Sachs SA 2-440 Repair Instructions

(SJ

SACHS

Repair Instructions No. 4072.8 E SACHS

SA

2-440

Snowmobile Engine

Edition December

FICHTEL & SACHS

1970

AG . D-8720

SCHWEINFURT

CONTENTS

Introduction In

stallation

Te

chnical

R

epoi

Di

smontling the engine

Work

Assembling

Engine with BaSCH Bendix.

In

structions

Instructions end

Test-running

loying

lubricotion Tightening Trouble-s

dimensions

deta

r tools

end

ossembly

on

ind

ivi

dual

components

Replocing

Reploci

Receil

Mogneto

Replocing ignition

Replocing

Corburettor Decorbonizing

Ignition timing

Operation, Storter

BOSCH Bendix-pinion

up

hooting

crankshaft

ng

fan shoft

starter

. . . . . . . .

generator

the

flonged

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

the

Fa

end

ond

end

the

engine

ond

torques

engine

wiring

. . . . . . . . . . . . . _

........

mointenance

ults . . . . . . . . . . . . . . . . . . . . . . .

diegram

wiring

diogram

running-in

.. _ ...

moi

ntenonce

for bolts

chart

. . .

i

ig

beorings

beor

ceils

end

hub,

exhaust

pinion

type

period

chert

ond

...

ings

ignition

the

muffler,

type

ond

lubricotion

for

magneto

for

mogneto

electric

nuts

.

lead

s with

mogneto flyw

the

cylinders

.....

electric

starter

of

generator

(type DG)

spark

heel

ond

.

(type DG)

the

electric

12 V 40 W ond

12 V

...

plug

the

storter

75

(fold-out (fold-out page)

terminals

cam

cylinder

.

12 V 75 W

W

heads

Poge

2

poge)

4

6

10

12 12

15 16

17

18

22

23

27

32 33

35

36

38

40

41

42

43

44

INTRODUCTION

This manual is designed to

give

dealers and

their

staff

all

guidance and information necessary

to

enable them to

pro-

vide

and efficient

repair

and maintenance service, but

it

is in

no way intended as a substitute

for

the

practical and theo-

retical training available to person ne I

at

our

Service

Training

School.

It will be found useful as a ready reference in

day-to-day

workshop

practice.

Gur

illustrated Spare Part s List, which shows the

various

components in detail, will also be found helpful when used in conjunction with

this

booklet.

Naturally

, good maintenance and

repair

work

and

efficient

servicing call

for

good

equipment, a well-equipped

workshop

and ski lied personnel. Dealers

are requested to make this manual and all

SACHS

Service Bulletins, which contain technical

modifications

,

available to

every

individual

responsible

for

actual

servicing

.

The

proper

place

for

this

kind

of

technical

infor-

matio

l1', is

in

the

workshop

and

not

in

the

filing

cabinet. We hope that this manual will be

of

real practical assistance

to

all

our

dealers, agents and associates.

FICHTEL

&

SACHS

AG

0-8720

SCHWEINFURT

Service Department

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TECHNICAL

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DATA

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/un·'" I"gine ond

....tri< pr

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on

oi.

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Fot date.minin" Ihe

1o

Ge.mon Stondord

Hg

ond

b.

multiplied by

01

temperatur.

ee

'l

= 2O'C),

01

OIItp

.. t

;.

mtO'ured

b" _ 760

of

'L _ 2O'C

± S .,..

pow"

DIN

Ihe

<orr.er

opplie.

10

01

mm

HiI

output

o,cordin

6270

(bo ..

IlbovI outp"t

io

..

10"0.

" fully

11

boro-

on<!

(68'FI,

736

h,"lo

0

"I

g

mm

.97.

,~

"-

,

-

glP5h

,

..

'"

..

,

W,

..

,

''',

-

,~

4000

5000

~

...

,

~OOO

U/minl.pm)

M

V/m'"

'""

..

....

U/mi"

""

1000

,,,

.

It,lb

'"

~

"

•

(.pm)

(b/HPh

'.'

..,

...

U

.,

(rp",j

In

'he in'

".u

01

ledoni,ol

p.ogr

...

