch

Number

of Hole

Weiqhts

9 3/4"
6 3/4
3 7/8
9

9

S

7

ize

/8

1

Seco

nd

aryClutch

Spring

Sp

rin

q

White

11

Whit

Whi

te

White

e

11

11

11

am

C
44°

44°

44°

44°

Lo

cati

2

2

2

2

on

Li t 0 -in U A

S

TC-

7010

IG-1

Page 15

Temperature

-40°F to O°F
O°F to

+40°

F

-40°F to +40°F

Temperature

~40°

F

to

O°F

O°F

to +40°F

-40°F to

+40°F

(Further Fine Tuning

Component

MainJet

Power

Main

Power

Jet

Need

NeedleJet

Thrott

le

Pi lot Jet

AirScrew

le

Speed

Id

Component

Main

Main
Power
Jet

Jet
Jet

Jet

Need

Needle

Th

rot t

le

Pil ot Jet

AirScrew

Idle

Speed

CARBURETOR

RECOMMENDATIONS

Liq

uifire

Sea Level

To

4000 Ft.

1

60
Jet
Jet
Jet

le

95

150*

90 *

6DH8­159 QO*

Valve

3.5 *
30 *

1-1/2 *

2000-2500

Sportfi re
Sea

Level

To

4000

2

10
200
170*

le

Jet

6F27-3 *

159 QO*

Valve 3.0 *

25

1-1/2 *

2400-2700

MayBeRequired )

400

60

1
140

3 *

6D
159

1-1/ 2

2000-250

4000

Ft .

60

*

6F27
159

*

1-1/2 1-1/2

2600-30

0 Ft.

To

00

50

90

Ft.

6000

And

Abov

140

85

130

85

H8-2

QO

3.5
25

0

Ft.

To

2000

6000

80

6DH

8-1

159

3.5
20

-1/

1

-2500

An

d
00 Ft. Above
20

0 180
190 170
170

-3
QO

3.0 3

25

00

170

F2

7-3

6
159

.0
25

2600-3000

Ft.

e

QO

2

Ft.

QO

Temperature

-40°F to
O°F

to

-40°F to

O°F

+40°F

+40°

* Standard

f\'gu:~'~79)

Component

Main

MainJet
Jet
Needle

Throttle

F

P

A

Id

Equipment

Needle

il

ot
ir
le

Jet

Jet

Valve

Jet
Screw
Speed

440

Trailfire

Sea Level

To

4000

240

230
6F27-3
166

3.5 * 3.5
25*
1* 1

1800-2300

Ft .

*

QO

600

4000

Ft.

To

6000 Ft. Ab

23

0

2

20

6

F2

166

7-3

QO

*
*

0 Ft.

An

d

ov

e
210
200

6F27-3
166

QO

3.5

25

25

1

2700-3200

270

!

it'

0-3

D

200

~

n

USA

TC

S

Page

-70
IG-

1O

1

16

Temperature

-40°F to O°F
O°

F to +40°F

-40°F to +40°F

Temperature

and

Below
+30°F
+60°

Above

F

-30°F and

-30°F to
+30°F to
+60°F

Main

-40FOto+70°F Thr

CARBURE

TOR

RECOMMENDAT

(Further Fine T

340 Tra

Component

Main

Jet

MainJet

J

et

Need

le 6

Needle J

Thrott

Pi lot J

Air Sc

Idle

le

et

rew

Spee

et
Valv

e 3

d

Sea Level

Component

Main

Main
Ma

in J

Ma

in Jet

Air

Jet
Jet

et

Jet

Air Bleed

3000 F

.8x

Pi lot Jet 80*

ottl

e Valve

Byp

ass

PilotScrew

MainNozz

le

Id

le

Speed

1.0-1.1-1.2*
3/4*

4.0* 4

2200-2400

IONS-Co

un

ing May

il

fi

Be

re

Sea Level

To

3000 Ft.

200
190*

F27

-3* 6F27-3

166-06* 166-06

.0*

30*

1-1/2*

180

0-2300

•

Spitf

ire

3000

To

t.

6000
195
180

*

170

155 140

To

180
165
155

ntinued

Require

30
6000 Ft.

1-1/2 1-1/ 2

2000

Ft .
Ft.

d)

00 Ft.
To

6000

And

Abov
190
180

6F
166

170
160
27-3

-06

3.0 3.0
30 30

-2500

60

To

900

00 Ft.

0 Ft.
1

65

150

2000

9000

-2500

And

Abov

150

140
140 130
130

120

1.0* 1.0 1.0 1.0
2x

4* .8

210*

x2x4
80
210

1.0-1.1-1.2
3/4

.0

2200-2400

.8x2x4 .8

80 80

210

-1.

1.0

1-1.2 1.0

3/4 3

4.0 4.0

2400-2

700

24

x2x4
210

-1.1
/4

00-2700

Ft.
e

Ft .

e

-1.2

* Standard

II LL

~-79)

Equipment

STC-70l0

I

G-'l

Page

17

Essential Tools

Piston Pin Service

Set

Cra

nkshaft Bearing

Service

Bea

ring

Se

Tool

Adapter Kit
Flywheel Pul
Dial Indicator

Br

acket

lywh

eel Holding

F

Tool
Fa

n Holding

te

Win

r Spring

ding

Tool

Star

Clutch Puller
Clutch Align

To

ol
Timin
CD

g Indicator

Ignition Tester J

Wi ring Harness

Adapter

Track Cl ip Press

t

ler

Tool

ment

SERVICE

Li

gui

fir

e

Sportfire Trail

JDM­JDM-8
JDM-

JDM
JDM-

JD

M-64-l

7

33

-9
lO

JDM
JDM
JD

JD
JDM-lO

JDM-64-

JDM-112* JDM

JDM-

JDM-4l-l

N/A

JDM-

DM

-74

JDM-

74A

113

15

-6

JDM-

JDM-4l

J
J
JDM

JOM-

JDG-46

TOOLCHART

-7

-8 J

M-33
M-9

1

-1l

2

113

-1 J

DM-8

1 JDM

DM

-15

-74

74A-6

N/

A

JDM-

34

0
fir

JD

M-7

DM-

8

JDM

-33

JDM-

9

JDM-lO

JDM

-64-l

JDM-1l2

JDM

-1l

DM

-4l

-l

-8l

JDM-1

5

JDM-74

74A-6

N/

A N

e Trai

JDM
JDM
JDM

JDM
JDM-lO

JDM

JDM

3

JDM

JDM

JDM
JDM­JDM

J

DM-74

440

lfire

Spitfire

-7 JDM-7

-8

-33 J

-9

-64

-l

JDM-64-l

-112 N/A

-113

-4l

-l

-81
15

-74
A-6

JDM-7

/A

JDM

-8

DM-33

JDM-9
JDM- lO

JD~1-11

JDM- I03
JDG-47

JDM

-15

JDM

-74
4A-6

N/A

3

Conve

nience Tools

S

nowmobileDolly

Bench Mounted

Fixture
RingCompressor
Piston

Pl

Lock

ier

Pressure Testing

Tool

diatorAdapte

Ra

Kit
Mikuni

Tool
Ca

rburetor

Sy

H-Pull

Carburetor

Ki

nchronizer

er

Bearing

* Use

JOM-112

Ring

t

Pu11er

to hold

0-0524S

JDM­JDM-35 J

JDM-36
JOM-44

16

T

0-0524ST

JDM-

16 JDM-16 JDM-16

DM

-35 J
JDM-36 J
JDM

-44

D-0524ST

DM

-35

DM

-36

JO

M-44

0-0524ST

JDM-35
JDM

-36 JDM-36

JDM

-44 JDM-44

D

-052
JDM

-16

JDM

-35

4ST

r

OG-56

J

JOM-l09-A

JOG-57

0-01200AA
D-0

1218AA

oil

pump

gear during re

N/A

JDM-l09-A

N/

A

0-0

1200AA

D-01218AA

N/

A

JDM-I09-AJDM-I09-A

N/

A

N

/A

N

/A

moval

or instal

lat

N/

A N

N/

A

N/

A

N/A

ion.

/A

JDM-I09-A

N/A

N

/A

N/A

S

TC-

Page

7010

IG-

18

l

Liquifir

General

-

Instrum

Highconsole holds temperature gauges,
tac
standard equipment.

e

Features

440Liquid
A

luminum
Section andTPR
32"Ski
Sport
Heavy
Rubber

entat

hom

Wi

eter

Cooled

Tunnel,Stee l Center

Stance.
ndshield andSeat.

DutySuspension andMo

Track.

ion

and

speedometer

Oil InjectedEngine.

Pan

Sidepanels.

lded

wh

ich are

0 -

Suspension

Des

igned to support the molded rubber

trac

k and

onahigh

DeepSnow

Has a longer rear
springs
swing
driver
on the rear reduces ski pressure a
transfers
traction

prov

ide t

performance s

Suspension Kit

andshock.

arm

pivot

we

ight force

more

.

forwa

weigh

hestre

(BM

swing

It

rd to al

on
t to the

ngth required

nowmobi

211

arm,

brings the rear
the re

le.

69)
softer

low

ar.
trac

more

Weight
nd

k for

L

it

ho in U

SA

STC-7010

IG-l

Pa

ge 19

Molded

Rubber

Track
Reinforced with fiberglass rod
Replaceable

45°

side of

wear
rib

cl ips.

is

the leading edge.

Reference
TM12

17

Track

Adjustment

Adjust to 1/2" slack.

Reference
TM1217

Section
Gr

oup 15

Section
Group

s.

