VEHICLES

Bolens

BOLENS
1969-1972
Engine Model Make Model Displ. Carburetor Make Model 1969 Diablo Rouge 503 Sprint 620 . . . Sprint 621 . . . . Sprint 624 . . . . S-295 TW315 S-340 VAI-399 TW-400 TW-292 01) TW-295 01) TW-340 01) TR-399 01) TR-440 01) (80292Bolens (80295Bolens (80340Bolens (80399Bolens (80440Bolens Bolens Bolens Bolens Kiekhaefer Kiekhaefer Kiekhaefer 3Z440 2Z300 2Z300 2Z340 440S 440S 440S 438CC 292CC 292CC 336CC 433CC 433CC 433CC Tillotson Tillotson Tillotson Tillotson Tillotson Tillotson Tillotson MR89A 1972 HR89A HR89A HR89A HD95 HD95 HO94A 18:35 14:30 14:30 14:30 35-2 35-2 35-2 35-2 Bolens Salsbury Salsbury Salsbury Salsbury Salsbury Salsbury 1805550 1806790 1806790 1806790 1807135 1807135 1807135 3Z400 396CC Tillotson HR89A 17:35 35-2 Bolens 1805550 2Z340 336CC Tillotson HR89A 14:30 35-2 Bolens 1805306 2Z300 292CC Titlotson HR89A 14:30 35-2 Bolens 1805306 2Z15.70 310CC Tillotson HL279A(2) 12:28 35-2 Bolens 1805306 Hirth JLO JLO Bolens JLO Bolens JLO Kohler Kohler 54R3. L297 L297E 2Z15 L297 2Z15 L340 K399-2 K399-2 300CC 296CC 296CC 310CC 296CC 310cc 336CC 399CC 399CC Tillotson Tillotson Tillotson Tillotson Tillotson Tillotson Tillotson Tillotson Tillotson HR3A HR28A HR28A HR28A 1970 HR28A HL279A(2) HR57A HR42A HR42A 1971 9:26 12:30 12:30 12:30 12:30 14:30 14:30 18:35 18:35 Own Own Own Own Own Own Own Own Own 180-1047 1805-306 1805-306 1805-306 1805-306 1805-306 180-5306 180-5306 180-5306 Sprocket Ratio Chain Size Make Clutch Shaft Center Beit Number

83293 83295 83340 83433/WT . . . 83440/WT 83440/SS

of lower chain sprocket and that tube The engine is l u b r i c a t e d by oil is open and clean. On models with enclosed chain case, mixed with the fuel. Correct fuel-oil fluid level should be maintained at ratio is 20:1. Only regular gasoline and lower housing plug opening using a branded Air Cooled Two Cycle EnSAE 50 engine oil. SAE 90 Multipurgine Oil is recommended. pose G^ar Oil may be substituted if Some models use a guarded, open SAE 50 oil is not available. drive chain which is automatically luSki legs (spindles) are e q u i p p e d bricated by a t u b e l e a d i n g from crankcase bleed valve. Chain should with pressure gun fittings and should be spray lubricated after storage and be lubricated after each 25 hours with inspected regularly to see that end of low temperature grease. Drive train and track are equipped tube is directly above center groove with self a l i g n i n g sealed bearings which do not require lubrication.

LUBRICATION

ADJUSTMENT

Fig. 2Schetnotic view of steering armt, tie rodf and drag iink (early modeis) showing proper method of oHachment. Loter modeis use two identicol t i e rods and ski iink (steering arm) has oniy one attaching hole; refer to Fig. 3.

STEERING SKIS. Steering skis should be parallel with each other and with vehicle frame when handle bar is in a normal straight driving position. Tie rod or drag link can be adjusted after disconnecting either end and steering arms are interchangeable from left to right side. On 1969 models, refer to Fig. 2. Connect tie rod to inner hole of both steering arms, and drag link to outer hole of right steering arm as shown. On later models, two interchangeable tie rods are used as shown in Fig. 3. With handle bar properly positioned, disconnect either tie rod as required and adjust to correct length making sure threads are equalized on both ends of rod. DRIVE CHAIN. Drive chain should have V4'% inch deflection measured from a straight edge midway between upper and lower sprockets. To adjust the open drive chain on models so equipped, loosen the two bolts (A Fig. 4) and turn adjusting screw (B) until tension is correct. Hetighten bolts (A) after completing the adjustment. On models with enclosed drive chain, remove large plug (AFig. 5) to check tension and adjust by loosen37

Fig, 3Schematic view of steering arms and associated parts usd on late models.

Fig. 4 T o adlHst modeis with open bolts ( A ) and tum ttnsion

drlv* chain tension on chain, ioosMi the two adfusting bolt ( B ) is correct.

Bolens
Fig. 8ExplodMl vlow of chotn cose ond ossoclotod ports ttsod on modols with onclosod choin.
1. 2. 3. -I. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Intermediate shaft Spacer Snap ring Oil seal Bearing cone Bearing cup Adjusting screw Eccentric housing O-rlng Disc Drive sprocket Nut Upper cover Lower cover Snap ring Driven sprocket Chalncase Bearing o n seal

FI9. 5Viw of nglii* compaitment OH late mochln* showing points of adiustment.

A. Chaincaw cover B. Adjuating screw C. Brakuntt

14 16

LEVER ADJUSTWSNT NUTS

q lovor position Is adfvstod ot coblo onehor nuts. Woor odfustmont Is oltolnod by removing e o t t t r pin and turning castollatod nut to componsoto for woar*

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ing cap screw (B) in eccentric housing. Push cap screw down in slot to tighten chain, or up to loosen. If cap screw bottoms in slot before slack is removed, i n s t a l l bolt in alternate threaded hole which has appeared at top of slot. Tighten cap screw securely and reinstall plastic plug when tension is correct.

one notch and reinstall cotter pin. Hand lever travel is adjusted at the two anchor nuts. 12 11
q. toExploded view of torque sensing driven sheave.
1. 2. 3. 4. 5. 6. 7. 8. 9. O-ring Eccentric housing Bearing cup Bearing cone Oil seal Snap ring Spacer Hub Fixed flange 10. 11. 12. 13. 14. 15. 16. 17. Moving flange Floating hub Bushing Torque spring Nylon shoe Intermediate shaft Thrust washer Snap ring

TRACK. To adjust track tension, raise rear of machine until track is clear of ground, then measure distance between running board and lowest point of swing arm as shown at (D^Fig. 7). Measurement should be BRAKE. Friction disc for the cali- 3-3% inches for 1969 models; four per type disc brake is combined with inches for 1970 models and as follows the main drive (upper) s p r o c k e t for 1971 machines: on early models (see Fig. 6). Late Models 295 & 340 4% in. models use fixed face of driven sheave Model 292 4H in. as friction surface as shown at (C To adjust the track, loosen the two Fig. 5). clamp bolts (1) and turn adjusting Brake should not drag when released bolt (2) until measurement is correct. but should fully engage before hand NOTE: Whenever track tension has lever touches handlebar grip. To adjust for wear, remove cotter pin (Fig. been adjusted, alignment MUST be 6) and turn castellated nut until there checked as outlined in TRACK SERVis a slight drag on brake disc, back off ICE Section of this manual.

OVERHAUL

Fig. 7To adiust track tonsion, raiso roar of mochlno and loosen clomp scrow nuts (11. Turn adiusting scrows (2) oqually until distance CD) is as outlined in toxt.

1. 2. 3. 4.

Bolt Weight unit Moving flange Spring

'>. Sprint? cap *>. Idler 7. Flange & hub

9Exploded view of centrifugal drive sheave used on BOLENS Sprint.

SKIS. Steering skis, spindles and associated parts are interchangeable from right to left. Skis have renewable wear runners. Ski springs are equipped with a conical r u b b e r bumper which should be installed to rear. IMPORTANT: DO NOT tighten locknut on bumper stud tight against spring leaf, or action of the spring will be restricted. TORQUE CONVERTER. Refer to Fig. 9 for an exploded view of torque converter drive sheave and to Fig. 10 for driven sheave. Torque spring (13Fig. 10) should be preloaded 4 turn (one cam) when unit is assembled.

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