1984 Sprintfire

1984 Sprintfire
J.L-
JOHN DEERE
INTRODUCTION
Read this manual carefully to learn how to operate
and service your snowmobile correctly.
SAFETY
A
This safety alert symbol identifies impor·
tant safety messages in this manual. When
you see this symbol, be alert to the possi·
bility of personal injury, and carefully read
the message that follows.
DIRECTIONS
"Right-hand" and "left-hand" sides are determined
by facing in the direction of forward snowmobile
travel.
The warranty does not cover (a) John Deere
snowmobiles used for competitive racing, altered
for high performance or with high-performance kits;
(b) products which have been altered or modified
in ways not approved by John Deere, including setting fuel delivery above specifications or otherwise
overpowering of products; (c) depreciation or
damage caused by normal wear, accident, lack of
reasonable and necessary maintenance as specified in this manual, improper maintenance, improper protec.tion in storage, or improper use or
abuse; (d) normal maintenance and replacement of
service items such as filters, spark plugs, belts,
brake linings, cutting blades and hoses, unless
such items are defective; (e) transportation, mailing and service call charges for warranty service.
MEASUREMENTS
This operator's manual contains Sl metric
equivalents which follow immediately after the U.S.
customary units of measure.
WARRANTY
Warranty is provided as part of John Deere's support program for customers who operate and maintain their equipment as described in this manual.
MACHINE NUMBERS
Write the Product Identification Number and
Engine Serial Number on the page provided in
Specifications section. Your dealer needs this information when ordering parts.
1
lfECEIV£D $£pi§ 1§§3
Assembly
UNPACK COMPONENTS
1. Skis.
2. Windshield.
3. Operator's manual.
4. Bag of parts.
ASSEMBLE COMPONENTS
Install Skis
1. Remove ski bolts, washers, lock nuts, cotter pins
and rubber ski spring stops from bag of parts.
2. Tip snowmobile on its side and insert bushing
into spindle. Use Never-Seez on bushing.
3. Install rubber ski spring stop over spindle.
4. Position ski over stop.
5. Use two drift punches as shown to align ski with
hole. Remove top drift punch first and install ski
bolt.
6. Install washer and nut. Tighten nut to 39 lb-ft (52
N·m). Install cotter pin.
!<33136
2 Assembly
Install Windshield
1. Remove washers, pan head screws, speed nuts,
and rubber spacers from bag of parts.
2. Install windshield using screws, washers, and
speed nuts. Position each rubber spacer between windshield and tab as shown.
3. Attach hood lanyard cable to screw (A).
M33137
M30888
..
Assembly
PREDELIVERY CHECKLIST
CAUTION: When starting snowmobile, sup·
port machine so track is clear of ground.
Check throttle for proper operation.
1. Align skis and check steering linkage.
2. Check track tension and align.
3. Check brakes. Adjust if necessary.
4. Check adjustment and operation of choke,
throttle and oil injection pump. Bleed line from
oil tank to pump if necessary.
5. Check coolant level. Leave cap off surge tank
and start engine to see if coolant is flowing
through system. A swirling action will be present in tank when coolant is flowing. Stop
engine and replace cap.
6. Start engine and check idle speed.
7. Check speed limiter system.
8. Check emergency stop and key switch.
9. Check operation of all lights.
A. Coolant Temperature Warning Light
1. Remove wiring harness from engine
temperature sender.
2. Use a jumper wire to ground wiring
harness to engine.
3. Start engine and warning light should
light.
4. Reinstall wiring harness to temperature
sender.
B. Oil Level Warning Light
1. Remove oil switch from oil tank.
2. Allow float to bottom out on electrical
terminals.
3. Start engine and warning light should
light.
4. Replace oil switch in oil tank.
10. Aim and adjust headlight.
11. Test drive or dynamometer test snowmobile.
(Do not exceed break-in speed.)
12. Install accessories desired by customer.
3
4
Assembly
DELIVERY CHECKLIST
1. Explain operator's manual to customer.
2. Instruct customer about snowmobile operation.
3. Explain fuel and oil injection system. Use
regular (leaded or un-leaded) gasoline with an
anti-knock index of 87 or higher.
NOTE: Regular (leaded) gasoline is preferred but
unleaded gasoline is acceptable. DO NOT
USE GASOHOL.
4. Explain to ct~stomer the use of pre-mix gasoline
and oil in a 50:1 ratio for the first tank of fuel.
Customer should also fill the oil tank with John
Deere 2-Cycle Oil or a BIA certified 2-cycle
engine oil. After break-in use gasoline only in
fuel tank and a 2-cycle oil in oil tank.
5. Tell customer about 10-hour or 200 mile (322
km) check up.
Break-in Period
\
Do not exceed 30 mph (48 km/h) for the first 100
miles (160 km), or force the machine at full throttle
in deep snow. An occasional short burst of power
on hard-packed snow will not be harmful.
t'
Assembly
5
PERFORM THESE 10 HOUR OR 200 MILE (322 km) CHECKS
The following inspection must be performed on your new John Deere snowmobile. This should be done at approximatelythe first 10 hours or 200 miles (322 km) of operation. It will help assure you of top performance and avoid premature failure of critical components. Your John Deere dealer is qualified to perform this inspection.
Contact your dealer to arrange for an appointment. You are obligated to deliver the snowmobile to the dealer. Any
normal maintenance or repair work required, not covered by warranty, will be charged to you should you decide to
have the work done.
The inspection check list is as follows:
OKAY
NEEDS
REPAIR
1. Track tension.
2. Drive belt, drive, and driven sheaves.
3. Carburetor adjustment.
4. Carburetor mounting hardware.
5. Operation and adjustment of brake, throttle, oil injection pump, and
choke lever controls.
6. Condition of ski wear rods.
7. Suspension hardware.
8. Suspension slide wear bars.
9. Ski alignment.
10. Operation of headlight, stop-taillight, dimmer switch, emergency stop switch,
warning lights and oil level switch.
