Sachs SA 340, SA 340 SS (super sport), SA 370 Repair Instructions

c(SJ

SACHS

-

Repair Instructions No. 4075.8 E $ACHS

Type

Snowmobile

SA340

Engine

.

340

370

SS

(super

sport)

~

Edition

FICHTEL&SACHS

December

1969

AG · 8720

SCHWEINFURT

.

·~·

CONTENTS

Preface Installation {with Installation (with Installation

Technical

Repair Taking Work

Asse Test

Engine

Instructions

BOSCH solenoid

Instructions

BOSCH

In

structions and BOSCH iner Laying-up Lubrication

Tightening

Repair Engine

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

dimensions

solenoid-controlled

dimensions

inertia-pinion

dimensions

data

tools

and

down

the

on

individual SACHS (without

spe

dismantling Changing Recoil

star

Flywheel

Replacing Carburettor Decarbonizing

mbling

the

-runn

ing

and

with

BOSCH

with

BOSCH

Operation,

Starter

faults and and and

and wiring

solenoid-controlled

tia-pinion

the engine ..

and

torques dimensions fault

s .

for

type

for

assembly

SACHS

starter)

SACHS

starter)

SACHS

jig

SA 340 ..

.

SA 340

SA 370

and

...

and

engine

parts

. . .

cial

extracting

crankshaft

ter

..

dynamo

the

magneto

the

bearings

.

..

housing

tool for

crankshaft

engine)

..

. . .

..

centering tool

or

. 0 • ..

the

. . . . 0 • • 0 • • • • • • • • •

the

exhaust

engine

. . . . . .

running-in

solenoid-controlled

inertia-pinion

maintenance

o o o o o

wiring

d i

agram

wiring

diagram

wiring

diagram

-controlled diagram

wirin g d i

agram for

type

maintenance chart

for

bolts and

..

.

...

muffler,

the

engine

type

and

lubrication

••••

for

dynamo

for

dynamo

for

dynamo

starter (Type

for

dynamo

starter

(Type DD) . . . . . . . . . .

dynamo

starter

(Type DG)

o

••

nuts

. . . .

cylinder

..

. o • ...

starter

o

•••

magneto magneto 12 V 75 W .

magneto

DD) . . .

magneto

.

SA

340 SS

..

SA

340 SS

oil

.

flywheel

and

•••••

. . . . .

(Type DD)

(Type DG)

of

electric starters

o • •

12

12 V

12 V 75

.

seals

cylinder head

••

• •

V 40 W .

40

Wand

......

Wand

Folding

Folding Folding Foldi

.

ng

Page

2

sheet

sheet sheet sheet

4

6

9

11

13

16

18

19

22 23

28

29

30

31 33

34 35

36

37

38

39

40

41

42 44

PREFACE

This

manual guidance an

efficient intended training school.

It workshop details found

Of service workshop,

.

Dealers circulars available It for

available

will

be

of

helpful when

course,

to

are

is

emphasized

u,se

in

is

designed

and

information

repair

as

and

a substitute

to

found

useful

practice.

the

various

good

maintenance

customers

and

trained

requested

containing

to

every

that

the

workshops

to

necessary

maintenance

for

personnel

as a ready

Our

illustrated

units

and

used

in

call

for

personnel.

to

make

technical

individual

all

information

give

dealers

to

service,

the

practical

at

our

customer

reference

Spare

their

construction

conjunction

and

repair

good

equipment,

this

manual

information

responsible

of

and

not

and

enable

Parts

with this

work

and

for

this

nature

for

their

them

to

but

it

is

in

and

theoretical

service

in

day-to-day

List,

containing

, will

booklet.

and

a well

and

all

modifications

actual

servicing.

is

office

staff all

provide

no

way

training

also

be

efficient

fitted-out

SACHS

intended

filing.

We to

2

hope

all

our

that

this

dealers,

manual

agents

will

and

be

of

real

practical

associates.

FICHTEL & SACHS

SCHWEINFURT

Service Dept.

assistance

AG

Technical

Descripti

Type: Fan-cooled single-cylinder two-stroke gasoline Direction Swept

Bore:

~

Stroke :

Comp

Output:

Ignition:

Ignition

Contact b reaker

Pole shoe

Spark

Carburettor:

Carbure ttor setting :

Air

Exhaust muffler:

Method

Engine lubricati

w

Data

on:

of

rotation: Anti-clockwise

capaci

ty:

ression

ratio:

ti

ming:

gap:

plug:

cleaner:

of

starting:

•

on:

SACHS

SA

340

9

22

HP (DIN

) at

525

0 rpm

12 V

12 V 75

240

= 1 tu

rn

T 1

open

BOSCH M

Main jet = 1 turn open

Idling j

et

SAC

HS

as

cu in.)

in.)

rJ;

3

36

75

cc

(20.503

.5

mm (2.972

I

26

i

BOSC

0.4 ± 0.05

running engine

running engine 7 ...

I

Tl

LLOTSON diaphr

HD-13

~

12 V

stopped engine : 0.2 ... 0 runn ing engine: 4.1.. .4.7

40

W equipme nt : stopp

W equipment: sto

I

Swirl-type exhaust silencer

on

,~·

request solenoid-controlled starte r 12 V 0.4 H

or

inerti

necessary battery

Two

-stroke mixture mixed

SA

340

seen on the output sh

75

mm

(2.779 in 11

HP

(DIN)

H flywheel magneto 40Wor

.4

mm mm

mm (0.

ed

engine

pped

engine

BOSCH M

A 1

'h''

(38.10

Intake silencer

Recoil starter

a-pini

on type

SS

(super sport)

.)

at

6000

rpm

12

V75

W

before

TDC

before

TDC (0.1968 ... 0.2283

016

± 0.002 in.)

32

...

36

14

...

18

25

...

29

11

260

T 1

agm

car

burettor

mm

dia

Main j

Idl

starter

}2 Volt

32

25

: 1 ratio

I

engine

aft

of the engine

I

'·

I

(0.00

79 ... 0.01

mm

(1.2598

...

(

0.5511

mm mm

mm (0.2756 ... 0

...

(0.9842 ... 1.

I

.)

I

et

= 1

in

1f,

g jet = 1 t

12

V- 0.4

.. ,

38

Ah

HP.

23.5 with carburett

24.5 wi

57

in.l in.

1.4

173 in.l

0.7087 1417

.4331

HR-1

turn open

urn

open

P.

SA

CHS

SA

368

cc (22.4

55

rJ;

79

mm

(3.1

9.7

HP

(DIN)

or HR-

HP (DI

N)

th carbu rettor

in. in.l

in.

BOSCH M 240

8 A

1'

11•"

(

30.

370

cu in.) 10

at

5250

at 5250

HD-

T 1

16

mm

in.

)

rpm

18

A

rpm

13

A

dia.

)

REPAIR TOOLS

AND

ASSEMBLY

JIG

'{J

14,6

21,

-

1

2

·

~

'{J

6

~

,._

.

..;

'fJ21

,9

Cj

3

4

9

12

13

14

~

17

4

11

15

16

F &

SI..071:22/2

lllustr.

No.

1 2 3 4

5

6

7 8

9 10 11

12 13

14

15 16

Part number

0276 065101

1447 020 000.8

011

1449

000.8 0976 088 100 0976

111

100 Retaining lever

0276161

101

0276 164 102

1476 012 000

0977 063105

0276 135 000

137 6 020 000.8

0276 170 000 1476 013 000.8

1447 009 000.8 1476 014 024.8

1476 014 000.8

1447 009

001

147 6 014 023.8

Repa

I

Gudgeon I

nsert Locating pin Protective

Oil

seal

Ex

tra

.8

Thrust b

spare Extractor Ti

ming Revolu

rque

To-

xt

ractor sleeve

E

cons

1476

1440 027 001.8 h

1476 012 000.8 Clampi ng ring, Extractor

of

tractor

Ex

(recoil Clampin

.8

xtr

actor

E

bea

D

es

cription

ir

too

ls

pin ex

tractor

for gudgeon

cap,

for

piston

14 mm

extra

ctor

dia. bore

extractor

ctor hook

gauge

ti

ear

ing a·ssy.,

part

for

on

counter

4 mm

for

magn

for

(1

0276161

eto

fly

spark

advanc

piece

101

whe

)

el M 50x1

e

key X

assy

.,

isting of:

011

roll

000.8 extra

she

lls

er

bearings

shells

st

arter)

g ring,

shells f

ctor

exagon

thrust

I.

D.

for

sleeve head

bearing

bolt assy.

58 mm X X

inner races

NJ 306 C3

bearing

NA

bushing

. . . . . . .

I.

D.

85.5 mm

or groo

ved

ball

ring 6306 C3

for

engine

tn tn

0 0 0

.... ....

""

<(

<( <(

tn tn tn

X X

X

X X X X X X X X

X

X X X X X

X X

X

X X

X

X X

,.._

""

X X X X X X

X

X X

X X X

X

X X

X

I

17

0276

081

18

0276 082 000 Swi

19

0276 085 005 S

20

0977 0

41

000

Assembly jig

Clamping

ve

base

l unit

etscrew

Mounting

plate

X X X X

X X X X X X

I

X

I

5

TAKING

DOWN

THE ENGINE

Remove

etc

U Un Rem

When

se

Fi

all

deflector

the

giving

conn

engine

.).

nscrew

screw exhaust mu

ove

quence indicated.

g.

1

ections

from engine

on

cyl

inder

on

ffl

er, i.e.

man

and clean thoroughly bef

the

engine a gen

eral

to

frame

SACHS SA

ifold

and

ove

rhaul , comp

and

340

and

bracket.

ore

taking

unit (cables, ele

SA 370,

onents shou

Exhaust electric

Fig. 1

Scr sembly bolts adjoining illustration.

Pull Remove

carburettor Rem

insulating Rem

sary. Unsc

Re

Fig. 2

Detach Un Hold

lev screw hub

Rem s

Unscrew ga

if there is one.

down.

muffler, carburettor

starter

ew

dow

jig w ith 3_

M l 0 x 40, as shown in the

off impu

ov

e rns.ul

ove flan

rew

coil

starter, starter

reco

lock nut in the

sta·rter h

er

(3,

th e n

with

ove

pace

r.

sket.

ctric

ld

be removed in t

n engine on the as-

hexagon

lse pipe

int

ake

sile n

(2)

.

ating

flange.

ge

{l) only

electric

spr 2 cylin

starter

il

starte

ub with r

repair too

ut

and re

ing ri

ng

dri

fan

(l)

starter

connections

hecid

(4).

cer

(3) and

sleeves

if

neces-

(5).

hub

and

r.

hub

etaining

l no. 5), un-

move starter

and

washer.

cal pins

and

remo

he

and

fan

(2)

ve

.

Fig. 2

6

Cover

plate

(onl y

and

fixing

wit

(l

).

Fig. 3

Unscrew lead

and

cover

Detach leads and 3 of remove fan

Note:

Remove _

housing

nection, if

the

terminal

housing

cover

for

electric starter con-

fitted.

When removing

pull

the

insu

l

ead through

T

ake

Note:

Rem

ove

on

ly

if

Re

mov

circuit

Detach

in_s

ulator

mount

Re

lating hose .

care of c!owel

. ·

short-circuiti

necessary.

e ·ru

bber

ing button.

short-cir

. :

part

s in

fan

housing

clip

for

h 40 W

equipm

at term

box

(3)

flanges on

the

fan

tub

ng

cap

(2)

c~itin

g.le

reverse ord

ignition

ent)

inal

s 1, 2

(6)

and

.

fan

housin

(5)

with

es.

button

and short

·

ad

f

rom

er.

g,

F & SL.-075: 22

Fi

g. 3

-

Magneto

Fig. 4

F

it

.

4)

F

it no. pull

th

e ex

no

Labyrinth ring ba

Fig. 5

Un On

pull of pull rubber cap

protect

to

threaded

ret

aini

5)

to

off

the fly

tra

. 7

).

se

plate

screw lab

engin e

ignition

the

spark

off

rubber

flywheel

ive

ng lever (l , magne

ctor

wit

(2)

ignition lead Un

screw

rem

and

).

armature

ove

(on

insul

Woodr

and tion lead ment)

ead

l Remove

cap

(re

pair too

end

of

crankshaft. repa

to

flywheel

wheel

by

(2,

repair tool

and

armature

yrinth

rin

g (5).

h 40 W equipm

lead

with

spri

plug terminal

sleeve (1) a

and

screw

socket.

base

it together w

ly with

40 W eq

ating

tube (w

uff

key

.

ir tool

means

ng

out the

plat

e (4)

ith

igni-

uip-

l no .

and

of

ent,

out

(6),

nd

ith

Fig. 4

Fig. 5

7

Fig. 6

Use only genuine

SACHS

spares.

Cylinder

head,

cylinder and

piston

Fig. 6

Unscrew

cylinder

head

and

linder.

On

SACHS SA 340 SS,

cylinder

Pull

Dang

( rings

Remove

off

er

.)

head

cylinder

of

cylinder

gasket.

without

breaking

flange

remove

twisting.

gaske

Note:

The

cylinder

twice.

A

(see

cylinder

Use

Spare

piston

be

rebored.

Place

cylinder

s

lott

ed

wooden

Cov

er

the

two

sar

y,

force gudgeon tool

no.

tool

no. 2).

When

fitting should the

be

piston

ves. (Danger

can

appropriate

Parts

List).

with chromium

bearing

surface

on

board

crankcase,

wire

circlips. If

out

gudgeon

extractor

1}

and

insert

the

steel

taken

rings

are

of

breaking

be

home-made

(1

take

(3,

(2,

band,

to

ensure

in

their

rebored

-pla cannot

).

neces-

pin with

repair

piston

rings.) Remove

slotted

wood

en

board.

Crankcase and crankshaft

Fig. 7

Unscrew 6 hexagon screws

from

crankcase.

socket

Unscrew hexagon head bolt Fig.

3)

t

apping

er

takeoff

rubber Remove

tak

eoff

care

of

Unscrew oil

drain

Uns

crew

side

from

he

at

it

F)

for

(grooved Clean

all

for

wear

and split

the

hammer.

crankcase

side

dowel

screwed cock

crankcase

the asse

to

1 00

removing

ball parts

and rep

crankcase

side slightly

ha lf

with a

half

and

gasket.

tubes.

nipple {1}

(2).

half

magneto

mbly

...

150 ° C (212 .. . 302 °

the

bearing)

jig

crankshaft .

thoroughly,

lace

when ne-

power

cessary.

cy-

piston

t.

piston

ted

out

repair

care

that

groo

head

{4, by

pow

Take

and

check

-

8

WORK

ON

INDIVIDUAL

PARTS

SACHS

special extracting tool

for

(without dismantling the engine)

FICHT

EL

da

mag

ed

oil

necessary.

& SACHS

Engine t

roubles

relatively short time. When

replacing

Extracting oil

Fig. 8

Before

ext

racting

to

record

sure si

on

x, o new same

or

oil

seal can

dimension.

Note:

If

the

correct

ion

is

s troubles bor tati

not

may

es

in the era n kcase

ng

parts

parts.

AG

have

sea

ls

caus

oil

can

ed seal

be

repla

by leak

s,

the

deve

seals

the

oil

ord

seal be

er

that the

dimen-

to

the

dim

en-

installation

y,

in

be fitted

installation

adhered to, engine

occur

by

closed oil

or

by

moving

again

ro-

st other

loped a special

ced w

ing

or

foll

owing

F

crankshaft oil seals

ithout a major

damaged

poin

ig.

8

extra

disasse

oil

seals can thu s be

ts should

cting

be

tool

mbly

borne

by

of

in m

means

the

engi

remedied

ind:

F l S

of

ne

which being

1n

077:

l

a

Fi

g.

If outs or not

9

the

ide

other

be

oil seal

by

means

locking

extracted

is locked t

owards

of a collar

element, it can-

.

Q

(a)

Fig. 9

9

Fi

Fi9.

F

ig.

10

Place

the

sition

extracting tool

in such a

ho

oks

(4) grip behind

steel rim of

on

the

si

cylinder

care

that

rew

(3)

sc Screw in

oil

seal.

F & S

400:58

g.

10

Fig.

11

If the gap sheet steel narro

w and

can n

ot compl

position,

racting

ext hooks

(l) in in c

Rem

ount

as

described

Note

:

If the

oil

dation

),

break.

There

11

to knock

force fit by

way

th

e o

legs

screws {1

shaft

in a

st s

il

(2)

(5)

lign

crew

two head

are thru

betwee

rim

of

oil

the

extracting tool

ete

leg

tool

off

lin

and

ly

one leg

and

ed

ext

take

under Fi

seal has

got

the sheet steel rim m

fore it

th

e oi I sea I out

mea ns

of a tub

in

po-

that the two

the sheet

seal. Pre-ten-

even

ly with

),

taking

and thr

ust

ment.

and

extra

n sha

ft

and

seal is t

oo

be placed

of

ert

the

bot

ins

position.

ract

oil seal

g. l 0.

stuck (

oxi

is

advisab

of

e.

ct

in

h

-

ay

le

its

Fitting

Fi

g. 12

10

the

oil

seal

Fig.

