Johnson SKEE-HORSE 25-201R Service Manual Download

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Summary of Contents for SKEE-HORSE 25-201R

Page 1: ..._ __ _ _ _ ____ _ _ _ o _ 0 ___ O l o DhnsDn SKEE HORSE SERVICE MANUAL o 30 HORSEPOWER MODELS 25 201R 25 201RA 25 201RSA 11 70 PART NO 261894 LITHO U S A OUTBOARD MARINE CORPORATION 1970 ALL RIGHTS RESERVED ...

Page 2: ... USE AN APPROPRIATE CONTAINER FOR MIXING AND STORING THE FUEL To prepare the snowmobile fuel properly pour into a SEPARATE clean container half the amount of gasoline required and add all the required lubricant Thoroughly shake this partial mixture Next add the balance of gaso line necessary to bring the mixture to the required ratio of 24 l Again thoroughly agitate the mixture A clean funnel equi...

Page 3: ...RODUCTION SPECI FI CATID NS GENERAL SNOWMOBI LE IN FO RMATION TROUBLE SHOOTING TUNE UP PROCEDURES FUEL SYSTEM IGNITION AND ELECTRICAL SYSTEM MANUAL STARTER ENGINE DRIVE TRAIN STEERING TRACK AND SUSPENSION LUBRICATION AND STORAGE ...

Page 4: ...an but will also provide more basic informa tion for the guidance of the less experienced man The Parts Catalogs contain complete listings of the parts required for replacement In addition the exploded views illustrate the correct sequence of all parts This catalog can be of considerable help as a reference during disassembly and reassembly The Section Index on page 1 1 enables the reader to locat...

Page 5: ...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 sometimes arise If a service question does not appear to be answered in this manual you are invited to write to the Service Department for additional help Always be sure to give complete information including model number...

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Page 7: ...c TABLE OF CONTENTS 2 1 SECTION 2 SPECIFICATIONS SPECIFICATIONS 2 2 TORQUE SPECIFICATIONS 2 3 I I I ...

Page 8: ... Skee Horse Lubricant Carburetor Needle Adjustment High speed Low speed RPM Ratings or SAE 30 SB or SD oil One turn off seat minimum 1 to 1 1 4 turn off seat Idle 1300 1600 Approx 2700 Transmission belt engaging speed Maximum RPM at which neutral lockout will operate Approx 2000 Ignition Breaker point gap 020 to 022 Spark plug Champion J7J or equivalent Spark plug gap 028 033 inch Condenser capaci...

Page 9: ...6 24 12 15 Setscrew Rear Sprocket 3 8 16 18 20 Nut Rear Suspension to Frame 5 16 24 12 15 Nut Runner to Ski 5 16 18 90 100 Nut U Bolt to Saddle 10 12 Spark Plug 20 20 1 2 Nut Throttle Cable Adjusting Screw 5 16 18 60 80 Nut Tie Rod 3 8 24 18 20 Screw Truck to Frame 3 8 16 25 30 Screw Truck to Frame 7 1 6 14 25 30 Screw Secondary End Cap to Shaft 3 8 16 22 25 Screw Drive Sprocket 1 4 20 15 17 Screw...

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Page 11: ... 3 GENERAL SNOWMOBILE INFORMATION TABLE OF CONTENTS TWO CYCLE ENGINE OPERATION 3 2 CARBURETION 3 3 IGNITION 3 3 POWER FLOW 3 4 PRIMARY DRIVE 3 4 NEUTRAL LOCKOUT 3 5 SECONDARY DRIVE 3 5 REVERSE TRANSMISSION 3 5 I I I ...

Page 12: ...uretion The downward motion of the piston compresses this mixture and forces it through the intake ports into the cylinder See Figure 3 2 The inrushing 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 the cylinder As the piston begins its up stroke it clo...

Page 13: ...forward of the jets to restrict the flow of air When the choke shutter is closed more gas oline and less air is allowed into the air stream resulting in a richer fuel air mixture When normal operating temperature is reached the choke is opened and the standard ratio of gasoline and air allowed to flow from the carburetor IGNITION The ignition system provides a high voltage electric current which c...

Page 14: ...ee Figure 3 7 The primary sheave assembly halves are separated by a compression spring in the hub of the movable sheave half As the engine speed increases centrifugal effect forces a garter spring in the 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 diame...

Page 15: ...ve Spring R will then push the plunger inward The neutral lockout balls will then move outward through the splined shaft The movable sheave will now be locked out in the neutral position See Figure 3 7 SECONDARY DRIVE The secondary drive mechanism incorporates a torque sensing device that detects the need for more power for steep inclines or deep snow The mechanism immediately forces the secondary...

