Kawasaki LTD 440 Shop Manual

QUICK

REFERENCE GUIDE

SECTION

SPECIFICATIONS
MAINTENANCE
BRAKE SYSTEM
CABLES

CARBURETOR
CHAINCASE/JACKSHAFT

This

quick

reference
you in
cedure.

• Bend the pages

• Refer to the sectional table of

locating a desired

black
number
edge at each
page .

tents for the
the
required.

tab

of

with the

specific

guide

back

to match the

the

desired section

black

table of

exact

pages to locate

topic

or

will assist

topic

or

tab on the

contents

procedure

CHASSIS

pro-

COOLING SYSTEM
DRIVESHAFT

ELECTRICAL SYSTEM

con-

ENGINE
FUEL SYSTEM

IGNITION SYSTEM

INSTRUMENTS
MUFFLER
OIL INJECTION

SILENCER

STARTER, RECOIL
STORAGE
SUSPENSION
STEERING SYSTEM

TORQUE CONVERTER SYSTEM

TRACK
APPENDIX

GENERAL SPECIFICATIONS

SPECIFICATIONS

1-

1

General

Service

Torque
Gear
Engine
Port

Specifications
General
Engine
Carburetor
Drive
Belt

Gearing ........................

Electrical

Engine ....

Ign ition

Chasis ....

Engine

Ratio

Dimensions ..........

...

. . .

........

....

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

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

Converter

.......

Specifications

Chart

Performance

...

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

Components ..............................

...

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

........

. .

.. ..

Torques

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

Chart.

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

. .

. . .

......... ..

Curves

TABLE

....

......

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

...

.....

OF

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

.

......

..

. ..... . ....

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

. . .

. .... ..

.

....

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

.....

..........

...........

CONTENTS

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

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

.....

.. ..

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

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

. ..... .....

........

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

..

...........

..

. ....

.

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

....

.

...

.

...

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

...

. .... .

....

.....

.........

........

. .. .

.. ..

........

.......

...

. .... .

...

. .

....

.. .......

...... . .

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

. ..

......

. . . . ....

..........

. .

.. ..

...... .....

........

.........

. . .

.. ..

. .

.......

..

. .

........

........ 1-4

.. ..

........

....

.. ..

....

..

. .

.......

.....

.... 1-2

......

...

. ..
... 1-3

. .

..

. .

....

. .

..

.

...

..

..

...

. 1-2

1-2
1-2

1-3
1-3
1-4
1-4

1-5
1-6
1-6

1-7
1-11
1-12
1-12

1-2

GENERAL

General

Length

Width

Height

Weight

Engine

SPECIFICATIONS

(with

windsh

(approximate

GENERAL SPECIFICATIONS

LTD

440

(manual)

103

in.

(2616

mm)

40.5

in.

(1029

mm)

35.8

ield)

dry)

(909

455
(206

LTD

in.

Ib

440

mm)

kg)

(manual)

LTD

440 (electric)

103
(2616

40

.5 in.

(1029

35

.8 in.

(909

481
(218

LTD

440

in.

mm)

mm)

mm)

Ib

kg)

(electric)

Model

Number

Displacement

Bore X Stroke

Number

RPM - Full

RPM

Starter

I

of

-Idle

Carburetor

Make

Mode

l

I

dentifi

cation

Type

of

Carburetor

Cylinders

Throttle

Marki

ng

TC440D-A201

26.6C.1.
(436

cc)

2.

677

X 2.

362

(68X

60

mm)

2

8,200

2,500

Manual

Keihin

BD 40-

B
B

Open

36
36

rewind

36

AL
AR

Vent

with

(left

(right

in.

Accelerator

side)

side)

Pump

TC440D-A204

26.6

C.I.

(436

cc)

2.

677

X 2.

(68 X 60

2

8,200

2,500

Electric

362

mm)

in.

Pilot

Jet

Main

Jet

Power

Power

Idle

Accelerator

Float

Enrichener

Idle

F

Screw

Valv e Seat

Speed

loat

Height

Jet

Air

(fuel)

Jet

(fuel)

Pump

System

Screw

Lever

Screw

70

98

180

180

2.5

Turns

Flush

with

0.

047

in. (1.2 mm)

Dual

Position

2,

500

RPM

0.590

in. (

avoid

compressing

carburetor

Open

Bottom

Cable

(final

15

mm) -

gasket

of

Lever

orifice

adjustment)

surface

diameter

Carburetor

float

valve

.

tilted

20°

to 30°

spring. Measured

from

from

vertical

top

of

to

float

to

Drive

Converter

Engagement

Speed

4,

400

RPM

(approximate)

GENERAL

SPECIFICATIONS

1-3

Spring

Weight

Ramp

Total

Belt

Part

Outside

Width

Thickness

PI N

and

Part

Numbers

Part

Number

Gram

Weight

Number

Circumference

of

Top

(overall)

Color

(each

Surface

(each

ramp)

ramp)

92081-3011 -White
92081-3001 -Yellow
92081-3002 -Black
92081-3004 -Pink
92081-3005
92081-3006 -Blue

11

OG0628
92019-008 -Nut
13042-3001 -Washers
13042-3002 -Washers

39152-3007 -Marked "F"

57.6

grams

LTD

440

59011-3502

46.69±0.19
(1,185.9±4

1.25

± 0.

(31.7±0.8

0.53

± 0.

(13

.5 ±

- Red

- Bolt,

(manual)

.8 mm)

03

in.

mm)

03

in.

0.8

mm)

in.

(standard)

(optional)

(optional)

(optional)

(optional)

(optional)

Silver

2.3

grams

7.3
(1) 0.5

(1) 1.0

grams

46.5

gram
gram

grams

LTD

440

(electric)

59011-3502

46.69 ± 0.19 in.
(1,185

.9 ± 4.8 mm)

1.25 ± 0.03
(31 .

7±0.8

0.

53±0.03

(13

.5 ± 0.8 mm)

in.

mm)

in.

Belt

Taper

Gearing

Top

Sprocket

Lower

Sprocket
Sprocket
Chain

(Silent

Chain

Tensioner

Drive

Chain

Angle

Overall

Type)

Tension

Ratio

Spring

30°

LTD

22

38

1.73
66
Green
Self

± 2°

440

(manual)

Teeth
Teeth

to

1

Pitch

Adjusting

30°

LTD

22
38

1.73

66
Green
Self

± 2°

440

Teeth
Teeth

to 1

Pitch

Adjust

(electric)

ing

1-4

GENERAL

SPECIFICATIONS

Electricical

Type

Headlight-part

-type

Tail/Brake

Instrument

Battery

Electrolyte

Engine

Components LTD

12

number

Light

Lights-temperature

-speedometer

-tachometer

Volume

92069-3507

12 V 60/55 W quartz

G.E. No.

G.E.
G.E. No.
G.E. NO.

N/A

N/ A 1.5

SERVICE

440

(manual)

VAC,

120

W

1157

No

.

363

1816
1816

SPECIFICATIONS

LTD

440

(electric)

12

VDC,

120

W

92069-3507

12 V 60/55 W quartz

G.E. No.

G.E. No.
G.E . No.
G.E . No.

12
hour
at
discharge

(1.4

VOLT

capacity

10

hour

quarts

liters)

1157

363

1816

1816

22

rate

ampere

Effective
Piston
Pi
Pi
Piston
Piston
Piston
Connecting
Connecting
Connecting
Crankshaft
Crankshaft
Cylinder
Cylinder

-Measured

ston
ston

Pin
Ring
Ring

Pin
Skirt
Skirt

Bore
Head

Compression

Diameter

End
End

Bore ...

Clearance
Diameter

Rod
Rod

Rod
End
Run

with

....

Gap
Gap

Radial Play
Side
Small

Play
Out

.

Capacity-

standard

Ratio

..

(Top) . .
(Bottom)

.........

.

Clearance

End

Diameter

(Maximum)

(Maximum)

. .

spark

...

. . .

........

.

plug

...

....

....

. .. . . .

...

.. .....

. .

.

installed

.

...

.

. ....

....... 0.7085 -0.7087

..

. .... . . .

..... 2.6744

9056

. . 0.

..2.6

in.

0.

008

6752

- 0.001 in.

9060

......

6781

- 0.

in.

- 0.
in.

in.

. .

...... 0.008 -0.

.

0.4713 -0.4803
.0.002 -0.004

- 2.

.. 0.0008

. .

.. 0.016

- 0.

.. .....

. .

.

...... 0.002

774

- 2.

.....

7.1 to 1
(17.995 -18.000
016

in.

(02

- 0.4 mm)

016

in. (0.2 -

in. (11 .

97

in.

(005 -0.10

(67

.931 -67.

(002

020

in. (0.4 - 0.5 mm)

(23003 -23.014

.... 0.008

in . T.

I.

(68.005 -68.023

.

... 18.

0.4

-12.20

950

- 0.

03

in. (0.2 mm)

R.

(0 .

05

6cc ± 0.4

mm)

mm)
mm)
mm)
mm)
mm)

mm)

mm)

mm)

cc

Ignition

SERVICE

SPECIFICATIONS

1-5

Spa rk Plug
Ignition
Ignition

+

operating

Timing (Dynamic)
Timing

Lighting
Exciter
Pulser

Primary

+

Secondary

NOTE:

Defective

Gap ......

(B.T.D.

Item

Co il

Co il

Coi l

Item

Winding

winding

conditions

IGNITION

...

C.) ....

coils

is the

....

.. .

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

...

. . . . . . .. ..

...........

Ohmmeter

IGNITION

Ohmmeter

cannot

always

recommended

RISE TIME

....

. . ....

........

...

....

..........

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

.....

. ..

...

. . . . .

.......

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

MAGNETO RESISTANCE TESTS

Leads

Yellow-Yellow

COIL

Leads

High

Tension-High

be

detec

test

Connected

Red

-Groun

Red-Wh

ite

RESISTANCE TESTS

Connected

B

lue-Groun

ted

using

method

.

d

d

Tension

this

test

Between

Between

alone.

SPARK ARC DURATION

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

210 at 6,500

Use

of a coil

.

...

0.
6,

0.024

RPM (engine

. . 0.

102

Resistance

0.19

ohms ± 20

165

ohms ± 20

18.5

ohms

Resistance

19

ohms ± 20

000

ohms ± 20

tester

in. (0.6 mm)

in. (2.61

± 20%

which

cold)

mm)

%

%

%

%

simulates

Q)

'"

~

'0

>

~

'0

'"

c

o

OJ

Q)

(J)

~

Q)

c..

40

~

30

..

'"

!l

0

>

20

...

:0

'C

c

0

u

~

10

0

100% J_ - - - ---::0

90%-,---

I

10%

J--

I

I

o t

!.-10·12

Rise

time

; time between 10%and 90%

of

secondary peak voltage

SECONDARY

VOLTAGE

,

-

2000

ENGINE

3000

SPEED (RPM)

I

I

.

.1

1000

-'-'-

i

I

I

I

- -

--

J.I

second:'

OUTPUT

4000

5000

-

--

'C

<

0

0

6000

"

"

"

u

"

c

co

>

'"

e;,

Z

0

i=

<::

a::

::J

0

IJ

200

u

~

:1.

I

,

100

a

1000

2000

3000

4000

ENGINE SPEED (RPM)

IGNITION

/

/

TIMING

-

--

CURVE

,

I'

/

f

1000

2000

4000

3000

ENGINE SPEED (RPM)

5000

6000

5000

r-..

........

7

000

6000

r--

8000

1-6 SERVICE

Chassis

SPECIFICATIONS

Converter

Offset

Distance

Converter Center Distance

Drive

Chain

Brake

Lever

Track

Tension
Steering
Tie

Rod End

Tension

Movement

Alignment.

Adjustment

...

.....

......

Engine Torques

Cylinder

Cylinder

Crankcase-6

Head

-8 mm

mm

size

size

....

.....

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

. ...

.

. .

. . .

Stud

Jam

. .

...

. .. . .

...

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

....

. ..

....

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

Nut

Dimension ......

LTD

440

19
(2.6

16
(2.2

70
(0 .8

16
(2.2 kg-m)

. .... ....

..

(manual)

It

Ib

kg-m)

It

Ib

kg-m)

in. Ib

kg-m)

It

Ib

....

. . . .. .

.. 0.525

..........

3/4 in.

(19

mm)

. . . . . 1-1 14 in .

. .

.. ......

...

. .... ..

maximum

.

...

to 0.

588

... ... . .. . 12

...........

.

...........

deflection

Skis

parallel

in.

(13.3

or

(32

LTD

19

(2.6

16

(2.2

70
(0.8

16
(2.2

to

14.9

in.

(305

Self

Adjusting

Self

Adjusting

(5 to 8 Ib

118 in.

mm)

maximum

440

(electric)

It

Ib

kg-m)

It

Ib

kg-m)

in. Ib

kg-m)

It

Ib

kg-m)

toe

mm)

mm)

pull)

out

Flywheel

Recoil

Carburetor

Gearcase

Starter

Holder

Mounting-6

to

-8

Cylinder

mm

size

mm

size

72

It

Ib

(10.0 kg-m)

70

in. Ib

(0.8

kg-m)

45

in. Ib

(0.5

kg-m)

60

in. Ib

(0 .7

kg-m)

12

It

Ib

(1.7

kg-m)

72
(10

70
(0 .8

45
(0 .5

60

0.7

12
(1

It

.0

in. Ib

in. Ib

in. Ib

kg-m)

It

.7

Ib

kg-m)

kg-m)

kg-m)

Ib

kg-m)

TORQUE CHART

QUANTITY

TORQUE CHART 1-7

CONTROLS

Brake

lever
Ignition
Throttle

switch

lever

CABLES

Brake

cable -jam
Enrichener
Enrichener
Oil

pump

cable -jam
Speedometer
Throttle

cable -jam

HOOD

Headlamp
Hinge

bracket

Hood

hinge

Hood

latch

SEAT AND

Control
Control
Fuel
Oil
Seat

panel
panel

level

level

gauge

to

tunnel -bolts 4

DESCRIPTION

AND

SWITCHES

locking -allen

mounting -face

locking -allen

nuts
cable -jam
lever

mounting -nut

cable

nut

housing

to

band

holder

to

housing

hood -screws

mounting -nuts

CONSOLE

bracket

to

bracket -screws

gauge

panel

panel

screw

nut

screw

nut

nuts

to

hood -screws

holder -screws

to

chassis -nuts

mounting -screws

mounting -screws

LTD

440

1

1

1

2
2
1
2
2
1

4
4
6
4 1/ 4

3 1 / 4

2 #
4 #
4 #

SIZE

8mm

-

8mm

5/

16

6 mm

-

6 mm

-

6 mm

#

10

#

10

1/ 4

10
10
10

1/ 4

TORQUE

25

in. Ib (0.3

30

in. Ib (0

25

in. Ib (0.3

50

in. Ib (0.6

20

in. Ib (0.2

Hand

tighten

20

in. Ib (0.2

Hand

tighten

20

in. Ib (0.2

25

in. Ib (0.3

50

in. Ib (0.6 kg-

25

in. Ib (0.3

Compress

95

in. Ib (1.1

20

in. Ib (0.2

20

in. Ib (0.2

20

in. Ib (0.2

35

in. Ib (0.4

kg-m)

.35

kg-m)

kg-m)

kg-m)
kg-m)

kg-m)
kg-m)

kg-m)
kg-m)

rubber

kg-m
kg-m)
kg-m
kg-m)
kg-m)

m)

)
)

STEERING

Handlebar
Handlebar
Steering
Steering

Tie

rod

end -jam

Tie

rod

end

Tie

rod

end

SKI AND

Shock
Shock
Ski
Ski
Ski
Ski
Ski spring

absorber

absorber
saddle
skeg
spring
spring

holder -allen

holder
arm to
column

to

spindle -bolt

mount

nuts

to

steering

to

steering

SPINDLE

to
to

to

spindle -nut

to

ski -nuts

to

saddle -nuts

to

ski, front -nut

to

ski, rear -nut

screws

steering

to

chassis -bolt

arm -nuts
column -nut

ski -nut
ski

saddle -nuts

column -bolt

4

1
2
4
4
3
1

2
2
2
6
4
2
2

1/4

3/8

3/ 8
5/

16
3/ 8
3/ 8
3/ 8

3/ 8
3/ 8 31 ft
3/ 8
5/

16
3/ 8
3/ 8
3/ 8

105

in. Ib (1.2

35

ft Ib (4.8

30

ft Ib (3.9

20

ft Ib (2.8

120

in. Ib (1.4

30

ft Ib (3.9

30

ft Ib (3.9 kg-

31

ft Ib (4.0

Ib (4.0

46

ft Ib (5.7

120

in. Ib (1.4

46

ft Ib (5.7

25

in. Ib (0.3

31

ft Ib (4.0

kg-m)

kg-m)

kg-m)

kg-m)

kg-m)

kg-m)

m)

kg-m)
kg-m)
kg-m)

kg-m)

kg-m)

kg-m)

kg-m)

1-8

TO RQUE

CHART

SUSPENSION

Front

pivot

shaft

Idler

wheel

shaft
Limiter
Rail
Rear axle
Rear

Rear
Rear
Rear
Idler

Rear
Suspens
Front
Fr
Rear
Suspension
Suspension
Suspension

strap

wear

axle
limit
pivot

suspension

whee

suspension

spring

ont

spr

spring

strip
adjusting

locking -bo

er

strap

shaft

ls to rail

ion

brackets
cam

ing

cam

cam

shock

shock
brace

DESCRIPTION

to

tunnel -bolt

mounting -bolt

to

swing

arm -nuts

retaining -nut

bolt -jam

lt

to

pivot

to

tunnel -bolt

arm

to

pivot

brackets -nut

arm

to

to rail ­mounting,
mounting, rear

mounting -nuts

absorber
absorber

shaft -bolts

TORQUE

nut

arm -nut

arm

assembly -bolt

rail

bracket -bolt

nuts

front -bolt

- b

olt

mounting,
mounting, rear -nut

front

- b

CHART

QUANTITY

LTD

olt

(CONTINUED)

440

2
2
4
2
2
2

1
2
2
4
2

38

2
2
4
1
1
2

SIZE

3/ 8
3/ 8
1/4
1/ 4
3/ 8
3/ 8

1/4
3/ 8
3/ 8
3/ 8
3/ 8

1/ 4
3/ 8
3/ 8
5/

16
3/ 8
3/ 8
3/ 8

TORQUE

25

ft Ib (3.5

25

It

Ib (

35

45

in. Ib (0.5

25

in. Ib (0.3

120

in. Ib (1.4 kg-

25

ft Ib (3.5

45

in. Ib (0.5

25

ft Ib (3.5 kg-m)

25

ft Ib

(35

25

ft Ib (3.5

25

ft Ib (3.5

120

in. Ib (1.4

35

in. Ib (0.4

120

in. Ib (1.4

45

in. Ib

(05

25

It

Ib
15
25

(35 kg­ft Ib (1.9
ft Ib

(35

kg-m)
kg-m)

kg-m)
kg-m)

m)

kg-m)

kg-m)

kg-m)
kg-m)
kg-m)

kg-m)

kg-m)

kg-m)

kg-m)

m)
kg-m)
kg-m)

DR

IVE SHAFT

Bearing
Locking

CHAINCASE

Lower
Top
Cha
Chaincase
Chaincase
Chaincase
Jackshaft
Jackshaft
Jackshaft
Jackshaft
Speedometer

housing
collar

sprocket

sprocket

in t

ensioner

bearing
bearing
bearing
bearing

to

tunnel -nuts

- s

et

screw

AND

JACKSHAFT

to

driveshaft

to

jackshalt

moun

cover

mounting

drain

plug -bolt

to

chassis -nuts

retainer
retainer
retainer
retainer

drive

adaptor

BRAKE

B

rake

caliper

to

chaincase -nuts

DRIVEN CONVERTER

Coupling
Cover
Driven

to

fixed

to

movable

converter

sheave -bolts

sheave

to

jackshaft -bolt

- b

olt

- b

olt

ting -bolts

- b

olts

adjusting bolt -jam
housin

g -

to

chassi

to

chassi

- s

crews

nuts

s,

front

s,

rear -bolt

nut

- bolt

3
2

1
1 5/ 8
2

6

1

4 5/

1 3/ 8
2 1/4
1 3/ 8
1

1

2

6

16

1

16

5/
1/ 4

1/2
1/ 4

1/ 4

-

16

3/ 8

-

3/ 8

6mm
6mm

5/8

12

ft

Ib

(1.7 kg-m

70

in. Ib (0.8

35

ft Ib

(48

50

ft Ib

(69 kg-

70

in.lb
70
Judgement

18ft
20
18ft
19ft

31

120

35

120
50
50

(0.8

in. Ib

(08 kg-

Ib (2.6 kg-

ft Ib (2.8

Ib (2.5 kg-m)
Ib

(26 kg-

ft Ib (4.1

in. Ib (1.4

ft Ib (4.8

in. Ib (1.4

in.

lb

(0.6 kg-

It

Ib (6.9

)

kg-m)

kg-m)

m)

kg-m)

m)

m)

kg-m)

m)

kg-m)

kg-m)

kg-m)

kg-m)

m)

kg-m)

TORQUE CHART 1-9

DESCRIPTION

DRIVE CONVERTER

Cover

to

movable

Drive

converter

Ramp

and

Roller

and

Weight

ENGINE

Engine
Engine
Exhaust mount
Mount
Exhaust

ramp

MOUNT

mount

to

damper

manifold -nuts

pin

pin

engine

sheave -bolts

to

crankshaft -bolt

assembly

assembly

assembly -nut

AND EXHAUST

to

chassis,

mount

damper

to

engine

TORQUE

mounting -bolts
mounting -bolts

(special)

recoil

-"

to

side -nuts

allen

screws

bracket -nuts

mount

plate -nuts

CHART

QUANTITY

LTD

440

6
1
6
6
3

2
4
5
6
4

(CONTINUED)

SIZE

6mm
1/2
6mm
6mm
6mm

3/ 8
8mm

16

5/
1/ 4
8mm

TORQUE

120 in.l
70
96in.lb(1.1
120 in.l
60

35
12ft
60
120
120

b (1.4

ft

Ib (9.7

b (1.4

in. Ib (0.7

ft

Ib (4.8
Ib (1.7

in. lb (0.7

in . Ib (1.4

in. Ib (1.4

kg-m)

kg-m)

kg-m)

kg-m)

kg-m

kg-m
kg-m)

kg-m)

kg-m)
kg-m)

)

)

CHASSIS

Bumper
Bumper
Bumper
Bumper
Fuel
Outer
Outer
Rear
Snow
Passenger

trim
and
and
to

pump

guide
guide

stay

flap

clamp
hood

guide

hood

hinge

pan -nuts

to

tunnel -nuts

and

brace

and

inner

to

tunnel -bolt

spacer

mounting -nut

handle

to

brace -nuts

to pan ­to pan -

to pan -

guide

grips -nuts

HEAT EXCHANGER AND

Heat

exchanger
Radiator
Radiator
Radiator
Heat

exchanger

duct
duct
duct

(radiator)

brace

to

brace

to

to

brace -nut
cover

chaincase -bolt
chassis -bolts

ENGINE GEARCASE

Gearcase

Gearcase
Gearcase
Gearcase

ENGINE LIQUID

Thermostat
Thermostat

drain

plug -bolt

fill

plug -bolt
mounting -bolts
mounting -bolts

COOLING

housing
housing

mounting -bolts
vent

plug -bolt

nuts
nuts

nuts

to

pan -nuts

DUCT

to

duct -nuts

SYSTEM

2
4
4

7

2
4
4

2

2
4

4 1/ 4

1

2

4 1/ 4

26

1
1

3

2

3

1

1/4
1/4
1/ 4
1/ 4
1/ 4

#
#1

3/ 8

1/ 4

5/

1/ 4
5/

#

6mm

Bmm

6mm

Bmm

6mm

Bmm

10

16

16

10

70

in. Ib (0.8

70

in. Ib (0.8

70

in. Ib (0 .8

70

in. Ib (0.8

35

in. Ib (0.4

20

0

in. Ib (0 .2

20

in. Ib (0.2

19

ft Ib (2.7

50

in. Ib (0.6

120

45

in. Ib (0.5

60

in. Ib (0.7

18ft

95

in.lb

50

in. Ib (0.6

50

in. Ib (0.6

96

in. Ib (1.1

60

in. Ib (0.7

12

ft Ib (1.7

60

in. Ib (0.7

12ft

in. Ib (1.4

Ib (2.5

Ib (1.7

(1.1

kg-m)
kg-m)
kg-m)
kg-m)
kg-m)
kg-m)
kg-m)

kg-m)

kg-m)

kg-m)

kg-m)
kg-m)

kg-m

kg-m)

kg-m

kg-m)

kg-m

kg-m)

kg-m)

kg-m)

kg-m)

)

)

)

1- 10 TORQUE

CHART

TORQUE

DESCRIPTION

ENGINE LUBRICATION SYSTEM

Elbow

fitting

to

oil

Oil

pump

inlet

Oil

pump

Oil

mounting -bolts

pump

outlet

CYLINDER HEAD AND CYLINDER

Carburetor
Cylinder
Cylinder

head
mounting -bolts

CRANKCASE

Lower

crankcase

Lower

crankcase

Lower

crankcase

tank

plate

mounting -screws

nozzles

holder

to

cylinder -bolts

mounting -bolts

to

upper -bolt

to

upper -bolt

to

upper -nut

CHART

QUANTITY

LTD

440

3
4
3
3

4

12

B

1
9
4

(CONTINUED)

SIZE

-

4mm
6mm
Bmm

Bmm
Bmm
Bmm

6mm
Bmm
Bmm

TORQUE

Judgement
13

in.

lb

(015

60

in. Ib (0.7

50

in. Ib (0.6

45

in. Ib

19ft

Ib (2.6

16ft

Ib (2.2

70

in. Ib
16
16ft

(O.B

ft Ib (2.2

Ib (2.2 kg-m)

(05

kg-m)
kg-m)
kg-m)

kg-m)
kg-m)
kg-m)

kg-m)

kg-m)

PISTON

Flywheel

AND

CRANKSHAFT

mount

ing -

RECOIL STARTER

Pawl retainer

Recoil

assembly

Starter

pulley

to

rope

mounting -bolt

to

flywheel -bolts

MAGNETO

CDI

igniter
Ignition
Stator

mounting

coil

mounting -screws

plate

mounting -screw

nut

reel -

bolt

1

1
3
3 6 mm

2 1/4
4

2 5 mm

1B mm

Bmm
6mm

6mm

72

ft Ib

11

ft Ib (1.6

70

in. Ib (O.B

70

in. Ib (O.B

60

in.lb

70

in. Ib (O.B

30

in . Ib

(10

(0.7
(0.35

.0

kg-m)

kg-m)

kg-m)
kg-m)

kg-m)
kg-m)

kg-m)

GEAR

RATIO CHART 1

-11

I

I-

w

w

I-

""-

0

a::

w

co

2

::l

z

I

I-

w

~

u

0

a::

0-

(/)

z

w

~

x

0

36

37

38

39

*69

40

*Theoretical
NOTE:

GEAR

17

2.18

*75

MPH

64 64 64 66

Red

2.