11 . Engine head bolts and exhaust manifold nuts.
12. Steering component hardware (steering arms, tie rods and handlebars).
13. Coolant level.
DEALER COMMENTS:
DN•r~me ----------------------------------------------------------------Town
~-----------------------------------------------------------------------
1
Contents
Page
Safety ...................................................................... 2
Identification .......................................................... 5
Preparation .............................................................
Filling Fuel Tank ...............................................
Filling Oil Tank ..................................................
Fuel Mix For Break-In Period ..........................
Fuel For Temperatures of
- 20°F (- 29°C} or Below ............................
6
6
6
6
6
Operation ................................................................ 7
Break-In Period .................................................. 7
Before Operating ............................................... 7
Starting Engine .................................................. 7
Emergency Starting .......................................... 8
Stopping Engine ................................................ 8
Lights .................................................................. 9
Clearing Track ................................................... 9
Towing ................................................................. 9
Transporting ..................................................... 10
Dressing For The Weather ............................. 10
Service ..................................................................
Service Interval Chart .....................................
Spark Plugs ......................................................
Carburetor and Oil Injection Pump ..............
Choke System ..............................................
Adjusting Choke Plunger ...........................
Adjusting Throttle Cable ............................
Adjusting Oil Injection Pump ....................
Replacing Carburetor Main Jet .................
Carburetion Recommendations ................
Speed Limiter System ....................................
In-Line Fuel Filter ............................................
Oil Injection Pump ..........................................
Air Intake Silencer ..........................................
Liquid Cooling System ...................................
Draining and Filling System ......................
Drive System ....................................................
Replacing Drive Belt ...................................
Adjusting Brake ...........................................
Slide Suspension .............................................
Replacing Wear Bars ..................................
Adjusting Track Tension ............................
Adjusting Rear Suspension Springs ........
Adjusting Front Suspension Springs .......
11
11
12
13
13
13
14
15
15
16
16
16
17
17
18
18
19
19
20
20
21
21
22
22
Page
Skis .................................................................... 22
Replacing Ski Wear Rods .......................... 22
Replacing Ski Wear Plates ........................ 23
Aligning Skis ................................................ 23
Eliminating Loose Steering ....................... 23
Lighting System .............................................. 24
Adjusting Headlight .................................... 24
Replacing Headlight ................................... 24
Replacing Stop-Taillight ............................. 25
Replacing Oil Level Warning Light .......... 25
Replacing Coolant Temperature
Warning Light .......................................... 25
Tightening Hardware and Components ........... 26
Adjusting Glove Box Door Latch ...................... 26
Storage .................................................................. 27
Trouble Shooting ................................................. 28
Specifications ...................................................... 30
Accessories .......................................................... 32
•
Safety
CAUTION: Improper use or maintenance by
the operator can result in injury. Follow
these safety suggestions.
Preparation
Before starting the engine, read your operator's manual from oover to oover. Knowledge can prevent
accidents.
•
A/ways operate your throttle and brake oontrols several
times before you start the engine. Stuck or frozen rontrots oould cause serious injury or damage.
Know your oontrols. Learn how to stop in an emergency.
Know your state, provincial, federal and local laws pertaining to snowmobiling. Respect property of others.
Don't spoil this fine winter sport by creating a bad
image.
Never add fuel when smoking or while engine is running. Use a safe gasoline oontainer. Always use fresh,
clean fuel of the proper mixture. See page 6.
M23365
Wear clothing designed for snowmobiling . . . avoid
frostbite. Never wear scarves, loose belts, or clothes
that oould catch on moving parts or tree limbs.
Always wear eye and headgear protection to guard
against injury.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear earplugs or any suitable
hearing protective device that is oomfortable when
wearing a snowmobile helmet to protect against objectionable or unoomfortable loud noises. Always wear an
approved helmet to guard against head injury.
.
Avoid sun blindness. Wear properly tinted goggles or
face shield. Never wear yellow eye protection in the
bright sun.
Do not allow anyone to operate snowmobile without
proper instructions. Take proper precautions before allowing young operators to drive.
Always use the "buddy" system. Remember you can
drive farther in 30 minutes than you can walk in a day.
Carry adequate tools and repair items for emergency
field repairs.
Don't overload your snowmobile ... use sleds to carry
provisions.
•
)
Safety 3
Always carry emergency survival supplies when going
on long trips. Let friends and relatives know your destination and expected arrival time.
Operation
Give complete and undivided attention to your snowmobile ... don't be a show-off.
Do not operate snowmobile in crowded areas or steer
the machine toward persons.
Do not operate snowmobile too dose to avalanche
areas, or on other unsafe terrain where spills could
occur.
Observe all state, provincial, federal and local regulations, especially those with regard to operating on
streets and highways.
MZ!t2t
When crossing highways (where permitted by law}
always stop, look both directions, and cross at a 90-degree angle. Post guards when crossing in groups.
Do not operate snowmobiles on or near railroad
tracks. Trains cannot always be heard above sound of
snowmobile engine ... it is difficult to escape from between tracks.
Skiers and snowmobiles don't mix on the same hillsides. Avoid ski slopes.
Never operate snowmobile on rivers or lakes without
first chect<ing thickness of ice. If you go through the ice,
don't panic. Conserve energy.
Never operate snowmobile at night without lights.
Keep headlight and taillight areas free of snow.
Keep all shields in place ... all guards and protective
hoods.
Never open new trails at night. Follow established
trails. Unseen barbed wire or guy wires can cause serious injury or death.
Always use both hands for steering.
Avoid operating snowmobile at excessive speed. Always be aware of terrain.
If throttle sticks, don't panic. Turn emergency stop
switch on the right-hand handlebar. See page 8.
Always allow adequate stopping distance based on
ground cover conditions. Remember, ice requires a
greater stopping distance. To avoid skidding, don't apply brakes rapidly on ice.
Ice or hard surfaces do not provide the same stability
as snow. Drive slower on these surfaces. Do not accelerate rapidly.
M2J 366
4
'
Safety
Be sure tool box lid is closed at all times. An open lid
could cause interference with steering or possible contact with the throttle lever producing unexpected
acceleration.
Do not speed through wooded areas. Hidden obstruc-
.~
tions, hanging limbs, unseen ditches, and even wild animals can cause accidents.
Do not tailgate when riding trails. Rear end collisions
can cause injury and machine damage.
Don't mix alcoholic beverages with snowmobiling.
Keep feet on footrests at all times. Do not permit them to
hang over sides. Do not attempt to stabilize machine
with feet when making turns or in near-spill situations.
Broken limbs could result.
()
Select a riding position suited to the terrain upon which
you're operating. Do not stand on seat, stunt, or showoff.
Do not jump snowmobile. Operator injury or machine
damage could result.
Keep hands and feet out of the track area ... be especially careful when freeing your snowmobile from deep
snow.
When towing a sled, use a solid towbar. Do not use
ropes or other flexible tow straps. See page 9.
Observe fuel supply regularly. Do not travel farther than
your fuel will permit you to return.
Remove key from switch whenever you leave your
machine unattended.
Never drive your snowmobile onto a tilt-bed trailer.
Winch it on.
Always secure snowmobile firmly to trailer. Be sure
trailer lights are operative.
Maintenance and Storage
Check over your snowmobile regularly. This will prevent
many problems from occurring.
I·
J
Do not attempt to make repairs to your snowmobile
While engine is running.
Keep matches away and do not smoke while filling the
fuel tank. Avoid possible explosions.
Check skis and steering components frequently to see
they are in good condition. Keep all hardware tight.
Never lift the rear of the snowmobile to dear the track.
Chunks of ice or rocks may be thrown rearward. Tilt
machine on one footrest when clearing track ... and
keep all persons dear of area. Keep hands and feet
clear of track.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
M22122
M221ZI
0
5
Identification
A -shock Abeorbers
B-8kla
C -front Bumper
D-Hoocl
E-Headllght
F -Wlndahleld
0-Brake Control
H-8eat
I -Rear Bumper
J -Tract(
K-Pan
L --8kJ Spring
M33171
A-snow Flap
B -Rear Bumper
C -s1op·Taillight
D-8eat
E -fuel Tank
F -Throttle Control
G-Hood
H -Sid Handle
I -ski
J -Recoil Start
K --s.rtal Number
L-Trad(
M33172
Preparation
~~
I
FILLING FUEL TANK
IMPORTANT: Use regular leaded or un-leaded
gasoline with an anti-knock index of
87 or higher. Never use gasoline
that has been stored for a long time.
M33173
NOTE: Regular gasoline is preferred but un-leaded
gasoline is acceptable. DO NOT use
gasoline-alcohol mixtures, such as
gasohol, or ethynol·blend gasoline.
NOTE: When running snowmobile in powder snow or
blowing snow add gasoline de-icer to the fuel
tank. Use ONLY 8 ounces (0.24 L) per tank of
fuel. Fuel tank holds approximately 5 U.S.
gallons (18.9 L).
~
-
r
J
CAUTION: Excessive amounts of gasoline
de-Icer will lean out the fuel mixture and
could cause engine damage.
FILLING OIL TANK
NEVER ALLOW OIL TANK TO BECOME EMPTY. Use
John Deere 2-cycle oil or a BIA approved 2-cycle
engine oil. Oil tank holds approximately 5.0 U.S. pints
(2.4 L). Refill tank immediately when oil level warning light is on.
IMPORTANT: If other than John Deere 2-cycle ollls
used, It must meet BIA (Boating Industry Association) test quallflcatlonTCW.
Never use dirty or contaminated oil.
The oil and oil tank must remain
clean to avoid oil Injection pump failure and engine damage.
i
II
v
FUEL MIX FOR BREAK-IN PERIOD
For the first tank of fuel, pre-mix gasoline and oil In a
50:1 ratio (1 pint of oil with 6 U.S. or 5 Imperial gallons)
and fill fuel tank. Fill the oil tank with John Deere 2-cycle
oil or its equivalent.
•
After the break-in period, use ONLY GASOLINE in the
fuel tank and John Deere 2-cyde oil or its equivalent in
the oil tank.
FUEL FOR TEMPERATURES OF - 200F (- 29°C) OR BELOW
IMPORTANT: Use a 50:1 gasoline and oil pre-mix In
the fuel tank and fill the oil tank with
2-cycle oil. DO NOT use straight gasoline In the fuel tank. The oil Injection
system may not function efficiently
at - 20'"F (-29"C) and this could
cause engine failure.
l
7
Operation
BREAK-IN PERIOD
Do not exceed 30 mph (48 km/h) for the first 100
miles (160 km) or force the machine at full throttle
in deep snow. An occasional short burst of power
on hard-packed snow will not be harmful. Operating
snowmobile above 40°F (5°C) may result in hard
starting or reduced performance, especially at high
altitude.
BEFORE OPERATING
1. Clean windshield with a damp cloth. Do not use gasoline, solvents, or abrasive cleansers.
2. Check skis, wear rods, and all steering components.
Check steering for a full right and left-hand turn.
3. Check track for proper tension.
4. Check fuel and oil levels. Oil level must be checked
each time that fuel is added.
5. Check throttle and brake controls for free operation
and proper adjustment.
6. Start engine and test operation of emergency stop
switch, key switch, headlight dimmer switch, headlight, and stop-tailight.
STARTING ENGINE
A
CAUTION: Be sure area In front of machine
Ia clear. Be prepared to apply brake to prevent snowmobile movement.
With no choke and no throttle, pull recoil start
handle to turn engine over two or three times.
Flip choke lever straight up (normal position) in
extremely cold weather, flip choke over center
all the way (richer position).
Emergency stop switch must be in center
position.
Insert key and turn key switch "ON." DO NOT
open throttle lever.
Pull recoil start rope.
When engine starts, allow it to run briefly before
closing choke.
a
1.
2.
3.
4.
5.
6.
If engine becomes "flooded," close the choke.
Hold the throttle in wide open position. Pull start
rope until engine "pops." Release throttle. Pull
recoil start rope until engine starts.
NOTE: Remove and dry spark plugs if engine is extremely flooded.
IMPORTANT: DO NOT permit engine to Idle for
long Intervals. Shut engine off whenever you atop.
M33174
8 Operation
Warm Starting
With emergency stop switch in center position and key
swtich "ON," pull recoil start rope.
NOTE: DO NOT use choke and open throttle slightly.
EMERGENCY STARTING
1. Raise the hood.
NOTE: Leave belt guard in place. Do not raise or re-
move it:
2. Push secondary clutch in slightly to relieve belttenslon. This allows for easier starting.
3. Wind rope counterclockwise around dutch.
CAUTION: DO NOT wind rope .-ound your
hand. Use "T' handle from tool kit. When
starting engine, use a aharp, crt.p pull on
rope ao rope comea free of dutch. DO NOT
allow rope to become tangled In drive belt
when engine etarta.
4. Keep all people clear of snowmobile when starting
engine with emergency start procedure.
A CAUTION: Knotted end of rope comea free
. . of clutch when rope Ia pulled. Knotted end
could anap Into a bystanders face and
cause pereonalln)ury.
STOP ENGINE
1. Release throttle lever.
2. Apply brake.
3. Turn emergency stop switch up or down.
4. Before restarting, stop switch must be turned to
the center position. Always check stop switch
before attempting to start engine.
5. Turn key switch "O FF". Remove key when leaving machine unattended.
r\
\.. ) 1
.....
Operation 9
LIGHTS
NOTE: The lights are automatically "ON" whenever
the engine is running
1. Stoplight comes on when brake is applied.
2. Push dimmer switch rearward for low beam.
3. Push dimmer switch forward for high beam.
NOTE: If one filament of bulb fails, the other beam can
still be used. See page 24 for adjusting headlight and changing bulbs.
CLEARING TRACK
1. Clear track after operating in slushy snow.
2. Tip machine on its side until track clears the ground.
3. Spin track at moderate speed until snow and ice are
thrown clear.
A CAUTION: Be sure no one Is behind
. . machine when clearing track. Injury could
result from Ice or rocks thrown from track.
IMPORTANT: If track freezes, free the track manually. Do not use the engine to break
track loose because It will burn and
damage the drive belt.
TOWING
CAUTION: Always use a solid tow bar when
possible. Flexible ropes or pull straps do
not allow for control on turns or when
stopping.
1. Remove drive belt.
2. Connect only one ski of disabled machine to the tow
machine.
3. DO NOT use rear bumper for towing.
4. When towing with a rope or strap run o:>pe through
ski handle and around spindle. Do not loop rope or
strap through both skis, as this may damage the
steering tie rod.
10 Operation
TRANSPORTING
When transporting snowmobile on a trailer. close the
fuel shut-off valve to prevent flooding of the engine.
DRESSING FOR THE WEATHER
\
1. To be safe from frostbite, dress for the wind and
weather.
2. Wear protective clothing and accessories.
3. The chart provides a guide and illustrates the danger zones.
CAUTION: Always wear a snowmobile helmet with face shield or goggles. The helmet
provides both warmth and protection
against head Injury.
WIND CHILL CHART
l!h
ESTIMATED
WIND SPEED
IN MPH
ACTUAL THERMOMETER READING (°F.)
50
40
30
-30
-40
-50
20~.·30
20
10
-10
0
-20
-60
EQUIVALENT TEMPERATURE (°F.)
calm
50
40
30
5
48
37
27
16
-40
-50
-60
6
-5
-15
-26
-36
-47
-57
-68
10
40
28
16
4
-9
-21
-33
-46
-58
-70
-83
-95
15
36
22
9
-5
-18
-36
-45
-58
-72
-85
-99
-112
20
32
18
4
-10
-25
-39
-53
-67
-82
-96
-110
-124
0
-15
-29
-44
-59
-74
-88
-104
-118
-133
13
-2
-18
-33
-48
-63
-79
-94
-109
-125
-140
27
11
-4
-20
-35
-49
-67
-82
-98
-113
-129
-145
26
10
-6
-21
-37
-53
-69
-85
-100
-116
-132
-148
25
30 1S
30
28
35
40
(Wond speeds
greaterthan
40mph have
hltleaddotoonal effect.)
-
-- -
UTILE
DANGER
INCREASING
DANGER
(for properly clothed
person)
Danger from freezong of exposed flesh
-
GREAT
DANGER
Ml0123
M10123
""
w,
11
Service
SERVICE INTERVAL CHART
Every
As
Needed
Item
Clean windshield
150
Dally
Miles
Every
300
Miles
Annually
Page
7
X
Check coolant level.
X
18
Check condition of skis and steering.
X
22, 23
Check track condition and tension
X
21
Check throttle oontrol operation.
X
13, 14
Check operation of brakes.
X
20
Check emergency stop and key switches.
X
8
Check lighting system.
X
9
See your John
Check ooolant temperature warning light.
X
Deere Dealer
Check oil level warning light.
X
Deere Dealer
Check oil injection pump drive belt.
X
See your John
Deere Dealer
Check oil injection pump and cable.
X
15
Check in-line fuel filter.
X
16
X
17
See your John
Check in-line oil filter.
X
Check drive belt oondition.
X
19
Check carburetor adjustments.
X
X
X
14, 15
Check choke adjustments.
X
X
X
13
Check ski alignment.
X
23
Check headlight adjustment.
X
24
Check ski wear rods and wear plate.
X
X
22, 23
Check slide suspension wear bars.
X
X
21
·x
15
X
26
Service drive and driven sheaves.
X
19
Store snowmobile properly.
X
27
Oil throttle cable.
Check all oomponents for oondition and
tightness.
.
