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2 TABLE of CONTENTS Page 220 and 250 Models Model 9-3 Rocket and Lightning Models 9-4 Hurricane (644ccl Models General Lubricants, Adhesi ves and Sealers MAX, 440 MIX and 440 SIR Models 9-15 MarkI(644ccl and MarkII(644ccl Models srr, 400 srr, 440 srr, 340 Trr and 440 Trr Models SIR Model

3 SECTION 9 - TOOLS D1ENCU N Y SN O WMOBILES

4 INDEX Page 220 and 250 Models Model 9-3 Rocket and Lightning Models 9-4 Hurricane (644cc) Models 9-5 General 9-7 Lubricants, Adhesives and Sealers MAX, 440 MIX and 440 SIR Models 9-15 MarkI(644cc} and MarkH 1644cc} Models SIT, 400 SIT, 440 SIT, 340 T IT and 440 TIT Models SIR Model 9 20 NOTICE Tools marked "NLA" are!:fo!tonger 4ooilable. If part number is superseded by a different part number, the new part number will follow the description: Tool [igures are shoum for reference and identification.

5 220 and 250 MODELS 1. C BEARING PULLER PLATE Removes hall hearing from crankshaft C Al - BALL BEARING PULLER Removes hall hearing from crankcase end caps. C Replacement spring 3. C TRUARC SNAP RING PLIERS (Expanding Type) Removes and installs snap rings. 4. C TRUARC SNAP RING PLIERS (Compressing Type) Removes and installs snap rings. 5. C Al - FIXED JET REMOVAL TOOL Assures easy removal of fixed high speed jets from carhuretors. 6. C Al - BEA RING REMOVING A ND INSTA L L- ING KIT A hearing removing and installing kit allows addition of various adaptors. This eliminates the purchase of larger, more expensive mandrels for each hear ing. It also provides for greater versatility and is adaptahle to other products. NOTE: DO NOT order individual tools, following, if C A 1 is ordered. C Nut, puller C Washer, pull er C Plate, puller C Shaft, pulier C Dr iver Head C Adaptor, bearing C Puller, head C Driver Head C Driver Head C Rod, driver C Washer, pilot 272R1 TOOLS 9-1

6 7. C A2 - PISTON PIN TOOL Retains piston pin needle bearings during installation of piston on connecting rod. 8. C FLYWHEEL HOLDER Holds flywheel while removing or torquing flywheel nut. 9. C Al - LOCK RING TOOL - PISTON PIN Removes and installs piston pin lock rings. 10. C BEAR ING ADAPTOR Installs crankcase roller bearing with C Al kit. " 11. C SPACER FORK (Centermain Bearing) Aids installation of centermain bearing assembly to correct depth. 12. C FLYWHEEL PLUG Used in removal of flywheel from crankshaft with.. 5/8-18 bolt from clip former tool....~'" 13. C RIN G COMPRESSOR Compresses piston rings for installation of pistons into cylinders. 14. C PROTECTOR CAP Protects threads on flywheel stud during removal of clutch bell. 15. C Al - PISTON PIN TOOL Removes (and installs) piston pin from pisto n. 16. C BEA RING ADAPTOR Installs crankcase ball bearing with C Al kit C CLUTC H CLAMP Holds sliding half of clutch for installation of clutch bell assembly. 18. C ADAPTOR, TORQU E WRENCH To torque cylinder nuts with C torq ue wrench. 19. C OIL SEAL PROTECTOR Prevents damage to adaptor oil seal when installing on front drive shaft. 20. C PULLER PLATE SPROCKET Removes sprocket from jackshaft. 21. C Al - DR IVE N SHEAVE WEDGE Removes driven sheave from jackshaft. 22. C A l - LOCKR ING INSTALLING TOOL Aids in installing piston pin lockrings T OOLS 272R1

7 1. C TRUARC SNAP RING PLIERS (Expanding Type) Removes and installs snap rings. 200 MODEL 2. C A1-BELTWRENCH Holds flywheel while removing flywheel nut C SNAP RING PLIERS (Compressing Type) Removes and installs snap rings. 4. C ~ - OIL SEAL DRIVER Installs oil seal in crankcase. 5. C PULLER PLATE, BALL BEARING For pulling hearings from end of crankshaft. 6. C A1- PULLER Separates crankcase halves. 7. C A1 - PISTON PIN TOOL Removes and installs piston pin and piston pin hearings. 8. C PULLER PLATE SPROCKET Removes sprocket from jackshaft. 9. C DRIVE SHEAVE PULLER Removes drive sheave from crankshaft. 10. C SPR ING TOOL Installs roller arm springs on sliding half of drive sheave. 11. C BOGIE WHEEL SUPPORT PLATE Supports hogie wheel hearing during removal from hogie tuhe R1 TOOl S- 9-3

8 ROCKET and LIGHTNING MODELS 1. C A1-BELTWRENCH Holds flywheel while removing flywheel nut. 2. C PULLER PLATE, BALL BEARING Fo r pulling bearings fro m end of crankshaft. 3. C FLYWHEEL HOLDER Holds flywheel while removing or torquing flywheel nut. 4. C RING COMPRESSOR Compresses pisto n rings for installation of pistons into cylinders. 5. C A1 - PISTON PIN TOOL Removes (and installs) piston pin from piston. 6. C PULLER PLATE SPROCKET Removes sprocket fro m jackshaft. 7. C DRIVE SHEAVE PULLER Removes drive sheave from crankshaft. 8. C DRIVE SHEAVE HOLDER Holds drive sheave while removing or torquing sheave. (Superseded by C ) 9. C SPRING TOOL Installs roller arm springs on sliding half of drive sheave. 10. C BOGIE FLIPPER Flips bogie wheel sets from shippin g to runmng position TOOLS 272Rl

9 1. C EXPANDING PLIERS Removes and installs snap rings. HURRICANE (644cc) MODEL 2. C SNAP RING PLIERS (Compressing Type) Removes and installs snap rings. 3. C A1- BEARING REMOVING AND INSTALL- ING KIT A bearing removing and installing kit allows addition of various adaptors. This eliminates purchase of larger, more expensive mandrels for each hearing. It also provides for greater versatility and is adaptable to other products. NOTE: DO NOT order individool tools, following, if C Al is ordered. C Nut, puller C Washer, puller C Plate, puller C Shaft, puller C Driver Head C Adaptor, bearing C Puller, head C Driver Head C Driver Head C Rod, driver C Washer, pilot 4. C PULLER PLATE - BALL BEARING For pulling bearings from end of crankshaft. 5. C A1 PULLER Part of idler arm removal tools. 6. C A2- PISTON PIN TOOL Retains piston pin needle bearings during installation of piston on connecting rod. 7. C FLYWHEEL HOLDER Holds flywheel while removing or torquing flywheel nut. 8. C Al - LOCKRING TOOL - PISTON PIN Removes and installs piston pin lockrings. 9. C DRIVE SHEAVE PULLER Removes drive sheave from crankshaft. 272R1 TOOLS - 9-5

10 f 'H 10. C SPRING TOOL Installs roller arm springs on sliding half of drive sheave. 11. C A1 - LOCKRIN G INSTA LLING TOOL Aids in installing piston pin lockrings. 12. C DRIVE SHEAV E HOLDER Holds drive sheave while removing or torquing sheave C Al - ADAPTOR (Compression Gauge) Adapts standard compression gauge to 18mm spark plug hole. 14. C EXHAUST PIPE TOOL Used for installing and removing exhaust pipe on cylinder. 15. C BOGIE WHEEL SUPPORT PLATE Supports bogie wheel hearing during removal fro m hogie tube. 16. C ENGINE STAND Used to support engine for ease of disassembly and reassembly. 17. C A2 - TIMING FIXTURE Used to static-time the ignition. 18. C RING COMPRESSOR Compresses piston rings for installation of pistons into cylinders. 1B 9~ - TOOLS 272Rl

11 GENERAL 1. HELI-COll KITS No. of Kit No. Size Inserts oc a1 y OC A1 5/ oc a4 14mm Spark Plug 20 OC / C / C mm Spark Plug o Superseded by Keensert Kits Each Heli-Coil Kit listed above contains one Heli-Coil tap, one inserting tool and a supply of inserts for the given thread, plus instruction pamphlet. Packed in reuseable clear plastic box es. Heli-Coil Inserts C y x 3/8" C y x 3/8" C /16-18 x 13/32" C /8-16 x Yo" C mm.242 (Die-Cast Blocks) C mm Heli-Coil C mm Heli-Coil Inserts (5) NOTE: Order separate replacement pieces if y ou already have the heli-coil kits: Replacement Pieces Part No. Description C mm Heli-CoiI Tap C Heli-Coil Tap 5/ 16 x C CAP SCREW DRIVER 272Rl TOOLS - 9-7

12 3. C A2 - FLYWHEEL PULLER Pulls flywheel. NOTE: For use on 200, Rocket and Lightning Models, modify puller by drilling holes marked "A " on template at right. Also order 3 screws (2~"x6mmj (C-1O-58174j. (a) C-lo Replacement Center Screw, '12-13 C l Replacement Center Screw, '12-20 (b) C-l Replacement Screw, %-20 C-l Replacement Screw, %-28 C-lo Replacement Screw, 5 / 1 ~2 4 Trace This Template fo r Modification Puller C A2. of Flywheel 4. C PISTON RING EXPANDER Removes (and installs) piston rings from pistons. 5. C MAGNETO ANALYZER Analyzes complete ignition system with out removing magneto or distributor from engine. C Batte ry, Analyzer (7'12 Vo lt) 6. C TORQUE WRENCH A 300 in. lb. (53.25kg/cm) torque wrench with 3/8" (9.53mm) drive. Used to accurately torque connecting rod nuts, screws, spark plugs, etc TOOLS 272Rl

13 I 7. C A3 - END CAP PULLER - UNIVERSAL Removes crankcase end caps without disassembling powerhead. Used to remove Hurricane (644cc) flywheel. C-l Screw x 2% C-l Screw, center puller C-l Screw %-20 x 3 C-1O Screw x 2-1/16 C Nut %-20 7 Trace This Template for Modification of End Cap ~ Puller C A3. ~ o DRILL 2 HOLES (11/32") o ~ ~O do o 00 0 o ~ o DRILL 4 HOLES (9/32") 8. C COMPRESSION TESTER 1lI~~~~ Tests compression in cylinders. Registers O-to-200 lbs. ~ per sq. in. 9. C FUEL PRESSUR E GAUGE For engine testing... "clean" dial indicates fuel pressures up to 15 lb. sq. in. (1.055kg/cm 2 ). 10. C UN IV ERSAL ELECTRONIC SERVI CE TACHOMETER and DWELL METER All 2 or 4-cycle engines. RPM, to 10,000. Dwell reading for snowmobiles, outboards, inboards and auto ignitions. C Sensing Ring (For C ) (Superseded by C ) 11. C TORQUE WRENCH A 200 ft. lb. (27.6mkg) torque wrench with %" (12. 7mm) drive. For torquing flywheel nuts, spark plugs, etc. 775R 3 TOOLS ~-~----

14 12. C A 1 - SLID E HAMMER PULLER Used as part of idler arm installing tools and bearing removal. Also fits other applications. C Jaws - Replacement, Slide Hammer Puller 13. C A2 - TIMING LITE Accurately " times" any 2 or 4-cycle engine with 12-volt DC system. Molded plastic case virtually unbreakable, light weight, modem design. Operates without "spark lag" throughout entire RPM range, from idle position to wide-open throttle. 14. C PISTOLUBER GREASE GUN High pressure 12" flexible hose allows easy access to grease fittings o n snowmo biles, outboards and stern drive units. Multipurpose Lubricant (C ) tube screws directly on grease gun to prevent possible contaminat ion of lubri cant. Light weight and easy-touse, the Pistolub er Grease Gun is ideal for resale to customers. 15. C TIMING LEAD Used to connect timing lite between spark plug and spark plug protector. 16. C VOA (VOLT-OHM AMPERE) EL ECTRI CA L T ESTER Used to test components of ignition systems. 17. C CLIP FORMER TOOL Installs clips and washers in track. C l Bolt, Clip Former Too l 18. C DIAL INDICATOR Sets timing. (Superseded by C Al) TOOLS 775R3

15 19. C (Supersedes C ) - UNIVERSAL ELECTRONIC SERVICE TACHOMETER and DWELL 20. C KEENSERTS, SPARK PLUG MASTER KIT C Keenserts. Spark Plug Refill Kit C Keenserts,14-20 Thread Repair Kit C Keenserts Refill Kit C Keenserts. 5/16-18 Thread Repair Kit C Keenserts, 5/16-18 Refill Kit C Keenserts. 3/8-16 Thread Repair Kit C Keenserts, 3/8-16 Refill Kit C A1 -THUNDERBOLT IGNITION ANALYZER The analyzer will test and locate defective components in all Mercury Marine Thunderbolt Ignition Systems. Consists of a tester and VOA meter. 775R3 TOOLS 9-11

16 LUBRICANTS, ADHESIVES and SEALERS 1. C COMPOUND (DC4) 1A. C GLU E (2 oz. tube) 2. C NEOPR ENE (% pint) Seals electrical connections to prevent corrosion. 3. C ADHESIVE COMPOUND Used to apply assorted-color emblems (medallions)... 3% oz. kit sufficient to apply 15 to 20 medallions C GASKET SEALER COMPOUND Used between crankcase and cylinder block as a machine d surface seal. (Superseded by C ) 5. C CORROSION and RUST PREVENTIVE (Case of 12 cans) (Superseded by C ) 6. C MARINE CLEANER (Case of 12 cans) (Superseded by C ) 5 6 marine cleaner Q uoc-.. Corrosion ant rust preventi v ' 7. C LOCT IT E TYPE " A" (locc) 8. C EPOXY KIT TOOLS 775R2

17 9. C ANTI-CORROSION GREASE Specially processed to provide a good lubricating coating for all external moving surfaces. (Case of 12-8 oz. cans) (Superseded by C ) 10. C MULTIPURPOSE LUBRICANT For lubrication of ext ernal parts... high dielectric qualities... 8 oz. tub e. (Case of 12-8 oz. tubes) (Superseded by C ) l~t --- / ~ - H ~ I ~,f I ;: (J.Q S ~~ i~ 11 t 11. C STORAGE SEAL (Case of oz. spray cans) (Superseded by C ) Q""_... storage seal 12. C LOCQUIC PRIMER GRADE "T" (6 oz. spray can) Used with Loctite to accelerate curing speed C RESIWELD EPOXY KIT Bolt retainer compound, to be used on end cap bolts of 644cc engines. 14. C FORMULA 50-D OIL (Case of 48-8 oz. cans) 14 ~~~! QU'C.K.'LV." 15. C SNOWMOBILE OIL (Case of oz. cans) 775R2 TOOLS

18 440 MAX, 440 MIX and 440 SIR MODELS I 1. C EXPAND ING PLI ERS Removes and inst alls snap rings. 2. C A l - BELT WRENCH Holds drive sheave while removing (instal ling) sheave, 3. C SNAP RI NG PLIERS (Compressing Ty pe) Removes and installs snap rings. 4. C A 1 - FIXED JET REMOVAL TOOL Assures easy removal of fixed high speed jets from carburetors. 5. C A1 - BEARING REMOVING and INSTALLING KIT A bearing removing and installing kit allows addition of various adaptors. This eliminates the purchase of larger, more expensive mandrels for each bearing. It also provid es for greater versatility and is adaptable t o other products. NOTE: DO NOT order individual tools, following, if C Al is ordered. C Nut, puller C Washer, puller C Plate, puller C Shaft, puller C Driver Head C Adaptor, bearing C Puller, head C Driver Head C Driver Head C Rod, driver C Washer, pilot 6. C PULLER PLATE, BALL BEARING For pullin g bearings from end of crankshaft. 7. C FLYWHEEL HOLDER Holds flywheel while removing or torq uing flywh eel nut. 775R2 TOO LS

19 8. C RING COMPRESSOR Compresses pisto n rings for installation of pistons into cylin ders. 9. C Al - DRIVE SHEAVE PULLE R Removes drive sheave from crank shaft. 10. C PISTON PIN TOOL Removes (and installs) piston pin from piston. 11. C Al - PULLER CROSS BLOCK KIT Used to remove bogie wheels and idler arms if an arbor press is unavailable. NOTE: DO NOT order individual tools, foll owing, if C A 1 is ordered. C-l Bolt, cross block to puller plate C Washer, pilot C Washer, bolt support 12. C IDLER ARM PLATE 12 Used to pull idler arms. 13. C BOGIE WHEEL SUPPORT PLATE Supports bogie wheel bearing during removal (installation) from bogie tube TOOLS 1272

20 MARK I (644cc) and MARK n (644cc) MODELS 1. C EXPANDING PLIERS Removes and installs snap rings. 2. C A1 - BELT WRENCH Holds drive sheave while removing (installing) sheave. 3. C SNA P RING PLIER S (Compressing Ty pe) Removes and installs snap rings. 4. C A1 - FIXED JET REMOVAL TOOL Assures easy removal of fixed high speed jets from carburetors. 5. C A1 - BEA RING REMOVING AND INSTA LLI NG KIT A bearing removing and installing kit allows addition of various adaptors. This eliminates purchase of larger, more expensive mandrels for each bearing. It also provides for greater versatility and is adaptable to other products. NOTE : DO NOT order individual tools, fo llowing, if C Al is ordered. C Nut, puller C Washer, puller C Plate, puller C Shaft, pull er C Driver Head C Adapto r, bearing C Puller, head C Driver Head C Driver Head C Rod, driver C Washer, pilot 6. C PUL LER PLA TE, BALL BEAR ING For pulling bearings from end of crankshaft. 7. C A2 - PISTON PIN TOOL Removes (and installs) piston pin from piston. Retains piston pin needle bearings during installation of piston on connecting rod TOOLS

21 8. C FLYWHEEL HOLDER Holds flywh eel while removing or torquing flywheel nut. 9. C Al - LOCKRING INSTALLING TOOL Inst alls piston pin lockrings. 10. C ENGINE STAND Used to support engine for ease of disassembly and reassembly. 11. C RIN G COMPRESSOR Compresses piston rings for installation of pistons into cylinders. 12. C Al - DRIVE SHEAVE PU LLER Removes drive sheave from crankshaft, 13. C Al - PULLER CROSS BLOCK KIT Used to remove bogie wheels and idler arms if an arbor press is unavailable. _---' o[llj j NOTE: DO NOT order individual tools, following, if C Al is ordered. C-l Bolt. cross block to puller plate C Washer. pilot C Washer. bolt support 14. C IDLER ARM PLATE Used to pull idler arms. 15. C BOGIE WHEEL SUPPORT PLATE Supports bo gie wheel bearing during removal (installation) from bogie tube, 16. C RIN G COMPRESSOR Compresses piston rings for installation into cylinders. 17. C EXHA UST PIPE TOOL Used for installing (and removing) exhaust pipe on cylinder TOOLS 374 R 1

22 340 SIT, 400 SIT, 440 SIT, 340 TIT and 440 TIT MODELS 1. C SNAP RING PLI ERS (Expanding Type) Removes and installs snap rings. 2. C Al -BELTWRENCH 3. C SNAP RING PLIERS (Compressing Type) Removes and installs snap rings. 4. C A 1 - PISTON PIN TOOL Removes (and installs) piston pin from piston. 5. C PULLER PLATE, BALL BEARING For pulling hearings from end of crankshaft. 6. C A l - DRIVE SHEAV E PULLER Removes drive sheave from crankshaft (all mod els, except 400 SIT). 7. C SPANNER WRENCH For use in adjusting suspension shock absorbers, 8. C TIMING TOOL Used to static-time the ignition. 775Rl TOOLS ~-19

23 340 SIR MODEL 1. C A1 - PISTON PIN TOOL Removes (and installs) piston pin from piston C SNAP RING PLIERS (Expand ing Type) Removes and installs snap rings C A1 - BELT WRENCH 3 4. C SNAP RING PLI ERS (Compressing Type) Re moves and installs snap rings C PULLER PLATE, BALL BEARING Fo r pulling bearings from end of crankshaft. 6. C A1 DR IVE SHEAVE PUL LER Removes drive sheave from crankshaft C SPANNER WRENCH Fo r use in adjusting suspension shock absorb ers TOOLS 775