Brut LC44 User manual

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294 QUICK SERVICE CHART
CHOKE LINKAGE ADJUSTMENT 28
SET UP PROCEDURE 2 STEERING ADJUSTMENT
AND SKI ALIGNMENT
28
TROUBLE SHOOTING
THE TWO ENGINE
TIMING
28
CYCLE ENGINE 3 SERVICING
DRIVEN CLUTCH 28
DR IVE BELT PREVENTIVE MAINTENANCE 8 SERVICING
DRIVE CLUTCH 28
1973
BRUT SNOWMOBILE 10 SKAG REPLACEMENT 29
BRUT'S LIQUID COOLED ENGINE 10
HEADLIGHT REPLACEMENT 29
BRUT SPECIFICATIONS
11
HEADLIGHT ADJUSTMENT 29
ENGINE
TIMING
11
TAILIGHT-BRAKE LIGHT REPLACEMENT 29
BRUT SERVICE TOOL USTING BRAKE ADJUSTMENT 29
BRUT SNOWMOBILE
CUTAWAY
DRIVE BELT REPLACEMENT 29
1972 LC44
ELECTRICAL SCHEMATIC 12 CLUTCH
ALIGNMENT
30
1973-74 LC29 ELECTRICAL SCHEMATIC 13 RIDE ADJUSTMENT 30
1973 LC44 1974502 ELEClRICAL SCHEMATIC 14
SPR ING TENSION 30
SUSPENSION 15 SHOCK TENSION 30
DRIVE SHAFT REMOVAL
15
DRIVEN CLUTCH ADJUSTMENT 30
I NVOLUTE DRIVE SPROCKET REMOVAL 16
TRACK ADJUSTMENT AND ALIGNMENT
31
CLUTCH REMOVAL
16
DRIVE CHAIN ADJUSTMENT
31
DRIVE INSTALLATION
16 COOLING SYSTEM 32
BRAKEINSTALLATMlM
17 LUBRICATION 32
SUSPENSION INSTALLATION
17
FUEL MIXTURE
32
ENGINE REMOVAL
18 GASOLINE 32
ENGINE DISASSEMBLY 20
OIL
32
ENGINE ASSEMBLY 22
FUEL MIXING RATIO
32
PISTON RING INSTALLATION 25
MIXING INSTRUCTIONS 32
THROTTLE
LINKAGE ADAJSTMENT 28
DEALER WARRANTY CLAIM
INFORMATION 34

Page l
Clutch Offset
Center to Center of Clutch
Proper Belt
Po in t Settin
T im ing
Pl ug Gap
Carburetor Adjustment
Id le Speed
Spark Plug
NUT SIZE
5/8 Clutch
10 mm
12 mm
14mm
. ~E
Flywheel
']~
Ski Adjustment
LC 29 QUICK SERVICE CHART
1/2"
Fixed
Br utanza Belt #13126-or #13126·14 ~ ...
. 012" - . 017"
3.5 mm or .138" B.T.D. C.
MUST BE COM PLETED AT FUll SPARK
ADVANC E
.020
High 1 turn
Lo w ' ·1/8 turn
1500 -2 000 RPM
Standard B7ES NGK
Replacement N3 Or N3G Champion
Hard running
BBE S NGK or N 2G Champion
BOLT TORQUE S PE CI FIC AT IONS ,
TORQUE
35 ft .l b s.
.' .r •• '·~ , 'r .. ", •• 60 in. Ibs.
~. -.'
'.'
. 18 ft. l
bs .
25 ft. Ibs .
.... _" "
".
60 ft. Ibs.
... _""---- _. -
1/ 4" toe out
Oil - use a B.I.A . endorsed oil with T,C.W. specs .
ST wi ll so state on the can. Mix accord ing to oil manufacturers direction s.
Gas - Use a good grade of leaded fu el from a statio n that moves a lot of gas (gasoline that s et s dormant can lo se
up to 50% of the octane in a 30 day period.)

Una-ate the liquid cooled BRUT snowmobile. Be cautious
that the upholstery is not tom or the finish on the cowl
scratched.
2. Check all
parts for shortages. If there should happen to be
a
shortage on some ~ you must file a warranty claim
within
10 days to receiwe credit for any parts which you
use from your- own ~
3. Install springs in suspellsion, set suspension shock and
install suspension in c:ha!iIsis.
4. Align trade. Refer to Semce Manual page -;.. & "fl} i
5. Install skis and sb!eIiI. post and adjust toe out to ~".
6. Check coolant IewL This ~ should be 1·1 W' below the
neck on surge 1ank.
7. Check chain c:aIe oil Ina and chain tension.
S. Check belt aIigi.ueilt. 'The offset should be W'.
9. Check brake and 1hrottIe cable for adjustment and
operation. Adjust if fF y.
10. Inspect choice ....... IioIL
11. Install windshield.
12. Prepare to surt engine.. It is advisable to have a squ itt
bottle handy when SIaftiI. a new engine. Remove drive
belt,
pour about one bIbIespoon of oil through the
carburetor intAlke of eKh cyfnder, pull the starter rope a
couple of times to distrhJle oil in engine. Give engine a
small amount of gas oil mixture from squirt bottle. Make
sure kill
button and .. ition switI:h are on, pull choke out
and pull th~ If me engine does not start in one or
two pulls, add a little mere gas oil mix.
13. After engine starts,
set the idle adjustment also the idle
speed.
14. Run engine a few minutes at slow RPM to clear out excess
fuel and oil. Shut engine off.
15. Install drive belt, raise rear of machine, check for clutch
operation and track alignment .
16. Check high low beam on head light also tail and brake
lights.
17. Set high speed adjustment on carburetor.
18. Machine should be cleaned up before delivery to cus·
tomer.
19. Be sure warranty registration is filed with in 10 days of
date of sale. Th is is a Federal Law on all motorized
vehicles. BRUTANZA ENGINEERING reserves the right
to reject all warranty on machines not registered within
proper time l
20. Steps 1 thru 19 should be repeated again after about 10
hours or 100 miles of driving.
A
couple of hours well spent on pre·delivery and a check up
can save you, the dealer, many hours' of work and many dollars
in the course of the winter. It will also make for a very good
relationship with your customer .
Page 2

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D. SPARK TEST
IF
There is no spark or
the spark "tracks" up
the nose
No
spark with new plug
SPARK PLUG CONDITION
IF
The plug shows excessive
heat:
BIis1ered Nose
Melted Electrodes
Aluminum or lead
"Beading"
"Bridged" Electrodes
The cylinder pressure
is above 150 p.s.i .•
SPARK GAP TEST
IF
The ignition system pro-
duces less than 7 mm of
spark
STAGE 1\
TROUBLESHOOTING -CONTINUED
Connect the plug to its wire,
rest plug shell against head;
crank the engine.
THEN
Try the same test with a new
plug.
Go on to STAGE II, ELECTRICAL.
Check
the firing end for unusual
deposits and conditions.
THEN
Check the carburetor for lean
settings and if OK, go on to
other checks for overheating.
The carburetor settings may be
too rich
OR, the air supply to the car·
buretor may be choked
OR, the exhaust system may be
overly restrictive.
Use a conventional spark plug hole
gauge. Crank the engine until the
gauge will go no higher.
Remove
the cylinder and examine the:
Cylinder head
Piston
Piston rings
Cylinder
Check
for proper tolerances.
Check for unauthorized modification.
Connect a spark gap tester - start
the engine. THEN
Proceed with the next step.
Page 4

TR OU BLESHOOTING - CON TI NU ED
D. IGNITION TIM I NG CHECK Follow
the normal ignition timing
prOC«fures using a dial gauge and
point checker.
IF TH
EN
You find loose Of Clean connections and reconnect
improper wire connec- properly.
lions
The contact points do
Clean until they do .
not open and close
properly
When the points are The poinu may be "grounded" or
physica ll y open and
"open" permanently (replace or
you do not get a normal repair).
point checker resistance
reading OR,
the primary coil is open or
the windings are not insulated
(replace).
IF
THEN
The ignition timing is
The engine will run hot and maybe
excessively advanced
detonate (adjust as necessary).
The timing is excessively The engine will
not produce nor-
retarded mal
honepower (adjust IS neces·
"'V).
E. STROBE LIGHT TEST S
tart tile engine with a strobe
(tim
ing) light connected and
watch the marks provided
on the
flywheel and backing plate. Rev
the engine slowly through the
rpm range.
l!' THEN
A machine with centrif-Performance will be poor. (Re·
ugal advance mechanism move the flywheel
and clean and
does
not go to fun lube
the automatic advance.)
advance
The strobe l ig ht indi- Poor performance and overheating
cates
that the malks will result (note
any obvious
"st ray" from align- crankshaft deflection and
go
ment 1/ 4" or mOle
on to STAGE III, CRANKSHAFT
DEFLECTION).
Q!!
there are random
flashes
in addition
to normal ignition
Page 5