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Page 17: ... 4 1 SECTION 4 TROUBLE SHOOTING TABLE OF CONTENTS DESCRIPTION 4 2 COMPRESSION 4 2 SPARK PLUGS 4 3 TROUBLE SHOOTING PROCEDURES 4 4 TROUBLE SHOOTING GUIDE 4 7 ...

Page 18: ...unctions They compress the mixture of fuel and air in the cylinders before ignition and receive the force of the power after ignition For maximum compression the cylinder must be round and the piston and piston rings correctly fitted to it The rings must be properly seated in the ring grooves and free to expand against the walls of the cylinder The rings will not retain the force of combustion if ...

Page 19: ... spark ignites the compressed mixture of fuel vapor and air in the cylinder See Figure 4 1 Spark plugs are made in a number of heat ranges to satisfy a variety of operating conditions The heat range of a spark plug refers to its ability to dissipate heat from its firing end to the cylinder head The heat range established for any spark plug is determi ned in design by the length of the path which t...

Page 20: ...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 too lean j High speed needle bent or bowed k Engine flooded 1 Leaf valves not functioning properly m Faulty gaskets n Spark plugs fouled improperly gapped dirty or broken o Loose or broken wire or frayed insulation in electrical...

Page 21: ...il or condenser 4 5 h Breaker points burned dirty or improperly gapped i Cylinder gasket or leaf plate gasket blown j Leaking crankcase seals k Coil lead grounded on chassis RUNNING HIGH SPEED ONLY 1 High speed miss a Water in fuel b Spark plug heat range incorrect c Spark plugs improperly gapped or dirty cracked insulator d Ignition wires loose or broken or faulty insulation e Coil or condenser w...

Page 22: ...ezes up a No lubricant in gas or no fuel b Fuel connector faulty c Cylinder or crankshaft scored d Bent or broken rod crankshaft or stuck piston e Ignition failure f Frozen bearing 3 Engine knocks excessively a Incorrect gas lubricant ratio b Spark plug wrong heat range c Flywheel loose d Crankshaft end play excessive e Carbon in combustion chambers and exhaust ports or on pistons f Worn or loose ...

Page 23: ...tor by jumping across large terminals of starter solenoid Eliminate possibility of poor ground by running cable direct from nega tive battery lug to starter motor body Check for weak battery If engine turns over this I would indicate defective solenoid starter switch or broken lead If engine turns over this would indicate poor ground r recheck terminals and cables I a o c m m en z o Z g g C D m ...

Page 24: ...utput characteristic voltage to spark plug Recommended use of Neon light spark plug tester Ii SAFETY PRECAUT ION Do not allow open spark in engine compartment area where fuel is present be cause of potential fire hazard Check timing Check key in flywheel It might have been lost or sheared off allowing flywheel to rotate on crank shaft causing engine to be out of time Primer might have air t leak o...

Page 25: ...uel Check ignition primary Check spark plugs Check coil and condenser these sometimes break down when they become warm Check points and timing Run engine with air intake housing off If carburetor blows excessive fuel back out venturi pull leaf valve assembly and check for cracked broken or badly seated leaves Clogged vents in fuel tank cap will cause a vacuum in fuel system resulting in vaporizing...

Page 26: ... might have pulled loose from wire Coil high tension lead and terminal Check back into Engine Runs Rough Most ignition failures are due to malfunctions found in primary system See Section 7 f See Section 7 NOTE When checking coil be sure to use probe around coil tower area 1Coil See Section 7 Check flywheel magnet polarity and strength during ignition system examination I N ...

Page 27: ...5 2 FUEL SYSTEM 5 2 IGNITION SYSTEM 5 2 COMPRESSION 5 2 NEW VElllCLE DELIVERY 5 3 TUNE UP PROCEDURES 5 3 IGNITION TIMING ADJUSTMENT 5 5 COMPRESSION RELEASE VALVE ADJUSTMENT 5 5 CARBURETOR ADJUSTMENTS 5 5 lllGH SPEED NEEDLE VALVE 5 5 LOW SPEED NEEDLE VALVE 5 6 IDLE ADJUSTMENT SCREW 5 6 SPARK PLUGS 5 6 ...

Page 28: ...e season and at every tune up A stale fuel mix ture may cause hard starting stalling and faulty operation An alter native to the removal of fuel at the end of the season is the use of OMC 2 4 FUEL CONDITIONER This additive stabilizes the fuel and prevents gumming and varnishing Inadequate fuel delivery as the result of a faulty fuel pump or clogged filter will affect high speed performance Incorre...

Page 29: ...ustomer understands how to operate the engine correctly especially such things as the neutral lockout com pression release choke electric starting and reverse shift lever TUNE UP PROCEDURES Components which affect engine power and performance can be divided into three groups namely 1 items affecting compression 2 items affecting ignition 3 items affecting carburetion Any tune up procedure should c...

Page 30: ...d play tolerance is 011 to 026 d If compression and bearing condition checks are not satisfactory engine overhaul is required see Section 9 e Test for adequate spark at each cylinder using a spark checker Inspect and test points condenser magneto COils ignition coils timing and spark plug high tension leads see Section 7 f Check spark plugs to be sure they are the correct type Clean spark plugs an...

Page 31: ...oints in good condition or 022 for a new point set COMPRESSION RELEASE VALVE ADJUSTMENT Check for 1 32 to 1 16 clearance when compression release knob is pushed in See Figure 5 2 Turn out on jam nut and correct clearance with adjustment screw shown in Figure 5 3 Operate compression release knob to check for binding in cable Lubricate the compression r elease actuator with Rykon EP 2 grease CARBURE...

Page 32: ...l ad justment should be made to engine as necessary See Figure 5 5 IDLE ADJUSTMENT SCREW The Idle Adjustment Screw Figure 5 5 when turned to the right or clockwise will increase the engine idle speed Recommended idle speed is 1300 to 1600 rpm NOTE This adjustment must be made with the neutral lockout knob out or in the neutral position and engine warm t r h o ii SAFETY PRECAUTION r f k _M HL Opera...

Page 33: ...TS DESCRIPTION 6 2 FUEL FLOW 6 2 CARBURETOR DISASSEMBLY CLEANING RE PAm AND REASSEMBLY HD SERIES 6 2 FUEL PUMP 6 6 REMOVAL 6 6 CLEANING INSPECTION AND REPAm 6 6 REASSEMBLY 6 6 FUEL PRIMER 6 7 Am FILTER 6 7 FUEL TANK 6 7 FUEL LINE TIE STRAPS 6 7 ...

Page 34: ...ned and inspected at regular intervals depending on service conditions Clean the entire carburetor by flushing with fuel and blow dry with compressed air before disassembly The carburetor should be inspected for cracks in the casting bent or broken shaft loose levers or swivels and stripped threads REMOVAL a Select a clean work area Dirt and carelessness are the cause of most carburetor trouble b ...

Page 35: ...from the inlet needle point Some HD carburetors are equipped with a rubber tipped needle a brass inlet seat and a copper gasket The installation instructions below apply to both types of inlet seats The inlet needles and seats are matched and tested for leaks at the factory and the parts must be kept in matched sets When installing the insert cage into the carburetor body use a new gasket Do not f...

Page 36: ...e inlet seat to 40 50 inch pounds of torque 2 Adjust the inlet control lever so that the center of the lever that contacts the metering diaphragm is flush to the metering cham ber wall see Figure 6 6 3 Install new welch plugs at the nozzle well and by pass chamber if needed Place the new welch plug into the casting counter bore convex side up and flatten it to a tight fit using a 5 16 inch flat en...

Page 37: ...ing the leaf valve assembly DO NOT damage or interchange the leaves d The leaves must be flat to maintain a seal with the leaf valve body DO NOT under any circumstances bend or flex the leaves by hand 6 5 1 Carburetor Gasket 2 Flange Gasket 3 Throttle Shutter 4 Carburetor Body 5 Throttle Shaft Clip 6 Return Line Elbow 7 Return Line Screen 8 Idle Speed Bracket 9 Bracket Screw 10 Throttle Shaft Retu...

Page 38: ...rews attaching pump and filter assembly to mount ing plate see Figure 6 10 and remove pump and filter assembly NOTE Filter assembly may be removed for cleaning and inspec tion without removing pump assembly by removing filter cap screw see Figure 6 11 SAFETY PRECAUTION Do not allow fuel to drip on hot engine or exhaust manifold because of potential fire hazard CLEANING INSPECTION AND REPAIR a The ...

Page 39: ...e Section 12 b The importance of using a fresh clean fuel mixture cannot be overstressed Gum will form in old fuel which will clog filter screens fuel passages carburetor orifices leaf valves and check valves Remove tank to empty old fuel Reinstall it and begin with a fresh supply every season c To disconnect and remove the tank for cleaning remove nuts and bolts from hold down straps snap fuel ga...

