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Asse sembly ly Instr tructi tions - SS57 Sno-Skat Unpacking th the Kit: Care must be exe xerc rcis ised ed in unpacking the Kit to to avoid bending or scra ratc tchin ing the vario ious components. As th the part rts ar are unpacked lay them out neatl tly and check the part parts against the enclosed Par Parts List List.. Notify us immediatel ediately y of any short shortages. ages. Settin ing up for Asse sembly ly: It is best to to set et th the Body in an uprig ight posit ition on the edges of two sa saw-hors rses es or on top of a cra rate. This will allow you to ea easil ily work around and underneath th the 1 Sno-Skat. NOTE: The dir irect ctions 'L 'Left & Right' t' and 'Upper & Lower referred referred to in the following inst struct ctions are re dete term rmined by standing behind the Sno-Skat and looking forward. 'Insi Inside' refer efers s to the side of a part part which is closes closest t to an imagiaginary center line line running down the length of the Sno-Skat. 'Outsi utside' refer efers s to the side fart farthest hest from from the above defined center line. Lubrication: All Bearing earings are are lifet lifetim ime lubricated lubricated and sealed. sealed. Follow manufacturer anufacturer''s re recommendatio ion on Engine and peri riodic ical ally oil #24 Driv ive Chain with th lig ight oil il. ASSEMBLY: 1. Inser Insert t threaded threaded ends of #3 Pull ulls into into 1/2" holes on inside inside of # 1H Bracket Brackets. s. Slid ide 3/8 /8 WI Washer over each protr trudin ing thre readed end of #3 Pulls ls and loosely tu turn on two 3/8 /8 Nuts ts. (Note: #3 Pull ll must lie ie flat agains st t insid ide of #1H Brack cket) t) 2. From the right right side side inser nsert the #15 Pivot Rod through the 5/8 slot slot in#l in#lH H Bracket and then into the 5/8 hole in #3 Pull ll. In pro roper ord rder sli lide onto #15 Rod, #14, 12 and 13 Tubes spacin ing them with th #26 Track ck Idle lers rs. Inse sert rt end of Rod into to left #3 Pull ll and #1H Brac acke ket. t. Shim out ends of #15 Rod with th 5/8 WI Wash shers rs on each si id de of Body and secu cure re with th 5/8 /8 Snap Ring.
Secure each Bearing with 1/4 WI W asher, Lock Washer, and Nut. set screws in #27 Bearings with Allen W rench provided.
Secure the two
6. Insert each #7 Leg Assembly in their respective #1I Tubes. (Note: on each side the #7B Stop must point forward - note drawing showing proper location of #7 "left" Leg). Slide #8 Arm over end of respective #7 Leg and secure by driving in 5/16 x 2 Spring Pin. (Note: any play can be taken up with 7/8 W I Washer between top of #11 Tube and #8 Arm). 7. Insert #4 Tiller Assembly into the center #1I Tube of #1 Body Assembly. (Note: use 7/8 W I Washers between top of #1I Tube and #4C Plate to raise #4C Plate so it is level with the #8 Arms on each side). Below use 7/8 WI Washers to shim out lower end of #4A Tiller and secure with 1-1/2 x 1/8 Cotter Pin. 8. Following the Drawing, insert Pin ends of #9 Links into respective 3/8 holes of #8 Arms and mating 3/8 holes in #4C Plate. Secure both left and right Links below using 3/8 W IW ashers and 1 x 1/8 Cotter Pins. 9. Slide #10A Bracket of #10 Ski Assembly onto the end of its respective #7 Leg. Shim with 7/8 WI Washers and secure with 2-1/2 x 1/8 Hitch Pin. (Note: at this time check steering mechanism by moving #4 Tiller back and forth to see that everything moves freely without binding and that all parts are secure - #4C Plate should move approximately 23° off center both left and right before hitting #1F Stop). 10. M ount #11 Bracket against Engine Case using 5/16-24 x 1/2 Cap Screws and 5/16 Star Washers over each Screw end. Slide #16 Clutch Assembly on Engine Shaft and shim out (between Engine Case and Clutch) with 3/4 WI Washers until Clutch rotates freely and clears the above 5/16-24 x 1/2 Cap Screw heads by approximately 1/16". Remove Clutch from Engine Shaft. Remove Snap Ring retainer from Clutch Shaft and remove the Sprocket and Clutch Drum Assembly from the Clutch Body. (Note: do not tamper with Clutch Shoes) Insert 3/16 square Key on Engine Shaft and slide the remaining Clutch Body Assembly (less Sprocket and
13. Take the end of the Control Cable from the #20 Control (mounted on the left side of the #4B Tiller Handle) and insert it into the hollow #19 Bushing. Slide the #23 Brake Return Spring over the Cable and insert the end of Cable into the single 1/4" hole in end of top "loop" of #17 Brake Band. From the side slide the #18 Connector into the above "loop" and engage the Control Cable in the Connectors' slot. W ith a Phillips screwdriver tighten this Connector so it is squeezing down on the Control Cable. (Note: at this point check the left #20 Control so that squeezing the Control will apply sufficient pressure on the Brake Band so as to completely stop the #16 Clutch from rotating - you may want to cut off some of the end of the Cable as only about 1/8" can be protruding out the other side of the #18 Connector inside the upper "loop" of the #17 Band). NOTE: The #19 Bushing can be screwed in or out to make finer Brake adjustments. 14. In a similar fashion insert the remaing #20 Control Cable into the #19 Bushing mounted on the Engine and pass it through the slotted arm below. From below mount the #18 Connector, locating it such that when you squeeze the #20 Control on the right side of #4B Handle you open the throttle on the carburator. (Note: to achieve the safest operation you must set this adjustment so that when the #20 Right Control is released the throttle will return to the idle position by itself). Again, this finer setting can be accomplished by screwing the #19 Bushing in or out. 15. Loop the #24 Drive Chain over the 42 tooth Sprocket on the #6 Drive Shaft Assembly and connect the Chain ends with connector link provided. By tilting the Engine slightly, drop the Engine into the Engine Compartment of #1A Body Assembly. (Check that #20 Brake Control Cable is not being pinched against the edge of Engine Compartment - it should make a large loop as it comes out of the Engine Compartment). Slide Engine rearward and loop other end of #24 Chain over the Sprocket on the Clutch. Slide Engine forward and align Engine mounting holes with slots in the #1B Mount. Slip a 5/16 W IW asher over end of each 5/16-18 x 1 Cap Screws and from inside the Engine Compartment insert into Engine mounting
18. Assemble Track Segments using steel pins provided. (Note: put light oil on pins before inserting to make them slide - check that pins are pressed completely into Track and recessed each side). Before inserting last pin, thread Track over #26 Track Idlers, around Sprockets on #16 Drive Shaft Assembly and under #5 Boggie Assembly. Join the two ends of Track with final pin. (Note: check that arrows (molded into Track) point in the direction of forward travel and that the smooth side of the Track is to the inside. 19. In the rear draw up evenly on the threaded ends of the #3 Pulls until the slack is out of the Track (without stretching it). Check that the Track moves freely by hand - loosen if necessary - and then tighten the second 3/8 Nut against the first to hold position. 20. M ount the #2 Hood Assembly over the Engine and line up the three 5/16 holes on each side with their respective mating holes in the #1D Braces. Using a 5/16 WI Washer on each 5/16-18 x 3/4 Cap Screw insert (from outside) into holes and secure inside with 5/16 WI Washer, Lock Washer and Nut. 21. Take the roll of plastic Trim Edging and on the lower front corner of the #2 Hood start sliding the Edging on, working your way neatly around the two corners and down to the bottom of the other side - at this point cut off remaining Edging cleanly with a "tin snips". Repeat this procedure again on the inside edge making sure you have pushed the Edging on as far as it will go. 22. At this point you have completed Assembly of your "Sno-Skat". It is now important that you take time to go completely over the machine again following the above assembly instructions and check your work. Constantly look for tightness of bolts and proper location and fit of various components. Especially important are the two Control Cables - they must be adjusted and secure so they tighten and release their respective Brake Band and Throttle. Also that the Cables are not cut or pinched and that they are free to move. OPERATION:
