Johnson Evinrude 1975 rotary snowmobile service manual

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. . Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

/ 1-2 The snowmobile has been designed - and built for dependable, high performance. 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 experienced 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 ) Downloaded from www.Manualslib.com manuals search engine

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 serviceman to reread discussions of theory along with specific service information. 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 Downloaded from www.Manualslib.com manuals search engine

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c 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 Downloaded from www.Manualslib.com manuals search engine

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. ) Downloaded from www.Manualslib.com manuals search engine

c 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 Downloaded from www.Manualslib.com manuals search engine

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c 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 Downloaded from www.Manualslib.com manuals search engine

Johnson Evinrude 1975 rotary snowmobile service manual

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