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CHASSIS
TO REPLACE TOP SHROUD
1.
Remove right and left half end caps from the
rubber
trim
strip
by removing two screws and two lock
nuts.
2.
Remove the center
front bumper bolt.
3.
Lift
up
rubber bumper
strip
and drill out rivets.
4.
Remove the
rubber bumper strip.
5
.
Remove bracket
holding
steering
column to the
top
shroud
by removing two
screws,
two nuts and a
holding plate.
Remove
fasteners from inside storage
compartment
on
top
shroud.
6.
Remove
gas
cap and support angle which holds
the fuel intake to
the
top
sh
roud.
To
release the
support
angle remove one
screw
and
one
nut from the top
shroud.
7.
Disconnect
wiring loom at connector plug
.
8.
Remove light switch by removing two nuts from
the
outside
of the switch
on
Models
5811
and 5812.
Models
5814 and 5815
do not have a separate light
switch.
9.
Remove
ignition
switch by removing the nut on
the
backside of the switch.
Then push switch
out.
NOTE: Models
5814
and
5815
have the light
switch
and
ignition switch
combined in
one
location.
10.
Remove
wire holding clips from the edge
of
the
access hole
on
the
top
shroud.
11.
Remove head lamp assembly from the front of
the shroud by removing two
screws and
two nuts
.
12. Use reverse procedure
from
that stated above
to install new top
shroud
.
13.
Use either a pop rivet
gun
and pop rivets or flat
head
screws and
lock nuts to
secure
new 'top shroud.
If
flat head
screws
are
used,
work
th
rough
the
access
opening.
TO REPAIR TOP SHROUD
.If the top shroud is fractured
or
punctured, repair
with Polyester resin and fiber glass cloth. See chassis
parts diagram for paint information.
NOTE: The repair materials
are
not supplied or kept
in
stock by
the
manufacturer.
However,
they
can
be
purchased locally through auto
parts
or marine supply
companies
.
. TO REPLACE FUEL TANK
1. Remove access cover
on
top
shroud.
2.
Loosen clamp which holds intake fuel
line
to the
fuel
intake
plug by unscrewing
it.
The best tool to do
this is a
pair of
long handle adjustable pliers.
3.
Remove fuel
outlet plug
(See Figure 1). Use same
method to remove as stated above.
4.
Remove clutch guard and drive belt as
shown
being done in Figure 2.
5.
Loosen
brackets
located
at
bottom of chain
housing (See
Figure
3).
Use vice grips to hold bolts
Figure
1
Figure 2
while loosening nuts.
Remove only one completely.
Swing
bracket back
to free bottom
of
chain
housing.
6.
Remove
the
brake
cable
from
the brake
arm
by
loosening the allen screws (See Figure 3).
7.
IMPORTANT: Place sled on its
left
side
for a few
minutes to
let the oil in
the
drive shaft
run into the
chain case. This will lessen spillage of
oil when the
chain case
is
removed and the sled
is
on
its side. Drain
chain case by
removing
check plug.
8.
Remove all fasteners marked
"A"
in
Figure 3 to
release the chain case.
9.
Pry off chain case and driven clutch
with two
long heavy screw drivers or similar
tools
.
Figure 3
10.
Release
track
tension by
loosening adjusting
bolts as shown
in
Figure 4.
11.
Place sled on its
left
side.
12.
Remove the three lacer pins
from the
belt
splice
and remove the track from
the
sled.
13.
Remove the front boggie assembly by
removing
a bolt and a washer from each
end
of the
boggie
shaft.
Figure 5 shows a
boggie assembly with a
washer and a
bolt
to be
removed.
14. With a screw driver carefully pry
the rubber oil
seal from the bearing retainer on the
drive
shaft
(See
Figure 6) on both right and
left hand sides.
15.
Figure 7 shows the drive shaft
and driving
sprockets being
removed.
Pull shaft
towards the side
which has the chain housing removed.
This will free
the drive shaft and sprockets for
removal.
- 4 -
)
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