Kawasaki ASTRO SA340-A1, ASTRO SA440-A1 Assembly & Preparation Manual

ASTRO

SA340-A1 SA440-A1

SNOWMOBILE

ASSEMBLY&

PREPARATION

MANUAL

1

Notice

This

manual mobile is assembled correctly and given presale preparation. Your

deserves a formance that

end.

selling dealer assumes sole

The

any

unauthorized

your

to specifying Factory Directed Claims) mobile

to Dealers

is provided to ensure

customer

safe, reliable

of the steps listed here is essential to

modifications

Service

which is

ready for sale.

Binder

must

be

snowmobile,

for

any Service

Modifications

performed

that

the

expects and

responsibility

prior

to sale. Refer

before

the

and per-

snow-

proper

for

Bulletins

(Special

snow-

SAFETY

THIS SPECIAL DURES WHICH, LOWED, COULD RESULT JURY,

THIS CAUTION SYMBOL IDENTIFIES SPECIAL INSTRUCTIONS

WHICH,

COULD RESULT DESTRUCTION

Whenever heed ing and

WARNING

OR

IF

you see the symbols

their

instructions!

maintenance

INSTRUCTIONS

LOSS

AWARENESS

I

WARNING

SYMBOL

IF

NOT CORRECTLY FOL-

OF

NOT STRICTLY OBSERVED,

IN

OF

EQUIPMENT.

Always

practices.

I

IN

LIFE

.

OR

DAMAGE

IDENTIFIES

OR

PERSONAL IN-

PROCEDURES

shown

follow

PROCE-

TO,

OR

above ,

safe operat -

t

tr

· .

Assembly

Uncrate Handlebar Suspen

Skis ........

Headlight ................

Windshield Tool Kit / Safety Clutch Clutch Drive Chaincase Brake Circuit Enrichen Throttle Ca

Ig Spark L Fuel Headlight

Ta

Fan Belt

Track Adju Test Ride Sp

ecific

Engine Carburet

Fuel ...... ....................

Drive Syst Electrical S

Torque

& Pr

..............

sion

Owner

Labels ...........

Alignment Center

Chain

..

.........................

Board ......... .......... .....

er

' Cable ....................... ................ .........

rbu

retor

nition

ubrication

Timing

PI

ugs .... ....................

Mix ...................... .....

Adjus

il/ Brake

Tension

stments

(Operational

ations

...

or

em ......... ........ ........ ........ ......... ........

Chart ........

Table

eparation .. .................. ......... ......... .......... .......

......

..................... ...

........ .

. . ..............................

Distance

...........................

...................

Control..

Adjustments

tment ... .....

Light

....... .......... .......

.............................

Settings

ystem

...

.....................

..

........ ........

..

.................................................................... , ........

..

. .......................

Manual

...............

Check ....... ........

..

.......... .......................................................................................... ..............

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.. ..

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Checks) ........................................................................................

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nts

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...... ......... ........

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.............................. 3

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....

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...

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......... ........ 1 6

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..

5

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5

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6

10 10

11 12

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12 13 15

13

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15

16 16 16 16

16

.

16

TABLE OF

CONTENTS

1

Assembly

Uncrate

& Preparation

With

assi

stance, or snowmobile snowmobile

from

for

shipping

the

use

of a hoist,

skid.

damage

carefully

Thoroughly

and

missing

liftthe

inspect

parts.

the

Remove

the

bolt

1 .

Unscrew skid . See

the

top and end

skis,

then

the

nuts

Figure

remove

securing

2.

panels

from

the

carton.

the

side panels. See Figure

the

ski

spindles

to

Un-

the

Handlebar

Adjust

tion

foot

Check nesses

through

vide closed.

the

handlebar

and

evenly

pounds

1.

the

for

the

adequate

See

(1.0

routing

proper

Figure

for a comfortable

torque

Cutaway

cutaway

the

four

to 1.2 kg-mI. See

Section

of

the

positioning.

section

free

movement

3.

Allen

of

cables

They

in

when

screws

Figure

Hood

and

the

driving

to 7

3.

wire

should

hood

the

posi-

har-

pass

to

pro-

hood

to

9

r

is

1. Ski Spi ndle

WaRNING

To

prevent equipment when

2

raising

ASSEMBLY

personal

with

approved

the

snowmobile.

& PREPARATION

I

injury, use

safety

lifting

hooks

Suspension

The

snowmobile springs pension

disconnected

arms

. See Figure 4.

1.

2. Rear

is

Front

shipped

from

the

Suspension

with

front

Arm

the

suspension

and

rear

sus-

1.

Position front arm

hole in justing measured adjusting

the

suspension

. Put

the rear the nuts

from

bolt.

snowmobile

springs

suspension

to

1-1 / 2

the

washer

on its side and place

over

the

suspension

arm

inches

face

springs

and

tighten

(38 .1

to

the

through

mm)

end

the

when

of

the

the ad-

the

Always springs equally. breakage slide

wear

adjust

on

each

Unequal

or

excessive

strips. See

the

side

tension

preload

of

the

wear

Figure

(tension)

suspension

can

cause

to

one

side

5.

of

the

arm

spring

of

the

Check

1. Place a long board (or

the

ski

against clearance ski so the

the

that

front

alignment

edge between the

clearance

and rear

of

and

the

handlebar

suitable track

board and ski.

measured

ski. See

straight

and

is

Figure

centering

measure

Position

the

same

7.

6

.

edge)

the the

at

2.

Tighten on

The

suspension for average the

suspension

by

following

Manual.

the

both

sides to 7/ 8

driver

front

suspension

spring

weight. The

adjustment,

the

procedure

inch

preload

to

outlined

(22.2

dimensions operator

satisfy

Skis

With

the

snowmobile

stall

the

skis

with

side.

Torque

4.5 kg-m). right

position.

the

then

See

still

the

nuts

return

Figure

positioned

bolt

28

to

the

6.

heads

32

snowmobile

spring

foot

adjusting

mm).

may

rider

in

on its side, in-

towards

pounds

given

change

comfort,

the

to

nut

are

Owner

out-

(3.9

to

its

up-

1. Tie Rod End Straight

2.

3.

Measure

ASSEMBLY & PREPARATION

Edge

Against

Clearance

Track

Here

7

3

NOTE:

edge

2.

Be

sure

while turning the tie

Check required end Figure 7.

If

inch

on the

steering

the

, loosen

adjusting

the

dimension

(32 mm), reposition

the

ski

dimension

linkage failure. S

the

ski

remains

handlebar

the

bolt

to

I

WARNING'

spindle

and

rod

for

centering.

lock

nuts

center

shown as

necessary

prevent

para lIel

to

the

straight

end adjusting bolt.

If

centering

and

turn

the

tie

the

handlebar.

exceeds

the

steering

to

1-1/ 4

arm

reduce

possible

ee

Figure

8.

is

rod

See

9

Headlight

1.

Tie Rod End

2.

Locknuts

3.

1-114 Inch (32

Adjusting

mm)

Bolt

Maximum

Secure flat

washers headlight clamps be

10

, and

pinched

.

the

wire

headlight

, and

lockwashers

harness

position

when

the

to

the

hood

through

wire

harness

hood

is closed . See

with

the

provided. Route

the

retaining

so

it

will

Figure

bolts,

the not

1

3.

To

align

the

other

ski,

move

both

the

center ing bolt (located distance front

4. Torque steeri ng recommended

4

ASSEMBLY

linkage

from

and

all

system

ofthe

snowmobi

play.

Turn

below

rear

the

ski to ski

of

the

skis. See Figure 9.

hardware

. Ref

er

values.

& PREPARATION

le

the

tie

muffler)

when

(nuts

to

the

to

remove

rod

, bolts, etc.)

torque

ski

tips

the

end

adjusting

to

obtain

measured

chart

towards

steer-

equal

at

the

in

the

for

the

1.

2.

3.

