1. Engine .. Power transmission. Drive unit . Steering system ...

CHAPTER 1. GENERAL

1-1. Specifications . .

1 -2. Service data ..

1-3. Construction ...

1-3- 1. Engine ..

Power transmission.

Drive unit .

Steering system

Chassis ...

TABLE OF CONTENTS

1

3

5

5

12

14

15

.... .. ... ..... ..... .. . 15

1-3-2 .

1-3-3.

1-3-4.

1-3-5.

1-3-6. Electrica l system . ..... .... ........ ...... ... ..... .... .. .. .. ................. . . 15

22 1-4. Tools.

CHAPTER 2. ENGIN E

2-1. Removing the engine ....... . .. . .... .. .. ... .. .. .. .... ..... . 27

2-2. Manual starter . . . ... .... ... . .. . . .. . .. .. . ... . . . . 31

Removal .......... . . .. ... . .. . .. .. .. . .. .... .... ...... .. ... .... . 32

Disassembly . ............. 32

2-2 - 1.

2-2-2.

2 -2-3.

2-2-4.

2-2-5.

Cleaning and inspection. . ........... .. ...... .. .. .. .... .... ..... .. .. .. . .. .... .. ... .. ... ... . .. .. ... ... ... ... .. 33

Assembly ............. ... ..... ... .. 33

Installation

2 -3 . Primary sheave

2 -3-1. Disassembly ... ... .. .. . ........ . .. ........ .. .. ..

2-3 -2. Cleaning and inspection .

2-3-3. Assembly.

2-4 . Flywheel magneto ...... ... ... .. ... .... .. .. .. .. .

34

35

36

37

38

39

40

41

46

47

47

48

49

50

2 -4-1. Removal ....... .. .. .

2 -4-2.

2 -4 -3 .

Inspection ... .... .... ... ............ . ..

Installation

2 -5. Carburetor ..

2-5- 1. Rem oval ...

2 -5-2. Disassembly .... ..................... ..

2-5-3.

2 -5-4.

Cleaning and inspection

Assembly .......................... ...... .. .... .... .. ..

2-5-5. Installation

2-5-6. Adjustment. . ... . .. . ... . .. .. ... .... ..... ......... ... .. .. ... ..

2-5-7 . Main jet replacement ... ........ .

...... ...... ... .... .. 51

51

53

2-6. Oil pump ... ...... ... ...... ......... . .. . ..... ... .. .... ... ...... ........... .. ...... .. .. .. .. ....... .. .. .. .. .... .. .... . .. 54

2 -6- 1. Removal .. . . . . . . . . . ... .. .. .. .. .. ...... 54

2-6-2. Disassembly.. .................. . ...... ........ . 55

2-6-3. Cleaning and inspection . .. . . . .. ... . 57

2 -6 -4. Assembly. 58

2-6-5. Installation ... 58

2 -7. Engine

2-7-1

2 - 7-2.

2-7 -3-

Disassembly ...

Cleaning and inspection ... ...... ...... ..... .. .... ... .. . .. .

Assembly . . ................ .. .. .. . ................. .

2-8. Engine mounting.

59

.. ..... .... ... .... . ............. ... .... .. 62

63

.. ..... ..... 70

.... .. .... .. .... .. ... ...... .. .. ... .... ..... . 71

CHAPTER 3. POWER TRAIN

3-1. Secondary sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5

3 - 1- 1. Removal .. ...... . ........ ........... ... ... ....... .... ................ ....... . .. ..... ........ .. .. ... .... .. .. .. ....... .. .. 76

3-1-2. Cleaning and inspection ............... ... .... .... .. .... .. ................... 77

3-1 -3. Assembly .. ... ...... .... .... ....................... ... ...... ... ..... .. . .... ................. ..... .. ..... ... .... .... .. ...... 77

3- 1-4. Installation ......... .. ......... .. .. ...... .. ... .. .. .......... ..... ........ .. 78

3-1-5. Adjustments.. ........ ...... .... .. ............. ........... .............................. 78

3-2. Disc brake ..... ... .. ....... ...... ... .. .. .... .. ...... ... .............. ..... ... ..................... .. .... .. ... 81

3-3.

Removal .. ............................ ...... ........................... ..... ... .......... .... . 82 3-2-1 .

3 -2-2.

3-2-3.

3-2-4.

Cleaning and inspection .. .. .. ........... .... ........ .... . ......... .. .... ...... .. ..... .. ......... ..... ...... .... 82

Inspection ....... .... .... ... ........ .. .... ... .. ............ ..... .. .. .. .. ..... ......... 83

Adjustment ............ .... .. .

Front axle.. .. ........ .................. . .. .... ..... .... .. ..... .. ... ...... . .. . ..

3 -3-1 . Removal .......................................... ... .... .

3 -3-2.

3 -3-3.

3-3-4.

Disassembly ............. .. ...... ......................... .

Cleaning and inspection.......... ..... ....... .. .... .. ...... .. ..

Assembly ......................... .... .. ....... .. .................. .. .. .. .. ................. .... ..

.. ..... ... .. ....... ... 83

84

. .. .. .. ...... 85

86

86

87

3-3-5. Installation.. ................ .. .. .................................................. ... ....... ... .. 87

3-4. Rear axle .. .... .. ... .. ........... ... .. .... .. .. ... .... ... .. .. ....... .. .. ............... .. ..... .... ......... .... .............. .. ..... .... . 88

3-4-1. Removal............ .. .... .................. .. ........ ............. ...... .................. 89

3-4-2. Disassembly.. ..... ....... ... .... .. ............... ..... ...... .... ..... .... ................ ... ....... .. 89

3-4-3. Cleaning and inspection... ....... ...... ...... ...... .. ...... .. ... 90

3-4-4. Assembly. ................. .. .. ...... .... .. .. ... ... .. ........... ... .... ... .. .. .... ............ ................. 91

3-4-5. Installation .... ....... ......... .... .. ... ....... .......... .... .. .. .. ..... .. ....... ........... ........... .. .... .... .. .. .... 91

3-5. Bogie wheels ...... .. ......... .. ................................... .. ... ... ..... .. .. .. ... . .......... 92

3-5- 1. Removal ................... ... ..... ...... ........................... .. ........ ... ....... .. .. .. .... ........... .. ........ .. 93

Cleaning and inspection ........ ..... ...... .... .. .......... . .. 93 3-5-2.

3-5-3. Installation ... ...... .. .. ........... .. ... .... ..... . ..... ...... .. ... . . ...... .... .. .................. 94

3-6. Drive track ......................... .. ............ .. ..... ... ................. .. 94

3-6-1.

3-6-2.

Removal ........ .. .. ............... .... ..... .. .. .... .... ... ... ....... ........ .. ... ........ .. ..... .. .... .. .. .. 94

Cleaning and inspection .. .... .......................... .. ..... ....................... . 94

3-6-3. Installation ..... .. ... .. ............ ..... .... ...... .. ..... .. ................ . . . . ....... 95

3-6-4. Adjustment. .. ......................... ............. .. ... ... 95

3-7. Chain housing.. .... ..... ... ........................ .. ..... ........ .. ....... ........................... 97

3-7-1 . Removal.... ..... ...... ..... ......................... .......... ......... ... . ...... ..... ... .. .. 98

3-7-2. Disassembly. . .......... ... .. .. .. ... ............. ...... ........ .. ... ..... .......... ......... . 98

3-7-3.

3 -7-4.

3-7-5.

Cleaning and inspection .. .. .. ..

Assembly ..... ... ......... ...... .. .. .... ... .... .... .. ...... ............. .. .

Installation .. .. .. ........... ... .. ............. ... ....................... . .. ........ ......... .

3-7-6. Chain adjustment ... .. .. ....... .......... ............... ..

CHAPTER 4 . STEERING (SKI) AND CHASSIS

4-1. Steering ................................ .. .. ...... ................. .. .... .. ... . .... . ....... .. .. .... .... ... ........ .

4-1 - 1. Removal ... ............ ..... ... ... .. ... ... ...... .... ... .

Cleaning and inspection ............ .. ..

Installation .. .. ..... ................................... ....... .. .. ... .. .

99

.. 100

. ............. . 100

... 101

.103

4-1-2.

4-1-3.

4 - 1-4. Adjustment ..... ....... .. ......................... ........ ........ .. .... .. .. ..... ... .. .... .............. . .

. ... 104

. .. 105

. ... 105

. . . 106

4-2. Ski .

4-2-1.

4-2-2.

4-2-3.

4 -2-4.

. ............... 107

Removal .............. .......... .... ........... ........... .... .. ........ .. ... .. .. .. .. ... ...... .. .108

Cleaning and inspection .. ..... .......... ........... . ... ... ................. .......... ....... ... . . ......... 108

Installation ........ ....... ... ...... .. .. .... ..... .................. .... .. .. . ............. .. . ................ 109

Adjustment ....... .. .................... .. .................. ..... .. .......... ..... .. ......... .... ......... ....... .. .109

4 -3. Chassis and air shroud .... .... ... ..... .... ...... ......... .... .. ... ... ............... .. . .

4 -3-1. Removal ...... ...... .... ............ ...... ..... ... . .... ... .. .. . .... .. ... ........ ... ...... ... .

4-3-2. Installation ... .................. .... .. ........ .. .... .. ............ . ...... .... ... .. ..... .. .. ................ ..... .

. .. 110

... 110

. 111

4 -4. Rider's seat.......... .. .................... .. .... .... ..... ........................... .... ..... ... ... ... .. .. .. .. .. .. .. . 111

4 -4-1. Removal .. .. .. .. . . .. .. .. . . .. .. .. . . .. .. .. .. . . ... .. .. .. . .. .. . .. .. .. .. .. .. . .. .......... 111

4 -4 -2. I-nstallation........ .. .. ... ...... ..... .. .... .. ..... .. ..... ... ....... .. ...... ... ... .. .... .. .. .. .. . 111

CHAPTER 5. ELECTRICAL SYSTEM

5-1. Wiring diagram ...... .... ........................ ........ .. .. ..... ..... ........... ... ....... ..... ........ .......... .. .... ... ...... 113

5-2. Ignition circuit.. .. ...... .............. .. ......... ... ........... . ..... . .. 114

5-3. Ignition tim ing adjustment ........... .. .... ............ .... ... ... ........ .. .. .... .. ... ..... .. .. .. ... ........... .... .. ......... 121

5-4. Lighting circuit.. .. .. .... ........ ...... ........ .. .... .. .. . .. .. .... .. . .. .. 124

CHAPTER 6 . TROUBLE SHOOTING

Hard starting ............... ....... .... .

Poor low speed engine operation ....... ..... ........... .. .......... ..

High speed operation problems .... .. .......... .. ..... .. .. .. .......... .. ... .. ..

Troubles at both low and high speeds

. ... 125

. .. 125

. .. 125

. 126

SOMMAIRE

CHAPITRE I. GENERALITES

1-1. Caracteristiques ...... ..... .. .... ........ ........ ... .. ....... ... ...... .. ... ............... ... ...... ... ... . ... ... ............ .... ..... .. . 2

1-2. Donnees d'entretien............ ..... ... ... ... ........ ........... ... . ... ...... . ..... ..... .. . .... .. .. ..... ... .. ............ . ..... ...... . 4

1-3. Construction.. ... .. ... ..... .... ... ... ..... .... .... ............ ..... ...... ..... .. ... .. .. ........... .............. ... ...... ... ... .. ....... 5

1-3-1 . Moteur ..... ..... .. ......... ........... ......... .... ... .. ...... ..... .... ....... .............. ...... .. .. ... ........ .. ..... .... ... 5

1-3-2. Transmission de Ia puissance ..... ...... ............... ........ .... ... ...... .. .... .. . ......... ... .... ... ........ ..... .. 12

1-3-3. Unite de commande .... ..... .... .... ..... .. ....... ......... . ...... .... ... .... .. .. .... ..... .. .... ............ ........ ...... 14

1-3-4. Systeme de direction ... ....... ......... ......... ........ ... . ..... ......... ...... .. .. ..... . .. ... .... . .. .. ... .... ....... .. .. 15

1-3-5. Chassis .... .......... ........ ... ...... ....... .... ... ... .... ... ... ..... . .. . ...... ..... ..... ... .......... .......... .. ........ ... . 15

1-3-6. Systeme electrique ... ... .......... ..... ... .... ..... .............. .. ... ... .. .... .... .......... .. . .... .. ... ... ..... ..... .... . 15

1-4. Outils .... .. ... ..... .... ..... .... ... ........ ........ ... ...... ... ...... .. ....... ........ ..... .... .... .. .. ... .. ....... .. ... .. .... ... ... .... ... 22

CHAPITRE 2. MOTEUR

2-1. Demontage du moteur... ........ ...... .... .... ... .... .... .... ...... . .. . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 2 7

2-2. Demarreur manuel ............... .............. .......... .. ... .. .. ..... ... .......... .. .. ... ....... ...... .... . .... .... .... .. .. .. .... ... 31

2-2-1 . Depose .. .... ....... ...... .... ..... .. .......... ................ ... ......... .. ........... .. ......... ...... ...... . .. ..... ... .... .. 32

2-2-2. Demontage ..... ...... ...... .... ..... ................ ... ..... ... .. ..... ... .. . ..... .. . ...... ..... ...... ... .. .. ... ........ ..... . 32

2-2-3. Nettoyage et controle ...... .. .. ..... .......................... ... ... ..... .... . ....... ..... .. ... .. ... ..... ... .. ..... ... ... 33

2-2-4. Montage ........ ..... .. .... .......... ........ .. ...... ... .. ... ...... ... ..... ....... .. ... ... . .. ..... .. ... . ... .... ...... ... ..... .. 33

2-2-5. Installation ..... ....... ......... ... .... ... ... .. ..... . .......... .. .. ... .. ... ...... .... ..... ...... .... ..... ..... .. ..... ..... ... . 34

2-3. Poulie primaire .... .......... .... ...... ..... ......... ... ...... .... ..... ..... .. ....... .... ... .... .. .... ... . .. ..... . ...... ...... ... ....... 35

2-3-1. Demontage .... .... ............ ....... ....... ... .. ..... .... ...... .... ........ ..... . ...... .... ...... ...... .. .... . .. ... ..... .... 36

2-3-2. Nettoyage et controle (Inspection) ........ ... ....... ........ ........... . .. ... ..... .. . ....... ... ... .. ... .... .. ...... .. 3 7

2-3-3. Montage .... ... .... ...... ........ ........ .......... ... ..... ... ......... ... .. ....... . .. .... .. . .... ... .. ... ... ..... ...... ... ..... 38

2-4. Magneto a volant ....... ........ ......... ..... ..... .. ... .. .. .... .... ...... .. ...... .. ....... .. ..... .... ... .... ..... .. ... ..... ....... ... 39

2-4-1. Demontage ........ .......... .. ... ........ ........ .... .. .... ........ ... ...... ..... ... . .. .. .. ... ... ... ..... ... ..... .......... .. 40

2-4-2. Controle .... ..... .. . · ....... .. .. ...................... ...... .. ...... .... ..... ....... . ............... . .. ..... .... ... .. ...... ..... 4 I

2-4-3. Installation .... .. ....... .... .... .... .. .. ...... .. ... ............. ............... .. .... .... . .. . ...... .... . ..... .. . ... .... ..... .. 46

2-5. Carburateur .... .. ... ............ ........... ... ... .... ..... ... .... ........ ... ........ .. . ... ..... ....... .. ..... .. ..... ... ... ..... ...... ... 4 7

2-5-1.

2-5-2.

2-5-3.

2-5-4.

2-5-5.

2-5-6.

Depose ....... .... ................ ....... ....... ...... .. .......... .... ....... .... .. ...... .. ... . ......... .... .... .. ... .... ..... . 47

Demontage .. .... ... .. .. ...... ..... .. ...... ..... ............ .. ...... . ..... .... .. ... .... ..... .. ... ...... ... .. ... .......... ... .. 48

Nettoyage et inspection .. ............. ..... ...... . ... ........ .... ..... .. .... ..... .... . ... ...... ...... .. ..... .. ..... ..... . 49

Montage .. ... ... ... ...... .... .......... .... .. ....... .. ........ .. ......... .. .. .... ..... ... .. .. .... .... .... ... .... ...... .. ... .... 50

Installation .......................... ..... ........ .. .... ..... .... .... ....... ....... .. .. . ... . ..... ... .. ....... .... ........... .. 5 l

Reglages .. .... ..................... ............. .......... .... ... .. .... .... .. ... ........ . .... ... ...... ...... . ... .. ... .. .... .... 51

2-5-7. Rem placement du gicleur principal .... . ... .. .. ........ .. ... ...... ... .... ...... .. .... .. ... . ... ..... ... .... ... ... ..... 53

2-6. Pompe a huile ... ...... ............................ ..... ............ ...... ..... .. ... ... .... .. .. .. .. .... ......... .. .. .... .... ..... ... .... 54

2-6-1. Depose .... .. ... ............. .. ... ........ ... .... ... .. ... ....... ...... .. ...... ... .. .. ... ...... . ......... ... ...... .......... ... . 54

2-6-2. Demontage ..... ... ... ..... ........ .. ... ...... ...... ........ ...... .. ... .... ... ...... ...... ...... .... . ..... .... .. .... ... ...... . 55

2-6-3. Nettoyage et inspection ..... ........ ... ... ... ....... .. .............. ... ... ... .. ... .. ... .... .... . .. ...... ......... .. ...... 57

2-6-4. Montage .. .... .. ...... ... ... ........ ........ .. ..... ... ....... ... ..... ......... ... . ... ... . .... .. .... .. .......... ... ···· ·.·· ····· · 58

2-6-5. Installation .... ..... ... ................... .............. ............ ........ .. ..... .. .. ... .. .. .... .. . .... ... .. ... .... .. .. ..... 58

2-7. Moteur .. ....... .... .. .... ........ .... ... ........... ... ..... .... .. ..... .... .. .. .... ..... ...... .... ........ ... .. ... .. .. ... .. ..... ... ... .. .. . 59

2-7-1 . Demontage ................................................... .. ...................... .. .................... .. ..... .. .... ..... 62 2-7-2. Nettoyage et inspection .. .. ........ .. .... ... .. .... .. .... . ... ................... ........ .... ..... .. ... .... .. .. ............ 63 2-7-3. Montage ...................... .... ............................... .. ...... ... ...... .. ............ ... ............................ 70

2-8. Montage du moteur .... .. ........ .. .... ........... .... ...... . ........................................ .. . .. .. ............. .. ...... .. .. 71

CHAPITRE 3. TRAIN D'ENTRAINEMENT

3- I. Poulie secondaire ..... ..... ..... ... .. .. ............ ......... ...... ... ........ .... .. .. ... ..... . ... ... ......... ... ... .. .. .. ..... .. .... .. . 7 5

3-1-1. Depose .. ..... .... .... ..... ... ..... ...... ............ ... ... ... ........ . .... ........... ..... ......... .... ...... .. .... ... ..... .. . 76

3-1-2. Nettoyage et inspection ...... .. ... ...... ...... .. ........... ... ... ......... ..... . .. ... ....... ... .. ...... .... .. ... . ... ..... 77

3-1-3. Montage .... ...... .... .. ... .. ..... ..... ....... ........... .... ... ........ ..... .. .... ..... ..... ..... ...... ... ........ ..... ...... . 77

3-1 -4. Installation .... ..... .... ....... .......... ...... .... ... ..... .. .. ........... .... ...... ...... .. .... ... .... .. ....... .... ....... .. . 78

3-1-5. Reglages .... ................ ... .. ..... ...... ... .... .. ... .. ..... .. ...... . .... ..... ... ...... .... ... .... ..... .. .. ... ..... ... ..... . 78

3-2. Frein a disque ........ .... .... .. .. ....... .... ............. .... .... .... .. ... ..... ..... .. ..... ... . ...... .... ..... ..... ...... .. ...... ... .. . 8 I

3-2- I. Depose ...... ... ... .... .......... ... .... ......... .. .... ... . .. .. ... ... ... ... ... .. ... .. .. .. .... ... ..... ....... .... ... .... ... .. ... 82

3-2-2. Nettoyage et inspection ... ...... ... .. .... ... .. ..... .. .... .. .. ..... ....... ...... .. ..... ....... . ... .. .... ... .... ....... ... . 82

3-2-3. Installation .. .................. ........ ... ...... ....... ...... ..... .. .... .... .... ... ... .. .. ............ ... ... ... .. ...... .. .. ... 83

3-2-4. Reglages .... ............... ...... ..... ..... ...... ..... .. .. .... . ..... ...... .. .. ..... ... ... .... .. .. ..... ....... ... .. ... .... .. .... 83

3-3. Arbre avant ... .... ..... ...... ........ .... ..... ... ........ ...... ... ......... . .... .. .. ..... . ...... .. .. .... .. .. ...... .. .. ........ ....... ... 84

3-3-1.

3-3-2.

3-3-3.

3-3-4.

3-3-5.

Depose .... . ..... ....... .... ...... ... ....... ... ... ... ........ ....... .... .. ...... . ..... ..... .. ... .. ... ......... ....... .. ... .. ... 85

Demontage ... .. ... ............ ........ .. .. .... .... ............. ..... .... .. . ... ... ...... .. ... ..... .... ... .... ....... ..... .... . 86

Nettoyage et inspection ........... ... ........ ... ... ..... .. ... ...... ...... .... .. .. .. .... .. .... ........ .. .. ....... .. ....... 86

Montage ....... ................ ..... ...... ..... .. .... . ..... ..... .. ..... .... .............. ... ..... ....... .. ... .... .... .. .... .. .. 87

Installation ....... ........ .. ..... .. ..... .... .. .... ... ...... ..... ...... .... ... .. ....... ... .. ... .. .. ......... ...... .... ........ . 8 7

3-4. Arbre arriere .... ... .. .... ..... ... ........ .... ..... ... .... ... ..... .... ... ...... ... .... ..... .. .. .... ....... ... ..... .. ..... .. ... .. ..... .. .. 88

3-4-1. Depose ...... ...... ... ...... ... .... ... .... ...... ........... .... .. .. ...... ..... ...... .. .. .. ........ ..... ... ... .. .. .. .... ....... . 89

3-4-2. Demontage .. .. ....... ....... ......... ...... .... ... ... ... ... .. .... ... . .. ... ...... ..... .. .......... ... .... ..... .... ...... .. .... 89

3-4-3. Nettoyage et inspection .. ......... .... ... ... ... ..... . ...... .. ... . ..... ...... .......... ..... ... ......... ..... ..... ... ..... 90

3-4-4. Montage ...... ...... ... ......... .... .... ... .... .. .. ... .. ... ....... ........ .. .. .... .... .... ...... .. ... ..... .. ...... .. .... ..... .. 9 1

3-4-5. Installation .. .... ........... .......... ...... ..... .... .. ........ . ... ... ..... . ...... ..... .... ..... .. ... ..... .. .. ... .......... .. . 91

3-5. Bogies .... .... .. ..... .............. ... ... .... ...... .. ......... ... .... ... ............ .. .. ..... .. ... . ........ .. .. .. .. .. ..... ... ... .... .... ... 92

3-5-1. Depose .... . ....... .. ... .. .. ... .. ..... ...... ...... ... .... .. .... .... ... .. .......... . ... ... ... ...... ..... ... ... ... .. ... ... ....... 93

3-5-2. Nettoyage et inspection ...... ... ....... ..... ....... ... .... .. .... .. .. ... ...... ............ ... ..... .... ... ... .... ... .... ... 93

3-5-3 . Installation .. ... ... ... .... .... ........... ...... ............. . ..... .. ... .. .... . .... ... .. ... . ..... ..... ... ..... .. .. .. ..... ...... 94

3-6. Chenille ........... ... ........ ........ ... .... .. .... .. .... ... .... ... ..... . .. .. ... .. .. .... ... ... . .... .... . ........ . ..... ... .. ... .. ... ... ... .. 94

3-6-1.

3-6-2.

3-6-3.

3-6-4.

Depose ..... ...... ... ... ... ..... ...... .... .... ............. .. ..... .. ... . .. .... . ...... .. ..... . .. .... .. ... .... ........ ........ .. . 94

Nettoyage et inspection ........ .... .. .. ............ ....... .. .. ... ... ........ .. .... ...... ...... .... ... ... ... . .. ....... .. .. 94

Installation ... ... .. ....... ....... ..... .. ... ... ... .... .. ... ...... ......... .... .. .... .. . ... . .. ..... ... ... ... ....... ..... ... .... . 9 5

Reglage ... .. ...... .. .. ..... ... ....... .... .... ....... ... ..... .... ...... ...... .. .... .... .. . ... .... ... ... ...... .... ....... .. .... .. 95

3-7. Boitier de chaine .. .. .. ........ .. ..... ... .... ... .. ... .. .. ....... ..... ...... ... ... ....... .. ..... ... .. .. .... .... ....... ...... ..... ... .... 97

3-7-1 . Depose .... ... .. .... .... ..... ... .... ..... ...... .. ... .. .. .... ... .... ....... .. ... ...... .. .... ... .. . ... ... ... .... ... ...... ........ 98

3-7-2. Demontage ............... .. ..... ...... .. .... ............ . ...... ... ..... ..... ... .... ..... ...... ..... ... . ... .... .... .. .... .... . 98

3-7-3. Nettoyage et inspection ... .... ..... .. ... ... .. ... .... .. ... .. ... ... . .. .... ... ........ .......... .... ... ............. ....... . 99

3-7-4. Montage ... ......... ..... ... .... ... ...... ... .... .......... .. .... . ... .... ... ..... .. .... . ...... ..... . .. ...... ... ..... .... .... .... IOO

3-7-5. Installation ..... ... .... .. ...... .. .... .. .. ... ... ......... ...... .. ..... .. ... .... ..... .. ... ..... ..... ... .. ....... .. ... .. ...... .. . 100

3-7-6. Reg! age de Ia chaine .... ... ... .... .... ........ ..... .... ... .... ...... .. ...... ......... .... ... .... .......... ... .... .. .... .. I 01

CHAPITRE 4. DIRECTION (SKI) ET CHASSIS

4- I. D.irection .. .... .. ........ .... ...... .... .... .... ... ......... ... .... ....... ... .. .... . ... ..... ... .... .. .. .. ....... . .. ... ... . ....... .. ........ I 03

4-1 - I. Depose ... .. .. ..... .... .... ..... ... ....... .... .. ........ ....... .. .. ... .. .... ....... ....... .. ...... ..... ... .. ... .... ... .... .. ... 104

4-1-2. N cttoyage ct inspection ... ... ..... ..... .. ... ..... .. .... ... .. .. ... . ......... .. .. ...... ... ...... .... ..... ...... .... .. ... ... 105

4-1-3. Installation ....... ..... .. .. .................. ...... ..... . ..... .... ..... .... .. . .... .... ... . ..... ... ... .... ... .... ........ .. .. .. 105

4-1-4. Reglage .. ...... ..... ... ........ ..... ... ........ ... . ... ..... ... ... .. ... .... .... ......... .... .. ..... ........ ..... ... ........ ..... 1 06

4-2. Ski .... . .. .. ..... . .. . .. ... .. ..... . . ... . . .. ... . . .. .. .... .... . ... . . .... .. ..... . ....... .. .. .. ... .... ......... . ... .. .. ... .. ... ... .. ... ... . .. .. . .. I07

4-2-1. Depose ... .. ......... ........... .... .... .. ............... ....... . ...... ... .. . ... .... ..... ... .. ...... .. . ....... ..... ....... .. .. . 108

4-2-2. Ncttoyage et inspection .... ........ .. ....... .... .. ........ ... .... ... ...... ..... . .. .... . .... .. .. .. .. ... .. ........ ..... ... . 108

4-2-3. Installation ........ ..... .. ... .... .... ...... ......... .... ...... ......... ... . .. ....... .... ... . .. ... .. ...... ... ...... ... ......... 109

4-2-4. Reglage .. ....... ..... ... ..... ... ......... .. ...... .... ... ....... ......... .. .. ..... ... .. ..... .. .... .. ..... . .. .. .. ......... ....... 109

4-3. Chassis et capot .. .... ... ...... ..... ... ...... .... .... .... .. .... .. ...... .... .... ..... .... .......... .. . .... ............. ... ... .... ...... .II 0

4-3-1. Depose ... .. ........ ..... .. .. .... ........ ....... ... ................. .............. . .......... .. ..... .. .. .... ... .... .. ... ...... . 110

4-3-2. Installation ..... .... ..................... ............... ............ .......................... ......................... ....... 111

4-4. Siege ... . ..... .. ...... .. ..... .... ......... ..... .......... ... .. ........ ... .. ......... . .. ........ ...... ................ ....... .... ...... .... .. 111

4-4-1. Depose ..... .. ..... ... ... .... ...... ................... .................. ..... ........ ..... .. .. ......... ..... ... .... .. .. ... .. .. .II I

4-4-2. Installation ....... .... ...... ........ ..... .... ............... ...... .... ...... ... ..... ......... ..... ... ... .... .. .... .. .... .. ... .Ill

CHAPITRE 5. SYSTEME ELECTRIQUE

5- l. Scheme de ciiblage .......... .. ...... ...... ... .. .......................... .......... .. ...... ..... ... .. .. ..... .... ..... ... ... ... .. .... . 113

5-2. Circuit d'allumage ... ...... ..... .. ... ... .. .... .... ... ....... .. ..... ........... .... ...... ... ..... .......... ...... ......... .... ... .... ... 114

5-3. Reg! age de l'avance a l'allumage ........... ........ ... ....... ........... ... .. . ..................... ... ...... .... .... .. ..... ..... 121

5-4. Circuit d'eclairage .. ... ......... .... .... .... ........... ............. ..... ... .......... ......... .. ..... ... ... ..... ... .... ... ......... .. . 124

CHAPITRE 6. DEPANNAGE

Demarrage difficile ... .. .... .............. .... ..... .. ..... .... ....... ........ ..... .. .... . .. .... ... .... ... ..... ..... ... .. ... ... .... .... 129

Fonctionnement du moteur a faible vitesse defectueux .... .. ... .. .. .. ..... ......................... ..... ...... ...... .... 129

Problemes de fonctionnement a hautes vitesses ..... ..... ....... .... ..... ..... .... .. .... . .. ... ..... ... ...... ... ... .... .... . 129

Prob1emes a haute et faib1e vitesses ..... .. ...... .. .. ....... ........ ..... .......... .... .. ...... ........... ................. ..... 130

GENERAl GENERALITE

CHAPTER 1. GENERAL

1-1. Specifications

MODEL GS338G

Dimensions:

Length (w/skis) 96.1 ins. (2.440 mm.)

Width 33.3 ins. (845 mm.)

Height (w/windshield) 38.6 ins. (980 mm.)

Engine:

Type Air-cooled 2-stroke 5-port

No. of cylinder 2

Bore and stroke 2.362 x 2.346 ins. (60 x 59.6 mm.)

Displacement 20.63 cu.in. (338 c.c.)

Max. horsepower 25 HP/ 5.500 r.p.m.

Carburetor KEIHIN CDX42-38 x 1

Lubrication system "Autolube" oil injection

Magneto output Flywheel magneto 12V.-70W. @3.000 r.p.m.

Starting system: Recoil hand starter

Track and suspension :

Track Molded rubber. steel reinforced

Width 15 ins. (380 mm.)

length on ground 39 ins. (990 mm )

Suspension wheels 12 rubber wheels. bearing mounted

Drive sprocket Single polyurethane. 9 teeth

Wheel sprocket Single polyurethane. 9 teeth

Transmission:

Type Automatic centrifugal engagement. infinitely variable 3.5 : 1 ~ 1 : 1

Drive chain Duplex roller chain enclosed in oil bath

Frame:

Type Fabricated steel

Cowl :

Type Reinforced fiberglass (removable)

Seat: Removable

Fuel tank:

Capacity 4.5 US gals. (17.0 lits.)

Oil tank capacity 2.4 qts. (2 25 lits.)

Front bumper: Chromed tubular steel

Electrical:

Headlight 12V.-60/ 60W High-low beam Taillight 12V.-8W

Stoplight 12V.-23W Ignition key switch 3 -position. on dash

Brake:

Type Disc brake Control Handle lever. left-hand operated

Throttle:

Type Handle lever. right-hand operated

Kill switch:

Type Push button. right-hand operated

Accessories: Emergency starter rope. Service tool kit

Optional equipment parts: Tachometer and speedometer

- 1 --

GENERAL GENERALITE

CHAPITRE I. GENERALITES

1-1. Caracteristiques

MODELE GS338G

Dimensions et poids:

Longueur (sans skis) 2.440mm

Largeur 845 mm

Hauteur (sans pare-brise) 980mm

Moteur: Type Deux-temps, refroidissement par air, a 5 lumieres

Nb. de cylindres 2

Alesage et course 60 x 59,6 mm

Cylindree 338 cm3

Puissance maxi 25 ch. a 5.500 tr/mn

Carburateur KEIHIN CDX42-38 X I

Graissage Systeme d'injection d'huile Autolube

Puissance du volant magnetique 12V-70W a 3.000 tr/mn

Demarreur: Lanceur manuel a reenroulement ---

Chenille et suspension:

Chenille Caoutchouc moule, armature d'acier

Largeur chenille 380 mm

Longueur surface portante 990 mm

Suspension I 2 galets caoutchouc montes sur roulements

Pignon d'entrainement I pignon en polyurethane (9 dents)

Pignon AR I pignon en polyurethane (9 dents) -

Transmission: Type Embrayage centrifuge automatique et variateur (3,5/ I ~ 1/1)

Entrainement Chaine a rouleaux duplex baignant dans l'huile

Chassis: Type Acier usine

-

Capot: Type Plastique arme (amovible)

Selle: Banquette amovible . -

Reservoir de carburant:

Capacite I 7 litres 1--

Reservoir d'huile:

Capacite 2,25 litres

Pare-choc A V: Tube d'acier chrome -- - --

Equipement electrique:

Phare 12V -60W /60W Feux de route et de croisement

Feu AR 12V-8W

Feu stop 12V-23W

Contact a cle 3 positions (au tableau debord)

Frein: Type Frein a disque

Commande Main gauche, levier au guidon

Accelerateur: Commande Main droite, levier au guidon

Commutateur d'arret d'urgence:

Commande Par poussoir actionne par Ia main droite

Accessoires: Corde de lanceur de secours, trousse d'outillage

En option : Compte-tours et indicateur de vitesse

- 2-

1-2 . S ervice Data

MODEL

ENGINE

Cylinder head tightening torque

Piston clearance Lubrication oil

(Recommended oil)

Ignition timing

Compression ratio

Idling speed

Spark plug (S.T.D.)

GENERAL

GS338G

Nuts: 16.6 ~ 19.5 ft-lbs. (2.3 ~ 2.7 m-kgs.)

0.0018 ~ 0.0020 in. (0045 ~ 0.0 50 mm)

1st: YAMALU BE 2 -stroke oil

2nd: Another brand 2-stroke oil labeled

"B IA certified for service TC-W"

With dial gauge and point checker

B.T.D.C. 1 5± 0 1 mm.

6.58: 1

1,800±100 r.p.m.

1':-J .G.K. B-7HS

GENERA LITE

1-------------------!--------------------------------Carburetor:

Model

Main jet (S.T.D.)

Optional main jet

Pilot screw

Slow jet (S.T.D.)

Partial jet (S.T.D.)

Fuel level

Valve seat

KEIH IN CDX42-38 x 1 (88400)

#140

#145 #1 35 #1 30

1-1/4

#60

#70

+0.079. ( + 2 ) 0.1 96 _ 0 _196 ln . 5 _ 5 mm.

0.07¢ in. (1.8¢ mm) 1------------------t----------- --------------------------

Oil pump:

Minimum stroke

Maximum stroke

0 .008 ~ 0.009 in. (0 20 ~ 0.25 mm)

0.06 ~ 0.07 in. (1 65 ~ 1.87 mm.) 1------------------ -l-------------------------- -- --

DRIVE:

Clutch: Primary spring

Secondary spring

V-belt

Sheave distance

Sheave offset

Part No. 90501 -45162 (Color code: Black)

Part No. 90508-35073 (Color code: Not painted)

Part No. 820- 17641-00

Outer line length :

10 63± 0 07 ins.

02 + 0020. . 4 - 0.059 ln.

1.101±i3mm (2 70 ± 2 mm)

(6.0 + 0 5 ) - 1.5 mm.

--

1-------------------~------------------ ----·- ---------

Chain housing:

Oil capacity

Oil Reduction ratio (Drive chain

sprocket/Driven chain sprocket)

0.45 qt. oz. (430 c.c)

SAE 1 OW/30 motor oil "MS" detergent

12/ 23 1-----------------+------ -- ------------ -------------

Suspension:

Track deflection 0 . 79 ~ 0 .98 in/22 lbs. (20 ~ 25 mm./1 0 kg.)

Brake:

Brake pad wear limit 0.04 in. (1.0 mm)

Gap between pad and disk 0 .008 ~ 0.04 in. (0 2 ~ 1 .0 mm.)

BODY:

Ski width (S.T D) 26.3 ins. (670 mm.)

Note:

The research and engineering departments of Yamaha are continual ly striving to further perfect the GS338G Snowmobile. Im­

provements and modifications are therefore inevit able. Information rega rding changes will be forwarded to all Authorized Ya­

maha Snowmobile Dealers as soon as it is available.

- 3 -

GENERAL

1-2. Donnees d'entretien

MODELE

MOTEUR: Couple de serrage de Ia culasse Jeu du piston Huile de graissage (recommandee)

Calage de l'allumage

Rapport volumetrique Regime de ralenti Bougie (S.T.D.)

Carburateur Modele Gicleur principal (d'origine) Gicleurs principaux en option Vis de ralenti Gicleur de ralenti (d'origine) Gicleur partie) (d'origine)

Niveau d'essence

Siege de pointeau

GENERALITE

Ecrous: 2,3 ~ 2,7 m-kg 0,045 ~ 0,050 mm 1. Huile deux-temps Yamalube

GS338G

2. Autre marque d'huile repondant aux prescriptions BIA pour service TC-W

Avec Jauge a cadran et controleur de vis platinee 1,5±0,1 mm AV. P.M.H.

6,58: 1 1.800±100 t/min N.G.K. B-7HS

KEIHIN CDX42-38 x I (88400) #140 #145, 135 et 130 1-1/4 #60 #70 +2

5_5 mm

¢1,8 mm ~---------------------------------+-----------------------------------------------------------------

Pompe ahuile Course minimum Course maximum

0,20 ~ 0,25 mm 1,65 ~ 1,87 mm

~------------------------------+-~----~--------------------------------------------·---·--TRANSMISSION: Poulies:

Ressort de poulie primaire Ressort de poulie secondaire Courroie trapezoidale

Distance entre poulies:

Decalage des poulies:

Piece No. 90501-45162, Couleur de til: Noir Piece No. 90508-35073, Couleur de til : Non colore Piece No. 820-1 7641-00 Longueur de circonference ext: 1, 108 ± 8 mm 270±2 mm

+0,5 6,0 -),5 mm

~------------------------------~--------------------------------·---------------------------Carter de chaine:

Contenance d'huile Huile Taux de reduction (Pinion menant/ pinion mene de chaine)

Suspension: Fleche de Ia chenille:

Frein: Limite d'usure des plaquettes de frein Jeu plaquette-disque

CHASSIS: Ecartement des skis (d'origine)

Remarque:

430 cc (0,45 oz.) Huile moteur detergeante SAE 10W/ 30W "MS" 12/23

20 ~ 25 mm/10 kg

1,0mm 0,2 ~ 1,0 mm

670mm

Les departements de recherche et d'etude de Yamaha s'efforcent d'ameliorer sans cesse Ie motoneige GS338G. Par consequent, des modifications sont done inevitables. Tous Ies concessionnaires Motoneiges Yamaha seront avises des que possible de toutes modifica­tions ou alterations.

- 4 -

GENERAL

2. Operation As the piston moves upward, the pressure in the

crankcase drops below atmospheric pressure. and the

mixture is d rawn into the crankcase from the car­buretor. As the piston moves downward, the piston

seals off all parts and compresses crankcase volume un­

til it is above atmospheric pressure. During engine operation, alternating positive and

negative pressure pulses are caused in the crankcase and carried through the impulse port to the fuel pump

drive chamber. This causes the fuel pump diaphragm to vibrate up and dow n. The up and down pump

diaphragm action sucks fuel out from .the fuel tank. through the outlet. check valve. and inlet control valve,

then to the regulator chamber. The main diaphragm is forced downward by the inlet

tension spring through the inlet control lever. At the same time. it is forced upward by the diaphragm spring.

But it is so designed that the upward force is greater than the downward force.

The in let control valve is usually separated from the valve seat. But when fuel flows into the regulator

chamber. the fuel weight and pressure in the chamber

rises. This rising pressure forces the main diaphragm

downward against the force of the diaphragm spring. As the main diaphragm is forced downward, it causes

the inlet control lever to close the inlet control valve, and thus the fuel stops flowing in. (That is, it also

prevents the pressure inside the regulator chamber from

rising.) In this manner. a constant regulator chamber pressure is maintained. This chamber pressure is variable. An adjusting screw is located in the bottom of the carburetor. If this screw

is turned in, it pushes more firmly against the diaphragm spring.

This results in more pressure through the carburetor before the fuel valve is shut off. If the screw is backed­out. the diaphragm spring relaxes. It then takes less fuel pressure to shut off the fuel valve .

The amount of fuel pressure is registered in a fuel level

tube attached to the outside of the carburetor. Fuel level height will rise and fall with the level tube as the

adjustment screw is screwed in and out. Once the fuel level has been stabilized by adjustment,

then there are two adjustments to control fue l to the

carburetor venturi . The fuel (under constant pressure) is metered by the slow adjusting screw or by the main ad­

justing screw, it is discharged through the idle discharge

chamber port and the main discharge port into the ven­turi. As this fue l enters the carburetor venturi, it is broken up, vaporized and ca rried a long by the air rushing into the

crankcase.

- 11 -

GENERA LITE

2. Fonctionnement Lorsque le piston se deplace vers le haut, Ia pression dans le

carter descend sous Ia pression atmospherique, et le me­

lange est attire dans le carter du carburateur. Lorsq ue le

piston se deplace vers le bas, les segments de celui-ci per­

mettent Ia compression du volume du carter jusqu'a ce qu'il

soit au-dessus de Ia pression atmospherique. Durant le fonctionnement du moteur, des impulsions de

pression negatives et positives alternativement ont lieu dans le carter et sont acheminees par l'intermediaire de !'orifice

d'impulsion a Ia chambre de commande de Ia pompe a es­

sence. Ainsi Ia membrane de Ia pompe a essence vibre vers

le haut et le bas. Cette action de Ia membrane permet !'as­piration de !'essence a partir du reservoir d'essence, par l'in­

termediaire du clapet de retenue et de Ia soupape de com­

mande d'admission a Ia chambre de regulation. La membrane principale est forcee vers le bas par le ressort

d'admission par l'intermediaire du levier de commande d'admission. Au meme moment il est force vers le haut par

le ressort de Ia membrane. Mais sa conception est telle que Ia force vers le haut est plus grande que Ia force vers le bas.

La soupape de commande d'admission est generalement se­

paree du siege de Ia soupape. Mais lorsque !'essence s'e­

coule dans Ia chambre de regulation, le poids de !'essence et

Ia pression dans Ia chambre augmentent. Cette augmenta­tion de pression force Ia membrane vers le bas contre Ia force du ressort de Ia .membrane. Lorsque Ia membrane

principale est forcee vers le bas, le levier de commande d'admission ferme Ia soupape de commande d'admission, et

par suite !'essence ne penetre plus a l'interieur (c'est a dire aussi, empeche !'augmentation de Ia pression a l'interieur de Ia chambre de regulation). De cette fa<;:on, une pression

constante dans Ia chambre de regulation est maintenue.

La pression de cette chambre est variable. Une vis de re­

glage est situee a Ia partie inferieure du carburateur. Si

cette vis est vissee, elle pousse plus fermement contre le res­

sort de Ia membrane. II en resulte plus de pression a l'interieur du carburateur avant que Ia soupape d'admission de !'essence soit fermee.

Si Ia vis est devissee, le ressort de membrane se relache. il faut done moins de pression d'essence pour fermer Ia sou­

pape d'essence. La quantite de pression d'essence est enregistree dans un tube de niveau d'essence fixe a l'exterieur du carburateur.

Le niveau d'essence variera done avec le niveau du tube

lorsque Ia vis de reglage sera vissee et devissee.

