PARTS AND SERVICE MANUAL

Transcription

1 PARTS AND SERVICE MANUAL SKI-DADDLER SNOWMOBILES MARK IV AND MARK V AMF WESTERN TOOL DIVISION Parts and Servie Department Whiteford Road, York, Pennsylvania, 70 77/88-77 AMF INCORPORATED PAR T NO. 007

2 ~~~~~~~ WARRANTY CERTIFICATE ~~~~~~t> I AMF SKI-DADDLER SNOWMOBILE ~ PART! Q AMF as manufaturer guarantees, to the origi~al retail purhaser, eah new snowmobile to be free 0 ~ defets in material and workmanship under normal use. The manufaturer's obligation under this warranty ~ is expre~sly limited to re~airing or replaing ~ny defetive part under the on~itions set forth as follows: Q ~. ThIs warranty applies only to defets disovered between the date of retail purhase and the first day ~ of the following month of May. ~. The part alleged to be defetive shall be reported in writing to an authorized AMF dealer within thirty ~ days of the disovery of the defet. ~ 3. This warranty does not apply to items whih are overed by the original manufaturer's warranty, Q ~ suh as engines, starters, batteries, drive belts, and light bulbs (see Warranty Certifiate, Part II, Condi- ~ tions). These items are warranted separately by their respetive manufaturers through their authorized ~ servie dealers.. This warranty is voided if the snowmobile is operated on other than snow or ie, in ompetitive raing, ~ ~ in ommerial usage, or has been used as a demonstrator. Q ~ s. 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 Q ~ expense. ~ 8. For other than predelivery laims, the warranty will not apply to Series XX, high-performane models. ~ 9. AMF reserves the right to inorporate hanges in design into this produt without obligation to make ~ these han{.:es on units previously sold. 0. No express, implied or statutory warranty other than that herein set forth is made or authorized to be made by AMF. ~ ~ ~ ~ ~ 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. ~~7:~;~:~ty does not apply to: ~. Engine tune-up, leaning or replaement of spark plugs. ~. Ski alignment. 3. Brake, variable-speed, or tration-belt adjustment, or variable-speed-belt replaement.. Brake lining or ski wear-rod replaement. Q S. 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 adjust- ~ ment, or luth or tration belt damage due to running engine at high RPM on kikstand, or with variablespeed 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. zo. 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. Q. Any parts replaed as a result of normal wear. ~~ ~ IS. Deterioration of rubber or fabri omponents. 6. Fasteners. ~ NOTE: Save the Ski-Daddler Inspetion Reord, Form No. 77QA attahed to the snowmobile. This Q ~ inspetion tag identifies your sled by model and serial numoer and should be shown to your dealer when ~ ~ making any laim under the AMF Warranty. ~,,~~~~~~~~~~~~~~~~~~ ~ 00Z7

3 ~~~~~~~ WARRANTY CERTIFICATE ~~~~~~ ~ ~ Dealer's Responsibility ~ ~ During the warranty period it wiil be neessary for the dealer to: Q ~. 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 AIlowane Request Form, No. A, and submit it to AMF through his dis- Q tributor, 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 arid that the warranty period ~ is stiii in eret. 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: Q ~. Replae, lean or adjust spark plugs, ignition points and ondenser. ~ ~. Perform engine tune-up and adjust arburetor. Q ~ 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 or-season months. Q ~ 8. Have 0-hour inspetion of snowmobile made by his dealer. ~,,~~~~~~~~~~~~~~~~~~~ ~ IMPORTANT ~ WHILE THE WARRANTY COVERS DEFECTS IN MATERIAL AND WORKMANSHIP, CERTAIN MAINTENANCE ITEMS AS LISTED BELOW ARE CONSIDERED NORMAL OPERATING EXPENSE ITEMS AND ARE NOT COVERED UNDER THE WARRANTY.. Engine tune-up leaning or replaement of spark plugs.. Ski Alignment. 3. Brake, variable speed, or tration belt adjustment, or variable speed belt replaement.. Brake lining or ski wear rod replaement. 5. Paint, body dents, damaged fiberglass, and. hrome or trim damage 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. Broken windshields. 8. Any modifiations other than fatory reommendations. 9. Tration belt failure due to misalignment or abuse. 0. Use of sled for ompetition raing willi void the Warranty', NOTE: SAVE THE SKI-DADDLER INSPECTION RECORD, FORM NO. 77QA ATTACHED TO THE SNOWMOBILE STEERING COLUMN. THIS INSPECTION TAG IDENTIFIES YOUR SLED BY MODEL AND SERIAL NUMBER AND SHOULD BE SHOWN TO YOUR DEALER WHEN MAKING ANY CLAIM UNDER THE AMF WARRANTY. 007

4 WARRANTY FLAT-RATE LABOR SCHEDULE,). Remove and replae hain ase over.... / hour. Remove and replae hain and adjust tension....._... / hour 3. Remove and replae driven luth or bearings or V -belt.... / hour. Remove and replae drive luth.... / hour 5. Remove and replae engine mount and/or strap (MARK IV)... hour RemoVe and replae engine mount and/or strap (MARK V)... -/ hours 6. Remove and replae drive sprokets, drive shaft or bearings.... hour 7. Remove and replae tration belt (endless) and adjust.... hours 8. Remove and replae rear idler shaft assembly or bearings..... / hour 9. Remove and replae rear support arms ().... / hour 0. Remove and replae throttle able.... / hour. Remove and replae brake able..... / hour. Remove and replae bogie support half (lor both).... / hour 3. Remove and replae bogie wheel..... / hour. Remove and replae steering spindle Remove and replae spindle arm.... / hour / hour 6. Remove and replae arburetor / hour ) 007

5 ~I CONTENTS lesia~ TABLE OF CONTENTS Page INTRODUCTION..... PREDELIVERY INSTRUCTIONS Install Ski Assembly.... Install Windshield Assembly Ativate Battery.... Install Kikstand Assembly Fuel Mixture Instrutions Lubriation..... SERVICE AND REPAIR Hood Removal and Installation Hood Assembly Repair.... Replae Lamp Assemblies... 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 Adjustment.. To Remove Starting Motor Assembly To Remove Engine and Support Assembly- Mark IV Only. To Remove Engine and Support Assembly-Mark V Only To Remove Gas Tank.. To Remove Muffler To Remove Bogie Wheel To Remove Bogie Wheel and Support Assembly To Remove Bogie Wheel Torsion Springs.. To Remove Tration Belt Take-Up Assembly To Remove Sproket Seals and Bearings To Remove Drive Sproket Assembly To Remove Tration Belt Tration Belt Adjustment Spark Plug Replaement Wiring Diagrams Troubleshooting.... ILLUSTRATED PARTS LIST J5 5 J J

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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 970/97 AMF MARKIV and MARK V series 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 list identifies the Ski-Daddler series lassifiation, orresponding model numbers and engine designation overed in this manual.,:---series Classifiation Model Number Engine IMARK IV-300 SD5PI0B JLO 95 MARK V-00 SD8P7A Hirth 399 MARK V-00E SD8E7A Hirth 399 MARK V-00DE SD8E5B Kohler 399 MARK V-500DE SD8E0B Hirth 93 MARK V-60 SD8PA Hirth 63 I Manufaturer's engine ode number SD5P0B P = Prepared f~r eletri~ starter; E = Equipped WIth eletric starter Tration belt width in inhes Ski-Daddler 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. "l\i ~I INTRODUCTION IMPORTANT To keep the AMFWarrantyinfore, be ertain to use only AMF -Approved replaement parts. The AMF-Warranty does not apply to parts overed by the original manufaturer's warranty suh as engine or engine parts, starters, belts, arburetor battery or other omponents or aessories not ~anufatured by AMF. Should any laim arise onerning these items, follow the manufaturer's instrutions. 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. PREDEL/VERY INSTRUCTIONS The 97 Ski-Daddlers are shipped ompletely assembled exept for the windshield assembly, the ski assembly and the kikstand assembly. On the eletri-start models, the battery is installed but not ativated. These assemblies, plus the attahing hardware will be found in the shipping ontainer. Carefully open the arton and immediately inspet the equipment for any damage or missing items. IMPORTANT: The owner must retain the Ski Daddler Inspetion Reord, FormNo. 77QA. This form must be shown to the dealer should any laim arise under the AMF Warranty. Install Ski Assembly Plae the spindle pads (figure ) in the spring mounting braket with the thiker setion and the diretional arrow on the pad pointing forward. NO"TE: The spindle pads and attahing hardware, loknuts and 3-/-inh length srews, will be found in the plastic bag shipped with the sled. Figure LOCKNUT SPIND LE PAD (THICK SECTION FORWJ>.RDJ 007 3

8 PREDEL I VERY INSTRUCTIONS Install the ski assembly by seuring the spring mounting braket and spindle pad to lower end of spindle tube assembly as shown in figure. Apply 30 foot-pounds torque to the loknut. Do not overtighten bolt as the ski assembly should float freely on the spindle. Repeat proedure for opposite ski. NOTE: Properly installed skis should toe out 0- to /-inh at the front end (see figure ) and should be symmetrial about the enterline of the sled. To align the skis, refer to the Steering and Ski Alignment proedures. right- and left-hand mounting strips to the hood. " Remove the mounting strips. J 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. Be ertain to position the 7/8-inh length srew in the end position shown in figure. Engage the ends of the mounting strips to the trim strip on the windshield and then tighten the srews, starting at the ends 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. Attah the hood harness lip to the 7/8-inh length srew and seure with loknut. Ativate Battery-Models SD IBE0B, SDIBE5B and SD IBE7 A Only ) Remove the hood and headlight assembly. Refer to Hood Removal and Installation. TOE OUTo-TO I-INCH MAXIMUM Figure Before ativating the -volt storage battery, disonnet the battery ables and remove the battery. Ativate the battery in aordane with theinstrutions ontained on the pakage ontaining the eletrolite sulfuric aid. Reinstall the 'battery as follows: Ilstall Windshield Assembly Disonnet hood harness at the quik disonnet. Remove hood and headlight assembly. Refer to Hood Removal and Installation proedure. Bak off the loknut (figure ) and remove the 7/8-inh length srew used to seure the hood harness lip and the end of the right-hand mounting strip to the hood. Remove the remaining srews seuring the Plae -volt battery on the battery support plate with positive (+) terminal post forward. Attah the negative (-) battery able (and the BLACK wire lead from igarette lighter SD8E0B only) to the negative terminal post. NOTE: Cigarette lighter is standard equipment on Model SD8E0B only. May be purhased as an aessory item for any snowmobile equipped with ) a battery. 007

9 ~IPREDELIVERY INSTRUCTIONS e.~si3 ~ C Attah the positive (+) battery able (and the RED wire lead from igarette lighter SD8E0B only) to the positive terminal post. Position the holddown strap aross the battery and over the holddown rods. Seure the strap and battery using loknuts and washers. Do not overtighten. Replae the hood and headlight assembly. Install Kikstand Assembly - Models SO IBE0B, SO IBE5B and SO IBP A Only The attahing hardware required for kikstand installation will be found in the plasti parts bag shipped with the Ski-Daddler snowmobile. Chek ontainer against the following list to be ertain no parts are missing or damaged. Part No. Desription Qty 3775 Kikstand assembly - 8 inh 33 Spring 3786 Long spaer, - /3 LG Short spaer, 3/3 LG 8575 Hex head bolt, /- 8 THD by - / IN Hex head bolt, /-8 THD by -7/8 IN Loknut, /-8 THD Formed washer Flat washer, 7/6 ID During initial installation, assemble all omponents loosely as shown in figure 3. After ompleting, ~., ~~ ~!! ::::::i/! : ~'H LOCKNUT(6)~ ~ _ FLAT WASHER SHORT - <- SPACER -, - KICKSTAND '-.. () ~. ' - BRACKET.> ' ;r ', --- SCREW ()/ _.> "".s::;a A " ;- LONG SPACER ()~~ SC REW () ~ SPRING () Figure 3 the installation, tighten all nuts and bolts seurely but do not overtighten. Chek the installation by setting the sled on the kikstand as shown in figure 3. Fuel Mixture Instrutions WARNING Never fill the gasoline tank while the engine is hot. Wipe off any spilled gasoline before attempting to start engine. The orret oil-to-gasoline ratio is 0: (0parts regular gasoline to part oil). Too muh oil will ause arbon deposits. Too little oil or a poor mix will ause insufficient 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 prepared exlusively for use in air-ooled, -yle engines. IMPORTANT: Some outboard motor oils ontain a detergent that works well in outboard motors that operate at muh lower temperatures beause they are water ooled. However, the detergents may ause spark plug fouling in the air-ooled engines used on Ski-Daddler snowmobiles. Use a mixture of gasoline and oil as shown in the Fuel Mixture Chart. Neve'r use gasoline left over from the summer or previous winter. 5 3 FUEL MIXTURE CHART OIL (Ounes) o V / ", "" / ", ~ ",'" / ~ / /~ / ~/ /"" / v,.. U.S. Gallons Imperial Gallion. T- o GASOLINE (Gallons) GASOLINE/OIL RATlO - 0 to ", 007 5

10 ~t... 5iMlal SERVICE AND REPAIR I~ 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. Lubriation There are three lubriation areas that require attention on a regular basis. A low temperature grease must be applied to the zerk fittings loated on the steering spindle tubes; on eah bogie wheel after approximately eah 0 hours of use; and the hain ase housing whih must be heked after' eah 0 hours of use and No. lithium bearing grease replaed as required. NOTE: Do not add grease to hain ase housing on Model SDI8PA. This unit has a self-lubriating system. The bearing up retainers that hold the seal bearings in the tration belt take-up assembly 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 sproket bearing retainers during normal maintenane. Grease may also be applied as required to the wearplates and U-strap seuring the steering olumn to the roll bar. SERVICE AND REPAIR Hood Removal and Installation To remove the hood and headlight assembly, disonnet the hood and the sled wiring harness at the quik-disonnet below the onsole on the righthand side of the sled. Release the hood lath assemblies and then remove the hood and headlight assembly by lifting bak end first. To install the hood and headlight 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 to seure the hood to the main frame. Connet the sled wiring harness to the hood wiring harness at the quik-disonnet below the onsole on the right-hand side of the sled. Hood Assembly Repair AMF Fiberglass Repair Kits are available through your authorized AMF Distributor. For large repairs, order AMF Fiberglass Repair Kit No Smaller repairs an be made with Repair Kit No Paint all repaired areas on the hood using AMF -Orange olor paint available in easy-to-use spray ontainer, AMF Part No Follow the instrutions in the kit when making repairs. Replae Lamp Assemblies Headlight. To replae the headlight bulb, raise the headlight assembly; remove the srews seuring the over assembly and remove the over assembly. Remove the defetive bulb and replae with new bulb. See illustrated parts list for orret replaement part numbers. Taillight. Remove taillight lens to expose the taillight bulb. Remove the defetive bulb and replae with a new bulb. See illustrated parts list for orret replaement part numbers. Steering and Ski Assembly Alignment Good steering ability requii'es that the skis be properly set and aligned with the sled body when the steering handle is plaed in the straight-ahead position. 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. Properly aligned skis should toe out 0- to /-inh maximum at the front. Therefore, the overall measurement at the front end of the skis should be /- inh greater than at the rear. If the skis or steering mehanism are not properly set, adjust as follows. Plae steering handle in a straight-ahead position. Remove the hood and headlight assembly. Refer to Hood Removal and Installation

11 o Remove the bolt (, figure ), two spaers (), bottom spaer and loknut seuring the rod end bearing (3) to the spindle arm (6). ~I SERVICE AND REPAIR It"' Mla ~ Remove spindle arm (8) and rotate ski and spindle tube one noth in the required diretion; replae and seure spindle arm to the spindle tube. Apply 0 foot-pounds torque to the loknut (6). Rehek the skis for proper toe out and alignment as previously desribed. To Remove Drive Chain Remove the hood and headlight assembly. Refer to Hood Removal and Installation. Figure Loosen the jam nuts () seuring both rod end bearings (3) to the tie rod (5). NOTE: If both skis need adjustment, repeat proedure for the opposite ski. 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 show:! in figure. With skis properly set and steering handle in the straight-ahead position, rotate tie rod (5, figure ) as required to bring rod end bearing (3) in line with the spindle arm (6).! CAUTION! 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. Loosen the bolts (, figure 5) 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 (). Seure rod end bearing (3) to spindle arm (6) as illustrated. Chek for proper alignment and then tighten jam nuts () to seure both rod end bearings. 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: C Remove srew (5, figure 5) and loknut (6) seuring spindle tube assembly (7) to spindle arm (8). Figure 5 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 on all models exept SD8PA

12 Drive Chain Adjustment SERVICE AND REPAIR A properly adjusted drive hain (figure 5) should have a /8- to /-inh slak. Chek and adjust hain as follows: Remove the loknut seuring the hain over top and remove hain over top. Rotate the upper sproket to tension one side of the hain and then hek the opposite side for proper slak. If adjustment is required, loosen the srews () seuring the am uprights () on eah side. 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 ase over. To Remove Variable-Speed Drive Selt Remove the drive hain. Refer to paragraph To Remove Drive Chain. Remove the luth guard assembly. NOTE: Variable-speed drive belt installation proedures are the reverse of removal exept that the belt must first be plae 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. Variable-Speed Drive Selt Adjustment Proper tension for a new drive belt should be obtained when the luth enters are set to the B dimension shown in figure 6 for the appliable model snowmobile. A B C (TORQUE) FT-LB MODEL NO..0 G-3/ 5 SD5P0B / 70 SD8P7A.300 G-3/ 70 SD8E7A.300 -/ 70 SD8E5B / 70 SD8E0B.300 -/ 90 SD8PA ENGINE JLO 95 HIRTH 399 HIRTH 399 KOHLER 399 HIRTH 93 HIRTH 63 CLUTCH () Loosen the loknut (9, figure 5) and serrated washer (0). During reassembly, apply 0 footpounds torque to the loknut (9). Push the driven luth toward the drive luth suffiiently to allow removal of the variable-speed drive belt from the drive luth. Remove the loknuts (7, figure ) 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 (9) and drive belt lear of the brake assembly (0) and remove the variablespeed drive belt. Install replaement drive belt. Use AMF Part No. 377 on Model SD5P0B; AMF Part No. 000 on ModeISD8PA; AMF Part No. 007 on Model SD8E5B; and AMF Part No. 390n all other models. Figure 6 HOLDDOWN NUTS VIEW 0 Proper tension for a used dri ve belt is obtained when opposite sides of the belt an be squeezed, between the drive luthes, to the following dimensions as measured between the top and bottom outside surfae of the belt. SD5P0B SD8PA SD8P7A SD8E7A SD8E5B SD8E0B -3/- to 3-/ inhes -/- to -3/ inhes - to -/ inhes - to -/ inhes - to -/ inhes - to -/ inhes 8 007

13 VICE AND REPAIR o 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. IMPORT ANT: 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 (9, figure 5) seuring the luth rod t'ensioner 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 () in the diretion required to obtain proper belt tension. Hold this position while tightening the loknut (9) to seure the luth rod tensioner. Be ertain the washer (0) and bar serrations are properly engaged. Apply 0 foot-pounds torque to the loknut (9). To Remove Drive Cluth Remove the hood and headlight assembly. Refer to Hood Removal and Installation.! CAUTION:] Always disonnet spark plug wires before working on the engine or drive elements. Remove the luth guard assembly. Loosen the loknut (9, figure 5) and serrated washer (0) seuring the luth rod tensioner () to the main frame. During reassembly, apply 0 foot-pounds torque to the loknut (9). Push the driven luth toward the drive luth suffiiently to allow removal of the variable-speed drive belt from the drive luth. To remove the drive luth from Models SD5PlOB and SD8PA only, remove the luth adapter bolt and washer. If neessary, use a luth puller and remove the drive luth. During reassembly, apply 5 foot-pounds torque to the luth adapter bolt on Model SD5P0B only, and 90 foot-pounds torque on Model SD8PA. NOTE: If the luth nut is removed from the drive luth used on Model SD5P0B, reinstall the nut, apply 5 foot-pounds torque and be ertain to engage the lokplate tangs. To remove the drive luth from Models SD8P7A, SD8E7A, SD8E5B and SD8E0B, remove the luth adapter bolt and washer, flatten the lok plate tangs and remove the luth nut and lok plate. If neessary, use a luth puller to remove the drive luth. During reassembly, apply 50 foot-pounds torque to the luth nut and then apply 70 foot-pounds torque to the luth bolt. Be ertain to engage the lok plate tangs. Reassembly is the reverse of removal. Perform variable-speed drive belt adjustment and drive luth alignment proedures. Drive Cluth Alignment Remove the hood and headlight assembly. Refer to Hood Removal and Installation.! CAUTI:?~: : J Always disonnet spark plug wires before working on the engine or drive elements. Remove the luth guard. Loosen the engine holddown nuts (figure 6) se-, uring 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 6. Rotate driven luth 90-degrees and repeat proedure. 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 and headlight assembly. Refer to Hood Removal and Installation.! CAUTION! Always disonnet the sparkplugwires before working on the engine or drive elements

14 SERVICE AND REPAIR Disonnet brake able and housing at brake mounting braket and at brake atuating lever. Remove the two 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 7) 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. Release the tank-to-arburetor gas line (figure 8). Wipe up any spilled gasoline immediately. NOTE: On all Mark V series Ski-Daddlers, release the arburetor-to-tank recirulating gas line at the re Cirulation elbow. Be ertain to note the position of the gas lines to insure proper reassembly. Wipe up any spilled gasoline immediately. o Figure 8 IMPORTANT: Model SD5PI0B uses a fuel pump attahed to the inside surfae of the onsole tongue with two srews and nuts. If neessary to replae the fuel pump, be ertain to note the position of the fuel lines to insure proper reassembly. Wipe up any spilled gasoline immediately. Figure 7 To Remove Carburetor Loosen the throttle and if used, the hoke ontrol able adjustment srews and release both ables at the arburetor (see figure 8). Remove the srews seuring the air intake filter or baffle (figure 9) and hoke ontrol braket mounted on arburetor used on Models SDI5PI0B, SD8E0B and SD8E5B only. Remove the impulse line at the arburetor used on all models exept SDI5PI0B. Figure

15 Remove the nuts seuring the arburetor to the intake manifold and remove the arburetor. NOTE: Do not damage gaskets when removing arburetor. Installation is the reverse of removal. Adjust arburetor as desribed in Carburetor Adjustment proedures. Carburetor Adjustments The Tillotson Model HD and HR arburetors used on Ski-Daddler Models SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA are equipped with a reirulation system. :: ~AUTION Never run the engine with the arburetor-to-tank reirulating gas line disonneted (see figure 8) The Bendix Model arburetor used on Ski-Daddler Model SD5P0B is a floattype arburetor and does not require a reirulation system. The fuel is SERVICE AND REPAIR pumped to the arburetor through an external fuel pump mounted on the onsole assembly. The arburetion system maintains a fuel reservoir in the float hamber to insure smooth starting and idling harateristis. 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 highspeed jet (DO NOT FORCE). Then open the highspeed jet (figure 8) to the settings shown on the arburetor settings hart for your partiular engine (see figure 0). The high- and low-speed jet adjustment srews for the Bendix arburetor used on Model SD5P OB are loated on top of the arburetor and are identified as HI and LO. The engine an be seriously damaged if operated with a lean gas mixture (highspeed jet turned in too far). CARBURETOR SETTINGS CHART MODEL NO. ENGINE HIGH SPEED JET LOW SPEED JET SD8E0B Hirth 93 SD8E7A Hirth 399 SD8P7A Hirth 399 SD8PA Hirth 63 SD8E5B Kohler /8 + /8 Open /8 Open /8 + /8 Open Open /8 + /8 Open Open /8 + /8 /8 Open /8 Open /8 5/8 _ 0 Open./8 + /8 Open - 0 SD5P0B JLO 95 + /8-0 Open / + /8 Open - 0 NOTE: The arburetor settings shown are for normal operation at sea level. For high altitude operation and for extreme temperature variations, the settings may have to be adjusted aordingly. Figure JO 007

16 SERVICE AND REPAIR Turn the low speed jet (idle-mixture srew) shown in figure 8 all the way in (DO NOT FORCE), then open as shown in figure 0 for the partiular model sled. This adjustment 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 8 shows a throttle- wire adjustment srew. If the throttle plate fails to open ompletely when the throttle ontrol lever is depressed, loosen the throttle-wire adjustment srew and readjust the wire as required to open the throttle. Remove the onsole door assembly by turning the door fastener ounterlokwise to release. Remove the srews, washers and loknuts seuring the onsole tongue assembly to the tool box and to the mini-onsole (see figure ). ) To Remove Starting Motor Assembly-Models SO J BE0B, SO J BE5B and SO J BE7 A Only Remove the hood and headlight assembly. Refer to Hood Removal and Installation.! CAUTION I Always disonnet spark plug wire before working on the engine or drive elements. Disonnet the battery-to-solenoid positive (+) able at the battery to prevent sparking and possible shorting. Disonnet the solenoid-to-starting motor able at the starting motor. Figure J Remove the drive luth. To Remove Drive Cluth. Refer to paragraph Bak off the two nuts seuring the starting motor assembly to the engine. Remove the engine wiring harness, ground wire and the battery-to-starting motor ground wire attahed to the upper stud and remove the starting motor assembly. Reassembly is the reverse of removal. To Remove Engine and Support Assembly- Models SO J BE0B, SD IBE5 B" SO J BEl A, SO J BP7 A and SOJBPJA Only Remove the hood and headlight assembly. Refer to Hood RemOVal and Installation.!: ~~~TI~~ :: I Always disonnet the sparkplugwires before working on the engine or drive. elements. Loosen the flexible tube lamps seuring the muffler exhaust tube to the engine exhaust manifold and release the exhaust tubes. Disonnet the throttle and hoke ontrol ables and remove the arburetor as desribed.in paragraph To Remove Carbuetor. Remove the starting motor assembly. Refer to paragraph To Remove Starting Motor Assembly, Models SDI8E0B, SD8E5B and SD8E7A only.. Remove the heat shield loated between the engine and the muffler. Remove the attahing hardware at the muffler braket and/or heat shield braket and at the top near the steering olumn. 007

17 SERVICE AND REPAIR o. Remove the bolts (0, figure ), spaers and nuts seuring the steering linkage to the steering olumn arm (9). During reassembly, apply 5 footpounds torque to the nuts seuring the steering linkage. base. Remove the straps for reassembly. During reassembly, apply 5-foot-pounds torque to the nuts seuring the engine base. Installation is the reverse of removal. To Remove Engine and Support Assembly-Model SD5P0B Only Remove the hood and headlight assembly. Refer to Hood Removal and Installation. Always disonnet the sparkplugwires before working on the engine or drive elements. Remove the onsole door assembly by turning the door fastener ounterlokwise to release. Figure Remove the bottom otter pin seuring the steering olumn to the main f:rame steering olumn support. On models equipped with an eletri starter, disonnect the wiring harness atthe battery, eletrial panel, taillight and engine. Release the wire V -lips in the tool box and at the foot rest and remove the wiring harness. On manual start models disonnet the wiring harness at the taillight and engine. NOTE: Replae the metri nut after removing the blak ground lead from the engine. Remove the two srews, formed washers and loknuts at eah end of the roll bar and remove the roll bar, steering olumn and mini-onsole as a unit. Remove the loknuts and washers seuring the engine mounting straps to the main frame studs, and remove the engine, engine base and mounting straps. Remove the arriage bolts, nuts and washers seuring the engine mounting straps to the engine Remove the six srews, washers and loknuts seuring the onsole tongue assembly to the tool box and to the mini-onsole (see figure ). Remove the drive luth. To Remove Orive Cluth. Refer to paragraph Loosen the flexible tube lamps seuring the muffler exhaust tube to the engine exhaust manifold and release the exhaust tubes. Disonnet the throttle and hoke ontrol ables and remove the arburetor as desribed in paragraph To Remove Carburetor. Disonnet the yellow wire lead and the blak wire lead at the engine and the blak ground wire lead at the starter over. Replae the metri nut to seure the over after removing the blak wire lead. Remove the heat shield loated between the engine and the muffler. Remove the attahing hardware at the muffler braket, heat shield braket and at the top near the steering olumn. Remove the loknuts and washers seuring the engine mounting straps to the main frame. NOTE: During reassembly, tighten the loknuts justsuffiiently to permit the washers to be turned by hand - then tighten the loknuts one additional turn. Lift the engine until the engine mounting straps lear the studs shown in figure. Rotate the engine 007,3

18 SERVICE REPAIR ounterlokwise and remove the engine toward the rear and lear of the sled. Remove the arriage bolts, washers and loknuts seuring the mounting straps to the engine base. Remove the mounting straps and bar washers. NOTE: During reassembly, the mounting straps and bar washer must be seured to the engine base before installing the replaement engine. Installation proedures are the reverse of removal. To Remove Gas Tank Remove the hood and headlight assembly. Refer to Hood Removal and Installation.! CAUTION! 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 ). 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 line (6) and the reirulating gas line (7) 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. pressure relief valve (8). These items are to be installed on the replaement tank. To Remove Muffler Remove the hood and headlight assembly. Refer to Hood Removal and Installation. I CAUTION! Always disonnet the sparkplugwires before working on the engine or drive elements. Loosen the flexible tube lamp seuring the flexible exhaust tube to the muffler and release the tube. NOTE: All Mark V series Ski-Daddlers have dual exhaust tubes and muffler. 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 Bogie Wheel Always disonnet the sparkplugwires before working on the engine or drive elements. Raise bak end of Ski-Daddler so that tration belt lears the ground. Remove the loknut (3, figure 3) seuring the bogie wheel assembly () to the axle shaft and remove the wheel. 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 Figure J3 J 007

19 o During reassembly, torque the loknut (3) to 8 foot-pounds. Be ertain the wheel assembly () is installed with grease fittings on the outside. To Remove Bogie W heel and Support Assembly! CAUTIO~:] Always disonnet the sparkplugwires before working on the engine or drive elements. Raise bak end of Ski-Daddler so tration belt lears the ground. Remove the srews (, figure 3) and washers seuring the bogie wheel support shaft () to the main frame. Remove the bogie wheel and support assembly. Reassembly is the reverse of removal. To Remove Bogie Wheel Torsion Springs Remove the bogies as desribed in paragraph To Remove Bogie Wheel and Support Assembly. Remove the support shaft and separate the bogie wheel support halves. Pry the tabs up suffiiently to remove the torsion springs. NOTE: The torsion springs are identified as right- and left-hand springs. Note the diretion of the oils and the position of the springs to failitate reassembly. Reassembly is the reverse of removal. To Remove Tration Belt Take-Up Assembly Remove the rear bogies. Refer to paragraph To Remove Bogie Wheel and Support Assembly. Release trak tension by loosening adjusting bolts (5, figure 3). Release the support arm torsion springs on-. neted to the main frame. Remove the right- and left-hand adjusting angle loknuts (6), washers and arriage bolts seuring the tration belt take-up assembly to the main frame. ~I SERVICE AND REPAIR leia~ Remove the tration belt take-up assembly as a unit. NOTE: The tration belt take-up assembly onsists of the rear spr oket assembly, spaer and asso Ciated hardware held together by the rear support arm assemblies. If neessary to remove seals, sprokets or idler wheel, proeed as follows. Carefully pry the oil seal away fr om the rear support arm assembly (8, figur e 3) and remove the support arm and adjusting angle (9) lear of the sproket shaft and bearing. Remove the press- on bearings and oil seals. During reassembly repak bearings with No. lithium bearing grease. Remove the srews (0) and nuts seuring the sproket plate and the sproket. to the drive shaft. Remove the plate and sproket. To remove the idler wheel, r emove the srews (0) and nuts seuring the sproket plates and remove the idler wheel by strething the wheel over the sproket plates. Reassembly is the r everse of r emoval. During reassembly follow instrutions outlined in paragraphs Trak Alignment and Trak Tension Adjustment. To Remov e Sproket Seals and Bearings Sproket seals and bearings are loated on eah end of the tration belt take-up assembly and the drive sproket assembly drive shafts. To replae the seals or bearings it will be neessary to remove the tration belt take-up assembly or the drive sproket assembly as des ribed in the appliable paragraph. To Remove Drive Sproket Assembly Remove the hood and headlight 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 loknut seur ing the hain over and remove the hain over top

20 ~t... SiMI3 SERVICE AND REPAIR I~ Remove the lower sproket from the drive sproket shaft and remove the sproket and hain as desribed in paragraph To Remove Drive Chain. Remove the bogie wheel and support assemblies. Refer to paragraph To Remove Bogie Wheel and Support Assembly. Remove the tration belt take-up assembly. Refer to paragraph To Remove Tration Belt Take Up Assembly. Using a srew driver, arefully pry the oil seals (figure ) away from the bearings at eah end of the drive shaft. Remove the srews and nuts seuring the sproket plates to the idler wheel. Remove the idler wheel by strething wheel over the sproket plate. Reassembly is the reverse of removal. During reassembly follow instrutions outlined in the paragraphs Trak Tension Adjustment, Trak Alignment and Drive Chain Adjustment. To Remove Tration Belt Remove the bogie assemblies. Refer to paragraph To Remove Bogie Wheel and Support Assembly. Remove the tration belt take-up assembly. Refer to paragraph To Remove Tration Belt Take Up Assembly. NOTE: It is not neessary to disassemble the tration belt take-up assembly when removing the tration belt. () Remove the drive sproket assembly. Refer to paragraph To Remove Drive Sproket Assembly. Remove the trati."on belt. Figure Remove the arriage bolts and nuts seuring the bearing retainer to the hain ase side of the main frame. Remove the retainer. During reassembly apply No. lithium bearing grease to the bearing retainers. Move the drive shaft and sproket assembly toward the hain side until the opposite end of the shaft lears the bearing retainer. Remove the drive sproket assembly. To replae the sprokets, remove the ball bearing and oil seal. Remove the srews and nuts seuring the support plate and sproket to the drive shaft and sproket plate assembly. Remove the sproket. Reassembly is the reverse of removal. During reassembly follow instrutions given in paragraphs Tration Belt Alignment, and Drive Chain Adjustment. 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 Tration Belt Tension Alignment Set the snowmobile on a level surfae and raise the bak end so the tration belt lears the ground. Stand to rear of sled and visually hek the spae between the frame tunnel and the edges of the tration belt. On a properly aligned trak this spae should be the same

21 If the trak is not entered, loosen the two loknuts (, figure 5) on that side where the edge of the trak is losest to the inside edge of the tunnel. Tighten the adjusting srew (3) until trak is entered. SERVICE AND REPAIR should have a /- to I-inh sag at the enter. This an be determined as follows: Rest a straight bar (figure 6) of suffiientlength along the top surfae and near the edge of the trak. Insert the straight bar through the bak end of the snowmobile and hek for proper sag. Repeat proedure on opposite side and note the differene, if any, in the trak tension. STRAIGHT BAR /" TO " (MK IV) '~ TO -/" (MK V) Figure 6 Figure 5 Never run the engine inside a building without first opening all doors and windows to insure proper ventilation. With the bak end of the snowmobile raised, start the engine. Allow trak to rotate several turns and then rehek trak alignment to ensure that proper alignment is maintained. Mter trak alignment is omplete, tighten all loknuts () and then hek tration belt tension as desribed in the following paragraph. Tration Belt Tension Adjustment IMPORTANT: Always hek the tration belt for proper alignment before performing the tration belt tension adjustment proedures. Set the snowmobile on a lean, flat surfae. NOTE: A properly tensioned trak should have a - to -/ -inh sag at the approxim<\.te top enter of the trak exept for Model SDI8PA, whih If adjustment is neessary, loosen the two loknuts (, figure 5) on eah side of the sled just suffiiently to allow movement of the belt-adjusting angle (). Turn the adjusting srews (3) lokwise to tighten and ounterlokwise to loosen until proper trak tension is ahieved. IMPORTANT: Adjust both srews (3) equally so as not to disturb the trak alignment. [~~~UTION Never run the engine inside a building without first opening ali doors and windows to insure proper ventilation. Raise the bak end of the snowmobile until the trak lears the ground. Start the engine and allow trak to rotate several turns. Then repeat the trak tension adjustment proedure to ensure that proper tension is maintained. Retighten the loknuts () on both sides of the snowmobile. Spark Plug Replaement To maintain good engine performane the ondition of the spark plugs should be heked periodially and the gap reset to O.00-inh using feeler gauge

22 ~t 5IIMI3 SERVICE AND REPAIR I~ During reassembly, apply 8 to 0 foot pounds torque. Spark plug ondi tion may be determined by the olor. A arbonized plug is blak; a burnt plug is pale grey, whereas a normal funtioning spark plug is brown. ertain the gas tank-to- arburetor line used on all Mark V series Ski-Daddlers is onneted to the OUT fitting on the gas tank outlet and to the inlet fitting on the arburetor. The reirulating, arburetorto-tank line must be onneted to the IN fitting on the gas tank outlet (figure ) and to the reirulating elbow (figure 8). {\ \ J SPARK PLUG CONVERSION CHART MODEL NO. ENGINE LIGHT SERVICE SEVERE SERVICE CHAMPION AC CHAMPION AC SD8E0B Hirth 93 SD8E7A Hirth 399 SD8P7A Hirth 399 SD8PA Hirth 63 SD8E5B Kohler 399 SD5P0B JLO 95 *No AC onversion for light servie spark plug. K-8 K-8 K-8 K-7 K-8 K-9 * K-7 SN8F * K-7 SN8F * K-7 SN8F SN8F K-60R SN8F * K-7 SN8F SN83F K 8 SN8F When replaing spark plugs, refer to the preeding hart to insure proper spark plug heat ranges for your partiular engine. NOTE: Replaementplugs should be U.S. Champion, AC spark plugs or equivalent available at your authorized Ski-Daddler Dealer. Wiring Diagrams Eletrial wiring diagrams are provided for the trained tehni.ians using this manual. Eah diagram is identified with the model number of the snowmobile to whih it applies (see figures 7, 8, 9 and 0). Troubleshooting ENGINE HARD TO START. Fuel line bloked or leaking; ruptured fuel-pump diagram; water in fuel, flooded, loose impulse line; ignition or swith wiring loose or grounded; spark plug(s) fouled or faulty; ontat breaker points pitted or burned. ENGINE 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. ENGINE STOPS, FUEL TANK HALF EMPTY. Be ENGINE OPERATES IRREGULARLY. Spark plug loose, fouled or faulty; ignition swith wiring grounded; 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; :;trburetor or fuel line partly logged; arburetor setting too lean; ignition timing too slow. EXCESSIVE FUEL CONSUMPTION. Carburetor fuel line or gas tank leaking; hoke losed; inorret arburetor setting

23 () n ()... '"... "'" WIRING DIAGRAM, MODEL SD8E0B BLACK, - - ~ ~)E L LOW-BLAC~~ I YELLOW t :: YELLOW ) YE LLOW ~ YELLOW -l RECTIFIER ENGINE I HIRTH-93 I NOT USEOJ!ROWN I I I, I I, STARTER BLACK CABLE ASSEMBLY WHITE WHITE-GREEN WHITE-GREEN BLACK RED RED r GREEN r : BLACK ' -' I,~, (-)TACHOMETER* -0 TAILLIGHT FLASHER SWITCH I FLASHER r--~left <>-7 WH ITE -BLACK I OFF ) BLUE-BLACK <~ I WHITE-RED I L_ ~(RIGHT BLUE IGN ITION SWITCH,,, / OFF LIGHTS ON START *QUICK KILL 53 SW,!0!, ~ ~ I i '0' / L ~ - _J I \W",H~ I T=E 7\ I L _ 50 ''-- t 530.~ J BLUE WHITE BLU E BLUE HI-LO BEAM QUICK SWITCH DISCONNECT DISCONNECT I-~ LO GREY ~ L _~> HI ORANGE ~ ORANGE ~ BLACK GROUND AT± STARTER BOLT - I~ : BLACK I :< :<: HEADLIGHT BLUE GREEN RED ~ GROUND AT STARTER BOLT ~." ::ti ::: ~." = ~ i! :; *OPTIONAL EQUIPMENT Figure J7

24 WIRING DIAGRAM, MODELS SD8PA and SD8P7A F=L::,, , -l NOT USED{O _.. _... ENGIN E HIRTH-63 (FOR MODEL SDIBPIA) I HIRTH-399 (FOR MODEL SD IBP7A) I i: I L5 -= lo- I L:: _ -.J ~ -- - YELLOW I CI:a ", ~ ::: ~ = ~ ~ ~ :;; YELLOW 0,) Q WH ITE WH ITE- RED WHITE- RED RED >- RED _ r- ~B!::!LA~C~K~» BLACK GREE~ --=---='I"- )TACHOMETER* GROUNDI _ BLUE BLUE BLACK >>elack -- WIRE «-= GROUND AT ENG INE STARTER BOLT 3b OFF \ IGNITION SWITCH LIGHTS I ON I ("/ I I I ~( ~ I I I I I '-----~---,+-+, I LJ I *QU ICK KILL SWITCH L.J START / TAILLIGHT SDIBPIA- REQ'D BLU E SD IBP7A- I REQ'D YELLOW BLACK BLUE BLUE QUICK DISCONN ECT BLACK BLUE BL UE HEADLIGHT *OPTIONAL EQUIPM ENT ~... '" "'" u Figure J8 u (J

25 ~ n () (') "'"... '-l '" WIRING DIAGRAM, MODELS SD8E58 and SD8E 7A BLACK YELLOWru-OW-BLAC~ I YELLOW ~- ~T~:j.--!Y.!::EL~L~OW!!..-I-~!) YELLOW ~f-~ --l~y:..::e~ll::;:o:..::w,-- --, RECTIFIER -l NOT USEDO _"_ 00 ", ~ ENGINE KOHLER 399 (FOR MODEL SDI8E5B) HIRTH399 (FOR MODEL SDI8E7A) I i BLACK STARTER (}TACHOMETER* ~ WH ITE I WH ITEI WHITE-RED WHITE - RED I I OFF \ IGNITION SWITCH LIGHTS, ON L -.,, r +-f-, I lj I*QUICK KILL SWITCH L..J. I RED ~~.~~ ""~, TAILLIGHT SD8E5B- REQ'D BLUE SDI8E7A- REQ'D BLUE BLUE ORANGE BLACK REOt-(fBLACK -6-).. ~ TBLACK BLUE GREEN '=' GROUND AT ENGINE STARTER BOLT r -- I I I I I ~~ *CIGARETTE LIGHTER BATTERY 3 AMP HR '= GROUND AT ENGIN E STARTER BOLT ~." ~ ::: C':a." = :.. ~ ~ :; *OPTIONAL EQUIPMENT Figure J9 ~

26 WIRING DIAGRAM, MODEL SD5P0B ~ OFF \ *QUICK KILL SW ITCH ' { ~ JLO 95 ENGINE WHITE IGNITION SWITCH LIGHTS \ ON I , I I,- I I NOTU"D START / 53...l...-.-f BLACK WHITE RED I I J YELLOW YELLOW RED_ «BLACK» BLACK GRi?;;"-==----=[ ')TACHOMETER*, >>- BLACK --< -./ GR~~~~I r> BLUE ~f-(----, YELLOW TAILLIGHT BLUE YELLOW GROUND AT ENGINE -= STARTER BOLT BLACK BLUE QUICK DISCONNECT BLACK BLUE BLUE BLACK YELLOW ~." ~ ::: ~." = ~ ~... ~ BLACK BLACK *OPTIONAL EQUIPMENT u figure 0 u o

27 o THROTTLE CONTROL. Exessive play in throttle ontrol lever aused by loose throttle ontrol able. 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. BRAKES. Exessive play in handbrakeduetoloose brake able or worn pads. TRACTION BELT. Poor tration; hek tration belt for alignment and tension; worn sprokets or flipped bogies. CLUTCH. Automati luth fails to engage at ~I SERVICE AND REPAIR lesla~ proper RPM's (see figure ). Chek variablespeed drive belt for proper tension and alignment. CLUTCH ENGAGEMENT SPEEDS CLASS ENGINE ENGINE RPM MARK IV JLO to 500 MARK V-00 Hirth to 600 MARK V-00E Hirth to 600 MARK V-00DE Kohler to 600 MARK V-500DE Hirth to 00 MARK V-60 Hirth to 700 Figure 007

28 o

29 PARTS LIST ILLUSTRATED 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 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 and identifies the model Ski-Daddler for whih the part applies. If no model designation follows the part nomenlature, the part applies to all models overed in the partiular figure. Quantity. This olumn provides the total number of items required per assembly. 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 itera 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. Figure & Index Number Part Number Desription Qty SKI-DADDLER, MARK V, MODEL NO. SD8E0B SKI-DADDLER, MARK V, MODEL NO. SD8P7A SKI-DADDLER, MARK V, MODEL NO. SD8E5B SKI-DADDLER, MARK V, MODEL NO. SD8E7A SKI-DADDLER, MARK V, MODEL NO. SD8PA SKI-DADDLER, MARK IV, MODEL NO. SD5P0B HOOD AND HEADLIGHT ASSEMBLY (Used on SD8E0B... only) (See figure ) 0068 HOOD AND HEADLIGHT ASSEMBLY (Used on SD8E7A and SD8E5B only) (See figure ) Q 0067 HOOD AND HEADLIGHT ASSEMBLY (Used on SD8P7A 0 and SD8PA only) (See figure ) 005 HOOD AND HEADLIGHT ASSEMBLY (Used on SD5PI0B... only) (See figure ) WINDSHIELD, 5 IN. (Used on SD5P0B only).o.o g 3709 WINDSHIELD, 8 IN. (Used on SDI8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) BUMPER ASSEMBLY, RH (Used on SD5PIOB only) (See figure ) 007 5

30 PARTS LIST I~ Figure J. Sh eet J of ) o 6 007

31 PARTS LIST o Figure & Index Number Part Number Desription Qty BUMPER ASSEMBLY, RH (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure ) BUMPER ASSEMBLY, LH (Used on SD5P0B only) 0 0 (See figure ) BUMPER ASSEMBLY, LH (Used on SDI8E0B,. SDI8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure ) CONSOLES AND STEERING ASSEMBLY (Used on SD5PI0B only) (See figure 3) CONSOLES AND STEERING ASSEMBLY (Used on SD8E0B only) (See figure 3) CONSOLES AND STEERING ASSEMBLY (Used on SD8E5B.0 only (See figure 3) CONSOLES AND STEERING ASSEMBLY (Used on SD8P7A. only) (See -figure 3) CONSOLES AND STEERING ASSEMBLY (Used on SD8E7A only) (See figure 3) CONSOLES AND STEERING ASSEMBLY (Used on SD8PA only) (See figure 3) SCREW, Truss HD, /-8 THD by -/ IN. LG "00"00" WASHER, Formed ' 0 o LOCKNUT, /-8 THD 0 0 SCREW, HEX HD, 3/8- THD by IN. LG. 0 WASHER, Plain, 3/3 IN. ill... '" 0 LOCKNUT, 3/8- THD SCREW, Truss HD, /-8 THD by 5/8 IN. LG 0 (Used on SD8E0B, SD8E5B and SD8PA only) LOCKNUT, /-8 THD (Used on SD8E0B, 00.0 SD8E5B and SD8PA only) SKI AND SPRING ASSEMBLY (Used on SD5P0B only) (See figure 3) SKI AND SPRING ASSEMBLY (Used on SD8E0B, 000 SD8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure 3) REAR HANDLE ASSEMBLY (Used on SD8E0B, SD8E5B and SD8PA only) BOLT, HEX HD, /-8 THD by -/ IN. LG... (Used on SDI8E0B, SD8E5B and SD8PA only) WASHER, Plain, 9/3 IN. ill by IN. OD (Used on SD8E0B~ SD8E5B and SD8PA only) WASHER, Formed (Used on SD8E0B, SD8E5B and SD8PA only) WASHER, Plain (Used on SD8E0B, SD8E5B and. SD8PA only) LOCKNUT, /-8 THD (Used on SDI8E0B, SD8E5B and SD8PA only) KICKSTAND ASSEMBLY (Used on SDI8E0B, SD8E5B and SDI8P!A only) SPRING, Kikstand (Used on SDI8E0B, SD8E5B and SD8PA only) BOLT, HEX HD, /-8 THD by -7/8 IN. LG. 0 (Used on SDI8E0B, SD8E5B and SD8PA only) 007 7

32 PAR T Figure & Index Number Part Number Desription Qty SPACER, Long (Used on SD8E0B, SD8E5B and SD8PA only) SPACER, Short (Used on SD8E0B, SD8E5B and... SD8PA only) WASHER, Formed (Used on SD8E0B, SD8E5B and SD8PA only) LOCKNUT, /-8 THD (Used on SD8E0B, SD8E5B and SD8PA only) BOLT, HEX HD, /-8 THD by -/ IN. LG (Used on SD8E0B, SD8E5B and SD8PA only) WASHER, Formed (Used on SD8E0B, SD8E5B and SD8PA only) WASHER, Flat (Used on SD8E0B, SD8E5B and SD8PA only) LOCKNUT, / -8 THD (Used on SD 8E0B, SD8E5B and SD8PA only) REAR CONSOLE, SEAT AND TOOL B OX ASSEMBLY (Used on SD8E0B only) (See figure ) REAR CONSOLE, SEAT AND TOOL BOX ASSEMBLY (Used on SD8E5B and SD8PA only) (See figure ) SEAT AND TOOL BOX ASSEMBLY (Used on SD8P7A and SD8E7A only) (See figure 5) SEAT AND TAIL LAMP ASSEMBLY (Used on SD5P0B only) (See figure 5) LOCKNUT, /- 8 THD (Used on SD8E0B, SD8E5B and SD8PA only) LOCKNUT, /-8 THD (Used on SD8P7A and... SD8E7A only) WASHER, Plain, 7/ 6 IN. ID by 5/8 IN. OD (Used on SD8E0B, SD8E5B and SD8PA only) 688 WASHER, Plain, 7/6 IN. ID by 5/8 IN. OD (Used on SD8P7A and SD8E7A only) LOCKNUT, 5/6- THD (Used on SD8E0B, 0 SD8E5B and SD8PA only) 9000 LOCKNUT, 5/ 6- THD (Used on SD8P7A and 0 SD8E7A only) WASHER, Plain (Used on SD8E0B, SD8E5B and SD8PA only) HINGE, Hith BOLT, HEX HD, /- 8 THD by -/ IN. LG WASHER, Plain, 9/3 IN. ID by 5/8 IN. OD LOCKNUT, /:..8 THD MODEL TAG, Ski-Daddler POP RIVET ENGINE AND SUPPORT ASSEMBLY (Used on SD5P0B... only) (See figure 6) 008 ENGINE AND SUPPORT ASSEMBLY (Used on SD 8E0B... only) (See figure 7) 005 ENGINE AND SUPPORT ASSEMBLY (Used on SD8P7A 0 only) (See figure 7) 006 ENGINE AND SUPPORT ASSEMBLY (Used on SD8E7A..... only) (See figure 7) f') ) ) 8 007

33 ~I PARTS LIST Figure & Index Number P art Number Desription Qty ENGINE AND SUPPORT ASSEMBLY (Used on SD8PA only) (See figure 7) ENGINE AND SUPPORT ASSEMBLY (Used on SD8E5B. only) (See figure 7) BOLT, Carriage, 3/8- THD by -/ IN. LG NUT BUSHrnG SPACER, Rubber... WASHER, 3/3 IN. ill by -/ IN. OD (Used on 3 mounts only-see item 53) LOCKNUT, 3/8- THD... 0 SHOCK MOUNT (UsedonSD8E0B, SDI8P7A, SDI8E7A,... and SD8PA only) HEAT SHIELD ASSY (Used on SD8E5B and SD8PA only).., HEAT SHIELD ASSEMBLY (Used on SDI8E0B, SD8P7A, SD8E7A and SD5PI0B only) GROMMET, Heat shield. PAD, Heat shield (Used on SDI8E0B, SDI8E5B, SDI8PA,. SD8E7A and SD5PI0B only) HEAT SHIELD (Used on SD8E0B, SDI8P7A, SDI8E7A, and SD5PI0B only) HEAT SHIELD (Used on SD8E5B and SD8PA only) SPACER, Heat shield SCREW, Truss HD, /-8 THD by 5/8 IN. LG. (Used on SDI8E0B, SDI8P7A, SDI8E7A, SD8PA and SD5PI0B only) SCREW, HEX HD, /-8 THD by / IN. LG (Used on SD8E5B only) WASHER, Plain (Used on SDI8E0B, SDI8P7A, SDI8E7A, SD8PA and SD5P0B only) WASHER, Plain (Used on SD8E5B only) LOCKNUT, /-8 THD (Used on SDI8E0B, SDI8P7A, SDI8E7A, SD8PA and SD5PI0B only) LOCKNUT, /-8 THD (Used on SD8E5B only) WASHER ASSEMBLY (Used on SDI8E0B, SDI8P7A, SD8E7A and SD5PIOB only) BATTERY SUPPORT AND ELECTRICAL ASSEMBLY (Used on SD8E0B only) (See figure 7) BATTERY SUPPORT AND ELECTRICAL ASSEMBLY (Used on SD8E5B and SD8E7A only) (See figure 7) BOLT, HEX HD, /-8 THD by 3/ IN. LG..... (Used on SDI8E0B, SD8E5B and SD8E7A only) BOLT, HEX HD, /-8 THD by 5/8 IN. LG.. (Used on SDI8E0B, SD8E5B and SD8E7A only) WASHER, Plain, 9/3 IN. ill by 5/8 IN. OD. (Used on SD8E0B, SD8E5B and SD8E7A only) LOCKNUT, /-8 THD (Used on SDI8E0B, SD8E5B and SD8E7A only) TRACTION BELT TAKE-UP ASSEMBLY (Used on SD8E0B SDI8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure 8) TRACTION BELT TAKE-UP ASSEMBLY (Used on SD5PIOB only) (See figure 8)

34 PARTS LIST Figure. Sheet of Q / \ \ \ \ \ I \ \-~\ ; - Ilr I / ~ I I / I I I / I I / I I / / / / / / I I' ) I I ~ 00«0)'" NNN www

35 ~I PARTS LIST lemi i~ Figure & Index Number Part Number Desription Qty BOLT, Carriage, 5/6- THD by 3/ IN. LG WASHER, Flat, 5/6 IN. ID LOCKNUT, 5/6- THD BOGIE ASSY (Used on SD5P0B only) (See figure 9) BOGIE ASSY, Middle and rear (Used on SD8E0B, SD8P7A,... SD8E5B, SD8E7A and SD8PA only) (See figure 9) BOGIE ASSY, Front (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure 9) SCREW, HEX HD, 5/6- THD by 3/ IN. LG WASHER, Lok BELT, Tration, 5-inh (Used on SD5P0B only) BELT, Tration, 8-inh (Used on SD8E0B, SD8P7A, SD8E5B and SD8E7A only) BELT, Tration, 8-inh (Used on SD8PA only) DRIVEN CLUTCH AND CASTING ASSY(UsedonSD8E0Bonly) (See Fig.0) DRIVEN CLUTCHAND CASTING ASSY (Used on SDl8,E5Bonly) (See Fig. 0) DRIVEN CLUTCH AND CASTING ASSY (Used on SD8PA only) (See Fig. 0) DRIVEN CLUTCH AND CASTING ASSY (Used on SD8P7A and.... SD8E7A only) (See figure 0) DRIVENCLUTCHAND CASTING ASSY (Used on SD5P0B only) (See Fig. 0) BOLT, HEX HD, 3/8- THD by -/ IN. LG WASHER, Spring lok DRIVE SPROCKET ASSY (Used on SD5P0B only) (See figure 0). DRIVE SPROCKET ASSY (Used on SD8E0B, SD8P7A, SD8E5B and SD8E7A only) (See figure 0) DRIVE SPROCKET ASSY (Used on SD8PA only) (See figure 0).. GAS CAP ASSY, Tank (See figure ).. MAIN FRAME ASSY - Weldment (Used on SD5P0B only) MAIN FRAME ASSY - Weldment (Used on SD8E0B only).. MAIN FRAME ASSY - Weldment (Used on SD8P7A and SD8E7A only). MAIN FRAME ASSY - Weldment (Used on SD8E5B only).... MAIN FRAME ASSY - Weldment (Used on SD8PA only) GREASE FITTING SUPPORT, Heat shield (Used on SD8E0B, SD8P7A, SD8E7A and SD5P!OB only) SUPPORT, Heat shield (Used on SD8PA and SD8E5B only)... BRACKET, Heat shield (Used on SD8E0B, SD8P7A, SD8E7A and SD5P0B only) BRACKET, Heat shield (Used on SD8PA and SD8E5B only) Figure & Index Number Part Number Desription Qty HOOD AND HEADLIGHT ASSY (Used on SD8E0B only) (See figure )... HOOD AND HEADLIGHT ASSY (Used on SD8E7A and... SD8E5B only) (See figure ) HOOD AND HEADLIGHT ASSY (Used on SD8P7A and... SD8PA only) (See figure ) REF REF REF 007 3

36 ~o 9 t)~, Use d on, 3~ _~:.J /

37 PARTS LIST Figure & Index Number Part Number *350 *007 * *Inludes appliable items -7 through -8. Desription HOOD AND HEADLIGHT ASSEMBLY (Used on SD5PI0B. REF only) (See figure ) CLIP, Hood RIVET... 3 PLATE, Hood GAS LID AND HINGE ASSEMBLY (Used on SDI8E0B,... SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) GAS LID AND HINGE ASSEMBLY (Used on SD5P0B only)... SCREW, RD HD, 0.-3 THD by / IN. LG. " ". ".... LOCKNUT, 0-3 THD HINGE ASSEMBLY (Used on SD5P0B only) LOCKNUT, 0-3 THD (Used on SD5PI0B only) SPRING, Flat (Used on SD5PI0B only) ESCUTCHEON, Gas over (Us ed on SD5PI0B only) NUT, Spring, 3/6 IN. (Used on SD5PI0B only) GAS LID ASSEMBLY (Used on SD5P0B only) RUBBER BU\WER, Gas lid... " HEADLIGHT ASSEMBLY (Used on SD8E0B only) HEADLIGHT ASSEMBLY (Used on SD8E7A and.... SD8E5B only) HEADLIGHT ASSEMBLY (Used on SD8P7A, SD8PA.. and SD5PI0B only) JAM NUT, HEX HD, /- 0 THD SPACER LOCKNUT, /- 0 THD COVER ASSEMBLY, Headlight SCREW, PAN HD, 8-3 THD by -/ IN. LG SHAFT, Pivot SHAFT, Spring SCREW, Truss HD, 8-3 THD by 3/8 IN. LG... SPRING, Extension " BRACKET, RH BRACKET, LH HARNESS, Hood (Used on SD8E0B only) HARNESS, Hood (Used on SD8P7A, SD8E5B,... SD8E7A, SD8PA and SD5P0B only) HEADLIGHT (Used on SD8E0B only) HEADLIGHT (Used on SD8E7A and SD8E5B only)... HEADLIGHT (Used on SD8P7A, SD8PA and SD5PI0B only) HOUSING ASSEMBLY (Consists of items 7 and 8)..... RIVNUT, 8-3 THD HOUSING GROMMET, Air dut AIR DUCT, Hood TRIM STRIP, RH (Used on SD5P0B only) TRIM STRIP, RH (Used on SD8E0B, SD8P7A,... SDI8E5B, SD8E7A and SD8PA only) TRIM STRIP, LH (Used on SD5PI0B only) TRIM STRIP, LH (Used on SD8E0B, SDI8P7A,.... SDI8E5B, SD8E7A and SD8PA only) SCREW, Truss HD, /- 0 THD by 5/8 IN. LG SCREW, Truss HD, /-0 by 7/8 IN. LG.... LOCKNUT, /-0 THD Qty

38 MMld PARTS LIST Figure & fudex Number Part Number Desription Qty CABLE TIE JACKNUT, Molly ESCUTCHEON, Side NUT, Spring STRIKE RIVET HOOD (Used on SD5PI0B only) HOOD (Used on SDI8E0B, SDI8P7A, SD8E5B and..... SD8PA only) CATCH, Hood.... '" RIVET GUIDE, Hood " LOCKNUT, /- 8 THD SPACER COVER, Bumper BUMPER ASSEMBLY, RH (Used on SD5PI0B only). 0 BUMPER ASSEMBLY, RH (Used on SDI8E0B,..... SDI8P7A, SDI8E5B, and SD8PA only) BUMPER ASSEMBLY, LH (Used on SD5PI0B only).... BUMPER ASSEMBLY, LH (Used on SDI8E0B,.... SD8P7A, SDI8E5B, and SD8PA only) GAS LID (Used on SD8E0B, SDI8E5B, SDI8P7A, SD8E7A and SD8PA only) Figure & Index Number Part Number Desription Qty *3700 * CONSOLES AND STEERING ASSEMBLY (Used on SD8E0B... REF only) (See figure ) CONSOLES AND STEERING ASSEMBLY (Used on SD8P7A... REF only) (See figure ) CONSOLES AND STEERING ASSEMBLY (Used on SD8E5B... REF only) (See figure ) CONSOLES AND STEERING ASSEMBLY (Used on SD8E7A... REF only) (See figure ) CONSOLES AND STEERING ASSEMBLY (Used on SD8PA... REF only) (See figure ) CONSOLES AND STEERING ASSEMBLY (Used on SD5PI0B... REF only) (See figure ) STEERING-LINKAGE ASSEMBLY (Used on SD5PI0B only)... STEERING LINKAGE ASSEMBLY (Used on SDI8E0B,... SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) ARM, Spindle BOLT, HEX HD, 3/8- THD by -3/ IN. LG SPACER SPACER NUT, 3/8- THD '" TIE ROD ASSEMBLY (Used on SD5P0B only) TIE ROD ASSEMBLY (Used on SDI8E0B, SDI8P7A,.... SD8E5B, SD8E7A and SD8PA only) BOLT, HEX HD, 3/8- THD by - / IN. LG... *Inludes appliable Items - through

39 r Figure & Index Number Part Number * *006 * ~I PARTS LIST Desription SP AC ER ,, NUT,3/8-THD ,.,..,.,. ROD END , ,,.,.,.,.,.. JAM NUT, HEX, 3/8- THD ,.,.,.,.,.. TIE ROD (Used on SD5PI0B only)......,.,.,..... TIE ROD (Used on SDI8E0B, SDI8P7A, SDI8E5B,.,... SD8E7A and SD8PA only) BOLT, HEX HD, /-8 THD by -7/8 IN. LG...,.,.,... WASHER, Plain, / IN. ill U- STRAP WEARPLATE WEARPLATE LOCKNUT, /-8 THD '... GRIP, Hand THUMB CONTROL ASSEMBLY 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 BRAKE CONTROL ASSEMBLY HAND CONTROL ASSEMBLY THROTTLE CABLE, HOUSING AND BOOT ASSEMBLY (Used on SDI8E0B, SDI8P7A, SDI8E7A, SD8PA and SD5PI0B only) THROTTLE CABLE, HOUSING AND BOOT ASSEMBLY. (Used on SD8E5B only) STEERING HANDLE AND COLUMN ASSEMBLY.,,. STEERING COLUMN ASSEMBLY (Used on SD8E0B, SD8P7A, SD8E7A, SD8PA and SD5PI0B only) STEERING COLUMN ASSEMBLY (Used on SD8E5B only) CONSOLE DOOR ASSEMBLY (Used on SD8E5B and SD5PI0B only) CONSOLE DOOR ASSEMBLY (Used on SD8E0B only). RETAINER, Console door (Used on SDI8E0B,.. SD8E5B and SD5PI0B only) FASTENER, / turn (Used on SDI8E0B, SD8E5B and.... SD5PI0B only) DOOR, Console (Used on SD8E5B and SD5PI0B only) DOOR, Console (Used on SD8E0B only).... CONSOLE TONGUE ASSEMBLY (Used on SD8E0B and SD8E5B only) CONSOLE TONGUE ASSEMBLY (Used on SD5PI0B only). SCREW, Truss HD, /-8 THD by 5/8 IN. LG,. (Used on SD5PI0B only) SCREW, Truss HD, /-8 THD by 5/8 IN. LG (Used on SDI8E0B, SDI8P7A, SD8E5B and SD8E7A only) WASHER, Plain (Used on SD5PI0B only), WASHER, Plain (Used on SDI8E0B, SD8P7A, SDI8E5B, SD8E7A and SD8PA only) LOCKNUT, /-8 THD,. * 3-3 inludes appliable items -0 through inludes appliable items -, -3 and -0 through Qty

40 PARTS LIST Figure 3. Sheet of 33 Used on SD8E0Bonly ~ 3/ 37 6, \ ~ 36

41 PARTS LIST Figure & Index Number Part Number Desription Qty *009 *005 *0050 *005 *0053 * * 3- inludes appliable items -9 through -60. CLIP-ON RECEPTACLE, Console door (Used on SDI8E0B, SD8E5A and SD5PI0B only) DECAL, Console tongue (Used on SD8E0B and SD8E5B only). DECAL, Console tongue (Used on SD5PI0B only) CONSOLE TONGUE (Used on SD8E0B and SD8E5B only) CONSOLE TONGUE, Modified (Used on SD5PI0B only).. MINI-CCDNSOLE ASSEMBLY (Used on SD8E0B only) MINI-CONSOLE ASSEMBLY (Used on SD8P7A only). MINI-CONSOLE ASSEMBLY (Used on SD8E5B only) MINI-CONSOLE ASSEMBLY (Used on SD8E7A only) MINI-CONSOLE ASSEMBLY (Used on SD8PA only) MINI-CONSOLE ASSEMBLY (Used on SD5PI0B only).. SCREW, /-8 THDby -/ IN. LG. WASHER, Plain..... WASHER, Formed LOCKNUr, /-8 THD..... BAR, Console support (Used on SD5PI0B only) BAR, Console support (Used on SD8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) RIVET... 0 PLATE, Console bak-up.... SWITCH, Key (with keys). SWITCH, Toggle, positions (Used on SD8E0B only) SWITCH, Toggle, 3 positions (Used on SD8E0B only) BOOT, Rubber, toggle swith (Used on SD8E0B only) DECAL, LH (Used on SD5PI0B only) DECAL, LH (Used on SD8E0B only).. DECAL, LH (Used on SD8E5B only).. DECAL, LH (Used on SD8P7A only)... DECAL, LH (Used on SD8E7A only)... DECAL, LH (Used on SD8PA only).. CONTROL, Choke (Used on SDI8E0B, SD8E5B and. SD5PI0B only) LIGHTER, Cigarette (Used on SD8E0B only).. DECAL, RH (Used on SDI8E0B, SD8E5B, SD8PA and SD5PI0B only) DECAL, RH (Used on SD8P7A and SD8E7A only) MINI-CONSOLE.... AIR DUCT, LH (Used on SDI8E0B, SD8E5B and... SD5PI0B only) AIR DUCT, RH (Used on SDI8E0B, SD8E5B and. SD5PI0B only) BRACKET, Console SCREW, Flat HD, 0-3 THD by 5/8 IN. LG LOCKNUT, 0-3 THD.. ROLL BAR (Used on SDI8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) ROLL BAR (Used on SD5PI0B only) BRACKET, Flasher (Used on SD8E0B only). SCREW, Pan HD, 0-3 THD by -/ IN. LG (Used on SD8E0B only) WASHER, Plain (Used on SD8E0B only).... LOCKNUT, 0-3 THD (Used on SD8E0B only)

42 PARTS LIST I~ 5 ~ 6~, ~ 7~ t----- _ ","",,' 3 ) ) ~ 0~ I~OO ----a / j,., 93 ~~ ~~:9~ gr:

43 PARTS LIST Figure & Index Number Part Number Desription Qty , *375 * *37 * * * * FLASHER (Used on SD8E0B only)..... COTTER PIN, 3/6 IN. DIA by -3/ IN. LG.... WASHER, Steering olumn. BUSHING, Steering olumn support SPRING, Spindle... BUSHING, Plain.. BUSHING, Flange SPINDLE.. SKI AND SPRING ASSEMBLY (Used on SD5P0B only) (See figure ) SKI AND SPRING ASSEMBLY (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure ) SCREW, HEX HD, 3/8- THD by 3-/ IN. LG LOCKNUT, 3/8- THD. PAD, Spindle. SKI SPRING ASSEMBLY (Used on SD5PIOB only) SKI SPRING ASSEMBLY (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) C OTTER pm.... PNOT pm, Spring.... PIN", Pivot BRACKET ASSEMBLY, Spring mounting.. SCREW, HEX HD, 3/8- THD by -/ IN. LG WASHER, Flat, 3/8 IN. ill..... LOCKNUT, 3/8- THD. BUMPER ASSEMBLY BUMPER p late, Spring.... LEA F SPRING, Top LEAF SPRING, Middle LEAF SPRIN'G, Main BUMPER, Main leaf.... SPRIN'G, Mam leaf LEAF SPRING (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) WEAR PLATE, Ski... It SKI AND WEAR ROD ASSEMBLY WEAR ROD ASSEMBLY, Ski-weldment LOCKNUT, /-8 THD..... SKI ASSEMBLY FUEL PUMP (Used on SD5P0B only).... SCREW, Truss HD, 0-3 THD by -/ IN. LG... (Used on SD5P0B only) LOCKNUT, 0-3 THD (Used on SD5P0B only) REF REF * 3-78 inludes appliable items -8 through inludes appliable items -86 through inludes items -9 and inludes items -96 and -97. C 3-00 inludes items -0 through

44 \ \ \,/, PARTS LIST I~ a;m=:f~~~f;gure ~ \ \ \ \ \ \ \ \ \ \ 0 007

45 ~I PARTS LIST IM.aij Figure & Index Number Part Number Desription Qty * REAR CONSOLE, SEAT AND TOOL BOX ASSEMBLY (Used on SD8E0B only) (See figure ) REAR CONSOLE, SEAT AND TOOL BOX ASSEMBLY (Used on SD8E5B and SD8PA only) (See figure ) SEAT SCREW, PAN HD, Self-tapping, No. 8 by 5/8 IN. LG.... LATCH, Spring SCREW, PAN HD, Self-tapping, No.8 by 5/8 IN. LG CLIP, Wiring REAR CONSOLE ASSEMBLY (Used on SD8E5B and.... SD8PA only) REAR CONSOLE ASSEMBLY (Used on SD8E0B only). SCREW, Truss HD, /-8 THD by 5/8 IN. LG.... WASHER, Flat LOCKNUT, /-8 THD COVER, Taillight lens SCREW, Mahine oval HD, 6-3 THD by 3/ IN. LG... NUT, Molly jak, 6-3 THD LENS, Taillight BRACKET AND SOCKET ASSEMBLY (Used on SD8E5B and SD8PA only) BRACKET AND SOCKET ASSEMBLY (Used on SD8E0B only). RIVET WASHER, Rivet burr BULB, Taillight (Us ed on SD8E5B and SD8PA only).. BULB, Taillight (Us ed on SD8E0B only) TIE, Cable WIRE, Taillight ground WIRE, Taillight WIRE, Taillight, left turn signal (Used on SD8E0B only). WIRE, Taillight, right turn signal (Used on SD8E0B only)... STUD, Rear onsole, 8-3 THD by 5/8 IN. LG.... WASHER, Rear onsole LOCKNUT, 8-3 THD... CONSOLE, Rear CONSOLE, Rear, upper CONSOLE, Rear, lower RIVET WASHER, Flat, 3/3 ID by / OD BUMPER, Kikstand SCREW, RD HD, /-8 THD by - / IN. LG WASHER, Plain SPACER LOCKNUT, /-8 THD BRACKET, Rear onsole, RH BRACKET, Rear onsole, RH TOOL BOX, Weldment GROMMET, Rubber REF REF * Seat Cover, Blak, AMF Part No. 009 available as optional equipment. 007

46 PARTS LIST I~ Figure 5 9~ ~, ~I ',j!> ~ ~:, r'~, ~ \\ ~ \\ ~'I \ \ r-" I / 8 6 b I l~ 007

47 C Figure & Index Number Part Number *0036 ** Desription RTS LIST SEAT AND TOOL BOX ASSEMBLY (Used on SD8E7A and SD8P7A only) (See figure ) SEAT AND TAIL LAMP ASSEMBLY (Used on SD5PI0B only).,. (See figure ) SEAT, Blak (Used on SD8E7A and SD8P7A only)..... SEAT, Orange (Used on SD5P0B only) SCREW, PAN HD, 6-3 THD by 3/ IN. LG (Used on SD8E7A and SD8P7A only) LATCH, Spring (Used on SD8E7A and SD8P7A only) SCREW, PAN HD, 6-3 THD by 3/ IN. LG (Used on SD8E7A and SD8P7A only) CLIP, Wiring (Used on SD8E7A and SD8P7A only).... SCREW, PAN HD, 6-3 THD by 3/ IN. LG NUT, Molly jak, 6-3 THD '"... TAILLIGHT MOUNT ASSEMBLY TAILLIGHT MOUNT BULB, Taillight SCREW, PAN HD, 6-3 THD by 3/ IN. LG..... (Used on SD8E7A a.nd SD8P7A only) CHAIN, 5-Links (Used on SD8E7A and SD8P7A only)... RETAINER, Spring (Used on SD8E7A and SD8P7A only) RECEPTACLE, Seat lip (Used on SD5PI0B only). SCREW, PAN HD, 6-3 THD by 3/ IN. LG. 0 (Used on SD5P0B only) TOOL BOX, Weldment (Used on SD8E7A and SD8P7A only). GROMMET, Rubber (Used on SD8E7A and SD8P7A only)... * Seat Cover, Blak, AMF Part No available as optional equipment. ** Seat Cover, Orange, AMF Part No available as optional equipment. Qty REF REF L Figure & Index Number Part Number Desription Qty C ENGINE AND SUPPORT ASSEMBLY (Used on SD5P0B... REF only) (See figure ) PIPE, Engine exhaust BRACKET, Throttle IMPULSE LINE WIRING CONNECTIONS, L95 engine COVER, Air intake. ' CLIP, Cable " BRACKET, Choke ontrol CARBURETOR (See figure ) DRIVE C LUTCH ASSEMBLY, 780 Series BOLT, Cluth adaptor LOCKWASHER, INT. Tooth, / IN. ID ENGINE, JLO BOLT, HEX HD, 7/6- THD by -/ IN. LG LOCKWASHER, 7/6 IN. ID BASE, Engine BOLT, Carriage, 5/6- THD by IN. LG

48 PARTS LIST Figure 6 = "'.<... \ 0 ~' I L... = 007

49 PARTS ST -... Figure & Index Number Part Number Desription Qty BAR WASHER WASHER, Plain LOCKNUT, 5/6- TRD MOUNTING STRAP CLAMP, Flexible tube EXHAUST TUBE, Flexible BAND ASSEMBLY, Mounting SCREW, HEX RD, /-8 THD by 3/ IN. LG WASHER, Plain, 9/3 IN. ID by 5/8 IN. OD LOCKNUT, /-8 THD MUFFLER CLUTCH GUARD AND DECAL ASSEMBLY DECAL, Safety BOLT, HEX HD, /- 0 THD by -3/ IN. LG SCREW, RD HD, /- 0 THD by -/ IN. LG CONNECTOR, Tubing reduer IMPULSE LINE, Fuel pump-to-engine GAS LINE, Fuel pump-to-arburetor TUBING, Carburetor vent SPRING, Compression SLED HARNESS Figure & Index Number Part Number Desription Qty ENGINE AND SUPPORT ASSEMBLY... REF (Used on SD8E0B only) (See figure ) 005 ENGINE AND SUPPORT ASSEMBLY 0 0 REF (Used on SD8P7A only) (See figure ) 006 ENGINE AND SUPPORT ASSEMBLY... REF (Used on SD8E7A only) (See figure ) 003 ENGINE AND SUPPORT ASSEMBLY... REF (Used on SD8PA only) (See figure ) 007 ENGINE AND SUPPORT ASSEMBLY... REF (Used on SD8E5B only) (See figure ) EXHAUST MANIFOLD, 5-degree (Used on SDI8E0B,... SD8P7A and SD8E7A only) 009 EXHAUST MANIFOLD (Used on SD8PA only) EXHAUST MANIFO.LD, 5-degree (Used on SDI8E0B,... SD8P7A and SD8E7A only) 0093 EXHAUST MANIFOLD (Used on SD8PA only) EXHAUST ELBOW (Used on SD8E5B only) EXHAUST ELBOW (Used on SD8E5B only) IMPULSE LINE (Used on SDI8E0B, SDI8P7A,... SD8E7A and SD8PA only) 3090 IMPULSE LINE (Used on SD8E5B only) WillING CONNECTIONS (Used on SDI8E0B, SDI8P7A,... SD8E7A and SD8PA only) 3888 WillING CONNECTIONS (Used on SD8E5B only) CLIP, Cable (Used on SD8E0B and SD8E5B only) BRACKET, Choke ontrol (Used on SD8E0B only)

50 [P!~:ttMI3 PARTS LIST l ~7 ~7 n I B Figure 7, 3~)[ ~-~ "~ Used on SD8E5B only----' -- Used on SD8E5B only j 7 [_~o-6 ~ I " _';~~~ ~;;:::::::;!:::-=~-r

51 PARTS LIST Figure & Index Number Part Number Desription Qty SCREW, RD HD, /-8 THD by 5/8 IN. LG (Used on SD8E0B only) AIR INTAKE SILENCER (Used on SDI8P7A, SDI8E7A, and SD8E7A only) CARBURETOR (Used on SDI8E0B, SDI8P7A, SD8E7A and SD8PA only) CARBURETOR (Used on SD8E5B only). GASKET (Used on SDI8E0B, SDI8P7A, SD8E7A. 0 and SD8PA only) BRACKET, Throttle (Used on SDI8E0B, SDI8P7A, SD8E7A and SD8PA only) DRIVE CLUTCH ASSEMBLY (Used on SD8E0B only) DRIVE CLUTCH ASSEMBLY (Used on SDI8P7A,.. SD8E5B and SD8E7A only) DRIVE CLUTCH ASSEMBLY (Used on SD8PA only). BOLT, HEX HD, /-0 THD by 5 IN. LG STUD (Used on SD8E5B only) 0 CABLE, Battery-to-ground (Used on SDI8E0B,. SD8E7A and SD8E5B only) STARTING MOTOR ASSEMBLY (Used on SDI8E0B, SD8E7A and SD8E5B only) ENGINE, 93 (Used on SD8E0B only) 0 0 ENGINE, 399 (Used on SD8P7A and SD8E7A only).... ENGINE, 63 (Used on SD8PA only). ENGINE, 399 (Used on SD8E5B only)..... BOLT, HEX RD, /-3 THD by -/ IN. LG..... (Used on SDI8E0B, SDI8P7A, SD8E7A and SD8PA only) LOCKWASHER, / IN. ID... (Used on SDI8E0B, SDI8P7A, SD8E7A and SD8PA only) BASE, Engine (Used on SDI8E0B, SDI8P7A, and SD8E7A only) BASE, Engine (Used on SD8E5B only) BASE, Engine (Used on SD8PA only) BOLT, Carriage, 5/6- THD by IN. LG BAR WASHER (Used on SDI8E0B, SDI8P7A, SD8E7A and SD8PA only) BAR WASHER (Used on SD8E5B only). WASHER, Plam LOCKNUT, 5/6- TRD SHOCKMOUNT... 0 PAD, Shokmount (Used on SDI8E0B, SDI8P7A,. SD8E7A and SD8PA only) MOUNTlliG STRAP. ClAMP, Flexible tube... e. 0 CLAMP, Flexible tube (Used on SD8E5B only) EXHAUST TUBE, Flexible, long. (Used on SDI8E0B, SDI8P7A, and SD8E7A only) EXHAUST TUBE, Flexible (Used on SD8PA only) EXHAUST TUBE, Flexible (Used on SD8E5B only).0 EXHAUST TUBE (UsedonSD8E0B, SD8P7AandSD8E7Aonly EXHAUST TUBE, Flexible (Used on SD8PA only) EXHAUST TUBE, Flexible (Used on SD8E5B only)

52 PARTS LIST ) Figure & Index Number Part Number Desription Qty BAND ASSEMBLY, Mounting..... SCREW, HEX HD, 5/6- THD by 3/ IN. LG.... WASHER, Plain, /3 IN. ID by /6 IN. OD LOCKNUT, 5/6- THD MUFFLER WELDMENT (Used on SDI8E0B, SDI8P7A,. and SD8E7A only) MUFFLER WELDMENT (Used on SD8E5B only) MUFFLER WELDMENT (Used on SD8PA only). CLUTCH GUARD AND DECAL ASSEMBLY. (Used on SDI8E0B, SD8E5B and SD8PA only) CLUTCH GUARD AND DECAL ASSEMBLY (Used on SD8P7A and SD8E7A only) DECAL, Safety (Used on SDI8E0B, SD8E5B and SD8PA only) DECAL, Safety (Used on SD8P7A and SD8E7A only) STORAGE ~BATTERY (Used on SDI8E0B, SD8E5B and SD8E7A only) BATTERY HOLDDOWN ROD, Long. (Used on SDI8E0B, SD8E5B and SD8E7A only) BATTERY HOLDDOWN ROD, Short. (Used on SDI8E0B, SD8E5B and SD8E7A only) BA TTERY HOLDDOWN STRAP.. (Used on SDI8E0B, SD8E5B and SD8E7A only) LOCKNUT, /-8 THD (Used on SDI8E0B, SD8E5B and SD8E7A only) BATTERY SUPPORT AND ELECTRICAL ASSEMBLY (Used on SD8E0B only) (See figure ) BATTERY SUPPORT AND ELECTRICAL ASSEMBLY (Used on SD8E5B and SD8E7A only) (See figure ) LOCKNUT, 3/8-6 THD (Used on SD8E5B only).... SLED HARNESS (Used on SD8E0B only)... SLED HARNESS (Used on SD8E5B and SD8E7A only) SLED HARNESS (Used on SD8P7A and SD8PA only).. ELECTRICAL COMPONENT ASSEMBLY... CABLE ASSEMBLY, To battery (+) JUMPER LEAD RECTIFIER. SCREW, PAN HD, 8-3 THD by / IN. LG. LOCKNUT, 8-3 THD.. FUSE, 5 amp FUSE HOLDER SCREW, Flat RD, 6-3 THD by 7/6 IN. LG LOCKNUT, 6-3 THD.. 0 RESISTOR, Fixed, 0 ohms ±5%, 50W BOLT, HEX HD, /-8 THD by 5/8 IN. LG LOCKNUT, /-8 THD SOLENOID, Eletri start SCREW, PAN HD, 0-3 THD by / IN. LG LOCKWASHER, Internal tooth No. 0 (Under loknut) LOCKNUT, 0-3 THD LOCKWASHER, Internal tooth 5/6 IN. DIA... BATTERY SUPPORT, Weldment... LEAD, Retifier. REF ) 8 007

53 ~I PARTS LIST Figure & Index Number Part Number Desription WASHER, Shakeproof, 3/6 ID... OIL LINE (Used on SD8PA only)... CHECK VALVE, Lubriation (Used on SD8PA only)... CAP ASSEMBLY, Carburetor (Used on SD8E5B only)... BOLT, HEX HD, /-0 THD by IN. LG... 3 (Used on SD8E5B only) LOCKWASHER, Internal, / ID (Used on SD8E5B only)... 3 SPACER, Carburetor ap (Used on SD8E5B only)... 3 SPRING, Compres~iol!... Qty Figure & Index Number Part Number Desription Qty TRACTION BELT TAKE-UP ASSEMBLY (Used on. REF SDI8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) (See figure ) TRACTION BELT TAKE-UP ASSEMBLY (Used on SD5PI0B. REF only) (See figure ) SCREW, Adjusting BLOCK, Adjusting WASHER, Flat, 5/6 IN. ID, LOCKNUT, 5/6- THD..... REAR SUPPORT ARM AND SPRING ASSEMBLY, RH REAR SUPPORT ARM AND SPRING ASSEMBLY, LH.. ANGLE, Belt adjustment, LH..... ANGLE, Belt adjustment, RH SCREW, HEX HD, 3/8- THD by -3/ IN. LG.. 0. SPACER, Rear support arm..... LOCKNUT, 3/8- THD RET AINER SPRING, Rear torsion, LH..... SPRING, Rear torsion, RH. 0 REAR SUPPORT ARM ASSEMBLY, LH.. REAR SUPPORT ARM ASSEMBLY, RH.... REAR SPROCKET ASSEMBLY (Used on SD5PI0B only). REAR SPROCKET ASSEMBLY (Used on SDI8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) BEARING GREASE ' SEAL SPROCKET SUPPORT PLATE ASSEMBLY SCREW, HEX HD, /-8 THD by 3/ IN. LG LOCKNUT, /-8 THD WHEEL, Idler (Used on SDI8E0B, SDI8P7A, SDI8E5B,... SD8E7A and SD8PA only) SCREW, HEX HD, /-8 THD by 3/ IN. LG (Used on. 9 SDI8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) LOCKNUT, /-8 THD (Used,on SDI8E0B, SDI8P7A,. 9 SDI8E5B, SD8E7A and SD8PA only) 007 9

54 PARTS LIST I~ Figure 8 5 ~ " ~ p- -t..-= _----! - J J! t3: ~ 6 " ~,,_-<""~! " I " ""'" ;~ L.---y 8 6 /' ~J / Figure & Index Number Part Number Desription Qty SPROCKET SUPPORT PLATE ASSEMBLY (Used on... SDI8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) SPROCKET, Idler 0 0 REAR SHAFT AND SPROCKET PLATE ASSEMBLY... (Used on SD5P0B only) REAR SHAFT AND SPROCKET PLATE ASSEMBLY 0 (Used on SDI8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) Figure & Index Number Part Number Desription Qty BOGIE ASSEMBLY (Used on SD5PI0B only) (See figure )... REF BOGIE ASSEMBLY, Middle and rear (Used on SDI8E0B,... REF SD8P7A, SD8E5B,SD8E7A and SD8PA only) (See figure ) TORSION SPRING, Bogie, RH (Used on SD5P0B only)... 3 )

55 ~I PARTS LIST lesia~ "- Figure & Index Number Part Number Desription Qty TORSION SPRING, Bogie, RH (Used on SDI8E0B, SD8P7A, SDI8E5B, SD8E7A and SD8PA only) TORSION SPRING, Bogie, LH (Used on SD5P0B only) TORSION SPRING, Bogie, LH (Used on SD8E0B,.... SD8P7A, SDI8E5B, SD8E7A and SD8PA only) BOGIE WHEEL AND SUPPORT ASSEMBLY - HALF (Used on SD5P0B only) BOGIE WHEEL AND SUPPORT ASSEMBLY - HALF..... (Used on SDI8E0B, SD8P7A, SDI8E5B, SD8E7A and SD8PA only) WHEEL, Bogie (Used on SD5PI0B only).... WHEEL, Bogie (Used on SDI8E0B, SDI8P7A, SD8E5B, SD8E7A and SD8PA only) LOCKNUT, 5/8-8 THD (Used on SD5PI0B only).... LOCKNUT, 5/8-8 THD (Used on SD8E0B, SD8P7A,.. SD8E5B, SD8E7A and SD8PA only) BOGIE SUPPORT ASSEMBLY - HALF (Used on SD5PI0B only). BOGIE SUPPORT ASSEMBLY - HALF (Used on SDI8E0B,.. \ SD8P7A, SD8E5B, SD8E7A and SD8PA only) SUPPORT SHAFT, Bogie wheel (Used on SD5P0B only)... SUPPORT SHAFT, Bogie wheel (Used on SD8E0B,... SD8P7A, SD8E5B, SD8E7A and SD8PA only) BOGIE WHEEL AND SUPPORT ASSEMBLY - HALF (Used on SD5P0B only) BOGIE WHEEL AND SUPPORT ASSEMBLY - HALF.... (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) WHEEL, Bogie (Used on SD5P0B only)... _.... WHEEL, Bogie (Used on SD8E0B, SD8P7A,..... SD8E5B, SD8E7A and SD8PA only) LOCKNUT, 5/8-8 THD (Used on SD5PI0B only).... LOCKNUT, 5/8-8 THD (Used on SD8E0B, SD8P7A,... SD8E5B, SD8E7A and SD8PA only) SUPPORT ASSEMBLY, Bogie (Used on SD5P0B only) SUPPORT ASSEMBLY, Bogie (Used on SD8E0B,..... SD8P7A, SD8E5B, SD8E7A and SD8PA only) BOGIE ASSEMBLY, Front (Used on SDI8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) (See figure ) TORSION SPRING, Bogie, RH (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) TORSION SPRING, Bogie, LH (Used on SD8E0B,... SD8P7A, SD8E5B, SD8E7A and SD8PA only) WHEEL, Bogie (Used on SD8E0B, SD8P7A,.. SD8E5B, SD8E7A and SD8PA only) LOCKNUT, 5/8-8 THD (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) SHAFT, Bogie axle (Used on SD8E0B, SD8P7A,.... SD8E5B, SD8E7A and SD8PA only) BUSHING, Bogie (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD8PA only) SUPPORT SHAFT, Bogie wheel (Used on SD8E0B, SDI8P7A, SD8E5B, SD8E7A and SD8PA only) REF

56 PARTS LIST lij Figure 9 ---:;;?' < ' ~ 8 Used on Models SO J 8E0B, SO J 8E5B SOJ8E7A,SOJ8PJA and SOJ8P7A ~ FRONT BOGIE ASSEMBLY 007

57 PARTS LIST Figure & Index Number Part Number Desription SUPPORT ASSEMBLY, Bogie, RH (Used on SD8E0B,... SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) SUPPORT ASSEMBLY, Bogie, LH (Used on SDI8E0B, 0. SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) BOGIE WHEEL AND SUPPORT ASSEMBLY - HALF 0 (Used on SDI8E0B, SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) WHEEL, Bogie (Used on SDI8E0B, SDI8P7A,... SDI8E5B, SD8E7A and SD8PA only) LOCKNUT, 5/8-8 THD (Used on SDI8E0B, SDI8P7A,... SDI8E5B, SD8E7A and SD8PA only) SUPPORT ASSEMBLY, Bogie (Used on SDI8E0B,....,... SDI8P7A, SDI8E5B, SD8E7A and SD8PA only) Qty Figure & Index Number Part Number Desription Qty r ' CHAIN COVER, Top ROLLER CHAIN, 35-, 00-pith (Used on SDI8E0B,.. SDI8P7A, SDI8E5B, SD8E7A and SD5PI0B only) ROLLER CHAIN, 35-, 0 pith, (Used on SD8PA only). COTTER PIN, 3/6 IN. by -3/ IN. LG SPROCKET, 35-, 5 teeth (Used on SDI8P7A,... SDI8E5B, SD8E7A and SD5PI0B only) SPROCKET, 35-, teeth. (Used on SD8E0B and SD8PA only) SPACER BOLT, HEX HD, 5/6-8 THD by 7/8 IN. LG... WASHER, Chain over..... DRNEN CLUTCH AND CASTING ASSEMBLY.... (Used on SD8E0B only) (See figure ) DRNEN CLUTCH AND CASTING ASSEMBLY (Used on SD8E5B only) (See figure ) DRNEN CLUTCH AND CASTING ASSEMBLY (Used on SD8PA only) (See figure ) DRNEN CLUTCH AND CASTING ASSEMBLY (Used on SD8P7A and SD8E7A only) (See figure ) DRNEN CLUTCH AND CASTING ASSEMBLY.... (Used on SDf5PI0B only) (See figure ) ROD TENSIONER, Cluth STUD, 3/8- THD by - / IN. LG LOCKNUT, 3/8- THD SPROCKET, 35-, 9 teeth (Used on SD8E5B and... SD5PI0B only) SPROCKET, 35-, teeth (Used on SD8E0B only).... SPROCKET, 35-, 3 teeth (Used on SD8PA only). 0 SPROCKET, 35-, 8 teeth (Used on SD8P7A and... SD8E7A only) COTTER PIN, 3/3 IN. by -/ IN. LG REF REF REF REF REF

58 PARTS LIST I~! lml==~~~~-=~---;f;gure JO

59 PARTS LIST Figure & Index Number Part Number Desription Qty NUT, Slotted, /-0 THD WASHER, Flat, 7/3 IN. ID by IN. OD SPACER CLAMP, Bearing.. STUD WASHER, /3 IN. ID by /6 IN. OD... LOCKNUT, 5/6 - THD BEARING, Driven luth. HUB AND DISC ASSEMBLY. LOCKNUT, 3/-6 THD KEY, Woodruff, No.9, 3/6 IN. by 3/ IN. LG.. DISC BRAKE ASSEMBLY. BOLT, HEX HD, 5/6-8 THD by 3/ IN. LG.... LOCKWASHER, Internal tooth.... LOCKNUT, 5/6- THD BRAKE BRACKET ARM, Brake braket CALIPER, Dis brake BELT, Variable speed (Used on SD5P0B only) BELT, Variable speed (Used on SD8E0B, SD8P7A. and SD8E7A only) BELT, Variable speed (Used on SD8PA only) BELT, Variable speed (Used on SD8E5B only) DRIVEN CLUTCH AND SHAFT ASSEMBLY (Used on SD8E0B only) DRNEN CLUTCH AND SHAFT ASSEMBLY (Used on SDI8P7A, SD8E5B and SD8E7A only) DRNEN CLUTCH AND SHAFT ASSEMBLY (Used on SD8PA only) DRNEN CLUTCH PND SHAFT ASSEMBLY (Used on SD5P0B only) DRNEN CLUTCH MOUNTING (Make from 396) WASHER, Serrated LOCKNUT, 5/6- THD RING, Cirular push -on PIN, Sprirlg CAM, Right sid eo CAM, Left side a 0 e. 0 WASHER, Plain, 7/3 IN. ID by IN. OD SHAFT, Cluth mounting BEARING RETAINER AND PLATE ASSEMBLY 0.0 BOLT, Carriage, 5/6- THD by 3/ IN. LG BOLT, Carriage, 5/6- THD by 5/8 IN. LG LOCKNUT, 5/6- THD CHAIN COVER ASSEMBLY, Bottom (Used on SD8E0B, SD8P7A, SD8E5B, SD8E7A and SD5P0B only) CHAIN COVER ASSEMBLY, Bottom (Used on SD8PA only) DRNE SPROCKET ASSEMBLY (Used on SD5P0B only) (See figure ) DRNE SPROCKET ASSEMBLY (Used on SD8E0B, SD8P7A, SD8E5B and SD8E7A only) (See figure ) DRNE SPROCKET ASSEMBLY (Used on SD8PA only) (See figure ) REF REF REF 007 ss