SAFETYNOTICEThisShopManual has beenpreparedprimarily foruse byprofessional snowmobilemechanics,whoare already familiarwithall serviceproceduresrelatingtoBombardier made snowmobiles,andsecondlytoassist themechanically oriented snowmobiler whohas limitedaccess toan au-thorizeddealer, or preferstoperformhis ownservicing. 'In eithercase, special tools must be used, whererequired, and a goodsense of safetynecessary.If indoubt, contact your dealer forassistance. 'Thismanuai emphasizes particular informationdenotedbythewordingand symbols;i+WARNING: Identifies an lnstructlonwhich, if not followed; could cause personal....r_.1 .,'CAUTION: Denotes an ifnot followed, Cbl,J19 severely .damage components.oNOTE: Indicatessupplementary informationneeded tofully complete an instruction.Although the mere reading of such information does not eliminate the hazard, your understandinqof theinformation will promoteitscorrectuse. /"/"(':,;'cllmproperbelt,ahgle. ". .: in' drive',pulley'.causeqby:"a(Frozenortoo tighttrack:b)RusteddriveofsJriven , ,pulleyshf3fts. 'd)Incorrectcentrifugal' 'governor"CAUSEExcessive slippagecaused"by:a) Insufficient pressure onbeltsides.Considerable.. use ..'3."Beliwornexcessively intop width., ,(DFlIVE'S'ELTl;PAGE 2SECTION02SUB-SECTION02 (DRIVEBELT)5. Belt sides wornconcave.~ 0"9'''' "9".CAUSE REMEDYIa) Roughorscratchedpulley a) Repair orreplace.1'1surfaces.b)Unspecifiedtypeof belt. b) Replace belt withcorrect).\Bombardier belt..6. Belt desintegration. .)CAUSE REMEDYIa) Excessive belt speed. a) Usingunspecifiedtypeof? belt. Replace belt with~~ I ) ~proper typeof belt.b)Oil onpulleysurfaces. b)Clean pulleysurfaceswith~ ~ ~ ,fineemeryclothandlubri-catewithlowtemperaturegrease.c) Incorrectgearratio. Install specifiedsprocket(correct gearratio),7. Belt edge cordbreakage.{~CAUSE REMEDY-,J Q ~a)Pulley misalignment. a) Alignpulleys.IJ ' l ~I8. Flex cracksbetweencogs.,CAUSE REMEDYa)Considerableuse,belt a) Replace belt.I..wearingout.0,9. Shearedcogs, compressionsectionfractureortorn.,\CAUSE REMEDYa) Improperbelt installation. a) Refer to Installationsection.Ib)Beltrubbingstationary b) Checkdrivecomponents.object onpulleys.c) Violent engagement of c) Grease, replace springordrivepulley. drivepulley ....(DRIVEBELT), PAGE 3SECTION02SUB-SECTION02(DRIVEBELT)10. Belt "Flip-Over"athigh speed.(DRIVEBELT), PAGE4CAUSEa) Pulley misalignment.b)Belt excessive speed.c) Incorrectsprocket ratio.REMEDYa) Alignpulleys.b)Usingunspecifiedtypeofbelt. Replace belt withcorrect Bombardierbelt.c) Install specifiedsprocket(correct gearratio).c((IWARNING: Drivepulley repairsthat include anyIdissassembly or assemblyprocedures must beperformed by an authorized Bombardier dealer, orothersuchqualifiedperson. Sub-component in-stallationandassemblytolerancesrequirestrictadherence toprocedures detailed.SECTION 02SUB-SECTION 03 (DRIVE PULLEY)IDRIVEPULLEYROLLERROUND SHAFT TYPEElan andSpirit1. Retaining bolt2. Washer3. Governor cup4. Slidinghalf ess'v5. Spring6. Springseat7.Bearing8. Fixed half9. Nut10. Counterweight11. Shouldered pin12. Bushing13. Roller14. Shim15. Shim(DRIVEPULLEY),PAGE 1SECTION 02SUB-SECTION 03 (DRIVE PULLEY)REMOVALWith engine cold, remove spark plug(s) then bringP.T.O. (Power TakeOff) pistonat T.D.C. (TopDeadCenter)position.Rotatedrivepulley45clockwisethen insert enoughstarter ropeintocylindertofill it completely.WARNING: Spring pressurecanforceassemblyapart; therefore, it is imperativethat thegovernorcupbeheld firmlyduringgovernorretainingboltremoval.Ifnecessary toremove fixedhalf, slide a lengthofsteelpipe over shaft. Attachwitha 5/16"nutand bolt, as il-lustrated. Thefixedhalf canthenberemovedwithapipe wrench.IApplyLoctite242or equivalent onthreadsthentorquenutsto14 N-m(10 ft-lbs)._ CAUTION: Do not disassemble counterweight un-.. less replacement is necessary.@Asrequired, maximumof two(Z). Used toobtainaneutral functionof thedrivepulleywhenengineis idl-ing: refer toINSTALLATION.@)Used toobtaincorrect pulley alignment,refer to sec-tion02-05.CLEANINGClean pulley faces and shaftwith fine steel wool and drycloth. Clean slidinghalf bushingwithclean dry cloth.INSTALLATION..............._--Protective sleeveLock crankshaft in position as explained in removal pro-cedure. Makesurecrankshaft isrotated45 counter-clockwise from T.D.C. position and that cylinder iscompletelyfilledwitha starterrope.Clean crankshaft extension threads andapply Loctite242 or equivalent theninstall fixedhalf on extension.Pack inside ofpulley shaftwithHigh PerformanceDrivePulley Lubricant.(........._ .....-5/16" boltDISASSEMBLY&ASSEMBLYCDAt assembly, lubetorquebolt to61 N-m(45 ft-lbsl, .@@ Shouldered pin bushings must be installed inslidinghalfas per illustration.0Bearingisreplaceableandcanberemovedandin-stalledwitha standardpuller andpusher.