Polaris Playmate 1971 Guida all'installazione

1971

• • a • •:

" "

---

S#OP

M~NUA,L

INTRODUCTION

This Manual

has

been prepared

a guide to maintenance, disassembly

and

assembly

the Polaris snowmobiles.

reading this Manual carefully,

you

can obtain knowledge

the machine,

which

will

helpful

maintenance.

The meaning

maintenance

perform

preventive maintenance

and

justment

your

snowmobile

keep

top

running condition.

accord-

ance

with

the instructions supplied

this Manual,

all

machines

should

inspected

and

serviced

periodically

This Manual is

divided

into

sections showing detailed photographs, cover-

ing construction details, disassembly, inspection, maintenance,

and

assembly

specific parts

the machine.

POLARIS INDUSTRIES

Division

textron

nc.

Service Department

Roseau, Minn.

TABLE

OF CONTENTS

MODEL

SPECIFICATIONS

...

. .

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

PLAYMATE

-CHARGER -

-MUSTANG -

VOYAGER

ENG

INE

DATA

.....

175cc -795cc

1 - 2

COMMON SPECIFICATIONS FOR

ALL

MODELS.

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

TORQUE PATTERNS

CONDENSED SERVICE

DATA

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

ELECTRICAL

SYSTEM

INFORMATION

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

9 -

WIRING SCHEMATICS

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

-14

TROUBLE

SHOOTING

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

INSTRUCTION FOR

FUEL

PUMP.

.........

....

..........

16 -18

MODEL

OF 62 -24

INSTRUCTION FOR CARBURETOR

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

19 -26

MODEL

-30

INSTRUCTION FOR POLARIS ENGINES

........

...

.........

-43

CONSTRUCTION

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

27 -29

STARTING

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

REMOVAL

OF ENGINE

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

-32

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

...

-36

-ASSEMBLY OF ENGINE

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

37 -43

BODY

AND

TRIM

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

44 -

DISASSEMBLY OF BODY,

TRIM

& CONSOLE

DRIVE

AND

BRAKE

...........

DISASSEMBLY OF CHAINCASE

STEERING

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

STEERING DISASSEMBLY

STEERING ASSEMBLY

..........

46 -47

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

TRACK

AND

SUSPENSION.

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

...........

DISASSEMBLY OF

TRACK

& SUSPENSION

.......

...........

.49

ASSEMBLY OF

TRACK

& SUSPENSION

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

POWER

SLIDE

TRACK

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

POWER

SLIDE

TRACK

ALIGNMENT.

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

DRIFT

SKIPPER -

TRACK

TENSION

........

DRIFT

SKIPPER -

TRACK

ALIGNMENT

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

...

u..

...J

:iE

PLAYMATE

Track Type -all rubber

Track Length on

Ground

32"

Track Width -

12"

Overall Length W/Ski -

92"

Width -

1/2"

Height W/Windshield -

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 -

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.

Volt

electric start available on

398,432,

& 488

MODEL

Track Type -rubber w/steel talons

Track Length on Ground -

45"

Track Width -

1/2

Overall Length W/Ski -107"

Width -

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

795cc

....

(/,)

e::(

(/,)

..J

:2E

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 -

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

volt

electric start u

OYAGER

ack Type -rubber w/

steel

talons

Track Length on Ground -

45"

ack Width -30"

Overall Length W/

i -

108"

dth

1/2"

ight W/Wi

ndsh

eld

49"

Height

Less

Wind

shie

ld - 36 1/

Weight - appr

. 590

Ibs

usp

nsi

on - st

dard bogie

Transmi

ion - f

ward

reverse

uel

city - 5.9

Engine - 488cc

Pola

ris Star 2 cycle w/el

tric

start

ENGINE

DATA

POLARIS

EC17P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

Cylinders

Displacement -

Cu.

. (cc)

RPM -Standard

Carburetor

Make, Model & Size

Number

Used

Ignition

Make & Model

Type -Energy Transfer

(mm)

5S(mm)

175

(cc)

(4,000 5,000)

Mikuni

VM24

Ida Denki

( )

Capacitor Discharge ( )

Magneto (

Breaker

Point

Gap -Inch

(mm)

.010

-.017

Automatic

Timing

Advance -Yes ( )

(x)

Tim

ing Checked

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

flywheel)

NGK

B7ES -

AC43XL

.017

.020

Volts

Watts

20 - 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

POLARI

S EC29P

Bore -

hes

(mm)

Stroke -

s (mm)

No.

Cylinde

Displacement -

. (c

RPM -Standard

Carburetor

Make, Model &

Number

Ignition

S(mm)

55.6 (mm)

294

(cc)

(6,000 6,500)

Mikuni

VM26

26mm.

Make & Model Kokusan

Type

- Energy Transfer ( x )

Capacitor Discharge ( )

Magneto ( )

Breaker

Point

Gap -Inch (mm) .

010

.017

(inch)

Automatic

Timing

Advance -

Yes

(x)

( )

Timing Checked

at-

Setting -

°BTDC;

Inches (mm)

Spark Plug Make & Model

Spark Plug Gap -Inch (mm)

Alternator

Output

Fuel/Oil Ratio

Advance (

Retard

(x)

- .

012

(use marks

flywh

eel)

AC43XL

NGK

B7ES

.017

.020

Volts

Watts

-1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

)

ENGINE

DATA

POLARIS

EC34P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

Cylinders

Displacement -Cu.

. (cc)

RPM -Standard

Carburetor

Make, Model & Size

Number

Used

Ignition

(mm)

55.6

(mm)

335

(cc)

(6,000 6,500)

Mikuni

VM26

26mm

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

Setting -

°BTDC

: Inches (mm)

Spark Plug Make & Model

Spark Plug Gap -

ch (mm)

Alternator

Output

Fuel/Oil

Ratio

Special

Oil

Recommendations:

( )

Advance (

Retard

(x)

80 -.012

(use

marks

flywheel)

AC43XL

NGKB7ES

.017 -.020 (in.)

Volts

75 Watts

20 - 1

Polaris Snowmobile

Oil

POLARIS

EC40P

Bore -Inches

(mm)

Stroke -Inches

(mm)

No.

Cylinders

Displacement -Cu. In.

(ee)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition

Make & Model

(mm)

398

(cc)

(6,000 6,500)

Mikuni

VM30

Kokusan

Type

-Energy Transfer

(x)

Capacitor Discharge ( )

Magneto ( )

Breaker Point Gap -Inch (mm) .

010

.017

Automatic

Timing

Advance -

Yes

(x)

Timing

Checked

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 -

(use marks

flywheel)

AC43XL

NGKB7

.017 -.020

Volts

watts

20 - 1

Polaris Snowmobile

Oil

ENGINE

DATA

POLARIS

EC44P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

Cylinders

Displacement -Cu. In. (cc)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition:

67.75

(mm)

432

(cc)

(6,000

6,500

)

Mikuni

VM30

Make & Model Kokusan

Type

-Energy Transfer (

Capacitor Discharge ( )

Magneto ( )

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

Automatic

Timing

Advance

Yes

(x)

( )

Timing

Checked

-Advance (

Retard

(x)

Setting -

°BTDC:

Inches

(mm)

.012

(use marks on flywheel)

Spark Plug Make & Model

AC43XL

NGKB7ES

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

020

Alternator

Output

Volts

Watts

Fuel/Oil

Ratio

20 - 1

Special

Oil

Recommendations: Polaris Snomobile

Oil

POLARIS

EC50P

Bore -Inches (mm)

Stroke -Inches

(mm)

No.

Cylinders

Displacement -Cu. In. (cc)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition:

Make & Model

72 (mm)

(mm)

488 (cc)

(6,000 6,500)

Mikuni

VM30

30mm

Kokusan

Type

-Energy Transfer

(x)

Capacitor Discharge ( )

Magneto ( )

Breaker

Point

Gap -Inch (mm) .

010

- .

017

Automatic

Timing

Advance

Yes

(x)

()

Timing

Checked

-Advance (

Retard

(x)

Setting -

°BTDC:

Inches (mm)

.012

(use

marks

flywheel)

Spark Plug Make & Model

AC43XL

B7ES

(NGK)

Spark Plug Gap -Inch

(mm)

.017 -

.020

Alternator

Output

Volts

Watts

Fuel/Oil

Ratio

- 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

)

ENGINE

DATA

POLARIS

STAR EC65PF

Bore -Inches

(mm)

Stroke -Inches (mm)

No.

Cylinders

splacement -

. (ee)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition

.75

(mm)

649

(cc)

(7,000)

Tillotson

Make & Model Kokusan

Type

-Energy Transfer

()

Capacitor Discharge (

Magneto ( )

Breaker

Point

Gap -

Inch

(mm) None

Automatic

Timing

Advance -

Yes

(x)

Timing

Checked

( )

Advance

)

Retard ( )

Setting -

°BTDC:

Inch

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

Spark Plug Make &

Mod

Spark Plug Gap -Inch (mm)

with

timing

light

AC41XL

NGKB8ES

030

Alternator

Output

Volts

Watts

Fuel/Oil

Ratio 20 - 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

POLARIS

STAR EC79PF _

Bore -

ches

(mm)

Stroke -Inch

(mm)

Cylinders

Displacement -Cu.

. (cc)

RPM -Standard

Carburetor:

Make, Model & Size

Number

Used

Ignition

(mm)

795

(

)

(7,000)

Tillotson

Make & Model Kokusan

Type

-Energy Transfer

()

Capacitor Discharge

(x)

Magneto ( )

Breaker Point Gap -Inch (mm) None

Automatic

Timing

Advance -

Yes

(x)

No ( )

Timing

Checked

-Advance

(x)

Retard ( )

Setting

_oBTDC

: Inch

(mm)

3.5 max.(mm) 5,000ck

with

timing

light

Spark Plug Make & Model

Spark Plug Gap -Inch (mm)

AC41XL

NGKB8ES

.0300

Alternator

Output

Volts

Watts

Fuel/Oil Ratio

- 1

Special

Oil

Recommendations: Polaris Snowmobile

Oil

I-

::::>

I-

e:(

u..

Cyl.

Oisp.

(CC)

175

294

335

398

436

488

648

795

Engine Year

Models

Built

EC17P 1969·1970

29P

1969·1970

EC35P 1969·1970

EC40P 1969·1970

EC44P 1969·1970

EC50P 1969·1970

EC65P 1969

··

1970

EC79P 1969·1970

COMMON SPECIFICATIOI\1S FOR

ALL

MODELS

BOLT TORQUE

Standard Piston

Skirt

No. Piston Ring Crank·

Cylinder Stroke

Bore Cyl.

Bore (MM)

Clearance End Gap

Head

Case

(MM) Cyl. (Inches) (Inch

) 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.

·23

2 .005/.007

.010/

.016 18

ft.

21·23

72 60 2

.00

55/.0075 .012/.0175 18 ft. lb. 21·23

67.75

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

- - 3 .0055/.0075

.012/

.0175 18

. lb. 21·23

CD CD

CRANKCASETORQUE?ATTERN

RUNNING TIMING CAN

CHECKED BY

MOVING

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.

T.O.C. T.O

.C.

T.O

.C.

T.O.

-- - 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 --

CYLINDER

HEAD TORQUE PATT

R.P.M.

Engine I

6,000 i

6,000

.....

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