60

60

15

Track

Stud Kit

WearClip

Install

Reference

TM1217

I

nstall

new

Replaceme

wear

cl ips

nt

wi
Section

G

roup

Installation

18

or 36 studs per track usi

th JDG-46.

60

15

the pattern called out in the instal lation
instructions.
because of

Stud locati ons are critical

wheel

locations~

ng

STC-70

IG~l

Page20

10

Drive

Shaft

Hexagon drive

shaft

has three drive

sprockets .

Adjustable

Heavy duty

Chain

Case

roller

Tension

er

bearingdesi gn.

The chain tensioner requires more chain
tr

avel than previous years for the

gear
Tu

tight then

rat

ios.

rn adjusting screw in unti l finger-

back

off

1/4

-tu

rn.

same

Reference

TM-1217

102C

Primary Clutch

Disassembly:

and

Mark cover

mb

reasse

ly.

moveable s

Assembly:

App

ly Loct

nd

installnuts

a

ite

601

to pivot

snu

Install cover without spri

cover
Tight en pivot

moveable

bo

lts

to

boltnu

moves freely.

20ft.l

nutsifnecessary un

Remove

cover

cover, instal l spring, reinstall

and

torque cover bolts to 20ft.

1bs.

ti

on

Sec
Group

heave

50

25

for

boltthreads

g but nottight .

ng

and

tighten

bs.

ts andc

Lo

til

moveable is free.

heckthat

osen pivot

bo

lt

(.AIJgu.1·-79)

Reference

TM-121

7

Sec

t ion

Group15

t t t ho in USA

50

-----'---

-

---

S

TC-

7010

IG

-I

Page

21

SecondaryClutch

Limi

tin

g washer prevents sheaves

openingfar

hu

into

T

he

washers standard.

Clutc h Alignment

C

heckalignmentwit

b area if

secondary will have 2 anti-creep

enoug

h to al

ove

h 3/811key stock.

lowbelt

rspeeding occurs.

from
to drop

Ad

d or

unt il di

Reference

M-

T

Coo

ling System
A radiato

driven water
eng

ine.

remove

me

1217

was

hers behind secondary

nsion

r,

is

1.28-inches.
Se

cti

Gr

oup

heatexchanger andgea

pump

coo

l the Liq

on

15

uif

50

r

ire

Coo

ling

Use
Adapter
Systemshould hold

System

JOM-44

to check cooling sys

Reference

TM-1217

PressureTest

Pressure Tester

10

psi for 2

S

ection

Group

and

JOG-56

tem

pressure.
min

utes.

20

15

' i thc inU::A

S

TC-70
Page

l0

IG-l

22

Cooling

Use
Adap

Replaci

System

JD
ter

hou

ld release

s

Reference
TM-

1217

ng

Cap

Pressure Test

M-44 Pressure Tester

to

check

cap pressure. Cap

at

13 psi .

Sect ion
Group 15

and

Testing

Thermost

andJOG-

20

at

Place thermostat in a container of water

ith

w

a thermometer.

be

fully

Reference
TM-1217

open

at

108°F

Therm

.

Section
Group

ostat should

20

15

56

Dra

ining

Remove

L

Reinsta
Remove

Fil l rad
ethylene glycol ant
mixture

ift

and

Fil ling

drain plug.

rear

of

11

plug.

bleed plug.

iatorwith
starts

Cooling

snowmob

a 50/50mixture of

ifreezeand

to

come

System

ile to drain system.

out bleed hole.
Reinstall bleed plug.
Continue
Run

for
l.

leve

filling until radiat or is full .

five

minutes and rec

Coolant recovery ta nk should be ap
mately 1/2 fu

ll.

water unti l

heck

coo

prox

lant

i-

AuI!st -79)

Reference
TM-

1217

Section

Group15

Li

20

t

ho

in U

.:l

/\

Fi

reburst

Th

e 440 oi l

engine

In

dustri

Servic i

Re

mov

cran

gear.

STC

Pa

Engine

isbuilt

es to John D

ng

Pump

inject

Gearcase

ed, l iquid cooled

by Kawasaki Heavy

eer

e specifica t ions.

ing t he gearcase coverexposes the

ksha

ft gear,idl

ergear

and oi l pump

-70l0
IG

-l

ge 23

Ifoil
JDM
removed

Re

moving

To replace the cranks
or sea

remove

Bearing Pull er, D

27501

TM-1217

)

Insta l

pump gear i s being r

-112 to hold gearwhile
.

Reference

TM-1217

Cra

nkshaft GearandBeari

haftgear,

l,disasse

all

mble t he engine and

threeat

once wi th D-0121

-01200AA

Pilot .

Reference

ling

Cran

kshaft GearandBea

emov

ed, use

nu

t is

Section 20
Group

10

ng

H- P

u11

Section 20

Gro

up

10

rin

bearing

8AA

er and

g

(August-79)

Use heat to expa

bearing

Ref

T

for

erence

M-1217

inst

ndcranksh
alla

tio

n.

