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