Adj

Retaining Headlight

Llsti ng

Clamps Connector Screws

To provide the

headlight headlight contacts Figure 10.

the

adequate

harness

adjusting

rim

screws

at

the

clearance

connector,

until

front

of

for

installation

turn

the

headlight

the

housing.

of four lens

See

Remove harness bulb lens and

the

connector

and

secure

bulb

connector

Windshield

Remov e shield

the

with

protective

the

from

the

onto

assembly

the

bulb

fasteners

lens

the

with

film

and

provided

and

install

terminals.

into

the

retaining

install

. See

the

Insert

headlight

the

Figure

wire

the

ring.

wind-

11

.

Tool

Check Kit and

Safety

Kit/Owner

the

storage

Owner

Labels

Insure

located

that

and

Manual

bag

to

be

Manual.

r-I-W-A-R-N-.

al/

safety

secure. See

sure

N-G---',

decals

Figure

it

contains

are

12.

the

properly

Tool

ASSEMBLY & PREPARATION

12

5

Clutch

The

clutch

(11.5

m m) pulley clutch

on moveable

Alignment

alignment

as

measured

the

drive

clutch

pulley

(offset)

from

. See

the

to

the

Figure

should

back face

edge

13.

be

of

0.454 ofthe

the

inch

fixed

driven

the

locknut

Figure 15.

the

chassis and

clip.

and

Install

the

chaincase

the driven

secure

the

mounting

clutch

clevis

support

with

nuts

. See

arm

safety

to

1.

Fixed Pulley on Drive

2.

Moveable

If

adjustment

loosen frame, and slide to engine

Clutch

The

(262

If quired, chaincase screw. disconnected clevis the tain

the

bolts

obtain

the

mount

0.454

Center

clutch

adjustment

chaincase, turn

10.3

center

mm) . See Figure 14.

loosen

and

The

from

inch

of

the

securing

the

bolts.

of

the

driven

from

the (262

Pulley

engine

inch

on

clutch

the

left

(11.5

Distance

distance

clutch

four

mounting

lock

nut

clutch

the

chassis

yoke.

While

the

setscrew

mm)

center

Clutch

Driven

alignment

engine

mm)

should

center

support

to

or

right

offset. Tighten

be

for

the

by

pushing

as

distance.

Clutch

is

required,

the

mounting

as

necessary

10.3

distance

nuts

adjusting

arm

must

removing

forward

required

13

the

inches

is re-

on

the

set-

be

the

on

to ob-

Tighten

Drive Chain

Drive

chain

tension pulley (9.5 to

outer

12.7

edge can

mm)

1.

Locknut

2.

Setscrew

3.

Mounting

is

. See Fi

correct

be

freely

gure

Nuts

when

turned

16.

the

3/ 8

driven

to

1/ 2

clutch

inch

6 ASSEMBLY 8tPREPARATION

Brake

1.

3/ 8 to

If

adjustment

ceed as

1.

2.

follows:

Loosen

driven

snowmobile

tensioned.

Turn tighten

the

clutch

the

adjustment

the

Chaincase

NOTE: Use

when

filling

the

112

of

the

chain

locknut

pulley

to

allow

locknut.

Sno*

chaincase.

Inch (9.5 to 12.7

tension

and setscrew,

towards

the

setscrew

Jet

Chain

is

the

chain

until

Lubricant

then to

mm)

required,

rotate

front

of

be

properly

it

is

tight

provided

pro-

the the

and

Check clutch

slight

very the

brake lever

(19

mm)

DO damage could

the

brake

can be moved back

when

NOT

result

adjustment

brake drag

movement

applying

OVERTIGHTEN

to

components,

on

WARNING

the

to be

sure

the

driven

and

forth

with

just

the

brake disc

is less

brake. See Figure 18.

than

and

3/ 4

t

the

brake

because

or

personal

injury

a

that

inch

R

...

emove pour This provides and bearings. See

the

entire

upper

can

the

plug

of

proper

Figure

in

the

lubricant

17.

chaincase

into

level

cover

the

chaincase

for

the

and

chain

.

ASSEMBL

Y &

PREPARATION

7

If

brake nut back move

adjustment

while

simultaneously

and

forth

with

the

is

required,

until

the

disc. See

turn

moving

brake

Figure 19.

the

pads

the

adjusting driven just

clutch

begin

to

1.

Wire

Harness

2.

Connector

3. Light

ing

Color

System

Enrichener Control

With

the

enrichener

of

free

enrichener

movement

cable

when

lever

should

raised. See

at

off, the

have

Regul

1/

ator

outer

16

inch

Figure

casing

(1.5

mm)

21.

of

1.

Brake

Adj

usti ng

2. Brake Disc

3. Brake Pads

Nut

Circuit Board

Check board cure connector minals.

8

the

to be

. The

circuit

See Figure

connectors

sure

board

color

that

they

should

20.

on

the

are

properly

identifies

be

wiring

the

wire

attached

ASSEMBLY & PREPARATION

panel

located and se-

circuit

harness

to

the

and ter-

1.

1/ 16 Inch

2.

Locknut

3.

Adjusting

(1

.5

Screw

mm)

(

NOTE:

cable If a

loos en tain the

Engine

free movement

djustment

the

locknut

corre

ct

flooding

of

the

and

clearance.

Throttle Cable

may

is less

than

enrichener

turn

the

occur

1/ 16

cable is

adjusting

if

the

enrichener

inch (1.5 mm).

required

screwto

ob-

Idle

The idle speed

,

open to adjust Figure 22.

Make lines

Screw

from

the

specifications

the

sure

are

secure

screw

coil

bound,

engine

the

fuel

init (screw

page. Use a

idle speed

pump

and

free

ial

adjustment

turned

to

2,000

pulse li ne

of

kinks

is 3

in

tight), refer

tachometer

R.P.M . See

and

all the

or

sharp

turns

and

fuel

bends.

If

a gap

handlebar

full on

the

cable

With

the

hold

the

that

check

1. The opens

2.

The

gnp

If

adjustment locknut, cable as

22

ure

.

throttle

failure

air

silencer

throttle

:

throttle

fully.

throttle

.

and

turn

required,

[:~~~!!~~]

between

grip

, exc

.

lev

slide

lever is

of

the

the' adjusting

the

is

present

essive

cable ends

er

and

remov

at

the

ins

tight

throttle

tighten

stress

ed

ide

throttle

when the

which

from

full

the

against

is

screw

the

lev

lever

may

be

could

the

throttle

carburetor

the

required, loosen

on

locknut.

er

and

is

at

placed

cause

carburetor

position

handlebar

the

throttle

See Fig-

and

bore

the

Ignition Timing

1. Remove

2.

,

3.

both

cator

in

the

side

of

the

rotate

and

Disconnect

the Connect

continuity wire to a

the

adjust

ignition

connector.

clean

Check

spark pl ugs

spark

plug hole on

engine. Manually

engine

the

one

tester

engine

dial

' red and

coil

test

to

Connect

to

Top Dead

indicator

primary

lead

the

ground.

and

install a dial

the

turn

Center (T.D.C.)

to

zero.

white w i

of a timing

magneto

the

wires

ndings.

end

other

See Fi

right

the

tester

gure

hand

clutch

going

buzzer

of

the

23 .

indi-

to

or

red

lead

1.

Locknut

2. Adj usti ng

Screw

3.

4. Idle

Carburetor Adjustments

Air

Screw

The

carburetor opened cations

1.5

page

air

turns

and

screw

off

its

see

is

properly

seat. Refer

Figure 22.

Air

adjusted

Screw

to

the

when

specifi-

4.

Very

rection soon as dims check timing

inch

5.

Repeat cylinder spark plug ing magneto

1.