Secti
Gr

aft

oup

gear and

on

20

10

Litho in

US

A

S

TC-

Page

7010

IG-

24

1

Shimming

Crankshaft End Play

Set the cranksha
half

and tap the

shaft .

he

ck cl earance be

C

washer andbearing

Add

shi

ms

as necessary.

Reference

TM

-1217

Crankcase

Torqu

Torque crankcase ha

s

how

n.

R

efer

ence

TM

-1217

e S

ft

flywh

equ

in lower

eel end of cra nk-

twe

en innerthru

on

flywh

ence

eel end.

cti

Se
Group

cr

on

ank

20

10

rdware in t he sequence

Section 20

Gr

oup

10

case

st

Rep

lac i

ngGear

This be

case

arin

g can be easi ly pressed in and

Cov

er Bearing

out of gearcase cover

re

move

d. Use t he proper si ze d

Refer ence
TM-1

21

7

S

himmingOil Pump Drive Ge

Measure t he
case cover ga

dimensio

sketflange and the

bearing.

aft

er

seal has been

riv

e pl

tion

Sec
Group

20

10

ar

n between the ge

ar

ate

s.

(AuQust

-79)

L

ith

o in U

SA

STC-70

IG-1

Pa

ge 25

10

Shimming

Measure the
case
s

haft

Sub

trac
from
difference
of s

hims.

Reference

TM-12

Oil Pump D

fl

ange and the outeredge of crank

gear.

t the crankshaf t g

the gearcase cover dimension. T

determines the

17

dim

riv

e Gear -

ension

Con

betwe

en the crank

ear

dim

amoun

Section 20

Group

10

tinu

ed

ension

t andsize

he

li

ng

Oil

lin

enoug

Pump

g theoil
es mustbe in
main

h oi

bearing will not

l.

nde

r head

Instal

Wh

en installin

cti

inje

ho

s
receive

TM

Cyl

inder Head TorqueSequence

Torque the cyl i

hatch pattern.

Reference

TM-12

on

wn or the

Reference

-12

17

17

pump

stall

Section
Group

bolt

Section
Group

the oi l

ed as

20

10

s in a cross

20

10

(August-79)

it

ho in USA

L

STC-70l0

IG- l

Page

26

LUbric

Water

atin

g Water

Pum

p

Annual ly or

whe

lubricate t he in

w

ith

Molybd

enum

Pump

n replac i

sid
disu lphide grease.

Reference

Left

TM.:.121

Hand

7

Engin

e Hardware Torque

1. Cap screws - 8 ft.lbs.

2. Socket scre
R

ef

erence

TM

-12i7

ws

Drive and

ngawa

e of drive

Secti

on

Group

12ft.lbs.

Se

ction20

Group

Replacing

ter

cou

pli

20

10

10

pump

ng

Rig

ht Hand Engine Hard

Nu

1.

ts - 12ft.

ware

lbs.

2. Cap screws 31ft.lbs .
R

ef

erence

TM-1217

Torque

Se

ctio

Group

n 20
10

(Augus

t-79)

Lit

ho

in U

SA

Gearcase

Oi

STC-7010

IG-

1

Page 27

1

Drain ing

Dra
Fi

andFil

in oil

ll

gearcase thr

40 cc of 10

Ch

ecking Gearcase Oil Level

il

level should be 1/2 to 3/4 ful l

O

in

sight

Gearcase Vent

Keep gearcase vent clea n a
allt i
a

mes

nd

leak i nto crankcase.

Reference

TM-1

21

7

ti

Oil Injec

Oil

both

on

issupp

pisto

gear dr iven oi l p

l i ng GearCase

fro

mdra i n plug.

ough

W4

0 engine oi

fil

l plugwith

l.

gauge.

nd

open

or pressur e can bui ld up

Section 10
Group

10

System

lied

to

mai

n be

arin

gs a

nd

ns by external l i nes fr om a

ump.

at

Theamou

peed

s

IMPORTANT:

-61j-6.t
mi.

x..twt

c.

he.c.b.tha..t-6ome.oil

o

il

OilPum

nt of oil increases wi th engine

(see page 10. )

em

has

e.

ou.

fT..e.-6

envo.oi:

p

The oil pump is

cr~nksh

aft

provides t he

am

on the

c

s

tr

oke of the piston

Whene.veJt

bee

n.

e£.

00fT..the.

gea

.

