Kawasaki intruder ST440-A4 Shop Manual

Foreword

This

manual

mobile

However, formation who

desires to nance and mechanics, procedures out

maintenance ever the doubts maintenance, and repair by

qualified

In

order avoid the

costly mistakes,

text, thoroughly procedures before work

carefully

tools

or equipment ments are used, and adversely

Whenever their

instructions!

and

maintenance

is designed

mechanics

it

contains

to make

repair the must

owner

his

ability

mechanics.

to

perform

equ

ipment

should

can on

Iy

affect

you see

in a

enough

it

useful

perform

work

proper

be understood

and repair

has

to

do

the familiarize

starting

in a clean area .

is specified,

not

be used. Precision be made the

use

safe operation

the

Always

practices.

IWARNING'

primarily

properly

for

use by

equipped shop.

detail and basic

to

the

snowmobile

his

own

basic

. A basic knowledge

use

of

tools, and

in

workshop

order

satisfactorily. Wheninsufficient the

work,

should

work

the

mechanic

work,

experience

the

adjustments,

be carried

efficiently

should read

himself

and

then

with

Whenever

makeshift

measure-

if

the

of

substitute

symbols

follow

proper

of

shown

instruments

the

snowmobile

below,

safe

tools

operating

snow

user

mainte-

to

carry

out

only

and to

the

do

the

special

tools

may

heed

in-

of

or

This

manual

is divided

into

the

following

four

sections:

-

(1) Specifications

This section cations, a formance

(2)

Maintenance

contains

complete

curves.

The procedures minor explanation of the

repair are described

on

the

major

components

mechanic

general

torque

and Theory

for

inspection,

the

structure

to

better

and

technical

chart

and

of

Operation

adjustments

in

this

and

function

and

assembly

understand

specifi-

engine

per-

and

section. An

of

each

enables

what

he

is

doing.

(3) Repair

.

This section disassembly, which repair. vided to

shows

the

best

inspection, assembly, and

are necessary

Assembly

for

and

proper

installation

explain special points.

method

maintenance

notes are pro-

for

removal,

installation

and

This structions rectly injury, or

This structions strictly or

NOTE:

more

warning

or

followed,

loss

caution

observed,

destruction

Indicates

efficient

symbol

procedures

could

of

life.

symbol

or

procedures

could

of

equipment

points

and

convenient

identifies

which

result

identifies

which

result

.

of

particular

operation.

special

if

in

special

in

damage

in-

not

cor-

personal

in-

if

not

to,

interest

for

Appendix

(4)

The appendix

miscellaneous ence and

in

the back

information,

conversion

charts, special tools,

diagram, and an index.

This shop

mechanic mobiles.

followed

manual

in

All

procedures contained

closely.

has been prepared

servicing

of

the

including

the

KAWASAKI

manual

metric

to

within

contains

refer-

wiring

assist

snow-

should

the

be

FOREWORD

Model Identification

ST440-A4

ii

MODEL

IDENTIFICATION

Quick Reference Guide

SECTION

"f"

peci Icatlons ............................................................................................... .

S

Maintenance and Theory ....................................................... ..

"

..

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

Repair ............................................................................................................ .

Appendix ....................................................................................................

...

.

Using locating a desired topic shop

manual. sired section above of

the contents for the exact page(s) procedure required .

the

quick reference

Bend

table

of

contents

the

with

for

guide

or

procedure pages back the

black tab on

that

section . Refer

to

locate

will

until

assist

contained

you

the

you in

match

right

to

specific

quickly

within

the

this

the

de -

hand

side

table

of

topic

or

QUICK REFERENCE GUIDE

iii

Specifications

General Se rvice Torque

Ratio

Gear

Engine

Table

Spec

ifications

Specifications

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Chart ............

Performance Curves/Port

of

Contents

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

........

Dim

..

.........

. ....

ensions

...

......

. . . 1-7

. .

..

Page

1-13 1-14

SPECIFICATIONS

1-1

GENERAL

General Specifications

Overall Length . Overall Width Overall Height (With Windshield) Dry

Weight (Approximate) . .

ENGINE

Model Displacement Bore x Number Engine Engine Starter

IGNITION

Ignition

Spark Plug .

..

Stroke

of RPM RPM

.....

System

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

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

. . .

.....

.

...

. . . . . .

...

Cylinders

at Full at Idle

..

.......

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

...... _ ...

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

Throttle

Speed

...........

. . ....

......

...

......

.......

. .

.......

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

...

..........

...

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

.. ..

. .

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

.........

...... ...

... _ ...................

. .

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

...........

. .

........

....

......

........

. . .

.

.....

...

........

.

......

.....

.

.....

... .

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

_ .

........

.

...........

.

...

.........

..

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

.

... ...

.....

....

..

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

.....

.

....

...

.

......

...

.......

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

.

........

103 in. (2616 mm)

...

.....

. . .

....

2.677 x 2.362 in. (68 x 60 mm)

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

.

......

40.5 in. (1029 mm)

40.5

in.

(1029 mm)

.. ..

..

425 Ib (193 kg)

.......

. . Electric and Manual

Capacitor Discharge

7,100

....

26.6

..

TA440C-D201

C.1.

to

7,300 2,500

NGK

(436cc)

RPM RPM

(C.

D.)

BZ-9EV

2

CARBURETOR

Make

Carburetor Carburetor Model .

Identification Marking . .

of

Type Main Jet Air Jet Needle Jet Throttle Pilot Jet By

Pilot Outlet . . . . .

Air Fl Starter Jet Type Starter Econo (Power) Jet

Carburetor ... .

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

Jet .........

Needle .........

Slide (Cut Away) .

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

Pass

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

Screw .....

oat

Valve

of

Float Chamber ....

SYstem

....

......

.. ..

. .

...

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

Seat

...

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

....

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

.....

..

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

.......

....

. .

.....

.

........

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

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

.......

...

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

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

......

.....

..

. .

......

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

.

.....

..

.. ..

......

....

..........

.

.....

....

........

..........

...

......

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

. . .

.....

......

..

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

.........

..

......

.

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

.....

.

....... ..

...

..

..........

.

...........

.....

.

...........

.

.........

..........

.

......

....

........

..

. .

.....

.

....

..... ..

.

..

.

..

LEFT

SIDE

.

Mikuni . VM . . Open . . None None . . .

. . . .

. .

.

. . . . .

32

Econo Jet

L32 / 185

Vent

155

6DH7 -3 0-4

0.098 in. (2.5 mm) 0.098 in. (2.5 mm) 25

0.055 in. (1.4 mm)

0.031 in. (0.8 mm) 0.

1.5 Turns 1.5 Turns

0.059 in (1.5 mm)

0.059 in. (1.5 mm) Special

Dual Position Cable 140 RoundReverse

Type

Mikuni VM 32 Econo Jet

R32/189

Open

155

6DH7-3

0-4

25

0.055 in. (1.4 mm) 031

0.059 in. (1.5 mm)

0.059 in . (1.5 mm)

Special

Dual Position Cable 120 Round Reverse

RIGHT

SIDE

Vent

in. (0.8 mm)

Type

1-2

GENERAL

SPECIFICATIONS

FUEL/OIL

Gasoline Oil

........

.........

.

.....

. .... .

.....

.

...

...... ...

...

.......

..

Premium

....

. . . . .

or

regular leaded (minimum pump posted octane number 89)

....

Kawasaki Snowmobile Oil

(B.I.A. certified

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

Oil

Tank Capacity

Fuel

Tank Capacity ..........

DRIVE

CONVERTER

Engagement Drive Converter

Part Number and Col

Spring Spri

ng

Part Number and Col

Spring Length - New

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

Speed

(approximate RPM) ...

RPM

. .

.........

or or

with

no load ± 0.25 in. (6.3 mm)

..

.....

....

.....

. .

...

(Standard) .......

(Optional)

.......

.

...........

......

.

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

........ .

....

.

.....

......

..

....

.

... ...

. . .

.......

. . .

..

. . . . . . . . .

. .

.......

.. ..

.........

.

....

. .

.. ......

. . . 8.0 Gallons (30.2 liter

..

.......

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

...

. . . .

...

. .

.. ..

...

.....

3.96 in. (Yellow

. . 2.5 Quarts (2.37 liters)

. . . 92081-3004 (Pink)

3.54 in.

3.74 in. (Red) (94.9 mm)

4.14 in.

4.33 in. (Black) (110.0 mm)

4.74 in.

Number Spring Wire Diameter Spring Rate Spring Compression ± 5.5 Ib (2.5 kg)

of

Spring Coils

±2.8Ib

(All

Colors)

±0.01

in. (0.2 mm)

in. (0.05 kg-mm)

.. .......

All

Colors ... ........

All

Colors ....

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

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

...

.....

. .

.......

.

.....

.

...

77.2 Ib @ 2.54 in. (35.6

........

. .... .

.....

...

. .

. . .

...

.....

. .

.. . 56 1b in. (1.0 kg-mm)

kg

55.1 Ib @ 2.54 i

66.1

Ib @ 2.54 i

Ib @ 2.54 in. (40.7 kg @ 64.5 mm) (Blue)

88.2

n.

(25.4 kg @ 64.5 mm) (Pink)

n.

(30.4 kg @ 64.5 mm) (Red)

99.2 Ib @ 2.54 in. (45.6 kg @ 64.5 mm) (Black)

123.2 Ib @ 2.54 in. (55.9 kg @ 64.5 mm) (White) Spring Outside Diameter ± 0.025 in. (0.63 mm) Weight Part Numbers (Standard)

........

Ramp Part Number and Identification (Standard) Weight - Total gram weight (Standard)

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

All

.

.........

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

Colors

...

.

.....

..

. . .

....

.......

. . . .

.....

.

...

. . . . .

....

.

.........

. . . . . . . .

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

. . .

.....

...

....

T.C.

W.)

..

Oil Inject ion

s)

.

.......

3600

. . . 7,100-7,300

92081-3001 (Yell ow)

92081-3005 (Red)

92081 -3006 (Blue)

92081-3002 (Black)

92081-3011

(P

ink) (89.9 mm)

(Blue) (105.2

(Wh

ite) (120.4 mm)

. .

.. .......

(White)

).

(100.5 mm)

mm)

. 6

0.197 in. (5.0 mm)

@ 64.5 mm) (Yel low)

. 2.28 in. (57.9 mm)

.....

..

110G0628

13042-3002

92019 -008

..

39152 -3005

.....

..

63.1

"E"

grams

Part Number

13042-3001

13042 -3002 92019-008 92001-3009 92001-3003 92001-3015

110G0620

110G0628 39152-3005

DRIVE

CONVERTER COMPONENT

Component

Weight,0.031 in. (0.8 mm) Weight, 0.062 in. (1.6 mm)

Nut,

special 6 mm

Bolt,

aluminum, 6 x 15 mm

Bolt,

aluminum, 6 x 20 mm

Bolt,

steel, 6 x 16 mm

Bolt

, steel, 6 x

Bolt,

steel, 6 x 28 mm

Weight

Assembly E

20

mm

WEIGHT

thick thick

CHART

GENERAL

Gram Weight

0.5

1.0

2.3

1.8

2.1

5.3

6.0

7.3

47.5

SPECIFICATIONS 1-3

DRIVE

CONVERTER

Total Ramp

Weight-Grams

55 .1 grams

55.6

grams

56.1 grams

RAMP

Number

Weights

WEIGHT

of

Install

0 1 2

COMBINATIONS

Weight (0.5 gram each)

0.031 in. (0.8

ed

mm)

Part

Number

13042-3001

0

0.5 gram

1.0 gram

USING

thick

BOLT

PART

NUMBER

Bolt

6 x 16

Part Number Part

92001-

3015

5.3 grams

mm

92001-3015 (6 x

Nut

Special

Number

92019-008

2.3 grams

16

mm

STEEL)

Ramp Weight Part

Number

39152-3005

47.5 grams

To

permit

weights

NOTE ramp

r-

------

proper

Part

Installed

:

as

shown in

installation

Number

weight

illustration

~~

c--

------

INCORRECT

and

[:~~~!!~~J

security

13042-3001 (0.031 in., 0.8

positioning

.

RAMP

~~

------

of

must

not

WEIGHT

~

nut,

exceed 0.5 gram difference on

do

not

exceed a

mm

thick)

POSITIONING

r

----------------------------

maximum

on 6 x 16

mm

a

, t

~

NUT

~

NUT

~~

~

~WE

t

D

~

IGH~:MP

CORRECT

~

WEIGHTS

of 2 installed

bolts.

each

side

of

-,

(f.}~

\

~

'"

BOLT

~

WEIGHTS

~

RAMP

BOLT

""

WEIGHT

DRIVE

Weight-Grams

1-4

CONVERTER

Total Ramp

55 .8

56.3

56.8

57.3

57.8

58.3

58.8

59.3

GENERAL

RAMP

Number

Weights

To

permit

weights

NOTE for

two

weight illustration.

SPECIFICATIONS

Installed

0 1 2 3 4 5 6 7 3.5 grams

proper

Part

Number

: One weight Part

weights Part

positioning

WEIGHT

of

installation

COMBINATIONS

Weight

0.031 in. (0.8 mm)

and

13042-3001 (0.031 in.,

Number

does

13042-3001 (0.031 in ., 0.8

not

exceed 0.5 gram difference on

USING

(0.5 gram each)

Part

Number

13042-3001

0 6.0

0.5 gram

1.0 gram

1.5 grams

2.0 grams

2.5 grams

3.0 grams

thick

BOLT

PART

NUMBER

Bolt

6 x 20 mm

Part Number

110G0620

grams

6.0 grams

6.0 grams 2.3 grams

110G0620

Nut

Special

Part

Number

92019-008

2.3 grams

(6 x 20

[::~~~~~~:]

security

13042-

of

nut,

0.8

3002

(0.062 in., 1.6

do

mm

not

thick)

exceed a

on

6 x

mm

thick)

each

side

maximum

20

mm

thick)

may providing of

ramp

of 7 installed

bolts

.

be

substituted

that

installed

as

shown in

mm

STEEL)

Ramp Weight Part

Number

39152-3005

47.5 grams

Total Ramp

We

ight

-Grams

Numb

Weights

USING

er

of

Installed

DRIVE

BOLT

CONVERTER

PART

NUMBER

Weight (0.5 gram each)

0.031 in. (0.8 mm) Part

13042-3001

RAMP

92001-3003 (6 x 20

Numb

er

WEIGHT

thick

COMBINATIONS

mm

ALUMINUM)

Bolt

6 x

20

mm

Part

Number

92001-3003

Nut Special

Part Number

92019-008

Ramp

Weight

Part Number

39152-3005

51.9 grams

52.4 grams

52.9 grams

53.4 grams

53.9 grams

54.4 grams 54

.9 grams

55.4 grams

To

permit

weights

NOTE: for we illustration

DRIVE

Weight-Grams

CONVERTER

Total Ramp

57.1 grams

57.6 grams 1

58.1 grams

58.6 grams

59.1 grams 4

59.6 grams

60.1 grams 6

60.6 grams 7

61.1 grams 61

.6 grams

62.1 grams

62.6 grams

63.1 grams

63.6 grams 13

64.1 grams 14

64.6 grams

65.1 grams

65.6 grams

Part

two

weights Part

ight

pos

Number

Weights

0 1

2 3 1.5 grams 2.1 grams 2.3 grams 4

5 2.5 grams 6

7 3.5 grams

0

0.5 gram

1.0 gram 2.1 grams 2.3 grams

2.0 grams

3.0 grams 2.1 gra

2.1

grams 2.3 grams

2.1 grams

2.1

grams

2.1

grams 2.3 grams

ms

2.1 grams 2.3 grams

2.3 grams

47.5 grams

47.5

47.5 grams

[:~~~!!~~::]

proper

installation

Number

On

e weight Part

itioning .

RAMP

Installed 13042-3001

0 0 7.3 grams 2.3 grams 47.5 grams

2 3 1.5 gram

5 2.5 grams

8 9

13042-3001 (0.031 in., 0.8

Numb

does

WEIGHT

of

10 5.0 grams

11 12

15 16 17

and

security

Number

not

COMBINATIONS

Weight (0.5 gram each)

0.031 in. (0.8 mm)

13042-3002 (0.062 in., 1.6 mm

er 13042-3001 (0.031 in

exce

ed

Part Number Part

0.5 gram 7.3 grams 2.3 grams 47.5 grams

1.0 gram

2.0 grams

3.0 grams 7.3 grams

3.5 grams

4.0 grams

4.5

5.5 grams

6.0 grams

6.5 grams

7.0 grams

7.5 grams

8.0 grams

8.5 grams

of

0.5 gram

USING

thick

grams

nut

, do

mm

.,

differenc

BOLT

not

exceed a

thick)

0.8

mm

e on e

PART

Bolt

110G0628

7.3 grams 2.3 grams

7.3 grams 2.3 grams 47.5 grams

7.3 grams 2.3 grams

7.3 grams

7.3 grams 2.3 grams

7.3 grams 2.3 gr

7.3 grams 2.3 grams

7.3 grams 2.3 grams 47.5 grams

7.3 grams 2.3 grams

on 6 x

thick)

ach

side

6 x

28mm

Number

maximum

20

mm

thick)

may be subs providing of

ramp as shown in

NUMBER

of

7 installed

bolts

.

titut

ed

that

in stall ed

110G0628

Nut

Part

92019-008

2.3 grams 47.5 grams

2.3 grams

(6 x

28

Special Ramp Weight

Numb

er

am

s

mm

Part

39152-3005

47.5 grams

grams

STEEL)

Number

To

permit

proper

installation

weights

NOTE: for weight illustration.

Part

Number

One weight Part

two

weights Part

positioning

[:~~~~=1

and

security

13042-3001 (0 .031 in., 0.8

Number

does

not

Number

13042-3002 (0.

13042-3001 (0.031 in ., 0.8

exceed 0.5 gram difference on

of

nut,

do

not

mm

thick)

062

in., 1.6 mm

exceed a

on 6 x

mm

thick)

each

side

maximum

28

mm

thick)

may be s providing of

ramp

GENERAL

of

bolts.

that

as

17

installed

ubstituted

install ed

shown in

SPECIFICATIONS

1-5

DRIVEN

CONVERTER

Cam Angle (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cam Angle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spring Part

Spring Color . ....

Spri

ng

Spring Wire Diamteer ...........

Number Spring

Number

Length - New

of

Spring Coils .

. . .

...

....

...........

......

with

...

......

no load .............

. . .

...........

. . . . .

....

. . .

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

......

.....

...

. . ......

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

. .... .

.....

....

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

. . . .

.......

. .

...

. .

...

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

.....

.

........

..

.....

. .

....

..

......

..

. . 6.3 in. (160.0 mm)

. .

. . 0.177 in . (4.5

. .

...

.. ......

Preload - Counterclockwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 B2

BELT

Part Number .... ....

Outside Width

Thickness -

Circumference . .

of

Top

Surfaces .......

Top

of

Belt Taper Angle ....

belt

......

to

. . . .

....

bottom

....

...

..

. . . . .

.........

...

........

.. ..

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

of

lug .

...........

. . .

......

....

.

. . ........

..

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

.....

....

...

.

...

..

.....

..

...

..

....

..

....

. .

...

......

.....

....

......

46.62 ± 0.19 in. (1.184 ± 4.8 mm)

1.25 ±

0.03

....... 0.53 ± 0.03

..

in. (31.7 ± 0.8 in. (13.5 ± 0.8 mm)

..

35

..

30°

92081-3003

....

Black

mm)

7 ± 1/8

or

Cl

59011 -3502

mm)

0

BRAKE

Replace brake tab

to

brake di

pads

as

sc meas

a set when the distance

ures le

ss

than

...

. . . .

from

....

outer

..

surface

....

of

brake pad

....

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

...

......

....

GEARING

Top

Sprocket ....

Lower Spr

ocket

Sprocket Overall Ratio ....

Chain

(Silent

Type) . ........

Cha

in Tensioner Spri

Dri

ve

Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRACK

AND

Track

Type ........

Track Width

Track

Length .

SUSPENSION

..

...

.....

ng

....

. .........

..........

..

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

...

. .

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

....

..

......

..

...........

.

......

...

.......

. .

....

. . .... .

.....

.

..... ..

. . . ....

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

.......

.....

......

. . .

...

.

........

.......

....

.

. . . .

..

.

..

....

...

..........

.

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

......

.

.....

...........

.

....

. .......

...

Rubber (Internal Dri

..

...

. ....

. . ....

....

.......

..

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

..

. .

...

..... . ....

..

...

.. .......

ve

Lug)

......

...........

...

..........

.

Molded

.

......

........

..... .

121

Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1/4 in. (6.4 mm)

21 39 Teeth

. .

...

..

1.86

....

66 Pitch

...

..

Self

Adjusting

in Fiberglass Bar 15 in. (381

in. (3,073.4 mm)

.. Slide Rail

Teeth

to

Green

mm)

1

1-6

GENERAL

SPECIFICATIONS

ELECTRICAL

COMPONENTS

Type . . . Headli

Ta

il/Brake

Instrument Battery . Electrolyte

FRAME

Frame . .

.. .. ..

ght

Bulb Part Number . . .... . .... . .

Light ....... .....

Light

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

Volume

...

. . .

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

. .........

.........

...

.......

. . . ......

. .

...

. ...... ...

.... . .

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

.......

. . . . . .....

...

. . ........

..

. ........

..

...

. . .

.. ..

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

. .

...

. . . . . . . . . .

.. ..

. .

........

...

..

...

12 Volt

.....

...

22 amper e

. .

.....

. . . . . . . .

....

.

...

. . . . .

.........

......

Aluminum all

...

........ .

.....

. . .... . . . . .

/ho

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

...

urs capacity @ 10 h

. .

...

....

oy and

12

......

. . . .... G.

our discha

1.5 quarts (1.4 lit

HSLA

ste

el

VDC,

120 W

92069

-3501

V,

60/60 W

G.E.# 1157

E.#1816

rge rate

ers)

construct ion

ENGINE

Effective Compression Ratio .....

Piston Ri Pisto

Piston Skirt Clearance . . .........

Connecting Rod Connecting Rod Connect i

Crankshaft End

Crankshaft Run Cylinder

*Measured

ng

End

Gap

(Top)

n Ring End Gap

ng

Rod Small End Diameter . . . .

Head

with

(Bottom) ...... . . . . . . . . . . ......

Radial Play . . . ..........

Side Clearance

Play (ma

Out

Capacity* . . .

sta

ndard spark plug installed.

ximum)

(maximum) .

...

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

Service Specifications

.....

...

. .

........

...

..........

..... .

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

..

. . . . . . .

. . ......

..........

.....

......

.. ..

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

......

. .......

....

...

......

. .

......

. . ....

..........

....

..

.........

.. .. ..

. .........

....

...

. . . . . . . ....

.. ..... ..

.

...... ...

... ...

...

..... .

...

. . . . . . . . . 0.016-0.

.. ..

...

. . . .

..

. . . .

.....

. .....

...

....

........

..

0.008-0.

. . . 0.008-0.016 in .. (0.2-0.4 mm) .. 0.002 ..

0.0008-0.

. . 0.787-0.

. . .... . 0.015 in. (0.38 mm)

...

. . . 0.002 in. (

. . . . . . . ....

. .

......

016

in. (0.2-0.4 mm)

-0.004 in. (0.05-0. 10 mm) 001

in. (0.02-0.03 mm)

020

in. (0.4-0.5 mm)

789

in. (20.0-20.5 mm)

T.I.R.)

.. .. 18.3 + .4 cc

(0.05 mm)

. 7.3 to 1

SERVICE SPECIFICATIONS 1-7

IGNITION

Spark Plug Gap

Ignition

Igni

tNOTE:

ditions

CARBURETOR

A Idle Screw Setting (Final)

Float

Timing

tion

Timing (B.T.D.C .) ..............

Item

Lighting Exciter Coil Pulser Coil

Item

tSecondary

Defective coils cannot always

is

the

recommended test method.

ir

Screw Setting

.....

Arm

Adjustment

.......

(Dynamic) . .........

Coil

winding

(Initial)

. . . ........

. .

...

... ...

......

..........

.........

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

.......

. .

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

......

........

MAGNETO

Ohmmeter

CDI

IGNITER

Ohmmeter

Hi

gh

be

detected using this test alone.

...

.........

....

. . . .... . .

..........

RESISTANCE TESTS

Leads

Yellow·Yellow Red

·Ground

Red

·White

Leads

Tension-High Tension

. . .

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

..

......

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

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

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

Connected Between

RESISTANCE TESTS

Connected Between

.......

...

Use

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

.

.. ..

.....

. .

...

....

.....

. . .

of

a coil tester

.....

...

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

. . .

......

. .. .

...

. .

........

. . . . . .

..... .

..

......

.. .....

. . . 0.073 in. (1.86

Re

0.18 oh m ± 20 %

160 ohms ± 20%

17

ohms ± 20%

Resistance

5,700 ohms ± 15%

which

simulates operating con-

........

....

Parallel

to

Body

0.024 in. (0.6 mm)

180@6500R

sistance

. 1.5 Turns Open

..

6 Turns

2,500 R.P.M.

Gasket Surface

Off

.P.M.

mm)

Seat

CHASSIS

Converter Offset Distance

Converter Center Distance . . Drive Chain Tension Brake Lever Movement

Track Tension Steering Tie Rod End

GENERAL

Cylinder Head Bolts . Crankcase Flywheel

Re

Spark Plug .......

Holder (Carb.) Bolts .......

Driven Gear Gearcase

Alignment ... . .

Adjustment

ENGINE

Bolts and Nuts ......

Nut ...

coil

Bolt

...

Nut ...

Bolts (Socket Head) .... . . . . . . .

.......

...

...........

TORQUE

.....

..........

......

.......

.....

...

.........

..

. ..........

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

. . .......

.......

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

Stud Jam

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 in. Ib (0.6 kg-m)

Nut

SPECIFICATIONS

...

..

...

.....

. ......

...

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

.....

.... . . .

. . . . . . . . .

......

.

.......

Dimension

..........

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

..........

..

....

.....

...

.....

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

.... .

. .

... . . .

. . . .... .

...

.....

...

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

...

......

.

........

..

. .......

. . .

.......

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

... ...

...

..........

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

...

. . ....

......

. 3/4 in. (19 mm)

.......

. . . . .

......

. . . .

...

.... 0.525

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

...

.......

.

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

.....

.. ..

. ......

..

......

........

.......

. .

....

.........

....

. .

...

....

...... ...

..

maximum

. .

..

....

.........

.....

. .

...

..

. ........

to

0.588 in. (13.3

. . .... .... Self Adjusting

deflection

Skis parallel

. 1-1/4

...

. . .

....

in.

......

. ....

......

...

....

. .

to

14.9 mm)

..

12 in. (305 mm)

. . 3/4 in. (19 mm)

(5

to

8 Ib pull)

or

1/8 in. toe

(32 mm) maxi

16

ft

Ib (2.2 kg-m)

16

ft

Ib (2.2 kg-m)

60

ft

Ib (8.3 kg-m)

20

ft

Ib (2.7 kg-m)

45

in. Ib (0.5 kg-m)

12

ft

Ib (1.6 kg-m)

12

ft

Ib (1.6 kg-m)

out

mum

SERVICE

1-8

SPECIFICATIONS

Torque Chart and Loctite Table

Description

ENGINE

Engine Muffler Engine PTO

ELECTRICAL

Ign Voltage regulator Brake and Ta Tail lamp

DRIVE

Dr Cover

Roller and pin assembly in movable Weight ramp and pin assembly Weight ramp -

DRIVEN

MOUNT

mount

mounting

mount

to

ition

switch -

throttle

il

lamp

lens to

door -nut

CONVERTER

ive converter

to

movable

CONVERTER

AND

EXHAUST

to

damper -nuts

- nuts

to

chassis - nuts 2

chassis - screw

SYSTEM

nut

mounting -nut

lever - lockscrew

mounting

to

nut

- screws

crankshaft -

sheave -bolt

AND

bolt

to

BRAKE

sheave -bolt

spider -

bolt

Quantity

6

4

5

1 2

1 2 2

1 6 6 6 3

Torque

105 in. Ib (1.21 kg·

60-70

in. Ib (0.69-0.81

31

ft

Ib (4.28

80-90 in. Ib (0.92-1.04

30

in . Ib (0.35 kg ·

105

in.lb

(1.21 20-25 in. Ib (0.23-0.29 50 in. Ib (0.57 kg· 32

in. Ib (0.37

65-70ftlb 8-10ft 8-10 6-

8ft

4-5

ft Ib (0.5-0.7

(9.0-

Ib (1.1 -1.4 kg·ml

ft

Ib (1.1-1.4 k

Ib

(0.8-1.1kg·ml

ml

kg·ml

ml

kg·ml

ml

kg·ml

10kg·ml

g·ml

kg·ml

Loctite

kg·ml

Driven

converter Coupl ing Coupling

Caliper

CHAINCASE

Chaincase

Chaincase cover Jackshaft bearing retainer Jackshaft bearing retainer Top Jackshaft - bearing retainer adjusting

Tensioner arm -

Lower

Bearing retainer cap -

NOTE: Loctite Generally, No. 222 fastener diameter essary formula lent

to

sprocket

to

remove a fastener.

on

which may

to

jackshaft -

fixed

sheave -bolt

flange -

chaincase -

mounting

each

bolt

nut

AND

JACKSHAFT

- nuts

mounting

bolt mounting -bolt

formulas

is

fastener requiring Loctite.

be

substituted

- screws to to

- screw

nut

are

is

used

on fasteners up

greater than

bolt

chassis chassis -front

selected on the

5/16

Be

careful when applying extra force

is

Loctite

- rear

bolt

bolt -jamnut

basis

to

in. (8

mml,

Loctite

"Lock

of

the

diameter

5/ 16 in. (8

'n Seal,"

mml

No. 242

No. 222 and No. 242

is

product

1 40-50

8-10ft

6 6

8-10ft

ft

35

2

ft

18

4

70 in. Ib

6

31

1 1 1 1 2 1 2

of

the fastener, and the strength

diameter.

specified.

number 21, blue.

Loctite

as

this risks damaging the parts.

are

ft

19

ft

40-50

10-

20ft

70

in . Ib (0.

ft

35

105 in . Ib (1.21 kg

If a particularly

may significantly increase the

industrial designations. The consumer equiva-

ft

Ib (5.53-6.

Ib (1.1-1.4 kg·

Ib (4.84 kg·

Ib (2.5 kg·

(0. Ib (4.28 kg· Ib (2.63 kg ·ml ft

Ib (5.53-6.92 kg·

Ib (1.38-2.

Ib (4.84 kg·

ml

81

kg·ml

ml

81 kg·

ml

strong bond

92

kg·ml

ml

77kg·ml

ml

·ml

of

the bond required.

is

required,

Use

only

or

the

torque

nec-

the specified

TORQUE

CHART

1-9

TORQUE

CHART

(CONTINUED)

Description

SUSPENSION

Rear suspension arm to track guard pi Rear suspension arm Rear

axle -

bolt Idler shaft Shock absorber Swing arm - bolts Wear strip attaching Cross shaft Front Suspension brace

Limiter

DRIVE

Bearing housing - bolts Locking

SKI

AND

bolt

mounting

pivot

shaft

strap - nuts

SHAFT

collar set screw

SPINDLE

bolt

s

mounting

- nuts

- bolts

to

chassis

-

front

- nuts 2

- bolts

and rear - bolts

pe

- nuts

Quantity

2 2 2 2

2

2 4 2 4 4

3 2 72 in.

Torque

11

ft.

lb

. (1.52

kg'm)

30

ft.

lb. (4.15 kg'm)

25

ft.

lb. (3.46 kg'm)

ft.

lb

25 35 25 25 i 30 25 25 45 in. lb. (0.51 kg'm)

18

. (3.46 kg'm)

ft. lb

. (4.84 kg'm)

ft

. lb. (3.46

n. lb. (0.29 kg'm)

ft.

lb . (4.15 kg'm)

ft

. lb. (3.46

ft.

lb. (3.46 kg'm)

ft

. lb. (2.5

lb. (0.83 kg'm) 222

kg

'm)

Loctite

Ski

skeg

attaching -

Front

spring

mount -bolt Shock absorber Saddle

to

spring -

Spindle

Rear spring

STEERING

Handle holder Steering arm Steering column Steering arms Steering post T Tie rod jam R H tie rod Handle bar

Ti Tie rod adjusting

NOTE: Generally,

fastener diameter

sary formula which may

to

ski saddle -

mount -bolt

to

mounting

ie

rod jam -

e r

od

to

nut

-

nut

to

steering arm -

to

steering column

adjusting - nuts (RH)

Loctite

#222

remove a fastener.

on

each

be

substituted

nut

(wear runner)

to

ski and spindle -

bolt

nut

bolt spindle -

to tie rods - nuts

- nuts

formulas

bolt

tie rod -

(LH) (RH)

is

fastener requiring

nut

- bolts

nut

mounting

(LH)

are

selected

used

on fasteners

greater than

Be

is

Loctite

nut

- screws

on

the

basis

of

the

diameter

up

to

5/16

in. (8

mm)

diameter.

5/16

in. (8

mml,

#242

is

specified.

careful when applying extra force

Loctite. "Lock

Loctite

'n Seal,"

#222

product

and

#242

number 21, blue.

120 in.

6

25 in.

2

31

4

46

4

46

2

31

2

1 35 2

30

1

30 30 ft. lb. (4.15 kg'm)

2 4

18

2

100-120 in. lb. (1.15-1 .

2

100-120 in. lb . (1.15-1.38 kg'm)

1

30ft

4

105 in. lb. (1.21 kg'm)

2

100-120 in. lb. (1.15-1.38 kg'm)

2

100-120 in. lb. (1.15-1.38 kg 'm)

of

the

fastener, and the strength

If

a particularly strong

Loctite

as

this risks damaging

are

may significantly increase the

industrial designations. The consumer equivalent

Ib_

(1.4 kg'm)

lb. (0.29 kg'm)

ft

. lb. (4.28

ft.

lb. (6.36 kg'm)

kg

'm)

ft. lb. (6.36 kg·m)

ft

.

lb

. (4.28 kg-m)

ft

. lb. (4.84 kg'm)

ft.

lb. (4.15 kg'm)

ft

. lb. (4.15

ft

. lb . (2.5 kg'm)

. lb. (4.15 kg'm)

the

kg

'm)

parts.

bond

38

kg'm)

of

the bond required.

is

required,

torque

Use

only

the specified

or

the

neces

-

1-10

TORQUE

CHART

CHASSIS

Description

Quantity

Torque

Loctite

Snow

flap

to

bulkhead Hood guide and Hood guide, Passenger Pan

brace

Rear s

tay

Trim

attaching·

Seat

attaching·

FUEL

SYSTEM

Fuel

pump

Primer

pump -nut

CABLES

Brake cable Enrichener cable assembly· nuts Enrichener assembly Speedometer Throttle

FAN

Air Fan

cable assembly - nuts

CASE

shroud

case

trim

front handle attaching - nuts 4 attaching· attaching·

screws 2

bolts

assembly

jam,

cable - nuts

AND

mounting

to

crankcase

nut

mounting

bumper

nuts

AIR

and

screws

bolts 2

mounting·

pal·

nut

SHROUD

bolts

mounting

50 in. Ib (0.57

2

- screws 8

hood hinge attaching - nuts

nuts 2 35 in. Ib (0.40

nuts

18

12

20 in. Ib (0.23 kg' 70 in. Ib (0.8 10

ft

Ib (1.38

70 in. Ib (0.81 kg'

2

19

ft

Ib (2.63 kg ' 20 in. Ib (0.23 kg ' 35 in.

4

1

2

1 1 Hand Tighten

2

4

Ib (0.40

30

in. Ib (0.35 kg'

50 in.

Ib

(0.57 15-20 in. Ib (0.17·0.23 kg ' Hand Tighten

15·20 in. Ib (0.17·0.23 kg'

60 in. Ib (0.69

1(}'12

ft

Ib (1.4-1.7

kg'ml

kg'ml kg'ml

kg'ml

kg·ml

ml

222

kg·ml

HOOD

Hood hinge - nuts Hood latch

INSTRUMENT

I nstrument panel bracket Gauges

I nstrument panel - screws

CRANKSHAFT

Flywheel -

CRANKCASE

Cyl inder head - nuts Spark pl Crankcase - bolts

band·

to

panel - nuts

nut

ug

screws

PANEL

AND

CYLINDER

INSTRUMENTS

nut

6 4

3 6

6 15

1 60

16

2 8

Ib (0.29

25 in. Compress rubber

0.06 in. (1.55

95 in.

Ib

11

in . Ib (0.13 kg' in.lb

ft

Ib (8.30 kg'

ft

Ib (2.2 kg'

16 20

ft

Ib (2.77 kg'

16

ft

Ib (2.2

(1.09

(0.17

mml

kg'ml

ml

TORQUE

CHART

1-

11

EXHAUST

Descri

ption

Quantity

Torque

Loctite

Exhaust

COl

Stator Wire clamps Exciter Lighting

ELECTRICAL

COl igniter

Ignition

RECOI

Drive plate Starter Starter

manifold

MAGNETO

plate

mounting to

coil and pulser coi I

coil

mounting

coil

L

STARTER

mounting -nut pulley mounting

- nuts 4

- screws

stator plate - screws

mounting

mounting -bolt

- screws

-screw 2

- bolts

mounting

s

- screws

8-10ft

2 5-6

Hand tighten

2

Ib (1.11-1.

ft

Ib (0.69-0.83 kg·m)

2 35 in . Ib (0.40 kg-m) 2

35 in. Ib (0.40 kg-m)

2

60 in. Ib (0.69 kg·m) 5-6

ft

Ib (0 .69-0.83 kg·m)

1

8-10ft 5-6

3

5-6

3

Ib (1.11-

ft

Ib (0.69 -

ft

Ib (0.69 -0.83 kg·m)

1.38kg

0.83

38 kg·m)

·m)

kg·m)

1-12

TOROUE

CHART

Gear Ratio

Chart

I

f-

w w

f-

lL

0

a:

w

en

:2'

~

z

I

f-

w

~

U

0

a:

0-

til

Z

w

:::

a:

0

36

37

38

39

40

Dri ve Sproc ket · Number

17 18 19

2.18 2.06 1.95

*6

6 MPH

64

R

ed

2.24

*

64 MPH

64

Pink

2.

35

'6

1 MPH

66

P

ink

*6

9 MPH ' 73 MPH

64 64

Pink

2.

11

' 68 MPH

64

Green

2.22

' 64 MPH '

66

Pink

of

Teeth

20

L

90

' 75 MPH '

64

R

ed

Gr

een

2.

05

'

70

MPH ' 73 MPH

66

Red

2.

11

68

MPH

66

Gr

een Green Tension er Spring

1.80 Gear Ratio

80 MPH

64

Pi

nk

1.90

* 75 MPH

66 66

R

ed

1.95

66

Pink

2.

00

' 72 MPH

66

21

1.76

*

81

MPH

66 66

Re

d

1.

81

*79 MPH

Pi

nk Green

L 86

' 77 MPH

66

Green

22

1.68

*85

MPH

Pink T

1.73

' 83 MPH

66

Speed Chain Pitch Tension

G

ea

r Ratio Speed Ch

ain Pitch

ens

ioner Spring

I

Gear Ratio Speed Chain Pitch Tensioner Spring

Gear Ratio Speed Cha

in P Tensioner Spring

Gear Ratio Spe

ed

Ch

ain Pitch

er

itc

Spring

h

Color

---

Black

White

Red

Orange

Pink Yellow Green Blue

*Theo retical

NOTE:

All

MPH

at 7100

top

speeds based on

2.50

3.00

3.38

3.

38

3.75

RPM

0.96

overdrive

in

conv

erter

and

engine

RPM

at 7100.

Chain Tensioner Springs

Length Wire Dia.

(63.50

in.

(63.

in.

(76.

in.

(76.20

in.

(85.85 mm)

in.

(85.85

in.

(95.25 mm)

in.

(95.25 mm)

in.

50 20

mm) mm) mm) mm)

mm)

0.049

0.055

0.049

0.055

in. in. in. in.

0.049 in.

0.055 in.

0.

049

in.

0.055

in.

(1.245 (1.397 mm) . (1.245 (1.397 mm) (1.245mm) (1.397 mm) (1.245 (1.397 mm)

mm)

GEAR

RATIO

CHART

1-13

ENGINE

80

70

60

ex:

L.U

S

50

0

a..

L.U

CJ)

ex:

0

I

40

30

20

10

CJ)

CO

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--

f-

LL

L.U

6

ex:

0

f-

40

30

20

10

PERFO

- - - -

- -

- - - -

- - -

--

RM

--

- - - - - - -

--

-

ANC

- - - -

-

vEt-

[k/

~

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~

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RPM

-

FUEL

- CONSUMPTION /

r---L2

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/'

/

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o 0 0 0 0 0 0 0 0

o 0 0 0 a a

o a a a

M

~

ENGINE

ST440-A4

E

- -

HP

TORQUE-

~

00

ro

CURVES

-

0

00

-

2.2 I

2.0 I

1.

8

1.

6

1

.4

1.

2

1 . 0

0.8

0.6

0.4

ex:

a..

2:.

CJ)

~

--1

L.U

~

LL

V

~

A

EXHAUST

PORT

-.;;;

~

PORT

r

B

C

!

8

1.575 in. (40.0 mm)

A =

B

1.272 in. (32.3

=

1.189 in. (30.2

C

=

D

1.890 in . (48.0

=

E

1.

228 in. (31.2

=

F

3.807 in. (96.7 mm)

=

DIMENSIONS

TOP SURFACE OF

D

INTAKE

PORT

B

mm) mm) mm) mm)

CYLINDER

F

I

E

1

0.555 in. (14

G

=

H

1.906 in. (48.4

=

I

1.906 in. (48.4

=

0.555 in . (14.1

J

=

0.795 in. (20.2

K =

0.799 in. (20.3

L =

H

t§J

r--

L---"

.1

mm) mm) mm) mm) mm) mm)

PORT

-K-

I

~+

NOTE:

Port

width

does

not

include

the

chamfer. Port

1-14

ENGINE

PERFORMANCE

CURVES

height

AND

and

height

PORT DI

location

MEN

includes

SIONS

the

chamfer. Port

chamfer = 0.039

in. (1.0

mm)

Mainten ance and Theo

ry

Table

Maintenance Lubrication Engine Theory C

arburetor Ignition Electrical System Theory of Operati on 2Charging and Ins Co

nverter Sys

Chaincase and Gear ing Oper ation

Trac

k,

Suspension and Steering

tem

Sys

Engine Inspection . . . . . . . . . . . . . . . . . . . . .

Crankc ase Press Engine Ge Compression Check

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-

Carburetor Fuel Filters Fuel Pump

Fuel Pump Pre ssure Test . . . .

Fuel Pump Primer Fuel Tank & Throttl e Cable

Oil Pump

Synchroni Enrichener Ignition

Ignition Ig

nition

Cleaning , In spe

Gapping th e Spark

Oil Inj ec

Oil Inj ection System

Bleedin g . . ................ .

Oil Pump

Elec

tric

al Syst em .......

Key S Headlight Bulb Replaceme

Ta

illBr Speedo Voltage

C

onverter

C

onverter

Without

Converter Center Distance

Without

Chart

The

System Theory

tem

Operation ....

ar

Pump .

to

Carburetor

zation . . . .

Cable

Sys

tem

Timing Check Timing

tion

Sys

Outl

witch

Adjustment

ake Lig

meter

Reg

Alignm

Offset

Special Tool

5

7001-3503

Speci al Tool

57001 -

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

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

of

Operation

ory

of

trument

Theory

ur

case

Adjustments

........

Output

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

Liner ...........

Adjustment .......

Adjustment

..

. . . . . .

Adjustment ....

ction

tem ..........

et Tube Purgin g . .. . . . 2-42

......

nt

ht .......

. .

...

ulation .... ........

ent

........

Alignment

3503

.

.. ..

. ....

. . .

....

. . . . 2-4

.....

......

. . .

Operation . ....... . 2-13

of

Operat ion .... 2-23

Circ

uit

s .... . . . 2-

of

Operation . .

...

....

..

. . . . . . . . . . . 2-32

..

e Test . . . . . . . . . . . .

......

.........

.......

....

. .

......... . . . 2-

........

.

......

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

Test

..

and

Plug ... . . . .

....

.. ..

........

.....

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

.......

. .

......

. .

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

......

..

.......

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

.. .....

............. 2-

....

.. ..

. . . .

...... 2-37

. .

...

. . .

...........

.......

. .

...

. . ....

...

. . .

...

. .......

. .

.........

......

........

...

.......

. .... . . 2

....... ..

......

..

........ . 2-

..

....

. 2-

.. 2-36

. . . . . 2-

....

2-37

...

. 2-

2-38

. ....

...

. . . . . 2-42

...

.. 2-39

. . .

....

..

. 2-43

. 2. . 2. . 2-

. 2-

2-39 2-39

2-40 2-41

2-41

2-45

of

2-3 2-5

24

27 2-30 2-

32

2-34 2-3

4

34

2-35

35

2-35

36 36 37 37

43 43

44 44 44

-44

46

Cont

Suspension

Track

Storage . . .

ents

Jackshaft

immi

Sh

Conve

Tool

Converter

Special Tool PI N 57001-3503 ... ..

Converter

Special Tool PI N 57001 Converter Be

lt ... .

Converter

Brake

Brake Brake Pad

Chain Tension . . . . .

Gear Ratio Steering Sys

Ski S

ki

Sk i Spring Preload .....

Ride Handling Sw

ing

Adjustments Track Tension Track

Preparation Removal Carburetor

ng . ......

rt

er

PI N 57001 -3503

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

..

. . . . . .....

Adjustment .....

Chart

tem Alignment

Skeg . .... . ....... ....

Adjustments .........

Adjustment

Arm

Al

ignment ......

.......

from

Bearing Retaine r

. . .

....

Ali

gnme

nt Using Special

........

Center Dis Offs

et

Parallelism . . . . . . .

Lubricat

Wear

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

Adjustment .......

for

Storage .....

Synchron

tanc

e Using

Alignment

-3503

.. .. .. .. ..

ion ... . .

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

.....

Inspecti on .

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

...

. . . ..

.. .....

. .... . .

. . .

Adjustment ...

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

Storage . .

.......

........

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

.....

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

. . .

... ...

izati on . . .... .... .

..........

...

Using

....

...

. .

...

....

. . . . . . .

.. ..

. . . .....

...

. . .

...

. .

...

.. ..

. . . .

. . . . .

. ....

...

. . . .

...

. .

.. .....

...

....

. . .

....

. . . .

...

....... .

...

. . .

. .

....

. . . .

. .... . . . .

. . .

......

..

. .

.

. .

. . .

.

. . . .

.

2-

47 2-47 2-

47 2-49

2-49 2-

50

2-51 2-52 2-52 2-53 2

-53

2

-54

2-

55

2-

55

2-

56

2-

56

2-

56 2-56 2-

56 2-5

7 2-57 2-58 2-

58

2-

59 2-59 2-60 2-

61

;1

TABLE

OF

CONTENTS

2-1

Maintenance Chart

Frequency

Operation Install

Check

adjustment

Check

adjustment

Check

adjustment Replace

fuel Check Replace drive

sure converter sheaves are clean and dry)

Check drive and alignment

new

carburetor

throttle

enrichener

in-line

filter

ignition

driven

spark

converter

plugs

cable x x

timing

belt

(be

converter

Every

480

or

Hours

km

20

Use

Every

960

or

Hours

km

40

Use

x

Beginning

of

Each

Season

x

First

80-160

or

5-10

Hours

km

Use

x x

x

x x

Every

1450

or

Hours

60

x

km

Use

End

of

Each

Season

Page

Refer-

ence

2-41

2-35

2-37

2-39

2-

36

2-39

2-50

2-45

Check drive bushings

Clean and inspect drive and converters

Check drive tensioner

Adjust and check

Check ski Check Check

security chart

as a guide)

Inspect ski skegs x

for

wear

Measure rail

wear

Adjust

converter

for

wear

driven

chain

guides

track

tension

alignment

brake

adjustment

fasteners

(use

torque

wear

strips

headlight

of

for

slide

x

x x x

x x

x

3-95

3-96 3-103

2-53

2-58

2-55 2-52

1-9

2-56

3-117

2-43

Check fan

Check battery

electrolyte level

belt

tension

x

MAINTENANCE

x

CHART

3-67

2-24

2-3

Lubrication

Point Lubricant

Chart

Frequency

Illustration

CONTROL CABLES Inner

cabl~s

CHAINCASE HOUSING

LPS, WD-40 Dri-Slide or

s

imil

ar l

temperature

ca

lubri

DEXRON automat transm fluid.

Level should be above center si

ght

glass

higher

ow

nt.

ic

issi

than

,

II

on

of

but

the

not

top .

Once a season and ev

of

Check level every 20 operation.

ery

20 hours

operation.

hours

of

ENGINE CASE OIL LEVEL

2-4

GEAR-

LUBRICATION

KAWASAKI GEARCASE OIL

or 10W-40 motor

that

oil or

exceeds API

service

ifications,

as

Shell

AND

ICE

Level

should be above center sight

glass

but

not higher the

top.

CHART

meets

SE

FIRE

.

of

than

ENGINE

spec-

such

Change

100

Check every mi of

Drain and r at end each season.

les

use.

after

miles.

or

20 hours

of

ef

initial

300

ill

Engine Theory

Introduction

Engines

All

internal

by a four

are: 1. Intake, 2. and

4. Exhaust.

fuel/air

A compressed,

A

two-stroke

complish Each

following

the

engine

1. Intake: of through

2.

Compression: Near

stroke,

starts fuel/air volume.

part

mixture

all

of

the

. (See

On

fuel mixed

the

back up.

to

combustion

cycle

Compression,

must

burned,

engine

four

path

the

an

intake

mixture

uses

parts.

parts

of

Figure

upstroke

with

open

port

This

to a fraction

Two-Stroke

of

and

can

the

air

the

of

engines

operation.

be

drawn

exhausted.

only

two

be

easily

fuel/air

2-1.)

of

the

is

drawn

in

the

bottom

is closed,

upstroke

Operation

are

characterized

The

four

parts

3.

Combustion,

into

the

engine

strokes

understood

mixture

piston a charge

into

cylinder

and

compresses

of

the

.

the

its

through

engine

former

to

ac-

by

down-

piston

the

,

3.

Combustion: When pressed, down.

4. Exhaust: gases and

The

piston

power

the

crankshaft

The

most air

have

into

the

cylinder

the

lower

effectively

drawing

piston presses 55°-60 upper inder mixture through

This

exit

the

cycle is ready

is

stroke

intake

the

of a two-stroke

complex

been crankcase.

wall

edge

increases

in

the

blocks

the

° BBDC (before

edge

of

wall

that

in

the

these

it

is i

gnited

is

called

After

mixture

the

through

carried

to

the

.

part

of

mixed

(the

of mixture

the

intake

the

piston

are

connected

crankcase,

transfer

the

power

the

through

in

the

As

the

intake

the

in

bottom

ports

mixture

and

the

power

stroke,

now

open

to

start

each

by

the

engine

cycle.

carburetor,

piston

port) piston. volume

. On its

port

the

crankcase. At

uncovers

to

the

under

into

the

has

been

forces

rotating

After

The risin g

of

and

dead

pressure,

the

stroke

the

exhaust

again

step

is

perhaps

the

it

rises, a

is

uncovered

the

crankcase,

return

lightly

center),

ports

in

crankcase

cylinder.

com-

piston

.

burned

port,

.

from inertia

fuel

is

drawn

hole

piston

trip,

com-

about

the

. The

rushes

one

of

the

and

in

by

the

cyl-

o

Figure 2-1

o

ENGINE

THEORY

OF

OPERATION

o

2-5

There are the

crankcase,

two

-stroke

is called

fer

used because inder combustion enging" the

After rises, closing opening above

two

separate

and

terminology,

the

intake;

or scavenging

the

helps

to chamber exhaust.

the

piston

passes BDC (bottom dead center)

the

intake again. The

the

piston

the

flow.

new

clean

transfer

is

compressed TDC (top dead center), the

mixture

The

piston

until

the edge of through the

piston, and one

starts

is

driven

exhaust

the

piston

all

four

burning

downward

port

. The

basic

crankshaft.

Intake

A

two-stroke

carburetor. To

get

the be an etor

opening

bore . The opens and closes either side

fuel/air

The and

takes a certain

engine

mixture

from

intake

of

TDC. (See

mixture

's

into

the

amount

intake

second

only

actions: the

into

the

second is called

The

word

mixture

the

. This is

flowing

exhaust

and

known

exhaust as

the

spark

.

by

is

uncovered two-stroke

parts

in

just

complete

intake

the

timing

same

tract

the

crankcase,

crankcase

is "

number

Figure

in

the

intake

of

time

first

the

cylinder

first

intake

the

"scavenge"

into

the

out

as

ports

mixture

the

plug

the

trapped

piston

is

fired

combustion

by

the

engine

two

strokes

rotation

starts

with

there

to

the

symmetrical,"

of

degrees

2-2.)

tract

has

to

get

into

. In action trans

is

cyl-

of

the

"scav-

, and nears

and

upper

goes

of

the

must

carbur-

on

inertia,

the

it

crankcase. The

more

time

crankcase. If

-

crankcase mospheric direction

. The 600 ABDC, would BTDC,

seem ideal

just on a piston intake and the the

to

all

the mixture open intake.

sooner

there

the

pressure

and

the

transfers

which

after

the

port

remain

crankcase

to

the

is

to

intake

mixture

is

the

to

open transfer

engine

open

cylinder

the

intake

draw

the

is

opened

will

be

will

generally

same

the

intake

ports

this

until

1150 ATDe

pressure

would

is opened,

mixture

higher

flow

close

as

into

too

soon,

than

in

the

at

1200 BTDC. It

at

about

close . However,

would

require

as

meant

be

to

lost

transfer

back

the the the

at-

wrong

around

115

the

well

out

0

,

Transfer

Transfer mixture scavenge the exhaust direction exhaust transfer such a way inder,

haust

The size portant small , port of the scavenging. The crankcase vol lower

from

exhaust

. As will ports

pushing

port.

for

the

is

too

inertia

flow

the

ports are

the

exhaust

port

opens before

gases are

the

pressure

no

longer

aim

that

it

the

and

shape

efficient

transfer

large,

the

of

the

gases

after

it leaves

transfer

ume

crankcase

designed

crankcase

from

already

in

flow

the

incoming

will

sweep

exhaust

of

the

scavenging

flow

will

flow

speed

will

the

port

. The

larger

pressure

to

move

to

the

cylinder,

the

cylinder.

the

transfers

traveling

the

cylinder

of

its

own

fuel/air

throughout

gases

toward

transfer

. If

be

restricted

will

affect

port,

the

resulting

passage is

the

.

the

fuel/air

and

Because

do,

in

the

drops,

accord. The

mixture

the

ports

are

they

are

. If

drop

. The lack

direction

in poor

part

passage,

right

of

to the the

in

cyl-

ex-

im-

too

the

of the

the

TYPICAL

0

89

ABDC

2-6

ENGINE

PISTON

TDC

BDC

Figure

THEORY

VALVE

ENGINE

2-2

OF OPERATION

76°

89°

ATDC

BBDC

Timing

of

the

transfer

ports

runs

BBDC to about 600 ABDC. The cannot haust

mix less symmetrical transfer open into

open

would

the

new

power

port

too

the

crankcase .

(or

about

long,

until

after

flow

charge

none

is

important

some

the

into

the

and

the

at

all).

BDC . The

to

of

the

exhaust

crankcase. This

exhaust,

Transfer

closing good mixture

Compression

Compression occurs as closes presses fraction pression of

mechanically

the

of

its

intake and

fuel/air

original

any

sealed .

mixture

kind,

the

piston

exhaust

volume

the

in

. To

from

transfer

does

port

cylinder

will

on

ports

the

cylinder

achieve

cylinder

about

or

the

resulting

timing

point

of

filling.

flow

its

upstroke

and

must

60

ports

ex-

would

in

is

the

back

com-

to

a

com-

be

0

If

The

cylinder

from

the

tween

both compression and gasket standing

head gaskets are aluminum. asbestos sheets. The head to just

leaking.

The piston is a close the special cast iron grooves and press wall bustion withstand without down

Most piston the

the

."

the

final

to

on the

engines

rings. Their job is

piston and cylinder.

head,

cylinder itself. The

he'3d

This gasket

high

Others

cylinder, squeezing

right

seal is made by piston

prevent

past

high

deforming

cylinder

have one or

in

most

and

the

combustion

must

temperatures

simply a sheet

are a

amount

fit

rings which circle

outward

leakage

the

piston. The piston rings

temperatures

while

wall.

engines,

joining

cylinder

be capable

and pressures.

sandwich

must

be fastened

the

head gasket

of

force

in

the

cylinder

against

of

compression

rubbing

two

to

constantly

compression

seal

the

is

surface

is sealed

by

the

of

copper

of

copper and

to

keep

rings

. These are

the

and

pressures

gap

separate

be-

against

"head

of

with

Some

or

tightly

with

it

from

bore,

but

piston in

cylinder

or

commust

up and

sealing

between

-

FLAT

RINGS

The compression ratio different from displacement two-stroke

SDC

second engine in Figure displacement

method

KEYSTONE

Figure

ways

. The

to

above

engines

can

entire

TDC

may

the

are

. As an example,

2-4 with a 60

be

figured

RINGS

2-3

may

be

cylinder

be used, or

exhaust

generally

as

"DYKES"

RING

measured in

displacement

just

port. Kawasaki

rated by

imagine

mm

stroke . Its

shown.

two

the

the the

New

piston rings do the

cylinder

This

initial

The cross-section

its design. Rings having a section are type

of

has a wedge-shaped

3). This type its groove has ring and its groove are designed outward bustion

should sometimes

should always manufacturer's

A

third

This

ring piston. It is placed so

that

the

edge

i nder

wall cylinder combustion of

the

cylinder

rings

not

conform

wall,

wear

called

ring

has

of

against

stroke for

not

be

also have a "

type

of

is

usually

one

side

slightly

duri

wall

twisting

stroke

upper leg

wall

for

must

be

"broken in." The

exactly

but

is

the

of

a ring is an

"flat"

parallel

cross-section . (See Figure 2-

ring

called a

nonparallel walls

the

cylinder

better

installed

be

installed

instructions.

ring

is used alone on a

at

the

of

the

. The ring is forced

ng

the

of

the

a good seal.

to

they

gradually

break-in

rings

. The groove

walls. Another

"key-stone"

wall

sealing

upside

top"

carefully

the

"Dykes"

upper

"L"

shape

upstroke by

ring

outward. During

gas pressure on

"L"

forces

tiny

irregularities

wear

to fit.

period.

important

rectangular

. The shape

to

force

during

. Key-stone rings

down.

and

"bottom"

following

edge

of

protrudes

against

the

it

out

part

cross-

for

type

of

ring and

of

the

Flat rings

pattern

single-ring the

piston,

above

the

drag

of

the

inside

against

com-

ring.

new

of

this ring

the

ring

and

the

cyl-

the the

the

o

Figure

2-4

BORE = 60 STROKE = 60

mm

ENGINE

THEORY

OF

OPERATION

2-7

2

V=m WHERE: V r = 112 bore - 30

h = stroke -

17

V = (3

V If

ume can

h

=

displacement

60

= 3.

1416 .1416

) (9) (6)

=

169.6

the

be

cc or approximately

engine has a total

of

20

cc

at TDC,

figured.

mm

Vl + V2

R=---

volume

mm

or 3 em

or

then

6 em

170

combustion

the

compression ratio

cc

chamber

vol-

The compression ratio sure of the compression ratio, will

use its fuel, up to a with a high horsepower of gas low

er

further

The

burned, more heat more expansion that

means more

fuel used and

efficiency

the

compression ratio

for its size and go

than

an

otherwise

compression ratio.

the

mixture

the

hotter

will

the

be produced.

of

the

horsepower

the

engine

Combustion

of

an

engine

of

the

engine.

more

efficiently

certain

further

identical

is compressed before

combustion

Greater

combustion

for

size.

is one

The

point.

will

put

engine

will

heat

products, and

the

higher

the

engine

An

engine

out

on a

with

be and

means

amount

mea-

the

more

gallon

a

it

is

the

of

WHERE: R

= compression

V =

displacement

V

=

volume

170 + 20

R=---

20

at

TDC -20

-

R = 9.5

This is

However, cylinder of look like these.

V

WHERE:

V r

h = distance

17

V = (3.1416)

V

called the

if

we

at

the

closing

at BDC,

=1Tr

=

displacement

= 112 bore -

top

=

3.1416

the

2

h

from

of

exhaust port -

compression ratio

30

(3)2

= 113.1 cc or about

V1 + V2

R=--

-

113 + 20

R=----

20

R = 6.7

This is

ratio, and is

compressi on ratio.

usually

always

ratio

volume -170

cc

"th

eoretical"

measure

volume

mm

top

(4)

called the

the

of

the

above

or

of

cylinder

40

113

lower

3 cm

cc

compression ratio.

total

volume

exhaust

mm

cc

"actual

than

port instead

calculations

exhaust

to

or

port

4 cm

" compression

the

theoretical

of

the

might

Combustion trodes The spark voltage instant.

will

try

power

ignite

the

6500

revolutions

for

this

so

that

TDC

at

When that

is mixture front"

flame

across speed.

common flame

defines

detonation.

front

burning

Normal

bustions hard, the

an even related

The standard

the to a laboratory

ability two produce adding petroleum makes detonation

metallic, front

mixture

"o

octane,

petroleum

is

of

a spark

plug

electricity

If

the

to

run

stroke

mixture

lead is

peak

cylinder

high

the

spark

between

ignites

travels

moves

the

mixture

combustion

the

combustion

There

and

is

detonation.

travels

resulting

burning

to

the

ctane"

that

set

the

Octane

to

resist

gasoline

tetra-ethyl

distillates

it

burn

.

started

ignition

backward;

will

to

speeds.

the

across

are several

all

hammering

octane

of a gasoline

gasoline's

of

procedure

detonation

by a

plug

in

receives a

to

ignite

comes

be lost. The

at

18°

per

minute

start

the

pressures

plug

fires,

its

mixture

the

across

as

is a

are

almost

in an

of

the

of

laboratory more

resistant

ratings

distillate

to

meet

of

lead

. The

more

spark

across

the

combustion

timed

the

too

before

mixture

it

electrodes.

around

combustion

the

it

goes.

single chamber

types

undesirable.

Detonation

from

instantaneously

explosion

mixture.

the

burning

conditions.

are

which

to

fuels

octane

or

"lead"

slowly,

surge

mixture

too

soon

late and

ignition

top

and

up). The reason

burning

will

occur

ignites

it,

combustion

flame

at

of

abnormal

the

gasoline

is a

speed

the

assigned

compares a fuel's

that

of a mixture

. Oil

requirements

certain

in

the

chamber.

of

at

the

engine

part

of

is

timed

dead

center

in

just

the

mixture

That

front

sounds

Detonation

number

gasoline

thus

burning

and a "flame

chamber.

chamber,

traveling

just

the

The

like a

engine

used.

the

. The

through

rather

which

under

The

high

according

companies

high-octane

gasoline avoiding

elec -

high-

right

the

(at

time

after

The

right

com

most

than

er

is

by

to

-

is

a

to

of

2-8

ENGINE

THEORY

OF

OPERATION

When place. The molecules carbon-diox

the mixture

molecules

of

!he

ide,

water,

burns, a

of

air

to

traces

chemical reaction

fuel

comb ine

produce

carbon-monoxide,

of

other pounds, and heat. Heat is absorbed by and

combustion engine bustion

them th

The shape a chamber more

is wasted,

products increases

to expand. This expansion is what

e actual

power

of

factor

in its

with

res

istant induce mixture tion

resistant;

per

unit

of

Smoot

hly

surfaced designed. having a bustion

top of

squirt chamber

Mixture

squish

chamber roof

the

piston (at

out

roof as with the lowest the

sphere.

be a smoothly

with

a squis h area

allows

a

smooth

chamber, especially

products

but

heat

in

the

engine's combustion

ability

few

projections

to

resist

to detonation. Ch

turbulenc

and

volume

e are more

chamb

detonate less than

combustion

turbulence

area :

that

TDC), causing

from

the

surface

An

ideal

finished,

between

piston

area

combustion

almost

around

scavenging

when

. Heat absorbed by

that

goes

their

pressure,

engine.

detonation. A smooth

and

irregularities

highly

ers

with

less surface area

chambers

can be induced by

is a

part

comes very close

the

piston and

nears TDC. The shape

per

unit

chamber

sphe rical

the

edge. This design

flow

scavenging

lowest.

takes

with

oxygen

various com-

the

engine

the

into

the

com-

forcing

produces

chamber

is is

ambers that

detona-

others

.

are

easily

of

the

com-

to

the

mixture

to

the

of

volume

is

would

chamber,

across

flow

the

is

Another design should so

the

to

travel plug front center, far

. Part

mined bottom piston st

rengthen its center and

As

the

consideration

is

spark

be

placed

flame

to reach

is on

of

has

the

by

one

to

flame

the

combustion

the

of the

is

generally shaped

to

take

rai se

the

piston

the connecting

around cylinder piston's inder during off-set. crankp of

inder the of

its

circle,

and

being

wall

during

compression. The

in

the

in travel

the

piston's

wall.

The

crankpin

does, and

combustion

plug

placement.

near the

front

will

all

po in

edge

of the

travel

all

front only

top

of

the

chamber

center.

up

Some

space

compression

is

forced

rod

downward,

increases.

away

then

back again.

thrust

against one side

combustion,

direction

near

TDC.

sideways

piston

reach es TDC

piston "sla

is

minimized

--~

..

~

.

in

combustion

The

have

ts

center

of the

of

the

the shortest distance

chamber.

chamber,

the

way

across. From

has

to

travel

chamber

pi s

at

in

the

shape

ton.

It beco

TDC. The

in a

gentle

pistons

have a raised

combustion

ratio.

the

The

crankpin

from the

centerline

This

results

and the piston opposite

bore

the This lessens motion

again

slightly

p"

at

1""

.....

. (See F

----

igure

OFFSET

chambe

spark

plug

chamber

If the

the

flame

half

is

deter

mes

top

of arc

chamber

angularity

move

of

in

of

the

other

is s

lightly

direction

the

impa

st

the

before

the

instant

2-5.)

the

as

the

to

of

the the

cyl

side

of ct

cyl-

r

-

s

-

Compression high

compression

to

avoid

use a

lower

ratio

deto

nat ion. A l

octane gasoline.

is

imp

ortant

requires a high

ow

compression

to

combustion

octane

engine

. A

fuel

can

The compression pressure produced by an engine

is a more accurate

detonation than i

pression pressure is bustion risi

Another i

gnition hot, on may

flame

the plug

flame

ignition will

lead

chamber,

ng

piston.

type of

. If

the

or a fleck

the

head of

be

front

of

ignited before

traveling

fires, its

front

with

creates advanced

soon overheat.

to

ser ious

measure

ts

compression

the

before

of

pressure

ignition,

abnormal combustion

combustion

carbon

the

piston

flame

a small,

chamber

on

the

chamber

heats

the

plug fires. This starts a

across

front

the

meets

sharp

timing

Detonation

engine

damage .

and

its resistance

ratio

. Com-

in

the

com-

produced by

is

pre-

becomes

very

surface

up,

the

mixture

chamber. When

the

preignition

sound

. The pre-

, and

the

engine

preignition

to

the

or

can

Figure

2-5

ENGINE

THEORY

OF

OPERATION

2-9

The

piston drical only

when when pand

evenly

through

and for

extra (See Figure expand The

wall greater motion across an elliptical shape. p

ands

cannot

shape the

of

the piston

into a cylindrical

the

engine

as

the

strength;

2-6

more

thickness

to

hand

the

or

the

engine it

head,

.) The

than

le

piston.

be

made

piston

was

hot. A

heats up.

the

skirt

upper

the

skirt, and

near

the

stresses

The

bores and

As

the

shape and

in a perfectly

would

cold, and

Near

piston

is

part

the

piston will expand

piston

fit

piston

the

walls

thin

to

of

must

piston

of

the

must

heats up,

fits

the

cylinder

not

does

ring

grooves

are

save

weight.

the

piston

be

smaller.

bores is

reciprocating

be

made

the

cylinder

cylin-

fit

well

not

ex-

thicker

will

more

with

it

ex-

The last into exhaust port. This forces the gases right piston forces the rest

through

The exhaust system consists exhaust port haust exhaust gases quickly and excessive noise.

.

Engine Crankcase Design

bit

of pressure

the

exhaust system

direction.

the exhaust

manifold, and a

After

through

in

bottom dead center, the rising

of

port

the

cylinder

with

the opening

the

.

of

cylinder

muffler.

easily

is released

to

move in

burned

a passage

head,

It removes

while

of

gases

from

an

reducing

the the

out

the

ex-

the

The

rather

makes

when

Usually across about The diameter. (if available) directions sured taper

it

checking

the

0.1875

other

not

.

important

This

odd

piston skirt

half

at

each

only

Figure

shape

piston

at

in. (5

of

piston

is

measured

four

for

of

to

know

is

measured

900 to

mm)

different

position

size,

PISTON SHAPE

(EXAGGERATED)

2-6

the

piston

where

to

cylinder

with a micrometer

the

piston

up

from

the

bottom

clearance

with a dial-bore

positions,

. The

but

is

cylinder

for

roundness

when

to

measure

clearances

bores,

edge.

the

cylinder

gauge

and

in

is

mea-

cold

two and

Theory, of

the

understood.

The supports use ball bearings

These two of race, and

the

which balls 2-7

The crankcase is designed to

crankshaft. In order crankshaft, the crankcase is

The crankcase

mating

.

match perfectly. A sealing rather Kawasaki

seals

function,

the

engine are important,

lower

crankcase

the

ball beari ngs are very

hardened steel races separated by a caged set

steel balls. The

the

crank turns,

roll on the

from

rubbing

.)

surfaces

than

two-stroke

and cylinder base baskets have to

and design

end

(crankcase)

contains

main

for

crankshaft

crankcase carries

the

outer

against

must

of

a gasket, to

of

the

but

not

functions

the

crankshaft,

bearings.

the

inner

to

be

the

engines

Snowmobile

main

bearings.

strong

is

fitted

the

race rolls on

race. The cage keeps

each other. (See Figure

totally

install

airtight

crankcase halves

and remove

split

and

compound

insure

. The

horizontally.

upper portion

complete

engines

and consist

to

the

outer

race.

the

enclose

oiltight.

is used,

airtightness

crankshaft

be

airtight

until

are

and

of

inner

As

balls

the

the the

The

must

on

oil

.

Exhaust

Th-e

design

major The speed

height

useful

exhaust

BBDC. The The

higher

angle

.

2-10

of

effect

range

of

the

power

port

height the

ENGINE

the

on

the

of

exhaust

range

opens

exhaust

and

of

THEORY

system

characteristics

the

engine

port. Proportionately,

of

the

engine

closes

the

port

port,

OF

and

increases

at

about

determines

the

wider

OPERATION

timing

of

the

decreases. The

the

engine

with

800 to

its

timing.

exhaust

has

the the

90

a

.

0

Figure

2-7

To

achieve wheels pletely the

connecting

space

good

are

designed

as possible.

inside

the

crankcase

rod . There is

crankcase

compression, the

to

fill

the

Between

.

crankcase

the

crankwheels

very

little

crank-

as

com-

wasted

is

CONNECTING ROD

END)

(BIG

CRANKP

IN

crankshaft

The parts

. A caged crankpin the the sideways, and each side

The misaligned pressed perfectly There the Figure

. The

needles

connecting

of

crankshaft

because

together.

aligned

is a

specified

big

end

2-9

.)

@)

RIGHT

WRONG

is pressed

needle

crankpin

roll

on

rod. The

held

the

big end.

can

on

bearing

Figure 2-8

together

bearing

rolls on

the

inside

connecting

by

two

thrust

twist

or

loosen

it

consists

The

crankwheels

the

crankpin.

side and radial

of

the

connecting

from

separate

is used

the

needles,

of

the

large

rod is located

washers,

and

of

separate pieces

must

(See Figure

clearance

rod. (See

on

end

one

become

2-8.)

RIGHTW

WRONG

the

and

of

on

be

for

THRUST

WASHERS

A+B+C+D

= SIDE

E =

RADIAL

Figure

Engine Lubrication

This

snowmobile cated by a variable mixture depending on When gets less oil.

Under

Automatic engine down

from

the

engine

full

throttle,

oiling

only

as

on visible

engine

pump

about

engine

110

speed and

needs less oil, as at an idle,

the

engine

is economical because

much

oil as

exhaust

E

CLEARANCE

2-9

is

automatically

which

to 1 to

it

emissions

may change

about

throttle

will be fed more oil.

it

needs. This also cuts

.

lubri-

the

25

to

opening.

gives

the

1,

it

Figure

2-10

ENGINE

THEORY

OF OPERATION

2-11

Kawasaki intruder ST440-A4 Shop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual