Johnson Skee-horse 25-201r User manual

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· ·

SKEE-HORSE

SERVICE

MANUAL

o

30

HORSEPOWER

MODELS

25-201R

25-201RA

25-201RSA

11

·

70

PART

NO.

261894

LITHO

U.S.A.

©

OUTBOARD

MARINE

CORPORATION

1970

ALL

RIGHTS

RESERVED

AVAILABLE

IN

ONE

QUART

CANS

AND

IN

6

PACKS

FROM

YOUR

JOHNSON

DEALER

170

2.0

FUEL

RECOMMENDATIONS

The

correct

fuel

mixture

ratio

is

24

parts

of

a

good

grade

regular

gaso-

line

to

one

part

lubricant.

For

ease

of

measurement,

this

is

equivalent

to

one

quart

of

lubricant

to

six

gallons

of

gasoline,

one

pint

of

lubricant

to

three

gallons

of

gasoline,

or

1/3

pint

of

lubricant

to

each

gallon

of

gasoline.

Use

only

Johnson

Lubricant

or

a

reputable

automotive

engine

oil,

SAE 30

SD

or

SB.

Avoid

use

of low

price

third

grade

(SA

light

duty)

oils.

DO

NOT USE

MULTIPLE

VISCOSITY OILS, SUCH

AS

10W30, OR

ANY OUTBOARD MOTOR OILS

OTHER

THAN JOHNSON OUTBOARD

LUBRICANT.*

*EVEN THOUGH JOHNSON OUTBOARD LUBRICANT

IS

ADVER-

TISED

AS

A 50:1 RATIO LUBRICANT, IT

IS

IMPERATIVE

FOR

SNOWMOBILE USE THAT IT

BE

MIXED AT A 24:1

GAS-

LUBRICANT RATIO.

DO NOT POUR GASOLINE OR LUBRICANT

DIRECTLY

INTO

VEHICLE

FUEL

TANK. USE

AN

APPROPRIATE

CONTAINER

FOR

MIXING

AND

STORING

THE

FUEL

.

To

prepare

the

snowmobile

fuel

properly,

pour

into

a

SEPARATE,

clean

container

half

the

amount

of

gasoline

required

and add

all

the

required

lubricant.

Thoroughly

shake

this

partial

mixture.

Next,

add

the

balance

of

gaso-

line

necessary

to

bring

the

mixture

to

the

required

ratio

of

24:l.

Again,

thoroughly

agitate

the

mixture.

A

clean

funnel

equipped

with

a

fine

screen

should

be

used

when

pouring

the

fuel

mixt~re

into

the

vehicle

tanle

24

to

1

lubricant

is

prediluted

to

provide

excellent

mixability

with

gaso-

line

at

low

temperatures.

The

addition

of

this

dilutent

does

not

in

any

way

affect

the

lubrication

qualities

of

the

lubricant.

Whenever

is is

necessary

to

mix

fuel

and

lubricant

at

temperatures

below

0°

F,

the

lubricant

should

be

prediluted

with

gasoline

to

improve

its

mixability.

The

lubricant

should

be

prediluted

with

approximately

one

part

gasoline

to

one

part

lubricant.

Predilution

of

the

lubricant

should

take

place

with

the

lubricant

temperature

above

O°F.

Do

not

use

kerosene

or

fuel

oils

for

pre-mixing.

SECTION

1

INTRODUCTION

SPECI

FI

CA

TID

NS

GENERAL

SNOWMOBI

LE

IN

FO

RMATION

TROUBLE

SHOOTING

TUNE

-

UP

PROCEDURES

FUEL

'

SYSTEM

IGNITION

AND

ELECTRICAL

SYSTEM

MANUAL

STARTER

ENGINE

DRIVE

TRAIN

STEERING,

TRACK

AND

SUSPENSION

LUBRICATION

AND

STORAGE

1-2

1

The

snow

machine

has

been

designed

and

built

for

dependable,

high )

performance.

