SECTION V PARTS LISTS

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Clarissa Weaver
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1 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. f parts are not common to all models, the differences are indicated in the Parts Lists. Page 5-2 shows a serial number code for determining, from the machine's identification tag, the exact configuration of the snowmobile and the supplied parts. The first column of the parts list indicates the item number of the parts location drawing. The second column is the Chaparral ndustries part number, and the third is the description of the part. Please order spare parts and replacements using both the part number and the full description. Note procedure and order form on page 5-51 and 5-52 for terms and standard packaging of bulk items. The fourth column indicates the number of parts used in each assembly. The fifth column, flat rate time, is the amount of time, in tenths of an hour, that removal and replacement of the part should require. This figure is the only time which Chapparal ndustries will accept as a labor charge under warranty claims (See Section One). Do not compound flat rate time. Each time shown represents complet e removal and replacement time, and includes removal of mounting hardware or other parts which must be removed for access. RETURN AUTHORZATON PROCEDURE n the past, we have received many parts returned for credit without sufficient justification. As a result we are now instituting a new return authorization procedure. We will supply all distributors or dealers with a five-part snapout form which must be filled out completely by the dealer and submitted to Chaparral prior to shipment of the part. ',. >c1 f the return is justified, Chaparral ndustries will return to the dealer or distributor one approved copy of the request along with a red shipping tag which will carry the same serial number as the form

MPORTANT EFFECTVE MMEDATELY, NO RETURNED GOODS WLL BE ACCEPTED BY CHAPARRAL NDUSTRES UNLESS THE RED RMA TAG S ATTACHED, AND THE FREGHT HAS BEEN PREPAD.

2 MPORTANT EFFECTVE MMEDATELY, NO RETURNED GOODS WLL BE ACCEPTED BY CHAPARRAL NDUSTRES UNLESS THE RED RMA TAG S ATTACHED, AND THE FREGHT HAS BEEN PREPAD. f the return is not justified, a copy of the request form will be returned to indicate the reason for the rejection. Copy disposition: 1. Retained for Chaparral office records. 2. Retained for Chaparral nspection. 3. Retained for Chaparral Receiving. 4. To be returned to the dealer or distributor showing approval or disapproval 5. To be retained by the originating dealer or distributor. Pages 5-53 through 5-66 contain a straight numerical parts list showing the retail prices of all parts. These prices supersede all other printed prices that utilize the same part number. Also included are the Dealer's Parts Kit, the Chaparral Standards List, the bulk hardware list for all snowmobiles, and the Chaparral Engine Parts List and Prices

3 SKYLARK FRE BRD FREBRD SS MODEL THUNDERBRD DSPLACEMENT SERAL NO. ~ Manufacturer C248 (248 CCW) H292 (292 HRTH) H338 (338 HRTH) C339 (339 CCW) C398 (398 CCW) F398 (398 Chaparral) H399 (399 HRTH) 8432 (432 SACHS) F438 (438 Chaparral) H438 (438 firth) H650 (650 HRTH) ~splacement \ thru Skylark thru Firebird thru Firebird SS thru Thunderbird

Figure 5-1 HOOD ASSEMBLY TEM PART QTY. PER FLAT RATE NO. -- NO. DESCRPTON ASSY. TME 1 42396 Hood, Thunderbird 1 0.3 2 41397-1 Decal, L. H. 1 41397-2 Decal, R. H. 1 3 tems 3 and 4 4 No longer used.

5 Figure 5-1 HOOD ASSEMBLY TEM PART QTY. PER FLAT RATE NO. -- NO. DESCRPTON ASSY. TME Hood, Thunderbird Decal, L. H Decal, R. H. 1 3 tems 3 and 4 4 No longer used Hold-down Assembly 2 6 M22-20 Screw 2 7 W01-06 Washer 2 8 N06-06 Nut 2 9 ~~ Windshield (Thunderbird, Firebird and Skylark) Windshield Trim 1 11 ~ Screw 4 12 W01-06 Washer 4 13 N06-06 Nut 4 14 M22-08 Screw 4 15 W01-06 Washer 4 16 N06-06 Nut Cable Guide, Hood Grill Nameplate (Thunderbird) Nut Hinge Fitting, Hood Hinge Fitting, Hood Aluminum Foil Clevis Pin 2 24 P26-12 Cotter Pin Windshield (Firebird SS only) Windshield Trim (Firebird 1 SS only) Grill (Firebird SS only) Nameplate (Firebird SS) Nameplate (Firebird) Tape Tape Tape, L. H Tape, R. H Decal, Side L. H Decal, SideR. H Decal Hood (Firebird, Firebird SS, 1 and Skylark)

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Figure 5-2 CHASSS AND PAN ASSEMBLY TEM PART QTY. PER FLAT RATE - NO. - NO. DESCRPTON ASSY. TME 1 41122 Bumper, Side 2 0.

7 Figure 5-2 CHASSS AND PAN ASSEMBLY TEM PART QTY. PER FLAT RATE - NO. - NO. DESCRPTON ASSY. TME Bumper, Side M20-20 Screw 6 3 W01-06 Washer 6 4 N06-06 Nut 6 5 B05-26 Bolt 2 6 W01-07 Washer 2 7 N06-07 Nut 2 8 M20-28 Screw 2 9 W01-07 Washer 2 10 N14-06 Nut Rear Bumper (Firebird) Rear Bumper (Thunderbird) Hitch, Rear Hitch Support 1 13 N06-08 Nut Bogie Hanger Clutch Cover (with Sachs engine) Clutch Cover (Chaparral engines) Clutch Cover (Hirth and CCW 1 engines) 16 M04-11 Machine Screw 2 17 W06-01 Washer 2 18 N15-06 Nut Hinge Pin Foot pad, L.H. (Firebird) Foot pad, R.H. (Firebird) Foot pad, L.H. (Thunderbird) Foot pad, R.H. (Thunderbird) Foot pad, L.H. (Firebird) Foot pad, R.H. (Firebird) Foot pad, L.H. (Thunderbird) Foot pad, R.H. (Thunderbird) M07-20 Screw 4 23 N06-06 Nut 4 24 B18-32 Bolt Sleeve and solator Assembly Mount, Motor Mount, Motor (Thunderbird) solator, Motor Mount Flanged Washer 4 29 W02-08 Washer 4 30 N06-08 Nut

TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME 31 41128-1' Chain Case 1 1.0-3 31128 Gearbox (Skylark only) 1 1.

8 TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME ' Chain Case Gearbox (Skylark only) B18-32 Bolt 2 33 W01-08 Wa sher 2 34 N06-08 Nut Tiller Support Weldment 1 (Skylark and Firebird SS) Tiller Support Weldment 1 (Firebird and Thunderbird) Pan Assembly (Skylark and Firebird SS) Pan Assembly (Firebird and Thunderbird) Decal, Reflective Decal, Reflective 1 38 B20-21 Bolt N06-06 Nut Front Bumper Chassis Assembly (Skylark) Chassis Assembly (Firebird SS) Chassis Assembly (Firebird) Chassis Assembly (Thunderbird Frame (Skylard, Firebird, 1 Firebird SS) Frame (Thunderbird) Stiffener, L H Stiffener, R. H Bulkhead, Front Bulkhead, Front (Thunderbird) Support, Foot L.H. (Firebird, Firebird SS and Skylark) Support, Foot R. H. (Firebird, Firebird SS and Skylark Support, Foot L. H (Thunderbird) Support, Foot R.H (Thunderbird) Spindle Channel Assembly (Firebird, Fire bird SS and Skylark) Spindle Channel Assembly Spindle Channel Assembly 1 (Thunderbird)

TEM PART QTY. PER FLAT RATE NO. NO. DESCRPTON ASSY. TME 31120-1 0 Bracket, Bumper 1 0.

9 TEM PART QTY. PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Bracket, Bumper Bracket, Bumper Spindle Support W eldment 1 (Firebird, Firebird SS and Skylark) Spindle Support Weldment 1 (Thunderbird) Spacer, Spindle (Firebird, 4 Skylark, Thunderbird) Spacer, Spindle (Firebird SS) Bulkhead, Rear (Firebird) Bulkhead, Rear (Thunderbird) Bulkhead, Rear (Skylark) Bulkhead, Rear (Fire bird SS) Hood Latch Clip , Saddle Bag (Ro H.) (L.H.) Mounting Bracket (R. H. ) (L. H. )

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Figure 5-3 DASH ASSEMBLY TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME -- 41555-1 Dash Assembly 1 0.

11 Figure 5-3 DASH ASSEMBLY TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Dash Assembly Choke Assembly (Used with 650 Hirth engine) Choke Assembly (Used with 400 and 440 Chaparral, 340 and 440 Hirth engines on Thunderbirds) Choke Assembly (Used with 340 Hirth engine) Choke Assembly (Used with 400 and 440 Chaparral engines on Firebirds) Knob Shaft Washer 1 4 W02-06 Washer Retaining Ring Hose Clamp Flex Shaft (Used with 1-1 Choke) Flex Shaft (Used with 1-2 Choke) Flex Shaft (Used with 1-3 Choke) Flex Shaft (used with 1-4 Choke) Dash Receptacle, 1/4 turn Receptacle, Latch Nut Nut Access Door Assembly Access Panel, Louver Stud Assembly Retaining Ring Fastener, 1/4 Turn Spring Clip 2 B02-07 Roll pin, 3/32 by 0.44 in. 4 lg

TEM PART QTY PER FLAT RATE NOo NO. DESCRPTON ASSY. TME 12 31573 Decal, Dash 1 13 31565 Switch Assembly 1 0.1 14 31572-1 Decal, nst. Panel L. H.

12 TEM PART QTY PER FLAT RATE NOo NO. DESCRPTON ASSY. TME Decal, Dash Switch Assembly Decal, nst. Panel L. H Decal, nst. Panel R. H Headlight Headlight Bracket Assy N06-04 Locknut 2 18 M21-10 Screw 2 19 N06-06 Nut 2 20 M21-06 Screw Dash Assembly Dash Assembly A Blind Nut Dash Access Door Assembly Receptacle, 1/4 turn 1 24 M21-10 Screw 2 25 N06-06 Nut 2 26 M21-08 Screw 2 26A Support Bar 2 27 N06-06 Nut Speedometer ~ Decal Nameplate Nut Decal (Skylark only) 1 Located on Engine Choke (Firebird SS and Skylark)

13 FGURE 5-4. S EAT BOX

Figure 5-4 SEATBOX AND GAS TANK ASSEMBLY TEM PART QTY PER FLAT RATE NO. - - NO. DESCRPTON ASSY TME 41040 Seat Box Assembly (Firebird) 1 0.5 42040 Seat Box Assembly (Thunderbird) 1 1 41075 Seat 1 0.

14 Figure 5-4 SEATBOX AND GAS TANK ASSEMBLY TEM PART QTY PER FLAT RATE NO. - - NO. DESCRPTON ASSY TME Seat Box Assembly (Firebird) Seat Box Assembly (Thunderbird) Seat Gas Tank Assembly Closure, Side Closure, Side Closure, Center Closure, Rear Serial Tag Decal Taillight Assembly Bulb Lens, Taillight Gasket, Taillight 1 9 M18-12 Machine Screw, Round Head 1 10 N06-05 Nut Hinge 1 12 Ml7-10 Wood Screw 4 13 W01-05 Washer Flap Assembly Flap Assembly 1 15 M20-12 Machine Screw 1 16 N06-06 Nut Nameplate Nut Wiring Harness (Skylark) Wiring Harness Closure, Rear Closure, Front Closure, Side (Firebird) Closure, Side (Thunderbird) Grommet Bracket Assembly, Dash Mounting Bracket Assembly, Dash Mounting Catch 2 26 M17-10 Wood Screw 4 27 W01-05 Washer Trim Trim Trim Sealer Sealer

15 TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY TME Seat 1 32 M17-10 Screw 8 33 W01-05 Washer Grommet 1 35 B05-26 Bolt 1 36 W01-07 Washer 1 37 N06-07 Nut 1 38 M20-20 Screw 2 39 WOl-06 Washer 2 40 N06-06 Nut Bumper, Rear 1 42 M18-12 Screw 4 43 N06-05 Nut Decal, cc 1 45 M17-10 Screw 8 46 WOl-05 Washer Taillight Bulb 1 48 M18-12 Screw 2 49 N06-05 Nut Seat, Skylark Decal, CC Gas Tank Enclosure Assembly Side Tank Holdown Side Tank Holdown Closure, Tank Holdown Closure, Tank Holdown

16 . D D

17 Figure 5-5 GAS TANK ASSEMBLY TEM PART QTY PER FLAT RATE NO, NO, DESCRPTON ASSY. TME Gas Tank (Skylark) Gas Tank (Firebird and Thunderbird) Gas Tank (Firebird SS) Cap and Gage (Skylark) Cap and Gage (Fire bird SS~ Cap and Gage (Firebird and Thunderbird) Weight, Gas line Line, Gas Washer, neoprene 2 6 Wo2-10 Washer 1 7 N05-10 Nut, Lock, 1/2-20.UNC, Aluminum Tank Fitting Line, Gas Fuel Filter Assy Line, Gas Cushion, Gas tank Tank, Fitting Washer, Neoprene 4 15 W02-10 Washer 2 16 N05-10 Nut, Lock Line, Gas

18 6-1-71

Figure 5-6 CONTROLS, TLLER BAR AND SK ASSEMBLY TEM PART QTY PER FLAT RATE NO. - NO. - DESCRPTON ASSY " TME 1 41343 Handle Grip 2 2 31364 Brake Control Assembly 1 0.

19 Figure 5-6 CONTROLS, TLLER BAR AND SK ASSEMBLY TEM PART QTY PER FLAT RATE NO. - NO. - DESCRPTON ASSY " TME Handle Grip Brake Control Assembly (Skylark only) Brake Control Assembly Lever (Used on 31364) Lever n Cable and Housing 1 (Used on 31364) Cable and Housing Clevis (Used on 31364) Clevis and Switch Spring, Return Spring, Strain Throttle Control Assembly 1 Oo3 (Skylark only) Throttle Control Assembly (All Hirth Engines) Throttle Control Assembly (CCW, Chaparral, Sachs) Lever (Used with 39358) Lever, Thumb Cable (Used with 39358) Cable (Used with ) Cable (Used with ) 1 3A Kill Switch TillerBar Weldment 1 Tiller Support 5 Part shown for reference 1 6 B05-24 Bolt 2 7 N06-07 Nut Fitting, Zerk Tie Rod Assembly Rod End, R.H. 1 Oo1 10 N04-08 o Jam Nut, L.Ho 1 N05-08 o Jam Nut, R.Ho Tie Rod 1 12 B01-28 o Bolt, Tie Rod 1 l2a B Belt 2 13 N06-08 o Nut 3 14 B01-16 o Bolt 1 15 W04-08 Washer

TEM PART QTY PER FLAT RATE NO. - NO. - DESCRPTON ASSY. TME 16 41387 Rod End, L.H. 1 0.1 17 31379 Steering Arm, R.H. 1 0.2 18 31379 Steering Arm, L H. 1 0.2 19 B01-28 Bolt 2 20 N06-08 Nut 2 21 31378 Wave Washer 2 22 31014 Bushing, Spindle 4 0.

20 TEM PART QTY PER FLAT RATE NO. - NO. - DESCRPTON ASSY. TME Rod End, L.H Steering Arm, R.H Steering Arm, L H B01-28 Bolt 2 20 N06-08 Nut Wave Washer Bushing, Spindle A Bushing, Tiller Spacer 4 23A Spacer Spindle Ski Assembly, L. H Ski Assembly, R. H Bolt, Ski Hanger 2 26 N08-08 Nut 2 W01-08 Washer 4 P26-12 Cotter pin Bolt 2 28 P26-12 Cotter pin 2 29 W Washer 2 30 N Nut 2 31 BOl- 60 Bolt 1 32 W Wao aer 2 32A Washer Bumper, Ski N06-08 Nut 1 35 B01-48 Bolt 1 36 W Washer 1 37 NOS-08 Nut Skag Weldment 1 39 N06-07 Nut Bolt 1 41 W Washer 2 42 N Nut Castle 1 43 P Cotter Pin 1 44 B08-48 Bolt 1 45 W Washer 2 46 N06-09 Nut 1 47 B08-52 Bolt 1 48 W01-09 Washer 2 48A Spacer 2 49 N Nut 1 50 B Bolt

TEM PART QTY PER FLAT RATE NO. NO, DESCRPTON ASSY, TME 51 W01-08 0 Washer 2 52 N06-08 ' Nut 1 52 40664 ' Shock 1 54 40591 ' Ski W eldment 1 0.

21 TEM PART QTY PER FLAT RATE NO. NO, DESCRPTON ASSY, TME 51 W Washer 2 52 N06-08 ' Nut ' Shock ' Ski W eldment Spring, Top Spring, Center ' Spring, Main ' Hanger, Ski Skag Weldment Wear Plate

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23 Figure 5-7 BRAKE ASSEMBLY TEM PART QTY. PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Bracket, Brake Spring, Return Spring, Strain Caliper Assembly Brake Pad Brake Pad 1 6 B03-08 Bolt 2 7 W03-07 Washer 2 8 N02-06 Nut 2 9 B05-08 Bolt 2 10 W03-07 Washer, Star Clevis 1 12 Bolt (furnished with 31367) 1 13 Spacer (fm nished with 31367) 1 14 Nut (furnished with 31367) Clevis and switch 1 16 Bolt (furnished with 42367) 1 17 Spacer (furnished with 42367) 1 18 Nut (furnished with 42367) Chain Case (see figure 5-8) Clutch (seefigure 5-8)

24 ? t!>o-,. " ~~ 9 a ~ sv, CHAPARRAL DRVEN SHEAVE (j) 1-' -:J 1-' FGURE 5-8. CHAN CASE

Figure 5-8 CHAN CASE ASSEMBLY TEM PART QTY. PER FLAT RATE NO. -- NO. DESCRPTON ASSY. TME 41128-1 Chain Case Assembly 1 1.0 41128-3 Chain Case Assembly 1 1. 0 1 41133 Cover, Chain Case 1 0.

25 Figure 5-8 CHAN CASE ASSEMBLY TEM PART QTY. PER FLAT RATE NO. -- NO. DESCRPTON ASSY. TME Chain Case Assembly Chain Case Assembly Cover, Chain Case B02-16 Bolt 7 3 W04-06 Washer, Lock Oil Plug, 1/2-13 UNC "0" Ring, Cover 1 6 B01-16 Bolt 1 7 W04-06 Washer, Lock Washer Sprocket, Drive, 15 Tooth Sprocket, Drive, 17 Tooth Sprocket, Drive, 19 Tooth Snap Rin~ Spacer, nput Shaft Cup, Bearing "' Cone, Bearing "< Seal nput Shaft Retainer, nput Shaft Washer, Retaining Shaft, nput Key (1/4 x 3/16 x in.) 1 19 B01-16 Bolt 1 20 W04-08 Washer, Lock Washer Stud, Adjusting 1 23 N02-08 Nut 1 24 M14-10 Screw 1 25 W02-06 Washer 1 26 W06-06 Washer dler Assembly Arm, dler Bearing and Sproc~t 1 Assembly Shaft, dler Washer 1 31 B18-32 Bolt 2 32 W01-08 Washer 2 33 N06-08 Nut, Lock 2 34 B17-12 Bolt 2 ' 35 W01-06 Washer N06-06 Nut, Lock

TEM PART QTY. PER FLAT RATE NO. NO. DE SCRPTON ASSY. TME 37 B01-16. Bolt 1 38 W04-08. Lock Washer 1 39 31259-1. Washer 1 40 31136. Sprocket 1 41 411137-1. Chain, 15 Tooth 1 411137-2.

26 TEM PART QTY. PER FLAT RATE NO. NO. DE SCRPTON ASSY. TME 37 B Bolt 1 38 W Lock Washer Washer Sprocket Chain, 15 Tooth Chain, 17 Tooth Chain, 19 Tooth 1 42 B17-18.Bolt Washer, Gasket 3 44 WOl- 06. Washer 3 45 N Nut, Lock Flangette Gasket, Flangette Spacer, nput Shaft "0" Ring, Flangette Bearing, inch Collar Shaft Shaft 1 53 P07-32.Pin Chain Case Clutch (All other engines) Clutch (Used with 650 Hirth) Clutch (Skylark & Firebird with Hirth) Key (1/4 x 3/16 x in.) Washer Key (1/4 X 1/4 X in.) Brake Flange Assembly 1 (- 3 Assembly only)

Figure 5-9 TRACK ASSEMBLY TEM PART.. QTY PER FLAT RATE NO. -- NO. DESCRPTON ASSY. TME 39183 Track Assembly (Skylark) 1 1.

27 Figure 5-9 TRACK ASSEMBLY TEM PART.. QTY PER FLAT RATE NO. -- NO. DESCRPTON ASSY. TME Track Assembly (Skylark) Track Assembly (Firebird SS) Track Assembly (Firebird) Track Assembly (Thunderbird) Rear dler Assembly 1 (Skylark and Firebird) Rear dler Assembly 1.8 (Thunderbird) Axle (Thunderbird) dler Wheel Bearing G. Lock Collar 2 5 P07-32.Roll Pin, 5/ 16 in. dia. 3 bv l-5/8 in. long Spacer (Thunderbird) Track Hanger Assembly 1.8 (Skylark) Track Hanger Assembly 1.8 (Thunderbird) Track Hanger (Firebirds) Track Tightener 1. 8 Weldment, R. H Track Hanger Weldment 2.8 (Skylark and Firebird) Track Hanger W eldment 2 o8 (Thunder bird) Track Tightener 1.8 Weldment, L.H Spring, Rear, R. H Spring, Rear, L. H o Washer, Flat Spacer Pivot Tie Tube, Rear 1.8 (Skylark and Firebird) Tie Tube, Rear 1.8 (Thunderbird) 15 B Bolt, 3/8-16 UNC by 2 3 in. long, l. 25 min. thd. 16 W Lockwasher, 3/8 in

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28 01 t-v 00 3 ~~ 3 ~ ~-~32 ~! ' J., o, '0 --> REAR DLER ASSEMBLY ~ ~ ---- ~ ~ TRACK HANGER ASSEMB LY 0') f-'...:j f-' FGURE 5-9. TRACK ASSEMBLY

TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME -- 17 Part shown for reference 18 Part shown for reference 19 Part shown for reference 20 B05-12.Bolt 2 21 W01-07 0. Washer 2 22 N06-07.

29 TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Part shown for reference 18 Part shown for reference 19 Part shown for reference 20 B05-12.Bolt 2 21 W Washer 2 22 N06-07.Locknut Adjusting Bolt, stud Bolt, Adjusting 2 25 Part shown for reference. 26 B Bolt, Adjusting 2 27 W Washer, Lock Track (Skylark) Track (Firebird SS) Track (Firebird) Track (Thunderbird) Bogie Assembly 3 (Skylark and Firebird) See page following Bogie Assembly 3 (Thunderbird) See page following Flangette 1 31 B Bolt Bearing, Fafnir 1 RAlOONPPB 33 W01-07 Washer 3 34 N06-07 Locknut Lock Collar Sprocket, Drive (Skylark and Fire bird) Sprocket, Drive (Thunderbird) Sprocket (Firebird 'SS) 37 P Roll Pin, 5/16 in. dia. 2 by 2. 0 in. long Axle, Front (Skylark and Firebird) Axle, Front (Firebird SS) Axle, Front (Thunderbird)

Note See page 5-23 dated 10-1-70 for parts identification BOGE ASSEMBLY TEM PART QTY. PER FLAT RATE NO. NO. DESCRPTON ASSY. TME 31205 Bogie Assembly, (Skylark, REF.

30 Note See page 5-23 dated for parts identification BOGE ASSEMBLY TEM PART QTY. PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Bogie Assembly, (Skylark, REF. 5 Fire bird, and Firebird SS) Bogie Assembly, (Thunderbird) REF Spring, Bogie, R.H Spring, Bogie, L.H. 1 3 Part shown for reference 4 Part shown for reference Spacer, Main Axle 2 (Thunderbird) Bogie Bracket, 2.2 Weldment Axle, Main (Skylark and 1.5 all Firebirds) Axle, Main (Thunderbird) Center Bogie Bracket 1 Weldment 9 B12-16 Bolt, Self locking 4 1/4-20 by 1 in. lg. 10 W Washer, Flat Wheel, Bogie Axle, Short (Skylark and 1.5 all Firebirds) Axle, Short (Thunderbird) Axle, Long (Skylark and 1.5 all Fire birds) Axle, Long (Thunderbird) Spacer, Bogie Axles 4 (Thunderbird)

31 TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Part shown for reference 18 Part shown for reference 19 Part shown for reference 20 B05-12.Bolt 2 21 W Washer 2 22 N06-07.Locknut Adjusting Bolt, stud Bolt, Adjusting 2 25 Part shown for reference. 26 B Bolt, Adjusting 2 27 W Washer, Lock Track (Skylark) Track (Firebird SS) Track (Firebird) Track (Thunderbird) Bogie Assembly 3 (Skylark and Firebird) See page following Bogie Assembly 3 (Thunderbird) See page following Flangette 1 31 B05-12 Bolt Bearing, Fafnir 1 RAlOONPPB 33 W01-07 Washer 3 34 N06-07 Locknut Lock Collar Sprocket, Drive (Skylark and Fire bird) Sprocket, Drive (Thunderbird) Sprocket (Firebird 'SS) 37 P Roll Pin, 5/16 in. dia. 2 by 2.0 in. long Axle, Front (Skylark and Firebird) Axle, Front (Firebird SS) Axle, Front l 1.0 (Thunderbird)

32 01 c..:l ~ 20 ~ h 22 ' 28 ~ ~ f-' -..:) f-' FGURE MUFFLER AND ENGNE MOUNTNGS - HRTH

Figure 5-11 MUFFLER AND ENGNE MOUNTNGS HRTH TEM PART QTY PER FLAT RATE NO. NO. DE SCRPTON ASSY TME 1 41313-1 Muffler Weldment (650 on Fire- 2 0.

33 Figure 5-11 MUFFLER AND ENGNE MOUNTNGS HRTH TEM PART QTY PER FLAT RATE NO. NO. DE SCRPTON ASSY TME Muffler Weldment (650 on Fire bird SS and Thunder bird) Muffler Weldment (292, 400 and on Skylark and Firebird SS) Muffler Weldment (340 on Firebird) Muffler Weldment (400 and 440 on Firebird SS) Muffler Weldment (292 and o. 3 on Firebird SS) Muffler Weldment (440 on Firebird) Band Assy. (650, 292, 340, 400, on Firebird SS and Thunder - bird) Bracket (440 on Firebird) Bracket (292, 340 on Skylark, Fire- 1 bird and Thunderbird) Clamp Assembly (440 on Firebird) Bracket (650, 400 and 440 on 1 Firebird SS and Thunderbird) Bracket (292, 340 on Firebird SS) 1 4 B03-14 Bolt 3 5 W02-06 Washer 3 6 Nl0-06 Nut 3 7 B03-12 Bolt 2 8 WC2-06 Washer 2 9 Nl0-06 Nut 2 10 B03-20 Bolt 2 loa Spacer (440 on Firebird) 2 11 W02-06 Washer 2 12 Nl0-06 Nut Flex tubing (292 on Skylark) Flex tubing (400 and 440 on Firebirds) Flex tubing (440 on Firebird) \ Flex tubing (292 and 340 on Firebirds) Flex Tubing (340 and 650) on Firebird, Firebird SS, and Thunderbird Clamp, Tubing As Req Clamp, Tubing As Req Exhaust (292 on Skylark) Exhaust Manifold (650) on Hirth, Firebird SS and Thunderbird)

34 TEM PART QTY PER FLAT RATE NO. NO. DE SCRPTON ASSY TME Exhaust Manifold (440, 400, 240) on Firebird and Firebird SS Exhaust Manifold (340) on Firebird SS and Thunderbird Engine, 292 Hirth Engine, 292 Hirth Engine, 340 Hirth Engine, 400 Hirth Engine, 440 Hirth Engine, 650 Hirth Drive Belt (Used with , 3, 4, and 5 engines) Drive Belt (Used with , engines) q- 7 Drive Clutch, 770 (Used with engines) Drive Clutch, 770 (Used with engines) Drive Clutch, 910 (Used with engines) Drive Clutch, 910 (Used with engines) Drive Clutch, 910 (Used with engines) Drive Clutch, 910 (Used with engines) 1 19 B07-72 Bolt (Used with , engines) 1 B07-84 Bolt (Used with through - 5 engines) 1 20 W02-10 Washer 1 21 W03-10 Washer Bar, Motor Mount (Used with engine) Bar, Motor Mount (Used with through -5 engines) Bar, Motor Mount Spacer, Motor Mount (Used with engine) 4 24 B06-28 Bolt 4 25 W03-10 Lockwasher, star 4 26 W02-09 Washer (Used with engine) 27 B18-20 Bolt (Used with engine)

35 TEM PART QTY PER FLAT RATE NO. NO. DE SCRPTON ASSY TME 28 W03-10 Washer (Used with engines) 29 W02-08 Washer 4 30 N06-08 Nut Sleeve Wire Clip (292 on Skylark) Wire Clip (all others ) Female Terminal (292 on Skylark) Female Terminal (all others) Wiring Harness (all except 292 on 1 Skylark)

36 <:Jl C..:> 0) ~ ta y 0) 1-' -;J 1-' FGURE MUFFLER AND ENGNE MOUNTNGS - CHAPARRAL

37 Figure 5-12 MUFFLER AND ENGNE MOUNTNGS CHAPARRAL TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME Muffler Weldment (400 and Chaparrals on Firebird SS) Muffler Weldment (398 and Chaparrals on Firebird and Thunderbird) 1A Stub Exhaust Bracket (Firebird SS Engine) Bracket (Firebird - Both 1 engines) Bracket (Thunderbird - Both 1 engines) Bracket (Both Engines- 1 Firebird SS) Band Assembly 2 4 B03-14 Bolt 3 5 W02-06 Washer 3 6 N10-06 Nut 3 7 B03-12 Bolt 2 8 W02-06 Washer 2 9 N10-06 Nut Spacer (Firebird Flex tubing ( 440 Engine on 1 Firebird and Thunderbird) Flex tubing (All others) Clamp, Tubing As Req Clamp, Tubing As Req Exhaust Manifold, 440 Engine 2 on Firebird SS Exhaust Manifold, 400 Engine 2 on Firebird SS Engine, 400 Chaparral Engine, 440 Chaparral Drive Belt Drive Clutch, 910 (Used with engines) Drive Clutch, 910 (Used with engines) Drive Clutch, 910 (Used with Engines)

38 TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME 17 B07-84 Bolt 1 18 W02-10 Washer 1 19 W03-10 Washer Bar, Motor Mount Bar, Motor Mount Spacer, Motor Mount 4 22 B06-40 Bolt 4 23 W03-10 Lockwasher, Star 4 24 Washer, Star 4 25 Bl8-24 Bolt 4 26 W02-08 Washer 4 27 N06-08 Nut Wire Clip Wire Harness

39 Figure 5-13 MUFFLER AND ENGNE MOUNTNGS ccw TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME -- l Tubing (-5 and -8 engines) Wire Clamp Assembly (-5 and 1-8 engines) Muffler Weldment (-5 and engines) Muffler Weldment (-1 Engine) Clamp Assembly (- 5 and Mounting Bracket Clamp Assembly ( -1 Engine) 1 5 B03-12 Bolt 2 6 W02-06 Washer 2 7 Nl0-06 Nut Flex Tubing (- 5 and - 8 Engines) Flex Tubing (- 1 Engine) Wire Clamp Assembly (-5 and 2-8 Engines) Wire Clamp Assembly (-1 2 Engine Engine Assembly, Engine Assembly, Engine Assembly, Exhaust Manifold (-1 engine) Exhaust Manifold (-5 engine) Exhaust Manifold (-7 engine) Drive Belt, 910 (-5 and Engine) Drive Belt, 770 (-1 Engine) 1 12 B07-84 Bolt (-5 and -8 Engines) 1 B07-72 Bolt (-1 Engine) 1 13 W03-10 Lockwasher, Star 1 14 W02-10 Washer Drive Clutch, 910 (-5 and Engine) Drive Clutch, 770 (-1 Engine) Motor Mount Bar (- 5 and Engines) Motor Mount Bar (-1 Engip.e) Spacer, Motor Mount (-5 and 4-8 Engines) 1 in. High Sleeve (-5 and -8 Engines) 4 19 W03-10 Lockwasher, Star (-5 and -8 4 Engines)

40 '

41 TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY TME W03-09 Lockwasher, Star (-1 Engine) 4 20 BOS-82 Bolt 4 21 N06-08 Nut 4 22 W02-08 Washer 4 23 W03-10 Washer 8 24 B01-20 Bolt 4 25 W01-09 Washer Sleeve (- 1 and -5 engines) Wire Clip (-1 engine) Female Terminal (-1 engine) Wiring Harness (-5 and engines)

42 CJ1.p.. t-.:1 26 ~ 8 ~~-----J / (j) f-4 -J f-4 FGURE MUFFLER AND ENGNE MOUNTNG SACHS

Figure 5-14 MUFFLER AND ENGNE MOUNTNGS SACHS TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY TME 1 31313-4 Muffler Weldment 1 0.

43 Figure 5-14 MUFFLER AND ENGNE MOUNTNGS SACHS TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY TME Muffler Weldment Clamp Assembly 1 3 B03-12 Bolt 2 4 W10-06 Washer Muffler Bracket W eldment N10-06 Nut Flex Tubing Clamp Assembly Tubing Engine Assembly 440 Sachs Drive Belt, B07-84 Bolt 1 13 W03-10 Lockwasher, Star 1 14 W02-10 Washer Drive Clutch, Motor Mount Bar Spacer Motor Mount 4 7/16 in. High Sleeve 4 19 W03-10 Lockwasher, Star 4 20 B06-28 Bolt 4 21 N06-08 Nut 4 22 W02-08 Washer 4 23 W03-10 Washer 8 24 B01-20 Bolt Wire Clamp Heat Shield Wire Clip Wire Harness

44 01 ~ ~ ~~ ~ ) '-' -.:! '-' FGURE KEHN CARBURETOR ASSEMBLY

Note Tillotson carburetor 31277-5, pages 5-36 and 5-37 dated 10-1- 70 are still used with current production 250 CCW engines. Figure 5-15 KEHN CARBURETOR ASSEMBLY TEM NO. PART NO.

45 Note Tillotson carburetor , pages 5-36 and 5-37 dated are still used with current production 250 CCW engines. Figure 5-15 KEHN CARBURETOR ASSEMBLY TEM NO. PART NO. DESCRPTON QTY PER ASSY. FLAT RATE TME M W Gasket (Part of Carburetor) 1 Throttle Assembly (Refer to item figure Bracket 1 Bolt (Part of Carburetor) 1 Screw 2 Lockwasher 2 Deflector (Used with , 1-5, and - 8 Carburetors) Deflector (Used with , 1-9 and -11 Carburetors) Nut (furnished with engine) 2 Washer (furnished with engine) 2 Return line to gas tank Throttle hose clamp 1 Flex tubing 1 Carburetor (Used with Hirth engines ) Carburetor (Used with CCW engines) Carburetor (Used with Chaparral engines) Carburetor (Used with CCW engines) Carburetor (Used with Sachs engines) Carburetor (Used with Chaparral engines) Gas line to filter 1 Gas line to engine 1 Plate, Cover AR

46 u 3 15 c::::;~ 9 ~~ -- FGURE WALBRO CARBURETOR ASSEMBLY

47 Figure 5-16 WALBRO CARBURETOR ASSEMBLY TEM PART QTY PER FLAT RATE NO. NO. DESCRPTON ASSY. TME 1 Gasket (Part of Carburetor) 1 2 Throttle Assembly (Refer to item figure Bracket 1 4 Screw (Part of Carburetor) 1 5 Washer (Part of Carburetor) 1 6 M09-08 Screw 2 7 W04-06 Lockwasher Deflector 9 Nut (furnished with engine) 2 10 Washer (furnished with engine) 2 11 Gas line return 1 12 Gas line to filter 1 13 Gas line to engine 1 14 Hose Clamp (See Choke 1 Assembly) 15 Flex tubing (See Choke 1 Assembly) Carburetor (Used with Hirth engines) Carburetor (Used with Hirth engines) Carburetor (Used with Hirth engines) Carburetor (Used with Hirth engines) Carburetor (Used with Hirth engines) Plate, Cover AR

48 DEALER PARTS KT TEM NO. DESCRPTON QUANTTY Bushing, Spindle Bushing, Tiller Lens, Tail Light (SK & SP) Lens, Tail Light (FB & TB) Tank, Gas (SK, FB, TB) Cap & Gauge (SK) Cap & Gauge (SP) Cap & Gauge (FB & TB) Line, Gas 5 ft Fuel Filter Assy Latch, Hood Chain (15 Tooth) Chain (1 7 Tooth) Chain (19 Tooth) Bearing, 1'' Oil Plug Brake Pads 6 sets Drive Sprocket (SK) Drive Sprocket (SP) Sprocket (FB & TB) Collar, 1" Lock Axle, Main Axle, Main Bogie Brkt. Assy Bogie Brkt. Center Spacer Main Axle Spacer Bogie Axle Axle, Front Bogie, Long Axle, Front Bogie (TB) Axle, Rear Bogie, Short Axle, Rear Bogie, (TB) Wheel, Bogie dler Wheel Track Hanger W eldment Spring, Rear L o H o Spring, Rear R o H o Washer, Flat Adjusting Bolt Stud Bolt, Adjusting 4 B12-10 Bolt (Bogie Assy) 4 B07-84 Clutch Bolt 1 B07-72 Clutch Bolt

49 DEALER PARTS KT (Continued) TEM NO. DESCRPTON QUANTTY Flex Tubing Grease Fitting Throttle Cable & Housing (K eihen) (SK) Throttle Cable & Housing 1 (300 & 340 H Walbro WR) Throttle Cable & Housing 1 (340 & 400 ccw Keihen HR) Throttle Cable & Housing 1 ( 440 S, 400 & 440 C Keihin HD) Throttle Cable & Housing 1 (400, 440 & 650 H Walbro WD) Brake Cable & Housing (SK) Brake Cable & Housing (FB) Brake Cable & Housing (SP & TB) Clevis (SK & FB) Clevis & Switch (SP & TB) Spring 4 B01-16 Bolt Spindle Wave Washer, Spindle Steering Arm Rod End, R.Ho Rod End, L.Ho Hood Decal, L.H Hood Decal, R.H Headlight Light Bulb 60 W Light Bulb 45 W Decal (SK) Decal (SP) Decal (FB) Decal (TB) Windshield (SK, FB, TB) Windshield (SP) Trim - Chrome Vinyl (SK, FB, TB) Trim - Chrome Vinyl (SP) Wire Harness Foot Pad Fwd., LoR Foot Pad, LoR Foot Pad Fwd., RoHo Foot Pad, RoHo Spring

50 DEALER PARTS KT (Continued) TEM NO. DESCRPTON QUANTTY Switch, gnition Nut, gnition Switch Windshield Bolt 12 N06-06 Windshield Locknut Ski Weldment (SK, FB, TB) Ski Weldment (SP) Hanger, Ski Spring, Main Spring, Center Spring, Top Bolt, Spindle Bolt, Spindle 2 PZ6-12 Cotter Pin Wear Plate Skag Weldment 6 N06-07 Locknut Bolt, Ski Hanger Bumper, Ski 4 N07-08 Locknut Drive Belt Drive Belt Bearing Cup Bearing Cone Diode Motor Mount Bar Motor Mount Bar (TB) Carb Kit (Keihin HR) Carb Kit (Keihin HD) Carb Kit (Walbro WR) Carb Kit (Walbro WD)

51 PROCEDURE FOR PARTS ORDERS Chaparral ndustries will strive to offer the best in a parts and service program in the Snowmobile industry. n order to do this we will need help from our dealers and distributors in ordering parts from the factory. Our dealer parts package will be adequate for the initial requirements of stocking parts. However, for additional parts orders the following procedure will need to be followed: 1. Preferably all orders submitted in writing on customer purchase order giving quantity, part number, description, price and method of shipment, etc. Sample attached. 2. Orders phoned in must be submitted with complete information as described in number one above. Phone orders should be held to a minimum and for emergencies only. Emergency shipments must allow sufficient time for shipment or pick up after received by Chaparral ndustries. 3. Because of costs involved in processing and shipping individual orders it will be necessary for us to establish the minimum dollar value to orders processed. Dollar value is net invoice after applicable discounts. 4. Back orders will be automatically written unless specifically instructed to cancel. Back orders will be shipped at the earliest possible time when the parts or accessories become available. We will do all possible to hold back orders to a minimum, but will need your assistance so that duplicate orders are not written. Note Chaparral ndustries will not accept orders directly from dealers who are operating under a distributor. Parts must be ordered from that distributor

/-.J- 1 5995 North Washington Street Denver. Co!

52 /-.J North Washington Street Denver. Co!orado80216 (303) Mfl/f; fkt f;/;z: r~> NDUSTRES, nc_ SUBSDARY OF HTCO ORDER FORM Date: Sold To: Date to Ship: Ship To: Order No. FOB D Pay & Charge SHP VA: D Truck D P.P D Air 0 Rail 0 Prepaid Ocollect TERMS: D SD/BL 0 Net 30 D Ltr. of Cr. D C. O.D. 0 Floor Plan QUANTTY DESCRPTON PRCE/EA TOTAL l J ~ C ' Salesman's Signature Purchaser's Signature _j

... TX-L MODEL NUMBER CONTENTS 2-3 BODY. 4-6 HOOD ASSEMBLY IGNITION ASSEMBLY. 8-9 SEAT ASSEMBLY STEERING ASSEMBLY.

... TX-L MODEL NUMBER CONTENTS 2-3 BODY. 4-6 HOOD ASSEMBLY IGNITION ASSEMBLY. 8-9 SEAT ASSEMBLY STEERING ASSEMBLY. .. ~ : l~ :;~, ~ 0 J-I-'olaris I I '. ... TX-L MODEL NUMBER 080639 CONTENTS BODY. HOOD ASSEMBLY IGNITION ASSEMBLY. SEAT ASSEMBLY... STEERING ASSEMBLY. CHAINCASE ASSEMBLY. DRIVE CLUTCH. DRIVEN CLUTCH. DRIVE