Snowmobile SPITFIRE KEEP OM-M68421 AND MARK IT FOR MACHINES BELOW SERIAL NO. 155,001 RLE THIS REVISED MANUAL.

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1 SPTFRE Snowmobile (Serial No. 155,001-1'10,~ ) ~ JOHN DEERE RLE THS REVSED MANUAL. KEEP OM-M68421 AND MARK T FOR MACHNES BELOW SERAL NO. 155,001 OM- Horion Works ssue FO lmto N USA.

2 To The Operator This safety alert symbol identifies important safety messages in this manual. When you see this symbol, be alert to the possibility of personal injury and arefully read the message that follows. This operator's manual ontains Sl Metri equivalents whih follow immediately after the U.S. ustomary units of measure. When in need of major parts or servie, be prepared to provide your John Deere dealer with both the mahine and engine serial numbers. Reord these serial numbers in the spae below. This operator's manual is prepared for: John Deere SPTFRE Snowmobiles (Serial No. J34AK M- ). JOHN DEERE SPTFRE SNOWMOBLE Mahine Serial No. Engine Serial No. Snowmobile Serial Number Date of Purhase (To be filled in by purhaser) ( Engine Serial Number

3 Assembly UNPACK COMPONENTS 1. Skis. 2. Windshield. 3. Operator's manual. 4. Bag of parts. nstall Skis 1. Remove ski bolts, washers, lok nuts and otter pins from bag of parts. 2. nsert bushing into spindle. Use Never-Seez on w ffi bushing. ~ 3. Position ski under ski saddle. (.) 4. nstall ski bolt with head of bolt faing out. 5. nstall washer and lok nut. Torque nut to 39 ft-lbs (52 Nm). 6. nstall otter pin through ski bolt. nstall Windshield 1. Remove washers, srews, J-lip and retaining nuts from bag of parts. 2. Use srews and washers to seure windshield to hood. NOTE: nstall J-lip behind srew "A". Plae headlight wiring harness in J-lip. nstall hood lanyard behind srew "8". ASSEMBLE COMPONENTS

4 PREDELVERY CHECK LST CAUTON: When starting snowmobile, support mahine so trak is lear of ground. Chek throttle for proper operation. 1. Align skis and hek steering linkage. 2. Chek trak tension and align. 3. Chek brakes. Adjust if neessary. 4. Chek operation of hoke and throttle. Adjust if neessary. 5. Fill fuel tank with 40:1 mix. 6. Start engine and hek idle speed. 7. Chek emergeny stop and key swith. 8. Chek operation of all lights. 9. Aim and adjust headlight. 10. Test drive or dynamometer test snowmobile. 11. nstall aessories desired by ustomer. DELVERY CHECK LST 1. Explain operator's manual to ustomer. 2. nstrut ustomer about snowmobile operation. NOTE: BREAK-N PEROD: Do not exeed 30 mph (48 kml h) for the first 25 miles (40 km), or fore the mahine at full throttle in deep snow. An oasional burst of power on hard-paked snow will not be harmful. 3. Explain fuel-oil mixture. Use regular leaded or nonleaded gasoline with an anti-knok index of 88 or higher. Use a 40:1 ratio for first tank of fuel and a 50:1 ratio thereafter. NOTE: Regular (leaded) gasoline is preferred but non-leaded gasoline is aeptable. 4. Tell ustomer about 10-hour or 200 mile hek up.

5 3 PERFORM THESE 10 HOUR OR 200 MLE CHECKS The following inspetion must be performed on your new John Deere snowmobile. This should be done at approximately the first 10 hours or 200 miles of operation. t will help assure you of top performane and avoid premature faiiure of ritial omponents. Your John Deere dealer is qualified to perform this inspetion. Contat your dealer to arrange for an appointment. You are obligated to deliver the snowmobile to the dealer. Any normal maintenane or repair work required, not overed by warranty, will be harged to you should you deide to have the work done. The inspetion hek list is as follows: NEEDS OKAY REPAR 1. Trak tension. 2. Drive belt, drive, and driven sheaves. 3. Carburetor adjustment. 4. Carburetor mounting hardware. 5. Operation and adjustment of brake, throttle, and hoke lever ontrols. 6. Condition of ski wear rods. 7. Suspension hardware. 8. Suspension slide wear bars. 9. Ski alignment. 10. Operation of headlight, stop-taillight, dimmer swith, and emergeny stop swith. 11. Engine head bolts and exhaust manifold nuts. DEALER COMMENTS: 12. Steering omponent hardware. Dealer Name Town Date

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7 1 Contents Page Safety dentifiation Preparation Mix Fuel Fill Fuel Tank Operation Before Operating Start Engine Stop Engine Lights Clearing Trak Towing Dressing For The Weather Servie Servie nterval Chart Spark Plugs Carburetor Choke System Adjusting Choke Adjusting Carburetor Cheking Float Level Main Jet Chart n-line Fuel Filter Air ntake Silener Drive System Replaing Drive Belt Adjusting Brake Slide Suspension Replaing Wear Bars Adjusting Trak Tension Adjusting Suspension Springs Skis Replae Ski Wear Rods Replae Ski Wear Plates Aligning Skis Eliminating Loose Steering Lighting System Adjusting Headlight Replaing Headlight Replaing Stop-Taillight Tightening Hardware and Components Storage Trouble Shooting Speifiations Aessories OOA

8 a Safety A CAUTON: DO NOT arry a passenger. mproper use or maintenane by the operator an result in injury. Follow these safety suggestions. M23365 Preparation Before starting the engine, read your operator's manual from over to over. Knowledge an prevent aidents. Always operate your throttle and brake ontrols several ) times before you start the engine. Stuk or frozen ontrols ould ause serious injury or damage. Know your ontrols. Learn how to stop in an emergeny. Know your state, provinial, federal and loal laws pertaining to snowmobiling. Respet property of others. Don't spoil this fine winter sport by reating a bad image. Never add fuel when smoking or while engine is running. Use a safe gasoline ontainer. Always use fresh, lean fuel of the proper mixture. See page 6. Wear lothing designed for snowmobiling... avoid frostbite. Never wear sarves, loose belts, or lothes that ould ath on moving parts or tree limbs. Always wear eye and headgear protetion to guard against injury. Prolonged exposure to loud noise an ause impairment or loss of hearing. Wear earplugs or any suitable hearing protetive devie that is omfortable when wearing a snowmobile helmet to protet against objetionable or unomfortable loud noises. Always wear an approved helmet to guard against head injury. Avoid sun blindness. Wear properly tinted goggles or fae shield. Never wear yellow eye protetion in the bright sun. Do not allow anyone to operate snowmobile without proper instrutions. Take proper preautions before allowing young operators to drive. Always use the "buddy" system. Remember you an drive farther in 30 minutes than you an walk in a day. Carry adequate tools and repair items for emergeny ) field repairs. Don't overload your snowmobile... use sleds to arry provisions.

9 Safety 3 Always arry emergeny survival supplies when going on long trips. Let friends and relatives know your destination and expeted arrival time. Operation Give omplete and undivided attention to your snowmobile... don't be a show-off. Do not operate snowmobile in rowded areas or steer the mahine toward persons. Do not operate snowmobile too lose to avalanhe areas, or on other unsafe terrain where spills ould our. Observe all state, provinial, federal and loal regulations, espeially those with regard to operating on streets and highways. When rossing highways (where permitted by law) always stop, look both diretions, and ross at a 90- degree angle. Post guards when rossing in groups. Do not operate snowmobiles on or near railroad traks. Trains annot always be heard above sound of snowmobile engine... it is diffiult to esape from between traks. Skiers and snowmobiles don't mix on the same hillsides. Avoid ski slopes. Never operate snowmobile on rivers or lakes without first heking thikness of ie. f you go through the ie, don't pani. Conserve energy. Never operate snowmobile at night without lights. Keep headlight and taillight areas free of snow. Keep all shields in plae... all guards and protetive hoods. Never open new trails at night. Follow established trails. Unseen barbed wire or guy wires an ause serious injury or death. Always use both hands for steering. Avoid operating snowmobile at exessive speed. Always be aware of terrain. f throttle stiks, don't pani. Turn emergeny stop swith on the right-hand handlebar. See page 8. Always allow adequate stopping distane based on ground over onditions. Remember, ie requires a greater stopping distane. To avoid skidding, don't apply brakes rapidly on ie. e or hard surfaes do not provide the same stability as snow. Drive slower on these surfaes. Do not aelerate rapidly. M23364 M23366

10 4 Safety Be sure tool box lid is losed at all times. An open lid ould ause interferene with steering or possible ontat with the throttle lever produing unexpeted aeleration. Do not speed through wooded areas. Hidden obstru- ) tions, hanging limbs, unseen dithes, and even wild animals an ause aidents. Do not tailgate when riding trails. Rear end ollisions an ause injury and mahine damage. Don't mix aloholi beverages with snowmobiling. Keep feet on footrests at all times. Do not permit them to hang over sides. Do not attempt to stabilize mahine with feet when making turns or in near-spill situations. Broken limbs ould result. Selet a riding position suited to the terrain upon whih ) you're operating. Do not stand on seat, stunt, or show-off. Do not jump snowmobile. Operator injury or mahine damage ould result. Keep hands and feet out of the trak area... be espeially areful when freeing your snowmobile from deep snow. When towing a sled, use a solid towbar. Do not use ropes or other flexible tow straps. See page 9. Observe fuel supply regularly. Do not travel farther than your fuel will permit you to return. Remove key from swith whenever you leave your mahine unattended. Never drive your snowmobile onto a tilt-bed trailer. Winh it on. Always seure snowmobile firmly to trailer. Be sure trailer lights are operative. Maintenane and Storage Chek over your snowmobile regularly. This will prevent many problems from ourring. Do not attempt to make repairs to your snowmobile while engine is running. Keep mathes away and do not smoke while filling the fuel tank. Avoid possible explosions. Chek skis and steering omponents frequently to see they are in good ondition. Keep all hardware tight. Never lift the rear of the snowmobile to lear the trak. Chunks of ie or roks may be thrown rearward. Tilt mahine on one footrest when learing trak... and keep all persons lear of area. Keep hands and feet lear of trak.

11 5 dentifiation A-Shok Absorbers B-Skis C-Front Bumper D-Hood E-Headlight F -Windshield G-Brake Control H-Seat -Rear Bumper J-Trak K-Pan L-Ski Spring M26719 A-Snow Flap B-Rear Bumper C-Stop-Taillight D-Seat E-Fuel Tank F-Throttle Control G-Hood H-Ski Handle 1-Ski J -Reoil Start K-Serial Number l-trak

12 a Preparation MX FUEL MPORT ANT: Use regular leaded or non-leaded gasoline with an anti-knok index of 88 or higher, mixed with 2-yle oil in the proper ratio. Never use gasoline that has been stored for a long time. ) NOTE: Regular (leaded) gasoline is preferred but \ non-leaded gasoline is aeptable. J Use John Deere 2-yle oil or an equivalent BA approved 2-yle oil. Mixing is improved if the oil is at room temperature. The orret fuel-oil mixture is 40:1 ratio for the first tank of fuel and 50:1 ratio thereafter. See page 25. CAUTON: Use safe mixing proedures. - Use an approved ontainer for storage and refueling. - Mix fuel outdoors. -Do not smoke. -Do not spill fuel. 1. Pour half the gasoline into ontainer. 2. Pour in all the oil. 3. Shake mixture vigorously. 4. Pour in remaining gasoline. 5. Shake mixture vigorously. NOTE: Mix gasoline and oil in a separate ontainer - never mix in the snowmobile fuel tank. Agitate stored mixtures thoroughly before using. FLL FUEL TANK CAUTON: Use safe refueling proedures. -Fuel snowmobile outdoors. -Do not smoke. -Avoid spilling fuel. Do not overfill. - Clean fuel tank of any spilled fuel. Fill tank to bottom of. filler nek. Fuel tank holds 5.5 U.S. gallons (20.8 L).

13 7 a Operation BEFORE OPERATNG 1. Wipe windshield with a lean damp loth. Do not use gasoline, solvents or abrasive leaners. 2. Chek skis, wear rods, and all steering omponents. Chek steering for a full right and left-hand turn. 3. Chek trak for proper tension. 4. Chek fuel level. 5. Chek throttle and brake for proper operation. START ENGNE Engine Break-n Do not exeed 30 mph (48 km/h) for the first 25 miles (40 km), or fore the mahine at full throttle in deep snow. A CAUTON: Be sure area in front of mahine.. is lear. Be prepared to apply brake to prevent snowmobile movement. 1. With no hoke and no throttle, pull reoil start handle to turn engine over two or three times. 2. Pull out on hoke knob. 3. Emergeny stop swith must be in enter position. 4. nsert key and turn key swith "ON." DO NOT open throttle lever. 5. Pull reoil start rope. 6. When engine starts, allow it to run briefly before pushing hoke knob in. NOTE: Choke knob an be pushed in gradually for smooth engine performane during warm-up. f engine beomes "floo~ed", push in on hoke knob. Hold the throttle in wide open position. Pull start rope until engine "pops". Release throttle. Pull reoil start rope until engine starts. NOTE: Remove and dry spark plugs if engine is extremely flooded. MPORTANT: DO NOT permit engine to idle for long intervals. Shut engine off whenever you stop. Warm Starting With emergeny stop swith in enter position and key swith "ON," pull reoil start rope. NOTE: DO NOT use hoke and open throttle slightly. Choke Knob

14 8 Operation Emergeny Starting 1. Raise hood and use tool kit provided with snowmobile to remove reoil starter. 2. Knot one end of rope and wind rope around reoil starter. 3. Wind opposite end of rope around spark plug wrenh from tool kit. 4. Pull on rope to start engine. Carry an extra rope for emergeny starting. STOP ENGNE 1. Release throttle lever. 2. Apply brake. ) 3. Turn emergeny stop swith up or down. 4. Before restarting, stop swith must be turned to the enter position. Always hek stop swith before attempting to start engine. 5. Turn key swith "OFF." Remove key when leaving mahine unattended. LGHTS NOTE: The lights are automatially "ON" whenever the engine is running. 1. Stoplight omes on when brake is applied. 2. Turn dimmer swith one for low beam. 3. Turn dimmer swith again for high beam. NOTE: f one filament of bulb fails, the other beam an still be used. See page 19 for adjusting headlight and hanging bulbs. CLEARNG TRACK 1. Clear trak after operating in slushy snow. 2. Tip mahine on its side until trak lears the ground. 3. Spin trak at moderate speed until snow and ie are thrown lear. A CAUTON: Be sure no one is behind mahine when learing trak. njury ould result from ie or roks thrown from trak. MPORTANT: f trak freezes, free the trak manually. Do not use the engine to break trak loose beause it will burn and damage the drive belt.

15 Operation 9 CAUTON: Always use a solid tow bar when possible. Flexible ropes or pull straps do not allow for ontrol on turns or when stopping. 1. Remove drive belt. 2. Connet only one ski of disabled mahine to the tow mahine. 3. DO NOT use rear bumper for towing. 4. When towing with a rope or strap, tie to only one ski. Do not loop rope or strap through both skis, as this may damage the steering tie rod. 1. To be safe from frostbite, dress for the wind and weather. 2. Wear protetive lothing and aessories. 3. The hart provides a guide and illustrates the danger zones. A CAUTON: Always wear a snowmobile helmet with fae shield or goggles. The helmet provides both warmth and protetion against head injury. TOWNG DRESSNG FOR THE WEATHER WND CHLL CHART M26770 M10123 ESTMATED WND SPEED N MPH ACTUAL THERMOMETER READNG ( F.) EQUVALENT TEMPERATURE ( F.) alm ~ (Wind speeds LTTLE NCREASNG GREAT greater than 40 mph have DANGER DANGER DANGER littleaddi- (for properly lothed tiona effet.) person) Danger from freezing of exposed flesh

16 Servie SERVCE NTERVAL CHART tem Clean Windshield Chek Condition of Skis and Steering Chek Trak Condition and Tension Chek Throttle Control Operation Chek Operation of Brakes Chek Emergeny Stop and Key Swithes Chek Lighting System Chek n-line Fuel Filter Chek Drive Belt Condition Chek Carburetor Adjustments Chek Choke Adjustments Chek Ski Alignment Chek Headlight Adjustment Chek Ski Wear Rods and Wear Plates Chek Slide Suspension Wear Bars Use Never-Seez on Throttle Cable End Chek All Components for Condition and Tightness Chek Drive and Driven Sheaves Store Snowmobile Properly Every Every As Needed Daily Miles Miles Annually Page X 7 X X 16 X 12 X 15 X 7-8 X 8 X X 14 X 14 X X X 12 X X X 12 X X 18 X X 19 X X 17 X X 16 X 12 X 20 X X 21 SPARK PLUGS NOTE: Spark plugs are Champion ON-3 (John Deere Part No. AM55045). Removing Spark Plugs CAUTON: High-energy ignition systems an produe injurious eletrial shok. Stop engine and remove key before working on ignition. 1. Stop engine. 2. Pull onnetors from plugs. MPORT ANT: Do not pull on wire to remove onnetors. Pull on onnetors only. 3. Remove plugs.

17 Cheking Spark Plug CAUTON: Do not hold the plug or plug wire in your hand when heking for spark. High-energy ignition systems an produe injurious eletrial shok. 1. Reonnet spark plug wire to plug. 2. Lay plug on the engine fins. 3. Pull the reoil start rope and hek for spark. New plugs are gapped at inh (0.635 mm). The gap will widen in proportion to the hours and miles of use. When plug gap reahes inh (1.143 mm) or if plug malfuntions, replae it. MPORTANT: Do not regap the plug, always replae it! Plug Appearane Tan or Cooa Brown Blak or Sooty Possible Cause Proper fuel mixture, good ombustion. Fuel mixture too rih, poor ombustion. (. Servie 11 White or Light Tan Fuel mixture too lean, hot ombustion. NOTE: Replae plug if appearane is abnormal, engine starts hard or malfuntions. nstalling Spark Plug 1. Clean plug seating surfae on ylinder head. 2. nstall plugs and torque to 10 to 12 ft-lbs (14 to 16 Nm). 3. nstall spark plug wires. CARBURETOR MPORTANT: Do not run engine when adjusting arburetor. The arburetor is a float-type, fixed main jet arburetor. The float in the fuel bowl maintains a onstant fuel level in the bowl. The fixed main jet eliminates high-speed adjustments. Altitude and temperature variations may require arburetor hanges and adjustments. Continued on page 12

18 12 Servie Choke System A separate metered hoke system is used. The system is opened and losed by a hoke plunger. Do not open the throttle when starting the engine, otherwise the fuel-air mixture will be too lean for starting. A-Jam Nut B--Adjusting Sleeve Adjusting Choke 1. Remove air intake silener. 2. Push hoke knob in (losed). 3. Look in the hoke plunger hole in the arburetor throat. Plunger should be all the way down in the bore. 4. To adjust plunger, loosen jam nut (A) and turn adjusting sleeve (B) lokwise. Tighten jam nut. MPORTANT: Plunger must be down tight in the bore or arburetor will run "rih". This will affet engine performane. 5. Pull out on hoke knob and look in hoke plunger hole. Plunger should raise and be all the way up in the bore. Adjusting Carburetor 1. Remove air intake silener. 2. Bak idle speed adjusting srew out until it no longer ontats the arburetor throttle lever. dle Speed Adjusting Srew 3. Look in arburetor throat to make sure butterfly valve is ompletely losed. 4. Loosen jam nut (A) on throttle able. Turn adjusting sleeve (B) until able is just snug and the butterfly is losed. Tighten jam nut. Use Never-Seez on throttle able end in the throttle lever. A-Jam Nut B-Adjusting Sleeve

19 Servie Look in arburetor throat and ompress the handgrip throttle lever until it ontats handgrip. Butterfly valve should be in full open position and parallel with arburetor bore. Repeat Steps 2 through 4 if neessary. Release throttle lever. 6. Turn idle speed adjusting srew in until it ontats throttle lever. Turn in one additional turn for preliminary idle speed adjustment. 7. Lightly seat idle mixture srew and then open one to two turns for initial mixture adjustment. 8. nstall air intake silener and warm up engine. 9. Turn idle mixture srew in (lean) or out (rih) to obtain an even engine idle. 10. Readjust idle speed adjusting srew to obain an engine idle speed of 2000 rpm. Cheking Float Level NOTE: The fuel/eve/ in the float hamber is regulated by the float. 1. Remove air intake silener, fuel lines and arburetor. 2. Remove float hamber body. 3. Turn arburetor on its side. Touh float (A) lightly with finger until it just ontats needle valve (B). Float should be parallel with edge of float hamber (C). 4. f adjustment is neessary, bend the float arm. 5. After adjustment, tap the float lightly. f it is adjusted orretly, it will boune from spring resistane of the needle valve ?Y A-Float B-Needle Valve MAN JET CHART C-Fioat Chamber Carburetor and luth hanges, adjustments or modifiations may be neessary for operation at altitudes above 3,000 feet (914 m). See your John Deere dealer for these hanges. TEMPERATURE Below - 30 F - 30 to + 30 F Below - 35 C - 35 to - 1 C Main Jet Main Jet * + 30 to + 60 F Above 60 F - 1 to + 16 C Above 16 C Main Jet Main Jet ALTTUDE Sea Level 3,000 ft. (914 m) *Fatory nstalled.

20 14 Servie N-LNE FUEL FLTER Change the filter annually or when ontamination builds up in the one. ) AR NTAKE SLENCER The first indiation of trash in the silener will be loss of power and performane. The engine will run "rih" beause adequate air will not be mixing with the fuel. 1. Remove silener sreen. 2. Shake or blow out the sreen to remove any trash. 3. nstall silener sreen. DRVE SYSTEM ) Replaing Drive Belt The drive belt should be replaed if its width is redued by 1/8 inh (3.18 mm). A narrow belt redues snowmobile top speed. Corret width is 1-1/4 inhes (31.75 mm). f drive belt wears rapidly, drive and driven sheaves may be out of alignment. See your John Deere dealer. )

21 Servie 15 A belt worn narrow in one area is aused by trying to free a frozen trak with the engine. Free a frozen trak manually before starting engine. A CAUTON: Keep fingers out of area between driven sheave halves. f driven sheave stiks, use are in opening it to prevent hand from being pinhed. 1. Push in on enter of driven sheave and lift belt up and over sheave half. 2. Remove belt from drive sheave. MPORTANT: Never pry belt over sheaves. 3. nstall belt in reverse sequene. Always install belt so that number on belt an be read when viewed from left-hand side of snowmobile. NOTE: As belt wear inreases or if belt strethes, remove "anti-reep" shims (A) from behind retaining washer (8). When new belt is installed, replae shims. Torque ap srew to 20 ft-lbs (2 7 Nm). After installing a new belt, if snowmobile has a tendeny to reep at idle speed, add a shim. A-"Anti-Creep" Shims B-Retaining Washer Adjusting Brake 1. Apply the brake ontrol lever and measure the distane from the lever to the handgrip. t should be 1 to 1-1/2 inhes (25 to 38 mm). 2. Adjust brake by loosening jam nut (A) and tightening adjusting srew (B). Tighten jam nut. /). CAUTON: DO NOT adjust jam nuts on.. brake able. 3. Chek brake tension. 4. Readjust if neessary. NOTE: Be ertain dowel on end of brake able is seated properly in reess of brake ontrol lever. 5. After brake adjustment, hek operation of stoplight swith. f stoplight does not work, hek for a defetive swith. A-Jam Nut B-Adjusting Srew

22 16 Servie SLDE SUSPENSON Replaing Wear Bars When running in marginal snow onditions, hek wear bars daily. 1. Tip snowmobile on its side. 2. Chek wear bars in several plaes for raks, thin areas and sand or gravel imbedded in the bar. NOTE: Sand or gravel imbedded in the wear bars ats as an abrasive and will destroy the steel grouser bars in the trak. 3. f any of these onditions exist, see your John Deere dealer for wear bar replaement. ) M2467?Y A-Jam Nut 8-Adjusting Srew Adjusting Trak Tension Chek trak tension and alignment frequently. A loose trak auses exessive slap and ould damage the trak, tunnel or slide assembly. A tight trak requires additional-power to operate. 1. Suspend or support snowmobile so trak is lear of ground. 2. Loosen jam nuts (A) on trak adjusting srews (B). 3. Turn adjusting srews (B) to tension trak. 4. Measure below the lower shok absorber mount for learane of flush to 1/4 inh (6.35 mm) between trak and slide wear bar. Both sides should be equal. Tighten jam nuts. After Adjustment 1. Start engine and allow the trak to rotate slowly several times. Shut off engine and allow trak to oast to a stop. DO NOT APPLY BRAKE TO STOP TRACK. 2. Chek alignment. Rear idler wheels should run in enter of drive lugs. 3. Slide rail wear bar should be in middle of eah slide rail opening of trak. 4. f either Step 2 or 3 indiates a need for adjustment, repeat the proedure. NOTE: Trak will run to the loose side. f trak is too far to the left, tighten the left adjusting srew to ) move the trak to the right.

23 Servie 17 Adjusting Suspension Springs Ride the snowmobile. f the suspension bottoms frequently, inrease the rear spring preload. To inrease the preload, move the springs from the bottom position (A) to the top position (8). M24678.Y A- Bottom Position B- Top Position Replae Ski Wear Rods Wear rods should be replaed when they are worn to one-half their original size. 1. Remove lok nuts seuring wear rod to ski. 2. Pry rod down to free studs from holes. 3. Slide rod forward to remove rod from rear hole. 4. nstall new rod in opposite sequene. SKS Replae Ski Wear Plates Replae wear plates when exessively worn. 1. Raise front of snowmobile. 2. Remove otter pin (D) and drilled pin (A). 3. Lift spring (C) and remove wear plate (B). 4. nstall new wear plate (8). 5. Lower spring (C) and install drilled pin (A) and otter pin (D). N26722 A-Drilled Pin B-Wear Plate C-Spring D-Cotter Pin Continued on page 18

24 18 Servie Aligning Skis When properly aligned, skis are parallel and handlebars are positioned straight ahead. ) 1. Loosen jam nuts (D). Gold-olored tie rod ends (C) have left-hand threads. Loosen opposite normal rotation. 2. Turn tie rods to align skis. Measure from straight edges of skis; not tapered ends. M26723 MPORTANT: When adjusting tie rods (B), length from enter hole-to-enter hole should not exeed 13-1/4 inhes (33.6 em). 3. Tighten jam nuts (D). Hold tie rod (B) with vie grips when tightening jam nuts. This prevents stripping the threads in the ball joint. MPORTANT: After jam nuts are tight, be sure tie rod ends (A) still swivel freely. A-Tie Rod End B-Tie Rod C-Gold-Colored Tie Rod End D-Jam Nuts Eliminating Loose Steering A CAUTON: Chek steering omponents.. and hardware frequently for ondition and tightness. The two major auses of loose steering are: 1. Exessively worn tie rod ends (A). 2. Exessively worn spindle bushings. 3. Replae or tighten parts as required. )

25 Servie 19 LGHTNG SYSTEM ,--25 ''---: ; (7.6 m) 24-3/4" (628 mml Adjusting Headlight 1. Position snowmobile on a flat surfae with the headlight 25 feet (7.6 meters) from a vertial surfae. 2. Have operator on seat and headlight on HGH beam. Light beam enterline should be straight ahead and 24-3/4 inhes (628 mm) above ground level. 3. Loosen or tighten the two left-hand adjusting srews to raise or lower the light beam. 4. Loosen or tighten the right-hand adjusting srew to move the light beam right or left. Replaing Headlight 1. Disonnet wiring from light. 2. Unhook wire end from slot. 3. Remove wire lamp and headlight. 4. nstall new headlight in opposite sequene. Replaing Stop-Taillight 1. Remove lens. 2. Push and turn bulb ounterlokwise to remove it. 3. nstall new bulb in opposite sequene. MPORT ANT: Be sure bulb loking tabs math slots.

26 20 Servie TGHTENNG HARDWARE AND COMPONENTS ) Chek hardware and omponents for tightness, wear and damage on a yearly basis. Replae any parts that are questionable. /). CAUTON: Worn, bent or damaged ski and A steering omponents are unsafe. 1. Wear rod nuts. 2. Ski bolts. 3. Steering arm bolts. 4. Tie rod end bolts. 5. Drive shaft bearing ap srews. 6. Driven sheave ap srew. 7. Muffler lamp. 8. Throttle and hoke ables. 9. ntake manifold nuts Carburetor attahment. 11. Engine mounting bolts. 12. Drive sheave ap srew. 13. Suspension ap srews. 14. Shok absorber srews.

27 21 Storage ' Thoroughly lean snowmobile. Polish hood, pan and tunnel with automotive-type wax. Use upholstery leaner on seat. Touh up all bare metal parts with paint. Chek ap srews and omponents for tightness. Order any new parts required. Siphon fuel from tank. Start and run engine out of fuel at DLE SPEED. Replae in-line fuel filter. Remove spark plugs and add one teaspoon of 2-yle oil in eah ylinder. Pull reoil start rope six or seven times to lubriate ylinder walls. Replae plugs. 7. Remove drive belt and oat drive and driven sheaves with light grease. 8. Support snowmobile so trak is lear of ground. Loosen trak adjusting srews. 9. Plae over on snowmobile and store inside. PLACE SNOWMOBLE N STORAGE REMOVE SNOWMOBLE FROM STORAGE 1. Wipe grease from drive and driven sheaves. nstall drive belt. 2. Fill fuel tank with properly mixed fuel. 3. Chek throttle and brake ontrols for proper adjustment and operation. 4. Adjust trak tension. 5. Review operating and safety suggestions. 6. Start engine and test operation of all swithes and lights. 7. Ride snowmobile at slow speed until you are sure it is operating properly.

28 Trouble Shooting ) ENGNE LGHTS Engine Starts Hard or Will Not Start Fuel tank empty. Emergeny stop swith in "STOP" position. Plugged in-line fuel filter. Fuel pump malfuntioning. Faulty ignition system. gnition timing inorret. dle set too high. Engine Laks Power or Aeleration Running on one ylinder. Throttle able improperly adjusted. mproper fuel mixture. Carburetor out of adjustment. Restrited in-line fuel filter. gnition timing inorret. Center distane between drive and driven sheaves too short for belt. Engine Bakfires and Runs Unevenly gnition timing inorret. Engine Overheats Carburetor too "lean". ntake manifold or arburetor leaking. Stoplight Not Working Bulb burned out. Stoplight swith defetive. Stoplight swith "frozen". ) Lights Won't Light Bulbs burned out. Loose eletrial onnetions. Faulty lighting oil. )

29 Trouble Shooting 23 POWER TRAN AND CHASSS Cluth Does Not Disengage Engine idles too fast. Faulty luth. Short drive belt. Cluth engages slowly Faulty luth. Strethed or worn drive belt. Exessive Drive Belt Wear Freeing frozen trak with engine. Drive and driven sheaves misaligned. Driving long distanes at luth engagement speed. Rapid Trak Wear Operating on bare ground. Trak improperly tensioned. SKS AND STEERNG Loose Steering Worn tie rod ends. Worn spindle bushings. Poor Maneuverability Worn ski wear rods. Loose steering linkage.

30 Speifiations SNOWMOBLE SPECFCATONS Component Engine Fuel System Chassis and Tunnel Trak and Suspension Power Train Eletrial System tem Manufaturer Model Number of Cylinders Bore Stroke Displaement Carburetor Mfgr. Carburetor Number Tank Capaity Fuel Mixing Ratio Material: Tunnel and Pan Hood Windshield Overall Length Overall Width Overall Height Weight (Approx.) Suspension Type Trak Material Trak Width Transmission: Type Manufaturer Primary Seondary Final Drive Ratio: Seondary Cluth Brake Drive Belt Spark Plug (Champion) Spark Plug Gap Timing Lighting Coil Capaity Light Bulbs: Headlight Stop-Taillight *Manufatured for John Deere by Kawasaki Heavy ndustries, Japan **Manufatured for John Deere by Comet ndustries, Rihmond, ndiana. Speifiation John Deere "Fireburst"* TB340A Two 60 mm 60 mm 339 Mikuni AM U.S. gal. (20.8 L) 50:1 See page 6. Aluminum Sheet Molded Compound Polyarbonate 98 in. ( mm) in. (844.6 mm) 38.0 in. (965.2 mm) 275 lbs. (1 25 kg) Slide Suspension Rubber 15 in. (38.1 em) 2-Sheave Variable John Deere (94C Comet)** John Deere Low - 4.5:1, High :1 Mehanial Disk M68416 ON-3 (AM55045) in. (0.635 mm) See page BTDC with engine running at 6500 rpm ( in. BTDC) (2.76 mm BTDC) 120 Watts AM52959 AM52619 ) )

31 Speifiations 25 FUEL AND OL MXTURES Ratio NOTE: UNTED STATES CANADA Oil leaded Fuel Ratio Oil leaded Fuel 40:1 1 pt. 5 gal. 40:1 1 U.S. pt. 4 mperial gal. (0.473 L) (18.9 L) (0.473 L) (18.2 L) 50:1 1 pt. 6 gal. (0.473 L) (22.7 L) 1 mperial pt. 5 mperial gal. (0.568 L) (22.7 L) 50:1 1 U.S. pt. 5 mperial gal. (0.473 L) (22.7 L) 1 mperial pt. 6 mperial gal. (0.568 L) (27.3 L) United States gallon ontains liters and the Canadian mperial gallon ontains liters. (Speifiations and design subjet to hange without notie.).

32 Aessories 1. Speedometer. 2. Tahometer. 3. Protetive Cover. 4. Hith. 5. Trak Stud Kit. )

33 JOHN DEERE SERVCE LTERATURE AVALABLE... To order these publiations, fill out the form below and mail it with payment to the address given. Make heks payable to Deere & Co. Servie Publiations. Please allow three weeks for delivery. Pries inlude handling, taxes and postage to anywhere in the U.S.A. and Canada. PARTS CATALOG j_ ! : 1 1 John Deere Distribution Servie Center Department SP rd Ave. ~ Moline, ll Please send to.. Name 1 A parts atalog ontaining exploded view illustrations and lists of all parts is useful when purhasing servie parts. Helps identify the orret parts. Useful in assembling and disassembling. OPERATOR~ MANUAL lw a: ~ h li3 Address Town State Zip _ Order Prie Title No. Qty. Eah Parts Catalog SPTFRE Snowmobile PC-1623 $ 1.50 Operator"s Manual SPTFRE Snowmobile M68928 $ 1.00 Servie or Tehnial Manual - SPTFRE Snowmobile TM-1191 $14.00 NOTE: f you want manuals or atalogs for equipment not shown on this list, list the model number, serial number and name of the equipment below. lllioo;, S"te Re<;deot< add 5% foe ROT D ~ Chek or money order in U.S. dollars enlosed... Total (Do not send ash or stamps) SP-317 Litho in U.S.A. MAR-78 Pries subjet to hange without notie. An extra opy of the operator's manual may be important if the opy furnished with your mahine is misplaed. SERVCE OR TECHNCAL MANUAL The servie or tehnial manual is a servie guide for your mahine. nluded in the manual are speifiations, diagnosis and adjustments, illustrations of speial assembly and disassembly proedures, and wiring diagrams.

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