/ )

~,
1973 -- --
EVINRUDE~ , ~~
& JOHNSON
SNOWMOBILE

. PART NO. 406144

 1-1

INTRODUCTION

SECTION 1
INTRODUCTION
SPECI FICATIONS

GEN ERAL SNOWMOBI LE INFO RMATION

SAFETY SYMBOLS

THE PURPOSE OF SAFETY SYMBOLS IS TO

ATTRACT YOUR ATTENTION TO POSSIBLE
TROUBLE SHOOTING
DANGERS. THE SYMBOLS, AND THE EX-
PLANATIONS WITH THEM, DESERVE YOUR
CAREFUL ATTENTION AND UNDERSTAND-
ING. SAFETY WARNINGS DO NOT, BY THEM-
SELVES, ELIMINATE ANY DANGER. THE IN- TUNE-UP PROCEDURES
STRUCTIONS OR WARNINGS THEY GIVE ARE
NOT SUBSTITUTES FOR PROPER ACCIDENT
PREVENTION MEASURES.
FUEL SYSTEM

SYMBOL MEANING

A SAFETY FAILURE TO OBEY A IGNITION AND

ELECTRICAL SYSTEM
~WARNING SAFETY WARNING MAY
RESULT IN INJURY TO
YOU OR TO OTHERS.

o PROHIBITED WARNS YOU AGAINST AN

ACTIVITY WHICH IS, OR
MANUAL STARTER

MAY BE, ILLEGAL IN

YOUR AREA.
ENGINE
ADVISES YOU OF INFOR-

E
MATION OF INSTRUC-
ONOTE TIONS VIT AL TO THE
OPERATION OR MAINTE-
NANCE OR YOUR EQUIP- L--_D_R_IV_E_T_R_A_IN_ _ _ _ _ _ _ _
MENT.

Before proceeding with any repair or adjust- STEERING, TRACK AND SUSPENSION
ments on this snowmobile, see~ SAFETY
WARNINGS on inside front cover and on pages:
6-6, 7-3, 7-11, 8-2, 9-5, 10-2, 10-3, and 12-5.
LUBRICATION AND STORAGE
1- 2

The snow machine has been designed and built for dependable, high
performance. It is important to every snow machine owner to be able
to receive skilled and thorough service for his vehicle when necessary.
It is important to the service dealer to be able to offer the type of skilled
service which will maintain the customer's satisfaction.

This manual, together with the regularly issued service bulletins and
Parts Catalogs, provide the serviceman with all the literature necessary
to service this snowmobile. An effort has been made to produce a
manual that will not only serve as a ready reference book for the ex-
perienced serviceman, but will also provide more basic information for
th e guidance of the less experienced man.

The Parts Catalogs contain complete listings of the parts required

for replacement. In addition, the exploded views illustrate the correct
sequence of all parts. This catalog can be of considerable help as a
reference during disassembly and reassembly.

The Section Index on page 1-1 enables the reader to locate quickly any
desired section. At the beginning of each Section is a Table of Contents
which gives the page number on which each topic begins. This arrange-
ment Simplifies locating the desired information within this manual.
Section 2 lists complete specifications on the snowmobile. All general
information, including 2 cycle engine theory, trouble shooting, and tune
up procedures, are given in Sections 3 through 5 of this manual.

3703 1

Figure 1-1
 1-3

Sections 6 through 11 provide fully illustrated, detailed, step-by-step

disassembly and reassembly instructions and adjustment procedures.
Section 12 provides lubrication and storage information. In this way,
the texts treat each topic separately; theory and practice are not
intermixed. This makes it unnecessary for the experienced service-
man to reread discussions of theory along with specific service in-
formation. Illustrations placed in the margins provide unimpeded
reading of explanatory text, and permit close relationship between
illustration and text.

Read this manual carefully to become thoroughly familiar with the

procedures described, then keep it readily available in the service shop
for use as a reference. If properly used, it will enable the serviceman
to give better service to the snowmobile owner, and thereby build and
maintain a reputation for reliable service.

This service manual covers all phases of servicing the snowmobile,

however, new service situations sometimes arise. If a service question
does not appear to be answered in this manual, you are invited to write
to the Service Department for additional help. Always be sure to give
complete information, including model number and vehicle serial
number.

All information, illustrations, and specifications contained in this

literature are based on the product information available at the time of
publication. The right is reserved to make changes at any time without
notice.

1. Neutral Control Knob 8. Tachometer (Accessory)

2. Headlight Connectors 9. Safety Stop Switch
3. Hand Brake 10. Throttle
4. Ignition/Lights Switch 11. Choke Lever
5. Parking Lock 12. Compression Release Knob
6. Hi-Low Beam Headlamp 13. Primer
Switch 14. Manual Starter Handle
7. Speedometer/Odometer 15. Engine Cover Removal
(Accessory) 16. Hood Removal

Figure 1-2
)
 2-1

SECTION 2
SPECIFICATIONS

TABLE OF CONTENTS

SPECIFICATIONS. . . . . . . . . . . . . . . . . . 2- 2

TORQUE SPECIFICATIONS . . . . . . . • . • . 2-3

Snowmobile Special Service Tools - 27, 30, 32 H.P.

PART NO. DESCRIPTION

378103 Flywheel Puller

404032 Wrench - Primary Drive
* Truarc Pliers
426020 Ring Compressor
383966 Spring Winder
* Heli-Coil Installers and Inserts
404068 Riveting Tool
375632 Spark Plug Wrench
114146 Splined Wrench
113971 Flywheel Holding Tool
261906 Disassembly Tool (Primary Drive)
261132 Retaining Ring - Bearing Puller
261131 Half Steel - Bearing Puller
261129 Extractor - Crankshaft Bearing
317829 Driver
317830 Cone

* Refer to the Tool Catalogue

2- 2

SPECIFICATIONS

Ci) PROHIBITED: Snow Vehicles are not manufactured for highway use and
the manufacturer does not represent that they are equipped with all the devices
legally required for such use.

Length. . . . . . . . . . 95.5 inches

Width. . . . . . . . . . 30.8 inches
Height. 38.8 inches with windshield
32.4 inches without windshield
Engine. OMC 2- cycle opposed twin
Rating . Standard 27 HP @ 5800 rpm
High Performance 399 cc 30 HP @ 6000 rpm
High Performance 437 cc 32 HP @ 6000 rpm
Starter •.• . . . Manual rewind
Variable speed drive Centrifugal operated sheave engages V-belt
Overall ratio . · . . . . . 3.33 to 1
Final drive . . • ASA 35 double chain
Sprocket ratio standard · . . . . . . . 16:30
optional sprocket · . . . . . . . 13:30
Muffler . Tuned for maximum performa nce
Brake . . . . . . . Disc type, hand operated
Throttle. . . . . . . . . . . Thumb operated
Track. Specially designed flexible track, fully adjustable
Width . . . . . . . . . . . . . . . . . . . 15.4 inches
Skis Formed steel, equipped with shock-absorbing leaf springs and
replaceable wear runners
Seat Vinyl coated cover, molded urethane foam cushion
Hood · . Molded fiberglass
Headlamp . . . . . . . . . . . . Sealed beam GE 4002
Taillamp/Stoplamp . . . . . . . • . . . . . . . . . . . GE 1157
Fuel Tank . . . . . Capacity 5 Imperial gallons, 6 U.S. gallons
Lubrication . . . . . . . OMC brand 50: 1 lubricant
Carburetor Needle Adjustment
High speed 1-1/4 turns off seat minimum
Low speed 1 to 1/4 turns off seat
RPM Ratings
Idle . . . . . 1300 - 1600
Transmission belt engaging speed . 2500 - 2900
Maximum RPM at which neutral control will operate . Approx. 2000
Ignition
Breakerless magneto C.D. (Capacitor Discharge) ignition
Spark plug . . . . . . . • . • . Champion UJ2J
Spark plug gap . . . . . . . . . .028 - .033 inch
Advance sensor coil resistance .• 14-16 ohms
Retard sensor coil resistance . • . 27-29 ohms
Magneto charge coil resistance (2 coils) total of 875 ± 75 ohms
Ignition coil secondary resistance . 1900 ± 190 ohms
Lighting coil resistance (3 windings) . . 6.5 ohms
Engine
Bore and stroke . . Standard engine. 2-3/4 x 2-1/4 inches
High performance engine 399 cc . 2-5/8 x 2-1/4 inches
High performance engine 437 cc . 2-3/4 x 2-1/4 inches
Piston displacement . Standard engine . . • . . 26.7 cubic inches (437 cc)
High performance engine
30 HP . . . • . • . • . . 24.35 cubic inches (399 cc)
High performance engine
32 HP . . . . . . . . . 26.7 cubic inches (437 cc)
CompreSSion ratio. Standard engine . . . . . . 6.8 to 1
High performance engine. ..... 7:1
Cylinder compreSSion Standard engine Minimum . . . . . 105 PSI
High performance engine Minimum 120 PSI
Ring diameter . Standard engine. . • . . • 2-3/4 inches
High performance engine 39966 2- 5/8 inches
High performance engine 43766 2-3/4 inches
Ring thickness . 1/16 inches
Clearances
Piston - wrist pin. . Press fit
Piston ring gap . . .007- .017
Piston ring - ring groove .002-.004 1
Cylinder piston . . Top of piston to cylinder .012-.015
Bottom of piston to cylinder .006-.008
Specifications and features may be changed at any time without notice and without
obligation towards vehicles previously manufactured.
 2- 3

TORQUE SPECIFICATIONS

PART APPLICATION SIZE TORQUE

IN./ FT./
LBS. LBS.

*Nut Ball Joint to Steering Arm

and Steering Column 3/ 8- 24 18 -20
*Nut Bearing Cup to Chas sis 6- 8
Screw Brake Lever to Handle Bar #10 - 32 13 - 15
* Compression Relief Valve
and Plug 14- 16
*Screw Connecting Rod 29 - 31
*Screw Crankcase 60 - 80 5- 7
*Nut Cylinder to Crankcase 18- 20
Nut Drive Sprocket 1/ 2-20 25- 35
*Screw Engine Frame to Main
Frame 3/ 8- 16 18-20
*Screw Engine to Engine Frame
Ass embly 33 - 38
*Nut Exhaust Manifold to Cylinder 5/ 16- 24 10- 12
Screw Exhaust Pipe to Muffler 3/ 8-16 18- 20
*Screw Flangettes to Frame 3/ 8-16 20 -25
*Nut Flywheel 40 -45
*Nut Front and Rear Truck Axles 5/ 8- 18 35 - 45
*Screw Idler Axle to Frame 3/ 8- 16 20-2 5
* Bolt Primary End Cap to Main
Shaft 3/ 4-16 90-100
*Screw Ratchet Mount to Flywheel 5- 7
*Screw Ratchet to Ratchet Mount 5- 7
*Nut Rear Axle Pivot 5/ 16-24 12 - 15
Setscrew Locking Collars 5/ 16- 18 70- 90
*Nut Runner to Ski 5/ 16-18 90- 100
*Screw Sensor Mounting Plate 5-7
* Spark Plug 20 - 25
*Screw Stator Assembly to
Mounting Plate 5-7
* Nut Steer ing Arm to Ski Column 3/ 8-24 18-20
* Nut Throttle Cable Adjusting
Screw 5/ 16-18 60 - 80
* Nut Tie Rod Jam Nut to Ball
Joi.nt 3/ 8-24 14- 16
* Nut Track Adjusting Bracket to
Chassis 5/ 16- 24 12 - 15
*Screw Truck to Frame 3/ 8-16 25 - 30
*Screw Truck to Frame 7/ 16- 14 25- 30
*Nut U Bolt to Saddle 25- 30
Screw #6 7-10
Screw I #8 15-22
Screw General #10 25-35 2-3
Screw Torque #12 35 - 40 3-4
Screw Requirements 1/ 4 60-80 5- 7
Screw 5/ 16 120-140 10-12
Screw 3/ 8 220 - 240 18-20

Specifications and features may be changed at any time without notice

and without obligation towards vehicles previously manufactured.

*Use Torque Wrench

)
 3-1

r
SECTION 3
GENERAL SNOWMOBILE INFORMATION

II

TABLE OF CONTENTS

TWO-CYCLE ENGINE OPERATION. • • • • • • 3-2

COMPRESSION . • . . . . • . • • . • . . • • • • • •• 3- 2

CARBURETION . . . . • • . • • • • • • • • . . • . •• 3-3

IGNITION. . • . • • • • . • • . . . . • . • • . • • • •• 3-4

LIGHTING SYSTEM . . . . . . . . • . • • • • . . •• 3-4

POWER FLOW. . . . • . • • • • • • • • • . • • . •• 3-5

PRIMARY DRIVE. . • . • • . • . . . • . • • • •• 3-5
NEUTRAL CONTROL. • . . . . • • • • • • . .• 3-6
SECONDARY DRIVE. • • . • . • • • . • . • . •. 3-6
3-2

POW E R STROKE - DOWN TWO CYCLE ENGINE THEORY

COMBUSTION OF
FUEL-AIR An internal combustion engine is one in which fuel is burned inside the
engine: a charge of fuel is introduced into a combustion chamber
(cylinder) within the engine and ignited. The energy released by the
expansion of the burning fuel is converted to torque by the piston, con-
necting rod, and crankshaft.

Internal combustion engines are classified as either four-cycle or

two - cycle engines. The "four" and the "two" refers to the number of
piston strokes required to complete a power cycle of intake, compres -
Sion, power, and exhaust. A piston stroke is piston travel in one direc -
tion only; up is one stroke , down is another. In a four-cycle engine,
two crankshaft revolutions, or four strokes, are required for each power
cycle. In a two-cycle engine only one crankshaft revolution is required
AXIS OF
per power cycle.
ROTATION
1 7 133

In a two- cycle engine, the ignition of the fuel-air mixture occurs as

FLgure 3- 1 the piston reaches the top of each stroke. The expansion of gases drives
the piston downward (see Figure 3- 1). Toward the end of the downward
stroke, ports which lead from the cylinder to the exhaust system are
uncovered. The expanding exhaust gases flow into these ports, reducing
FUEL INTAKE AND EXHAUST
pressure in the cylinder. Immediately after, intake ports are opened.
L E AF VALVES
These ports connect the cylinder with the crankcase where a mixture
CLOSED
of fuel and air has been developed by carburetion. The downward motion
of the piston compresses this mixture and forces it through the intake
ports into the cylinder. See Figure 3-2 .

The inrushing charge of the fuel-air mixture helps to eject (scavenge)

the last of the exhaust gases from the cylinder. At this point, the mo-
mentum of the flywheel is required to return the piston to the top of the
cylinder. As the piston begins its up- stroke, it closes the intake and
exhaust ports and begins to compress the fuel-air mixture trapped in the
cylinder. See Figure 3-3. The upward motion of the piston also re-
duces the pressure in the crankcase. The resulting crankcase suction
opens leaf valves which admit a fresh charge of air and fuel from the
carburetor into the crankcase, thus preparing for the next power cycle.
EXHAUST Near the top of the piston stroke, the compressed fuel-air mixture is
PORT OPEN ignited, the piston is driven downward, and the power cycle is repeated.
17 134
At full throttle, this cycle may be repeated more than five thousand
times every minute.
Figure 3-2

COMPRESSION STROKE - UP

FUEL FROM
COMPRESSION
LEAF VALVE
OPEN CARBURETOR
The pistons and piston rings perform two functions. They compress
the mixture of fuel and air in the cylinders before ignition, and receive
the force of the power after ignition. For maximum compreSSion, the
cylinder must be round and the piston and piston rings correctly fitted
to it. The rings must be properly seated in the ring grooves and free
to expand against the walls of the cylinder. The rings will not retain
the force of combustion if the pistons and cylinder walls are excessively
worn, scored, or otherwise damaged, or if the rings become stuck in
grooves because of carbon accumulation. Escape of compression past
the piston rings is referred to as "blow-by" and is indicated by dis-
coloration or carbon formation on the piston skirt.

EXHAUST Cylinder bores normally wear with operation of the engine. The de-
PORT CLOSED gree of wear will vary with length of operation, efficiency of lubrication,
17135 and general condition of the engine. Excessive cylinder wear results
in loose fitting pistons and rings, causing blow-by, loss of compreSSion,
Figure 3-3 loss of power and inefficient performance.
 3-3

Piston rings are formed in such a manner that when installed on the
piston, they bear against the cylinder wall with a light, even pressure.
Excessive ring pressure against cylinder wall increases friction, caus-
ing high operating temperature, sluggish performance, and abnormal
wear or scoring. Insufficient pressure allows blow-by, which reduces
power, and causes overheating and carbon formation on piston skirt.
Since the ring tends to flex as it follows the cylinder contour during
engine operation, clearance or gap must be provided between the ring
ends to prevent butting. The ring gap also allows the ring to expand
(elongate) as engine temperature rises during operation. Insufficient
gap clearance will cause the ring to bend or warp as it flexes and ex-
pands; excessive gap clearance will permit loss of compression.
Compression leakage may also occur at spark plugs. A cracked spark
plug insulator will cause similar trouble. Although compression is pri-
marily dependent on the piston, rings, and cylinder. these other sources
of leakage should be investigated when compression loss is noted.
Compression leakage will occur if the compression relief valve link-
age is adjusted with insufficient clearance on the cable ends. The relief
valves vent combustion chamber pressure through a by-pass port. INDUCED LOW / VENTURI
PRESSURE ~
Compression may also be affected by the fuel induction and exhaust

?~
systems. Since the fuel vapor is first compressed in the crankcase.
leakage here will affect engine performance. Possible trouble spots
include leaf valve assemblies, seals between crankcase halves, and
crankshaft bearing seals. Exhaust ports which have become clogged
because of excessive deposits of carbon will hinder the efficient transfer
of exhaust gases.
FUEL FORCED UPWARDS
Excessive carbon build-up on piston heads or elsewhere in the cylin- BY ATMOSPHERIC PRESSURE
17 136
der walls can result in a loss of power.
Following the trouble shooting procedures in Section 4 and the recom- Figure 3- 4
mended tune- up procedures given in Section 5 will assure that all areas
affecting fuel induction , compression, and exhaust will be considered as
part of every trouble shooting procedure. An engine with low or uneven
compression cannot be successfully tuned for peak performance. It is
essential that improper compression be corrected before proceeding
HOLE F OR FUEL INTAKE
with an engine tune-up.
PUMP PULSE MANIFOLD
CARBURETION
Gasoline, in its liquid state. burns relatively slowly with an even
flame. However, when gaSOline is combined with air to form a vapor,
the mixture. becomes highly inflammable and burns with an explosive
effect. To obtain best results, the fuel and air must be correctly pro-
portioned and thoroughly mixed. It is the function of the carburetor to
accomplish this.
Gasoline vapor will burn when mixed with air in a proportion from
12:1 to 18:1 by weight. Mixtures of different proportions are required
for different purposes. Idling requires a relatively rich mixture; a
leaner mixture is desirable for maximum economy under normal load
conditions; avoid lean mixtures for high speed operation. The carbure-
tor is designed to deliver the correct proportion of fuel and air to the
engine for these various conditions.
The carburetor is essentially a simple metering device. A diaphragm
and valve system allows a constant fuel supply to be maintained in the
metering chamber at atmospheriC pressure. Needle valves permit a
precise amount of fuel to flow from the metering chamber to the car-
buretor throat. The upstroke of the piston creates a suction which
draws air through the leaf valves and the carburetor throat. At a LEAF
particular point the throat is restricted by a venturi (see Figure 3- 4). STOP LEAVES
The venturi has the effect of reducing air pressure in the air stream, LEAF PLATE AND BAS E ASS E M .
creating a partial vacuum which draws fuel from the discharge port. 17088

As it is rushed along to the firing chamber, the fuel is swirled about in

the air stream and vaporized. Figure 3-5
3- 4

A throttle or butterfly valve in the throat regulates the amount of air )

drawn through the carburetor. To vary the speed of the engine, the
throttle opens or closes, regulating the amount of fuel-air mixture
drawn into the engine.
A richer fuel mixture is required for starting a cold engine. A sec-
ond shutter. called a choke, is placed into the throat forward of the jets,
to restrict the flow of air. When the choke shutter is closed, more gas-
oline and less air is allowed into the air stream resulting in a richer
fuel-air mixture. When normal operating temperature is reached, the
choke is opened and the standard ratio of gasoline and air allowed to
flow from the carburetor.
The system which controls the intake of the fuel - air mixture in the
two cycle engine consists of a set of leaf valves which serve the same
purpose as the intake valves on a four cycle engine. The leaf valves are
GROUND thin, flexible metal strips mounted between the carburetor intake mani-
ELECTRODE CENTER fold and crankcase.
ELECTRODE
When the piston is on the up-stroke. it creates a partial vacuum in the
crankcase. Atmospheric pressure forces the leaves away from the body
(see Figure 3-5). opening the passage between the carburetor and
crankcase. When the piston is on the down-stroke, it compresses the
crankcase charge, forcing the leaves against the passage opening, and
sealing off the crankcase from the carburetor. Since the opening and
cloSing may occur in excess of five thousand times per minute, the
leaves must be thin and flexible.
IGNITION
The magneto capacitor discharge (C. D.) ignition system generates a
high voltage electric current which jumps the spark plug gap within the
cylinder and thus ignites the compressed fuel-air mixture in the cylin-
der. See Figure 3-6.
This system is made up of the following major components:
1. Flywheel assembly 4. Sensor plate assembly
2. Sensor rotor 5. Power Pack I assembly
3. Stator and charge coil assembly 6. Ignition coils
17 138
The following sequence of events will illustrate how this system works.
Figure 3-6 The flywheel rotates around the stator and charge coil assembly.
(See Figure 3-7.) The magnets in the flywheel and the (2) charge coils
generate a voltage. This voltage (AC) flows into the Power Pack 1.
Here it is changed to DC and stored in a capacitor. At the same time
the sensor rotor rotates by the sensor coils and a smaller AC voltage
is generated. This smaller voltage flows into the Power Pack I and
causes an electronic switch in the Power Pack I to turn on allowing the
voltage stored in the capacitor to discharge into the primary of the
ignition coils.
One thing to note in this system is that there are two sensor coils.
Below the idle RPM range and up to approximately 900 RPM, the retard
sensor turns on the electronic switch in the Power Pack I. At RPMs
over 900 the advance sensor coil generates enough voltage to turn on the
electronic switch in the Power Pack I before the retard sensor does.
So, we have an automatic electronic advance built into the system.
The ignition coil primaries receive the voltage from the Power Pack I,
building up the secondary voltage high enough to fire across the spark
P - PERMANENT MAGNET
plug gaps.
N - NORTH POLE SHOE
S - SOUTH POLE SHOE LIGHTING SYSTEM
F - FLYWHEEL
C - LAMINATED COIL CORE The alternator coils produce alternating current which changes in
17 137 frequency and voltage in proportion to the engine speed.

Figure 3- 7 The alternator A.C. output is used to operate lamps.

 3-5

POWER FLOW
The transmission assembly transmits power from the engine to the
front axle which propels the vehicle along the track. The primary
sheave assembly is attached directly to the crankshaft. The secondary
sheave assembly has its own mounting pedestal and is larger in diam-
eter than the primary sheave assembly. The two are connected by a
transmission belt.

PRIMARY DRIVE

The primary sheave is centrifugally operated and engages the trans-

mission belt when the engine speed reaches 2500 to 2900 rpm. When
the engine is rotating at idle speed or below 2500 to 2900 rpm, the trans-
mission belt rides on a ball bearing between the halves of the primary
sheave assembly (see Figure 3-8). The primary sheave assembly
halves are separated by a compression spring in the hub of the movable
sheave half.
As the engine speed increases, centrifugal effect. forces a garter
spring in the end cap outward against the contour of the end cap and
axially against the movable sheave half. As the sheaves are brought
together, the transmission belt is forced outward to ride on a larger
diameter of the primary sheave assembly, increasing belt speed (see
Figure 3-9). Since the belt length remains constant, the secondary
sheave halves spread apart, allowing the belt to ride on a smaller diam-
eter. In this way, the engine transmits power through a variable ratio,
presenting the engine with a mechanical advantage most favorable for
the speed at which it is operating.

A - NEUTRAL LOCKOUT BALLS

B - GREASE FITTING
C - END CAP ASSEMBLY
D - GARTER (ACTIVATING)
SPRING
E - MOVABLE HALF OF SHEAVE
F - BELT
G - FIXED HALF OF SHEAVE
H - NEUTRAL LOCKOUT
PLUNGER
I - CRANKSHAFT
J - IDLER BALL BEARING
LOCKOUT K - COMPRESSION SPRING
POSITION
PRIMARY SHEAVE ASSEMBLY
PRIMARY SHEAVE ASSEMBLY
37028 3702.9

Figure 3-8 Figure 3-9

3-6
NEUTRAL CONTROL
A neutral control mechanism is used to prevent the drive from engag-
ing during starting, warm-up period, and idle. When the neutral lockout
plunger is actuated, a cone on the end of the plunger raises two balls
through the splines of the primary sheave assembly and into the path of
the movable sheave half, preventing it from engaging the belt. The
neutral control will operate only when the engine is at idle speed.

SECONDARY DRIVE
The secondary drive mechanism incorporates a torque sensing device
that detects the need for more power for steep inclindes or deep snow.
The mechanism immediately forces the secondary sheaves closer to-
gether to increase the drive ratio and provide a higher torque to the
drive chain and track.

The drive ratio varies from 3.3 to 1 in low to .97 to 1 in high which
yields an overall drive range of approximately 3.33 to 1. Power is
transmitted from the secondary sheave assembly through a drive chain
to the front axle.

The ratio between the secondary sheave and the front axle is 16:30.
An optional upper sprocket is available to change this ratio to 13 :30 for
high torque requirements.
 4-1

SECTION 4
TROUBLE SHOOTING

TABLE OF CONTENTS

DESCRIPTION. . . • . . . . . . . . . • • • • . . . .• 4-2

TROUBLE SHOOTING PROCEDURES ..•••• 4-3

STARTING. . • • . . . . . . • . • • . . . • • • •• 4-3
STARTING - MANUAL STARTER. . . • • .• 4- 4
RUNNING - LOW SPEED ONLY. . . . . • •• 4-4
RUNNING - HIGH SPEED ONLY. • • • • • •. 4-4
RUNNING - HIGH AND LOW SPEED. • . •. 4-5
4- 2

DESCRIPTION
This section provides trouble shooting procedures for the snow ma-
chine. Steps to be followed in determining causes of unsatisfactory per-
formance are outlined.

Being able to locate the cause of trouble in an improperly operating

snow machine is as important as being able to correct the trouble. A
systematic approach to trouble shooting is important if the trouble is to
be located and identified in minimum time.

Any service operation can be broken down into three steps:

1. Identifying the problem

2. Determining the cause of the problem, and

3. Correcting the problem.

Familiarity with the factors which affect two-cycle engine perform-

ance is important in making a correct service diagnosis. Factors
which affect engine performance include the quality of the fuel and fuel
mixtures. compression, ignition, and proper drive system adjustment.
Engine theory, compression, carburetion. ignition and power flow are
discussed in Section 3. Correct fuel mixture for this snowmobile is
outlined on the inside front cover, and fuel blending is discussed in Sec-
tion 12. Familiarity with factors which contribute to abnormal per-
formance of an engine are similarly helpful. The skilled mechanic's
experience is a great asset here.
 4-3

TROUBLE SHOOTING 1. Leaf valves not functioning properly

PROCEDURES
m . Faulty gaskets
Trouble shooting to determine the cause of any
operating problem may be broken down into the fol- n. Spark plugs fouled, improperly gapped, dirty
lowing steps: o r broken

a. Obtaining an accurate description of the trouble. o. Loose or broken wire or frayed insulation in
ignition system wiring
b. Preliminary inspection.
p. Sheared sensor hub key
c. Use of Trouble Check Chart to analyze engine
performance. q. Faulty coils

An accurate description of the trouble is essential r. Key switch. connector or grounded switch
for trouble shooting. The owner's comments may wire
provide valuable information which will serve as a
clue to the cause of the problem. s. Binding in engine

A preliminary inspection should include the follow- t. Faulty sensor, charge COils, Power Pack I
ing checks. or connecting wiring.

a. Correct spark plugs 2. Engine won't turn over

b. Throttle linkage properly adjusted a. Cylinder wall corrosion, seized piston or

bearing
c. Tank filled with fresh. clean fuel of the proper
mixture b. Engine improperly assembled after repair

d. Spark at each spark plug

e. Carburetor adjusted correctly 3. Cranks over extremely easily

f. Compression. Turn flywheel by hand or with a. Spark plug(s) loose

recoil starter. If compression is present , it
can be felt when turning through one complete b. Cylinder or pistons scored
revolution of the flywheel. If little or no com-
pression exists in both cylinders. engine will c. Rings worn or carboned
spin very easily.
d. Faulty crankcase gasket or crankseal(s)
STARTING
e. Broken or damaged leaf valves
1. Hard to start or won't start

a. Empty gas tank

4. Won't start, but kicks back and backfires
b. Incorrect gaS- lubricant ratio
a. Leaf valves broken or not seating
c. Old fuel, or water or dirt in fuel system
b. Sensor leads on Power Pacl: I terminals #6
d. Fuel line improperly connected & #8 reversed

e. Fuel line kinked or severely pinched c. Timing out of adjustment (check sensor hub
key)
f. Engine not primed
d. Advance sensor faulty or out of adjustment
g. Clogged fuel line or fuel filter
e. Power Pack I faulty
h. Clogged check valve

i. Carburetor adjustments too lean 5. No spark one cylinder

j. Low speed needle bent or bowed a. Faulty ignition coil, wire, or connections

k. Engine flooded b. Faulty Power Pack I

4- 4

6. No spark both cylinders b. Starter housing bent

a. Faulty charge coil c. Grease on pawls or spring

b. Faulty sensor coil d. Dry starter spindle

c. Faulty Power Pack I

d. Gr ounded ignition switch and/or wi r e RUNNING - LOW SPEED ONLY

e . Flywheel not properly charged 1. Low speed miss

f. Faulty ignition coils or leads a. Incorrect gas - lubricant ratio

7. Weak spark both cylinders b. Carburetor idle adjustment too lean or too
rich
a. Ignition switch or connection leakage
c. Leaf valve standing open or preloaded shut
b. Weak charge coil output
d. Spark plugs improperly gapped, dirty, or
c. Weak Power Pack I output broken

d . Weak ignition coil output e. Loose or broken ignition coil wires

8. Engine can be started by using primer, but dies f. Spark plug terminal loose
out when primer is not used -- - - -
g. Weak coil output
a. Fuel pump inoperative
h. Cylinder gasket or leaf plate gasket damaged
b. Fuel line or check valve between primer
pick - up and carburetor clogged i. Leaking crankcase gaskets or crankshaft
seals
c . Fuel filter screen in fuel pump or carburetor
inlet screen clogged j. Arcing around ignition coils or arcing in ig-
nition switch
d. Leaf block base plate reversed
k. Loose connections or intermittent grounding
e. Carburetor inoperative of leads in the: ignition coil. Power Pack I,
charge coils , sensor coils, and ignition switch
ST ARTING - MANUAL STARTER

1. Manual starter pulls out, but starter does not RUNNING - HIGH SPEED ONLY
engage flywheel
1. High speed miss
a. Friction spring bent or burred a. Water in fuel

b. Grease on pawls or spring b. Carburetor inlet needle sticking

c. Pawls bent or burred c. Spark plugs improperly gapped or dirty,

cracked insulator
d. Pawls frozen (water) in place
d. Ignition coil - weak output
2. Starter rope does not return
e. Engine improperly timed
a. Recoil spring broken or binding
f. Exhaust ports or exhaust system carboned
b. Starter housing bent
g. Combustion chambers carboned or fouled
c. Loose or missing parts
h. Arcing around ignition coils or arcing in ig-
d . Grease on pawls or spring nition switch

3. Clattering manual starter i. Loose connectioris or intermittent grounding

of leads in the: ignition coil, Power Pack I,
a. Friction spring bent or burred charge coils, sensor coils. and ignition switch
 4-5

2. Poor acceleration. top rpm is low 4. Engine runs at high speed only by using hand
primer
a. Incorrect gas - lubricant ratio
a. Fuel lines or passages obstructed
b. Old fuel
b. Fuel line leaks or fuel filter obstructed
c. Fuel hoses plugged or kinked
c. Fuel pump not supplying enough fuel
d. Fuel filter restricted (fuel pump or carbu-
retor) d. Leaf block base plate reversed

e. Fuel pump or pulse line faulty e. Dirt or packing behind needles or seats

f. Incorrect carburetor adjustments f. Carburetor adjustments

g. Inlet needle and seat worn or sticky g. Fuel cap vent clogged

h. No spark advance
RUNNING - HIGH AND LOW SPEED
i. Spark plugs dirty or improperly gapped
1. Engine overheats
j. Loose, broken, or badly insulated high ten-
sion leads a. Incorrect gas - lubricant ratio or improperly
mixed fuel
k. Ignition coil weak output
b. Engine not assembled correctly during repair
1. Leaf valves not properly seated, or broken (binding)

m. Piston rings stuck or piston scored c. Lean mixture (carburetor adjustment)

n. Excessive carbon on pistons and cylinder d. Cooling fan obstructed

head

o. Compression relief valve improperly ad- 2. Engine seizes (stops suddenly)

justed or faulty
a. No lubri cant in gas, or no fuel
p. Exhaust ports or exhaust system carboned up
b. Rod or main bearing seized
q. Charge coils, Power Pack I faulty
c. Cylinder or piston scored or seized

3. Engine knocks excessively

3. Idles well, but acceleration poor, dies at full
throttle a. Incorrect gas - lubricant ratio
a. Fuel lines or passages obstructed b. Flywheel loose

b. Fuel filter clogged c. Crankshaft end play excessive

c. Faulty fuel pump or pulse line d. Carbon in combustion chambers and exhaust
ports. or on pistons
d. Fuel cap vent clogged
e. Worn or loose bearings, or pistons
e. High speed nozzle or jet clogged
f. Loose assemblies. bolts. or screws
f. Dirt or packing behind needles and seats
g. Manual starter not centered
g. Choke partly closed

h. High speed needle set too lean

4. Excessive fuel consumption
i. Advance sensor faulty
a. Carburetor casting porous
j. Advance and retard sensor leads interchanged
on Power Pack I. b. Deteriorated carburetor gaskets
4-6

c. Carburetor improperly adjusted g. High speed adjustment lean

d. Hole in metering diaphragm h. Spark plugs fouled or misfiring

7. Engine misfires

a. Spark plugs dirty, fouled

5. Vibrates excessively or runs rough and smokes
b. Grounding or leakage of secondary leads
a. Too much lubricant mixed with gas
c. Ignition coil faulty
b. Idle or high speed needles too rich
d. Grounding or leakage of ignition switch,
c. Air passage to carburetor obstructed
switch wire or connection
d. Faulty ignition
e. Loose connections at: ignition coils, charge
coils, Power Pack I, and sensor coils

6. No power under heavy load 8. Spark on only one cylinder

a. Faulty carburetion a. Ignition coils

b. Faulty ignition coil(s) b. Power Pack I output

c. Ignition timing off 9. Engine will start and idle, but quits on accel-
erating
d. Carbon build-up on piston head, exhaustports,
or exhaust system a. Check advance sensor coil and leads

e. Cylinder scored or rings stuck b. Check Power Pack I output

f. Compression relief valve open c. Check timing

 5-1

SECTION 5
TUNE-UP PROCEDURES

TABLE OF CONTENTS
DESCRIPTION. . . . . . . . . • . . . . . . . . . . .. 5-2

FACTORS AFFECTING PERFORMANCE. . .. 5-2

FUEL SYSTEM. . . . . . . . . . . . • . . . . . • 5-2
IGNITION SYSTEM. . . • • . . • • • . . . • . .. 5-2
COMPRESSION. . . . . . . • • • • • • • • . • .• 5-2

NEW VEHICLE DELIVERY . • . . • . . . . • . " 5-3

TUNE- UP PROCEDURES . . • . • . . . . • • . •. 5-3

COMPRESSION CHECK. . . . . . . . . • . . • • • . 5-5

IGNITION TIMING CHECK. . . . . . • • • . . • .. 5-5

COMPRESSION RELEASE VALVE

ADJUSTMENT. . . . • . . . . . . . . • . . . . . .. 5- 5

CARBURETOR ADJUSTMENTS. • • • • . • • •. 5-5

HIGH SPEED NEEDLE VALVE •.•••••• 5-5
LOW SPEED AND IDLE ADJUSTMENT
SCREW. . . • • . • • • • . . • • • • • • • • • • • • • • 5-6

SPARK PLUGS •••••••••..•.•••••••. 5-6

5-2

DESCRIPTION
The purpose of a tune -up is to restore power and performance which
have been lost through wear or deterioration of one or more parts of
the snow machine. The successful completion of a tune-up depends on
an understanding of principles of two-cycle engine operation, and a fa -
miliarity with factors affecting performance. This section gives com-
plete tune-up procedures. Refer to Section 3 for principles of operation,
and to Section 4 for trouble shooting procedures. Lubrication proce -
dures and instructions for storage are included in Section 12.

FACTORS AFFECTING PERFORMANCE

In the normal operation of an engine, the operator may not be fully
aware of the decrease in performance which takes place slowly over a
long period of time. Economical, trouble-free operation can best be
assured if a complete tune -up is performed at least once each year,
preferably at the start of the season.

It is seldom advisable to attempt to improve performance by correct-

ing one or two items only . Time will be saved and more lasting results
obtained by following a definite and thorough procedure of analysis and
by correcting all items affecting power and performance.

FUEL SYSTEM

A fresh fuel mixture, with the correct ratio of lubricant and gasoline,
is necessary for peak engine performance. The tank should be removed,
emptied of oil fuel, rinsed out, installed and refilled with a fresh supply
at the beginning of the season and at every tune-up. A stale fuel mix-
ture may cause hard starting, stalling, and faulty operation. Inadequate
fuel delivery, as the result of a faulty fuel pump or clogged filter, will
affect high-speed performance. Incorrect carburetor needle adjust-
ments may cause operating difficulties at any speed. Faulty choke
operation or incorrect use of the manual choke by the operator may
cause hard starting, rough running, or poor fuel economy. See Section
3 for a discussion on carburetion.

IGNITION SYSTEM

A good ignition system is of prime importance for peak engine per-

formance. A weak spark. which may be the result of faulty ignition
system components, will cause hard starting, misfiring, or poor high-
speed performance. The spark plugs and ignition system components
are frequently checked first in a tune-up because of their importance
to the operation of the engine. See Section 3 for a discussion on ignition
theory. and Section 7 for complete ignition system analysiS.

COMPRESSION

Compression must be well sealed by the piston and piston rings in the
cylinder to realize maximum power and performance. See Figure 5- 1.
A compression check is important because an engine with low or uneven
compression cannot be tuned successfully to give peak performance.
It is essential that compression be checked before proceeding with an
engine tune-up.
 5-3

NEW VEHICLE DELIVERY

Complete instructions for putting a new snowmobile into operation
are included in the Owner Manual and assembly instruction packed with
each snowmobile. Be sure the customer receives this manual and
understands the instructions given in it. The following list is a reminder
of important things to check when putting a new snowmobile into op-
eration.
a. Be sure spark plugs a r e insta lled a nd tightened securely with
spark plug ga skets in place.

b. Be sur e spark plug wires are securely attached to spark plug ter -
minals.

c . Be sure the correct gasoline and lubricant mixture is used. P our

mixture into tank through a fine mesh strainer.

d. Caution the customer not to operate a new engine at continuous full

power until at least one tankful of fuel has been used. During this
time, short periods of full power may be used. Instruct the cus -
tomer to follow the break-in procedure described in the Owner
Manual.

e. Be sure that the customer understands how to operate the engine

correctly, especially such things as the neutral control, compres-
sion release and choke.

TUNE-UP PROCEDURES
Components which affect engine power and performance can be divided
into three groups, namely:

1. items affecting compression,

2. items affecting igniti on,

3. items affecting carburet ion .

Any tune-up procedure should cover these groups in the orde r given.
Correction of items affect ing carbur etion should not be attempted until
a ll item s affecting compr e ssion and igniti on have been corr ected s a tis-
factorily. Attempts to overcom e compression or ignition system defi-
ciencies by altering carburetor settings will result in poor overall
performance or increased fuel consumption. This section covers only
those parts of a tune-up which invoh' e ad justments, c leaning , and check-
ing for performance. Trouble shooting procedures are covered in Sec-
tion 4. Repair and replacement of parts, as determined through trouble
shooting , is covered in Sections 6 through 11.

a . Test run vehicle, checking particularly the following :

1. Neutral control

Call transmission be locked in neutral when machine is at rest

and engine at idle speed?
5-4

2. Function of compression release

3. Function of brake

4. Engine performance

5. Ski alignment and handling

6. After running snowmobile, reduce engine speed to idle and pull

neutral control knob out to lock transmission in neutral. Ac-
celerate engine to see if transmission is in neutral. Neutral
control cannot be engaged above approximately 2000 rpm.

b. Check compression, see page 5- 5.

c. If engine knocks, check for loose flywheel. Remove manual starter

and fan housing (see Section 8). Rock flywheel back and forth and
listen for knocks.
Excessive wear in crankshaft journal bearings can be detected by
moving flywheel back and forth. Check for end play by pushing and
pulling on flywheel. End play tolerance should not exceed .019"
after installation.

If excessive end play is suspected remove carburetor and leaf

valve assembly. If motion between main bearing outer race and
crankcase is detected engine must be overhauled.

d. If both compression and bearing condition checks are not satisfac-

tory, engine overhaul is required (see Section 9).

e. Test ignition system using spark checker and neon C.D. Tester.
Inspect high tension leads. See Section 7.

f. Check spark plugs to be sure they are the correct type. Clean
spark plugs and regap. or replace as necessary.

g. Remove and drain fuel tank. flush, and clean thoroughly (see Sec-
tion 6). Install tank, refill with fresh fuel mixture, and check
primer operation.

h. Inspect fuel pump and hoses. Clean filter. or replace filter ele-
ment and gasket.

i. Inspect and clean fuel screen behind carburetor fuel inlet elbow.

j. Thoroughly lubricate snow machine (see Section 12).

k. Tighten all external bolts, nuts, and screws, and retorque spark
plugs to specified torque.

1. Check track tension and ski alignment (see Section 11).

m. Start engine and allow to warm up. Check track alignment (see
Section 11).

n. Repeat test run on vehicle. Check carburetor needle adjustments.

o. After engine has run sufficiently to indicate satisfactory condition,

stop and restart it several times. Operate it at high and low
speeds. Check acceleration from low to high speed.

p. Clean and dry snow machine thoroughly, before returning it to

customer. Fog motor for storage, using OMC Accessories Rust
Preventative Oil.
 5-5

COMPRESSION CHECK
An automotive type compression gage may be used as follows: Make
certain that choke is open, throttle is wide open, and both spark plugs
are removed. THE COMPRESSION RELEASE KNOB MUST BE COM-
PLETELY IN. Turn the engine over quickly three or four times with
the manual starter. Compression should be 105 pounds per square inch
minimum on the standard engine and 120 pounds per square inch mini-
mum on the high performance engine. See Figure 5-1.

IGNITION TIMING CHECK

See Section 7 for procedure to check spark timing. Figure 5-1
COMPRESSION
COMPRESSION RELEASE VALVE
ADJUSTMENT

Check for 1/32" to 1/ 16" clearance when compression release knob is

pushed in. See Figure 5-2. Turn out on jam nut and correct clearance
with adjustment screw shown in Figure 5-3. Operate compression re-
lease knob to check for binding in cable. Lubricate the compression
release actuator with OMC Grease #114154.

CARBURETOR ADJUSTMENTS
HIGH SPEED NEEDLE VALVE 170 82

o NOTE Figure 5-2

TO MAINTAIN ADEQUATE CYLINDER LUBRICATION, THE

HIGH SPEED NEEDLE VALVE SHOULD NEVER BE LESS THAN
1-1/ 4 TURNS OPEN. "LEANING OUT" OF THE HIGH SPEED
NEEDLE VALVE WILL RESULT IN SERIOUS DAMAGE TO THE
ENGINE.

For average use, the engine will operate satisfactorily with the car-
buretor adjusted as it left the factory. If it becomes necessary to read-
just due to altitude or climatic conditions follow these instructions care-
fully.

The correct high speed needle valve setting is obtained as follows:

1. Turn high speed needle valve in until lightly seated. Back out
(counterclockwise) 1-1/4 turns. See Figure 5-4. Figure 5-3

2. Start engine and allow warm up time of 3-4 minutes. Turn choke
lever to "open" position.

3. Drive snowmobile at full throttle to observe engine performance.

4. Open high speed needle 1/8 turn (counterclockwise).

5. Repeat steps #3 and #4 until engine begins to loose power slightly

or 4 cycles ("loads up" and fires on every other revolution).

6. From this setting turn high speed needle in 1/8 turn (clockwise).

7. Drive snowmobile at full throttle to observe engine performance.

8. Repeat steps #6 and #7 no more than is necessary to obtain smooth

performance and maximum power. Figure 5-4
5-6

DNOTE THE HIGH SPEED NEEDLE VALVE SHOULD NEVER

BE SET LEANER THAN 1-1/4 TURNS OPEN.

Two cycle engines are lubricated by oil that is drawn into the crank-
case with the fuel charge. Although they will start and run with a
leaner mixture, serious engine damage may result from too lean a
setting.

A. TOO LEAN A SETTING if engine misses, backfires, and runs

rough. Open high speed needle 1/8 turn more (counterclock-
wise). Repeat this test procedure until engine begins to 4-
cycle (loads up). At this point turn high speed needle 1/8 turn
in (clockwise) until smooth engine performance is obtained.

B. TOO RICH A SETTING if engine 4-cycles (loads up and fires on

every other revolution). Condition noticed also by a loss of
power. Turn high speed needle in 1/8 turn (clockwise) until
smooth engine performance is obtained.
LOW SPEED AND IDLE
AD.JUSTMENT SCREW
(See Figure 5- 5)
1. Pre-set "low speed needle valve" one turn open.
2. Turn "idle adjustment screw" to the left (counterclockwise) until
throttle plate is completely closed and screw is not in contact with
throttle lever.
3. Start engine and allow warm up time of 2 or 3 minutes. If engine
will not idle, turn "idle adjustment screw" to right to keep engine
running. Turn choke lever to "open" position.
4. Turn "idle adjustment screw" to attain the recommended idle
speed of 1300-1600 rpm.
5. Accelerate engine. If a flat spot (hesitation to accelerate) is noted,
readjustment of low speed needle is necessary. Turn "low speed
needle" counterclockwise 1/8 turn at a time. Reset "idle adjust-
ment screw" to attain 1300-1600 rpm each time low speed needle
is adjusted.
6. Accelerate engine then release throttle. Engine should return to
Figure 5-5 idle speed. If engine does not idle immediately, adjustment of the
low speed needle may be necessary. Turn low speed needle
clockwise to reduce amount of fuel to the engine. Reset "idle ad-
justment screw" to attain 1300-1600 rpm each time low speed
needle is adjusted.

D NOTE

Operating above recommended idle rpm can result in neutral

control not operating. If it is necessary to idle at above r ecom -
mended rpm, check neutral control to insure it can be operated.
See page 3-6.
PULL COVER STRAIGHT
L OFF WITH SLIGHT TWI ST SPARK PLUGS
USing the correct spark plug is most important for efficient operation.
The recommended spark plug for your engine is Champion UJ2J. The
proper spark plug gap is .028" - .033".

SPARK Remove rubber covered spark plug terminal by pulling straight off,
PLUG with a slight twist, see Figure 5-6. Remove spark plugs for inspection
or replacement as necessary.

When reinstalling spark plug, clean the spark plug seat in cylinder
17 18 2
head. Be sure spark plug gasket is in place and tighten plug securely.
(Recommended torque, 20 to 25 ft. lbs.). See page 7-14 for additional
Figure 5-6 information on spark plugs.
 6-1

SECTION 6
FUEL SYSTEM

TABLE OF CONTENTS

DESCRIPTION. • • • • • • • • • • • . • . . . . . • . 6-2

FUEL FLOW •.•.•••.•••••••...•.. 6-2

CARBURETOR . • • . . . • . • . • . • • • . . • • . 6-2
DISASSEMBLY, CLEANING, RE-
PAIR AND REASSEMBLY ..•••••. 6-3

LEAF VALVES. . . . • • • . • • • • • • • . . • • • 6-5

FUEL PUMP . • . • . • . • • • • . . • • • • • • . . 6-6

REMOVAL .••.•••..• .••••.••• 6- 6
CLEANING, INSPECTION, AND
REPAIR. • • • . • • • • • • • • . . . • • . . 6-6
REASSEMBLY .••••••.•.•.•••• 6-6

FUEL PRIMER • • . • • • • • • • • . • • • • • • • . 6-7

AIR FILTER. • • . . • • • • • • • . • . . • • • • • . 6-7

FUEL TANK .••••••.•.•••..•.•••• 6- 7

FUEL LINE TIE STRAP • . • • • • • . . . • • . . 6-8

6-2

DESCRIPTION
The complete fuel system consists of the gas tank assembly .a nd lines,
the primer assembly, the fuel pump and filter assembly, the carburetor,
and the leaf valve assembly. This section gives complete service
procedures on all components of the fuel sy!Otem, and carburetor adjust-
ment's. Principles of carburetion are discussed in Section 3.
FUEL FLOW
Fuel is drawn from the fuel tank by the fuel pump, which is operated
by changes in crankcase pressure. These changes in crankcase pres-
sure are transmitted to the fuel pump via the pulse line. Fuel filter
screens are located in the fuel tank, at the end of the fuel pick-up tube,
at the inlet to the fuel pump and in the carburetor inlet. The filter
elements remove water, dirt, or other impurities from the fuel before
the fuel passes into the engine. The primer assembly, operated from
the control panel, injects raw fuel into the crankcase before starting
(see Figure 6-1).

FUEL FILTER AND PUMP

CARBURETOR
1-4--- PULSE LINE
FILLER CAP
FUEL _ _ _~

LINE :::Z13d~§~~-
CHECK
VALVE
I
FUEL RETURN LlNL

FUEL SUPPLY LINE

FUEL
TANK
PRIMER VALVE
27 130

Figure 6-1
CARBURETOR
The carburetor used on this snowmobile is the diaphragm operated,
HD series Tillotson. The carburetor should be cleaned and inspected
at regular intervals, depending on service conditions.
DISASSEMBLY, CLEANING, REPAIR AND REASSEMBLY
1. a. Remove throttle cable using the following procedure: Depress
thumb throttle lever. Hold throttle in open position. Slip end of
throttle cable through nylon pivot pin. Loosen jam nut on intake
manifold and turn cable fitting out of manifold. See Figure 6-2.

b. Remove air filter, fuel lines and mounting screws from carburetor.

2. Select a clean work area. Dirt and carelessness are the cause of
most carburetor trouble.
DNOTE

Some solvents and cleaners have a damaging effect on the syn-

thetic rubber parts used in carburetors. It is best to use a
petroleum product for cleaning. Do not use alcohol, lacquer,
acetone thinner, benzol or any solvent with a blend of these in-
gredients unless the rubber parts and gaskets are removed. If
you are in doubt about your solvent, test a used part in it and
observe the reaction.

3. Clean the entire carburetor by flushing with fuel and blow dry with
compressed air before disassembly. The carburetor should be in-
..J
spected for cracks in the casting, bent or broken shaft, loose levers
Figure 6-2 and stripped threads.
 6-3

a. Remove the idle speed mixture screw (14), washer and tension
spring. Inspect for damaged threads (see Figure 6-5).

b. Remove the metering diaphragm cover (29), the metering dia-

phragm (28), and gasket (27). Inspect the cover for nicks, dents,
or cracks that might hamper operation. Inspect the metering dia-
phragm; the center plate must be riveted securely to the diaphragm
and the diaphragm should be free of holes and imperfections. The GOOD
gasket should be replaced if there are holes or creases on its
sealing surface. The parts must be reassembled in the correct
order. The gasket should be assembled onto the carburetor body
casting first, then the metering diaphragm is assembled next to
the gasket.

c. Remove the hinge pin retaining screw (25), the hinge pin (23), inlet
control lever (26) and the inlet tension spring (24). Use caution in
removing these parts. Spring pressure may push the inlet control
WORN
lever out of the casting. Inspect the parts for wear or damage.
The inlet control lever must rotate freely on the hinge pin.
1 /142,

d. Handle the inlet spring carefully. Do not stretch this spring or

change its compression characteristics. If in doubt about its Figure 6-3
condition, replace it.

e. Remove the inlet needle (22). Remove the inlet seat assembly
using a 3/ 8- inch thin wall socket. Remove the inlet seat gasket.

f. The inlet seat assembly consists of a brass cage and a rubber in-
sert for the inlet needle seat. Assemble the insert into the cage
with the molded rim side away from the inlet needle point.
(
Some HD carburetors are equipped with a rubber tipped needle, a
brass inlet seat and a copper gasket. The installation instructions
below apply to both types of inlet seats.

The inlet needles and seats are matched and tested for leaks at the
factory and the parts must be kept in matched sets. When installing
the insert cage into the carburetor body, use a new gasket. Do not
force the cage, as you may strip the threads or distort the insert. Use
a torque wrench to apply 40 to 50 inch-pounds torque. The needle and
seat assembly must be clean to insure correct performance.

g. Remove and inspect the pOints of the high speed and idle mixture
screws. See Figure 6-3. Through misuse, either mixture screw
point may be bent (extruded) from being forced into the casting seat
or possibly broken off in the casting (see Figure 6-5). If either
mixture screw is damaged, be sure to inspect the casting. If the
adjustment seats are damaged, a new body casting is required.
Check for clogged inlet and return line screen.

IMPORTANT
Do not alter return line elbow opening..s. This elbow controls
inlet pressure and fuel flow to prevent vapor locking in carbu-
retor and fuel pump.

h. Welch plugs seal the idle by-pass ports and main nozzle ball check
valve from the metering chamber. Accumulated dirt can usually
be blown out through the mixture screwholes. However, an unusu-
ally dirty carburetor requires the removal of these plugs. Drill
just through the welch plug carefully with a 1/ 8" drill. Drilling
too deeply may ruin the casting or the ball check valve. Use a
small punch to remove the plug.
6-4

TOO HIGH Inspect the idle by-pass holes to insure they are not plugged. Do not
push drills or wires into the metering holes. This may alter carbure-
DEPRESS HERE THEN PUSH tor performance. Blow plugged holes clean with compr essed air. Re-
/ TAB DOWN move the main nozzle ball check assembly (21), pressing it into the
primary venturi. Press the new part in where required so its bottom
surface is flush with the nozzle well surface. The nozzle pipe must be
below the welch plug to receive enough fuel. An engine with a defective
check ball (19) will not idle unless the high speed mixture screw is shut
off. Replace the faulty parts.
i. Remove any worn choke or throttle shafts before cleaning. Leave
WALL
unworn shafts in and clean the whole assembly.
TOO LOW
Mark the throttle (3) and choke (16)shutters before removing them so
DEPRESS HERE
that they can be reassembled correctly. The edges are tapered for
exact fit into the carburetor bores. Remove two screws and pull the
shutter out of the carburetor body. Remove the throttle shaft clip (5)
and pull the shaft out of the casting. Examine the shaft and the body
bearings for wear. If the shaft shows excess ive wear, replace it. If
the body bearing areas are worn, r eplace the body casting. Remove the
choke shaft (33) from the body carefully so that the friction ball (17) and
INLET PRY UP HERE spring (18) will not fly out of the casting. Inspect the shaft and bushings.
CONTROL
LEVER 1. Adjust the inlet control lever so that the center of the lever that
contacts the metering diaphragm is flush to the metering cham-
STRAIGHT ber wall. Check with straight edge. See Figure 6-4.
EDGE
2. Install new welch plugs at the nozzle well and by-pass chamber
if needed. Place the new welch plug into the casting counter-
CHAMBER bore convex side up and flatten it to a ti ght fit, using a 5/ 16
WALL inch flat end punch. If the installed welch plug is concave, it
may be loose and cause an uncontrolled fuel leak. The correctly
INLET installed welch plug is flat. Stake plug at outer edge in three
CONTROL ~~~~~~~ places to install.
LEVER
3. Assemble the gaskets, diaphragms and castings in the correct
order.

4. Assemble the throttle shaft into the carbur etor body and attach
the throttle shaft Clip before assembling the throttle shutter.
Figure 6-4 With the shaft secured in place, assemble the shutter into the
shaft. Be certain that the shutter fits accurately into the
throttle bore in the closed position.

5. Assemble the choke friction spring and ball into carburetor

body and assemble the shaft into position. Assemble the shutter
to the choke shaft. Be certain that the choke shutter fits tightly
to the carburetor bore in the closed position.

6. Assemble the carburetor to the intake manifold. Install fuel

lines and air filter to carburetor. See procedure on page 6-8
for installing new fuel line tie straps.

7. Assemble throttle cable to carburetor in reverse order of dis-

assembly. See page 6-2. Adjust throttle cable so that carbu-
retor butterfly valve is full open when thumb throttle lever
touches handle grip.
 6-5

r 1.
2.
3.
Carburetor Gasket
Flange Gasket
Throttle Shutter
4. Carburetor Body
5. Throttle Shaft Clip
6. Return Line Elbow
7. Return Line Screen
B. Idle Speed Bracket
9. Bracket Screw
10. Throttle Shaft Return Spring
11. Throttle Shaft Sleeve
12. Idle Speed Screw
13. Throttle Shaft
14. Idle Speed Mixture Screw
15. Choke Valve
16. Choke Shutter
17. Choke Friction Ball
lB. Choke Friction Spring
19. Check Ball
20. Welch Plugs
21. Check Valve Nozzle
22. Inlet Needle
23. Hinge Pin
24. Inlet Tension Spring
25. Hinge Pin Retaining Screw
26. Inlet Control Lever
27. Diaphragm Gasket
2B. Metering Diaphragm
29. Diaphragm Cover
30. High Speed Mixture Screw
31. Fuel Hose Elbow
32. Inlet Line Screen
33. Choke Shaft
27144

1 1 088
Figure 6-5 INTAKE
HOLE FOR MANIFOLD
FUEL PUMP GASKE T
When the lever on the carburetor is returned to the idle posi -
tion, there must be 1/16" minimum over travel in hand lever.
PUL SE ACTION
I
Slot in throttle lever must align with slot in cable support
bracket. Torque nut on cable adjusting screw to 60-B.O inch
pounds.

1. A carefully rebuilt HD model carburetor should perform well. The

two most likely causes of carburetor failure are dirt and a care-
less repair job.
m. See page 5- 5 for needle valve adjustment procedure.

LEAF VALVES

a. Separate the intake manifold from the crankcase body, removing

the gasket and leaf plate and base assembly.

b. Rinse leaf valves and leaf valve body in cleaning solvent. Do not
blow dry with air pressure, as damage to leaves may result.

c. Inspect the leaf valve assembly and disassemble if necessary (see

Figure 6- 6). Special caution is necessary in disassembling the
leaf valve assembly. DO NOT damage or interchange the leaves. BODY
LEAF PLATE AND BASE ASSEM.
d. The leaves must be flat to maintain a seal with the leaf valve body.
DO NOT under any circumstances bend or flex the leaves by hand. Figure 6- 6
6-6

Clean, inspect, and immediately reassemble the leaf valve assem-

FUEL PUMP bly, rather than leave it apart for reassembly later.
BODY
e. The leaves are designed to maintain contact with the leaf valve
body, and to spring away from the leaf valve body when predeter-
mined vacuum is applied. Inspect leaf plate assembly and replace
leaf valve body assembly if damaged.
f. Check tightness of leaf valve retaining screws and tighten any that
appear loose.

INSTALLATION
a. Secure leaf plate assemblies to base, using a new leaf plate gasket,
MOUNTING
apply Gasket Sealing Compound #317201. Align leaf plate and base
HOLES assembly on crankcase. Install intake manifold on crankcase using
17089
a new intake manifold gasket. Be certain that elongated hole in
base plate aligns with passage in intake manifold. Obstruction of
Figure 6-7 this passage will prevent fuel pump operation via the pulse line.
Fasten with screws and lockwashers. See Figure 6-6.
b. Attach primer check valve hose to check valve on manifold.
c. Attach assembled carburetor to intake manifold with screws, nuts,
and lockwashers, using a new carburetor gasket.

FUEL PUMP
REMOVAL
a. Disconnect three hoses from fuel pump and filter assembly (see
FILTER FILTER Figures 6-7 and 6-8).
CAP 17089
b. Remove two screws attaching pump and filter assembly to mounting
plate (see Figure 6-7), and remove pump and filter assembly.
Figure 6-8 NOTE: Filter assembly may be removed for cleaning and inspec-
tion without removing pump assembly by removing filter cap screw
(see Figure 6-8). Clean the filter cover and fuel connectors in
solvent and blow dry.

~ SAFETY WARNING
Do not allow fuel to drip on hot engine or exhaust manifold because
of potential fire hazard.

CLEANING, INSPECTION, AND REPAIR

a. The fuel pump components are not serviced separately. If a mal-
function occurs, replace the complete pump.

b. Check for a clogged filter element. The fuel filter element on an

engine that has been in storage may be clogged without appearing
to be. During storage, volatile agents as well as anti-gum and
anti - varnish agents evaporate from the gasoline that remains in the
fuel filter. The result is contamination of the filter element with
a clear form of varnish. This varnish is not readily soluble in
gasoline or cleaning solvent; therefore, the filter should be re-
placed at the start of each season. NOTE: Since the purpose of
the filter is not only to trap dirt but also to prevent moisture from
entering the carburetor, do not attempt to run the engine with the
filter element removed.
REASSEMBLY
a. Reassemble the fuel filter. Do not overtighten filter cap to fuel
pump body.
b. Attach fuel pump and filter assembly to plate with screws and
gasket.
-
 6-7

c. Reconnect fuel hoses and secure with new tie straps per procedure
below. Refer to Figure 6-1 for hose positions.

FUEL PRIMER

a. The primer is a simple pump which pumps raw fuel from the fuel
line, thru check valves, directly into the intake manifold above the
leaf valves (see Figure 6-1).

b. To check operation of the primer, disconnect hose from manifold

check valve. A spurt of fuel should be evident when the plunger is
depressed. If little or no fuel is discharged, check the valves in
the fuel line, and fuel line fitting for leakage or sticking (refer
Figure 6-1).

AIR FILTER

The carburetor is equipped with an automotive type paper air filter

element that should be cleaned once during the operating season, and
replaced after a year's service. When pores in paper are plugged, Figure 6-9
engine will receive a rich fuel/air mixture and run rough and get poor
fuel economy. To clean filter element, shake to dislodge dirt particles
and blow with compressed air from inside, holding nozzle about two in-
ches from filter. 00 NOT wash or oil filter element. See Figure 6-9.

FUEL TANK
a. For correct fuel and lubricant mixtures and break-in instructions,
see Section 12, and inside front cover.

b. The importance of using a fresh clean fuel mixture cannot be

overstressed. Gum will form in old fuel which will clog filter
screens, fuel passages, carburetor orifices, leaf valves and check
valves. Remove tank to empty old fuel. Reinstall it and begin
with a fresh supply every season.
Figure 6-10

c. Drain and clean the fuel tank prior to off season storage. Remove
straps and turn tank upside down. Remove adapter and fuel pick-up
line in tank to check and clean filter screen. If adapter was re-
moved, it is not necessary on reassembly that the adapter seat be
tight against the end of the threaded boss on the fuel tank. Apply
G.E. RTV -102 silastic adhesive sealer on adapter threads and
immediately install to fuel tank. See Figure 6-10.

d. Clean the ta.llk with gasoline poured through a filtering funnel.

Cover the fuel line opening and agitate the tank. Empty it through
the fill opening. Use more gasoline to flush the fuel line opening.
Then reinstall the tank and hoses. See follOwing procedure to
install new fuel line tie straps.

e. Check to see there are no leaks at fuel hose connections.

6-8

FUEL LINE TIE STRAP

a. Fuel line tie strap, part no. 262081 must be replaced with a new
strap after its removal. (Cut tie strap head to remove.)

b. Assemble the new strap around the fuel line with the serrated
side toward the inside. See Figure 6-11.

c. Snug up the head on the strap per Figure 6-12.

d. Tighten head on strap with pliers as illustrated in Figure 6-13.

Figure 6-11

172.6 4

Figure 6-12

Figure 6-13
 7-1

SECTION -;,
IGNITION AND ELECTRICAL SYSTEMS

TABLE OF CONTENTS

DESCRIPTION 7-2
TEST EQUIPMENT . . • . . . . • • . . • . . . .. . . • . . • . . • . . • . • . . • . . . . • . • • . . . 7-2
C. D. IGNITION SYSTEM TROUBLE SHOOTING . . . . • • • • • •.. ••. • • . .. . • • •••• 7-3
INTRODUCTION . •. . .. . •• .. . . . . . .. , . . . . ..• . . . . . • .. . . •• . . . •• 7-3
DO'S AND DONT'S .•.••••••••.•. . .. . • . • .. •••••.•• • • .. • • •.• .. 7-3
TEST # 1 IGNITION COILS OUTPUT CHECK •••••••••••••.••••••••••• 7-4
TEST # 2 IGNITION SWITCH CHECK •••••••••••••••••••••••••••••• 7-5
TEST # 3 CHARGE COIL OUTPUT CHECK •••••..••••••••••••••••••• 7-6
TEST #4 RETARD SENSOR COIL OUTPUT CHECK •••••••••••••••••••• 7-7
TEST # 5 POWER PACK I OUTPUT CHECK ••••••••••••••••••••••••• 7-8
TEST # 6 IGNITION SWITCH CONTINUITY GROUND CHECK ••••••••••.•.• 7-9
TEST #7 ADVANCE SENSOR COIL RESISTANCE CHECK • • . . . • ••..• • •• • . 7-10
TEST #8 RETARD SENSOR COIL RESISTANCE CHE CK • •• • ...•••••• . .• . 7-10
TEST #9 CHARGE COIL RESISTANCE CHECK . . . . • • • • . • • • . . . . . . . .••. 7-10
TEST #10 IGNITION COIL CONTINUITY. POWER AND INSULATION CHECKS . • 7-10
TEST #11 IGNITION TIMING CHE CK . • ..• . . . . .• .. . . . . • • • • •••. • • •• 7-11
IGNITION SYSTEM REP AIR .. ••• . ••.•• • .. • .••.•••••••••.••. • •••.• . 7-12
DISASSEMBLY •.•.••••.••••.••••••••• • •• • • • • . ••• . •• • ••• • •• 7-12
RE ASSEMBLY •. . ••••.•.•••. . . . • . . . . . . . • . • • . . • . • • . . ..•.•• . 7-13
IGNITION TI MING . . . . • .. .•••.. . . . . . . . .••.. . . . . . . . • • . . • • . • . . •• • • 7-14
SP ARK PLUGS . . . . . .• . . . . • • . . . . . . • . . . . . • . . . .•.• • •. • •••••••.•• . 7-14
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . 7-16
LIGHTING COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7-16
LIGHTING COIL RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
LIGHTING AND CHARGE COIL REPLACEMENT •••••••••••••••••••••• 7-16
SAFETY STOP-SWITCH TEST ••••••••••••.••••••••••••••••••••• 7-17
DIMMER SWITCH TEST •••••••••••••••••••••••••••••••••••••• 7-17
BRAKE LAMP SWITCH TEST ••••••••••••••••••••••••.•••••••••• 7-17
HEADLAMP ADJUSTMENT •••••••••••••••••••••••••••••••••••• 7-17
WIRING DIAGRAM ••••••••••••••.•••••••••••••••.•••• AT BACK OF MANUAL
7-2

DESCRIPTION
The ignition system is made up of the following major components:

1. Flywheel assembly
2. Sensor rotor
3. Stator and charge coil assembly
4. Sensor plate assembly
5. Power Pack I assembly
6. Ignition coils
Because the engine is a two-cycle, twin opposed cylinder design, two
ignition coils are used to supply spark simultaneously to both cylinders.
GROUND An automatic spark retard/advance system has been incorporated to
27069 provide easier starting. (See Figure 7-1.)
The electrical system consists of the alternator coilS, headlights and
Figure 7-1 taillights, light and ignition switches and wiring. The alternator coils
produce alternating current which changes in frequency and voltage in
proportion to engine speed. Alternating current is then used to power
the headlights and taillights. See wiring diagram at end of manual.

This section gives complete service procedures on all components of

the ignition and electrical systems. Principles of the magneto C.D.
(capacitor discharge) ignition system are discussed in Section 3.

TEST EQUIPMENT
The test procedures outlined in this section require the use of the
following equipment.

1. Multimeter (see Figure 7-2) or an ohmmeter.

2. Needle point spark checker, gap set to 1/2". See Figure 7-3.
3. Neon test light M-80 (Figure 7-4) or S-80 (Figure 7-5).
4. Power clamp on timing light. See Figure 7-6.

5. Ignition coil analyzer. See Figures 7-7, 7-8 and 7-9.

27098 6. Volt-ohm-amp meter Model 700VOA Merc-O-Tronic, See Figure

Figure 7-2 7-10.

II

27070 2.7072

Figure 7-3 Figure 7-4 Figure 7-5

 7-3

l~
1

J \
GRAHAM

Figure 7-6 Figure 7- 7

MERC-O-TRONIC
c. D.
IGNITION SYSTEM Figure 7-S
TROUBLE SHOOTING
INTRODUCTION
An understanding of the theory of the C.D. ignition system is an in-
valuable asset in following the C.D. ignition trouble shooting procedure.
See Section 3 for a discussion of the C.D. ignition theory. All the
following tests can be conducted without the removal of the flywheel.

C.D. IGNITION SYSTEM DO'S AND DONT'S

1. Do make sure that all connections are clean and tight, especially
ground connections. Poor connections mean problems.
2. Do make sure that all plug-in connectors are fully engaged and free
of corrosion. Loose or corroded connectors mean problems. 2.7100 STEVENS
3. Do make sure that all wiring is located properly so there is no Figure 7-9
chance of rubbing against any edges that can cause wear and insula-
tion breakdown. This can create a difficult service problem.
4. Do make sure test equipment is in good working order before
troubleshooting the system. Poor test equipment will not solve a
problem.
5. Do use proper tools when working on system components. Wrong
tools could damage components.

~ SAFETY WARNINGS (6 AND 7)

6. Do return key switch to OFF position after each test before touch-
ing any system leads. This will discharge capacitor in Power Pack
I and prevent a possible high voltage electriC shock.
7. Don't hold spark plug wires in your hand while checking for spark.
A severe electrical shock could result. Use insulated pliers de-
Signed for this purpose.
37 1 18

S. Don't remove potting compound from Power Pack, as this will void
any warranty. Figure 7-10
9. Don't pull on high tension leads at the ignition coils. You might
break the insulation or connection.
10. Don't open or close any plug-in connectors while the engine is
running. You might cause damage to the system.
11. Don't attempt any tests other than those listed in the trouble-
shooting procedure. You might cause damage to the system.
12. Don't connect an electric tachometer into ignition system. You
might damage the system. (This does not include the electronic,
sensor type tachometers.)
7-4

13. Don't connect this sytem to any voltage source other than what is
specified. You might damage the system.

EJ NOTE
When connecting neon test light lead to Power Pack I be sure to
use spade terminal to insure good connection.

o NOTE

When connecting test equipment leads or reconnecting engine

wiring leads to Power Pack I always refer to the diagram pro-
vided. You must hook leads in correct location or possible
damage to system will result.

When removing Power Pack I cover plate, make sure you place
it alongside Power Pack 1 in same direction it was removed.
This will assure correct terminal identification. Also, replace
black (ground) wire from terminal #4 and screw to Power Pack
#1 after cover is removed before conducting following tests.

TEST #l IGNITION COILS OUTPUT CHECK

A. Pull high tension leads off spark plugs.

B. Connect spark gap checker with 1/2" gap. See Figure 7-11.

C. Put ignition switch in "RUN" position, remove plugs for easier crank-
ing and use starter rope to crank. See Figure 7-11.

1. Strong steady spark from both coils, system is good.

REPLACE GROUND
ADVANCE CHARGE WIRE AND NUT AFTER
SENSOR COIL
REMOVING COVER
POWER
PACK #1

ADVANCE

COMMON
IGNITION SWITCH ~----ofto<J7
IN "RUN" RETARD
POSITION

NEEDLE POINT
SPARK CHECKER
1/ 2" GAP

27092

Figure 7-11
 7-5.

2. Weak, erratic or no spark from one ignition coil, switch ignition

coil leads on Power Pack I - repeat test. Spark on same cylinder
still erratic replace coil. Spark on opposite cylinder erratic re-
place Power Pack I.

3. Weak, erratic or no spark from both coils, go to next test (#2).

TEST #2 IGNITION SWITCH CHECK

A. Disconnect orange/black lead from Power Pack terminal #5. See

Figure 7- 18. Figure 7-12

B. With ignition key in "RUN" pOSition, check from orange/black lead

to engine ground with ohmmeter set on Hi ohm scale. There should
be no reading or infinite reading on meter indicating ignition switch
not shorted and lead not grounded.

C. If less than 500k ohm reading, remove terminal connectors from

ignition switch (see Figure 7-12) and remove ignition switch from
dash panel. Turn ignition key to "RUN" position and take a resist-
ance reading across the magneto and ground terminal of the ignition
switch. See Figure 7-13.

D. If infinite reading indicated find problem in orange/black stripe lead.

E. If less than 500k ohm reading indicated, replace ignition switch.

F. Reconnect key switch lead to terminal #5 on Power Pack I.

Z70 69

Figure 7-13

OFF POSITION RUN POSITION

GROUND
The magneto terminal
and ground terminal are
connected together .

LIGHTS/RUN POSITION
o No ignition swit ch ter-
m inals are connected
together.

ALTERNATOR
The battery and lights
alternator are connected

AESUG"T' together. The A and Y

terminals are connected
together.
y

IGNITION SWITCH INTERNAL CONNECTIONS

Figure 7-14
7-6

TEST #3 CHARGE COIL OUTPUT CHECK

A. Remove charge coil brown/ white stripe lead from Power Pack
terminal No.1.

B. Use Neon tester S80 or M80. Connect neon tester black lead to
charge coil brown/ white stripe lead and tester blue lead to engine
ground. See Figure 7-15.

C. Remove spark plugs for easier manual cranking of engine.

D. Set neon tester rotary switch to position #2. Depress load button
"B. "

E. Turn ignition switch to "RUN" position and crank engine with manual
starter (with ignition switch "RUN") and observe neon tester light.
See Figure 7-15.

1. If light is bright and steady, charge coils are good. Check Power
Pack I output (Test #4).

2. If light is intermittent or no light, check for grounding or open

leads to charge coils. Also check charge coils for correct resist-
ance (Test #9).
F. Remove tester leads and reconnect charge coil lead to terminal #1
on Power Pack #1.
REPLACE GROUND
ADVANCE CHARGE WIRE AND NUT AFTER
SENSOR COIL DEPRESS POWER REMOVING COVER
LOAD PACK #1
8UTTON "8"

ADVANCE
~"';""'';';;'~K) 8
COMMON
~-""''''''''''1-O7
RETARD
6
8LACK

IGNITION SWITCH
IN " RUN" POSITION

NEEDLE POINT
SPARK CHECKER
1/ 2" GAP

~
~
V"" ©/ v . - . . . - _ - - - '
Qe, RED

RED

%~~
27082

Figure 7-15
 7-7

TEST #4 RETARD SENSOR COIL INPUT CHECK

A. Connect needle point spark checker as illustrated. See Figure 7-16.

B. Remove retard sensor white/ green stripe lead and advance sensor
lead white/ black stripe from Power Pack terminals #6 and #8.
(Do not allow leads to touch ground~) See Figure 7-16.
C. Connect neon tester S80 or M80 black lead to Power Pack terminal
#6 and blue lead to sensor common (terminal # 7). Set rotary switch
to position #3. See Figure 7-16.

D. Turn ignition switch to "RUN".

E. Crank engine with manual starter, and at same time rapidly tap neon
tester load button "B". See Figure 7-16.

1. If there is spark across both gaps, check retard sensor leads and
check sensor coil for correct resistance (Test #8).

2. If there is no spark on both coils, go to test #3. If there is no

spark on one coil go to tests #4 and #10.
F. Remove tester leads and reconnect sensor leads #6 and #8 on Power
Pack I.

ADVANCE CHARGE REPLACE GROUND

SENSOR COIL WIRE AND NUT AFTER POWER
SET NEON PACK #1
REMOVING COVER

TAP LOAD
BUTTON ADVANCE
"B" @ Os 4....,--.,.---

1__~~~__--~t:tiiC50~M~M~O:N~lrr~7
BLUE

I
RETARDrR\
QI

~~~

IGNITION SWITCH
IN "RUN" POSITION

NEEDLE POINT
SPARK CHECKER
1/ 2" GAP

~ ~~_ _ _ _R_E_D_ _- ,
~ RED

%~.........

l7 0 95

Figure 7-16
7-8

TEST #5 POWER PACK I OUTPUT CHECK

A. Remove ignition coil orange primary leads from terminals # 2 and 3

of Power Pack I.

B. Use neon tester S80 or M80. Set rotary switch on tester to position
#1. Hook tester black lead to Power Pack I terminal #2 or #3, and
tester blue lead to engine ground. See Figure 7-17.

C. Remove spark plugs for easier manual cranking of engine.

D. Depress load button "A" and crank engine with manual starter·
(with ignition switch "RUN") and observe light. See Figure 7-17.

1. If tester light is bright and steady, check ignition coils, test #10.

2. If tester light is weak or erratic, check ignition switch, test #5.

E. Remove tester leads and reconnect ignition coil primary leads to

terminals # 2 and #3 on Power Pack 1.

REPLACE GROUND
ADVANCE CHARGE
WIRE AND NUT AFTER
SENSOR COIL SET NEON POWER REMOVING COVER
LIGHT TO 1
DEPRESS
LOAD
BUTTON "A"
ADVANCE

COMMON

RETARD

=
IGNITION SWITCH
SENSOR
IN "RUN" POSITION
COIL

NEEDLE POINT
SPARK CHECKER
1/ 2" GAP

2;708S

Figure 7-17
 7-9

(
TEST #6 IGNITION SWITCH CONTINUITY GROUND CHECK

A. Connect spark gap checker with 1/2" gap. See Figure 7-18.

B. Put ignition switch in "RUN" position, remove plugs for easier

cranking. See Figure 7-18.

C. Use manual starter to crank engine and observe spark at the needle
point spark checker.

D. If weak, erratic, or no spark, disconnect ignition switch lead on

Power Pack terminal #5. Repeat test, cranking engine with rope.

E. If spark is strong and steady, check leads going to ignition switch

for grounds and check ignition switch.

REPLACE GROUND
ADVANCE CHARGE
WIRE AND NUT AFTER
SENSOR COIL POWER REMOVING COVER

ADVANCE

COMMON
~----+07 3 ()o!t--..,.
TESTS "2" AND "6D" ---I~--~~~t<)

SENSOR
COIL

NEEDLE POINT
SPARK CHECKER
1/2" GAP

~ ~~_ _ _ _R_E_D_ _- ,
© RED

%~..........

27092

Figure 7-18
7- 10

TEST #7 ADVANCE SENSOR COIL RESISTANCE CHECK

An engine that will start and idle, but dies out when accelerating, and
with timing light connected will show the red fin (retard timing mark)
and not the yellow fin (advance timing mark) when running has a bad
advance sensor or Power Pack I. If previous tests on the Power Pack I
were negative, a resistance check of the advance sensor coil should be
made.
A. Remove the white/black stripe lead from terminal #8 of the Power
Pack I, the black/white stripe lead from terminal #7, and the white/
green stripe lead from terminal #6. Check for 14 to 16 ohms re-
sistance between leads #7 and #8. See Figure 7-19. If sensor coil
Figure 7-19 resistance does not come within these tolerances, it must be replaced.

B. Coil or leads must not be shorted to ground. On ohmmeter hi ohms

scale, check for a reading of infinity from either coil lead to ground.
If there is a leakage to ground, check coil and leads and insulate area
of leakage with tape.

TEST #8 RETARD
~ .- SENSOR COIL RESISTANCE CHECK

An engine that is hard starting, kicks back, and with timing light con-
nected will show yellow fin when cranking, has a defective retard sensor
coil or Power Pack. If previous tests on the Power Pack were negative,
a resistance check of the sensor coil should be made.

A._ Remove the white/black stripe lead from terminal #8, the black/white
stripe lead from terminal #7 and the white/green stripe lead from
terminal #6. Check for 27 to 29 ohms resistance between leads #6
and #7. See Figure 7-20. If retard coil r.esistance does not come
within these tolerances, it must be replaced.

B. Retard coil or lead must not be shorted to ground. On ohmmeter hi

ohms scale, check for a reading of infinity from either coil lead to
Figure 7-20 ground. If there is a leakage to ground, check retard coil and leads
and insulate area of leakage with tape.

--
TEST #9 CHARGE COIL RESISTANCE CHECK

A. Remove the brown/white stripe lead from Power Pack I terminal #1.
Check for a total resistance of the two charge coils from lead to
ground of 875 ± 75 ohms. See Figure 7-21. If resistance of the
charge coils does not come within these tolerances, they must be
replaced.

TEST #10 IGNITION COIL CONTINUITY, POWER AND INSULATION

CHECKS

To determine accurately the condition of the ignition coil, an ignition

analyzer should be used. Without the use of test equipment, coils may
be replaced needlessly. A wide variety of ignition analyzers are avail-
able from various manufacturers. The use of the Graham, Merc-O-
Tronic, or Stevens ignition analyzers, and their adapter for C.D. ignition
are particularly recommended. See Figures 7-7, 7-8 and 7-9.

Detailed instructions for the use of any tester are provided with the
unit; therefore, only general information is given here. All components
of the ignition system should be checked, even though replacing a single
part seems to have corrected the trouble.
Figure 7-21
 7- 11

The following values are provided for checking the ignition coil
580916 short, 580944 long.

Graham Tester Model 51

Maximum Secondary 1900 ± 190
Maximum Primary Resistance test too low for reading on recom-
mended test equipment
Coil Index 60
Minimum Coil Test 9
Gap Index 50

Merc- O- Tronic
Operating Amperage 1.4
Secondary Continuity 22 to 26 (index number)

Stevens Tester Model MA 75 2.7104 LEAD

Switch A Index Adjustment 20
Figure 7-22

A SAFETY WARNING

Perform all tests on a wooden or insulated bench top to prevent

leakage or shock hazards. Follow the eqUipment manufacturer's
instructions. A low reading on the tester indicates a weak coil
which must be replaced. No attempt should be made to improve
this spark by increasing primary current; a coil is >defective if METER
it cannot be made to give a good · reading on the specified pri- OUTPUT
mary current.

11.1NOTE
r Zero meter before performing the continuity test.

A. CONTINUITY TEST (using MERC-O-TRONIC TESTER)

Remove ignition coils. Connect meter leads to coil primary and
secondary leads and turn meter selector switch to "Coil Continuity."
See Figure 7-22. Index reading should be between 22 and 26.

B. POWER TEST (using MERC-O-TRONIC TESTER) COIL PRIMARY

Connect meter leads to adapter. Adapter red lead to coil ground
2.7105 COIL SECONDARY
lead. Adapter black lead to coil primary. See Figure 7-23. Con -
nect coil high tension lead to meter output lead. Turn meter sel- Figure 7-23
ector to "Coil Power Test" and apply power to coil. Secondary
voltage should produce a steady spark at meter spark gap at 1.4
amps (black figures on number 1 scale). Check insulation by probing
the coil and entire secondary lead with the grounded test probe. See
Figure 7-24. Arcing will be apparent wherever the insulation has
broken down, due to moisture or carbon trails. METER

TEST #11 IGNITION TIMING CHECK I· •

RETARD TIMING CHECK

Connect test light to 12 volt source. Remove spark plugs to release

compression for easier manual turning of engine. Clamp the test light
electronic pickup on a spark plug wire. (Arrow on pick-up must point
toward ground. Connect spark checker to high tension leads and ground
to engine. Turn ignition switch to "RUN" position. It will be required
that one person pull the starter rope vigorously, and a second person
aim the test light at the timing slot and check the retard (red) fin. on the COIL SECONDARY
2.7 106
flywheel which should be visible at cranking speed in the timing slot.
See Figures 7-25 and 7-26. Figure 7-24
7-12

ADV ANCE TIMING CHECK

Connect timing light to 12 volt battery. Clamp timing light electronic

YELLOW pickup to one high tension lead. Run engine at idle speed (1300 - 1600
RPM) and aim · timing light at timing slot. The advance (yellow) fin
should be visible in the timing slot. See Figure 7-26.

IGNITION SYSTEM REPAIR

DISASSEMBLY

a. Remove starter assembly (see Figure 7-27), outer fan housing, air
filter, cover from top of ignition cOils, engine cover and Power
Pack cover.

b. Remove three screws attaching ratchet and ratchet mount to fly-

wheel (see Figure 7-28). Remove ratchet mount.

c. Remove flywheel nut (see Figure 7-29). Use spark plug wrench
FLYWHEEL BOSS handle in hole on rim of flywheel to keep flywheel from turning
17 144
KEYWAY while removing nut.

d. Secure flywheel puller (Service Tool #378103) to flywheel with

Figure 7-25
5/16"-8 screws and remove flywheel from crankshaft. See Figure
7-30.

e. The magneto charge coils, alternator coils and sensor coils are
now accessible for servicing. See Figure 7-33.

ELECTRONIC

Figure 7-26

Figure 7-27 Figure 7-28

 7-13

f. The wave washer and rotor can now be removed. See Figure 7-33.

g. Remove 4 screws holding lighting and charge coil assembly to

stator plate. Assembly can now be removed from stator. See
Figure 7-31. Sensor coils can now be removed for replacement
if necessary.

h. Remove two screws, and sensor plate assembly can be removed.

See Figure 7-32.

REASSEMBLY

a. Install sensor plate assembly and sensor coils. Important - Leads

Figure 7-29 must be secured properly to prevent pinching or chafing.

b. Install rotor and wave washer. If sensor coils were removed,

check for .010" gap between rotor and advance sensor coil. Use a
.010" diameter wire or .010" plastic feeler gauge (Service Tool
#604659) only, as a flat metal feeler gauge will not fit curvature.
See Figure 7- 33. Adjust if necessary by loosening screws secur -
ing the coil. Torque sensor screws 12 - 16 inch pounds.

Figure 7-30

Figure 7-31

-
Figure 7-32 Figure 7-33
7-14

c. Install lighting and charge coil assembly.

d. Install flywheel. See Figure 7-34.

e. Place washer and flywheel nut in position. Hold flywheel with bar
and torque flywheel nut to 40 - 45 foot pounds. See Figure 7-35.

f. Reassemble remaining parts in reverse order of disassembly.

Figure 7- 34

IGNITION TIMING
Ignition timing is fixed. Therefore, if timing is found to be off in test
#11, either the sensor lead wiring to the Power Pack I is switched, or
the sensor hub key is sheared or missing.

SPARK PLUGS
The condition and appearance of spark plugs taken from an engine may
be a guide to the type and source of engine trouble. Proper spark plug
heat range and normal engine conditions will produce powdery deposits
of a rust brown to grayish or tan color on the firing end of the insulator,
and a minor degree of electrode wear (see Figure 7-36). Highly leaded
fuels may produce white to yellowish powdery deposits on the firing end
of the spark plug. These deposits will not interfere with normal spark
plug performance if plugs are cleaned at regular service intervals. See
page 4-3 for a discussion on spark plug heat range.

17151A

Figure 7-36 Figure 7-37 Figure 7-38

 7- 15

a. If the insulator tip is an exceptionally light tan or whitish color, or

the center electrode burned away, the heat range may be too hot
(see Figure 7 -3 7) •

b. A dark, black or sootish coloration, or wet appearance, ordinarily

indicates the heat range as being too cold (see Figure 7 -38). Black,
sooty deposits on the entire firing end of the spark plug result
from incomplete combustion due to an overly rich air-fuel mix-
ture, incorrect choke setting, or misfiring caused by faulty ignition
components.
c. A definite white coloration may indicate the presence of moisture
in the combustion chamber. Similar deposits are caused by pre-
ignition.
d. Oil fouling deposits wet, sludgy deposits and is a result of mis-
firing or of excessive oil in the fuel mixture (see Figure 7-39). 171 5 1

Figure 7-39
e. Burned or overheated spark plugs may be identified by a white,
burned, or blistered insulator nose, and badly eroded electrodes.
Excessive deposits in the combustion chamber, a lean fuel mixture
or improperly installed spark plugs can cause overheating.

The condition of spark plugs may provide an indication of other con-

ditions requiring attention. Inspect each plug and gasket as it is re-
moved. Inspect each plug for worn electrodes, glazed, broken, or
blistered porcelain, and replace plugs where necessary. Plugs that are
severely carbon fouled, that have blistered or cracked insulator tips, or
plugs that have eroded electrodes must always be replaced. Plugs that
are slightly contaminated with deposits, or which have wider than rec-
ommended gap settings can be cleaned and regapped for further use.
Plugs that appear slightly contaminated can be cleaned by careful
scraping, using a small knife or similar instrument. After combustion
deposits have been removed, bend the side electrode back slightly so
that the center electrode can be filed flat.

DO NOT clean plugs on abrasive blasting machines. This type of

cleaning tends to remove the hard, smooth finish from the insulator tip
and reduces the tip's resistance to the formation of combustion deposits.
Blasting also tends to pack the abrasive between the insulator top and
17146
the metal shell of the plug. If the abrasive is not removed before in--
stalling the plug, it may pass through the engine, causing piston or
cylinder wall scoring. Figure 7-40

After the plug has been cleaned, adjust the gap to .028 to .033 inch by
bending the side electrode. Adjust only the side electrode, as attempting
to bend the center electrode will crack the insulator. Use a round wire
feeler gage to measure gap adjustment (see Figure 7-40).

Poor engine performance and premature spark plug failure may re-
sult from improper spark plug installation. Before installing the plug,
be sure the plug seat in the cylinder head is cleaned and free from
obstructions. Clean and inspect spark plug hole threads. Tighten spark
plugs to 20 - 25 foot pounds, USing a torque wrench.

Improper installation is one of the greatest single causes of unsatis-

factory spark plug performance. Improper installation is the result of
one or more of the following:

1. Installation of plugs with insufficient torque to correctly compress

the gasket.

2. Installation of plugs using excessive torque can strip the threads in

the cylinder head.
7-16

3. Installation of plugs on dirty gasket seal.

4. Installation of plugs in corroded spark plug hole threads.

LIGHTING SYSTEM
TROUBLE SHOOTING

When a lighting failure occurs, first check the bulbs, then the electri-
cal connections throughout the circuit before proceeding with electrical
testing. A visual inspection may be all that is required to locate the
trouble. Refer to wiring diagram at end of manual.

a. Wiring. The importance of connections which are good electrically

and mechanically throughout the circuit cannot be overemphasized.
The largest percentage of electrical system failures are caused by
one or more loose or dirty connections. Check for corroded or
loose connections, and for worn or frayed insulation.

b. Connections. Although connections are easily made, care must be

used when fastening terminals together. If connectors are not as-
sembled properly, one or more of the terminals may back out of
the housing, preventing one or more of the electrical circuits
from operating. To eliminate problems due to improper connec-
tions, examine the terminals on both halves of the connectors after
assembly to be sure that all terminal ends are in place.

If a visual inspection of the electrical system shows all components

to be in good condition, an electrical inspection will be necessary to de-
termine which component of the lighting system is the cause of trouble.

LIGHTING COILS

The lighting coils are replaceable along with the charge coils as an
assembly. See Figure 7-31. The lighting coils can be checked for
their correct reSistance without removal of the flywheel as shown in
the following test.

LIGHTING COIL RESISTANCE TEST

a. Disconnect alternator lead at quick disconnect.

b. Connect ohmmeter, black meter lead to engine ground and red lead
to yellow alternator lead. Resistance reading 1.5 ohms.

c. Repeat test (b) on yellow/ gray stripe lead. Resistance reading 2.8
ohms.

d. Repeat test (b) on green lead. Resistance reading 2.2 ohms.

LIGHTING AND CHARGE COIL REPLACEMENT

a. Follow steps "a" thru "g" of "IGNITION SYSTEM REPAIR - DIS-

ASSEMBLY."

b. Disconnect lighting and charge coil leads.

c. Remove lighting and charge coil assembly.

d. Install and connect new lighting and charge coil assembly. Make
certain that coil laminations are flush with bosses on fan housing.

e. Reassemble as described on page 7-13.

 7-17

SAFETY STOP - SWITCH TEST

Pull connector apart and connect continuity meter across two stop
switch leads.

1. Depress button - full continuity

2. Depress button - "HUN" position - no continuity

DIMMER SWITCH TEST

2.72.30

a. Disconnect lights connector

Figure 7-41
b. Ignition switch "Off". Connect continuity meter, one meter lead to
engine ground other meter lead to black/white stripe wire terminal
at male headlamp connector.

c. Depress button - full continuity

Depress button second time - no continuity

BRAKE LAMP SWITCH TEST

a. Pull connectors apart (near brake switch).

b. Connect continuity meter to each of the terminals.

c. Pull up on switch plunger - full continuity.

d. Release plunger - no continuity.

".1 NOTE
If brake is not properly adjusted brake switch will not function
properly.

HEADLAMP ADJUSTMENT (See Figures 7-41 and 7-42)

Headlamp is adjustable for elevation of beam and right or left throw

of beam.

For elevation, turn both adjustment screws in or out equally. With

high beam on, adjust elevation of beam so that center of high intensity
zone is 2 inches below center of lamp at a distance of 25 ft. from head-
lamp.

For right or left throw of beam, adjust either screw until proper aim
is obtained.

HICH INTENSITY
70NE

37 0 60

Figure 7-42
 8-1

SECTION B
MANUAL STARTER

TABLE OF CONTENTS

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . . . 8-2

CLEANING, INSPECTION AND REPAIR .. . . . . . . . . . 8-2

REASSEMBLY . . . . . . . . . . . . . . .. . . . . . . . . . . . . 8-3
8-2

DESCRIPTION
The manual starter converts straight line motion to rotary motion
necessary to crank the engine. Pawls on the starter pulley engage the
flywheel ratchet when the starter rope handle is pulled. When the en-
gine starts, centrifugal force moves the pawls outward, disengaging
them from the ratchet. A recoil spring is wound as the rope is pulled
and unwinds as the starter handle is returned to the starter housing.

o NOTE

Never release handle at end of stroke, allowing rope to snap

back. Serious damage will result.

REMOVAL AND DISASSEMBLY

l::l..SAFETY WARNING

It is good practice to wear safety glasses while disassembling

and reassembling manual starters because of the rewind spring.

a. Remove hood and engine cover.

b. Remove three screws attaching manual starter assembly to fan

housing. Remove starter assembly from fan housing.

c. Pull starter rope out and untie knot in handle while holding rope.

d. Ease rope back into starter until starter spring is fully unwound.

e. Remove spindle screw, and remove all components of starter pulley

spindle assembly (see Figure 8- 1).

f. Jar the housing, pulley side down, on bench to dislodge spring

washer and pulley from housing.

CLEANING, INSPECTION,
AND REPAIR
a. Wash metal components in solvent and blow dry with compressed
air.

SPINDLE SPACER

@@@b~~~J
SPACER/ /
\~.vO
FRICTION
RING

FLYWHEEL
SCREEN
\
SPRING
r
SCREW
172.54

Figure 8-1
 8-3

17. InDpcot "p.inS fQ. l;>.oken e nd loops or insufficient tension.

r c. Examine starter pawls and ratchet for excessive wear.

d. Ing~~(!t friction ring and spring, spindle billlhing, Bpindle, and re -

hlners.

e. Inapect rope and di~card if frayed. Replace with starter rope cut
length of 73 - 3/4 inches.

f. Examine pulley and housing rope eye for sharp edges and rough
surfaces that might cause rope fraying. File and polish as neces-
sary.

REASSEMBLY
a. Rewind starter spring using fixture base #383966.

b. Place outside spring end loop on starter housing anchor pin.

c. Replace starter pulley and inside spring end loop fitted on starter
pulley pin.

d. Grease hub of pulley before installing bushing.

e. Grease inside of bushing and install spindle, spring washer and

friction ring, in bushing. Fasten with screw, washers and nut.

f. Wind pulley counterclockwise until tight.

r g. Unwind pulley clockwise until pulley anchor hole lines up (approx.)

with starter rope hole in starter housing.

h. Lock starter pulley in position by aligning holes in pulley and

housing and inserting a nail or pin through them.

i. Tie a knot in one end of starter rope. If installing a new rope,

be sure length measures 73-3/ 4 inches. Fuse nylon strands over 172.62

an open flame at each end for about one-half inch. Rope ends
must be stiff to hold in pulley. Figure 8-2

j. Insert rope through pulley and starter housing. See Figure 8-2.
Seat rope knot firmly in pulley. Tie a slip knot in starter rope and
allow pulley to rewind.

k. Install pawls, r etainers, and screws, if they have been removed.

1. Assemble starter rope to handle and secure with knot.

m. Pull on starter rope to make certain that pawls work properly.

When starter rope is pulled, pawls should pivot to engage flywheel
ratchet. On releaSing rope, pawls should retract to starting posi-
tions.

n. Attach manual starter assembly to fan housing with three screws.

I_ INOTE
Do not apply grease to starter spring. Many lubricants, including
OMC Type "A", solidify in cold weather, and will make the
starter inoperative.
 9-1

SECTIONS
ENGINE

TABLE OF CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 9-2

ENGINE REMOVAL • • • • • . . . • . . • . . • • •• 9-2

DISASSEMBLY . . . . . . . . . . . . . . . . . . . .. 9-3

CLEANING, INSPECTION, AND REPAIR. . .. 9-5

CYLINDERS. . . . . . . . . . . . . . . . . . .. 9-5
GASKETS AND GASKET SURFACES. . .. 9-6
PISTONS. . . . • . . . . . . . . . . . . . . . .. 9-6
BEARINGS. . . . . . . . . . . . . . . . . . . .. 9-7

ASSEMBLY OF ENGINE. . . . . . . . . . . . . .. 9-8

PISTONS, WRIST PINS, AND
CONNECTING RODS . . . . . . . . . . . .. 9-8
PISTON RINGS. . . . . . . . . . . . . . . . .. 9-8
CRANKSHAFT . . . . . . . . . . . . . . . . .. 9-9

CYLINDERS. . • • . • • . . • . . • . • . • . • . . .• 9-10

INSTALLATION • . . . . . • • . . . . . • • • . . • . 9-11

BREAK-IN. . . • • . . . . . . . . . . . • • • . . • •• 9-12

MUFFLER. . . . . . • . . . . . . • • . • . • . . . .. 9-12
REMOVAL. . . . . • . . • . . . . . • . . • • •. 9-12
INSTALLATION. . . . . • . . . . • . . . • •. 9-12
9-2

DESCRIPTION
The snow machine is driven by a two-cycle, twin-opposed cylinder,
air-cooled engine. This section gives instructions for removal and
overhaul of the engine. Principles of two-cycle engine operation are
discussed in Section 3. Trouble shooting procedures are given in
Section 4.

ENGINE REMOVAL
1. Before removing hood:
a. Disconnect headlight wiring. Separate connectors by squeezing
top and bottom tabs of connector and pull. See Figure 9-1.
b. Remove gas cap and release hood latches.
Figure 9-1 c. Lift off hood and engine cover.
d. Replace gas cap.
2. Remove belt guard and transmission belt. See Section 10.
3. Remove throttle cable using the following procedure: Depress
thumb throttle lever. Hold throttle in open position. Slip end of
throttle cable through nylon pivot pin. Remove jam nut on intake
manifold and turn cable fitting out of manifold. See Figure 9-2.

4. Disconnect compression relief at mounting bracket.

5. Disconnect inlet hose from fuel pump. See Figure 9-4. Discon-
nect primer line from intake manifold. Disconnect fuel return line
from carburetor.
6. Remove ignition system cover by removing the three screws and
washers. Disconnect wiring going to switch at quick disconnect. -
)

7. Remove pipe to muffler screws. See Figure 9-21.

8. Remove screws securing heat shield.

9. Remove primary drive. See Section 10.
10. Remove four nuts and washers attaching engine frame to chassis.
11. Engine, exhaust manifold can now be lifted high enough to remove
Figure 9-2 nuts from exhaust manifold studs on 30 and 32 HP.
12. Engine. Remove four bolts anchoring manifold to muffler on 27 HP.
13. Remove engine assembly from chassis.

LPULL COVER
STRAIGHT OFF
WITH SLIGHT TWIST

AS~~~-SPARK PLUG
17 182

Figure 9-3 Figure 9-4

 9-3

DISASSEMBLY

r
a. Remove carburetor, intake manifold and leaf valve assembly. For
detailed instructions, see Section 6.

b. Remove spark plugs.

c. Remove exhaust manifolds.

d. Remove flywheel and rotor as described in Section 7.

e. Remove cylinder and crankcase group from engine frame assembly.

f. Remove compression relief valve.

g. Remove the cylinder stud nuts and lockwashers. The cylinder

barrel can now be removed from the crankcase. See Figure 9-6.

DNOTE

Cylinders and pistons can be serviced with only the cylinder

barrels removed.
(
h. Remove screws from crankcase halves and drive out two alignment
roll pins from flywheel side. Heat up crankcase halves in bearing
area to apprOximately 250°F. Tap crankcase with rawhide mallet
to break seal and separate crankcase halves.

r
Figure 9-5
9-4

FRONT
CYLINDER COMPRESSION
HOLE PLUG

qL --»
,/
/
-----./

CRANKCASE HALF
(PRIMARY DRIVE SIDE) REAR

,/,/~U5h
CYLINDER

,/ ~
<...--- ~
--
--- --- ........

CRANKCASE HALF
PRIMARY DRIVE SIDE .....

~CONNECTING ROD
SEAL r SCREW

/ CRANKSHAFT ~ ______ CONNECTING

V
jJI~
ROD CAP

'(0 ///,,",,," ,.--....

BEARING
RETAINER GASKETS
CRANKCASE HALF
FLYWHEEL SIDE

CONNECTING
ROD
~
~.c::::,\
t I

PISTON BEARING

r"\. ~ ~~
\
~ NEEDLE

a~~\
~J BEARING ASSEMBLY

WRIST
BOTTOM
~ PIN GASKET

PISTON RING
SET

Figure 9-6
 9-5

DNOTE

Pistons, connecting rods, and caps are matched parts. Because

of this, it is essential to maintain their original positions at
reassembly. Mark each connecting rod and cap, piston, and SIDE
bearing component to assure correct mating during reassembly. MARKED
Also mark the cylinders and crankcase halves from which they "LOOSE'
are removed. UP
DRIFT _ _ _ _~I
PIN

i. Remove connecting rod caps. Remove connecting rods from crank- MOUNTING
shaft.

j.. Reinstall matched caps on connecting rods.

Figure 9-7
k. Remove rings from pistons. DO NOT try to save the rings.
Install a complete set of new rings on every overhaul.

IBtl1NOTE
Open end of wrist pin retainer must face the top of the piston.

1. If necessary to remove connecting rods from pistons, remove

wrist pin retaining rings, using screwdriver in slot in piston.
Press out wrist pin to free piston from connecting rod. See Figure
9-7. Piston wrist pin hole marked "Loose" should be up when
pressing out wrist pin to prevent piston damage.

CLEANING, INSPECTION, AND REPAIR

A SAFETY WARNING
When using trichlorethylene as a cleaning agent, use in a well
ventilated area at normal room temperatures, and under no
circumstances heated. Trichlorethylene vapors are poisonous.

CYLINDERS

a. Remove carbon from exhaust ports and cylinder heads. Carbon

accumulation in exhaust ports restricts flow of exhaust gases and
has a considerable effect on motor performance. Carefully scrape
carbon from cylinder heads and exhaust ports with scraper or
other Suitable tool. Exhaust ports and all exhaust passages must
be free from carbon deposits to insure maximum performance.
Clean compuession relief valve and check for free action.

b. Check cylinder walls for excessive wear. Measure cylinder bore

for size and straightness by using an inside micrometer or dial
bore indicator. If wear is excessive, badly scored, replace cyl-
inders. Major portion of wear will be in port area and area cov-
ered by ring travel. See SpeCifications, Section 2.
9-6

GASKETS AND GASKET SURFACES

a. Discard all gaskets, seals, and a-rings. Use only new gaskets and
seals in reassembly.

b. Remove all traces of dried cement and old gasket material, using
trichlorethylene or lacquer thinner.

Figure 9-8

c. Check gasket faces for flatness. Under certain conditions, gasket

faces may warp or spring, particularly where thin sections are
flanges are employed and are subject to temperature changes. To
correct flatness, lay a sheet of No. 120 emery c!oth on a surface
plate or piece of plate glass (see Figure 9 -8). Place part to be
surfaced on emery cloth and move slowly back and forth several
times in a figure 8 motion, exerting evenly distributed, light pres-
sure. Lift part from surface plate to observe results. If surface
is actually warped or sprung, high spots marking contact with lap-
ping surface will take on a dull pOlish, while low areas will retain
their original state. To insure flatness over entire surface, con-
tinue surfacing until entire gasket surface has been polished to a
Figure 9-9 dull luster. Finish surfacing with No. 180 emery cloth.

THIS EDGE PISTONS

Figure 9-10 a. Carefully remove carbon deposits from piston head. Inspect ring
grooves for carbon accumulation, excessive wear, or damage to
ring seats. Carefully scrape carbon from ring grooves (see Figure
9-9, making certain that carbon clinging to bottom and sides of
grooves has been thoroughly removed, without scratching or other-
wise damaging the grooves. A suitable tool for cleaning ring
grooves can be made by breaking a piston ring, grinding an angle
on the edge, and breaking the lower sharp edge to prevent damage
to lower ring land (see Figure 9-10).
Figure 9-11

b. Check pistons for roundness, taper, excessive skirt wear, and

scoring. Piston skirts must be perfectly round and unscratched to
prevent entry of exhaust gases into crankcase chamber. Check
piston size, taper, and roundness, using a micrometer (see Figure
9-11). Check clearance between piston and cylinder before rein-
stalling piston (see Figure 9-12). Check tolerances on specifica-
tion page 2-2.

Figure 9-12
 9-7

c. Before installing new piston rings, check gap between ends of ring
r by placing ring in its respective cylinder bore (see Figure 9-13).
Press ring down in bore slightly with bottom of piston to square it
up. Discard and replace with new ring if gap is excessive (see
Section 2, Specifications).

d. Check each ring in its respective ring groove for tightness or bind-
ing by rolling the ring around the piston groove (see Figure 9-14).
Check for groove side clearance with feeler gage (see Figure 9 -15)
(see Section 2, Specifications).

BEARINGS

a. Work area where bearings are to be serviced must be free from

oil and dirt. DO NOT spin ball or roller bearings before they are
cleaned. Dirt in the races could cause serious damage.
Figure 9-13

b. Clean bearings while they are still on crankshaft by emersing

them in a cleaning solvent and turning outer race of bearing.
Flush all dirt from around balls and separators. Tank should be
equipped with a screened false bottom to prevent settlings from
being stirred up in the bearings. Agitate bearings frequently until
all oil, grease, and sludge have been loosened and can be flushed
out. Bearings with especially heavy carbon depOSits or hardened
grease should be soaked in a separate container of solvent.

c. Use a spray gun with air filter and a cleaning solvent to flush each Figure 9-14
bearing until all dirt and residue have been removed. Blow
solvent out of bearings, USing dry, filtered air. Be careful not
to spin bearings by force of air.

d. ~nce dry bea.rings rust rapidly, lubricate them immediately in

hght, clean OIl. Rotate them a few times to spread the oil film
and place them in a clean, covered container for inspection.

e. Discard and replace any bearing that shows any of the following:
Figure 9-15
1. Rusted balls, rollers, or races.

2. Fractured ring. This may be caused by forcing a cocked bear-

ing off a shaft or by too heavy a press fit.

3. Worn, ga'-led, or abraided surfaces. These may be caused by

too loose a fit, or a bearing locked by dirt and turning on the
shaft or in the housing.

4. Badly discolored balls, rollers, or races. This is usually due to

an inadequate supply of lubricant. Moderate discoloration is
not a cause for discard.
9-8

f. If bearings must be replaced, remove the old bearings using the

following procedure: Use special bearing removal tool shown in
Figure 9-16. Position lips of half shells behind bearing and over
extractor. Slide retaining ring over half shells. Turn extractor
center screw to remove bearing. This tool is a must if main
bearing replacement is required. Do not lose shims between
bearing and crankshaft throw.

ASSEMBLY OF ENGINE
HALF 17111

SHELLS Refer to exploded views for correct sequence of assembly. Make

no forced assemblies unless press fits are called for. Make no dry
assemblies. Lubricate all moving parts with a light film of oil. Be
sure all parts are clean and free from dirt and grit. Perfectly good
cylinder walls, pistons, and rings can be ruined in a few minutes of
EXTRACTOR operation if grit remains after assembly. Work in clean surroundings
PART NO. 261129 and with reasonably clean hands. Coat all bearing surfaces, cylinder
walls, etc., with clean oil before assembly. NOTE: Use new gaskets
HALF SHELLS
and seals throughout when reassembling the engine. Apply Perfect
Seal #4 to both sides of crankcase gasket before assembly.
PART NO. 261131

PISTONS, WRIST PINS, AND CONNECTING RODS

'-I
RETAINING RING
PART NO. 261132

11112

NOTE
Figure 9-16 Pistons are not interchangeable with one another. The wrist pin
hole is offset in different directions.

Piston Identification-
Piston Stamped No.1 on head, place in front cylinder nearest bumper.
Piston Stamped No. 2 on head, place in cylinder nearest driver.

a. Install wrist pin needle bearing in connecting rod.

b. Apply a coat of oil to wrist pin, making sure the surface is clean.
Place a drop of oil in each pin hole in piston.

c. Oil wrist pin bearing in connecting rod. Heat piston in water

approximately 140°F. Insert wrist pin through hole in loose side
of piston. Place connecting rod in position in piston, then complete
wrist pin installation in an arbor press.

d. Replace retaining rings, using Driver #317829 and Cone #317830,

making certain they seat securely in the groove provided.

e. Check piston with micrometer to determine whether piston has

been distorted during assembly. Maximum permissible distortion
is .003 below wrist pin boss only.

PISTON RINGS

a. Install the piston rings on each piston. Spread each ring with a
ring expander just enough to slip it over the head of the piston and
into place (see Figure 9-17). Be sure that the rings fit freely in
the piston ring grooves.

b. Be sure that piston rings are correctly positioned in piston ring

grooves. When installed on the piston, rotate rings to seat gaps
Figure 9- 17 against dowel pins.
 9-9

CRANKSHAFT

I- I NOTE

Shims must be installed on crankshaft, between the bearing and

thrust face of crankshaft on flywheel end.

a. Install crankshaft shims and journal bearings on crankshaft, using

an arbor press. Be sure to support properly to prevent distortion.
Shims must be installed on crankshaft, between the bearing and
thrust face of crankshaft. Crankshaft end play should not exceed
.019" after installation. Total dimension across bearing should
be 4.933" ± .001". See Figure 9-18.

b. Remove connecting rod caps from connecting rods. Apply a coat of

OMC Needle Bearing Grease (Part No. 378642) to connecting rod
bearing area. Assemble needle bearing (16) and retainer halves,
with connecting rod and connecting rod caps.

I lliil: I NOTE

Connecting rod caps are matched. Do not interchange connecting

rod caps or turn them end for end.

c. Assemble piston and rod assembly to crankshaft with piston ring

dowel pins faCing top of engine. Attach caps to connecting rods.

d. Draw sharp pencil down four machined corners of connecting rod

and cap assembly to insure proper alignment. (See Figure 9-20.)
If misalignment offset edge will be felt with pencil pOint. If align-
ment is necessary, tap into alignment with drift pllilCh. If align-
ment is satisfactory, tighten connecting rod cap screws to specified
torque.

IBljlNOTE

It may be necessary to heat crankcase halves for easier instal-

lation of crankshaft.

e. Spread film of OMC Gasket Sealing Compound #317201 to both sides

of gaskets.

f. Insert screws and finger tighten. Insert roll pins, locate and drive
in. Torque bolts to 1/2 required torque (2-3 ft. lb.). Final torque
bolts to 5-7 ft. lb. Trim gasket material from open areas of
crankcase.

4.933" ± .001"

17153

Figure 9-18 Figure 9-19

9-10

g. Check crankshaft end play. It should not exceed .019".

h. Crankshaft tapered end must be kept clean (free of grease and

fingerprints) before installation of primary sheave assembly.

i. Install crankshaft seals in crankcase.

CYLINDERS

a. Coat cylinder gaskets with OMC Gasket Sealing Compound #317201

diluted with an equal amount of castor oil. Install cylinders to
crankcase using new gaskets. Use a ring compressor (Special tool
426020) to install pistons in cylinders. Tighten nuts in correct
sequence to specified torque (see Figure 9 -20).

b. Assemble exhaust manifolds to cylinder barrels if they were

removed. The gasket surfaces on cylinders and manifolds must be
clean and smooth. Place new exhaust manifold gaskets over
cylinder studs and assemble exhaust manifolds. See Figure 9-6.

c. Install leaf valve assembly, intake manifold and carburetor. For

detailed instructions, see Section 6. Apply OMC Gasket Sealing
Compound # 317201 on intake manifold gaskets.

d. Attach cylinder and crankcase group to engine frame. Use Loctite

Grade D on engine frame mounting screws.

e. Install compression relief valve using Dupage High Temperature

Thread Compound applied to the threads.

f. Install alternator/charge coil assembly, sensor plate assembly,

and cable clamp as described in Section 7.

g. Install sensor rotor and flywheel as described in Section 7.

4 1

~~ 01l
~ 2 3

17161>

Figure 9-20
 9-11

INSTALLATION

( 1. Install engine and frame to chassis. Secure pipe to muffler

screws.

2. Install heat shield.

3. Install ignition system cover.

4. Install fuel inlet and return lines to carburetor and pulse and
primer lines to intake manifold on crankcase.

5. Reconnect compression relief cable to compression relief valve.

See Section 5 for adjustment procedure.

6. Install spark plugs and connect leads.

7. Reconnect throttle to carburetor. See Section 6 for cable adjust-

ing procedure.

8. Install belt guard and transmission belt. See Section 10.

9. Replace hood and secure hood latches.

10. Reconnect headlight wiring.

11. Install remaining parts in reverse order of disassembly.

BREAK-IN

1. For the first tankful of fuel the vehicle must be operated at

reduced speeds.

2. Allow engine to warm up before putting vehicle in gear. start

out slowly; avoid jack-rabbit starts. DO NOT overspeed engine.
Operation in extreme cold weather can cause a slow down in the
drive and track mechanism. When this occurs, block up rear of
snowmobile and place front edge of skis against stationary
object and run to free mechanism. DO NOT over-speed or run
vehicle for prolonged periods while snowmobile is blocked up,
as this can damage drive lugs on track.

3. Observe fuel mixing precautions as described in inside front

cover.

IMPORTANT

Adjust drive chain tension after the first 10 hours of operation.

Refer to Section 10 for drive chain adjustment instructions.

Adjust track tension after the first 10 hours of operation. Refer

to Section 11 for track tension and track alignment adjustment
instructions.
9-12

MUFFLER
REMOVAL

Muffler replacement requires engine removal. See Page 9-2, steps

1 thru 10.

1. Slide engine back to clear exhaust system.

2. Remove four muffler mounting screws.

3. Loosen muffler.

4. Disconnect tie rods from steering column arm.

5. Muffler can now be removed from well.

INST ALLATION

Place muffler in well. Install muffler and tighten nuts equally and
securely. Reconnect tie rods to steering column arm.

Figure 9-21
 10-1

SECTION 10
DRIVE TRAIN

TABLE OF CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

TRANSMISSION BELT INSPECTION AND

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .. 10-2
BELT REMOVAL. • • • • • • • • • • . • • • • • • • • •• 10-2
REPLACEMENT .•.•.••••••••••..•.••• 10-2

PRIMARY DRIVE. . . . . . . . . . . . . . . . . . . . . . . .. 10-2

REMOV AL OF PRIMARY SHEAVE
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . .. 10-2
DISASSEMBLY OF SHEAVE WHILE ON
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3
CLEANING, INSPECTION AND REPAIR . . . . . . . 10-3
REASSEMBLY .. . . . . . . . . . . . . . . . . . . . . .. 10-4

DRIVE CHAIN • . • • • • • • • • • • • • • • • • • • • • • • • •• 10-4

REMOVAL •••••••••••••••••••••••••• 10-4
INSTALLATION. • • • • • • • • • • • • • • • • • • • . •• 10-5
ADJUSTMENT •...••..••..•••.••.••••• 10-5
LUBRICATION ..•••.••.•.•••.•..•.••• 10-5

BRAKE ••.•••.•••.•.••••..••••••••••••• 10-5

DESCRIPTION. . • • • • • . • • • • • • • • • . . • . • •. 10-5
REMOV AL ••••••••••.•••.••.••••..•. 10-5
REPAIR • • • • • • • • • • • • • • • • • • • • • • • • • • •• 10-6
BRAKE CABLE AND CAM ASSEMBLY •.•.•.• 10-6
BRAKE ADJUSTMENT. • . • • • . . • • • • • • • • • •• 10-6

SECONDARY DRIVE. • • • • • • • • • • • • • • • • • • • • •• 10-7

DISASSEMBLY. • • • • • • • • • • • • • • . • • . • • • .. 10-7
CLEANING AND INSPECTION ••••••••••••• 10-8
REASSEMBLY. • • • • • • • . • • • . • • • • • • • • • •• 10-8
10-2

DESCRIPTION
This section gives complete service instructions on the snowmobile
drive train. A brief discussion of the power flow system is included
in Section 3.

TRANSMISSION BELT
INSPECTION & REPLACEMENT
A belt measuring less than 1-1/16" across the width or outer surface
must be replaced with a new one. Worn belt may be retained and used
as a spare. A spare belt should be carried at all times.
NOTE
Figure 10-1 00 NOT RUN ENGINE WITHOUT BELT.
BEL T REMOVAL

a. Remove four wing fasteners and belt guard, Figure 10-1.

b. Put brake in lock position.

c. To release belt, pull secondary sliding sheave while twisting to

left, Figure 10-2.

d. Work belt over top of sheave, Figure 10-3.

ASAFETY WARNING
Keep fingers from between halves of secondary sheave when
performing next step.
2.7020
e. Ride belt off sheave as sheave is twisted to right and closed, Fig-
ure 10-4.
f. Work belt out from under bottom of sheave and 'between steering
column and end cap, Figure 10-5.
g. Move belt from around primary drive, Figure 10-6.

REPLACEMENT

Assemble in reverse order of disassembly.

PRIMARY DRIVE
REMOVAL OF PRIMARY SHEAVE ASSEMBLY

NOTE

Primary drive assembly is dynamically balanced. Before dis-

assembly mark relative position of end cap and pulley assembly
CD , sliding sheave @ and fixed sheave @ for proper align-
ment on reassembly. See Figure 10-9.

After removing the transmission belt as described above, the primary

sheave assembly can be removed using the follOwing procedure:

1. Remove starter housing. See

Section 7.

2. Remove ratchet mount.

3. Attach Service Tool No.

Figure 10-5 )f 113971 to flywheel with three
bolts. See Figure 10-7.
 10-3

Figure 10-B

Figure 10-7

4. Use flat, open end wrench (Service Tool No. 404032) on the square
nut on back side of the fixed sheave. See Figure 10-B.

5. While holding the service tool attached to the flywheel, rap the open
end wrench with a rawhide mallet in counterclockwise direction.
(Power take-off end of crankshaft has right hand thread.) After nut
is loosened, the primary sheave assembly can be turned off the
crankshaft.
Figure 10-9
DISASSEMBLY OF SHEAVE WHILE ON ENGINE
( 1. Remove transmission belt (see Page 10-2).

2. Remove two screws securing lock plate to end cap assembly (see
Figure 10-9).
A SAFETY WARNING
Primary sheave is spring loaded. Clamp primary sheaves to-
gether with strap (Service Tool No. 261906) (see Figure 10- 11)
before proceeding with following steps.

3. With flat, open end wrench (Service Tool No. 404032) on inside, and
socket wrench on outside, break loose end cap bolt from main shaft
(see Figure 10-10).

4. Finish removing bolt with strap holding sheave halves together. Figure 10-10
Remove end cap assembly.

5. Remove strap while pressing movable half of sheave toward fixed

half of sheave (see Figure 10-12).
l!£liii.U NOTE
When used with Service Tool 113971, spline wrench service tool
can be used to remove main shaft and sheave assembly from
engine.

CLEANING, INSPECTION AND REPAIR

a. Clean all parts with a cleaning solvent such as Trichloroethylene
(see SAFETY WARNING page 9-5) and blow dry with compressed
air.
b. Remove sliding sheave and inspect spline (Ref. 1), primary sheave
bearing (Ref. 2), compression spring (Ref. 3) and garter (activating)
spring (Ref. 4) (see Figure 10-13).
c. Align holes vertically in fixed shaft and sheave assembly, neutral
lockout balls should fall through holes freely. Figure 10-11
10-4

Figure 10-12 Figure 10-13

REASSEMBLY

Internal threads and taper on fixed shaft and sheave must be

cleaned prior to reassembly. When assembling fixed shaft and
sheave to crankshaft be certain that fixed shaft and sheave is
securely tightened to crankshaft.
1. Place compression spring on shaft with closed side of spring cup
toward bearing.

2. Place movable half of sheave on shaft, compress spring and lock in

place with strap (Service Tool No. 261906). Lubricate splines
with OMC Part No. 114154 BEFORE REASSEMBLY. See Figure
10-11
3. Assemble actuating spring, then assemble end cap on shaft, making
sure end cap splines engage shaft splines.
4. Apply Loctite to end cap bolt.
5. Tighten end cap bolt to correct torque. See Page 2-3.
6. Assemble lock plate to end cap. Locks on lock plate may engage
bolt by turning lock plate over. Otherwise, a slight loosening or
tightening of bolt may be necessary in order to align bolt with lock.
7. Clean inside of sheave halves of any grease that may have accumu-
lated on them.
8. Reinstall transmission belt as described on page 10-2.

DRIVE CHAIN
REMOVAL

It :nNOTE

Extreme caution should be taken when removing chain case cover,

to overcome distortion of cover and.damaging chain case.

1. Remove chain case cover. Oil will drain from chain case when
Figure 10-14 cover is removed.
 10- 5

2. Loosen chain (see "Adjustment").

( 3. Remove cotter pin and nut from upper drive sprocket (see Figure
10-15) •

4. Remove sprocket and chain from upper shaft.

5. Chain can now be removed from lower sprocket.

INST ALLATION

1. Assemble in reverse order of disassembly.

2. Adjust chain per "Adjustment."

3. Add chain lubricant per "Lubrication."

Figure 10-15

ADJUSTMENT ADJUSTMENT NUT

Total slack must be 1/4" ± 1/16" as shown in Figure 10-15. To

measure this distance, first remove the chain case cover. (Note: Oil
will drain when cover is removed unless snowmobile is tilted on its
side.) Place a straightedge over the chain at the sprockets, press in on
the center of the chain and measure the slack at this point. If the chain
requires adjustment, use the follOwing steps:
I
1. Loosen adjusting screw locknut (see Figure 10-16).

2. To tighten chain, pivot the eccentric adjustment downward (see

Figure 10-16).

3. To loosen chain, pivot eccentric adjustment upward (see Figure

10-16).

LUBRICATION
SCREW LOCKNUT
The drive chain is lubricated by oil in the chain case. Should it be 37062
necessary to add oil use only OMC Type "C" and follow these instruc-
tions. Remove rubber plugs (top and bottom). Pour oil in top hole until Figure 10-16
it reaches level as shown in Figure 10-14. (It will hold approximately
4 oz.) Replace plugs.

BRAKE
DESCRIPTION ..

The brake is caliper disc type with long lasting fibre pads (pucks).

REMOVAL
a. Loosen brake adjustment nut. See Figure 10-17.
b. Remove .b rake control cable from actuator cam arm.
c. Remove brakelamp plunger spring from actuator cam arm. See
Figure 10-18.

d. Disconnect brakelamp wiring at quick disconnect. See Figure

10-18.
e. Remove brake bracket to chain case screws.
10-6

BRAKE
REPAIR
BRAKE iADJUSTMENT
CABLE_ / NUT a. Disassemble brake assembly as required, noting relative positions
WASHER ACTUATOR of components to assure correct reassembly (see Figure 10-17).
~ I C 7 ARM b. Inspect brake pucks. If the free floating puck is one half of its
original 1/2" thickness, it should be replaced. When the fixed
,,~ {o/~
o __ __~/~/
puck is worn so that there is only 1/32" protruding from the
carrier, it should be replaced. Use a contact cement to secure

// SPRING
new puck to carrier.
o NOTE
Keep all oil and grease from puck surfaces. Braking action
BRAKE // BACKUP will be impaired by contaminated puck slipping on brake disc
surface.
PI~ WT::cKS
~~bl\
BRAKE CABLE AND CAM ASSEMBLY

~ 06 a. Assemble in reverse order of disassembly.

b. Adjust brake.

II1I1INOTE
BODY
When reassembling brake to chain case be certain that brake
body does not contact edge of secondary sheave.
BRAKE
BRAKE ADJUSTMENT

Brake adjustments can be made by turning the adjustment nut clock-

wise to tighten brake. See Figure 10-19.
/
/
a. Turn the nut until there is a slight drag on the brake, then back
.(
MOUNTING
. BRACKET
- ---- ---- ____
-_
the nut off 1/4 to 1/2 turn.

b. Work brake lever three times to insure that there is no cable slip
at clamp screw.

/
->
,/
c. Turn adjusting fitting located on brake bracket out until hand lever
,/ will just allow the parking brake lock to be engaged. When park-
,/ ing brake lock is released the hand lever must return to free
pOSition.

d. Actuate hand lever and set parking brake lock to insure proper ad-
justment has been obtained.
17 156

e. Tighten nut on cable adjusting fitting on the brake bracket. When

Figure 10-17 brake is off pucks should not drag on brake sheave.

Figure 10-18
 10-7

SECONDARY DRIVE

DISASSEMBLY

1. Remove gas tank.

2. Remove belt guard (see page 10-2).

3. Remove transmission belt (see page 10-2).

4. Remove brake assembly (not necessary to disconnect cable) (see

page 10-5).

5. See Figures 10-20 and 10-21 for following steps. Remove chain
case cover (6). Caution should be taken not to warp cover.

6. Loosen chain (see page 10-5). Figure 10-19

7. Remove cotter pin (7), nut (8) and upper sprocket (9).

8. Remove outer bearing cone washer (10), outer bearing cone (11)
and bearing spacer (12).

9. Remove eccentric adjusting screw (13).

10. Remove chain case support stud (2).

11. Loosen the four chain case mounting screws (22).

12. Pull chain case away from fixed face and shaft (15).

13. Remove eccentric (17).

14. Remove O-Ring (16).

15. Remove seal (18) and cone (21) from eccentric. Figure 10-20
16. Press cups (19) from eccentric.

Figure 10-21
10-8

CLEANING AND INSPECTION

)
-'
1. Clean bearing in trichloroethylene (see SAFETY WARNING on page
9-5).

2. Check bearing for wear or roughness.

3. Check shaft, sheaves, woodruff keys and Delrin ramp shoes (20) for
excessive wear.

REASSEMBLY

1. Assemble movable half of sheave (see Figure 10-21 (1), (3), (4),
(14) and (20» to shaft.

2. Press bearing cups into eccentric.

3. Grease inner bearing cone with OMC No. 114154 grease, and install
on shaft.

4. Install seal. NOTE: A new seal must be used if shaft was pressed
from eccentric.

5. Insert woodruff key in shaft.

6. Engage spring ends in holes in movable sheave and end cap.

7. Preload spring by holding end cap stationary and rotating movable

sheave clockwise to engage next ramp on end cap (approximately
1/ 3 turn).

8. Compress spring to allow installation of end cap retaining ring.

9. Replace retaining ring.

10. Assemble fixed face and shaft into chain case.

11. Assemble eccentric to shaft through drive sprocket side.

12. Replace eccentric adjusting bolt.

Figure 10-22
 10-9

13. Reinstall chain case support stud.

r 14. Tighten chain case mounting screws.

15. Reinstall bearing spacer.

16. Assemble bearing cone to shaft.

17. Replace upper sprockets, nut and cotter key.

18. Torque nut to 25 ft. lbs. Continue torquing until cotter key can be
inserted.

19. Assemble brake assembly on sheave and secure with mounting bolts.

20. Reinstall brake assembly to chain case mounting boss.

21. Clean inner surfaces of sheave halves of grease.

22. Reinstall transmission belt.

23. Grease assembly thru fitting on eccentric adjustment. Two pumps

from a grease gun is sufficient. OMC Grease Part No. 114154 is
recomm'e nded.

24. Check for proper position of secondary drive assembly. Distance

from center of primary drive shaft to center of secondary drive
(top) sprocket must be 11-9/ 32" ± 1/ 16". See Figure 10-22.

25. Replace drive chain and adjust. See page 10-5.

26. Chain case seal groove should be cleaned. NOTE: A new chain
case cover seal must be used.

27. Apply 3M cement to seal.

28. Drive chain lubrication - refer to Section 12.

29. Replace belt guard.

30. Replace gas tank.

31. Primary and secondary alignment should be 2-1/ 16" plus or minus
1/16", measured from flanged edge of fixed primary sheave to
flanged edge of fixed secondary sheave.
J

-
 11-1

SECTION 11
STEERING, TRACK AND SUSPENSION

TABLE OF CONTENTS

DESCRIP nON. . . . . . . . . . . . . . . . . . . . . . . . . .. 11 - 2

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 11-2
CLEANING, INSPECTION AND REPAIR . . . . . . . 11-2
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 11-2
SKI ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 11-3

TRACK AND SUSPENSION ••.•••••••••••.•.•• 11-3

TRACK TENSION ADJUSTMENT •.•.••.••••• 11-5
TRACK ALIGNMENT ADJUSTMENT •••.••.•• 11-5
REMOVAL OF TRUCKS AND TRACK ••••.•.• 11-5
FRONT AXLE DISASSEMBLY ••••••••••..•• 11-5
FRONT AXLE DISASSEMBLY STEEL HUB .•.•. 11-5
REAR AXLE DISASSEMBLY. . . • • . • . • • • • • •• 11-6
TRUCK DISASSEMBLY ••••......••••.••• 11-6
CLEANING, INSPECTION AND REPAIR .•••••• 11-6
Molded Track •••••••••• . • • • . • • . • •• 11-6
Trucks and Axles. • . • . • • • • . • • • • • . . •. 11-6
ASSEMBLY. . • • . • • . • • • • . • • • • • • • . • • • •• 11-7
Front Axle ••.•••••••••••••••••••. 11-7
REASSEMBLY •••.••••••.••••••••••••• 11-7 I
Front Truck ••••••.•••.•.••••.•••• 11-7

III
Middle and Rear Trucks ••.••• ..• •...• 11-7
Rear Axle ••..•.••.••••.••••...••• 11-7
INSTALLATION .••••••.••.•••••••••••• 11-7

(
11-2

DESCRIPTION
This section gives complete service instructions on the snowmobile
steering, tracks and suspension.

STEERING
DISASSEMBLY
1. Support front end of snowmobile to remove weight from skis.

2. Scribe ski column and steering arm to maintain original position for
reassembly of skis. See Figure 11-1.

3. Remove nut, cotter pin, lockwasher and screw from saddle and
bushing. Remove ski and spring assembly from ski column. See
Figures 11-2 and 11-3.

4. Remove steering arms from ski column. See Figure 11-4.

5. Disassemble leaf springs, if required, for servicing.

CLEANING, INSPECTION AND REPAIR

a. Remove all dirt and old grease from ski columns and from inside
ski column tube.

b. Inspect ski column and bushing and replace if worn or bent.

Figure 11-1
c. Inspect ski runners and replace if worn. (See torque specs.)

-
d. Inspect leaf springs for cracks or weakness.
I

e. Inspect tie rods and ball jOints. Replace if worn or damaged.

f. Check for 1/16" end play in steering column. Correct by moving

steering column support.

REASSEMBLY
a. Reassemble skis to leaf springs. Lubricate pivot points using
SAE #10 oil. See Figure 11-3.

b. Lubricate ski columns (see page 12-4) and assemble in steering

column tube. Note do not interchange right and left ski columns.

c. Attach steering arms to ski columns noting original position.

Tighten to torque value shown in Section 2. Adjust ski alignment
Figure 11-2 as described below.

)
Figure 11-3 Figure 11-4
 11-3

d. Apply grease to outside of bushing and assemble to ski column as

shown in Figure 11-2. Secure with screw, lockwasher, locknut and
cotter pin. See torque specs.

SKI ALIGNMENT
a. Ski alignment is necessary when skis are not parallel with each
other and the vehicle body, with the handle bar in the normal
straight-driving position.
b. If alignment is necessary, loosen the outer jam nuts, see Figure
11-4. Do not attempt to loosen these nuts without first holding the
ball jOint. Next remove lock nut from ball joint. Turn ball joint
clockwise to toe skis out or cOWlterclockwise to toe skis in.
Hold the ball joint with a wrench to prevent turning (see Figure
11-5) and tighten jam nuts when skis are parallel. Replace ball
joint lock nut.
c. In order to verify your ski alignment use the measurements shown
in Figure 11-5.
d. The ski columns are not identified right and left. One flanged side
is shorter. This shorter side must be kept to the inside of the
snowmobile. Do not interchange or assemble in reverse.
e. There should be approximately the same amoWlt of threads showing
on each end of the tie rod when the skis have been adjusted.
ALL MEASUREMENTS
CENTRE TO CENTRE
TRACK AND SUSPENSION
TRACK TENSION ADJUSTMENT BALL JOINTS
Track tension must be checked after the first ten hours of operation
and then every 25 hours, or as required, to maintain effiCient, econom-
ical operation. Improper adjustment will result in Wldue wear to the
track and drive components.
Track tension is checked when the track is not supporting the weight
of the snowmObile, and the pivot arm is pulled down.
Track tension is correct when the distance from the bottom of the
STEERING ARMS
pivot arm bearing bore to the Wlderside of the running board is 2-5/ 8 ±
1/32" on both sides. See Figure 11-6. CORRECT INCORRECT
If adjustment is necessary, perform the following steps on both sides 37312

of the vehicle.
Figure 11-5
a. Vehicle should be in right side up position with track off the groWld.
b. Loosen track tension lock nuts and lock nut on pivot arm adjusting
screw. See Figure 11-6.
c. Adjust track so that the dimension shown in Figure 11- 6 is obtained.
PIVOT ARM
d. Measure distance from front edge of adjusting bracket to anchor.
If this distance is not equal on both Sides, loosen the adjustment on TRACK TENSION
the side nearest to the rear Wltil the distance from front edge of
the adjusting bracket to the anchor is equidistant within 1/ 32 inch.
See Figure 11-6.

VIEW FROM TOP

I '------'
PIVOT EQUAL
ARM BOTH
ADJUSTING SIDES ADJUSTING

EQUAL BOTH 'SIDES

WITHIN 1/32"

17159

Figure 11-6

TRACK TOO FAR TO LEFT 2 7060

Figure 11-7
11-4

~
\e@~~

Figure 11-8 - - - - - -
 /'
11-5

TRACK ALIGNMENT ADJUSTMENT

To check for proper track alignment, with snowmobile blocked up
start engine and run track at slow speed. Drive sprocket must be cen-
tered in track slots as shown in Figure 11-7. If track is too far to the
left, either left track adjusting bracket is too far forward, or right track
adjusting bracket is too far to the rear. If alignment cannot be ob-
tained, check for bent pivot arms, loose bearings in pivot arms, de-
formed slots in adjusting bracket, or bent running board in area of ad-
justing bracket.

ASAFETY WARNING

Do not run at high speed. Keep clothing and hair away from
track to avoid becoming entangled.
1. Tighten (turn clockwise) "pivot arm adjusting screw" on left Side
and loosen "pivot arm adjusting screw" on right side.

2. Recheck track tension. Run track at slow speed and check align-
ment. Repeat procedure until sprocket is centered in track slots.

3. Tighten jam nuts and track tension nuts, and recheck track ten-
sion. Use same procedure to correct alignment if track is too far
to the right.

REMOV AL OF TRUCKS AND TRACK

1. Support snowmobile so that weight is removed from track.
2. Release track tension. See Page 11-3.
3. Remove pivot axle bolts from front and main trucks. See Figure
11-9. Truck assemblies are now free of chassis.
4. Remove bearing cup from front axle on side opposite the drive
sprocket. Remove 3 nuts and lockwashers.
5. Loosen screw - bearing retainer in bearing cup on chain case.
6. Remove chain case cover.
7. Remove cotter pin, bottom sprocket and washer. See Figure 11-10.
8. Slide axle to right and drop left end of axle out bottom of chassis.
9. Front axle with bearings and seals is now free of chassis.
10. Remove four track tension locknuts. See Figure 11-6. Rear axle
can now be removed.
11. Trucks, axles and track are now free of the chassis.

Figure 11-9 Figure 11-10

FRONT AXLE DISASSEMBLY
1. Turn bearings by hand. If they do not turn freely, if there is ex-
cessive play, or if they are rough, they must be replaced. Remove
bearings with bearing puller or arbor press. Take care not to
damage seal which will come off with bearing.
2. Inspect drive sprockets. Check for excessive wear. If they must
be replaced, proceed as follows.
FRONT AXLE DISASSEMBLY STEEL HUB
(
1. Remove collars from axle. See Figure 11-8.
2. Remove wheel assembly and sprocket spacers.
3. Remove screws from steel hub and remove sprocket.
 .
11-6

REAR AXLE DISASSEMBLY

1. Remove retaining ring and bearing retainer. See Figure 11-11.

2. Push pivot arm towards sprocket. See Figure 11-11.

3. Check bearings using the same procedure described under Front

Axle Disassembly.

4. Remove bearings only if they must be replaced, or if sprocket

must be replaced.

5. Inspect sprocket for excessive wear. (Refer to Front Axle.)

TRUCK DISASSEMBLY (See Figures 11-12 and 11-13)
Figure 11-11
1. Remove lock nuts from truck axles.

2. Remove pivot arms, spacers, bushings, and springs from pivot axle.

3. Wheels and spacers will now slide .off truck and pivot axles.

CLEANING, INSPECTION AND REPAIR

Turn wheel by hand. If it does not turn freely, if there is excessive
play, or if it is rough, wheel must be replaced.
Molded Track
1. A torn track cannot be vulcanized. It must be replaced if torn be-
yond use.

2. Small cracks will not hamper the operation of the snowmobile.

3. Liquid neoprene can be applied to cracks or frays to help restore

its original appearance. )
Trucks and Axles
1. Axles - check for straightness by rolling ona flat surface. If drive
axles are bent they must be replaced. Truck axles may be
straightened.

2. Splines Front Axle - inspect for excessive wear.

3. Check to see that oil plug in front axle is in place and does not leak.
REFERENCE PICTURE

REAR TRUCK PIVOT

ARM

TRUCK
AXLE

17305 FRONT TRUCK 17306

Figure 11-12 Figure 11-13

 11-7

4. Check condition of seals on front axle and replace if seal lip is not
tight on axle.

5. Check truck bushings for cracks or excessive wear. Replace if

damaged. See Figures 11-12 and 11-13.

ASSEMBLY

Front Axle

Assemble drive sprocket to front axle, secure with screws. Apply a

light oil to seals and assemble to front axle. Seat seals after axle is
assembled to chassis.
Figure 11-14

REASSEMBLY

Front Truck

Assemble wheels and spacers on axle. Application of a light oil on

the axles will assist in this procedure. Apply OMC Part No. 114154
grease in bore of bushings and assemble to pivot axles. See Figure
11-12.

Assemble front truck with spring in position shown in Figure 11-14.

Lock spring in place as shown in Figure 11-14.

Middle and Rear Trucks

Assemble wheels and spacers to their original position on the front

and rear truck axles. Application of a light oil on the axles will assist
in this procedure. Apply OMC Part No. 114154 grease in bore of bush-
ings and assemble to pivot axles. Assemble pivot arms and springs.
See Figures 11-11 and 11-12. Figure 11-15

Rear Axle

Assemble sprocket, bearings, bearing retainer, retaining ring, pivot

arms and brackets to rear axle. Use a clean light oil to assist in this
assembly. Apply OMC Part No. 114154 grease to pivot arm bushings
before assembly. See Figure 11-11.

INSTALLATION

1. Install trucks and front and rear axle assemblies inside track and
install to snowmobile chassis. The rear spring is loose when
installing front and rear axles to bearing cups. Before adjusting
track tension, place spring arms inside spring tabs. See Figure
11-15.
2. Adjust track tension as describetl on Page 11-3.

3. Install spacer, drive chain sprocket and cotter pin on front axle
and replace drive chain. See Page 10-4.

(
J
 12-1

(
SECTION ,2
LUBRICATION AND STORAGE

TABLE OF CONTENTS

ENGINE LUBRICATION. • • • . . . • . • . . . .. 12-2

OMC 2+4 FUEL CONDITIONER • . •. ..• 12-2

LUBRICATION RECOMMENDATIONS . • . • • • 12 - 4

PREVENTIVE MAINTENANCE •• • . • . . . •• 12-5

AIR FILTER. • . • • • • • . • . • . . • . . . • • 12-5
( FUEL FILTER SCREEN, FUEL PUMP .. 12-5
FUEL FILTER SCREEN,
CARBURETOR . . • . • . . . • . . . . . • • . 12-5

STORAGE • . . . . . • . • . • • • • • . . . • . . . •. 12-6
PREPARATION FOR STORAGE. • • • • •• 12-6
REMOVAL FROM STORAGE . • . . . • • •• 12-6

(
 12-1

SECTION ,2
LUBRICATION AND STORAGE

TABLE OF CONTENTS

ENGINE LUBRICATION . . . • . . . • • • . . . .. 12- 2

OMC 2+4 FUEL CONDITIONER •.•.• . • 12- 2

LUBRICATION RECOMMENDATIONS. • • • •• 12-4

PREVENTIVE MAINTENANCE . • • . • . . . • . 12-5

AIR FILTER. • • • • . . . . • • . . . • . . • •. 12-5
FUEL FILTER SCREEN, FUEL PUMP .. 12-5
FUEL FILTER SCREEN,
CARBURETOR • • . . • . . . . . . . . . • •. 12-5

STORAGE •••• . •. •. . • • • . • . . . . . . . •• 12- 6

PREPARATION FOR STORAGE. • • . . •• 12-6
REMOVAL FROM STORAGE . • . . • . • •• 12-6
12-2

ENGINE LUBRICATION
Since fuel vapors are first compressed in the crankcase of the two-
cycle engine, the most practical method of lubrication is by mixing the
lubricant with the gasoline. As the mixture of lubricant and gasoline
enters the crankcase, the gasoline is vaporized, leaving the lubricant to
lubricate the bearings and other moving parts. Eventually the lubricant
reaches the combustion chamber where it is burned and discharged
through the exhaust ports. In this way the fuel mixture conveys to the
engine's moving parts a metered amount of lubricant in proportion to
the speed of the engine.

Both optimum performance and lubrication depend on maintaining the

correct ratio between gasoline and lubricant in the fuel mixture. The
use of too little lubricant leads to premature wear and early break-
down. A fuel mixture richer in lubricant than recommended is not only
wasteful but will contribute to faulty performance, and to excessive
carbon accumulation in the cylinders and on the spark plugs. Frequent
spark plug replacement can often be traced to an excess of lubricant in
the fuel mixture. Instructions for the mixing of fuel during break-in
and normal operation as given here and in the Owner's Manual should
be followed exactly.

The use of additive compounds, such as tune-up compounds, tonics,

friction reducing compounds, etc., is discouraged. OMC Accessories
Engine Cleaner and OMC Accessories Break-In Lubricant should be
used as necessary according to instructions. See inside front cover for
recommended fuel mixture.

OMC 2+4 FUEL CONDITIONER

OMC 2+4 Fuel Conditioner is recommended for added protection to

your snowmobile engine. It is especially recommended as an additive
between extended periods of snowmobile use. OMC 2+4 Fuel Condi-
tioner is available from your dealer.

OMC 2+4 Fuel Conditioner features are as fOllows:

• Fuel Stabilizer - prevents formation of gum and varnish deposits in

fuel system for one year of storage. Eliminates need for draining
fuel for storage.

• Carburetor Cleaner - dissolves gum and varnish deposits in carbu-

retor and fuel system.

• Corrosion Resistance - protects carburetor, fuel system and in-

ternal engine parts from corrosion.

• De-icer - prevents carburetor icing and gas line freezeup.

• Absorbs moisture and water in fuel system.

• Extends spark plug life by reducing fouling and misfire.

 12-3

r To avoid cylinder scoring and premature engine wear, it is important

that the gasoline and lubricant be properly mixed prior to putting the
fuel in the tank. This is especially true in zero or sub-zero climates.
Unless the fuel and lubricant are properly mixed, the engine could op-
erate on a mixture which is too lean until the gasoline and lubricant
have been agitated; by then, damage would have occurred and the engine
would have to run on an excessively rich mixture.

ID NOTE

The correct fuel mixture ratio is 50:1 or 1 pint of lubricant to

6 U.s. gallons (4.8 Imperial gallons) of gasoline. (See inside
front cover.)

l i .INOTE
DO NOT POUR GASOLINE OR LUBRICANT DIRECTLY INTO
VEHICLE FUEL TANK. USE AN APPROPRIATE CONTAINER
FOR MIXING AND STORING THE FUEL.

To prepare the snowmobile fuel properly, pour into a SEPARATE,

clean container half the amount of a good grade of regular leaded
gasoline required and add all the required lubricant. Thoroughly agitate
this partial mixture. Next, add the balance of gasoline necessary to
bring the mixture to the required ratio of 50:1. Again, thoroughly
agitate the mixture. A clean funnel equipped with a fine screen should
be used when pouring the fuel mixture into the vehicle tank.

50 to 1 lubricant is prediluted to provide excellent mixability with

gasOline at low temperatures. The addition of this dilutant does not in
any way affect the lubrication qualities of the lubricant.

Whenever it is necessary to mix fuel and lubricant at temperature

below 32°F (O °C), the lubricant should be prediluted with gasOline to
improve its mixability. The lubricant should be prediluted with ap-
prOximately one part gasOline to one part lubricant. Predilution of the
lubricant should take place with the lubricant temperature above 32° F.

Do not use kerosene or fuel oils for pre-mixing.

( NOTE: Thorough agitation is required to completely mix or blend the

fuel; the lubricant adheres to the bottom and Sidewalls of the container
unless agitated. Simply pouring the gasOline onto the lubricant CANNOT
accomplish thorough mixing.
12-4

LUBRICATION RECOMMENDATIONS )

37117

Figure 12-1

TIME MAINTENANCE LUBRICANT

~
Every 25 hrs. Ski Pivots (Leaf spring connections to skis) SAE 10 Oil
Once a season Ski columns (grease fittings). OMC Grease #114154
After 10 hrs. then Drive Chain - oil bath - Refer to Page 14 OMC Type "C"
every 25 hrs.
CD Once a season Secondary Drive (grease fitting. Two pumps of grease OMC Grease #114154
gun).
CD Once a season Primary Drive (grease fitting - 1/ 3 to 1/ 2 teaspoon. OMC Grease #114154
(normal use) Do not over lubricate).
Twice a season
(extended use)
)
Specified lubricants available from your dealer
 12-5

PREVENTIVE MAINTENANCE

TIME MAINTENANCE

After first 10 hrs., then every Adjust Chain Tension

50 hrs. or as required See Page 10-4

After first 10 hrs., then every Adjust Track Tension

25 hrs. or as required Check Track Alignment
(See Section 11)

Twice a season (see below) Clean Air Filter

Once a season (see below) Clean or install new Fuel Pump

Filter Screen

Once a season (see below) Clean Filter Screen under Carburetor

Fuel Inlet Elbow

AIR FILTER

The carburetor is equipped with an automotive type paper air filter Figure 12-2
element that should be cleaned once during the operating season, and
replaced after a year's service. When pores in paper are plugged,
engine will receive a rich fuel/air mixture and run rough and get poor
fuel economy. To clean filter element, shake to dislodge dirt particles
and blow with compressed air from inside, holding nozzle about two COVER.
inches from filter. 00 NOT wash or oil filter element. See Figure
12-2.
~W:~~ER
~ SCREW

FUEL FILTER SCREEN, FUEL PUMP

:I a::;:-X SCR EE N
~
SAFETY WARNING (~6~
~ GASKET
Exercise care to prevent fuel spillage while removing fuel
filter when engine is hot. 17056

Figure 12 - 3
The fuel filter is attached to the fuel pump. To inspect for sediment
or water accumulation, back off the mounting screw approximately three
turns (counterclockwise) and remove the cover together with the screen,
gasket and mounting screw. Remove and wash filter screen with clean
solvent and brush. Assemble filter as shown in Figure 12-3, being
careful to assemble gasket and filter screen on fuel filter cover.
Tighten mounting screw securely with screwdriver (do not over-tighten).

FUEL FILTER SCREEN, CARBURETOR

~ SAFETY WARNING

Exercise care to prevent fuel spillage in removing fuel line

when engine is hot.

( The carburetor fuel inlet screen should be cleaned annually. To

clean screen, remove fuel line and fuel inlet elbow. Do not remove
screen.
12-6

STORAGE
PREP ARATION FOR STORAGE

a. Add one ounce of OMC 2+4 f1el conditioner to each gallon of gaso-
line in tank and mix thoroughly. Run engine a few minutes until
-
mixture is in fuel lines, and carburetor, where it can prevent
gumming of check valves and carburetor jets.

b. Wash machine. Be certain to hose out undercarriage. Clean seat-

ing with automotive foam type upholstery cleaner.

c. Treat engine with OMC Accessories Engine Cleaner.

d. Remove fuel pump filter screen and clean or replace. See Page
12-4.

e. Remove air filter, run engine with neutral control knob pulled out
and inject OMC Rust Preventative Oil (with oil can) rapidly into
carburetor until engine stops.

f. Turn off ignition and replace fuel pump filter screen.

g. Clean air filter. See page 12-5.

h. Block rear of unit off ground to take weight off track.

i. Clean carburetor fuel filter screen. See Page 12-5.

j. Drain and clean fuel tank (see Section 6).

k. Remove transmisssion belt. See Section 10.

)
~

1. Rub bottom of skis, and other unprotected surfaces of vehicle with

cloth saturated in OMC Rust Preventative.

m. Store in dry, well-ventilated area.

REMOVAL FROM STORAGE

a. Fill tank with fresh fuel mixture.
b. Tune-up engine (see Section 5).
Co Lubricate all pOints, as described under "Lubrication."
d. Adjust track for proper tension, and check track alignment (see
Section 11).
e. Align skis (see Section 11).
f. Check brake and throttle control adjustments.
g. Tighten all screws and nuts.
h. Clean irmer surfaces of primary and secondary sheave halves of
oil and grease. Replace transmission belt.
i. Test vehicle, checking particularly the following items:
1. Function of neutral control
2. Function of brake
3. Engine performance
j. Thoroughly clean any surfaces that need refinishing, and touch-up.

,,~\

'~I:f\L-··"'~