Kawasaki SA340-A1, SA440-A1 Quick Reference Manual

"'-

,

Quick Reference Guide

SECTION

Specifications .........................................................................

Maintenance

and Theory

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

Repair .......................................................................

Appendix .....................................................

...

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

...

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

....

.......

...

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

...........

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

....

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

...

..

........

.

Using locating a desired topic or shop

manual.

sired section above

the

of contents procedure

the

table

for

quick

Bend

of

contents

the

required

reference

the

with

exact page(s)

.

guide procedure

pages back

the

black

for

that

will

assist

contained within

until

you

tab

on

the

section. Refer

to

locate

the

you

match

right

to

the

specific

QUICK

in

quickly

this

the

hand

side table topic

REFERENCE

de-

of or

GUIDE

ii

,).',Jf~

"

SPECIFICATIONS

Table of Contents

General Specifications .... .

Service Specifications

Torque

Gear Ratio Engine Port

Chart . .

Chart .

Performance Curves

Dimensions

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

........

.......

......

.

...

.......

.........

...

......

.......

.

...

....

.

........

.

.. ..

.....

.

........

.....

......

. . . .

.

...

. . .

.......

...

......

. . . . 1-2

.. ..

.. .. ..

1-4 1-5 1-9

1-10

1-11

/

TABLE OF

CONTENTS

1-1

GENERAL

SPECIFICATIONS

MOD

GENERAL

Overall Length . Overall Width Overall Height (No Windshield) Dry

Weight

ENGINE

Models

Displacement

Bore x Stroke . .

Number Engine Engine

Starter . . . .

IGNITION

Ignition

Spark Plug

.........

of RPM RPM

System . . ....

...

. .... .... . .

...

..... ..

(Ap

proximate)

. .

...

..

. . . . .

......

..

. . . . .

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

at Full

Throttle .............

at Idle

Speed

...

. .

...

..

.......

......

....

.....

ELS

. . .

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

.....

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

......

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

......

. . .... . .

.....

SA340-A1

......

.

....

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

. . .... .

..

...........

......

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

.... . . .

...

..

. .

......

... .......

AND

......

. . .

.....

..

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

...

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

..

...

. .

......

..........

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

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

.....

.. ........

.......

...........

.

.....

...

...........

.

...

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

. (SA340-A 1) 2.362 x 2.362 inches (60 x 60 mm)

(SA440-A

(SA340-A 1) 6,500

.

...

. . . . . ..

SA440-A1

. .

102

inches (2.590 mm)

.....

.

..

......

..... . 35-1 /2 inches (902 mm)

. .....

...

.....

28

inches (711 mm)

.........

..

Type Type

(SA340-A

(SA440-A

1) 2.677 x 2.362 inches (68 x 60 mm)

RPM

...

.....

..

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

....

...

.....

355 pounds (161 kg)

340T

A,

used

on

SA340-A

440T

A,

used

on

SA440

1)

20.7 C.I. (339cc)

1)

26.6 C.I . (436 cc)

(SA440

.

.......

. Magneto - Breaker Point

. . .

-A 1) 6,800 . .

2,000

Manual rewind

...

NGK

1

-A 1

RPM RPM

BR-SES

CARBURETOR

........

...

.......

....

......

...

....

..

...

. . . ....

...

...........

...

.. ..

....

......

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

...

.....

.

......

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

.. ......

....

. .... . . .

......

.......

.....

.......

.....

.

.....

....

..

...........

....

. . . . .

. . . . . . . . .

. . . . . .....

Carburetor Make Carburetor Model . . Setting No. . Type

of Carburetor ... . . . .

Main Jet . . . . .

Air

Jet . . .

Jet

Needle Needle Jet . Thrott

le

Slide

Pilot

Jet . .... .... .

Pass

By Pilot Air Screw

Float Starter Jet . Type Starter System

FUEL

Gasoline

Oil . . ....

Gasoline/Oil Ratio .... ....

Fuel Tank Capacity .....

....

Outlet ...

Valve Seat .

of

Float Chamber . . .

.......

. . .

.... ....

.. ..

...

.......

. . .

.

....

.. ..

........

...... ..

.....

...

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

. . .

...

....

. . .

....

. . .

.....

.

........

..

......

...

.....

......

. ....

.... ....

.

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

..

.

........

.......

.... ....

.

........

. . . . . . .

... .......

....

.....

..

. . . . .

....... ...

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

........

.......

....

...

. .

.

......

. ..........

. .... . . .

...

(25

to

...

.....

....

. . . .

......

.

.......

.....

. .

......

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

.

..........

.........

......

...

........

......

1) 1 quart

...

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

..

.....

.

....

. .

......

..

...

..

. . .

. ;

......

...

. .

. . Regular leaded

.........

..........

. . . .

....

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

......

.........

..

.....

......

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

(0.94 liters)

...

......

..

........

..

. .

. . . .

. . . . .

......

..

....

..

. . . .

MODEL

SA340-A 1

.....

.. ..

...

....

. . .

. .

Mikuni Mikuni VM 34

.

...

.

...

. . . . Open

.....

. 260 . . . None None . . .

.....

. . . . . . 1.4 Dia.

...

. . . 1.5 Dia. 1.5 Dia.

...

(minimum

.. ..... ..

of

oil

....

6DH3-3 6DH4-3 . . 2.5 2.5

25 25

. 0.8 Dia. 0.8 Dia.

. . 1.5 Turns 1.5 Turns

. . 2.0 Dia. 2.5 Dia.

. Standard Standard . Cable Cable

pump

to

6.25 gallons (23 .6 liters) . .

...

Zinc

VM 34-130

Vent

P-6

posted octane number 89)

... B.I.A. certified T.C.W.

.. 6.25

gallons (23.6 liters)

SA440

-A 1

VM

34

Zinc VM34-131 Open

Vent

310

P-6

1A

Dia.

of

gasoline

1-2 GENERAL SPECIFICATIONS

DRIVE

CONVERTER

SA340-A1

MODEL

SA440-A1

Engagement Speed (approximate rpm) Maximum Spring Part Spring Spring Spring Spring Length - New wi Number Number Spring Wire Diameter . Spring Rate (standard) Spring Rate (optional) Spring Compression @ 1.25 Inches (standard) . Spring compression @ 1.2 5 Inches (optional) Weight Part Weight Color (standard) Weight Markings (standard) .

Weight Thickness . . . .

Weight -

Ramp Part

DRIVEN

Cam Spring Spring Spring Length - New Sp

ring Diameter ... .

Spring Wire Diameter Spring

Drive Converter rpm

Number

Part Number Color Color

of Spring Coils (standard) of

Spring Coi

(standard)

(optional) (standard) (optional)

th

no load* . · . . ·

ls

(optional)

· . · .

·

· .

Number

(standard)

. .

Total

gram weight

Number

Pa

rt

Number

050845 050803 050777 050778 050779 050776 050836

CONVERTER

Angle .

Part

Color . . . . . .

Preload - Counterclockwise

.....

Number ...

(standard) .

· . · .

.

... ...

. . ....

...

. . .

with

no load . .... .

......

..

.......

· .

·

.....

. .

. . . · .

.

· .

. .

· . .

.

. . .

· .

· . · .

· .

..

...

....

..

.......

..

· . . .

· .

Black Gre Whit Yellow

Black Red Red

. ....... . .

. .

....

...

. .

........

...........

...

. .

·

· .

..

· ...

. . .

· .

. .

·

...

· .

· . · .

...

.

·

. . .

. .

..

. . .

. . . .

· . · .

· . . · . .

. .

· .

· . · ..

· .

·

..

· .

·

· . .

· .

Color

.. ..

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

..

....

. . . .

Optional Weights

en

e

.......

. .

..........

. .....

.....

· . . .

·

..

·

...

· . .

·

..

· .

· . · .

· .

·

..

· . .

·

..

.

· .. · . · .

.

....

..

·

· . .

· . . · . . ·

·

...

· . .

· .

..

· . · .

· .

.

· .

. . .

· .

·

.. . .

.......

.

.......

.

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

.....

· . · .

· .

· . .

· ..

· .

. . . .... . .

....

.....

. . . . .... . . .

. ....

· .

· . · .

· .

·

...

. .

...

· .

..

· .

..

·

..

· . · ..

· .

Markings

0146-279 0146

-136

0146

-107 0146-123 0146

-135 0146-106

0146-286

. .

...

.

..

.

. .

..

.

...

. .

3500 6500 050760 050786 Yellow Green

4.35±0.187

5.35

5.0

0.187

inch 45-53Ibs 60-66 I bs

145·1651bs 192-212Ibs 050835 Black 0146-278

0.250

6.475 050851 050851

30

050774

Black

4.60

2.

0.156

2nd

inch

0

inches

880

inches

hole - 1/3

/in. /i n.

.

turn

3500

6800 050760 050786 Yellow Green

4.

35

± 0.187

5.35

5.0

0.187 inch 45-53 Ibs/in.

60-66 Ibs

165Ibs.

145-

192-212Ibs.

050836

Red

0146-286

0.250

8.800

Gram Weight

5.457

9.279

4.958

6.992

4.479

5.958

8.

800

0

30

050774

Black

inches

4.60

2.880 inches

0.156

2nd

hole -

/in.

inch

inches

1/3

turn

BELT

Part

Number Outs ide Circumference . Width -Top Thickness Belt

Taper Angle .

BRAKE

M

inimu

GEARING

Top

Sprocket Lower Sprocket Cha

in - Doub

Drive Chain Tension (free movement)

*

After approx lo

ss

surface

Top

of

belt

m Brake

Sprocket . .

of

spring compression

.........

Overall

le

imate

Pad

Ratio

row

35

ly

to

bottom

Thick

ness

. . .

.....

.......

....

. .

50 miles, the spring

. .

..

. .

.......

will

occur because

of

lug

........

...

..

.......

. .... .

....

..........

will

..

. .

........ ...

.

.....

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

.....

. . . .

take a

of

..........

....

.......

. . .

........

"set"

and lose 0.25 (1/4)

the decreased spring length.

.

..

. . . . .

....

..

...

05065504

43. 5 ± 0.25 inches 1-1

/4 ± 1/32 inches

..

. .

.

. .

.

0.56 ± 0.03

0

30

1/16 inch

18 teeth

37 teeth

2.05

90

pitch

3/8

to

of

an

inch

to

1

1/2 inch

of

inch

its

total

length.

GENERAL SPECIFICATIONS

05065504

43.5

± 0.25 inches

1/32

1-1/4 ±

0.56 ± 0.03 inch

0

30

1/16inch

19 teeth 36 teeth

1.87

to

90

pitch

3/8

to

No

inches

1

1/2

inch

significant

1-3

TRACK

Track Track Track L Susp

AND SUSPENSION ..

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Molded rubber

Width

en

sion

........

eng

th ...

........

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

.

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

.......

.

..........

. .

... ...

....... .. ..

. . . . .... . .

...

.......

.

.. .........

...

..

. . . .

....

.....

........

...

..

. . . . . . 15 inches (381

. .........

. . .

......

with

116

inches (2,946 mm)

..

.....

. Slide rail

steel bars

mm)

ELECTRI

Type Headlight T

Instru

FRA ME

Frame . . . . .

E

NGINE

Effectiv Piston Ring Side Play (Top Ring)

Piston Ring Side Play (

Piston Ring End G

Pi

Conne c

Connecting Rod

Crankshaft End

Crankshaft R un O

CAL COMPONENTS

........

.........

ail/

Brake

Light

ment

Lights . .

e Compression Ratio

ston Ski

rt Clearance

ting

Rod Radial Play

.

..........

.

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

.......

..

.. ..

ap .....

Small End Diameter ... .

Play

ut

..

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

........

Bot

tom

. . . .

.

.........

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

.

.........

. .....

....

SERVICE

..........

....

Ring)

..

.......

....

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

.....

.

...

.......

....

. . .

......

..

. . . .

....

..........

..

. .

...

. .....

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

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

..

........

.....

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

.....

. . . .

....

..

... ...

..

. .

............ .... . . . G.E. No. 1035

.

....

. . . . . . .

.....

Aluminum

SPECIFICATIONS

SA340-A1

. ....

..

.

6.6:1

.

..........

. . . . .

..

. . .

......

.........

....

......

. . .

_ . . . . .

. . . . . .

. .

...

....

.

..

.

0.004-0.006 in. (0.102-0.152 mm)

. .

0.002-0.004 in. (0.051 -0.102 mm) .006-0.0 14 in. (0.152-0.

0.0008-0.0022 in. (0.

020

. . .

0.0008-0. (0.020-0.

.

0.7875-0.7880 in. (20.003-20.015 mm)

0-0.030 in.

(0.0-0.762 mm)

0.0012

(0.

030

356

-0.056 mm) 0012

030

in.

mm) (max)

. . . .

...

....

...

alloy and steel

MODEL

mm)

in.

mm)

. . 12 volts - 100

. .... Stanley

.. _ ...

. . G.

construction

SA440-A1

6.6

:1

0.004-0.006 in.

0.102-0.152 mm)

0.002 -0.004 in. (0.051-0.102 mm)

0.008-0.016 (0.020-0.406

0.0008-0.0022 in. (0.020-0.056

0.0008-0.0012 in.

(0.020

-0.

030

0.7875-0.7880 in.

(20.0030-0 . (0.0-0.762 mm)

0.0012

(0.030

20.015

030

in.

mm) (max)

E.

in.

mm)

watt

A5988

No. 57

mm)

s

IG

NITION

Spark Plug Gap

Ignition

t Remove spark plug

Timing

NOTE: conditions

1-4 SERVICE SPE

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

.......

Item L

Lighting Coil Yell ow-Br Exciter

Primary tSecondary

Defective coils cannot always be detected

Coil

Item

caps

is

the recommended test

.

.....

....

..... .

method

CIFICATIONS

....

.

....

.....

. . . . . . .

Red

or White-Grou nd

Ignitio

Red

or white to ground

High tension

usi

.

. . . . . . . 0.020-0.

(0.5-0.6 mm)

..

250 or 0.139 i

Magneto

eads

own

n Coil

Lea

ds

l

ead

to

ground

ng this test alone.

024

in.

n.

Use

of

a coil tester which simulates operating

0.020

-0.

024

(0.5-0.6 mm)

250 or 0.139 in.

Resistance

0.18 Ohm ± 10% Ohm

1.13

1.

61

5165

± 10%

Resistance

Ohm

± 10%

Ohm ± 10%

in.

CARBURETOR

Air

Screw Setting

Idle Screw Setting ...

CHASSIS

Converter Offs et Distance . .......

Converter Ce Drive

Chain Tension (free movement) . . .

Brake Lever Movement ......

Track Tension . . . .

Steering Tie Rod

Alignment

Adjusting Stud ......

......

nter

Distance ......

...

.......

. .

.....

. . .

...

. ....

...

.. ..

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

. . .

.. ..

. .

...........

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

.. .......

......

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

.......

..

. .

.....

. . . .... . .

. . .

...

. . . . . . . . . .

.. ..

..

. .

...

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

. . . ....

. . .....

. .... . . . .

...

. . . .

.....

...

.........

...

....

. .

......

. . . . .

...

. .

.. .. ..

SA340

1.5

turns off seat

3

turn

s open

bound

initial

R.P.M.

final)

..

.....

....

..

...

.... 3/8 to 1/2 inch (9.5

........

.. 3/4

inch maximum

...

. . ....... 1-

M

ODEL

-A l

1.5 tu

from

(2,

000

.

.......

.....

.

.......

. . . . . Skis parallel

3 turns open

coil

bound

R.P

0.454 inches (11.5

... :.

10.3 inch

. . . .

defle c

tion

114

inch (32 mm) maximum

40-A

SA4

rns

off seat

ini

tial (2,000

.M.

fin

al)

es (262 mm) to

3/4

inch (19

(5 to 8 Ibs pu

or

1/8

from

12.7

inch t

l

coil

mm)

mm) mm)

ll)

oe

in

GENERAL

Cylinder Head Bolts ... ....

Crankcase Flywheel Recoil Spark Plug

ENGINE

Bolts and Nuts ... . . . .......

Nut

Bolt

... ...

TORQUE SPECIFICATIONS

. . .

...

......

...

..

. . . . .

. .......

TORQUE

ENGINE

Engine Muffl

Engine mo

E

LECTRICAL

Volta Brak e and Volta Tail lamp lens

ead

H He

MOUNT & EXHAUST

rubber mo

er m

ounting

unti

ng screws

SYSTEM

ge

regulator

throttle

ge

regulator

mounting

lamp housing

adla

mp

rim

mounting

unt

nuts

mounting

lever lock screw

mounting

scre

mounting screws

scr

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

. . .

.......

........

...

....

.....

CHART

Descri

ption

nut

screw (grounded

ws

ew 1 50 in. Ibs. (0.5 8 kg-m)

.

...

. . .

......

...

. .....

. . . . ....

to

chassis)

..

....

...

. . .

. .

...

.....

.. .......

AND

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

......

. . .......

......

. . .... .

...

..

....

...

....

. .

. . .

.....

....

. 16 ft/

......

...

........ 60

...

. . . . .

.........

. . .

LOC-TITE TABLE

Quantit y

30

4 4 10 ft . 4

1 1 25 1 95 in . 2 50 in. Ibs. (0.058 kg-m) 4

ft. Ibs.

30

ft

. Ibs. (4.1 5 kg-m)

95

in. Ibs. (1.09 kg-m)

ft.

11 ft. Ibs. (1.52 kg-m)

Torque

(4.15 kg-m)

Ibs. (1.38 kg-m)

Ibs

. (3.46 kg-m)

Ib

s. (1.09 kg-m)

...

lb

16

ft/lb

.. 5 ft/lb

20

ft/lb

(2.213 kg-m) (2 .213 kg-m)

(8.3 kg-m) (0.7 kg-m)

(2.7 kg-m)

Loc-

Tite

DRIVE

Spider Spider assy Sp

,.

Ramp

Movable s

Drive converter assembly to cran

CONVERTER

assy

ider

assy

mounting

hea

. - roll er bear

. set scre

. -

set

ve

to bearing housin g

ing

mountin

ws

screw nuts 3

screws 3

ksh

g nuts

mountin

aft bo

g socket scre

lt

ws

3 3

3

1

35-48 in. Ibs. 35-48 in.

35-48 in. 24-30 in. 15-17 55-60

Ibs. (OAO-0.55 kg-ml Ib Ib

ft.

Ibs.

ft. Ibs.

SERVICE

(0040

-0.55 kg-ml

s.

(0.40-0.55 kg-

s. (0.28

-0. (2.07 -2.35 kg(7.61-8.30 kg-m)

35 kg-

ml ml ml

SPECIFICATIONS

1-5

\

Oescri?tion

10ROUE CHARI

~CON1\NU

\

EO)

Quantit'!

\

"\

ot(\ue

\

\..oc-lite

~

DRIVEN

Disc brake Mounting Nut Nut -mounting screw - clevis retainer Nut

CHAIN

Chain Chain Top Chain Cap Top Bearing Tensioner stopper

Jam nuts - chain

Bottom

Tensioner stopper

SUSPENS

Rear suspension bracket Mounting Rear axle

Axle Mounting Mounting Nut Nuts Attaching Attach

Wear

Cross shaft Mounting Mounting Mounting

CONVERTER & BRAKE

to stationary

screw - clevis retainer

- securing

- caliper

case

sprocket

case

- speedometer drive adapter sprocket bearing retainer ring

bracket

- shock absorber

- eye

ing nuts -

strip

front

to

mounting

CASE

mounting cover

mounting

cover plugs 2 20 in. Ibs. (0 .23 kg-m)

support

sprocket

assy

case

ION

screws - washer

support

mountin

screws -

nut -idler

bolts

to

nuts - screws

support

attaching screws

mounting

screws -

screws - suspension brackets -

bolt -idler

sheave

mounting

to

caliper

to

brake

bracket

nuts

screws 2 20 ft. Ibs. (2.77 kg-m)

screw 1 19

to

clevis

mounting

brackets

limiters

shaft

to

suspension brackets

upper

shaft

screw

set screws

nut

mounting

to

limiters

mounting

g screws

to

front

bolt

rear suspension arm

to limiters

brackets

screws

idler

shaft

screw

cam

support

mounting

nuts

suspension arm

to

cam

nut

screws

chassis

front

bracket 2

screws 3

and rear

18

3

95 in. I bs.

1

95

120 in. Ibs. (1.38 kg-m)

1

95

1

4

1

1 1

2

1 1

4 2 8 8 2 1 1

4

2

9 4 2 8

1

19

17 ft. Ibs. (2.35 kg-m)

Hand 95 95 95

17 in. 55 95

17 95 95 95

95

ft.

17

30

ft.

Adjust

95

in. Ibs. (1.09 kg-m)

95

in.

60

in. Ibs. (0.69 kg-m)

30

ft. ft.

15

25

ft_ ft. Ibs. (2.63 kg-m)

19

(1.09 kg-m)

in. Ibs. (1.09 kg-m)

ft. Ibs. (2.63

ft.

Ibs. (2.63 kg-m)

Tighten

in.

Ibs. in. Ibs. (1.09 kg-m) in . lbs. (1.09 kg-m)

Ibs. (0.20 kg-m)

kg

-m)

(1.09 kg-m)

ft. Ibs. (7.61 kg-m)

in. Ibs. (1.09 kg-m)

ft

. Ibs. (2.35 kg-m) in. Ibs. (1.09 kg-m) in. Ibs. (1.09 kg-m) in.

Ibs.

(1.09 kg-m)

in . Ibs. (1.09 kg-m)

Ibs.

(2.35 kg-m)

Ibs.

(4.15 kg-m)

Ibs.

(1.09 kg-m)

Ibs.

(4.15 kg-m)

Ibs.

(2.07 kg-m)

Ibs. (3.46 kg-m)

242

242 242

DRIVE

Bearing housing Bearing housing Nuts

SKI & SPINDLE

Attaching Attaching

Screw Nut

1-6

SHAFT

mounting

grease

- bearing housing

nut

- skeg (ski wear runner)

nuts - spring

sp

indle

to spring saddle

- spindle

to

spring saddle

TORQUE CHART

screws fitting mounting

to ski

screws

to

ski

3 1 3

4 4 2 2

95

in. Ibs. (1.09 kg-m)

40 in.

Ibs. (0.46 kg-m)

95

in. Ibs_ (1.09 kg-m)

ft.

Ibs. (2.07 kg-m)

15 10

ft.

Ibs.

(1.38 kg-m)

40 ft.

Ibs.

(5.53 kg-m)

45

ft.

Ibs.

(6.22 kg-m)

I

TORQUE

CHART

(CONTINUED)

S

TEERING

Nut

- steering column

Nuts·

steering arms Steering Steering Ti Tie Nut Handle bar

CHASSIS

Snow

Hood Hood Attaching Passeng Pan

FUEL

Fuel Air Att

column column

e rod jam

rod jam

· R H tie rod

brace attach ing screws

silencer support

aching nuts · fuel

nut

-

nut·

to

steering column

flap

mounting guide and guide,

front

nuts·

er

handles attaching nuts

SYSTEM

pump

assy

Description

to

tie rod

to

tie rods mounting mounting

nuts, upper

screws, lower

LH

RH

to

steering

front

bumper and hood hinge attaching nuts

rear bumper and snow

mounting

screws

bumper

pump

column

mounting

screws

screw

assy

and air silencer support

screws

flap

Quantity

1 4 2 2 2 2

1 4

4

12 18

8

4

2

1

3

Torque

35

ft.

Ibs. (4.

84

30

ft.

Ib

s.

(4.15 kg·m)

17

ft.

Ibs. (2.35 kg-m)

13

ft.

Ibs. (1.80 kg-m)

35

ft.

Ibs. (4.84 kg-m)

ft.

Ibs. (4.84 kg·m)

35 30

ft.

Ibs. (4.15 kg-m)

95

in. Ibs. (1.09 kg-m)

95

in. Ibs. (1.09 kg-m)

95

in. Ibs. (1.09 kg·m)

95

in.lbs.

(1.09 kg·m)

95

in.lbs

. (1.09 kg·m)

60 in.

Ibs

. (0.69 kg-m)

95

in. Ibs. (1.09 kg·m)

95 in.

Ibs.

(1.09 kg-m) 95 in. Ib 95

s.

(1.09 kg-m)

in.lbs. (1.09 kg-m)

Loc-Tite

kg-m)

242

CABLES

Brake cable jam nuts

cable

Choke Choke

CRANK

Flywh

CRANKCASE & CYLINDER

Cylinder head nuts (long) Cylinder head nuts (short) Spark plug Cylinder head Crankcase Crankcase nuts

INTAKE & EXHAUST

Mounting

Intake I ntake

Exhaust

assy

cable pal

& PISTONS

eel

nut

NGK

bolt

bolt manifold manifold

manifold

nut

BR8ES

bolt

stud

- carburetor holder bolts

(long)

bolts (short)

nuts

12

ft

2

1 1

1

2 16-19-1 /2 6 2 8

1 16 ft. Ibs. (2.21 kg-m)

10

I

2 2 4 4

. Ibs. (1.66 kg-m)

6

ft.

Ib

s.

(0.83 kg-m)

Hand Tighten

60

ft.

Ibs. (8.30 kg-m)

16·19-1/2 ft. Ibs. (2.2-2. 20

ft.

Ibs

. (2.

16-19-1/2

16

ft.

Ibs. (2.21 kg-m)

40 in. Ibs. (0. 4

-5

ft

. Ibs. (0.55-0.69 kg-m)

ft. Ibs.

4-5

10ft.

Ibs. (1.38 kg-m)

ft.lbs

. (2.2-2.70 kg-m)

70

kg-m)

ft.

Ibs.

(2.2-2.70 kg-m)

62

kg-m)

(0.55-0.69 kq-m)

kg-m)

TOR QUE

CHART

1-7

TORQUE

CHART (CONTINUED

)

FAN

CASE & AI R

Fan assembly Air

shroud

Fan

MAGNETO

Breaker S

tator

Exciting

stator plate

Condenser

ELECTRICAL

Coil bracket

Ignition

RECOIL

Drive plate Sta

rter

Starter

case

contact

plate

coil # 1,

coi l

pulley mounting

mounting

to

STARTER

mounting

SH

ROUD

to

pulley

mounting

screws

crankcase

mounting

stator plate

mounting mounting screws

mounting

exciting

bolts

screw 2

screws

coil

screws

mounting

screws 2 5-6

nut

bolts

Description

nut

s

# 2 and

screw

lighting

coil

to

Quantity

1

11

4 10-12

3 5-6

4 2

4 5-6

1 3 5-6 ft. 3

Torque

30

ft.

Ibs.

(4.5 kg-m)

Use

impact

driver

ft.

Ibs. (1.4-1.7 kg-m)

Use

imp

act

driver

ft.

Ibs. (0.69-0.83 kg-m)

Use Use

impact impact

ft.

driver driver

Ibs. (0.69-0.83 kg-m)

ft. Ibs. (0.69-0.83 kg-m)

ft. Ibs. (1.11 -1.38 kg-m)

8-10

Ibs.

(0.69-0.83 kg -m)

5-6

ft.

Ibs.

(0.69-0.83 kg-m)

Loc-Tite

222

NOTE: required. required, the the specif ied consumer

Loc-Tite formulas are selected on the

Generally,

or

torque

equivalent which may

#222

the fastener diameter

necessary

formula

to

is

remove a fastener.

on each fastener requiring Loc -

basis

used

on fasteners

is

greater than 5/16 inch (8

Be

careful when applying

be

substituted

is

Loc-

up

of

to 5/1

Tit

e " Lock 'n

the diameter

6 inch (8

mm),

:#

242

extra

e. Loc-Tite #

Sea

of

the fastener, and the strength

mm)

diameter.

is

specified. Loc-Tite may

force

as

222

and

l,"

product

If

a particu

this

risks damaging the parts.

