Table of Contents General Information/Foreword ......................................... 2 Snowmobile Identification ............................................. 2 Recommended Gasoline and Oil.................................. 3 Break-In Procedure ...................................................... 3 Genuine Parts............................................................... 3 Preparation for Storage ................................................ 3 Preparation after Storage ............................................. 4 Torque Conversions (ft-lb/N-m) .................................... 4 Torque Specifications ................................................... 5 Engine Torque Diagram (B-25 Carburetor) .................. 6 Engine Torque Diagram (B-24 Carburetor) .................. 7 Engine Specifications ................................................... 8 Carburetor Specifications (B-25) .................................. 8 Carburetor Specifications (B-24) .................................. 9 Track Specifications ..................................................... 9 Front/Rear Shock Spring .............................................. 9 Rear Suspension Spring............................................... 9 Front Shock Absorber................................................... 9 Rear Shock Absorber ................................................... 9 Engine (B-25 Carburetor) ................................................ 10 Removing.................................................................... 10 Disassembling ............................................................ 12 Servicing Components................................................ 15 Assembling ................................................................. 22 Installing...................................................................... 25 Engine Oil ................................................................... 28 Recoil Starter .............................................................. 29 Troubleshooting Engine.............................................. 30 Engine (B-24 Carburetor) ................................................ 31 Removing ................................................................... 31 Disassembling ............................................................ 33 Servicing Components ............................................... 36 Assembling ................................................................. 42 Installing ..................................................................... 46 Engine Oil ................................................................... 50 Recoil Starter .............................................................. 50 Troubleshooting Engine.............................................. 52 Fuel System...................................................................... 53 Pre-Maintenance Checks ........................................... 53 In-Line Fuel Filter........................................................ 53 Carburetor (B-25) ....................................................... 58 Carburetor (B-24) ....................................................... 58 Throttle Cable ............................................................. 61 Troubleshooting Fuel System ..................................... 63
Electrical System..............................................................64 Transistorized Ignition System ....................................64 Testing Ignition Switches (Wiring Harness).................64 Testing Electrical Resistances ....................................65 Testing Idle Switch ......................................................66 Testing Handlebar Warmer Elements .........................66 Testing Handlebar Warmer Switch..............................66 Testing Headlight Switch.............................................67 Testing Tether .............................................................67 Testing Key Switch......................................................67 Testing DC Regulator..................................................68 Testing AC Regulator (with RPM Limiter) ...................68 Starter Relay Solenoid ................................................69 Starter Motor ...............................................................69 Drive Train/Track/Brake Systems ...................................70 Drive Belt.....................................................................70 Drive Clutch.................................................................70 Driven Clutch...............................................................72 Drive Clutch/Driven Clutch ..........................................73 Dropcase .....................................................................73 Track ...........................................................................75 Brake System ..............................................................77 Troubleshooting Track ................................................80 Rear Suspension ..............................................................81 Removing Skid Frame.................................................81 End Cap ......................................................................81 Wear Strip ...................................................................81 Rear Suspension Arm/Rear Springs ...........................82 Rear Idler Wheels and Axle.........................................83 Slide Rail .....................................................................83 Installing Skid Frame...................................................85 Steering and Body............................................................86 Steering Post...............................................................86 Ski ...............................................................................88 Ski Wear Bar ...............................................................88 Tie Rods ......................................................................88 Spindle ........................................................................89 Ski Alignment ..............................................................90 Front Suspension A-Arms ...........................................90 Belly Pan .....................................................................92 Seat Assembly ............................................................92 Gas Tank/Fuel Pump Assembly..................................93 Headlight Assembly ....................................................94 Wiring Diagram .................................................................95
1
