Polaris TX Starfire Owner'S Manual Download

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Summary of Contents for TX Starfire

Page 1: ...OWNERS TECHNICAL MANUAL 3 50...

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Page 5: ...nual covers not only technical and service information but a certain amount of theory related to the contents enclosed All information and specifications are printed to the best of our knowledge at th...

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Page 7: ...TX Starflame Torque Patterns Twin Cylinder Ignition Kokusan Denki Breakerless Flywheel Trouble Shooting Twin Cylinder Ignition Circuit Checking Of CDI Unit By Tester Three Cylinder Ignition Trouble S...

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Page 9: ...e changed These changes were made to further improve the handling characteristics of this machine As compared to the 1972 Polaris TX Starfire the 73 chassis is 6 longer Note A This is required for imp...

Page 10: ...ial Rubber with machine riveted cleats or molded rubber Standard gear ratio 13 35 16 39 16 35 17 35 Ignition Type Kokusan Capacitor Discharge Timing Specs 5000 3 5mmBTDC 3 5mmBTDC 3 5mmBTDC 3 75mmBTDC...

Page 11: ...rake levers to positions better suiting the individual s driving style for maximum control and safety WARNING The brake lever is part of the master cylinder assembly and will not function properly if...

Page 12: ...dically Before each race we strongly recommend that the following be inspected 1 Check brake hoses and fittings for signs of abrasion and leakage 2 Check fluid level in master cylinder If low use ONLY...

Page 13: ...top bleeder valve to direct fluid away from painted surfaces Refer to Fig 2 Item A 3 Squeeze brake lever slowly a full stroke and hold to release air through tube unscrew top bleeder valve 3 4 turn Cl...

Page 14: ...r 1973 TX Starfire performance machine comes equipped with the following sprocket ratios Machine 294 335 440 650 Gears 13 35 16 39 16 35 17 35 Chain pitch Optional sprockets are as follows Number of t...

Page 15: ...6 1 67 64 1 70 68 1 78 68 1 84 64 1 86 66 1 95 68 2 06 62 2 05 66 2 16 66 2 19 62 2 30 64 2 32 62 2 41 66 2 42 64 2 50 62 2 56 66 2 60 64 2 70 60 2 73 66 2 79 64 2 91 60 2 93 64 3 00 64 3 18 64 3 25 6...

Page 16: ...kly basis The proper amount of oil is pint 237cc in an empty case DRIVE CHAIN TENSION To maintain lasting chain and sprocket life the drive chain tension is very important Chain tension should be chec...

Page 17: ...2 The sheave offset is 5 8 0 This is adjusted by either adding or removing the spacer washers from behind the driven clutch After alignment you should very carefully start the engine accelerate the ma...

Page 18: ...ity it is important that weekly all nuts bolts and tie rod ends be checked for looseness or stress damage Ski tow in should be checked at the same time Skis should be parallel when in the straight ahe...

Page 19: ...nt for most conditions it will be necessary to add or remove some of these cleats depending on the track and conditions you are running on IMPORTANT After every day of racing check track mate rial cle...

Page 20: ...installed because many people have their own ideas of which stud is the best How ever we do recommend the carbide tipped ice stud available from Special Sports Products Corporation 1573 Pinecrest Dri...

Page 21: ...gnment will cause the track to run against one side of the slide rail or the other causing dragging action and also resulting in poor performance The proper tension is accomplished by the following 1...

Page 22: ...k to see that track is well centered between tunnel and slide rail To adjust loosen lock nut and tighten adjuster bolt on side where track is closest to frame Tighten lock nut and recheck alignment WA...

Page 23: ...NOTES 21...

Page 24: ...ove track See opposite page NOTE Leave chaincase as is It is not necessary to remove cover chain or gears 1 Remove slide rail 2 Loosen front drive shaft bearing lock collar 3 Loosen only the bottom tw...

Page 25: ...TRACK REMOVAL Con t 3 LOOSEN BOTTOM SUPPORT BOLTS 2 LOOSEN LOCK COLLAR 4 SLIDE SHAFT INTO BEARING 23...

Page 26: ...on t When reinstalling slide rail be certain that you use the proper mounting holes in the tunnel See diagram NOTES PROPER MOUNTING HOLE THIS HOLE MAY BE USED IF LESS SKI PRESSURE IS DESIRED 24 PROPER...

