Disconnect the fuel hose from the carburetor. Clogged or loose pilot jet Remove the pilot jet, clean it with compressed air and then install it. Using a flat-blade screwdriver, remove the four belly pan plugs covering the engine mounting cap screws; then remove the cap screws. Account for two exhaust-manifold shroud gaskets. Remove the two screws securing the timing sensor; then loosen the screws securing the wiring harness retainer tab.
Slide the pump free of the crankcase. Lay the mounting plate aside out of the way. Remove the Allen-head cap screws securing the stator plate. After replacing the spark plug with a colder type, tune the carburetors again. And, it provides you a better understanding of the working components of your snowmobile.
Grasp the crankshaft at either end and carefully lift it from the crankcase. Size of Drill in Inches No. Use a piston-pin puller only. Every Clymer snowmobile service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer snowmobile repair manuals are the cheapest way to keep your snowmobile running properly. These areas are the following. Another asset that makes snowmobile engine repair easier, is access to service manuals and parts catalogues.
See the viscosity chart for details. Discard the cylinder head gasket. By performing this inspection, warranty cost can be reduced and customer satisfac- tion can be increased. Account for a key and alignment washers. If the drive chain is excessively dirty, it should be removed and cleaned prior to being lubricated see Drive Chain and Sprockets in Section 8. Using a plastic-tipped hammer, tap on each cap screw head until the case halves separate.
Remove the cylinder head cover. Remove the cap screw and washer securing the driven pulley; then slide the driven pulley off the driven shaft. See below for complete list of models covered. Remove the knot at the handle and remove the handle; then thread the rope through the bushing in the console. Make sure that the main jet is fully tightened. Remove the cap screw securing the impeller to the shaft. Open the belt guard; then remove the drive belt.
Make sure that the pilot jet is fully tightened. Using a spanner wrench to secure the flywheel, remove the flywheel cap screw, lock washer, and flat washer. When replacing with new rings, replace as a complete set only. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. Each operator should be instructed to drive the snowmo- bile for several minutes at a low throttle setting to warm the belt up before using wide-open-throttle.
Remove the springs securing the expansion chamber to the exhaust manifold, front end, and resonator. Remove the two Allen-head cap screws securing the stator backing plate to the crankcase. Account for the C-ring and five bearing retaining pins. By using a dry, graphite-based chain lubricant, dirt buildup on the drive chain will be minimized. Adjust the carburetor s and choke cable on carbureted models and throttle cable on all models.
Check and, if necessary, clean the carburetor air vents, fuel passages and the float valve. Make sure that the pilot jet is fully tightened. Secure the crankshaft using a spanner wrench; then remove the cap screw securing the water pump impeller. The subsequent pages give detailed procedures. Air leaking into the carburetor joint. For example, if a 400 main jet is recommended for regular unleaded gasoline, a 410 main jet must be installed if using an oxygenated gasoline.