Full page fax print - Vintage Snowmobiles
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1. a ES e a U ee Fa E 2 os Tuma OU ww s EI _ 2 u 3 jititagesnowmobile com vintagesnowmobile com n vintagesn pumobile com vi te ge Toca m a ile a x aiam iem mmm mum de SPARK TEST 2 4 There is no spark or the spark tracks up the nose No spark with new plug STAGE Il SPARK PLUG CONDITION IF The plug shows excessive heat Blistered Nose Melted Electrodes Aluminum or lead Bridged Electrodes The plug shows excessive carbon deposits CYLINDER COMPRESSION IF The cylinder pressure is below 100 p s i The cylinder pressure is above 150 p s i SPARK GAP TEST IF The ignition system pro duces less than 7 mm of spark TROUBLESHOOTING CONTINUED Connect the plug to its wire rest plug shell against head crank the engine THEN Try the same test with a new plug Go on to STAGE II ELECTRICAL Check the firing end for unusual deposits and conditions THEN Check the carburetor for lean settings and if OK go on to other checks for overheating The carburetor settings may be too rich OR the air supply to the car buretor may be choked OR the exhaust system may be overly restrictive Use a conventional spark plug hole2. SNOWMOBILE SERVICE MANUAL 294 QUICK SERVICE CHART SET UP PROCEDURE TROUBLE SHOOTING THE TWO CYCLE ENGINE DRIVE BELT PREVENTIVE MAINTENANCE 1973 BRUT SNOWMOBILE BRUT S LIQUID COOLED ENGINE BRUT SPECIFICATIONS ENGINE TIMING BRUT SERVICE TOOL LISTING BRUT SNOWMOBILE CUTAWAY 1972 LC44 ELECTRICAL SCHEMA TIC 1973 74 LC29 ELECTRICAL SCHEMATIC 1973 LC44 1974 502 ELECTRICAL SCHEMATIC SUSPENSION DRIVE SHAFT REMOVAL INVOLUTE DRIVE SPROCKET REMOVAL CLUTCH REMOVAL DRIVE INSTALLATION BRAKE INSTALLATION SUSPENSION INSTALLATION ENGINE REMOVAL ENGINE DISASSEMBLY ENGINE ASSEMBLY PISTON RING INSTALLATION THROTTLE LINKAGE ADJUSTMENT TABLE OF CONTENTS 10 10 11 11 11 11 12 13 14 15 15 16 16 16 17 17 18 9 CHOKE LINKAGE ADJUSTMENT STEERING ADJUSTMENT AND SKI ALIGNMENT ENGINE TIMING SERVICING DRIVEN CLUTCH SERVICING DRIVE CLUTCH SKAG REPLACEMENT HEADLIGHT REPLACEMENT HEADLIGHT ADJUSTMENT TAILIGHT BRAKE LIGHT REPLACEMENT BRAKE ADJUSTMENT DRIVE BELT REPLACEMENT CLUTCH ALIGNMENT RIDE ADJUSTMENT SPRING TENSION SHOCK TENSION DRIVEN CLUTCH ADJUSTMENT TRACK ADJUSTMENT AND ALIGNMENT DRIVE CHAIN ADJUSTMENT COOLING SYSTEM LUBRICATION FUEL MIXTURE GASOLINE OIL FUEL MIXING RATIO MIXING INSTRUCTIONS DEALER WARRANTY CLAIM INFORMATION 1 LC 29 QUICK SERWICE CHART Clutch Offset Center to Center of Clutch Proper Belt _ Point Setting Brutanza Belt 012 017
3. 3 5 mm or 138 B T D C MUST BE COMPLETED AT FULL SPARK ADVANCE Plug Gap 2 sa 020 _ Carburetor Adjustment High 1 turn Low 1 1 8 turn Idle Speed 1500 2000 RPM Spark Plug Standard B7ES NGK Replacement N3 Or N3G Champion Hard running BBES NGK or N2G Champion BOLT TORQUE SPECI FICATIONS SIZE 5 8 Clutch 35 ft Ibs Ski Adjustment 1 4 toe out Oil use a B I A endorsed oil with T C W specs ST will so state on the can Mix according to oil manufacturers directions Gas Use a good grade of leaded fuel from a station that moves lot of gas gasoline that sets dormant can lose up to 5096 of the octane in a 30 day period THE NEW BRUT SNOWMOBILE SET UP PROCEDURE Uncrate the liquid cooled BRUT snowmobile Be cautious that the upholstery 5 not tom or the finish on the cowl scratched Check all parts for shortages If there should happen to be a shortage on some part you must file a warranty claim within 10 days to recerve credit for any parts which you use from your owm stock Install springs suspension set suspension shock and install suspension in chassis Align track Refer to Service Manual page 2 amp BX gt 5 Install skis and steering post and adjust toe out to Check coolant level This lever should be 1 172 below the neck on surge tank 7 Check chain case od level and chain tension 8 Check belt alignment The o
4. 20 UNC X 1 2 Pan Head Screw 3 1 4 X 026 X sa OD Flat Three 3 of each of above 6 1 2 grams weight 1 21510 11 Orange 5 coil 192 wire spring 3 to 3 1 4 Length LC50 Pert 21300 17 Same as LCH with exception each weight to have four 4 24250 14 1 4 X 026 X 1 2 OD Flat Washer This will equal 7 grams per weight This clutch should be set to engage at 3800 to 4000 RPM and have a shift pattern of 7500 to 7700 Higher Eneagement will mean a higher RPM at the start of movement Lower engacement will mean lower RPM at the start of movement The length of spring mainly controls the engagement RPM The size of wire and number of coils will determine the amount of weight you need to shift the clutch at a given FP Note vosition of marks on cover and stationary before disassembling clutch Note cosition of marks on moveable face and stationary face when cover is not yet asserblec his is the neutral position of the spring When the cover is placed on the moveable face note the position of the cover mark in relation to the moveetle mrk i cormressine spring and installine assembly nut rotate the clutch ocver back and forth noting the approximately 1 2 free movement possible Leave the cover in the counterclockwise position of this movement This positions the pads cf the moveeble arsinst the helix ramps of the cover At this point note the mark cn the cover and the mark on the stationary These two m
5. CLAIM WARRANTY ALLOWANCE REQUEST b HOLO ALL PAATS 60 DAYS AFTER MAILING COLAIM 4 34 3 9 FOR WARRANTY CONSIDERATION CLAM MUST AE FILED WITHIN 10 DAYS OF TOWNES NAME 5 DN ALES ANY 400084 460 Po Dealer lure L ELLES I A BAT OF AX EIL X sni test foe m CoA unt MANE A 0 c LC Lad ES LJ wo L i THE ROPARS BELOW WERE MADE AT BEQUEST AND 10 THE Claw 5 waway ACCEPTED BY AUT ANZA RONG WELL OFALE IN PULL OWNERS ona ture X SEDYE OF WORD DEFEC TON LCERTUEY THAT WORK BEEN COMPLETED Of ALER BGNATURE DEALER SICUATURE REMARKS 4x0 D soa we TOTAL LABOR TOTAL PARTS TOTAL CREDIT FILLOR FP a GOLD TO FACTORY GATEN COPY A 3 w VLL ANTI 5 A 55 a o M Bonus Clutch Section W 502 Setup DRIVE CLUTCH SET UP LC29 Part 21300 13 1 21505 1 eight 1 21518 10 Shoe l 24704 12 5 64 X 5 16 Roll Pin 1 24200 20 1 4 X 20 UNC X 1 4 Pan Head Screw Three 3 of each of above Three grams each weight 1 21510 10 Yellow 5 1 2 coil 175 wire spring 3 1 2 to 3 3 4 Length LC44 21300 14 1 21505 11 eight 1 21518 10 Shoe 1 2470412 5 64 X 5 16 Roll Pin 1 28020021 1 4 X
