Scorpion Whip . Service. Manual Engine Section
Contents
1. 2227 55 zu e ica gt 1 FIG 5 18 EYE BOLTS Remove the two whiz lock screws secur ing the rear suspension plates to the rear axle Release track tension by loosening the two track tension adjusting screws Remove the hex screws and nuts which fasten the rear suspension plates to the rear suspension weldment Remove the rear suspension plates Remove the two whiz lock screws located on the side of the tunnel in front of the footrests which secure the front pivot shaft to the tunnel See Fig 5 7 Remove the Para Slide from the tunnel and track SERVICE MANUAL 1976 SCORPION WHIP TRACK TENSION WHIZ LOCK SCREW REAR SUSPENSION PLATE REAR SUSPENSION WELDMENT HEX SCREW ADJ SCREW FIG 5 19 FIG 5 20 5 13 SERVICE MANUAL 1976 SCORPION WHIP B DISASSEMBLY 1 Bracket axle adjustment Remove the four hex screws and lock nuts which secure the brackets to the rails Springs front suspension Place the suspension flat on the floor Push down on the torque arm weldment until the spring hooks clear the front cross shaft Keeping pressure down on the torque arm with one hand grasp the spring hooks with the other hand and swing the assembly upward so that the hooks clear the cross shaft Torque Arm Weldment Remove the two hex head screws that fasten the torque arm weldment to the rail assembly 5 14 AXLE ADJUSTING BRACKET HEX SCREW2. FIG 3 11 YELLOW REGULATOR CONNECTOR SENSING ELEMENT TRANSISTOR AMPLIFIER MOUNTING VOLTAGE REGULATOR SCHEMATIC BRACKET FIG 3 12 3 6 SERVICE MANUAL 1976 SCOPRION WHIP VOLTAGE REGULATOR CHECKS Resistance across regulator Two most common catastrophic failure modes of the regulator may be identified by simply checking the resistance of the regulator Normal resistance across the regulator is approxi mately 155 160 a Burned out sensing element The symptom of a burned out sensing element is a significantly increased resistance reading Shorted SCR Shorted SCR is characterized by a significantly reduced resistance reading Set point check Use test circuit as shown below Read voltage across regulator Value should 13 8 5V 100W OPEN 120V REGULATOR SET POINT TEST CIRCUIT FIG 3 13 3 7 SERVICE MANUAL 1976 SCOPRION WHIP ELECTRICAL CONTROL AND DISTRIBUTION Functional Description Power is supplied continuously to the brake light switch so that any time power is being generated the brake light will go on if the brake is applied Power to all the other items is supplied through the ignition switch in the LIGHTS mode HEADLIGHT HARNESS CONNECTOR IGNITION SWITCH CONNECTOR Grounding of the System is accomplished at three VOLTAGE REGULATOR locations CONNECTOR 1 Tothe chassis at the rear end 2 the chassis from wire harness at eng connector
3. FRONT CROSS SHAFT E FIG 5 22 TORQUE ARM WELDMENT FRONT SUSPENSION SPRING 4 Rail Assembly Remove the screws which secure the front cross shaft to the rails Remove the screw which fastens the wear strip to the rail Slide the wear strip off the rear end of the rail C ASSEMBLY 1 Prior to assembly insure that all com ponents are clean and all worn or damaged parts have been replaced 2 Apply a coat of low temperature grease to all shafts prior to assembly use Scor pion clutch lube 906800 3 Reverse procedure as outlined for Disassembly TORQUE REQUIREMENTS FOR ASSEMBLY ARE TORQUE ITEM Screws amp nuts which fasten axle adj brack ets to rails secure torque arm weldment amp cross shafts to rails 50 60 Ft Lbs 15 19 Ft Lbs SERVICE MANUAL 1976 SCORPION WHIP HEX SCREWS FIG 5 23 WEAR STRIP SCREW FRONT CROSS SHAFT 2 See FIG 5 24 WEAR STRIPS TORQUE ARM WELDMENT SERVICE MANUAL 1976 SCORPION WHIP SPECIAL ADJUSTMENTS PARA SLIDE REAR SPRING ADJUSTMENT The rear spring adjustment governs preload and should be correlated with the weight of the rider or riders normally using the machine Too much spring tension will result in a harsh ride and increases the weight carried on the skis thus increasing steering effort Too little spring tension will result in the bot toming out of the suspension a harsh ride and shortene
4. 3 Remove driven unit from chaincase tapping shaft lightly with plastic mallet Remove snap ring and washer from cam top and slide off shaft See Figures 4 13 4 14 4 15 CAM TOP HELICAL RAMP CAM BOTTOM FIG 4 13 FIG 4 15 4 9 SERVICE MANUAL 1976 SCOPRION WHIP 4 Remove key and main spring See Figure 4 16 KEYWAY KEY 5 This should allow cam bottom and movable sheave to be removed as a unit See Figure 4 17 and disassembled if necessary See Figure 4 18 CAM BOTTOM FIG 4 18 4 10 SERVICE MANUAL 1976 SCORPION WHIP 6 Stationary sheave may then be unbolted from clutch shaft See Figures 4 19 and 4 19A and bearings be pressed off if necessary STATIONARY SHEAVE CLUTCH SHAFT FIG 4 19 FIG 4 19 A SERVICE MANUAL 1976 SCORPION WHIP DRIVEN CLUTCH INSPECTION Inspect snap ring groove for wear Inspect Helical ramps for wear and breakage See Fig 4 13 Inspect bronze bushing in cam bottom for any signs of looseness or slippage should be staked in solidly Rotate and check bearings visually Inspect sheaves for cracks particularly around bolt holes Check splines and threads on sprocket side of main shaft for wear crossthreading etc RE ASSEMBLY OF DRIVEN CLUTCH Attach stationary sheave to clutch shaft Assem ble cam bottom and movable then place on shaft followed by the woodruff key and main spring Place cam t
5. CHANNEL SURGE w CHAMBER TO NEEDLE VALVE FIG 2 7 IDLE NEEDLE FUEL ENRICHENER VALVE LEVER IDLE SPEED SCREW FUEL INLET THROTTLE LEVER FIG 2 8 MOUNTING SCREWS 4 2 9 SERVICE MANUAL 1976 SCORPION WHIP MAIN AIR JET Carburetor Reassembly Reassemble in reverse process of disassembly In stall components on top of the carburetor first followed by the float bowl assembly Specific care should be exercised in the following areas a The fuel pump leaf spring should be flat to center between the two castings when seated Carefully position the idle feed tube and tube pressure spring During installation wind the float support spring turn from rest position for correct loading See FIG 2 10 Slide the fuel bowl gently over the point of the idle feed tube A slight tension against the tube pressure spring should be felt just before the bowl seats on its gasket NEEDLE VALVE FIG 2 11 FIG 2 9 FUEL BOWL GASKET FUEL BOWL ASSEMBLY FLOAT SUPPORT SIDLE FUEL FEED TUBE FLOAT VALVE LEVER SERVICE MANUAL 1976 SCORPION WHIP Adjustments BEND THIS LEVER TO ADJUST FLOAT HEIGHT IF NECESSARY 1 IDLE FUEL The idle needle See FIG 2 8 is usually set one 1 turn open The set ting will vary with operator preference or changing conditions 2 HIGH SPEED FUEL The fuel supply is 11 16 limited fixed high speed jet See FIG 2 6
6. Secure case open side up in bench vise Tie a knot at one end of the rope Secure knotted end in the center of reel 2 Pull rope taut and wind entire rope around reel in an anti clockwise direction until the free end protrudes through the notched section of the reel Apply a light film of Lubriplate equivalent to center hub of case and install the reel Push down and rotate reel in an anti clockwise direction until the hook en gages with the free end of main spring Ten sion will be felt when reel and spring are pro perly engaged Fig 1 61 1 62 Rotate reel a maximum of three complete turns in an anti clockwise direction Do not exceed three turns hold reel in this position and feed free end of rope through case at the rope guide hole Install rope guide Loosely knot the rope to prevent recoil Apply a light film of Lubriplate or equivalent to pawls 6 and install them on the reel in the pawl retainers Fig 1 63 See Fig 1 49 for part identification numbers Install cup washer 7 flat side down spring 6 and return spring Ensure that plain end of return spring is properly engaged in the retaining hole in reel hub FIG 1 57 FIG 1 59 9 Install friction plate 5 over reel hub Manipulate plate until eye end of return spring engages and locks crosswise in retaining slot 10 Rotate friction plate until the three notches are aligned with pawls when pawls are at
7. Drive shaft with track drive sprockets The power from the engine is transmitted through this system to the track in sequence of elements listed above to propel the machine The drive clutch belt and driven clutch serve as a torque converter The torque converter on the snowmobile down shifts to a lower ratio as the track load in creases as readily as it up shifts when the track load decreases To accomplish the automatic shifting the movable sheave of the driven clutch is fitted with a helical ramp which is guided by a follower This sheave is con trolled by a spring pre stressed in torsion and compression to hold the sheaves together at the maximum pitch diameter Under acceleration the torque from the engine is greater than the demand from the track The drive clutch then closes forcing the belt outward between the sheaves Belt tension and wedging action is unbalanced at the driven clutch and the sheave faces are wedged open against the helical This action winds up and compresses the spring Under steady running all forces are balanced and the belt chooses a ratio at which this balance exists Under deceleration the driven sheave is stalled slightly which unbalances the forces so that the sheave is forced to a new larger pitch diameter Belt tension is thus increased the wedging action opens drive sheave and a new lower pitch diameter is chosen to again bring all forces to balance 4 2 SERVICE MANUAL 1976 SC
