Evinrude & Johnson E-1532, Service Manual

Page 1: ...1973 EVINRUDE JOHNSON SNOWMOBILE PART NO 406133...

Page 2: ...TO THE OPERATION OR MAINTE NANCE OF YOUR EQUIP MENT Snowmobile Special Service Tools 21 H P PART NO 378103 404032 426020 383966 404068 375632 114146 113971 114147 261906 261132 261131 261129 DESCRIPT...

Page 3: ...of considerable help as a reference during disassembly and reassembly The Section Index on page 1 1 enables the reader to locate quickly any desired section At the beginning of each Section is a Table...

Page 4: ...wered in this manual you are invited to write to the Service Department for additional help Always be sure to give complete information including model number and vehicle identification number All inf...

Page 5: ...perate without lights 7 SAFETY STOP SWITCH This switch allows the operator to stop engine power instantly Depress button to stop engine depress again and release to allow restarting of engine The safe...

Page 6: ...SECTION 2 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS 2 2 TORQUE SPECIFICATIONS 2 3 2 1...

Page 7: ...urethane foam cushion Hood Molded fiberglass with built in headlight Headlamp Sealed beam GE 4482 Taillamp black tape in back of bulb GE 161 Stoplamp silver tape in back of bulb GE 168 Fuel tank 6 U S...

Page 8: ...ar Sprocket 3 8 16 18 20 Nut Rear Suspension to Frame 5 16 24 12 15 Nut Runner to Ski 5 16 18 90 100 Nut Saddle to Spring 3 8 24 25 30 Spark plug 20 25 Nut Throttle Control Cable 30 40 Nut Tie Rod 3 8...

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Page 10: ...ION 3 GENERAL SNOWMOBILE INFORMATION TABLE OF CONTENTS TWO CYCLE ENGINE THEORY 3 2 COMPRESSION 3 2 SPARK PLUGS 3 3 CARBURETION 3 4 IGNITION 3 4 POWER FLOW 3 5 PRIMARY DRIVE 3 5 SECONDARY DRIVE 3 5 3 1...

Page 11: ...At this point the momentum of the flywheel is required to return the piston to the top of the cylinder As the piston begins its up stroke it closes the intake and exhaust ports and begins to compress...

Page 12: ...spark plug provides a gap inside the combustion chamber across which the high voltage from the ignition coil can be discharged The resulting spark ignites the compressed mixture of fuel vapor and air...

Page 13: ...nder normal load conditions avoid lean mixtures for high speed operation The carbure tor is designed to deliver the correct proportion of fuel and air to the engine for these various conditions The ca...

Page 14: ...nst the movable half of sheave As the sheaves are brought together the transmission belt is forced outward to ride on a larger di ameter of the primary sheave assembly increasing belt speed see Fig ur...

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Page 16: ...ROUBLE SHOOTING TABLE OF CONTENTS DESCRIPTION 4 2 TROUBLE SHOOTING PROCEDURES 4 2 STARTING 4 2 STARTING MANUAL STARTER 4 3 RUNNING LOW SPEED ONLY 4 3 RUNNING HIGH SPEED ONLY 4 3 RUNNING HIGH AND LOW S...

Page 17: ...ate description of the trouble b Quick tune up An accurate description of the trouble is essential for trouble shooting The owner s comments may provide valuable information which will serve as a clue...

Page 18: ...rk plug terminal loose g Weak coil or condenser h Breaker points burned dirty or improperly gapped 4 3 i Cylinder gasket or leaf plate gasket blown j Leaking crankcase seals k Coil lead grounded on ch...

Page 19: ...ricant in gas or no fuel b Fuel connection faulty c Cylinder or crankshaft scored d Bent or broken rod crankshaft or stuck piston e Ignition failure f Frozen bearing 3 Engine knocks excessively 4 a In...

Page 20: ...5 2 IGNITION SYSTEM 5 2 COMPRESSION 5 2 NEW VEHICLE DELIVERY 5 3 TUNE UP PROCEDURES 5 3 COMPRESSION CHECK 5 4 IGNITION TIMING ADJUSTMENT 5 4 COMPRESSION RELEASE VALVE ADJUSTMENT 5 5 CARBURETOR ADJUSTM...

Page 21: ...d performance FUEL SYSTEM A fresh fuel mixture with the correct ratio of lubricant and gasoline is necessary for peak engine performance The tank should be removed emptied of old fuel rinsed out insta...

Page 22: ...ely 1 items affecting compression 2 items affecting ignition 3 items affecting carburetion Any tune up procedure should cover these groups in the order given Correction of items affecting carburetion...

Page 23: ...primer operation i Inspect fuel pump fuel filter and hoses j Thoroughly lubricate snow machine see Section 12 k Tighten all external bolts nuts and screws and retorque spark plugs to specified value 1...

Page 24: ...to open position 3 Drive snowmobile at full throttle to observe engine performance Observe all safety warnings while driving 4 Open high speed needle 1 8 turn counterclockwise 5 Repeat steps 3 and 4...

Page 25: ...1100 1200 rpm each time low speed needle is adjusted 6 Accelerate engine then release throttle Engine should return to idle speed If engine does not idle immediately adjustment of the low speed needl...

Page 26: ...Needle Valves 6 4 Carburetor Body 6 4 Core Plugs 6 4 REASSEMBLY OF CARBURETOR 6 5 General Instructions 6 5 Float and Float Chamber 6 5 Low Speed Needle 6 5 High Speed Needle 6 5 Choke 6 5 REASSEMBLY O...

Page 27: ...o the engine The primer assembly operated from the control panel injects raw fuel into the crankcase before starting see Figure 6 1 14 FUEL FILTER AND PUMP CHECK VALVE IN LINE FUEL LINE PRIMER Figure...

Page 28: ...edle valve 1 from carburetor See Figures 6 3 and 6 4 b Remove high speed needle valve 2 from carburetor c Remove four screws 3 attaching float chamber 4 to carburetor body 5 Remove float chamber and g...

Page 29: ...nicked scratched or worn out of round it will not give satisfactory service See Figure 6 6 The valve seat and needle are a matched set if either is worn both parts must be replaced Use a new gasket wh...

Page 30: ...al gaskets and 0 rings because leaks may develop after the engine is back in use Check the Torque Chart in Section 2 for correct torque recommenda tions during reassembly Float and Float Chamber see F...

Page 31: ...er any circumstances bend or flex the leaves by hand Clean inspect and immediately reassemble the leaf valve assem bly rather than leave it apart for reassembly later e The leaves are designed to main...

Page 32: ...d REASSEMBLY a Reassemble the fuel filter Do not overtighten filter cap to fuel pump body b Attach fuel pump and filter assembly to plate with screws c Reconnect fuel hoses FUEL PRIMER a The primer is...

Page 33: ...eat be tight against the end of the threaded boss on the fuel tank Apply G E RTV 102 on adapter threads and immediately install to fuel tank d Clean the tank with gasoline poured through a filtering f...

Page 34: ...DESCRIPTION 7 2 TEST EQUIPMENT 7 2 MAGNETO 7 3 REMOVAL 7 3 TESTING 7 4 FLYWHEEL 7 4 BREAKER POINTS 7 4 CONDENSER 7 5 MAGNETO DRIVE COILS 7 5 IGNITION COILS 7 6 HIGH TENSION LEADS 7 6 REASSEMBLY 7 6 SP...

Page 35: ...dures outlined in this section require the use of an ohmmeter or multitester also called a volt ohm milliammeter These instruments can be obtained from local or national electronics supply houses see...

Page 36: ...ch B Index Reading 22 using MA 12 Adapter MAGNETO REMOVAL a Remove starter housing see Figure 7 4 housing guard and outer fan housing b Remove three screws attaching ratchet and ratchet mount to fly w...

Page 37: ...from one contact surface to the other and will generally be blue in color Severe pitting burning or bluing can usually be traced to such condi tions as a faulty condenser or deposits of foreign mater...

Page 38: ...tion failure 4 Capacity Determined by the design and condition of the condenser For a complete check of the condenser use a tester see Figure 7 11 which will test the condenser for correct capacity se...

Page 39: ...herever the insulation has broken down due to moisture or carbon trails Check leads for continuity REASSEMBLY a Install magneto drive coils making certain that coil laminations are flush with bosses o...

Page 40: ...y leaded fuels may produce white to yellowish powdery deposits on the firing end of the spark plug These deposits will not interfere with normal spark plug performance if plugs are cleaned at regular...

Page 41: ...the abrasive between the insulator top and the metal shell of the plug If the abrasive is not removed before in stalling the plug it may pass through the engine caUSing piston or cylinder wall scoring...

Page 42: ...ENSITY ZONE Figure 7 27 To check the regulator first set the voltmeter to the 30 volt DC range and then connect the voltmeter leads across the pink and pink black leads at the resistor Connect the red...

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Page 44: ...8 1 SECTION B MANUAL STARTER I I TABLE OF CONTENTS DESCRIPTION 8 2 REMOVAL AND DISASSEMBLY 8 2 CLEANING INSPECTION AND REPAIR 8 2 REASSEMBLY 8 3 a STARTER ROPE REPLACEMENT 8 4 I...

Page 45: ...amage will result REMOVAL AND DISASSEMBLY SAFETY WARNING It is good practice to wear safety glasses while disassembling and reassembling manual starters because of the rewind spring a Remove three scr...

Page 46: ...f Wind pulley counterclockwise until tight g Unwind pulley clockwise until pulley anchor hole lines up approx with starter rope hole in starter housing h Lock starter pulley in position by aligning ho...

Page 47: ...ting a nail or pin through them c Remove handle from rope and remove old rope from pulley d Cut new starter rope to length of 73 1 4 inches Fuse ends of rope over open flame for about one half inch Ro...

Page 48: ...NDERS 9 5 GASKETS AND GASKET SURFACES 9 5 PISTONS 9 5 BEARINGS 9 6 ASSEMBLY OF ENGINE 9 7 PISTONS WRIST PINS AND CONNECTING RODS 9 7 PISTON RINGS 9 7 CRANKSHAFT 9 7 CYLINDERS 9 8 INSTALLATION OF ENGIN...

Page 49: ...ansmission belt See Section 10 3 Remove throttle cable using the following procedure Depress thumb throttle lever Hold throttle in open position Slip end of throttle cable through nylon pivot pin Remo...

Page 50: ...ow be removed from the crankcase See Figure 9 6 1 1I n NOTE If it is necessary that only the cylinders and pistons be serviced this can be accomplished with only the cylinder barrels removed h Remove...

Page 51: ...rods from pistons remove wrist pin retaining rings using Truarc No 1 pliers Service Tool 303857 see Figure 9 7 Press out wrist pin to free piston from connecting rod See Figure 9 8 Piston wrist pin h...

Page 52: ...ess Under certain conditions gasket faces may warp or spring particularly where thin sections or flanges are employed and are subject to temperature changes To check for flatness lay a sheet of No 120...

Page 53: ...balls and separators Tank should be equipped with a screened false bottom to prevent settlings from being stirred up into the bearings Agitate bearings frequently until all oil grease and sludge have...

Page 54: ...ist pin installation d Replace retaining rings lettered side out making certain they seat securely in the groove provided e Check piston with micrometer to determine whether piston has been distorted...

Page 55: ...leakage NOTE Heat crankcase halves with a heat lamp to approximately 250 0 for 15 minutes This allows easier installation of crankshaft f Replace crankcase alignment roll pins driving in carefully wi...

Page 56: ...putting vehicle in gear Start out slowly avoid jack rabbit starts DO NOT overspeed engine Op eration in extreme cold weather can cause a slow down in the drive and track mechanism When this occurs bl...

Page 57: ...ace muffler in well Apply muffler cement to muffler inlet 2 Place engine back on mounting studs and exhaust manifold over muffler inlet 3 Pry muffler up into place with screw drivers on both sides of...

Page 58: ...DISASSEMBLY OF SHEAVE WHILE ON ENGINE 10 3 CLEANING INSPECTION AND REPAIR 10 3 REASSEMBLY 10 4 DRIVE CHAIN 10 4 LUBRICATION 10 4 ADJUSTMENT 10 5 REMOVAL 10 5 INSTALLATION 10 5 REPAIR 10 5 BRAKE 10 5...

Page 59: ...to right and closed Fig ure 10 4 e Work belt out from under bottom of sheave and between steering column and end cap Figure 10 5 f Move belt from around primary drive Figure 10 6 REPLACEMENT a Loop on...

Page 60: ...ing with following steps 3 With flat open end wrench Service Tool No 404032 on inside and socket wrench on outside break loose end cap bolt from main shaft see Figure 10 10 4 Finish removing bolt with...

Page 61: ...age 2 3 5 Assemble lock plate to end cap Locks on lock plate may engage bolt by turning lock plate over Otherwise a slight loosening or tightening of bolt may be necessary in order to align bolt with...

Page 62: ...ssemble in reverse order of disassembly 2 Adjust chain per ADJUSTMENT above 3 Add chain lubricant per LUBRICATION above REPAIR A broken drive chain can be repaired with master links available from you...

Page 63: ...erly at bottom of actuator cam c Install adjusting fitting S and nut 9 to brake body 10 d With cable installed in hand lever insert brake end of cable 11 through adjusting fitting S Pull the cable thr...

Page 64: ...necessary to disconnect cable see page 10 5 5 See Figures 10 20 and 10 21 for following steps Remove chain case cover 6 Caution should be taken not to warp cover 6 Loosen chain see page 10 5 7 Remove...

Page 65: ...ve See Figure 10 21 I 3 4 14 and 20 to shaft 2 Press bearing cups into eccentric 3 Grease inner bearing cone with OMC No 114154 grease and install on shaft 4 Install seal NOTE A new seal must be used...

Page 66: ...sion belt 23 Grease assembly thru fitting on eccentric adjustment Two pumps from a grease gun is sufficient OMC grease part no 114154 is recommended 24 Check for proper position of secondary drive ass...

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Page 68: ...TRACK AND SUSPENSION 11 3 TRACK TENSION ADJUSTMENT 11 3 TRACK ALIGNMENT ADJUSTMENT 11 3 REMOVAL OF TRUCKS AND TRACK 11 4 FRONT AXLE DISASSEMBLY 11 4 REAR AXLE DISASSEMBLY 11 5 TRUCK DISASSEMBLY 11 5...

Page 69: ...Remove all dirt and old grease from ski columns and from inside ski column tube b Inspect ski column and bushing and replace if worn or bent c Inspect ski rwmers and replace if worn See torque specs...

Page 70: ...ed down Track tension is correct when the distance from the bottom of the pivot arm bearing bore to the underside of the running board is 2 3 4 1 32 on both Sides See Figure 11 6 If adjustment is nece...

Page 71: ...nd seals is now free of chassis 10 Remove four track tension locknuts See Figure 11 6 Rear axle can now be removed 11 Trucks axles and track are now free of the chassis PIVOT AXLES 17303 Figure 11 8 F...

Page 72: ...ers bushings and springs from pivot axle 3 Wheels and spacers will now slide off truck and pivot axles CLEANING INSPECTION AND REPAIR Track Rivets and tread bars are serviceable Part numbers are liste...

Page 73: ...ts to front axle Observe SAFETY WARNING on Page 11 4 Drive roll pins in sprockets Press bearings on axle Apply a light oil to seals and assemble to front axle Seat seals after axle is assembled to cha...

Page 74: ...E LUBRICATION 12 2 OMC 2 4 FUEL CONDITIONER 12 2 LUBRICATION RECOMMENDATIONS 12 3 PREVENTIVE MAINTENANCE 12 4 AIR FILTER 12 4 FUEL FILTER 12 4 STORAGE 12 5 PREPARATION FOR STORAGE 12 5 REMOVAL FROM ST...

Page 75: ...n excess of lubricant in the fuel mixture Instructions for the blending of fuel as given here and in the Owner s Manual should be followed exactly See inside front cover for recommended fuel mixture T...

Page 76: ...e a season Drive Chain See Page 10 4 OMC Type C Every 25 hrs Pivot POints Leaf spring connection to skis SAE 10 Oil Once a season Normal Use Primary Drive OMC grease Part No 114154 Twice a season Exte...

Page 77: ...and blow with compressed air from inside holding nozzle about two inches from filter DO NOT wash or oil filter element See Figure 12 2 When reassembling tighten wing nut until 3 to 4 threads show bey...

Page 78: ...and clean fuel tank see Section 6 j Remove transmission belt see Section 10 k Rub bottom of skiS primary and secondary drive sheaves and other unprotected surfaces of vehicle with cloth saturated in...

Page 79: ...LS OFF POSITION MAGNETO o GROUND LIGHTS RUN POSITION LIGHT COILS UGH U RUN POSITION o The magneto terminal and ground terminal are connected together The light coils and lights terminals are connected...

Page 80: ...DIMMER SWIT CH P INK BRAKE LAMP SWITCH w l i u J OJ DARK BLUE LIGHT BLUE HEAOLAMP LOW BEAM IGH GROUN AM V REAR OF HEADL AMP HIGH T ENSION LEADS IGN ITION COILS WIRING DI AGRAM 37058...

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