Amf Ski-daddler Quick start guide

c

c·

PARTS

AND

SERVICE

MANUAL

1970-1971

SKI-DADDLER

SNOWMOBILES

MARK

IV

AND

MARK

V

AMF WESTERN TOOL DIVISION

Parts and Service Department

Whiteford Road, York, Pennsylvania,

17402·717/848-1177

AMF INCORPORAT

ED

PAR

T

NO.1

002472

~

~~~~~~

WARRANTY CERTIFICATE

~~~~~~t>

I AMF SKI-DADDLER SNOWMOBILE

~

PART!

Q

AMF

as

manufacturer

guarantees,

to

the

origi~al

retail purchaser, each

new

snowmobile

to

be free

01

~

defects

in

material

and

workmanship

under

normal

use.

The

manufacturer's

obligation

under

this

warranty

~

is

expre~sly

limited

to

re~airing

or

replacing

~ny

defective

part

under

the

con~itions

set

forth

as

follows: Q

~

1.

ThIs

warranty

applIes

only

to

defects

dIscovered

between

the

date

of

retaIl purchase

and

the

first

day

~

of

the

following

month

of

May.

~

2.

The

part

alleged

to be

defective

shall

be

reported

in

writing

to

an

authorized

AMF

dealer

within

thirty

days

of

the

discovery

of

the

defect.

~

3.

This

warranty

does

not

apply

to

items

which

are covered

by

the

original

manufacturer's

warranty,

Q

~

such

as

engines, starters, batteries, drive

belts,

and

light

bulbs

(see

Warranty

Certificate,

Part

II,

Condi-

~

tions).

These

items

are

warranted

separately

by

their

respective

manufacturers

through

their

authorized

~

service dealers.

4.

This

warranty

is

voided

if

the

snowmobile

is

operated

on

other

than

snow

or

ice,

in

competitive

racing,

~

in

commercial

usage,

or

has

been

used

as

a demonstrator. Q

~

s.

The

warranty

registration

card and 20-hour

inspection

checklist

card

must

be

mailed

to

AMF

within

~

seven

days

of

date

of

purchase

to

qualify

for

the

warranty

.

~

6.

Damage

or

deterioration

resulting

from

misuse,

neglect,

accident, transit,

alterations

or

unauthorized

repair

shall

in

no

event

be

deemed

a

defect

in

material

or

workmanship.

~

7.

This

warranty

does

not

cover

normal

wear

or

maintenance

items,

which

are considered

to

be

operating

Q

~

expense.

~

8.

For

other

than

predelivery

claims,

the

warranty

will

not

apply

to

Series

XX,

high

-performance

models.

~

9.

AMF

reserves

the

right

to

incorporate

changes

in

design

into

this

product

without

obligation

to

make

these

chan{.:es

on

units

previ

ously

sold.

10.

No

express,

implied

or

statutory

warranty

other

than

that

herein

set

forth

is

made

or

authorized

to

be

made

by

AMF.

PART

II

This

warranty

covers

defects

in

material

and

workmanship,

however,

certain

items

are considered

normal

operating

expense

items

and are

not

covered

under

this

warranty.

~~7:~;~:~ty

does

not

apply

to:

~

1.

Engine

tune-up,

cleaning

or

replacement

of

spark

plugs.

~

2.

Ski

alignment.

~

3.

Brake,

variable-speed,

or

traction-belt

adjustment,

or

variable-

speed-belt

replacement.

4.

Brake

lining

or

ski

wear-rod replacement. Q

S.

Paint,

body

dents

and

damaged

fiberglass,

chrome

or

trim

due

to

use.

~

6.

Engine

damage

due

to

lack

of

sufficient oil

in

fuel

mixture,

incorrect oil, too lean carburetor

adjust-

~

ment,

or

clutch

or

traction

belt

damage

due

to

running

engine

at

high

RPM

on

kickstand,

or

with

variable-

speed

belt

removed.

7.

Damaged

or

broken

windshields.

Q

~

8.

Any

snowmobile

which

shall

be repaired

or

altered

outside

an

AMF

authorized

repair service

facility

~

in

anyway

that

in

AMF's

judgment

affects

its

operation

or

reliability.

~

9.

Traction-belt

failure

due

to

misalignment

or

abuse.

~

zo.

Use

of

sled

for

competition

racing

will

void

the

warranty.

11.

Lamps

and

lens

(headlight

and

taillight).

Q

12.

Snowmobile

when

AMF

-

approved

parts are

not

used

in

repair

or

replacement

.

~

13.

Any

snowmobile

for

which

warranty

registration

card

has

not

been

returned

in

accordance

with

the

~

instructions

provided. Q

~

14.

Any

parts

replaced

as

a

result

of

normal

wear.

~~

IS.

Deterioration

of

rubber

or

fabric

components.

16.

Fasteners.

~

NOTE:

Save

the

Ski

-

Daddler

Inspection

Record

,

Form

No.

4477QA

attached

to

the

snowmobile.

This

Q

~

inspection

tag

identifies

your

sled

by

model

and serial

numoer

and

should

be

shown

to

your

dealer

when

~

making

any

claim

under

the

AMF

Warranty.

~

,,~~~~~~~~~~

~~~~~~~~

~

100Z472

c

~~~~~~~

WARRANTY CERTIFICATE

~~~~~~

~

Dealer's

Responsibility

~

During

the

warranty

period

it

wiIl be

necessary

for

the

dealer

to:

Q

~

1.

Be

responsible for

warranty

service

to

the

consumer

on

warranted

items

regardless

of

geographical

~

2.

Mail

to

AMF

within

seven

days,

after

completion,

predelivery

inspection

warranty

registration

card

location

of

original purchase.

~

and

20-hour

inspection

checklist

card.

,

~

3.

Complete

a

Warranty

AIlowance

Request

Form,

No.

4414A,

and

submit

it

to

AMF

through

his

dis- Q

tributor,

where

applicable,

within

thirty

days

after

repairs

have

been

made

.

~

4.

Determine

if

the

unit

or

part

requiring repair

or

replacement

is

covered

under

this

warranty

.

~

5.

Determine

if

the

customer

warranty

has

been

properly

registered

arid

that

the

warranty

period

is

stiII

in

eRect.

~

6.

Hold

all

defective

parts

replaced

under

this

warranty

until

AMF

disposition

instructions

are received

or

~

until

warranty

credit

is

received.

~

7.

Identify

all

defective

parts

returned

to

AMF

under

warranty

by

the

applicable

warranty

request

number.

~

8.

Assume

the

full

cost

of

pick-up

charges

or

travel

expenses

required

to

perform

warranty

service.

Owner's

Responsibility

~

During

this

warranty

period

it

may

become

necessary

for

the

owner

to:

Q

~

1.

Replace,

clean

or

adjust

spark

plugs,

ignition

points

and

condenser.

~

2.

Perform

engine

tune-up

and

adjust

carburetor. Q

~

3.

Adjust

and

align

skis.

~

4.

Add

oil

and

lubricants.

~

5.

Adjust

brake.

6.

Assume

the

full

cost

of

freight

for

return

of

defective

warranted

parts

to

the

factory.

~

7.

Perform

proper

storage

of

snowmobile

during

oR

-

season

months.

Q

~

8.

Have

20-hour

inspection

of

snowmobile

made

by

his

dealer.

~

,,~

~~~~~~~~~~~~~~~~~~

~------

-----------IMPORTANT------------------~

100

2472

WHILE

THE

WARRANTY

COVERS

DEFECTS

IN

MATERIAL

AND

WORKMANSHIP, CERTAIN

MAINTENANCE

ITEMS

AS

LISTED

BELOW

ARE

CONSIDERED

NORMAL OPERATING

EXPENSE

ITEMS

AND

ARE

NOT

COVERED

UNDER

THE

WARRANTY.

