SCORPION 1975 LIL' WHIP Service Manual Download | Manualshive

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Summary of Contents for 1975 LIL' WHIP

Page 1: ... 1975 Scorpion Lil Whip Service Manual Engine Section 1 l ...

Page 2: ...e Rockwell 2 cycle Twin Cylinder engine is of the loop scavenged third port type the most widely used design today It uses a mixture of gasoline oil and air for combustion lubrication and cooling It fires on every stroke of each piston There ore two power strokes for every revolution of the crankshaft As the piston moves upward in the cylinder it draws the fuel air mixture into the crankcase throu...

Page 3: ...ixture scavenges the combustion area giving it a fresh charge and the cycle is then repeated See Fig 1 1 D Because lubrication is dependent on the m1xmg of oil and fuel it is extremely important that good quality oil and gasoline are properly mixed The proper ratio of oil to gasoline wi ll prevent possible engine overheating piston or cylinder scoring or eventual engine seizure Too much oil and no...

Page 4: ...severe engine damage For these reasons intermediate lengths of pipe betweeen the cylinder and the muffler are particularly critical TUNED MUFFLERS Tuned mufflers allow the engine to exhaust its spent charge into an adequate volume and properly matched muffling system More im portant the mufflers that are tuned incorporate designs that suck the exhaust gas from the cylin der allowing fuel and air t...

Page 5: ...ging and return fuel air mixture to the cylinder It gives a supercharging effect even though it operates from the exhaust rather than the intake side Over scavenging is also retarded by moderate muffler back pressure Silencing is accomplished after power is maximized by acoustical packing in the resonator outlet tube plus chambering and baffling which gives an effective 2 pass muffler design SERVI...

Page 6: ...ING BEFORE TDC CENTRIFUGAL 0 18 to 020 WEIGHT RETARDED BREAKER POINT GAP 014 to Ol6 SPARK PLUG THREAD 14mm x 1 25 3 4 reach SPARK PLUG GAP 020 0 5mm SPARK PLUG BOSCH ORIGINAL W260T2 EQUIPMENT TYPE OF ENGINE COOLING Axial Flow Fan ROTATION OF CRANKSHAFT Counterclockwise PTO side CARBURETOR Walbro FUEL OIL RATIO As Specified on Scorpion Oil Container GASOLINE 95 octane minimum lead free not acceptab...

Page 7: ...IFOLD NUTS FAN HOUSING SCREWS FAN WHEEL NUT PTO SIDE TABLE OF SPECIFICATIONS 2F 295 2 28 32 Ft Lb 16 18Ft Lbs 56 72Ft Lbs 16 18 Ft Lbs 16 18 Ft Lbs 22 24 Ft Lbs Tightening Sequence for Cylinder Base Nuts All Models Tightening Sequence for Cylinder Head Nuts Fan Housing Intake Manifold and Recoil Starter Clamps 8 0 75 290 1 7 ...

Page 8: ...Remove four 4 screws holding the recoil assembly to the fan housing See Fig 1 4 See pages 1 28 A B C for recoil starter disassembly B Lower Fan Pulley and Carrier Assembly 1 8 Remove the three 3 hex head bolts on the carrier Remove carrier lower pulley assembly and V belt See Figs 1 5 1 6 J FIG 1 4 FIG 1 5 FIG 1 6 ...

Page 9: ...6 drill or a suitable punch through the indexing hole into the im peller body With a 17 mm socket wrench remove the fan nut lock washer pulley halves and spacers See Figs 1 7 1 8 1 9 FIG 1 8 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 1 7 FIG 1 9 1 9 ...

Page 10: ...w the three bolts through the puller into the flange and tighten evenly With a socket wrench tighten the puller bolt until the flywheel loosens on the crankshaft See Figs 1 10 1 11 1 12 1 13 NOTE It is important that care is taken to remove the positioning key in crank shaft before attempting to remove the flywheel assembly Failure to do this could result in damage to advance mechanism l 1 0 FIG 1...

Page 11: ... _ l_ E Intake Manifold Assembly Remove the four 4 intake manifold nuts and washers Remove manifold assembly and insulators See Fig 1 14 SERVICE MANUAL 1975 SCORPION LIL WHIP Hfk oo 00 FIG 1 14 1 11 ...

Page 12: ...ng With a socket type 5 mm Allen wrench and impact driver remove the four 4 mounting bolts holding fan housing to crankcase See Fig 1 15 Remove fan housing from crankcase See Fig 1 16 Unplug connector housing coil wires Note color coding of wires Remove armature plate assembly and wires as a unit from fan housing 1 12 FIG 1 15 l FIG 1 16 ...

Page 13: ...ing the end of fan shaft with a soft hammer With a flat punch and hammer tap the inner race of the fur thest bearing in the housing See Figs 1 17 1 18 1 19 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 1 17 FIG 1 18 FIG 1 19 1 13 ...

Page 14: ...wrench and remove the eight 8 spring washers The cylinders may be removed See Fig 1 21 NOTE I M P 0 R T A N T If removal of cylinders only is required care must be taken that the crankcase seal is not disturbed The removal of the PTO cylinder will allow the placement of two bolts and nuts with flat washers to apply constant pres sure to crankcase assembly Bolts should be placed in the center two h...

Page 15: ...point where piston may sti ll be held in hand Push the pin out K To separate the crankcase halves hold upper portion of crankcase assembly in one hand lifting slightly and tap the end of the crank case with a soft hammer The crankcase will separate and the crankcase may be removed See Fig 1 22 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 1 22 1 15 ...

Page 16: ...around the outer bearing race and around puller assembly Slide the retaining ring over the half shells Using two 2 27 mm wrenches turn the center bolt clockwise with one wrench and use the second wrench to hold the puller body Before removing the PTO side crankshaft bearing insert a 1 2 20 UNF bolt 1 2 long to protect the internal thread of the crankshaft FIG 1 23 FIG 1 24 FIG 1 25 ...

Page 17: ...essary that al l bearing outer surfaces be wiped clean of foreign material so that proper sealing will occur After installing PTO thrust washer and oi l seal inside groove of oil seal coated with light grease place the crankshaft carefully into the lower crankcase half and properly position all componenets See Figs 1 28 Placement of the upper crankcase half may now be made Be certain that the cent...

Page 18: ... and free from car bon deposits and the piston rings must fit freely in their grooves Rings are marked for proper side up The arrow on the crown of pistons must point toward exhaust side of engine Piston pins needle bearings check plates and circlips may now be installed ac cording to the procedure below Always use new circlips See Figs 1 30 1 31 1 32 1 33 CIRCLIP OPENING HERE r FIG 1 31 1 18 r FI...

Page 19: ...all one circl ip in piston 3 Heat the piston sufficiently to allow pin to push into piston and install pin 4 Install second circlip See Fig 1 3 1 for correct orientation of circlips SERVICE MANUAL 1975 SCORPION LIL WHIP 0 FIG 1 32 FIG 1 33 J 19 ...

Page 20: ...ee Fig 1 37 Cylinder base nuts may now be torqued to sixteen 16 to eighteen 18 foot pounds as outlined on specification page The proper piston height can be measured at the top of the cylinder The edge of the crown of the piston must not protrude above the top of the cylinder with the piston in the top dead center position If the piston does protrude above the cylinder a thicker base gasket must b...

Page 21: ...cylinder heads Install head gaskets with the wide side of inner metal flange of the gaskets up toward the cylinder heads Torque cylinder head nuts to twenty eight 28 to thirty two 32 foot pounds SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 1 37 1 21 ...

Page 22: ... lubricate the inner groove of the oil seal with a light grease See Fig 1 38 Install new o ring and apply sealant material around o ring surface see Fig 1 41 Install the armature plate wires through hole in fan housing and install armature plate with hold down screws washers and lockwashers See Fig 1 39 Place fan housing assembly over crankshaft and position to crankcase assembly Install the four ...

