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ENGINES

Bolens

BOLENS
CONDENSED SERVICE DATA
Year Made ENGINE M O D E L . . . . Bore(mm) Inches Stroke(mm) Inches No. of Cylinders Displacement (cc) . . . . Cubic Inches Horsepower (o RPM . . Cooling Type Carburetor Model . . . . Number Used Ignition Type Point Gap (mm) . . . . Inch Timing Advance? . . . . Timing BTDC (mm) . . Inch Measured At Sprak Plug: Bosch KLG Champion Electrode Gap (mm) Inch . . Fuel/Oil Ratio 1970 T2-2Z15 60 2.362 55 2.165 2 310 18.9 HL279A 2 1971 2Z15.70 60 2.362 55 2.165 2 310 18.9 HL279A 1 1971 2Z340 62 2.441 55 2.165 2 332 20.3 24(6000 Centrifugal Fan HR89A HR89A 1 1 -BOSCH Energy Transfer Magneto0.35-0.45 0.014-0.018 Yes Yes 2.35 2.25 0.093 0.093 Advance Advance W260T1 FFIOO L5 0.6 0.024 20:1 W260T1 FFIOO L5 0.6 0.024 20:1 1971 2Z300 58 2.283 55 2.165 2 291 17.8 1971 3Z400 55 2.165 55 2.165 3 393 24.0 28@6000 HR89A 1 1971 3Z440 58 2.283 55 2.165 3 432 26.4 32(0)6000 HR89A 1

No 2.2 0.087 W260T1 FFIOO L5 0.6 0.024 20:1

No 2.2 0.087 W260T1 FFIOO L5 0.6 0.024 20:1

No 2.2 0.087 W260T1 FFIOO L5 0.6 0.024 20:1

No 2.2 0.087 W260T1 FFIOO L5 0.6 0.024 20:1

CARBURETOR ADJUSTMENT

MAINTENANCE CARBURETOR. On 1970 model TW-315, twin carburetors are used. Adjustment instructions are carried on an instruction plate attached to carburetor deflector as shown in Fig. 1. Recommended adjustment specifies that high speed jet for left hand cylinder be V4 turn farther open than right

hand setting. Normal adjustment range is l-V^. turns open from closed position for right hand (No. 1) carburetor. Refer to appropriate Carburetor paragraphs in FUNDAMENTALS Section for additional adjustment and overhaul information. IGNITION AND TIMING. Breaker points for No. 1 (flywheel end) cylinder

Fig. 1-On SPRINT, TW-315, an Adjustment Plate is attached to carburetor baffle. Check to see that plate Is in place and that main jet for No. 2 carburetor is V4-turnrichas shown.

3-EKploded view of 2Z15 engine. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Oil seal Front crankcase Bearing Shim Pin bearing Front crankshaft Pi8ton pin Piston Piston rings Gasket Dowel Crankshaft lock screw Pulse fitting Center crankcase Rear crankshaft Rearcrankcase Rear bearings Snap ring Oil seal Snap ring Gasket Cylinder Gasket Cylinder head Special nut Sparkplug Gasket Exhaust pipe 6 4 3

CO\i . Fig. 2-Breaker plate with flywheel removed. Wires leading to ignition coils are identical and continuity should be checked to make sure correct wire leads to No. 1 coll.

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Bolens
are to the right when looking at magneto plate with flywheel removed. Refer to Fig. 2. To adjust and synchronize ignition timing first adjust No. 1 set of points to recommended gap, then adjust timing for No, 1 cylinder using a timing gage and suitable continuity tester; and moving breaker plate as required until timing is correct. With No. 1 piston properly timed, move timing gage to No. 2 cylinder and synchronize the timing by adjusting gap at No. 2 points. Timing must be synchronized as nearly alike as possible. LUBRICATION. The engine is lubricated by mixing oil with the fuel. Air Cooled Two Cycle Engine Oil and Regular Gasoline mixed at the ratio of 20:1 are recommended. Mix fuel and oil thoroughly using a separate container before pouring mixture into fuel tank. For cold weather blending, pre-mix the oil with a small amount of gasoline and shake thoroughly until mixture is liquid, then blend with remainder of fuel. Do not use kerosene or fuel oil for premixing. REPAIRS TIGHTENING TORQUES. Recommended tightening torques are as follows: Values are given in ft.-lbs. Cylinder head nuts 20 Crankcase nuts 10 Crankshaft clamp screw 30 Flywheel nut 80 DISASSEMBLY AND REASSEMBLY. Refer to Fig. 3 for exploded view of engine. When service is required, first remove engine, then remove carburetors, cooling shrouds, ignition block, recoil starter, flywheel and magneto. Remove cylinder heads. Heads are interchangeable, but No. 1 (magneto side) head is installed with fins running parallel with crankshaft while No. 2 (output side) head is installed with cooling fins crosswise. Remove cylinders, piston pins ad pistons. Pins are full floating and can usually be pushed out after removing retaining rings. Heat pistons slightly using mild heat, if necessary. Crankshaft units are keyed together and retained by a clamp screw (12) and split counterweight. Refer to Fig. 4. Loosen the screw and remove nuts from crankcase through-studs; then tap on crankshaft (Fig. 5) to separate the doweled housings. The five crankshaft bearings are a tight press fit in housings at room temperature but can be easily removed after heating housings with an electric heat gun or other form of mild heat. If bearings are renewed, measure depth of each housing half (Fig. 6); add the two measurements and subtract the distance between crankshaft shoulders (Fig. 7); then add shims (4Fig. 3) as necessary so end clearance in each crankshaft half is 0.008-0.012 (inch), measured without gasket (10). Shims (4) are available in thicknesses of 0.1, 0.2 and 0.3 mm (0.004, 0.008 and 0.012 in.).

ENGINES
Arrow on piston crown must be installed toward exhaust port side of cylinder block. Refer to the appropriate following paragraphs for inspection and overhaul notes.

PISTON RINGS AND CYLINDER. Cast iron cylinder can be rebored, and pistons and rings are available in oversizes of 0.010 and 0.020 as well as standard. Arrow on top of piston crown must be installed toward exhaust port. Cylinder head is symmetrical and interchangeable. Cooling fins must be installed as shown in Fig. 8 on two cylinder models and as shown in Fig. 9 on three cylinder engines.

CRANKSHAFT AND CONNECTING ROD. The crankshaft and connecting rod for one cylinder is only available as an assembled unit. Wear of parts at rod big end can be tested by rocking small end of rod. Play should not exceed 1/16 inch.

Fig. 8-On BOLENS Twins, No. 2 cylinder head is instaiied with fins crosswise as shown. Refer aisq to cyiinder heads in Fig. 3.

Fig. 4-Lock screw (12~Flg. 3) clamps crank' shafts together by means of spiit weight and countersunk hole indicated by arrows.

Fig. 6-Measuring crankcase depth to determine thickness of crankshaft shims.

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Fig. 5-Use soft drift and hammer to crankcases after removing stud nuts and clamp screw,

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Fig. 7-Measuring crankshaft length to determine shim pack thickness.

Fig. 9-On Three Cylinder Engines, cylinder head fins run paraiiei to crankshaft as shown.

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