Kawasaki Invader SS340-A2, Invader SS440-A2 Assembly & Preparation Manual

Notice

to

Dealers

SAFETY

I

WaRNING

AWARENESS

I

This manual snowmobile proper and deserves a performance that

any unauthorized to Bulletins Modifications snowmobile

presale preparation.

end.

The

selling dealer

your

is

of

Snow

is

the steps I isted here

specifying which

ready

is

provided

assembled

safe,

reliable snowmobile, and

assumes

modifications

Products Binder

must be performed before the

for

to

ensure

correctly

Your

customer expects

sole responsibility

prior

for

Factory

sale.

and given

is

essential

to

sale.

any Service

that

the

for

Refer

Directed

to

This warning instructions correctly injury,

This instructions

strictly

or

destruction

Whenever you heed operating and maintenance practices.

their

followed,

or

loss

caution

observed,

symbol

or

procedures which,

of

life.

symbol

or

procedures which,

could

of

equipment.

see

the symbols shown above,

instructions! Always

identifies special

could

result

identifies special

result

in

if

not

in

personal

if

not

damage to,

follow

(

safe

c

Table

of

Contents

Dealer's Assembly and Preparation Check List................................................................

Assembly............................................. .............................................................................. 1

Uncrate .

Skis ............................................................................................................................. 1

Suspens

Windshield......................................................................................... .......................... 2

Handlebar...............................

Tool Kit/Owner Manual ................................................... ........................................... 3

Safety Labels................................................ .............................................................

Preparation.....

Suspension

Ski Spring Preload .................................................

Steering Alignment...............................

Chaincase . ........................ .... ............... .................... .

Brake.....................

Wiring Harn ess............................................................. .....................

Enrichener

Engine Coolant....... .

Drive and Driven Converter Alignment.... ....

Oil Bleeding

Engine Gearcase .......................................................................................................... 13

Fuel. ............................................. ......... ...................................................................... 14

Fuel/Oil Mixture (Ratio) .................................. ........................................................... 14

Engine

Synchronization Purging Air From

Ignition Timing Check ................................................................................................ 16

Headlight

Tail/Brake Light Track

Test

Ride (Operational Checks)................................................ ............

Specifications ...................................................................................................................... 22

Engine .........

Carburetor

Fuel. ....................... ...................... ........................... .................................... ................ 22

Drive

Electrical System .........................................................................................................

Torque Wiring Diagram

..

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

Installation ........................ ...................... ................................................ .............. 1

ion..

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

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

..

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

Ride Adjustment.........

Handling Adjus Front

Suspension Swing Arm ..................... .............. .................................... ......... 4

Cable

Filling Cooling System

to

CenterJackshaft

Converter Offset Distance ..................................................................................... 10

Parallelism

Tank ...................................................................................................................... 12

Adjustments

Track Tension ....................................................................................................... 19

Track Alignment .............................................

System ......... .......................................... ............................................................ 22

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

-Center Distance ..................................................................................... 9

Bearing Retainer Shimming ................................................................... 10

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

Oil Injection System ..................................................................................... 12

Break-I n ........................................................................................................... 14

Adjustment

.. .........

Settings ...................................... ....... ........................................................ 22

..

............................................................... ........................................ .... ..... 24

................................................................................................ 1

..

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

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

..

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

tment ........................ .................................................................... 3

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

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

Adjustment... ..

..

.................................................................................................. 8

of

Oil

Pump and Carburetors ............................................................ 15

Oil

Pump

................................................................................................. 18

Test

.................................................................................................. 18

................................... ......................................... .......................... 19

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

.. ..

................ ................................................................. 6

................................................................................. 7

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

Outlet

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

Tubes

.. .....

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

...................................................... 4

.. ..

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

.. ..

................................................ 8

....

........................ .................................... 8

................................................................... 16

.. ..

.................................................. 19

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

......... ....................................................... 22

.. ..

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

.. ..

............... 6

..

................ ......... 7

.. ......

..

3 3

..

5

11

20

22

.... 23

ii

INVADER

TABLE

OF CONTENTS

Dealer's

Assembly

and Preparation

Check

List

Remove the Assembly & Preparation Check List

following each check list

the procedures

item

as

it

for

1 D REMOVE 2 D SKIS - install - torque all bolts. 3 D SKI SHOCKS 4 D SUSPENSION 5 0 6 D

1 D STEE RING - align skis -components secure. 2 D 3 D 4 D 5 D

'6 D WI '7 0 CIRCUIT

8 D SUSPENSION - adjust. 9 D NUTS. BOLTS.

'10

11 0 FUEL 12 D

'13 D OIL

14 0 THROTTLE '15 '16 '17 DOlL

1 D

2 D ENGINE STOP SWITCH - check operation. 3 D 4 D

5 0

6 D CLUTCHES - smooth operation -correct RPM.

7 D

outlined

is

completed.

your

records.

I hereby cert bile listed below in accordance with the following check list, and in compliance

saki:

WINDSHIELD -mount HANDLEBARS

CLUTCH CLUTCH CHAIN BRAKE

D ENGINE GEAR

ENRICHENER

D CARB D FAN

CONTROL

SUSPENSION -check slider ride adjustment. STEE RING - action

ENGINE

BRAKES

KAWASAKI

ify

that

prior

(Iia"

check

each

item when completedl.

CRATE

mount

engage

- adjust

ALIGNMENT CENTER TO CENTER - check adjust.

CASE - add lube

- clean disc -adjust.

RING HARNESS - electrical connectors secure.

BOARD

OTHER

recommended oil

/IMPULSE

PUMP - check/adjust.

BELT

TANK -fill

check

binding

promptly. smoke present

LUBRICATION

LINES

CONTROL

CABLE

SYNCHRONIZE

- check/adjust (axial fan modelsl . w/recommend

for leaks.

CABLES -

in

any steering position · returns freely .

· recoil starter works properly. engine starts

good

throttle

but

· adequate -smooth stopping power.

in

this

manual.

Be

sure

to

sign all sections

SNOWMOBILE

to

delivery to the first retail purchaser assembly and preparation servicing was performed

- check

for

damaged & missing parts.

to

spindle - torque bolts.

springs.

to

hood.

to

proper position - torque bolts.

- check/adjust.

if

required - check

- electrical connectors

FASTENERS - check -tighten.

as

required.

- check/adjust.

throttle,

is

free

not

- check l

- secure and no kinks.

- check/adjust.

- check/adjust

ed

brand injection

brak e -works

lock

to

lock - no

response and return. Exhaust

excessive (oil inje

DEALER'S

PREPARATION CHECK LIST

for

leaks.

secure.

evel-add

(twin

carb mod

oil

-

without

looseness_

ction

models).

from

Verify

storage

compliance

of

the

case.

form

Complete

by

placing a check (I) in

as

they

ASSEMBLY & PREPARATION CHECK

with

the established procedures prescribed by Kawa-

SAFETY

DECALS - properly installed.

TOOL

KIT

- complete - installed.

BY:

LINE

TO

COOLANT

TANK -fill

SB

models

TIMING

Taillight

UNUSUAL COOLANT FUEL

OR

LEVEL

BY:

PUMP - (all

SYSTEM - check operation -

OIL

secure

SA &

CARBURETOR CARBURETOR

IGNITION

ELECTRICAL

o Headlight D Brake

o

TRACK -adjust

ION BY:

SPEEDOMETER(fACHOMETER

els

l.

TEST

7 D

8 D

ASSEMBLY

'18 D OIL

'19

0 ENGINE

20

D SPARK PLUGS - check/gap.

21

D GAS

22 D 23 D

, 24 0 PRIMER - check operation.

25 0 26 D

27

0

PREPARAT

RIDE

8 D g

0 NO

'10

D NO

11

D NO

'12

D COOLANT

13 D CONTROLS - properly positioned.

TEST

RIDDEN

are

completed.

oil

- check level.

(pre-mix 40

onlyl

- check

AIR

SCREW - adjust.

IDLE

SPEED -adjust.

- check/adjust.

tension -align.

