Ski-Doo ALPINE VALMOMT User manual

ski-doD.
ALPINE
VALMOMT

In 1957 and 1958, tests began on
what IS considered the forerunner of the
Ski-Doo' We experimented with many
different frames and
engines-in search
of a light
machine for one or two pas-
sengers By the fall of '58, the first pro-
totype was ready Initial tests made it
obvious the machine could hold ItS own
in the recreation market. Production be-
gan one year later and 225 machines
were sold at about $1
,000 each.
Like
it's predecessors the' 73 Ski-Doo
snowmobile is a combination of light-
ness, economy, strength and depend-
ability And yet,
with all this, it has one
other additional feature ... personality
Each model In each series has a
com-
plexity of characteristics that distin-
guishes itself as part of a bold breed
... the Ski-Doo snowmobiles.
At Bombardier. we fully realize that the
purchase of a snowmobile is a very im-
portant decision For this reason, we
have ensured
that each Ski-Doo snow-
mobile is backed up by an international
Ski-Doo Distributor and Dealer Network
whose factory trained personnel are
equipped to give you
prompt and ef-
ficient service wherever you are in Snow
Country
Furthermore. each dealer is prepared to
serve you
with information. parts and
accessories. Feel free to
contact him.
At this
time we would like to thank you
for your patronage and
welcome you to
Winter. Enjoy yourself but remember:
Safety depends on you. the driver.
the
condition of your vehicle and nature of
the terrain.
All of the information. illustrations and
component! system descriptions con-
tained in this manual are correct at the
time of publication However, Bomb-
ardier Limited reserves the right to
make changes in design and specifica-
tions. and / or to make additions to or
improvements in its
products Without
imposing any obligations upon Itself to
Install
them on its products previously
manufactured.
This manual has been published by the
Technical Information Centre. Bomb-
ardier
limited. 8600 Decarie Blvd,
Montreal 307, Quebec. Canada.
'Trademark Bombardier Limited

tol-
710,592 -
AI! rights reserved t["Bomt'ardier
LUBRICATION 10,11, 12
MAINTENANCE 13, 14, 15, 16, 17
EMERGENCY GUIDE 17
TROUBLE SHOOTING 18, 19
OFF-SEASON STORAGE 20, 21
SPECIFICATIONS , 22, 23
WARRANTY 24
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
Skandic
Carry-Boose
Bombardier
"The touowmo are trade marks of Bomb-
ardier
Ski-Doo Valmont
Ski-Boose T'NT
Nordic Elan
Alpine Blizzard
PATENTS and DESIGNS
This vehicle by or more
lowing

2
To many of us, Winter is a revealing ex-
perience. Weather, atmospheric condi-
tions, snow surfaces, individual driving
habits and vehicle usage have consider-
able affects. We ask
that you familiarize
yourself
with them ... read 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 periodically
upheld
... all aimed toward a more en-
joyable
Winter season.
Observe the following precautions:
• Throttle mechanism should be
checked for free movement before
starting engine.
• Engine should be running only when
pulley guard is secured in place.
•Never run engine without drive belt
installed Running an unloaded engine'
can prove to be dangerous.
•Never run the engine at high R.P.M.
when the track of the vehicle is raised
off the ground.
• It can be dangerous to run engine
with the cab open.
•Prolonged sitting while riding over
rough terrain may cause kidney andIor
spinal discomfort, specially for the driver
or passenger having an existing back
weakness.
• Gasoline IS flammable and explosive
under certain conditions. Always per-
form procedures in a well ventilated
area Do not smoke or allow open
flames or sparks in the vicinity. If gaso-
line fumes are noticed while driving, the
cause should be determined and cor-
rected
without delay.
•Under 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, roads or
highways. In most States and Provinces,
it is considered an
illegal operation.
• Hidden telephone guy wires or road-
side ditches can
cause serious accidents.
• Your snowmobile is not designed to
be driven or operated on black top, bare
earth, or other abrasive surfaces Abnor-
mal and excessive wear of critical parts
is inevitable.
•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.