6. brake disc then brake assembly Make sure round end of actuating pin is toward actuating lever Adjust brake so brake lights operates when brake is applied Page 17 SUSPENSION INSTALLATION With track and driveshaft installed you can now install suspension Raise machine rear approximately 30 off ground on secure stand Slide suspension into track Line up front two 2 mounting bolts insert and tighten Slide 27 2 or 27 4 block under track positioned just behind second set of front idler wheels Drop rear of machine down Push down or up on machine rear while holding rear suspension mounting shaft until shaft is in line to insert mounting bolts Tighten bolts and align suspension See page 23 for track adjustment and alignment 499 amp ENGINE REMOVAL Loosen linkage swivel screws on choke and throttle on the carb next to the coolant pump Remove choke cable from choke cable bracket Remove throttle cable at throttle lever next to handle grip Remove 3 8 nut holding tie rod ends to steering post frog Note On assembly place right hand tie rod end below steering frog and left hand tie rod end on top of steering frog Remove two 2 1 4 nuts at upper steering bracket Lift steering post away from engine compartment Disconnect CDI unit lead to engine Disconnect the two 2 yellow lighting wires and black ground wire leading from stator unit Disconnect spark plug leads Remove cotter
7. gauge Crank the engine until the gauge wil go no higher THEN Remove the cylinder and examine the Cylinder head Piston Piston rings Cylinder Check for proper tolerances Check for unauthorized modification Connect a spark gap tester start the engine THEN Proceed with the next step TROUBLESHOOTING CONTINUED Page 5 IGNITION TIMING CHECK IF You find loose or improper wire connec tions The contact points do not open and close properly When the points are physically open and you do not get a normal point checker resistance reading IF The ignition timing is excessively advanced The timing is excessively retarded STROBE LIGHT TEST IF A machine with centrif ugal advance mechanism does not go to full advance The strobe light indi cates that the marks stray from align ment 1 4 or more there are random flashes in addition to normal ignition Follow the normal ignition timing procedures using a dial gauge and point checker THEN Clean connections and reconnect properly Clean until they do The points may be grounded or permanently replace or repair OR the primary coil is open or the windings are not insulated replace THEN The engine will run hot and maybe detonate adjust as necessary The engine will not produce nor mal horsepower adjust as neces sary Start the engine with a strobe timing light conn
8. holes in crankcase Do not force stator in it should slide in by hand snugly Do not rotate stator holes must line up Grease and install seal on magneto side LC29 Coat breaker cam with thin coat of grease Connect timing equipment light buzzer or ohm meter to white primary lead adjust point gap to get correct timing Point gap should be between 012 and 017 Page 26 Key rotor on crankshaft Torque 18mm nut to 55 ft Ibs gQesrowrr 3gesnow 3qesnowt gesnow neennu Install dust cover next to rotor stator assembly with 6mm screws On 1972 models spacer ring must be in place before installing lower belt pulley With ring in position install pulley with 6mm screws Slide v belt over pulley and install recoil and spacer ring 1972 only on crankcase Slide outlet water pipe on manifold and torque 6mm nuts to 60 inch Ibs With brackets mounted on water pump slide belt over pump pulley and screw brackets onto cylinder with three 3 8mm bolts Tighten belt with tightener bracket until you reach 1 2 deflection in belt Install water inlet hose and bypass hose and tighten clamps Fit exhaust gasket on manifold and install muffler with 8mm nuts Install the two 2 carbs closest to clutch Throttle bracket fits under carb nearest clutch The 1 4 spacer fits center carb and carb closest to coolant pump AV X threads using adjusting jam nuts Slide linkage rods th
9. vit A NONE MU UTI Y i m 0971 ms T VL lx 44 ki 4 j E 4 M mH Torque 10mm bolts to 25 ft Ibs Torque 8mm bolts to 18 ft Ibs With depth micrometer measure from seal plate mounting surface on case to outer race of shaft ball bearing Y Choose from three 3 thicknesses of gaskets to place under seal plate If micrometer measures from 091 and up use 2mm 008 if it measures from 081 to 091 use mm 012 if it measures from 080 and down use 5mm 020 Install correct gasket and seal plate bend lock tabs over plate bolts Place piston pin bearing connecting rod then place piston pin spacers on ends of bearings being careful not to drop them Lubricate piston pin bearings HW LS end ote oa 2 ur Slip piston over connecting rod holding bearing and spacer in place Slide piston pin through piston bearing and spacers then install remaining snap ring On 1973 models with L ring pistons the L ring locator pin must face intake port and on bottom ring the locator pin must be between exhaust and transfer port On 1972 models with standard pistons both locator pins must be between the transfer and the exhaust port Note F on piston should point toward flywheel side of engine Install cylinder base gasket Put one snap ring on each piston before installing on rod so you don t have to squeez