""1

r •

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rv.

,h,

r'''"

' 1o

in

trod

...

ce

modilicoti

onl

wilhout

noti'

l.

Technical

data

Type: Cooling :

Direclion of rololion of

engine

:

Copocily: Bore : Strake:

Compress ion Oulput : Cronkshoft beo rings : 4 on li-friclion

Eng

ine lubricot ion :

Ignition :

Ignition timi

Contocl

Pole shoe

Spork plug:

Corburetlor

Corb

Air inlok

Storling m

breoker

urellor

e:

ratio

: 9.3 10 1

ng:

gop

:

sett

elhod

gop

: 0.4 ± 0.

:

ina .

,

Siopped Runn

Siopped Running engin

TlllOTSON

Tw

o-cylinde r Iwo-cycle

Anliclockwise

Oil.in.gasoline

mognelo

BOSCH

engine

ing

:

engine

:

engine:

e:

BOSCH

diophrogm

Moin jel: 1'1. lurns Idl

ing jet : 1 lurn

on

request BOSCH Bendix-pinion type

elect r

(necessory

Fon-Iype

oir coolil1g

(seen on cronkshofl p.

43

7 ce (26.

(/)

67.5 mm (2. mm

(2.402 in

61

35

HP

(OIN)

gosoline

/oil

generolor

0.25 ... 0.

30

3.

25

mm

50

.. .4

.00

mm

05

mm

(0.0

...

29

mm

\0.

11

mm

7 ...

(see note on

0.2756 ...

W260T2

corburellor

open

via 1 inloke stock

Recoil slo r

ic

storler

bollery

gosoline

646

cu. in

657 in.)

.)

01

6500

beoring

lubri

cotion

ratio

25

12 V 75

bef

ore TDC

before 16

± 0

9843

... 1.1417 in'l

0.4331 in.

orW240

poge

HO

ler

12 V - 0.4

12

V 32 ...

engi ne

I. o. side)

.)

rpm

s

,

: 1

W or 40 W

!O.0098

TDC 0.1378

.002 in.)

T 1

24) 131'

/1-

HP

38 Ah)

---

... 0.0118 in'l

... 0.

(0 38.10

---

1575 in.

mm

--

---

)

--

bhoust

pipe:

Exhousl muffler :

Exhousl moni ond inlerm

150

lenglh

fo

ld (F & S

ediole

pipe

mm

(5.906 in.) (nol

Swirl

(F & S

part no. 1473019001)

pari

42

type

mm

no.

supplie

3673

(1.654 in.)

d by F & S)

003

001)

L C.,

I

3

REPAIR

TOOLS AND ASSEMBL Y

~

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5

6

~

11

,8

Ä

~

1

7,8

2

JIG

n

~17.9

3

7

4

~

9

8

4

21

18

12

10

~

13

~

14

r:ri

15

11

16

C1i

17

IlIuslr.

No

.

1 2 3 0977

Porl

0276065 0977

069 068

No.

4 3676004001

5 3676005000

3676002000

6

0976

7

111 8 0276035100 9 1476018000

10 11

12

0276170000 0276175000 14

76013000 1476011000 1440027001 14

760

13 14

15

16

120 1447009000 1476014025

1476014000 144701 0

17 1476015000

18

19 20 21

0276081000 0276082000 0276085005 0977

041

101 000 000

100

00

000

I

Repair

.oolt

Gudgeon pin extroclor In

ser

t for gudgeon pin extroctor

locoti

ng

WithdrowoJ

Fitting tool for flonged hub Retaining fork Retoining lever

Ignition timi ng gauge Adju T orque wrench

Revolution counter Extroctor sleeve

Threoded sleeve H

ex

Thrust Clomping

Extroctor Extroctor

Clompi

Extractor

deep

pin for piston

1001

sting

pin for flyweight

ossy.

head bolt . replocement ports

beorin g for

ring,

58

roller beoring inner roce NJ

shells for cylindricol

shells

ring,

sh

ells

for bearing

75

for

ng

groove ball beari ng

Ass.mbly jig

Clomping ba Swivel unit

se

Clamping ball

Assemb

ly brocket

Denomination

f

1476

mm

I.

D.

mm

I.

D.

6305 N C3

013 000

206 E C3

bush

(recoil starter)

NA

5

DISMANTLING

THE ENGINE

Detach

all

contral

cables

between

engine

ond

frame

.

$crew

off

cover

(wit

h inscription SACHS) .

Pul1

ignition

leads

with

rubber

boots

out

of

the

recesses

ond

remove

cover.

Disconnect

electrical

wir

ing

bet

ween engi

ne

end

frame

cf

the

terminals

(2

end

3,

F

ig.42).

Remove

exhaust

muffler,

exhoust

tube

end

manifold

.

Remove

the

engine

end

clean

it

thoroughly

be

fore

toking

it

aport.

When

giving

the

engine 0 general

overhaul,

components

should

be

dismounted

in

the

seque

nce

ind

icated

.

f ig. l

Fig. 2

6

I"take stack, carburettor

and recoil starter

Fig. l

Mount engine

on

asse

mbly

i

i~

(repair tools

no. 18, 19, 20 ond 21)

with 2 hex

head

bolts M

'0 x 30

,

os

shown

in

the ill

ustration

.

Sc

rew

off intoke

stack

(5)

wit h

rei

nforcement

ring

(4)

.

Pull

off

impulse pipe

(2)

.

Remove

carburettor

(3)

(ta king

co

re

of

insulati ng sl

eeves

a nd

go,ket).

Unscrew

rec

oi l

starte

r

(1)

to-

gether

with inser

ted laby

rinth

ring.

V-pulle

ys

and V-belt

Fig. 2

Use retoining

fork

\3,

repoir

too

l

no

. 6)

to hold

the

id

er

pulley half

(l),

os

shown

in

the

illust

ratio

n.

Unscrew

nut

and

remove

idle

r

pulley

half

(taking

ca

re

of

wosh-

ers). Unscrew

pulley

(4)

and

remo

ve

it

together

with

V-belt

(5).

Remo

ve

secand

idler

pulley half

together

with

washers.

Remove

Woodruff

key from

fan

shaft

(2).

Magneto

Fig. 3

Use no

os

unscrew

Remove

Fig. 4

Repos itio n

shown

retaining

.

7)

10

hold

shown

nut

washer

in

the illustration,

flywheel

lever

magneto

in

Ihe

(2).

(1)

retaining

(3,

repo;r

illustration,

.

lever,

move mogneto Ilywheel

means

cf

pair

tao

Remo

ve

crankpin

withdrowol

I no. 4

).

Woodruff

.

tao

key

tao

flywheel ,

end

os

end

re·

(2)

by

I (1, re-

from

I

Fan housing, fan

plote

Fig. 5

Unscrew

out Detoch

plote

uns

Ion

(3)

crew

fan

housing

(1)

(sliding lit).

leads

ot

the

ormature

end

(2)

fram

terminals

plote

armature

end

take

ormoture

ond

.

Fig. 4

Fig

. S

7

Fig. 6

Fi

g.7

Fi

g.8

8

Cylinder cover halves

and

upper

part

of

intake manifold

Fig

. 6

Unscrew self-Iocking nut (1,

Fig

.

41)

end

threoded

pin.

Unscrew 4 serews

(1)

ond

remove eylinder cover hclves intoke ond exhaust

side

(2

ond 3).

Unscrew

upper

port

of

inloke

monifold.

Lower

part

of

intake

manifold

F

ig.7

Unloek nuts (1), unscrew lower

port of intoke monifold

(2)

and

remove both gaskets. Exhaust tubes, cylinder

heads

and

cylinders

Fi

g.8

Unscrew exhoust tubes

(1)

with

on

ordinory

strap

wrench, only

if

neeessory.

Un

serew eylinder

heeds

(3)

end

remove eylinder heod ge skets. AHention

Mark

ey

linder

ond

piston (power

lakeoff

side)

tagether.

Remove eylinder s

(2)

end

eylinder

flonge

gasket

s.

Note

:

The

Alu-Chromel cylinders eon-

not

be

rebored

.

eylinders

end

pistons

are

divid-

ed

info to l

erance

groups A, B

and

C.

