Service manual

ManualsBrandsAMF ManualsSnowmobilesMARK V SD1BE2DA

~p.!Mlal

SERVICE

AND

REPAIR

I~

• Remove the

heat

shield

located

between the

engine and the muffler. Remove the attaching

hard-

ware

at

the

muffler

bracket,

heat

shield

bracket

and

at

the top

near

the

steering

column.

• Remove the bolts (10,

figure

12),

spacers

and

nuts

securing

the

steering

linkage to the

steering

column

arm

(9). During

reassembly,

apply 15 foot-

pounds

torque

to the nuts

securing

the

steering

linkage.

Figure

12

• Remove the bottom

cotter

pin

securing

the

steering

column to the

main

frame

steering

column

support.

•

Oisconnect

the

wiring

harness

at

the

battery,

electrical

panel,

rear

console and engine.

Release

the

wire

V

-clips

in

the

tool box and

at

the foot

rest

and

remove

the

wiring

harness.

• Remove

the

two

screws,

formed

washers

and

locknuts

at

each

end of

the

roll

bar

and

remove

the

roll

bar,

steering

column and

mini-console

as

a unit.

• Remove

the

locknuts and

washers

securing

the

engine mounting

straps

to

the

main

frame

studs,

and

remove

the engine, engine

base

and mounting

straps.

• Remove

the

carriage

bolts,

nuts

and

washers

securing

the

engine mounting

straps

to

the engine

base.

Remove

the

straps

for

reassembly.

During

12

reassembly,

apply

25

foot-pounds

torque

to

the nuts

securing

the engine

base.

•

Installation

is

the

reverse

of

removal

.

To

Remove

Gas

Tank

• Remove the hood and headlight

assembly.

Refer

to Hood Removal and

Installation.

!

CAUT~ON

1

Always

disconnect

spark

plug

wires

before

working on

the

engine

or

drive

elements.

• Check

gas

cap and

indicator

assembly

to be

cer-

tain

tank

is

empty,

or

nearly

empty.

• Remove the

gas

cap and

indicator

assembly

(1,

figure 12).

• Remove the bolts (3) and

washers

securing

the

gas

spill

chute (2) to the

main

frame

and

remove

the

gas

spill

chute.

)

• Disconnect the

tank-to-carburetor

gas

line

(6) )

and the

recirculating

gas

line

(7)

at

the

gas

tank

outlet fitting (5). Wipe up any

spilled

gasoline

immediately.

• Remove the

gas

tank

(4) by

carefully

sliding

the

tank up and away

from

the

main

frame.

IMPOR-

TAm:

Do

not damage the

gas

tank

outlet

(5) when

removing

the tank.

L

CAUTIO~:

I

Do not

attempt

to

make

any

repairs

to

the

gas

tank. Use

extreme

care

when

removing

the

gas

tank.

Do

not

remove

tank

near

flame

or

open

fire.

• Gas

tank

installation

procedures

are

the

reverse

of

removal.

NOTE:

If

the

original

tank

is

not to

be

installed,

it

will

be

necessary

to

remove

the

gas

tank

outlet

(5)

and the

attached

gas

line

filter;

also

the

pressure

relief

valve (8).

These

items

are

to

be

installed

on the

replacement

tank.

To

Remove

Muffler

• Remove

the

hood and

headlight

assembly.

Refer

to

Hood Removal and

Installation.