10. will protect to 47 F Periodically check coolant with anti freeze hydrometer To check coolant level run machine enough to warm up Coolant level should be approximately 177 below top of tank Also check system periodically for loose clamps LUBRICATION Your Brut has two lubrication points One is the chain case which has an oil bath reservoir for the drive chain Main tain oil level with No 10 weight nondetergent oil To check correct oil level make sure machine is on level surface Loosen or remove check plug at bottom of chain case If oil does not appear when removed open filler plug at top of chain case and add oil until oil appears at check hole For 1973 models only See page 23 DRIVE CHAIN ADJUSTMENT for 1972 model There is a lube fitting on slide suspension frame near front idler wheel Use only Brut Track Suspension Lubricant which has a low melting point This lubricant is not a substitute for no snow conditions and does not permit your Brut to be run for distances without some moisture or snow for normal slide rail suspension lubrication Brutanza has available an optional suspension wheel kit for marginal snow conditions FUEL MIXTURE Your Brooten engine is a two cycle or two stroke snowmobile engine which requires you to mix lubricating oil with the gasoline The carburetor draws this gas oil mixture into the crankcase for the engine to lubricate internal moving parts GASOLINE Use a good grade of cle
11. BRUT 294 IGNITION SWITCH ENGINE ELECTRICAL 5 973 BRUT 440 974 BRUT 502 pl abeg SUSPENSION m Remove suspension To remove suspension remove the four 4 3 8 locking bolts mounting suspension to chassis Plug air bleed hole in gas cap turn machine on to one side Then pull out suspension 1974 also has locks on front suspension lock bolts DRIVE SHAFT REMOVAL To remove drive shaft the chain case must be removed and the suspension must be removed On the left side of the machine is a locking collar positioned on the spherical bearing in the flangette Photo at right Loosen allen screw turn collar opposite way it was installed Note punch mark in locking hole Slide collar over shaft then push shaft into chain case hole and pull out bottom Chaincase assembly must be removed before drive shaft can be removed Two photos below Remove chain case drive elements Remove chain by removing snap ring on upper sprocket and bolt on lower sprocket Remove chain tensioner by backing out tightener bolt CLUTCH REMOVAL Remove three 3 Phillips head screws holding bumper and hood extrusion onto nosepan on left side of machine only Remove 7 16 clutch bolt then large nut on clutch Thread clutch puller into threads of large clutch nut Bearing on end of puller will press against end of crankshaft and pull clutch by tightening puller against crankshaft This is not necessa
12. Engage spring with anchor point in ramp and anchor point in moveable face Rotate movable face 1 2 turn or 180 counter clockwise after spring tension is taken up Push stationary ramp down on hub shaft and lock under key Replace snap ring Release stationary ramp to seat against snap ring SERVICING DRIVE CLUTCH Disassemble drive clutch by removing large nut and installing clutch puller in clutch Grab moveable face with cover assembly firmly with one hand and turn puller until clutch comes off Holding moveable face of clutch in both hands and puller facing floor tap puller against a firm object It should separate from stationary hub Remove puller and clutch will come apart Inspect clutch arms to make sure they are not sticking Clean and examine all parts Replace if worn Page 28 SKAG REPLACEMENT The skag is a wear rod attached to each ski bottom to aid in turning and prevent wear on actual ski blade Check con dition of skag wear often and replace skags when worn down near ski To replace remove nut holding skag in place With a solid bar bend skag outward until bolt is free from its ski hole Place a 1 piece of wood between skag and ski blade just behind front ski bolt With hammer tap on wooden block forcing skag forward until back pops out of slot With new skag push front sloped end into front ski slot with 1 wood en block positioned in front of rear skag bolt While guiding rear of skag toward
13. RIVE BELT PREVENTIVE MAINTENANCE Treatment Align pulleys Replace or tighten engine mount Grind or polish pulley s Check driver pulley for smooth actuation Consult dealer Check bearing seals and clean pulley surfaces Consult Oper ator s Manual Inspect converter Check driver pulley for smooth actuation Grind or polish pulley 5 Consult dealer Replace belt Rotate track by hand until free Repair or re place con verter Reduce engine RPM Reduce engine RPM See Operator s Manual See Operator s Manual and reduce center distance Replace bearing E u a Page 8 6 Concave worn belt side s 7 Belt disintegration 8 Belt flip over at 9 Belt edge cord broken 10 Flex cracks between cogs 11 Sheared cogs compression section fractured or torn 12 Broken belt Page 9 c Excessive ride out on driver pulley Drive misalignment Rough or scratched pulley s surface Excessive slippage Excessive belt speed Sheave misalignment causing belt flip over Excessive slippage causing heat build up in belt Excessive operation in low gear position Pulley misalignment Excessive belt speed c Excessive ride out on driver pulley Incorrect belt length Pulley misalignment Improper belt installation Engagement speed too high Co