Page 27: ...o 2 adjustments for driver weight For drivers between 100 160 pounds put the springs in the lowest position for drivers 160 pounds and over put the springs in the top position refer to item no 1 2 Fro...

Page 28: ...ling characteristics for your style of riding Slide rails should be visually inspected weekly for worn or dam aged parts if worn or damaged they must be replaced prior to continued use WARNING Never o...

Page 29: ...ew belt NOTE Drive belts must be kept free of dirt grease oil and moisture both when in use and in storage BELT REMOVAL AND INSTALLATION See Diagram 1 With hood off open the driven sheave by pushing a...

Page 30: ...mum amount of horsepower from the engine to the ground This is accomplished by weights and a spring inside the unit reacting to overcome the centrifugal force applied to it from the engine The spring...

Page 31: ...re too heavy too much weight you will have a good engagement the engine RPM s will be low and drive the clutch into high gear then the RPM s will gradually increase See diagram no 2 Diagram 2 RPM 10 0...

Page 32: ...ed RPM and stay there on both up shifting and down shifting See diagram no 3 Diagram 3 RPM 10 000 8 000 6 000 4 000 2 000 NOTE It is essential that the drive clutch be disassembled weekly and cleaned...

Page 33: ...ch should run 9 000 9 000 9 000 9 000 Optional Weights Part Number 5630090 5630089 5630068 5630064 Weight of Weight in grams Q 38g p 42g M 47g H 50g 5630096 5630080 T 32g N 54g Optional Springs 179 17...

Page 34: ...re place if necessary Spring too heavy replace with lighter dia spring OR Moving surfaces dirty clean and oi I Replace weight with next lighter weight Check engine over for possible loss of horsepowe...

Page 35: ...better balance and less maintenance As stated above this clutch is relatively maintenance free We suggest visual inspection weekly Lubrication is necessary be tween the helix hub and the stationary sh...

Page 36: ...component of the TX Starflame two cycle engine is the piston When the piston moves upward in the cylinder 1st stroke it draws fuel into the crankcase while also com pressing fuel in the combustion cha...

Page 37: ...ep surplus fuel tightly capped to prevent evaporation loss of volatility and power Too little oil means inadequate lubrication too much oil means spark plug fouling rapid carbonization and over heated...

Page 38: ...Connecting Rod Brg Type Needle Bearing Cylinder Material Large fin aluminum casting w chrome liner Number of Main Bearings 5 5 7 7 Type of Main Bearings Ball Ball Ball Ball Piston Type High silicone...

Page 39: ...ew engines We strongly recommend a break in period of 30 minutes operating time During the first 15 minutes maximum throttle should not exceed 4 000 RPM with no load The second 15 minute break in peri...

Page 40: ...suggest that you install new piston rings Do not hone the 1973 Starflame cylinders as you will damage the chrome liner A break in period of 10 15 minutes should be followed as per item no 1 after re...

Page 41: ...he lip point no 1 and unwind lock from piston To replace put point no 2 into snap ring groove and spiral into pin bore ring groove NOTE These retainers should be replaced with new retainers after they...

Page 42: ...CD CD CD CD CD 0 PTO CYLINDER HEAD TWIN CYLINDER CRANKCASE 14 17 Ft Lbs on new head gasket 14 17 Ft Lbs 13 15 Ft Lbs on used head gasket 24 28 Ft Lbs PTO CD 0 CD 0 CD CD j CD PTO THREE CYLINDER CRANK...

Page 43: ...TWIN CYLINDER IGNITION CRANKSHAFT C O IGNITION UNIT IGNITION COIL 41...

Page 44: ...vancer Weight 4 5 kg including ring gear Moment of inertia 219 kg cm2 including ring gear 2 Construction 2 1 Outline This GK 352 type flywheel magneto applys a new control unit called Capacitor Discha...

Page 45: ...erates high voltage 2 4 CDI Unit CDI unit has an outer appearance as shown in drawing In the steel case are incorporated diodes and thyristers etc and to provide a shock proof construction the whole p...

Page 46: ...it disconnected 5 Checking of Sparking Time Since this igniter is of breakerless system sparking time rarely goes out of order But if necessary use a strobe light for checking If the timing mark of a...

Page 47: ...or when a secondary coil does not generate high voltage check the following points 1 Exciting Coil Using a tester Ohm meter check the continuity between coil plate and lead wire black If resistance m...

Page 48: ...ead wire white should be oo 2 When connected lead wire white to terminal of tester and lead wire brown to terminal electricity must flow 3 When connected in contrastwith the above electricity must not...

Page 49: ...NOTES 47...

Page 50: ...ng 3 Disconnection of secondary winding 4 Short circuit of secondary winding 00 In 3 4 normal resistance to be 1100 ohms 4 Flywheel 1 Breaking of exciter coil normally 250 ohms magneto between plate a...

Page 51: ...el 1 Breaking of exciter coil magneto 2 Layer short of exciter coil 3 Layer short of pulser coil 5 CDI Unit 1 Deterioration of CDI unit SPARKS CAN BE 1 Flywheel 1 Breakage of key slot of crankshaft OB...

Page 52: ...COIL IGNITION COIL BLACK OFF TO INDICATE OFF CON ABOUT 20HMS WHITE ON TO INDICATE ON CON ABOUT 20HMS BLACK WHITE BLACK RED ON OFF OFF CON BROWN OFF OFF OFF OFF ORANGE CON OFF OFF OFF NOTE CON represe...

Page 53: ...THREE CYLINDER IGNITION CRA N KSHAFT C D IGNITION 51...

Page 54: ...ting Output Moment of inertia 2 Construction 2 1 Introduction 500 1 000 RPM Max 12 000 RPM 7 mm or more at 500 RPM 16 mm and less at 7 000 RPM 12V 75W AC at 4 500 RPM 13V or more at 4 500 RPM 16V and...

Page 55: ...in the inside center which are of laminated steel plates with plastic powder coating Out of six four pole cores are directly wound coils and two leads are led out to light two bulbs 12V 37 5W each In...

Page 56: ...ages when the engine operates in the inverse direction The parts are molded together with polyester resin in the steel case for providing para shock construction Furthermore as this CDI unit is intend...

Page 57: ...couplers in series 3 Mounting and Dismounting of Generator 3 1 Mounting 1 To mount the stator on an engine confirm that any dust and or chips are not left on the surfaces to be set together and give c...

Page 58: ...occasional that a low intelligence strobe light shows the timing retarded as it has retarded radiation itself 3 2 Dismounting 1 To dismount this ignition system pull out the rotor first Draw out hexag...

Page 59: ...xciter Coil II Pulser Coil If the tester shows resistance 20 22 ohms between lead wire green and the lead wire blue and if it is co be tween the stator and the lead wire either green or blue it is nor...

Page 60: ...ck to the minus 6 If a pointer of tester swings once and then resets when connected the lead wire black with white stripe to the plus and the lead wire orange to the minus 7 If current f lows when con...

Page 61: ...e off first and then exciter lead gets off the main thyristor would be damaged due to overvoltage 2 Off of coupler between the CDI unit and ignition coils damage of the main thyristor due to over volt...

Page 62: ...ected portion is normal However to measure the spark output in inverse revolution be sure not to raise its speed over 500 RPM Since this unit has applied a circuit which dis solves only ignition signa...

Page 63: ...NOTES 61...

Page 64: ...it of lead wire 1 2 3 4 1 2 3 4 5 1 Breaking of primary winding I 0 _ 7 _n_ Short circuit of primary windi Breaking of secondary winding J 0 11 850 _n_ Short c1rcu1t of secondary wmdmg Breaking of exc...

Page 65: ...onnection of reverse rotation 0 prevention coil w 5 CDI unit 1 Wrong circuit of red white black white SPARK CAN BE 1 Magneto 1 Breakage of key slot of crankshaft OBTAINED BUT 2 Adverse magnetizing of...

Page 66: ...Y REVERSE ROTATION COIL COIL LEAD LEAD LEAD PREVENTION COIL RED WHITE BLACK WHITE BLACK ORANGE BLUE GREEN RED OFF 2M fl OFF OFF OFF OFF m 0 WHITE OFF OFF 200 500 _fl_ OFF ON ON s 0 BLACK WHITE ON OFF...

Page 67: ...CONNECTOR ENGINE CONNECTOR JYELLO 1 TWIN CYLINDER ENGINE CONNECTOR _ Q O ELLOW THREE CYLINDER THREE WAY MOLDED CONNECTORS YELLOW l RED WHITE LEADS TO TACHOMETER I BROWN R ED W HI TI BROWN YELLOW DIAG...

Page 68: ...Starter j MIKUNI CARBURETORS AND FUEL PUMPS I needle I I I I I Pilot jet I I I Main 1 1 J c Air Fuel Mixture 66...

Page 69: ...or wear of the valve spring 2 Damage of the di aphragm or the membrane 3 Leak of wave motion pressure 4 Leak of fuel due to poor piping Corrections 1 Replacement of the pump assembly 2 Replacement wi...

Page 70: ...pump should hold 11 P S I of pressure a If the leak is due to the joint of the top body and the bottom body replace the di aphragm and the gasket with new ones b If the leak is due to the joint of th...

Page 71: ...w 30 m m 1 from the center of the main bore STARTER SYSTEM The starter system is designed to make the engine start quickly in cold weather It is constructed with functional parts such as a starter jet...

Page 72: ...xture from the pilot outlet to secure smooth operation of the engine When the throttle valve opens wider approximately above 1 8 of the diameter of the main bore gasoline injects through the needle je...

Page 73: ...ttle valve with the throttle cable attached and the throttle open With your eye you can adjust accurately by matching the corner of the cutaway of the throttle valve with the upper surface of the main...

Page 74: ...tep operate for 5 10 minutes by idling If the rotations of the engine are normal during that time the adjustment is complete If abnormal remove the ignition plug and check the condition of combustion...

Page 75: ...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 malfunction...

Page 76: ...RDER AND ADJUSTMENT A carburetor is a vessel with a lot of precision jets and a con stant fuel level It is so constructed that when the negative pressure of intake of the engine functions proper conce...

Page 77: ...ation between the degree of the opening of the throttle valve and the functional systems and the parts to adjust is as follows Throttle Valve Degree of Opening 0 1 8 1 8 1 4 1 4 3 4 3 4 Full Open Func...

Page 78: ...e jet needle has 5 levels of groove When the grip goes upward 2nd 1st levels the space between the jet needle and the needle jet becomes smaller and the fuel air mixture becomes lean When the grip goe...

Page 79: ...nctioning due to clog adjustment Over height of the fuel level Remove the float chamber and measure the height from the level of the float chamber packing to the float arm when the mixing body is plac...

Page 80: ...nd adjusted for its given engine size The following service and trouble shooting information will be a great benefit to you MAIN NOZZLE HIGH SPEED MIX SCREW VALVE SEAT INLET CONT ROL VAL VE INLET CON...

Page 81: ...maged or deformed c Check the gasket between the pump and mixing body and also the gasket inside the pump body Replace if necessary d Check the 0 ring in the mixing body and pump body and replace if n...

Page 82: ...dard or one of the two sizes of oversize seats available but always use a flat punch so as not to damage the inside part of the new seat e Check the inlet control lever and pin and replace if necessar...

Page 83: ...aul procedure a FUEL LEVEL b IDLE MIXTURE SCREW c IDLE SPEED SCREW d HIGH SPEED MIXTURE SCREW a FUEL LEVEL Install fuel level checking parts and start the engine Loosen lock screw and turn the adjustm...

Page 84: ...ust idle speed as per engine manufacturer specifications d HIGH SPEED MIXTURE SCREW Adjust high speed mixture screw so as to reach maximum revolution This adjustment should be made with throttle valve...

Page 85: ...the fuel leve l turn the screw clockwise to lower the fuel level turn the screw counter clockwise 83 Idle mix screw High speed mix screw Washer Screw 8 rcau A_ ttac_ h the screw and washer after adJU...

Page 86: ...e CAUSES CORRECTIONS 1 Choking in the fuel line 1 Ciean fuel line with compress ed air 2 Fuel pump not working 2 Check the component parts the impulse tube and the check valve 3 lnsufficient fuel supp...

Page 87: ...with engine idling 3 Check and clean fuel line 4 Replace fuel filter 5 Adjust fuel level a To obtain constant performance the carburetor should be cleaned and checked at reasonable intervals b Dust or...

Page 88: ...ject to a stringent Polaris quality control program to insure maximum dependability Polaris A Textron Company will not warranty any snow mobile used for racing or competitive use including the 1973 TX...

Page 89: ...hen operating this machine familiarize yourself with it before any full throttle runs Get the feel of the braking system and always connect the cord for the tether stop swit ch to your self before sta...

Page 90: ...NOTES 88...

Page 91: ...___________________________________ Street Address _______________________ Telephone No ___ City ________ State _____ Zip Code _____ TX Starfire Serial Number TX Starflame Engine Number ______________...

Page 92: ...P laris A textronIcompany ROSEAU MINNESOTA part No 9910206...

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