1970 CCW 340 Service Manual - Vintage Snow

TECHNICALSERVICE MANUALOPERATION, SERVICE AND REPAIRofc. c. w.ENGINESModelsC. C. W. 340 & C. C. W. 400 ·NOVEMBER 1970PRINTED IN CANADACANADIAN CURI/SS-WRIGHT, LIMITED500 CARUNGVIEW DRIVE, REXDALE, ONTARIOPHONE: 677-3930-TELEX: 02-29647 ..• I

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•• • 5-10LIST OF ILLUSTRATIONSFIGURENUMBER TITLE PAGE1-1 MODEL K EC 340/400 ENGINE LEFT SIDE . .. . . .. 1-22-1 TWO STROKE ENGINE OPERATING PR INCIPLE . . . . .2-2 SAWAFUJI IG N ITION SYSTEM . .. .... . . .. . . .... 2-32-3 KOKUSAN IGNIT ION SYSTEM . . .. ... . . ... . . . . . 2-32-4 L IGHTING SY STEM-MANUAL START. Previous toEngine Serial Numbers 340-2903614 and 400-2809570.Light taken from lighting coil. (AC 12 V 35W) . . .. . . 2-52-5 LIGHTING SY ST EM-EL ECTRIC START . Previous t oEngine Serial Numbers 340-2903614 and 400 -2809570.Lights powered from battery . . ... .. ... .... . . .. . . 2-52-6 LIGHTING SYSTEM- MANUAL START. 340S onlyprevious to serial number 340-2903614.L ights taken from lighting coil. (AC 12V 75W). . .. .. 2-62-7 LIGHTING SY ST EM-MANUAL START. EngineSerial Numbers 340·2903614, 400-2809570 andsubsequent.One Headlamp. 12 volt, 35 watts.One Tail lamp, 12 volt, 3 watts. . ..... . ... . . ... . . 2-82-8 LIGHTING SYSTEM - MANUAL START . EngineSerial Numbers 340-2903614, 400-2809570 andsubsequent.Two Headlamps, 12 volt, 35 watts.Two T aillamps, 12 volt,. 3 w atts. . . . . . . . . . . . . . 2·92-9 LIGHT ING SY STEM- EL ECT RIC START. EngineSerial Numbers, 340-2903614,400-2809570 andsubsequent.One or two head and tail lamps.Battery charging. . . . . . ....... . .. .. . .. . . . ... 2-1 02-10 TYPICAL WIRING SCHEMATIC.8 POLE CONNECTOR, MANUAL START . .. .... . .. 2-112-11 TYPICAL WIRING SCH EMATIC.8 POLE CONNECTOR, EL ECTRIC START . ..... . .. 2-122-1 2 TYPICAL WIRING SCHEMATIC. 340's ONLY.6 POLE CONNECTOR, MANUAL START . . . .. .. . . 2-132-12A TYPICAL WIRING SCHEMATIC. 340-G-E,6 POLE CONNECTOR, MANUAL START . ... .. . ... 2-142-1 3 TYPICAL WIRING SCHEMATIC.6 POLE CONNECTOR, ELECTRIC START .. .. . . . . . 2-153-1 CYLINDER COVER REMOVED ... .. . .. . . . ... . . . 3-2FIGURENUMBER TITLE PAGE3-2 INTAKE AND EXHAUST MANIFOLDS REMOVED . 3-23-3 RECOIL STARTER AND HIGH T ENSIONCOILS REMOVED . .. ... . . .. . ... . .. . . . ... .. . . . 3-23-4 STARTER CUP AND FAN BELT PULLEY . . . .. . . . 3-33-5 FAN COVER REMOVED . . ..... . . . . .. . . .. ... . . 3-33-6 REMOVING FLYWHEEL . . . . .. . .. .. . .. . . .. . .. . 3-43-7 FAN COVER CASE REMOVED .. . . . . .. ... . . . . .. 3-43-8 MAGNETO REMOVED .. . .. .. ..... .. ... . . . ... . 3-53-9 CYLINDER HEADS REMOV ED .. . . . .. . .. . . . .... 3-63-10 CYLINDERS REMOVED .... ... ... .... .. .... .. 3-63-11 REMOVING PISTONS . .. .... . . .. . . ... .. .. ..... 3-83-1 2 UPPER CRANKCASE HALF R EMOVED . . . . . . . .. . 3-84-1 FAN COVER A SSEMBLY . .. .. . .. . ... . ..... . .. . 4-24-2 RECOIL STARTER A SSEMBLY .. .. .. . . . .. .. . . .. 4-34-3 FLYWHEEL ASSEMBLY (340S) . .... . .. . . .. .. . . . 4-44-4 FLYWHEEL ASSEMBLY (340, 340G, 400) .. ..... . 4-64-5 STATOR A SSEMBLY (Sawafuji Ignition) . . . . . . ... . 4-74-6 STATOR ASSEMBLY (Kokusan Ignition) . . . . ... .. . 4 -84-7 PISTON AND CRANKSHAFT A SSEM BLY . . . .. . .. 4-94-8 OIL SEALS IDENTIFICATION . . ... . .. . . .... . .. . 4-95-1 CRANKCASE LOWER HALF (Oil seal retaining circlips· · · · · · · · · · .. . . . ... . . .... .. . . . . . . . . . . ..... .. 5-1 I5-2 CRANKCASE BOLT TORQUING SEQUEN CE . . ... . 5-2 ·5-3 INSTALLING PISTON, RINGS AND PINS . ... . .. . . 5-25-4 INSTALLING CYLINDERS ... . .• ....... .. .. .. . 5-35-5 CYLINDER HOLD-DOWN NUT TORQUINGSEQUENCE . . .... . . . .. . ... . .. . . . . . . . ... . ... . 5 -35-6 INSTALLING CYLINDER HEADS . .. ... .. . . .. . . . 5-45-7 CYLINDER HEAD HOLD-DOWN NUT TORQUINGSEQUENCE . ... .. .. . . ..... . . . .... .. . .. . .... . 5-45-8 STATOR ASSEMBLY INSTALLED . . . . .. . .. . .. . . 5-55-9 FAN COVER BACKING PLATE ANDFLYWHEEL INSTALLED ....... . .• .. ... . ... . 5-55-10 FAN COVER, STARTER CUP AND FANBEL T PULLEYINSTALLED ..... . . ... . . . . ... . . . .... . .. . . . . . 5-65-11 HIGH TENSION IGNITION INSTALLED . . ... . . .. . 5-65-12 RECOIL STARTER INSTALLED .. .. .. . .. . . .. .. . 5-65-13 ADJUSTING CONTACT BREAKER POINTS . . .. .. . 5-85-14 ADJUSTING ENGINE IGNITION TIMING .. .. .. . .. 5-9C.C.W. TOOL LIST . . .. ... .. . . . .. . . . .. .. . . . .. . 1-3/LIST OF TABLESTABLENUMBER TITLE PAGE1-1 TECHNICAL DATA . .... ... . . ....... .. .... . . . 1-12-1 TROUBLESHOOTING CHART .. . . .. . . . .. . ... ... 2-162-2 LUBRICATION CHART .. . . . . ... . . . .... . . . ... 2-203-1 FITS AND TOLERANCES . . ... . .. .. . . . .. .. . . . 3-105-1 CRANK VERSUS PISTON ANGLE ...... .... . .. .. 5-95-2 TORQUE SPECIFICATIONS . . .. .. o • • 0 0 0 0. 0 0 0 0 0 0 5-105-3 METRIC/LINEAR CONVERSION FORMULAS . 05-4 LIST OF APPROVED CARBURETORS 0 0 . 0 0 o o •• o. 5-10

TABLE OF CONTENTSSECTIONPAGEINTRODUCTION AND TECHNICAL DATA . .... . 1-11.1 Introduction .... ... ... .. .. . .. . . . .... 1-11.6 Model Designation . . ..... ............. 1-11.8 Technical Data ............... . ...... 1-11.9 Tools, Special & Standard Requirement ... 1-1ILLUSTRATION OF SPECIAL TOOLS . . ..... . .. 1-1SECTION3.3 .93.3.103.3.113.3.123 .3.133.3.14PAGEFlywheel Assembly . . . . . . .. ... . . . . . ... 3-9Cylinder Heads and Cylinders . .. . ... . ... 3-9Pistons, Pins and Rings .... . . .. .. .. .. . . 3-9Crankshaft and Connecting Rods . .... . . . 3-9Crankcase .. ..... .. .. . .. . . .. . .. . .. .. 3-9Fits and Tolerances .. _. . .. . ..... .. .... 3-9IIIllOPERATION AND SERVICE INSTRUCTIONS .. .. 2-12.1 Principles of Operation ...... . ...... . .. 2-12.2 Sequence of Operation ....... .. . . . . . .. 2-12.3 Ignition Systems ...... ............. . . 2-22.3.1 General .......... ...... .. .. . . . . . .. . 2-22.3.2 Description . . ........... .. . . . ..... . . 2-22.3.2.1 Sawafuji Ignition (Magneto) . . ...... . ... 2-22.3.2.2 Kokusan Ignition (Magneto) . . . . . .. .. ... 2-22.3.3 Operation . .. . . . . ... . .. . .. . ...... . . . 2-22.4 Detonation and Pre-Ignition ...... . . .... 2-22.4.4 Pre-Ignition ...... . . . . ........ . . . . .. . 2-42.5 LIGHTING SYSTEMS .... .. ... . . . . ... 2-42.5.2 Operation of Lighting Systems . ....... . . 2-42.5.2.1 Engines previous to Serial Numbers Model340-2903614 and Model 400-2809570 ... ... . 2-42.5.2.2 Engines Serial Numbers Model 340-G-E 2903614 and Model 400-S-G-E 2809570and subsequent . . . . . ..... ... ..... . . .. 2-42.5.2.3 Model 340S only. Engines with serial numbers2903614 & subsequent. See fig. 2-12 .. . .. 2-72.6 PERIODIC SERVICING ........... . ... 2-72.6.1 Spark Plugs . . .. .......... . . . ... . ... . 2-72.6.2 Fan Belt .......... . .. ...... . . . . ... . 2-72.6.3 Trouble Shooting .... ... ..... . .. . ... . 2-72.7 OPERATING INSTRUCTIONS . .... ... 2-192.7.2 Starting the Engine ..... . . .... _. . .. . . 2-192.7.2.1 Starting with recoil starter ..... . . . . .... 2-192.7.2.2 Starting with electric starter .. . . . ... . . . 2-192.7.3 Stopping the Engine _..... .. .... . .... 2-192.8 Lubrication .......... .......... . ... 2-19DISASSEMBLY, CLEANING AND INSPECTION .. . 3-13.1 PREPARATION FOR DISASSEMBLY .... 3-13.2 DISASSEMBLY ................ .. ... 3-13.3 CLEANING AND INSPECTION ... ... ... 3-73.3.13.3.23.3.33.3.43 .3.53.3.63.3.73.3.8Cleaning ........................... 3-7Inspection ...... . ....... .. . ... . . . ... 3-7General ..... . ........ . .. . ..... ..... 3-7Spark Plugs ... . .......... . .......... 3-7Fan Cover .. . . . . .. .......... . .. . ... . 3-7Recoil Starter . . ..... . . . .. .. . .. . . . ... 3-7Electric Starter . . . ... ...... . . .. . _ .. . . 3-7Magneto Assembly ... . .. .. . ........ .. 3-7IVvREPAIR AND REPLACEMENT .... ........ . . .. 4-14.14.24.34.44.54.64.6. 14 .6.24.74.7.14.7.24 .84.8.1GENERAL ................. ........ 4-1FAN COVER .... ... . ... .... . ...... . 4-1RECOIL STARTER . .. .... . ..... ..... 4-1FLYWHEEL ASSEMBLY (340S) . . . . . ... 4-5FLYWHEEL ASSEMBLY (340E, 340G,400) ..... - .... . .. ... .. . - . . . . . . . . . . 4-5STATOR ASSEMBLY (340S) . . . .. ... . . . 4-5Contact Breaker Point Set . ..... . .. . . . . . 4-5Condenser and Oil Felt Pad .. .. . . . . .. . . 4-10STATOR ASSEMBLY (340E, 340G, 400). 1-10Contact Breaker Point Set .. ........ ... 4-10Condenser and Oil Felt Pad ......... . .. 4-10CRANKSHAFT .. .... ..... . ........ . 4-10Oil Seal and Outer Bearing . ... ... .. ... 4-10REASSEMBLY, TESTING AND ADJUSTMENTS . . 5-15.1 GENERAL ........ ....... ..... . . . .. 5 -15.2 REASSEMBLY .. ... . .. .... . ......... 5-15.2.1 Crankcase and Crankshaft . .... _. . ... .. . 5-15.2.2 Pistons, Pins and Rings .. .... .... . . .... 5-15.2.3 Cylinders . .. ..... .. . .. .. ... . . .. . . . . . 5-25.2.45.2.55.2.65.2.75.2.85.2.95.2.10Cylinder Heads .. . .. . . . . . . . ... . .... . . 5-4Stator Assembly . . . . ..... . . . . .. . ... .. 5-5Fan Cover Case and Flywheel .... . .. . . .. 5-5Fan Cover, Starter Cup andFan Belt Pulley ......... . _ ... . . _ . . . .. 5-6Electric Starter ....... . .... . .. ...... . 5-7High Tension Ignition .. . . . .... ........ 5-7Recoil Starter ........... . .. . . . ...... 5-75.2.11 Intake and Exhaust Manifolds ...... ... .. 5-75.2.12 Covers . . .. . . . ....... .. .. . ..... . .... 5-75.2.13 Engine Installation .. . ....... . ... .. . .. 5-75.3 TESTING AND OVERHAUL .. . . . .... .. 5-75.45.4.15.4.25.4.35.4.45.4.4.15.4.4.25.4.4.3ADJUSTMENTS . . . .... .. ..... ... .... 5-7Carburetor ............... .. .. .... ... 5-7Spark Plugs . . .. ..... .... . . ... . ...... 5-7Contact Breaker Point .... . . ........ ... 5-7Engine Ignition Timing .... . . . ........ . 5-7Preferred Method ... .. ... . _... . ...... 5-7Alternate Method .. . . . ....... . .. .. .. . 5-8Crankshaft Angle Versus Piston Travel .... 5-8

cSECTION 1INTRODUCTION AND TECHNICAL DATA--......_.1.1 INTRODUCTION1.2 This manual co nta ins instructions for the operation,service, and repair of Canadian Curtiss-Wright CCW 340 andCCW400 two cycle engines.1.3 The model CCW340/400 engine is shown in Figure 1-1.One illustration is used, since the two engines are sim ilar inexternal appearance. These engines are designed for use invarious snowmobi le configurations and are suitable for use inAll Terrain Vehicles or simil ar app lications.1.4 The instructions detail the procedures and tools requiredto ensure efficient operation, servicing and rep air ofthe engine and component parts. Refer to Parts Catalogue fortool cross-reference.Engine nuts, bolts and threads are metric except for theengine mounting bolts, which are 7/16" SAE coarse, and thepower take off (P.T.O.) end of the crankshaft which is 1/2"SAE fine (20TPI).1.5 Carburetion data for the engine models covered in thismanual is detailed under sepa rate instructions. For carburetortechnical requirements refer to Appendix I, or toapplicab le manufacturer's specifications.1.6 MODEL DESIGNATION1.7 The letters and numbers in the subject engine modelsdesignate the following: -ccw340/400Manufacturer's type designation.Cubic centimeter displacement- S Manual Start- E Electric Starter- G Geared flywheel (for subsequent electricstarter installation.SER IAL NOS. MODEL YEARCOMMENC IN G18 ccw 400 196919 ccw 340 196928 ccw 400 197029 ccw 340 19701-1NOTESa. Model 340S includes a Sawafuji ignition system comprisingof one low tension generati ng coil and two high tensioncoils of opposite polarity. This system is not interchangeablewith other models.b. Models 340E, 340G, and 400 includes a Kokusan ignitionsystem comprising of two low tension generating coils andtwo high tension coils all of the same polarity. This systemmay be interchanged between all models excepting 340S.c. The model 400 uses a smaller fan pulley than the 340models and has an increased bore size to 65 mm. The pistonstroke is the same in both engines.1.8 TECHNICAL DATATable 1-1 details specificatio ns appl icable to the modelsCCW 340 and CCW 400 engines.1.9 TOOL REQUIREMENTThe following is a list of too ls required for the overhaul andadjustment of models CCW 340 and CCW 400 engines:a. Special Tools ReferenceTool, Flywheel puller Part 43-0790-90 Para. 3.2. 1 ( 1)Tool, Main Spring, Starter Rewind. 43-0797-60 Para. 4.4Tool, Bearing puller (crankshaft). Part 43-0791 -70 Para. 4.8.1Tool, Flywheel Locking. Part43-0798-40 Para. 3.2.1 (j)Tool, Fan Pulley Locking. 43-0792-50 Para. 4.2.1 (a)b. Standard Tools10/13 mm spanner13/21 mm Box spanner and hand le22 mm spanner22 mm socket wrench and ratchetPiston ring removal toolPiston ri ng compresso rPiston ring groove cleaning toolCirclip removal toolTorque wrench (pounds feet)Dial indicatorDegree wheelFeeler GaugeSpark plug tapSpark plug wire gaugeThread Cleaning toolsWire brush (spark plugs)Soft metal (non ferrous)scraperPh ill ips screw driver setCommon screw driversSoft hammer

Fig. 1-1 Model KEC 340/400 Engine -1-2Left Side View from Flywheel end.

CCWTOOLLIST43-0797-60REWIND SPRING TOOL43-0791-70BEARING PULLERc43-0790-90FLYWHEEL PULLER43-0798-40FLYWHEEL LOCK43-0792-50FAN LOCK1-3

TABLE 1-1 TECHNICAL DATA -1970 MODELS SECTION ISPECIFICATION ccw 340 ccw 400Cycle: Two stroke Two strokeNumber of cylinders: Two TwoCapacity: 339 cc (20.9 cu .in.) 398 cc (24.3 cu. in.)Stroke: 60 mm (2.36 in.) 60 mm (2.36 in.)Bore: 60 mm (2.36 in.) 65 mm (2.56 in.)Compression ratio : 8.5 8.5Rating: 25 BHP at 5800 rpm 30 BHP 5800 rpmMaximum torque :(23 lbs. ft.) at 5250 rpm (27.31bs. ft.) at 5500 rpmSpecific fuel consumptionunder full load: 400 gr/ps.h (0.881b/ps.h) 400 gr/ps.h (0.881b/ps.h)Ignition system: Auto-advanced flywheel ignition Auto-adva nced flywheel ignitionwith lighting coii12V- 75Wwith lighting coii12V- 75WContact breaker gap: 0.3 to 0.4 mm (.012 to .016 in.) 0.3 to 0.4 mm (.012 to .016 in.)Ignition timing settingwhen fully advanced : 230 BTDC 230 BTDC(Static timing setting): BTDC go (.015" BTDC on Piston) so (.015" BTDC on Piston)Spark Plug: NGK B 8H or equivalent NGK B SH or equivalentSpark plug gap: 0.5 to 0.6 mm (0.020 to 0.024 in.) 0.5 to 0.6 M.M. (0.020 to 0.024 in.)Starter system : Rewind starter with emergency Rewind starter with emergencystarting pulley or electric starter starting pulley or electric starter(output 0.5 kw)(output 0.5 kw)Carburetor: Tillotson HR or equivalent Tillotson HR or equivalentFuel: Mixture, gasoline of known brand Mixture, gasoline of known brandand special air cooled two strokeand special air coo led two strokeengine oil. (See Table 2-2) engine oil. (See Table 2-2)Mixture ratio : 20:1 (at normal operating conditions) 20:1 (at normal operat ing cond itions)Rotation direction of engine: Left hand (standard configuration) Left hand (standard configuration)see toward the power take off endsee toward the power take off endof the engine.of the engine.Weight: 60 lbs. 60 lbs.Inlet port, timing 1380 1380height 23mm 23mmwidth 42mm 46mmExhaust port, timing 1680 1680height 23mm 23mmwidth 28mm 38 mmPiston height: 67mm 67mmPiston ring, chromium plate, top 1 1Piston ring, gray cast-iron, bottom 1 1Cylinder head, volume 16.35 cc 17 ccCooling fan, blades 8 8ratio 1.81 :1 t81 :1Magneto, make 340S only Sawafuji Kokusan340 GE Kokusan KokusanIGNITION COILS (340S) Sawafuji KokusanResistance, primary .4 ohms 1.4 ohmsResistance, secondary 8,500 ohms 5,500 ohmsCurrent rating 1.75/2.25 amps 1.5/1.75 ampsSpark in free air 8 mm @500 RPM 9 mm @500 RPM(three need le gap) 15 mm@ 5,500 RPM 16 mm @5,500 RPM0.1-4

TABLE OF CONTENTSSECTIONPAGEINTRODUCTION AND T ECHNICAL DATA .. .. . . 1-11.1 Introduction ............ ... ..... .... . 1-11.6 Model Designation .. .... . .......... .. . 1-11.8 Technical Data ... ....... . ......... .. 1-11.9 Tools, Special & Standard Requirement .. . 1-1ILLUSTRATION OF SPECIAL TOOLS . . .. ... . . . 1-1SECTION3.3 .93.3.103.3. 113.3. f23.3.133.3.14PAGEF ly wheel Assembly .... .. . . . . . . ... . .. . 3-9Cylinder Heads and Cylinders . ..... .. ... 3-9Pistons, Pins and Rings .. . . . . . . .. . .. . :. 3-9Crankshaft and Connecting Rods ...... . . 3-9Crankcase . ... . ........... .. . . . .. ... 3-9F its and T olerances . .. . . . . . . .. . .. .... . 3-9IIIllOPERATION AND SERVICE INSTRUCTIO NS .. . . 2-12.1 Principles of Operation .. . : • ..... . .. . .. 2-12.2 Sequence of Operation ... . . . ......... . 2-12.3 Ignition Systems . . . .. .. .. . ... . . . ... . . 2-22.3.1 General .... ... . . . . .. .. . ...... . .... . 2-22.3.2 Description . ... .. . .. .... .. ... . ..... . 2-22.3.2.1 Sawafuji lgnitfon (Magneto) .. . ... . . . . . . 2-22.3.2.2 Kokusan Ignition (Magneto) . . ... . . . . .. . 2-22.3.3 Operation .. . . . . ........ . . . . . . .. .. .. 2-22.4 Detonation and Pre-Ignition . . . .. . ... ... 2-22.4.4 Pre-Ignition . . . ..... . ...... . .... . ... . 2-42.5 LIGHTING SYSTEMS .. . .. . ... . . .... . 2-42.5.2 Operation of lighting Systems . . .. . . . ... 2-42.5.2.1 Engines previous to Serial Numbers Model340-2903614 and Model 400-2809570 . ...... 2-42.5.2.2 Engines Serial Numbers Model 340-G-E 2903614 and Model 400-S-G-E 2809570and subsequent . . . .. . ... . .. . . .. .. . . . . 2-42.5.2.3 Model 340S only. Engines with serial numbers2903614 & subsequent. See fig. 2-12 . .... 2-7·2.6 PERIODIC SERVICING ... . ..... . . ... . 2-72.6.12.6.22.6.32.7Spark Plugs . . ... . .. · . . ..... .. . .. . .... 2-7Fan Belt . .. ... .... .. ........ . . . . .. . 2-7Trouble Shooting ....... . . . . . . . .. .... 2-7OPERATING INSTRUCTIONS ....... . 2-1 92.7.2 Starting the Engine .. . .. ... ... . . . ... . 2-192.7.2.1 Starting with recoil starter . . ... . . . .. . .. 2-192.7.2.2 Starting with electric starter .. . . .. . .... 2-192.7.3 Stopping the Engine ............. .. .. 2-192.8 lubrication .. . ... .. .. . . .. . .. .. ..... 2-1 9DISASSEMBLY, CLEANING AND INSPECTIO N . .. 3-13.1 PREPARATION FOR DISASSEMBLY .. . . 3-13.2 DISASSEMBLY ...... .. ...... .. ... .. 3-13.3 CLEANING AND INSPECTION .. ... ... . 3-73.3.1 Cleaning .. . ... . . . . ...... ... . . ..... . 3-73.3.2 I nspectio"n ... . . . . ... . .. . . ... .. .. . . . . 3-73.3.3 General ................ . .. .. .... . . . 3-73.3.4 Spark Plugs .......... .. . . . . .. . . . .... 3-73.3.5 Fan Cover ........ .. . .. . . . . . ... . . . .. 3-73.3.6 Recoil Starter . . . . . ... . ... .. . . .. . . . .. 3-73.3.73.3.8Electric Starter . . . .... . . .. ..... . .. .. . 3-7M agneto Assembly . . .... . ... .. ....... 3-7IVvREPA I R AND REPLACEM EN T ... _. ... .. . ... . . 4-14.1 GENERAL . . ... . .. . ... ............. 4-14.2 FAN COVER ... . ............ _. .".... 4-14.3 RECOIL STARTER •.. .. . . ..... ... .. . 4-14.4 FlYWHEEL ASSEM BLY (340S) ... _... . 4-54.5 FlYWH EEL A SSEM BL Y (340E, 340G,4.64.6.14.6.24.74.7.14.7.24.84.8.1400) . .. · ... . . . ...... . . . . . .... . ... . . 4-5STATOR ASSEM BLY (340S) . .. .. .. . . _. 4-5Contact Breaker Point Set .. . . . . ... . ... . 4-5Condenser and Oil Felt Pad . .... .. ... .. 4-10STATO R ASSEMBL Y (340E, 340G, 400) . 1-10Contact B rea~er Point Set . . . . .. .. . ... . 4-10Condenser and Oil Felt Pad . .. .. .. .. . . . 4-10CRANKSHA FT .. . . .... . ." . ... . ...... . 4 -10Oil Seal and Outer Bearing ... . .. . .... . 4-10REA SSEMBLY, T ESTING AND ADJUSTMENTS .. 5-1!,).1 GENERAL . ... ... . ... .............. 5-15.2 REASSEMBLY .·.. .... .... .... . ... ... 5-15.2.1 Crankcase and Crankshaft . . ..... . ... . .. 5-15.2.25.2.35.2.45.2.55.2.65.2.75.2.85.2.95.2.105.2.115.2.125.2.135.35.45.4.15.4.25.4.35.4.45.4.4.15.4.4.25.4.4.3Pistons, Pins and 13 ings ... . . .. .. . .. . . . . 5-1Cylinders .. .. . . ... . ... .... .. : ." . . . . .. 5-2Cylinder Heads . ... .. . . . . ..... . ..... . 5-4Stator Assembly . .... . .. . . . . . . .. . . . .. 5-5Fan Cover Case and Flywheel ... . . .. . ... 5-5Fan Cover, Starter Cup andFan Belt Pulley . . . . .... . ..... . . . . . . . . 5-6Electric Starter ........ . .. . .. .. , . . .. . 5-7High Tension Ign it ion .. . . ... ... ... . • .. 5-7Recoil Starter .. . .. . . . ... .. . .. .. .. .... 5-7Intake and Exhaust Man.ifolds .... . . .... . 5-7Covers . ... .......... .. . . ... .... . .. . 3-7Engine Installation . . ... .. .... . . . . . . . . 5-7TESTING AND OVERHAUL .. ......... 5-7ADJUSTMENTS ....... .. .... . ..... .. 5-7Carburetor . .. . . . ...... . ... . .... . . : .. 5-7Spark Plugs .. . . .... . . .. . . ... . . . . ... . 5-7Contact Breaker Point ... . . .. ......... . 5-7Engine Ignition Timing . . . .. .. .... . .. .. 5-7Preferred Method .. . . ..... . . . . ... . ... 5-7Alternate Method .. . ... . . . .. . ... . . .. . 5-8Crankshaft Angle Versus Piston Travel . .. . . 5-8

LIST OF ILLUSTRATIONSFIGURENUMBER TITLE PAGE1-1 MODEL KEC 340/400 ENGINE LEFT SIDE ....... 1-22-1 TWO STROKE ENGINE OPERATING PRINCIPLE .. .. .2-2 SAWAFUJI IGNITION SYSTEM .. . .. ............ 2-32-3 KOKUSAN IGNITION SYSTEM .... .. ......... . . 2-32-4 LIGHTING SYSTEM - MANUAL START. Previous toEngine Serial Numbers 340-2903614 and 400-2809570.Light taken from lighting coil. (AC 12V 35W) . ..... 2·52-5 LIGHTING SYSTEM-ELECTRIC START. Previous toEngine Serial Numbers 340-2903614 and 400-2809570.Lights powered from battery ......... . ... . .... .. 2-52-6 LIGHTING SYSTEM-MANUAL START. 340S onlyprevious to serial number 340-2903614.Lights taken from lighting coil. (AC 12V 75W). . .... 2-62-7 LIGHTING SYSTEM-MANUAL START. EngineSerial Numbers 340-2903614, 400-2809570 andsubsequent.One Headlamp. 12 volt, 35 watts.One Tail! amp, 12 volt, 3 watts ....... . ..... . ... . 2·82-8 LIGHTING SYSTEM- MANUAL START. EngineSerial Numbers 340-2903614, 400-2809570 andsubsequent.Two Headlamps, 12 volt, 35 w atts.Two Taillamps, 12 volt,. 3 watts. . .... . . 2-92-9 LIGHTING SYSTEM-ELECTRIC START. EngineSerial Numbers, 340-2903614,400-2809570 andsubsequent.One or two head and tail lamps.Battery charging. . . . . .. .... .... . . . .. .. 2·102-10 TYPICAL WIRING SCHEMATIC.8 POLE CONNECTOR, MANUAL START . . ........ 2-112-11 TYPICAL WIRING SCHEMATIC.8 POLE CONNECTOR, ELECTRIC START ..... . . .. 2-122-12 TYPICAL WIRING SCHEMATIC. 340's ONLY.6 POLE CONNECTOR, MANUAL START ......... 2-132-12A T YPICAL WIRING SCHEMATIC. 340-G-E,6 POLE CONNECTOR, MANUAL START . .... . .. .. 2-142-13 TYPICAL WIRING SCHEMATIC.6 POLE CONNECTOR, ELECTRIC START ..... .. .. 2 -1 53-1 CYLINDER COVER REMOVED . .. .. ... ....... .. 3-2FIGURENUMBER TITLE PAGE3-2 INTAKE AND EXHAUST MANIFOLDS REMOVED . 3-23-3 RECOIL STARTER AND HIGH TENSIONCOILS REMOVED . ..... . . ... . . ... . ........ ... 3-23-4 STARTER CUP AND FAN BELT PULLEY .... . . . . 3-33-5 FAN COVER REMOVED . . .. . . ..... . . .... . .... 3-33-6 REMOVING FLYWHEEL .. .. . ... .... . . .. .. . ... 3-43-7 FAN COVER CASE REMOVED . .......... . .... . 3-43-8 MAGNETO REMOVED . ..... . ... . .... . . . .. .... 3-53-9 CYLINDER HEADS REMOVED . ....... . . ..... . . 3-63-10 CYLINDERS REMOVED . . .. . . .. ..... . . . .. .. . . 3-63-11 REMOVING PISTONS ..... . .. . .. .... ... ... . ... 3-83-12 UPPER CRANKCASE HALF REMOVED .... . . .... 3-84-1 FAN COVER ASSEMBLY . . . . .. .. . ..... . .... . .. 4-24-2 RECOIL STARTER ASSEMBLY ...... .. . ........ 4-34-3 FLYWHEEL ASSEMBLY (340S) . .. .... .. .. .. .. .. 4-44-4 FLYWHEEL ASSEMBLY (340, 340G, 400) ........ 4-64-5 STATOR ASSEMBLY (Sawafuji Ignition) . .. . .. .. .. 4-74-6 STATOR ASSEMBLY (Kokusan Ignition) . . . . . ..... 4 -84-7 PISTON AND CRANKSHAFT ASSEMBLY ... .'. ... 4-94-8 OIL SEALS IDENTIFICATION . ... . .... .. . .. .... 4-95-1 CRANKCASE LOWER HALF (Oil seal retaining circlips. . .. .. ... . ....... . .. . . . .. . ........ . ....... . 5-15-2 CRANKCASE BOLT TORQUING SEQUENCE .. . . .. 5-25-3 INSTALLING PISTON, RINGS AND PINS .. ...... . 5-25-4 INSTALLING CYLINDERS . . ........... . . .... . 5·35-5 CYLINDER HOLD-DOWN NUT TORQUINGSEQUENCE ........ ... ............ ... . ..... . 5-35-6 INSTALLING CYLINDER HEADS ...... ......... 5-45-7 CYLINDER HEAD HOLD-DOWN NUT TORQUINGSEQUENCE .... .. .. . . . .... . ... ..... . ........ 5-45-8 STATOR ASSEMBLY INSTALLED . .. .... ... .... 5-55-9 FAN COVER BACKING PLATE ANDFLYWHEEL INSTALLED . .... ..... .... .. . . . . 5-55-10 FAN COVER, STARTER CUP AND FANBEL T PULLEYINSTALLED ...... ............ ... . . . ........ 5-65-11 HIGH TENSION IGNITION INSTALLED . . . . .. ... . 5-65-12 RECOIL STARTER INSTALLED . . ... . . .. . ... .... 5-65-13 ADJUSTING CONTACT BREAKER POINTS ....... 5-85-14 ADJUSTING ENGINE IGNITION TIMING ........ . 5-9C.C.W. TOOL LIST .. .. ..... ....... .. . . . . . .... 1-3LIST OF TABLESTABLENUMBER TITLE PAGE1-1 TECHNICAL DATA . ........ .. ...... .. ... .... 1-12-1 TROUBLESHOOTING CHART ..... ..... . . . ..... 2-162-2 LUBRICATION CHART ............ . . . ..... .. 2-203-1 FITS AND TOLERANCES .. ..... . .... . . .. . ... 3-105-1 CRANK VERSUS PISTON ANGLE ........ . . ... . . 5 -95-2 TORQUE SPECI FICATIONS . . .......... . ... .. .. 5-105-3 METRIC/LINEAR CONVERSION FORMULAS ..... 5-105-4 LIST OF APPROVED CARBURETORS . ...... . .. . 5-10

-SECTION 1INTRODUCTION AND TECHNICAL DATA1.1 INTRO DUCTION1.2 This manual contains instructions for the operation,service, and repair of Canadian Curtiss-Wright CCW 340 andCCW400 two cycle engines.1.3 The model CCW340/400 engine is shown in Figure 1-1.One illustration is used, since the two engines are similar inexternal appearance. These engines are designed for use invarious snowmobile configurations and are suitable for use inAll Terrain Vehicles or similar applications.1.4 The instructions detail the procedures and tools required to ensure efficient operation, servicing and repair ofthe engine and component parts. Refer to Parts Catalogue fo rtool cross-reference.Engine nuts, bolts and threads are metric except for theengine mounting bolts, which are 7/ 16." SAE coarse, and thepower take off (P.T.O .) end of the crankshaft which is 1/2"SAE fine (20TPI).1.5 Carburetion data for the engine models covered in thismanual is detailed under separate instructions. For carburetortechnical requirements refer to Appendix I, or toappl icable manufacturer's specifications. ·1.6 MODEL DESIGNATION1.7 The letters and numbers in the subject engine modelsdesignate the following:-ccw340/400Manufacturer's type designation.Cubic centimeter displacement- S Manual Start- E Electric Starter- G Geared flywheel (for subsequent electricstarter installation.SERIAL NOS. MODEL YEARCOMMENCING18 ccw 400 196919 ccw 340 196928 ccw 400 197029 ccw 340 19701-1NOTESa. Model 340S includes a Sawafuji ignition system comprisingof one low tension generating coil and two high tensioncoils of opposite polarity. This system is not interchangeable with other models.b. Models 340E, 340G, and 400 includes a Kokusan ignitionsystem comprising of two low tension generating coils andtwo high tension coils all of the same polarity. This systemmay be interchanged between all models excepting 340S.c. The model 400 uses a smaller fan pulley than the 340models and has an increased bore size to 65 mm. The pistonstroke is the same in both engines.1.8 TECHNICAL DATATable 1-1 details specifications applicable to the modelsCCW 340 and CCW 400 engines.1.9 TOOL REQUIREMENTThe following is a list of tools required for the overhaul andadjustment of models CCW 340 and CCW 400 engines:a. Special Tools ReferenceTool, Flywheel pu ller Part 43-0790-90 Para. 3.2. 1 ( 1)Tool, Main Spri ng, Starter Rewind. 43-0797-60 Para. 4.4Tool, Bearing puller (crankshaft). Part43-0791-70Para. 4.8.1Tool, Flywheel Locking. Part 43-0798-40 Para. 3.2.1 (j)Tool, Fan Pulley Locking. 43-0792-50 Para. 4.2.1 (a)b. Standard Tools10/13 mm spanner13/21 mm Box spanner and handle22 mm spanner22 mm socket wrench and ratchetPiston ring removal toolPiston ring compressorPiston ring groove cleaning toolCircl ip removal toolTorque wrench (pounds feet)Dial indicatorDegree wheelFeeler GaugeSpark plug tapSpark plug wire gaugeThread Cl eaning toolsWire brush (spark plugs)Soft metal (non ferrous)scraperPhillips screw driver setCommon screw driversSoft hammer

Fig. 1-1 Model KEC 340/400 Engine -·•1-2Left Side View from Flywheel end.

CCWTOOL LISTc43-0797-60REWIND SPRING TOOL43-0791-70BEARING PULLERc43-0790-90FLYWHEEL PULLERc43-0798-40FLYWH EEL LOCK43-0792-50FAN LOCK1-3

TABLE 1-1TECHNICAL DATA -1970 MODELSSECTION ISPECIFICATIONCycle:Number of cylinders:Capacity:Stroke:Bore:Compression ratio:Rating:Maximum torque:Specific fuel consumptionunder full load:Ignition system:Contact breaker gap:Ignition timing settingwhen fully advanced :(Static timing setting): BTDCSpark Plug:Spark plug gap:Starter system:Carburetor:Fuel:Mixture ratio :Rotation direction of engine:Weight:Inlet port, timingheightwidthExhaust port, timingheightwidthPiston height:Piston ring, chromium plate, topPiston ring, gray cast-iron, bottomCylinder head, volumeCooling fan, bladesratioMagneto, make 340S only340 GEIGNITION COILS (340S)Resistance, primaryResistance, secondaryCurrent ratingSpark in free ai r(three needle gap)ccw 340Two strokeTwo339 cc (20.9 cu. in.)60 mm (2.36 in.)60 mm (2.36 in.)g_525 BHP at 5goo rpm(23 lbs. ft.) at 5250 rpm400 gr/ps.h (O_gglb/ps.h)Auto-advanced flywheel ignitionwith lighting coii12V -75W0.3 to 0.4 mm (.0 12 to .016 in.)230 BTDCgo (.015" BTDC on Piston)NGK B gH or equivalent0.5 to 0.6 mm (0.020 to 0.024 in.)Rewind starter with emergencystarting pulley or electric starter(output 0.5 kw)Tillotson HR or equivalentMixture, gasoline of known brandand special air cooled two strokeengine oil. (See Table 2-2)20:1 (at normal operating conditions)Left hand (standard configuration)see toward the power take off endof the engine.60 lbs.13go23mm42mm16g023mm2gmm67mm1116.35 ccg._j>Jit)1.g1:1 J/Sawafuji V' '""~ e eKokusanSawafuji.4 ohmsg,500 ohms1.75/2.25 ampsg mm @500 RPM15 mm@ 5,500 RPMccw 400Two strokeTwo39g cc (24.3 cu. in.)60 mm (2.36 in.)65 mm (2.56 in.)g.530 BHP 5g00 rpm(27.3 lbs. ft.) at 5500 rpm400 gr/ps.h (o.gglb/ps.h)Auto-advanced flywheel ign itionwith lighting coii12V- 75W0.3 to 0.4 mm (.012 to .016 in.)230 BTDCgo (.015" BTDC on Piston)NGK B gH or equivalent0.51o 0.5 M.M. (0.020 to 0.024 in.)Rewind starter with emergencystarting pulley or electric starter(output 0.5 kw)Tillotson HR or equivalentMixture, gasoline of known brandand special air cooled two strokeengine oil. (See Tab le 2-2)20:1 (at normal operating conditions)Left hand (standard configuration)see toward the power take off endof the engine.60 lbs.13go23mm46mm16go23mm3gmm67mm1117 ccg1.g1 : 1KokusanKokusanKokusan1.4 ohms5,500 ohms1.5/1.75 amps9 mm @500 RPM16 mm@ 5,500 RPMJ1-4

SECTION ncOPERATION AND SERVICE INSTRUCTIONSc2.1 PRINCIPLES OF OPERATIONa. The CCW two stroke engine is designed to complete in onerevolution, or two strokes of the piston, the completecycle of (a) fuel/air induction, (b) compression of the fuelmixture, (c) combustion, (d) exhaust of the burned gases.b. The construction of the engine requires a sealed crankcaseand a cylinder having four carefully positioned ports asfollows:1. Carburetor inlet for induction of the fuel/air mixture.2. Two transfer ducts leading to transfer ports fortransferring the mixture from the crankcase to thecombustion chamber.3. Exhaust port for exhausting the burned gases.c. The first stroke of the piston, from bottom dead center(B.D.C.) to the top dead center (T.D.C.), has twofunctions:1. To induce a mixture of fuel and air into the crankcasevia the carburetor.2. To compress the charge in the combustion chamber.d. The second stroke of the piston, from T.D.C. to B.D.C.,also has two functions:1. To uncover the exhaust ports and allow the burnedgases to escape.2. To compress the fuel mixture in the crankcase andtransfer it through the two transfer ducts to thecombustion chamber.2.2 SEQUENCE OF OPERATION (see Figure 2-1)a. As the crankshaft rotates, the piston moves from theB.D.C. position, thus creating a depression (or partialvacuum) in the crankcase. When the piston uncovers theFig. 2-1c1\1COMPRESSIONANDINDUCTANCECOMBUSTIONOFCHARGE2-1FUEL TRANSFERLOOP SCAVENGE

carburetor inlet port, fuel/air mixture, metered by thecarburetor, is admitted to the crankcase.b. Continued upward movement of the piston will compressthe charge in the combustion chamber until, at a pointnear T.D.C., the spark from the spark plug will ignite themixture.c. Resultant expansion of the ignited fuel will push thepiston toward· B.D.C. Moving downward, the piston firstuncovers the exhaust port and allows the hot gases, stillunder considerable pressure, to escape to atmospherethrough the exhaust system.d. Continuing downward, the piston will now uncover thetwo transfer ports and close the carburetor inlet port. Themixture in the crankcase and lower part of the cylinder isdisplaced by the piston and conducted through thetransfer ducts to the combustion chamber above thepiston. The fresh charge, entering through the twotransfer ports will form a loop (see Figure 2-10), thusscavenging the cylinder of burned gases.e. The cycle will repeat continuously as from paragraph (a)until the engine ignition is switched off.2.3 IGNITION SYSTEM2.3.1 GeneralThe ignition system used with model CCW 340 and CCW 400engines is basically the same as systems used with mostconventio nal two stroke engines. It consists of a low tensionmagneto, two high tension ignition coils, two ignition sparkplugs, spark plug (high tension) lead wires, an ignition switchand the required electrical wiring.Modei340S engines differ from 340E, 340G, and 400 enginesin magneto design. Magnetos in use on the model 340Sincorporate only one low tension generating coil. All othermodels covered in this manual use two low tension generatingcoils. Refer to paragraphs 2.4.2.1 and 2.4.2.2.2.3.2 DescriptionThe magneto assembly is mounted to the engine crankcase atthe flywheel end. It functions to generate low tensionimpulses in the primaries of the ignition coils. Two sets ofcontact breaker points, one set for each cyl inder, are installedin the magneto. 0 uring engine operation, a cam, mounted onthe flywheel, opens and closes the breaker points in sequence.A condenser, wired in parallel across each set of breakerpoints, protects the points from damage caused by selfinductedelectrical surges in the primary coil. Lighting andbattery charging coils (see paragraph 2.5) are mounted on themagneto coil plate. The coils produce the electrical powerrequired to operate a 12-volt lighting system and to chargethe battery used with electric started engines.Low tension (primary wires) leading from the magneto areencased in a protective cover and routed through a grommetlocated in the fan cover case, to the ignition coupler on thefan cover.2.3.2.1 Sawafuji Ignition (See Figure 2-2)The magneto used with model 340S (SAWAFUJI) ignitionsystems has one low tension generating coil. Each end ofthecoil is connected in parallel to the primary of one ignition coiland one breaker point set. The condensers and breaker point2-2sets are grounded to the magneto frame through a commonground.2.3.2.2 Kokusan Ignition (See Figure 2-3)The magneto used with model 340E, 340G and 400( KO KUSAN) ignition systems has two low tension generatingcoils. One end of each coil is grounded to the magneto frame.The other end of the coil connects in parallel to the breakerpoint set and the primary of one ignition coil.2.3.3 Operation (See Figures 2-2 and 2-3)The ignition switch is connected in parallel with the primarywindings of the ignition coils. Operation of the ignitionswitch to the "RUN" position, opens a circuit between thewindings and allows the contact breaker points to control theignition circuit.The flywheel incorporates four permanent magnets and abreaker point cam and auto advance mechanism. In operation,as the flywheel rotates, an electrical current is generatedin the low tension generating coil. The rotating breaker pointcam activates the breaker points, opening and closing them inaccordance with a timed ignition sequence. (Refer to SectionV, paragraph 5.4.4). Closing the points causes the buildup ofa magnetic field in the ignition coils. Opening the pointscauses a very rapid collapse of the field, thus inducing a highvoltage current in the secondary windings of the coil. Hightension spark plug wires conduct the high voltage current tothe spark plugs.Self induced high voltage current in the primaries is momentarilystored in the condensers to prevent arcing across thepoint contacts. When the contacts next close, the condenserswill discharge back to the ignition coils, thus assisting in thebuildup of the magnetic field in the coils.The ignition circuit will continue to function until theignition switch is turned to the "0 FF" position which willmaintain a circuit and prevent ignition.2.4 DETONATION:-The internal combustion engine is designed to induce acombustable mixture of gasoline and air into the cylinderwhich is subsequently ignited by a spark plug, and theresultant gas expansion utilized to produce the power stroke.Some considerable care is taken in the design to ensure thatthe combustion takes place at a controlled rate, but undercertain conditions the charge will burn at a highly excessivE)rate, producing abnormal gas temperatures and pressures inthe cylinder. This condition is called detonation and may,therefore, be defined as the rapid and uncontrolled burningof the chargewh ich commences at the point of ignition by thespark plug and is completed prematurely over a very shortmovement of the piston.2.4.1 The causes of detonation are many and varied, but allhave the common effect of overheating the charge towardsthe spontaneous combustion temperature of the fuel. Consequently,when the charge is further heated by compressionand ignited by the spark, the flame spread rate is very rapidindeed, resulting in the formation of the high pressure wavewhich impinges on the combustion chamber surfaces tocreate the sound of detonation of "pinging" which is sofamiliar to many people.2.4.2 It cannot be emphasized too strongly that if detonationis allowed to persist, serious damage may result to theJ

-IcPOINTSErL.T.COILTO1-IGNITION1 -SWITCHIGNITIONCOILPOINTSErK~WHITEWHITEFig. 2·2SAWAFUJI MAGNETO340S ONLyL~6or8 POLEcGNITIONCOILK~L.T.COILPOINT. SEI',--,CONDENSER,,IGNITIONCOILI IcL.T.COILPOINTSETFig. 2·3KOKUSAN MAGNETO340G-E400 S-G-EONDENSEfI~ER~2- 36or8 POLE_.1'0IGNITION1-sWITCH ·;-­II).,../WHITE~0:::~H0:::P...oK~IGNITIONCOIL

engine. Overheating of the engine can cause distortion of thecylinder and cylinder head, seizing and burning of pistons,breaking of cylinder flanges and studs etc.,In addition, prolonged detonation may lead into pre-ignitionof the charge and even more serious consequences to theengine. It is essential, therefore, that detonation should berecognized and the cause eliminated as soon as possib1e.2.4.3 Most of the common causes of detonation can beeasily rectified: -1. High compression pressures. (CCW 340/400 = 175-180PSI. cold at 500 RPM .)2. Incandescent points in the combustion chamber due toash deposits.3. Wrong type of spark plugs. (See Table 1-1)4. Spark plug overheated due to seat washer being worn ormissing.5. Incorrect ignition timing. (See section 5.4.4)6. Weak carburetor settings.7. High ambient temperatures. (Over 950 F.)8. Partially choked exhaust system causing high back pressure.2.4.4 PRE-IGNITION may be defined as the prematureburning of the charge due to spontaneous combustion, andbefore the specified timed ignition point by the spark plug.The resultant gas expansion, acting on the rising piston, generatesextreme temperatures and pressures in the combustionchamber and frequently results in broken pistons, bentconnecting rods, twisted or bent crankshaft and damagedbearings.Pre-ignition is usually caused by overheating and can bereadily identified by the very heavy knocking which is due togas expansion on the rising piston. It is usually preceded bydetonation, but certain conditions such as an under-sized orchoked exhaust system, will cause the engine to go straightinto pre-ignition without detonation. It is imperative that theengine should be stopped at once by closing off the air supplyto the carburetor. It will be apparent that the engine cannotbe stopped by switching off the ignition.2.5 LIGHTING SYSTEM2.5.1 Vehicle lighting is provided by lighting and batterycharging coils in the magneto, and the necessary wiring andlight switches required to operate the system.2.5.2 Operation2.5.2.1 Engines Previous to Serial Numbers:-Model 340-2903614, Model 400-2809570. Typical vehiclelighting circuit, See Figure 2-11.Engines bearing serial numbers previous to 340-2903614 or400-2809570 are equipped with an eight terminal ignitioncoupler. The lighting and battery charging circuits includetwo separate coil windings which produce 75 watts AC(alternating current) during magneto operation. 0 ne coilwinding supplies the power required to operate the lightingsystem and the other winding supplies the power required tocharge a 12 volt battery for use with electric started engines.MANUAL STARTED ENGINES(SeeFigu re2-4)Singleheadand tail lamp ( 12 V. 35 W-12 V. 3 W)a. The two wires from the battery charging coil winding are lamp life.2-4blue in colour. Both of these wires are routed to theignition coupler.The lighting coil winding is yellow in colour. One end isrouted to the ignition coupler and the other is grounded atthe magneto.A headlamp and tail lamp with maximum rating of 35watts may be installed on the vehicle. The wire to operatethe light switch is connected to the yellow terminal in theignition coupler.MANUAL STARTED ENGINES (See Figure 2-6)Twin headand tail lamps ( 12 V. 35 W- 12 V. 3 W).See drawing Number E 340S-150. Two 12 volt, 35 watthead lamps are connected in series with the single yellow wjre.Three 12 volt, 3 watt tail (or speedometer) lights completethe circuit in a series parallel connection with a ballast resistorrated 7 ohms, 40 watts. A parallel circuit with a single poledouble throw switch is shown connected across the headlamps.In the event of a lamp failure, the switch can be placedin left or right position to provide a circuit to the remaininghead and tail lamps.N.B.-This circuit can be omitted if not required.Materials required:-Load resister 7 ohms, 40 wattsSPOT Switch, 5 amps. 1These items are available from Canadian Curtiss-Wright,Limited.ELECTRIC STARTED ENGINES. (See Figure2-5)b. On engines equipped with an electric starter, the two bluewires at the ignition coupler are plugged into a C.C.W.rectifier, part number 43-071 0-00,· and the AC is convertedto DC (direct current). The black wire is grounded.From the rectifier, DC is routed through a 7.5 ampere fuseto the battery. Power to operate the lights is taken fromthe battery.2.5.2.2 Engines with Serial Numbers Modei340-G-F2903614, Modei400-S-G-E 2809570 and Subsequenta. Engines bearing serial numbers as above are equipped witha six pole term inal coupling for the ignition and lightingcircuits. In addition, the separate lighting and batterycharging coils as per paragraph 2.5.2.1 have been changedto a single center tapped coil. The ends have beenterminated in two yellow wires and the internally centertapped ground connection has been extended by a brownwire to the terminal block.·N.B.This brown wire may be disconnected provided a satisfactoryground is maintained between the lighting circuits and theengine.The coil is rated at a nominal 12 volt 75 watt maximum andcan be connected to meet the various electrical configura·tions.1. ONE HEAD LAMP 12 V 35W- ONE TAIL LAMP 12V3WSee Figure 2-7A ballast resistor rated at 5.3 ohms 40 watts must beconnected in parallel with the head lamp to prevent lamp burnout. It will be noted from Figure 2-7 that an alternativeresistor at 7 ohms 40 watts will raise the operating voltageacross the lamp to give a better light at the cost of reduced0

II~I I~I .I~I IFig. 2-4340 S-G400 S-GI-

uFigure 2-6G uNmIBLUEY.t:jLLVWIIA c.c.w.I I RECTIFIER~I I~IIIIIII~I I-4xn-I I---Yxr-LI 1I12 VOLTBATTERYI I~~Il )HEADLA~lCOUPLER8 POLE

2. Two Headlamps 12V35W - Two Tail Lamps 12V3W(See Figure 2-8)The head and tail lamps are connected in parallel across oneyellow wire and ground through the lighting switch, and theballast resistor is, of course, unn ecessary.3. Electrical Start Engines (See Figure 2-9)On engines equipped with an electric starter motor, a fullwave rectifier, CCW Part No. 43-0715-10, is connected to thetwo yellow wires at the terminal coup ler and the A. C. outputis converted to D.C. 7.5 amp fuse is connected to the D.C.output red wire and the circuit is completed via the lightingswitch to charge the battery. Head and tail lamps areconnected across the battery term inals as shown in Figure2-9.2.5.2.3 Model 340S only. Engines with serial numbers2903614 & subsequent. See fig. 2-12.Engi nes bearing serial numbers as above are equipped withSawafuji magnetos & six pole connectors for lighting &ignition circuits. The separate lighting and battery charg ingcoil, have been retained as per paragraph 2.5.2.1.2.6 PERIODICSERVICING2.6.1 Spark PlugsRemove, inspect, clean and/or adjust spark plugs at regularintervals as necessary. (See Section Ill, para. 3.3.4). Discardex cessively burnt or damaged plugs. Install only specifiedspark pi ugs after adjusting to proper gap. (Table 1-1) .2.6.2 Fan BeltPeriodically check fan belt for wear, fraying and propertension. A properly adjusted fan belt should leave app ro ximately1/4 inch side play when flexed by hand at a point nearcenter of belt length.Adjust fan belt tension as follows:a. R-emove 19 mm nut, lockwasher and plain washer fromthreaded end of fan shaft, using locking tool Part No.43-0792-50.b. Remove outer pulley. Remove spacer(s), as required, toachieve pro per tension.c. Install outer pu lley, plain washer, lockwasher and nut.Ensure belt is properly engaged between pul ley halves.Tighten nut securely.NOTE: Retain su rp lus spacer( s) for use when a new belt is tobe installed.2.6.3 TroubleshootingTable 2-1 lists probable causes of engine malfunction andremedial action required to correct faul ts. For spark plug,breaker points and engine timing specificatio ns, refer toT echnicall nformation, Table 1-1.cc2-7

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TABLE 2-1TroubleManual starterrope comes out butpawls don't engage.Manual starter ropedoesn't return.Electric starterinoperativeHard to startor won't startImpossible to adjustidleTROUBLE SHOOTING CHARTProbable Cause1. Lack of friction platereturn spring action.2. Defective pawls.1. Recoil spring broken or bent2. Pulley housing warped or bent3. Starting pulley worn.1. Loose electrical connections.2. Poor ground3. Faulty battery or circuits.4. Faulty electric starter1. Carburetor adjustments toolean (not allowing enough gasto engine).2. Inoperative diaphragm orflappervalve.3. Engine not being choked to start4. Spark plugs improperly gapped,dirty or broken.5. Magneto breaker points improperlygapped or dirty.6. Head gasket blown or leaking7. Empty gas tank or improper fuelmixture.8. Water in fuel system9. Weak coil or condenser10. Obstructed fuel system11. Air leak in crankcase or inletsystem.12. Primarywirebroken.13. Engine not timed properly.14. Secondary wire not connectedor spark plug protector notinstalled properly.1. Spark retarding mechanism notworking properly.2. Pistons or rings worn.3. Faulty carburetor2-16Remedy1. Check friction plate returnspring.Replace spring as required.2. Check for broken or bentpawls. Replace pawls asrequired.1. Replace spring.2. Replace housing.3. Replace pulley.1. Retighten connections.2. Secure ground connection.3. Check, recharge or replacebattery.4. Check starter solenoid.Repair or replace.5. Inspect starter motor for evidenceof moisture and broken or wornbrushes. Dry out as necessary.Replace brushes as required.6. Check starter switch. Replaceif required.7. Check harness or connector forbroken wire. Repair or replace.1. Adjust carburetor. Referto Manufacturer's Specifications.2. Refer to Manufacturer'sSpecifications.3. Ensure choke is fully closed.4. Remove plugs. Clean, adjust orinstall new plugs.5. Clean, adjust or replace points.6. Replace gasket7. Refill tank with specifiedfuel/oil mixture (See Table 1-1).8. Drain fuel from carburetor. Addcarburetor de-icer as requiredto fuel.9. Replace faulty coil orcondenser10. Disconnect fuel lines-clearobstruction. Flush system.Connect fuel lines.11 . Check crankcase pressureTable 3-1.12. Repair or replace primaryw1re.13. Re-time engine to properspecifications.14. Secure secondary wire orspark plug protector.1. Repair retard mechanism2. Replace as necessary.3. Check carburetor, check valve.Refer to Manufacturer's Specifications.

corTABLE 2.1TROUBLE SHOOTING CHARTMissing at low speed 1. Incorrect carburetor idle 1. Adjust idle - Refer towon't idle smoothly adjustment. Manufacturer's Specifications.or slowly 2. Spark plugs improperly gapped 2. Clean, adjust or installor dirty.new plugs.3. Head gasket blown or leaking 3. Replace gasket.4. Loose or broken magneto wires 4. Repair or replace wires.5 Magneto breaker points 5. Adjust, clean or installimproperly gapped or dirty.new points.6 Weak coil or condenser 6. Replace coil or condenser7. Improper fuel mixture 7. Refuel, using specified( 1) Too much oil fuel/oil mixture (See Table 1-1 ).(2) Too little oil8. Leaking crankshaft seal 8. Replace seal.cMissing at high speed 1. Spark plugs improperly gapped 1. Clean, adjust or install newor intermittent spark. or dirty plugs.2. Loose or broken magneto wi res. 2. Repair or replace wires.3. !Magneto breaker points improperly 3. Clean, adjust or installgapped or dirty.new points.4. Weak coli or condenser 4. Replace coi l or condenser5. Heat range of spark pl ug 5. Instal l specified spark plugs.mcorrect.6. Leakmg head gasket. 6. Replace head gasket.7. Engine improperly timed . 7. Re-time engine.Coughs, spits, slows 1.1dleorhighspeedjets 1 to 5.down, surges too lean. Adjust carburetor or fuel pump.2. Leaking gasket flange. Refer to Manufactu rer's Specifications.3 Inlet control lever settoo low4. Pulsalion line obstructed5 Fuel pump not supplying enoughfuel due to:( 1) Punciured diaphragm(2) Inoperative i lapper valve.6. Crankca::e not properly seal ed. 6. Reseal crankcase.7. Idle or main carburetor nozzle 7. Refer to Manufacturer'sobstructed.Specifications.8. Fuel line obstructed. 8. Remove fuel line. Clearobstruction. Replace line.9. Carburetor inlet needle and 9. Refer to Manufacturer'sseat obstructed .Specifications.10. Welch plug leaking. 10. Refer to Manufacturer'sSpecifications.Overheating 1. Carbu 1etor too lean 1. & 2. Adjust carburetor.2 Carburetor too rich Refer to Manufacturer'sSpecifications.3 lnconect t:ming 3. Retime engine to Specifications.4. Too much carbon 4. Remove cylinder heads. Cleantop of pistons and insidecompression chamber. Clean outexhaust port.5. Spark plug too hot 5. Instal l specified spark plugs.6 Air deflector not Installed 6. Install air deflector.7. A1r leak in manifo ld 7. Tighten nuts or change gaskets.8. Crank case seal leaking 8. Fit new seal.Vibrates excessively or 1. Idle or high speed carbureto r 1. to 5. Adjust carbureto r. Referruns rough and smokes. adjustmenl too rich. to Manufacturer's Specifications.2. Choke not opening properly(bent linkage).2-17}'

TABLE 2.1· ,, " . ; TROUBLE SHOOTING CHARTJ Inlet control lever too high(carburetor floods) .4. ldle~irbleed plugged.5. Welc'h plug loose.6. Muffler obstructed7. Engine not secured tightly toengine support.8. Water in gas.9. Water in the ignition switch.6. Check and clea r muffler.7. Tighten engine mounting bolts.B. Add carburetor de-icer fluidas required.9. Dry out switch, using suitablede-icer spray or heat.). ·Won't start, kicks back.. ,,.:~~ nd backfires.· • .1. Spark plug wires reversed2. Flywheel key. missing or-sheared3. Faulty condenser4. lmpropertiming5. Faulty breaker points6. Unhooked spark retardingmechanism-or spring broken1. Install wire correctly .2.:- Replace key.3. Replace condenser4. Re-time engine5. Adjust or replace points.6. Reconnect mechanism or replacespr1ng .No acceleration, low topR.P.M., hard to startGood spark but engineruns on one cylinder.1. Spark plugs improperly gappedor dirty.2. Magneto breaker points improperlygapped or dirty.3. Faulty coi I or condenser.4. Loose or broken magneto wires.5. Blown head gasket.6. Inlet lever adjustment too low7. Crankcase leaking1. Leaking cylinder head2. Magneto wires broken inside(coil ground broken).3. Cracked cylinder wall4. Defective spark plug.5. Breaker points improperly gapped6. Crankcase seal leaking.1. Clean, adjust or install newplugs.2. Clean, ad just or install newpoints.3. Replace coli or condenser.4. Repair or replace magneto wires.5. Replace head gasket.6. Refer to carburetor manufacturerSpecifications.7. Instal l new seal .1. Check head for warps, cracks.Install new gasket and cylinder head2 Repair or replace wires.3. Replace fau lty cylinder.4. Clean. adjust or instal lnew plug5. Re-adjust po ints.6. 1nstallnewsealJNo acceleration . Idleswell but dies down whenput to full throttle.1. High speed needle settoo lean.2. Dirt behind needle and seat.3. High speed jet obstructed.· 4. Inlet lever set too low.5. Choke partly closed .6. Silencer obstructed.7. Fuel pump not supply ing enoughfuel due to:( 1) Punctured diaphragm(2) Flapper valves distorted.8. Fuel line obstructed.9. Not enough oil in gas.10. Breaker points improperly. gapped or dirty.11. Engine improperly timed.1. to 7.Adjust carburetor. Refer toManufacturer's Specifications8. Remove fuel line. Clearobstruction. Replace line.9. Refuel. using specified" fuel/oil mixture.10. Adjust, clean or install newpoints.11. Re-time engine to specificationsEngine run~ b~~us ingchoke at high speed1. High speed needle set too lean.2. Dirt behind needle and seat.2-181. & 2. Adjust carburetor.Refer to Manufacturer'sSpecifications.

TABLE 2.1TROUBLE SHOOTING CHART3. Fuel line obstructed4. Inoperat ive fuel pump3. Remove line, clear obstruction,replace line.4. Refer to Manufacturer's SpecificationsNo power under heavyloadCranks over extremelyeasy on one or bothcylinders. Loss ofcompression.f:ng1ne won't crankover. Unable to rotateflywheel.1. Magneto breaker points improperly 1. Clean, adjust or install newgapped or dirty.points.2. Ignition timing too far advanced 2. Adjust timing3. Magneto co il plate loose3. Check magneto and secure coilplate.4. Fau lty carburetion4. Refer to Manufacturer'sSpecifications.1. Scored piston due to:( 1) Not enough oil in gas.(2) Lack of cooling2. Blown head gasket.3. Loose spark plug1. Replace faulty piston.2. Replace head gasket.3. Check plug for security.4. Head bo lts not tight enough 4. Torque head bolts to properspecifications.1. Piston rusted to cylinder wall 1. Remove piston and cylinder.Replace defective parts.2. Crankshaft seized to bearing2&3. Disassemble engine.(main or ro d).Replace defective parts.3. Broken connecting rod.4. Flywheel seized to coil plate. 4. Remove flywheel.Replace defective parts.5. Engine improperly assembled after5. Recheck re-assembly procedure.repa 1r.2.7 OPERATING INSTRU CTIONS2.7.1 Preparation For Operation:Ensure that the fuel tank is filled with the co rr ect mixture ofrecommended gasoline and special air-cooled two strokeengine oil . See Table 1-1.CAUTION: When fil ling or ~opping up the fuel tank, use afuel strainer to prevent po ssible contam inationof engine and fuel system components.2. 7.2 Starting2.7.2.1 Sta rting the engine using recoil sta rter.a. Adjust throttle lever to approx imately one-half fu ll openposition.b. Close carburetor choke lever. When starting a warm engineit may not be necessary to close the choke.c. Switch the ign ition to the RUN position .d. Pul l lightly on the handle of the rope unt il a click is heardwhen the pu lley engaged with the flywheel and then pullstrong ly on the rope. Let the handle return quickly to theoriginal posit ion. Do not let go of the handle until the ropehas fully retracted.e. If engine does not start, repeat step (d) and adjust throttlelever as required until the engine starts.f. After the engine has started, gradual ly open the chokelever and close throttle lever until the engine runssmoothly at idling speed (1000-1200 rpm). When theengine is running at normal operating temperatu re thechoke shou ld remain in the fully open position.2-19NOTE : If the engine fails to start after repeated attempts,refer to Trouble Shooting Chart, Tabl e 2-1.2.7.2.2 Starting the engine using electric starter.a. Adjust throttle lever to approximately one-h alf full openposition.b. Cl ose. carburetor choke lever. When starting a warm engineit may not be necessary to close the choke.c. Engage the applicable ignition switch. If engine does notstart within 5 seconds, disengage the ignition switch.Adjust throttle lever as required; wait approximately 30seconds and repeat the starting procedure.d. After the engine has started, gradually open the chokelever and close t he throttle lever until the engine runssmoothly at idling speed (1000-1200 rpm). When theengine is running at normal operating temperature thechoke should remain in the fully open position.NOTE : If the engine fails to start after repeated attempts,refer toT rouble Shoot ing Chart, Table 2-1 .2.7.3 Stopping the EngineTo stop the engine, close throttle; switch off the ignition. Donot stop engine by grounding the spark plugs or disconnectingspark plug wires.2.8 LUBRICATIONLubricati on chart, Table 2-2, detai ls periodic lubricationrequirements. Further periodic lubrication of these engines isnot required.

TABLE 2-2LUBRICATION CHA·RTComponentPeriodicityType/MethodAccessRecoil StarterCenter hub.Main spring.Pawls.0 nee yearly orduring overhaulGrease, low temper·ature, Lubriplate orequivalent (by hand)Remove recoilstarter cover.Remove frictionplate. (See·Section Ill,Para. 3.2.1 d andSection IV, para.4-3).ElectricStarter driveshaft andspring (ifinstalled).Once yearly orduring overhaulGrease, low temperature,Lubriplate orequivalent (by hand)Remove starter(See Section Ill,Para. 3.2.1g).Contact BreakerPoints (oilfeltpads)Once yearly orduring overhaul1 or 2 drops goodquality lightmachine oil (oilcan).Remove recoilstarter and starterpulley. (SeeSection Ill, Para.3.2.1 d and 3.2.1 h).Lubricate throughbreakerpoint accesshole.Contact BreakerPoint CamOnce yearly orduring overhaulGrease, low temperture,Lubriplate orequivalent. Lightlycoat governorassembly and flywheelcollar (by hand)Remove flywheel(See Para. 3.2.1 j)Remove snap-ring.Lift out cam.Replace cam andsnap ring. (SeeSection IV, Para.4.4).The following is a list of recommended brands of two strokeengine oil: ·Esso SnowtracVeedol SnowmobileShell Two Cycle SnowmobileMercury 50 New Formula "Quicksilver""Bardahl" Snowmobile VBA2-20

SECTION mccDISASSEMBLY, CLEANING AND INSPECTION3.1 PREPARATION FOR DISASSEMBLYa. Remove muffler and exhaust pipe as applicable. Disconnectelectrical wiring and controls. Remove enginemounting bolts; place engine on a suitable workbench.b. Thoroughly clean exterior surfaces of engine, usingsuitable cleaning solvent.3.2 DISASSEMBLYNOTE: To prevent loss and expedite reassembly procedures,keep attaching hardware with each part as it isremoved.3.2.1 Disassemble the engine as follows:a. Disconnect spark plug wires at spark plugs. Remove plugs.b. Remove the ten bolts securing cylinder cover to engtnebody. Remove cover. See Figure 3-1c. Remove the four hold-down nuts, washers and lockwasherssecuring intake and exhaust manifolds to cylinders.Remove manifolds. Remove intake manifold with carburetorattached. Remove carburetor if it requires servicing.Refer to applicable carburetor manufacturer'sspecifications. Remove insulators from intake side.Discard gaskets.Figure 3-2.d. Remove the four bolts securing recoil starter to fan cover.Remove starter to expose starter cup and fan belt pulley.Figure 3-3.e. Disconnect coupler attached to fan cover. Remove twobolts secu ring coil cover to fan cover. Remove cover toexpose high tension coils.Figure 3-3.f. Remove the two bolts and spacers securing high tensioncoils to fan cover. Remove coils with spark plug wiresattached.g. Remove the two hold-down nuts, two attaching boltsand lockwashers securing electric starter to engine body (ifso equipped) . Remove starter.Remove starter.h. Remove the three bolts securing starter cup, fan beltpulley and window plate (if installed) to flywheel. Pulloutward and up on pulley to remove from flywhee l.Remove fan belt.1. Remove the two Phillips screws securing ignition terminalcoupler and bracket to fan cover, and four bolts securingfan cover to fan cover case. Remove fan cover to exposeflywheel.3-1J. Lock the flywheel using CCW Tool Part #43-0798-40remove the nut, lockwasher and flat washer securingflywheel to crankshaft. Remove the flywheel as follows:1. Install flywheel puller to the three tapped holes inflywheel.2. Tighten the center bolt of puller to 40 pounds-feetmaximum.3. Using a wooden mallet or block and hammer, tap eachside of the flywheel alternately while maintaining thetorque setting on center bolt until the flywheel isremoved.CAUTION: 1. Do not over torque center bolt on flywheelpuller. Excessive torque may result in breakingthe puller attachment bolts.2. Do not hammer on end of crankshaft toremove flywheel. Damage to the shaft orbearings may result.Figure 3-6.k. Remove the four bolts seCL'ring fan covercase to crankcase.Remove covercase.Figure 3-7.I. Remove the two screws secunng stator assembly tocrankcase. Remove stator assembly.Figure 3-8.NOTE: Unless being serviced, stator assembly should bestored inside flywheel to ensure retention of magneticproperties.m. Remove the five hold-down nuts securing each cylinderhead to cyl inder. Remove cylinder heads.Discard cylinder head gaskets.Tool: 13 mm box spanner.NOTE: Before proceeding any further check crankshaft forbend and twist as follows :1. Check for twist:(a) Rotate eng ine to T.D.C . on No. 1 cylinder using a dialindicator mounted on the cylinder.(b) Install and zero a degree wheel on the crankshaft.(c) Rotate crankshaft 1800. The piston on No. 2 cylindershould be at T.D.C. Permissable tolerance is 20.2. Check for bend on either end :(a) Mount a dial indicator at the junction of the paralleland tapered sections of the shaft.(b) Zero the indicator. Rotate the crankshaft one fullturn. Permissable run out is 0.003 inch on one rotation.n. Remove the four hold-down nuts securing each cylinderto crankcase. Remove cylinders to expose piston andconnect ing rod assemblies. Discard cylinder base gaskets.Figure 3-10.CAUTION: If disassembly is discontinued after cylinder orpiston removal , ensure that crankcase is keptcovered to prevent ingress of dirt or foreignobjects to crankcase.

JCylinder Coverexhaust manifoldIntake manifoldFig. 3-1 Cylinder CoverRemovedFig. 3-2 Intake and ExhaustManifolds RemoveddisconnectJFig. 3-3 Recoil starter and high tension coils removed3-2

Fig. 3-4 Starter cup and fan belt pul ley removed .cFig. 3-5 Fan cover removed3-3

)Fig. 3-6Removing flywheelFig. 3-6AFig. 3·7 Fan cover case removed3·4

ccStator a·ssemblyi ------Fig. 3-8 Stator assemb ly removed3-5

Fig. 3-9 Cylinder heads removed)Fig. 3-10Cylinders removed3-6

cco. Refer to Section IV, Figure 4-7Before removing pistons (5), ensure that the piston crownis marked with an arrow directed toward the exhaust port.If no arrow is legible, inscribe the piston crown acco r­dingly. Using a suitable circlip removal tool, remove oneof the two circlips (7) securing each piston pin (6) inposition. Use a propane torch or cloth soaked in hot waterand heat the pistons until warm to the touch ( 1200-1400F). Use a soft drift to push the pins out from the oppositeside. Remove needle bearings ( 1 0) from connect ing rodssmall end.CAUTION : Exercise care when removing piston pins toprevent damage to needle bearings. Keep bearingsadequately protected until time of assembly.Figure3-11.p. Remove piston rings from piston ring groove, using asuitable ring removal tool .q. Remove the ten bolts, plain washers and lockwashersjoining the two halves of crankcase. Separate crankcase bypulling the two halves apart. Remove the crankshaft.Remove the four seal retaining circlips from crankcaselower half. (Refer to Sect ion V, figure 5-1).CAUTION: Do not use a screw driver to pry the crankcaseapart. If necessa ry, use a soft hammer and tap thecase lightly on either end.Figure 3-123.3 CLEANING ANO INSPECTION3.3.1 CleaningPri or to inspection clean all parts, except the magnetoassembly, by immersing and soaking in a suitable cleaningsolvent or using specified methods. Clean the crankshaftbefore cleaning other components, to protect bearings frompossible damage due to dirty cleaning solvent. Thoroughlydry all parts after cleaning.Pay particular attention to the fo llowing special instructions:a. Spark plugs:Remove light carbon deposits by brushing lightly with awire brush. If plug is excessively dirty and proper clean ingequipment is not available, install a new spark plug.b. Piston ring grooves, piston crowns, cylinder heads:Use the proper groove cleaning tool for cleaning pistonring grooves. Normal cleaning methods should be sufficientfor clean ing piston crowns and cylinder heads.c. Spark plug holes and exhaust ports:Carefully remove heavy carbon deposits from these areas,using a soft metal (non-ferrous) scraper. Use a spark plugtap to clean threads.CAUTION: Do not scrape down to base metal su rfaces whenremoving heavy carbon deposits. Exercise carewhile cleaning spark plug holes, to preventdamage to the threaded area.d. Magneto:Thoroughly dryclean the magneto using compressed air orsuitable cleaning materials. Ensure no moisture or oilyfilm remains after clean ing.3.3.2 Inspection3.3.3 Generala. After disassembly, clean all parts in accordance withparagraph 3.3.1. Inspect all parts for obvious damage,3-7wear, cracks, and evidence of corrosion; attaching hardwareand attachment holes for wear and condition ofthreads. If it is necessary to dress the threads, use suitablethread cleaning tools. Repair or replace damaged parts andany parts that fail to meet appl icable specifications. Referto Section IV, Repair and Replacement.b. Perform addition al inspections as detailed in paragraphs3.3.4 to 3.3.13.3.3.4 Spark Plugs Inspection and Adjustmenta. Inspect spark plugs for general condition, cracked orbroken insulators and burned electrodes.Guide to spark plug serviceability:1. Center electrode burned brown indicates plug isfunctioning normally.2. Center electrode burned white indicates the plug is toolow in thermal value. Discard plug and install new plugof specif ied type.3. Center electrode burned black indicates the plug is toohigh in thermal value. Discard plug and install new plugof specified type.b. Adjust spark plug gap to 0.6 to 0.7 mm. (0.023 to 0.025)in). Bend the outside (ground) electrode only. Use a sparkplug wire gauge to measure the gap. Discard plug ifelectrode is burned ex~ssively or if specified gap cannotbe maintained.c. Inspect spark ~lug wires fo r condition of insulation;rubber bushings for splitting or deteri oration ; tips forsecurity. Replace defective wires.3.3.5 Fan Coversa. Inspect fins for cracks; fan for blade damage, freedom ofmovement and evidence of binding . Dress out nicks ordents. Replace fan if a blade is cracked or broken since thebalance will be affected.b. Inspect fan belt for stretch, fraying and deterioration .3.3.6 Recoil Startera. Pull starter rope out and permit it to recoil. Do not let ropesnap back on recoil. Rope should pull out smoothly andrecoil without hesitation. A weak or incomplete recoilindicates a defective or maladjusted main spring.b. Check for smooth operation of pawls. When the rope ispulled out, pawls should move outward; when the roperecoils, pawls should move inward.c. Inspect handle and rope guide for general condition andsecurity of attachment.3.3. 7 Electric Starter (if installed)a. Inspect drive shaft and spring for condition, smoothoperation and security. Lubricate in accordance withLubrication Chart. Table 2-2. ·NOTE: Disassembly or repair of electric starters shou ld beperformed by authorized dealers only. R~placedefective starters if overhaul facilities are not available.3.3.8 Magneto Assemblya. Inspect coil plate for damage and security.b. Inspect low tension generation coil(s) and lighting coi lsfor general condition and security.c. Inspect contact breaker points and condensers for condition;breaker points for wear, burning or pitting. Serviceablepoints appear a greyish frosty color. If points are in

)Fig. 3-11 Removing pistons()Connecting rods0Fig. 3-12 Upper Crankcase half removed3-8

cserviceable condition, the condenser can be consideredserviceable. Inspect oil felt pads for cond it ion andsecurity; lubricate in accordance with Lubrication Chart,Table 2-2.d. Inspect all electrical connections for security; insulationfor chafing and deterioration.3.3.9 Flywheel Assemblya. Inspect cam, governor weight(s) and spring(s) for generalco nd iti on and security; cam for wear, particu Ia rly at pointof contact with governor weights.b. Check flywheel taper for snug fitting. When placed oncrankshaft hand tight, the flywheel should not wobble.c. Inspect magnets for nicks, scores or burrs. Use a suitab lestone to smooth off high spots.d. Inspect ring gear and teeth (if installed) for wear, generalcondition and security.e. Lubricate cam, governor weight and spring in accordancewith Lubrication Chart, Table 2-2.3.3.1 0 Cylinder Heads and Cylindersa. Inspect cylinder heads and cylinders for pitting, scoringand evidence of corros ion.b. Check cylinder heads for warp or distortion as follows:1. Place cylinder head, flat side down, on a surface plateor suitable measuring device.2. Using a feeler gauge, measure amount of distortion atpoint of contact between cylinder head and surfaceplate.Take a reading at each of the five I ocat ions betweencylinder head hold down studs.Maximum allowable distortion at any one location is0.002 inch.c. Check cylinders for distortion as follows:1. Install a serviceable head on cylinder to be checked.Do not install hold down nuts.2. Using a feeler gauge, measure amount of distortion atpoint of contact between cylinder head and cylinder.Take a reading at each of the five locations betweencylinder head hold down studs.Maximum allowable distortion at any one location is0.002 inch.d. Using a dial indicator or suitable measuring device, checkinside diameter of cylinders. Cylinders, worn beyondstandard tolerances, may be rebored to accomodate theinstal lation of oversize pistons. Refer to Table 3-1 forstandard and oversize fits and tolerances. The oversizeslisted in the table are the maximum allowable. Discardcylinders that requ ire boring in excess of tolerance shown.Replace with serviceab le cylinders.NOTE: Rebored cylinders should be honed with a finefinishing stone.3.3.11 Pistons, Pins and Ringsa. Inspect pistons, pins and rings for scoring and wear; pistoncrowns for pitting, evidence of corrosion and distortion.b. Check diameter of pistons, pins and pin bore; piston ringend and side clearances. Refer to Table 3-1 for method ofinspection and tolerances.c. Discard any parts that fail to meet applicable specificationsand note the following:1. If cylinder has been inspected and found serviceab le,replace defective piston with new standard size piston.3-92. If cyl inder has been rebored and hor)ed, replacedefective piston with oversize piston as listed in Table3-1.3.3.12 Crankshaft and Connecting Rodsa. Inspect threads on each end of shaft. The mating nut onthe flywheel end of the shaft should turn on all the way byhand without excessive looseness.Use a suitable thread cleaning tool to remove burrs fromthe threads. Replace worn nuts.b. Check tapered surface of flywheel end of shaft for scoringand wear. When placed on the shaft hand t ight, theflywheel should not wobble.c. Inspect keyway and Woodruff key for damage and wear.Replace worn keys.d. Inspect ball bearings for wea r, free movement andsecurity.e. Using Vee blocks (2) on a flat surface, support thecrankshaft on the center main bearings. Mount dialindicators at junction of tapered and parallel sections ofthe shaft and rotate crankshaft by the connecting rods.Refer to Tab le 3-1 for tolerances.f. Check crankshaft for bend or twist on the crankshaftjournals. Use a dial indicator placed on the main bearingjournals. Zero the indicator. Rotate crankshaft one fullturn. Refer to Table 3-1 for tolerances.g. Check connecting rod diameter at small end; side andvertical clearance at large end. Refer to Table 3-1 formethod of inspection and tolerance.h. Check connecting rod twist as follows:1. Insert a bar, 100 mm long or any other convenientlength, into the connecting rod small end . Centralizethe rod using a depth gauge and lock in position.2. Support connecting rod horizontally. Using a dialindicator measure the maximum height at oppositeends of the bar when the rod is twisted to the right andto the left. Any variation indicates connecting rodtwist. RefertoTable3-1 for tolerance.1. Check connecting rod tilt as fo llows:1. Repeatsteph(l).2. Support connecting rod vertically. Using a dial testindicator, measure the amou nt of movement at ends ofbar when bar is tilted to the right and to the left. Thedifference between the two readings indicates theamount of tilt. Refer to Tab le 3-1 for toleran ce.3.3.13 Crankcasea. Inspect crankcase mating surfaces for deep scratches,scoring and pitting.b. Inspect bearing and oi l sea l retaining inserts for wear,scoring or conditions which could cause leaks.c. Inspect at tach i ng dowel pins for wear and security.d. Discard crankcase if normal repair procedures are notsufficient to correct defects.3.3.14 Fits and TolerancesTable 3-1 lists standard fits and tolerances to be checkedduring inspection of pistons, piston pins, cylinders andcrankshaft. It also lists allowab le oversizes of pistons andrings. If suggested method of inspection is not avail ab le, usesuitable measuring devices.j

CCW Model 340-400TABLE 3-1 (FITS AND TOLERANCES)TolerancesStd. Size Inches Method ofComponent ln. Mm Minus Plus Remarks InspectionCylinder *2.36 60 N/A .0007 *Model 340 0 iall ndicatorConnecting Rod, small end#2.56 65 N/A #400.867 22 N/A 0003.0008Dial Indicatorbig end 1.261 '32 N/A .0004.00 1side clearance .014 N/A.016'vertical clearance N/A .0004 Dial Indicator.0015twist .003 Measured at ends of bar Dial Indicator3.94" centred in smallend (See Manual)bend N/A .001Crankshaft N/A .0035 Measured at junction Dial Indicatorpermissable misalignment dueof taper and parallelto bend or twist. sections (see manual) .Crankshaft, end float N/A .003 Feeler gauge.JPiston, at *2.36 60 *340 MicrometerTop land#2.56 65 N/A.011#400.012Piston Pin, c/1 .007 N/A.008Bottom of skirt .004.0047 N/APiston Pin Bore .709 18 .0004 N/A Dial IndicatorPiston Pin .709 18 .0003 N/A MicrometerPiston Ring, No.1 .083 .0025 N/A Feeler Gaugesgroove clearance .004end clearance .004 N/A.012Piston Ring, No. 2 .083 .0014 N/Agroove clearance .003end clearance .004 N/A.012)3-10

SECTION 1VQREPAIR AND REPLACEMENTcc4.1 GENERAL4.1.1 The repair and replacement instructions detailed inthis sect ion are included to assist in the disassembly,replacement of defect ive parts and- assembly of majorsub-assem blies. It is not necessary to completely disassemblethe sub-assem blies unless inspection procedures revealdefects. Perfo rm only those steps necessary to gain access tothe defective part(s} and to effect the necessary repairs.4.2 FAN COVER (Seefigure4-1)4.2.1 Disassemblya. Remove nut (2}, lockwasher (3}, and pla in washer (4}from threaded end of fan shaft. Spacer (5) is permanentlysecured to ou ter pulley (6).Tool: 19 mm box spanner, Locking tool, Part No.43-0792-50.NOTE: Drill one 1/4" hole in pulley to take pin of lockingtool.b. Remove outer half (6) of fan belt pulley, spacers (7, 8, 9)inner half ( 1 0) of pulley, and spacer ( 11) from shaft.c. Tap I ightly on end of fan shaft to remove fan ( 16) from fancover.d. Inner bea ring (15) should rem ain on fan shaft assemblyand can be rem oved by sliding it off the shaft. To removeouter bearing ( 12), turn the case over; use a suitable softdrift to tap bearing out of retainer. Remove spacer ( 13}. Itis not necessary to remove snap ring ( 14) unless it is founddefective. Use suitable removal tool to remove snap ring.e. Clean al l parts, except bearinqs, usinq suitable clean ingsolvent. Wipe bearings clean, using a clean cloth moistenedwith cleaning solvent. Thoroughly dry al l parts aftercleaning.4.2.2 Assemblya. Replace defective parts.b. Install snap ring ( 14) if it has been removed .c. Insta ll outer bearing (12). Turn case over; install spacer( 13) and inner bearing ( 15). Ensure bearings are properlyseated with no evid ence of binding. If necessary, use a softsteel drift to tap bearings into position. Ensure that no dirtor foreign material enters bearings.d. Reverse disassembly steps (a) to (c). Tighten reta ining nutsecurely, using lock tool No. 43-0792-50.e. Check fan for proper operation.4-14.3 RECOIL STARTER (See Figure 4-2)4.3.1 Disassemblya. Untie the knot in the rope at rope handl e ( 15). Removehandle and al low the rope to recoil slowly into the case( 12). Unscrew and remove rope guide ( 13).b. Remove retaining nut (2), lockwasher (3) and flatwasher(4) from threaded shaft of reel hub ( 1 0).c. Manipulate friction plate (5) on reel hub until eye end ofreturn spring (7) aligns with retaining slot (22) . Removefriction plate.d. Remove the three pawls (6).e. Remove return spring (7), sp ring (8) and cup washer (9).Note position of plain end of return spring in the springretaining ho le in reel hub.f. Remove reel (10). Unwind the rope; lift and untie theknotted end from center hub of reel.g. Lift long ro ll ed end of main spring ( 11) from the fixedspring retaining pin in the case and carefully remove thespring.h. Clean all parts, except rope, using a su itable clean ingsolvent. If rope requires clean ing, wash it in a solution ofsoap and water. Thoroughl y dry all parts after cleaning.1. Inspect all parts for obvious damage and wear.4.3.2 Assemblya. Replace defective parts.b. Install main spring as follows:1. Secure main spring winding tool, part number43-0797-60, or equivalent tool, circul ar end up, in asuitable bench vise.2. Start with the long rolled end of main spring ( 11) andwind spring into circular end of tool in a clockwisedirection.3. Remove tool from vise. Grasp th e too l by its handleand lower the tool , with spr ing installed, into case (1 2).4. Secu re the long roll ed end of spring over the fixedspring retaining pin. Remove winding too l. Apply alight film of Lubriplate, or equ ivalent, to spring.c. Secure case, open side up, in bench vise.d. Tie a knot at one end of t he rope. Secure knotted endaround center hub of reel (10) . Pull rope taut and windentire rope around reel in an anti-cl ockwise directionuntil the free end protrudes through the notched sectionof the reel.e. Apply a light film of Lubriplate, or equivalent, to centerhub of case and install the reel. Push down and rotate

16I~D1.2.3.4.5.6.7.8.Fan coverRetain ing nutLockwasherPlain washerSpacerOuter pulleySpacerSpacer9. Spacer10. Inner pulley11. Spacer12. Outer bearing13. Spacer14. Snap ring15. Inner bearing16. FanFIGURE 4-1 FAN COVER ASSEMBLY .4-2

61. Starter pulley 12. Case2. Retaining nut3. Lockwasher13. Ropeguide14. Rope4. Flatwasher 15. Handle5. Friction plate 16. End piece6. Pawl (each 3) 17. Bolt, starter to fan cover7. Friction plate return spring attaching8. Spring9. Cup washer10. Reel11. Main spring18. Lockwasher19. Flatwasher20. Bolt, starter pulley to flywheelattaching21. Lac kwasher22. Slot, return spring retaining23. Hook, main spring retainingGFIGURE 4-2RECOIL STARTER ASSEMBLY4-3

2D11.2.3.4.I;5.6.··

c--·-reel in an anti-clockwise direction until the hook (23)engages with the free end of main spring. Tension will befelt when reel and spring are properly engaged.f. Rotate reel a maximum of three complete turns in anant i-c I ockwise direction. 0 o not exceed three turns; holdreel in this position and feed free end of rope through caseat the rope guide hole. Install rope guide. Loosely knotthe rope to prevent recoil.g. Apply a light film of Lubriplate or equivalent to pawls (6)and install them on the reel in the pawl retainers.h. Install cup washer (9) flat side down, spring (8) andreturn spring (7) . Ensure that plain end of return spring isproperly engaged in the retaining hole in reel hub.1. Install friction plate (5) over reel hub. Manipulate plateuntil eye end of return spring engages and locks crosswisein retaining slot (22).J. Rotate friction plate until the three notches are alignedwith pawls when pawls are at the recoil position.k. Install flatwasher (4) , lockwasher (3), and nut (2) .Tighten nut securely.I. Untie the temporary knot in free end of rope and installthe rope hand le. Tie a permanent knot and fit handlesecurely.m. Check starter for proper operation. When handle is pulledoutward, pawls should move outward.NOTE: If main spring is to be installed without the use of aspring winding tool, wind main spring into case in ananti-clockwise direction. Clockwise installation onthe winding tool is necessary to ensure correctanti-clockwise installation of the spring when tool isplaced upside down in the case.4.4 FLYWHEEL ASSEMBL Y-SAWAFUJI-MODEL340S(See Fig. 4-3)4.4.1 DisassemblyNOTE: Complete disassembly of flywheel assemb lies shou ldbe performed by authorized dealers only. The autoadvance mechanism is pre-set during manufactureand should require no further adjustment. If inspectionreveals faulty governor parts or defective magnets,install a new flywheel assembly or returnflywheel to overhaul facility.a. Remove snap ring (2) securing breaker point cam (3) toflywheel collar, using a suitable snap ring removal tool.Lift cam off co ll ar. Check cam and collar for scoring andwear; governor weight stop screw ( 1 0) for wear andsecu rity. Replace defective parts.4.4.2 Assemblya. Apply a light film of Lubriplate or equivalent to outersurface of flywheel collar.b. Reverse removal procedure.c. Lubricate in accordance with Lubrication Chart, Table2-2.d. Check mechanism for proper operation.4-54.5 FLYWHEEL ASSEMBL Y-KOKUSAN-MODELS340E, 340G and all400 MODELS (See Figure 4-4)4.5.1 DisassemblyNOTE: Complete disassembly of flywheel assemblies shouldbe performed by authorized dealers only. Theauto-advance mechanism is pre-set during manufactureand should require no further adjustment. Ifinspection reveals faulty governor parts or defectivemagnets, install a new flywheel assembly or returnflywheel to overhaul facility.a. Remove snap ring (3) securing breaker po int cam (4) toflywheel collar, using a suitable snap ring removal tool.Lift cam off collar. Check cam and coll ar for scoring andwear; governor weight stops fo r wear and security.Replace defective parts.4.5.2 Assemblya. Apply a light film of Lubriplate or equivalent to outersurface of flywheel collar.b. Reverse removal procedure.c. Lubricate in accordance with Lubrication Chart, Table2-2.d. Check mechanism for proper operation.4.6 STATOR ASSEMBL Y-SAWAFUJI - MODEL 340S(See Figure 4-5)NOTE: Complete disassembly of stato r assemblies should beperformed by authorized dealers only. Normal disassembly should be restricted to removal and replacementof defective contact breaker point sets, oil feltpads or condensers. If inspection reveals additionalmaintenance requirements, install a new assembly orreturn stator to overhaul facility.4.6.1 Contact Breaker Point setsNOTE: Removal and installation procedure is appl icable toboth point sets.4.6.1.1 Removala. Loosen electrical terminal connecto r (28) securing condensorprimary wire at co ntact breaker point set (7) .0 isconnect primary wire.b. Remove retaining screw ( 18), lockwasher (16) and washer( 17) securing contact breaker po ints to coil plate (2).Remove breaker point set.4.6.1.2 Installationa. Apply a light film of Lubriplate or equ ivalent to pivotshaft.b. Reverse removal procedure.CAUTION: Ensure no lubricant gets on breaker pointsduring installation. Contaminated points willburn during engine operation.c. Adjust points to specified gap. Refer to Section V,Paragraph 5.4.3.

1. Flywheel assembly with ring gear2. Flywheel assembly, less ring gear3. Snap ring4. Cam5. Washer6. Governor Spring (2)7. Governor weight (2)8. Lug, spring to governor weightattaching9. Flywheel10. Ring, governor weight attach ing11 . Screw, lug plate to flywheel attaching12. Spring washer13. Ringgear14. Bolt, ring gear15. Spring washer16. Window plateFIGURE 4-4 FLYWHEEL ASS EMBLY (KOKUSAN MAGNETO) 340E, 340G, 4004-6

22526 27-~~ ,~--! 1424 ~ ~~12fill @~- I22C-28,-..1. Stator assembly2. Coil Plate3. Primary Ignition Coil4. Lighting co il5. Condenser (White)6. Condenser (Red)7. Po int Set8. Oilfelt & Holder9. Protector10. Coupler 19. Screw11. Washer 20. Spring Washer12. Screw 21. Screw13. Spring washer 22. Washer14. Washer 23. E Ri ng15. Screw 24. Bracket, Coupler16. Spring washer 25. Rubber Bushing17. Washer 26. Spade Connector18. Screw 27. Spade Connector28. Terminal ConnectorFIG. 4-5STATOR ASSEMBLY (SAWAFUJI IGNITION)4-7

12931 ~--/";4! ,~r-13 12l !'---,-l ,)71. Stator Assembly .2 Coil Plate. Generating Coil3. Low Tens10~· · Coil4. Lighting (Red)Condenser . )6. 5. Con d e nser (White7 PointSet8 . Oil . F e It & Holder9· Protector1 o: Coupler11 _ Washer12. Screw13. Spring Washer14_ Washer15 Screw16. · Sprm · g Washer17_ Washer18. Screw19_ Screw2o_ Screw2 1. Screw r .2 2. Spri ng Wa~~~ Coil Attaching23. Bolt, lgnitPiate Attaching24. Bolt, Coil25. W~she r Ignition Coil26. Primary27 Clamp. d Connector28. Spa/ Connector29. Spa ~ t Coup ler30. Brae : r·Bushing31 . Rubb I Connector32. TermmaFIG. 4-6 (KO K USAN IGNITION)4-8

c1. Crankshaft ass'y 8. Piston ring# 12. Ball bearing 9. Piston ring# 23. Oil seal 10. Needle bearing4. Oil seal 11 . Washer5. Piston (note inscribed arrow) 12. Spring washer6. Piston pin7. Circlip13. Nut14. Woodruff keyFIGURE 4-7PI STON AND CRANKSHAFT ASSEMBLYFig. 4-8 Oil seals identification4-9

4.6.2 Condensers and Oil Felt PadsNOTE: Removal and installation procedure is applicable toboth condensers.4.6.2.1 Removala. Loosen electrical terminal connector (28) and disconnectprimary wire at contact breaker point set (7) .b. Unsolder condenser wires at terminal on low tensiongeneration co il (3) and at connector on eng ine body. .c. Remove retaining screw (15) and washer (16) secunngcondenser an d oil felt pad (8) to co il plate (2). Removecondenser and oil felt pad . Check pad for condition andreplace if lubricating capacity is questionable.4.6.2.2 Installationa. Reverse removal procedure. Resolder condenser wires atprimary coi l and ignition coupler. .b. Secure condenser primary wire to contact breaker po1ntset at term inal connecto r (28).c. Lubricate oi l felt pad. Refer to Lubrication Chart, Table2-2.4.7 STATOR ASSEMBL Y-KOKUSAN- MOOELS 340E,340G, and ALL 400 MODELS. (See Figure 4-6)NOTE: Complete disassembly of stator assembl ies should beperformed by authorized dealers only. Normal disassembly should be restricted to removal and replacementof contact breaker po int sets, oil felt pads orcondense rs. If inspection reveals additional maintenancerequirements, install a new assembly orreturn stato r to overhaul facility.4. 7.1 Contact Breaker Point SetsNOTE: Removal and installation procedure is applicable toboth point sets.4.7.1.1 Removala. Loosen electrical terminal connector (32) securing ignitionwiring at contact breaker point set (7) .Disconnect the wires.b. Remove retaining screw (18) or (20) as appl icable,lockwasher (16) and washer (17) securing breaker pointset to co il plate (2). Remove breaker point set.4.7.1.2 Installationa. Apply a light film of Lubriplate or equ ivalent to pivotshaft.b. Reverse removal procedure.

SECTION VREASSEMBLY, TESTING AND ADJUSTMENTSc5.1 GENERAL. 5.1.1 Prior to reassembly, check al l parts for cleanliness andserviceability in accordance with paragraph 3.3.5.1.2 During assembly, tighten all screws, bolts and nutssecurely. Ensure that correct torque values are applied wherespecified. Do not overtorque.5.1.3 Use only new gaskets and seals during assemblyprocedure.5.1.4 During assembly, lubricate all bearings and frictionsurfaces with new, clean two stroke engine oil.5.1.5 If procedures are discontinued during assembly,ensure that intake and exhaust ports, spark plug holes and allother open ings are covered to prevent ingress of dirt orforeign objects to cylinders and crankcase.5.2 REASSEMBLY5.2.1 Crankcase and Crankshaft (See Figure 5-1)a. Place crankcase lower half on work bench with flanged fancover end to right hand side; insert the four seal retainingcirclips .Install the crankshaft into lower half of crankcase withexternally threaded (flywheel) end of shaft toward righthand side. (See Section Ill, figure 3-12). Ensure that sealretaining circlips do not become dislodged.b. Apply a liberal amount of two-stroke engine oil tocrankshaft and bearings.c. Apply a good quality, non hardening sealing compoundevenly to seal ing surfaces of both crankcase halves.d. Reseat the crankcase halves; ensure that the two dowelpins are properly engaged with mating holes in crankcaseupper half.e. Refer to Figure 5-2 ..Install four 8 x 65 and six 8 x 45 attaching bolts, washersand lockwashers. Install the four longer bo lts at locations2, 3, 4 and 7. Loosely tighten the four bo lts at locations"A", then torque al l bolts down evenly to 15-18 footpoundsmaximum in acco rdance with sequence shownin the illustration.5.2.2 Pistons, Piston Rings and Pins (See Figure 5-3)a. Lubricate piston pin needle bearing with two-strokeOilseal Retaining circlipsFig. 5-1 Crankcase Lower Half5-1

®-------41--------1. 3 }---------{ l--------1. 7"'Cc:"'-0~ca......."' s:00.."'Cc:"'Qi.r; "'s::?:u..6 }---------{ 1-------'{ 2 1---- - ---1 )---------{ 4AAFig. 5-2 Crankcase Bolt Torquing Sequenceengine oil and install bearing into connecting rod smallend.b. If both piston pin retaining circl ips have been removedfrom piston, use a su itable tool and install a ci rclip at onepiston pin bore.c. Use a propane torch or cloth soaked in hot water and heatpiston until warm to the touch {120 to 14QOF). Ensurethat the arrow on piston crown is directed toward theexhaust port and al ign piston pin bore with center bore ofconnecting rod . Lubricate piston pin and, using a softdrift, push pin into piston until it bottoms on the installedcirclip. Exercise care to prevent damage to needle bearing.Install remaining circlip.d. Install piston rings in ring grooves, using a suitable ringinstalling too l. Ensure that piston ring gap is correctlypositioned at the ring groove locating pin .e. Repeat steps {a) to {d) for second piston.5.2.3 Cylinders (See Figure 5-4)a. Install new base gaskets over cylinder hold down studs.b. Cylinders are identified by the letters "L" {left hand ) and"R" {right hand) stamped on the cylinder flange. Locateright hand {No. 1) cylinder at flywheel end of crankcase.c. Lubri cate pistons, rings and cyl inders with two-strokeengine oil.d. Place a su itable wooden block between piston and)Piston RingsLocating Pin_;Fig. 5-3 Installing Pi stons, Rings and Pins5-2

ccrankcase to steady the piston. Using a piston ringcompressing tool, compress rings flush with piston.e. Slide cylinder over piston and ring assembly. Remove ringcompressing tool.f. Repeat steps (c), (d) and {e) for No.2 cylinder.g. Install cylinders over hold down studs and secure witheight washers, lockwashers and hold-down nuts. Torquenuts down evenly, in accordance with the sequence shownin Figure 5-5, using the wrench provided. Recommendedtorque is 15-18 foot-pounds maximum.c:Fig. 5-4 Installing Cylinders® CD ® CDc"Cc:wNO: 2 NO: I....:::Cl).c:0 >-a, u..ll!ctl1-..::: w @ wCl)0Q..@"Cc:wQjFig. 5-5 Cylinder Hold-down nut torquing sequence5-3

)Fig. 5·6 Installing Cylinder Heads"Cc:Cl)-0a,..ll::co......Cl)::0c..NO . 2NO. I® CD @ CD0(1)0(5) (5)Q)"Cc:Cl)Q;Cl)..r:.::>u:::)Fig. 5-7 Cylinder head hold-down nut torquing sequence5-4

c5.2.5 Stator Assembly (See Figure 5-8)a. Install and secure stator to engine crankcase using twoPhillips head screws. Position ignition wire bundle in therecess provided, and install rubber grommet.5.2.6 Fan Cover Case and Flywheel (See Figure 5-9)a. Install and secure fan cover case to crankcase using fourSx 28 bolts, plain washers and lockwashers.b. Place a Woodruff key in the slot on the crankshaft. Ensureflywheel center bore and tapered end of crankshaft arefree of oil or grease. Align keyway and key;slide flywheelContact BreakercCoil Plate retainings screwsFig. 5·8 Stator assembly installedFig. 5-9 Fan cover backing plate and flywheel installed5-5

on to shaft as far as it will go. Rotate flywheel to ensurefreedom of movement with no evidence of binding. Lockthe flywheel using CCW Tool #43-0798-40; install flatwasher, lockwasher and nut. Tighten nut to 40-50 poundsfeet maximum torque. Set timing to proper specifications.Refer to paragraph 5.4.4.5.2. 7 Fancover, Starter Cup and Fan Belt Pulley (See Figure5-1 0)a. Install and secure fan cover to fan cover case using four 8 x35 bolts, plain washers and lockwashers. Secure ignitionterminal coupler and bracket using two Phillips headscrews.Jr ~,.>~-;a......2. ]s::cou..Fig. 5-10Fancover, StarterCup and Fan belt pulley installedFig. 5-11High Tension Ignition Installed()Fig. 5-12Recoil Starter Installed5-6

cb. If a window plate was removed during disassembly,replace it behind fan belt pulley with a lip facing outward.Install and secure fan belt pulley and starter cup toflywheel using three 6 x 22 bolts and lockwashers. Installfan belt and adjust to proper tension. (Refer to Section II,Paragraph 2.6.2.)5.2.8 Electric Starter (if so equipped)a. Install and secure electric starter to hold down studs atcovercase. Secure to crankcase using two 8 x 20 bolts,washers and lockwashers.5.2.9 Ignition Coils-Testing and Installationa. Coil output can be tested on a Merc-0-Tronic or othercomparable analyzer. See Table 1-1 for specifications. Athree needle air gap tester may also be used. See Table 1-1.Note:-A 12 vo!t battery will be required on the oldermodel of Merc-0-T ron ic analyzers.b. Install and secu re high tension ignition coils to fan coverusing two 6 x 65 attach ing bolts and spacers. Connect lowtension wires to igniti.on coupler.c. Install and secure coil cover using two 6 x 10 bolts, plainwashers and lockwashers. Figure 5-115.2.1 0 Recoil Starter (See Figure 5-12)a. Install and secure recoil starter to fan cover using four 6 x22 bolts, flat washers and lockwashers.5.2.11 Intake and Exhaust Manifoldsa. Install two new intake manifold gaskets and the twoinsulators over intake manifold hold down studs.b. Install two additional new gaskets over insulators andmount intake manifold to hold-down studs. Secure withfour flatwashers, lockwashers and hold-down nuts. Do notovertorque the nuts.c. Install two new exhaust manifold gaskets and mountexhaust manifo ld to hold-down studs. Secure with fourflat washers, lockwashers and hold-down nuts.Do not overtorque the nuts.5.2.12 Coversa. Install and secure cylinder cover and adapter to engineusing four 6 x 10 and six 6 x 12 attachment bolts andlockwashers; install the four shorter bolts at intake andexhaust manifold sides of cover. Start each attachmentbolt before tightening any bolts; then tighten all boltssecurely. Ensure spark plug wires are properly secured asshown in figure 5-12.5.2.13 Engine Installationfl. Install engine to app licable mounting location; attachmuffler and tailpipe; connect electrica l wiring and controls.b. Remove protective plugs from spark plug holes; installspecified plugs and connect high tension leads.c. Check engine for proper operation. Refer to paragraph5.3.5.3 TESTING AFTER OVERHAUL5.3.1 GeneralA five to ten percent power lo ss may be expected on a newlyoverhiluled engine until it has been subjected to a suitablerun-in period. Carefully run the engine nt varying enginespeeds for the first twenty-five hours of operation.5-75.4 ADJUSTMENTS5.4.1 Carburetor (Refer to applicable manufacturer'sspecifications)5.4.2 Spark Plugs (Refer to Section Ill, Paragraph 3.3.4)5.4.3 Contact Breaker Points (See Figure 5-13)a. Remove recoil starter, starter cup and fan belt pulley.b. Remove window plate (Kokusan magneto only).c. Loosen applicable breaker point retaining screw.d. Adjust breakerpointsgapto0.014±.002inch. Useafeelergauge to measure the gap.e. Tighten breaker point retaining screw.f. Check engine ignition timing. See Paragraph 5.4.4.g. Replace window plate, starter cup, fanbelt pulley andrecoil starter.5.4.4 Engine Ignition Timing (See Figure 5-14)After engine overhaul or whenever contact breaker pointshave been replaced or adjusted, check and/or adjust ignitiontiming to ensure continued engine operating efficiency.5.4.4.1 Preferred MethodThe recommended method of engine ignition timing is with adial indicator and a timing light having a self containedbattery. This method is conside red the most co nvenientmeans of determining piston position in respect to true topdead center.Time the engine as follows:a. Remove recoil starter, starter cup and fan belt pulley;remove window plate (if installed).b. Remove spark plugs; disconnect ignition at coupler.c. Install a su itable dial indicator into No. 1 cylinder sparkplug hole.d. Rotate flywheel to locate No.1 piston position at true topdead center. True top dead center is that point on theindicator scale where the pointer begins to reversedirection of motion. Zero the dial indicator at true T.D.C.e. Refer to figure 5-13. Adjust No. 1 cylinder breaker pointgap to 0.014 inch. This point set has red ignition wiring.Connect one lead of a timing light to the red wire atignition coupler and the other lead to ground.f. Rotate flywheel until pointer of dial indicator reaches0.015 inch before true top dead center. At this instant thetiming light shou ld go out to indicate breaker points juststarting to open .If necessary, adjust ignition co il plate to the right or to theleft until the light goes out. Secure ignition coil plate inthis position; recheck piston travel to verify timingaccuracy.NOTE: If coil plate cannot be adjusted enough to accuratelyset No. 1 cylinder timing, recheck breaker po int gap.Gap may be re-adjusted to 0.014±.002 inch to obtaindesired timing sequence. Breaker point gap mustremain within specified tolerance.g. Remove dial indicator and install it into No.2 cylind erspark plug hole. Disconnect timing light from ignitioncoupler.h. Adjust No.2 cylinder breaker point qap to 0.014 inch.This po int set has red ignition wiring. Connect one leadof timing light to the red wire at coupler and the otherlead to ground1. Locate No. 2 piston position at true T.D.C. Refer toprocedura l step (d).•

Co.il Plate retainings screwsFig. 5-13Adjusting Contact Breaker PointsJ. Rotate flywheel until pointer of dial indicator reaches0.015 inch before true T.D.C. At this instant th e timinglight should go out to indicate breaker points just startingto open. If necessary, point gap may be re-adjusted to0.014±.002 inch to obtain the desired timing sequences.Breaker point gap must remain within specified tolerance.Recheck piston travel to verify timing accuracy.k. Replace window plate, starter cup, fan belt pul ley andrecoil starter.I. Replace spark plugs; check:engine for proper operation.m. Using a Stroboscope, cher:k' ignition timing setting, autoadvance mechanism,·when fully advanced in accord ancewith specifications, Table 1-1 .5.4.4.2 Alternate Method (See Figure 5-14)As an alternate method of engine ignition timing, use the twosets of reference marks on the flywheel and the top deadcenter (zero) reference line marked on the fan cover. Thereference marks on the flywheel include a 'T' wh ichindicates piston position at top dead center when alignedwith the zero reference line on fan cover, and 50, so and 100reference lines in advance of top dead center. One set ofreference lines is 1800 opposed to the other set. If using thealternate method, time the engine as follows:a. Remove spark plugs; disconnect ignition at coupler.b. Remove recoil starter, starter cup and fan belt pu ll ey.Remove window plate (if installed).c. Refer to Figure 5-13.Adjust No. 1 cylinder contact breaker point gap to 0.014inch. This point set has white ignition wiring. Connect onelead of a timing light having a self contained battery, orsuitable instrument to the wh ite wire at coupler and theother lead to ground.d. Rotate flywheel until No. 1 piston is approach ing topdead center and the nearest SD reference line is al ignedwith the zero reference I ine on the fan cover. At th is5-8instant, the timing light should go out or suitableinstrument should activate to indicate No. 1 cylinderbreaker points ju st starting to open. If necessary, adjustignition coil plate to the right or to the left until thecorrect ind ication is given. Secure ig~itL~n co il plate in thisposition. Recheck timing to verify accuracy.NOTE: If coil plate cannot be adjustedefwugh to accuratelyset No. 1 cylinder timing, recheck breaker point gap.Gap may be re-adjusted to 0.014±.002 inch to obtaindesired timing sequence.e. Refer to Figure 5-13.Adjust No.2 cylinder contact breaker point gap to 0.014inch. This point set has red ignition wiring. Connect onelead of timing light or suitable instrument to the redwire at coup ler and the other lead to ground.f. Rotate flywheel 180° to the opposite set of referencemarks. Adjust flywheel until No.2 piston is approach ingtop dead cen ter and the nearest so reference I ine is alignedwith the zero reference I ine on fan cover.At this instant the tim ing light shou ld go out or suitab leinstrum ent shou ld activate to indicate No. 2 cylinderbreaker points just starting to open. If necessary, breakerpoints may be re-adjusted to 0.014±.002 inch to obta indesired timing sequence. Recheck timing to verifyaccuracy.g. Replace window plate, starter cup, fan belt pulley andrecoil starter.h. Replace spark plugs; check engine for proper operation.i. Using a stroboscope, check ignition timing setting, au toadvance mechanism when fully advanced, in accordancewith Specifications, Table 1-1.5.4.4.3 Crankshaft Angle Versus Piston TravelTable 5-1 lists piston position rel ative to crank angle..·()

cFig. 5·14Setting Engine Ign ition Tim ing- Aiternate MethodcCrank AngleTABlE 5-1CRANK ANGlE VERSUS PISTON TRAVElDistance fromTop Dead BTDCso 0.006.'• 6 0.0087 0.0118 0.0159 0.0 1810 0.02311 0.02812 0.03313 0.03814 0.04415 0.05116 0.05817 0.06518 0.07319 0.08120 0.08921 0.09922 0.10823 0.11824 0.12925 0.13926 0.15027 0.16228 0.17429 0. 18630 0.1985-9

TABLE 5-2TORO.UE SPECIFICATIONSlocationCrankcaseCylinder HeadCylinder to CrankcaseFlywheel to CrankshaftFan PulleyTypeScrewsNutsNutsNutNutSize8mm.8mm.8mm.14mm.12mm.lbs. Ft.12-1515-1812-1545-5028-31)Multiply(Known)Millimeters (mm)Inches (in.)Centimeters (em)Inches (in.)Kilometers (km)Miles(mi)Meters (m.)Feet (ft.)Cubic Centimeters (cc.)Cubic Inches (cu. in.)Liters (I.)Gallons (qal.)Liters (I)Quarts (qt.)Cubic Centimeters icc.)Fluid ounces (fl.oz.)Kilograms (kg.)PoundsGrams (g.)Ounces (oz.)Metric Horsepower (ps)Brake horsepower (bhp.)Kilogram-meter (kg.-m.)Foot-pounds (ft.-lbs.)Square millimeters (sq.mm)Square inchesTABLE 5-3METRIC/LINEAR CONVERSION TABLEby0.0393725.4.39372.54.62141.6093.281.3048.06116.387.2643.7851.057.946.033929.572.205.4536.0352728.351.014.98597.235.13830.00155645.2to Obtain(Unknown)InchesMillimetersInchesCentimetersMilesKilometersFeetMetersCubic InchesCubic CentimetersGallonsLitersQuartsLitersFluid OuncesCubic CentimetersPoundsKilogramsOuncesGramsbhp.ps.Foot-poundskg.-m.sq. 1n.sq. mm.TABLE 5-4LIST OF APPROVED CARBURETORSCCWModelCarburetor ManufacturerModelFuel ReturnYes No340340340340400400400400WalbroTillotson, DiaphragmTillotson, 0 iaph ragmBendix Zenith, Float ChamberTillotson, DiaphragmTillotson, DiaphragmWalbro, DiaphragmBendix, DiaphragmWR6HR92HR99A1408.5/013586HR101AHR 100AWR616Y10/013599*YesYes*YesYes*NoNo*Not Requir ed5-10

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