14. an fresh gasoline Don t use gasoline that has been stored in containers for a long time since storage can result in a gum that can plug carburetor jets plug carburetor jets OIL Use a good grade of two cycle engine oil which states on the label that it is blended for snowmobiles If your spark plugs are fouling a lot there is a good chance that you are not using a good oil for your Brooten engine a a Hob qu FUEL MIXING RATIO Mix 20 parts of gasoline to 1 part of oil a 20 1 ratio which is 5 gallons of gas to 1 quart of oil Too much oil will cause plug fouling smoking and excessive carbon formation Too little oil can cause engine overheating with resulting piston seizure or engine bearing failure MIXING INSTRUCTIONS Never mix gasoline with oil in your snowmobile s fuel tank Use a clean container Fill it about half full of gas Add oil and shake the mix well Then add the remaining amount of gas to fill the container with mixed fuel When refueling your snowmobile use a funnel with a fine screen to prevent spilling and entry of dirt and water into the tank Always reshake the fuel container if it s been sitting around for even a few hours to prevent oil from settling out of gasoline WARRANTY FILING INSTRUCTIONS Warranty is not something a company gives out just to be good Joes It is the only feed back we get to check on the machines in the field We desperately need the cooperation of everyone on this matter to ke
15. arks must be in this position after the clutch is assembled If an increase of approximately 100 shift 15 desired move the cover mark an additional 1 2 clockwise of the static point of the stationary mark DO NOT EXCEED 1 2 INCH If decreese of approximately 1 100 is desired move the cover mark an additional 1 2 eourtercelockise of the static point of the stationary mark DO NOT EXCEED 1 2 INCH The size of srin wire and amount of coils will determine the amount of RPM you will lose or 1 rotating the cover a given distance UNDER NO CIRCUPSPMNCES SHOULD ANY PRESSURE BE PUT ON THE SPRING BY ROTATING aes ntj l Clutch to over Rev the Engine The shift Rt to be thrown off 3 The serine to bind on shaft not letting clutch shift into high gear A The zs to hit ram towers on moveable and prevent return to neutral o over Bev to the point where considerable damage may result ais VEMM RU Screws In Arms The addition of one 1 washer on each arm 1111 lower the shift range RPM bv 50 200 RP of one 1 washer will raise the shift range by 50 200 RP Varyire the zort of washers will not change the engagement RP Turnine the cover counterclockwise will tend to eliminate the rattle encountered when starting amd stommine however it will lower shift RPM PLEASE TAFE NOTE DECAL ON CLUICH main reason for this is to insure that the
16. e Condenser Capacity Condenser Insulation Secondary Coil Resistance Spark Plug Cap Resistance IF THEN Discrepancies are noted There will be starting plug fouling and performance prob lems caused by weak spark or no spark Replace components as necessary 9 UWITIQ nowm 6 SHOWMO S0 0Wmo m r tac n vinta je 1 vintagesm agesne snoV noWr sng a JW Symptoms 1 Uneven belt wear on one side only 2 Belt glazed ex cessively or has baked appearance 3 Belt worn excessively in top width 4 Belt worn narrow in one section 5 Belt too tight during engine idle Cause a Pulley misalignment b Loose engine mount s c Rough or scratched pulley surface Excessive slippage caused by a Insufficient pressure on belt sides b Excessive horsepower for belt and converter c Excessive oil on pulley surfaces d Insufficient pre load on driven spring e Excessive operation in low gear position a Excessive slippage b Rough or scratched pulley surface c Improper belt angle d Considerable use belt wearing out Excessive slippage in driver pulley caused by a Locked track b Converter not functioning properly c Engine idle speed too high a Idle speed too high b Incorrect belt or belt length Incorrect drive center distance d Idler bearing seized D
17. e 6mm pump pulley bolts Remove 6mm dust cover bolts Remove 18mm nut on rotor Install puller and remove rotor Amoi 2 Tr qx DI uoc N 42 v8 E Remove Phillips head seal screws on magneto side remove seal Bend lock tabs and remove seal plate on clutch end of crankshaft Now you can disassemble crankcase Remove 18 12 remaining 8mm bolts and two 2 10mm bolts With plastic hammer tap on one half of crankcase holding the other half When case separates shaft can be removed A i Vie tag intage intages UN snow 250 Dow owmge JIWMOE IOW mot nowmm r wasa z E nOowrnor Page 21 ri DCE arm E ENGINE ASSEMBLY Lay crankcase lower half on workbench Place crankshaft in crankcase Install rotor key in crankcase being careful not to damage key Greasa labyrinth seal and oil bearings Install spacer ring next to ball bearings on magneto side Apply gasket sealer on upper half of crankcase and fit onto lower half carefully Page 22 Tap clutch end of shaft with plastic hammer to position shaft correctly in case Install 18 12 8mm bolts and two 2 10mm bolts and torque tighten according to pattern in illustration below Use same pattern for 294cc i oU 4 a E 4 DT en dt T MORIE TON
18. e snap ring between two pistons PISTON RING INSTALLATION Expand ring until it just slips over piston Do not expand any further than necessary to barely clear ring over piston Be sure ring is correctly positioned so ring notch slides into ring locating pin correctly With rings in place set pistons aside After pistons have been installed bolt on cylinders Position cylinders so intake port or carb side is toward side of crankcase with impulse fittings Place wooden block under piston so it sits solid on crankcase With ring compressor over piston rings slide cylinder onto piston Caution Ring ends will catch in transfer ports so you must press them with your fingers Do not force cylinders on When rings do not catch cylinder will slide on with little effort With cylinders in place place inlet coolant manifold on cylinders and torque 6mm nuts to 60 inch Ibs Then tighten four 4 10mm nuts securely on base of cylinder Caution Be sure coolant manifold is torqued in place first to properly align cylinders Place heads on cylinders and install outlet coolant manifold on heads and torque 6mm manifold nuts to 60 inch Ibs Now torque 8mm head nuts to 17 ft Ibs using the following pattern 6 4 1 gt HEAD TORQUE e 5 25 LC29 Mount stator plate center of slots Install stator with three 3 Phillips head screws after aligning stator with machined
