Ski-Dootrack should clear center bogie wheelsby iy4 to 11^ inches. On 1967 and1968 models and 1969 Model 5813, dis-tance (A—Fig. 8) should measure3y4-3% inches.

NOTE: When track tension has beenadjusted, alignment MUST be checkedas outlined in the special TRACKSERVICE Section of this manual.

OVERHAUL

SKIS AND STEERING. Skis, skilegs (spindles), bushings and steeringarms are interchangeable from right

to left. Skis are equipped with renew-able wear bars which must be in-stalled with curved end to rear.

DRIVE TRAIN. On Model 5810Power Sled, the drive chain is in theopen and procedure for renewal isevident after shields are removed.

To remove the chain housing onSno-Scout and Super Scout, first re-move drive belt and disconnect brakecable at brake arm. Remove the se-curing U-Bolt and one bolt and nutfrom clamp strap, then swing the straparound out of the way. Remove the

Moctol

Alpine.Alpine.Alpine.

R-6 . . .RR-8 . , .RD-8..

Make

. JLO

. Kohler

. JLO

RotaxKohlerRotaxRotax

SKI-DOO1962-1972

VEHICLEShousing and torque converter drivensheave as a unit, by using suitable prybars to slide the housing from frame.After disconnecting the drive chainand removing the chain tightenerbolt (5—Fig. 2), the driven sheave,bearing housing, shaft and drivesprocket can be removed from hous-ing as an assembly. Driven sprocketmust be brought to top of housing andpried out through upper side opening.

Refer to the special SERVICE SEC-TIONS elsewhere in this manual fortrack service information and pro-cedures.

- Engine—

Model

LI 52K141LI 97

165K141250250

Displ.

148CC16.2cl198CC

163CC16.2ci247CC247CC

CartHirator

Make Model

1962Tillotson HL233BCarter NTillotson HL233B

THIotSfCarterTillotsonTillotson

1963HL233BNHL233BHL233B

SprocketRatio

9:269:269:26

9:269:269:269:26

- Clutch-ChainSize Make

OwnOwnOwn

OwnOwnOwnOwn

ShaftCenter

BeltNumber

A R - 6 , . .B R - 9 . . .R D - 9 . . .

RotaxRotaxRotax

165250250

163CC247CC247CC

TillotsonTillotsonTillotson

1964HL233BHL233BHL233B

9:269:2612:39

OwnOwnOwn

ChaletOlympique..Alpine

Olympique..Super Olym.

Alpine

ChaletOlympique...Super Olym. .AlpineSuper Alpine.

RotaxRotaxRotax

RotaxRotax

Rotax

RotaxRotaxRotaxRotaxRotax

'Pulley Rim, Clearance.

Olympique. . .Super OlymSuper 370 . . .AlpineSuper Alpine.

RotaxRotaxRotaxRotaxRotax

Olym. 12/3 . . . RotaxOlym. 12/3SS. RotaxOlympique 320 RotaxOlym. 320SS.. RotaxOlympiaue 370 Rotax

165250250

250250

250

165250300300300

250300370300370

300292320340370

163CC247CC247CC

247CC247CC

247CC

163CC247CC299CC299CC299CC

247CC299CC368CC299CC368CC

299cc292CC318CC335CC368CC

TillotsonTillotsonTillotson

TillotsonTillotson(Dual)Tillotson(Dual)

TillotsonTillotsonTillotsonTIHotsonTillotson

TillotsonTillotsonTillotsonTillotsonTillotson

TillotsonTillotsonTillotsonTillotsonTillolson

1965HL233BHL233BHL233B

1966HL233AHL209A-HL210AHL209A.HL210A

1967HL233AHL233AHR7AHR7AMD4A

1968HL233BHR7AHD8AHfl7AHD8A

1969HR7AHD21AHR17AHD21AHD8A

9:269:2612:39

9:269 26

12:39

9:269:2610:2512:3913:39

9:2610:2511:2512:3913:39

10:2510:2511:2411:2516:34

OwnOwnOwn

OwnOwn

Own

OwnOwnOwnOwnOwn

OwnOwnOwnOwnOwn

OwnOwnOwnOwnOwn

-KV.*

Vk*

570-0409570-0409

570-0409

570-0410570-0409570 0409570-0409570-0409

570-0411570-0411570-0411570-0411570-0411

570-0411570-0411570-0411570-0411570-0411

*Rim clearance, measured as sriown at (B —Fig. 9).

170

VEHICLES

Modal 1

Nordic 371Alpine 370 . . . .Alpine 640T'NT 399T'NT 669

Olym. 1 2 / 3 . . .Olympique 335Olympique 399Nordic 399 . . . .Nordic 640 . . . .Skandic 335. . .TNT 292TNT 340T'NT 399TNT 640Alpine 399R...Alpine 399ER .Invader 640ER.

Elan 250Olympique 300Olympique 335Olympique 399Nordic 399. . . .Nordic 640E ..Alpine 399R...Alpine 540ER .Vatmont 399R.Valmont 640ERTNT 292T'NT 340TNT 440TNT 640TNT 775Skandic

Etan250.Otympique 300Otympique 335Otympique 399Skandic 335. . .Nordic 440 . . . .Nordic 640ER .TNT 292TNT 340TNT 400TNT 440T'NT 640TNT 775Valmont 440R.Valmont 440ERAlpine 640ER .

Maka

RotaxRotaxRotaxRotaxRotax

RotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotax

RotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotax

RotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotaxRotax

Modal

371370640399669

300335401401640335292340400641401401640

247302337401401640401640401640292342435641775337

247302337401337434640292343398435641775434434640

Dlspl.

368CC368CC635CC399CC6G9CC

299CC335CC399CC399CC635CC335CC292CC335CC399CC635CC

^ 399CC399CC635CC

247CC299CC335CC399CC399CC635CC399CC635CC399CC635CC292CC335CC437CC635CC771 cc335CC

247CC299CC335CC399CC335437CC635CC292CC339CC399CC437CC635CC771 cc437CC437CC635CC

Cai'uurs

Maka

TillotsonTiltotsonTillotsonTillotsonTitlotson

TiltotsonTillotsonTitlotsonTitlotsonTtllotsonTillotsonTillotsonTitlotsonTillotsonTillotsonTillotsonTillotsonTiltotson

TillotsonTillotsonTillotsonTillotsonTillotsonTillotsonTitlotsonTillotsonTillotsonTitlotsonTillotsonTillotsonTillotsonTiltotsonTiltotsonTittotson

TillotsonTitlotsonTiltotsonTiltotsonTillotsonTitlotsonTtltotsonTiltotsonTitlotsonTitlotsonTillotsonTillotsonTillotsonTHIotsonTiltotsonTillotson

Modal

1969 Cont.HR16AHD8AHD21AHD21AHD21A

1970HR37AHR17CHR16BHR40AHD20AHR69AHD22AHD22AHD21AHD20AHR16BHR16BHD20A

1971HR73AHR74AHR75AHR76AHR40AHD20BHR16BHD20BHR40AHD66AHD22BHD22BHD73AHD20BHD20BHR69A

1972HR73AHR74AHR75AHR76AHRHDHDHDHDHD104AHDHDHDHDHDHD

SprockatRatio

16:3413:3913:2916:3420:34

10:2511:2516:3416:3420:3412:3316:3416:3416:3420:3413:3913:3913:25

10:2515:3515:3416:3416:3420:3413:3913:2913:3913:2915:3416:3416:3420:3422:3412:33

10:2515:3515:3416:3412:3316:3420:3415:3416:3418:3418:3420:3422:3413:3913:3913:29

ChainSIza

Pliitrh

Maka

OwnOwnOwnOwnOwn

OwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwn

OwnOwnOwnOwnOwnOwnOwnOwnOwnOwn

\ OwnOwnOwnOwnOwnOwn

OwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwnOwn

ShaftCantar

1 % *i % *1 %*1 % '1 % *

i % *1 %*1 %*1 %*1 %*1 %'1 %*1 %*1 ' / i *1 %*FixedFixedFixed

1 %'*•

1 7 ^ *1 ^^*1 %*1 %•1 ^ *FixedFixedFixedFixed1 %*1 ^ 8 *

17/8»

1 %•1 '/8»1'/8*

1'/8*1 %*1 %*1 '/e*1 '/8*

1 %*1 '/«*1 % *1 ^ *1 % *1 %*1 %*FixedFix*jdFixed

>ki-Doo

BaHNumbar

570-0411570-0411570-0414570-0411570-0414

570-0411570-0411570-0411570-0411570-0414570-0411570-0411570-0411570-0411570-0414570-0411570-0411570-0414

570-0411570-0411570-0411570-0411570-0411570-0414570-0411570-0414570-0411570-0414570-0411570-0411570-0411570-0414570-0414570-0411

570-0411570-0411570-0411570-0411570-0411570-0411570-0414570-0411570-0411570-0411570-0411570-0414570-0414570-0414570-0414570-0414

Rim clearance, measured as shown at (B—Fig. 9).

LUBRICATION

The vehicle manufacturer recom-mends the use of "SKI-DOO" two-cy-cle engine oil at the ratio of 20:1.

The drive chain runs in an enclosedchain housing which contains oil toa level approximately even withlower sprocket hub. SA£] 80 Hypoidgear lubricant or "SKI-DOO" chaincase oil are recommended as thelubricant. Single track models areequipped with a level plug (10—^Fig.7). On Alpine and Invader models,insert a wire through top inspectionopening as shown in Fig. 1 and main-tain oil level 3 to 4 inches from bot-tom of case.

The ski-legs (spindles) are equippedwith grease fittings at upper end. Lu-bricate weekly with "SKI-DOO"Grease or an equivalent low-tempera-ture grease.

9 lat« Alpina/lnvadar Modalswith Forward-Naufral-RavarM Transmlttloii.lubricont laval can b« meosurad with astiff wira working through inspactlon holaon left side of cose as shown. Fill withSkl-Doo Oil through flltar plug (F) to alavel of 3-4 Inches from bottom of case.

F

171

Ski-Ooo VEHICLES

Bogie wheels are equipped withgrease fittings. Lubricate weekly, oroftener under adverse conditions orcontinuous usage, with "SKI-DOO"grease or equivalent. Late modelshave grease fittings at each end oftrack idler axle. Lubricate sparinglywhen bogie wheels are greased.

Lubricate steering linkage and han-dle bar bushing twice monthly (lowtemperature grease).

Each week during use season, re-move drive belt spread driven sheaveand apply a light coating of low tem-perature grease to shaft. Slide movingpulley back and forth to distributethe grease and wipe off any excess.Each month remove drive pulley cen-trifugal unit and apply a light coat oflow temperature grease to flyweights.On 1971 and later pulley, pack ^aftarea with grease working through re-taining bolt hole. Lubricant is meteredto sliding area during operation. Onall models use care not to get grease

Flq. 2—To adiusf chain tention on qtrack modds, IOOSM adiusting bolt (B)and pHth down to tiqiitm (or up to IOOSM)chotn. Eoriy Alpino models have two slmltor

tonsioMrs.

« 3*-ClMln tensioner (2) on iote Ai-pino/lnvoder/Voimont models with Forword-Heutrol-Reverse tronsmlssion is lo-cated on right side off chain housing andadiustment can be made after removing

adjusting boit (1) .

on belt or allow buildup which willbe thrown on belt during operation.

ADJUSTMENT

STEERING SKIS. To adjust thesteering linkage on early models, re-move hood and loosen locknuts oneach end of tie rod, then turn centertube until distance between skis mea-sures the same front and rear. To ad-just handle bar, disconnect drag linkat either end.

Late models (Except Elan) use twodrag links which should be equallyadjusted.

DRIVE CHAIN. The roller drivechain should have approximately V^-inch of deflection. Direct measurementis not possible on early models withchain case not equipped with inspec-tion cover. The need for adjustmentcan be determined by carefully rock-ing the driven pulley and noting thefree movement, or backlash.

All 1971 and later models exceptAlpine and Valmont have an auto-matic chain tightener and adjustmentis not required.

Recommended procedure for allmodels requiring adjustment is tomake 3 checks, turning driven pulleyone complete turn between checks.Deflection should not exceed ^-inchat any time.

Adjustment on early models is by

Fig. 4—Some iate modeis have a brakedrum built into fixed face of driven sheave

as shown.

wm

means of the bolt in eccentric bearinghousing between driven pulley andupper end of chain case as shown inFig. 2. Alpine models before 1969 havetwo eccentric housings as shown inFig. 8. To adjust the chain, back offthe locknut and push down on jambolt until it stops with moderate pres-sure applied; then push up approxi-mately tV-inch and tighten the lock-nut. On Alpine models both bolts (S)must be moved at the same time andsame amount.

On 1969-1971 Alpine, Invader andValmont Series with forward-neutral-reverse transmission, chain adjust-ment is by means of eccentric ten-sioner (2—Fig. 3) located on left sideof gear box. To adjust the chain, re-move locking cap screw (1) and turntensioner while checking deflectionthrough inspection hole on oppositeside of case.

BRAKE. Chalet, Olympique andSuper 370 Models before 1969 andsome later machines were equippedwith a shoe type brake which usesthe fixed face of driven sheave as afriction surface. On many late modelsthe brake shoe rides in a drum builtinto rim of driven sheave as shownin Fig. 4.

All Alpine and Invader Models useH-H Caliper Type Disc Brake whichmay be adjusted and serviced as out-lined in BRAKE paragraph of TRACKDRIVE Section elsewhere in this man-ual.

Wear adjustment of shoe-type brakeis made at brake cable anchor. Ad-justment is correct when brake is fullyapplied with end of lever Vi-inch fromhandle bar grip.

TRACK. To adjust track tension,raise rear of vehicle until track isclear of ground. Apply down pressureat center of track and measure thedistance from track to center bogie

Fig. 5—To adiust track tension, loosen thetwo clamp bolts (B) and turn adfustlngscrew (A) . Both sides must be adjusted

alike. Refer to text.

Pig. 6—^n 1949-1970 Models TensionerCiamp Boit is iocated in center of suspen-sion spring as shown at (1) . Adiusting

fcrtw (2) is at rear as shown.

172

VEHICLES Ski-Doo

wheels. Distance should be 2^-3inches and equal on both sides oftrack (Both sides of BOTH tracks onAlpine and Invader Models).

To adjust track tension on earlymodels, refer to Fig. 5. Loosen clampbolts (B) and turn adjusting screw(A), making the same adjustment onboth sides of single track models orat all four adjusting points on Alpine.

On late models loosen locknuts (1—Fig. 6) in center of suspension springs,then tighten adjusting screws (2) anequal amount. (Four tensioners on Al-pine and Invader Models).

NOTE: When track tension has beenadjusted, alignment MUST be checkedas outlined in TRACK SERVICE sec-tion of this manual.

OVERHAUL

SKIS. Skis, ski legs (spindles),springs and steering arms are inter-changeable for right or left side ofvehicle. Tie rod ends have right handand left hand threads and are notinterchangeable. Skis are equippedwith wear bars which are retainedby a nut on center stud. Wear bars canbe installed either end forward.

CHAIN CASE. On single track mod-els, the chain case serves as the sup-port for driven sheave at upper endand left hand bearing for track driveshaft at lower end. To remove thechain case, first block up rear of ve-hicle and completely loosen track. Re-move hood and torque converter drivebelt. On early models, loosen drivechain tension. On 1971 models withself-adjusting drive chain, a tensionreleaser tool is available from themanufacturer, and is necessary forchain case overhaul. Remove the two

V^ „ 14

Fig. 8 — Exploded viewof driven sheove and as-sociated parts used on

eariy Aipine i odels.S. Adjusting screws1. Outer cam2. Spring3. Cam ahoes4. Spring pin5. Shaft6. Moveable face7. Fixed face8. Spacer9. Drive sprocket

10. Chain case11. Eccentric12. Eccentric13. Bracicet14. Spacer15. Brake disc16. Wave washer

clamps (11 & 12—Fig. 7) and suuportrod (3) which hold the chain case tovehicle frame. Work the drive axleseal from lower end of chain case,work the axle from splined lowersprocket and lift off the chain caseand driven sheave as an assembly. Becareful not to lose the shims (5) ifshims are present. These shims, to-gether with spacer shims located be-hind torque converter drive sheave,are used for drive belt alignmentwhen vehicle is assembled.

Standard sprocket ratios for mostmodels is given in tables at beginning ofthis section.

Drive chain (8), upper sprocket (7)or driven sheave can be removed afterremoving inspection cover (13). Re-move the shaft nut and jam bolt (2),then withdraw driven sheave and ec-centric bearing housing (1) as an as-sembly. Driven sprocket (9) can bewithdrawn from inspection coveropening after removing upper shaftand sheave assembly. Assemble byreversing the disassembly procedure.Tighten nut (14) to provide a very

11 m

Fiq. 7—Expioded view ofdrive chain housing, sup-ports and associatedparts used on eariy mod-

els.1. Eccentric housing2. Lock bolt3. Support rod4. Socket5. Shim6. Chain case7. Drive sprocket8. Drive chainI). Driven sprocket

10. Inspection plug11. Clamp12. Support bracket13. Inspection cover

slight pre-load to shaft bearing.When reinstalling the chain case, be

sure drive axle oil seal is in goodcondition or a new one installed. Re-position the chain case and installclamps loosely. Reinstall support rodthen insert the removed shims (5) inthe same position from which theywere removed and tighten clamp nutssnugly. Drive sheaves should be prop-erly aligned as shown in Fig. 9. Offset(A) should be ^^-inch on all modelsexcept 1970 TNT 340, on which anoffset of %-inch is recommended. Thevehicle manufacturer provides an'*Adjusting Bar" (straight-edge). Part

—C

Fig. 9—Schematic view of torque conver*\er showing points of adlustment. Offset(A) is V2-inch on all models except 1970TNT 340, which shouid be Vi-inch. Rimciearance (B) should be ZVA inches for1967 Chalet ond IVt inches for other mod-

eis.

A. OffsetB. Rim clearanceC. Adjusting shims

173

Ski-Doo VEHICLES

No. SK-1623, which can be used formeasuring the offset. Adjust by vary-ing the shim pack (5—Fig. 7) or byremoving the drive puliey and addingspacer shims at point shown at (C—Fig. 9). Distance (B) between sheaverims shouid be 3^-inches on ChaletModel or 1%-inches on Olympique^Super Oiympique and Alpine Models.Distance (B) can be varied by short-ening or lengthening support rod (3—Fig. 3).

On Alpine models, the chain case(10—Fig. 4) serves as support fordriven sheave. The lower half of chaincase is built into vehicle frame.

To remove the chain case, loosenboth tracks to reduce drive chain ten-sion. Remove belt guard, brake discand left support bracket (13), thenremove drive belt. Remove inspectioncover and unhook drive chain; thenunbolt and remove chain case.

DRIVE. Refer to the appropriate ser-vice section elsewhere in this manual foroverhaul information on torque con-verter and associated parts. The vehiclemanufacturer recommends the follow-ing method to block the piston and keepcrankshaft from turning when removing

R9. 10 — Exploded vi«wof Forword-H«itral-R*-verse Transmfulon uMdon I nvader/Alpin«/Vol-ment modds so equlppod.

1. Housing2. Bottom plate3. Support4. Drive shaftr». Oil sealti. Snap ringT. BearinK8. Shim (0 Snuii^n. Sliding Hear

10. Washer11. Sprocket12. Xeedle bearingia. Spacer1-J. Snap rint!ir>. Shift rail10. Shift fork17. Detent18. Shift shaft11). Shlma•JO. Shims21. Needle iiearitiK22. Countersiiaft K«'23. Spacer24. Countershaft25. Washer2«. Needle bearing'27. Idler sprocket

5 6 7 8 M P H 12 8 13 14 7 6

28. O-rlnB29. EccentrU* housing'

'iO. Lock screw:n. Shift lever

the drive pulley. With spark plug re-moved from single cylinder engines orpto side spark plug removed from twin,slowly turn crankshaft in normal direc-tion until exhaust port iS closed and com-pression begins. Feed a spare starterrope or similar clean rope into spark

plug hole, then turn piston up againstrope until crankshaft stops. Firstremove the centrifugal governor boltand withdraw governor, moving flangeand spring, then insert a punch in crosshole in pulley shaft and turn in normaldirection of engine rotation.

174