Ski-Daddler 5811-0000 Manual de usuario

.

MODELS

5811

-0000,

-0100

5812-0

000

I

-0200

PA

TS AND SERVICE

MANUAL

AMERICAN

MACH

INE

&

FDUNDRY

CDMPANY

CONSUMER

PRODUCTS

SALES

DIVISION

PARTS

&

SERV

I

CE

DEPARTMENT

Whiteford

Road

,

York.

Pennsy

lv

an

ia

17402.

Area

Code

717

848-

11

77

PART

NO

.

37949

TABLE

OF

CONTENTS

Page

WARRANTY

SER

VICE

..............

2

TABLE

OF

CONTENTS

.............

3

CHASSIS

..........................

4

To

R

epl

ace

Top

Shroud

...........

4

To

Repa

ir

Top

Shroud

............

4

To

Replace

Fuel

Tank

............

4

STEERING

........................

6

Ski

Alignment

.

..................

6

POWER

TRAIN

...................

, 7

To

Remove

Torque

Converter

Belt

............

.

...............

7

To

Remove

Driving

Clutch

Bell

Housing

.........................

7

To

Remove

Chain

Housing

and

Driven

Clutch

....................

7

To

Replace

Drive

Chain

..........

8

TRACK

OROUP

....................

9

To

Remove

Drive

Track

..........

9

Track

Alignment

.................

10

Brake

Adjustment

................

11

To

Remove

Boggie

Wheels,

Bog

-

gie

Springs,

and

Boggie

Wheel

Bearings

.....•..................

11

To

Remove

Idler

Sprockets

........

11

Bearing

Cover

Replacement

.......

11

To

Remove

Drive

Sprockets

.......

11

CARBURETOR

MODEL

5811

..

0

••••••

12

CARB

URETOR

MODEL

5812

.........

12

ELECTRICAL

INFORMA

TION

.......

13

Head

Lamp

......................

13

Tail

Lamp

......................

13

REPAIRMAN'S

REFERENCE

WIRING

DIAGRAM

..............•..........

14

LUBRICATION

INSTRUCTIONS

......

15

-3-

Page

FUEL

MIXTURE

•..................

15

FUEL

MIXTURE

INSTR

UCTIONS

....

15

CHASSIS.

0

••••••••••••••••••••••••

16

CHASSIS

PAR

TS

LIST

..............

17

SKIS

AND

STEERING.

0

•••••••••••••

18

SKIS

AND

STEERING

PAR

TS

LIST

...

19

ENGINE,

ELECTRICAL

AND

FUEL

ELEMENTS

........

0

••••••••••••••

20

ENGINE,

ELECTRICAL,

AND

FUEL

ELEMENTS

PAR

TS

LIST

.....

21

DRIVE

TRACK

............

...•....

22

DRIVE

TRACK

PARTS

LIST

........

23

CARBURETOR

MODEL

5811 -

HL

20914

.........................

24

CARB

URETOR

MODEL

5811

PARTS

LIST

......................

24

CARB

URETOR

MODEL

5811 -

HL

210A

..........................

25

CARB

URETOR

MODEL

5811

PAR

TS

LIST

...........

..

.........

25

CARB

URETOR

MODEL

5812

-

HR

2A

...

.

.......................

26

CARBURETOR

MODEL

5812

PAR

TS

LIST

......................

26

CHASSIS

TO

R

EPL

ACE

TOP

SHROUD

1.

Remove

right

and

left

half

end

caps

from

the

aluminum

trim

s

tr

ip

by

removing

two

screws

and

two

lock

nuts.

2.

Remove

rubber

bumper

s

trip

from

trim

strip

around

top

shroud

by

prying

out

with

a

screw

dr

i

ver

.

3.

Remove

pop

rivets

by

drilling

them

out.

4.

Remove

aluminum

trim

strip.

5.

Remove

bracket

holding

st

ee

ring

col

-

umn

to

the

top

sh

roud

by

removing

two

screws,

t\\"O

nuts

and

a

holding

plate

.

Remove

fasteners

from

inside

storage

compartment

on

top

shroud

.

6.

Remove

gas

cap

and

sup

port

angle

wh

ic

h

ho

lds

the

fuel

intake

to the

top

shroud

.

To

release

the

support

an

gle

remove

one

scre\v

and

one

nut

from

the

top

shroud

.

7.

Disconnect

wiring

loom

at

connector

plug

.

8.

Remove

light

switch

by

removing

two

nuts

from

the

outside

of

the

s\v

itch

.

Then

push

switch

out.

9.

Remove

ignition

s

witch

by

removing

nut

on

the

backs

ide of

the

s

witch

.

Then

push

switch

out.

10.

Remove

wire

holding

clips

from

the

edge

of the

access

hole

on

the

top

shroud.

11.

Remove

headlamp

assembly

from

the

front

of the

top

shroud

by

removing

two s

crews

.

and two

nuts.

12

.

Use

reverse

procedure

from

that

s

tated

above

to

install

new

top

shroud.

13

.

Use

either

a

pop

rivet

gun

and

pop

rivets

or

fla

t

head

screws

and

lock

nuts

to

se

cure

new

top

shroud.

If

flat

head

screws

are

u

sed,

work

thro

ugh

the

acces

s

opening

.

14

.

If

you

have

difficulty

in

replacing

rub-

berbumper

strip,

use

a

small

amount

of

trim

cement

to

keep

it

in

place.

TO

REPAIR

TOP

SHROUD

If

the

top

shroud

is

fractured

or

punctured,

repair

with

polyester

resin

and

fibre

gl

ass

cloth.

See

CHASSIS

parts

list

for

pa

int

in-

format

ion.

NOTE:

The

repair

materials

are

not

sup-

plied

or

kept

in

stock

by

the

manufacturer

.

However,

they

can

be

purchased

locally

through

auto

part

s

or

marine

supply

com

-

panies.

TO

REPLACE

FUEL

TANK

1.

Remove

access

cover

on

top

shroud

.

2.

Loosen

clamp

which

hol

ds

intake

fuel

line

to the fuel intake

plug

(See

Figure

1) .

Remove

fuel

intake

plug

by

unscrewing

.

The

be

st

tool

to

do

this

is

a

pair

of

long

handled

adjustable

pliers

.

3.

Remove

fuel

outlet

plug

(See

Figure

1).

Use

s

ame

method

to

remove

as

stated

abo

ve .

F

igure

1

4.

Loo

s

en

bracket

located

at

bottom

of

chain

housing

(See

Figure

2).

Use

vice

grips

to

hold

bolt

s

while

loosening

nuts.

Remove

only

one

completely

.

Swing

bracke

t

back

to

free

bottom

of

chain

hous

ing

.

5.

Remove

"U"bolt

completely

(See

Figure

2)

by

removing

two

nuts.

Figure

2

shows

wrenches

on

fasteners

to

be

removed.

6.

Remove

brake

cabl

e

from

brake

arm

by

removing

the

screw

(See

Figure

3) .

7.

Pry

off

chain

case

and

driven

clutch

with

two

long

heavy

screw

drive

rs

or

similar

tools.

8.

Place

rear

of

snowmobile

on

the

kick

-

stand.

9.

Release

track

tension

by

removing

both

right

hand

and

left

hand

adjuster

pla

te

s (See

Figure

4).

Remove

all

fas

teners

holding

a

d-

juster

plates

to

the

frame.

.

10.

Remove

the

track

tensiol!-fip~ing

s

by

-4-

)

Figure

2

c

Figure

3

Figure

4

-5-

pushing

the

extended

top

end

toward

the

center

and

pulling

down.

Use

same

procedure

on

both

sides

(See

Figure

5).

Now

the

rear

support

arms

and

idler

sprockets

can

be

re

-

moved.

Figure

5

11.

Tip

snowmobile

up

on

its

right

side.

12.

Remove

the

three

boggie

assemblies

by

removing

a

bolt

and

a

washer

from

each

end

of

the

boggie

wheel

support

shaft.

Figure

6

shows

bolt

and

washer

to

be

removed.

13. Now

the

only

thing

holding

the

track

in

place

is

the

driving

sprockets

and

drive

shaft.

To

remove:

a.

With

a

screw

driver

carefully

pry

rubber

oil

seal

from

the

bearing

retainer

Figure

6

on

the

drive

shaft

(See

Figure

7)

on

both

right

and

left

hand

sides.

b .

Figure

8

shows

the

drive

shaft

and

driving

sprockets

being

removed.

Pull

shaft

towards

the

side

which

has

the

chain

housing

removed.

This

will

free

the

drive

shaft

and

sprockets

for

removal.

Figure 7

Figure 8

NOTE:

When

replacing

drive

sprockets

and

drive

shaft,

add

one

-two

ounces

of

oil

to

center

of

shaft.

Also

check

oil

level

in

chain

housing

after

it

is

reinstalled.

The

oil

level

shouldbe

approximately

2~

inches

deep

in

the

chain

housing

(approximately

5

ounces).

Do

not

overfill

as

overfilling

can

cause

leakage

at

vent

hole

and

possibly

get

oil

on

torque

con-

verter

belt.

14

.

Figure

9

shows

screws

and

nuts

to

be

removed

to

remove

fuel

tank

retainer

plate.

15.

Remove

retainer

plate

(See

Figure

10).

16.

Remove

bearing

retainer

which

holds

the

drive

sha

ftby

removing

four

nuts

and

bolts

(SeeFigure

8).RerrlOve

cha

in

case

bolt

on

the

opposite

side

of

theBearingR

etaine

r.

17.

Remove

fuel

tank.

18.

Reassemble

in

opposite

order

as

stated

Figure

9

Figure

10

above.

19.

During

reassembly

follow

instructions

un

d e r TRACK

TENSION

ADJUSTMENT,

TRACK

ALIGNMENT

AND

BRAKE

ADJUST

-

MENT.

STEERING

Skis

should

be

properly

aligned

so

they

are

parallel

to

each

other

and

parallel

with

the

drive

track

when

the

steering

handle

is

in

the

str

aight

ahead

position.

Figure

II

shows

skis

properly

aligned.

Measure

the

distance

be

-

tween

the

skis

at

the

front

and

at

the

rear.

The

distances

should

be

equal.

Figure

llshows

the

front

measuring

points.

SKI

ALIGNMENT

1.

Center

steering

handle,

check

to

see

that

right

hand

ski

is

parallel

with

the

drive

track.

2.

If

right

hand

ski

is

not

parallel

to

drive

track

adjust

drag

link.

If

a

large

amount

of

adjustment

appears

necessary,

remove

spin

-

dle

arm

retaining

bolt

with

zerk

fitting

(See

Figure

12).

Remove

the

spindl

e

arm

from

the

spindle.

3.

Align

right

hand

ski

so

that

it

is

parallel

-6

-

)

..

I

}(

.

'-

FRONT

MEASURING

POINTS

Figure

11

Figure

12

with

track

and

replace

spindle

arm

on

the

spindle

making

sure

that

the

splines

are

align

-

ed

and

securely

tighten

retaining

bolt.

4.

Measure

skis

front

and

rear

making

sure

that

both

skis

are

in

alignment.

If

the

skis

are

not

in

alignment

with

each

other,

ad-

just

tie

rod

by

loosening

the

lock

nuts

and

rotating

tie

rod.

POWER TRAIN

TO REMOVE TORQUE CONVERTER

BELT

Remove

the

belt

guard

and

use

a

screw

driver

or

similar

tool

to

pry

driven

sheaves

apart

as

shown

in

Figure

13

.

Pull

the

drive

belt

down

into

the

driven

sheave

halves.

This

will

make

enough

slack

in

the

drive

belt

to

easily

pull

it

up

over

the

driving

clutch.

Re

-

move

other

end

from

driven

clutch.

Replace

in

reverse

order.

Mter

replacing

the

belt

check

the

b

elt

tension

.

There

should

be

lOi

inches

between

the

center

of

the

driving

clutch

and

the

driven

clutch

(See

Figure

13).

If

ad

-

justment

is

neces

sary,

loosen

nuts

securing

engine

and

slide

it

backward.

The

engine

can

be

moved

backwards

a

total

of

i

inches.

Figure 13

TO REMOVE

DRIVING

CLUTCH

BELL

HOUSING

1.

Remove

the

bolt

assembly

from

the

out-

side

of

the

bell

clutch

housing

(See

Figure

13).

2.

Hold

the

two

halves

of

the

clutch

to-

getherwhen

removing

the

bell

clutch

housing.

IMPORTANT

:

Remove

housing

with

care

to

preven

t

any

possible

damage

to

the

clutch

assembly

.

3.

When

replacing

bell

clutch

housing

make

sure

the

weight

s

fit

into

the

notches

on

the

outer

sheave.

4.

Lubricate

bearing

and

spring

retainer

before

reassembly

.

TO REMOVE

CHAIN

HOUSING

AND

DRIVEN CLUTCH

1.

Remove

drive

belt

as

stated

above.

2.

Loosen

bracket

at

bottom

of

the

chain

housing

(See

Figure

14) .

Use

vice

grips

to

hold

bolts

while

loosening

nuts.

Remove

only

one

completely.

S\\'ing

bracket

back

to

free

bottom

of

chain

housing.

3.

Remove

"U"bolt

completely

(See

Figure

14)

by

removing

two

nuts

.

Figure

14

shows

wrenches

onfasteners

to

be

loosened

and

re-

moved.

- 7 -

Figure

14

4.

Remove

brake

cable

from

brake

armby

removing

the

screw

(See

Figure

15).

5.

Pry

off

chain

and

drive

housing

with

two

long

heavy

screw

drivers

or

similar

tools.

6.

If

it

becomes

necessary

to

remove

chain

housing

from

the

driven

clutch,

follow

instructions

unde

r

TO

REPLACE

DRIVE

CHAIN.

7.

Reassemble

in

reverse

order

as

stated

above.

TO

REPLACE

DRIVE

CHAIN

1.

Remove

chain

housing

as

stated

above.

2.

Remove

rubber

access

plug

(See

Fig-

ure

13).

3.

Remove

cotter

and

nut

(See

Figure

16)

.

4.

Remove

sprockets

and

chain

(See

Fig-

Fi

gure

15

CHAIN AND DRIVE HOUSING

Fi

gu

re

16

ure

16

).

5.

Remo

ve

chai

n

adjus

ting

bo

lt

as

sem

bly

(See

Figure

13)

and

remo

ve d

riv

en

c

lu

tch.

Th

e

la

r ge

sp

rocket

at

the

bottom

of

t

he

ch

ain

housing

will

ha

ve

to

be

pulled

to

the

top

ac-

cess

hole

and

pried

out

with

a

scr

ew

driver

or

similar

tool.

6.

Put

in

t

he

new

chain

and

repl

a

ce

the

large

sprocket

by

driving

it

in

wit

h a

fibre

hammer

as

shown

in

Figure

17.

7.

Reassemble

in

reverse

order.

8.

Check

oil

level

in

bottom

of

chain

case

when

it

is

reassembled.

The

oil

level

should

be

2 - 2!

inches

deep

in

the

chain

case.

Mea

-

sure

with

a

wire

inserted

through

the

top

ac-

cess

plug.

Also

see

LUBRICATION

instruc

-

tions.

Figure 17

- 8 -

)

c

-r

'--

TRACK GROUP

TO

REMOVE

DRIVE

TRACK

1.

Loosen

bracket

located

at

bottom

of

chain

housing

(See

Figure

18).

Use

vice

grips

to

hold

bolts

while

loosening

nuts.

Remove

only

one

completely.

Swing

bracket

back

to

free

bottom

of

chain

housing.

2.

Remove

"U"bolt

completely

(See

Figure

18)

by

removing

two

nuts.

Figur

e

18

shows

wrenches

on

fasteners

to

be

loosened

and

re-

moved.

Figure 18

3.

Remove

brake

cable

from

brake

arm

by

removing

the

screw

(See

Figure

19)

.

4.

Pry

off

cha

in

and

drive

hous

ing

\\lith two

long

heavy

screw

drivers

or

similar

tools.

5.

Place

rear

of

snowmobile

on

the

kick-

stand.

Figure 19

- 9 -

6.

Release

track

tension

by

removing

both

right

hand

and

left

hand

adjuster

plates

(See

Figure

20).

Remove

all

fasteners

holding

ad

-

juster

plates

to

the

frame.

7.

Remove

the

track

tension

springs

by

pushing

the

extended

top

end

toward

center

pulling

down.

Use

same

procedure

on

both

sides

(See

Figure

21). Now

the

rear

support

arms

and

idler

sprockets

can

be

removed.

8.

Lay

snowmobile

on

its

right

side.

9.

Remove

the

three

boggie

assemblies

by

removing

a

bolt

and

a wa

sher

from

each

end

of

the

b

rt

shaft.

F

~.;;..;;..;-,;

Figure

20

Figure

21

BOL

T AND A WASHER

TO

BE

REMOVED

Figure

22

shows

bolt

and

washer

to

be

removed.

10. Now

the

only

thing

holding

the

track

in

place

is

the

driving

sprockets

and

drive

shaft.

To

remove

:

a.

With

a

screwdriver

or

similar

tool

carefully

pry

out

rubber

oil

seal

from

the

bearing

container

on

the

drive

shaft

(See

Figure

23)

on

both

right

and

left

hand

sides.

Figure

23

b.

Figure

24 shows the

drive

shaft

and

sprockets

being

removed.

Pull

shaft

to-

wards

the

side

which

has

the

chain

housing

removed.

This

will

free

the

drive

shaft

and

sprockets.

•

• ,

,

11.

Insert

new

track

and

reassemble

in

reverse

order

as

stated

above.

Also,

read

carefully,

and

make

adjustments

that

follow.

12. When

replacing

drive

sprockets

and

drive

shaft,

add

one -two

ounces

of

oil

to

shaft.

Also

check

oil

level

in

chain

housing

after

it

is

reinstalled.

The

oil

level

should

be

from

2 -

2~

inches

deep

in

the

chain

hous-

ing.

TRACK

TENSION

ADJUSTMENT

Track

tension

should

be

checked

periodi-

cally

as

long

life

and

efficiency

of

the

track

depends

largely

on

correctness

of

tension

adjustmentandalignment.

To

adjust

tension:

1.

Lift

the

back

of

the

SKI-DADDLER off

the

ground

wi

th

the

s

ta

nd .

2.

Check

track

tension-

by

measuring

the

distance

between

the

bottom

of

the

running

board

and

the

bottom

edge

of

the

suppor

t

arm.

Measurement

should

be

3"

minimum

and

3~"

maximum.

Figure

25

shows

point

of

measure-

ment.

3.

If

adjustment

is

needed,

loosen

two

bolts

(No.1,

Figure

25) on

each

side

that

secure

the

adjuster

plate

(No.2,

Figure

25).

Turn

adjusting

bolt

(No.3,

Figure

25)

clock-

wise

to

tighten

and

counterclockwis

e to

loosen

J

until

proper

3"to

3~

"measurement

is

achieved

oneachside.

Adjustbothsides

equally.

Track

should

have

a

slack

of

about

2"

to

2

~"

in

the

center.

4.

Before

retightening

bolts

(No.1,

Figure

25)

check

the

track

alignment

as

outlined

be

-

low.

TRACK

ALIGNMENT

1.

With

the

unit

still

blocked

up,

run

the

engine

so

that

the

track

will

turn

slowly.

2.

Stand

at

the

rear

of

the

machine

and

check

to

see

that

the

teeth

of

the

rubber

Figure

25

-10-

Ski-Daddler 5811-0000 Manual de usuario

Manuales populares de Vehículo todoterreno de otras marcas