8. Open Circuit Faulty Switch s Separated Connector s Cut Wiring Wiring shorted to ground Damaged Insulation Faulty Regulator Shorted SCR Shorted or open lighting coil Faulty regulator Incorrect regulator set point too low Faulty regulator Incorrect Set Point too high Failed bulb Intermittent short in wire harness 1 Open or shorted windings in ignition coils stator Open or shorted windings in external ignition coil Shorted condenser dirty or worn Damaged burned points BOO OM 1 Burned or fouled plugs 2 See Engine Trouble Shooting Section See Engine Trouble Shooting Section TROUBLE SHOOTING ELECTRICAL REMEDY Repair or replace faulty or damaged element Repair or replace damaged or faulty element Replace regulator Replace armature plate Replace regulator Replace regulator and failed bulbs Replace bulb Repair or replace wire harness 1 Replace armature plate 2 Replace external coil 3 Replace condenser 4 Replace points Replace plugs Determine that correct plugs are being used CHECK ENGINE TROUBLE SHOOTING 1976 Scorpion Whip Service Manual Clutch Drive section SERVICE MANUAL 1976 SCOPRION WHIP DRIVE SYSTEM Functional Description The main elements included in this system are 1 Drive Clutch Drive Belt Driven Clutch Chain Case with sprockets chain and chain tensioners
9. 3 Tothe stator plate on the engine MAIN ELEMENTS 1 Main Wiring Harness HI LO im 2 Seat Wiring Harness BEAM SWITCH ex 3 Taillight Wiring CONNECTOR gt E W 4 Safety Stop Switch SWITCH E Y N gt SEAT HARNESS 5 Break Light Switch CONNECTOR a CONNECTOR 6 Hi Lo Beam Switch 7 Ignition Switch SPEEDOMETER TACHOMETER CONN s ENGINE CONNECTOR SAFETY STOP SWITCH CONNECTOR FIG 3 14 SAFETY STOP SWITCH HARNESS gt HARNESS TAILLIGHT HARNESS HEADLIGHT HARNESS BRAKE LIGHT SWITCH HARNESS FIG 3 15 6 8 SAFETY STOP de PI RE I SWITCH 000007 LIGHTING COILS IGNITION COIL 2000000 IGNITIO E SWITCH 0000 1 4 HI LO TAILLIGHTS SWITCH VOLTAGE WIRING SCHEMATIC COLOR CODED REGULATOR ELECTRICAL DISTRIBUTION amp CONTROL 1976 LIL WHIP FIG 3 16 diHM NOIdYODS 9461 39235 SERVICE MANUAL 1976 SCOPRION WHIP WIRING CODE ELECTRICAL DISTRIBUTION amp CONTROL COLOR FUNCTION FROM TO Black Black White Green Orange Orange Black Red Tan White Yellow Yellow Black Yellow Red Hot Hot Hot Hot Hot Hot Hot Hi Ground Ground Ground Ground Ground Hot Hot Ground Hot Hot Hot Hot LO Hot Hot Hot Ground Hot Eng Connector Engine Igniti
10. 32 Ft Lb 16 18 Ft Lbs CYLINDER BASE NUTS 16 18 Ft Lbs FLYWHEEL NUT 44 50 Ft Lbs INTAKE MANIFOLD NUTS 16 18 Ft Lbs FAN HOUSING SCREWS 16 18 Ft Lbs FAN WHEEL NUT 22 24 Ft Lbs RING GEAR SCREWS 6mm 6 7 Ft Lbs RING GEAR SCREWS 8mm 10 12 Ft Lbs Tightening Sequence for Cylinder Base Nuts All Models C G 2 PTO SIDE Tightening Sequence for Cylinder Head Nuts Fan Housing Ring Gear Flange Intake Manifold and Recoil Starter Clamps SERVICE MANUAL 1976 SCORPION WHIP CUYUNA TWIN CYLINDER ENGINE 3 d MODELS 2F 400 8 2 440 9 DISASSEMBLY A Recoil Starter Remove four 4 screws holding the recoil assembly to the fan housing See Fig 1 4 See pages 1 28 A B C for recoil starter disassembly B Lower Fan Pulley and Carrier Assembly FIG 1 5 Remove the three 3 hex head bolts on the carrier Remove carrier lower pulley assembly and V belt See Figs 1 5 1 6 FIG 1 6 SERVICE MANUAL 1976 SCORPION WHIP Upper Fan Belt Pulley Assembly Insert a 3 16 drill or a suitable punch through the indexing hole into the im peller body With a 17 mm socket wrench remove the fan nut lock washer pulley halves and spacers See Figs 1 7 1 8 1 9 FIG 1 9 SERVICE MANUAL 1976 SCOPRION WHIP FIG 1 12 NOTE It is important that care be taken in Flywheel Magneto Remove the crankshaft nut using a 27 mm socket w
11. 6 Tighten engine mounting to engine support bolts 7 Water in gas 7 Add carburetor de ice fluid as required SERVICE MANUAL 1976 SCORPION WHIP TROUBLE SHOOTING CHART TROUBLE PROBABLE CAUSE REMEDY Won t start kicks back 1 Spark plug wires reversed 1 Install wire correctly and backfires 2 Flywheel key missing or 2 Replace key sheared 3 Faulty condenser 3 Replace condenser 4 Improper timing 4 Re time engine 5 Faulty breaker points 5 Adjust or replace points 6 Unhooked spark retarding 6 Reconnect mechanism or mechanism or spring replace spring broken No acceleration low 1 Spark plugs improperly 1 Clean adjust or install new top R P M hard to gapped or dirty plugs start 2 Magneto breaker points 2 Clean adjust install new improperly gapped or points dirty 3 Faulty coil or condenser 3 Replace coil or condenser 4 Loose or broken magneto 4 or replace magneto wires wires 5 Blown head gasket 5 Replace head gasket 6 Float lever adjustment too 6 Refer to high Carburetor Section 7 Crankcase leaking 7 Install new seal 8 Main high speed jet too rich 8 Change jet Good spark but 1 Leaking cylinder head 1 Check head for warps cracks engine runs on one Install new gasket and cylinder 2 Magneto wires broken cylinder head inside coil ground 2 Repair or replace wires broken 3 Cracked cylinder wall 3 Replace faulty cylinder 4 Defective sp
12. Fig 1 36 With the use of a ring compressor lower cylinders one at a time over the pistons Install base washers and nuts finger tight See Fig 1 37 1 38 Temporarily install the intake manifold without gaskets and tighten manifold nuts to sixteen 16 to eighteen 18 foot pounds See Fig 1 39 Cylinder base nuts may now be torqued to sixteen 16 to eighteen 18 foot pounds as outlined on specification page The proper piston height can be measured at the top of the cylinder The edge of the crown of the piston must not protrude above the top of the cylinder with the piston in the top dead center position the piston does protrude above the cylinder a thicker base gasket must be used See specification page for dimensions and color coding It is important that only one cylinder at a time be adjusted or crankcase will separate and lose it s seal FIG 1 38 1 20 SERVICE MANUAL 1976 SCORPION WHIP Oil cylinders and pistons before installing cylinder heads Install head gaskets with the wide side of inner metal flange of the gaskets up toward the cylinder heads Torque cylinder head nuts to sixteen 16 to eighteen 18 foot pounds See Fig 1 40 NOTE The head gasket for the 400 cc engine has an additional hole in it to dis tinquish it from the 440 cc gasket FIG 1 39 FIG 1 40 1 21 SERVICE MANUAL 1976 SCORPION WHIP D Fan Housing and Impeller Bearings Clean fan shaft hub Instal
13. S RE n ra D M e rt ME 3 22 n E I de T 7 a 1 m T oe ie y Li 4 tis i vU A va NN FIG 2 3 SERVICE MANUAL 1976 SCORPION WHIP High Speed Circuit 1o a SEDE ITUR vA A Ki L p 1 T 5 Pe l Throttle Valve Valve is wide open to allow full air and fuel flow metered to control top engine speed 2 Main Fuel Nozzle As the throttle opens air velocity increases through the venturi and the resultant vacuum draws fuel from the main nozzle FIG 2 4 3 High Speed Fixed Jet Fuel is fed to the fixed jet hole from the bowl reservoir The hole may be varied in size by exchanging the jet on which sizes are stamped Larger engines require larger jet holes for greater fuel con sumption Too large creates a rich mixture too small a dangerous lean mixture Note High altitudes require a smaller jet to compensate for the thinner air Note Air Intake Silencer Regulations re quire the noise created by air rushing into the carburetor be reduced to a minimum WF models are finely calibrated in tune with original equipment Silencers both Intake and Exhaust Anytime the characteristics of either are changed or removed a risk of burning out an engine exists and Warranty is void 2 7 SERVICE MANUAL 1976 SCORPION WHIP Carburetor Disassembly Fuel Pump and
14. The jets are available in TA y a d various sizes and the optimum size used will depend upon temperature altitude etc A smaller jet permits less fuel flow 4 gt 22 po scio RIMIS 7 22 PAMO 2 xy 3 FLOAT With fuel bowl removed and float assembly in place turn the body casting upside down so that float assem bly is at top Sight along uppermost sur face of float and adjust by bending metering lever so that top surface of float is 1 1 16 above body casting sur face See FIG 2 12 Adjustment may also be accomplished using the special tool available for this purpose See FIG 2 13 IDLE FUEL FEED TUBE FLOAT ADJUSTMENT GAUGE FIG 2 13 2 11 a e d 1976 scorpion Whip Service Manual Electrical Section SERVICE MANUAL 1976 SCORPION WHIP ELECTRICAL SYSTEM Hy White System is divided LIGHTING COILS Power Generation B Ignition C Voltage Regulation D Electrical Control and Distribution POWER GENERATION Functional Description Electrical AC power used for lighting and tacho meter operation is generated by rotating a per manently magnetized flywhee around two sta tionary coils 1 120 watt and 1 23 no load voltage increases with engine RPM and could reach 32 volts RMS To maintain the voltage at the required system level 13 14 volts an external voltage regu
