Polaris Playmate 1971 Shop Manual

1971

1

---

S#OP

M~NUA,L

• • a • • :

..

..

" " to'

.

~.

.

-

INTRODUCTION

This Manual

assembly

By

reading this Manual carefully,

which

The meaning
justment
ance
inspected

This Manual is
ing construction details, disassembly, inspection, maintenance,
of

will

with

specific parts

has

been prepared

of

the Polaris snowmobiles.

be

helpful

of

of

your

the instructions supplied

and

serviced

in

maintenance.

maintenance

snowmobile

periodically

divided

of

into

the machine.

is

to

sections showing detailed photographs, cover-

as

a guide to maintenance, disassembly

you

can obtain knowledge

to

perform

keep

.

it

in

preventive maintenance

in

top

running condition.

this Manual,

all

of

machines

and

the machine,

and ad-

In

accord-

should

and

assembly

be

POLARIS INDUSTRIES

Division

of

textron

II

nc.

Service Department

Roseau, Minn.

,.

j

TABLE

OF CONTENTS

c

c

MODEL

ENG

COMMON SPECIFICATIONS FOR

CONDENSED SERVICE

ELECTRICAL

WIRING SCHEMATICS

TROUBLE

INSTRUCTION FOR

INSTRUCTION FOR CARBURETOR

INSTRUCTION FOR POLARIS ENGINES

SPECIFICATIONS

PLAYMATE

INE

DATA

175cc - 795cc

TORQUE PATTERNS

SHOOTING

MODEL

MODEL

CONSTRUCTION
STARTING
REMOVAL

DISASSEMBLY OF ENGINE. . . . . . . . . . . . . . . . . . . .

.

RE

- ASSEMBLY OF ENGINE

- CHARGER -

.....

SYSTEM

OF 62 - 24

VM

- 30

....................................

OF ENGINE

...

. .

..................

TX

- MUSTANG -

ALL

MODELS .

DATA

.............................

INFORMATION

..............................

.................................

FUEL

PUMP .

..............................

..........................

.....................

.........

......................

.......................

........

VOYAGER

..................

....

...

..........

.........

..

11

16 - 18

19 - 26

27
27 - 29

31
33
37 - 43

1 - 2

3-

9 -

10

- 14

15

- 43

30

- 32

- 36

6

7

8

.

...

c

BODY

AND

TRIM

................................

DISASSEMBLY OF BODY,

DRIVE

STEERING

TRACK

AND

BRAKE

DISASSEMBLY OF CHAINCASE

............

STEERING DISASSEMBLY
STEERING ASSEMBLY

AND
DISASSEMBLY OF
ASSEMBLY OF
POWER
POWER
DRIFT
DRIFT

SKIPPER ­SKIPPER -

...........

SUSPENSION .

TRACK

TRACK
SLIDE
SLIDE

TRACK
TRACK

TRACK
TRACK

44 -

45

TRIM

& CONSOLE

.

.

..............

& SUSPENSION

& SUSPENSION

TENSION. . . . . . . . . . . . . . . . . . . . . . . 50

ALIGNMENT.

TENSION
ALIGNMENT

.

...................

.......

....................

. . . . . . . . . . . . . . . . . .

........

..............

.

..........

...........

.

...........

...

46 - 47

.

49 -51

..

..

48

.49

49

50
51
51

en

Z

o

~

u

u..

U

W

Q.

en

...J
W

Q

o

:iE

n

PLAYMATE

Track Type - all rubber
Track Length on

Ground -32"

Track Width -

12"

Overall Length W/Ski -

92"

Width -

31

1/2"

Height W/Windshield -

41

1/2"

Height

Less

Windshield -

29"

Weight - approx. 290

Ibs.

Suspension - standard bogie

Transmission - Torque - 0 - Matic
Fuel Capacity - U.S. - 3.5 gal.

Engine - 175cc Polaris 1 cyl.

('

CHARGER

Track Type - all rubber
Track Length on Ground -

45"

Track Width - 15

1/2

"

Overall Length W/ Ski -

107"

Width -

31

1/2"

Height W/VVindshield -

41"

Height

Less

Windshield -

29"
Weight - approx. 420 Ibs.
Suspension - Polaris

Driftskipper

Transmission - Torque - 0 -

Matic

Fuel Capacity - 5.9

gals.

Engine Options -

294

Polaris 2 cyl.
335 Polaris 2 cyl.
398 Polaris 2 cyl.
432 Polaris 2 cyl.
488 Polaris 2 cyl.

12

Volt

electric start available on

398,432,

& 488

n

TX

MODEL

Track Type - rubber w/steel talons
Track Length on Ground -

45"

Track Width -

15

1/2

"
Overall Length W /Ski - 107"
Width -

31

1/2"

Height W/Windshield -

40"

Height

Less

Eindsh ield -

34"

Weight - approx. 390 Ibs.

Suspension - Polaris Power Slide
Transmission - Torque - 0 .

Matic
Fuel Capacity - 5.9 gal.
Engine Options - 294cc

to

795cc

....

(/,)

z

o

l-

e::(

U

u.

U

W

0-

(/,)

..J
W

C

o

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u

MUSTANG

Track Type - all rubber
Track Length on Ground -

45"

Track Width -

20"

Overall Length W/Ski -

110"

Width -

33"

Height W/Windshield -

45"

Height

Less

Windshield -

31

1/2"

Weight - approx. 475

Ibs.
Suspension - Driftskipper
Transmission - Torque -

0 - Matic

Fuel Capacity - 5.9

gals.

Engine Options - 398 Polaris 2 cyl.

488 Polaris 2 cyl.

Available

with

12

volt

electric start

u

V

OYAGER

Tr

ack Type - rubber w/

steel

talons

Track Length on Ground -

45"

Tr

ack Width - 30"

Overall Length W/Ski -

108"

Wi

dth -39

1/2"

He

ight W/Wi

ndshield -49"

Height

Less

Wind

shie

ld - 36 1/

2"

Weight - approx. 590

Ibs

.

S

uspensi

on - standard bogie

Transmi

ss

ion - forward

reverse

F

uel Capa

city - 5.9 gal.

Engine - 488cc

Pola

ri s Star 2 cycle w/electric

start

o

N

ENGINE

DATA

J

POLARIS

Bore - Inches (mm)
Stroke - Inches
No.

of

Cylinders
Displacement ­RPM - Standard

Carburetor

Model & Size

Make,
Number

Make & Model
Type -

Breaker

Automatic

Tim

Setting-

Spark Plug Make & Model
Spark Plug
Alternator

Used

Ignition

Point

ing Checked

(mm)

Cu. In. (cc)

Energy Transfer
Capacitor Discharge ( )
Magneto (

Gap - Inch

Timing

°BTDC;

Gap - Inch (mm)

Output

Advance - Yes ( )

at

-

Inches (mm)

EC17P

62
5S(mm)

175
(4,000 5,000)

Mikuni

Ida Denki

( )

(mm)

.010

No
Advance (
Retard
23°

(use marks

NGK

.017 -.020

12

(mm)

1

1

x)

(cc)

VM24

- .017

(x)

(x)

- .012

B7ES -

Volts

on

flywheel)
AC43XL

35

Watts

POLARI

Bore -Inc
Stroke -Inches (mm)
No.
Displacement -Cu. In. (c
RPM - Standard

Make,
Number Used

Make & Model Kokusan
Type

Breaker

Automatic

Timing Checked

Setting -

Spark Plug Make & Model
Spark Plug
Alternator

hes

(mm)

of

Cylinde

Carburetor

Model & Size

Ignition

- Energy Transfer ( x )

rs

Capacitor Discharge ( )
Magneto ( )

Point

Gap - Inch (mm) .

Timing

°BTDC;

Gap - Inch (mm)

Output

Advance -

at-

Inches (mm)

S EC29P

5

55.6 (mm)

294

c)

(6,000 6,500)

Mikuni

010 -.017

Yes
No
Advance (
Retard
SO

(use marks
AC43XL -NGK

.017 -.020

12

S(mm)

2

(cc)

2

(x)

( )

- .

VM26

(x)

012

Volts

(inch)

on

26mm.

flywh

B7ES

75

Watts

)

eel)

Fuel/Oil

Special

Ratio

Oil

Recommendations: Polaris Snowmobile

20 - 1

Oil

Fuel/Oil Ratio

Special

Oil

Recommendations: Polaris Snowmobile

3

20

-1

Oil

J

c

ENGINE

DATA

POLARIS

Bore -

Stroke - Inches

No.
Displacement
RPM - Standard

Make, Model & Size
Number

Make & Model Kokusan
Type

Breaker
Automatic

Timing

Setting -

Spark Plug Make & Model
Spark Plug
Alternator

Inches (mm)

(mm)

of

Cylinders

- Cu. In. (cc)

Carburetor

Used

Ignition

- Energy Transfer

:

Capacitor Discharge ( )
Magneto ( )

Point

Gap - Inch (mm) .010 - .

Timing

Checked

°BTDC

Gap -Inch (mm)

Output

Advance -

at

-

: Inches (mm)

EC34P

62

(mm)

55.6

(mm)

2

335

(cc)

(6,000 6,500)

Mikuni

2

(x)

Yes

(x)

No

( )
Advance (
Retard

0

8

- .012

(use

marks
AC43XL
.017

- .020 (in.)

12

Volts

VM26

017

(in.)

(x)

on

flywheel)

NGKB7ES

75 Watts

26mm

POLARIS

Bore - Inches
Stroke - Inches
No.

of

Cylinders
Displacement
RPM - Standard

Carburetor:

Make, Model & Size
Number

Ignition

Make & Model
Type

-

Breaker Point Gap ­Automatic

Timing

Setting _ oBTDC:

Spark Plug Make & Model
Spark Plug
Alternator

(mm)

(mm)

- Cu. In.

Used

:

Energy Transfer
Capacitor Discharge ( )
Magneto ( )

Timing

Checked

Gap - Inch

Output

(ee)

Inch (mm) .

Advance -

at

-

Inches (mm)

(mm)

EC40P

65

(mm)

60

(mm)

2

398

(cc)

(6,000 6,500)

Mikuni

VM30

2

Kokusan

(x)

010 -.017

Yes

(x)

No ( )
Advance (
Retard

0

8

-

.0

(use marks
AC43XL
.017 - .020
12

12

Volts

(x)

on

NGKB7

75

30

mm

flywheel)

ES

watts

Fuel/Oil

Special

Ratio

Oil

Recommendations:

c

20 - 1

Polaris Snowmobile

Oil

4

Fuel/Oil Ratio

Special

Oil

Recommendations:

20 - 1

Polaris Snowmobile

Oil

ENGINE

DATA

)

POLARIS

Bore ­Stroke - Inches
No.
Displacement - Cu.
RPM - Standard

Make, Model
Number

Make & Model Kokusan
Type

Breaker Point Gap ­Automatic

Timing

Setting -

Spark
Spark
Alternator

Inches (mm)

(mm)

of

Cylinders

In. (cc)

Carburetor:

& Size

Used

Ignition:

- Energy Transfer (
Capacitor Discharge ( )
Magneto ( )

Inch (mm) .010 - .017

Timing

Checked

°BTDC:

Plug Make & Model
Plug Gap - Inch (mm)

Output

Advance

at

-

Inches

EC44P

67.75

(mm)

60

(mm)

2

432

(cc)

(6,000

Mikuni

2

x)

Yes

(x)

No

( )
Advance (
Retard
SO -.012

(mm)

(use marks on flywheel)
AC43XL
.017 - .
12

Volts

6,500

)

VM30

(x)

NGKB7ES

020

75

Watts

30

mm

POLARIS

Bore - Inches (mm)
Stroke - Inches
No.

of

Cylinders
Displacement - Cu.
RPM - Standard

Carburetor:
Make, Model
Number

Make & Model
Type

Breaker
Automatic

Timing

Setting -

Spark
Spark Plug Gap - Inch
Alternator

Used

Ignition:

- Energy Transfer

Point

Checked at-

Plug Make & Model

(mm)

In. (cc)

& Size

Capacitor Discharge ( )
Magneto ( )

Gap - Inch (mm) .

Timing

°BTDC:

Output

Advance

Inches (mm)

(mm)

EC50P

72 (mm)
60

(mm)

2

488 (cc)

(6,000 6,500)

Mikuni

VM30

2

Kokusan

(x)

010

- .

017

Yes

(x)

No

()

Advance (

Retard

SO -.012

(use

marks
AC43XL
.017 -

12

.020

Volts

(x)

on

B7ES

75

30mm

)

flywheel)

(NGK)

Watts

Fuel/Oil

Special

Ratio

Oil

Recommendations: Polaris Snomobile

20 - 1

Oil

Fuel/Oil

Special

5

Ratio

Oil

Recommendations:

20

- 1

Polaris

Snowmobile

Oil

)

c

ENGINE

DATA

c

POLARIS

Bore ­Stroke - Inches (mm)
No.
Di
RPM -

Make, Model
Number

Make & Model Kokusan

Type

Breaker
Automatic

Timing

Setting -

Spark Plug Make &
Spark Plug Gap - Inch (mm)
Alternator

Inches

of

Cylinders

splacement -Cu. In. (ee)

Standard

Carburetor:

Ignition

- Energy Transfer

Checked

(mm)

& Size

Used

:

Capacitor Discharge (
Magneto ( )

Point

Gap -

Inch

Timing

°BTDC:

Output

Advance -

at

-

Inch

Mod

STAR EC65PF

67

.75

(mm)

60

(mm)

3

649

(cc)

(7,000)

Tillotson

3

()

x)

(mm) None

Yes

(x)

No

( )
Advance
Retard ( )

es

(mm) 3.5 max.(mm) 5,00Ock

with

timing

el

AC41XL

0

030

.
12

Volts

HD

(x

)

light

NGKB8ES

75

Watts

POLARIS

Bore -Inches
Stroke - Inch
No. of

Cylinders
Displacement - Cu.
RPM -

Make, Model
Number

Make & Model Kokusan
Type

Breaker Point Gap ­Automatic

Timing

Setting

Spark Plug Make & Model
Spark Plug Gap - Inch (mm)
Alternator

Standard

Carburetor:

Ignition

- Energy Transfer

Checked

_oBTDC

(mm)

es

(mm)

& Size

Used

:

Capacitor Discharge

Magneto ( )

Timing

Output

Advance -

at

: Inch

STAR EC79PF _

75

(mm)

60

(mm)

3

In

. (cc)

795 (cc
(7,000)

Tillotson

3

()

(x)

Inch (mm) None

Yes

(x)

No ( )

- Advance
Retard ( )

es

(mm)

3.5 max.(mm) 5,000ck
with

timing

AC41XL

0

.030
12

Volts

)

HD

(x)

light

NGKB8ES

75

Watts

Fuel/Oil

Special

Ratio 20 - 1

Oil

Recommendations: Polaris Snowmobile

c

Oil

Fuel/Oil Ratio

Special

6

20

- 1

Oil

Recommendations: Polaris Snowmobile

Oil

2

0:

w

I-

~

Q.

W

::::>

a

0:

o

I-

o

2

e:(

en

2

o

l-

e:(

U

u..

U

W

Q.

en

2

o

~

~

o

u

n

Cyl.
Oisp.
(CC)

175

294

335

398

436

488

648

795

Engine Year
Models

Built

EC17P

1969·1970

EC

29P

1969·1970
EC35P 1969·1970
EC40P

1969·1970
EC44P 1969·1970

EC50P

1969·1970

EC65P

1969

··

1970

EC79P

1969·1970

CD

®

n

COMMON SPECIFICATIOI\1S FOR

ALL

MODELS

BOLT TORQUE

Standard Piston

Skirt

No.

Piston Ring

Crank·

Cylinder

Stroke

To

Bore Cyl.

Bore

(MM)

Of

Clearance

End Gap

Head

Case

(MM)

Cyl.

(Inches)

(Inch

es

)

Bolts

62 58 1 .004/.006 .010/.016 21·23 11·13
58

55.6 2

.0035/.0055 .008/.014 18 ft. lb. 21·23

62 55.6 2 .004/.006 .010/.016

18

ft.

lb.

21·23

65 60 2

.0045/.0065 .010/.016 18

ft.

lb.

21

·23

68

60

2 .005/.007

.010/

.016 18

ft. lb.

21·23

72 60 2

.00

55/.0075 .012/.0175 18 ft. lb. 21·23

67.75

60

3 .0045/.0065 .010/.016 18 ft. lb. 21·23

- -

3

.0055/.0075

.012/

.0175 18 ft. lb.

21·23

CD

0)

CD CD

@

CD

CD

®

CD

CD

CRANKCASETORQUE?ATTERN

RUNNING T IMING CAN

BE

CHECKED BY

MOVING

T

HE

ADVANCE

CAM TO THE FUL L ADVANCE

POS

IT ION.

SPARK PLUG GAP: .017 - .020

STATIC

TIMING

RUNNING

TIMING

Degree

M.M.

Inches

Degree

M.M. I

nches

Before

Before Before Before Before Before

T.O.C. T.O.

C.

T.O.C. T.O

.C.

T.O

.C.

T.O.

C.

-

- -

23

0

- -

8

0

.27 .

012

23

0

2.3 .093

8

0

.27 .012 23

0

2.3 .093

8

0

.29 .012 23

0

2.5 .099

8

0

.29 .

012

23

0

2.5 .099

8

0

.29 .

012

23

0

2.5 .099

- -

- 23

0

-

-

-

-

-

23

0

- -

CD

CD

CD

CD

CD

CD

CYLINDER

HEAD TORQUE PATTERN

I

I

I

R.P.M.

Engine

I

!

6,000 i
6,000
6,000
6,000
6,000
6,000
6,000
6,000

.....

z

o

l-

e:(

~

a:

o

u.

Z

w

()

>

a:

w

en

Cl

w

en

Z

w

Cl

Z

o

()

Year

1971

1971
1971
1971
1971
1971

1971
1971

1971

1971
1971
1971
1971
1971
1971

u

Model

Make

Playmate Polaris

Charger Polaris
Charger Polaris
Charger Polaris
Charger Polaris
Charger Polaris

Mustang Polaris
Mustang Polaris

Voyager Polaris

Charger

TX

Polaris

Charger

TX

Polaris

Charger

TX

Polaris

Charger

TX

Polaris

Charger

TX

Polaris

Charger

TX

Polaris

CONDENSED

SERVICE

DATA

Engine

Carburetor

Model Displ.

Make

EC17P

175cc

Mikuni

EC29P

294cc

Mikuni

EC34P

335cc

Mikuni

EC40P

398cc

Mikuni

EC44P 432cc

Mikuni

EC50P 488cc

Mikuni

EC40P 398cc

Mikuni

EC50P

488cc

Mikuni

EC50P

488cc

Mikuni

EC29PF 294cc

Mikuni

EC34PF 335cc

Mikuni

EC40PF

398cc

Mikuni

EC44PF

432cc

Mikuni

EC65PF

649cc

Tillotson

EC79PF

795cc

Tillotson

u

Model

Sprocket

Clutch

Bolt

Center

Ratio

Make

Ad

j. (In.)

VM26

12·42

Drummond

11 1/10

VM26

13-39

Polaris

11

1/10

VM26

13-39

Polaris

11 1/10

VM30

15-39

Polaris

11 1/10

VM30

15-39

Po

laris

11

1/10

VM30

17-39

Polaris

11 1/10

VM30

13-39

Polaris

11 1/10

co

VM30

15-39

Polaris

11

1/10

VM30

13-39

Po

laris

131

/4

VM26

13-39

Polaris

11

1/10

VM26

13-39

Polaris

111/10

VM30

15-39

Polaris

11

1/10

VM30

15-39

Polaris

111/10

H-D

19-39

Polaris

11 1/10

H-D

21-39

Polaris

11

1/10

u

ELECTRICAL SYSTEM INFORMATION

THE WIRE HARNESS

The Mustang and Charger have one standard wiring harness again this ye
electric

All
the exhaust pipes and care should be taken

ELECTRIC START SYSTEMS

Electric
adding a circuit breaker, a rectifier, a
and

To charge
This
an 8 amp circuit breaker,

There are
TX
amperes

for lights, with
they
start

start

models using any engine . . . The TX model s have their own harness,

harnesses are protected by Grayline tubing. This

to

avoid this.

start

systems may be installed

solenoid wire assembly

the

battery,

is

accomplished by a pair

two

alternator systems used this year. A

models, and a

of

current

the

are connected

system,

the

the

to

35

watt

going

to
remaining
off

the

battery acts as a voltage regulator .

to

connect

alternator's A.C. (alternating current)

of

protect

system

the

battery. With

current

alternator circuit,

on

all engines

lead wire, and a starter with solenoid, plus

the solenoid

diodes

mounted

the

alternator coil, should one

is

on Playmate models. Each alternator coil has

going

to

in

the

lights off,

to

the

battery. The lights will

not

the

is

a high temperature tubing,

in

the

Charger and Mustang. The existing wiring harness

the

main harness.

output

parrallel

75

battery;

in

a square shaped rectifier. This rectifier

of

watt

alternator system

all

the

hence

these diodes fai

current

they

ar

which

is

designed

as

does

but

the

needed

must

be rectified

l.

is

found

the

goes

to

the

rectifier, from which it

not

operate with the engine

cannot

discharge

for

either electric

the

Playmate.

it

will melt if allowed

battery

to

on

all

Chargers, Mustangs, and

capacity

the

battery.

cables, battery,

D.C. (direct current).

is

of

producing three

not

or

non-

to

touch

is

used,

protected by

is

tapped

running

In

the

electric

)

as

An 8 amp circuit breaker

eliminate

and

LIGHTING

The lighting system for
is

a dual beam headlamp, four taillamps, and

single beam headlamp and

The warning light
rough going

Mustangs and Chargers use a

All

25

watt

NOTE: When

prevents excessive
hood

is

ACCESSORIES

The electrical system
necessary wiring instructions are
panel wiring diagram

the

danger

on

or

slows down suddenly. The sensor

head lamp - Polaris Part No.

the

voltage from being applied

off.

the

hood

is

or

is

included

of

fire due

the

Charger and TX consists

two

Mustang

is

removed,

designed

the

applicable wiring harness drawing.

on

to a short

taillight lamps.

is

designed

60

watt

4030005

the

to

accept

included with each

the

instrum

headlamp - Polaris Part No.

or

headlight becomes disconnected and all ligh

the

ent

panel

in

the

electric start system

circuit.

of

a dual beam headlamp and

two

warning light lamps. The Playm

to

warn a snowmobile driver behind , when

is

an inertia switch mounted

4030007

G.E. No. 4568.

to

the instrument and taillights, should

speedome

ter, ta

chometer, and cigafe

option

. If additional information

in

the

or

two

G.E. No. 4454. The Playmate uses a

tt

to

protect

taillamps.

ate

lighting system consists of a

the

instrument panel.

ting circuits become ope

the li_hts be

lighter as standard

is

needed,

the

On

the Mustang, there

snowmobile

turn

ed

consult

the

wiring harness

in

front

hits

n.

This

on

when the

options. The

instrument

For

special equipment, such as hourmeters, ammeters, etc.,

contact

the

Polaris Service Department.

9

)

c

TROUBLE SHOOTING HINTS (Electrical)

c

Manual S

El

tart

Will

Not Sta

rt

1.

Check

the

ignition switch

2. Check auxiliary shut-off switch.
the

3. Check

4. Check wiring from

5. Check

6. Disconnect

ectric

Start

Will

Not

1. Check

If starter

2.

a. Check

Ch

b.

Battery

1. Check for bad connections.

2. Check alternator

Lights

1.

The engine must be running before

2. Check
them

3. Check for burned

4. Check

5. Disconnect

fuel supply.

the

engine

the

spark plug(s).

the

engine connector

Start

the

six items above.

eck

Will

Don't

to

out

for

doesn't

the
the

Not

work:

wires between

battery cables and battery.

Charge

output.

Work

see

that

the

headlight harness connector

from excessive voltage.

out

lamps.

loose connections and shorted wires.

the

taillight connector. If the headlight works, this indicates a short in

that

it

is

in

the

to

the

coil(s), and

to

eliminate any shorts

the

starter solenoid and b

the

lights will work.

run position .

to

the

is

spark plug(s).

that

may be in

atte

ry.

connected, as th

the

main harness wiring.

is

cuts

off

all lights

the

to

prevent burning

wiring

to

the

taillight.

c

10

(~

FLYWHEEL

MAGNETO

GENERATOR

EXTERNAL

IGNITION

COIL

IGNITION STARTING SWITCH

WIRING

SCHEMATIC (VOYAGER)

EXTERN

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IGNITIO

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STARTING

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IGNITION

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STARTER

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EXTERNAL

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-:-

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SPARKPLUG

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::::::=-

a---.

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INCLUDED

..

(II)

...

WIRING SC

HEMATIC (PLAYMAT E)

ITEM

1

2

3
4
5

FLYWHEEL- MAGNETO- GENERATOR

6
7
8
9

"-I]Q-,

.

CD

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IGNITION-LIGHT

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STARTING SWI

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CD

SPARKPLUG 1

ENG

INE

DISCONNECT

B

u

u

REO,

1

1

1
1
1
1
2

1

1

I'

1

-<

TAIL

LIGHT

DISCONNECT

PART

NO,

DESCR

IPTION

2460071

ENGINE

CONNECTOR ASSEMRI V

4110003

IGNITI

ON-LITE SWITCH

2460070

MAIN HARNESS

2460069

HEADLIGHT

HARNESS

4030008

HI'anllf1HT

4020023

CONNECTOR

2.

432008

T

AIL

LIGHT

ASSEMBL

Y

2460068

TAIL

LIGHT

WIRE

5223409

WIRING HARNESS CLIP

HEADLIGHT

/

.~

CD

<~l

~

o;t

....

CONNE~

,I

TAIL LIGHT

u

TROUBLE SHOOTING

Engine fails

1.

ignition switch

a.

out

b.

fuel line kinked

c.

fuel filter clogged

d.

fuel

e.

choke

f.

chokes

g.

No spark

2.
spark plug fouled

a.

secondary coil dead

b.

primary coil

c.

ignition points

d.

shorted ignition switch

e.

No

3.

4.

5.

S.

7.

8.

9. Burned pistons

compression

crankcase plug

a.

headgasket

b.

bad rings

c.

Engine idles

restricted fuel flow

a.

clogged main

b.

Engine runs

clogged fuel filter

a.

track tension (incorrectly

b.

incorrect main

c.

throttle

d.

chain in chain case

e.

front

f.

Engine runs

incorrect air mixture setting

a.

throttle

b.

dirt

c.

Engine runs

chokes are

a.

fuel

b.
c.

carburetor
too

d.

needle

e.

f. incorrect float level

Engine runs

incorrect main

a.

in

b.

incorrect spark plug

c.

a.

Too

running condition. See service Bulletin No. 27.
b.

Lean
line, clogged fuel filter, loose impulse tube, rep eated running
c.

Improperly mixed fuel and oil

Some two-cycle oil

should

be
d. Overchoking.
balance resulting in erratic performance. Crankcase should be drained periodically
ance

is
important
e.

In

occurs. Correct timing

to

start

off

of

fuel

pump

impulse hose cracked

on

but

throttle

stuck

open so engine flooded (Mikuni Carb.)

shorted

is

blown

or

piston

but

fails

jet

but

fails

slides

not

hanger

on

but

fails

stop

screw incorrectly adjusted

in pilot

pump

large main jet

correct

room

noticed. Drains are located low

whenever starting problems are experienced.

correct

jet

but

overloads with fuel

not

diaphragm

slides are

and

seat

but

overheats

timing

hot

a spark plug such

carburetor

temperature

timing

handle compressed

or

wires disconnected

or dead

dirty

or

pitted

is

out

to

accelerate

to

reach maximum R.P.

jet

fully

open

too

tight

drift

skipper in wrong hole location

to

idle

seating (twisted cable)

is

ruptured (cause

not

synchronized

not

seating properly

jet

mixture. This can happen from improper adjustment, loose carburetor, restricted fuel

on

the

market mixes very poorly

if possible and mixed vigorously. Mixture ratio should be

If engine

of

ignition spark. See Service Bulletin No. 27. Check timing whenever piston burning

after

installing new piston.

or

leaking

sed

by

as

BSE. Never use these in Polaris Twin Engines. A loose plug can create a

or

poor grade

is

overchoked, fuel may accumulate in crankcase and

on

the

M.

backfire)

front

out

of

gas, etc.

of

gasoline

or

with difficulty especially

of

or

oil. Regular grade gasoline should be used.

the

crankcase for draining purposes. This

at

low temperatures. The oil

20

to

1.

throw

air-fuel ratio

or

at

any

time

erratic perform-

is

hot

out

of

especially

15

INSTRUCTION

FOR

FUEL

PUMP

(MODEL

DF

62 - 24)

c

c

1.

Model
as shown in fig. 1
the
function.
creates

2. Functions

Model
diaphragm,
A,

2-1.

The pressure in

When
capacity
fuel

2-2.

When
capacity
pump
through fuel

As

Summary

62-24

opening

62-24

the

pump

the

is

drawn

the

chamber

mentioned above, intake actions and discharge actions are repeated alternately

fuel

pump

is

an air pressure

by

the

up

of

the

carburetor

Our

Model OF 62-

the

pumping function.

and

constructions. (Fig. 2)

fuel

pump

is

the

inlet valve,

chamber,

Intake action (Fig. 2)

the

pressure in

of

the

pump

into

the

Discharge action.(Fig. 3)

pressure in

of

the

chamber

is

delivered

chamber

the

crank

the

chamber

pump

the

C.

crank

reduces.

the

fuel chambers

chamber

chamber

crank

by

type

pump.

and

down

motions

throttle

24

constructed with functional parts such as

outlet

chamber

chamber

pressure

valve.

makes

the

valve,

Band

is

led

to

becomes negative,

expands.

from fuel chamber B

becomes positive,

At

that

from

of

In

diaphragm move up and down

the

membrane etc., and

C,

chamber

At

that

moment,

the

In

a 2-cycle engine,

the

piston.

either case,

the

air chambers 0 and

A through

moment,

the

elbow

the

the

the

through

the

inlet valve closes and

on

the

The

waves of pressure vary according

wave has enough amplitude

is

furnished with

the

passage

diaphragm moves in

inlet valve

the

diaphragm moves

discharge side

the

elbow

by

bottom

E.

opens

the

pressure in

the

of

the

on

the

the

outlet

to

to

the

crank

chamber

to

the

to

make

the

pressure in

body,

the

wave

the

and

side

in

the

the

make

the

crank

chamber

the

top

body,

the

wave motion pressure chamber

motion

way shown in fig. 2,

the

of

way shown in fig.

valve opens, and

float

the

in

outlet

valve closes, and

intake.

chamber

pump

the

bottom

the

of

the

function.

changes

rpms

and

fuel

pump

which

cap,

the

body.

and

the

the

3,

and

the

fuel in

the

carburetor

c

of

2- 3. Actions

(a)

Inlet valve

The

inlet valve opens
let valve closes
flow

of

fuel.
(b) Diaphragm.
The

diaphragm functions

(c)

Fuel chambers
Basically, pumping action
provided. However, under such conditions

(1)

The

(2) Bubbles

(3)

The

chamber.

The

fuel chambers
as possible,
chamber, and

3. Disassembly and reassembly.

In

disassembly and reassembly, care should be used

or

ed

to

battered. When disassembled, all parts should be washed

principal functional parts.

and

outlet

valve.

on

the

on

the

intake

to

Band

C,

is

flow

of

fuel tends

tend

to

occur

fuel level is

Band

keep

the

to

make

not

C,

the

amplitude

the

fuel level stable.

intake

stroke

of

stroke

and opens under

increase

possible

stable

air chambers 0 and

or

decrease

air chambers 0 and

without

there

to

be

intermittent,

in

the

fuel pipes.

due

to

large pulsations

of

the

fuel pressure as small as possible

the

fuel chambers

diaphragm and closes on

the

positive pressure,

the

capacity

E,

and membrane.

are some troubles such

and

the

E,

and

to

handle all parts with proper

of

the

Band

C,

pumping efficiency drops.

of

fuel pressure on

the

membrane perform

out

in gasoline

the

discharge stroke. Therefore,

thus

pump

chamber

the

air chambers 0

as:

the

on

the

tools

or

kerosene, and blown

operating

by its

and

needle valve

to

keep

the

needle valve

so

that

to

prevent

up

in

flow

of

they

E,

and

and

the

of

the

will

the

the

backward

down

motions.

the

membrane

carburetor

fuel

as

constant

carburetor

not

be scratch-

dry

with an air·

out-

float

float

16

compressor.

3- 1. Instructions

(a) Whenever disassembled,
new ones.

(b) Care
on

the

side

(c) As shown
retainer

inlet, and a round screw
ularly,
for

(d)
the

(e)
tend

3-2.

Dip
elbow
side.

and

extreme

fear

that

Be

careful

gasket

Pay particular

to

cause leakage

In

spection

the

pump

on

the

on

discharge side

on

should be used

of

the

top

in

fig. 4, reassemble

set screws. A

care should be used

they

should damage

not

the

side

attention

after

in gasoline

disassembly.

the

cap

gasket,

not

to

reassemble

body.)

the
countersunk
is

used

for

the

to

have

the

diaphragm.

to

make mistakes in

of

the

bottom

to

of

fuel

or

reassembly.

or

kerosene and check

is

closed with a finger and compressed air of

body). These parts should be replaced with new ones whenever reassembled.

the

joint

air.

the

membrane,

the

cap gasket in a wrong order. (The membrane should be reassembled

valve retainer

screw is used for

valve retainer which has no countersink

the

the

s which

that

at

top

of

the

order

of

must

there are no bubbles

the

diaphragm, and

the

center

of

the

guide. Care should

the

valve retainer which has a countersink

countersunk

reassembly

be sealed tight. If

of

screw

the

at

each

11

Ib

the

gasket should

on

the

on

the

side

diaphragm and

th

ey

are scratched

joint

by

an air-tight

s.

is

blown from

be

be

used as

on

the

side

of

the

outlet. Partic-

of

inlet free

the

the

from

gasket. (Reassemble

or

battered,

test

elbow

replaced with

to

the

valve

side

of

the

scratches

they

will

in which

on

the

the

intake

)

4. Causes

of

Troubles
pressure.

Causes

1.

2.

3.

4.

5.

6.

7.

this

of

trouble

LOQse

attachment

valve,

or

Damage

Leak

of

of

Leak

Other

leaks.

Presence
Clog

of

the

of

pump

the

of

the

wave

fuel

of

trouble

damage

diaphragm

motion

due

dust

and

filter.

and

corrections.

show

themselves in a reduction

of

the

inlet valve

or

wear

of

the

or

the

membrane.

pressure.

to

poor

pieJing.

impurities.

and

the

outlet

valve spring.

of

discharge volume

Corrections

1.

Replacement

2.

Replacement with a new

the

placed

3.

Check

from

4.

Check
intake and discharge.

5.

Make

and:

(a)
and
the

(b)
and
gasket with new ones.

6.

Check

7.

Clean

due

to

the

fall

of

by

the

pump

gasket and

at

all joints

the

the

the

If

the

the

gasket with new ones.

If

the

the

the

at

regular interoals.

the

the

same

time

of

crank

chamber

fuel pipe and

air-tight

bottom

cap, replace

inlet valve and

test

leak

is

due

body, replace

leak

is

due

gasket

.)

passage

according

to

to

the

both

discharge

assy.

one

. (When reassembled,

cap

also should be

of

to

the

the

elbow

the

joint

the

the

joint

membrane and

the

outlet

and

the

wave motion

bottom

on

the

to

paragraph 3-2,

of

the

diaphragm and

of

the

valve.

sides

top

top

the

intake

re-

body.

of

body

body

cap

17

c

ElBOW -

IN

CAP

ELBOW -OUTlEJ

MEMBRANE

LET

TOPBOuY

c

OIAPHRAGM

PUMP

Figure 2

Figure 3

DISK

ENGINE

ROOM

CHAMBER

VALVE

VALVE

c

GUIDE

CORRECT

Figure 4

INCORRECT

18

INSTRUCTION FOR

CARBURETOR

(MODEL

VM

- 30)

This manual has been prepared for those
to

Polaris Model

constructions and functions.

1. Constructions and functions .

Model

VM-30

the

float system,

1-1.

The

When

level,

sticks fast

The

1- 2.

The

such as a starter jet, a

When
the
the
most

Float

float

system

the

fuel flowing

the

float rises. When

to

standard level

Starter

starter

the

engine starts with
engine works
starter

emulsion tube, absorbed

suitable

EC-40,

carburetor

the

system (Fig.

is

the

needle seat, preventing

of

system - Choke system (Fig. 2)

system

on

concentration

44,

50

snowmobile so

has varying constructions depending

pilot system,

the

11

designed

is

the

to

maintain a

from

the

fuel

the

buoyancy

gasoline

designed
starter

is

set

at

to

make

emulsion

the

throttle

fuel nozzle. By this negative pressure

into

of

fuel-air mixture

main system, and

pump

below

tube,

who

engage in maintenance and repair

that

they

may work with proper understanding

upon

varying driving conditions,

the

starter system (initial starting device!.

constant

of

further

the

engine
and a starter plunger etc.

valve closed and

the

height

of

gasoline during operation.

into

the

float chamber through

the

float

and

the

fuel pressure

delivery

30

mlm

plunger chamber, mixed again with air from

for

of

gasoline,

± 1 from

start

quickly in cold weather.

the

initial starting, and delivered

thereby

the

center

of

starter plunger wide

the

fuel

is

measured

of

Model

the

needle valve reaches

of

the

fuel

pump

holding

the

the

standard level

main bore.

It

is

constructed

open,

the

by

the

the

to

the

engine

VM-30

intake negative pressure

starter jet, mixed with air in

carburetor

and

knowledge

and

is

constructed

the

constant

balance,

starter

through

the

needle valve

of

gasoline.

with functional parts

air inlet, made

the

fuel nozzle.

installed

of

its

with

fuel

of

the

In

this

starter

system, you can be sure

measured and

1-3.

The

pilot system

Fuel for idling

from

the by-pass,

is

determined by

riched. When

When

the

fuel-air

approximately above
the

time

the

air cleaner

1-4

. Main system (Fig. 5 & 6)

The

main system

The

fuel during
ing intermediate-speed driving
system. The

air measured

the

constant

Pilot system (Fig. 3 & 4)

is

designed

is

measured by

and

the

the

air screw

throttle

mixture

and

valve opens slightly during low-speed driving, gasoline injects through

from

the

amount

of

the

is

designed for delivering fuel between low·speed driving and high·speed driving.

the

fuel during intermediate-speed driving flows into

by

the

fuel -air

delivered

air screw. When

is

the

pilot

1/8

of
of injection from

throttle

low·speed driving

air-jet

to

of

initial starting

mixture

to

deliver gasoline during idling

the

pilot-jet, mixed with

to

the

opened

outlet

the

diameter

valve.

(the

opening of

make a fine spray of fuel-air

ratio

is

engine through

the

air screw

the

amount

to

secure

smooth

of

the

the

needle

is

delivered,

the

always secured.

is

of

air increases and

main bore, gasoline injects through

as

throttle

without

and

the

air regulated with

the

pilot outlet. The

closed

the

operation

jet

is

chiefly performed

shown in fig. 4, from

valve

mixture

any

low-speed driving.

amount

is
the

of

the

fuel-air mixture

of

the

above

1/4),

needle

of

good quality.

skill

of

operation, since

the

air-screw, mixed again with

concentration

air

is

reduced and

engine. When

by

the

the

pilot system and

the

fuel

jet

through

both

of

fuel -air

the

fuel-air

is

lean.

the

by-pass in addition

the

throttle

the

needle jet.

cutaway furnished

is

largely delivered

the

main

valve
The

the

main system. Dur-

jet

and mixes with

fuel and air are

the

mixture

for idling

mixture

to

opens

wider,

adjustment

on

the

side

from

the

air

is

en-

the

main

the

of
of

•

19

c

The

point

of

the

jet
throttle
main
livery

2. Adjustments.

When
of

valve. During high-speed driving (the opening of

jet

and mixed with

to

the

engine.

the

engine has dual carburetors, it

each carburetor.

The

needle

is

tapered

the

air measured by

following items should be followed cautiously and accurately.

to

is

adjust

the

the

flow

the

air jet

prerequisite

of

fuel-air mixture in accordance with the opening

the

throttle

to

make a fine spray of fuel-air mixture

for

full engine performance

valve

is

above

3/4)

to

maintain

the

fuel

is

measured

of

good quality

the

equal operation

of

by

for

the

the

de-

c

2- 1. Adjustment

Make adjustment with some degree

rise when fully closed. However,

the

fuel-air mixture during

plunger

2- 2. Adjustment

With
wire attached and
of
lock

2- 3. Adjustment

cannot

your

eye

the

throttle

nuts

as

well as

Set

Find

the

air screws

the

(a)

each carburetor evenly, setting

(b) Warm

(c)
ing

(d) Return each screw

of

choke wire.

be opened

or

plug gauge, adjust

the

valve with

air screw

up

the

out

and

to

of

throttle

throttle

the

the

starter wire.

of

idling and synchronization.

of

engine completely.

set

the

one

by

the

initial starting will get confused if

its full width.

wire.

open. With

upper surface

each carburetor

position where

one

about

of

the

of

play for

the

play must be adjusted

the

opening

the

number

1/2

throttle

the

of

your

eye,

of

the

at

the

at

about

the

each time. In this case, be sure

valve evenly and set

starter wire so

each

throttle

you

can adjust accurately

main bore. After adjustment, be sure

standard return number and

1,000

number

of

that

without

the

valve from

rpm which

rpms

of

the

at

the

normal

the

starter plunger

excess and deficiency, since

degree

is

engine becomes maximum by opening

of

play

the

side

of

by

matching

then

a little higher

to

use a tachometer.

number

of

of

each

the

is

so excessive

the

air cleaner with

the

corner

to

fasten

fasten

the

throttle

than

normal idling speed.

rotations

of

carburetor

concentration

that

the

the

of

the

the

cable adjuster

stop

idling.

may

not

of

starter

throttle

cutaway

screw

of

or

clos-

c

(e) Find

air screws

(f)

normal

(g)

the
age

is

(h)

time,

the

combustion seems

2-4.

The density

in

the

carburetor should be changed according

During

out

and

set

the

position once more where engine rotation becomes maximum by opening

one

by

one

about

1/16

If

the

number

number

Remove

engine

is

constant

larger and adjust so as

In

the

last step, operate for 5-

the

adjustment

Adjustment

of

the

idling and low-speed driving, make adjustment according

of

rotations has changed

of

rotations

the

plug cap

in

air varies according

of

or

not

to

is

complete. If abnormal, remove the ignition plug and check

to

be somewhat over, return

accordance

each time.

of

idling by means

each cylinder

at

that

time.

make

the

10

to

the

altitude and

to

the

in

the

adjustment mentioned in paragraph (e), set once more

of

each

throttle

and

check whether

If

not, return

down percentage constant.

minutes by idling. If

altitude and

to

the

the

the

air screw, and if somewhat under, fasten

the

temperature.

the

change

of

stop screw.

the

throttle

the

temperature. It
the

density

to

the

20

down percentage in

stop screw

rotations

of

procedures mentioned

is

the

on

the

of

the

engine are normal during

the

necessary
air.

side where

condition

the

that

in

number

the

of

combustion. If

the

air screw.

the

delivery

paragraph

or

closing

of

rotations

down percent-

2-3

of

the

.

at

the

the

that

fuel

of

During intermediate

table.

and

high speed driving, make

adjustment

by means

of

the

main

jet

according

to

the

following

Jetting

294
335
398
436
488

3. How

For

initial starting in cold weather,
careful
the

fuel

gine with
warm, activitate

4. Overhaul service.

you

As
are mostly

and blow

4-1.

to

handle.

Initial starting.

not

to

open

the

throttle

for

the

starter

drops

the

choke

engaged.

throttle

may

have

understood

due

to

the

wear

dry

with an air-compressor. Observe

Starter

system.

0-5000

240-220
250-230
270-250
290-270
310-280

and

slightly

by

of

ft.

start

valve. If

the

intake

After

warm up,

(about

the

preceding explanations, a

parts

and

the

you

of

1/3).

the

5000-10,000

engine with
open

the

return

clog
the

ft.
220-200
230-210
250-230
270-250
280-260

the

choke

the

throttle

fuel becomes weak. When

choke

by

dirt

following instructions.

valve,

to

normal position. When starting an engine

carburetor

and

dust

Inlet Needle & Seat

full open. On this occasion, it

the

. In overhaul service, use gasoline

1.2

1.2
1

.5

1

.5

1

.5

is

necessary

negative pressure working

the

engine has

has little mechanical functions, and

for

started,

the

warm

that

for

to

injection

up

the

is

already

troubles

washing

be

of

en·

out

The

starter

jet

is

driven

into

the

(a)

(b) Be careful in handling

scratches

(c)
new one.

4- 2. Pilot system.

(a)

oline

(b)

(c) When
pilot

4-3.

(a) Be sure
scratches when reassembling. (Excessive tightening

4- 4.

on

the

base prevent a

Since a damaged

Be

sure

to

use

and

blow

dry

with an air-compressor.

If

the

taper

of

the

pilot

outlet

and

the

Main system.

to

use

Float

system.

or

worn

proper

tools

the

air screw

jet

and

the

by-pass etc.).

proper

tools

float

the

starter plunger, since scratches

tight

seal which may cause a fuel leak while driving.

rubber

cap

for

overhauling

is

disfigured

air screw are disassembled, carefully clean

for

disassembling

chamber

of

body. Jets

the

starter

allows

the

pilot jet, and be careful

or

worn, replace it with a

the

main

is

a cause

should never be cleaned

on

the

circumference cause malfunctioning and

the

jet

of

disfigure

invasion

and

of

water from outside, replace it

not

new

one.

the

passages

the

needle jet, and be careful

or

damage.)

by

drills

or

to

make scratches. Wash

on

the

side

wire.

of

the

not

out

body

to

with

in gas-

(the

make

a

.

)

Be

(a)

careful

not

to

bend

the

float

guide pin

in

handling. If

21

bent,

the

pin causes malfunctioning

of

the

float.

c

(b) The needle valve can be disassembled into
wear

or

scratches, use

(c) Every time overhaul

the

complete needle valve assembly.

is

performed, replace

5. Disorder and adjustment.

the

valve seat and

the

float chamber packing with a new one.

the

float valve. When

it

is

replaced because

of

c

A carburetor
pressure

engine.

Accordingly,
of

the

Disorders

When

(1)
(2) When
(3) When
(4) When
(5) The ignition

(6) Exhaust gas

When

(1) The engine
(2) When
(3) Acceleration
(4) The ignition
(5) Rotations are irregular.
(6) Exhaust gas

is

a vessel with a

of

intake

of

except

fuel-air mixture due

of

the

the

fuel-air mixture

The

the

fuel-air mixture

for

engine due

rotations sound overwrapped and intermittent.

the
the

the

the

lot

of

precision jets and a

the

engine functions, proper concentration

the

mechanical disorders most carburetor problems are caused by an abnormal concentration

to

accumulated

to

an abnormal fuel-air mixture are as follows:

is

too

rich:

choke

is

opened,

engine

is

warmed up,

air cleaner

plug becomes dark and dusty,

is

is

choke

is

plug

is

is

removed,

rich.

is

too

lean:

over-heated.

is

opened,

poor.

is

burnt.

lean.

dirt

and

the

condition becomes worse.

the

condition becomes worse.

the

condition becomes better.

the

condition becomes better.

dust

constant

and wear

fuel level. It

of

fuel-air mixture

of

parts.

is

so constructed

is

obtained

that

for

when

the

operation

the

negative

of

the

c

Our

carburetor

checked whether
must be adjusted for a specific

The relation between
just

is

as follows:

the

When

·systems and

5- 1. Degree

When

the

When

the

5-

2.

When

the

is

so constructed

the

Throttle
Degree

Fu nctional system

Parts

condition

then

opening

opening

Degree

cutaway

valve

of

to

adjust Air screw

of

adjust

of

opening: 0 - 1/8, air screw.

is

closed,

is

opened,

of

opening: 1/8 - 1/4, air screw,

of

cause

the

degree

opening

disorder

the

the

throttle

that

the

parts

of

disorder

throttle

parts in question.

the

the

opening.

of

the

and

the

amount

amount

valve

is

due

opening

0-1/8

Pilot system

degree

of

of

is

made larger,

to

adjust vary according

to

an over-rich mixture

of

the

throttle

1/8 -

Pilot system Main system
Main system
Throttle
Air screw

of

opening have been confirmed, first check and clean

air reduces and

air increases and

throttle

the

fuel-air mixture becomes rich.

the

valve.

the

negative pressure which works

to

the

degree

of

or

to

an over-lean mixture, confirm

valve and

1/4

fuel-air mixture becomes lean.

valve

the

functional systems and

1/4-3/4

Jet

Needle Main

throttle

on

the

opening. After having

what

parts

the

parts

to

ad-

3/4

- Full open

Main system

jet

the

functional

needle jet reduces, and

22

the

fuel-air mixture becomes lean.

When

the

cutaway

The

rich.

(Note) The adjustment

the

5- 3.

The
and

When
the

5-4.

When
ture

6. Check and adjustment

The overflow during driving
valves,

Needle valve - Worn.

Float - Malfunctioning due

Float arm - Malfunctioning

Over-height

cutaways are prepared

idling

is

not

The

jet

needle has 5 levels of groove. When

the

needle jet becomes smaller and

the

grip goes downward (4th &

fuel-air mixture becomes rich.

The degree

the

larger number

becomes lean.

the

clog

of

of

the

throttle

of

the

in

disorder, make adjustment by

degree

of

opening:

of

the

opening:

is

used,

of

dirt

and dust, and

Spring

is

damaged
Spring seat
Clogged with dirt and dust. - Cleaning.

the

fuel level (Fig. 10)

is

worn

to

due

valve

is

made smaller,

at

intervals

opening can be made either by

1/4 -3/4,

the

of

the

or

operation

the

or

worn. - Replacement with a new one.

or

scratched.

bent

guide pin. - Adjustment.

to

clog. - Adjustment.

of

0.5

the

jet needle.

the

grip goes upward (2nd & 1st levels)

the

fuel-air mixture becomes lean.

5th

levels),

the

3/4

- full open, main jet.

fuel-air mixture becomes rich. When

float system.

of

the

malfunctioning

the

m/m alternately.

air screw.

space between

engine could be caused

of

the

negative pressure which works

the

throttle

the

float etc.

valve

or

jet needle and

the

smaller number

by

a loose

the

air screw. However, so far as

the

space between

the

needle

attachment

on

the

needle jet becomes

jet

becomes larger and

is

used,

the

due

the

jet

fuel-air mix-

to

worn needle

)

needle

)

Remove
the
is

Note: (1)

the

float chamber and measure

mixing

within 17.0 -17.5.

body

If

the

check
(2) The
mate value
actual measurement

the

is

placed up-side

the

fuel level

pressure

fuel level obtained by means

of

the

down

and

is

too

high even when

of

the

fuel

in

the

standard level of gasoline for adjustment.

of

the

gasoline level should be made.

height from

the

float chamber packing

fuel pump.

of

the

the

the

height of

height

level

of

of

the

float arm

the

float chamber packing

is

removed. Make

the

float arm

In

order

is

is

a rough estimation

to

confirm

adjustment

within

the

to

the

float arm when

so

that

the

the

above mentioned size,

to

get

the

accurate level

of

height

approxi-

gasoline,

23

c

FLOAT

Figure 1

FLOAT

F

LOAT GUID E PIN

AR~.~

c

STARTER

---

I

-~--=--

I I 1 I

I I

--

-----

~

GUM

-

---

---

CAP

-

--

------

----

-

--

- ,

-

-1

I I I I

1

II

I 1

I I

~I

1 I

I I

I I

1 I

IL

JET

CABLE

CABLE

PLUNGER

ADJUSTER

ADJUSTER

SPRING

P

LUN

GER CAP

STARTER

PLUNGE

INLET -STARTER

INLET -BREEO

STARTER

LOCK

R

AIR

EMULSION

NUT

AI R

TUBE

1

I~

I

II

1~L-_---1

THROTTlE

VALVE

c

Figure 2

24

)

H '----

Figure

---L.J

PILOT

3

'--;

JET

THROTTlE

THROTTLE

VALVE

STOP SCREW

I:

II

)

AIR

JET

Figure

THROTTlE

JET

BY - PASS

PILOT 0 UTlET

4

NEEOLE

VAL

VE

J

25

c

c

AIR

JET

NEEDLE

MAIN

JET

JET

Figure 5

THROTTLE

JET

VALVE

NEEDLE

c

AIR

JET

Figure 6

26

MAIN

THROTTLE

NEEDLE

JET

JET

VALVE

JET

NEEDLE

INSTRUCTION FOR

POLARIS

ENGINES

The Polaris Star Engines series was designed

is

lasting. This manual

1.

2. Construction

The

haust ports are effected

effected by compressing action taking place in

The

The

cylinder and

Star

Engine Features

1)

Simple construction, trouble-free operation.

2)

Manipulation and

3) Excelling

4) Light,

5) Vertical 2-cylinder alternately firing

6) A

7) Two float

EC

lubrication

fan side

2-cycle engine with

resulting

fuel supply adjustment

series engines are air-cooled, 2 cycle, 2-cylinder gasoline engines. The opening and closing

of

of

the

the

intended

in

durability, withstanding long hours

compact

in

a very

type

by

the

engine moving parts

engine

drive shaft side cylinder

to

help you get full efficiency from

adjustment

and high power

compact

carburetors assure

the

moving pistons

is

called

has been reduced

output.

the

lubrication oil mixed
engine.

is

required.

is

front

side and

is

the

to

be light weight, easy

to

of

type,

makes vibration very slight.

that

the

fuel supply

in

the

cylinders.

the

crankcase.

effected by

No.2

the

the

drive shaft side

cylinder.

to

start, quick

your

engine.

a minimum.

severe operating conditions.

in

the

fuel, no complicated lubrication system

to

the

cylinder

The

scavenging

lubrication oil which has been mixed

is

called rear.

to

accelerate, dependable, and long

is

exact and positive. No cumbersome

out

of and suction into

The

fan side cylinder

in

of

the

the

is

required,

intake and ex-

the

cylinder are

fuel.

is

the

)

No. 1

The

EC

series engines incorporate

ers, one magnetogenerator,

as

a whole are built light and durable.

two

the

following auxiliary units:

ignition coils and one recoil starter. The individual parts as well as

Outside view

of

two

EC

series Engines.

carburetors, one

or

two

fuel

pumps,

two

air clean- )

the

engine

as

a

J

27

3. Cautions

c

3-1.

Crankcase and Relating Parts

a)

The crankcase

10

mm screws and 8 mm screws. The

while

the

8 mm screws should be tightened

the

correct

b)
lower casting halves have been clamped together. Never assemble

c)
after putting
fan side, before finally tightening
with
push

torque

The bore in

When putting

the

the

crankshaft shifted towards

the

bearing

is

an aluminum alloy casting consisting

10

mm screws should be tightened

to

2.3·2

.7

kg

values when re-assembling

the

crankcase and some

the

upper

and

the

crankshaft into position, then strike lightly on

the

the

outer

race sidewise, resulting

Strike

lightly

screws (for

to

the

specified

the

engine.

other

parts have been machined

lower half crankcase castings together, first temporarily tighten

screws

to

the

specified

drive shaft end, when

in

befo

upper

re

tightening

and

lower crankcase)

torque.

burning

the

cap

of

of

two halves,

·m (16.6 ·

the

19.5

two

the

drive

torque

. If

the

crankcase rear cover

bearing when

the

upper and lower halves, fastened by

to

3.1·1.7

ft. - Ib.) .

at

odd halves into one crankcase.

shaft

the

crankcase castings are clamped together

the

kg-m

Be

sure

our

factory after

to

drive

the

is

fastened,

engine starts.

(22.4·26.8 ft·lb) torgue,

to

tighten these screws

the

crankshaft towards

the

upper and

the

rear cover will

the

screws,

the

to

c

Make

adjustment

of

suitable

3- 2. Crankshaft, Connecting Rod and Relating Pans

a)

The crankshaft

two

central crankshafts, one rear crankshaft, two crank pins,

two

connecting rods, one intermediary bushing and five ball bearings, built into one piece using a precision fixture.

the

front

On
assembling
ever a crankshaft needs

b)

The tightening

3-3.

Made
it. The

stand wearing and preserves gas-tight contacting with

Cylinder and Cylinder Head

of

an aluminium alloy casting, with good heat conductivity,

liners are precision castings made

part

and re -assembling

of

the

torque

is

composed

crankshaft

of

to

be replaced, an assembled complete crankshaft must be exchanged as whole.

for

by inserting packings

thickness

.

Figure 1

of

individually machined parts made of carbon steel, viz.

is

built a magnetogenerator while

the

crankshaft into individual components

the

magnetogenerator fixing

of

special alloy cast iron,

the

two

needle bearings for connecting rod large ends,

the

rear part serves as

is

only possible

nut

is

66

ft-Ibs.

the

cylinder contains cast iron liners, integrally cast in

the

bores are finished by honing so

piston rings which move inside.

one

the
at

front

output

our

crankshaft,

shaft. Dis-

factory. When-

that

they

with-

c

28

a)

Whenever

placed. Tighten

b)

The cylinder head
combustion chamber
ever

the

to

2.3 -

2.7

the

cylinder

the

four cylinder mounting screws

is

is

shaped specially so

cylinder head

is

kg-m (16.6 -19.5 ft-Ib).

3- 4. Piston and Piston Ring

is

to

be disassembled and re-assembled,

to

3.1 - 3.7 kg-m (22.4 - 26.8 ft.-Ibl.

made

of

an aluminum alloy casting, designed

that

knocking

is

minimized and high

disassembled, remove carbon deposit from

the

cylinder mounting packing

to

have good cooling characteristics. The

the

inside. Tighten

output

power

must

also be

is

obtained. When-

the

six tightening screws

re-

)

The pistons are machined from aluminium -silicon alloy stocks, possessing high heat resistivity and very
of

heat expansion. In order

scavenging

position by means
position

holes opening inside

of

as

shown

in

Fig. 2.

two

to

prevent

the

the

split ends

cylinder bore,

of

the

piston rings

the

piston rings are retained

to

locating pins. When exchanging a piston, assemble

Ex hau st

port

,.---

-..

Drive

shaft

side

locating pin

--

/'

........

locating

~

"F"

pin

Fanside

mark

"

interfere with

in

the

piston ring grooves

the

new piston

(stands

for

front)

the

suction, exhaust and

in

the

Figure 2

When

the

engine has been
provide a good sealing
made

of

special alloycast iron, are used. These piston rings sometimes get stuck in

should be removed whenever

3-5.

Starting Device

in

operation for a long period of time, carbon will be depositing

fit

for

the

cylinder, so

the

pistons are disassembled.

that

the

high pressure

gas

is

not

on

the

top

of

lost,

two

rectangle section piston rings,

the

piston ring grooves. This deposit

low coefficient

in

the

proper

correct relative

the

pistons.

To

The

EC

series engines are started by means

if

the

recoil starter

The

recoil starter

is

out

of

order,

the

pu~ley

has been specially designed

3- 6. Carburetor and Fuel Pump

The

. fuel

pump

and

the

carburetor, by means

pOSition, are

These units are most susceptible
sticking, as a result

important

of

auxiliary units.

to

any

which fuel supply

3- 7. When mounting an ignition coil

to

the

coil base

4.

4-1.

Mixed

fuel consisting

engine.

Operation

Fuel

to

be used.

of

20

part

gasoline and 1

of

a recoil starter, which

is

fixed

to

the

fan cover.

engine can also be started by a rope, after removing

for

this purpose.

of

which correct

foreign particles

to

the

engine may be hindered. Exercise greatest care

on

the

snowmobile, make certain

part

2 cycle lubrication oil.

amount

in

the fuel, even a very small

of

fuel

the

is

fed into

ground

amount

29

As

an emergency starter,

the

recoil-starter main body.

the

engine regardless

can be a cause

in

filling

the

is

complete from

the

of

for

a valve

fuel tank.

ignition

its

J

4-2.

Starting

c

Before starting
ture

is

too

a)

Pull

the

b)

1.
after

2.

4- 3. Warming

After starting

control gradually

lubrication

4- 4. Stopping Engine

When stopping

4- 5. The

4- 6. Breaker points gap

the

engine, close

rich, push back

Recoil Starting

rope forcefully, after confirming

Electric Starting

If

the

engine fails

the

engine has completely stopped.

Never engage

up

the

motor,

as

the

engine gets warm. Never run

and burn out.

the

engine, allow it

electrode gap

the

throttle

the

choke control partly.

to

start

at

the

starter while

idle

the

engine for 2

to

idle down before turning switch off.

in

the

spark plug

should be adjusted

completely and pull the choke control completely out. When air-fuel mix-

the

position where

the

first

attempt,

the

engine

or

3 minutes, with

is

.012

- .

to .012 -.017

the

017

the

cylinder compression starts.

repeat several times. (Engage

is

still rotating.

the

choke partially pulled

engine

at

high speed;

inch.

inch.

without

load

the

starter each time,

out

. Push back

the

moving parts may lose

the

only

choke

c

c

30

A-1.

1.

Removal of Engine

Disconnect headlight cowl connector, unsnap 4

or

cowl

cone.

nose cone fasteners and remove nose

)

2. Remove drive belt from Ramp style
in

Fig.

A-1.

Grasp

shown
each hand and rotate

unit

will open

to

be slipped over side

3. Disconnect exhaust pipe by removing

springs which hold pipe
A-2.

4. Disconnect all electrical wires, "Engine Con­nector",

5. Use vise grips

to

clamp off

no gas leakage.

allowing sufficient slack

as shown

in

or

hose clip shown

gas

flow

Use

one

in

opposite directions, this

of

driven clutch.

to

manifold. See Fig.

Fig.

A-3.

in

gas

line, so there will be

all safety precautions.

side

clutch, as

of

clutch

for

the

in

Fig. A- 3,

belt

two

in

Figure

Figure

A-

A-

1

2

..

)

6. Disconnect
assembly
Then pull cable down through console and free.

throttle

on

handle bar, as shown

cable,

at

throttle

in

control

Fig. A-

4.

31

Figure

Figure

A-

A - 4

3

J

A-1.

Removal

of

Engine

c

c

7.

8.

B-1.

1.

On all electric
cable first and remove positive cable on sole­noid, isolate
battery
cautions, as grounding
cause a fire. As shown

Remove 4

and

Lift engine

Installation

Install engine

Use

a)

b)

c)

d)

may result. Again, use all safety pre-

two

in

all precautions.

Use

care when placing engine

avoid damage

wiring.
Make sure
used,

as

After
motor

Install drive belt by placing drive belt

drive clutch first, then open driven clutch

using same procedure as when removing drive
belt, shown

start

or

tape end

motor

mount

rear of engine

out

carefully.

of

Engine

in

the

to

fuel pump, carb!Jretors and

the

proper alignment tool

shown in Fig.

motor

mount

in

is

nuts

Fig.

models, remove ground

of

cable

or

damage

of

positive cable could

in

Fig. A- 5.

plate nuts,

as

shown in Fig.

reverse order

B-1.

aligned properly,

to

55 ft-

A-1.

Ibs.

two

of

in

machine

removal.

in

front

A-5

torque

to

Figure A - 5

.

to

is

on

TOOL NEEDED:
One piece

1.

2. Place key

1/2"

key stock,

Remove drive belt, as shown in Operator's Manual.

so driven clutch

stock
shown. Distance between key stock and driven
clutch

"e"

must

of

driven clutch, as shown in
tions",
(4)
Move engine

if this distance

motor mount

in

21

inches long.

is

closed.

"A"

against drive clutch

be an equal

is

nuts fr o

place and tighten a

c

1/2 inch

not

equa

nt

and rear as shown.

on

"0",

l.

Loosen four

ll

nuts.

"both

"B",

as

each end

loca-

32

Motor

Mount

Nuts

Figure B - 1

1-1

Disassembly

of

Engine

1.

tools required

The

in

figure

shown

Rotor

1.

Flywheel Puller

2.

Clutch Puller

3.

Aluminum Clutch Puller

4.

1-1.

Puller

Figure

for

disassembly

1·

2A

of

engine are

Figure

Figure

1·

1 ·

J

1

2B

2. To remove drive clutch, remove retaining bolt No.1, remove retaining
Figure 1
retaining
crankshaft, Figure

-2A.

Use proper wrench, and

bolt

No.2.

Figure

1-2B

1

·3

Use

tap

with hammer

clutch puller No.2870030

.

on

wrench handle

to

pull stationary face off

3. Remove carburetors.
nuts on each carburetor. As shown
1-3.

4.

Remove fan housing. It

move recoil starter unless
on ignition system. Then remove recoil
fan housing,

bolt

No.2,
to

as

free

sho".vn

Two

standard half inch

is

not

necessary

it

is

necessary

in

figure

1-4.

in

to
and

figure

to

reo

work

not

Figure

1·4

33

c

5.

Remove

As

shown

the

four

in

figure 1-5.

bolts

on

rewind starte r pulley.

Figure 1-5

c

6. Remove
in
pound
magneto-assembly will always result.

7.

Remove

stator

special

the

manner shown

on

plate assembly as shown

nut

on

crankshaft end. Damage

the

two

hold-down screws

fly-wheel, pull fly -wheel
in

figure 1- 6. Do

in

figure 1- 7.

to

in

not
the

the

Figure 1 - 6

8.

Remove the four screws
crankshaft seal. If
pletely disassembled,

itself when

should be split carefully. Pry

plying pressure

in

figure

1-8.

the

at

Take care

case

in

the

engine

the

seal will

is

split. The crank case

the

bolt hole areas as shown

not

c

the

fly-wheel side

is

come

out

the

to

distort

to

of

be com-

out

by

seal, ap-

the

seal.

Figure 1 - 7

Figure 1 - 8

34

9. Remove
move cover, also air shielding plate,
lower. Refer

10. Remove cylinder head nuts, remove head, re-

move cylinder base
and

the

rear fan cover

to

gaskets. As

figure 1-

nuts

shown

mount

9.

and remove cylinders

in figure

bolts

1-10.

and

upper

reo

and

)

Figure 1 - 9

Remove snap ring

11.

shown

12. Insert
wrist pin
do

strain

Refer

in

figure

appropriate

out.

on

connecting

to

figure 1- 12.

1-11.

driver

Use

from

each side

into

wrist pin

caution

to

avoid

rod. Remove pistons.

of

piston, as

putting

and

tap

un-

Figure 1 -

Figure 1 -

10

)

11

35

Figure 1 - 12

)

c

13.

Remove fuel

1-13.

pump

assembly as shown

in

figure

Figure 1 - 13

c

14. Remove

plate.
gasket loose
drive a screwdriver between
seal plate
to

1-14.

15. Remove

ing brackets with a

seal surface loose, and split

er half
are removed. Refer

the

cap

Tap

the

and

to

break

sealing surface will result. Refer

crank

of

crank

screws from

corners

case bolts,

of

the

remove

case. Make sure

the

the

plate loose, as damage

then

soft

hammer

to

figure 1- 15.

the

drive side seal

plate

to

break
seal plate. Do
the

crankcase and

to

tap

the

fan hous-

to

break

the

lApper

and low-

all

of

the

the

not

figure

the

bolts

Figure 1 -

14

16.

Do

not
Damage
as

shown

use this

to

in figure

method

the

sealing surface will always result,

1-16.

c

to

split crank case.

36

Figure 1 -

Figure 1 -

15

16

2-1

. Re-assembly of engine

1.

2.

Locate

the

ure 2-

Put
crankcase

crankshaft

labyrinth seal with grease, as shown in fig-

1.

a thin

coat

sealing surface. Refer

in lower half

of

appropriate

of

case. Coat

sealer on entire

to

figure

2-2

J

Figure 2 - 1

.

Figure 2 - 2

3. Note

4.

that
spacer ring on
case

next

to

Replace upper-half

screws with care. Strike

shaft

before tightening

in Operation

Torque
small cap screws
figure

large

2-4.

on

some engine model

the

fan housing side

the

main bearing. See figure 2- 3.

of

crankcase and replace cap

lightly

on

the

cap screws, as shown

In

structions

cap

screws

to

Torque

18

Pattern Page 7

on

page 2a-Fig_

to

25

foot

foot

pounds, as shown

s,

there is

of

end

pounds

of

J

a

crank-

Figure 2 - 3

crank-

1.

and

in

37

Figure 2 - 4

)

c

2-5.

Install cylinder base gaskets. As shown in figure

2- 5.

Figure 2 - 5

c

6. Install
sure
tween
stall

7.

Grease

connecting rod .
on

the

side

the

fuel

pump

mount

that

there

is a heat

the

mounting

the

fuel pumps. As shown in figure

the

wrist pin bearing and install

end

of

toward

brackets and crankcase. In-

Put

the

the

bearing with

the

bearing. See figure 2-

brackets, making

barrier and gasket be-

connecting rod spacers

the

2-6.

in

the

counter-sunk

7_

Figure 2

- 6

8. The piston
ward
pins will be

engine. As

the

is

installed with

fan. In

toward

shown

this

in

the

figure

c

the

position

exhaust

2-8.

F marking to-

the

ring

locator

side

of

the

38

Figure 2

Figure 2

- 7

- 8

2-9.

Replace
driver, again being
necting rod.

the

wrist pin with an appropriate

See figure

careful

2-9.

not

to

damage con-

Figure 2 - 9

10. Install piston rings
just enough so
down into groove.

11. Do

not

use

the

method sometimes employed as
this bad
rings will result. Do
than
surely result. See

example shows, or serious damage

necessary

as

by

that

fatigue

figure

spreading
the

As

shown

not

2-11.

the

piston ring will slide

in

figure

spread

the

of

ring material will

end

of

rings

2-10.

rings more

to

Figure 2 -

10

12.

liberally

stall
is
shown

lubricate

the

cylinder, making sure

toward

in

the

appropriate side

figure

2-12.

the

piston and rings, and in-

the

of

exhaust

engine.

port

As

39

Figure 2 -

Figure 2 -

11

12

)

c

2-13.

When installing cylinders, an
compressor should be used; however, if intense

is

exerted,

care
der using
rings. As shown in figure 2-13. Tighten base
nuts

evenly

sult.

Torque

foot

pou nds.

it

is

possible

your

finger

to

or

damage

cylinder mounting

to

appropriate

to

install

the

cylin-

carefully compress

cylinder base may

nuts

to

ring

the

re-

22.4

Figure 2 - 13

c

14. This

15.

is

an

example
ring damage occurs during assembly.
stalled properly,

up

squarely with

the

rings

may

must

be lined
ing will result.
place ring will almost always cause damage
the

rings. Unless

method

2- 14.

The

meter

der. The

EXH,

cylinder. In this position,
cylinder head will be over
figure

should

head gasket

of

metal on

cylinder

to

be installed

2-15.

of

how

the

the

exhaust

the

exhaust
catch on
up

true

The

use

extreme

be avoided. Refer

is

installed with
the
head

port

the

port.

with

the

of

a screw driver

care

gasket

is

clearly marked with

on

the

the

exhaust

most

To

must

side

of

engine

The

piston

is

exerted, this

to

the

large dia-

toward

the

exhaust

deflector in

port. See

frequent

be

in-

be lined

or

cylinder

or

wedg­to

re-

to

figure

cylin-

side

of

the

Figure 2 -

14

Figure 2 -

16.

Use

pattern
evenly in
head

nuts

three

to

shown

stages.

19

foot

on

page 7, tighten down

Torque

pounds. See Figure 2- 16.

the

cylinder

C Figure 2 - 16

40

15

2- 17. Replace

inside surface
install carefully, so as

of

the

lip

the

inner fan housing. Lubricate

of

crankcase seal with grease and

not

to

damage

seal. See figure

2-17

.

the

the

inner

)

18

. Mount

stator

ment
figure

19. Coat
coat
is

the

2-19.

the

stator

plate assembly and locate

plate adjustment

slots. Tighten

2-18.

the

contact

of

grease. A special silicon cam lubricant

proper grease

at

the

center

of

cap

screws securely. See

breaker cam with a very thin

to

use. Refer

to

the

adjus

figure

Figure 2 -

t-

Figure 2 -

17

18

J

20. Replace the woodruff key
align

the

key-way
crank shaft key; carefully install
of

crank shaft.

the

fiber

rub

catch

on

the

point

mis-alignment. Carefully rotating

wheel while installing usually prevents damage .

See figure

2-20.

Use

block

contact

in

extreme

on

in

the

fly wheel with

care

ignition points

breaker cam causing

crank shaft, and

the

the

fly wheel

to

be sure

do

the

that

not

fly

41

Figure 2 -

Figure 2 -

19

20

J

c

2-21.

Torque
See figure

the

fly-wheel

2-21.

nut

to

66

foot

pounds.

c

22. Connect timing light

tion lead. Line

and timing mark

wheel

housing. Adjust

to

points

rotated past this lower timing mark.
er gauge
The
As

Adjust

23.

buretor side
as

the

break

to

point

gap should be between .011

shown in figure 2- 22.

point

first

the

the

contact

measure

gap

on

of

engine)

set

of

points result. See figure

to

the

white primary igni-

timing mark

on

the

exhaust side ignition

when

the

resulting

number

to

the

on

bottom

the

crank

Use

point

1 cylinder (car-

same

point

the

of

shaft

a feel-

to

.017.

2-23.

fly

fan

is

gap.

gap

Figure 2 -

Figure 2 - 22

21

24. Attach timing light

primary
mark

mark
two
the
(not
then adjust number 1 cylinder breaker points,
carburetor side,
wheel

shown

lead. Rotate fly wheel

on

the

at

the

breaker plate mounting screws

number 1

the

two

is

rotated

in

figure

to

fly wheel

top

of fan housing. Loosen

set

of

breaker points in position

screws

to

break

past upper timing mark.

2-24

.

c

number 1 cylinder red

so

that

timing

is

in

line with timing

that

that

locate

stator

plate)

contact

when fly-

Figure 2 - 23

the

hold

As

Figure 2 - 24

42

2-25.

Re-install

ure

2-25.

outer

fan housing. As shown in

fig-

J

26. Re-install carburetor, making sure heat barrier

and gaskets are in

2-26.

place. As shown

in

figure

Figure 2 -

Figure 2 -

25

26

J

)

43

3-1

. Disassembly

of

Body

& Trim

c

1.

Drain fuel
container
Figure

2. Remove tail light lens,
Tee Pee.

3. Remove
side.

tank

and

3-1.

See Figure 3-

four

nuts,

See Figure

completely.

use hose

at

3-2.

Use

on

fuel filter end. See

one

from each side of

2.

base

of

Tee Pee,

appropriate

two

each

Figure 3 - 1

Figure 3

- 2

c

4.

Lift

Tee Pee up

Pee and

5.

Disconnect tail light wires, and gas
Gas
be removed
ure

6. With
approximately 1 inch and
holddown. See Figure 3 - 4.

tank,

3-3.

both

tank

Tee

to

clear cap screws,

back. See Figure

Pee and

completely

hands, grasp seat firmly, slide back

tilt

Tee

3-3.

tank

hose.

bumper

from machine. See Fig-

lift

are

up

now

free

of

free

body

to

Figure 3

•

- 3

c

Figure 3 - 4

44

3-1.

Disassembly

of

Body, Trim & Console

Remove

7.

Figure

8. Chisel rivets inside nose pan, remove parting
line extrusion.

9. Disconnect
assembly and brake cable from brake handle
assembly.

all

bumper bolts, remove bumper. See

3-5.

See Figure 3- 5.

throttle

See Figure 3- 6.

cable from

throttle

handle

J

Figure 3 - 5

Figure 3 - 6

10. Disconnect all electrical wires from console
machine.

11. Disconnect speedometer cable.

12. Remove
See Figure 3-

13. Remove
handle bar.

14. Remove steering post grommet,

sole

four

bolts holding console in plac

7.

four

bolts

on

handle bar and remove

See Figure 3- 7.

up

carefully. See Figure 3- 7.

then

lift con-

to

e.

Figure 3 - 7

J

45

4-1.

Disassembly

of

Chaincase

c

Remove chaincase

1.

cap

screws, see Figure 4- 1.

2. Release chain adjusting bolt. See A - Figure

4-2

.

3. Remove cap screw
kets. See B - Figure

4. Pull sprockets off shafts, then remove sanp ring

on

lower shaft.

front

cover by removing 8

on

upper and lower sproc-

4-

2.

Figure 4 - 1

c

5. Remove

pull clutch

cap

screw

on

end

off

shaft. See Figure 4- 3.

of

driven clutch,

Figure 4 - 2

Figure 4 - 3

c

46

4- 1. Disassembly

of

Chaincase

Remove

6.

machine. See Figure

7. On right hand side
carriage bolts which hold flangettes and bearing

to

four bolts which hold

4-4.

of

machine, loosen 3 nuts

body. See Figure 4- 5.

chaincase

to

on

)

Figure 4 - 4

Figure 4 - 5

8.

Loosen" bearing lock, first

head

set

screw,

then

turning

9. Slide collar back. Move drive shaft
side

10. Brake assembly may be removed
chaincase rear cover.

11. Heat

from case.

collar until loose. See Figure

of

the

machine and

on

case may be used

See Figure 4- 7.

by

loosening socket

using a punch and hammer

drop

down.

to

remove bearings

4-6.

to

the

by

removing

Figure 4 - 6

right

Figure 4 - 7

47

5- 1. Steering Disassembly

c

1. Remove

A ·

2. Remove rod
clockwise. See B . Figure

3.

Remove
post

mounting
bar weldment. See C . Figure 5-

4.

lift

flange,

out

5. Remove spindle

sliding steering arm

5-1.

nut

on

rod end bearings.

Figure

5-1.

end

cotte

r pin

weldment

steering

then

. See D - Figure 5- 1.

. Also

bracket

post

drop

by

four

each. See

bearing by

at

four

and

up

steering

removing steering arm bolt,
up

turning

5- 1.

lower end

bolts

four

to

clear lower bearing

post

and

off

of

in

steering

bolts

in

1.

down

. See E · Figure

counte

steer

post

handle·

and pull

r·

ing

Figure 5 - 1

c

6.

Spindle will
raising machine up.

7. Remove ski assembly

See B . Figure 5- 2.

bolt.

5- 2.

Steering Assembly

1. Assemble steering in
assembly, use a lubricant

le

spind
ing.

2.

Steering skis should be parrallel with each
and
normal straight driving position,
may be
wise,

housing bushing, and nylon flange bush -

with

vehicle frame, when handle bar

made

by

or

counter-clockwise, whichever

drop

down

See A . Figure 5- 2.

by

removing

the

turning

rod

through

reverse

on

end bearings clock-

body

spr

ing saddle

order

of

saddle bushing,

adjustment

is

needed.

when

dis·

other

is

in

Figure 5 - 2

c

48

6- 1. Disassembly

of

Track & Suspension

1. Loosen

2. Remove driftskipper
machine
screws,
cap screws on
figure

3. Remove drive
bers

track

on

follow

6-

1.

1,2,3,4

adjusting bolts. See Figure 6-

its side,

the

same procedure for

opposite

shaft

on

page

or

slide rail

then

remove

side

of

machine. See

and

track

. Refer

46

and 7,8,9 on page 47.

by

two

tilting

the

to

1.

cap

two

Num-

Figure 6 · 1

4.

Assemble machine
assembly. Use care in assembling all parts,
insure proper

in

the

reverse

track

tension, track alignment.

order

of

dis-

to

49

6- 2. Power Slide

c

c

1.

Track Tension ­and

support

of

track can be determined by exerting approxi­mately
center

cleat taking one side

ween

mately
the
(A) and tighten
screws (8)
justment

2. Track
made
and running
ment
the
the
Start
the
the
right,
track slowly and readjust if necessary. Tighten
lock nuts (A).

fifteen pounds

of

the

the

track and slide rail should be approxi-

one inch. (See arrows in drawing.) If

track needs adjustment, loosen lock nuts

on

Alignment - A periodic check should be

to

determine

will cause excessive wear

slide rail. Check by supporting

machine with

the

engine and accelerate slowly

track.

left side track adjusting screw, if

the

right adjusting screw. Again run

lift

the

rear

of

if

off

the

ground. Proper free play

of

pull downward

track. Use a scale and attach

at

a time. Distance

or

as

necessary

both sides

evenly

If

the

track runs

loosen

on

the

the

track adjusting

to

provide equal ad-

of

the

track.

that

the

track

the

slide rails. Misalign-

to

track

off

to

the

the

the

machine

on

the

to

is

centered

track and

the

rear

the

ground.

to

turn

left, tighten

to

the
the

a

be-

of

3. Ride Adjustment - The Power
is

easily adjusted for a firmer ride
leading leg
hooks

4. Maintenance - With
Snowmobile

the

or

missing cleats. Replace

to

avoid damage
Make
bolts
NEVER make this maintenance check with

engine running.

of

the

of

the

mounting brackets (C).

supported

track

by

hand

to

it

a periodic practice

and nuts

suspension spring

the

rear

off

the

to

check

as

track

or

suspension system.

to

on

the

suspension system.

Slide Suspension

by

placing

in

the

upper

of

your

Polaris

ground,

for

soon as possible

check for loose

broken,

rotate

bent

the

the

c

50

6-3

. Driftskipper

1. Track Tension - Lift
and

support
tween the track and
should be approximately one inch. (See arrows

on

diagram.) If
loosen
track adjusting screws

vide

equal adjustment
When proper adjustments have been made,
tighten

2.

Track Alignment - A periodic check should be

made
and running
Misalignment can cause excessive sprocket wear.
Check by supporting rear
off

ground.

to

turn
against
justing screw (A)
track

slowly

if

the

lock nuts

lock nuts.

to

determine

evenly

Start

track. If sprockets run close

one

side

to

the

rear

of

the

machine

off

the

ground. Free play be·

center

of

suspension

the

track needs adjustment

(B)

and tighten

(A)

as required

on

both

sides

that

the

track

is

on

the

rear idler sprockets.

of

machine with track

engine and accelerate slowly

of

track clips, tighten track ad-

on

that

side

of

the track. Run

check and readjust if necessary.

unit

or

loosen

to

pro-

of

track.

centered

to

or

3. Drift Skipper Adjustment - See Figure 6-3

1. Normal setting, best

snow conditions.

for

2. Perfect

weight transfer
on

the

but

reduces maneuverability.

3 - 4. These

ory

to

side

of

be used in adjusting suspension.

any

skis, this will provide

holes are

make it interchangeable

the

suspension rail.

for

operator

to

the

put

an average on

who

track

and less weight

better

in

the

part

They

all

desires more

traction

at

the

fact-

for

either

are

not

to

Figure 6 - 3

51

c

c

..

c

-"'it

,/ .

"

o

i

o

o