24

*73

MPH

64

Pink

2.

35

MPH

66

Pink

MPH

All

top

2.06

*79

Pink

2.

*77

Green

2.22

*73

66

Pi

at

speeds

18

MPH

11

MPH

64

MPH

nk

8,200

based

R.P.

RATIO CHART

Drive Sprocket ·

1.90

*86

Red

1.95

*84

Green

2.

*80

66

Red

2.

*77

66

Green

M.

on

.96

19

MPH

64

MPH

05
MPH

11

MPH

overdrive

Numb

*86

*84

*82

er o f Tee

20

1.80

*91 MPH

64

Pink

1.

90

MPH

66

Red

1.95
MPH

66

Pi

nk

2.

00
MPH

66

Green

in

converter

th

21 22

1.76

*93

MPH

Red

1.81

*90

MPH

66

Pink

1.86

*

88

MPH

66

Green

and

engine

1.

68

*97

MPH

66

Pink

73

1.

*94

MPH

66

Gree

n

(Standard)

RPM

at 8,200

G

ear Ratio

S

peed

Chain P

itc

ensioner Sp

ar Ratio

eed

in

Pitch

ensioner Sp

ear Rat

io

Ratio

ain Pitch

Sprin

h

ring

ring

rin

T

Ge
Sp
Cha
T

Gear Ra t io
Speed
Chain Pitch

Tensioner Spring

G

Speed

Ch ain Pitch

Tensioner Sp

Gear
Speed
Ch

Tensioner

.

g

g

Color

Black
White
Red
Orange
Pink
Ye l

low

Green

Blue

CHAIN

TENSIONER

Length

2.

50

in.

(63.50

2.

50

in.

(63.50

3.

00

in.

(76.20

3.

00

in.

(76.20

3.

38

in.

(85.85

3.

38

in.

(85.85

3.

75

in.

(95.25

3.75 in. (95.

25

SPRINGS

mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)

0.

049

0.

055

0.

049

0.

055

0.049

0.

055

0.049 i

0.055 i

Wire

Dia.

in. (1.

245

in. (1.

397

in.

(1.245

in. (1

.397

in.

(1.245

in.

(1.397

n.

(1.245

n.

(1.397 mm)

mm)
mm)

mm)
mm)
mm)
mm)
mm)

1-12 ENGINE PERFORMANCE CURVES

ENGINE PERFORMANCE CURVE

1---

f--

1--

-,-

.-

t--

t--lL

H.

P.

tJ

f-

(/)
(J)

..J

"

l-

LL

W

=:l

a

a:

0

I-

40

30

20

10

f--

1----

1----

~-.-

o

o
o

cry

../

.-/.

/'

f--

~-

I'\...

1//

V

o

o
o

"<t

_.-

,-

~-

17

III

IJ

//

FUEL

b'"

./

CONSUMPTION

'"

o

000000

o

000000

o

o

l!)

<D <D

ENGINE RPM

r

.-

V

l!)

0

I'- I'-

V

~-I--~-

TORQUE

~

l/

l!)

0

co co

1--

~

~

l!)

2.2

2.0

1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

a:

I

CL.

I

(/)

"

(J)

..J
..J

w

=:l

LL

I

EXHAUST

PORT

i

B

C

A =
B =
C =
D = 1.
E =
F = 3.
G =

PORT

TOP SURFACE OF CYLINDER

0

INTAKE

BG

1.575

in.

(40

in.

(29.7mm)

in.

(32.6mm)

in.

(50.0mm)

in.

(34.1

in.

(99.6mm)

in.

(14.6mm)

.0mm)

mm)

1.169

1.263
969

1.343
929

0.575

DIMENSIONS

1

P

OR

T j

F

H = 1.

878 in.

I =

1.878

J = 0 .

575

K =

0.650

L =

0.551 in.
M=0.441
N =

0.307

(47.7mm)

in.

(47.7mm)
in. (1
in. (16

(14.0mm)
in.

(11.2mm)
in.

(7.8mm)

4.6mm)

L K

.5m

m)

1

NOTE:

Port

width

does

not

incl

ude

the chamfer

. Port hei

ght

and

height

tocat

ion

includes

the

chamfer. Port

Chamfer

= 0.031 in.

(0.8

mm)

MAINTENANCE

MAINTENANCE 2-1

Table

Maintenance ..................

Maintenance

Chart

.....

...

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

of

. .

.........

Contents

. .

......................... 2-1

. .

...

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

2-2

2-2

MAINTENANCE

MAINTENANCE CHART

Operation

~

Spark
Carburetor -check
Throttle
,oil
Enrichener
F

Ignition

Drive

Plugs -replace

cable -adjust

Pump

cable -adjust

cable -adjust

ilt

ers, fuel & oil -

timing -

belt -replace

adjustment

replace

check

Converter alignment -check
Converter
Converters -clean
Drive

bush

converter

ing

wear -check

& i

nspect

mount

bolt

Torque
Chain
Chaincase
Track,

tensioner

guides -check

lubricant -check

tension

& ali

gnment

check

Beginning

of

Each

Season

160

5-10

First

80

Use

to

km

Hours

Every

480

or

Hours

km

20

Use

Every

960

or

Hours

km

40

Use

Every

1450

or

Hours

60

km

Use

End

of

Each

Season

X
X X
X X X
X X X
X X X
X

X

X

X

X X

X

X

-

X

X

X

X X
X X

-

X X X

Ski

alignment -check
Brake
Ski skegs -check
Coolant

lubricant level &

adjustmen

t -

pump/gearcase

vent

check

wear

hole

check
Coolant pump/gearcase

change
Fasteners -check

(Use
Suspension
Suspension

lubricant

torque

to r

chart as
wear

strips -check

spring

cams

que

guide)

replace
Headlight -adjust
Coolant

level & freeze

protection -check
Cylinder

Battery

Battery -charge
during

head -check

electrolyte

storage

)

level -

(once a month

-

-

-

-

torque

check

X X

X X

X

X

X X

X

X

X

X

X
X X X

X X
X X
X

X

X

X

X

X
X

Up

Tune

X

BRAKE SYSTEM

BRAKE SYSTEM 3-1

Brake ................

Brake
Brake
Brake
Brake
Brake
Brake

Ad j

ustment.
Pad
Disassembly ...
Inspection
Assembly ...
Pad

Brake
Fixed

Brake

Pad

Pad

Pad

Wear

Replacement

Disassembly .......

Repl

Assembly

Table

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

...

........

Inspection ...

.. ..

. .

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

. . .

.......

acemen

........

. .

......

......

t.

.. ..

of

....

. ....

. . .... . . . .

Contents

........ ..

. .

...

...

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

....

. .... . .

.........

....

...........

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

......

.......

. . .

....

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

. .. . . . .

...

....

....

...................... 3-10

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

. . .

............. 3-4

......

. . . .... ....

. . .

. ....

...

...

. . . .

. .

.....

....

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

...

. .

.. ..

. .

........

..........

.....

......

. .

......... 3-10

....

. . .

...

3­3-3

.

3-4
3-6
3-6

3-10
3-10

1

3-2

BRAKE SYSTEM

BRAKE

1 BOLT,
2 BRACKET,
3 SPACER,
4 RIVET
5 PAD
6 CALIPER
7 NUT, insert,
8 SPRING, pad return
9 PAD,

10

RING

3/8-24 x 2.00

brake

caliper

3/8-24

movable

cable

11

RING, retaining
1 2 SHAFT,
13

STATOR

14

PLUG,

15

SCREW,

16

SPRING, torsion

17

BALL

18

ROTOR

19

BEARING,

20

WASHER,

brake

friction

friction

thrust

thrust

plug

21-

21

DISC ASSY,
22 WASHER,
23

LEVER,
24

RING,
25

PIN,
26 PIN,
27 RETAINER,
28

SPRING,
29

GUARD,

brake

snap

clevis

hair

brake

brake

special

clevis

brake

neoprene

return

disc

BRAKE SYSTEM

3-3

BRAKE

Braking

a

mechanically

and

hub

assembly
ment) on
men t

the jacksha

between
movement
vehicle

Brake

I

WARNING

...,.

____

ing

operation which

Adjustment

to

possible

snowmobile

This

model

disc

brake.

1.

Apply

lever

movement

than

3/4 i

action

is

operated

float

the

may

cause a rattling

Ilmproper

.. _ may

personal

or

its

components.

is

equipped

To

check

the

brake

n.

(19mm).

applied

to

the

caliper. The

(free

left

ft

to

mainta

brake caliper

is

norma

brake

cause

brake

injury

with a self-adjusting

for

proper

firmly

which

and

should

brake

disc

brake

to right

in

proper

sound

pads

move­. This

dur

l.

adjustment
failure

and

damage

adjustment:

measure

be

no

greater

disc

ali

gn-

ing

lead-

the

by

to

If n

ecessary,

1.

Back
bracket

1. Brake Cable Bracket.

2.

Upper

3.

4.

5.

Jam

Lower

Jam
Adjusting
Brake Lever

both br

about 1/

Nut.
Nut.

Screw

adju

ake

st brake

cable

as

jam

follow

nuts awa

4 in. (6.4 mm).

s:

y from

1.

2.

3/4

in.

(19

Release
tance

.

•

This

1/8

in. (3.2 mm).

mm)

Brake

the

brake

dimension

Applied.

handle

should

and

be

measure

no

greater

dis-

than

2.

Remove cable slac

• Pull

bra
brake cam lever
to brac

3. Turn
bot

4. Ch

ec

h jam

ket.

low

er jam

nuts to

k hand

dimension

5. Ap

ply

brake

until

correct

mm) at bra

k .

ke

cable

and snug

nut

up

50 in.lb (0.6 kg-m).

leb

ar

brake lever

with

brake

firmly

and

measurement

ke

lever

upward

to

bracket

released.

turn

is

achieved.

without

upper

and

for

manual

of

3/4

moving

jam

nut

torque

correct

adjuster

in.

(19

1.

1/8

in.

(3.2

mm)

Brake

Released

NOTE
increases
men
decreases

.

6. Perform

: Cl

ockwise rotation

the ha

ndleb

t, a nd count

the m

easu

Brake

e r -

rement.

Pad

of

ar

brak

clockwi

Wear

th e

adjuster

e lever meas

se

rotati

Inspection.

screw

ure

o n

-

3-4

BRAKE SYSTEM

Brake

1.

1.

Pad

Wear

Measure movable

•

Apply
Measure pad

•
face

114 in.

(6.4

brake

of

brake

mm)

Minimum

Inspection

firmly

pad tab to

2. If measurement is l
replace

both

brake

• Refer to Brake Pad

ur

e.

ced

brake

pad

.

thickness

.

ess

than

pads.

Replacement

thickness.

from

outer

brake

disc

11

4 in. (6.4 mm)

.

sur-

pro-

3.

Unfasten
remove

1.

Speedometer

2.

Key

.

3.

Chaincase

4. Drain

speedometer

key

.

Adapter.

Cover.

chaincase

• Place oil drain pan
pan .

•

Unscrew

chaincase

and remove

5.

Unhook

cha

in

lubricant.

cover

cover

.

tensioner

drive adapter

under

hole in low

mounting

spring .

and

er

bolts

Brake
NOTE: Before di

brake,
Pad Wear

1. Remove

Disassembly

sass

embling

check

Refer to Battery Removal procedur

•

brake

Inspection

batt

ery (e

pad

wear

procedure

lectric

self

. Refer to Brake

.

start

2. Remove lower battery bracket.

• Unfasten

1.

Lower

Battery

mounting

Bracket

bolts.

adjusting

mod els only).

e.

1.

Top Sprocket

2.

Chain

.

Tensioner

3.

4.

Lower

Sprocket.

6.

Remove

• Unfasten

•

Pu

ll spr

space

7. Remove

•

Refer to

8. Remove

• Refer to Be

.

Spring

.

upper

sprocke

ocke

rs found

air

silencer

Silencer

drive

sprocket

and

space

t bolt.

ts

off shaft

behind

and

sproc

.

Removal procedure.

belt.

lt

Removal procedure.

ket.

r.

slide

off

9.

Unfasten le

provide

removal.

1.

Trim

.

ft

side

clearance

trim from lower pan to

for driven

converter

1.

Return

2.

Retainer

3.

Brake

4.

Brake

5.

Brake

Spring

.
Cable.
Cable
Lever

.

Bracket.

.

BRAKE

SYSTEM

3-5

10

. Remove

• Unfasten

•

Slide
enough to remov e

1.

Bearing

2.

Beariri

3.

O-Ring.

4.

Bearing.

5.

Bearing

Cap

'g R

Cap

brake

jack

jackshaft

Nut.

etainer:

.

disc.

shaft bearing retainer cap.

out

of

chaincase

brake

disc.

far

12. Unbolt

•

13

. Remove movable pad.

caliper

Remove

brake

spacer, and

from

disc

• Place a rag

1.

2.

Top
Peg.

brake
should

•

Unhook
chaincase

Brake

mechanism

be

dropped

movable

pegs and remove pad .

Pad

Spring

chaincase.

cable

guard.

behind

to

.

brake

.

bracket, cal

chaincase

catch

pad

parts

springs

iper

under

if

they

from

11. Disconnect
Unhook

•

• Pull

• Remove

•

Unf

brake

brake

hair

pin from

clevis

aste n jam

cable

.

return

spring

clevis pin.

pin.

nut

s and remove

bracket.

.

cable

from

14. Remove

• Unfasten

•

Slide

NOTE

: Be

balls

when removing se

1

5.

Remove self-adj

• As

an

chaincase

16

. Slide

thrust

rotor.

brake

lever and

careful

lever and neoprene washer.

snap

ring.

washer

from rotor shaft.

not to lose the three steel

lf-adjusting

usting

mechanism .

mechanism.

assembly, push mec hanism

.

bearing and

thrust

washer

out

off

of
of

3-6

BRAKE

1.

Thrust

Washer
Thrust
Rotor
Brake

tator.

Steel

Bearing.

.

Shaft.

Ball.

2.

3.

4.

5. S

6.

17. Separate

18.

stator
Remove

and

• Remove

SYSTEM

.

rotor

shaft.

brake

shaft

retaining

and

thr

from stator.
ring

ee

stee

s from

l balls from

shaft.

• Remove

•

1.

Stator.

2.

Friction

3. Set

•

Thread

Plug.

Screw.

Use a scr
push

friction

set

shaft

ibe

screw

from stator.

out

of

stator

or

another suitable

plug

out

of

(LH

stato

thread).

tool

r.

to

1.

Stator.

2.

Torsion

3.

Brake

4. Retaining

Shaft.

• Remove
turning
springs.

1.

Torsion

2.

Brake

3.

Shaft.

Stator.

Springs.

Rings

as

Springs.

.

torsion

shown.

springs

Be

careful

from

not

shaft by
to

distort

Brake

I

....

action

Inspection

WARN

____

will

ING

I

Do

...

solvent,

be

impaired

1. Clean all metal

2.

3.

4.

5.

6.

Inspect
thrust

• If
replace

Check

• If ball
and

Inspect

• If

Examine

• If

Check

•

If

steel

washer

any

parts

them.

stator

pockets

rotor.

brake

threads

tors

springs

brake

pads

are

are

are

set.

• If

movable
in . (6.3 mm)
metal

back

Brake

1.

Assembly

Thread

•

Screw
thirds

stator

stator

of

brake

tor.

not

subject

oil,

or

by

oily

parts

in cl

eaning

balls,

thrust

.

show pitting

and

rotor

.

are

worn, replace

shaft.

damaged, replace

ion

spr

ings.

distorted, replace

pad

wear.

worn

unevenly,

pad

measures

overa

ll

thickness

ing),

replace

onto

brake

until

shaft

shaft.

approximately

extends

brake

grease.

or

pads
Braking

greasy

pads.

solvent.

bearing, and

or discoloration

stator

shaft.

them.

replace

less

than 0.25

(including

pad

set.

two-

through

to

,

pad

sta-

BRAKE

SYSTEM 3-7

NOTE:

I

WARNING

'"-

installation
braking.

2.

Parts have LH thread .

_____

Position torsion

• Eyes on
end of

ITorsion

.installed

of

springs

springs

spring

brake

shaft.

springs

as

will

ends

shown.

result

on

brake

must

must

Incorrect

in

loss

be

of

shaft.

face slotted

1.

Ring

(Full

2. Ri

ng

NOTE:

(C-

Type).

Brake

Circle).

shaft

turning

to the operation of the

i~m.

If set

self

adjust. If set

screw

is too loose, the

screw

not release properly,

brake

overheating

and the

on.

resistance

self-adjusting

brake

is too tight, the

which

will

brake

result

light

is

critica

mechan-

will not

brake

in the

staying

l

will

1.

Brake

Shaft

2.

Torsion

Slot.

Spring

3. Test torsion
and tension.

1.

Spr

ings

2.

Springs

Turn.
Won't

Turn

"Eyes".

springs

.

for

correct

installation

5. Install

Use one

set screw.

• Torque

• Turn set
tion
turn.

1.

Tighten

2.

Stator

.

friction

of

the

set

plug

follow

screw

and set

ing

to

1.9

methods

or

screw

in until it bottoms on

plug, then tighten an

DO

NOT overtighten set screw.

1/8

Turn.

screw

in.lb.

additional

into stator.

to

adjust

fric

1/8

-

• Hold

• Turn torsion

brake

shaft

springs

1. The torsion

in vice.

by hand in

springs

shaft.

•

Attempt

tion

to turn

2.

If torsion springs will turn, replace

springs

them.

4.

Position rings on

• Install full

•

Slide

C-type

circle

ring

brake

ring first.

into

shaft.

groove on shaft.

direction

should turn on

by

hand in

direc-

6.

Test for

•

proper
Temporarily
without

the steel

set

screw

install

balls

torque.

rotor on

.

• While holding the stator, turn rotor

alternating

• When
shaft
screw

directions.

turning

must

the rotor in

not turn. If the

is too loose.

direction

shaft

brake

turns, set

shaft,

in

1,

the

3-S BRAKE SYSTEM

1.

Shaft

Must

Not

Turn

2.

3.

4.

5.

Shaft
Stator
Rotor.
Brake

Must
.

Shaft

Turn.

.

.

1.

2.

Brake
Pad

Pad

Radius.

.

• When
shaft
the set

turning

must

screw

• If nece ssary,
above requirements.

Slide rotor

7.

S.

Thread

9.

Lubricate

•

Lightly

off

stator

rotor and stator.

coat

grease.

10. Position steel

11.

Mount

•

rotor

Guide

torsion

• Turn rotor
of

ball

pockets

NOTE:

beneath the

catch

12. Position

Place a rag

any

parts

• Align

brake

rotor/stator

tabs

case.

•

Slide

rotor/stator

the rotor in

turn. If the

is too tight.
adjust

of

brake

complete

ball

balls

in

onto

stator

spring

until

balls

.

behind

mounting

that

may

on stator

assembly

direction

shaft

does not turn,

set

screw

2, the

to meet

shaft.
ly

onto

brake

shaft.

pockets

stator

assemb

with

ball

pockets

ly.

lithium

.

tab into slot of rotor.

fit

into

deepest

the

chaincase

part

area. The rag wil l

drop

during

assembly

assemb ly in chaincase.

with

slots in

into pl

chain-

ace

.

1.

Return

Spring

.

14. Install neoprene

washer, brake

lever, and

snap ring.

• Note

correct

position

of

brake

lever.

,
.

1.

Chaincase Slot

2.

Stator

Tabs

13. Assemble movable

s

.

brake

pad and

as shown.

springs

1.

Neoprene

2.

Brake

3.

Snap

15.

Mount
cable

•

16

. Install bear ing retainer

17.

Slide jackshaft

•

• Position

•

Washer.

Lever

Ring

.

brake

bracket

Torque

Apply
disc

splines

Slide

jackshaft

.

caliper, caliper

, and

bolts to

through

coat

ing of NEVER-SEEZ to

.

brake

• Fit bear in g retainer
bearing retainer.

disc

35

disc

into

ft

O-ring

between

posit

O-ring

spacer, brake

guard to

cha

Ib (4.S kg-m).

on bearing.

disc

into chai

brake

ion.

into

groove of

incase.

ncase

brake

pads.

.

1.

Bearing

2.

Bearing

3.

O-Ring

4.

Bear

Bearing

5.

18. In

Cap

.

ing

.

stall top

•

Torque

(6.9 kg-m

Nut

Retainer.

Cap

.

.

sprocke

sprocket bolt

).

t and spacer.

to

50

ft Ib

1.

Chaincase

2. Sight

3.

4.

I

.....

reduce
plug

Gauge.
Speedome
Drive

Adapter.

WARNING

____

braking

with

disc.

Fill

Plug.

ter

Key.

Iprevent

••

vent

brake

actio

hole

BRAKE

oil

mist

components,

n,

by

installing

pointed

away

SYSTEM

from

coating

which

from

3-9

may

the

brake

fill

1.

Top Sprocket
Chain.

2.

3.

Tensioner

4.

Lower

Sprocket

19.

Mount

• Fit

O-r

•

Torque

20. Install l
21

. In

stall tensioner
retainers.
Mount

22.

• Use new

•

Torque

23. Add

chaincase lubr

• Use Dexron
fluid .

•

Add
center

.

Spring

.

.

jackshaft

ing into

nuts

to

eft

side

trim on lower pan.

chaincase

O-ring

bol ts

to

lubricant

and top of

bearing retainer cap.

cap

groove.

70

in. Ib (0.8 kg-m).

spring

and

hair

cover.

sea

l.

70

in. Ib (0.8 kg-m).

icant.

II

automatic

until level is

sight

transmission

between

gauge.

pin

24. Insert
cover
square

NOTE:
within

speedometer
hole

hole in lower

Speedometer

chaincase
rotated when
sprocke

25.

t mount bo lt.

Connect

• Hold drive
on cha

• Inse rt end
of adapter.

• Slid e

not use f
components
adapter

26.

Mount

brake

• Thread one l

• Insert

• Install

I

WARNING

,

____

pin,

and

clevis

27.

Install

clevi s

retainer.

•

Mount
is toward

• Insert
clevis.

• Install

while

rotating key to align with

key

cover

proper

ly

speedometer

adapte

inca

se cover.

of

flexible

adapter

into position on cover.

orce

during

are

will

slide

cab

le in

ock

nut

cable

through bracket.

seco

nd lo

cknu

I

To

avoid

••

function,

retainer

pin, hair

clevis

retainer

chaincase

clevis

hair

pin from

pin in

key

through

sprocke

should be

hole and

chaincase

t mount bolt.

centered

cannot

engaged with lower

drive

r near

key

adapter

mounting

into

.

threads

square

assembly. When

properly

easily

brake

onto

into

cable.

position

cable

aligned,

bracket.

t on cable.

possible

install
as

follows:

so

brake

clevis

pin,

and

that slott

pin,

clevis

ed side

.

clevis

chaincase

pin.

side

be

hole

Do

.

mal

hair

-

of

3-10

1.

2.

3.

28.

BRAKE SYSTEM

Retainer
Hair

Pin

Clevis

.

Pin.

Mount

•

Secure

heat

ware installed in

.

lower

shield

batt

battery

brack

ery bracke

bracket

et

with

sequence

t.
to footrest

mounting

shown .

and

hard-

FIXED PAD REPLACEMENT

1. Drill

1.

Fixed

2. Rivet.

2.

3.

out

brake

• Use a 5

Brake

Position new

pad rivet.

/32

in. (4 mm) drill.

Pad.

brake

Rive t new pad to ca

• Use a

drift

to s

upport

pad on

liper

rivet.

• Spread the rivet

with

caliper

as shown.

.

the head of a new

a punch.

29.

Install battery.

• Refer to Battery Install ation procedure.

Brake

I

~

require
replace
braking

Pad

WARN

____

Replacement

ING

IThe

._

pads

replacement

brake

pads

action.

fixed

have

at

the

as a set

and

been

same

movable

designed
time.

to

insure

BRAKE PAD DISASSEMBLY

1.

Refer to Brake

• Perform

Disassembly

steps 1 thr

procedure.

ough 13.

brake

to

Always

good

1. Rivet.

BRAKE PAD ASSEMBLY

1.

Refer to Brake

• Perform

Assembly

steps

13

procedure.

through 29.

CABLES

BRAKE CABLE 4-1

Brake

Enrichener

Oil

Thrott

Cable ...
Brake
Brake
Brake

Enrichener
Enrichener
Enrichener
Enrichener

Pump

Cable ...