15. compressed fuel air mix ture burns and expands thereby forcing the piston downward on a power stroke FIG 1 1 As the downward stroke of the piston turns the crankshaft it also starts to compress the fuel air mixture in the crankcase simultaneously opens the exhaust port and closes the intake port See Figs 1 1 B amp C After the exhaust port is fully open and the take port is fully closed further piston travel starts to open the transfer ports The com pressed fuel air mixture from the crankcase then travels up the transfer ports and into the combustion area After most of the burned exhaust gases have left the cylinder an incoming charge of fuel air mixture scavenges the combustion area giving it a fresh charge and the cycle is then repeated See Fig 1 1 D Because lubrication is dependent on the mixing of oil and fuel it is extremely important that good quality oil and gasoline properly mixed The proper ratio of oil to gasoline will prevent possible engine overheating piston or cylinder scoring or eventual engine seizure Too much oil and not enough gasoline can lead to incomplete combustion fouled plugs carbon build up and muffler clogging SERVICE MANUAL 1976 SCORPION WHIP SERVICE MANUAL 1976 SCOPRION WHIP EXHAUST SYSTEMS SELECTION Selection of an exhaust system including exhaust manifold intermediate pipes elbows and muffler is a result of thorough test procedures i
16. inlet check valve Section 2 Fuel enrichening valve not 2 Ensure enrichening valve is not pulled up to start pulled up 3 Spark plugs improperly 3 Remove plugs Clean adjust or gapped dirty or broken install new plugs 4 Magneto breaker points 4 Clean adjust or replace improperly gapped or dirty points 5 Head gasket blown orleaking 5 Replace gasket 6 Empty gas tank or improper 6 Refill tank with specified tuel mixture fuel oil mixture 7 Water in fuel system 7 Drain fuel from carburetor Add carburetor de icer as re quired to fuel 8 Weak coil or condenser 8 Replace faulty coil or condenser 9 Obstructed fuel system 9 Disconnect fuel lines Clear obstruction Flush system Con nect fuel lines 1 33 SERVICE MANUAL 1976 SCORPION WHIP TROUBLE Impossible to adjust idle Missing at low speed or won t idle smoothly or slowly Missing at high speed or intermittent spark 10 12 13 1 C2 TROUBLE SHOOTING CHART PROBABLE CAUSE Air leak in crankcase or inlet system Primary wire broken Engine not timed properly Secondary wire not connected or spark plug protector not installed properly Spark retarding mechanism not working properly Pistons or rings worn Faulty carburetor Incorrect carburetor idle adjustment Spark plugs improperly gapped or dirty Head gasket blown or leaking Loose or broke
17. lean Adjust carburetor Refer to 2 Leaking gasket flange Carburetor Section 3 Inlet control level set too low 4 Pulsation line obstructed 5 Fuel pump not supplying enough fuel due to 1 Punctured diaphragm 2 Inoperative inlet check valve 6 Crankcase not properly 6 Reseal crankcase sealed 7 Idle or main carburetor 7 Refer to Carburetor nozzle obstructed Section 8 Fuel line obstructed 8 Remove fuel line Clear obstruction Replace line 9 Carburetor inlet needle and 9 Refer to Carburetor seat obstructed Section Overheating 1 Carburetor too lean 1 and 2 Adjust carburetor 9 Carburetor too rich Refer to Carburetor Section 3 Incorrect timing 3 Retime engine to Specifica fions 4 Too much carbon 4 Remove cylinder heads Clean top of pistons and inside compression chamber Clean out exhaust port 5 Spark plug too hot 5 Install specified spark plugs 6 Engine fan belt loose or 6 Replace or adjust broken 7 Air leak in manifold 7 Tighten nuts or change gaskets 8 Crankcase seal leaking 8 Fit new seal Vibrates excessively 1 Idle needle or high speed 1 to 4 Adjust needle or change or runs rough and carburetor jet too rich jet Refer to Carburetor Sec smokes 2 Enrichening valve not operot tion ing properly bent linkage 3 Float lever too high car buretor floods 4 Air bleed plugged 5 obstructed 5 Check and clear muffler 6 Engine not secured tightly
18. 1976 Scorpion Whip Service Manual Engine Section SERVICE MANUAL 1976 SCORPION WHIP ENGINE SYSTEM Functional Description 2 CYCLE ENGINE FUNDAMENTALS The Cuyuna 2 cycle air cooled gasoline engine particularly the axial fan cooled twin cylinder engine has become very popular today for snowmobiles It is uniquely qualified for this ap plication because of its high power output light weight and ease of lubrication with fewer moving parts than other conventional 2 cycle and 4 cycle engines INTAKE However in order to get the best possible use and ensure that it retains its high degree of dependability and endurance it must receive proper care and maintenance Therefore it is necessary for us to know something about the basic fundamentals of this engine and how it functions ee OPERATION The Cuyuna 2 cycle Twin Cylinder engine is of the loop scavenged third port type the most widely used design today uses a mixture of xi UST gasoline oil and air for combustion lubrication and cooling It fires on every stroke of each piston There are two power strokes for every revolution of the crankshaft As the piston moves upward in the cylinder it draws the fuel air mixture into the crankcase through the intake manifold while at the same time compressing fuel that has been forced into the combustion chamber See Fig 1 1A TRANSFER As the piston nears top dead center the spark plug is fired and the
19. Gaskets m Remove four 4 mounting screws See FIG 2 5 Lay out parts in sequence shown in FIG 2 6 Do not remove rubber fuel pump valves unless replacements are available Inspect all parts openings needles valves valve seats and any other func tioning part for clogging or damage See Fig 2 7 Clean parts with a mild solvent or regular fuel mixture Repair or replace parts as necessary AIR JET HIGH SPEED FUEL JET gt MOUNTING SCREWS 4 Fuel pump cover assembly Fuel pump leaf spring Pump gasket Pump diaphragm Fuel pump body assembly Surge chamber diaphragm Surge chamber gasket Throttle bracket plate Fuel pump to body gasket Idle Fuel feed tube Also see FIG 2 13 Carburetor body assembly with float bowl assembly IDLE FUEL FEED TUBE FUEL CHANNEL 3 A INLET SURGE CHAMBER PART THROTTLE HOLES ENRICHENER PORT Fuel Bowl and Gasket 1 Remove four 4 mounting screws See FIG 2 8 Lay out parts sequentially as shown in FIG 2 9 Check all parts openings valves valve seats and other functioning parts for clogging or damage Clean repair and replace as necessary Clean parts with a mild solvent or regular fuel mixture Clean all sediment from the bottom of the bowl Remove the main jet and idle feed tube Blow air through the idle feed circuitry and main air bleed circuit SERVICE MANUAL 1976 SCOPRION WHIP
20. ICE MANUAL 1976 SCORPION WHIP Rotate flywheel counterclockwise to top dead center and adjust dial to zero Place selector knob on ohmmeter to R x 1 Ohm meter needle will indicate a closed circuit See Fig 1 67 Move the centrifugal weights in flywheel to the full advanced position See Fig 1 68 1 68 Rotate flywheel counterclockwise com plete revolution to between 102 and 112 See Fig 1 69 FIG 1 69 1 31 SERVICE MANUAL 1976 SCORPION WHIP At this point the breaker points for No 1 cylinder should open Break contact This will show on the ohmmeter Needle will move to the left If this does not occur the ar mature plate needs adjusting This is ac complished by loosening the hold down screws and turning plate either left or right while observing needle action With proper positioning needle should move to left with slight movement of armature plate and flicker back with opposite plate movement Tighten hold down screws securely Re check procedure See Fig 1 70 Nees NOTE FIG 1 70 Fig 1 70 flywheel has been removed for clarity of illustration E Remove dial indicator assembly and install in No 2 cylinder fan side See Fig 1 71 Attach positive lead of ohmmeter to No 2 cylinder terminal in connector housing Rotate flywheel counterclockwise to top dead center Set dial indicator to zero Again move centrifugal weights in flywheel to full advance
21. N WHIP REAR SUSPENSION 5 Remove the two whiz lock screws securing the rear suspension plates to the rear axle 6 Release the track tension by loosening the two screws TRACK TENSIONING res Pe 7 Remove hex screws and nuts SCREW on the two suspension plates See Fig 5 6 Remove plates REAR SUSPENSION IG 5 6 PLATES 5 4 8 Remove the two whiz lock screws located on the side of the tunnel in front of the footrests Para Rail now removed from the track and tunnel B DISASSEMBLY 1 Bracket axle adjustment Remove the four 4 hex screws and lock nuts SERVICE MANUAL 1976 SCORPION WHIP WHIZ LOCK SCREWS D a wr 7 7 a FIG 5 7 HEX SCREWS FIG 5 8 AXLE ADJUSTING BRACKET 5 5 SERVICE MANUAL 1976 SCORPION WHIP 2 Front Suspension Springs Place suspension on the floor and install spring release tool FRONT SUSPENSION SPRINGS To release the springs from the spools the rear of Para Rail Snowmobile Suspen sion must be held down while downward pressure is applied with the right arm and upward pressure with the left arm 3 Linkage Arm Remove the two screws and washers Remove the two button head screws and spring retainers SPRING RETAINER LINKAGE ARM FIG 5 11 5 6 SERVICE MANUAL 1976 SCORPION WHIP BOGEY WHEEL SHAFT Bogey Wheel Remove the shaft This will allow the bogey wheel tube spacer
22. ORPION WHIP DRIVE CLUTCH DISASSEMBLY 1 Raise hood and clutch guard See Figure 4 1 2 Remove clutch attaching bolt and bell re taining bolt Use impact wrench capable of 75 or more ft lbs torque In the field alternate method may be used Making sure ignition is off run engine up on compression using 34 socket and ratchet Strike ratchet with plastic or rubber mallet See Figure 4 2 3 Remove bell housing See Figure 4 3 FIG 4 3 4 3 SERVICE MANUAL 1976 SCORPION WHIP 4 Movable sheave should slide off spline easily Next remove spring and retainer See Figure 4 4 5 Remove snap ring retainer and idler bearing if necessary See Figures 4 5 and 4 6 4 4 FIG 4 6 6 If necessary to remove stationary sheave in sert plug 2 13 16 long x 3 4 diameter in stationary center hole and re insert bell retainer bolt Tightening bell bolt will force stationary off crankshaft See Figure 4 7 7 Removing torque plug retainer will allow torque plug to be removed and inspected See Figure 4 8 SERVICE MANUAL 1976 SCORPION WHIP 4 5 SERVICE MANUAL 1976 SCORPION WHIP 8 Detaching springs and weight arm retainers will allow weight arms to be removed See Figures 4 9 4 10 4 11 DRIVE CLUTCH INSPECTION Inspect weight arm bushings and rollers for cracks and flat spots Also check snap rings on weight arm shaft ends Inspect torque plug for fit and wear Should have n
23. P FUNCTIONAL DESCRIPTION The four main elements of a snowmobile suspen sion are 1 Skis 2 Track Suspension 3 Seat 4 Operator All elements work together to perform the sus pension functions to the optimum degree The suspensions are basically designed to 1 2 3 4 Protect the operator from physical abuse or injury Keep the operator from being ejected from his operating position and controls Prevent damage to the machine Increase ground contact and improve trac tion The 1976 Whip suspension a single unit working as a whole as opposed to the multiple unit bogey suspension is provided in two types 5 2 The Para Rail amp Snowmobile Suspension which has the advantage of being able to traverse marginal snow conditions without damaging effects and The Para Slide T M which with flat track surface and system openness is especially suited for deep snow and side hill operation SERVICE MANUAL 1976 SCORPION WHIP SUSPENSION SYSTEM Para Rail A REMOVAL 1 Raise and block rear of vehicle off the ground 2 Remove the two hex cap screws and washers which secure the rear suspension mounting shaft to the tunnel 3 Drop the back end of the suspension and FIG 5 1 track from the tunnel 4 Remove nuts from the two eyebolts NOTE In Figs 5 3 through 5 6 the track has been removed for clarity of illustration FIG 5 3 5 3 SERVICE MANUAL 1976 SCORPIO
24. ark plug 4 sean adjust or install new plug 5 Breaker points improperly 5 Re adjust points gapped 6 Crankcase seal leaking 6 Install new seal acceleration Idles 1 Low speed needle set too 1 6 6 well but dies down lean Adjust carburetor when put to full 2 Dirt behind needle and seat Refer to Carburetor throttle 3 High speed jet obstructed Section 4 Float lever set too low 5 Silencer obstructed 6 Fuel pump not supplying enough fuel due to 1 Punctured diaphragm 2 Non functioning check valves 7 Fuel line obstructed 7 Remove fuel line Clear obstruction Replace line 8 Not enough oil in gas 8 Refuel using specified fuel oil mixture 9 Breaker points improperly 9 Adjust clean or install new gapped or dirty points 10 Engine improperly timed 10 Re time engine to specifica 1 36 tions SERVICE MANUAL 1976 SCORPION WHIP TROUBLE SHOOTING CHART TROUBLE PROBABLE CAUSE REMEDY No power under 1 Magneto breaker points 1 Clean adjust or install new heavy load improperly gapped or points dirty 2 Ignition timing too far 2 Adjust timing advanced 3 Magneto coil plate loose 3 Check magneto and secure coil plate Cranks over 1 Scored piston 1 Replace faulty piston extremely easy on 2 Blown head gasket 2 Replace head gasket one or both cylinders 3 Loose spark plug 3 Check plug for security Loss of compression 4 Head bolts not tight 4 Torque head bolts
25. ces fuel into throttle bore through or more openings depending the operational phase of the engine 2 2 The function of each element of the carburetor is described below See Fig 2 1 14 15 16 SERVICE MANUAL 1976 SCORPION WHIP Engine Impulse Actuates fuel pump diaphragm with alternating pressure vacuum pulses from engine revolutions Fuel Pump Diaphragm Fluctuates in response to engine impulse Draws fuel into surge chamber with upward vacuum stroke of engine piston Pushes fuel with pressure downward stroke of engine piston through outlet check valve Fuel Inlet Fitting Fuel drawn through line from tank Fuel Channel Fuel is routed into surge chamber Surge Chamber Fuel accumulates waiting for inlet check valve to open for passage at engine piston down stroke Surge Diaphragm Reciprocates with pump diaphragm balancing to at mospheric pressure cushions pulsations Leaf Spring Assists pump diaphragm when engine impulses are weak at starting and idle circuits Inlet Check Valve When opened by engine vacuum allows fuel passage from surge chamber into pump chamber feeding to outlet check valve Outlet Check Valve Opened by engine pressure pulse forcing fuel down through inlet valve needle passage Fuel Channel Routes fuel to inlet needle valve Filter Screen Fuel is filtered before fed into inlet needle valve Cleanse screen when servicing by flushing or air strea
26. chain Loosen locking collars on front drive bearings see Fig 4 21 Remove speedometer drive adaptor and flanges Slide drive shaft through chaincase mounting hole until right side clears main frame and remove It is necessary to detach forward end of pararail to gain clearance for entire removal of front drive shaft See Sus pension Section REMOVAL OF FRONT DRIVE SPROCKET Punch out spirol pins see Fig 4 21 4 22 Then taking care to see that the shaft is clean slide sprockets off To reassemble reverse procedure 4 14 LOCKING COLLARS oe SPIROL PIN FIG 4 2 SERVICE MANUAL 1976 SCORPION WHIP SPIROL PINS FIG 4 22 BEARING COLLAR O RING BEARING FLANGES Inspection of Drive Shaft Observe shaft for signs of stress cracks and ben ding check bearings and collars for breakage Check sprockets for loosening of pin holes NOTE Small cracks in the white material of the drive sprocket are not signs of failure but a result of shrinkage during manufacture SERVICE MANUAL 1976 SCORPION WHIP TROUBLE SHOOTING The operating diameter of the drive and driven clutch governs the ratio of reduction or ad vantage in the snowmobile drive train Therefore to gain maximum performance and economy these areas cannot be overlooked The following are some symptoms causes and cures fo aid trouble shooting the clutch drive system TROUBLE Engine Overspeed Excessive vibratio
27. components See Figs 1 30 Placement of the upper crankcase half may now be made Be certain that the center seal is lined up with the crankcase split line Tap upper crankcase half to seat with lower alf SERVICE MANUAL 1976 SCORPION WHIP AP 2mm 1 4 T gt j EM BEARING yak FIG 1 28 L SEAL BEARING FIG 1 29 SERVICE MANUAL 1976 SCORPION WHIP Install two crankcase holding bolts in the center holes of the PTO side of crankcase Fig 1 31 Tighten finger tight C Piston Cylinder and Cylinder Heads FIG 1 31 The pistons must be clean and free from car bon deposits and the piston rings must fit freely in their grooves Rings are marked for proper side up The arrow on the crown of pistons must point toward exhaust side of engine Piston pins needle bearings check plates and circlips may now be installed ac cording to the procedure below Always use new circlips See Figs 1 32 1 33 1 34 1 35 CIRCLIP OPENING HERE FIG 1 33 SERVICE MANUAL 1976 SCORPION WHIP Oil the piston pin end bearings Install one circlip in piston Heat the piston sufficiently to allow pin to push into piston and install pin Install second circlip See Fig 1 33 for correct orientation of circlips FIG 1 34 SERVICE MANUAL 1976 SCORPION WHIP Install base gaskets on the cylinder studs and position against the cylinder flanges see
28. d life to the suspension components will occur 1 The proper spring tension may be obtained by having the rider s sit on the machine in the normal sitting position and measure the distance between the floor and the bottom of the running board at the rear of the machine either side This measurement must be 47 106 2 adjust loosen the nuts on the eye bolts and adjust accordingly making certain that each spring is tightened or loosened the same amount 3 Repeat Step 1 and tighten the nuts on the eye bolts securely when the 4 to 6 measurement is attained ADJUSTING NUTS EYE BOLT NOTE When 300 165 combin ed passenger weight is norm 1T ally carried machine a heavy duty spring kit should be installed on machine This kit is available at your Scorpion Distributor as accessory item FIG 5 25 TRACK TENSION ADJUSTMENT Proper track tension is extremely important to assure long life of all associated components and efficiency of the track drive system The track tension should be checked at the following intervals f When the machine is new dealer preparation After the first 10 hours Every 30 days or 200 miles of operation At the start of each snow season The following procedure applies to all Slide r equipped Scorpion snowmobiles P The track should be at room temperature or should have been recently run to
29. d position Rotate flywheel coun terclockwise while watching dial indicator The needle must make one full revolution and stop at between 102 and 112 At this point needle should move to left indicating point contact open If this does not occur points need slight adjustment Re check procedure FIG 1 71 1 32 SERVICE MANUAL 1976 SCORPION WHIP TROUBLE SHOOTING CHART _ TROUBLE Manual starter rope comes out but pawls PROBABLE CAUSE Lack of friction plate return spring action REMEDY Check friction plate return spring Replace as required don t engage 2 Defective pawls 2 Check for broken bent pawls Replace pawls as re quired Manual starter rope Recoil spring broken or 1 Replace spring doesn t return bent 2 Pulley housing warped or 2 Replace housing bent 3 Starting pulley worn 3 Replace pulley Electric starter 1 Loose electrical 1 Retighten connections inoperative connections 2 Poor ground 2 Secure ground connection 3 Faulty battery or circuits 3 Check recharge or replace battery 4 Faulty electric starter 4 Check starter solenoid Repair or replace 5 Inspect starter motor for evidence of moisture and broken or worn brushes Dry out as necessary 6 Check starter switch Replace if required 7 Check harness or connector tor broken wire Repair or re place Hard to start or 1 Inoperative diaphragm or 1 Refer to Carburetor won t start
30. e flow can be ad justed by the Fuel Idle Needle SERVICE MANUAL 1976 SCORPION WHIP Part Throttle Circuit 2 6 Throttle Valve Fuel is being fed through idle circuit As the Throttle Valve is opened a series of three holes is ex posed progressively offering smooth ac celeration as they increase fuel flow Part Throttle Holes Three holes are skillfully located and carefully sized to feed measured fuel drawn by vacuum as each hole is allowed to flow with opening of the Throttle Valve Venturi This acts as a restriction to the air rushing through the carburetor bore into the engine to fill the vacuum left by the piston movement As the air velocity increases at the venturi the pressure is dropped according to the degree Throt tle Valve is opened As the Part Throttle holes are exposed to the drop pressure fuel rushes in to help bring the air pressure up The Idle Feed hole con tinues to flow for the same reason Air is also fed by the Idle Air Vent Jet affecting the vacuum which lifts fuel up the feed tube A smaller jet delivers less air and therefore a richer mixture especially at early part throttle i p __ _ a E CN NR GE wee M 522 i Ve gt mi VNLT BE cH Ne Qe AA T pibus ert AER FULL a c x es sci y x Ex a 4 P Ta a a F m gt
31. ent governs preload and should be correlated with the weight of the rider or riders normally using the machine Too much spring tension will result in a harsh ride and increases the weight carried on the skis thus increasing steering effort Too little spring tension will result in the bot toming out of the suspension a harsh ride and shortened life to the suspension components will occur 1 The proper spring tension may be obtained by having the rider s sit on the machine in the normal sitting position and measure the distance between the floor and the bottom of the running board at the rear of the machine either side This measurement must be 45 106 2 To adjust loosen the nuts on the eye bolts and adjust accordingly making certain that each spring is tightened or loosened the same amount 3 Repeat Step 1 and tighten the nuts on the eye bolts securely when the 4 to 6 measurement is attained NOTE When 300 lbs combined passenger weight is normally carried on machine a heavy duty spring kit should be installed on machine This kit is available at your Scorpion Distributor as an accessory item 5 9 SERVICE MANUAL 1976 SCORPION WHIP TRACK TENSION ADJUSTMENT Proper track tension is extremely important to assure long life of all associated com ponents and efficiency of the track drive system The track tension should be checked at the following intervals 1 When the machine is new deale
32. he crankcase will separate and the crankcase may be removed See Fig 1 24 FIG 1 24 SERVICE MANUAL 1976 SCOPRION WHIP L Crankshaft Bearings To remove crankshaft end bearings use FIG 1 25 bearing puller 444 31 807 0 See Figs 1 25 1 26 1 27 Slip the puller half shells around the outer bearing race and around puller assembly Slide the retaining ring over the half shells Using two 2 27 mm wrenches turn the center bolt clockwise with one wrench and use the second wrench to hold the puller body Before removing the PTO side crankshaft bearing insert a 1 2 20 UNF bolt 1 2 long to protect the internal thread of the crankshaft 2 E a 5 FIG 1 26 3 fir ET FIG 1 27 1 16 ASSEMBLY A Crankshaft Bearings Heat crankshaft bearings in oil or oven to approximately 180 degrees Slide bearing on crankshaft Crankcase Inspect and clean both halves of crankcase The proper sealant material such as Per matex Hy Tack Spray should be now sprayed on crankcase sealing surfaces See Fig 1 29 Before installing crankshaft into crankcase lower half of it will be necessary that all bearing outer surfaces be wiped clean of foreign material so that proper sealing will occur installing PTO thrust washer and oil seal inside groove of oil seal coated with light grease place the crankshaft carefully into the lower crankcase half and properly position all
33. l circlips and spacer Use grease to hold spacer in place Pack bearings in medium grease into housing with sealed surface outward See Figs 1 18 1 19 Install fan and shaft E Fan Housing and Armature Plate Install new seal in fan housing Lubricate the j inner groove of the oil seal with a light 7 grease See Fig 1 38 Install new o ring and apply sealant material around o ring surface see Fig 1 41 Install the armature plate wires through hole in fan 4 housing and install armature plate with hold 9 down screws washers and lockwashers See Fig 1 39 Place fan housing assembly over crankshaft and position to crankcase assembly Install the four Allen head screws and lockwashers and tighten evenly until fan housing is against crankcase assembly See Fig 1 40 e FIG 1 39 1 22 Torque to sixteen 16 to eighteen 18 foot pounds Connect ignition wires to external ignition coil and to connector housing Check ground wires for proper position Install ignition cable bracket to fan housing Intake Manifold Install spacers gaskets and intake manifold Fig 1 44 Torque nuts evenly to sixteen 16 to 18 foot pounds Upper Fan Pulley Assembly Install the tapered washer Install pulley half shims second pulley half tapered washer lock washer and nut Use 3 16 drill bit or punch to hold fan assembly and tighten nut See Fig 1 45 Flywheel Assembly Check advance mechanism f
34. lable the following procedure may be employed to achieve track tension 1 The track should at room temperature or should have been recently run to remove any stiffness caused by cold weather 2 Elevate the rear of the machine 3 Apply ten 10 Ibs of force or weight evenly distributed across the track under both bogey wheels located on the third bogey axle ahead of the rear idler wheels 4 To make adjustment loosen the lock nuts the track adjustment bolts as well as the rear suspension mounting screws rear of tunnel just below seat and either tighten or loosen the adjustment bolts to achieve the 14 inch clearance between track and bogey wheels 5 Remove ten 10 lbs force or weight and retighten the lock nuts on the track ad justment bolts as well as the rear suspen sion mounting screws SERVICE MANUAL 1976 SCORPION WHIP 5 11 SERVICE MANUAL 1976 SCORPION WHIP SUSPENSION SYSTEM PARA SLIDE T M pem CAP SCREWS l Raise and block the rear end of the 4 i d 3 4 vehicle off the ground Remove the two cap screws and washers which secure the rear suspension moun ting shaft to the tunnel Drop the back end of the suspension and track from the tunnel Remove nuts from the two eye bolts 5 T FIG 5 17 NOTE In Fig 5 19 and 5 10 the track has been removed for clarity of illustration NUTS REAR SUSPENSION MOUNTING SHAFT