NOISES. LEAKS.

LEAKS.

- check - add

each

item

LIST

on

the s

injection modelsl

to 1 BIA

approved

for

leaks.

Light

D Instrument &

Lights

Signature

- check operation.

50/50

mix

Signature

of

box

Retain

nowmo

bleed-

oil

adj

ust

Indicator

as

required.

the

check

preceeding

completed

-

list

ii

o OWNER'S

D OWNER'S

3 0

WARRANTY

Dealer Name

Address

___________

• Applicable models only · refer to assembly instruction provid

49007

DEALER'S

ASSEMBLY & PREPARATION

MANUAL

nance - install.

SAFETY

install.

oughly - install.

-35

If

CERTI

____________________

01

it

is

desired

to

utilize

· explain contents /proper mainte-

HANDBOOK

FICATE

_

the French

- explain

contents-

- explain warranty

white copy· dealer

portion

of

CHECK

CUSTOMER

thor

-

,DEALER

this check list,

DELIVERY

DELIVERED

VERIFICATION

_

Signature

ed

by Kawasaki for specific models.

file/canary

please

remove the carbon

LIST

4 D CONTROLS - explain location/operation - properly

of

copy· owner

positioned

BY:

Dealership Manager

for

customer.

Date

sheet

and

insert in proper location_

Signature

Printed

in

U .

S.A.

INVADER

Assembl y

Skis

Uncrate

Observe this

Bend over prevent personal injury or possible vehicle damage.

Using a from from the the seat. assembly and sp and discard during

pry the the

base

of

snowmobile

[:~!~~~

all

exposed

bar, separate crate. C snowmobile

Next,

arefully

the

crate. Remove the

unscrew the nuts securing the ski

indle

the

hardware

assembly.

€]

the

remove plastic covering

by

cutting

to the

as

during

crate fasteners to

top

and side panels

the plastic along

windshield

bottom

it

will

(See

Figur

the crate

not

e 1.)

step

be

from

used

Installation

Place the provide a protected finish following:

1.

I nstall spray installation (See

snowmobile

of

the

or

soapy

Figure

snowmobile.

ski

of

2.)

on its side.

surface

attitude

water

the ski saddle over the damper.

to

prevent

Then

damper.

on

the

Be

marring

perform

Apply

damper

sure

the the

Silicone

to

ease

to

1.

Ski

Assembly

2.

Ski S

Observe this

To

prevent personal injury, use lifting

equipment

WARNING

with approved

when raising the snowmobile.

With

assistance,

the

snowmobile inspect the missing parts.

Open case hardware.

INVADER

hood

containing

or

the

use

from

snowmobile

and remove plastic

the

ski and

pindle

I during

of

a hOist,

the

crate. T

for shipp ing damage and

windshield

safety

carefully

bag

from

hooks

horoughly

storage

mounting

lift

1. Ski

2.

3.

2.

Fill

the

grease groove

sp

indle

sleeve pressure (ep) grease, and insert sleeve spindle.

(See

Attitude

Gr

ease

Groove

Ski Saddle

with a low

Figure 2.)

Damper

or

cut temperature

away

area

of

extreme

into

ASSEMBLY 1

the

3.

Secure the ski assembly hardware supplied. flat

washer are installed on the inboard side

the ski assembly, then

ft.

Ibs.

(6.2 -

6.5

1.

Be

kg-m).

Flat

Washer

to

the spindle

sure the torque

(See

Figure 3.)

nut

the

with

and large

nut

45 -47

the

of

Handlebar

Prior

to

securing the handlebars, check the lower handlebar holder Apply handlebar holder

35

ft.

Ibs.

1.

Lower Handlebar

2.

Console

for

security

(5 kg-m)

mounting

to

the steering pole.

torque

bolt.

(See

Holder

to

the lower

Figure 5.)

Suspension

The snowmobile springs adjusted provide characteristics no adjustments

satisfactory

is

shipped

during

for

average driver weight.

are

required.

with

production

ride

the suspension

assembly

and

handling

Normally,

to

Windshield

Remove the plastic covering and install the

windshield

Figure 4.)

with

the o-ring fasteners provided.

(See

Check for the console at the handlebar holder, and have

adequate free movement rubbing during vehicle operation.

the

routing

proper positioning. They should

Observe this

Adjust

the handlebar so

windshield,

of

the cables and

to

prevent binding

[:~~~!!~~]

it

during

does

when turning in either

(See

not

wire

harnesses

pass

through

Figure 5.)

or

step the

direction.

Adjust position and evenly securing the handlebar holder, kg-ml.

the handlebar

(See

Figure 6.)

for a comfortable

torque

the

four

to

105 in.

driving

socket screws

Ibs.

(1.2

2 ASSEMBLY

INVADER

Tool

Kit/Owner

Manual

Preparation

Check the storage Tool

Kit,

Owner's Manual and Safety Handbook.

Safety

Insure located

Labels

that

all

and

secure.

box

to

be

sure

WARNING

safety labels are

(See

I

Figure 7.)

it

contains the

properly

Suspension

Ride Adjustment

Ride

Adjustment position cam, using the special

Rotating the cam towards the heavy pre-load position stiffer pre-load resulting in a Figure 8.)

of

will

ride. I f

position,

may

be

varied

the shock absorber spring adjusting

tool

provided in the

increase spring pre-load, resulting in a

the

cam

is

rotated towards the

this

will

decrease spring pre-load,

softer

ride

for

by

changing the

tool

the operator.

kit.

light

(See

1. Spring

2.

Cam

3.

Heavy Pre· load Position

4.

Light

NOTE:

spring capacity

Handling Adjustment

The handling adjustment spring tension

I ncreasing spring tension

press pressure. Reducing the spring tension, front ground and the ski pressure in ski pressure response.

An

optional

kit

is

available

of

the snowmobile.

harder on the ground, resulting in

of

the suspension

Cam

Adjusting

Pre-load Position

heavy-duty shock absorber

to

increase the load carrying

is

controlled

of

the

front

causes

to

have

will

affect

Tool

suspension springs.

the suspension

less

pressure on the

to

increase. A change

the vehicle's steering

by

changing

causes

less

to

ski

the

INVADER

PREPARATION 3

Front

Suspension

Swing

Arm

The tension (pre-load)

on

each

side

of

the

equal. Excessive tension cause spring breakage one side Figure

The

spring arm on each side should desired steering response and terrain

To

1. I nsta

be

and snow

change spri

57001shown.

of

the slide wear strips.

9.)

positioned

conditions

ng

tension:

II

spring adjusting

3507

onto

(See

Figure 9.)

of

suspension

of

or

as

required,

in

the

end

the

front sprin

arm

must be

one spring can

excessive wear

of

the

susp

to

achieve the

effort

your

of

for

area.

tool, the

spring arm

Part No.

gs

to

(See

ension

existing

as

Changing the

arm

will affect the amount

the ride characteristics factory positioned suspension bracket. This since characteristics

it

mounting pos

assembly,

in the

results in

of

1.

Front

of

the

upper

the

the snowmobile. (

Suspension

ition

of

ski

the

snowmobile.

front

swing arm was

hole

position

best overall

Bracket

the

front

lift

along with

of

the

was

See

Figure 10.)

swing

During

front

selected

ridin

g

1.

Spring

2.

Spring

3.

Spring Retainer

Observe this

Front spring techniques

2.

Apply a firm with

arm

prepared transferred spring arm

3.

Install the spring arm

necessary desired.

suspension springs are

load

may

both

hands and

out

of

the

for

to is

to

obtain

Adjusting Arm

WARNING'

and

result

grip

on the spring adjusting

detent the heavy spring load the spring adjusting tool 2S the

lifted

out

the

Tool

during

improper

in

personal

carefully

in the spring retainer.

of

the retainer detent.

into

the

handling

under

heavy

adjusting

injury.

lift

the spring

retainer

characteristics

detent

to

tool

Be be

If

swing arm mounting sensitive resulting

Front

load. Remove

location

hole, the

to

weight

in

slightly

snowmobile

transfer

more

WARNING'

suspension arm

spr

ing tension

is

changed

ski

lift.

is

under

to

becomes

during

acceleration,

heavy spring

from

the suspension springs before relocating the front

possible personal

swing arm assembly

injury.

to

prevent

Ski Spring Preload

Three ski spring

Center Hole Position the end snowmobiling. (See

positions

mounting

bolt

was installed in

normally

have been

bolt:

no

change

Figure 11.)

provided

During the

center

is

required

for

factory

hole in

the

lower

more

front

the

front

ass·embly,

the

for

general

ski

4

PREPARATION

INVADER

1.

Spring

Mounting

Positions

Rear Hole Position rear hole increase

with

recommended

speed

ront

F hole

the s

spring travel. maximum

NOTE: into

To

change

weight

follows

as

1.

Remove

2.

Open stand on from

of

the

spring arch, and result in a

greater spring travel.

for

trail

riding.

Hole Position -Placing

of

the

ski

will

pring

arch, and result in a

Th

is

stability

the

of

Always same

:

hood

mounting

mount

position

the

preload

snowmobile

nut

from

and

front

Installation

ski

will

deep snow

increase spring preload, reduce

position

during

bumper

bolt

high speed

the

on each ski.

of

the ski

is

on the skis, and proceed

front

with

assi

.

of

the

bolt

in

reduce spring preload,

softer

This

operation

the

stiffer

shou Id

front

spring

stance

to

relieve spring tension

bolt

ride

be

operation

ski spring

spring,

mounting

from

position

or slow

in

the

front

with

used

be

sure the

another,

bolt.

the

ride

is

less

for

.

bolt

1.

Straight

2.

Measure Distance Here

2. When the outside edge handlebar

3.

If

the handlebar requires centering, loosen lock adjusting stud in the center

NOTE: parallel rod length adjusting stud.

center

for

(jam) nuts and

the

handlebar. (S

Be

sure

to

the

straight

Edge Against

line

of

the

centering.

the

center line

of

track,

turn

ee

edge

the

ski

is

check t

the t ie

direction

Figure 13

of

the ski remain s

while

Track

parallel

he

rod

necessary

.)

turning

to

the

steering

the

length

to

the

tie

3.

With

weight slide spring position

4.

Inst

all

Steering

Check

1.

INVADER

the ski

Place a long board against

re

measu center the

distance measured between the ski center line and edge and rear

still

on

rub

strip

of

ski, and insert bolt

nut

and

torque

Alignment

alignment

the

right

hand edge

the

distance between

line

of

the

of

board

of

the ski. (S

front

bumper, remove

to

align

25 in. lb. (0

and handlebar cente rin

(or

suitable st

ski. Position the ski

is

the

ee

Figure 12.)

with

desired hole

.

.29

kg-m).

raight

of

the track, and the

board and

same at

the

edge)

so

front

bolt,

g.

that

1.

2.

3.

Tie

Rod Locknuts 1-1

/4 Inch (32

Length

Adjusting

mm)

Maximum

PR

EPARATION

Stud

5

WARNING

The dimension

not

exceed 1-1/4 inches (32

adjusting between the possible steering linkage failure.

stud

shown

must

two

I

in

Figure

mm)

remain centered

lock

nuts,

13

to

must

and

the

prevent

5.

Tighten

the steering system. nut (1.1 - 1.4 kg-m). Refer for fasteners in

all

the

s on

tie

rod

recommended

the

Chaincase

hardware (nuts, bolts, etc.) in

Torque

assemblies

torque

steering system.

the

100 -120

to

the values

lock

torque

of

(jam)

in. Ib

chart other

s.

4.

To

align

the

towards the center

remove

lock equal distance when measu red at the skis.

the

nuts and

(See

Figure 14.)

steering linkage

other

turn from

ski,

move

of

the

tie

ski center

front

both

snowmobile

play

. Loosen

rod

to

obtain

to

ski center

and rear

ski

of

tips

to

the

an

the

NOTE:

F

luid

Check the chaincase between

If plug in the chaincase and Automatic until proper Figure 15.)

Use

when

the

additional

correct

lubrication

DEXRON

filling

center and

fluid

Transmission F

level

II

the

chaincase.

fluid

the

is required, remove

is

attained

for

the

Automatic

level.

luid

chain and bearings. (

Fluid

top

of

the

pour DEXR

into

. T his

Transmission

level must"be

sight gauge.

the

upper

ON II

the chaincase

provide

s the

See

1.

Equal Distance

2.

Tie

Rod

3. Exposed Threads

WARNING

After

proper number end.

If ends are steering linkage failure

Figure 14.)

PREPARATION

6

alignment

of

exposed threads

the

left

not

adjusted equal/y, possible

hand

Front

And

I

is

obtained, check

at

and

right

may

Rear

i./ie

each

rod

hand

rod

occur. (See

Brake

Check

forth

and

s.

Next,

pad

less

than

applied .

to

be

with

3/4

(See

1.

2.

sure

check

Upper Fluid

just

inch (19

Figure 16.)

Fill

Level S

the

brake disc can

a very

that

the brake lever

mm)

Plug

ight

Gauge

be

slight

drag on the brake

movement

when brakes are

moved back

is

fully

IN

VADER

(

NOT

E: Do The cam (arm) off

position. Improper

incorrect

T

he

brake disc and movement maintain This

movement

vehicle

not

brake

from

proper

operation

disturb must

function

hub

left

alignment

may result in a

and

Wiring Harness

brake cable adjusting nuts.

be

centered on the pins in

adjustment

and

premature

assembly

to

right) on

between the brake pads.

is

a normal

will

must

jackshaft

rattle

heard

condition

result in

wear.

float

.

the

(free

to

during

Observe this

DO

NOT because personal

If

the

brake lever

(19

mm),

adjust

to

nut

move

adjusting brake disc back and begin

WARNING

OVERTIGHTEN

damage

injury

the

while

with

to

could

result.

movement

brake

by

simultaneously

forth

until

the

disc.

I

during

components,

exceeds

tightening

the brake pads

(See

moving

Figure 17.)

3/4

the

step

or

inches

brake

the

just

Check the connectors on sure

they

are

properly

located and secure.

Enrichener Cable

With

the Enri chener lever

slid up the casing,

1/16

in ch (1.5

shown .

(See

the

mm)

free

Figure 18.)

enrichener cable should have

the

wiring

harness

Adjustment

down,

movement

and plastic

when raised

to

boot

be

as

1. Brake

2.

Brake Disc

3.

Brake

4. Brake Cable

INVAD

ER

Adjust

Pads

ing

Nut

Adjusting

Nuts

1.

Plastic

2.

1/16

3.

Locknut

4.

Adjusting

Boot

inch (1.5

Screw

mm)

PREPARATION

7

If

adjustment

turn

the movement. reposition foreign

system.

matter

is

required, loosen

adjusting screw

After

boot

over enrichener

from

adjustment

entering

to

the

obtain

fitting

the

lock

the

or

checking,

to

enrichener

nut

and

correct

prevent

NOTE: Ca (1.5

Engine

Coolant and antifreeze and 45% system. against freezing (-45°C). A Prestone coolant mm)

Engine

ble free

mm)

flooding

movement

may

is

occur

less

Coolant

Observe this

Approximately coolant the reservoir tank. To be sure the level

is

1/2 in. (6 -

Supply -Use

water

This

level

of

the

[:~~~!!~~::J

1/8

in.

will

always appear on the

adequate, always

12

mm)

a 55/

(55%

recommended

major

II

or

must

tank

ETHLENE

water),

down

brand

Dowgard)

be

top

when cool.

fill

of

the tank top.

45

mixture

when

mixture

to

approximately

of

is

within

if

the

Enrichener

than

during

(3.18

to

filling

antifreeze (such recommended . T

1/4 - 1/2 in. (6 - 12

1/16 inch

floor

coolant

within

of

antifreeze

GLYCOL

the

will

step

of of

1/4 -

base cooling protect

-50°F as

he

1.