1. Engine tune-

up

cleaning

or

replacement of

spark

plugs.

2. Ski Alignment.

3. Brake,

variable

speed,

or

traction beltadjustment,

or

variable

speed

belt replacement.

4. Brake lining

or

sk

i

wear

rod replacement.

5.

Paint,

body

dents,

damaged

fiberglass,

and.

chrome

or

trim

damage

due

to use.

6. Engine

damage

due

to l

ack

of sufficient oil

in

fuel

mixture, incorrect oil, too lean

carburetor

adjust-

ment,

or

clutch

or

traction belt

damage

due

to

running engine

at

high

RPM

on kickstand,

or

with

variable

speed

belt removed.

7. Broken windshields.

8. Any modifications other

than

factory recommen-

dations.

9. Traction beltfailure

due

to misalignment or abuse.

10.

Use

of sled for competition racing

willi

void the

Warranty',

NOTE:

SAVE

THE

SKI-DADDLER

INSPECTION

RECORD,

FORM

NO.

4477QA

ATTACHED TO

THE

SNOWMOBILE

STEERING

COLUMN.

THIS

INSPECTION TAG

IDENTIFIES

YOUR

SLED

BY

MODEL

AND

SERIAL

NUMBER

AND

SHOULD

BE

SHOWN

TO

YOUR

DEALER

WHEN

MAKING

ANY

CLAIM UNDER

THE

AMF WARRANTY.

,)

WARRANTY

FLAT-RATE

LABOR

SCHEDULE

1. Remove and

replace

chain

case

cover

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

.

1/4

hour

2. Remove and

replace

chain and

adjust

tension

..•...............................

_.•.•.

1/4

hour

3. Remove and

replace

driven

clutch

or

bearings

or

V

-belt

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

.

1/2

hour

4. Remove and

replace

drive

clutch

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

.

1/2

hour

5.

Remove and

replace

engine mount

and/or

strap

(MARK IV)

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

. 1

hour

RemoVe and

replace

engine mount

and/or

strap

(MARK

V)

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

..

1-1/2

hours

6. Remove and

replace

drive

sprockets,

drive

shaft

or

bearings

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

. 1

hour

7. Remove and

replace

traction

belt

(endless) and

adjust

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

. 2

hours

8. Remove and

replace

rear

idler

shaft

assembly

or

bearings

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

..

1/2

hour

9. Remove and

replace

rear

support

arms

(2)

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

.

1/2

hour

10. Remove and

replace

throttle

cable

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

.

1/4

hour

11. Remove and

replace

brake

cable

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

..

1/4

hour

12. Remove and

replace

bogie

support

half

(lor

both)

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

.

1/2

hour

13. Remove and

replace

bogie wheel

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

..

1/4

hour

14. Remove and

replace

steering

spindle

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

..

15. Remove and

replace

spindle

arm

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

.

1/4

hour

)

1/4

hour

16. Remove and

replace

carburetor

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

..

3/4

hour

1002472

c

~I

TABLE

OF

CONTENTS

INTRODUCTION .

..•..

PREDELIVERY

INSTRUCTIONS

Install Ski

Assembly

. . . .

Install

Windshield

Assembly

Activate

Battery . . . .

Install Kickstand

Assembly

Fuel Mixture Instructions

Lubrication . . . . .

SERVICE

AND

REPAIR

Hood

Removal

and

Installation

Hood

Assembly

Repair . . . .

Replace Lamp

Assembli

es.

. .

Steering

and

Ski

Ass

embly

Alignment

To

Remove

Drive Chain ..

....

.

Drive Chain

Adjustment

. . . . . .

To

Remove

Variable-Spe

ed

Drive

Belt.

Variable-Speed Drive Belt

Adjustment.

To

Remove

Drive Clutch

Alignment

. .

To

Remove

Driven Clutch .

To

Remove

Brake

Assembly

Brake

Adjustment

. .

To

Remove

Carburetor . .

Carburetor

Adjustment.

.

To

Remove

Starting Motor

Assembly

To

Remove

Engine

and

Support

Assembly

-Mark

IV

Only.

To

Remove

Engine

and

Support

Assembly-Mark

V

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.

.

To

Remove

Traction Belt Take-Up

Assembly

To

Remove

Sprocket Seals

and

Bearings

To

Remove

Drive Sprocket

Assembly

To

Remove

Traction Belt

Adjustment

Spark Plug Replacement

Wiring Diagrams

Troubleshooting.

. . .

ILLUSTRATED

PARTS

LIST

1002472

CONTENTS

leSia~

Page

3

4

5

6

7

8

9

.10

.11

· 12

· 13

· 14

·

14

.14

15

J5

15

J5

16

17

18

J8

25

c

INTRODUCTION

This

manual

has

been

prepared

to

provide

all

authorized

AMF

Ski-

Daddler

Dealers,

Distributors

and

technicians

with

the

instructions

necessary

to

service

and

maintain

the

1970/1971 AMF MARKIV

and MARK V

series

Ski-

Daddler

snowmobiles.

The

series

classification

for

each

snowmobile

is

clearly

shown on

the

left-hand

side

of

the

console

control

panel.

The

Model

Number

and

Serial

Number

are

permanently

stamped

on

the

nameplate

attached

to

the

rear

right-hand

side

of

the

main

frame

as-

sembly.

When

ordering

accessories

or

replacement

parts,

always

indicate

the

correct

Model

Number

and

Serial

Number

as

shown on the

nameplate.

The

following

list

identifies

the

Ski-Daddler

series

claSSification,

corresponding

model

numbers

and

engine

designation

covered

in

this

manual.

,:

---se

ries

"l\i

Classification

Model

Number

Engine

IMARK

IV-300

SD15PI0B

JLO

295

MARK

V-400

SD18P27A

Hirth

399

MARK

V-400E

SD18E27A

Hirth

399

MARK V-400DE SD18E25B

Kohler

399

MARK V-500DE SD18E20B

Hirth

493

MARK

V-640

SD18P21A

Hirth

634

SD15P10B

111

I

Manufacturer's

engine code

number

P =

Prepared

f~r

electri~

starter;

E =Equipped

WIth

electriC

starter

Traction

belt

width

in

inches

Ski-Daddler

This

manual

is

presented

in

two

sections.

The

first

section,

Maintenance,

provides

the

instructions

necessary

for

maintenance

and

service

while

the

second

section,

the

Illustrated

Parts

List

is

pro-

vided

to

facilitate

the

ordering

of

spare

and

replace-

ment

parts.

The

Parts

List

section

also

contains

a

numerical

listing

of

all

items

shown

in

the

Illustrated

Parts

List.

Thus,

if

the

part

number

is

known

but

not

its

application,

refer

to

the

numerical

list.

If

the

part

number

is

not

known,

locate

the

item

on the

illus-

tration

to

obtain

the

index

number

keyed

to

the

applicable

parts

list.

1002472

3

~I

INTRODUCTION

IMPORTANT To

keep

the

AMFWarrantyinforce,

be

certain

to

use

only AMF

-Approved

replacement

parts.

The

AMF-Warranty

does

not apply

to

parts

covered

by

the

original

manufacturer's

warranty

such

as

engine

or

engine

parts,

starters,

belts,

carburetor

battery

or

other

components

or

acces-

sories

not

~anufactured

by AMF. Should any

claim

arise

concerning

these

items,

follow

the

manufac-

turer's

instructions.

If

the

information

in

this

manual

is

not

applicable

to

all

models,

the

exceptions

will

be

notedand

the

cor-

rect

information

for

the

particular

model

will

be

given.

PREDEL/VERY

INSTRUCTIONS

The

1971

Ski-Daddlers

are

shipped

completely

as-

sembled

except

for

the

windshield

assembly,

the

ski

assembly

and the

kickstand

assembly.

On

th

e

electric-start

models,

the

battery

is

installed

but

not

activated.

These

assemblies,

plus

the

attaching

hardware

will

be

found

in

the

shipping

container.

Carefully

open

the

carton

and

immediate

ly

inspect

the

eqU

ipment

for

any

damage

or

missing

items.

IMPORTANT:

The

owner

must

retain

the

Ski-

Daddler

Inspection

Record,

FormNo.

4477QA.

This

form

must

be

shown

to

the

dealer

shouldany

claim

arise

under

the

AMF

Warranty.

Install Ski

Assembly

•

Place

the

spindle

pads

(figure

1)

in

the

spring

mounting

bracket

with

the

thicker

section

and

the

directional

arrow

on

the

pad

pointing

forward.

NO

"TE:

The

spindle

pads

and

attaching

hardware,

locknuts

and

3-1/4-inch

length

screws

,

will

be

found

in

the

plastiC

bag

shipped

with

the

sled.

Figure 1

L

OCKNUT

SP

IND

LE

PAD

(THICK

SECT

ION

FORWJ>.RDJ

PREDEL

I

VERY

INSTRUCTIONS

•

Install

the

ski

assembly

by

securing

the

spring

mounting

bracket

and spindle

pad

to

lower

end of

spindle

tube

assembly

as

shown

in

figure

1. Apply

30 foot-pounds

torque

to

the

locknut. Do not

over-

tighten

bolt

as

the

ski

assembly

should float

freely

on the

spindle.

•

Repeat

procedure

for

opposite

ski.

NOTE:

Properly

installed

skis

should toe out

0-

to

1/2-inch

at

the

front

end

(see

figure

2)

and should

be

symmetrical

about the

centerline

of the

sled.

Toalignthe

skis,

refer

tothe

Steering

and Ski Align-

ment

procedures.

TOE

OUTo-TO

1I2-INCH

MAXIMUM

Figure 2

Il1stall

Windshield

Assembly

•

Disconnect

hood

harness

at

the

quick

disconnect

.

• Remove hood and headlight

assembly.

Refer

to

Hood Removal and

Installation

procedure.

• Back off the locknut (figure

2)

and

remove

the

7/8-inch

length

screw

used

to

secure

the

hood

harness

clip

and the end of

the

right-hand

mounting

strip

to

the

hood.

• Remove

the

remaining

screws

securing

the

4

right-

and

left-hand

mounting

strips

to the hood. "

Remove the mounting

strips.

J

• Remove the

protective

plastic

cover

from

the

windshield.

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

andwindshieldtothe hood

assembly

starting

at

the

center

and working

to

the

sides.

Be

certain

to

position

the

7/8

-i

nch length

screw

in

the

end

position

shown

in

figure

2.

• Engage the ends of

the

mounting

strips

to the

trim

str

ip

on the windshield and then tighten

the

screws,

starting

at

the

ends

and working to

the

center.

Remove the

protective

covering

from

the

mounting

strips.

NOTE:

Check

mounting

strips

for

sharp

edges

or

corners.

Use a fine tooth

file

to

smooth

any

sharp

edges

and

corners.

• Attach the hood

harness

clip to

the

7/8-inch

length

screw

and

secure

with locknut.

Activate

Battery-Models

SD

IBE20B, SDIBE25B

and

SD

IBE27A

Only

)

• Remove the hood and

headlight

assembly.

Refer

to

Hood Removal and

Installation.

Before

activating

the

12-volt

storage

battery,

disconnect

the

battery

cables

and

remove

the

battery.

Activate the

battery

in

accordance

with

theinstruc-

tions

contained on

the

package

con-

taining

the

electrolite

sulfuriC

acid.

Reinstall

the'

battery

as

follows:

•

Place

12-volt

battery

on the

battery

support

plate

with

positive

(+)

terminal

post

forward.

• Attach

the

negative (-)

battery

cable

(and the

BLACK

wire

lead

from

cigarette

lighter

SD18E20B

only) to

the

negative

terminal

post.

NOTE:

Cigarette

lighter

is

standard

eqUipment on

Model SD18E20B only. May

be

purchased

as

an

accessory

item

for

any snowmobile equipped with )

a

battery.

1002472

C

c

•

Attach

the

positive

(+)

battery

cabl

e (and

the

RED

wire

lead

from

cigarette

lighter

SD18E20B

only)

to

the

positive

terminal

post.

•

Position

the

holddown

strap

across

the

battery

and

over

the

holddown

rods.

Secure

the

strap

and

battery

using

locknuts

and

washers.

Do

not

over-

tighten.

•

Replace

the

hood

and

headlight

assembly.

Install Kickstand

Assembly

-Models

SO

IBE20B,

SO

IBE25B

and

SO

IBP21 A

Only

The

attaching

hardware

requir

ed

for

kickstand

installation

will

be

found

in

the

plastic

parts

bag

shipped

with

the

Ski-Daddler

snowmobile.

Check

container

against

the

following

list

to

be

certain

no

parts

are

missing

or

damaged.

Part

No.

Description

Qty

37175

Kickstand

assembly

-18

inch

1

32234

Spring

2

37186 Long

spacer,

1-

11/32

LG 2

33778

Short

spacer,

13/32

LG 2

181575 Hex

head

bolt,

1/4

-28 THD by 4

1-

1/2

IN.

181578 Hex

head

bolt,

1/4-28

THD

by

2

1-7/8

IN.

9000123 Locknut,

1/4-28

THD 6

33808

Formed

washer

6

446188

Flat

washer,

17/64

ID 4

•

During

initial

installation,

assemble

all

compo-

nents

loosely

as

shown

in

figure

3.

After

completing

,

~.,

~~

~1!!1

::::::i/

!

~'H

'

:

LOCKNUT(6)~

~

_

FLAT

WA

SHER (4)

@....

SHORT

-

<-

SPACER

- , -

KICK

S

TAND

'-.. (2)

~

.

' -

BRACKET

.>

'-....

--

...;r

'

,

___

---

SCREW (2)/ _

.>

...

--

---

""

.s::;a

A

"-

---

;- LONG SPACER

(2)~~

SC

REW

(4)

~

SPRING (2)

Figure 3

1002472

5

~IPREDELIVERY

INSTRUCTIONS

1e.~Si3

~

the

installation,

tighten

all

nuts

and

bolts

secure

ly

but

do

not

overtighten.

•

Check

the

installation

by

setting

the

sled

on

the

kickstand

as

shown

in

figure

13.

Fuel

Mixture

Instructions

WARNING

Never

fill

the

gasoli

ne

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

(20parts

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.

Fuels

containing

additives

are

not

recommended

for

use

in

Ski-Daddler

engines.

For

mixing

with

gaso-

line,

use

AMF-nondetergent

oil

prepared

exclu-

sively

for

use

in

air-cooled,

2-cycle

engines.

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

Ski-Daddler

snowmobiles.

Use

a

mixture

of gasOline

and

oil

as

shown

in

the

Fuel

Mixture

Chart.

Neve'r

use

gasoline

left

over

from

the

summer

or

FUEL

MIXTURE

CHART

OIL

(Ounces)

o 4 8

12

16

20

24 28

32 36

40

5 /

/~

/

~/

4 V

",

/""

/

",

""

/

",

~

",'"

/

~

3

2

/

v,..

U.

S.

Gallons

Imperial

Gall

i

on.

T-

o

GASOLINE

(Gallons)

GASOLINE/O

IL

RATlO

-

20

to

1

~t

...

5iMlal

SERVICE

AND

REPAIR

I~

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 a

container

with about one gallonof

gasoline

and

mix

thoroughly.

Then add additional

amounts

of

gasoline

as

shownon

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.

Lubrication

There

are

three

lubrication

areas

that

require

atten-

tion on a

regular

basis.

A low

temperature

grease

must

be applied to the

zerk

fittings

located

on the

steering

spindle

tubes; on

each

bogie wheel

after

approximately

each

20

hours

of

use;

and the chain

case

housing which

must

be

checked

after

'

each

10

hours

of

use

and No. 2

lithium

bearing

grease

re-

placed

as

required.

NOTE:

Do

not add

grease

to

chain

case

housingon

Model SDI8P21A.

This

unit

has

a

self-lubricating

system.

The

bearing

cup

retainers

that

hold the

seal

bearings

in

the

traction

belt

take-up

assembly

should

be

repacked

with No. 2

lithium

bearing

grease

whenever

the

bearings

are

removed

during

normal

maintenance. No. 2

lithium

bearing

grease

may

also

be applied to the

inside

of

the

drive

sprocket

bearing

retainers

during

normal

main-

tenance.

Grease

may

also

be applied

as

required

to the

wear-

plates

and

U-strap

securing

the

steering

columnto

the

roll

bar.

SERVICE

AND

REPAIR

Hood

Removal

and

Installation

• To

remove

the hood and

headlight

assembly,

dis-

connect 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 andheadlight

assembly

by lifting

back

end

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.

6

• 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

repairs,

order

AMF

Fiberglass

Repair

Kit No.

1510693.

Smaller

repairs

can

be madewith

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

headlight

bulb,

raise

the

headlight

assembly;

remove

the

screws

securing

the

cover

assembly

and

remove

the

cover

assembly.

Remove

the

defectivebulband

replace

withnewbulb.

See

illustrated

parts

list

for

correct

replacement

part

numbers.

Taillight.

Remove

taillight

lens

to expose the

tail-

light

bulb. Remove the

defective

bulb and

replace

with a new bulb. See

illustrated

parts

list

for

cor-

rect

replacement

part

numbers.

Steering

and

Ski

Assembly

Alignment

Good

steering

ability

requii'es

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

mea-

surement

at

the

front

end ofthe

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

position.

• Remove the hood and

headlight

assembly.

Refer

to Hood Removal and

Installation.

1002472

o

c

•

Remove

the

bolt

(1,

figure

4), two

spacers

(2),

bottom

spacer

and locknut

securing

the

rod

end

bearing

(3)

to the

spindle

arm

(6).

Figure 4

•

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.

• Move the affected

ski

into

proper

alignme

nt

and

recheck

measuring

points

to

insure

that

the

skis

toe

out

0-

to

1/2-inch

maximum

at

the

front

end and

are

in

the

same

orientation

with the

sled

body

as

show:!

in

figure

2.

• With

skis

properly

set

and

steering

handle in the

straight-ahead

position,

rotate

tie

rod

(5,

figure

4)

as

required

to

bring

rod

end

bearing

(3)

in

line

with

the

spindle

arm

(6).

•

Secure

rod

end

bearing

(3)

to spindle

arm

(6)

as

illustrated.

Check

for

proper

alignment and then

tighten

jam

nuts

(4)

to

secure

both

rod

end

bearings.

NOTE:

If

a

greater

adjustment

is

required

than

that

permitted

by

the

steering

linkage

assembly,

it

will

be

necessary

to align

the

ski

by making

the

adjust-

ment

at

the

spindle

tube

assembly

as

follows:

C •Remove

screw

(5,

figure

5)

and locknut

(6)

se-

curing

spindle

tube

assembly

(7)

tospindle

arm

(8).

1002472

7

~I

SERVICE

AND

REPAIR

It"'§Mla

~

• Remove

spindle

arm

(8)

and

rotate

ski

and

spindle

tube one notch

in

the

required

direction;

replace

and

secure

spindle

arm

to the spindletube.

Apply 20 foot-pounds

torque

to the locknut (6).

•

Recheck

the

skis

for

proper

toe out and

al

i

gn-

ment

as

previously

described.

To

Remove

Drive Chain

• Remove the hood and headlight

assembly.

Refer

to Hood Removal and

Installation.

! CAUTION!

Always

disconnect

spark

plug

wires

before

working on the engine

or

drive

elements.

• Remove the locknut

securing

the

chain

cover

top

and

remove

chain

cover

top.

• Loosen the

bolts

(1,

figure

5)

on both

cam

up-

rights

(2)

and

rotate

the

cam

and

shaft

(3)

as

re-

quired

to

loosen

the

chain

tension.

During

reassem-

bly, apply 30 foot-poUnds

torque

to the

bolt

(1).

Figure 5

• Remove the

cotter

pin,

slotted

nut and

washer

securing

the top

sprocket

to

the

driven

clutch

shaft.

Remove

the

top

sprocket

and chain

together.

•

Reassembly

is

the

reverse

of

removal.

Perform

drive

chain

adjustment

procedures

and add

No.2

lithium

bearing

grease

as

required

to the chain

case

on

all

models

except

SD18P21A.

SERVICE

AND

REPAIR

Drive Chain

Adjustment

A

properly

adjusted

drive

chain

(figure

5)

should

have

a

1/8-

to

1/4-inch

slack.

Check and

adjust

chain

as

follows:

•

Remove

the

locknut

securing

the

chain

cover

top

and

remove

chain

cover

top.

•

Rotate

the

upper

sprocket

to

tension

one

side

of

the

chain

and

then

check

the

opposite

side

for

proper

slack.

If

adjustment

is

required,

loosen

the

screws

(1)

securing

the

cam

uprights

(2)

on

each

side.

•

Rotate

the

cam

(3)

counterclockwise

to

tighten

or

until

the

chain

is

properly

tensioned.

Hold

the

cam

in

this

position

while

tightening

the

cam

upright

bolts

(1)

on

each

side.

Be

certain

the

lateral

align-

ment

between

the

drive

clutch

and

the

driven

clutch

(4)

is

maintained

while

the

cam

upright

bolts

are

tightened.

•

Recheck

chain

tension

before

replacing

the

chain

case

cover.

To

Remove

Variable-Speed Drive Selt

•

Remove

the

drive

chain.

Refer

to

paragraph

To

Remove

Drive

Chain.

•

Remove

the

clutch

guard

assembly.

•

Loosen

the

locknut (9,

figure

5)

and

serrated

washer

(10).

During

reassembly,

apply 10

foot-

pounds

torque

to

the

locknut

(9).

•

Push

the

driven

clutch

toward

the

drive

clutch

sufficiently

to

allow

removal

of

the

variable-speed

drive

belt

from

the

drive

clutch.

•

Remove

the

locknuts

(7,

figure

4)

securing

the

bearing

clamps

(8)

and

remove

the

bearing

clamps.

During

reassembly,

apply 5

foot-pounds

torque

to

the

locknuts

(7).

•

Lift

the

driven

clutch

(9) and

drive

belt

clear

of

the

brake

assembly

(10) and

remove

the

variable-

speed

drive

belt.

•

Install

replacement

drive

belt.

Use AMF

Part

No. 37172

on

Model SD15P10B; AMF

Part

No.

1002110 on ModeISD18P21A; AMF

Part

No. 1002147

on Model SD18E25B; and AMF

Part

No. 349140n

all

other

models.

8

NOTE:

Variable-speed

drive

belt

installation

pro-

cedures

are

the

reverse

of

removal

except

that

the

belt

must

first

be

place

around

the

driven

clutch

and

then

around

the

drive

clutch.

After

installation,

per-

form

the

drive

chain

adjustment,

variable-speed

belt

adjustment

and

the

drive

clutch

alignm

en

t

procedures.

Variable-Speed Drive Selt

Adjustment

Proper

tension

for

a new

drive

belt

should

be

ob-

tained

when

the

clutch

centers

are

set

to

the

B

dimension

shown

in

figure

6

for

the

applicable

model

snowmobile.

A B C

(TORQUE)

MODEL

NO

.

FT-LB

.240

1G-3/4

45

SD15P10B

.300

10-3/4

70

S

D18P27A

.300 1G-3/4

70

SD18E27A

.

300

11-1/2

70

SD18E25B

.

300

10

-3/

4

70

SD18E20B

.300

11-1/2

90

SD18P2

1A

Figure 6

ENGINE

JLO

295

HIRTH

399

HIRTH

399

KOHLER

399

HIRTH

493

HIRTH

634

CLUTCH

780

910

1190

HOLDDOWN

NUTS

VIEW

0

Proper

tension

for

a

used

dri

ve

belt

is

obtained

when

opposite

sides

of

the

belt

can

be

squeezed,

between

the

drive

clutches,

to

the

following

dimensions

as

measured

between

the

top

and

bottom

outside

surface

of

the

belt.

SD15P10B

SD18P21A

SD18P27A

SD18E27A

SD18E25B

SD18E20B

2-3/4-

to

3-1/4

inches

4-1/4-

to

4-3/4

inches

4-

to

4-1/2

inches

4-

to

4

-1

/2

inches

4-

to

4-1/2

inches

4-

to

4-1/2

inches

1002472

()

o

c

Measurement

must

be

taken

as

close

to

the

drive

clutch

flanges

as

possible.

Be

certain

the

driven

clutch

does

not open when

belt

is

squeezed.

IMPORTANT: Do

not

use

antislip

belt

dressing.

Belt

slippage

is

a

safety

feature

which

prevents

overstressing

drive-system

components.

• To

adjust

drive

belt

tenSion,

loosen

the

locknut

(9,

figure

5)

securing

the

clutch

rod

t'ensioner

to

the

main

frame

assembly.

NOTE:

If

the

drive

belt

is

wearing

unevenly,

check

alignment

as

described

in

Drive

Clutch

Alignment

procedures.

• Move

the

driven

clutch

(4)

in

the

direction

re-

quired

to

obtain

proper

belt

tension.

Hold

this

posi-

tion

while

tightening

the

locknut

(9)

to

secure

the

clutch

rod

tensioner.

Be

certain

the

washer

(10)

and

bar

serrations

are

properly

engaged. Apply 10

foot-pounds

torque

to

the

locknut

(9).

To Remove Drive Clutch

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

!

CAUTION:]

Always

disconnect

spark

plug

wires

before

working on

the

engine

or

drive

elements.

•

Remove

the

clutch

guard

assembly.

•

Loosen

the

locknut (9,

figure

5)

and

serrated

washer

(10)

securing

the

clutch

rod

tensioner

(11)

to

the

main

frame.

During

reassembly,

apply 10

foot-pounds

torque

to

the

locknut

(9).

•

Push

the

driven

clutch

toward

the

drive

clutch

sufficiently

to

allow

removal

of

the

variable-speed

drive

belt

from

the

drive

clutch.

• To

remove

the

drive

clutch

from

Models SD15P-

lOB and SD18P21A only,

remove

the

clutch

adapter

bolt

and

washer.

If

necessary,

use

a

clutch

puller

and

remove

the

drive

clutch.

During

reassembly,

apply

45

foot-pounds

torque

to

the

clutch

adapter

bolt

on Model SD15P10B only, and 90

foot-pounds

torque

on Model SD18P21A. NOTE:

If

the

clutch

nut

is

removed

from

the

drive

clutch

used

on Model

SD15P10B,

reinstall

the

nut, apply 125

foot-pounds

torque

and

be

certain

to

engage

the

lockplate

tangs.

10

02

472

9

VICE

AND

REPAIR

• To

remove

the

drive

clutch

from

Models

SD18P27A, SD18E27A, SD18E25B and SD18E20B,

remove

the

clutch

adapter

bolt

and

washer,

flatten

the

lock

plate

tangs

and

remove

the

clutch

nut and

lock

plate.

If

necessary,

use

a

clutch

puller

to

re-

move

the

drive

clutch.

During

reassembly,

apply

150

foot-pounds

torque

to

the

clutch

nut and

then

apply 70

foot-pounds

torque

to

the

clutch

bolt

.

Be

certain

to

engage

the

lock

pl

ate

tangs.

•

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.

!

CAUTI:c?~:

: J

Always

disconnect

spark

plug

wires

before

working

on

the

engine

or

drive

elements

.

•

Remove

the

clutch

guard.

•

Loosen

the

engine holddown

nuts

(figure

6)

se-

,

curing

the

engine

supports

to

engine mount

straps.

•

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

set

to

the

A

dimension

as

shown

in

figure

6.

Rotate

driven

clutch

90-degrees

and

repeat

procedure.

•

Tighten

engine holddown

nuts

and

recheck

align-

ment.

Apply

25

foot-pounds

torque

when

tightening

the

engine holddown

nuts.

To

Remove Driven Clutch

NOTE:

The

procedures

required

to

remove

the

driven

clutch

are

the

same

as

those

described

in

paragraph

To

Remove

Variable-Speed

Drive

Belt.

To

Remove Brake

Assembly

•

Remove

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

!

CAUTION!

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

SERVICE

AND

REPAIR

•

Disconnect

brake

cable

and housing

at

brake

mounting

bracket

and

at

brake

actuating

lever.

•

Remove

the

two

bolts

and

lockwashers

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.

Brake

Adjustment

• 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

(3)

as

required.

Tighten

jam

nuts.

Figure 7

To

Remove

Carburetor

•

Loosen

the

throttle

and

if

used,

the

choke

control

cable

adjustment

screws

and

release

both

cables

at

the

carburetor

(see

figure

8).

•

Remove

the

screws

securing

the

air

intake

filter

or

baffle

(figure

9)

and choke

control

bracket

mounted on

carburetor

used

on Models

SDI5PI0B,

SD18E20B and SD18E25B only.

•

Remove

the

impulse

line

at

the

carburetor

used

on

all

models

except

SDI5PI0B.

10

•

Release

the

tank-to-carburetor

gas

line

(figure

8). Wipe up any

spilled

gasoline

immediately.

NOTE:

On

all

Mark

V

series

Ski-Daddlers,

release

the

carburetor-to-tank

reCirculating

gas

line

at

the

re-

Circulation

elbow. Be

certain

to

note

the

position

of

the

gas

lines

to

insure

proper

reassembly.

Wipe up

any

spilled

gasoline

immediately.

Figure 8

IMPORTANT: Model

SD15PI0B

uses

a fuel

pump

attached

to

the

inside

surface

of

the

console

tongue

with two

screws

and

nuts.

If

necessary

to

replace

the

fuel pump,

be

certain

to

note

the

position

of

the

fuel

lines

to

insure

proper

reassembly.

Wipe up

any

spilled

gasoline

immediately.

Figure 9

1002472

o

c

•

Remove

the

nuts

securing

the

carburetor

to

the

intake

manifold and

remove

the

carburetor.

NOTE: Do not

damage

gaskets

when

removing

carburetor.

•

Installation

is

the

reverse

of

removal.

Adjust

carburetor

as

described

in

Carburetor

Adjustment

procedures.

Carburetor

Adjustments

The

Tillotson

Model

HD

and HR

carburetors

used

on

Ski-Daddler

Models SD18E20B, SD18P27A,

SD18E25B, SD18E27A and SD18P21A

are

equipped

with a

recirculation

system.

1::

~AUTION

1

Never

run

the

engine with

the

carbu-

retor-to-tank

recirculating

gas

line

disconnected

(see

figure

8)

The

Bendix

Model

carburetor

used

on

Ski-Daddler

Model SD15P10B

is

a

floattype

carburetor

and

does

not

require

a

recirculation

system.

The fuel

is

SERVICE

AND

REPAIR

pumped

to

the

carburetor

through

an

external

fuel

pump

mounted on

the

console

assembly.

The

carbu-

retion

system

maintains

a fuel

reservoir

in

the

float

chamber

to

insure

smooth

starting

and

idling

characteristics.

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

(DO

NOT FORCE).

Then

open

the

high-

speed

jet

(figure

8)

to

the

settings

shown on

the

carburetor

settings

chart

for

your

particular

engine (

see

figure

10).

The

high-

and

low-speed

jet

adjustment

screws

for

the

Bendix

carburetor

used

onModelSD15P1

OB

are

located

on top of

the

carburetor

and

are

identified

as

HI

and LO.

The

engine

can

be

seriously

damaged

if

operated

with a

lean

gas

mixture

(high-

speed

jet

turned

in

too

far).

CARBURETOR SETTINGS CHART

MODEL NO. ENGINE HIGH·SPEED JET LOW·SPEED JET

SD18E20B Hirth 493 + 1/8 +

1/8

1 Open 1·1/8 Open

-0 - 0

SD18E27A Hirth 399 +

1/8

+ 1/8

1 Open 1 Open

-0 - 0

SD18P27A Hirth 399 +

1/8

+

1/8

1 Open 1 Open

-0 - 0

SD18P21A Hirth 634 +

1/8

+

1/8

1·1/8

Open

1·1/8 Open

-0 - 0

SD18E25B Kohler 399 +

1/8

1·5/8 _ 0 Open 1.

1/8

+

1/8

Open

- 0

SD15P10B JLO 295 1 + 1/8

-0 1·1/2 + 1/8

Open Open

-0

NOTE:

The

carburetor

settings

shown

are

for

normal

operation

at

sea

level.

For

high

altitude

operation

and

for

extreme

temperature

variations,

the

settings

may

have

to

be

adjusted

accordingly.

Figure

JO

1002472

11

SERVICE

AND

REPAIR

•

Turn

the

low

speed

jet

(idle

-mixtur

e

screw)

shown

in

figure

8

all

the

way

in

(DO

NOT FORCE),

then open

as

shown

in

figure

10

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

clutch

engaging

speed

by

adjusting

the

idle

-

speed

screw.

NOTE: Do

not

use

the

low

-s

peed

jet

to

adjust

for

idle

speed.

NOTE:

Figure

8

shows

a

throttle

-

wire

adjustment

screw.

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

open

the

throttle.

To

Remove

Starting

Motor

Assembly-Models

SO

JBE20B,

SO

JBE25B

and

SO

JBE27A

Only

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

!

CAUTION

I

Always

disconnect

spark

plug

wire

before

working

on

the

engine

or

drive

elements.

•

Disconnect

the

battery-to-solenoid

positiv

e (+)

cable

at

the

battery

to

prevent

sparking

and

possible

shorting.

•

Disconnect

the

solenoid-to-starting

motor

cable

at

the

starting

motor.

•

Back

off

the

two

nuts

securing

the

starting

motor

assembly

to

the

engine.

Remove

the

engine

wiring

harness,

ground

wire

and

the

battery

-to-s

tarting

motor

ground

wire

attached

to

the

upper

stud

and

remove

the

starting

motor

assembly.

•

Reassembly

is

the

reverse

of

removal.

To

Remove

Engine

and

Support

Assembly

-Models

SO

JBE20B,

SD

IBE25B"

SO

J

BE2l

A,

SO

JBP27A

and

SOJBP2JA

Only

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood RemOVal and

Installation.

!:

~~~TI~~

:

:I

Always

disconnect

the

sparkplugwires

before

working on

the

engine

or

drive

.

elements.

12

• Remove

the

console door assembly

by

turning

the

door

fastener

counterclockwise

to

release.

•

Remove

the

screws,

washers

and

locknuts

se-

curing

the

console

tongue

assembly

to

the tool

box

and

to

the

mini-console

(see

figure

11).

Figure

J1

•

Remove

the

drive

clutch.

Refer

to

paragraph

To

Remove

Drive

Clutch.

•

Loosen

the

flexible

tube

clamps

securing

the

muffler

exhaust

tube

to

the engine

exhaust

manifold

and

release

the

exhaust

tubes.

•

Disconnect

the

throttle

and

choke

control

cables

and

remove

the

carburetor

as

described

.

in

para-

graph

To Remove

Carbuetor.

•

Remove

the

starting

motor

assembly.

Refer

to

paragraph

To Remove

Starting

Motor

Assembly,

Models SDI8E20B, SD18E25B and SD18E27A only.

• .

Remove

the

heat

shield

located

between

the

engine and

the

muffler.

Remove

the

attaching

hard-

ware

at

the

muffler

bracket

and/or

heat

shield

bracket

and

at

the

top

near

the

steering

column

.

1002472

)

o .Remove

the

bolts

(10,

figure

12),

spacers

and

nuts

securing

the

steering

linkage to the

steering

column

arm

(9). During

reassembly,

apply

15

foot-

pounds

torque

to

the

nuts

securing

the

steering

linkage.

c

Figure 12

• Remove the bottom

cotter

securing

the

steering

column to the

main

f:rame

steering

column

support.

• On

models

equippedwithan

electric

starter,

dis-

conneCt the

wiring

harness

atthe

battery,

electrical

panel,

taillight

and engine.

Release

the

wire

V

-clips

in

the tool box and

at

the

foot

rest

and

remove

the

wiring

harness.

On

manual

start

models

disconnect

the

wiring

harness

at

the

taillight

and engine. NOTE:

Replace

the

metric

nut

after

removing

the

black

ground

lead

from

the

engine.

• Remove the two

screws,

formed

washers

and

locknuts

at

each

end of the

roll

bar

and

remove

the

roll

bar,

steering

columnand

mini-console

as

a unit.

• Remove the locknuts and

washers

securing

the

engine mounting

straps

to

the

main

frame

studs,

and

remove

the engine, engine

base

and mounting

straps.

• Remove

the

carriage

bolts,

nuts and

washers

securing

the engine mounting

straps

to

the

engine

1002472

1,3

SERVICE

AND

REPAIR

base.

Remove

the

straps

for

reassembly.

During

reassembly,

apply 25-foot-pounds

torque

to

the

nuts

securing

the engine

base.

•

Installation

is

the

reverse

of

removal.

To

Remove

Engine

and

Support

Assembly-Model

SD15P10B

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 console

door

assembly

by

turning

the

door

fastener

counterclockwise

to

release.

• Remove the

six

screws,

washers

and locknuts

securing

the

console tongue

assembly

to

the tool

box and

to

the

mini-console

(see

figure

11

).

• Remove the

drive

clutch.

Refer

to

paragraph

To Remove

Orive

Clutch.

• Loosen the flexible tube

clamps

securing

the

muffler

exhaust

tube to

the

engine exhaustmanifold

and

release

the

exhaust

tubes.

•

Disconnect

the

throttle

and choke

control

cables

and

remove

the

carburetor

as

described

in

para-

graph

To Remove

Carburetor.

•

Disconnect

the

yellow

wire

lead

and the

black

wire

lead

at

the engine and the

black

ground

wire

lead

at

the

starter

cover.

Replace the

metric

nut

to

secure

the

cover

after

removing

the

black

wire

lead.

• Remove the

heat

shield

located

between the

engine and the

muffler.

Remove the

attaching

hard-

ware

at

the

muffler

bracket,

heat

shield

bracket

and

at

the top

near

the

steering

column.

• Remove the locknuts and

washers

securing

the

engine mounting

straps

to the

main

frame.

NOTE:

During

reassembly,

tighten the locknuts

justsuf-

ficiently

to

permit

the

washers

to

be

turned

by

hand -

then

tighten the

locknuts

one additional

turn.

• Lift

the

engine until

the

engine mounting

straps

clear

the

studs

shown

in

figure

11. Rotate the engine

SERVICE

REPAIR

counterclockwise

and

remove

the

engine

toward

the

rear

and

clear

of

the

sled.

•

Remove

the

carriage

bolts,

washers

and

locknuts

securing

the

mounting

straps

to

the

engine

base.

Remove

th

e mounting

straps

and

bar

washers.

NOTE:

During

reassembly,

the

mounting

straps

and

bar

wa

sher

must

be

secured

to

the

engine

base

before

installing

the

replacement

engine.

•

Installation

procedures

are

the

reverse

of

removal.

To

Remove

Gas

Tank

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

!

CAUTION!

Always

disconn

ect

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

12).

•

Remove

the

bolt

s

(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)

and

the

recirculating

gas

line

(7)

at

the

gas

tank

outlet

fitting

(5). Wipe up

any

spilled

gasoline

immediately.

•

Remove

the

gas

tank

(4)

by

carefully

sliding

the

tank

up and away

from

main

frame.

IMPORTANT:

Do

not

damage

the

gas

tank

outlet

(5)

when

removing

the

tank.

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

J4

pressure

relief

valve

(8).

These

items

are

to

be

installed

on

the

replacement

tank.

To

Remove

Muffler

•

Remove

the

hood and

headlight

assembly.

Refer

to Hood

Removal

and

Ins

t

allation

.

I

CAUTION!

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Loosen

the

flexible

tube

clamp

securing

the

flex-

ible

exhaust

tube

to

the

muffler

and

release

the

tube.

NOTE: All

Mark

V

series

Ski-Daddlers

have

dual

exhaust

tubes

and

muffler.

•

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.

•

Raise

back

end of

Ski-Daddler

so

that

traction

belt

clears

the

ground.

•

Remove

the

locknut

(3,

figure

13)

securing

the

bogie

wheel

assembly

(2)

to

the

axle

shaft

and

re-

move

the

wheel.

Figure

J3

1002472

o

c

•

During

re

a

ssem

bly

,

torque

th

e locknut

(3)

to

28

foot-pounds.

Be

certain

the

wheel

assembly

(2)

is

installed

with

grease

fittings

on the

outside.

To

Remove

Bogie W

heel

and

Support

Assembly

!

CAUTIO~:]

Always

disconnect

the

sparkplugwires

before

working

on

the

engine

or

drive

elements.

•

Raise

back

end of

Ski-Daddler

so

traction

belt

clears

the

ground.

•

Remove

the

screws

(1,

figure

13) and

washers

securing

the

bogie wheel

support

·

shaft

(4)

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.

•

Pry

the

tabs

up

sufficiently

to

remove

the

torsion

springs.

NOTE:

The

torsion

springs

are

identified

as

right-

and

left-hand

springs.

Note

the

direction

of

the

coils

and

the

position

of

the

springs

to

facili-

tate

reassembly.

•

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.

•

Release

track

tension

by

loosening

adjusting

bolts

(5,

figure

13).

•

Release

the

support

arm

torsion

springs

con-

.

nected

to

the

main

frame

.

•

Remove

the

right-

and

left-hand

adjust

ing

angle

locknuts

(6),

washers

and

carriage

bolts

securing

the

traction

belt

take-up

assembly

to

the

main

frame.

1

0024

72 15 .

~I

SERVICE

AND

REPAIR

le2ia~

• Remove the

traction

belt

tak

e

-up

assembly

as a

unit.

NOTE:

Th

e

tra

c

ti

on be

lt

t

ake-

up

asse

mbly

cons

ists

of

th

e

rear

sp

r

ocke

t

assembly

, sp

acer

an

d

ass

o-

Ciated h

ardware

hel

d

toge

th

er

by

th

e

re

ar

support

arm

assemblies.

If

necessary

to

remove

seals

,

sprockets

or

idler

wheel,

proceed

as

follows.

•

Carefull

y

pry

the

oil

seal

away fr

om

the

rear

support

arm

assemb

ly (8, figure 13)

an

d

re

mo

ve

th

e

support

arm

and

adjusting

ang

le (9)

cl

e

ar

of

th

e

sprocke

t

shaft

and

bear

ing

.

•

Remove

the

press

-on

bear

ings and o

il

seals

.

During

reassembly

repack

bea

r

ings

with No. 2

lithium

bearing

grease

.

•

Remove

the

screws

(10) and nuts

se

curi

ng

th

e

sprocket

plate

and the sprocket.

to

the

driv

e

shaft

.

Remove

the

plate

and

sprocket

.

• To

remove

the

idler

wheel, r

em

ove

the

sc

re

ws

(10) and

nuts

securing

the

sprocke

t plat

es

and

re-

move

the

idler

wheel by

stretching

th

e w

he

el

over

the

sprocket

plates.

•

Reassembly

is

the

r

everse

of removal.

During

reassembly

follow

ins

tru

c

tions

outlined

in

para-

graphs

Track

Alignme

nt

and T

rack

Te

nsion

Adjus

t-

ment.

To

R

emo

ve S

pro

cket Seals

and

Bearings

•

Spro

ck

et

seals

and

bear

i

ngs

are

located

on

each

end of the

tr

a

ctio

n

belt

take-up

assembly

and

the

d

rive

sp

ro

cke

t

ass

embly

drive

shafts.

To

replace

th

e

seals

or b

ea

ri

ngs

it

will

be

necessary

to

remove

the

traction

be

lt

tak

e

-up

assembly

or

the

drive

sprocket

assembly

as

de

s

cribed

in

the

applicable

paragraph

.

To

Remove

Drive Sprocket Ass

embly

•

Remove

the

hood

an

d h

ea

dlight

assembly

and

set

the

machine

on

its

right-

h

an

d

side.

Always

disconnect

spark

plug

wires

before

working

on

th

e engine

or

drive

elements.

•

Remove

the

lockn

ut

se

cur

ing

the

cha

in

cover

and

remove

the

chain

cover

to

p.

~t

...

SiMI31

SERVICE

AND

REPAIR

I~

• Remove the

lower

sprocket

from

the

drive

sprocket

shaft

and

remove

the

sprocket

and chain

as

described

in

paragraph

To Remove

Drive

Chain.

• Remove

the

bogiewheel and

support

assemblies.

Refer

to

paragraph

To Remove Bogie Wheel and

Support

Assembly.

• Remove the

traction

belt

take-up

assembly.

Refer

to

paragraph

To Remove

Traction

Belt

Take-

Up

Assembly.

• Using a

screw

driver,

carefully

pry

theoil

seals

(figure 14) away

from

the

bearings

at

each

end of

the

drive

shaft.

Figure 14

• Remove the

carriage

bolts

and

nuts

securing

the

bearing

retainer

to

the

chain

case

side

of the

main

frame.

Remove

the

retainer.

During

reassembly

apply No. 2

lithium

bearing

grease

to the

bearing

retainers.

• Move the

drive

shaft

and

spr

ocket

assembly

toward

the chain

side

until

the

opposite end of the

shaft

clears

the

bearing

retain

er

. Remove

the

drive

sprocket

assembly.

• To

replace

the

sprockets,

remove

the

ball

bearing

and oil

seal.

Remove

the

screws

and nuts

securing

the

support

plate

and

sprocket

tothe

drive

shaft

and

sprocket

plate

assembly.

Remove the

sprocket.

16

• Remove the

screws

and nuts

securing

the

sprocket

plates

to the

idler

wheel. Remove

the

idler

wheel by

stretching

wheel

over

the

sprocket

plate.

•

Reassembly

is

the

reverse

of

removal.

During

reassembly

follow

instructions

outlined

in

the

para-

graphs

Track

TensionAdjustment,

Track

Alignment

and

Drive

Chain Adjustment.

To

Remove

Traction Belt

• Remove the bogie

assemblies.

Refer

to

para-

graph

To Remove Bogie Wheel and Support

As-

sembly.

• Remove the

traction

belt

take-up

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 tracti."on

belt.

•

Reassembly

is

the

reverse

of

removal.

During

reassembly

follow

instructions

given

in

paragraphs

Traction

Belt

Alignment, 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

trac-

tion

belt

alignment

and then complete the

traction

Traction Belt Tension Alignment

• Set the snowmobile on a

level

surface

and

raise

the

back

end

so

the

traction

belt

clears

the ground.

• Stand to

rear

of

sled

and

visually

checkthe

space

between the

frame

tunnel and the edges ofthe

trac-

tion

belt.

On

a

properly

aligned

track

this

space

should be the

same.

1002472

()

AMF SKI-DADDLER Quick start guide

Popular Offroad Vehicle manuals by other brands