Amf Mark iv sd15p1da User manual

PARTS

AND

SE

RVICE

MANUAL

SKI-DADDLER

SNOWMOBILES

MARK

IV

[SD15P1DA]

MARK

V

[SD1BE2DA]

1969-1970

WESTERN TOOL DIVISION

Des Moines, Iowa 50302

AMF INCORPORAT

ED

PART

NO

.

37851

REVISED

and

REPRINTED

IIINI=

107n

.---------

WARRANTY

Warranty

service policy

is

printed

below

and

on the

warranty

registration card included

with

the

unit. The registration card must be

filled

in

and

mailed

to

the

manufacturer.

The card

is

postage

paid

.

Warranty

service

will

be

handled

by

all

authorized

AMF

Ski.Daddler dealers.

SERVICE

---------,

• •

SNOWMOBILES

• •

Your

Manual

No.

_________

is

a registered number.

Additional

parts

and

service

information

will

automatically

be sent

to

you.

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

~~

WARRANTY

CERTIFICATE

~t.

~~

AMF

SKI-DADDLER

SNOWMOBILE

~~

;

~

AMF

WESTERN

TOOL

DIVISION

warrants this vehicle

to

the first retailpurchaser

to

be

free from defects in

mao

~

terial

and

workmanship for a period

of

ninety days from its first operation (thirty day limit on commercial use

and

f~

thirty day limit on rental service). This shall

be

limited to replacing free

of

charge, F.O.B., Des Moines, Iowa,.any

~

~)

defective

part

provided that:

~,

~

1.

Vehicle has

not

been subject to accident or misuse.

;

~

2. No repairs or alterations have been made outside

of

our factory or factory approved service station in any

~

respect which in our judgment affects its condition or operation.

f~

3. Defective parts

must

be

returned by authorized dealer within

30

days after failure.

~

~)

4.

That

our examination

of

the

part

has disclosed to our satisfgction the defect.

r.;

.~

5.

Warranty does

not

apply,

if

the vehicle in question has been used by

an

authorized dealer or any otherperson

'\

.

~

prior

to

the original retail sale.

~

This warranty does

not

cover normal wear or apply

if

the sled has been subject

to

misuse, competition raci

,!g,

negli·

f~

gence, accident, or submersion under water, or operated on any surface other

than

snow or ice.

~

~)

AMF

WESTERN

TOOL

DIVISION

shall not

be

responsible for damage in transit or handling by any common

~,

~.

contract carrier.

\Jj Under no circumstances, within or without the warrantyperiod, will the Company

be

liable for damages, for loss

of

~f"

~~

use, or damages resulting from delay or any consequential damages.

f""

\~'

This warranty is in lieu

of

all other warranties expressed or implied,

and

all other obligations or liabilities on the

'

~~"i

~

part

of

AMF

WESTERN

TOOL

DIVISION.

The Company reserves the right

to

incorporate changes in design into

f'"

this product without obligation

to

make

these changes on units previously sold.

~

IMPORTANT

f~

~~

While

the

warranty

covers defects in material and

workman-

~~

~)

ship, certain

maintenance

items

as

listed

below

are considered

~,.

f4

normal

operating

expense items and are

not

covered

under

the

fl

~)

warranty.

?~

~

1. Engine

tune-up

cleaning

or

replacement

of

spark plugs.

clutch

or

traction

belt

damage

due

to

running

engine

at

~

~~

2. Ski

Alignment.

high

RPM

on

kickstand,

or

with

variable speed belt

~.

removed.

3 Brake, variable speed,

or

traction

belt

adjustment,

or

~

~)

. variable speed

belt

replacement. 7. Broken windshields.

f~

f4

4.

Brake

lining

or

ski

wear

rod replacement.

8.

Any

modifications

other

than

factory

recommendations.

~

~)

5. Paint,

body

dents,

damaged

fiberglass, and

chrome

Of

g. Use

of

sled

for

competition

racing

will

void

warranty

f~

~

trim

damage

due

to

use

10

. Traction belt failure

due

to

misalignment

or

abuse.

~

~)

6 Engine

damage

due

to

lack

of

suffiCient

od

In fuel

mlx-

r.;

l

'"".

000"'"''

",I.

'"" 1o,"

wbo,","'

,d,o"mo",.

