Model Range:
Colt, Colt SS, Charger, Charger SS, Mustang, ATX (TX), Colt 55, Custom II, Electra, TC, TX, TX-L, S/S 340, Cobra, Gemini, Apollo, Galaxy, Centurion, TXC, TX-L Indy, Cutlass, Cutlass SS
Target Audience:
Owners and technicians working on 1972-1981 Polaris snowmobiles seeking to perform maintenance, repairs, and overhauls.
Historical Context:
Polaris snowmobiles from the 1970s and early 1980s were key players in the burgeoning snowmobiling industry, known for their utility and performance.
Value Proposition:
Provides a singular, comprehensive resource covering a decade of Polaris snowmobile models, offering significant cost savings compared to professional labor.
Industry Competitors:
This manual covers models that competed with offerings from manufacturers like Ski-Doo, Arctic Cat, and Yamaha during this period.
Manual Aids:
Section index tabs, table of contents per section for quick information retrieval.
Usability:
Designed for ease of use, with clear instructions, illustrations, and logical section organization.
User Level:
Graduated complexity of information, making it accessible to beginners while providing the detail professionals require.
Major Systems:
Engine, Transmission (Torque-O-Matic Drive), Drive System (Chaincase), Braking System, Suspension Systems, Body, Steering, Electrical Systems (Body & Engine)
Engine Components:
Cylinder, Piston, Crankshaft, Bearings, Seals, Ignition System (CDI, Magneto), Cooling System (Air), Exhaust System.
Drive Train:
Drive Clutch (Primary), Driven Clutch (Secondary), Drive Belt, Chaincase, Drive Sprocket, Driven Sprocket, Track System.
Braking System:
Brake Caliper, Brake Disc, Brake Lever, Brake Cable/Line, Master Cylinder (if applicable).
Suspension Systems:
Front Suspension (e.g., leaf spring, trailing arm), Rear Suspension (e.g., bogie wheel, slide rail), Shocks, Springs.
Body And Steering:
Handlebars, Steering Post, Steering Bushings, Body Panels, Seat, Windshield, Skis.
Electrical Systems:
Lighting (Headlight, Taillight), Ignition Switch, Kill Switch, Wiring Harness, Battery (if applicable), Recoil Starter Mechanism (if manual ignition).
Engine Electrical:
Ignition system components (magneto, coil, points if applicable, CDI unit), lighting circuits, starter system (recoil or electric).
Diagnostic And Repair:
Inspection, Service, Overhaul, Troubleshooting, Tune-up, Maintenance, Component Identification, Unit Repair, Removal and Installation, Disassembly and Assembly, Diagnosis and Testing
Engine Repair:
Top-end rebuild (cylinder head, piston, rings), bottom-end overhaul (crankshaft, bearings, seals), valve adjustment (if applicable), timing adjustment.
Carburetor Service:
Disassembly, cleaning, reassembly, jetting adjustments, float bowl service, idle speed and mixture adjustments.
Clutch Service:
Clutch inspection, belt replacement, clutch spring replacement, roller/weight inspection and replacement, clutch alignment.
Chaincase And Brake:
Chain inspection and replacement, lubrication, brake pad replacement, caliper service, bleeding procedures (if hydraulic), cable adjustments.
Suspension Maintenance:
Shock absorber inspection and replacement, ski alignment, slider inspection and replacement, bogie wheel and bearing service.
Electrical Diagnostics:
Wiring diagram interpretation, troubleshooting electrical faults, ignition coil testing, stator testing, lighting circuit checks.
Body And Trim:
Body panel removal and installation, seat cover replacement, windshield replacement, handlebar grip replacement.
Troubleshooting Methodology:
Structured approach to identifying problems based on symptoms, with clear cause-and-effect relationships.
Depth:
Comprehensive: From basic maintenance to complete engine and suspension overhaul, suitable for DIY enthusiasts and professional mechanics.
Diagnostic Tools:
The manual implies the use of standard automotive and snowmobile tools for diagnosis and repair, such as multimeters, feeler gauges, and torque wrenches.
Torque Specifications:
Essential torque values for critical fasteners are provided to ensure proper assembly and prevent component failure.
Digital Characteristics:
Searchable text, easily transferable across devices, printable pages.
Search Functionality:
Full text search capability within the PDF document.
Visual Aids:
Detailed drawings, clear photographs, exploded parts views.
Image Resolution:
High-resolution images and diagrams suitable for printing at legible sizes.
Physical Format Equivalent:
Digital, printable sections simulate a tabbed binder.
Print Material Equivalent:
High-resolution printable pages for on-site reference.
Engine Types Covered:
Various Polaris 2-stroke engines across the specified model years and ranges. Specific engine displacements (e.g., 244cc, 294cc, 340cc, 400cc, 440cc) are detailed within the manual but vary by specific model and year.
Performance Data Access:
Details on horsepower, torque, and operating parameters are provided for each covered engine variant.
Tuning Parameters:
Includes specifications for ignition timing, compression ratios, and fuel-air mixture settings.
Fuel And Carburetion:
Comprehensive coverage of carburetion systems, including tuning, cleaning, and overhaul procedures for relevant carburetor models (e.g., Mikuni, Tillotson).
Cylinder Configurations:
Primarily single and twin-cylinder configurations for the 2-stroke engines.
Routine Maintenance:
The manual provides guidance on recommended service intervals for engine tuning, lubrication, belt inspection, and brake checks.
Tune Up Recommendations:
Guidance on spark plug replacement, ignition timing checks, and carburetor adjustments as part of routine tune-ups.
Lubrication Requirements:
Details on specific lubrication oils for the engine (e.g., 2-stroke oil types and ratios), chaincase, and other components are provided.
Coolant Type:
Not applicable, as these are air-cooled 2-stroke engines.
Chaincase Oil Type:
Specific grades and capacities of oil for the chaincase are detailed.
Common Wear And Tear:
Troubleshooting sections implicitly address common issues such as carburetor fouling, clutch wear, track tension, and ignition system problems prevalent in this era of snowmobiles.
Ignition Problems:
Common issues with CDI units, spark plugs, and ignition coils are covered in troubleshooting.
Track And Suspension Wear:
Wear on track components, sliders, and suspension bearings are addressed.
Polarismotorsports:
Polaris has a long-standing reputation for manufacturing snowmobiles, beginning in the mid-1950s. This manual covers a significant era of their snowmobile development.
Polarismotorsports Innovation:
Polaris was instrumental in the development of snowmobile technology during this era, including improvements to suspension and drive systems.
Product Development:
The listed models represent various iterations of Polaris's recreational snowmobile line during a period of significant innovation and competition in the industry.
Model Lineup Overview:
The diverse model names (Colt, Charger, Mustang, Electra, TX, Starfire, Cobra, Gemini, Apollo, Centurion) reflect Polaris's strategy to cater to different rider preferences and performance levels.
Manufacturing Era:
Covers models produced from 1972 through 1981, a period of growth and diversification for Polaris.