Oil

Pump Cable
Oil Pump
Oil

Pump
Oil Pump Cable

le

Cable .........

Throttle
Throttle
Throttle
Throttle

Table

...

. ..... .. . . .

Cable
Cab le
Cable Insta lla tion

Removal .... ..

Inspection

Cab le . . .. . .. .

Cable
Cable

Cable Inspection ... .. .

Cable

.......

Cable
Cable

Cable
Cable
Cable
Cable

Adjustment
Remova l .

Inspection .......

Installation

.......

Adjustment.
Removal . .

Installation

......

Adjustment ....

Removal ......

Inspection

Installation ....

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

of Contents

...

.......

. .

.....

...

......

.....

....

. ......

.....

.....

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

.....

......

......

.....

.. ..

..........

..........

. .....

...

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

......

. ..

...

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

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

.......

. . .

......

...... .

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

...

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

. ..

.........

. ..

. ..

...........

...

.............................. 4-7

..

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

. .

....

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

......

....

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

.. ..

.......

....

.....

. ..

....

. .. . . . .... .

......

......

. ....

......

.......

........

. ..

..

................ 4-5

.

......

...

. .....

......

.

............... 4-7

.......

......

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

.........

...

..

...

.

....

..

....

....

. ......

..

....... 4-4

....

. .

.. .. .. 4-4

.......

. .. . ..... .. 4-5

..........

......

...........

..... ......

. .

. . .....

....... 4-6

. 4- 1

..

4-3
4-3
4-3
4-3
4-3

4-4

..

4-5

. . 4-6

4-6

. .

4-6
4-7

4-2 BRAKE CABLE

CABLES

3

~

I

4

1

I

©J

6

I

/

r

9

r

9

)0

10

1 NUT,
2
3 CABLE,
4 CABLE, LH
5 NUT,
6
7 CABLE,

enrichener

HOUSING ASSY,

RH

carb

carb

RING,

special

snap

jam

throttle

mounting.

enrichener

enrichener

enrichener

8 CABLE, oil

9 PIN,
10
11
12
13

hair

PIN,

cable

CABLE ASSY,

NUT, jam,
BAND,

pump

5/16-24

cable

brake

tie

BRAKE

Brake

1.

Separate

• Remove

• Slide cl

•

Unhook

2.

Unscrew

3.

Disconnect

•

Remove

•

Unhook

CABLE

Cable

Removal

cable

end from clevis retainer.

hair

pin.

evis

pin out.

cab

le end from

locknuts

cable

snap

cab

from cable.

end from brake lever.

ring.

le end from lever.

clevis

retainer.

2.

Mount

cable

• Thread

• Insert

• Install

I

WARNING

L,.

____

pin,

3.

and

Connect

•

...

clevis retainer

Mount

is toward

• Insert
clevis.

• Install

4.

Check

cable

• Cable
handl eba r in

• Be certain
bends

•

Secure
prevent
may lead to malfun

5.

Adjust

brake.

• Refer to Brake

ENRICHENER

ENRICHENER CABLE

in

brake

one

locknut

cable

through bracket.

second

ITO

function,

clevis

clevis

locknut

avoid

assembly.

retainer so that slotted side

chaincase

clevis

hair

pin from

pin in

routing.

must

apply

any

cable

or

kinks.

cable

with tie

chafing

Adjustment

CABLE

cable

onto

bracket.

cable.

on cable.

possible

install

as

follows:

brake

clevis

maI-

pin,

.

clevis

chaincase

pin.

side

and return freely with

steering position.

casing

of

outer

ction

bands

.

has no

sharp

as needed to

cas in

g,

which

procedure.

4-3

hair

of

•

1.

Snap

2.

4.

Ring.

Cable

End.

Note routing
snowmobile

Brake

1.

Cable

Check

• Cable
not,

2.

Inspect

• If there are
replace

3.

Examine

• If

protective

is kinked,

Brake

Cable

1. Attach
Hook

•

• Insta ll

.

Inspection

cable

operation.

should

replace

cable

any

cable.

cable

replace

Installation

cable

to

cab

le end

snap

of

cable

move freely

cable.

ends

.

signs of fraying

casing.

coating

is damaged

cable.

brake

lever.

onto

brake

ring.

and remove from

within

casing. If

or

kinking,

or

casing

lever.

Enrichener

1.

Check

•

Cable

enrichener

Set

enrichener lever

(down).

•

Slide

boot

• Cable
mm)

casing

free

shown.

1.

Boot.

2.

Free

3.

4.

2.

Movement

Adjuster
Lock

.

Nut.

If necessary,

•

Loosen

• Turn

adjuster

free movement.

• Tighten locknut.

3.

Reposition boot
prevent

enr

foreign

ichener

Adjustment

up

cab

should

movement

.

adjust

locknut.

to

over

system .

cab

le free movement.

in

off

le, off of adjuster.

have

1/16

when

enrichener

obtain

enr

ich

material

1/16

ener

from

cab

in. (1.5 mm)

adjuster

position

in. (1.5

raised

le.

entering

as

to

4

-4

ENRICHENER CABLE

Enrichener

1.

Separate
control

• Place e
up) pos
removal.

•

Unscrew enrichen

1.

Cold

Start Pos

2.

Remove

carburetor.

•

Unscrew enrichen

Cable

Removal

enrichener lever ass

console

nrichen

ition

.

er lever in "cold sta

to

allow

er mounting nut.

ition.

enrichener

plun

er

ger

plun

embly

mo

unting

assembly

ger ca p.

rt"

from

(full

nut

from

1.

Enrichener

2.

Housing.

3.

Spring.

4.

Plunger

5 .

Cap.

.

•

Carefully
ing.
cap

• Pull

Plunger

and
cables

Enrichener

1.

2. I

Check

•
nspect

• If

cable
Cable
not

, replace

there

replace

3. Examine

• If

protective

kinked, replace

is

Lever

.

pul l

cables

Cable

should

cab

le ends.

are

cable

cable

cap

will

pull

.

from cap.

Inspection

operation

move

cable.

any signs

.

casing

coating

cable

from

out

.

freely

of

.

is

damaged

enrichener

of

hous

with

in

cas

fray

ing

or

or

.

hous

ing

with

ing. If

kinking

cas

ing

-

,

1.

Cab

le Adjuster.

2. P

lunger
pring

Cap

.

3. S

4.

Plunger.

3. Disconnec
Com

press

de

cab

4.

•

• Sli
Unscrew

5. Remove

•

Tap spring

.

t plu

plun

le

plunger

cables

pin from l

nger from

ger

spring.

end

from plunger.

cap

from

from

control

enrichener

cable

lever. -

ever

with drift.

cable

adjuster.

Enrichener

1.

Thread

2.

Connect plunger

3.

Attach

•

•

• Position

•

•

4.

Mount
ment

•

• Set

•

.

5.

Attach

• Position

• Tighten

6.

Adjust

•

Cable

Installation

plunger

cables
Insert
i

nstallation

to

cables

of
be insta lled on
reach
Check
housing

the

left

to see

.

cable
Slide
cable
Insert
plunger

plunger

ends

remain in

spring

as shown.

pin

enrichener lever

panel.

Posi tion lever

contro
allow
Tighten

l lever in

mount

mounting

plunger

ing

cap

plunger

enrichener plunger

enrichener
Refer to
Procedure

Enrichener

.

cap

onto

and

spring

control

into

cap. The

the left

side

carburetor.

that

spr

ends

in

into

housing

secur

assembly

"full

nut

installation

nut

to

carburetor

in

carburetor

cable

cable

to cable.

lever.

cap.

Note
longer
side

ing is in

plunger

position

ing

control

assemb

in

pane

up"

snug

ly with

.

Cable

adjuster.

correct

cable

of

the

posit

must

cap

ion in

.

. Be

certa

in plunger.

lever to

ly on i

nstru-

l.

posit

ion to

.

pliers

.

body.

cap.

Adjustment

to

in

.

OIL

PUMP

Oil

Pump

1.

Remove silencer.

CABLE

Cab

• Refer to

2.

Adjust

LH

tion.

• Turn idle speed
counterclockwise
pletely

• If LH

butterfly
refer to
cedure

.

le

Adjustment

Silencer
carburetor

closes

carburetor

will

Throttle

Removal'proc

to

fully

screw

on LH

until LH

butterfly

bore.

not

close

Cable

Adjustment

edure.

closed

posi-

carburetor

com-

completely,

pro-

1.

lock

2. O

3.

5.

Nuts.

il

Pump

Stop

lever.

Pin.

Reinstall silencer.

• Refer to

6.

Adjust

•

idle speed .

Refer

to

cedure.

Silencer

Carburetor

OIL PUMP CABLE

Installation procedure.

Adjustment

pro-

4-5

1.

Idle

Speed

2.

Oil

Pump

3.

Stop Pin

3.

Position oil

• Push

• It may be
adjustment

I

WARNING

....

____

cable
tor
in.
cable
this
engine

housing

brackets.

(1.6

mm),

to

cable

idle
damage
to

the

operator.

4.

Adjust

• Loosen l

• Hold
adjust
inner

•

Torque

•

Check
when
in LH
throttle

Screw.

lever.

.

pump

pump lever

IWhen

••

measure

extends

If

distance

loo

sen

dimension

properly

speed

to

the

snowmobile

oil

pump

ock

pump

lock

cable.

lock

adjustment.

oil

pump

carburetor

lever

lever in

until

necessary

to

allow

adjust

"full

it

contacts

to loosen cable

lever to

ing

oil

amount

below

upper

given.

could

is

greater

lock

Failure

result

upper

nut

adjustment,

or

personal

cable.

nuts

on

pump

lever

against

nuts

to remove all

nuts

to 20 in. Ib (0.2 kg-m).

Adjustment

lever and

move

is

activated.

throttle

simultaneously

off"

position.

stop pin.

contact

pump

the

oil

pin .

cable,

pump

carbure-

than

1/16

and

adjust

to

adjust

in

improper

resulting

in

injury

cable.

stop pin and

slack

from

is

correct

butterfly

as

Oil

Pump

1.

Remove air

• Refer to

2.

Disconnect
linkage.

• Pull

•

1.

Top

Bracket.

2.

Hair

Pin

3.

Unfasten
bracket.

• Loosen lo

•

Unscrew

4.

Unhook
lever.

Cable

hair
Remove
linkage.

.

cable

cable

Removal

silence

Silencer

oil

pump

pin from

cable

adjuster

ck

nut.

adjuster

end from oil

r from carburetors.

Removal procedure.

cable

pump

pin

from

cable

from

from top

carburetor

pin.

carburetor

carburetor

.

pump

contro

l

4-6

OIL PUMP CABLE

1.

Upper
Control

Remove

•

Mark
nut

Jam

Lever.

with

2.

5.

• Loosen
cable

Nut.

cable
location

tape,

lower

from

housing

adjuster

of

upper

as

shown.

adjusting

from

boss.

housing

cable

nut

and

boss.

adjusting

remove

1.

1/16

in

.

(1.6

mm).

4.

Connect

oil

linkage.

• Install

•

Insert

•

Secure
prevent

cable

hair

cable

chafing

may lead to malfu

5.

Synchronize

• Refer to Oil Pump

pump

pin.

pin

oil

cable

retainer

with

tie

of

nction

pump

Cable

into

bands

outer

.

with

carburetors

Adjustment.

to

carburetor

cable

pin .

as needed to

casing,

which

.

Oil

Pump

1.

Check

•

Cable
not,

2.

Inspect

• If

there

replace

3.

Examine

• If

protective

is

Oil

Pump

1.

Mount

• Position
possible

•

Finger

2.

Hook

I

WARNING

'-,.

____

cable
tor
in.
cable
this
engine

housing

bracket.

(1.6

mm),

to

cable

idle
damage
to

the

operator.

Cable

cable

replace

should

cable

are

Inspection
operation.

move

cable.

ends.

any

signs

cable.

cable

casing.

coating

kinked, replace

Cable

adjuster

cable

upper

tighter.

I

When

...

measure

to

Installation

onto

adjusting

original

lower

end

onto

adjusting

extends

If

distance

loosen

dimension

properly

speed

to

the

upper

given.

could

adjustment,

snowmobile

freely

of

fraying

is

damaged

cable.

housing

position.

adjusting

pump

amount

below

is

greater
jam

Failure

result

or

within

or

boss.

nut

as

closely

nut.

control

oil

pumr:>

the

upper

than

nut

and

to

in

resulting

personal

casing. If

kinking,

or

casing

as

lever.

cable,

011

pump

carbure-

1/16

adjust
adjust

improper

in

injury

THROTTLE
Throttle

1.

Set

Cable

idle

• Refer to
cedure.

2.

Adjust

• With

idle
mm) free

• To

adjust
turn
when

CABLE

Adjustment

speed.

Carburetor

throttle

throttle

position,

cable.

ever

there

play

free play, loo sen

cable

free

adjuster.

play

Adjustments

on

handle

should be

between lever

Retighten

is correct.

bar

1/16

and

lock

pro-

control

in. (1.6

housing
nut

and

lock

at

nut

3.

Fasten

cable

adjuster

bracket.

•

Screw
adjuster

imum

•

Tighten

adjuster

extends

below

lock

top

nut.

into

top

1/16

bracket.

to

top

carburetor

bracket

in. (1.6 mm)

until

the

max-

1.

Free

Movement.

Throttle

1.

2.

Cable

Removal

Disconnect cable from carb uretor linkage .

• Pull

•

Unfasten
bracke

• Loosen l

•

hair
Remove
linkage

.

cable

t.

Unscrew

pin from

cable

throttle

pin

adjuste r from top

ock

nut.

adjuster.

cable

from

car

carburetor

pin.

bureto

THROTTLE CABLE 4-7

Throttle Cable

1. Position
Route

r

•
front

2.

Connect cable

Installation

thrott

cab

le through

of

stee

le cable.

ring pole.

to

throttle lever

instrument

on

pane

l in

handlebar

control.

Hook

cable

end

onto

3.

•

•

•

Install

•

Slide

cable

Attach

snap

cable

adjust

Screw adju

casing

ring to

er.

ster

throttle

into

cable

into top

control

casing.

lever.

assembly.

carburetor

bracket.

• Do

not

I

WARNING

L..

____

po

ssible
carburetor
may

otherwise

jury.

4.

Connect

sert

• In

• Attach

tighten lock

I

Th
installed

holder

result,

rottle cable

nce between

bol

...

interfere

throttle cable
cab

le pin

hair

pin to

nut

at

this

time.

as

ts.

Throttle

causing personal

to

as

shown.

cab

pin

shown

hair

malfunction

carburetor

le pin .

must

to

avoid

pin

linkage.

be

and

in-

1. Cable

2.

Hair

Pin.

3.

Remove
handlebar.

• Pull

• Unh

4.

Carefully
pane l hole.

Throttle

1.

Check

•

Cab

no

2.

Inspect

• If
replace

3.

Examine

• If
is kinked,

Adjuster.

cable

from

snap

ring from

ook

cable
pull

Cable

Inspection

cable operation.

le

should

t,

rep l

ace

cable.

cable ends

there

are

any

cable.

cable

casing.

protective

coating

replace

throttle

cable

end

from

cable

through

move freely

.

signs

of

is damaged

cable.

control lever

casing.

throttle

lever.

ins

within

fraying

casing. If

or

or

on

trument

kinking,

casing

1.

Pin.

2.

Hair

Pin.

5.

Check

•

Cable
return
ing

6.

Adjust

Refer to Throttle

•
cedure.

cable

must
free

posit

ion.

throttle

routing.

operate

ly

with

cable.

without

handlebar

Cable

Adjustment

binding

in

any

and

steer-

pro-

CARBURETOR

CARBURETOR

5-

1

Carburetor
Carburetor

Fl
Cold
Pil

Main System . . .. . . . .

Power

Acce
Carburetor
Carburetor

Idle

Pilot

Main

Power

Accelerator
Carburetor

Carburetor

Carburetor

Carburetor

Carburetor

Carburetor

Carburetor

Carburetor

Carburetor
Carb u

Carburetor

Carb u

Carburetor

Theory
System

oat Bowl ...

Start

ot

System . .....

System ... .... .. . . . .... . . .. .....

lerator Pump . .

Troubleshooting
Tuning ...

Adjusting

Jet ... ..

Jet

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

System

Servicing

I

dle

Speed

I

dle

Adjust

Accelerator

retor

Holders

retor

Table

of

Operation . .

Functions

...

. .. . . .

...

Enrichener

Screw

........

....

Pump

Adjustments ...................

Screw .......

Screw

Pump
Synchron
Synchron

Removal ... . .......

Disassembly
Cleaning

Assembly ...... .. .............

Installat

. . .
Holder
Holder
Holder

...

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

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

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

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

. ..

...

. . ....

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

........

...........

Screw

ization . . .. .... ........

ization,

. . .

ion .. . ..........

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

Remov al .
Inspection

Installation ... ....

of

Contents

.......

......

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

. .

...

. .. .

.......

.........

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

...

. .

.....

. .. .

.

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

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

. .

....... .

Mechanical

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

....

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

......

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

. ..

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

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

........

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

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

. .. .... ..

. ..........

...

. .

...

...

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

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

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

...

. .

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

. .. .

....

. .. . .. .

......

.......

...

..

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

. ..... .....

. .....

....

....

. . .

.........

.......

.....

...

. .

......

...

.......

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

..

. .

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

. .

...

. . .

.......

...

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

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

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

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

........

. ........

.........

. .

.......

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

. .

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

. ..

........

. ........ .......... 5-

........

. ........

..... ..

. .

......

. .. .

......

......

.. .. ..

......

....

. .
. . .

....

....

.....

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

. .

........

.. ..

. .. .

....

. .

...

...

. .. . .

...

...

. ......

......

........

. ..

.....

........ 5-2

. ..

...

5-3

..

5-3

.......

. .. .....

.......

...

. .... .

. ..

. .

. .......

.....

......

...... 5-15

5-3

. .

..

5-4
5-4
5-4

.....

5-5
5-5

. .

...

5-6

....

5-6

. 5-6

5-6
5-7

....

5-7

.

5-7

...

5-7
5-7

....

5-8
5-8

....

5-8

5-9
5-10
5- 13
5- 15

5- 18

19

...

. 5- 19

...

. 5- 19

. .. . 5-19

5-2

CARBURETOR THEORY

CARBURETOR
CARBURETOR THEORY

The

carburetor

8040-36

mm

tle and an

The
the
The
the speed and
carburetor's

lever on the handlebar. When the
the
opened, more
runs fast
tle is closed, le ss fuel and
and

. It has a 40

venturi. The

accelerator

carburetor

amounts

carburetor

lever, the

er

and

it

slows

used on th is mod el is a Keihin

mm

B040-36

pump.

's

job

is to

requir

ed for efficient

also

allows

power

thr

ott

throttle

fuel and

puts

down.

output

le is

contro

is opened

air

out

enter

more

OF

OF OPERATION

throttle bore and a 36

has a

butterfly

mix

fuel and

the rid

of

the engine. The

lled

by a cable

or

the engine and

power

air

enter

OPERATION

thr

air

combustion

er

to control

to a

rider

moves

closed

. If the

the

. If it is

throt-

engine

ot-

in

it

are

usually

that

the engine receives at one time

ranges from an

1: 17. At very
through the
broken
cold

, these

they

.

would
prov ide a very ri ch
of the

ridden . The range of

extremely

slow

engine speeds

carburetor

up

into small droplets. If

droplets
in a warm engine. It is

fuel

will

1: 18

'r

FU

R

::

EL/A

IR 1: 10

ATIOS

1:8

I 1 6

RICH 1:4

of

mixture

be burned.

;

./

fuel/air

or

another

rich 1 :6 to a very lean

the

flow of air

is

slow

and the fuel is

the

engine is

fuel

will

not vaporize as

necessary

to

./

v

/'

/

/

insure

i"'-..

that

"

ratios

to

some

1.

Air

Flow.

2.

Venturi.

3.

Throttle

4.

Throttle

The
engine
burning
parts
engine a fract
I

ncomplete
extra
operational

Within the
be burn ed in the eng in
power
amount

tion is the
ance. To take advantage of the limited
of

air

urround

s
molecules
Max imum
imum
Max imum

each molecule
air

to
of fuel. Maximum
efficiency

Somewhere between maximum

maximum

Valve

.

Bore

.

fuel/air

does not remain

ratio is

of air. This ratio is

fuel required at high

and

of

availabl e for

burning

insure

mixtur

e ratio needed

about

ion of the tim e it is running.

vapori zation at l
fue

l/air

acceptab

economy

air

entering the eng ine for

limiting factor for

eac h

air

to insure that all

power

effi

economy

of fuel

maximum use from a given

of the available fuel.

economy

one

ratio is

le

must

combustion,

molecule

is

obtained

ciency

is gained by

with

economy

is

where

cons

tan

t.

The ideal

part

of fuel to 14.7

only

delivered to the

ow

speeds and the

speeds

usually

fuel/air

e, a balance

of the

several molecules of

is

mean

richer.

ratios

be reached. The

maximum

it

is

necessary

with enough fue l

of

the a

ir

is utilized.

by

gain ing max -

available

surrounding

maximum

pow

most

snowmobiles

by

the

that

the

that

can

between

combus-

perform-

amount

to

air.

quantity

burning

er

and

When warmed up, the eng ine speed at idl e is
low, and
that
The mixture at idle is rich, about
hard
being developed, the
around
are much grea t
is
snowmobile

tim
carburetor
sparingly.

The
the
omy and somewhere in between. The
responds
and
demanded

Carburetor
principles
state
through a
smaller

will
decrease

A

duces
through
tions, the
60% of the
tor,
pressure.
atmospher
what
through the

air

flow

incomplete

acce

leration , wh en maximum

1 :12. The

er

why

fuel

economy

is ridden at

e.

At cru ising

is

substantia

This

results

carburetor

fue l and

air

that

undergo an in

carbureto

which

forces

air

to

the

to the

by speed and load.

operation is based on the

of flui d

when a

tub

e and

diameter

in

pressure

r has a

a l

ow-pressure

it

into

the engine.

pressure

pressure

is

almost

The

ic

pressure

the fuel to

carbure

through

atomization

actual
for high

speeds, air

must

for extremes of pow

rider's

engine

(known as a venturi), the fluid

difference

the

carbureto

of

the fuel

1:10

mixture

amounts

power

drops

full

l,

but

in a s

have the

needs

in the

dynamics

fluid (such

encounters

crease

as it passes through it.

venturi

area when

Under

in t

he

at

the

mouth of the

at

outside

and

mix

tor.

ratio

of

fuel and air

operation.

rapidly

throttle

the fuel is metered

lightly

. These principl es

in

inside it th

venturi

between
venturi
with

much of the

flow

through the

lean

ability

er

by

supp

exact

as air) is

an area

velocity

average

will

atmospher

pressure

the

air

r is so low

occurs.

. Und er
pow
might

when a

mixtur

to meter

or

carburetor

lying

quantities

flowing

and a

at

air

condi-

be

carbure-

outside

flowing

er

be

This

eco

n-

fuel

basic

of

pro-

flows

only

ic

is

is

e.

CARBURETOR

To

supply
engine
separate
the

for fuel and air, the

systems. They

cold

start

SYSTEM

the

widely

enrichener,

FUNCTIONS

differing

are

1)

3) the

the main system, 5) the power

accelerator

the
together to
mixture

it

needs

pump. All

supply

under

the engine with the

all speed and load

ditions.

needs

carburetor

of the

has

the float bowl, 2)

pilot

system, 4)

jet

system, and 6)

six

systems work

fuel/air

six

con-

CARBURETOR SYSTEM FUNCTIONS

1.

Air

Flow.

2.

Reduced

3.

Vent.

4.

Fuel

5.

Atmospheric

Pressure.

Level.

Pressure.

5-3

1.

Float Bowl

The float bowl is the fuel

five

carburetor

systems. Fuel flows into the float

supply

for the

other

bowl through the float valve when the fuel lever

drops

in the bowl
the fuel
valve.

flows

This

determined

The fuel level

eng

ine

will
reason for
occurs

in the venturi. The float bowl is vented to

allowing

in,

the

system

level in

maintains

the

affects

run

throughout its entire range. The

this

is the

the atmosphere, so there is a
psi

pushing

down on the
the float bowl. When the
pressure

float

tubes"
engine
less, and the
less. The
surface

than the

is on the

bowl,

including
which
is running,

lead

surface

into

the

pressure

atmospheric

of

the fuel in the bowl is much greater

pressure

acting
tube. Therefore, the level of fuel
rises as the fuel is
where
droplets

it is released

.

The fuel level
If too low, the
would

not be

decreased

able
the bowl and into
cause

hard starting and lean mixtures. If the fuel

is

pushed

most

to

the

level is too high, too much fuel
venturi and the
fuel leve l is
Always

set the fuel level correctly.

engine

adjusted

the valve to open. As

float rises and

closes

the fuel at a pre-

float bowl.

how rich

drop

surface

engine

or

in

pressure

pressure

of

the fuel in

is stopped,

lean the

that

of 14.7

this

of all the fuel in the

the fuel inside the "feed

the venturi. When the

pressure

in the feed

pressure

in

the

tubes

acting

venturi

is

also

on the

on the fuel in the feed

in

the feed tube

up into the venturi

int

o the air stream as tiny

important

pressure

pull

enough fuel up

air

would

by

changing

at low speeds.

in the venturi

stream .

is

pulled

This

into

run too rich. The

the float level.

out

would

the

the

is

of

2.

Cold

Start

Enrichener

When the
it from the
as when the
ting an atomized
extra fuel must be fed to
start

enr
allows
the valve is opened,
connect
throat
ing through the passage
reservoir on the

engine

is cold, the fuel

carburetor

engine

is warmer. To be sure

fuel/air

ich

ener

system has a

a very rich

mixture

air

ing the mouth of

downstream

of

side

does not atomize as well

mixture

the

into the engine. When

flows

the

the throttle. The

draws

of

the float bowl, mixes

with it, and both fuel and

engine. The reservoir is r

efilled

bowl through a small hole.

the

initial
system is very rich and
tion

1.

