Page 1: ...8J SACHS c I f r Repair Instructions No 4054 8 E 4 SACHS Snowmobile Engine TypeSA280A 280 290 340 C competition F I C HTEL SACHS G 8 7 20 S C H WE I N F U R T...
Page 2: ...Q I 0 t r...
Page 3: ...e DD Engine with BOSCH inertia pinion type starter Type DG Operation maintenance and lubrication of electric starters Starter faults Instructions and wiring d iagram for dynamo magneto 6 V 36 W Page 2...
Page 4: ...eir construction will also be found helpful when used in conjunction with this booklet Of course good maintenance and repair work and efficient service to customers call for good equipment a well fitt...
Page 5: ...7 mm before TDC 0 1614 0 1850 in 4 1 4 7 mm b TDC 0 1614 0 1850 in I 0 4 0 05 mm 0 01 6 0 002 in Co ntact breaker gop Pole shoe ga p 6 V 36 W equipment 16 19 mm 0 62992 0 74B03 in 12 V 40 W equipment...
Page 6: ...REPAIR TOOLS AND ASSEMBLY JIG 8 4 C 17 8 4 5 6 I 10 12 e r l m t ru 13 9 17 15 16 18 5119 CJi20 CJi 21 22 23...
Page 7: ...o 4 21 7 mm dia bore Adjustable reamer 17 5 19 5 mm 0 689 0 768 in Torque key Revolution counter Extractor for oil seals Extractor hook 3 mm 1 piece spare part for 0276161 101 Extractor hook 2 mm Thru...
Page 8: ...agon head bolts M 10 x 40 as shown in the adjoining illustration Remove intake silencer 1 Unscrew adapter flange and take off cover plate 2 or un screw intake silencer Fig 302 p 53 with cover plate Pu...
Page 9: ...e and fan housing Fig 3 Unscrew fixing clip 3 for igni tio n lead not in the case of 75 W equipment and cover l Detach leads at terminals l 2 and 3 of the terminal box 5 and remove fan housing 4 Note...
Page 10: ...CHS SA 280 A and SA 280 cylinders can be rebored three times and those of the SA 290 and SA 340 C twice Use appro priate piston see Spare Parts List When fitti ng new or replacement cylinders and pist...
Page 11: ...off side slightly with a rubber ham mer Remove crankcase half power takeoff side and gasket Take care of dowel tubes Unscrew screwed nipple 1 and oil drain cock 2 Unscrew crankcase half magneto side f...
Page 12: ...IN p t o side cylindrica l rol ler bearing X cylindrical roller bearing X mag neto side cylindrical roller bearing X grooved ball bearing X SA 290 18 resp 20 HP DIN p t o side cylind rica l roller bea...
Page 13: ...e When replacing oil sea ls the following points should be borne in mind Extracting oil seals Fig 8 Before extracting oil seal be sure to establish insta llation dimen sion x o or y in order that the...
Page 14: ...in inclined position Remount leg and extract oil seal a described under Fig l 0 Note f the oil seal has got stuck oxi dation the sheet steel rim may brea k Therefore it is advisable lo knock the oil s...
Page 15: ...ankcase half on the magneto side until it strikes a stop Press in crankshaft oil seal until flush only after the crank case halves have been screwed together Have a look at the table of crankshaft bea...
Page 16: ...shims 2 Fig 13 between the spacer 3 Fig 13 and the inne r race of the cylindrica l roller bearing 1 Fig 13 on the crankpin power takeoff side Fitting the inner race of the cylindrical roller bearing...
Page 17: ...e crank pin 2 washer 2 mm thick 3 spacer 5 mm thick bevel pointing towa rds crankshaft web 4 washer 1 5 mm th ick bevel pointing towards crankshaft web 5 power ta keoff side crank pin Fig 17 3 piece c...
Page 18: ...to the connecting rod and lightly se cure it by means of two washers 2 and two nuts 3 Press guide rail uniformly against the two studs and tighten nuts 3 Clamp the connecting rod by means of eccentric...
Page 19: ...Insert reamer and with the aid of adjusting nuts q and p ad just it to the diameter of the bore of the sma ll end bushing Fig 20 F S 05 17 Fig 21 Remove reamer from the bushing slacken lock nut p alte...
Page 20: ...arter for engine running in clockwise direction Recoil starter for eng ine running in a nti clockwise direction as seen on the power toke off side of the crankshaft F S S 40 54 l B Fig 23 18 Dismantli...
Page 21: ...n in il lustration For anti clockwise starting direction insert coil spring the other way round Check if coil spring lies flat and even Bend the e nd of the spring up wards a little Fig 26 Fit the cor...
Page 22: ...urns so that the starter grip is pul led back until it encounters the stop Let cord run back Fit the housing in position and screw tight The recoil starter is available for clockwise or anti clockwise...
Page 23: ...ll out cord approx 50 em 19 7 in and hold the pulley with a home made retaining clip see adjoining illustration Fig 31 Remove retaining bolt from star ter handle a nd ope n clamping sleeve m by tappin...
Page 24: ...open side downwards on the work bench Brake the ejecting coil spri ng with the starter housing Note If the starting disc must be re placed or inserted for the other starting directio n heat the bush...
Page 25: ...exit until stop is encountered Release coil spring 1 2 turns until the recess for the soldering nipple in the pulley rests near the cord duct of the housing Lubricate the cord lightly with Molycote b...
Page 26: ...low shows the two starting directions Fig 37 Recoil starter for engine running in clockwise direction Recoil starter for engine running in anti clockwise direction as seen on the power toke off side o...
Page 27: ...spring Hold coil spring firmly with both thumbs see illustration and by raising each thumb let out spring on alternate sides Note Replace bush 2 Fig 42 only if necessary using the extractor shells rep...
Page 28: ...44 Fig 43 Nate When converting starting direc tion reposition cord guide 2 also Fit starter handle with stop and clamping ring on to cord Lay starter cord around clamp ing taper and pull it into clamp...
Page 29: ...n the contacts the slider or the pivot pin are badly worn also when the bearing bush is worn or if the contact arm or the spring is damaged l Unscrew cutout lead and if fitted noting correct sequence...
Page 30: ...ing below off bearing pin Grease bearing pin and bearing surface for flyweight in flywheel with heat resisting grease Fit thrust washer 0 3 mm thick on bearing pin hang spring 6 into place in flyweigh...
Page 31: ...titudes above 1000 metres 3280 ft adjustments of the carburettor setting will be required As the air density is reduced at high altitudes the supply of gasoline to the carburettor should be restricted...
Page 32: ...e 10 B By pass passage 11 Butterfly valve 12 Main jet orifice 13 Carburellor housing 14 Throat of carburettor venturi 15 Main fuel outlet 16 Choke 17 Fuel passage from pump to control chamber 18 Inlet...
Page 33: ...orking order Checking and cleaning the fuel filter in good time helps to achieve satisfactory func tioning of the carburettor and longer engine service life Special maintenance instructions 1 If pump...
Page 34: ...er to red heat by means of a welding torch or in a forge f ire I No modif ications should be made to the exhaust muffler as any such alterations will be detrimental to performance fuel consumptio n an...
Page 35: ...o crankcase half heat up inner ring on engines equipped with grooved ball bearing and screw the two hal ves together by means of 4 hexa gon socket head screws M 8 x 35 and 2 hexagon socket head screws...
Page 36: ...x 60 Tig hten bolts diagona lly with a torque of 4 6 4 8 kpm 33 3 34 7 ft lb for M 10 x 55 and with a torque of 2 2 2 6 kpm 15 9 18 8 ft lb forM 8 x 60 Armature base plate and labyrinth ring Insert W...
Page 37: ...ockwise rotating magneto flywheel and the mark R on clockwise rotating magneto fly wheel is lined up with the hole marked RL in the magneto housing Fig 54 Take care when fitting magneto flywheel on to...
Page 38: ...17 in Running engine 7 11 mm 0 2756 0 4331 in Gauge Ignition timing gauge or depth gauge 0 4 mm 0 016 in feeler gauge The magneto flywheel is provided with two punched marks 0 is in line with the mark...
Page 39: ...carried out the pole shoe gop a Fig 56 should measure between 32 36 mm 1 2598 1 4173 in and the pole shoe gop a Fig 57 between 25 29 mm 0 9843 1 141 7 in Magneto flywheel with screwed on contact brea...
Page 40: ...nuts M 6 a nd spring washers Note Fit also cover flanges for electric starter connection if provided Connect leads to screw terminal 5 as follows Connect lighting lead ye llow to te rminal1 and 2 Conn...
Page 41: ...r cap in po sition Fig 59 Fig 60 Secure cover 1 Fig 59 ignition lead with rubber sleeve 1 Fig 5 and fixing clip 3 Fig 59 and earth lead brown in case of right hand carburettor with 3 fillister head sc...
Page 42: ...th two hexagon head screws M 8 x 20 and washers Connect impulse pipe 4 Fig 1 to connection on crankcase Place on both insulating bushes insulating flange carburettor fit impulse pipe to connection on...
Page 43: ...until smoking stops and engine runs satisfactorily If the idling speed fluctuates too much or is too high turn the idling jet adjusting screw anti clockwise to open the jet until the engine runs smoo...
Page 44: ...fully engaged Even if looth on tooth engagement occurs the switch will close a s the spring is spring connected to the g uide ring and the lever is therefore not hindered in its movement when startin...
Page 45: ...inertia of the pinion result in a force which causes the pinion to run along the shaft and engage with the gear rim When the pinion has reached the stop on the armature shaft the drive becomes positiv...
Page 46: ...ts are dirty or jam they should be cleaned w ith a clean gasoline damped rag not with waste w ool as this easily sheds fibres and well dried Do not sandpaper fi le or use knives on the bright ground s...
Page 47: ...damaged parts loose so that switch is not on burnt out 7 Magnetic switch of starter damaged only with solenoid controlled starter 8 Loss of current in leads too great leads damaged lead connections lo...
Page 48: ...d of the dynamo magneto is 36 Watt as otherwise the bulbs may fuse Care should be taken to ensure a good earth connection from the engine via the chassis to the lamps Fi 63 Aa Load 6 V 36 W Bs Short c...
Page 49: ...connecting up a rectifier to charge a battery The bulbs should be so selected that the total load of the dynamo magneto is 40 Watt as otherwise the bulbs may fuse Care should be taken to ensure a goo...
Page 50: ...gneto is 50 Watt For reaching the 75 Watt o resistance of 25 Watt must be added Core should be token to ensure o good earth connection from the engine via the chassis to the lamps r 1 C1a Ag 1 I I I I...
Page 51: ...lbs should be so selected that they give a total load of 40 Watt Care should be taken to ensure proper wire cross sections for starter operation and a good earth connection beiween battery chassis and...
Page 52: ...nected up The bulbs should be so selected that they give a total load of 50 Watt Care should be taken to ensure proper wire cross sections for starter operation and a good earth connection between bat...
Page 53: ...connected up The bulbs should be so selected that they give a total load of 50 Watt Care should be taken to ensure proper wire cross sections for starter operation and a good ea rth connection between...
Page 54: ...crankshaft connecting rod and main bear ings against corrosion 2 To protect the cylinder a nd the piston place the piston at top dead center unscrew the sparking plug and pour 3 5 cc 0 106 0 1 76 fl o...
Page 55: ...on system Engine and exhaust muffler Recoil starter Pinion on sliding pinion starte r pinion on iner tia pinion type starter and toothed rim on magneto flywheel Cylinder connecting rod bearings cranks...
Page 56: ...Cylinder head 2 2 2 6 kpm only SA 340 C M 8 X 60 15 9 18 8 ft lb 0240 056 001 3 Armature base plate M 5 X 12 0 4 0 5 kpm 2 9 3 6 ft lb Nuts F S No I Qty l Used an I Dimensi l ightening torque 1942 00...
Page 57: ...78 72 0 033 0 020 2 834 0 00129 0 00078 72 5 0 033 2 853 0 00129 0 020 0 00078 Piston assy No 1486 029 015 1486 029 016 1486 029 017 1486 029 01 8 I Punched l d ia white in measure dio red 71 71 5 72...
Page 58: ...86 030 005 1486 030 006 standard l si rebore 2nd rebore sta ndard lsi rebore 73 73 5 74 1415002 105 1415 002 100 1415 002 101 standard l si re bore 2nd rebore sta ndard l si rebore 1416 001 000 1487 0...
Page 59: ...020 mm 3 091 0 00129 0 00078 InS Piston ossy no 1486 037 005 1486 037 006 1486 037 007 Punched l dio white 1n measure dia red 78 78 25 78 5 Piston ring no 1415 008 000 1415 008 001 1415008 002 Piston...
Page 60: ...r 1 Engine not getting adequate fuel d Lack of compression because 2 Spark plug glows due to incorrect 1 Piston rings broken heat value 3 Spark plug shorted dirty or 2 Piston and cylinder worn vitrifi...
Page 61: ...I l ft lbs 3000 4000 000 6000 7000 U min RPM r 18 17 16 15 14 13 12 11 g PS h t lbs HPh sao 1 1 1 0 400 0 9 0 8 0 7 300 3000 4000 5000 6000 7000 U min RPM In the interest of technical progress we rese...
Page 62: ...0 6000 7000 g PSh 600 500 1 00 300 3000 1 000 5000 u lmin rpml l HPh tl t3 t 2 t1 tO M U8 6000 7000 Uimin rpml In the interest of technical progress we reserve the right to introduce modifications wit...
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