Snowmobiles. 340 TRAILFIRE and TRAILFIRE LX ALE THIS NEW MANUAL. Horicon W rks. OM-M69139 Issue E1 LITHO IN USA. (Serial No.

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1 340 TRALFRE and TRALFRE LX Snowmobiles (Serial No. 190,001-~t)(X) ) ~ JOHN DEERE ALE THS NEW MANUAL Horion W rks OM-M69139 ssue E1 LTHO N USA

2 a To The Operator n 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. Reord the snowmobile and engine serial numbers in () the spae below. M28303 Snowmobile Serial Number This operator's manual is prepared for the following snowmobiles: John Deere 340 TRALFRE (Serial No. J34FL M- ) John Deere TRALFRE LX (Serial No. J44FL 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 w a: w... ::;) u 1. Skis 2. Windshield 3. Rear Bumper and Snow Flap Support 4. Operator's Manual 5. Bag of Parts 6. Fuel Tank Cap and Gauge. Chek Contents of Bag of Parts A - Ski Spring Stop (2 used) B - Ski Pivot Bolt (2 used) C x 314-lnh Flat Washer (2 used) D lnh - 24 Lok Nut (2 used) E - Cotter Pins (2 used) F - gnition Keys (2) G - Windshield Retaining Rings (7 used) H - John Deere Medallion x lnh Cap Srews (4 used) J x 1 12-lnh Flat Washer (6 used) K lnh - 20 Lok Nut (6 used) L x lnh Cap Srews (2 used) NOTE: Hith plate and otter pin (not shown) are inluded in the bag of parts with the 440 Trailfire Snowmobile only. M27880 nstall Skis NOTE: Bushing is fatory inst~lled in steering spindle. 1. nstall rubber ski spring stop over spindle. Stop is held in plae by the ski sa d~le. 2. Position ski so that rear hole of ski is aligned with spindle. nstall ski bolt with head of bolt faing out. 3. nstall X 31 4-inh flat washer and 318-inh lok nut. Torque nut to 39 ft-lbs (52 Nm). nstall otter pin through bolt. f.f24900

4 nstall Windshield 1. Bend a hook on the end of a 3/32-inh brazing rod. 2. Plae windshield on hood. 3. Plae the bent end of the rod through the hole in the windshield and hook the 0-ring. 4. Pull the 0-ring halfway through hole and remove hook. nstall Rear Bumper Assemble rear bumper and snow flap support to tunnel as shown. A-Snow Flap Support B-Rear Bumper C-1/4 x 1-3/4-lnh Cap Srew D-1/4 x 1-1/2-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 desired 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 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. Start engine and hek idle speed. 6. Chek emergeny stop and key swith. 7. Chek operation of all lights. 8. Aim and adjust headlight. 9. Test drive or dynamometer test snowmobile. 10. nstall aessories desired by ustomer. 11. Chek hain ase oil level. 1. Explain operator's manual to ustomer. 2. nstrut ustomer about snowmobile operation. 3. Explain fuel and oil injetion system (Trailfire LX). Use regular (leaded or non-leaded) gasoline with an anti-knok index of 88 or higher. DELVERY CHECK LST (_ 4. Explain to ustomer the use of pre,.mix gasoline and oil in a 50:1 ratio for the first tank of fuel (Trailfire LX). Customer should also fill the oil tank with John Deere 2-Cyle Oil or a BA ertified 2-yle engine oil. After break-in use gasoline only in fuel tank and 2-yle oil in oil tank. 5. On 340 Trailfire, use a 40:1 ratio for the first tank of fuel and a 50:1 ratio thereafter. 6. Tell ustomer about 10-hour or 200 mile hek up. 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.

