1972–1975 John Deere 300, 400, 500, 600, 800, JDX4, JDX4 Special, JDX6, JDX8, JD295/S & JD340/S Snowmobile Factory Service Manual Set (P/N SM-2100)
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John Deere Models Covered & Key Technical Specifications
Models: 300, 400, 500, 600, 800, JDX4, JDX4 Special, JDX6, JDX8, JD295/S, JD340/S
Models & Model Codes:
300 — John Deere: 3000C (S/N 20,001–30,000; Kohler K295-2AX); J300D (S/N 30,001–; Kohler K295-2AXY).
400 — John Deere: 4000A (S/N 2,551–11,000; CCW KEC-340); 4000B (S/N 11,001–20,000; CCW KEC-340/4); 4000C (S/N 20,001–30,000; CCW KEC-340/5); J400D (S/N 30,001–; Kioritz KEC-340/5).
500 — John Deere: 5000A (S/N 2,551–11,000; CCW KEC-440); 5000B (S/N 11,001–20,000; CCW KEC-440/4); 5000C (S/N 20,001–30,000; CCW KEC-440/5).
600 — John Deere: 6000B (S/N 2,551–20,000; CCW KEC-440/4); 6000C (S/N 20,001–30,000; CCW KEC-440/5); J600D (S/N 30,001–; Kioritz KEC-440/5).
800 — John Deere: J800D (S/N 30,001–; Kioritz KEC-440/22).
JDX4 — John Deere: JDX4B (S/N 2,551–20,000; Kohler K295-2AX); JDX4D (S/N 30,001–; Kioritz KEC-340/22A).
JDX4 Special — John Deere: JDX4C (S/N 20,001–30,000; CCW KEC-340/5).
JDX6 — John Deere: JDX6C (S/N 20,001–30,000; CCW KEC-400/22); JDX6D (S/N 30,001–; Kioritz KEC-400/22).
JDX8 — John Deere: JDX8B (S/N 2,551–20,000; CCW KEC-440/21); JDX8C (S/N 20,001–30,000; CCW KEC-440/22); JDX8D (S/N 30,001–; Kioritz KEC-440/22A).
JD295/S — John Deere: JD295/SC (S/N 20,001–30,000; Kioritz KEC-295RS/2).
JD340/S — John Deere Service Textbook coverage; JD/Kioritz KEC 340 RS/2 engine.
Sub-models / Variants: Bogie Suspension, Slide Suspension, Bogie-Slide Suspension, 2-Cylinder 2-Cycle. JD295/S: optional bogie, slide, or bogie-slide suspension. JD340/S: slide suspension.
Model Years: 1972–1975 (1972, 1973, 1974, 1975)
Serial Numbers: 2,551– (SM-2100); model-specific ranges are listed above. Starting serial identifiers for J300D, J400D, J600D, J800D, JDX4D, JDX6D, and JDX8D: J300D 030001M, J400D 030001M, J600D 030001M, J800D 030001M, JDX4D 030001M, JDX6D 030001M, and JDX8D 030001M, respectively.
Component Serial Breaks: 300 recoil starter: S/N 20,001–21,504 and 21,505–; 300 standard final-drive ratio: S/N 20,001–22,625 and 22,626–30,000. Revised rear-idler spacing: JDX4 S/N 9304–20000; 400 S/N 15834–; 500 S/N 14183–; JDX8 S/N 7996–20000. Bogie mounting and steering-column/spindle changes: S/N 20,001–. Heavy-duty suspension kit standard on 600: S/N 20,001–. Kohler lighting-coil configuration: engine S/N 722605695–732701000 and 732701001–.
Transmission Variants: Two-sheave variable transmission with enclosed-chain final drive. Salsbury 780: 300 S/N 20,001–, 400 and JDX4 through S/N 20,000; Salsbury 910: 500 through S/N 11,000; Salsbury 850: 500 S/N 11,001–20,000, 600 and JDX8 through S/N 20,000. John Deere (Comet) 100C drive / 90D driven: 400, 500, 600, JDX4 Special, JDX6, and JDX8 S/N 20,001–30,000; 101C drive / 90D driven: 400, 600, 800, JDX4, JDX6, and JDX8 S/N 30,001–. JD295/S: 101C drive sheave described in the detailed clutch section. JD340/S: John Deere (Comet) 102C primary / 900 secondary. Modification Program 160 also fitted Comet sheaves to many earlier 500, 600, and JDX8 machines.
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Engine type: 2-cylinder, 2-cycle, air-cooled
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Crankshaft runout: 0.0035 in. maximum for the listed CCW/Kioritz engines except JD295/S; 0.0012 in. for Kohler-powered 300/JDX4; 0.0008 in. for JD295/S; 0.002 in. maximum for JD340/S
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Fuel tank capacity: 6.50 U.S. gallons (plastic), 5.50 U.S. gallons (steel); JD295/S: 2.2 U.S. gallons; JD340/S: 9.00 U.S. gallons
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Overall length: 103.4 in. for SM-2100 models; JD340/S: 104 in.
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Overall width: 34.5 in. for SM-2100 models; JD340/S: 40 in.
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Chain case capacity: 5 oz. (150 ml) for SM-2100 models
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Flywheel nut torque: 60 ft-lbs for CCW/Kioritz engines; 85–90 ft-lbs for Kohler engines
John Deere Manual Features & Content Preview
This John Deere factory service manual set combines SM-2100, August 1974, for the 300, 400, 500, 600, 800, JDX4, JDX4 Special, JDX6, JDX8, and JD295/S with a separate JD340/S Service Textbook. Coverage follows the model, engine, and serial-number distinctions in each publication.
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Engine repair: Engine analysis, crankcase pressure testing, removal, disassembly, inspection, and overhaul for CCW/Kioritz piston-ported and reed-valve engines and Kohler piston-ported engines.
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Fuel system: Walbro, Bendix, and Mikuni carburetor repair, inlet-needle pressure testing, metering adjustments, dual-carburetor synchronization, and main-jet selection.
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Electrical diagnosis: Magneto and capacitor-discharge ignition testing, ignition timing, stator and lighting-coil service, wiring diagrams, and electric-start component testing.
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Power train: Salsbury and John Deere (Comet) sheave repair, drive-belt alignment, chain-case and shaft service, band-brake adjustment, and JD340/S hydraulic-brake repair.
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Suspension and tracks: Bogie and slide suspension service, rear-idler rebuilding, track replacement, tension and alignment checks, ski spindles, and steering repairs.
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Workshop references: Component inspection limits, torque tables, electrical test specifications, and illustrated engine, clutch, and electrical service tools.
The set is suited to technicians and experienced owners familiar with two-stroke engine work and the use of measuring instruments, ignition testers, and dedicated clutch tools.
Engine Analysis and Overhaul
Separate overhaul groups distinguish piston-ported CCW/Kioritz engines, reed-valve engines, and Kohler engines. Inspection covers cylinders, pistons, rings, connecting rods, bearings, crankshaft runout, and end play, alongside recoil-starter disassembly and rebuilding.
Crankcase pressure testing with the JDM-44 tool helps investigate suspected air leakage after lean-running piston damage. This provides a way to investigate the cause of a failure before replacement parts are installed.
The Kohler assembly instructions warn that excess crankcase adhesive can contaminate crankshaft and connecting-rod bearings and damage the engine.
Carburetors and Fuel Delivery
The fuel chapters explain carburetor operation as well as repair. Walbro coverage includes model-specific metering-lever springs and needle-valve breakaway testing; Bendix coverage addresses the float and fuel-valve assemblies.
Mikuni sections cover float level, starter-plunger adjustment, synchronization, and jet selection. The JD340/S textbook adds a temperature-and-altitude jet chart with different left- and right-hand carburetor requirements, helping distinguish a deliberate calibration difference from mismatched parts.
Ignition, Wiring, and Starting Systems
Electrical sections separate conventional magneto ignition from capacitor-discharge systems. They include coil and condenser tests, switch checks, timing procedures, starter-motor overhaul, and charging-system diagnosis.
Illustrations include serial-specific electric-start wiring diagrams, the JD295/S wiring diagram, carburetor operating-section views, the exploded recoil-starter assembly, and the JD340/S driveline cross section.
The JD295/S and JD340/S wiring harnesses have no provision for an electric-start kit. Electric-start coverage elsewhere in the set should not be read as applying to those models.
Clutches, Brakes, and Running Gear
The power-train chapters distinguish Salsbury assemblies from John Deere (Comet) designs, including bushing differences, driven-sheave service, belt alignment, chain tension, and shaft bearings. The JD340/S textbook adds its primary and secondary sheaves, Kelsey-Hayes master cylinder, brake caliper, pad replacement, and bleeding procedures.
Its brake-fluid warning explains that unsuitable hydraulic or mineral oils can damage cups and seals.
Suspension coverage includes Gates “Poly,” Goodyear Pathfinder, and Goodyear Grouser Bar tracks, with track-failure analysis and variant-specific removal and installation details. SM-2100 excludes hood, console, tunnel, and pan repair procedures, although its introduction gives limited minor-damage guidance.
Follow the publications’ precautions for rotating tracks, spring-loaded clutch assemblies, and high-energy ignition. Complex internal engine or structural work should be performed or verified by qualified service personnel.
A Preview of JD340/S Inspection and Adjustment Data
These examples are a small selection of the JD340/S textbook’s engine-checking and carburetor-adjustment data.
The engine specification sheet lists compression pressure of 110–130 psi with the engine cold and the throttle wide open, with no more than 10 psi difference between cylinders.
The Mikuni float-level illustration specifies 0.90 ± 0.04 in. between the baffle plate and the top edge of the float arms, measured with the carburetor inverted.
Text Search, Bookmarks, and PDF Contents
Search and diagram detail: Embedded text supports searches across both publications, although the opening contents page has no searchable text. PDF bookmarks link to the main system sections and wiring diagrams. Small wiring labels on the checked diagrams require zooming.
One printable, English-language PDF contains 340 pages total, including the publications’ covers, contents pages, and section-divider pages.
| Publication | Pages |
|---|---|
| SM-2100 Snowmobile Service Manual | 310 |
| JD340/S Service Textbook | 30 |
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