:#

242

are

industrial designations. The

number 21, blue.

of

larly

strong

significantly

the bond

bond increase

Use

only

is

1-8

TORQUE CHART

G')

m

~

-4

o

C')

J:

~

-4

...

cD

,

GEAR

RATIO

CHART

DR

IVE

SPROCKET - NUMBER

OF

TEETH

15

16

17

18

19

2.00 : 1 Gear Ratio

34

*62 MPH

88 Chain Pitch

:r:

I-

UJ UJ

2.33

:1

2.19: 1

I-

Gear Ratio

LL

0

0:

35

*53

MPH

*

57

MPH

UJ

co :2:

88 Chain Pit

ch

88 Chain Pitch

::>

z

I-

UJ

2.40:1

1.90:

1

~

u

Gear Ratio

0

0:

0...

36

*52

MPH

*65

MPH

(/)

z

UJ

>

88

Chain Pitch

90

Ch

ain

Pitch

0:

0

2.18: 1

2.06: 1

Gea

r Ratio

Ge

ar

Ratio

37

*57

MPH

*60

MPH

90 Chain Pitch 90 Chain Pitch

-

*Theoretical

MPH

@ 6500

RPM

NOTE: A ll

top

speeds

based

on 1: 1 clutch ratio and engine

RPM

at 6500 .

20

21

1.6

2:

1

Gear

Ratio

*77

MPH

90

Chain Pit

ch

1.75: 1 Gear Ratio

*

71

MPH

90 Chain Pitch

.

- -

--

ENGINE PERFORMAN

340 ASTRO

45

40

CE

CURVES

C/l

0

I

a:

L.U

5:

0

a..

L.U

a:

35

30

25

20

15

10

5

f'./

~

a a a.

M ..r

a a a

a. a.

..,--

/

V

F

/

UEL

CON

a

I.!)

ENGINE

440 ASTRO

HORSEPOWER

YN

/

SUMPTION

TORQUE

-

a a a.

<0

RPM

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

-

a a a

a

I.!).

a.

<0

r--

a

I.!).

r--

60

40

20

1.60

1.40

1.20

1.00

0.80

C/l

CIJ

-1

f-

---

u..

L.U

=>

d

a:

o

f-

a:

I

r::i...

I

C/l

---

CIJ

-1

L.U

=>

u..

a:

L.U

5:

0

a..

L.U

C/l

a:

0

I

45

40

35

30

25

20

15

10

5

r--..

/X-....

a

o

q

M

/

.---r

/

,I

~EL

.......

a a

o.

..r

/

TORQUE

I'

CONSUMPTION

--

a

o

q

I.!)

ENGINE

RPM

HORSEPOWER

I---

/

r\

--..

'"

-"

a a a a a a

0.

<0

L!l.

<0

0 0

O.

r-- r--

L!l.

60

40

20

1.60

1.40

1.20

1.00

0.80

C/l

CIJ

-1

f-

---

u..

L.U

=>

d

a:

o

f-

a:

I

a..

I

C/l

---

CIJ

-1

L.U

::::>

u..

....

1-10

ENGINE

PERFORMANCE

CURVES

t

B

PORT

DIMENSIONS

MODEL

=

A

B

=

C

=

D =

E

=

F

=

G =

H =

I = 1.93 in. (48.9 mm)

J

=

SA340-Al

1.42 in. (36

1.48 in. (37.5 mm)

0.93 in. (23.5

1.61 in.

1.16 in. (29.5

3.76 i

0.56 in. (14.1 mm)

1.93 i

0.56 in. (14.1 mm)

(41

n.

(95.5 mm)

n.

(48.9 mm)

mm)

c

t

Ht

F

MO

DEL

SA440-A 1

1.57 in. (40

A =

1.52 in (38.5 mm)

B

=

0.93 in. (23.5 mm)

C =

1.81

D =

1.16 in. (29.5

E

=

3.76 in. (95.5

F

=

0.56 in. (14.1

G =

1.93 in. (48.9

H

=

1.93 in. (48.9

I

=

0.56 in. (14.1

J

=

in.

(46

mm)

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

PORT

DIMENSIONS

1-11

1-

MAI

NTENA NCE

MAINTENANCE

LUBRICATION

THEORY

Two-Stroke Carburet

Ignition Electrical Torque Torque Driven Chain Case Tra

MAINTENANCE

Two Fuel Ignition Electrical

Converters ....

Drive

Chain Case Track,

STORAGE

OF

OPERATION:

or

System

System ......

Conver

Converter System ..........

Converter .......

and

ck,

Suspens

-Cycle Engine System

System

Converter and Driven Co

Alignment

and

Suspension

.....

Table

CHART

CHART ...

Engine .

.. .. ..

........

ter

Gearing

ion,

. .

...

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

...

..

.......

Gearing ...... .

. .

. . .

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

.....

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

and Steering

.....

...........

.......

..

. . .

.......

. . . .

and Steer

.....

Of

Contents

...

......

. .....

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

.

.. .....

.

........

.....

...

......

...........

. .

.....

.. ..

System

...

.....

...........

...

.

...

.....

..

...

nverter

ing System

.

...

. . . . ......

..

. . . . . .

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

.. .. ..

....

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

. .

......

. .

.. ..... ..

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

.... . .....

. ......

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

. . . . . . .

...

....

.

......

...

..... . . .

. . . . .

. . . . . .

. . . .

.

......

. . ......

. ....... . .

. .... . .

.....

....

. . . . . . .

.....

...

..

. . .

....

.....

. .

....

. . . .

..

...

....

..... 2-36

Page

2-3 2-4 2-6

..

.

2-6

.

13

2-

.

2-22

..

.

2-

22 2-22 2-

23

.

2-

24

..

.

2-

25

..

.

2-25

. .

2-26 2-

26

. . .

2-

26 2-

27

. .

2-29

.

2-31

2-

32

... 2-35

. .

2-39

TABLE OF

CONTENTS

2-1

Maintenance

Chart

Frequency

Operation Install

plugs Check carb uret

adjustment Check th

adjustme Check

adjustmen Rep De-carbon engine and

exhaust Check breaker

Check i

new

rott nt

enrichener

t

lace

fue

gni

tion ti

spark

or

le cable x

cable x

l f il

ter

points

ming

Beginning

of

Each

Season

x

First

50-100

Miles

5-10

or

Hours

Use

x

x x

x

Every

300

or

Hours

x

Miles

20

Use

Every

600

or

Hours

Miles

40

Use

x

Every

900

or

Ho

Miles

ur

s Use

x

60

End

of

Each

Season

x

Page

Refer-

ence

•

Replace drive belt (be

converter

sure are clean and

dr

Check and al

ignment

Check d rive conver bushings

Clean and drive and converters

Check adj

Adjust track tens ion and check

Check ski align

Adjust

Check fastene rs f

secur chart

ive

dr

iven con

dr

ive chain

ustment

brake

it

y (use t

as a guide)

dry

converter

for

wear

inspect

dr

iven

align

orque

pu lIeys

)

verter

ter

men

ment

or

x

x x

t

x

x x

x

x x

x

Inspect ski for

wea

Measure rail

wear

Adjust headlight

r

wear

str

run

ips

ners

of

slide x

x

MAINTENANCE

CHAR

T

2-3

Lubrication Chart

Lubrication

Point

Lubricant

Frequency

Illustration

CONTROL CABLES Inner

cables

CO

DRIVEN Ramp surfaces

NVERT

sliding

ER

LP

S,

WD-40, Dri-Slide si

milar temperature lu

bricant

L

ow temperature

grease.

or

low

.

Once a season

and every

of

operation.

Once a season and every hours

20

of

operation.

hours

CHAIN CASE

HOUSING

SUSPENSION ARMS,

Rear

Front and

Sno

Jet

Chain

Lubrican

Low temperature E.P. (Extreme Pressure ) Grease .

t.

Check level every

20

hours

Once a season and every

hours

of

40

of

operation .

opera

tion.

2-4

LUBRICATION CHART

LUBRICATION CHART (CONTINUED)

lubrication

STEER COLUMN

FRO BEARING

ING

NT AXLE

Point

Lubricant

Low

temperature

E.P

. Grease .

Apply 3 pumps

of

grease

nd-

operated

ha grease gun. CAUTION:

The seal may be

dislodged by grease, check afte r greasing be

aring .

with

the

Frequency

Once a season and every hours.

Once each season.

a

40

Illustration

.....

LUBRICATION

CHART

2-5

Theory the

I

ntrod

All

by a are: 1. Intake, 2. and

A compressed,

A

comp

Each following the the

1. Intake: On

2. Compression :

Two-Stroke

uction

internal

four

4. Exhaust.

fuellair

two-stroke

lish

of

the

engine

charge engine

stroke, starts fue

II air

volume.

of

combustion

part

cycle

mixture

burned, and

engine

all

four

parts

path

(Figure 2-1

the

of

fuel

through

the

intake

back up. This

m ixtu re

Operation for

Engine

engines

of

operation. The

Compression,

must

be

exhausted

uses

parts.

can be eas ily

of

the

fuellair

).

downstroke

mixed

Near

with

an open

the

port

is closed,

upstroke

to a fraction

drawn

only

air

port

bottom

are

characterized

3.

Combust

into

the

.

two

strokes

understood

mixture

of

the

is

drawn into

in

the

of

the

and

compresses

of its

four

the

parts

ion,

engine,

to

ac-

by

through

piston

the

cylinder.

down-

piston

the

former

3.

Combustion: presse

d,.

down

. This is called

4. Exhaust: rises aga in, through cycle is ready

The piston is power the

The intake most air

into the the

a

effectively drawing pi presses 55°-60° upper ind mixtu through

stroke

crankshaft

complex

have been

the

crankcase.

cyli

nder

lower

ston

blocks

the

BBDC (before

edge of

er

wall re

in these

in

that

When

it

is ign ited

After

pushing

the

now

to

carried

to

the

.

of a two

part

mixed

wall (the

edge

of

increases

the

mixture.

the

mixture

the

piston

are

conn

the

crankcase,

transfer

the

mixture and

forces

the

power

the

power

open

start

through

-stroke

of

the

in

the

As

the pi

intake

the piston. The

the

volume

intake

in

the

bottom

uncovers

ected ports

stroke,

the

burned

exhaust

again.

each

the

rot

engine

cycle.

After

carburetor, it

ston

port)

On its

port

and lightly

crankcase. At

dead center),

to

the

under

into

has been

the

stro

ke.

the

gases

port.

and

step

from

ating

inertia

is

perhaps

the

fuel

is

drawn

rises, a

is

uncovered

of

the

return

ports

crankcase. The

pressure,

the cylin

hole

rising piston

crankcase,

trip,

in

the

rush

er.

com-

piston

out the

one

of

the

and

in

by

the

com-

about

the

cyl-

es

2-6

THEORY

OF

OPERATION

Figure 2-1

o

There are the

crankcase , and two-stroke is called fer

or used because inder helps to clean the

combustion engin

After rises, closing

opening

above

TOC

the

two

separate intake actions:

termino

the

int

ake;

scavenging

the

log

the

flow.

new

second

y,

only

into

the

second is called

The

word

mixture

flowing

the

first

intake

"scavenge"

exhaust

chamber.

g"

the

exhaust

the

piston passes

the transfe

the

intak

the

piston is compressed as

This

is

.

BOC

(bottom dead

r and

exhaust

e again. The

known

mixture

the

piston nears

(top dead center), the spark plug is fired and

mixture

starts

burning

.

first

into

cylinder. In

action

the

trans

into

the

cyl-

out

of

the

as

"scav

center

ports, and

rapped

is

) it

-

crankcase. The more time there crankcase.

crankcase

mos

pheric

dir

ection. The 600 ABOC, wo

uld seem

BT

OC, on a piston int

ake to and all

the

mixture

th

e open intake.

just

remain

the

If

th e intake is opened too soon,

pressure

and

which

ideal

after

port

crankcase to the

Transfer

sooner

is

to

will

the

mixture

transfers

is

the

to

open

the

transfer

engine

open

cylinder

the

intake is opened,

draw

the

mixture

be

higher

will

flow

generally

same the

close

as

1200 BTOC. It

intake

at

ports close. However,

this

would

until

1150 ATOC as

pressure

would

meant

be lost back

than

in

the

about

require

to

the

into

the the

at-

wrong

ataround

115

the

well,

transfer

out

0

The piston is

unt

il the edge of the piston. The through the

piston, and

dr

exhaust

all

four

iven

downward

port

is uncovered by

basic parts

one

complete

by

the

two

-stroke engine goes

in

just

two

rotation

crankshaft.

Intake

A

two

-stroke

ca

rbu reto

To

get

the

be an opening

the opening

push

the The intake closes of

The

the same

TOC

fuel/air

and takes a

89°

ABOC 89° BBOC

engine's

r.

mixture into

to

or

mixture

timing

Figure

2-2

mixture

certain

TYPICAL

intake

tract

starts w i

the crankcase, there must

the

carburetor. There is a valve in

the pi ston on its

back

out

through

is "s

ymmetrical,"

number

of

degrees on

downstroke

the

).

in

the

amount

PISTON

intake

VALVE

TOC

of

tract

time

ENGINE

to

combus

the

tion

uppe r

strokes of

of

the

th th

will

carburet

or.

it opens and

either

side

has inertia,

get

into the

76° ATOC

Trans

fer

ports

are

designed to move mixture scavenge the the exhaust port opens before exhaust direction. As exhaust trans

e

such a inder, haust

The size and shape portant small, port of the flow scavenging. Recent port s

till

c

arefully enter of the

Timing BB ca haust mix less

symmetrical transfer open too long,

into

from

the

crankcase to

exhaust

gases are already

the

pressure in

will

no

longer

fer

ports

aim

the

way

that

it

will

pushing

the

port.

for

efficient

the

transfer

is too large,

inertia

of

after

s can be made

the

it

the

gases

leaves

almost

get good scavenging

controlling

the

cylinder

the crankcase

lower

the crankcase pressure.

of

the

OC to

nnot

about

open

would

the

new

power

. The

volume.

transfer

600 ABOC. The

until

after

flow

into

charge and the

(or

none

about

port is

important

some

the crankcase.

the

from

the

traveling

the

cylinder

flow

of

its

incoming

sweep

exhaust

of

the

fuel/air

throughout

gases

transfer

scavenging.

flow

will

be restricted.

flow

speed

will

affect

the

port,

studies

indicate

as large as possible

at

low

the

angle

transfer

at port

The larger

ports

runs

the

exhaust

the

crankcase. This

exhaust

at

all).

Transfer

BOC. The closing

to

good

of

the

mixture

the

fuel/air

cylinder,

and to

cylinder. Because

transfers

own

toward

If

will

drop. The lack

the

resulting

do,

in

the

right

drops,

accord. The

mixture

the

ports

are

they

are too

If

direction

in

that

transfer

the the

in

cyl-

ex-

imthe

of

poor

and

engine

which

speeds by

the

passage is

the

passage,

from

about

transfer

does

or

gases

ports

the

part

60

ex-

would

resulting

port

point

cylinder

will

timing

filling.

flow

of

back

in

is

the

If

0

BOC

Figure

2-2

Compression

closes the

presses the

fr

action

pression mechanically

of

occurs

intake

fuel/air

its

original

any

sealed.

as

the

and

mixture

volume.

kind,

piston

exhaust

in

the

on its upstroke

ports the To

cylinder

and

cylinder

achieve

must

INTAKE

com-

to

com-

be

2-7

a

The

cylinder

from the

tween

the

both compression and

gasket."

standing head gaskets are s a

luminum. Others asbestos sheet to

the

cylinder, squeez ing

ju

st the

head, in

cylinder

head

itself. The

and

This gasket high

temperatures

are a

s.

The head must be

right

amount

most

the

cylinder

combustion

must

imply

a sh

sandwich

of

force to

engines,

be capable and

the

leaking.

fit

in

circle

the cylind

rings

es

up

or

two

the

ton

the

or

must

and

compression sealing

The pi ston is a close

the final seal is made by pis

steel alloy rings and

pr

ess

outward

vent

leakag e

the

piston. The piston temperature while

inder

Mo

st

rubbing

wall.

engines

whi

of

compression

s and

constantly

have one

ch

against

pressur

piston rings. Their job is to seal

the

piston and cylinder.

These rings are them

wear ) onger. Plain

but

wear

more

seal

sooner

mu

st be

conform

inder

initial

The cross-sec

exactly wall, wear

when

"broken

but they is the brea

tion

sometimes

quickly

they

in."

to

tiny

of

a ring is an

chrome

iron

rin

and

for

are new. N

The n

irr

egulariti es

gradually wear

k-in

period.

its design. Ring s having a sec tion type has a

This type

it

s groove has ring outward

bus should sometimes should ma

are

called

of

ring has parallel

wedg

e-shaped cross-section (see Figure 2-3).

of

ring is called a

non-parallel

and its groove

aga

inst

tion stroke for

not

be

also have a

always

nufactu

be

rer' s instructions

"flat"

are

the

cylinder

better

installed

install

rings. The groove

walls.

Another

"key-ston

walls.

designed to

wall

sealing. Key-stone ring s

upside

"top"

ed

carefully

.

is separate

joining

surface

is sealed

by

the

of

pressures

eet

of

copper or

of

copper a

fastened

head gasket

keep

cylinder

bore,

rings. These are

piston

er

in

wall

grooves

combustion

withstand

with

out

deforming

down

the

on the cyl-

gap

between

plated to make

gs seal j

thi

ew

rectan

s reason

ew

piston rings

rings

to

imp

ortant

gu l

ust

of

the

fit. This

ar

type

e"

rin

The shape

for

ce

the

during

down.

and

the

Flat

"bottom"

following the

be-

against

"head

with

. Some

nd

tightly

with

it

from

but

to pre-

past

high

as well

they

do

not

cyl-

part

of

cross-

for

thi

of

ring

g and of

the

ring

com ring

s

and

-

Th

e compress ion di fferent from BDC to TDC displ

acement

wo-s

troke engines are

t second method. engine displ

acement

s

FLAT

RINGS

ways

in Fi

KEYSTONE

RINGS

Figure 2-3

rat

io

may

be

. The

above

ent

may

the

ire cyli

be used, exhaust generally

As

an

example

gure

2-4

with a 60

can be figured as sh

"

DYKES

RIN G

measured

nder

displacement

or just

port. Kawasak

rated by

, imagine the

mm stroke. Its

own.

in

,

"

two

the

i

the

third

type

of

A

This ring is

piston . so the

inder cylinder

It

is placed

that

one

edge slightly. The

wall

combustion

of

the

upper leg

cylinder

2-8

wall

COMPRESSION

ring is

usually

side

of

during

twisting the ring

stroke the gas

of

for

a good seal.

the

"Dykes"

used alone on a s

at

the

upper

"L"

ring

shape

is

forced

edge

protrudes

again st

the upstroke by the drag

outward.

pressure

the

"L"

forces

it

out

patt

ern ring.

ingle-rin

of

the

piston,

above

the

cyl-

of

the

During

the

on the in side

against

the

g

BORE = 60 mm ST ROKE = 60 m m

Fi

gure

2-4

2

V

=n-r

WHERE:

=

displacement

V

r =

112

= stro

h

7r

=

3.1416

V

(3.1416)

V

169.6

If

the

engine has a

ume

of

can be

h

bore = 30

ke = 60

(3) (6)

cc

or

20

cc

at

figured

.

volume

mm

or

3 cm

mm

or

6 em

approximately

total

combustion

TDC,

then

the

170

cc

chamber

vol-

compression ratio

The compression ratio sure

of

the

efficiency compression ratio, will

use its

with

a high

horsepower

of

gas

lower

The

further burned, more

heat

fuel, for

than

an

compression ratio.

the

hotter

will more expansion that fuel

means

used and

more

the

up to a

compression

its size

otherwise

mixture

the

be produced.

of

the

horsepower

the

engine

of

an

of

more

and

the

engine

certain

ratio

go

identical

engine

efficiently

further

point.

will

is one

. The

put

on a

engine

higher

the

An

out

is compressed before It

combustion

will

Greater

for

the

be and

heat

products, and

amount

size.

mea-

the engine engine

more

gallon

with

IS

the

means

of

a

R

WHERE:

R - compression

V -

displacement

V -

volume

at

170 + 20

R

20

R 9.5

This is called

However,

cyli

nder

of

at

SDC, the

look I ike

V =7I"r2h

at

the

if

the

we

se.

the

compression

WHERE:

=

displacement

V

= 112 bore =

r

= distance

h

top

of

exhaust

from

71"=3.1416

(3.141 6) (3)2 (4)

V V 113.1 cc

or

ratio

volume -170

TDC -

20

"theoretical"

measure

closing

of

volume

30

mm

or

top

of

port = 40

about

113

cc

compression ratio.

the

total

the

exhaust port

ratio

above

3 em

cylinder

mm

cc

volume

calculations

exhaust

port

to

or

4 em

of

the

instead

might

Combustion

Combustion is trodes of a

The spark plug receives a

voltage instant. wi

power

ign ite 6000 for so TDC

When

that

mixture

front"

flame

burning Normal

electricity

If

II

try

to

stroke the revolutions

this

lead is

that

peak

at

high

the

is

ignites

travels

front

combustion

the

across the speed. There are several types bustions common

metallic,

hard, flame the

front

mixture

an even

related to the

started

spark

by a spark across

plug

in

the

timed

to

ignite

the

ignition

run

backward; too late and part

will

m ixtu re at

to

cylinder

comes too soon

be lost. The

17°

before top dead

per

minute

start

the

mixture

pressures

speeds.

spark plug fires,

between

moves

mixture

its electrodes . That

the

mixture

across

the

across

as

is a

combustion

it

around

combustion

the

it

goes.

single

chamber

and all are undesirable. The

is

detonation. Detonation

hammering

travels

resulting

burning

octane

almost

of

from

instantaneously

in

an explosion

the

mixture.

of

the

gasoline used.

the

elec-

combustion

mixture

ignition

surge

at

the is

chamber.

of

high-

the

right

engine

of

the

timed

center

and up). The reason

burning

will

occur

ignites

the

in

just

mixture

time

after

burning

it,

and a "flame

chamber. The

combustion

flame

at

of

chamber,

front

traveling

just

the

abnormal

right

com-

most

sounds

the

engine

like a

. The

through

rather

than

Detonation

to

(at

is

V

+ V

1

R

2

V2

113 + 20

R

20

R = 6.7

This is

ratio, and is a

usually

called

Iways

the

"corrected"

lower

compression ratio.

than

compression

the

theoretical

"octane"

The

defines

that standard set the octane ,

detonation.

of a gasoline

gasoline's

of

laboratory

the

more

Octane

ratings

resistant

to a laboratory procedure ability two

produce gasoline to

adding petroleum

makes

detonation

to

resist

petroleum

detonation

distillate

meet

tetra-ethyl

of

distillates. The "lead"

it

burn

more

.

lead

is a

burning

conditions

speed

the

number

. The

gasoline

which

under

higher

are assigned according

which

to

that

fuels.

octane

or

certain

slowly,

compares a

of a mixture Oil

companies

requirements

high-octane

in

the

gasoline

thus

avoiding

fuel's

COMBUSTION

a

is to

of

by

2-9

When

molectJles carbon-dioxide, pounds, and heat. Heat is absorbed by the and combustion products. Heat absorbed by engine bustion them the

The shape a chambe r more resista induce tion per

Smoothly designed . having a squish area: bustion top squirt chamber with the sphere . be a smoothly with allows chamber"

lowest.

the

mixture

place. The

actual

factor

resistant; and

unit

of

molecules

of

is

wasted,

products

to expand. This expansion is

power

of

in its

with

mixture

of

volume

surfaced

Mixture

chamber

the

piston (at TDC), causing

out

from

roof

the

lowe

An

a squ ish area

a

smooth

espec ially

burns, a

of fuel

the

air

to

water,

but

incr

eases

in

the

engine's

ability

nt

as

st

to

few

projections

to

detonation.

turbulence

chambers

detonate

combustion

turbulence

roof

between

the

piston nears TDC. The shape

surface area per

ideal

finished,

around

scavenging

chemical

combine

produce carbon-monoxide,

traces

heat

that

combustion

when

of

that

their

engine

combustion

resist

detonation. A smooth

are more

with

less

that

is a

comes

the

aimost

the

scavenging

reaction takes

with

oxygen

other

various

engin

goes

into

the

pressure,

what

.

and

irregulariti

Chambers

highly

less surface area

than

chambers

can be induced by

part

very

the

piston and

unit

chamb

spherical

edge . This design

flow

forcing

produces

chamber

detona-

others.

are easily

of

the

close

to

mixtur

of

volume

er

would

chamber,

across the

flow

com-

the

com-

is

es is

that

com-

the

e to

the

is

shou

Id

be placed near the cent

so

the

flam

e f ront w ill have

to

travel to reach all

plug is on one edge

e

front

has to travel all center, the far.

of

Part min

ed by the top bottom piston is strengthen c

enter

and

ra

As

the

connecting around its circle, cylinder piston's inder durin

g compression. The set, in the crankpin travel of

the

in

der

wall

the crankpin does, and piston

of

combustion

flame

the

combustion

of

the

generally

its

center

to take up space in

ise

the

compression ratio.

piston is forced

rod increases . The

and

then

being

wall

piston's

thrust

during

direction

near

. The piston reaches TDC

is

points

of

the chamber, the

the

front

only

chamber

of

the

piston. It becomes

chamber

away

back again.

combustion,

sideways

minimized

at

shaped

. Some

the

downward,

from

against

piston

opposite

TDC. This lessens

motion

er

of

the

shortest

of

the

chamber

way

across . From

has to travel

shape is

TDC. The top

in a gentle

pistons

combustion

the

one

"slap"

(Fi9ure

have a ra ised

the

crankpin

centerl

This

results

side

and

the

hole

is

the

against

slightly

at

2-5)

angularity

ine

of

other

slightly

direction

the

the instant

.

chamber

distance

. If

the

flame

the

half

as

deter-

the

of

the

arc

to

chamber

of

moves

of

the

in

the

cyl-

side

off-

of

impact

the

cyl-

before

Compression high

compression ratio

to

avoid

use a

The compression is a more accurate detonation pression bustion rising piston. ratio may

Another ignition. hot

on

may flame the flame

ignition will

lead to serious

Another design is spark plug placement. The spark plug

lower

or

a fleck

the

be

front

plug fires, its

front

soon overheat.

ratio

is

important

detonation. A low

octane

than

pressure

chamber, before

An

leak, causing

type

If

the

head

of

ignited

traveling with

creates advanced

consideration

gasoline.

pressure

measure

its

is

the

engine

of

abnormal

combustion

of

carbon

the

piston heats up,

before

engine

the

across

flame

a small,

Detonation

to

combustion.

requires a high

compression

produced by an

of its resistance

compression ratio. Com-

pressure

ignition,

with a high

low

compression

combustion

chamber

on the

front

damage.

chamber

plug

the

meets

sharp

timing,

and

in

combustion

fires. This

octane fuel

engine

in

the

produced by

compression

pressure.

is pre-

becomes very

surface

the

mixtur

starts

chamber.

the

sound

and

preignition

When preignition . The pre-

the

engine

chamber

can

to

com-

the

or

can

A

--

...... ~ ...

_----OFFSET

e a

Figure 2-5

2-10

COMBUSTION

The piston

drical shape only

when

when the engine

pand evenly

through

and are thicker save expand more The

wall

greater to handle motion across the piston with

an expands cylinde

cannot

or

the

engine

as

it

the hea

for

extra strength;

weight.

of

r.

