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Johnson Evinrude 1975 rotary snowmobile service manual
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45 HP MODELS: E265RC, j265RC
© OUTBOARD MARINE CORPORATION 1974 ALL RIGHTS RESER VED
SN MOBILE DIVISION/OUTBOARD MARINE CORPORATION, 3031 NORTH 114th STREET, MILWAUKEE, WISCONSIN 53222
OUTBOARD MARINE CORPORA-TION OF CANADA LTD., PETERBOROUGH, CANADA. .
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SECTION 1
INTRODUCTION
SAFETY SYMBOLS
THE PURPOSE OF SAFETY SYMBOLS IS TO
ATTRACT YOUR ATTENTION TO POSSIBLE
DANGERS. THE SYMBOLS, AND THE EX-
PLANATtONS WITH THEM, DESERVE YOUR
CAREFUL ATTENTION AND UNDERSTAND-
ING. SAFETY WARNINGS DO NOT, BYTHEM-
SELVES, ELIMINATE ANY DANGER. THE IN-
STRUCTIONS OR WARNINGS THEY GIVE ARE
NOT SUBSTITUTES FOR PROPER ACCIDENT
PREVENTION MEASURES.
SYMBOL
A SAFETY
L..lWARNING
o PROHIBITED
DNOTE
MEANING
FAILURE TO OBEY A
SAFETY WARNING MAY
RESULT IN INJURY TO .
YOU OR TO OTHERS.
WARNS YOU AGAINST AN
ACTIVITY WHICH IS, OR
MAY BE, ILLEGAL IN
YOUR AREA.
ADVISES YOU OF INFOR-
MATION OF INSTRUC-
TIONS VIT AL TO THE
OPERATION OR MAINTE-
NANCE OR YOUR EQUIP-
MENT.
Before proceeding with any repaiXr adjust-
ments on this snowmobile, see SAFETY
WARNINGS on inside front cover and on page/:?:
5-5, 5-7, 6-7, 6-9, 7-4, 7-13, 7-18, 7-20,
8-2, 9-2, 9-3, 10-2, 10-3, 10-4, 11-3, 11-4,
12-5, 12-6 and 12-8.
INTRODUCTION
SPECIFICATIONS
GEN ERAL SNOWMOBI LE IN FORMATION
TROUBLE SHOOTING
TUNE-UP PROCEDURES
FUEL SYSTEM
IGNITION AND
ELECTRICAL SYSTEM
MANUAL STARTER
ENGINE
~ __ D_R_IV _E __ T_ RA_I_N ____________ ~ __ ~~
STEERING, TRACK AND SUSPENSION
LUBRICATION AND STORAGE
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1-2
The snowmobile has been designed - and built for dependable, high per-
formance. It is important to every snowmobile owner to be able to re-
ceive skilled and thorough service for his vehicle when necessary. It
is important to the service dealer to be able to offer the type of skilled
service which will maintaIn the customer's satisfaction.
This manual, together with the regularly issued service bulletins and
Parts Catalogs; provide the serviceman with all the literature necessary
to service this snowmobile. An effort has been made to produce a
manual that will not only serve as a ready reference book for the ex-
perienced serViceman, but will also provide more basic information for
the guidance of the less experienced man.
The Parts Catalogs contain complete lfstings of the parts required
for replacement. In addition, the exploded views illustrate the correct
sequence of all parts. This catalog can be 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 of Contents
which gives the page number on which each topic begins. This arrange-
ment simplifies locating the desired information within this manual.
Section 2 lists complete specifications on the snowmobile. All general
information, including R.C. engine theory, trouble shooting, and tune
up procedures, are given in Sections 3 through 5 of this manual.
\
37323
Figure 1-1
)
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I
C sections 6 through 11 provide fully illustrated, detailed, step-by-step
disassembly and reassembly instructions and adjustment procedures.
Section 12 provides lubrication and storage information. In this way,
the texts treat each topic separately; theory and practice are not
intermixed. This makes it unnecessary for the experienced service-
man to reread discussions of theory along with specific service in-
formation. Illustrations placed ' in the margins provide unimpeded
reading of explanatory text, and permit close relationship between
illustration and text.
Read this manual carefully to become thoroughly familiar with the
procedures described, then keep it readily available in the service shop
for use as a reference. If prope 'rly used, it will enable the serviceman
to give better service to the snowmobile owner, and thereby build and
maintain a reputation for reliable service.
This service manual covers all phases of servicing the snowmobile,
however, new service situations sometimes arise . If a service question
does not appear to be answered 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 serial
number.
All information, illustrations, and specifications contained in this
literature are based on the product information available at the time of
publication. The right is reserved to make changes at any time without
notice.
1. Hand Brake and Parking Lock 8. Ignition/ Lights Switch
2. Hi-Lo Beam Headlight Switch 9. Manual Starter Handle
3. Tachometer 10. Instrument Panel Door
4. Speedometer/Odometer 11. Hood Latches
5. Safety Stop Switch
6. Throttle
12. Choke
13. Neutral Control
7. Primer 14. Reverse Control
Figure 1-2
1- 3
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2-1
SECTION 2
SPECIFICATIONS
TABLE OF CONTENTS
SPECIFICATIONS ....... • ........... 2- 2
TORQUE SPECIFICATIONS ...... •••... 2-3
Snowmobile Special Service Tools - 45 H.P.
PART NO.
378103
318501
318502
319990
*
383966
*
291030
114146
162282
263308
318665
385996
DESCRIPTION
Flywheel Puller
Center Guide for Flywheel Puller
Three Screws for Flywheel Puller
Wrench - Flywheel Nut
Truarc Pliers
Spring Winder
Reli-Coil Installers & Inserts
Spark Plug Wrench - 12mm
(11/16") Hex.
Splined Wrench
Drive Alignment Gauge
Disassembly Tool (Primary Drive)
(Clamp)
Sensor Adjustment Gauge
Static Air Leak Gauge
* Refer to the Tool Catalogue
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2-2
SPECIFICATION S
o PROHIBITED: Snow Vehicles are not manufactured for highway use and
the manufacturer does not represent that they are equipped with all the devices
legally required for such use.
Length . ........ 107 inches
Width
Height
Starter
Variable speed drive.
Overall ratio.
Final drive ...
Sprocket ratio
Reverse transmission
Muffler.
Brake .
Throttle
Track
Width.
Skis ...
Seating capacity
Hood ..... .
Headlight ... .
Taillight/stoplight
. . . . . . . .. 37 inches
44.9 inches with windshield
37 inches without windshield
. . . . . Electric and manual
Centrifugal operated sheave engages V- belt
. . . . .. 5 to 1
Silent drive chain
. . . . . 17 to 39
Dog clutch and bevel gears
Single, tuned muffler for quiet operation
. . . . . . . . Disc type, hand operated
. . . . . . . . . . . . . Thumb operated
. Polyurethane - Specially designed-fully adjustable
. . . . . . . . . . . . . . . . . . . .. 20.4 inches
Formed steel, equipped with shock - absorbing leaf
springs and replace a ble wear runners
. f- . Two adults. Vinyl coated cover,
molded urethane foam cushion
· . Molded fiberglass
Sealed beam GE 4002
· ...... GE 1157
· .... OMC 262779 Tach and speedometer light
Fuel tank . . . Capacity 5 Imperial gallons, 6 U.S. gallons
Evinrude, Johnson or OMC 50:1 rotary combustion lubricant
Regular leaded or unleaded
Lubrication.
Gasoline ..
Carburetor . . ........................ OMC float type
RPM Ratings
Idle . ....
Transmission belt engaging speed . . . . . . . . . .
Maximum RPM at which neutral control will operate.
Ignition
Breakerless magneto C.D. (Capacitor Discharge) ignition
· .... 1100- 1400
· Approx. 2900-3300
· . . . Approx. 2000
Spark plug . . . . . . . . . . . Champion UP-77V (Surface Gap)
Spark plug gap. . . . . . . . . . . . . Fixed
Ignition sensor coil resistance . 26-30 ohms
Magneto charge coil resistance (2 coils) total of . 860 ± 75 ohms
Ignition coil secondary resistance . . . . . . . . 1700-2400 ohms
Lighting coil resistance (See Section 7) . . . . . . . . 0.38 ohms ± 10%
Battery ...... 12 volt Canada Prestolite No. 2920, U.S.A. PrestoliteNo. 9955X,
32 ampere hour rating, manifold vented. Dimensions in inches
are approximately 7- 3/4 long, 5-1/8 wide and 7-1/4 high (to top
of terminals). Weight dry 17 lbs., wet 21.4 lbs.- Electrolyte
to fill 0.44 U.S. gallons. Specific gravity 1.265.
Engine .... .
Rating ... .
Displacement
Type .....
Compression ratio
Rotor housing width
OMC Rotary Combustion
. . . . . . . . . . . . . . . . . . 45 HP @ 6500 RPM
. . . . . . . . . . . . . . . . . . . 32 cubic inches (528cc)
Single rotor, air cooled housing, charge cooled rotor, side
inlet port, peripheral high performance port with pro-
gressive carburetor linkage
8.5 to 1
Apex seal height - normal.
3.058"
0.354"
0.315"
3.062"
0.092"
- minimum.
Rotor housing width . . .
Side seal nominal height
Specifications and features may be changed at any time without notice and without
oblig~tion towards vehicles previously manufactured.
)
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2-3
TORQUE SPECIFICATIONS
PART APPLICATION SIZE TORQUE
IN. !
LBS.
* Nut Ball Joint to Steering Arm and Rod End to Steering Column 3/ 8-24
Nut Cable to Solenoid
36-60
Nuts Carburetor 110-120
Screw Drive Sprocket - Chain 5/16-24
Screw Engine Frame to Main Frame 3/ 8- 16
*Nuts Engine thru Bolts 1/ 4-28 75-85
Screw Engine to Engine Frame Assembly 3/ 8-16
*Nuts Exhaust Flange 5/ 16-18 60-84
*Screw Flangettes to Frame 3/ 8- 16
##Nut Flywheel (See Primary Drive - Reassembly) 1-3/ 8-12
* Nut Front and Rear Truck Axles 5/ 8-18
*Screw Idler Axle to Frame 3/ 8- 16
Nuts Insulator Block
•
5/ 16-18 75-85
# Screw Intake Passage Cover to Fan End Housing #10- 24 25 - 35
Setscrew Locking Collar Front Axle 5/ 16- 18
* Bolt Primary End Cap to Main Shaft 3/ 4-16
*Screw Primary Sliding Sheave to Hub 5/ 16-18 350-375
Nut Ratchet Tube 1" - 16
Bolt and Rear Axle Pivot
Nut 5/ 16-24
Setscrew Rear Idler Wheel 3/ 8- 16
Nut Rear Suspension to Frame 5/ 16-24
* Nut Runner to Ski 5/ 16-18
90-100
*Screw Secondary End Cap to Shaft 3/ 8-16
# Screw
Sensor Shield to Flywheel End Housing
#10- 24 25-35
*Screw
Shifter Clevis to Pinion Shaft
1/ 4-28
160-180
* +
Spark Plug Cold 12mm 150-180
Nut Throttl e Cable Adjusting Screw 5/ 16 - 18
60-80
*Screw Truck to Frame 3/ 8-16
*Screw
Truck to Frame 7/ 16 - 14
*Nut
U Bolt to Saddle
Screw #6 7-10
Screw #8 15-22
Screw #10 25-35
Screw #12 35-40
Screw
General
1/ 4
60-80
Screw
Torque
5/ 16
120-140
Screw
Requirements
3/ 8
220-240
Screw 7/ 16
340-360
.J
Specifications and features may be changed at any time without notice and without obligation towards
vehicles previously manufactured.
*Use Torque Wrench
##Apply Loctite Retaining Compound #40 Flywheel Nut (OMC Part No. 386951)
# Apply Loctite Compound TL242
+Exercise care to avoid over to rqueing (especially in a hot engine) or damage to the rotor housing
may result.
FT ./
LBS.
18-20
10-12
15-17
18-20
18-20
5-7
20-25
90-110
35-45
20-25
6-7
10-12
90-100
29-31
40-45
12-15
18- 20
12-15
22-25
2-3
12-15
25-30
25-30
10-12
2-3
3-4
5-7
10-12
18-20
28-30
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GENERAL SNOWMOBILE
TABLE OF CONTENTS
SECTION 3
INFORMATION Ell
ROTARY COMBUSTION ENGINE THEORY. .. 3-2
RC ENGINE PARTS NOMENCLATURE
AND FUNCTION. . . . . . . . . . . . . . . . . . .. 3-3
COMPRESSION. . . . . . . . . . . . . . . . . . . .. 3-5
CARBURETION . . . . . . . . . . . . . . . . . . . .. 3-5
COOLING . . . . . . . . . . . . . . . . . . . . . . . .. 3-6
IGNITION. . . . . . . . . . . . . . . . . . . . . . . .. 3-7
LIGHTING SYSTEM . . . . . . . • . . . . . . . . .. 3-8
POWER FLOW. . . . . . . . . . . . . . . . . . . .. 3-8
PRIMARY DRIVE ................. 3-8
NEUTRAL CONTROL . . . . . . . . . . . . . .. 3-9
SECONDARY DRIVE ............... 3-9
REVERSE TRANSMISSION. . . . . . . . . . .. 3-10
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If you're in need of a comprehensive service manual for the Johnson Evinrude 1975 rotary snowmobile, this 109-page resource has got you covered. It encompasses detailed information for the 45 HP r265RC and J265RC sleds, making it an invaluable asset for both professional mechanics and DIY enthusiasts.