Photo Page 346
Thought I'd send some photos of my recent addition.
It's a 1969 Bolens Sprint 620.  Has a 296cc JLO engine.
I am looking for an original airbox for it if anyone has one lying around.
Darryl. - darryl34@telus.net
Thanks Darryl for the great Pictures and restoration info!
The process of getting this thing going started pretty near right away. I had I figured a couple of months before we had enough snow anyway. Besides I don't have a garage so I didn't want to end up working on this "thing" in sub zero temperatures.

I started by removing the fuel tank. It would need to be drained and inspected. It turns out there was no rust inside and I ended up flushing it 3 times and re installing it including a new fuel filter between it and the carb.

I had taken the carb apart totally and inspected everything. I held the diaphrams over a light with a magnifying glass to look for superficial holes or cracks, everything looked o.k. They say this doesn't really tell you much but worked for me. The carb was soaked over night and put back together .Looking on the internet I found a tillotson site with helpful hints/info and carb settings.
I had to replace the Plug wire connector for the spark plug and replace the boot as well. It turns out that the plug that was in it was the wrong one. Locating the correct plug was a chore as well. Here's a hint, If you have a old rare sled with a pretty common engine, try finding a well known sled maker (arctic cat for instance) that uses the same engine, then get the plug for it.
In my case, Arctic Cat used the JLO 296cc engine in 1969 too.

Well, except for fuel and a primer bulb, this thing was ready for a test burn .Canadian Tire helped with a primer bulb I mixed regular gas at 20:1. This turned out to be the correct mix as I found out later. I've always heard more oil in your mix is better than not enough.You don't want to lean it out, If you do, expect to buy a new piston or worse !

Fuel is in, carb was primed, looks like it was ready to go. It fired on the third pull not bad I guess, after all, who knows when it was ran last. It ran pretty well with a little adjustment. I let it run for a while to heat up then shut it down, and ran it again, no starting problems. Quite happy with the engine. I figured out at this time I need a new piece of flex pipe on the exhaust as it was leaking pretty good, what next I figured. Spent $13.00 for a replacement. Pretty near any automotive parts outlet has it. Can. Tire worked for me. Hey, don't worry its only money!  If the flex pipe is old and just will not let go of your pipe, take the manifold off, and cut the flex pipe with an angle grinder or what have you. Just be careful not to cut through to the pipe.

I began next on the track and bogie set up. The track (a two piece they call it) was a little worse than I thought as far as the cleats go, I ended up replacing a few rivets, a few cleats and had the rest welded by a friend who is a welder by trade which makes things a little cheaper. The bogie suspension was a challenge.  I was in need of four springs. I wanted to keep the thing all original. The first place I checked was www.kpx-kimpex.com and their online parts catalog. It turns out the springs that would have worked were discontinued in 2002, my luck. Next, I sent out countless e-mails to sled salvage yards pretty near all over the freaking continent. Had no luck their either. I was having my doubts that I would have this thing ready for winter if at all. I had been on the hunt for a couple / three weeks by this time. I even debated on putting a slide rail suspension in it.

This is about the time I had met up with Stephen in washington state via my parts/info e-mail search. He had some old bolens stuff and was kind enough to offer some copies of original literature on the bolens sleds, owners manual, parts lists and JLO engine parts lists. This stuff saved me alot of time. He has two Bolens sprints himself and his help in answering my questions was great. He also kinda talked me out of the slide rail idea, thanks Stephen.
After giving it even more thought I gave up on the search for the original bogey springs, ditched the slide rail idea and contacted a local sled guy. I ended up getting two sets of bogie wheel springs from an old ski doo. They are pretty common and would not be a problem replacing if I had to do it again. I then cut eight 3/4" x 1"x1/4" thick metal tabs and took the whole lot back up to my buddies to get the tabs welded on the shafts as the old ski doo's were .(See Photo). Back in buisness and ready to carry on. Before putting it all back together and installing the wheels and track, I pulled the pivot shafts and steel woolled them and greased them. The tab for the front bogies were tacked in place for now. I will get the tab welded up when I load it on the truck before use. I reinstalled the wheels and track and aligned it. It is actually not too bad having a jointed track, it did save me alot of time.

I was slowly getting this thing together now the main problems were repaired. I figured I'd leave the seat for now as I didn't feel like another big job. I decided to do the windshield next. I had nothing really to go by other than a photo, then I remembered one was for sale on e-bay a while back, and I had written down dimensions in my book. (It sold for $19.99 u.s.by the way). I picked up a piece of 3mm lexan cut to 16" by 26", it cost me $30.30,tax incl. Shop around for this stuff, I called four glass shops and got prices of $26.00 plus tax to $50.00 .Don't waste your time or money on plexiglass its no good and wont last. Spend the extra !

Lexan is quite soft,and fairly flexible. It was very easy to work with. I measured and marked it at 24" wide at the bottom,tapering to 18" at the top,15" tall. I put a small bowl on the top edges and marked the top corners to get them rounded. I used a jig saw with a fine blade cutting close to the edge of a table to avoid any accidents. To Finish, I picked up some car door protector strips to frame the edge of the glass. Turned out really well.  A little more to come,including finished photo's.  Continued on page 347
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