Service manual

ManualsBrandsAMF ManualsSnowmobilesMARK V SD1BE2DA

PARTS

AND

RVICE

MANUAL

SKI-DADDLER

SNOWMOBILES

MARK

[SD15P1DA]

MARK

[SD1BE2DA]

1969-1970

WESTERN TOOL DIVI SION

Des Moines, Iowa 50302

AMF INCORPORAT

PART

37851

REVISED

and

REPRINTED

IIINI=

107n

Summary of content (62 pages)

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PARTS AND SERVICE MANUAL SKI-DADDLER SNOWMOBILES MARK IV [SD15P1DA] MARK V [SD1BE2DA] 1969-1970 WESTERN TOOL DIVI SION Des Moines, Iowa 50302 AMF INCORPORATED PART NO .
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. - - - - - - - - - WARRANTY SERVICE - - - - - - - - - , Warranty service policy is printed below and on the warranty registration card included with the unit. The registration card must be filled in and mailed to the manufacturer. The card is postage paid. Warranty service will be handled by all authorized AMF Ski.Daddler dealers. • • SNOWMOBILES • • Your Manual No. _ _ _ _ _ _ _ _ _ is a registered number. Additional parts and service information will automatically be sent to you.
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J )
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GUARANTEE FLAT-RATE LABOR SCHEDULE Models MARK IV (SD15Pl0A) MARK V (SD18E20A) 1. Remove and replace chain case cover 1/4 hour 2. Remove and replace chain and adjust tension 1/4 hour 3. Remove and replace driven clutch or bearings or V-belt •..............•....•.•.....•.... 1/2 hour 4. Remove and replace drive clutch 1/2 hour 5. Remove and replace engine mount and/or strap ............................................ . Remove and replace engine mount and/or strap ...................................
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~t!Mlal I~ CONTENTS ) TABLE OF CONTENTS Page INTRODUCTION . . . . . . .3 PREDELIVERY INSTRUCTIONS In stall Ski Assembly . . . . Install Windshield Assembly Activate Battery- Mark V Only Fuel Mixture Instructions Lubrication . . . . . .3 .3 .4 .4 .4 .5 .5 .5 .5 .5 .6 .6 .7 .7 .7 .8 .8 .8 .8 .9 .9 .9 10 SERVICE AND REPAIR Hood Removal and Installation Hood Assembly Repair . . . . Replace Lamp Assemblies. . . Steering and Ski Assembly Alignment To Remove Drive Chain. . . . . . .
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INTRODUCTION INTRODUCTION This manual has been prepared to provide all authorized AMF Ski-Daddler Dealers, Distributors and technicians with the instructions necessary to service and maintain the 1970 AMF MARK IV (SDI5PI0A) and MARK V (SDI8E20A) Ski-Daddler snowmobiles. This manual is presented in two sections.
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) Install Windshield Assembly • Remove the screws securing the left- and righthand mounting strips to the hood. Remove the mounting strips. • Remove the protective plastic cover from the windshield. Place the windshield in position On the hood assembly. Replace the mounting strips as shown in figure 2. • Using the original screws, loosely secure the mounting strips and windshield to the hood assembly starting at the center and working to the sides.
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~I SERVICE AND REPAIR leMla~ c FUEL MIXTURE CHART assemblies and then remove the hood and headlight assembly by lifting rear section first. GASOLINE-Oil RATIO 2 0 I L 1-1/2 ./ P I N ./ 1/2 T S / • To install the hood and headlight assembly, place the hood in position on the sled so that the forward hood clip and the bottom edge of the hood engages the clips along the inside edge of the bumper strip.
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~t.aMlal SERVICE AND REPAIR I~ Taillight. the seat assembly move the bulb. See Remove taillight lens and cover, or lift assembly to expose the rear console containing the twin taillight bulbs. Redefective bulb and replace with a new illustrated parts list. • Move the affected ski into proper alignment and recheck measuring points to insure that the skis toe out 0- to 1/2-inch maximum at the front end and are in the same orientation with the sled body as shown in figure 2.
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~I SERVICE AND REPAIR c to the main frame. During reassembly, apply 10 foot-pounds torque tel> the locknut (9). CAUTION! Always disconnect spark plug wires before working on the engine or drive elements. • Push tlte driven clutch toward the drive clutch sufficiently to allow removal of the variable-speed drive belt from the drive clutch. • Release the chain cover straps and remove the chain cover tou.
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~eSial SERVICE AND REPAIR I~ • Move the driven clutch (4) in the direction required to obtain proper belt tension. Hold this position while tightening the locknut (9) to secure the clutch rod tensioner. Be certain the washer (10) and bar serrations are properly engaged. Apply 10 foot-pounds torque to the locknut (9). J • Remove the clutch guard. • Loosen the engine holddown nuts securing the supports to the engine mount straps as illustrated in figure 6.
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SERVICE AND REPAIR c geld • Release the hose clamp and disconnect the impulse line at the carburetor. Wipe up any spilled gasoline immediately. • Remove the two bolts and locknuts securing the mounting bracket to the driven clutch mounting. • Remove the brake assembly. • Release the tank-to-carburetor gas line (figure 10). Wipe up any spilled gasoline immediately. • Installation procedures are the reverse of removal. Refer to Brake Adjustment procedures.
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~t'·':4Mlal SERVICE AND REPAIR I~ carburetor-to-tank recirculating gas line disconnected. • Disconnect the battery-to-solenoid positive (+) cable at the battery to prevent sparking and possible shorting. When adjusting the carburetor, best results will be obtained if the adjustments are made on a warm engine. During carburetor adjustments, DO NOT FORCE ADJUSTMENT SCREWS INTO SEATS. • Disconnect the sOlenoid-to-starting motor cable at the starting motor.
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SERVICE AND REPAIR c • Remove the heat shield located between the engine and the muffler. Remove the attaching hardware at the muffler bracket, heat shield bracket and at the top near the steering column. To Remove Engine and Support Assembly-Mark IV Only • Remove the hood and headlight assembly. Refer to Hood Removal and Installation. [ C~~TION • Remove the locknuts and washers securing the engine mounting straps to the main frame.
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~p.!Mlal SERVICE AND REPAIR I~ • Remove the heat shield located between the engine and the muffler. Remove the attaching hardware at the muffler bracket, heat shield bracket and at the top near the steering column. reassembly, apply 25 foot-pounds torque to the nuts securing the engine base. • Remove the bolts (10, figure 12), spacers and nuts securing the steering linkage to the steering column arm (9). During reassembly, apply 15 footpounds torque to the nuts securing the steering linkage.
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VICE AND REPAIR c To Remove Bogie Wheel and Support Assembly Always disconnect the spark plug wires before working on the engine or drive elements. Always disconnect the sparkplugwires before working on the engine or drive elements. • Loosen the flexible tube clamp securing the flexible exhaust tube to the muffler and release the tube. NOTE: The Mark V Ski-Daddler has dual exhaust tubes and muffler. • Place the Ski-Daddler on the kickstand.
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SERVICE AND REPAIR NOTE: The traction belt take-up assembly consists of the rear sprocket assembly, spacer and associated hardware held together by the rear support arm assemblies. If necessary to remove seals or sprockets, proceed as follows. • Carefully pry the oil seal away from the rear support arm assembly (8) and remove the support arm and adjusting angle (9) clear of the sprocket shaft and bearing. • Remove the press- on bearings and grease seals.
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VICE AND REPAIR c • Remove the drive sprocket assembly. Refer to paragraph To Remove Drive Sprocket Assembly. • Remove the traction belt. • Reassembly is the reverse of removal. During reassembly follow instructions given in paragraphs Traction Belt Adjustment, and Drive Chain Adjustment. Traction Belt Adjustment IMPORT ANT: The traction belt must be checked regularly for proper alignment and tension.
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~eM131 SERVICE AND REPAIR I~ ) 1:: CAUTION ENGINE STOPS. Fuel tank empty; fuel flow obstruct ed; ignition system faulty. Spark plug(s) fouled or dirty. Engine too hotandpistons seizing; carburetor setting too lean or incorrect grade of oil being used. Never run the engine inside a building without first opening all doors and windows to insure proper ventilation. ENGINE STOPS, FUEL TANK HALF EMPTY. Carburetor-to-tank fuel line connected incorrectly.
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SERVICE AND REPAIR c CLU1'CH. Automatic clutch fails to engage at proper RPM's: Mark IV, 2000 to 2400 RPM; Mark V, 2100 to 2500 RPM. Check variable-speed drive belt for proper tension and alignment. TRACTION BELT. Poor traction; check traction belt for alignment and tension; worn sprockets or flipped bogies.
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SERVICE AND REPAI ) Mark V Only -Ifr== -==-~---;;J '(75WJI I I r I I NG1NE HIRTH 49312 I FUSE AGA-6 I I __ YELLOW .. ~TARTER YELLOW YELLOW/BlACIC U YELLOW BLACK RE BLACK BLAe GND AT STARTER BOLT z .•" SWITCH r~ _It~"",-/""""""'--<~I L L"'j - LEFT WHITE/BLACK OFF WHITE/RED ~ ~ ~ ~ m ~ 0 ~ .~ CIGARETTE LIGHTER 4-1+-·Hj- _ __ _ _ _ I J GND AT STARTER BOLT RIGHT - - - - -a"'LiJ'EGREY r:T.l 1~~!tllj=t!j=~'~"~C~'=E' c 21 L l ORANGE (LOI II (MI) (I.
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c C This Illustrated Parts List is provided to facilitate the procurement of spare parts and sled disassembly in support of all Ski-Daddler models covered in the Maintenance Section of this manual. Where component parts or assemblies are common to all Ski-Daddler models, no model designation follows the item description. Where the component part or assembly applies to a specific Ski-Daddler model, the model designation will follow in the description column.
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c PARTS-LIST SECTION Where no code letter appears in the model column, the part applies to all models. This portion of the dealer's manual consists of two sections, an illustrated parts list and a numerical index. All model codes will be listed at the bottom of each parts listing to provide a ready reference. PARTS LIST The parts-list portion consists essentially of exploded-view illustrations, keyed to the figure reference column by index numbers.
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I \.
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c Figure 1.
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Figure 1.
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c c Figure 1.
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Figure 1.
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C Figure 1. Sheet 5 of 5 Figure & Index Number 1-74 - 75 - 76 -77 -78 Part Number 120382 37113 34929 37266 37683 37013 34932 37778 Description LOCKWASHER . •. ••. •••••••••••. ••••. . ••. . DRIVE SPROCKET ASSEMBLY (See figure 9) •. DRIVE SPROCKET ASSEMBLY (See figure 9) .• GAS CAP AND INDICA TOR ASSEMBLY (See figure 10) GAS CAP ASSEMBLY (See figure 10) ••.. .•.• MAIN FRAME ASSEMBLY . •. ••. •••••. . •. . MAIN FRAME ASSEMBLY •••••••••. •••••• SPACER •••. •••••••. •. •••.
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) Figure 2.
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c Figure 2.
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Figure 2. Sheet 3 01 3 Figure & Index Number 2 - 37 -38 -39 - 40 -41 - 42 - 43 - 44 - 45 -46 - 47 - 48 -49 -50 - 51 Part Number 125680 9000462 34992 445170 35011 34271 35017 34986 34989 34271 35005 9000123 34983 37591 37080 35000 37081 35001 Description SCREW, Truss, HD, 1/4-20 by 5/8 ••.•.•.• RIVNUT, 1/4-20 .•••.•.••••••••••••••••• ESCUTCHEON, Side •••••••••••••••.•••• NUT, Spring .•.•.•••••• • •..•... .. .••.•.• STRIKE •.••••.•••.••••••.••.• •.• •.••••• RIVET .•.•....•......• •.......•••. .... HOOD ...
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Figure 3.
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Figure 3 .
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C Figure 3.
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) F,gure · 3.
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C Figure 3. Sheet 5 of 5 Figure & Index Number 3-78 -79 -80 -81 -82 -83 -84 -85 -86 Part Number 33730 37249 33746 34917 37246 34919 9413314 34918 37247 181620 120394 9000124 Description LEAF SPRING, Middle . . . . ••. ••. . . . . . . . . •• LEAF SPRING, Main .•••..•.•.•.•. •..••• WEAR PLATE, Ski ..•• .• .•..... .....•.•... SKI AND WEAR ROD ASSEMBLY ...•...•...• SKI AND WEAR ROD ASSEMBLY • . . . . . . . . . . . WEAR ROD ASSEMBLY, Ski • . . . . . . • . . . • . . • . LOCKNUT, 1/4-20 ........••..•••.•.•...
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Figure 4. Sheet 1 of 2 ) 13 6. \ \ 35 \ \ \ \ \ \ \ \ \ ' VLk.
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c Figure 4.
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) Figure 5.
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c Figure 5.
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) fjgw .. 5. Sheet 3 of 3 Figure & Index Number 5-45 -46 -47 -48 -49 -50 Description Part Number 37616 37615 37624 37623 37622 37621 RA.MP PLATE •••••••••••••••••••••••••••• SPIDER ............................... . ROLLER KIT ........................... . SPRIN'G KIT .••••...••.•.•.••.••••.•.••• MOVABLE FACE .•••.•.••••••••••••••••• FIXED FACE ................•...........
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c figure 6.
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Figure 6. Sheet 2 of 3 J DETAIL A 38 30 55 ...
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Figure 6. Shee' 3 01 3 C Figure & Index Number ,,-... '- Part Number 6-44 -45 -46 -47 -48 -49 -50 -51 -52 -53 -54 -55 -56 -57 -58 -59 37936 37720 37719 37718 37717 37631 37716 37715 37714 37713 37712 33979 37064 37065 37062 9000123 37765 -60 -61 -62 34015 37410 37071 37094 34014 37410 37387 37385 436695 9000121 37386 37382 37381 133427 9000126 37377 181003 900012.
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]
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c Figure 7 Figure & Index Number 7- Part Number 37203 34924 -1 -2 -3 -4 -5 -6 -7 -8 -9 - 10 - 11 -12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 -21 - 22 - 23 32266 32265 456145 9000124 34683 34684 181651 33705 9000125 32237 33356 33357 706 33346 33347 37199 37196 33417 37197 30079 37192 181566 9000123 37144 37200 37198 Description TRACTION BELT TAKE - UP ASSEMBLY (Se e figure 1) TRACTION BELT TAKE - UP ASSEMBLY (See figure 1) SCREW, Adjusting . . . . . •. •. •. •. . . . . ••. . .
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L Figure 8 . 5nee' 1 of 2 ) )5 "- _,; ~~ 21 .
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c Figure 8. Sheet 2 of 2 Figure & Index Number 8-1 -2 Part Number 37083 34901 33712 33712 33711 33711 37085 34902 -3 -4 -5 -6 33713 33713 9000393 9000393 37086 34907 37084 33754 37088 34903 -7 -8 -9 -10 -11 - 12 - 13 -14 - 15 -16 -17 -18 -19 -20 - 21 33713 33713 9000393 9000393 37089 34908 34904 33712 33711 33713 9000393 33909 33907 33754 34906 34905 34903 33713 9000393 34908 Description BOGIE ASSEMBLY (See figure 1) •.•.•••.•••• BOGIE ASSEMBLY, Middle and rear .•••.
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Figure 9. Sheet 1 of 3 ) 20 LD_E_TA_IL_ A_ _ _ _ MARK V only _~_ _ _ __ 4 .
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c Figure 9.
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Figure 9. Sheet 3 of 3 Figure & Index Number 9-43 -44 -45 -46 -47 -48 -49 -50 -51 -52 - 53 -54 -55 -56 -57 -58 -59 -60 -61 -62 -63 -64 -65 -65A Part Number 34965 37024 9000326 9000321 9000124 37294 37287 37289 37251 37288 37113 34929 34648 30079 37192 181566 9000123 33659 37114 34931 37610 37609 37724 37604 37603 37602 37608 37933 37607 37722 Description SHAFT, Clutch mounting .• •• •.•••••••••. BEARING RETAINER AND PLATE ASSY BOLT, Carriage, 5/16-24 by 7/8 •••••••• BOLT, Carriage, 5/16-24 by 5/8 .••.•...
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Figure 10 c 11 1 6 12~~ ,5 ' ' ' '- ~ , ~~ ~9 RECIRCULATING TO CARBURETOR ~180 ~ J~ 13 C Figure & Index Number 10-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 Part Number 37266 37683 37274 37357 181561 147579 37273 30489 37454 37268 37277 30489 37267 37270 37271 34154 37264 37259 Description GAS CAP AND INDICATOR ASSEMBLY (See figur e 1) GAS CAP ASSEMBLY (See figure 1) ••...•.. SPILL CHUTE, Gas ••••.•••.•••.••..•.. SPILL CHUTE, Gas ••.•.•.•..
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c - NUMER ICAL INDEX Part No.
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) Part No.
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C Part No.
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) Part No.
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C Figure & Index Part No. Number 9000302 (Cont) 1- 52 3- 27 9000305 1- 5 9000321 9- 46 1- 63 9000322 9000323 5- 21 6-22 1-40 9000324 9000326 9-45 c -- Qty Part No. 3 4 4 3 2 4 4 4 3 9000393 9000461 9000462 Figure Figure & Index Number Qty Part No.
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