The

than

thi

ckness

the

pi ston. The piston

elliptic

al shape.

into a cylindrical

be made in a perfectly

the

piston

was

heats up. Near

d (Figure 2-6), the piston

upper

the

near

the str

would

was

cold, and

hot. A piston does

part

skirt, and

the

esses

bosses and

As

the

fit the

the

skirt

of

the

must

piston pin holes is

of

the

will

must

piston

shape and

cylin-

cylinder

not

fit

well

not

ex-

ring grooves

walls

is

thin

to

pis

ton

will

be smaller.

reciprocating expand

heat

more

be made

s up,

it

fits the

exhaust ri g piston through

The exhaust haust exhaust excessive noise .

port.

ht

direction. After

for

ces

the

exhaust

system cons

port

manifold,

gases

This

forces

the

re st

through

and a

quickly

Engine Design

Theory, of the

under

the

engine are

low

stood.

function,

er

end

and

important, but

the

bottom

of

port.

ists of

the

muffler

and

design

(crankca

gases

dead center,

the

cylinder

easily

se)

to

move

burned

a passage

head, an ex-

. It removes the

while

of

the

upper

not

complete

function

in

the

ri s

gases

from

reducing

portion

until

s

the ing out

the

are

The

rather makes

when Usually across the about 3/1 edge. The inder gauge in measured taper.

it

check ing

the piston is measured

diameter

(if

two

directions at

Figure

odd shape

important

skirt 6 inches other

. This is measured

available)

not

only

to

piston

at

900 to

(5

half

of

at

four

each position. The

for

PISTON SHAPE

(EXAGGERATED)

2-6

of

the

piston when cold

know

mm)

piston clearance is

size,

where

to

cylinder

with a micrometer

the

piston

up

from the bottom

with a dial-bore

different

but

position s, and

for

roundnes

to

clearances.

measure

bosses,

the

cylinder

s and

cyl-

is

The crankcase supports the use ball

These two of

race, and the wh balls

The crankcase is designed cranks crankshaft,

The crankcase

mating match

rather

Kawasaki

seals

(Figure 2-7).

bearings

ball

bearings

hardened steel races separated by a caged set

steel balls. The

the

crank

turns,

ich roll on

from

rubbing

haft

. In

the

surfaces

perfectly. A sealing

than

two-stroke

and

cylinder

contains

main

bearings.

for

the

are very strong and consi st

crankshaft

crankcase

the

inner

the

outer

against

order

crankcase is sp

must

a gasket,

to

be

of

the

to

engines. The

base baskets have

the

crankshaft, and

Snowmobile

main

bearings.

is

fitted

to

carries race. The cage keeps the

install

airtight

crankcase

the

outer

race rolls on

each other.

to

totally lit

compound

insure

enclose

and remove the

horizontally

and

oiltight.

halv

airtightness on

crankshaft

to

engines

the

inn

race.

the

es

must

is used,

be

airtight

of

er

As

balls

the

.

The

oil

Exhaust

Th

e design major The speed range he

ight useful exhaust BBDC. The he

The

higher

angle. The

last

into

the

effect

of

the

pow

er range

port

bit

exhaust

of

the exhaust

on

the

characteristics

of

the

engine

exhaust

opens and closes

ight

of

the exha

of

pressure

system

port. Proportionately,

of

the

port

ust

port,

in

system and

engine

determines

the

with

timing

of

the

increases

decreases. The

at

about

wider

cylinder

the

800 to

the

is released

opening

engine.

with

its

timing.

exhaust

of

has a

the the

90

the

0

Figure

2-7

EXHAUST

2-11

To achieve good crankcase compression, wheels pletely the space inside the crankcase.

The

parts. A caged crankpin. The

the

the sideways each side

The misaligned pressed together. The perfectly

There is a specified side and radial clearance the

are designed

as possible.

connecting

crankshaft

crankpin needles roll connecting

, and

held

of

the big end.

crankshaft

because

aligned on

big end bearing (Figure 2-9).

to

fill

the

crankcase as

Between

rod. There is

is pressed

needle bearing is used on

rolls

on

the

rod. The

by

two

can

twist

it

consists

the

together

on

inside

of

connecting

thrust

or

loosen and become

of

crankwheels

crankpin (Figure 2-8).

very

the

washers,

the

crank-

crankwheels

little

wasted

from

separate

needles, and

large end

rod is located

one

separate pieces

must

com-

the

of

on

be

for

is

Lubrication

The

lubricating carried gasoline and oil used as a engines. The by the

gasoline, and

Depending upon dations, the ratio can vary some may be even higher).

Some

cated by a variable

mixtu

depending on When gets less

entirely

British

from

snowmobile

re

from

the

engine

oi

I.

oil

for

most

in

the

fuel. Petroil is a mixture

term

"petroii"

from

the

"oil."

the

manufacturer's recommen

of

gasoline

16

to

1, all

engines

pump about engine

18

speed and

needs less oil, as

snowmobile

fuel

in these

was

two

words "petro

to

oil

the

way

are

automatic

which

to 1

to

engines

two-stroke

prob

ably

termed

l"

for

in

a petroil

to

50

may

change

about

throttle opening

at

an idl

to

ally l

50

mix

1 (and

ubri-

the

to

e,

is

of

-

1,

.

it

@)

RIGHT

WRONG

CONNECTIN'G ROD

(BIG END)

THRUST

WASHERS

A+B+C+D = SIDE

RIGHTW

WRONG

Figure

E =

Figure

2-8

CLEARANCE

RADIAL

2-9

CRANKPIN

CLEARANCE

I

Under Automatic engine down

full

throttle, oiling is

only

as

on visible

the

economical

much

exhaust

engine

oil as

emissions.

it

needs. Thi s also

Cooling

All

snowmobile

heat is produced by bustion extra and

The piston is coming flowing

by usually inder overheating.

The by overheating is piston seizure. the against piston onto treme side because clearances and cause seizure. A

loss

can be cleaned, and more damage new

cylinder

gouges

products can absorb

heat

cylinder

from

across

contact

hotter

head, and is

most

common

overheated

the

until

the

cylinder

heat. A piston

of

power.

severe seizure

from

piston and

must

on

engines

combustion

is absorbed by

head.

cooled by

the

bottom,

the

top

during

with

the

cylinder

than

the

first

form

piston cylinder it

begins

that

be

the

wall.

to

melt

wall

will

side

runs

uneven

If

a severe seizure

honing

mild

the

may

cylinder

seizure

damage

the

rebored

walls.

A severe seizure can

need

in

the

piston,

the

new

by

the

walls.

cylinder

component

of

engine

expanding

Friction

. Pieces are rubbed

and

welded

seize

hotter. Inc

cylinder

lock

the

bore.

to

clean

will

be fed

because

to

be cooled.

than

hor

fuel/air

the

scavenging, and

walls or

damage caused

This

adds h

fir

st

on

expansion can also

feels

is

slight,

bore honed. A

engine solid. The

requir

Someti

up

more

it

gives

cuts

More

the

comsepower cylinder

new

The piston is

damaged by

is caused by

and pressing

there

orrect

lik

es

scratches

. This walls

mixture

the

cyl-

eat

to

by ex-

the

exhaust

piston

e a sudden

the

piston

fitting mes

and

dam-

oil.

the

,

the

off

a

the

2-12

LUBRICATION

..

•

age

the

connect

ponents

The water. cooled the exposed heat system become clogged engine

shou

cylinder

At present Kawasaki is developing models. An

cylinder and head

to

given up. If

may overheat.

ing

ld

always

and head

air. The

rod and cranksha ft. These

air

more

the

be

examined

may

be cooled by

cooled

which

cooling

with

engine

increase

area exposed,

fins

foreign

for

damage.

has

fins

the

or

fan

material,

com-

air

or

water

on

area

more

intake

the

VENTURIMEASU

REMENT

1

I I

engine

The fan

blows

heads and

engine

and

most overheat tended period

The average

percentage

Aluminum

minum identica

bare

aluminum wear quickly. chrome others the

iron lin

m inu m

Small

minum will Fau

lty

of

uneven

aluminum cylinder

Carbure

Introduction

The mixing for

efficient combustion

carbureto

A

common

the bore

snowmobiles. The

the

smallest part

The carburetor is the

movement

chooses

I

machine

control from a virtual that

the e

w

ithin its

is cooled by

coo ling

draws

will

not

sno

if

they

of

conducts

cylind

I

iron

plate

have a

er

of

the cylinder

bubbles

insulate

cylinder

heat

of

r.

method

or

venturi

the

at

the

rider

ngine operating

the

air

flowing

air

across

the

heat

be cooled as effectively at an idle,

wmobile

are

allowed

of

time

.

sno

wmobile

lightweight

heat

er

or

head

one. The

because

Some

lining

cast-in

must

between

castings

transfer

cylinder

they

alum

to

make

iron

be in

the

liner, create problems because

from

fins.

the

out

of

the

engines

to

idle

engine

aluminum

very quickly.

will

inum

liner

over

the

contains a high

run

walls

would

cylinders have a

them

wear

. To cool properly,

contact

its

iron

creating

the

iron

over it. A

cylinders and

engine

will

gradually

for

an ex-

components.

An

cooler

be too soft and

entire

than

cannot

acceptably;

with

the

surface.

and

the

a hot-spot.

liner

tor

fuel

and air

measurement

of

the

of

his

engine

desired rate.

can choose a speed

crawl

will

in is the

for

referring

size. This the

venturi

rider's

machine

speed

to

flat

out. The rider expects

respond

range.

the

amounts

function

to

carburetors

method

is

the

(Figure 2-10).

primary

. The

that

will

With

a squeeze

instantly,

required

of

is used

diameter

control

carburetor

propel

anywhere anywhere

. The

alu-

alualu-

to

the

over

of

an

be

the

is in of

the the

The

carburetor

in

the

form which slide, aided by

and jets, regulates engine. When of engine

the

mitted

and power.

The

mixture

The

changing needs ditions of

each 15

"th

a

Due to

speeds or the

richer.

Within burned and economy entering factor tage bustion,

molecule that tained by the availab le

surrounding molecules given mum

uncovers

fuel/air

, causing

slide is

to

carburetor

which

fuel/air

of

fuel

to

eoretical"

fraction

actual

the

in the engine, a balance

for

of

the

all

of

quantity burning

receives

of a pull

numerous

the

mixture

lowered,

the

engine,

reaches

ratio

load and speed. The ideal

air

is

about

grams

mixing

of

the

incomplete

additional

operational

acceptable

must

the

engine

maximum

limited

it

is necessary to

with

enough

the

air

gaining

air. Maximum

.. each

of

air

of

efficiency

Figure

the

slide is lifted, a

flows

it

to

controls

must

of

the

of

time

be reached.

amount

is utilized.

maximum

molecule

to

fuel.

2-10

the

message

on

a cable. This

air

passage

ports, passages, needles,

flow

under

produce

less

fuel/air

causing

the

be adjusted

engine

1 :15

or

air.

This

ratio, and is

that

the vaporization fuel

required

fuel/air

for

combustion

performance.

of

fuel

Maximum

insure

maximum

Maximum

of

the

~

from

to

the

of

fuel

and

greater

the

slide

more

power.

mixture

it

to

reduce speed

amount

engine

air

burning

economy

of

(Figure 2-11).

for

particular

burning

one

gram

is an

only

engine

of

at

ratio

ratios

between

The

amount

is

To

available

surround

molecules

fuel

with

economy

available fuel.

the

rider

lifts a slide

engine. This

air

into

the

quantity

into

the

When

is ad-

of

fuel/air

to

meet

the conratio

of

fuel

"ideal"

achieved

is

fuel

high

is

that

the

take advan-

for

each

to power efficiency is gained by

use

or

for

running.

at

low

speeds,

usually

can be

power

of

air

limiting

com-

air

insure

is ob -

several

from

is

maxi-

to

of

a

CARBURETOR

2-13

these droplets would

~

..

::::::::::::

••

•.

IAiRFLO~

.. . . .

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

~

.

.•.

...•

...

a very rich will

When and air

incomplete atom ization mixture

acceleration,

developed, The greater economy drops rapidly

ridden ing speeds,

stantial,

results in a

in a

be

burned

warmed

flow

actual

for

at

but

of

warm

the

fu

engine. It is necessary

mixture

.

up,

through

idle is rich,

when

mixture

amounts

high

power

II

th rottle

air

flow

the

fuel

slightly

fuel

will

to

insure

the

engine

the

maximum

ratio

of

operation.

much

through

is

lean

not

vaporize as

that

speed

carburetor

of

the

fuel

about

fuel

when

metered

mixture

1:10.

might

and

a

of

the

carburetor

power

.

to

some

of

the

at

idle is

is so

low

occurs. The

Under

is being

be

around 1 :1

air

are much

This

is

why

snowmobile

time.

At

sparingly.

they

provide

fuel

low, that

hard

2.

fuel

is

cruis-

is sub-

This

Somewhere mum

economy is

ually

ridden. The range engine from (Figure 2-12). of broken up

FUEL/AIR

RATIOS

an

air

through

LEAN

1

~

RICH

receives

extremely

into

1: 1:

1: 1 0 1 :8 1 :6 1

:4

between

where

at

At

very

the

carburetor

small

18 16

14 12

./'

U).

Y'~

Figure 2-11

maximum

most of

fuel/air

one

time

rich

1:6

slow

engine

is

droplets

. If

/

/"

"6

<'«'

""

~

(;'

Figure

2-12

power

snowmobiles

or

to

a very lean 1

slow

the

L

r"..

and maxi-

ratios

another speeds

and

the

engine

"'I

"

q,

~

it

fo

are us-

that

the

ranges

:17

the

flow

fuel

is

is cold,

""~

~

<'<,

0""

""

~

carburetor

The

fuel

and air

somewhere to the engine and

rider's

in

load.

Theory

Carburetor operation is based on

ciples when a fluid and (known

pressure as 2-13).

of

fluid

encounters

as a

undergo

VELOCITY

an

LOW CONSTRUCTION

must

have

for

extremes

in

between.

needs by

the

exact

&

Operation

dynamics

(such as air) is

venturi

incr

ease

it

passes

I~IGH

supplying

quantities

an area

or

in

through

VENTURI

VELOCIT~I

the

ability

of

power

The

carburetor

demanded

. These

constriction), velocity and a decrea se

principles

flowing

of

the

UJ::=:qC

HIGH LOW PRESSURE

PRESSURE

Air

is

drawn engine. This the

large

section,

point

in

then

the past a time

(one second).

the

point

soon be a severe

carburetor. To

with the

same

point

in

air

entry

no loss.

entry

in

the

achieve

Figure

in

from

flows

section and

of

amount

the

venturi

If

venturi

pressure

the

through

If

1000

the

carburetor

of

only

in

one

the

2-13

air

the the cc

air

(1000

in

the

900

cc

::Iecond,

build-up same

to

meter

or

economy

fuel

and

the

basic

state

through a tub

smaller

the

venturi

LOW

VELOCITY

: 6

HIGH

PRESSURE

sil

encer

carburetor,

smaller

of

air

flow

in

one

cc)

must

same

amount

could

there

in

front

flow

volume,

the

and

responds

air

to

the

by speed

prin

that

e

diam

eter

fluid

will

in

(Figure

into

the

both

venturi

past a

second,

flow

of

flow past

would

of

the

-

2

-14

CARBURETOR

a

ir

how the tube

flow

must

much constric . The

.

flow

faster

tion

smaller

faster

through

depends on

or

venturi

the

is

venturi,

the

how

than

the

venturi

much

the

rest

faster

. Exactly

smaller

of

the

air

cross-sectiona l area

The

A2 = 3.14 x 13

A2=3.14x169

of

the

venturi

is:

2

41

mm

-,--

-'--

Figure entry The carbur

The

2-14

diameter

venturi

etor

.

velocity

shows a carburetor

of

air) is inversely area of the

the

entry

tube. To

and

equations:

1 =

1T'r

A A2 = 1T'r2

1 2

2

Figure

of

41

mm

dimension

the

air

(or a single

proport

find

the

ventur

2-14

with a maximum

and a

venturi

is

the "size"

"particle"

ional

to

the

cross-sect ional

the

cross-sectional area

i use

the

26m

of

26

of

follow

,-,-

'-

in

m

'-

mm

the

of

ing

A2 = 520.66

The ratio

of

mm

A 1

2

to

13

19.585

A 2 is:

520.66

of

the

The area than

the versely throug than

h the ve

through

Occurring drop in duced

air

pressure carburetor sect

ion.

Under

the

venturi

sure in

the entry

as atmosp

area

proportional

heric

venturi

of

the

entry.

to

nturi

is

the

entry

along

with

pressure

in the

allows

to accelerate

average

will

be

approximately

(which

pressure).

the

conditions,

Metering System

The carburetor consists systems to supply The main system,

mix

fuel

(Figure 2-15).

is

handled

with

supply

air

fuel by a pilot

as

it

2'f3

is

about

Since

the

about

tube

2-112

the

area,

2-112

.

velocity

venturi

air

flowing

through

60%

is

approximately

of a number

and

air

as

fuel

pump

system,

and

is needed by

or

2.53:1 .

time

s less

velocity

is

the velocity

times

greater

increase is a

region.

This

through

the

venturi

the

press

ure

of

the

pres-

the

same

of

separate

required

and

starter

float

the

. Fuel

bowl.

system

engine

in-

re-

the

in

Where: A 1 is

the

area

of

the

entry

A 2 is the area

r1

is the radius (112

r2

is th radius

1T'

is a constant.

express A1 and

larger

the

The cross-sectional area

3.14 x 20.5

3.

14 x 420.25

1319.

entry

585

of

the

of

the

3.14 A2

in a ratio to

is

than

2

mm

2

venturi

the

diameter)

venturi

the

of

find

ventur

i.

the entry is:

the

how

ent

ry

much

The Float Bowl

The float fuel for the The ca

rburetor . The

cavity is vented

inside the

the

Fuel level and a needle valve.The valve seals of

fuel in the

and the needle valve sea

l. fuel bowl, the contact fuel.

the

main

float

bowl.

rides on

against

This a

pump

with

bowl

(or

other

and

pilot

chamber

to

bowl

in

the

bowl

llows

to

flow

floats

rise,

the

valve seat,

THEORY

float systems

systems; and

is

attached

upper

the

atmosphere,

is

the

float

needle

drops,

moves

fuel

pumped

into

the

pushing

AND

chamber) is

which

to

portion

same

bowl

as

is

controlled lower arm,

and

valve seat.

the

floats

down

from

bowl.

the

shutting

OPERATION

the

meter

the

starter

the

bottom

of

the

so

pressure

end

of

the

When

away the

As

fuel

nee

dle

off

air

the

upper

drop

tank

enters

valve

the

source

the

fuel;

system.

of

the

chamber

pressure

outsid

by

floats

needle

end

the

level

slightly,

from

the

by

the the

into

flow

2-15

of

e

of

AIRFl

REDUCED PRESSURE

..

t

FUEL

LEVEL

FLOAT

The

fuel

level

affects

will

run

throughout

this

is

the

drop venturi. phere, so psi) float sure is on the bowl,

which

running,

the atmospheric fuel

acting

level in leased 2-16).

The

low, not

and

starting and lean

too high, too

and

is adjusted by

towards bending

Always

The

float

there

pushing

bowl.

pressure in

of

the feed

float

the

be

into

the

down

When

including

lead into the

the

pressure

in

pressure

the

bowl

on

the

fuel

fuel in

into

able to pull

the

tube

the

level is

decreased

the

air much

engine

the needle valve lowers the fuel level,

it

away

set

the

Figure

how

its

entire

in

pressure

bowl

is a

pressure

on

the

engine

surface

the

is

up

air

would

bending

fuel

of

fuel

venturi.

in

feed

acting

much

in

the

feed

tube

into

the

stream

important

pressure

enough stream. This mixture

fuel

run

frm

the

level

2-15

rich

or

lean

the

range. The reason

that

occurs

is vented to

of

1.03

surface

is stopped,

all

the

inside

When

the

venturi

tubes

on

the

greater

feed tube. Therefore,

ratios. If

is pulled

the

at

than

rises, venturi

as

tiny

at

low

in

the

fuel

up

would

too rich. The

tab. Bending

valve raises

the

kg-cm2

of

the

fuel

this

fuel

in

the

"feed

the

engine

is less, and

is also less. The

surface

the

pressure

pushing

where

droplets

out

the

into

correct

the

it

(Figure

speeds. If too venturi

of

the

cause hard

fuel

level is

the

venturi

float

the

level.

engine

for

in

the

atmos-

(14.7

in

the

pres-

float

tubes"

is

of

the the

fuel

is re-

would

bowl

level

tab

and

level.

Figure

Metering performed by a system has a range is effective,

system takes up and This system to components are tem, illustrates

the

"overlap"

another

pilot

system and

the

fuel

number

but

insures

overlap

and

the

air

of

throttle division another

will

be

throttle

starter

between

the

Throttle Slide

The

amount mined in a closely

the

carburetor body. The controlled by a cable and closed"

the slide the slide is raised through slide is in a venturi, venturi

or

air slide. This is the

most

is used on all Kawasakis.

At

lower

throttle the

cutaway throttle. mixture

higher coming air. The

stant

at

of

air

enter

ing

by

the

throttl

e slide. The

fitting

position,

for

the

and the area

in a venturi. The size

passage changes

common

throttle

slide affects

The

will

cutaway

any

bore

little

the

air

to

venturi

known

is higher

be

and

lower

constant

position,

as a variable

type

positions,

felt

most

at a constant

offers

fuel

supply

directly

or

flow

higher,

into

under

found

mixture

the

less

throttle

2-16

in

the

proper

separate systems. Each

positions between leaves transition

smooth

slid

e,

system . Figure 2-

the

carburetor

throttle

above

movement

spr

ing. In

no space

through

more

the

engine.

it

blocks the of

the

with

the

on

snowmobiles

the ratios.

from

about

cutaway,

throttle

resistance

remains

position, and

amounts

in

which

where

off

is gradua

from

. The

slide becomes a

venturi

cutaway

metering

main

fuel

components.

is

deter-

slide rides

the

venturi

of

the

slid e is

the

"fully

remains

the venturi. As

air

actual

position

The

the

position. The

relatively

will

When

part

venturi

type. It is

effect

1/8

to

leaner to

the

under

of

is

it

one

l.

one

sys-

17

in

flow

the the

the

and

the

of

1/3

the

in-

con-

the

2-16

METERING SYSTEM

MAXIMUM

T

EFFECT

J_~~~--L....--~

MINIMUM

PILOT

0

SYSTEM

1/

8 1/2

THROTTLE

3/4

FULL

additional the

cutaway, richer adjustment made carburetor

mixture.

from

air

results the

of

the

idle

(Figure 2-18).

in a

greater

The

fuel/air

to

the

leaner

air

slide

full

mixtur

flow

cutaway

ratio

as

venturi

THROTTLE

e. The

resistance,

provides

the

transit

action

Figure 2-

lower

and

for

ion is

of

the

POS

ITION

17

slide,

jet

needle,

a

soon as venturi asse mbly, the system full system

there

to

draw

components

throttle

only

. The

needle

is

enough

fuel

up

main

throttle

in

that

OVERALL

LENGTH

jet,

into system meter

slide

it

carries

and

the

main

air

flow

through

the

main

jet/needle

takes effect. The

fuel

from

1/ 8

is

part

of

the

jet

needle.

jet.

main

throttle

the

main

As

the

jet

to

t

CUTAWAY

t

Figure

Main

Four separate with

System

the

air

systems

: The

main

the pilot system for low

starter

The

the

system

largest

main

to

assist

portion

system. The

of

2-18

meter

system

speed

starting

the

mete

components

the

fuel

for

normal

running,

with

a cold engine.

ring

is

are

and

mix

runn

and

performed

: The thr

ott

ing,

the

by

le

it

The

jet

up and

Figure

needle rides in

down

with

the

2-19

the

throttle

slide. The

THROTTLE

FIRST TAPER

SECOND TAPER

slide

and

moves

needle

SLIDE

itself

2-

17

is

tapered end. Figure

needle. The needle is tapered in double engines. The length

tions

needle, rounded indicates

than

indicate the taper

stands the bottom

15'

indicated by the would of showing

needles used by referred actually cates the groove in

6DH3-3 well

groove

at

its

lower

end and has grooves

2-19 show

taper

of

. The

60

for

grooves), and

(15 letter B and so on. A needle marked 6DH3

be

10 and a

as

from

needle is used in

marking

the needle and

first

number

off

that

the

mm

in length. The

the taper

taper. The

minute)

the

letter

between

bottom

the

taper

Kawa

to with

stamped on

would

telling

refer

that

the top.

s a typical double taper j

two

larger

s on a needle indicate

the

taper

is

the

overall

to the lowest

needle is

of

the

taper

increments

60

another

the

at

each section. The

of

the top

second l

angles are graduated in

A a

taper

and

70

taper

angles

saki. Needles are

the

needle.

which

to

the

clip

10

least

50

lett

ers

section

etter

with a taper

of

30'

mm

with

of

20.

Refer

of

the

number

This

the

clip belongs. A

needle

should

be in

stages. This

two-stroke

of

length

mm.

mm

on

the

stands

indicated by

a top

double

sometimes

which

number

described, as

at

its top

et

the

both sec-

of

the

Thus

a 5

but

less

needle

first

letter

(closest to

for

the

of

15'

taper

to

chart taper

is

not

indi-

the

third

CLEARANCE

NEEDLE TAPER ANGLES

00 15'

A

00 30'

B

00 45'

e

0

D 1

E

F 1

G

H

The top

slide, and the tapered

jet

. The

needle center jet

jet. The inside the diameter the Subtracting the ameter between

The clearanc e is 0.1

20,

slide is closed. When rises

of

is fed fuel

non-tapered

outside

of

the

out

0'

10 15'

0

30'

10 45'

0

0'

2

of

the needl e is

jet

fits

the

venturi.

from

the

diameter

section

of

the

needle j

diameter

the

jet

gives

them.

2.680

-2.512

68

needle blocks

of

the

jet

fastened

end

extends into

in

the

The

low

float

of

the

of

the

et

used is 2.

of

the

of

the

mm mm

.

168

mm

mm.

As

the

jet

the

slide is lifted,

until

the

0

I 2

0

2

J

0

K 2

0

L

3

0

M

3

0

N

3

0

3

0

P 4

to

carburetor

er

end

of

chamber

jet

is

needle

680

needle amount

is

needle

shown

when

tapered

15' 30' 45'

0'

15' 30' 45'

0'

the

throttle

the

needle

body in

the

needle

by

the

main

greater

. The

2.512

from

of

in Figure 2-

the

section

than

insid

mm

mm.

the

clearance

throttle

needle

the

e

and

di-

ar-

Figure 2-

rives at taper and

With

bowl and

and the needle. The double serves

amount amount

Changing the position amount

the

is

to

the

needle as

the

throttle

is

drawn

through

to

accelerate

of

of air

of

upper

increase

available fuel. The needle is moved by

end

of

the

clearance

the

needle is

slide raised,

by reduced pressure,

the clearance area

the

flow

fuel

can keep

in

higher

throttle

of

the

20

jet.

fuel

taper

rate

up

needle

The

effect

between

lift

ed.

from up

into

between

of

the

of

the

fuel

with

increasing

positions.

changes

of

the

needle

so

the

jet

float

jet

the

L

the

2-

18

THROTTLE SLIDE

moving needle .

the

clip up

Moving

needle delays

the

mixture

(because

Raising mixture

2-21

).

. This is

if

the the by

advancing

the

clip

needle

or

down

clip

towards

fuel

flow

known

goes up,

(lowering

the

fuel

in

the

increase,

as

lowering

the

needle the flow

grooves

the

on

top

of

leaning

the

needle

the the out

sits lower).

clip)

richens

the

increase (Figure

PRIMARY

CHOKE

RESERVOIR

GROOVE

PRIMARY

ENTRANCE

LEANER

2

3

4

AIR

PRIMARY

NEEDLE

JET

5

RICHER

Figure 2-

The which past

primary

surrounds

the

/

passages in

jet

in

the carburetor. Air pa

ssages and

with

Figure 2-21

the entrance atmospheric venturi

Around needle and sectional fuel

flow

3/ 4

throttle, the

the

area

is

determined

jet

becomes

of

the

main

by

the

clearance

grea

ter than

jet.