A cam on the pump

pum

ping ac

pump

the.

fu.twtbe.d, use 50: 1

0.<.M:t.:ta.nb.

has

r driven

tionand

lever sh

.

oil

gone.

off

aft

varies t he

Ln]e.c.U.

and

out:

00

the

pisto

another

on

n

(AuQus

t-79)

Litho in U

SA

------

Fill

ing and Bleeding OilInject ionS

STC

Page

yste

-7010
IG

-l
28

m
Fi l l oil reservoir with 2-cycleoil
R

em

ove bleed plug

til

out un
Th

e alternative i s to runwith 50:1

until oil level in reserv

Reference

TM-121

C

hecking

Runeng

checkflow

Yo

u s

hou

one minute

Cyl inder
Crankcase

Reference
TM

-1217

no airbubbl

7

Oil

PumpFlow

ine with 50:1 fuel

from

ld get the following f

at

Outlets- 1.68 to 2.

Outlet

and

al low oi l to run
es appear.

Se
Gr

each outlet .

3,000 rp

m.

3.35 to 4.06 cc
Se

Group

oir

ction
oup

mi

cti

on

goes do

20

10

xture a

low

03

20

10

.

mix
wn.

nd

in

cc

(August-79)

Litho in U

SA

S

TC-7
Page

0l0

IG

-l
29

Power

Jet

Carburetor

Thepower
be

jet

ted c

jet al

loser

lows

to the engines fuel

requirements in al l ranges.

Power

Jet Carburetor

Th

e main jet andpowerjet

in t he f

loat

bowl.

Fuel is drawn
a passage in the
pick up t o the ven

fr

om the

Jet

fl

turi.

oat

Reference

TM

-12l7

the carbu

Locati ons

are locat ed

main

bowl

jet t hrough
and

Sect;'on30

Gr

oup 10

ret

or to

up

the

Powe

r Jet Function

I

nco

ming air going through t he

jetcreates

a l ow pressure which
fuel through the power j
lin

e. W

e

noug

power

hen

the airf

h the fuel is discharged through t

nozzleinto the venturi .

Reference

TM-1217

Rep

lac i

ngPow

Remove

er Jetand Main J

t he f

loatbowl
jet or mai n j et .
is

the

rn

ain j

power

et.

jet and the hex head is the

Reference

TM-1

21

7

powerair

et

up

the

lowbecomesst

Section 30
Group

10

et

to replace a

Th

e slotted headjet

ect

ion 30

S
Tr

ou

p 10

draws

exter

rong

powe

nal
he

r

(August-79)

it

ho i n U

L

SA

ho

both

ke

chok

e cables evenly until

Adjusting C

Adju

st

0.030 inch free play ex
lever with t

R

ef

erence

TM

-1217

Ch

oke Cable Sychroni zation

he

consoledo

istson

wn.

Section
Group

STC- / U1U

Page

choke

30

10

IG

-l
30

Pull

up

on

each cableto make sure each

is adj uste d eq

Synchronizi

Adjust

s

am

e t imewhen the

ng

Carbur

both slidevalves to move

depressed.
cable

Mak

fr

ee play on lever .

e sure that both are flush or

the carburetor bore

thro

tt

le.

Refere nce

TM

-1217

ually.

etors

throttl

Le

ave a smallamo

at

wideopen

Section
Group

at

e leveris

unt of

abov

30

10

the

e

(August-79)

Adj

ust ing Oi l

R

em

ove left hand carbur

Adjustoil
whenthr
moving at e
sl ide valve
depressed.

Reference

TM

ott

-1217

Pump

pump

Cab

le

etor

.

cableto set again

le lever is released and

xac

wh

t ly t

en t

hesame

hrott

le lever is

time as the

Se

cti

on

Gr

oup

10

Litho in U

30

st

stop

start

SA

L

ub

rica t ingThrottle Cable

STC-70

IG

Page 31

l0

-l

Lubricate t hr
WD40 or

LP

S lubricant .

ottle

cable

Reference

TM-121

Fu

el Pump

Va

cuumoperated with a fuel shut

7

valve to prevent fuel f
e

ng

ine

is

not running.

If

fuel runs out of carbur
the engine is shut
p

um

p.

ef

erence

R

TM-

12

l7

off

annuall

Se

cti

Group

on

y with

30

10

-off

lowwhen the

etor

li newhen

, r eplace the fuel

cti

on

Se

30

Group 20

(August-79)

L

it

ho i nUSA

S

TC-

7010

I

Page 32

G.,.l

RPMLimi

ter

Limit s the engine
3750

when

Al

so limi t s t he top

9000.

Checki

ng

RPM

Hol d the t

the throt t le
not

go

above approxi

Reference

TM-121

7

the th

Limi

ter

hrott

lever.

rpm

to approxi

rottl

e lever

rpm

to approximately

le

lever pivotand depress

En

gine s

mately3750

mate

is

released.

peedsho

rpm.

Section 40
Gr

oup

10

ly

uld

Eng

ine

To
f
markon

rpm

Tim

ing

check timing, t he f i rst

lywhee

l s

the f

hou

ld al ignwith the timing
lyw

heel hou

.
Reference

TM-1217

lineon

singat

6500

Section 40
Group10

the

(Augu

st-79)

Li t

ho

in U

SA

TC

-70lO

S

IG

Page 33

-l

SPORTFIRE

ANDTRAILF

port

f ire General Features

S

l.