2.

Observe this

DO

NOT

WA

TER. 100% antifreeze

a

55

/45

2.

Slowly

reservoir capacity

3. When thermostat continue

mm)

12 Reinstall pressure cap.

NOTE: engine, properly

Recheck

to

USE 100%

mixture

fill

tank

is

approximately

coolant

housing, reinstall

filling

down

insure

cool engine.

Vent

Plug

Pressu

re

Cap

[:~~~]before

ANTIFREEZE

will

of

antifreeze

the

cooling

appears

until

from

the

coolant

opening.

system

one gallon.

at

level

is

neck in reservoir tank.

level

level remains adequate

OR

freeze before

and

water.

through

Cooling

vent

opening in

vent

plug, and

1/4 - 1/2 inch (6 -

after

running

the

system

the

to

Filling Cooling

Observe this I

Use

care removing the pressure cap when the engine result. Remove pressure cap only

120°F

1.

Remove vent plug housing and pressure cap (See

Figure 19.)

8

PREPARATION

System

WARNING

is

hot

when engine temperature

(50°C).

I

during

or

severe burns

from

top

from

could

reservoir

is

below

of

thermostat

reservoir tank.

Drive

and

Alignment

Correct

12.0 inches distance obta

is

correctly

converter

0.525 -0.588

ined when

sheaves.

Driven

(304

.8

alignment

in stalled between

Converter

center-to -center distance

mm)

and

inch

(13.3 -14

gauge PIN

converter

.9

57001-3503

drive

and driven

of

offset

mm)

INVADER

is

Center-To-Center Distance

I f adjustment of the converter center distan r

equired:

ce

is

NOTE: ali gnment alignment. Check the flatness gauge with

Improper

gauge

a strai

will resu ght

handling or misuse

lt in inaccurate converter

of

the alignment

edge

pri

or

to

each use.

1. Remove the converter guard and dri

NOTE: Dri runni

ng

2.

Rotate the driven converter movable clockwise, between the the stationary movab le keep the stationary and

ve belt will

tests on the engine

not

are

be

reinstalled

comp

leted.

and insert the alignment

sheaves

with

sheave.

the deep notch facing

Carefully rel

sheave, allowing the spring tension

gauge

in position between the

movable

sheaves. (See

20).

ve

of

belt.

sheave

ease

Figure

the

unti

gaug

the

e

to

1.

Loo s

en

the jackshaft bearing retainer

bolts and the adjusting

bolt

loc

knut.

mounting

(See

Figure 21.)

l

1. Bearing Retainer

2. Adjusting

3. Adjusting

4.

Bearing Retainer Shims

5.

Parallel

Bolt Bolt

Mounting

Locknut

Bolts

1.

3.

Center distance ali gnment

converter.

Al

ignment Gauge PIN 57001-3503

is

correct if the notch in the

gauge

(See

fits

ove

r the shaft

Figure 20.)

on

the dri

ve

2.

Loo

sen the

four

chaincase

mounting

bolts and three bolts securing the radiator brace bracket a

sse

mbly

Figure 22

to

the

chassis

.)

1.

Chaincase

2.

Radiator Brace Bracket

Mounting

and chaincase.

Bolts

Bolt

(See

I

NVADER

PREPARATION

9

3. Move the

4.

chainc

To turn contacts and

obtain

insure

the

tighten

ase

12.0

adjusting

the

jackshaft

forward

inches

correct

jackshaft

the

locknut

bearing retainer and

or

rearward,

(304

.8

center distance is

bolt

so

bearing retainer flange,

. (See Figure 21. )

as

mm)

center distance.

the head

required,

maintained,

of

the

to

bolt

3.

Position the

top

the

surface

Observe this

The bearing retainer

until

the

jackshaft

(168.15

mm)

centerline.

bottom

[:~~~!!~~:]

of

the

retainer parallel

of

the chassis.

should

centerline

(See

during

be

is

6.

Figure 21.)

62

above the track drive

to

step

inches

shaft

To

prevent

failure, reshim

changing

5. Tight

en all

radiat

or procedures listed Retainer S

premature

center

bolts

brace

himming

jackshaft

th

e bearing retainer

distance.

and nuts

bracket

.

for

assembly, then

under

Jackshaft Bearing

the

Jackshaft Bearing Retainer Shimming

After

adjusting center-

jackshaft

1.

Remove the lower

converter

bearing retainer

pan and un screw the

to

the

to-center

left

side

jackshaft.

as

follows:

aluminum

(See

distance, shim

bolt

securing driven

Figu

bearing

after

chaincase and

perform

the

trim

from

re

23.)

4. Install the space between the top excessive preloading

Tighten

5. bearing retainer.

6.

Pos jackshaft and check Converter

iti

of

on

"U"

shaped shims,

cha

ssis.

all

bolts

the

This

of

and nuts on the

driven

Converter Offset Distance

After for

Correct surface gauge touches drive converter.

checking center-

proper

converter offset.

offset

of

the

the base

distance

shallow

(See

Figure 24.)

to-center

of

as

required,

bottom

the

converter

is

notch

the

of

retainer and

procedure prevents

jackshaft

Offset

distance, inspect

obtained

on

the

fixed

sheave

to

fill

bearings.

jackshaft

onto

when the

alignment

the

Distance.

of

the

1. Aluminum

2.

Retaining

2.

Remove (

See

10

PREPARAT

the

shims

Figure 21.)

ION

Bolt

below

Trim

the

bearing retainer.

@D@

24

INVADER

If

adjustment

1.

Remove the

to

the

left

offset

side alum inum

lower pan, and unscrew the

driven converter

to

the jackshaft.

23.)

2.

SI

ide the driven converter

or

add bore

converter offset.

remove shims,

of

driven converter

(See

Figure 25.)

distance

from

as

required,

to

is

required:

trim

from

bolt

securing

(See

Figure

jackshaft and

from

the

obtain correct

Parallelism

1.

After

check ing the center-to-center and distance, parallelism must measuring dimensions A and B

be

checked by

as

shown.

Figure 26.) Compare dimensions A and B

1 and

against Notes

II.

offset

(See

1. Driven Converter

2.

Shims

AVAILABLE

PI N

92025-3501 .032 92025-3502 92025-3503

3.

Reinstall driven converter and

bolt

40

- 50

ft.

Ibs. (5.5 - 6.9 kg-m) .

4.

Position and secure

aluminum

with

screws and nuts.

SHIMS

THICKNESS

INCH

(0.8 mm) .063 INCH (1.6 mm) .100

INCH (2.5 mm)

torque

trim

onto

the lower pan

special washers are installed under the head each

screw

pattern on the

5.

I nspect drive and driven converters

to

prevent damaging the decal

aluminum

trim.

parallelism.

mounting

Be

sure the

for

correct

of

1.

Alignment

NOTE

I: Dimension A

than dimension

NOTE

dimension B

2.

II:

If

dimension A

Dimension A must never exceed

by

Gauge PI N 57001 -35

must

be

equal

B.

more than 0.02 inch (0.5

is

less

than dimension

to

mm).

parallelism between the drive and driven

is

not

converters adjusted

as

follows:

correct. Parallelism must

03

or

more

B,

be

INVADER

PREPARATION

11

a.

Loosen engine engine.

b.

Move the toward necessary.

install of engine brackets on the chassis.

the shims

the

mount mount

the

large

mounts

right

the

front

After

bolt

in each

on the

side the converters

as

to

fill

and the slotted engine

right

of

the engine either

or rear, whichever required on either side

the

space

(See

of

side

are

between the

Figure 27.)

the

two

of

the

parallel,

mount

is

The

use

of

lubricants such

and

"super

The

DIRT

capacity

Check the oil tank vent tube

1.

Proper vent tube pump.

2.

Tie Band Installation off

installed

3.

Vent action position end tank and away and pads).

oils"

are

oil

tank

has

TO

ENTER

is 2-1/2 quart

Routing

will

tube, reducing oil

too

tight

Tube

Position -

possible

of

vent tube higher than

NOT

RECOMMENDED.

no

filter.