35. lator is utilized See VOLTAGE REGULATION MAIN ELEMENTS 1 Magnetic Flywheel 2 120 watt coil mounted on stator plate 3 23 watt coil mounted on stator plate Jy eer Aera A 000000000 LIGHTING CONNECTOR ENGIN FIG 3 1 POWER GENERATION SCHEMATIC CONNGETOE FIG 3 3 3 2 SERVICE MANUAL 1976 SCORPION WHIP IGNITION Functional Description See SCHEMATIC FIG 3 7 Cuyuna engines are equipped with a flywheel magneto type ignition An electrical current is generated by rotating a permanently magnetized flywheel about the ignition coil The current initiated in this coil in turn energizes the primary coils of the external ignition coils The secondary coils of the external ignition coils are situated in the force field generated by the primary coils When the points close causing an interruption of the current flow through the primary winding its force field immediately collapses and generates a very high voltage in thesecond coil This voltage in the region of several thousand volts will jump the spark plug gap causing ignition to begin The collapsing lines of force cut through the primary windings raising the voltage in that circuit also As this occurs the condenser absorbs the gene rated current to reduce the tendency to overload the points As soon as the voltage level in the primary winding drops below that of the condenser current again flows in the original direction energizing the s
36. m Inlet Valve Seat Hole through which fuel feeds when needle valve drops slightly away Inlet Needle Valve As float rises it pushes valve into seat closing off fuel passage When float drops needle opens hole in seat allowing fuel to flow into bowl reservoir Lever Raises and lowers with float to activate inlet needle valve Float Raises and lowers to maintain fuel level as fuel is used Fuel Bowl Reservoir Constant level of fuel stored and maintained by float action on lever to open and close inlet needle valve 2 3 SERVICE MANUAL 1976 SCORPION WHIP FIG 2 1 2 4 The four operational phases of the Walbro Float Carburetor used on the 1976 Whip are 1 Starting operation 2 idle operation 3 Part throttle operation 4 Full throttle operation Detailed performance of the carburetor in each of the four phases is described below Figures 2 1 through 2 4 are schematic diagrams and as such are accurate functional representations of the carburetor but in some features deviate from actual physical ap pearance Starting Circuit A Enrichment Valve In operation when control lever is up vertical elimates choke Like opening a faucet an extra column of fuel is introduced through the valve into carburetor bore as engine is cranked offering easier quicker starts This valve may be left open until engine is warm ports mixing with the fuel Start amp Idle Fuel Feed Tube Fuel Enrich
37. ment Valve and idle circuit volume ratio valve is open tor the idle position H Idle Feed Hole Additional fuel discharged from this port into throttle bore for starting COLOR CODE Fuel Air Crankcase Impulse Air B Throttle Valve Must be at idle position freeing both hands for starting Required air is drawn in through the air bleed drawn by engine vacuum up tube through part throttle passage into D Enrichener amp Idle Feed Ports Tube picks up at these two pockets for starting full Air Bleeds Vacuum draws in air at these four points to mix with fuel in metered F Enrichener Port Fuel and air mixture flows into throttle bore when enrichener G Idle Needle Fuel is also drawn through the idle needle circuit which is pre set SERVICE MANUAL 1976 SCORPION WHIP Idle Speed Circuit i p die T EI _ FIG 2 2 1 Throttle Valve Remains closed air being drawn through Idle Air Vent 2 Enrichment Valve Closed as engine warms 3 Fuel Idle Needle As engine requires needle is turned in to lean mixture or turned out to allow greater fuel flow like a water faucet During break in open 17 turns then close about v2 turn after break in 4 Idle Air Vent Engine vacuum draws air through this interchangeable fixed jet as well as through the part throttle progression holes 5 Fuel Idle Passage All fuel for idling is drawn through this passage Th
38. n magneto wires Magneto breaker points improperly gapped or dirty Weak coil or condenser Improper fuel mixture 1 Too much oil 2 Too little oil Leaking crankshaft seal Spark plugs improperly gapped or dirty Loose or broken magneto wires Magneto breaker points improperly gapped or dirty Weak coil or condenser Heat range of spark plug incorrect Leaking head gasket Engine improperly timed 10 Os amp OS CONT REMEDY Check crankcase pressure 3 6 PSIG Repair or replace primary wire Re time engine Secure secondary wire or spark plug protector Repair retard mechanism Replace as necessary Check carburetor check valve Refer to Carburetor Section Adjust idle Refer to Carburetor Section Clean adjust or install new plugs Replace gasket Repair or replace wires Adjust clean or install new points Replace coil or condenser Refuel using specified fuel oil mixture Replace seal Clean adjust or install new plugs Repair or replace wires Clean adjust or install new points Replace coil or condenser Install specified spark plugs Replace head gasket Re time engine SERVICE MANUAL 1976 SCORPION WHIP TROUBLE SHOOTING CHART TROUBLE PROBABLE CAUSE REMEDY Coughs spits slows 1 Idle or high speed jets too 1 105 down surges
39. n of drive train Excessive noise from front drive system CAUSE Drive clutch may not be closing fully This can be checked by drawing a line on the face of the sheave drive or driven with a crayon from the center outward Then running the machine at top speed will tell you how far the clutch closed by erasure of the line by the belt If the clutch is closing fully the belt may be wrong length or the center to center distance of the clutches may be off Finally check the number of teeth on upper and lower sprockets Tachometer may be reading incorrectly high Belt may be worn and too narrow to achieve correct ratio see belt specs Track may be too loose allowing sprockets to slip over drive lugs or ratchet Chain may be slipping over teeth on sprockets Malfunction of front drive bearings Chain case may be dry of oil REMEDY Disassemble clutches examine and replace malfunctioning parts Replace belt Correct center to center dis tance see belt specs Replace incorrect sprocket Replace tach Replace belt Correct track tension Check broken or chain tensioners replace weak Replace bearings Disassemble and check chain sproc kets and chain case cover seal O ring re place worn parts and reassemble Refill with oil check level and check for leaks 1976 scorpion Whip Service Manual Suspension section SERVICE MANUAL 1976 SCORPION WHI
40. nvolving measurement of fuel con sumption horsepower and noise level Contrary to popular belief the exhaust system is not only for quieting the engine but also serves to in crease horsepower output Changes made to the original equipment exhaust system by changing any component in the system can result in loss of power and or severe engine damage For these reasons intermediate lengths of pipe betweeen the cylinder and the muffler are particularly critical TUNED MUFFLERS Tuned mufflers allow the engine to exhaust its spent charge into an adequate volume and properly system More im portant the mufflers that are tuned incorporate designs that suck the exhaust gas from the cylin der allowing fuel and air to rapidly replace it and also cram over scavenged fuel and air mixture from the exhaust pipe back into the cylinder using sound waves and sound energy This is ac complished at the speed of sound which allows the engine to produce higher torque at higher RPMs 1 4 Donaldson FIG 1 2 Courtesy of Donaldson FIG 1 3 HOW TUNING WORKS The megaphone effect of the expanded intake tube scavenges exhaust gas from the cylinder allowing rapid replacement of the fuel air mix ture from the crankcase Reflected sound waves and sound energy stop over scavenging and return fuel air mixture to the cylinder lt gives a supercharging effect even though it operates from the exhaust
41. o more than 020 space between torque plug and casting Inspect idler bearing for freedom of rollers and retention of lubricant FIG 4 10 Inspect snap ring groove on stationary and spring retainer for wear Inspect bell housing for cracks particularly in center area near spline FIG 4 11 4 6 SERVICE MANUAL 1976 SCORPION WHIP RE ASSEMBLY OF DRIVE CLUTCH CAUTION stationary has been removed assure that there is no grease on either the shaft or sheave before re assembly Re install idler bearing snap ring retainer and spring Place weight arms on movable sheave after checking them for lubrication Attach retainers checking to see that the small locating hole in the bearing aligns with the detent on inner face of retainer Install torque plug and torque plug retainer Install bell housing checking alignment with stub on torque plug provided for this purpose Place spring washer and bell retainer bolt on next assuring that the bolt has bottomed out securely in proper alignment Install clutch bolt Torque on both bolts to 50 ft 5 4 7 SERVICE MANUAL 1976 SCORPION WHIP DRIVEN CLUTCH DISASSEMBLY 1 Remove brake cable at chain case end DRIVEN SHAFT LOCKING BOLTS 2 Remove chain tensioners unbolt and remove top sprocket and chain TOP SPROCKET CHAIN CHAIN TENSIONER BOTTOM SPROCKET FIG 4 12 FIG 4 12 4 8 SERVICE MANUAL 1976 SCORPION WHIP
42. on Coil Safety Switch Connector Brake Switch Engine Connector Engine Ignition Coil Safety Switch Connector Brake Switch Connector Hi Lo Beam Switch Hi Engine Connector Engine Connector Voltage Regulator Connector Instrument Connector Taillight Ignition Switch Connector Engine Connector Engine Connector Voltage Regulator Connector Brake Switch Connector Brake Switch Connector Hi Lo Beam Switch Connector Lo Ignition Switch Connector Ignition Switch Connector Hi Lo Beam Switch Connector Engine Connector Engine Connector Safety Switch Connector Ignition Switch Brake Switch Connector Safety Switch Connector Ignition Switch Connector Brake Switch Headlight Connector Hi Chassis Roll Bar Bracket Voltage Regulator Connector Instrument Connector Headlight Connector Chassis Tunnel Electric Start Regulator Connector Instrument Connector Instrument Connector Brake Switch Connector Ignition Switch Connector Brake Lights Headlight Connector Lo Taillights Hi Lo Beam Switch Connector Instrument Connector Voltage Regulator Connector Voltage Regulator Connector SERVICE MANUAL 1976 SCORPION WHIP TROUBLE No lights Dim lights Burned out lights all Burned out lights individual Burned out lights Engine won t run Weak or no spark Engine won t run Adequate spark Unacceptable Engine Performance PROBABLE CAUSE
43. op on shaft preloading spring turn and install washer and snap ring Upon replacing the driven clutch in chaincase check to assure that the O ring in chaincase bore is intact and in good condition Also check O ring in chaincase cover before installation Connect brake cable See Fig 4 12 4 12 SERVICE MANUAL 1976 SCORPION WHIP DRIVE BELT SPECIFICATIONS Drive belt width 11 8 13 16 inches Drive belt outside diameter 43 1 8 43 1 4 inches Clutch offset Drive to Driven 3 8 inch Center to center distance 10 inches Drive clutch to Driven clutch DRIVE CLUTCH ALIGNMENT BAR FOR MEASURING 3 8 OFFSET DRIVEN CLUTCH wv d FIG 4 20 4 13 SERVICE MANUAL 1976 SCORPION WHIP CHAINCASE DISASSEMBLY Remove brake cable at chain case end Remove cover tensioners upper and lower bolts Remove sprockets with chain Remove bearing flange bolts and brake cable Taking care to check number of shims between the chaincase and the tunnel and their specific locations remove the chaincase from the tunnel When the chaincase is reassembled to tunnel assure that the spacers go back where they were Before tightening case to tunnel be sure to adjust case to achieve correct center distance of 102 between center of driven and drive clutches Reverse procedure to install REMOVAL OF FRONT DRIVE SHAFT Remove brake cable at chain case end Remove chaincase cover tensioners lower sprocket and
44. or free operation lubricate inside cam surface Grooved area Slide assembly over crankshaft and align key ways SERVICE MANUAL 1976 SCOPRION WHIP FIG 1 44 1 23 SERVICE MANUAL 1976 SCORPION WHIP Install key lockwasher and nut in that order Tighten securely See Fig 1 46 Follow Timing Procedure Section as next step Lower Fan Pulley Assembly Install pulley half belt second pulley half recoil carrier lockwashers and bolts evenly while rotating crankshaft The proper belt deflection should be 1 8 on each side Proper adjustment can be made by adding or removing shims between upper pulley halves See Fig 1 47 J Recoil Starter Install the recoil starter assembly and tighten securely See Fig 1 48 1 24 FIG 1 48 RECOIL STARTER Disassembly See Fig 1 49 for recoil start breakdown and Fig 1 50 for Recoil Starter Assembly nh Recoil Starter Remove retaining nut 11 spring washer 12 and Thrust washer 8 from threaded shaft of reel hub Fig 1 51 Manipulate friction plate 4 on reel hub until eye end of return spring 9 aligns with retaining slot Remove friction plate Fig 1 52 1 53 Remove the three pawls 3 Fig 1 54 Remove return spring 9 spring 6 and cup washer 7 Fig 1 53 Note position of plain end of return spring in the spring retaining hole in reel hub Unwind the rope lift and untie the knotted end from cen
45. r preparation 2 After the first 10 hours 3 Every 30 days or 200 miles of operation 4 Atthe start of each snow season The following procedure applies to all Para Rail Snowmobile Suspension equipped Scorpion snowmobiles 1 The track should be at room tem perature or should have been recently run to remove any stiffness caused by cold weather 2 Elevate the rear of the machine 3 Adjust each Track Jack to one and one quarter inch 1 TRACK ADJUSTMEN BOLTS 5 10 REAR SUSPENSION MOUNTING SCREWS 4 Insert both Track Jacks between the track and both bogey wheels located on the third bogey axle ahead of the rear idler wheels 5 If the track is properly tensioned the green ring should be just visible or aligned with the lip of the cylinder Ad justment is required if the green ring is not visible or is above the lip of the cylinder 6 To make adjustment loosen the lock nuts on the track adjustment bolts as well as the rear suspension mounting screws rear of tunnel just below seat and either tighten or loosen the ad justment bolts until proper adjustment is measured on both Track Jacks green ring aligned with lip on cylinder 7 Retighten the lock nuts on the track ad justment bolts as well as the rear suspension mounting screws NOTE Track Jacks are available at Scor pion Inc lt is an accessory item Part 901736 IN THE EVENT Track Jacks are not avai
46. rather than the intake side Over scavenging is also retarded by moderate muffler back pressure Silencing is accomplished after power is maximized by acoustical packing in the resonator outlet tube plus chambering and baffling which gives an effective 2 pass muffler design SERVICE MANUAL 1976 SCORPION WHIP SERVICE MANUAL 1976 SCORPION WHIP TABLE OF SPECIFICATIONS ENGINE MODEL DESCRIPTION 2 362 2 559 2 658 60 mm 65 0mm 67 5mm 2 362 STROKE 60mm IGNITION SYSTEM Bosch LIGHTING COIL VOLTAGE AND 150W 12V 150W OUTPUT 12V 150 12V 150W 0 TIMING BEFORE TDC CENTRIFUGAL TIMING BEFORE TDC CENTRIFUGAL WEIGHT RETARDED 018 to 020 018 to 020 018 10 020 BREAKER POINT GAP 014 to 016 SPARK PLUG THREAD 14mm x 1 25 3 4 reach 920 020 020 CHAMPION CHAMPION CHAMPION N 3 N 3 N 3 SPARK PLUG ORIGINAL EQUIPMENT TYPE OF ENGINE COOLING Axial Flow Fan ROTATION OF CRANKSHAFT Counterclockwise PTO side CARBURETOR Walbro W F FUEL OIL RATIO As Specified on Scorpion Oii Container GASOLINE 95 octane minimum lead free not acceptable TYPE OF OIL Special 2 Cycle Snowmobile Oil Do not exceed indicated advance as this will result in severe engine damage 1 6 SERVICE MANUAL 1976 SCORPION WHIP TABLE OF SPECIFICATIONS CUYUNA CUYUNA CUYUNA TORQUE SPECIFICATIONS 340 400 440 CYLINDER HEAD NUTS 28
47. rce or weight evenly distributed across the track approximately midpoint in the flat span of the rails To make adjustment loosen the lock nuts on the track adjustment bolts as well as the rear suspension mounting screws rear of tunnel just below seat and either tighten or loosen the adjustment bolts to achieve 1 7 8 inches between the top of the track cleats and the bottom of the slide runners at mid point in the flat span Remove ten 10 lbs force or weight and retighten the lock nuts on the track ad justment bolts as well as the rear suspen sion mounting screws
48. remove any stiffness caused by cold weather Elevate the rear of the machine Set the Track Jack at 1 and add a 3 8 shim underneath it Insert the Track Jacks with shims bet ween the slide rail runners and the track cleats about midpoint in the flat span of the rails If the track is properly tensioned the green ring should be just visible or aligned with the lip of the cylinder Adjustment is required if the green ring is not visible or is above the lip of the cylinder To make adjustment loosen the lock nuts on the track adjustment bolts as well as the rear suspension mounting screws rear of tunnel just below seat and either tighten or loosen the adjustment bolts until proper ad justment is measured on both Track Jacks green ring aligned with lip on cylinder Retighten the lock nuts on the track ad justment bolts as well as the rear suspen sion mounting screws NOTE Track Jacks are available at your Scoprion Dealer They are accessory items SERVICE MANUAL 1976 SCOPRION WHIP TRACK JACK FIG 5 26 TRACK TENSION ADJUSTING BOLTS 5 17 SERVICE MANUAL 1976 SCORPION WHIP In the event Track Jacks not available the following procedure may be employed to obtain proper track tension The track should be at room temperature or should have been recently run to remove any stiffness caused by cold weather Elevate the rear of the machine Apply ten 10 lbs of fo
