SPORTFIRE. Snowmobile FILE THIS NEW MANUAL. Horicon Works OM-M68674 Issue 19 LITHO IN U S A. td.oool- 155GOO JOHN DEERE

Transcription

1 440 SPORTFRE Snowmobile td.oool- 155GOO ~ JOHN DEERE FLE THS NEW MANUAL Horion Works OM-M68674 ssue 19 LTHO N U S A

2 To The Operator - - Snowmobile Serial Number 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. n '"\ Reord the snowmobile and engine serial numbers in the spae below. ~ ; This operator's manual is prepared for the following snowmobiles: John Deere 440 Sportfire (Serial No. J44SJ M ) Snowmobile Serial No. Engine Serial No. Date of Purhase (To be filled in by purhaser.) Engine Serial Number u u

3 ASSEMBLY Unpak Components 1. Skis 2. Windshield 3. Rear Bumper and Snow Flap Support 4. Operator's Manual 5. Bag of Parts Chek Contents of Bag of Parts A - Ski Spring Stop (2 used) B - Ski Pivot Bolt (2 used) C - 13/ 32 x 3/4-lnh Flat Washer D - 3/ 8-lnh - 24 Lok Nut E - Cotter Pins (2 used) F - gnition Keys G - Windshield Retaining Rings (6 used) H - John Deere Medallion - 1/4 x 1-3/4-lnh Cap Srews (4 used) J - 9/ 32 x 1 /2-lnh Flat Washer (6 used) K - 1 / 4-lnh - 20 Lok Nut (6 used) L - 1/4 x 1-1/2-lnh Cap Srews (2 used) ~00 eee Jjl M24899 nstall Skis NOTE: Bushing is fatory installed in steering spindle. 1. nstall.rubber ski spring stop over spindle. Stop is held in plae by ski saddle. 2. Position ski so that rear hole is aligned with spindle. nstall ski bolt with head of bolt faing out. 3. nstall 13/32 x 3/4-inh flat washer and 3/8-inh lok nut. Torque nut to 39 ft-lbs (52 Nm). nstall otter pin through bolt.

4 nstall Windshield 1. nstall windshield tabs through holes in hood. 2. Seure windshield tabs to hood with rubber retaining rings. nstall Rear Bumper Assemble rear bumper and snow flap support to tunnel as shown. A-Snow Flap Support 8-Rear Bumper C-1/4 x 1-1/2-lnh Cap Srew D-1/4 x 1-1/4-lnh Cap Srew E-9/32 x 1/2-lnh Flat Washer F-1/4-lnh - 20 Lok Nut Position Handlebars 1. Loosen lok nut seuring handlebars in down position. 2. Use plasti mallet to loosen aluminum blok before moving handlebar. 3. Move handlebar to des'ir'ed position. nstall two 1 4 x 1-3/ 4-inh bolts and 1 4-inh lok nuts. Tighten all four nuts seurely. ' 4. nstall John Deere medallion. )

5 1. PREDELVERY CHECK LST CAUTON: When starting snowmobile, support mahine so trak is lear of ground. Chek throttle for proper operation. Align skis and hek steering linkage Chek trak tension and align. Chek brakes. Adjust if neessary. Chek operation of hoke and throttle. Adjust if neessary. Fill fuel tank with 40:1 mix. Start engine and hek idle speed. Chek emergeny stop and key swith. Chek operation of all lights. Aim and adjust headlight. Test drive or dynamometer test snowmobile. nstall aessories desired by ustomer. lw a: l!i! ~ () 1. Explain operator's manual to ustomer. 2. nstrut ustomer about snowmobile operation. 3. Explain fuel-oil mixture. Use REGULAR LEADED OR NON-LEADED FUEL 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. Break-n Period Do not exeed 40 mph (64 km/h) for the first 25 miles (16 km), or fore the mahine at full throttle in deep snow. An oasional burst of power on hard-paked snow will not be harmful. DELVERY CHECK LST 4. Tell ustomer about 1 0-hour hek up. See reverse side of this sheet.

6 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 failure 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 REPAR 1. Trak tension. 2. Drive belt, drive, and driven sheaves. 3. Chain ase oil level. 4. Carburetor adjustment. 5. Carburetor mounting hardware. 6. Operation and adjustment of brake, throttle, and hoke lever ontrols. 7. Condition of ski wear rods. 8. Suspension hardware. 9. Suspension slide wear bars. 10. Ski alignment. 11. Operation of headlight, stop-taillight, dimmer swith, and emergeny stop swith. 12. Fan belt tension. 13. Engine head bolts and exhaust manifold nuts. 14. Steering omponent hardware. ) DEALER COMMENTS: ~

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

8 Safety ) M23365 Preparation CAUTON: DO NOT arry a passenger. mproper use or maintenane by the operator an result in injury. Follow these safety suggestions. 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 your 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. Avoid sun blindness. Wear properly tinted goggles or fae shields. 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" on long trips. 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 fights. 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. 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. M23364 M23366

10 4 Safety Prolonged exposure to loud noise an ause impairmentor loss of hearing. Wear earplugs or any suitable hearing protetive devie ttiat 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. Do not speed through wooded areas. Hidden obstrutions, 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. ) M221 22

11 5 a dentifiation A-Shok Absorbers B-Skis C-Front Bumper 0-Hood E-Headlight F-Windshield 0 G-Brake Control H-Seat ~ -Rear Bumper J-Trak K-Pan L-Ski Spring M25446 A-Snow Flap B-Rear Bumper C- Stop-Taillight 0-Seat E- Throttle Control F-Fuel Tank G-Hood H-Ski Handle -Reoil Start J-Trak K- Snowmobile Serial Number ' M254_47

12 Preparation MX FUEL MPORTANT: 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. 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 a 40:1 ratio for the first tank of fuel and a 50: 1 ratio thereafter. See page 29. A 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 proe- A dures. Fuel snowmobile outdoors. Do not smoke. Avoid spilling fuel. Do not overfill. Clean area around fuel tank of any spilled fuel. Fill tank to bottom of filler nek. )

13 7 Operation Do not exeed 40 mph (64 km/h) for the first 25 miles (16 km), or fore the mahine at full throttle in deep snow. An oasional burst of power on hard-paked snow will not be harmful. BREAK-N PEROD 1. Clean windshield with a 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. Start engine and test operation of emergeny stop swith, key swith, headlight dimmer swith, headlight and stop-taillight. BEFORE OPERATNG STARTNG ENGNE A A CAUTON: Be sure area in front of mahine is lear. Be prepared to apply brake to prevent snowmobile movement. Cold Starting 1. With no hoke and no throttle, pull reoil start to turn engine over two or three times. 2. Flip hoke lever straight up (normal position). n extreme old weather, flip hoke over enter all the way (riher position). 3. Emergeny stop swith must be in enter position. 4. Turn key swith "ON". DO NOT press throttle lever. 5. Pull reoil start rope. 6. When engine starts, allow it to run briefly before pushing hoke lever down. NOTE: f hoke was in rih position, push down to normal position and allow engine to warm up. 7. f engine beomes "flooded", lose the hoke. 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 plugs if engine is extremely flooded. MPORTANT: DO NOT permit engine to idle for long intervals. Shut engine off whenever you stop. Normal Choke Riher Choke M25451 Emergeny Stop Swith

14 ( '..., 8 Operation Warm Starting 1. Emergeny stop swith must be in enter position. 2. Turn key swith "ON". 3. Pull reoil start rope. NOTE: DO NOT use hoke. Emergeny Starting 1. Use tools provided with snowmobile to remove re- ) oil starter. 2. Knot end of rope and wind rope around reoil starter. 3. Pull on rope to start engine. Carry an extra rope for emergeny starting. STOPPNG ENGNE 1. Release throttle lever. 2. Turn emergeny stop swith up or down. T i,:;~,. - ;(0flflj~ ~(... j J rt j',% 3. Apply brake. 4. Before restarting, emergeny stop swith must be turned to enter position. Always hek emergeny stop swith before attempting to start engine. 5. Turn key swith "OFF". Remove key before leaving mahine unattended.

15 Operation 9 LGHTS NOTE: The lights are automatially "ON" whenever the engine is running. 1. Stoplight omes on when brake is applied. 2. Turn dimmer swith to 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 pages 22 and 23 for adjusting headlight and hanging bulbs. M25454 CAUTON: Always use a solid towbar when possible. Flexible ropes or pull straps do not allow for ontrol on turns or when stopping. 1. Remove drive belt. 2. Seure skis of disabled mahine to tow mahine. 3. DO NOT use rear bumper for towing. TOWNG 1. Clear trak after operating in slushy snow. 2. Tip mahine on its left side until trak lears the ground. CLEARNG TRACK 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. MPORT ANT: f trak freezes, free it manually. Do not use the engine to break trak loose. The drive belt will be burned and damaged.

16 10 Operation DRESSNG FOR THE WEATHER 1. To prevent 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. The helmet provides both warmth and protetion against head injury. WND CHLL CHART M10123 ESTMATED WND SPEED N MPH alm (Wind speeds greater than 40 mph have littleaddi tional effet.) ACTUAL THERMOMETER READNG ( F.) EQUVALENT TEMPERATURE ( F.) 20~ -~ LTTLE NCREASNG GREAT DANGER DANGER DANGER (for properly lothed person) Danger from freezing of exposed flesh

17 11 Servie SERVCE NTERVAL CHART Every Every As tem Needed Daily Miles Miles Annually Page Clean windshield. X 7 Chek Chek ondition of skis and steering. X 20,21 trak ondition and tension. X 18,19 Chek throttle ontrol operation. X 14,15 Chek operation of brakes. X 17 Chek emergeny stop and key swith. X 8 Chek lighting system. X 9 Chek hain ase oil level. X 17 Chek hain tensioner. X 18 Chek in-1 ine fuel filter. X 15 Chek drive belt ondition. X 16,17 Chek arburetor adjustments. X X X 13, 14,15 Chek hoke adjustments. X X X 13 Chek fan belt tension. X X 16 Chek ski alignment. X 21 Chek headlight adjustment. X 22 Chek ski wear rods and wear plates. X X 20 Chek slide suspension wear bars. X X 18 Use Never-Seez on throttle able end. X 14 Chek all omponents for ondition and tightness. X 24 Servie drive and driven sheaves. X 16 Store snowmobile properly. X 25

18 12 Servie SPARK PLUGS 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. MPORTANT: Do not pull on wire to remove onnetors. Pull on onnetors only. 3. Remove plugs. Cheking Spark Plugs A CAUTON: Do not hold the plug or plug.. wire in your hand when heking for spark. 1. Reonnet spark plug wire to plug. 2. Lay plug on engine. 3. With ignition "ON," pull 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. Plug Appearane Possible Cause ) Tan or Cooa Brown Blak or Sooty White or Light Tan Proper fuel mixture, good ombustion. Fuel mixture too rih, poor ombustion. Fuel mixture too lean, hot ombustion. NOTE: Replae plug if appearane is abnormal, engine starts hard or malfuntions. nstalling Spark Plugs 1. Clean plug seating surfae on ylinder head. 2. nstall plugs and tighten to 10 to 12 ft-lbs (14 to 16 Nm) torque. 3. Connet spark plug wires.

19 Servie 13 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 main jet hanges. MPORT ANT: DO NOT run engine with air intake silener removed. To do so will ause engine to run lean and ould ause engine failure. 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. Adjusting Choke Plunger 1. Remove air intake silener. 2. Plae hoke lever down (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 and turn adjusting sleeve lokwise. This moves plunger down. Tighten jam nut. MPORTANT: Plunger must be down tight in bore or the arburetor will run "rih". This will affet engine performane. 5. Raise hoke lever and look in hoke plunger hole. Plunger should raise enough to expose at least half the hole opening. 6. Start and run engine until it idles smoothly. 7. nsert a inh (0.762 mm) feeler gauge between hoke lever and dash (dash must be in down position). This should indiate free-play and should not affet engine idle.

20 14 Servie Adjusting Throttle Cable 1. Remove air intake silener. 2. Lok throttle lever against handgrip with a lamp or strong rubber band. 3. Plae your finger in throat of arburetor so you an feel the bakside of the throttle valve. 4. Loosen jam nut and turn adjusting sleeve until the bakside of throttle valve is flush with the bore. Tighten jam nut. NOTE: No part of the throttle valve should restrit air flow through the arburetor throat when throttle is in the wide open position. Use Never Seez on the throttle able end in the throttle lever. dle Adjusting Srew 5. Turn idle adjusting srew ounterlokwise until the tip is flush with inside of bore. 6. Remove lamp or rubber band from throttle lever. This allows throttle valve to fully seat in bore. 7. Turn idle adjusting srew lokwise until srew ontats throttle valve. Turn srew lokwise two additional turns. This gives preliminary idle speed. 8. Look into throat of arburetor and slowly ompress throttle lever. The throttle valve should begin to rise; if not, repeat Steps 2, 3, and Turn air srew in until slight seating resistane is felt. 10. Bak air srew out 1-1/2 turns. 11. nstall air intake silener and run engine until operating temperature is reahed. f idle speed is not orret, turn idle adjusting srew in or out until idle speed is orret (2400 to 2700 rpm). MPORTANT: NEVER use air srew to set engine idle. Air srew should be adjusted as explained in Step 10. Air Srew )

21 Servie 15 Cheking Float Level NOTE: The fuel level in the float mixing hamber is regulated by the float. f the float is puntured, fuel overflow may our. 1. Remove air intake silener, fuel lines and arburetor from engine. 2. Remove float hamber body and gasket. 3. nvert arburetor. Float arm (B) should be parallel with edge of mixing hamber (A). f adjustment is neessary, bend only the float arm atuating tab. A-Mixing Chamber 8- Fioat Arm Carburetor and luth hanges, adjustments or modifiations may be neessary for operation at altitudes above 4000 feet (1219 m). See your John Deere dealer. MAN JET CHART Temperature Main Jet Power Jet Altitude *Fatory nstalled 0 F to - 40 F 210 ( - 18 C to - 40 C} 0 F to + 40 F 200* ( - 18 C to + 5 C) * Sea Level to 4000 Feet (1219 m) N-LNE FUEL FL TEA Change the filter annually or when ontamination builds up in the one.

22 16 Servie AR NTAKE SLENCER The first indiation of trssh 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. Chek silener daily if snowmobile has been run through attails or weeds. 1. Remove silener. 2. Shake or blow out silener to remove any trash. 3. nstall silener. MPORTANT: DO NOT run engine with air intake silener removed. Serious engine damage will result. CHECKNG FAN BELT TENSON Remove fan over. Use your finger to deflet belt as shown. f more than 3/8-inh (9.52 mm) defletion is possible or if belt ondition is questionable, see your John Deere dealer. DRVE SYSTEM Serviing Drive and Driven Sheaves One a year, servie the drive and driven sheaves. See your John Deere dealer for this servie. 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 inhes ( ) mm).

23 f drive belt wears rapidly, drive and driven sheaves may be out of alignment. See your John Deere dealer. 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. 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 the left-hand side of the snowmobile. NOTE: As belt wear inreases or if belt strethes, remove spaer washer (A) from behind re taining washer (B). When new belt is installed, replae washer. Torque ap srew to 20 ft-lbs (27 Nm). f snowmobile has a tendeny to reep at idle speed after installing a new belt, add a 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 and turning ap srew in. Retighten jam nut seurely. A 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. Cheking Chain Case Oil Level 1. Park snowmobile on a level surfae. 2. Remove lower plug from hain ase. f oil flows from this hole, oil level is satisfatory. 3. To add oil, remove upper plug and add SAE 90 oil until it flows from lower hole. 4. nstall plugs. Servie 17 A-Spaer Washer B- Retaining Washer

24 18 Servie Cheking Chain Tensioner 1. Turn snowmobile on its left side. Remove hain ase over. 2. Chek hain tensioner for wear. When tensioner is worn until only 1/16 inh (1.588 mm) of material ) remains, replae the tensioner. 3. nstall over. Add oil to hain ase if required. Wipe any spilled fuel from the pan or sheaves. 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. A-Jam Nuts 8-Adjusting Srews 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.

25 Servie 19 After Adjusting Trak Tension 1. Start engine and allow 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. Adjusting Suspension Springs Ride the snowmobile to determine adjustment requirements. Front Springs f the front springs are tightened too muh, the ride will be stiff and the front of the snowmobile will seem light and lift up when power is applied. Added lift is fine for deep snow but makes the ride hoppy on rough surfaes. Front torsion springs are not the only adjustment for ski lift, but they do ontribute. To redue spring tension, turn adjusting nuts ounterlokwise. Be sure that at least two threads of the adjusting srews protrude through the nuts. Rear Springs To inrease tension, move the springs from the bottom position (A) to the top position (B). A-Bottom Position 8- Top Position

26 20 Servie SKS Replaing 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. M24959Y ) Replaing Ski Wear Plates Replae wear plates when exessively worn. 1. Raise front of snowmobile. 2. Remove otter pin (A) and drilled pin (B). 3. Lift spring and remove wear plate (C). 4. nstall new wear plate. 5. Lower spring and install drilled pin and otter pin. M25469 A-Cotter Pin 8- Drilled Pin C- Wear Plate ) )

27 Servie 21 Aligning Skis When properly aligned, skis are parallel and handlebars are positioned straight ahead. 1. Raise front of snowmobile slightly to take weight off skis. rjji:'! (~, SP>R!TFRE M254'!0 2. Disonnet right tie rod from steering arm. 3. Loosen jam nut on right tie rod end. The left tie rod jam nut does not need to be loosened, it is staked to the rod. 4. Turn right tie rod end (in or out) to align skis. Measure from straight edge of skis; not tapered ends. Distane should be equal at loations shown. MPORTANT: When adjusting tie rod, DO NOT exeed 1-5/16 inhes (33.34 mm) between tie rod and enter of tie rod end. 5. Tighten jam nut on tie rod. Hold tie rod when tightening jam nut. This prevents stripping threads in ball joint. MPORTANT: After jam nut is tight, be sure tie rod end swivels freely. 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 (B). A-Tie Rod End 8-Spindle Bushing 3. Replae or tighten parts as required.

28 22 Servie LGHTNG SYSTEM 25' (7.6 m) 16-1/4" (41.2 em) M2JJ26 Adjusting Headlight 1. Position snowmobile on a flat surfae with the headlight 25 feet (7.6 m) from a vertial surfae. 2. With operator on seat and headlight on " HGH" beam, light beam enter line should be straight ahead and 16-1/4 inhes (41.2 em) above ground level. 3. Loosen or tighten the two adjusting srews to raise or lower the light beam. 4. Loosen or tighten the adjusting srew to move the light beam right or left. ) )

29 Servie 23 C Replaing Headlight 1. Disonnet wiring from light. 2. Unhook wire end from slot. 3. Remove wire lamp and headlight. 4. Reverse proedure to install new headlight. Replaing Stop-Taillight 1. Remove lens. 2. Push and turn bulb ounterlokwise to remove it. 3. nstall new bulb in opposite sequene. MPORTANT: Be sure bulb loking tabs math slots. Replaing Speedometer 1. Pull the bulb soket out of the instrument. 2. Push and turn bulb ounterlokwise to remove bulb from soket. 3. nstall new bulb in opposite sequene.

30 24 Servie TGHTENNG HARDWARE AND COMPONENTS M2547? Chek hardware and omponents for tightness, wear and damage on a yearly basis. Replae any parts that are questionable. A A CAUTON: Worn, bent or damaged ski and steering omponents are unsafe. 1. Wear rod nuts. 2. Ski bolts. 3. Steering arm bolts. 4. Tie rod end bolts. 5. Seondary shaft bearing ap srews. 6. Driven sheave ap srew. 7. Muffler springs. 8. Throttle and hoke ables. 9. Carburetor attahment. 10. Engine mounting bolts. 11. Drive sheave ap srew. 12. Suspension ap srews. 13. Shok absorber srews. ) )

31 25 Storage Plaing Snqwmobile in Storage 1. Thoroughly lean snowmobile. 2. Polish hood, pan and tunnel with automotive-type wax. Use upholstery leaner on seat. Touh-up all bare metal parts with paint. 3. Chek ap srews and omponents for tightness. Order any new parts required. 4. Siphon fuel from tank. Start and run engine out of fuel at DLE SPEED. 5. Replae in-line fuel filter. 6. Remove spark plugs and add 1 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. Change oil in hain ase. 9. Support snowmobile so trak is lear of ground. Loosen trak adjusting srews. 10. Plae over on snowmobile and store inside. Removing Snowmobile 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.

32 Trouble Shooting ) Engine Engine Starts Hard or will Not Start Fuel tank empty. Emergeny stop swith in "OFF" 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. Engine Bakfires and Runs Unevenly gnition timing inorret. Engine Overheats Carburetor set too lean. ntake manifold or arburetor leaking. Engine fan belt slipping or broken. Fan blade(s) broken off. Lights Stoplight Not Working Bulb burned out. Stoplight swith defetive. Lights Won't Light Bulbs burned out. Loose eletrial onnetions. Faulty lighting oil.. ' " :f., '

33 Trouble Shooting 27 Power Train and Trak Cluth Does Not Engage Properly Engine idles too fast. Faulty luth. Short drive belt. Cluth Engages Slowly Faulty luth. Strethed or worn drive belt. Exessive Drive Belt Wear Driving long distanes at luth engagement speed. Freeing frozen trak with engine. Drive and driven sheaves misaligned. Rapid Trak Wear Operating on bare ground. Trak improperly tensioned. Skis and Steering Loose Steering Worn tie rod ends. Worn spindle bushings. Poor Maneuverability Worn ski wear rods. Loose steering linkage.

34 Speifiations ) SNOWMOBLE SPECFCATONS COMPONENT TEM 440 SPORTFRE Engine Manufaturer John Deere "Fireburst"* Model TA440B No. of Cylinders 2. Bore 68 mm Stroke 60 mm Displaement 436 Fuel System Carburetor Manufaturer Mikuni Carburetor No. AM55055 Tank Capaity 8 Gals. (30.3 L) Fuel Mixing Ratio See page 29 Chassis and Body Tunnel Aluminum Pan Themoplasti Rubber Windshield Polyarbonate Overall Length 102 in. (259.1 em) Overall Width 39 in. (99.1 em) Overall Height 35 in. (88.9 em) Weight (Approx.) 385 lbs. (175 kg) Trak and Suspension Suspension Slide Suspension Trak Material Rubber Trak Width 15 in. (381 mm) ) *Manufatured for John Deere by Kawasaki Heavy ndustries, Japan )

35 Speifiations 29 SPECFCATONS-Continued COMPONENT TEM 440 SPORTFRE Power Train Transmission 2-Sheave Variable Manufaturer: Primary Model Seondary John Deere (Comet)* 102C ~ohn Deere Final Drive Ratio 1.86:1 Eletrial System Spark Plug (Champion) N2 (AM52640) Spark Plug Gap Timing Lighting Coil Capaity Light Bulbs: Headlight Taillight Speedometer Tahometer *Manufatured for John Deere by Comet ndustries, Rihmond, ndiana QN2 (AM55044) in. (0.635 mm) 18 BTDC, engine running at 6500 rpm. 120 Watts AM53887 AM52619 AM52847 AM52847 FUEL AND OL MXTURES UNTED STATES CANADA Ratio Oil Fuel Ratio Oil Fuel 40:1 1 pt. 5 gal. 40:1 1 u.s. pt. 4 mperial gals. (0.473 L) (1 8.9 L) (0.473 L) (18.2 L) 50:1 1 pt. 6 gal. (0.473 L) (22.7 L) 1 mperial pt. 5 mperial gals. (0.568 L) (22.7 L) 50:1 1 U.S. pt. 5 mperial gals. (0.473 L) (22.7 L) 1 mperial pt. 6 mperial gals. (0.568 L) (27.3 L) NOTE: United States gallon ontains liters and the Canadian mperial gallon ontains liters. (Speifiations and design subjet to hange without notie.)

36 Aessories Tahometer Protetive Cover Hith Eletri Start Kit Trak Stud Kit Two-Passenger Seat Bak Rest Kit Carburetor Primer Kit Handlebar Heater Kit Carbide Wear Rods Extra Coverage Windshield

37 31 MEMORANDA

38 32 MEMORANDA ) \

39 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.!_ ! :: John Deere Distribution Servie Center ll 1 Department SP rd Ave. Moline, ll Please send to... Name 1 PARTS CATALOG 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- 15 Address _ Town State Zip Order Prie Title No. Qty. Eah Parts Catalog SPORTFRETM Snowmobile PC-1743 $ 3.00 Operator's Manual SPORTFRE Snowmobile OM-M68674 $ 1.00 Servie or Tehnial Manual SPORTFRE Snowmobile TM-1222 $12.25 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. 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. llinois State Residents add 5% for ROT D Chek or money order in U.S. dollars enlosed... Total (Do not send ash or stamps) Pries sl.bjet to hange without notie. SP-31 7 L~ho in U.S.A. MAR-78

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