WHILE

s (2.37 liters).

- Sharp bends reduce

flow

.

To

under certain conditior)s

from

brake components (disc

as

"tune

-up

DO

NOT

FILLING.

for:

or

oil

flow

Tie

band may pinch

to

the

prevent siphoning

ALLOW

Oil

kinks

to

oil

pump,

top

tonics"

tank

in the

the

oil

of

oil

if

1.

Engine

2.

Shims

3. Engine

c.

Securely tighten the large bolts in the engine (See

Oil

Tank

We

recommend using Kawasaki

This

oil piston ring varnish and deposits

n

an

I Snowmobile TC

-W

oil

will

indicate the TC-W rating on the container.

the

B.I.A.

container,

mounts

Figure 27.)

is

specially

along

with

emergency

Oil

may

be

certification

the

oil

Mounting Mount

after

formulated

excellent

situation

is

not

available, a

substituted.

must

not

Bracket

Bolt

parallelism is obtained.

Snowmobile Oil.

to

give

combustion

lubrication

when Kawasaki

B.I.A.

All

does

not

appear on the

be

used.

minimum

chamber

qualities.

cert

certified

two

ified

oils

If

Observe this

Failure to bleed

line can cause severe

Bleeding Oil Injection

After the air

2.

3.

filling

from

1.

Remove the screws needed and remove the air silencer assembly.

Loosen

hand carburetor

Remove the bleed screw

oil

pump

air

bubbles Visually check the entire length to

be removed; then Figure 28.)

[:~~~!!~~:]

out

air

during

trapped

the oil

enginf! damage.

System

the

oil

tank

for

the

first

time, bleed

oil

pump

to

provide the

the

clamp screw and separate the

and

are

sure

inlet

tube

as

follows:

instrument

from

its r

allow

oil

removed

that

all

reinstall bleed screw. (

panel

additional

ubber

from

to

drain

from

of

the air

holder.

the side

the

mounting

clearance

until

inlet

of

has

step

left

of

the

all the

tube.

the tube

been

See

PREPARATION

12

INVA

DER

(

1.

Oil Pump

2.

Bleed Screw

Inlet

Tube

To

fill

or

add

lubricant

fill

plug (located on

Shell

XL

100

10W30 non-foaming engine

the

filler level. Gearcase capacity (40 cc).

opening

(See

to

Figure 30.)

top

raise

to

the gearcase, remove

of

gearcase) and

is

approx

lubricant

to

imately

pour

oil

into

proper

1.35 oz.

NOTE: performing assembly should from completed .

Engine

Components inside the gearcase drive the oil injection

Lubricant above the center higher than the

Reinstall

Engine Gearcase servicing.

Oil Pump

the

not

left

be

installed

Outlet

Gearcase

pump

level

and

coolant

is

correct of

top. (See

the sight

Figure 29.)

hand carburetor

Air

silencer

until

Purging

Tubes procedure

pump.

when the

gauge,

oil

appears

but

after

Air

not

is

NOTE: the previous procedure.

After

carburetor

so and tighten

NOTE: installed

Tubes procedure

Engine initial end foreign drain the gearcase, remove drain plug.

29.)

The

carburetor

filling

that

float

The air silencer assembly should

until

gearcase

100

of

each

matter

the

eng

into

rubber holder. Position

bowl

does

clamp screw.

Purging

miles

season,

present in the

Air

is

completed.

oil should

of

engine operation, and at the

to

has

been removed

ine gearcase, reinstall

not

contact

from

Oil Pump

be

drained

remove any

gearcase

impurities

during

carburetor

front

frame

not

Outlet

after

cavity.

(See

Figure

be

the

or

To

1.

Breather Hole

2.

Oil Level Sight Gauge

3.

Drain Plug

INVADER

Observe this

~~0!?~J

during

gearcase breather hole

may

cause excessive

oil consumption resulting in extensive

engine damage. (See Figure 29.)

PREPARATION

step

13

To

insure proper operation

between the engine for

accumulated obstructions in the

breather hole, located above gauge.

gearcase

Fuel

Use

regular

minimum

89.

Gasoline fumes are heavier than can

pilot

heater, clothes dryer, etc. tank

and

or

premium

PUMP POST

I

waR

.. I ..

become explosive

light

only

free

in

from

an

area

pilot

a furnace,

lights and sparks.

leaded gasoline

OCTANE

G I

that

of

the

oil

seal

and crankcase, check

gearcase

the

gearcase

NUMBER

if

exposed

hot

Fill

the fuel

is

well ventilated

air

sight

with

and

to

a

water

OF

a

Fuel/Oil

The

fuel-to-oil

controlled The

oil

pump

the

fuel/oil increasing 25

to 1 at

Mixture

ratio required

at

the

engine

is

a variable

ratio

with

throttle

maximum

(Ratio)

oil

pump.

ratio

is

approximately

position

power.

is

automatically

pump;

to

approximately

at

110

31

idle,

to

1

Before removing remove any ice, snow, fuel tank opening fresh fuel

Fill the fuel the

gasoline, antifreeze system components

pump may

A

major

Heet) should

following the container with

mixture

tank

using a funnel

Each fuel system. Moisture

time

or

result in severe damage.

brand

the manufacturer's recommendations on

antifreeze.

filler

to

.

tank

slowly

the fuel tank

carburetor)

of

Gasoline

be

added

for

proper

(See

Figure 31.)

cap

from

or

water

prevent

and

pour

with a fine

must

be added

contained

(fuel

tank, lines, fuel

could

Antifreeze

to

the fuel tank

mix

the fuel tank,

from

around the

contamination

the fuel

mesh

screen.

is

filled

freeze

ratio

with

to

the

in fuel

and

(such

of

gasoline

of

into

as

by

Each time

adequate

oil

tank

be maintained

damage.

gas

oil

level in the

assures

to

Engine Break-In

To

insure adequate components during gasoline-tothree (3) gallons obtained of

Kawasaki gallons (11.4 liters) gasoline and

the

initial

have been consumed.

oil

by

thoroughly

oil

three gallons

lubrication

ratio

is

of

Snowmobile

will

tank

is

filled-check

oil

proper

ear

gasoline. This

no longer

fuel/oil

prevent

ly

recommended

mixing 1 pint

of

serious engine

of

break -in, a 25-to-1

Oil

gasoline.

be

gasoline and

for

tank. A

internal engine

with

required

full

ratio

will

for

the

ratio

can

(0.47 liter)

three (3)

Pre-mixing

oil

after

first

be

mix

14

PREPARATION

INVADER

(

For

proper hard packed snow at throttle,

Limit minutes, then 15

minute

or

two

complete.

engine break-in, run the machine on

with

occasional bursts

the

full

speed

return

intervals.

tanks

of

gasoline are used, break-in

approximately

operation

to

cruising speed

After

10 hours

to

3/8

full

1-1/2

for

of

operation

to

112

speed.

to

10

to

is

2

2.

Push contacts the stop pump

33.)

the

is

at the dead idle

oil

pump

lever

pin;

forward

this

insures the

position.

(See

until

Figure

it

oil

Synchronization

of

and Carburetors

Synchronization extremely lubrication

Remove the

and

the

air silencer assembly. Remove the drive

belt

and

perform

1.

Loosen the idle stop screws throttle bores.

(See

of

the

oil

important

and peak performance.

instrument

slides

Figure 32.)

to

the

following

bottom-out

Oil

Pump

pump

and carburetors

assure adequate engine

panel

mounting

procedure.

so

that

in the

carburetor

screws

both

is

1.

Lever

Stop

2.

Slack Removed

3. Cable

3.

Adjust carburetor The soon advanced.

4.

Loosen the and, the stop pin, remove all the slack. is

correct the simultaneously activated.

the

throttle

as

the

while

throttle

so

that

slide should begin

throttle

(See

Figure 32.)

locknuts

holding

when the lev

slide in the

as

(See

Figure 33.)