19. ected and watch the marks provided on the flywheel and backing plate Rev the engine slowly through the rpm range THEN Performance will be poor Re move the flywheel and clean and lube the automatic advance Poor performance and overheating will result note any obvious crankshaft deflection and go on to STAGE CRANKSHAFT DEFLECTION STAGE III CARBURETOR INSPECTION IF Y ou find dirt or bits of metal There is a flaw in either diaphragm or the check valve sheet IF The fuel inlet valve needle and seat is damaged The mounting flange is warped MUFFLER INSPECTION IF It appears to be clogged with deposits You can hear loose metal pieces or silencing material when you shake the muffler CRANKCASE PRESSURE CHECK IF The pressure leaks at a rate of 1 2 Ib min The pressure leaks at a rate greater than 1 Ib min TROUBLESHOOTING CONTINUED Remove disassemble and inspect the carburetor THEN The carburetor will cause engine flooding wash clean The carburetor may not deliver enough fuel and the engine will run hot or perhaps will not start at all replace damaged parts THEN The fuel will not be controlled and the engine will be flooded Air will leak into the intake port and cause a lean mixture surface grind the flange Remove the muffler THEN The engine will not produce normal horsepower and may over heat clean out the
20. en severely jounced Page 30 TRACK ADJUSTMENT AND ALIGNMENT To work on track lift rear of machine and set on secure stand about 4 to 8 off the floor To make track adjust ments 1 Loosen rear idler wheel tie down rod A allowing the idler wheels to turn freely as adjustments are being made Break lock nuts B away from adjustment nuts C on both sides of suspension allowing you to move the idler shaft and wheels forward and back for adjustment Correct track drop is 1 1 2 away from the slide frame D to inside sliding part of track Do not pull down on track to get this measurement and make sure that track is free of ice and snow or other weight Correct tension and alignment should result in an even drop on both sides To check track alignment start engine with machine on stand and turn track over slowly Caution do not run track fast when checking alignment and clear all tools away from track and suspension areas before starting engine After adjustments have been made stop ma chine and shut off engine Measure distance from rear of suspension upright E to rear of adjusting nut C on both sides Measurements should be equal If there is misalignment side of track closest to tunnel must be tightened If track is already very tight then adjusting nut on track side fartnest from tunnel must be loosened Adjusting for drop and alignment you should wind up with correct track tension and alig
21. ep the BRUT updated and running properly In view of this we are going to get tougher on the warranty program We have been very lax in the past as to filing claims on time This year the warranty claims must be filled out completely and turned in within 10 days of date of repair If this rule is not complied with you are taking LAIN NO seu Ow TAGS att 8 FA WARRANTY CLAIM aet af OATS AFTER MAH ING CLAIM 13481 FILED WITHIN 10 DAYS E tann ar oot Ue two sm COMME PCS CAS eA r Lives Te c Er Toe aoo 8T AMD TF am 4 NOT cm umm Tee OF ac tw Pint Q aO D ev LJ wc rto TOTAL LABOR TOTAL PARTS TOTAL CREDIT f TA chance on getting the claim rejected No claim has been rejected yet for this reason however if it continues to be a problem there will be no other choice but to do so GROUP CLAIMS There will be times this year when we will use a group claim On any group claim there will be a bulletin issued with a group claim number If there is no group claim number assigned refer to samples Use Regular Warranty Procedure for each unit ZA tr NO MUST APPT AR s ON TAGS ATTACHED APPLICAGLE FARTS ENGINEERING INC 1 UIMIL IBN WARRANTY
22. ffset should be 9 Check brake and throttle cable for adjustment and 10 11 12 operation Adjust if necessary Inspect choke operation Install windshield Prepare to start engine It is advisable to have a squirt bottle handy when starting a new engine Remove drive belt pour about one tablespoon of oil through the carburetor intake of each cylinder pull the starter rope a couple of times to distribute oil in engine Give engine a small amount of gas mixture from squirt bottle Make sure kill button and ignition switch on pull choke out and pull through If the engine does not start in or two pulls add a little more gas oil mix 13 14 15 16 17 18 19 20 After engine starts set the idle adjustment also the idle speed Run engine a few minutes at slow RPM to clear out excess fuel and oil Shut engine off Install drive belt raise rear of machine check for clutch operation and track alignment Check high low beam on head light also tail and brake lights Set high speed adjustment on carburetor Machine should be cleaned up before delivery to cus tomer Be sure warranty registration is filed within 10 days of date of sale This is a Federal Law on all motorized vehicles BRUTANZA ENGINEERING reserves the right to reject all warranty on machines not registered within proper time Steps 1 thru 19 should be repeated again after about 10 hours or 100 miles of driv
23. from driven unit remove from drive clutch Reminder driven clutch should be pulled open completely Installation Mount belt on drive clutch Grab moveable face of driven clutch with both hands on opposite sides of rim diameter and turn moveable face backwards then push to compress the clutch spring With clutch completely open push belt down between sheaves and slide belt over stationary sheave CLUTCH ALIGNMENT Offset from drive to driven clutch is 5 16 with salsbury salsbury and 1 2 with the salsbury brutanza Adjust by adding or subtracting washers on drive shaft under driven clutch To adjust parallel positioning alignment of drive and driven clutches loosen four 4 chaincase bolts and rotate chaincase in slots until clutches are parallel Then recheck offset RIDE ADJUSTMENT SPRING TENSION Increasing or decreasing the spring tension by adjusting the eye boit at the front of the spring will alter the firmness of the suspension When adjusting spring tension always have tension on friction shocks completely released Shock adjust ment will overcome severe machine bottoming Adjust the eye bolt so that 1 1 2 2 inches of thread shows past the nut for a normal 175 Ib rider Increase the amount of thread showing for a heavier person SHOCK TENSION After adjusting spring tension to fit rider adjust friction shocks by tightening castellated nut Shocks should be adjusted so suspension will not bottom wh
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25. ing A couple of hours well spent on pre delivery and a check up can save you the dealer many hours of work and many dollars in the course of the winter It will also make for a very good relationship with your customer Page 2 vintagesnowmobile com vintagesnowmobile com vocali vintagesnowmobile sgouBLESHOOTING TH TWO STROKE ENGINE C mob le com vi vintagesnowmobile com vintagesnowmobile com vintagesnowmobile com vin Cont Vititag cont Viritagesnowiiopile com vin vintagesnowmdalhile com E com vintagesnowmobile com vill vintagesnowrreoeMBRESSION y Inithe crankcase t pump fuel cO m vintagesnowmobile com vif Vintagesnowmobile com cete pers MENE com vintagesnowmobile com vintagesnowmghilg com vintagesnAawmebile com vintagesnowmobile com VIR n RE DAT Ql caa ie RR Op SE ud SPs win VINTA st ges m r involved and require more special Vini iagesnovwmobie com vin 1 vintagesnowmobile com vintagesnowmobile com vintagesnowmobile com vif vintagesnowmobile com vintagesnowrmebile com vintagesnowmobile com vir it VITICO ORC ST SPARK PLOG CONDITION AG SNOWF IODC R move the plug check the heat 516 com vini vintagesnowmobile com vintagesnowmobile com vintagesnowmobile com VIRB vintagesnowmobile com vintagesnowmobile com vintagesnowmobile com vini Vvintagesnmywmobiedom vintagesnowmobile nemiswimissgesnowmobile com Ving vintagesnowmobile com vintagesnowmob
26. key at base of steering post Page 18 Disconnect temperature gauge line from engine and plug manifold with small cork Remove coolant hoses and plug with corks so coolant does not spill Remove 7 16 lock nuts holding front motor mounts to chassis Page 19 Remove the six 6 8mm bolts on rear pair of motor mounts Lift engine and drain coolant Be careful not to break the plugs or drop engine during removal ENGINE DISASSEMBLY Remove the 1 2 carb nuts Next remove the 8mm exhaust manifold nuts and 8mm bolts in crankcase holding on the muffler Remove 6mm nuts holding both coolant manifolds in place then remove manifold after disconnecting coolant bypass hose Remove 8mm head nuts then remove heads while carefully prying up gaskets with table knife or similar tool E t 1 a e wa n 18 ag the p un u 3 ZH T FEE P Mw v T 4 Ls x MEE i 1 Remove the three 3 8mm bolts holding water pump mounting brackets to end cylinder then remove water pump and brackets Remove motor mounts on top and bottom of engine Remove 10mm cylinder nuts and slide cylinders off pistons With snap ring pliers remove piston pin snap ring Remove piston pin being careful not to apply excessive side pressure to connecting rod Remove piston pin bearing and bearing spacers Page 20 Remove 6mm recoil bolts and remove recoil Remov
27. le slowly watching the scale 2 take reading when the sheave first moves fter it has moved from 3 8 to 5 let the pressure off the scale very slowly until the sheave starts to original position Take your next meadinc When starts to move Do this several dises not 2 the readings each time You should get r sing on the pull of 18 19 lbs and on e return reading of 11 5 14 lbs or an average 2 l pull and 1 release of 15lbs
28. muffler The engine will not produce nor mal horsepower and may overheat replace or repair the muffler Seal the intake and exhaust ports and connect a pressure checking device Pressurize the engine to 10 p s i THEN The air fuel mixture will become lean enough to be noticed as a hot plug reading The machine will suffer from short plug life The air fuel mixture may become lean enough to cause preignition detonation and perhaps melting of the piston crown LL LULU L L com Viniag TROUBLESHOOTING CONTINUED Page 7 CRANKSHAFT DEFLECTION Remove the primary drive unit CHECK and the magneto from the ends of the crankshaft With a NOTE Crankshaft de magnetic stand mount the dial flection can be either gauge and check the deflection bearing freeplay the on each end end will move up and down without rotating the crankshaft or crankshaft misalign ment the end will wobble as it is turned IF THEN Deflection is greater The crankshaft seals can be than recommended tol stretched to the point that erance an air leak will occur this will not be detected by a static pressure test The engine will overheat due to lean mixture AND OR the ignition contact points can be opened at the improper time This will cause overheating and poor performance In either case major engine work is necessary IGNITION COMPONENT CHECKS Use appropriate instruments to test th