It

is

important

to

every

snow

machine

owner

to

be

ab

le

to

receive

skilled

and

thorough

service

for

his

vehicle

when

necessary.

It

is

important

to

the

service

dealer

to

be

able

to

offer

the

type

of

skilled

service

which

will

maintain

the

customer's

satisfaction.

This

manual,

together

with

the

regularly

issued

service

bulletins

and

Parts

Catalogs,

provide

the

serviceman

with

all

the

literature

necessary

to

service

the

Skee-Horse·

snowmobiles.

An

effort

has

been

made

to

produce

a

manual

that

will

not

only

serve

as

a

ready

reference

book

for

the

experienced

serviceman,

but

will

also

provide

more

basic

informa-

tion

for

the

guidance

of

the

less

experienced

man.

The

Parts

Catalogs

contain

complete

listings

of

the

parts

required

for

replacement.

In

addition,

the

exploded

views

illustrate

the

correct

sequence

of

all

parts.

This

catalog

can

be

of

considerable

help

as

a

reference

during

disassembly

and

reassembly.

The

Section

Index on

page

1-1

enables

the

reader

to

locate

quickly

any

desired

section.

At

the

beginning

of

each

Section

is

a

Table

of

Contents

which

gives

the

page

number

on

which

each

topic

begins.

This

arrange-

ment

simplifies

locating

the

desired

information

within

this

manual.

Section

2

lists

complete

specifications

on

the

1971

snowmobiles.

All

general

information,

including

2

cycle

engine

theory,

trouble

shooting,

and

tune

up

procedures,

are

given

in

Sections

3

through

5 of

this

manual.

17029

Figure

1-1

(

Sections 6

through

11

provide

fully "

illustrated,

detailed,

step-by-step

disassembly

and

reassembly

instructions

and

adjustment

procedures.

Section 12

provides

lubrication

and

storage

information.

In

this

way,

the

texts

treat

each

topic

separately;

theory

and

practice

are

not

intermixed.

This

makes

it

unnecessary

for

the

experienced

service-

man

to

reread

discussions

of

theory

along with

specific

service

in-

formation.

lliustrations

placed

in

the

margins

provide

unimpeded

reading

of

explanatory

text,

and

permit

close

relationship

between

illustration

and

text.

Read

this

manual

carefully

to

become

thoroughly

familiar

with

the

procedures

described,

then

keep

it

readily

available

in

the

service

shop

for

use

as

a

reference.

If

properly

used,

it

will

enable

the

serviceman

to

give

better

service

to

the

snowmobile owner, and

thereby

build and

maintain

a

reputation

for

reliable

service.

This

service

manual

covers

all

phases

of

servicing

the snowmobile,

however,

new

service

situations

sometimes

arise.

If

a

service

question

does

not

appear

to

be

answered

in

this

manual, you

are

invited

to

write

to

the

Service

Department

for

additional help. Always

be

sure

to give

complete

information,

including model

number

and

vehicle

serial

number.

All

information,

illustrations,

and

specifications

contained

in

this

literature

are

based

on

the

product

information

available

at

the

time

of

publication.

The

right

is

reserved

to

make

changes

at

any

time

without

notice.

1.

Instrument

Panel

Door

10.

Speedometer/Odometer

2.

Neutral

Lockout

(Accessory)

3.

Reverse

Control

11.

Throttle

4. Headlight

Retracting

Lever

12.

Primer

5. Hand

Brake

and

Parking

Lock

6.

Tachometer

(Accessory)

7. Choke

8.

Fuel

Level

Gauge

9.

Compression

Release

13.

Ignition/Lights

Switch

14. Manual

Starter

Handle

15.

Lighter

(Electric

Start

Models)

Figure

1-2

1-3

I

J

)

J

c

(

TABLE

OF

CONTENTS

2-1

SECTION

2

SPECIFICATIONS

SPECIFICATIONS.

. . . . . • . . • . • . . . . • .

2-2

TORQUE

SPECIFICATIONS

..••...•.•.