Locknuts

all

of

lever

on the

the

er

the

throttle

cable on the

oil

the slack

on the handlebar is

pump

on

the

LH

is

removed.

to

oil

pump

lever against

Adjustment

oil

pump

carburetor

cont

rol lever

raise

cable

move

LH

as

and

is

1.

Throttle

2.

Adjust

3.

Air

4. Idle

INVADER

Cable

ing Screw

Screw

Stop

Screw

Adjusting

Locknut

Screw

32

5.

Adjust oil simultaneously activated.

6.

Turn carburetors, in Then, back (initial adjusted when opened 1.5

7.

Perform steps under Purging Pump

R H carbu

pump

lever and

the idle stop screws, on

adjustment).

Outlet

retor

both

as

the

until

the spring

off

each screw six

Tubes.

throttle

Air

screw

PREPARA

cab

control

is

complete

turns

Air

le

so

that

slides move

lever

both

coil bound.

turns

is

properly

off

its seat.

From

TlON

Oil

15

is

Purging Air From Oil Pump Outlet Tubes

Remove and belt and

Any cause serious internal engine damage. Purge air

Observe this

the

instrument

the

air silencer assembly. Remove

perform

air bubbles in

from

these tubes

the

WARNING

Failure to disconnect the oil

following

the

oil

as

follows:

panel

procedure.

pump

I during

mounting

outlet

tubes

the

step

pump control cable when performing this procedure will damage the cable. The damaged oil

pump

control cable will prevent the throttle from returning to the idle position, resulting in automatic clutch engagement when the engine

which

may

lead to personal injury.

is

started,

drive

will

the

Observe this

(:~~!~~::J

during

Poor engine

performance and engine damage will

result.

3.

Temporarily carburetor guard

Start

4. screw s 3,000 idled purge all tubes.

5.

Remove rubber inner

check

lever and cable control

into

the engine and

for

control

the

POSition

assemblies and secure

proper

equally, R.P.M.

the

band, and reconnect

lever on

Stop

one

minute. This

the

air

air silencer assembly; release

cable

operatjon

the

position with

turn

to

obtain

the

from

by

the

to

the lever.

of

the

activating

handlebar.

air

engine idle speed engine

oil

silencer

clip

both

after

is

ample

oil

pump

the

pump

the

step

onto

converter

pins.

idle stop

it

time

outlet

oil

pump

Be

sure

control

throttle

the

of

has

to

the

to

1.

The

oil

di

sconnected pump disturb

inner

L..-___

2.

Attach a rubber control will

the

to

the

cable.

____

1.

2.

3. Rubber Band

4.

cause

outlet tubes. (See

pump

Oil Oil Pump

Mount

lever in

inner

from

prevent

cable

(See

______

Pump I nner

Bol t

the

maxi

control

the

control

damage

locknuts

Figure 34.)

Control

band

to

the

wide

mum

Figure 34.)

cable lever on

to

cable .

when removing the

___

Lever

hold

open

flow

must

the

Do

not

34

_

__

Cable

the

oil

pump

position. This

of

oil

through

be

oil

...J

6.

I nstall the air carburetors and check between air silencer securely

NOT

E: On SS440 models, plastic adapters on silencer plastic econo

7.

Secure springs. Install long springs on tab retainers and silencer

8.

Install the

instrument

during

installation,

jet

the

tab

si

lencer assembly

that

body

installation.

properly

the

carburetors

to

prevent

fitting.

air silencer

retainers.

mounting

panel assembly.

into

short

screws

Ignition Timing Check

Remove

foll

the

drive

owing procedure .

belt

prior

onto

the

rubber

and carburetors

position

prior

to

breakage

position

upper

springs on

to

performing

with

secu

of

silencer

lower

re

the

seals

fit

the

air

the

four

the

PREPARATION

16

INVADER

1.

Ins

tall engine. the

pointer chassis, engine. (

a fabricated

For acc

so

See

uracy,

to

the engine rather than the

the

pointer

Figure 35.)

timing

it

is

can

pointer

important

move

onto to

attach

with

the

5.

With

the drive guard secured in place, run 6,500 the opening in the converter guard over the when the the Figure 36.)

R.P.M.

pointer

timing

mark

as

belt

removed and the converter

Direct

the

timing

pointer.

on the converter aligns

the

The

timing

light

the

light

timing

flashes.

engine at

through

directly

is

correct

with

(See

2.

Remove

indicator

hole.

3. Rotate the drive converter in the normal direction find clockwise TDC. Make a fixed Figure 35.)

4.

Remove dial

spark plugs, check

a.

b.

Install spark plugs and

- 2.8 kg-m)

both

spark plugs and install a dial

into

the R H

of

rotation

TDC.

sheave opposite the

Plug gap

inch (0.

Be the seat on

Next,

to

0.108 inch (2 .75 mark

indicator

is

properly

66

mm).

sure washer

the

torque

.

that:

cylinder

(counterclockwise)

turn

the drive converter

on the drive converter

timing

and before installing

adjusted

is

installed on plug and

head

apply

18 -

spark plug

mm)

pointer.

to

is

clean.

20 ft. Ib

before

0.024

s.

to

(See

(2.5

If

the

1.

Remove to mounting flywheel.

timing

is

incorrect, proceed

muffler

stator plate; then loosen stator plate

screws

(See

and manual starter

through

Figure 37.)

as

follows:

for

access

the holes in the

Observe this

not

Do

engine

is

powerful

hot

the would

INVADER

result.

WARNING

I during

touch the spark plug leads while

running

as

they

electrical shock. Do

exhaust

system

will transmit a

not

touch

. A severe burn

Observe this

[:~~~!!~~]

during

not

to damage the coil windings.

PREPARATION

step

17

2.

Turn

the

stator plate retard timing) plate screws. onto emergency starter rope, and recheck

timing;

to

correct

exhaust

Temporarily

as

required (clockwise

counterclockwise

timing

manifold,

to

advance

and tighten stator

position

start engine using

tim

muffler

ing.

Observe this I

If

adjusting the headlight indoors, provide

WARNING

I during

proper ventilation to prevent possible carbon monoxide poisoning.

3.

When the

the

timing

install

NOTE:

properly before tightening

4.

Make sure

I nstall drive into

proper

Be

certain the air silencer hose

to

the

installed,

ignition light, replace the recoil starter and

muffler

positioned in

rear

after the converter guard

as

in engine damage.

Headlight

1.

Position headlight away.

locked position.

Adjustment

the

points

The

headlight must

assembly.

the

muffler

belt

and

position

timing

lip

the

with

is

on insulation washer slotted

mounting

secu

re

clip

incorrect position

snowmobile

at

a wall

on a level

25

be

correct, remove

muffler

nuts.

converter guard pins.

is

may

feet

in

bracket

directed

is

re-

result

floor

so

the

(7,620 mm)

the

up

and

is

NOTE:

snowmobile prevent the vehicle assure

3.

4.

Be

sure

while

proper

Turn

headlight beam

below

Figure 38.)

If

headlight adjustment

adjusting screws

aiming.

on

the

is

properly

is

centered and aimed 2 inches

the reference

an

operator

the engine

from

headlight high beam. The

mark

as

required.

is

seated on the

is

running

creeping ahead, and

aimed when the high

(51

on

the

wall.

is

required,

(See

turn

Figure 39.)

to to

mm)

(See

the

2.

Measure the distance center the dimension measured (reference

Figure 38.)

of

the headlight and mark

from

~

1.

Wall

2.

25 Feet (7,620

3. Reference Mark (center floor)

4.

2 Inches

PREPARATION

18

(51

mm)

Below Reference Mark

the

floor

to

the

wall at

mark).

----'"I--

-

----

-

of

headlight

(See

Check the operation

-----

38

to

Tail/Brake

The switch

The brake

in the brake lever housing on the handlebar. Brake lights and the key switch.

1.

