Kawasaki LTD 440 Shop Manual

QUICK

REFERENCE GUIDE

SECTION

SPECIFICATIONS MAINTENANCE BRAKE SYSTEM CABLES

CARBURETOR CHAINCASE/JACKSHAFT

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quick

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topic

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contents

procedure

CHASSIS

pro-

COOLING SYSTEM DRIVESHAFT

ELECTRICAL SYSTEM

con-

ENGINE FUEL SYSTEM

IGNITION SYSTEM

INSTRUMENTS MUFFLER OIL INJECTION

SILENCER

STARTER, RECOIL STORAGE SUSPENSION STEERING SYSTEM

TORQUE CONVERTER SYSTEM

TRACK APPENDIX

GENERAL SPECIFICATIONS

SPECIFICATIONS

1-

1

General

Service

Torque Gear Engine Port

Specifications General Engine Carburetor Drive Belt

Gearing ........................

Electrical

Engine ....

Ign ition

Chasis ....

Engine

Ratio

Dimensions ..........

...

. . .

........

....

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

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

Converter

.......

Specifications

Chart

Performance

...

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

Components ..............................

...

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

........

. .

.. ..

Torques

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

Chart.

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

. .

. . .

......... ..

Curves

TABLE

....

......

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

...

.....

OF

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

.

......

..

. ..... . ....

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

. . .

. .... ..

.

....

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

.....

..........

...........

CONTENTS

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

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

.....

.. ..

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

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

. ..... .....

........

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

..

...........

..

. ....

.

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

....

.

...

.

...

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

...

. .... .

....

.....

.........

........

. .. .

.. ..

........

.......

...

. .... .

...

. .

....

.. .......

...... . .

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

. ..

......

. . . . ....

..........

. .

.. ..

...... .....

........

.........

. . .

.. ..

. .

.......

..

. .

........

........ 1-4

.. ..

........

....

.. ..

....

..

. .

.......

.....

.... 1-2

......

...

. .. ... 1-3

. .

..

. .

....

. .

..

.

...

..

...

. 1-2

1-2 1-2

1-3 1-3 1-4 1-4

1-5 1-6 1-6

1-7 1-11 1-12 1-12

1-2

GENERAL

General

Length

Width

Height

Weight

Engine

SPECIFICATIONS

(with

windsh

(approximate

GENERAL SPECIFICATIONS

LTD

440

(manual)

103

in.

(2616

mm)

40.5

in.

(1029

mm)

35.8

ield)

dry)

(909

455 (206

LTD

in.

Ib

440

mm)

kg)

(manual)

LTD

440 (electric)

103 (2616

40

.5 in.

(1029

35

.8 in.

(909

481 (218

LTD

440

in.

mm)

Ib

kg)

(electric)

Model

Number

Displacement

Bore X Stroke

Number

RPM - Full

RPM

Starter

I

of

-Idle

Carburetor

Make

Mode

l

I

dentifi

cation

Type

of

Carburetor

Cylinders

Throttle

Marki

ng

TC440D-A201

26.6C.1. (436

cc)

2.

677

X 2.

362

(68X

60

mm)

2

8,200

2,500

Manual

Keihin

BD 40-

B B

Open

36 36

rewind

36

AL AR

Vent

with

(left

(right

in.

Accelerator

side)

Pump

TC440D-A204

26.6

C.I.

(436

cc)

2.

677

X 2.

(68 X 60

2

8,200

2,500

Electric

362

mm)

in.

Pilot

Jet

Main

Jet

Power

Idle

Accelerator

Float

Enrichener

Idle

F

Screw

Valv e Seat

Speed

loat

Height

Jet

Air

(fuel)

Jet

(fuel)

Pump

System

Screw

Lever

Screw

70

98

180

2.5

Turns

Flush

with

0.

047

in. (1.2 mm)

Dual

Position

2,

500

RPM

0.590

in. (

avoid

compressing

carburetor

Open

Bottom

Cable

(final

15

mm) -

gasket

of

Lever

orifice

adjustment)

surface

diameter

Carburetor

float

valve

.

tilted

20°

to 30°

spring. Measured

from

vertical

top

of

to

float

to

Drive

Converter

Engagement

Speed

4,

400

RPM

(approximate)

GENERAL

SPECIFICATIONS

1-3

Spring

Weight

Ramp

Total

Belt

Part

Outside

Width

Thickness

PI N

and

Part

Numbers

Part

Number

Gram

Weight

Number

Circumference

of

Top

(overall)

Color

(each

Surface

(each

ramp)

92081-3011 -White 92081-3001 -Yellow 92081-3002 -Black 92081-3004 -Pink 92081-3005 92081-3006 -Blue

11

OG0628 92019-008 -Nut 13042-3001 -Washers 13042-3002 -Washers

39152-3007 -Marked "F"

57.6

grams

LTD

440

59011-3502

46.69±0.19 (1,185.9±4

1.25

± 0.

(31.7±0.8

0.53

± 0.