At

size

of

between

the

cross-

this point, th

the

main jet.

differential.

a

ir

arr

e

the as

needle

ives at

reservoir,

they

jet

type

needle

the

point

needle . Th is reservo ir is

the

carburetor

front

(away

from the

flows

into

the

fuel

and

is

drawn

to

this

passage is

pressure

depression.

The size

leave the

(Figure

the air

Air

of

reservoir

helps

center

2-23).

jet

at

body

in

this

reservoir

out

and

the

flow

the

jet

with

break

metering

22

has a "reservoir"

which

the

fuel

connected

to

engine)

jet,

into

a very

where

the

small

end

through

it

venturi.

at a point

exit

is

subject

is aided by

is

very

high

up

the

pressure

small,

velocity.

drops

portion

exits

of

mixes

of

near

so

of

by

air the the

The

to

the

At

fuel

the

The

needle enters engine dropl fuel

. Fuel

ets

spray is vaporized by atomization venturi improves

the

venturi for

rather

jet

pre-atomizes

enters

than a flow

of

the

final

the

venturi

or

fuel

in the needle

burn

the engin ing

engine.

Atomization buretor

needle

fuel, all

on lar

ger

of

the

fuel in is accomplished by use jet

. The

owing

two-stroke

primary

rich er

type t

mixtures,

engines

the

fue

l be

atomization

in a spray

dribble

. The atomized

e heat. The

efficiency

a s

nowm

obile

of a "primary

ends

to flow

and

is used

(Figure 2-22).

fore

into

of

jet

of the

type"

more

mostly

the

tiny

and

car-

it

Surro which

unding

extends up

two-thirds

needle . This lip creates a res

ervoir extra the as a choke the of

the

more richening taller jet

to

greater

and

vacuum

float

bowl.

primary

determines

amount

needle

turbulence

of primary achieve

needle

effect

The I ip

choke. The

of

extra

jet. A taller

the

choke

approximate

of

the

into

the

venturi

generates

vacuum

behind

are located.

helps

pull

on

the

needle

height

the

amount

depression

primary

and

suct

ion,

mixture

allows

at

use

higher

ly the

THROTTLE SLIDE

reservoir

in

front

turbulence

the

lip

where

At

high

RPM,

more

fuel

jet

is

of

the

of

turbulence,

at

the

venturi

choke

will

leading

RPM.

of a smaller

same

mixture

is a lip

of

the

which

the

this

up

from

known

primary

and

exit

create

to

Using

main

ratio

2-19

a a

at

full

throttle

in

the medium

The needle

2-24

is a

jets

of

the

PRIMARY

but a decr

throttle

jet

is id e

ntified

chart for ident

primary

MAIN

JET

type.

CHOKE

ease

in

position.

by its diamete

ifying the

RESERVOIR

fuel

consumption

size

r. Fi

of

gure

needle

The adjustable outside

of which turn into jet poi the closed and

closed posi the the metering creases in

ratio richer.

Wh

throttl

jet

livered

This

mately

sectiona l area

and

sectional area there than of available.

of

the

float

the

screw

can be varied

open. The

the

main

system

metered

nts

(10

main

en the

e slide

determine

working

th

e needle

are no restrictions

the

main

fuel

jet tion

jet

can pass

the

main

cutaway,

the

for

the

relationship

3/ 4

throttle. At

restrictions

jet

metering

indicates

metering

flow.

size steps) can be obtained

one

only

screw

main

system

amount

of the clearance

jet

becomes

of

the

determines

screw

bow

l.

A plastic cap on

from

screw

which

A variable range

turn

the

amount

through

is

turned

system,

begins

needle, needle jet, and

of

main

to

of

the

is located on

the

adjustment

closed

air

continues

this

to

nearly

allows

supplemen

open position . In

of

fuel

the

main

open

making

to

meter

fuel

that

entering the engine.

point,

between greater jet. When

fuel

main

how

than

flow

jet;

much

fuel

ts

metered by system.

fuel

the

should

until

the

this any

and

fuel

the

head

setting

one

to

bleed

the

main

of

between

flow in-

fuel/air

fuel,

main

be de-

approxi-

cross-

needle

the

crossoccurs, greater

the

will

the

full

100

the

As

the

size

be

The last jet buretors). The the float the cover only removed removing jet carburetors jet

component

and

bottom

to

insure

through

meters screw.

the meter

bowl

of

for

the

all

equipped

0

N 2.

0

P

Q

550

2.

600

2.650 2.655

2.700

Figure

of

ing scre w (not on all car-

main

jet is attac hed to

cover.

the need

the

carburetor

fuel

An

that

fuel

main

cleaning

to

with

1 2 3

2

.555

2.605

2.705

2-23

the

main system

the inside

"0"

ring is used

le jet

assemb

can enter th e needle

jet. The

or

from the eng in

the

main

an adjustable

2.560

2.610

2.660

2.

710

ly to

main

changing

e.

system

NE

EDLE JET INSIDE DIAMETERS

2.

2.6 2

.665

2.715

is

the

main

to

seal

the

float

jet

can be

without

The

main

except on

metering

565

15 2.

of

jet

4

2.

570 620

2.670

2.720

Main

jet

size is indicated by

on

the

jet. There are

each

with a different

25

shows

pares

bers stamped on

Use extreme care replacement

numbers

the

engine

their

can

each type

flow

of

the

result

will

(MM)

different

numbering

of

rat

es in cc per

the

jets.

when

same type.

in

not

run

jet

changing

total

properly

5 6 7 8

2.575

2.625

2.675

2.725

2.590

2.630

2.

680

2.7

30

2.595

2.635

2.685

2.

735

the

number

types

of

system. Figure 2-

and Figure

minute

main jets. Use a

Matching

confusion

.

2.

590

2.640

2.690

2.

740

stamped

main

2-26

to

the

only

as

2.595

2.

2.695

2.

num

to

9

645

745

jets,

com-

-

the

why

,

2-20

THROTTLE

SLIDE

Figure 2-

24

AMAL

REVERSE

~-=r

l=r

.256 in. (6.5

~

400r---~----~

300~--~--~----+---~~~

C

~200~--~~~-7~+---~--~----

U

mm)

Figure 2-25

~~

----,---

.138 in. (3.5

mm)

~

-,--~~

----+---~

---.

+---~

~

THROTTLE

SLIDE

~

VENTURI

PI

LOT

BYPASS

PI

LOT

OUTLET

-I

#100 #150

Pilot

Fuel and air throttle or slow series pilot meter air. At opening proper

Fuel is trudes series of where ways. These before

(Figure 2-28).

Air ca The pilot increase in air

The

System

openings

of

jet

amount

drawn

into

the a ir

it

for

t.he

rburetor

taper

system .

passageways

to

meter

the

holes

enters

pilot and is

air

screw

fits

supp

low main

of

through float

drilled

is

holes

the

system

flow

in

the cent

#200

Figure 2-26

#250

(Figure

ly

at low

is

controlled

The

pilot

system

in

the

fuel,

and a

engine

fuel

introduced

all

venturi through

metered

is tapered

speed and

system

chamber. The

ow

as

can

or

air.

the

pilot

in

its body

fuel

to

enters

from

by

to

the screw

er

of

#300

#350

2-27)

speeds

by

carburetor

pilot air

from

be

the

provide a

a passageway,

and

the

pilot

system,

consists

body, a

screw

small

thrott

not

provide

jet

which

pilot

jet

at

the

passage-

mixed

the

pilot

is backed out.

with

pilot

front

air

gradual

small

of

to

le

the

pro-

has a

point

air

outlet

of

the

screw.

and

a

Figure

PILOT JET

Figure

2-27

2-28

o 0

[J

POWER

JET

SYSTEM

2-21

turning passageway. The

1 to 1-

If

the

screw the of justment changing

At tion) carburetor bypass. enters When venturi from mixes

the

screw

3/4

turns

pilot

mixture

out

further

air

scr

ew

in

air

supplied,

of

pilot

jets.

idle speeds (very

air

from

the

is

supplemented

At

these

from

the

throttle

increases, and

both

the

with

the

all

normal

out

from a lightly

appears

will

farth

er

resulting

mixtures

low,

air

passage in

almost

pilot air

is opened,

outlet

air

flowing

the

way

in closes

air

screw

too

lean

the

will

cut

in a richer

can also be effected by

"closed"

by

closed

passag e

fuel/air mixture and

the

through

setting

seated position.

rich, backing

mixture. Turning

down

the

mixture. Ad-

thr

ottle

the

front

air

from

throttle

air

settings,

and

flow

through

bypass,

the

now

where

venturi.

the

is

from

the

air

amount

posi-

of

the

pilot

air

bypass.

the

exits

it

Fuel/air somewhat mixtures. tion entering

Starter

Starting flow mixture. hot overcome these mixture provide these added to sists which carburetor lifted air throttle engine

ways from Here

buretor Atomization

emulsion

an the starter

it,

similar These float enters the atomization through

mixtures

richer

Low

does

not

the

engine.

System

a cold

and poor

In a cold

enough to vaporize

than

that

the

of a jet

opens

and

by a cable.

inlet

passage and

slide is closed,

must

. This creates

the

bowl

it

is mixed

and

drawn

of

tube, a long

fuel

and

jet

is

drawn.

to

the

holes

allow

chamber

of

small

metered

than

engine

promote

engine

atomization

engine

difficulties

provided by

richer

carburetor air

come

into

through

to

the

passages (Figure 2-29).

mixtures, a starter

to

meter

passages

into

Lifting

through

enough

the

with air

into

fuel

for

This

pilot

a small

be mixed

below

fuel

by the

mid

speed

good

presents

the

requires

. The

the

venturi.

the

outlet

the

chamber

from

the

venturi

starter

tube

which

tube

jet

and

amount

the

allows

pilot

-range, at

low

atomization

problems

that

require

engine

droplets

the

pilot

starter

fuel,

from

the

The

plunger

to

the

air

that

the

starter

suction

below

the

front

and

mixtures

which

the

has holes

air

bleed needle jet.

of

with

the

starter

it

to

flow

system are

partial

throttle

of

parts

of

fuel. To

an eve n

system. To

system is

system

and a

venturi.

protrudes

fuel

plunger

front

plunger

uncovers

goes

passage-

to

draw

the

plung

of

the

engine

is aided by

from

drilled

air

from

fuel

before

plunger.

more

throttle

posi-

the

fuel

low air

a rich

are

not

richer

con-

of

the the

If

the

to

the

fuel

er .

car -

into

the

The

easily

is

in

it

Figure

The rotor, (Figure 2-31), also called

has

four

magnets evenly spaced ference. tates rent

The points and condenser act

the as a nition vents voltage points as tension sion coil

Electrical

The

.

tail

headlight ignition

CUlt snowmobile

4. Power to operate

erated in the

As

the

crankshaft

around

in

low

switch

coil pr

the

coil,

inducing

the

low

tension

coil induces a high voltage

which

coil Voltage. The

to open and close

imary

the point

from

s separate.

causes

winding

jumping

System

snowmobile

/ stop li

beam

switch, light

board. A

's

electrical

ght, headlight

switch,

regulator,

schematic

electrical system is

the

electrical

lighting

coil on

2-29

the

about

the

turns,

coil.

the

, brake

speedometer,

representation

the

flywheel

an

alternating

together

ignition

the

. The condenser pre-

the

gap

Discharging

spark plug

system

and a

shown

components

the

engine

circuit

between

in

the

to

consists

light

tachometer

printed

to

flywheel

circum-

ro-

cur-

turn

off

points act

to

the

ig-

the

low

high

ten-

fire

.

of

switch,

cir~

of

the

in Section

is

gen-

flywheel.

,

l

a

Ignition

The breaker condenser

plugs. See Figure

spark

2-22

STARTER SYSTEM

System

point

(capacitor), breaker points, coils and

ignition

2-30.

system consists

of

Torque

A

a

torque torque Th verter

converter

is converter consists

mounted

Converter

sensing, variable ratio, sheave -type

is used to

to

the

drive

basically

power

the

of a drive

take-off

snowmobile

con-

of

the

en-

.

i -

1 . Condenser

2.

Breaker Points

3.

Permanent

4.

Low

Tension

(Primary)

5.

Ignition

6.

High

7. Spark Plug

Switch

Tension

Magnets

Coil

gine, a through which verter

driven

the

chain

transmits

to

the driven

converter

case and

rotary

motion

converter

which

gearing,

. See

drives

from

the

track

and a V-belt

the

drive

figure

2-32.

Figure

Figure 2-31

con-

2-30

1. Rotor

2.

Magnet

3. Coils

4. Breaker Point

5.

Starter

6.

Condenser

Plate

s

method

The converter converter as needed by through hills

. The

maximum

Torque

o rive

The

drive

to

prov

of

snow

of

transmitting

by

means

enab les

varying

clutch horsepower

mUltiplic

the

snow

automatically

Converter

converter

ide

maximum

and load condi

of a belt

ation

track

to

depths, and up

at

all

on

the

snowmobile

performance

tions

power

pull

operating

from

to the

of

the

shifts

engine

snowmob to

conditions

System

is

under

(Figure 2-33).

the

drive

driven

torque

and

down

maintain

designed

all

types

ile

.

1. Drive

2.

3. Driven

Converter

V-Belt

Figure

IGNITION

Converter

2-32

SYSTEM

2-23

How

eve

r, the main funct

control the engine RPM through the shi

ion

of the

weights

ft

pattern.

is

to

1.

Roller/

2.

Spider Ass

3. Spring

4.

Mov

able Sheave

5.

Ra

mp

6.

Drive Be

7. Sta

tionary

Figure

Weights

embly

lt

Sheave

2-33

The ramp is designed so the peak file is the ter

istics

torque

major

of

the

curve

factor

shift

the

of

the

in

determining

pattern.

shift

engine

Driven Converter

The power the drive

dr

iven converter. The

closed positions the outside

that drives

converter

by

the driven

the

belt

circumference

the

track

through

driven

torque

at idle, or

the

convert with

of

the

pattern

. The

the

is

transm

T.C.

belt

converter

er

spring

the

engine

driven

is w i

ramp

charac-

itted

to

is held

. This

off

flanges

thin pro-

from

the

at .

There are

fo

rmance char

They are as

1. Spring

2.

Weights

3. Ramps

The

primary

the ini

sheave and engine pattern. A enga sulting

A heavy ment

down

"set"

of

spring spring

The drive trol gage throughout taken e weight

low

tial

RPM

gement

in speeding up

or speed and the shift

after

its

total

tension

length.

converter

engine RPM. A

ment

not

ngine

er

damage

will

engine

thr

ee variables

acteri s

follows

function

engagement

T.C. belt. The

throughout the

weak

speed and

strong

patt approximately length. However,

RPM, and the

to

exceed specified

decrease

RPM

tics of the

:

of

betw

or

light

spring

maximum

ern. The

will

occur

contains

lighter

total

shift

will

occur. By

engagement

throughout

maximum engine the

that

will

change

drive convert

the spring

een

spring

shift

will

engine

drive spring will

50

mil no significant

due

six

weight

maintain

patt

s is

the

movable drive

spring

driv

e converter

will

decrease

patt

ern.

incr

ease engage-

RPM, but sl es, and lose 1/4" to

the

weights th

will

high

ern. Care must be

engin

contra

RPM, and also

the

shift patt

the

per-

to

con

tro

also

affect

shift both

RPM, re-

ows

ta ke a

loss

decreased

at con-

increase e

er RPM

e RPM

st, a heavy

ern.

er.

of

n-

or

l

s

1. Spring

2. Torque Bracket

3.

Movable Sheave

4. Drive

5. Stationary Sheave

As th e engine speed increases are spread apart all small

er

diamet

flange diameter varies the

matica

be

lly providing

tw

een

er

the drive and driven

Fi

of

Be

lt

gure

owing

the

Assembly

2-34

the

flanges

most

the driven

belt

. This change

drive

favorable ratio

converter

flanges

to

ride on a

ratio, auto -

for

of

the

2 -

24

ELECTRICAL

SYSTEM

speed and load at

(Figure 2-34).

which

the

machine

is opera

ting

Cha

The converter

sprocket, housed sealed drive

The top (drive) tached by

tom shaft from

in

Case and Gearing

chain

case provides a

shaft

and

the

drive

within

housing

chain

sp

(driven) sprocket is

by splines.

the

driven

cha in and

the

chain

which

. See Figure

sprocket

lines

to

the driv

The

converter

mounting

front

case. The

contains

2-35

in

attached

drive

chain

to

drive

driven

.

the

en

converter

the

for

the

shaft. The

sprocket are

chain

lubricant

chain

case is at-

to

the

transfers

track

drive

track

case is a

. The bot-

Track, Suspension, and

Steering

The suspens ion system consists

slider and

The

track

mobile. provided by the arms justment can also be steering

the

provides

Support

attached

for

control.

System

skis. See Figure

flotation

for

the

sliders.

to

the

sliders

the

weight

adjusted

of

for

of

2-36.

and

propels

track

and

Adjustable

allow

the

rider(s).

snow

the

track

the

suspension

spring-loaded

suspension

Suspension

conditions

driven

drive

for

the

drive

power

shaft.

and

snow-

ad-

and

is

1. Chain Case

2. Drive Sprocket

3. Driven Sprocket

4. Drive Chain Figure

2-35

Figure

2-36

DRIVEN

CONVERTER

2-25

Two

skis are mobile bar

at

wear

and aids in

tem

connected

steeri ng

for

the

steering

bottom

arm,

attached

control

of

steering

to

the

tie

rod and

the

Maintenance

to

the

front

and

flotation. A wear

ski

protects

control. The

ski consists

handlebars

of

the

ski

steering

of

a spindle,

.

snow-

from

sys-

Two-Cycle

Engine

Inspection

Inspect residue evident.

the

engine

around

and

mating

flanges. Replace seals

Compression Check

A

simple rope noticeable resistance.

Use a compression gage ment. A compression reading cylinder

than

cylinders.

compression check is

slowly.

10

is

minimum

percent

The

starter

. There

difference

for

Fuel System

Carburetor

to

rope

accurate

of

should

between

flanges

if

pull

should

90

to

be no

for

leakage is

the

starter

display

measure-

95

psi per

more

the

two

oil

Pilot

Air

1.

2. Idle Speed Figure

Screw

2-37

Fuel Tank and Lines

Inspect lines and

the

fuel

connections

tank

for

leaks .

leaks

Screw

Also

or

check all

kinks .

fuel

The

pilot

air

screw

112

to 2

turns

engine

however, mid should

adjustment

The 6 tight). Use a and

idle speed is

may idle

range

be

idle speed

turns

adjust

problems

throttle

adjusted

range. See Figure 2-37.

out

from

tachometer

the

2,000

Fuel Pump

Inspect loose

fit

the

or

fuel

leaks .

Fuel Filter

Inspect the replace it.

fuel

should

out

from

smoothly

may operation . The

for

screw

the

idle speed

RPM. See Figure 2-37.

pump

filter.

the

occur

best

should

coil

bound

to

screw

and pulse

If

normally

seated position.

out

in

idle

be

measure

it

is

be positioned

of

these

the

transition

pilot

within

adjusted

(screw

engine

so

that

line

dirty

settings;

air

screw

the

correct

from 3 to turned

speed

the

engine

clamps

or

leaking,

An

to

in

for

Throttle Control Cable

With

the

engine

from

the

carburetor,

full

throttle

1. The

2. The

throttle

opens fully.

throttle

grip.

If loosen the locknut, and screw Figure 2-38.

on the

off

and

the

hold

the

position and check

slide inside

lever is

adjustment

throttle

tight

of

the

cable as required. See

air

silencer

throttle

that:

the

against

throttle

turn

carburetor

Enrichener Control Cable

With

the

enrichener

of

the

enrichener

mm)

of free

39.

movement

NOTE: Engine

richener inch (1.5 mm).

cable free

lever

cable

should

when

flooding

movement

at

off,

the

have 1/ 16 inch

raised. See Figure 2-

may

occur

is less

removed

lever

handlebar

is required,

the

adjusting

outer

casting

if

the

than

at

the

bore

(1

en-

1/ 16

.5

2-26

TRACK.

SUSPENSION.

AND

STEERING

SYSTEM

If adj

ust

ment

the

loosen obtain the co

loc

of

knut

rrect

the

enrichener

and

turn

clearance.

cable is required,

the

adjusting

screw

to

Ignition

System

Ignition Coils

1. Locknut

2.

Adjusting

Figure

Screw

2-38

Ignition ever,

checked

coils do

they

for

not

should

tightness.

require regular service;

be kept clean and

the

Condenser

Make

sure

all

pecially In spect

the

Buildup condenser.

the

movable

connections

condenser

contacts

contact

on

stationary

are

tight

and clean, es-

hold

down

for

metal buildup.

indicates

contact indicates shorted

screw.

weak

Buildup condense

Points

Check tion. Check the

are severely pitted .

the

points

contacts

every

100

to

150

hours

for

gap and condition. A gray color

is

normal.

Replace

the

points

Ignition Timing Adjustment -

Static

1. If

the move the

muffler

move

ignition

the

timing

muffler

up

to

manual

requires

mounting

rest on top

starter

and

adjustment,

nuts, and

of

the

engine. Re-

fan

pulley

how

terminals

on

of

opera-

of

if

they

re-

swing .

-

r.

NOTE: allows

cylinder

adjusted flywheel. spark may are accessible wheel.

2.

3.

4.

1.

1/16

L

2.

3.

Adjusting

Inch (1.5

Locknut

Figure 2-

mm)

Screw

5.

39

The

cutout

the

adjustment

. The

through

If

the result

See Figure 2-40.

Adjust mm). When

stator plate

Turn tation

(3.5

full

rotated wheel), and hold position to adjust

Rotate points break (buzzer changes dims slightly), and mounti

Re-check change

one set

the

until

mm)

advance (levers against

towards

the

ng screws. See Figure 2-41.

after

on

the

left

side of

of

the

points

engine

B.T.D.C.

the

for

the

right

the

cutout

points

. The advance

through

of

properly adjusted, loosen

mounting

in

the

dial

the

stator plate assembly

timing

tightening

on

the

are

out

of

both

cutouts

points

the

Move

outside

the

to

screws. See Figure 2-41.

normal

indicator

the

the diameter

flywheel

magneto

tighten

to

be

the

flywh

points

mechanism

screws.

for

the cylinder right

tolerance, a

0.

014

direction

is

at

advance levers

stop

and levers

base assembly.

tone

the

sure

can be

side

in

the

inch (0.35

0.

139

pins when

of the

in

until

or

the

stator

it did

eel

left

of

the

weak

levers

fly

the

of

ro-

inch

to

fly-

this

the

light

plate

not

-

FUEL

SYSTEM

2-27

6. Install plug hole and continuity wire.

Adjust

indicator

the

and

the

dial

indicator

connect

light

to

the

points

reads

advance levers are at

0.139

into

the

to break

inch (3.5

the opposite

the

opposite spark

timing

ignition

when

mm)

full

buzzer

advance.

or

coil

the

dial

B.T.D.C.

Ignition Timing

Dynamically

curate

spark plug and

cylinder

pointer

marks. timing clutch

1/16"

another

make drive clutch. before top dead center, (39.69 the

top dead and connect a Remove converter guard. Run

the

aim correct,

the

on engine

Do

or

timing a warm

method

using a dial indicator .

which With mark

aligned

(26.99

mm)

the

timing

the

clutch

speed is

of

will

the

piston

on

the

with

mm)

mark

Timing

in

the

center

timing

torque

light

and

6000

timing

find

be used

stationary

the

for

on

for

counterclockwise

mark. Replace

light

converter

the

at

will

flash

the

\WARNINGI

not

exceed

serious

engine

damage

Check-Dynamic

engine

any engine. Remove on e

top dead

at

top dead center, make a

pointer.

every degree

the

stationary

the

ASTRO is

which

to

the

engine

the

pointer.

as

pointer

RPM.

speed

is

the

most

center

Make a fix

to

check the

sheave

Now

would

the

high tension

belt

and secure the

at

6000 If the

the

measured mark

are align ed when

of

7000

will

result.

for that

ed rigid

of the drive

measure

of

timing

sheave

25

degrees

be

1-9/1

dire

cti on

spark plug

RPM and

timin

RPM

timin

ac-

and

of

the

fro

wire.

g is

g

6"

m

Cutout

1.

2.

Advance Lever

Figure

in

Flywheel

2-

40

Repeat If

essary

the

ignition

adjustments

above procedure

timing

is in correct, make the nec-

to obtain

for

the

th e

correct

oth

er c

ylinder.

timin

g.

\WARNINGI

Do

not

start

the

convert

er

guard

engine

in

place.

without

the

driv

e

Cleaning, Inspecting, and Gappi ng

the

Spark Plug

Normal

and

rect spark plug heat range. See

plugs have

slight

electrode

brown

wear.

to

greyish

This indicates the cor-

-tan deposits

figure 2-42.

1. Stator Plate

2. Breaker Point

2-28

IGNITION

Mounting

Figure 2-41

SYSTEM

Screws

Carbon posits

tion,

overchoking,

Figure

fouled

which

2-43.

2-42

plugs

may

be caused by

weak

·

show

coil,

Figure 2-

dry,

over-rich

or

worn

fluffy

43

black de-

carbur

cables. S

e-

ee

Worn

out, eroded electrodes and a pitted

are

indications

plugs

for

smoo

ther

Wet, oily deposits carburetor

low

speed operation,

or

worn

breaker points. These plugs can

degreased and reinstalled. See Figure

of

better

fuel

engine

adjustment

performance. See Figure

long service. Replace old spark

economy,

may

be caused by

being too rich, prolonged

improper

quicker

the

fuel-to-oil

insulator

starting

2-44

low

speed

mixture,

usually

2-45.

and

.

be

1. Gap Washer

2.

Figure

Burned electrodes indicate timing, can cause

Inspect spark plugs electrodes. Clean Adjust (0.5 ground center Figure 2-47.

Before

washer

head is clean. to

18

the

to

2-44

or

blistered

low

octane

this

condition

gap to

0.6

mm)

. In regapping, adjust side electrode. Do electrode;

installing

is

installed

Install

20

ft. Ibs. (2.5 to 2.7 kg-m).

Figure

insulator

overheating

fuel

or

. See Figure

Figure 2-

for

cracked porcelain and

the

electrodes

the

specified

the

insulation

the

spark plugs, be

and

the

spark plug and

and badly eroded

. Improper spark

lean

46

0.020

not

attempt

seat on

2-45

fuel/air

with a point

will

mixtures

2-46

.

to

0.024 only

to bend

crack. See

sure

the

cylinder

tighten

worn

file.

inch

the the

the

it

Figure

2-47

Electrical System

Ignition

The ignition graphite once a year. The vent

freezing

cold

weather.

NOTE:

lubricant.

Headlight

Adjustment The

headlight

horizontally. To

check the

front

of

wall

and

See Figure

The

headlight

the

snowmobile

is

off

to

light

using

Figure

Switch

Do

the

snowmobile

illuminate

2-48.

the

2-49.

switch

of

not

aim

beam

. If

right

should

the

ignition

use an excessive

can be adjusted

of

the

25

the

low

should

the

aim

or

to

the

horizontal

graphite

switch

headlight, feet

beam

be

of

left,

adjusting

be

lubricated

(7,260

of

directly

the

headlight

adjust

with

will

also pre-

in

extremely

amount

vertically

position

mm)

from

the

headlight.

in

front

beam

the

head-

screws. See

of

or

the

a

of

Do

not

clean sandblaster. Grit cylinder severe damage.

during

old

spark

may

engine

be

released

operation

plugs

with

into

the

causing

Measure of

the

sion measured (reference mark).

a

NOTE:

mobile vehicle aiming.