"'

~

..

~

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

Include

the

complete

(8

digit)

model

number

as

shown

on

Model

Plate

when

ordering

parts

or

asking

for

information.

Due

to

slight

engineering

changes,

this

is

for

identification

purposes

only

.

J

)

r""-

~

GUARANTEE

FLAT-RATE

LABOR SCHEDULE

Models

MARK

IV

(SD15Pl0A)

MARK

V

(SD18E20A)

1.

Remove

and

replace

chain

case

cover

2.

Remove

and

replace

chain

and

adjust

tension

3.

Remove

and

replace

driven

clutch

or

bearings

or

V

-b

elt

•..............•....•.•.....•....

4.

Remove

and

replace

drive

clutch

5.

6.

7.

8.

9.

10.

11.

12.

Remove

and

replace

engine

mount

and/or

strap

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

.

Remove

and

replace

engine

mount

and/or

strap

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

.

Remove

and

replace

drive

sprockets,

drive

shaft

or

bearings

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

.

Remove

and

replace

traction

belt

(endless)

and

adjust

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

..

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

..

Remove

and

replace

rear

idler

shaft

assembly

or

bearings

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

.

..........

.

Remove

and

replace

rear

support

arms

(2)

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

.

Remove

and

replace

throttle

cable

Remove

and

replace

brake

cable

Remove

and

replace

bogie

support

half

(lor

both)

1/4

hour

1/4

hour

1/2

hour

1/2

hour

1

hour

(Mk IV)

2

hours

(Mk

V)

1

hour

2

hours

1/2

hour

1/2

hour

1/4

hour

1/4

hour

1/2

hour

13.

Remove

and

replace

bogie

wheel

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

1/4

hour

14.

Remove

and

replace

steering

spindle

1/4

hour

15.

Remove

and

replace

spindle

arm

............................•..............................

......

1/4

hour

16.

Remove

and

replace

carburetor

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

....

...

.

...

.•........

....

......

.........

...

....

..

...

3/4

hour

1

~t!Mlal

CONT

E

NTS

I~

T

AB

LE

OF

CONTENTS

INTRODUCTION . . . . . .

PREDELIVERY

INSTRUCTIONS

In

stall Ski

Assembly

. . . .

In

stall Windshield Asse

mbly

Activate Battery-Mark V

Only

Fuel Mixture Instructions

Lubrication . . . . .

SERVICE

AND

REPAIR

Hood Removal

and

Installation

Hood

Assembly

Repair . . . .

Replace Lamp

Assemblies.

. .

Steering

and

Ski

Assembly

Alignme

nt

To

Remove

Drive

Chain.

. . . . . .

Drive Chain

Adjustment

. . . . . .

To

Remove

Variable

-S

p

ee

d 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

-Mark V Only

To

Remove Engine

and

Support

Assembly-Mark

IV

Only.

To

Remove

Engine

and

Support

A

ssemb

ly-Mark V Only

To

Remove

Gas

Tank

..

To

Remove Muffler

To

Remove

Bogie

Wheel

To

Remove

Bogie

Wheel

and

Support

A

ssemb

ly

To

Remove Bogie

Wheel

Tor

sion Spring

s.

.

To

Remove

Traction Belt Take-

Up

Assembly

To

Remove Sprocket Seals

and

B

ea

rings

To

Remove

Drive Sprocket Asse

mbly

To

Remove Traction Belt

Traction Belt

Adjustment

. .

Spark Plug Interchangeability

Wiring

Diagrams

Troubleshooting . . . .

ILLUSTRATED

PARTS

LIST

2

P

age

.3

. 3

.4

. 5

.5

. 5

. 6

. 7

.7

. 8

.8

. 9

.9

10

II

J2

J3

13

J4

J5

J6

• J

)

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 AMF

MARK

IV

(SDI5PI0A) and

MARK

V (SDI8E20A)

Ski-Daddler

snowmobiles.

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.

If

the

information

in

this

manual

is

notapplicable to

the

Mark

IV and

Mark

V

models,

the

exceptions will

be

noted and

the

correct

information

for

the

parti-

cular

model will

be

given.

PREDEL/VERY

INSTRUCTIONS

The 1970

Ski-Daddlers

are

shipped

completely

as-

sembled

except

for

thewindshield

assembly,

the

ski

assembly

and on the

electric-start

models,

the

battery

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.