Page 23: ...cers gaskets and intake manifold Fig 1 41 Torque nuts evenly to sixteen 16 to 18 foot pounds G Upper Fan Pulley A ssembly Install the tapered washer Install pulley half shims second pulley half tapered washer lock washer and nut Use 3 16 drill bit or punch to hold fan assembly and tighten nut See Fig 1 42 H Flywheel A ssembly Check advance mechanism for free operation lubricate inside cam surface ...

Page 24: ... Install pulley half belt second pulley half recoil carrier lockwashers and bolts evenly while rotating crankshaft The proper belt deflection should be 1 8 on each side Proper adjustment can be made by adding or removing shims between upper pulley halves See Fig 1 44 J Recoil Starter Install the recoil starter assembly and tighten securely See Fig 1 45 1 24 FIG 1 43 FIG 1 44 FIG 1 45 ...

Page 25: ...h retaining slot Remove friction plate Fig 1 49 1 50 3 Remove the three pawls 3 Fig 1 51 4 Remove return spring 9 spring 6 and cup washer 7 Fig 1 50 Note position of plain end of return spring in the spring retaining hole in reel hub 5 Unwind the rope lift and untie the knotted end from center hub of reel remove reel 2 Fig 1 52 6 Lift long rolled end of main spring 5 from the fixed spring retainin...

Page 26: ...arts except rope using a suitable cleaning solvent If rope requires cleaning wash it in a solution of soap and water Thoroughly dry all parts after cleaning 8 Inspect all parts for obvious damage and wear 1 26 0 Q FIG 1 49 FIG 1 47 FIG 1 48 0 0 FIG 1 50 ...

Page 27: ...SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 1 5 1 FIG 1 52 FIG 1 53 1 27 ...

Page 28: ... reel in an anti clockwise direction until the free end protrudes through the notched section of the reel 5 Apply a light film of Lubriplate or equivalent to center hub of case and install the reel Push down and rotate reel in an anti clockwise direction until the hook en gages with the free end of main spring Ten sion will be felt when reel and spring are pro perly engaged Fig 1 58 1 59 6 Rotate ...

Page 29: ...12 Untie the temporary knot in free end of rope and install the rope handle Tie a permanent knot and fit handle securely 13 Check starter for proper operation When handle is pulled outward pawls should move outward NOTE If main spring is to be installed without the use of a spring winding tool wind main spring into case in an anti clockwise direc tion Clockwise installation on the winding tool is ...

Page 30: ...linder P T O side See Fig 1 61 B Attach negative lead of ohmmeter to engine ground Attach positive lead of ohmmeter to No 1 cylinder terminal in connector housing See Fig 1 62 C Rotate flywheel counterclockwise until points are on the high side of cam on No 1 cylinder Points are at maximum open posi tion observed through opening in flywheel Check gap with wire gauge and adjust to 015 if necessary ...

Page 31: ... R x 1 Ohm meter needle will indicate a closed circuit See Fig 1 64 Move the centrifugal weights in flywheel to the full advanced position See Fig 1 65 Rotate flywheel counterclockwise one com plete revolution to between 102 and 112 See Fig 1 66 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 1 64 FIG 1 65 FIG 1 66 1 31 ...

Page 32: ...ely Re check procedure See Fig 1 67 NOTE In Fig 1 67 flywheel has been removed for clarity of illustration E Remove dial indicator assembly and install in No 2 cylinder fan side See Fig 1 68 1 32 Attach positive lead of ohmmeter to No 2 cylinder terminal in connector housing Rotate flywheel counterclockwise to top dead center Set dial indicator to zero Again move centrifugal weights in flywheel to...

Page 33: ...gapped or dirty 6 Head gasket blown or leaking 7 Empty gas tank or improper fuel mixture 8 Water in fuel system 9 Weak coil or condenser 10 Obstructed fuel system REMEDY 1 Check friction plate return spring Replace as required 2 Check for br oken or bent pawls Replace pawls as re quired 1 Replace spring 2 Replace housing 3 Replace pulley 1 Adjust carburetor Refer to Carburetor Section 2 Refer to C...

Page 34: ...le oil Leaking crankshaft seal 1 Spark plugs improperly gapped or dirty 2 Loose or broken magneto wires 3 Magneto breaker points improperly gapped or dirty 4 Weak coil or condenser 5 Heat range of spark plug incorrect 6 Leaking head gasket 7 Engine improperly timed REMEDY 10 Check crankcase pressure 3 6 PSIG 11 Repair or replace primary wire 12 Re time engine 13 Secure secondary wire or spark plug...

Page 35: ...Idle or high speed carbu retor adjustment too rich 2 Choke not opening properly bent linkage 3 Inlet control lever too high carburetor floods 4 Idle air bleed plugged 5 Welch plug loose 6 Muffler obstructed 7 Engine not secured tightly to engine support 8 Water in gas REMEDY 1 to 5 Adjust carburetor or fuel pump Refer to Carburetor Section 6 Reseal crankcase 7 Refer to Carburetor Section 8 Remove ...

Page 36: ...ing 7 Install new seal Good spark but 1 Leaking cylinder head 1 Check head for warps cracks engine runs on one Install new gasket and cylinder cylinder head 2 Magneto wires broken 2 Repair c r replace wires inside coil ground broken 3 Cracked cylinder wall 3 Replace faulty cylinder 4 Defective spark plug 4 Clean adjust or install new plug 5 Breaker points improperly 5 Re adjust points gapped 6 Cra...

Page 37: ...se spark plug 4 Head bolts not tight l Piston rusted to cylinder wall 2 Crankshaft seized to bearing main or rod 3 Broken connecting rod 4 Flywheel seized to coil plate 5 Engine improperly assembled after repair REMEDY l 2 Adjust carburetor Refer to Carburetor Section 3 Remove line clear obstruc tion replace line 4 Refer to Carburetor Section l Clean adjust or install new points 2 Adjust timing 3 ...

Page 38: ...f ...

Page 39: ...1975 Scorpion Lil Whip Service Manual Carburetor Section 2 1 ...

Page 40: ...ses a reduced pressure at the metering diaphragm which opens the needle valve More fuel enters through the needle valve into the carburetor bore where it is mixed with in coming air The four operational phases of the Walbro Carburetor used on the 1975 Lil Whip are 1 Starting choke operation 2 Idle operation 3 Part throttle operation 4 Full throttle operation Detailed performance of the carburetor ...

Page 41: ...needle valve 28 The metering lever spring 29 tran smits a force through the metering lever 30 and seats the inlet needle valve 28 against pressure The metering diaphragm 1 O is pulled upward by engine suction which is tran smitted through the idle discharge port idle hole 14 secondary idle holes 16 and part throttle feed holes 17 The diaphragm action depresses the metering lever 30 and unseats the...

Page 42: ... mixes with air from the secondary idle holes 16 This rich mixture passes around idle needle 12 through the idle discharge port 14 where it mixes with ad ditional air passing the throttle valve 19 at point 15 2 4 Secondary fuel pump FIG 2 2 IDLE OPERATION 1V por return 1fuel inlet Power needle COLOR CODE Fuel Air Crankcase Impu lse Air Fuel I Vapor L ...

Page 43: ... through the part throttle holes 17 All ports except the main nozzle feed progressively as throttle valve opens for smooth ac celeration Air is intermixed through air bleed nozzle 25 FIG 2 3 PART THROTTLE OPERATION Venturi 23 Choke valve 24 Air bleed nozzle 25 Needle valve 28 Vapor return line f itting to f uel tank 1Vapor return Fuel inlet 22 Throttle valve 19 Main nozzle 21 Throttle bore 20 Part...

Page 44: ...scharge at five discharge ports parallel to power needle 22 This is noted by comparing Fig 1 and Fig 4 At full throttle operation fuel passes around the power needle 22 and is discharged through the main nozzle 21 During full throttle air is mixed with fuel in the main nozzle 21 through the nozzle air bleed 25 Suction or vacuum created by the engine s piston action draws fuel and air as the ports ...