Chrom

2.

High

3.

Sport

4.

Aluminum

5.

Sport sea

6.

Hood

440

Trailfire

l.

New p

2.

High

3. Redesigned

IRE

e s

hoc

ks andgrab

consol e and spe

wind

shie

ld.
suspension.
t.

louvers

to

rel

ease

New Features

ain

t and graphic s.

consoleand speedomete

wind

shie

ld.

bar.

edometer.

engine h

r.

eat.

4.

Seat strap.

5.

Hood

louvers to re lease e

340 Trai lf i re NewFe

Newpa

l.

High

2.

3.

Redes

4. Seat s
Hood

5.

int

consol

igned

trap

ouv

ers to

l

and graphic s.

e.
wind

.

atures

shield

.

reduce engine

ng

ine

he

he

at

at.

.

(August-79)

Lit

ho in U

SA

STC-7010

-l

IG

Page 34

Steering

All l ocknuts are the pla

type and s
except
s
bo1t .

Both t
crimped
are made on the right side only.

Thesteeringcolumn
c

ent

and pan.

Pitman arm bea
a

nd

C

enterPan Section

System

sti

ho

uld be replacedwhen r

for

the pitman

lotted

with a co

hetie rod and drag l ink are

wh

ich means stee ring adj

er t he pitmanarm between engine

rin

is lubricated in prod

Reference
TM-

12

17

arm

tter

g has been redesign

pin t

can be a

ct

Se
Group

c insert

emo

nut which is

hroug

uction.

ion 60

h t

ustme

djuste

20

d to

ved

he

nts

ed

Th

e pan is r i

st rength.
Po

rt ions of

sect ions are primered to prevent

TP

R sections are sl ightly thicker.

Center pan

to pr

mount
Th

a

ng

ine

E

The
a

st
to support the weight required

flexi

interchangeable.

ov

ide eas

bo

lts.

e tunnel is aluminum to reduce

nd

prevent rust .

Bas

es

Sportfire

nd

t he Tr

ill

made of

ng

or cracking.

bbed

pa

hol

ail

f ires are redesi gned but

to provide a

n covered

e loc

ation

ier

access to

enginebase is a
stee

l.

by

s are rel ocated

Both
Th

ey are not

the

eng

are

dditio

TPR

rust.

ine

weig

luminu

designed
wi

thout

nal

ht

m

•

-

(August

- I

-79)

Li

tho in U

SA

tfireEngine

Spor

C-

7010

ST

IG-l

Page 35

440 fan cooled engi
15

%more power than t he

It

has aring ge

a

cooling

ar

l

ire.

f
carbure
Liqui

lf

Trai

Both
air intake
Mik
440 has a

ger cooling fan than the 440 Tr

fi

ire Engine

the

uni Slide Valve Carburet ors.

air deflector and sl ight ly

Fu

el is supplied

tor

re

sect

34

0 and t
ductsand rec

rin

ne

has appr

oximately

440Trailfire.

ar,

an airint

ake

duc
ail

byapowerjet

as was explained in the

ion.

he

440 engines have

ali

brated

Th

e

g gear as standard equipment .

t,

-

Eng

ine Snubber

The

eng

ine snubber limit s engine move-

ment under peak load.
center di stance or al ign

snubber. Thread snubber in

Wh

en adj

ment,

un

to .040" clearance exist s between s

a

nd

engine crankcase

IMPORTANT:Va
e.ng.<.

ne..

not: M e.

Reference Se

M-1197

T

Cl

utches

and

tighten lock nut .

hY/.U.bbeJtt»aLl

cti

on

Group

The 102C Primary is standard on all 3

Th

models.
to match carb
end

perfor

The secondary w

e 440has been reca

uret

ion andincrease low

mance.

ill

have only t

creep washers.

ust

ing
loosen t he
til

.030"

nubbe

gn

50

25

librat

wo

ant

ed

i-

r

(August-79)

Lithoin U

SA

Secondary C

Th

e S

portf

efficient

h (Spo

ire has a compoundcam to

ly control

rtfir

rpm

e)

throughout t

lutc

shif t pattern. As the sl ide showsthe
compoun
reaches a
red s
sta

Ch

ecking Cent erDistance and Offset

Th

e engine has been moved forward to t he
furthe
JDM

and ce

s

ha

the notch in the t

d cam startsoutat 480and

0

32

angle as compared to the

hade

d area

nda

rd 440cam.

st

end of the specificat ion.

whi

ch represents a

-81 isstil l used to check al
nterdis

ft willf

tancebut the s

it

tig

ht againstfront of
oo

l.

