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Yamaha SL292C 1971, Service Manual

The Yamaha SL292C 1971 service manual is a comprehensive and essential resource for owners and enthusiasts of this iconic vintage snowmobile. Available for free download at manualshive.com, this manual provides step-by-step instructions, detailed diagrams, and maintenance tips to keep your SL292C running smoothly and at its best.

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Summary of Contents for SL292C 1971

Page 1: ... ...

Page 2: ...aer who is in possession of the requisite bas c prod st l j 0v Jl ed e Other information is produced by the U S distributor Yam ha 1 1 i e r Jt i i Cc rpo ation i1C1 is necessary to provide total technical coverage regarding the prodi I C II _ _ I The Research Engineering and Service Departments of r amah t or r t i 1 I str v rig to further improve all models manufactured by the compan 1 difie ic ...

Page 3: ...der models and twin cylinder models These two books will be used as the basic service manuals for this year s models This manual contains service information for standard and GP models equipped with a 292 c c cylinder It al so includes specifications of 1971 to 1973 models for convenie11ce of Yamaha service technicians YAMAHA MOTOR CO LTD ENGINEERING SERVICE DEPARTMENT ...

Page 4: ... I ...

Page 5: ...ankcase CHAPTER 4 POWER TRAIN 4 1 4 2 4 3 4 4 4 5 Disc Brakes and Secondary Sheaves Chain Case and Front Axle Removal Bogie Wheels Removing the Track Removal Rear Axle CHAPTER 5 STEERING SKIS AND CHASSIS 5 1 5 2 5 3 5 4 5 5 Steering Skis Chassis and Shroud Seat Luggage Box CHAPTER 6 TIGHTENING BOLTS AND NUTS CHAPTER 7 ELECTRICAL 7 1 7 2 7 3 Ignition System Lighting System Wiring Circuit CHAPTER 8 ...

Page 6: ...ry Sheaves 74 9 2 Secondary Sheaves 74 9 3 Drive Belt 74 9 4 Primary Sheave and Secondary Sheave Alignment 74 9 5 Chain and Chain Case 78 9 6 Breakes 78 9 7 Track 79 9 8 Adjusting the Track 79 9 9 Skis 80 APPENDIX 1 INSPECTION AND MAINTENANCE 81 APPENDIX 2 CONVERSION TABLE 82 ...

Page 7: ...sable r p m under all operating conditions The drive ratio will vary from 3 5 1 1 1 thus giving maximum acceleration and cl imbing ability Diaphragm Carburetor The Yamaha snowmobiles have one diaphragm type carburetor This carburetor incorporates an internal metering device which always meters the correct air fuel mixture to the engine regardless of vibration or machine position Superior Braking A...

Page 8: ... mm 50 in 1 270 mm 12 rubber wheels bearing mounted Single polyurethane 9 teeth Single polyuret hane 9 teeth Automatic centrifugal engagement infinitely variable 3 5 1 1 1 Duplex roller chain enclosed in oil bath 25 13 1 923 1 Fabricated steel Reinforced fiberglass removable Removable Fiberglass reinforced in the engine room 5 0 U S gal 19 0 Q 2 1 U S qt 2 0 Q Chromed tubular steel Chromed tubular...

Page 9: ...ssories Emergency st arter rope Tool kit SL292C 12V 60 60W 12V 8W 12V 23W Oise brake Handle lever left hand operated Handle lever right hand operated Yes Yes 3 GENERAL Specifications i GP292B 12V 60 60W 12V8W I 12V 23W I I Disc brake I Handle lever left hand operated I I I Handle lever right hand operated I Yes Yes I I I ...

Page 10: ... x 2 76 in 292 c c 17 6 cu in 20 BHP 5 500 r p m One diaphragm type Mikuni Autolube oil injection Flywheel magneto 12V 40W 3 000 r p m N G K B 7ES Manual recoil starter with add I emergency rope starter Molded rubber steel reinforced 15 in 38 1 mm 50 in 1 270 mm 12 rubber wheels bearing mounted Single polyurethane 9 teeth Single polyurethane 9 teeth Automatic centrifugal engagement infinitely vari...

Page 11: ...Type Control Thrott le Type Accessories MODEL Emergency starter rope Tool kit Seat spring upper Spark plug SL292 Disc brake Handle lever left hand operated Handle lever right hand operated Yes Yes No Yes B7Hz 5 GENERAL Specifications ...

Page 12: ...0 mm 12 rubber wheels bearing mounted Single polyurethane 9 teeth Single polyurethane 9 teeth Automatic centrifugal engagement infinitely variable 3 5 1 1 1 Duplex roller chain enclosed in oiI bath 25 13 1 923 1 Fabricated steel Reinforced fiberglass removable 0 102 in 2 6 mm B T D C Removable Fabricated steel located behind backrest 4 0 gal 15 0 Q 2 1 qt 2 0 Q Chromed tubular steel Chromed tubula...

Page 13: ...er right hand operated Handle lever right hand operated Tachometer Center of the steering handle bar Left hand side of the instrument panel Speedometer I I I A ccessories I Emergency starter rope Yes Yes I Servi ce tool Yes Yes I Optional equipment parts Electric starter Expansion muffler SS kit I Speedometer SR kit Tachometer I High windshield I I Note The research and engineering departments of ...

Page 14: ...1804 90890 01806 5 90890 01816 6 90890 018 l 7 90890 01804 90890 01011 90890 01819 7 Fig 1 1 3 7 Crankshaft setting tool 4 a Spacer 90890 01818 4 b Crank setting bolt 90890 01020 4 c Crank setting tool Boss 90890 010 19 Ignition timing setting tool Dial gauge stand assembly 90890 01825 Crankshaft assembly disassembl ing and reassembling jigs 6 a Crank j ig 6 b Press box 6 c Press pin 6 d Support p...

Page 15: ...h 5 12 x 10 mm Open end wrench 6 8x 7 mm Open end wrench GENERAL Tools 5 4 16 18 13 17 10 Ph ii ips head screw driver 11 Philips head screw driver large 12 Philips head screw driver medium 13 Philips head screw driver small 14 Slot head screw driver medium 15 Slot head screw driver small 16 T type socket wrench 17 L type socket wrench 18 Torque wrench and sockets Fig 1 3 4 4V 5 e _ 6 7 Screw drive...

Page 16: ... choke lever Return to its original position when the engine wi ll rev smoothly c Pull the starter Firmly grasp the starter handle and pull slo r ily until engagement of the mechanism can be felt Then pull briskly but be careful not to pull the cable so far out that it bottoms This will result in longer cable Iife Sometimes an engine will start better at a certain throttle opening A little practic...

Page 17: ...end is fastened with two 13 mm nuts located beneath the seat As for the front end the SL292C double seat is secured w ith a panhead screw and the GP2928 with a 10 mm bolt Note The 10 mm bolt means that its distance across flats of the hexagon head is 10 mm Note Before removing the double seat disconnect the stop ta ii lamp connector at the front of the daub le seat Fig 2 1 Fig 2 2 I I f p I I I I ...

Page 18: ...val 2 1 3 Removing the Silencer Remove the five panhead screws indicated by arrows On the GP292B a lock washer is used at the carburetor intake and therefore it should be bent f lat 0 1 Fig 2 6 I _ _ _ _ I f Fig 2 7 12 8 I IT ...

Page 19: ......

Page 20: ...ecting the Throttle Wire Loosen the screw and remove the throttle wire from the carburetor Note After installing the throttle wire be sure to bend the wire end I n l1 I Fig 2 10 2 1 6 Disconnecting the Decompression Cable Remove the air shroud and remove tl1e decompression cable I I Fig 2 1 1 Fig 2 12 2 1 7 Removing the Tachometer Cable Remove the tachometer cab le from the oil pump by turn ing th...

Page 21: ...move the two 13 mm bolts setting the muffler to the frame Fig 2 15 Fig 2 16 ENGINE Engine Removal Remove the four 13 mm bolts and remove the exhaust pipe from the engine Fig 2 17 2 1 10 Removing the Sub Muffler Remove the two 13 mm bolts A coil spring and a gasket are installed at the joint between the main muffler and the sub muffler The spring is used as a shock absorber while the gasket is used...

Page 22: ...de while turning to the right and pull the drive belt upward at the center of its upper section Then remove it by pulling toward the sliding sheave I I Fig 2 19 I Fig 2 20 Fig 2 21 I t I 2 1 12 Removing the Engine Mounting Bolt Loosen the four 17 mm bolts on the engine lower bracket held to the frame Fig 2 22 16 ...

Page 23: ...e to the engine during assembly 0 0 t 15 16 3 I 4 i 5 9 10 I I 12 C 14 8 Fig 2 23 Ref No Description O ty Ref No Description Q ty 1 BRACKET engine upper 1 12 WASHER 2 4 2 BOLT stud 4 13 BOLT engine mounting 2 I 1 3 WASHER lock 4 14 BRACKET guard drive 1 4 NUT 4 15 GUARD drive 1 5 BRACKET engine lower front 1 16 ARM fitting 1 6 BRACKET engine lower rear 1 17 Cl RCLIP E 6 1 7 BRACKET engine lower ri...

Page 24: ...t be necessary to com pletely dismantle the starter assembly Tt1 is step wouId only be followed if replacement of tl1e starter rope or main return spring was required Fig 2 26 2 2 4 _ II 1 r It is important when reassembl ing the main return spring that the spring be installed in the correct posi rion and coiled in the proper direction Notice in tl1e picture that the spring is hooked to the center...