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Page 41: ...SCRIPTION 7 9 SPECIFICATIONS 7 10 INSTALLATION 7 10 BATTERY SERVICING 7 10 BATTERY CARE 7 11 BATTERY TESTING 7 11 BATTERY CHARGING 7 12 SLOW CHARGING 7 12 WARRANTY 7 12 STARTER SYSTEM 7 12 DESCRIPTION 7 12 MAINTENANCE 7 13 STARTER SYSTEM TP 3TING 7 13 STARTER CIRCUIT TESTING 7 13 STARTER MOTOR TESTING 7 14 INSPECTION OF STARTER MOTOR 7 15 BELT TENSION 7 16 ALTERNATOR 7 16 TROUBLE SHOOTING 7 16 CHE...

Page 42: ...arge the bat tery Direct current is then used to power the head and taillight and the electric starter motor See wiring diagrams at end of manual This section gives complete service procedures on all components of the ignition and electrical systems breaker point adjustment and starter motor belt adjustment Principles of magneto operation are dis cussed in Section 3 TEST EQUIPMENT The test procedu...

Page 43: ... 000 Maximum Primary 4 0 Coil Index 60 Minimum Coil Test 30 Gap Index 50 Merc O Tronic 0 9 1 3 to 1 7 ohms Operating Amperage Primary Resistance Secondary Resistance 60 to 70 index number Stevens Tester Switch B Index Reading 0 8 to 1 0 Stevens Tester Model MA75 Switch B Index Reading 22 using MA 12 Adapter MAGNETO REMOVAL a Pull starter rope out and tie knot See Figure 7 4 b Remove one screw from...

Page 44: ...let line from fuel pump See Figure 7 10 m Remove three bolts securing manual starter assembly See Fig ure 7 10 n Remove three screws holding air filter See Figure 7 10 o Air duct can now be removed p Remove eight screws and separate outer fan hOUSing from inner fan housing See Figure 7 11 q Remove three bolts securing ratchet mount assembly to flywheel See Figure 7 11 r Hold flywheel with bar from...

Page 45: ...post clean before installing new breaker pOints to ensure a clean surface for the breaker point bushing to pivot on see Figure 7 16 Turn the eccentric adjusting screw into the plate until it bottoms so that there is adequate screw engagement to hold breaker point gap of 020 for used points in good condition or 022 for new points Set pOints on highest point of cam lobe Breaker point spring tension ...

Page 46: ...e bosses on the magneto plate the gap between the flywheel magnet and coil heels may be too great Connections that are not clean and tight will cause high resistance which will limit current flow Visually inspect the coil mounting and connections before condemning a coil Test the coil for correct reSistance using the ignition analyzer NOTE Magneto drive coils can be tested for correct resistance w...

Page 47: ...elco U 1901 1948792 distributor lubricant to oiler wick and to point cam follower on side toward cam rota tion e Install cam on crankshaft over Woodruff key and rotate to position shown in Figure 7 21 f Adjust breaker points using a feeler gage and with the breaker cam and key installed on the crankshaft see Figure 7 21 Point gap should be set to 020 022 inch with the breaker arm on the high lobe ...

Page 48: ...ode wear see Figure 7 25 Highly leaded fuels may produce white to yellowish powdery deposits on the firing end of the spark plug These deposits will not interfere with normal spark plug performance if plugs are cleaned at regular service intervals See page 4 3 for a discussion on spark plug heat range a If the insulator tip is an exceptionally light tan or whitish color or the center electrode bur...

Page 49: ...inch by bending the side electrode Adjust only the side electrode as attempting to bend the center electrode will crack the insulator Use a round wire feeler gage to measure gap adjustment see Figure 7 29 Poor engine performance and premature spark plug failure may re sult from improper spark plug installation Before installing the plug be sure the plug seat in the cylinder head is cleaned and fre...

Page 50: ...lded cover and anchored plates to reduce possibility of vibration damage Battery is shipped dry and activated with an electrolyte INSTALLATION To provide maximum protection from battery acid damage in the event of accidental upset special spill proof battery caps see Figure 7 31 are supplied with the vehicle Make certain the original caps are removed and these special caps are installed The hold d...

Page 51: ...ent intervals by making specific gravity readings with a battery hydrometer see Figure 7 33 Note that a hydrometer reading is not accurate if water has been added re cently due to the fact that the water may not be mixed with the electrolyte Self discharge will cause storage batteries to become discharged and sulphated if they are not properly maintained in storage To minimize self discharge store...

