Evinrude & Johnson E-2035Q 1973 Service Manual Download

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Summary of Contents for E-2035Q 1973

Page 1: ...1973 EVI RUDE JOHNSON SNOWMOBILE PART NO 406151...

Page 2: ...SULT IN INJURY TO YOU OR TO OTHERS WARNS YOU AGAINST AN ACTIVITY WHICH IS OR MAY BE ILLEGAL IN YOUR AREA ADVISES YOU OF INFOR MATION OF INSTRUC TIONS VIT AL TO THE OPERATION OR MAINTE NANCE OR YOUR EQ...

Page 3: ...n but will also provide more basic information for the guidance of the less experienced man The Parts Catalogs contain complete listings of the parts required for replacement In addition the exploded...

Page 4: ...ter service to the snowmobile owner and thereby build and maintain a reputation for reliable service This service manual covers all phases of servicing the snowmobile however new service situations so...

Page 5: ...I I j I j I J j...

Page 6: ...61132 261131 261129 317829 317830 604659 DESCRIPTION Flywheel Puller Wrench Primary Drive Truarc Pliers Ring Compressor Spring Winder Heli Coil Installers Inserts Spark Plug Wrench Splined Wrench Flyw...

Page 7: ...Ratings Idle 1000 1200 Transmission belt engaging speed Approx 2500 2800 Maximum RPM at which neutral control will operate Approx 2000 Ignition Breakerless magneto C D Capacitor Discharge ignition Sp...

Page 8: ...w Rear Sprocket 3 8 16 18 20 Nut Rear Suspension to Frame 5 16 24 1 90 100 I 12 15 Nut Runner to Ski 5 16 18 Nut U Bolt to Saddle 10 12 Spark Plug 20 25 Nut Throttle Cable Adjusting Screw 5 16 18 60 8...

Page 9: ...J...

Page 10: ...LE INFORMATION TABLE OF CONTENTS TWO CYCLE ENGINE OPERATION 3 2 COMPRESSION 3 2 CARBURETION 3 3 IGNITION 3 4 LIGHTING SYSTEM 3 4 POWER FLOW 3 5 PRIMARY DRIVE 3 5 NEUTRAL CONTROL 3 6 SECONDARY DRIVE 3...

Page 11: ...hing charge of the fuel air mixture helps to eject scavenge the last of the exhaust gases from the cylinder At this point the mo mentum of the flywheel is required to return the piston to the top of t...

Page 12: ...ts which have become clogged because of excessive deposits of carbon will hinder the efficient transfer of exhaust gases Excessive carbon build up on piston heads or elsewhere in the cylin der walls c...

Page 13: ...engine consists of a set of leaf valves which serve the same purpose as the intake valves on a four cycle engine The leaf valves are thin flexible metal strips mounted between the carburetor intake ma...

Page 14: ...y voltage high enough to fire across the spark plug gaps LIGHTING SYSTEM The alternator coils produce alternating current which changes in frequency and voltage in proportion to the engine speed This...

Page 15: ...end cap outward against the contour of the end cap and axially against the movable sheave half As the sheaves are brought together the transmission belt is forced outward to ride on a larger diameter...

Page 16: ...evice that detects the need for more power for steep inclindes or deep snow The mechanism immediately forces the secondary sheaves closer to gether to raise the transmission ratio and provide a higher...

Page 17: ......

Page 18: ...TING TABLE OF CONTENTS DESCRIPTION 4 2 TROUBLE SHOOTING PROCEDURES 4 3 STARTING 4 3 STARTING MANUAL STARTER 4 4 STARTING ELECTRIC STARTER 4 4 RUNNING LOW SPEED ONLY 4 4 RUNNING HIGH SPEED ONLY 4 4 RUN...

Page 19: ...2 Determining the cause of the problem and 3 Correcting the problem Familiarity with the factors which affect two cycle engine perform ance is important in making a correct service diagnosis Factors...

Page 20: ...ter or dirt in fuel system d Fuel line improperly connected e Fuel line kinked or severely pinched f Engine not primed g Clogged fuel line or fuel filter h Clogged check valve i Carburetor adjustments...

Page 21: ...ing parts d Grease on pawls or spring 3 Clattering manual starter a Friction ring bent or burred b Starter housing bent c Grease on pawls or spring d Dry starter spindle STARTING ELECTRIC STARTER 1 St...

Page 22: ...oken or badly insulated high ten sion leads k Ignition coil weak output 1 Leaf valves not properly seated or broken m Piston rings stuck or piston scored 4 5 n Excessive carbon on pistons and cylinder...

Page 23: ...r passage to carburetor obstructed d Faulty ignition 6 No power under heavy load a Faulty carburetion b Faulty ignition coil s c Ignition timing off d Carbon build up on piston head exhaust ports or e...

Page 24: ...YSTEM 5 2 IGNITION SYSTEM 5 2 COMPRESSION 5 2 NEW VEHICLE DELIVERY 5 3 TUNE UP PROCEDURES 5 3 COMPRESSION CHECK 5 5 IGNITION TIMING CHECK 5 5 COMPRESSION RELEASE VALVE ADJUSTMENT 5 5 CARBURETOR ADJUST...

Page 25: ...engine performance The tank should be removed emptied of old fuel rinsed out installed and refilled with a fresh supply at the beginning of the season and at every tune up A stale fuel mix ture may ca...

Page 26: ...al e Be sure that the customer understands how to operate the engine correctly especially such things as the neutral control compres sion release choke electric starting and reverse shift lever TUNE U...

Page 27: ...condition checks are not satisfac tory engine overhaul is required see Section 9 e Test ignition system using spark checker and neon C D Tester Inspect high tension leads See Section 7 f Check spark p...

Page 28: ...T IN SERIOUS DAMAGE TO THE ENGINE For average use the engine will operate satisfactorily with the car buretor adjusted as it left the factory If it becomes necessary to read just due to altitude or cl...

Page 29: ...ance Use follOwing pro cedure for changing idle speed 1 Disconnect the idle switch connector which can be reached thru the instrument panel door 2 Turning the idle switch clockwise increases idle spee...

Page 30: ...TS DESCRIPTION 6 2 FUEL FLOW 6 2 CARBURETOR DISASSEMBLY CLEANING RE PAIR AND REASSEMBLY BENDIX FLOAT TYPE 6 2 FUEL PUMP 6 6 REMOVAL 6 6 CLEANING INSPECTION AND REPAIR A 6 6 REASSEMBLY 6 6 FUEL PRIMER...

Page 31: ...before starting see Figure 6 1 PRIMER VALVE IN LINE PRIMER TEE W INTEGRAL CHECK VALVE Figure 6 1 CARBURETOR FUEL TANK FILLER CAP AND GAUGE ___ _ __VENT LINE i FUEL TANK 37315 The carburetor used on th...

Page 32: ...ect on the syn thetic rubber parts used in carburetors It is best to use a petroleum product for cleaning Do not use alcohol lacquer acetone thinner benzol or any solvent with a blend of these in gred...

Page 33: ...Valves a Inspect the tapered end of the needle valves for grooves nicks or scratches replace if necessary See Figure 6 8 Blow through lower end of high speed needle valve to make sure it is open to or...

Page 34: ...hand Clean inspect and immediately reassemble the leaf valve assem bly rather than leave it apart for reassembly later e The leaves are designed to maintain contact with the leaf valve body and to sp...

Page 35: ...uble in gaSOline or cleaning solvent therefore the filter should be re placed at the start of each season NOTE Since the purpose of the filter is not only to trap dirt but also to prevent moisture fro...

Page 36: ...n reassembly that the adapter seat be tight against the end of the threaded boss on the fuel tank Apply G E 102 Silastic Adhesive Sealant on adapter threads and immediately install to fuel tank e Inst...

Page 37: ...1 J D...

Page 38: ...12 DISASSEMBLY 7 12 REASSEMBLY 7 13 IGNITION TIMING 7 14 SPARK PLUGS 7 14 BATTERY 7 16 DESCRIPTION 7 16 SPECIFICATIONS 7 16 REMOVAL AND INSTALLATION 7 16 BATTERY SERVICING 7 17 BATTERY CARE 7 17 BATTE...

Page 39: ...lternating cur rent output is rectified changed to direct current by a full wave diode bridge rectifier and used to charge the battery Direct current is then used to power the headlamp and taillamp an...

Page 40: ...st equipment will not solve a problem 5 Do use proper tools when working on system components Wrong tools could damage components A SAFETY WARNINGS 6 AND 7 6 Do return key switch to OFF position after...

Page 41: ...ystem will result When removing Power Pack IS cover plate make sure you place it alongside Power Pack in same direction it was removed This will assure correct terminal identification Also replace bla...

Page 42: ...ing ignition switch not shorted and lead not grounded C If less than 500k ohm reading remove terminal connectors from ignition switch see Figure 7 11 and remove ignition switch from dash panel Turn ig...

Page 43: ...o position 2 Depress load button B D Crank engine with electric starter or manual starter with ignition switch in RUN position and observe neon tester light See Figure 7 14 1 If light is bright and st...

Page 44: ...igure 7 15 D Crank engine with electric starter or manual starter with ignition switch in RUN position and at same time rapidly tap neon tester load button B See Figure 7 15 1 If there is spark across...

Page 45: ...blue lead to engine ground See Figures 7 18 and 7 16 C Depress load button A and crank engine with electric starter or manual starter with ignition switch in RUN position and observe light See Figure...

Page 46: ...th ignition switch in RUN position See Figure 7 17 D If weak erratic or no spark disconnect ignition switch lead on Power Pack terminal 4 Repeat test cranking engine with manual starter E If spark is...

Page 47: ...rom terminal 1 the black white stripe lead from terminal 2 and the white green stripe lead from terminal 3 Check for 27 to 29 ohms resistance between leads 3 and 2 If retard coil reSistance does not c...

Page 48: ...R Connect meter leads to adapter adapter red lead to coil ground lead adapter black lead to coil primary See Figure 7 19 Connect coil high tension lead to meter output lead Turn meter selector to Coil...

Page 49: ...f air duct d Remove air silencer e Remove 3 screws manual starter f Remove manual starter g Remove 3 screws air duct to carburetor h Remove fuel pump hoses i Remove ratchet j Remove grommet and positi...

Page 50: ...emoved for replacement if necessary r Remove two screws and sensor plate assembly can be removed See Figure 7 28 REASSEMBLY a Assemble in reverse order of disassembly b Install rotor and wave washer I...

Page 51: ...er the sensor lead wiring to the Power Pack I is Switched or the sensor hub key is sheared or missing SPARK PLUGS The condition and appearance of spark plugs taken from an engine may be a guide to the...

Page 52: ...that have eroded electrodes must always be re placed Plugs that are slightly contaminated with deposits or which have wider than recommended gap settings can be cleaned and regapped for further use P...

Page 53: ...r battery selection is very important The battery recommended for best performance is a 12 volt 32 ampere hour battery or better with a minimum of 2 2 minutes cold starting capacity at 150 amperes dis...

Page 54: ...rfilled electrolyte BATTERY CARE Check the following at regular intervals 1 Clean battery top and terminals by washing with a solution of am monia or baking soda Keep caps tight so that solution does...

Page 55: ...a battery being charged or jumped are highly explosive Keep battery in a ventilated area and away from cig arettes and open flames when charging or jumping Turn off battery charger before removing ca...

Page 56: ...r sheave is disengaged when at rest and when engine is running The rotation of the starter motor drives the pin on the mo tor shaft against the cam on the movable half of the sheave forcing it to move...

Page 57: ...speed with a volt age reading between 9 5 volts minimum and 10 5 volts maximum starter motor is satisfactory If available voltage reading at the starter motor is low review the following chart for pro...

Page 58: ...e test c Check each armature coil for open circuits by rotating torque wrench handle through a 180 degree arc after initial torque reading has been noted This must be done quickly Torque should be uni...

Page 59: ...es replace if worn to one third their original 3 8 length or if damaged or cracked Replace brush springs if weak b Inspect brush springs Springs should have a pressure of 35 to 90 ounces when compress...

Page 60: ...cessary to de termine which component of the charging system is the cause of trouble ALTERNATOR COILS The alternator coils are replaceable along with the charge coils as an assembly See Figure 7 49 Th...

Page 61: ...and wiring diagram at end of manual ALTERNATOR AND CHARGE COIL REPLACEMENT SEE ALTERNA TOR AND IGNITION SYSTEM REPAIR SAFETY STOP SWITCH TEST Pull connector apart and connect continuity meter across t...

Page 62: ...s indicating continuity switch closed Pressing the throttle lever should cause the meter to read infinity switch opened Releasing the throttle lever should cause the meter to again read 0 ohms HEADLAM...

Page 63: ......

Page 64: ...8 1 SECTION a MANUAL STARTER TABLE OF CONTENTS DESCRIPTION 8 2 REMOVAL AND DISASSEMBLY 8 2 CLEANING INSPECTION AND REPAffi 8 3 REASSEMBLY 8 3...

Page 65: ...ull starter rope out and tie knot at starter housing Handle as sembly can now be removed b Pull rope thru hole in air duct c Untie knot and ease rope back into starter until starter spring is fully un...

Page 66: ...ve the hand crank and bushing Lift pulley off base plate holding spring in pulley e Place pulley and spring into starter housing making certain that spring loop is lined up exactly with pin in starter...

Page 67: ...pe to make certain that pawls work properly When starter rope is pulled pawls should pivot to engage flywheel ratchet On releasing rope pawls should retract to starting posi tions k Attach manual star...

Page 68: ...REPAIR 9 5 CYLINDERS 9 5 GASKETS AND GASKET SURFACES 9 6 PISTONS 9 6 BEARINGS 9 7 ASSEMBLY OF ENGINE 9 8 PISTONS WRIST PINS AND CONNECTING RODS 9 8 PISTON RINGS 9 8 CRANKSHAFT 9 9 CYLINDERS 9 10 INST...

Page 69: ...and belt See Section 10 b Disconnect brakelamp switch c Remove right tie rod and ball joint assembly d Remove nuts and 2 bolts securing steering column bracket to engine e Disconnect primer line from...

Page 70: ...emove spark plugs d Remove power frame e Remove exhaust manifolds f Remove cylinder and crankcase group from engine frame assembly g Remove compression relief valve h Remove the cylinder stud nuts and...

Page 71: ...DE REAR CYLINDER SEAL 0 PISTON RING SET PI N FRONT CYLINDER COMPRESSION HOLE PLUG aL REAR EXHAUST MANIFOLD CONNECTING ROD r SCREW CRANKSHAFT ____ CONNECTING V ROD CAP c CRANKCASE HALF BEARING FLYWHEEL...

Page 72: ...nd of wrist pin retainer must face the top of piston m If necessary to remove connecting rods from pistons remove wrist pin retaining rings using screwdriver in slot in position Press out wrist pin to...

Page 73: ...rve results If surface is actually warped or sprung high spots marking contact with lap ping surface will take on a dull polish while low areas will retain their original state To insure flatness over...

Page 74: ...ngs Agitate bearings frequently until all oil grease and sludge have been loosened and can be flushed out Bearings with especially heavy carbon deposits or hardened grease should be soaked in a separa...

Page 75: ...before assembly PISTONS WRIST PINS AND CONNECTING RODS DNOTE Pistons are not interchangeable with one another The wrist pin hole is offset in different directions Piston identification Pis ton Stamped...

Page 76: ...o crankshaft with piston ring dowel pins faCing top of engine Attach caps to connecting rods d Draw sharp pencil down four machined corners of connecting rod and cap assembly to ensure proper alignmen...

Page 77: ...anifold gaskets d Attach cylinder and crankcase group to engine frame Use Loctite Grade D on engine frame mounting screws e Install compression relief valve using high temperature thread compound appl...

Page 78: ...edometer and tachometer if used m Install right hand tie rod n Reconnect compression relief cable to compression relief valve See Section 5 for adjustment procedures o Reinstall brake caliper to secon...

Page 79: ...front cover IMPORTANT Adjust drive chain tension after the first 10 hours of operation Refer to Section 10 for drive chain adjustment instructions Adjust track tension after the first 10 hours of oper...

Page 80: ...6 ADJUSTMENT PROCEDURES 10 6 BRAKE 10 6 DESCRIPTION 10 6 ADJUSTMENT 10 6 REMOVAL 10 6 REPAIR 10 7 BRAKE CABLE AND CAM ASSEMBLY 10 7 SECONDARY DRIVE 10 7 DISASSEMBLY 10 7 CLEANING AND INSPECTION 10 9...

Page 81: ...THOUT BELT REMOVAL IJA SAFETY WARNING Keep fingers from between halves of secondary sheaves when removing belt a Remove two hair pins anchoring belt guard See Figure 10 1 b Rotate secondary drive to o...

Page 82: ...end cap assembly see Figure 10 9 d With flat open end wrench Service Tool No 404032 on inside and 1 1 8 deep socket wrench on outside loosen end cap bolt See Figure 10 10 SAFETY WARNING Primary sheav...

Page 83: ...spring cup toward bearing See Figures 10 12 and 10 13 3 Place sliding sheave assembly on shaft compress spring and lock in place with strap Service Tool No 261906 4 Assemble activating spring and end...

Page 84: ...chain adjustment Remove rubber plug and check position of chain relative to forward edge of hole See Figure 10 15 Outer edge of chain should line up with edge of hole when chain is properly adjusted I...

Page 85: ...4 Adjust position of chain case and secondary sheave so that it is aligned with primary sheave 5 Tighten two screws 4 through bottom of chassis into chain case 6 Tighten two screws through chain case...

Page 86: ...that there is only 1 32 protruding from the carrier it should be replaced Use a contact cement to secure new puck to carrier o NOTE Keep all oil and grease from puck surfaces BRAKE CABLE AND CAM ASSE...

Page 87: ..._ WASHER JLO OUTER BEARING _ NEEDLE riA I I I CRADLE VENT __ BEARING J Ii 7 r _I THRUST rD lD J UPPORT WASHERS _______ ROD O G i SEAL o PINION THRUST m GEAR BEARING TRANSMISSION SHAFT HOUSING 1IIiIID...

Page 88: ...nt see Page 10 6 REVERSING TRANSMISSION DESCRIPTION In forward operation the power flow from the secondary sheave is transmitted to the input shaft and gear directly to the clutch dog which engages th...

Page 89: ...a Clean all parts with a cleaning solvent such as Trichloroethylene and blow dry with compressed air See SAFETY WARNING on page 9 5 b Inspect shafts and output shaft splines for wear c Turn bearings...

Page 90: ...These ccnterlines must cross as shown in Figure 10 28 SHIFT CONTROL ROD ADJUSTMENT a Assemble control rod thru dash panel b Place transmission in forward operating position c Attach end of control ro...

Page 91: ...D J...

Page 92: ...BLY 11 3 SKI ALIGNMENT 11 3 TRACK AND SUSPENSION 11 3 TRACK TENSION ADJUSTMENT _ 11 3 TRACK ALIGNMENT ADJUSTMENT 11 3 REMOVAL OF TRUCKS AND TRACK 11 4 FRONT AXLE DISASSEMBLY 11 4 REAR AXLE DISASSEMBLY...

Page 93: ...r correct reassembly Re move steering arm from ski column See Figure 11 2 d Remove ski columns CLEANING INSPECTION AND REPAIR a Remove all dirt and old grease from ski columns and from inside ski colu...

Page 94: ...ed after the first ten hours of operation and then every 25 hours or as required to maintain efficient economical operation Improper adjustment will result in undue wear to the track and drive compone...

Page 95: ...axle See Section 10 h Loosen set screws from bearing locking collars and rotate collars counterclockwise to free axle from bearings i Disconnect speedometer j Remove three screws flangette to chain ca...

Page 96: ...XLE CROSS SHAFT FRONT AXLE ASSEMBLY CENTER SPACER FRONT TRUCK IDLER WHEEL BEARING FRONT AXLE OUTER BUSHING TRUCK 1 T v I 0 REAR AXLE I a REAR AXLE SPACER 6P PIVOT CENTER PIVOT AXLE AXLE REAR AXLE SPAC...

Page 97: ...SEMBLY See Figure 11 7 Refer to Figure 11 7 for assembly of sprocket wheels to front axle Driving lugs on sprockets must be in line with each other a Assemble bearings flangette gasket and 0 ring to c...

Page 98: ...LY a For sequence of assembly of sprockets bearings pivot arms and brackets refer to Figures 11 5 and 11 7 b Lubricate the outside of the pivot bushing with OMC Grease 114154 c Lubricate outside face...

Page 99: ...D...

Page 100: ...E OF CONTENTS ENGINE LUBRICATION 12 2 OMC 2 4 FUEL CONDITIONER 12 2 FUEL BLENDING 12 3 LUBRICATION RECOMMENDATIONS 12 4 PREVENTIVE MAINTENANCE 12 5 FUEL PUMP FILTER SCREEN 12 5 STORAGE 12 6 PREPARATIO...

Page 101: ...o an excess of lubricant in the fuel mixture Instructions for the mixing of fuel during break in and normal operation as given here and in the Owner s Manual should be followed exactly The use of addi...

Page 102: ...ed lubricant Thoroughly agitate this partial mixture Next add the balance of gaSOline necessary to bring the mixture to the required ratio of 50 1 Again thoroughly agitate the mixture A clean funnel e...

Page 103: ...10 oil CD Drive Chain oil bath See page 10 5 Dexron ATF After 10 hrs then every 25 hrs of operation CD Reversing transmission See page 10 10 Dexron ATF Once a season CD Primary Drive disassembly requ...

Page 104: ...e fuel filter is located under the air silencer Lift the hood and remove five wing nuts securing air silencer to air duct Remove air silencer The fuel filter is attached to the fuel pump See Figure 12...

Page 105: ...t off track h Drain and clean fuel tank see Section 6 i Provide for proper battery maintenance as described in Section 7 j Remove transmission belt See Section 10 k Rub bottom of skis and other unprot...

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