2.

taillight

is

in

light

Hor

izontal

Vertical

light

will

operate

the

"Run/Lights"

is

activated

operation

Adjusting Screws

Adjusting

of

the headlight

Screws

Test

only

position.

by

a switch

is

independent

low

beam.

when the key

mounted

of

the

other

INVADER

Track

Adjustments

When raising the rear

off

the ground, place the stationary object and is

properly secured to prevent personal

injury.

I WARNING I

of

the snowmobile

ski

be

sure the vehicle

tips against a

3. Loosen the rear axle side; then through decrease and track.

turn

the rear axle adjusting

rear

track

the

clearance between the wear

(See

Figures

locking

openings clockwise

41

bolt

and 42.)

on

either

nuts

to

strip

Track

Tension

WARNING'

To

prevent personal injury, never adjust

track tension with the engine running.

1. Raise the rear

is

off

the gro

secure

hang a 5 - 8 lb. (2.2 - 3.6 kg)

the

NOTE:

side

impossible

2.

T strip

mid

Do

to

he

clearance

to

the

point

adjust

to

1-1/4 - 1-

measured pivot

arm

snowmobi

of the track.

not

position

track

get

an

the

top

1/2

directly

bolt.

of

the

snowmobile

und

for its

le

tension

accurate adjustment.

from

the

edge

in. (31 - 38

bel

(See

Figure 40.)

entire

so

it

the

snowmobi

bottom

of

the

ow

the rear suspension

so

cannot

weight

as

it

of

track

mm)

the

track

length and

fall;

then

from

le

on its

would

the wear

should

be

when

1.

Rear

Axle

Adjusting

4. When the

both exposed threads

Th

is

alignment.

5.

Remove

proper

adjusting nuts have the same

is

a good starting

weight

tension

protruding

from

the track.

Observe this I WARNING ' during

To

avoid possible personal injury, do

Nuts

is

atta ined,

through point

area

before starting

engine.

be

number

the nut.

for

track

step

not

is

sure

of

1.

1-1/4 - 1-

INVADER

1/2

in. (

31

- 38

mm)

6.

Start

lever few

Track

NOTE: between sprockets) occurs braking,

Track

The the rear

on

both

the

only

revolutions.

Alignment

If

the

tighten

Alignment

track

is

idler

sid

es.

engine and push on the enough

ratcheting (slippage

drive lugs on the

the

aligned when the distance between wheel and edge

(See

to

turn

Stop

the engine and

check.

during

track

Figure 42.)

hard acceleration

slightly.

the tra ck

track

of

the

PREPARATION

slowly

or

and the drive

track

throttle

perform

jumping

or

is

equal

19

a

Test Ride

1.

Rear

Axle

2.

Edge

3. Dimension Equal on

4.

Idler

After adjust

performing

track

alignment

Observe this I

To

prevent injury, never adjust or measure

Locking

of

Track

Wheel

Track

as

WARNING

Bolts

Both

Tension procedures,

follows:

I during

track alignment while the engine running.

If

the

track

runs

to

adjusting

1/2

turn;

alignment.

nut

then

on

the

restart

one side,

the

tighten

same side,

engine and recheck

Sides

is

the rear axle

approximately

the

(Operation

al

Checks)

[:~~~!!~~:]

Improper engine warm-up could result

extensive engine damage.

Liquid coo lant, and engi operating

Test ride the s following:

•

• ENGINE

• SUSPENSION

cooled engines require

to

allow

cylinders) to

ne a minimum

at

sustained

CONTROL

The

throttle without steering

STEERING

Steering should be lo

ck-t

steering linkage.

Recoil

s

tarts promptly.

respon

binding

position

o-Iock

starter

se and

internal

obtain

of

full

nowm

CABLES

and brake

and

.

with

no excessive looseness in

works proper

return

proper

components

proper

five

(5)

throttle

ob ile and check

contro return

smooth

ly

Test

.

for

in

warm

up

of

(pistons

clearances. Run

minutes

R.P.M.

ls

must

fre

and free

and

good

before

for

the

operate

ely in any

from

the

engine

throttle

If

track alignment requires considerable

adjustment, track tension should be

rechecked to prevent damage to drive or

suspension system.

When axle l

NOTE:

tightened, check (tubing) slide rail brackets, preventing rotat to maintained.

track

alignment

ocking

ing. Loose spacers

float

TEST

20

bolts.

After

over

and

RIDE

is correct,

the

rear axle

to

be

sure

the

rear axle squeeze against

will

proper

track

(OPERATIONAL

tighten

bolts that

the

permit the rear axle

alignment

CHECKS)

the

have been

the spacers

spacers

from

cannot

rear

the

be

A

dju

sted

operates

•

EMERGENCY

Check

•

CONVERTERS

Test

R.P.M.,

BRAKES

•

When activated, the brak adequate released, there should

•

INSTRUMENT

Check

for

smooth

operat

ion in all

for

smoo

7,800 -8,000

smooth

for

proper

average

Iy.

STOP SWITCH

th

S

switch

operation

at

full

stopp

in g of

be

no

indicati

ons.

driver

positions

and

correct

throttle.

es

sho

the

brake drag.

weight

uld

track;

INVA

and

.

engine

result in

when

DER

COOLANT

The engine

TEMPERATURE

coolant vary, depending conditions snow will snowmobile periods will

cause

than when

and operating

conditions,

be

higher than operation

in deep

of

idl ing

coolant

the

speed.

temperature can and

upon

air temperature, snow

speeds.

engine

coolant

powder

or

operating at slow speeds

temperatures

engine

is

operated

I n marginal

temperatures

snow. Prolonged

to

be

of

hotter

at

will

the

high

During

the

test ride, listen (rattles, squeaks, etc.) inspection and

Upon

completion

correction.

of

following:

1. Brake

2.

Engine gearcase

3.

Cooling system

adjustment

lubricant

coolant

for

any unusual noises

that

may

warrant

Test Ride, check the

level

Engine long

in be needle

coolant

as

the temperature gauge needle remains

the

green area. The engine may

operated when the temperature

is monitor frequently. the red area inspect

cooling system

in

the

temperature

yellow,

is

but

temperature needle indications

Stop

of

engine

the

if

needle moves

temperature

for

proper

"NORMAL"

continue

use

caution and

gauge

operation.

as

to

gauge

into

and

4. Retorque drive converter 70

ft.

Ibs.

(9.0 - 10.0 kg-m)

5.

Thoroughly for

fuel

6.

Fastener check - Perform a general inspection to

check fasteners

chart

as a gu

inspect the engine

or

oil

leaks and repair

ide

for

mounting

for

security.

tighten i

bolt

compartment

as

required.

Use

ng

hardware when

required.

65

torque

-

INVADER

TEST

RIDE

(OPERATIONAL

CHECKS)

21

Specifications

ENGINE

Type

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

Displacement ....................................................................................... (340) 20.7 C.1.

Bore X Number

Ignition System .................................................................................. Capacitor Discharge (C.D.)

Ignition

Spark Plug .............................................................................................................

Spark Plug Gap ............................................................................................ 0.024 inch (0.6 mm)

Carburetor Make and Engine R.P.M. at Full

Engine

Stroke ........................................................... (340) 2.362 x 2.362 inches (60 x

(440) 2.677 x 2.362 inches (68 x

of

Cylinders .............

Timing

Gearcase

.......................................................................... 0.108 inch B.T.D.C. (2.75 mm)

Capacity ................................................................................... 1.35 oz. (40 cc)

Model ..................................

Throttle ......

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

....

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

............................................................. 7,800 - 8,000 R.P.M.

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

(440)

(440) 26.6

(440)

C.1.

NG

K B R-9 EV

Mikuni Mikuni

(339.3 cc)

TC340A TC440A

(436 cc)

60

mm)

60

mm)

VM32 VM36

"1

CARBURETOR SETTINGS

Air

Screw .......... .............. .................................................................................. 1.5 turns

Idle Screw ......................................... 6 turns open

from

coil bound

initial

(3,000 R.P.M. final)

FUEL

Gasoline ..................... Regular

Oil.

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

Gasoline/Oil

...

.............................. Kawasaki Snowmobile Oil

Ratio ..................................................................................................

or

Premium Leaded,

minimum

pump

posted octane number 89

or

B.I.A. certified TC-W oil

..

Oil Injection

DRIVE SYSTEM

Drive Belt Width ...................

Belt Outside Circumference ....................

Drive Converter

Converter Center Distance ..................... .............

Offset ............................................................. 0.525 - 0.588 inches (13.3 - 14.9 mm)

...

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

......

.......

......

............... 46-5

..

.................................... 12 inches (304.8 mm)

..

1-1/4 inches (31.7 mm)

/8

inches (1,184 mm)

ELECTRICAL SYSTEM

Type ......................................................................................................... ... 12

H.eadlight

Tail/Brake

Instrument Lights ............................................ ....................................................... G.E. No. 363

...

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

Light

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

Volts

- 120 Watts

..

Stanley 5988

G.

E.

off

seat

No. 1157

22 SPECIFICATIONS

INVADER

Torque Chart

DESCRIPTION TORQUE

CABLES & CONTROLS

Brake & Brake

Enrichener Speedometer Throttle

CHAINCASE & JACKSHAFT

Chaincase Chaincase Jackshaft

Jacks Jackshaft bearing Bearing

Bearing

CHASSIS

Hood Hood Passenger

Pan brace

Tr Se

CHASSIS

Radiator Radiator

throttle

cable

mounting -nuts cover

bearing

chassis - rear

haft

bearing

chassis·adjusting

locking lock

guide a

screws

guide,

hood

hinge

handle attaching

im

attaching

at

attac

hing

COOLANT

assy assy

lever -

jam -nuts

cable assy -

cable -

ass

y -

mounting

retainer

bolt

retainer

front

bolt

retainer

bolt -jam

collar

(locking tor

nd

trim

front

bumper

attaching -nut

attaching -nuts

- screws

bolts

SYSTEM

to

chaincase -

to

chassis -

nut nuts nuts

nut

- set screw

mounting

lockscrew

s

- screws

to to

que)

-

and

bolt

bolts

20-25

in.lb.

50

in.lb. (0.6 15-20 in.lb. (0.1-0.2 Hand 15-20

18

ft.lb. (2.5

70

in.lb.

31

ft.lb.

19

ft.lb.

10-20 ft.lb. 36 in. 36

in.lb. (0.4

20

in.lb.

70

in.lb.

18

ft.lb.

70

in.lb. (0.8

20

in.lb

35

in.lb.

70

in.lb.

18

fUb.

(0.2-0.3 kg-m)

kg-m) Engine

tighten

in.lb.

(0.1-

0.2

kg-m)

(0.8 kg-

m) (4.2 kg-m) (2.6

.kg-m)

(1.3-2.7 kg-

lb.

(0.4 kg-m)

kg-

m)

(0.2

kg-

m)

(0.8

kg-m)

(2.5 kg -

m)

kg-m)

. (0.2 kg-m)

(0.4

kg-m)

(0.8 kg-

m)

(2 .5 kg-

m)

kg-

m)

kg-m)

m)

DESCRIPTION

ENGINE

EXHAUST

HOOD

INSTRUMENT

&

RECOIL

SKI & SPINDLE

MOUNT & EXHAUST

Muffler

mounting -nuts

mount

Exhaust

Hood

INSTRUMENTS

Gauges Temperature

Starter Starter

Ski Shock Spindle

manifold -nuts

hinge -

to

I

nstrument

unit -nut

STARTER

Dri

ve

plate

pulley mounting -bolts

skeg

Front

spring

absorber

spindle -nuts

to

Rear spring

panel -

ski saddle -

to

chassis -

nuts

PANEL

nuts

panel - screws

gauge sending

mounting -nut

mounting -bolts

mount -bolt

to

ski

and

mount -bolt

nut

nuts

TORQUE

60-70

in.lb.

31

ft. lb.

8-

10

25

in.

11

in.lb.

32 in.lb. 20 ft.lb. (2.7 kg-m)

8

-10ft.lb. 16-18 5-6

18 ft.lb. (2.5 kg-

25

in.lb

31

ft.lb.

46

ft.lb.

31

ft.lb. (4

(0.7-0.8 kg-m)

(4.2

kg-m)

ft. lb. (1.1 -1.3 kg-m)

lb.

(0.2 kg-

m)

(0.1 kg-m) (0.3

kg-m)

(1.1 -

ft.lb.

1.3

(2.2-2.5 kg-m)

(0.6-0

.8 kg-m)

. (0.2 kg-m)

m)

(4 .2 kg-m) (4.8 kg-m )

.3 kg-m )

kg-m)

DRIVE

CONVERTER

Drive Cover Roller

sheave -

Weight

spider -

Weight

DRIVEN

Driven Coupling Windage cover

Brake disc Caliper

ENGINE,

Cyl

inder

Flywheel

Spark

Holder

case

Gear

converter

to

and

ramp and ramp -nut

CONVERTER & BRAKE

converter

GENERAL

plug

(carb.)

movable

bolt

to fixe

to

chaincase -

head

nut

bolts

to

crankshaft -bolt

sheave -

assembly

assy

to

jackshaft -bolt

d sheave -

to

sheave - screw

hub

mounting

nut

bolts

(socket

head)

bolt

in

movable

to

bolt

- screw

65-70

ft.lb.

8-

10

ft.lb. (1.1-1.4 8-10ft.lb 6-8

4-5

40-50

8-10ft

6.5-8

55-60 in. 35

16 60 20 45

12

. (1.1 -

ft.lb

. (0.8-1.1 kg-

ft.lb

. (0.5-0.7 kg-m)

ft.lb. (5.5-6.9

.lb. (1.1-1.4 kg-m)

ft.lb.

lb.

ft.lb.

(4.8 kg-m)

ft.lb.

(2.2 kg-

ft.lb.

(8.3 ft.lb. (2.7 kg-m) in.lb

. (0 .5 kg-m)

ft.lb.

(1.6

(9.

0-10

kg-m)

1.4 kg-

m) m)

kg-m)

(0.9-1.1 kg-m)

(0.6-0.7 kg-

kg-

kg-m )

m)

m) m)

STEERING

Handle

holder -bolt Steering Steering Steering arms

Upper

Lower Tie Tie

RH

Handlebar

SUSPENSION

Rear suspension Rear

Idler· shaft -bolts Shock Suspension Swing

Front

arm column

steering post steering

rod

jam -nut

rod

jam -nut

tie

rod

mounting

axle -

absorber

arm -bolts

pivot

to

spindle -bolt

to

tie

to

tie

post

(LH) (RH)

to

steering

to

holder

- screws

arm -bolt

bolts

mounting -nuts

to

chassis -

shaft -bolts

rod -nut

rods -

nuts

mounting -nuts

mount

ing -

nuts

arm -nut

clamp

bolts

35

ft.lb.

30

ft.l

30

ft.lb. (4.1

30

ft.lb

18 ft.lb.

20

ft.lb 100-120 100-120 30

ft.lb. 105

in.lb.

30

ft.lb. (4.1

25

ft.lb.

25

ft.lb.

35

ft.lb. 25 ft.lb. 25

ft.lb. 25

ft.lb. (3.4

(4.8

kg-

b. (4.1 kg-m)

. (4.1 kg-m) ..

m)

kg-

m)

(2.5 kg-

m)

(2.7

kg-m)

in.lb.

(1.1 in.lb. (1. (4.1 kg-m )

(1.2

kg-m)

(3.4

kg-m )

(3.4 kg-

m)

(4.8

kg-

m)

(3.4

kg-m)

(3.4

kg-m) kg-m)

1-1

1.3

kg-m)

.3 kg-m)

INVADER

TORQUE

CHART

23

~

:E

:II

Z

G')

o

l>

G')

:II

l>

~

z

<

l>

o

m

:II

...J

(5

U

a:

w

'3

:::J

0..

-'

(5

U

a:

UJ

>-

u

X

w

EME

RGENCY

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Kawasaki Invader SS340-A2, Invader SS440-A2 Assembly & Preparation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual