BOMBARDIER ski-doo Alpine 1975 User manual

YOUR KEY
TO WINTER
In the past sixteen years, over seven million people have
discovered
that winter can be both fun and enjoyable. The key of
course is to do as
you have done ... participate in the exciting,
invigorating sport of snowmobiling. We commend
your decision,
and
thank you for selecting the Ski-Doo snowmobile as your
partner in the many winter seasons to come.
To
truly enjoy this wonderful sport, we urge you to join your
local snowmobile club. You will find its activities and trail
systems are planned
for both fun and safety.
If your area does not have such benefits, you can find added
social
enjoyment by forming a new club and assisting with the
layout, construction and marking of a snowmobile trail. You
will find the activities both stimulating and rewarding. And only
you can make it happen.
We also suggest
that you enroll in a safety/driver education
program. The benefits derived are invaluable
toward the safe and
saneoperation of any snowmobile.
We, at Bombardier
Limited, fully realize the ramifications
associated with the sport, and toward this end this manual is
prepared.
Please take the time to have every member of your
family read and fully understand the content of this manual ...
Ride safe ... and have fun!
Laurent Beaudoin,
President -Executive
Officer,
Bombardier Limited.

®
This manual has been published by the
TECHNICAL INFORMATION CENTRE
SERVICE DEPARTMENT
BOMBARDIER LIMITED
VALCOURT, QUEBEC, CANADA.
Bombardier
Elite
Everest
"The following are trademarks of Bombardier
Limited.
Ski-DoD T'NT
Ski-Boose Elan
Nordic Blizzard
Alpine Carry-Boose
PA TENTS and DESIGNS
This vehicle is covered by one or more of the
following patents and design registrations.
Canadian Patents: 605, 317 710, 592 - 724,
395 - 853, 505 - 895,749 - 897, 747 - 914,
457 - 916, 204
United States Patents: 2,899,242 - 3,066,546 -
3,536,153 - 3,637,254 - 3,666,323
3,673,884 - 3,693,884 - 3,693,992 -
3,704,918_
Canadian Designs: 01/217 F/28172 -D1/249
F/31317 and 316 -032,479 - 032,535 -
032,655 to 657 - 032,661 to '669 - 33,982
-33,933 - 34,006 and '007.
United States Design Patents:
Des. 221,332 to '334-
Des 221,637 and '638-
Des. 222,244 to '247
Others: Swedish Design No. 6038-
Swiss Design No. 104,756-
Norwegian Design No. 51,444.
Other patent and design applications pending.
WHAT YOU SHOULD KNOW
BEFORE FIRST RiDE 2
SERVICE
AREAS 3
CONTROLS/INSTRUMENTS ...... 4, 5
fUEL MIXING 6, 7
--~---~---_.~~
BREAK-IN PERIOD 7
PRE-START
CHECK 8
STARTiNG PROCEDURE.. 9
LUBRICATION " .. 10,11,12
MAINTENANCE 13,14,15,16,17
EMERGENCY GUiDE 18
TROUBLE SHOOTING 19,20
OFF-SEASON STORAGE , . 21,22
PRE-SEASONPREPARATION 23
SPEC! FICATIONS 24
WARRANTY .. "25,26,27
All rights reserved©Bombardier Limited 7974

2
To many of us, Winter is a revealmg ex-
penence Weather, atmospheric condi-
tions, snow surfaces, individual driving
habits and vehicle usage have consider-
able affects We ask that familiarize
yourself
with them the owner's
manual, it has been prepared to ac-
quaint you with the operation of your ve-
hicle, its safety aspects and systems as
well as preventative maintenance
procedures that must be penodically
upheld . all aimed
toward a more en-
jovable Winter season
Observe the following precautions:
• Throttle mechanism should be
checked for free movement before
startmq engine
•Engine should be runmng only when
pulley guard is secured in place.
e Never run engine Without drive belt
installed Running an unloaded engine
can prove to be dangerous.
oNever run the engine at high R.P.M.
when the tracks of the vehicle are raised
off the ground.
oIt can be dangerous to run engine with
the cab open.
oProlonged Sitting while nding over
rough terrain may cause kidney and / or
spinal discomfort, specially for
the driver
or passenger having an existing back
weakness.
oGasoline is flammable and explosive
under certain conditions. Always
procedures in a well ventilated area. Do
not smoke or allow open flames or sparks
in the
vicinity. If gasoline fumes are no-
ticed
while driving, the cause should be
determined and corrected
without delay.
oUnder no circumstances should you
wear loose clothing or
scarves that
could become entangled with moving
parts of your snowmobile.
.. Your snowmobile is not designed to
be operated on public streets, road or
highways. In most Statesand Provinces, it
is considered an illegal operation.
•Hidden telephone guy wires or road-
side ditches can cause serious
accidents.
e Your snowmobile is not designed to
be dnven or operated on black top, bare
earth or
other abrasive surfaces Abnor-
mal and excessive wear of critical parts
is inevitable.
It! Always wear an approved snow-
mobile safety helmet. Be informed on
local laws legislating the sport.
@ Maintain your vehicle In top mechani-
cal
condition at all times.
Please read and understand all other
warnings contained elsewhere in
this manual.

CANADIAN DISTRIBUTORS
BROO;<S EQUIPMENT LTD MiHlitobJ
1515 Edward s.. ~,)C'~J. atchewan
P.O. Box Wrnnip<"g R3C 2U{3 M<'J~i
HUDSON'S BAY CO North-Wesr Territories
121 Richmond W,:'~;t, Fr.nnklin ;)istrict &
Toronror Ont.
Maine
New Heutpstu-o
Vermont
Sud du MichiHdtl
indiana
Ohio
HEATH iNTERNATiONAL, INC
33737 32 MilR Hoec.
Richmood , Mich 48062
TIMBERLAND MACHINES iNC.
, 0 Main St. North, Lencester ,
New
Hampshire 03584
Arkansas. Atabeme
\I1ississipi, Tennessee
W. Virginia
Iowa
Illinois, Minnesota
Nor rh Dakota.
Dakota
M3;';,'ddl!JS3B;::~
Connecticut
Rhode lslend
Coverage Area
AMERiCAN DISTRiBUTORS
CRAIG TAYLO~~ EQUlPMENT CO.
r.o. Sox 3338. AndlOragf,'
Alaska 99501
30MSARO\ER CORPORATION.
325 South Lake AVe!.
Duluth 2. Minn. 55302
Name of Distributors
BOMBARDiER EAST iNC
Railroad St.. Lee
Massachussetts 01232
Est of Ontario
Ontario
l:lf
Mi:l(;Jda!en !sliJrtd
Nova SCDt;;)
Now Bsunswick
Coverags Area
bri1.isl\ Columbia
BOM3ARDIER ~ONf'ARIO} LTD
28 Curri,,, St. Barrie. o.«
BOMBARDIER LIMnED
EASTERN CANADA D!STRIBLn jO-~"j
01VtS10N
(At!a:ltic Branch)
P.O. Box 670 Shediac , N.B.
BOM8ARDIER LIMITED
EASTERN CANADA DISTRIBUTION
DIVISiON
[Ouebec Branch)
1350 Nobel. Bouche-ville. Ooc.
Name of Distributors
ALPiNE DISTR~8UTORS
3206 28th Avenue. Vernon S."
J.W. RANDALL UMlTED
P.O. Box 757, Corner Brook
Newfour-dtand
TRACK EQUI?M::NT LTD
14325 114th ;':,vc.
Edmondton. Atta
Newfoundland
Lacradcr
ELUOTT & HUTCHtNS lNC
Eost Main Street R02d,
Malone. NP.\N York 12953
New York
Pennsvtvenia
New Jersey
Maryland
Delaware
3

4
Steering
Rotation of the handlebar causes a push
pull
action on the steering linkage and
forces the ski to turn In
the required di-
rection Incorporated In the crash pad-
ded handlebar are the
dimmer SWitch,
cut-out button, brake ancJthrottle levers:
Throttle lever (A)
Located on nght Side of handlebar
When depressed, the lever controls the
engine speed and the engagement of
the transmission. When lever IS re-
leased engine speed returns automat-
icallv to Idle
Brake lever (B)
Located on left Side of handlebar. When
lever IS depressed, the brake IS applied
When released, it automatically returns
to its original position Braking effect
IS
proportionate to the applied pressure on
the lever.
Ignition/light Switch (C)
Key operated, 4 position SWitch,
(OFF/LiGHTS/ON/START) To start
engine, turn key fully clockwise to
START position and hold Return key to
ON position
immediately engine has
started. To illuminate
both headlamp
and taillight turn key to LIGHTS
position
Headlamp Dimmer Switch (D)
The dimmer SWitch, located on left Side
of handlebar, allows correct selection of
headlamp beam To obtain HI or Low
beam simply depress switch
Note: The angle of your headlamp
beam has been pre-adjusted prior to de-
livery Should you wish readjustment,
remove headlamp chrome nng and
turn
upper or lower adjusting screws to ob-
tain desired beam position
Cut-Out Button IE)
A push-button switch located on nght
side of handlebar For emergency stops,
press
button down Into lower position
Before re-starting engine always de-
press button II1to released upper
position
The driver of this vehicle should familiar-
ize himself
with the function of this de-
vice by using It several
times on first
outing, thereby being
mentally prepared

UP before
starting engine
Down to
stop engine
Forward
Reverse
for emergency situations requiring Its
use.
After such a situation, the source of
malfunction should be determined and
corrected before re-startmq engine.
Manual Starter (F)
Auto-rewind type located at lower nght
side of console. To start engine, pull
handle (See Starting Procedure)
Choke (G)
Apush-pull button Pull button to en-
gage choke, push to disengage The
choke should always be used for easier
cold engine starts After engine is
warmed up however, It IS not necessary
to use choke when starting
Gear Shift lever (H)
A 2 position, (FORWARD/REVERSE)
gear shift lever.
Push up for forward and
down for reverse.
Warning: Do not activate gear shift lever
While
snowmobile is in motion.
Access Door (J)
To gain access to the carburetor or
spark
plugs. 11ft pressure lock tab and
pull open access door To adjust locking
device
turn nut In required direction
Fuel Gauge
Graduated dipstick gauge with screw on
fuel
tank cap. Unscrew cap and with-
draw dipstick to check fuel level.
Seat Compartment
Remove backrest ana titt seat. Idea! lo-
cation for spare plugs, belt, rope, etc
Tips
Emergency materials should be
wrapped in foam or similar materia!
This will prevent possible damage to
breakable
Items when traveling over
rough or
bumpy terrain
5

•
•
1&
ins one
correct fuel
6
With Ski-Doo snowmobiles, the oil must
be added to the In pre-mea-
sured
amounts then both oil and gaso-
line should be mixed to-
gether before the tank
Which Gasoline to Usa
The correct gasoline is gasoline.
(not less than 92 octane), available
from
all service stations.
Cautio!"!: Never experiment with other
than recommended fuels or fuel ratios.
Never use no lead
methanol or similar products.
Which OJ! to Use
Use concentrated Ski-Doo oil available
from your Ski-DOG dealer. This type of
oil has specially
formulated oil bases to
meet
the lubrication requirements of the
Bombardier-Rotax
enouqh ~h0rf.lL:.Hl'! we do nor recommend
no lead 9a501'085
Caution: The carburetors of the Ski-Doo
snowmobile have been calibrated for a
mixture of gasoline and concentrated Ski-
Doo oil.
Unless absolutely necessary, do
not use
regular snowmobile oil.
if such oil is used,
observe
mixing instructions on the con-
tainer, Never use outboard or straight
minerai oils,
fuel Mixing Ratio
The importance of using the correct fuel
mixture cannot be overstressed. Prior ex-
perience has shown
that an incorrect fuel
ratio results in serious engine damage,
The correct
fuel/oil ratio is 50!1
5recommended
can of 50!1 Ski-Doo
mixture.
Note: To facilitate fuel mixing, oi should
be kept at room temperature.
fuel Mixing Procechua
To mix the gasoline and oil always use a
separate clean container Never mix
directly In your snowmobile tank For
best results. acquire two containers. ei-
ther plastic or metal Draw from one un-
til empty then use the second one.
Warning: Gasoline is f!ammable and
explosive under certain conditions.
Always perform procedures in a well
ventilated area. Do not smoke or al-
low open flames or sparks in the vi-
cinity. If gasoline fumes are noticed
while driving, the cause should be
determined and corrected without
delay. Never add fuel whil4:l engine is
I'l.ll1ning.

1. Pour approximately one gallon of gaso-
line
into aclean container.
I . Add the full amount
of concentrated
Ski-Doo oil.
IiI. Shake the container thoroughly.
IV. Add the remainder of the gasoline.
V. Once again thoroughly the con-
tainer. Using a funnel a fine mesh
screen to prevent the
entry of water and
foreign particles, transfer
mixture from
container into the snowmobile tank.
Nota: When usmq pre-mixed fuel. al-
ways shake the
container thoroughly as
the oil has a
tendency to settle
Warning: Never 'top up' gas tank before
placing vehicle in a warm area. At certain
temperatures, gasoline will expand and
overflow.
Fuel Consumption
A good idea IS for you to rate the fuel
consumption of your snowmobile at the
first
opportunity Starting with a full fuel
tank, mark the time of your departure
then note
time elapsed until tank is
half-full. Repeat on different occasions
to get a mean average of your snow-
mobiles' consumption and length of
running
time under varYing conditions
With Ski-Doo snowmobile a
break-in period is required before running
the vehicle at
full throttle. Manufacturer's
recommendation for the Bombardier-
Rotax engine is 10 hours. Dur-
ing
this period, maximum throttle shou!d
not exceed 3/4. However, brief full accel-
erations and speed variations
contribute
to a good break-in. Continued wide open
throttle accelerations, 'cruis-
ing' speeds and ugging are detrimental
during the break-in period.
inspection
After the first 10 hrs of operation, each
Ski-Doo snowmobile must have an inspec-
tion check. This inspection is at the ex-
pense
of the vehicle owner.
7

8
fuel Tank Quantity
Check that there is sufficient fuel in the
tank for your tnp. Agood habit to ac-
quire is to refill
the tank before starting
out each day.
Since mixed fuel has a tendency to
settle overnight, agitate the fuel in the
tank by standing on
the footboards and
rocking the vehicle from side to side
Steering Operation
Check operation of steering mechanism
by moving the ski several times from
side to side. If roughness or binding is
felt, check for ice or snow that may be
blocking the mechanism.
Throttle and Brake
Depress and release levers several
times to check that they operate easily
and smoothly The
throttle lever should
return to the idle position when re-
leased The brake lever should be fully
applied
when It has minimum clearance
from the handlebar grip (see Main-
tenance, Brake). If the levers do not re-
turn swiftly. remove cables and/or
housings and replace. Re-check lever
operation.
Warning: Throttle mechanism
should be checked for free move-
ment before starting engine. Once
ail components are checked and
functioning properly, you can start
your Ski-Doo snowmobile.
Tips
By raising the outer attachment of the
bogie wheel sets vehicle manoeuverabil-
Ity in deep snow will increase You will
note
that there are partially dnlled
holes. located approx 1fa
fI above the
onginal cross shaft holes of the frame.
To reposition bogie wheel sets. dnll
holes fully through usmq a
716 fI dia drill
Remove capscrews securing bogie
wheel cross shafts to frame and reinstall
in
new position
Note: Once holes have been drilled.
both positions are interchangeable.

OFF
-START
Up before
starting engine
Down to
stop engine
Warning: Never run the engine at
high
RPM when the tracks of the ve-
hicle are raised off
the ground.
Note: Before starting the engine make
sure the cut-out
button is in the released
upper position.
1. Insert key in Ignition
switch
2 Engage choke. (Choke is not neces-
sary if engine is
warmed up).
3. Test throttle operation then apply
throttle lever slightly.
4 Turn Ignition key clockwise until
starter engages.
Caution: Do not engage starter longer
than
30 seconds. If engine does not
start on first try, key must be turned fully
back to OFF each time,
Allow starter to
cool for 2 minutes before repeating
procedure
5. Release
throttle and key immedi-
ately engine has started Disengage
choke
6
Allow the engme to warm up before
operating at full throttle.
If for some reason the vehicle cannot be
started electrically, place ignition in ON
position and start engine manually
Caution: Never operate the Ski-Doo
snowmobile with the battery removed or
disconnected.
Flooding
If cold engine is difficult to start. contin-
ued choking will only lead to a 'flooded'
condition.
If engme has not started after the first
few trys but appears ready to start. re-
turn choke to OFF position Depress
throttle lever fully and try to start the
engine.
Warning: Release throttle lever im-
mediately after engine starts.
If engine will not start, check for pos-
sible
Cd use.
9

on
from
Guard Removal
1. Remove cab.
2. Puli out retarruno
bolt to
3. Move toward front of ve-
hicle to disenoaqe it from bracket.
W;aullinl::!: Engiine should be n.mning
guard is secured in
Cab Removal
Unlock latches (2), disconnect junction
block at right side of engine, remove
fuel
tank cap and lift cab
Warning: It can be dangerous to nm
engine with cab off ..
frequency of lubrication
it is recommended that the steering
mechanism and suspension be lubricated
or after every 40 hours of
operation, However, if the vehicle is
operated in wet snow, the suspensionand
steering system should be lubricated more
10

DrivEl Bait Removal
1. Removecab and ley
2. Remove hair cotter and brake ad-
nut (A). Detach brake Iswitch
119 and remove lower brake lever (B).
3. Remove the two bolts disc bra-
ke bracket to the frame. Pivot the brake
bracket assembly half a turn.
4. Open the driven Twist and
push the sliding half then
hold in open
position.
5. Slip the belt
out from the drive pulley
and remove from vehicle passing it
under the driven pulley disc brake
assernblv.
6. To install drive belt follow reverse
procedure Check brake
",rii"<,trr,,,r,t
Warning: Never I"I..!!"I the angins with-
out dr-ivill belt installed. Running an
unloaded engine can prove to be
dangerous.
Steering Mechanism
Using light machine oil, lubricate the
spring located on top of steering col-
umn housing. AI!ow oil to run in. Oil the
mobile
contact point at bottom end of
steering arm. Using a small brush,
dipped in
low temp grease, lubricate
steering arm ball joint. Grease the ski
leg at grease fitting until new grease ap-
pears at the joint. Lubricate spring cou-
pler bolt
with oil.
Gearbox Oil level
The gearbox oil capacity is 16 OlS. To
check level:
1. Remove rubber inspection cover locat-
ed on bottom right side of gearbox.
2, Using a rigid piece of wire as d
check oil level. Oii ievel must reach 3
1/4" on dipstick. To fill, remove filler
cap, from top of gearbox. Refill as re-
quired using Ski-Doo chaincase oil.
11

12
Bogie wheels
Grease the suspension bogie wheels with
low-temperature grease. Pump through
the
grease fitting at the center of each
wheel
until new grease appears at the
joint of inner side of shaft. To grease the
inner side bogie wheels,
tilt vehicle on its
side and apply pressure on track to ex-
pose grease fi tti ngs.
Rear Axles
Lubricate the rear axles with low-
temperature
grease. Pump grease through
the rear axle fittings.
Caution: Always use a low-pressure grease
gun.
Driven Pulley
With cab removed. grease the driven
pulley shaft as follows
1. Remove pulley guard and slip off
drive belt. Open the driven pulley. (push
and
twist sliding half).
2. Thoroughly clean the driven pulley
shaft.
3
Apply alight coat of low-temp grease
on
the shaft Always lubricate lightly
and
wipe off surplus.
Note: Activate the sliding half several
times to distribute lubricant over full
length of shaft Be careful that lubricant
does
not get on inner halves of pulley.

Carbonized Normal Burnt
Code
W1
W2
W3
W4
W5
W6
W7
W8
Code
M1
M2
M3
M4
M5
M6
Weekly
Spark Plugs
Battery
Suspension Springs
Tracks
Track Tension &Alignment
Carburetor Adjustment
Drive Belt Condition
Drive Chain Tension
Monthly
Carburetor Flange Nuts
Brake
Steering Adjustment
Engine Head Nuts
Engine Mount Nuts
Vehicle General Inspection
Page
13
14
14
14
14
15
16
16
Page
16
17
17
17
17
17
(W1) Spark Plugs.
1. Open access door. Disconnect spark
plug wires and remove plugs.
2. Check condition of plugs.
4& Abrownish tip reflects ideal condi-
tions. (proper carburetor adjust-
ment. spark plug heat range.
etc)
4& A black insulator tip indicates foul-
ing caused by; carburetor idle
speed mixture too rich. incorrect
fuel mixing ratio. wrong type of
spark plug (heat range). or exces-
sive idling
4& Alight grey insulator tip indicates a
lean mixture caused by; carburetor
idle speed mixture adjusted too
lean. wrong spark plug heat range.
incorrect fuel mixing ratio. or a
leaking seal or gasket.
Caution: Having a spark plug with too
hot a heat range will cause senous en-
gine
damage if the severity of engine
operating conditions are greater than
the plugs' intended range
3Check spark plug gap using a wire
feeler
gauge Gap must be .020"
4. Reinstall plugs and connect wires.
Caution: If when checking spark plug
color. you find
that the engine is not
running under Ideal conditions. contact
your authorized Ski-Doo dealer.
13

14
(W2) Battery
Remove battery caps then check elec-
trolyte level at each eel! . Electrolyt?
level must touch bottom of filler hole. If
necessary,
add distilled water.
(W3) Suspension Springs
VVith engine off, visually Inspect suspen-
sion spnngs Replace any weak or oro-
ken spring
(W4) Tracks . . ,
lift rear of vehicle and support It off the
ground. Place gear shift lever in forward
position With engine off, rotate tracks
by hand and Inspect condition. If bad
cuts or missinq track inserts are noted,
see your dealer.
Note: Without these inserts conttnu~1
abrasion would wear and cut the track
therefore, always a missing or
damaged insert as soon as possible
(W5) Track. Tension arid A!ignmelnt
Lift the rear of vehicle and support it off
the Using a rule, check track ten-
sion at the second set of wheels
from rear.
The tension of each track should be 2
1/4"+1/8" between top inside of
track and bottom of footboard
To adjust track use the fol proce-
dure:
1. Loosen link plate spring lock nuts (4)
located on inner side of fink plate springs.
2. Tum adjuster bolts clockwise to tight-
en tracks, counter-clockwise to slacken.
3. Start engine and allow tracks to rotat~
slowly. Check if tracks are wei I centered
and turn evenly on the rear sprockets.
The distance between track and
!ink plates snould be equal.
Tocorrect
1. Turn Inner side adjuster bolt(s) coun-
tor-clockwise to track closer to
center link plate(s). turn clockwise to
Withdraw track(s) from link platers).
2 Tighten link plate sprrnq lock nuts.
3. Rotate tracks slowly and recheck
chl~ck:ing track aii!!liillent,
ensure that the track is of all particles
which could be thrown out while track is
feet and etothina
clear

(W6) Carburetor Adjus·tmlmt
Maximum Thrott~e O~)erlil1g
With off and air silencer tube re-
moved, depress throttle lever at handlebar
and hold.
Throttle should be
horizontal when the lever touches
the handlebar
To adjust for maximum ioosen
screw at
point where cable carburet-
or throttle 'lever. Clamp throttle lever to
handlebar. With hold carburetor
throttle lever in fully open , pul!
cable IJnt: I taut and screw. Un-
throttle lever from handlebar. In-
stall air silencer tube.
W,nl1:in!~: Before carburet-
or throttle leiler must return to idle
tion . Do not start engi-
ne unless this is verified.
Idle Mixture Adjustment (A)
l\ primary adjustment (with engine off)
should be made by first turning Idle Mix-
ture Screw clockwise until closed.
Back off
screw %of a turn counter-
clockwise
Note: Do not close too tightly as needle
andl or seat can be damaged
For final adjustment, start engine and
allow It to warm up Turn Idle Mixture
Screw until engine reaches maximum
RPM and obtain asteady Idle and a
fast response of the engine to the
throttle.
idle Speed Adjustment (B)
Turn the Idle Speed Adjustinq Screw
clockwise to increase Idling speed.
counter -C lockwise to decrease.
Air Silencer Box
When operating the vehicle In tempera
tures 30
aF,
the rubber p!Ufj
must block the side orifice and the
rubber vent must be positioned on the s!d(;~
of the silencer box to allow cold air circu
lation. In temperatures below 30°F the
rubber plug must block the entry ottresh
air and the rubber vent must low the
warm air emitted from the engine
to be directed over the carburetor
Caution: Observe tem o er atu re
cha nges and
iocate accordingly
Incorrect location of plugs may cause
carburetor ice-up or engine overheating
15

16
(W7) Drive Belt Condition
With engme off, inspect drive belt If
belt IS less than ?Is" wide or if it shows
abnormal or uneven
wear it should be
replaced,
Note: Probable cause of abnormal wear
is pulley misalignment. Contact your
dealer
(W8) Drive Chain Tension
Run vehicle forward so that true free-
play can be taken Check tension then
turn driven pulley
Vz turn counter-clock-
wise and recheck Starting from max-
rrnum reading, adjust chain tension to
1;4" free-play.
1. Remove capscrew locking chain ten-
sioner in place (Tensioner is located at
bottom left of gearbox).
2 Rotate the tensioner as required to
obtain correct chain tension,
3 Replace capscrew to lock chain ten-
stoner In place.
(M1) Carburetor flange Nuts
After the first, 2 hours of operation,
check tightness of carburetor flange
nuts. Open tab locks, tighten nuts and
close tab locks.
Caution: Tab locks must be replaced
after opening them three times,

(M2) Brake
Brake should be fully applied when lever
is 1" from handlebar. To adjust:
1. With cab removed, slacken cable lock
nut (A) located at cable end nearest fra-
me. Manoeuver the lower brake lever and
brake cable
until the pin pushers are seat-
ed
directly in the "cam" of brake lever.
Lock cable in position.
2. Remove the hair pin and tighten the
caliper
nut (B) until a disc (puck friction
is felt. Back off nut slightly.
3. Check operation of brake.
Note: Always check the stop light to
see
if it functions after performing brake ad-
justment. To adjust, loosen stop-light
switch lock nuts (C) and adjust to proper
length.
(M3) Steering Adjustment
Ski should be perpendicular to handle-
bar. To align:
1. Remove
bolt securing handlebar to
steering column.
2. Remove handlebar to expose splined
end
ofsteering column
3. Reposition handlebar on splines so
that It is perpendicular with ski. Install
and tighten
bolt to 30-35 ft/lbs.
(M4) Engine Head Nuts
After the first 5 hours of operation, check
that enginehead nuts are tight and equally
torqued (13 to 17
ft/lbs when cold).
(M5) Engine Mount Nuts
With cab- and pulley guard removed,
check engine
mount nuts. Retighten if
necessary.
(M6) Vehicle General Inspection
With cab removed. check electrical wir-
ing and
components. retighten loose
connections. Check for stripped wires or
damaged insulation Repair or replace
as necessary Thoroughly
inspect the
vehicle and tighten loose bolts. nuts and
linkage. Install cab and clean the
chassis.
17

18
Burnt Light Bulb
If headlamp is burnt. stop engine and
remove cab. Unfasten bulb retainer
clips
Detach bulb and replace. If tail-
light is burnt. expose bulb by rernovmq
red plastic lens To remover
unscrew the
two (2) Phillips head screws.
Note: Before replacing bulb, check con-
dition of fuse.
Broken Throttle Cable
Remove throttle cable and replace
Check lever operation If necessary re-
place housing. Do not start the engine
until handlebar and carburetor levers re-
turn swiftly.
Broken Rewind Starter Rope
Abuse of the rewind starter may cause
the rope to fray and break. Should this
situation arise, remove starter. Transfer
rope grip to
your emergency rope. Place
starter
unit in seat compartment. Make a
knot at the end of emergency starter rope
and wind rope around starting pulley.
Pull vigorously as per usual manual start.
See
your dealer for immediate repair of
starter
unit.
Emergency Materials
In addition to those tools which the man-
ufacturer provides, you should also carry
the
following:
Tools: General Purpose PIiers-vAdjustable
Wrench
(3/4" opening)-Flashlight.
Spare Parts: Spark Plugs-Drive belt-
Headlamp and Tailight bulbs-Throttle
Cable and Housing-Starting and towing
rope-Fuses.
Important: Always carry spare plugs and
drive belt.