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

PIN

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

next

of

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

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

next

step

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

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.)

next

hit

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

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

next

step

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

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