VEHICLES Bolens

BOLENS1969-1972

Model

Diablo Rouge503

Sprint 620 . . .Sprint 621 . . . .Sprint 624 . . . .

S-295TW315S-340VAI-399TW-400

TW-292 (80292-01)

TW-295 (80295-01)

TW-340 (80340-01)

TR-399 (80399-01)

TR-440 (80440-01)

83293832958334083433/WT . . .83440/WT83440/SS

Make

HirthJLOJLOBolens

JLOBolensJLOKohlerKohler

Bolens

Bolens

Bolens

Bolens

Bolens

BolensBolensBolensKiekhaeferKiekhaeferKiekhaefer

Engine

Model

54R3.L297L297E2Z15

L2972Z15L340K399-2K399-2

2Z15.70

2Z300

2Z340

3Z400

3Z440

2Z3002Z3002Z340440S440S440S

Displ.

300CC296CC296CC310CC

296CC310cc336CC399CC399CC

310CC

292CC

336CC

396CC

438CC

292CC292CC336CC433CC433CC433CC

Carburetor

Make

TillotsonTillotsonTillotsonTillotson

TillotsonTillotsonTillotsonTillotsonTillotson

Tillotson

Titlotson

Tillotson

Tillotson

Tillotson

TillotsonTillotsonTillotsonTillotsonTillotsonTillotson

Model

1969

HR3AHR28AHR28AHR28A

1970HR28AHL279A(2)HR57AHR42AHR42A

1971

HL279A(2)

HR89A

HR89A

HR89A

MR89A

1972HR89AHR89AHR89AHD95HD95HO94A

SprocketRatio

9:2612:3012:3012:30

12:3014:3014:3018:3518:35

12:28

14:30

14:30

17:35

18:35

14:3014:3014:30

ChainSize

35-2

35-2

35-2

35-2

35-2

35-235-235-2

ClutchShaft

Make Center

OwnOwnOwnOwn

OwnOwnOwnOwnOwn

Bolens

Bolens

Bolens

Bolens

Bolens

SalsburySalsburySalsburySalsburySalsburySalsbury

BeitNumber

180-10471805-3061805-3061805-306

1805-3061805-306180-5306180-5306180-5306

1805306

1805306

1805306

1805550

1805550

180679018067901806790180713518071351807135

LUBRICATION

The engine is lubr ica ted by oilmixed with the fuel. Correct fuel-oilratio is 20:1. Only regular gasoline anda branded Air Cooled Two Cycle En-gine Oil is recommended.

Some models use a guarded, opendrive chain which is automatically lu-bricated by a tube leading fromcrankcase bleed valve. Chain shouldbe spray lubricated after storage andinspected regularly to see that end oftube is directly above center groove

of lower chain sprocket and that tubeis open and clean.

On models with enclosed chain case,fluid level should be maintained atlower housing plug opening usingSAE 50 engine oil. SAE 90 Multipur-pose G^ar Oil may be substituted ifSAE 50 oil is not available.

Ski legs (spindles) are equippedwith pressure gun fittings and shouldbe lubricated after each 25 hours withlow temperature grease.

Drive train and track are equippedwith self a l igning sealed bearingswhich do not require lubrication.

Fig. 2—Schetnotic view of steering armt,tie rodf and drag iink (early modeis) show-ing proper method of oHachment. Lotermodeis use two identicol tie rods and skiiink (steering arm) has oniy one attaching

hole; refer to Fig. 3.

Fig, 3—Schematic view of steering armsand associated parts us«d on late models.

Fig. 4—To adlHst drlv* chain tension onmodeis with open chain, ioosMi the twobolts ( A ) and tum adfusting bolt (B)

ttnsion is correct.

ADJUSTMENT

STEERING SKIS. Steering skisshould be parallel with each other andwith vehicle frame when handle baris in a normal straight driving posi-tion.

Tie rod or drag link can be ad-justed after disconnecting either endand steering arms are interchange-able from left to right side. On 1969models, refer to Fig. 2. Connect tierod to inner hole of both steeringarms, and drag link to outer hole ofright steering arm as shown.

On later models, two interchange-able tie rods are used as shown inFig. 3. With handle bar properly posi-tioned, disconnect either tie rod asrequired and adjust to correct lengthmaking sure threads are equalized onboth ends of rod.

DRIVE CHAIN. Drive chain shouldhave V4'% inch deflection measuredfrom a straight edge midway betweenupper and lower sprockets. To adjustthe open drive chain on models soequipped, 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 drivechain, remove large plug (A—Fig. 5)to check tension and adjust by loosen-

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Bolens

FI9. 5—Vi«w of •nglii* compaitment OHlate mochln* showing points of adiustment.

A. Chaincaw cover B. Adjuating screwC. Brak«untt

Fig. 8—ExplodMl vlow ofchotn cose ond ossoclotodports ttsod on modols with

onclosod choin.

1. Intermediate shaft2. Spacer3. Snap ring-I. Oil seal5. Bearing cone6. Bearing cup7. Adjusting screw8. Eccentric housing9. O-rlng

10. Disc11. Drive sprocket12. Nut13. Upper cover14. Lower cover15. Snap ring16. Driven sprocket17. Chalncase18. Bearing19. on seal

LEVERADJUSTWSNTNUTS

ing cap screw (B) in eccentric hous-ing. Push cap screw down in slot totighten chain, or up to loosen. If capscrew bottoms in slot before slack isremoved, ins ta l l bol t in alternatethreaded hole which has appeared attop of slot. Tighten cap screw se-curely and reinstall plastic plug whentension is correct.

BRAKE. Friction disc for the cali-per type disc brake is combined withthe main drive (upper) s p r o c k e ton early models (see Fig. 6). Latemodels use fixed face of driven sheaveas friction surface as shown at (C—Fig. 5).Brake should not drag when releasedbut should fully engage before handlever touches handlebar grip. To ad-just for wear, remove cotter pin (Fig.6) and turn castellated nut until thereis a slight drag on brake disc, back off

q lovor posi-tion Is adfvstod ot cobloonehor nuts. Woor odfust-mont Is ol»tolnod by re-moving eo t t t r pin andturning castollatod nut to

componsoto for woar*

one notch and reinstall cotter pin.Hand lever travel is adjusted at thetwo anchor nuts.

TRACK. To adjust track tension,raise rear of machine until track isclear of ground, then measure dis-tance between running board and low-est point of swing arm as shown at(D—^Fig. 7). Measurement should be3-3% inches for 1969 models; fourinches for 1970 models and as followsfor 1971 machines:Models 295 & 340 4% in.Model 292 4H in.

To adjust the track, loosen the twoclamp bolts (1) and turn adjustingbolt (2) until measurement is correct.

NOTE: Whenever track tension hasbeen adjusted, alignment MUST bechecked as outlined in TRACK SERV-ICE Section of this manual.

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16

Fig. 7—To adiust track tonsion, raiso roarof mochlno and loosen clomp scrow nuts(11. Turn adiusting scrows (2) oqually until

distance CD) is as outlined in toxt.

1. Bolt •'>. Sprint? cap2. Weight unit *>. Idler3. Moving flange 7. Flange & hub4. Spring

9—Exploded view of centrifugal drivesheave used on BOLENS Sprint.

10

12 11

q. to—Exploded view of torque sensingdriven sheave.

1. O-ring2. Eccentric housing3. Bearing cup4. Bearing cone5. Oil seal6. Snap ring7. Spacer8. Hub9. Fixed flange

10. Moving flange11. Floating hub12. Bushing13. Torque spring14. Nylon shoe15. Intermediate shaft16. Thrust washer17. Snap ring

OVERHAUL

SKIS. Steering skis, spindles and as-sociated parts are interchangeablefrom right to left. Skis have renew-able wear runners. Ski springs areequipped with a conical rubberbumper which should be installed torear.

IMPORTANT: DO NOT tightenlocknut on bumper stud tight againstspring leaf, or action of the spring willbe restricted.

TORQUE CONVERTER. Refer toFig. 9 for an exploded view of torqueconverter drive sheave and to Fig.10 for driven sheave. Torque spring(13—Fig. 10) should be preloaded4 turn (one cam) when unit isassembled.

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