2.

slowly, rotate

of

rotation

the

buzzer

slightly

the

(0.145

the

reading

is

correct,

the

by

timing

end

, stop

mm)

timing

installing

hole

of

Continuity

Dial

the engine

on

the

before

procedure

on

buzzer

the

Light

Indicator

and

observe

changes

rotating

the

indicator

T.D.

the

left

or

continuity

white

dial

C.

dial

side,

wire

ASSEMBLY & PREPARATION

in

its

the

tone

or

the

engine

indicator.

will

be

See

for

the

indicator

and

connector.

normal

tester. As

the

light

and

If

at

0.006

Figure

light

23 .

left

hand

in

connect-

to

di-

the

the the

9

Ignition Timing

1. If

the

ignition

move

the

move

the

muffler

the

muffler

up to rest

manual

Adjustment

timing

requires

mounting

on

top

starter

and

adjustment

nuts, and

of

the

engine

fan

pulley

re-

swing

. Re-

.

NOTE:

allows hand

der

side of

toler

mechanism

cutout

The

the

cylinder.

can be

the

ance, a

in

cutout

adjustment

The

adjusted

flywheel.

weak

levers

the

flywheel.

on

the

of

points

through

If

spark

are

accessible

See

left

side

the

for

the

may

result.

Figure 24.

of

points

right

cutout

points

through

the

for

hand

on

are

The

flywheel

the

left

cylin-

the

right

out

of

advance

either

1.

Magneto

2. Breaker Point

5. Re

6.

-check

change Install the dial ind i

plug continuity wir

e.

indicator and

after

hole

Adjust

the

and

light

advance

Spark Plugs

Base

timing

tightening

cator

connect

to

the

points

138

levers

Mounting

to

be

the

into

the

opposite

to

break

inch

are

Screws

Screw

sure

screws the

opposite

timing

when

(3.5

at

full

it

.

ign

mm)

advance

did

not

spark

buzzer

ition coil

the

dial

B.T.O.C.

.

or

Adjust

2. mm).

neto

3.

Turn tation (3.5

mm)

full

advance, (levers when the

flywheel),

in

this

assembly.

4. Rotate poi

nts

dims

mounting

1.

2.

one

When

base

the

engine

until

B.T.O.C .

rotated

position

the

break

slightly)

screws.

Cutout Advance

set

of

properly

mounting

in

the

dial

towards

and

to

magneto

(buzzer , and

in

Flywheel

Lever

points

adjusted,

screws.

the

indicator

Move

against

the

hold

the

adjust

base

changes

tighten

See

Figure

to

normal

the

advance

outside

flywheel

the

assembly

the

0.014 loosen

See

direction

is

at

the

magneto

tone

magneto

25.

inch

the

Figure

of

0.138 levers to

stop

diameter

and

levers

until

or

the

(0.

35

mag-

25. ro-

inch pins

of

base

the

light

base

Adjust the spark plug gap to 0. to 0.6 mm). See

Figure 26

1. Gap

2. W a

.

sher

020to 0.024

inch

(0.5

26

10

ASSEMBLY & PREPARATION

Before is

Install

pounds

installing

the

installed and the seat on

the spark plug and torque

(2 .5 to 2.8 kg-m).

lubrication

If

requir

ed,

lubricate

ing

column

pressure) greas

with a low

e.

See Figures

spark plugs, be sure

the

suspension

temperature

cylinder

27

head is clean.

it

to

18

arms

E.P. (extreme

and

28

the

washer

to

20

and steer-

.

foot

Excessive bearing of

the

damage

With

a hand operated grease gun, apply

of grease into the

may

end

.

grease

cause

cap

resulting

fitting

applied

the

seal

on

See Figure 29.

to

the

front

to

be

pushed

in

possible

bearing

three

the

axle bearing end cap.

axle

out

pumps

1.

Grease Fitting

2. Axle Bearing End Cap

3.

Seal

29

ASSEMBLY & PREPARATION

11

Fuel

Mix

Fuel

and

oil

MUST

damage

The

recommended

quart (0.94

gallons pump mix

the

side . See Figure 30.

to

the

liters)

(23.6 liters) of

posted

fuel

octane

and oil by

be PROPERL Y

engine

fuel

mix

of B.I.A.

gasoline, with a minimum

number

shaking

will

result.

ratio

certified

of 89, and

the

MIXED

is

25

to

T.C.W. oil

can

or

1. Add to 6.25

thoroughly

from

side

one

to

Headlight

1. Position headlight

away

.

2.

Measure of

the

headlight

sion

measured

Adjustment

the

snowmobile

points

the

at a wall

distance

and

(reference

__

___

from

mark

_

on

a level

25

feet

the

floor

the

wall

mark)

. See

2......------1

__

_

_____

floor

(7,

620

to

the

at

the

dimen-

Figure 31.

9?

CD

so

the

mm)

center

__

Start

the

engine

minutes

Adjust turning

to provide

Engine idle speed is idle speed is

clutch lever is released. automatically

lever is used

condition

may

the

not

could

engine idle speed

and

run

proper

I

WARNING'

adjusted

disengage

engage

during

result

idle speed

screw

it

at

low

speed

engi

ne

warm-up

2,000

or

when

in

R.P.M.

too fast. the drive

when

the

throttle

the

clutch

the

Enrichener

starting. Either

personal

to 2,000

on

the

injury

carburetor

30

for 3 to

.

If

R.P.M . by

5

the

may

.

1.

Wall

2.

25

3. Reference

4. 2 Inches

NOTE: mobile vehicle

aiming

3.

Feet

If

adjusting proper monoxide

Turn

ventilation

Be

sure

while

from

.

on

properly

and

aimed 2 inches

mark

on

(7,620

Mark

(51

mm)

the

poisoning

an

the

engine

creeping

the

headlight

aimed

the

wall.

mm)

center

WARNING'

headlight

to

operator

of

Below

prevent

.

is seated on

is

running

ahead, and to

high

when

the

(51

See

mm)

Figure 31.

headlight

Reference

indoors,

possible carbon

beam

high

beam

below

to

Mark

provide

to

prevent

assure

.

The

headlight is

the

31

floor)

snow-

the

proper

is

centered

reference

12

ASSEMBLY

8r.

PREPARATION

4. If justing

headlight

screws

adjustment

as

required

is

required, turn

. See

Figure

the

32.

ad-

32

brake

light

to

glow

the

brake lever, loosen

cable

out

er casing and the return brake lever nuts

on

the

spri

for

outer

ng

constantly. To

move

on

the

brake

full

return

casing

the

to

. See

allow

lock

nuts

outer

assembly

off

and

Figure 33.

full return

on

the

casing

. Recheck

tighten

of

brake

towards

the

lock

-

1.

Horizontal

2.

Vertical

Check

the

operation

Tail/Brake

The

taillight

in

the

The brake brake operation key

switch

Whenever is required. result Injury.

If

the

sition, the

will

"Run/Lights"

light

lever

housing

is

independent

.

repositioned

in

brake lever

brake

Adjusting

light

operate

position.

is

activated

on

WARNING'

the

outer

readjustment

Failure

component

to

does

switch

Adjusting

of

the

only

by a

the

of

the

casing

readjust

damage

not

return

will

remain

Screws

headlight

when

the

switch

handlebar.

of

other

the

of

the

or

to

mounted

brake

the

on,

low

beam

key

switch

Brake

lights

and

cable

brake

could

personal

full

causing

is

off

in

light

pothe

.

is

the the

Track

Adjustments

While

raising

place

the

skis

be

sure

the

prevent

personal

Track Tension

1.

With

the

track

brace

the

snowmobile

a 5

to 8 pound

poi

nt

of

the

1.

Locknuts

2.

Return

WARNING'

the

snowmobile

against a stationary

vehicle

off

the

(2.2

track.

is

injury.

ground

so

to

3.6

Spring

properly

it

cannot

kg)

weight

off

for

the

ground,

object

secured,

its

entire

fa II,

then

from

and

to

length

hang

the

,

mid

ASSEMBLY & PREPARATION

13

2. The cleara nce the top of wh

en measured

the

sorber upper

from

track

directly

mount

the

bottom

should

of

be 3/ 4

below

the

wear strip

inch

the

bolt. See Figure 34.

to

(19

mm)

shock ab-

1.

3/ 4 Inch

2. Shock

3. If necessary, requir

ed to

(19

mm)

Absorber

turn

the

obtain

the

Upper

rear axle

tra ck clearance. See Figure 35.

Mount

adjusting

specified

Bolt

wear

bolts as

strip-to-

1.

Rear Axle

2.

Lock (Jam)

Track

Remove and push slowly a few check

The track is

rear

Alignment

To

prevent

alignment

the

alignment.

idler

wheel

Injury, never

while

weight

throttle

revolutions,

aligned

and edge

sides. See Figure 36.

Adjusting

Nut

WARNING'

the

engine

from

the

only

enough

then

when

of

the

measure

is

running.

track,

to

stop

distance

track

Bolts

start

turn

the

between

is equa

track

the

engine

the

engine

Ion

l.

track

and

the

both

When

the

4. adjusting sured

from

proper

bolts are

the

bolt head

tension

the

is

attained,

same

to

the

length

rear axle bracket.

See Figure 35.

14

ASSEMBLY & PREPARATION

be

sure

when

both

mea-

If

the

justing

then

track

bolt on

restart

runs

the

to one side,

same side,

engine

and recheck

tighten

the

rear axle ad-

approximately

the

1 / 2

turn,

alignment

.

move a spacer reduce crease

the

from

between

belt

deflection,

belt

deflection. Re-install

or

the

pulley

add a

the

Test Ride

(Operational Checks)

halves

spacer

fan

to

in-

guard.

1.

Idler

2. Edge

3.

Dimension

When on

Fan

track

alignment

both

rear axle

Belt Tension

Remove

a

10 deflection See Figure 37.

the

pound

fan (5 kg)

should

Wheel

of

Track

adjusting

guard

force

be 5/

Equal

On

is correct,

bolts

to

test

applied

32

inch

Both Si

tighten .

fan

belt

to

des

the

tension. With

the

belt,

(3.5

to

4.5 mm).

lock

the

nut

belt

Test ride following:

•

CONTROL

The

throttle without ing

position

•

STEERING

Steering

with

lock linkage.

•

ENGINE

Recoil starts and re

•

SUSPENSION

Adjusted smoothly.

•

EMERGENCY

the

snowmobile

CABLES

and

binding

.

should

no excess ive

starter

promptly.

turn.

for

average

brake

and

be

smooth

works

Test

STOP

and

controls

return

and

looseness

proper

for

good thr

driver

weight

SWITCH

check

freely

free

ly

and

must

in

from

in

the ste

the

ottle

and

for

operate

any

steer-

lock-to

ering

engine

response

operates

the

-

. I

If

adjustment

move

the

1. 5/

of

outer

32

4.5

the

pulley

Inch (3.5

mm)

fan

belt

from

to

Deflection

tension

the

fan

is

required,

shaft

and

rere-

Check

•

CLUTCHES

Test R.P

operation

for

smooth

.M.

(340-6,500/400-6,800)

• BRAKES

When quate leased,

During (rattles, squeaks, and

When

thoroughly or

oil leaks.

TEST

activated, smooth

there

the

test

correction

the

test

inspect

RIDE

.

ride is

in

all

switch

operation

the

brakes

stopp ing

should

ride, listen

etc

be

.)

that

completed

the

engine

should

of

the

no

brake drag.

for

may

compartment

(OPERATIONAL

positions

and

correct

at

result

track;

any

unusual

warrant

, open

CHECKS)

.

engine

full

throttle

when

inspection

the

hood

for

in

ade -

re-

noises

and

fuel

15

.

SPECIFICATIONS

ENGINE

Type ..............

Displa cemen t ..............

Bore X Stroke Number of

Ignition System ....

Ignition Timing .................................................................

Spark Plug ......

Spark Plug Gap ..................................................................

Carburetor Make and Model ......................................................................... .......

Engine R.P.M. at Full Trottle .

CARBURETOR

Air

Screw .....

Idle Scr e

Cylinders

w......

...

....

...

.....................

...

.................... .................................

................

...

...........

.. ..

...

................................................................. ................................................

...... ................

..............

........................................ (340)

................

...

.....................................

........

...

......................

(440) 2.

.. ..

..........

....

.......................................................

0.

138

inch B.T.D.C. (3.5 mm) Full advance position

................................................................

.. ..

.......

.. ..

................. .... (340)

2.362

0.006

0.

.............................. (340)

677

inch B.T.D.

020

to 0.

x 2. x 2.

SETTINGS

.......... ....

............

...............................................................................

....

............

... 3 turns

open

from

coil

bound

FUEL

........................ (340)

(440)

20.7

C.1.

(339

(440)

26.6 C.1.

362

inches

362

inches

C.

.. ..

024

inch (0.5 to 0.6 mm)

.. ..

...

.. ..

. 1.5

initial

(60 x (68 x

.. ..

.................... 2

(0.

145

.....

..

......

Mikuni

(440)

turns

(2,

000

mm) Static

NGK BR-8ES

6,500 6,800

R.P.M. final)

340

TA

440

TA

.3 cc)

(436

cc)

60

mm)

60

mm)

Magneto

VM34 R.P.M. R.P.M.

off

seat

-

Gasoline ....

Oil .......

Gasoline/ Oil Ratio ...................................

DRIVE

Drive Belt Drive Belt Outside

Clutch Offset .....

Clutch Center Distance .......... .............

ELECTRICAL

Type ................................................................................................ ............

Headlight .....

Tail/ Brake Light ...................

Instrument

TOOL SIZE

10

mm

7/ 16 inch

.............. ...................... Regular leaded

...

......

.. ..

..............

....

..................................................................... .

SYSTEM

Width

...............

Circumference

...

................................

...

.................................................

........................

SYSTEM

............................

Lights

...........

.. ..

..............................................

.. ..

................................................

.....................

.........

TORQUE

BOLT

DIAMETER

6

mm

1/ 4

(minimum

............................. (25 to

to 6.

.......

.........................

...............

....

................................

....

............. .......

....

..............................

CHART

pump

25

................. 10.3

........

...

............

posted

...

..... B.

1) 1 quart

gallons

............. 1-1 / 4

.. .. 43-1/2 inches (1,

..........................

(23.6

.. 0.454

......

.. ..

............... G.E. No.

...

..........

...

RECOMMENDED

5

TO 6 ft

7

TO 9 ft

Ibs (0.7 TO 0.8 kg-m) Ibs (1.0 TO 1.2 kg-m)

octane

IA

12

............. G.E. No.

certified

(0.

94

liters)

inches inches

inches

Volts -

Stanley

number liters)

of

gasoline

(31

105

(11

(262 mm)

120

TORQUE

89)

T.C.W.

of

oil

.7 mm)

mm)

.5 mm)

Watts

A5988

1035

57

112 inch

16

inch

9/ 5/ 8 &

16

SPECIFICATIONS

11/16

inch

5/ 3/ 8 7/

16

14

28 47

TO TO

TO

18

ft

Ibs (2.0 TO 2.5 kg-m)

32

ft

Ibs (3.9

52

ft

Ibs (6.5 TO 7.2 kg-m)

TO

4.5 kg-m)

f

SPEEDOMETER

PRINTED

BOARD

HEADLIGHT

CIRCUITRY-----.j

7

IGNITION

~

LIGHT REGULATOR

ASSEMBLY

TAIL/ STOP LIGHT

ASSEMBLY

TACHOMETER

I

ENGINE

COLOR NO

10 11

12. BLACK-WHITE

DESCRIPTION

1. BLACK

2. WHITE

3.

RED

4. YELLOW

5. BLUE

6. BROWN

7. GREEN

8. LIGHT GREEN

9. TAN . GRAY . ORANGE

17

< < l

Kawasaki ASTRO SA340-A1, ASTRO SA440-A1 Assembly & Preparation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual