Parts and Service Manual

Transcription

1 Parts and Servie Manual

2 ~~~~~~~ WARRANTY CERTIFICATE ~~~~~~0 ~ AMF SKI-DADDLER SNOWMOBILE ~ ~, PART I ~ ~ AMF as manufaturer guarantees, to the original retail purhaser, eah new snowmobile to be free of defets in ~ material and workmanship under normal use. The manufaturer's obligation under this warranty is expressly limited ~ to repairing or replaing any defetive part under the onditions set forth as follows: ~. This warranty applies to a minimum period of 90 days of in-season use. For purposes of warranty, the ~ season is onsidered as November through Marh 3. Should a unit be purhased late in the season, the unused Q ~ portion of the 90 day period shall be arried over to the beginning of the following season. ~. The part alleged to be defetive shall be reported in writing to an Authorized AMF Dealer within the Q warranty period exept if the defet is disovered with less than 30 days of the warranty period remaining, it shall be ~ ~ reported within 30 days of disovery of the defet. I 3. This warranty does not apply to items whih are overed by the original manufaturer's warranty, suh as engines, starters, batteries, drive belts, and light bulbs (see Warranty Certifiate, Part II, Conditions). These items are ~ ~ warranted separately by their respetive manufaturers through their authorized servie dealers. ~. This warranty is voided if the snowmobile is operated on otber than snow or ie, in ompetitive raing, in ~ ommerial usage, or has been used as a demonstrator. ~ 5. The warranty registration ard and 0-hour inspetion heklist ard must be mailed to AMF within seven ~ ~ days of date of purhase to qualify for the warranty. ~ ~ 6. Damage or deterioration resulting from misuse, neglet, aident, transit, alterations or unauthorized repair ~ ~ shall in no event be deemed a defet in material or workmanship. ~ 7. This warranty does not over normal wear or maintenane items, whih are onsidered to be operating ~ expense. ~ 8. XX 300, 30 and 00 high performane models will arry the normal Ski-Daddler warranty when purhased for and used as a purely pleasure mahine. Pre-delivery laims will be allowed on the remaining Series ~ XX Models. I 9. AMF reserves the right to inorporate hanges in design into this produt without obligation to make these ~ hanges on units previously sold. 0. No express, implied or statutory warranty other than that herein set forth is made or authorized to be made I ~ ~ ~ byamf. ~ ~ PART II ~ ~ This warranty overs defets in material and workmanship, however, ertain items are onsidered normal operating ~ ~ expense items and are not overed under this warranty. ~ ~ Conditions: ~ ~ This warranty does not apply to: ~.' Engine tune-up, leaning or replaement of spark plugs. ~I Ski alignment. 3. Brake, variable-speed, or tration-belt adjustment, or variable-speed-belt replaement. ~. Normal wear parts replaement suh as brake lining, ski wear-rod, tration belt leats, suspension system ~I ~ bearings, or plasti runners. ~ 5. Paint, body dents and damaged fiberglass, hrome or trim due to use. ~ 6. Engine damage due to lak of suffiient oil in fuel mixture, inorret oil, too lean arburetor adjustment, or ~ luth or tration belt damage due to running engine at high RPM on kikstand, or with variable-speed belt removed. ~ 7. Damaged or broken windshields. Q ~ 8. Any snowmobile whih shall be repaired Or altered outside an AMF authorized repair servie faility in ~~ anyway that in AMF's judgment affets its operation or reliability. 9. Tration-belt failure due to misalignment or abuse. 0. Use of sled for ompetition raing will void the warranty.. Lamps and lens (headlight and taillight). Q ~. Snowmobile when AMF-approved parts are not used in repair or replaement. ~ ~ 3. Any snowmobile for whih warranty registration ard has not been returned in aordane with the ~ ~ instrutions provided. ~. Any parts replaed as a result of normal wear. ~ 5. Deterioration of rubber or fabri omponents. 6. Fasteners. ~ NOTE: Save the Ski-Daddler Inspetion Reord, Form No. 77QA attahed to the snowmobile. This inspetion tag Q ~ identifies your sled by model and serial number and should be shown to your dealer when making any laim under ~ ~ the AMF Warranty. ~ ) <i~~~~~~./~~~~~~~~~~~~~ 00363

3 r""==:::y=~ WARRANTY CERTIFICATE ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ During the warranty period it will be neessary for the dealer to:. Be responsible for warranty servie to the onsumer on warranted items regardless of geographial loation of original purhase.. Mail to AMF within seven days, after ompletion, predelivery inspetion warranty registration ard and 0-hour inspetion heklist ard. 3. Complete a Warranty Allowane Request Form, No. A, and submit it to AMF through his distributor, where appliable, within thirty days after repairs have been made.. Determine if the unit or part requiring repair or replaement is overed under this warranty. 5. Determine if the ustomer warranty has been properly registered and that the warranty period is still in effet. 6. Hold all defetive parts replaed under this warranty until AMF disposition instrutions are reeived or until warranty redit is reeived. 7. Identify all defetive parts returned to AMF under warranty by the appliable warranty request number. 8. Assume the full ost of pik-up harges or travel expenses required to perform warranty servie. Owner's Responsibility During this warranty period it may beome neessary for the owner to:. Replae, lean or adjust spark plugs, ignition points and ondenser.. Perform engine tune-up and adjust arburetor. 3. Adjust and align skis.. Add oil and lubriants. 5. Adjust brake. 6. Assume the full ost of freight for return of defetive warranted parts to the fatory. 7. Perform proper storage of snowmobile during off-season months. ~ 8. Have 0-hour inspetion of snowmobile made by his dealer. ~ <!~~.~~~~~~~~~~~~~~~~~ P IMPORTANT ~ FOR HIRTH ENG IN E PARTS AND WARRANTY, CONTACT LOCAL ENGINE SERVICE AGENCY OR WRITE TO: Teledyne Wisonsin Mot or 90 South 53rd Street Milwaukee, Wisonsin 536 ATTN : Wisonsin-Hirth Engine Dept

4 FLAT-RATE LABOR SCHEDULE. Remove and replae hain ase over Remove and replae hain and adjust tension Remove and replae driven luth or V-belt Remove and replae di-iven luth bearings Remove and replae drive luth Remove and replae engine mount and/or strap Remove and replae drive sprokets Remove and replae drive shaft Remove and replae drive sproket bearings Remove and replae tration belt (endless) and adjust Remove and replae rear idler shaft assembly or bearings Remove and replae rear support arms () Remove and replae throttle able Remove and replae brake able Remove and replae steering spindle Remove and replae spindle arm Remove and replae arburetor Remove and replae Suspension System / hour / hour / hour 3/ hour / hour hour hour / hour 3/ hour -/ hours / hour / hour / hour / hour / hour / hour 3/ hour / hour 00363

5 TABLE OF CONTENTS CONTENTS Page INTRODUCT ION PREDELIVERY INSTRUCTIONS Install Ski Assembly Ski Damper Adjustment Install Windshield Assembly Fuel Mixture Instrutions Lu briation..... SERVICE AND REPAIR Hood Removal and Installation Hood Assembly Repair.... Steering and Ski Assembly Alignment To Remove Drive Chain..... Drive Chain Adjustment To Remove Variable-Speed Drive Belt Variable-Speed Drive Belt Adjustment To Remove Drive Cluth Drive Cluth Alignment... To Remove Driven Cluth To Remove Brake Assembly Brake Adjustment.... To Remove Carburetor. Carburetor Adjustments To Remove Engine. To Remove Gas Tank.. To Remove Muffler... To Remove Sproket Sea ls and Bearings To Remove Drive Sproket Assembly To Remove Suspension Assembly To Remove Tration Belt Tration Belt Adjustment.... Tration Belt Alignment Tration Bell Tension Adjustment Suspension System Adjustment Spark Plug Replaement Wiring Diagrams. Troubleshooting ILLUSTRATED PARTS LIST ilii

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7 INTRODUCTION This manual has been prepared to provide all authorized AMF Ski-Daddler Dealers, Distributors and tehniians with the instrutions neessary to servie and maintain the AMF High-Performane Series XX Ski-Daddler snowmobiles. The series lassifiation for eah snowmobile is learly shown on the left-hand side of the onsole ontrol panel. The Model Number and Serial Number are permanently stamped on the nameplate attahed to the rear right-hand side of the main frame assembly. When ordering aessories or replaement parts, always indiate the orret Model Number and Serial Number as shown on the nameplate. The following hart identifies the Ski-Daddler series lassifiation, orresponding model numbers and engine designation overed in this manual. Series Classifiation Model Number Engine XX-300 SD5M8B 9 XX-30 SD5M6B 30 SD5M8B T I Eng;ne manufaturer's ode number Manua l start Tration belt width in inhes Ski-Daddler INTRODUCTION lesia~ The windshield and ski assemplies will be found in the shippi ng ontainer. Carefully open the ontainer and immediately inspet the equ ipment for any damage or missing items. The spindle pads and loknuts will be found in the plasti bag. The bushings and srews are installed on the spring mounting braket to retain the ski-damper during shipping. IMPORTANT: The owner must retain the Ski-Daddler Inspetion Reord, Form No. 770A. This form must be shown to the dealer should any laim arise for missing or damaged parts. Install Ski Assembly Remove the srew (3, figure ) and bushing seuring the ski-damper to the spring mounting braket. Plae the spindle pad (, figure ) in the spring mou nting braket with the thiker setion and the diretional arrow on the pad pointing forward. Seure the ski assembly to the lower end of the spindle assembly by inserting the srew (3) and bushing through the ski damper, spring mounting braket and spindle tube as illustrated. Apply 30 foot-pounds torque to the loknut (). Do not overtighten loknut as ski assembly should float freely on the spindle. This manual is presented in two setions. The first setion, Maintenane, provides the instrutions neessary for maintenane and servie while the seond setion, the Illustrated Parts List is provided to failitate the ordering of spare and replaement parts. The Parts List setion also ontains a numerial listing of all items shown in the Illustrated Parts List. Thus, if the part number is known but not its appliation, refer to the numerial list. If the part number is not known, loate the item on the illustration to obtain the index number keyed to the appliable parts list_ If the information in this manual is not appliable to all models, the exeptions will be noted and the orret information for the partiular model will be given. PREDELIVERY INSTRUCTIONS The AM F Ski-Daddler snowmobiles are shipped ompletely assembled exept for the windshield assembly and the ski assembly. SKI-DAMPER ASSEMBLY--:.l-..-/ ADJUSTING NUT Figure 00363

8 ~NMlal PREDEL/VERY /NSTRUCT/ONSI~ NOTE: Be ertain to install skiis with pivot of ski damper forward and adjusting nut to outside of Ski-Daddler as illustrated. Repeat proedure for opposite ski. NOTE: Properly installed skiis should toe out 0- to /-inh at the front end and should be symmetrial about the enter I ine of the sled. If neessary, refer to paragraph Steering and Ski Assembly Alignment proedures. Ski Damper Adjustment To adjust the ski damper assemblies, remove the otter pin (figure ) and tighten or loosen the adjusting nut as required to ahieve the desired tension. Replae otter pin and repeat proedure on opposite ski assembly. Install Windshield Assembly Disonnet hood harness at the quik disonnet. Remove hood assembly. Refer to Hood Removal and I nstallation proedure. Remove the srews (figure ) seuring the right- and left-hand mounting strips to the hood. Remove the mounting strips. Remove the protetive plasti over from the windshield. Plae the windshield in position on the hood assembly. Replae the mounting strips as shown in figure. Using the original srews, loosely seure the mounting strips and windshield to the hood assembly starting at the enter and working to the sides. Engage the ends of the mounting strips over the trim strip on the windshield and then tighten the srews, starting at the sides and working to the enter. Remove the protetive overing from the mounting strips. NOTE : Chek mounting strips for sharp edges or orners. Use a fine-tooth file to smooth any sharp edges and orners. IM PORTANT: Before replaing the hood assembly, hek the steering olumn to insure that it is not too loose nor too tight. Adjust the bolts seuring the steering olu mn and U-straps at the roll bar and tahometer braket as required to obtain the desired feel and to insure good steering response. Replae the hood assembly. Fuel Mixture Instrutions ) WINDSHIELD TRIM MOUNTING STRIP, LH WARNING' Never fill the gasoline tank while the engine is hot. Wipe off any spilled gaso line before attempting to start engine. The orret oil-to-gasoline ratio is 0: (0 parts regular gasoline to part oil). Too muh oil will ause arbon deposits. Too little oil or a poor mix will ause insuffiient lubriation and possible engine damage. IMPORTANT: Gasoline and oil should be mixed at temperatures above zero. At temperatures below zero gas and oil mix with diffiulty. Fuels ontaining additives are not reommended for use in Ski-Daddler engines. For mixing with gasoline, use AMF Nondetergent oil, Citgo, Rislone or Kendall oil prepared exlusively for use in air-ooled, -yle engines. Figure IMPORTANT: Some outboard motor oils ontain an additive that works well in outboard motors that operate at muh lower temperatures beause they are water ooled. However, the additives may ause spark plug fouling in the air-ooled engines used on Ski-Daddler snowmobiles

9 Use a mixture of gasoline and AMF oil as shown in the Fuel Mixture Chart. Never use gasoline left over from the summer or previous winter. IMPORTANT: the new no-lead anti-pollution gasolines may ontain additives that ontribute to higher ombustion temperatures and varnish formations that may ause engine seizing. Use only normal leaded regular and premium gasolines when mixing for use in the Ski-Daddler engines. Mix the gasoline and oil thoroughly in a lean ontainer kept for this purpose only. The best way to ensure a good mix is to pour the oil into a ontainer with about one gallon of gasoline and mix thoroughly. Then add additional amounts of gasoline as shown on the Fuel Mixture Chart. Fill Ski-Daddler gas tank from this separate ontainer of mixed fuel. Use a funnel with a fine-sreen strainer when filling the tank. FUEL MIXTURE CHART OIL (Ounes) o ~--r--+--~ ~--+-~~~~ ~ SERVICE AND REPAllOeMI3~ No. lithium bearing grease may also be applied as required to the wearplates and U-straps seuring the steering olumn tahometer braket to the roll bar. SERVICE AND REPAIR Hood Removal and Installation To remove the hood assembly, release the hood lath assemblies and remove the hood assembly by lifting rear portion first. To install the hood assembly, plae the hood in position on the sled so that the forward hood lip and the bottom edge of the hood engages the lips along the inside edge of the bumper. Engage the left- and right-hand lath assemblies and insert safety pins to seu re the hood to the main frame. Hood Assembly Repair AMF Fiberglass Repair Kits are available through your authorized AM F Dealer. For large repairs, order AM F Fiberglass Repair Kit No Smaller repairs an be made with Repair Kit No Paint all repaired areas on the hood using AM F-Orange olor paint available in easy-to-use spray ontainer, AMF Part No Follow the instrutions in the kit when making repairs. GASOLINE (Gallons) ~--t r--+---~~~ ~+-~ GASOLINE/OIL RATIO - 0 to Steering and Ski Assembly Alignment Good steering ability requires that the skis be properly set and aligned with the sled body when the steering handle is plaed in the straight-ahead position. Remove any play in the skis by pulling the skis toward the enter of sled before taking measurements. To determine that the skis are properly aligned, measure the distane between the inside edges of the skis at the front end and at the rear. Lubriation A low-temperature grease must be applied to the zerk fittings loated on the steering spindle tubes; after approximately eah 0 hours of use. The hain ase housing must be heked after eah 0 hours of use and No. lithium bearing grease added as required. The bearing up retai ners that hold the drive and idler sproket seal bearings should be repaked with No. lithium bearing grease whenever the bearings are removed during normal maintenane. No. lithium bearing grease may also be applied to the inside of the drive and idler sproket bearing retainers during normal maintenane. Properly aligned skis should toe out 0- to -inh maximum at the front. If the skis or steering mehanism are not properly set, adjust as follows: Plae steering handle in a straight-ahead position. Remove the hood assembly. Refer to Hood Removal and Installation. Remove the bolt (, figure 3 ), two spaers (), bottom spaer and loknut seuring the rod end bearing (3) to the spindle arm (6). Loosen the jam nut () seuring the rod end bearing (3) to the tie rod (5)

10 SERVICE AND REPAIR Move the affeted ski into proper alignment and rehek measuring points to insure that the skis toe out 0- to /-inh maximum at the front end and are in the same orientation with the sled body as shown in figure _ NOTE: If both skis need adjustment, repeat proedure for the opposite sk i. With skis properly set and steering handle in the straight-ahead position, rotate rod end bearing (3, figure 3) as required to bring rod end bearing in line with the spindle arm (6). Seure rod end bearing (3) to spindle arm (6) as illustrated. Chek for proper alignment and then tighten jam nut () to seure rod end bearing. NOTE: If a greater adjustment is required than that permitted by the steering linkage assembly, it will be neessary to align the ski by making the adjustment at the spindle tube assembly as follows: Remove srew (5, figure ) and loknut (6) seuring spindle tube assembly (7) to spindle arm (8). Remove spindle arm (8) and rotate ski and spindle one noth in the requ ired diretion; replae and seure spindle arm to the spindle. Apply 0 foot-p6unds torque to the loknut (6). Rehek the skis for proper toe out and alignment as previously desribed. NOTE: Sk i-damper adjustment is not normally requ ired during ski-alignment proedures. However, if adjustment is desired, tighten or loosen the ad justing nut shown in figure as required to obtain the desired tension. To Remove Drive Chain Remove the hood assembly. Refer to Hood Removal and Installation. Always disonnet spark plug wires before working on the engine or drive elements. Remove the loknut seuring the hain over top and remove hain over top and spaer sleeve. Loosen the bolts (, figure ) on both am uprights () and rotate the am and shaft (3) as required to loosen the hain tension. During reassembly, apply 30 foot-pounds torque to the bolt (). Remove the otter pin, slotted nut and washer seuring the top sproket to the driven luth shaft. Remove the top sproket and hain together. Reassembly is the reverse of removal. Perform drive hain adjustment proedures and add No. lithium bearing grease as required to the hain ase. Drive Chain Adjustment A properly adjusted drive hain (figure ) should have a /8- to l/-inh slak. Chek and adjust hain as follows: Remove the loknut seuring the hain over top and remove hain over top and spaer sleeve. ) ) ) Figure 3 Figure 00363

11 Rotate the upper sproket to tension one side of the hain and then hek the opposite side for proper slak. If adjustment is req uired, loosen the bolts () seuring the am uprights () on eah side. During reassembly, apply 30 foot-pou nds torque to the bolts (). Rotate the am (3) ounterlokwise to tighten or until the hain is properly tensioned. Hold the am in this position while tightening the am upright bolts () on eah side. Be ertain the lateral alignment between the drive luth and the driven luth () is maintained while the am upright bolts are tightened. Rehek hain tension before replaing the hain over, top and spaer sleeve. To Remove Variable-Speed Drive Belt Remove the drive hain. Refer to pa ragraph To Remove Drive Chain. Remove the luth guard assembly. Loosen the loknut (8, figure 3) and serrated washer (7). During reassembly, apply 0 foot-pounds torque to the loknut (8). Push the driven luth toward the drive luth to permit removal of the variable-speed drive belt from the drive luth. If neessary the drive belt an be removed from the drive luth after the driven luth is removed from the bearing lamps. Remove the loknuts (7, figure 6) seuring the bearing lamps (8) and remove the bearing lamps. During reassembly, apply 5 foot-pounds torque to the loknuts (7). Lift the driven luth and drive belt lear of the brake assembly and remove the variable-speed drive belt. Install replaement drive belt. Use AMF Part No on Models SD5M6B and SD5M8B ; NOTE: Variable-speed drive belt installation proedures are the reverse of removal exept that the belt must first be plaed around the driven luth and then around the drive luth. After installation, perform the drive hain adjustment, variable-speed belt adjustment and the drive luth alignment proedures. SERVICE AND REPAIR Variable-Speed Drive Belt Adjustment USIA Proper drive belt tension is obtained when opposite sides of the belt an be squeezed between the drive luthes to -3/ to 3-/ inhes as measured between the top and bottom outside surfae of the belt. Measurement must be taken as lose to the drive luth flanges as possible. Be ertain the driven luth does not open when belt is squeezed. IMPORTANT: Do not use antislip belt dressing. Belt slippage is a safety feature whih prevents overstressing drive-system omponents. To adjust drive belt tension, loosen the loknut (8, figure 3) seuring the luth rod tensioner to the main frame assembly. NOTE: If the drive belt is wearing unevenly, hek alignment as desribed in Drive Cluth Alignment proedures. Move the driven luth (9) in the diretion required to obtain proper belt tension. Hold this position while tightening the loknut to seure the luth rod tensioner. Be ertain the washer (7) and bar serrations are properly engaged. Apply 0 foot-pounds torque to the loknut (8). To Remove Drive Cluth Remove the hood assembly. Refer to Hood Removal and Installation. Always disonnet spark plug wires before working on the engine or drive elements. Remove the luth guard assembly. Loosen the loknut (8, figure 3) and serrated washer (7) seuring the luth rod tensioner to the main frame. During reassembly, apply 0 foot-pounds torque to the loknut (8). Push the driven luth toward the drive luth to permit removal of the variable-speed drive belt from the drive luth. If neessary remove belt after drive luth is removed from engine

12 ~t!mi3 SERVICE AND REPAIR I~ To remove the drive luth, remove the luth adapter bolt and washer. If neessary, use a luth puller and remove the drive luth. NOTE: During reassembly apply 50 to 60 foot pounds torque to the luth bolt. Reassembly is the reverse of removal. Perform variable-speed drive, belt adjustment and drive luth alignment proedures. Drive Cluth Alignment Remove the hood assembly. Refer to Hood Removal and Installation. Tighten engine holddown nuts and rehek alignment. Apply 5 foot-pounds torque when tightening the engine holddown nuts. To Remove Driven Cluth NOTE.: The proedures required to remove the driven luth are the same as those desribed in paragraph To Remove Variable-Speed Drive Belt. To Remove Brake Assembly Remove hood assembly. Refer to Hood Removal and Installation. Always disonnet spark plug wires before working on the engine or drive elements. Remove the luth guard. Loosen the engine holddown nuts (figure 5) seuring the engine supports to engine mount straps. Plae a straightedge on the fixed fae of the drive luth and move the engine until the offset between the straightedge and the front and rear edges of the driven luth is set to the A dimension as shown in figure 5. Rotate driven luth 90- degrees and repeat proedure. A B (TORQUE) MODEL NO. ENGINE CLUTCH FT LB ± 5 SD5M8B Series ± 5 SD5M6B Series -J I_ ~ STRAIGHTEDGE DRIVEN CLUTCH Always disonnet the spark plug wires before working on the engine or drive elements. Disonnet brake able and housing (3, figure 6) at brake mounting braket and at brake atuating lever. Remove the bolts and lokwashers seuring the mounting braket to the driven luth mounting. Remove the brake assembly. Installation proedures are the reverse of removal. Refer to Brake Adjustment proedures. Brake Adjustment To adjust the brake pads (5, figure 6) to the disk (), remove the otter pin () and tighten or loosen the astle nut () as required to permit the brake pads (5) to just lear the brake disk. Reinstall the otter pin. To adjust for exessive play in brake able or lever position, loosen jam nuts (6) and move brake housing (3) as required. Tighten jam nuts. Chek brake ation after eah adjustment to insure proper brake operation. If neessary apply lotite antiseize lubriant to the atuating am lever (9, figure 6) and the steel pins (0) as follows: DRIVE CLUTCH Figure 5 HOLD DOWN NUTS VIEW 0 Remove the otter pin () and the astle nut (). Remove the atuating am lever (9) and apply lubriant to the am lever surfae that ontats the pins (0). Remove the pins and apply lubriant to the pins. Reassemble the am lever and pins

13 SERVICE AND REPAIR Carbu retor Adjustments When adjusting the arburetor, best results will be obtained if the adjustments are made on a warm engine. During arburetor adjustments, DO NOT FORCE ADJUSTMENT SCREWS INTO SEATS. TO ADJUST CARBURETOR - Close the high-speed jet (DO NOT FORCE). Then open the high-speed jet (figure 7) to the settings shown on the arburetor settings hart for the partiular engine (see figure 8). Figure 6 WARNING I Do not allow antiseize lubriant to ontat the brake pads (5, figure 6) or disk (). To do so will result in brake slippage. To Remove Carburetor Remove the loknut seuring the throttle rod srew to the arburetor linkage. Remove the throttle rod srew and jam nuts. Remove the srews seuring the ram tube to the arburetor and remove the ram tube. Disonnet the fuel lines at the arburetor. Wipe up any spilled gasoline immediately. Be ertain to note the position of the gas line and impulse lines to insure proper reassembly. The engine an be seriously damaged if operated with a lean gas mixture (high-speed jet turned in too far). Turn the low-speed jet (idle-mixture srew) shown in figure 7 all the way in (DO NOT FORCE), then open as shown in figure 8 for the partiular engine. This ad justment ontrols the mixture at idling speeds. A lean idle mixture will result in poor aeleration. Keep the idle speed slower than the luth engaging speed by adjusting the idle-speed srew. NOTE: Do not use the low-speed jet to adjust for idle speed. NOTE : Figure 7 shows a throttle-wire. If the throttle plate fail s to open ompletely when the throttle ontrol lever is depressed, loosen the throttle-wire adjustment srew and readjust the wire as required to ensure that the throttle opens fully and returns freely. Remove the jam nuts and lokwashers seuring the arbu retor to the intake manifold and remove the arburetor. Remove the gasket. Do not damage the gasket if required for reassembly. NOTE: Replaement arburetors are supplied with a new gasket. Installation is the reverse of removal. Adjust the arburetor as desribed in the Carburetor Adjustment proedures. Figure

14 SERVICE AND REPAIR CARBURETOR SETTINGS CHART ) SERIES MODEL NO. CLASSIFICAT ION ENGINE HIGH-SPEED JET LOW-SPEED JET + /8 + /8 SD5M8B XX Open - /8 Open /8 + /8 SD5M6B XX-3O 30 Open -/8 Open The above arburetor settings are for fatory stok engines, exhaust systems, arburetion and various altitudes may require different settings for satisfatory operation. To Remove Engine Figure 8 Remove the hood assembly. Refer to Hood Removal and Installation. Always disonnet the spark plug wires before working on the engine or drive elements. Remove the drive luth. Refer to paragraph To Remove Drive Cluth. NOTE: The Illustrated Parts list setion of this manual ontains detailed exploded views of the engine and support assemblies whih will be helpful if referred to during engine removal proedures. For engine maintenane instrution, refer to the engine manual supplied with eah sled. Remove the ap srews and washers seuring the arburetor heat shield to the intake manifold and remove the heat shield. Remove the heat shield attahed to the roll bar and main frame between the engine and the muffler. Disonnet the engine wiring harness and loosen or remove all wiring holddown lips. Disonnet the ground lead. Remove the loknuts, washers, rubber spaers and bushings seuring the engine and engine mounting straps to the main frame. NOTE: The arriage bolts are held in position with Tinnerman nuts and need not be removed. Do not remove the shok mounts unless it is neessary to replae them. During reassembly, tighten t he loknuts suffiiently to allow a 5/6-inh learane between bottom of the shok mount and top surfae of the main frame. IMPORTANT: Be ertain all wiring and gasoline lines are lear before attempting to remove the engine. Disonnet the gas lines at the arburetors. Disonnet impulse lines at the engine. Wipe up any spilled gasoline immediately. Note the position of all lines to insure proper reassembly. Remove the apsrews and spring lokwashers seuring the left and right-hand intake manifold to the engine. Remove the intake manifolds, arburetors and ram tubes as a unit. Remove the engine-to-manifold gasket if required for reassembly. NOTE: New, replaement engines are supplied with new engine-to manifold gaskets. 8 lift the engine and engine mounting straps until the straps are lear of the arriage bolts and remove the engine and straps as a unit..release the exhaust manifold at the engine. Refer to paragraph To Remove Muffler. Remove the bolt and washers seuring the engine to the engine mounting plate and remove the engine. During reassembly, apply lo-tite to the bolt threads and tighten bolts to 8 foot-pounds torque. Installation is the reverse of removal )

15 SERVICE C To Remove Gas Tank Remove the hood assembly. Refer to Hood Removal and Installation. Always disonnet spark plug wires before working on the engine or drive elements. Chek gas ap and indiator assembly to be ertain tank is empty. or nearly empty. Remove the gas ap and indiator assembly (. figure 9). Remove the bolts (3) and washers seuring the gas spill hute () to the main frame and remove the gas spill hute. Disonnet the tank-to-arburetor gas lines (6) at the gas tank outlet fitting (5). Wipe up any spilled gasoline immediately. Remove the gas tank () by arefully sliding the tank up and away from main frame. IMPORTANT: Do not damage the gas tank outlet (5) when removing the tank. Do not attempt to make any repairs to the gas tank. Use extreme are when removing the gas tank. Do not remove tank near flame or open fire. Gas tank installation proedures are the reverse of removal. NOTE: If the original tank is not to be installed. it will be neessary to remove the gas tank outlet (5) and the attahed gas line filter; also the pressure relief valve (7). These items are to be installed on the replaement tank. To Remove Muffler Remove the hood assembly. Refer to Hood Removal and Installation. Always disonnet the spark plug wires before working on the engine or drive elements. Loosen the lamp seuring the muffler to the dualexhaust manifold. Figure 9 Loosen the bolt and nut seuring the muffler to the mounting band assembly. Remove the muffler. Installation proedures are the reverse of removal. To Remove Sproket Seals and Bearings Sproket seals and bearings are loated on eah end of the drive sproket assembly drive shaft. To replae the seals or bearings it will be neessary to remove the drive sproket assembly as desribed in the following paragraph. To Remove Drive Sproket Assembly Remove the hood assembly and set the mahine on its right-hand side. Always disonnet spark plug wires before working on the engine or drive elements. Remove the suspension assembly. Refer to paragraph To Remove Suspension Assembly. Remove the lower sproket from the drive sproket shaft and remove the sproket and hain as desribed in paragraph To Remove Drive Chain. Using a srew driver. arefully pry the oil seals (figure 0) away from the bearings at eah end of the drive shaft

16 SERVICE AND REPAIR Pivot the suspension assembly and tration belt about the front axle to approximately go-degrees. ) Remove srews and lokwashers seuring the suspension assembly to the front end of the main frame and remove the suspension assembly. Installation is the reverse of removal. During reassembly, follow the instrutions outlined in paragraphs Tration Belt Tension Adjustment, Tration Belt Alignment and Suspension System Adjust ment. DRIVING SPROCKETS Figure 0 To Remove Tration Belt To remove or replae the tration belt it is neessary to first remove the suspension assembly and then the drive sproket assembly. Refer to the appliable paragraphs for removal proedures. Remove the arriage bolts and nuts seuring the bearing retainers to eah side of the main frame. Remove the retainers. During reassembly apply No. lithium bearing grease to the bearing retainers. IMPORTANT: When installing the tration belt, follow the instrutions outlined in paragraphs Tration Belt Tension Adjustment, Tration Belt Alignment and also rehek Suspension System Adjustment. Move the drive shaft and sproket assembly toward the hain side until the opposite end of the shaft lears the other side. Remove the drive sproket assembly. NOTE: With the removal of the drive sproket assembly, the tration belt will also be free for removal. To replae the sprokets, remove the ball bearing, grease seal, ol lar and idler wheel. Remove the srews and nuts seuring the support plate and sproket to the drive shaft and sproket plate assembly. Remove the sproket. Reasse mbly is the reverse of removal. During reassembly follow instrutions outlined in the paragraphs Tration Belt Tension Adjustment, Tration Belt Alignment and Drive Chain Adjustment. To Remove Suspension Assembly Remove the hood assembly and set the mahine on its right-hand side. Always disonnet spark plug wires before working on the engine or drive elements. Remove the srews (figure ) and lokwashers seuring the bak end of the suspension assembly to main frame. Tration Belt Adjustment IMPORTANT: The tration belt must be heked regularly for proper alignment and tension. When neessary to adjust the belt, first perform the tration belt alignment and then omplete the tration tension adjustment. Tration Belt Alignment Set the snowmobile on a level surfae and raise the bak end. Stand to the rear of sled and visually hek the spae between the slide rail and the edges of the trak. NOTE: On a properly aligned trak this spae should be the same. Start the engine and again visually hek to be ertain the trak remains entered whi le the trak is running. If the trak is not entered, stop the engine and on that side where the edge of the trak is losest to the slide rail, rotate the adjusting srew (figure ) until trak is entered. Pull the trak for a few revolutions and then start the engine and rehek alignment. Stop the engine and lok the adjustment srew in this position. After trak alignment is omplete, hek trak tension as desribed in the following paragraph. )

17 Tration Belt Tension Adjustment Set the snowmobile on a lean, flat surfae and raise the bak end of the sled. Chek tration belt tension by firmly pulling the trak downward at the enter of the trak. A properly tensioned trak should have a - to -/-inh learane between the plasti runner and the trak leats at the approximate bottom enter of the trak. NOTE: Do not attempt this with the engine running. Tration belt leats are sharp and must be handled arefully. If adjustment is neessary, loosen the loknuts (figure ) on eah side of the sled and rotate the adjusting srews as required to obtain proper trak tension. IMPORTANT: Adjust both srews equally so as not to disturb the trak alignment. Retighten the loknuts on both sides of the snowmobile., Never run the engine inside a building without first opening all doors and windows to insure proper ventilation. ~ SERVICE AND REPAIR lesl3~ Raise the bak end of the snowmobile until the trak lears the ground. Start the engine and allow the trak to rotate several turns. Then, stop the engine and repeat the trak tension adjustment proedure to ensure that proper tension is maintained. Suspension System Adjustment The suspension system may be adjusted for a soft or firm ride, or for varying snow onditions. If a firmer ride is desired, adjust the jamnuts (figure ) to tighten the eyebolts loated on eah side of the trak. Loosen the eyebolts if a softer ride is desired. Adjust front or rear sets of eyebolts equally. Spark Plug Replaement To maintain top engine performane the ondition of the spark plugs should be heked periodially and the gap reset to 0.00-inh using a wire gauge. During reassembly apply 8 to 0 foot-pounds torque. Spark plug ondition may be determined by the olor. A arbonized plug is blak; a burnt plug is pale gray, whereas a normal funtioning spark plug is brown. When replaing spark plugs, use AMF-approved spark plugs to insure proper spark plug heat ranges for a partiular engine. NOTE: The Spark Plug Chart is provided to identify spark plugs for light or severe servie. 'C JAMNUTS h~=;:='rl -:':;;:;:;:==l\ PROPER TENSION l -TO lf.z -INCH PULL Figure 00363

18 ~emial SERVICE AND REPAIR III SPARK PLUG CHART ) MODEL NUMBER ENGINE LIGHT SE RVICE SEVERE SERVICE SD5M8B (XX-300) SD5M6B (XX-30) (N60 or *XL) (N57 or XC) (N60 or *XL) (N57 or XC) *Optional ENGI NE STOPS. Fuel tank empty; fuel flow obstruted; ignition system faulty. Spark plug(s) fouled or dirty. Engine too hot and pistons seizing; arburetor setting too lean or inorret grade of oil being used, impulse line loose. I I ~-=-~-~-~-~-~-~-~-~~~E~N ~GI~N ~E WIR~~ ---- ~ CONNECTIONS...l o '" U...l <{ W...J > II> BLACK RED RED I,, Wiring Diagrams The eletrial wiring diagram (figure ) is provided for the trained tehniians using th is manual. Troubleshooting I I I, I, I Figure HIRTH 9 ENGINE HIRTH 30 ENGINE : BLACK TACHOMETER BLACK BLUE BLACK QUICK-KILL SWITCH ;~r: ENGINE HARD TO START. Fuel line bloked or leaking; ruptured fuel-pump diaphram; water in fuel, flooded or loose impulse line; ignition or swith wiring loose or grounded; spark plug(s) fouled or faulty; ontat breaker points pitted or burned; quik-kill swith in off position. _ ENGINE OPERATES IRREGULARLY. Spark plug(s) loose, fouled or faulty; ignition swith wiring shorted; arburetor out of adjustment or dirty. Engine holddown bolts loose; ignition timing off. ENGINE WORKING FOUR-STROKE. Choke shut; arburetor settings inorret; dirt preventing arburetor inlet needles from seating properly. ENGINE LOSES POWER. Poor ompression due to loose head and rankase bolts. Faulty ignition; timing; piston rings stiking due to the use of improper oil. Carbon deposits in ylinder. ENGINE BACKFIRES THROUGH CARBURETORS. Carburetor fuel-supply hannel logged. Carburetor set too lean. ENGINE BACKFIRES THROUGH EXHAUST. Inorret or faulty spark plug(s); faulty ignition oil or ondenser; loose ignition wiring. ENGINE OVERHEATS. Insuffiient or inorret grade oil in fuel mixture; arburetor or fuel line partly logged; arburetor setting too lean; ignition timing too slow. BRAKES. Exessive play in handbrake due to loose brake able or worn pads. TRACTION BELT. Poor tration; hek tration belt for alignment and tension; worn sprokets. CLUTCH. Automati luth fails to engage at proper RPM's. (see figure 3). Chek variable-speed drive belt for proper tension and alignment

19 CLUTCH ENGAGEMENT SPEEDS CLASS ENGINE ENGINE RPM XX ± 300 XX ± 300 Figure 3 EXCESSIVE FUEL CONSUMPTION. Carburetor fuel line or gas tank leaking; hoke losed; inorret arburetor setting. ~I SERVICE AND REPAIR lesla~ SKI ASSEMBLY. Poor steering ability due to loose skis; worn wear rod. Poor riding harateristis due to loose or defetive ski-dampers. STEERING. Poor steering ability aused by improperly adjusted skis; steering linkage loose or out of adjustment. U-braket bolts on roll bar too tight or too loose. Spring, U-braket loose. THROTTLE CONTROL Exessive play in throttle ontrol lever aused by loose throttle ontrol able. r

20 ILLUSTRATED PARTS LIST PARTS LIST This setion of the dealer's manual onsists of an illustrated parts list and a numerial index. PARTS LIST The parts-list onsists essentially of exploded-view illustrations keyed to the figure-referene olumn by index numbers. The Parts List is arranged in the following olumns: Figure-and-Index Number. The number preeding the dash refers to the figure number on whih the item is shown. The number following the dash is the index number keyed to the item shown on the exploded view. Part Number. The part number olumn identifies the item by its assigned part number. Desription. The desription olumn identifies the part with desriptive nomenlature. Quantity. This olumn provides the total nu mber of items required per assembly. Model Code. This olumn identifies, by ode letter, the Ski-Daddler models for whih the part applies. The following lists the ode-to-model relationship: Model SD5M8B SD5M6B Code A B Where no ode letter appears in the ode olumn, the part is used on all models to whih the partiular figure applies. All model odes will be listed at the bottom of eah parts list page to provide a ready referene. NUMERICAL INDEX The numerial index is provided to afford dealers and distributors with a means of determining to whih models their stok applies. The index onsists of the following three olumns: Part-Number Column. The part-number olumn tabulates all parts alled out in the parts list. The part numbers are listed in numerial order starting with the first digit in the number. Index-Number Column. The index-number olumn reflets the figure-and-index number of the part within the Parts List. The number preeding the dash refers to the figure number on whih the item is shown. The number following the dash loates the item within the given figure. Quantity Column. The quantity olumn reflets the total number of parts required for the partiular figure-and-index-number appliation. In ertain ases, quantities differ between sled models. This irumstane is overed by providing the larger quantity for the partiular figure-and-index number. In referring to the given figure-and-index number in the parts-list setion, the proper quantity per sled may be determined. Addendum. Numbers added. ) 00363

21 PARTS LIST PSl3 Figure Number Part Number Desription Oty Model Code SKI -DADDLER, Model No_ SD5M8B SKI-DADDLER, Model No. SD5M6B WINDSHIELD, 5-lnh _ HOOD ASSEMBLY (See figure ) BUMPER ASSEMBLY, RH (See figure ) _ BUMPER ASSEMBLY, LH (See figure ) SCREW, Truss HD, /-8 by -/ IN. LG WASHER, Formed LOCKNUT, /-8 THD SCREW, HEX HD, 3/8- by IN. LG WASHER, Plain, 3/3 ID... _ LOCKNUT, 3/8- THD _ SKI AND SPRING ASSEMBLY, RH (See figure 3) SKI AND SPRING ASSEMBLY, LH (See figure 3) SEAT ASSEMBLY (See figure ) MUD FLAP, 5-lnh SCREW, PAN HD, 0-3 by 3/ IN. LG... _ STRAP, 5-lnh LOCKNUT, 0-3 THD..... _ CLUTCH GUARD AND DECAL ASSEMBLY DECAL, Safety _ STRAP, Cluth guard BOLT, HEX HD, /-8 by -3/ IN. LG , BOLT, HEX HD, /-8 by 3/ IN. LG WASHER, / ID _ LOCKNUT, /-8 THD _ ENGINE AND SUPPORT ASSEMBLY (See figure 5) ENGINE AND SUPPORT ASSEMBLY (See figure 5) SHOCK MOUNT BOLT, Carriage, 3/8- by -/ IN. LG NUT _ BUSHING SPACER, Rubber _... WASHER LOCKNUT, 3/8- THD HEAT SHIELD '.... SUPPORT, Heat shield SCREW, Truss HD, /-8 by 5/8 IN. LG WASHER, Plain, / ID LOCKNUT, /-8 THD SLED HARNESS CLiP TRACK ASSEMBLY A B A B A - SD5M8B B - SD5M6B

22 en." <E' n o o W 0> W I\) u

23 PARTS LIST C Figure Number Part Number Desription Oty Model Code l * *3796 GUIDE RIVET, 3/6 DIA by 0.65 IN. LG CLEAT RIVET, 3/6 DIA by 0.57 IN. LG BELT, Trak, 3-lnh BELT, Trak, 6-lnh.... SUSPENSION ASSEMBLY (See figure 6) BOLT, HEX, 3/8- by IN. LG LOCKWASHER,3/8 ID SPROCKET ASSEMBLY, Drive (See figure 7) DRIVEN CLUTCH AND MOUNTING ASSEMBLY (See figure 7).... DRIVEN CLUTCH AND MOUNTING ASSEMBLY (See figure 7).... GAS CAP ASSEMBLY, Tank (See figure 8) MAIN FRAME ASSEMBLY BODY STRIP, Wear POP RIVET WASHER, 3/6 IN FOOT PAD, LH FOOT PAD, RH POP RIVET CABLE TIE INSTRUCTION MANUAL ASSEMBLY (Not illustrated)..... INSTRUCTION MANUAL ASSEMBLY (Not illustrated) PARTS BAG ASSEMBLY, Engine (Not illustrated) A B A B A - SD5M8B B - SD5M6B *Item 60, Instrution Manual Assembly ontains Ski-Dadd ler doumentation. Not shown. * Item 6, Contains metri tools for engine maintenane. Not shown

24 Figure \ 5 ~ 3 9 )

25 PARTS LIST C Figure Number Part Number Model Desription Oty Code r HOOD ASSEMBLY (See figure ) REF AB CLIP, Hood RIVET 3 PLATE, Hood GAS LID AND HINGE ASSEMBLY SCREW, RD HD, 0-3 THO by / IN. LG LOCKNUT, 0-3 THD HINGE ASSEMBLY LOCKNUT, 0-3 THD SPR lng, Flat DECAL, Gas over GAS LID ASSEMBLY BRACKET, Support RUBBER BUMPER, Gas lid TRIM STRIP, RH TRIM STRIP, LH SCREW, Truss HD, /-0 THD by 5/8 IN. LG 7 JACKNUT, Molly, /-0 7 ESCUTCHEON, Side NUT, Spring 6 STRIKE RIVET HOOD AI R DUCT, Hood LOCKNUT, /-0 THD WASHER CATCH, Hood RIVET GUIDE, Hood 6 LOCKNUT, /-8 THO 6 SPACER, Bumper 6 COVER, Bumper BUMPE R ASSEM BL Y, RH (See figure ) REF BUMPER ASSEMBLY, LH (See figure ) REF STOP, Hood SCREW, HEX HO KLICK PIN DECAL, Raing, A - SD5M8B B - S05M6B

26 PARTS LIST I~ Figure. 3 (Sheet of ).. ) /~ ~ r ~ 7 L

27 Figure Number Part Number Desription ~I PARTS LIST 3- *3700 STEERING LINKAGE ASSEMBLY ARM, Spind le BOL T, HEX HD, 3/8- THD by -3/ IN. LG SPACER SPACER LOCKNUT, 3/8- THD TIE ROD ASSEMBLY BOL T, HEX HD, 3/8-THD by -/ IN. LG SPACER LOCKNUT, 3/8-TH D ROD END JAM NUT, HEX, 3/8- THD TIE ROD BOL T, HEX HD, /-8 THD by -7/8 IN. LG WASHER, Plain, / IN. ID U-STRAP WEARPLATE WEARPLATE LOCKNUT, /-8 THD GRIP, Hand THUMB CONTROL ASSEMBLY, Throttle. - 3 SCREW, RD HD, 0-3 THD by -3/8 IN. LG LOCKNUT, 0-3 THD LEVER, Thumb SCREW, Truss HD, 6-3 THD by 3/8 IN. LG SPACER CLAMP, Thumb ontrol KILL-SWITCH ASSEMBLY CLIP, WIRE BRAKE CONTROL A SSEMBLY HAND CONTROL ASSEMBLY THROTTLE CABLE, HOUSING AND BOOT ASSE MBLY STEER ING HANDLE AND COLUMN ASSEMBLY -3 * STEERING COLUMN ASSEMBL Y SCREW, / 8 THD by IN. LG WASHER, Plain, / IN. ID U-STRAP WEARPLATE WEARPLATE LOCKNUT, /-8 THD TACHOMETER COVER, Tahometer Oty 3 ItaSI3~ Model Code A - SD5M88 B - SD5M6B * 3- inludes appliable items - through 3 * 3-3 inludes appl iable items 0 through