12

Before

fitt

pace a·ro

s wi

th a littl

and ligh To

oil seal sh

arp

sh

ell slee ve. If necessary, p

sm

sh

arp edges.

und the tens e hea t-resisting

tly smear

protect

th e sea

from damag

edges on the

ooth adhesive

Place o il seal in pos

ing the o

pr

ess

it

in

e,

8).

by

taking

dim ens

tub lation

ig.

(F The oil seal

when

bei

ng pressed in.

means

care

ion

must

il

seal,

ion

the

sea

ling

lip

e caused

shaft

tape arou

ition a

of a suitab

of

exact

x, o

not

be

fil

l the

spri

grease

lin

g l

of

, use

instal-

and

tilted

ng ip.

the

by

ut

nd

le

y

Changing crankshaft bearings

H

eat

crankcase

bearings

In

sert new

strike a stop

ess

in

Pr side case

new

until

halves

hal

and

crankshaf

outer

. Press in oil

grooved

they

strike a sto

have

ves

races

been

to

about

t oils of

roller

sea

ls (with

ball

bearings

p. Press

screwed

100 ... 150 ° C (212

seals.

bearings into

in

together.

sealing lips

into

the

crankshaft

the

inwards)

warm

oil

...

302 ° F). Remo

wa rm

crankcase

until t

crankcase

seals

until flush only

hey

are

halves

ve

outer

halves

flush.

on

after

the

races

until

magneto

the

crank-

of

they

Removal bearings ing

Fig. 13

Pull

off

ed ball

the

appropr

(9

and

7)

a nd wi

pair

tool no.

Remove sat

ing

washers

of and

inner

bearing

6),

clamping

thdrawal

spacers

inner

grooved

race

(4)

iate

extractor

11

to

(3)

(2).

races

(1)

and

by

rings

tool

16). and

of

roller

ball

bear-

groov-

means

shells

(8

(10, re-

compen-

of

and

F&S

1..075:25

Fi

g.

13

11

Fig. 14

The

diff

(3, Fig .

erence

13) and

power takeoff side.

of

0.90 mm is

the inn e r

rac

tak

e o f

en

the

up

by

cylindrica

Gauging

Fi

g.

14

Permissible mm (0.0039 ... 0.0079 in.).

Example:

Inse

rt

inner cylindrical into

outer

C

rankcase power takeoff

side:

seali

(with

gas

ra·ce

of

bear

Crankcase s

ide:

seali

inn

erraceofbearing

C

rankcase

Dimension crankshaft,

over

both crank

with

a 5 mm thick

s

pac

er

on

takeoff

and

side - 79.00 mm Axial

play Pe rmissible axia play

Difference

to

be taken

inser

ting shims (2, Fig. 13) betwee

l rolle r

bearin

g (1, Fig. 13)

axial

play

of

crankshaft

axial

play

race

of

roller

bearing

race.

ng surfac

ket)

to

e

inner

ing 40.60 mm

magneto

ng su

rface

to

+ 39.

gap

of

measured

power

magneto

up

webs,

l

n the spac

on

80.10 mm

1.10 mm

- 0.20 mm

0.90 mm

the crank

0.1

50

...

0.2

mm

er

-

Fitting the inner race of the cylindrical roller bearing

Wh

en fitting the

Fig.

13

on

way

s be positioned betwee

that

it ca n be s

in

po

sition.

Ne

ver clam

the

inner

uns

erviceable

crankpin

upported

p th e

race

by

.

inner

race of

pow

crankshaft

the

er

at

cylindrical

takeoff sid e),

n th e

two

bo th e nd s, the re

in a

vice at a crankpin

rolle r bearing (

an

inte rmedia te

crank webs

by permitting the

striking it. This will crush the we

. This

12

or

at bs

do

not

plate

(5, Fig. 13) should a l-

plate must

crankshaft

the

webs

and render

forg

be

and

the

et spa ce rs 3,

of

such a si

to lie fre ely

neve

r try

cra·nkshaft

to

ze

fit

Sachs SA 340, SA 340 SS (super sport), SA 370 Repair Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual