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1971 l'A]<!"S MANUA,L

VOt/A4E]<!

MUS"AN4 CJ..IA7<4E7<

"X CJ..IA7<4E7<

l',LAt/MA7,E

c

CONTENTS

BODY AND TRIM. . .. GROUP I

DRIVE AND BRAKE. . GROUP II

STEERING ....... . . GROUP III

TRACK AND SUSPENSION. · GROUP IV

ENGINE MOUNTINGS. . GROUP V

CARBURETOR. .GROUPVI

ELECTRICAL. · GROUP VII

ENGINES ... GROUPVIII

RACING MODELS. · GROUP IX

c

)

)

)

c

BODY & TRIM

l - Group I

BODY & TRIM (MUSTANG)

ITEM NO. PART NO. PART DESCRIPTION QTY. J

2631076 NOSE CONE ASSEMBLY (INCLUDES ITEMS 1 THRU 24)

1 5440061 NOSE CONE 1

2 7621203 1/8 x .634 POP RIVET 8

3 7010002 LATCH 4

4 7558206 . NO.4 FLAT WASHER 8 5 5430080 AIR SCOOP L.H. 1

5430081 AIR SCOOP R.H. 1 6 7071162 DECAL "POLARIS MUSTANG" L.H. 1

7071163 DECAL "POLARIS MUSTANG" R.H. 1 7 5430083 DASH GRILL 1

8 7621201 1/8 x .481 POP RIVET 8

9 5510012 JIFFY TRIM 1

10 5210181 LATCH SPACER 2 11 7670009 PUSH ON NUT 12

12 7071192 SHROUD DECAL 1 13 7541901 10· 32 WELL NUT 5 14 7511904 10·32 x 3/4 PAN HD. MACH. SCR. 5 15 7071194 SAFETY DECAL (NOT SHOWN)

16 5430088 HOOD LOUVER

17 5223396 ATTACHING BAND 1 18 7071149 DECAL "STAR POWER BY POLARIS" 1 19 4030007 HEADLIGHT 1 20 522;'126 RETAINING RING 1 21 7527601 NO.6· 20 x 3/8 PAN HD. CUTTING SCR. 4 22 7621315 5/32 x .625 POP RIVET (BLACK) 5 23 5430082 GRILL 1 24 7071191 DECK DECAL R.H. (NOT SHOWN) 1

7071190 DECK DECAL L.H. (NOT SHOWN) 1 25 5850015 WINDSHIELD 1 26 5521004 WINDSHIELD TRIM 1 27 7071172 DECAL "398" L.H. 1

7071171 DECAL "398" R.H. 1 7071174 DECAL "488" L.H. 1

) 7071173 DECAL "488" R.H. 1

28 1012010 MAIN BODY WE1.DMENT • 398 488M & 398E 1 1012016 MAIN BODY WELDMENT 488E 1

29 7542103 1/4·20 FLEX LOC NUT 8 30 5710020 BUMPER PLUG ' 2 31 7512107 1/4·20 x 11/4. PH. PAN HD. MACH. SCR. 8 32 5223523 PARTING LINE EXTRUSION 1 33 7621"302 5/32 x .379 POP RIVET 4 34 2670025 FRONT BUMPER 1 35 5410021 RUBBER GROMMET 5 36 5420034 SPONGE ROPE 28"· SIDE 2

5420033 SPONGE ROPE 11" FRONT 2 37 7010001 MAGNETIC LATCH 1 38 7527809 NO.8 x 5/8 PH. HD. TAPPING SCR. 5 39 2681058 CONSOLE CUSHION 1 40 2681043 SEAT CUSHION 1 41 2511054 TEE PEE WELDMENT 1 42 5332227 GAS TANK SPACER 1 43 7542303 5/16·18 FLEX LOC NUT 4 44 5420051 TAl LLiGHT SPACER 1 45 5221308 TAILLIGHT SUPPORT 2 46 5430075 LENS SUPPORT 2 47 5430076 TAII.LlC,HTENS 2 48 4030001 TAILLIGHT BULB 6 49 7527810 NO.8· 32 xl 1/4 PH. REC. SCR. OVAL HD. 2 50 7527808 NO.8· 32 x 1 PH. OVAL HD. STL. CUT SCR. 4 51 SEE GAS TANK ASSEMBLY 1 52 7621401 3/16 x .527 POP RIVET 5 53 5223228 BACKING· MUD FLAP 1 54 541d116 MUD FLAP 1 55

. 2670022 REAR BUMPER 1

56 5420064 GAS TANK PAD 1 57 7512310 5/16·18 x 1 HEX HD. CAP SCR. 4 58 7522004 NO. 10 x 1/2 PH. DRIVE HD. SELF TAP SCR. 6 59 5210409 SAFETY WALK 2

1-1

600~ & lR\tI\ \\\J\US1ANG)

c

c

BODY & TRIM (CHARGER)

ITEM NO. PART NO. PART DESCRIPTION QTY.

2631075 NOSE CONE ASSEMBLY (lNCLUOES ITEMS 1 THRU 24)

1 5440062 NOSE CONE 1

2 7010002 HOOO LATCH 4

3 5210181 HOOO LATCH SPACER 2

4 7621203 1/8 x .634 POP RIVET 8

5 7558206 NO.4 FLAT WASHER 8

6 7071164 DECAL "POLARIS CHARGER" L.H. 1

7071187 DECAL "POLARIS CHARGER" R.H. 1

7 7670009 PUSH ON NUT 18

8 5430080 AIR SCOOP L.H. 1

5430081 AIR SCOOP R.H. 1

9 5430083 DASH GRILL 1

10 7621201 1/8 x .481 POP RIVET 8 11 5510012 HOOD TRIM (NOT SHOWN) 1

12 7621315 5/32 x .625 POP RIVET (BLACK) 5 13 7071192 SHROUD DECAL 1

14 5430082 GRILL 1 15 7511904 NO. 10 · 32 x 3/4 PAN HD. MACH. SCR. 5 16 7541901 NO. 10·32 WELL NUT 5 17 5223208 ATTACHING BAND 1 18 7071188 DECK DECAL L.H. (NOT SHOWN) 1

7071189 DECK DECAL R.H. (NOT SHOWN) 1

19 7071149 DECAL "STAR POWER BY POLARIS" (NOT SHOWN) 1

20 4030007 HEADLIGHT 1 21 5221126 RETAINING RING 1 22 7527601 NO. 6 · 20 x 3/8 PAN HD. CUTTING SCR. 4 23 7071194 SAFETY DECAL (NOT SHOWN) 1 24 5430088 HOOD LOUVER

25 7071178 DECAL " 294" L. H. 1 70711 77 DECAL "294" R.H. 1 7071 180 DECAL "335" L.H. 1 7071179 DECAL "335" R. H. 1 70711 82 DECAL " 398" L. H. 1 70711 81 DECAL "398" R.H. 1 J 7071184 DECAL "432" L. H. 1 7071183 DECA L " 432" R.H. 1 7071186 DECA L "488" L.H. 1 70711 85 DECAL "488" R.H. 1

26 5521 004 WIN DSHIELD TR IM 1 27 5850011 WINDSHIELD 1 28 1011 045 MAIN BODY WELDMENT · 294 & 335 cc 1

1011046 MAIN BODY WELDMENT · 398 & 432 cc 1 1011053 MAIN BODY WELDMENT· 488M & 398 432 &488E

29 7621302 5/32 x .379 POP RIVET 4 30 2670023 FRONT BUMPER 1 31 5410021 RUBBER GROMMET 3 32 5420039 SPONGE ROPE 23 1/2" SIDE 2

5420038 SPONGE ROPE 8 1/2" FRONT 2 33 7010001 MAGNETIC LATCH 1 34 7527809 NO.8 x 5/8 PH. HD. TAPPING SCR. 6 35 2681058 CONSOLE CUSHION 1 36 2681045 SEAT CUSHION 1 37 2511070 TEE PEE WELDMENT 1 38 5332227 GAS TANK SPACER 1 39 SEE GAS TANK ASSEMBLY 1 40 4030001 TAILLIGHT BUL8 2 41 5430075 TA ILLIGHT SUPPORT LENS 2 42 5430024 TA ILLIGHT LENS 2

43 7527808 NO.8· 32 x 1 PH. OVAL HEAD STL. CUT SCR . 4

44 7621401 3/16 x .527 POP RIVET 4

45 5223229 BA CKING· MUD FLAP 1

46 54101 15 MUD FLAP 1

47 7542303 5/16·1 8 FLEX LOC NUT 4 48 2670022 REAR BUMPER 1 49 7512310 5/16·18 x 1 HEX HD. MACH. SCR. 2 50 5420064 GAS TANK PAD 1 51 5223522 PARTING LINE EXTRUSION 1

52 5710020 BU MPE R PLUG 2 53 7512107 1/4·20 x 1 1/4 PH. PA N HD. MACH. SCR. 6 54 7542103 i /4 20 F LEX LOC NUT 6 55 5210409 SAFETY WALK 2 56 5221410 GAS TANK REINF ORCEMENT PLATE 1

--'

1- 3

BODY & TRIM (CHARGER)

c

c

c 1-4

BODY & TRIM (TX CHARGER)


2631076 NOSE CONE ASSEMBLY (INCLUDES IT EMS 1 THRU 16) 1

1 5440064 NOSE CONE 1

2 7071153 RACING STRIPE DECAL 1

3 7621203 1/8 x .634 POP RIVET 16

4 7010002 LATCH 4

5 5210181 LATCH SPACE R 2


7 7071158 DECAL "TX" L.H. 1 7071159 DECAL "TX" R.H. 1

8 7071161 DECAL "POLARIS" L.H. 1 7071160 DECAL "POLARIS" R.H. 1

9 7621201 1/8 x .481 POP RIVET 8 10 5510012 HOOD TRIM MOLDING (NOT SHOWN) 1 11 5223473 ATTACHING BAND L.H. 1 12 5223474 ATTACHING BAND R.H. 1 13 7511904 NO. 10 - 32 x 3/4 PAN HEAD MACH . SCR. 6 14 7541901 NO. 10 - 32 WELL NUT 6 15 5510012 HOOD TRIM - ENGINE CAVITY 1 16 7071149 DECAL "STAR POWER BY POLARIS" 1 17 5850019 WINDSHIELD 1 18 5521004 WINDSHIELD TRIM 1 19 7071167 DECAL "CHARGER 300" (NOT SHOWN) 1

7071168 DECAL "CHARGER 400" 1

20 1011050 MAIN BODY WE LDMENT 294 - 335 cc 1 1011051 MAIN BODY WE LDMENT 398 - 432 cc

21 5710020 BUMPER PLUG 2 22 7512107 1/4 - 20 xl 1/2" PH. OVAL HD. MACH. SCR. 6 23 7542103 1/4 - 20 FLEX LOC NUT 6 24 5223522 PARTING LINE EXTRUSION 1 25 7621302 5/32 x .379 POP RIVET 4 26 2670023 FRONT BUMPER 1 27 5420039 SPONGE ROPE 23 1/2" LONG ?

5420038 SPONGE ROPE 8 1/2" LONG 2

28 2681050 SEAT CUSH ION 1 29 2511070 TEE PEE WELDMENT 1 30 7512310 5/16 - 18 x 1 HEX HEAD CAP SCR. 4 31 SEE GAS TANK ASM . 1 32 5430075 TAILLIGHT TRIM 2 33 5430024 TAILLIGHT LENS 2 34 7527808 NO . 8 - 32 x 1 PH. OVAL HD. STL. CUT SCR. 4 35 4030001 TAILLIGHT BULB 2 36 7542303 5/16 - 18 FLEX LOC NUT 5 37 5223229 BACKING - MUD FLAP 1 38 7621401 3/16 - .527 POP RIVET 4 39 5410115 MUD FLAP 1 40 2670022 REAR BUMPER 1 41 5420064 GAS TANK PAD 1 42 5332227 GAS TANK SPACER 1 43 5210409 SAFETY WALK 2 44 5221410 TANK R E INFORCEMENT PLATE 1 45 5221421 SLEEVE CLAMP 1 46 5430087 RECOIL SLEEVE 1

1-5

BODY&TRIM (TX CHARGER)

c

\-6

CONSOLE (MUSTANG - CHARGER)


1 5440067 CONSOLE INSTRUMENT PANEL 1

2 7522008 NO. 10 - 24 x 3/4 PH. HD. MACH. SCR. 4

3 3280010 ANGLE JOINT DRIVE COUPLING 4 4 5410081 STEERING POST GROMMET 1

5 CHOKE ASSEMBLY (SEE ENGINE BOOK) 1 6 5430033 CHARGER PLUG 1 7 2870098 TACHOMETER 1 8 7071150 INSTRUMENT DECAL 1 9 OPTIONAL PRIMER BULB/W HEX NUT 1 10 3280001 SPEEDOMETER 1 11 7542804 IGNITION SWITCH TRIM NUT 1 12 4110012 IGNITION KEY 2 13 7542504 LIGHT SWITCH TRIM NUT 1 14 OPTIONAL CIGARETTE LIGHTER ASM. 1 15 4110010 LIGHT SWITCH 1 16 4110009 IGNITION SWITCH 1 17 3280003 SPEEDOMETER INSERT EXTENSION 1 18 3280002 SPEEDOMETER BUSHING 1 19 3280009 FLEX SHAFT 1 CHECK THE INSTRUMENT PANEL WIRING DIAGRAM FOR LOCATION OF THE FOLLOWING PARTS:

2460054 MERCURY SWITCH 1 4020045 TAB 2 4020046 HOLDER 2 7080046 PANDUIT STRAP 3 4060064 RECTIFYER 1 2434008 CIRCUIT BREAKER 1 7527604 NO.4 - 40 x 1/2 SLT. PAN HD. STAND. SCR. 2 7522009 NO. 10 - 24 x 1/2 SLT. PAN HD. STAND. SCR. 1 7522008 NO. 10 - 24 x 3/4 SLT. PAN HD. STAND. SCR. 1

1-7

c

c

c

CONSOLE (MUSTANG - CHA RGER)

1-8

CONSOLE (TX CHARGER)

ITEM NO. PART NO. PART DESCRIPTION QTY. )

1 5430054 TX HEAD LIGHT HOUSING 1

2 5430055 TXINSTRUMENTPANEL 1

3 7511916 NO. 10 x 5/8 PH. HD. SH. METAL SCREW 8

4 7511937 NO. 10 xl 1/4 PH. HD. SH. METAL SCREW 2

5 4030007 SEAL BEAM UNIT - GE 4454 1

6 5221126 RETAINING RING 1

7 7527601 NO.6 - 20 x 3/8 PAN HD. SCREW

8 2870098 TACHOMETER & HARDWARE 1

9 3280001 SPEEDOMETER & HARDWARE 1

10 7071102 DECAL 1

11 3280009 FLEX SHAFT 1

12 3280004 ANGLE JOINT DRIVE COUPLING 1

13 3280003 SPEEDOMETER INSERT EXTENSION 1

14 3280002 SPEEDOMETER BUSHING 1

15 7071152 CONSOLE DECAL 1

16 7542804 IGNITION SWITCH TRIM NUT 1

17 4110012 IGNITION KEY 2

18 7080038 CHOKE CONTROL - TI LLOTSON CARBURETOR 1

19 3160101 PRIMER BULB W/NUT (OPTIONAL) 1

20 7542804 LIGHT SWITCH TRIM NUT 1

21 5440055 TX CHARGER CONSOLE 1

22 7521201 1/8 x .481 POP RIVET 10

23 4110010 LIGHT SWITCH 1

24 3160102 1/4 - 28 HEX NUT 1

25 4110009 IGNITION SWITCH 1

26 7071194 SAFETY DECAL )

)

1-9

CONSOLE (TX CHARGER)

c

c

c 1-10

GAS TANK ASSEMBLY

)

J


1 2511069 GAS CAP· CHARGER 1 2 2511068 GAS CAP· MUSTANG & TX CHARGER 1 3 2511041 GAS TANK· ALL MACHINES 1 4 7080003 HOSE CLAMP - ALL MACHINES 2 5 5420063 REAR GAS LINE· ALL MACHINES 1 6 5410021 RUBBER GROMMET - MUSTANG 1 7 5331006 STEEL GAS LINE· ALL MACHINES 1 8 7071127 TANK DECAL - ALL

)

1- 11

GAS TANK ASSEMBLY (VOYAGER & PLAYMATE)

c

ITEM NO. PART NO. PART DESCRIPTION QTY. 1 2511044 GAS CAP - PLAYMATE 1

2 2511043 GAS CAP & GAUGE - VOYAGER 1

3 2511041 GAS TANK - VOYAGER 1 2511042 GAS TANK - PLAYMATE 1

4 7080003 HOSE CLAMP - BOTH MACHINES 1 5 5420056 RUBBER GAS LINE - PLAYMATE 1 6 5420065 RUBBER GAS LINE - VOYAGER 1 7 5410021 GROMMET - VOY AGE R ON L Y 1 8 5331006 STEEL GAS RETURN LINE - VOYAGER ONLY 1 9 5420077 20" GAS RETURN LINE - VOYAGER ONLY 1

10 7071140 TANK DECAL - BOTH MACH!NES 1 c 1-12

BODY&TRIM (PLAYMATE)


1 5440054 NOSE CONE 1

2 7521201 1/8 x .481 RIVET 16


4 7010002 LATCH 4

5 7071096 R.H. DECAL 1

7071095 L.H. DECAL 1

7071197 DECAL - 164 - l.H. 1

7071198 DECA l - 164 - R.H. 1

6 7541901 NO. 10 · 32 WELL NUT 5

7 7511904 NO. 10 - 32 x 3/4 PAN HD. MACHINE SCREW 5

8 5223465 ATTACHING BAND 1

9 5850018 WINDSHIELD 1

10 5521019 TRIM BAND 1

11 7621410 3/16 x_902 POP RIVET 4

12 7558201 NO. 10 - S.A.E. FLAT WASHER 4

13 5430038 GRILL 1

14 4030008 SEALED BEAM UNIT 1

15 5221126 ATTACHING RING 1

16 7527804 NO.6 x 20 x 3/8 PAN HD. SCREW 4

17 SEE GAS TANK ASSEMBLY 1

18 1011015 MAIN BODY WELDMENT 1

19 5710018 BUMPER PLUG 4

20 7512127 1/4 - 20 x 1 1/2 PH. OVAL HD MACHINE SCREW 8

21 7542103 1/4 - 20 FLEX LOC NUT 8 22 7671302 5/32 x .379 POP RIVET 4

23 2670011 BUMPER 1

24 5223206 PARTING LINE EXTRUSION 1

25 5223466 HOOD LATCH HOLD DOWN STRAP 2 )

26 7621301 5/32 x .504 POP RIVET 4

27 5420039 SPONGE ROPE 23 -1/2" LONG 2 5420038 SPONGE ROPE 8 - 1/2" LONG 2

28 7527602 NO.6 x 1/2 WOOD SCREW 15

29 2652015 CONSOLE COVER CATCH 1 30 7020010 CONSOLE COVER HINGE 1 31 7621201 1/8 x .481 POP RIVET ::l

32 2681031 CONSOLE CUSHION 1 33 2681029 SEAT CUSHION 1 34 2681030 BACK REST 1 35 2511030 GAS TANK TEE PEE 1 36 7541909 NO.8 PAL NUT 4 37 5221137 TAILLIGHT BACKING PLATE 2 38 4030001 TAILLIGHT BULB 2 39 5430011 TAILLIGHT LENS 2 40 7511812 NO.8 - 32 x 1/2 SLT. ROUND HD. SCREW 4 41 7542303 5/16 - 18 FLEX LOC NUT 6 42 7512310 5/16 - 18 x 1 HEX HD. CAP SCREW 6 43 2670021 REAR BUMPER 1 44 5420060 GAS TANK PAD 1

)

1-13

600'( & ltt\M ~PLA'l\\llA"£)

c

c

c

BODY&TRIM (VOYAGER)

ITEM NO. PART NO. PART DESCRIPTION QTY. ) 1 5440070 SHROUD 1

2 7621201 POP RIVET 16

3 7010002 HOOD LATCH 4

4 7558205 NO. 8 WASHER 16

5 7071195 DECAL - VOYAGE R - L.H. 1 7071163 DECAL- VOYAGER - R.H. 1

6 7071174 DECAL - 488 - L.H. 1 7071173 DECAL - 488 - R.H. I 1

7 5430030 SIDE GRILL - UPPER R.H. 1 5430031 SIDE GRILL - UPPER L.H. 1

8 7670009 PUSH ON NUT 12 9 7621315 5/32 x .625 POP RIVET (BLACK) 1 10 7071196 DECAL - SHROUD 1

11 7541901 10- 32 WELL NUT 5 12 7511914 10 - 32 x 1 SLOTTED PAN HD. SCR. 5 13 5223527 WINDSHIELD BAND 1 14 5850016 WINDSHIELD 1 15 5521002 WINDSHIELD TRIM 50 INCH 1

16 7071149 STAR POWER DECAL (NOT SHOWN) 1 17 5430083 DASH GRILL 1 18 7621303 5/32 x .629 POP RIVET 3 19 7071194 SAFETY CHECK DECAL (NOT SHOWN) 1 20 7558201 NO. 10 WASHER 3 21 7527803 8-32xl/2SCR. 1 22 5430036 GRILL 1

23 4030004 HEADLIGHT 1 24 5221126 ATTACHING RING 1 25 7527805 6-32x 1/2SCR. 4 26 1013005 MAIN BODY WELDMENT 1 27 7512307 5/16 - 18 x 3/4 HEX HD. CAP SCR. 4 28 5222076 COVER - LOWER CHAINCASE 1 29 5710016 BUMPER PLUG 2 J 30 7512127 1/4 - 20 xl 1/2 PHILLIPS OVAL HD. SCR. 8 31 7511904 10 - 32 x 3/4 SLOTTED PAN HD. SCR. 8 32 7542103 1/4 - 20 HEX FLEX LOC NUT 8 33 5223188 PARTING LINE EXTRUSION 1 34 2670007 FRONT BUMPER 1 35 7512108 1/4 - 20 x 3/4 SLOTTED PAN HEAD SCR. 1 36 5440059 COVER - LOWER SPEEDOMETER HOUSING 1 37 5420005 SPONGE ROPE TUBING 4 38 5410021 FUEL LINE GROMMET 2 39 5410081 STEERING POST GROMMET 1 40 7527603 NO.7 x 3/4 WOOD SCREW 10 41 2681036 SEAT SPACER 1 42 2681035 SEAT 1 43 7621410 3/16 x .312 POP RIVET 6 44 7210002 5 INCH TEE HINGE 2 45 2870081 NON- SKID RUNNING BOARD 2 46 5420064 GAS TANK PAD 1 47 2670020 REAR BUMPER 1 48 7620102 1/8 x .375 POP RIVET 6 49 7558402 5/16 WASHER 4 50 7542313 5/16 - 18 HEX NUT 4 51 4030001 TAILLIGHT BULB 6 52 5430026 TAILLIGHT HOUSING 2 53 5430025 WRAP AROUND LENSE 2 54 7527808 NO.8 - 32 x 1 PHILLIPS OVAL HEAD SCR. 4 55 7527810 NO.8 - 32 xl 1/4 PH. OVAL HD. SCR. ?

56 5221308 SUPPORT LENS 1 57 5420051 TAILLITE SPACER 1 58 SEE GAS TANK ASM. 1 59 5332227 GAS TANK SPACER 1 60 7621202 1/8 x .375 POP RIVET 6

7010008 SNAP 6 61 2511023 TEEPEE ASM. 1 62 7010009 CAP 6

7010010 SOCKET 6

1-15

BODY&TRIM (VOYAGER)

c

c \-16

CONSOLE (VOYAGER)


1 5430040 CONSOLE INSTRUMENT PANEL 1

2 7511934 NO. 10 - 24 x 3/4 PH. HD. MACHINE SCREW 4

3 7541906 NO. 10 - 24 FLEX·LOC NUT 4

4 5410081 STEERING POST GROMMET 1

5 5410021 RUBBER GROMMET 1

6 5430035 POLARIS PLUG 1

7 7071102 DECAL - MANUAL START 1 7071103 DECAL - ELECTRIC START 1

8 7071101 INSTRUMENT DECAL 1

9 3160101 PRIMER BULB W/HEX NUT 1

10 7080038 CHOKE CONTROL - TILLOTSON CARBURETOR 1

11 7542804 IGNITION SWITCH TRIM NUT 1


13 7542504 LIGHT SWITCH TRIM NUT 1

14 5430041 LIGHTER PLUG 1

15 3160102 1/4 - 28 HEX NUT 1


17 4110010 LIGHT SWITCH 1

18 3280001 SPEEDOMETER 1

19 3280005 FLEX SHAFT 1

20 3280004 ANGLE JOINT DRIVE COUPLING 1

21 3280003 SPEEDOMETER INSERT EXTENSION 1

22 3280002 SPEEDOMETER BUSHING 1

23 2870060 TACHOMETER 1

24 2434007 FUSE HOLDER - ELECTRIC START ONLY 2

25 2434006 20 AMP FUSE - ELECTRIC START ONLY 1

26 2434005 7·1/2 AMP FUSE - ELECTRIC START ONLY 1

27 2870009 CIGARETTE LIGHTER ASSEMBLY 1 )

)

1-17

c CONSOLE (VOYAGER)

c

c

.- 18

5

ITEM NO.

1

I

PART NO.

7080038

2 3 4110012

--4~-- 7542804

5

6

7071143

3160102

4110009

CONSOLE (PLAYMATE)

CHOKE CONTROL PART DESCRIPTION

IGNITION KEY

__ ~IG~NIIIT liON SW __ -",CONSOLE DEITCH TRIM NUT

CAL

1/4 - 28 HEX NUT

IGNITION SWITCH

1-19

----CD )

4

)

QTY.

2

c

DRIVE & BRAKE ASSEMBLY

c Group II

CHAIN CASE ASSEMBLY (CHARGER - MUSTANG - TX CHARGER)

ITEM NO. PART NO. PART DESCRIPTION QTY. J 1 5610028 CHAINCASE FRONT COVER 1

2 5410043 CHAINCASE COVER "0" RING 1

3 7712801 RETAINING RING .500 DIA. 1

4 7558702 .927 O.D. x .031 THRUST WASHER 2

5 3553002 .500 I.D. x .688 O.D. x .500 ROLLER BEARING 1

6 3221011 I DLER SPROCKET RC35- 2 11 TOOTH 1

7 7511905 NO. 10 - 24 x .50 PH. DRIVE TRUSS HD. SEM 7

8 5210116 IDLER SLIDE RETAINING PLATE 1

9 5020075 IDLER SHAFT 1

10 5610032 IDLER SLIDE 1

11 5610052 CHAINCASE 1

12 1910004 BRAKE BAND ASSEMBLY 1

13 7080037 BRAKE CABLE 1

14 5610027 BRAKE DRUM 1

15 7714201 RETAINING RING 1.125 DIA. 2

16 5610051 CHAINCASE REAR COVER 1

17 7512325 5/16 - 18 UNC - 2A x .75 NYLOCK HEX HD. CAP SCREW 6

18 7721103 3/16x3/16x 111/16SQUARE KEY 1

19 5020130 JACKSHAFT 1

20 3514303 205 BALL BEARING - 2 SEALS 3

21 7727001 NO.9 WOODRUFF KEY 1

22 7542301 5/16 - 18 HEX NUT 1

23 5020076 ADJUSTING BOLT 1 24 7713901 RETAINING RING .984 DIA. 1

25 7661806 DOWEL PIN 2

26 5210121 BEARING RETAINING PLATE 1

27 7577901 5/16 LOCK WASHER 2

28 7512120 1/4 - 20 x 1.00 HEX HD. SEM 8

) 29 7512604 HEX HD. PLUG 2

30 3222007 DRIVEN SPROCKET RC35 - 2 39 TOOTH 1

31 3221012 DRIVE SPROCKET RC35 - 213 TOOTH 1

3221008 DRIVE SPROCKET RC35 - 215 TOOTH 1

3221009 DRIVE SPROCKET RC35 - 217 TOOTH 1 3221010 DRIVE SPROCKET RC35 - 219 TOOTH 1

32 3224005 ROLLER CHAIN 35 - 2 90 PITCHES 1

3224006 ROLLER CHAIN 35 - 2 92 PITCHES 1

--

11-1

c CHAIN CASE ASSEMBLY

lCHARGER _ MUSTANG - TX CHARGER)

,,-2

j

/I! ( ! --.1

CHAIN CASE MOUNTING (MUSTANG) J

'--------- )


1 1332015 CHAINCASE ASSEMBLY· 398 1

1332024 CHAINCASE ASSEMBLY · 488 1

2 7721103 3/16 SQUARE KEY 1

3 DRIVEN CLUTCH (SEE CLUTCH ASSEMBLIES) 1 4 5221207 DRIVEN CLUTCH CAP 1

5 7577908 5/16 DISHED TOOTH LOCK WASHER 1 6 7512328 5/16·18 x 3·1/4 HEX HD. CAP. SCR. 1 7 3211007 DRIVE BELT RAMP 1

3211021 DRIVE BELT· NEW 30° RAMP CLUTCH 1 8 7512413 3/8·16 x 2 CARRIAGE BOLT 4 9 7542402 3/8·16 FLEX LOC NUT 4 10 7621303 5/32 x .629 POP RIVET 5 11 5221131 CLOSE OFF HOLD DOWN 1 12 5410069 CHAINCASE CLOSE OFF 1 13 7556401 7/8 MACH. BUSHING (STANDARD RAMP) 3

7556401 7/8 MACH. BUSHING (ALUM. 30° RAMP) 1

11-3

CHAIN CASE MOUNTING (CHARGER - TX CHARGER) c

----

c


1 1332015 CHAINCASE ASSEMBLY 294 - 335 1

1332024 CHAINCASE ASSEMBLY 398 - 432 1

1332026 CHAINCASE ASSEMBLY 488 1

2 7721103 3/16 SQUARE KEY 1

3 DRIVEN CLUTCH (SEE DRIVEN CLUTCH ASM.) 1

4 5221207 DRIVEN CLUTCH CAP 1

5 7577908 5/16 DISHED TOOTH LOCK WASHER 1

6 7512328 5/16 - 18 x 3 1/4 HEX HEAD CAP SCREW 1

7 3211007 DRIVE BELT - RAMP CLUTCH 1

3211021 DRIVE BELT 30° RAMP CLUTCH 1

8 7512456 3/8 - 16 x 4" CARRIAGE BOLT 4

9 7542402 3/8 - 16 FLEX LOC NUT 4

10 5210346 CHAINCASE BRACE 1 11 5610054 CHAINCASE SPACER 1

12 7556401 7/8 MACH. BUSHING (STANDARD RAMP) 3

7556401 7/8 MACH. BUSHING (ALUM. 30° RAMP) 1

c 11-4

DRIVE CLUTCH ASSEMBLY (HIGH PERFORMANCE)

J

ITEM NO. PART NO. PART DESCRIPTION GTY.

1321079 DRIVE CLUTCH COMPLETE 294,336,398,432, &488 1 1 1321077 STATIONARY FACE AND HUB 294,336,398,432, &488 1 2 5010010 SPACER 2 3 3515801 BEARING 1 4 5630001 BUSHING 2 5 5331057 SPACER 1 6 7041002 SPRING 1

7 1321036 MOVEABLE FACE AND ARM WELDMENT 1

8 3225008 PIN 16

9 7661001 COTTER PIN 18

10 3225009 LONG PIN 3

11 3225001 NO. 60 ROLLER LINK ASA 3

13 5221113 ATTACHING CUP 3

14 5010045 CENTER WEIGHT 3

15 3225007 PIVOT LINKAGE 6 16 5010046 LINKAGE WEIGHT 6 17 5230036 DRIVE PLATE AND COVER 1 18 5210152 LOCKING CLIP - BOLT 3 19 7512334 5/16 - 24 x 3/8 HEX HEAD CAP SCREW 3 20 5020016 RETAINING BOLT 1 21 7575202 7/16" INTERNAL LOCK WASHER 294 336 398 432 & 488 1 22 7512527 I 7/16-UNFx41/4RETAININGBOLT294 336 398 432 &488 1

)

11-5

DRIVE

c

PART NO. r 1321117

1321118

7542402

2 7555806

3 5630022 4 7661806

5 5010083 6 7041009

7555807 5010084

3563603 10 7670015

11 5210401

5210402

12 5010085

13 3225015

14 5910004

15 3225017

16 3565902

17 7661003

18 3225018

19 5910005

20 1321071

1321116

7512529 7555805

7577905

c

CLUTCH ASSEMBLY o ALUMINUM) (30

~ I

PART OEseR IPTION

(294- 335) DRIVE CLUTCH A~~. (398 _ 432 _ 488)

TCH A . DRIVE CLU LaC NUT 3/8 - 16 FLEX

3/8 WASHER

COVER PIN 1/4" DOWEL

BUSHING H SPRING - CLUTC

SPECIAL WASHER

THREADED PIN

SLEEVE BEARING

G CLIP RETAININ HT (294,335) CLUTCH WEIG T (398,432,488) CLUTCH WEIGH

TUBE

PIN

SPIDER

PIN G SLEEVE BEARIN

COTTER PIN

ROLLER VABLE

SHEAVE - MO MACHINED SHEAVE ASM. - CAST

EAVE ASM. - _ SH BOLT RETAINING

WASHER OaF WASHER 7/16 SHAKEPR

11-6

13

"

".

QTY.

3

3

1

3

3

3

3

DRIVEN CLUTCH ASSEMBLY (300 ALUMINUM)

J

t~ (j)


1322039 CLUTCH ASM. 1

1 1322040 STATIONARY FACE ASM. 1

2 1322041 MOVEABLE FACE ASM. 1

3 7041004 SPRING 1 )

4 5430078 RAMP BUSHING 3

5 5630026 RAMP 1

6 3565903 BRONZE SLEEVE 1 11/16 I. D. x 1 7/8 O.D. 1

7 7714803 5107· 156SNAP RING 1

)

II -7

DRIVEN CLUTCH ASSEMBLY

c


1322016 STANDARD RAMP CLUTCH ASSEMBLY 1 1 1322017 STATIONARY FACE ASSEMBLY 1 2 1322018 MOVEABLE FACE ASSEMBLY 1 3 7041004 SPRING 1 4 5630004 RAMP 1

c 5 5430012 BUSHING - RAMP 3 6 3565901 BRONZE SLEEVE 1 7 7714801 RETAINING RING 1

c 11-8

TRANSMISSION & CHAIN CASE MOUNTING (VOYAGER)

c

c ITEM NO. PART NO. PART 0 ESCR IPTION QTY.

1 1332025 ASSEMB LY - CHAINCASE 1

2 5610028 FRONT COVER - CHAINCASE 1

3 7512412 SCREW - HEX HEAD CAP 3/8 - 16 x 2 CAD. PLATED 2

4 7512413 3/8 - 16 UNC - 2A x 2 CARRIAGE BOLT 2

5 7542402 3/8 -16 FLEX LOCK NUT 8

6 1341020 ASSEMBL Y - TRANSMISSION 1

7 1322016 CLUTCH - RAMP 103/4 DIA. 7/8 BOR E 1

8 7512507 7/16 - 20 UNF - 2A x 4 1/2 HEX HEAD CAP SCREW 1

9 7721103 SQUARE KEY - RAMP CLUTCH 1

10 7512412 SCREW HEX HEAD CAP 3/8 - 16 x 2 4

11 7558501 3/8 SAE STEEL WASHER 16

12 3211003 BELT -- DRIVE DAYCO RACING NO. 13801 1 13 7577902 5/16 DISHED TOOTH LOCK WASHER 1

14 5221207 CAP - DR IVEN CLUTCH 1

c 11 - 9

CHAIN CASE MOUNTING (PLAYMATE)

)

)


1 1332017 CHAIN CASE 1 2 7721103 3/16 SQUARE KEY 1

3 1322021 DRIVEN CLUTCH 1

3 1322016 RAMP CLUTCH (TX MACHINE ONLY) 1 4 7558401 5/16 I.D. x 1-3/8 O.D. FLAT WASHER 1 4 5221207 DRIVEN CLUTCH CAP (TX MACHINE ONLY) 1 5 7577901 5/16 DISHED TOOTH LOCK WASHER 1

6 7512328 5/16 - 18 x 3-1/4 HEX HD. CAP SCREW 1

7 3211007 DRIVE BELT 1

8 7512329 5/16 - 18 x 1-3/4 HEX HD. CAP SCREW 4

)

11 - 10

DRIVE CLUTCH ASSEMBLY (PLAYMATE)

c ITEM NO. PART NO. PART DESCRIPTION QTY.

1 3250006 INNER SHEAVE & HUB 1 2 3250009 BRONZE BEARING 2

3 3250008 SPRING CUP 1

4 3250007 SPRING 1

5 3250005 OUTER SHEAVE 1

6 3250001 CLUTCH COVER 1

7 7556107 9/16 SAE FLAT WASHER 1

8 5020175 9/16 x 1" RETAINING SLEEVE 1

9 7575003 5/16 INTERNAL LOCK WASHER 1

10 7512368 5/16 - 18 x 5 HEX HD CAP SCREW GRADE 5 1

1321081 CLUTCH ASSEMBLY COMPLETE

.:

II - 11

CHAIN CASE ASSEMBLY (PLAYMATE)

ITEM NO. PART NO. PART DESCRIPTION QTY. ) 1 5610028 CHAINCASE FRONT COVER 1

2 5410043 CHAIN CASE COVER "0" RING 1

3 7712801 RETAININ G RING .500 DIA. 1

4 7558702 .9270.0 . x .031 TH RUST WASHER 2

5 3553002 .5001.0. x .6880.0. x .500 ROLLER BEARING 1

6 3221015 IDLE R SPROCK ET RC-3511 TOOTH 1

7 7511905 No. 10 - 24 x .50 PHILLIPS DRIVE T RUSS HEAD SEM 7

8 5210116 IDLER SLID E RETAININ G PLATE 1

9 5020075 ID LER SHAFT 1

10 5610032 IDLER SLIDE 1

11 5610052 CHAIN CASE 1

12 1910004 BRAKE BAND A SSEMB LY 1

13 7n~nn':l7 BRAKE CAB.LE 1

14 !;fl10027 BRAKE DRUM 1

15 7714201 RETAINING RING 1.125 DIA. 2

16 5610051 CHAIN CASE REAR COVER 1

17 7512325 5/16 - 18 UNC - 2A x .75 NYLOCK HEX HEAD CAP SCREW 6

18 7721103 3/16 x 3/16 x 111/16 SQUARE KEY 1

19 5020130 JACKSHAFT 1

20 3514303 205 BALL BEARING - 2 SEALS 3

21 7727001 No.9 WOODRUFF KEY 1

22 7542301 5/16 - 18 HEX NUT 1

23 5020076 ADJUSTING BOLT 1

24 7713901 RETAINING RING .984 D IA. 1

25 7661806 DOWEL PIN 2

26 5210121 BEARING RETAINING PLATE 1

27 7577902 5/16 LOCK WASHER 2

28 7512120 1/4 - 20 x 1.00 HEX HEAD SEM 8 J 29 7512604 HEX HEAD PLUG 2

30 3223006 DRIVEN SPROCKET RC- 35 42 TOOT H 1

31 3221014 DR IVE SPR OCKET RC- 35 12 TOOTH 1

32 3224012 ROLLER CHA IN 3590 PITCHES 1 ,

..... \

.~

-,

II - 12

CHAIN CASE ASSEMBLY (PLAYMATE)

c " '. ,

.,

" - 13

TRANSMISSION & CHAIN CASE ASSEMBLY (VOYAGER)


1 1341020 ASSEMBLY - TRANSMISSION 1

2 1341011 GEAR SHIFT LEVER ASSEMBLY 1

3 1341012 SHIFTING BRACKET ASSEMBLY 1

4 5221255 SHIFTING LINK 2

5 5221256 SHIFTING BAR 1

6 5223461 CONNECTION BAR 2

7 3230261 SHIFTER DOG 1

8 3230262 GEAR - PINION 1

9 3230263 GEAR - OUTPUT 1

10 3230264 SHAFT BEVEL GEAR 1

11 3514303 BALL BEARING PP205 4

12 3514901 BALL BEARING NPP 206 1

13 3515401 BALL BEAR ING 207 1

14 3553003 N EEDLE BEAR IN G - 1010 FAFNER 1

15 3553004 NEEDLE BEARING - 1110 FAFNER 1

16 3554703 NEEDLE THRUST BEARING - 1018 FAFNER 1

17 3554704 BEAR ING RACE 2

18 5410101 "0" RING 1

19 5430042 BEAR ING SHIFTER RING 1

20 5630019 HOUSING - TRANSMISSION 1

21 5630020 PLATE - TRANSMISSION COVER 1

22 5630021 HOUSING - SHIFTING SHAFT 1

23 5910002 SHIFTER RING 1

24 5910003 SHIFTING FORK 1 25 6230021 SHAFT - SPLINE 1 26 6230022 SHAFT - PINION GEAR 1 27 7030002 KNOB - TRANSMISSION HANDLE 1 28 7041008 SPRING - COMPRESSION 1 29 7042002 EXTENSION SPR ING 1 30 7051501 PLUG - PIPE 1/8" 2 31 7051504 VENT - TRANSMISSION 1 32 7727001 NO.9 WOODR UFF KEY 2 33 3221011 SPROCKET - IDLER 1 34 3553002 BEARING 1 35 5020075 IDLER SHAFT 1 36 5020076 ADJUSTING BOLT 1 37 5210116 RETAINING PLATE 1 38 5210121 RETAINING PLATE - BEARING 1 39 5610032 IDLER SLIDE 1 40 5610029 CHAINCASE 1 41 7511905 SCREW - TRUSS HEAD SEM 10 - 24 x 1/2 PHILLIPS 7 42 7712801 RETAINING RING 1 43 7558702 THRUST WASHER 2 44 1910004 BRAKE BAND ASSEMBLY 1 45 7080037 BRAKE CABLE 1 46 5610027 BRAKE DRUM 1 47 7714201 RETAIN ING RING 2 48 3221008 SPROCKET 15 TOOTH 1 49 3222007 SPROCKET 39 TOOTH 1 50 3224005 ROLLER CHAIN 1 51 5410043 "0" RING - CHAINCASE COVER 1 52 7512120 HEX HEAD SEM 1/4 - 20 xl 8 53 7512325 SCREW NYLOCK 5/16 - 18 x 3/4 2 54 5610064 FRONT COVER - VOYAGER CHAINCASE 1 55 7713901 RETAINING RING 1 56 7512313 5/16 - 18 x 2 HEX HEAD CAP SCREW 4 ) 57 7512317 SCREW HEX HEAD CAP 5/16 - 18 xl 1/2 2 58 7512325 SCREW HEX HEAD CAP 5/16 - 18 x 3/4 2

II - 14

TRANSMISSION & CHAIN CASE ASSEMBLY (VOYAGER)

c


59 7552901 5/16 SPLIT LOCK WASHER 4

60 7714203 SNAP RING 1

61 7512467 SET SCREW 1

62 7542404 JAM NUT 1

63 7512161 SCREW - 1/4· 28 UNF x 3/4 SOCKET HEAD 1

64 7512163 SCREW - HEX HEAD CAP - 1/4 • 20 x 1 1/4 3

65 7542101 1/4 . 20 HEX BIWAY LOCK NUT 7

66 7512110 1/4 . 20 x 2 HEX HEAD CAP SCREW 1

67 7512126 1/4 . 20 x 1 1/2 HEX HEAD CAP SCREW 3

68 7558301 1/4 SAE WASHER 12

69 7512102 ,- 1/4 - 20 x 1/2 HEX HEAD CAP SCREW 2

70 7571801 1/4 EXTERNAL LOCK WASHER 2

71 7713402 SNAP RING 1

72 7577901 5/16 DISHED TOOTH LOCK WASHER 2

73 7512604 PLUG 1/2 HEX HEAD 1

74 7512641 PLUG - ALLEN HEAD - VOYAGER 1

7512637 PLUG - ALLEN HEAD - INNOVAR 1

c 75 7571801 1/4 INCH SHAKEPROOF LOCKWASHER 5

76 7542108 1/4 - 20 HEX NUT NYLOCK

77 7512121 1/4 - 20 x 1 1/2 BLOTTED PAN HEAD MACH SCREW 1

78 7721103 KEY 1

79 7714202 SNAP RING 1

II -15

DRIVEN CLUTCH ASSEMBLY (PLAYMATE)

)

ITEM NO. PART NO. )>\.

PART DESCRIPTION QTY.

1322021 Driven Clutch Complete 1 1 1322020 STATIONARY FACE & HUB 1 2 1322004 MOVEABLE FACE & HUB 1 3 3564502 BUSHING 1 4 3562601 BUSHING 3 5 7041001 SPRING 1 6 5230013 SPRING RETAINER 1 7 7114401 SNAP RING 1

)

.~ .. II -16

.. DRIVE CLUTCH ASSEMBLY

(1970 30° ALUMINUM RACE CLUTCH)

I


1321150 CLUTCH ASSEMBLY FOR ENGINE SIZE 294 - 335 1

1321149 CLUTCH ASSEMBLY FOR ENGI NE SIZE 392 - 436 - 488 1

1321072 CLUTCH ASSEMBLY FOR ENGINE SIZE 648 - 795 1 1321166 CLUTCH ASSEMBLY FOR ENGI NE SI ZE 792 1

t----

SOLD AS COMPLETE ASSEMBL Y ONLY

SEE PRICE SUPPLEMENT FOR EXCHANGE PRICE

11-18

DRIVE CLUTCH ASSEMBLY (SALSBURY - MODEL 770)

,~----------~ ,---------~/

CD


1321093 DRIVE PULLEY - 30 MM TAPERED BORE, .190" OFFSET 1

1 0601190 FIXED FACE AND HUB ASSEMBLY 1

2 0601210 MOVEABLE FACE ASSEMBLY 1

3 0690112 SERVICE KIT - SPRINGS, PINS, BUSHINGS, SCREW, 1 SET

CLAMP, AND RETAINING CLIP

4 0690116 SERVICE KIT - ROLLER ARM ASSEMBLY 1

5 0601216 SPIDER AND PIN ASSEMBLY 1

6 0702967 RAMP PLATE 1

7 0690088 SERVICE KIT - SCREWS, WASHERS, AND LOCK PLATE 1

8 0703046 SPACER 1

9 0900009 RETAINING RING 1

10 0702978 CUP WASHER 1

11 3211020 BELT (NOT SHOWN) FOR MODEL 770 SALSBURY DRIVE 1

AND DRIVEN CLUTCH COMBINATION

11-19

ITEM NO. PART NUMBER

PART DESCRIPTION QTY. 292cc 336cc 398cc 436cc 488cc

1 1211228 1211221 1211313 1211314 1211315 ENGINE 1 2 3080482* STARTING MOTOR 1 3 3080411 * 3080411 3080454 3080454 3080454 MUFFLER ASSEMBLY 1 r- 4 3080389 3080433 3080467 3080466 3080483 CARBURETOR ASSEMBLY 2 5 3080442 3080442 3080277 3080277 3080277 MAGNETO ASSEMBLY 1 6 3080431 3080431 3080226 3080226 3080226 RECOIL STARTER ASSEMBLY 1 7 3080346* FUEL PUMP ASSEMBLY 2 8 3080417* IGNITION COIL 1

3080418* IGNITION COIL 1 *REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ENGINES LISTED.

I I

/ I / 1'/ I I I I I

I I I I I I

C I I 2 I I I I I I I

/1 I I J ,

ITEM NO. PART NUMBER

PART DESCRIPTION 292cc 336cc 398cc 436cc 488cc 1 3080411 3080411 3080454 3080454 MUFFLER ASSEMBLY

2 3080479* MAGNETO ASSEMBLY

3 3080431 3080431 3080226 3080226 RECOIL STARTER COMPLETE

4 3080417* IGNITION COIL

3080418* IGNITION COl L

5 3080346* FUEL PUMP ASSEMBLY

6 3080389 3080433 3080467 3080466 CARBURETOR ASSEMBLY 7 1211230 1211229 1211319 1211320 ENGINE

*REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ENGINES LISTED.

QTY.

1

1

1

1 1

2

2

1

\ -~

STEERING ASSEMBLY

( Group III

STEERING ASSEMBLY (CHARGER - MUSTANG - TX CHARGER)

ITEM NO. PART NO. PART DESCRIPTION QTY

MUSTANG CHARGER & TX )

1 1823044 1823044 STEERING POST WELDMENT 1

1823045 STEERING POST WELDMENT (TX CHARGER) 1

2 1823023 1823023 HANDLE BAR WELD 1

3 5430001 5430001 HANDLE BAR GRIP 2

4 2010012 2010012 BRAKE CONTROL ASM. 1

5 2010008 2010008 THROTTLE CONTROL ASM. 1

6 411001'3 4110013 KILLSWITCH 1

7 7512465 7512465 3/8 - 16 x 3/8 SOCKET HD. SET SCR. 2

8 7080001 7080001 THROTTLE CABLE - TILLOTSON CARB. 1

7080039 7080039 THROTTLE CABLE (MIKUNI CARBURETOR) 1

9 7010016 7010016 CLIP 1

10 7512157 7512157 1/4-20x 1/2 CARRIAGE BOLT 4

11 7542103 7542103 1/4 - 20 FLEX LOC NUT 4

12 7511936 7511936 10- 24 x 1/2 PHILLIPS RD. HD. MACH. SCR. 4

13 7541906 7541906 10 - 24 FLEX LOC NUT 4

14 5020082 5020079 TIE ROD 2

15 7512410 7512410 3/8 - 24 x 1 3/4 HEX HD. CAP SCR. 2

16 7542401 7542401 3/8 - 24 HEX NUT 4

17 3574202 3574202 NYLON FLANGE BEARING 1

18 7556401 7556401 7/8 I.D. x 16 GA. MACH. BUSHING 1

19 7542411 7542411 3/8 - 24 FLEX LOC NUT 4

20 7060103 7060103 ROD END BEARING 4

21 5221092 5221092 STEERING ARM 2

22 7661501 7661501 5/32 x 1 - 1/4 COTTER PIN 1

23 3573902 3573902 SPINDLE HOUSING BUSHING 4 - . 24 1821Cl05 1821010 SPINDLE 2

25 5410055 5410055 SKI STOP 2 1820131 1820131 SKI ASSEMBLY COMPLETE 2

26 5010059 5010059 SADDLE BUSHING 2 ?7 751?43!'> 7512435 3/8 - 24 x 3 HEX HD. CAP SCR. GRD. 5 4 28 7542403 7542403 3/8 - 24 FLEX LOC NUT 8 29 7512405 7512405 3/8 - 24 x 1 1/4 HEX HEAD CAP SCR. 4 30 7542303 7542303 5/16 - 18 FLEX LOC NUT 2 31 5210007 5210007 SKI SPRING PLATE 2 ~? 704~OO~ 704~OO~ TOP SUPPORT SPRING 2 33 7043002 7043002 CENTER SUPPORT SPRING 2

34 7043010 7043010 MAIN LEAF SPRING 2 35 5010002 5010002 SKI SPRING BUSHING 2 36 1820132 1820132 SKAG WELDMENT 2 37 1820130 1820130 SKI 2 38 5430003 5430003 WEAR PLATE 2 39 7662001 7662001 3/8 x 2 - 3/4 CLEVIS/PIN 2 40 7661401 7661401 1/8 x 1 COTTER PIN 2 41 5221227 5221227 SPRING SADDLE 2

III - 1

STEERING ASSEMBLY (CHARGER - MUSTANG - TX CHARGER)

III - 2

STEERING ASSEMBLY (PLAYMATE)


1 5430001 HANDLE GRIP 2

2 2010006 CONTROL HANDLE ASSEMBLY 2

3 7512308 5/16 - 18 x 5/16 SOCKET HEAD SET SCREW 2

4 1823014 STEERING POST ASSEMBLY 1

5 7080019 THROTTLE CABLE 1

6 SEE CHAIN CASE ASSEMBLY 1

7 7512108 1/4 - 20 x 3/4 SLT. PAN HD. MACHINE SCREW 2

8 7542101 1/4 - 20 LOC NUT 4

9 3574202 NYLON FLANGED BEARING 1 10 7556401 7/8 I.D. MACHINERY BUSHING 1

11 766~501 5/32 x 1·1/4 COTTER PIN 1

12 7512404 3/8-24 x 1·1/2 HEX HD. CAP SCREW 2

13 7558501 3/8 S.A.E. WASHER 6

14 7542403 3/8 - 24 FLEX LOC NUT 6

15 7060101 ROD END BEARING 2

16 7542401 3/8-24 HEX NUT 4

17 5020163 TIE ROD 2

18 7060103 ROD END BEARING 2

19 5221092 STEERING ARM 2

20 7512410 3/8-24 x 1·3/4 HEX HD. CAP SCREW 2

21 3573901 SPINDLE HOUSING BUSHING 4

22 1821010 SPINDLE 2

23 5010001 SKI SADDLE BUSHING 2

24 7512406 3/8-16 x 3 HEX HD. CAP SCREW 4

25 7542402 3/8 - 16 FLEX LOC NUT 8

26 7512407 3/8 -16 x 1·1/4 HEX HD . CAP SCREW 4

27 5221001 SKI .SADDLE 2

28 7043002 TOP LEAF SPRING 2 )

29 7043006 MAIN LEAF SPRING 2

30 5210007 SPRING PLATE 2

31 5430003 SKI WEAR PLATE 2

32 7662001 3/8 x 2·3/4 CLEVIS PIN 2

33 7661401 1/8 x 1 COTTER PIN 2

34 1820103 SKI SKAG 2

35 1820102 SKI 2

36 7542303 5/16 - 18 FLEX·LOC NUT 2

)

III - 4

STEERING ASSEMBLY (PLAYMATE) ,...-

c

c III - 5

STEERING ASSEMBLY (VOYAGER)

ITEM NO. PART NO. PART DESCRIPTION QTY. J 1 1820102 SKI WELDMENT 2

2 1820103 SKAG WELDMENT-SKI 2

3 5010002 BUSHING-SKI SPRING 2

4 5210007 SPRING PLATE-SKI 2

5 5221001 SADDLE-SPRING 2

6 5430003 WEAR PLATE-SKI SPR ING 2

7 7043001 MAIN SPRING LEAF 2

8 7043002 SPRING SUPPORT LEAF NO. 1 2

10 7512406 3/8-16 x 3 HEX HEAD CAP SCREW 4

11 7512407 3/8-16 xl 1/4 HEX HEAD CAP SCREW 4

12 7542302 5/16-18 BIWAY HEX LOCK NUT 2

13 7542402 3/8- 16 FLEX LOCK NUT 8

14 7661401 1/8 x 1 COTTER PIN 2

15 7662001 CLEVIS PIN 3/8 DIA x 23/4 2

16 5010001 BUSHING SKI SADDLE 2

17 1821004 . SPINDLE WELDMENT 2

18 3573901 BUSHING 4

19 5221092 STEERING ARM 2

20 7512410 SCREW HEX HEAD CAP 3/8-24 x 13/4 2

21 7542411 3/8-24 THIN FLEX LOCK NUT 2

22 5020161 ROD-TIE 2

23 7060103 ROD END BEARING TOUREK P 36·3 4

24 1823035 ASSEMBLY-LOWER STEERING POST 1

25 1011135 BRACKET - STEERING ASSEMBLY 1

26 7512108 1/4-20 x 3/4 SLOTTED PAN HEAD MACHINE SCREW 2

27 7542103 1/4- 20 HEX FLEX LOCK NUT 2

7R 71>1>1R03 ROLL PIN 3 )

29 1 Sl?"l()41 Wi=LDMENT -STEERING POST 1

30 5430001 HANnLF RAR GRIP 2

31 2010008 THROTTLE HANDLE ASSEMBLY 1

32 2010011 RRAKE HANDLE 1

33 THROTTLE CABLE 1

34 ll!:!UU::!7 BRAKE CABLE ASSEMBLY 1

35 7547401 <l/R. -?4 HFX NLJT 4

''If> 3c"74?fl? NYLON FLANGED BEARING 1

37 7551>401 7/R ID X 16 GA MACHINERY BUSHING 1 38 , 7661501 5/32 X 11/4 COTTER PIN 1

39 7512308 5/16- 18 X 5/16 SOCKET HEAD SET SCREW 2

111-6

STEERING ASSEMBLY (VOYAGER)

c

c

c III - 7

TRACK ASSEMBLY

r Group IV

/

( ~

ITEM NO.

1 2 3

ITEM NO.

1

2 3

RUBBER TRACK ASSEMBLY (MUSTANG - CHARGER)

~ I

/

(MUSTANG)

PART NO. PART DESCRIPTION OTY.

1511003 TRACK ASSEMBLY 1 5240011 CLIP 84 5240014 CLIP WASHER 84

~ I

----------- -------,-----~

PART NO. PART DESCRIPTION

1510108 RUBBER TRACK ASSEMBLY

5240011 CLIP

5240014 CLIP WASHER

IV -1

(CHARGER)

/'

, ,

,)

OTY.

1 42 42

,1

)

)

r

/ (

\

ITEM NO.

1 2 3

-GROWSER BAR TRACK ASSEMBLY

(CHARGER - TX CHARGER)

PART NO. PART DESCRIPTION QTY.

1510113 TRACK ASSEMBLY 1 5223258 CLEAT 37 7621401 3/16 POP RIVET 444

..

IV - 2

GROWSER BAR TRACK ASSEMBLY (MUSTANG)

)

---~~--~ --~\

\

) /

/ I

( , '~

-)


1 1510107 TRACK ASSEMBLY 1 2 5221299 CLEAT 37 3 7621401 3/16 POP RIVET 518

I

~I

IV-3

IDLER SPROCKET ASSEMBLY (MUSTANG & CHARGER - DRIFTSKIPPER)

1

c ITEM NO. PART NO. PART DESCRIPTION QTY

1 1590132 SPROCKET ASM. 1

2 5410082 8 TOOTH SPROCKET 1 ~.

3 3514506 1.0001.0. BEARING 2

4 5221289 SPROCKET FLANGE 2

5 7542103 1/4·20 HEX NUT 8

6 7512102 1/4·20 x .38 HEX HD. CAP SCA. 8

/" I

IV-4

DRIFT SKIPPER ASSEMBLY (MUSTANG -RUBBER TRACK)

ITEM NO. PART NO. PART DESCRIPTION GTY. )

1540285 DRIFT SKIPPER ASM. 1

1 IDLER SPROCKET - 8 TOOTH (SEE IDLER SPROCKET ASM.)

2 1540262 SIDE RAILASSY- LH 1

3 1540263 SIDE RAILASSY- RH 1

4 1540281 SUSPENSION ARM ASSY 1

5 5020141 SHAFT -SUSPENSION 2

6 5332088 TUBE-SUSPENSION 2

7 5332223 TUBE-BOGIE WHEEL 1

8 5020146 SHAFT -BOGIE WHEEL 3

9 5332081 BUSHING- BOGIE AXLE 4

10 5020165 SHAFT -SUSPENSION ARM 1

11 5332142 TUBE-SUSPENSION 2

12 7556103 WASHER- SPECIAL 2

13 7041011 SHOCK ABSORBER 1

14 1540283 CLEVIS & SHOCK MOUNT ASSY 1


16 7043002 SPRING-SUPPORT LEAF NO.1 2


18 5010097 BUSHING-SKI SPRING 2


20 5020145 SHAFT-BOGIE WHEEL 1

21 1543002 BOGIE WHEE L ASSY 14

22 7512475 3/8 -16 UNC TRUSS HD. MACH SCREW 4

23 7542402 3/8 -16 FLEX LOC NUT 4 _. 24 7662001 CLEVIS PIN 3/8 x 2 3/4 4

25 7661401 COTTER PIN 1/8 x 1.0 4

26 5332153 PLUNGER-ADJUSTMENT 2

27 7512464 3/8 - 16 x 3 1/2 HEX HD. CAP SCR. 2 )

28 7542404 3/8 - 16 UNC HEX NUT - REG. 2

29 7512462 3/8 - 16 HEX HD. CAP SCR x 1.0 12

30 7512530 7/16 - 20 x 21/4 HEX HD. CAP SCR. 1

31 7512463 3/8 - 16 x 3.5 HEX HD. CAP SCR. 4

32 7542402 3/8 - 16 UNC FLEX LOC HEX NUT 4

33 7558505 3/8 STD WROUGHT WASHER 22




37 7542503 7/16 - 20 UNF FLEX LOC HEX NUT 1

38 5332105 THREADED ROD 1

39 7542402 FLEX LOC NUT 3/8·16 2

40 7552905 WASHER-DOME 2

41 5332103 SPACER-IDLER 2

42 7556509 WASHER SPECIAL 1.00 1.0. 2 43 5332104 SPACER IDLER 2 44 5332085 IDLER SHAFT 1 45 1594005 IDLER WHEEL 1

46 5221386 TAKE UP IDLER RH 1 47 5221398 TAKE UP IDLER LH 1 48 5430067 SLIDE TRACK 2

49 7621401 POP RIVET 4

50 5410117 STOP 2

J IV-5

O\t\fl S\(\Pp£\t ~SS£M6\.1 lNlUSi ANG-RUBBER iRACK)

r-

\

DRIFT SKIPPER ASSEMBLY (CHARGER)

-ITEM NO. PART NO. PART DESCRIPTION QTY.

1540264 DRIFT SKIPPER ASM. 1

1 IDLER SPROCKET - 8 TOOTH (SEE IDLER ASM.) 1

2 1540262 SIDE RAI L ASSY. - LH 1

3 1540263 SIDE RAIL ASSY. - RH 1

4 1540260 SUSPENSION ARM ASSY 1

5 5020174 SHAFT - SUSPENSION 2

6 5332088 TUBE - SUSPENSION 1

7 5332080 TUBE - BOGIE WHEEL 1

8 5020144 SHAFT - BOGIE WHEEL 2

9 5332081 BUSHING - BOGIE AXLE 6 10 5020165 SHAFT - SUSPENSION ARM 1

11 5332142 TUBE - SUSPENSION 2 12 7556103 WASHER - SPECIAL 2 13 7041011 SHOCK ABSORBER 1

14 1540258 CLEVIS & SHOCK MOUNT ASSY 1



17 7043003 SPRING-SUPPORT LEAF NO.2 2 18 5010097 BUSHING-SKI SPRING 2 19 5332084 TUBE-BOGIE WHEEL 1 20 5020145 SHAFT-BOGIE WHEEL 1 21 1543002 BOGIE WHEEL ASSY 13

22 7512471 3/8 - 16 UNC TRUSS HD. MACH. SCR. 4 23 7542402 3/8 - 16 UNC FLEX LOC NUT 4 24 7662001 CLEVIS PIN 3/8 x 23/4 4

25 7661401 COTTOR PIN 1/8 x 1.0 4 26 5332153 PLUNGER-ADJUSTMENT 2 27 7512464 3/8 - 16 x 3 1/2 HEX HD. CAP SCR. 2 28 7542404 3/8 - 16 UNC HEX NUT - REG. 2 29 7512462 3/8 - 16 HEX HD. CAP SCR. x 1.0 12 30 7512530 7/16 - 20 HEX HD. CAP SCR. 21/4 LG. 1 31 7512463 3/8 - 16 x 3.5 HEX HD. CAP SCR. 6 32 7542402 3/8 -16 UNC FLEX LOC HEX NUT 6 33 7558505 3/8 STD WROUGHT WASHER 24 34 7553001 3/8 SPLIT LOCK WASHER 8 35 7542503 7/16 - 20 UNF-FLEX LOC HEX NUT 1 36 5221386 TAKE UP IDLER - RH 1 37 5332085 IDLER SHAFT 1 38 7542402 FLEX LOC NUT 3/8 - 16 2 39 5332106 THREADED ROD 1 40 7552905 WASHER - DOME 2 41 1594005 IDLER WHEEL 2 42 5332101 SPACER IDLER 2 43 7556509 1" MACH. BUSHING 2 44 5332102 SPACER-IDLER 2 45 5410117 STOP 2 46 7621401 3/16 x .527 POP RIVET 4 47 5221398 TAKE UP IDLER LH 1 48 5430067 TRACK SLIDE 2

I

IV-7

DRIFT SKIPPER ASSEMBLY (CHARGER)

IV-8

SLIDE RAIL ASSEMBLY (MUSTANG)

ITEM NO. PART NO. PART DESCRIPTION QTY. )

1540803 SLIDE RAIL ASM. 1

1 7512304 5/16 · 18x 1 HEX HD. CAP SCREW 6

2 7558403 5/16 STANDARD WASHER 6

3 1543002 BOGIE WHEEL 2

4 5332093 TUBE SPACER - BOGIE WHEEL 2

5 1540271 RAIL FORMING BRACKET R.H. 1

6 5020155 BOGIE WH EE L SHAFT 1

7 5332092 BOGIE WHEELSPACER 2

8 7542303 5/16 - 18 FLEX LOC NUT 4

9 7512451 3/8 x .500 SHOULDER SCREW 4

10 1540908 PIVOT ARM ASSEMBLY 2

11 1540270 RAIL FORMING BRACKET L.H. 1

12 5521015 RAIL - TRACK 2

13 5521014 SLIDE TRACK 2

14 7512163 1/4 - 20 x 1 1/4 HEX HD. CAP SCREW 2

15 7542103 1/4- 20 FLEX LOC NUT 15

16 7040121 FRONT SPRING - L.H. 1

17 1540907 TUBE & BRACKET ASSEMBLY 1

18 1540909 SUSPENSION ARM ASSEMBLY 1

19 7040120 FRONT SPRING - R.H . 1

20 1540910 SUSPENSION TUBE & SUPPORT ASSEMBLY 1

21 7041010 SHOCK 2

22 7040118 REAR SPRING - R_H. 1

23 1540282 SUSPENSION ARM ASSEMBLY - REAR 1 24 7512111 1/4 - 20 x 3/4 HEX HD. CAP SCREW 1

25 5223463 LIMITER STRAP 1

26 1540911 TUBE & SPRING ADJUSTER ASSEMBLY 1

27 7040119 REAR SPRING - L.H. 1

28 5020157 PIVOT SHAFT 2 29 5020141 SUSPENSION SHAFT 2 30 7555701 11/32 WASHER 4

31 7512329 5/16 - 18 x 1 3/4 HEX HD. CAP SCREW 4 32 7542402 3/8 -16 FLEX LOC NUT 6

33 7552905 DOMED TYPE LOCK WASHER 2 34 1594005 IDLER WHEEL 2

35 5332123 IDLER SHAFT SPACER 2 36 1540276 REAR HANGER ASSEMBLY 2 37 1540302 IDLER SHAFT 1

38 5020156 PIVOT ARM SHAFT 1

39 5332124 IDLER ROD 1 40 7542404 3/8 - 16 HEX NUT 2 41 7512423 3/8 - 16 x 2314 HEX HD. CAP SCREW 2 42 7512401 3/8 - 16 x 1 CAP SCREW 2 43 7512133 1/4 - 20 x 1 3/4 HEX HD. CAP SCREW 12 44 7511816 NO 8 - 18 X 1 PHILLIPS DRIVE PAN HEAD THREAD CUT SCREW 8 45 5410126 STOP 4 46 7558205 NO.8 FLAT WASHER 2 47 7556103 SPECIAL WASHER

IV -9

< I ~

o

()

21

13

(j

22

~@~

43

15

-,

rj

29

13

'" r--C m

'" -» s -~r--I

~»

'" '" m ~

'" ~

SLIDE RAIL ASSEMBLY (CHARGER - TX CHARGER)

ITEM NO. PART NO. PART DESCR IPTION QTY. )

1540277 SLIDE RAIL ASM. 1

1 7512304 5/16· 18 x 1 CAP SCREW 6

2 7558403 5/16WASHER 6

3 .1543002 BOGIE WHEEL 2

4 5332093 SPACER - BOGIE WHEEL 2

5 1540271 R.H. RAIL FORMING BRACKET 1

6 5020149 BOGIE WHEELSHAFT 1

7 5332092 SPACER - BOGIE WHEELSHAFT 2

8 7542402 3/8 - 16 F LEX - LOC NUT 4

9 7512451 3/8 - 16 x 1/2 SHOULDER SCREW 4

10 1540272 PIVOT ARM ASSEMBLY 2

11 1540270 L.H. RAI L FORMING BRACKET 1

12 5521015 TRACK RAIL 2

13 5521014 TRACK SLIDE 2

14 7512163 1/4 - 20 x 1 1/4 HEX HD. CAP SCREW - 1 1/4 IN. LG. 2

15 7542103 1/4 - 20 FLEX LOC NUT 15

16 7040121 FRONT SPRING L.H. 1

17 1540267 TUBE AND BRACKET ASSEMBLY 1

18 1540273 SUSPENSION ARM ASSEMBLY - FRONT 1

19 7040120 FRONT SPRING R.H. 1

20 1540274 SUSPENSION TUBE AND SUPPORT ASSEMBLY 1

21 7040123 SHOCK 2

22 7040118 REAR SPRING - R.H. 1

23 1540280 SUSPENSION ARM ASSEMBLY - REAR 1

_24 7512111 1/4 - 20 x 3/4 HEX HD CAP SCREW 1 25 5223463 LIMITER STRAP 1

26 1540269 TUBE AND SPRING ADJUSTER ASSEMBLY 1

27 7040119 REAR SPRING· L.H. 1 )

28 5020150 PIVOT SHAFT 2

29 5020140 SUSPENSION SHAFT 2

30 7555701 SPECIAL WASHER 4

31 7512329 5/16 - 18 x 1 3/4 HEX HD. CAP SCREW 4

32 7542303 5/16-18 FLEX LOC NUT 8 33 7552905 DOME TYPE LOCK WASHER 2

34 1594005 IDLER WHEEL 2

35 5332123 SPACER - IDLER SHAFT 2

36 1540276 REAR HANGER ASSEMBLY 2

37 1540287 IDLER SHAFT 1

38 5020151 PIVOT ARM SHAFT 1

39 5332179 IDLER ROD 1

40 7542404 3/8 - 16 HEX NUT 2

41 7512423 3/8 - 16 x 23/4 HEX HD. CAP SCREW 2

42 7512401 3/8 -16 x 1 CAP SCREW 2

43 7512133 1/4 - 20 x 1 3/4 HEX HD. CAP SCREW 12

44 7511816 NO.8 - 18 x 1 PH. DR. PAN HD. THR. CUT SCR. 8

45 5410126 STOP 4


47 7556103 SPECIAL WASHER

-/ ---

IV - 11

SLIDE RAIL ASSEMBLY (CHARGER - TX CHARGER)

c

c IV -12

DRIVE SHAFT ASSEMBLY (MUSTANG RUBBER TRACK)

J


1590609 DRIVE SHAFT ASM.

1 1590611 OUTPUT SHAFT WELDMENT 1

2 5410082 SPROCKET 8 TOOTH 2

3 5221269 FLANGE· SPROCKET 2

4 3514501 BEARING WITH LOCK COLLAR 1

5 5221329 FLANGETTE 1 )

6 7512301 5/16 - 18 x 3/4 CARRIAGE BOLT 3

7 7542303 5/16 - 18 FLEX LOC NUT 3

8 7512308 5/16 - 18 x 5/16 SOC HD. SET SCREW 2

9 7512102 1/4 - 20 x 1/2 HEX HEAD CAP SCREW 16

10 7542103 1/4-20FLEX LOCNUT 16

IV - 13

c ITEM NO. PART NO.

1590617

1 1590616

2 5410085

3 5221269

4 3514501

5 5221019

6 7512301

7 7542302

8 7512308

9 7512102

10 7542103

DRIVE SHAFT ASSEMBLY (MUSTANG GROWSER BAR TRACK)

PART DESCR IPTION

DRIVE SHAFT ASM.

OUTPUT SHAFT WELDMENT

SPROCKET 7 TOOTH

FLANGE - SPROCKET

BEARING W/LOCK COLLAR (1 INCH)

FLANGETTE

5/16-18 x 3/4 CARRIAGE BOLT

5/16-18 FLEX LOC NUT

5/16 - 18 x 5/16 SOC HD. SET SCREW

1/4 - 20 x 1/2 HEX HEAD CAP SCREW

1/4 - 20 FLEX LOC NUT

IV -14

QTY.

1

1

2

2

1

2

3

3

6

16

16

/'~ J

DRIVE SHAFT ASSEMBLY (CHARGER RUBBER TRACK)

.~.


1590145 DR IVE SHAFT ASSEMBLY 1 1 5410082 8 TOOTH SPROCKET

2 1590144 DRIVE SHAFT WELDMENT 1 3 5221269 SPROCKET FLANGE 2 4 1594004 IDLER WHEEL ASSEMBLY ?

5 5330009 SHAFT SPACER 2 6 7556501 1" 1.0. x 1 112" 0.0. x 18 GA. MACH BJ,!S.HIN~ ? 7 5010008 1" LOCK COLLAR 2 8 3514501 1" BEARING W/LOCK COLLAR 1 9 5221329 FLANGETTE 1 10 7512301 5/16 - 18 x 3/4 CAR RIAGE BOLT 3 11 7542303 5/16 - 18 FLEX LOC NUT ::l

12 7512102 1/4 - 20 x 1/2 HEX HEAD CAP SCREW 8 13 7542103 1/4 - 20 FLEX LOC HEX NUT 8 14 7512308 5/16 - 18 x 5/16 SOCKET HEAD SET SCREW 4

)

IV-15

DRIVE SHAFT ASSEMBLY (CHARGER & TX CHARGER - GROWSER BAR TRACK)

c

c ITEM NO. PART NO. PART OESCR IPTION QTY.

1590140 DRIVE SHAFT ASSEMBLY 1

1 1590135 DRIVE SHAFT WELDMENT 1

2 5410085 SPROCKET - 7 TOOTH 2


4 1594004 IDLER WHEEL ASM. 2 5 5010008 LOCK COLLAR 2 6 3514501 BEARING W/LOCK COLLAR 1 7 5221329 FLANGETTE 1 8 7512307 5/16 - 18 x 3/4 HEX HEAD CAP SCREW 3 9 7542303 5/16-18 FLEX LOC NUT 3 10 7512308 5/16 - 18 x 5/16 SOC. HD_ SET SCREW 6 11 7512102 1/4 - 20 x 1/2 HEX HD. CAP SCREW 16 12 7542103 1/4 - 20 FLEX LOC NUT 16

c IV -16

c

c

c

( . \

,"--/

~

ITEM NO.

1 2 3

--

PART NO.

5410060 5240011 5240014

RUBBER TRACK ASSEMBLY (PLAYMATE)

~ I

----------- --------_/\

PART DESCRIPTION

RUBBER TRACK

CLIP

CLIP WASHER

IV - 18

/

QTY.

1 34

34

,

\ . )

GROWSER BAR TRACK ASSEMBLY (VOYAGER)

)

ITEM NO. PART NO. PART DESCRIPTION OTY.

1 1520101 SUPER VOYAGER TRACK ASSEMBLY 1

2 5240007 CLEAT-CHANNEL 74

3 7621401 3/16 BLIND RIVET SD66LFBS 592

4 5410016 SUPE R VOY AGE R BE L T TRACK 1

5 1592006 DRIVESHAFT ASSEMBLY 1

6 3514501 1 INCH BEARING WITH LOCK COLLAR - 1

5221172 FLANGETTE - ONE INCH BEARING 2

3280010 ANGLE JOINT DRIVE - SPEEDOMETER f- LEFT SIDE ONLY 1

7512301 5116 -18 x 3/4 CARRIAG E BOLT 3

3280003 INSERTION EXTENTION 1

3280005 FLEX SHAFT SHORT - 1

7 1541502 BOGIE ASSEMBLY - VOYAGER 3

8 1592505 IDLER SHAFT ASSEMBLY 1

9 1542514 L. H. HANGER WELDMENT 1

1542515 R. H. HANGER WELDMENT 1

10 1542516 IDLER ARM L.H. WELDMENT 1

1542517 IDLER ARM R.H. WELDMENT 1

11 7040127 SPRING HANGER LEFT 1

7040126 SPRING HANGER RIGHT 1

12 1540303 TRACK TIGHTENER ASSEMBLY - LEFT 1

1540304 TRACK TIGHTENER ASSEMBLY - RIGHT 1

13 7512470 BOLT HEX HEAD MACHINE 3/8 - 16 x 3 2

7542402 3/8 - 16 FLEX LOCK NUT 2

7558501 3/8 SAE STEEL WASHER 2

14 7!'i1n04 5/1fl . 1R x 1 HEX HEAD CAP SCREW NYLOCK 2

7555701 11/32 x 1 .1/4-0. D. x 1/8 FLAT WASHER 2

)

IV -19

BOGIE ASSEMBLY (PLAYMATE)


1 1543002 BOGIE WHEEL 4

2 1540204 BOGIE TUBE WELDMENT 2

3 7040101 SPRING 2

c 4 5020088 MAIN BOGIE SHAFT 1

5 7512401 3/8 - 16 x 1" NYLOCK HEX HD CAP SCREW 2


7 5020089 BOGIE WHEE L SHAFT 2

8 7542801 5/8 - 11 CASTLE NUT 4

9 7558703 SPACER 4 10 7661401 1/8 x 1" COTTER PIN 4

c IV - 20

BOGIE ASSEMBLY (VOYAGER)

)

(2)


1 1541502 BOGIE ASSEMBLY - VOYAGER 3

2 7542801 5/8 HEX CASTLE NUT 12

3 7553401 5/8 SPRING LOCK WASHER 12

4 1543002 BOGIE WHEEL ASSEMBLY 18

5 7040101 BOGIE SPRING 9

6 1541601 BOGIE TUBE WELDMENT - INNER 6 )

7 1541602 BOGIE TUBE WELDMENT - OUTER 6

8 5020167 SHAFT - BOGIE WHEEL 6

9 5020033 SHAFT - MAIN - BOGIE TUBE 3

10 7661401 1/8 x 1 COTTER PIN 12

11 7512401 SCREW - HEX HEAD CAP NYLOCK 3/8 - 16 x 1 6

12 7553001 3/8 SPRING LOCK WASHER 6

J IV -21

DRIVE SHAFT ASSEMBLY (PLAYMATE RUBBER TRACK)


1 5410025 DRIVE SPROCKET 1

2 1590139 IDLER SHAFT WELDMENT 1


4 5332139 SHAFT SPACER 2

5 7556501 BUSHING 2

6 1594004 IDLER WHEEL 2

7 7512102 1/4·20 x 1/2 HEX HEAD CAP SCREW 8

8 7542302 1/4 - 20 FLEX LOC NUT 8

9 5010008 1" LOCK COLLAR 2

10 3514501 1" BEARING W/LOCK COLLAR 1

11 7512308 5/16 - 18 x 5/16 SOC HEAD SET SCREW 6

12 5221019 FLANGETTE 1

13 7512301 5/16 - 18 x 3/4 CARRIAGE BOLT 3

14 7542302 5/16 - 18 FLEX LOC NUT 3

c IV -22

HANGER ASSEMBLY (PLAYMATE)

ITEM NO. PART NO. PART DESCRIPTION QTY. J RIGHT HAND HANGER ASSEMBLY

1 1542515 HANGER ARM WELDMENT 1

2 1542517 IDLER ARM WELDMENT 1


4 1542519 PLATE TRACK TlGHTNER 1

5 7040103 SPRING 1

6 7555701 1 1/4 x 5/16 x 1/8 WASHER 1


8 7542303 5/16 - 18 FLEX LaC. NUT 4

9 7512301 5/16 - 18 x 3/4" CARRIAGE BOLT 1

10 7512310 5/16 - 18 x 1" HEX HEAD CAP SCREW 2

11 7512304 5/16 - 18 x 1" CAP SCREW (NYLOCK) 1

12 7512322 5/16 - 18 x 2 1/2 - SEMS 1

13 7512321 5/16 - 24 x 3/8 - SEMS 1

14 7512308 5/16 - 18 x 5/16 SOC. HD. SET SCREW. 2

LEFT HAND HANGER ASSEMBLY




18 1542520 PLATE TRACK TIGHTNER 1

19 7040102 SPRING 1

20 7555701 1 1/4 x 5/16 x 1/8 WASHER 1

21 7558402 5/16 SAE FLAT WASHER 1

22 7542303 5/16 - 18 FLEX-LaC. NUT 4

23 7512301 5/16 - 18 x 3/4" CARRIAGE BOLT 1

24 7512310 5/16 - 18 x 1" HEX HEAD CAP SCREW 2

25 7512304 5/16 - 18 x 1" CAP SCREW (NYLOCK) 1

26 7512322 5/16 - 18 x 2 1/2 - SEMS 1 )

27 7512321 5/16 - 24 x 3/8 - SEMS 1

28 7512308 5/16 - 18 x 5/16 SOC. HD. SET SCREW 2

J

IV-23

HANGER ASSEMBLY (PLAYMATE)

c

c

IV-24

HANGER ASSEMBLY (VOYAGER)

ITEM NO. PART NO. PART DESCRIPTION OTY. ) RIGHT HANGER ASSEMBLY




4 1542542 PLATE TRACK TIGHTNER 1

5 7040126 SPRING 1

6 7555701 1 1/4 x 5/16 x 1/8 WASHER 1


8 7542303 5/16· 18 FLEX LaC NUT 3

9 7512301 5/16·18 x 3/4" CARRIAGE BOLT 1 10 7512310 5/16·18 x 1·· HEX HEAD CAP SCREW 2

11 7512304 5/16 . 18 x 1" CAP SCREW (NY LOCK) 1

12 7512415 3/8·16 x 2 1/2 HEX HEAD CAP SCREW 1

13 7512321 5/16 . 24 x 3/8 SEMS 1 14 7512308 5/16 - 18 x 5/16 SOC HD SET SCREW 2

15 7542402 3/8 - 16 FLEX LaC NUT 1 16 7553001 3/8 - LOCK WASHER 1

LEFT HANGER ASSEMBLY

17 1542514 HANGER ARM WELDMENT 1 18 1542516 IDLER ARM WELDMENT 1 19 3514501 1" BEARING W/LOCK COLLAR 1

20 1542541 PLATE TRACK TIGHTENER 1 21 7040127 SPRING 1

22 7555701 1 1/4 x 5/16 x 1/8 WASHER 1

23 7558402 5/16 SAE FLAT WASHER 1 24 7542303 5/16 - 18 FLEX LaC NUT 3

25 7512301 5/16 - 18 x 3/4" CARRIAGE BOLT 1 26 7512310 5/16 - 18 x 1" HEX HEAD CAP SCREW 2 ) 27 7512304 5/16 - 18 x 1" CAP SCREW (NYLOCK) 1 28 7512415 3/8 - 16 x 2 1/2 HEX HEAD CAP SCREW 1 29 7512321 5/16 - 24 x 3/8 - SEMS 1 30 7512308 5/16 - 18 x 5/16 SOC HD SET SCREW 2 31 7542402 3/8 - 16 FLEX LOCK NUT 1 32 7553001 3/8 LOCK WASHER 1

IV -25

HANGER ASSEMBLY (VOYAGER)

--

IV-26

DRIVE SHAFT ASSEMBLY (VOYAGER GROWSER BAR TRACK)

..;

--(,p, i ~ ;t' 12 .~""'------


1 1592006 DRIVESHAFT ASSEMBLY 1

2 1592005 DRIVESHAFT WELDMENT 1

3 1594004 IDLER WHEEL WELDMENT ASSEMBLY 4

4 5010008 SET COLLAR - DRIVESHAFT 6

5 5221044 FLANGE SPROCKET 2

6 5332063 SPACER - IDLER - DRIVESHAFT 2 7 5410029 SPROCKET - 7 TOOTH 2 8 7512102 1/4 - 20 x 1/2 HEX HEAD CAP SCREW 16 9 7512308 5/16 - 18 x 5/16 SOCKET HEAD SET SCREW 8 10 7542103 1/4 - 20 HEX FLEX LOCK NUT 16 11 7556501 1 1.0. xl 1/20.0. x 18 GA. MACH. BUSHING 2 12 3514501 BEARING WITH LOCK COLLAR 1 13 5221019 FLANGETTE 2 14 7558403 5/16 FLAT WASHER 3 15 7512301 5/16 -18 x 3/4 CARRIAGE BOLT 3 16 7542302 5/16-18 FLEX LOCK NUT 3

IV -27

IDLER SHAFT ASSEMBLY (PLAYMATE)

c

c ITEM NO. PART NO. PART DESCRIPTION QTY.

1 5410025 8 TOOTH SPROCKET 1



4 1594004 IDLER WHEEL ASSEMBL Y 2 5 5332139 SHAFT SPACER 2 6 7556501 1" 1.0. x 1 1/20.0. x 18 GA. MACH BUSHING 4 7 3514501 1" BEARING WITH LOCK COLLAR 2 8 5332140 SHAFT SPACER 2 9 7512308 5/16 - 18 x 5/16 SOC. HD SET SCREW 4 10 7512102 1/4 - 20 x 1/2 HEX HEAD CAP SCREW 8 11 7542103 1/4 - 20 FLEX LOC NUT 8

IV - 28

IDLER SHAFT ASSEMBLY (VOYAGER)

)


1 1592505 IDLER SHAFT ASSEMBLY 1


3 1594004 IDLER WHEEL WELDMENT ASSEMBLY 4

4 5010008 SET COLLAR - DRIVESHAFT 6

5 5221044 FLANGE SPROCKET 2

6 5332063 SPACER - IDLER - DRIVESHAFT 2

7 5410029 SPROCKET - 7 TOOTH 2

8 7512102 1/4-20x 1/2 HEX HEAD CAP SCREW 16

9 7512308 5/16 - 18 x 5/16 SOCKET HEAD SET SCREW 8

10 7542103 1/4 - 20 HEX FLEX LOCK NUT 16

11 7556501 1 1.0. x 1 1/20.0. x 18 GA. MACH. BUSHING 2

12 3514501 1 INCH BEARING WITH LOCK COLLAR 2

J IV -29

c

ENGINE MOUNTINGS

r Group V

294cc - 488cc POLARIS (STANDARD - MANUAL & ELECTRIC)

ITEM NO. PART DESCRIPTION PART NUMBER QTY. ?Q4"" 33~ 3g~r- 4:~?r-r- 4R~

1 POLARIS ENGINE 1211239 1211240 1211326 1211327 1211328 1 2 EXHAUST GASKET - 2 3 LOCK WASHER 2 4 HEX NUT ~ COMES W/ENGINE - SEE ENGINE PARTS BOOK 2 5 CARBURETOR GASKET 2 6 LOCK WASHER 2 7 HEX NUT 2 8 CARBURETOR - 2 9 SPRING 7042006* 2 10 MUFFLER 1260198* 1

11 MANIFOLD 1260159 1260159 1260157 1260157 1260157 1

12 VIBRATION DAMPER CAP 5221250* 4 13 UPPER VIBRATION DAMPER 5410079* 4 14 7/16· 20 FLEX LOC NUT 7542503* 4 15 7/16 SAE FLAT WASHER 7558507* 4 16 MOTOR MOUNT PLATE 5223406 5223406 5221262 5221262 5221262 1 17 MOTOR MOUNT BUSHING 5332042* 4 18 - LOWER VIBRATION DAMPER 5410080* 4 19 - FLAT WASHER 5210296* 4 20 7/16 SPLIT LOCK WASHER 7553101* 4 21 7/16·14 x 2 1/2 HEX HD. CAP SCR. G5 7512524* 4 22 FUEL LINE 18" 5420072* 1 23 FUEL LINE COMES W/ENGINE 2 24 FUEL FILTER 2530006* 1 25 FUEL LINE 41/2" 5420016* 1 26 SPARK PLUG 3070136* 2 27 DRIVE CLUTCH ----, 1 28 WASHER ~ SEE CLUTCH ASSEMBLY 1

) 29 RETAINING BOLT ~ 1 30 ENGINE GROUND STRAP 2460052* 1

FOR ELECTRIC START 398, 432 488

31 BATTERY CABLE - 33" 2460106* 1 32 BATTERY CABLE - 23" 2460105* 1 33 1/4·20 x 3/4" HEX HD. CAP SCA. 7512111* 2 34 1/4·20 FLEX LOC NUT 7542103* 2 35 BATTERY BOX HOLD DOWN STRAP 2450009* 1 36 BATTERY BOX COVER 5430072* 1 37 BATTERY 4140001* 1 38 BATTERY PAD 5420018* 1 39 BATTERY BOX 5430073* 1 40 STARTER 4060054* 1

OPTIONAL PRIMER PARTS

41 "T" FITTING 7052005* 1 42 10" PRIMER LINE 5420048* 2 43 PRIMER VALVE 3160104* 1 44 6" PRIMER LINE 5420055* 3 45 "Y" FITTING 3160105* 1

* REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ALL ENGINES LISTED

V -1

294cc - 488cc POLARIS (STANDARD - MANUAL & ELECTRIC)

26

~ ~ ~

c V-2

294cc - 488cc POLARIS (FREE AIR)

ITEM NO. PART DESCRIPTION PART NUMBER

QTY. 294cc 335r.r- 39Rr.r- 432r-r- 48Rr.r-

1 POLARIS ENGINE 1211241 1211242 1211329 1211330

2 EXHAUST GASKET - 2

3 LOCK WASHER 2 4 HEX NUT r-- COMES W/ENGINE - SEE ENGINE PARTS BOOK 2 5 CARBURETOR GASKET 2 6 LOCK WASHER 2

7 HEX NUT 2

8 CARBURETOR - 2

9 SPRING 7042006* 2

10 MUFFLER 1260198* 1

11 MANIFOLD 1260159 1260159 1260157 1260157 1

12 VIBRATION DAMPER CAP 5221250* 4 13 UPPER VIBRATION DAMPER 5410079* 4

14 7/16·20 FLEX LOC NUT 7542503* 4

15 7/16 SAE FLAT WASHER 7558507* 4

16 MOTOR MOUNT PLATE 5223406 5223406 5221262 5221262 1

17 MOTOR MOUNT BUSHING 5332042* 4

18 LOWER VIBRATION DAMPER 5410080* 4

19 FLAT WASHER 5210296* 4

20 7/16 SPLIT LOCK WASHER 7553101* 4

21 7/16·14 x 21/2 H.H. CAP SCR. G5 7512524* 4

22 FUEL LINE 18" 5420072* 1

23 FUEL LINE COMES W/ENGINE 1

24 FUEL FILTER 2530006* 1 25 FUEL LINE 4 1/2" 5420016* 1

26 SPARK PLUG 3070136* 2

27 DRIVE CLUTCH ---, 1

28 WASHER ~ SEE CLUTCH ASSEMBLY 1 )

29 RETAINING BOLT ---.J 1

30 ENGINE GROUND STRAP 2460052* 1 OPTIONAL PRIMER PARTS

31 ''T'' FITTING 7052005* 1

32 10" PRIMER LINE 5420048* 2

33 PRIMER VALVE 3160104* 1

34 6" PRIMER LINE 5420055* 3

35 "Y" FITTING 3160105 1


)

V-3

294cc - 488cc POLARIS (FREE AIRl

c

V-4

\~,~

IJ

c

c

c

164cc & 175cc POLARIS (PLAYMATE)


1 1211215 ENGINE -164cc 1 1211223 ENGINE - 175cc 1

2 EXHAUST GASKET- 1 3 FLAT WASHER 4 4 LOCK WASHER - SEE ENGINE PARTS BOOK 4 5 5/16 HEX NUT 4 6 INTAKE GASKET - 1 7 3080139 SPARK PLUG 1 8 3080166 CARBURETOR 1 9 3080161 GAS LINE 1

10 7080003 7/16 HOSE CLAMP 3 11 2530006 FUEL FILTER 1 12 5420056 38" GAS LINE 1

13 5420057 10" GAS LINE 1 14 3080151 FUEL PUMP 1 15 5020164 CLUTCH RETAINING BOLT 1 16 7575201 1/2 INTERNAL LOCK WASHER 1 17 7558711 1/2 I.D. x 2 O.D. WROUGHT WASHER 1 18 1321081 CLUTCH 1 19 5221250 UPPER VIBRATION DAMPNER CAP 4 20 5410079 UPPER VIBRATION DAMPNER 4 21 5221273 MOTOR MOUNT PLATE 1 22 5332042 COMPRESSION BUSHING 4 23 5410080 LOWER VIBRATION DAMPNER 4 24 5210296 MOTOR MOUNT WASHER 4 25 7512454 3/8 - 16 x 2·1/4 HEX HD. CAP SCREW 4 26 7542301 5/16 - 18 HEX NUT 4 27 7558403 5/16 FLAT WASHER 4 J 28 1260144 MUFFLER 1

V- 5

164cc& 175cc POLARIS (PLAYMATE)

9

488cc POLARIS (VOYAGER ELECTRIC START)


1 1211 3 15 ENGIN E - 488 cc 1 2 EXHAUST GASKET - 2

3 LOCK WASHER 4

4 HEX NUT I- COMES WITH ENGINE 4

5 INTAKE GASKET 2

6 LOCK WASHER 4

7 HEX NUT - 4

8 3080483 CARBURETOR 2 9 3070136 SPARK PLUG 2 10 3080718 AIR BAFFLE 1 11 1260157 MANI FOLD 1 12 7042006 SPR ING 4 13 1260178 EXHAUST ELBOW 1 14 1260177 MUFFLER 1 15 4060016 STARTER 1 16 2460052 GROUND STRAP 1 17 7542506 7/16 - 14 FLEX LOC NUT 4 18 7558507 7/16 FLAT WASH ER 4 19 5221262 MOTOR MOUNT PLATE 1 20 5332042 MOTOR MOUNT BUSHING 4 21 5410080 LOWER VIB RATION DAMPER 4 22 5210296 FLAT WASHER 4 23 7553101 7/16 SPLIT LOCK WASHER 4

24 7512524 7/16 - 14 x 2 1/2 HEX HD. CAP seR 4

25 5223370 HOLD DOWN ROD 1

26 5223260 BATTERY HOLD DOWN BAR 1 27 7542303 5/16 - 18 FLEX LOC NUT 2 28 5410079 UPPER VIBRATION DAMPER 4

29 5221250 VIBRATION DAMPER CAP 4 30 1321079 DRIVE CLUTCH 1 31 7575202 7/16 LOCK WASHER 1 32 7512527 RETAINING BOLT 1 33 4010035 9" BATTERY CABLE 1 34 7512111 1/4 - 20 x 3/4" HEX HD. CAP SCR. 2 35 4010036 40" BATTERY CABLE 1 36 7542103 1/4 - 20 FLEX LOC NUT 2 37 4140001 BATTERY 1 38 5420018 BATTERY PAD 1 39 FUEL LINE --, 2 40 FUEL LINE - CUT FOR TEE FITTING f- COMES W/ENGINE 2 41 "Y" FITTING ---l 1 42 5420052 21/2" FUEL LINE 1 43 2530006 FUEL FILTER 1 44 5420016 4 1/2" FUEL LINE 1 45 5420075 3" FUEL LINE 2 46 7052007 TEE FITTING 1 47 5420076 18" FUEL LINE 1 48 7052003 TEE FITTING 2

V-7

488" PO\."tl\S ~\IO'i A,GER ELEC1R\C S1 A,Rl)

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1971 e,LEC~7<.~CA,L

SVS~t:A4

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MUS~AN4

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l',LAVMA~E

1971

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CONTENTS

CRANKCASE & CYLINDER - FREE AIR . . . . . . . . . . . . . . . . . 1 - 2

CRANKCASE & CYLINDER - STANDARD ................. 3 - 4

CRANKSHAFT & PISTON - STANDARD & FREE AIR. . . . . . 5-6

MAGNETO & IGNITION COIL - FREE AIR ....

MAGNETO & IGNITION COIL - STANDARD ...

7 -8

9 - 10

FUEL PUMP - STANDARD & FREE AIR. . . . . . . . . . . . • . .. 11- 12

CARBURETOR & AIR CLEANER - STANDARD & FREE AIR. . .. 13 - 14

STARTER MOTOR - STANDARD. . . . . . . . . . . • . • . . . . . . 15 - 16

RECOIL STARTER - FREE AIR ..•..........

RECOIL STARTER - STANDARD ........... .

17 - 18

19 - 20

BLOWER HOUSING - STANDARD ........•..••..••.•. 21 - 22

MUFFLER - STANDARD & FREE AIR ................. 23 - 24

ACCESSORY & TOOLS .......................... 25 - 26

CRANKCASE & CYLINDER - FREE AIR TYPE

ITEM NO. PART DESCRIPTION PART NUMBER QTY. 294cc 335cc 398cc 432cc 488cc

1 CRANKCASE COMPLETE 3080735 3080735 3080736 3080736 1 J 2 KNOCK PIN 3080373* 4 3 NAME PLATE 3080382 3080591 3080593 3080595 1 4 RIVET 3080590* 4 5 BOLT WITH WASHER 3080738 3080739 3080740 3080740 6 6 BOLT WITH WASHER 3080741* 4 7 BOLT WITH WASHER 3080742 3080742 3080743 3080743 2 8 SPRING WASHER 3080281 * 8 9 WASHER 3080356*

, 8

10 SPRING WASHER 3080051* 16 11 WASHER 3080142* 16 12 STUD 3080745 3080745 3080746 3080746 8 13 BLIND PLUG 3080446* 2 14 SPECIAL OIL SEAL 3080244* 1

REAR CRANKCASE COVER - INCL. 1 15 16

15 REAR CRANKCASE COVER 3080748* 1 16 OIL SEAL 3080006* 1 17 PACKING REAR CHAMBER COVER 3080297* 12 18 DRAIN PLUG 3080045* 2 19 SPECIAL FIBER PACKING 3080114* 4 20 SPECIAL BOLT 3080445* 4 21 LOCK WASHER 3080749* 4 22 ROUND HEAD SCREW 3080750* 4 23 SPRING WASHER 3080077* 4

CYLINDER COMPLETE -INCL. 2 24 - 27

24 CYLINDER - INCL. 25 - 27 3080402 3080751 3080449 3080753 2 25 STUD 3080283* 10

) 26 STUD - MUFFLER 3080016* 4 27 STUD - CARBURETOR 3080452* 4 28 PACKING - CYLINDER 3080755 3080755 3080300 3080300 ?

29 CYLINDER HEAD 3080756 3080757 3080453 30804Qli 2 30 GASKET - CYLINDER HEAD 3080387 3080407 3080248 3080250 2 31 NUT 3080119* H1- 1?

32 NUT 3080047* 8 33 NUT 3080043* 4 34 PACKING - CARBURETOR 3080252* 4 35 INSULATION PLATE 3080434* 2 36 SPARK PLUG 3070136* 2 37 SPARK PLUG CAP 3080302* 2 38 GROMMET 3080460* 1

MAGNETO COVER COMPLETE - 1 INCL. 40, 41

39 MAGNETO COVER 3080763 3080763 3080764 3080764 1 40 FELT 3080455* 1 41 BOLT 3080354* 4 42 SPRING WASHER 3080051* 6 43 WASHER 3080078* 6 44 BOLT 3080292* 1 45 GASKET - MUFFLER 3080143* 2

J * INDICATES PARTS WHICH ARE INTERCHANGEABLE ON ALL ENGINES

1

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---------~ ; ~ -----® ~ @--- - ®

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CRANKCASE & CYLINDER - STANDARD TYPE

ITEM NO. PART DESCRIPTION PART NUMBER QTY. 294cc 335cc 398cc 432cc 488cc J

1 CRANKCASE COMPLETE -I NC. 3080735 3080735 3080736 3080736 3080737 1 2·7,12,13,18,19,39

2 KNOCK PIN 3080373* 4 3 NAME PLATE 3080382 3080591 3080593 3080595 3080596 1 4 RIVET 3080590* 4 5 BOLTW!WASHER 3080738 3080739 3080740 3080740 3080740 6 6 BOLT W/WASHER 3080741* 4 7 BOLT W/WASHER 3080742 3080742 3080743 3080743 3080743 2 8 SPRING WASHER 3080281* 8 9 WASHER 3080356 8 10 SPRING WASHER 3080051* 14 11 WASHER 3080142 14 12 STUD 3080745 3080745 3080746 3080746 3080746 8 13 BLIND PLUG 3080446* 2 14 SPECIAL 01 L SEAL 3080244* 1

REAR CRANKCASE COVER COMPo 1 INCl. 15. 16

15 REAR CRANKCASE COVER 3080748* 1 16 OIL SEAL 3080006* 1 17 PACKING - REAR CRANKCASE 3080297* 1

COVER 18 DRAIN PLUG 3080045* 2 19 SPECIAL FIBER PACKING 3080114* 4 20 SPECIAL BOLT 3080445* 4 21 LOCK WASHER 3080749* 4 22 ROUND HEAD SCREW 3080750* 4 23 SPRING WASHER 3080077* 4

CYLINDER COMPLETE - INC. 24 - 27 2 24 CYLINDER 3080402 3080751 3080449 3080753 3080610 2

) 25 STUD 3080283* 10 26 STUD - MUFFLER 3080016* 4 27 STUD - CARBURETOR 3080452* 4 28 CYLINDER PACKING 3080755 3080755 3080300 3080300 3080301 2 29 CYLINDER HEAD 3080758 3080759 3080245 3080247 3080246 2 30 NUT 3080284* 2 31 CYLINDER HEAD GASKET 3080387 3080407 3080248 3080250 3080249 2 32 NUT 3080119* 8 33 NUT 3080047* 8 34 NUT 3080043* 4 35 CARBURETOR PACKING 3080252* 6 36 INSULATION PLATE 3080434* 2 37 SPARK PLUG 3070136* 2 38 SPARK PLUG CAP 3080302* 2 39 GROMMET 3080460* 1 40 RUBBER SPARK PLUG PROTECTOR 3080761* 2

J I

« REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ALL ENGINES LISTED

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CRANKSHAFT & PISTON - STANDARD TYPE & FREE AIR

PART NUMBER ITEM NO. PART DESCRIPTION 294cc 335cc 398cc 432cc 488cc QTY. )

1 CRANKSHAFT COMPLETE - INCL. 3080765 3080765 3080766 3080766 3080767 1 2,3,4

2 CRANKSHAFT SPACER 3080447* 1 3 BEARING 3080004* 4 4 SPECIAL BEARING 3080243* 1 5 PISTON 3080383 3080768 3080261 3080637 3080262 2 6 PISTON PIN 3080384 3080126 3080266 3080268 3080267 2 7 PISTON RINGS 3080385 3080218 3080258 3080260 3080259 4 8 SNAP RING - PISTON 3080357 3080357 3080770 3080770 3080770 4 9 NEEDLE BEARING 3080410 3080410 3080265 3080265 3080265 2 10 PISTON PIN SPACER 3080386 3080592 3080299 3080299 3080299 4 11 SPECIAL NUT 3080771* 1 12 SPRING WASHER 3080772* 1 13 KEY 3080364* 1

~)

) * REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ALL ENGINES LISTED

5

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MAGNETO & IGNITION COIL - FREE AIR

PART NUMBER ITEM NO. PART DESCRIPTION 294cc 335cc 398cc 432cc 488cc QTY.

MAGNETO ASS'Y. INCL. 1 - 36 3080479* 1

) 1 COIL PLATE 3080414* 1 2 ADJUSTI NG PLATE 3080367* 1 3 ADJUSTING PLATE 3080366* 1 4 LIGHTING COIL 3080271* 1 5 CONTACT BREAKER 3080272* 2 6 CONDENSER 3080273* 1

7 CONDENSER 3080274* 1 8 EXCITING COIL 3080417* 1 9 EXCITING COIL 3080418* 1

10 WASHER 3080422* 4 11 SPRING WASHER 3080528* 4 12 PHI LLiPS SCREW 3080859" 2

PHILLIPS SCREW 3080860* 2 13 OIL FELT 3080423* 1 14 FELT HOLDER 3080419* 1 -15 CLAMP 3080424* 1 16 PHILLIPS SCREW 3080504* 1 17 SPRING WASHER 3080529* 1 -18 FLYWHEEL 3080276* 1 19 CAM 3080420* 1 20 SNAP RING 3080425* 1 21 GOVERNOR WEIGHT 3080421* 2 22 GOVERNOR SPRING 3080834* 1 --- _ . .--

GOVERNOR SPRING 3080835* 1 23 LUG PLATE 3080427* 2 24 SNAP RING 3080836* 2 28 PHILLIPS SCREW 3080507* 1 29 PHILLIPS SCREW 3080508* 1

) _.

30 PAN HEAD SCREW 3080504* 1 31 PAN HEAD SCREW 3080509* 2 .--32 PAN HEAD SCREW 3080510* 2 33 PAN HEAD SCREW 3080511* 2 -34 SPRING WASHER 3080529* 2 -------._-

7 35 SPRING WASHER . __ 308052~':' ._. __ .-36 FLAT WASHER 3080533* 4 -40 GROMMET ___ 3080861.* __ 4 41 IGNITION COIL COMPLETE 3080838* 1 -.--.----42 CONNECTOR 3080839* 1 .- -43 CONNECTOR 3080840* 1 ---44 BOLT 3080841 2 ._---45 SPRING WASHER 3080077 4 - - ----_._-46 WASHER 3080348 2 47 BOLT 3080291 2 ---_._--._._--48 WASHER 3080078 __ . ?

- - - -._-----------

---- ._----_. ._-

- ---

----_.

--------_. -

-------- --

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® (FREE AIR

TYPE ONLY)

MAGNETO & IGNITION COIL - STANDARD

PART DESCRIPTION PART NUMBER

QTY. ITEM NO. 294cc 335cc 398cc 432cc 488cc MAGNETO ASS'Y. - INC. 1·39 3080831 3080831 3080832 3080832 3080832 1

) 1 STATOR ASS'Y. -INC. 3 ·17,30, 3080275* 1

32,33,35,36 2 ADJUSTING PLATE 3080367* 1 3 ADJUSTING PLATE 3080366* 1 4 LIGHTING COIL 3080271* 1 5 CONTACT BREAKER 3080272* 2 6 CONDENSOR INC. 6,29 3080273* 1 7 CONDENSOR INC. 33,38 3080274* 1 8 EXCITING COIL INC.10·12 3080417* 1 9 EXCITING COIL -INC. 10·12 3080418* 1 10 WASHER 3080422* 4 11 SPRING WASHER 3080528* 4 12 SCREW 3080859* 2

SCREW 3080860* 2 13 OIL FELT INCl. 14 3080423* 1 14 FELT HOLDER 3080419* 1 15 CLAMP 3080424* 1 16 SCREW 3080504* 1 17 SPRING WASHER 3080529* 1 18 FLY WHEEL 3080833 3080833 3080276 3080276 3080276 1 19 CAM 3080420* 1 20 SNAP RING 3080425* 1 21 GOVERNOR WEIGHT 3080421* 2 22 GOVERNOR SPRING 3080834* 1

GOVERNOR SPRING 3080835* 1 23 LUG PLATE 3080427* 2 24 SNAP RING 3080836* 2 25 BLOWER 3080611 3080611 3080616 3080616 3080616 1

) 26 BOLT 3080837* 4 27 SPRING WASHER 3080530* 4 28 SCREW 3080507* 1 29 SCREW 3080508* 1 30 SCREW 3080504* 1 31 SCREW 3080509* 1

32 SCREW 3080510* 2 33 SCREW 3080511* ? 34 WASHER 3080529* 2 35 WASHER 3080529* 7 36 FLAT WASHER 3080533* 4-2 37 RING GEAR 3080594 3080594 3080594 1 38 BOLT 3080533 3080533 3080533 4 39 SPRING WASHER 3080529 3080529 3080529 4 41 IGNITION COl L 3080838* 1 42 CONNECTOR 3080839* 1 43 CONNECTOR 3080840* 1 44 SCREW 3080841* 2 45 SPRING WASHER 3080077* 4 46 WASHER 3080348* 2 47 BOLT 3080291* 2 48 WASHER 3080078* 2

) * INDICATES PARTS WHICH ARE INTERCHANGEABLE ON ALL ENGINES LISTED.

9

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25

41

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(FREE AIR TYPE ONLY)

FUEL PUMP - STANDARD & FREE AIR


QTY. 294cc 335cc 398cc 432cc 488cc ) FUEL PUMP ASS'Y. - INCL. 1 . 12 3080842* 1

1 BOTTOM BODY 3080852* 1

2 TOP BODY 3080853* 1

3 BODY CAP 3080854* 1

4 PACKI NG (BOTTOM) 3080843* 1 5 _ DIAPHRAGM 3080844* 2

6 VALVE 3080845* ?

7 PACKING 3080846* 2

8 SCREW 3080847* ?

9 PACKING (TOP) 3080848* 1

10 SCREW 3080849* 6

11 "0" RING 3080850* 1

12 BOLT 3080107* ?

13 SPRING WASHER 3080077 ?

14 FUEL PIPE 3080851* 2 15 WASHER 3080078 2

16 INSULATION PLATE (A) 3080473 1

17 PACKING -(A) 3080475 2

)

) * REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ALL ENGINES LISTED.

11

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CARBURETOR & AIR CLEANER - STANDARD TYPE & FREE AIR

ITEM NO. PART DESCRIPTION PART NUMBER QTY. 294cc 335cc 39_~c 432cc 488cc ) CARBURETOR ASM. - INCL. 1 ·41 3080805 3080806 3080807 3080808 3080809 1

2 CABLE ADJUSTER ASSM. 3080810* 1

4 MIXING CHAMBER TOP 3080512* 1

5 SPRING 3080811 * 1

6 "E" RING 3080546* 1 7 PLATE 3080513* 1

8 JET NEEDLE 3080812* 1

9 THROTTLE VALVE 3080813* 1 10 NEEDLE JET 3080814 3080814 3080815 3080815 3080815 1 11 MIXING CHAMBER BODY ASSM. 1 12 SCREW & WASHER 3080160* 1 13 PLATE 3080816* 1 14 BANJO BOLT 3080178* 1 15 WASHER 3080177* 2 16 BANJO CONNECTOR 3080176* 1 17 FLOAT ARM 3080817* 1 18 FLOAT PIN 3080363* 1 19 NEEDLE VALVE 3080523* 1 20 PACKING 3080524* 1 21 PILOT JET 3080174* 1 22 NEEDLE JET SETTER 3080818* 1 23 WASHER 3080172* 1 24 3.7 "0" RING 3080819* 1 25 AIR SCREW 3080537* 1 26 SPRING THROTTLE STOP SCREW 3080820* 1 27 THROTTLE STOP SCREW 3080168 3080168 3080538 3080538 3080538 1 28 SPRING THROTTLE ADJUSTER 3080169* 1 29 STARTER PLUNGER ASSY. 3080540* 1 30 WASHER 3080542* 1

) 31 SPRING - PLUNGER 3080821* 1 32 PLUNGER CAP ASSY. 3080822* 1 33 SCREW 3080597* 1 34 SPRING WASHER 3080823* 1 35 "0" RING 3080824* 1 36 PACKING - FLOAT CHAMBER 3080536* 1 37 FLOAT CHAMBER BODY 3080856* 1 38 FLOAT ASSY. 3080534* 2 39 CAP 3080535* 2 40 MAIN JET NO. 100 3080862 1

MAIN JET NO. 105 3080863 1 MAIN JET NO. 110 3080864 1 MAIN JET NO. 115 3080865 1 MAIN JET NO. 120 3080866 1 MAIN JET NO. 125 3080867 1 MAIN JET NO. 130 3080868 1

41 BANJO BOLT 3080826* 1 42 WASHER 3080827* 1 43 SCREW & WASHER 3080380* 4 44 AIR CLEANER 3080828* 1 45 BAND 3080829* 1 46 SCREW 3080359* 1 47 CHOKE WIRE COMPLETE 3080830* 1 48 CAP 3080515* 1

--.--- - -- -- J


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STARTER MOTOR - STANDARD ENGINE

PART NUMBER ITEM NO. PART DESCRIPTION 294cc 335cc 398cc 435cc 488cc OTY. )

1 ARMATURE ASSEMBLY 3080557* 1

2 THRUST WASHER (1) 3080558* 2

3 THRUST WASHER (2) 3080559* 1

4 THRUST WASHER (D) 3080560* 1

5 THRUST WASHER (A) 3080561* 1

6 THRUST WASHER (E) 3080562* 2 7 THRUST WASHER (C) 3080563* 1 8 BRAKE PLATE 3080564* 1

9 BRAKE SPRING 3080565* 1

10 STARTER CASING 3080566* 1 11 REAR COVER ASSEMBLY 3080567* 1

12 GEAR CASE BEARING METAL 3080568* 2 13 BRUSH SPRING 3080569* 2 14 BRUSH 3080570* 1 15 BRUSH 3080571* 1

16 PINION ASSEMBLY 3080572* 1

17 GEAR CASE ASSEMBLY 3080573* 1

18 SHIFT LEVER 3080574* 1 19 LEVER PIN 3080575* 1 20 MAGNETIC SWITCH ASSEMBLY 3080576* 1 21 BRUSH COVER 3080577* 1 22 DUST COVER (A) 3080578* 1 23 DUST COVER (B) 3080579* 1 24 SPECIAL BOLT 3080580* 2 25 BOLT 3080581* 2 26 SPLIT PIN 3080586* 1 27 ROUND HEAD PHILLIPS SCREW 3080587* 1 28 ROUND HEAD PHILLIPS SCREW 3080588* 1 29 BEARING COVER 3080582* 1

) 30 FIELD COIL ASSEMBLY 3080583 1 31 SETSCREW 3080584 4 32 BLIND CAP 3080585 1 33 COLLAR 3080044 2


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RECOIL STARTER - FREE AIR TYPE

PART NUMBER QTY. ITEM NO. PART DESCRIPTION 294cc 335cc 398cc 432cc 488cc .-

RECOIL STARTER COMPLETE - INCl. 3080791 3080791 3080792 3080792 1

) 1·20

1 CASE COMPLETE 3080794* 1 2 REEL COMPLETE 3080795* 1 3 RATCHET 3080798* 1 4 RETURN SPRING 3080799* 1 5 SPRING 3080208* 1 6 WASHER (A) 3080500* 1 7 WASHER (B) 3080802* 1 8 RETAINER 3080501* 1 9 WIRE ROPE 3080803* 1 10 HANDLE 3080212* 1 12 WIRE GUIDE 3080215* 1 13 WIRE CLAMP (A) 3080235* 1 14 WIRE CLAMP (B) 3080234* 1 15 STARTING PULLEY 3080233 3080233 3080619 3080619 1 16 RETURN SPRING (B) 3080210* 1 17 NUT 3080489* 1 18 SPRING WASHER 3080804* 1 19 BOLT 3080291* 6 20 SPRING WASHER 3080077* 10 21 BOLT 3080146* 4

)


17

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RECOIL STARTER - STANDARD TYPE

PART NUMBER QTY. ITEM NO. PART DESCRIPTION 294cc 335cc 398cc 432cc 488cc

RECOILSTARTER COMPLETE 3080431 3080431 3080226 3080226 3080226 1 )

INCL.-1·20 1 CASE 3080793* 1 2 REEL 3080795* 1 3 RATCHET 3080796 3080797 3080798 3080797 3080797 3 4 RETURN SPRING (A) 3080800* 1 5 SPRING 3080208* 1 6 WASHER (A) 3080500* 1 7 WASHER (B) 3080801 3080801 3080802 3080802 3080802 1 8 RETAINER 3080501* 1 9 WIRE ROPE 3080803* 1 10 HANDLE 3080212* 1 12 WIRE GUIDE 3080215* 1 13 WI RE CLAMP (A) 3080235* 1 14 WI RE CLAMP (B) 3080234* 1 15 STARTli\lG PULLEY 3080233 3080233 3080619 3080619 3080619 1 16 RETURN SPRING 3080210* 1 17 NUT 3080489* 1 18 SPRING WASHER 3080804* 1 19 BOLT 3080291* 6 20 SPRING WASHER 3080077* 10 21 BOLT 3080146* 4


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BLOWER HOUSING - STANDARD TYPE


QTY. 294cc 335cc 398cc 432cc 488cc

1 BAFFLE (UPPER) 3080779 3080779 3080780 3080780 3080780 1

) 2 BAFFLE (LOWER) 3080435 3080435 3080781 3080781 3080781 1

REAR BLOWER HOUSING COMP.- 1

INCL. 3,4,5 3 BLOWER HOUSING - REAR 3080783 3080783 3080450 3080450 3080450 1 4 FELT 3080455* 1 5 STUD 3080286* 2 6 BOLT 3080287* 3 7 BOLT 3080109* 4-5 8 BOLT 3080288* 1 9 BOLT 3080289* 2 10 BOLT 3080290* 7

11 SPRING WASHER 3080077* 16 12 SPRING WASHER 3080051* 7 13 WASH"R 3080078* 6 14 WASHER 3080142* 6 15 BOLT 3080355 3080355 _3080292 3080292 3080292 1

16 BLOWER HOUSING FRONT 3080784 3080784 3080240 ::!ORO?40 1 17 MUFFLER GASKET 3080143* 4 18 BAFFLE 3080785 3080785 3080786 3080786 3080786 1 19 BOLT 3080787* 1 20 BOLT 3080788* 2 21 CLAMP - RUBBER 3080789* 1 22 CLAMP LOCK - METAL 3080790* 1

)

J * REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ALL ENGINES LISTED

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MUFFLER STANDARD & FREE AIR

PART NUMBER QTY. ITEM NO. PART DESCRIPTION 294cc 335cc 398cc 432cc 488cc )

MUFFLER ASS'Y' - INCL. 1 ·3 1

1 MUFFLER 1260198* 1

2 EXHAUST MANIFOLD 1260159 1260159 1260157 1260157 1260157 1

3 COIL SPRING 7042006* 2

4 NUT 3080285* 4

5 SPRING WASHER 3080051* 4

)


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24

\ \ \

ACCESSORY & TOOLS


QTY. 294cc 335cc 398cc 436cc 488cc TOOLSET 3080278

) FL Y WHEEL PULLER 2870107*

FLY WHEEL PULLER ADP. FOR 648 - 795 3080708

BOLT - FOR FLYWHEEL PULLER 3080706

..

)

-

J * REFERS TO PARTS WHICH ARE INTERCHANGEABLE IN ALL ENGINES LISTED ABOVE.

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Documents