Download 1965 Model 5813-0000
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CRUISER 2 2 MODEL 5813·0000 PARTS AND SERVICE MANUAL ~F AMERICAN MACHINE & FDUNDRY CDMPANY CONSUMER PRODUCT S SALES DIVISION PARTS & SERVICE DEPARTMENT Whiteford Road, York, Pennsylvania 17402· Area Code 717 848-1177 PART NO. 37950 TABLE OF CONTENTS Page WARRAN TY. . . . . . . . . . . . . . . . . . . . .. 1 TABLE OF CONTENTS . . . . . . . . . . . 2 SER VICE INSTR UCTIONS .•..•..... 2 BODY PAR TS . . . . . . . . . . . . . . . . . . . . 4 BODY PARTS LIST . . . . . . . . . . . . . . . . 5 STEERING, SKIS, AND UPPER DRIVE ELEMENTS . . . . . . . . . . . . . . . . 6 STEERING, SKIS, AND UPPER DRIVE ELEMENTS PAR TS LIST. . .. 7 DRIVE BELT AND LOWER DRIVE ELEMENTS. " . . . . . . . . . . . • . . . . . . . 8 DRIVE BELT AND LOWER DRIVE ELEMENTS PARTS LIST .•..•..... 9 ENGINE, ELECTRICAL, AND FUEL . . . . . . • . . . . . . . . • . . . . . . . • . . . . 10 ENGINE, ELECTRICAL, AND FUEL PAR TS LIST . . . . . . . . . . . . . . . . II Page CHAIN CASE COMPLETE AND PAR TS LIST . . . . . . . . . . . . . . . . . . . . . . 12 WIRING DIAGRAM . . . . . . . . . . . . . . . . 13 BLOCK AND HOOD . . . . . . . . . . . . . . . 14 BLOCK AND HOOD PARTS LIST .... 15 FLY WHEEL, MAGNETO DIAGRAM AND PARTS LIST . . . . . . . . . . . . . . . . . . 16 CRANKSHAFT DIAGRAM AND PAR TS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 GENERATOR, SOLENOID DIAGRAM AND PARTS LIST ..•.•..... 18 MANIFOLD, MUFFLER DIAGRAM AND PARTS LIST .•..•.•••..•....•. 19 CARB URETOR AND PAR TS LIST. .. 20 ENGINE OPERATING IN STRUCTIONS ..••.•.•.••..•...••.• 21 All information in the preceding section relative to Models 5811 and 5812 apply to Model 5813 except the information under POWER TRAIN on pages 7 & 8, "Brake Adjustment" and "To Remove Drive Sprockets" on page 11. New copy for t he latter is below. TOR E MOVE DRIVE SPR OCKETS 1. Remove the battery from the sled. A . Re move cables from battery terminals. B. Remove battery hold-dow n fasteners. 2. Place rear of sled on kick-stand. 3. Release track tension by removing both right hand and left hand adjuster plates. R emove all fasteners holding adjuster plates to the frame (See Figure 1) . 4. Remove track tension springs by pushing the extended top end toward the center and pulling down. Use same procedure on both sides (See Figure 2) . 5. Remove the three screw s, lock washers, 1.nd nuts that hold the bearing retainer to the right side of the sled (See Figure 3) . 6 . Turn sled up on its right side. With the sle d on its right side, the grease in the gear case will not run out as much as it would if the sle d were on its left side. 7 . R emove lacer pins from the drive track by bending the ends s traight a nd pulling them ou t. 8 . Pull belt to one side s a you can gain ac ces s to the drive sprockets . 9. Remove the set s crew in the collar at both ends of the drive shaft. There is a notch FASTENERS ADJUSTER PLATE Figure 1 Figure 2 - 2- BOLT AND WASHER • c DRIVE SPR OCKETS COLLAR SET SCREW BEARING RETAINER Figure 3 in each collar. Insert a punch into the notch. Tap the punch lightly to loosen the collar (See Figure 3). 10. Remove the three screws which secure the chain case cover (See Figure 3). 11. Remove the bolt and washer from the end of the drive shaft (See Figure 4). Tap on the drive sprockets with a hammer. Tap them to the right side. This will free the drive shaft from the gear shaft. 12. Loosen set screws which hold the drive sprockets in place. Slide them off the left end of the drive shaft. 13. Replace or repair sprockets. 14. Reassemble in opposite order. 15. When replacing the drive shaft into the gear case, align the large sprocket and the spacer behind it with your finger before inserting the drive shaft (See Figure 5). Insert shaft and align notches on the end of the drive shaft with those on the sprocket in the gear case. Figure 4 Figure 5 -3 - AMF SKI-DADDLER SNOWMOBILE BODY PARTS For Parts List - 22 See Page 5 ALL UNNUMBERED PARTS INTER·CHANGEABLE WITH OPPOS ITE SIDE ~d ~~~ 88 "",""" ~/ I 72 52 /J.J 5t l- J 2~ ~ ~"'-29' ! ~ ~ 49 41 l-'-' 37 45 I IF> 44 / ~ 'lila . Vl) m... If"00 _ \)= 46'a 40 43 - 0 \42 eJ 39 38 \)= I- d~ I / ;:1. 29 IOr:e .l>- ~ G; 12 » ~. --13 •• • .;:.;: Q i 2 1":--. 54I - o 26~"It-10 ~-64 48 " II .. II I»m> B-. (D..~ I -. 19 17 26 - ~ 'l 15 ~~. ry. 18~ o ----- ~~ 57 ~1~"'-t 62 ._____<P' -A-· , ---------- 66 • 84 J 'I'§) ~ ~ 83- 1'9> '" ., "'" )2 81 63 ~~~ITY6 ~~- . O~" 60 65 ~ 18 - ~ ~69 l- 51 0 0'61 1)=,8 ~22 -30 ~OI J~ ~64 31 J 68 '~o ~9 860 11 ~~ 35 28 ~ I 3~ 34 tiS u • AMF SKI-DADDLER SNOWMOBILE ALWAYS GIVE THE FOLLOWING INFORMATION WHEN ORDERING REPAIR PARTS: • .. c l. THE PART NUMBER 2. THE PART NAME 3. QUANTITY DESIRED 4. THE MODEL NUMBER-58130000 SEND PART ORDERS TO ATTENTION OF: PARTS DEPARTMENT, P. O. BOX 377, DES MOINES, IOWA 50302 Your Unit is Right Hand (R.H.) or Left Hand (L.H.) as you stand behind it. DO NOT USE KEY NUMBERS WHEN ORDERING REPAIR PARTS, ALWAYS USE PART NUMBERS. BODY PARTS FIGURE 1 PARTS LIST FOR MODEL 58130000 Key No. Port No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 304 18 30295 30555 30529 30376 30377 30394 30395 30396 30397 30398 30399 30233 30245 30246 2251 8728 121913 121926 941 7373 11 2726 125680 120854 30275 457509 94 133 14 120691 995355 30276 30400 30409 30412 30268 30624 30269 30414 29080 29081 29266 30363 31151 30362 120622 132764 Description Windshield Rubber Spacer Rubber Bumper Strip Alu mi num Trim Strip End Cap Trim- R.H. End Cap Trim-L.H . Kick Stand Tube Hand Rail Tube Hood Access Lid Tote Pouch Seat Back Seat Snap-Male Half Spri ng-Latch Hoo k Latch Hook 7/ 32" x 3/4" Washer Formed Washer * 1/4" -20 X 11/4" Hex Hd. Sc. * 1/4" -20 X 11/2 II Hex Hd. Sc. *No. lOx % II Flat Washer * 1/16" x 1f2" Cotter Pin * 1/4 II - 20 x % II Truss Hd. Mach. Sc. * 1/4II -20 x %" Hex Hd. Sc. 3/16" x % II Pop Rivet No. 10-24 Lock Nut 1/4" -20 Lock Nut No. 10-24 x 1 % II Flat Hd. Sc. 1/4" -20 x 1" Truss Hd. Sc. 1fs II Pop Rivet Fuel Inlet Tube Assy. Seat Back Tube Assy . Fuel Ta nk Reta iner Plate Assy. Gas Cap Chain Fue l Level Indicator Main Frame Assy. Ta i l Lamp Door Tail Lamp Lens Rubber Spacer Ta il Lamp Seat Back Cover Tail Lamp Grou nd Wire *No. 8-32 Hex Nut *No. 8-32 x % II Rd . Hd. Mach Sc. Key No. Part No. 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 134186 271482 30581 30218 30630 16615 134244 996907 4575 14 30283 30219 16634 30417 31450 30229 30263 30264 30265 30270 24180 30278 30279 120706 308 10 31763 30365 30488 132911 30635 30605 30272 30171 122007 9415988 122027 30633 22780 120272 996407 271184 30587 30285 16439 30631 *No. 6 -32 x 1" Ova l Hd. Sc. No. 6-32 Lock N ut Glove Box Lid Head Lamp Assy. Windshie ld Trim Stri p R.H . Light Switch Deca l *N o. 8 -32 x 11/4 II Ova l Hd. Sc. *No. 10-32 Keps Nut *No. 8-32 Lock Nut Sponge Pad Latch Ign ition Decal Hood Fue l Tank Gas Line--Long Gas Tank Inlet Fitting Gas Tank Outlet Fitting Fue l Fi lter Fuel Pick-Up Tube Hose Clamp "O"Ring 11/2" O.D. " 0" Ring 1 1/4 II O.D. *%" -20 x 1/2" Hex Hd. Sc. Hood Grommet Rubber Strip Support Ang le Hose Clamp *N.o. 10-32 x %" Rd. Hd . Sc. Clutch Guard Plastic Hood Trim Hinge J- Bolt *5/16" - 18 x %" Hex Hd. Sc. *5/ 16"-18 Lock Nut *5/16"- 18 x 11/4" Hex Hd. Sc. Bumper 5/ 16"- 18 Curved Hd. Bolt 5/1 6"- 18 x 1" Truss Hd. Sc. *5/1 6" Wa sher *5/ 16"-18 Lock Nut Rear Brake Mounting Bracket Plate (Glove Box Lid) Decal F.N.R. Windshield Trim Tape L.H. For Illustration See Page 4 *Standard Hardware Items may be purchased loca lly. c Description All replacement parts will be supplied in cu rrent production co lors or in a neutral co lor. - 5- AMF SKI-DADDLER SNOWMOBILE 55-, 36 56 1Pr/ ~18 ~ -47 32 37 e 26 / 43 48 COl 41 &>,,43 \ .....-49 ru 6i--r' ~43 69 ~"t>, 35 20 J / /' \ \ \\ < '",- o \ ' ) 0 \ 62 \~~~ STEERING, SKIS, FRAME AND TOP DRIVE ELEMENTS '. \ 60 1 )9 '3 ~ .. 46 ~. ~ 12 ~JJ 4)3~10 1 8 9 For Parts List - ~~/4 ~~Iq 13- : ... 19 ~ 2 See Page 7 oa ~- ALL UNNUMBERED PARTS INTER-CHANGEABLE WITH OPPOSITE SIDE ) FIGURE 2 - 6- AMF SKI-DADDLER SNOWMOBILE c STEERING, SKIS, FRAME AND TOP DRIVE ELEMENTS FIGURE 2 PARTS LIST FOR MODEL 58130000 c Key No. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 30247 8441 28762 137185 997314 30369 28764 28766 28770 29645 28769 995365 995224 30799 706 21777 28416 28907 121222 30673 2347 30117 120233 30149 120382 20202 24054 302 11 30212 30224 30251 27128 120396 30282 120854 29032 30284 Description Bumper Pad Spring Roller Spring Pivot Pin * Va" X 1" Cotter Pin 1/4 "-20 Centerlo ck Nut Ski Wear Rod Assy. Spring Plate Leaf Spring Main Leaf Spring Middle Leaf Spring Spring Mounting Bracket % "-24 x 11/4/1 Hex Hd. Sc. %" - 24 Slotted Nut Ski and Wear Rod Assy. Grea'se Fitting Spacer Bushing Hand Grip Hand Control Assy. *3/32" x %" Cotter Key Bra ke Sp ring Bracket Spring Spind le Bolt *%/1 - 16 xl/1 Hex Hd. Sc. Spring (Spindle) * '%" Lock Washer Throttle Contro l Cable "U" Strap Column Support Plate (Upper) Thumb Lever (Throttle Control) Brake Cable Spacer Bushing Cab le Clamp *%/1 Washer Housing (Brake Cable) *%/1_20 x %/1 Hex Hd. Sc. Cable Ferrule Cable Housing Key No. Part No. 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 120383 457507 30575 25188 121893 124925 142443 181643 995364 999101 9413314 995339 30414 30579 181 652 9415 106 181650 424339 120614 30060 30403 30081 30124 180079 30228 30561 30535 30576 8103 30592 30392 28783 28784 30390 120638 31406 * Standard Hardware Items May Be Purchased Locally Description *Lock Washer *No. 10-32 Lock Nut Square Key Swivel Button * 1/4 "-20 x 7Ja" Hex Hd. Sc. *%" -24 Jam Nut No. 10 -32 x 1 %" Rd. Hd . Sc. *%/1-24 x 1 1/2 " Hex Hd. Sc. %"-24 x 2%" Hex Hd. Sc. *No. 10-32 x %" Self Tap. Sc. * 1/4 " -20 Lock Nut No. 8-32 x %" Socket Hd. Sc. Main Frame Assy. Steering Handle & Column Assy. % "-24 x 3" Hex Hd . Sc. * %" -30 Lock Nut % /1 -24 X 2 1/2 " Hex Hd. Sc. *No. 10-32 x 1" Rd. Hd . Sc. *No. 10-32 Hex Nut Spindle Arm Tie Rod Rod End Bearing Spindle Tube Assy. 5/16/1-18 x 1" Hex Hd. Sc. Foot Pad Drag Link No. 706 Hi - Pro Key Washer (Disc Brake) Flat Washer Front Brake Mounting Bracket Driven Clutch Disc Brake Disc Brake Hub Apex Gear Case Complete *5/16/1 Lock Washer Lever Assy. For Illustration See Page 6 All replacement parts will be supplied in cu rrent production colors or in a neutral color. -7- AMF SKI-DADDLER SNOWMOBILE DRIVE BELT AND LOWER DRIVE ELEMENTS 21 \ 27 \ -ru26 15 ~ 29 24 ~ \ _:n ~:((\, ()'"". -Q\ 25 15 XJ·~· ' 5 ff ' ~)6 3\ ~~IV ~I --9)~ -~~- ~ 10 13.~ (Xl I 4 22 8 - ____ ~GII$ -- ----- "" _.'::> "'- 18 -r\ -i_~-®l·(28 f ~ ~~35 37 34 '-... ~ '-... '-... '-..... 31 12 11 '-... 45~"'-'-,- 39 24 33 26 /@~ ~ 1 'V' 0 'q ~L\), ...0 51 15 42 ~ @,\ @ ~ ~ Q 36 ( 4 49 49 41 43 For Parts List - See Pa ge 9 A LL UNNUMBE RED PARTS INTER-CHANGEABLE W ITH OPPOSI TE SIDE 50 FIGURE 3 . u 14 n • n () AMF SKI-DADDLER SNOWMOBILE DRIVE BELT AND LOWER DRIVE ELEMENTS FIGURE 3 PARTS LIST FOR MODEL 581 30 00 0 -0 I Key No. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 706 2483 29956 29975 30464 30463 30145 28776 122007 122065 138485 181595 456145 30620 94 15988 29980 29981 29984 29985 30017 30100 30621 30085 24 25 29945 30079 Description Grease Fitting Spring Washer Spacer Ad justing Block Rear To rsfon Spring R.H. Rear Torsion Spring L.H. Retainer Spring 5/ 16"- 18 x 3" Hex Hd. Sc. *5/16"-18 x %" Hex Hd. Sc. *5/ 16"- 18 x 2" Hex Hd. Sc. *5/ 16" Lock Washer *5/16"-24 x %" Hex Hd. Sc. 5/16" Washer Short Hinge Wire *5/16"- 18 Lock Nut Belt Ad just. Angle Assy. R.H. Belt Adjust. Angle Assy. L.H. Rear Support Arm Assy . R.H. Rear Support Arm Asy. L.H. No. 40 Sprocket-26 Tooth Traction Belt Assy. Long Hinge Wire Rear Sprocket Comp lete Consists of (24 -25-26-27 -28-29-38) Not Ill us. Rubber Sprocket-9 Tooth Grease Seal - --- - * Standard Hardware Items May Be Purchased Locally Key No. Part No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 30080 120222 997316 29955 30087 30402 29944 29942 29954 29953 30560 12022 1 31802 31803 30577 41 42 43 44 45 46 47 48 49 50 51 998010 120638 30523 30524 998503 12 1887 9413314 31073 31074 31075 8288 Oescri ption Ball Beari ng *No. 10-24 x %" Mach. Sc. No. 10-24 Lock Nut Sprocket Support Plate Assy . Bogg ie Wheel & Support Assy. Boggie Wheel & Support Shaft Bogg ie Wheel Spr ing Boggie Tire Bogg ie W heel Half (Outer) Boggie W hee l Ha lf (Inner) Bearing Back Up Plate *No. 10- 24 x %" Mach. Sc. Rear Shaft Assy. W/ Plugs Bogg ie Support Assy. W/ Plugs Drive Sprocket Assy . Consists of (24-~7-28-43-44 - 45-46-47 ) - 5/ 16"-18 x %" Carriage Bolt *5/ 16" Split Lock Washer Plate Hub 5/ 16"- 18 x 5/ 16" Set Sc. * 1/4"-20 x %" Hex Hd. Sc. * 1/4" -20 Lock Nut Link Belt Bearing Link Belt Collar Link Belt Stamping Snap Ring -- -- -- For Ill ustration See Page 8 All rep lacement pa rts wi ll be supplied in cu rrent production colors or in a neutra l co lo r. AMF SKI-DADDLER SNOWMOBILE ENGINE, ELECTRICAL AND FUEL ELEMENTS • 11 ~12 . 48 31 ~ ~9-\1 00 33 46 g \, ,," a 39~~ 40~ • 35-W 36--® ~ ..... ~12 -46 EJ-27 Fo r Parts List - LJ-26 ~28 10 ~ 35~ 9 18 ~ See Page 11 ALL UNNUMBERED PARTS INTER-CHANGEABLE WITH OPPOSITE SIDE 38 ~ ~@-. 4 34 37 ~~ 46_ r 32 9 43 ~44 41 I 30 25 5"e o-~ 51-- 6 20 - 16 ~1~ -~i\ l-47 o 6 FIGURE 4 -10 - AMF SKI-DADDLER SNOWMOBILE ENGINE, ELECTRICAL AND FUEL ELEMENTS FIGURE 4 PARTS LIST FOR MODEL 58130000 Key No. Port No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 30556 29677 30557 30393 9416107 999701 999101 3039 1 26032 29073 306 18 30389 30612 30614 30615 30616 30617 135629 31470 20 21 22 23 24 25 3324 30572 9415106 446363 30568 30613 Descriptio n Rubber Engine M ounting Pad Connector Exhaust Pipe Variable Speed Belt * % " - 16 Lock Nut %"-20 x %" Hex Hd. Self Tap Sc. *No. 10-32 x %" Self Tap Sc. Drive Clutch Key Switch Light Switch Wiring Harness Wiring Clip Lead Wire (Battery to Sol eno id) Lead Wire (Regulator to Grou-nd) Lead Wire (Regulator to Gen.) Lead Wire (Solenoid to Regulator) Lead Wire (Regular to Generator) * 1/2 " Shakeproof Washer Voltage Regulator (See Engine Manual) Solenoid Engine Base Assy. * %" -24 Lock Nut *%" Washer Engine Mount Plate Lead Wire (Battery to Ground) * Standard Hardware Items May Be Purchased Loca lly Key No. Pa rt No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 30176 30178 30180 30375 16635 30603 30610 30628 2 1970 30676 30629 30573 30574 119117 30642 30601 30602 126177 120386 Engine 120380 180124 30489 120382 995246 124829 Description Air Cleaner Screen Air Cleaner Cover Air Cleaner Mount Plate Air Cleaner Stud Kill Button Decal Anchor Bracket (Throttl e Cable) Clutch Spacer Carburetor (Till otson HR- 3A) Washer Intake Manifold Ga'sket In su lator Block Special Screw 1/4 " Square Key *3/32 x %" Cotter Pin Carbureto r Adapter Arm Assy. Battery Hold Down Assy. Battery Hold Down Rod 1/4"-20 Wing Nut 1/4" Washer See Footnote Below 1/4" Lock Wa'sher %" - 16 x 11/4" Hex Hd . Sc. Hose Clamp (Carburetor) * %" Split Lock Wa sher 1/4"-20 Acorn Nut %" - 16 Jam Nut For Illustration See Page 10 All prices subject to change without notice. All repla cement parts will be supplied in current production colors or in a neutral color. ( Replacement engines and parts are obtainable from the Eng ine Manufacturer' s authorized Service Stations who are also to be contacted in regards to the Engine Wa rranty. See your Engine Manual for location of these stations. -11 - AMF SKI-DADDLER SNOWMOBILE CHAIN CASE COMPLETE For Parts List See Below FIGURE 5 CHAIN CASE COMPLETE FIGURE 5 PARTS LIST FOR MODEL 58130000 Key No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 * Part No. 31814 31815 31816 31817 3 1818 31819 31820 31821 31822 31823 3 1824 31825 31826 31827 31828 31829 31830 31831 31832 31833 31834 31835 31836 31837 Key No. Description Housing Drive Sprocket & Bushing Shifter Shaft Reverse Pinion Reverse Shaft Reverse Gear Taper Bearing Bushing Shift Lever Sprocket-. Driven Input Shaft Output Shaft Inspection Cover Cover Plate Fulcrum & Nut Washer -Axle Gasket for Inspection Cover Gasket for Cover Plate "0" Ring for Flang et Gasket for Flanget Shaft & Bearing Roller Spacer-Output Collar-Input Timken Bearing 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Standard Hardware Items May Be Purchased Locally Part No. 31838 31839 31840 3184 1 31842 31843 31844 3 1845 31846 31847 31848 31849 31850 31851 31852 31853 31854 3 1855 31856 31857 31858 31859 31860 Descripti on Spring fo r Detent 5/16" Nut Snap Ring Snap Ring Seal- Input Shaft Dust Cap Expansion Plug Torrington Bearing Seal Oilite Bea ring Set Screw 1/8" x 1" Roll Pin Breather Stud Lever Ball Chain (by li nk) Bearing & Collar Flanget Detent Ball 5/16/1 Lock Washer %" Bolt 1/8" x 1f2" Roll Pin 1/4" Bolt , For Illustration See Above All replacement pa rts will be supplied in cu rrent production colors or in a neutral color. -12- , T REPAIRMAN'S REFERENCE WIRING DIAGRAM ~ Z o w U ~ w !!? w 1I01Vln9311 39"1101\ '"~ '" '"Z '"« :I: o o o :I: :z: u .... ~ '" .... :I: :I: g u .... ~ Z ) o liE ;:: ~ c The wIring diagram shown here is a technical explanation of the circuitry on this unit. It is intended for use by repairman or owners capable of readin g and using wiring diagrams. The various component parts have been labeled. See your Serv ice Dealer for part numbers, price and o rdering - information. A lso see your Service Dealer for ava ilable Service Manual. We recommend that unless you are fully qualified to make repairs on the electr.i cal system on this unit, you take it to a competent repairman for such work or adjustments. 13- BLOCK AND HOOD ~- 38 --=----41 ~ll i'39 5 6 7 40 37 lIi t~ 36 35 8 9 34 10 12--13-- - 28 a----27 ~--13 - - -14 y 18 - 14 - ) BLOCK AND HOOD PAR TS LIST ENGINE TYPE 2054-SRB x 18 (AMF) C ITEM 4 ( NOS. QUANTITIES DESIGNATION 549x398 Cover for air shroud EAZI02B Connection clamp for grounding wire 884x7 Insula tin g washe r DIN84 - 5S M3xl5 Screw for connection clamp 549x399 Shield for cylinder 836x43 Terminal for ignition cable SOx39 Spark plug BOSCH M 225 - T 1712x142 Cylinder head 759xl81 Gasket for Cylinder head 10 205xl78 Cylinder II 759x183 Gasket for cylinde r base 12 DIN931 - 5S M8x65 Screw for c rank case 13 DINI37 A8 Lockwasher 14 DIN934- 5S M8 Nut for crankcase 15 DIN835 - 5S MIOx22 Stud for cylinder 16 9244x159 Crankcase assembly 17 343x135 Roll pin 18 318x340 Impulse tub e 19 7 3x2 1S "0" ring seal for crankcase 20 DIN8 35-5S MIOx70 Stud for crankcase 21 DINI37 AIO 10 Lockwash e r 22 DIN934 - 5S MIO 10 Nut for c rank case and cylinder 23 DIN7603 A8xll, 5 Washer for drainage plug 24 DIN933- 5D M8xl58SZ Plug for c r ankcase drainage 25 954x87 26 22Zx366 4 Straight fittin g for fuel pump 27 DIN93 1- 5S M8x60 Screw for crankcase Stud for mounting crankcase 28 582x33 29 DINI37 A8 Main bearing plate fly wheel end 30 DIN931-5D M8x20 Screw for main bearing plate 31 73x219 110" ring seal for crankcase 32 73x217 "0" ring seal for crankcase 4 Lockwasher 33 DIN931-5S MIOxl60 Screw for crankcase 34 549x385 Air guidance tin 35 DINI25 10,5 Plain washer for mounting cylinde r head 36 DIN931-8G M IOx45 Screw for mountin g cylinder head 37 819x77 Screw for mountin g cylinder head and cover for air shroud 38 DIN84-·5S M6xl0 Screw for fixing cover for air shroud 39 SI3x62 Rubber nipple for ground i ng wire 40 8 13 - H Rubber nippl e fo r ignition cable 41 DIN433-St 6,4 Plain washe r c - 15 - FLY WHEEL AND MAGNETO ~~ l}-34 ) ~ 33 ~ 35 \ \ ~i> 2:7-,22 ,, ,, 6 \ 19 25 23 28 -,\1 ~-30 ~29 \,- 31 11 FLY WHEEL AND MAGNETO PARTS LIST ENGINE TYPE 2054-SRB x 18 (AMF ) ~ 4 NOS. QUANT DESIGNATION DESIGNA TION 19 141x234 .05 20 DIN84- 5S M6x12 4 9 . 30 21 DIN137 A6 4 110.00 22 78 7x 160 1. 80 23 141x235 Ignition cab le for cyl. No. 1 24 9Z8 1x1 34 Fly wheel magne to assembly Fan DIN433-St 8 ,4 82x127 Screen for cooling air intake 549x397 Air sh roud 810x2 78 Cov e r for a ir shroud DIN137 A6 Lockwasher .05 DIN933 -5D M6x 12 Sc rew for mounting and air shroud .15 Stud for fixin g air shroud 10 DIN137 A8 Lockwasher 11 DIN934- 5S M8 Nut for fixing air shroud 15 QUANT I .1 5 Plain washer 954x86 14 NOS . Screw for mounting screen Breaker c over 13 ~ DIN 3 16-4D M8x15 287x32 12 PRICE 583x24 1 Fly wheel DIN7976 Bz 4 . 8x 19 S c rew for mounti ng fan Ignition cabl e for cyl. No . 2 Screw for mounti ng fly wheel magneto Lockwasher Marked bushing f or ignition c able No. 1 25 547x6 26 DI N835 - 5D M8x15 27 209x82 Nut for mounting fly wheel 28 141x237 Wire for stop button 29 141x238 Wire for s top button 30 9367x24 Stop button 31 DIN933-5S M3x8 Screw for stop button 32 929x179 Support clip for insulating sheath 33 204211 005 Ignition Coil 34 237 330 037 Condensor 35 217013 006 Contact S e t 4 Stud for fixing ai r shroud 2.30 . 60 .05 . 08 52.00 .15 DIN64-5S M5x15 Screw for fixing armature plate • 15 DIN137 AS Lockwasher .05 16 DIN433 St 5, 3xlO Plain washer .05 17 787xl61 Marked bushing f o r ignition cable No. . 25 18 143x1 60 Insulating sheath 1. 00 - 16 - CRANKSHAFT 2 8 l, 14 CRANKSHAFT PARTS LIST ENGINE TYPE 2054 - SRB x 18 (AMF) ITEM NOS. QUANTITIES DIN73123 - B2 0 4 10 DESIGNATION 6- standard Piston assembl - do - 0 ,2 5 mm 9020x29 9020x29 - R I 9020x29 -R 2 9020x2 9 - R3 9020x29 - R4 -d o - 0.50 mm O· S. - do - 0 .7 5 mm . S. - do - I • 00 rnm O. O . S. S. 4 Retaining ring for piston pin 240xl25 240x 125- RI 240x12 5-R Z 240x1Z5-R3 240x125-R4 Piston rin _ do - O. 25 ~-mS~ndard DIN73121-K D20x14x60 Piston pi n DIN93 1- 5D M8x40 Screw f or r ope starte r sheave DINI 3 7 A8 Lockwasher -do - 0 , 50 mm O· S. -d o- 0 , 75 mm O· S. - do - 1, 00 mm O: ~: 334x92 Rope starter sheave 9002x l 0 Starting rope assembly 9493x80 Oil sea l f .0. and fly whee l OerndcrankShaft, T 3Zlx39 ~hru s t washer for Y whee.l end In . am bearing. II 1212-202 - 109 Cam for break e r contacts 12 9341 xl 44 Main hearin g . fly wheel end 13 DIN6885 St Key for mountin g cam and fly wheel A5x5x30 c 14 9090x72 Crankshaf t assembly 15 934 1x66 Main bearing T . 0 . end 16 321x143 Th ustend wash er for main bea Ting T. rO. . 17 1652xl80 Main bearin g pate, 1 T. O. end 18 DINI37 A8 Lockwasher 19 DIN931 - 5D M8x20 Screw for main b Piston . ea ri ng plate 20 7 32x80 ptn bushing 17 - GENERATOR AND VOLTAGE REGULATOR 4 ) 5 ~J 8 9 r ".. - I I I I :~ \ \ 7 14 8 13 crt 16 12 15 GENERATOR AND VOLTAGE REGULATOR PARTS LIST ENGINE TYPE 2054 - SRB x 18 (AMF) ITEM NOS. QUANTITIES DESIGNATION 9281x1l3 Starter generator assembly DlN9 34- 5S M8 Nut for adjusting strap DlNI37 A8 Lockwasher DlNI25 8,4 Plain washer for adjusting strap 1552x603 Strap (or s tart e r gene rator belt adjustment DlN933 - 5D M8x25 Screw for mounting adjusting strap DlN934 - 5S MIO Nut for fixing starter gene ratar DlNI 3 7 AIO Lockwasher 112x93 Stud for mounting starter gene rator 10 221x149 Driven pulley on sta rte r generator II 332x52 Belt for starter gene rator 12 9448x34 Current voltage regulator assembly 13 889x215 Spacer for mounting s tart er genera - 14 1552x604 Support bracket for starter generator 15 813x49 Rubber hood for cable terminal 16 B13x63 Rubber hood for cable terminal tor -1 8 - MANIFOLD AND MUFFLER c 12 1 ~11 2 I 13 I I I MANIFOLD AND MUFFLER PARTS LIST C ENGINE TYPE 20S4·SRB x 18 (AMF) ITEM NOS. QUANTITIES DESIGNATION 9003x484 Muffle r DIN933 - SD M8x2S Screw for muffler strap 929x246 Muffl er st r ap DIN9 34- M8 Laitan Nut for muffler strap DIN939-SD M8xl8 4 Stud for exhaust pipe 9003 x 48S Pipe nippl e for muffler mounting 7 S9x l82 Ga ske t for pipe nipple for muffler 73xl42 Ga sket for intake manifold 903x301 Intake manifold 10 DIN939-SD M8x2S II DINI3 7 A8 Lockwasher 12 DIN934- SS M8 Nut for intake manifold 13 DIN939- SD M8x 22 Stud fo r intake manifold 14 DINI37 A6 Lockwasher IS DIN9 33 -SS M6x l S Screw for support at carbure t or 4 StUQ for intake manifold c - 19- NOTICE: Parts liste d on this page available from--Tillotson Mfg . Co. -Part s &: Service Di vision- - 761 - 69 Berdan Ave. - - Toledo, Ohio- - or through any Authorized Tillotson Servic e outlet. Ref. No. 1 2 3 4 5 6 7 8 9 10 11 II.) 0 I 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 29 30 31 32 33 34 35 36 37 38 39 40 41 42 4.3 44 45 46 47 48 49 50 51 52 (*) HR-3A Part No. 014387 02531 013737 04784 08805 014359 0143 56 08942 010393 0103 92 058 012473 012475 014402 05322 014319 012930 014230 014229 013335 010098 010530 010529 010527 010571 014321 08793 011428 01,1401 014326 0788 010513 013406 013269 013546 010165 013434 014323 011103 03114 010511 014334 014361 09678 0992 01974 014324 014320 08942 012305 GS-199 RK-756 * * * * * * * * * * * * * * * * * * * * * * * * Part Name Body (Service) Body Channel Welch Plug ( 2) Body Channel Welch Plug Choke Friction Ba ll Choke Fric ti on Spring Choke Shaft & Lever· Choke Shutter Choke Shutter Screw & Lockwasher (2) Choke Wire Connec tion Choke Hire Connection Ret. Clip Choke IHre Ret. Screw Diaphragm Gasket Diaphragm Diaphragm Cover Economiser Check Ball Flange Gasket Fuel Pump Gasket Fuel Pump Diaphragm (Pulse) Fuel Pump Diaphragm (Valve) Fuel Pump Body Fuel Pump Body Screw & Lockwasher (6) Fuel Strainer Screen Fuel Strainer Cover Gasket Fuel Strainer Cover Fuel Strainer Cover Ret. Screw Idle Mixture Screw Idle Mixture Screw Spring Idle Mixture Screw Washer Idle Mixture Screw Packing Idl e Speed Screw Idl e Speed Screw Spring Inlet Contr ol Lever Inlet Control Lever Fulcrum Pin Inl et Control Lever Fulcrum Pin Ret. Screw Inlet Needle, Seat & Gasket Iniet Seat Gasket In le t Tens ion Spring High Speed Mixture Screw High Speed Mixture Screw Spring High Speed Mixture Screw Washer High Speed Mixture Screw Packing Nozz le Check Va l ve Th rottl e Shaft & Leve r Throttle Shaft Clip Throttle Shaft Clip Lockwasher Throttle Shaft Clip Ret. Screw Throttle Shaf t Re turn Spring Throttle Shutter Throttle Shutter Screw & Lockwasher (2) Throttle Wir e Ret . Screw Gasket & Packing Set Repair Parts Kit J..JI 1& -. ---------. II--!>o ~ -:31 ., 3 0 .4P'V /' 2 I lI,g~ 333~:~ ........ II ~ "",~ .... ~ ( \" ···c·'·. L .~\. \. '....:.:. ~ ' I ·:·~·.t-- 1 8 ..I~.'··:5>.1--19 p..J~~}--20 Indicates conten t s of Repair Parts Kit specific ations are subject to change without notice. u ENGINE OPERATING INSTR UCTIONS FOR ENGINE TYPE 2054-SRB x 18 ( A) Do not start this engine until you have carefully read the instructions on opera ting the engine. 1. Fill fuel tank with correct fuel mixture The MAG engine type 2054-SRB is a 2 - stroke engine which runs using a GASOLINE - OIL MIXTURE. During the period of"RUNNING - IN", thatmeansfora period of about 40 HOURS, a gasoline- oil mixture which contains 5% oil, should be used. After this period the proportion of oil should be 4%. c 2. Starting procedure a) Set throttle about l/2 open b) Set choke control into position closed c) Start the engine by operating the starting switch d) After engine starts, open choke fully. Less choking is neces sary in warm weather or when engine is warm than when it is cold. Should flooding occur, open choke fully and continue starting. 3. Warm-up period When starting a gasoline engine, the engine should be allowed to warm up to operating temperature, before the load is applied. This requires only a few minute s of running at moderate speed. Racing an engine or gunning it, to hurry the warm - up period, is very destructive to the polished wearing surfaces on pistons, rings, cylinders, bearings, etc. 4. Running - in period The various wearing surfaces on pistons, rings, cylinders, bearings, etc., in a new engine have not been glazed, as they will be with continued operation, and it is in this period of "R UNNING-IN" that special care must be exercised, otherwise the highly de sired glaze will not be obtained. A new wearing surface that has once been damaged by carelessness will be ruined forever. Therefore, operate the engine at light loads for a period totaling about 40 HOURS, before maximum load is applied. This will greatly increase engine life. c 5. Stop the engine a) Set throttle into idle position. b) Press stop switch and hold it down until engine stops. B) Safety precautions 1. Precaution is the best insurance against an accident. 2. Never fill fuel tank while engine is in oper.ation, to avoid the pos sibility of spilled fuel causing a fire. 3. Never operate engine in a closed building unless the exhaust is piped outside. This exhaust contains carbon monoxide, a poisonous, odorless and invisible gas, which if breathed cause s serious illnes s and possible death. 4. Keep engine clean. This engine is air - cooled. 1£ cooling system becomes clogged, serious damage may result. Therefore, keep the blower screen free from dirt. C) Maintenance adjustments - 21- 1. After the fir st 20 hours of running a) Tighten cylinder head screws to 32 foot pounds torque. b) Tighten fixing nuts and screws for the main parts as follows: - Screws and nuts for crankcase (M8 thread) Screws and nuts for crankcase (MIO thread) Nuts for intake manifold Nuts for exhaust pipe Nuts for air shroud Nuts for carburetor Nuts for cylinder Nuts and screws for starter generator = 18 foot pound s = 32 foot pounds = 18 foot pounds = 18 foot = 18 foot = 18 foot = 32 foot = 18 foot pounds pounds pounds pounds pounds c) Check the tension of the starter generator belt and if necessary adjust it. 2. Every 100 hours of running a) Check the sparkplugs. The spark plug gap should be twenty thousandths (.020) of an inch, and plugs should be kept clean both inside and out. If the porcelain insulator is cracked, replace with a new plug of correct heat range, like BOSCH M225 - T 1, or equal. The thread is 18 millimeters. When mOl.;tnting either old or new plug thoroughly clean threads in cylinder heads before installation. b) Clean the blower screen if dirty. c) Adjust the starter generator belt if it is too unbended. 3. Every 200 hours of running a) Repeat procedures as mentioned under paragraph 2, a, b, c, d, (Every 100 hours of running). b) Breaker points adjustments Magnetos are properly adjusted and timed before leaving the factory. The breaker point gap of BOSCH type 0204402001 should have an opening of .015 inch at full separation. If the spark become s weak after continued operation, itmaybe necessary to re-adjust the breaker points. To do this first remove the cover on the magneto. c) Check carbon brush. Check dynamo if it is worn out and replace if neces sary. d) Removing of the oil carbon Carbon oil is set up at the places as follows - due to the burning of the added lubrication oil in the fueL - in the on the in the in the in the cylinder head pi ston he ad exhaust pipe transfer part exhaust silencer D) TROUBLES CAUSES AND REMEDIES 1. Three prime requisites are es s ential to starting and maintaining satisfactory operation of gasoline engines. They are: - a proper fuel mixture in the cylinder - good compression in the cylinder - good spark, properly timed, to ignite the mixture If all three of these conditions do not exist, the engine cannot be started. As a guide to locating any difficulties which might arise, the following causes are listed under the three headings: Fuel Mixture, Compression and Ignition. -22 - ) In each ca s e the cause s of trouble are given in the order ln which they are :most apt to occu r. In :many cases the re:medy is apparent, and in such c ases no further re:medies are sugge sted. 2. Starting difficultie s / Fuel :mixture - No fuel in tank. Fuel pu:mp diaphrag:m worn out, so pu:mp does not apply carburetor with fuel. Fuel pu:mp diaphrag:m worn out, so pu:mp doe s not supply carburetor with fuel. Carburetor not choked sufficiently, especially if engine is cold. Water, dirt, or gum in gasoline interfering with free flow of fuel to carbure tor. - Poor grade or stale gasoline that will not vaporize sufficiently to fo r m the prope r fuel mixture. - Carburetor flooded, caused by too much choking especially if engine is hot. 3. Compression - If the engine has proper compression, conside r able resistance will be en countered in the pull on the starting sheave. If this resistance is not en counte r ed, compres s ion is faulty. Following are some reasons fo r poor compres sion: - Cylinder dry due to engine having been out of use for some time . - Loose spark plug or broken spark plug. In this case a hissing noise will be heard in cranking engine due to escaping gas mixture on compression stroke. - Damaged cylinder head gasket or loose cylinder head . This will likewi se cause hissing noise on compres si on stroke. - Piston rings stuck in piston due to ca r bon accumulation. If ring s are stuck very tight this will neces sitate removing pistons. S cored cylinder. This will require reboring of the cylinder and fitting with new piston and rings. If scored to o severely an entirely new cylinder may be nec essary. 4. Ignition - Ignition cable disconnected from magneto, coil, or s park plug. - Broken ignition cables, cau sing short circuits. - Ignition cable wet or oil soaked. - 5. Spark plug insulator broken. Spark plug wet or dirty. Spark plug point gap wrong. Condensation on spark plug electrode s . Magneto b reaker points pitted or fused. Magneto breaker arm sticking. Magneto c o ndenser leaking or grounded. Spark timing wrong. Correct timing. 140- . 160 before T. D. C. Engine misses - S p ark plug gap inc o rrect . - Wo rn and leaking ignition cable. - Weak spark. - Loose connections at ignitio n cable. - Magneto breaker points pitted or worn. - Water in gasoline . -23- - Poor compres sion. 6. Engine stops - Fuel tank empty. - Water, dirt or gum ln gasoline. Gasoline vaporized in fuel line s due to exce s si ve heat around engine. - Air vent hole in fuel tank cap plugged. Engine scored or stuck due to lack of oil.