SCORPION Super Stinger 1975 Service Manual Download

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Summary of Contents for Super Stinger 1975

Page 1: ... io 1975 Scorpion Super Stinger Service Manual Engine Section 1 ...

Page 2: ...he 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 oi l 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 thr...

Page 3: ...cylinder an incoming charge of fuel air mixture scavenges the combustion area giving it a fresh charge and the cycle is then repeated SeeFig l 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 will prevent possible engine overheating piston or cylinder scoring or even...

Page 4: ...wer and or severe engine damage For these reasons intermediate lengths of pipe between 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...

Page 5: ...waves and sound energy stop over scavenging 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 a...

Page 6: ...112 WEIGHT ADVANCED TIMING BEFORE TDC CENTRIFUGAL 0 18 to 020 018 to 020 018 to 020 WEIGHT RETARDED BREAKER POINT GAP 014 to 0 16 SPARK PLUG THREAD 14mm x 1 25 3 4 reach 020 020 020 SPARK PLUG GAP 0 5mm 0 5mm 0 5mm SPARK PLUG BOSCH ORIGINAL W260T2 W260T2 W260T2 EQUIPMENT TYPE OF ENGINE COOLING Axial Flow Fan ROTA TION O F CRANKSHAFT Counterclockwise PTO side CARBURETOR Walbro FUEL OIL RATIO As Spe...

Page 7: ...28 to 32 ft lbs 16 to 18 ft lbs 44 to 50 ft lbs 56 to 72 ft lbs 56 to 72 ft lbs 16 to 18 ft lbs 16 to 18 ft lbs 22 to 24 ft lbs 6 to 7 ft lbs not applicable not applicable 10 to 12 ft lbs not applicable 10 to 12 ft lbs Tightening Sequence for Cylinder Base Nuts 0 0 8 0 PTO SIDE 0 G 0 8 Tightening Sequence for Cylinder Head Nuts Fan Housing Ring Gear Flange Intake Manifold and Recoil Starter Clamps...

Page 8: ...tarter 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 l 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 FIG 1 4 A FIG 1 5 FIG 1 6 ...

Page 9: ...per Fan Belt Pulley Assembly Insert a 3 16 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 FIG 1 7 FIG 1 9 1 9 ...

Page 10: ...he 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 FIG 1 12 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 1 10 ...

Page 11: ... MANUAL 1975 SCORPION SUPER STINGER E Intake Manifold Assembly Remove the four 4 intake manifold nuts and washers Remove manifold assembly and insulators See Figs 1 14 1 15 0 0 i oo 00 FIG 1 14 FIG 1 15 1 l l ...

Page 12: ...using 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 16 Remove fan housing from crankcase See Fig 1 17 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 16 FIG 1 17 ...

Page 13: ...ION SUPER STINGER Remove the fan by tapping 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 18 1 19 1 20 FIG 1 18 FIG 1 19 _ FIG 1 20 l 13 ...

Page 14: ...socket wrench and remove the eight 8 spring washers The cylinders may be removed See Fig 1 23 NOTE IMP 0 R TAN 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 tw...

Page 15: ...at gun or propane torch Heat only to the point where piston may still 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 24 1 i FIG 1 24 1 15 ...

Page 16: ...ls 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 25 FIG 1 26 FIG 1 27 ...

Page 17: ...shaft into crankcase lower half of it will be necessary that all bearing outer surfaces be wiped clean of foreign material so that proper sealing will occur After installing PTO thrust washer and oil seal inside groove of oil seal coated with light grease place the crankshaft carefully into the lower crankcase half and properly position all components See Figs 1 30 Placement of the upper crankcase...

Page 18: ...ean 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 32 1 33 1 34 1 35 CIRCLIP OPENING HERE FIG 1 33 1 18 J F...

Page 19: ...1 Oil the piston pin end bearings 2 Install one circlip in piston 3 Heat the piston sufficiently to allow pin to push into piston and install pin 4 Instal l second circlip See Fig 1 33 for correct orientation of circlips 0 FIG 1 34 FIG 1 35 1 19 ...

Page 20: ... See Fig 1 39 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 th e cylinder with the piston in the top dead center position If the piston does protrude above the cylinder a thicker base gasket mus...

Page 21: ... head gaskets with the wide side of inner metal flange of the gaskets up toward the cylinder heads Torque cylinder head nuts to sixteen 16 to eighteen 18 foot pounds See Fig 1 40 NOTE The head gasket for the 400 cc engine has an additional hole in it to dis tinquish it from the 440 cc gasket FIG 1 39 FIG 1 40 1 21 ...