tat

STC-7010

IG

-1

Page 36

more

he

ignme

nt

ionary

ef

erence

R

TM

-1197

Front Suspension Spri

ngs

ct

ion 50

Se
Group25

The front bear ing shaftwill be changed

to s

tee

l and the beari ngs to a stronger

ri

black mate

al during product i on as a

runni ng change.
Adju

st

springs to a

threads exposed through

R

efere

TM-

nce

1197

minim

nu
Section 60

Gr

um of 1/ 2" of

t .

oup

10

Rear Suspension Springs

nda

Sta
to 1
position. '79 spri ngs can be inst
to provide a sof

rd equipment springs are equivalent

97

9 top locationwhen in t he bottom

all

terri

de. The spr i

hel per kitcan be usedwith eit her spring.

ed

ng

(August-79)

Litho i n U

SA

S

TC-70ID

IG-l

. Page

37

RubberTrack

Prov

ides t hetraction and stabil i ty of
bb

a ru
clea

ts.

Adjustto 3/8" slack ma

Reference

TM

-1197

Stud Inst

Star
S
or heavy (15) pat tern.

Th

rods

st

portfi

e heavy patt ern requires carbide w

and

WithLow

er trac k and the grabbing

all

ation

uds are rec
re and Tr

both requ

Pro

ommend

ail

fir

ire

fileCleat

ximum

Sect ion 60
Group

ed for t he

es in aligh

tunnel wear str i ps.

.

10

s

pow

t (10)

er of

ear

Sp

eedom

eterDriv

Th

e speedometer d

all

inst
hand drive shaft

Do not instal l a nut on the top
it
sheave.

ed without removingthe left

willrub

e Instal

riv
bea

on

the seco

lati
e can be easi ly
ring.

nda

on

boltor

ry moveable

(August-79)

Lit ho in U

SA

S

TC-

7010
IG-l

Page 38

SPITFI

Genera

Fireburst

RE

l Features

Color and

l.

Handlebar

2.

at

oper
Canted spi nd

3.
s

tability

Dipstick

4.

Engine

rn

.

switch a
de

re

Kill

4.

same

340

freeair

cedures a
engine except t he simp
syste

graph

is set back

or .

on corne

fuel gauge.

sig

n as Tr

engine.

similar to the fan cooled

le

nd

ics.

design

dimm

er

clos

f or more

rs.

er sw

ailfire.

Al

l service pro-

lif

itc

ied ignition

to t he

hes,

®

Butterf

Intake Block Washer

ly Carburetor

Th

e carb

Thema
machined aluminum and has a s

in

si

larg

was

A
fuel
distribut

uretor

in nozzl e is di e cast instead of

de dia mete
er

.

her in the
for

hot s
ionduri ng idl e.

has been reca

r.

The mai n ai r jet i s

int

ake block accumu

tar

t ing andimproves fuel

lib

malle

rat ed.

r

lates

(August-79)

L

ith

o in U

SA

•

Susp

ension

Th

e rear idler shaft

increase durabi l ity.

bb

er TrackWithLow Profile Cleats

Ru

Ident ical to the

is

square to

Sp

ort f i re and Trai lfire.

STC-7010

IG

-l

Page 39

r:

Adjust to 3

R

ef

TM

-1191

On

e Piece Wiring Harness

The

terminal block has been eliminated

wh

ichwill

n

ect

ion p

Reference

TM-

/811slack m

erence

change elect rical

oints.

1191

aximum

Se
Group

Section 40
Gr

cti

oup

on

.

60

10

test

17

con-

(August-79)

Simpl if ied Ignition

Spitfire

The
unit and the ig
one assembly.

R

efer

ence

TM

-11

91

ignit ion syst

System

nit

ion coil

Sec

tion

Group

em

has the CD

combined

40

12

Litho in U

in

SA

STC- 70l0

IG

-l

Page 40

TESTING

SPITFIRE

IGNITION SYSTE

Ilun

o 0 10 'J

M

JDt·1-74TESTER

'0 10

I

/lOICATClIt

zo 0

@

O~KXJ

LQ\l

~CH

t)

Make

1.

2. Set test
Crankengine.

3.

Results:

(August-79)

connections as

Indicator
Indi cator

er

on

(high) 60.

shown

Lights ­Does

Not Li ght - Proceed to Test #2.

Test #1

above.

System

(CD

andCoil Output)

OK

L

it

ho

in U

SA

TES

TING

SPITFIREIGNITIONSYSTEM-Cont

inued

S

TC-

Page

7010

IG-

41

l

Jm~-7

"'lilT

o

4 TESTER

30 10

IH~20

~

10 W

LOW @)iGH

60

rg

o 100

10

1.

Make

2. Set tes

3.

Crank

Results: I

(August-79 )

connections as

teron

engine.

nd

icator

Indicator

Test #2 (ExciterCoil

shown

(hi

gh)

35.

Lights - Proceed to Test#3.
Does

Not

above.

Light -

Rep

laceExci ter Coil.