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7 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 1 0 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 reguired, not overed by warranty, will be harged to you should you deide to have the work done. The inspetion hek list is as follows: OKAY 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. (Steering arms, tie rods and handlebars). DEALER COMMENTS: Dealer Name Town Date

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9 1 Contents Page Safety dentifiation Preparation Trailfire Mix Fuel Fill Fuel Tank Trailfire LX Fill Fuel Tank Fill Oil Tank Fuel Mix For Break-n Period Fuel For Temperatures Of - 20 F ( - 29 C) or Below Operation Break-n Period Before Operating Starting Engine Stopping Engine Lights Towing Clearing Trak Dressing For The Weather Transporting Servie Servie nterval Chart Spark Plugs Carburetor and Oil njetion Pump Choke System Adjusting Choke Plunger Adjusting Throttle Cable Adjusting Oil njetion Pump Cheking Float Level Oil njetion Pump n-line Oil Filter Main Jet Chart n-line Fuel Filter Air ntake Silener Cheking Fan Belt Tension Page 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 Bulb Replaing Speedometer and Tahometer Bulbs Lubriation Steering Column Bushing Trak Drive Shaft Bearing Tightening Hardware and Components Adjusting Glove Box Door Lath Storage Trouble Shooting Speifiations Aessories :

10 Safety CAUTON: mproper use or maintenane by the operator an result in injury. Follow these safety suggestions. 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 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 pages 6 and 7. M23365 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. A void 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". 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.

11 Safety 3 r 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. M23364 f throttle stiks, don't pani. Turn emergeny stop swith on the right-hand handlebar. See page 9. 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. M23366

12 4 Safety 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 1 0. 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. M

13 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 ) J M28304 A-Snow Flap B-Hith (TRALFRE LX only) C-Rear Bumper D-Stop-Taillight E-Seat F-Throttle Control G-Fuel Tank H-Hood - Ski Handle J -Reoil 'Start K-Trak L-Snowmobile Serial Number ' M28305

14 Preparation 340 TRALFRE 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 33. 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 A CAUTON: Use safe refueling proedures. 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.

15 Preparation 7 TRALFRE LX FLL FUEL TANK MPORT ANT: Use regular leaded or non-leaded gasoline with an anti-knok index of 88 or higher. Never use gasoline that has been stored for a long time. NOTE: Regular (leaded) gasoline is preferred but non-leaded gasoline is aeptable. NOTE: When running snowmobile in powder snow or blowing snow add gasoline de-ier to the fuel tank. Use ONLY one 12 oune an per tank of fuel. CAUTON: Exessive amounts of gasoline de-ier will lean out the fuel mixture and ould ause engine damage. NEVER ALLOW OL TANK TO BECOME EMPTY. Use John Deere 2-yle oil or a BA approved 2-yle engine oil. Oil tank holds 3.5 U.S. pints (1. 7 L). MPORT ANT: f other than John Deere 2-yle oil is used, it must meet BA (Boating ndustry Assoiation) test qualifiation TCW. Never use dirty or ontaminated oil. The oil and oil tank must remain lean to avoid oil injetion pump failure and engine damage. FLL OL TANK M28307 For the first tank of fuel, pre-mix gasoline and oil in a 50:1 ratio (1 pint of oil with 6 U.S. or 5 mperial gallons) and fill fuel tank. Fill the oil tank with John Deere 2-yle oil or its equivalent. After the break-in period, use ONLY GASOLNE in the fuel tank and John Deere 2-yle oil or its equivalent in the oil tank. FUEL MX FOR BREAK-N PEROD FUEL FOR TEMPERATURES OF -20 F (-29 C) OR BELOW MPORTANT: Use a 50:1 gasoline and oil pre-mix in the fuel tank and fill the oil tank with 2-yle oil. DO NOT use straight gasoline in the fuel tank. The oil injetion system may not funtion effiiently at - 20 F (- 29 C) and this ould ause engine failure.

16 Operation BREAK-N PEROD 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. BEFORE OPERATNG 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. Normal Choke Riher Choke STARTNG ENGNE 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 extremely 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.

17 Operation 9 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. Raise the hood. Raise the belt guard. 2. Plae start rope from tool kit around primary luth as shown. 3. Pull on rope to start engine. M28308 STOPPNG ENGNE 1. Release throttle lever. 2. Turn emergeny stop swith up or down. 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.

18 10 Operation 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 25 and 26 for adjusting headlight and hanging bulbs. M24911 TOWNG CAUTON: Always use a solid tow bar when possible. Flexible ropes or pull straps do not allow for ontrol on turns or for stopping. 1. Remove the drive belt. 2. Connet only one ski of disabled mahine to the tow mahine. 3. DO NOT use rear bumper for towing. M When towing with a rope or strap, run rope through ski handle and around ski spindle. Do not loop rope or strap through both skis. This may damage the steering tie rod. CLEARNG TRACK 1. Clear trak after operating in slushy snow. 2. Tip mahine on its left side until trak lears the ground. 3. Spin trak at moderate speed until snow and ie are thrown lear. h CAUTON: Be sure no one is behind maft hine when learing trak. njury ould result from ie or roks thrown from trak. MPORTANT: f trak freezes, free it manually. Do not use the engine to break trak loose. The drive belt will be burned and damaged.

19 Operation 11 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. CAUTON: Always wear a snowmobile helmet. The helmet provides both warmth and protetion against head injury. WND CHLL CHART 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 tional effet.) person) Danger from freezing of exposed flesh M10123 TRANSPORTNG Close fuel shut-off valve when transporting the snowmobile. Shut-off valve should also be losed when snowmobile is stored. Valve is off when handle is straight up. M28309

20 Servie SERVCE NTERVAL CHART Every Every As tem Needed Daily Miles Miles Annually Page Clean windshield. X 8 Chek on~ition of skis and steering. X 23,24 Chek trak ondition and tension. X 21,22 Chek throttle ontrol operation. X 14,15,16 Chek operation of brakes. X 20 Chek emergeny stop and key swith. X 9 Chek lighting system. X 10 Chek hain ase oil level. X 20 Chek hain tensioner. X 20 Chek in-line fuel filter.. X 18 Chek in-line oil filter. X 17 Chek oil injetion pump. X 17 Grease L.H. trak drive shaft bearing. X 27 Grease steering olumn bearing. X 27 Chek drive belt ondition. X 19 Chek arburetor adjustments. X X X 14,15,16 Chek hoke adjustments. X X X 14 Chek fan belt tension. X X 18 Chek ski alignment. X 24 Chek headlight adjustment. X 25 Chek.ski wear rods and wear plates. X X 23 Chek slide suspension wear bars. X X 21 Lubriate throttle able. X 16 Chek all omponents for ondition and tightness. X 28 Servie drive and driven sheaves. X 19 Store snowmobile properly. X 29

21 Servie 13 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 spark plug wire 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 Tan or Cooa Brown Blak or Sooty White or Light Tan Possible Cause 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 20 ft-lbs (27 N m) torque. 3. Connet spark plug wires.

22 16 Servie Adjusting Oil njetion Pump MPORTANT: The oil injetion pump lever must be adjusted to move off the peg at exatly the same time that the arburetor throttle valves start to rise. Adjust oil injetion pump as follows: 1. Loosen the two jam nuts seuring the oil injetion pump ontrol able adjusting sleeve. 2. Bak sleeve out to tighten able or turn in to loosen able. Cable should have slight free-play; it should not be strethed tight. 3. Press the throttle lever on the handgrip and observe throttle valve and oil injetion pump ontrol lever. The throttle valve and lever should start to move at exatly the same time. 4. When adjustment is orret, tighten the jam nuts seuring the oil injetion pump ontrol able adjusting sleeve. M28310 MPORT ANT: Lubriate throttle able one eah season with LPS or WD-40. Hold the throttle lever against the handgrip and allow lubriant to run down able. DO NOT use engine oil or silion spray. These lubriants may destroy the plasti omponents of the throttle able or ause ontrol able to beome stiky in old temperatures. Cheking Float Level NOTE: The fuel level in the float mixing hamber is regulated by the float. 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 B-Fioat Arm

23 Servie 17 Chek oil flow annually. See your John Deere dealer for this servie. OL NJECTON PUMP N-LNE OL FLTER Replae oil filter annually or immediately if oil level in tank does not drop. Minimum oil level at bottom of tank must be 3 inhes (76 mm) for oil pump to funtion orretly. \\ ' M28312 MAN JET CHART Carburetor and luth hanges, adjustments, or modifiations may be neessary for operation at altitudes above 4000 feet. See your John Deere dealer. TEMPERATURE SNOWMOBLE 0 F and Below 0 F and Above - 18 C and Below - 18 C and Above ALTTUDE Main Jet Main Jet 340 Trailfire * Trailfire LX * Sea Level to 4000 Feet (1 219 m) *Fatory nstalled

24 18 Servie N-LNE FUEL FLTER Change the filter annually or when ontamination builds up. 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. 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.

25 Servie 19 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 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. 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 the left-hand side of the snowmobile. NOTE: As belt wear inreases or if belt strethes, remove spaer washer (A) from behind retaining washer (8). 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. A- Spaer Washer 8-Retaining Washer

26 20 Servie 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 AP-GL5 gear oil until it flows from lower hole. 4. nstall plugs. M?R.'=114 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.

27 Servie 21 SLDE SUSPENSON The slide suspension system requires lubriation between the plasti wear bar and metal grouser bar. The absene of lubriation (snow or water) auses the plasti wear bar to wear rapidly and in severe ases, literally melt away. Operation of the snowmobile under the following onditions should be avoided. 1. Dirt 2. Roks 3. Sand 4. Grass 5. Bare Pavement 6. Snow permeated with dirt and sand. 7. Glare ie surfaes MPORT ANT: When running on ie or hard paked snow at high-speed, the wear bars will heat up. Either redue speed, or frequently stop and apply ie or snow to the trak to lubriate the wear bars. 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. 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) an 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. A-Jam Nuts B-Adjusting Srews

28 22 Servie 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 B-Top Position

29 Servie 23 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. M23322Y. 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. M26?14 A- Cotter Pin B-Drilled Pin C- Wear Plate

30 24 Servie 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. 2. Disonnet drag link from steering arm. 3. Loosen jam nuts on tie rod ends. Gold-olored tie rod has left-hand threads. Loosen nuts opposite normal rotation. 4. Turn tie rod to align skis. Measure from straight edge of skis; not tapered ends. Distane should be equal at loations shown. MPORTANT: DO NOT exeed 1-5/16 inhes (33.34 mm) between tie rod. and enter of tie rod end when adjusting tie rod. 5. Tighten jam nuts on eah end of tie rod (A). Hold tie rod when tightening jam nuts. This prevents stripping threads in ball joint. MPORTANT: After jam nuts are tight, be sure tie rod ends swivel freely. 6. Turn drag link (B) as required to position handlebars straight ahead. Reonnet drag link to steering arm. U\11 M Eliminating Loose Steering /). 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). 3. Replae or tighten parts as required.. A-Tie Rod End B-Spindle Bushing

31 Servie 25 LGHTNG SYSTEM 25' (7.6 m) 16-1/ 4" (41.2 em) M Ad justing 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.

32 26 Servie Replaing Headlight Bulb 1. Disonnet wiring harness from the light bulb. 2. Push and turn bulb ounterlokwise to remove bulb. 3. nstall new bulb in opposite sequene. MPORTANT: Be sure bulb loking tabs math slots. 4. Connet wiring harness to light bulb. Replaing Stop-Taillight Bulb 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 and Tahometer Bulbs 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.

33 Servie 27 LUBRCATON Steering Column Bushing Lubriate grease fitting at the lower end of the steering olumn one eah year. This should be done prior to the summer storage period. Apply 2 to 3 shots of multipurpose grease. M28318 Trak Drive Shaft Bearing The left-hand bearing is subjeted to large amounts of water during some types of running. The bearing should be re-lubriated after any exessive use in very wet onditions. Use 2 to 3 shots of multipurpose grease. Also lubriate the bearing when the snowmobile is prepared for summer storage. M28319

34 28 Servie TGHTENNG HARDWARE AND COMPONENTS M28320 Chek hardware and omponents for tightness, wear and damage on a yearly basis. Replae any parts that are questionable. A CAUTON: Worn, bent or damaged ski and.. steering omponents are unsafe. 1. Wear ~od 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 lamp. 8. Throttle and hoke ables. 9. ntake manifold nuts. 10. Carburetor attahment. 11. Engine mounting bolts. 12. Drive sheave ap srew. 13. Suspension ap srews. 14. Shok absorber srews. Adjusting Glove Box Door Lath 1. Open glove box door. 2. Loosen srews and move lath forward or rearward. 3. Tighten srews. M28321

35 29 Plaing Snowmobile 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. Drain fuel tank until there is approximately 1 gallon ( L) of fuel in the tank. Add 2 ounes (59.1 ml) of fuel stabilizer to the fuel tank. Run engine for 5 minutes to distribute the fuel through the system and arburetor. Drain fuel tank. 5. Replae in-line fuel fifter. 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. Storage 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 oil tank (Trailfire LX) and fuel tank. 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.