Page 25: ...y reassembled it should be checked for proper starter action Follow the example as shown in the picture and pull the starter rope out approximately 3 5 in 76 2 127 mm At this time the three starter pawls should come out When attached to the engine this would engage the starter pulley causing the engine to turn Fig 2 29 19 ...

Page 26: ...eturn 9 PLATE drive 10 WASHER flat I 11 WASHER spring r I II 12 NUT II Ii L 22 23 I 25 _ 5 I I I 7 20 21 Fig 2 30 15 14 6 8 I I 9 10 I I 12 O ty Ref No Description 1 13 ROPE 1 14 HAND LE starter 1 15 CONNECTOR 1 16 COVER sheave 3 17 SCREW round head 1 18 WASHER spring 1 19 PULLEY starter 3 20 BOLT 1 21 WASHER spring r 1 22 BOLT 1 23 WASHER spring 1 24 EMBLEM 1 25 CLAMP fuel pipe 20 19 16 I I 18 7 ...

Page 27: ... 34 the primary sheave cap is provided with a weight As the engine speed increases the weight is pulled by centrifugal force in the direction of the circumference Then th is movement is converted into the force which turns in the direction of the axle and pushes the sliding sheave The drive belt is driven as a result of being held tight between the sliding sheave and fixed sheave As the engine spe...

Page 28: ... CAP COMP BOLT WASHER lock WASHER 10 2 28 3 2 Cl RCLIP S 30 COLLAR PRIMARY SLIDING SHEAVE COMP I I 5 I 4 3 2 10 9 8 14 Fig 2 35 O ty Ref No Description Q ty 1 8 SPRING primary 1 1 9 NUT bearing 1 1 10 WASHER 28 36 2 1 1 11 SEAT spring 1 1 12 BEARING 6205 1 2 13 PRIMARY FIXED SHEAVE COMP 1 1 14 V BELT 1 22 ...

Page 29: ...the inner sheave off of lhe shaft Th is tool is the one that was used to remove the magneto f lywheel only the long screws are used to hold the special tool in place rather than the short ones As you w iiI notice in the picture a wrench is used to hold the special tool so that it will not turn as the T handle is screwed in Fig 2 37 ENGINE Removal of Primary Sheave Removing the Oil Pump 2 3 6 As sh...

Page 30: ...over _ I Fig 2 42 2 4 4 To separate oil pLimp drive cover 1 f ron1 oil pLimp drive cover 2 remove the pa11head screw on the cover 1 side and the flat head screw on the cover 2 side c Fig 2 43 0 Fig 2 44 2 4 5 When instal Iing the idle gear and drive gear 2 coat them with anti freeze grease Beacon 325 or Aero ShelI 7A If the oil pump drive gear cover is already installed on the engine f irst remove...

Page 31: ... 2 4 7 To remove drive gear 2 remove the circlip on the warm shaft end To install drive gear 2 be sure to insert the dowel pin into the warm shaft Drive gear 2 Fig 2 49 c Fig 2 50 2 4 8 For assembly reverse the procedure ford isassembly 2 4 9 A ring gear is attached to the rear side of the primary fixed sheave When installing coat it with anti freeze grease Beacon 325 or Aero ShelI 7A Fig 2 51 25 ...

Page 32: ...LIP S 10 13 GEAR idle Wl1en the tachometer option is installed this blind cap should be removed and the driven gear should be installed instead 1 1 5 o s 18 8 9 10 I I 12 13 14 15 16 19 22 20 23 21 Fig 2 52 O ty Ref No Description 1 14 BEARING B6000 2RS 1 15 CI RCLI P S 10 1 16 COVER pump drive 2 1 17 Cl RCLI P R 26 1 18 SCREW panhead 1 19 WASHER plain 2 20 WASHER spring 1 21 BOLT 1 22 Pl N dowel ...

Page 33: ...eto flywheel can now be removed This requires the use of special puller that you will find in our special tool kit Be sure to use the three short screws that come with the puller when removing the flywheel Note Immediately after the flywheel is removed take the woodruff key off the shaft and in same satisfactory way attach it to the flywheel so that it is not lost Fig 2 55 2 5 4 All parts of the m...

Page 34: ...R spring 1 3 SCREW panhead 5 25 4 18 LEA D WI RE ASS Y 1 4 WASHER spring 4 19 PLATE timing 1 5 CONTACT BREAKER ASS Y 1 20 ROTOR ASS Y 1 6 SCREW panhead 4 12 21 SCREW panhead 3 7 WASHER spring 1 22 FAN 1 8 WASHER plain 1 23 BOLT 6 9 CONDENSER 1 24 WASHER spring 6 10 SCREW panhead 4 10 1 25 WASHER plain 6 11 WASHE A spring 1 26 COVER hole 1 12 LUBRICATOR 1 27 NUT crankshaft 1 13 SCREW panhead 4 10 1...

Page 35: ...screws that hold the air shroud in place Fig 2 58 ENGINE Removal of Fancase and Air Shroud 2 6 2 Straighten the bent positions of lock washers 1 and 2 and remove the bolts The fancase 1 and 2 can be removed out of the crankcase Note that a packing agent gasket is applied to the mating surfaces of the fancases 1 and 2 Fig 2 59 29 ...

Page 36: ...SCREW panhead WASHER lock 1 WASHER lock 2 BOLT SCREW panhead SCREW panhead 13 14__ o 15 15 14 11 13 rel 14 15 13 5 Fig 2 60 l 8 1 Q ty Ref No 1 10 1 11 1 12 2 13 1 14 1 15 5 16 5 17 2 18 30 9 4 Description DEF LECTOR Al R SHROUD cylinder 1 AIR SHROUD cylinder 2 SCREW bind WASHER spring WASHER plain STAY clamp GROMMET air shroud cylinder PIN dowel 4 13 8 O ty 1 1 1 6 6 6 1 1 2 ...

Page 37: ...top any carbon broken parts or other contaminations from fal Iing into the engine r r __ Fig 2 62 ENGINE Top End Removal 2 7 3 The piston assembly is removed at this time Use a needle nose pliers to remove the piston pin clip Use a soft drift pin to push the piston pin out to allow a pair of pliers to grip and completely remove the piston pin Once the piston pin has been removed the piston can be ...

Page 38: ...D cylinder 13 14 12 2 8 18 20 19 1 Fig 2 65 O ty Ref No Description O ty 1 12 SOLT stud 2 1 13 NUT holding 6 2 14 WASHER holding 8 5 19 2 6 6 3 15 PLUG spark 8 7E 1 2 16 SCREW panhead 1 2 17 GASKET screw 1 4 18 PROTECTOR 1 1 19 SCREW panhead 2 1 20 WASHER spring 2 1 21 Pf PE joint 1 1 The crankcase has a drain screw This screw is used to empty the crankcase before the engine is stored away for lon...

Page 39: ...e removed by dividing the crankcase into two halves right and left Fig 2 66 2 8 2 r The seven screws holding the crankcase are located on the magneto flywheel side Fig 2 67 ENGINE Crankshaft Ass y Removal 2 8 3 After removing alI screws divide the crankcase by using the crankcase dividing tool special tool as shown in the iilustration Fig 2 68 2 8 4 Push the crankshaft out of the crankcase by usin...

Page 40: ...pring 4 11 WASHER plain 4 12 BOLT engine mounting 2 Installing the engine bracket 1 The engine bracket lower should be instal loo with special care so that it will not be positioned with the upside down or with the inside out or with the right side on the left Ref No 13 14 15 16 17 18 19 20 21 22 23 24 Fig 2 71 34 C 5 6 7 1 4 16 17 Description O ty WASHER lock 2 2 BOLT engine mounting 2 1 WASHER l...

Page 41: ...cting rod big end crank pin and bearing should be checked Excessive wear of the connecting rod big end is checked by measuring the axial play of the connecting rod small end when it is moved from side to side with your fingers The axial play should not exceed 0 080 2 mm After the crank pin and bearing are replaced maximum axial play should not exceed 0 032 0 04 0 8 1 0 mm Ref No 10 11 12 13 14 15 ...

Page 42: ... the crankshaft support the crankshaft at its both ends and measure the points as illustrated below with a dial gauge The runout should be 0 0008 0 02 mm or less at journales A and B 0 0016 0 04 mm or less at C and 0 002 0 05 mm or less 0 0008 0 02 mm or less C A Support Interstice 0 01 0 25 mm Interstice 0 01 0 25 mm ___ B D Support 40 40 Both ends 0 02 0 5 mm 3 1 4 For procedures for disassen1bl...

Page 43: ... 2 The brake disc is removed at this time This is done by removing the nut and spring washer the brake disc itself and on some machines the shims immediately behind it Yo J will notice in the illustration that the shims are situated in front of the brake disc This is merely for purpose of identification as they actually are located behind the brake disc Fig 4 2 4 1 3 Once the brake disc has been r...

Page 44: ... be reinstalled in their original positions I Fig 4 5 4 1 6 This illustration shows the entire secondary sheave assem bly removed and assembled on the bench Normally this should be the extent of disassembly but if a problem arises in the secondary sheaves themselves then additional break down will be required This will be accomplished by first removing the roll pin at the right hand end of the sha...

Page 45: ...t 4 1 8 When installing the secondary sliding sheave feed the Shell A lvania grease 2 or 3 between the sheave and the secondary st1aft v Shell ALVAN IA grease 2 or 3 I y Fig 4 10 39 P OWER TRAIN Disc Brakes and Secondary Sheaves ...

Page 46: ...P 2 SECONDARY SLIDING SHEAVE COMP 3 SHAFT secondary 4 PfN spring 5 SPRING secondary 6 SEAT spring 7 SHOE lamp 8 COLLAR distance 1 9 SPROCKET chain drive 13T fl Fig 4 11 8 O ty Ref No 1 10 1 11 1 12 1 1 1 1 1 1 40 9 3 10 11 12 Description O ty COLLAR distance 3 1 COLLAR 2 1 SHIM 17 2 25 0 2 1 SHIM 17 2 25 0 3 1 SHIM 1 7 2 25 0 4 1 SHIM 17 2 25 0 5 1 SH IM 17 2 25 0 6 1 SHIM 17 2 25 0 7 1 ...

Page 47: ...Axle Removal 4 2 2 Return to the left side of the snowmobile You will find at the bottom of the chain case the chain case cover Remove the six retaining bolts and remove the chain case cover It should be noted that an oil drip pan should be placed beneath the snowmobile as oil will drain out of the chain case once the cover has been removed Note This cover need only be removed if the driven sprock...

Page 48: ... a special tool Nut removal tool or a 26 mm socket wrench Fig 4 18 The right hand axle l1ousing is held in place by tl1ree bolts 1 0 mm At this ti n1e rernove tl1e bolts from t l1e frame and pL1 II o ff the housing I Fig 4 19 4 2 5 Place t he snowmobile with tl1e left side down Straighten the lock washer and remove the bolt Then whether the sprocket or the chain case can be removed The sprocket is...

Page 49: ...he right hand side and pull the right end of the shaft backward and downward sliding the shaft free It is most likely t hat the track wil l drop out as the axle is being removed This completes the removal of the front axle assembly from the frame Fig 4 23 P OWER TRAIN Chain Case and Front Axle Removal 4 2 8 Front Axle Installation When installing the front axle the front axle end should be inserte...

Page 50: ...1 WASHER lock i 12 BOLT l 13 CHAIN RS40V 68L I CHAIN RS40V 66L It I 14 JOINT chain 15 RING rubber housing 16 CAP housing _ 27 29 27 21 9 10 I I 12 13 15 16 17 18 19 Fig 4 25 O ty Ref No Description O ty 1 17 GASKET 1 1 18 PLATE 1 1 19 BOLT 6 1 20 WASHER 6 1 21 BOLT 4 2 22 WASHER spring 4 1 23 WASHER plain 4 1 24 CAP2 1 1 25 BEARING B6203C3 1 26 01 L SEAL SD 22 32 5 U R 1 27 0 RING 3 1 113 2 1 28 H...

Page 51: ...cription Q ty 1 F RONT AX LE COMP 1 11 BEARING B6004 special 1 2 WHEEL sprocket 1 1 12 CIRCLIP R 44 1 I 3 COLLA R 4 13 HOUSING front axle 1 I 4 RIM sprocket wheel 2 1 14 BOLT 3 I 11 5 BOLT 4 15 WASHER spring 3 6 WASHER lock 2 16 WASHER 1 7 GUIDE WHEEL COMP 2 17 I 1 NUT 1 I I 8 PLATE 25 5 38 2 4 18 I 1 CAP 1 11 I 9 Pl N spring 4 19 I CLIP w ire 1 10 01 L SEAL SD 25 34 7 1 I v 45 ...

Page 52: ...ased Precautionary Note If the snowmobile is immobile or stored for more than a week the rear of the machine should be raised and placed on blocks This will prevent the rubber bogie wheels from flattening under the weight of the machine Bogie wheel Suspension spring J _ Fig 4 29 After installation be sure to bend the spring end stoppers at f our places Fig 4 29 4 4 REMOVING THE REAR AXLE 4 4 1 Ren...

Page 53: ...35 4 4 3 Installing the Rear Axle Before installing the rear axle the bogie wheels must be installed on the frame As illustrated install the pivot rear arm on the rear axle with the rear axle positioned on the inside of the track In this case the rear arm pivot should be positioned outside of the track Install the collar on the rear arm Fig 4 36 _ Insert the pivot rear screw into the pivot hole in...

Page 54: ...machine I I JI I I _ _ Fig 4 39 Install the inside washer and plain washer and secure the rear pivot screw with the nut After tigt1tening tl1e nut lock the nut with the cotter pin lj rr I Fig 4 40 4 5 TRACK REMOVAL 4 5 1 The front axle rear axle and bogie wheel assemblies must be taken out of the chassis in order to remove the track The track can t hen be Iifted out of the chassis 4 5 2 If the cen...

Page 55: ... portion of the jig inside the track and the A portion outside the track Install the two bolts in the B through the A and C jigs and tighten them Then tighten the center bolt i 5 f 1 12 I f J 33 m z 5 I v 120 30 I t I I 40 2 _J 15 1 134 I 134 I r v 160 1 I 1I 0 33 52 15 T I 15 28 f 35 i 110 1 20 1 3 1 1 Link plate 20 52 i 15 Link plate 1 B 20 _l 85 Drive track Fig 4 42 49 ...

Page 56: ...nt in controlling parallelisr11 of the skis while the sr1owmobile is in motion Skis are supported on 5 leaf springs that are pivoted at the rear of the ski and free to expand and contract on a wear plate at the front part of the ski This wear plate should be greased often to reduce friction between the spring and wear plate Fig 5 1 2 Ski Parallelism ParaIlelisrn of the skis is cl1ecked by n1easuri...

Page 57: ...d rust The shroud is painted fiberg lass and should require little mainlenance Checking for cracking will insure it from serious damage The windshield is clear PVC and should require no maintenance When it is cleaned you should attempt to wash off any dirt of mud first and then wipe it off This will keep scratches to a minimum 5 4 SEAT The seat is a single unit of foam chips covered with vinyl If ...

Page 58: ... covered terrain causing bolts and nuts to loosen In particular the bolts and nuts as illustrated below shouId Headlight rim b ind screw Steering relay rod lock nut be carefully tightened and locked with a bond wt1en tl1e machine is serviced Rear burnper bind screw Oil tank bind scre1 v Foot rest tighten ing boIt Fig 6 1 52 I 1 l r ...

Page 59: ... 2 LIGHTING SYSTEM Lighting current is generated in a similar manner by the lighting coil located on the point plate The lighting system is of a balanced output type design for the headlight and taillight Overloading of the lighting system by adding on lighting equipment is not recommended Because the Iighting system is of a balanced output type burning out of either the headlight or taillight can...

Page 60: ...G W L Br OFF 0 x x x 1 x 0 x x 2 x x 0 x 3 x x x 0 G G _ B 1 8 t _ y y B L B L Speedorneter 12V 2W Tachon1eter 12V 2W High 12V 60W Low 12V 60W y y B J t B v B 4 J 4 Stop lamp Tail lamp L L 12V 23 N 12V SW G G 0 0 Gy Gy Ki ll Switch B R W t Spark plug B Y ______ R W B B Ignition coil B W Fig 7 2 54 ...

Page 61: ...n fram between t he points to remove residue Repea t th is procedure untiI the points are clean _ 0 Fig 8 1 b Remove the spark plug and cylinder holding nut I Fig 8 2 c Install the dial indicator holder on the bolt Put the dial indicator into the indicator and lock it with the bolt Install the dial gauge on the dial indicator and insert the adapter into the dial gauge then adjust the ignition timi...

Page 62: ...wi ll also be correct When tl le rnark on tt1e f lywheel aIigns w i th tl1e pointer on tl1e stator a spark is produced With the earn advanced Wl1e1 1 tl1e mark o r the flywl1eel magneto aligr1s with tl1e pointer on tt1e dinamo stator a spark takes place with tl1e advanced ignit ion ti 111ing Po int r I Fig 8 9 j As illustrated when the mark on the flywheel magneto aligns with the pointer on the di...

Page 63: ...xture according to engine speed The regulator of t he diaphragm type carburetor plays a role similar to the float of the float type carburetor The fuel level in the float chamber is likened to the regulator internal pressure Accordingly the regulator internal pressure must be kept at a constant level just as the fuel level of the float chamber ty p carburetor because a proper air fuel mixture must...

Page 64: ...gh speed at a proper rate according to fuel consumption in the engine 2 To remove the carburetor disconnect fuel line pressure pulse line disconnect the pump operating rod and then loosen the carburetor from the cylinder Cleaning of the carburetor and any carburetor parts should be done in clean gasoline on solvent After any dirt of film build up has been removed all parts should be blown off with...

Page 65: ...ustment The idling speed should be set according to the following table Idling r p m SL292C 1 100 r p m I I I GP292B 1 100 r p m I For smooth idling the slow adjusting screw must be correctly set so that an optimum fuel air mixture may be fed to the engine The setting of the slow adjusting screw wil I greatly affect the engine performance from starting to acceleration in the range of low and mediu...

Page 66: ...d that the engine still runs smoothly This is necessary to prevent engine overheating _ Fig 8 18 u For adjt1stment follow the following steps 1 First back otit tt1e mair1 adjustir1g screw as specified 2 To adjust tl1e n1air1 adjusting screws run the snow n1obile at t1igt1 speed ar1d find tl1e rar1ge of selting posi tions number of turns ou t at wt1icl1 tl1e er1gi ne runs clear1ly Set tl1e 111ain a...

Page 67: ...ightened too much ENGINE MAINTENANCE Carburetion and Fuel System The main jet must be selected according to the temperature and altitude of the area where the snowmobile is operated For detaiIs on the main jet replacement procedure refer to the Technical Service Information which will be published later on Plug screw Main jet Fig 8 19 Replacing the Locked Main Jet Remove the plug screw To remove u...

Page 68: ...e spring in correct position for the guide of the 0 Do no t try to overhaul or replace the choke niechanisrn rec klessly If tl1e sl1aft is bent or tl1e lever is damaged can replace Be careful not to lose t he fric tion ball or t l1e spri11g After replaced the cho ke valve fixing screw s n1ust be hamn1ered firmly If not loose screw s rnay cause a fatal damage for the engine N ever forget to insert ...

Page 69: ...ontrol lever end is incorrect in height o Fuel pump operation is not smooth o Both carburetors do not synchronize 63 Remedy Remove inlet valve and clean it Replace inlet control valve When replacing it make sure the seat surface is free of scratches 1 Replace inlet control lever 2 Reinstall inlet control lever correctly Adjust the end of lever to the position as shown in Fig 8 23 Reinstall main di...

Page 70: ... place For cleaning gasoline should be used Solutions including alcohol acetone lacquer thinner benzol etc should not be used as cleaning agents for they will damage the synthetic rubber in the carburetor When the primer pump is used for the diaphragm type carburetor it should not be squeezed more than one time or an excess amount of fuel will be fed to the cylinder Fuel filter is attached in the ...

Page 71: ...etor throttle valve 2 Turn pump control lever so that it is set to the match mark on the oil pump Adjust can be made by turning the pump control rod nuts 3 After adjustment fully tighten the nuts by holding bottom nut while tightening top nut When fully open the carburetor mold as shown in Fig 8 25 and adjust to the marking Fig 8 26 At maximum stroke of the pump dismounted from the snowmobile I Th...

Page 72: ... I I 16 CAP blind I I 17 SCREW plug 18 I WASHER plain I I1 19 IJ OIAPHRAGM 1 2 1 3 4 5 6 0 0 c 0 0 0 _ 0 f Qo 0 0 0 20 I 25 I 23 i 9 24 l Fig 8 28 O ty Ref No 1 20 2 21 1 22 1 23 24 1 25 1 26 27 1 28 1 29 1 30 1 31 1 32 2 33 1 34 1 35 1 36 1 37 1 38 1 39 66 14 13 15 12 Description O ty SPRING main d iaphragm 1 SEAT spring 1 BODY pump 3 1 NUT lock 1 SCREW stop 1 SCREW panhead 6 0 RING 1 WASHER plai...

Page 73: ...l I I I I I I Marking Fig 8 29 ENGINE M INllENANCE Autolube Note 67 When the pump control lever reaches the maximum working range the center line of the lever and the marking on the case should be in line In this case the carburetor throttle valve is in the full open position I I I ...

Page 74: ...l PE delivery 3 240 1 I 3 SHIM plunger 5 8 10 0 1 U R 19 NOZZLE 1 I 4 PLATE adjusting 1 20 SHAFT pump control 1 5 WASHER spring 1 I 21 SHIM 1 _ 6 NUT 1 22 COVE A adj ust pulley 1 I 7 OIL SEAL S 10 21 5 1 23 Cl RCLI P E 9 1 8 PLATE starter 1 24 SCREW panhead 2 I 9 PIN cotter 1 25 LEVE A pump control 1 I 10 SCREW bind 1 26 WASHER plain 1 11 GASKET breather 1 27 WASHER spring 1 I I _ 12 I BALL 5 32 i...

Page 75: ...en top and bottom should not exceed 0 002 0 05 mm If upon inspect ion of the cyl inder bore scoring of the cy Iinder wal I is observed hone or rebore untiI these scores d isappear Before assembly always clean the carbon from the exhaust port Also wash out the cy Iinder with solvent or soap and water to insure that al I hone materiaI has been removed Fai lure to do this may result in premature w ea...

Page 76: ... in the ring groove as shown in the illustration This is especially critical when instalIing the cylinder over the piston I II Fig 8 36 7 The up and down play of the pisto11 rings in tl1e piston ring groove should be checked witl1 a feeler gaL1ge Tolerar ce shoLrld be 0 001 0 0027 0 03 0 07 mm for both upper and lower rings 0 001 r J 0 002 L 0 03 0 07 111n1 Fig 8 37 8 Installing the piston The pis...

Page 77: ...ton to force the ring against the cylinder wall This action is considerably slower than that of the keystone type ring and will allow more blow by With blow by heat cannot be dissipated from the piston ring to the cylinder wall and as was mentioned earlier excessive combustion heat will cause the oil film to breakdown creating additional gum deposits The keystone ring sllows for much better heat t...

Page 78: ... tl1e ring end gap w ith a feeler gauge If the gap rneasured is in tl1e range of 0 0012 to 0 0020 0 3 to 0 5 mm tt1e ring is in satisfact ory condi tion If more than 0 0020 0 5 mm t he ring face is excessively worn Ren1ove the ring from the cyl inder and keep it in a free position Then measure the ring end gap If the gap measured is less than 0 0012 0 3 mm th e ring is con sidered to be fatigued w...

Page 79: ... may easily occur and in the worst case serious engine troubles may resu It 4 When a good seaI between the piston ring bottom and the ring groove bottom is noticed the piston ring is considered to smoothly slide in and out on the ring groove bot tom in a correct manner 8 5 4 Before replaci r1g the piston ring remove carbon accumu la tions from the gap between t he ring and the groove The piston ri...

Page 80: ...e removed and the secondary shaft greased This will keep the sheave from binding up from lack of lubrication 9 3 DRIVE BELT Tension of the drive belt is adjusted by maintaining a pre determined distance between the centers of the primary and secondary sheaves It should be 10 8 270 mm Adjustment is made by shifting the engine after loosening the four mounting bolts Note New belt width is 1 24 31 mm...

Page 81: ... moving the engine back and forth To move the engine tt1e four engine lower bracket mounting bolts should be loosened Fig 9 4 f Fig 9 5 F W O 111111 1 111 1111111 f j I I 4 How to set the off set between sheaves The sheave off set can be set by moving the engine sideways To move the engine the four engine upper bracket mounting bolts should be loosened Fig 9 6 Fig 9 7 __ F W D _ I _ 75 I ...

Page 82: ...Sheave off set Remove the V belt and allow the secondary sliding sheave to contact the secondary fixed sheave Then as iilustrated place the sheave gauge against inner sheave surfaces If the sheaves are parallel tt1e gauge will touch at all four spots see arrows Fig 9 8 I Sheave off set Fig 9 9 16 z I l lI I I I I I ...

Page 83: ...en measure the distance be tween the primary shaft and the secondary shaft by placing the 9 2 in 233 0 1 mm scale side of the sheave gauge between the shafts If both sheave shafts contact the sheave gauge at the positions indicated by arrows t he distance is correct Fig 9 10 Secondary shaft Sheave distance Fig 9 11 77 I Sheave gauge Sheave gauge Bearing Primary shaft I ...

Page 84: ...l tension check Fig 9 12 2 The cover located at the bottom of the chain case has a window in it to check for proper oiI level The oi I level should be topped up fill through the rubber oil filler tube to maintain the oil level near the top of the window Never let the oil level drop below the window bottom If the chain case oil is emptized completely then refill with 24 fl oz 710c c of 10W 30 motor...

Page 85: ...achine raised and make sure that the tension of the track is even at both sides If the tension is uneven it should be adjusted in the fo lowing manner A Sprocket wheel Rear arm Rear arm B A B N G A B When shifted to right Properly tighten the right track adjust screw and loosen the left track adjust screw 0 1 3 mm A 8 Good A B Fig 9 17 5 After the track tension is adjusted correctly the clearance ...

Page 86: ...e ski This wear plate should be greased often to reduce friction on the spring and wear plate 9 9 2 Parallelism of the skis is checked by measuring from center to center outside of one ski to inside of other ski Adjustment of parallelism is accomplished by adjusting the tie rod length Correct center to center distance of tl1e skis is 24 1 613 mm A B A B o 394 10 mm Fig 9 18 Note 80 Measure the dis...

Page 87: ...uaIity detergent automotive 1OW 30 oiI in that order of preference 2 The factory recommends Aeroshell Grease 7 which is a synthetic aircraft lubricant having a useful temperature range to 100 F 3 The factory recommends a molybdenum disulfide grease Shell Lithal MOS Grease and Aeroshell Grease 17 conform roughly to these specif ications 4 1OW 30 detergent automotive motor oil 5 The factory recommen...

Page 88: ...inches cu in Liters 2 Gallons gal u s U S gallons Imperial gallons 2 205 0 4536 0 061 16 387 0 264 3 785 1 2 4 546 Pounds Kilograms Grams g Ounces oz VOLUMES Cubic inches Imperial gallons c c Liters Q Gallons U S Quarts qt Liters Cubic centimeters c c Imperial gals FIuid ounces fI oz Liters 0 03527 28 35 77 26 1 057 0 946 0 0339 29 57 Ounces Grar11s cu in Quarts Liters Fluid ounces CC OTHER S Metr...

Page 89: ... MEMO I ...

Page 90: ...I I I II I _ i I I I I I I I I I I I I I I I l l l I i I I 1 1 I 1 1 7 I I I I I I I 1 I I l l1 I 1 l I I l I I 1 I I I J I LIT 12618 39 00 SINCE 1887 1 HAMAMATSU JAPAN r r I I I J i v _ PRINTED IN JAPAN 72 7 5 1x1 G ...

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