IGNITION

the

distance

headlight

Be

when

from

and

sure

an

operator

the

engine

creeping ahead and

DYNAMIC

from

mark

is

TIMING

the

floor

to

the

wall

at

See Figure

is seated on

running

to

assure

CHECK

the

center

the

dimen

2-48.

the

snow-

prevent

proper

2-29

-

the

Replacement

1.

Wall

2.

25

Feet

3. Reference

4. 2 Inches

1-+-----(

(7,620

Mark

(51

-

mm)

Center

mm)

------

Below

2

).------,=--i~

-- --

- - - -

--~-

4

Of

Headlight

Reference

to

Mark

Floor

Replace headlight, placing

turb

light

1. Remove the

2. Push

3. With

Install the removal.

the

headlight

through

the

bulb

the

headlight

bulb

as

follows:

headlight.

down

counterclockwise.

"top" See Figure 2-50.

socket can that towards

for

the

retaining

the socket is

the

headlight

bulb

from

the

access

from

inside

adjustments.

wire

while

proper indexing

be

pulled

top. See Figure

bulb

the

harness

turning

The

retainin

ring removed,

out

of

installed

in

the rear

hole in

the

the hood does n Replac e

connector

the

retainin

g ring is marked

during

the

with

ihsta!lation.

the

headlight. Note

the

2-50.

reverse order

hoo

the

from

bulb

wid

of

the

d.

Re-

ot

dis-

head -

the

g ring

and

e tab

of

Illuminate the

high

the

reference

the

vertical

the

beam

adjusting

Figure

high

beam . For proper

should

mark. If

be 2 inches (51 adjustment

screws. See Figure

2-48

headlight

mm)

is required, use

aim

below

2-49.

1. Retaining Ring Wide

2.

Tail/Brake

Replace the tail and brake the

lens, secured by 2

the

lamp

from

the

Tab On Socket

Figure

Light

screw

socket. See Figure

Speedometer

The speedometer cable year . Remove speedometer and

the

should

cable

lubricate

2-

50

light

bulb

by r

s, and

from the rear

the

be

lubric

cable

then

2-5

ated once a

with

emov

removin

1.

of

graphit

ing

g

the

e.

1. Horizontal

2.

Vertical

2-

30

ELECTRICAL SYSTEM

Adjusting

Figure 2-

Screws

49

Voltage Regulator

Check the connection on voltage regulator. clean and tight.

Make

the

sure

circuit

the

board

from the

connection

is

(

If

e

ngine

is

run

disconnected, all

with

the

lights will

voltage regul

burn

ator

out.

[

Circuit Board

Check s

ure

the

connectors on

they

are

clean

the

circuit

and secure.

board

to

be

o

1. Fixed Sheave

2.

Movabl e Sheave

Converter Center Distance Adjustment

Th e converter (262

mm)

. See Figure

Figure

center

On

Drive

On

2-52

distance

2-53.

Converter

Driven

should

Converter

be

10.3

Figure 2-51

Converters

Drive Converter and Driven Converter

The

converter

(11

.5

mm) fixed sheave on the

driven

If

adjustment loosen ing frame, and slide necessary

set. Tighten (5.15 kg-mi.

the

alignment

as

measured

the

converter

of

bolts

securing

to

obtain

the

engine

the

Alignment

(offset)

from

drive

converter

movable sheave (Figure 2-52).

converter

the

engine

the

0.454 mount

should

the

back face

alignment

engine

left

inch

bolts

to

the

to

the

or

(11.5

to

be

right

mm)

30

0.454 of

the

edge

is re-

mount-

as

off

ft. Ibs.

of

-

If

adjustment quired, case and the The nected from case, inch nut 2-54. the clip.

loosen

driven

and chassis and

from

the

turn

(262

the

Install

converter

yoke.

the mm)

of

the the locknut

the

chassis by While setscrew

center

chain

the

secure

Figure

converter

four

support

pushing

case

driven

2-53

mounting

for

the

arm

removing

forward

as

required

distance.

mounting

converter

the

clevis

center

nuts

adjusting

Tighten

distance

on

the setsc

must

be

discon

the

clevis

on

the

to

obtain

the

nuts. See Figure

support pin

with

chain

rew.

chain

10.3

lock-

arm

safety

is

-

to

TAIL/BRAKE

LIGHT

2-31

1.

Locknut

2.

Setscrew

3.

Mounting

l~

Nuts

Figure

Drive Converter Special

Correct

inches (262 mm), and

0.454 ment tween

2-55.)

Converter

Alignment

205207

converter

inches

gauge PI N

drive and driven

center-to-center

(11.5

205207

Alignment

mm)

2-54

and Driven

converter

is obtained

is

correctly

converter

Gauge

distance

offset

sheaves. (Figure

Center-To-Center Distance

1. Remove

2. Rotate sembly

between sheaves. sheave assembly reta in gauge and moveable sheave

3. Rotate drive is correctly positioned in

If

adjustment

4. is required, loosen ing

converter connected from clevis pin case fore case screw port jam pin assembly.

belt

guard

driven

clockwise, and

converter

of

nuts

and

support

from

or

aft

mounting

and secure

bea

ring arm

nut, and

connect

and remove

converter

Carefully

allowing

in

posit

ion assemblies

assembly

the

converter

the

four

adjusting

bearing

the

chassis by removing

the

yoke. Position

as required.

nuts

securely. Tighten

with

bolt

to

drive

moveable sheave as-

insert

ali

gnment

release moveable

spring

between

.

until

the

alignment

center

chain

setscrew

arm

must

Tighten

jam

nut. proper chassis

length

with

Using

of

10.3

distance when installed

case

. The driven

align-

belt.

gauge

tension

stationary

hex

gauge.

distance

mount-

be dis-

the

Adjust

, lock

the

clevis

be-

to

shaft

the chain chain

set-

sup-

the

1.

Alignment

Offset

1. Correct mm) tionary gauge

2.

If mounting

bolts. tionary gauge. Tighten all

Distance

off-set

is obta ined

sheave

when

adjustment

Slide

sheave

Parallelism

1.

When distances, measuring Figure against Notes

checking

2-56A.

Tool

Figure

distance fits

gauge is position ed

is necessary, loosen

bolts and

engine

the

parallelism

dimensions

Compare

I,

II, and III.

2-55

0.454 inches (11.5

when

fits

mounting

drive

into

recess

two

back and

into

recess

center-to-center

must

A and B as

dimensions

205207

converter

of alignm

on

hex shaft.

four

engine

muffler

bolts securely.

be

forth

in

che

mountin until

alignment

and

offset

cked by

shown

A and B

sta-

ent

g

sta-

in

2-

32

CLUTCH CENTER DISTANCE

ADJUSTMENT

NOTE

sion B.

I:

Dimension A must

be

more

than

dimen

-

NOTE

3ion

NOTE

B,

2.

II:

Dimension A must

B

by

more

III:

If

dimension

correct

If parallelism driven be adjusted as

a. Loosen and rotate

b. alignment the

correct

offset

dimension

pulley

engine the

Loosen

chassis

chain "U"

position

than 1/16

as described

between

and

NOTE: Never use

washers

per

bolt.

A is

A is less

engine

is

not

correct

follows

engine

washers

. See Figure

and

Or

case

chain

more

:

muffler

into

mounting

than

never

exceed

inch (1.6 mm).

more

than

dimens

in

Offset

than

. Parallelism

the

as required

case spacer

2-56B 2 ali

Dista nce.

dimension

crankshaft

mounting

correct

bolts. Install

to

.

gnment

dimen

ion

B,

and

must

bolts

position

between

obtain

"U"

-

.

Drive Belt

Inspe

tween To remove

1.

ct

the

the teeth,

Remove guard forward.

drive

the

at

the

See

1.

Figure

belt

or

drive

safety

top, and

Figure

Spacer

2-568

for

worn

ply

separations.

belt:

which

2-57

areas, cracks be-

secures

swing

the

.

belt

the

belt

guard

1. Distance

2. Distance "

3.

Alignment

"A"

8"

Gauge PI N

Figure

2-56A

DRIVE

205207

CONVERTER AND

2.

Disconnect from from

DRIVEN

1. Belt

2.

3.

4. Clevis Pin

the

the yoke.

Guard

8elt

Guard

Driven

the

chassis

Converter

Figure

driven

CONVERTER

2-57

converter

by

removing

ALIGNMENT

Support

Arm

support

the

clevis

arm

2-33

3. Rotate the movable towards towards

required to apply sheave. See Figure

the

rear

of

steering

half

the

post.

the

2-58.

vehicle

of

the

driven

while pushing

Assistance

brake while

sheave

may

be

rotating

it

Use

caution

from

the under and

4. Roll the verter. Then relea Figure

a heavy

hands

2-59.

IWARNIN

when

driven

drive

converter

clear when

belt

removing

spring

up and

se

the

G'

the

drive

belt

sheave sin

load.

Keep

relea

sing

off

movable sheave. See

sheave.

the

ce

it

fingers

driven

is

con-

1. Drive

2. Driven Converter

3. Driven

4. Install the chassis, and secure clip.

driven

Belt

Converter

Figure

converter

Movable Support

2-59

the

Sheave

Arm

support

clevis pin

arm

with

to

the

safety

5.

Work

the

silencer,

verter.

To install the

With

1.

2. Open the

3. Roll the

the converter, and

around

ease

installation

pulley, being and

position

Figure

drive belt

then

remove

new

belt:

drive

belt

work

the

driven

drive

belt

careful

in the

2-58

past

in

position

the

belt

driven

converter

converter of

the

over

not

driven

the

carburetor

it

from

the

around

past

the

support

movable sheave

drive

belt.

the

top

of

to

pinch

converter.

and

drive con-

the

carburetor

the

movable

your

fingers,

air

drive

arm.

to

5.

Position

the safety clip. Close the hood and lock

6. the

NOTE:

in the same

Drive

DO

CONVERTER. drive

shifting

failure

Clean the year. Use a rag dipped in acetone remove

No. 260 and No. 320 No.

400

the

clutch

hood latches.

Always

reinstall

direction

guard

used be lt so

as it

Converter

NOT converter

water

emery

LUBRICA

Any

lubricant

will

drastically

characteristics, resulting

and

reduced

drive

converter

and oil. Remove

cloth

drive belt

emery

.

and secure

it

did

TE

sheave

rust

cloth and

into

position

it

will

original

THE

applied

ly.

DRIVE

to

change

in

clutch

life.

surfaces liquid cleaner

or

rub

ber

polish

it

with

rotate

the the

once a

to

with

J

.

2-34

DRIVE

BELT

D riven

Converter

"..

Lubricate

perature sliding vent contact

Brake

Check converter slight brake lever mm)

all

grease .

surface

to

remove

surfaces

Adjustment

the

brake

when

ramp sliding surfaces

Lubricate

with a graphi

.

brake adj

can

be

drag

movement

apply

grease

moved

ing

and

ustment to

back

on

the

is less

the

brake. See

brake disc

the

te

lubricant.

rubber

be

and

than

with

movable

Use a

from

sure

the

forth

with

and

3/4

Figure

low

sheave

the

driven

just

that

inch

2-60.

tem-

sol-

belt

the (19

a

1. Brake

2. Brake Disc

3. Bra

Adjusting

ke

Pads

Figure

2-61

Nut

Figure

2-60

(WARNINGI

DO

Component could

If brake nut

wh verter gin

to move

NOT

result.

adjustment

ile si

back

OVERTIGHTEN the

multan

and

with

damage

is

eous

forth

the

or

required,

ly

moving

until

the

disc. See

personal

turn

the

brake

Figure

brake.

the

driven

pads

2-61.

injury

adjusting

con-

just

be-

Chain Case And Gearing

Drive

Drive verter to track shaft

If

adjustme

ceed as

J

1 _ Loosen

Chain

chain

sheave

112

inch (9.5

drive

does

follows:

the

driven

of

the

properly

Adjustme

tension

shaft not

nt

of

the

snowmobile

tensioned

is

outer

to 12.7

sprocket

rotate.

the

chain

locknut

converter

correct

edge can be

.

mm)

with

tension

and

sheave

to

allow

when

setscrew,

nt

the

freely

(Figure

one

hand

is

required,

towards

the

driven turned

2-62). Hold

then

chain

so

the

con-

3/8

drive

pro-

rotate

front

to

be

1. 3/ 8

to

1/ 2

Inch

(9.5

Figure 2-62

to

12.7

mm)

DRIVE

CONVERTER 2 -

35

2.

Turn and

the

adjustment

tighten

setscrew

the locknut.

until

it is

tight

urity

of

c alignment components.

fasteners (nuts, bolts, etc.). Proper ski

cannot

be

maintain

ed

with

worn

Chain Case and Gearing

Lubrication

The drive chain operates

and is lubricated by a

level described Jet

for To Remove

top (fill plug) and ure

Pour Sno through tom

Install the upper and case cover.

should

below.

Chain

th

fill

2-63.

Lubricant

is appl ication.

the

chain case:

the

plugs

Jet

the

top hole

hole

lower

be checked every

If

bottom

Chain

edge.

in

special

filling

which

in

the

Lubricant

until

lower

an enclosed

chain oil.

is required, use

is specially

chain

case cover,

(oil level plug). See Fig-

into

it

is level

plugs

chain

20

formulated

the

chain

with

into

The oil

hours

only

at

the

case

as

Sno

the

case

bot-

chain

Ski Alignment

Alignment each season,

hard side impact. ponents

follows:

1. Place a long board (or against

clearance

the same ure

should be checked

whenever

or

are replaced. Check

the

edge

between

ski

so

that

at

the

front

2-64

.

when

of

the

clearance

and rear

the

at

the

beginning

ski is subjected

steering

the

suitable

track, and

board and ski. Position

ski

measured

of

the

system comalignment

straightedge)

measure

ski. See Fig-

is

of

to

as

the the

a

1.

Fill Plug

2. Oil Level Plug

Figure

2-63

Track, Suspension, and

Steering

The steering system checked

2-36

periodically

CHAIN

System

components

for

excessive

CASE

AND

wear

GEARING

should

and se-

DRIVE

be

CHAIN

1. Tie

2. Straightedge Measure

3.

2.

When the

centering

3.

If locknuts and in bar. See Figure

the

ski is parallel

track, check

.

the

handlebar

the

direction neces sary

NOTE: Be sure

straightedge ing

bolt.

while

ADJUSTMENT

Rod

End

Clearance Here

Figure

the

requir

turn

the

2-65.

the

ski

turning the

Against

2-64

to

the

steer ing

es

centering,

tie

rod end

to

remain

tie

Track

outside

han

adjusting

center

the

s parallel

rod

end adju

edge

dlebar

loosen

handle-

to

of

for

the

bolt

the

st-

J

Ski Runners

Excessively the

r

handling

the

bottom since the snowmob mended worn ner

replacement.

Suspension

The

1.

Tie

2. Locknuts

3. 1-1 / 4

If

the

dimension

exceeds 1 Sect

ion 3 and

system

components.

Rod

End Adjusting

Inch (

Figure

I

WARNING

-1/4

inch

check

32

mm)

2-65

shown

(32

for

Bolt

Maximum

'

in Figure 2-65

mm),

damaged

refer

steering

to

slider

comfort The

adjustments

on

the

on each side

arms

.

R ide Adjustment

Ride

adjustment

tension

justment driver

worn

ski

runners

of

your

snowmobile.

of

each ski

wear

rate depends on

ile is operated on. Replacement is recom-

at

when

any

the

point.

should

runners

Refer

can

The

be inspected

the

are

more

to

section 3 for

greatly

runners

surface

than

Adjustment

suspension

.

suspension springs. A

of

the

rear

nut

will

or

passenger

is

consist

the

front

is

controlled

arm

stiffen

weight.

fully

adjustable

of

changing

suspension

and rear

by

changing

only.

Tightening

the

ride and

See Figure 2-67.

the

suspension

carry

reduce

on

often,

the

3/4

ski

run-

for

rider

pre-load

spring

the

ad-

more

is

4. To align towards

move the stee

end to obtain an equal distance when

skis. See F

the

adjust

ing bo

measured

other

center of the

ring

linkage play.

lt

(located

at

the

igure 2-66

ski, move both ski tips

front

.

snowmobile

Turn

below the

from

and rear

the

tie

muffler)

ski

of

to

re-

rod

to ski

the

Rod

End

1. Tie

2. Equal Di stance Front

5. Tighten all the

steering system.

the

Adjusting

Figure

hardware

2-66

Bolt

And

Rear

(nuts, bolts, etc.) in

Front

1.

2. Rear Suspension

3.

4.

5.

Suspension

Adjustment Adjustment Suspension

Figure

SKI

Nut Nut

Springs

2-67

ALIGNMENT

Arm

Arm (Ride) (Handling)

2-37

Always

springs equally can

cause

68.

adjust

on each

. Excessive t

the

spring

pre-load

side

bre

(tension)

of

the

suspension

ension

akage. See

of

one

Figure

of

the

arm

spring

2-

2. The clearance strip

to

the

top

(19

mm)

when

shock absorber upper

2-69.

from the

of

the

track

measured

mount

bottom

should

of

be 3/ 4 inch

directly

below

bolt. See Figure

the

wear

the

Figure 2-

68

Handling Adjustment

The

handling

the

spring

ure

2-67.

AllY changes to snowmobile's

are

tightened,

harder pressure . Loosening the the

suspension

ground, causing change in ski pressure

ing response.

adjustment

tension

on the

of

the

adjusting

handling

the

front

ground

to

have less

the

is

controlled

the

front

arm

nuts

characteristics.

of

the

suspension

and

results

nut

s causes

pressure

ski

pressure

will

affect

the

only. See Fig -

will

to

vehicle steer-

Track Tension Adjustment

IWARNINGI

While

ground,

object

personal

raising

place

and

secure

injury

the

.

snowmobile

skis

against a stationary

the

vehicle

to

by

changing

change

If

in

the

increase. A

off

prevent

the

nuts

presses

less ski

front

on

the

of

1.

3/4

2. Shock

Inch (19

Absorber

Figure

mm)

Upper

2-69

Mount

Bolt

1.

With

the

track

completely

the

snowmobile

10

to mid

2-38

pound

point

SKI RUNNERS

so

it

(2.2 to 3.6 kg) we

of

the track.

off

cannot

the

fall,

ground,

then

ight

brace

hang a 8

from

the

1. Rear

2.

Locknut

Axle

Figure

Adjusting

2-

70

Bolts

)

3. If necessary, requir

as

to

-track clearance. See Figure

4.

When the proper tens

both ad

measured

bracket.

turn

ed to

obtain

justing

bolts are

from

See Figure

the

rear axle

the

ion

the bolt

2-70,

spec ified

is

the

same

head

Track Alignment

.... , W-A-R-N-'-N-G-',

To

prevent

alignment while the engine is running.

injury,

never

measure

adjusting

2-70.

bolts

wear strip

attained, be sure

to

length

the

when

rear axle

track

-

Storage

Preparation for Storage

1.

Wash the snowmobile from

2. Remove buretor running fied T.C. gine fler

outlet cates the vent carbu retor.

snowmobile.

by hosing

the

suspens

the

and

at idle

W.

when

pipe occurs. This proce

internal

rust. Replace

ion.

air

intake silencer

start

the

eng ine.

speed, slowly

oil

into

the

excessive smoking

engine co

air

Thoroughly

off

all

With

inject

carbure

tor

mponents

intake sil e

dirt

from

. Stop

from

ncer

clean

and

the

B.I.A.

the

dure

the

grime

car -

engine

certi-

en -

muf

lubri-

to pre -

on

the

-

Remove the and push slowly a few check the al

The track the

rear

on both sides. If the

adjusting turn, alignment

the

idler

track

bolt

then

.

weight

ignment.

is

runs

restart

from

throttle

revolutions,

aligned

wheel

See F

on

and edge

to

one

the

same

the

only

when

igur

the

track, start

enough

then

stop

the

distance

of

the

e 2-71 .

side,

tighten

side,

approximately

engin e and recheck

the engine

to

turn

the

engine

between

track is equal

the

rear axle

track

and

1/2

the

3. Siphon

4. Lubricate

5.

Plug the openings muffler

6. Replace the fuel

7. Check the

8. Remove the

DO CONVERTER.

9. Apply a l verter

10

. Block the

ground'to and track.

remaining

th

e suspe nsion and steering

outlet

NOT

sheaves to

with

chain

drive

LUBRICA

ight

coat

rear

remove

fuel

from

of the

filter.

case

prevent

of the s

weight

a rag

lubricant

belt.

TE

of

oil to both

air

the

fuel

intake

or

rust. nowmobile

from

silencer

masking tape.

level.

THE

driven

the

tank.

column.

and

DRIVE

con-

off

the

suspension

Idler

1.

2. Edge

3.

Wheel

of

Track

Dimension

Fi

Equal On Both Sides

gure

2-71

11

. Loosen

the

12.

Cover the

and dust. Store the

13. area.

the

track

rear axle adjus

tension

snowmobile

.

snowmob

ile

to

in

ting

protect

a dry,

Removal From Stora ge

1. Fill

2. Remove

the

the air

fuel

the

intake

tank

with

plugs

(masking tape

silence r and

TRACK

fresh fuel

muffler

ALIGNMENT

bolts to

it

from

well

ventilated

mixture.

or

rags)

outlet.

relieve

dirt

from

2-39

3. Remove sheaves pulleys

4. Install a Adjust

5.

6.

With

the

start

the

oil

from

using a suitable

must

be clean and dry.

new

drive

belt.

the

track

tension.

rear

of

the

snowmobile

engine. Rotate

the

driven

solvent. The

off

the

track

converter

clutch

the

ground

several re-

volutions alignment.

7. Check brake and

8. Replace of

operation. This

lubricate

on

the

at

low

the

spark plugs

the

engine

old spark plugs.

speed and check

throttle

will

control

after

allow

dur

ing storage

adjustments.

the

first

the

track

112

hour

oil used

to

collect

to

2-40

STORAGE

17

.

REPAIR

Table

Troubleshooting . ....... ..............

Electrical Flow Muffler

Ai

r Intake Silencer . .... .

Carburetor . .

Fuel Pump Engi Removing

Recoil Starter ........

Air Shroud .

Flywheel Cylinder Crankcase

Brake

or

Emergency

Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-46

Headlamp

Ignition

Tachometer

Printed C

Tail Lamp

Light

Thrott

Brake Enrichener

Drive Converter . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Driven Converter

Chain Brake Drive Chain

Slide Rail Suspension ......

Front

Middle Idler Shaft and Wheels

Troubleshooting . . .

Charts

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

. .

...........

......

.....

ne

Removal

Heads, Cylinders

Light Switch,

Brake Lever

Switch

ircuit

Regulator Replacement ...

le Cabl e

Cable.

Case Caliper

Idler Shaft

......

External Components

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

Magneto & Fan Housing

Assembly . .

Assembly.

Stop

Switch

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

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

.. ..

.....

Board Replacement

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

....

. . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Cable

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

....

. _ . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

...

......

Replacement .......

and

..

.......

. . .

..........

...

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

...........

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

and

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

Dimmer

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

Wheels ........

Light

. . . . . . . . . . . . . . . . 3-45

or

Throttle

.

.........

... ...

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

....

..

. .

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

. . . ....

. . . ..

......

.

Pistons .........

.

..........

. . .

. . . . . . . . . . . . . 3-54

...

......

.........

.......

Switch

. .

..........

.. .. .. ..

........

.. ..

.

. .

.........

. . .

.......

. . .... . 3-64

....

.......

..

. 3·2

....

...

..

....

. . 3-22

....

. 3-27

..... 3-28

.

..

.....

...

..

. . 3-47

......

. 3-47

..

...

. 3-48

.....

......

. . . . 3-59

. 3-

.....

3-65

3·9 3-19 3·22 3-22

3-26

3-28

3·31 3-32 3-39 3-43

3-47

3-48

3-50

3-61

61

Of

Contents

Limiters . . . . . .

Rail Wear

Rear Axle and Wheels ....

Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . 3-

Fr

ont

Fr

ont

Suspension Rai ls . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Wea

Drive Repair

Steering and Skis ... . . . .

Repa

Steeri

Repair

Seat

Fuel

Str

and

Rea

and

Rear

r Strips

Shaft

of Drive S

ir

of

the Track .

ng

Arm

of

the Skis ... . ..... ............

...

..

Tank

...

.....

ips

........

r Springs .... .

Sus

....

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

and

Track

haft .......

and

Ski Removal

.......

......

. . . . .

pension

Arms

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

....

.........

. .

....

..

.........

.....

..

...

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

....

. . .

...

.......

...

.

......

.......

..........

...

.....

.

......

..

. _ . . _. 3-69

....

. . .

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

...

.....

.

.....

....

..

......

...

....

.....

..

. . 3-

.

..

...

..

. 3. 3-

, 3-73

65 65

3-66

66

3-

67 67

3-68

3-70 3-

71

3-71

3-74 3-75 3-76

TABLE OF

CONTENTS

3-1

Troubleshooting

Isolating a correcting

proach amount solved by

Identify

1.

2.

Determine

malfunction

the

trouble. Use a good sys

to

locate

of

time. All

following these

the

problem

cause of

is as

problem in

service operati ons can be

three

the

steps:

problem

import

tematic

the

ant

as

ap-

minimum

Obtain the troubl tenan

isol ate

is not detected as a terrelated portion

from

ce

history

the

enough

problems

guide

of Section 3 for

the

owner

e,

operating conditions, and

. In

trouble.

, and

. Use

in solving

problems exist,

an accurate descr iption

many

cases,

Sometimes

the

cause has created

the

problem. If addit ional

major

these

solving

Troubleshooting

refer

repair procedures.

will

the

other un-

to

appropr iate

of

main-

help

to

problem

Charts

in-

3. Correct

Engine does

spark.

the

problem

Problem

not

start

- no

Condition

ENGINE

1.

Key swit

functioning.

2.

Emergency stop

OFF

position

ing.

Spark

3. or damaged .

4. Plug cap(s) damaged, leaking or shorted.

5.

High

ground

6. Defective breaker poi nts.

7.

Defective exciter

ch

not

or ma

plug(s) fouled,

tensi

on wire(s) loose,

ed or

shorted

ON

or

switch lfun

.

coil.

ction

oiled

mal-

in

-

Remedy

1. Turn

2. place stop

3. Replace spark plug(s).

4. Replace

5. Service coil(s).

6.

7. Replace

switch

Move

Replace

switch

switc

plug

high

breaker exciting

ON

or

to

ON

h.

cap(s).

tension

points. coil.

replace .

or

re-

wire(s)/

Engine

get

fuel.

3-2

will

not

start

- does

TROUBLESHOOTING

8.

Defectiv

9. Defective i

10. Improper

We

11.

1.

not

Fuel Cracked, broken or

2. fuel

line

3.

Obstructed

in-line

4.

Carburetor

functioning

5.

Impulse

broken or pinched.

e condenser(s).

gnition

breaker

ak

flywhe

tank

.

filter.

el magnets.

empty.

or damaged

or fu el

.

line

is cracked,

coil.

point

pinched

pump

gap .

mal-

8. Replace condenser(s).

9. Replace

10. Adjust 11

. Replace

1.

Fill

2. Replace

3. Replace in-line

4. Serv ice or

the

5. Replace

fuel

ignition

breaker

the

flywheel.

tank

with

the

fuel

the

carburetor

pump.

the

impulse

coil.

points.

fuel.

line

filter.

.

line.

TROUBLESHOOTING (CONTINUED)

Problem

I

Engine

not

does

Engine fuel

will

not

start

get fuel. (cont)

will

not

start

not

ignite.

-

6.

Carburetor adjusted in-

correctly.

1. tor,

Air

silencer

-

Condition

leak

between

seal

or

carb

int

ure-

ake

6.

Adjust

1. Tighten nuts.

Remedy

the

carburetor.

mounting

bolt

and

manifold.

Carburetor adjusted in-

2.

Adjust

the

carburetor.

2.

correctly.

3.

Water

in carburetor.

3. Disassemble and clean carburetor.

4. Engine is flooded.

switch

OFF, re-

4.

Turn

key

move spark plug and dry it -

5. No compression

broken ri

hole in piston

ngs, scored piston,

or

(worn

damaged

or

crank engine over Install spark plug and engine. If

engine

flood, check

5.

Check compression, re-

place

worn

or damaged parts.

5-10

continues

carburetor

times

start .

.

to

cylinder).

Engine does

not

rpm fluctuates.

idle

or

idle

6.

Blow

n head gasket.

1.

Air

screw

adjusted

correctly.

2.

Idle

screw adju

correctly.

3.

Defective

fuel

valve).

Idle

4. bedded

screw

in main

broken and

carbureto

body casting.

5.

Impulse line cracked ,

kinked or broken.

6.

Enrichener

cable adjusted

incorrectly.

7.

Oil seals leaking .

8.

Air

leak (pressure

check engine).

sted

pump

in-

(check

em-

r

6. Replace head gasket.

1.

Adjust

2.

3. Service

air

idle

the

screw

fuel

.

pump

valve).

4. Replace the idle the

main

carburetor

screw

body

casting.

5. Replace

repair

impulse

or

line.

6.

Adjust

enrichener

cable.

7. Replace oil seals.

8. Disassemble and replace

or

worn,

defective,

damaged parts .

(check

and

TROUBLESHOOTING

3-3

Problem

Condition

Remedy

Engine develops runs on

one cylinder.

power

loss

1.

or

Fouled

plug(s).

2.

Obstruction

muffler

In-line filter

3.

4. Excessive carbon in

exhaust

5. Damaged

6.

Low

7.

Da

8. Damaged head gasket.

9.

Broken (

si

on

10.

Defective plug cap(s).

or

.

port(s

or

crankcase pressure.

maged piston.

shor

leads.

defective spark

inside

obstructed.

ted)

).

worn

of

buildup

rings.

high

ten-

1. Replace

2. Remove place

3. Replace

4. Clean

5.

Replace

6.

Check crankcase

replace oil seal

7.

Replace piston and related

component(s).

8.

Replace gasket.

9.

Replace

coil.

10. Replace

the

obstruction

muffler.

in-line

exhaust

the

complete

spark plug(s).

filter

port(s).

rings.

for

or

gasket.

ignition

cap(s).

or

re-

.

leaks;

Engin e over heats.

Engine backfires; has lar

running

Note: Engine may overheat.

condition.

eventually

irregu-

1.

Incorrect spark plug(s).

2. Cooling

Air

3. tor,

int

ders.

4. Caburetor adjusted in correctly.

5. Excessive carbon deposits in

combustion

haust

6. Damaged rings caused by excessive carbon

1. High s

horting

2.

Fouled or

plug (heat range too hot).

3.

Air

and

int

4.

Air leak betw

manifold and cylinders .

fin

leak

betw

ake

manifold

port or

tension

out

leak

between

ake

manifol

s obstructed .

een

carbure-

or cylin

chamber, ex-

muffl

er .

buildup.

lead

wire

.

incorre

ct spark

d.

een

carburetor

intak

e

1.

Install

2. Clean cooling

3.

Replace gaskets,

mounting

-

4.

Adjust

5. Clean affected

6.

Clean or replace rings.

1.

Replace

coil.

2. Replace spark plug stall spark plug having colder heat range.

3. Check make sure

4.

Install

gaskets.

correct

hardware

carburetor

new

spark plug(s).

fins

components

complete

it

is

not

intake

.

tighten

.

ignition

or

holder to

warped.

manifold

.

in-

....

3-4

TROUBLESHOOTING

TROUBLESHOOTING (CONTINUED)

Problem

Engine

Engine stops (suddenly) running

four

.

-cycles.

after

Condition

1.

Carburetor

ju

sted.

Dirt

2. and valve seat.

1.

2. fu el filter.

3. Fuel pinched.

4. Spark plug bridged.

5. Seized piston(s).

6.

7. Defect ive exciter

between

Defective Obstruct

Seized cranks haft.

ion

line

obstructed

incorrectly

needle valve

ignition

in

fuel

coil.

ad-

tank

or

Remedy

1.

Adjust

2. Service carburetor.

1. Replace

2. Clean

3. Remove move line

.

4. Replace spark plug.

5. Replace piston and

fected

6. Replace affected

7. Replace

carburetor.

ignition

or

replace

obstruction,

pinched

components

area

crankshaft

components

exciter

coil.

filter.

from

.

coil.

re-

fuel

any af-

and

any

Engine stops (gradually) running.

Drive converter engages be-

fore specified rpm.

Drive converter engages after

specified rpm.

after

1.

Obstruction

fuel fi Iter.

2.

Fuel line obst ructed

pinched.

3. Damaged head gasket(s).

4. Loose

5.

Loose spark plug(s).

DRIVE CONVERTER

in fuel

cylinder

tank

or

head.

1 . Incorrect spring.

2.

Weak

3.

1 . Incorrect s

2.

Incorrect

or

Incorrect

damaged spring.

we

ight

s.

pring

.

weights.

or

1. Clean

2. Remove obstruction, remove line.

3. Replace head gasket(s).

4.

Tighten

to

correct

5. Tighten spark plug(s) to

correct

1 . I nsta

Replace spri ng

2.

Install

3.

or

replace

pinched

cylinder

torque .

torque.

II

correct

area

spring.

weights.

filter.

from

head

1 . Install correct spring.

2.

Install

correct

weights.

fuel

nuts

3.

Dirty

movable sheave.

3.

Clean movable sheave.

TROUBLESHOOTING

3-5

Problem

Condition

Remedy

Drive

converter

specified rpm.

Maximum rpm

Shifting

drive

too

high.

drive

too

low.

too quickly.

engages

converter

after

4.

Worn

ramps

5.

Bushing

(flat spots) rollers

.

excessively

ter.

1.

Incorrect

2.

Incorrect

angle

too steep at to

3.

Short

center

1.

Incorrect

belt

to

heavy).

2.

Incorrect

angle

3. Long center

1.

Incorrect

too

belt

to

heavy).

in

hou

on

inside diame-

weights.

ramps

or

center

weights

ramps

flat

at

or

center

weight

sing

(ra

mp

p).

incorre

distance.

(too

(ramp

top).

incorr

ect

dis

tan

ce.

s (too

worn

ct

and

4. Replace ro ll

5.

Replace

quir

ed.

1. Install

2. I

nstall

Install

3.

correct

center

1.

Install

2. Install

3. I

nstall correct c

enter

Install

1.

components

correct correct

new

offset

distance.

correct

new

offset

distance.

correct weights.

ers

belt

and

belt

and

ramps

weights. ramps.

and

center

weights.

ramps

.

and

center

.

as re-

establish

to

establish

to

Shifting

Belt deposits

too

slowly.

on

stationary

sheave and moveable sheave.

converter

Drive engage at hard

and

idle -

stalls

will

not

dis-

engine

starts

because of

belt drag.

Incorrect

2. angle

3.

Weak

4.

Driven

correct

1.

Incorrect

2.

Incorrect

angle

3.

Spring

4.

Driven

too

ramps

too flat).

drive

spring

(too loose).

weights

ramps

steep).

too

strong.

spring

spring.

tight.

1.

Wrong

center

offset

distance.

and

1. Loose moveable bushing

2. Drive

ference

setscrews.

belt

outside

below

specification

(ramp

preload in -

(too

light).

(ramp

preload too

center

she

ave

circum

s.

to

-

Install

2.

3. Replace

correct

spring

4. Correct spr

1. Install

2. Corr

3. Replace

ect

correct

ramps

spring

4. Decrease

1. Remove

establish

nt

er

ce

1.

Stake

screws

Replace

2.

correct

to

center

movable

.

belt

drive

ramps.

.

in

g preload.

weights.

.

spring

deposits

offset

distance.¢

sheave set

belt

preload .

and

3. diameter tions.

3-6

TROUBLESHOOTING

Thickness

exceeds

of

belt

on

specifica-

insid

3. Check drive belt specifica -

e

ti

ons (be

dia

met

lt

er).

thickness

on

inside

TROUBLESHOOTING (CONTINUED)

Side not sive

of

belt

normal,

heat

buildup.

Problem

glazed

caused by exces-

or

baked -

1. In

correct

slippage .

2. Too under sli ppage.

3. spring

4. Drive ment

5.

operation

6. Drive

converter center"

7.

verter sheave

much

heavy load - excess iv e

Weak

.

rpm

Improper

Oil

or or

surface

Condition

DRIVE BELT

belt

- excessiv e

throttle

drive

conver

converte

too low

converter

"offset/cente

is incorrec

grease on

driven

r engage-

drive converter

(sticking, etc

conve

.

and

t.

drive

applied

ter

.).

driven

r to

con -

rter

1.

Inst

all

correct

2. Tell throttle dition; ins

3. test; s

pring

4. see

5. Remove converter; one

6. new

7. belt

driver

under

tall

Perform

install

is

weak.

Adjust

Check

Clean sheaves;

engagement

specifications.

is needed.

and

belt

if

one

Remedy

drive

to

decrease

heavy

new

spring

new

and

install

one

is needed.

pressure

spring

rep

new

adjust,

is needed.

load

belt.

air

drive

belt

install

belt.

con-

if

rpm -

if

new

Lugs

worn

B

elt

worn

Cracks

Rattle in

at

chain

off

in

base

inside

one

of

case.

spot.

belt

of

belt.

lug.

1.

Drive

converter suddenly too

2.

Center too too

1. Track frozen front drive

2.

Incorrect

3. Idle speed

4.

Improper

converter Continuous

snowmob

1. In

(engagement

high)

.

to cent

far apart

short

.

or

.

over

ile is operated.

CHA

correct

track

opera tion

chain tens

er

or

belt

to

skid

ground.

tension.

too

high.

revving

IN

CASE

engages

speed

distance

frame,

of

driv

when

ion.

1. Remove converter; one

2. distance longer

1. Free belt.

2.

install

3. Reduce idle new

e

4. Repair converter

Decrease

belt.

1.

is needed.

Alter

center

or

belt.

track

Adjust

new

belt.

Adjust

and repair

install

to

install

and

track

tension

belt.

rpm

or

replace

and

install

rpm

and

chain

tension.

new

center

install

and

drive

install

drive belt,

and

new

if

new

install

belt.

new

:-

2.

Chain

justable

stretched

limit.

beyond ad-

2.

Install

sprockets.

new

TROUBLESHOOTING

chain

and

3-7

Problem

Condition

Remedy

Chain

Edge

Track is grooved burnt

slippage.

slips

off

of track is

on inside s

sprockets.

frayed

.

(w

orn) or

urfa

ce.

1. In

correct

2.

Chain

justable

3.

1.

2.

3.

limit

Sprocket

Incorrect Sprocket

Sprockets

1. Track is

2.

Track tunnel, correct.

1.

Track

strikes

yet

tension

chain

stretched

.

teeth

chain

teeth

misaligned.

TRACK

misaligned

rivets

alignment

tension.

beyond

worn.

tension.

worn

is

too

.

in

is

tight.

ad-

1.

Adjust

2.

Install

sprockets.

3.

Install

chain

.

Adjust

1.

2.

Install

chain.

3.

Align

bottom

1.

ment.

2.

correct

1.

ment.

sprocket.

Set

track

Remove

type rivet.

Set

track

chain

new

chain

new

top

tension

chain

sprockets

tension

sprockets

sprocket

tension

rivets

tension

and

.

and

.

with

and

install

and

align-

ratchets or hits on

Track

tunnel

body Accelerated

Low

engine

sh

ifts

completely driven range

High take s driven

ratio).

converter

(1

to

engine

too

converter

(top).

rail s

rpm

1 ratio).

rpm yet be

long

to s

trip

w ear.

yet

belt

th

rough

operating

lt

hift

through

range

(1

to 1

2. Rear

turn

Track

idler

or

otherwise

tension

1. Slide rail(s)

2. Badly

tac

ts

3. Track is

Weak

1.

I

heavy.

Dirt

2.

ti

ona

worn

slide

rail.

misaligned.

DRIVEN CONVERTER

spr

ing

ncorrect

on

moveable

ry

sheave

wheels

is

bent

clip

or

spring -too

.

do

damaged.

too

loose.

.

that

broken

or

not

con-

spring

sta-

2.

wheels

and

Set ment.

1. install

2.

clip .

3. ment

.

Rotate end on crease stall

1. I nsta

2.

Install

Straighten

Install

Set

driven

Clean

new

and

alignment

track

tension

new

track

.

converter

spring

new

spring.

II

correct

sheaves

rear

set

track

.

slide

rails.

rail

tension

of

spring

tension

idler

tension

and

align

rail(s)

strip

and

clockwise

to

or in-

spri ng.

.

-

or

and/or

align-

in-

3. or

3-8

TROU

BLESH

OOTING

Excessi

stationary

vely

worn

sheave

moveable

.

3.

Install

new

components.

Electrical Troubleshooting Using

GENERAL DESCRIPTION

The

locating igni

ohmmeter

An

followi

.

Ohmmeter

ng

test

procedures are designed

tion

system

malfunct

ions using an

MAGNETO WIRING CONNECTIONS

for

1. CHECKING MAGNETO WIRING CONNECTIONS

a. The

ignition

wrong be done accurately. Only should be connected

b.

Use

move

the

TO

SAFETY SWITCH

wiring

coil uses couplers

connection.

the

flywheel.

flywheel

between

All

rotor

puller

Do

may be damaged.

the

wiring

wires

together

(a

special tool) to re-

not

magneto

to

prevent

connections

of

like

by

the

use a

hammer,

and any

must

colors

couplers.

or

TO

LIGHTS

s z

o S

....J 0

....J

a::

~

co

o

w

a::

EXC

COILS

ITER

BLACK

\'...

__

- CONDENSER

ELECTRICAL

TROUBLESHOOTING

LIGHTING

COIL

USING

AN

OHMMETER

3-9

2. Checking The Ignition

Do

not use

s

istan

large capacity).

Coils

an

improper tester (insulation re-

ce testers or other

Ma

gneto And

tes

ters w ith a

battery

of

To locate circuit, etc wi

nding

.

t

the

.)

cause measure

of

trouble (broken

the

~

o~OI

? +

resi

stance

coil. s

of

hort

each

PART TO BE M EASURED

MEASUR

RESISTANCE *

*

Re

sistance measuremen

otherwise

ED FROM

the

rea

ding will

EXCITER COIL (1)

RED TO GROUND

1.1

±

.H1

ts

on

the exciter

be zero ohms. Points

co ils

EXCITER COIL (2)

WHITE TO

must

may

be

1.1 ± .

be

made

opened

GROUND

H1

w ith

by

rotat

LIGHTING COIL

YELLOW

.2 ± .

the

poi

nts

ing

the

TO BROWN

02£2

open ,

engine

.

3-10

ELECTRICAL TROUBLESHOOTIN G

3. Checking The Ignition Coils

IGNITION

COIL

HIGH TENSION

VALUE

BE

MEASURED

RESISTANCE *

*

Remove wires

**

Defective coi ls

simulates

at

their

TO

spark

plug

connectors

cannot always

operating

--==:6

PRIMARY WINDING

RED

OR

WHITE

1.2 ±

caps

from

high tension

to

make

resistance measurements.

be

detected

condition

is the

/RED

c:::.e

=Jiiiiii<~

SECONDARY WINDING

TO

GROUND HIGH TENSION

.H1

most

wires

using

reliable

this

and

test

5200 ± 500n

disconnect

alone. Use

method.

,/

TO

red,

white

of

coil

OR

BLACK

GROUND

and

tester

which

WHITE

black

ELECTRICAL

TROUBLESHOOTING

3-11

4. Checking The Condensers

A good condenser

with

an

ohmmeter.

should

A shorted

TERMINAL

read open

condenser

CONDENSER

-

when

__

checked

will

not

-...~

allow condenser from its screw

any spark to be produced.

attaching

it before

mounting

measuring

MOUNTING

FOOT

Disconnect

base by removing

resistance .

the the

* The

condition

To

check condenser

ITEM TO

BE

CHECKED

RESISTANCE

of a

condenser

performance, a condenser

*

cannot

CONDENSER

TERMINAL TO MOUNTING FOOT

INFINITE (OPEN)

be checked

using tester

a resistance

must

be used.

measurement

alone.

3-12

ELECTRICAL TROUBLESHOOTING

5. Checking The Breaker Points

POINTS OPEN

I

..

MOUNTING

SCREW

TERMINAL

RESIST

* Resistance meas

from

the breaker arm .

ITEM

MEASURED

ANCP

urement

must

BREAKER

MOUNTING SCREW TO TERMINAL

be made

with

points

POINTS

INFINITE

open and

with

wire

lead removed

ELECTRICAL

TROUBLESHOOTING

3-13

6.

TROUBLESHOOTING - USING OHMMETER

the

NOTE: nection of

the

wires NOTE:

puller

following

troubleshooti

Connections

errors, couplers are used

flywheel

are color coded.

Magnet

(special tool)

must

magneto, and

removal; use

to

notes

ng procedures.

be correct . To avoid con-

remove the

the

when

for

ignition

flywheel

magnets

performing

connections

coil.

All

magnet

from

the

flywh

eel magneto. Never using a be damaged. Observe

The and possible To are defective, check listed ings obtained are previous tables, must be

hammer.

troubleshooting

conditions

determine

on

whether

the previous page. If

replaced.

not

the

attempt

The

magneto

table lists

which

the

magneto

the

resistance readings values

within component

or

crankshaft

ignition

would

or

the

resistance read-

the range given in

is defective and

to remove

problems

cause

ignition

them.

will

coils

the

Problem

No spark is produced

The engine starts pick up speed

but

will

not

ELECTRICAL

1.

Defective

coil (1)

2.

Defective

coil (2)

3. Defective mary

winding

4. Defective ondary

5. Shorted

6. Spark resistance should

7.

Wrong

8. Shorted condenser

1.

Defective

coil (1)

TROUBL

Condition

magneto

ignition

winding

point

s

plug is shorted -

between

be 1 M n

wire

connections

magneto

ESHOOTING

exciter

coil pri-

coil sec-

electrodes

or

more

exciter

Remedy

1. Replace coil (1)

(2)

2.

Replace

3.

4. Replace

5.

Replace

coil

ignition

points

coil

6. Replace spark plug

7. Connect

8. Replace

1. Replace coil (1)

wires

condenser

correctly

2. coil (2)

3.

4.

5. sistance should

6.

The

engine

but

will

The engine tends

3-

14

is cranked again

not

start

to

ELECTRICAL

1.

coil (1)

2. Defective magn eto

coil (2)

kick back

TROUBLESHOOTING

1.

Defective

Improper

Wrong Shorted

Worn Defective

Improper

magneto exciter

timing

point

gap

spark plugs. Re-

between

read 1 M n or more

poi nts

electrodes

magneto

timing

exciter

2.

Replace coil (2)

3.

Adjust

1500

4.

Adjust

5.

Replace spark plugs

6.

Replace

1. Replace coil (1)

Replace coil (2)

2.

1.

Adjust

rpm to

timing

rpm to

point

points

idle speed

2000

gap

rpm

to

idle at

rpm

for

1500

1/

7.

Electrical Troubleshooting -

Using A Condenser Tester

1. Remove

by removing

the

condenser

the

screw

from its

attac

mounting

hing

it.

plate

TERMINAL

2. Check the capaci measuring

te

rminal

between its

using a suitable

CONDENSER

tance

of the condenser by

mounting foot and

conde nser tester.

ITEM TO

MEASURED TERMINAL

CAPACITANCE

BE

CONDENSER

TO

MOUNTING FOOT

.18 uf

ELECTRICAL

TROUBLESHOOTING

3-15

Ignition

Stop

Switch

and Emergency

Test, Including

Associated Cir'cuits

1.

Disconnect board.

2.

Turn

the

on.

3.

Connect P,C. board into

(ohms X 1 scale).

4. If

the

open

(To

verify, activate should read O. activate emergency stop read 0.)

the

ignition

ohmmeter

that

ohmmeter

circuit

and

black plug

and

emergency

leads

engine

registers

the

switches

Turn

from

to

the

connector

infinity,

ignition on

ignition

switch,

engine

stop

two

was

ther

should

switch,

switch

meter

to

P.C.

switches

pins

on

plugged

e is an

be good.

meter

and

should

Be

sure to

ceeding,

5.

If

the rea connected to and 7 below.

6.

Disconnect fr om P. place

emergency

nector back

7.

Disconnect igni

from

P.C. board. If

P.C

. board. If

co

nnector back

black connector ohmmeter switch from

. If

P.C.

turn

ding

emergency

C.

board. If

into

reads

ohmmeter

board to

both

switches

is 0 or very low, keep

P.C.

board and proceed to steps 6

stop

ohmmeter

stop

switch,

P.C

. board and proceed to step

tion

switch

ohmmeter

into P.C. from

board and

back

infinity,

reads 0, replace

ignition swit

on

before pro-

switch

reads

infinity,

if

not

connector

reads 0, replace

re ads

of

infin

disconne

ignition switch,

replace

ch.

ohmmet

connect

plug con-

(white)

ity,

plu

igniti

wiri

er

or

re-

g

ct

If on ng

IGNITION

SWITCH

IGNITION

SWITCH

HARNESS

WIRING

BLACK

CONNECTOR

3-16

IGNITION

SWITCH

AND

EMERGENCY

STOP SWITCH TEST

Magneto

Light

Regulator Tests

Alternator

and

Headlight and Circuit Test

Headlight

These consistently

(Filaments barely overvoltage than

1. Raise

2.

3. Set

4. Set

tests

should

or

usually

broken

the

While

ground,

object, secured, to

Connect connector NECT FROM P.C. yellow brown

Do

ones.

the

rear

track

is free

ralsmg

place

and

be prevent

multitester

on

wire

wire.

multitester

ignition

not

activate

be

conducted

all

the

lights

light.)

the

sure

P.C

and

switch

Bulbs

have

melted

of

the

snowmobi

to

rotate.

the snowmobile

skis

against a stationary

the

personal

leads

. board. DO NOT DISCON-

BOARD

the

other

at

25

volts

in

"ON"

brake

light

if

are

which

vehicle

injury.

at

. Hook

to

AC. position

during

bulbs

extremely

filaments

is

engine one

fail

le.

Make

off

properly

lead

the

(lights

test.

burn

due

rather

the

(white)

to

black

out

dim.

to

sure

the

or

off).

Before neto properly.

1. Check

2.

proceeding

alternator

good . a.

Disconnect

b.

Connect

ground c.

Connect

high d.

Set

e.

If

ohms f.

Test moving filament

g.

If

Check to see connector.

a. Raise sure

and

to

see

one

terminal

the

beam

ohmmeter

headlight

the

terminal.

ohmmeter

the

filament

the

low

the

ohmmeter

to

the

the track

with

these

voltage

if

headlight

lead

of

the

other

scale

reads

is

faulty.

beam

lead

low

beam

malfunction

if

voltage

rear

of

is free

to

tests, be

regulator

bulb

connector.

the

ohmmeter

headlight.

ohmmeter

to

ohms

infinity

in

is

the

or

the

from

.

still

present

snowmobile.

rotate.

sure

are

filaments

lead

X 1.

more

same the

high

exists

, proceed.

at

mag-

working

are

to

the

to

the

than

way

by

beam

headlight

Make

2

Excessive 5

which

turned

5.

Start

the RPM. The If

the

and

voltage regu read s less it

reads probably increase RPM. If exceeded

placed. (Before tions

on

is

properly

With

6.

engine

regulator

When voltage

DO NOT

the

problem

wiring

age

does

shorted

voltage

may

on.

engine. voltmeter should

voltage

than 8-11 higher,

open

RPM

the

22

regulator

grounded

from

voltage

reading

RUN OVER

to

lighting increase

and

burn

reads

and

slowly.

voltage

V,

the

replacing

still

P.C.

regulator should

is in

should

may

lator

is in good

the

coil

exist

during

out

bulbs

DO NOT RUN OVER

read 8-

8-11 volts,

are

probably

volts, proceed

the

voltage

is

not

working.

DO NOT EXCEED

reading

running

board

2000

the

be replaced.

did

regulator

make

condition

to chassis.)

disconnect

(single

is

increase

RPM. If

magneto

from

P.C. board. If

regulator

test

if

lights

11

volts

the

magneto

OK. If

to

No.6.

regulator

To be

not

stabalize

should be re-

sure

and

yellow

disconnected

to

14-20

it

does not,

lighting

is

most

4 &

are

2000

AC.

sure,

3000

or

connec-

case

voltage

wire).

the

volts.

coil or

volt-

likely

is

it If

While

ground,

object, secured,

b.

Run

Set

c. d.

Check

wire

(low

(high

beam). Be

and

beam

high

or

e.

If voltage is beam, nection shorted is good, and

light

to

the

beam

test

.

raising

place

and

engine

voltmeter

check

to

the

be

to

prevent

for

voltage

beam)

switch

low.

headlight

P.C. board,

wires

proceed

switch.

switch

IWARNING'

the

snowmobile

skis

against a stationary

sure

the

vehicle

personal

at

2000

RPM.

to

25

volts

between

and

black

sure

light

switch

is

set

to

proper

not

present

in

headlight to

If

taillights, etc. work

test

and

tests

at

harness

check

harness

for

before

is

injury

AC .

black and

either

for

the

off

properly

.

and

green

is

turned

beam,

high

good

for

burned

. If

harness

beam

proceed

light

the

brown

wire

either

or

low

con-

switch switch

on

or

MAGNETO

ALTERNATOR

AND

LIGHT

REGULATOR

TESTS

3-

17

Light

1.

2.

3.

4.

5. Disconnect

6. Connect

7.

8.

9.

Switch

Disconnect from

P.C.

Connect

using Turn Ohmmeter

switch could be faulty.

Turn Ohmmeter

switch step 4 ing

If 0 the voltage regulator is OK, and lights, (headlights, tail, brake, etc) is be removed and inspected

key

from

was output

in

the

ohmmeter

ohms

or

ohmmeter

is was

P.C.

Test

white

board.

X 1 scale.

switch

should

wiring

switch

should

faulty. If it reads 0 and

infinity,

the

obtained in steps 4 and 8 above and

from

on.

from

on.

P.C.

the

board

ignition

between

read

O.

P.C.

from

between

read

the

board to

magneto

circuitry.

switch

red and blue leads

If it reads

board to key

key

switch.

Band L terminals

O.

If it does

problem

the

The board

or

infinity

the

is in

key

switch

alternator

there

the

replaced.

connector

key

switch

not

key

reading

in

the

wir

.

and

are no

problem

should

Stop and Tail Light

1. Check stop

.

-

make socket housing.

2. P.C. board.

3. To check between

Xl).

4.

To

meter

the

should read 1 - 2 ohms.

5.

If the readings in steps 3 and 4 read than the and inspect tacts again.)

6.

If reading in step 3 headlight, and

tion

nator

only

is in the

board

sure

Disconnect

wiring

the

Ohmmeter

check

wiring

between

connector

specified

to

proceed to the tests

voltage

the

taillight

P.C.

or

replace.

taillight

it is

tail

brown

or

the

wiring

instrument

regulator

board. Remove and inspect P.C.

bulb

before

making

lamp

to

should

to

the

(ohms X 1 scale).

read

tail

to

does

a good

(green)

taillight

lead and black lead

read 2 - 3 ohms.

stop

light,

green and black

infinity stop

taillight.

was

OK and

for

and key

not

function

connection

connector

connect

the

light

. Remove seat

(Check

lights

the

magneto switch

testing

ohmmeter

wires

Ohmmeter

higher

problem

bulb

the

taillight,

do

not

tests. If

the

problem

and

in

from

(ohms

ohm

in

is

in

con-

func

alter

-

Beam

1.

2. Connect

3.

4.

5.

6.

Switch

Disconnect black beam P.C.

board.

ohmmeter

to beam Turn Turn

infinity

Connect to beam

Turn

switch

beam

.

ohmmeter

switch

beam

switch

O.

7.

Turn

beam

infinity.

8.

If any of faulty, replace

9.

If all above tests headlight magneto switch board. The board spected or replaced.

switch

the

power, and

alternator,

tests

were

Test

switch

to

brown

(ohms X 1.)

to

low,

to

high,

to

brown

.

to high,

to low,

tests in steps 3, 4, 6, or 7

the

beam were

the

voltage regulator, and key

OK

the

should

connector

and orange

meter

should

meter

and green

meter

switch. OK and

headlight

problem

be removed and

read O.

should read

should

there

is in

the

from

wires

read

were

is

no

circuit,

P.C.

in-

7.

If reading in step 4

for

the brake

If

the brake I

8. lights board. Remove and inspect replace.

Brake

Before proceeding lever is adj uted so it makes good brake

1. Disconnect orange brake from

2. blue scale).

3.

The

4. Squeeze the brake lever. The read

5.

If

obtained, replace the brake

function

Switch

switch.

the

Connect

wires

ohmmeter

O.

the

ight

P.C.

ohmmeter

to the brake

readi ngs in steps 3 and 4 are

light

switch

OK

Test

with

board.

should

was

OK proceed

switch

tests

the

problem

this

test

between

light

read

.

OK and

make sure brake

switch

infinity (open)

ohmmeter

light

is in

P.C.

contact

the

switch.

to

the

test

the

other

the

P.C.

board

with

connector

yellow

(ohms X 1

and

.

should

or

not

3-18

MAGNETO ALTERNATOR

AND

LIGHT REGULATION TESTS

• I

IGNITION COIL

BRACKET

~

IGNITION

COIL

(MAG

SIDE)

FLOW

DISASSEMBLY

l SNOWMOBILE

+

IGNITION

CO

IL

(PTO SIDE)

MUFF

RECOIL

STARTER

CHA

-

ENGINE INS

•

+

LER

I

1

PULL

EY

CAP

LOWER

FAN

PULLEY

ROPE

PAW

RECOIL

ROPE

RT

I

LS

PULLEY

TALLED

EXHAUST

MANIFOLD

r

AIR SHROUD

(EXHAUST SIDE)

SPR

ING,

AIR

SHROUD

(TOP)

HEADSI

,

.-

INTAKE

MANIFOLD

~

AIR SHROUD

(INTAKE SIDE)

~

POINT

CAM

,r

* FLYWHEEL

POINTS,

CONDENSER

EXITER COILS

FAN

COVER

UPPER

•

PULLEY

HALVES

FA

N,

I

t

MAG

OIL SEAL

t

FAN

HOUS I

FAN

r

FAN BEARIN

I

STATOR PLATE

GS

t

LEAD

WI

RES

NG

l

*PISTONS, RINGS,

,

A

IR

NCER

,

PIN,

WRIST

SI

LE

1

CARBURETOR

* CYLINDE

,

AND BEARINGS

J

TORQUE

CONVERTER

PTO

SEAL

+

RS

OIL

* Removal, insta llation, disasse

NOTE:

This chart is designed to aid in dete ponent you wish to rem ove and

mbly, or

follow

assembly re

rmining

prope r removal sequence. Select

the arrow s leadin

quir

es use

g to

of

special tool(s).

that

point

FLOW

on

the

th e

chart

CHART

com-

.

3-19

w

,

N

o

"T1

r-

o

~

(")

::I:

»

::t1

-f

Headlamp

Wiring

Harness

Muff

ler

Spring

s

,

I H

oo

d 1

Flow

Chart

Engine

Removal

Snowmob

il e

I

~

Torque

I

Carburetor

Converte

r

Guard

'Drive

I

mpulse

Torque

Line

Converte

r

Ru

bber

Mount

Bolts

~

I

Remove

the Engine

I

'

Rem

oval ,

installation,

disassembly,

or

assembly requ ires

use

of

specia l

tool(s)

.

1

NOTE:

This chart

is

designed

to aid

in

determin

ing

proper

removal seque nce. Sel

ect

the

co

mpon

ent

you

wish

to

remove

and

follow

the

arrows

leading

to

that poi nt on

the

ch

art.

~

Engi

ne/

PC

Board

Wiring

Harness

•

Re

coil Starter Hand

le

FLOW

CHART

..

DISASSEMBLY

IGNITION COIL

BRACKET

IGNITION RECOIL STARTER

COIL

(MAG SIDE)

IGNITION

COIL

(PTO

SIDE)

-

ENGINE

SNOWMOBILE I

•

STARTER

PULLEY

CAP

LOWER

FAN

PULLEY

+

ROPE

PAWLS

RECOIL SPRING,

ROPE

REMOVED

EXHAUST

MANIFOLD

I

AIR SHROUD

(EXHAUST SIDE)

PULLEY

(INTAKE

AIR SHROUD

(TOP)

IHEADSI

INTAKE

MANIFOLD

AIR SHROUD

SIDE)

* FLYWHEEL

FAN

COVER

+

UPPER

PULLEY HALVES

FAN,

FAN

I

BEARINGS

FAN

HOUSING

t

POINT

CAM

* R

emoval, installation, disassembly, or assembly requires

se

of special tool(s).

u

NOT

E: This chart sequence . follow

the

POINTS,

CONDENSER

EXITER

is

Select the component you

arrows

COILS

designed to aid in determining proper removal

leading to

STATOR PLATE

I

t

MAG

OIL SEAL

that

point on the chart.

+

LEAD

WIRES

wish

to remove and

t

* CYLINDERS

r

*PISTONS, RINGS,

WRIST

I

PIN,

AND BEARINGS

ENGINE MOUNT

PLATE

PTO

SEAL

OIL

+

CRANKCASE

.-

CRANKSHAFT

•

CRANKSHAFT

BEARINGS

FLOW

CHART

3-21

Muffler

Removal

1. Remove

2. Remove cure

the

air

two

springs

muffler

intake

to

the

sil

(1,

encer

Figure exhaust

.

3-1)

which

manifold.

se-

Air

Intake Silencer

Removal

Disconnect 3-2). Remove sil

encer flange snowmobil

the

by pullin g

. Remove

e.

spring

the

carburetor

the

extensions

carburetor

air

intake

from

and

sil

(1

and

the

seal

encer

2,

air

from

Figure

intake

the the

3. Remove cure

4. Remove

carefully flange.

two

the

muffler

the separating

Installation

Install cedure. on the

the

muffler

Make

rubber

nuts

muffler

by

sure

the

mounts.

and washers (2)

to

the

mounting

from

reversing

muffl

the snowmobil

the

exhaust

the

er

is

which

brackets.

removal

properly

se-

e,

manifold

pro-

seated

Installation

Ins

tall

the

air intake

moval

procedure

1.

2.

3.

4.

silencer

.

Spring Spr

ing

Carburetor

Air

Int

ake S

by reversi

Extension Extension

ilen

cer

ng

the

re-

i

~

1.

Spring

2.

Nut

and

Washer

3.

Muffler

4.

Exhaust

Figure

3-

22

MUFFLER

Manifold

3-1

Carburetor

Removal

1. Remove the

2. Un sc pull

Compress

3.

sp

ring

thr

ough the move needle

the

carburetor

fuel

line

opening.

rew

the

mixing

out the

the

throttle

the

from its seat . Slip the

slot

spr ing,

from

the

Figure

valve. See F

throttle

in

the

piston

valv

e.

3-2

fu el s

upply

See Figure 3-3.

body

top

assembly

igure 3-4

spring

piston

valve plate,

and

throttle

valve plate. Re-

line

. Plug

pull

and jet

I

j

and .

the

cable

I

1.

Throttle

2.

Enrichener

3.

Fuel Supply Line Silencer

4.

Cable

/ Carburetor Seal

Figure 3-3

1.

Starter

2.

Enrichener

3.

Starter

Plunger

Cable

Plunger

Cap

-

Figure

Disassembly

1. Select a carburetor. caused by

2.

Clean with

1.

Mixing

2.

Throttle

3.

Throttle

4. Piston Valve Plate

5.

Jet

4.

Unscrew

the

cable.

I

enrichener

5.

Pull the Remove

carburetor flange. See Figure

the

starter

Unscrew

carburetor

the

Body Top

Valve

Spring

Needle

Figure 3-4

starter

plunger

cable. See Figure 3-5.

silencer/carburetor

to release

the

fitting

from

plunger

and

the

Assembly

cap and remove

the

disconnect

intake silencer.

3-3.

enrichener

seal

from

the

not

buretor

3.

Remove 3from gasket (11).

4.

To

upper

5.

Push

float bly (22) and place in a secure location to prevent

6.

To remove

(such

through

the

compressed

blow

until

6)

and separate

the

remove the

carburetor

out

arm

damage.

as

of

clean

work

Most

dirt

in

carburetor

high

pressure

it is disassembled.

four

screws

upper

main

the

float

(15). Remove

the

needle

a penci

its bore.

3-5

Carburetor

area

for

disassembling

carburetor

the

system.

with

air

before disassembling. Do

air

with

the

float

carburetor

jet

(14),

body. Remove

arm

pin (10) and remove

the

jet

l)

to

push

problems

fuel

and

through

washers

chamber

body. Remove

unscrew

float

(32), use a

the needle

jet

valve

(21

washer

blow

the

, Figure

body

from

(13).

assem-

soft

jet

the are

dry

car-

(1

B)

the

rod

up

DISASSEMBLY

OF

CARBURETOR

3-23

7. Remove thin

-bladed

the

pil ot

screwdriver.

jet

(12) by

unscrewing

with

a

8. Remove (8) and

(7).

the

pilot

throttle air

adjusting

stop

screw

(9)

and

(6) and

spring spring

26

-~

~

28-

C:J

30--

JI-

r~

e

"

23

22

~~

8-

2

@J-3

~-4

e-

0

~

5

~

7 6

12

~

I

l

1.

Carburetor

2.

Starter

3.

Washer

4.

Spring

5.

Starter

6.

Pilot

Screen

7.

Spring

8.

Spring

9.

Throttle

10. Pin

11. Gasket

12. Pilot

13. Washer

14.

Main

15. Float

16. Cap

17. F

loat

18. Float

19.

Drain

20.

a-Ring

21.

Screw

22. Float Valve

23.

Washer

24. Screw

25. Plate

26.

Cap

27. Spring

28. Plate

29.

Clip

30.

Needle

31.

Throttle

32

. Needle

Plunger

Air

Adjusting

Stop

Jet

Arm

Chamber

Screw

Jet

Valve

Jet

Assembly

Cap

Screw

Body

Assembly

3-24

CARBURETOR

VM

---19

Figure

34

3-6

CARBURETOR

Cleaning Carburetor

Thoroughly fuel/ oil mixture. Inspect all drilled holes, openings and fuel passages in

through

air from

the

Reassembly

1. Place the spring (8, Figure 3-6) on stop body .

2. Insert

screw screw for

3. Install

to

clean all parts

the passages. Remove

fuel

bowl.

of

Carburetor

screw

Turn

initial

25

(9) and install in

in

the

spr ing (7) and

(6) in

all the

the

to

the

way

in

adjustment.

float valve assembly (

30

inch-pounds.

wit

h a

the

body. Bl

screw

carburetor

then

about

turn

ow

pilot

body.

out

mild

solvent

compressed

any

sediment

the

carbureto

10

turns.

air

adjust

Turn

1-3/ 4

22

) and

thrott

ing

the

turns

tighten

or

le

r

4. Hold

5. Guide the

6.

7.

8.

the throttle sembly in one hand. Place the spring in and compress extends beyond

throttle

Insert the end of the cable

the

throttle

While the plate. Then release

Install the c the ger tight.

Slide spri See Figure

keeping the spring compressed, release

throttle

the

throttle

slot in the

ating

inside

mixing

Tighten

the

ng

over

cable and

the

spring so

the

spring.

valve over

valve slot.

valve and

the

valve

throttle

the

throttle

body top assembly and

the

starter

the

plunger

end

install

spring.

into

valve

throttle

of

the

mixing

the

through

the

mates

valve bore.

cap,

enrichener

3-5.

body top as-

the

throttle

the

piston

carburetor

with

cable locknut.

washer

the

hole

the

Install

tighten

cable.

cable

cable.

valve

top

in

so

lo-

fin

and

-

4. Install arm seated.

Invert

5. between buretor. The base.

6.

Install of whi jet

7. Install

8.

Position Install bottom.

9.

Position a body. Place the chamber body (18). Hold the and

buretor casti ngs. Secure washers

the

float

(10

).

the

carburetor

the

float

the

needle

the

carburetor. Hold

le

installing

(14).

the

pil

ot

the

floats

the

float

new

float

bowl

. Check

(21).

arm Be

sure

arm

jet

the

jet

(12). Do

(17)

s wi

th

gasket (11)

carburetor

together

for

proper

with

(15 ) and secure

the

and check

and the base

must

(32)

down the washer

on the brass

and

alignment

the

be parallel to

through

needle

(13) and

not

overtighten.

float

chamber

pins

on

the

body

on

carburetor

invert

four

screws

with float

is

securely

alignment

of

the car-

the

jet

in place

main

pins

at

carburetor

the

float

body

the

car-

of

the

two

with

the

top

the

9. Place the carburetor

plunger cap. Bend

10. Connect bure

the

cable end and spring .

tor

11. Raise

ground . Sta bure

tor

manual.

Troubleshooting

Carburetor related

.

as too rich are as fo

When th e

1. Engine

2. The c

3. The

llows

ondition

t.

ho

condition

(choke) is opened.

hole in the

body and

the

fuel

vent

hose. See Figure

the

rear

rt

the

adjustments

malfunctions

or

too lean a fuel

:

fuel

/ air

mixture

nois

e is

grows

washer

supply

of

engine

dull

worse

starter

Insert

tighten

plate line

the

snowmobile

and

in

Section 2

mixture.

is too rich:

and

intermittent.

when

worse

plunger

the

plunger

against

and

3-3.

perform

can be

the

when

over

the

into

the

starter

cap.

the

car

off

the

car-

of

this

identified

Symptoms

engine

the

starter

-

is

Installation

1. Install buretor air intake silencer.

2.

Screw

4) to

the

3.

Insert

Of

Carburetor

the

silencer/carburetor

flange and install

the

mixing

throttle

jet

body top assembly (Figure

cable.

needle into

the

carburetor

the

thro

seal

to

ttle va lve.

the car-

on the

3-

4. The

5. Exhaust gases are heavy.

6. Spark

Wh

1. The engine becomes overheated.

air

en

condition

sile

ncer is removed.

plugs

become

fuel/air

mixture

may

is too lean,

improve

fouled

slightly

.

CARBURETOR 3-

when

the

25

2.

The

condition

opened.

improves

when

the

starter

is

Fuel Pump

Removal

3. Acceleration

4.

Spark

5. The lack

If a fuel throttle clean

usually cleaning carburetor

plugs

revolutions

of

power

carburetor

mixture

the

problems,

is

working

carburetor

caused by a clogged

does

not

tuning

Tuning

Different

cording

1. Pilot eighth (1/ 8)

Throttle

2.

fuel

to

Air

one

fourth (1/ 4)

the

Screw -from

Valve

is

poor.

burn.

of

the

is noticed.

is

experiencing

first

properly.

. A rich or lean

improve may

be necessary.

metering

throttle

components

setting:

opening

Cutaway -one

throttle

engine

too

rich

check

Then

carburetor

closed

to

disassemble

air

or

fuel

.

opening.

fluctuate

or too lean

see

that

fuel

mixture

passage. If

performance,

function

throttle

eighth (1/ 8)

to

and

the

and

is

ac-

one

to

1. Remove

2. Remove end

3. Remove fuel

4. Remove

air

intake

fuel

of

fuel line. See Figure

fuel

pump.

two

Disassembly

1.

Remove six

2.

Lift

off phragm relation

Grommets

3. have move

main body (B).

replacements

grommets

retainer

body cover (A), gaske t (2) (5). Note to

body

(3)

inlet

outlet

fuel

cover

cannot

(3)

silencer

line

pump

screws

the

position

(A).

be

before

and

from

carburetor.

from

fuel

pump

3-7.

and

impul

se

line from

mounting

reinstalled.

removing them. Re-

check

(1,

Figure

of

valves (4)

bolts.

3-8).

and

gasket (2)

Be sure

. Plug

dia-

in

to

from

Jet

3.

4.

Tuning

at fuel more

in

formance

checked metering

The fuel

in

the mixture

positioned 1/ 2

than

large.

The the five are clip

ing leans

lower

Needle

three

Main opening

enables

any

throttle

metering

or

less

one

fuel

pilot from

richens

turn

two

jet

needle system can be

position

grooves

numbered 1 through 5 from

is

normally

the

out

pos i

and

Needle

fourths Jet -three

of

whenever a change

system.

air

the

. The

1/ 2

indicates

turns

clip

the

tion

(3/ 4)

.

adjustment setting

devices

fuel

than metering other

systems

screw

pilot

jet.

fuel

/ air mi

pilot

to 2 turns

the

out

of

the

clip on

at

the

top

installed

to a higher

fuel/air

richens

with

regulates

air

indicates

Jet

- one

fourth (1/ 4)

throttle

fourth

by

standard. Because a system can

Turning

screw

pilot

of

in

mixture.

the

opening.

(3/ 4)

to

full

of

the

fuel/air

replacing

parts designed

, all

is made

air

xture. Turning

from

jet

the

jet

the

needle. The grooves

the

position

Moving

fuel/air

the

affect

systems

that

the

pilot

should

full

in. Less

is

too

pilot

tuned

needle

top

to

NO.3

groove.

on

mixture

to

mixes

be

small.

by

. There are

bottom. The

the

throttle

mixture standard to

meter

change

the

per-

should

one

fuel

with

air

screw

out

leans

normally

than

More

jet

is too

changing

Mov-

needle

clip to a

.

to

be

Cleaning

Clean body castings (A,

not

Do Damage to

Be sure fuel of

clean

any

obstructions.

rubber

diaphragms

line

and

1. Fuel

2. Fuel

3.

Impulse

4. Fuel Pump

Figure

B,

C)

with a mild

diaphragms

will

occur.

impulse

Inlet

Line

Outlet

Line

3-7

line

Line

with

fittings

solvent.

solvent

are

clear

.

-

3-26

CARBURETOR

Reassembly

5---

1-

1

--

-

-2

~---

o 4

-8

-

3

1. Install diaphragm

2. Install check valves (4) in main body pump

3.

Install s

ure

(B).

4. Install body cover (A). Be

cover (A)

(B).

5.

Install six

crisscross pattern.

lower

(5) on

casting (C).

diaphragms

to

align

tabs on gasket (2) and

aligns

retaining

gasket (6, Figure 3-8) and

pump

(B).

with

casting (C).

using

Position

(5) and upper gasket (2).

gasket (2) and

screws

Installation

1. Connect

2.

Install

Arrows

indicate

3. Install

impulse

fuel

on

direct

two

inlet

top

fuel

line

to

bottom

line

and

of

body cover (A, Figure

ion

of

fuel

pump

mounting

new

main

sure

(1) and

fuel

flow.

grommets

body (B)

main

body

tab on body

main

body

tighten

fitting.

outlet

bolts.

in

lines.

3-8)

(3) on

Be

a

4----0

3

5-

--

6

---

A.

Body Cover

B.

Main

Body

C.

Pump Cas

ting

Fi

gure

~

1. S

2.

3.

4. Valve

5.

6. Gasket

3-8

crew

Ga

sket

Grommet Diaphragm

4. Replace

air

intake

silence

Engine Removal

1. Remove

2. Remove belt guard (Figure 3-9). Remove

3. Dis gine

4. Remove rope.

5. Disconnect gine

6.

Remove by loosening clamp engine. If the

7.

Use a spring disconnect

8.

Remove and spacers. Use a socket while

the

hood.

the

retainer

connect

or

as

carburetor

the

circuit

starter

the

shown

the

carburetor

the

four

removing nuts.

pins and remove

wiring

board as required.

handle

fuel

in Figure

repair in

puller

two

harness

and

impulse

from

screw

is to be removed,

structions

tool

or

exhaust

engine

r to carburetor.

the

drive

from

the

tie

a knot in

line

from

the

3-10.

the

engine

and

pulling

a long

springs.

mounting

wrench

from

refer

.

wire

hook to

bolts,

to hold bolts

drive

belt

en-

the

en-

mount

the

to

nuts

.

FUEL PUMP

9. Remove

the

engine

ENGINE

from

the

snowmobile

REMOVAL

.

3-27

Removing External Components

1. Remove lockwasher. Install bolt the drive converter.

the

(tool no.

1. Drive

drive converter

the

drive

205196)

Converter

and

See Fi

mounting

converter screw gure

Puller

in

to

3-11 .

Bolt

bolt

and

puller

remove

1. Drive

2.

Drive

Figure

Belt Belt

Guard

3-9

Figure 3-11

2. Remove the

3. Remove the spark plugs.

4. Remove the

Recoil

exhaust

engine

Starter

manifold

mounting

Removal

1.

Remove star rope

to

into

the

ter

handle

prevent rope

recoil case.

from

and

suddenly

.

tie

plate .

knot

in

starter

retracting

1. Impulse Lin e Figure

3-28

RECOIL STARTER

3-10

2.

Remove

starter assembly to engine and remove assembly. (Figure 3-12)

three

slotted hex head bolts

securing

starter

Disassembly

1. Release recoil

I'

1. Slotted Hex Head Bolts (3)

Figure

3-12

handle reel to

2.

Remove

taining

slight

spri

remove cover.

3.

Remove starter starter turn rust, di

from

spin

the

cover

downward

ng

tension

the pawl assembly. Figure

spring

sto

rted or

spring

starter

slowly

nut

and

to

the

pressure

from

return

springs,

and

pressure

weakened

rope and

.

washers

starter

retaining

spring,

pawls

tension

on

3-14.

by

allowing

securing assembly. Exert cover to

cover and

pressure

and

washer

Check

spring

condition.

removing

the

remove

slowly

spring,

the

for

breaks,

recoil

re-

from

re-

Inspection

1.

Pull

the

starter

127.0

chips or excessive wear. See Figure

Listen for any cate a broken or the starter rope for excessive condition .

mm)

and

grinding

rope

out

examine

noise

worn

starter

3-5

the

starter

which might indi-

spring . Examine

inches

wear

(76.2-

pawls

3-13

or

frayed

for

.

1.

2. Pressure Spri ng

3.

4.

5.

4.

To

replace starter assembly. starter rope.

ng

securi

knot

Return Starter Pawl

Pawls Washer

starter

Install

Spring

Springs

Figure

as

3-14

rope, remove recoil reel

Untie

new

shown

knot and remove

starter

in Figure

rope and

3-13.

from

tie

a

IWARNINGI

1.

Starter Pawls

2. Starter Rope Figure

3-

13

Exercise

from shou accide

Wear assembly

care

starter assembly. All

ld

be

rel

eased

ntly

dise

safety

glasses

components

when

ngaging

removing

to

prevent

and

when

.

recoil

spring

causing

repairing

RECOIL STARTER 3-

reel

tension

from

injury.

starter

29

1. Recoil

2. Spri

n~

Figure 3-

Spring

Hook

15

5. With

recoil reel removed, as s 3-15, exam crystallization or abnormal bends. Exerc ise care wh

en handling recoil case spring should stalling a new recoil spring to recoil case .

in

from remain

e recoil spring

accidently disengaging. Spring

in

the

recoil case.

recoil

spring, attach

hown

to

for

prevent

When

Reassembly

1.

Thoroughly assembling starter. Reassemble shown temperature lent) on recoil reel and recoil spr in

2.

Apply rope in notch COUNTERCLOCKWISE from

notch and

clean all parts removed pri

in Figure 3-6.

grease (Texaco

correct recoil spring

Apply

of

recoil reel and rotate ree l

four

allow

rope to

components

a l

ight

2346EP

tension

turns.

rewind

coat

or

g.

by placing

Release rope

in Figure

cracks,

recoil

in-

hook

in

or

to re-

as

of

low-

equiva-

.

2

15

t~l

.

A

~

",

~

I

1112

10

9

13

1

1.

Hex Head Bolt

2. Starter Handle

3. Starter Rope Recoil Case

4.

5.

Recoil Spri

6. Recoil Reel

7.

Washer

8. Spring

9. Return Spri ng 10

. Retai ner Cover

11. Washer 12

. Lockwasher

13.

Nut

14.

Starter

15. Pawl

ng

Pawl

Spring

J

3-30

RECOIL STARTER

Fi

gure

3-16

r'

3.

Secure sta hex head bolts . Insert guide in chassis and attach

starter

serve

rter

rope.

starter

assembly to

Pull starter a operat

ion.

engine

starter

few

using

three

rope

through

handle

to

times and ob-

NOTE:

starter rope to engage secu rely.

Before bolts are

tightened

pawls,

Air Shrouds

Removal

1.

Using an impact driver, remove eleven loc

kwashers shroud must heads because LOCTITE

during

2. Remove ex shroud

gaskets.

to engi ne. (Figure

be used to

assembly.

haust

and

washers

3-17)

prevent

four

nuts

and

manifold,

to engine. (Figure

gaskets and

stripping

was

lockwashers

pull

then

tighten

securing

Impact

applied to

exhaust

3-18)

slightly

screws,

driver

the

screw

screws

securing

Discard

on

bolts

main

air

3.

Remove ers

securing

take air

1. Exhaust

2. Gaskets

3. Exhaust Figure

six

bolts,

intake

shroud

to

Manifold

Air

Shroud

3-18

lockwashers

manifold,

engine. Discard gaskets.

and

flat

wash-

gaskets and

in-

1.

Ma

in Engine

2.

Impact Driver

Figure

3-17

Shroud

Inspection

1.

Thoroughly

blow

2.

Inspect ru st.

3.

Check intake and Check gasket surfaces and clean scraper.

dry

using

air

clean

air

shrouds

compressed air.

shrouds

for

exhaust

cracks,

manifolds

Reassembly

1.

Reassemble

manifolds assemble (2 each per cylinder) one side

of

using brass

exhaust Ibs. (1.38 kg-m) and intake 5 ft. Ibs. (0.

air

shrouds, intake and

to engine. Using

exhaust

hardware

and intake air shrouds.

previously

manifold

55-0.69

mounting

kg-m).

AIR

SHROUDS

in a

solvent

distortion

for

cracks.

using

exhaust

new

gaskets,

on

Secure

removed . Torque

nuts

to

10 ft.

manifold

bolts

3-31

and

or

a

each

to

4-

If

cylinders

or

cylinder

heads

have

removed intake manifold bolts must

secured heads

before

and

torquing

cylinders.

nuts

securing

been

be

NOTE:

Use an impact

screws

2.

3.

Flywheel

Apply

are tight.

Always

ensure Install rubber

prevent unnecessary

LOCTITE to

driver

use

new

proper connections.

damper

Magneto

Housing

REMOVAL

FLYWHEEL MAGNETO

1. Remove socket. Insert a long rod through shaft

flywheel

slots in

from

starter

rotati ng (Fig

main

to assure

gaskets

to intake

engine

retaining

pulley

ure

air

main

during

noise.

nut

or

large

to

3-19).

shroud

screws.

air

shroud

reassembly to

air

shroud

to

and Fan

using a 18

screwdriver

prevent

mm

crank-

1. Fan Cover 3-

Figure

20

f

Figure

2. Remove five to

fan

3. Remove starter Remove

3-32

FLYWHEEL

screws

housing

three

pulley

fan

belt

(Figure 3-20).

and fan

3-19

securing

bolts and

drive

from

fan pulley. (Figure

MAGNETO

plastic

washers pulley

AND

fan

securing

to

flywheel.

FAN

cover

3-21)

HOUSING

4.

1. Starter Pulley

2.