IMPORTANT: The

owner

must

retain

the Ski-

Daddler

Inspection

Record,

Form

No.

4477QA.

This

form

must

be shown to

the

dealer

should any

claim

arise

under

the AMF Guarantee.

Install Ski

Assembly

• Remove

the

locknut and

screw

at

the

spring

mounting

bracket

(figure 1).

•

Place

the

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

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.

3

INTRODUCTION

Figure I

•

Repeat

Install

Ski

Assembly

procedures

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.

If

alignment

is

necessary,

refer

to the

Steering

and

Ski Alignment

procedures.

MOUNTING

STRIP,

RH

MOUNTING

STRIP,

lH

,W

I

NOSH

I

ElO

TR

1M

\--

--"

(8

TOE

OUT

0-

TO

liZ-INCH

MAXIMUM

Figure 2

Install

Windshield

Assembly

•

Remove

the

screws

securing

the

left-

and

right-

hand mounting

strips

to

the

hood.

Remove

the

mounting

strips.

•

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

and

windshield

to

the

hood

assembly

starting

at

the

center

and

working

to

the

sides.

•

Engage

the

ends

of

the

mounting

strips

in

the

trim

strip

on

the

windshield

and

then

tighten

the

screws,

again

starting

at

the

center

and

working

to

the

sides.

NOTE:

Check

mounting

strips

for

sharp

edges

or

corners.

Use

a

fine

tooth

file

to

smooth

all

edges

and

corners.

Activate

Battery-Mark

V

Only

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood

Removal

and

Installaion.

Before

activating

the

12

-v

olt

storage

battery,

disconnect

the

battery

cables

and

remove

the

battery.

Activate

the

battery

in

accordance

with

the

instruc-

tions

contained

in

the

battery

package.

Reinstall

the

battery

as

follows:

•

Place

12-volt

battery

On

the

battery

support

plate

with

positive

(+)

terminal

post

forward

(see

figure

3).

•

Attach

the

positive

(+)

battery

cable

and

the

RED

wire

lead

(from

cigarette

lighter)

to

theposi-

tive

terminal

post.

•

Attach

the

negative

(-)

battery

cable

and

the

BLACK

wire

lead

(from

cigarette

lighter)

to

the

negative

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.

4

Figure 3

-Mark

V

Only

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.

Fuels

containing

additives

are

not

recommended

for

use

in

Ski-Daddler

engines.

For

mixing

with

gaso-

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

w

ell

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

the

Fuel

Mixture

Chart.

Never

use

gasoline

left

over

from

the

summer

or

)

c

FUEL

MIXTURE

CHART

GASOLINE-Oil

RATIO

2

0

I

1-1/2

L V

./

V

P

I

N

1/2

T

S

./

~

/

~

2 3 4 5

GASOLINE.

GALLONS

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

addadditional

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

locat

ed

under

the

gas

lid

and hinge

assembly.

Lubrication

Refer

to

the

lubrication

chart

for

lubrication

of

grease

fittings,

type

of

lubricant

and

frequency.

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

~I

SERVICE

AND

REPAIR

leMla~

assemblies

and

then

remove

the

hood and

headlight

assembly

by

lifting

rear

section

first.

• To

install

thehood 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

headlight

lamp

assembly,

simply

raise

the

headlight

assembly,

remove

the

screws

securing

the

cover

assembly

and

remove

the

cover

assembly.

Remove

the

defective

head-

light

and

replace

with new

lamp

assembly.

See

illustrated

parts

list.

LUBRICATION

CHART

PART

LOCATION

TYPE

OF LUBRICATION FREQUENCY

STEERING SPINDLES GREASE

ZERK

FITTINGS ON LOW-TEMPERATURE GREASE 20 HOURS

SPINDLE HOUSINGS

DRIVE

CHAIN

CHAINCASE HOUSING

NO.2

LITHIUM

BEARING GREASE 20 HOURS

BOGIE WHEELS GREASE

ZERK

FITTING

IN LOW-TEMPERATURE GREASE 20 HOURS

CENTER OF BOGIE WHEEL

SPROCKET BEARINGS REAR SPROCKETS

NO.2

LITHIUM

BEARING

GREASE 40 HOURS

STEERING COLUMN U-STRAP

AND

WEARPLATES

NO.2

LITHIUM

BEARING GREASE AS REQUIRED

AT

ROLL

BAR

5

~t.aMlal

SERVICE

AND

REPAIR

I~

Taillight.

Remove

taillight

lens

and

cover,

or

lift

the

seat

assembly

to

expose

the

rear

console

assembly

containing

the

twin

taillight

bulbs.

Re-

move

the

defective

bulb

and

replace

with

a new

bulb.

See

illustrated

parts

list.

Steering

and

Ski

Assembly

Alignment

Good

steering

ability

requires

that

the

skis

be

properly

set

and

aligned

with

the

sled

body when

the

steering

hand1:e

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-

cedllre

for

the

opposite

ski.

Figure 4

6

• Move

the

affected

ski

into

proper

alignment

and

recheck

measuring

points

to

insure

that

th

e

skis

toe

out

0-

to

1/2-

inch

maximum

at

the

front

end

and

are

in

the

same

orientation

with

the

sled

body

as

shown

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

en

d

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:

•

Remove

screw

(5,

figure

5),

washers

and

locknut

(6)

securing

spindle

tube

assembly

(7)

to

spindle

arm

(8).

Figure 5

•

Remove

spindle

arm

(8)

and

rotate

ski

and

spindle

tube

one

notch

in

the

required

direction;

replace

and

secure

spindle

arm

to

the

spindle

tube.

Apply 20

foot-pounds

torque

to

the

locknut

(6).

•

Recheck

the

skis

for

proper

toe

out

and

align-

ment

as

previously

described.

To

Remove

Drive Chain

•

Remove

the

hood

and

headlight

assembly.

Refer

to

Hood

Removal

and

Installation.

)

c

CAUTION!

Always

disconnect

spark

plug

wires

before

working on

the

engine

or

drive

elements.

•

Release

the chain

cover

straps

and

remove

the

chain

cover

tou.

• 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 chaintension. During

reassem-

bly, apply 30 foot-pounds

torque

to the bolt (1).

• Remove the

cotter

pin,

slotted

nut and

washer

securing

the top

sprocket

to the

driven

clutchshaft.

Rell10ve

the

top

sprocket

and chain

together.

During

reassembly,

add No.2 Lithium

bearing

grease

to

the

chain

case.

•

Reassembly

is

the

reverse

of

removal.

Perform

drive

chain

adjustment

procedures.

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:

•

Release

the

chain

cover

straps

and

remove

the

chain

cover.

• Check chain

for

proper

slack.

If

adjustment

is

required,

loosen

the

screws

(1)

securing

the

cam

blocks

(2)

on

each

side.

• Rotate the

cam

(3)

counterclockwiseto

tighten

or

until the chain

is

properly

tensioned. Holdthe

cam

in

this

position

while tightening the

cam

block

screws

(1)

on

each

side.

Be

certain

the

lateral

alignment

between the

drive

clutch and the

driven

clutch

(4)

is

maintained while the

cam

block

screws

are

tightened.

• Recheck chain

tension

before

replacing

the chain

case

cover.

To

Remove

Variable-

Speed

Drive Belt

• 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)

securing

the

clutch

rod

tensioner

(11)

7

~I

SERVICE

AND

REPAIR

leSaaij

to the main

frame.

During

reassembly,

apply 10

foot-pounds

torque

tel>

the locknut (9).

•

Push

tlte

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)

and

washers

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 away

from

the chain

case.

• Remove the

variable-speed

drive

belt.

NOTE:

Variable

-s

peed

drive

belt

installation

pro-

cedures

are

the

reverse

of

removal

except

that

the

belt

must

first

be

placed

around the

driven

clutch

and then around the

drive

clutch.

After

installation,

perform

the

drive

chain

adjustment,

variable-speed

belt

adjustment

and the

drive

clutch

alignment

procedures.

Variable

-S

peed

Drive Belt

Adjustment

Proper

tension

for

a new

drive

belt

should be

ob-

tained

whenthe clutch

centers

are

set

apprOximately

10-3/4

inches

apart

(see

figure

6).

Proper

tension

for

a

drive

belt

that

has

been

used

is

obtained when

opposite

sides

of

the

belt

can

be squeezed, between

the

drive

clutches

to the following dimensions:

Mark

IV

Mark

V

2-3/4

to

3-1/4

inches

4 to

4-1/2

inches

The

measurement

must

be

taken

between the top

and bottom outside

surfaces

of the

belt

a..T1d

as

cl

ose

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.

Use of

belt

dreSSing will void the

owner's

guar-

antee

as

belt

slippage

is

a

safety

feature

which

prevents

overstressing

the

drive-system

compo-

nents.

• To

adjust

drive

belt

tension,

loosen

the locknut

(9,

figure

5)

securing

the

clutch

rod

tensioner

to

the

main

frame

assembly.

NOTE:

If

the

drive

belt

is

wearing

unevenly,

check

drive

belt

alignment

as

described

in

Drive

Clutch

Alignment

procedures.

~eSial

SERVICE

AND

REPAIR

I~

• Move the

driven

clutch

(4)

in

the

direction

re-

quired

to

obtain

proper

belt

tension. Hold

this

position

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.

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

torqu

e 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

Mark

IV

drive

clutch,

remove

the

clutch

adapter

bolt

and

washer

securing

the

drive

clutch,

if

necessary

use

aclutchpuller.

During

re-

assembly,

apply

70

foot-pounds

torque

tothe

clutch

adapter

bolt.

NOTE: To

remove

the

Mark

V

drive

clutch,

flatten

the

tangs

on the

lock

plate

and

remove

the

clutch

bolt,

lock

plate,

Belleville

washer

andthe r.etaining

washer.

During

reassembly,

apply

70

foot-pounds

torque

to

the

clutch

bolt.

•

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.

{

CAUTION

I

Always

disconnect

spark

plug

wires

before

working on the engine

or

drive

elements.

8

• Remove the clutch

guard.

• Loosen the engine holddown nuts

securing

the

~ngine

supports

to the engine mount

straps

as

illustrated

in

figure

6.

•

Place

a

straigh

ted

ge on

the

fixed

face

of

the

drive

clutch and move

the

engine until

the

offset

between the

straighte

dge 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

whentightening

the engine holddown nuts.

DIMENSION MARK

IV

MARK V

DR

I

VEN

CLUTCH

®

INCHES

0.240 0.30

L

DRIVE

CLUTCH

t

VIEWe~

Figure 6

To

Remove

Driven Clutch

VIEW"

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

Always

disconnect

the

sparkplugwires

before

working on

the

engine

or

drive

elements.

• Disconnect

brake

cable

at

brake

mounting

bracket

and

at

brake

actuating

lever.

J

)

c

• 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.

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

(7)

as

required.

Tighten

jam

nuts.

Figure 7

To

Remove Carburetor

To gain

access

to

the

carburetor,

remove

the

con-

sole

door

assembly

by

turning

the

door

fastener

counterclockwise to

release

the

door

lock.

• Loosen

throttle-

and

choke-control

cable

adjust-

ment

screws

and

release

both

cables

at

carburetor

(see

figure

8).

Do

not

misplace

throttle-wire

reinforcement.

• Remove the

three

screws

.

securing

the

air

intake

filter

(figure}O) and choke

control

bracket

mounted

on

the

Mark

IV

carburetor

'only.

•

Release

the

throttle

extension

spring

and hook

at

the

carburetor

throttle

control

lever.

9

SERVICE

AND

REPAIR

geld

•

Release

the

hose

clamp

and disconnect

the

im-

pulse

line

at

the

carburetor.

Wipe up any

spilled

gasoline

immediately.

•

Release

the

tank-to-carburetor

gas

line

(figure

10). Wipe up any

spilled

gasoline

immediately.

•

Release

the

carburetor-to-tank

recirculating

gas

line

at

the

recirculation

elbow. IMPORTANT:

Be

certain

to

note

the

position

of the gas

lines

to

insure

proper

reassembly.

Wipe up any

spilled

gasoline

immediately.

Figure 8

-Mark

V Only

• Remove

the

metric

nuts

securing

the

carburetor

to the intake manifold and

remove

the

carburetor.

NOTE:

Do

not damage

gaskets

when remOving

carburetor.