Page 52: ...e is delivered to the original owner Should a battery fail due to inherent defects during the first three 3 months of service it will be replaced on a nO Charge basis Bat teries that fail during the balance of the warranty period 15 months will be replaced on a prorata basis STARTER SYSTEM DESCRIPTION The electric starter system consists of the starter motor starter solenoid and the necessary cabl...

Page 53: ...perage Draw Test a Ground spark plug high tension leads so that engine can be cranked without firing Place clamp on DC ammeter capable of reading at least 200 amperes around starter motor lead see Figure 7 36 b Turn ignition switch to START and observe amperage reading with engine cranking Current should be between 75 amperes mini mum and 140 amperes maximum after initial surge I DO NOT operate st...

Page 54: ... the general mechanical and electrical condition of the starter motor The stalled torque test is used to determine whether or not the starter motor has sufficient torque to crank the engine for fast starting N0 Load Test a Connect starter with an ammeter in series to a 6 volt source see Figure 7 39 Use a tachometer or rpm indicator to indicate armature speed b Ammeter should indicate 60 amperes ma...

Page 55: ... commutator segments to a depth of approximately 1 32 inch The undercut must be flat at the bottom triangular groove cuts are unsatisfac tory and should extend beyond the brush contact area for the full length of each insulated groove see Figure 7 43 f After commutator has been undercut sand lightly with No 00 sand paper to remove burrs left during the undercutting process After sanding clean comm...

Page 56: ...der Battery Testing Battery Inspection and Battery Care b Wiring The importance of connections which are good electrically and mechanically throughout the circuit cannot be overemphasized The largest percentage of electrical system failures are caused by one or more loose or dirty connections Check for corroded or loose connections and for worn or frayed insulation Check the battery cables for pos...

Page 57: ...ne low reading and one high reading Repeat the test procedure for the other diodes by connecting the test leads between adjacent terminals If a test light is used light should show with connections in one direc tion only If lamp lights or fails to light in both directions the diode is defective Connect leads to correct terminals See Figure 7 45 and wiring diagram at end of manual ALTERNATOR COIL R...

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Page 59: ...c 8 1 SECTION a MANUAL STARTER TABLE OF CONTENTS DESCRIPTION 8 2 REMOVAL AND DISASSEMBLY 8 2 CLEANING INSPECTION AND REPAIR 8 3 REASSEMBLY 8 3 STARTER ROPE REPLACEMENT 8 4 ...

Page 60: ... will result REMOVAL AND DISASSEMBLY a Raise hood b Pull starter rope out and untie knot in handle while holding rope c Ease rope back into starter until starter spring is fully unwound d Remove three screws securing starter assembly to outer fan hous ing Because of the rewind spring it is good practice to wear safety glasses when disassembling and reassembling the manual starter e Remove screw pu...

Page 61: ... pulley and spring loop d Carefully remove 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 housing Press pulley into starter housing forcing out pin which held spring f Apply standard Oil Rykon EP 2 to spindle and spindle bushing Many lubricants incl...

Page 62: ...e until rope is fully unwound Lock starter pulley in position by aligning holes in housing and pulley and inserting a nail or pin through them c Untie knot and remove rope from rope handle Remove rope from starter assembly d Cut new starter rope to length of 73 3 4 inches Fuse ends of rope over open flame for about one half inch Rope end must be stiff to hold in pulley Tie knot in end of rope and ...

Page 63: ... 9 3 CLEANING INSPECTION AND REPAIR 9 6 CYLINDERS 9 6 GASKETS AND GASKET SURFACES 9 6 PISTONS 9 7 BEARINGS 9 7 ASSEMBLY OF ENGINE 9 8 PISTONS WRIST PINS AND CONNECTING RODS 9 8 PISTON RINGS 9 9 CRANKSHAFT 9 9 INSTALLATION 9 10 BREAK IN 9 12 9 1 SECTIONS ENGINE ...

Page 64: ... movable half of sheave as shown in Figure 9 1 c Work belt between primary and secondary sheave See Figure 9 2 d Disconnect neutral lockout cable from actuator arm and move belt between actuator arm and primary sheave See Figure 9 3 e Disconnect throttle cable at carburetor Loosen jam nut and turn out on throttle cable fitting Pull cable through intake manifold See Figure 9 4 f Disconnect choke ca...