3. Fan Belt

Install remove

to

flywheel

flywheel.

remove flywheel

Fan Drive Pulley

Figure 3-21

puller

tool no.

Use side

key.

T56019

cutters

(Figure 3-22)

-011 and

or

small

drift

NOTE: Place

prevent rotor or particles .

flywheel

magnets

on a non-magnetic

from

attract

ing

metal

area

filing

to

7.

Remove

s

stator assembly to crankcase. Remove assembly and slide electrical leads rubber

two

screws

grommet.

and

(Fig ure

four

3-24)

washers

securing

stator

through

1.

Flywh

eel Puller

Figure 3-

5.

Prior

to

removing aligning When original position. (Figure 3-23).

6. Using leads

mark

reassembling

needle nose pliers remove electrical

from

cord

starter

from

connector

stator

22

assembly scribe

plate to crankcase.

timing

can be set

.

an

at

8.

Refer to Figure 3-

magneto

of

9.

Remove Remove Remove

fan

housing

3-27)

3-26,

components.

ignition

clamp

two

sec

screws

and remove

Figure

coil leads

25

uring

3-24

for

securing

disassembly

from

cord

leads to

ignition

fan

coil

coils. (Figures

sequence

connector

housing.

bracket

.

to

,

1 . Scribe

Figure 3-

Mark

23

FLYWHEEL

MAGNETO

1.

Clamp

Figure 3-

AND

FAN

26

HOUSING

3-33

9

I-

I

1.

Flywheel

2.

Cam Screw

3.

4.

Advance

5.

Washer "E"

6.

7.

Advance

8.

Cam Stator

9.

10.

Wiring

11.

Grommet

12.

Screw

13. Screw

~

1\

30

31

Cw- I

4

I

33

Assembly

Holder

Weight

Ring

Spring

Assembly

Harness

31

34

'

_

~

14

. Condenser

15

. Breaker

16.

Screw

17.

Lighting

18.

Screw

19

. Exciting Coil (no.

20

. Collar

21

. Exciti ng Coi I (no.

22.

Screw

23. Cam Felt 24

. Clamp

25. Washer

26. Washer

Contact

Coil

1 )

2)

27. Spark Plug

28. Cap Grommet

29.

30. Screw

31.

Washer

32.

Ignition

33

. Bolt

34. Washer

35. Bracket Ignition

36.

37.

Screw

38

. Clamp

Coil (no. 1)

Coil (no . 2)

I

3-34

FLYWHEEL

MAGNETO

AND

FAN

Figure 3-25

HOUSING

1.

Fan Housing

1.

Mounting

2.

Ignition

Bracket

Coils

Figure

3-27

Removal

FAN

HOUSING

1. Remove housing to crankcase and remove

(Figure 3-28)

2. Usi

remove sembly to

ng

four

fan

nut

pulley

fan

nuts

and

washer

housing .

holder tool no.

Screws

washers

securing

fan

housing.

205208

fan as-

fan

Figure

3.

Remove

shaft

NOTE: Spacers are used

halves to

spacers increases fan

reassembly

behind outboard of proper belt

fan

. (Figure

adjust

place

the

inside

the

alignment

pulley

3-29)

fan

half

pulley

outside

halves and spacers

belt

.

3-28

between

tension.

belt

of

the

half

pulley

the

Using

tension.

spacers

and

the

half

to

from

fan

pulley

fewer

During

removed

balance

maintain

fan

\

..

....

FLYWHEEL

o

MAGNETO

o

1. Spacers

2.

Pulley Halves

Figure 3-

AND

FAN

29

HOUSING

3-35

4.

Using a heat aluminum removed

Do

not

bare

hands

fan

from

IWARNING'

contact

or

gun

case

fan

case.

heated

severe

or

propane

allowing

fan

burn

could

torch,

bearings

housing

result.

to

with

heat

be

Check fan belt

7.

Check

8.

damaged fins. Check

9.

damage.

cooling

threads

excessive

for

fan

on all

assembly

mounting

wear.

for

missing

studs

or

for

5.

Using

and

Tru-Arc

two

spacers

or

circlip

from

fan

30)

NOTE: Circlip is used to

bearings. Spacers are to

eliminate

side loads

installed

when

pliers

housing.

correctly

between

shaft

remove

nut

is

circlip

(Figure

tightened.

3-

position

bearings

Reassembly

FAN HOUSING

1.

Install circlip in

2. ·Usi ng a heat

aluminum bearings.

NOTE: Insert

bearings to tightened

eliminate

. (Figure 3-31)

fan

housing.

gun

fan case

two

spacer

side loads

or

housing

propane

washers

when

torch

and

between

shaft

heat

insert

nut

is

1 . Spacers (2)

2. Circlip

3.

Inspection

1.

Check breaker

wear. Clean

2. Inspect all lead

condition.

3.

Check magnets clean or particles

4. Check

5.

Inspect

6.

Check bearings

magnet

point

that

woodruff

fan

housings

Bearings

Figure

points

in

area to remove

key and

for

3-30

for

Pitting

contacts

wires

magnets

for

rotor assembly.

may have attracted.

keyway

for

cracks

discoloration

using

cracks

any

or

excessive

bias tape.

or

Thoroughly

metal

for

damage.

or

distortion.

and

wear.

frayed

filings

1. Spacers

Figure

3.

Install attach number previously removed and attach pulley halve to shaft. Secure

shaft

fan

pulley

of

using

assembly

halve to shaft.

pulley

washer

3-31

through

spacer

and

nut. Tighten

Magneto

1.

Reassemble all sembly.

components

Assemble

washer

pulley

bearings and

same

s to

shaft

as

remaining

halves

securely.

to

stator

as-

to

3-36

FLYWHEEL MAGNETO

AND

FAN

HOUSING

2.

Insert electrical leads crankcase and crankcase. assembly. Secure

screws and (Figure 3-32).

Align

reinstall timing

stator

washers

through

stator

mark

assembly using

previously removed.

made

grommet

assembly

during

in

to

dis-

two

1. Timing Figure 3-

3.

Install fan four removed . Tighten electrical leads to cord connector. (Figure 3-

33) .

Secure

4. bolts and four washers. Tighten securely. If

leads leads housi ng. Insert black leads and attach red and (Figure

housing

nuts and

ignition

were

removed

into

clamp

3-34)

.

coils to fan

Mark

32

to crankcase. Secure using

eight

nuts

and secure white

washers

securely.

from

cable clamp

into

leads to

previously

Attach

housing

using

clamp

cord connector

stator

two

insert

to

fan

leads.

5.

Rotate fully correct

0.

014 breaker poi nt check secure

35).

Figure

crankshaft

opened. Insert feeler gauge

point

setting.

inch

(0.35 mm) is obtained.

mounting

point

setting

to

insure

3-34

until

Adjust

after

proper

number

point

screw

mounting

point

one

setting

securely. Re-

gap. (Figure

points

to

check

Tighten

screw

are

until

is

3-

Figure

3-33

FLYWHEEL

1.

Stator plate

2.

Breaker

MAGNETO

point Figure

AND

mounting

3-35

FAN

HOUSING

screws

3-37

6.

Install dial indicator in and locate correct

0.145 continuity

lead. Timing can advanced position by

mm B.T.D.C.) using a buzz box

light

number

timing

connected to red

be

position

checked in retard

swinging

one

cylinder

(0.006

magneto

advance arm.

inch

wire

or or

NOTE: If

correct loosen stator plate

rotate stator (Figure 3-36). Rotating stator rotation advances

timing

plate

on

number

until

timing.

correct

one

cylinder

mounting

timing

plate opposite

screws

is obtained.

is

not

and

engine

Figure 3-

10. Check deflection to belt. Correct belt

inch (3.5 to ment is required remove or add spacers between fan measurement will

fan

belt

ten

with

ten

4.5

mm). (Figure

pulley halves

is obtained. Removing spacers

increase belt tension.

37

sion by

pounds (5 kg) force applied

deflection

measuring

should

3-38)

If

until

be

5/32

adjust correct

belt

-

....

.I

Figure 3-

7.

Install dial indicator in and connect buzz box white Timing

mm)

required, readjust

points only. Tighten breaker

screw

screws are secured.

8.

Install

flywheel

and

Ibs. (8.3 kg-m) .

9.

Install

pulley

and lockwashers. Tighten bolts evenly to

prevent

NOTE: Install

shoulder

magneto

should

of

number

securely. Recheck

woodruff

to crankshaft and secure

flywheel

fan

to

flywheel.

distortion

toward

wire

be

one cylinder. If

the

key

nut. Torque

belt, fan drive

of

fan

drive pulley

flywheel.

36

number

or

lead and check

within

to

Secure using

0.005

point

gap on

timing

crankshaft. Reassemble

flywheel

pulleys. (Figure 3-37).

two

continuity

inch

adjustment

number

point

after

with

nut

pulley

and

three

with

mounting mounting

machined

cylinder

light

to

timing.

(0.127

is

two

washer

to

60

ft.

starter

bolts

1. 5/

32

inch (3.5 to

Figure

4.5

3-38

mm

deflection)

3-38

FLYWHEEL MAGNETO

AND

FAN

HOUSING

11. Secure plastic fan cover Tighten damaging

five

the

screws

fan cover.

evenly

to

fan housing.

to

prevent

NOTE: Dying

will

indicate

the

gasket surface before you begin

high

spots

after

some sanding.

Cylinder Heads, Cylinders And Pistons

Cylinder Heads

REMOVAL

1.

Remove spark plugs.

2.

Remove securing cylinder heads mm remove cylinder heads and gaskets. Discard gaskets. (Figure 3-39).

eight

nuts, lockwashers and

socket and 3

to

cylinders, using a 8

inch

extension.

washers

Carefully

Cylinders

REMOVAL

1.

Gently tap cylinder seal.

2.

Carefully remove cylinders studs. prevent piston or crankcase. (Figure

Hold piston

from

with a soft

during

suddenly contacting studs

3-40)

mallet

from

cylinder

to release

crankcase

removal

to

Figure

INSPECTION

1. Remove excessive carbon head usi

2.

Inspect cooling

3.

Wash using compressed air.

4. Place a of the head to detect any warpage. several spots. If can on a surface circular motion to remove high spots.

ng a nonferrous

fins

cylinder head in solvent and

straight

be

corrected by using no.

edge across

plate and rubbing head in a

3-39

for damage.

slight

distortion

from

inside

carbon scraper.

the

gasket surface

400

cylinder

blow

Measure

is

present

sandpaper

3. INSPECTION

1.

dry

2.

in

it

3. Check cylinder

4.

CYLINDER

Figure

Remove and discard cylinder base gaskets.

Check the Thoroughly clean all carbon deposits

exhaust ports and cylinder

Using an ihside

for

"out

3-41

HEADS,

of

).

CYLINDER

cylinder

wall

micrometer

round"

3-40

for damaged or broken fins.

walls.

for excessive scoring.

check cylinder bore

or

"taper"

AND

condition

PISTONS

. (Figure

from

3-39

NOTE: To check for

bore move

0

90

at a ti me. The

obtained

mm).

the

should

micrometer

not

Figure 3-41

out

of

round

in a circular

difference

exceed 0.002 inches

of

in

measurements

the

cylinder

direction,

(0.05

Figure

2.

Using piston remove piston piston

from

pins

connecting

NOTE: Keep piston

and mark pistons

reassembly.

3.

Using a ring expander tool remove rings piston. Rings have are

numbered

top ri ng.

left and

one

3-42

puller

from

rod (Figure 3-43).

bearings

right

identification or

two.

tool

no. 57001 -

pistons

together

to assure

Number

and remove

as

a set

correct

from

markings

one is

910

and

the

NOTE: To check

move

the

micrometer the cylinder. The obtained (between top and bottom) exceed 0.002 inches (0.05 mm).

5.

Hone or rebore measurements inches (0.05 mm).

6.

Wash to

Failure

wearing

cylinder

insure

to

or scoring

for

difference

obtained

with

all honed

do so may

taper

from

the

cylinder

solvent

material

of

the

of

the

top to

in

the

in

step 4 exceed 0.002

or

soap and

has been removed.

result

cylinder

Pistons

REMOVAL

1.

Seal crankcase

a

sharp

Discard circlips. (Figure

steel

with

pointer

clean

remove

3-42)

shop rag and

cylinder

the

measurement

should

as

in

and piston .

piston

bore,

bottom

required

water

premature

using

circlips

of

not

if

s

1.

Piston

.

puller

Figure 3-43

tool no.

57001-910

3-

40

CYLINDER HEADS,

CYLINDERS

AND

PISTONS

NOTE: Do not

A ring expand er sp ring, remove prevent damage.

INSPECTION

1.

Remove all carbon grooves an d pist

int

erc hange rings between pistons.

ring

is installed inside

expand

on

from

skirt

er

.

spring

bottom

carefully

pisto n dome,

to

ring

NOTE: If piston dome or sk

damaged, replace piston and

2. Check Measure cylinder bore. Mic

2.

3622-2.3681

the

(68.0-68.15

two measu

0.0020 suremen inch (0.05 Using a diameter pin bottom.

Su

btract the cylinder bore meas between

0.

0008-0.0020

ment

exceeds 0

of piston and piston rings is required.

3.

Check piston one pin

piston-to-cylinder

smallest

340cc

hole and

the

inch

diameter

engine

mm)

rements of an inch (0. ts

vary

mm)

micrometer

of each piston at

piston

two

measurements

inch

.002

outside

.

inside

rometer

inches (60.001 -

and

for

the

must

by

more

the

cylinder

3/16

skirt

urement

(0.02-0.05

0 inch (0.05

for

wear

micrometer

irt

is scored

piston

2.6772-2.6831 inches not

05

measure

inch

measurement

rings.

wall diameter reading

60.089

440cc

vary by

mm). If

than

0.0020

must

right

angle to piston

(4.76

. The

must

mm). If

mm)

or

damage. Using a

measure

or

clearance.

of

the

must

engine. The

more

the

be replaced.

the

mm) from

from

difference

be

measure-

replacement

be

mm)

for

than

mea-

of

an

outside

the

between

piston

F

igure 3-44

Measure

T h i c k n es s

.......-::::::::::::::::::::

::::::::::

L

T

~~vcc=:::::=::~::::::

Meas

ure Thickness at This Point

Figure

Thickness

::::

::::::

:::!~:::::::::::::::::--.

3-45

at

This

Point

Measure inch ceeds set.

4. Check piston

5.

6. Check piston ring gap by i

ment

(15.994-15.999

limit

inside snap gauge approximately 1/ 4 (6

.35 mm) gauge and microm

0.6298 surement limits, replace piston, piston bearing.

Check needle bearings and needle bearing cage for

into

cyli nder exist. Insert feeler gauge the ends of Maximum inch (0.7 mm).

obtained

replace piston

into

measure

ete

r.

Piston

-0.6301 inch (15 .99obtained is

wear

or

near

the

ring

must

mm). If

hole

diameter

piston

gap should

it

using

pin hole di

not

overheating

the

bottom

piston ring. (Figure

be 0.6

measurement

and needle bearing

hole. Remove snap

a one inch outside

16.0

nserting

between

297-0.6299

by i

nserting

ameter

mm). If mea-

within

and needle

.

piston ring

where

opening in

not

exceed 1/64

ex-

an

inch

must

be

specified

7. Check top and

no ports

3-44)

CYLINDER HEADS,

Figure

bottom

Using a

the

center arc of both rings. (Figure 3M

easureme ri ngs shou mm). If me ring

micrometer

top and

s.

bottom

nt

obtained

td

be

0.0775-0.0787

asurement

CYLINDERS

3-46

piston

measure the

rings

for exceeds

AND

ring

at

the

top and

inch (1.95

PISTONS

thi

ckn ess.

thickness

ends

limits

bottom

replace

of

and

45)

-1.99

3-41

8. Check top and bottom piston ring SA340-A

width

and center arc.

0.

097-0.105

bottom ring should be

28

2.

within

1:

Using a

of

the

top and

Width

inch (2.46-

mm). If

the

the specified

micr

ometer

bottom

of

the

2.67

0.082-0.090

width

of

measurem

width:

measure

rings at top ring should be mm).

Width

inch (2.08-

the

rings is

ents

replace

rings.

Model

the

SA440-A1:

width

of

the and center arc . (Figure should Width

inch (2. not

9.

be 0.1107-0.1187

of the bottom ring

63-2.83

within

the

Install rings in ring grooves of piston and check

Using a

top and

3-46) Width

mm). If the

specified

micrometer

bottom

inch

should

width

limits

rings at

of

the

(2.81 -3.

be

0.1037-0.1117 of

the

replace

the

ring groove clearance.

NOTE: The rings are stamped is

the

top ring. Ring expander is inserted inside

number

1 and 2; 1

bottom ring. Place a

and

Using a feeler gauge measu re between measurements

Table 3-1 replace piston, rings and

straight

push

edge along the side of

the

rings into

the

rings

the

and

obtained exceeds

the

piston ring grooves.

the

ring

limits

grooves.

specified in

piston

set.

Mod

el

the

ends

of

the

not

the

measure

the

ends

top ring

01

mm).

rings is

rings.

piston

clearance

If

pin as a

Figure

3-47

TABLE 3-1 . STANDARD

RING/GROOVE CLEARANCE

SERVICE LIMIT

TOP RING

0.004-0.006 (0.

10 -0.15

BODOM

0.002 -0.004 (0.05 -

New

cire/ips

serious

RING

0.10

engine

inch mm)

inch

mm)

must

damage.

Must

be

not

inch

not

inch

used

exceed

(0.15

exceed

(0.10

to

mm)

prevent

REASSEMBLY

1.

Install

2. Apply

new

cyli nder base gaskets on crankcase.

light

coat

of

oil

to

piston

pin bearings and insert needle bearings into upper connecting rod.

Install piston

3. pointing sert piston no.

57001-910

piston. Secure piston

toward

to

connecting

exhaust

and

using

draw

rod

side. (Figure

piston piston pin

pin carefu lly

using

with pin new

3-47)

puller

circlips.

0.006

0.004

needle

arrow

tool into

In-

4. App ly a

light cylinders and outside rings

with

locating pins on piston and using

ng

compressor tool no. T57001

ri press

the

rings and ins tall cylinders over

pistons. (Figure

5.

Make

position

Install

sure

to

prevent

new

head gaskets to cylinders

Figure

coat of oil

piston

3-48)

breakage.

3-48

of

rings

to

pistons.

are

the

in

Align

-1

correct

metal section of gasket facing cylinders .

6. Set cylinder head s in place on correct c the

eight

and loosely install

lockwashers. Do

intake

manifold

is insta

not

tighten

nuts, washers and

cylin

der

lled. Refer

to

for correct torque.

NOTE: The long studs of

7.

the

Install spark plugs and

nuts

are installed on

PTa

side cylinder head.

torque

to

the

20

(2.77 kg-m).

inside

piston

30

with

ylind

nuts

Section

outsid

ft. Ibs.

. ...

of

com-

wide

ers

until

2

e

3-

42

CYLINDER

HEADS,

CYLINDERS

AND

PISTONS

Crankcase Assembly

REMOVAL

1. Remove ten nuts, lockwashers, one bolt,

crankcase halves. (Figure

lockwasher

and

3-49)

washer

washers

securing

and

IN

SPEC

TION

1.

Wash

us

Inspect crankcase halves

2. sc that

3. Check oil seals

tion. Replace seal

Check

crankcase halves in

ing

compressed air.

uffing

or any

may cause a crankcase leak.

for

washers

for

cleaning

for

imperfection

wear

, cracks

if

damage is suspected.

damag

e.

solvent,

scoring, in

the

or

deteriora

dry

pitting,

castings

-

Fi

gure 3-49

2. Usi ng a soft mallet to break seal and remove

Never screwdriver su crankcase

rfaces

pry

unusable

crankcase

or

will

be dama

gently

halves

similar

.

tap crankcase studs

low

er

crankcase

apart

tool.

ged

Sealing

making

half

with

.

4. Clean

5.

taper on

6.

7. coloration,

bearings if damage is suspected.

If bearings

57001-158

crankshaft

compressed air. Check

external Check

scor ing or signs Check rubber Check ings should rotate

binding or

keyway

threaded

PTO

both

crankshaft

require

to

for

internal

ends

"0"

wear,

grinding

replacement, use

remove bearings. (Figure 3-51)

in

cleaning

damage. Inspect

end

for

threads

of

crankshaft

of

excessive

rings

main

outer

or

skuffing.

freely

noise

solvent,

damaged

for

wear.

for

damage.

bearings

After

on

crankshaft

evident

dry

using

magneto

threads.

damage. Check

for

scratches,

for

dis

oiling

puller

bear-

with

no

. Replace

tool no.

-

3.

Carefully remove Remove oil seals and shaft. (F

igure

crankshaft

3-50)

1.

Oil Seals

Figure

3-50

wa

from

shers

crankcase.

from

crank

-

Figure 3-

8. If bearings are replaced you crankshaft rect end play exists

installed across flyweight. chart and install bearings crankshaft. Refer measurement and insta ll

and

shim

in

crankcase.

the

outsid e surfaces

Add shims as

areas. Add

bearings

CRANKCASE

51

as

required to assure

when

Measure

of

required

one

to

Figure 3-52

shims

one and

two.

ASSEMBLY

must

each

measure

crankshaft

distance

crankshaft

per

and

for

as

cor-

is

"A"

shim

two

to

correct

required

3-43

9.

New

bearings are easily installed on

shaft

after heating inside bearing race

heat

gun

or propane torch.

After

bearing is

heated properly, slide bearing into correct

position on crankshaft.

crank-

with

.....

a

t-----

A

-----!.~

NOTE:

bearings onto

SHIM CHART - DISTANCE

Measure bearing one bearing three. (Figure shim bearing crankshaft.

SHIM CHART - DISTANCE

8e

sure rubber

when

crankshaft.

DISTANCE

1.9551-1.0634 (49.66-49.87

1.

9469-1.9547

(49.45

1.9373-1.9465 (49.22-49.44

-49

.65

distance

chart

and place

two

and three and install bearing

DISTANCE

to

"0"

heating. Do

"A"

inch

mm)

inch

mm)

inch

mm)

"8"

from

outside . surface

3-52)

the

necessary

"8"

rings are removed

not

hammer

"A"

SHIMS REQUIRED

None

outside

of

Refer to

shims

"8"

SHIMS

bearings

2

4

surface

unmounted

the

following

between

three

REQUIRED

from

of

to

Figure

10. Check connecting rod side play by feeler gauge and crankshaft side clearance mm).

11. Check for excessive necting rod big end by the

connecting rod big end is moved up and

down

. Radial play should

0.0012

Place crankshaft in a

12.

and place a dial guage against each bearing. Rotate

difference in gauge readings

is

the measurements (0.08 mm)

between

flyweight. is

inches (0.

the

crankshaft

obtained exceeds

the

crankshaft

3-52

connecting

(Figure

0.016-0.020

radial clearance

measuring

not

020-0.030

flywheel

slowly.

runout

must

inserting

rod big end

3-53)

inch

(0.41-0.51

the

exceed 0.

mm).

alignment

The

for

each bearing

at

that

0.003

be replaced.

maximum

Correct

of

con-

distance

0008-

jig,

point.

inch

-

a

If

8.0158-8.0256

(203.61

8.0119-8.0157

(203

8.0080-8.0118

(203.41-203.50

8.0040-8.0079

(203.31

8.0001 -8.

(203.21-203

7.9962-8.000

(203.11

7.9922-7.9961

(203.01-203.10

7.9898-7.9921

(202

3-44

-203.85

.51-203.60

-203.40

-

.94-203.00

CRANKCASE ASSEMBLY

0039

.30

203.20

inch

mm)

inch

mm)

inch

mm)

inch

mm)

inch

mm)

inch

mm)

inch

mm)

inch

mm)

6+1,

None

1

2

3

4

5

6

5+2 ,

4+3

Figure

3-53

•

,...

INSTALLATION

1.

2.

3.

Install

Oil all

Align with fully

3-54)

"0"

bearings

crankshaft

recess in upper crankcase

insert

rings

to

crankshaft

.

labyrinth

crankshaft

bearings

seal

aligning

half

into

crankcase. (Figure

.

and care-

1.

Aligning

Figure

4. Install coat

install oil seals to crankshaft.

washers

of

grease to

in

crankcase grooves.

inner

3-54

section

Apply

of

oil seal and

a

Figure

Brake Light Dimmer

Light

3-55

Switch,

Brake Lever Assembly

Removal

NOTE: Entire brake lever assembly

placed to replace brake switch.

1. Remove brake cable bly.

~

-

1

/,'

~

'

-

2

3

2

light

from

switch

brake lever assem-

must

or

dimmer

or

be re-

light

When surface scratched

wear. the cloth

5.

Apply

and

6.

Secure crankcase halves washer

washer.

sequence

ft. Ibs. (2.21 kg-mI.

NOTE:

prevent

replacing

that

which

Always

shaft

before

crankcase sealer to

carefully

Apply

distortion

remove

surface

installing

attach

washers

Tighten

shown

torque

BRAKE LIGHT

bearings,

oil

seal

will

cause excessive

any

using

number

new

crankcase halves.

and one bolt,

hardware in Figure

in

one

of crankcase halves.

crankshaft

contacts

irregularities

400

oil

seals.

lower

crankcase

using

ten

lockwasher

evenly and in

3-55.

third

increments

SWITCH,

may

be

seal

on

emery

nuts, lock-

Torque to

DIMMER

half

and

the

16

to

LIGHT

SWITCH,

1. Socket Housing, 3 Position

2.

Socket Connector

3. Socket Housing, 2 Position

4. Lock

5. Lever Pivot Pin

6. Brake Lever

7. E

8.

BRAKE LEVER

Screw

Clip

Washer

Figure

3-56

ASSEMBLY

3-45

2.

Insert a screwdriver handlebar pull

to

handle

loosen

grip

from

between

the

grip

handlebar

handle

from

.

the

grip

bar,

and and

Insert a screwdriver

2. handlebar pull

to

handlegrip

loosen

from

between

the

grip

handlebar

handlegrip

from

the

.

bar,

and and

3. Remove brake

circuit

board.

4. Loosen lock

sembly

from

socket

screw

handlebar

and

housings

slide

(Figure

Installation

1.

Install in reverse to

2. Check brake

Section

Emergency

25

brake

ft

lever

order

. Ibs. (3.36 kgm).

lever

2.

assembly

of

removal.

adjustment

Stop or Throttle Lever Assembly

Removal

NOTE: Entire

placed

1. Remove

to

sembly.

throttle

replace

throttle

lever

emergency

cable

from

assembly

stop

from

printed

brake

on

Tighten

as

3-56).

the

handlebar

lock

described

lever

Switch

must

switch.

throttle

lever as-

as-

screw

be re-

in

3. Remove

printed cated.)

4. Loosen lock throttle

&

~'

the

circuit

lever

-1

1. Socket

2.

Socket

3. Lock

4. Lever Pin

5.

Throttle

6.

Washer

7. E Clip

throttle

board. (Note

screw

assembly

2

Housing,

Connector

Screw

Lever

Figure 3-

socket

(Figure 3-57),

from

57

housing

where

the

handlebar.

2 Position

it

and

from

is lo -

slide

Figure

3-58

1. Socket

2.

Socket

3.

Machine

4. Rubber

5.

Headlamp

6. Lamp

7.

Machine

8.

Adjusting

9.

Bulb

10

. Bulb

11.

Wiring

12. Bracket

13. Rivet

Housing

14. 15

Gasket

16. Washer

17. Lockwasher

18 .

J-Clip

19.

Capscrew

Housing Connector

Screw

Spacer

and

Screw

Retainer

Harne

Assembly

Housing

Lens

Spring

ss

Rim

Assembly

3-

46

EMERGENCY STOP SWITCH, THROTTLE LEVER ASSEMBLY

Kawasaki SA340-A1, SA440-A1 Quick Reference Manual

Specifications and Main Features

Frequently Asked Questions

User Manual