B.
IF
You find dirt or bits
of metal
There
is a flaw in
either diaphragm
or
the check valve sheet
The fuel inlet valve
(needle and seat) is
damaged
The mountingflange
is warped
MUFFLER INSPECTION
IF
It appean to be
clogged with deposits
You can hear loose
metal pieces
or
silencing material
when
you shake the
muffler
C. CRANKCASE PRESSURE CHECK
The pressure leaks at
a rate greater than
llb./min.
STAGE III
TROUBLESHOOTING -CONTINUE,D
Remove, disassemble and inspect
the carburetor.
The carburetor will cause engine
flooding (wash clean).
The carburetor may
not deliver
enough fuel and the engine will
run hot or perhaps will not
start at all (replace damaged
parts).
The fuel will
not be controlled
and
the engine will be flooded.
Air will leak into
the intake
port and cause a lean mixture
(surface grind
the flange).
Remove
the muffler.
The engine will
not produce
normal horsepower and may over·
heat (clean out the muffler).
The engine will
not produce nor·
mal horsepower and may overheat
(replace
or repair the muffler).
Seal the intake and exhaust ports
and connect a pressure checking
device. Pressurize
the engine
to 10 p.s.i.
The air/fuel mixture will become
lean enough to be noticed as a
"hot" plug reading. The machine
will suffer from short plug life.
The air/fuel mixture may become
lean enough
to cause preignition,
detonation, and perhaps melting
of the piston crown.
Page 6

CHECK
NOTE:
flection can be either
bearing freeplay (the
end will move up and
down without rotating
the crankshaft) or
crankshaft misalign-
ment (the end will
Remove the primary drive unit
and the magneto from the ends
of the crankshaft. With a
magnetic stand, mount the dial
gauge and check the deflection
on each end.
The crankshaft seals can be
stretched to the point that
an air leak will occur (this
will not be detected by a
stati c pressure test). The
engine will overheat due to
lean mixture.
AND/OR, the ignition contact
points can be opened at the
improper time. This will
cause overheating and poor
performance.
In either case, major engine
work is necessary.
Use
appropriate instruments to
test the:
Condenser Capacity
Condenser Insulation
Secondary Coi I Resistance
Spark Plug Cap Resistance
There will be starting, plug
fouling,
and performance prob-
lems
caused by weak spark (or
no spark).
(Replace components as necessary ).

'C'nn'\A,rn DRIVE BE l!m eREVENTIVE MAINTENANCE n\A'II'Y\"I""il~
Symptoms
c. Rough or scratched
pulley surface
Excessive slippage caused by:
a. I
nsufficient pressure
on belt sides
Excessive
horsepower
for belt and converter
Excessive oil on
pulley surfaces
d. I
nsufficient pre-load
on driven spring
e. Excessive
operation
in low gear position
a. Excessive slippage
Improper belt angle
Considerable use, belt
wearing out
Excessive slippage in
driver pulley caused by:
a. Locked
track
Converter not functioning
properly
c. Engine idle speed too
high
a. Idie speed
too high
b. I
ncorrect belt or
belt length
c. I ncorrect drive center
Align pulleys
Replace
or
tighten engine
mount
c. Grind or polish
pulley(s)
a. Check driver
pulley for
smooth actuation
b.
Consult dealer
c. Check bearing
seals and
clean pulley
surfaces
d.
Consult 0 per-
ator's Manual
e. Inspect
converter
a. Check driver
pulley for
smooth
actuation
b. Grind or polish
pulley(s)
c. Consult dealer
d. Replace belt
a. Rotate track
by hand until
free
b. Repair
or re-
place con-
verter
c. Reduce engine
RPM
a. Reduce engine
RPM
b. See Operator's
Manual
c. See Operator's
Manual and
reduce center
distance
Replace bearing
Page 8

6. Concave worn belt side(s) a. Excessive ride-out a. Repair or replace
on driver pulley driver pulley
b.
Drive misalignment b. Align pulleys
c.
Rough or scratched
c.
G ri nd or pol ish
pulley(s) surface pulleys
d.
Excessive slippage & Repair or replace
driver pulley
7. Belt disintegration
a. Excessive belt speed
a.
Reduce engine RP
at high speed
b. Sheave misalignment b. AI ign sheaves
causing belt flip-over
c. Excessive slippage
c.
Inspect converter
causing heat build-up
in belt
Excessive operation
d.
Inspect converter
in low gear position
a.
Pulley misalignment a. Align pulleys
b.
Excessive belt speed b. Reduce engine RP M
c. Excessi'le ride-out
c. Repair or replace
on driver
pu Iley
driver pulley
d.
Incorrect belt d. See Operator's
length Manual
9. Belt edge cord broken a.
Pulley misalignment
a. Align pulleys
b.
Improper belt b. See Operator's
installation Manual
c. Engagement speed
c.
Reduce engagement
too high speed
Flex cracks between cogs
a.
Considerable use, a.
Replace belt
belt weari
ng out
b. Bent pulley(s) flange
b.
Repair or replace
causing belt flutter pulley
c.
Excessive operation c. Inspect converter
in low gear position
d. Extremely low temperature d.
Warm up belt slow ly
Sheared cogs, compression a.
Improper belt a. See Operator's
section fractured or torn installation
Manu.al
b. Belt rubqing stationary
b. Check drive
object components
c.
Idler bearing seized c.
Replace bearing
a.
Engagement RPM too a.
Reduce engagement
high
RPM
b.
Belt hanging up in b. Belt too short;
bottom of driven pulley replace
c.
Locked track c.
Rotate track by
hand until free