M

ount

only pistons

and

eylinders

which belong

10 the

same

toler

-

enee

group.

The eylinders

are

morked wit h

eorresponding letters

(A, B or

Cl

01

Ih

e uppermosl eooling fin. In

toleronee

group

A pistons with-

out rings

end

gudgeon

pins

are

ovailable

separately

(see

spore

parts list)

,

Pistons

and

ne

edle

Fig. 9

Piece piston

led

wooden

on

home-mode

board

(41.

Cover the cronkcose,

bearing

wire circlips. out

gudgeon pin extroctor ond

insert

When make sure ore

in

If

necessory, force

pin with

(3,

repair

(2,

repOlr

fitting the steel bond,

thot

their

the piston rings

grooves

s

slol-

toke

out

gudgeon

tao

I no. 1)

tao I no. 2).

. (Donger of

breoking piston rings.) Remove Remave

mark

it

,slotted

needle

taget

wooden

bearing

her

with

board

(1)

the

.

and cor- F

responding connecting rod eye. Note

:

When

replocing wolch toleronce mark necting rads (see

needle

spore

bearings,

on

con-

pari

lisll· Unscrew crankcose from as-

sembly

jig.

ig

. 9

s

Crankcase

Fig. 10

Unscrew screw plug

Unscrew 12 nuts from lower

and

crankshaft

Ihreaded

(21.

nipple

(11

ond

part

of crankcose.

Split crank.case by slightly top- Fig.

ping with 0

F

ig.1

Remove ail seals

out disc halves ( cylindricol pins

Clean When

rubber

mallet.

1

(1

and

3), take

cronkshaft (4) both locking

1,

Fi~

.

321

ond

bolh

(2).

oll ports thorough

giving the

ly,

check for

engine a general

Use

only

genuine

Fig.

weor

overhoul oll sealing elements should be reploced.

10

11

and

reploce

SACHS

if

necessory.

spare parts.

F&

S40U'1I

9

WORK

ON

INDIVIDUAL

COMPONENTS

Replacing

Of

Ihe cronkshoft

end

Ihe cylindrical roller

Removal

Fig.

12

Remove

(

1)

01

Remove (7)

by

sleeve (3,

cf

outer race

beoring

inner

meons

repoir

crankshaft

inner roc

.

of

Remove shims

bearings

beorings

(4)

race

(1)

suitabl e

tools no . 12, 13, 14, 15, 16

{Bl

.

only Ihe

bearing

es

cf

cylindricol roller bearing end roller eoge from inner

of

cylindricol roll

edrector

on the

cylindricol roller

shells (5

deep

er

groo

power

bearings

bearing

end

ond 17)

ve ball

tokeoff s

end

--4

ond

6),

clamping

.

beoring

ide

can

deep groove

the

deep

rings

on Ihe

be

replaced

groove

(2)

mogneto

.

ball

bearing

Fe S 4072:

ball

bear

ond

extroctor

side

s.

27

roc::e

ing

A"ention

If

shims

have

cylindricol roller

10

been

domoged

bearing, reploce

dur

ing the

Ihem by

operation

new

ones

cf

removing Ihe inner

.

race

of

Ihe

Measurin9

Perm issib

.he

le axi

axial

play

al

ploy 0.3 ... 0.6

of

.he

cra

nks

haf.

mm

(0.0118 ... 0.0236 in.)

Fig. 13 Fig. Fig. 13

Before meosuri ng, the

crankcose

In

sert

locking disc halves

clean

the grooves for

the

locking disc halves

.

(1)

into

upper

port

of

Example:

Upper

port

of

Distonce

Fig.

14

Fitting dimensio n Dimension to cylindrical Widlh Width

Distance Fitting dimension

Existing axial Perm

issi

Difference The

difference p. t. o. roller

bearing.

Fitting beari

ng.

H

eot

deep

10

aboul

Slip d

eep

ring

9roo

In

sert

shims (8, Fig. 12) on

beoring

After the

During this

cronkwebs. This

crcnkshaft

cronkcose:

between

01

ball

of

roller

in

the two locking disc halves

of

cronkshaft crankshaft roller

bearing

fram

bearing

upper

port

of

cronkcose

cronkshoft

ploy

ble aXial

side

the

70 ... 80 'e (158 ... 176 'F) .

ve pointing

unlil

bearing

play

to

be

compensoted

of

0.4

. The shims

deep

9roove

it

reache

ball

has

operation

piece

mm

is

are

bearing

towards

s 0 s cooled , a suitable pie

must

con lie freely in position.

:

deep

groove

seat

compensated

to

be

placed

ball

bearing

(wilh on

cronkp

cronkweb). crankpin fop

be

(collor

off

, press

lorge e

p. t.

by

directly

and

0-rin9

o.

facing

inner

ce

of

nough

in

ball

inserting shims

the

removed)

mogneto

side

towards

roces

material

10

14

cronkcose

bearing

below

the

inner

ond inner side

and

fit

cronkweb).

completely

should

be

supported

.

seat

inner

race

unlil a

inner

209.4

175

+ 17.0

+ 16.0

- 208.5

(8,

Fig. 12)

of

ro

be

ct

in

the

upper port

mm

.5

mm

208.5

mm

209.4

mm mm

0.

9mm

0.

5mm

OAmm

on

roce

the

roce

ce into

ploced

.he

of

the cylindrical

cylindrical roller

of

roller

stop

is

of

cylindrical roller

the

ir seafs.

between

bolh ends

8.2441

6.9095

0.6693

0.6299

8.2087

8.

2441

8.2087

0.0354 in.

0.0197

0.0157

crankp

bearing

reached

so

thot

of

in

in in

in

in.

(0 -

the the

.

. .

.

in

11

Never

clamp

the

crankshoft

inner

roces

by

unserviceoble

Piece

auter

(groove Wel bearings

for

O-rings (5, Fig. 11) slightly with oil

.

hommering

. •

race

cf

O-rin~

facing

in

cylindricol

towords

0 vise

ol:a

cronkpin

. This will crush

roller

bearing

cronkweb)

end

the

with

.

insert

or

of

the

webs

roller

them into

webs,

end

cage

ond

render

onlo

the

auter

never

Iry

the

cronkshoft

the inner

roces

of

10

ra

fit

ce

the

~eplacing

. Fig.

15

fan

shaft

bearings

) Mtallation . .

:. F-

i11

deep

.

when

Force first

a

stop

Insert

F

orce

pressure

Recoil

gtöove

instolling thot

is

reoched

fan

in second

on

starter

deep

shaft

the

ball

groove

(in

and

fit

deep

outer

bearing

the

encosed

ball

doing

washer

groove

roce

half

with"hi

sides

~

so,

of

bearin

ball

the

\ \

.g into

exert

press

(2

~

mm = 0.0787 in. thick)

beoring

\Ji!P

"'"

ure

).

gh

the

Removal

Fig.

1S

There

is

bearings

Deep

groove

only

be

side

from which they nove

fitted .

Heat

fon housing (

100

...

150'( (212 ...

take

out

beerings housing port. Take tween

the

Note :

't

' Remove lock ring

only if

necessary

temperature

pointing

warm

on

the

until 0

stop

towords

houslng outer

race

:-

.,

•• s

reac~ed

bearing

onJite

Dismantling

Fig.

16

,

Take

out

•

,~e~

7

/ /

",

out

s'p

flng ring, fricti wosher (0.1 ~ 0.0039 in. thick) and

starter

0 lock

ri

n9

the

boll

between

fon

housing.

bearings

towords

1)

10

in

remov.ed

302'F)

balh

deep

groove

by slightlY knocking

ogoinst 0 wooden

core

of wosher

beorings

.

in

bearing

.

grease

cylinder

bearing).

(in

doing

. Take

.

side

so, exerl

the

of

outside

the

...

laby~inth

brake spr

pawls

ring

ing

on

(4

and 5).

(1)

.

(2). shim,

plate

baln

can

the

been

cbaut

end

ball

the

sup·

be·

seat

car

until

(3),

e

.

Fig.

16

12

""s

«171

: J1

Sachs SA 2-440 Repair Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual