Amf 1970 ski-daddler sd15m21 a Quick start guide

)

PARTS

AND

SERVICE

MANUAL

~970

SKI-DADDLER

SNOWMOBILES

MARK

VI

[SD15M21

A]

MARK

xx

[SDI5M11A]

MARK

xx

[SDI5M22A]

MARK

xx

[SDI5M23A]

AMERICAN

MACHINE

&

FOUNDRY

COMPANY

CONSUMER

PRODUCTS

SA

L

ES

DIVISION

PARTS

&

SERVICE

DEPARTMENT

Whiteford

Road,

York,

Pennsylvania

17402

PART NO

37894

-

o

c

~I

TABLE

OF

CONTENTS

INrRODucrloN

PREDELIVERY

INSrRUCTlONS .

Install Ski

Assembly

. . . .

Install Windshield Ass

embly

Fuel Mixture Instructions

Lubrication . . . . . .

SERVICE

AND

REPAIR

Hood Removal

and

Installation

Hood

Assembly

Repair . . . .

Replace Lamp Assemblies . . .

Steering

and

Ski

As

s

embly

Alignment

.

°To

Remove

Drive Chain

Adjustment

To

Remove

Variable-Speed Drive

Belt.

Variable-Speed Drive Belt

Adju

s

tm

ent

To

Remove

Drive Clutch

Alignment.

.

To

Remove

Driven Clutch .

To

Remove

Brake

Assembly

Brake

Adjustment

. 0 • •

To

Remove

Carburetor-Mark

VI

and

Mark

XX

295

only

To

Remove

Carburetor-Mark

XX

399

and

439

only.

Carburetor

Adjustment

. . . . . . . .

Throttle Plate

Adjustment,

HD

Carburetor . . . . .

Throttle Plate

Adjustment,

HR

Carburetor . . . . .

To

Remove Engine

and

Support

Assembly-Mark

VI

only

To

Remove

Engine

and

Support

Assembly-Mark

295

only

CONTENTS

To

Remove

Engine

and

Support

Assembly-Mark

XX

399

and

439

only

To

Remove

Gas

Tank

..

To

Remove

Muffler

To

Remove

Bogie

Wheel

To

Remove

Bogie

Wheel

and

Support

Assembly

To

Remove

Bogie

Wheel

Torsion

Springs.

0

To

Remove

Traction Belt Take-Up

Assembly

To

Remove

Sprocket Seals

and

Be

arings

To

Re

move

Drive Sprocket

Assembly

To

Re

move

Traction Belt

Adjustment

. .

Spark Plug Interchangeability

Wiring

Diagrams

Troubleshooting.

. • . . .

Iu.usrRArED PARrS

L1sr

.

Pag

e

3

3,

3

4

5

6

7

8

9

10

JJ

12

13

14

15

16

J6

16

c

INTRODUCTION

This

manual

has

been

prepared

to

provide

all

authorized

AMF

Ski-Daddler

Dealers,

Distributors

and

technicians

with

the

instructions

neces

sar

y

to

service

and

maintain

the

following 1970 AMF S

ki-

Daddler

snowmobiles.

Model

Designation

Mark

VI

(SD15M21A)

Mar

k XX (SD15MllA)

Mark

XX (SD15M22A)

Mark

XX

(SD15M23A)

Engine

Hirth

171R 634cc

JLO

L-295R

AMF

399BP

AMF 439BP

This

manual

is

presented

in

two

sections.

The

first

section,

Maintenance,

provides

the

instructions

necessary

for

sled

maintenance

and

service

while

the

second

section,

the

Illustrated

Parts

List

is

provided

to

assist

in

the

identification

of

all

major

assemblies

and

component

parts.

For

engine

maintenance,

refer

to

the

vendor

manual

for

the

particular

engine

or

the

AMF Engine

Main-

tenance

Manual

issued

for

all

AMF

engines.

If

the

information

in

this

manual

is

not

applicable

to

all

models,

the

exceptions

will

be

noted and

the

correct

information

for

the

particular

model

will

be

given.

PREDELIVERY INSTRUCTIONS

The

1970

Ski-Daddlers

are

shipped

completely

as-

sembled

except

for

the

windshield

assembly

and

the

ski

assembly.

These

assemblies,

plus

the

attaching

hardware

will

be found

in

the

shipping

carton.

Carefully

open

the

carton

and

immediately

inspect

the

equipment

for

any

damage

or

missing

items.

Install Ski

Assembly

•

Remove

the

locknut

and

screw

at

the

spring

mounting

bracket

(figure

1).

•

Place

th

e

spindle

pad

in

the

spring

mounting

bracket

with

the

thicker

section

and

the

directional

arrow

on

the

pad

pointing

forward.

NOTE:

The

plastic

bag

containing

the

spindle

pad

will

be

found

in

the

storage

compartment.

•

Install

the

ski

assembly

by

securing

the

spring

mounting

bracket

and

spindle

pad

to

lower

end of

3

~I

INTRODUCTION

IMS1dij

spindle

tube

assembly

as

shown

in

figure

1. Apply

30

foot-pounds

torque

to

the

locknut.

Do

not

over-

tighten

bo

lt

as

t

he

ski

assembly

should

float

freely

on

the

spindle.

•

Repeat

Install

Ski

Assembly

procedures

for

opposite

ski.

Figure 1

NOTE:

Properly

installed

skis

should

toe

out0-

to

1/2-inch

at

the

front

end

(see

figure

2)

and

should

be

symmetrical

about

the

centerline

of

the

sled.

If

alignment

is

necessary,

refer

to

the

Steering

and

Ski

Alignment

procedures.

Install

Windshield

Assembly

•

Remove

the

screws

securing

the

left-

and

right-

hand mounting

strips

to

the

hood.

Remove

the

mounting

strips.

•

Remove

the

protec

t

ive

cover

from

the

wind-

shield.

Place

the

windshield

in

position

on

the

hood

assembly.

Replace

the

mounting

strips

as

shown

in

figure

2.

•

Using

the

original

screws,

loosely

secure

the

mounting

strips

and

windshield

to

the

hood

assembly

starting

at

t

he

center

and

working

to

the

sides.

•

Engage

the

en

ds of

the

mounting

strips

in

the

trim

strip

on

the

windshield

and then

tighten

the

screws,

again

sta

r

ting

at

the

cen

t

er

and

workingto

the

sides.

NOTE:

Check

mounting

strips

for

sharp

edges

or

corners.

Use

a fine tooth

file

to

smooth

all

edges

and

corners.

PREDEL/VERY

/NSTRUCT/O

HOUNTING

STRIP,

RH

HOUNTING

STRIP,

LH

\WI:D

_

~:IELD

TRIH

~

•

TOE

OUT

0-

TO

1/2-

INCH

MAXIHUM

Figure 2

Fuel

Mixture

Instructions

I

WARNING

I

Never

fill

the

gasoline

tank

while

the

engine

is

hot. Wipe off

any

spilled

gasoline

before

attempting

to

start

engine.

The

correct

oil-to-gasoline

ratio

is

20: 1 (20

parts

regular

gasoline

to

1

part

oil). Too

much

oil

will

cause

carbon

deposits.

Too

little

oil

or

a

poor

mix

will

cause

insufficient

lubrication

and

possible

engine

damage.

IMPORTANT:

Gasoline

and

oil

should

be

mixed

at

temperatures

above

zero.

At

temperatures

below

zero,

gas

and

oil

mix

with

difficulty.

4

Fuels

containing

additives

are

not

recommend

ed

for

use

in

Ski-Daddler

engines.

For

mixingwithgaso

-

line,

use

only

oil

that

is

recommended

for

use

in

air-cooled,

2-cycle

engines

such

as

an

AMF

oil

or

an

equivalent

good

grade

of SAE 30

or

40

non-

detergent

motor

oil.

IMPORTANT: Some

outboard

motor

oils

contain

a

detergent

that

works

well

in

outboard

motors

that

operate

at

much

lower

temperatures

because

they

are

water

cooled.

However,

the

detergents

may

cause

spark-plug

fouling

in

the

air-cooled

engines

used

on

your

Ski-Daddler

.

Use

a

mixture

of

gasoline

and

oil

as

shown

in

Fuel

Mixture

Chart,

figure

3.

Never

use

gasoline

left

over

from

the

summer

or

Mix

the

gasoline

and

oil

thoroughly

in

a

clean

con-

tainer

kept

for

this

purpose

only.

The

best

way

to

ensure

a good

mix

is

to

pour

the

oil

into

the

empty

container

and then add a

small

amount

of

gasoline

and

mix

thoroughly.

Then

add

additional

amounts

of

gasoline

as

shown on

the

Fuel

Mixture

Chart.

Fill

Ski-Daddler

gas

tank

from

this

separate

container

of

mixed

fuel.

Use

a funnel with a

fine-screen

strainer

when

filling

the

tank.

The

gas

cap

is

located

under

the

gas

lid

and

hinge

assembly.

GASOLINE-OIL RATIO

2

0

I

1-1/2

L V

./

/

P

I

N

1/2

T

S

/ /

/

",.-

2 3 4 5

GASOLINE.

GALLONS

FUEl MIXTURE CHART

Figure 3

Lubrication

Refer

to

the

lubrication

chart

for

location

of

grease

fittings,

type of

lubricant

and

frequency.

)

SERVICE

AND

REPAIR

PART

LOCATION

TYPE

OF

LUBRICATION

FREQUENCY

Steering

spindles

Grease

zerk

on

spindle

Low-temperature

grease

20

hours

housings

Drive

chain

Chain

case

housing

No.2

Lithium

bearing

grease

20

hours

Bogie

wheels

Grease

zerk

in

center

of

Low-temperature

grease

20

hour

s

bogie wheel

Sprocket

bearings

Rear

sprockets

No.2

Lithium

bearing

grease

40

hours

LUBRICATION CHART

SERVICE

AND

REPAIR

Hood

Removal

and Installation

• To

remove

the

hood and

headlight

assembly,

disconnect

the

hood

and

the

sled

wiring

harness

at

the

quick-disconnect

below

the

console

on

the

right-hand

side

of

the

sled.

Release

the

hood

latch

assemblies

and

then

remove

the

hood and

headlight

assembly

by

lifting

rear

section

first.

• To

install

the

hood

and

headlight

assembly,

place

the

hood

in

position

on

the

sled

so

that

the

forward

hood

clip

and

the

bottom

edge of

the

hood

engages

the

clips

along

the

inside

edge of

the

bumper

strip.

•

Engage

the

left-

and

right-hand

latch

assemblies

to

secure

the

hood to

the

main

frame.

•

Connect

the

sled

wiring

harness

to

the

hood

wiring

harness

at

the

qUiCk

-disconnect

below

the

console

on

the

right-hand

side

of

the

sled.

Hood

Assembly

Repair

AMF

Fiberglass

Repair

Kits·

are

available

through

your

authorized

AMF

Distributor.

For

large

re-

pairs,

order

AMF

Fiberglass

Repair

Kit No.

1510693.

Smaller

repairs

can

be

made

with

Repair

Kit No. 1510765.

Paint

all

repaired

areas

on

the

hood

using

AMF

-Orange

color

paint

available

in

easy-to-use

spray

container,

AMF

Part

No.

1510828. Follow

the

instructions

in

the

kit

when

making

repairs.

Replace Lamp

Assemblies

Headlight. To

replace

the

headlightlamp

assembly,

simply

raise

the

headlight

assembly,

remove

the

screws

securing

the

cover

assembly

and

remove

5

the

cover

assembly.

Remove

the

defective

head-

light

and

replace

with new

lamp

assembly.

See

illustrated

parts

list

section

for

correct

part

numbers.

Taillight.

Remove

taillight

lens

and

cover

to

ex-

pose

the

taillight

bulbs.

Remove

the

defective

bulb

and

replace

with a new bulb. See

illustrated

parts

list

section

for

correct

part

numbers.

Steering and Ski

Assembly

Alignment

Good

steering

ability

requi

res

that

the

skis

be

properly

set

and

aligned

with

the

sled

body when

the

steering

handle

is

placed

in

the

straight

-ahead

position.

To

determine

that

the

skis

are

properly

aligned,

measure

the

distance

between

the

inside

edges

of

the

skis

at

the

front

end and

at

the

rear.

Properly

aligned

skis

should

toe

out

0-

to

1/2-inch

maximum

at

the

front.

Therefore,

the

overall

measurement

at

the

front

end of

the

skis

should

be

1/2

inch

greater

than

at

the

rear.

If

the

skis

or

steering

mechanism

are

not

properly

set,

adjust

as

follows.

•

Place

steering

handle

in

a

straight-ahead

posi

-

tion.

•

Remove

the

hood

assembly

.

•

Remove

the

bolt

(1,

figure

4), two

spacers

(2),

bottom

spacer

and

locknut

securing

the

rod

end

bearing

(3)

to

the

spindle

arm.

•

Loosen

the

jam

nuts

(4)

securing

both

rod

end

bearings

(3)

to

the

tie

rod

(5).

NOTE:

If

both

skis

need

adjustment,

repeat

pro-

cedure

for

the

opposite

ski.

~eMlal

SERVICE

AND

REPAIR

I~

NOTE: DUring

reasembly,

apply

proper

torque

to

the

clutch

bolt

as

shown

in

figur

e 6.

•

Reassembly

is

the

reverse

of

removal.

Perform

variable-speed

drive

belt

adjustment

and

drive

clutch

alignment

procedures.

Drive Clutch Alignment

•

Remove

the

hood

and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

Always

disconnect

spark

plug

wires

before

working

on

the

engine

or

drive

elements.

•

Remove

the

clutch

guard.

•

Loos

en

the

engine holddown

nuts

securing

the

engine

supports

to

the

engine mount

straps

as

illustrated

in

figure

6.

•

Place

a

straightedge

on

the

fixed

face

of

the

drive

clutch

and

move

the

engine

until

the

offset

between

the

straightedge

and

the

front

and

rear

edges

of

the

driven

clutch

is

as

shown

in

figure

6.

Rotate

driven

clutch

90-

degrees

and

repeat

pro-

cedure.

•

Tighten

engine holddown

nuts

and

recheck

align-

ment.

Apply

25

foot-pounds

torque

when

tightening

the

engine

holddown

nuts.

DrMENS

~

ION

MARK

VI

295

R

399

439

A

INCHES

0.30

0.240

0.30

l

l--fA)

B

INCHES

12-

1/2

I

'"'"

C

FT

-LB

TORQUE

70

~.

:::

S

TR

Ar

GH

T

EDGE

.

~:

DRIVEN

CLUTCH

Figure 6

To

Remove

Driven Clutch

10-

3/4

11

-

1/2

11

-1/2

45 45

70

HOLDDOWN

NUTS

VIEWe

NOTE:

The

procedures

required

to

remove

the

driven

clutch

are

the

same

as

those

described

in

paragraph

To

Remove

Variable

-S

peed

Drive

Belt.

8

To

Remove

Brake

Assembly

•

Remove

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Disconnect

brake

cable

(8,

figure

7)

at

brake

mounting

bracket

(9)

and

at

brake

actuating

lever

(3).

•

Remove

the

two

bolts

and

locknuts

securing

the

mounting

bracket

to

the

driven

clutch

mounting.

•

Remove

the

brake

assembly.

•

Installation

procedures

are

the

reverse

of

re-

moval.

Refer

to

Brake

Adjustment

procedures.

Figure 7

Brake

Adjustment

~

Always

disconnect

spark

plug

wires

before

working

on

the

engine

or

drive

elements.

• To

adjust

the

brake

pads

(5,

figure

7)

to

the

disk

(1),

remove

the

cotter

(2)

and

tighten

or

loosen

the

castle

nut

(4)

as

required

to

permit

the

brake

pads

(5)

to

just

clear

the

brake

disk.

Reinstall

the

cotter

pin. To

adjust

for

excessive

play

in

brake

cable

or

lever

pOSition,

loosen

jam

nuts

(6)

and

move

brake

housing

(7)

as

required.

Tighten

jam

nuts.

c

To

Remove Carburetor-

Mark.

VI

and

Mark.

XX

295 only

(ESj

Always

disconnect

spark

plug

wires

before

working on

the

engine

or

drive

elements.

• Loosen the

throttle

control cable

adjustment

screw

and

release

cable.

On

Mark

VI

only,

re-

lease

throttle

control linkage

at

the

carburetor.

•

Release

the

throttle

extension

spring

and hook

at

the

carburetor

throttle

control

lever

on the

Mark

XX

295 only (s

ee

figure

8).

•

Release

the hose

clamp

and

disconnect

the

im-

pulse

line

at

the

carburetor.

Wipe up any

spilled

gasoline

immediately.

• Rel

ease

the tank

-to-car

buretor

gas

line.

Wipe

up any

spilled

gasoline

immediately.

• Remove the locknuts

securing

the

carburetor

to the

carburetor

adapter

and remove the

car-

buretor.

NOTE:

Do

not

damage

gaskets

when

removing

carburetor.

• In

stal

lation

is

the

reverse

of removal. Adjust

carburetor

as

described

in

Carburetor

Adjustment

procedures.

figure

8

9

ERVICE

AND

REPAIR

To

Remove Carburetor-

Mark.

XX

399 and 439 only

~

Always

disconnect

spark

plug

wires

bef

ore

working on the engine

or

drive

elements.

•

Release

the hose

clamps

and

disconnect

the

tank-to-carburetor

gas

line

(figure

9)

at

the

car-

buretor.

Wipe up any

spilled

gasoline

immediately.

• Remove

th

e locknut

securing

the

throttle

arm

screw

to the

throttle

arm.

figure

9

IMPORTANT:

Before

loosening

th

e

jam

nuts, note

the

space

betweenthebottom

jam

nutandthe

throttle

control

l

ever

.

This

space

must

be

maintained

during

reassembly.

• Loosen the

jam

nuts between the

throttle

arm

and

the

throttle

control

lever

and

remove

th

e

throttle

rod

screw.

• Remove the

jam

nut and

lockwashers

securing

the

car

buretor

to

the intake manifold and

remove

the

carburetor.

•

Installation

is

the

reverse

of

removal

except

that

the

throttle

rod

screw

must

be

insert

edthrough

the

throttle

control

lever

and into the

throttle

arm

SERVICE

AND

REPAIR

I~

sufficiently to

take

up the

play

in

the

throttle

control

lever.

• Adjust

carburetor

as

described

in

carburetor

adjustment

procedures.

Carburetor Adjustment

When adjusting the

carburetor,

best

results

will

be

obtained

if

the

adjustments

are

made on a

warm

engine. During

carburetor

adjustments,

DO

NOT

FORCE ADJUSTMENT SCREWS INTO SEATS.

• TO ADJUST CARBURETOR -Close the high-

speed

jet

as

shown

in

figure

10

(DO

NOT

FORCE).

Then open

as

indicated

in

the

carburetor

adjustment

chart,

figure

11

for

the

particular

model

Ski-

Daddler.

•

Turn

the

low

speed

jet

(idle-mixture

screw)

as

shown

in

figure

10

all

theway

in

(DO

NOT FORCE),

then open

as

indicated

in

figure

11

for

the

particular

model

sled.

This

adjustment

controls

the

mixture

at

idling

speeds.

A

lean

idle

mixture

will

result

in

poor

acceleration.

Keep the

idle

speed

slower

than the clutchengaging

speed

'by adjustingthe

idle-speed

screw.

NOTE:

Do

not

use

the

low-speed

jet

to

adjust

for

idle

speed.

Throttle Plate Adjustment,

HD

Carburetor

Figure

8 shows the

throttle-wire

adjustment

screw

used

on

all

Mark

VI

and

Mark

XX

295

series

sleds.

If

the

throttle

plate

fails

to open completely when

the

throttle

control

lever

is

depressed,

loosen

the

throttle-wire

adjustment

screw

and

readjust

the

wire

as

required

to fully open the

throttle.

SKI-DADDLER

MODEL

CARBURETOR

MKVI

Tillotson

HD

Carburetor

MK

XX

399 and

439

Tillotson

HR

Carburetor

MK

XX

295

Tillotson

HD

Carburetor

Throttle Plate Adjustment,

HR

Carburetor

Set the choke

controls

(figure

10)

tooff-choke

posi-

tion.

This

will

permit

inspection

of the

throttle

control

plate

located

inside

the

carburetor.

Check

to

ensure

that

both

throttle

plates

are

in

the

fully

open position when the

throttle

control

is

de-

pressed.

To

adjust

the

throttle

control

plate,

pro-

ceed

as

follows:

• Loosen the locknut and

jam

nut

securing

the

throttle

rod

screw

to the

throttle

arm.

Figure

JO

CARBURETOR

ADJUSTMENT

HIGH-SPEED

JET

LOW-SPEED

JET

(TURNS)

1-1/8

:

~/8

Open

1-1/8

+

1/8

Open

- 0

2-1/4

+

1/4

Open

- 0

1-1/4

+

1/8

Open

- 0

1-1/8

+

1/8

Open

- 0

3/4

:

~/8

Open

Figure JJ

JO

)

•

Turn

the

throttle

rod

screw

as

required

to

adjust

the

throttle

control

plate

to the fully open

position

when the

throttle

control

is

depressed.

• Tighten the locknut and

jam

nut

at

the

throttle

arm

(figure 10) to

secure

the

throttle

rod

screw.

To

Remove

Engine

and

Support

Assembly-

Mark

VI

only

• Remove the hood and headlight

assembly.

Refer

to Hood Removal and

Installatio

n.

Always

disconnect

the

sparkplugwires

before

working on the engine

or

drive

elements.

• Remove

the

drive

clutch.

Refer

to

paragraph

To Remove

Drive

Clutch.

NOTE:

Figure

5,

Illustrated

Parts

List

section

of

this

manual contains a

detailed

explodedviewofthe

engine and

support

assembly

showing

all

attaching

hardware.

For

engine

maintenance

instructions,

refer

to the engine manual.

• Loosen the flexible tube

clamps

securing

the

muffler

exhaust

tubes

to the engine exhaustmanifold

and

release

the

exhaust

tubes.

•

Disconnect

the

throttle

control

cableand

remove

the

carburetor

as

described

in

paragraph

To

Re-

move

Carburetor.

• Disconnect the

wire

leads

at

the engine.

• Remove the bolts and

washers

securing

the

engine mounting

frame

to the main

frame.

• Lift

the

engine until the engine mounting

frame

clears

the shock mounts and

remove

the engine

tow

ard

the

rear

of the

sled.

• Remove the

bolts

and

washers

securing

the

mounting

frame

to

the engine

base

and

remove

the

mounting

frame.

NOTE: During

reassembly,

the

mounting

frame

ml.lst

be

secured

to the engine

base

before

reinstalling

the engine.

•

Installation

procedures

are

the

reverse

of

removal.

JJ

~I

SERVICE

AND

REPAIR

le2la~

To

Remove

Engine

and

Support

Assembly-

Mark 295

only

• Remove the hood and headlight

assembly.

Refer

to Hood Removal and

Installation.

Always

disconnect

the

spark

plu

g

wire

before

working on the engine

or

drive

elements.

• Remove the

drive

clutch.

Refer

to

paragr

aph

To Remove

Drive

Clutch.

NOTE:

Figure

6,

Illustrated

Parts

List

section

of

this

manual contains a

detailed

explodedviewofthe

engine and

suppor

t

assemb

ly

showing

all

attaching

hardware.

For

engine maintenance

in

s

truction

s,

refer

to

the engine manual.

• Loosen the flexible tube

clamp

securing

the

muffler

exhau

st

tube to the engine exhaustmanifold

and

release

the exhaust tube.

• Disconnect the

throttle

control

cable

anqremove

th

e

carburetor

as

described

in

paragraph

To

Re-

move

Carburetor.

• Disconnect the

wire

lead

at

the engine.

• Remove the locknuts and

washer

s

securing

the

engine and engine mounting

strap

s to the

main

frame.

During

reassembly,

tighten

th

e locknuts

sufficiently to allow a

5/16-inch

clearance

as

shown

in

figure

12.

• Lift the engine until the mounting

straps

clear

the

carriage

bolt

s and

shock

mounts. Remove

the

unit

toward

the

rear

of the

sled.

NOTE:

Do

not

remove

the

carriage

bolt

s,

shock mounts

or

bushings unle

ss

necessary

for

replacemen

t.

5

16

Figure

J2

§

SERVICE

AND

REPAIR

'IRING DIAGRAM

lARK

XX

399CC

(SD

J

5M22A)

'ARK

XX

439CC

(SD

J

5M23A)

IGNITION SWITCH

OFF

ON

RED

TACHOMETER

BLACK

GREEN

NOT

USED

TAIL

LAMP

G:J«

BLACK)

'1fLUE

..

~-+--~~

~.

~~~~

BLUE

YELLOW

WHITE

RED

WHITE

Figure

20

J8

BLACK

-=

GROUND

TO

ENG

INE

QUICK

DISCONNECT

AMF

399

AND

439

ENGINE

----:G~

WHITE

I

!

c

•

Turn

the

throttle

rod

screw

as

required

to

adjust

the

throttle

control

plate

to

the

fully open

position

when

the

throttle

control

is

depressed.

•

Tighten

the

locknut

and

jam

nut

at

the

throttle

arm

(figure

10) to

secure

the

throttle

rod

screw.

To

Remove

Engine

and

Support

Assembly-

Mark

VI

only

•

Remove

the

hood

and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Remove

the

drive

clutch.

Refer

to

paragraph

To

Remove

Drive

Clutch.

NOTE:

Figure

5,

Illu

st

rated

Parts

List

sec

tion

of

this

manual

contains

a

detailed

explodedviewof

the

engine and

support

assembly

shOwing

all

attaching

hardware.

For

engine

maintenance

instructions,

refer

to

the

engine

manual.

•

Loosen

the

flexible

tube

clamps

securing

the

muffler

exhaust

tubes

to

the

engine

exhaust

manifold

and

release

the

exhaust

tubes.

•

Disconnect

the

throttle

control

cable

and

remove

the

carburetor

as

described

in

paragraph

To

Re-

move

Carburetor.

•

Disconnect

the

wire

leads

at

the

engine.

•

Remove

the

bolts

and

washers

securing

the

engine mounting

frame

to

the

main

frame.

•

Lift

the

engine

until

the

engine mounting

frame

clears

the

shock

mounts

and

remove

the

engine

toward

the

rear

of

the

sled.

•

Remove

the

bolts

and

washers

securing

the

mounting

frame

to

the

engine

base

and

remove

the

mounting

frame.

NOTE:

During

reassembly,

the

mounting

frame

mqst

be

secured

to

the

engine

base

before

reinstalling

the

engine.

•

Installation

procedures

are

the

reverse

of

removal.

JJ

VICE

AND

REPAIR

To

Remove

Eng

ine

and

Support

Assembly

-

Mark

295

only

•

Remove

the

hood and

headlight

assembly.

Refer

to Hood

Removal

and

Installation.

Always

disconnect

the

sp

ark

plug

wire

before

working

on

the

engine

or

drive

elements.

•

Remove

the

drive

clutch.

Refer

to

paragraph

To

Remove

Drive

Clutch.

NOTE:

Figure

6,

Illustrated

Parts

List

section

of

this

manual

contains

a

detailed

exploded

view

of

the

engine and

support

assem

bly

shOwing

all

attaching

hardware.

For

engine

maintenance

instructions,

refer

to

the

engine

manual.

•

Loosen

the

flexible

tube

clamp

securing

the

muffler

exhaust

tube

to

the

engine

exhaust

manifold

and

release

the

exhaust

tube.

•

Disconnect

the

throttle

control

cable

anqremove

the

carburetor

as

described

in

paragraph

To

Re-

move

Carburetor.

•

Disconnect

the

wire

lead

at

the

engine.

•

Remove

the

locknuts

and

washers

securing

the

engine and engine mounting

straps

to

the

main

frame.

During

reassembly,

tighten

the

locknut

s

sufficiently

to

allow

a

5/16-inch

clearance

as

shown

in

figure

12.

•

Lift

the

engine until

the

mounting

straps

clear

the

carriage

bolts

and

shock

mounts

.

Remove

th

e

unit

toward

the

rear

of

the

sled.

NOTE: Do

not

remove

the

carriage

bolts,

shock

mounts

or

bushings

unless

necessary

for

replacement.

5

16

HOUNTING

STRAP

SHOCK

HOUNT

Figure

J2

-

~t4

JL

.M131

SERVICE

AND

REPAIR

I~

•

Remove

the

bolts

and

washers

securing

the

engine

base

and mounting

straps

to

the

engine.

NOTE:

During

reassembly,

the

mounting

strap

and

engine

base

must

be

secured

to

the

engine

before

installing

the

engine on

the

sled.

Apply

Loc-

Tite

to

the

bolt

threads.

•

Installation

procedures

are

the

reverse

of

re-

moval.

To

Remove Engine

and

Support

Assembly-

Mark

XX

399

and

439

only

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Remove

the

drive

clutch.

Refer

to

paragraph

To

Remove

Drive

Clutch.

NOTE:

Figure

7,

Illustrated

Parts

List

section

of

this

manual

contains

a

detailed

explodedviewof

the

engine

and

support

assembly

showing

all

attaching

hardware.

For

engine

maintenance

instructions,

refer

to

the

engine

manual.

•

Release

the

springs

securing

the

muffler

exhaust

tubes

to

the

engine

exhaust

manifold

and

release

the

exhaust

tubes.

•

Disconnect

the

throttle

control

cable

at

the

throttle

actuator

and

remove

the

carburetors

as

described

in

paragraph

To

Remove

Carburetor.

•

Remove

the

bolts

securing

the

muffler

bracket

to

the

engine. Remove

locknut

that

secures

the

heat

shield

and engine mounting

strap

to

the

main

frame

and

remove

the

heat

shield

and

muffler.

•

Disconnect

the

engine

wiring

harness

at

the

engine.

•

Remove

the

locknuts,

spacers

and

washers

se-

curing

the

engine mounting

straps

to

the

main

frame.

Remove

the

engine, engine

base

and mounting

straps

as

a unit.

During

reassembly,

tighten

the

locknuts

sufficiently

to

allow

a

5/16-inch

clearance

as

shown

in

figure

12.

NOTE:

Do

not

remove

the

carriage

bolts,

shock

mounts

or

bushings

unless

necessary

for

replace-

ment.

J2

•

Remove

the

bolts

and

washers

securing

the

engine

base

and mounting

straps

to

the

engine.

During

reassembly,

apply

Loc-Tite

to

the

bolt

threads.

•

Installation

is

the

reverse

of

removal.

NOTE:

When

replacing

the

engine,

remove

the

starter

cover

plate

from

the

new

engine

to

permit

installa

-

tion

of

the

muffler

bracket.

To

'Remove

Gas

Tank

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

Always

disconnect

spark

plug

wires

before

working

on

the

engine

or

drive

elements.

•

Check

gas

cap

and

indicator

assembly

to

be

cer-

tain

tank

is

empty,

or

nearly

empty.

•

Remove

the

gas

cap

and

indicator

assembly

(1,

figure

13).

•

Remove

the

bolts

(3)

and

washers

securing

the

gas

spill

chute

(2)

to

the

main

frame

and

remove

the

gas-spill

chute.

•

Disconnect

the

tank-to-carburetor

gas

line

(6)

at

the

gas

tankoutletfitting

(5). Wipe up

any

spilled

gasoline

immediately.

Figure J3

)

C •

Remove

the

gas

tank

(4)

by

carefully

sliding

the

tank

up and away

from

the

main

frame.

IMPOR-

TANT: Do

not

damage

the

gas

tank

outlet

(5)

when

removing

the

tank.

c

Do

not

attempt

to

make

any

repairs

to

the

gas

tank.

Use

extreme

care

when

removing

the

gas

tank. Do

not

remove

tank

near

flame

or

open

fire.

•

Gas

tank

installation

procedures

are

the

reverse

of

removal.

NOTE:

If

the

original

tank

is

not

to

be

installed,

it

will

be

necessary

to

remove

the

gas

tank

outlet

(5)

and

the

attached

gas

line

filter;

also

the

pressure

relief

valve

(7).

These

items

are

to

be

installed

on

the

replacement

tank.

To

Remove Muffler

•

Remove

the

hood

and

headlight

assembly.

Refer

to

Hood RemOVal and

Installation.

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Loosen

the

flexible

tube

clamp

securing

the

flexible

exhaust

tube(s) to

the

muffler

and

release

the

tube. NOTE: On

Mark

XX 399

and

439 only,

release

the

springs

securing

the

muffler

tubes

to

the

engine

exhaust

manifold.

•

Loosen

the

bolt

and

nut

securing

the

muffler

to

the

mounting

band

assembly.

Remove

the

muffler.

•

Installation

procedures

are

the

reverse

of

removal.

To

Remove

Bogie

Wheel

~

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Remove

the

locknut

(3,

figure

14)

securing

the

bogie

wheel

assembly

(2)

to

the

axle

shaft

and

re-

move

the

wheel.

•

During

reassembly,

torque

the

locknut

(3)

to

28

foot-

pounds.

Be

certain

the

wheel

assembly

(2)

is

installed

with

grease

fittings

on

the

outside.

J3

SERVICE

AND

REPAIR

figure

J4

To

Remove

Bogie

Wheel

and

Support

Assembly

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Remove

the

screws

(1,

figure

14) and

lock-

washers

securing

the

bogie wheel

support

shaft

to

the

main

frame.

•

Remove

the

bogie

wheel

and

support

assembly.

•

Reassembly

is

the

reverse

of

removal.

To

Remove

Bogie

Wheel

Torsion Springs

•

Remove

the

bogies

as

described

in

paragraph

To

Remove

Bogie Wheel and

Support

Assembly.

•

Remove

the

support

shaft

and

separate

the

bogie

wheel

support

halves.

•

Remove

the

torsion

springs.

NOTE: The

torsion

springs

are

iq.entified

as

right-

and

left-hand

springs.

Note

the

direction

of

the

coils

and

the

position

ofthe

springs

to

facilitate

re-

assembly.

•

Reassembly

is

the

reverse

of

removal.

To

Remove Traction Belt Take-Up

Assembly

•

Remove

the

rear

bogies.

Refer

to

paragraph

To

Remove

Bogie Wheel and

Support

Assembly.

~eMlal

SERVICE

AND

REPAIR

I~

•

Release

track

tension

by

loosening

the

right-

and

left-hand

adjusting

nuts

(6,

figure

14)

and

the

adjusting

bolts

(5).

•

Release

the

support

arm

torsion

springs

con-

nected

to th

e

main

frame.

•

Remove

the

right-

and

left-hand

adjusting

angle

locknuts

(6),

washers

and

carriage

bolts

securing

the

traction

belt

take-up

assembly

to

the

main

frame.

•

Remove

the

traction

belt

take-up

assembly

as

a

unit.

NOTE:

The

traction

belt

take-up

assembly

consists

of

the

rear

sprocket

assembly,

spacer

and

asso-

ciated

hardware

held

together

by

the

rear

support

arm

assemblies.

If

necessary

to

remove

seals

or

sprockets,

proceed

as

follows.

•

Carefully

pry

the

oil

seal

away

from

the

rear

support

arm

assembly

(8)

and

remove

the

support

arm

and

adjusting

angle

(9)

clear

of

the

sprocket

shaft

and

bearing.

•

Remove

the

press-on

bearings

and

grease

seals.

•

Remove

the

screws

(10) and

nuts

securing

the

sprocket

plate

and

the

sprocket

to

the

drive

shaft.

Remove

the

plate

and

sprocket.

•

Reassembly

is

the

reverse

of

removal.

During

reassembly

follow

instructions

outlined

in

para

-

graphs

Track

Alignment

and

Track

Tension

Adjust-

ment.

To

Remove

Sprocket Seals

and

Bearings

•

Sprocket

seals

and

bearings

are

located

on

each

end of

the

traction

belt

take-up

assembly

and

the

drive

sprocket

assembly

drive

shafts.

To

replace

the

seals

or

bearings

it

will

be

necessary

to

remove

the

traction

belt

take

-up

assembly

or

the

drive

sprocket

assembly

as

described

in

the

applicable

paragraph.

To

Remove

Drive Sprocket

Assembly

• Remove the hood assembly and set the machine

on

its

right-hand

side.

cr=B

Always

disconnect

spark

plug

wires

before

working

on

the

engine

or

drive

elements.

14

•

Release

the

chain

cover

straps

and

remove

the

chain

cover

top.

•

Remove

the

lower

sprocket

from

the

drive

sprocket

shaft

and

remove

the

sprocket

and

chain

as

described

in

paragraph

To Remove

Drive

Chain.

•

Using

a

screw

driver,

carefully

pry

the

oil

seals

(figure

15) away

from

the

bearings

at

each

end of

the

drive

shaft.

Figure 15

•

Remove

the

carriage

bolts

and

nuts

securing

the

bearing

retainer

to

the

chaincase

side

of

the

main

frame

and

remove

retainer

and

chaincase.

• Move

the

drive

shaft

and

sprocket

assembly

toward

the

chain

side

until

the

opposite

end of

the

shaft

clears

the

bearing

retainer.

Remove

the

drive

sprocket

assembly.

NOTE: When

replacing

the

drive

sprocket

assem-

bly, add No. 2

Lithium

bearin

-g

grease

to

the

sprocket

bearings.

• To

replace

the

sprockets,

remove

the

ball

bearing

and

oil

seal.

Remove

the

screws

and

nuts

securing

the

support

plate

and

spro

ck

et

to

the

dri

ve

shaft

and

sprocket

plate

assembly.

Remove

the

sprocket.

•

Reassembly

is

the

reverse

of

removal.

During

reassembly

follow

instructions

outlined

in

the

para-

graps

Track

Tension

Adjustment,

Track

Align-

ment,

and

Drive

Chain

Adjustment.

To

Remove

Traction Belt

•

Remove

the

bogie

assemblies.

Ref

er

to

para-

)

c

graph

To

Remove

Bogie Wheel

andSupportAssem

-

bly.

•

Remove

the

traction

belt

take

-u

p

assembly.

Refer

to

paragraph

To

Remove

Traction

Belt

Take

-

Up

Assembly.

NOTE:

It

is

not

necessary

to

dis-

assemble

the

traction

belt

take

-up

assembly

when

removing

the

traction

belt.

•

Remove

the

drive

sprocket

assembly.

Refer

to

paragraph

To Remove

Drive

Sprocket

Assembly.

•

Remove

the

traction

belt.

•

Reassembly

is

the

reverse

of

removal.

During

reassembly

follow

instructions

given

in

paragraphs

Traction

Belt

Adjustment

and

Drive

Chain

Adjust-

ment.

Traction Belt

Adjustment

IMPORTANT:

The

traction

belt

must

be

checked

regularly

for

proper

alignment

and

tension.

When

necessary

to

adjust

the

belt,

first

perform

the

Traction

Belt

Alignment

described

below and

then

complete

the

Traction

Belt

Tension

Adjustment

procedures.

Traction

Belt

Alignment

•

Set

the

snowmobile

on

the

kickstand

on a

level

surface.

• Stand

to

rear

of

sled

and

visually

check

the

space

between

the

frame

tunnel

and

the

edges

of

the

traction

belt.

On a

properly

aligned

track,

this

space

should

be

the

same.

•

If

the

track

is

not

centered,

loosen

the

two

lock-

nuts

(1,

figure

16) on

that

side

where

the

edge of

the

track

is

closest

to

the

inside

edge of

the

tunnel.

Tighten

the

adjusting

screw

(3)

until

track

is

centered.

Then

tighten

the

locknuts

(1).

•

Take

the

sled

on a

short

run

and

then

recheck

traction

belt

alignment.

•

After

track

alignment

is

complete,

check

trac-

tion

belt

tension

as

described

in

the

follOwing

para-

graph.

Traction

Belt

Tension

Adjustment

IMPORTANT: Always

check

the

traction

belt

for

proper

alignment

before

performing

the

traction

belt

tension

adjustment

procedures.

J5

~I

SERVICE

AND

REPAIR

It!Sla~

TRACTION

BELT

TAKE

-

UP

ASSEMBLY

Figure J6

•

Set

the

snowmo

bile

on a

clean,

flat

surface.

NOTE: A

properly

tensioned

track

should

have

a

1

to

1-1/4-inch

sag

at

the

approxi

ma

te

top

center

of

the

track.

This

can

be

dete

rmine

d

as

follows:

•

Rest

a

straight

bar

(figure

17) of

sufficient

length

along

the

top

surface

and

near

th

e edgeof

the

track.

Insert

the

straight

bar

through

the

back

end of

the

snowmobile

and

check

for

proper

1

to

1-1/

4-inch

sag.

Repeat

procedure

on opposi

te

side

and

note

the

difference,

if

any,

in

the

track

tension.

•

If

adjustment

is

necessary,

loosen

the

two

lock

-

nuts

(1,

figure

16) on

each

side

of

the

sled

just

sufficien

tly

to

allow

movement

of

the

belt-adjusting

angle (2).

TRAC

TI

ON

BELT

Figure

J7

~eMlal

SERf/ICE

AND

REPAIR

I~

•

Turn

th

e a

?ju

sting

screws

(3)

clockwise

to

tighten

and

_

counterclockwise

to

loosen

untilprope~

_

track

tension

is

achieved.

IMPORTANT:

Adjust

both

screws

(3)

equally

so

as

not

to

disturb

the

track

alignment.

•

Retighten

the

locknuts

(1)

on

both

sides

of

the

snowmobile.

Take

the

sled

on a

short

run

and

then

recheck

traction

belt

tension.

Spark Plug Interchangeability

The

following

tabulation

is

provided

to

show

correct

spark-plug

interchangeability.

Bosch

Champion

AC

Autolite

Lodge NGK

M175Tl

UK-I0

M84 BZ3 HTN18

AB-6

M225Tl

K-9

M83 - -

A-7

M240Tl

UK-7 - - --

Wiring

Diagrams

Electrical

wiring

diagrams

are

provided

for

the

trained

technicians

using

this

manual.

Each

dia-

gram

is

identified

with

the

model

number

of

the

snowmobile

to

which

it

applies.

Troubleshooting

ENGINE HARD TO START.

Fuel

line

blocked

or

leaking;

ruptured

fuel-pump

diaphragm;

ignition

or

switch

wiring

loose

or

grounded;

spark

plug(s)

fouled

or

faulty;

contact

breaker

pOints

pitted

or

burned.

ENGINE STOPS.

Fuel

tank

empty;

fuel

flow

ob-

structed;

ignition

system

faulty.

Spark

plug(s)

fouled

or

dirty.

Engine

too

hotandpistons

seizing;

carburetor

setting

too

lean

or

incorrect

grade

of

oil

being

used.

ENGINE STOPS,

FUEL

TANK

HALF

EMPTY.

Carburetor-to-tank

fuel

line

connected

incorrectly.

Be

certain

the

gas

tank-to-carburetor

line

is

con-

nected

to

the

inlet

fitting

on

the

carburetor.

ENGINE

OPERATES

IRREGULARLY.

Spark

plug

loose,

fouled

or

faulty;

ignition

switch

wiring

J6

grounded;

carburetor

trouble.

Engine

holddown

bolts

~

oose;

carburetor

dirty.

Ignition

timi,ng. off.

ENGINE WORKING

FOUR-STROKE.

Choke

shut;

carburetor

settings

incorrect;

dirt

preventing

car-

buretor

inlet

needles

from

seating

properly

.

ENGINE LOSES POWER.

Poor

compression

due

to

loose

head

and

crankcase

bolts.

Faulty

ignition;

timing;

piston

rings

sticking

due

to

the

use

of

improper

oil.

Carbon

deposits

in

cylinder.

ENGINE BACKFIRES THROUGH CARBURETORS.

Carburetor

fuel-supply

channel

clogged.

ENGINE BACKFIRES THROUGH EXHAUST.

In-

correct

or

faulty

spark

plug(s);

faulty

ignition

coil

or

condenser;

loo

se

ignition

wiring.

ENGINE OVERHEATS.

Insufficient

or

incorrect

grade

oil

in

fuel

mixture;

carburetor

or

fuel

line

partly

clogged;

carburetor

setting

too

lean;

ignition

timing

too

slow.

EXCESSIVE

FUEL

CONSUMPTION.

Carburetor

fuel

line

or

gas

tank

leaking;

choke

closed;

incorrect

carburetor

setting.

THROTTLE

CONTROL.

Excessive

play

in

throttle

control

lever

caused

by

loose

throttle

control

cable.

STEERING.

Poor

steering

ability

caused

by

im-

properly

adjusted

skis;

steering

linkage

loose

or

out

of

adjustment.

U

-strap

bolts

on

roll

bar

too

tight

or

too

loose.

Ski

spring

mounting

bracket

loose.

BRAKES.

Excessive

play

in

handbrak

e

due

to

loose

brake

cable

or

worn

pads.

TRACTION

BELT.

Poor

traction;

check

traction

belt

for

proper

alignment

and

tension.

CLUTCH.

Automatic

clu

tch

fails

to

engage

at

3200

to

3700

RPM;

check

drive

belt

for

proper

tension.

ELECTRICAL

SYSTEM.

For

problems

involving

the

electrical

system,

check

for

defective

wires,

poor

ground

and

loose

connections.

)

c WIRING DIAGRAM

MARK

VI

634CC (SDJ5M2JA)

RED

IGNITION SWITCH

OFF

ON

ERVICE

AND

REPAIR

TACHOMETER

BLACK BLACK

GREEN

NOT

USED

TAIL

LAMP

Cf:j«

BLACK)

BLACK

-=

GROUND

TO

ENGINE

QUICK

DISCONNECT

USiA

'!BLUE

..

r-

~~~

-=~

~~

HEADLIG

HT

60

WATT

HIRTH

171

R ENGINE

31b

31

WIRING DIAGRAM

MARK

XX

295 (SDM J5 J J

A)

IGNITION

SWITCH

OFF LIGHTS

ON

I

BLUE

YELLOW

NOT

USED{o----=:.:..:.::...:..:.~___._--

-----i~

WHITE

BLACK

WHITE I I

I I I

~

--

-

-~

Figure

J8

WHITE BLACK

BLACK BLACK

""=='--

NOT

USED

-=

GROUND

TO

ENGINE

TACHOMETER

RED

BLA

CK

TAIL

LAMP

( BLUE (

BLA

CK

)

START

,/

BLUE HEADLIGHT

60

WATT

BLUE

RED

JLO

295R

ENGINE

YELLOW ( YELLOW

~;L-(7-5W-)-YEL:~

~~~

------

~~~===4

1

--

~~

I

I I

WHITE/RED

( BLACK L _I

:AGNETO

I

__

J

Figure

J9

17

NOT

°USED

SERVICE

AND

REPAIR

WIRING

DIAGRAM

MARK

XX

399CC (SDJSM22A)

MARK

XX

439CC

(SO

J

SM23A)

IGNITION SWITCH

OFF

ON

RED

TACHOMETER

BLACK

GREEN

NOT

USED

TAIL

LAMP

ccr«

BLACK)

':!fLUE

"

~-+--~

~M.~=+~~

31b BLUE

YELLOW

31

WHITE

RED

WHITE

Figure

20

18

BLACK

-=

GROUND

TO

ENGINE

QUICK

DISCONNECT

WHITE

AMF

399

AND

439

ENGINE

r--""---

-

:G~

I

)

AMF 1970 SKI-DADDLER SD15M21 A Quick start guide

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