North Dakota
Dakota
Missouri
Upper Michigan
Lower Michigan
Indiana
Maine
New Hernpshrre
Vermont
INTER~JATIONAl INC.
TIMBERLAND MACHINES INC
10 Main St
New Hampshire
Coverage Area
Massachusetts
Connecticut
Rhode Island
California New Mexico
Nevada Arizona
Kansas
Nebraska
Washington
Oregon
CO. Alaska
AMERICAN DISTRIBUTORS
Maryland
Delaware
District of Columbia
VIrginia
West Broadwav.
Idaho Falls.
Name of Distributors
BOMBARDIER EAST !NC:
Railroad
Massachusetts 01238
BOMEiARDIE:R WEST INC
ELUOTT HUTCHINS INC.
New York
East
Mam ~T'l:>cd' O,~"r<
Malone.
Coverage Area
British Columbia
Quebec
Manitoba
Saskatchewan
North-West
Territories
Newfoundland
Brook,
Name of Distributors
DISTRIBUTORS
-
28th Ave. Vernon. BC
LTD.
N.B.
CANADIAN DISTRIBUTORS
BOMBAR:DIER (lNTARIO LTD
Ont.
BOJVlB)~RD!IERQUE. LTD.
1 Nobel St. Bouchervilla.
BROOKS
EQUIPMENT LTD.
Box
985, Winnipeg 21 . Man.
BAyeD
Hichrnond W.
3

de-
press button into released upper
Kill Button (E)
Abutton switch located on
of handlebar. For emergencystops,
button down into lower
driver this vehicle should Jamillar-
ize himself with the function of 1his de-
vice it several times first
Headlamp Dimmer Switch (D)
The dimmer switch. located on left side
of handlebar. allows correct of
hO'::lnl':1l"i"1n beam. To obtain Hi or Low
deoress SWltC h
of your
beam
Note:
beam has been prE~-a{JIUS!Eld
Should you
remove
chrome and turn
or
lower screwsto ob-
desired beam nr\0,T,""
switch
Ignition/Light Switch (C)
(Manual Models
Key ed.
(OFFI
first turn
To stop
wise to
clockwise
nates both and
t::lllilrtl,t
Ignition/Light Switch
(Electric Models
Key operated, 4
(OFF/ L1GHTSIONI
engine, turn ful
START
n"C~I1'lr\l'" Return
ON immediately
To Illuminate both
and taillight turn to
Steering
Hotation of the handlebar causes a
action on the <:::1",.-,,",""'"
the ski to turn in the l"Clrn,"'c::.,.'l
rection. in the crash
ded
handlebar are the dimmer
kill button, brake and throttle 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 returns automat-
to idle.
Brake Lever (B)
Located left side of handlebar. When
lever is the brake is aooueo
When released, it autornaucauv
to its ,..., ... "-e , n·"" n,,,\cl1'jr\/"i
4

OFF ON
~I~
Access Door (J)
To gain access to the carburetor or
spark lift lock tab and
open access To
turn nut in required direction.
Fuel Level
Fuel level can be checked, at
time, by removing cab and ,",1-:\1'"\1'.,"-'11""
translucent tank.
Seat Compartment
Remove backrest and tilt seat Ideal lo-
cation for spare belt. rope, etc.
Tips
Emergency materials should be
wrapped In foam or similar material,
This
will damage to
breakable over
or
Gear Shift Lever (H)
A 3 (FORWARD/PARK; RE-
" ... ,--, ..... , gear shift lever. Push up for for-
ward, center for and down for
reverse.
Warning: Do not activate gear shift
lever
while snowmobile is in motion.
Never run the engine at high R.P.M.
when lever is in park position.
Tachometer (I)
The tachometer reoisters
of the
Direct reaornq
cates (in , the
elutions per (R.P.M.)
for
situations its
use.
After asituation, the source of
malfunction should be determined and
corrected before
Manual Starter (F)
Auto-rewind located at lower
side of To start engine,
handle. (See Procedure)
Choke (G)
Apush-pull button. Pull button
gage choke, push to
choke should always be
cold e sta rts After is
warmed however, It IS not necessa ry
to use when C'T".:lrhr"lr"I
5

40:1
Fuel Mixing Procedure
To mix the and oil use a
separate container.
Never mix
directly in your snowmobile tank. For
best results, acquire
two containers,
ther plastic or metal. Draw from
one un-
til empty then use the second one,
Warning: Gasoline is flammable and
explosive under certain conditions.
Always perform procedures in awell
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
while engine is
running.
• Pour the full amount of Ski-Doooil re-
quired for the
total mixture into the
container.
• Add approximately half the amount of
Caution: The carburetors of the 1 973
Ski-Doo snowmobile have been cali-
brated for a mixture of and
concentrated Ski-Doo oil.
Unless do not use
regular oil. such oil IS
used, observe mixing instructions on the
container. Never use outboard or
straight mineral oils.
Fuel Mixing Ratio
The of the correct fuel
mixture cannot be overstressed. Prior
experience has shown that an incorrect
fuel ratio results in serious dam-
age. The correct
fuel/oil ratio 40/1
5gallons, recommended gasoline
plus 1
pint Ski-Doo oil =correct fuel
mixture.
Note: To facilitate fuel m oil
should be kept at room temperature.
With Ski-Doo snowmobiles,
the oil must
be added to the gasoline in
sured amounts then both oil
line should be
before the tank.
Which Gasoline to Use
The correct is regular uasoline.
less 88 ,available
all service stations.
Caution: Never ClV(""\orlrYIt:tnt
than Y''''',,",,'-''VV'i''V"\,,",,",·..jnrl
Never use no lead
methanol or similar r"'oducts.
Which Oil to Use
Use concentrated Ski-Doc" oil avail-
able from Ski-Doo" dealer. This
of oil formulated oil
to meet
ments of the Bombardier-Rotax
01 1\~11 II:;:;.
6

With Ski-Doo snowmobile engines. a
break-in period is required before fun-
ning the vehicle at full throttle. Manu-
facturer's recommendation for the
Bombardier-Rotax engine is 10 to 15
operating hours. During this period,
maximum throttle should not exceed 3,4.
However, brief full accelerations and
variations
contribute to a good
Continued wide open throttle
accelerations, prolonged 'cruising'
soaeos and are detrimental dur-
ing the nn~rll<'-In
Inspection
After the break-in period, we suggest
that each Ski-Doo snowmobile has an
check. This
inspection is at
the discretion and expense of the ve~
hicle owner.
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
then note time elapsed until half-
full. Repeat on different
occasions to
get amean average of your snow-
mobiles' consumption and of
running
time under varying
gasoline to be mixed.
•Shake the
container +h~ .. rA' ,,,,hh,
• Add the remainder of the casoline
•
Once again the
container.
• a funnel with a fine mesh
screen to prevent
the of water
and foreign mixture
from container into the snowmobile
tank.
Note: When using
ways shake the ,..,,....""+ r: "n'''r
the oiIhas a to settle.
Warning; Never 'top up' gas tank be-
fore placing vehicle in a
warm area.
At certain temperatures, gasoline
will expand and overflow.
7

8
Fuel Tank Quantity
Check that there is sufficient fuel in the
tank for your trip. A good 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 mecha nism.
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
all 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 drilled
holes, located approx 1 ¥S 11 above the
original cross shaft holes of the frame.
To reposition bogie wheel sets, drill
holes fully through usmq a
5Ae 11 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
/LIGHTS
.".,.ON
-START
OFF
ON
LIGHTS
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 kill button is in the released up-
per
Electric Starting:
1. Insert key in ignition switch.
2. Engage choke. (Choke is not neces-
sary if engine is warmed
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 does not
start on first try, key turned fully
back to OFF each time. Allow starter to
cool for 2 minutes before
procedure.
5. Release throttle and
immedl-
ately engine has started. Disengage
choke.
6, Allow the engine to warm up before
operating
at full throttle.
Caution: Never operate the Ski-Doo
snowmobile with the battery removed or
disconnected.
Manual Starting
1. Insert in ignition and turn to ON
position.
2 Engage choke. (Choke is not neces-
sary if engine is warmed up).
3. Test throttle operation then apply
throttle lever slightly.
4, Grasp manual starter handle firmly
and pull slowly until a resistance is felt
then pull vigorously and engine wit!
start. Allow handle to return slowly to its
original position. If engine does not
start. repeat
the procedure.
Note: Do not its
fullest extent or allow to
"fly back" to its fHH"lln;;;;1 n.f"\C'lf',r-,r"'\
5. Release throttle and
choke immediately has
6. Allow the engine to warm up before
operating at full throttle.
9

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 run
engine
with cab off.
10
Code
Code
Bi-Monthly ~20 hours)
BM1 Drive Pulley
Code Monthly (40 hours)
M 1 Driven
Page
11 Pulley Guard Removal
1. Remove cab.
2. Pullout retaining clip and push on
spring bolt to disengage pin from
bracket.
3. Move pulley guard toward front of ve-
hicle to disengage it from bracket.
Warning: Engine should be running
only when pulley guard is secured in
place.
Drive Belt Removal
1. Remove cab and pulley guard.
2. Remove hair
cotter pin and slacken
brake adjusting screw (A), Disengage
brake housing from lower brake lever (B).
3, Remove the
two (2) bolts holding
lower disc brake bracket to the frame
(C). Disconnect light switch connector.
Pivot the brake bracket assembly half a
turn.
4. Open the driven pulley. Twist and
push the sliding half then hold in open
position.
5. Slip the belt out from the drive pulley
and remove from vehicle by passing it
under the driven pulley and disc brake
assembly.
6. To install drive belt follow reverse
procedure. Check brake adjustment,
Warning: Never run the engine with-
out drive belt installed. Running an
unloaded engine can prove to be
dangerous.

(W1) Steering Mechanism
Using light machine oil, lubricate the
spring located on top of steering col-
umn housing.
Allow oil to run in. Oil the
mobile contact point at bottom end of
steering arm. Using a small brush,
dipped in low lubricate
steering arm bail Grease the ski
leg at fitting until new grease ap-
pears the joint. Lubricate spring cou-
pler bolt
with oiI.
(W2) Gear Box Oil Level
All 440R and 440ER models have an
oil capacity of 12 ozs. The
640ER
model has an oil capacity of 16 02S. To
check level:
1. Remove rubber inspection cover lo-
cated on bottom right side of gear box.
2. Using a rigid piece of wife as dip-
stick, check oil level. On
440R and
440ER models, oil level must reach
21,4 /I on dipstick. On 640ER model. oil
level must reach 3% /I To fill, remove
filler cap (red cap), from
top of gear box.
Refill as required using Ski-Doo" chain
case oil.
"Trademark Bombardier Limited
(W3) Suspension
Grease the suspension bogie wheels
with low-temp grease, using alow pres-
sure grease gun" Pump through the
grease fitting at
the centre 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 fittinqs. Also grease rear
axles at grease fittings.
11

(8M1) Drive Pulley
Note: The drive pulley of the Alpine
640ER model is self-lubricating and re-
quires manual lubrication only at
storage.
1. Remove cab and pulley guard then
slip off drive belt.
2 Remove centrifuga I governor as
follows:
• Remove spark plugs and position
the left side (P.T.O,) piston 3AI/ to
11;4 1/ before top dead ce nter.
making sure that the piston closes
the exhaust port.
•Accede by the spark plug hole and
pack the cylinder
with o/t
6
lJ
dia.
rope.
• Pull manual starter to rotate crank-
shaft until piston bears against
"cushioning' .
• Unscrew centrifugal bolt, remove
centrifugal governor, outer half and
12 spring then pull rope from spark
plug hole.
3Thoroughly clean the inner
shaft using fine steel wool and a clean
cloth.
4. Apply a light coat of low-temp
grease to the four (4) flyweights of the
centrifugal governor.
5Install spring and outer half. Making
sure that the mark on inner
pulley half with the aligning
mark of the outer pulley half, pack inside
of pulley shaft
with low-temp. grease.
6Using light machine oil. lubricate the
governor bolt threads and install gover-
nor. Torque bolt to
33-40 ft fibs.
Note: Installation procedure is reversed
insuring that the rope is inserted into
same cylinder when piston is 3A II ap-
prox. after
top dead center.
Warning: Make sure that the gover-
nor bolt is fully tightened before re-
moving rope from cylinder.
(M1) Driven Pulley
With cab removed, grease the driven
pulley shaft as follows:
1 Remove guard and
drive belt. Open driven
and twist sliding half)
2Thoroughly dean the driven pulley
shaft.
3Apply alight coat of low-temp
on the shaft. Always lubricate
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

Carbonized
Normal
Burnt
(W1) Spark Plugs.
1. Open access door. Disconnect
plug wires and remove plugs.
2Check condition of plugs.
• A brownish tip reflects ideal condi-
tions, (proper carburetor adjust-
ment. spark plug
heat range, etc)
• 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.
• A light grey insulator 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 serious eow
gine damage jf the severity of
operating conditions are greater
the plugs' intended range.
3. Check spark plug gap using a wire
feeler gauge. Gap must be .020"
4. ReinstaIIplugs 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 then check elec-
trolyte level at cell. Electrolyte
level must touch bottom of filler hole. If
necessary, add distilled water.
(W3) Suspension Springs
With engine off, visually inspect
sion springs. Replace any weak or
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 missing track inserts are noted,
see your dealer.
Note: Without these inserts continual
abrasion would wear and cut the track
therefore, always replace a or
damaged insert as soon as possible.
(W5) Track Tension and Alignment
Lift the rear of vehicle and support it off
the ground. Using a rule,
check track
tension. On Valmont models, take mea-
sure at the middle set of wheels.
On Alpine model,
check measure at the
second set of bogie wheels from rear.
The
tension of each track should be
2%
II ± /I between top inside edge of
track and bottom of footboard.
To adjust track use the following
procedure:
1Loosen link plate spring
lock nuts (4)
located on inner side of link plate
springs.
2. Turn
outer side adjuster bolt(s) clock-
wise to
tighten track(s). counter-clock-
wise to slacken.
3.
Start engine and allow tracks to ro-
tate slowly. Check if tracks are well
centered and turn evenly on the rear
sprockets. The
distance between track
edges and link plates should be equal.
To correct:
1. Turn inner SIde bolt(s) coun-
ter-clockwise to bring track closer to
center link turn clockwise to
withdraw link plate(s).
2 Tighten link lock nuts.
3. Rotate and recheck
alignment.
Warning: Before checking track
alignment, ensure that the track is
free of all particles which could be
thrown out while track is rotating.
Keep hands, feet and
clothing clear
of track.

Air Silencer Box
Located in the front section of the stor-
compartment. When operating the
\1r>~"",,",I!C'> in temperatures exceeding
30
0F the
two (2) rubber plugs must
block
the engine SIde orifices to allow
cold air circulation. In be-
low 30
0Fthe plugs
tioned to block the side
This will trap the warm air being emitted
from the engine and direct it to the car-
buretor. Plug determines circu-
tatinq air temperatures.
Caution: Observe temperature
changes and locate plugs accordingly.
Incorrect location of plugs cause
carburetor ice-up or engine 11\1,~rhj~~tmn
Clothing. placed in underseat
rnent. can restrict the plug Iseat air
flow.
Idle Mixture Adjustment (A)
Aprimary adjustment (with off)
should be made by first turning Mix-
ture Screw fully clockwise until closed.
Back off screw
3,4 of aturn counter-
clockwise.
Note: Do not close too tightly as needle
and
lor seat can be damaged.
For final adjustment, start engine and
allow it to warm up. Turn Idle Mixture
Screw until engine reaches maximum
R.P.M and obtain a idle and a
fast response of the to the
throttle.
Idle Speed Adjustment (8)
Turn the Idle Speed Adjusting Screw
clockwise to increase idling speed,
counter-clockwise to decrease.
(W6) Carburetor Adjustment
Maximum Throttle Opening
With engine off, unscrew the Idle
Speed Adjusting Screw until a
gap ex-
ists between screw end and carburetor
shaft lever. Depress the throttle lever at
handlebar a
ndhold. Throttle butterfly
should be horizontal when the lever
gently touches the handlebar grip. To
adjust for maximum opening. loosen
screw at point where joins car-
buretor lever.
With finger. hold throttle le-
ver in fully open position pull cable
downward until taut. screw.
Warning: Before starting engine,
carburetor throttle lever must return
to idle position by contacting
with
the tip of Idle Speed Adjusting
Screw. Never start engine unless
this situation isverified.
15

16
(W7) Drive Belt Condition
With engine off, inspect drive belt. If
belt is less tha n
Ya fI 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 V2 turn counter-clock-
wise and recheck. Starting from max-
imum reading, adjust chain tension to
1ft! JI free-play.
1. Remove capscrew locking chain ten-
sioner in place. is located at
bottom left of
2. Rotate the as required
to
obta In correct cha in tension.
3. Replace
capscrew to lock chain ten-
sioner in
(M1) Carburetor Flange Nuts
After the first 2hours of operation,
check tightness of
carburetor
nuts. Open tab locks, tighten nuts
close tab locks.
Caution: Tab locks must be
after opening
them three times.
(M2) Brake
Brake should be applied when lever
is
1" from handlebar. To adjust:
1.
With cab removed, slacken cable
lock
nut located at cable end nearest
frame.
Manoeuver the lower brake lever
and brake cable
until the pin pushers
are seated
directly in the "cam" of
brake lever. Lock cable in position.
2.
Tighten the caliper nut until a
disc I
puck friction is felt. Back off nut
slightly.
3. Check operation of brake.
Note: Always check the stop
see if it functions after performing
adjustment. To adjust, loosen sr ori-norrr
switch lock nuts and adjust to proper
length.
(M 3) Steering Adjustment
Ski should be perpendicular to handle-
bar. To align:
1. Remove bolt handlebar to
steermo column.
2. Remove handlebar to expose splined
end of steering
column.
3. Reposition handlebar on so
that it is perpendicular with Install
and fully
tighten bolt.
(M4) Engine Head Nuts
With cab removed, check that
head nuts are tight and equally torqued.
{16 to 18 ft / lbs when cold).

(M5) Engine Mount Nuts
With cab and console removed. check
ne
mount nuts. Retighten if
necessary,
(M6) Vehicle General Inspection
With cab removed, check electrical wir-
ing and retighten loose
connections, for wires or
rl:::lr'Yi:::lr'lorl insulation, or replace
inspect the
loose nuts and
cab and clean the
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 removing
red plastic lens. To remover unscrew the
two (2) Phillips head screws.
Broken Throttle Cable
Remove throttle cable and
Check lever operation. If necessary re-
housinc. Do not start the
until levers swiftly.
Broken Rewind Starter Rope
Abuse of the rewind starter may cause
the to fray and break. Should this
suuanon arise, remove starter unit using
10 mm wrench supplied in tool kit.
Transfer rope grip to your emergency
rope. Place starter unit in seat compart-
ment. Make a knot at the end of emer-
gency starter rope and wind rope
around starter Pull vigorously as
per usual manual See your dealer
for
immediate of starter unit.
Emergency Materials
In addition to those tools which the
manufacturer provides, you should also
carry
the following:
Tools: General Purpose Pliers-Adjust-
able Wrench (~" opening)-Flashlight.
Spare Parts: Spark Plug-Drive belt-
Headlamp and Taillight bulbs-Throttle
Cable and Housing-Starting and tow-
ing (electric models).
Important: Always carry spare
and drive belt,
17

18
TROUBLE SHOOTING GUIDE
What To Do
Check the tank level and fill up with correct gas-oil mixture Check for possible
clogging of fuel line, Item 5.
Check for fouled or defective spark plug Disconnect spark plug wire, unscrew
plug and remove from cylinder head Reconnect wire and ground exposed plug on
engine head, being careful to hold away from spark plug hole Follow engine start-
ing procedure and check for spark If no sparks appear, replace spark plug If
trouble persists, check item 3.
Disconnect spark plug wire from plug, unscrew the spark plug cap then hold wire
about Ys// from the cylinder head Follow engine starting procedure and If no
sparks appear, It means a faulty ignition system. Do not attempt to repair. Contact
your dealer.
Disengage choke,
wait 60 seconds or more then depress throttle lever fully
and try to start engine Release throttle lever immediately after engine starts.
Remove and clean the fuel filter Change filter cartridge If necessary Check condi-
tion and connections of fuel lines. Check the cleanliness of the fuel tank. Clean tank
if necessary. (See Fuel Tank, Storage Section).
First make
primary adjustments on carburetor (See Maintenance Section). If car-
buretor is still faulty, contact your dealer for repair
Drain the fuel tank and refill with the correct gas / oil mixture.
Breaker pornts may be worn or out of adjustment. Contact your dealer
Running with a lean fuel mixture may produce excessive engine wear resulting In
poor engine compression If this occurs, contact your dealer at once.
In the case of a seized enqrne. contact your dealer. Seizure IS a direct result of
poor lubrication.