//'1\/ SAFETYNOTICE TheBombardier snowmobile Shop manualhasbeenprepared inorder to assist skilled rnechanic's intheefficientrepairandmaintenanceofBombardiersnowmobiles, SafetyfeaturesmaybeimpairedifotherthangenuineBombardierpartsareinstalled, Torquewrenchtighteningspecificationsmustbestrictlyadheredby,Lockingdevicesmustbe installed or replacedby new ones,where specified,If the efficiency of a locking device isimpaired, itmustberenewed, Thismanualemphasizesparticularinformationdenotedbythewordingandsymbols; o WARNING:Identifiesaninstructionwhich,ifnotfollowed,couldcausepersonalinjury, CAUTION:Denotesaninstructionwhich,ifnotfollowed,couldseverelydamagevehicle components, NOTE:Indicatessupplementaryinformationneededtofullycompleteaninstruction, Although the merereadingof suchinformation does not eliminate the hazard,your understanding oftheinformationwillpromoteitscorrectuse, Ie INTRODUCTION ThisShopManualcoversthe followingBombardier made 1980 snowmobiles: Elan- Spirit Citation3500MirageI Citation4500/EMirageIIIE CitationSSMirageSpecial Everest5001500E- Futura500/500E EverestLC- FuturaLC Blizzard5500- GrandPrixSpecial Blizzard' 7500- SuperSonic Blizzard9500- UltraSonic Alpine640 Elite450LlC DEFINITIONOFNUMBERING SYSTEMS Themanualmakesusesofa2-partdigitalnumbering system(i,e,01-01),inwhichthefirstdigitrepresents theSection,theseconddigittheSub-section, 01-01 / ~ sectionsub-section Thenumerotationatthebottomofeachpageassists theuserinpagelocation. ARRANGEMENTOFTHEMANUAL TheManualISdiVidedintonine(9)malarsections: 01Tools 02Technicaldata 03Engine 04Electrical 05 Transmission 06Suspension 07Steeringandskis 08Frameandhood 09Warranty Eachsectioniscomprisedofvarioussub-sections,and againeachsub-sectionhasonemoredivision. Ex.:05TRANSMISSION 07Chaincase Steelchaincase Aluminumchaincase 1980BOMBARDIERSNOWMOBILES SHOPMANUAL ILLUSTRATIONS&PROCEDURES Anexploded view isconveniently located atthe beginning ofeachsection. andismeanttoassisttheuserin identifyingpartsandcomponents. Theillustrationsshowthetypicalconstructionofthe different assembliesand,inallcases,may not reproduce the full detail or exact shapeof the parts shown,however, theyrepresentpartswhichhavethesameorasimilar function. Whensomethingspecialapplies(suchasadlustment" etc),thespecificpartsarecircledandreferredtointhe text. Asmany of the procedures In this manual areInterrelated, we suggest,that beforeundertaking any task,youread andthoroughlyunderstandtheentiresectionorsub-sectioninwhichtheprocedureiscontained. Anumber of proceduresthroughoutthe bookrequirethe useofspecialtools,Whereaspecialtoolisindicated, refertosection01.Beforecommencinganyprocedure, besurethatyouhaveonhandallthetoolsrequired, orapprovedequivalents. GENERAL Theinformation,illustrations andcomponent! systemde-scriptionscontainedinthismanualarecorrectattime ofpublication.BombardierLimited,however,maintains a policy of continuous improvement of its products without Imposinguponitselfanyobligationtoinstallthemon productspreviouslymanufactured. BombardierLimitedreservestherightatanytimeto discontinueorchangespecifications,designs,features, modelsorequipmentwithoutincurringobligation. ThismanualISpublishedbythe TechnicalPublications BombardierLimited Valcourt,Quebec,Canada. 1980SHOPMANUAL TABLEOFCONTENTS SECTIONSUB-SECTION 01TOOLS 02TECHNICALDATA 03 01- Enginetolerancemeasurements ENGINE 02- Engines 03- Timing 04- Carburetor 05- Airintakesilencerandfueltank 06- Rewindstarter 04-01- Electriccharts ELECTRICAL 02- Testsprocedure 03- Electricstarter 04- Battery 05- Alternator 06- Sparkplugs 05 01- Pulleyguard TRANSMISSION 02- Drivebelt 03- Drivepulley 04- Drivenpulley 05- Pulleyalignment 06- Brake 07- Chaincase OB- Gearbox 09- Drivechain 06 01- Boglewheel SUSPENSION 02- Slidesuspension 03- Rearhub 04- Driveaxle 05- Track 01Steenngsystem 07 STEERING/SKI 02- Skisystem 08 01-Hood HOODANDFRAME 02- Frame 09 WARRANTY ITEM Dialindicator(T.D.C.gauge). 414104700 Tonetimer. 414099000 Circuittester(continuitylight). 414012200 Bombardierignitiontester. 419003300 KiNITIOIl TESTEn'" o :

USE Enginetiming,todetermineT.D.C. Enginetiming(static). Enginetiming(static). Continuitytests. Engineelectricalcomponentstests. SECTION01 (TOOLS) TOOLS APPLI CABLETO Allenginetypes. Allenginetypes. Allenginetypes. Allenginetypes. (TOOLS).PAGE1 SECTION01 (TOOLS) Trackinsertinstaller Heavyduty 419002700 0!l o!l Insertblock 529000300 e Cleatblock 529002600 1\1\1\ Linkplatespringlever. 529000600 Drivepulleyretainer. 529001700 (TOOLS).PAGE2 !!J cJ .-/ i5'--

TrackInsert. FemaleJI9 -_-.,,1 PES . block {Q\ Forindexationofgovernorcup. I I Alltypesoftrack. Alltypesoftrack. Allmodelswith linkplatesprings. Squareshaftdrive pulley. ( Drivepulleypuller. 529002100 c::c===c-----gg 860414200(metric) c:=!==::J)u (utl@ID MagnetohOUSingholder. 420976550 ~ (00) Toremovedrivepulleyfrom crankshaft. SECTION01 (TOOLS) Tapershaftengines Singlecylinderengine types. (TOOLS).PAGE3 SECTION01 (TOOLS) Pullerassembly. 420876296 With145mmscrew. ~ ~ ~ ~ g ~ ~ ScrewM8x70(2) ScrewM8X40(2) CrankshaftprotectorPTO CrankshaftprotectorMa9 Distancering Pullerring Halfringass'y Distancering Pullerrin9 Halfringass'y (TOOLS).PAGE4 420841200 420840680 420876550 420876555 420876560 420977480 420276020 420876565 420977490 420977470 engine377,354,454,503 engine247,277,444,464,640 Allenginesexcept247,640 377engineonly allexcept247engine allexcept640engine allexcept640engine 377,464enginesonly 377,464,640enginesonly 377,464,640enginesonly Allenginetypes. Oilsealsleeve 247engines PTO420977910 MAG420276900 Waterpumpoil sealsleeve 354,444,454,464 waterpump420876490 rotaryvalve420876495 Rotaryva Iveshaftpusher. 420876610 Ballbearingpusher. 420876500 Bearingsimulator. 640engine ~ Q 420B76160 @ Belttensiontester. 414348200 (!" '[" !q:", (d:------4"[Q Toavoidoilsealdamagedunng crankshaftInstallation. ~ ~ Odsealsleeve(oncrankshaft) ToInstallwaterpump ballbearing, Whenadjustingcrankshaftplay. Pressure adjustment Deflection adjustment 32mm (11") SECTION01 (TOOLS) LiquidcooledRotary valveengines 354,444,454,464 enginetypes. Allmodelsexcept MirageI,Citation3500 MirageIIIE,Citation4500/E MirageSpecial,CitationSS (TOOLS),PAGE5 SECTION01 (TOOLS) Cylinderaligningtool. 640engine 503engine 354-454engines 420876170 420876171 420876575 [..- ...-I f503engines420240275 g '" '"""' '" "",0 Connectingrodholder. 420977gOO Armatureplatecontactsetpivot pinremover(socket). 420876530 Fanholder 640engine420977880 503engine420876355 377engine420876357 @:::::::::::;; (0) (TOOLS).PAGE6 Connectingrod 1M Toremovecontactsetpivotpin fromarmatureplate. TWincylinderengine types. Allsinglecylinder engines Allenginetypes usingbreaker pornttypeIgnition. Twincylinder fan-cooledengines Protectioncap. 247,277,640engines 18mm420976890 354,377,444,454,464,503 22mm420876402 Engine Oilsealpusher. 247engine420977920 277engine420277865 420876660 J,@) Oilsealpusher. 420876510 464engine 420876500 Rotaryvalveoil sealpusher L 420876600- 354,454engine 420876605- 464engine o Protectcrankshaftend,when usingbearingpuller. Protectloncap V DJLL 011sealpusher Puller Toinstallwaterpump oilseal. ToInstallrotaryvalve shaftoilseal SECTION01 (TOOLS) Allenginetypes. Allsinglecylinder enginetype. 354,444,454,464 enginetypes. 354,454,464englOes (TOOLS),PAGE7 SECTION01 (TOOLS) Polyamldringpusher 277engineMAG420273930 PTO420273940 ~ - A d 1 Crankshaftfeelergauge. 503engine MAG420876625 PTO420876620 ts2J Crankshaftlockingtool 420876640 Injectionpumpgear holder 377engine420876690 464engine420277900 ~) (TOOLS!.PAGE8 Toinstall polyamldring incrankcase. Tolockcrankshaft \ 277engine Magside: All503enginesupto no.3181891 andengines no.3181921to 3181937. PTO:All503engines 277.377 464engines. 464.377engine equippedwith oilinjection LOCTITESEALANTKIT413702600I contains PSTPipeSealantwithTeflon(50mL)I 413702300 GasketEliminator515(50mL) 413702700 RetainingCompoundRC/601(10mL) 413703100 Threadlocker242(10mL) 413703000 Threadlocker271(10mL) 413702900 SuperBonder495(3-gramtube) 413703200 LOCK'NSEAL (242)BLUE, MEDIUMSTRENGTH24mL 413702500 LOCK'NSEAL (271)RED HIGHSTRENGTH6mL 747020000 GASKETELIMINATOR515 50mL 413702700 Forthreadlocking,threadseallng, gasketing,bondingandretaining applicationsonengines,pulleys andfastenersetc. SECTION01 (TOOLS) Amedium-strengthadhesiveforGeneralpurpose,nuts, threadlockingandthreadseallOg.boltsscrews, Vibration-proofsnuts,boltsandMagnetoringnut,crank-screws.casestuds,etc. High-strengththreadlocklOgIandstuds threadseallngadhesiveforlargeunder1d,a, parts. Sealsinstantly,FormetaltometalIOnallenginecrankcases. assembly.Replacesgaskets. (TOOLS),PAGE9 SECTION01 (TOOLS) RETAININGCOMPOUND601 10 mL 413703100 PRIMERCRANKCASESEALANT (SPRAY)6oz 413702400 STRIPPERNO57 413702100 ANTISEIZE LUBRICANT 413701000 -; ANTi SeizE lll6n.'"p,lIl METALPROTECTORLPS. NO1SPRAY 413902200 (TOOLSI,PAGE10 tiANoiE'..;: ~ : ~ ~ Restoresfitbetweenbearingsand worncrankcase. Veryfastcurepnmer.PrimerNF provideshxturingInonly15-30 secondswithfuJIcurein4hours orless.Onpartlifeis30minutes andpartsshouldbeassembledas soonaspossibleafter adhesiveis applied. Forcleaningmatingsurfacesbe-foreassembly. Protectsmovingandstationary partsagainsthightemperature seizing.Preventsrustandcorro-siononparts exposed to highheat. Generalservicelightlubricant. Protectsagainstrust.Displaces moisture.Protectsallelectrical systemsandignitionsystems. Allenginesexcept247, 277. Mainly usedwhenassem-blingenginecrankcase. Used to cleanmating SUf-faces before applying Loc-lite515(GasketElimina-tor). Unpaintedsurfacesof drivepulleycountershaft. For storage protection,on driveanddrivenpulleys, Hightensioncoilprotec-tionfrommoisture. METALPROTECTORL.P.S. NO3SPRAY 413900800 SILICONEDIELECTRICGREASE 3oz 747018002 GREASETUBE 14oz 498028100 CLUTCHLUBE 413800700 INJECTOROIL 413801500 CHAINCASEOIL 413801200 BOMBARDIEROIL 50/1 496013200 I ~ II~ -:: ImYJII HeavyDutyRustpreventIVelubri-cant.Protectsbaremetalparts againstrustandcorrosion. Specialdielectricgreasethatpre-ventsmOistureandcorrosion build-upinelectncconnections. MultipurposeLithiumbased grease foruseovera widetemper-aturerange. SpecialJowtemperaturemetallic lubricantforclutchshaftsonly. Highqualitylubricantwithgood resistancetohighoperat'lngtem-peratures.Lowfoamingaction. Speciallyformulatedallforchain androllerlubrication.Assures properlubricationatlowtempera-tures. SECTION01 (TOOLS) For storage protection.on baremetalparts. Onallelectricconnec-tions.Hightensioncall. Sparkplugconnections. Connectorhousings,etc. For Idler bearings.skllegs. leafspringcushionpads. oilsealinteriorlips,etc, Citation3500.Citation 4500/E.MirageI. MirageII/E.Elanand Spiritdrivepulleys. Rotaryvalvelubncanton 354-444-454and464 engines. Chaincaselubricant onall models. Specially formulated oil that meetsIAllmodels. lubricationrequirementsofthe Bombardier-Rotaxengine. (TOOLS).PAGE11 SECTION02 TECHNICALDATALIST TOLERANCEANDWEARLIMIT- ENGINES IGNITIONTIMINGSPECIFICATIONS CARBURETORSPECIFICATIONS IGNITIONGENERATINGCOIL,TRIGGERCOILANDLIGHTING COILRESISTANCECHART BOMBARDIERIGNITIONTESTERDIALPOSITIONS BOSCHSPARKPLUGCHART VEHICLEMODEL/DRIVEBELTNUMBER DRIVEPULLEYSPECIFICATIONS DRIVENPULLEYSPRINGTENSION PULLEYALIGNMENTSPECIFICATIONS SPROCKETANDCHAINSPECIFICATIONS TRACKTENSIONSPECIFICATIONS(BOGIEWHEELSUSPENSION) TRACKTENSIONSPECIFICATIONS(SLIDESUSPENSION) TRACKSPECIFICATIONS STEERINGSYSTEMTORQUESPECIFICATIONS SKISYSTEMTORQUESPECIFICATIONS METRICINFORMATIONCHART (TECHNICALDATALIST).PAGE1 SECTION02 SUB-SECTION03-01,(ENGINETOLERANCESMEASUREMENT) TOLERANCESANDWEARLIMIT - 1980ENGINES ENGINECYLINDERBOREPISTONTOWALLMAXIMUMRINGCRANKSHAFT TYPE(NOMINAL)CLEARANCEENDCAPENDPLAY STDOVERSIZEMIN.- MAX.MIN.- MAX. 24769.00mm69.50mm0.065-0.200mm0.20-0.35mm020-0.40mm (2.7165")(2.7362")(0026-.00B")(00B-.014")(.00B-.016") 27772.00mm72.25mm0.060-0.200mm0.20-0.35mm0.20-0.40mm (2.B346")(2.B445")(0024-.00B")(00B-014")(.00B-.016") 35459.50mm59.75mm0.OBO-0.1BOmm0.15-0.30mmN.A. (2.3425")(2.3524")(0031-.007")(006-.012") 37762.00mm62.25mm0070-0.200mm0.20-0.35mmNA (2.4409")(2.450B")(0028-.00B")(00B-.014") 44469.50mm69.75mm0.070-0200 mm0.20-0.35mmNA (27362")(2.7461")(002B-.00B")(00B-014") 45467.50mm67.75mm0.090-0.200mm0.20-0.35mmNA (2.6575")(2.6673")(0035-.00B")(OOB-O 14") 46469.50mm69.75mm0.070-0200mm0.20-0.35mmN.A. (2.7362")(2.7461")(0028-.00B")(008-014") 50372.00mm72.25mm0.060-0.200mm0.20-0.35mmNA (28346")(2.B445")(0024-.00B")(00B-014") 64076.00mm76.50mm0.070-0.220mm0.25-0.40mm0.20-0.40mm (2.9921 ")(3.0118")(.002B-.OOB")(010-016")(008-016") N A: notapplicable (TECHNICALDATALIST).PAGE2 SECTION02 SUB-SECTION03-03,(IGNITIONTIMING) 1980IGNITIONTIMINGSPECIFICATIONS ENGINEIGNITIONDIRECTINDIRECTEDGECAP TYPETYPEMEASUREMENTMEASUREMENT B.T.D.C.B.T.D.C. f ~ ~ .. ' ..'.,,!' n 'hFl ~ ~ ~ r )110>??il c 247Breaker 3.98mm0.25 NA 7-10mm (.157".010) (.275-394") 277BreakerNA 2.60mm0.25812mm (.102".010)(.315-.4 72") 354 CD 1.39mm0.25 NANA (.055".010) 377 Breakers 2.07mm0.25 NA 8-12mm (.081"01O)(.315-.4 72") 444 Breakers 2.35mm0.25 NA 812mm (.093"01O)(.315.4 72") 454 CD 1.39mm0.25 (.055".010) NANA 464Breakers 2.07mm0.25 NA 8-12mm (.081"010)(.315-.472") Breakers 2.07mm0.25 N.A. 812mm 503 (. 081"a 10)(.315-.4 72") 640 BreakersNA 3.62mm0.25710mm (.143"01 0)(275-.394") NAnotapplicable StroboscopIctlmln9at6000R.P.M. (TECHNICALDATALIST).PAGE3 SECTION02 SUB-SECTION(03-04) CARBURETORSPECIFICATIONS MODELENGINECARBURETORLOWSPEED TYPETYPEADJ MikuniJr ELAN&SPIRIT247VM28-2421 iturn CITATION3500, MIRAGEI277VM34-2281 iturn CITATION4500/E, MIRAGEII IE377VM-34-2291turn CITATIONSS, MIRAGESPECIAL3772XVM30-11111turn EVEREST500/E FUTURA500/E 503VM36-831turn EVERESTLC, FUTURALC464VM34-22711turn BLIZZARD5500 GRANDPRIXSPECIAL5032XVM34-20311turn BLIZZARD7500MAG:VM34-230 SUPERSONIC354PTa:VM34-2331 iturn BLIZZARD9500PTa:VM36-88 ULTRASONIC454MAG:VM36-861turn ALPINE640ER640VM34-2151 -tturn ELITE450LC444VM34-2011turn - --.-L- ---- -- --(TECHNICALDATALIST).PAGE~ IDLE SPEED R.P.M. 1100-1300 1100-1300 I , 2000, , 1800-2000 1800-2000 2000 1800-2000 1800-2000 1800-2000 1800-2000 1800-2000 ---SECTION02 SUB-SECTION(03-04) 1980MIKUNICARBURETORSPECIFICATIONS c" !j S ~ (f VM28-242160 VM30-111150 VM34-201370 VM34-203220 VM34-215280 VM34-227380 VM34-228220 VM34-229280 VM34-230290 VM34-233260 VM36-83310 VM36-86320 VM36-88 300 oJetneedlelastdigit indicates"E"clip positionfromtop. Ex.:6HD2-3:3rd slotfromtop. CDTurningclockwisewill enrichthemixtureand counterclockwisewill leanit. 0 0-,,0 // if

2 0 GJ m !'-len m -m -f mO 2-1 -< G) 0 "a 2 2 m m 0 !:!J w SECTION03 SUB-SECTION02,(ENGINES) 377ENGINETYPE ENGINESUPPORTANDMUFFLER ,---@ 1'0 ~ U i 8 (377ENGINETYPE),PAGE2 ''@J ~ ~ o 1, l T ~ 1.377 Rotaxengine 2.Enginesupport 3.Lockwasher10 mm(3) 4.Hexagonalhead capscrew MIOX25 mm(3) 5.Hexagonalhead capscrew MIOX35 mm(2) 6.Hexagonalelasticstopnut10 mm(2) 7.Cup(2) B.Rubber shear mount(3) g.Bushing(3) 10.FlatWasher10.5 X21X2mm(3) I I.Lockwasher10 mm(2) 12.Hexagonalhead capscrewM lOx45mm(3) 13.Hexagonalelaslic stopnut10 mm 14.Gasket(4) 15.Exhaustmanifold ENGINESUPPORT ANDMUFFLER REMOVALFROMVEHICLE Removeordisconnectthefollowings(ifapplicable)then liftengineoutofvehicle. Pulleyguard,drivebelt. eMuffler. eAirintakesilencer. ..Throttlecableatcarburetor. "Fuellinesandpulsationline. O NOTE:Securefuellinessothattheopenedends arehigherthanthefuellevelinthetank. eHoodretainingcable. "Rewindstartercable. eWiringharness. +WARNING:Beforedisconnectinganyelectrical wireinstartersystemalwaysfirstdisconnectthe batterycable, ..Enginesupportnuts. SECTION03 SUB-SECTION02,(ENGINES) 16.LockwasherBmm(4) 17.Hexagonal socket head capscrew MBX30 mm(4) I B.Connector 19.Spnn9(6) 20 Muffler 2I.Muffler support 22.Hexagonalhead capscrew M6X7.00X40 mm 23.Spnng 24.Flatwasher6.4X14X1.5 mm 25.Hexagonalelastic stopnut6mm 2.6.Spring(2.) 2. 7.Sprin9 2.B.Washer 2.9."Loctite222 or 242" DISASSEMBLYANDASSEMBLY 0Apply "Loctite222or242"onthreadsthentorque to20N"m(15ft-Ibs). @@Torqueto20N"m(15ft-Ibs) . @@Torqueto55N"m(40ft-Ibs). INSTALLATIONINVEHICLE Toinstallengineonvehicle,inverseremovalprocedure. However,payattentiontothefollowings: eChecktightnessofenginemountnuts. eAfterthrottle cableinstallation,checkmaximumthrot-tleslideopening. "Checkpulleyalignment. (377ENGINETYPE).PAGE3 SECTION03 SUB-SECTION02,(ENGINES) BOTTOMEND ! ~ ~ llr(l) @@ @~II rrD 15I 16 I.Crankcaselower half 2.Crankcaseupper half 3.LockwasherSmm(10) 4.Hexagonal screw MSX45 mm(2) 5.Hexagonal screw MSX70mm(S) 6.Lockwasher6mm(4) 7.Hexagonal screw M6X40 mm(4) S.. 'Loctite515" 15 g."Loctite242" (blue,mediumstrength) 10.Stud MSX167 mm(S) II.Cablegrommet 12.Rubber plug(5) 13.Crankshaft 14.Sal/ beanng6206 (2) 15.ShimImm(2) 16.Spacer I 7.Seal.P.T.O.side IS.Sail bearing6207 19.O'ring 20.Seal,magnetoside 21.Woodruff key3X3.7 mm (377ENGINETYPE).PAGE4 @ () '10 10 12 11--@ 3- - ~~ , ~ " - ~W-0 -0 B-12 o ~ 9 ~1{@", I,(}) @,' I @ BOTTOMEND CLEANING Discardallseals,gasketsand"0" rings. Cleanallmetalcomponentsisanon-ferrousmetal cleaner. Removeold sealantfromcrankcasematingsurfaceswith Bombardiersealantstripper . .., CAUTION:Neveruseasharpobjecttoscrape ...awayoldsealantasscoremarksincurredare detrimentaltocrankcasesealing, DISASSEMBLYANDASSEMBLY (2) CD 0Crankcasehalvesare factory matched andthere-fore,arenotinterchangeableassinglehalves. Prior to joining of crankcasehalves,apply" Loctite515" (no,4137027)onmatingsurfaces. Positionthecrankcasehalvestogetherandtightennuts (orbolts)byhandtheninstallarmatureplate(tighten) onmagneto sidetocorrectly alignthecrankcasehalves, Torqueboltsto21Nom(15h-Ibs)followingillustrated sequence. 800Torque to21N'm(15ft-Ibs), SECTION03 SUB-SECTION02,(ENGINES) @@To remove bearings from crankshaft use a protective cap andspecialpuller,asillustrated.(SeeTools section). PTO.side

Magnetoside 0 ==0 Priortoinstallation,placebearingsintoanoilcontainer heatedto100C(210F), Thiswillexpandbearingsandeaseinstallation.Install bearingswithgrooveasperexplodedview, P,T,O,side Atinnerbearinginstallation,providea freeplayof2mm (,080")forlubricationbetweenbearingandcrankshaft blade,usingPIN420876620tool. (377ENGINETYPE),PAGE5 SECTION03 SUB-SECTION02,(ENGINES) @@At installation.applyalightcoatoflithiumgrease oninsidediameterlipofseal. ForP.T.O.sideouterbearinglubrication,itisnecessary toprovidea freeplayof0.80 mm(.030")betweenseal andbearing. PTQ.Side 'I' I "l (377ENGINETYPEI.PAGE6 28 SECTION03 SUB-SECTION02,(ENGINES) OILINJECTIONPUMP '_6 @ 183116'j I fffP'""17 ,.\:J.II I

Q27@ 29I"'lr 28 10

'/ ..--.... I __ 1 (J I u 29 o IT

(J?\l). _ )";\180 $ aU 1.Injection01/tank 2.Sealer9"(229 mm) 3.Grommet 4,Maleconnector 5.Gasket 6.Oiltankcap 7.Retainer rod 8,Hexa90nalwasherheadself-tapping screw M6X30 mm 9.Retainingwasher 10Hexagonalelastic stopnut8mm 11,Oil line38 mm(1.5") 12.01/ line356 mm(14") 73.Spnngclipor clamp(4) '-- // 6-3

4

I@"" I 8I I147 I 14.Filter 75.Oil 76,Oil pumpmountingflange 17O'ring 18.Oil pump 19,Washer6.2 mm(2) 20.Gear 27 teeth 27,Locknut6mm 22.Lockwasher5mm(2) 23.Cylindncal slotted screw M5X16 mm(2) 24.Ball bearing 25.Gear9teeth 26,Banjogasket(4) 27.Banjo(2) 28.Banjobolt (2) 29,Oil line325 mm(13") 30.Clamp(4) 31.Self-tapping screwM5X76 mm(4) (377ENGINETYPE),PAGE7 SECTION03 SUB-SECTION02,(ENGINES) OILINJECTIONPUMP CLEANING Cleanallmetalcomponentsinanon-ferrousmetal cleaner. DISSASSEMBLYANDASSEMBLY O NOTE:Oilpumpcomponentsarenotavailableas singleparts. .., @@CAUTION:Onelectricstartmodels,itis 'If'recommendedtoinstallblackrubberlines (P I N414 2867)thatwillnotbealteredbybattery fumes. @@At assembly,alwayscheckforclamptightness. @@@lTo removeretainingnut.lock gear inplaceusing no.420876690 tool. no.420876690tool At assembly,applyalightcoatofgreaseongear teeth. (377ENGINETYPE),PAGE8 OILINJECTIONPUMPADJUSTMENT A)Prior toadjustingthepump,makesureallcarburetor adjustmentsarecompleted. Eliminatethethrottlecablefreeplaybypressingthe throttleleveruntilalightresistanceisfelt,thenhold Inplace.(Asmallrubberbandcanbeused).The aligningmarksonthepumpcastingandonthelever mustalign.Ifnot,loosentheadlusternutandadlust accordingly . Retightentheadlusternut. Adjuster nut Bleeder ~ ~ . ~ ~ . ~ B)Alloillinesshouldbefullofoil.Ifrequired,bleed the main oil line(between tank and pump) by loosening thebleederscrewuntilallairhasescapedfromthe line. Makesurethetankissufficientlyfilled. Checkthesmalloillines(betweenpumpandintake manifold).Ifrequired,fillthelinesbyrunningthe engineatidlespeedwhileholdingthepumplever infullyopenposition. (

\)V IV\Vf"'"./I0 @ o I -@--6 C)-22 C)-23 c:ru, I 24 SECTION03 SUB-SECTION02,(ENGINES) TOPEND 1,Cylinderflangegasket 2.Cylinder.P.T. 0.side 3.Cylinder,magnetoside 4.Cylinderhead gasket(2) 5.Cylinderhead 6.Washer8.4mm(8) 7.Hexagonalnut8mm(5) 8.Distancenut8X33 mm(3) g.Intakemanifold gasket(4) 10.Intakemanifold 11.Lockwasher8mm(4) 12.HexagonalheadboltM8X40mm (2) 13.G'ring 14.Intakemanifold cover 15.HexagonalheadboltM8X74mm (2) 16.Lockwasher6mm(2) 17.HexagonalheadboltM6X25mm (2) 18.Intakemanifold (2) 19.Hexagonal socket head bolt M8X35 mm 20.NOisedamper 21.PiSton(2) 22.Rectangular ring(2) 23.Rectangular ring(2) 24.Needlebearing(2) 25.Gudgeonpin(2) 26.Circlip(4) (377ENGINETYPE).PAGE9 SECTION03 SUB-SECTION02,(ENGINES) TOPEND CLEANING Discardallgaskets. Cleanallmetalcomponentsinanon-ferrousmetal cleaner. Scrapeoffcarbonformationfromcylinderexhaustport, cylinderheadandpistondomeusingawoodenspatula. O NOTE:Theletters"AUS"(overanarrowonthe pistondome)mustbevisibleaftercleaning. Cleanthepistonringgrooveswithagroovecleanertool. orwithapieceofbrokenring. DISASSEMBLYANDASSEMBLY 000At cylinder andlor cylinder headinstallation,use PIN'420876171aligningtooltoensuresealingof intakemanifoldandexhaust(SeeToolssection),before tighteningcylinderheadnuts. no.420876171tool (377ENGINETYPE).PAGE10 Crosstorquecylinderheadnutsto20Nom(15It-Ibs); torqueeachcylinderheadindividually. 00positionnutsanddistancenutsasillustrated. distancenuts Torquenutsto20Nom(15ft-Ibs). o Installagasketoneachsideoftheairdeflector. @@@Torqueto20Nom(15It-Ibs) @Installintakemanifoldwithidentificationmarks towardscylinderhead. ~ ~~ - , Identificationmarks Positionnoisedamperasperfollowingillustration. F"\) ,Ino"edamper6'=[I J

PTOsidecylinder @@@Placeacleanclothovercrankcasetoprevent circlipsfromfallingintocrankcase.Useapointedtool toremovecirclipsfrompiston. ... CAUTION:When tappingout gudgeonpins,hold '" pistonfirmlyinplacetoeliminate thepossibilities oftransmittingshockandpressuretotheconnecting rod. SECTION03 SUB-SECTION02,(ENGINES) Atassembly.placethepistonsovertheconnectingrods with the letters "AUS" (over an arrow on the piston dome) facinginthedirectionoftheexhaustport. EXHAUST

Pistontowallclearanceshouldbe: MINIMUM:0.070mm(.0028") MAXIMUM0.200mm(008") O NOTE:Oncecirclipsareinstalled.turneachcircltp sothecirclipbreakisnotdirectlyonpistonnotch Removeanyburrsfrompistoncausedthroughcirclip installationusingveryfineemeryc!otch . Clrclipbreak Pistonnotch (377ENGINETYPE).PAGE11 SECTION03 SUB-SECTION02,(ENGINES) MAGNETO 0-11 /j-12 o

I"0 S1llfr17I o 32 I3031 8 I

,d 2S-l)bJ 2S-l)bJ-"'e_29 (377ENGINETYPE),PAGE12 o 7.Armature plate 2,Lightingcoil7 7OW 3.PhillipscylindricalheadscrewM5X 28 mm(2) 4.Generator cOil 5.Distancesleeve7 7 mm(2) 6.Lightingcoil3o.W 10 7.PhillipscylindricalheadscrewM5X 32 mm(2) 8.Femaleconnector 9.Condenser(2) 70.Contact breaker(2) 7 7.Rubber cap(2) 72,Femaleconnector(2) 73.Lubricatingwick 74.Magnetonng 75,Washer5,3mm(2) 76.Lockwasher5mm(2) 77.Allenscrew M5X78mm(2) 34@ & 78.Lockwasher6mm(4) 79,Allenscrew M6X7 7.5mm(4) 20.Magnetohousln9 27,Fanpulley 22.Starting pulley 23.Lockwasher8mm(3) 24.Allenscrew M8X72mm(3) 25,Lockwasher22 mm 26.Hexagonal nut 22X7,5mm 27."Loctite 242" (blue,medium strength) 28,Ignitioncoil (2) 29.Self-tappmgscrew M5X22 mm 30..Protectioncap(4) 37,Hightensioncable250.and780.mm 32.Suppressor cap 33.SparkplugW3C(W275T2) 34."Loctite277" (red,highstrength) 25 @ MAGNETO CLEANING Cleanallmetalcomponentsinanon-ferrousmetal cleaner. .. CAUTION:Cleanarmatureandmagnetousing "onlyacleancloth. DISASSEMBLYANDASSEMBLY 000 Whenever a coilisreplaced.the air gap (distance betweencoilendandmagnet)mustbeadjusted. Tocheckairgap.insertafeelergaugeof0.30-0.45 mm(.012"-.018")betweenmagnetandcoilends.If necessarytoadjust,slackencoilretainingscrewsand relocatecoil. 0To replacea condenser.it is first necessary to unsolder thetwo(2)blackleadsusingasolderingiron.The condensercanthenbedrivenoutofthearmatureplate usingasuitablepusherandhammer.Toreinstall,inverse procedure. @Whenreplacingcontactbreakers.applyalightcoat ofgreaseonlubricatingwick. SECTION03 SUB-SECTION02,(ENGINES) @@Toremoveorinstallmagnetoretainingnut.lock crankshaftinpositionwithspecialhold-onsupportas illustrated.(SeeToolssection). hold-on specialpuller With magneto retaining nut removed.install specialpuller ontohold-onsupport. Tightenpullerboltandatsametime.taponbolthead usingahammer toreleasemagnetofromitstaper. At assembly.clean crankshaft extension (taper) then apply Loctite242orequivalent. Installmagnetoretainingnut(withLoctite242on threads)andtorqueto85Nom(63ft-Ibs). (377ENGINETYPE).PAGE13 SECTION03 SUB-SECTION02,(ENGINES) COOLINGSYSTEM @16 1.Fanhousing 2.Circlip 3.Shim1.0 mm(2) 4.Ball bearing(2) 5.Fanshaft 6.Woodruff key3X5mm 7.Distancesleeve 8.Pulleyhalf 9.Shim0.5 mm 10.Fan I 1.Lockwasher16 mm 12.Hexagonal nut16X1.5 mm 13.Fanbelt 14.Fancover 15.Cylindercowl 16.Speed nut (8) I7.Cylinderhead cowl 18.Cowl sealingstrip380 mm 19.Lockwasher8mm(3) 20.Hexagonal screwM8X9mm(2) 2I.Hexa90nal screw M8X16 mm 22.Wasker4X15.8 mm(6) 23.Screw 4.8X76mm(6) 24.Lockwasher6mm(4) 25.Allenscrew M6X30 mm(4) (377ENGINETYPE).PAGE14 .0

@@@I @ COOLINGSYSTEM CLEANING Cleanallmetalcomponentsinanon-ferrousmetal cleaner. DISASSEMBLYANDASSEMBLY 00 It is firstnecessary toheat bearinghousing to65 C (150F)toremoveorinstallbearing. @Fanbeltfree-playmustbe6mm(t").Toadjust. installorremoveshim(s)betweenpulleyhalves.Install excessshim(s)betweenfanandlockwasher. @Toremoveorinstallfanpulleyretainingnut.lockfan pulleywithspecialholderwrench.(SeeToolssection). Atassembly.torquenutto65Nom(48ft-Ibs) holderwrench @Agasketmustbeplacedonbothsides(innerand outer)ofintakeandexhaustholes. SECTION03 SUB-SECTION02,(ENGINES) (377ENGINETYPE).PAGE15 ENGINESUPPORT &.MUFFLER 26-4--(,") I.Carriageboltt-24 XIt" (4) 2.Threadedbushing(4) 3.Spacer(4) 4.Insulating rubber(4) 5.Bracket(2) 6.Springleaf (2) 7.Washer(4) 8.Nut(4) 9.Enginesupport 70.Stud (4) I I.Distancesleeve(4) 12.Washer(4) 13.Lockwasher(4) 14.Nut(4) 15.Bolt5/ 16-24X13116" (6) 16.Washer(6) 17Nut5116-24 (6) lB.Support 19.Bolt5/76-IBX1"(2} 20.Bolt5/ 16-IB XIt" (2) 2I.Washer(4) 22.Nut5/16- 18 (2) 23.Alternator 24.Belt 25.ail tank 26.Hoseclamp 27ail tanksupport SECTION03 SUB-SECTION02,(ENGINES) 444 TYPEENGINE 2B.Hose120 mm 29.Exhaust gasket(2) 30.Exhaustmanifold 3I.Lockwasher6mm(6) 32.Allenscrew M6X22(6) 33.Spnng(4) 34.Muffler 35.Exhaust pipe 36.Exhaustgrommet 37.Asbestos string 3B.Bolt5116- IBX3t"(2) 39.Cup(4) 40.Bushing(2) 4I.Spnng(4) 42.Cup(4) 43.Muffler clamp(2) (444ENGINETYPE).PAGE1 SECTION03 SUB-SECTION02,(ENGINES) ENGINESUPPORT ANDMUffLER REMOVALFROMVEHICLE Disconnectorremovethefollowingsfromvehicle: - Pulleyguardanddrivebelt. - Intakesilencerandthrottlecable. - Fuellines.primerandpulsationlines.fueltank. - Electricalwires(atengine.alternator.starter). +WARNING:Beforedisconnectinganyelectrical wireinstartersystem,always firstdisconnectthe batterygroundcable. - Drainthecoolingsystemanddisconnecthosesat engine. - Removeenginemountnutsthenliftenginefrom vehicle. DISASSEMBLYANDASSEMBLY @lAtassemblyoncrankcase,apply"Loctite242"on threads. @Torqueto36Nom(26ft-Ibs). @Torqueto32Nom(23ft-Ibs). @Torqueto21Nom(15ft-Ibs). INSTALLATIONONVEHICLE Toinstallengineonvehicle,inverseremovalprocedure. However,payattentionto thefollowings: "Checktightnessofenginemountnuts. eAfter throttlecableinstallation,checkcarburetor max-imumthrottleslideopening . ..Checkpulleyalignmentandalternatorbelttension. (444ENGINETYPE),PAGE2 ( 23 @i I

27 Ift.",'._\,0 33""'/ 20-' '-0 1.Fanadapter 2.Fan 3.Boltt -20 X,.. (4) 4.Washer(4) 5.Nutt-20 (8) 6.Lockwasher8mm(3) 7.Nut8mm(3) 8.Grille(radiator) 9.Coolanttank 1080lt5/ 76-18X3!"(4) 7 1.Rubberdamper(8) 72.Radiator 13.8ushing(4) 74.Washer(4) 15.Nut5/ 16-18 (8) 16.Washer(4) 1 7.Drainvalve 18.Plug 79.Overflowhose(635 mm) 20.Inlethose(radiator) 27.Hoseclamp(4) 22.Thermostat 26 SECTION03 SUB-SECTION02,(ENGINES) COOLINGSYSTEM 23.Sealingring 24.Sensor 25.Outlethose(engine) 26.Hose(380 mm) 27.Hoseclamp(2) 28.Upperdeflector 29.Sidedeflector(2) 30.Washer(7) 31.Poprivet(7) 32.Plug(2) 33.Cylinder head outlet collar (444ENGINETYPE).PAGE3 SECTION03 SUB-SECTION02,(ENGINES) COOLINGSYSTEM INSPECTION Checkgeneralconditionofhosesandclampstightness. DRAININGTHESYSTEM Todrainthecoolingsystem,removethecoolanttank cap. RemovetheR. H.accessgnll,andconnectalengthof plastichosetotheradiatordrainvalveinordertodrain thecoolingsystemoutsideofthebody, Openthedrainvalve. valve DISASSEMBLY&ASSEMBLY @Tocheckthermostat,putItinwaterandheatwater. Thermostat should open when water temperature reaches 43"C(110"F). @@Applypipethreadsealanttoavoidleaks. (444ENGINETYPE),PAGE4 REFILLINGTHESYSTEM Capacity: 6.25liters (1.4Imp,gaL)(1. 7US.gaL) 60%concentratedantifreeze+40%water Torefillthecoolingsystem,unscrewtheplugontop ofthecylinderhead,thenslowlypourtheliquidintothe coolanttankuntilitreachestheplugholeinthecylinder head,Reinstalltheplug.Continuetopourtheliquidin thecoolanttankuntilthecoolantlevelreaches25mm (1")belowfillerneckofreservoir. Withthepressurecapremoved,startenginetoallow thecoolanttocirculateandletitrununtilnormal temperatureisreached.Stopengine. Thenrecheckcoolantlevel,ensuringthatitis25mm (1")belowfillerneckofreservoir. I.Crankcaselower half 2.Crankcaseupper half 3.Lockwasher8mm(14) 4.Hexagonal screw M8X70 (8) 5.Hexagonal screw M8X45 (2) 6.Lockwasher6mm(2) 7.Hexagonalscrew M6X35 (2) B.AI/enscrew M8X40 (4) g.Stud MIOX37 (4) 10.Distancesleeve12mm(4) II. Lockwasher10 mm(4) 12.NutMIO (4) 13.Angulartube(oil outlet) 14.Angular tube(oil inlet) 15.Plug 16.Stud MIOX184.5 (8) 17.Junctionblock plate lB.Lockwasher5mm(2) 19.Cyllndncal head screw M5X12 (2) 20.Crankshaftassembly 2 I.Woodruff key3X3.7 22.Distancering(2) 23.8al/ beanng6206 (3) 24.O'ring(3) 25.0/) seal(2) 26.Stopring(2) 27."Loctile242" (medIUmstrength) 2B."Loctite515" 29."Loctile2 71 ..(highstrength) 30.Oil seal(2) @ 22 ./J I~ @W1 ~ ~ 3-"", 5J '0 ---e:J "-@ @--- SECTION03 SUB-SECTION02,(ENGINES) 'r~ ~ ~ . ~ " " , ~ ' 7 '8 q) BOTTOMEND ,-----'5 ~ 0 (444ENGINETYPE).PAGE5 SECTION03 SUB-SECTION02,(ENGINES) BOTTOMEND CLEANING Discard alloilseals,gaskets,"0" rings and sealingrings. CleanalJmetalcomponentsinanon-ferrousmetal cleaner. Removeoldsealantfromcrankcasemating surfaces with Bombardiersealantstripper. .., CAUTION:Neveruseasharpobjecttoscrape Vawayoldsealantasscoremarksincurredare detrimentaltosealing. DISASSEMBLY&ASSEMBLY 0@@Crankcase halvesare factory matched andthere-fore, arenot Interchangeable or available as single halves, Prior toJoining of crankcasehalves,apply" Loctite515" (no,413702700)onmatingsurfaces . .., CAUTION:Beforejoiningof crankcasehalvesbe .",surethatcrankshaftrotaryvalvegeariswell engagedwithrotaryvalveshaftgear. Positionthecrankcasehalvestogetherandtightennuts byhandtheninstallarmatureplate(tighten)onmagneto sidetocorrectalignthecrankcasehalves. Torqueboltsto22N'm(16ft-Ibs)followingillustrated sequence. 16 14 13 15 000Torque to22N'm(16It-Ibs), 0At assemblyoncrankcase,apply"Loctite242"on threads. @Torqueto35N'm(26It-Ibs). @)Apply"Loctite242"onthreadspriortoassembly. @It isrecommended towrap"Teflon"pipe tapearound threads. (444ENGINETYPE),PAGE6 @Because of cap nuts,cylinder studs have to bescrewed Intocrankcasesothattheydonotprotrudefurtherthan 15.6cm(6.140"),Ifitisnotpossibletoobtainthis length,awashermustbeaddedbetweencylinderhead capandcapnut, Apply"Loctite242"onthethreadsofthetwostuds screwedabovetheintakeports . 15.6em Longerthreadedpartofstudshouldbescrewedinto crankcase. @Toremovebearingsfromcrankshaft,useaprotective capandspecialpullerasillustrated, Protectivecap Specialpuller Priortoinstallation,placebearingsIntoanoilcontamer andheattheoilto100C(212F),Thiswillexpand bearingandeaseinstallation. Installbearingswithgrooveoutward. Atassembly,applyalightcoatoflithiumgreaseon seallips, L Toinsureadequateoilsupplytothebearingonthe magnetoside,installoilsealwithagapofatleast 0.8mm(,030") withbearing,OnPTO,sideinstalloil sealflushwithcrankcase,nomorein. @Crankshaftcenteroilsealsmaybereplacedata crankshaftrebuildshop. SECTION03 SUB-SECTION02,(ENGINES) (444ENGINETYPE),PAGE7 SECTION03 SUB-SECTION02,(ENGINES) ROTARYVALVE&COOLANTPUMP 33-1 34-35-37 38 ___ 39--l1li\l 40-11141 I 42 7.Rotaryvalveshaft 2.Oil seal 3.Ball beanng6203 4.Shim0.5 mm 5.Distancesleeve24.5 mm 6."Loctite2 77"(red- highstrength) 7.Shim0.5 mm B.O'rlng 9.Gear /0,Spring 7 7.Springseat 72:Circlip @)

,I: 17," Toremoverotaryvalveshaftassemblyfromcrankcase, firstremovepumpimpeller@andcirclip@,USingan appropriatepusher(PIN420 876610)andafiber hammer,driveoutshaftassembly. tool Atassembly,apply "Loctne515"onbeanngandrotary valveshaftmatingsurfaces. I::!::d;::::f--/ ? Apply "Loctlte515" ToInstallshaftassemblyandoilseal,useno, 420876600pusher. (444ENGINETYPE),PAGE9 SECTION03 SUB-SECTION02,(ENGINES) (!)Through@Rotaryvalveshaftassembly. Ifitisnecessarytodisassemblecomponentsofrotary valveshaftassembly.compressspringcup@inorder toremovecirclip@. Cleanrotary valveshaftandinsideof distancesleeve. Atassembly,apply"Loctite271"insideofdistance sleeve. @Using a sUitable pusher.pushpump bearing with shield facingrotaryvalve. Toremovebearing Toinstallbearing 420876510 tool No420876500 tool (444ENGINETYPE).PAGE10 @@Frompumpside.usingno.420 876510pusher. installoilseals(withlithiumgreaseonlips)asper illustrations. Keepinmindthat: - distanceringopeningmustbeinlinewithcrankcase draininghole. - 35%oftheareabetweenfirstandsecondoilseal (firstoilsealbeingflushwithcrankcase)must befilled withlithiumgreaseorequivalent. Firstallseal Distance nng opening Distancenng @Apply"Loctite242"onthreads. Thirdor!seal Rotaryvalveadjustmentwithreplacedcrankcase havingnotimingmarks. 1980 444 type:1410 opening 510 closing Using angle finder.mark crankcaseat1410 frombottom edgeofmagnetoSideinletport. .~ .' Markhere '0 f:f, SECTION03 SUB-SECTION02,(ENGINES) Fromtop edgeof magneto sideinletport,mark crankcase at61o. Tocorrectlyinstalltherotaryvalveproceedasfollows: - Turningcrankshaftcounter-clockwise.(drivepulley side)bringmagnetosidepistontoTopDeadCenter uSingaT.D.C.gauge. - Positiontherotaryvalveongeartohaveedgesas closeaspossibletothemarks. O NOTE:TherotaryvalveISasymmetrical,therefore. atassemblytrypositioningeachsideofdiscon geartodeterminebestinstallationposition . @@Torqueto20Nom(16ft-Ibs). MagnetoSidepiston mustbeatToe Timingmark (444ENGINETYPE).PAGE11 SECTION03 SUB-SECTION02,(ENGINES) TOPEND 5 ""=>..,,, 3-------2II: 1514c=:: @ @--16 (444ENGINETYPE),PAGE12 7,Gasket 2.Cylinder block 3.Cylinder head gasket(2) 4Cylinder head gasket 5.Cylinder head 6.Washer70. 5mm(8) 7Holder bracket 8.NutM70(8) 9,Stud M6X75(2) 70.Socket(coolantoutlet) 7 7.Lockwasher6mm(2) 72.Nut M6 (2) 73.Piston(2) 74.Rectangular ring(2) 75,Semi-trapez ring(2) 76.Needlebeanng(2) 77,Gudgeonpin(2) 78.Circlip(4) TOPEND CLEANING Discardallgaskets. Cleanallmetalcomponentsinanon-ferrousmetal cleaner. DISASSEMBLY&ASSEMBLY (2) Becauseofcapnuts.cylinderstudshavetobe screwedintocrankcasesotheydonotprotrudefurther than15.6cm(6.140").Ifitisnotpossibletoobtain thislength.awashermustbeaddedbetweencylinder headandcapnut. 15.6em Priortowashers (2)installation,applysiliconesealant onwasherseatofcylinderhead,aroundstud. Torquecylinderheadnutto3SN'm(2Sft-Ibs)following illustratedsequence. Silicone sealant SECTION03 SUB-SECTION02,(ENGINES) @@@Placeacleanclothovercrankcasetoprevent circlipsfromfallingintocrankcase,thenuseapointed tooltoremoveGirclipsfrompistons. Drivethegudgeonpinsinoroutusingasuitabledrive punchandhammer. Scrapeoffcarbonformationfromcylinderexhaustport, cylinderheadandpistondomeuSinga woodenspatula. O NOTE:Theletters"AUS"(overanarrowonthe pistondome)mustbevisibleaftercleaning. Cleanthepistonringwithagroovecleanertool,orwith apieceofbrokenring. 'til' CAUTION:Whentappinggudgeonpininorout '" ofpiston,holdpistonfirmlyinplacetoeliminate thepossibilitiesoftransmittingshockandpressureto theconnectingrod. Allassembly,placethepistons overtheconnectingrods withtheletters AUS(overanarrowonthepistondome) facIOgdirectionoftheexhaustport. ~ ,I , ~ ' " " ;' i ~ ~ ~ OncetheGlrclipsareinstalled,turneachClrcllpsothat thecirclipbreakisnotdirectly inlinewithpistonnotch. Usingveryfineemerycloth,removeanyburrsonpiston causedthroughcirclipinstallation. Pistonnotch Pistontowallclearanceshouldbe: MINIMUM 0.070mm (.OO2S") MAXIMUM 0.200mm (.OOS") (444ENGINETYPE).PAGE13 SECTION03 SUB-SECTION02,(ENGINES) MAGNETO

22 32 30---1 I.Armature plate 2.Lightingcoil 3.Generator coil 4.Femaleconnector(2) 5.Condenser(2) 6.Contact breaker(2) 7.Femaleconnector(2) 8.Rubbercap(2) g.Lubricatingwick 10.Magnetoring I I.Washer5.3 mm(2) 12.Lockwasher5mm(2) 13.AI/enscrew M5X18 (2) 14.Lockwasher6mm(4) 15.AI/enscrew M6X11.5 (4) 16.Magnetohousing 17.Stud M8X15 (3) (444ENGINETYPE).PAGE14 CD ---0

1 .... l,;::..-.,,,, ,/;:,'-> .., I,'t,_ 1..:,.....,,' "/r\}._,:{ /"'/,''/ III) 1/, ,,11'- I1,'/ lit :r:;l'::"':-:vr" /1 1;'1,.",'/7

CJl:7?r ,lidI11 4CD12 CD CD@6 op- 24 1----23 , 18.Lockwasher8mm(3) 19.Nut M8(3) 20.NutM22X1.5 CD 10 2I."Loctite 242" (blue,medium strength) 22.Cablegrommet 23.Ignitioncoil bracket 24.Lockwasher6mm(2) 25.NutM6(2) 26.Ignitioncoil (2) 27.Lockwasher5mm(6) 28,Cylindrical head screw M5X20.(6) 29.Protectioncap(4) 30.Ignitioncable440. mm,magneto Side 30.Ignitioncable560.mm,P.T.0.side 3I.Suppressorcap(2) 32.Sparkplug(W260.MZ2)(2) @ 21 MAGNETO CLEANING Cleanallmetalcomponentsinanon-ferrousmetal cleaner. ,., CAUTION:Cleanarmatureandmagnetousing "t"onlyacleancloth. DISASSEMBLY&ASSEMBLY 00 WheneveracoilISreplaced.theairgap(distance betweencoilendandmagnet)mustbeadjusted. Tocheck air gap.insert a feeler gaugeof0.30-0.45mm (.012-.018")betweenmagnetandcoilends.Ifneces-sarytoadjust,slackencoilretainingscrewsandrelocate coil. o Toreplacea condenser,itisfirstnecessary tounsolder theblackleadusingsolderingiron.Thecondensercan thenbedrivenoutof thearmatureplateusingasuitable pusherandhammer.Toreinstall.inverseprocedure. (s)Whenreplacingc o n t ~ c tbreakers.applyalightcoat ofgreaseonlubricatingwick. @@@Apply"Loctite242"onthreads. SECTION03 SUB-SECTION02,(ENGINES) 66)@Withmagnetoretainingnutremovedandhold-on supportinplace,Installspecialpullerontohub. Tightenpullerboltandatsametime,taponbolthead usingahammertoreleasemagneto. Hold-onsupport At assembly,clean crankshaft extension (taper) then apply "Loctite242" Installmagnetoretainingnut(with"Loctite242"on threads)andtorqueto80N'm(60ft-Ibs). (444ENGINETYPE).PAGE15 271 25 33 28- !"'(f) Gl m m ~m

-I m(") z-l m( Glo '"1::1 ZZ m m 0 S!2 w SECTION03 SUB-SECTION02,(ENGINES) 503ENGINETYPE ENGINESUPPORT andMUfFLER I

30-28, 32-$ 33-61 (503ENGINETYPE).PAGE2 19-f...

".,-19C"',...,...8-1 /

/ 7 4_ 5--

2 I o 11 --12 10 7.503 Rotaxengine 2.Sparkplug grommet(2) 3.Enginesupport 4.Flat washer705 mmX27X2mm (4) 5.Lockwasher70mm(4) 6.Hexagonal nut70 mm(4) 7.Crosssupport 8.Carriagebolt~- 76X7t" (2) 9.Internaltoothdishedwasher(2) 7O.Hexagonal elastic stopnut~ - 76(4) 7 7.Rubber shear mount 72.Washer(2) 73.Carriage bolt 7176- 74X2 r(thread-ed7t")(2) 74.Retainer plate(2) 75.Washer(4) 76.Threadedbushing 7 7.Rubber sleeve(2) 78.Sleeve(2) 79.Damper (4) 20.Hexagonal elastic stop nut 7/76- 74(2) 27.Gasket(4) 22.Exhaustmanifold ENGINESUPPORT ANDMUffLER REMOVALFROMVEHICLE Removeordisconnectthefollowings(ifapplicable)then liftengineoutofvehicle. ..Pulleyguard,drivebelt. 41\ 29.Hexa90nal head screw M8X16 (3) 30 Hexagonal nutM 18X1.5 31."Loctite242" (blue.medium strength) 32.Grommet 33.Grommet 34.Ignitioncoil(2) (640ENGINETYPE)PAGE8 19 1.Armature plate 2.Condenser(2) 3.LightingcoilI100W 4.CylindricalPhillipshead screwM5X 2B(2) 5.Generator coil 6.Distance sleeve11mm(2) 7.Lighting coil30.W B.CylindricalPhillipshead screwM5X 32(2) 9.Femaleconnector(6) 10Femaleconnector(4) 11.Rubber cap(4) 12.Breaker point set(2) 13.Lubricatingwick 14.Magnetoring 15.Flatwasher(2) 16.Lockwasher (B) 17.AI/enscrew M5XIB (2) lB.Spring seat 19.Camspong 20..Breaker cam 21.Lockwasher (4) 22.AI/enscrew M6XII. 5(4) 23.Magneto housing 24.Centrifugal weightspong 25.Centrifugalweight 26.Bearing screw 27.Starting pulley 35.Cylindrical slottedheadscrewM5X 22(6) 36.Protectioncap(2) 37.Ignitioncable(20.0.mm) 3B.Protectioncap(2) 39.Sparkplug protector(2) 40 Sealing sleeve(2) 41.SparkplugM4A2(M24o.TI)(2) 30 MAGNETO CLEANING Cleanallmetalcomponentsinanon-ferrousmetal cleaner. _CAUTION:Cleanarmatureandmagnetousing Yonlyacleancloth. DISASSEMBLY&ASSEMBLY 0To replacea condenser.it is firstnecessary to unsolder thetwo (2)black leads.Thecapacitor canthenbedriven outofthearmatureplateusingasuitablepusherand hammer.Toreinstall,inverseprocedure. 00 Magnet 7- 10mm (.275-394") 8- 12mm (315~.472") Edgegap \.-'\ Ifedgegapismoreorlessthanspecified.theproblem lieswithengineinternalcomponents(crankshaftoutof ali9nment,brokenWoodruffkey,loosebreakercam, etc.);correctivemeasuresshouldbeapplied. SECTION03 SUB-SECTION03,(IGNITIONTIMING) (IGNITIONTIMING).PAGE3 SECTION03 SUB-SECTION03,(IGNITIONTIMING) IGNITIONTIMING- TWOCYLINDERENGINES (377,444, 464, 503,640TYPES) Two methods aredetailedin this section;the first using thetimingmarksstampedontheengine,thesecond usingaTopDeadCentergauge. TIMINGMARKSPROCEDURE 1.Disconnectsparkplugwiresandremovesparkplugs. 2.Removerewindstarterassemblyfromenginethen remove the fanprotector,starting pulley and"V" belt. ONaTE: Theupper breakerpointcontrolsthetiming ofthemagneto sidepistonandthelowerbreaker pointcontrolstheP,T,O.sidepiston. 3.Rotatecrankshaftuntilbreakerpoints,visiblethrough magneto ringopening,arefullyopened.Adjustpoints settingto0.35mm0.05(.014".002)using a feelergaugeandscrewdriver,asillustrated.Repeat procedureforotherpoint.Adjustbothsidesequally. ONaTE:Breakerpointsgapcanchangeupontight-ening.Alwaysrecheckaftertightening. 4.Disconnectjunctionblockatengine thenconnectone lead of a timing light (flashlight type)or of a tone timer, tothebluewire(mag.side)leadingfromengine. Connectotherwiretoground(metallicportionofthe engine). 5.Slackenthetwo(2)armatureplateretainingscrews andturntiminginstrumentON.Rotatecrakshaftuntil mag.sidepistonapproachestopdeadcenterand timingmarksalign(for 640 engine type,holdcentrif-ugaladvancemechanisminfulladvanceposition). (IGNITIONTIMING),PAGE4 d:::':;\'>.'"Retar?ed "'X:pOSition Full advance position Rotate armature plate until timinglight fluctuatesor tone signallevelvaries.Retightenretainingscrews. 6.Ignitiontimingcanchangeupontighteningtherefore, rotatethemagneto counter-clockwisetof a turnand slowly turnthemagnetoback ina clockwisedirection. Assoonasthetimingmarksalignthetiminglight shouldfluctuate,orthetonesignallevelshouldvary. Readjustifnecessary. ~ /~ ~~ o o Tooearly:TurnarmatureplateclockWise ~ / f". o o Toolate:Turnarmatureplatecounter-clockwise 7.Disconnect timinginstrumentwire fromblue wire then reconnectit to theblue/red wire (PTO. side)leading fromengine.Rotatecrankshaft untilPTO. sidepiston approachestop deadcenter.Assoonastimingmarks align.timing light should fluctuate,or tone signal sound levelshouldvary.Ifnecessarytoadjust,proceedas follows: eIftimingistooearlydecreasebreakerpointsgap towardlowerlimit,i.e.0.30mm(.012"),then r.echecktiming. eIftimingistoolateincreasebreakerpointsgap towardupperlimit,i.e.OAOmm(.016"),then rechecktiming. ~ /~ ~ o o Tooearly:DecreasePOintsgap ~ / ~ f" o o --Toolate:IncreasePOintsgap -SECTION03 SUB-SECTION03,(IGNITIONTIMING) TOCGAUGEPROCEDURE 1.D,sconnectsparkplugwiresandremovesparkplugs. 2.Removerewindstarterassemblyfromenginethen remove the fanprotector,starting pulley and"V" belt. NOTE:Theupper breakerpointcontrolsthetiming ofthemagnetosidepistonandthelowerbreaker pOintcontroltheP.T.O.sidepiston. 3.Rotatecrankshaftuntilbreakerpoints.visiblethrough magnetoringopeningarefullyopen.Adjustpoints settingto0.35mm0.05(.014".002)using afeelergaugeandscrewdriver,asillustrated. Repeatprocedureforotherpoint.Adjustbothside equally. ~ _ o ~ O NOTE:Breakerpointsgapcanchangeupontight-ening.Alwaysrecheckaftertightening. 4.Disconnectjunctionblockatenginethenconnectone leadofatiminglight(flashlighttype)oratonetimer, tothebluewire(mag.side)leadingfromengine. Connectotherwiretoground(metallicportionofthe engine) . 5.InstallandadjustT.D.C.gaugeonengineasfollows. GRotatemagnetountilmag.sidepistonisjustbefore topdeadcenter. (IGNITIONTIMINGJ.PAGE5 SECTION03 SUB-SECTION03,(IGNITIONTIMING) eWithgaugeinadaptor.adjustrollersothatitis parallelwithdialface.Tightenrollerlocknut. Outerrmgsetscrew Roller locknut =-eLoosenadaptorlocknutthenholdinggaugewith dialfacetowardmagneto.screwadaptorinmag. sidesparkplughole. eSlidegaugefarenoughintoadaptortoobtaina readingthenfingertightenadaptorlocknut. eRotate magneto untilmag.sidepiston isat top dead center. oUnlockouterringofdialandturnituntil"0"on dialalignswithpointer. sLockouterringinposition. 6.Slackenthetwo(2)armatureplateretainingscrews andturntiming ON. eRotatemagnetocounter-clokwiseuntilspecified pistonpositionbeforetopdeadcenterisreached. (IGNITIONTIMING).PAGE6 Engine type 377 444 464 503 640 Direct measurement B.T.D.C. 207mm0.25I (.081"010) 2.35mm0.25I (.093"01O) 2.07mm0.251 (.081"010) 2.07mm0.25 (.081".010) N.A. Indirect measurement B.T.D.C. N.A. NA NA NA 3.62mm0.25 (.143"01O) Slowlyrotatearmatureplateuntiltiminglightfluctuates oruntiltonesignalsoundlevelvaries.(For640engine type,holdadvancemechanismcentrifugalleverinfull advanceposition.)Retightenretainingscrews. a NOTE:Ignition timingcanchangeupontightening. Alwaysrecheckaftertightening. 7.Disconnect timinginstrument wire frombluewire then reconnectit to theblue I redwireleadingfromengine. RemoveT.D.C.gaugefrommag.sideandreinstall ItonP.T.O.side.aspreviouslydetailed. 8.RotatecrankshaftuntilP.T.O.pistonapproaches T.D.C. As soon as same specified piston position before top deadcenter asonmag.sideisreachedthetiming lightshouldfluctuateortonesignallevelvary.(for 640enginetype,holdadvancemechanisminfull advanceposition). Ifnecessarytoadjust.proceedasfollows. With piston at specified position,slackenlower breaker point retainingscrew thenreadjustbreakerpointsgap untilfluctuatesortonesignallevelvaries. "IftimingIStooearlydecreasebreakerpointsgap towardlowerlimit,i.e.0.30mm(.012"),then rechecktiming. "Iftimingistoolateincreasebreakerpointsgap towardupperlimit,i.e.OAOmm(.016"),then rechecktiming. O NOTE:Breakerpointsgapcarchangeupontight-ening.Alwaysrecheckaftertightening. EDGEGAPVERIFICATION Byfollowingeither of theproceduresmentionedherein theedgegap willautomaticallybeadjusted,However, if theedgegapistobeverified,proceedasfollows: eFromtimingmarks,rotatemagnetoclockwise* of aturn,thenslowlyturnmagnetobackcounter-clockwiseuntiltiminglightfluctuatesoruntiltone signalsoundlevelvaries(for 640 engine type,hold advancemechanisminfulladvanceposition). Atthispointcheckthedistancebetweengenerator coilendandmagnet(edgegap),witha stripcard-boardofappropriatewidth.(Refertothefollowing table.) SECTION03 SUB-SECTION03,(IGNITIONTIMING) Enginetype 377,444, 464,503 640 o Magnet~ Edgegap 8- 12mm (.315- A72") 7- 10mm (.275-394") Edgegap y ~ Ifedgegapismoreoflessthanspecified,theproblem lieswithinengineinternalcomponents(crankshaftout ofalignment,brokenWoodruffkey,loosebreakercam, etc.).Correctivemeasuresshouldbeapplied. (IGNITIONTIMING).PAGE7 SECTION03 SUB-SECTION03,(IGNITIONTIMING) C.D.IGNITION- 354-454ENGINETYPES FOREWORD OnmodelsequippedwithaC.D.Ignitionsystem.plug firingISinitiatedbyanelectricalpulse.Thispulseis releasedwhenametalprojectionontheflywheelhub rotatesnearthetriggercoil.Therefore,timingmustbe performedwhiletheengineisrunning. A stroboscopic timing light suchasSunPTL45.Snap-On MT215B.BoschEFAW169A.orasuitableequivalent. plusa12voltbatteryareneeded. IGNITIONTIMING TimingprocedureforthisenginetypeIScomposedof fourmainphases,allbeingequallyimportant: 1.Positionofthearmatureplate. 2.Positionofthetimingmarksonmagnetoring. 3.Airgapbetweentriggercoilandmagnetoring. 4.Timingverificationusingastroboscopic timinglight. 1. Toobtainbestgeneratorcoilperformance,position thearmatureplateonthecrankcase withtheretaining capscrewsinthemiddleoftheplateslots. .., CAUTION:Whenassemblingmagnetoringon "crankshaft,cleancrankshaftextension(cone)and threads.Apply"Loctite 242" (no.4137025) oncone andthreads.Torqu.eboltto80N'm(60ft-lbs). (IGNITIONTIMING).PAGE8 2.Checkthepositionofthetimingmarks(foreach cylinder)onmagnetoring:repunchifnecessary. Withthepistonpositionedat1.40mm(.055") B.T.D.C ..magneto ringmark shouldalign withcentral markoncrankcase(aroundtiminghole). II Crankcase centralmark 3.Checkairgapbetweenmagnetoringandtriggercall. Thegapshouldbe0.8to1.2mm(.031to.047"). 4.Check timing using a stroboscopIc timing light (oneach cylinder). WARNING:Placeskitipsagainstthewall,raise rearofvehiclesothetrackisnotincontactwith thegroundandplaceitonastandequippedwitha protector.Make sure nobody passesbehindthevehicle duringtimingprocedure. Magnetoringmarkandcrankcasecentralmarkshould alignat6500RPM. u Crankcase centralmark SECTION03 SUB-SECTION03,(IGNITIONTIMING) If necessary to adjust:unscrew slightly the two (2)screws holdingtriggercoilbracket.thenmovebracketupor down. O NOTE: Carburetor side trigger call controls magneto sideIgnitionandexhaustsidetnggercoilcontrols P.T.O.sideIgnition. Ifcorrecttimingisimpossiblewithtriggercoilbraket travel,stopengine,removebracketfromcrankcaseand relocatethetriggercoilonitsbracket. (IGNITIONTIMING).PAGE9 MODEL ELAN&SPIRIT CITATION3500, MIRAGEI CITATION4500/E, MIRAGEIIIE CITATIONSS, MIRAGESPECIAL EVEREST5001 E FUTURA5001 E EVERESTLC, FUTURALC BLIZZARD5500 GRANOPRIXSPECIAL BLIZZARD7500 SUPERSONIC BLiZZARO9500 ULTRASONIC ALPINE640ER ELITE450LC SECTION03 SUB-SECTION04,(CARBURETOR) CARBURETORSPECIFICATIONS ENGINECARBURETORLOWSPEEDIDLE TYPETYPEADJSPEED MikunikR.P.M. 247VM28-24211turn1100-1300 277VM34-22811turn1100-1300 377VM34-2291turn 2000 377 2XVM30-1111 !turn 1800-2000 503VM36-831turn1800-2000 464VM34-2271!turn2000 5032XVM34-20311turn1800-2000 MAG:VM34-230 354PTOVM34-2331 ~turn1800-2000 PIO:VM36-88 454MAG:VM36-861turn1800-2000 640VM34-21511turn1800-2000 444VM34-2011turn1800-2000 -(CARBURETORSPECIFICATIONS).PAGE1 SECTION03 SUB-SECTION04,(CARBURETOR) & ,,0 1/ 0: f_,.jf / \ \ \ '\t,:.-?..... ....".Y,f Ir\I/lt,' ,"-.,. "'- '- -..... / "

I11 32 (REWINDSTARTER).PAGE3 SECTION03 SUB-SECTION06,(REWINDSTARTER) REMOVAL Removeboltsandwasherssecuringrewindstarterto engine,thenremoverewindstarter. O NOTE: On some models,the hood requires support-Ingbeforeremovingstarterhousing.Theretaining cableISattachedtooneoftherewindstarter.8ttachlng bolts, OnoilInjectionmodels,removeoilinjectionpumpfrom rewindstartercover. DISASSEMBLY&ASSEMBLY Priortoinstallingstartergriponnewrope,itISfirst necessarytofusetheropeendwithalitmatch.Pass ropethroughstartergnp,andtieaknotIntheropeend. Fusetheknotwithalitmatchthenturntheknotdown andpullthestartergripovertheknot. 000 Toremoveropefromrewindstartermechanism, firstremovelocknng,lockspnng,Clrclip,pawllockand pawl.Fully extend rope andhold sheaveInposition.USing apOintedtool,disengagekeyandpulloutrope. ~U(J ~ - ~ ~ Toinstallrope,proceedasfollow: - Rotatesheavecounter-clockwiseSIX(6)turnsto achievecorrectrecoiltenSion.HoldInPOSition, IREWINDSTARTER),PAGE4 - While holding sheave under tension,fat ate sheave until thestarterhOUSingorificeandsheaveorificealign. ~Insertropethroughbothonficesuntilropeisvisible Inthekeyclamphousing, ~PositionthekeyclampInItShousingthenpushIn tolocktherope. 00At assembly,positionspringouterendIntospring gUidenotchthenwindthespringclockwiseIntoguide. WARNING:Sincethespringistightlywound insidetheguideitmayflyoutwhentheguide ismanipulated,Alwayshandlewithcare, BeforeInstallingspnngass'yIntostarterhousing,lubri-catespnngWithlightmachineoil(L,P,Sno.1). Also apply low temperature greaseonhOUSingshaftbase. Positionspnngassemblyintostarterhousingasillustrat-ed,thenplaceropesheaveIntostarterhOUSingmaking surethatthesheavehubnotchengagesInthespring hook. 0@@Posltlonpawl,pawllockandc"clip. @@InstalllockspnngandlubncateWithmolybdenum basegrease. @Installlocknng, INSTALLATION OnallInjectionmodels,reinstallallpumponrewind starterassembly. ReinstallreWindstarterassemblyonengine. O NOTE:Ifapplicable,connecthoodretainingcable torewindstarterretainerbolt. MODEL ELAN,SPIRIT CITATION3500,MIRAGEI CITATION4500,MIRAGEII CITATION4500E,MIRAGEliE CITATIONSS,MIRAGESPECIAL EVEREST500,FUTURA 500 FUTURA500E,EVEREST500E EVERESTLC,FUTURALC SECTION04 SUB-SECTION01,(ELECTRICCHARTS) HEADLAMPTAILLIGHT WATTWATT 60/605/21 45/455/21 45/455/21 45/455/21 45/455/21 45/455/21 45/455/21 45/455/21 BLIZZARD5500,GRANDPRIXSPECIAL45/455/21I BLIZZARD7500,SUPERSONIC BLIZZARD9500,ULTRASONIC ELITE ALPINE 45/455/21 45/455/21 45/455/21 45/455/21 COLOURCODE BK-BLACK WH-WHITE RD-RED BL-BLUE YL-YELLOW GN-GREEN GY-GREY VI-VIOLET OR-ORANGE BR-BROWN (ELECTRICCHARTS).PAGE1 en r m ~ :0 (") (") I l> ~ !! MAGNETO BL SPARK PLUG IGNITIONCOIL * CD 0 0 0 0 LIGHTINGCOil (75W) BRAKELIGHTCOil {23W} IGNITIONGENERATORCOIL HEADlAMP(60/60WI TAllLAMP(5-21WI BRAKE LIGHT SWITCH 1980 WHjIl-' -'-- 31BK BR ELAN SPIRIT I ;:~ > , >-'" IGNITIONSWITCH 0 OFF ON BKBK GY HEADlAMP DIMMER SWITCHKILL SWITCH m r m CO-; OJ COCOI OJ -; f!! " Gl m W SABKGN Lr- VVWH II IlV-I'. )'f' :0 -< " m en GN/BK BK 8K.. BL BL/RDMBRSR 4115 4 "'"14 , RD RD/GN GN YL RD CDLIGHTINGCOIL110W LIGHTINGCOIL30W IGNITIONGENERATORCOIL 8) FUSE130A.I FUSE1.1A.J FUSE115A.I 1980 oBK EVERESTLC FUTURALC (2)HEADLAMP145/45WI TAlllAMP(5121WI RD/ BL LIGHT15WI OR/BK_ TETHER Knrl CUT,DUT BSWITCH c= BKI PTD(O()OJ@ RD/MAGI v,:;'m OFF r-_____......!R"D'---'"""('-"6"";4-111ON

RD/GN91-2.-.START IGNITION SWITCH YL/GY r\'-+__ -. L--{++__.!:R;!!D:...... ,....'LIGHT ____-+-I-+-__71_ ,'SWITCH RD/BL...g,RD/Bl r'1 "...L2SPEEDOMETER )RD/Bl;3: "",RgDI'-1Y..cL__ rF-fC-f\ b)Pulleymisalignment.b)Alignpulleys. c)Roughorscratchedpulleyc)Repairorreplacepulley l---l.lfi, surfaces.half. 2.Beltglazedexcessivelyorhavingbakedappearance. CAUSEREMEDY

Excessiveslippagecausedby: a)Insufficientpressureonbelta)Checkdrivepulleyforworn sides.ormissing flyweights! rollers.

b)Rusteddriveordrivenpul- b)Cleanshaftwithsteelwool q:--< leyshafts.andlubricatewithlowtem-aperaturegrease. ) c)Oilonpulleysurfaces.c)Cleanpulleysurfaceswith fineemeryclothandclean cloth. d)Incorrectcentrifugalgover- d)Installcorrectgovernor. nor. 3.Beltwornexcessivelyintopwidth. CAUSEREMEDY ....ConSiderable a)Excessiveslippageduetoa)Carryoutinspection. use irregularoutwardactuationb)Repairorreplacepulley. movementofdrivepulley.c)Usingunspecifiedtypeof b)Roughorscratchedpulleybelt. surfaces.Replacebeltwithcorrect c)Improperbeltangle .Bombardierbelt. ...Newbeltd)Considerableuse.d)Replacebeltif3mm('\") lessthanrecommended width(seeTechnicalData). 4.Beltwornnarrowinonesection. CAUSEREMEDY I I Excessiveslippageindrive I pulleycausedby: I a)Frozenortoolighttrack.a)Liberatetrackfromiceor I checktracktensionand I I alignment. I I b)Drivepulleynotfunctioningb)Repairorreplacedrivepul-I Iproperly.ley. IIc)Engineidlespeedtoohigh.c)ReduceengineRPM. I Id)Incorrectbeltlength.d)Usingunspecifiedtypeof I Ibelt.Replacebeltwithcar-I IrectBombardierbelt. I e)Incorrectpulleydistance.e)ReadlusttospeCifications.I I I I I I ----(DRIVEBELT),PAGE4 6.Beltsideswornconcave. (. angle ) 6.Beltdesintegration. :> > 1/ = 7.Beltedgecordbreakage.

I 8.Flexcracksbetweencogs. SECTION05 SUB-SECTION02(DRIVEBELT) CAUSEREMEDY a)Roughorscratchedpulleya)Repairorreplace. surfaces. b)Unspecifiedtypeofbelt.b)Replacebeltwithcorrect Bombardierbelt. CAUSEREMEDY a)Excessivebeltspeed.a)Usingunspecifiedtypeof belt.Replacebeltwith propertypeofbelt. b)Oilonpulleysurfaces.b)Cleanpulleysurfaceswith fineemeryclothandlubri-catewithlowtemperature grease. CAUSEREMEDY a)Pulleymisalignment.a)Alignpulleys. CAUSEREMEDY a)Considerableuse.belta)Replacebelt. wearingout. 9.Shearedcogs,compressionsectionfractureortorn. CAUSEREMEDY a)Improperbeltinstallation.a)RefertoInstallationsec-tion. b)Beltrubbingstationaryob- b)Checkdrivecomponents. Jectonpulleys. c)Violentengagementofc)Grease.replacespringor dflvepulley.drivepulley. (DRIVEBELT).PAGE5 SECTION05 SUB-SECTION02(DRIVEBELT) 10.Belt" Flip-Over"athighspeed. CAUSE a)Pulleymisalignment. b)Beltexcessivespeed. (DRIVEBELT).PAGE6 REMEDY a)Alignpulleys. b)Usingunspecifiedtypeof belt.Replacebeltwithcor-rectBombardierbelt. ( @ '@. @ I o @ 05

"COUNTERWEIGHT ASS'y

'J I 5 +WARNING:Drivepulleyrepairsthatincludeany dissassemblyorassemblyproceduresmustbe performed byanauthorizedBombardier dealer,or other suchqualifiedperson.Sub-componentinstallationand assemblytolerancesrequirestrictadherencetoproce-duresdetailed. SECTION05 SUB-SECTION03,(DRIVEPULLEY) DRIVEPU LLEY ROLLERROUNDSHAFT TYPE ElanandSpirit @ (!);'rr;;_ 7.Retainingbolt 2.Washer 3.Governor cup 4.Slidinghalf ass 'y 5.Spnng 6.Springseat 7.Beanng B.Fixedhalf g.Nut 7O.Counterweight 7 7.Shouldered pin 72.Bushing 73.Roller 74.Shim 75.Shim o (0 (DRIVEPULLEY),PAGE1 SECTION05 SUB-SECTION03,(DRIVEPULLEY) REMOVAL WithengIOecold,removesparkplug(s)thenbringPTO, (PowerTakeOff)pistonatT,D,C.(TopDeadCenter) position. Rotatedrivepulley450 clockwisetheninsertenough starterropeintocylindertofillitcompletely, WARNING:Springpressurecanforceassembly apart;therefore,itisimperative that thegovernor cupbeheld firmlyduringgovernor retainingboltremo-val. Ifnecessarytoremovefixedhall,slidea lengthofsteel pipeovershaft.Attachwitha5/16"nutandbolt,as illustrated.Thefixedhalfcanthenberemovedwitha pipewrench, p, otectlvesleeve r-& ! ! '--" f.l 5/16"bolt DISASSEMBLY&ASSEMBLY 0At assembly,torqueboltto61Nom(45ft-Ibs), 0@Shouldered pinbushingsmustbeinstalledinsliding halfasperillustration. Bushmg shoulder Bushmg shoulder CDBearingISreplaceableandcanberemovedandIn-stalledwithastandardpullerandpusher. (DRIVEPULLEYi,PAGE2 @ApplyLoctite242orequivalentonthreadsthen torquenutsto14Nom(10It-Ibs). .. CAUTION:Donotdisassemblecounterweitht "..unlessreplacementisnecessary. @Asrequired,maximumoftwo(2).Usedtoobtaina neutralfunctionofthedrivepulley whenengIOeisIdling. refertoINSTALLATION. @)UsedtoobtalOcorrectpulleyalignment,referto section05-05. CLEANING CleanpulleyfacesandshaftwithflOesteelwooland dry cloth.CleanslidIOghalfbushing withcleandrycloth, INSTALLATION Lock crankshaftinpositionasexplained inremovalproce-dure.Make surecrankshaftisrotated450 counterclock-wise fromT,D.C,positionand thatcylinderiscompletely filledwithastarterrope. Cleancrankshaft extensionthreads andapply Loctlte242 orequivalenttheninstallfixedhalfonextension. PackinsideofpulleyshaftwithHighPerformanceDrive PulleyLubricant. Installgovernorcupcorrectlyasperillustrationmaking surethattherollersareslidingontheirramp. t{Z)-y Positionretainingboltthenlubetorqueto61Nom(45 ft-Ibs) . +WARNING:Shim(s)@is(are)usedtoobtaina neutralfonctionofthedrivepulleywhenengine isidling.Proceedasfollowswhenretainingboltis torqued: Withanewdllvebeltinstalled.youshouldbeableto Inserta minimum of0.80 mm(.030") thick feeler gauge on each side of the dllve belt simultaneously when pushing dllvebelttoSitonbeallng. 080 mm feeler gauge SECTION05 SUB-SECTION03,(DRIVEPULLEY) 080 mm feeler gauge Shlm@locatedbetweengovernorcupanddllvepulley shaftwillhelpyouto obtaincorrectadjustment.Usenot morethentwo(2)shims. (DRIVEPULLEY).PAGE3 SECTION05 SUB-SECTION03,(DRIVEPULLEY) ROUNDSHAFT (TAPER)TYPE MirageI,MirageIII E Citation3500,Citation4500/E I 2

51 .6

" 11 .,

" 19 18 10 o @ +WARNING:Drivepulleyrepairsthatincludeany dissassemblyorassemblyproceduresmustbe performed by anauthorizedBombardier dealer, or other suchqualifiedperson.SUb-componentinstallationand assemblytolerancesrequirestrictadherencetoproce-duresdetailed. (DRIVEPULLEY).PAGE4 @ 8lV;./:) 1l5'@" )5II 14 I.Innerhalf 2.Washer 3.Innerrace 4.Needlebearmg 5.Washer 6.Sprmgseat 7.Spring B.Outerhalf g.Counterwelthtass'y 10.Rollerass'y II.Leverass'y 12.Bushingkit 13.Shouldered Pinass'y 14.Governorcup 15.Washer 16.Lockwasher I 7.Capscrew lB.Puller 19.Puller pin 20.Shim 16@ CAUTION:MirageandCitationmodelsare equippedwithdrivepulleysofMETRICdimen-sions. REMOVAL: Withenginecold.disconnect thetwo muffler springsand lift upthe muffler untildrivepulleycan beeasily removed. Lock the crankshaftby usingoneof the followingmethod: Insert the crankshaft locking tool P/N 420876 640into theimpulseholeoftheengine.Slowlyrotatethecrank-shaftuntilitlocksintoposition . CAUTION:Donotuseanytype ofpinother than the toolPIN420 876640 supplied with the tool kit. OR: Removesparkplug(s}thenbringP.T.O.pistonatT.D.C. position. Rotatedrivepulley45clockwisethenInsertenough starterropeintocylindertofillitcompletely. +WARNING:Springpressurecanforceassembly apart;therefore,itisimperative that thegovernor cupbeheld firmly during governor retainingboltremo-val. Ifitisnecessarytoremovefixedhalf.usedrivepulley pullerno.529-0028.529-0030 . CAUTION: This pulleyhasmetric threads.Donot usestandardthreadpuller. Removestarterropeblockingpiston.thenreblockpiston afterhavingturned45counter-clockwisefromT.D.C. position;orinstallcrankshaftlockingtool. Installpullerinpulleyshaftthentighten.atthesame timeknockslightlyonpullerheadtodisengagepulley fromenginecrankshaft. SECTION05 SUB-SECTION03,(DRIVEPULLEY) DISASSEMBLY&ASSEMBLY @Atassembly.torqueboltto61N'm(45ft-Ibs). @ShoulderedpinbushingsmustbeInstalledInsliding halfasperillustration. Bushing shoulder o Beanngisreplaceable. Bushing shoulder CDBearinginnerracecanalsobereplaced.Toremove theinnerrace:Secureinnerraceinaviceandbreak openusingachiselandhammer. + WARNING:Safety goggles must be worn asmetal piecesmaybeprojected. (DRIVEPULLEY).PAGE5 SECTION05 SUB-SECTION03,(DRIVEPULLEY) ToInstallanewinnerrace: UseapressorplastichammerasIllustrated.Makesure theinnerraceisflushwiththebearingseat. ~~ ~ - ~":15='---=\ ~ ,, ~ . 0@ApplyLoctlte242orequivalentonthreadsthen torquenutsto14N'm(1Oft-Ibs). _CAUTION:Donotdisassemblecounterweitht Yunlessreplacementisnecessary . WARNING:Shim(s)@is(are)used to obtain a neu-tralfonctionofthedrivepulleywhenengineis idling. Proceed as follows when retaining bolt is torqued: WithanewdnvebeltInstalled.youshouldbeable. to insert a minimumof 0.80 mm(.030") thick feeler gauge on each side of the dnve belt simultaneously when pushing drivebelttositonbearing. 080mm feeler gauge 080 mm feeler gauge Shim@locatedbetweengovernorcupanddrivepulley shaftwillhelp youtoobtaincorrectadjustment.Usenot morethentwo(2)shims. (DRIVEPULLEY).PAGE6 CLEANING Cleanpulleyfacesandshaftwithfinesteelwooland drycloth.Cleanslidinghalf bushingwithcleandrycloth. INSTALLATION Lockcrankshaftinpositionasexplamedinremovalproce-dure.Makesurecrankshaftisrotated45 counterclock-wisefromT.D.C.positionandthatcylinderiscompletely filledwithastarterrope. PackinsideofpulleyshaftwithHighPerformanceDnve PulleyLubricant. Installgovernorcupcorrectlyasperillustrationmaking surethattherollersareslidingontheirramp. Ramp Positionretainingboltthenlubeandtorqueto61N'm (45ft-Ibs). SECTION05 SUB-SECTION03,(DRIVEPULLEY) ROLLERSQUARESHAFT WITHDURALONBUSHING

1 N 7.Fixedhalf 2.Slldmghalf 3.Guard 4.Bolt 5.Springseat 6.Spnng 7.Allenscrew B.Hubplug @ 9.Internal toothlockwasher 7O.Bolt 77."Duralon"bushmg 3 o CitationSS',MirageSpecial', Everest,Futura,Blizzard5500, GrandPrixSpecial,Elite 12. 600 I."I@ i, C-.- Ie;;@

II ilI,{\" o@I 72.Governorcup 72aElitemodel 73.Locktab 74.Retammgbolt 75.Counterweightass 'y 76.Rmggear(electricmodels) 77.Screw 78.Counterweight 7g.Bushmg 20.Shouldered pm 27.Nut 22.Roller 12 Thesemodelsareequippedwithmetncdrivepulleysexceptfortheshoulderedpinsthathavestandardthreads (DRIVEPULLEY),PAGE7 SECTION05 SUB-SECTION03,(DRIVEPULLEY) WARNING:Drivepulleyrepairsthatincludeany disassembly or assemblyprocedures must beper-formedbyanauthorizedBombardierdealer,orother suchqualifiedperson.Sub-componentinstallationand assemblytolerancesrequirestrictadherencetoproce-duresdetailed. REMOVAL Somepulleycomponentsaremarkedtoinsureproper assembly.If components lack such marks.marking should bedonemanuallybeforedisassembly.asper illustration. INDEXINGMARKSINLINE (2)Fixedhalf CDSlidinghalf CDGovernor cup @,' IIIII @Hubplug l ~ j Withenginecold.removesparkplugsthenbringP.T.O. (PowerTakeOff)pistonatT.D.C.(TopDeadCenter) position.Rotatedrivepulley450 clockwisethenInsert enoughstarterropeintocylindertofillitcompletely. Opentablockandremoveretainingbolt. Removedrivepulleyassemblyusingappropriatepuller. PIN529002100onallstandardthreadtapershaft pulleys or PIN860414200onCitation andMirage models (met-ricthreads) Removestarterropeblockingpiston.thenreb lockpiston afterhavingturned450 counter-clockwisefromT.D.C. position. InstallpullerInpulleyshaftthentighten.atthesame timeknockslightlyonpullerheadtodisengagepulley fromenginecrankshaft. (DRIVEPULLEY).PAGE8 DISASSEMBLY&ASSEMBLY Removeslidinghalfassemblyandgovernorcup. CAUTION:Donot taponthegovernorcup. Thegovernorcupcanbeeasilyremovedbyinserting two(2)t"Xl"NCboltsandtighteningalternately untilcuppullsout. Someboltsofthedrivepulleyhaving"Loctite"ontheir threads,itisadvisabletouseatoolsuchasanimpact to break the"Loctite" sealbefore attempting to unscrew. 0Torqueto7N'm(5ft-Ibs). 0Apply"Loctite242"onthreadsthenscrewInuntil headISflushwithhubplug.Donotallowheadtobite Intohubplug. @Atdisassembly.holdhubplugfirmlyagainst sliding half until the two(2)bolts are completely removed. Thiswillpreventdamageoftheslidinghalfthreads.At assembly.apply"Loctl1e242"onthreadsofboltsthen torqueto1 6N'm(12ft-Ibs). @To installorremove"Duralon"bushingfromhubplug usea suitable pusher and hammer or press.Install bushing asperillustration. @ . ~ J ., CAUTION:Becarefulwheninstallingslidinghalf .. assemblyonsquareshaftofdrivepulley toavoid scratches on "Duralon" bushing causedby square shaft edge. @Torqueto85N'm(63ft-Ibs). @ApplyLoctite24r onthreads. @Some drivepulleyshaveanoffsetInthehubplug. Shoulderedpinbushings withshouldermustbeInstalled Inthesehubplugs. ~BushingI Bushinglocation Inrelationwith theoffset Offset @@Apply .. Loctite242onthreadsandtorqueto14 N'm(10ft-Ibs) . ., CAUTION:Donotdisassemblecounterweights "unlessreplacementisnecessary. SECTION05 SUB-SECTION03,(DRIVEPULLEY) INSPECTION&CLEANING Drivepulleyshouldbeinspectedannually. CheckgeneralconditIOnofpulleyandInspectDuralon bushingfaces,asperillustrations. Telloncoating Teflon impregnated cloth GOOO GOOD WORN(mustbechanged) Teflon Impregnated cloth Teflon Impregnated cloth ClothsIScratched ortornand fiberglassbacking ISVISible Inside of slidinghalf shouldbecleaned with a cleancloth. Thesquareshaftcanbecleanedwithfinesteelwool andacleancloth. (DRIVEPULLEY).PAGE9 SECTION05 SUB-SECTION03,(DRIVEPULLEY) INSTALLATION Cleancrankshaftextensionus'mgfinesteelwoolanda cleancloth. .. CAUTION: When installing drive pulley onengine, Yreferencemarkonfixedhaltslidinghalfand governorcupmustbeinline. Lock crankshaft inpositionasexplainedinremovalproce-dure.Make surecrankshaftISrotated450 counterclock-wisefromT.D.C.positionandthatcylinderIScompletely filledwithastarterrope. Installfixedhalfoncrankshaftextensionthenposition slidinghalfassemblyonfixedhalfsquareshaft. .. CAUTION:Becarefulwheninstallingslidinghalf Yassemblyonsquareshaftofdrivepulley to avoid scratches on"Duralon" bushing causedby square shaft edge. Installgovernorcupmakingsurethattheshaftendrests ingovernorcupseating,Positionretainingboltwitha newlocktabthentorqueto85Nom(63ft-Ibs) . .. CAUTION:Incorrect seating of shaft endingover-Ynor cup can cause crankshaft bending. When pulley iscompletelyassembledalwaysmeasuredistanceof bothpulleyhalvestomakesurethatthepulleyis properlyinstalled.Distancemustbe76mm(3"). (DRIVEPULLEY).PAGE10 Pushonsliding halftowards governorcup 10remove allpossibleslack whenmeasunng 76mm (3") Liftrearofvehicleofftheground.Installdrivebeltand pulleyguardthenstartengineandapplythrottleand brake.2-3times.Stop engine andretorque retaining bolt. Bendonesideoflocktabovergovernorbolt. 7 I Iii' "-"_______12 "-. SECTION05 SUB-SECTION03,(DRIVEPULLEY) ROLLERSQUARESHAfTBEARINGTYPE WITHDURALONBUSHING Alpine II@

3 I 2 ,.

"',,""-"." " COUNTERWEIGHTASS'Y 1.Ret8lningbolt 2.Tabwasher 3.Governor cup 4."Duralon" bushing 5.Slidinghalf 6.Spring 7.Fixedhalf B.Ring g.Bearing 10.Springseat 17.Stopnut 12.Counterweight 13.Shouldered pin 14.Bushing 75.Roller 16.Spacer 1 7.Setscrew 7B.Shim (DRIVEPULLEY).PAGE11 SECTION05 SUB-SECTION03,(DRIVEPULLEY) WARNING:Drivepulleyrepairsthatincludeany disassembly or assemblyproceduresmust beper-formedbyanauthorizedBombardierdealer,orother suchqualifiedperson.Sub-componentinstallationand assemblytolerancesrequirestrictadherencetoproce-duresdetailed. REMOVAL Withenginecold.removesparkplugsthenbringP.T.O. (PowerTakeOff)pistonatT.D.C.(TopDeadCenter) position. Rotatedrivepulley450 clockwisetheninsertenough starter ropeintocylinder to fillitcompletely.Install"U" clamp(SeeToolsSection)overpulleyhalves.Open lockingtabandremoveretainingbolt. II ..cC'"U" clamp Pushandturndrivepulley to disengage" U" clamp then carefullyremoveslidinghalf. WARNING:Springpressurecanforceassembly apart;therefore,it isimperative that thegovernor cupbeheldfirmlyduringslidinghalfremoval. Ifitisnecessarytoremovehalf.useaopen-end wrenchonthesquaresection.closelyheldagainsthub. (DRIVEPULLEY).PAGE12 DISASSEMBLY&ASSEMBLY Someboltsofthedrivepulleyhaving" Loctite"ontheir threads,itisadvisabletouseatoolsuchasanimpact to break the "Loctite" sealbefore attempting to unscrew. 0)Torqueto118N'm(87ft-Ibs). 00To installorremove"Duralon"bushingfromhub pluguseasuitablepusherandhammerorpress.Install bushingasperillustration.

I-.-_ :.-.L. Q r 0 =--_CAUTION:Becarefulwheninstallingslidinghalf "assemblyonsquareshaftofdrivepulley toavoid scratches on"Duralon" bushing causedby square shaft edge. 00To removeandinstalluseabearingseparator andafterwardsastandardpullerandpusher. O NOTE:Items00shouldbepress-fittedtogether. Donotremoveinnerhalfbearingunlessdamaged andreplacementisnecessary. " '" Beanng separator 9 Torque shouldered pinlock nut to14 N'm (10 ft-Ibs)after havingapplied" Loctite242"orequivalentonthreads. _CAUTION:Donotdisassemblecounterweights Yunlessreplacementisnecessary. @APply"Loctite242"onthreadsthenscrewinuntil headisflushwithslidinghalf. INSPECTION&CLEANING Drivepulleyshouldbeinspectedannually. Checkgeneralconditionof pulleyandinspect" Duralon" bushingfaces.asperillustrations. Tefloncoating Teflon Impregnated cloth GOOD GOOD Teflon Impregnated cloth ,;frm....:a::.:.::-:..--

..... __ Teflon Impregnated cloth WORN(mustbechanged) ClothISscratched ortornand fiberglassbacking ISvisible Inside of slidinghalf should becleaned witha cleancloth. Thesquareshaftcanbecleanedwithfinesteelwool andacleancloth. SECTION05 SUB-SECTION03,(DRIVEPULLEY) INSTALLATION Lockcrankshaftinpositionasexplained inremovalproce-dure.Makesurecrankshaftisrotated450 counterclock-wise fromT.D.C.positionandthatcylinder iscompletely filledwithstarterrope. Installfixedhalfoncrankshaftextensionthenposition slidinghalfassemblyonfixedhalfsquareshaft. _CAUTION:Becarefulwheninstallingslidinghalf Vassembly onsquareshaftof drivepulley toavoid scratches on"Duralon" bushing causedby square shaft edge. Installgovernorcupmaking surethattheshaftendrests ingovernorcupseating. _CAUTION:Incorrect seating of shaft endingover-Vnorcupcancausecrankshaftbending.When pulley is completely assembled always measure distance ofbothpulleyhalvestomakesurethatthepulleyis properly installed.Distance must be97 mm (33/ 16"). Lubricatethreadsofretainingboltwithantiseizinglubri-cant.Positionretainingboltwithanew lockingtabthen torqueto118N'm(87ft-Ibs).Bendonesideoflocking taboverretainingbolthead. (DRIVEPULLEY).PAGE13 SECTION05 SUB-SECTION03,(DRIVEPULLEY) SQUARESHAfT WITHTHREECOUNTERWEIGHT ASSEMBLIES Blizzard7500plus, Blizzard9500plus SuperSonic UltraSonic I' I 18 20 @c------ \25

c' @@ @ /I,. 7.Retamingbolt 2.Tablock 3.Governorcup 4.Bolt 5.Bolt 6.Tablock 7.Ramp B.Bolt 9.Internaltoothlock washer 7O."Ouralon"bushing 7 7.Hub plug 72.Allenscrew 73.Spring (DRIVEPULLEY).PAGE14 13 74.Spongseat 75.Bolt 76.Guard (ro//ers) 7 7.Slidinghalf 7B.Fixedhalf 79.Nut 20.Counterweight 3 27.Nylonwasher5.7 mm(.200") 22.Shouldered Pin 23.Roller 24.Nylonwasher3.3 mm(.730") 25.Bushing WARNING:Drivepulleyrepairsthatincludeany disassembly or assembly proceduresmust beper-formedbyanauthorizedBombardierdealer,orother suchqualifiedperson.Sub-componentinstallationand assemblytolerancesrequirestrictadherencetop r o c e ~ duresdetailed. REMOVAL Somepulleycomponentsaremarkedtoinsureproper assembly.If components lack suchmarks.marking should bedonemanually beforedisassembly.asperillustration. INDEXINGMARKSINLINE _,I" (2)Fixedhalf o Slidinghalf CDGovernor cup o Hubplug Withenginecold.removesparkplugsthenbringP.T.O. (PowerTakeOff)pistonatT.D.C.(TopDeadCenter) position. Rotatedrivepulley450 clockwisetheninsertenough starterropeintocylindertofillitcompletely. Opentablockandremoveretainingbolt. Removeslidinghalfassemblywithgovernorcup. Toremovefixedpulleyhalf.usedrivepulleypuller.(See ToolsSection). O NOTE:Removestarterropeblockingpiston.then reblockpistonafterhavingturned450 counter-clockwisefromT.D.C.position. Installpullerinpulleyshaftthentighten.atthesame timeknockslightlyonpullerheadtodisengagepulley fromenginecrankshaft. SECTION05 SUB-SECTION03,(DRIVEPULLEY) DISASSEMBLY&ASSEMBLY Someboltsofthedrivepulleyhaving"Loctlte"onthe" threads.it isadvisable to breakthe"Loctite"sealbefore attemptingtounscrew. (i)Torqueto85N'm(63It-Ibs). 0Glnstall rampsandtorqueboltsasperillustra-tion. Torqueto 1 2N'm(9It-Ib,) Bendlockmg~ tabover the2bolts Ramp @@Atdisassembly.holdhubplugfirmlyagainst slidinghalfuntilthethree(3)boltsarecompletelyre-moved.Thiswillpreventdamageoftheslidinghalf threads.Atassembly.apply"Loctite242"onthreads ofboltsthentorqueto16N'm(12ft-Ibs). @@@To install or remove"Duralon"bushing fromhub plug.useasuitablepusherandhammer orpress.Install bushingasperillustration. (DRIVEPULLEY).PAGE15 SECTION05 SUB-SECTION03,(DRIVEPULLEY) "Duralon"bushing'P14 Apply"Loctite242"on threads.then tightenuntil screw slightly restsagainstbottomof"Duralon"bushinghole . ., CAUTION:Becarefulwheninstallingslidinghalf "assemblyonsquareshaftofdrivepulleyto avoid scratches on "Duralon" bushing causedby square shaft edge. @Torqueto5Nom(4It-Ibs). @@lAtreassembly. apply "Loctite242" on threads and torqueto1 6Nom(12ft-Ibs) . ., CAUTION:Donotdisassemblycounterweight ...unlessreplacementisnecessary. @@@ Rollersandnylonwashersmustmovefreely; installthemasperillustration. Widewasher (DRIVEPULLEY).PAGE16 INSPECTION&CLEANING Drivepulleyshouldbeinspectedannually. Checkgeneralconditionof pulley andinspect"Duralon" bushingfaces,asperillustration. GOOD TefloncoatingI; GOOD WORN(mustbechanged) Teflon ImpregnatedI r cloth Teflon Impregnated cloth Teflon Impregnated cloth ClothISscratched ortornand fiberglassbacklOg ISvIsible Inside of slidinghalf shouldbe cleaned with a cleancloth. Thesquareshaltcanbecleanedwithfinesteelwool andacleancloth. INSTALLATION Cleancrankshaftextensionusingfinesteelwoolanda cleancloth . ., CAUTION: When installing drive pulley on engine, "referencemarkonfixedhalf,slidinghalfand governorcupmustbeinline. Lockcrankshaftinpositionasexplainedinremovalproce-dure.Makesurecrankshaftisrotated450 counterclock-wise fromT.D.C.positionandthatcylinderiscompletely filledwithastarterrope. Installfixedhalfoncrankshaftextensionthenposition slidinghalfassemblyonfixedhalfsquareshaft. ., CAUTION:Becarefulwheninstallingslidinghalf "assemblyonsquare shaftofdrivepulley toavoid scratches on "Duralon" bushing causedby square shaft edge. ( Installgovernorcupmakingsurethattheshaftendrests ingovenor cupseating.Positionretaining bolt witha new lockingtabthentorqueto85Nom(63ft-Ibs). _CAUTION:Incorrect seatingof shaft endingover-'fIfnorcupcancausecrankshaftbending.When pulley is completely assembled always measure distance ofbothpulleyhalvestomakesurethatthepulleyis properlyinstalled.Distancemustbe76mm(3"). Pushonsliding halftowards governorcup toremove allpossibleslack whenmeasurmg Liftrearofvehicleofftheground.Installdrivebeltand pulleyguardthenstartengineandapplythrottleand brake,2-3 times.Stop engine andretorque retainingbolt. Bendonesideoflockingtabovergovernorbolt. SECTION05 SUB-SECTION03,(DRIVEPULLEY) (DRIVEPULLEY).PAGE17 4 o REMOVAL Removepulleyguard,drivebeltandmuffler. Slackensteeringcolumnbolts. Releasechaintension.Removecotterpinandnutsecu-ringpulleydriveshafttochaincase. O NOTE:Attachtoframetopreventitfallinginside ofchaincase. Pull driven pulley towardengine and removefrom vehicle. DISASSEMBLY&ASSEMBLY 01n order tomeasuredrivenpulley spring tension,pulley halvesmustbeseparated.Todothis,insertlengthof illdia.rodbetweenthehalves.Checktensionusing afishscalepositionedgoowithpulleyaxle. ~ SECTION05 SUB-SECTION04(DRIVENPULLEY) DRIVENPULLEY ElanandSpirit 1.Fixedhalf 2.Sliding half 3.Releasespring 4.Outer cam 5.Camslider shoe 6.Roll pin Springtensionpre-loadshouldbe3.6kg(8Ibs) Tocorrectspringtension,eitherrelocatespringendin slidingpulleyhalforgraduallyrotateoutercam. INSTALLATION Withdrivechaintensionreleased,holduppersprocket andchaininpositiontheninsertassembleddrivenpulley shaftthroughchaincaseandsprocket. Installspringwasherandcastellatednut. Tightencastellatednutfullythenbackoffnut1 /6of aturn. Lockinpositionwithanewcotterpin. ... CAUTION:Itisimportantthatnutisbackedoff Yordamagemayoccurduetoaburntorseized bearing. ApplychaintenSion. Installmufflerandlightensteeringcolumnbolts. Installdrivebeltandpulleyguard. (DRIVENPULLEY),PAGE1 SECTION05 SUB-SECTION04(DRIVENPULLEY) Citation,Mirage 7.Countershaft 2.Key 3.Adjuster nut 4.Tablock 5.Circ/ijJ 6.Screw(metric) 7.Brakedisc B.Outer cam 9.Shoe. 70.Sprin9 7 7.Slidingpulleyhalf 72.Shim 73.Fixedpulley half 74.Shim 75.Spacer (DRIVENPULLEY).PAGE2 ,-37 -36 -35

32 -tf'Z!!) """'lllCiiiiQI;::::7I1ii:"'=7' OUT' OnAlpinemodel.checktightnessofgearboxattaching bolts.Ifnecessary,removeshim(s)fromcrankshaft.The enginecanalsobeslidoneithersidebyslackeningthe enginebracketfromthesupport,forbetteradlustment. WARNING: Always torque drive pulley bolt within specifications.(SeeTechnicalData). SECTION05 SUB-SECTION05(PULLEYALIGNMENT) PULLEYALIGNMENT Citation,Mirage OffsetX&Y34mm(111132"). Measureoffset(usualmethod). i" squarebar Length:48em(19In.) Nominal distance between pulleys 1-1c:::>l T IIX" T "Y" - Dimension"X"mustneverexceeddimension"Y". - Dimension"Y"canexceeddimension"X"by1.6 mm(1I16"). Ifthedriven pulleyistoo farinorout,it canbecorrected byslidingittowardappropriateside. Toadjust: - Loosenthebearingretainernut(removecotterpin) . - Opentheadjusternuttablock. - Turnadlusternutsoastomovethepulleytoproper alignmentlocation(adjusternutcanbeturnedboth ways).Makesurepulleyalignmentischeckedwith the adjuster nut restingagainst the drivenpulley ass'y. - Ifrequired,removethebearing,bushingetc. - Removeoraddshimssothatthebearingremains centeredinthebearingcage.(Shimsare.032" thick eachPIN504105700). - Reinstallbushing,bearingandouterwasher. - Firmlytightenbearingretainernutandinstallanew cotterpin. I (PULLEYALIGNMENT).PAGE1 SECTION05 SUB-SECTION05(PULLEYALIGNMENT) - Bendthetablockoftheadjusternut. .., CAUTION:Makesurethelocktabissecurein "thedrivenpulleykeyway. Everest,Futura, Blizzard5500,7500,9500, GrandPrixSpecial, SuperSonic,UltraSonic OFFSETX&Y34mm(111/32"). Floatingtypedrivenpulleyrequiresaspecialprocedure tocorrectlymeasureoffset. - Installa1/16"gaugebetweenpulleyandbearing plate. - Thenmeasureoffset(usualmethod). IMPORTANT:Make suredriven pulley assembly isfully seatedagainstbearingflangewhenmeasuringoffset. ~ "squarebar Length:48em(l 9In.), Nominal distance between pulleys iizsJ T "X" T "Y" - Dimension"X"mustneverexceeddimension"Y". - Oimension"Y"canexceeddimension"X"by1.6 mm(1/16"). (PULLEYALIGNMENT).PAGE2. - Adjusttheoffsetbyaddingorremovingshims. With1 /1 6"shimInplace.pushassembly inagainstbearingplate ~ 1/16/1Shim ~ O NOTE:Toaddorremoveshims.pulleyassembly mustberemovedasperdrivenpulleyremoval procedure. - When alignment iscompleted.remove1/16" gauge. Ifpulleywasremoved: Reinstallthepulley.outershims.lockwasherandbolt. Torqueto9N'm(7ft-Ibs). IMPORTANT:Maximumfree-play shouldnot exceed3 mm(l") . .., CAUTION:Alwaysapplyanti-seizecompound "(Loctiteanti-seizelubricantP /N41370 1 a 00) onthecountershaftbeforefinalassembly. DISTANCEADJUSTMENT (exceptCitationandMirage) Toobtainmaximumvehicleperformance,adjustpulley distanceasfollows: 1 . Adjustpulleydistancetonominaldistance.(Referto TechnicalData). 2.Installanewdrivebeltonvehicle.Priortofinal adjustment.the drivebeltmust havea break-inperiod timeofonetotwominutes. 3.Thefinaladjustmentofpulleydistanceshouldbe performedbyusingthebeltdeflectionmethodas follows: - POSItionreferenceruleondrivebelt.Usingwooden ruleandfishscale.apply6.8kg(15pounds) pressureondrivebelt. - Deflectionmustbe32mm(1t"). \IWoodenrule OrusingNo.4143482Tool Pressure adjustment Deflection adjustment 32mm Tocorrect.decreaseorincreasedistancebetweenpul-leys. SECTION05 SUB-SECTION05(PULLEYALIGNMENT) (PULLEYALIGNMENT).PAGE3 0--0--- 0

, '"d. I' I---12 l'''''-..."r@ 7 ,/) j/' /'/ /'/'

o ----- ,-, [ i ,(i) 18 17 II ----19 ill SECTION05 SUB-SECTION06(BRAKE) DISCBRAKE Mirage,Citation 7.Bracket 2.Brakeleverand linmg 3.Bushing 4.Spring 5.Flatwasher 6.Nut 7.Barrel B.Barrel 9.Cotter pin 70.Pin 7 7.Springwasher 72.Pulley 73.Stop plate 74.Cablebracket(Europe) 75.Brakeswitchbracket 76.Screw 7 7.Flatwasher 7B.Nut 79.Cable (DISCBRAKE).PAGE1 SECTION05 SUB-SECTION06(BRAKE) Removethefollowing: airsilencer, brakeretainernut,thenpulloutbrakeassembly, brakelightswitch, pulley, brakecable(disconnectandremove). Assemblyandinstallation,reversetheprocedure. 0Whenreinstallingcaliperbrakeass'y,alwaysalign caliperass'ysothatthebrakedisciswellcentered betweenthebrakepads. CDReplacewhenpadthicknessislessthan3mm( ~ " ) . (VAlwaysreinstallanewcotterpinatassembly. @Installpulleyshaftinouterholeofthebrakelever. Makesuretheguardlocktabisinsertedinthebrake leverhole. +WARNING: Always readjust the brake light switch afteradjustingorremovingthebrakeassembly. (DISCBRAKE),PAGE2 INSPECTION: Measurethethicknessofthebrakepads.Iflessthan3 mm(1;")thepadandleverassembly shouldbereplaced. ADJUSTMENT: Brakeshouldapplyfullywhilethebrakecontrolleveris approximately13mm( ~ " )fromthehandlebargrip. Ifadjustmentisrequired,turnthebrakecableadjuster counterclockwiseuntilthebrakedisccannolongerturn thenbackofftheadjusterapproximately1 ~turns.Re-checkbrakeoperation. Brakecable adjuster + WARNING:Whenever the brake is readjusted, the brake light switchoperationmust alsobechecked andadjusted, Alpine 18 Elite SECTION05 SUB-SECTION06(BRAKE) SELFADJUSTINGDISCBRAKE 7.Nut(nylon) 2.Washer 3.Spacer 4.Squarewasher 5.Bolt 6.Brakeswitchsupport 7.Brakecableand housing B.CirC/ip g.Spring 70.Hair pincotter 7 7.Releasespong 72.Lever Everest,Futura, Blizzard,GrandPrix Special,SuperSonic, UltraSonic,Alpine, Elite 73.Brakesupport 74.Ratchetspring 75.Ratchetwheel 76.Brakepad 77.Caliper 78.Nut 79.Bolt 20.Washer 27.Retainingplate 7_ 8 J (SELfADJUSTINGDISCBRAKE),PAGE1 SECTION05 SUB-SECTION06(BRAKE) REMOVAL Disconnectbrakeswitchandbrakecable. Removenutsand/orboltssecuringbrakesupportto chaincase. Slidebrakecaliperass'yfrombrakesupport. DISASSEMBLY&ASSEMBLY @)@To easehair pincotter assembly.activate lever and wedgetwo(2)screwdriverbladesbetweencaliperand brakepadtoreleaselevertension . . Applylow temperaturegreaseonthreadsandspring seatpriortoinstallation.Atassembly.fullytightenthen backofftturn. 0At assembly.torqueto20Nom(15ft-Ibs). CLEANING&INSPECTION Measure thicknessofbrakepad.Iflessthan3mm(k"). thepadshouldbereplaced. Cleanallmetal componentsina generalpurposesolvent. Dryusingcleancloth. (SELFADJUSTINGDISCBRAKE).PAGE2 INSTALLATION& ADJUSTMENT Slidecaliperass'yontoItssupportthensecuresupport tovehicle. - Activateleverbyhanduntilratchetklickisnolonger heard. - Securebrakecablehousingtolever.slidespringover cablethenattachcabletohousingwithadjusternut. - Usingadjusternut.adjustuntilthereisnofree-play betweenthebrakeleveranditshousing.andthere isagapof57mm3(2 t" ")betweenlever andcaliper. AdjusterJf.5lmmj nutii II i1'1'{'\"{ o NOTE:Itmaybenecessarytochangebrakelight switch support position to obtain recommended gap betweenleverandcaliperhousing. Connectbrakelightswitchandcheckoperation.Adjust Ifnecessaryusmgtwo(2)adjusternuts. ~ ( 0 @I CD 8-, 3 4 ~ l I :::'\@ ~ I " I 7 o DISASSEMBLY& ASSEMBLY 0@@At assembly.torque shoeretainingnut.However shoe must be able to pivot when slight pressure is applied. 00@Whenattachingbrakeleverassemblytochain-casebracket.tightennutuntilleverpivotsfreelyandall sideplayiseliminated. o NOTE:Lubricatealimovingmetalpartsofbrake withlightmachineoil. WARNING:Avoidgettingoilonbrakeshoe. INSPECTION Checkbrakeliningforwear.Ifnecessary.replace. o NOTE:Ifoiltracesarefoundonliningordrum. checkchaincaseoilsealforcorrectinstallation positionordamage.Replaceasneeded.Wipeoilfrom pulleyandreplacebrakeshoe. I.Brakeshoe 2.Brakelever 3.Spring SECTION05 SUB-SECTION06,(BRAKE) DRUMBRAKE ElanandSpirit 4.Brakelightswitchspring 5.Spacer 6.Cablelock 7.Nut B.Bolt(cable) g.Bolt 10.Nut II.Bolt(shoe) 12.Nut(shoe) INSTALLATION&ADJUSTMENT Connectbrakecabletobrakeleverandadjustsothat brakeappliesfullywhenleveris25mm(1H)from handlebargrip. o NOTE:Priortocableinstallation.makesurecable housingadjustingnutsarelocatedhalfwayan adjusterthreads. Ifafinaladjustementisindicated.usehousingadjusting nuts . -Housing adjustingnuts Cablehousing Checkbrakelightoperation.Ifnecessary.loosenbrake lightswitchlocknutsandadjust. (BRAKE).PAGE1 27-@ I"@

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,l,lr 7.Chaincase 2.Chaintensioner 3.Bushing 4.Spring 5.Spacer 6.Washer 7.Bolt B.Nut g.Gil retainer nng 70.Bearingcup 7 7.Conebeanng 72.GJ!seal 73.Chain 74.Sprocket 20 SECTION05 SUB-SECTION07,(CHAINCASE) STEELCHAINCASE -22 75.Spacer 76.Cotter pin 77.Springwasher 7 B.Castellated nut 7g.GJ!level plug Elan,Spirit 20..Access plug(lower) 27. Access plug(upper) 22.Breather 23.Bracket 24."U" clamp 25.Spacer plate 26.Shim 2 7.Hingerod (STEELCHAINCASE),PAGE1 SECTION05 SUB-SECTION07(CHAINCASE) REMOVAL Removepulleyguard,drivebeltandinspectioncover. Releasechaintension. Releasetracktension. Pryoilsealfromchaincase(lowerpart)anddrainoil. Disconnectbrakecable. Pry out lower access plug.Removecotter pinandspacer. Removenutonhingerodatchaincasebracket. Fromtheinnersideofframe,removethenutsecuring chaincaselowerbracket.Removebracket. Removenuts,washersand"U"clampholdingthe chaincasetotheframe. Removechaincaseshim(s)ifapplicable.Movechaincase towardsdrivepulleytodisengagehingerod. Removedriveaxle. Usingtwo (2)large screwdriversinsertedbetweenchain-caseandframe,prycompleteassemblyfromvehicle. INSPECTION Visuallyinspectchainforcracked,damagedormissing linkrollers.Inspectfordefectivebearingcones,bearing cupsandoilretainerring.Inspect sprocketsfordamage, wear. DISASSEMBLY&ASSEMBLY @Positionoilretainerringthensitbearingcupin chaincaseaperture.Cupmustbeseatedsothatwide taperendisfacingoilretainerring. (CHAINCASE)PAGE2 BearingcupOilretainerring ConvexeSide towardallsea! @Using anappropriatepusher,pressoilsealmtochain-casehub.Oilsealmustsitflushwithcasehubedge. @@Place lower sprocket with longer flange toward track sideofchaincase.(Forpropersprocketandchainuse, seeTechnicalData.) _Longerflange

INSTALLATION Positionassembledchaincaseanddrivenpulleyinloca-tion.Installdriveaxle.(Ensurethatspacer hasremained onaxle).Installspacerandcotterpintosecurelower sprockettoaxle.Installloweraccessplug.Installhinge rod,lowerbracket,"U"clampandpreviouslyremoved aligningshim(s). Installoilsealintochaincaseflange. O NOTE:Agapofapproximately1.6mm(1/16") shouldexistbetweentheendchalncaseflangeand oilseal. 7Jb,;'Y7Y7'7"";: 1,6 M Beanng 011seal Spnng Proceedwithpulleyalignment.Applychaintension. PourBombardierchaincaseoilintochaincaseuntilflush withoillevelplug. Connectandadjustbrake.Applytracktension. Installdrivebeltandpulleyguard. 7.Chaincase 2.ChainTensioner 3.Bushing 4.Spacer 5.Spong 23 22 I 32 .I ~, ~ ~ : ~ 6.Hexagonal HeadCapScrew 7.Bearing B.Seal g.Stopper Spacer20 70.SnapRing 77.Spacer 72.Sprocket 73.SpringWasher 74.Hexagonal Slotted Nut 75.Cotter Pin 76.DrivingChain 77.Spacer 78.Sprocket 7g.SnapRing 20.ChaincaseCover 27.DRing 22.Hexagonal Washer Head Taptite Screw 23.Breather 24.Plug 25.FlatWasher8mm 26.Lockwasher 8mm 21 6 45 SECTION05 SUB-SECTION07(CHAINCASE) ALUMINUMCHAINCASE @@ I I 2@II Citation3500,MirageI Citation4500/E,MirageIIIE CitationSS,MirageSpecial 12 16 7 8 9 10 ~ ~@ ,~ ~18 28 29 @ 27 2625 30 31 27.Hexagonal Head CapScrew M8X25 28.Connecting Link Single,r' PitchDou-ble 29.CrankedLinkSingle,i" PitchDouble 3 g.Cranked LinkDouble,i" PitchDouble 3 7.InnerLink,~ "PitchDouble 32.RopeGuide (CHAINCASE),PAGE1 SECTION05 SUB-SECTION07(CHAINCASE) REMOVAL Remove: - suspension - injectionoilreservoir(ifapplicable) - batteryandbatteryholder(ifapplicable) - chaincasecoveranddraintheoil Pryoutdriveaxleoilsealfromchaincase.Removecotter pins,nuts,washers,sprocketsandchain.Removebolts andnutssecuringchaincasetoframe. INSPECTION Visuallyinspectthechainforcracked,damagedormiss-inglinkrollers.Inspectfordefectivebearing,sprockets. DISASSEMBLY&ASSEMBLY Removetheoilseal,snapringandbearingfromthe chaincase. INSTALLATION Install the chaincase to the frame (do not tighten).Position thedriveaxleintolocation. Priortolowersprocketinstallationensurethatthe spacer@isonthedriveaxle. Reinstallthesprockets,chain,flatwashers. @@Reinstallspringwasherandslottednut,torqueto 10Nom(7ft-Ibs). @Installnewcotterpin. @Reinstallsn