49. rench Pull the flywheel by attaching flywheel puller 444 31 843 2 to the flywheel flange using bolts provided Screw the three bolts through the puller into the flange and tighten evenly With a socket wrench tighten the puller bolt until the flywheel loosens the crankshaft See Figs 1 10 1 11 1 12 1 13 removing the flywheel assembly because the positioning key located in the keyway may stay in its original position and thereby cause damage to the advance mechanism A small icepick or screwdriver may be used to loosen and remove the key 1 10 FIG 1 11 FIG 1 13 Intake Manifold Assembly Remove the four 4 intake manifold nuts and washers Remove manifold assembly and insulators See Figs 1 14 1 15 SERVICE MANUAL 1976 SCORPION WHIP 1 zu gt JH Na n FIG 1 14 lm me ES SERVICE MANUAL 1976 SCORPION WHIP F Fan Housing and Armature Plate Assembly Remove screw holding spark plug wire bracket to fan housing With a socket type 5 mm Allen wrench and impact driver remove the four 4 mounting bolts holding fan housing to crankcase See Fig 1 16 Remove fan housing from crankcase See Fig 1 17 FIG 1 16 Unplug connector housing coil wires Note color coding of wires Remove armature plate assembly and wires as a unit from fan housing SERVICE MANUAL 1976 SCOPRION WHIP Remove the fan by tapping the end of fan shaft wi
50. s bearing and remaining washers to be free from suspension Fig 5 12 TUBE SPACERS Spools Remove the two screws and washers from the wheel shaft Push shaft through rails and spools are removed Fig 5 13 Rails Remove the remaining eight 8 screws and washers This will allow the rails to be removed from the remaining shafts RAIL FIG 5 13 bogey wheels and tube spacers The Para Rail Snowmobile Suspension is completely disassembled at this time SHAFT RETAINING SCREWS 2 FIG 5 14 5 7 SERVICE MANUAL 1976 SCORPION WHIP ASSEMBLY Prior to assembly procedure ensure that all components are clean and all defective parts have been replaced Apply a coat of low temperature grease to all shafts prior to assembly Use Scorpion clutch lub 906800 Reverse procedure as outlined for disassem bly NOTE Ensure that all tube spacers and bogey wheels are assembled in their respective areas on the shafts Torque requirements for assembly are 5 8 TORQUE 50 60 Ft Lbs Screws securing rear idle wheels and front suspension shaft in position 15 19 Ft Lbs Screws and nuts which fasten axle adj brackets to rails secure bogey wheels and shafts and secure suspension pivot shaft to suspension plate and shock mounting bracket SERVICE MANUAL 1976 SCOPRION WHIP SPECIAL ADJUSTMENTS PARA RAIL REAR SPRING ADJUSTMENT The rear spring adjustm
51. ter hub of reel remove reel 2 Fig 1 55 Lift long rolled end of main spring 5 from the fixed spring retaining pin in the case and carefully remove the spring Fig 1 56 IB TF 31 712 8 2T 9 8 6 SERVICE MANUAL 1976 SCORPION WHIP yc 10 18 19 20 FIG 1 49 1 25 SERVICE MANUAL 1976 SCORPION WHIP 7 Clean all parts except rope using a suitable cleaning solvent If rope requires cleaning wash it in a solution of soap and water Thoroughly dry all parts after cleaning 8 Inspect all parts for obvious damage and wear FIG 1 50 FIG 1 52 77 T P T M ue FIG 1 53 1 26 SERVICE MANUAL 1976 SCORPION WHIP FIG 1 54 FIG 1 55 FIG 1 56 1 27 SERVICE MANUAL 1976 SCORPION WHIP Assembly 1 1 28 Replace defective parts Install main spring as follows a Secure main spring winding tool part number 43 0797 60 or equivalent tool circular end up in a suitable bench vise b Start with the long rolled end of main spring 5 and wind spring into circular end of tool in a clockwise direction Fig 1 57 Remove tool from vise Grasp the tool by its handle and lower the tool with spring installed into case 1 Fig 1 58 d Secure the long rolled end of spring over the fixed spring retaining pin Fig 1 59 Remove winding tool Fig 1 60 Apply a light film of Lubriplate or equivalent to spring
52. th a soft hammer With a flat punch and hammer tap the inner race of the fur thest bearing in the housing See Figs 1 18 1 19 1 20 FIG 1 20 1 13 SERVICE MANUAL 1976 SCORPION WHIP G Remove spark plugs with spark plug wrench See Fig 1 21 H Cylinder Heads Remove cylinder head nuts with 13 mm socket wrench Mark cylinder heads before removal from cylinder Remove and discard gaskets See Fig 1 22 Cylinders Remove the eight 8 cylinder base nuts using a 13 mm socket wrench and remove the eight 8 spring washers The cylinders may be removed See Fig 1 23 NOTE IMPORTANT If removal of cylinders only is required care must be taken that the crankcase seal is not disturbed The removal of the PTO cylinder will allow the placement of two bolts and nuts with flat washers to apply constant pres sure to crankcase assembly Bolts should be placed in the center two holes adjacent to the fan side cylinder See Fig 1 31 The second cylinder may now be removed FIG 1 23 SERVICE MANUAL 1976 SCORPION WHIP Piston and Wrist Pin With needle nose pliers remove circlips from pistons Heat the piston with a heat gun or propane torch Heat only to the point where piston may still be held in hand Push the pin out To separate the crankcase halves hold upper portion of crankcase assembly in one hand lifting slightly and tap the end of the crank case with a soft hammer T
53. the recoil position 11 Install flatwasher 8 lockwasher 12 and nut 11 Tighten nut securely 12 Untie the temporary knot in free end of rope and install the rope handle Tie a permanent knot and fit handle securely 13 Check starter for proper operation When handle is pulled outward pawls should move outward NOTE If main spring is to be installed without the use of a spring winding tool wind main spring into case in an anti clockwise direc tion Clockwise installation on the winding tool is necessary to ensure correct anti clockwise installation of the spring when tool is placed upside down in the case SERVICE MANUAL 1976 SCORPION WHIP FIG 1 61 FIG 1 63 1 29 SERVICE MANUAL 1976 SCORPION WHIP TIMING PROCEDURE NOTE Recoil starter carrier lower pulley assem bly and spark plugs should be removed before beginning timing procedure A Install the dial indicator assembly into spark plug hole of No 1 cylinder P T O side See Fig 1 64 Attach negative lead of to engine ground Attach positive lead of ohmmeter to FIG 1 64 No 1 cylinder terminal in connector housing See Fig 1 65 Rotate flywheel counterclockwise until points are on the high side of cam on No 1 cylinder Points are at maximum open posi tion observed through opening in flywheel Check gap with wire gauge and adjust to 015 if necessary See Fig 1 66 FIG 1 65 SERV
54. to proper specifications Engine won t crank Piston rusted to cylinder 1 Remove piston and cylinder over Unable to wall Replace defective parts rotate flywheel 2 Crankshaft seized to 2 amp 3 Disassemble engine bearing main or rod Replace defective parts 3 Broken connecting rod 4 Flywheel seized to coil 4 Remove flywheel Replace plate defective parts 5 Engine improperly 5 Recheck re assembly assembled after repair procedure AEQ LIS LLLLULUCILCOLCGIHLLSO LL AIeuLOL LL A kX e WaRRBEEE NN aAa a 1 37 1976 Scorpion Whip Service Manual Carburetor Section SERVICE MANUAL 1976 SCORPION WHIP Functional Description General The purposes of the carburetor are 1 to provide the amount of fuel that the engine needs in operation and 2 to properly mix the fuel with air so that it will vaporize Pulsations from the engine crankcase through the impulse line actuate the carburetor fuel pump to move the fuel from the fuel tank into the carburetor The fuel level in the car buretor fuel reservoir is maintained by a float controlled needle valve that opens as the level drops and closes as the fuel rises to a specific level The engine fuel demand deter mines the air flow through the carburetor throttle bore The air flow rate varies the pressure differential on the fuel in the reservoir This pressure differential for
55. ystem This occurrence and the re versal happens several times each cycle creating a powerful long duration spark for more reliable ignition MAIN ELEMENTS Ignition Coil Stator Condensers 2 Breaker Points 2 Ignition Coils External 2 Spark Plugs 2 SPARK PLUGS i Cx EXTERNAL FIG 3 3 COILS ENGINE CONNECTOR STATOR FIG 3 5 3 3 SERVICE MANUAL 1976 SCORPION WHIP POINTS SEE ENGINE DISASSEMBLY IGNITION COIL STATOR SECTION 1 FOR FLYWHEEL wy a AND STATOR REMOVAL u e B L AOT CONDENSERS FIG 3 6 IGNITION COIL STATOR CONDENSER 1 LL V EXTERNAL IGNITION COILS CONDENSER IH SPARK PLUG POINTS 15 3 SPARK PLUG T ENGINE CONNECTOR FIG 3 7 IGNITION SCHEMATIC 3 4 SERVICE MANUAL 1976 SCORPION WHIP STATOR IGNITION COIL TO EXTERNAL COIL CONNECTORS ERE 5 3 E B 7 zt 3 d 2 FIG 3 8 EXTERNAL COIL COIL TO SPARK PLUG LEAD EXTERNAL COIL GROUND FIG 3 9 3 5 SERVICE MANUAL 1976 SCORPION WHIP VOLTAGE REGULATION Functional Description The voltage regulator is connected across the lighting coils in parallel with the electrical load of the sled Under operating conditions the voltage drop across the regulator is such that 13 8 volts RMS is supplied to the snowmobile lighting circuit
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