<:
.-
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-----1
12 Service
SPARK PLUGS
NOTE: Spark plugs are Champion QN-2
(John Deere Part No. AM55044).
Removing Spark Plugs
CAUTION: High-energy Ignition systems
can produce Injurious electrical shock.
Stop engine and remove key before work·
lng on Ignition.
1. Stop engine.
2. Pull connectors from plugs.
IMPORTANT: Do nut pull on wire to remove connectors. Pull on connectors only.
3. Remove plugs.
Checking for Spark
A CAUTION: Do not hold the plug or plug wire
. . In your hand when checking for spark. High·
energy Ignition systems can produce In·
jurlous electrical shock. DO NOT remove
plugs from engine for this test. If crankcase
Is full of fuel and engine Is turned over,
gasoline may spew out spark plug hole,
causing a fire hazard.
1. Reconnect spark plug wire to a spare plug .
2. Lay plug on the engine
3. Pull the recoil start rope and check for spark.
New plugs are gapped at 0.025 inch (0.635 mm). The
gap will widen in proportion to the hours and miles of
use. When plug gap reaches 0.045 inch (1.143 mm) or if
plug malfuntions, replace it.
IMPORTANT: Do not regap the plug, always replace It!
Plug Appearance
PosalbleCeUM
Tan or Cocoa Brown
Proper fuel mixture, good
combustion.
Black or Sooty
Fuel mixture too rich, poor
combustion.
White or Light Tan
Fuel mixture too lean, hot
combustion.
NOTE: Replace plug if appearance is abnormal, engine starts hard or malfunctions.
Installing Spark Plugs
1. Clean plug seating surface on cylinder head.
2. Install plugs and torque to 20 ft-lbs (27N·m).
3. Install spark plug wires.
NOTE: See page 30 for spark plug recommendation.
Service
13
CARBURETOR AND OIL INJECTION PUMP
IMPORTANT: Do not run engine when adjusting
carburetor.
The carburetor is a float-type, fixed main jet carburetor.
The float in the fuel bowl maintains a constant fuel level
in the bowl. The fixed main jet eliminates high-speed
adjustments. Altitude and temperature variations may
require carburetor changes and adjustments.
Choke System
A separate metered choke system is used. The system
is opened and closed by a choke plunger. Do not open
the throttle when starting the engine, otherwise the fuelair mixture will be too lean for starting.
Adjusting Choke Plunger
1. Remove air intake silencer.
2. Place choke lever down (closed).
3. Look in choke plunger hole In carburetor throat.
Plunger should be all the way down in bore.
4. Loosen jam nut securing adjusting sleeve to
brass choke adapter.
5. Turn adjusting sleeve clockwise to move
plunger down.
6. Tighten jam nut tight against brass choke
adapter.
7. Start and warm up engine until it idles smoothly.
Do not run at idle for more than 5 minutes.
8. Insert a 0.030 inch (0.762 mm) feeler gauge between choke lever and dash. This indicates freeplay and should not affect idle.
9. Flip choke lever up to first position and the
engine should stop. This indicates the choke is
operating properly.
M30900
I \
~----1
14 Service
Adjusting Throttle Cable
1. Remove air intake silencer.
2. Tape throttle lever tight against handgrip.
3. Place your finger in carburetor throat. Loosen
jam nut and turn adjusting sleeve clockwise (in)
until the backside of throttle valve is flush with
the inside of bore. Tighten jam nut.
NOTE: When throttle valve is adjusted correctly, no
part of the valve will restrict air flow through
the carburetor.
4. Turn the idle adjusting screw counterclockwise
until the screw tip is flush with inside of bore.
5. Remove tape from throttle lever and allow throttle valve to fully seat in bore.
d
I
6. Turn idle adjusting screw clockwise until the
screw contacts the throttle valve. When screw
contacts valve, the valve will begin to rise. Turn
idle adjusting screw two additional turns
clockwise. This gives a preliminary idle speed
setting.
7. Look in throat of carburetor and slowly compress throttle lever on handgrip. Throttle valve
should begin to rise, if not repeat steps 2, 3 and
4.
8. Carefully turn pilot air screw clockwise (in) until a slight seating resistance is felt.
9. Turn pilot air screw counterclockwise (out) 1-112
turns.
Service 15
Adjusting Oil Injection Pump
IMPORTANT: Adjust the oil injection pump lever
to move at exactly the same time
that the carburetor throttle valve
starts to move. Never run the engine
without oil supply to the oil pump,
even If premix is used. If oil pump
runs dry, pump failure will result.
t
I
1. Loosen jam nuts (A} of oil injection pump cable.
Back sleeve (B) out to tighten cable or in to
loosen cable.
2. Adjust cable so straight edge of oil pump con·
trol arm aligns with vertical mark on oil pump
body. Tighten jam nut.
3. Press throttle lever on handgrip and observe
throttle valve and oil injection pump control
lever. Both should start to move at exactly the
same time.
IMPORTANT: Lubricate throttle cable once each
season with LPS or WD-40. Hold the
throttle lever against the handgrlp
and allow lubricant to run down
cable. DO NOT use engine oil or
silicone spray. These lubricants
may destroy the plastic com·
ponents of the throttle cable or
cause control cable to become
sticky In cold temperatures.
Replacing Carburetor Main Jet
1. Remove throttle valve assembly from top of
carburetor.
2. Loosen clamp securing carburetor to intake
manifold.
3. Loosen clamp securing intake silencer boot to
carburetor.
4. Turn carburetor 90 degrees.
A CAUTION: Fuel In carburetor float bowl
. . drains out when hex. plug Is removed. Place
sufficient material under carburetor to soak
up spilled fuel, when plug Is removed. Avoid
fires due to smoking or careless
maintenance practices.
5. Use a 17 mm wrench to remove hex. plug from
bottom of carburetor.
6. Replace main jet.
7. Reverse procedure to install carburetor.
II
16 Service
CARBURETION RECOMMENDATIONS
Sea Level to
4000 Feet
(1219 m)
Temperature
Below 0°F
( -18°C}
Above 0°F
( -18°C)
All
Temperatures
4000 to 8000
Feet
(1219 to 2438 m)
8000 Feet
and Above
(2438 m)
Component
Main Jet
175
155
135
Main Jet
165
145
125
6DH4·2
(159) P-4
2.5
30
1·3/4 Turns
Open
6DH4·2
(159} P-4
2.5
35
1·112 Turns
Open
6DH4·2
(159) P-4
2.5
30
1·112 Turns
Open
2000·21 00 rpm
2400·2500 rpm
2400·2500 rpm
Jet Needle
Needle Jet
Throttle Valve
Pilot Jet
Air Screw
Idle Speed
SPEED LIMITER SYSTEM
The function of the speed limiter system can be
checked by holding the throttle lever pin rearward
and pressing the throttle lever slowly. If the system
is functioning correctly, the engine will "miss" or
"cut out" at 2800 to 3000 rpm.
The speed limiter system provides two types of pro·
tection; it limits engine speed to 2800 to 3000 rpm
if the throttle lever is released and the carburetor
slides stick open and it limits maximum engine
speed to 6700 to 7300 rpm in the event of a broken
belt at wide open throttle.
IN-LINE FUEL FILTER
Change the filter annually.
Service
IN-LINE OIL FILTER
Replace oil filter annually or immediately if oil level in
tank does not drop.
OIL INJECTION PUMP
Check oil injection pump (A) oil flow annually. See
your John Deere dealer for this service.
AIR INTAKE SILENCER
The first indication of trash in the silencer will be loss of
power and performance. The engine will run "rich" because adequate air will not be mixing with the fuel.
1. Remove silencer screen.
2. Shake or blow out the screen to remove any trash.
3. Install silencer screen.
IMPORTANT: DO NOT run engine with air Intake
silencer removed.
17
"'
I,
!I
18 Service
II
LIQUID COOLING SYSTEM
The liquid cooling system is pressurized. A heat exchanger is located in the tunnel . Snow against the exchanger cools the system.
I
~..
\!-)
A warning light is incorporated in the system and
will turn on if the temperature reaches 205°F
(96°C). The radiator cap releases pressure at 12 to
13 psi (82.7 to 89.6 kPa) allowing the cooling system
to overflow.
t
IMPORTANT: Running on hard-packed snow or Ice
or pulling loads may cause overheatIng. If coolant temperature warning
light goes on, reduce load and Immediately run In loose snow or shut off
engine.
During the initial break-in period, operate the snowmobile for five minutes. Allow the engine to cool slightly
before opening the surge tank cap to check coolant level. Coolant level should be one inch below the filler
neck. Capacity of the system is approximately 5 quarts
(4.7L).
If coolant is lower than two inches below filler neck,
coolant must be added. Use a 50-50 solution of ethylene glycol anti-freeze and water. DO NOT use any anti-freeze containing a radiator stop-leak. NEVER add
radiator stop-leak to the cooling system.
IMPORTANT: DO NOT exceed the recommended
50-50 solution. Never add anti-freeze
to fill the system until after checking
the solution with a hydrometer. A 5050 solution should give approximately a -40"F ( -40"C) reading.
Check solution when engine Is completely warmed up.
Draining and Filling System
Draining System (2 Year Intervals Only)
1. Remove drain screw and pressure cap.
2. Remove lower hose from heat exchanger.
3. Raise rear of snowmobile slightly to drain system.
Replace drain screw and lower hose.
I
IJ
4. Wash engine and compartment with clean water.
M29122
(,
~
Service
19
Filling System
1. Connect lower hose to heat exchanger and replace
drain screw.
2. Position snowmobile on a level surface.
3. Fill the system with a 50-50 solution of ethylene glycol anti-freeze and water to bottom of filler neck on
surge tank. System capacity is approximately 5 U.S.
quarts (4.7 L).
4. Check all hose connections for leaks.
5. Block up track so engine can be run safely. Start engine and check for coolant flowing in system. There
will be a swirling action in the top of the surge tank
when coolant is flowing. Install pressure cap.
DRIVE SYSTEM
Replacing Drive Belt
The drive belt should be replaced if its width is reduced
by 1/8 inch (3.18 mm). A narrow belt reduces snowmobile top speed. Correct width is 1-1/4 inches (31.75
mm).
If drive belt wears rapidly, drive and driven sheaves
may be out of alignment. See your John Deere dealer.
'
I
A belt worn narrow in one area is caused by trying to
free a frozen track with the engine. Free a frozen track
manually before starting engine.
A
a
CAUTION: Keep fingers out of area between
driven sheave halves. If driven sheave
sticks, use care In opening It to prevent
hand from being pinched.
1. Push in on center of driven sheave and lift belt up
and over sheave half.
2. Remove belt from drive sheave.
IMPORTANT: Never pry belt over sheaves.
3. Install belt in reverse sequence. Always install belt
so that number on belt can be read when viewed
from left-hand side of snowmobile.
NOTE: As belt wear increases or if belt stretches, remove "anti-creep" shims (A) from behind retaining washer (8). When new belt is installed,
replace shims. Torque cap screw to 20 ft-lbs
(27 Nm). After installing a new belt, if snowmobile has a tendency to creep at idle speed, add
a shim.
M29124
A-Anti-Creep Shims
B-Retalnlng Washer
20 Service
Adjusting Brake
1. Apply the brake control lever and measure the distance from the lever to the hand grip. It should be 1 to
1-1/2 inches (25 to 38 mm).
1-1-1/2"(25-38 mnJ.)
M30912
2. Adjust brake by loosening jam nut (A) and tightening
adjusting screw (B). Tighten jam nut.
A CAUTION: NO NOT adjust jam nuts on
. . brake cable.
3. Check brake tension.
4. Readjust if necessary.
NOTE: Be certain dowel on end of brake cable is
seated properly in recess of brake control/ever.
A-Jam Nut
8--Ad)uatlng Screw
5. After brake adjustment, check operation of stoplight
switch. If stoplight does not work, check for a defective switch.
SLIDE SUSPENSION
The slide suspension system requires lubrication between the plastic wear bar and the track grouser bar.
The absence of lubrication (snow or water) causes the
plastic wear bar to wear rapidly and in severe cases,literally melt away.
,.
;. .,...
,
.
Operation of the snowmobile under the following conditions should be avoided.
1. Dirt
2. Rocks
3. Sand
4. Grass
5. Bare Pavement
6. Snow permeated with dirt and sand.
7. Glare ice surfaces
IMPORTANT: When running on Ice or hard pack
snow at high-speed, the wear bars
will heat up. Either reduce speed, or
frequently atop and apply Ice or
snow to the track to lubricate the
wear bars.
(
Service 21
Replacing Wear Bars
When running in marginal snow conditions, check wear
bars daily.
1. Tip snowmobile on its side.
2. Check wear bars in several places for cracks, thin
areas and sand or gravel imbedded in the bar.
NOTE: Sand or gravel imbedded in the wear bars acts
as an abrasive and will destroy the steel grouser bars in the track.
3. If any of these conditions exist, see your John Deere
dealer for wear bar replacement.
Adjusting Track Tension
Check track tension and alignment frequently. A loose
track causes excessive slap and could damage the
track, tunnel or slide assembly. A tight track requires
additional power to operate.
1. Suspend or support snowmobile so track is clear of
ground.
2. Loosen rear idler wheels through bolt.
3. Loosen jam nuts (A) on track adjusting screws (B).
4. Turn adjusting screws (B) to tension track.
5. Measure below the lower shock absorber mount for
clearance of flush to 1/4 inch (6.35 mm) between
track and slide wear bar. Both sides should be
equal. Tighten jam nuts.
6. Tighten rear idler wheels through bolt to 25 ft-lbs (34
N·m).
After Adjustment
1. Start engine and allow the track to rotate slowly several times. Shut off engine and allow track to coast to
a stop. DO NOT APPLY BRAKE TO STOP TRACK.
A
a
CAUTION: Do not stand behind snowmobile
when track Is running.
2. Check alignment. Rear idler wheels should run in
center of drive lugs.
3. Slide rail wear bar should be in middle of each slide
rail opening of track.
4. If either Step 2 or 3 indicates a need for adjustment,
repeatthe procedure.
NOTE: Track will run to the loose side. If track is too far
to the left, tighten the left adjusting screw to
move the track to the right.
M30914
A· Jam Nut
8 · Adjusting Screw
C · Through Bolt
24 Service
LIGHTING SYSTEM
~~==-========-====~
24 - 3/4"
(628 111ll)
f.
M29136
Adjusting Headlight
1. Position snowmobile on a flat surface with the headlight 25 feet (7.6 meters) from a vertical surface.
2. Have operator on seat and headlight on HIGH
beam. Light beam centerline should be straight
ahead and 24-3/4 inches (628 mm) above ground
level.
3. Loosen or tighten the two left-hand adjusting screws
to raise or lower the light beam.
4. Loosen or tighten the right-hand adjusting screw to
move the light beam right or left.
M33177
Replacing Headlight
1. Disconnect wiring harness from light bulb.
2. Push and turn bulb counterclockwise to remove
bulb.
3. Install new bulb in opposite sequence.
IMPORTANT: Be sure bulb locking tabs match
slots.
4. Connect wiring harness to light bulb.
1.129130
Service 25
Replacing Stop-Taillight Bulb
1. Remove lens.
2. Push and turn bulb counterclockwise to remove it.
3. Install new bulb in opposite sequence.
IMPORTANT: Be sure bulb locking tabs match
slots.
Ml0919
Replacing Oil Level Warning Light
1. Pull the plastic bulb socket out of backside of the instrument console.
2. Push and turn bulb counterclockwise to remove bulb
from socket.
3. Install new bulb in opposite sequence.
NOTE: Do not damage light bulb during disassembly
and assembly of socket from instrument
console.
Replacing Coolant Temperature Warning
Light
1. Pull the plastic bulb socket out of backside of the instrument console.
2. Push and turn bulb counterclockwise to remove bulb
from socket.
3. Install new bulb in opposite sequence.
NOTE: Do not damage light bulb during disassembly
and assembly of socket from instrument
console.
M29133
26 Service
TIGHTENING HARDWARE AND COMPONENTS
M33178
\
Check hardware and components for tightness, wear
and damage on a yearly basis. Replace any parts that
are questionable.
A CAUTION: Worn, bent or damaged ski and
. . steering components are unsafe.
1. Wear rod nuts.
2. Ski bolts.
3. Steering arm bolts.
4. Tie rod end bolts.
5. Drive shaft bearing cap screws.
6. Driven sheave cap screw.
7. Muffler spring.
8. Throttle and choke cables.
9.1ntake manifold nuts.
10. Carburetor attachment.
11. Engine mounting bolts.
12. Drive sheave cap screw.
13. Suspension cap screws.
14. Shock absorber screws.
Adjusting Glove Box Door Latch
1. Open glove box door.
2. Loosen screws and
backward.
3. Tighten screws.
M29135
move latch forward
or
27
a
Storage
PLACE SNOWMOBILE IN STORAGE
1. Thoroughly clean snowmobile.
2. Polish hood, pan and tunnel with automotive-type
wax. Use upholstery cleaner on seat. Touch up all
bare metal parts with paint.
3. Check cap screws and oomponents for tightness.
Order any new parts required
IMPORTANT: Use John Deere Gasoline Storage
Stabilizer (TY6295) or equivalent In
the fuel tank. Gasoline storage stabl·
llzer should always be used when
storing the snowmobile to prevent
carburetor varnishing and partial
plugging of carburetor jets. Either of
these conditions could cause the engine to run lean and result In piston
seizure and engine failure.
4. Replace in-line fuel filter.
5. Remove spark plugs and add one teaspoon of
2-cycle oil in each cylinder. Pull recoil start rope six
or seven times to lubricate cylinder walls. Replace
plugs.
6. Remove drive belt and ooat drive and driven
sheaves with light grease.
7. Support snowmobile so track is dear of ground.
Loosen track adjusting screws.
8. Place oover on snowmobile and store inside.
REMOVE SNOWMOBILE FROM STORAGE
1. Wipe grease from drive and driven sheaves. Install
drive belt.
2. Fill fuel tank and oil tank.
3. Check throttle and brake oontrols for proper adjustment and operation.
4. Adjust track tension.
5. Review operating and safety suggestions.
6. Start engine and test operation of all switches and
lights.
7. Ride snowmobile at slow speed until you are sure it
Is operating properly.
I
.....,
a
Trouble Shooting
ENGINE
Engine Starts Hard or Will Not Start
Fuel tank empty.
Emergency stop switch in "STOP" position.
Plugged in-line fuel filter.
Fuel pump malfunctioning.
Faulty ignition system.
Ignition timing Incorrect.
Idle set too high.
Engine Lacks Power or Acceleration
Running on one cylinder.
Throttle cable improperly adjusted.
lmproperfuel mixture.
Carburetor out of adjustment.
Restricted in-line fuel filter.
Ignition timing incorrect.
Center distance between drive and driven sheaves too
short for belt.
Engine Backfires and Runs Unevenly
Ignition timing incorrect.
Too lean fuel mixture
Engine Overheats
Carburetor too "lean".
Intake manifold or carburetor leaking.
lnsuffieient snow for heat exchanger
LIGHTS
Stoplight Not Working
Bulb burned out.
Stoplight switch defective.
Stoplight switch "frozen".
Lights Won't Light
Bulbs burned out.
Loose electrical connections.
Faulty lighting coil.
011 Level Light Not Working
Bulb Burned out.
Sender not working
t
Coolant Temperature Light Not Working
Bulb burned out.
Sender not working.
Trouble Shooting 29
POWER TRAIN AND CHASSIS
Clutch Does Not Disengage
Engine idles too fast.
Faulty clutch.
Short drive belt.
Clutch engages slowly
Faulty clutch.
Stretched or worn drive belt.
Excessive Drive Belt Wear
Freeing frozen track with engine.
Drive and driven sheaves misaligned.
Driving long distances at clutch engagement speed.
Rapid Track Wear
Operating on bare ground.
Track improperly tensioned.
SKIS AND STEERING
Loose Steering
Worn tie rod ends.
Worn spindle bushings.
Poor Maneuverability
Worn ski wear rods.
Loose steering linkage.
a
Specifications
SNOWMOBILE SPECIFICATIONS
Component
Item
Specification
Engine
Manufacturer
Model
Number of Cylinders
Bore
Stroke
Displacement
John Deere "Fireburst"*
TC340E
Two
60 mm
60 mm
339 cc
Fuel System
Carburetor Mfgr.
Carburetor Number
Tank Capacity
Fuel Mixing Ratio
Oil Tank
Mikuni
AM55676
5.0 U.S. gal. (18.9 L) (Approx.)
50:1 See page 6
5.0 U.S. Pints (2.4 L) (Approx.)
Chassis and Tunnel
Material:
Tunnel
Pan
Hood
Windshield
Overall Length
Overall Width
Overall Height
Weight (Approx.)
Aluminum
Thermoplastic Rubber
Sheet Molded Compound
Polycarbonate
98 in. (2489 mm)
37.4 in. (950 mm)
38.0 in. (965 mm)
330 lbs. (150 kg)
Track and Suspension
Suspension Type
Track Material
Track Width
Slide Suspension
Rubber
15 in. (38.1 em)
Power Train
Transmission:
Type
Manufacturer
Primary
Secondary
Final Drive Ratio:
Secondary Clutch
Brake
Drive Belt
.
Electrical System
Spark Plug (Champion)
Spark Plug Gap
Timing
Lighting Coil Capacity
LightBulbs:
Headlight
Stop-Taillight
Speedometer Light
Coolant Light
Oil Level Light
*Manufactured for John Deere by Kawasaki Heavy Industries, Japan
**Manufactured for John Deere by Comet Industries, Richmond, Indiana.
2-Sheave Variable
John Deere (1 02C Comet)**
John Deere
Low-4.5:1, High-1.13:1
Mechanical Disk
M68715
QN-2 (AM55044)
0.025 in. (0.635 mm)
Align Mark on Stator with Mark on
Crankcase
160Watts
AM53887
AM52619
AM52847
AM55550
AM55550
Specifications 31
FUEL AND OIL MIXTURES
CANADA
UNITED STATES
Ratto
011
Leaded Fuel
40:1
1 pt.
(0.473 L)
5gal.
(18.9 L)
50:1
1 pt.
(0.473L)
6gal.
(22.7L)
Ratto
on
Leaded Fuel
40:1
1 u.s. pt.
(0.473L)
41mperial gal.
(18.2 L)
1 Imperial pt.
(0.568L)
51mperial gal.
(22.7 L)
1 u.s. pt.
(0.473 L)
5 Imperial gal.
(22.7 L)
1 Imperial pt.
(0.568L)
6 Imperial gal.
(27.3 L)
50:1
NOTE: United States gallon contains 3.785 liters and the Canadian Imperial gallon contains 4.543 liters
(Specifications and design subject to change without notice.)
When in need of major parts or service, be prepared
to provide your John Deere dealer with both the
product (A) and engine (B) numbers. Record these
numbers in the space below.
This operator's manual is prepared for: John Deere
SPRINTFIRE Snowmobiles (PIN No. MOSPNTX
285001).
JOHN DEERE SPRINTFIRE SNOWMOBILES
Product Identification No.-- - - - - - - Engine Serial No. - - - - - - - - - - -
Product Identification Number
Date of Purchase - - - - - - - - - - (To be filled In by purchaser)
M30887
Engine Serial Number
I
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