When

replacing

carburetor

on

the

Mark

V

sleds,

do not

remove

the

throttle

bracket

unless

it

is

necessary

due

to

a damagedb:racket

or

when

replacing

the

gaskets.

•

Installation

is

the

reverse

of removal. Adjust

carburetor

as

deSCribed

in

Carburetor

Adjustment

procedures.

Carburetor Adjustment

The

carburetor

used

on

the

Mark

IV

and

Mark

V

Ski-Daddlers

is

a

Tillotson

Model

HD

carburetor

equipped with a

recirculation

system

for

better

sled

performance.

NOTE:

Never

run

engine with

the

~t'·':4Mlal

SERVICE

AND

REPAIR

I~

carburetor-to-tank

recirculating

gas

line

discon-

n

ected.

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.

NOTE: To

gain

access

to

the

carburetor

adjust-

ments,

remove

the

console

door

assembly

by

turning

the

door

fastener

cOWlterclockwise

to

release.

• TO ADJUST CARBURETOR -

Close

the

high-

speed

jet

shown

in

figure

8

(DO

NOT FORCE).

Then

open

as

shown

in

the

carburetor

adjustment

chart,

figUre 9.

SKI-DADDLER

MODEL

CARBURETOR

MK

-IV

Tillotson

HD

39A

(AMF No. 37258)

MK-V

Tillotson

HD

39A

(AMF No. 37258)

•

Disconnect

the

battery-to-solenoid

positive

(+)

cable

at

the

battery

to

prevent

sparking

and

possible

shorting.

•

Disconnect

the

sOlenoid-to-starting

motor

cable

at

the

starting

motor.

•

Back

off

the

upper

nut

securing

the

battery-to-

starting

motor

negative

(-) groWld

cable.

•

Back

off

the

two

nuts

securing

the

starting

motor

assembly

to

the

engine.

Remove

the

groWld

wire

from

the

engine

wiring

harness

and

the

battery-to-

s

tarting

motor

groWld

wire

attached

to

the

upper

stud

and

remove

the

starting

motor

assembly.

•

Reassembly

is

the

reverse

of

removal.

CARBURETOR

ADJUSTMENT

LOW-SPEED

JET

HIGH

-SPEED JET

(TURNS) (TURNS)

1-1/8

+

1/8

Open

-0

3/4

:

~/8

Open

1-1/8

+

1/8

Open 1 +

1/8

Op

-0 -o

en

Figure 9

•

Turn

the

low

speed

jet

(idle-mixture

screw)

shown

in

figure10

'

all

the

way

in

(DO NOT FORCE),

then

open

as

shown

in

figure

9

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-speed

jet

to

adjust

for

idle

speed.

NOTE:

Figure

10

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

readju

st

the

wire

as

required

to

open

the

throttle.

To

Remove

Starting Motor

Ass

emb

ly-Mark V Only

•

Remove

the

hood and

headlight

assembly.

Refer

to

Hood RemOVal and

Installation.

Always

disconnect

spark

plug

wire

before

working

on

the

engine

or

drive

elements.

Figure

JO

)

c

To

Remove Engine

and

Support

Assembly-Mark

IV

Only

• Remove

the

hood and headlight

assembly.

Refer

to Hood Removal and Installation.

[

C~~TION

1

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

parag~aph

To Remove

Drive

Clutch.

• Loosen the flexible tube

clamps.

securing

the

muffler

exhaust

tube to

the

engine exhaustmanifold

and

release

the

exhaust tubes.

Figure

11

• 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.

11

SERVICE

AND

REPAIR

PSld

• Remove

the

heat

shield

located

between

the

engine and the muffler. Remove theattaching

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.

• Lift the engine until

the

engine mounting

straps

clear

the

studs

shown

in

figure

11. Rotate

the

engine counterclockwise and

remove

the engine

toward

the

rear

and

clear

of the

sled.

• Remove the

carriage

bolts,

washers

andlocknuts

securing

the mounting

straps

to the engine

base.

Remove the mounting

straps

and

bar

washers.

NOTE: During

reassembly,

the mounting

straps

and

bar

washer

must

be

secured

to

the

engine

base

before

installing

the

replacement

engine.

•

Installation

procedures

are

the

reverse

of

removal.

To

Remove Engine

and

Support

Assembly

-Mark V

Only

• Remove the hood and headlight

assembly.

Refer

to Hood Removal and Installation.

!

CAUTION

I

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

Drive

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.

• Remove the

starting

motor

assembly.

Refer

to

paragraph

To Remove

Starting

Mot0r Assembly.

~p.!Mlal

SERVICE

AND

REPAIR

I~

• 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 bolts (10,

figure

12),

spacers

and

nuts

securing

the

steering

linkage to the

steering

column

arm

(9). During

reassembly,

apply15foot-

pounds

torque

to the nuts

securing

the

steering

linkage.

Figure

12

• Remove the bottom

cotter

securing

the

steering

column to the

main

frame

steering

column

support.

•

Oisconnect

the

wiring

harness

at

the

battery,

electrical

panel,

rear

console and engine.

Release

the

wire

V

-clips

in

the

tool box and

at

the foot

rest

and

remove

the

wiring

harness.

• 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

base.

Remove

the

straps

for

reassembly.

During

12

reassembly,

apply

25

foot-pounds

torque

to

thenuts

securing

the engine

base.

•

Installation

is

the

reverse

of

removal

.

To

Remove

Gas

Tank

• Remove the hood and headlight

assembly.

Refer

to Hood Removal and

Installation.

!

CAUT~ON

1

Always

disconnect

spark

plug

wires

before

working on

the

engine

or

drive

elements.

• Check

gas

cap and

indicator

assembly

tobe

cer-

tain

tank

is

empty,

or

nearly

empty.

• Remove the

gas

cap and

indicator

assembly

(1,

figure 12).

• 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) )

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

the

main

frame.

IMPOR-

TAm:

Do

not damage the

gas

tank

outlet

(5) when

removing

the tank.

L

CAUTIO~:

I

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 (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

Installation.

c

Always

disconnect

the

spark

plug

wires

before

working on the engine

or

drive

elements.

• Loosen the flexible tube

clamp

securing

the

flexible exhaust tube to the

muffler

and

release

the

tube. NOTE: The

Mark

V Ski-Daddler

has

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

spark

plug

wires

before

working on the engine

or

drive

elements.

•

Place

Ski-Daddler

on the kickstand.

• Remove

the

locknut (3,

figure

13)

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.

Figure

13

VICE

AND

REPAIR

To

Remove

Bogie

Wheel

and

Support

Assembly

Always

disconnect

the

sparkplugwires

before

working on the engine

or

drive

elements.

•

Place

the

Ski-Daddler

on the kickstand.

• Remove the

screws

(1,

figure

13) and

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

thebogie

wheel

support

halves.

• 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 ofthe

springs

to

facilitate

re-

assembly.

•

Reassembly

is

the

reverse

of

removal.

To

Remove

Traction Belt Take-Up

Assembly

•

Place

Ski-Daddler

on the kickstand.

• 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

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.

SERVICE

AND

REPAIR

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

TensionAdjust-

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.

Always

disconnect

spark

plug

wires

before

working on the engine

or

drive

elements.

•

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

screwdriver,

carefully

pry

the

oil

seals

(figure

14)

away

from

the

bearings

at

each

end of

the

drive

shaft.

14

Figure 14

• Remove the

carriage

bolts

andnuts

securing

the

bearing

retainer

to the chain

case

side

of the

main

frame.

Remove the

retainer.

• Move

the

drive

shaft

and

sprocket

assembly

toward

the chain

side

until the c>pposite end of

the

shaft

clears

the

bearing

retainer.

Remove the

drive

s

procket

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.

•

Reassembly

is

the

reverse

of

removal.

During

reassembly

follow

instructions

outlined

in

the

para-

graphs

Track

Tension Adjustment,

Track

Align-

ment, and

Drive

Chain Adjustment.

To

Remove

Traction Belt

•

Place

the Ski-

Daddler

on

the

kickstand.

• Remove the bogie

assemblies.

Refer

to

para-

graph

To Remove Bogie Wheel andSupport

Assem-

bly.

• 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.

c

• 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

trac-

tion

belt

alignment and then complete the

traction

belt

adjustment

procedures.

Traction Belt

Alignment

• Set the snowmobile on the kickstand on a

level

surface.

• Stand

to

rear

of

sled

and

visually

checkthe

space

between the

frame

tunnel and the edgesof the

trac-

tion

belt.