(DRIVE PULLEY), PAGp(Install governor cupcorrectlyas per illustrationmakingsure that therollers are slidingontheir ramp.0.80mmfeelergaugeSECTION 02SUB-SECTION 03 (DRIVE PULLEY)0.80mmfeelergaugePositionretaining boltthen lube torqueto61N.m (45ft-lbsl.WARNING: Shimis) islare) usedto obtain aneutral fonction of the drive pulley whenengine isidling. Proceedas followswhen retaining bolt istorqued:With a new drive belt installed,you should be able toin-sert aminimumof 0.80mm(,030") thick feelergaugeon each sideof the drive belt simultaneously whenpushingdrivebelt tositonbearing.Shim locatedbetweengovernor cup and drive pulleyshaft will help you to obtaincorrect adjustment. Use notmorethentwo(2) shims.(DRIVEPULLEY), PAGE3SECTION 02SUB-SECTION 03 (DRIVE PULLEY)ROLLER SQUARESHAFT WITHDURALONBUSHINGIOlympique, Nuvik, Citation,Everest, Futura, T' NTRV, Sonic, Elite312a((1. Fixed half2. Sliding half3. Guard4. Bolt5. Spring seat6. Spring7. Allen screw8. Hubplug9. Internal toothlockwasher10. Bolt11. "Durelon" bushing12. Governor cup(DRIVEPULLEY), PAGE412a. Elite model13. Lockingtab14. Retainingbolt15. Counterweight ass'y16. Ring gear (electricmodels)17. Screw18. Counterweight19. Bushing20. Shouldered pin21. Nut22. Roller(SECTION 02SUB-SECTION 03 (DRIVE PULLEY)WARNING: Drivepulleyrepairs that include anydisassembly or assembly procedures must be per-formed byanauthorized Bombardier dealer, orother suchqualifiedperson. Sub-component in-stallationandassemblytolerancesrequirestrictadherencetoprocedures detailed.Remove starter rope blocking piston, then reblockpistonafterhavingturned45 counter-clockwisefromT.O.C. position.Install puller inpulleyshaft thentighten, at thesame. timeknockslightlyonpuller headtodisengagepulleyfromenginecrankshaft.REMOVALDISASSEMBLY&ASSEMBLYINDEXINGMARKSINLINESomepulleycomponentsaremarkedtoinsureproperassembly. If components lack such marks, markingshouldbe donemanuallybeforedisassembly, as per il-lustration.CAUTION: Be careful wheninstalling sliding halfassembly on square shaft ofdrive pulley toavoidscratches on "Duralon" bushing caused by squareshaft edge.@ Torqueto85 Nm (63 ft-lbsl.@Apply"Loctite 242" on threads.I Some boltsof the drive pulleyhaving"Loctite" on theirthreads,it is advisable to use a tool such as an impact tobreak the"Loctite"seal beforeattempting tounscrew.@Torqueto7 N.m (5 ft-lbs).CD Apply "Loctite242" onthreadsthenscrewinuntilhead is flush withhubplug. Donot allowhead tobiteintohubplug.@@>At disassembly, hold hub plug firmly againstsliding half until thetwo (2) bolts arecompletely re-moved. This will prevent damage of the sliding halfthreads. At assembly, apply "Loctite 242"on threads ofboltsthentorqueto16 Nsrn(12 ft-lbsl.@Toinstall or remove "Duralon" bushing fromhubpluguse a suitable pusher andhammer orpress. Installbushingas per illustration.Governor cupoHub plug Sliding halfCDFixed halfWith engine cold, remove spark plugs then bringP.T.O.(Power TakeOff) pistonat T.O.C. (TopDeadCenter)position. Rotatedrivepulley45 clockwise theninsertenoughstarter rope intocylindertofill it completely.Open tab lock and remove retaining bolt. Removeslidinghalt assembly andgovernor cup.It isnecessaryto removefixed half, usedrive pulleypuller (See Tool Sectionl.ONOTE:On Citationmodel, fixed half is screwed in.Toremoveit, use a1 1/8"wrenchonthesquaresection, closelyheld against hub.(DRIVE PULLEY), PAGE 5 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ - - - - - - - - : - - - - - - - - - - - _ . _ . ~ - - - - - ~ - - - - - - - _ . _ - - _ . - - - - ~ - . - - ~ _ .SECTION 02SUB-SECTION 03 (DRIVE PULLEY)(@Some drive pulleys have an offset in thehub plug.Shouldered pin bushings with shoulder must be in-stalled in thesehubplugs.Insideof sliding half should becleanedwith acleancloth. Thesquareshaft canbe cleanedwithfinesteelwool and a cleancloth.(Push on slidinghalftowardsgovernor cuptoremoveall possible slackwhenmeasuringINSTALLATIONClean crankshaftextensionusingfinesteel wool andaclean cloth.CAUTION: When installing drive pulley on engine,referencemarkonfixedhalf, slidinghalfandgo-vernor cupmust be inline.Lock crankshaft in position as explained in removal pro-cedure. Make surecrankshaft isrotated45 counter-clockwise from T.D.C. position and that cylinder iscompletelyfilledwitha starter rope.Install fixedhalf oncrankshaft extensionthenpositionslidinghalf assemblyonfixedhalfsquare shaft.CAUTION: Be careful wheninstallingslidinghalfassembly on square shaft of drivepulley toavoidscratches on " Duralon" bushingcaused by squareshaft edge.Install governor cup making sure that the shaft end restsingovernorcupseating. Positionretainingbolt withanewlockingtabthentorqueto85 Nom (63 ft-lbs).CAUTION: Incorrect seating of shaft end in gover-nor cup can cause crankshaft bending. Whenpul-leyis completelyassembledalwaysmeasure dis-tanceof bothpulleyhalves tomake sure that thepulleyisproperlyinstalled. Distancemust be 76mm(3").Teflonimpregnatedcloth'TeflonI impregnatedclothGOODTefloncoatingGOODWORN (must be changed)OffsetBushinglocationinrelationwiththeoffsetINSPECTION& CLEANINGDrivepulleyshouldbe inspectedannually.Checkgeneral conditionof pulleyandinspect "Dura-Ion"bushingfaces, as per illustrations.@ Apply "Loctite242" onthreadsandtorqueto14Nom (10 ft-Ibsl.CAUTION: Do not disassemblecounterweightsunless replacement is necessary.TeflonimpregnatedclothCloths is scratchedortornand. fiberglass backingis visibleLiftrear of vehicleoff theground. Install drive beltandpulleyguardthen start engineandapply throttleandbrake, 2-3times. Stop engineandretorque retainingbolt. Bend one side of lockingtabover governorbolt.((DRIVEPULLEY!, PAGE 6SECTION 02SUB-SECTION 03 (DRIVE PULLEY)ROLLER SQUARE SHAFT BEARING TYPEWITHDURALONBUSHINGAlpine7II@cbJ6I7. Retaining bolt2. Tab washer3. Governor cup4. "Dureton" bushing5. Slidinghalf6. Spring7. Fixed half8. Ring9. Bearing70. Spring seat77. Stopnut72. Counterweight73. Shouldered pin74. Bushing75. Roller76. Spacer77. Set screw78. Shim(DRIVEPULLEY), PAGE 7SECTION 02SUB-SECTION 03 (DRIVE PULLEY)(r- ~ . ' . ~Bearingseparator(cTorque shouldered pinlock nut to 14 Nsrn(10 ft-lbs)after having applied "Loctite 242" or equivalent onthreads.CAUTION: Do not disassemble counterweightsunless replacement is necessary.@Apply"Loctite242" onthreads thenscrewinuntilhead is flushwithslidinghalf.CAUTION: Be careful wheninstallingslidinghalfassemblyonsquareshaft of drivepulleytoavoidscratches on "Duralon" bushingcaused by squareshaft edge.@Toremoveandinstall use abearingseparatorand afterwards a standardpullerandpusher.o NOTE: Items shouldbe press-fittedtogeth-er. Do not remove inner half bearing unlessdamagedandreplacement is necessary.WARNING: Drivepulley repairsthat includeanydisassemblyor assemblyprocedures must be per-formed by anauthorized Bombardier dealer, orother suchqualifiedperson. Sub-component in-stallation and assembly tolerances require strictadherencetoprocedures detailed.If it is necessary toremovehalf, use a 1 1/8"open-endwrenchon the square section, closely held againsthub.DISASSEMBLY&ASSEMBLY"U" clampPush and turndrive pulley to disengage "U" clamp thencarefullyremoveslidinghalf.WARNING: Springpressurecanforce assemblyapart; therefore, it is imperative that thegovernorcupbeheld firmlyduringslidinghalf removal.Some boltsofthe drivepulleyhaving"Loctite" on theirthreads, it is advisable touse a tool such as an impact tobreak the"Loctite"seal beforeattemptingtounscrew.(!)Torqueto118 N.m(87 tt-lbsl.0Toinstall orremove"Duralon"bushingfromhubpluguse a suitablepusher andhammeror press. Installbushingas per illustration.With engine cold, remove spark plugs thenbringP.T.O.(Power TakeOff) piston at T.D.C. (TopDeadCenter)position.Rotatedrivepulley 45clockwisethen insert enoughstarter rope into cylinder tofill it completely. Install "U"clamp (SeeTools Section) over pulley halves. Openlockingtabandremoveretainingbolt.REMOVAL(DRIVEPULLEY), PAGE8r ~ o r -~ ~ ~ - - - - ~ - - - - - -- - - , . - - _ . _ - - - - - ~ . _ - - - ~ _ . _ - - - - - ~ . _ . _ - - - - - ~ - - - - - - ~ - - = _ . -SECTION 02SUB-SECTION 03 (DRIVE PULLEY)INSPECTION& CLEANING INSTALLATIONDrivepulleyshouldbeinspectedannually.Checkgeneral conditionof pulleyandinspect "Dura-Ion" bushingfaces, asper illustrations.TefloncoatingGOODTeflonimpregnatedclothLockcrankshaft in position as explainedin removal pro-cedure. Makesurecrankshaft isrotated 45counter-clockwise from T. D. C. position and that cylinder iscompletelyfilledwithstarter rope.Install fixedhalf oncrankshaft extensionthenpositionslidinghalf assemblyonfixedhalf squareshaft.CAUTION: Be careful wheninstallingslidinghalfassemblyonsquareshaft of drivepulleytoavoidscratcheson "Duralon" bushing caused by squareshaft edge.Install governor cup makingsure that the shaft end restsingovernorcupseating.Insideof sliding half should becleanedwith acleancloth. Thesquareshaft canbecleanedwithfinesteelwool anda cleancloth.CAUTION: Incorrect seatingof shaft end in gover-nor cupcan cause crankshaft bending.When pul-leyiscompletelyassembledalwaysmeasuredis-tanceof bothpulleyhalves tomakesure that thepulley isproperlyinstalled. Distance must be 97mm(33/16").Lubricatethreads of retainingbolt with antiseizinglubri-cant. Positionretainingboltwitha new locking tab thentorqueto118 N.m(87 tt-lbs). Bend one side of lockingtaboverretainingbolt head.TellonimpregnatedclothClothis scratchedortornandfiberglassbar:'kingis visibleGOODWORN (must be changed)Teflonimpregnatedcloth(DRIVE PULLEy!' PAGE 9~ ~ ~ ~ - ~ - - - - - - - - ~ , - - - - - - - - - - - - - - ~ - - - - - - ~ - - - ._-.,....,...,.,SECTION02SUB-SECTION03(DRIVEPULLEY)SQUARE SHAFT WITHTHREE COUNTERWEIGHT ASSEMBLIESI7. Retainingbolt2. Lockingtab3. Governor cup4. Bolt5. Bolt6. Lockingtab7. Ramp8. Bolt9. Internal toothlockwasher70. "Durelon" bushing77. Hub