Lorsque le niveau de !'essence est stabilise par reglage, deux reglages pour commander !'essence au venturi du carbura­

teur doivent etre effectues. L'essence (sous pression cons­tante) est mesuree par Ia vis de reglage lent ou par Ia vis de

n!glage principal, iJ est libere par !'orifice de liberation de Ia chambre et par !'orifice de liberation principal dans le ven­

turi. Lorsque !'essence entre dans le venturi du carburateur, elle

est pulverisee, vaporisee et transmise par I' air dans le carter.

GENERAL

1 -3-2. Power transmission

Engine power is transmitted to the drive track in the follow­

ing manner:

0 The primary sheave mounts di rectly to the engine crankshaft. It transmits power to the secondary sheave

through the V-belt.

0 The secondary sheave unit and chaincase drive sprocket are mounted on the same shaft. Power passes from the secondary sheave. through the drive sprocket. then

down through a chain to the driven sprocket mounted

on the front axle.

0 As the front axle turns. it rotates a single attached sprocket. The sprocket meshes with. and turns . the track.

1. Primary sheave As the engine speed increases. the weights located in­side the primary sheave cap are thrown outward by cen­

trifugal force. overcoming the primary spring force. This causes the primary sliding sheave to be pushed toward the primary fixed sheave. As a resu lt. the V-belt is gripped between the sliding sheave and the fixed sheave. Engine power is now be­

ing transmitted to the drive track through the complete

drive system. The V-belt begins turning at about 2,600

~ 2.700 r.p.m. As engine speed increases. the sliding sheave moves further toward the fixed s heave and squeezes out the V­

belt radially. Since the length of the V -belt rema ins constant. the V-belt on the side of the secondary sheave is pulled by the primary sheave and forced to move

toward the shaft. This causes the ratio of the primary sheave diameter to secondary sheave diameter to change; that is. the reduction ratio is automatically

changed according to the load and speed of the engine.

To sum up, the reduction ratio between the crankshaft and the secondary sheave varies from 3. 5 : 1 to 1 1.

2. S econdary sheave

This secondary sheave operates in the following manner:

a. When at rest or at slow speed (and high track load), the

secondary sliding sheave is forced against fixed sheave by the secondary spring.

b. As engine rpm increases. and primary sheaves are forc­ed together. the V-belt is pulled down closer to the

center of the secondary sheaves.

The V-belt wedges the tw o secondary sheaves apart. In other words. the diameter of the circle formed by the V­

belt on the primary sheave becomes larger. while the diameter on the secondary sheave becomes smaller.

- 12 -

GENERALITE

1-3-2. Transmission de Ia puissance

La puissance du moteur est transmise a Ia piste d'entrainement

de Ia fac;:on suivante: 0 La puolie primaire est couplee directement au vilebrequin.

Elle transmet Ia puissance a Ia poulie secondaire par l'in­

termediaire d'une courroie en V.

0 L'unite de poulie secondaire et le pignon de commande de Ia chaine sont montes sur le meme arbre. La puissance est transmise de Ia poulie secondaire par l'intermediaire du pig­

non de commande de chaine, puis par l'intermediaire de Ia

chaine au pignon de chaine commande monte sur !'axe avant.

0 Lorsque !'axe avant tourne, il assure Ia rotation d'un pignon de chaine. Le pignon s'engrene et permet le mouvement des chenilles.

I. Poulie primaire Lorsque Ia vitcsse de rotation du moteur augmente, les

poids situes a l'interieur du couvercle de Ia poulie primaire sont projetes vers l'exterieur par Ia force centrifuge, neutra­lisant Ia force du ressort primaire. Par suite Ia poulie mo­bile primaire est poussee vers Ia poulie fixe primaire. D'au­

tre part, Ia courroie en V est serree entre Ia poulie mobile et

Ia poulie fixe. La puissance du moteur est maintenant

transmise aux chenilles par l'intermediaire du systeme de

commande complet. La courroie en V commence a tourner a environ 2.600 ~ 2.700 tpm.

Lorsque Ia vitesse de rotation du moteur augmente, Ia pou­lie mobile se deplace vers Ia poulie fixe et serre Ia courroie en V, de fac;:on radiale. La longueur de Ia courroie etant

constante, celle-ci du cote de Ia poulie secondaire est tiree par Ia poulie primaire et obligee de se deplacer vers !'axe. Par suite le rapport entre le diametre de Ia poulie primaire et le diametre de Ia poulie secondaire change; c'est a dire que

le rapport de reduction est automatiquement modifie en fonction de Ia charge et de Ia vitesse du moteur.

Pour resumer, le rapport de reduction entre le vilebrequin et

Ia poulie secondaire varie de 3,5 : I a I : I. 2. Poulie secondaire

Cette poulie fonctionne de Ia fac;:on suivante:

a. Au repos ou a faible vitesse (et forte charge), Ia poulie se­

condaire mobile est appliquee contre Ia poulie fixe par le

ressort secondaire.

b. Lorsque Ia rotation (tpm) du moteur augmente, et que les poulies primaires sont pressees ensembles, Ia courroie en V est tiree vers le bas vers le centre des poulies secondaires.

La courroie en V maintient les deux poulies secondaires se­

parees. En d'autres termes, le diametre du cercle forme par Ia courroie en V sur Ia poulie primaire devient plus grand,

tandis que Ie diametre sur Ia poulie secondaire devient plus petit.

2-2. Manual starter

Tools required: wrench 10 mm box

13 mm

Slotted

box wrench

d Screwdriver he a (medium)

ENGINE

2-2 • manuel Demarreur

. I necessaires: Outt s 10 mm

Clef a tube

. b 13 mm ) Clef a tu e , '" ndue (moyen . our tete ,e Tournevts P

----------:=:~--- 11 2. Ecrou

ur Cable (corde)

MOTEUR

---------~~~---- d demarre I 3. . d de· marreur I. CofTrel u . . ce u ambour de pouhe I 4. Po,gn .

2. T demarreur Conncclcur . 13. Rope Rcssorl du d I 5. d pouhc - e Starw "'""' 3· ooom"" ' ,. Co""'"'' ' ' '""" "' " · ' G Osoo< do ' . . . "" '"'"'''

2. Shea

ve drum Connector Ressorl de nasque I 7. v, s a l (grover)

" 5 "'"' " " " .

spring Sh ave cover . . men! d I 8 Ron d'arret 0 6)

3. """" <6. ' d.'""''"' . do oommoo ' · d.'"""" (8 o. ; U · · 4 o.;., ,,., ''" ""d "''" ""'"" do ' ''""' " ''""" "' '"'"'"""' . Th

rust washer . 17. Spring washer 6. Ressorl de retour 20. Calc de plaque rcur

S g <8 '"o" 3 '""; O<d" dom" . o,;""'""'"" " · """'"'"9 18 D·" .5·0 61 . ""'"" do """' "

6

· ng Sh,·m drive plate · 8. mmande

22

Boulon '"""' "" 20. 9

. Ploqoo do 00

·

; '"""' "''"' 2< '""" '""" W. "'""'""'"' H ''"'"" g D ,;., '"" 22. Soh R ooodoUo '"'"" h

II.

Flat was er 23. Bolt

10 '''''' • .,,., F;g 2. 17 11.

02 N"' -3<-

ENGINE

2-3-3. Assembly

1. Grease the oil pump drive gear and prepare to install the

primary fixed sheave.

Thoroughly clean the tapered portions of the primary

shaft and fixed sheave. and fit the sheave to the shaft.

2. Install the bearing. spring seat and washer. and tighten

the bearing nut.

To tighten the nut; lock the crankshaft with the special

tool (which was used in disassembling). or by inserting

an iron rod into the starter pulley.

Nut tightening torque: 433.98 ~ 694.37 in-lbs. (5.0 ~ 8.0 m-kgs.)

3. Grease the spline. insert the primary spring onto the

shaft. push the sliding sheave over the shaft. put the

collars into the primary shaft collar groove. and install

the circlip.

4. Install the primary sheave cap on the primary shaft. and

fasten it with the lock washer and bolt. Bend the

washer lobe to lock the sheave cap.

MOTEUR

2-3-3. Montage

I. Graisser le pignon d'entrainement de Ia pompe a huile et se

pn!parer a installer Ia poulie primaire fixe.

Nettoyer entierement les parties chanfreinees de l'arbre pri­

maire et de Ia poulie fixe, et adapter Ia poulie sur l'arbre.

2. Monter le roulement, le siege du ressort et Ia rondelle, et

serrer l'ecrou du roulement. Pour serrer l'ecrou, bloquer le vilebrequin avec l'outil spe­

cial (qui a ete utilise pour le demontage), ou en pla9ant une

tige de metal dans Ia poulie du demarreur.

Le couple de serrage de l'ecrou est le suivant: 5 ~ 8 m-kg

3. Graisser Ia cannelure, inserer le ressort primaire sur l'arbre,

pousser Ia poulie mobile sur l'arbre, placer le collier dans Ia

gorge de l'arbre primaire et installer le jonc d'arret.

4. Installer le capot de Ia poulie primaire sur l'arbre primaire,

et le serrer avec Ia rondelle frein et le boulon.

Courber Ia rondelle afin de bloquer le capot de Ia poulie.

- 38-

ENGINE

b. Check the carburetor body and pump body, and if crack­ed or holed. replace.

c. Check the threaded portion of the stop screw. and if

damaged. replace. d. Check the main diaphragm for center plate position and

any other defect. Replace. if any defect is found.

e. Check the check valve for cracks and holes. replace if damaged.

f. Check the arm pin. float arm, valve pin, and needle valve

for wear or breakage. If excessively worn or broken. replac e .

g. Check the arm spring for spring fatigue . If it is too severe. replace.

h. Check the pump body gaskets. upper and lower. Replace any defective one.

i. Check the pump diaphragm. If bent or holed. replace. j. Check the gasket located over the pump diaphragm. If

damaged. replace.

k. Check the metering needles on the ends of main ad­

justing screw and slow adjusting screw. If any needle is

damaged. the needle seat is considered to be scratch­ed. Replace the carburetor body.

Check the idle bypass hole for clogging. If clogged. clean with compressed air. Never use a wire.

m. Check the main nozzle for clogging, and if necessary, blow with compressed air.

n. Don't disassemble the choke mechanism unnecessari­ly. If the shaft or the choke lever is bent. replace.

2-5-4. Assembly

Reverse the procedure for disassembly.

Note: 1. The assembly operation should be performed with the

main diaphragm completely in the groove in pump body

2. 2 . Take care so that the check valve is installed in the cor­

rect position. Fit the rubber around the check valve lip into the pump body groove. Align the valve seat with

the check valve hole. If not aligned. the pump will not

work. or low performance will result. 3 . When installing the arm spring. it should be aligned with

float arm guide pin. 4. The choke mechanism should not be disassembled. 5. When assembling. be careful not to reverse the position

of gaskets. Carburetor failures are often caused by dust

and incorrect service.

MOTEUR

b. Contr6Ier le corps du carburateur et le corps de pompe et s'ils sont feles ou troues du carburateur et le corps de

pompe et s'ils sont feles ou troues les remplacer.

c. Contr61er Ia partie filetee de Ia vis de butee; si elle est dete­rioree, Ia remplacer.

d. Verifier que Ia membrane principale est bien centree ou

pour tout autre defaut. La remplacer si un defaut est cons­

tate. e. Verifier que le clapet ne comporte pas de crevasse ou de

trou; le remplacer s'il est defectueux.

f. Verifier Ia goupille, le bras de flotteur, Ia valve de pointeau,

et le pointeau; s'ils sont uses excessivement ou casses les rem placer.

g. Verifier que le ressort n'est pas detendu; s'il est trop dur le rem placer.

h. Verifier les garnitures Uoints) de corps de pompe, superieur et inferieur et les remplacer s'ils sont defectueux.

1. Contr6Ier Ia membrane de Ia pompe. Si elle est courbee ou

trouee Ia remplacer.

J. Verifier Ia garniture situee sur Ia membrane de Ia pompe. Si elle est deterioree Ia remplacer.

k. Contr6Ier les pointeaux de debit sur les extremites de Ia vis

principale de reglage et de Ia vis de reglage et de Ia vis de re­glage de ralenti.

Si un pointeau est deteriore, le siege de celui-ci est considere comme raye. Remplacer le corps de carburateur.

I. Verifier que !'orifice de derivation n'est pas encrasse; s'il est cncrasse le nettoyer avec de !'air com prime. Ne jamais uti ­

liser de til. m. Verifier que Ia principale tubulure n'est pas encrassee, et si

necessaire injecter de !'air comprime.

n. Ne pas demonter le mecanisme diffuscur si cela n'est pas necessaire. Si !'axe ou le levier du diffuseur est courbe, le rem placer.

2-5-4. Montage

lnverser Ia procedure du demontage.

Remarque:

-50 -

I. L'operation de montage doit etre effectuee, Ia membrane

principale etant entierement dans Ia gorge du corps de pompe 2.

2. Faire attention que le clapet soit installe dans Ia bonne posi­tion. Disposer le caoutchouc autour du bord du clapet dans Ia gorge du corps de pompe. Aligner le siege du clapet

avec !'orifice du clapet. S'il n'est pas aligne Ia pompe ne

fonctionncra pas, et de mauvais resultats en resulteront. 3. Lors de !'installation du ressort, il doit etre aligne avec Ia

goupille du bras de flotteur.

4. Lc mecanisme diffuseur nc doit pas etre demonte. 5. Lors du montage, faire attention a ne pas inverser Ia posi­

tion des joints. Les pannes de carburateur sont souvent

causees par Ia poussiere et un service incorrect.

ENGINE

2 - 5-5. Installation

For installation. reverse the procedure for removal.

Tight ening torque for spacer and carburetor:

No tightening torque for carburetor mounting nuts can

be specified for reason of its construction. and therefore.

they should be tightened w ith a wrench with special

care.

Tightening torque :

164.91 in-Jbs. ( 1. 9 m -kgs.) for spacer and cylinder

Tightening torque:

60.76 in-lbs. (0. 7 m-kg) for carburetor and air duct

2 -5-6. Adjustments

1. The carburetor is properly adjusted and subjected to a

stringent test at the factory. and therefore. it should not

be disassembled or adjusted unnecessarily.

However. according to operating conditions or

geographical conditions (weather. altitude. etc.). it may

require readjustment. cleaning and inspection. In t his

case the following parts must be readjusted.

a. Adjusting screw to control the pressure (fuel level) in

the regulator chamber.

b. The adjust screw to control the mixture when the

engine idles.

c. The throttle stop screw to control the id ling speed.

d. The main jet to control the mixture when throttle open­

ing is larger.

Note: As the throttle opening increases. the adjust screw.

slow jet and partial jet functions. in that order. For

details. refer to the carburetor manual.

2. Adjusting the regulator chamber internal pressure (fuel

level) The performance of the diaphragm type carburetor

depends greatly on the condition of the regulator. and

therefore. the regulator must be adjusted very carefully.

To adjust. first remove the fuel level pipe cap. and run the engine at idling speed so that the fuel moves up into

the fue l level pipe. Adjust the fuel level as specified

with the adjusting screw (located in the carburetor bot­

tom).

MOTEUR

2-5-5. Installation

Pour !'installation inverser Ia procedure du demontage.

Couple de serrage pour entretoise et carburateur:

Des couples de serrage pour les ecrous de montage du car­

burateur ne peuvent pas etre specifies pour des raisons de

construction et c'est pourquoi, ils doivent etre serres avec

une clef en prenant des precautions speciales.

Couple de serrage:

l ,9 m-kg pour entretoise et cylindre

Couple de serrage :

0, 7 m-kg pour carburateur et conduit d'air

2-5-6. Reglages

I . Le carburateur est soigneusement regie et rigoureusement

controle en usine. II ne faut jamais le demonter ou modifier

son reglage sans necessite.

Toutefois, certaines conditions d'utilisation du scooter ou

circonstances geographiques (climat, altitude, etc.) peuvent

dieter une modification des reglages. D'autre part, apres

demontage du carburateur pour le nettoyage et le controle,

il faudra reglcr les organes suivants :

a. Vis de reglage de Ia pression (niveau d'essence) dans Ia

chambre <;le regulateur.

b. Vis de rcglage (qui regie Je dosage du melange lorsque le

moteur tourne au raleti).

c. Vis butee d'acce!erateur (qui regie le regime de ralenti ).

d. Gic!eur principal (qui regie le dosage du melange dans le

circu it de marche).

Remarque:

A mesure que l'ouverture des gaz augmente, Ia vis de re­

glage, le gicleur du ralenti et lc gicleur partie! entrent suc­

ccssivcment en j eu. Pour plus de details, se reporter au ma­

nuel du carburateur.

2. Le reglage du niveau consiste ici a regler Ia pression a J'intcrieur de Ia chambre de regulateur. Le bon fonctionne­

ment d'un carburateur a diaphragme depend avant tout de

J"etat du regulateur. Par consequent, ce dernier doit etre

regie avec un soin tout particulier, en procedant comme

suit.

Commencer par enlever Je bouchon du tube de contole du

niveau d'essence, et faire tourner le moteur au ralenti, de

tel lc sorte que !'essence monte dans le tube de controle. Re­

gier au niveau specifie a !'aide de Ia vis prevue a Ia base du

carburateur.

- 51 -

EN GIN E MOTEUR

Fig. 2 -96

- 73 -

POWER TRAIN

3 -2 . Disc brake

Tools requ ired :

Pliers d wrench 19 mm -

open-en ··--------- - - -

1. Brake disk complete 1 Caliper body 2

2 . d complete 3 . Caliper bo y

4 . Pin

5 Pin

6. Cotter pin

7 Pin

8. Plain washer

. g 1 9 Return spnn . Return spring 2 10.

11 . Bolt

12 . Nut

13. Spring washer

14 . Nut

15. Shim

3-2. , d" ue Frein a •sq

Outils necessaires:

. 3 -1 4 F1g.

- 81 -

Pinces Clef plate 19 mm

Disque de frein mble I I. . d'etrier ense 2 Corps ble 2

. d'etrier ensem 3. Corps

4 . C heville

5. C heville

6. Goupille

7 C heville . . Rondelle ordinaJre 8.

RAINEMENT TRAIN D'E=N_T _ _ _

Ppel I Ressort de ra 9. pel 2 I 0. Ressort de rap

II. Boulon

l2. Ecrou

13. Rondelle grover

l4. Ecrou

l5. C ale

POWER TRAIN

·e wheels 5 Bog• 3- 0

Tools required:

wrench 13 mm box

Chisel

S teel hammer

Track assem bly 1.

2 . Pivot arm

3 . Spring

4 . Pivot shaft

5. Bot!

TRAIN NEMENT D'ENTRAI

3-5. Bogies

Outils necessaires :

Lock washer 6 . . wheel 7 . Suspension

Bearing (B6004) B. Circl ip (R-42 ) 9.

10. Wheel cap

Fig. 3 -39

- 92 -

Clef a tube .13 mm C iseau a frOid

Marteau d'acier

1. Chenille

2. Bras de pivot

3 . Ressort

4. Axe du pivot

S. Boulon

6. Ronclelle grover

suspensio n 7. Roue. 6004)

Rou lcmcnt (B 8. . - (R-42) 9. Jonc d arret

Capuchon de roue 10.

POWER TRAIN

2 . Alignment a . Start the engine, and support the rear of the snow­

mobile with a stand. Let the drive track rotate. and

check if it shifts to one side. b. The drive track shifts to the left.

In this case. tighten the left-side track adjusting screw.

and loosen the right-side adjusting screw. c. The drive track shifts to the right.

Tighten the right-side track adjusting screw. and loosen

the left-side adjusting screw.

d. Until the track is aligned, the above operations must be

repeated. After the adjustment run the drive track, and

check. If still not aligned. readjust so that the gaps on

both sides of the track become even.

3. Recheck track tension after adjusting alignment.

4. After the track is completely adjus ted, tighten the pivot

rear screw lock nut. and install the cotter pin.

Pivot rear screw lock nut:

Tightening torque: 130.20 in-lbs. ( 1. 5 m-kgs.)

Bend the track adjusting screw lock washers.

TRAIN D'ENTRAINEMENT

2. Alignement

a . Demarrer le moteur, et placer l'arriere du motoneige sur un

support Faire tourner la chenille, et contr6ler si elle se de­

place sur un cote.

b. La chenille se deplace vers Ia gauche.

Dans ce cas, serrer Ia vis de reglage de Ia chenille gauche, et

desserrer Ia vis de reglage du cote droit. c. La chenille se deplace vers Ia droite.

Serrer Ia vis de reglage droite de Ia chenille, et desserrer Ia

vis de reglage du cote gauche.

d. Les operations precedentes doivent etre etfectuees jusqu'a

ce que Ia chenille soit alignee. Apres le reglage, faire tour­

ner Ia chenille et controler. Si elle n'est toujours pas

alignee, reajuster afin que les intervalles sur les deux cotes

de Ia chenille soient egaux.

3. Verifier de nouveau Ia tension de Ia chenille apn!s le reglage

d'aligncment.

4. Apres le reglage complet de Ia chenille, serrer l'ecrou de

blocage de Ia vis arriere du pivot, et placer Ia goupille. Couple de serrage de l'ecrou de blocage de Ia vis arriere de

pivot: I ,5 m-kg

Plicr les rondelles de blocage des vis de reglage de Ia che­

nille.

- 96 -

STEER IN G (SK I) AND CHASSIS

4 -3-2 . Installation

For insta ll ation. reverse the procedure for removal.

N ote:

1 If any part of the chassis is corroded or rusty, it should be sandpapered and coated with rustproof paint.

2. The we lded portions should be checked period ica ll y. if

any part is found separated or cracked. it shou ld be

re pa ired .

3. Check the shroud for cracks. and if cracked. repair.

4 -4. Rider's seat

4 -4 -1 . Removal

1. Remove the two bolts at the front part of the seat.

2. Remove the two nu ts from the in side of the frame under

the rear part of the seat. 3. Disconnect the taillight lead wire at the connector at the

front part of the seat.

4. Lift the rear side of the seat slightly, and pull it rear­

ward.

4 -4 -2. Installation

For installation. reverse the procedure for removal. The seat is held to the frame together with the engine cowl.

and therefore. care s hould be taken so that the seat moun­ting flange is positioned under the engine cowl.

DIRECTION (SKI) ET CHASSIS

4-3-2. Installation

Pour !'install ation, inverser Ia procedure de demontage.

Remarque:

I. Si une piece du chassis est corrodee ou rouillee, elle doit etre passee au papier de verre et enduite de peinture anti -rouille.

2. Les parties soudees doivent etre controlees periodiquement.

Si une partie est dessoudee ou felee, elle doit etre reparee.

3. Verifi er si le capot n'est pas !ele, si c'est le cas le reparer.

4-4. Siege

4-4- I. Depose

I. Deposer les deux boulons a Ia partie avant du siege.

2. Deposer les deux ecrous de l'interieur du chassis sous Ia partie arriere du siege.

3. Deconnecter le ti l de lanterne arriere au connecteur situe a Ia partie avant du siege.

4. Soulever legerement l'arriere du siege, et le ti rer en arriere.

4-4-2. Installation

Pour !'installation, inverser Ia procedure du demontage. Le siege est maintenu au chassis avec le capot de moteur, et c'est pour­

qua i, des precautions doivent etre prises afin que le tlasque de montage du siege soit place sous le capot du moteur.

-111 -

TROUBLESHOOTING

CHAPTER 6. TROUBLESHOOTING

Hard starting

1. The engine is hard to start or will not start.

a. Out of gas.

Remedy: Add fuel.

b. Fuel has deteriorated, or dust or water presents in fuel

passages.

Remedy: Clean the fuel tank and fuel passages.

c. Fuel lines are connected loosely or improperly.

Remedy: Check the joints. and correct.

d. Fuel line is pinched or flattened.

Remedy: Relocate item that is pinching the fuel line.

e. Pu lse line for fuel pump is disconnected. (Fuel pump

does not operate.)

Remedy: Connect pulse pipe. (To carb and crankcase.)

f. Fuel filter or fuel line is clogged.

Remedy: Replace the filter. or clean the line.

g. Carburetor's slow adjuster is set incorrectly

Remedy: Readjust.

h. Spark plug is wet.

i. Spark plug is faulty, plug gap is incorrect. or electrodes

are fouled.

Remedy: Replace the spark plug. or clean. Adjust the

plug gap.

j. Cylinder head gasket or cylinder base gasket is faulty.

Remedy: Replace.

k. Ignition system parts are loose or damaged. Wiring or

insulation is faulty.

Remedy: If damaged. replace. Otherwise. correct

I. Flywheel magneto woodruff key is broken.

Remedy: Replace.

m. Breaker points are burnt or fouled. or the point gap is in­

correct. when timing is properly adjusted.

Remedy: Replace. or correct.

n. Compression pressure is low.

Remedy: Replace piston rings and or piston.

o. Fuel tank vent line is kinked or clogged.

Remedy: Correct or clean.

2. The engine crankshaft will not turn.

a. Piston has stuck to cylinder wall because of rust. or

seizure.

Remedy: Correct.

b. Connecting rod big end bearing has seized.

Remedy: Replace. Check the crankshaft for bends.

and if faulty. correct.

c. Connecting rod or crankshaft is broken or twisted.

Remedy: Replace.

d. Oil pump drive gear is jammed.

Remedy: Replace.

e. Crankshaft main bearings have rusted. broken or seized.

3. Engine crankshaft turns too easily.

a. Spark plug is loosely mounted.

Remedy: Tighten.

b. Piston-to-cylinder clearance too great.

Remedy: Replace piston and rings.

- 125-

DEPANNAGE

c. Hole melted in top of piston.

Remedy: Replace. Check for cause of overheating.

d. Piston rings are worn .

Remedy: Replace. Check cylinder wall and piston for

wear.

4. Eng ine will not start. but kick-back or back-fire takes

place.

a. Flywheel woodruff key is broken.

Remedy: Replace.

b. Ignition timing is incorrect.

Remedy: Readjust.

Poor low speed engine operation

a. Carburetor slow speed adjustment is incorrect.

Remedy Readjust.

b. Spark plug gap is incorrect. or electrodes are fouled or

damaged.

Remedy: Readjust the gap. Clean or replace spark

plug.

c. High-tension wire is faulty.

Remedy: Replace.

d. Spark plug cap is loose.

Remedy: Tighten.

e. Ignition source coi l or condenser is fau lty.

Remedy: Detect the cause. and replace the faulty

part.

f. Breaker points are burnt. fouled. or point gap is in­

correct.

Remedy: Replace. or clean and readjust.

g. Cylinder gasket is leaking.

Remedy Replace.

h. Crankcase sealing surfaces or oil seals are leaking.

Remedy: Reseal/ Replace.

i. Ignition coil grounding is faulty.

Remedy: Correct.

High speed operation problems

1. Engine will not operate properly at high speeds.

a. Carburetor high speed mixture screw is improperly ad­

justed

Remed"y : Readjust.

b. Ignition timing is incorrect.

Remedy Readjust.

c. Spark p lug heat range is incorrect.

Remedy: Replace.

d. Spark plug gap is incorrect. electrodes are fouled. or

porcelain is cracked.

Remedy: Adjust. c lean or replace.

e. High-tension wire is faulty.

Remedy: Correct or replace.

f. Ignition source coil or condenser is faulty.

Remedy: Check for the cause. and replace.

g. Breaker points are burnt. fouled. or point gap is in­

correct.

Remedy: Replace. c lean or adjust.

TROUBLESHOOTING

h. Carbon build-up in the combustion chamber.

Remedy: Clean .

2. Poor acceleration from low to high speed.

a. Fuel is too old .

Remedy: Replace .

b. Fuel line is clogged, or pinched.

Remedy: Clean or correct.

c. Fuel filter is clogged.

Remedy: Replace .

d. Fuel pump is clogged.

Remedy: Clean.

e. Carburetor slow speed screw and high speed screw are

incorrectly adjusted.

Remedy: Readjust.

f. Fuel level is incorrectly adjusted.

Remedy: Readjust.

g. Carburetor fuel passage is clogged .

Remedy: Clean.

h. Ignition timing is incorrect.

Remedy: Readjust.

i. Spark plug is fouled . or plug gap is incorrect.

Remedy : Clean or readjust.

j . High-tension wire is loosely connected. broken. or poor­

ly insulated.

Remedy: Correct or replace.

h. Ignition source coil or condenser is faulty.

Remedy: Check for cause. and replace .

I. Breaker points are burnt or worn. or point gap is in­

correct.

Remedy: Replace or readjust.

m. Piston rings are stuck or scratched.

Remedy: Replace .

n. Excessive carbon on piston head or cylinder head.

Remedy: Clean.

3. The engine idles smoothly, but shows poor acceleration.

At full throttle. misfires.

a. Fuel line is clogged.

Remedy: Clean.

b. Fuel filter is clogged.

Remedy: Replace .

c. Fuel pump is faulty.

Remedy: Correct.

d. Carburetor fuel level is low.

Remedy: Adjust.

e. Main nozzle or main jet (high speed mixture screw) is

clogged.

Remedy: Clean.

f. Choke valve is partially closed .

Remedy: Adjust.

g. High speed mixture screw is incorrectly adjusted.

Remedy: Adjust.

h. Breaker points are burnt fouled . or point gap is in­

correct.

Remedy: Replace. or clean and adjust.

i. Ignition timing is incorrectly adjusted .

Remedy: Adjust.

j. Fuel tank vent pipe is clogged or pinched.

Remedy: Replace .

- 126-

DEPANNAGE

4. The engine runs only when the primer pump is used.

a. Fuel line is clogged .

Remedy: Clean .

b. Fuel line is leaky

Remedy: Correct.

c. Fuel filter is clogged.

Remedy: Replace.

d. Fuel pump does not discharge enough fuel.

Remedy : Correct.

e. Carburetor fuel level is low.

Remedy: Adjust.

f. Inlet control valve is clogged.

Remedy: Clean.

g. Carburetor-to -crankca se pulse line leaks.

Remedy: Replace or reconnect.

Troubles at both low and high speeds

1. Engine overheating .

a. Oil tank is empty.

Remedy: Refill.

b. Carburetor is adjusted incorrectly. and mixture is lean.

Remedy: Adjust.

c. Oil pump is incorrectly adjusted (Oil pump output is in­

sufficient.)

Remedy: Adjust.

d Air inlet or outlet for forced air-cooling system is clog ­

ged.

Remedy: Adjust

2 . The engine stalls suddenly.

a. Fuel tank is empty.

Remedy: Refill.

b. Oil tank is empty.

Remedy: Refill . Correct engine seizure.

c. Fuel line is disconnected

Remedy: Connect.

d. Connecting rod is bent broken . or crankshaft is damag­

ed.

Remedy: Overhaul .

e. Piston has seized.

Remedy : Correct.

f . Connecting rod big end bearing has seized.

Remedy: Replace.

g. High-tension wire is disconnected. or ignition circuit is

faulty.

Remedy: Correct.

3 . The eng ine knocks .

a. Oil pump output is insufficient.

Remedy: Adjust.

b. Spark plug heat range is incorrect.

Remedy Replace.

c. Magneto flywheel is loosely mounted .

Remedy: Tighten . Check woodruff key.

d. Connecting rod big end is worn .

Remedy: Replace .

e. Crankshaft bearing is worn .

Remedy: Replace.

TROUBLESHOOTING

f. Excessive carbon in combustion chamber, exhaust port

or on piston head.

Remedy: Clean.

g. Flywheel magneto key is broken.

Remedy: Replace.

h. Carburetor adjustment is incorrect. and mixture is too

lean . Remedy: Adjust.

4. The engine lacks power under heavy load.

a. High speed mixture is incorrectly adjusted, and thus

mixture is too lean or too rich.

Remedy: Adjust.

b. Cylinder or piston is scratched.

Remedy: Replace.

e. Excessive carbon on the piston head or in combustion

chamber.

Remedy: Clean .

d. Ignition timing is retarded .

Remedy: Adjust.

e. Breaker points are fouled, or point gap is incorrect.

Remedy: Clean or adjust.

f. Fuel pump output is insufficient.

Remedy: Adjust.

5. The engine runs roughly.

a. Fuel level is too high.

Remedy Adjust.

b. Slow speed and high speed mixture screws are in­

correctly adjusted. and mixture is too rich.

Remedy: Adjust.

c. Choke is not fully opened.

Remedy: Check for cause, and adjust.

d. lg[lition timing is incorrectly adjusted.

Remedy : Adjust.

6. Fuel consumption is too high.

a. Pump diaphragm has a hole.

Remedy : Replace.

b. Carburetor gaskets are leaking.

Remedy: Replace .

c. Fuel level is too high.

Remedy: Adjust.

d. Slow speed and high speed screws are incorrectly ad­

justed, thus making the mixture too rich.

Remedy : Adjust .

7. Exhaust gas is smoky, and the engine runs roughly.

a. Oil pump output is too much.

Remedy : Adjust.

b. Fuel is too old.

Remedy: Replace fuel.

- 127-

DEPANNAGE

TROUBLESHOOTING

CHAPITRE 6. DEPANNAGE

Demarrage difficile

I. Le moteur est difficile a demarrer ou ne demarre pas.

a. Plus de carburant. Remede: ajouter du carburant.

b. Le carburant est defectueux, ou de Ia poussiere, ou de l'eau est presente dans les canalisations.

Remede: nettoyer le reservoir de carburant et les canali­

sations. c. Les conduits de carburant sont desserres ou mal connectes.

Remede : controler les joints et corriger. d. La canalisation de carburant est pincee ou aplatie.