Output )

L

ith

o in U

SA

STC-7010

IG

-1

Pa

ge 42

TESTINGSPITFIREIGNI

JD

M-74TES

"'SlT"'~

~

~

<:)

TER

30 10

60

0 10

to

~

o

~

LOW

~1iH

~

TION

SYS

TEM-Co

ntinued

Test #3

1. Make connections as s

2. Settes

3. Cr
Results: Indicator Lights -

(August-79)

ank

ter

on

engine.

icator

Ind

(hi

Does Not Light - ReplacePulser Coil .

hownabove.

gh)

35.

•

Re

(Pul

place

ser

CoilOutput)

Co

il /CD Unit .

Litho in USA

1.

Th

e Liquifire secondary

A.

Prev

ent

sheaves

B.

Op

en sheaves to reduce cree p.

2. The Liqui fi re oil i njec
A.

B.
C.

50:1
More
Less

at

al l engine speeds.

at

idleand less

at

idl e and more

QUIZ

clu

tch has a limi t i ng washerto:

fro

m openi

ti

on system provides a fu

ng

too

far.

at

wide open t hrottle.

at

wide

open

throttle.

el/oi

STC-7010

IG-1

Page 43

l mixture of:

3. The Liq

wi

th 10W40 engi ne oi

uif

i re engine gearcase should be kept 1/2 to 3/ 4 f ul l in

l.

th

e sight gauge

(

A. True.

4.

Th

5. The

6. The

B. Fa1

power

e

A.

B.Mid-

C.

D.
PM

R

A. Top R

B.
C.

compound

A. Affects top end.

B.
C. Affects complete

se.

jet

affects:

Idle to mid

-r

ange.

range only.

Mi

d-range t o wide open

Wideopenthrottle

Lim

i ter limits :

PM

.

RPMto

below engagement.

Both.

cam

on the

Affects

low

end.

only.

Sportfire

shift

throttle.

secondary:

patter

n.

7. The rubb

model s.

A. Liqui fi re.

B.Sportf

C. Trai1fi re.

D.

8. TheSpitf
A.

B.

C.

(Augus

t-79

) Li t ho inUSA

er

t rac kwith

Sp

itfire.

ire

ignition

Coi

l output

CD

unit

Exciter

ire.

test
output
coi l t est.

low prof i le c

syste

mel imina

.

test.

leatsis used

tes

the need for :

onwhichof

t he fol

low

ing

UDENTEVALUATIONQUESTIONNAIRE

ST

STC-7010

-l

IG

Page 44

Your

questions as spec

frank andhonest evaluat ion wi l l

if

ically andcomp

apprecia te d very much.

not be

Title

nstructor'sName:

I

Date of

Did

Whatelse,

What

sig

ned.

of Course:

comp

letion

the course

if

spec

ificimprovements

of t his

meet

your expectations? Please explai n.

anything,

(U

se the reve

form:

would

you

could be

he

lp us

lete

ly as possi ble. Your suggest ions will be

rse

side if necessary. )

like

to have covered in a programof t hi s type?

made

?

improv

e our course. Please answerall

Th

e eval uat ion need

Was

there any

How

has t his

Wou

ld you reco

What

Thank

other com

you

conflicting

program

mmend

ments

helped

t his course to others? Why or whynot?

or suggestions

instructions?

you?

for taking the time to

do

comp

In what sessions?

you have?

lete

thi s evaluat ion.

(August-

79

)

Li

tho in U

SA

STC-7010

IG-

Page

45

l

TRAININGMATERIALRE
TOTHEINSTRUC
Yo

ur frank andhonest evaluat ion will hel p us toimprove our cou

al l questions as spec

be apprec

iated

TOR:

ifical

very much.

ly and complete

(U

se t he reverse side

ly as possib

PORT

le.

if

necessary. ) Please sendth

Trai ning Materi al Report to:

Service Trai ning
JOHN
Hor

DEERE

HORICONWORKS

icon, Wisconsin

Coordi

53

nator
032

Titleof course:

Instructo
Date of completion of
How

many

How

many

Were

r:

times did
students

t he students:

you

were

this

for
present
present?

m:

this

class

?

You

r s

rse

. Please answer

uggest

ions will

is

men

instructiona

Were
Was

Does

Comme

you

it

it

nts:

a. experienced service
b. newserv

provided with

ice

men

enough

presented as suggested?

need

to be changed:

Were the students able to meet the
Should the objectives be rewritten?

Comments:

object

c. off ice and/or
d. c

l inf

ustome

ormati

rs

on?

ives of the class?

man

agem

ent

personnel

(August-79 )

Litho in U

SA

ST

C-

Pa

7010
IG-l

ge 46

A

1-

2. C

A

3.

4.

C

5.

C

6. C

B,

7.

8. B

C, 0

ANSWERSTO

MUL

TIPLECHOICE

QUI

Z

(August-79)

Litho in U

SA