Page 22: ... Lubricate the inner groove of the oil seal with a light grease See Fig 1 41 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 42 Place fan housing assembly over crankshaft and position to crankcase assembly Install the four ...

Page 23: ...ers gaskets and intake manifold Fig 1 44 Torque nuts even ly to sixteen 16 to 18 foot pounds G Upper Fan Pulley Assembly H 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 45 Flywheel Assembly Check advance mechen ism for free operation lubricate inside cam surface G...

Page 24: ...ly 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 47 J Recoil Starter Install the recoil starter assembly and tighten securely See Fig 1 48 l 24 FIG 1 46 FIG 1 47 f FIG 1 48 ...

Page 25: ...ining slot Remove friction plate Fig 1 52 1 53 3 Remove the three pawls 3 Fig 1 54 4 Remove return spring 9 spring 6 and cup washer 7 Fig 1 53 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 55 6 Lift long rolled end of main spring 5 from the fixed spring retaining pin ...

Page 26: ...Clean all parts 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 FIG 1 52 1 26 FIG 1 50 FIG 1 51 ...

Page 27: ...SERVICE MANUAL 1975 SCORPION SUPER STINGER FIG 1 54 FIG 1 55 FIG 1 56 1 27 ...

Page 28: ... around reel in Jn anti clockwise direction until the free end J udes through the notched section of the 5 tpply a light film of Lubriplate or equivalent to center hub of case and install the reel Push down and rotate reel in an 9nti clockwise direction until the hook en ages with the free end of main spring Ten sion will be felt when reel and spring are pro j erly engaged Fig 1 61 1 62 6 otate re...

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 st arter for proper operati on When handle is pulled outward pawls shou ld move outward NOTE If main spring is to be installed without the use of a spring winding tool wind main spri ng into case in an anti clockwise direc tion Clockwise installation on the winding too...

Page 30: ...linder P T O side See Fig 1 64 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 65 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: ... zero Place selector knob on ohmmeter to R x 1 Ohm meter needle will indicate a closed circuit See Fig 1 67 Move the centrifugal weights in flywheel to the full advanced position See Fig 1 68 Rotate flywheel counterclockwise one com plete revolution to between 102 and 112 See Fig 1 69 FIG 1 67 FIG 1 68 FIG 1 69 1 31 ...

Page 32: ...ecurely Re check procedure See Fig 1 70 NOTE In Fig 1 70 flywhee l has been removed for clarity of illustration E Remove dial indicator assembly and install in No 2 cylinder fan side See Fig 1 71 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 flywhe...

Page 33: ... 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 Retighten connections 2 Secure ground connection 3 Check recharge or replace battery 4 Check starter solenoid Repair or replace 5 Inspect starter motor for e...

Page 34: ...n or slowly 2 Spark plugs improperly 2 Clean adjust or install new gapped or dirty plugs n 3 Head gasket blown or 3 Replace gasket leaking 4 Loose or broken magneto 4 Repair or replace wires wires 5 Magneto breaker points 5 Adjust clean or install new improperly gapped or points dirty 6 Weak coil or condenser 6 Replace coil or condenser 7 Improper fuel mixture 7 Refuel using specified fue l oil 1 ...

Page 35: ...g 1 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 Resealcrankcase 7 Refer to Carburetor Section 8 Remo...

Page 36: ...king 7 Install new seal Good spark but l Leaking cylinder head l Check head for warps cracks engine runs on one Install new gasket and cylinder cylinder head 2 Magneto wires broken 2 Repair or 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: ...oose spark plug 4 Head bolts not tight 1 Pi ston rusted to cylinder wa ll 2 Crankshaft seized to bearing main or rod 3 Broken connecting rod 4 Flywheel se ized to_ coil plate 5 Engine properly assem ed after repair REMEDY 1 2 Adjust carburetor Refer to Carburetor Section 3 Remove line clear obstruc tion replace line 4 Refer to Carburetor Section 1 Clean adjust or instal l new points 2 Ad just timi...

Page 38: ... leak 4 Leaking air silencer boots on early production models 5 Pick up in fu e l tank too long 6 Loose carburetor on intake manifold causing air leak 7 Leaking crankcase halves 8 Leaking crankcase sea ls 9 Leaking impulse fitting or plug 10 Intake manifold spacers cracked causing air leak 8 engine 11 Intake manifold misaligned 5 engine 12 Leaking cylinder head gaskets 13 Screen in 1973 5 engine c...

Page 39: ... 1975 Scorpion Super Stinger Service Manual Carburetor Section ...

Page 40: ...es 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 Super Stinger are 1 Starting choke operation 2 Idle operation 3 Part throttle operation 4 Full throttle operation Detailed performance of the carbure...

Page 41: ...ering 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 needle valve 28 and al...

Page 42: ...ough the idle discharge port 14 where it mixes with ad ditional air passing the throttle valve 19 at point 15 I FIG 2 2 IDLE OPERAT ION Power needle Choke valve rt J open u t 1 ___ Main fuel nozzle 2 4 Secondary fuel p mp Vapor return Part throttle holes _ Sec onclary idle holes 16 Point 15 Idle discharge port 14 i i iiiS Q E Idle pocket 13 Idle needle 12 Idle take off 11 Inlet fitting 1Fuel inlet...

Page 43: ...e 20 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 Venturi 23 Choke valve Air bleed nozzle 25 Needle valve Vapor return line fitting to fuel tank PAR T THROTTLE OPERATION l apo return 1 Fue i nJet 22 Throttle valve 19 Main nozzle 21 Throttle bore 20 Part t...

Page 44: ...nd WDA discharge at five discharge ports para e to power needle 22 This is noted by comparing Fig 1 and Fig 4 A t full throttle operation fuel passes around the power needle 22 and is discharged through the main nozzle 2 1 During ful l throttle air is mixed with fuel in the main nozzle 21 through the nozzle air b leed 25 Suction or vacuum created by the engine s piston action draws fuel and air as...

Page 45: ... See FIG 2 5 1 Cover Assembly 8 Fuel Pump Diaphragm 2 Fuel Inlet Gasket 9 Fuel Pump Gasket 3 Filter 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 Check diaphragms and gaskets thoroughly for cracks or leaks by holding them against light...

Page 46: ...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 chan...

Page 47: ...c ...

Page 48: ... necessary Engine will run with choke closed Do not use throttle in starting or engine will immediately flood 8 Open choke and let engine warm up 9 Turn idle mixture screw in to reach maximum R P M on Tach Continue turning until R P M start to drop 10 Screw idle mixture screw out to reach maximum R P M Continue out until R P M drop 11 Set idle mixture screw half w ay between drop points This is th...

Page 49: ...el line from 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 ...

Page 50: ...SERVICE MANUAL 1975 SCORPION SUPER STINGER r 2 12 ...

Page 51: ...ve surface of valve body 3 M etering lever spring 3 Remove plates and inspect not seated in dimple on spring Locate spring correctly metering lever See FIG 2 6 4 Leaking fuel pump 4 Install new diaphragm diaphragm 5 Foreign matter under 5 Blow through screen on umbrella check valve opposite side of Plate 13 See FIG 2 5 Umbrella check valve is orange colored rubber plug 6 Wrong angle or abused 6 Se...

Page 52: ...gms From incorrect de icing 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...

Page 53: ... 1975 Scorpion Super Stinger Service Manual Electrical Section I 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 on external voltage regulator is utilized See VOLTAGE REGULATION MAIN ELEMENTS 1 Magnetic Flywheel 2 120 watt coil mounted on stator plate ...

Page 55: ...pses 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 l...

Page 56: ...L 1975 SCORPION SUPER STINGER SEE ENGINE DISASSEMBLY SECTION 1 FOR FLYWHEEL AND STATOR REMOVAL ENGINE CONNECTOR 3 4 CONDENSER Ht STATOR FIG 3 7 SPARKPLUG EXTERNAL IGNITION COILS SPARK PLUG FIG 3 SIGNITION SCHEMATIC ...

Page 57: ... SERVICE MANUAL 1975 SCORPION SUPER STINGER STATOR IGNITION COIL TO EXTERNAL COIL CONNECTORS FIG 3 9 Ex TERNAL COIL COIL TO SPARK PLUG LEAD FIG 3 10 EXTERNAL COIL GROUND 3 5 ...

Page 58: ...Cell 4 Diac Trigger 5 Silicon Control Rectifier Thermatab The intensity of the light output of the light bulb directly indicates the RMS Voltage level When the intensity exceeds a specific level a sequence of events occurs a The light is sensed by the photo cell b A signal from the photo cel l actuates the diac c The diac triggers the SCR d The SCR conducts in effect short circuiting the lighting ...

Page 59: ... with respect to line 2 C1 wi ll 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 emitter col lector of Q 1 and into the gate of SCR SCR is turned on and shunts the output of the magneto In the second half cycle the shunting mechanism of the regulator ...