Page 65: ...ket on each side of snowmobile Remove three screws from rear of instrument panel Lift off instrument panel assembly r Remove fuel lines from fuel pump s Disconnect spark plug leads See Figure 9 8 Disconnect red lead from electric starter motor t Loosen two muffler clamps See Figure 9 27 Loosen screws retaining muffler to chassis u Remove four engine mounting bolts Engine and electric starter assem...

Page 66: ...tons can be serviced with only the cylinder barrels removed j Remove screws from crankcase halves and drive out two alignment roll pins from flywheel side Heat up crankcase halves in bearing area to approximately 450 F Tap crankcase with rawhide mallet to break seal and separate crankcase halves Pistons connecting rods and caps are matched parts Because of this it is essential to maintain their or...

Page 67: ...NG SET PIN 9 5 CYLINDER AND STUD ASSEMBLY COMPRESSION HOLE PLUG GASKETS EXHAUST MANIFOLD l EXHAUST MANIFOLD CONNECTING ROD r SCREW CRANKSHAFT CONNECTING V ROD CAP BEARING d _ RETAINER GASKETS O j BEARING SEAL r ROLL PIN Figure 9 10 BOTTOM GASKET CRANKCASE ASSEMBLY ...

Page 68: ... on motor performance Carefully scrape carbon from cylinder heads and exhaust ports with scraper or other suitable tool Exhaust ports and all exhaust passages must be free from carbon depOSits to insure maximum performance Clean compression relief valve and check for free action b Check cylinder walls for excessive wear Measure cylinder bore for size and straightness by using an inside micrometer ...

Page 69: ...ge 2 2 c Before installing new piston rings check gap between ends of ring by placing ring in its respective cylinder bore see Figure 9 18 Press ring down in bore slightly with bottom of piston to square it up Discard and replace with new ring if gap is excessive see Section 11 Specifications d Check each ring in its respective ring groove for tightness or bind ing by rolling the ring around the p...

Page 70: ...kshaft throw ASSEMBLY OF ENGINE Refer to exploded views for correct sequence of assembly Make no forced assemblies unless press fits are called for Make no dry assemblies Lubricate all moving parts with a light film of oil Be sure all parts are clean and free from dirt and grit Perfectly good cylinder walls pistons and rings can be ruined in a few minutes of operation if grit remains after assembl...

Page 71: ...s are matched DO NOT interchange retainer halves or turn them end for end c Attach connecting rod to caps Connecting rod caps are not inter changeable neither may the caps of the same rod be turned end for end Match marks are provided to assure correct assembly Draw a pencil over edge surface on both sides of rod to make cer tain that cap and rod are correctly aligned see Figure 9 24 If misaligned...

Page 72: ...rburetor and air cleaner For detailed instructions see Section 6 d Attach cylinder and crankcase group to engine frame e Install compression relief valve using Dupage High Temperature Thread Compound applied to the threads INSTALLATION a Install engine and frame to chaSSis Work exhaust manifolds into exhaust pipe Tighten clamps Tighten screws retaining muffler to chassis b Iristall primary sheave ...

Page 73: ...tall steering column First replace three bolts in lower flange Torque to specifications Install rubber bushing and yoke See Figure 9 7 o Reconnect speedometer and tachometer cables engine ignition light switch and cigarette lighter connectors p Reconnect compression relief cable to compression relief valve See page 5 5 for adjustment procedure q Screw shift handle back onto reverse operating rod r...

Page 74: ...e lugs on track 3 Observe fuel mixing precautions as described in inside front cover IMPORTANT Adjust drive chain tension after the first 3 hours of operation Refer to Section 10 for drive chain adjustment instructions Adjust track tension after the first 10 hours of operation Refer to Section 11 for track tension and track alignment adjustment instructions MUFFLER REMOVAL 1 Remove four muffler mo...

Page 75: ...DJUSTMENT 10 5 REMOVAL 10 5 REPAIR 10 5 BRAKE CABLE AND CAM ASSEMBLY 10 5 SECONDARY DRIVE 10 6 DISASSEMBLY 10 6 CLEANING AND INSPECTION 10 7 REASSEMBLY 10 8 REVERSING TRANSMISSION 10 8 DESCRIPTION 10 8 LUBRICATION 10 9 REMOVAL AND DISASSEMBLY 10 9 CLEANING INSPECTION AND REPAIR 10 9 ASSEMBLY AND ADJUSTMENT 10 10 REVERSING TRANSMISSION LINKAGE ADJUSTMENT 10 10 DESCRIPTION 10 10 ADJUSTMENT 10 10 SHI...

Page 76: ...he crankshaft DISASSEMBLY OF SHEAVE WHILE ON ENGINE a Remove one screw loosen other screw attaching neutral lockout bracket to chain case Move bracket downward b Remove belt see Section 9 c Remove two screws securing lock plate to end cap assembly see Figure 10 2 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 3...

Page 77: ...ft making sure end cap splines engage shaft splines 5 Before placing end cap bolt in shaft check to see that neutral lockout balls have not fallen from their holes in main shaft 6 Tighten end cap bolt to 90 100 ft lbs See Figure 10 7 7 If serrations do not allow alignment of holes in lockplate and end cap turn lockplate over and rotate until aligned position is obtained Torque lockplate screws to ...

Page 78: ... clockwise 3 To loosen chain turn adjusting screw counterclockwise 4 Retighten jam nut to 10 12 ft lbs 5 Apply EC1022 adhesive in groove of chain case prior to assembling seal Insert seal into groove with joint in line with top right cover mounting screw hole Replace chain case cover Torque the 6 screws 60 S0 inch lbs 6 Replace oil in chain case See Drive Chain Lubrication above REMOVAL AND INSTAL...

Page 79: ...from brake control pivot pin Com press brake return spring and remove pivot pin from control cable c Remove brake bracket to transmission screws REPAIR a Disassemble brake assembly as required noting relative positions of components to assure correct reassembly see Figure 10 12 b Inspect brake pucks If the free floating puck is one half of its original 1 2 thickness it should be replaced When the ...

Page 80: ...econdary washer spring cap spring and sleeve See Figure 10 13 d Slide movable sheave fixed sheave and brake disc assembly from transmission input shaft DO NOT strike sheaves with hammer Cast aluminum sheaves will bend CLEANING AND INSPE CTiON 1 Clean all parts except movable sheave bushing in trichlorethylene 13 shin 1 Is oilImpregnated DO NOT clean with solvent See SAFEtrv PRECAUTION on part 9 6 ...

Page 81: ... I I 1 SHAFT ____ ____ OU TPUT SHIFTER I DOG s PRING SH ERIN i AND SHAFT OUTER BEARING I J Oc II VE 7 r UPPORT WASHER I I ROD CRA DLE tJflit BEARING THRUST SEAL f jj 0 t J WASHERS l SHIM j RANSMISSION I 1 I ____ ____ I I THRUST BEARING CAP I BEARING CLEVIS I a I REVERSE 1 PINION I ER 1 I BRAKE DISC MOVABLE SHEAVE REVERSE IDL BEARING I SECONDARY S SECONDARY SPRING 10 13 Figure I I I I I DRIVE RAMP ...

Page 82: ...ts rotate in the same direction See Figure 10 14 At this time the pinion gear shaft and pinion gear are retracted from the thru shaft gears In reverse operation the power flow from the secondary sheave to the input shaft and gear is because of the release of the dog clutch and the engagement of the pinion gear see Figure 10 15 transferred to the output gear and shaft in reverse rotation Linkage ad...

Page 83: ...play d Inspect clevis clutch dog and cradle liner for wear or damage e Inspect 0 ring on pinion gear shaft Replace if required ASSEMBLY AND ADJUSTMENT a Install input shaft and gear Use Loctite bearing mount on the O D and I D of the sealed bearings see Figure 10 13 b Insert pinion shaft and assemble shim thrust washer thrust bear ing thrust washer pinion gear and bearing assembly and shifter dog ...

Page 84: ...k reverse locking by visually check ing center lines of reverse lock cleviS and lock plates These centerlines must cross as shown in Figure 10 19 SHIFT CONTROL ROD ADJUSTMENT a Assemble control rod thru dash panel b Place transmission in forward operating position c Attach end of control rod to linkage See Figure 10 18 Attach assist spring d Adjust shift control rod at connector and handle so that...

Page 85: ...CTION AND REPAIR 11 2 REASSEMBLY 11 2 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 11 4 TRUCK DISASSEMBLY 11 4 CLEANING INSPECTION AND REPAIR 11 5 TRUCKS AND AXLES 11 5 REASSEMBLY 11 6 II ...

Page 86: ...mbly b Remove ski and leaf spring assembly Disassemble leaf spring if required for servicing c Remove 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 column brackets b Inspect steering column bushing and replace if worn See Figure 11 2 c Inspect ski column upper and lower rubber m...

Page 87: ...urs 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 components Track tension is checked when the track is not supporting the weight of the snowmobile and the pivot arms are pulled down Track tension is correct if the distance from the bottom of the pivot arm bearing bore to the botto...

