Massey 1976 whirlwind User manual

1976
Massey
Wh ir lwind
INDEX
SECT IO N 1
SECT IO N 2
SEC T IO N 3
SEC T IO N 4
SEC T IO N 5
SER VICE MAN UAL · 1976 MA SSEY WHIRLWIND
E ng i ne
Ca rbure tor
E
lectr ical
Clutch
/D ri ve
Suspension

,...
SER VICE MANUAL - 1976 MASSEY WHI RLWIND
IGNITION
Fun cti on al De scr ipti on :
(See SCHEMATIC FIG. 3-7).
C uyu na engi nes are equ ippe d with a flywh eel
magneto ty pe i gniti on. A n e lec tr ica l cur re nt is
gene rated by r ot a tin g a pe r ma ne ntly magne t ize d
fl y wh eel abo ut th e i gn i ti on co il. The cur re nt
ini tiated in this coil in t urn e nerg izes t he pr i ma ry
co ils of th e ex ter na l ig ni ti on coils. The seco n da ry
coi ls of t he ex te rna l ig nit ion coils a re s itua te d in
t
he force fi el d ge nera ted by t he pr ima ry co ils.
Wh en th e po ints close, caus ing an int erru pt i on of
th e c urre nt fl ow th rou gh t he p rim ary wind ing , its
force
fi el d imm e di at ely co lla pses a nd ge ne ra tes a
very
hi gh v olt age in th e seco nd coil. Thi sv ol tage in th e
reg io n of se vera l t housand vo lts w ill jump t he s pa rk
p
lug gap caus i ng ig nit io n to beg in.
The co
llaps i ng lin es of force c ut thr ou gh t he pr i ma ry
w
ind i ngs , ra isi ng th e vo l tage in th at ci rcu it a lso.
As thi s occ urs, th e co ndense r absorbs th e ge ne -
rated c urren t to reduce the tend en cy to ove rloa d
the
po ints. As soo n as th e vo ltage lev el in the
pr imary w ind i ng d rops be low th at of t he conde nse r,
curren t aga in fl ow s in t he or ig ina l d irec tion,
ene rg izi ng th e system. This occu r re nce and th e re-
versa l happens seve ra l ti mes eac h cy cle crea ti ng a
powerf ul, l on g durat ion spark fo r more re l iab le
i gniti on.
MAIN ELEMENTS:
1. Ig niti on Coil (St at or)
2.
Condensers (2)
3.
Breaker Points (2)
4. I
gniti on Coils (Exte rn al) (2)
5.
Spark Pl ugs (2)
~---,r- SPARK PLUGS
EXTERNAL
COI
LS --=' -:'- ENGINE
! CONNECTOR
F IG. 3-4
F IG. 3-5
3-3

1976
Mass ey
Whirlwind
Service M anu al ·
.J
Enqine Section
1-1

SERVICE MAN UA L - 1976 MASSEY WHIRLWIND
EN GINE SYSTEM
. un cti on al Des cript ion:
2-CYCLE ENGINE F UNDAMEN TA LS
TRAN SFER
INTAKE
EXHI UST
FIG. 1-1
A
.ne Cuyuna 2- cycl e T win Cyli nde r eng ine is of
t he loop-scovenqed third po rt t ype , the most
w
ide ly use d des ig n tod ay . It uses a mi xtur e of
gaso l ine , oil and air for co mb ust io n, lu bri ca ti on
and coo l ing. It fi res on ever y st ro ke of eac h
pi ston. T he re a re two powe r st rokes for e ve ry
revo l ut ion of th e cra n ks ha ft.
The Cuyu na 2- cycl e a ir - coo l ed gasoli ne e ng i ne ,
p
arti cul arly th e ax ia l f an -cool ed tw in cylin de r
e
ng i ne , has bec om e ver y p opu l ar t od ay for
snow mob i les. It is un iqu ely q ua lif ie d for thi s ap-
p
lication beca use of it s hi gh p ow er ou tp ut, li ght
weig ht a nd ease of lu br ic ati on, with fewe r
moving p
art s th an ot he r c onv enti on al 2-cy cle
and 4-cy cle e ng i nes .
OPERATION
How ev er , in ord er to ge t th e best possible use
a
nd ens u re th at it r et ain s it s hi gh de gr ee of
dependab ility and en du ra nce , it mu st rec ei ve
proper ca re and m aint en an ce. Th er ef ore, it is
n
ec essa ry f or us to kn ow some thi ng abo ut the
bas ic fund am ent als. of thi s e ng i ne and how it
fun cti ons.
As th e do wnwa rd s troke of th e pi st on turn s th e
cr anksh af t, it a lso s ta rts to compress the
fu e l/ air mi xtur e in th e c ra n kcase and,
si
mu l taneo usly, ope ns th e ex ha us t po rt and
clos es th e intake po rt. S ee F igs. 1-1 B & C.
As the pis to n moves u pwa rd in th e cyli nde r it
draws t he fu el/ a ir mi xtu re int o th e crankcase
th rou gh t he int ak e manif ol d w h ile at the same
ti me comp ress ing fuel t ha t has bee n fo rced i nto
,. the combus t io n c hamb er. See Fig. 1-1A.
As t he pi st on ne ar s top dea d cen te r th e spa rk
p
lug is fi red and th e compresse d fu el/ air mi x-
tur e bu rns and expands t hereb y fo rci ng the
pis ton dow nward on a powe r s tro ke .
,.....
1-2

Aft er th e ex ha ust p ort is fully open and th e in-
take p
ort is ful ly closed, fu rth er pis to n tr av el
s ta rts to o pe n the tran sf er ports . The com -
pr ess ed fu el/a ir mixtu re from t he crankcase
th en tr av els up th e tr ansf er po rts and int o the
c
ombu st i on ar ea .
Aft er mo st of th e burn ed ex haus t ga ses hav e
le
ft th e cylin de r, an inco mi ng c harge of fu el / air
mi xtur e sca ve nges th e combus tion a rea giv ing it
a fresh ch arg e and th e cy cle is then repe at ed.
See Fig. 1-1 D.
Beca use lubri cati on is depe n de nt on th e m ixing
of oil and fu el, it is ex treme ly importa nt t hat
go od qu a lity oil and gaso li ne are properly
mi x ed . T he p ro pe r ra t io of oil to gaso l ine w ill
pr ev en t pos sib le e ng i ne over hea t ing, p iston or
cy
lin d er sco ring, or even t ua l eng ine se izure.
Too mu ch oil and n ot e noug h gaso l ine can lead
to incom pl ete c om bus t ion , fou led pl ug s, carbon
bu ild-up and muff l er clog gin g.
SER VICE MANUAL - 1 976 MASSEY WH IRLW IND
1-3

SERVICE MANUA L· 1976 MASSEY WHIRLWIND
-:XHAUS T SYSTEMS
SELECT ION
Se lec t io n of an exh au st s ys te m (in cl ud ing
ex ha ust m an if o ld, int erm ediat e p ip es, el bo w s
and muffl er ), is a resu lt of thor ou gh test
pr oce dur es inv olv ing mea sur em ent of fu el con-
su
mp t io n, h or s ep ow er and n oi se level. Co ntrary
to
popu la r beli ef, th e ex ha ust sys te m is n ot only
f
or qu ie ting th e e ng i ne , but also ser ves to in-
cr ease h or s ep ow er output. C ha nges m ad e to th e
or
ig i na l equip me nt ex ha ust sys te m by c ha ng ing
any
co mpo ne nt in th e sys te m can resu lt in loss of
pow er and /o r se ve re e ng i ne d ama ge. F or th ese
reasons,
int erm edi at e l en gth s af pip e betweee n
th e cylin de r and th e muff l er ar e p articu l arly
crit ica l.
TUN ED MUFFLERS
Tuned muff l er s a llo w th e e ng i ne to ex ha ust its
spent c
ha rge into an a de q ua te vo lum e and
roperlv m
at ch ed mu ff l ing s yste m. M or e im -
,J ort ant , th e muffl er s th at a re tun ed , inco rp or at e
des igns th at suck th e ex ha ust gas fr om t he cylin-
der al low i ng fu el and air to ra pi d ly replace it and
a
lso "cra m" o ve r-scave nged fu e l and air m i xtu re
fr om th e ex haus t p ipe ba ck int o th e cylin de r
u
sin g sou nd wa ves a nd sound e ne rg y. Th is is ac-
comp lished at th e sp ee d of sound whi ch a llo ws
the engine ta prod uce hi gh er tor qu e at h ighe r
RPMs.
1-4
D ona l ds on
F IG. 1-2
Tun ing
Co u rtesy o f D on ald so n M ufl ler Co
F IG. 1-3

HOW TUNING WORKS
The m eg aph on e e ffec t of th e expan ded i nt ake
tub e sca ve nges ex ha ust gas fro m th e cy lind er
all owing rapid r epla c em ent of th e fu el/ ai r mi x-
tur e fr om th e crankc ase. R efl ected sou nd w aves
and so und e ne rgy s to p o ve r-sca ve ng ing and
r eturn fu el/air mixtur e to th e cyli nder .It g ives a
su
perc harg ing e ffe ct e ve n th ou gh it operate s
from the exhaust rath er th an th e in take side.
Ov er -s cav en ging is al so r et ar d ed by mode ra te
muffl er ba ck pr essure. Sil en ci ng is accomp lis hed
aft er p ow er is m aximi z ed by aco ust ica l pack i ng in
th e res onat or outl et tub e pl us c hamber i ng and
bafflin g which giv es an e ffec ti ve 2 -pass muffl er
de
sign.
SER VICE MANUAL · 19 76 MASSEY WHIRLWIND
1-5

SER VICE MA NUAL - 1976 MA S SE Y WHIRLWIND
TABLEOF SPECIFICATIONS
JE
NG INE MODEl
DESCRIPTION CUYU
NA 3 40 CUYUNA 400 C
UYUNA 440
2.362 " 2 .55 9" 2.6 58 "
BORE (60
mm ) ( 65 .0mm )(67.5m
m)
STROKE 2.362"
(60mm)
DISPLACEMENT IN cc
338
398
428
COMP RESS IO N RAT ION (actu al) 12: 1 12:1 12:1
IGNITION SYSTEM Bosch Flyw
hee l Magn eto
LIGHTING COil VOLTAGEAND 12V-
150 W 12V 1 50W
1 2V 150W
OUTPUT
*TlMING B
EFORE TDC (CENTRIFUGAL .102 - .112 .102 - .112 .102 - .112
WEIGHT
AD VANCED )
TI
MI NG B EFORE TDC (CENTRIFUGAL .018" to .0
20"
.01 8" to .020" .01
8" to .02 0"
WEIGHT RETARDED)
BREAKERPOINT
GAP
.0 14" to .0 16"
SPARK PLUG THREAD 14mm. x 1.25 - 3/ 4" reach
.020 " .020" .020 "
SPARK PLUG
GAP
(0.5 mm .) (0.5mm.) (0.5mm.)
SPARK PLUG (ORIGINA L CHAMPION C
HA MP IO NCHAM P
IO N
E
QUIPM ENT) N-3 N-3
N-3
TYPE OF ENGINE COO LING
Ax ial Fl ow Fan
ROTAT
ION OF CRANKSHAFT Counte
rcloc kw ise (PTO side)
CARBU
RE TOR
Wa l br o W F
FU
EL /O il RATIO A s Specif
ie d on Mass ey app roved Oi l Contai ne r
GASOLINE 95
octa ne, mi n imu m (lead fr ee not acc ept ab le)
ITYPEOF Oil Special 2-Cycle S
no w mobile Oi l
* Do not exceed ind
icat ed advanc e, as this w ill result in severe engine d ama ge.
1-6

SERVICE MANUAL - 1976 MA SSEY WHI RLWIND
TABLEOFSPECIFICAT
IO NS
TORQ UE SPECIF ICAT ION S
CUYUNA CUYUNA
CU YUNA
34 0
400
440
.=
CYLINDER HEAD NUTS 28-32 Ft.-Lb. 16-1 8 Ft. - Lbs.
CYLINDER BASENUTS 16-18 Ft. - Lbs.
FLYWHEEL NUT 44-50 Ft. -
L!1 s.
INTAKEMANIFOLD NUTS 16-18 Ft. - Lbs.
FAN HOUSING SCREWS
16-18 Ft. - Lbs.
FAN WHEELNUT 22-24 Ft. - Lbs.
RING GEAR
SCRE WS (6m m.)
6-7 Ft. - Lbs.
RING GEAR
SCREWS (8mm.) 10-12 Ft. - l bs.
Ti
ght en ing Seque nce for Cyli nder Base Nut s
Al l Mod el s
0
0)
8
0)
PTO SIDE
0
0)
0
(0
Ti ght ening Sequence for:
Cyl
ind er Head N ut s, Fan Hous ing, Ring Gear F lange , Intake Ma ni fo ld
and Reco il
Starter C lamps
0)
8
0)
0
0
400
340
440
G)
00
CD
CD
1-7

SERVICE MAN UAL · 1976 MA SSEY WHI RL WIND
CUYUNA TWIN CY LINDER ENGINES
JDELSCUYUNA 400, 440
DISASSEM BL Y
A. R eco il S tarter
R emove four (4) screw s hol ding th e
re
coi l as semb ly to th e fan hous ing .
See F
ig . 1-4.
See
page s 1-28 A. B, C for reco il start er
di sass emb ly.
FIG . 1 ·4
B. l ow er Fan Pull ey and Carr i er A ss emb ly
R
em ov e the thr ee (3) h ex head bo lts on
the carr ie r. R em ov e c arr i er , low er pull ey
asse mbly and V-be lt. See Fig s. 1-5, 1-6.
1-8
F IG .1-5
FIG. 1-6

C. Upper Fan Belt Pull ey A ssem bly.
Ins ert a 3/ 16" drill or a suitab le punch
through th e ind e xin g h ol e int o th e irn-:
p
el l er : body . With a 17 mm soc ke t
wr en ch, r em ov e th e fan n ut , lock
wa sh er, pu ll ey halv es a nd sp ace rs. See
Fig s. 1-7, 1-8, 1-9. .
FIG. 1-8
SERV ICE MANUAL - 1976 MASSEY WHI RLWIND
FIG. 1-7
FIG. 1-9
1-9

SER VICE M ANUAL· 1976 MASSEY WHI RL WIND
F lyw hee l Ma gn et o
Remo ve the cranksha ft n ut us ing a 27
mm soc ke t w renc h. Pull the fl yw heel by
attac h ing fly wh e el pu ll er 444-31-843-2 to
th e fly w heel fl ange us ing bo lts provid ed.
Sc re w the three bolt s th rou gh the pu ller
into
th e fl ange and tig h ten e ve nly. W i th
a soc ke t wr ench , tig ht en th e pu ller bolt
unti l t he f lywh eel loosens on th e
crank s ha ft . S ee F ig s. 1-10, 1-11 , 1-12, 1-
13.
FIG. 1-12
NOTE: It is im porta nt tha t care be tak en in
r
emov ing th e fl ywh eel asse mb ly b ecau se th e
po siti oning k ey located in the k eyway m ay
s ta y in its origin al po siti on and th er eby ca use
damage to th e ad va nce mech ani sm. A s ma ll
~p ick or sc re wdr ive r m ay be us ed to loosen
.d r
emov e the ke y.
1-10
/
~ ' ~
/ .
/" yP
FIG. 1 -10
FIG. 1-11
FIG.
1-13

E. Int ak e M anif old Ass emb ly
Re mo ve the f our (4) i ntak e man ifo ld
nut s and washers. R emove manifo ld
asse mbly and insul at ors. See Fig s. 1-14,
1-15.
SERV ICE MANUAL - 1976 MASSEY WHIRLWIND
, ' j"
..... '
\
FI G. 1 -14
0 0 C JO
FIG . 1-15
1-11
....
-

SERV ICE MAN UAL · 1976 MASSEY WHIRLWIND
Fan Hou s ing and Armatur e P lat e Asse mb ly
R
em ov e screw ho lding s pa rk plug wir e
br a ck et to fa n hou sin g. With a soc ke t typ e 5
mm A l le n wr en ch and impa ct driv er , r em ov e
th e
four (4) mountin g b olt s ho ldin g fan
h ou s ing to cran kcase . (See Fig. 1-1 6).
Re mo ve fa n hou sing from cra nkc ase (See
Fig. 1-17).
FIG. 1-16
Un plu g con ne cto r hou sin g coi l w ir es. (N ot e
col
or co din g of wir es.) Remo ve ar ma t ure
pla te asse mbly and w ires , as a un it , fr om
f an housing.
1-12
\"-.-
F IG. 1-17

R emove the fan by toppin g th e end of f an
shaft with a so ft hamm er. With a fl at pu nch
and h amm er . t op th e inn er race of the fur-
thest be
aring in th e h ou sin g. See Figs. 1-18,
1
-19,1 -20.
SERV ICE MAN UAL · 1976 MASSEY WHI RLWIND ~
FIG. 1-18
-. c .s dP
FIG. 1- 20
1-13
-

SERVICE MANUA L· 1976 MASSEY WHIRLWIND
.--
~ Re mo ve spark plu gs with s pa rk pl ug
w
re nch. (See Fig. 1-21 .)
H. Cyli
nde r He ad s
Re
mo ve cylin de r he ad nut s with a
13 mm soc
ke t w re nch. M ar k cyli nde r
heads
be fo re removal from cyli nder.
Remove and di sc ar d gas kets. See Fig .
1-22.
I. Cyli nde rs
Remo ve th e eight (8) cylin de r base
nut s us in g a 13 mm soc ke t wr en ch and
rem
ov e th e e ig ht (8) spri ng w ash er s.
T
he cyli nders ma y be remove d. See
F
ig. 1-23.
NOTE: I M P 0 R TAN T
If removal of cyl inde rs on ly is re quir ed, care
must be take n that t he crankcase sea l is not
d isturb ed. The r emova l of t he PTO cyl ind er
w ill all
ow the p lacem en t of tw o bo lts and
nut s with f lat wa shers to app ly con stant pr es-
su
re to cra nkcas e ass emb ly. Bo lt s s hould be
p lac ed in the cente r two ho les (a dj acent to
t
he fan side cyl inde r). See F ig. 1- 31. The
second cy linde r m ay now be r em ov ed .
' ~
.1t, .-
" r«; ~
1
}
FIG. 1·23
1-14

J. Pi ston and Wri st Pin
With ne edl e nose pli ers, rem ov e c ir cl ips fr om
pi st on s. H eat th e pi st on with a heat gun or
pr opan e t orch . He at only to th e poin t wher e
pi st
on m ay still be h el d in h an d. Push th e pin
out.
K. To se pa ra te th e c rankcase h al ves, h ol d upper
po rti on of cra n kcase ass emb ly in on e hand,
liftin g slig ht ly a nd tap the end of th e crank -
case with a so ft hammer. The crankcase w ill
sepa ra te and th e crankcase ma y be
r
emov ed. See F ig. 1-24.
SER VICE MANUAL · 1976 MASSEY WHIRLW IND
\.
--
- -4 -I
;I
F IG. 1 -24
1-15

SERVICE MANUA L· 1976 MASSEY WHI RL WIND
L. Cr ank shaft Be ar ings
To r
em ov e cr ank shaft end be ar ing s, use
bea
ring pu ll er 4 44 - 31- 807 -0. See Fig s. 1-25,
1-26, 1-27. Slip the
pu ll er half s he lls around
th e ou te r b earing race and a ro und pull er
assemb ly. Sli de th e r etainin g r ing o ve r the
h
alf s he lls. Us ing tw o (2) 27 mm wr en ches,
turn th e cen te r bo lt clo ckwi se w ith o ne
wr ench and use th e seco nd wr en ch to hold
th e pu lle r b ody . Be fo re r em ovin g th e PTO
s
ide c ra nks ha ft be arin g, ins ert a112" 20 UNF
bo lt, 112" long, to pr ot ect the intern al thr e ad
of th e cra nks ha ft .
F IG .1-25
r
F IG .1-26
F IG .1-27
1-16

SER VICE M ANUAL - 1976 MASSEY WH IRLW IND
ASSEMBLY
A. Crank shaft B earin gs.
- t 1
F IG . 1-28 IL_SEAL
- BEARING
r
BEAR ING ~
• -e
\; -: r..
-
Crankca se.
He
at cr ank shaft beari ngs in oil (or o ve n) to
app
rox i ma te ly 180 de gr ees.
Slid e b earin g on cra n ks ha ft .
In
spect and cl ean b oth h alv es of cra nkca se.
The
prop er se al ant m at eri al such as Per-
mat ex Hy-Tack S pra y s ho uld be now spra y ed
on cr ank case sea l ing su rface s. See Fig . 1-29.
B
ef or e in stalling cra nks ha ft int o c ra n kca se
l
ow er h alf of it will be necess ary th at all
b
earin g ou te r su rfaces be wi ped cle an of
f
or eign m ateri al so th at p roper sea li ng w i ll
o ccur. Aft er in st allin g PTO thru st w asher a nd
oil seal (in sid e groo ve of oil sea l coa ted wi th
light g re ase ) p lace th e c ra nksha ft car efu lly
int o th e low er c ra n kcase h alf a nd prope rly
po sition all co mpo ne nts. See F igs. 1-30.
Pla c em ent of th e up p er crankcase h alf may
n ow be mad e. Be cer ta in th at t he cen ter s ea l
is
lin ed up with th e c ran kcase split line.
Tap upp er crank case h alf to sea t with low er
half .
B.
FI G. 1-29-
FIG. 1·30
1-17