306
c SAFETY NOTICE This Shop Manual has been prepared primarily for use by professional snowmobi le mechanics, who are, already familiar with all service procedures relating to Bombardier made snowmobiles, and secondly to assist the mechanically snowmobi ler who has limit ed access to an authori - zed dealer, or prefers to perform his own servicing. In either case, special tools must be used, where required, and a good sense of safety is deemed necessary. If in doubt, contact your dealer for assistance. This manual emphasizes particular information denoted by the wording and symbols; WARNING: Identifies an instruction which, if not followed, could cause personal injury. o CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary inf ormation needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your under- standing of the.information will promote its correct use. (1977 Supplementl

SkiDoo 72

Embed Size (px)

DESCRIPTION

72 SkiDoos Service Manual

Citation preview

c SAFETY NOTICE ThisShop Manual has beenpreparedprimarily for use by professional snowmobi lemechanics, who are, already familiar with all service procedures relating toBombardier made snowmobiles, andsecondlytoassistthemechanicallysnowmobi lerwhohaslimitedaccesstoanauthori -zed dealer, or prefers to perform his own servicing. Ineithercase,specialtoolsmustbeused,whererequired,andagoodsenseofsafetyis deemed necessary. If in doubt, contact your dealer for assistance. This manual emphasizes particular information denoted by the wording and symbols; WARNING:Identifiesaninstructionwhich,ifnotfollowed,couldcausepersonalinjury. o CAUTION:Denotesaninstructionwhich,if not followed,couldseverelydamagevehicle components. NOTE:Indicates supplementary information needed to fully complete aninstruction. Althoughthemerereadingofsuchinformationdoesnoteliminatethehazard,yourunder-standing of the.information will promote its correct use. (1977Supplementl ) ) c THE SKI-DOO SNOWMOBILE SHOP MANUAL DEFINITION OF NUMBERING SYSTEMS Themanualmakesusesofa2-partdigitalnumbering system(i.e.01-01), inwhich the first digit represents the Section, the second digit the Sub-section. 01-01 / ~ SECTIONSUB-SECTION Thenumerotationatthebottomofeachpageassists the user inpage location. ARRANGEMENTOFTHEMANUAL TheManualisdividedintonine(9)major sections:(01) Suspension,(02)Transmission,(03)Steering,(04)En-gine,(05)Electrical,(06)Chassis,(07)Tools,(08)Tech-nicalData,(09)Warranty. Eachsectioniscomprisedof varioussub-sections,and yet again, although not indicated inthe table of content, eachsub-sectionhasoneormoredivisions.Forexam-ple,Section01- SuspensionSub-section02.Slide suspension, contains three divisions,"GroundLeveler", "TorqueReaction",and"HighPerformance"slide suspensions. ILLUSTRATIONS & PROCEDURES Anexplodedviewisconvenientlylocatedascloseas possibletothewrittenproceduresandismeanttoas-sist the user inidentifying parts andcomponents.When somethingspecialapplies(suchasadjustment, ...etc), the specificpartsarecircledandreferredtointhetext. Asmanyoftheproceduresinthismanualareinter-related,wesuggestthatbeforeundertakinganytask, youreadandthoroughlyunderstandtheentiresection or sub-section inwhich the procedure iscontained. Anumberofproceduresthroughoutthebookrequire theuseofspecialtools.Whereaspecialtoolisindi -cated,refertosection7.Beforecommencinganypro-cedure,besurethatyouhaveonhandallof thetools required, or approved equivalents. GENERAL Alloftheinformation,illustrationsandcomponent / system descriptions containedinthis manual are correct attimeofpublication.BombardierLimited,however, maintainsapolicyofcontinuousimprovementofits products without imposinguponitself any obligationto install them onproducts previously manufactured. IThis manual has beenpublished by the TECHNICAL INFORMATION CENTRE SERVICE DEPARTMENT BOMBARDIERLIMITED VALCOURT,OUEBEC,CANADA (1977Supplement )(INTRODUCTION) , PAGE1 ) "."SLIDE SUSPENSION A.PPLICATION SUSPENSION TYPEAPPLICATION GroundLevellerOlympique 1973 T'NT F /C {15inches}1973 Elan294SS1974 Elan300SS1975 HighPerformanceT'NT F /A1973- 1974 Torque ReactionT'NT F /C,Everest1974 Torque ReactionT'NT F /C 1975- 1976 type 1T'NT F /A1975-1976 Everest1977 RV1977 Torque ReactionOlympique 1975-1976-1977 type 2T'NT 1977 Torque ReactionT'NT F /A245 RV1975 type 3 (1977Suppl ement) ) ) ) J ....... . ............ ...... . c DRIVE AXLE TYtPrESAPPLICATION CHART DRIVE AXLE WITH CENTER IDLERNordic 1974 DRIVE AXLE WITH TWO (2)SIDE IDLERSOlympique (slide)1974 DRIVE AXLE WITH TWO (2)INNER IDLERST'NT F /A1974,1975 DRIVE AXLE WITH TWO (2)INNER IDLERST'NT RV1976 TYPE1 DRIVE AXLE WITHHEXAGONAL SHAFTRV 2501975 INTERNAL DRIVE TRACK DRIVE AXLE WITH NARROW SPROCKETS,Elan1974,75,76,77 9TOOTHOlympique 1974, 75, 76, 77 Alpine 1974, 75, 76, 77 Elite 197L1,/5 DRIVE AXLE WITH NARROW SPROCKETS,T ' ~ J T1977 11TOOTHIRV1977 DRIVE AXLE WITH WIDE SPROCKETS,Olympique (slide)1975,76,77 NARROW SPACERS DRIVE AXLE WITH WIDE SPROCKETS,T'NT F /C &Everest1974,75,76 LARGE SPACEREverest1977 (1977 Supplement) ) ) ) ) ) ) ,....'.'.".. .".....'.'.' - ".DRIVE AXLE c c c DRIVE AXLE WITH CENTERIDLER 16 19 ~ - I :- ~ DRIVE AXLE WITH TWO SIDE IDLERS (1977Supplement)i(DRIVE AXLE),PAGE1 14, 6 DRIVE AXLE WITH TWO INNERIDLERSI 34 I ) DRIVE AXLE WITH NARROW SPROCKETS, 9 tooth ! IDRIVE AXLEI,PAGE 2(1977Supplement I ,.\:{, 'iii'::::':':':' ii:':': \i:,

,i 2. > -l!) ...J >-, 0 a:: DIMMER SWITCH BK

BK , I 1---..... YLIBL RDI-I." , , , .... -SPEEDOMETER ,!, _I-JI :..: ,>>- ...Jco ;;>-YL IGY VI /IOFF ON LIGHT IGNITION ILIGHT SWITCH GY ....... HEADLAMP tOptional on some models MAGNETO YL IIIBK SPARK PLUG o. 0'"YL/BK .... !=- _ ... ;:- YL 0...Q!:!.OR/WH 7s 41BKr'\..OR / BK BK VBKBRBR ,,: >- 4-\ ]J "-'-- -CDZ Z IGNITIONCOIL-GY -J.-RK"1 I BRYL /BR BK..... -= > >17 HEADLAMP >-----

- J> >->- ............-Cl 1I ~(.!) (.!)...J> > >->- ............ (.!)>-0 (.!)a: DIMMERSWITCH (1977Supplement l BK

_. . BLiRD PLUGSBL fBKr--0(03lf7" YL ....,"':" "':"ffr-IUIt-\L,j( YL -II-;/YLIGNPTOMAG IGNITION COILS'" VI BL L VI VI/WH BKr __ "'- VI / WH -m (0LIGHTING COIL - 75W GENERATOR COIL *') o LIGHTING COIL- 23W -YLIGY BR r-/ YL/GY

WHYL/WH '---TAILLIGHT if ORIBKYL / WH ;IIBKYL ..J Chart26 + BK YL VOLTAGE REGULATOR -II-YL "*" I>-3: (!) "- >"-> ...J >-...J >-...J >- > !I >J >-...... (!) 0 (!) KIL a: .-,-DIMMERSWITCH (1977Supplement) r--BK/ 01 YL G-}_..!t y..- ....YL/

RDI{ .. YL/GYY L,c::::::-. YL/GY/ '.l=3 BK BK/ , .,..,--- YL IGYy/,' YLIGY/'Z..,:' BKBK'i... BK/

""........... _-'--YLIGY r-:-/ II I LIC YL K-II ON VI VI/WH I OFF ... IGNITION ILIGHT SW BK GY GY/VI HEADLAMP TIONAL CHOMETER , \ \ I I I / OPTIONAL PEEDOMETER ""\ , , , I , . , ,,/ HT TCH MAGNETO /BK CDLIGHTING COIL(75W) CDBRAKELIGHT COIL(23W) oIGNITION GENERATORCOIL BRAKE LIGHT SWITCH Chart 29 YL BK GNIOR :.:: CD'-CI;o J: 3: :.::CI;CD(1977Supplement ) >-l:) '--J >-:.::DIMMER SWITCH -J >-KILL SWITCH IGNITION /LIGHTSWITCH iOFF ON HEADLAMP GNI RD MAGNETO BK GN / RD./ BLI RD -t I BK YL/GN CAPACITOR (3 CD YLYL 0 \ 1-"-YL a: "-"" GNOR/WH ....JJ aJ I"'\. OR/B K GN BL BLVI r:;'K1U:!- VI/ WH BL JO rr ...... :..: J: PTOMAG aJ ....... .......IGNITION COILS* BK a:a: 00 -'"="" GN I0ORIBK BRAKE SWITCH .. ::GN IORBK .1 151 lJ--WH ""-1--I * (81IBRYLI BR ....... TAILLIGHT -CDLIGHTING COIL 0 IGNITION GENERATORCOIL o BRAKE LIGHT COIL Chart 30 J: ......;; l YL J: ...... ;;;; ;; " V J: ;; "- lJ: KILL SWITCH (1977Supplement) YL I BK VOLTAGE REGULATOR YL VIVI

/."" VI / WHVI/WHYL YLlBR OFF ON YLIGY/ , LIGHT IGNITION SWITCH GY IVI ...... GY --BK -- ....... a: HEADLAMP aJ "-....J>->- ;; (!) ,"- >-....J >-(!) >-(!) G a:k!:r-'....... "" ..............,... ................ .. MAGNETO ......-----... TL /r---

GN / BKV ,I"BK BL/RD PLu9L- BL I \

0JLf YLYL IU rr["-. \L.. YL VOL TAGE REGULA TOR '--''-PTOMAG 1-IGf\/ITIONCOILS* VIYL BLVVI BK VI/WH L-I"'-VI / WH -m CDLIGHTINGCOIL ( o IGNITIONGENERATORCOILI>-*1 3: l? o FUSE (0.2AMP.)....:;.....:; --' >---' >-YL / GY BR r-V YL /GY 1 fO""1

WHYL/WH ........ TAILLI GHT --' >

. r-- ORI BKYL/WH>- >- .....] II ..... l?>-BRAKE LIGHT SWITCH. BKYL 0l? . a::

..--.-DIMMER KILL SWITCH Chart31 (1977 Supplement ) CDCD ......a:: 0 I,J--

TETHER CUT-OUT SWITCH ,....--/BK 01o C'1,- __YL /, YL/ I RD! {'lII YLIGYY L.,c:::::.. YL / GY/ \19 BK BK/ I'f.-,... --YLGYyD/,-YLI GY/ K:' BKBK1.. BK/ .... . ......... ,... _- YL IGY --:*/ IIIlIC YL (-liON VI VI / WH IOFF" IGNITION /LIGHT SV, BK GY GY I VI-l.-HEADLAMP 't TIONAL CHOMETER " \ \ I I I / OPTIONAL PEEDOMETER "., , , , I I . I I ," HT TCH t...... GENERATOR

BK BL/RD YL /BKGN , SPARK PLUGS I

,.!L ,.. 0CD IU BLBL

\ I-) '-- '-- b PTO MAG IGNITION COILS * YL BlVI VI / WH BK rL-CD RD .r7\l \ RD l...=::.--J ).. r-L0 =;::::::11a: + $ BATTERY r\.RD / GN 0 O-ROIBL --!-BKELECTRICSTARTER -/RD / BR -154I ( -*) --Chart 32 BR I1WH TAILLIGHT BKJ. L-

BRAKE LIGHT SWITCHI.........BKII I CDLIGHTING COIL- lOOWI (2)IGNITION GENERATOR COIL o oFUSE (0.2 AMP.) CDFUSE (14 AMPS) RD / WH 0 a: "I RD /WHI RD RECTIFIER BK - A.C. A.C.""\ Yl + o0 a:a: GN RD/GY RD :I::I: >> >> a:>-CD - >00 a:,\ ->- co t!) :; DIMMER GN YL BK BK RD IGY RDIGY BK BK RD / WH :.>- ::J\_..... __..,.,. ::::>- VIOFF * Ir1>VI / WH ---- ON IYL 3: ";;YL/ BL - ;;/"' LIGHT YL / GY CDLIGHTING COILIGNITIONLIGHT SWITCH o IGNITION GENERATORCOIL:;:; CDFUSE 10.2 AMP.)>- ;; I BKYLYLIBR(!) ":..: BRAKE LIGHT SWITCH:I ORIBK -lJ-:I J>-( WH YL - (!)1; 11. __:] I--.BRYLIBRI ... I,J BKI"---- H.-.l+KILLSWITCHTETHERT Optionalon TAILLIGHT'-b_ _CUT-OUTsome models .. ,.., ... 'IT,.....IDIMMERSWITCH Chart36 ( 1977 Supplemen t) '\. >

BR TAILLIGHT Chart 37 VOL TAGE REGULATOR -I -' > 0: -'CDVI> '--' VI > BK YL YL IBR (1977Supplement ) -

I "-:> I ......\> \ 0: CDBK > CD> > 0:-' CD CD'-'-> -'-'> '->'\ t:J > t:J > > '-t:J > > '-0 0: ... t:J --DIMMER SWITCH >"- "->I " -' :> >

1- C VI BK 11-( F BK IGNITIONSWITCH BK'" r-GY GY I VI -' ..... CD-'HEADLAMP '- > -' > -- LIGHT SWITCH MAGNETO BK BL'RDBK CDLIGHTING COIL GENERATOR COIL SPARKPLUGS o LIGHTING COIL o FUSE (14AMPS) GNVI PTOMAGVIVI "-BKIVI / WH VI / WH VI / WH / RD IGNITION COILS * RD RD 010 cr:cr:1/ RD RD IGY BATTERY ~ ~ o o o ~ 1 ~ ~ >-t!J ~ROn"I>1~ I~ I ~ I I , RDI GN ~ -.:.JIV- START IGNITONILIGHT SWITCH lE.l;~SOLENOIO SW ITCH RD BK STARTER RD IGY ~ m* (l;~ TAILLIGHT~ ~RD / WHI BR~::11::I II GVIII ]GV::VI~ HEADLAMP 0 cr:I ri-GI~ I III ~ I~ s " >>1 [ ~OR/BKD RD / WHJ BRAKE LIGHT SWITCH:BKRD RD OPTIONAL HORNCONNECTOR DIMMERKILL SWITCHSWITCH Chart38 i 1977Supplemert I GENERAL Recreational Products Produits R6creatifs IGNITION TESTER RESETINDICATOR -TheBombardierignitiontesterisanelectricalenergy measuringdevicecapableofmeasuringthepeakener -gy output of a coil. Thetest er isof solidstate constructionandperforms as (lcomparator.Thecorrectvalueofenergyoutputis indicatedineachtestandisthencomparedwiththe valuetakenfromthe engine beingtested . The energyoutputisverif iedbymeans of a 0-100 scale onthe tester.The greater the energy output, the greater valueindicationonthescale.Theindicationisinthe form of anincandescent lampthat lights whenthe scale knobis setatthepositioncorrespondingtothe energy output. Thotesterhastwoinputrangesselectedbyatoggle swit ch.TheLOWrangeissensitivetoACorDCvolt -Clgesfrom 05 to27 volts.TheHIGHrangeis sensitive to ACorDCvoltagesoffromapproximately75to500 volts. BOMBARDIER IGNITION TESTER o100 lOW@HIGH TEST CON DITION Alltests are performed onthe vehicle at cranking speed. Itwould seemlogicalthatremovalof sparkplugs would allow the engine to turn over faster, therefore raising the outputleveloftheignitionsystem.Itwasfoundthat vigorouscrankingagainstcompressioncausesthe flywheelto snapover,raisingthe output higher thanby crankingwithoutcompression.Ifoutputresultsare marginal,outputcanbemeasuredwithandwithout compression. Testvalueslistedaretakenagainstcom-pression. Always crank vigorously asinactualstarting. Readallinstructionsthoroughlyandasyoubecome familiarwiththistestinstrumentitwillbepossibleto testacompleteignitionsysteminamatter ofminutes. Always proceed inthe following order: 1.Connect tester P andN clip leads asillustrated. 2.Follow test procedure sequence. 3.Aftereverytestthatlightstheindicatorlamp,reset theindicator circuit by depressingthe resetbutton. (1977 SupplclJ)cnli(BOMBARDIERIGNITI ONTESTl:RI,PAGE1 :::,:::::,:::?::::.:::::::.ANALYSIS OF TEST RESULTS Indicator lamp lights at specific setting. Outputisasspecifi ed.Testresultsshouldrepeatthree times.Ifreadingsdonotrepeat,outputiserrati cand causeshouldbeinvestigated(looseconnecti onsor components, etc.). Indicator lamp lights at a lower setting. Thisindicatesthatthe output is lessthanthatdesigned tooperatethe engineina satisfactorymanner.The en-ginemayrunatalowersetting,butbethesubj ectto hardstarti ngandmi sfire.Becert ainthat correctengine crankingconditionsweremetbeforecondemningthe ignition. Indicator lamp does not light. Onecomponentisdefective.Proceedasinstructedto find defective component. Intermittent ignition problems Indealingwithintermittentproblemsthereisnoeasy diagnosis.Forexampl e,problemsthatoccuronlyat normal engine operatingtemperature have tobe tested under simi lar conditions. Inmostcasesoftemperatureand/or vibrationfailure, onlypartsreplacementcansolvetheproblemasmost ofthesefailuresreturntonormalwhenengineisnot running. Double trouble Thereisalwaysthepossibilityofmore thanonedefec-tivepart s.Ifaft eracomponenthasbeenreplaced,the problemstillpersist s,carefull yrepeatthe complet e t est procedure to findthe other defective part. ANALYSER TEST AND MAINTENANCE Atest simulat or isprovided with eachtester asa means to test the lamp, detector circuit, andbatteries. High scale t est a)PlaceswitchinHIGHpositi on.Plugthesimulator into anelectri c outlet (117VAC)for tenseconds. ~CAUTION:Aftercharging,donottouchplug "terminal s while pressingtestbutton. Amild shock will result . :47'"t,r i ':} / ItI){ b)Removethesimulatorfromtheout let,andconnect the"P" and"N" leadsfromthetestertothesimu-lator asindicat ed on t hebutton of the simulator. c)Setthetesterdialto50,orbelow.Depressthe buttonofthesimulator.Theindi catorlamponthe tester shoul d li ght. O NOTE:Foreachtestper formedbythesimulator, itmustberecharged Low scale test a)Place switch inLOW position b)Settester dialto 50,or below. c)ConnectNleadtonegativeterminalof12voltbat -tery.ConnectPleadt opositiveterminalof12volt batteryindi cator lamp should light. Iflamp does not li ght, checktesterbatteries.Ifthey are install ed correct ly andaregood, checkthe clipleadsfor faulty connections.If nofault canbefound,refertothe warrantystatementforinstructi onsforsendingthe tester back toElectro-Specialt ies, Inc. Battery replacement 1.Removethefour(4)screwssecuringcovertocase. 2.Carefully lift cover. 3.Repl acebatteries with size"C" Alkaline batteries.Be suretoobservepolaritymarkingsonbatteryholder or lamp will not li ght. 4.Instal lcoveroncasecarefull ybeingcertainthatno wiresarepinchedbetweencoverandcase.Secure cover. O NOTE:Weakbatterieswillnotimpair test eroper ation or cal ibrat ion . The light will grow dim. Theignitiontestermaygivefalsereadingsif therivets on the back cover come incontact with metal. Indicator knob ali gnment Checkindicatorknobalignmen tbyturningknobfully clockwi se.The whi temarkonthe knobmust alignwith no.100 onthescale. Ifthemarks doesnotlineup with the no.100, loosenthe knob set screw,line the markon theknobwithno.lOa,andtightenthesetscrew.Re-check alignment. o NOTE:Ifafteradjustment,theknobisturned full ycounter-clockwiseanditdoesnotexactly ali gn with the 0, it isof no consequence. (BOMBARDIERIGNI TIONTESTER),PAGE 2(1977 Supplement) . t>,', tZ ,,>,, -l is z (f) ---0 l> G) m "" ~ --J (f) C'0 '0 co 3 C1lOJPULLEY TYPE ELAN250R.R.S. 250 DeluxeRR.S. OLYMPIQUE300 MonoR.RS 300 Twin, 340 R.S.S. 440 R.S.S. EVEREST340 R.S.S. 440 R.S.S. T'NT340 R.SS 440 FreeAir R.S.S. 440FanCooled R.S.S. RV340 R.S.S. ALPINE640ERR.5S.Ibeanng) R.R.S.:RollerRoundShaft R.S.S.:RollerSquare Shaft (Bear ing):With Bearing Hub PlugWith"Duralon"Bushing . With "Duralon" Bushing. CD Wlth 4 std.washers no. 399901500 . COUNTERWEIGHT IDENTIFICATION E-4 D-2 E-4 C-3-L C-8-M C-3-L C-4-L C-4-L C-4-LCD C-4-L A-3 C-8 double Torque retaining bolt to specificationthenloosen andretorque to specific value . SPRINGSPRING NUMBERCOLOR 4142580Bronze 4142581Blue 4142581Blue 4141967light blue 4141967Light blue 4141967Light blue 4141966Pink 4141995Yellow 4141967Light blue 4141966Pink 4142835Red 4141966Pink After boltIStorqued, start engine and repeatedly apply throttle and brake.Stop engine and retorque. SPRINGLENGTHRETAINING BOLT mm (inch)TORQUE :::1.5(.060" )kg-m(ft-Ibs) 81.313.2001 5.1- 7.5(37-541 77.713.0601 5.1- 7.5(37-541 77.7130601 5.1- 7.5137-541 118.91468018- 94158-681 118.914.68018- 94158-681 118.914.6801'8- 94158-681 122.214.8101' 8- 94158-681 100.113.940) 8- 94158-681 118.914.68018- 94158-681 122214.8101 8- 94158-681 88.913.5001 8- 94158-681 122.214.8101 115-12.7183-921 WEAR PAD PART NO. 504220700 504220700 504 2207 00 504227700 5042277 00 504225000 504220700 504220700 '.. APPLICATION INNERHALFSHAFT SECTION 08 SUB-SECTION 02-03 VEHICLE MODEL PART NO.CLASSIFICATION 504 2211 00Forged'75 Elan250 Deluxe and 300SS 504221100Forged'75 Alpine (1st series), '74 '75 T'NT 440, '74 Everest 504220400Forged'74-'75 T'NT 340 504223300Machined'75 Alpine(2nd series), '75 T'NT 440 and Everest 504 224500Machined'75 T'NT 340 '75 Olympique 300340 504 224700Machined'75 T'NT R /V 245 504 2279 00'76 Alpine 504223300'76 Olympique PLUS 11977 Supplement)(WEARPADS APPLICATION),PAGE1 . .... . . . .') DRIVENPULLEYSPRINGTENSION 1974197519761977 kg1 (lbs2)kg 1 (lbs2)kg 1 (lbs2)kg:!: 1 (lbs2) ELANAllmodels36 (8)3.6(8)3.6(8) 3.6(8) OLYMPIQUEAllmodels3.6(8)3.6(8)36(8)3.6(8) NORDIC640ER3.6(8) T'NT F /A5.9(13)5.9(13) T'NT F /C3.6(8)5(11)3.6(8) EVEREST3.6 (8) 5 (11)3.6(8)3.6(8) T'NT3.6(8) RV2505.9(13)5.9(13) 3405.9(13)5.9(13) ALPINE440ER3.6(8) 640ER3.6(8)5.4(12)5.4(12)5.4(12) ELITE3.6(8)3.6(8) (1977SlIpplnrncntl( ( ) n I V ~ NPULLIY SPRINC;II NSIONI.PflGf1 :::..:.U } ELAN OLYMPIQUE NORDIC EVEREST TNT F /C TNT F /A ALPINE ELITE RV .I OI(!1- 0 U):-=+-' TNT F IC Q) >Q) EVEREST34.8-5.5(35-40)1.2- 1.6(9- 12) oc

F / A _+-'C

o>U ALPINE44.8-5.5(35-40)1.2- 1.6(9- 12) .Do. .2 c+-'C 2-Q)(ij ELITE64.8-5.5(35-40)1.2- 1.6(9- 12) ...... ..0 OlmOl' f=J::.- +-' +-'+-''+-1975-1976-1977 SKISYSTEM TORQUE SPECIFICATIONS SKILEAF SPRING IRUNNERSHOESPRING COUPLER SYSTEMSPRING COUPLERTO SKILEG TYPERETAININGBOLT kg-m(ft-Ibs)kg-m(ft-Ibs) ELAN(Allmodels except70.5-0.7(4-5) --,,-Cf'. EVEREST 1975-7694.8-5.5(35-40)1.2- 1.6(9- 12) .Doc.b j2>- 0 TNT & EVEREST 1977 U):-=+-' (/) Q)m+-' >Q) TNT F IA1975104.8-5.5(35-40)1.2-1.6(9- 12) oc

TNTRV114.8-5.5(35-40)1.2-1.6(9-12) _+-'c o>U .D.0..2 ELITE197564.8-5.5(35-40)1.2- 1.6(9- 12)C+-,C 2-Q)(ij +-'..0 ALPINE 1975-76124.8-5.5(35-40)1.2- 1.6(9-12) OlmOl' f=J::.- +-' 1977 134.8-5.5(35-40)1.2-1.6(9-12) +-'+-''+-11977SupplementlISKISYSTEMTORQUESPECIFICATIONS), PAGE 1 Cylinder taper I Measurecyli nderdiameter16mm(%")fromtopof cyli nderanddowntoJustbelowtheintakeport .Ifthe difference between eachmeasurement exceed 0.08 mm (003")thecyli ndershouldbereba redandhonedor should bereplaced ._-----ONE CYLINDERENGINE TECHNICAL DATA Cylinder out of round Measuring13mm(Y2")fromtop of cylinder with a cyl-indergauge,checkifthecylinderoutofroundismore than0.05 'mmLOO2").Iflarger,cylindershouldbere-bored andhoned or shouldbereplaced. ----------------13mm IY, ") 11977 Supplement)lONE CYLINDERENGINE, TECHNICALDATA), PAGE1 Piston to cylinder wallclearance Todetermine thisclearance,thepistonshouldbemea-sured8mm(5/'6 ")aboveitsbottom edgeandthecyl-indershouldbemeasured13mm(Y2")belowitstop edge. + Thedifferencebetweenthesetwomeasurements should be within specified tolerance. o NOTE:If cylinder diameter is0.1mm LOO4")larger thannominal, the cylinder should be rebored. Ringend gap Positionringhalf waybetweentransferport andintake port.Usingafeelergauge,checkringendgap.Ifgap exceedspecifiedtolerancetheringshouldbereplaced. Transfer port Pistonring/groove clearance Usinga feeler gaugecheckclearance betweenring and groove.Ifclearanceexceed0.20mmL008") ,replace piston. Crankshaft deflection Withthe crankshaftpositionedbetweena centerlathe, installa dialindicator ascloseaspossibletocrankshaft blade thenmeasure delfection oneach side.If deflect ion exceed0.08mmLOO3")thecrankshaftshouldbere-pairedbyaspecializedshoporitshouldbereplaced Connecting rodbigend axial play Usi ngafeelergaugemeasuredistancebetweencon- J) nect ingrodandthrustwasher.Ifaxialplayexceed0.5 mmL020"), the crankshaft should bereplaced. (ONECYLINDERENGINE.TECHNICALDATAl, PAGE2I~ ( 1 9 7 7Supplementl Connecting rodali gnment Check if connecting rodisbent asfollows: - Onceenginecrankcaseisassembledwiththepiston mountedonconnectingrodwithoutitspistonrings, position cylinder onpiston. ONaTE:Thecylinder /crankcasegasketmustnot beinstalled. - Rotatecrankshaftslowlyandatthesametimeob-servepistonmovementwithinthe cylinder.Ifpiston bearsagainstoneside(PTaormag.side),thecon-necting rodis bent. Equal di stance - Tocorrect,positionneedlebearingandgudgeonpin onconnect ingrodthenpryconnect ingrodas illust rated. (1977Supplement!(ONECYLINDERENGINE, TECHNICAL DATAl, PAGE3 TOLERANCE AND WEARLIMIT (ONE CYLINDERENGINE) YearEngine Cylinder bore(nominal)Piston to wall clearanceRingCrankshaft Type std.1st 0.5.2nd 0 . 5.Fitted toleranceWear limit End gapEndplay 197424769.0mm69.5mmNA0.065-0. 100mm0.165mm0.25- 1.60 mm0.1O-0AOmm 12.7165")12.7362")( 0026- 0039")(0065")(010-. 063")(004-. 016") 197430276.0mm76.5mm77mm0.080-0.115mm0. 195mm0.30-1.60 mm0.1O-0AOmm 12.9921")13.0118")130315")(0031 0045")(0076")(012-.063")(004-. 016") 197524769.0mm69.5mmNA0.065-0. 100mm0. 165mm0.25-1.60 mm0.10-0AOmm 12.7165")12.7362")(00260039")(0065")(010-. 063")(004-. 016") 197624769.0mm69.5mmNA0.065-0.100mm0.165mm0.25-1.60 mm0.1O-0AOmm 127165")12.7362")(00260039")(0065")(010-.063")(004-. 016") 197630276.0mm76.5mm77.0mm0.0800 115mm0. 195mm0.30-1.60 mm0.1O-0AOmm 129921")13.0118")130315")(0031 .0045")(0076")1.012-.063")(004.016") 197724769.0mm69.5mmNA0.0630.099mm0. 162mm0.25-1.60 mm0.1O-0AOmm 127165")127362")1.0025.0039")(0064")(010-. 063")1.004- 016") 197730276.0mm76.5mm77.0mm0.D78-0. 114 mm0.198mm0.25-1.60 mm0.10-0AOmm 12.9921")13.011 8")130315")1.0031 -. 0045")(0078")(010-. 063")(004-. 016") N.A.Not applicable lONE CYLINDERENGINE.TECHNICAL DATA).PAGE411977 Supplemen t ) St'CTION08 ,TWO CYLINDERENGINE TECHNICAL DATA Cylinder taper Measurecylinderdiameter16mm( %")fromtopof cylinderanddowntojustbelowtheintakeport.Ifthe differencebetweeneachmeasurmentexceed0.08mm 1.003")thecylindershouldbereboredandhonedor should bereplaced. ------Cylinder out of round Measuring13mm(Y2")fromtop of cylinder with a cyl-indergauge,checkif thecylinderout of roundismore than0.05mm1.002").Iflarger,cylindershouldbere-bored andhoned or should bereplaced. i, Piston to cylinder wall clearance Todetermine this clearance,thepistonshouldbemea-sured8mm( 5/16")aboveitsbottomedgeandthecyl-indershouldbemeasured13mm(12")belowitstop edge. (1977 Supplement)(TWO CYl. ENGINE TECHNICAL OAT A), PAGE1 Thedifferencebetweenthesetwomeasurements shouldbe within specified tolerance. O NOTE:If cylinder diameter is 0.1mm (.004")larger thannominal, the cylinder should berebored. Ringend gap Positionringhalf way betweentransfer port andintake port.Usingafeelergauge,checkringendgap.Ifgap exceedspecifiedtolerancetheringshouldbereplaced. Pistonring/groove clearance Usinga feelergauge checkclearancebetweenringand groove.Ifclearanceexceed0.20mm(.008")replace piston. Crankshaft deflection Withthecrankshaftpositionedbetweena centerlathe, installadialindicatorascloseaspossibletocrank-shaftblade,thenmeasuredeflectiononeachside.If deflectionexceed0.08mm(,003")thecrankshaft shouldberepairedbya specializedshoporit shouldbe replaced. Connecting rodbigendaxialplay Usingafeelergaugemeasuredistancebetweencon-nectingrodandthrustwasher.Ifaxialplayexceeds 0.50 mm(,020") the crankshaft should be replaced Connecting rodalignment Checkifconnecting rodisbent asfollows: - Onceenginecrankcaseisassembledwiththepiston mountedonconnectingrodwithoutitspistonrings, position cylinder on piston. O NOTE:Thecylinder /crankcasegasketmustnot beinstalled. - Rotatecrankshaftslowly,andatthesametimeob-servepistonmovementwithinthecylinder.Ifpiston bearsagainstoneside(PTOormag.side),thecon -necting rodisbent. (TWO CYLINDERENGINE TECHNICALDATA), PAGE 211977Supplement) ....... /I? ....Equaldistance - Tocorrect,positionneedlebearingandgudgeonpin onconnectingrodthenpryconnectingrodas illustrated. TOLERANCE AND WEARLIMIT (TWO CYLINDERENGINE). Cyl. bore nominal dimensionPiston to wall clearance EngineRingCrankshaft YeartypeStandardOversizeFitted toleranceWear limitend-gapend-play 197424854.0mm54.5mm0.050-0.085 mm0.135mm0.20-1.60 mm0.10-0.40 mm (2.1260"1(2.1457"1(0020-.0034"1(0054"1(008-.063"1(004-.016"1 197429457.0mm57.5mm0.050-0.085mm0.135mm0.20-1.60 mm0.10-0.40mm (22441"1(2.2638"1(0020-.0034"1(0054"1(008-.063"1(004-.016"1 197433859.5mm60.0mm0.080-0.115mm0.195mm0.20-1.60mm0.10-0.40mm (23425")(2.3622"1(0031-.0045"1(0076"1L008-.063"1(004-.016"1 197434359.5mm60.0mm0.080-0.115mm0.195mm0.20-1.60 mm0.10-0.40 mm (2.3425"1(2.3622"1(0031-.0045"1(0076"1(008-.063"1(004-.016"1 197434659.5mm59.75mm0.100-0.135mm0.235mm0.20-1.60 mmNA (2.3425"1(2.3524"1(0039-.0053"1(0092"1(008-.063"1 197439664.5mm64.75mm0.090-0.125mm0.215mm0.25-1.60 mmN.A. (2.5394"1(2.5492"1(0035-.0049"1(0084"1(010-.063"1 197440164.5mm65.0mm0.080-0.115mm0.195mm0.25-1.60 mm0.10-0.40 mm (25394"1(2.5591"1(0031-.0045"1~(0076"1(010-.063"1(004-.016"1 197443467.5mm68.0mm0.080-0.115mm.0.195mm0.25-1.60 mmNA (2.6575"1(2.6772"1(0031 - 0045")(0076"1(010-.063"1 197443667.5mm67.75mm0.110-0.145mm0.255mm0.25-1.60 mmN.A. (2.6575"1(2.6673"1(0043- .0057"1(010"1(010-.063"1 197444067.5mmN.A.0.053-0.153 mm0.216mm0.25-1.60mmNA (2.6575"1L0021 -.006"1(.0086")1.010-.063") 197464076.0mm76.5mm0.090-0.125mm0.215mm0.30-1.60 mm0.10-0.40mm (2.9921"1(3.0118")(0043-.0057" I(0084"1(012-.063"1(004-.016"1 N.A.: Not applicable (1977Supplement)(TWO CYL.ENGINE TECHNICAL DATAl, PAGE 3 TOLERANCE AND WEARLIMIT (TWO CYLINDERENGINE) Engine Cyl.bore nominal dimensionPiston to wall clearance RingCrankshaft YearTypeend-gapend-play StandardOversizeFitted toleranceWear limit 197524554.0mm54.25mm0.070-0.105mm0.175mm0.20-0.50 mm0.10-0AO mm (21260")(21358")(0028-0041 ")(0069")(008-020")(004-016") 197524854.0mm54.5mm0.0500.085mm0.135mm0.20-1.60 mm0.1O-0AO mm (2.1260")(21451")(00200033")(0053")(008-063")(004-016") 197529457.0mm57.5mm0' 0500.085mm0.135mm0.20-1.60 mm0.100AOmm (22441")(22638")(0020-0033")1.0053")(008-063")1.004-016") 197530555.5mm56.0mm0.050-0.085mm0.135mm0.20-1.60 mm0.10-0AOmm (21850")(22041")(0020-0033")(0053")(008-063")( .004-.016") 197534359.5mm60.0mm0080-0115mm0.1 95mm0.20-1 .60 mm0.100AOmm (23425")(23622")(0031-0045")1.0077")(008-063")(004-016") 1975 346.59.5.mm' . .o 100"{} 135mm0.235mmO.20- 1.60mmNA (23425")(23524")(0.093:'). 1.008,063".). 197543467.5mm68.0mm0.080-.0115mm0.195mm0.25-1.60 mmNA (26575")(2.6772")1.0031 -0045")(0071")(010-063") 1975436Q7.5mm67.75mm0.090-0.125mm0.215 mm0.25-1.60 mmNA (26575")(26673")(0035- 0049")(0085")(010-063") 197544067.5mmNA0.063-0.153mm0.216mm.0.25-1.60 mmNA (26575")(0025-006")(0086")(010-063") 197564076.0mm76.5 mm0.090-0110mm0.215mm0.30-1.60 mm0.10-0AOmm (29921")(30118")1.00350043")(0085")(012-063")(004- 016") 197624554.0 mm54.25mm0.070-0.105mm0.175mm0.20-0.50 mrl')NA (21260")(21358")(0028-0041 ")1.0069")(008-020") 197624854.0mm54.5mm0050-0085mm0.135mm0.20-1.60 mm.0.100AO mm (21260")(2.1451")(00200033")(0053")1.008-063")(004-016") 1976305.55.5mm56.0mm0.070-0.105 mm0.175mm0.201.60mm0.1O-0AO mm (21850")12.204 1")(0028-0041 ")(0069")(008-063")(004-016") 1976343595mm60.0mm0.080-0.115mm0.195mm0.201.60mm0.1O-0AO mm (23425")(23622")(00310045")(0077")(008-063")(004016") 1976345630mm63.25mmo.050-008!;imm0.135mm0.20-0.50 mmNA (2A803")(2A902")(00200033")1.0053")1.008020") 1976434675mm60mm0.080-0.115mm0.195mm0.251.60 mmNA (26575")(26772")1.0031-0045")1.0077")(010-063") 1976440675mmNA0.0.33-0.153mm0.216mm0.25-1.60 mmNA (26575")(0013006")(0086")1.010063") 197664076.0mm76.5mm0.070-0.105mm0.175mm0.30-1.60 mm01O-0AO mm (2.9921")(30118")1.0028-0041 ")(0069")(012-063")(004016") N.A.: Not applicable IIWOCYlENGINElECHNICAIDATA),PAGE4(1977Supplement) .......... ., i...t ..............,.'\ ................ . ,. SECTION 08 04-02

TOLERANCE AND WEARLIMIT (TWO CYLINDER ENGINE) Cyl.bore nominal dimension Engine Type YearStandard 1977248b4.0mm (2.1259") 197730555.5mm (2.1850") 197734359.5mm (23425") 197734563.0 mm (2.4803") 197734659.5mm (23425") 197743667.5mm (26574") 1977440*67.5mm (26574") 1977440**67.5mm (26574") 197764076.0mm (29921") N.A..Notapplicable Castiron sleeve cylinder Nikasil coated cylinder Oversize 54.5mm (21456") 56.0mm (2.2047") 60.0mm (23622") 63.25 mm (2.4901 ") 59.75mm (23524") 67.75mm (2.6673") 68.0mm (2.6771") NA 76.5mm (30118") Piston to wall clearance RingCrankshaft end-gapendplay Fitted toleranceWear limit 0.0480083 mm0.132mm0.201.60mm0.100.40mm (00190033")(0052")(008063")( 004016") 0.068-0.104mm0.173mm0.201.60mm0.100.40 mm (00270041 ")(0068")(008063")(004016") 0.0780.114mm0.198mm0.201.60 mm0.100.40mm (.0031".0045")(0078")(008063")(004016") 0.048-0.083mm0.132mm0.20-0.51mmNA (0019-.0033")(0052")(008-020") 0.099-0.134mm0.233mm0.20-1.60 mmNA (0039-0053")(0092")(008-063") 0.089-0.124mm0.213mm0.251.60mmNA (0035-0049")(0084")(010-063") 0.068-0.114mm0.183mm0.25-1.60 mm0.10-0.40 mm (0027-0045")(0072")(010-063")(004-016") 0.078mm0.156mm0.25-160mm0.10-0.40 mm (0031")(0062")(010063")(004-.016") 0.068-0.104mm0. 173mm0.30-1.60 mm0.10-0.40 mm (0027-0041 ")(0068")(012063")(004016") (1977Supplement)(TWOCYL.ENGINE TECHNICAL DATA) , PAGE 5 /'","" (J 1974 IGNITION TIMING SPECIFICATIONS EngineIgnitionDirectmeasurementIndirect measurementEdge gap TypeTypeB.T.D.C.B.T.D.C. Elf ~ .. ~ illlJ}u] r ~ ' \ ] OJ C7 247BKPT3.98 mm 0.25NA6.5 mm1.5 (157" .010)(260".060) 248BKPT222 mm 0.252.29 mm0.259.0mm:!:2.0 (087":!:.010)(090":!:.010)(.354"!.080) 294BKPT2.39 mm!0.252.49 mm!0.309.0 mm!2.0 (094"!.010)(098"!.012)(.354" .080) 302BKPT3.98 mm 0.255.79mm0.416.5mm1.5 (157":010)(228":.016)(260":!:.060) 338BKPT307 mm!0.253.62 mm!0.276.5mm1.5 (121".010)(143" .011)(.260":!:.060) 343BKPT3.07 mm:!:0.25373 mm:!:0.306.5mm!1.5 (121".010)(147".012)(260":!:.060) 346CD207 mm!0.25N.A.NA (081"!.010) 396CD2.07 mm!0.25N.A.NA (081".010) 401BKPT3.07 mm!0.253.73 mm0.306.5mm1.5 (121": .010)(147"!.012)(,260"!.060) 434BKPT3.07 mm 0.253.30 n'1m:!:0.256.5mm1.5 (121":!:.010)(,130".010)(260":!:.060) 436CD2.07 mm:!:0.25NAN.A .. (,081"!.010) 440BKPT3.07 mm:!:0.253.30 mm0.256.5mm1.5 (121"!.010)(130".010)(,260".060) 640CD3.35 mm:0.253.48 mm!0.25NA (132".010)(137".010) 640BKPT3.95 mm 0.254.11mm!0.256.5mm:!:1.5 (156":!:.010)(162".010)(260":!:.060) NANot appli cable (1977Supplement)(IGNITION TIMINGSPECIFICATIONS), PAGE1 1975 IGNITION TIMING SPECIFICATIONS EngineIgnitionDirectmeasurementIndirect measurementEdge gap TypeTypeB.T.D.C.B.T.D.C. ~ f) ~ .. illU' ~ ln ([[rl] ;JC) 245CD1.20 mm 0.25NANA (047":t.010) 247BKPT3.98 mm 0.25N.A.6.5mm:t1.5 (157":t.010)(260":t.060) 248BKPT2.22 mm!0.252.29 mm 0.259.0mm!2.0 1.087":t.010)(090":t01O)1.276":t.060) 294BKPT2.39 mm:t0.252.49 mm:!:0.309.0 mm 2.0 (094":!:.010)(098":t.012)(276":t.060) 305BKPT3.07 mm:t0.253.73 mm:t0.306.5mm:t1.5 (121" .010)L147"!.012)(.260":t.060) 343BKPT3.07 mm:t0.253.73 mm:!:0.306.5mm:t1.5 L121":t.010)(147":t.012)1.260":t.060) 346CD2.07 mm:t0.25NANA (081"!.010) 434BKPT3.07 mm:!: 0.253.30 mm:!:0.256.5mm:t1.5 L121":t.010)(130":!: .010)(260":t.060) 436CD2.07 mm 0.25NANA (081":t.010) 440BKPT3.07 mm:t0.253.30 mm 0.256.5mm:t1.5 (121":t.010)(130":t01O)(.260":t.060) 440CD2.07 mm!0.252.21mm:t0.25NA (081":!: .010)(087":t.010) 640BKPT3.95 mm:t0.254.11mm 0.256.5mm:!:1.5 (156":t01O)(162":t.010)(260"!.060) N.A.Not applicabl e (I GNITI ON TIMINGSPECIFICATIONSI,PAGE2(1977 Suppl ement I ..1976 IGNITION TIMING SPECIFICATIONS EngineIgnitionDirectmeasurementIndirect measurementEdge gap TypeTypeB.T.D.C.B.T.D.C. ff . . .. fIt-=:]] :;r (J 245CD1.15mm 0.25NANA (045".010) 247BKPT3.98 mm0.25N.A.6.5mm1.5 (157".010)(260".060) 248BKPT2.22 mm0.252.29 mm0.259.0mm2.0 (087"!.010)(090".010)(0.354".079) 302BKPT3.98 mm0.25N.A.6.5mm1.5 (157"01O)(260"!.060) 305BKPT3.07 mm 0.253.73 mm0.306.5 mm1.5 (121".010)(147".012)(260".060) 343BKPT3.07 mm0.253.73 mm 0.306.5 mm1.5 (121".010)(147".012)(.260".060) 345CD1.0 mm 0.25NANA (039" 01O) 434BKPT307 mm0.253.30 mm 0.256.5mm 1.5 (121 ".010)(130".010)(260".060) 440BKPT307 mm0253.30 mm 0.256.5mm1.5 (121"!.010)(130".010)(260".060) 640BKPT3.95 mm0.254.11mm 0.256.5mm1.5 (156" 01O)(162".010)(.260".060) N.A.Not applicable 11977 IIGNITION TIMINGSPECIFICATIONSI, PAGE 3 1977 IGNITION TIMING SPECIFICATIONS EngineIgnitionDirectmeasurementIndirect measurementEdge gap TypeType B.T.D.C.~ B.T.D.C. . ~ .f) ~ . .. ~ . ~ illllr1hfri'}] ;.)~ 247 RKPT3.98 mm 0.25NA6.6mm:t15 (157":t.010)(260":.060) 248' :KPT2 22 mm:t0.252.29 mm:0.259.0mm 2.0 (087":t01O)(090":t.010)(0354":t.079) 30213KPT3.98 mm:0.25NA6.6 mm 1.5 (lb7":t01O)(260":t.060) 305 BKPT(i) 307 mm:0.25(i)373mm:t0.306.6 mm:t15 (121"!.010)(147":012)(.260":t060) 343 BKPTCD307 mm0.25CD3.73 mm!0.306.6mm:1.5 (121":t.010)(147".012)(260":t060) 345CD1.0 mm:0.25NANA (039":t.010) 346 13KPT2.52 mm:0.25NA6.6mm:t1.5 (100":t.010)(260":t060) 436 8KPT2.52 mm:t0.25NA6.6mm:t1.5 ( 100":.010)(260":060) 440 BKPT307 mm!0.253.30 mm:t0.256.6mm!1.5 (121".010)(130":t.010)(.260":t.060) 040 BKPT3.95 mm:t0.254.11mm:t0.256.6mm1.5 (156":.010)(162" : .010)(260":t.060) NA Not applicable (i)Frl l1t:rlqine serial No.2 852346andup,use2.11mm(083")fordirecttimingand246 ml1l( O ~ 7 " )for indirecttiming. CDFrom engine serialNo.2 930 685 andup,use 2.11mm(083") for direct timing and 246 111m(097")for indirect timing !IGNITION TIMINGSPECIFICATIONS),PAGE 4(1977Supplement) CARBURETOR SPECIFICATIONS LOWHIGH MAINSPEEDSPEEDIDLE ENGINEFUEL JETADJ.ADJ.SPEED YEARMODELTYPECARBURETORDIA.+Va-0+Va-0R.P.M. 1974ELAN250247HR-133-A.042" 3/. fixed1800-2200 1974ELAN2502 cyl.248HR-155-A.044"1fixed1800-2200 1974ELAN250DL248HR -155-A.044"1fixed1800-2200 1974ELAN29455294HR- 161 -A.051"%fixed1800-2200 1974OLYMPIOUE300302HR-132-A- %11800-2200 1974OLYMPIOUE340338HR-131- A.050"%fixed1800-2200 1974OLYMPIOUE400401HR-l34-A.052"%fixed1800-2200 1974OLYMPIOUE440434HR-135-A.045"'Ifixed1800-2200 1974T'NT300294HR-l64-A- 111800-2200 1974T'NT340343HD-l34-A- 111800-2200 1974T'NT440440HD-l38-A- 111800-2200 1974EVEREST440440HD-l38-A- 111800-2200 1974NORDIC640640HD- 133-A.067"1fixed1800-2200 1974ALPINE440434HD-108-A.054"%fixed1800-2200 1974ALPINE640640HD-124- A.073"%fixed1800-2200 1974ELITE440434HD-140-A.058"1fixed1800-2200 1974T'NT340F /A3462xHR-149-A- 11 Y.1800-2200 1974T'NT400F/A3962xHD-123-A- 1%1800-2200 1974T'NT440F/A4362x HRM-3A- 11Y.1800-2200 1975ELAN250247HR-133-A.042" 3/. fixed1800-2000 1975ELAN250 Deluxe248HR-165-A.044"1fixed1800-2000 1975ELAN30055294HR-166-A.051"%fixed1800-2000 1975OLYMPIOUE3oo, 300E305HR-169-A.051"1fixed1500- 1800 1975OLYMPIOUE34O,340E343HR-170-A.054"1fixed1500- 1800 1975T'NT34O,34OE343HD-l34-A- 111800-2200 1975T'NT44O,44OE440HD-l38-A- 111800-2200 1975EVEREST44O,44OE440HD-l38-A- 111800-2200 1975T'NTFI A3403462x HR-168- A- 11 Y.1800-2000 1975T'NTFI A4404362x HRM-5-A- 111800-2000 1975T'NT FIA245 R IV2452x VM-34-722601fixed3000 1975ALPINE640ER640HD-142-A.060"1fixed or 11500- 1800 1975ELITE440ER434HD-14O-A.058"1fixed1800-2200 11977 Supplement)(CARBURETORSPEC)FICATIONS), PAGE1 CARBURETORSPECIFICATIONS LOWHIGH MAINSPEEDSPEEDIDLE ENGINEFUEL JETADJ .ADJ .SPEED YEARMODELTYPECARBURETORDIA.~Yo- 0...Yo- 0R.P.M. 1976ELAN250247HR- 173-A.046"1fixed1500- 1800 1976ELAN250SS248HR- l72-A.042"1fixed1800-2200 1976OLYMPIOUE300 Mono302HR-174- A.045"1fixed1200- 1500 1976OLYMPIOUE3003OOE,Twin305HR- 169-A.051"1fixed1500- 1800 1976OLYMPIOUE340,340E343HR-170- B.054"1fixed1500-1800 1976OLYMPIOUEPlus 440434HR-176-A.049"1fixed1500- 1800 1976T'NT340,340E343HD-l48-A- 1115001800 1976T'NT EVEREST44O,440E440HD-147-A- 111500- 1800 1976T'NTR I V2502452 x VM 34-93no. 3001fixed3000 1976T'NT R IV3403452 x VM 34-94no. 3201fixed2500 1976ALPINE640ER640HRM-7-A- 1 Y.11500-1800 1977ELAN250247HR- 173-A.046"1fixed1500- 1800 ) 1977ELAN250 Deluxe248HR-l72-A.042"1fixed1800-2200 1977OLYMPIOUE300 Mono302HR-174-A.045"1fixed1200-1500 1977OLYMPIOUE300 Twin305VM 30-90no. 26011',:!:0fixed1500- 1800 1977OLYMPIOUE340343VM 30-91no. 2601 Y,0fixed1500-1800 1977OLYMPIOUE440440VM32-113no. 2901 Y,:!:0fixed1500- 1800 1977EVEREST340343HD-148-A- 111500-1800 OPTIONAL VM 30-98no. 2501 Y,0fixed1500- 1800 1977EVEREST440440VM34- 110no. 34011',0fixed1500- 1800 1977T'NT340346VM34- 118no. 3001 0fixed1800-2000 1977T'NT440436VM 36-53no. 35010fixed1800-2000 1977T'NT440440VM34- 11Ono. 34011', 0fixed1500- 1800 1977RV3403452xVM 34- 135no. 3201 0fixed3000-3200 1977ALPINE640ER640HRM-7-A- 1Y.11500- 1800 ICARBURETORSPECIFICATIONSI, PAGE 211977Supplement) Tilbsin IlJlcwlth hore C /I Applicable on: HD-124-A HD-133-A HD-138-A HD-147-A MODEL HD-l08-A HD-l34-A HD-123-A HD-148-A HD-140-A HD-142-A HD-124-A HD-133-A HD-138-A HD-147-A NOZZLE CHECK VALVE INSTALLATION POSITIOI\J Applicable on: HD-124-A HD-133-A Applicable on: HD-138-A HD-147-A NOZZLE CHECK VAL Vf PR!:SSDEPTHSPECIFICATIONS Bottom 01carburetor body Main Nozzle / Discharge Tube Not applicable .343" * .343" * Flush Main Nozzle Nozzle shoulder flush with well floor Not applicable Not applicable Bottom "I carburetor body Intermediate Nozzle Not applicable Not applicable .156" * Measurement taken between lowest point of nozzle and bottom of carburetor body. All mesurements1:.005" (1977Supplement)(CARBURETORSPECI FICATIONS). PAGE3 MIKUNI CARBURETOR SPECIFICATIONS CARBURETORMAIN JETJETNEEDLECUTPILOTAIR (Production)NEEDLE*J ETAWAYJETSCREW VM 34-72260 6DH4-2P-4(159)2.5351 turn VM 34-933006DH4-2P-O (159)1.5351 turn VM 34-943206DH4-2P-2(159l1.5301 turn VM30-902606DH2-3P-6 (159)1.5251 Y2turn VM 30-912606DH2-30 -0 (159)2.0251 Y2turn VM 30-982506F9-30 -2(159)3.5351 Y2turn VM 34-110 3406F9-3P-2(159)1.5201 Y2turn VM34-1183006F9-30 -2 (159)3.5351 turn VM32-1132906F9-40 -2(159)3.5351 Y2turn VM 36-53350611-2P-2 (159)3.5401 turn VM 34-1353206DH2-4p-o (159)1.5301 turn *6DH4,-3 indicates specific slot of the needle from top. 1975 RV 250MAIN JETAPPLICATION CHART ~ T U R EoC -450 C-350 C-250 C-1 50 C00 C100 C200 C300 C (0F)(-50)(-30)(-10)(10)(30)(50)(70)(90) Meters (Feet) ALTITUDE Sea level300290280270260250240230 600m (2,000)290280270260250240230220 1200m (4,000)270260250240230220210200 1800m (6,000)260250240230220210200190 2400m (8,000)240230220210200190180170 3,000m (10,000)230220210200190180170160 _CAUTION:Theseadjustmentsareguidelineonly,specifi cadjustmentsvarywitht emperature,altitude, .".atmospheric pressure and humidity. Always observe spark plug condition for proper jetting. (CARBURETORSPECIFICATIONS) , PAGE4(1977 Suppl ement) 1976 RV 250MAIN JET APPLICATIONCHART ~ T U R EoC -450 C-350 C-250 C-150 C00 C100 C200 C300 C (0F)(-50)(-30)(-10)(10)(30)(50)(70)(90) Meters (feet) ALTITUDE 0 (sealevel350330320310300290280270 600m (2,000)330320310300280270260250 1,200m (4,000)310300290280270260250240 1,800 m (6,000)300290270260250240230220 2,400 m (8,000)280270260250240220210200 3,000m (10,000)260250240230220210200190 _CAUTION:Theseadjustmentsareguidelineonly,specificadjustmentsvarywithtemperature,altitude, "atmospheric pressure and humidity. Always observe spark plug condition for proper jetting. 1976 RV 340MAIN JET APPLICATION CHART ~ T U R EoC -450 C-350 C-250 C-150 C00 C100 C200 C300 C (0F)(-50)(-30)(-10)(10)(30)(50)(70)(90) Meters (feet) ALTITUDE 0 Sealevel370360350330320310300290 600m (2,000)350340330320300290280270 1,200 m (4,000)330320310300290270260250 1,800 m (6,000)320300290280270260240230 2,400 m (8,000)300290280260250240230210 3,000 m (10,000)280270260250230220210200 CAUTION:Theseadjustmentsareguidelineonly,specificadjustmentsvarywithtemperature,altitude, atmospheric pressure and humidity. Always observe spark plug condition for proper jetting. (1977SlJpplp.ment)(CARBURETORSPECIFICATIONS), PAGE 5 1977 RV340 MAIN JET APPLICATIONCHART ~ T U R EoC -450 C-350 C-250 C-150 C00 C100 C200 C300 C (0F)(-50)(-30)(-10)(10)(30)(50)(70)(90) Meters (feet) ALTITUDE 0 Sea level 350340330320310300280270 600m (2,000)340330310300290280270250 1,200m 320310300 (4,000) 290270260250240 1,800 m (6,000)310290280270260240230220 2,400m (8,000)290280260250240.230220200 3,000m 270260250240220210200190 (10,000) _CAUTION:Theseadjustmentsareguidelineonly,specificadjustmentsvarywithtemperature,altitude, "atmospheric pressure and humidity. Always observe spark plug condition for proper jetting. (CARBURETORSPECIFICATIONS), PAGE6(1977 Supplement) ]) w " "(J) C1J 1J CD3 C1l~ (J) "0 :0 ?