Remede: localiser Ia piece qui pince Ia canalisation. e. Le conduit d'impulsions pour Ia pompe a carburant est de­

branche (Ia pompe a carburant ne fonctionne pas).

Remede: brancher le conduit entre le carburateur et le carter.

f. Le fil tre de carburant est encrasse ou Ia canalisation.

Remede : remplacer le filtre ou nettoyer le conduit. g. Le dispositif de reglage du ralenti sur le carburateur est mal

regie. Remede: reaJuster.

h. La bougie est humide. 1. La bougie est defectueuse, le capuchon de Ia bougie est

mauvais, ou les electrodes sont encrassees.

Remede: remplacer Ia bougie, ou Ia nettoyer. Ajuster le capuchon de Ia bougie.

j. Le joint de culasse ou le joint a Ia base du cylindre sont de­fectueux.

Remede: les remplacer. k. Les composants du systeme d'allumage sont reliiches ou

deteriores.

Le ciiblage ou l'isolement est defectueux. Remede: si le ciiblage est defectueux le remplacer; autre­ment, corriger.

I. Le contact de Ia magneto a volant est casse. Remede: le remplacer.

m. Les contacts platines sont brilles ou encrasses, ou l'espace entre les contacts est incorrect, lorsque l'avance est incor­rectement reglee.

Remede: remplacer ou corriger. n. Le taux de compression est faible .

Remede: remplacer les segments du piston ou le piston.

o. La prise d'air du reservoir de carburant est vrillee ou obs­truee.

Remede: corriger ou nettoyer. 2. Le vilebrequin du moteur ne tourne pas.

a. Le piston colle a Ia paroi du cylindre par suite de Ia rouille ou d'un grippage.

Remede: corriger.

b. Le roulement de Ia grosse extremite de Ia bielle est grippe. Remede: le remplacer. Controler le vilebrequin, s'il est courbe ou defectueux, le corriger.

c. La bielle ou le vilebrequin sont casses ou tordus. Remede: remplacer.

d. Le pignon de commande de Ia pompe a huile est grippe.

Remede: remplacer.

-128-

DEPANNAGE

e. Les roulements principaux du vilebrequin sont rouilles,

casses ou grippes.

3. Le vilebrequin du moteur tourne trop librement. a. La bougie est desserree.

Remede : Ia serrer.

b. Le jeu entre le piston et le cylindre est trop important. Remcde: remplacer le piston et les segments.

c. Creux fondu au sommet du piston.

Remede: remplacer. Trouver Ia cause du chauffage. d. Les segments du piston sont uses.

Remcde: les remplacer. Controler l' usure eventuelle de Ia paroie du cylindre et du piston .

4. Le moteur ne demarre pas, mais un retour d'allumage a lieu .

a. Le contact de Ia magneto est casse.

Remcde: remplacer.

b. L'avance a l'allumage est incorrect. Remcde: reajuster.

F onctionnement du moteur a faible vitesse defectueux

a. Le reglage de ralenti du carburateur est incorrect.

Remedc: rcajustcr. b. L'ecartemcnt des electrodes de Ia bougie est incorrect, ou

bien les electrodes sont encrassees ou dcteriorccs.

Remede: reajuster l'ecartement. Nettoyer ou remplacer Ia bougie.

c. Lc cable de haute tension est defectueux . Rcmcde : le remplacer.

d. Le capuchon de Ia bougie est reliiche. Remede: le serrer.

c. La bobine source d'allumage ou le condensateur est defec­tucux.

Remede: trouver Ia cause, et remplacer Ia piece defec­tueuse.

f. Les contacts platines sont brilles, encrasses ou leur ecarte­mcnt est defectueux.

Rcmede: remplacer, ou nettoyer et reajuster.

g. Le joint de culasse est defectueux . Remede: le remplacer.

h. Le joint de carter ou les joints a huile sont defectueux. Remede: n!parer les joints ou remplacer.

1. La mise a Ia masse de Ia bobine d'allumage est defectueuse. Rcmede: corriger.

Probh!mes de fonctionnement a hautes vitesses

I. Le moteur ne fonctionne pas correctement a hautes vites­ses.

a. La vis de melange de haute vitesse du carburateur est mal ajustee. Remcde: reajuster.

b. L'avance a l'allumage est incorrecte. Remede: reajuster.

c. La temperature de Ia bougie est incorrecte. Remede : Ia remplacer.

TROUBLESHOOTING

d. L'ecartement des electrodes de Ia bougie est incorrecte, les electrodes sont encrassees ou Ia porcelaine est felee. Remede : ajuster, nettoyer ou remplacer.

e. Le cable de haute tension est defectueux.

Remcde: le corriger ou le remplacer. f. La bobine source d'allumage ou le condensateur est defec­

tueux. Remede : verifier Ia cause et remplacer.

g. Les contacts platines sont bn}les, encrasses ou l'ecartement

entre les contacts est incorrect.

Remede : remplacer, nettoyer ou ajuster.

h. Calamine dans Ia chambre de combustion. Remede: nettoyer.

2. Faible acceleration de faible a haute vitesse. a. Le carburant est trop vieux.

Remede: le remplacer.

b. La canalisation de carburant est obstruee ou pincee. Remcde: nettoyer ou corriger.

c. Le filtre de carburant est obstrue. Remede: le remplacer.

d. La pompe a carburant est obstruee.

Remede: la nettoyer.

e. La vis de ralenti du carburateur et Ia vis de haute vitesse

sont incorrectement ajustees. Remede: reajuster.

f. Le niveau de carburant est incorrectement ajuste. Remede : reajuster.

g. L'admission du carburant dans le carburateur est obstruee.

Remcde: nettoyer. h. L'avance a l'allumage est incorrecte.

Remede: reajuster.

1. La bougie est encrassee, ou l'ecartement est incorrect. Remede: nettoyer ou reajuster.

DEPANNAGE

e. Le diffuseur ou principal gicleur est obstrue (vis de melange de haute vitesse).

Remcde: nettoyer. f. La soupape d'engorgement est partiellement fermee .

Remede: ajuster. g. La vis de melange de haute vitesse est incorrectement

ajustee. Remede: ajuster.

h. Les contacts platines sont brules, encrasses ou l'ecartement

entre les contacts est incorrect. Remcde : remplacer ou nettoyer et ajuster.

I. Avance a l'allumage incorrectement ajustee. Remedc: ajuster.

J. La prise d'air du reservoir de carburant est obstruee ou pincec. Remede : remplacer.

4. Le moteur tourne seulement lorsque Ia pompe d'amorc,:age est utilisee.

a . La canalisation de carburant est obstruee.

Remede: nettoyer. b. Fuite dans Ia canalisation.

Remede: reparer. c. Lc filtre de carburant est obstrue.

Remede : remplacer. d. La pompe a carburant ne fournit pas assez de carburant.

Remede : corriger. e. Lc niveau de carburant est faible .

Remcde: ajuster. f. Valve de commarrde d'adm ission obstruee.

Remede: nettoyer.

g. Fuites dans li aison carter-carburateur.

Remede: remplacer ou reconnecter.

J. Le cable de haute tension est deconnecte, casse ou mal

isole. Problemcs a haute et faible vitesses

Remede: corriger ou remplacer. k. La bobine source d'allumage ou le condensateur est defec­

tueux. Remede : trouver Ia cause et remplacer.

I. Les contacts platines sont brules ou uses, ou l'ecartement est incorrect. Remede: remplacer ou reajuster.

m. Les segments de piston sont casses ou feles .

Remede: remplacer. n. Trop de calamine sur Ia tete de piston ou Ia tete de cylindre.

Remede: nettoyer.

3. Le moteur tourne au ralenti regulierement mais accelcre dif­

ficilement. A pleine ouverture du papillon, rates d'allumage.

a. La canalisation de carburant est obstruee. Remede: nettoyer.

b. Le filtre de carburant est obstrue. Remede: le remplacer.

c. La pompe de carburant est defectueuse.

Remede: corriger. d. Le niveau de carburant du carburateur est faible.

Remede: ajuster.

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I. Chauffage du moteur. a. Le reservoir du moteur est vide.

Remede: le rempl ir.

b. Le carburateur est mal regie, et le melange est pauvre.

Remcde: ajuster. c. La pompe est mal ajustee (le debit de Ia pompe est insum­

sant).

Remede: ajuster.

d. L'admission et l'echappement d'ai r pour le refroidissement est obstrue ;

Remede: ajuster.

2. Le moteur cale subitement.

a. Le reservoir de carburant est vide. Remcde: le remplir.

b. Le reservoir d'huile est vide. Remede: le remplir. Corriger le grippage du moteur.

c. La canalisation du carburant est debranchce. Remede: rebrancher.

d. La bielle est courbee, cassee, ou le vilebreq uin est deteriore.

Remcde : reviser.

e. Le piston est grippe.

Remede: corriger. f. Le roulement de grosse extremite de Ia bielle est grippe.

Remede: remplacer.

TROUBLESHOOTING

g. Le cable de haute tension est debranche, ou le circuit d'allu­mage est defectueux. Remede: corriger.

3. Le moteur cogne. a. Le debit de Ia pompe a huile est insuffisant.

Remede: ajuster. b. La temperature de Ia bougie est incorrecte.

Remede: remplacer. c. La magneto a volant est desserree.

Remede: serrer. Controler le contact. d. La grosse extremite de Ia bielle est usee.

Remede: remplacer. e. Le roulement du vilebrequin est use.

Remede: remplacer. f. Trop de calamine dans Ia chambre de combustion, pipe d'e­

chappement ou sur Ia culasse. Remede: nettoyer.

g. Contact de Ia magneto a volant casse. Remede: remplacer.

h. Reglage du carburateur incorrect, et melange trop pauvre. Remede: remplacer.

4. Le moteur manque de puissance sous des charges impor­tantes.

a. Le melange pour hautes vitesses est mal regie, et par suite le melange est trop pauvre ou trop riche. Remede: ajuster.

b. Le cylindre ou le piston est fele. Remede: remplacer.

c. Trop de calamine sur Ia culasse ou dans Ia chambre de combustion. Remede: nettoyer.

d. L'avance a l'allumage est retardee. Remede: ajuster.

e. Les contacts platines sont encrasses, ou l'ecartement est in­correct. Remede: nettoyer ou ajuster.

f. Le debit de Ia pompe a carburant est insuffisant. Remede: regler.

5. Le moteur tourne rudement. a. Le niveau de carburant est trop eleve.

Remede : ajuster. b. Les vis de reglage de melange pour faible et haute vitesses

sont incorrectement ajustees, et le melange est trop riche. Remede: ajuster.

c. Le diffuseur n'est pas completement ouvert. Remede: trouver Ia cause et ajuster.

d. L'avance a l'allumage est incorrectement reglee. Remede : ajuster.

6. La consommation de carburant est trop importante. a. La membrane de Ia pompe est trouee.

Remede : Ia remplacer. b. Les joints du carburateur fuient.

Remede: les remol>!ser. c. Niveau de carburant trop deve.

Remede: ajuster. d. Vis de melange de ralenti et de haute vitesse incorrectement

ajustees, par suite le melange etant trop riche. Remede: ajuster.

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DEPANNAGE

7. Le gaz d'echappement est fumeux, et le moteur tourne rude­ment.

a. Le debit de Ia pompe a huile est trop important.

Remede: ajuster. b. Le carburant est trop vieux.

Remede: remplacer le carburant.