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DRIVE SHAFT REMOVAL
To remove drive shaft, the chain case must be removed
and the suspension must
be removed. On the left side of
the machine is a locking collar positioned on the spherical
bearing in the flangette. (Photo at right) Loosen allen
screw, turn collar opposite way it was installed. Note
punch mark in locking hole. Slide collar over shaft, then
push shaft
into chain case hole and pull out bottom.
SUSPENSION
Remove suspension. To remove suspension remove the
four (4) 3/8" locking bolts mounting suspension to chassis.
Plug air bleed hole in gas cap, turn machine on to one side.
Then pull
out suspension. 1974 also has locks on front
suspension lock bolts.
Chaincase assembly must be removed be fo re dr i ve shaft
can be removed. (Two photos below) R em ove chain case
drive elements. Remove chain by removing snap ring on
upper sprocket and
bolt on lower sprocket. Remove
chain tensioner
by backing out tightener b olt.

ree (3) Phillips head screws holding bumper
and hood e rusi on onto nosepan on left side of machine
only. e 7/ 16" clutch bolt, then large nut on
ad clutch pu lIer into threads of large
• earing on
end of puller will press against
a and pull
clutch, by tightening puller
ary on models equipped with
i e Clu tch .
LATION
be on flangette side of shaft with
eccent ri c po ' on facing tunnel before installation.
Before in a ili ng chaincase, be sure snap ring is on
shaft. machine lying on left side, fit track into
tunne . Then push driv eshaft into chaincase hole
and hac rough sph erical bearing mounted on
the flangette. Holding drive sprockets as close to
ce nter of tunnel as possible slide chaincase onto
dr iv e shaft. Snug chaincase tightly up against tunnel.
Slide top sprocket spacer over spline and install
sproc ets and chain. Screw bolt in driveshaft to
ho ld chain sprocket on apd center track drive
sp rockets.
INTERNAL DRIVE SPROCKET REMOVAL
With drive shaft removed, remove the track drive sprocket .
With long
1/ 4" punch, pound out 5/16" roll pin from
shaft. Drive sprocket should slide off.
Slip snap ring on top drive sprocket in chaincase to hold
it in position. Install chain tightener assembly and
tighten chain so there is 1/2" deflection in chain. Jam
locking nut on tightener bolt. Check "0" ring seal on
chaincase cover and install if O.K. Be careful not to
damage jackshaft seal when installing chaincase cover.
Go back
to driveshaft inside tunnel and slide lock collar
into position next to flangette bearing. Turn collar lock
with punch and tighten with socket wrench.
Page
16

BRAKE INSTALLATION
Place inner brake puck
in chaincase cover. Install brake
disc, then brake assembly. Make sure round end of
actuating pin
is toward actuating lever. Adjust brake so
brake lights operates when brake
is applied.
J
With track and driveshaft installed, you can now install
suspension. Raise machine rear approximately 3~'' off
ground on secure stand. Slide suspension into track. Line
up front two (2) mounting bolts, insert and tighten.
Slide a 2"x2" or 2"x4" block under track, positioned
just behind second set
of front idler wheels. Drop rear of
machine down. Push down or up 6n machine rear while
holding rear suspension mounting shaft until shaft
is in
line to insert mounting bolts. Tighten bolts and align
suspension. (See page 23 for track adjustment and
alignment.)

E NGI E RE OVAL
Loosen linkage swiv el screws on choke and throttle on the
carb next to the cool ant pump. Remove choke cable from
choke cable bracket. Remove
throttle cable at throttle
lever next 0 handle ~i p.
Remove two (2) 1/4" nuts at upper steering bracket. Lift
steering post away from engine compartment.
Disconnect COl unit lead
to engine. Disconnect the
two (2) yellow lighting wires and black ground wire
leading from
stator unit. Disconnect spark plug leads.