36 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.

37 Trouble Shooting 31 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.

38 Speifiations SNOWMOBLE SPECFCATONS Component tem 340 TRALFRE TRALFRE LX Engine Manufaturer John Deere " Fireburst"* John Deere " Fireburst" * Model TA340A TA440A No. of Cylinders 2 2 Bore 60 mm 68 mm Stroke 60 mm 60 mm Displaement Fuel System Carburetor Manufaturer Mikuni Mikuni Carburetor No. AM55053 AM55054 Tank Capaity 7.5 Gals. (28.4 L) 7.5 Gals. (28.4 L) Fuel Mixing Ratio See page 33 See page 33 Chassis and Body Tunnel Alum inum Aluminum Pan Thermoplasti Rubber Thermoplasti Rubber Hood Sheet Molded Compound Sheet Molded Compound Windshield Polyarbonate Polyarbonate Overall Length 102 in. ( mm) 102 in. ( mm) Overall Width 37 in. (939.8 mm) 37 in. (939.8 mm ) Overall Height 37 in. (939.8 mm) 37 in. (939.8 mm ) Weight (Approx.) 370 lbs. (1 67 kg) 375 lbs. (170 kg) Trak and Suspension Suspension Slide Suspension Slide Suspension Trak Material Rubber Rubber Trak Width 15-3/ 4 in. (400 mm) 15-3/ 4 in. (400 mm) *Manufatured for John Deere by Kawasaki Heavy ndustries, Japan

39 Speifiations 33 SPECFCATONS-Continued Component tem 340 TRALFRE TRALFRE LX Power Train Transmission 2-Sheave Variable 2-Sheave Variable Manufaturer: Primary John Deere (Comet)* John Deere (Comet)* Model 102C (Comet) 102C (Comet) Seondary John Deere John Deere Final Drive Ratio: 2.06:1 (Standard) 1.86:1 (Standard) Brake Mehanial Disk Mehanial Disk Drive Belt M66345 M66345 Eletrial System Spark Plug (Champion) QN-3 (AM53941) QN-3 (AM53941) Spark Plug Gap in. (0.635 mm) in. (0.635 mm) Timing 22 BTDC with engine run- 22 BTDC with engine running ning at 6000 rpm (.1 09 in. at 6000 rpm (.109 in. BTDC) BTDC) (2.76 mm BTDC) (2.76 mm BTDC) Lighting Coil Capaity 120 Watts 120 Watts Light Bulbs: Headiight AM53887 AM53887 Taillight AM52619 AM52619 Speedometer AM52847 AM52847 Tahometer AM52847 AM52847 *Manufatured for John Deere by Comet ndustries, Rihmond, ndiana 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) (18.9 L) (0.473 L) (18.2 L) 50:1 1 pt. 6 gal. 1 mperial pt. 5 mperial gals. (0.473 L) (22.7 L) (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.)

40 Aessories Speedometer Tahometer Protetive Cover Hith Bak Rest Kit Eletri Start Kit Trak Stud Kit Sport Seat Extra Coverage Windshield Handlebar Heater Kit Suspension Wheel Kit

41 MEMORANDA 35

42 36 MEMORANDA

43 37 MEMORANDA

44 38 MEMORANDA

45 MEMORANDA 39

46 40 MEMORANDA

47 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. j_ PARTS CATALOG John Deere Distribution Servie Center Department SP rd Ave. Moline, ll Please send to.. Name Address Town State Zip Order Prie Title No. Qty. Eah Parts Catalog 340 and 440 TRALFRE PC $ 3.00 Snowmobile Operator"s Manual 340 and 440 TRALFRE OM-M69139 $ 1.20 Snowmobiles Servie or Tehnial Manual 340 and 440 TRALFRE TM-1197 $14.00 Snowmobiles 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. llinois State Residents add 5% for ROT. o: Chek or money order in U.S. dollars enlosed... Total (Do not send ash or stamps) 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'S MANUAL - -= D 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. SP-317 Li1ho in U.S.A. MAR-78 PriCes subjet to hange w~hout notie.

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