On a

properly

aligned

track

this

space

should be the

same.

•

If

the

track

is

not

centered,

loosen

thetwo

lock-

nuts (1,

figure

15)

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.

Never

run

the engine

inside

a building

without

first

opening

all

doors

andwin-

dows to

insure

proper

ventilation.

• With the snowmobile on

its

kickstand,

start

the

engine. Allow

track

to

rotate

several

turns

and then

recheck

track

alignment

to

ensure

that

proper

align-

ment

is

maintained.

•

After

track

alignment

is

complete, tighten

all

locknuts

(1)

and then

check

traction

belt

tension

as

described

in

the following

paragraph.

J5

VICE

AND

REPAIR

Figure

J5

Traction Belt Tension

Adjustment

IMPORTANT: Always check the

traction

belt

for

proper

alignment

before

performing

the

traction

belt

"tension

alignment

procedures.

• Set the snowmobile on a clean,

flat

surface.

Do

not

use

the

k~ckstand.

NOTE: A

properly

tensioned

track

should have a

1

to

1-1/

4-inch

sag

at

the

approximate

top

center

of the

track.

This

can be

determined

as

follows:

•

Rest

a

straight

bar

(figure 16) ofsufficientlength

along the top

surface

and

near

the

edge of

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 opposite

side

andnote the

difference,

if

any,

in

the

track

tension.

•

If

adjustment

is

necessary,

loosen

thetwo

lock-

nuts (1,

figure

15) on

each

side

of the

sled

just

sufficiently to

allow

movement ofthe

belt-adjusting

angle (2).

•

Turn

the

adjusting

screws

(3)

clockwise

to

tighten and counterclockwise

to

loosen

until

proper

track

tension

is

achieved. IMPORTANT: Adjust

both

screws

(3)

equally

so

as

not to

disturb

the

track

alignment.

~eM131

SERVICE

AND

REPAIR

I~

1::

CAUTION

Never

run

the

engine

inside

a

building

without

first

opening

all

doors

and

win-

dows

to

insure

proper

ventilation.

TRACTION

BELT

Figure

J6

•

Set

the

snowmobile

on

its

kickstand

and

start

the

engine.

Allow

track

to

rotate

several

turns

and

then

repeat

the

track

tension

adjustment

procedure

to

ensure

that

proper

tension

is

maintained.

•

Retighten

the

locknuts

(1)

on

both

sides

of

the

snowmobile.

Spark Plug Interchangeability

The

following

tabulation

is

provided

to

show

correct

spark-plug

interchangeability.

Bosch

Champion

AC

Autolite

Lodge

NGK

M175T1 UK-10 M84 BZ3 HTN18

AB-o

M225T1 K-9 M83 HTN18

A-7

M240T1 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.

J6

ENGINE STOPS.

Fuel

tank

empty; fuel flow

ob-

struc

ted;

igni

t

ion

system

faulty.

Spark

plug(s)

fouled

or

dirty.

Engine too

hotandpis

t

ons

sei

zing;

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-carbure

t

or

line

is

con-

nected

to

the

OUT

fitting

on

the

gas

tank

outlet

and

to

the

inlet

fitting

on

the

carburetor.

The

recir-

culating

line,

carburetor-to-tank

must

be

connected

to

the

IN

fitting

on

the

gas

tank

outlet

(figure

12)

and to

the

recirculating

elbow

(

figure

8).

ENGINE

OPERATES

IRREGULARLY.

Spark

plug

loose,

fouled

or

faulty;

ignition

switch

wiring

grounded;

carburetor

trouble.

Engine

holddown

bolts

loose;

carburetor

dirty.

Ignition

timing

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.

Car

bon

deposits

in

cylinder.

ENGINE BACKFIRES THROUGH CARBURETORS.

Carburetor

fuel-supply

channel

clogged.

ENGINE BACKFIRES THROUGH EXHAUST.

In-

correct

or

faulty

spark

plug(s);

fa

ul

ty

ignition

coil

or

condenser;

loose

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-bracket

bolts

on

roll

bar

too

tight

or

too

loose.

Spring,

U-bracket

loose.

BRA-KES.

Excessive

play

in

handbrake

due to

loose

brake

cable

or

worn

pads

.

)

AMF MARK IV SD15P1DA User manual

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