Air

2.

Enrichener

3.

Reservoir

4.

Orifice.

5.

Enrichener

shot

it

is

leaner (though

Passage.

Plunger

.

Cable

of

mixture

Open.

.

during

still

spraying

of

that

will

engine

plunger

. The

valve

through a passage

carburetor

and the

air

fuel up from a

air

pass into the

from the float

It is

designed

from the

following

so

enrichener

opera-

rich).

into

get-

burn,

cold

that

mov-

that

5-4

CARBURETOR SYSTEMS FUNCT IONS

3.

Pilot System

The

pilot

system

when

it is idling, at very small
and low
speeds, the

engine

engine
speed throu gh the
pilot

system has very small passages to
fuel und er these
tion is

incompl
velo cities and
pilot

system is tuned to

supplies

fuel to the engine

throttle openings

speeds. At very low

uses littl e air and the a

carburetor

conditions.

ete

because

turbul

ence. To

is very low. The

Also, fuel atomiza-

of very l

counte

supply a fairly

r this, the

ture.

Air

for the

pilot

air

is

drawn from

the

pilot

past

the

flows

to the
buretor. The
the

carburetor
plate (when
which

idle

is

adjust

pilot

sys

tem

comes

through the

jet in the mouth of the carburetor. Fuel

the float bowl and passes through

jet.

The

air and fuel passages

pilot

jet and from there the

pilot

chamber

pilot

chamber

throat

it

is

controlled

upstream

clos

ed) and one downstream,

by

a needle valve called the

screw. When the

in the top of the

has

fuel/air

thr

ee exits into

of

the

throttle
closed, the three upstream exits (called
holes) allow
air

mixes with the fuel going
throat past the idle adju
plate begins to open, a
pen. The
around

by-pa

the
reverses and the hole
instead of an
furth e

r,
other
more

two by-pass holes, allowing more and

fuel to mix
throttle
reversal in the
to the

air

to e

nter

the

pilot

int

o the

st

screw

. As the

number

engine

the

ss hole

speed rises as more air fl

throttle

plate. The

closest

to the

flow

becomes

air

the same

inlet. As the

flow

with

the air

throttle

reversal

rushing

happens

plate and into the eng ine.

pilot by-pass

transition

from the

holes is important

pilot

chamber. This

carburetor

of

things
direction

throttle

a fue l

plate

around the

This

system to the

main system.

engine

ir

flow

supply

ow

rich

mix-

join

just

mix

car-

throttle

plate is
by-pass

throttle

hap-

ows

plate

outlet

opens

in the

flow

air

in

The small size

jets

and
flow

pil
throttle

buretor
pilot

limit

through it. At small

ot

system

openings, the total

is so great

system is a very sma ll

of

the

the amount

reaches

its maximum flow. At large

that

pilot

syste

of

fuel and

throttl

flow

the

cont

percentage

m passages

air

e openings, the

through

ribution

flow.

4.

Main System

At

intermediate

main system

to large

supp

lies a large part of the fuel

throttle

openings, the

needed. The main system has a main j
picks

up fuel near the bottom
vertical passage
buretor
behind

"wall"
carburetor
engine

imum fuel

throat upstream of the

a primary choke.

around the front of the fu el

throat. It

speeds. The main syst

output

dumps

increases

at ju

st

The main system may be rejetted

the

main jet. Be very careful when chang ing the
main jet. Engine damage
heating
is

time. Be sure to use
same
jet

best

caused

to

type

by

change

as

originally

a main jet
main

in the main system.

only

of

the float bowl. A

the fuel

into

throttle

The

primary

choke

outlet

fuel

flow

over

could

jets

em reac
1/4

result from

that

only

hes m

throttle.

by

changing

is too sma ll. It

one si

Keihin main jets

installed. There is no air

that

can

the

car-

of

of

that

et

that

the

car-

valve

in the

at high

over-

ze

at a

of

the

is a

ax-

the

1.

Pilot

2.

3.

4.

By-Pass

Idle

Adjust
Pilot Jet
Air

Passage.

.

Holes.

Screw

.

1.

Primary

2.

Main

3.

Air
Air/Fuel

4.

5.

Power

The

jet

throttle
and at
speed ,
needed

Choke

Jet.

.

Mixture

System

power

reaches

, the

wide

it

is

by

.

.

system

takes

maximum output. At just

power

pouring

open

system

throttle

in

about

the engine.
fuel from the bottom of
through a
it with
the
buretor
along the roof

jet

air

which

carburetor

throat through

in the main

comes

mouth, and
of

the throat.

over

starts

and peak engine

65%

The

power

the

float

carburetor

through

dumps

three

when the main

over

1/4

to

contribute

of

the total fuel

system

bow

body

an

air

it

int

outlets

l,

meters

, mixes

jet

o the

spaced

takes

above

car-

,

it

CARBURETOR SYSTEM FUNCTIONS

5-5

Outlets
and

outlet
Outlet
at
wide
make

1.

2.

3.

4.

5.

three

higher

open throttle,

outlet

Power
Power
Power
Power
Power

three

and

two

one

is in

the

starts flowing

speeds. At high

there

one flow

Air

Jet.

Port

1.

Port

2.

Port

3.

Jet

(fuel).

are near

mouth

first, then

engine

is

as wel

l.

the

throttle

of

the

carburetor.

outlet

speeds

enough air

valve

flow

two

and

to

vents

fuel

back-flow
system is
prev

ents
chamber.
outlet, ready to be
also prevents air

activated. The

fuel

back-flow

This

keeps a charge

squirted

from being
system on the return s
with

out

the

needle
siphon
running. Note th
work
then opened. From a
if
pump

out

of

the

only if the

the

thrott

le is

opened

will not be activated

system while

at

throttle

bout

CD--

into

the

troke

check

the

accelerator

is alm

1/4

farther,

float

bowl when

needle

into

the

of

into

the

sucked

of

the

pump. Finally

valve, fuel

the

ost

throttle

the

.

check

valve

diaphragm

fuel

near

engine. It

into

could

engine

pump

closed and

and above,

accelerator

the

the
the

,

is

will

The

power

ing

either
changing
tur

e ratio,

and

throttle

to

work. In
power
opening
makes
speeds

system

the fuel j

the air

but

it

opening

creasing

system

sca les.

the

power

and small

may

et

jet

not

also

changes

at

which

the

cut-

in up

Decreasing

system

er

throttle

be rejetted by

or

the

only

air

jet

the

start

the main system, be very cauti

ing jet sizes to avoid engine
he

at

ing.

JET

POWER

CHANGE

Larger

SYSTEM

MIXTURE

Leaner

ADJUSTMENT

Air

Small

er

Richer

Fu

Larger

el

Sma

ller

Richer
L

eane

r

air

jet. Note

changes

the

the

size

rpm

the

engine

system

pushes

and

the air jet

to flow

at lower

open ings. As

ous

when

damage

from over-

SYSTEM

S

TART

POINT

Higher
Lower

No

Change

No

Change

chang-

that

mix-

speed

begins

the

throttle

size

with

chang-

1.

Accelerator

2.

Diaphragm.

3.

Ball

4.

Need

Check

le

Check Valv

Pump

Valve.

CARBURETOR

Carburetor

tified

as too rich

Symptoms

related

are as

Rod

.

e.

TROUBLES

malfunctions

or

too le an a fuel mix

follows:

HOOTING

can

be id

en-

ture

.

6.

Accelerator

When

mixture
instant.
extra

the

go ing

The

fuel into
conditions
diaphragm
needle check

Pump

throttl

into the

accelerator

the

. The

using

accelerator

one

valv

e is

opened
engine

pump

carburetor

ba ll

check

e.

The ball

from an idle,

is too lean

throat

pump

check

the

for

an

squirts a little

under

these

is a small

valve and

one

valve pre-

When the fuel/a

1.

Engine noise is

2. The

condition

is hot.

3.

The

condition

enrichener

4. The

5.

6.

cond
the air
Exhaust
Spark

plugs

ition may improve

sil

encer

gases are heavy.

ir

mixture

dull

grows

grows

is

opened

is removed.

become

is TOO RICH:

and

int

ermittent.

worse

when the

worse

.

slightly

fouled.

wh

engine

en

the

when

5-6

CARBURETOR TROUBLE SHOOTING

When

1.

2.

3.

4.

5.

lean fuel
that
assemb
lean fuel
air
carburetor

fuel/air

The

engine

The

cond

enrichener

Acceleration
Spark
The
lack

If a

plugs

revolutions

of

power

carburetor

mixture

the

throttle

le and

mixture

or

fuel passage. If cl

performance,

mixture

becomes

is TOO LEAN:

overheated.

ition improves

is

opened

is

poor

.

.

burn.

of

the

is

notic

ed.

is

experiencing

prob

lems,

is

working

clean

is

usually

the

carbur

caused

eaning does

carburetor

be necessary.

CARBURETOR

D

iff

erent fuel

accord

1.

2.

3. Main

4.

ing

Idle

Adjust

just

over

Pilot

Jet

Jet

full

throttle
Power System - from just above
tle to full

5.

Accelerator
about

opened

Tuning

mixture

at
standard
designed

to

TUNING

metering

to

the

throttle

Screw

1/8

- from

throttle

.

- from ju st

- from ju st below
.

throttle

.

Pump - from ju st
1/4 throttle,
.

enables

any

fuel

meter

throttl

me

tering
more

adju stme

e se

setting

off

when

tting

or less
dard. Because a change
system
systems
whenever a change

can

, all

affect

the

perform ance

systems should

is made

system .

engine

when

fluc

tuat

th

e and

too rich or too

fir

st check to see

prop

erly. Then dis­etor. A rich or

by a

clo

gged

not impro

tuning

component

s function

ve

may

:

clo

sed

throttl

e to

idl

e to 1/2

1/4

throttle to

thr

ott

le.

1/4 throt-

off

idle to

the

throttl

e is

nt

of the fuel/air

by replacing the

devi

ces with

parts

fuel than sta n-

in one fuel metering

of

other

be checked

to

one

fuel metering

e

1.

Idle A

dju

st

Screw

.

Pilot

Jet

- controls

the

pil

ot

sys

tem . If the engine idl es prope rly
the idle
decrease
three

adju

st

screw less

the size of the pil

turns

out

of

the idle adjust scr
needed for a good idle, i
pilot je

t. Always

PILOT

Idle

Adjust

Less

than 1 Turn

1

t03TurnsOut

More

than 3

change jets in one size

SYSTEM

Screw

Out

Turns

Out

the flow

of

all the fuel to

than one

nc

ot jet.

rease

If more than

the

ADJUSTMENT

Pilot

Jet

Decrease
Si

zeOK

In

crease

with

turn

out

ew

are

size of th e

steps

Size

Size

,

.

IDL

100%~--~--

IDLE

Idle Adjust

flowing

from
engine.
richen
tur
out

s the mix

e. If it is necessary to use le ss

or

mor

idle, ch e

E ADJUST SCREW

~--

----+-------+-----

118

1/4

THROTTLE

Screw

the

idle

Turning the

ture. Turning it

e than

ck

the

thr

pilot jet.

112

VALVE

OPENING

- re

gul

outlet port cl

idle adjust scr

ee

turn

s out to

POWER

SYSTEM

3/4 WOT

ated fuel/a

osest

in l

eans

the mix-

tha

n one turn

get a proper

to

ew

--~

ir

mix

the

ou t

1

1.

Pilot Jet.

Main

Jet -regulates

main system.
adjustments
Change
help

the

prevent

There

must

main

engine

is no main

be

made

jet

only

damage

all

to

one

the

air

the

size

from

fue l from

jet

, so

main

jet

at

a time to

overheat

the
many
itself

ing.

.

1.

Main

Jet.

Accelerator

CARBURETOR TUNING

Pump -

squirts

a little

extra

5-7

fuel

into the mouth of the carburetor when the throt-

tle is opened.
about

114

tips

of

the

face

of

the
system
screws

(increase

three
accelerator
drawn
Thus,

into

the

The

throttl

adjuster

plastic

pump

the

pump

low

end

sys

tem

e.

The

standard

screws

pump

fuel

output),

turns in.

stroke

chamber

is richer.

works

setting

even

lever. To

turn

This

incr

so

that

and

from

idle

has

the

with

the

sur

richen

the

eases

the

adjuster

the

more fuel is

discharged.

to

-

Power

for

fuel and
changed
changes
system
on

ly

changes

operat

operating
makes
system
sma ll
moves
low

er

er

engine

the

starting

the

POWER

JET

CHANGE

Larger

Air

Smaller
Larger

Fuel

Smaller

System

for

the

- has

one

for

air. Both

tuning. Changing

mixture

ing range.

the

ratio

Changing

mixture

range as well. A larg

air

mixture

jet

power

leaner,
point
makes

system

higher

the

speed.

SYSTEM

MIXTURE

Leaner
Richer

Richer
Leaner

two

identical

jets, one
jets
the

over

the

entire

the

air

ratio, it moves

er

air

jet

but

also moves the

in

the

RPM range. A

mixture

starting

richer, and

point

ADJUSTMENT

SYSTEM

START

POINT

Higher
Lower

No

Change

No

Change

can

fuel

power

jet

not

be

jet

not
the

only

to a

1.

Adjuster

2.

Accelerator

3.

Outlet.

CARBURETOR

Carburetor

1.

Screw.

Pump

SERVICING

Adjustments

IDLE SPEED SCREW

• Initial
screw
shaft

adju

so

that

link

age. Then,
approximately
contact

• Final

with

adjustment
warm, by
obtain

the
RPM. Use
speed

.

Rod.

stment -Unscrew

it

does

not

contact

turn

screw

1-112

the

turning

turn s

throttle

is

achieved

idle

after

linkag

speed

recommended

tachometer

to

monitor

idle speed

throttle

inward

it

makes

e.

with

engine

screw

engine

engine

to

idle

1.

Power

Air

2.

Power

Jet

Jet.

(fuel).

1.

Idle

Speed

Screw.

5-8

CARBURETOR SERVICING

NOTE:

operate

ance
mended method of
is with a Kawasaki
Spec
buretor

2.

It is

important

in

unison

between LH and

ial Tool PIN 57001 -

Sync

IDLE ADJUST SCREW .

• Initial
screw
Then,

• Final

adjustment
warm nd
idle RPM. Use a
engine
screw
on each
stab

le idle as well as good

re

sponse. To lean

(cl

ockwise

wise)

screw

for

hronization procedure.

adjustment

into

carburetor

unscrew

operating

idle speed and

if req

uir

carburetor

) screw. Open

to richen fuel delivery.

that

both

correct

RH

cylinders. The

carburetor

Mercury

3510.

- Turn idle
until lightly

2-

1/2

turns.

is

obtained

at

the

tachometer

ed . Turn i

equally

out

fuel delivery,

throttle

power

synchronization

Synchro

Refer to Car-

recommended

adjust

dle

adjust

(counterclock

valves

output

recom-

Tuner,

adjust

seated.

with

engine

to

monitor

idle speed

screw

to achieve

accelerat

close

bal-

ion

1.

Normal.

2.

Increase

3.

Decrease

-

Carburetor

It is
function
ciency, both
most
buretors
(special tool). If

perform
tion, Mechanical.

The
vacuum
Measurement of
ing on the position of
valve.
restriction
vacuum measurement.
re

stricts
measurement.

Adjust

mea sures
buretors

output.

output

.

Synchronization

extremely

in uni so

effective

is to use a

procedure

Mercury

within

Opening

air

throttle

by

important

n.

For maximum

cylinders

method of
Synchro

this

the

on

air

flow, which

valve bal

equally

performing the following

must

Mercury

for

Carburetor

Synchro

the

engine

vacuum

throttle

flow,

causes a higher

at i

dle

that

work

synchroniz

Tuner

Tuner

will

the

carburetor

valve

resulting

Closing

ance

speed

both

carbureto

power

Synchro

is not available,

int

so

and

equa

lly. The

ing

Synchron

measures

ake

system

vary

depend-

throttle

reduces

in a lower

throttle

vacuum

that

vacuum

for both

procedure

effi­car-

Tuner

iza-

the

valve

car

rs

.

­.

1. Idle

Adjust

Screw.

3. ACCELERATOR PUMP SCREW.

• Normal Position - End
flush with bottom of lever.
In

crease

•

Turn

plete turns) so
beyond bottom

will

• Decrease
Insert
screw
obtain

Accelerator

adjusting

not

provide

Accelerator

screw

inw

ard to

desired

screw

that

of

additiona

into lever hole shown. Turn

result.

of

Pump

inward

tip

of

lever. More than 3

Pump

reduce

adjuster

(1

screw

l fuel output.

fuel

screw

Output

to 3

com-

extends

turns

Output

output

-

­to

@~:~:m

converter

1.

Warm up engine.

•

For
restartin
for

I

WARNING

.....

____

parts.

2.

Install vacuum

3509)

• Turn

• Remove
holes.

•

Screw

::

::~epne~~;

guard

several minutes.

in each carburetor.

proper

g,

I

Avoid

••

touch

off

engine.

screw

pickup

in

position

adjustment

start

engine

personal

rotating

pickup

plugs

adapters

~ss~:~:~~

with

and

and

Injury.

or

fitting

from vacuum

into

;:~~:~

clip

pins.

ease

allow

hot

(PIN

carburetors

of

it to run

Do

not

engine

92005-

pickup

.

1.

Fitting.

2.

Vacuum

3.

Tubing

3.

Connect

• Attach one
each

• It may be
piece
Tuner
with adapters.

Screw

(3/32

Plug.

in.).

Synchro

pick

up

necessary

of

3/32

tubing

Tuner

tube

adapter

in.

ends

to carburetors.

from

Synchro

.

to

tubing

to

into the

insure

Tuner

to

install a short

Synchro

a good seal

5.

If necessary,

• Adjust

screw
screw

ward to

1.

Idle

Speed

2.

Synchronizer

CARBURETOR SERVICING

synchronize

RH

carburetor synchronizing

to equalize

inward

increase

Screw.

Screw.

to

reduce

vacuum.

carburetors.

vacuum

readings. Turn

vacuum

or

5-9

out

-

1.

Carburetors.

2.

Mercury

4.

Check
speed.

• With

CORRECT

Synchro

ings

Tuner.

carburetor

engine

on

idling, observe vacuum read-

Synchro

synchronization

Tuner.

INCORRECT

at idle

6.

Adjust

idle speed.

• Turn idle speed
idle

mended

7. Disco.nnect

• Pull

tubes

• Remove

• Install

Carburetor

1. Remove

screw

Synchronization,

air

• Refer to

I

WARNING

Lw

_____

failure
causing

I

.control

or

throttle

personal

RPM.

Synchro

from

pick

up fittings.

plugs

silencer

Silencer

Use

care

malfunction

injury.

pick

2. Remove carburetors.

• Loosen

• Pull

•

Cover

carburetor

off

carburetor

carburetors

entering.

screw

Tuner

to

.

obtain

recom-

up fittings.

and washers.

Mechanical

from carburetors.

Removal procedure.

not

to

kink

or

cables.

holder

clamps

damage

Component

could

result,

.

assembly.

to

prevent

dirt

from

5-10

CARBURETOR SERVICING

9. Set engine idle speed.

• Refer to
cedure

Carburetor

.

Adjustments

pro-

1.

Holder

Clamp

.

3.

Adjust
tion.

• Loosen idle speed

• If

4. Set LH

in.

• Open LH

• With

throttle

valve

is

fully

RH

throttle

loosen

(1

insert a
between bottom of
throttle
and let it seat on

s
drill

carburetor

carb

.6 mm).

1/16

valve. release the valve

carburetor

lowly

turn idl e speed

bit

falls out.

valves to

closed.

valve

uretor

throttle

carburetor

in.

(1.6

drill

throat facing downward,

fully

closed

screw

synchronizing

until

is

not

fully

opening

throttle

mm)

drill

bit

carburetor

bit.

screw

LH

valve and

in until the

posi­throttle
closed,

screw.

to

1/16

in space

bore and

slowly

Carburetor

1. Remove

•

I

WARNING

....

___

explosive
nace,
Perform
well

ventilated

flames

2.

Disconnect
each

• Push on end of

• Plug fuel tube

Removal

air

Refer to

_

if

exposed

hot

water

maintenance

and

sparks.

carburetor
avo id damage to
siphoning

silencer

Silencer

I

Gaso

._

than

and

fuel

action

.

Removal procedure.

line

fumes

air

and

to a pilot

heater,

only

free

tube

.

tubes

carburetor

ends

from fuel tank.

light

clothes

in an

from

from inlet

during

to

prevent

are

can

become

from a fur-

dryer, etc.

area

pilot

fitting

removal to

fittings.

heavier

that

is

lights,

of

possible

1.

Idle

Speed

Screw

2. Drill Bit.

3.

Throttle

4.

Synchronizer

5. Set

6. Position

7.

8.

Valve.

RH

in.

(1.6

• Repeat
tor, using
to set

•

Tighten

Synchronize

• Refer to Oil Pump Cable
cedure.

Install

•

air

Refer to Sil

.

Screw.

carburetor

mm).

procedure

carburetor

RH

carburetor

carburetors

carburetor

oil

pump

silencer.

encer

throttle

Installation procedure.

opening

given for LH

synchronizing
.

in holders.

holder

with

clamps.
carburetors.
Adjustment

to

1/16

carbure-

screw

pro-

1.

Fuel

Tubes

Push

On

2.

3.

Enrichener

4.

Enrichener Cap

End.

3. Remove

buretor

• Loosen

•

Unscrew

4.

Disconnect
cable

from

I WA

RNING

...

____

failure
causing

NOTE:
cable
ments are
ary

or

personal

During removal,

or

oil

disturbed, readjusting

during

• Pull
oil

pump

•

Remove
cables

.

Locknut.

.

enrichener cable

.

adjuster lock

enrichener

oil

pump

carburetor

I

Use

._

throttle

pump

assembly.

hair

care

control

malfunction

injury.

cable

pins

from

cable

pin .

top

carburetor

attached).

from each

nut.

plunger

cab

le and

assembly

not

to

not

throttle

kink

disturb

will be

bracket

cables.

do

adjustmen

cap.

throttle

.

or

damage

Component

cou

ld

result,

throttle

ts. If

adjust

necess-

cable

pin and

(with

car-

-

1.

Top

2.

Oil

3.

Throttle

Bracket

Pump

Cable.

Cable

CARBURETOR

5.

Remove

•

.

.

1.

Holder Clamp.

carburetors

Loosen

both

holder

SERVICING

from

holders

clamp

.

screws

5-11

.

5-12

CARBURETOR SERVICING

'

~f

I 4-i II

I

~/

l

a

t-

I

~-9

I

~~

5-~7-"

6 '

I

~-10

I

1

12

1 CARBURETOR
2 SCREW, pan head, 5 x
3 TUBE,
4

SCREW, idle
5 SPRING ,
6 WASHER
7

SCREW
8 CAP,
9

SPRING ,

10

PLUNGER, e

11

SPRING

12

SCREW

13

O-RING
1 4 VALVE, float
15

CLIP, float valv e
16

FLOAT
17

PIN, float

air

idle

enrichener

enrichener

ASSY

vent

adjust

screw

plung

nrichen

pivot

14mm

er

plunger

er

30-~

29-

27~_,

ry~,"

L2" __

18

SCREW

19

SCREW, pan head, 3 x 5mm

20

BAFFLE

21

RETAINER,

22

VALVE,

23

SCREW, pan head 4 x

24

O-RING,

25

COVER, main

26

SCREW, pan head 4 x
27 HOUSING,
28

SEAL
29

SPRING,
30DJAP
31

CAP,
32

ROD,
33

JET, main

34

JET,

0-24

.

~

1; -28

"'

-28

check

cover

diaphragm

HRAGM

accelerator

accelerator

power

-25

check

accelerator

valve

jet

pump

pump

--,

16mm

12mm

pump

35

FITTING, fuel

36

SCREEN,

37

RETAINER,

38

NUT, 6mm

39

WASHER,

40

LEVER, le
LEVER,

41

COLLAR,

42

SPRI

NG

43

LEV E

R,

44

SCREW, pan head, 4 x 16mm

45

JET, pil

46

SEAT,

47

BRACKET,

48

BRACKET, bottom

ot

float

inlet

power

ft

right

spr

accelerator

screen

spring

throttl

thr

ing

valve

top

carburetor

jet

, 6

e

ott

mm

le

pump

carburetor

Carburetor

Disassembly

5.

Unfasten
screw.

CARBURETOR SERVICING

float

bowl

baffle

by

removing the

5-13

~

These
and
run

1.

2.

parts

if

they

properly.

Se

lect

the

carburetor.

are

caused
Clean the
high

compressed

[~~~~

is

completely

be

damaged.

3.

Separate the

• Remove the

four

brace.

~:kan9o:

are ali

are

a clean

flash-point

gned

misaligned

work

Most

by

dirt

outside

solvent

air.

~~o~~~

disassembled

carburetors

two

screws

with

:re~~:t~lea~:IV~h~~!~~~

during

the

area for

carburetor

in the system.

of

the

b~~:

brackets

lock

washers

manufacture

engine

carburetor

and

may

not

disassembling

problems

with a

blow

dry

with

ch~~:u~;~:rs~~~i~:~

or

the

float

may

1.

Baffle

.

by

taking

out

the

of each

6.

Screw.

Remove

• Be careful

• Pull

accelerator

pump

the
the two
float bowl.

the

a-rings

the

push

float bowl.

not

to lose the

housing

between the

rod and

pump

and the

rubber

housing.

spring

diaphragm

housing

cap

between

or

and

free of

1.

Float

Bowl

Screws.

