Polaris Playmate 1971 Shop Manual Download

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Summary of Contents for Playmate 1971

Page 1: ...1971 1 a to S OP M NUA L ...

Page 2: ...orm 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 ofspecific parts of the machine POLAR...

Page 3: ...RETOR 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 TR...

Page 4: ...dth 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...

Page 5: ...rque 0 Matic Fuel Capacity 5 9 gals Engine Options 398 Polaris 2 cyl 488 Polaris 2 cyl Available with 12 volt electric start u VOYAGER Track Type rubber w steel talons Track Length on Ground 45 Track Width 30 Overall Length W Ski 108 Width 39 1 2 Height W Windshield 49 Height Less Windshield 36 1 2 Weight approx 590 Ibs Suspension standard bogie Transmission forward reverse Fuel Capacity 5 9 gal E...

Page 6: ...l NGK B7ES AC43XL 017 020 12 Volts 35 Watts 20 1 Special Oil Recommendations Polaris Snowmobile Oil POLARIS EC29P Bore Inches mm Stroke Inches mm No of Cylinders Displacement Cu In cc RPM Standard Carburetor Make Model Size Number Used Ignition 5S 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 0...

Page 7: ...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 In...

Page 8: ... 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 ...

Page 9: ...0 Alternator Output 12 Volts 75 Watts Fuel Oil Ratio 20 1 Special Oil Recommendations Polaris Snowmobile Oil 6 POLARIS STAR EC79PF _ Bore Inches mm Stroke Inches 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 m...

Page 10: ...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 0055 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 THE ADVANCE CAM TO THE FUL L ADVANCE POSIT ION SPARK PLUG GAP 017 020 STATIC TIMING RUNNING TIMI...

Page 11: ...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 Adj 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 Polari...

Page 12: ...ghts 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 instrument panel in the electric start system to protect the wiring harness and eliminate the danger of fire due to a short circuit ...

Page 13: ...tems above 2 If starter doesn t work a Check the wires between the starter solenoid and battery b Check 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 this cuts off all lights to prevent burning ...

Page 14: ...IL IGNITION STARTING SWITCH WIRING SCHEMATIC VOYAGER EXTERNAL IGNITION COIL 7 5 AMP STARTING STARTER MOTOR SOLENOID f h tthl l AM l iC f ATi i I J LIJ L i 4 I I 1 DUAL BEAM HEADLITE I I L I I I 1 I 1 I J TO SPEEDOMETER It TACHOMETER LITE IF INCLUDEP ...

Page 15: ...Jr 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 SWITCH 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 LITES I 1 I I T u I I L f I I L _ _ _ _ J u N ...

Page 16: ...STARTING MOTOR L 4 BREAKER r i SP R I I L J EXTERNAL IGNITION COIL IGNITION STARTING SWITCH SPARKPLUG EXTERNAL IGNITION COIL a lAMP r t l BAT I I LII SED ON MUSTANG ONLY ___ I __ I I LITE SWITCH DUAL BEAM HEADLITE I I WARN ING 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 ...

Page 17: ...GINE 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 IGNITION LITE SWITCH 2460070 MAIN HARNESS 2460069 HEADLIGHT HARNESS 4030008 HI anllf1HT 4020023 CONNECTOR 2 432008 TAIL LIGHT ASSEMBL Y 2460068 TAIL LIGHT WIRE 5223409 WIRING HARNESS CLIP HEADLIGHT CD l o t CONNE I TAIL LIG HT u ...

Page 18: ...in jet e needle and seat not seating properly f incorrect float level 8 Engine runs but overheats a incorrect main jet b incorrect 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...

Page 19: ...et 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 th...

Page 20: ...p 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 Ibs 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 pre...

Page 21: ...c ElBOW IN LET OIAPHRAGM c VALVE GUIDE c ELBOW OUTlEJ CAP MEMBRANE ENGINE ROOM PUMP CHAMBER Figure 2 Figure 3 DISK VALVE CORRECT INCORRECT Figure 4 18 TOPBOuY ...

Page 22: ...l air mixture for initial starting and delivered to the engine through the fuel nozzle In this starter system you can be sure of initial starting without any skill of operation since both fuel and air are measured and the constant fuel air mixture ratio is always secured 1 3 Pilot system Fig 3 4 The pilot system is designed to deliver gasoline during idling and low speed driving Fuel for idling is...

Page 23: ...tle stop screw of each carburetor evenly setting the number at about 1 000 rpm which is a little higher than normal idling speed b Warm up the engine completely c Find out and set the position where the number of rpms of the engine becomes maximum by opening or clos ing the air screws one by one about 1 2 each time In this case be sure to use a tachometer d Return each screw of the throttle valve ...

Page 24: ...soline for washing out and blow dry with an air compressor Observe the following instructions 4 1 Starter system a The starter jet is driven into the float chamber body Jets should never be cleaned by drills or wire b Be careful in handling the starter plunger since scratches on the circumference cause malfunctioning and scratches on the base prevent a tight seal which may cause a fuel leak while ...

Page 25: ...engine is over heated 2 When the choke is opened the condition becomes better 3 Acceleration is poor 4 The ignition plug is burnt 5 Rotations are irregular 6 Exhaust gas is lean Our carburetor is so constructed that the parts to adjust vary according to the degree of throttle opening After having checked whether the cause of disorder is due to an over rich mixture or to an over lean mixture confir...

Page 26: ...ment of the float system The overflow during driving or operation of the engine could be caused by a loose attachment due to worn needle valves the clog of dirt and dust and the malfunctioning of the float etc Needle valve Worn Spring is damaged or worn Replacement with a new one Spring seat is worn or scratched Clogged with dirt and dust Cleaning Float Malfunctioning due to bent guide pin Adjustm...

Page 27: ... I 1 I I I GUM CAP I I I I I 1II CABLE ADJUSTER I II I 1 CABLE ADJUSTER LOCK NUT 1 L _ 1 I I PLUNGER SPR I NG I 1 I I I I I 1 I IL STARTER JET PLUN GER CAP STARTER PLUNGE R INLET STARTER AIR INLET BREEO A I R STARTER EMULSION TUBE Figure 2 24 THROTTlE VALVE ...

Page 28: ... THROTTlE VALVE H L J THROTTLE STOP SCREW I II PILOT JET Figure 3 THROTTlE VAL V E JET NEEOLE BY PASS AIR JET PILOT 0 UTlET Figure 4 J 25 ...

Page 29: ...c THROTTLE VALVE JET NEEDLE A IR JET NEEDLE JET MAIN JET Figure 5 c THROTTLE VALVE JET NEEDLE AIR JET NEEDLE JET MAIN JET c Figure 6 26 ...

Page 30: ...nd positive No cumbersome fuel supply adjustment is required 2 Construction The EC series engines are air cooled 2 cycle 2 cylinder gasoline engines The opening and closing of the intake and ex haust ports are effected by the moving pistons in the cylinders The scavenging out of and suction into the cylinder are effected by compressing action taking place in the crankcase The lubrication of the en...

Page 31: ...ng of the bearing when the engine starts Strike lightly before tightening the cap screws for upper and lower crankcase to the specified torque Make adjustment by inserting packings of suitable thickness Figure 1 3 2 Crankshaft Connecting Rod and Relating Pans a The crankshaft is composed of individually machined parts made of carbon steel viz one front crankshaft two central crankshafts one rear c...

Page 32: ... in operation for a long period of time carbon will be depositing on the top of the pistons To provide a good sealing fit for the cylinder so that the high pressure gas is not lost two rectangle section piston rings made of special alloycast iron are used These piston rings sometimes get stuck in the piston ring grooves This deposit should be removed whenever the pistons are disassembled 3 5 Start...

Page 33: ...tarter each time only after the engine has completely stopped 2 Never engage the starter while the engine is still rotating 4 3 Warming up After starting the motor idle the engine for 2 or 3 minutes with the choke partially pulled out Push back the choke control gradually as the engine gets warm Never run the engine at high speed without load the moving parts may lose lubrication and burn out 4 4 ...

Page 34: ...ed over side of driven clutch 3 Disconnect exhaust pipe by removing the two springs which hold pipe to manifold See Fig A 2 4 Disconnect all electrical wires Engine Con nector as shown in Fig A 3 5 Use vise grips or hose clip shown in Fig A 3 to clamp off gas flow in gas line so there will be no gas leakage Use all safety precautions 6 Disconnect throttle cable at throttle control assembly on hand...

Page 35: ...rs and wiring b Make sure the proper alignment tool is used as shown in Fig B 1 c After motor is aligned properly torque motor mount nuts to 55 ft Ibs d Install drive belt by placing drive belt on drive clutch first then open driven clutch using same procedure as when removing drive belt shown in Fig A 1 TOOL NEEDED One piece 1 2 key stock 21 inches long 1 Remove drive belt as shown in Operator s ...

Page 36: ...t No 2 Figure 1 2A Use proper wrench and tap with hammer on wrench handle to free retaining bolt No 2 Use clutch puller No 2870030 to pull stationary face off crankshaft Figure 1 2B Figure 1 3 Figure 1 4 33 3 Remove carburetors Two standard half inch nuts on each carburetor As shown in figure 1 3 4 Remove fan housing It is not necessary to reo move recoil starter unless it is necessary to work on ...

Page 37: ...ve the two hold down screws in the stator plate assembly as shown in figure 1 7 Remove the four screws in the fly wheel side of crankshaft seal If the engine is to be com pletely disassembled the seal will come out by itself when the case is split The crank case should be split carefully Pry out the seal ap plying pressure at the bolt hole areas as shown in figure 1 8 Take care not to distort the ...

Page 38: ...e move cylinder base nuts and remove cylinders and gaskets As shown in figure 1 10 11 Remove snap ring from each side of piston as shown in figure 1 11 12 Insert appropriate driver into wrist pin and tap wrist pin out Use caution to avoid putting un do strain on connecting rod Remove pistons Refer to figure 1 12 35 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 12 ...

Page 39: ...the plate loose as damage to sealing surface will result Refer to figure 1 14 15 Remove crank case bolts then tap the fan hous ing brackets with a soft hammer to break the seal surface loose and split the lApper and low er half of crank case Make sure all of the bolts are removed Refer to figure 1 15 16 Do not use this method to split crank case Damage to the sealing surface will always result as ...

Page 40: ...e is a spacer ring on the fan housing side of crank case next to the main bearing See figure 2 3 4 Replace upper half of crankcase and replace cap screws with care Strike lightly on end of crank shaft before tightening the cap screws as shown in Operation Instructions on page 2a Fig_ 1 Torque large cap screws to 25 foot pounds and small cap screws to 18 foot pounds as shown in figure 2 4 Torque Pa...

Page 41: ... As shown in figure 2 6 7 Grease the wrist pin bearing and install in the connecting rod Put the connecting rod spacers on the end of the bearing with the counter sunk side toward the bearing See figure 2 7_ 8 The piston is installed with the F marking to ward the fan In this position the ring locator pins will be toward the exhaust side of the engine As shown in figure 2 8 38 Figure 2 5 Figure 2 ...

Page 42: ... in figure 2 10 11 Do not use the method sometimes employed as this bad example shows or serious damage to rings will result Do not spread the rings more than necessary as fatigue of ring material will surely result See figure 2 11 12 liberally lubricate the piston and rings and in stall the cylinder making sure the exhaust port is toward the appropriate side of engine As shown in figure 2 12 39 F...

Page 43: ...s may catch on the port The cylinder must be lined up true with the piston or wedg ing will result The use of a screw driver to re place ring will almost always cause damage to the rings Unless extreme care is exerted this method should be avoided Refer to figure 2 14 15 The head gasket is installed with the large dia meter of metal on the gasket toward the cylin der The cylinder head is clearly m...

Page 44: ...er cam with a very thin coat of grease A special silicon cam lubricant is the proper grease to use Refer to figure 2 19 20 Replace the woodruff key in crank shaft and align the key way in the fly wheel with the crank shaft key carefully install the fly wheel of crank shaft Use extreme care to be sure that the fiber rub block on ignition points do not catch on the contact breaker cam causing point ...

Page 45: ...3 Adjust point gap on number 1 cylinder car buretor side of engine to the same point gap as the first set of points result See figure 2 23 24 Attach timing light to number 1 cylinder red primary lead Rotate fly wheel so that timing mark on the fly wheel is in line with timing mark at the top of fan housing Loosen the two breaker plate mounting screws that hold the number 1 set of breaker points in...

Page 46: ...2 25 Re install outer fan housing As shown in fig ure 2 25 26 Re install carburetor making sure heat barrier and gaskets are in place As shown in figure 2 26 43 J Figure 2 25 Figure 2 26 J ...

Page 47: ...base of Tee Pee two each side See Figure 3 2 4 Lift Tee Pee up to clear cap screws tilt Tee Pee and tank back See Figure 3 3 5 Disconnect tail light wires and gas tank hose Gas tank Tee Pee and bumper are now free to be removed completely from machine See Fig ure 3 3 6 With both hands grasp seat firmly slide back approximately 1 inch and lift up free of body holddown See Figure 3 4 44 Figure 3 1 F...

Page 48: ...ndle assembly and brake cable from brake handle assembly See Figure 3 6 10 Disconnect all electrical wires from console to machine 11 Disconnect speedometer cable 12 Remove four bolts holding console in place See Figure 3 7 13 Remove four bolts on handle bar and remove handle bar See Figure 3 7 14 Remove steering post grommet then lift con sole up carefully See Figure 3 7 J Figure 3 5 Figure 3 6 F...

Page 49: ...re 4 1 2 Release chain adjusting bolt See A Figure 4 2 3 Remove cap screw on upper and lower sproc kets See B Figure 4 2 4 Pull sprockets off shafts then remove sanp ring on lower shaft 5 Remove cap screw on end of driven clutch pull clutch off shaft See Figure 4 3 46 Figure 4 1 Figure 4 2 Figure 4 3 ...

Page 50: ...ure 4 5 8 Loosen bearing lock first by loosening socket head set screw then using a punch and hammer turning collar until loose See Figure 4 6 9 Slide collar back Move drive shaft to the right side of the machine and drop down 10 Brake assembly may be removed by removing chaincase rear cover 11 Heat on case may be used to remove bearings from case See Figure 4 7 Figure 4 4 Figure 4 5 Figure 4 6 Fi...

Page 51: ...ndle by removing steering arm bolt sliding steering arm up and off See E Figure 5 1 6 Spindle will drop down through body when raising machine up See A Figure 5 2 7 Remove ski assembly by removing spring saddle bolt See B Figure 5 2 5 2 Steering Assembly 1 Assemble steering in the reverse order of dis assembly use a lubricant on saddle bushing spindle housing bushing and nylon flange bush ing 2 St...

Page 52: ...n remove two cap screws follow the same procedure for the two cap screws on opposite side of machine See figure 6 1 3 Remove drive shaft and track Refer to Num bers 1 2 3 4 on page 46 and 7 8 9 on page 47 4 Assemble machine in the reverse order of dis assembly Use care in assembling all parts to insure proper track tension track alignment Figure 6 1 49 ...

Page 53: ...ssive wear to the track and the slide rail Check by supporting the rear of the machine with the track off the ground Start the engine and accelerate slowly to turn the track If the track runs to the left tighten the left side track adjusting screw if to the right the right adjusting screw Again run the track slowly and readjust if necessary Tighten lock nuts A 3 Ride Adjustment The Power Slide Sus...

Page 54: ...salignment can cause excessive sprocket wear Check by supporting rear of machine with track off ground Start engine and accelerate slowly to turn track If sprockets run close to or against one side of track clips tighten track ad justing screw A on that side of the track Run track slowly to check and readjust if necessary 3 Drift Skipper Adjustment See Figure 6 3 1 Normal setting best for an avera...

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