Page 45: ...2 5 1 Cover Assembly 8 Fuel Pump Diaphragm 2 Fuel Inlet Gasket 9 Fuel Pump Gasket 3 Fi Iter Screen 10 Fuel Pump Leaf Gasket 4 Filter Plate 11 Valve Springs 3 5 Check Valve Diaphragm 12 Pressure Spring 6 Fuel Pump Check Valve Gasket 13 Metering Diaphragm Assembly 7 Fuel Pump Plate 14 Metering Diaphragm Chec diaphragms and gaskets thoroughly for cracks or leaks by holding them against light Clean as...

Page 46: ...N CONJUNCTION WITH FINAL CHECK VALVES AND DIAPHRAGMS 1 It is not necessary to remove Inlet Needle Valve assembly but it may be easier to work in this area without them See Procedure Above 2 Remove three circuit plate screws FIG 2 6 3 Remove circuit plate check valve diaphragm and gasket FIG 2 7 4 Inspect check valve diaphragm 5 Remove low and High speed needles if necessary for cleaning grooves ch...

Page 47: ...op timum speed of the machine tends to level off or increase slightly Such increase is insignificant in normal operation and there is an attendant in creased likelihood of burned plugs or pistons Variables which will affect the optimum high speed carburetor setting are a Temperature As temperature drops the air becomes more dense and the pumping diaphragm less flexible Both conditions require a ri...

Page 48: ... seats lightly 5 Back off one complete turn 6 Close choke priming if necessary to start engine 7 After engine starts open choke and let engine warm up 8 Turn idle mixture screw in to reach maximum R P M on tachometer Con tinue until R P M drop is indicated 9 Turn idle mixture screw out to reach maximum R P M Continue out until R P M drop is indicated 10 Set idle mixture screw half way between drop...

Page 49: ...the fuel in let connector on the carburetor 2 Connect the leak detector Scorpion P N 907000 pressure line to the carburetor fuel inlet connector 3 Remove the carburetor vapor return line and hold your finger over the carburetor fitting 4 Pressurize the carburetor with the leak detector plunger pump Do not exceed 12 PSI The needle valve properly seated should hold a constant 8 psi FIG 2 11 2 11 ...

Page 50: ...SERVICE MANUAL 1975 SCORPION LIL WHIP 2 12 ...

Page 51: ... CAUSE 1 Foreign obstacle under inlet needle 2 Diaphragm lever adjust ment OFF 3 Metering lever spring not seated in dimple on metering lever 4 leaking fuel pump diaphragr 1 5 Foreign matter under umbre lla check valve 6 Wrong angle or abused metering portion of high speed needle 7 leaking check valve in primer 8 Choke cable is not activating choke FIG 2 12 2 13 ...

Page 52: ...REMEDY 1 Disassemble wash and blow clean 2 See FIG 2 13 Should be 020 above surface of valve body as shown 3 Replace diaphragm 4 Replace diaphragm 5 Replace as necessary 6 Replace as necessary 7 Replace as necessary 8 Replace diaphragm check valve assembly See pro cedure P 2 8 9 Replace fuel pump diaphragm 10 Remove bottom plate and clean screen 11 Check complete system from fuel pick up in tank t...

Page 53: ...1975 Scorpion Lil Whip Service Manual Electrical Section 3 1 ...

Page 54: ...ation is generated by rotating a per manently magnetized flywheel around two sta tionary coi Is 1 120 watt and 1 23 watt The no load voltage increases with engine RPM and could reach 32 volts RMS To maintain the voltage at the required system level 13 14 volts an external voltage regulator is utilized See VOLTAGE REGULATION MAIN ELEMENTS 1 Magnetic Flywheel 2 120 watt coil mounted on stator plate ...

Page 55: ...s and generates a very high voltage in the second coil This voltage in the region of several thousand volts will jump the spark plug gap causing ignition to begin The collapsing lines of force cut through the primary windings raising the voltage in that circuit also As this occurs the condenser absorbs the gene rated current to reduce the tendency to overload the points As soon as the voltage leve...

Page 56: ...L 1975 SCORPION LIL WHIP SEE ENGINE DISASSEMBLY SECTION l FOR FLYWHEEL AND STATOR REMOVAL t CONDENSER Hlo STATOR FIG 3 6 SPARKPLUG EXTERNAL IGNITION COILS T SPARK PLUG FIG 3 7 IGNITION SCHEMATIC ENGINE CONNECTOR 3 4 ...

Page 57: ...I J l SERVICE MANUAL 1975 SCORPION LIL WHIP STATOR IGNITION COIL TO EXTERNAL COIL CONNECTORS FIG 3 8 EXTERNAL COIL COIL TO SPARK PLUG LEAD FIG 3 9 EXTERNAL COIL GROUND 3 5 ...

Page 58: ...he regula tor drqps out of the system providing maximum avail able voltage to t e load at decreased speeds In the first half of the operating cycle when line 1 is positive with respect to line 2 C1 will charge through CR1 C1 R2 and CR2 until the voltage drop across C1 reaches the level necessary to cause Z 1 to conduct At this point Q1 will draw base current and then pass current through CR 1 the ...

Page 59: ...SERVICE MANUAL 1975 SCORPION LIL WHIP ell LINEl__J Cl LINE2 I Z7 I L I 7Z 7 Z III REGULATOR CONNECTOR FIG 3 12 MAGNETO VOLTAGE REGULATOR SOLID STATE P N 043299 SCR I 3 7 ...

Page 60: ...lished at three locations 1 To the chassis at the rear end 2 To the chassis from wire harness at eng connector 3 To the stator plate on the engine MAIN ELEMENTS 1 Main Wiring Harness HI LO SWITCH HEADLIGHT HARNESS CONNECTOR IGNITION SWITCH CONN VOLTAGE REGULATOR CONNECTOR 2 Seat Wiring Harness 3 Taillight Wiring CONNECTOR Harness 4 Safety Stop Switch 5 Break Light Switch 6 Hi Lo Switch 7 Ignition ...

Page 61: ...GULATOR I 1 I D I SAFETY STOP I SWITCH 1 IGNITION _SWITCH FIG 3 15 HI LO TAILLIGHTS SWITCH BRAKE LIGHT I WIRING SCHEMATIC COLOR CODED ELECTRICAL DISTRIBUTION CONTROL 1975 LIL WHIP z m c a t f m a s n m 3 z c r 0 en n 0 a 0 z r r J ...

Page 62: ...lator Connector Connector Instrument Connector Ground Instrument Connector Headlight Connector Ground Taillight Chassis Tunnel Green Hot Ignition Switch Connector Electric Start Regulator Connector Orange Hot Engine Connector Instrument Connector Orange Black Ground Engine Connector Instrument Connector Red Hot Voltage Regulator Brake Switch Connector Connector Hot Brake Switch Connector Ignition ...

Page 63: ...L WHIP SPECIAL TESTING ELECTRICAL Regulator Tests 1 Set point check P N 043299 Use test circuit as shown below Read voltage across regulator Value should be approximately 13 8 volts 120V lOOW s n REGULATOR SET POINT TEST CIRCUIT 3 11 ...

Page 64: ... Set Replace regulator and failed Point too high bulbs Burned out Failed bulb Replace bulb lights individual Burned out lights Intermittent short in wire harness Repair or replace wire harness Engine won t run 1 Open or shorted windings in 1 Replace armature plate Weak or no ignition coils stator spark 2 Open or shorted windings 2 Replace external coil in external ignition coil 3 Shorted condenser...

Page 65: ...1975 Scorpion Lil Whip Service Manual Clutch Drive Section 4 1 ...

Page 66: ...ical ramp which is guided by a follower This sheave is con trolled by a spring pre stressed in torsion and compression to hold the sheaves together at the maximum pitch diameter Under acceleration the torque from the engine is greater than the demand from the track The drive clutch then closes forcing the belt outward between the sheaves Belt tension and wedging action is unbalanced at the driven ...

Page 67: ...nch capable of 75 or more ft lbs torque In the field alternate method may be used Making sure ignition is off run engine up on compression using socket and ratchet Strike ratchet with plastic or rubber mallet See Figure 4 2 3 Remove bell housing See Figure 4 3 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 4 1 FIG 4 2 FIG 4 3 4 3 ...

Page 68: ...CORPION LIL WHIP 4 Movable sheave should slide off spline easily Next remove spring and retainer See Figure 4 4 5 Remove snap ring retainer and idler bearing if necessary See Figures 4 5 and 4 6 4 4 FIG 4 4 FIG 4 5 FIG 4 6 ...

Page 69: ...in stationary center hole and re insert bell retainer bolt Tightening bell bolt will force stationary off crankshaft See Figure 4 7 7 Removing torque plug retainer will allow torque plug to be removed and inspected See Figure 4 8 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 4 7 FIG 4 8 4 5 ...

Page 70: ... cracks and flat spots Also check snap rings on weight arm shaft ends Inspect torque plug for fit and wear Should have no more than 020 space between torque plug and casting Inspect idler bearing for freedom of rollers and retention of lubricant Inspect snap ring groove on stationary and spring retainer for wear Inspect bell housing for cracks particularly in center area near spline 4 6 FIG 4 9 FI...

Page 71: ...ecking to see that the small locating hole in the bearing aligns with the detent on inner face of retainer Install torque plug and torque plug retainer Install bell housing checking alignment with stub on torque plug provided for this purpose Place spring washer and bell retainer bolt on next assuring that the bolt has bottomed out securely in proper alignment Install clutch attaching bolt Torque ...

Page 72: ...UAL 1975 SCORPION LIL WHIP DRIVEN CLUTCH DISASSEMBLY 1 Remove chain case cover 2 Remove chain tensioners unbolt and remove top sprocket and chain DRIVEN SHAFT LOCKING BOLT CHAIN CHAIN TENSIONER BOTTOM SPROCKET 4 8 ...

Page 73: ... chaincase tapping shaft lightly with plastic mallet Remove snap ring and washer from cam top and slide off shaft See Figures 4 16 4 17 4 18 CAM TOP CAM BOTTOM FIG 4 17 SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 4 16 FIG 4 18 4 9 ...

Page 74: ...IL WHIP 4 Remove key and main spring See Figure 4 19 KEYWAY KEY 5 This should allow cam bottom and movable sheave to be removed as a unit See Figure 4 20 and disassembled if necessary See Figure 4 21 4 10 FIG 4 19 FIG 4 20 FIG 4 21 ...

Page 75: ...ry sheave may then be unbolted from clutch shaft See Figures 4 22 and 4 23 and bearings can be pressed off if necessary STA TIONARV SHEAVE CLUTCH SHAFT SERVICE MANUAL 1975 SCORPION LIL WHIP FIG 4 22 FIG 4 23 4 11 ...

Page 76: ... bolt holes Check splines and threads on sprocket side of main shaft for wear crossthreading etc RE ASSEMBLV OF DRIVEN CLUTCH Attach stationary sheave to clutch shaft Assem ble cam bottom and movable then place on shaft followed by the woodruff key and main spring Place cam top on shaft preloading spring 1 3 turn and install washer and snap ring Upon replacing the driven clutch in chaincase check ...

Page 77: ...IONS Drive belt width 1 1 8 1 3 16 inches Drive belt outside diameter 43 1 8 43 1I 4 inches Clutch offset Drive to Driven 3 8 inch Center to center distance 101 2 inches Drive clutch to Driven clutch CLUTCH ALIGNMENT BAR FOR 3 8 OFFSET DRIVEN CLUTCH FIG 4 24 4 13 ...

Page 78: ...2 between center of driven and drive clutches Reverse procedure to install REMOVAL OF FRONT DRIVE SHAFT Remove brake cable at chain case end Remove chaincase cover tensioners lower sprocket and chain Loosen locking collars on front drive bearings see Fig 4 25 Remove speedometer drive adaptor and flanges Slide drive shaft through chaincase mounting hole until right side clears main frame and remove...

Page 79: ...haft Observe shaft for signs of stress cracks and ben ding check bearings and collars for breakage Check sprockets for loosening of pin holes NOTE Small cracks in the white material of the drive sprocket are not signs of failure but a result f hrinkage during manufacture 0 RING FIG 4 27 4 15 ...

Page 80: ...ine by the belt If the clutch is closing fully the belt may be wrong length or the center to center distance of the clutches may be off Finally check the number of teeth on upper and lower sprockets Tachometer may be reading incorrectly high Belt may be worn and too narrow to achieve correct ratio see belt specs Track may be too loose allowing sprock ets to slip over drive lugs or ratchet Chain ma...

Page 81: ... 1975 Scorpion Lil Whip Service Manual Suspension Section 5 1 ...

Page 82: ...ct the operator from physical abuse or injury 2 Keep the operator from being ejected from his operating position and controls 3 Prevent damage to the machine 4 Increase ground contact and improve trac tion On the 1975 Lil Whip the track suspension trailing arm bogey is a multiple type suspen sion unit which simply means that it has five 5 separate components It also possesses the advantage of bein...

Page 83: ... 21 SERVICE MANUAL 1975 SCORPION LIL WHIP 2 23 20 21 NOTE All identifying numbers in subsequent explanation and in structions refer to the numbers on this page FIG 5 1 5 3 ...

Page 84: ...MBLV A REMOVAL 1 Raise and block vehicle off the ground Loosen the two 2 sliding nuts 17 TENSION PIVOT BOLT SLIDING NUTS 2 Remove the two 2 bolts 6 from the draw blocks 7 This will relieve the track tension and permit easy removal of the bogey units DRAW BLOCKS 5 4 FIG 5 2 FIG 5 3 ...

Page 85: ...d on the bogey unit to release the two spring tangs from the tunnel Remove the remaining three units in the same man manner Note For ease of accessibility always work from rear toward the front when removing or in stalling SERVICE MANUAL 1975 SCORPION lll WHIP FIG 5 4 FIG 5 5 FIG 5 6 5 5 ...

Page 86: ...the two 2 draw blocks 7 Remove the two 2 bolts 5 washers 16 and lock washers 4 Remove the four bolts 18 and rear end is disassem bled and ready for complete removal REAR IDLER SP 2 Bogey Springs 20 Two Wheel Weldments 26 Unwrap the spring anchor from the spring tang in the two bogey weldments to remove springs from the bogey weldments 26 1 FIG 5 8 LsPRING ANCHOR ____ 5 6 FIG 5 7 FIG 5 9 ...

Page 87: ...t the anchors are peened down as close to the weldment as possible If this is not done track damage could occur FIG 5 1 0 C ASSEMBLY Reverse procedure for disassembly can be used However the bogey weldments can be installed easier by installing the rear springs 12 in their respective notch in the tunnel and by installing the draw blocks 7 after the installation of the four 4 bogey weldments TORQUE...

Page 88: ...ion will result in the bottoming out of the suspension A harsh ride and shortened life to the suspension components will occur 1 Proper spring tension is a function of operator weight and preference Therefore the correct setting can only be determined by a trial ride 2 To adjust move spring tang to desired slot making certain that each spring is tightened or loosened the same amount Check track al...

Page 89: ...ck tension should be checked at the following intervals 1 When the machine is new dealer preparation 2 After the first hour and 10 hours 3 Every 30 days or 200 miles of operation 4 At the start of each snow season 5 Upon hearing track sprocket ratcheting Ratchet ing is most noticeable under hard acceleration or a braking condition Ratcheting is best explained as a harsh grinding or thumping noise ...

Page 90: ... 5 1 2 5 If the track is properly tensioned the green ring should be just visible or aligned with the lip of the cylinder Adjustment is required if the green ring is not visible or is above the lip of the cylinder 6 To make adjustment loosen the two tension pivot bolts and the two sliding nuts See Fig 5 2 Either tighten or loosen the adjustment bolts until proper adjustment is measured on both Tra...

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