plug72. Allen screw73. Spring(DRIVEPULLEY), PAGE 10Blizzard 6500Plus374. $piing seat75. Bolt76. Guard(rollers)77. Slidinghalf78. Fixed half79. Nut20. Counterweight27. Nylonwasher5.7mm(.200")22. Shouldered pin23. Roller24. Nylonwasher 3.3 mm(.730")25. Bushing(.C i/SECTION02SUB-SECTION03(DRIVEPULLEY)WARNIN4: Drivepulleyrepairsthat includeanydisassembly or assembly procedures must be per-formed by anauthorized Bombardier dealer, orother suchqualifiedperson. Sub-component in-stallation and assembly tolerances require strictadherencetoproceduresdetailed.REMOVALSomepulleycomponentsaremarkedtoinsureproperassembly. If components lack such marks, markingshouldbe donemanuallybeforedisassembly, as per il-lustration.Install puller inpulleyshaft then tighten, at thesametimeknockslightlyonpuller headtodisengagepulleyfromenginecrankshaft.DISASSEMBLY&ASSEMBLYSome boltsofthedrive pulleyhaving"Loctite" on theirthreads, it is advisable to break the "Loctite" seal beforeattemptingtounscrew.G)Torqueto85 Nom (63 ft-Ibs).00Install rampsand torquebolts asper illus-tration.INDEXING MARKSINLINETorqueto12N.m(9 ft-lbs)Bend lockingtab overthe 2 boltsRamp@ At disassembly, hold hubplug firmly againstsliding half until the three (3) bolts are completelyremoved. Thiswill prevent damageof thesliding halfthreads. Atassembly,apply"Loctite 242"on threads ofboltsthentorqueto16 Nom (12 ft-lbs).@@@ To install or remove "Duralon" bushing fromhubplug, use a suitablepusher andhammer or press.Install bushingas perillustration.Governor cupoHubplugCDFixed halfSliding halfWith engine cold, remove spark plugs thenbringP.T.O.(Power TakeOff) piston at T.D.C. (TopDeadCenter)position.Rotate drive pulley 45clockwisethen insert enoughstarterropeintocylindertofill it completely.Opentablockandremoveretainingbolt.Removeslidinghalf assemblywithgovernorcup.Toremove fixedpulleyhalf, use drive pulley puller. (SeeToolsSection).ONaTE:Remove starter ropeblockingpiston, thenreblock piston after having turned 45counter-clockwisefromT.D.C. position.I.'J(DRIVEPULLEY), PAGE11SECTION02SUB-SECTION03(DRIVEPULLEY)(TeflonimpregnatedclothTeflonimpregnatedclothClothis scratchedortornandfiberglass backingis visibleGOODGOODWORN (must be changed)TeflonimpregnatedclothINSTALLATIONInsideof sliding half should becleanedwith acleancloth. Thesquare shaft canbe cleanedwithfinesteelwool and a clean cloth.Clean crankshaftextensionusinqfinesteel wool andaclean cloth._ CAUTION: Wheninstallingdrive pulley on engine,.. referencemarkon fixedhalf, slidinghalf andgo-vernor cupmust be in line.Lock crankshaft in positionas explained in removal pro-cedure. Makesurecrankshaft isrotated 45counter-clockwise from T.D.C. position and that cylinder iscompletelyfilledwitha starter rope.Install fixedhalf oncrankshaft extensionthenpositionslidinghalf assembly onfixedhalf square shaft._ CAUTION: Be careful wheninstallingslidinghalf.. assemblyon square shaft of drivepulleytoavoidscratches on "Duralon" bushingcaused by squareshaft edge.Install governor cup making sure that the shaft end restsingovenor cupseating. Positionretaining bolt withanewlockingtabthentorqueto85 N.m(63 ft-lbs).Tefloncoating ---NarrowwasherINSPECTION&CLEANINGDrivepulleyshouldbe inspectedannually.Checkgeneral conditionof pulleyandinspect "Dura-Ion" bushingfaces, as perillustration."Duraton" Apply "Loctite 242" on threads, then tighten untilscrew slightly rests against bottom of "Duralon"bushinghole._ CAUTION: Be careful wheninstallingslidinghalf... assemblyon square shaft of drivepulleytoavoidscratcheson "Duralon"bushing caused by squareshaft edge.@Torqueto5 Nsrn(4 ft-lbs).@@At reassembly, apply "Loctite 242"on threads andtorqueto16 N.m(12 ft-lbs)._ CAUTION: Do not disassembly counterweight un-.. less replacement is necessary.@@@Rollersandnylon washers must movefreely;install themas per illustration.IDRIVE PULLEY), PAGE12CAUTION:Incorrect seatingof shaft end in gover-nor cupcan cause crankshaft bending. When pul-leyis completelyassembledalwaysmeasuredis-tanceof bothpulleyhalves tomake sure that thepulley isproperlyinstalled. Distancemust be76mm(3"),SECTION02SUB-SECTION03(DRIVEPULLEY)Push onslidinghalf towardsgovernor cuptoremoveallpossible slackwhenmeasuringLift rear of vehicleofftheground. Install drivebelt andpulley guard then start engineandapply throttleandbrake, 2-3times. Stop engine andretorque retainingbolt. Bendonesideof lockingtabovergovernorbolt.IDRIVEPULLEY), PAGE13SECTION 02SUB-SECTION 04 (DRIVEN PULLEY)DRIVENPULLEYTYPE1Elan and Spirit1. Fixed half2. Slidinghalf3. Release spring4. Outer cam5. Cam slider shoe6. Roll pinREMOVALRemove pulleyguard, drivebeltandmuffler.Slacken steeringcolumnbolts.Releasechaintension. Remove cotter pinandnut se-curingpulleydrive shaft tochaincase.o NOTE: Attachtoframe toprevent itfallinginsideof chaincase.Pull drivenpulleytowardengineandremovefromve-hicle.DISASSEMBLY &ASSEMBLYIn order to measuredriven pulley spring tension,pulley halves must beseparated. To do this, insertlengthof 1/8"dia. rodbetweenthehalves. Cheekten-sionusinga fishscale positioned900withpulleyaxle.. (Refer toTechnical Data for correct springtension).To correct springtension, eitherrelocate springendinslidingpulleyhalf orgraduallyrotateoutercam.INSTALLATIONWithdrivechaintensionreleased, holdupper sprocketand chain in position then insert assembled drivenpulley shaft throughchaincase and sprocket.Install springwasher and castellatednut.Tightencastellatednut fullythenbackoff nut 1/6 of aturn.Lockinpositionwitha newcotterpin._ CAUTION: It isimportant that nut isbacked off orY damage may occur due to a burnt or seized bear-ing.Applychaintension.Install muffler andtightensteeringcolumnbolts.Install drivebelt andpulleyguard.(DRIVENPULLEY),PAGE 1SECTION 02SUB-SECTION 04 (DRIVENPULLEY)TYPE 2Olympique, Nuvik,Citation1. Fixed half2. Sliding half3. Release spring4. Outer cam5. Cam slider shoe6. Roll pin7. Disc8. Bolt9. Spacer(REMOVALRemove pulleyguardanddrivebelt.Remove brakeassemblyandtool box.Remove chaincasecover.Remove air silencer boxandcarburetor.Releasechaintensionthen removecotterpinand cas-tellatednutsecuringdriven pulley to chaincase. Pulloutdrivenpulleyassembly.DISASSEMBLY&ASSEMBLYIn order tomeasure drivenpulleyspringtension, the.pulley halvesmust beseparated. Todothis .. insert alengthof 1/8"dia. rodbetweenthehalves. Check ten-sionusingafishscalepositioned900withpulleyaxle(Refer toTechnical Data for correct springtension).IDRIVEN PULLEY), PAGE2Tocorrect springtensioneither relocatespringendinslidingpulleyhalf, orgraduallyrotateouter cam.INSTALLATIONWithdrivechaintensionreleased, holduppersprocketand chain in position then insert assembled drivenpulleyshaft throughchaincaseand sprocket.Install springwasherandcastellatednut.Tightencastellatednut fullythenback offnut 1/6" ofaturn.Lockinpositionwitha newcotterpin._ CAUTION: It is important thatnut is backed off or.. damagemayoccurdue toa burntor seized bear-ing.Applychaintension. Positionchaincasecover andre-plenishwithchaincaseoil.Install brake assembly andtool box.Install carburetorandair silencerbox.Install drivebelt andpulleyguard.1 2 - ~I~ - ~~ I -r I C\. p13 15~14 I16 .1. Fixed half2. Sliding half3. Releasespring4. Outer cam5. Cam slider shoe6. Roll pin7. Disc8. BoltREMOVALRemove pulleyguardanddrivebelt.Detach driven pulley support from upper column .bracket.Remove brake assembly andtool boxorbattery.Remove chaincase cover.2SECTION 02SUB-SECTION04 (DRIVEN PULLEY)TYPE 3.Everest, Futura, TNT,RV, Sonic799. Spacer(Everest, Futura andTNT)10. Support11. Snap ring12. Nut13. Bracket14. Retainer pin15. Hair pincotter16. Hair pinretainingwire.Remove air silencer boxand carburetor.Releasechaintensionthenremovecotterpin and cas-tellated nut securing driven pulley to chaincase. Pull outdrivenpulleyassembly.(DRIVENPULLEY). PAGE 3SECTION 02SUB-SECTION 04 (DRIVEN PULLEY)DISASSEMBLY&ASSEMBLY01nordertomeasure drivenpulleyspringtension, thepulley halvesmust beseparated. Todothis, insert alengthof 1/8" dia. rodbetweenthehalves. Checkten-sionusinga fishscalepositioned900withpulleyaxle.(Refer toTechnical Datafor correct springtension).Tocorrect springtensioneither relocatespringendinslidingpulleyhalf, orgraduallyrotateoutercam.@) Toremovedrivenpulley support itmay be necessarytouse a puller.(DRIVENPULLEYI, PAGE4INSTALLATIONWithdrivechaintension released,holduppersprocketand chain in position then insert assembled drivenpulleyshaft throughchaincaseandsprocket.Install springwasher andcastellatednut.Tightencastellatednut fully thenbackoff nut 116 of aturn.Lockinpositionwitha newcotterpin._ CAUTION: It is important that nut is backed off or.. damagemayoccur duetoa burnt or seized bear-ing.Applychaintension. Positionchaincasecover andre-plenishwithchaincaseoil.Install brakeassemblyandtool boxorbattery.Install carburetorandairsilencer box.Connect driven pulley support to steering upper col-umn.Install drivebelt andpulleyguard. \-\(./(" . ~ I114111177. Fixed half2. Sliding half3. Release spring4. Outer cam5. Cam slidershoe6. Roll pin7.Disc8. Bolt9. Spacer (support)70. SupportSECTION 02SUB-SECTION 04 (DRIVENPULLEY)TYPE 4Blizzard6500Plus877. Snapring72. Nut73. Ball joint74. Bracket75. Retainer pin76. Hair pincotter77. Hair pinretaining78. Lockwasher79. Bolt(DRIVENPULLEY).PAGE 5SECTION 02SUB-SECTION 04 (DRIVEN PULLEY)REMOVALRemovepulleyguardanddrivebelt.Detachdrivenpulleysupport fromenginebracket.Removebrakeassemblyandtool box.Remove chaincasecover.Remove air silencer boxandcarburetors.Releasechaintension thenremovecotterpinandcas-tellatednut securingdrivenpulley tochaincase. Pulloutdrivenpulleyassembly.DISASSEMBLY & ASSEMBLY(DInordertomeasure drivenpulleyspringtension, thepulley halvesmust beseparated. Todothis, insert alengthof 1/8" dia. rodbetweenthehalves. Check ten-sionusinga fishscalepositioned900withpulleyaxle.(Refer toTechnical Datafor correct springtension).Tocorrect springtension either relocatespringendinslidingpulleyhalf, orgraduallyrotateouter cam.@) Toremovedrivenpulleysupport itmay be necessarytouse a puller.(DRIVENPULLEY), PAGE6INSTALLATIONWithdrivechaintensionreleased, holdupper sprocketand chain in position then insert assembled drivenpulleyshaft throughchaincaseandsprocket.Install springwasher andcastellatednut.Tightencastellatednut fully thenbackoff nut 116 of aturn.Lockinpositionwitha newcotter pin._ CAUTION: It is important that nut is backed off or damagemayoccur duetoa burnt or seized bear-ing.Applychaintension. Positionchaincasecover andre-.plenishchaincaseoil.Install discbrakeassemblyandtool box.Install carburetorandairsilencer box.Connect drivenpulleysupport toenginebracket.Install drivebelt andpulleyguard.(((1. Fixed half2. Sliding half3. Release spring4. Outer cam5. Cam slidershoe6. Roll pin7. Drive shaft (transmission)8. Spacer9. Bearing10. Support11. Disc12. Spring13. Rollpin14. ShimREMOVALRemovepulleyguardanddrivebelt.Removediscbrakeassembly.Positiona woodenblockunderthedriveshaft thenus-ing a hammerand a pinpunch, removerollpin @lock-ing disc in position. Tapon inner sideof brakeandbracket assembly todisengageit frombearing.Remove exhaust manifoldfromengine.Removelower bracket of steeringcolumnattachedtothe gearbox. Slacken upperbracketof steeringcolumn.Disconnect transmissionrodfromgearbox.Removegearboxupper housing.Release chain tensionthen separate chain at connectinglink.Withdrawdrivenpulley.DISASSEMBLY&ASSEMBLYCD01f necessary heat hub of fixed pulley and outercamtofacilitateremoval.SECTION 02SUB-SECTION 04 (DRIVENPULLEY)TYPESAlpine12@JInorder to measuredriven pulley spring tension, thepulley halvesmust beseparated. Todo this, insert alengthof 1/8"dia. rodbetweenthehalves. Checkten-sionusinga fishscalepositioned900withpulleyaxle.(RefertoTechnical Datafor correct springtension).Tocorrect springtensioneither relocatespringendinslidingpulleyhalf, orgraduallyrotateoutercam.(DRIVENPULLEY), PAGE 7SECTION 02SUB-SECTION 04 (DRIVEN PULLEY)INSTALLATIONPositiondriveshaft of assembleddrivenpulleysothatretainer washersalignwithslotsof gearboxcasing.Retainer washerApply athin coat of "Loctitecrankcase sealant", orequivalent, oncontact surfaceof gearboxcasing.Instal gearboxcoverand secure with eight nuts. Torquenutsto27 N.m (20 It-los) in thefollowingsequence:(('-.Install gearboxrodandadjust. (See Section02-07),Install steeringcolumn.Install drivebelt andexhaust manifold.Install brake assemblyandbracket. Install rollpinsecu-ringdisctoshaft.Adjust chaintension. Checkgearboxoil level.Checkpulleyguard.Connect drivechainusinga connectinglink.The locking clipshouldbe installedoppositelytodrivenpulley.Position gear change fork ingearbox cover sothat italignswithslot of slidinggearingearhousing.Gearchangefork(DRIVENPULLEY), PAGE 86048o27305(SECTION 02I SUB-SECTION 04(DRIVEN PULLEY)t. Fixed half2. Slidinghalf3. Releasespring4. Roll pin5. Outer cam6. Cam slider shoe7. Drive shaft(transmission)8. DiscICD9. Spacer10. Supportn. Nut12. Hairpinretainingwire13. Support14. Retainer pin15. Hair pin cotter16. Roll pinTYPESREMOVALRemove pulleyguardanddrivebelt.Detachdrivenpulleysupport.Remove exhaust manifoldfromengine.Disconnect transmissionrodfromgearbox.Remove gearboxupper housing.Release. chain tension then separate chain at connectinglink.Withdrawdrivenpulleywithdriveshaft.(DRIVENPULLEY), PAGE9SECTION 02SUB-SECTION 04 (DRIVEN PULLEY)DISASSEMBLY & ASSEMBLYCD@lf necessary heat hub of fixed pulley andoutercamtofacilitateremoval.(DInordertomeasure drivenpulleyspringtension, thepulley halvesmust beseparated. Todothis, insert alengthof 1/8"dia. rodbetweenthehalves. Check ten-sionusingafishscalepositioned900withpulleyaxle.(Refer toTechnical Datafor correct springtension).Tocorrect springtension either relocatespringendinslidingpulleyhalf, orgraduallyrotateouter cam.INSTALLATIONPositiondriveshaft of assembleddrivenpulleysothatretainerwashersalignwithslotsof gearboxcasing.Retainerwasher(DRIVENPULLEY), PAGE10Connect drivechainusinga connectinglink.Thelockingclipshouldbe installedoppositely todrivenpulley.Position gear change fork ingearbox cover sothat italignswithslot of slidinggearingearhousing.Gear changeforkSlidinggear slotApply athin coat of "Loctitecrankcase sealant", orequivalent, oncontact surfaceof gearboxcasing.((cInstall gearboxcover andsecurewitheight nuts. Tor-que nuts to 27Nsrn (20It-lbs) in the following se-quence:SECTION 02SUB-SECTION 04 (DRIVEN PULLEY)6048o7Adjustchaintension. Check gearboxoil level.Install gearboxrod and adjust. (See Section02-07).Installexhaust manifoldtoengine.Install drivenpulleysupport.Install drivebelt and checkpulleyalignment.Install pulleyguard.lDRIVENPULLEYl, PAGE11, i'- - ~ - - - ~ - - -(((; ,SECTION 02SUB-SECTION05 (PULLEY ALIGNMENT)i PULLEY ALIGNMENTOFFSET ADJUSTMENT'--- WoodenruleDISTANCEADJUSTMENTToobtainmaximum vehicleperformance,adjust pulleydistanceas follows:1. Adjust pulleydistancetonominal distance. (Refer toTechnical Data).2. Installa newdrivebelt onvehicle.Prior tofinal adjustment, thedrivebelt must have abreak-inperiodtimeof one totwominutes.3. The final adjustment of pulley distanceshould beperformed by using -the belt deflection method asfollows:- Positionreferencerule on drive belt. Using wood-enruleandfishscale, apply6.8kg(15pounds)pressure ondrivebelt.- Deflectionmust be 32 mm(1 1/4").WARNING:Always torque drive pulley bolt withinspecifications. (See Technical Data).All other modelsIfthedrivepulleyis toofar inortoofar out, it canbecorrectedbyslidingtheslottedenginesupport towardappropriateside.T T/IX"SquarebarLength48 cm(19 inch)- Dimension"X"must never exceeddimension"Y".- Dimension "Y" canexceeddimension "X" by 1.6mm(1/16").(Refer toTechnical Data for dimensionvalue).Elan, Spirit, Citation, AlpineIf drivepulleyis toofar in, removedrive pulleyand addshirnts)oncrankshaft.CAUTION: Never use more than 5 shims oncrankshaft. 21. Rotaryvalve gear22. Spring23. Springcup24. Circlip25. Bearing26. Oil seal27. Distancering28. Washer29. Water pumpimpeller30. Washer31. Nut32. Gasket33. Water pumphousing34. Sealingring35. Bolt36. os tank37. Hoseclamp38. Gasket39. Oi! tankcap40. Grommet41. Hoseconnector42. Hoseclamp43. Hose 41 em44. Hose18em45. Spring,t""'.t....SECTION04SUB-SECTION02, (ENGINES)ROTARYVALVE&WATER PUMPREQUIREDTOOLSCLEANING1978444 type: 1400BTDCopening510ATDCclosingMARKHERE- h f - - - ~Fromtopedge of magnetoside inlet port, markcrank-case at 510.Using angle finder, mark crankcase at 1400frombottomedge of magnetoside inlet port.ApplyLoetite515Angle finder(4143529)Rotary valve adjustment with replaced crankcasehavingno timingmarks.Bearing -"'lUDISASSEMBLY&ASSEMBLYTDCgauge(414 1047)0Torqueto20 Nm(15 tt-lbs).0ApplyLoctiteLock'nSeal 242 onthreads.(?)At assembly, apply crankcasesealant (l.octite515)onbearingandrotaryvalve gear matingsurfaces.Discardall oil seals and "0"rings.fiemoveoldcrankcasesealant fromrotary valvegear,adjacent bearingandcapmatingsurface.Clean all metal components in a non-ferrous metalcleaner.1444 TYPEENGINE), PAGE13SECTION04SUB-SECTION02, (ENGINES) (' ..,To correctly install the rotary valve discproceed asfollows:Turningcrankshaft counter-clockwise, (drivepulleyside)bringmagnetoside pistontoTopDeadCenterusinga T.D.C. gauge.- Positiontherotaryvalvediscongear tohave edgesas closeas possibletothemarks.ONOTE: The rotary valve disc is asymmetrical,therefore, at assembly trypositioning each side ofdisc on gear to determine best installationposition.If it isnecessary todisassemblecomponentsof rotaryvalve shaft assembly, install assembly carefullyin a visecompressingspringcup @in order to remove circlip@.Magnetosidepistonmust be at T.D.C.Timingmark@Clean rotaryvalve shaft and inside of distance sleeve.At assembly, apply Loctite Lock'n Seal 271 insideofdistancesleeve.@Usingasuitable pusher, pushwater pump bearingwithshieldfacingrotaryvalvedisc.@@From water pump side, using a suitable pusher, in-stall oil seals (withlithiumgrease on lips) as per illustra-tion, keepinginmindthat:- distanceringopeningmust be in line withcrankcasedraininghole.- 35%of theareabetween first andsecondoil seal(first oil seal beingflushwithcrankcase)must be fill-ed withlithiumgrease orequivalent.(Distanceringopeningi..'Distance ringi 4 ! W ~ ~ ~ - Third oil sealFirst oil seal Second oil seal@Apply LoctiteLock'nSeal 242 onthreads.@through @Rotaryvalve shaft assembly.Toremoverotaryvalve shaft assembly fromcrankcase,first removewaterpumpimpeller @andcirclip.@Position special puller over shaft bore and screwpuller bolt intorotary valveshaft. Whileholdingpullerbolt, turnpuller nut clockwiseuntil shaft comesout.(444TYPEENGINE), PAGE14SECTION0402 (ENGINES) SUB-SECTION ,TOPEND0)51632gasket I' tier/crankcase 1 Cytlnu.

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0-43,I(TILLOTSON- HRMTYPE), PAGE1SECTION04SUB-SECTION05, (CARBURETOR)(:.t.j(thenpush tab down Depress here...Depress here...TOOLOWTOOHIGHCLEANING&INSPECTIONPump detector until inlet needlerelease pressureisreached(suddenpressuredrop), thenobservegaugereading; thesystemmust staypressurized.If pressuredrops completelythecause shouldbe investigated.Immerse carburetorin clean gas thenpressurize it toapressure lower thantheinlet needle releasepressure.The entirecarburetor shouldbe cleaned witha generalpurposesolvent anddriedwith compressed airbeforedisassembly.WARNING: Solvent with a low flash point such as. gasoline,naphtha, benzol, etc., shouldnot be us-ed as theyare flammableand explosive.Carburetor bodyand metal parts shouldbe cleaned in acarburetor cleaner solution following manufacturer'sinstructions.Check inlet needle tipcondition. If worn, theinlet nee-dle and seat must be replaced as a matchedset.Inspect all diaphragms. They shouldbe free ofholes orimperfections. Replace as needed.After assembly, leaktest carburetor asfollows: withboth idle speedand high speedadjustment screwsopenedandfuel returnoutlet plugged, connect a leakdetector tothefuel inlet. (See ToolsSection),r . : : : : : : ~ ~ 1 - Primary venturiAt assernblv.rensure theshutterhole faces down.Applya coat of "Loctite242" onthreads.@Springshouldbe woundclose to1/2 a turn.@The throttle shutter sides are slightlyangled to matchthecarburetor borewhenclosed. At assembly, makesure shutter is correctlypositioned.@) Adjust fulcrumlever so that thecenterof lever con-tactingthe meteringdiaphragmis flush withthemeter-ing chamberfloor.Metering chamber floorDISASSEMBLY&ASSEMBLYCDTest main nozzle check valve operationby alternatelyapplyingpressure andvacuumwith themouthonthesectionlocatedoncarburetorventuri side.The checkvalve must holdunderpressure andreleaseunder a vacuum. Exercicecarewhen pulling chokeshaft fromcarburetor. Frictionball and spring can "fly out"of thecasting.At assembly, position springfrictionball intocasting.Usingasuitable tool, depressfriction ball, at sametime, push chokeshaft intocarburetorbody.CD Primary venturi must be installedwith largest open-ingtowardfront of carburetor.Remove or disconnectthefollowingfromcarburetor:- air silencer- chokecable- throttlecable- fuel lines andpulsationlineOpen locktabs thenremovenutssecuringcarburetor.REMOVAL(TILLOTSON- HRMTYPE), PAGE2SECTION04SUB-SECTION05, (CARBURETOR)Low speedmixtureWith engine off, gently turn idlemixturescrewfullyclockwise until closed,thenback off 'l t/s turns+114-0counter-clockwise.CAUTION: When pulling heavy loads such as trailgroomer,it is strongly recommended to enrich theLow SpeedMixturebyturningthescrew1/4 of aturncounter-clockwise.Idle speedAllow engine to warmthenusing a screwdriver, turntheidlespeed adjustingscrewclockwisetoincrease idlingspeed, counter-clockwisetodecrease. Adjust to1500-1800 RPM.HighspeedmixtureA primaryadjustment, withengine off, shouldbe madeby firstturning high speed mixture screw fullyclockwiseuntil closed, thenback off1 1/4 turns +1/4 0 counter-clockwise.For final adjustment, start engineand allow it towarm.Drivethevehiclefor approximately1.6km(1 mile) at6,000RPM. (Thehighspeedjet will beoperational atthisRPM range). Stopthe engine immediately. Removespark plugandinspect plugface.Theplugfacewill indicatewhetherthemixtureis rich,normal orlean. Abrownishtipreflectsideal carburetoradjustment. Ablack insulator tipindicatesarichmix-ture. Light greyinsulator tipindicatesa lean mixture. Ifthemixtureisincorrect, readjust 1/8of aturn andre-checkcolor of sparkplugface.ONOTE:Thismethodappliedtoan enginein goodworkingcondition. If afteradjustment it is foundthereis considerabledeviationfromnominal set-ting, thecarburetor and/or theengine is malfunc-tioningandneeds repair.IMPORTANT: Whenoperatingthevehicleintempera-tureexceedingOC (32F), therubber plugmust blockthe engine side orifice and the rubber ventmust be posi-tionedonthesideof thesilencer boxtoallowcoldairAb""ok: .:.. .iQ . Side of I 1':1 'l I! : silencer.box'-"..n RUbber'.l ... Rubber plug In temperatures below OC (32F) and/or powdersnow, therubber plugmust blocktheentryof freshairon the side of the silencer box and the rubber vent mustallowthe warmair beingemittedfromtheenginetobedirectedoverthecarburetor .CAUTION: Observetemperaturechangesandlo-cate plugs accordingly. Incorrect location ofplugs.may causecarburetor ice-up or engine overheating.Idle speed screwl Fuel returninlet,Maximum throttleopeningWithengineoff andair silencer removed, holdthrottlelever at handlebar. Throttle butterfly should behori-zontalwhenthe lever gently touches the handlebar grip.Toadjust for maximumopening, loosen screwatpointcablejointsthrottleshaft lever. Clampthrottlelevertohandlebar. Withfinger, holdcarburetor throttle lever infully open position (UP), pull cable until taut andretightenscrew.CAUTION: Locktabsshouldbereplacedif bentmorethanthree(3) times. If indoubt, replace.WARNING: Before starting engine, carburetorthrottlelever must returntoidleposition(throttleshutter closed). Donot start engineunless thisisverified.ADJUSTMENTINSTALLATIONToinstall carburetoronengine, inverseremoval proce-dure. For identificationpurposes, thefuel returnline in-let on thetank maleconnector is stampedwiththelet-ters"IN".Airbubblesescapingfrominside the carburetor bore in-dicatesa leakinginlet needle. Bubblesescapingfromaleaking gasket or diaphragmindicates tightening orreplacement.ITILLOTSON HRMTYPE), PAGE 3(((,SECTION04SUB-SECTION05, (CARBURETOR):MIKUNICARBURETOR a-2528 r ...13-----14-----. 20 21-Efe .

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