2-3

I

J

2-2

Before

repair

your

proceeding

with

or

mai

n

tenance,

own

protection

SAFJ;'

.

TY

PRECAUTIONS

",

any

for

see

on

pages:

4-8,

5-6,

6-6,

7- 6,

7-10,

8-2,

9-2,

9-6,

10-2

and

11-4.

SPECIFICATION

S

CAUTION: Snow

Vehicles

are

not

manufactured

for

highway

use

and

the

manufacturE!r

does

not

represent

that

they

are

equipped

with

all

the

de-

vices

legally

required

for

such

use.

Length

.......

.

Width

.....

. .

Height

......

.

Engine

Rating

.

....

Start

er

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

..

103

inches

.

.......

......

37

inches

47-1

/ 2

inches

with

windshield

37

inches

without

windshield

OMC

2-cycle

opposed

twin

Maximum

30 hp

at

5800

rpm

Model

25-201R

and

25-201RA

......

.

Manual

rewind

Model 25-201RS

and

25-201RSA . . .

Electric

and

manual

rewind

. . . . . . .

Centrifugal

operated

sheave

Engages

V-belt

Variable

speed

drive

..

Overall

ratio

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

..

5.07

to

1

Final

drive

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

ASA 35 double

chain

Sprocket

ratio

. .

......

.....

....

.....

....

.

....

16

to

42

Reverse

transmission

...

......

..

.

...

Dog

clutch

and

bevel

gears

Muffler

.•..•

.

••.....•••

Single,

Tuned

muffler

for

quiet

operation

Brake

......

.

........

Disc

type,

hand

operated

Throttle.

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

....

.........

.

Thumb

operated

Track

...

. . . . . . . . . .

Specially

designed

fully

adjustable

Width . . . . . . . . . . . . . . . . . . . . . . . . . 20.5

inches

Skis

...........

Formed

steel,

equipped

with

shock-absorbing

leaf

springs

and

replaceable

wear

runners

Seating

capacity

......

........

Two

adults.

Vinyl

coated

cover,

molded

urethane

foam

cushion

Hood .

....

..

'. . . . . . . . . . . . . . .

Molded

polycarbonate

Lighting

. . . . . . .

Retractable

sealed

beam

headlight

and

taillight

Fuel

tank.

. . . . .

...

Capacity

5

Imperial

gallons,

6 U.S.

gallons

Lubrication

.........

...

24:1

using

Johnson

Skee-Horse

Lubricant

Carburetor

Needle

Adjustment

High

spe

ed

.........

.

Low

speed

...........

.

RPM

Ratings

or

SAE 30 SB

or

SD

oil

One

turn

off

seat

minimum

...

1

to

1-1/4

turn

off

seat

Idle

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

.

.......

. . 1300 -1600

Approx.

2700

Transmissi

on

belt

engaging

speed

..•.......

Maximum

RPM

at

which

neutral

lockout

will

operate

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

.

Approx.

2000

Ignition

Breaker

point

gap

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

020

to

.022

Spark

plug.

. . . . . . .

........

Champion

J7J

or

equivalent

Spark

plug

gap . . . . . . . . . . . . . . . . . . . .

..

.028 -.033

inch

Condenser

capacity

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

"

.18

-.22

mfd

Magneto

drive

coil

resistance.

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

..

.8

ohm

Ig

niti

on

coil

primary

resistance

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

1.5

ohm

Ignition

coil

secondary

resistance

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

..

10,000

ohms

Lighting

coil

resistance

.

...

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

..

.562

to

.678

ohm

Battery.

.

..

12

volt

Pr

estolite

Type

9948X

or

equivalent

with

a

mini-

mum

32

ampere

hour

rating,

and

with

a

minimum

of

2.2

minutes

cold

starting

capacity

at

150

amperes

discharge,

0°

Fahrenheit,

and

a

5-second

voltage

reading

of

7.8

volts.

Dimensions

in

inches

are

approximately

7-3

/ 4

long, 5-1/ 8 wide

and

7-1

/ 4

high

(to

top

of

terminals).

