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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of

Conte

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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

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15

16
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16
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16

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16

TABLE OF

CONTENTS

1

Assembly

Uncrate

& Preparation

With

assi

stance, or
snowmobile
snowmobile

from

for

shipping

the

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

Suspension

with

front

Arm

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

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

of

and

the

the

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

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

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

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