SECTION VI DEALER INSTALL ED EQUIPMENT

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Jewel Dalton
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1 SECTON V DEALER NSTALL ED EQUPMENT Chaparral ndustries, nc. offers several items of optional equipment which are to be installed by the dealer at the request of the customer. Accessory Gauges Figure 6-. Accessory Gauges Accessory gauges offered by Chaparral ndustries are a Cigarette Lighter (), and Ampere Gauge (2) for electric start models, a speedometer /odometer (3), and a Tachometer ( 4). Figure 6- shows the normal position for mounting this equipment.. Cigarette Lighter - The Cigarette Lighter hot lead is to be connected to the switch terminal marked "Battery", and the ground wire to the ground side of the switch. 2. Ampere Gauge - (See figure 6-2) The ammeter is to be connected into the line between the ignition switch and the solenoid. Disconnect this wire after mounting the Ampere gauge in the dash, and wire as shown in this figure

2 SOLENOD AMM-ETER, Figure 6-2. Ammeter Connection 3. Speedometer/Odometer -(See figure 6-3). After installing the Speedometer in the dash a s shown in figure 6-, remove the three bolts from the right side of the gearbox as shown in figure 6-3. Place the keyed end of the Speedometer cable into the gearbox output shaft, and replace the three bolts through the Speedometer cable cover LOWfQ, R,.tt. Sl Df Of FWD. BODY ASS'Y -- \ \, SPffDOMfTfR. CAe>Lf Figure 6-3. Speedometer Connection

3 4. Tachometer - (See figure 6-4) The Chaparall snowmobiles are furnished with a negative ground. For this installation, the red wire of the Tachometer is to be connected to the Magneto, and the black wire to ground. The white ' and green wires are not used in this installation, and must be taped over. The purpose of these wires is to provide for internal illumination of the Tachometer, but should not be used on these machines. TUR.N SWTCtt TO NO. CYL. Of fngnf NfG. GND. MAGNETO High Speed Sprockets Figure 6-4. Tachometer Connection The drive sprocket, part no. 32, furnished in these machines is either a 5 or 7 tooth sprocket. f the customer desires a higher top speed, the dealer may replace the existing sprocket with a 9 or 2 tooth sprocket. (Part Numbers 92 or 93. f this is done, a larger chain, Part Number 239-2, must also be used. Refer to figure 5-2 for details of the gearbox, drive sprocket, and chain

4 O'l fl::.. fngnt WQf ttaqnfss. O'l CJl #otf: UNWRAP ENGNf. WQ.f t!aq.ness TO UNCOVfQ.. YEL W l f. v t\ \'" : ATTACtt TO YH WQ.fS N [] : : : : : : f!c:.. ltaqnfss- CON N-ECT TO Q..fCTiflf.R. -=' / ::. CRMP TO YfL WQ.E ttaq.nfss-connf.ct /TO r.,at. SDE :,, /CONNECT TO LOWER. Tf. R.M. UCT. flf.ct. WQ.f \ trl... () ('j " ('j r:n... P' "... () " " :$ (Jq L.tt. tt AO LT. P.lFLN '-.. RED/ CONNfCT TO lalght WQ.f J CONNfCT SOLfNODTO TOP Tf.R.M. //CONNECT AT SWTCtt WQE tiar.nt:5s CONVEQSON -' -' -' O'l <:.D

5 VV' d J\' d s Q.U o_>:t J t: > o..,. uu a._.<( >-' oa l: tv L j c 6 t-z cl...llj.j... oc> - :tid en od <t z:s;; jt-:td= ([) -r>< <.!)...i!z... (/)lj.j J-! l) ijj...j lw Figure 6-6. Starter nstallation

6 cr;, cr;, rl_j, l, CAR.DUR.ETOR, (TOP V lt:w) Q.fMOVf / i : fxsr'g PLUG : f ittng W GAS LNf,, ' ' , ) r - -,' NSTALLAT ON foq. MODt:LS WTtt " TLLOTSON'' ttd SfQ.fS CAQP.>UQUOR.S ' '- --,\ G", Llf - t%,/t'---, / : : GAS LN LOCK NUT ' WAStlfQ Jlo'"'"' GAS TA"' WAU Jpnwz;aJ /, /! : ' : k nvan4..-.-l.._ NfOPQ.f.Nf ' WASfffQ. TANK f ittng (insta LL NSDE TANK) f-' f-' f-' cr;,. / ' ' J L 74 DA. tfo L : N Ll Nf WTt! GAS TANK SLOT ( :,..---J ':,u u,- -.'':':<' 5 ---m-""'=---j -_, ) Figure 6-7. High Altitude Kit

7 Electric Start Kit Frequently, the customer will specify a manual start unit in the interests of economy, and then will later decide to add the electric starter. For this reason, Chaparral ndustries supplies an electric start kit as a dealer installed option. Table 6- lists the parts contained in this kit. Figure 6-5 shows the wiring changes which must be made for this installation, and Figure 6-6 shows the physical details of the installation. High Altitude Kit The high altitude kit is essentially a means of pressurizing the gas tank with a return line from the carburetor to supply a more effective gasoline feed when the machine is operated at high altitudes. At altitude, a gravity feed system may not be sufficient for efficient operation. n such cases, the engine will "starve out", and lose power. Table 6-2 shows the parts which must be added for the high altitude kit, and Figure 6-7 shows how the parts are to be installed. TABLE 6-. Electric Start Kit Part No. Description Quantity 5 Battery Bracket 87 Wire Harness Conversion 79 Solenoid 7 Rectifier 72 Bolts, Ground Wire 76 Lock Nut Battery Cable 86-2 Battery Cable 86-3 Battery Cable 862 Washer Bolt Locknut Battery Box Holddown 867 Starter 869 Wing Nut J- Bolts 2 87 Battery

8 TABLE 6-2. High Altitude Kit Part No. Description Quantity 88 Return Gas Line 883 Fitting 99 Grommet 85 Tank Fitting 87 Washer 88 Washer, Neoprene 89 Lock Nut

SECTON V DEALER NSTALLED EQUPMENT For 97, Chaparral ndustries offers an expanded line of accessory equipment for dealer installation. The following accessory kits are now available.

9 SECTON V DEALER NSTALLED EQUPMENT For 97, Chaparral ndustries offers an expanded line of accessory equipment for dealer installation. The following accessory kits are now available. Touch Bar Suspension System Electric Start Kit - Hirth Engines Electric Start Kit - CCW Engines Tachometer Speedometer Primer Kit Ski Shock Kit ce Runners Lighter Passenger Back Rest Rear Flap Rocky Mountain Skis TOUCH BAR KT NSTRUCTONS A. B. c. D. E. Remove all bogie assemblies (save six bolts and lock washers). Locate a 3/32 in. diameter hole in body of each side, one inch above and seven inches forward of existing front bogie axle mounting hole. Place stiffener. plate on inside of body with center hole aligned with hole just drilled, keeping edge of plate parallel with bottom of body. Drill remaining three 3/32 inch diameter holes using plate as template (each side). Bolt plates in place. Mount side mounting bracket to existing bogie axle mounting holes (each side). Pre-assemble three bogie assemblies and touch bars, and slide assembly into position on inside of track (spring hanging loose ). Bolt front axle through new holes in body, bolt middle and rear axle through holes in side mounting brackets, use spacers at each end of axle (between axle and bracket). Use bolts removed from old bogie assemblies. Lift looped end of spring over tie bar on each bogie axle, starting at front axle, and re- tighten track

10 m!:>:) 7 i' 8 "\ ' -' -.. FGURE 6-. TOUCH BAR SUSPENSON SYSTEM

TOUCH BAR ASSEMBLY TEM PART QTY. PER LST NO. NO. DESCRPTON ASSY. PRCE 37 Touch Bar Assembly $22. B- 2 Bolt 6 2 3732 Plate, Stiffener 2 3 N2-8 Nut 6 4 Part shown for Reference See tem 26, Figure 5.:.

11 TOUCH BAR ASSEMBLY TEM PART QTY. PER LST NO. NO. DESCRPTON ASSY. PRCE 37 Touch Bar Assembly $22. B- 2 Bolt Plate, Stiffener 2 3 N2-8 Nut 6 4 Part shown for Reference See tem 26, Figure 5.:..7 5 Part shown for Reference See tem 27, Figure Spring, Bogie, R. H Spring, Bogie, L. H Axle Weldment Axle,Main Axle, Long Tube, Middle Bogie Axle Slide W eldment, Front Tube, End Bogie Axle Wheel, Bogie Part shown for Reference See tem 37, Figure Mounting Bracket, Side 3.75 ( R. H.) Mounting Bracket, Side ( L. H.) 8 B-2 Bolt 6 9 N2-8 Nut Clevis Pin P27-2 Cotter Pin Axle Weldment Slide Weldment, Rear '737 Slide Block Clip, Bracket Weldment Tube, Rear Middle Bogie Axle Axle, Medium 28 Part shown for Reference See tem 26, Figure Part shown for Reference See tem 27, Figure Spacer, Main Axle

12 a, ll- TOP VEW SDE VEW 4 e :J FGURE 6-2. ELECTRC START KT- HRTH ENGNES

13 :J Black (Existing) Green Red (Existing) VEW A-A Wiring sequence for switch connector. Wires attach to std. receptacle (3425) Black (Existing) SWTCH L8=4 GREEN5 T Tl ORANGE 5 Connector (3422) (Ref.) Remove tape from yellow engine wire and attach blade and connector plug into rectifier. 8 ENGNE Connect to Solenoid Terminal #86 -f 4'' YEL.DW 6p - Unplug yellow engine wire from starter switch, attach connector (3434) and plug into rectifier c:::j 88 c:::j 88A Top view of Solenoid 86 Connect to solenoid Terminal #88 c:::j 3 c:::::j 2 c::::j Top view of Rectifier WRNG CONVERSON FOR HRTH ENGNES : FGURE 6-3. HffiTH WRNG SCHEMATC

14 ELECTRC START KT DRTH ENGNES PARTS LST AND NSTALLATON NOTES tem No. -- Part No. Description Qty Per Assy Part of Wiring Harness Part of Wiring Harness 3643 B3-2 N N2-6 B3-6 W2-6 N SN9L Starter Battery Cable ( To Solenoid Terminal 88A ) Battery Cable ( To Negative Battery Post Battery Cable ( Positive Battery Post To Terminal 88 of Solenoid ) Solenoid, Bosch Green Wire ( Solenoid Terminal 86 to Switch Connector) Orange Wire ( Solenoid Terminal 88 To Switch Connector) Rectifier Yellow Wire To Yellow Engine Wires Clamp, Cable Bolt Nut Strip, Adhesive-Backed Bracket Assembly J- Bolt Wing Nut Bolt Washer Nut Holddown, Battery Battery NOTES Use 45 watt lightbulb ( Part No. 3642) in place of existing headlight bulb

15 2. 3. Use battery with center filler caps only. Gould SN9L or equivalent ( 2 volt, 32 ampere-hour). Holes drilled for mounting bolts ( tem ) must be 9/32 inch diameter. NSTALLATON NSTRUCTONS Hirth Engines CCW Engines A. Place Bracket Assembly (3628- for Hirth Engines, for CCW Engines) on the left side of spindle channel with the first set of holes 2. inches from the center line of the machine. Use this bracket in place as a template to drill eight. 28 in. diameter holes in the channel B. After drilling holes, install seven bolts and nuts to hold bracket in place. The eighth bolt and nut are to be used to install the cable clamp and cables. C. Place the adhesive-backed strips in place under the battery. D. Set the battery in place on the adhesive-backed strips and fasten securely with "J" bolts, hold-down, and wing nuts. E. Remove the cover plate from the engine and install the starter motor. F. nstall the battery cables and wiring as shown on the enclosed wiring drawing

') CX> TOP VEW SDE VEW 2 @ 5 4 e a 8 6 6 3 -'

16 ') CX> TOP VEW SDE VEW 5 4 e a ' -' -;j FGURE 6-4. ELECTRC START KT - CCW ENGNES

17 -' -' -.;J Black (Existing) Green Connector (3422) (Ref) Red (Existing) Black (Existing) VEW A-A GREEN S Wiring Sequence For Switch Connector Wires attach to Std. ORANGE SO" Receptacle (3425) Connect to Solenoid Terminal 8 to" z H E-t rn H rn X E::- BLACK 2 H. u E-t u,...; RECTFER L Unplug yellow engine Conn wire (existing) from t starter switch. Attach 4" splice (3427) between _l yellow engine wire and yellow rectifier wire. Connect to Battery Side of Solenoid ) (!) WRNG CONVERSON FOR CCW ENGNES FGURE 6-5. CCW WRNG SCHEMATC

18 ELECTRC START KT CCW ENGNES PARTS LST AND NSTALLATON NOTES Qty tem Part Per No. No. Description Assy Solenoid Starter Battery Cable ( To Negative Battery Post ) 4 Part of Green Wire ( Solenoid To Switch Connector ) Wiring Harness Battery Cable ( To Positive Battery Post ) 6 Part of Black Wire ( Positive Side Of Solenoid To Rectifier ) Wiring Harness 7 Part of Orange Wire ( Positive Side of Solenoid To Switch Connector ) Wiring Harness 8 Rectifier To Yellow Engine Wires Clamp, Cable B3-2 Bolt 8 N6-6 Nut Strip, Adhesive - Backed Hold Down, Battery Bracket Assembly 4 363'3 J- Bolt 2 N2-6 Wing Nut 2 5 B3-6 Bolt 2 W2-6 Washer 4 N6-6 Nut 2 6 Rectifier 7 SN9L Battery NOTES. Use 45 watt lightbulb ( Part No ) in place of existing headlight bulb

2. 3. Use Battery with center filler caps only. Gould SN9L ( 2 volt, 32 ampere - hour or equivalent. Holes drilled for mounting bolts (tem ) must be 9/32 inch diameter. -c.

19 2. 3. Use Battery with center filler caps only. Gould SN9L ( 2 volt, 32 ampere - hour or equivalent. Holes drilled for mounting bolts (tem ) must be 9/32 inch diameter. -c.- ndicates Sta-Kon splice (3427)-2 required (Hirth) 3 required (CCW) --c:::::j ndicates std. receptacle (3425)-4 req'd. and male connector (black) (3434) - 3 required. ---a:) ndicates eyelet fastener (3436). required. --a: ndicates fork-type fastener (3435). required. --- ndicates binding. Use tie fastener (3437). As required. All wires to be 6 Ga. Wire item numbers: Yellow Orange Green

RECOMMENDED LOCATON OF SPEEDOMETER & TACHOMETER Speedometer on right- use Cable 364-3 (24" long). Speedometer on left - use Cable 364-4 (42" long).

20 RECOMMENDED LOCATON OF SPEEDOMETER & TACHOMETER Speedometer on right- use Cable (24" long). Speedometer on left - use Cable (42" long). Both Speedo-location Tach-location Gages SKYLARK H None None No 338 H " " No 372 H " " No FREBRD H Right Side Left Side Yes 34 c Left Side Left Side No 34 J Right Side Left Side Yes 399 J Right Side Left Side Yes 4 c Left Side Left Side No 438 H Left Side Left Side No 44 c Left Side Left Side No 44 s Right Side Right Side No 493 H Left Side Left Side No 634 H Left Side Left Side No EXECUTVE -34 J Right Side Left Side Yes 399 J Right Side Left Side Yes 438 H Right Side Left Side Yes 44 s Right Side Right Side No 44 c Left Side Left Side No 34 & 4 c Left Side Left Side No 493 H Right Side Left Side Yes 634 H Left Side Left Side No

SPEEDOMETER KT TEM NO. 2 3 4 5 6 7 8 9 2 3 4 5 PART QTY. PER NO.

21 SPEEDOMETER KT TEM NO PART QTY. PER NO. DESCRPTON ARTCLE LST PRCE 3644 Speedometer Kit (Firebird) Speedometer Kit (Executive) 3758 Back-Up Ring 3436 Eyelet Fastener 343 Brown Wire, 6" 3426 Splice Existing brown wires between engine and switch Existing red wires between head light and switch 343 Red wire, 6" 3427 Sta-Kon Splice Cable, 24 in. Right Side Cable, 42 in. Left Side Front Axle (Shown for reference) Adapter Receptacle Chassis (Shown for reference) Drive Pin 364- Head, Adapter (Firebird) Head, Adapter (Executive) SPEEDOMETER KT NSTALLATON NSTRUCTONS A. Locate on right or left side of dash depending on engine and options. B. Cut a 3 inch diameter hole in dash at chosen location. C. Remove two nuts and ''U" Clamp from back of speedometer. D. nsert light bulb in hole and screw cable to back of speedometer, place complete unit through hole in dash. Slide back-up ring over rear of speedometer, replace ''U" clamp and tighten down one nut. Under remaining nut, plac2 eyelet fastener of brown wire and tighten down securely. E. Connect red speedometer wire to red wire between switch and head light, and connect brown speedometer wire to brown wire between engine and switch with supplied wire splices. F. Remove the three nuts and bolts from right front axle flangette. Press adapter receptacle in center hole of axle end. nstall drive pin, place

22 F. (Continued) adapter head over pin with three mounting holes over three flangette holes and reinstall three nuts and bolts, tighten securely. G. Route cable from speedometer dial housing to adapter head. (Do not make any sharp bends in cable). Attach end of cable to adapter head

23 E-t g p:; r E-t t:::l r r Pot w.... "' co co r p:; ::> g

24 E-t p:; ::r: u E-t. t- -<

TACHOMETER KT TEM NO. 2 3 4 5 6 7 8 9 PART QTY. PER LST NO.

25 TACHOMETER KT TEM NO PART QTY. PER LST NO. DESCRPTON ARTCLE PRCE 364 Tachometer 3758 Back-Up Ring 3426 Splice Sta-Kon Splice 343 Red Wire, 6 nches 343 Brown Wire, 6 nches (Ground) 3433 Black Wire, 6 nches (To Mag.) 3436 Eyelet Fastener Existing brown wires between engine and switch Existing red wires between Headlight and switch Existing black wires between engine and switch TACHOMETER KT NSTRUCTONS A. Locate on right or left side of dash depending on engine and other options. B. Cut a 3 inch diameter hole in dash at chosen location. C. Remove two nuts and "U" clamp from back of tachometer. D. Connect eyelet fastener of black wire to center terminal on back of tachometer. nsert light bulb holder in hole and place complete unit through hole in dash. Slide back-up ring over rear of tachometer, replace "U" clamp and tighten down on nut. Under remaining nut, place eyelet fastener of brown wire and tighten down nut securely. E. Connect black tachometer wire to black wire between engine and switch, connect red tachometer wire between switch and head light, connect brown tachometer wire to brown wire between engine and switch with supplied splicer

26 GO f/i!' t ,

SHOCK KT AND CE RUNNER TEM NO. PART NO. DESCRPTON QTY. PER ARTCLE LST PRCE 374-374-2 Shock Kit, L. H.

27 SHOCK KT AND CE RUNNER TEM NO. PART NO. DESCRPTON QTY. PER ARTCLE LST PRCE Shock Kit, L. H. Shock Kit, R. H. NOTE: Both kits have identical parts, bolts reversed in assembly B8-45 W W-8 N8-8 P26-2 N6-9 B B-52 N M2-2 N6-5 Bracket Weldment.Shock.Bolt Washer.Bolt Washer.Nut Cotter Pin.Nut.Bolt Bracket, Ski, R. H. Spacer Bracket, Ski, L. H..Bolt.Nut Spindle Bushing (Shown for reference) Spacer (Remove) Washer ce Runner Kit Runner, ce Screw Nut SHOCK KT NSTRUCTONS A. Remove bolts holding spring to spindle, remove ski assembly from snowmobile. B. Remove steering arm and pull spindles. C. Remove /4 in. spacer at top of spindle tube and replace with two flat washers provided. D. Slide bracket weldment over spindle and reinstall spindle and steering arms. (Make sure spindle is in correct direction and straight)

E. Remount ski using new hardware provided (do not over tighten nut). F. Remove bolt from front spring bracket. G. Mount right and left hand ski bracket with new hardware provided. H.

28 E. Remount ski using new hardware provided (do not over tighten nut). F. Remove bolt from front spring bracket. G. Mount right and left hand ski bracket with new hardware provided. H. nstall shock movable position up. CE RUNNERS NSTRUCTONS A. Use ice runner as a drill pattern, place runner against edge of ski with rear mounting hole 8-/4 inches from rear of ski. B. Drill five /32 inch diameter holes through ski. C. nstall five screws and nuts (screw heads down), tighten securely.. nstalling runners on inside of each ski will improve steering in both directions on ice. 2. nstalling runners on right side of each ski improves steering on ice, to right only. 3. nstalling runners on left side of each ski improves steering on ice, to left only

29 ... - ll E-4 - ::: 9...:. ) p

LGHTER KT TEM NO. 2 3 4 5 6 7 8 9 PART QTY. PER NO. DESCRPTON ARTCLE LST PRCE 378 Lighter Kit 378 lighter, (Balkamp 4-2272) 3782. Backup Plate, lighter R2-2.

30 LGHTER KT TEM NO PART QTY. PER NO. DESCRPTON ARTCLE LST PRCE 378 Lighter Kit 378 lighter, (Balkamp ) Backup Plate, lighter R2-2.Rivet 3436 Eyelet Fastener 343 Brown wire, 32 inch 3426 Splice 2 Existing brown wires, between engine and switch 3432 Yellow wire, 4 inch 3427 Sta-Kon Splice Existing brown wires, between engine and switch LGHTER KT NSTRUCTONS A. Locate on right side of dash (exact location customer option). B. Drill a 7/8 inch diameter hole in dash at chosen location. C. Unscrew clamp shell and remove lighter. D. Connect threaded terminal on cable to receptacle. nsert cable and receptacle through dash from front, or top, and place the back-up plate on back side around receptacle. Replace clamp shell. (Due to varying thickness of dash, it may be necessary to cut off large end of clamp shell to suit). E. Connect yellow lighter wire to yellow wire between engine and switch and connect brown lighter wire to brown wire between engine and switch with supplied wire splices

31 f..& f..& -:J 2 For H.R.Carburetors Only H. D. Carburetor Fitting,- -, 'L @_ _..., _..- ib ') c..:l FGURE 6-. PRMER KT

PRMER KT TEM NO. 2 3 4 5 6 7 8 9 2 3 PART QTY. PER NO. DESCRPTON ARTCLE LST PRCE 339- Primer Kit, (Tillotsen) 339-2 Primer Kit, (Keihin) 33-6 Spacer (H. R. Carburetors) 33-9 Gasket Line, Gas 4 /2 in.

32 PRMER KT TEM NO PART QTY. PER NO. DESCRPTON ARTCLE LST PRCE 339- Primer Kit, (Tillotsen) Primer Kit, (Keihin) 33-6 Spacer (H. R. Carburetors) 33-9 Gasket Line, Gas 4 /2 in. long (cut from 8 inch line) Same as item 3 (Shown for reference) 33-4 Valve Line 5 /2 in. long (cut from 8 inch line) 33-5 Tee Existing fuel line (Shown for reference) Line, 8 in. long (cut from 8 inch line) N6-6.Nut W-6 Washer Dash (Shown for reference) 33-8.Bulb PRMER KT NSTRUCTONS A. Cut fuel line mid-way between carburetor and fuel filter and install tee. B. Cut primer into three pieces (4 /2, 5 /2 and 8 inches long). C. Locate a 5/32 inch diameter hole on right side of dash. D. nsert bulb through hole in dash, slide washer over rear of bulb and install nut, tighten securely. E. Slide three pieces of tubing on three fittings on valve. The 5 /2 pieces on straight end, 4 /2 piece on opposite straight end, and 8 in. piece on angled end. F. Remove screw from carburetor fitting, (see note) and slide on 4. 5 long tubing, install 5 /2 long tubing on tee and install 8 long tubing on bulb. NOTE: With H. R. carburetors, the carburetor must be removed and gaslet and spacer installed

$., "" \ \ E--4... p.$

33 ., "" \ \ E p. :s t:l z < < E--4 <. to J: p:; p C!)

SEAT BACK AND REAR FLAP KTS TEM NO. 2 3 4 5 6 7 8 9 2 3 4 PART QTY. PER NO. DESCRPTON ASSY.

34 SEAT BACK AND REAR FLAP KTS TEM NO PART QTY. PER NO. DESCRPTON ASSY. LST PRCE Seat Box (Shown for reference) 3753 Support, Seat back 375 Bracket, Seat Mounting Plate, Spacer Hinge, (Shown for reference) Hinge Screws (Shown for reference) MU- Screw, No. Wood Cushion, Seat Back M-24 Screw, No. Wood Flap, Rear (Firebird) 3262 Flap, Rear (Executive) Rear Bulkhead (Shown for reference) 3672 Backup Strip (Firebird) Backup Strip (Executive) M4-2 Screw 5 M6-6 Locknut 5 SEAT BACK KT NSTRUCTONS A. Open seat box and remove hinge screws (6). Place seat support (2) in place with seat mounting brackets (3) and secure with wood screws (7). B. Place spacer plate (4) under hinge (5) and replace hinge screws. C. Close seat box and secure seat back cushion (8) with wood screws (9). FLAP KT NSTRUCTONS A. Use back-up strip as a drill pattern, place edge of strip along lower edge of rear bulkhead, centering it across body. B. Drill five 9/32 inch diameter holes through rear bulkhead. C. Slide flap and back-up strip behind bulkhead, align holes in bulkhead flap, and back-up strip. D. nstall five screws and nuts (screw head out), tighten securely '

35 ROCKY MOUNTAN SK KT TEM NO. PART NO. DESCRPTON QTY. PER ASSY. LST PRCE N6-7 Ski W eldment Skag Weldment Nut SPORT WNDSHELD KT NSTRUCTONS (Not llustrated) A. Remove all screws that hold existing windshield to hood and remove windshield. B. Align holes in hood with holes in sport windshield and replace all screws, tighten all screws securely. SPORT WNDSHELD KT TEM NO. PART NO. DESCRPTON QTY. PER ASSY. LST PRCE Windshield Trim ROCKY MOUNTAN SK KT NSTRUCTONS (Not illustrated) A. Remove hardware holding existing ski to spring and remove ski. B. Place Rocky Mountain ski in place and reinstall hardware as originally assembled /6-28

37 SECTON V DEALER NSTALLED EQUPMENT The following Accessory Kits will be available for the 972 Snowmobile line: Electric Start Kit - Hirth Engines Electric Start Kit - Chaparral Engines Shock Kit Tachometer Kit Speedometer Kit Seat Back Kit Flap Assembly Kit Stirrup Kit

> 9 /o-]l :. 2. 3. 4. 5. 6. 7. 8. 9... DRlLL A 9/32" DlA HOLE N SPNDLE CHANNEL PER DMENSONS-SHOWN. LOCATE BRACKET ASSY 2 ON SPNDLE CHANNEL.

38 > 9 /o-]l : DRlLL A 9/32" DlA HOLE N SPNDLE CHANNEL PER DMENSONS-SHOWN. LOCATE BRACKET ASSY 2 ON SPNDLE CHANNEL. USE THE 9/32" DlA HOLE TO LOCATE BRACKET PROPERLY, DRLL THE REMANNG SEVEN 9/32" HOLES. NSERT "J" BOLTS 3. NSTALL SEVEN BOLTS 4 AND NUTS. DO NOT NSTALL A BOLT N HOLE X. PLACE ADHESVE-BACKED STRPS 5 ON BRACKET 2 SET BATTERY 8 (NOT SUPPLED) N PLACE, LAY HOLD DOWN 9 OVER BAT TERY 8 NSERT "J" BOLTS 3 THRU HOLD DOWN 9 AND SCREW ON WNG-NUT SECURELY. REMOVE COVER PLATE 3 FROM ENGNE AND NSTALL START MOTOR 4 WTH ONE BOLT, LEAVE ONE BOLT OUT OF "Y" HOLE. BOLT BATTERY CABLE 2 TO"+" TERMNAL OF BATTERY. NSTALL WilliNG HARNESS 5 RUN HARNESS THRU CABLE CLAMP 6 AND MOUNT CLAMP WTH LAST BOLT AND NUT. RUN HARNESS UNDER TE ROD 7, UNDER MOTOR MOUNT BAR 8, AND THEN FOLLOW THE EXSTNG WRE HARNESS TO SWTCH AND ENGNE. REMOVE TAPE FROM YELLOW ENGNE WRE. ATTACH TO YELLOW HARNESS WRE WTH WRE SPLCE. ALSO UNPLUG YELLOW \VRE FROM SWTCH, CUT OFF TERMNAL AND CONNECT TO REMANNG YELLOW HARNESS WRE SPLCE. SEE SCHEMATC FOR WRNG CONNECTONS TO RECT 6 AND SOLENOD PLUG ORANGE 2 AND GREEN 9 WRES NTO SWTCH. (SEE DWG) 3. CONNECT NEG CABLE 2a TO STARTER WTH BOLT N "Y" HOLE AND POS CABLE 2 TO STARTER. 4. REMOVE 6 W HEADLGHT BULB, REPLACE WTH 45 W BULB PROVDED ELECTRC START KT-HRTH TEM PART NO. DESCRPTON QUANTTY > -' -' "" = 2 Rear of Switch \ n. cl -,, B3-2 N N2-6 B3-6 NOS FGURE 6-. HRTH ELECTRC START KT Parts Location Drawing Location Only Bracket Assembly J-Bolt Bolt Nut Strip, Adhesive Back Rectifier Sol enoid Battery (Not supplied- Gould SN9L or equal) Hold Down, Battery Wing Nut Bolt Nut Cable Assembly L oction Only Starter Wiring Harness Cable Clamp Location Only Location Only Location Only Location Only Location Only Location Only Light Bulb, 45 Watt Wire Tie 4

') H::.. DRLL A 9/32" DA HOLE N SPNDLE CHANNEL PER DMENSONS SHOWN. 2. LOCATE BRACKET ASSY 2 ON SPNDLE CHANNEL. USE THE 9/32" DA HOLE TO LOCATE BRACKET PROPERLY, DRLL THE REMANNG SEVEN 9/32" HOLES. 3.

39 ') H::.. DRLL A 9/32" DA HOLE N SPNDLE CHANNEL PER DMENSONS SHOWN. 2. LOCATE BRACKET ASSY 2 ON SPNDLE CHANNEL. USE THE 9/32" DA HOLE TO LOCATE BRACKET PROPERLY, DRLL THE REMANNG SEVEN 9/32" HOLES. 3. NSERT J BOLTS NSTALL SEVEN BOLTS 4 AND NUTS. DO NOT NSTALL A BOLT N HOLE X. 5. PLACE ADHESVE-BACKED STRPS 5 ON BRACKET SET BATTERY 8 (NOT SUPPLED) N PLACE, LAY HOLD DOWN 9 OVER BAT TERY 8 NSERT "J" BOLTS 3 THRU HOLD DOWN 9 AND SCREW ON WNG NUT O SECURELY. 7. REMOVE COVER PLATE 3 FROM ENGNE AND NSTALL START MOTOR 4 WTH ONE BOLT, LEAVE ONE BOLT OUT OF "Y" HOLE. 8. BOLT BATTERY CABLE 2 TO"+" TERMNAL OF BATTERY. 9. NSTALL WRNG HARNESS 5. O. RUN HARNESS THRU CABLE CLAMP 6 AND MOUNT CLAMP WTH LAST BOLT 4 AND NUT.. RUN HARNESS UNDER TE ROD 7, UNDER MOTOR MOUNT BAR 8, AND THEN FOLLOW THE EXSTNG WffiE HARNESS TO SWTCH AND ENGNE. REMOVE TAPE FROM YELLOW ENGNE WffiE, ATTACH TO YELLOW HARNESS WffiE WTH WRE SPLCE. ALSO UNPLUG YELLOW WffiE FROM SWTCH, CUT OFF TERMNAL AND CONNECT TO REMANNG YELLOW HARNESS WRE SPLCE. SEE SCHEMATC FOR WRNG CONNECTONS TO RECT 6 AND SOLENOD PLUG ORANGE 2 AND GREEN 9 WffiES NTO SWTCH. (SEE DWG) 3. CONNECT NEG CABLE 2a TO STARTER WTH BOLT N "Y" HOLE AND POS CABLE 2 TO STARTER. 4. REMOVE 6 W HEADLGHT BULB, REPLACE WTH 45 W BULB PROVDED ELECTRC START KT - CHAPARRAL TEM PART NO. DESCRPTON QUANTTY ') -' -'! -' A: _ J 2 Rear of Switch 22 ':tc±a 6 Wire Harness Q J ' 2 TOP VEW FGURE 6-3. FUJ ELECTRC START KT B3-2 N N2-6 B3-6 N Parts Location Drawing Location Only Bracket Assembly J-Bolt Bolt Nut Strip, Adhesive Back Rectifier Solenoid Battery (Not supplied - Gould SN9L or equal) Hold Down, Battery Wing Nut Bolt Nut Cable Assembly Location Only Starter Wiring Harness Cable Clamp Location Only Location Only Location Only Location Only Location Only Location Only Light Bulb, 45 Watt Wire Splicer Wire Tie 4 4

40 ') f-.' -:] f-.' Orange GNTON SWTCH Black Black ENGNE Green Red TAL LGNT HEADLGHT. ':". Red STARTER Yellow Yellow Brake Switch "':'" Red - Yellow ZENER DODE ':"' -= TAL LGHT Green SOLENOD ':"' RECTFER Diode 8 Amp Fuse + BATTERY Orange Black Red ') Cl.:l FGURE 6-2. ELECTRC START TWN CYLNDER SCHEMATC sheet 2

') t-' -.:) t-'. REMOVE BOLTS HOLDNG SPRNG BRACKET TO SPNDLE 2, REMOVE SK ASSEMBLY 3 FROM SNOWMOBLE. 2. REMOVE STEERNG ARM BOLT 4 AND NUT, PULL STEERNG ARM 5 FROM SPNDLE, AND REMOVE SPNDLE 2. 3. 4. PULL WAVE WASHER 6, BUSHNG 7, AND /4" SPACER 8.

41 ') t-' -.:) t-'. REMOVE BOLTS HOLDNG SPRNG BRACKET TO SPNDLE 2, REMOVE SK ASSEMBLY 3 FROM SNOWMOBLE. 2. REMOVE STEERNG ARM BOLT 4 AND NUT, PULL STEERNG ARM 5 FROM SPNDLE, AND REMOVE SPNDLE PULL WAVE WASHER 6, BUSHNG 7, AND /4" SPACER 8. REPLACE /4" SPACER 8 WTH TWO WASHERS 9. RENSTALL BUSH NG SLDE BRACKET OVER SPNDLE 2. RENSTALL SPNDLE 2 N TUBE, REPLACE WAVE WASHER 6, AND STEERNG ARM 5 REPLACE STEERNG ARM BOLT 4 AND NUT. 6. REMOUNT SK ASSEMBLY WTH NEW BOLT. 7. REMOVE BOLT FROM FRONT SPRNG BRACKET. 8. MOUNT RGHT 3a AND LEFT 3b SK BRACKET WTH NEW BOLT PLACE SHOCK 4 N POSTON AND MOUNT WTH BOLTS, WASHERS AND NUTS PROVDED. (AS A SAFETY MEASURE, DO NOT FORGET TO NSTALL COTTER PN a ON SPNDLE BELT.) SHOCK KT B8-52 B-52 B W-8 N6-8 N8-8 P W-9 B8-52 N6-9 Parts Location Bracket, Ski, L.H. 2 Bracket, Ski, R.H. 2 Spacer 2 Shock 2 Bolt Bolt Bolt 2 Bolt 2 Washer 8 Nut Nut Cotter Pin 2 Bracket, Weldment 2 Washer 8 Washer 8 Bolt 2 Nut < J ' ') U FGURE 6-4. SHOCK KT

) ). LOCATE CENTER OF 3 NCH DAMETER HOLE ON LEFT OR RGHT SDE OF DASH DEPENDNG ON OTHER OPTONS. (F TACHOMETER 2 S LOCATED ON RGHT SDE, SWTCH MUST BE MOVED. SEE SWTCH RELOCATON DRAWNG.) 2.

42 ) ). LOCATE CENTER OF 3 NCH DAMETER HOLE ON LEFT OR RGHT SDE OF DASH DEPENDNG ON OTHER OPTONS. (F TACHOMETER 2 S LOCATED ON RGHT SDE, SWTCH MUST BE MOVED. SEE SWTCH RELOCATON DRAWNG.) 2. DSASSEMBLE "U" CLAMP 6 AND RUBBER SHOCK RNGS 3 and 4 AND BACK-UP RNG FROM TACHOMETER. N SERT SHOCK RNG HALF 3 NTO 3" DA HOLE N DASH. 3. SLDE TACHOMETER HEAD 2 THROUGH SHOCK RNG 3 AND NSTALL SHOCK RNG REMANNG HALF 4 ANDRE ASSEMBLE "U" CLAMP. NOTE: BACK UP RNG MUST HAVE FLANGED SDE OUT. 4. CONNECT THREE WRES WTH SPLCES 9 PROVDED. CONNECT RED loa AND BLACK lla WRES BETWEEN HEADLGHT AND CONN SPLCE. CONNECT BLUE 2a TO BROWN 2 WRE FROM ENGNE. SWTCH RELOCATON / v f"{ TACHOMETER KT Part s Location Drawing Tachometer Splice Kit )......;]... FGURE 6-5. TACHOMETER KT

')... -:].... LOCATE CENTER OF 3 NCH DAMETER HOLE ON LEFT SDE OF DASH. 2. DSASSEMBLE "U" CLAMP 6 AND RUBBER SHOCK RNGS 3 and 4 FROM SPEEDOMETER 2 NSERT SHOCK RNG 3 NTO 3 NCH DA METER HOLE N DASH. 3. SLDE SPEEDOMETER HEAD 2 THROUGH SHOCK RNG 3.

43 ')... -:].... LOCATE CENTER OF 3 NCH DAMETER HOLE ON LEFT SDE OF DASH. 2. DSASSEMBLE "U" CLAMP 6 AND RUBBER SHOCK RNGS 3 and 4 FROM SPEEDOMETER 2 NSERT SHOCK RNG 3 NTO 3 NCH DA METER HOLE N DASH. 3. SLDE SPEEDOMETER HEAD 2 THROUGH SHOCK RNG 3. NSTALL SHOCK RNG REMANNG HALF 4 AND REASSEMBLE "U" CLAMP 6. NOTE: BACK UP RNG TO HAVE FLANGE SDE OUT. 4. CONNECT TWO WRES 9a and lla WTH WRE SPLCES 9 PROVDED. 5. REMOVE THREE NUTS 5 FROM RGHT SDE FRONT AXLE FLANGETTE AFTER REMOVNG TENSON FROM TRACK. 6. NSERT DRVE ADAPTER 8 HOLE PROVDED N AXLE. NSERT DRVE PN 9 NTO DRVE ADAPTER. 7. SLDE ANGLED DRVE JONT 2 and 2 OVER DRVE PN 9 AND ATTACH WTH THREE FLANGETTE NUTS 5 AND BOLTS ATTACH CABLE 2 TO ANGLED DRVE JONT 2 AND THE BACK OF SPEEDOMETER HEAD RETGHTEN TRACK SPEEDOMETER KlT Parts Location Drawing Angle Drive Joint 464- Drive, Adapter Adapter Receptacle Dial Housing Drive Pin 3426 Splice ') -:] FGURE 6-6. SPEEDOMETER KT

. OPEN SEAT, REMOVE FOUR SEAT HNGE SCREWS. 2. PLACE SPACER PLATE 3 BETWEEN HNGE AND SEAT, REPLACE FOUR SEAT HNGE SCREWS. 3. PLACE SEAT MOUNTNG BRACKET 5 N PLACE. 4.

44 . OPEN SEAT, REMOVE FOUR SEAT HNGE SCREWS. 2. PLACE SPACER PLATE 3 BETWEEN HNGE AND SEAT, REPLACE FOUR SEAT HNGE SCREWS. 3. PLACE SEAT MOUNTNG BRACKET 5 N PLACE. 4. SECURE SEAT MOUNTNG BRACKET 5 WTH 3 EACH WOOD SCREWS SLDE SEAT BACK 7 NTO PLACE AND CLOSE SEAT Mll SEAT BACK KT Parts Location Drawing Bracket, Seat Mounting Seat Back Assembly Plate, Spacer Screw, Wood, No ' -:J -' FGURE 6-7. SEAT BACK KT

) -' -::J -'. USE BACK-UP STRP AS A DRLL PATTERN. PLACE EDGE OF STRP ALONG LOWER EDGE OF REAR BULKHEAD, CENTER STRP ON BODY. 2. DRLL FVE 9/32 NCH DAMETER HOLES THROUGH BULKHEAD. 3.

45 ) -' -::J -'. USE BACK-UP STRP AS A DRLL PATTERN. PLACE EDGE OF STRP ALONG LOWER EDGE OF REAR BULKHEAD, CENTER STRP ON BODY. 2. DRLL FVE 9/32 NCH DAMETER HOLES THROUGH BULKHEAD. 3. SLDE FLAP 4 AND STRP BEHND BULKHEAD, ALGN HOLES N BULKHEAD, FLAP 4, AND STRP. 4. NSTALL FVE SCREWS 5 THROUGH BULKHEAD, FLAP AND STRP. PLACE NUTS 6 ON SCREWS 5 FROM NSDE OF BODY FLAP ASSEMBLY KT 4822 Parts Location Diagram 362 Flap Assembly (for 5 inch track) 362 Flap, Rear 3672 Backing Strip M2-2 Screw 5 N6-6 Locknut ) c.o FGURE 6-8. FLAP ASSEMBLY KT.

C).... USE 3/6" DA DRLL BT AND DRLL OUT NEXT TO LAST RVET ON SDE OF CHASSS. USE 3/8" DA DRLL BT AND DRLL OUT THE RVET HOLE. 2. PLACE NUT 2 ON STRRUP 3. 3. NSERT STRRUP 3 NTO 3/8" HOLE N CHASSS.

46 C).... USE 3/6" DA DRLL BT AND DRLL OUT NEXT TO LAST RVET ON SDE OF CHASSS. USE 3/8" DA DRLL BT AND DRLL OUT THE RVET HOLE. 2. PLACE NUT 2 ON STRRUP NSERT STRRUP 3 NTO 3/8" HOLE N CHASSS. PLACE NUT 4 ON STRRUP 3 FROM NSDE OF CHASSS (SEE DWG). 4. USE HOLES N STRRUP 5 AS TEMPLATE AND DRLL TWO 3/6" DA HOLES N CHASSS WNG 6 5. NSTALL TWO POP RVETS SECURE NUTS 2 and REPEAT PROCEDURES FOR OPPOSTE SDE. l- \.- c STRRUP KT 4835 Parts Location Diagram 447- Stirrup Weldment, L. H Stirrup Weldment, R.H. N6-8 Nut 2 R2-2 Rivet 4 \to\\\ t:;j \t\\ s\\\t C)... -.:)... FGURE 6-9. STRRUP KT

47 f-.' f-.'. REMOVE 8 WNDSillELD SCREWS and a. 2. REMOVE EXSTNG WNDSHELD 2 AND TRM. 3. PLACE TRM 3 AROUND EDGE OF MAX WNDSHELD 4 4. PLACE MAX WNDSHELD N POSTON AND REPLACE 8 WNDSHELD SCREWS and a Maxi - Windshield Kit Parts Location Drawing Windshield Trim," la 4826 f-.' f-.' FGURE 6-. MAX WNDSHELD KT

SECTION V PARTS LISTS

SECTION V PARTS LISTS SECTON V PARTS LSTS The Parts Lists and llustrations, Figures 5-1 through 5-14, indicate all parts used in the four basic models of the snowmobile,. and all currently available engine and carburetor options.