Target Audience:
Owners, DIY enthusiasts, and professional mechanics seeking detailed repair and maintenance information for the 1972 Polaris Charger 55 snowmobile.
Value Proposition:
Provides a comprehensive, digital resource for servicing a classic snowmobile, offering detailed instructions and diagrams that can save significant repair costs and time.
Download Type:
Instant Download PDF
Comprehensiveness:
477 pages of detailed, step-by-step procedures with illustrations, diagrams, and specifications.
Accessibility:
Designed to be easily readable and understandable for mechanics and DIY persons, even those with comparatively less experience.
Systems Covered:
Engine, Fuel System, Ignition System, Drive System, Suspension, Steering, Brakes, Electrical System, Chassis, Bodywork
Component Level Detail:
Provides detailed information on components, including their construction and function, prior to troubleshooting and servicing.
Type:
Workshop Service Manual / Repair Manual
Searchable:
PDF format allows for searching of keywords and text, enhancing usability.
Engine:
Detailed disassembly, assembly, inspection, and repair of the engine, including piston, rings, cylinder, crankshaft, connecting rods, and valves. Troubleshooting and diagnostics for engine performance issues.
Fuel System:
Carburetor adjustment, cleaning, and overhaul. Fuel pump operation and troubleshooting. Fuel line routing and inspection.
Ignition System:
Spark plug specifications, ignition timing, coil testing, and breaker point adjustment. Magneto system diagnosis.
Drive System:
Clutch (primary and secondary) inspection, adjustment, and replacement. Drive belt condition and tension. Chain case lubrication and inspection. Track system maintenance and adjustment.
Suspension:
Front and rear suspension component inspection, lubrication, and replacement. Shock absorber testing and servicing. Ski alignment and adjustment.
Steering:
Handlebar, steering post, and tie rod inspection and adjustment. Skag condition and alignment. Steering linkage lubrication.
Brakes:
Brake lever and cable adjustment. Brake shoe inspection and replacement. Brake drum cleaning and inspection. Troubleshooting brake performance issues.
Electrical System:
Wiring diagrams, lighting system troubleshooting, headlight and taillight bulb replacement, kill switch operation.
Chassis And Bodywork:
Frame inspection, seat mounting, windshield attachment, running board maintenance, general body panel inspection and repair.
Maintenance:
Scheduled maintenance (e.g., lubrication points, inspections), pre-ride checks, post-ride procedures, seasonal storage recommendations.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, including starting issues, poor performance, unusual noises, and electrical faults.
Repair:
Step-by-step instructions for removal, disassembly, inspection, repair, assembly, and installation of all major components and systems.
Adjustments:
Precise instructions for adjusting various systems, including carburetor, ignition timing, clutch engagement, and brake linkages.
Disassembly Assembly:
Comprehensive, sequential instructions for disassembling and reassembling all vehicle systems and components.
Diagnostics:
Information on diagnosis, testing, and fault finding for various systems.
Service Data:
Includes service data, crucial specifications, and allowable limits for various checks and adjustments.
Depth:
Comprehensive, bumper-to-bumper coverage suitable for both experienced mechanics and DIY enthusiasts. Includes detailed pictorial diagrams, exploded views, and torque specifications.
Diagrams And Illustrations:
Detailed illustrations, exploded diagrams, drawings, and photos guide users through service procedures.
Torque Specifications:
Includes specific torque values for critical fasteners, essential for proper assembly and reliability.
Wear Limits:
Provides wear limits for various components to ensure correct tolerances are maintained during repairs.
Special Tools:
References and illustrates necessary special service tools and equipment required for specific repair operations.
Pictorial Guidance:
Illustrations highlight fundamental principles and procedures for basic interventions, aiding in understanding repair processes.
Precautions:
Provides necessary precautions, special notes, and important points required for safe and effective service interventions.
Completeness Statement:
100% complete and intact, no missing or corrupt pages/sections.
Engine Type:
Two-stroke, Air-cooled (Specific engine displacement and model not detailed in product info, but typical for the era would be in the 300-400cc range, likely a single or twin cylinder).
Horsepower:
Not specified in product information, but typically in the range of 20-30 HP for snowmobiles of this era.
Carburetion:
Likely a single or dual carburetor setup (e.g., Mikuni, Tillotson) depending on the specific engine variant. Manual covers carburetor adjustment and overhaul.
Fuel:
Typical for the era: Pre-mix gasoline and oil.
Cooling System:
Air-cooled, requiring proper airflow for optimal performance and longevity. Manual covers any necessary adjustments or cleaning related to cooling.
Lubrication:
Manual provides details on lubrication points and frequency, crucial for the engine and drive train components.
Periodic Maintenance:
Emphasis on following the periodic maintenance chart for maximizing vehicle life and satisfaction.
Engine Oil Mix:
Manual specifies the correct two-stroke oil to gasoline ratio for the pre-mix fuel. Typically 20:1 or 32:1 depending on the specific engine.
Grease Type:
Manual will specify appropriate grease types for various lubrication points (e.g., bearings, steering components).
Lubricant Recommendations:
Specifies approved lubricants for all systems as per manual recommendations.
Common Wear Items:
Clutch components, drive belts, track, suspension bushings, and engine seals are common wear items for snowmobiles of this vintage. The manual addresses their inspection and replacement.
Troubleshooting Tips:
Includes specific advice on investigating unusual noises and changes in riding characteristics to address problems promptly.
Storage Procedures:
Manual includes guidance on proper off-season storage to protect the snowmobile from deterioration.