Page 60: ...o on if the brake is applied Power to all the other items is supplied through the ignition switch in the LIGHTS mode Grounding of the System is accomplished at three locations 1 To the chassis at the rear end 2 To the instrument panel 3 To the stator plate on the engine MAIN ELEMENTS 1 Main Wiring Harness 2 Seat Wiring Harness 3 Taillight Wiring Harness 4 Safety Stop Switch 5 Break Light Switch 6 ...

Page 61: ...TOP I SWITCH I Ill TACHOMETER MOVEMENT TACHOMETER SPEEDOMETER I LIGHTS I 1 TAILLIGHTS BRAKE LIGHT I HI LO SWITCH WIRING SCHEMATIC COLOR CODED ELECTRICAL DISTRIBUTION CONTROL 1975 SUPER STINGER 1 m c c 1 1 I m a s n m 3 z c I o U l I n 0 a U 0 z I c U m a I z C m a ...

Page 62: ...BRAKE LIGHT SWITCH BRAKE LIGHT YELLOW HOT IGNITION SWITCH HI LO SWITCH TAILLIGHT SPEEDOMETER LIGHT TACHOMETER LIGHT GREEN HOT IGNITION SWITCH ELECTRIC START BLUE HOT HI HI LO SWITCH HEADLIGHT WHITE HOT LO HI LO SWITCH HEADliGHT ORANGE HOT ENGINE CONNECTOR TACHOMETER ORANGE BLACK GROUND ENGINE CONNECTOR TACHOMETER RECOMMENDED TOOLS FOR SERVICING 1 Standard Screwdriver 1 4 blade 2 Phillip s Screwdri...

Page 63: ... read between 100 and 1000 ohms If resistance is less than 100 the SCR is shorted If the resistance is above 1000 generally the lamp has burned out opening the circuit See FIG 3 12 2 Set point check PIN 042748 043299 Use test circuit as shown below Read voltage across regulator Value shou ld be approximately 13 8 volts 120V lOOW s n 4 OPEN TEST REGULATOR SET POINT TEST CIRCUIT 3 11 ...

Page 64: ...ulator and failed regulator light bulb Incorrect Set bulbs Point too high 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 ...

Page 65: ... 1975 Scorpion Super Stinger Service Manual Clutch Drive Section 4 J ...

Page 66: ...elical 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 drive...

Page 67: ...Remove clutch attaching bolt and bell retaining bolt Use impact wrench capable of 75 or more ft lbs torque In the field alter nate 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 FIG 4 1 FIG 4 2 FIG 4 3 4 3 ...

Page 68: ...PION SUPER STINGER 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 u FIG 4 4 FIG 4 5 FIG 4 6 ...

Page 69: ... in sert plug 2 13 16 long x 3 4 diameter 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 FIG 4 7 FIG 4 8 4 5 ...

Page 70: ...or 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 ...

Page 71: ...f ter checking them for lubrication Attach retainers checking to see that the small locating hole in the bearing aligns with the detent on in ner 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 i...

Page 72: ...ERVICE MANUAL 1975 SCORPION SUPER STINGER DRIVEN CLUTCH DISASSEMBLY 1 Remove chciin case cover 2 Remove chain tensioners unbolt and remove top sprocket and chain TENSIONER 4 8 DRIVEN SHAFT LOCKING BOLT j ...

Page 73: ...R STINGER 3 Remove driven unit from chaincase tapping shaft lightly with plastic mallet Remove snap ring and washer from cam top and slide off shaft See Figures 4 13 4 14 4 15 CAM TOP HELICAL RAMP CAM BOTTOM FIG 4 14 FIG 4 13 FIG 4 15 4 9 ...

Page 74: ...ER STINGER 4 Remove key and main spring See Figure 4 16 KEYWAY KEY 5 This should allow cam bottom and movable sheave to be removed as a unit See Figure 4 17 and disassembled if necessary See Figure 4 18 4 10 FIG 4 16 FIG 4 17 FIG 4 18 ...

Page 75: ...AL 1975 SCORPION SUPER STINGER 6 Stationary sheave may then be unbolted from clutch shaft See Figures 4 19 and 4 19A and bearings can oe pressed off if necessary STATIONARY SHEAVE CLUTCH SHAFT FIG 4 19 FIG 4 19 A 4 11 ...

Page 76: ...und bolt holes Check splines and threads on sprocket side of main shaft for wear crossthreading etc RE ASSEMBLY 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 1j3 turn and install washer and snap ring Upon replacing the driven clutch in chaincase che...

Page 77: ...T SPECIFICATIONS 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 4 13 I ...

Page 78: ...stall REMOVAL OF FRONT DRIVE SHAFT Remove chaincase cover tensioners lower sprocket and chain Loosen locking collars on front drive bearings see Fig 4 21 Remove speedometer drive adaptor and flanges Slide drive shaft through chaincase mounting hole until right side clears main frame and remove It is necessary to detach forward end of para rail to gain clearance for entire removal of front drive sh...

Page 79: ...t 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 of shrinkage during manufacture 0 RING SPIROL PIN FIG 4 22 FIG 4 23 4 15 ...

Page 80: ... line by the belt If the clutch is closing fu lly 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 sprockets to slip over drive lugs or ratchet Chain ...

Page 81: ...n 1975 Scorpion Super Stinger Service Manual Suspension Section 5 l ...

Page 82: ...use 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 Super Stinger the track suspension Para Rail Snowmobi le Suspension is a unit type suspension which simply means that it is a sing le unit working as a whole as opposed to the multiple unit bogey type suspension It...

Page 83: ...SERVICE MA 975 SCORPION SUPER STINGER NUAL 1 FIG 5 1 PARA RAIL GROUP 5 3 ...

Page 84: ...ion we will refer to the Para Rail group for iden tification of component parts by the numbers l through 57 A REMOVAL l Remove the two hex cap screws 56 and washers 57 2 Raise and block rear of vehicle off the ground NOTE In Figs 5 3 through 5 6 the track has been removed for clarity of illustration 3 Remove the two nuts 51 from the two eye bolts 11 5 4 FIG 5 2 FIG 5 3 ...

Page 85: ...move the two whiz lock screws 20 securing the rear suspension plates to the rear axle 5 Release the track tension by loosening the two screws 46 6 Remove hex screws S3 and nut 5 4 on the two suspension plates Remove plates FIG 5 4 FIG 5 5 FIG 5 6 5 5 ...

Page 86: ...screws 20 located on the side of the tunnel in front of the footrests The para rail can now be removed from the track and tunnel B DISASSEMBLY PARA RAIL SNOWMOBILE SUSPENSION 1 Bracket axle adjustment 42 5 6 Remove the four 4 hex screws 21 and lock nuts 22 FIG 5 7 FIG 5 8 ...

Page 87: ...prings from the spools 18 the rear of Para Rail Snowmobile Suspension must be he ld down whil e down ward pressure is applied with the right arm and upward pressure with th e left arm 3 Linkage Arm 30 Remove the two screw s 25 washers 26 and 48 Remove the two button head screw s 33 and spring retainers 32 FIG 5 9 FIG 5 10 0 l FIG 5 11 5 7 ...

Page 88: ...ig 5 12 5 Spools 18 Remove the two screws 25 and washers 26 from the wheel shaft 23 Push shaft through rails 6 and spools are removed Fig 5 13 6 Rails 6 5 8 Remove the remaining eight 8 screws 25 and washers 26 This will allow the rails to be removed from the remaining shafts bogey wheels and tube spacers The Para Rail Snowmobile Suspension is com pletely disassembled at this time FIG 5 12 FIG 5 1...

Page 89: ...mperature grease to al l shafts prior to assembly Scorpion clutch lube 906800 may be used 3 Reverse procedure as outlined for disassem bly NOTE Ensure that all tube spacers and bogey wheels are assembled in their respective areas on the shafts Torque requirements for assembly are ITEMS TORQUE 20 50 60 Ft Lbs 21 15 19 Ft Lbs 22 15 19 Ft Lbs 25 15 19 Ft Lbs 53 15 19 Ft lbs 54 15 19 Ft Lbs I 5 9 I ...

Page 90: ... proper spring tension may be obtained by having the rider s sit on the machine in the normal sitting position and measure the distance between the floor and the bottom of the running board at the rear of the machine either side This measurement must be 4 1 2 to 6 2 To adjust loosen the nuts on the eye bolts and adjust accordingly making certain that each spring is tightened or loosened the same a...

Page 91: ...machine Adjust each Track Jack to one and one quarter inch 1 V4 4 Insert both Track Jacks between the track and both bogey wheels located on the third bogey axle ahead of the rear idler wheels 5 If the track is properly tensioned the green ring should be just visible or aligned with the lip of the cylinder Ad justment is required if the green ring is not visible or is above the lip of the cylinder...

Page 92: ...eight evenly distributed across the track under both bogey wheels located on the third bogey axle ahead of the rear idler wheels 4 To make adjustment loosen the lock nuts on the track adjustment bolts as well as the rear suspension mounting screws rear of tunnel just below seat and either tighten or loosen the adjustment bolts to achieve the 11 4 inch clearance between track and bogey wheels 5 Rem...

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SCORPION Super Stinger 1975, Service Manual

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