4.

Remove the float bowl.

Unhook

•

and
tor

1.

Accelerator

2.

Accelerator

3.

Cap.

lift

body.

Pump
Pump

the

accelerator

the bowl

Lever.
Rod.

straight

pump
off

the

push rod

carbure-

1.

Spring

2.

3.

7.

.
Diaphragm.
Housing.

Lift

out

the

float

with the float valve needle

attached

•

• To remove the needle from the float,

.
Unscrew
screw.

unsnap

the

the

float pivot pin retaining

wire

clips.

5-14

1.

Pivot

8.

CARBURETOR SERVICING

Pin

Retaining

It is

not necessa

seat for

or

cleaning.

worn, it shou

Screw.

ry to remove the

However,

Id

be removed .

float

if

it is damaged

valve

1.

Main

Jet.

10. Remove

the

power

jet.

~~~E1

may

create

is

installed.

•

Tighten
until
tor

•

Clamp

•

Alternately
body,

~=~~SgS~V:a:~~~~~r

leakage

self-tapping

seat

body.

self-tapping

using

(flooding)

begins

tap

on each

a mallet.

screw

to rotate

screw

side

o~O~~a~h~~~

when

new

seat

into

valve seat

within

carbure-

head in a vise.

of

carburetor

1.

11.

Power

Jet

(fuel).

Unscrew

the

pilot

system

jet.

1.

Self-tapping

•

Blow
area
through

9.

Unscrew

Screw

any

with

the

.

metal

compressed

fuel

inlet

main jet.

chips

fitting.

from

the

valve seat

air

directed

1.

Pilot

Jet.

12. Take
spring.

out

the

idle

adjust

screw

.,.

r

and

its

1.

Idle

Adjust

Screw.

13. Remove the

• Pull

out

power

retainer

air

jet.

and screen.

CARBURETOR SERVICING

1.

Carburetor
(B36Al left -B36AR right
Power

2.
Main

3.

4.

Power Air

5.

Pilot

1.

Screw
secure

• Push the

Jet

(fuel) #180

Jet #98.

Jet #180.

Jet #70.

ly

jet

hole.

Body

Marking

in the

.

screen

).

.

power

and retain

air

jet

and tighten

er

into

5-15

the

air

1.

Power

Air

2.

Screen.

3.

Retainer.

Carburetor

Thoroughly

or

fuel/oil
openings
compressed
any

sediment

Use

Jet.

Cleaning

mixture.

and fuel

air

of

carburetor

clean

all

parts

Inspect

passages

through the passages . Remove

from

the

fuel bowl.

cleaners

to remove gum and varnish

jets

and float chamber.

OR

WIRES to clean the jets

jets

will

resu It.

pect

Ins
damage in the
the float valve
signs

the float valve needle

sealing

assembly

of

wear

or

damage,

DO

(tapered) area. Replace

if the needle shows

scratches.

Carburetor

Check

identification
the

correct

carburetor

Assembly

all

the

carburetor

markings

components

cannot

be

calibrated

prior

are not installed, the

with

a mild solv

all

drilled

holes

in the body. Blo"";

may be
build-up

necessary

from the

NOT USE DRILLS

or

damage to the

tip

for wear

such

as grooves

parts

for

proper

to reassembly. If

properly.

ent

or

or

1.

Power

2.

3.

2.

Air
Screen.
Retainer.

Install the idle

•

Screw
lightly
number
Adjustments.

1.

Idle

Adjust

Jet.

adjust

it all the

and then

screw

way

back

of turns. Refer to

Screw.

with its

spr

ing .

in until it bottoms

it

out

the

specified

Carburetor

5-16

3.

1.

Pilot

4.

CARBURETOR SERVICING

Screw

Replace

Jet.

in the

the

pilot

power

jet.

jet.

1.

0.083

in. (2.1

7.

Use the small wire

mm).

valve on the float arm.

clip

to hang the

float

1.

Power

Jet

(fuel).

5.

Install the main jet.

•

Do

not overtighten

buretor

1.

Main

Jet.

6.

If the

float
the new one in
57001-3520)'

• If the tool

in until
the

it

carburetor

body

may be stripped.

valve

seat

with

is

not

available,

extends

0.083

body

or

threads

was

the

.

removed,

special

press

in.

(2.1

in the

car-

press

tool (PIN

the seat

mm) from

1.

Clip

.

Float

2.

3.

8.

Valve.

Arm.

Position the

float

the float valve in the seat.

•

Slide

the float pivot pin into the float.

• Tighten the pivot

1.

Pivot

Pin

Retaining

Screw.

in

the

pin

carburetor

retaining

body

screw

with

.

9.

Check

float level adjustment.

• Observe float level with
20°-

30°

from vertical to avoid

ing float valve

•

1.

2. 0.

3.

Adjustment

0.512
carburetor
location

Edge

of

512

to

20·

to

30·

• If
on

Float.

0.670 in.
From

adjustment

float arm

to

0.670

shown.

Vertical.

is

surface

(13

is required, bend metal tab

to

spring

.

correct

in. (13 to

when

to

17

mm).

obtain

carburetor

compress-

if edge of float

17

mm) above

measured in

correct

setting

tilted

is

.

11. Install

•

Shake
be sure

• Be sure
in the
in the

• Set

the
diaphragm.

• Tighten
Slip

•

1.

Housing.

2.

Spring.

3.

Diaphragm.

4.

O-rings

CARBURETOR SERVICING

accelerator

the

the
the

accelerator

float

the

spring

housing

the

the

rubber

.

pump

components

accelerator

ball valve is free.
two

O-rings

pump

bowl.

in place, and

over

screws

cap

the

secure

into place.

pump

are in

housing

carefully

spring

ly.

5-17

.

housing

place

, one

and one

and

to

put

1.

Bend

Tab

10. Lay the
that

the

1.

Lip

.

2.

Groove.

With

Screwdriver

diaphragm

lip

is in the groove.

.

against

the float bowl so

12.

Secure
tightening

1.

Baffle

2.

Float

the

float

the

Screw.

Bowl O-ring.

screw

13. Install float bowl

• Hook the
the

throttle

Be sure

•

acce

the

linkage.

large
the float bowl
that

the

accelerator

into the

• Insert the
nearest
do not

rubber

two

the

mouth of the

tighten

bowl baffle in

securely.

onto

carburetor

lerator

onto

O-ring

the

carburetor

pump

is in

pump

cap

as shown.

screws

with

them yet.

position

by

body.

push-rod

place

and

to
fit

body so

push-rod

lockwa

fits

shers

carburetor, but

5-18

1.

Accelerator

2.

Cap

3.

Accelerator

14.

Rejoin

brackets.

•

CARBURETOR SERVICING

Pump

Pump

the

all

Rod.

Lever.

carburetors
of

the

float

bowl

.

Tighten

with

screws.

the

two

Carburetor

1. Position

•

Tighten

1.

Holder

Clamp.

I

WARNING

L..

____

shown
tween
Throttle
sonal

to

hair

malfunction

injury.

Installation

carburetors

both

holder

I

Throttle

...

cable

avoid

pins

possible

and

in

holders

clamp

cable

pin

must

interference

carburetor

may

result,

pin

be

.

screws.

and

oil

installed

holder
causing

pump

as

be-

bolts.

per-

1.

Float

Bowl

15. Grease
shown

1.

Apply

Grease

Screws.

the

throttle

with

a non-freezing type grease.

Here.

shafts

through

INCORRECT

.!

the holes

CORRECT

16.

Check

carburetors

for

proper

tion.

• If

Mercury

available,

installation

• If

Mercury

not

chronization,

Synchro

Tuner

synchronize

is

completed.

Synchro

Tuner

available, perform

Mechanical

carburetors

Carburetor

synchroniza-

(special tool) is

after

(special tool) is

Syn-

at

this

time.

1.

Oil

Pump

2.

Throttle

3.

Interference

Cable.

Cable.

Problem.

2.

Connect
carburetor

•

Secure

oil

pump

assembly

top

cable

.

carburetor

buretors.

3.

• Install
cable

• Insert

Check

throttle

pin as

hair

oil

pump

shown

pin

to

cable

retainers

carburetor

tion.

• Refer to Oil Pump

Cable

cedure.

4.

Secure

• Ins

•

enrichener

ert

enrichener

and

tighten
Check
Refer to

cables

plunger

plunger

enrichener

Enrichener

procedure.

5.

Connect
carbu

6.

Inst

• Refer to

7.

Check

• Refer to
cedure

retor.

all

air

carburetor

fuel

tube

silencer

Silencer

Carburetor

.

to

assembly.

Installation

synchronization.

CARBURETOR HOLDERS

Carburetor

Holder Removal

1. Remove silencer.

• Refer to

2.

Disconnect

• Loosen both

3.

Unbolt

•

Remove

Silencer

carburetors

holder clamp

carburetor

carburetor

Removal procedure.

holders

bolts.

• Pull hold
from each

er

and

cylinder.

silencer

and

throttle

bracket

pin and oil

.

into

cable

synchroniza-

Adjustment

to carburetors.

into

cap.

cable

adjustment.

Cable

inlet

fitting

procedure.

Synchron

from holders.

screws

from

cylinders.

holder

spring

cable

to

to

car-

pump

pins.

pro-

carburetor

Adjustment

on each

ization

pro-

.

mounting

washer

1.

Holder
Silencer
Holder.
Plain

Washer.

Clamp.

Spring

2.

3.

4.

Carburetor

1.

Carefully

• If

holders

deteriorating,

Carburetor

1.

Be sure
holders
dry.

2.

Mount

• Position
side

•

Torque

3.

Reinstall

•

Refer
cedure.

4.

Install

• Refer to

CARBURETOR HOLDERS

Washer.

Holder Inspection

examine

show

replace

carburetor
any

signs

them .

Holder Installation

mounting

and

cylinder

holders

silencer

mounting

bolts

on

cylinders.

bolt

to

45

surfaces

flanges

spr

ing

washers

of

each

in. Ib (0.5 kg-m).

carburetors.

to

air

silencer

Carburetor

assembly.

Silencer

Installation

Installation

5-19

holders

of

of

.

cracking

carburetor

or

are clean and

on

out-

holder

.

pro

procedure.

-

CHAINCASE/JACKSHAFT 6-1

CHAINCASE/JACKSHAFT

Ta

ble

of

Contents

Chain ... .

Chain Removal ............

Chain Installation ...............

Chaincase ....... ..........

Chaincase
Chaincase
Chain case
Chaincase
Chaincase

Jackshaft ............ ...... .

Jackshaft
Jackshaft
Jackshaft

.. ..

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

Removal
Disassembly ...
Inspection ...
Assembly
Installation

Removal .
Cleaning and I
Installation

.......

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

...

........

. ....

. .

......

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

. .

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

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

.........

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

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

. . .

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

nspection ......

....... .

.......

.........

..

. .. .. .

. .... .... .

.......

...

. .

.. .........

...
...

....

........

...

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

. .

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

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

.. .. ..

. . .

........

. ..

...

.........

....

...

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

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

...

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

. .... ....

..........

. .......

.....

. .........

. .

....

....

....

......

. . . . 6-4

.....

.......

........

....... 6-8

... 6-3

6-3

. 6-3

6-4
6-5

6-6

. 6-6

. .

6-7
6-8
6-8

...

6-8

6-2

CHAINCAS

CHAINCASE & JACKSHAFT

E/J

ACKSHAFT

1

I

~

2

6

~

7

I

:/

I

I

I

l..,

1 ADAPTOR, speedomet

Y,

2 KE

3 BOLT,

4 COVER, chain case

5 GAUGE, oil level

6 SEAL,

7 SPRING,

8
9 CHAINCASE

10
11
12
13
14 WASHER, plain, 3/8"
15 RETAIN
16 NUT, in
17 BEAR

spee dometer ada ptor

1/4-20 x 1.00

"0"

ring

gr

een tensioner

CHAIN
NUT, inse rt,

NUT, insert, 5/1
PLUG, drain
BOLT,

IN

1/4-

3/

8-24 x 1.75

ER,

bearing

ser

t,

3/8-24

G

28

6-2

4

er drive

18

SEAL

"0"

ring

19

BOLT,

20

SHIM, bearing retainer

21 BOLT,
22

NUT, jam,

23

BOLT,

24

CAP, bearing retainer

25

JACKS HAFT

26

WASHER ,

27 BOLT,
28

SEAL, lower oil

29

BEARING, lower ball

30

SPACER, driven

31 RING, bearing retainer
32

SPROCKET,

33

WASHER

34

BOLT,

1/4-28 x 2.50
3/8-24
3/8-24 x 1.50

5/16-24 x 3.25

special

x 1.25

3/8-24

special

38

sprocket

tooth driven

35

ADAPTOR,

36

GUIDE,

37

BOLT,

38

WASHER, plai

39

PIN,

hair

40

TENS lONER ARM

41

SLEEVE,

42

BOLT,

43

WASHER,

44

SPROCKET, 22 tooth drive

45

SPACER, drive

46

RING,

47

BEARING,

48

SEAL,

49

PLUG,

50

NUT, i

speedometer

chain

1/4-28

tensioner

5/8-

18 x 1.00

special

bear

ing
upper

upper

fill

nsert

1/

x .

88

n,

1/

sprocket

retainer

ball

oil

4-28

4"

key

arm

CHAIN

6-3

CHAIN

Cha

in

1.

Remova

Remove

l

battery

(electric

star

t models only

• Refer to Battery Removal procedure.

2.

Remove

• Unfasten

1.

Lower

2.

Mounting

3.

Unfa sten
remove ke

lower

Battery

Bolts.

battery

mounting

Case

.

bolts.

speedometer

y.

case.

drive adapter

).

and

Chain

1.

2.

Insta

llation

Install sprocket spacers.

•

Thick

• Thin

Mount

•

Lip

space

space

r on bottom shaft.

sprockets

on

lower

r on top shaft.

ing.

• Torque
kg-

• Torque

lower

m).

upper

kg-m).

1.

Thick

2.

3.

4 .

Spacer.

Thin

Spacer

Sproc

.

ket

Lower
Upper Sprocket

Bolt.
Bolt.

and chain.

sprocket

sprocket

sprocket

goes toward bear-

bolt

to

35

ft Ib (5.0

bolt

to

50

ft Ib (7.0

1.

Key.

2.

Adapter

3.

Chaincase

4.

Drain

.

chaincase

• Place oil
pan.

•

Unscrew

and remove cover.

5. Remove

6.

• Pull

•

Remove

•

out

Unhook
Unscrew

slid e spro

•

Remove
sp

rocket.

Cover.

dra

in pan

chaincase

tensioner

hair

pin.

spr

ing from

chain

and sprockets.

sprocket

cke

ts off.

spacer found

lubricant.

under

cover

spr

ing.

tensioner

mounting

hole in lower

mounting

bolts

arm.

bolts

behind

and

each

3. Install chain

tensioner

• Refer to Chain Tension
chain

• Hook

• Install

1.

Tensioner Spring.

2.

Hair

Pin

4 .

Mount

• Use new

•

5.

Add chain

• Use DEXRON

spring

.

chaincase

Torque

guide

hair

O-ring
cover
case

positioning.

onto

pin.

cover.

bolts

lubricant.

II

fluid.

•

Add

lubricant

center

and top

of

spring.

tensioner

sea

l.

to

70

automatic

until

sight

level

gauge.

procedure

arm.

in. Ib (1.0 kg-

transmission

is

between

for

m).

6-4

CHAIN CASE

I

WARNING

,

____

reduce

with

6.

braking

vent

Insert
cover
square

I

Prevent

••

brake

action,

hole

pointed

speedometer

hole

while

hole in

rotating key to align

lower

oil

mist

components,

by

installing

away

from

key

through

sprocket

mounting

from

which

brake

chaincase

coating

may

fill

plug

disc.

with
bolt.

9.

Install battery.

• Refer to

CHAINCASE

Battery

Installation

procedure.

1.

Fill

Plug

2.

Key.

3.

Adapter.

4.

Sight

NOTE:

within

Vent

Gauge

.

Speedometer

chaincase

rotated when

sprocket

7.

mount

Connect

• Hold
on

chaincase

•

Insert
of

adapter.

•

Slide
not

use

drive

end

adapter

components
adapter

8.

Mount

•

lower
Secure
shield
installed

Hole

.

key

cover

properly

bolt.

speedometer

adapter

cover

of

flexible

into

force

during

are

will slide

battery

battery

bracket

in

sequence

easily

case

case

with

sho

uld be

hole

and

engaged

drive

near

mounting

centered

cannot

with lower

adapter

.

threads

.

key

into

square

position

properly

on cover. Do

assemb

into

position.

ly. When

aligned,

.
to footrest and heat
mounting

hardware

shown.

be

hole

Chaincase

1.

Remove

Refer to

•

2.

Remove

•

Unfasten

1.

lower

2.

3.

Battery

Mounting Bolts

Unfasten
remove key.

Removal

battery

lower

(electric

Battery

battery

mounting

Case.

.

Removal procedure.

case.
bolts

speedometer drive

start

.

models

adapter

only).

and

1.

lower

Battery

Case

.

@~

'>

/

/

/

"-

'

~"/'

~

';:,

.

~

~

\ ,

..

1.

Key

.

Adapter.

2.

3.

Chaincase

4.

Drain

• Place oil
pan .

•

Unscrew
and

5.

Disconnect

•

Unhook

• Pull

• Remove

•

Unfasten
from bracket.

Cover.

chaincase

lubricant.

drain

chaincase

remove cover.

brake

brake

hair

clevis

return spring.

pin from

pin.

lock

pan

under

cover

cable.

clevis

nuts and

hole in

mounting

pin.

remove

lower

bolts

cab

le

1.

Brake

2.

3.

4.

Cable.
Locknuts.
Hair

Pin

Return

.

Spring.

6. Loosen

• Refer to

7.

Remove
sprockets.

•

Unhook

•

Unscrew
slide

•

Remove
sprocket.

track

tension.

Track

tensioner

spring

sprocket

sprockets

spacer

Adjustment

spring,

from

tensioner

mounting

off.

found

procedure.

chain,

arms.

bolts

behind

each

and

and

1.

Chaincase

• Brake
with

Chaincase

1.

Unbolt

•

Remove
spacer, and

Mounting

disc

chaincase

will

Bolts.

slide

.

Disassembly

caliper

from

brake

disc

CHAINCASE

off

of j

chaincase

cable

bracket,

guard.

ackshaft

.

caliper

6-5

along

1.

Top

Sprocket

2.

Chain

.

Tensioner

3.

4.

Lower

Sprocket

8. Remove

• Remove chai
battery

• Pull

.

Spring.

.

chaincase

ncase

heat

shie

chaincase

.

mounting

bolts

ld bracket.

away from frame.

and

1.

Guard.

2.

Bra

cket.

3.

Caliper

4.

Caliper.

2.

1.

Brake

2.

Pegs.

Spacer.

Remove movable pad .

•

Unhook
chaincase

Pad

movable

pegs

Spring .

brake

pad

springs

and remove pad.

from

6-6

CHAINCASE

3.

Remove

•

• S

brake

Unfasten

lid

e lever and

lever and

snap

ring.

washer

neoprene

washer.

from rotor shaft.

7.

If

required

Use an

•

•

Bearings
case

, remove

appropr

must

cover.

bearings

iate puller.

be removed

and

sea ls.

toward

chain-

1.

Brake

Lever.

NOTE: Be
balls

4.

Remove

when

careful

removing

self-adjusting

• As an assembly,
chaincase.

5.

Remove

•

Unscrew

•

Be

tensioner

careful

sleeves.

not to lose

self-adjusting

push

arms

tensioner

not to lose

the

brake

mechanism

with

arm

mounting

tensioner

three

steel

mechanism.

mechanism.

out

chain

guides.

bolts

arm

pivot

of

.

Chaincase

1. Clean metal

2.

Examine bearings.

• If

3.

Examine

• If

Chaincase

1. If removed,

• Heat

2.

Insert

• Be

NOTE: The

Inspection

bearings

excessive

sprockets

parts

miss

ing teeth

Assembly

chaincase
heat gun,
bearing

installation.

bearing

certain

case

grooves.
lower

parts

in

show

wear,

replace

have any

or

splines, replace

install

new

with

or

small

retainer

rings are

chaincase
type. Pack area between
prevent

3.

excessive

Mount

tensioner

driveshaft

arms.

• Position sleeves in

•

4.

Torque

• Be
tightening
Bend

•
insure

Position

bolts

to

40

certain

arms

bolt.
tensioner
free movement.

self-adjusting

case.

• Align

tabs

on

stator

case.

cleaning

signs

solvent.

of

scor

them.

and

splined

chipped

seals

a high

propane

shafts.

, broken,

and bearings.

int

ensity

torch

rings.

fully

sea ted in

seal is a

the

lips with grease to

wear.

tensioner

arms

in. Ib (0.5 kg-m).

swing

arm,

freely

if

necessary, to

mechanism

with

slots

ing

them.

light,

to ease

chain-

double

.

after

in

cha

in

cha

or

or

lip

in­in-

1.

Tensioner

2.

Sleeves.

3.

Retainer

6.

Remove

Arms.

Rings.

upper

and

lower

rings.

• Pry

ends

of

retaining

rings

tool.

NOTE: It is
ings

or

Bearings
peated
seals

or
a high
torch

will

not

recommended

seals

and

unless

seals

removal may

the

chaincase. Heating

intensity

light, heat gun,

ease removal

replacement

are

press

damage

of

bearings.

bearing

retainer

with a suitable

to remove

is required.

fitted

the

and re-

bearings

chaincase

or

small

propane

bear-

and

with

1.

Chaincase

2.

Stator

5.

Install
snap

• Note

Slots

Tabs

.

brake

ring.

correction

.

lever,

neoprene

position

washer, and

of

brake

lever.

1.

Neoprene

2.

Brake
Snap Ring

3.

6.

Assemb
as sho

Lever

Washer.

.

.

le

movable

wn.

brake

pad

and

springs

2.

Install

sprocket spacers

• Thick

• Thin

3.

Mount

•

•

•

4. Install

• Ref

•

• Insta ll

Mount

5.

• Use

•

6. Add

• Use DEXRON

•

sprockets

Lip

on lo
ing.
Torque
kg-m).
Torque
kg-m).

chain

er
chain
Hook spring

chaincase

new

Torque

chaincase

fluid.
Add
center

spacer

spacer

guide po s

lubricant

on bottom.

wer

lower

upper

tensioner

to

Chain

hair

pins

O-ring

cover

and top

CHAINCASE

.

on

top

shaft.

and chain.

sprocket goes

sproc

ket

bolt

sprocket

bolt

spring.

Tension

itioning

onto

.

tensioner
.
cover.

seal.

bolts

to

70

in. Ib (0.8 kg-m).

lubricant.

II

automatic

until

level

of sight

gauge.

tow

ard

bear-

to

35

ft

Ib (5.0

to

50

ft Ib (7.0

procedure

arm

s.

tran smission

is

between

6-7

for

1.

Moveable

2.

Brake

Pad

7.

Mount

cable

Torque

8.

Chaincase

1.

Position
and

chain

bly

.

• Position
chaincase

•

Torque

Ib (2.5 kg-m).

Brake

Pad

Radius

brake

caliper,

bracket, and

caliper

Installation

brake

bolts

disc

case

onto jackshaft

battery

.

chaincase

caliper spacer, brake

disc

to

in

caliper

heat

mount

guard

35

to chain case.

ft Ib (4.8 kg-m).

and

slide

as an

assem-

shield

ing

bracket

bolts

to

disc

on

18

ft

I

WARNING

~

.

____

reduce
with

7. I

braking

vent

nsert
cover
square

I

Prevent

...

hole

brake

pointed

components, which

action, by

speedometer
hole

while

rotating

hole in lower

oil mist

installing

away

from

key

throu

key to align

sprocket

from

brake

gh

chaincase

mount

coating

may

fill

plug

disc.

with

bolt.

1.

Fill

Plug

2.

Key
Adapter

3.

4.

Sight

NOTE:
within

Vent

.

.

Gauge.

Speedomete

chaincase
rotated when
sprocket

mount

Hole

.

cover

properly

bolt.

r key s

hole and

engaged

hould

be

centered

cannot

with

be

lower

6-8

JACKSHAFT

8.

Connect

• Hold
on

speedometer

drive

chaincase

• Insert end
of

adapter.

•

Slide

adapter
not use force
component
adapter

9.

Mount

brake

• Thread one

• In

sert

cable

• Install second

I

WARNING

Lw

____

pin, and clevis

10.

Install

ITO

•• function, install clevis pin, hair

clevis

retainer.

•

Mount

clevis

is toward

• Insert

clevis

clevis.

•

In

stall

hair

adapter

near

cover.

of

flex ible

into

during

s

are

will slide

cable

easily

in

locknut

through bracke

lock

avoid possible

retainer

pin,

as

hair

retainer

chaincase.

pin from

pin in

clevis

drive

adapter.

mounting

key

into square hole

position

on cover.

assembly. When

properly

into

posit

brake

onto

cable

cab

le.

t.

nut

on

cable.

brake

follows:

pin,

and

so

that slott

chaincase

pin .

threads

Do

aligned,

ion.

bracket.

mal-

clev is

ed side

sid e of

1

2. Install battery.

• Refer to Battery Insta llation procedure.

Adjust track

13.
Refer to

•

JACKSHAFT

Jackshaft

1.

Remove

Refer to

•

2.

Remove driven converter.

• Refer to Driven

tension and alignment.

Track

Removal

drive

Belt

Adjustment

belt.

Removal

Converter

procedure.

procedure

Removal

cedure.

3.

Remove chain.

• Refer to Chain Removal procedure.

NOTE: It will not be

sprocket

4.

5.

6. Remove

Jackshaft

1.

for chain removal.

Remove ja

•

Unscrew

Slide

jackshaft

brake

Cleaning and Inspection

Check

jackshaft

necessary

ckshaft

nuts

from

disc

to remove bottom

bearing retainer

and

lift

off

cap.

chaincase.

from

brake cali

bearing.

• Turn bearing by hand.

• If bearing binds, has
or

is rough, replace it.

• Bearing is a press
bearing
is

okay

after

.

determining

excessive

fit

onto

shaft. Repl

that

.

pro-

cap

.

per.

end play,

ace

jackshaft

1.

Retainer.

2.

Hair

Pin.

3.

Pin.

11. Mou nt lower

•

Secure

shie ld

battery

bracket

installed

1.

Low

er

Battery

Case

battery

in

sequence

.

case.

case

to footrest and heat

with

mounting hardware

shown.

NOTE: Reduce effort required to install new

bearing by

expand

until

inner

it

contacts

placing bearing on a hot

race. Press bearing

shoulder

to

insure correct

light

onto

bulb

shaft

posi-

to

tioning.

2.

Ins

pect

brake

• Clean

• If

disc

3.

4.

Check

•

• If

Ins

Shaft
flat

surface

shaft

pect

jackshaft

shaft

• If there are
tortion, repl

Jackshaft

1.

Insta ll bearing

Installation

2. Position

3.

Slide

jackshaft

•

Apply
disc

sp lin es.

•

Slide jackshaft

• Fit

O-ring

4.

Install

chain

• Refer to Chain Installation

5.

Mount

• Fit

jackshaft

O-ring

• Torque

disc.

disc

with cleaning so

lvent

and dry.

is scored or warped, replace it.

for straightness.

must

roll easily and smoothly on a

.

is bent,

disc

repair

spl ines and

any signs

ace

shaft.

retainer

or

replace it.

thr

of

crack

O-ring

in brake caliper.

through

disc

into chain case .

eads.

ing

or dis-

on bearing.

coating of NEVER-SEEZ to

into

posit

ion.

into bearing retainer groove.

.

procedure

bearing retainer cap.

into cap

nuts

to

groove.

70

in. Ib (0.8 kg-m).

brake

.

1.

Jackshaft

2.

Retainer

3.

Bearing

4.

Bearing

.

Cap.
Retainer.
O-Ring.

6. Install

•

Torque

(6.9

7.

Check

•

Refer to

Install

8.

•

Refer to

9.

Mount left

driven

converter.

converter

kg-m).

converter

Converter

drive

belt.

Belt

side

JACKSHAFT

bolt

to 50 ft Ib

alignment.

Alignment

Installation

trim on

lower

6-9

procedure.

procedure.

pan.

CHASSIS

CHASSIS

7-1

Table

Seat

. .

........

Seat

Seat Installation ................

T

ail

Lamp ..........

Tail

Lamp

Tail Lamp In

Tunnel

Rub
Tunnel
Tunn

..

...........

Removal. ...

Removal.

sta

Str

ip .

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

Rub

Strip

el

Rub

Str

ip I

......

..

.....

....... .

llat ion

..........

Removal.

nstallation

of

Contents

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

......

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

...

.........

. .

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

......

. .

......

. .

......

.........

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

.

..........

.........

. . . .....

. .........

.. ..

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

..

. .....

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

..........

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

. .. . ..

..

.. ..

......

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

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

......

........ 7-2

...

.....

....

...

...

. . . 7-3

. .

....

... 7-3

7-2
7-2

7-2
7-2
7-2
7-2

7-2

SEAT

CHASSIS
SEAT

Seat

Removal

1.

Disconnect

tail lamp

• Unfasten tail lamp to main
nector

1.

Tail

Lamp

2.

Remove seat

Mounting

•

located in front

Connector

.

mounting

bolts

are located

wiring

of

bolts.

.

harness

fuel tank.

under

con-

tunnel.

3.

Secure

• Torque

TAIL

LAMP

Tail

Lamp

1.

Remove seat assembly.

•

2.

Unfasten tail lamp

seat.

mounting

m).

Removal

Refer to Seat Removal procedure.

bolts

body

to

35

in. Ib (0.4

assembly.

kg-

1.

Seat

Mounting

3.

Lift

seat

•

Carefully

under

Seat

Installation

1.

Connect

•

Slide

•

Attach

ness.

2.

Position seat

•

Be certain tail lamp
between seat frame and tunnel.

Bolts.

assembly

pull

from snowmobile.

tail lamp

fuel tank.

tail lamp wiring.

connector

tail lamp

under

connector

assembly

wiring

free, from

fuel tank.

to main har-

on snowmobile.

wiring

is not

pinched

1.

Tail

Lamp.

2.

Cover

3.

3.

Hole.

Outer

Sleeve.

Pull lamp

body

cover.

•

Carefully
cover.

Tail

1.

Lamp

Mount

Installation

lamp

cover.

•

Guide

tail lamp

cover.

•

Slide

outer

protect

wires

• Tighten lamp body

2.

Mount

•

seat

assembly

Refer to Seat

from storage

pull

tail lamp

body

in storage

wiring

sleeve on

from

Installation

compartment

wiring

compartment

through hole in

wiring

chafing

mounting

rearward to

on cover.

nuts.

on snowmobile.

procedure.

through

Cill:!lEl

in

seat

can

stripped,

~~

nbo~I~Sv~r:i~~:~n~

be

easily

replacement

stripped.

of

required.

TUNNEL

RUB

STRIP

S~~tts~ou~:~

If

blind

nuts

seat

frame

are

is

Rub
ness
at

any

strips

should

of material

point

along

measures

its

be

replaced

1/8

length.

when

in. (3 mm)

thick-

or

less

TU

NNEL RUB STRIP

7-3

Tunnel Rub Strip Removal

1.

Separate

•

Remove seat

seat

from tunnel.

mounting

tunnel.

•

Lift

seat

suff

ici

ently

tunnel,

being

careful

wiring.

2.

Remove

•

Unscrew

rub

strip

nut

from rail.

securing

tunnel.

•

Remove
access

•

Slide
downward

to

rub

snow

rub

strip

to

flap

strips.

rearward

clear

rear

bolts from

to

place

sideways

not to

nuts

pull

rub

strip

and lift flap for

while

tunnel

under

on

tail lamp

at rear

of

pulling

bulkhead.

NOTE:

will be
of
procedure

suspension

If

necessary

tunnel

rub

strip

for

access.

to relieve

arm .

does

not

to

swing

Refer to Ride

spring

slide

rear

Tunnel Rub Strip Installation

1.

Lubricate

required

2.

Slide
front

3.

Tighten

4.

Install

rail

rub

nuts

snow

rub

strips

for

installation

strips

strip

bracket.

securing

forward

.

rail at rear

flap spacers, washers, and

nuts.

•

Torque

Mount

5.

•

Refer to

If removed,

6.

nuts

seat

to

50

on tunnel.

Seat

Installation

reinstall

in. Ib (0.6 kg-m).

rear

and springs.

• Refer to

Suspension

cedure.

off

rail

suspension

Adjustment

tension

to

reduce

until

they

procedure.

suspension

Installation

easily,

out

from rear

effort

contact

of

tunne

arm

pro-

it

l.

1.

Snow

2.

Spacers

3.

Rail.

4.

Wear

S.

Bracket

Flap.

.

Strip.

(long

arm

toward

outside).

COOLING SYSTEM

COOLING SYSTEM 8-1

Coolant
Coolant
Cooling
Draini
Filling
Thermostat

Radiator

Heat

Flow -Thermostat
Flow -

System

ng

Coolant ...

Cooling

Thermostat
Thermostat
Thermostat

(Heat
Radiator
Radiator
Radiator

Exchanger ... .

Heat

Exchanger

Heat

Exchanger

Heat

Exchanger

Heat

Exchanger

Table

Closed ..............

Thermostat

Pressure

....

System ..

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

Removal
Inspection

Installation .......

Exchanger)

Removal ......

Inspection
Installation

........

Removal

Open .

Test. ...

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

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

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

......

...

.......

.......

....

...

...... ..

...... ..

......

Inspection
a-Ring
Installation

Replacement.

. .

...... : .........

...

.....

of Contents

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

........

. ..

...

........

...

..........

........

..

.. ..

.........

......

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

.

......

......

..

....

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

..

. ..

....

.....

........

.........

.

...

..........

.....

.........

.......

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

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

.........

.

...........

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

..

.....

........

. .

....

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

......

........

........

..

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

.......

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

......

........

. .

.....

.......

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

..

.....

...

......

. .

.........

.......

...

....

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

...

.. ..

.....

......

..........

....... 8-6

....

........ 8-6

....

....

.......

........... 8-6

.....

. . 8-2

. .

...

.

. ..

8-2
8-2
8-3
8-3
8-4
8-4
8-4
8-4

8-6
8-6

8-6
8-6
8-6

8-7

8-2

COOLANT FLOW

COOLING

COOLANT

When the engine is

cool

ant

vented, causing

increase as

within the

A

sma ll
coolant
the

water
allowing
temperature se
open when
temperature.

SYSTEM

FLOW -

flow

to the heat

it

engine

by-pass

flow

from

pump, which

coo l

ant

tting

coo

lant reaches the predetermined

THERMOSTAT

cold

coolant

is

conta

ined and

assembly

hose is

cylinder

reduces

to

climb

to

. The th

CLOSED

(thermostat closed),
exchangers

temperature

.

provided

head

outlet

selected

ermostat

is pre-

recirculated

to

permit

back

the

flow

rate

thermostat

begins

to

to

to

COOLANT

Once

FLOW -

the

thermostat

THERMOSTAT

has opened,

flows through the heat exchange

cooled
i

nlet

restriction
coolant
the

and
coolant

down) and

, ready to be

created by its small size, very little

flows through the

thermostat

Thermostat operation

closed

to maintain a

temperature.

returns

recycled

is opened.

Thermostat

to the

again. Due to the

by-pass

cyc

les between opened

nearly

Open

OPEN

rs

(where it is

water

hose when

constant

coolant

pump

engine

Thermostat

:\ , l

~:'

-

~

/

" "

, ,

. . ,

..

~

1. Cylinder Head

2. Thermostat

3.

By-Pass

4.

Water

Hose

Pump

Closed

1.

Radiator

2.

Heat

3. Thermostat

4.

COOLING

cooling
tection of the
water
boiling
in:

Exchanger

By-Pass

Proper

Hose

SYSTEM PRESSURE

pressure

system to provide

mixture

point

• Loss
(during boilover)
level.

•

Extensive internal
improper

factory

. Low

of

of

coolant

must

pressure

coolant

coolant

TEST

be

maintained

des

ired

boilover

recommended antifr

will r

educe

mixture

through

lowering

engine

level.

and may

overflow

coolin g system
damage

in the

pro-

eeze

the

result

hose

due

to

Pressure

1.

Disconnect
ting.

2.

Install test

• Using a
one end to

other

1.

Radiator

2.

Overflow

test

end

Fitting.

Tube.

the

cooling

overflow

tube

short

overflow

into

system as follows:

tube

from radiator

to

overflow

piece

of tubing,

fitting and place

container

of

fitting.

water

fit-

connect
.

6.

Reconnect

• Remove

DRAINING

1.

Place drain pan

• Coolant
tor

overflow

• System

2.

Connect

• Remove
neck

• Route hose
valve located on front
section.

• Remove
Slide

•

•

loosen

DRAINING COOLANT

original
test

tubing

COOLANT

under

will

be

hose.

capacity

drain

hose to

radiator

fitting.

underneath

clamp

overflow

drain

valve 3 turns.

overflow

from

snowmobile.

drained

is 1.2

out

gallons

coolant

overflow

of

and

cap

hose onto

8-3

tube to radiator.

fitting.

through

radia-

(4.5 liters).

drain

valve.

hose from

engine

lower

from

drain

drain

filler

to drain

crankcase

valve.

valve.

3.

Connect
coolant

• Remove

1.

Drain

2.

Clamp.

3.

Cap.

4.

Open drain valve and

2

cm
gauge. Any
and

• If
pressure

a hand held

drain valve at

cap

Valve.

)

pressure

must

be eliminated.

bubbles

pressure

cap

and retest.

• If no

bubbles
water,
water
and
point

pressure

along all sealing

cooling

leakage. Repair as

retest.

5.

Disconnect

• Close

pressure

drain

(0.5 kg-m).

• Install cap on
clamp.

pressure

front

of

engine.

from drain valve fitting.

apply

to

system

drop

appear

in

is

defective. Replace cap

are observed in

15

psi (1.0

while

indicates

container

container

observing

cap is good. Spray soapy

surfaces

system

components

necessary

tester.

valve.

Torque

fitting

and

to

45

secure

tester

kg-

leakage

of water,

of

engine
to

pin-

and

in. Ib

with

to

of

1.

Radiator

2.

Radiator

3.

Drain

4.

Cap.

5.

Clamp.

3.

4.

5.

FILLING

Use a

(55% ETHYLENE
45% water) when
recommended
freezing down to
A major brand of
or

Dowgard) is recommended. The
must
tank

Cap.
Overflow

Valve

Remove
drain more

lift

rear of
coolant
Close

drain

Remove

•

and

reconnect

•

Torque

.

radiator

freely.

snowmobile

to

drain

valve.

overflow

drain

Fitting.

• Install cap and

COOLING

55/45

mixture

GLYCOL

filling

mixture

approximately

antifreeze

be

within

1/4

to

top when cool.

cap

from heat exchanger.

hose from

to

radiator

valve to

clamp

SYSTEM

of

antifreeze and

base antifreeze and

cooling

will

(such as Prestone

1/2

in. (6 to

to allow

slightly

coolant

to

drain

fitting.

45

in. Ib (0.5 kg-m).

on drain valve.

system.

protect

_50· F

against

(-45°

coolant

12

mm)

allow

valve

water

This

C).

level

of

the

to

II

8-4

- THERMOSTAT

I

WARNING

....

____

burns
from
had
gauge
tom left

could

radiator

adequate

needle

area

I

Do

11.

when

result.

only

time

has

of

not

engme

after

to

returned

green

r~mo~e

Remove

cooling

cool

zone.

pressure

IS

hot
pressure

and

temperature

to

the

or

system

peg

at

cap

severe

cap

has

bot-

2.

Disconnect

cover.

3.

Separate

head.

•

Unscrew

coo l

ant

thermostat

cover

mounting

hose from

cover

from

bolts

thermostat

cylinder

.

[§]~[}

freeze
mixture

1.

1.

2.

2.

3. Run

THERMOSTAT
Thermostat

1.

at a warmer temperature

of antifr

Fill

cooling

• Loosen
cover.

• Remove

• Pour

•

Ca

• When
thermostat
Ib (1.7 kg-m

• Fill
below

Radiator
Vent

Plug.

Reinstall press ure cap.

engine

cool, and

Drain

• Refer to Draining

~:t:~~

system.

vent

cap

coolant

pacity

is 1.2

coolant

until

level is

radiator

Cap.

for several minutes,

recheck

Removal

coolant

u1s~O~/?O;/~~~rt!f~~:Z:~~

eeze

and

plug

from radiator.

in slowly.

gallons

appears

cover,

torque

),

and

continue

1/4

filler

coolant

from system.

Coolant

water.

at

top

(4.5 liters).

at

vent

to

1/2

neck.

level.

than a 55/45

of

thermostat

vent

opening

plug

to

filling.

in. (6 to

procedure

12

allow

12

mm)

it

to

.

in

ft

1.

Thermostat

2.

Gasket.

3.

Thermostat.

4.

Lift

• Remove

Thermostat

Heat
thermometer, check
opens
fails to open at
damaged in

Thermostat

1. Position

• Install so
cylinder

2.

Install

•

• Position

• Install

•

Connect

3.

4.

Pressure

• Refer to Cooling System Pressure
Fill cooling system.

5.

• Refer to Filling

Cover.

thermostat

thermostat

Inspection

thermostat

at

1080 F (420 C).

any
Installation

thermostat

head.

thermostat
Apply
cover

Torque

procedure.

cedure.

silicone

gasket.

cover

cover

bolts to

coolant

test

out

in a pan

this

way.

that

gasket.

.

hose to

cooling

of

cylinder

cover

gasket.

of

water. Using a

to see

Replace

temperature,

in

thermostat

cover

sealer

60

Cooling

that

cylinder

on

cylinder

to both

in. Ib (0.7 kg -m).

thermostat

system.

head.

thermostat

thermostat

or

if it

head.

spring

System

is in

head.

sides

cover

if it

is

of

.

Test

pro-

~

-1

7

I

~

COOLING SYSTEM 8

I

)

;'

-5

1 CAP,
2 EXCHANGER,
3 TUBE,
4 CLAMP, hose
5 CLAMP
6
7 CLAMP,
8 RIVET,
9 PIPE,

10

11

1 2 HOSE ,
13
14

pressure

1/4 x 24.00

HOSE,

PIPE

HOSE,
WASHER,

RIVET, 3/16

coolant

pipe

3/16

coolant

, coolant

coolant
coolant

heat

"

special

15

PAD,

exchanger

16

SCREW, special,

17

WASHER, seal

18

COVER, heat

19

O-RING , heat

20

EXCHANGER, heat

21

NUT, insert,

22

BRACKET,

23

WASHER, plain,

24 SOL T,

25

BRACE ASSY

26

NUT, insert,

27

WASHER, plain,

28

BOLT, special, 1/4-20

5/16-24

exchanger

5/16-24

radiator

1/4-28

10-24

exchanger

brace

5/16"

x .62

1/4"

x .62

x .

50

15

:':

~"':

'

" "

.. I

29

WASHER, plain,

30

BOLT,

31

BOLT, special, 5/16

32

DUCT ASSY

33

PAD,

34

BOLT,

35

PAD

36

HOSE,

37

BUSHING,

38

GROMMET,

39

WASHER,

40

PAD

41

CLAMP

1/4-28

radiator

1/4-28

coolant

grommet

spec

~16

~17

1/4"

x 1.

00

-24

to

duct

x .62

mounting

ial

x .62

8-6

RADIATOR (HEAT EXCHANGER)

RADIATOR
Radiator

1.

Drain

• Refer to Draining

2.

Disconnect

• Unfasten

(HEAT EXCHANGER)

Removal

coolant

from system.

Coolant

coolant

hoses from radiator.

radiator-to-exchanger

radiator.

•

Unfasten

engine-to-radiator

radiator.

• Pull overflow

tub

e from radiator

neck.

procedure.

hose at

hose

at

filler

3.

Pressure

test

cooling

system.

• Refer to Cooling System Pressure
procedure.

4.

Fill cooling system.

• Refer to Filling

HEAT
Heat

cedure

EXCHANGER

Exchanger

.

Removal

Cooling

System

Test

pro-

1.

Hoses.

2.

Shim

3.

4.

3.

Washer.

Grommet.

Bushing.

Remove

• Note
radiator

radiator

number

duct

bracket.

• Be careful not to lose
hardware.

@~

very

careful

store

radiator

4.

Lift

radiator

:~:iaat~~

of

radiator

in a

from duct.

NOTE: O-Ring
performed

Replacement

without

procedure

removing heat

may be

exchanger

from tunnel.

1. Drain coolant from system.

• Refer to Draining

2.

Remove seat assembly.

Coolant

procedure.

• Refer to Seat Removal procedure.

3.

Drill

out

exchanger

4.

Using a

exchanger

rivets

to tunnel.

sharp

and tunnel.

(3/16

knife,

in.)

securing

cut

seale r between

mounting bolts.

of shim

and

safe

washers

rear

radiator

t~::~:n:af::::g':::.

during

between

LH

mounting

mounting

removal,

fr:~

and

place.

~.':.:::

::

....

..

...

:::

::::

......

'"

~

.. ,

.

heat

Radiator

1. Flush radiator

2.

Radiator

1.

Inspection

Check

radiator for

• Repair as

Installation

Mount

• Install

radiator in duct.

any

with

nece

shim

clean

leaks

ssary

.

washers

water

or

tion.

•

Check
tered in hood
remove

• Torque
(0.6

2.

Connect

• Attach

• Attach engine

• Slid e

to see

that

radiator

outlet

shims

mounting

as required.

bolts

kg-m).

coolant

hoses to radiator.

radiator-to-exchanger

-to-radiator

overflow

tube onto radiator fitting.

opening. Add

to

.

damage.

in original

duct

is cen-

50

in. Ib

hose.

hose.

posi-

or

1.

Exchanger.

2.

Cut

Sealer

3.

Rivets.

5.

Disconnect

exchanger

Heat

1.

Examine all hoses and

•

Away.

from tunnel.

Exchanger

Check

for cuts,

Inspection

• Replace as required.

2. Flush

3.

Heat

1.

Remove heat

out
If there are
leakage,

replace

Exchanger

•

Carefully
exchanger

heat

signs

O-Ring
exchanger

peel

edges.

• Remove heat

•

Lift

off

cover

coo

lant

cracks,

exchanger

of

hoses

pipes

.

or

deterioration.

with clean water.

heat

exchanger

O-ring.

Replacement

cover.

insulating

exchanger

pad from heat

screws.

and remove O-ring.

and

lift

O-ring

1.

Pad.

2.

Cover

3.

O-Ring.

4.

Seal Was

HEAT EXCHANGER

2. Install

•

•

.

hers

Required

(*)

.

• Press
Mount

3.

• Use new seal

•

4. Pressure

• Refer to

Heat

new

O-ring.

Coat

O-ring

sea ler to

O-ring

cover

in

illustration.

Torque

(0.6

procedure

Exchanger

heat

kg-m).

test

with a thin

help

keep

into

heat

on heat exchanger.

washers

exchanger

cooling

Cooling

.

System Pressure

Installation

film

O-ring

exchanger

on

bolts

system.

bolts

of

in

position

to

8-7

silicone

.

groove.

indicated

50

in. Ib

Test

@~flill

except

tunnel

1.

2.

3.

4.

5. Position pad on heat

6.

7.

sealant

and

Can

nect

exc

hanger

Pres~ure

• Refer to
procedure.

Secure heat

•

Use

Sea l heat e

Apply

•
ant

• Use s
exchanger.

In

stall sea t assembly.

•

Refer to

Fill

coo

• Refer to
cedure.

~;a~O!:~~~~;:~I:~~

will

reduce

test

3/16

continuous

along

ilicone sealer

ling syste

cooling

coolant

and

pipes

cooling

Cooling

exchanger

in. rivets.

xchanger

bottom edge

Seat

Installation

Filling

insulate

hoses

System Pressure Test

m.

exchanger

efficiency.

between

.

system.

to tunnel.

to tunnel.

bead

of

of

exchanger.

exchanger

to

secure

procedure.

Cooling System pro -

b~~~~:~

from

heat

sili

cone

seal -

.

pad to heat

DRIVESHAFT

DRIVESHAFT 9- 1

Driveshaft

Driveshaft
Driveshaft
Driveshaft Installat

Serv i

cing ....

Removal

Repair .. ..

ion .... .. . .

Table

.......

.. ..

...

....

of

. ..

..........

. .......

. . .

...

.....

Contents

....

. ..

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

.. ..

. ..... .

.......

. .....

.......

..........

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

. ......

..........

.. ..

. . 9-3

. .

. 9-3

9-3

9-3

9-2

DRIVESHAFT

DRIVESHAFT

4

1 COLLAR ASSY
2 SCREW,

3

PIPE,

4 SPROCKET,
5 PIPE,
6 SHAFT,

1/4

outer

center

track

-28

x .62

spacer

track

space

drive

drive

r

7 BOLT,

HOUSING,

8
9 SEAL,

10

BEARING

11

NUT, insert,

5/16-24

bearing

"0"

ring

5/16-24

"'I

I

I

I

x .88

DRIVESHAFT

DRIVESHAFT SERVICING

9-3

DRIVESHAFT

Driveshaft

1. Remove

• Refer to

2.

Remove

• Refer to

3.

Remove

4.

Remove chain.

• With
is not

SERVICING

Removal

battery

(electric

Battery

suspens

ion.

Suspension

driveshaft

snowmobile

necessary

start

Removal procedure.

Removal procedure.

bearing housing.

positioned

to

drain

chaincase

cant.

• Refer to Chain Removal procedure.

5.

Remove driveshaft.

•

Slide

driveshaft

Driveshaft

1.

Check

Repair

bearing.

• Turn bearing
has

excess

place

it.

2.

Inspect driveshaft.

•

Check
If

•

Check

straightness

shaft

is bent,

shaft

from

chaincase.

by

hand. If bearing binds,

ive end play, or is rough, re-

with a

repair

for

or

replace

chipped

splines.

Check

3.

• To remove

• When

• Install

drive

sembly
mallet
block

of

sure

to align

sprockets

sprockets,

and

while

tap

supporting

for

excessive

loosen

sprockets

driveshaft

wood to prevent damage to shaft.

reassemb

sprockets,

lin g

index

marks

spacers, and

drive

as shown.

as shown .

• Position

sprocket

onto

shaft

shown.

• Place
tighten

collar

screw

assembly

to

70

in. Ib (0.8 kg-m).

again

models only).

on its side, it

lubri-

straight

edge.

it.

or

broken

wear.

collar

lightly

with

as-

a

on a

sprockets, be

washers

at

dimension

st

spacer

and

T T

1. 6.59±O.04

Drive

NOTE:

in.

Shaft

Installation

The lower

chaincase
type. Be sure area between
grease to

1.

prevent

Position

premature

driveshaft

in

track.

• Place
front frame, then
end of
not to damage sea

2.

Install bearing housing.

•

Lubricate
with

•

Position
"TOP"

•

Slide

• Torque

driveshaft

shaft

a-ring

grease.

bearing

facing

housing

bolts

bearing through hole in

carefully

into

chaincase,

l.

inside

upward.

onto bearing .

to

12

3. Install chain.

• Refer to Chain

Installation

4. Install suspension.

• Refer to

Suspension

cedure.

5. Reinstall

• Refer to

battery

Battery

(electric

Installation

seal is a

lips

driveshaft

chaincase,

bearing

housing

ft

Ib (1.7 kg-

Installation

start

double

is

packed

with

wear.

within

guide

being

splined

careful

housing

with

word

m)

procedure.

models only).

procedure.

lip

pro-

ELECTRICAL SYSTEM 10-1

ELECTRICAL SYSTEM

Battery ...

Battery
Battery
Battery
Battery
Battery

Charging

Charging
Regulator/Rectifier

Regulator/Rectifier

Key

Switch

Lighting

Lighting
Lighting

Lighting

Starter

Starter
Soleno

Starter

Starter
Starter
Starter
Starter
Starter
Starter

Switches .....................

Emergency
Dimmer
Brake

Volta

...

.........

Testing

Charging .......

Removal
Cleaning

Installation .......

and Instrument

and

Leakage
Current
Voltage

Circu

Continuity .....

Shorts

Circuit. .........

Motor

ge

Regulator Tests

Test
Output
Control

Tests

it

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

Circuit
Coil

to

Ground ...

Circu

Circuit

id

Switch

...........

Motor
Motor
Motor
Motor Disassembly
Motor
Motor

Stop Switch

Switch

Switch

.....

. .

..........

...

.......

Instrument

Tests ..............

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

Test

Test

Replacement

.....

........

Operation ............... . .

Tests

......

.. ..

it

Tests ......

Operation ...

Test ..........

Circu

it
Removal ..
Installation ...

Inspection

Assembly ......................

Test ..........

Test. ...

Table

...

. .

Circuits

.........

. . .

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

........

..

. .

..

.......

Tests

......

(manual

of

Contents

........

. .......

........

........

Circuits

.

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

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

....

...

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

Test.

. .

.....

.

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

........

...

...

..

...

...

.....

.......

. . ....

............................ 10

Operat

.

........

. .

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

....

...

......

. .

...

. .

.......

.. .......

....

.....

...

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

. .

...

...

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

..

...

......

.......

start

. ..

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

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

. .

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

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

...... .

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

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

. .

.........

........

....

.......

...... .. .

model)

. ........

..

. .....

. .........

........

..

. .

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

ion

........

..

...... .

..

. .... ..

. .

...

..................... 10-9

...

.. ..

.

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

.

....

. ..........

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

...

.

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

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

...

........

...

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

...

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

...........

. . .

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

. .

....

....

. .

...

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

......

.......

.......

........

.

...

....

................. 10

................. 10-21

. ..........

. .

.......

.

.........

..........

. .... . .

...

...

. ..

.......

.....

.......

.........

......

...

........ 10-10

..........

.

......

........

.

...

......

.....

..

. .. .

...

.......

....... .' 1 0-30

........

......

.....

..

. .....

.

.......

.

. ....

.

...

. .

...

. . . . 10-12

... 10-16

. .

....

...

....

....

...

.....

..

...
...

... 10-4

. . 10-4

... 10-4

... 10-7

... 10-8

10- 10

10-12
10-12
10- 12

. 10- 17

10- 18

..

10-18

. . 10-21

. 10
. . 10 ­.. 10-28

10-29
. . 10-29
. . 10-29

. . 10-30

10­10-2
10-3

-5

10

-5

10-7

10

-8

10-9

-17

-23
24

2

10-2

BATTERY

ELECTRICAL

The

snowmobile

a

battery

lights,

electric

BATTERY

I

WARNING

~

.

___

ELECTRICAL
NECTED.
regulator/rectifier.
could
personal

instruments,

starter.

cause a fire

and

the

I

...

Doing

injury.

SYSTEM

NEVER
BATTERY

r

electrical

necessary

CONNECTORS

so

may
Sparks

which

system

circuits

battery

RUN

damage

may

ENGINE

CABL

that

consists

to

charging

ES

DISCON

the

voltage

may

cause

of

operate

and

WITH

OR

occur

severe

5. Keep

6.

7.

-

8.

I

WARNING

~.

____

battery
generates
mable
tions.
this

Battery

the

weath

er

so
freeze and
discharged
eas

ily

it freezes.
Always
obstructio
pinched
cannot
explode
DON'T
WARDS,
result.
Do
tain items
that

gas

keep

or

escape

the

INSTALL

electrical

The negative side is gro

not

install

charging

I

...

and

hydrogen

and

explosive

Sparks

causing

Testing

battery

crack

n,

cause

Do
snowmobile

jumper

from

well-charged

that

the e

open

the

battery

the

battery

and

make sur

crimped

through

battery.

THE

unapproved

excessive

circuit cann

not

attempt

gas

jumper

severe

during

lectrolyte

the

batt ery. The more

becomes, the more

vent

e it

shut. If

this

BATTERY

sys

tem

accessories. Cer-

drain

ot

to

with

cables.

which

under

certain

cables

personal

does

hose free

does

battery

hose,

damage

und

on

rep l

ace

"jump"

a

The
can

may ignite

injury.

cold

not

not

get

gases

they

will

BACK-

cou

ed.

battery

.

start

booster

battery

be

flam

condi-

of

ld

-

The

battery
direct
which
serves
when
engine
charging
current
system

to
ruined
ing a few

of

1.

2.

3. Avoid

4.

current
is

as a back-up

the

is

circuit.

With

proper

last

several

long

the

battery

When
tery is
cell

marked

ary

tap
water
Never
battery.
tion
within

charge
Never
30

days
charge,
stand
for

any
charges.
sulphate
longer

stores

(12 VDC), in a

used for

engine

running,

circuit

used to

before

simp

the

low,

until

on

water

and

add

This

too

a very

quick-charging

will

let a good

and

without

length

take a charge.

starter

is

is

sent

start

care,

the

years, but

that

le

rules

.

level

of

add

only

the

level is

the

outside

is

not a substitute

will

shorten

sulphuric

will

strong

short

damage

without

never

charging

of
Once
(turn

it

white)

electrical

batt

electrical

motor

source

not

running

to

the

engine

battery

it

if it

is mistreated.

will

greatly

the

electrolyte

distilled

at

the

of

the

acid

make

the

and

will

time.

the

the

battery

ery

stand

giving

let a

it. If a

time,

is

discharged,

and

energy, 1 2

chemical

operation

of

power

energy

battery

) and to

can be

may

upper

the

life

solution

electrolyte solu-

ruin

battery. A

it

a s

discharged

it slowly self

the

for

. When the

from

(to

expec

be

completely

extend

in

the

water

to each

level lin e

battery.

for

distilled

of

the

the

plates.

for

more than

uppl

emental

battery

the

battery

volts

form

and

light

s

the
replace
lighting

ted
Follow-

the

lif

e

bat

Ordin-

battery.

to the

battery

quick

battery

stands

-dis-

plates

will

no

I

WARNING

~'

____

poisonous
installed
hydrogen
is

flammable

and

sparks (cigarettes, etc.) away
always
or

near

KEEP

EXTERNAL

minutes.

-

-

INTERNAL -Drink
milk

. Foll

or

vegetable oil.
CALL
EYES - Flush
GET

Water

mixture
and
charged
of
water
added,
proper
plates. Metal from
in
eventually

PHYSICIAN

PROMPT

The

escapes, which

the

should

the

bottom

I

Battery

"_sulfuric

and

causes

in

the

battery,

gas

which

and

explosive.

wear

eye

protection

the

battery.

POISON/DANGER

OUT

OF

REACH

ANTIDOTE

- Flush
large

ow

with

milk

IMMEDIATELY.

with

water

MEDICAL

electrolyte

in thi s soluti on

due to

battery.

electrolyte

the

so lution

chemical action

cause

is d

chemical act

concentrates

Consequen

becomes low

be

added

will

the

of

the

battery. This sed iment

an

int

electro

severe

electrolyte

und

er

with

of

magnesia

for

ATTENTION.

ilut

changes

. If sul

become

and

damaged plates coll

ernal short

lyte contains

acid

certain

Keep

when

OF

CHILDREN

wat

er

for

quantity

15

minutes.

ed su

to a

ion in the

tly,

when
, only di

phuric

too

will

which

burns.

generates

conditions

all

working

at l

of

water

, beaten egg

lphuric acid

gaseous

the acid in a

the

strong

damage

circuit.

i s

When

flames

and

on

east

or

battery

level

stilled

acid

is

for

the

ects

will

5

.

Specific

gravity

with a hydrometer
i

ndication
varies
contract
measured
thermometer
perature

Test

NOTE:
immedi
incorrect

of

battery

with

temperature

ion

of

electrolyte,

using a hydrometer

to

.

specific

Do

ately

gravity

not

after

readings

of

the

electrolyte

and

is

the

condition. Specific

due

to

expansion

and

must

determine

of

check
adding
will

result.

electrolyte

each

specific

water

battery

is measured

most

accurate

gravity

and

therefore

be

with a built-in

tem-

cell

by:

gravity

to

battery

as

•

All

cell

1.200,

battery

retested.

• Variation
between

questionable.

If

50

point

tery.

NOTE:

If

plates
(turned white) it
charge.

readings

of

more than

any

cells

Charge

variation

inside

will

no

uniform

mus

.t

be

50

means

battery

remains, rep l

battery

longer

accept

BA

TTERY 10-3

and

below

charged

points

and

(0.050)

serviceability

and retest.

ace

bat-

are

sulphated

and hold a

is

1.

Ins

ert

Be

•
from

only

mit

2.

Remove
gravity

• Hold
reading at bottom

surface

Read_G:h
Here

3.

Observe
rect

4.

Interpret

1.260

•

should

•

All

1.

charging

hydrometer

sure

tube

rubbing

enough

float

to raise freely.

hydrometer

of

electrolyte.

hydrometer

of

into

is

vertical

inside

electrolyte

fluid).

cell.

to

prevent

of

tube, and

into

and

observe

at eye level and take

of

meniscus

__

~

temperature

reading.

Electrolyte

~

0

>

g

~

..

0

,

~

E

::

Add

0.004

points

aOoF

(27°C)

below

BOoF

t27oCl.

readings

Temperature

to

or

subtract

of

120

+.016

110

+.012
+.008

100

+.004

90
80
70

-.

004

-.008

60

-.0

12

50
40

- .016

30

- .

020

20

-.024

10

-.028

o - .030

reading

for

0.004

points

as follows:

electrolyte

Correction

g

8

>

.~

!

each 1QoF (SoC)

for each

10°F

or above, battery is good and

perform

cell

readings

200, battery

.

correctly.

uniform

is

serviceable

tube

abo

ve

(GoC)

and

but

float

draw

to

per-

specific

(curved

and

cor-

above

requires

o

w

t;

w

~

_

OU

u9-.

:>oN

!::;;::

~'6

CI:

00

l?0

U

I-

LL

U

w

"-

en

Battery

I

WARNING

....

____

poisonous

installed
hydrogen
is

flammable

and

sparks
always
or

near

Battery

1.

28

t'....

1.24

1.20

1.16

1.12

1.08
1

.04

100

Charging

and

in

the

gas

wear

the

battery.

'""'"

CHARGE

90

80

TOTAL

I

Battery

••

sulfur

causes

battery,

which

and

(cigarettes,

eye

POISON/DANGER

KEEP

OUT

OF

ANTIDOTE

EXTERNAL

- Flush
minutes.
INTERNAL -Drink
milk. Follow

or

vegetable oil.
CALL
EYES - Flush

GET

PROMPT

NOTE: Remove

electrolyte

Removal

1.

Check

• If el
distilled
to
fill

with

PHYSICIAN

with

MEDICAL

battery

during

procedure

electrolyte

ectrolyte

water

lower

lin e on

battery

as

milk

ing.

State

of

Charge

GOOD

.......

50

REMA

CONDITION

r--....

40

30

INING

~

'"""'"

REQUIRED

70 60

CAPACITY

r--....

electrolyte

ic

acid

severe

burns.

electrolyte

under

explosive.

certain

Keep

etc.)

protection

REACH

with

large

of

when

OF

CHILDREN

water

for

quantity

magnesia, beaten egg

IMMEDIATELY.

water

for

15

minutes.

ATTENTION.

to

prevent
charging. Refer to
.

level.

level is low in

as

necessary

battery

level

will

any

case. Do

raise

during

to raise level

.......

to.......

.........

20

10

contains

which

When

generates

conditions

all

flames

away

and

working

at least

of

water

spillage

Battery

cell,

add

not

over-

charg-

0

is

on

5

or

of

10

-4

BATTERY

2.

Cover
towel,
electrolyte

~

battery.
excess
creating
plates
ing

deposits

cuits.

The

heat,

internal

may

filler

etc.,

during

openings

to

with
prevent
charging.

a cloth,
splashing

paper

of

I

WARNING

~.

____

components

I

Prevent

.. _ jury

by

always

and

possible

damage

removing

personal

to electrical

negative

in-

(-)

cable from battery first, then positive (+)

~~~r~~negc~~:~e~a~tdh~~~~:~~:

higher charging

which

shed

that

short

active

cause

can

material,

circuits.

internal

warp

rate

causes

the

plates

Also,

accumulat-

short

the

cir-

cable.

2.

Remove battery.

•

Disconnect
tery.

•

Carefully
bracket.

cab

les from termin als

lift

battery

out

of

mounting

of

bat-

Connect

3.

• Set
charge

NOTE: If
115°F
rate to
time.

4.

5.

Battery

1.

(45°C)

low

Disconnect

• The voltage

•

Check

hydrometer. A hydrometer reading

or

means

Install
cedure.

Removal
Unfasten
assembly.

12

volt

charger

charging

between 3 and 5 hours.

electrolyte

during

er the temperature. Increase

specific

above

additional

battery

clamp

rate at 3 to 4 amps and

temperature
charging, reduce

charger

should

gravity

is

good. A lower indi

as

outlined

and remove

to battery.

and

test

be

12

of

each cell with a

charging

in Installation

rises above

battery.

or

13

is

battery

charge

charging

volt

s.

of

1.26

cat

ion

necessary

pro-

cover

1.

Negative (

2.

Positive

3.

If

corrosion

and top

mended cl

Battery

Accum

and corrosion on

life and

outside
To clean

1.

.

2.

3.

4.

Cleaning

ulation of

reduce

of

battery

Remove

battery

• If
occur

Clean heavy
battery

• Fini sh
one
but
from

Rinse entire battery
Comp lete

(+)

surface

eaning

battery

battery

to

chass

and

cleaning

part

baking

use

care

enter

ly

dry

-)

Terminal

Terminal

or

dirt

are

present

of

battery, follow

procedures.

dirt

on top

terminals

its performance.

as clean and

proceed

from

is not removed, damage may

is

corrosion

cable

to

ing

cells

outer

can shorten

as

snowmob

components.

from te rminals

ends

with a wire

by

applying

soda

to

prevent

of

battery.

with

surface

on

terminals

surface

dryas

follows

four

clea

clear water.

of

Always

possible.

:

il e.

so luti on of

parts

ning

solution

of battery.

recom-

battery
battery

keep

brush

water,

of

.

Battery

Prior to
are free
dry

and

1.

Be sure
tioned
assembly.

2.

Lower

•

Guide
chaincase

Installation

battery

of

corros

battery

under

battery

ion,

is

protect

battery

vent

drain

installation

outer

fully

charged.

ive

pads

into mounting

tube

plug

be

surface

are

and hold down

downward

hole.

sure

terminals

is clean and

proper

case

ly

assembly .

through

posi-

cover

[p~~~Tlm

sion

of

electrolyte.

1.

Battery

~~~~~~~~t

chassis

Vent

components

Tube

c~~~~i~egsu~:

from

CHARGING

required

inb~~~~~!

expelled

magneto system.

2.

Lighting
on a plate near
will
rent (AC), as
flywheel

3.

Tachometer -used
speed in
Power to
by magneto

4. Regul
neto

tery. Mon
to predetermined safe level.

5.

1 2 VDC

during
ates

ning.

6.

Fuse ­and
within

7.

Wiring
nect
charging

AND INSTRUMENT CIRCUITS 10 -5

to

produce

Coil - a large

produce

ator/Rect

lighting

electric

lighting

components

system

and

and

single

the

rotation.

revolutions

operate

lighting

coil into

itors and

Battery -provides

system

prevents

to

Connectors

complete

sys

tem.

electrical

the

flywheel

phase

magnets

the

tachometer

coil

ifi

er -converts

DC

controls

starting

when

damage

by

10

amps.

the

coil

of

magnets,

alternating

pass by

to

measure

per

minute

output

to

charge

battery

power

of

engine
engine

to

wiring

limiting

- used to

circuits

energy

wire

is

(AC).

AC from mag-

neces

current

of

in a

mounted

which

cur-

during

engine

(RPM).

supplied

the

bat-

voltage

sar

and

oper-

is

not

run-

harness

flow

intercon

items

y

-

in

3.

Secure
assembly.

~~

regulator/rectifier

4.

Connect

•

•

•

•

battery

battery

Secure
tive

(+)

Connect

minal.

Coat

terminals

corrosion
Slide

boot

~~nnSo~~edv:~sa~~at~~~e

RED

terminal.

BLACK

.

over

by

fastening

will

cables.

cable

cable

with

terminal

result.

and

fuse

to negative (-)

grease to

for

Charging

As the

rounding
windings,
with two

Current

a

clamp

of

cover

c~;I~:~~

wire

to

posi-

ter-

prevent

protection.

solid-state
RPM a small
enters
verted to DC,

back

charging

unchecked,
exceed
charge
reaches
act

ivated wh ich
sends
ing coil

S

in

ce

Regul

Current
varies
follows:

and

Instrument

flywheel

the

which

cycles

leaves

the

Regulator/Rectifier

to

lighting

voltage

the

battery's

and

boil. Instead, when

14 to 14.5 volts, the

the

excess

reducing

there

are

ator

/Rec

flow

depending

rotates ,

magnets

generate

per

flywheel

the

Regu

lator/Rectifier.

charging

sent

to

coil. As

this

voltage

by-passes

current

charge

no

contacts

tifier

never

from

on

capacity

Circuits

magnetic

cut

through

alternating

lighting

voltage is

the

battery,

engine

also

the

key

increases.

supply

regulator

directly

avai lable to battery.

or

needs

Regulator/Rectifier

switch

lighting

revolution.
coi l and is

At

generated

where it is con -

and

RPM i

would

caus

ing it to

battery

the

battery

back

moving

to

be

position

Operation

fields

low

sur-

coil

current

sent

engine

and

returns

ncreases,

Left

soon

over-

voltage

circuit

and

to light -

parts,

the

adjusted.

as

to

is

CHARGING

Charging

the

following

1.

Flywheel -contains
nets,
ference,

AND

and

Instrument cir

components

even

ly

which

INSTRUMENT

cuits

.

four

permanent

spaced

provide

about

the

CIRCUITS

consist

the

circum-

magnetic

of

mag-

field

• Run
system is
terminal
switch

•

Run/Lights
as

described

to

supp

to L

terminal

position -current

availab

of

.

lying

le to

charge

key switch
position -current

for Run

power

of

key

and

position

to all

switch.

from

battery, at B

at

is

lights

charging

brake

light

available

in

addition

connected

TO

ENGINE

GROUND

BROWN

WHITE

SLEEVE

ON WIRE

LIG HT I

NG COIL

E

NGINE

MAGNETO

" " RED

BATTERY

w

Vl

::J

REGULATOR

/

RECTIFIER

o

3::

lwl

~

g~3::

---'

IO

~S:j

-=-

w

>-

KEY

SWI

TCH CONN ECTIONS

KEY

SWITCH

POSITI

ONS

" OFF"

" R

UN

/LIGHT

S"

"RUN"

"START"

CIRCUIT COMPLETE D

WHEN CONTACTS

MARKED

3::

- 0

0---,

w---,

a:

w

>-

G

-M

B-L

NONE

B-S

BL

ACK

/YELLOW

YELLOW/ RED

BROWN

IY

ELLOW

RED/

YELLO

W

TEMP.

BRAKE

LIGHT

SWI

TCH

--...L

BLUE

TACHOMETER

BROWN/YEL

LOW

3::

o -

-1-::::::- 0

...JZ

I...J

wO

--

>-~

Z w

-

'2;

w

t9

~O

w Z

O~

~

;i

a:

0

CD

HEADLIGHT

STOP-TA I L LIG HT

-=-

BR

OWN

(BRAKE LIGHT

)

BLACK

(COMMON )

Y

ELL

OW

(TA

IL

LIGHT)

-"

0

I

0

Ol

::J:

()

l>

I

::JJ

»

Ci)

:IJ

Z

G>

Ci)

Z

Ro

G>

»

Z

Z

(J)

0

-t

::JJ

Z

c:

(j)

3:

-i

m

:IJ

Z

C

-t

~

0

m

Z

::JJ

-i

0

()

c:

:IJ

~

()

(J)

c

=t

(j)

Regulator/Rectifier

I

WARNING

Lw.---

ELECTRICAL
NECTED.
regulator/rectifier.

could

personal

cause a fire

I

NEVER

•.

BATTERY

Doing

injury.

Tests

RUN

CONNECTORS

so

may
Sparks

which

ENGINE

CABLES

damage

that

may

DISCON-

the

may

cause

WITH

OR

voltage

occur

severe

CHARGING AND INSTRUMENT CIRCU ITS 10-7

•

Momentarily
holder

as

terminals

any

sparks

tor/rectifier.

touch

together

are observed, replace regula-

to

make

fuse

detect

and

terminals

possible

break

inside

arcing

contact.

If

NOTE: A worn

will

produce
corrected
CHECK

CONDEMNING
SYSTEM. A

MUST
SYSTEMS
cedure

Output

power

and

illuminate

ing

components

output

uncharged

sequence

in the
ing system is

Three separate
determine
tifier.

1. LEAKAGE

• Place

•

Disconnect
regu

numerous

until

BATTERY

FULLY

FOR

TESTS. Refer to Battery Testing pro-

to

evaluate

from the

to operate tachometer, charge

which

battery

proper

key

lator

out

or

badly

the

battery

CONDITION

OTHER

CHARGED BATTERY IS A

CONDUCTING

condition

charging

lights. Defects in any of

will

reduce

is

usually

. Perform the

provided to

operating

tests

operation

TEST

switch

holder

/rectifier.

sulphated

problems

is replaced.

properly

must

in OFF position .

and remove

that

PARTS

ACCURATE

.

system

charging

described

following

determine

.

be

conducted

of

regulator/rec-

battery

cannot

ALWAYS
BEFORE
OF

be

THE

supplies

battery

preced-

system

as

an

tests

if

charg-

fuse

to

at

@~~]![}

meter

damage

•

Connect
milliamp
holder

~a~ke~~rr~:a(~!v:~:e~o;~I~~~~~

will

result.

DC

milliampere

range)

observing

to

polarity

meter

terminals

as shown.

at

(250

fuse

1.

Fuse

2.

Holder

Regulator/Rectifier

\~2

'

O

'

~;

;~

..

:~~~

.

ENGINE M

1

I

AMPS

"

I------<i

AGNETO

BROWN

ST

ARTER

PURPL

E

10-8

CHARGING AND INSTRUMENT CIRCUITS

Meter

•
Any needle movement
which will
engine

rectifier

• Perform

2.

CURRENT OUTPUT TEST

NOTE:
ate at high RPM. Remove
converter
pins.

• Perform Leakage Test procedure.

•

Disconnect
regu

[~~flill

meter

damage

•

Connect
terminals
polarity

needle

drain

is not running. Replace

if

necessary.

Current

This

procedure

guard in normal

holder

lator/rectifier

~a~ke~~~~:

will

result.

DC

ammeter

at

as shown.

should

remain

indicat

battery

Output

requires

.

Test.

eng ine to

drive

belt

position

and remove fuse at

a(~:v:~:e~O;~I~~~~~

(10

amp range) to

fuse

holder

at

zero (0).

es leakage

charge

regulator/

and

secure

with

observing

when

oper-

clip

* 2 to 3

perform

* 5 to 7

low. Install
and retest.
form Voltage Control Test.

* No

o

Unplug

o

Check

o

Inspect

(open)
ween main
and

• Insert fuse and

• Perform Voltage Control Test.

3.

VOLTAGE CONTROL TEST

NOTE:
ate at high RPM. Remove
converter
pins.

This

• Perform Leakage
put

amps -current

Voltage

amps -battery

Output

tachometer

Lighting

main

or

pinched

regulator/rectifier

procedure

guard in normal position

Test

procedures.

new

or

Output

­Coil.

wiring

engine

secure

requires

Test

Contro

fully

connector

drive belt

output

l Test.

state of

charged

remains high,

and retest.
harness

(shorted)

connector.

with

engine

and

is good,

battery

for

wire

terminals

holder

to

and

with

Current

charge

per-

broken

bet-

cap.

oper-

secure

clip

Out-

BRO

WN

YElLO

W

~~~~~==

~

~+4=

STARTER

TO

TACHOMETER

1

@~

meter

damage

•

Connect

battery

~a~ke~~rr~:a(~:v:~:e~O;~I~~~~~

will

result.

DC

terminals

ENGINE MAGNETO

voltmeter

LIGHTING

COIL

as

(20

shown.

volt range) to

• Place
lights).

{I~~I'ill

meter

will

•

Manually
5,000

•

Observe
meter

key

switch

~~~~t

result.

start

RPM.

system

indication

in RUN

eUn~~n:le~~i~:~a;~:r

engine

output

as follows:

and

and

position

operate

interpret

(no

:~

at

•

Start

engine

• Place key
lights).

and

switch

operate

in RUN

S

TARTER

at 5,

position

000

RPM.

(no

.

•

Observe

as

*

14

voltage and

follows:

to

15
is good.
normal.

* Above 15.5

cuit

defective.

tifier

assembly

*

Below
cuit
tifier

•

Disconnect
belt.

Regulator/Rectifier

1.

Disconnect
from

the

2.

Remove

•

Unscrew
tor

/rectifier.

13.5

defective.

assembly

the

main harness.

regulator/rectifier.

locknut,

interpret

volts

- voltage

Charging

volts

System

- voltage
Replace
and retest.

volts

- voltage
Replace
and retest.

voltmeter

and

Replacement

regulator/rectifier

and

remove

indication

control

circuit

operating

control

cir

regulator/rec-

control

cir-

regulator/rec­reinstall

drive

connector

the

regula-

KEY SWITCH TESTS 10-9

Key

Switch

Positions

Key

Switch

Terminals

-

1.

Off

2.

Run/Lights

3.

Run

4.

Start

To

test

the

key

switch:

NOTE:

follow
obta in

Prior

the

procedure

access

to perform ing

for

Key

at

terminals

on

key

Switch

switch

switch

tests

Removal to

.

1.

Regulator/Rectifier.

2.

Main

Harness

3.

Install

regulator/rectifier

removal.

• Place
shown.

• Position main
terminal

•

Install

nut

to

•

Reconnect
to main

KEY S

trol
system.
marked
through

The

the

WITCH

G and M

RUN and OFF

Lights
Band
terminals

Ground

Wire.

regulator/rectifier

wiring

on

mounting

plain

washer

95

in. Ib (1.0 kg-m).

harness

and

regulator/rectifier

wiring

TES

harness

TS

terminals

of

the

circuit

are

operated

L.

Starter

Band

solenoid

S.

in reverse

onto

ground

bolt.

locknut.

.

key

switch

of

the

through

is

order

of

duct

as

wire

Tighten

connector

con-

ignition

terminals

activated

1.

Remove the main
from the

2.

Test

switch G and

•

Set

the

(X

100).

Connect

•
switch G terminal
meter

• With the
the

ohmmeter

(00).

Replace

moves

• Turn

Meter

•

(0).

Replace

not

move to

3.

Test

switch

•

Set

the

Connect

•
switch B terminal

• Turn

the
tion. The
closed

if the

meter

• With the

OFF, the

circu

it (00). Repl
not

observed.

4.

Test S terminal

• With

• Turn

(X

1),

minal
The

circu

ohmmeter

connect

and

the

ohmmeter

it (0).

meter

key

switch
ohmmeter
one

ohmmeter

lead to M.

key

switch

off

of

infinity

the

key

should

now

the

O.

Band

ohmmeter

one

ohmmeter

key

switch

ohmmeter

circuit

(0). Repl

does

key

switch

ohmmeter

of

one

other

key

switch

Replace

does

not

wiring

harness

terminals.

M terminals.

to high ohm

lead to

and the

in

the

RUN

should

show

the switch if

(00).

switch

switch

to OFF

indicate

if

the

closed

L terminals.

to low ohm

lead to

and

the

other

to

RUN/LIGHTS

should

ace

the

not

indicate

positioned

must

indicate

ace

the

key

switch.

still

on low ohm

ohmmeter

lead to

S.

to START

shou

Id

indicate a closed

the

key

ind i

cate

O.

connector

scale

the

key

other

ohm-

position,

open

circuit

the

needle

position.

circuit

needle

scale

the

does

(X

key

lead to L.

posi-

indicate

key

switch

O.

in

RUN or

an open

switch

if

00

scale

lead to B

ter

position.

switch if the

1).

a

is

-

10-10

LIGHTING CIRCUIT
With the

•
or RUN/LIGHTS, the ohmmeter
cate

an

Reconnect

5.
tor to

switch

sw

if

itch

Switch Insta

LIGHTIN G

Lighting

1.

12

when

2.

Fuse ­and
wi

3.

Key
circuit

4.

Instrument
face

5.

Brake

CIRCUIT

circuit

VDC

battery -power supply

engine

prevents

components

thin

sys

tem to

Switch -controls

by swi

of

instrument.

Light
brake light
brake

6.

Tail/Brake
whenever

lever on

key

tion. Brake

light

switch

7.

Headlight

selected
either
is

available

switch

8.

Headlight -illumin

Dimmer

po sition,

HI

or

is in

snowmobile.

key switch position

open

circuit

00

is

not

the main

terminals

(00). Re

observed.

wiring

harness connec-

and ref

llation .

components

is not

damage

by

10

consist

running

limiting

amps

.

to
.

wiring

operation

tching

current

flow ON

Lights -illuminates

Switch -controls

by

allowing

handl

Light -tail

switch

light

illumin

is

clo

sed.

cur

rent to

ebar

is activated.

is in

ates

light

Run/Lights

whenever

Switch -depending

allows
LOW beam
at

dimmer

Run/Lights

ates

current

of

headlight.

swi

tch only

position.

area

in

OFF, RUN,

mu

st

plac

e th e

er

to Key

of:

for system

harness

current

of light

or

numbered

opera

tion of

flow

when

operates

brake

flow

Current

when

ahead

indi-

key

flow

ing

OFF.

pos i-

upon

to

key

of

9.

Wiring

nect
lighting

Lighting

During

supplies

as

charge

when

tinued

a

point

unserviceable

and

Connectors

and

complete

system .

Circuit

engine
current

Operation

operat

to illumin ate all li

the battery.

the engine is not

use will

reduce

which may cause

(di

scharged

Brake light opera tion
other lights
brake

light swit
require
position

If

failure
tery power will be
and

the li

not

runn in

will

operate
system.
may

overstress

nents

resulting
permanently
electrical
mine

cause

When key
position, circuit
marked
battery

and

that

key switch be

for

operat

should

ghts

will not

g.

If engine is

from

Continued

damaged battery.

system

of

fuse

switch

Band

or

L,

charging

ch is

ion.

occur

disconnected

power

the

in

premature

as

is

and

- used to

the

circuits

ion the

All

charg

lights

running,

battery

the

state

battery

).

is

independent

will

illuminate anytime

activated. All

placed

to the

10

from key

operate

when

manually

rece

ived from

operation

in

electrical sys

failure

soon

as

possib

failure.

is

placed

complete

power

system)

between

is

for lights

intercon-

of

items

ing system

ghts

as

will

operate

how

eve

r,

con-

of

charge

to

become

from

other

lights

in

Run/Lights

amp

fus

e,

switch

engine

started, lights

charging

this manne

tem

compo-

as

well

Troubl

in

eshoo

le to

deter-

Run/Lights

contacts

available

(from

.

in

well

to

the

bat-

is

r

as

t

TO ENGINE GROUND

BROWN

BROWN

WHITE

SLEEVE

ON WIRE

LIGHT

ING

COIL

ENGI

NE

MAGNETO

r...

" RED

BATTERY

REGU LATOR,

RECTIFIE R

-:-

KEY SWITC H CONNECTIONS

KEY SWITCH

POSITIONS

" OFF"

"RUN

/LI GHTS"

" RUN "

"S

TART"

CIRCUIT COM PLETE D

WHEN CONTACTS MARKED

G-M

B-L

NO

NE

B-S

:;::

- 0

0-,

LU-,

a:

LU

>-

BLACK/YELLOW

YELLOW

/RED

BROWN

IY

ELLO

W

RED

IY

ELLOW

TEMP.

BRAKE

LIGHT SWITCH

----L

BLUE

TACHOMETER

STOP-

TAIL LIGHT

TACHOMETER L

IGHT

-=-

BROWN (BRAKE

LIGHT)

BROWN/

YELLOW

BLACK

(COMMON)

:;::

o -

--1

- = a

-lZ

I

....J

wO

--

>-::2:

z W

z

~

w

l?

:;::

0

LU

Z

O

u

a:

<i

_<.:la:

a:

0

to

HE

ADLIG

HT

YELLOW

!TAIL

LIGHT

)

c

C)

:::z::

-t

Z

C)

(")

lJ

(")

c:

-t

r

G)

I

-I

Z

G)

(")

::0

(")

c

=i

o

I

...

10-12

LIGHTING CIRCUIT

Lighting Coil

A

defective

following

the

• Inoperative

•

Battery
dead.

•

Lights

Test

lighting coil for two
through wires and
(shorted).

CONTINUITY

1.

Separate main

2.

Test

• Set

•

Connect
wire

Tests

lighting

conditions:

consistently

will

lighting

ohmmeter

one

in

engine

coil

may

result

or

erratic

not

illuminate

that

engine

co il with ohmmeter.

to low ohm

ohmmeter

half of connector.

tachometer.

undercharged

conditions,

no

wires

connector.

or

dim.

contact

scale

lead to a

in

any

of

or

continuity

ground

(Xn.

yellow

ENGINE

MAGNETO

•

Connect
engine

* No needle

lighting

ground and

* Needle moves

cates

Repair

3.

Reconnect

remaining

ground

coil

coil

or

wires

main

ohmmeter lead to

and observe meter.

movement

wires

coil

is

off

wires

or

replace

engine

(indicates

are

not

contacting

good.

of

infinity

are touch ing ground.

coil.

connector.

00),

(00), indi-

ENGINE

MAGNETO

•

Connect
other
nector

*

Resistance

has good
to ground.

*

No
reading, or

ing

3. Perform

SHORTS TO GROUND

1.

Complete
ing.

remaining

yellow

and observe

resistance

coil

shorts

wire

of

continuity,

(0)

should be replaced.

to

continuity

ohmmeter lead to

in

engine

meter

0.18

± 20%,

reading (00), very high

indication

ground

test

reading.

check

test.

prior

half

of con -

lighting

for

means

to

proceed-

shorts

coil

light-

Lighting

Defects

(broken)

following

A simple test can be

ing
using a portable
minimum requirements:

NOTE: If

volt

can be

fuse

vent

ness

Circuit

in

wire

conditions.

•

Fuse
lights

• Dim

•

Intermittent

circuit

•

•

•

•

to

12

volts 7 amps

Self

Built-in
Built-in

battery

battery

used

(10

amp)

damage to ammeter and

during

Tests

the

lighting

or

shorts

in

regulator/rectifier

are

turned

lights

or

lights

operation

determine

battery

tapering (reducing) charge.

automatic
ammeter.

charger

and

jumper

as a

substitute.

in

one of

test.

circuit

could

on.

conducted
defective

charger

output

reset

leads with

the

such

result

do

not illuminate.

of

lights.

capacity.

circuit

is

not
Be

jumper

vehicle

as an open

in

any

of

the

fails

when

on the
component
meeting

available , a 12

an

sure to instal l a

leads to

light-

these

breaker.

ammeter

wiring

by

pre­har-

2.

Test

lighting

• Set

•

ohmmeter

Connect

wire

in

engine

coil

one

ohmmeter

with

ohmmeter.

to high ohm

half

of

connector

scale

lead to a

.

(X1

00).

yellow

Perform

1.

Place key

2.

Disconnect

voltage

harness.

lighting

regulator/rectifier

circuit

switch

four

in RUN

wire

test

connector

as follows:

position

from main

.

to separate

wiring

•

1.

Voltage

3.

Connect
ing

nector

NOTE
leads
(ect

harness

: Be

from

wires

Regulator

battery

as shown.

sure

power

of main

Connector

charger

half

of

positive

source

wiring

leads to main

regulator/rectifier

(+)

and negative (-)

are

connected

harness.

to

wir-

con-

cor-

4.

Observe

as

follows:

• Meter

•

Meter
fails,

5.

Activate
ammeter and

Meter

•
proceed to

• No

ammeter

indicates

indicates

proceed

brake light

interpret

indicates

next

meter

indication

fails, proceed to

6.

Turn key
ammeter and

•

Meter
all
good.
and
for
Lighting

switch

interpret

indicates

lights

Pull

and

illuminate,

connectors
intermittent

Coil

tests for defects.

•

Lights
problem

do

not

is

operate

key

main harness. Refer to Key

• Dim
cates

lights

high

(low

resistance

main harness. Refer to Key

•

Circuit
shorted

Proceed to

breaker

wiring

next

LIGHTING CIRCU IT

indication

and

(0), proceed to

amps

to step

7.

or

circuit

switch,

10-13

interpret

next

step.

breaker

observe

as follows:

2 amps (approximately)

step.

or

step

circuit

7.

breaker

to RUN/LIGHTS, observe

as

follows

:

5 amps (approximately),

twist

while

lighting

on

wiring

watching

circuit

harnesses

ammeter

indications. Refer

and

Regulator/Rectifier
, meter i

switch

ammeter

(high amps) i

harness

ndicates

or broken

Sw

itch tests.

reading) i

in key

switch

Switch

or

key

(0),

wire

ndi-

tests.

ndicates

switch.

step.

is

to

in

or

AMPS

~

12 VOLT

BATTERY
CHARGER

E

NCINE MACNET

BRAKE

LICHT SWITCH

----L-

BLUE

BLACKIYELLO

W

YELLOW/RED

BROWN

/YELLO

W

O

REO

PUR

PlE

REO/YELLO

W

TEMP. GAGE LIGHT

T

ACHOMETER

LIGHT

STOP-TAil

LIGHT

HEADLIGHT

STARTER

10-14

LIGHTING CIRCUIT

7.

Turn key swi
connect
tors from

•

Speedometer

•

Tachometer

•

Te

•

Brake

• Tail

• Headl i

•

Headlight

1.

Speedometer

2.

Tachometer

3.

Tail/Brake

4.

Headlight

5.

Headlight

6.

Temperature

tch

the

follow

the

main

mperature

light

switch.

/brake

ght

light
dimmer
harness

Light

Light

Light

Harness

Dimmer Swi

Harness

Gauge

to RUN

ing

component

wiring

light.

light.

gauge light.

harness.

switch.
.

tch

light

position

harness.

and dis-

connec-

8. Turn key
observe

• Circuit
cates
switch
Meter

•

9.

Plug in

sequence

1,

then add No.

compare
chart

•

Current
or circuit
nent

switc

ammeter

breaker

shorted

. Refer to
indicates
connectors

shown

current

after

completing

draw

breaker

connected
appropriate
cause.

• If circuit
switch
short cir
or
switch

• No

or brake

cuit exi

main harness. Refer to

test

current
(broken wire) in lead to
nected.

10.

Remove
regu l

battery charger

ator /rec

h to

RUN/LIGHTS

and

int

erpre

fails

(high

main wiring

Key

Switch

(0),

proceed

one

(begin

2,

draw

then

with

add NO. 3

with

each

higher

than

fails

has

short

test

procedure

breaker

fails

light switch is

sts

either

to

determine

draw indicates

tifi

er

con nector

position,

t as

follows:

amps

) indi-

harness

or

test.

to

next

at a time in

connector

etc

.)

amps

shown

connection

recommended

indicates

compo-

circuit. Refer to

to

determine

when

in

dimmer

act

switch

ivated,

appropr

cause.

open

circu

component

and

reconnect

.

key

step.

the

No.

and

in

.

leads

iate

it

con-

KEY S

WITCH

LIGHTING CIRCU IT

BRAKE

BLUE

10-15

LICHT SWITCH

_L

~I~~

~

0 '0

AMPS

lQ

GROUND

12

VOLT

BATTERY

CHARGER

ENGINE

ENGI

NE MAGNETO

BATTERY

BROWN

S

TARTER

PURPLE

BLACK/YELLOW

YELLOW/REO

""==~---0 e >+-~O'---t'-"

BROWN

/YELLO

SPEEDOMETER

TEMP. GA

LIGHT

GE

W

LIGHT

TACHOMETER

LIGHT

BRO

WN

BLACK

YELLOW !TAIL

(BRAKE

[COMMON)

DIMMER SWIT

STOP

LlCHTJ

lIC~

o

HEADLIGHT

- T

AlL

LIGHT

CH

5;'"

roC::

....

Q)

oC::

0

"'0.

~E

....

0

~U

U.c

. u

Q)

ro

tt;UJ

E-

'x

0

o(iJ

....

0.

§:E

«~

...

-c

ro

Q)

...,

....

0

....

~::J

U

COMPONENT

0

Speed­ometer

Light

0.25

0.25

*Connect

e

Tachometer

Light

0.

25

0.50

and activate

CONNECTION

e*

Brake

Light

Switch

0

Tail

Light

0

0.5

0.50

switch

1.0 1.0 4.5

SEQUENCE

0 *

Dimmer

Sw

itch

O

Headlight

Harness

"

Low

or

High

Beam

3.5

8

0

Temp

Brake Gauge

Light

Light

2.0

0.25

6.5

6.75

10-16

STARTER CIRCUIT

STARTER

Electric

of:

1.

12

VDC

electr

2.

Fuse ­and

components

within

3.

Key Swit

ize s

tart

CIRCUIT

starter

system

Battery -provides

ic starting circui

prevents

damage to wiring

by

system to

ch -

er solen

10

controls

oid

sw itc

amps

components

power

t.

limiting

current

.

current

flow

h.

consist

to operate

harness

to

energ-

BROWN
YELLOW
YELLOW

EN

GINE

flow

CONNECTOR

4.

Starter
fl

ow

5.

Starter -converts
battery

Solenoid

between

to

mechanical

Switch -contro

battery

and

electrical

power for

tion.

6.

Wiring and

nect

and

starter

7.

Flywheel Ring Gear - means to

join

pinion

permit

electr

complete

system.

engine

ically.

Connectors

the

gear

of

starter

rotation

ls

starter

motor.

energy

engine

- used to i
circu

its

ntercon-

of

items

temporarily

with flywheel to

for

starting

current

from

rota-

in

BLACK

ENGINE GROUND

ENGINE

BATTERY

MAGNETO

RED

+

SOLENOID

UJ

en

::J

u..

COIL

RED

REGULATOR/

RECTIFIER

z

~

o

a:

CD

PURPLE

UJ

-1

a..

a:

::J

a..

,

1

RED

STARTER

• I

Starter Circuit Operation

When the

tion

it

minals

of

current
solenoid

to
windings
plunger
closed
tery and
Solenoid
current
it

is not
very large
the

key

rent

nece

ings

with

solenoid to

Starter

netic

attraction
mined
(c

ommutator

in

which

and

placement
relationship
magnetic

key

switch

completes a circuit

of the switch.

flow from battery, through

switch.

magnetize

to move

contacts

starter

switch
flow
practical

switch

ssary

by

wire

complete a circuit

motor

is

requirement

to

wires

mounted

is

to energize the solenoid
heavy
carry

motor

fields

operation
and repulsion,

field

segments) and brushes. Direction

is

wound

of

to

others, controls

within

is

This

Current

the

against

allowing

required

use

a heavy

designed

duty

the

starter

windings,

(wrapped) to form a

each

starter

the starter.

turned

between

allows

of

contacts inside

to START

Band S ter-

a small

key

flow

within

plunger,

the

contacts. The

between bat-

the motor to turn.
because
starter

on

instrument

to

carry

motor current.

depends

armature

of the high

motor.

duty

switch

the low

upon mag-

which

component

the

effects

amount

switch,
solenoid
causing

is

windings

posi-

Since

with

panel,

cur-

wind-

the

deter-

coil

with

of

engages with

engine
gear
armature
pinion
overrunning
sembly
key
has started.

I

L..

battery
generates
mable
tions.
this

. After the

drives

shaft

to move

to

assist

switch

WARNING

____

and

and

Sparks

gas

causing

is held in

...

hydrogen

@:§EI

seconds

15
for
position
still

cause

or
seconds
15

seconds.

when

spinning.

starter

CIRCUIT

has started, the ring

faster

which

in

damaged gears

position

to

"jump"

with

The

which

personal

can

certain

cables

flywheel

engine

pinion

is rotating

out

of

clutch

I

explosive

is

in

preventing

Do

not

snowmobile

jumper

from

severe

STARTER

ring gear to

assembly

mesh with the flywheel. An

incorporated

start

attempt

cables.

gas

under

jumper

~~nti~~:u~~~~t~~~ee

starter

of

will

operation,

Never

engine

This

will

to

jam.

overheat.

allow

turn

key

is

running

hasten

starter

switch

or

wear

10-17

crank

causes

pinion

after

a

may

injury.

the

than

the
as-

engine

start

booster

battery

be

flam-

condi-

ignite

if

t~~~r~e~

After

each

to

cool

to

start

starter

and

may

is

MAGNETIC

~-=r--...

MAGNETIC

When

it

causes
one
armature

(South pole). At the same time,
through the
ductors
field. The
conductor
field

ing in

force of field
ductor

from one
oppos

ing. The
commutator

rent in

the

tribute

During

moved

current

magnetic

field

winding

core to

brushes

which

magnetic

(being

winding)

armature

(commutator

field

ite

polarity

specific

segments

the

armature

magnetic

its force to

armature

away

is

applied

lines

(North pole) through the

the

generates

field around each

of

strongly

rotation

windings.

winding,

from the

placement

conductors

field and

the

rotation, the

from

starter

FIELD

FIELD

to

the

of force to pass from

opposite

to armature

a second

the same

repell each

away

from the

As each

segment)

it

approaches

adjoining

reverses the

will

continue

cranking

motor

SOUTH

POLE

(-)

BRUSHES

field windings,

field

winding

current

polarity

armature

exits

of

which
power

pinion
assembly

passes

winding

magnetic

armature

as the

other

result-

magnetic

the force
a force of

field

brushes

flow

of

reverses

to

output.

gear

wind-

con-

con-

and

cur-

con-

and

is

Solenoid

1.

Disconnect
terminal.

2.

Unplug
separate
harness.

3. Remove
soleno

4. Test

• Set

•

Switch

id switch.

solenoid windings.

ohmmeter
Connect
winding

Test

cable

small (purple)

solenoid

wires

meter leads

as shown.

from

battery

wire

switch

from both terminals on top

to low ohm

LOW

OHMS

-

(Xl)

from main

to soleno id

+

negative (-)

connector

sca

le (X1).

to

wiring

of

coil

10-18

5.

Observe
follows

•

•

6.

Test

•

STARTER MOTOR

meter

:

3.5

ohms

good,

proceed

If

resistance

specified,

Solenoid

With

ohmmeter still on l

(X

1),

connect

minals

as shown.

indication

(±

0.4)

to

reading

replace sol

Terminals.

meter leads

-

solenoid

next

step.

eno

and

coil

is

id

ow
to

switch

int

erpret

winding

other

.

ohm

solenoid

as

is

than

scale

ter-

9.

Int

• Sol

•

10.

Reconnect
minal.

ST

ARTER

erpret

enoid
closed
good.
Meter
is

defective

MOTOR

results

clicks

circuit

indicates

and

cable

as

follows:

and

(0), so l

open

must

to

battery

ohmmeter

enoid

circuit

be replaced.

assembly

(00), solenoid

negative (-)

indi

cates

is

ter-

7.

Observe
follows:

• Open

•

8.

Activate

•

With
as

•

Activate

BATTERY

12

met

circuit

solenoid

Meter
defective,
electric

(X1),

battery

indicate

starter

solenoid

ohmmeter

connect

shown.

as shown.

VOLT

er

indic

(00) - cont

good,

proceed

s low

will

not

motor

and

leads to sol

solenoid

co

•

-C

Kawasaki

LOW

OHMS

(Xl)

atio

n and

acts

resistance -solenoid

turn

. Repl

test

still

on low ohm

winding

int

erpret

in

off

position,

to

next

step.

off

current

ace

solenoid.

operation.

enoid

terminals

by

connecting

co

===

•

-C

Kawasaki

0

+

as

scale

0

,!

to

I

WAR

.....

battery
generates
mable
tions.
this

N I N G I Do

____

and

Sparks

gas

••

and

hydrogen

explosive

causing

@illill

seconds
15

seconds

for

15
position
still
cause

Starter

Poor

cases

connections

High

corroded

The

systematic

cuit

Preliminary

1. Place

tion to

2.

3.
tery

or

starter

of

seconds.

when

spinning.

starter

Motor

starter

results

resistance

connections.

following

approach

to

detect

Steps

emergency

prevent
test.
Attach
studs
wire to
Battery

less than 1 2

voltmeter leads

rather

detect

must

Charging

not

snowmobile
jumper

from

attempt

cables.

gas

under

jumper

severe

~~nti~~~u~~~::t~~~ee

will

overheat.

operation,

Never

engine

This

to

Circuit

motor

from HIGH RESISTANCE

or

is

defective

than to

be

volts

turn

is

will

hasten

jam.

Tests

performance

within

presence

procedure

component

usually

procedure

to

test

wires

stop

engine

fully

charged.

.

to

"jump"

with

The

which

personal

allow

running

caused

switch

from
to

connector

can

certain

cables

starter

key

switch

wear

provides

entire

or

components

to STOP

starting

threaded

of

high

Refer to

if

battery

a

may

injury.

start

booster

battery

be

flam-

condi-

ignite

t~~~r~e~

After

or

by loose

starting

resistance.

each

to

cool

to

start

starter

and

may

in many

at

wire

contacts.

cir-

.

pos

during

terminal

on

end

Bat-

measures

is

or

a

i-

of

+

LOW

(Xl)

OHMS

+

IT~

meter

4. If voltage

5.

damage

• Clean and

• Replace

internal

Set

voltmeter

and

proceed

~a~ke~~~~:a(~:v:~:e~o;~I~~~~~

will

drop

cable

resistance.

result.

is

greater

retighten

or

component

to

DC

as

follows:

than

specified:

connection

volts, low range (2.5)

.

having

high

.

ENGINE

GROUND

ENGINE

8A

TTER

Y

GROUND

RED

TEST 1 OF 4

1.

Connect

2.

Turn key to
voltage

indication.

3. If voltage
tions

or

STARTER MOTOR 1

meter as shown.

crank

exceeds

replace

engine

0.25 volt, clean

battery

and observe

ground

0-19

connec-

cable.

ENGINE

GROUND

.C Kaw

DC VOLT

STARTER

asa

ki

S

2 OF 4

TEST

1.

Connect

2.

Turn key to
voltage

3.

If voltage
tions

meter as shown.

crank

indication.

exceeds

or

replace

battery

eng ine and observe

0.25 volt, clean
positive

connec-

cable

.

RED

S

TARTER