Weight

dry

17

lbs.,

wet

21.4

lbs.

Electrolyte

to

fill

0.44

U.S.

gallons.

Specific

gravity

1.265

Engine

Bore

and

stroke

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

.

Piston

displacement

........

.

Compression

ratio

.........

.

Cylinder

compression

... ...

....

. .

Ring

diameter

Ring

thickness

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

.

Clearances

Piston

-

wrist

.....

.

2-3

/ 4 x

2-1

/ 4

inches

26.7

cubic

inches

(437 cc)

.

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

6.8

to

i

Minimum

105

PSI

. . .

..

2-3

/ 4

inches

. . . . . . . 1/ 16

inch

. . . . . . . .

press

fit

Pist

on

ring

gap

..

.

...........

, .007-.017

Piston

ring

-

ring

groove

.

Cylinder

-

piston

.....

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

..

.002-.004

.

..

Top

of

piston

to

cylinder

.012-

.015

Bottom

of

piston

to

cylinder

.006-

.008

Specifications

and

features

may

be

changed

at

any

time

without

notice

and

without ob

ligation

towards

vehicles

previously

manufactured.

(

TORQUE

SPECIFICATIONS

PART

APPLICATION

SiZE TORQUE

IN.

/

FT./

LBS. LBS.

*Nut

Ball

Joint

to

Steering

Arm

and

Steering

Column 3

/8

-24 18-20

Nut Cable

to

Solenoid

36-60

Screw

Coil

Clamp

to

Main

Frame

35-45

*Screw

Connecting

Rod

29-31

*Screw

Crankcase

60-80 5-7

*Nut

cYlinder

to

Crankcase

16

-

20

*Screw

Engine

to

Engine

Frame

Assembly

3/ 8-16 18-20

*Nut

Exhaust

Manifold

to

Cylinder

5/16

-

24

10-12

*Screw

FlangeUes

to

Frame

3/ 8-16 20-25

*Nut

Flywheel

40-45

*Screw

Engine

Frame

to

Main

Frame

3/ 8-16

18

-

20

*Nut

Front

and

Rear

Truck

Axles

5/8

-

18

50-60

*Screw

Idler

Axle

to

Frame

3/ 8-16 20-25

Setscrew

Locking

Collar

#10-32

25

-

35

Bolt

and

Rear

Axle

Pivot

Nut

5/ 16-24 12-15

Setscrew

Rear

Sprocket

3/ 8-

16

18-20

Nut

Rear

Suspension

to

Frame

5/ 16-24 12-15

*Nut

Runner

to

Ski 5/ 16-18 90-100

*Nut U

Bolt

to

Saddle

10-12

Spark

Plug

20

-

20-1/2

*Nut

Throttle

Cable

Adjusting

Screw

5/

16

-

18

60-80

*

Nut

Tie

Rod

3/ 8-

24

18-20

.

*Screw

Truck

to

Frame

3

/8

-16

25

-

30

*Screw

Truck

to

Frame

7

/1

6-14 25-30

*Screw

Secondary

End

Cap

to

Shaft

3/ 8-

16

22-25

Screw

Drive

Sprocket

1/ 4-20 15-17

*Screw

Shifter

Clevis

to

Pinion

Shaft

1/4-28

160-180

*

Screw

Primary

Sliding

Sheave

to

Hub

1/4-20

7-10

*

Bolt

Primary

End

Cap

to

Main

Shaft

3/4-16

90-100

Screw

#6 7-10

Screw

#8

15

-

22

Screw

#10 25-35 2-3

Screw

#12

35

-

40

3-4

Screw

1/4

60-80 5-7

Screw

5/

16

120-

140

10-12

Screw

3/8

220-240

18

-

20

Specifications

and

features

may

be

changed

at

any

time

without

notice

and

without

obligation

towards

vehicles

previously

manufactured.

*Use

Torque

Wrench

2-3

)

J

Johnson SKEE-HORSE 25-201R User manual

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