Polaris Playmate 1971 Install guide

1971

1

• • a • •:

..

.

" "

to

'

.

~.

-

---

S#OP

M~NUA,L

INTRODUCTION

This Manual

has

been prepared

as

a guide to maintenance, disassembly

and

assembly

of

the Polaris snowmobiles.

By

reading this Manual carefully,

you

can obtain knowledge

of

the machine,

which

will

be

helpful

in

maintenance.

The meaning

of

maintenance

is

to

perform

preventive maintenance

and

ad

-

justment

of

your

snowmobile

to

keep

it

in

top

running condition.

In

accord-

ance

with

the instructions supplied

in

this Manual,

all

machines

should

be

inspected

and

serviced

periodically

.

This Manual is

divided

into

sections showing detailed photographs, cover-

ing construction details, disassembly, inspection, maintenance,

and

assembly

of

specific parts

of

the machine.

POLARIS INDUSTRIES

Division

of

textron

II

nc.

Service Department

Roseau, Minn.

,.

j

c

TABLE

OF CONTENTS

MODEL

SPECIFICATIONS

...

. .

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

.

PLAYMATE

-CHARGER -

TX

-MUSTANG -

VOYAGER

ENG

INE

DATA

.....

175cc -795cc

1 - 2

..

3-

6

COMMON SPECIFICATIONS FOR

ALL

MODELS.

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

7

TORQUE PATTERNS

CONDENSED SERVICE

DATA

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

8

ELECTRICAL

SYSTEM

INFORMATION

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

9 -

10

WIRING SCHEMATICS

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

11

-14

TROUBLE

SHOOTING

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

15

INSTRUCTION FOR

FUEL

PUMP.

.........

....

..........

16 -18

MODEL

OF 62 -24

INSTRUCTION FOR CARBURETOR

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

19 -26

MODEL

VM

-30

INSTRUCTION FOR POLARIS ENGINES

........

...

.........

27

-43

CONSTRUCTION

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

27 -29

STARTING

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

30

REMOVAL

OF ENGINE

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

31

-32

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

...

33

-36

RE

-ASSEMBLY OF ENGINE

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

37 -43

BODY

AND

TRIM

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

44 -

45

DISASSEMBLY OF BODY,

TRIM

& CONSOLE

DRIVE

AND

BRAKE

...........

.

DISASSEMBLY OF CHAINCASE

STEERING

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

.

STEERING DISASSEMBLY

STEERING ASSEMBLY

.

..........

46 -47

.

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

48

TRACK

AND

SUSPENSION.

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

...........

.

49

-

51

DISASSEMBLY OF

TRACK

& SUSPENSION

.......

...........

.49

ASSEMBLY OF

TRACK

& SUSPENSION

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

49

POWER

SLIDE

TRACK

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

POWER

SLIDE

TRACK

ALIGNMENT.

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

..

50

DRIFT

SKIPPER -

TRACK

TENSION

........

.

51

DRIFT

SKIPPER -

TRACK

ALIGNMENT

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

...

..

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

Eindshield -

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

:2E

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/

Sk

i -

108"

Wi

dth

-

39

1/2"

He

ight W/Wi

ndsh

i

eld

-

49"

Height

Less

Wind

shie

ld - 36 1/

2"

Weight - appr

ox

. 590

Ibs

.

S

usp

e

nsi

on - st

an

dard bogie

Transmi

ss

ion - f

or

ward

reverse

F

uel

Ca

pa

city - 5.9

ga

l.

Engine - 488cc

Pola

ris Star 2 cycle w/el

ec

tric

start

o

N

ENGINE

DATA

POLARIS

EC17P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

of

Cylinders

Displacement -

Cu.

In

. (cc)

RPM -Standard

Carburetor

Make, Model & Size

Number

Used

Ignition

Make & Model

Type -Energy Transfer

62

(mm)

5S(mm)

1

175

(cc)

(4,000 5,000)

Mikuni

VM24

1

Ida Denki

( )

Capacitor Discharge ( )

Magneto (

x)

Breaker

Point

Gap -Inch

(mm)

.010

-.017

Automatic

Timing

Advance -Yes ( )

No

(x)

Tim

ing Checked

at

-

Setting-

°BTDC;

Inches (mm)

Spark Plug Make & Model

Spark Plug Gap -Inch (mm)

Alternator

Output

Fuel/Oil

Ratio

Advance (

Retard

(x)

23°

-.012

(use marks

on

flywheel)

NGK

B7ES -

AC43XL

.017

-

.020

12

Volts

35

Watts

20 - 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

POLARI

S EC29P

Bore -

In

c

hes

(mm)

Stroke -

In

c

he

s (mm)

No.

of

Cylinde

rs

Displacement -

Cu

.

In

. (c

c)

RPM -Standard

Carburetor

Make, Model &

Si

ze

Number

Us

ed

Ignition

5

S(mm)

55.6 (mm)

2

294

(cc)

(6,000 6,500)

Mikuni

VM26

26mm.

2

Make & Model Kokusan

Type

- Energy Transfer ( x )

Capacitor Discharge ( )

Magneto ( )

Breaker

Point

Gap -Inch (mm) .

010

-

.017

(inch)

Automatic

Timing

Advance -

Yes

(x)

No

( )

Timing Checked

at-

Setting -

°BTDC;

Inches (mm)

Spark Plug Make & Model

Spark Plug Gap -Inch (mm)

Alternator

Output

Fuel/Oil Ratio

Advance (

Retard

(x)

SO

- .

012

(use marks

on

flywh

eel)

AC43XL

-

NGK

B7ES

.017

-

.020

12

Volts

75

Watts

20

-1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

3

J

)

J

c

ENGINE

DATA

POLARIS

EC34P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

of

Cylinders

Displacement -Cu.

In

. (cc)

RPM -Standard

Carburetor

Make, Model & Size

Number

Used

Ignition

:

62

(mm)

55.6

(mm)

2

335

(cc)

(6,000 6,500)

Mikuni

VM26

26mm

2

Make & Model Kokusan

Type

-Energy Transfer

(x)

Capacitor Discharge ( )

Magneto ( )

Breaker

Point

Gap -Inch (mm) .010 - .

017

(in.)

Automatic

Timing

Advance -

Yes

(x)

Timing

Checked

at

-

Setting -

°BTDC

: Inches (mm)

Spark Plug Make & Model

Spark Plug Gap -

In

ch (mm)

Alternator

Output

Fuel/Oil

Ratio

Special

Oil

Recommendations:

No

( )

Advance (

Retard

(x)

80 -.012

(use

marks

on

flywheel)

AC43XL

NGKB7ES

.017 -.020 (in.)

12

Volts

75 Watts

20 - 1

Polaris Snowmobile

Oil

4

POLARIS

EC40P

Bore -Inches

(mm)

Stroke -Inches

(mm)

No.

of

Cylinders

Displacement -Cu. In.

(ee)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition

:

Make & Model

65

(mm)

60

(mm)

2

398

(cc)

(6,000 6,500)

Mikuni

VM30

30

mm

2

Kokusan

Type

-Energy Transfer

(x)

Capacitor Discharge ( )

Magneto ( )

Breaker Point Gap -Inch (mm) .

010

-

.017

Automatic

Timing

Advance -

Yes

(x)

Timing

Checked

at

-

Setting _oBTDC: Inches (mm)

Spark Plug Make & Model

Spark Plug Gap -Inch

(mm)

Alternator

Output

Fuel/Oil Ratio

Special

Oil

Recommendations:

No ( )

Advance (

Retard

(x)

80 -

.0

12

(use marks

on

flywheel)

AC43XL

NGKB7

ES

.017 -.020

12

Volts

75

watts

20 - 1

Polaris Snowmobile

Oil

ENGINE

DATA

POLARIS

EC44P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

of

Cylinders

Displacement -Cu. In. (cc)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition:

67.75

(mm)

60

(mm)

2

432

(cc)

(6,000

6,500

)

Mikuni

VM30

30

mm

2

Make & Model Kokusan

Type

-Energy Transfer (

x)

Capacitor Discharge ( )

Magneto ( )

Breaker Point Gap -Inch (mm) .010 -.017

Automatic

Timing

Advance

Yes

(x)

No

( )

Timing

Checked

at

-Advance (

Retard

(x)

Setting -

°BTDC:

Inches

(mm)

SO

-

.012

(use marks on flywheel)

Spark Plug Make & Model

AC43XL

NGKB7ES

Spark Plug Gap -Inch (mm) .017 - .

020

Alternator

Output

12

Volts

75

Watts

Fuel/Oil

Ratio

20 - 1

Special

Oil

Recommendations: Polaris Snomobile

Oil

POLARIS

EC50P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

of

Cylinders

Displacement -Cu. In. (cc)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition:

Make & Model

72 (mm)

60

(mm)

2

488 (cc)

(6,000 6,500)

Mikuni

VM30

30mm

2

Kokusan

Type

-Energy Transfer

(x)

Capacitor Discharge ( )

Magneto ( )

Breaker

Point

Gap -Inch (mm) .

010

- .

017

Automatic

Timing

Advance

Yes

(x)

No

()

Timing

Checked

at

-Advance (

Retard

(x)

Setting -

°BTDC:

Inches (mm)

SO

-

.012

(use

marks

on

flywheel)

Spark Plug Make & Model

AC43XL

B7ES

(NGK)

Spark Plug Gap -Inch

(mm)

.017 -

.020

Alternator

Output

12

Volts

75

Watts

Fuel/Oil

Ratio

20

- 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

5

)

c

ENGINE

DATA

POLARIS

STAR EC65PF

Bore -Inches

(mm)

Stroke -Inches (mm)

No.

of

Cylinders

Di

splacement -

Cu

.

In

. (ee)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition

:

67

.75

(mm)

60

(mm)

3

649

(cc)

(7,000)

Tillotson

HD

3

Make & Model Kokusan

Type

-Energy Transfer

()

Capacitor Discharge (

x)

Magneto ( )

Breaker

Point

Gap -

Inch

(mm) None

Automatic

Timing

Advance -

Yes

(x)

Timing

Checked

at

-

No

( )

Advance

(x

)

Retard ( )

Setting -

°BTDC:

Inch

es

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

Spark Plug Make &

Mod

el

Spark Plug Gap -Inch (mm)

with

timing

light

AC41XL

NGKB8ES

.

030

0

Alternator

Output

12

Volts

75

Watts

Fuel/Oil

Ratio 20 - 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

6

POLARIS

STAR EC79PF _

Bore -

In

ches

(mm)

Stroke -Inch

es

(mm)

No

.

of

Cylinders

Displacement -Cu.

In

. (cc)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition

:

75

(mm)

60

(mm)

3

795

(

cc

)

(7,000)

Tillotson

HD

3

Make & Model Kokusan

Type

-Energy Transfer

()

Capacitor Discharge

(x)

Magneto ( )

Breaker Point Gap -Inch (mm) None

Automatic

Timing

Advance -

Yes

(x)

No ( )

Timing

Checked

at

-Advance

(x)

Retard ( )

Setting

_oBTDC

: Inch

es

(mm)

3.5 max.(mm) 5,000ck

with

timing

light

Spark Plug Make & Model

Spark Plug Gap -Inch (mm)

AC41XL

NGKB8ES

.0300

Alternator

Output

12

Volts

75

Watts

Fuel/Oil Ratio

20

- 1

Special

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.

l

b.

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

CRANKCASETORQUE?ATTERN

RUNNING TIMING CAN

BE

CHECKED BY

MOVING

T

HE

ADVANCE

CAM TO THE FULL 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.

-- - 230 --

80 .27 .

012

230 2.3 .093

80 .27 .012 230 2.3 .093

80 .29 .012 230 2.5 .099

80 .29 .

012

230 2.5 .099

80 .29 .

012

230 2.5 .099

---230 --

CD

CYLINDER

HEAD TORQUE PATT

ER

N

I

R.P.M.

Engine I

!

6,000 i

6,000

.....

z

o

l-

e:(

~

a:

o

u.

Z

w

()

>

a:

w

en

Cl

w

en

Z

w

Cl

Z

o

()

Year

1971

u

Model Make

Playmate Polaris

Charger 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. (I

n.

)

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

ar

which

is

designed

for

either electric

or

non-

electric

start

models using any engine . . . The TX models have

th

eir own harness,

as

does

the

Playmate.

All

harnesses are protected by Grayline tubing. This

is

a high temperature tubing,

but

it

will melt if allowed

to

touch

the exhaust pipes and care should be taken

to

avoid this.

ELECTRIC START SYSTEMS

Electric

start

systems may be installed

on

all engines

in

the

Charger and Mustang. The existing wiring harness

is

used,

adding a circuit breaker, a rectifier, a lead wire, and a starter with solenoid, plus

the

needed

battery

cables, battery,

and solenoid wire assembly

to

connect

the solenoid

to

the

main harness.

To charge

the

battery,

the

alternator's A.C. (alternating current)

output

must

be rectified

to

D.C. (direct current).

This

is

accomplished by a pair

of

diodes

mounted

in

parrallel

in

a square shaped rectifier. This rectifier

is

protected by

an 8 amp circuit breaker,

to

protect

the

alternator coil, should one

of

these diodes fai

l.

There are

two

alternator systems used this year. A

75

watt

alternator system

is

found

on

all

Chargers, Mustangs, and

TX models, and a

35

watt

system

is

on Playmate models. Each alternator coil has

the

capacity

of

producing three

amperes

of

current

going

to

the

battery. With

the

lights off,

all

the

current

goes

to

the

rectifier, from which it

is

tapped

for lights, with

the

remaining

current

going

to

the

battery. The lights will

not

operate with the engine

not

running

as

they

are connected

off

the

alternator circuit,

not

the

battery;

hence

they

cannot

discharge

the

battery.

In

the

electric

start

system,

the

battery acts as a voltage regulator.

An 8 amp circuit breaker

is

included

on

the

instrum

ent

panel

in

the

electric start sy

st

em

to

protect

the

wiring harness

and eliminate

the

danger

of

fire due

to

a

short

circuit.

LIGHTING

The lighting system for

the

Charger and TX consists

of

a dual beam headlamp and

two

taillamps.

On

the

Mu

sta

ng

, there

is

a dual beam headlamp, four taillamps, and

two

warning light lamps. The Playm

ate

lighting system consists of a

single beam headlamp and

two

taillight lamps.

The warning light

on

the

Mustang

is

designed

to

warn a snowmobile driver behind, when

the

snowmobile

in

front

hits

rough going

or

slows down suddenly. The sensor

is

an inertia switch mounted

in

the

instrument panel.

All Mustangs and Chargers use a

60

watt

headlamp -Polaris Part No.

4030007

or

G.E. No. 4454.

Th

e Playmate uses a

25

watt

headlamp -Polaris Part No.

4030005

or

G.E. No. 4568.

NOTE: When

the

hood

is

removed,

the

headlight becomes disconnected and all

li

gh

ting circuits become ope

n.

This

prevents excessive voltage from being applied

to

the instrument and taillights, should

the

li

_hts be

turn

ed

on

when the

hood

is

off.

ACCESSORIES

The electrical system

is

designed

to

accept

the

speedome

ter

,

ta

chometer, and cigafe

tt

lighter as

st

andard

options. The

necessary wiring instructions are included with each

option

. If additional information

is

needed,

consult

the

instrument

panel wiring diagram

or

the

applicable wiring harness drawing.

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

contact

the

Polaris Service Department.

9

)

c

TROUBLE SHOOTING HINTS (Electrical)

Manual S

tart

Will

Not Sta

rt

1.

Check

the

ignition switch

that

it

is

in

the

run position.

2. Check auxiliary shut-off switch.

3. Check

the

fuel supply.

4. Check wiring from

the

engine

to

the

coil(s), and

to

the

spark plug(s).

5. Check

the

spark plug(s).

6. Disconnect

the

engine connector

to

eliminate any shorts

that

may be in

the

main harness wiring.

El

ectric

Start

Will

Not

Start

1. Check

the

six items above.

2. If starter

doesn't

work:

a. Check

the

wires between

the

starter solenoid and b

atte

ry.

b.

Ch

eck

the

battery cables and battery.

Battery

Will

Not

Charge

1. Check for bad connections.

2. Check alternator

output.

Lights

Don't

Work

1.

The engine must be running before

the

lights will work.

2. Check

to

see

that

the

headlight harness connector

is

connected, as th

is

cuts

off

all lights

to

prevent burning

them

out

from excessive voltage.

3. Check for burned

out

lamps.

4. Check

for

loose connections and shorted wires.

5. Disconnect

the

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

the

wiring

to

the

taillight.

10

(~

FLYWHEEL

MAGNETO

GENERATOR

EXTERNAL

IGNITION

COIL

IGNITION STARTING SWITCH

WIRING

SCHE

MA

TIC (VOYAGER)

EXTERN

AL

I

GN

ITIO

N COIL

7.5 AMP

STARTING

STARTER MOTOR

SOLENO

ID

f\

..h

tthl.::l

"AM'

l

iC-f

•

'ATi-i

: I \ J

LI

J L-i

~

~4

I

---------

1

DUAL

BEAM

HEADLITE

\

{:'''.~'

~'~'.~

I

-=--

I

L

I

1

I

1

I

J

TO SPEEDOMETER

It

TACHOMETER LITE IF INCLUDEP •

....

WIRING

SC

HEMATIC (MUSTANG -CHARGER -

TX

-MANUAL S

TART)

----

-.

-

-------------~

"./---

,

.....

,

.......

._-

FLYWHEEL

MAGNETO

GENERATOR

SPARKPLUG

rf>

~

-:-

ir

~-

l

i

-=-

___

J

I

LJr

I

L

__

-'

EXTERNAL

IGNITION

CO~~

M

SPARKPLUG

~

EXTERNAL

IGNITION COIL

(Twin Cylinders Only)

-=-

IGNITION

STARTING

SWITCH

u u

NQI~

1 - ON MUSTANG

ONLY

2 - MUSTANG, CHARGER, &

TX

LITE

SW

ITCH

' 7'

''--'

I h ' ------'

1/

L -"1"- _

.,..J

OFF 0 LO 6 HI

DUAL

BEAM

HEADLITE

1--

--

- -

--

I

I (NOTE

1)

\ I

WARNING

LITE

SWITCH

\ -' WARNING LIT

ES

I

/

....

\1 .

\ ( I

\ -- - [

~(

I

T

.

&u~

I I

L (f I I

L _ _ _ _ J

u

N

...

n

('

lit

t3

\

~

\

~~

i

L-,

n I

_

Li

FLYWHEEL MAGNETO

GENERATOR

"- "---

n

WIRING

SCHEMATIC (MUSTANG -CHARGER -ELECTRIC START)

"

",

\ \ STARTER

RECTIFI

ER

CIRCUIT

STARTING

MOTOR

~--

L---

----------------~~-4

--

---

~

BREAKER

,...

r-,

i

/

SP~R~

I

~

I

L

..

.-J

EXTERNAL

IGNITION COIL

-:-

IGNITION STARTING

SW

ITCH

SPARKPLUG

~

EXTERNAL

IGNITION COIL

~

::::::=-

a---.

!lAMP

r

--=t::.-l

BAT. I - I •

-=

LII

-

......--

\SED

ON

MUSTANG ONLY

~

___

~~

I

__

~

I

--

"I

LITE

SW

I

TCH

--,

DUAL BEAM

HEADLITE

~-

--------

I I

\ WARNI

NG

LITE

o SWITCH

\ L I

NG

"1'

,,

"i"""

I

W(£,I

dS(l)

: l

-1-

i

l 1 L I

.. J

TO

SPEEDOI'I

.ETER & TACHOMETER

LITE-IF

INCLUDED

..

(II)

...

WI

R

IN

G

SC

HEM

AT

IC (PLAYMATE)

ITEM

1

2

3

4

5

FLYWHEEL-MAGNETO-GENERATOR 6

7

8

9

"-I]

Q

-,

.

CD

L

f\1r1f

~

I

}D

-

(,

.;

' I

\ i

I)

,

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,

\..

j

'L.~

p ~

...

~

,

IGNITIO

N-

LIGHT

-

STARTING

SW

I

TCH

CD

SPARKPLUG 1

ENG

INE

DISCONNECT B

u u

REO,

1

2

1

I'

1

-<

TAIL

LIGHT

DISCONNECT

PART

NO,

DESCR

IPTION

2460071

ENG

I

NE

CONNECTOR ASSEMRI V

4110003 IGNITI

ON-LITE

SW

ITCH

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

1. Engine fails

to

start

a.

ignition switch

off

b.

out

of

fuel

c.

fuel line kinked

d. fuel filter clogged

e.

fuel

pump

impulse hose cracked

or

leaking

f.

choke

on

but

throttle

handle compressed

g. chokes

stuck

open so engine flooded (Mikuni Carb.)

2. No spark

a. spark plug fouled

b.

secondary coil dead

or

wires disconnected

c. primary coil

shorted

or dead

d. ignition points

dirty

or

pitted

e. shorted ignition switch

3.

No

compression

a. crankcase plug

is

out

b.

headgasket

is

blown

c.

bad rings

or

piston

4.

Engine idles

but

fails

to

accelerate

a.

restricted fuel flow

b.

clogged main

jet

5. Engine runs

but

fails

to

reach maximum R.P.

M.

a. clogged fuel filter

b.

track tension (incorrectly

sed

c.

incorrect main

jet

d.

throttle

slides

not

fully

open

e.

chain in chain case

too

tight

f.

front

hanger

on

drift

skipper in wrong hole location

S.

Engine runs

but

fails

to

idle

a.

incorrect air mixture setting

b.

throttle

stop

screw incorrectly adjusted

c.

dirt

in pilot

jet

7. Engine runs

but

overloads with fuel

a. chokes are

not

seating (twisted cable)

b.

fuel

pump

diaphragm

is

ruptured (cause

by

backfire)

c.

carburetor

slides are

not

synchronized

d.

too

large main jet

e. needle

and

seat

not

seating properly

f. incorrect float level

8. Engine runs

but

overheats

a. incorrect main

jet

b.

in

correct

timing

c. incorrect spark plug

9. Burned pistons

a.

Too

hot

a spark plug such

as

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

hot

running condition. See service Bulletin

No

. 27.

b.

Lean

carburetor

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

line, clogged fuel filter, loose impulse tube, repeated running

out

of

gas, etc.

c.

Improperly mixed fuel and oil

or

poor grade

of

gasoline

or

oil. Regular grade gasoline should be used.

Some two-cycle oil

on

the

market mixes very poorly

or

with difficulty especially

at

low temperatures. The oil

should

be

room

temperature

if possible and mixed vigorously. Mixture ratio should be

20

to

1.

d. Overchoking. If engine

is

overchoked, fuel may accumulate in crankcase and

throw

air-fuel ratio

out

of

balance resulting in erratic performance. Crankcase should be drained periodically

or

at

any

time

erratic perform-

ance

is

noticed. Drains are located low

on

the

front

of

the

crankcase for draining purposes. This

is

especially

important

whenever starting problems are experienced.

e.

In

correct

timing

of

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

occurs. Correct timing

after

installing new piston.

15

c

INSTRUCTION

FOR

FUEL

PUMP

(MODEL

DF

62 -24)

1.

Summary

Model

62-24

fuel

pump

is

an air pressure

type

pump.

In

a 2-cycle engine,

the

pressure in

the

crank

chamber

changes

as shown in fig. 1

by

the

up

and

down

motions

of

the

piston.

The

waves of pressure vary according

to

the

rpms

and

the

opening

of

the

carburetor

throttle

valve.

In

either case,

the

wave has enough amplitude

to

make

the

fuel

pump

function.

Our

Model OF

62

-

24

makes

the

diaphragm move up and down

by

the

pressure in

the

crank

chamber

which

creates

the

pumping function.

2. Functions

and

constructions. (Fig. 2)

Model

62

-

24

fuel

pump

is

constructed with functional parts such as

the

bottom

body,

the

top

body,

the

cap,

the

diaphragm,

the

inlet valve,

the

outlet

valve,

the

membrane etc., and

is

furnished with

the

wave motion pressure chamber

A,

the

pump

chamber,

the

fuel chambers

Band

C,

the

air chambers 0 and

E.

2-1.

Intake action (Fig. 2)

The pressure in

the

crank

chamber

is

led

to

chamber

A through

the

passage

of

the

wave

motion

in

the

bottom

body.

When

the

pressure in

the

crank

chamber

becomes negative,

the

diaphragm moves in

the

way shown in fig. 2,

and

the

capacity

of

the

pump

chamber

expands.

At

that

moment,

the

inlet valve

opens

and

the

outlet

valve closes, and

the

fuel

is

drawn

into

the

pump

chamber

from fuel chamber B

through

the

elbow

on

the

side

of

intake.

2-2.

Discharge action.(Fig. 3)

When

the

pressure in

the

crank

chamber

becomes positive,

the

diaphragm moves

in

the

way shown in fig.

3,

and

the

capacity

of

the

chamber

reduces.

At

that

moment,

the

inlet valve closes and

the

outlet

valve opens, and

the

fuel in

the

pump

chamber

is

delivered

by

pressure

from

the

elbow

on

the

discharge side

to

the

float

chamber

of

the

carburetor

through fuel

chamber

C.

As

mentioned above, intake actions and discharge actions are repeated alternately

to

make

the

pump

function.

2- 3. Actions

of

principal functional parts.

(a)

Inlet valve

and

outlet

valve.

The

inlet valve opens

on

the

intake

stroke

of

the

diaphragm and closes on

the

discharge stroke. Therefore,

the

out-

let valve closes

on

the

intake

stroke

and opens under

the

positive pressure,

thus

operating

to

prevent

the

backward

flow

of

fuel.

(b) Diaphragm.

The

diaphragm functions

to

increase

or

decrease

the

capacity

of

the

pump

chamber

by its

up

and

down

motions.

(c)

Fuel chambers

Band

C,

air chambers 0 and

E,

and membrane.

Basically, pumping action

is

possible

without

fuel chambers

Band

C,

the

air chambers 0

and

E,

and

the

membrane

provided. However, under such conditions

there

are some troubles such

as:

(1)

The

flow

of

fuel tends

to

be

intermittent,

and

the

pumping efficiency drops.

(2) Bubbles

tend

to

occur

in

the

fuel pipes.

(3)

The

fuel level is

not

stable

due

to

large pulsations

of

fuel pressure on

the

needle valve

in

the

carburetor

float

chamber.

The

fuel chambers

Band

C,

the

air chambers 0 and

E,

and

the

membrane perform

to

keep

the

flow

of

fuel

as

constant

as possible,

to

keep

the

amplitude

of

the

fuel pressure as small as possible

on

the

needle valve

of

the

carburetor

float

chamber, and

to

make

the

fuel level stable.

3. Disassembly and reassembly.

In

disassembly and reassembly, care should be used

to

handle all parts with proper

tools

so

that

they

will

not

be scratch-

ed

or

battered. When disassembled, all parts should be washed

out

in gasoline

or

kerosene, and blown

dry

with an air·

16

compressor.

3- 1. Instructions

on

disassembly.

(a) Whenever disassembled,

the

cap

gasket,

the

membrane,

the

diaphragm, and

the

gasket should

be

replaced with

new ones.

(b) Care should be used

not

to

reassemble

the

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

on

the

side

of

the

top

body.)

(c) As shown

in

fig. 4, reassemble

the

valve retainer

at

the

center

of

the

guide. Care should

be

used as

to

the

valve

retainer

and

set screws. A

countersunk

screw is used for

the

valve retainer which has a countersink

on

the

side

of

the

inlet, and a round screw

is

used

for

the

valve retainer which has no countersink

on

the

side

of

the

outlet. Partic-

ularly,

extreme

care should be used

to

have

the

top

of

the

countersunk

screw

on

the

side

of

inlet free

from

scratches

for

fear

that

they

should damage

the

diaphragm.

(d)

Be

careful

not

to

make mistakes in

the

order

of

reassembly

of

the

diaphragm and

the

gasket. (Reassemble

the

gasket

on

the

side

of

the

bottom

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

(e)

Pay particular

attention

to

the

joint

s which

must

be sealed tight. If

th

ey

are scratched

or

battered,

they

will

tend

to

cause leakage

of

fuel

or

air.

3-2.

In

spection

after

reassembly.

Dip

the

pump

in gasoline

or

kerosene and check

that

there are no bubbles

at

each

joint

by

an air-tight

test

in which

the

elbow

on

the

discharge side

is

closed with a finger and compressed air of

11

Ib

s.

is

blown from

the

elbow

on

the

intake

side.

4. Causes

of

trouble

and

corrections.

Troubles

of

this

pump

show

themselves in a reduction

of

discharge volume

due

to

the

fall

of

both

discharge

and

intake

pressure.

Causes

of

trouble

1.

2.

3.

4.

5.

6.

7.

LOQse

attachment

of

the

inlet valve

and

the

outlet

valve,

or

the

damage

or

wear

of

the

valve spring.

Damage

of

the

diaphragm

or

the

membrane.

Leak

of

wave

motion

pressure.

Leak

of

fuel

due

to

poor

pieJing.

Other

leaks.

Presence

of

dust

and

impurities.

Clog

of

the

filter.

17

Corrections

1.

2.

3.

4.

5.

6.

7.

Replacement

by

the

pump

assy.

Replacement with a new

one

. (When reassembled,

the

gasket and

the

gasket

cap

also should be

re-

placed

at

the

same

time

.)

Check all joints

of

passage

of

the

wave motion

from

the

crank

chamber

to

the

bottom

body.

Check

the

fuel pipe and

the

elbow

on

the

sides

of

intake and discharge.

Make

the

air-tight

test

according

to

paragraph 3-2,

and:

(a)

If

the

leak

is

due

to

the

joint

of

the

top

body

and

the

bottom

body, replace

the

diaphragm and

the

gasket with new ones.

(b) If

the

leak

is

due

to

the

joint

of

the

top

body

and

the

cap, replace

the

membrane and

the

cap

gasket with new ones.

Check

the

inlet valve and

the

outlet

valve.

Clean

at

regular interoals.

)

Polaris Playmate 1971 Install guide

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