charger playmate parts and service manual

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 , ,

•


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


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


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

•

•


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

•


E - 10

SEE

STEER ING

ENGINE MDUNTING-317cc HIRTH


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


'~~~ 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

•

. .

•


E - 14

SEE

STEERING

14 17 18


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


PART DESCRIPTION OTV.

I " f Ind icates content s o f Repair Part s Ki t

F- 3


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

- ]


44

45

'Vr:J---. 8 " '<;;(j 9 •

$--35

32-__ _

F- 6


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.

charger playmate parts and service manual

Documents