charger playmate parts and service manual
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1969 POLARIS CHARGER & PLAYMATE
PARTS AND SERVICE MANUAL
POLARIS INDUSTRIES Division of textronllM:.
Roseau , Minnesota 56751
CONTENTS
i SECTION - A · · . BODY & TRIM GROUP ,
• SECTION - B DRIVE & BRAKE GROUP · ·
SECTION - C · · · · STEERING GROUP
SECTION - D · · TRACK GROUP
SECTION - E · . ENGINE MOUNTING GROUP
SECTION - F · · · CARBURETOR GROUP
"-SECTION - G · · . WIRING GROUP
•
• •
SECTION - A
BODY & TRIM
GROUP
PLAY MATE BODY AND TRIM GROUP
ITEM PART NO. OTY. PER OTV. PER
NO. PART DESCRIPTION VEHI CLE 0<<< ..
26"011 NUSE CONE 1 NOSE 'ONE 2 LATCH
3 752120 1 18 , .481 POP RIVIT 4 4 'emo' 513' , .379 POP AlV IT 3
5 "H . DECAL
6 7071068 R.H. DECAL
GRILL LY 1 • 543002 1 GRILL 1
8
7~ 3/16 POP AlVIT 1
GR1L HINGE R.H. 10 54: 19 GRIL .. HINGE " H. 11 7661601 3 /.."......D'A .. ,3/4 ROLL PIN 2
J I
12 #8-18 , 112 PH. PAN HO. I ; SCREW 4
" ~ #6- 20,'12 PH. PAN HO I , SCREW 4
" ;EA~ -'ffi&-UNI
16 5221 '"
AlTACH ING AlNG w, -'-
" I mw
" TAi M BAND
19 AnACH ING BANC
20 #10-32 ,314 PAN HO .. ( SCREW 3
21 7541 901 #10- 32 WEll .. NL 3
22 MAIN BODY WELD 23 GRASP BAR 1
24 3/8-16, . HEX. HO. CAP SCREVI 4
4
26 HITCH
27 " ,314 HEX . HO. CA P SCREW
28 : NL 2
29 BUMPER
30 52232" HINGE
31 PIN
32 BACK
33 WOOD SCREW 2
34 TAIL LIGHT
~: 4030001 BULB 1
752760 1 #6 , 1" PH . OVAL HC WOOD SCFEW
37 REO LENS
38 I 1
39 544001
40 CHOKE
41 ., 10003 I I SWITCH
42 I I I SWITCH 1
43 5/32 , .. 379 POP AlV I 4
44 GAS TAN K
45 GAS CAP ' .. 46 TUBE 1
47 WIRE CLAMP
" '" '"" . I POP RIVI" , 49 fUEL liNe 2
50 ~ I
51 HOSE CLAMP 4
A - I
PLAY MATE BODY AND TRIM GROUP
•
•
.. ~
t
A -2
CHARGER BODY AND TRIM GROUP
ITEM PART NO . PART DESCRIPTION
alY. PER alY . PER
A- 3
'" • • •
( ( (
J3 14 11 I I ,~ ffFi,_ 22
" n :z: ~ :II G'J
23 m :II
,. A -<'"
V ' /' m
c c -< ..
~ 7' J:I
I 2 .. 28 C ...
:II 5 ~ . ~. ~I """-"""- ~ /' \ \ -3:
....-.. C1 / " :II 39
"- C 40
C 45
"D 44
ITEM NO. , :--.
S
• 7
--, I. lJ
12
" " 15
"
CHARGER CONSOLE GROUP
I.
13
PART NO. PART DESCRIPTION QTY. PER VEHICLE
GROUP
=NEl 3i60101 PRiMER KIT
~ITION SWITCH
I I SWITCH
E CUSH ION
~ I .,,-;.;PAN He I ; SCR EW 4
. TY PE LIP
268101: CONSOLE I
l60J02 --;;.;-~ NUT . 41 10004 ~SW"CH ~ , swrn
I 4
3573001 N' .ON ,
A - 5
I.
J 1
I I I
•
\ 7
".':~,~R ,
GAS TANK ASSEMBLY
5____..
•
6 -
, I
CHARGER
•
ITEM PART NO. PART DESCRIPT ION
OTY, PER OTY. PER NO. VEHICLE ASSEM .
,
2511011 GAS TANK ASSEMBLY 1 , 5710011 GAS TANK , 2 25 1101 2 GAS CAP ,
FUEL LI NE ASSEMBLY , 3 5410051 GASKET , 4 7052002 90° GAS LINE FITTING , 5 542 00 17 GAS LINE REAR , 6 542002 1 GAS LINE
,--7 2530002 FUEL FILTER 1
8 2520105 HEX NUl , 9 5331006 STEEL GAS LINE ,
A - 6
•
•
SECTION - B
DRIVE & BRAKE
GROUP
PLAY MATE DRIVE AND BRAKE GROUP
• ITEM
PART NO. PART DESCRIPTION QTY. PER QTY. PER
NO. VEHICLE ASSEM . 1 5440012 CHA IN CASE COVER • 1 2 7558402 5 / 16 FLAT WASH ER 7
3 75 12310 5/ 16-18 x," HEX. HD. CAP SCREW 1
4 7512304 5/ 16 18 xJ" NYLOCK HEX. HD. CAP SCREW 1
5 7577902 5/ 16 IN T. EXT. LOCK WASHER 1
6 3222009 1140 DRIVE SPROCKET 40 TOOTH 1
7 3224001 DRIVE CHA IN 1
8 1330103 JACKSHA FT WELDMENT 1
9 7727001 tl9 WOODRUFF KEY 2 10 7556501 ' " 1. 0. x '-1 / 2 0 .0 . x 18 GA . MAC HINE BUSHI NG 3 11 5610004 BRAKE DRUM 1
12 7512308 5/1 6 18 x 5/ 16 SOC . HD. SET SCREW 1 13 1910001 BRAKE BAN D WITH LIN IN G 1
14 5223019 BRAKE BAND BRACKET
15 7512102 1/4 20 x 112 HEX. HD. CAP SCREW 1
16 7542103 1/4 20 FLEX-LOC NUT 1
17 7727101 #91 WOO DRUFF KEY 1
18 7522002 #10-' /2 SLOT. PAN HD. TAPPING SCREW 1
19 54 10071 O ILER PA D
20 7512306 5/16-'8 x 1-1/4 HEX. HD . CAP SCREW 1
21 5330020 CHA IN T IGHTN ER BLOCK 1
22 7542301 5/ 16 18 HEX. NUT 1
23 7512309 5/ 16 1S x 2 HEx. HD. MACH INE SCREW 2
24 7542303 5/ 16- 1S FLEX-LOC NUT 7
25 351 3901 BEARI NG WITH LOCK COLLAR- 3/ 4 1. 0 . 2
26 5221018 FLANGETTE 4
27 755630 1 3/4 I .D. x 1-1/4 O.D. x 16 GA. MACHINE BUSH ING 4
·28 1322024 DRIV EN CLUTCH 1 ..
29 3211010 DRIVE SELT 1
3. 7558401 5/16 I.D. x 1-3/ S O. D. FLAT WASHER
31 7577901 5/ 16 INT. EXT. LOCK WASHER
8 - 1
• • ( (
SEE "a STEER ING ...
~ s: ~ m CI
1 ::a 1- -< m .. V -:~ 23 - 22 j l 7'~I~) I)~"-----y~~ \ \ ( \ I -- ~. ~ N -- ,
~ I, U,>< ,_- , 2 2
X 3 CI "--@ / ~ ID
10 / >.. " ?-~\ \ ::a l' ::-::
4 '--\ / m GJ ::a D C 11
CHAIN CASE ASSEMBLY
ITEM PART NO. PART DESCRIPTION
OTY. PER QTY . PER NO. C VEH ICLE ASS EM.
. FRONT COVER
2
~ 'COVER "0" RING 1
~ I , RING '" DI' . , . '.0. , .031 THRUST 2
•
5 .500 .. , .688 J.D.' .500 ROLLER I • 6 322 1011 IDLER ' • RC35-2 11 TOOTH 1
7 7511 905 >10-24 , .50 PH. DRIVE TRUSS HD. SEM
8 5210116 IDLER SLID E I ; PeA- E
9 TA", UP SHm
10 561 0032 IDLER 5L10E 1
11 , CASE
12 191000' BRAKE BAND
13 2050001 BRAKE CABLE
" 661002. BnA" DnUM
15 " 14201 RETA'N'~'NG 125D IA . 2
17 7512326 ' '' ' - " H" . HD. <SCREW 4
lB 7553001 3/ B SPRING , 19 5020072 I
20 J51400J 205 BA LL , 12 stALl
21 " 13901 RETAINING RING .984 DIA , 2
22 7727001 ,. , KEY
23 7542301 , , HEX NU
24
205 8ALI~1l SEAL
I
25 3514302 2
I
27 755850' 20 GA. , 1.25 0 .' . FLAl 2
28 " .75 CAP SCREW 2
29 7512 120 11' - 20,1.00 HEX. HD. SE" 8
30 75126{)4 HEX HD . PLUG 2
31 DRIVEN r RC35-2 39 TOOTH I
J2
112
OR:V~-2 13 TOOTH I
DRIVE TOO 1
DRIVE r RC35-2 21 TOOTH , 33 *CHAIN35-2 9011 1
CHAIN 35-2 921 I
ROLLER CHAIN 35-2 941 1
8 - 3
'" 1 ..
o
l 22 I
tD~ I
\ ~ 20 ! I.
• (
~
CHARGER
" / 25 ,. ,... . .,
/~ ~ I 1/28765 15 , 23 ~ '.' .. ~. • 3 2
2' ':>NfJ1{~ ~ ~/If / 1
\ <fJ~/ / " ~ iJ/ J. <~~!l 1J!r. /
'W~ .. ~. ~,.~ 7
, ~~4t/l/;;~~" , c . / t7;
( . '. (J'@.~
" 1'1!~ IIIKO/ /: "28 ~\U~~
""
n l: J) -2 n ~ en m ~ en en m s: III !(
CHAIN CASE MOUNTING
2 3
cLJi 5
6
/ ""
, I , ,
•
ITEM PART NO. PART DESCRIPTION
OTV. PER OTY . PER NO. CHARGER VEHICLE ASSEM.
1 CHAIN CASE 1
2 7512328 5/ 16-18 x 3Yo HEX HEAD CAP SCREW 1
3 7577901 5/ 16 OISHED TOOTH LOCK WASHER SHAKEPROOF
4818-16-02 1 • 4 7558401 5/ 161.0 . x 1-3 / 8 0.0 . FLAT WASHER 1
5 1322016 AAMP CLUTCH , , 7721101 3/ 16 x 3 / 16 x 1'~ KEY 1
7 7542402 ,j / 8-l6 FLEX-LOC NUT 4
9 75124 13 3 / 8-16 x 2 CARRIAGE BOLT 4 10 3211006 DRIVE BELT 275 CC - 380 CC 1
10 3211007 DRIVE BELT 399 CC - 744 CC 1
Note : Drive belt for sa lsbury 32 11010
8 -5
DRIVE CLUTCH ASSEMBLY
14
•
\~~ I J_ ~ l
6"fllfJ \
... 0 0
~ CHARGER
/0
ITEM PART NO. PART DESCRIPTION
QTV. PER QIY. PER NO. VEHICLE ASSEM.
1321004 DRIVE CLUTCH COMPLETE SACHS I 1
1321002 DRIVE CLUTCH COMPLETE WANKEL & 300 JLO 1
1321 001 DRIVE CLUTCH COMPLETE - POLARIS & 380 JLO 1
132 1003 DRIVE CLUTCH COMPLETE - HIRTH 1
I 1321029 DRIVE CLUTCH COMPLETE - KOHLER 1
1 1321009 I STATIONARY FACE AND HUB SACHS I
1 1321007 STATIONARY FACE AND HUB - WANKlE & 300 JLO 1
1 1321006 STATIONARY FACE AND HUB - POLARIS & 380 JLO I
1 1321008 STATIONARY FACE AND HUB H IRTH I 1
1 1321030 STATIONARY FACE AND HUB KOHLER 1
2 5010010 SPACER 2
J 351580 1 BEARING I
4 5630001 I BUSHING 2
5 7041002 SPRING I 1
6 1321005 MOVEABLE FACE AND ARM WELDMENT I 1
7 5020013 WEIGHTS 3
8 I 3225002 I PIVOT LINKAGE 3
9 3225003 PIN 3
10 5221032 ATTACHING CLIP 3
11 7661001 COTTER PIN 12
12 3225001 I 1160 ROLL ER LINK 3
13 7558301 1(4 SAE FLAT WASHER 3
14 5230014 DRIVE PLAT E AND COVER 1
15 5210029 LOCKING CLIp · BOLT 3
16 7512106 1/ 4 28 x 3/ 8 HEX . HEAD CAP SCR EW 3
17 5020015 RETAIN I NG 80LT SACHS. WANKEL 300 JLO 1
17 5020077 RETAINING 80LT HIRTH. KOHLER , POLARIS & 380 JLO 1
6 - 6
DRIVEN CLUTCH ASSEMBLIES
CHARGER
ITEM PART NO . PART DESCRIPTION
OTY.PER Q::~,';;R NO. VEHICLE
• 13"02' 1
, • FACE AND HUB
2 13"004 • FACE AND HUB
3
~ ,
• 3
5 704' 001 ''''' 'NG 6 5230013 ''''' 'NG RETA'NER 7 "440 ' SNAP " NO
"
ITEM PART DESCRIPTION
OTY . PER OTY.PER NO.
PART NO. VEHICLE ASSEM. 1322016 RAMP CLUTCH ASSEMBLY 1
1 1322017 STATIONARY FACE ASSEMBLY 1
2 1322018 MOV EABLE FACE ASSEMBLY 1
3 7041 004 SPRING 1
4 5630004 RAMP 1
5 5430012 BUSHING RAMP I 3
6 3565901 BRONZE SLEEVE I 1 - - -7 77 14801 RETA IN ING RING I 1
8-7
SALSBURY DRIVE CLUTCH
Item No. Part Number Part Description Quantity
1321028 Drive Pulley. Complete 3/4" bore, nylon weights Husqvama SM·1 50
1321031 Drive pulley. complete Fuji EC 16 OP. Nylon weights, tapered bore
1 0600120 Fixed face & hub assembly 1 . 1 0601134 Fixed face & hub assembly 1
2 0601 120 Movable face &: roller assembly (Includes items 3 &: 4) 1
3 0690098 Springs, pins & clips 1 sel
4 0690020 Roller weight&: arm assembly 1 sel
5 0100912 Bumper, mov.ble face 3
6 0601013 Drive plate &: pin assembly (includes item 5) 1
7 0102512 Ramp plate 1
8 0690088 Screw · service kit 1
9 0900009 Retaining ring 1
8 - 8
SALSBURY DRIVEN CLUTCH
..
4 5 7 8 9
1t9m No. Part Number Part Description Quantity
1322024 Driven pulley, complete 3/4" Yore 1
1 0901034 Cap screw 3
2 0601017 Fixed face & hub assembly 1
2 0601019 Fixed face & hub assembly 1
3 0601018 Movable face assembly 1
4 0702633 Cup. spring inner 1
5 0700274 Spacer 3
6 0702373 Spring (red) 1
7 0702387 Cup, spring outer 1
8 0702915 Plate·screw lock 1
9 0900176 Nut, hex 3
8 - 9
SECTION - C
o
STEERING GROUP
..
PLAY MATE STEERING GROUP
•
ITEM PART NO. PART DESCRIPTION e~~I~~: Qr,!, PER
NO.
~DLE 2
2 !LV 2
3 •• 5/16 50C. HD. SET SCREW 2 , 1823014 , P05T /lV 5
~:: ~E AND SAAKE CABLE 2
7 2 /'- 20 : NUT
• NYLON '~ • 755640 ' 718 ..• '6 GA . MACHI
10 7661501 5/32 • ,. /, 'TIER PIN 706010 ROD END .EAAlNG 2
12
~: 3/8-24 HEX. NUT 2
-"- TI@ 2
14 V'." . COTIER PI N 2 , ' 6 155850 3/ 8 5.A.E. ,
*. ' .3/H* HD. CA; :~::: 2
18 7512410 2 ,. , ARM 2
~ '573901
mE
I , 2
22 2
23 7512406 318- 16 • 3 HE<. HD. CAP SCREW 2
24 3/6-16 FI ; Nl 2 ,,, 2
'" ,,"- '6. '·' / 4 HEX. HD. CAP SCREW 2
26 522100 SKI , 27 MAIN LEAF SPRING , " TOP LEAF SPAI NG , 29 SPRING
30 521000' SPRING PLATE
" J,"-lO : NU' 3 • 32 3/'- '6.3 HEX. HD. CAP SCREW 33 """, SKI
34 ; NL
35 182011 SKI SKAG
37 "5<00' ~PlN
3fij .2·3/' :LEVIS PIN
38 SKI WEAR PLATE
C-l
PLAY MATE STEERING GROUP
o
.--21
•
•
C-2
CHARGER STEERING GROUP
ITEM PART NO. PART DESCRIPTION OTY. PER Q~~S:~R NO.
1 ~ ~ 2
2 LV 2 , 5/'~~. H"'-'ET SCREW 2
_S
~ -'-2
11." 1 '" " OLL PIN 3
8 18230 13 LOW'" I PO'T 1
• ~ ROOEN~ ,
10 , " TIE ROO 2
12 5" I i A" 2
13
,,,J. " i NL • 15 • ,. 755.'01 '/81.0. , 1. GA. MACHINE RY BUSHING ,
-" 76.'~ _5132 , 1·1/, COTTER PIN 1
16 2
19 5010001 SKI SPINDLE 2
20 3/8-1.", HE). He :AP SCREW 2
21 3/8-1. FLEX LOCK NUT 2
~ SKI 2
22 'IS-I." 1·1/ ' HEX HD. CAP SCREW 2
23 5221001 SKI
2' MAI N LEAF SPAING , 25 5010002 SPAINe
26 5210000 SPRING PLATE . 27 75"''' '/S-16 FLEX LOOK NUT. , 2S 7512496 ' IS-I."' HEX HD. CAP SCREW I
2. 1820102 ' K '
'0 ~ _51 i NL
3· SKI SKAG 1
32 l i S" I TER PIN 1
33 3/8" 2·31' CLEVIS PIN 1
" SKI WEAR PLATE ,
C - 3
CHARGER STEERING GROUP l
see CHAIN CASE ASSE M 8L Y
J39101l
I I j !
17----18
"'----29 ~----"
C- 4
SECTION - 0
TRACK GROUP
PLAY MATE HANGER ASSEMBLY
I~~~ PART NO. PART DESCRIPTION QTV . PER all. PER VEHICLE ASSEM.
1542508 ~~Y
, ARM 1 2 1542506 Il5LEifARM 1
3 3/ 4 1
4 1542507 r PlATE 1 --. ~ 1
6 5/ 16 1.0 .• 1·1 / 4 0.0. " 1/8 , I . , . I HEX. HD. CAP SCREW 1
8 : NUT , --. 751illO Ii< ' HEX. ' SCREW 2
10 7512106 I • 3/ 8 HEX. HD. CAP SCREW
755280' 1/ 4 SPL r LOC' , ,,- 755ilO1 378SPl floc, 1
13 75i24O: ~~D , SCREW 1
14 "1542511 iAiiM " 15 I OLEA ARM'
'6 3513901 314 1
r PlATE
18 SPRING L.H.
19 7555701 5/16 1. 0 .• 1·' / 4 O. • 18
20
21 'FLE~ 2
22 ,.' . HD. CAP SCREW 2
23 114- 28 .318 HEX. HC CAP SCREW
K ~ 174SPiJT .OC'
.OC'
26 3/8- 16 .2· ' 12 HEX . HC I E SCREW ,
0 - 1
---------- ----- -
•
,
PLAY MATE HANGER ASSEMBLY
LEFT HAND
22 26 j\ 17 25 I . ~ ~ II ..... --. l l1l 16 I ~
! I 14 0~
~~j I ~,~ ~_ , 15
~-~i>~ \ \ ~_ )' I' 23 2< I ~ ~ I r
~/ I @~~ 21
0-2
RUBBER TRACK ASSEMBLY
PLAY MATE
ITEM PART NO. PART DESCRIPTION
OTY. PER OTY. PER NO. VEHICLE ASSEM.
15 10106 TR CK AS MB Y 1 1 RUBBER TRACK 1
2 5240011 CLIP 34 , 3 5240014 CLIP WASHER ,.
D - 3
PLAY MATE BOGIE ASSEMBLY
2 7
•
7 3 •
ITEM PART NO. PART DESCR IPTION QTy'p;~ OTY. PER NO.
1540106 BOGIE 2
1 154300 BOGIE WHEEl 4 , BOGIE TUBE 2
3 70401 0 SPR ING 2
• ~
MAIN BOGIE SHAF
~ • JIB SPll ~OC~ 2 ,
BOG IE WHEEL SHAFT 2
• 51B 2
9 754280 5/8- 11 CASTLE NUT 4
10 76614. 118, • , PIN •
0-4
PLAY MATE IDLER SHAFT ASSEMBLY
ITEM NO.
J3
PART NO. PART DESCRIPTION
0 - 5
B
OTV. PER VEHICLE
J3
OTY. PER ASSEM.
o
PLAY MATE DRIVE SHAFT ASSEMBLY
B
•
•
OTY. PER OTY. PER VEHICLE ASSEM .
PART DESCRIPTION
•
0 - 6
RUBBER TRACK ASSEMBLY
CHARGER
ITEM QTY. PER OTY.PER PART NO. PART DESCRIPTION
VE HICLE ASSEM . NO. 1510104 RUBBER TRACK ASSEMBLY 1 • , TRACK BELT 1
2 52400 11 CLIP " 3 5240014 CLI P WASHER "
D - 7
GROWSER BAR TRACK ASSEMBLY
2
•
CHARGER
ITEM PART NO. PART DESCRIPTION OTV. PER OTY . PER NO, VEHICLE ASSEM.
15 10101 GRONSER BAR TRACK ASSEMBLY 1
1 TRACK BELT 2 2 5240007 CLEAT 37
3 7621401 3/ 16 BLIND RIV ET 296 3
•
D - 8
HANGER ASSEMBLIES
CHARGER
'~~M I PART NO. PART DESCRIPTION ?,~~,~:~ a..r;S:~R
1542517 };t!!!!9!Jif!!!!!_Y
1
1 4
~ PLATE TRACK 1
5 I , 114. 5/16 x / 8' 1 7 5/16 SAE FLAT 1
_8 5/ 16 - 18 . NUT 1 9 7512301 51'6 - 18 x 3/' " I ;eOL 1
10 5116 18 x . HEX HEAO CAP SCREW 2 11 5/ 16 - 18 x • CAP SCREW 1 12 5/16 - 18 x 21/2 , SEMS 1 13 751232 S/16*X3/8'~ 1 14 5/16-1' x 5/1' SO ,HD . SET SCREW 1
LEFT HAND 15 ARM 1
_ 16 IDLER ARM' 1 17 3514501 1 18 PLATE TRACK 1 19 70401 02 SPRING 20 7555701 / 4 x 5/16 x 1/8 2 '
*.SAEF~ 22
~ , 23 5/5- 18 xl/ ' , 80LT 24 5/ 16 - 18 x • HEX HEAD CAP SCREW 2 25 5/16 - 18 x 1" CA~ 1 26 5/ 16 - 18 x 2 1/2 -
•
Hi 751232 5/ 10 - 24 x 3/8 - SEMS I 5/16- 18 x 5/16 SOC, H[ , SET SCREW r 1 •
0 - 9
HANGER ASSEMBLIES
•
CHARGER
,
" - I 20
?~~ 27 / 15
D - 10
A SSEMBLY BOGIE
8 1 3 \ /
/5, 4 ~~~_> 2 :~~~~~;:;::: -~- "'-- / . < '5 7 1
" , 7 1 ,- _ 8 / / ' /' /
CHARGER
I \ ---- / 10 • 8 W , 2 W
W _
ITEM NO.
PART~
-+ '10 --.-
, A.
BOGIE
I
1 -
, W'
5" -
5/ ,-;;-
13 BOGIE WHEEL 1543002 SED WITH ( ' ) TOBEU
PART DESCRIPTION
LF~
lJ
D - 11
OTV.PER V EHICLE
3
Ol Y, PER ASSEM .
2 1
2
2
,
•
•
o.
•
•
, .
ASSEMBLY IDLER SHAFT
10 4
/'" I B 13 2
4 ~ 1/ " • - - ~C ~ ~ /.
%; -5 / / 6 10 9
ITEM OTY. PER aTY . PER ASSEM . ~;~~===i=~VE~HI~CL~E=F~~= PART DESCRr~ON
I I
D - 12
DRIVE SHAFT ASSEMBLY
10
/." /' q / I 8
~~~)J'-..J',;~)' 2 1
_ rp _______ / 3
~, -~ I 1,2 8
v !t!Jt-JJ I. " ~C @) I~
5 ~. 6 / /
10 •
•
PART DESCRIPTION ~~=Ct===:=j
•
•
D - 13
SECTION - E
•
ENGINE MOUNTING
• • I
FAIRBANI(S MORSE RECOIL STARTER
Item No. Part Number Part Description
1 3001139 Cover Rotor Assembly
2 3001130 Centering Pi n
3 3001134 Ring Retainer •
4 3001135 Cord
5 3001136 Friction Shoe Assemblv
6 3001128 Spring Brake
7 3001131 Washer - Fibre
8 3001132 Washer - Brake
9 3001127 Rotor
10 3001129 Spring Rewind
11 3001138 Cover Assembly ( Alodine Coated)
12 3001133 Washer Brake Retainer
13 3001137 Handle Assem bly
,
. ,
E - 1
•
•
•
FAIRBANI(S MORSE RECOIL STARTER
3
E-2
• ,
,~" Z,,~ _ (~,_~
r_" .J~C_"L_'" {'I:' 'I''''I<> 3 7 ,1 .-
~
ENGINE MOUNTING-150cc HUSGVARNA
ITEM PART NO. PART DESCRIPTION OTY. PER OTY. PER
NO. VEHICLE ASSEM. • 1201209 ENGINE e M 1
1 1211214 ENGINE IONLY) 1
2 GASKETS 2 3 HEX. NUT FURNISHED WITH ENGI NE 6 4 WASHER 4
5 1251012 r.:ARBURA TOA- HL ~230A 1 6 0011912 3/ 16 l( 3/ 16 l( 1-112 KEY 1
7 1321027 DR IVE CLUTCH 1
8 7577901 5/ 16 IN T. EXT. LOCK WASH ER 1
9 75 12329 5/ 16 18 x 1-3/ 4 HEX. HD. MACHINERY SCREW 1
I . 1270016 ENGINE MOUNT WELDMENT 1 11 7516702 8 ~ x 20 f.rt.1 HEX . HD. CAP SCREW 4 12 7552902 8 M\1 SPUT LOCK WASHER 4 13 7512307 5/ 16-18 x 3/ 4 HEX. HD. CAP SCREW 4
14 7542303 5/ 16 18 FLEX LOC NUT 4
15 5210131 MOUNTING STRAPS 2 16 7542403 3/8 24 FLEX LOC NUT 5
17 7542401 3/B 24 HEX . NUT 3 18 7553001 3/8 SPLIT LOCK WASHER 3 19 1260073 MUfFLER BRACKET WELDMENT 1
2. 7512123 1/4 20 x 2-1/4 RD . HD . MACHIfJERY SCREW 1
21 7542103 1/4 20 FLEX-LOC NUT 1
22 3"0001 ROUND ENGIN E MOUNT 4
23 1260076 MUFFLER WELDMENT 1
24 70800 12 MUFFLER CLAMP 1
25 5331028 FLEX TUBE 1 ,
E- 3
•
•
•
ENGINE MDUNTING-150cc HUSGVARNA
2
SEE
STEERING
5
!~/ -~~.
E- 4
ENGINE MOUNTING-164cc POLARIS
ITE M PART NO. PART DESCRIPTION QTY. PER OTV. PER
NO. VEHICLE ASSEM. •
12()1212 ENGINE (COMPLETE) , , 1211215 ENGINE (ONLY) , 2 GASKET 2
3 HEX. NUT , , WASHER FLflNISHED WITH ENGINE 2
5 CARBURATQR , , THROTTLE CABLE , 7 1321031 DRIVE CLUTCH , 8 757790 1 5/ 16 tNT. EXT. LOCK WASHER , 9 7512333 5/ 16 18 x 3-112 HEx. HD. CAP SCREW , ,. 521013 1 MOUNTING STRAPS 2
" 7542403 3/ 8 24 FLEX-LOG NUT 5 12 7542401 3/ 8 24 HEX. NUT 3 13 7553001 3/8 SPLIT LOCK WASHER 3 14 1260073 MUFFLER BRACKET WELDMENT , 15 7512123 114 2J x 2-1 / 4 RD. HD. II1ACHINERY SCREW , 16 7542103 114 20 FLEX-LOG NUT , '7 3110001 ROUND ENGINE MOUNT , 18 1260075 MUFFLER WELDMENT , 19 7080012 MUFFLER CLAMP , 2. 5331028 FLEX lUBe ,
E- 5
•
•
ENGINE MOUNTING-164cc POLARIS
I. 21
E - 6
----: ---"" -- , ,
, '
ENGINE MOUNTING-275cc & 298cc SACHS
'~~M 275P:'R~C PART DESCRIPTION OTY . PER OTY . PER VFH I ~I F ASSFM.
12012 11 1
1 1211213 1211212 =iI'LYI
1
4
I 4
-'-5 1251 00 1251 008 -14 , I ' LINE 1
7
~ FRONT GAS .lNE 2
8 PA lMER -112"
• , PRIMER HOSE-'"
10 PAlMER ,
11 31601(,. TEE 1
12 3160104 V ALVE -'-13 5221 017 AIR BAFFLE I ; "LATE
14 AIR BAFFLE COVER
15
~ QfuOc>;
1 /4-2O~ CAP SCREW WITH DRIll Fn HFAD 2
17 1/ 4
"- 7512110 1/4- 20,2 HE!. HD . MACH INE SCREW
I
20 1575201 1575201 112 IN T. LDCK WASHER
2' , /2 - 20, 4-112 HEX. HD. CAP SCREW
22 "60065 23 1260043 126004' 24 5331036 FLEX PIPE 25 1260051 11260051 1 MOUNTI NG BA ND 1
26 1512123 1'512123 1/ 4- 20,2-114 RD. HD. , SCREW
21 7$2801 17552801 1/ 4 SPlIT .DCK
28 15421 c>; 1'542105 1/ 4- 20 HEX. NUT :'8£: 1
29 1512102 11512
"" 1, CAPSCREW
30 7542103 115421(" 1/ 4- 20 FI : NUT 2
3' 3110002 10002 : MOUNl
32
:~ ~ ~ENGINE MOUNT 2
34 L~NGINE MOU'N' 1---35 1270028 R.H. : MOUNT 1
•
• 37 1502303 : NUT 2
38 1542402 3/ 8- 16 : NUT
39 7512407 3/ 8- 16 , 1· 1/ 4 HEX. HD. CAP SCREW 2
40 3 / 8-24 : NUT 4
41 15531 01 1553101 1116 SPLIT .OCK 4
42 751 6902 ~02 -'-"-MM , 30 ~EX. HD. CAP SCREW 4
1012
E- 7
ENGINE MDUNTING-275cc & 298cc SACHS
SEE
•
•
E- 8
ENGINE MOUNTING-300cc JLO
ITEM PART NO. PART DESCRIPTION my. PER OTV. PER
NO. VEH ICLE ASSEM . 1201220 TEl 1
1 ENGINE 10NLY 1
2
~ 4
, WITH..."'G.'."'. 4
4 2
5 1251 008 0 · 14
6 5420004 IMPU L5E LINE 1
5420016 FRONT GAS . INE 2
8 PRIMER 1/ 2·
9 5420028 PRIMER
10 PRIMER HOSE- 12· 1
3160 10S ·EE
12 VALVE
13 AIR BAFFLE liNG PLATE 1 ,. AIR BAFFLE COVER
15 7512109 1/ 4- 20,314 CAP SCREW WITH DPI .LE) HEAC 2
16 s: 11005 5AFETY WIRE
1/ 4
1B 75"" 0 1/ 4-20 ,2 HEX. HD . I E 'CReW
DRIVE CUTCH
20 13/ 16 SHAKE PROOF WASHER
21 RETA INING BOLT 1
22
23 EXHAUS I
24 FLANGE GASK' , 25 56 1004( R FLA NGE I -'-26 5/ 16-18 ,
27 7552901 5/ 16 SPLIT LOCK <
28 7542301 5/ 16- 18 HEX . NUT " 29 FLEX PIPE 1
30 126005 R MUUNTINC BAND
31 7512123 1/ 4-20 , 2· 1/ 4 RD. HD. . 'CREW
32 7552801 1/ 4 SPLIT ':OC K , 33
34 751" 02 1/ 4-20 , ,n He> HU CAe 'C",W --'-3S 75421 03 1/ 4-20 FLEHOC NUT " 3 6 311 0002 I MOUN"
" 31101M RUUND ONCINO MUUN) 2
38 ENGINE LEAF SPRING • 39 L. H. E~MUUNT
~ 4· 5/ 16-2 : NL 2
42 5/ 16- 18 : NLIT 2
43 3/8-)6 }~t4 HEX. HC . CAP SCREW
-'-44 2
45
~ 3/ B- 24 ; NLIT ,
7/ 16- ,.', / 4 HEX~CAe , C",W -'-47 , 48 1 CLAMP
E - 9
•
ENGINE MOUNTING-300cc JLO
E - 10
SEE
STEER ING
ENGINE MDUNTING-317cc HIRTH
ITEM PART NO. PART DESCRIPTION
QTY. PER my. PER NO. VEHICLE ASSEM.
1201218 ENGINE (COMPLETE) , , 1211210 EN GIN E IONlY) , 2 HEX . NUT 2
3 BOLT FURNISHED WI TH ENGINE , WASHERS , 5 GASKETS 2
6 1251008 CARBURETOR-HD-14 , 7 5420004 IMPULSE LINE , 8 5420016 FRONT GAS LINE 2 , 5420027 PRIMER HOSE 7-112" ,
'0 5420028 PRIMER HOSE , .. , " 5420029 PR IMER HOSE 12" , 12 3160105 TEE , 13 3160104 VALVE , 14 5221017 AIR BAFFLE ATTACH ING PLATE , 15 5230003 A IR BAF FLE COVER , 16 7512109 114 20 x 3/ 4 CAP SCREW WITH DRILLED HEAD 2
17 5311005 SAFETY WI RE
18 7558302 1/4 WROUGHT WASH ER
19 7512110 1/4 20 x 2 HEX. HD . MACHINE SCREW , 20 1321003 DRIVE CLUTCH , 21 7575201 1/2 INT. LOCK WASHER , 22 7512601 1/2 20 x 5-1/ 4 HEX . HD. CAP SCREW , 23 1260065 MU FFLER ASSEMBLY , 24 1260068 EXHAUST MANIFOLD
, 25 5331036 FLEX PIPE , 26 1260051 MUFFLER MOUNT ING BAND
, 27 7512123 1/ 4 20 x 2-1 / 4 RD. HD. MACH INE SCREW , 28 7552801 1/ 4 SPLI T LOCK WASHER , 29 7542105 1/4-LO HEX NUT
30 7512102 1/4 20)( 1/2 HEX. HD . CAP SCREW
31 7542103 1/ 4 20 FLEX-LOC NUT
32 3110002 RECTANGULAR MOUNT , 33 3110001 ROUND ENGINE MOU NT 2
34 7043004 ENGIN E LEAF SPRING ,
35 1270038 L.H . ENGINE MOUN T , 36 1270039 R.H. ENGINE MOUNT , 37 7542304 5/ 16 24 FLEX-LOC NUT 2 • 38 7542303 5/ 16 18 FLEX LOC NUT 2
39 7542402 3/8 16 FLEX-LOC NUT 2
40 7512407 3/8 16 x 1-1/4 HEX. HD. CAP SCREW 2
41 7542403 3/8 24 FLEX-LOC NUT , 42 7553201 112 SPLIT LOCK WASHER
, 43 7512612 1/2 13 x 1-1/2 HEX. HD. CAP SCREW , " 7080012 MUFFL ER CLAMP
,
E - 11
•
ENGINE MDUNTING-317cc HIRTH
SEE STE ERI NG
GROUP
\ 15 18;"
61" 6 171/
..... ~~~lJJ~P -~ "-~~l~
7 _ 8 (-9 _ ' .",.,.,\,"
~- \ /"O~'"' 20' 10 ! --..;, 21 13
i I . / /2 \ e · ...
23
I
E - 12
ENGINE MOUNTING-370cc POLARIS
'~~~ PA RT NO. PART DESCRIPTION QTY .PER Q~~S~R V EH ICLE
[TE J 1
1 1201306 ~'ONLYI 1
)W~ 4
,~ I
6 ~ • 7 FRONT GAS LINE 2
8 PRIMER
10 ~ ~2 11 TEE 12 VAlVE
13 AIR BAFFLE ~ Pli\TE 1
15 1/4- 20 , 314 CAP SCREW WITH I HEAD 2
16 S31I 005 SAFETY WIRE 1
1/ 4 1
18 1/ 4- 20 ,2 HEX. HI'. MACHINE SCREW
19 1321001 DRIVE CL UTCH
20 7116 INT LDCK WASHER
21 7116- 20,4· 112 HE<. HD. CAP SCREW 1
22 23 T MANIFDLD
24 FLEX PIPE
25 I 'BAND
27
EI 1/ 4 ~LOCK
t:+, ~~ . :APS~
~T 32 -'-
~' 34 . . H. MOUNT
35 R.H. ENGINE MOUNT -'-36 5/ 16- 24 ; NUT 2
37 5/16· 18 I ; NUT 2
38 3/ 8- 16 ; NUT -'-39 3/ 8- 16 ,H/ 4 HE<. HD. CAP SCREW 2
40 3/8- 24 ; NL --" 4 755320 · 1/2 Sl'L r LOCK --"-42 /2- 13, , .. HEX. He CAP SCREW -'-43 I CLAMP
E - 13
•
. .
•
ENGINE MOUNTING-370cc POLARIS
E - 14
SEE
STEERING
14 17 18
ENGINE MOUNTING-380cc JLO
ITEM PART NO . PART DESCRIPT ION
QIY. PER OTY . PER NO. VEH ICLE ASSE M.
120 1311 G NE ( M 1
1 1211305 ENG INE (ONlYI 1
2 HEX. NUT 4
3 WASHERS FURNISHED WITH ENGINE 4
4 GASKETS 2 . ,
5 1251008 CARBURETOR HO- 14 1
• 5420004 IMPULSE LINE 1
7 5420016 FRONT GAS LI NE 2
8 5420027 PRIMER HOSE 7-1/ 2" , , 5420028 PRIMER HOSE '" , 10 5420029 PRIMER HOSE 12" 1
11 3160105 TEE 1
12 3160104 VALVE 1
13 5221017 AIR BAFF LE ATTACHING PLATE 1
14 5230003 AIR BAFFLE COVER 1
15 7fi 121O" 1/ 4 20 x 3 / 4 CAP SCREW WITH DRILLED HEAD , ,. 5311005 SAFETY WI RE 1
17 7558302 1/4 WROUGHT WASHER 1
18 7512110 1/ 4 20 x 2 HEX . HD . fo.tACHINE SCREW , 19 132HlOi DRIVE CLUTCH
, 20 7575201 112 INT . LOCK WAS HER , 21 7512600 1/ 220x4·t / 1HEX. HD. CAP SCREW , 22 1260077 MUFFLER ASSEMBLY , 23 1260043 EXHAUST MANIFOLD 1
24 5331005 FLEX PIPE 1
25 5223220 MUFFLER MOUNTING BAND 1
2. 7512123 1/ 4 20 x 2-' 4 RD. HD. MACHINE SCREW 1
27 7552801 1/ 4 SPLIT LOCK WASHER 1
28 7542105 1/ 4 20 HEX. NUT 1
29 7512102 1/ 4 20 l( 1/ 2 HEX. HD. CAP SCREW 2
30 7542103 114-20 FLEX·LOC NUT 2
31 3110002 RECTANGULAR MOUNT 1
32 3110001 ROUND ENGINE MOUNT 2
33 7043004 ENGI NE LEAF SPRING 1
34 1270023 L.H. ENr;INE MOUNT 1
35 1270024 R.H . ENGINE MOU NT 1 • 3. 7542304 5 / 16 24 FLEX -LOC NUT 2
37 7542303 5/ 16--18 FLEX-LOC NUT 2
38 7542402 3/8 16 l( FLEX-LOC NUT 2
39 7512407 3/ 8 16 l( 1-1/ 4 HEX. HD. CAP SCREW 2
40 7542403 3/ 8 24 FLEX-LOC NUT 4
41 7553201 1/2 SPLIT LOCK WASHER 4
42 75126Cfj 1/2 13 x 1" HEX, HD. CAP SCREW 4
43 7080012 MUFFLER CLAMP 1
E - 15
ENGINE MDUNTING-380cc JLD
SEE STEERING
GROUP
ENGINE
•
•
,
--- -j\ - l " 25 28 27 2'
E -16
SECTION - F
CARBURETOR GROUP
TILLOTSON CARBURETOR HD13-A
orY.
•
(.) Indicates contents of Repair Parts Kit
F -1
J
TILLOTSON CARBURETOR HD13- A
F- 2
TILLOTSON CARBURETOR HD14-A
PART DESCRIPTION OTV.
I " f Ind icates content s o f Repair Part s Ki t
F- 3
TILLOTSON CARBURETOR HD14-A
13
56
6
~41 37
16
33
34
60 - 25
17
"
F- 4
TILLOTSON CARBURETOR HR18-A
PART DESCRIPTION OTY.
( >J Indicates contents of Repair Parts Kit
f-5
- ]
TILLOTSON CARBURETOR HR18-A
44
45
'Vr:J---. 8 " '<;;(j 9 •
$--35
32-__ _
F- 6
TILLOTSON CARBURETOR HR19-A
ITEM NO.
TILLOTSON PART NO .
( 0) Indicates contents of Repair Parts Ki t
PART DESCRIPTION
F - /
OTY.
• 52 /
31
33 _ _
"
": . _ 55
F- 8
• 5 - . 'v k, ." 0 ~-,
6 14 •
'.
u 0 o 0 - 19
~ o~ "" O
0",
'. '- " ,0'- 22
J ) - - 23
TILLOTSON CARBURETOR HL- 269 A
~ '''",. , , on.
, "'''''' B,d, 1~"i~1 ,
, ., , , , , - ''''000, '" S"i"
, S "0009' , "00097
, 7 """"" "So,_ & , B """"" , 9 """"03 , , '" "00'65 i , " "00099
, 'HlO'" ",.'" , 1 121 , "0029' "'·9' , " 121
, " "00"7 F,,' , ~
~ "Fuel Pump i , F", ,
_ IS F""om, w& ,,161 , " 'F,,' ,
, " C .. ,,, , 1 ,
" ~ 'F," , i , 'Id l~ j .S"i"
""""28 Idle i • W"Ii"
I" ''''0029 Id le i
" 'HXlOO9 ' Id" 75 "000" ' ldl,
28 """228 , CWOI
27 "' ''''33 , 1 • Fi.
I" """"3< ',.,,' , . ". 129 """227 ',.,,, "~dI,. s," & C,~"
130 "00036 I.'" s .. , C .. k" , """"70 ',.,,, T,.,i,. S"i.,
'Hi,""", i
"""' 79 'Hi,""", i , S"i"
Hi,""", i
135 3HXlO" High Speed i , ,,,,,., 36 3100107 , , , 37 """,,, TIi,,'''' CWOl A~m""
38 "0000' TIi,,"" Cw. "". ",' ,
" "''''' 'TIi"''', Cwo
4C ""'" ''',,'''' C""
" """'" ",,"', , " "000" "",,', n Ret. Clip , 03 3HXlO' ' TIi,,"" Wi" "". S,,_ , .. """'3' "",,', SIi," & C'""
, " ,,-- Thrott le Shaft Clip , " ,,-, Throttle Shaft Cl ip , " ,,-, TIi",,', >h," CIi, "". S,,_ , " 3100113 'TIi""" >h." ,
, TIi",,,, >hOI'" , 50 """"" ' TIi,,"" >hOI'" S,,_ & , " ""'" ' Co."" , , " 'HXl"3 i , ,
I') Indicatei contents of Repair Parts Kit
IPfice~ and specification$ are .... bject 10 change wi thout notice,1
F- 9
TILLOTSON CARBURETOR HL- 269 A
43
" 49
4 8
•• !!l
12
S 8
C;~$ltt't S'T
9 0«' '' , ....
7J '. VQO,.. 51 '\ °h '. .
'~.! -.~~
14
10
~EP"I~ \. - _,,\;,,~,S . ---.-.J
i: 0. ' ''~ ';; , S2
~O~ '. . ~ ....... "
16
17
I 18
15-1
F- l0
SECTION - G
WIRING GROUP
WIRING DIAGRAM
MANUAL START
, . '" // •
I YE l /BlK /
~ ~ ~ •
m • • NOT CONNECTED m NOT CO NNECTED ."
'", "0
I~\~"'< ~ c-
bJ 10- " 0 BLU r; ''0
'/ ~l " /-4- 2
." /
ENGINE MOUNT
/ \: -- -, -, NOT CONNECTEO I
•
'" (; RN
,,0
CHARG ER
ITEM PART NO . PART DESCR IPTI ON
OTV. PER OTY. PER NO. VEHICLE ASSEM.
I 2460030 WIRE HARNESS I
2 2460032 6 INCH GROUND WIRE I , 2460031 12 INCH ,(ELLOW WIRE 1
4 4020010 3·M WIRE CONNECTOR 5
5 4110003 IGNITION SWITCH 1 , 40600 13 RESISTOR 1 · 7 4110004 HIGH-LOW SWITCH 1 I 8 "'30004 HEAD I AMP UN IT , 9 2432004 TAIL LIGHT ASSEMBLY 2 • • 10 TAIL LIGHT DISCONNECT 1
G - 1
t ,
i i
PLAY MATE
• 1/\
ITEM NO.
\ 2
'3
PART NO.
WIRING DIAGRAM
• \
0
\ ,
PART DESCRIPTI ON
I I I
G - 2
• ENGINE
I
\ I
OTY. PER VEHICLE
7
\
Oll. PER ASSEM.
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