Page 88: ...om locking collars and rotate collars to free axle from bearings h Remove three screws flangette to chain case on left side of vehicle and three screws flangette to chassis on right side of vehicle i Remove front axle from chassis j Remove idler assembly Remove screw and washer from each end of axle FRONT AXLE DISASSEMBLY a Remove bearings and flangettes from axle b Drive out roll pins from track ...

Page 89: ...SEMBL W WHEEL l _ FRONT TRUCK AXLE REAR AXLE WHEEL SPACER I B ARINGh FRONT AXLE CENTER SPACER FRONT AXLE s SHORT UCK OUTER BUSHING BUSHING REAR AXLE A T_ _ v 0 SPACER d I q PIVOT j PIVOT AXLE REAR AXLE G AXLE OUTER _ _ crJllf j SPRING SPACER TRUCK SPACER PIVOT AXLE SPACER SHORT PIVOT BLJSHINr BEA ING ARM l __ I SCR C 0 W X I B E A R I N G __ PIVOT ARM BRACKET I _____ I aV 0 _____ I J REAR TRACK 1 ...

Page 90: ...to front axle b Assemble bearings flangettes gasket and O ring to front axle as sembly See Figure 11 6 Lubricate O D of left front bearing with OMC Type A to help seat O ring Assemble front axle as sembly to chassis c Fasten flangettes to chain case and chassis Torque six screws flangettes to chain case and flangettes to chassis 20 25 ft lbs Axle must be free to slide through the bearings d Assemb...

Page 91: ...DLER ASSEMBLY a Assemble idler wheels to shaft with retaining rings to inside to chassis b Place idler wheels on top of track Torque idler axle screws to chassis 20 25 ft lbs TRUCK REASSEMBLY 1 Assemble wheels and spacers to their original positions on the front and rear truck axles Application of a light oil on the axles will assist in this procedure Apply Standard Oil Rykon EP 2 grease under nyl...

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Page 93: ... 2 FUELS AND LUBRICANTS 12 2 OMC 2 4 FUEL CONDITIONER 12 2 FUEL BLENDING 12 3 LUBRICATION RECOMMENDATIONS 12 3 PREVENTIVE MAINTENANCE 12 4 AIR FILTER 12 4 FUEL FILTER FUEL PUMP 12 4 FUEL FILTER SCREEN CARBURETOR 12 4 STORAGE 12 4 PREPARATION FOR STORAGE 12 4 REMOVAL FROM STORAGE 12 5 ...

Page 94: ...gs such as SA SB or CA indicate oils for other applications and should be avoided Avoid the use of low priced light duty oil container marked only with SA deSignation or multiple viscosity oils such as SAE 10W30 EVEN THOUGH OMC BRAND OUTBOARD LUBRICANT IS ADVERTIZED AS A 50 1 RATIO LUBRICANT IT IS IMPERATIVE FOR SNOWMOBILE USE THAT IT BE MIXED AT 24 1 GAS LUBRICANT RATIO The use of higher priced p...

Page 95: ... the fuel mixture into the vehicle tank DO NOT POUR GASOLINE OR LUBRICANT DIRECTLY INTO VEHICLE FUEL TANK USE AN APPROPRIATE CONTAINER FOR MIXING AND STORING THE FUEL Whenever it is necessary to mix fuel and lubricant at temperature below 32 F O C the lubricant should be prediluted with gasOline to improve its mixability The lubricant should be prediluted with ap prOximately one part gasOline to o...

Page 96: ...is attached to the fuel pump See Figure 12 5 To inspect for sediment or water accumulation back off the mounting screw approximately three turns counterclockwise and remove the cover together with the screen gasket and mounting screw Remove and wash filter screen with clean gasoline and brush Assemble filter as shown in Figure 12 6 being careful to assemble gasket and filter screen on fuel filter ...

Page 97: ...transmission belt m Rub bottom of skis and other unprotected surfaces of vehicle with cloth saturated in OMC Rust Preventative n Store in dry well ventilated area r o Clean carburetor fuel filter screen See Page 12 4 REMOVAL FROM STORAGE a Fill tank with fresh fuel mixture Install battery b Tune up engine see Section 5 c Lubricate all pOints as described under Lubrication d Adjust track for proper...

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Page 99: ...NOTES ...

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Page 102: ... OHN SON MOTORS WAUKEG N ILLINOIS U S A ...

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Johnson SKEE-HORSE 25-201R, Service Manual

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