BOMBARDIER 1980 Shop Manual

in the efficient repair and maintenance of Bombardier snowmobiles, Safety features may be impaired if other than genuine Bombardier parts are installed, Torque wrench tightening specifications must be strictly adhered by, Locking devices must be installed or replaced by new ones, where specified, If the efficiency of a locking device is impaired, it must be renewed, This manual emphasizes particular information denoted by the wording and symbols; • • o WARNING: Identifies an instruction which, if not followed, could cause personal injury, CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components, NOTE: Indicates supplementary information needed to fully complete an instruction, Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use,

1980 snowmobiles: Elan - Spirit Citation 3500 Mirage I Citation 4500/E Mirage IIIE Citation SS Mirage Special Everest 5001500 E - Futura 500/500E Everest LC - Futura LC Blizzard 5500 - Grand Prix Special Blizzard' 7500 - Super Sonic Blizzard 9500 - Ultra Sonic Alpine 640 Elite 450 LlC DEFINITION OF NUMBERING SYSTEMS The manual makes uses of a 2-part digital numbering system (i,e, 01-01), in which the first digit represents the Section, the second digit the Sub-section, 01-01 /~ section sub-section The numerotation at the bottom of each page assists the user in page location. ARRANGEMENT OF THE MANUAL The Manual IS diVided into nine (9) malar sections: 01 Tools 02 Technical data 03 Engine 04 Electrical 05 Transmission 06 Suspension 07 Steering and skis 08 Frame and hood 09 Warranty Each section is comprised of various sub-sections, and again each sub-section has one more division. Ex.: 05 TRANSMISSION 07 Chaincase Steel chaincase Aluminum chaincase 1980 BOMBARDIER SNOWMOBILES SHOP MANUAL ILLUSTRATIONS & PROCEDURES An exploded view is conveniently located at the beginning of each section. and is meant to assist the user in identifying parts and components. The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function. When something special applies (such as adlustment" etc), the specific parts are circled and referred to in the text. As many of the procedures In this manual are Interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or sub- section in which the procedure is contained. A number of procedures throughout the book require the use of special tools, Where a special tool is indicated, refer to section 01. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. GENERAL The information, illustrations and component! system de- scriptions contained in this manual are correct at time of publication. Bombardier Limited, however, maintains a policy of continuous improvement of its products without Imposing upon itself any obligation to install them on products previously manufactured. Bombardier Limited reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This manual IS published by the Technical Publications Bombardier Limited Valcourt, Quebec, Canada.

TABLE OF CONTENTS SECTION SUB-SECTION 01 TOOLS 02 TECHNICAL DATA 03 01 - Engine tolerance measurements ENGINE 02 - Engines 03 - Timing 04 - Carburetor 05 - Air intake silencer and fuel tank 06 - Rewind starter 04- 01 - Electric charts ELECTRICAL 02 - Tests procedure 03 - Electric starter 04 - Battery 05 - Alternator 06 - Spark plugs 05 01 - Pulley guard TRANSMISSION 02 - Drive belt 03 - Drive pulley 04 - Driven pulley 05 - Pulley alignment 06 - Brake 07 - Chaincase OB - Gearbox 09 - Drive chain 06 01 - Bogle wheel SUSPENSION 02 - Slide suspension 03 - Rear hub 04 - Drive axle 05 - Track 01 Steenng system 07 STEERING / SKI 02 - Ski system 08 01 -Hood HOOD AND FRAME 02 - Frame 09 WARRANTY

414 1047 00 Tone timer. 414099000 Circuit tester (continuity light). 414 0122 00 ~&e@) Bombardier ignition tester. 419003300 ~--§J ~ •• KiNITIOIl TESTEn» '" o ,,~. : ":~'- USE Engine timing, to determine T.D.C. Engine timing (static). Engine timing (static). Continuity tests. Engine electrical components tests. SECTION 01 (TOOLS) TOOLS APPLI CABLE TO All engine types. All engine types. All engine types. All engine types. (TOOLS). PAGE 1

Heavy duty 419 0027 00 0 !l ~:TI~D=!j o !l Insert block 529 0003 00 e Cleat block 529 0026 00 1\ 1\ 1\ Link plate spring lever. 529 0006 00 Drive pulley retainer. 529 0017 00 (TOOLS). PAGE 2 !!J cJ .-/ i5'-- ~Ma)eJlg Track Insert . Female JI9 -_ -.,,1 PES ~~:=~- ;;;J;:::-=::::;::p:::;;~p01061 . block {Q \ For indexation of governor cup. I I All types of track. All types of track. All models with link plate springs. Square shaft drive pulley.

529 0021 00 c::c===c-----gg 8604142 00 (metric) c:=!==::J)u ( utl@ID Magneto hOUSing holder. 420 976 550 ~ ( 0 0) To remove drive pulley from crankshaft. SECTION 01 (TOOLS) Taper shaft engines Single cylinder engine types. (TOOLS). PAGE 3

With 145 mm screw. ~ ~ ~ ~ g ~~ Screw M8 x 70 (2) Screw M8 X 40 (2) Crankshaft protector PTO Crankshaft protector Ma9 Distance ring Puller ring Half ring ass'y Distance ring Puller rin9 Half ring ass'y (TOOLS). PAGE 4 420 841 200 420 840 680 420 876 550 420 876 555 420 876 560 420 977 480 420 276 020 420 876 565 420 977 490 420977 470 engine 377, 354, 454, 503 engine 247,277,444,464,640 All engines except 247, 640 377 engine only all except 247 engine all except 640 engine all except 640 engine 377, 464 engines only 377, 464, 640 engines only 377, 464, 640 engines only All engine types.

247 engines PTO 420 977 910 MAG 420 276 900 Water pump oil seal sleeve 354, 444, 454, 464 water pump 420 876 490 rotary valve 420 876 495 Rotary va Ive shaft pusher. 420876610 Ball bearing pusher. 420876 500 Bearing simulator. 640 engine ~ Q 420 B76 160 @ Belt tension tester. 414348200 ( ! " ' [" • ! q:", (d :------4"[ Q To avoid oil seal damage dunng crankshaft Installation. ~~ Od seal sleeve (on crankshaft) To Install water pump ball bearing, When adjusting crankshaft play. Pressure adjustment Deflection adjustment 32 mm (11") SECTION 01 (TOOLS) Liquid cooled Rotary valve engines 354, 444, 454, 464 engine types. All models except Mirage I, Citation 3500 Mirage IIIE, Citation 4500/E Mirage Special, Citation SS (TOOLS), PAGE 5

640 engine 503 engine 354-454 engines 420 876 170 420876171 420 876 575 [ .. - ... -I f 503 engines 420240275 g '" '"""' '" "",0 Connecting rod holder. 420 977 gOO Armature plate contact set pivot pin remover (socket). 420 876 530 Fan holder 640 engine 420 977 880 503 engine 420 876 355 377 engine 420 876 357 @:::::::::::;; (0) (TOOLS). PAGE 6 Connecting rod 1M To remove contact set pivot pin from armature plate. TWin cylinder engine types. All single cylinder engines All engine types using breaker pornt type Ignition. Twin cylinder fan-cooled engines

18 mm 420 976 890 354, 377, 444, 454, 464, 503 22 mm 420 876 402 Engine Oil seal pusher. 247 engine 420 977 920 277 engine 420 277 865 420 876 660 J, @) Oil seal pusher. 420876510 464 engine 420 876 500 Rotary valve oil seal pusher L 420 876 600 - 354, 454 engine 420876 605 - 464 engine o Protect crankshaft end, when using bearing puller. Protectlon cap V DJLL 011 seal pusher Puller To install water pump oil seal. To Install rotary valve shaft oil seal SECTION 01 (TOOLS) All engine types. All single cylinder engine type. 354, 444, 454, 464 engine types. 354, 454, 464 englOes (TOOLS), PAGE 7

277 engine MAG 420 273 930 PTO 420 273 940 ~-Ad1 Crankshaft feeler gauge. 503 engine • MAG 420 876 625 PTO 420 876 620 ts2J Crankshaft locking tool 420 876 640 Injection pump gear holder 377 engine 420 876 690 464 engine 420 277 900 ~ ) (TOOLS!. PAGE 8 To install polyamld ring in crankcase. To lock crankshaft \ 277 engine • Mag side: All 503 engines up to no.3 181 891 and engines no. 3 181 921 to 3181937. PTO: All 503 engines 277. 377 464 engines. 464. 377 engine equipped with oil injection

contains PST Pipe Sealant with Teflon (50 mL) I 413 7023 00 Gasket Eliminator 515 (50 mL) 413 702700 Retaining Compound RC/601 (10 mL) 413 7031 00 Threadlocker 242 (10 mL) 413 703000 Threadlocker 271 (10 mL) 413 7029 00 SuperBonder 495 (3-gram tube) 413703200 LOCK'N SEAL (242) BLUE, MEDIUM STRENGTH 24 mL 413702500 ~It:i.~-~ LOCK'N SEAL (271) RED HIGH STRENGTH 6 mL 747 020000 ~ ";;"'~r=:J\ GASKET ELIMINATOR 515 50 mL 413 702700 For threadlocking, threadseallng, gasketing, bonding and retaining applications on engines, pulleys and fasteners etc. SECTION 01 (TOOLS) A medium-strength adhesive for General purpose, nuts, threadlocking and threadseallOg. bolts screws, Vibration-proofs nuts, bolts and Magneto ring nut, crank- screws. case studs, etc. High-strength threadlocklOg I Fastene~~ and studs threadseallng adhesive for large under 1 d,a, parts. Seals instantly, For metal to metal I On all engine crankcases. assembly. Replaces gaskets. (TOOLS), PAGE 9

10 mL 413703100 PRIMER CRANKCASE SEALANT (SPRAY) 6 oz 413702400 STRIPPER NO 57 413 7021 00 ANTISEIZE LUBRICANT 413701000 -; ANTi SeizE lll6n.'"p,lIl METAL PROTECTOR LPS. NO 1 SPRAY 413 9022 00 (TOOLSI, PAGE 10 tiANoiE'..;: ~:~~ Restores fit between bearings and worn crankcase. Very fast cure pnmer. Primer NF provides hxturing In only 15-30 seconds with fuJI cure in 4 hours or less. On part life is 30 minutes and parts should be assembled as soon as possible after adhesive is applied. For cleaning mating surfaces be- fore assembly. Protects moving and stationary parts against high temperature seizing. Prevents rust and corro- sion on parts exposed to high heat. General service light lubricant. Protects against rust. Displaces moisture. Protects all electrical systems and ignition systems. All engines except 247, 277. Mainly used when assem- bling engine crankcase. Used to clean mating SUf- faces before applying Loc- lite 515 (Gasket Elimina- tor). Unpainted surfaces of drive pulley countershaft. For storage protection, on drive and driven pulleys, High tension coil protec- tion from moisture.

NO 3 SPRAY 413 9008 00 SILICONE DIELECTRIC GREASE 3 oz 747018002 GREASE TUBE 14 oz 498 0281 00 CLUTCH LUBE 413800700 INJECTOR OIL 413801500 CHAINCASE OIL 413 8012 00 BOMBARDIER OIL 50/1 496013200 I~ II ~ -:: ImYJII Heavy Duty Rust preventIVe lubri- cant. Protects bare metal parts against rust and corrosion. Special dielectric grease that pre- vents mOisture and corrosion build-up in electnc connections. Multi purpose Lithium based grease for use over a wide temper- ature range. Special Jow temperature metallic lubricant for clutch shafts only. High quality lubricant with good resistance to high operat'lng tem- peratures. Low foaming action. Specially formulated all for chain and roller lubrication. Assures proper lubrication at low tempera- tures. SECTION 01 (TOOLS) For storage protection. on bare metal parts. On all electric connec- tions. High tension call. Spark plug connections. Connector housings, etc. For Idler bearings. skllegs. leaf spring cushion pads. oil seal interior lips, etc, Citation 3500. Citation 4500/E. Mirage I. Mirage II/E. Elan and Spirit drive pulleys. Rotary valve lubncant on 354-444-454 and 464 engines. Chaincase lubricant on all models. Specially formulated oil that meets I All models. lubrication requirements of the Bombardier-Rotax engine. (TOOLS). PAGE 11

TOLERANCE AND WEAR LIMIT - ENGINES IGNITION TIMING SPECIFICATIONS CARBURETOR SPECIFICATIONS IGNITION GENERATING COIL, TRIGGER COIL AND LIGHTING COIL RESISTANCE CHART BOMBARDIER IGNITION TESTER DIAL POSITIONS BOSCH SPARK PLUG CHART VEHICLE MODEL/DRIVE BELT NUMBER DRIVE PULLEY SPECIFICATIONS DRIVEN PULLEY SPRING TENSION PULLEY ALIGNMENT SPECIFICATIONS SPROCKET AND CHAIN SPECIFICATIONS TRACK TENSION SPECIFICATIONS (BOGIE WHEEL SUSPENSION) TRACK TENSION SPECIFICATIONS (SLIDE SUSPENSION) TRACK SPECIFICATIONS STEERING SYSTEM TORQUE SPECIFICATIONS SKI SYSTEM TORQUE SPECIFICATIONS METRIC INFORMATION CHART (TECHNICAL DATA LIST). PAGE 1

TOLERANCES AND WEAR LIMIT - 1980 ENGINES ENGINE CYLINDER BORE PISTON TO WALL MAXIMUM RING CRANKSHAFT TYPE (NOMINAL) CLEARANCE END CAP END PLAY STD OVERSIZE MIN. - MAX. MIN. - MAX. 247 69.00 mm 69.50 mm 0.065-0.200 mm 0.20-0.35 mm 020-0.40 mm (2.7165") (2.7362") (0026-.00B") (00B-.014") (.00B-.016") 277 72.00 mm 72.25 mm 0.060-0.200 mm 0.20-0.35 mm 0.20-0.40 mm (2.B346") (2.B445") (0024-.00B") (00B-014") (.00B-.016") 354 59.50 mm 59.75 mm 0.OBO-0.1BO mm 0.15-0.30 mm N.A. (2.3425") (2.3524") (0031-.007") (006-.012") 377 62.00 mm 62.25 mm 0070-0.200 mm 0.20-0.35 mm NA (2.4409") (2.450B") (0028-.00B") (00B-.014") 444 69.50 mm 69.75mm 0.070-0200 mm 0.20-0.35 mm NA (27362") (2.7461") (002B-.00B") (00B-014") 454 67.50 mm 67.75mm 0.090-0.200 mm 0.20-0.35 mm NA (2.6575") (2.6673") (0035-.00B") (OOB-O 14") 464 69.50 mm 69.75 mm 0.070-0200 mm 0.20-0.35 mm N.A. (2.7362") (2.7461") (0028-.00B") (008-014") 503 72.00 mm 72.25 mm 0.060-0.200 mm 0.20-0.35 mm NA (28346") (2.B445") (0024-.00B") (00B-014") 640 76.00 mm 76.50 mm 0.070-0.220 mm 0.25-0.40 mm 0.20-0.40 mm (2.9921 ") (3.0118") (.002B-.OOB") (010-016") (008-016") N A: not applicable (TECHNICAL DATA LIST). PAGE 2

1980 IGNITION TIMING SPECIFICATIONS ENGINE IGNITION DIRECT INDIRECT EDGE CAP TYPE TYPE MEASUREMENT MEASUREMENT B.T.D.C. B.T.D.C. f~ ~ .. ' .. '.,,!' n 'hFl ~ ~ ~r )11 0> ?? il c 247 Breaker 3.98 mm ± 0.25 NA 7-10 mm (.157" ± .010) (.275-394") 277 Breaker NA 2.60 mm ± 0.25 8·12 mm (.102" ± .010) (.315-.4 72") 354 CD • 1.39 mm ± 0.25 NA NA (.055" ± .010) 377 Breakers 2.07 mm ± 0.25 NA 8-12 mm (.081" ±01O) (.315-.4 72") 444 Breakers 2.35 mm ± 0.25 NA 8·12 mm (.093" ±01O) (.315·.4 72") 454 CD • 1.39 mm ± 0.25 (.055" ± .010) NA NA 464 Breakers 2.07 mm ± 0.25 NA 8-12 mm (.081" ±010) (.315-.472") Breakers 2.07 mm ± 0.25 N.A. 8·12 mm 503 (. 081" ± a 10) (.315-.4 72") 640 Breakers NA 3.62 mm ± 0.25 7·10 mm (.143" ±01 0) (275-.394") N A not applicable • StroboscopIc tlmln9 at 6000 R.P.M. (TECHNICAL DATA LIST). PAGE 3

247 VM28-242 1 i turn CITATION 3500, MIRAGE I 277 VM 34-228 1 i turn CITATION 4500/E, MIRAGE II I E 377 VM-34-229 1 turn CITATION SS, MIRAGE SPECIAL 377 2XVM30-111 11 turn EVEREST 500/E FUTURA 500/E 503 VM36-83 1 turn EVEREST LC, FUTURA LC 464 VM34-227 11 turn BLIZZARD 5500 GRAND PRIX SPECIAL 503 2XVM34-203 11 turn BLIZZARD 7500 MAG: VM34-230 SUPER SONIC 354 PTa: VM34-233 1 i turn BLIZZARD 9500 PTa: VM36-88 ULTRA SONIC 454 MAG: VM36-86 1 turn ALPINE 640ER 640 VM34-215 1 -t turn ELITE 450 LC 444 VM34-201 1 turn - -- . - L- ---- -- -- (TECHNICAL DATA LIST). PAGE ~ IDLE SPEED R.P.M. 1100-1300 1100-1300 I , 2000 , , 1800-2000 1800-2000 2000 1800-2000 1800-2000 1800-2000 1800-2000 1800-2000 ---

c§" !j S ~ (f VM28-242 160 VM30-111 150 VM34-201 370 VM34-203 220 VM34-215 280 VM34-227 380 VM34-228 220 VM34-229 280 VM34-230 290 VM34-233 260 VM36-83 310 VM36-86 320 VM36-88 300 o Jet needle last digit indicates "E" clip position from top. Ex.: 6HD2-3: 3rd slot from top. CD Turning clockwise will enrich the mixture and counterclockwise will lean it. 0 0- ,,0 // if

GENERATOR COil, LIGHTING COil AND TRIGGER COil RESISTANCE CHART ENGINE GENERATOR TRIGGER MAIN LIGHTING TYPE COIL COIL COIL (large) 247' 3-3.7 ohms NA 0.38-0.58 ohm 271' 3-3.7 ohms NA 0.30-0.50 ohm 354 450-550 ohms 50-60 ohms 015-0.19 ohm 371' 3.2-3.7 ohms NA 0.30-0.50 ohm 444' 3.2-3.7 ohms N.A. N.A. 454 450-550 ohms 50-60 ohms O. 1 5-0. 1 9 ohm 464- 3.2-3.7 ohms NA 0.30-0.50 ohm 503- 3.2-3.7 ohms NA 0.30-0.50 ohm 640' 3.2-3.7 ohms NA 0.30-0.50 ohm • Ignition coil: -pnmary C"CUlt (between nos 1 and 1 5 terminals): 1.65-2.05 ohms -secondary circuit (between nos 1 and 14 terminals) 4850-5850 ohms CONDENSER CAPACITY 0.24-0.30 mfd N.A.. not applicable ADDITIONAL LIGHTING COl L (small) 1.85-2.35 ohms 2.13-2.63 ohms NA 2.13-2.63 ohms NA NA 2.13-2.63 ohms 2.13-2.63 ohms 2.13-2.63 ohms Components temperature must be around 20°C (70°F) when test IS performed. (TECHNICAL DATA LIST). PAGE 6

BOMBARDIER IGNITION TESTER ADJUSTMENT FOR 1980 COMPONENTS ENGINE GENERATOR TRIGGER MAIN LIGHTING ADDITioNAL TYPE COIL COIL COIL (large) LIGHTING COIL (small) 247 HIGH 75 LOW 85 LOW 85 277 HIGH 70 LOW 85' LOW 85' 354 HIGH 40 LOW 50 LOW 80 377 HIGH 80 LOW 85' LOW 85' 444 HIGH 80 454 HIGH 40 LOW 50 LOW 80 464 HIGH 80 LOW 85' LOW 85' 503 HIGH 80 LOW 85' LOW 85' 640 HIGH 80 LOW 85' LOW 85' L~._ - -~ - - -~ --~ '----- ------ , The two lighting coils (large one and small one) are connected In parallel and this parallel connection must be broken off for testing as each coil IS to be checked Individually. (TECHNICAL DATA LIST). PAGE 7

ENGINE SPARK PLUG NO. TYPE ELAN & SPIRIT 250 247 M175 T1 (M7A) CITATION 3500, MIRAGE I 277 W275 T2 (W3C) CITATION 4500/E, MIRAGE IIIE 377 W275 T2 (W3C) CITATION SS, MIRAGE SPECIAL 377 W275 T2 (W3C) EVEREST 500/E, FUTURA 500/E FUTURA 503 W275 T2 (W3C) EVEREST LC & FUTURA LC 464 W275 T2 (W3C) BLIZZARD 5500/GP SPECIAL 503 W275 T2 (W3C) BLIZZARD 7500/SUPER SONIC 354 W300 T2 (W2C) BLIZZARD 9500/ULTRA SONIC 454 W300 T2 (W2C) i ALPINE 640 ER 640 M240 T1 (M4A2) ELITE 450 LC 444 W2 7 5 T2 (W3C) - --- -- -- I (TECHNICAL DATA LIST). PAGE 8

1980 WIDTH ELAN and SPIRIT 570041100 30 mm (13/16") CITATION 3500 414394500 30 mm (1 3/16") MIRAGE I CITATION 45001 E MIRAGE IIIE i CITATION SS MIRAGE SPECIAL EVEREST 500/E 414375800 33 mm (1 5/16") I FUTURA 500/E EVEREST LC I FUTURA LC EVEREST 414375800 33 mm (15116")1 FUTURA BLIZZARD 5500 414375800 33 mm (1 5/16") GRAND PRIX SPECIAL BLIZZARD 7500 414375800 33 mm (1 5116") SUPER SONIC BLIZZARD 9500 414375800 33 mm (1 5/16") ULTRA SONIC ALPINE 640 ER 414375800 33 mm (1 5/16") ELITE 450 LC 414375800 33 mm (1 5/16") o NOTE: For longer belt life, always reinstall the drive belt in the same direction of rotation. (TECHNICAL DATA LIST), PAGE 9

CITATION 3500 & MIRAGE I CITATION 4500/E & MIRAGE IIIE CITATION SS & MIRAGE SPECIAL EVEREST 5001 E & FUTU RA 500 I E EVEREST LC & FUTURA LC BLIZZARD 5500 & GRAND PRIX SPECIAL BLIZZARD 7500 & SUPER SONIC BLIZZARD 9500 & ULTRA SONIC ELITE 450 LC ALPINE 640 ER TYPE R.R.S. R.R.S. R.R.S. R.S.S. R.S.S. R.S.S. R.S.S. R.S.S.R. R.S.S.R. R.S.S. R.S.S.B. COUNTER- ROLLER WEIGHT IDENTI- IDENTIFI- FICATION CATION mm (inch) E-4 Nylon 31.75 (1 t) B-2-K-S Fiber 31.75 (1 t) C-7-L Fiber 31.75 (It) A-3-S-H Fiber 25.4 (1 .15) C-6-L-H Fiber 25.4 (1 . 1 5) C-7-L-H Fiber 25.4 (1.15) C-6-L-H Fiber 25.4 (1.1 5) A-3-S Alu 15.75 (.62) A-3-S Alu 15.75 (.62) C-8 Fiber 34.04 (1.34) C-8 double Fiber 34.04 (1.34) R,S.S. Roller square shaft R,R.$._ Roller round shaft R.S.S_B Roller square shalt with bearing R S,S,R - Roller square shaft 3 ramps PIN SPRING LENGTH COLOR ± 1.5 mm (.060") 414-2580 Bronze 76.7 (3.02) 414-2581 Blue 77.7 (3.06) 414-4131 Olive 105.9 (4.17) 414-4065 Orange 96.5 (3.80) 414-2328 Gold 74.4 (2.93) 414-1967 Light blue 119.1 (4.69) 414-1967 Light blue 119.1 (4.69) 414-2610 Purple 73.7 (2.90) 414-2610 Purple 73.7 (2.90) 414-1967 Light blue 119.1 (469) 414-1966 Pink 122.2 (4.81) 0)1 Ramps no. 2442 G) Ramps no. 2422 CLUTCH RETAINING ENGAGE- BOLT MENT TORQUE R.P.M. Nom (ft-Ibs) - (f)(f) CD em roO 00 .--1 (f)- 0 mO OZ 2000-2200 61 (45) C :::!O ON ::J:I Z - (3 < (J1 2900-3200 61 (45) m • 0 '1:1 ~ c: 3600-3900 61 (45) r-r-m 3900-4200 85 (63) -< U) 2900-3200 85 (63) '1:1 m n - 3400-3700 85 (63) 'TI -n 3300-3600 85 (63) » ""II - 0 3800-4100 85 (63) :2 U) 3800-4100 85 (63) 3200-3500 85 (63) 2250-2400 118 (87)

kg± 1 (Ibs ± 2) ELANISPIRIT 3.6 (8) CITATION 3500, MIRAGE I 3.6 (8) CITATION 4500/E, MIRAGE IIIE CITATION SS, MIRAGE SPECIAL 5.9 (13) EVEREST 500/E, FUTURA 500/E 5.9 (13) EVEREST LC, FUTURA LC i BLIZZARD 5500/GRAND PRIX SPECIAL 5.9 (13) I BLIZZARD 7500/SUPER SONIC 5.9 (13) BLIZZARD 9500, ULTRA SONIC 5.9 (13) ELITE 450 LC 5.9 (13) ALPINE 640 ER 5.9 (13) - - - - - -- - - (TECHNICAL DATA LIST). PAGE 11

Nominal distance between f"e~ T T "X" "V" tt /I square bar Length- 48 em (19 In.) - Dimension "X" must never exceed dimension "Y". - Dimension "Y" can exceed dimension "X" by 1.6 mm (1/16") DIMENSIONS X and Y (offset) ELAN & SPIRIT 34mm(111/32") CITATION 3500, MIRAGE I 34 mm (1 11/32") CITATION 4500/E, MIRAGE IIIE CITATION SS, MIRAGE SPECIAL EVEREST 500/E, FUTURA 500/E 34 mm (1 11/32") EVEREST LC, FUTURA LC (0 BLIZZARD 5500 and GRAND 34 mm (1 11/32") PRIX SPECIAL (0 BLIZZARD 7500 and SU PER 34 mm (111/32") SONIC (0 BLIZZARD 9500 and ULTRA 34 mm (1 11/32") SONIC (2) ALPINE 34 mm (111/32") ELITE 450 LC 34 mm (1 11/32") (0With a 1/16" shim between driven pulley and bearing flange. Refer to section 05-05. (TECHNICAL DATA LIST). PAGE 12 NOMINAL DISTANCE (between pulleys) 44 mm (1 ~") fixed 35 mm (1 i") 35 mm (1 r) 35 mm (1 r) 35 mm (1 r) 44 mm (1 r) 42 mm (1 t") I

SPROCKET CHAIN PITCH AND UPPER/LOWER NUMBER OF LINKS ELAN and SPIRIT 250 10/25 -1" single, 62 CITATION 3500, MIRAGE I 15/34 i" double 86 CITATION 4500/E, MIRAGE II/E 16/33 i/" double 86 CITATION SS, MIRAGE SPECIAL 18/34 i" double 88 EVEREST 500/ E, FUTURA 500/ E 19/40 i!" triple 68 EVEREST LC, FUTU RA LC 17/34 i" triple 64 BUZZARD 5500, GRAND PRIX 21/38 i" triple 68 I SPECIAL BUZZARD 7500, SUPER SONIC 17/38 i!" triple 6 6 BUZZARD 9500, ULTRA SONIC 19/40 i/" triple 68 ALPINE 640 ER 17/38 il" triple 90 ELITE 450 LC 17/38 i/" triple 188 (TECHNICAL DATA LIST). PAGE 13

TRACK TENSION SPECIFICATIONS (SLIDE SUSPENSION) © toi' 1980 CITATION 3500, CITATION 4500/E 13mmW') MIRAGE I, MIRAGE II/E CITATION SS, MIRAGE SPECIAL EVEREST 500/E, EVEREST LC 13mmW') FUTURA 500/E, FUTURA LC BLIZZARD 5500 13mm(t") GRAND PRIX SPECIAL BLIZZARD 7 500 13mm(!") SUPER SONIC BLIZZARD 9500 13 mm (t") ULTRA SONIC ELITE 450 LC 13 mm W')l (TECHNICAL DATA LIST). PAGE 14 TRACK TENSION SPECIFICATIONS (BOGIE WHEEL SUSPEN- SION) 1980 ELAN and SPIRIT 250 35 mm (1 t") ALPINE 640 ER '57 mm (2t") - , Between top inside edge of track and center of second bogie wheel set retaining bolt (from rear).

ELAN SPIRIT CITATION 3500, CITATION SS MIRAGE I, MIRAGE SPECIAL CITATION 4500/E MIRAGE IIIE EVEREST 5001 E, EVEREST LC FUTURA 500/E, FUTURA LC BLIZZARD 5500 GRAND PRIX SPECIAL BLIZZARD 7500 SUPER SONIC BLIZZARD 9500 ULTRA SONIC ALPINE 640 ER ELITE 450 LC ------- ------ SECTION 02 SUB-SECTION (06-05) 1980 TRACK SPECIFICATIONS CLEAT AND GUIDE ARRANGEMENT TYPE 2: Narrow insert with shoulder TYPE 3: Wide guide (large track hole). TYPE TRACK WIDTH LENGTH (interior) PART NUMBER 1 570000600 38.1 em (15") 289.6 em (114") 1 570008500 38.1 em (15") 289.6 em (114") 2 5700091 00 38.1 em (15") 269.2 em (106") 2 570009200 38.1 em (15") 269.2 em (106") 2 570006900 38.1 em (15") 289.6 em (114") 2 570006800 38.1 em (15") 289.6 em (114") 3 570004500 41.9 em (16t") 314.9 em (124") 3 570006000 41.9 em (16t") 314.9 em (124") 2 570008600 38.1 em (15") 289.6 em (114") 2 570006800 38.1 em (15") 289.6 em (114") 2 570009300 38.1 em (15") 289.6 em (114") 2 570006800 38.1 em (15") 289.6 em (114") 2 570009300 38.1 em (15") 289.6 em (114") 2 570008000 38.1 em (15") 289.6 em (114") 1 570001400 38.1 em (15") 353 em (139") 3 570005600 38.1 em (15") 304.8 em (120") -- - - (TECHNICAL DATA LIST), PAGE 15

HANDLEBAR STEERING ARM TIE ROD RETAINING TO SKI LEG END TO BOLT (S) N"m (It-Ibs) STEERING ARM N"m (It-Ibs) N"m (It-Ibs) ELAN and SPIRIT 27 (20) 27 (20) CITATION 3500, MIRAGE I 26 (19) 42 (31) 27 (20) CITATION 4500/E, MIRAGE II/E CITATION SS, MIRAGE SPECIAL EVER EST 500 I E, & FUTU RA 500 IE 26 (19) 42 (31) 27 (20) EVEREST LC & FUTURA LC BLIZZARD 5500 26 (19) 42 (31) 27 (20) GRAND PRIX SPECIAL BLIZZARD 7500 26 (19) 42 (31) 27 (20) SUPER SONIC BLIZZARD 9500 26 (19) 42 (31) 27 (20) ULTRA SONIC ALPINE 42 (31) 42 (31) "61 (45) ELITE 42 (31) 42 (31) 27 (20) ~- - - ~- ~- -- • Ball bushing nut torque value. (TECHNICAL DATA LIST). PAGE 16

ELAN & SPIRIT CITATION 3500 & MIRAGE I CITATION 4500/E & MIRAGE IIIE CITATION SS & MIRAGE SPECIAL EVEREST 500/E & FUTURA 500/E EVEREST LC & FUTURA LC BLIZZARD 7500 & SUPER SONIC BLIZZARD 9500 & ULTRA SONIC ALPINE ELITE SPRI NG LEAF I RUNNER -LEAF COUPLER LEAF COU PLER SHOE TO SKI LEG RETAINING BOLT NUT· N'm (It-Ibs) N'm (It-Ibs) N'm (It-Ibs) 50 (37) 7 ( 5) 61 (45) 54 (40) 22 (16) 61 (45) 22 (16) 61 (45) 22 (1 6) 61 (45) 22 (16) 61 (45) 27 (20) 22 (16) 61 (45) 27 (20) 22 (16) - Tighten bolt, move ski by hand to check that it pivots easily on ski leg. Then tighten locking nut to specified torque. (TECHNICAL DATA LIST). PAGE 17 I

BASE UNITS DESCRIPTION UNIT length meter mass kilogram liquid liter temperature celsius pressure kilopascal torque Newton meter speed kilometer per hour PREFIXES PREFIX SYMBOL MEANING kilo k one thousand centi c one hundredth of a mill; m one thousandth of a • THE INTERNATIONAL SYSTEM OF UNITS (SYSTEME INTERNATIONAL) ABREVIATES "SI" IN ALL LANGUAGES. (TECHNICAL DATA LIST). PAGE t 8 SYMBOL m kg L °C kPa Nom km/h VALUE 1.000 0.01 0.001

CYLINDER TAPER ENGINE TOLERANCES MEASUREMENT PISTON TO WALL CLEARANCE Maximum: 0.08 mm (.003") Compare cylinder diameter 16 mm (i") from top of cylinder with down to just below the intake port. On rotary valve engines, measure just below auxiliary transfer port. facing exhaust port. If the difference ex· ceeds 0.08 mm (.003") the cylinder should be rebored and honed or should be replaced. Below the Intake port 16 mm from top CYLINDER OUT OF ROUND Maximum: 0.05 mm (.002") Measuring 1 6 mm (i") from top of cylinder with a cylinder gauge. check if the cylinder out of round is more than 0.05 mm (.002"). If larger. cylinder should be rebored and honed or should be replaced. Gudgeon p,n direction Measures to be compared ENGINE PISTON TO WALL CLEARANCE TYPE MINIMUM - MAXIMUM 247 0.065 - 0.200 mm (0026 - .008") 277 0.060 - 0.200 mm (0024 - .008") 354 0.080 - 0.180 mm (.0031 - .007") 377 0.070 - 0.200 mm (0028 - .008") 444 0.070 - 0.200 mm (0028 - .008") 454 0.090 - 0.200 mm (0035 - .008") 464 0.070 - 0.200 mm (0028 - .008") 503 0.060 - 0.200 mm (.0024 - .008") 640 0.070 - 0.220 mm (.0028 - .0086") - Measurement To determine piston to wall clearance. the piston should be measured right under the axis hole and the cylinder should be measured 16 mm (i") below its top edge. '- I) I. ( '0' I (ENGINE TOLERANCES MEASUREMENT). PAGE 1

The difference between these two measurements should be within specified tolerance. RING END GAP ENGINE RING END GAP MAXIMUM RING END TYPE (new ring) GAP (worn ring) 247.277 0.20 - 0.35 rnm 1.0 mm 377,444 (008 - .014") (.039") 454,464 503 354 0.15 - 0.30 mm 0.8 mm (.006 - .012") (.031") 640 0.25 - 0.40 mm 1.2 mm (010 - .016") (.047") Position ring half way between transfer ports and intake port. On rotary valve engines. position ring just below transfer ports. O NaTE: In order to correctly pOSition the ring in the cylinder. use piston as a pusher. Using a feeler gauge. check ring end gap. If gap exceeds specified tolerance the ring should be replaced. Transfer port Intake port (ENGINE TOLERANCES MEASUREMENT). PAGE 2 PISTON RING/GROOVE CLEARANCE MINIMUM 0.04 mm (002") MAXIMUM 0.20 mm (008") Usin9 a feeler gauge check clearance between rectangu- lar ring and 9roove. If clearance exceeds specified tole- rance, replace piston. , ~Y7r,",:0~:;~ f" CRANKSHAFT DEFLECTION Maximum: 0.10 mm (.004") Turn crankshaft on "V" shaped blocks: using a dial indicator measure deflection on each side as illustrated. If deflection exceeds specified tolerance. the crankshaft should be repaired or replaces. 'iiWl =.,- ~UJ' " .~-1 "',- Measure at 6 mm (tit) from the edge f Measure behind the key

CONNECTING ROD BIG END AXIAL PLAY TYPE MINIMUM - MAXIMUM 247.277 377.444 0.20 1.00 mm 503.640 (008 039") 354.454 464 OAO 1.00 mm (.016 .039") Using a feeler gauge measure distance between thrust washer and crankshaft balancer. If the distance exceeds specified tolerance. repair or replace the crankshaft. CONNECTING ROD ALIGNMENT Check if connecting rod is bent as follows: - Once engine crankcase is assembled with the piston mounted on connecting rod without its piston rings, position cylinder on piston. O NOTE: The cylinder/crankcase gasket must not be installed. - Rotate crankshaft slowly and at the same time observe piston movement within the cylinder. If piston bears against one side (PTO or mag. side). the connecting rod is bent. Equal distance in gudgeon pin direction ~ - To correct. position needle bearing and gudgeon pin on connecting rod then pry connecting rod as illustrat- ed. (ENGINE TOLERANCES MEASUREMENT). PAGE 3

CRANKSHAFT END-PLAY MINIMUM 0.20 mm (.OOB") MAXIMUM 0.40 mm (.01 6") O NaTE: Crankshaft end-play IS adjusted only when crankshaft and/or crankcase is replaced. One cylinder engines (247, 277) To determine crankshaft end-play. proceed as follows: a) Measure crankcase. To do this first measure each half from mating surface to bottom of bearing seat. Add measurements of both halves then add 0.30 mm (.012") for gasket displacement. Equal A. b) Measure the thickness of each ball bearing. Measure distance between bearing shoulders on crankshaft. Measure standard shims (247 type: P.T.O. side and 277 type: P.T.O. and MAG. sides). Add measurements. Total equals B. ·'1- Measunng thickness of ball bearing (ENGINE TOLERANCES MEASUREMENT). PAGE 4 Measurmg distance between beanng shoulders c) Subtract measurement B from measurement A minus tolerance. Total balance is distance to be shimmed. Shim(s) must be located between magneto side bear- Ing and crankshaft blade. Two cylinder engine (640) BEARING SIMULATOR NO. 420 B76 160 AVAILABLE SHIMS 0.15 mm (.006"). 0.2 mm (.OOB"), 0.3 mm (.012") Crankshaft end-play is adjusted with a shim(s) located between crankshaft and magneto side bearing. To deter- mine correct amount of shims, proceed as follows. Remove magneto side bearing(s) and existing shim(s). Slide the appropriate bearing simulator and retaining washers onto the crankshaft.

Position crankshaft assembly into crankcase lower half. making sure that retaining washers are correctly seated into the grooves. Gently tap crankshaft mag. side blade until PTO. side bearing bears against retaining washer. s P TO side retaining washer Any free-play between the bearing simulator and magneto side retaining washer (minus end-play) is the distance to be covered by shim(s). e; Beanng simulator '--r (ENGINE TOLERANCES MEASUREMENT). PAGE 5

LIST OF THE SECTIONS RELATING TO ENGINES 247 Elan and Spirit 250 277 Citation 3500 and Mirage I 354-454 Blizzard 7500 and Super Sonic Blizzard 9500 and Ultra Sonic 377 Citation 4500. SS and Mirage 4500. Special 444 Elite 464 Everest and Futura LC 503 Blizzard 5500 and Grand Prix Special 640 Alpine

13 12 11 6-~ i 5-~ i i ~-0 , - A-? SECTION 03 SUB-SECTION 02 (ENGINES) 247 ENGINE TYPE ENGINE SUPPORT AND MUFFLER 23@ 25 26 II "'-,J--l"', -----H) 5E~~{~~ " 2O-~ 21- ., 22- V-'? ~--16 ',,- '", '''-, " 21 T~~ 1 , ____ 1 13 "r~ e 1. Carnage bolt (4) 2. Threaded spacer (4) 3. Insulator rubber (4) 4. Support (2) 5. Washer (4) 6. Nut (4) 7. Bolt (4) B. Bracket g, Nut (4) 10. Air deflector 11. Rubber spacer (3) 12. Washer 73. Screw 14. Nut (4) 15. Lockwasher (4) 16. Stud (4) 17. Distance sleeve (4) 1 B, Muffler 1 g. Exhaust grommet 20.. Nut 21, Ret8iner washer (2) 22, Rubber washer (2) 23. Lockwasher (2) 24. Nut (2) 25. Stud M8 X 1 g (2) 26. Exhaust gasket (247 ENGINE TYPE), PAGEl

IENGINIE SUPPORT AND MUffLER REMOVAL FROM VEHICLE Remove or disconnect the followings then lift engine from vehicle . • Pulley guard. " Drive belt. co Muffler. .. Choke knob. It Decompressor . .. Throttle calbe. e Fuel lines . • E!ectrical connector. .. Separate steering column support at upper column. 11& Engine mount nuts. DISASSEMBLY & ASSEMBLY @Torque to 31 Nom (23 ft-Ibs). @Torque to 35 Nom (26 ft-Ibs). @Torque to 22 Nom (16 ft-Ibs). INSTALLATION ON VEHICLE To install engine on vehicle, inverse removal procedure. However, pay attention to the followings .. Check tightness of engine mount nuts, and drive pulley bolt. a After throttle cable installation, check maximum throt- tle slide opening a Check pulley alignment. (247 ENGINE TYPE). PAGE 2

2. Crankcase half (Mag side) 3. Polyamid ring 4. Dowel tube 10 mm X 15 (2) 5. Stud M8 X 56 (crankcase with studs) (2) Hexagonal head capscrew M8 X 64 (crankcase with screws) (2) 6. Stud M8 X 46 (crankcase with studs) (3) Hexagonal head capscrew M8 X 55 (crankcase with screws) (3) 7. Lockwasher 8 (5) Hexagonal nut 8 mm (crankcase with studs) (5) 8. Crankcase gasket 9. Distance sleeve 22 mm (2) 10. Stud M10 X 42 (4) 11. Lockwasher 10 (4) 12. Hexagonal nut 10 mm (4) 13.StudM8x 171(4) 14. Crankshaft SECTION 03 SUB-SECTION 02 (ENGINES) BOTTOM END 13 I ~I 7 D~I CD ~.@~ @-C-~~ K~'@ 7~1 CD o 15. Shim 1.0 mm @ 16. Shim O. I. 02. 0.3. 0.5. 1 mm 17. 8a// bearing 6305 (2) 18. Oil seal (2) 19. Woodruff key 5 X 6.5 22 20 "Loctite 242» (blue - medium strength) 21. Labyonth ong 22. Cylindrical slotted head screw M6 X 10 (4) 23. Spring seat 24. Spong 25. Breaker cam 26. Nut M18 X 1.5 23 24 25 (247 ENGINE TYPE). PAGE 3

BOTTOM END CLEANING Discard all oil seals and gaskets. Clean all metal components in a non-ferrous metal clea- ner. DISASSEMBLY & ASSEMBLY General Refer to Technical Data Section for component fitted tolerance and wear limit. If necessary. refer to Dnve Pulley Section to remove drive pulley. 00When disassembling/assembling crankcase halves. do not heat the crankcase. If heat is necessary, tempera- ture must not exceed 55°C (130°F). o Do not remove unless necessary. To remove. heat slightly with a butane torch then pry out using a sc-rewdriver. To install. apply oil on outside diameter then use a sUitable pusher. Chanfer towards inside of crankcase ®®0At assembly. torque to 22 N'm (16 ft-Ibs) follo- wing illustrated sequence. 3 (247 ENGINE TYPE). PAGE 4 @ Torque to 35 N'm (26 ft-Ibs). @@ Crankshaft maximum end-play should be: Minimum 0.20 mm (008") Maximum 0.40 mm (.016") O NaTE: Crankshaft end-play IS adjusted only when crankshaft and/or crankcase IS replaced. To determine end play: a) Measure crankcase. To do this, first measure each half from mating surface to bottom of bearing seat. Add measurements of both halves then add 0.32 mm (.012") for gasket displacement. Equals A. i~ b) Measure thickness of each ball beanng. Measure distance between crankshaft blades. Add measure- ments with thickness of standard shim 1 mm (.040") on P.T.O. side. Total equals B. "'1_1- Measunng thickness of ball beanng

tolerance. Total balance IS distance to be shimmed. Shim(s) must be located between magneto side beanng and crankshaft blade. @Ta remove bearings from crankshaft use a protective cap and special puller as illustrated. (See Tools Section.) Special puller .~ O NaTE: Prior to magneto side beanng Installation. _. install required shim(s) (crankshaft end play) on crankshaft extension. At assembly. place bearings into an oil container and heat the oil to 100 0 C (210 0 F) for 5 to 10 min. This will expand the bearings and permit them to slide easily on the shaft. @To remove Of install new seal into crankcase use an appropnate oil seal pusher as illustrated. (See Tools Section). SECTION 03 SUB-SECTION 02 (ENGINES) Oil seal pushAr II ~ no 420 977 920 Also, prior to crankcase adjoining. install a protector sleeve on each crankshaft extension to prevent oil seal damage (See Tools Section). Apply a light coat of lithium grease on seal lip. Seal outer surface should be flush with crankcase. @At assembly. position labyrinth nng with bevelled side on top. @@To remove or install magneto retaining nut. lock crankshaft in position with special hold·on support. (See Tools Section). / / ~ Hold-on support At assembly clean thoroughly and apply "Loctite 242" on threads then torque retaining nut to 73 N"m (54 h·lbs). (247 ENGINE TYPE). PAGE 5

TOP END ~-~ 18 / '\ I \ 22 14-@ ~~~-@ ! ;,- I 11 / "'. I " @ ~..a/ I • .,. 21 ~ I 7 (0 I 17 " 0 ~ 16 ~o 9-----~ 1. Piston ring 2. Piston 3. Gudgeon pin 4. Circlip (2) 5. Cylinder 6. Cylinder head 10 '- 11---~ @~/ -®~ 13C ® 7. Gasket (head/cylinder) 8. Gasket (cylinder/ crankcase) g Stud (2) 70. Gasket 7 7. Insulating flange 72. Locking tab (2) 73. Nut (2) 74. Flat washer (4) (247 ENGINE TYPE). PAGE 6 ~8 !rFiO--~ ~ 27 75. Nut (head) (4) 76. Locking sleeve 7 7. Decompressor 78. Cable 79. Switch housing 20. Cap nut 27. Knob 22. Spnng plate 23. Spring plate reinforcement 24. Spring lock 25. Lockwasher 26. Screw 27. Needle beanng

Clean all metal components in a non-ferrous metal cleaner. Scrape off carbon formation from cylinder exhaust port. cylinder head and piston dome using a wooden spatula. O NOTE: The letters "AUS" (over an arrow on the piston dome) must be visible after cleaning. Clean the piston ring grooves with a groove cleaner tool. or with a piece of broken ring. DISASSEMBLY & ASSEMBLY 000 Place a clean cloth over crankcase to prevent circlips from falling into crankcase. Use a pointed tool to remove circlips from piston. _ CAUTION: When tapping out gudgeon pins, hold 'Y piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod. At assembly. place the piston over the connecting rod with the letters" AUS" (over an arrow on the piston dome) facing in direction of the exhaust port. EXHAUST SECTION 03 SUB-SECTION 02 (ENGINES) Piston to cylinder wall clearance should be: Minimum - Maximum 0.065 - 0.200 mm (.0026") - (008") O NOTE: Once the circlips are installed turn each circlip so the circlip break is not directly on piston notch. Remove any burrs on piston caused through circlip installation with very fine emery cloth. Circlip break Piston notch @@Position cylinder head on cylinder with fins in line with crankshaft center line. Cross torque retaining nuts to 20 N'm (15 ft-Ibs). @Tab washer should be replaced if bent more than three (3) times. If in doubt replace. '(247 ENGINE TYPE). PAGE 7

COOLING SYSTEM l! MAGNETO AND 0. ~T 4S 10 ~ i l I I 11,1 . ~ I ~.'''''' ~ •• ,W ~ ~ ..... ~I CD 7 00'--- c::'!'Q;. I I 15 12 26--:/ /~ ~ I'~ I J".!P. CD 9 13 I . (Q .'.. ';';1(») @Jo C 33 35 I 1<§91 ff -34 n (1-33 ~-36 T 29- I. Armature plate 2. Condenser 3. Lubncatlng wick 4. Generator coil 5. Distance sleeve I I mm (2) 6. Lighting co'; (brake) 7. Phillips cyllndncal head screw M5 X 32 (2) 8. Lighting coil 9. Phillips cylindrical head screw M5 X 28 (2) 10. Contact breaker I 7. Female connector (5) 12. Magneto nng 13. Spnng seat 14. Cam spnng 15. 8reaker cam 16. Magneto housing (247 ENGINE TYPE). PAGE 8 'T-~,; 19 r . f" 18 @ 17 17. Spnng 18. Centnfugal weight 19. PivOt screw 20. Lockwasher (8) ........ 2 I. Allen bolt M6 X 22 (4) 22. Nut MI8 X 1.5 23. "Loctite 242" (blue - medIUm strength) 24. Fan 25. Nut M6 (4) 26. Washer (3) 27. Lockwasher (3) 28. Allen bolt M5 X 18(3) 29. IgnitiOn call 30. Ground cable 3 I. Junction block bracket 32. Cylindncal slotted head screw M5 X 22 (3) 41 45 [ 37 33. Protection cap 34. Igmtion cable 360 mm 35. Suppressor cap 36. Spark plug M7A (MI75T7) 37. Fan cowl 38. Stud M8 X 23 (3) 39. Lockwasher (4) 40. Nut M8 (4) 4 I. Air deflector 42. Spring washer (2) 43. Slotted flat head screw M5 X 8 (2) 44. Cable clamp 45. Cylindrical slotted head screw M3 X 16 46. Cable grommet

CLEANING Clean all metal components in a non-ferrous metal cleaner . ., CAUTION: Clean armature using only a clean y cloth. DISASSEMBLY & ASSEMBLY O NOTE: It should be noted that to correctly remove a "Loctite" locked screw, it is first necessary to tap on head of screw to break Loctite bond. This will eliminate the possibility of screw breakage. o To replace a condenser, it is first necessary to discon- tinue the two (2) black leads uSing a soldering Iron. The condenser can then be driven out of the armature plate using a suitable pusher. To reinstall, inverse procedure. When replacing contact breaker. apply a light coat of grease on lubricating wick. 0®® Whenever a call is replaced. the air gap (dls- stance between magnet and call end) must be adjusted. To check air gap. Insert a feeler gauge of 0.25-0.38 mm (.010" - . 0 1 5") between magnet and coil ends. If necessary to adjust. slacken retaining screws and relocate coil. Checkmg air gap @)With magneto retaining nut removed and hold-on support in place. install special puller onto hub. Tighten puller nut and, at same time, tap on bolt head using a hammer to release magneto from its taper. SECTION 03 SUB-SECTION 02 (ENGINES) Hold-on support At assembly, clean crankshaft extenSion (taper) then apply .. Loctite 242", position magneto on crankshaft with the keyway and the cam notch positioned as Illustrated. ," '-'-' , .. ;:;;::~ .. ~ .... --- // // @Atassembly. apply a small amount of grease into spring seating. @@Atassembly, apply" Loctlte 242" on screws threads. @At assembly, thoroughly clean threads and apply" Loc- tite 242", then torque retaining nut to 73 Nom (54 ft-Ibs). (247 ENGINE TYPE). PAGE 9

2. Engine support 3. Lockwasher B mm (6) 4. Bolt MB X 1.25 X 20. (6) 5. Cup (2) 6. Anchor pad (3) 7. Bushing (3) B. Flat washer 10.5 mm (3) g. Lockwasher 10 mm (2) 10. Bolt MIO X 150. X 50. (3) II. Nut IOmm 12. Gasket (2) 13. Air deflector 14. Exhaust manifold 15. Lockwasher B mm (2) 16. Bolt MB X 30. (2) I 7. Exhaust elbow lB. Spnng (6) 19. Muffler 20. Muffler support 21. Bolt M6 X 1.0.0. X 40. 22. Spring 23. Flat washer 6.4 mm 24. Nut 6 mm 25. Spnng (2) 18 26. Spring 27. Washer ~ 19 SECTION 03 SUB-SECTION 02 (ENGINES) 277 ENGINE TYPE ENGINE SUPPORT AND MUffLER o /-/ ./' ((/~I • ii 1~7 ,I @~,- : "'" a£=-~ ~f1~~ ,~ ® ...... l~ .r1i~ 6 7 8 9 ® (277 ENGINE TYPE). PAGE 1

ENGINE SUPPORT AND MUffLER REMOVAL FROM VEHICLE Remove or disconnect the followings then hft engine from vehicle. - Pulley guard and drive belt - Muffler - Throttle cable and Intake silencer - Fuel lines - Electrical connectors - Hood retaining cable - Bolts (3) securing engine support to chassis DISASSEMBLY & ASSEMBLY @@Torque to 21 N"m (15 ft-Ibs). @@Torque to 55 N"m (40 ft-Ibs). INSTALLATION ON VEHICLE To install engine on vehicle, inverse removal procedure. However, pay attention to the followings. .. Check tightness of engine mount nuts, and drive pulley bolt . .. After throttle cable installation, check carburetor max- imum throttle slide opening . .. Check pulley alignment. (277 ENGINE TYPE), PAGE 2

2. Crankcase half (P. T. 0..) 3. Polyamld ring, magneto side 4. PolyamJd ring, p, T. 0. side 5. Dowel tube 7 7.B X 75 mm (2) 6. Lockwasher 8 mm (5) 7. Hexagonal bolt M8 X 74 (2) B. Hexagonal bolt MB X 55 (3) 9, Gasket 70.. Stud M8 X 775 (4) 77, Crankshaft 72. Distance ring, P. T. 0. side 73. Ball beanng 630.6, P. T. 0. side 74. Seal, P. T. 0. side 75. Distance ring, magneto side 76, Shim G. 7, 0.2, 0.3 or 0..5 mm 7 7. 8all bearing 6305, magneto side 7 B. Seal, magneto side 79. "Loctite 242" (blue, medIUm strength) 20. Woodruff key SECTION 03 SUB-SECTION 02 (ENGINES) BOTTOM END 10-- @ @ !~" Iff (' ,..." (2) 6 10 fi I i(~ r~ CD (277 ENGINE TYPE). PAGE 3

BOTTOM END CLEANING Discard all seals and gaskets. Clean all metal components in a non-ferrous metal cleaner. DISASSEMBLY & ASSEMBLY General Refer to Technical Data (02) and Engine tolerances measurement (03-01) sections for some component fitted tolerance. If necessary, refer to Drive Pulley section (05-03) to remove drive pulley. 800000 not remove unless necessary. To remove, heat slightly with a butane torch then pry out using a screwdriver. ' To install, apply oil on outside diameter then use no. 420276930 pusher for magneto side and no. 420276940 pusher for P.T.O. side. (277 ENGINE TYPE), PAGE 4 Chanfer towards inside of crankcase \ ~! pusher no. polyamid nng o <:VAt assembly, torque to 21 Nom (15 ft-Ibs) following illustrated sequence. t! no o , @@Crankshaft end-play should be: Minimum 0.20mm (008") Maximum OAOmm (016") O NOTE: Crankshaft end-play is adjusted only when crankshaft and/or crankcase is replaced.

a) Measure crankcase. To do this first measure each half from mating surface to bottom of bearing seat. Add measurements of both halves then add 0.30 mm (.012") for gasket displacement. Equals A. Bearing seat b) Measure thickness of each ball bearing and of standard shims on each side (@ and @). Measure distance between bearing shoulders on crankshaft. Add mea- surements. Total equals B. Measuring the thickness of the ball beanng, SECTION 03 SUB-SECTION 02 (ENGINES) Measuring the distance between ball beanng shoulders c) Subtract measurement B from measurement A minus tolerance. Total balance is distance to be shimmed. Shim(s) must be located between magneto side bear- ing and crankshaft blade. @@Standard shims must be installed with the inside diameter rounded edge facing crankshaft blade. Rounded edge facmg crankshaft blade. @@Use appropriate puller to remove ball bearings from crankshaft (see Tools section). ~~~@~~~ p.T,a, Side Magneto Side Protective cap (PTO. Side) O NOTE: Prior to magneto side bearing installation, install required shim(s) (crankshaft end-play) on crankshaft extension. At assembly, place bearings into an oil contained heated to 100°C (210°F). This will expand the bearings and permit them to slide easily on the shaft. (277 ENGINE TYPE), PAGE 5

0@To remove or install a seal inside the crankcase, use no 420 277 865 pusher for magneto side and no. 420876 660 pusher for P.T.O. side. O NaTE: To remove seals. push from outside the crankcase towards the inside. To install push from the inside towards the outside. '\ REMOVAL (277 ENGINE TYPE). PAGE 6 \ l ~ "--~~1.-) C";::;-"-;:' ~- --:::'-::::-~ttl _ :...--=.... __ 0 =>... . "' , - INSTALLATION Before crankshaft installation. apply a light coat of lithium grease on sea! inside diameter lip. for a longer service life.

TOP END I. Needle bearing 2. PiSton 3. Rectangular nng 4. Semi-trapez nng 5. Gudgeon pin 6. Cij-clip (2) 7. Cylinder gasket 8. Cylinder 9. Cylinder head gasket 10. Cylinder head II. Washer 8.4 mm (4) 12. Distance nut 8 mm X 27.5 (4) 13. Gasket 14. Intake manifold 15. Lockwasher 8 mm (2) 16. Bolt M8 X 30 (2) 17. Insulating rubber (277 ENGINE TYPE). PAGE 7

TOP lEND CLEANING Discard all gaskets. Clean all metal components in a non-ferrous metal cleaner. Scrape off carbon formation from cylindre exhaust port. cylinder head and piston dome using a wooden spatula. O NOTE: The letters "AUS" (over an arrow on the piston dome) must be visible after cleaning. Clean the piston ring grooves with a groove cleaner tool, or with a piece of broken ring. DISASSEMBLY & ASSEMBLY o ®® Place a clean cloth over crankcase to prevent circlips from falling into crankcase. Use a pointed tool to remove circlips from piston . .., CAUTION: When tapping out gudgeon pins, hold .. piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod, At assembly, place the piston over the connecting rod with the letters" AUS" (over an arrow on the piston dome) facing in direction of the exhaust port. EXHAUST ~, ~II~ i~""~ Once the circlips are Installed turn each circlip so the circlip break is not directly on piston notch, Remove any burrs on piston caused through circlip installation with very fine emery cloth. p"ton notch I ( ~ \ -41:1 i~, clrclip break (277 ENGINE TYPE), PAGE 8 Cylinder to wall clearance should be: MINIMUM - MAXIMUM 0.060 - 0,200 mm (.0024) - (,008") ®®@ Position cylinder head on cylinder with nuts and push cylinder towards magneto while cross torquing nuts to 21 Nom (15 ft-Ibs). Push cylinder towards magneto @ Position insulating rubber as illustrated, ~\~~ .--;;;.

32 31~ ~J ~ 34-~ B-31 30-"'" " 9'Q 29-tl 7. Armature plate 2. Condenser 3. Lubricating wick 4. Generator coil 5. Distance sleeve 7 7 mm (2) 6. Lighting coil 30W 7. Screw M5 X 32 (2) B. Lighting coil 7 7 OW 9. Screw M5 X 2B (2) 70. Female connector (4) 7 7. Breaker point 72. Magneto ring 73. "Loctite 2 7 7 " (red high strength) SECTION 03 SUB-SECTION 02 (ENGINES) MAGNETO AND COOLING SYSTEM CD 0 ' 11- '-. ' L , 12 19 ,,@ II 21 7 4. Magneto housing 7 5. Lockwasher 6 mm (4) 76. Bolt M6 X 22 (4) 7 7. Lockwasher 7 B mm 7 B. Hexagonal nut 7 B mm 79. Fan 20. Lockwasher 6 mm (4) 27. Hexa90nal nut 6 mm (4) 22. Washer 23. Starting pulley 24. Lockwasher 6 mm (3) 25. Bolt M6 X 74 (3) 26. Washer 5.3 mm (3) 27. Lockwasher 5 mm (3) 2B. Bolt M5 X 7 B (3) 29. Ignition coil 1~ 38 36 ~ 39 30. Self-tapping screw M5 X 22 (3) 37. Protection cap (2) 32. Ignition cable 390 mm 33. Suppressor cap 34. Spark plug W3C (W275 T2) 35. Cable grommet 36. Fan cowl 37. Lockwasher 6 mm 3B. Screw M6 X 73 39. Self-tapping screw M6 X 30 (5) 40. Cylinder cowl 47. Rubber washer (4) 42. Cup (4) 43. Lockwasher B mm (4) 44. Bolt MB X 76 (4) 45. Bolt MB X 25 (3) (277 ENGINE TYPE), PAGE 9

MAGNETO AND COOLING SYSTEM CLEANING Clean all metal components in a non-ferrous metal cleaner . .., CAUTION: Clean armature using only a clean ." cloth. DISASSEMBLY & ASSEMBLY O NOTE: It should be noted that to correctly remove a "Loctite" locked screw, it is first necessary to tap on head of screw to break "Loctite" bond. This will eliminate the possibility of screw breakage. 0To replace a condenser, it is first necessary to discon- nect the two (2) black leads using a soldering iron. The condenser can then be driven out of the armature plate using a suitable pusher. To reinstall, inverse procedure. @When replacing breaker point. apply a light coat of grease on lubricating wick. 0®®Whenever a coil is replaced. the air gap (distance between magnet and coil end) must be adjusted. To check air gap. insert a feeler gauge of 0.25-0.38 mm (.010"-.015") between magnet and coil ends. If necessary to adjust. slacken retaining screws and relocate coi!. Checking air gap o o (277 ENGINE TYPE). PAGE 10 @@With magneto retaining nut removed. adjust special puller. Tighten puller bolt and. at same time. tap on bolt head using a hammer to release magneto from its taper. Puller O NOTE: To lock crankshaft in position. insert no. 420 876 640 locking rod in crankcase pulsation hole when piston is at T.O.C. (top dead center). At assembly. clean crankshaft extension (taper) then apply "Loctite 242" position magneto on crankshaft. Clean nut threads and apply "Loctite 242" on them before tightening nut to 85 Nom (63 ft-Ibs). @At assembly. apply "Loctite 242" on screw threads.

14 X 2i (2) 2, Flat washer (4) 5, VibratIOn absorber (4) 6, Engine support 7, Nut t - 24 (2) 8, Distance sleeve (4) g, Washer (4) 10 Lockwasher (4) II, Nut 10 mm (4) 12, Gasket (2) 13, Exhaust manifold (2) 14 Lockwasher (4) 0-21 <$-20 GJ-20 4JI-21 SECTION 03 SUB-SECTION 02, (ENGINES) 354, 454 ENGINE TYPES ENGINE SUPPORT &. MUFFLER 15, Allen bolt M8 X 30 (4) 16, Tuned pipe (P, T 0, Side) 17, Tuned pipe (magneto Side) 18, Spnng (4) I g, Rubber shear mount (2) 20 Washer (4) 21, Nut t - 16 (4) 24, Spnng 25, Coupler (2) 26, Tall pipe (P, TO, Side) 27, Tall pipe (magneto Side) 28, Spnng (4) 29, Muffler 30 Support 31, Spnng (2) 33, Bolt t - 20 X leu (3) 34, Washer (3) 38, Lockwasher (3) 39, Spnng 40 Spnng seat 41, Seal nng (4) 42, Bolt 5/16 - 18 X 2 r' 43, Reinforcing cross support 44, Stopper plate 45, Internal tooth dished washer (2) 46 Bushing (2) 47, Rubber bushing (2) 48, Threaded bushmg (2) 49, Retaining washer (2) 50 Spnng (2) 51, Retaining washer (2) 52, Bushing 53, Flat washer 54, Nut 5/ 16 - IB (354-454 ENGINE TYPES), PAGE 1

ENGINE SUPPORT & MUFFLER REMOVAL FROM VEHICLE Disconnect or remove the followings from vehicle: - Pulley guard and drive belt - Air silencer and throttle cable - Fuel lines, pnmer and pulsation lines - Muffler - Electric wires - Drain the cooling system and disconnect hoses at engme - Rotary valve oil reservoir - Disconnect rewind starter at engine DISASSEMBLY & ASSEMBLY @Torque to 35 0 m (26 ft-Ibs). @)Torque to 22 Nom (16 ft-Ibs). INSTALLATION ON VEHICLE To install engine on vehicle, reverse removal procedure. However. pay attention to the followings: • Check tightness of engine mount nuts . .. After throttle cable Installation. check carburetor maxi- mum throttle slide opening . .. Check pulley alignment. (354-454 ENGINE TYPES). PAGE 2

! ~-,' \ ~ 27\~ \IV" I ~ ~JfVJ I I) I ~ I r.;>, 21 - , 24 ® 17-~ 1. " I SECTION 03 SUB-SECTION 02, (ENGINES) COOLING SYSTEM 19 I @)-21 ,.r fJ ~ 7 Plug (2) 2. Dram valve 3. Tank support 4. ElastiC stop nut 70-24 (2) 5. Coolant tank 6. Flat washer 9132 X 518 (2) 7. ElastiC stop nut *-20 (2) 8, Clip nut (2) 9. Lockwasher 31 76 (2) 70. 80lt 70-24 X j," (2) 7 7. Pressure cap 7 2. Overflow hose 343 mm (73.5") 1. 73. Clip 74. Radiator (2) 75. Radiator protector (2) 76. Self-tappmg screw 70-24 X !" (2) 7 7. RiVet (38) 7 8. Elbow hose 79. "U" hose 20. Outlet hose 2 7. Clamp (6) 22. Hose 559 mm (27 75") 23. Clamp (2) 24. Sealmg nng 25. Thermostat 26. Sensor 27. Outlet collar (354-454 ENGINE TYPES), PAGE 3

COOLING SYSTEM INSPECTION Check general condition of hoses and clamp tightness. DRAINING THE SYSTEM To drain the cooling system, remove the coolant tank cap . • WARNING: Never drain or refill the cooling system when engine is hot. C'onnect a drain hose to the drain valve at pump housing. Open valve and drain system. O NOTE: Open end of drain hose should be lower than engme base. However. to completely drain the system. blow Into the tank through the vent tube while blocking the tank filler neck with one hand to prevent air leakage. (354-454 ENGINE TYPES). PAGE 4 DISASSEMBLY & ASSEMBLY 00@Apply pipe thread sealant to avoid leaks. @See If the cap pressunzes the system. If not. Install a new 13 Ibs cap. do not exceed 13 Ibs of pressure. @To check thermostat. put It In water and heat water. Thermostat should open when water temperature rea- ches 43°C (110°F) REFILLING THE SYSTEM Capacity: Approximately 5 liters (1.1 Imp. gaL) (1.3 U.S. gaL) 55% antifreeze + 45% water To refill the cooling system. unscrew plug on top of cylinder head. Refill tank and blow Into It through the vent tube. while maintaining the hand over the filler neck. until the liquid comes out at the plug hole on the cylinder head. O NOTE: It is necessary to refill tank as soon as it becomes empty. Screw plug on cylinder head and continue to pour the liqUid In the coolant tank until the coolant level reaches 25 mm (1") below filler neck. Reinstall tank cap and start engine; let engine run until It reaches its operating temperature and thermostat opens. Allow It to run a few minutes more. Stop engine and check coolant level.' refill as necessary . • WARNING: Always unscrew cap to the first step with a cloth to release pressure, before removing it.

BOTTOM END (g), I @ I @ ~~ 1 26 @ "-...~~ ~;~ oo~~J ~ 10 1 1. Crankcase upper half 2. Crankcase lower half 3. "Locwe 5 15" 4. Angular tube (0;/ mlet) 5. Bolt MB X lB B. Sealmg rmg 7. Angular tube (0;/ outlet) B. Cylmder stud (79 mm) (4) 9. Cylmder stud (104 mm) (4) 70. Junction block support 1 1. Lockwasher (2) 12. Screw M 5 X 12 (2) 13. Lockwasher B mm (10) 14. Bolt MB X 45 (2) 15. Allen bolt MB X 40 (4) lB. Bolt MB X 35 (2) 17. Stud Ml0 X 42 (4) lB . . Locwe 242·· 19. Lockwasher 10 mm (4) 20. Nut M 70 (4) 21 Crankshaft 22 Woodruff key 23. Needle cage beanng (2) 24 .. ·Loclite 242·· 25. Shim (I mm) 2B. Distance nng (2) 27. Bearmg (4) 2B . . -0 .. nng (5) 29. a,l seal (2) 30. Labynnth sleeve ® ® 22 1 26 1@ ~m(()) ~ 21 C!f ® 24 0 @~@ 13-], 11\,' @-J,J, 18-{(~~~1 ® --~ t13-@~a·"',3' 19- ~ -@ "'" @ ""_ "-13 @J-@ "'" n j!-@ ~ q @ (354-454 ENGINE TYPES). PAGE 5

BOTTOM END CLEANING Discard all all seals, gaskets, "0" nngs and sealing rings, Clean all metal components in a non-ferrous metal cleaner. Remove old "Loctite" from crankcase mating surfaces with Bombardier sealant stripper. ... CAUTION: Never use a sharp object to scrape " away old sealant as score marks incurred are detrimental to crankcase sealing. DISASSEMBLY & ASSEMBLY 000Crankcase halves are factory matched and there- fore, are not interchangeable or available as single halves. Prior to jOining of crankcase halves, apply a light coat of "Loctlte 515" (413 702700) on mating surfaces. ... CAUTION: Before joining of crankcase halves be ... Sure that crankshaft rotary valve gear is well engaged with rotary valve shaft gear. Position the crankcase halves together and torque bolts by hand, then Install armature plate (tighten) on magneto side to correctly align crankcase halves, Torque bolts to 22 Nom (1 6ft-lbs) following Illustrated sequence. o 15 7 3 9 5 13 16 B 12 4 10 6 14 NOTE: Torque the two smaller bolts (15 and 16) on magneto side to 13 Nom (10 ft-Ibs), 00@Apply "Loctlte 242" on threads pnor to assem- bly. (354-454 ENGINE TYPES), PAGE 6 @@Because of cap nuts, cylinder studs have to be screwed into the crankcase so that they do not exceed further than 82.5 mm (3.250") on exhaust Side and 57.5 mm (2.260") on Intake Side. n 575 mm Apply "Loctlte 242" on the threads of the two studs screwed above the intake ports . @@Torque to 22 Nom (16 ft-Ibs), @Torque to 14 Nom (10 ft-Ibs). @At assembly on crankcase, apply "Loctlte 242" on threads. @Torque to 35 Nom (26 ft-Ibs). @®@lTo remove beanngs from crankshaft, use a pro- tective cap and special puller as Illustrated. Prior to Installation, place bearings into an oil container previously heated to 1 OO'C (212' F). ThiS will expand bearing and ease installation. Install bearings With groove as per the follOWing illustration,

gap of 0.5 mm (.020") must be left between bearing and labyrinth sleeve to avoid axial forces to the beaflng. ., 0.5 mm @At assembly. apply a light coat of lithium grease on seal lips. To insure adequate oil supply to the bearings (magneto and PTO. sides). install oil seals with a gap of at least 0.60 mm (.025") with bearing. SECTION 03 SUB-SECTION 02, (ENGINES) (354-454 ENGINE TYPES). PAGE 7

ROTARY VALVE AND COOLANT PUMP '_31 37 ~ 32-10 ~-33 Q. 23 22 @ ~ I~iil I 25 2~ .. C ,.19 @ " ~ ~/?~, :~~~~-~:( .. ~> 38 _ ",.ji".". \~"---..\l 37 '" •.•.• ';"o'j Il~~· .. \·,,:~·r/;.·.r~,.,¥/j- · .... i, -~\ / .' .... " / ,_: \ • ~ \....... ... ... ~~, l~~1~':::-' ~t,:/ ... "'::',;\~:) " "fIf~,'" "" ® lj" i ,',to.! '." ~ .... ,~ I '. ~ ~.J .l... ® l";:J>.. .......... ,~,..· _-' II'"~ C\ ,,_ ~~~. ':'1', ' '. . ...... ,:. 4 ~", 7 5.

PUMP CLEANING Discard all all seals and "0" nngs Clean all metal components in a non-ferrous metal cleaner. DISASSEMBLY & ASSEMBLY @Torque to 20 N'm (15 ft-Ibs). ®Rotary valve adjustment when replacing crankcase having no timing marks. REQUIRED TOOLS Angle finder (4143529 00) ~ ~~ ~~ TOC gauge (4141047 00) ENGINE TYPE 354 - 454 TIMING MARKS opening, closing 132°.52° SECTION 03 SUB-SECTION 02, (ENGINES) For example: 132 ° opening 52 ° closlOg USing angle finder. mark crankcase at 132 ° from bottom edge of magneto side IOlet port. n f:j, From top edge of magneto side inlet port, mark crankcase at 52". -~ '©'// '"Q Magneto side Inlet port (354-454 ENGINE TYPES). PAGE 9

To correctly install the rotary valve disc proceed as follows: - Turning crankshaft counter-clockwise. (drive pulley side) bring magneto side piston to Top Dead Center uSing a T.D.C. gauge. - Position the rotary valve disc on gear to have edges as close as possible to the marks. O NOTE: The rotary valve disc IS asymmetrical. there- fore. at assembly try positioning each side of disc on gear to determine best installation position. Magneto side piston ~~stbeatTD,c ~ -~ Timing marks (2) 0At assembly. apply crankcase sealant "Loctite 515" on bearing and rotary valve shaft mating surfaces. Bearing (354-454 ENGINE TYPES). PAGE 10 Apply loctlte 515 (2) through @Rotary valve shaft assembly To remove rotary valve shaft assembly from crankcase, first remove coolant pump impeller@andclrclip0. Using the suitable pusher (P I N 420 876 610) and a fiber hammer. push shaft assembly. /, "'-- Tool no 420876610 If it is necessary to disassemble components of rotary valve shaft assembly. compress spring retaining CUP@1n order to remove circ!ip @. To install shaft assembly and oil seal. use pusher no. 420876 600 Tool no 420876600

At assembly apply "Loctite 271" Inside of distance sleeve. @Using a suitable pusher, push coolant pump bearing with shield opposite to rotary valve disc, To remove bearing To install bearing @@Uslng no, 420876510 pusher, Install all seals (with lithium grease on seal lips). SECTION 03 SUB-SECTION 02, (ENGINES) Distance ring opening must be in line with crankcase half draining hole, ~ ® Draining hole @Apply "Loctite 242" on threads. (354-454 ENGINE TYPES), PAGE 11

TOP END CD G1J ls-22 ;7 0- --------© o ~ '~2 ac~ G G ® ~---1O 17-C-~ I? (J-@ 0lj @l @ "-21 @- @- 16 --{)..-----I (354-454 ENGINE TYPES). PAGE 12 7. Cap nut MS (12) 2. Flat washer 8.4 mm (12) 3. Cylinder head 4. Coolant outlet coffar 5. Stud M6 X 75 (2) 6. Stud (head) M8 X 44 (72) 7. Gasket (2) 8. Gasket ("0" nng) (2) 9. Cylinder (2) 70. Cylinder/crankcase gasket (2) 77. Lockwasher 6 mm (2) 72. Flat washer 8.4 mm (S) 73. Cap nut MS (8) 74. Cylinder stud (79 mm) (4) 75. Cylinder stud (704 mm) (4) 76. "Loctite 242" 7 7. --L" ring (2) 7 S. Piston (2) 79. Gudgeon pm (2) 20. Clrcilp (4) 27. Needle beanng (2) 22. Silicone sealant 23. Nut M6 (2)

Clean all metal components in a non-ferrous metal cleaner. Scrape off carbon formation from cylinder exhaust port, cylinder head and piston dome using a wooden spatula. O NOTE: The letters" AUS" (over an arrow on the piston dome) must be visible after cleaning. Clean the piston ring grooves with a groove cleaner tool, or with a piece of broken ring. DISASSEMBLY & ASSEMBLY 00 0Prior to washer installation, apply silicone sealant around studs. Torque cylinder head nuts to 22 N'm (1 6 ft-Ibs) following illustrated sequence. ®®Because of cap nuts, cylinder head studs have to be crewed into the cylinder so that they do not protrude by more than 43 mm (1 ,7DD"). If it is not possible to obtain this length, add a washer between cylinder head and cap nut. Shorter threaded part of stud should be screwed into cylinder. 43mmtdE:f~ ~ ~ (\/' SECTION 03 SUB-SECTION 02, (ENGINES) When reassembling the cylinders to the crankcase, it is Important to have them properly aligned so that the cylinder head holes will match up with the studs. A special tool (as per illustration) (or cylinder head itself) can be used to align the cylinders. Cross torque cylinder nuts to 22 N'm (16 ft-Ibs). AlIgnmg tools no, 420 876 575 (354-454 ENGINE TYPES), PAGE 13

@@ Because of cap nuts, cylinder studs have to be screwed mto the crankcase so that they do not protrude by more than 82.5 mm (3.250") on exhaust side and 57.5 mm (2.260") on intake side. Apply "Loctite 242" on the threads of the two studs screwed above the intake ports. @@@Place a clean cloth over crankcase to prevent Clrclips from falling into crankcase then use a pointed tool to remove circlips from piston. . Drive the gudgeon pins or out using a suitable drive punch and hammer . ... CAUTION: When tapping gudgeon pin in or out '" of piston, hold piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod. At assembly, place the pistons over the connecting rods with the letters AUS (over an arrow on the piston dome) facing the direction of the exhaust port. (354-454 ENGINE 1YPES), PAGE 14 Piston to wall clearance should be: TYPE 354 454 MINIMUM 0.080 mm (.0031 ") 0.090 mm (0035") MAXIMUM 0.180 mm (007") 0.200 mm (008") Once the circlips are installed, turn each circlip so that the circlip break is not directly in line with piston notch. Using very fine emery cloth, remove any burrs on piston caused through circlip installation. ~ ~ >' , ~ ~. ~ Piston notch Clfclip break

@ MAGNETO :fJ ~o @.··VJ~ 00 .:0 @ . . I "<0 30 ® 24 I 23 CD ~ 17 f ~ #~ L 8 II 5 ~ 8 iJ 22 25 '1 12 34 35 1 ti~ ~9 ~@ 31 ·---33 8 17 16 15 32 7. Armature plate 75. Washer 6.4 mm (4) 2, Tngger cOils 76. Lockwasher 6 mm (4) 3. Magneto nng 77. Bolt M6 X 20. (4) 4. Electronic box (2) 78, Clip (up to serial number 3758 5. Protection cap (4) 777) 6, Ignition cable 540. mm 7 g. Lockwasher 6 mm (up to serial 7. Suppressor cap (2) number 3758 777) 8. Spark plug 454: W08 SC 20.. Cylindrical head screw M6 X 8 (W34D S2S) (2) (up to serial number 3758 777) 354: W 2 CO (W3DD MZ2) (2) 27. Magneto hOUSing (up to senal g. Protection cap (2) number 3777 747) 70. Connector hOUSing (2) 22. "Loctite 277" (red, high 7 7, Cable grommet strength) 72. Washer 5,3 mm (4) 23, Bolt M5 X 70. (8) 73, Lockwasher 5 mm (4) 24, Starting pulley (up to serial num- 74, Allen screw M5 X 78 (4) ber 3777 747) 25, Flywheel (up to serial number 3777747) 1..1 i!l\--.- 0 If '-0 26. Lockwasher 8 mm (3) 27. Bolt M8 X 25 (up to senal num- ber3777 747( (3) 28. Magneto housing (serial number 3777 748 and up) 29. Starting pulley (serial number 3777 748 and up) 3D. Hexagonal bolt M8 X 76 (serial number 3777 748 and up) 37. Female connector (73) 32. Round slotted head machine screw t-20 X V' (4) 33. Rubber spacer (4) 34. Lockwasher 22 mm 35. Hexagonal nut 22 X 7.5 mm 36. "Loctlte 242" (blue, medium strength) (354-454 ENGINE TYPES), PAGE 15

MAGNETO CLEANING Clean all metal components in a non-ferrous metal cleaner . .. CAUTION: Clean armature and magneto using '" only a clean cloth. DISASSEMBLY & ASSEMBLY 0To obtain best generator coil performance. position the armature plate on the crankcase with the retaining cap screws in the middle of the plate slots. CD Check air gap between magneto ring and trigger coil. The gap should be 0.8 - 1.2 mm (.031 - .047"). @@@To remove magneto. use special puller as illus- trated. Tighten puller bolt and at same time. tap on bolt head using a hammer to release magneto from its taper. (354-454 ENGINE TYPES). PAGE 16 At assembly. clean crankshaft extension (taper) then apply" Loctite 242". 0@At the re-Installation or verification of the ignition system electric connections, all the connections must be coated with lithium grease or dielectric grease to pre- vent corrosion. .. CAUTION: To prevent moisture, ensure no air is ". trapped within the connections. Do not use silicone sealant as contacts will corrode, @Prior to assembly. clean threads then apply" Loctite 242" . Torque to 80 Nom (60 ft-Ibs).

W en ..... C ..... OJ , en w " m m 0 2 -I " m z 0 z m :! -u C) 0 "" -u - 2 l> 2 0 GJ m !'-len m - m -f mO 2-1 -< G) 0 "a 2 2 m m 0 !:!J w

377 ENGINE TYPE ENGINE SUPPORT AND MUFFLER ,--- @ 1'0 ~Ui 8 (377 ENGINE TYPE), PAGE 2 ''@ J ~~ o 1 ,lT~ ®

2. Engine support 3. Lockwasher 10 mm (3) 4. Hexagonal head capscrew MIO X 25 mm (3) 5. Hexagonal head capscrew MIO X 35 mm (2) 6. Hexagonal elastic stop nut 10 mm (2) 7. Cup (2) B. Rubber shear mount (3) g. Bushing (3) 10. Flat Washer 10.5 X 21 X 2 mm (3) I I. Lockwasher 10 mm (2) 12. Hexagonal head capscrew M lOx 45 mm (3) 13. Hexagonal elaslic stop nut 10 mm 14. Gasket (4) 15. Exhaust manifold ENGINE SUPPORT AND MUFFLER REMOVAL FROM VEHICLE Remove or disconnect the followings (if applicable) then lift engine out of vehicle. • Pulley guard, drive belt. e Muffler. e Air intake silencer. .. Throttle cable at carburetor. " Fuel lines and pulsation line. O NOTE: Secure fuel lines so that the opened ends are higher than the fuel level in the tank. e Hood retaining cable. " Rewind starter cable. e Wiring harness. + WARNING: Before disconnecting any electrical wire in starter system always first disconnect the battery cable, .. Engine support nuts. SECTION 03 SUB-SECTION 02, (ENGINES) 16. Lockwasher B mm (4) 17. Hexagonal socket head capscrew MB X 30 mm (4) I B. Connector 19. Spnn9 (6) 20 Muffler 2 I. Muffler support 22. Hexagonal head capscrew M6 X 7.00 X 40 mm 23. Spnng 24. Flat washer 6.4 X 14 X 1.5 mm 25. Hexagonal elastic stop nut 6 mm 2.6. Spring (2.) 2. 7. Sprin9 2.B. Washer 2.9. "Loctite 222 or 242" DISASSEMBLY AND ASSEMBLY 0Apply "Loctite 222 or 242" on threads then torque to 20 N"m (15 ft-Ibs). ®@@Torque to 20 N"m (15 ft-Ibs) . @@Torque to 55 N"m (40 ft-Ibs). INSTALLATION IN VEHICLE To install engine on vehicle, inverse removal procedure. However, pay attention to the followings: e Check tightness of engine mount nuts. e After throttle cable installation, check maximum throt- tle slide opening. " Check pulley alignment. (377 ENGINE TYPE). PAGE 3

BOTTOM END !~~ llr(l) @@ @ ~ I I rrD 15 I 16 I. Crankcase lower half 2. Crankcase upper half 3. Lockwasher S mm (10) 4. Hexagonal screw MS X 45 mm (2) 5. Hexagonal screw MS X 70 mm (S) 6. Lockwasher 6 mm (4) 7. Hexagonal screw M6 X 40 mm (4) S. . 'Loctite 515" 15 g. "Loctite 242" (blue, medium strength) 10. Stud MS X 167 mm (S) I I. Cable grommet 12. Rubber plug (5) 13. Crankshaft 14. Sal/ beanng 6206 (2) 15. Shim I mm (2) 16. Spacer I 7. Seal. P. T. O. side IS. Sail bearing 6207 19. O'ring 20. Seal, magneto side 21. Woodruff key 3 X 3.7 mm (377 ENGINE TYPE). PAGE 4 @ ®() '10 10 12 11--@ 3-© -~ ~,~" ®-~ W-0 -0 B-12 o ~9~ 1{@", I ,(}) @ , ' I @

Clean all metal components is a non-ferrous metal cleaner. Remove old sealant from crankcase mating surfaces with Bombardier sealant stripper . .., CAUTION: Never use a sharp object to scrape ... away old sealant as score marks incurred are detrimental to crankcase sealing, DISASSEMBLY AND ASSEMBLY (2) CD 0 Crankcase halves are factory matched and there- fore, are not interchangeable as single halves. Prior to joining of crankcase halves, apply" Loctite 515" (no, 413 7027) on mating surfaces. Position the crankcase halves together and tighten nuts (or bolts) by hand then install armature plate (tighten) on magneto side to correctly align the crankcase halves, Torque bolts to 21 Nom (15 h-Ibs) following illustrated sequence. 800Torque to 21 N'm (15 ft-Ibs), SECTION 03 SUB-SECTION 02, (ENGINES) @@To remove bearings from crankshaft use a protective cap and special puller, as illustrated. (See Tools section). PTO. side (f([@~ Magneto side ({!(OJ~ 0 ==0 Prior to installation, place bearings into an oil container heated to 100°C (210°F), This will expand bearings and ease installation. Install bearings with groove as per exploded view, P,T,O, side At inner bearing installation, provide a free play of 2 mm (,080") for lubrication between bearing and crankshaft blade, using PIN 420876 620 tool. (377 ENGINE TYPE), PAGE 5

@@At installation. apply a light coat of lithium grease on inside diameter lip of seal. For P.T.O. side outer bearing lubrication, it is necessary to provide a free play of 0.80 mm (.030") between seal and bearing. PTQ. Side 'I' I "l (377 ENGINE TYPEI. PAGE 6

OIL INJECTION PUMP '_6 ~~26 @ 27-~ 18 31 16 19~ 'j I t5 'ii@~~~~ fffP'·" .l~.Y~ " 17 .\Q~I ,.\:J . I I ® I /I~~ ~ Q 27 @ 29 ~ I "'lr 28 10 --~ ~- ~O-5 9_~ ~cQ) ~~-- '/ ..--.... l~':l ~/ I __ 1 23~ (J I u ~ 29 o IT ~ f>laP~ (J?\l) . ,~' _ )";\180 $ ~ EIl'l>~ aU ~ 1. Injection 01/ tank 2. Sealer 9" (229 mm) 3. Grommet 4, Male connector 5. Gasket 6. Oil tank cap 7. Retainer rod 8, Hexa90nal washer head self-tapping screw M6 X 30 mm 9. Retaining washer 10 Hexagonal elastic stop nut 8 mm 11, Oil line 38 mm (1.5") 12.01/ line 356 mm (14") 73. Spnng clip or clamp (4) '-- // 6-3 ~1 ~ ~~I 4 ~ tS5fS!1 I@®"" I ® 8 I ~ I 14 7 I ® ® ® 14. Filter 75. Oil 76, Oil pump mounting flange 17 O'ring 18. Oil pump 19, Washer 6.2 mm (2) 20. Gear 27 teeth 27, Lock nut 6 mm 22. Lockwasher 5 mm (2) 23. Cylindncal slotted screw M5 X 16 mm (2) 24. Ball bearing 25. Gear 9 teeth 26, Banjo gasket (4) 27. Banjo (2) 28. Banjo bolt (2) 29, Oil line 325 mm (13") 30. Clamp (4) 31. Self-tapping screw M5 X 76 mm (4) (377 ENGINE TYPE), PAGE 7

OIL INJECTION PUMP CLEANING Clean all metal components in a non-ferrous metal cleaner. DISSASSEMBLY AND ASSEMBLY O NOTE: Oil pump components are not available as single parts. .., @@CAUTION: On electric start models, it is 'If' recommended to install black rubber lines (P I N 414 2867) that will not be altered by battery fumes. @@At assembly, always check for clamp tightness. @@@lTo remove retaining nut. lock gear in place using no. 420876690 tool. no. 420 876 690 tool At assembly, apply a light coat of grease on gear teeth. (377 ENGINE TYPE), PAGE 8 OIL INJECTION PUMP ADJUSTMENT A) Prior to adjusting the pump, make sure all carburetor adjustments are completed. Eliminate the throttle cable free play by pressing the throttle lever until a light resistance is felt, then hold In place. (A small rubber band can be used). The aligning marks on the pump casting and on the lever must align. If not, loosen the adluster nut and adlust accordingly . Retighten the adluster nut. Adjuster nut Bleeder ~~. ~~.~ B) All oil lines should be full of oil. If required, bleed the main oil line (between tank and pump) by loosening the bleeder screw until all air has escaped from the line. Make sure the tank is sufficiently filled. Check the small oil lines (between pump and intake manifold). If required, fill the lines by running the engine at idle speed while holding the pump lever in fully open position.

V IV \Vf "'"./ I 0 @~'\1l @ o I -@--6 C)-22 C)-23 ~-@ ~ c:ru, I ® ® 24 SECTION 03 SUB-SECTION 02, (ENGINES) TOP END 1, Cylinder flange gasket 2. Cylinder. P. T. 0. side 3. Cylinder, magneto side 4. Cylinder head gasket (2) 5. Cylinder head 6. Washer 8.4 mm (8) 7. Hexagonal nut 8 mm (5) 8. Distance nut 8 X 33 mm (3) g. Intake manifold gasket (4) 10. Intake manifold 11. Lockwasher 8 mm (4) 12. Hexagonal head bolt M8 X 40 mm (2) 13. G'ring 14. Intake manifold cover 15. Hexagonal head bolt M8 X 74 mm (2) 16. Lockwasher 6 mm (2) 17. Hexagonal head bolt M6 X 25 mm (2) 18. Intake manifold (2) 19. Hexagonal socket head bolt M8 X 35 mm 20. NOise damper 21. PiSton (2) 22. Rectangular ring (2) 23. Rectangular ring (2) 24. Needle bearing (2) 25. Gudgeon pin (2) 26. Circlip (4) (377 ENGINE TYPE). PAGE 9

TOP END CLEANING Discard all gaskets. Clean all metal components in a non-ferrous metal cleaner. Scrape off carbon formation from cylinder exhaust port, cylinder head and piston dome using a wooden spatula. O NOTE: The letters "AUS" (over an arrow on the piston dome) must be visible after cleaning. Clean the piston ring grooves with a groove cleaner tool. or with a piece of broken ring. DISASSEMBLY AND ASSEMBLY 000At cylinder andlor cylinder head installation, use PIN' 420876 171 aligning tool to ensure sealing of intake manifold and exhaust (See Tools section), before tightening cylinder head nuts. no. 420 876171 tool (377 ENGINE TYPE). PAGE 10 Cross torque cylinder head nuts to 20 Nom (15 It-Ibs); torque each cylinder head individually. 00position nuts and distance nuts as illustrated. distance nuts Torque nuts to 20 Nom (15 ft-Ibs). o Install a gasket on each side of the air deflector. @@@Torque to 20 Nom (15 It-Ibs) @Install intake manifold with identification marks towards cylinder head. ~~ ~-, Identification marks

~~C:::II~2) F" \) ~D ~= I~F ,I no"e damper 6'= ~~ [I J I~ ~\ PTO side cylinder @@@Place a clean cloth over crankcase to prevent circlips from falling into crankcase. Use a pointed tool to remove circlips from piston. ... CAUTION: When tapping out gudgeon pins, hold '" piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod. SECTION 03 SUB-SECTION 02, (ENGINES) At assembly. place the pistons over the connecting rods with the letters "AUS" (over an arrow on the piston dome) facing in the direction of the exhaust port. EXHAUST ~ ~ ~.'4 Piston to wall clearance should be: MINIMUM: 0.070 mm (.0028") MAXIMUM 0.200 mm (008") O NOTE: Once circlips are installed. turn each circltp so the circlip break is not directly on piston notch Remove any burrs from piston caused through circlip installation using very fine emery c!otch . Clrclip break Piston notch (377 ENGINE TYPE). PAGE 11

MAGNETO 0-11 /j-12 o ~~ I "0 S 1 llfr ~ 17 I o 32 I 30 31 8 ~I I tJ-~~n , d ~-30 ~ ~"'e-29 2S-l)bJ ~ 2S-l)bJ-"'e_29 (377 ENGINE TYPE), PAGE 12 o 7. Armature plate 2, Lighting coil 7 7 OW ~ ~/® 3. Phillips cylindrical head screw M5 X 28 mm (2) 4. Generator cOil 5. Distance sleeve 7 7 mm (2) 6. Lighting coil 3o.W 10 7. Phillips cylindrical head screw M5 X 32 mm (2) 8. Female connector 9. Condenser (2) 70. Contact breaker (2) 7 7. Rubber cap (2) 72, Female connector (2) 73. Lubricating wick 74. Magneto nng 75, Washer 5,3 mm (2) 76. Lockwasher 5 mm (2) 77. Allen screw M5 X 78 mm (2) 34 @ & 78. Lockwasher 6 mm (4) 79, Allen screw M6 X 7 7.5 mm (4) 20. Magneto housln9 27, Fan pulley 22. Starting pulley 23. Lockwasher 8 mm (3) 24. Allen screw M8 X 72 mm (3) 25, Lockwasher 22 mm 26. Hexagonal nut 22 X 7,5 mm 27. "Loctite 242" (blue, medium strength) 28, Ignition coil (2) 29. Self-tappmg screw M5 X 22 mm 30.. Protection cap (4) 37, High tension cable 250. and 780. mm 32. Suppressor cap 33. Spark plug W3C (W275 T2) 34. "Loctite 277" (red, high strength) 25 @

cleaner. .. CAUTION: Clean armature and magneto using " only a clean cloth. DISASSEMBLY AND ASSEMBLY 000 Whenever a coil is replaced. the air gap (distance between coil end and magnet) must be adjusted. To check air gap. insert a feeler gauge of 0.30-0.45 mm (.012"-.018") between magnet and coil ends. If necessary to adjust, slacken coil retaining screws and relocate coil. 0·To replace a condenser. it is first necessary to unsolder the two (2) black leads using a soldering iron. The condenser can then be driven out of the armature plate using a suitable pusher and hammer. To reinstall, inverse procedure. @When replacing contact breakers. apply a light coat of grease on lubricating wick. SECTION 03 SUB-SECTION 02, (ENGINES) @@To remove or install magneto retaining nut. lock crankshaft in position with special hold-on support as illustrated. (See Tools section). hold-on special puller With magneto retaining nut removed. install special puller onto hold-on support. Tighten puller bolt and at same time. tap on bolt head using a hammer to release magneto from its taper. At assembly. clean crankshaft extension (taper) then apply ··Loctite 242·· or equivalent. Install magneto retaining nut (with ··Loctite 242·· on threads) and torque to 85 Nom (63 ft-Ibs). (377 ENGINE TYPE). PAGE 13

COOLING SYSTEM @ 16 1. Fan housing 2. Circlip 3. Shim 1.0 mm (2) 4. Ball bearing (2) 5. Fan shaft 6. Woodruff key 3 X 5 mm 7. Distance sleeve 8. Pulley half 9. Shim 0.5 mm 10. Fan I 1. Lockwasher 16 mm 12. Hexagonal nut 16 X 1.5 mm 13. Fan belt 14. Fan cover 15. Cylinder cowl 16. Speed nut (8) I 7. Cylinder head cowl 18. Cowl sealing strip 380 mm 19. Lockwasher 8 mm (3) 20. Hexagonal screw M8 X 9 mm (2) 2 I. Hexa90nal screw M8 X 16 mm 22. Wasker 4 X 15.8 mm (6) 23. Screw 4.8 X 76 mm (6) 24. Lockwasher 6 mm (4) 25. Allen screw M6 X 30 mm (4) (377 ENGINE TYPE). PAGE 14 .0 °/~li0 ~A @@@I (j~ @

cleaner. DISASSEMBLY AND ASSEMBLY 00 It is first necessary to heat bearing housing to 65 ° C (150°F) to remove or install bearing. ®@Fan belt free-play must be 6 mm (t"). To adjust. install or remove shim (s) between pulley halves. Install excess shim (s) between fan and lockwasher. @To remove or install fan pulley retaining nut. lock fan pulley with special holder wrench. (See Tools section). At assembly. torque nut to 65 Nom (48 ft-Ibs) holder wrench @A gasket must be placed on both sides (inner and outer) of intake and exhaust holes. SECTION 03 SUB-SECTION 02, (ENGINES) (377 ENGINE TYPE). PAGE 15

26- 4--(,") I. Carriage bolt t-24 X It" (4) 2. Threaded bushing (4) 3. Spacer (4) 4. Insulating rubber (4) 5. Bracket (2) 6. Spring leaf (2) 7. Washer (4) 8. Nut (4) 9. Engine support 70. Stud (4) I I. Distance sleeve (4) 12. Washer (4) 13. Lockwasher (4) 14. Nut (4) 15. Bolt 5/ 16-24 X 13116" (6) 16. Washer (6) 17 Nut 5116-24 (6) lB. Support 19. Bolt5/76-IB X 1"(2} 20. Bolt 5/ 16-IB X It" (2) 2 I. Washer (4) 22. Nut 5/16- 18 (2) 23. Alternator 24. Belt 25. ail tank 26. Hose clamp 27 ail tank support SECTION 03 SUB-SECTION 02, (ENGINES) 444 TYPE ENGINE 2B. Hose 120 mm 29. Exhaust gasket (2) 30. Exhaust manifold 3 I. Lockwasher 6 mm (6) 32. Allen screw M6 X 22 (6) 33. Spnng (4) 34. Muffler 35. Exhaust pipe 36. Exhaust grommet 37. Asbestos string 3B. Bolt 5116- IB X 3 t " (2) 39. Cup (4) 40. Bushing (2) 4 I. Spnng (4) 42. Cup (4) 43. Muffler clamp (2) (444 ENGINE TYPE). PAGE 1

ENGINE SUPPORT AND MUffLER REMOVAL FROM VEHICLE Disconnect or remove the followings from vehicle: - Pulley guard and drive belt. - Intake silencer and throttle cable. - Fuel lines. primer and pulsation lines. fuel tank. - Electrical wires (at engine. alternator. starter). + WARNING: Before disconnecting any electrical wire in starter system, always first disconnect the battery ground cable. - Drain the cooling system and disconnect hoses at engine. - Remove engine mount nuts then lift engine from vehicle. DISASSEMBLY AND ASSEMBLY @lAt assembly on crankcase, apply "Loctite 242" on threads. @Torque to 36 Nom (26 ft-Ibs). @Torque to 32 Nom (23 ft-Ibs). @Torque to 21 Nom (15 ft-Ibs). INSTALLATION ON VEHICLE To install engine on vehicle, inverse removal procedure. However, pay attention to the followings: " Check tightness of engine mount nuts. e After throttle cable installation, check carburetor max- imum throttle slide opening . .. Check pulley alignment and alternator belt tension. (444 ENGINE TYPE), PAGE 2

2. Fan 3. Bolt t -20 X ,.. (4) 4. Washer (4) 5. Nut t-20 (8) 6. Lockwasher 8 mm (3) 7. Nut 8 mm (3) 8. Grille (radiator) 9. Coolant tank 10 80lt 5/ 76-18 X 3!" (4) 7 1. Rubber damper (8) 7 2. Radiator 13. 8ushing (4) 74. Washer (4) 15. Nut 5/ 16-18 (8) 16. Washer (4) 1 7. Drain valve 18. Plug 79. Overflow hose (635 mm) 20. Inlet hose (radiator) 27. Hose clamp (4) 22. Thermostat 26 SECTION 03 SUB-SECTION 02, (ENGINES) COOLING SYSTEM 23. Sealing ring 24. Sensor 25. Outlet hose (engine) 26. Hose (380 mm) 27. Hose clamp (2) 28. Upper deflector 29. Side deflector (2) 30. Washer (7) 31. Pop rivet (7) 32. Plug (2) 33. Cylinder head outlet collar (444 ENGINE TYPE). PAGE 3

COOLING SYSTEM INSPECTION Check general condition of hoses and clamps tightness. DRAINING THE SYSTEM To drain the cooling system, remove the coolant tank cap. Remove the R. H. access gnll, and connect a length of plastic hose to the radiator drain valve in order to drain the cooling system outside of the body, Open the drain valve. valve DISASSEMBLY & ASSEMBLY @To check thermostat, put It in water and heat water. Thermostat should open when water temperature reaches 43"C (110"F). @@Apply pipe thread sealant to avoid leaks. (444 ENGINE TYPE), PAGE 4 REFILLING THE SYSTEM Capacity: 6.25 liters (1.4 Imp, gaL) (1. 7 US. gaL) 60% concentrated antifreeze + 40% water To refill the cooling system, unscrew the plug on top of the cylinder head, then slowly pour the liquid into the coolant tank until it reaches the plug hole in the cylinder head, Reinstall the plug. Continue to pour the liquid in the coolant tank until the coolant level reaches 25 mm (1 ") below filler neck of reservoir. With the pressure cap removed, start engine to allow the coolant to circulate and let it run until normal temperature is reached. Stop engine. Then recheck coolant level, ensuring that it is 25 mm (1 ") below filler neck of reservoir.

2. Crankcase upper half 3. Lockwasher 8 mm (14) 4. Hexagonal screw M8 X 70 (8) 5. Hexagonal screw M8 X 45 (2) 6. Lockwasher 6 mm (2) 7. Hexagonal screw M6 X 35 (2) B. AI/en screw M8 X 40 (4) g. Stud MIO X 37 (4) 10. Distance sleeve 12mm (4) II. Lockwasher 10 mm (4) 12. Nut MIO (4) 13. Angular tube (oil outlet) 14. Angular tube (oil inlet) 15. Plug 16. Stud MIO X 184.5 (8) 17. Junction block plate lB. Lockwasher 5 mm (2) 19. Cyllndncal head screw M5 X 12 (2) 20. Crankshaft assembly 2 I. Woodruff key 3 X 3. 7 22. Distance ring (2) 23. 8al/ beanng 6206 (3) 24. O'ring (3) 25. 0/) seal (2) 26. Stop ring (2) 27. "Loctile 242" (medIUm strength) 2B. "Loctite 515" 29. "Loctile 2 71 .. (high strength) 30. Oil seal (2) @ 22 ./J I ~ @ W1 ~~ 3-"", 5J '0 ---e:J "-@ @---® SECTION 03 SUB-SECTION 02, (ENGINES) 'r ~~~. ~"",~'7 '8 q) BOTTOM END ,-----'5 ~0 (444 ENGINE TYPE). PAGE 5

BOTTOM END CLEANING Discard all oil seals, gaskets, "0" rings and sealing rings. Clean alJ metal components in a non-ferrous metal cleaner. Remove old sealant from crankcase mating surfaces with Bombardier sealant stripper. .., CAUTION: Never use a sharp object to scrape V away old sealant as score marks incurred are detrimental to ~rankcase sealing. DISASSEMBLY & ASSEMBLY 0@@Crankcase halves are factory matched and there- fore, are not Interchangeable or available as single halves, Prior to Joining of crankcase halves, apply" Loctite 515" (no, 413 7027 00) on mating surfaces . .., CAUTION: Before joining of crankcase halves be .", sure that crankshaft rotary valve gear is well engaged with rotary valve shaft gear. Position the crankcase halves together and tighten nuts by hand then install armature plate (tighten) on magneto side to correct align the crankcase halves. Torque bolts to 22 N'm (16 ft-Ibs) following illustrated sequence. 16 14 13 15 000Torque to 22 N'm (16 It-Ibs), 0At assembly on crankcase, apply "Loctite 242" on threads. @Torque to 35 N'm (26 It-Ibs). @)Apply "Loctite 242" on threads prior to assembly. @It is recommended to wrap "Teflon" pipe tape around threads. (444 ENGINE TYPE), PAGE 6 @Because of cap nuts, cylinder studs have to be screwed Into crankcase so that they do not protrude further than 15.6 cm (6.140"), If it is not possible to obtain this length, a washer must be added between cylinder head cap and cap nut, Apply "Loctite 242" on the threads of the two studs screwed above the intake ports . 15.6 em Longer threaded part of stud should be screwed into crankcase. @To remove bearings from crankshaft, use a protective cap and special puller as illustrated, Protective cap ~~~ Special puller );i;=.~ Prior to installation, place bearings Into an oil contamer and heat the oil to 100°C (212°F), This will expand bearing and ease installation. Install bearings with groove outward.

seal lips, L To insure adequate oil supply to the bearing on the magneto side, install oil seal with a gap of at least 0.8 mm (,030") with bearing, On PTO, side install oil seal flush with crankcase, no more in. @Crankshaft center oil seals may be replaced at a crankshaft rebuild shop. SECTION 03 SUB-SECTION 02, (ENGINES) (444 ENGINE TYPE), PAGE 7

ROTARY VALVE & COOLANT PUMP 33-1 34- 35- 37 38 __ _ 39--l1li\l 40-1 11 41 I ~ 42 7. Rotary valve shaft 2. Oil seal 3. Ball beanng 6203 4. Shim 0.5 mm 5. Distance sleeve 24.5 mm 6. "Loctite 2 77 " (red - high strength) 7. Shim 0.5 mm B.O'rlng 9. Gear /0, Spring 7 7. Spring seat 72: Circlip @) ~ 2Il~24 , I: 17, "

CLEANING Discard all all seals and "0" nngs. Remove old crankcase sealant from rotary valve gear and adjacent bearing. Clean all metal components in a non-ferrous metal cleaner. DISASSEMBLY & ASSEMBLY 8There are two Interchangeable types of rotary valve shaft. The first one IS made of a shaft with a pinion attached to it by means of a key and Allen screw. On the second type, the pinion and the shaft are machined together as a single part. First type tell ~ To remove rotary valve shaft assembly from crankcase, first remove pump impeller @ and circlip @. Position special puller over shaft bore (with pinion re- moved) and screw puller bolt into rotary valve shaft. While holding puller bolt. turn puller nut clockwise until shaft comes out. At assembly, apply "Loctlte 515" on bearing and rotary valve gear mating surfaces. Beanng~'· ~/ Apply "loctlte 515" SECTION 03 SUB-SECTION 02, (ENGINES) To Install shaft assembly, use a fiber hammer. Use a no, 420 876 505 pusher to Insert oil seal with lithium grease on seal lip, Second type (fIr," _I) ll> To remove rotary valve shaft assembly from crankcase, first remove pump impeller @ and circlip @ , USing an appropriate pusher (PIN 420 876 610) and a fiber hammer, drive out shaft assembly. tool At assembly, apply "Loctne 515" on beanng and rotary valve shaft mating surfaces. I::!::d;::::f--/ Beanng~· ? Apply "Loctlte 515" To Install shaft assembly and oil seal, use no, 420876 600 pusher. (444 ENGINE TYPE), PAGE 9

(!)Through@Rotary valve shaft assembly. If it is necessary to disassemble components of rotary valve shaft assembly. compress spring cup @ in order to remove circlip@. ® Clean rotary valve shaft and inside of distance sleeve. At assembly, apply "Loctite 271" inside of distance sleeve. @Using a sUitable pusher. push pump bearing with shield facing rotary valve. To remove bearing To install bearing 420876510 tool No 420876 500 tool (444 ENGINE TYPE). PAGE 10 @@From pump side. using no. 420 876 510 pusher. install oil seals (with lithium grease on lips) as per illustrations. Keep in mind that: - distance ring opening must be in line with crankcase draining hole. - 35% of the area between first and second oil seal (first oil seal being flush with crankcase) must be filled with lithium grease or equivalent. First all seal Distance nng opening Distance nng @ Apply "Loctite 242" on threads. Third or! seal

having no timing marks. 1980 444 type: 141 0 opening 51 0 closing Using angle finder. mark crankcase at 141 0 from bottom edge of magneto Side inlet port. . ~ .' Mark here '0 f:f, SECTION 03 SUB-SECTION 02, (ENGINES) From top edge of magneto side inlet port, mark crankcase at 61 o. To correctly install the rotary valve proceed as follows: - Turning crankshaft counter-clockwise. (drive pulley side) bring magneto side piston to Top Dead Center uSing a T.D.C. gauge. - Position the rotary valve on gear to have edges as close as possible to the marks. O NOTE: The rotary valve IS asymmetrical, therefore. at assembly try positioning each side of disc on gear to determine best installation position . @@Torque to 20 Nom (16 ft-Ibs). Magneto Side piston must be at Toe Timing mark (444 ENGINE TYPE). PAGE 11