29. nment Track should be run after each adjustment to see if corrected When track adjustment is correct tighten rear idler tie down rod then tighten locking nut against adjusting nut on both sides of suspension being careful not to move adjusting nut After locking all nuts start engine and check adjustment once more On track drive lugs period ically check point where lugs ride against rail If one side shows more wear than the other check track alignment DRIVE CHAIN ADJUSTMENT A well adjusted chain has 1 2 deflection A in travel between the two chain case sprockets Chain tension is ad justed by tightener bolt B To adjust chain tension loosen and back out lock nut C With an inch lb torque wrench torque tightener bolt to 10 inch Ib then back tightener bolt out 1 2 turn Turn lock nut in and jam against chain case being careful not to further tighten bolt When refitting chain case cover replace lubricating oil Add oil through filler plug D with check plug E removed When oil level reaches check plug level replace plug On 1972 models plug E is drain plug only When refitting chaincase cover add 1 2 cup oil through filler plug with drain plug in Page 31 COOLING SYSTEM Your Brut snowmobile is equipped with an exclusive Brooten liquid cooled two cycle engine Your cooling system requires an Ethylene Glycol based anti freeze and comes from the fac tory mixed 50 50 with water This mixture
30. nsiderable use belt wearing out Bent pulley s flange causing belt flutter Excessive operation in low gear position Extremely low temperature Improper belt installation Belt rubbing stationary object Idler bearing seized Engagement RPM too high Belt hanging up in bottom of driven pulley Locked track Repair or replace Align pulleys Grind or polish Repair or replace Reduce engine RPM Align sheaves Inspect converter Inspect converter Align pulleys Reduce engine RPM Repair or replace see Operator s Align pulleys See Operator s Reduce engagement Replace belt Repair or replace Warm up belt slowly See Operator s Check drive Replace bearing Reduce engagement Belt too short Rotate track by driver pulley pulleys driver pulley at high speed driver pulley Manual Manual speed pulley Inspect converter Manual components RPM replace hand until free BRUT S LIQUID COOLED BROOTEN ENGINE Dama i BRUT SPECIFICATIONS Fuel capacity mobile com virtagesnowrned gallons US ne Spark qap Soe oe eae 2x BAM AERE Height w windshield 7 Point gap EEZ only 72 2 s U01201 Width vene VIIIUQUCSIIOVTIIODIIC COTII VIPRSNESTIOVITEN Engine models 294ccliquid cooled Brooten twin cylinder Trackiwitthe com vintagesnowmobile com virffatfa
31. rear skag hole by hand tap on wooden block to drive skag backwards When skag bolts line up direct ly with holes use pry bar to remove wooden block and skag will snap into place Then replace lock nuts on skag bolts HEADLIGHT REPLACEMENT To replace headlight start by removing wiring plug on back of lens With fingers remove wire spring holding lens down Install new lens by first positioning it then reinsert wire spring and plug in electrical plug Replace with dual element 12 volt GE4454 bulb or equivalent HEADLIGHT ADJUSTMENT Four headlight adjustment screws enable you to adjust the beam up down and to either side Adjustments should be made for your particular driving condition Caution It is easy to overdrive your headlight at night Always use common sense and a safe speed at night Drive especially carefully on unfamiliar land TAILLIGHT BRAKE LIGHT REPLACEMENT To replace taillight first remove lens screws Take off lens and replace bulb with a 12 volt 1034 bulb Page 29 BRAKE ADJUSTMENT Remove cotter pin on castellated nut G page 23 and tighten nut until puck presses against disc and there is about 3 4 brake handle play DRIVE BELT REPLACEMENT Removal Squeeze the brake so brake pressure will hold the stationary sheave of the driven clutch Grab moveable sheave and rotate backwards then pull belt down into driven clutch V Lift and slide belt off stationary sheave of driven clutch When loose
32. rough Install two 2 front engine mounts with four 4 10mm choke swivels on the two 2 carbs colsest to magneto and bolts loop linkage rod around carb closest to clutch Replace Set engine in chassis and install six 6 8mm bolts the two swivel screw after looping linkage rod over swivel Mount 2 7 16 bolts on front mounts Set steering post in position choke cable on choke cable bracket and tighten securely and tighten all bolts Install third carb next to coolant pump Thread choke and throttle cables through linkage swivel and uw Install throttle cable on cable bracket Center bracket on tighten swivel screw Page 27 THROTTLE LINKAGE ADJUSTMENT Loosen linkage swivel screws on the two carburetors closest to clutch Squeezing the throttle the linkage rod should move freely inside swivels without activating the throttle shafts on these two carbs Back out all carburetor idle speed screws away from carb throttle shaft stops This will synchronize all butterflies in closed position Grasp linkage rod and push it hard enough so first carb butterfly closes completely The other two carbs should be closed also When they are all closed continue to hold down rod and tighten swivel screws securely Move throttle lever to check synchronization of all throttle shafts If synchronized turn idle speed screws until they just touch shaft stops then make an additional 3 4 turn on each screw Y ou must turn them more for proper idle b
33. ry on models equipped with Brutanza Drive Clutch DRIVE INSTALLATION Lock collar must be on flangette side of shaft with eccentric portion facing tunnel before installation Before installing chaincase be sure snap ring is on shaft With machine lying on left side fit track into tunnel Then push driveshaft into chaincase hole and back through spherical bearing mounted on the flangette Holding drive sprockets as close to center of tunnel as possible slide chaincase onto drive shaft Snug chaincase tightly up against tunnel Slide top sprocket spacer over spline and install sprockets and chain Screw bolt in driveshaft to hold chain sprocket on and center track drive sprockets INTERNAL DRIVE SPROCKET REMOVAL With drive shaft removed remove the track drive sprocket With long 1 4 punch pound out 5 16 roll pin from shaft Drive sprocket should slide off Slip snap ring on top drive sprocket in chaincase to hold it in position Install chain tightener assembly and tighten chain so there is 1 2 deflection in chain Jam locking nut on tightener bolt Check O ring seal on chaincase cover and install if O K Be careful not to damage jackshaft seal when installing chaincase cover Go back to driveshaft inside tunnel and slide lock collar into position next to flangette bearing Turn collar lock with punch and tighten with socket wrench Page 16 BRAKE INSTALLATION Place inner brake puck in chaincase cover Install
34. shoes om the arms stay a proper position The screws on the weight arm shoulc be installed with locktite or punched in to insure they they do not come out Should your engine seize or lock up for any reason the clutch 14 be dismantled for inspection of the shoes on the arms 245 d n pic hs ze 3 mI DRIVEN CLUTCH ADJUSTMENT set the Brutanza clutch on the LC 29 Brut it is meeeessry to set the driven clutch at 15 pull This be accomplished by using a 7 coil spring amp wrapping it amp term measure the pull exactly follow the instructions below 1 move drive belt 2 T ve drive engine clutch bolt 2 Imsta3ll bolt between sheaves on driven clutch Imetall the bolt so the sheaves can rotate on it careful not to jam threads into shaft small vise grip pliers Clamp 24 piece mf wire on the outer lip of the driven clutch gt this on as close to the engine head as possible with wire pointing to the rear of machine Seed Book on the end of your piece of wire you well meed to use a fish scale that reads to aprox 2m Hook scale to wire Stand to the rear of the clutch Pull on the scale to loosen up the moveable sheave move it aero Let off the pressure easy so you do M mot sat the moveable sheave to hard 7 Grab the brake with one hand the scale in the other 2583 pall the sca
35. tory set a 3 5mm BTDC in fully advanced position To set timing disconnect red wire leading from ignition points to ignition coil on cylinder next to magneto Connect one lead of an ohmmeter timing light or timing buzzer on connector leading from points Connect other lead to grounding surface on engine Insert an indicator in spark plug hole nearest magneto Position stator plate in center of slots Note It is best to set correct timing with stator in this position But if timing cannot be adjusted to point gap specs then position of stator must be changed Adjust point gap so points open when dial indicator reads 3 5mm or 138 The cam must be in full advance position Check point gap with feeler gauge and make sure point gap is within specs of 012 and 017 If not stator plate must be adjusted accordingly to set proper specs When timing is correct on magneto cylinder next set timing on cylinder next to clutch Disconnect white lead to coil Adjust timing by changing point gap only If stator plate is moved flywheel cylinder must be retimed SERVICING DRIVEN CLUTCH Position removed clutch with fixed face down Rotate moveable sheave approximately 35 clockwise and hold steady Press ramp down to clear key and rotate so key holds ramp down Remove snap ring then remove ramp Hold firmly to prevent sudden spring release Clean and examine all parts Replace if worn Slide moveable face onto hub replace key
36. tthnowmtr Engine models 439ccliquid cooled Brooten three cylinder Approximate weight yj boc cop bC44 us 395 IDS dra Approximate weight LC29 355165 dry APA 3nowm ENGINE TIMING LC44 3 5mm BTOC fully advanced m LC29 3 5mm BTDC fully advanced snow snowmc BRUT SERVICE TOOL LISTING Clutch puller Part No 23112 11 Salsbury 23112 12 Brutanza ocn Kiss Clutch alignment tool Part No 23122 10 Salsbury 23122 11 Brutanza Drive Flywheel puller Part No 23 12 10 Recommended Spark Plug NGK B7ES or Champion or eGcnowrTm igesnowrme jesnowmc BRUT SNOWMOBILE CUTAWAY esnowmc JACK SHAFT DRIVEN CLUTCH aesnowme DRIVE CHAIN gesnowme CCARBURETORScesnowm DRIVE CbLUTCHoesnOwn TIE ROD END agesnowmi esnowme SnOwimnt SPRING ADJUSTMENT col I J SHOCK ABSORBER Owm IAJ Ti I 1 cnnwrne BRA Y Y p aim L Y EE Se FRONT IDLER ADJUSTMENT NUTS WHEELS DRIVE SHAFT THE DOWN SUSPENSION SLIDE TRACK INTERNAL TRACK DRIVE SPROCKET T DH me ROD NUTS SNOW 11 Mis E DELL OU OUS ERN SPEEDOMETER ELECTRICAL SCHEMATIC 1972 BRUT 440 IGNITION SWITCH x E j YELLOW UD WHITE E I _ HELLOW BLACK EROJN ELECTRICAL SCHEMATIC
37. ut this should be done with engine running To set correct idle speed of 1500 rpm you must turn idle screws on all carburetors exactly the same amount CHOKE LINKAGE ADJUSTMENT Make choke adjustments the same as throttle so choke butterflies are all closed when choke cable is pulled Then when choke is pushed in butterflies should open all the way STEERING ADJUSTMENT AND SKI ALIGNMENT Position handle bars so they face straight ahead Adjust either ski so it is also facing straight ahead Adjust ski by loosening jam nuts at both ends of tie rod as necessary to align one ski If you cannot align one ski exactly you may have to index steering arm at spindle When handle bars and one ski are aligned measure distance from one ski to other at points on front and rear ski spring saddles There should be 1 4 toe out that is front of skis are spread 1 4 farther apart than rear If you do not have correct toe out loosen jam nuts on tie rod that has not been adjusted and turn whichever way necessary to get 1 4 toe out When steering is adjusted make sure all jam nuts and other nuts and bolts are tight ENGINE TIMING 1 44 The LC440 engine is equipped with capacitor discharge ignition CDI and timing is set in the factory at 3 5mm BTDC in fully advanced position Timing cannot be adjusted on this system and should never change LC29 The LC294 engine is equipped with breaker point magneto ignition system Timing is fac
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