(13

.5 ±

- Red

- Bolt,

(manual)

.8 mm)

03

in.

mm)

03

in.

0.8

mm)

in.

(standard)

(optional)

Silver

2.3

grams

7.3 (1) 0.5

(1) 1.0

grams

46.5

gram gram

grams

LTD

440

(electric)

59011-3502

46.69 ± 0.19 in. (1,185

.9 ± 4.8 mm)

1.25 ± 0.03 (31 .

7±0.8

0.

53±0.03

(13

.5 ± 0.8 mm)

in.

mm)

in.

Belt

Taper

Gearing

Top

Sprocket

Lower

Sprocket Sprocket Chain

(Silent

Chain

Tensioner

Drive

Chain

Angle

Overall

Type)

Tension

Ratio

Spring

30°

LTD

22

38

1.73 66 Green Self

± 2°

440

(manual)

Teeth Teeth

to

1

Pitch

Adjusting

30°

LTD

22 38

1.73

66 Green Self

± 2°

440

Teeth Teeth

to 1

Pitch

Adjust

(electric)

ing

1-4

GENERAL

SPECIFICATIONS

Electricical

Type

Headlight-part

-type

Tail/Brake

Instrument

Battery

Electrolyte

Engine

Components LTD

12

number

Light

Lights-temperature

-speedometer

-tachometer

Volume

92069-3507

12 V 60/55 W quartz

G.E. No.

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

N/A

N/ A 1.5

SERVICE

440

(manual)

VAC,

120

W

1157

No

.

363

1816 1816

SPECIFICATIONS

LTD

440

(electric)

12

VDC,

120

W

92069-3507

12 V 60/55 W quartz

G.E. No.

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

12 hour at discharge

(1.4

VOLT

capacity

10

hour

quarts

liters)

1157

363

1816

22

rate

ampere

Effective Piston Pi Pi Piston Piston Piston Connecting Connecting Connecting Crankshaft Crankshaft Cylinder Cylinder

-Measured

ston ston

Pin Ring Ring

Pin Skirt Skirt

Bore Head

Compression

Diameter

End End

Bore ...

Clearance Diameter

Rod Rod

Rod End Run

with

....

Gap Gap

Radial Play Side Small

Play Out

.

Capacity-

standard

Ratio

..

(Top) . . (Bottom)

.........

.

Clearance

End

Diameter

(Maximum)

. .

spark

...

. . .

........

.

plug

...

....

. .. . . .

...

.. .....

. .

.

installed

.

...

.

. ....

....... 0.7085 -0.7087

..

. .... . . .

..... 2.6744

9056

. . 0.

..2.6

in.

0.

008

6752

- 0.001 in.

9060

......

6781

- 0.

in.

- 0. in.

in.

. .

...... 0.008 -0.

.

0.4713 -0.4803 .0.002 -0.004

- 2.

.. 0.0008

. .

.. 0.016

- 0.

.. .....

. .

.

...... 0.002

774

- 2.

.....

7.1 to 1 (17.995 -18.000 016

in.

(02

- 0.4 mm)

016

in. (0.2 -

in. (11 .

97

in.

(005 -0.10

(67

.931 -67.

(002

020

in. (0.4 - 0.5 mm)

(23003 -23.014

.... 0.008

in . T.

I.

(68.005 -68.023

.

... 18.

0.4

-12.20

950

- 0.

03

in. (0.2 mm)

R.

(0 .

05

6cc ± 0.4

mm)

mm) mm) mm) mm) mm)

mm)

cc

Ignition

SERVICE

SPECIFICATIONS

1-5

Spa rk Plug Ignition Ignition

+

operating

Timing (Dynamic) Timing

Lighting Exciter Pulser

Primary

+

Secondary

NOTE:

Defective

Gap ......

(B.T.D.

Item

Co il

Coi l

Item

Winding

winding

conditions

IGNITION

...

C.) ....

coils

is the

....

.. .

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

...

. . . . . . .. ..

...........

Ohmmeter

IGNITION

Ohmmeter

cannot

always

recommended

RISE TIME

....

. . ....

........

...

....

..........

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

.....

. ..

...

. . . . .

.......

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

MAGNETO RESISTANCE TESTS

Leads

Yellow-Yellow

COIL

Leads

High

Tension-High

be

detec

test

Connected

Red

-Groun

Red-Wh

ite

RESISTANCE TESTS

Connected

B

lue-Groun

ted

using

method

.

d

Tension

this

test

Between

alone.

SPARK ARC DURATION

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

210 at 6,500

Use

of a coil

.

...

0. 6,

0.024

RPM (engine

. . 0.

102

Resistance

0.19

ohms ± 20

165

ohms ± 20

18.5

ohms

Resistance

19

ohms ± 20

000

ohms ± 20

tester

in. (0.6 mm)

in. (2.61

± 20%

which

cold)

mm)

%

simulates

Q)

'"

~

'0

>

~

'0

'"

c

o

OJ

Q)

(J)

~

Q)

c..

40

~

30

..

'"

!l

0

>

20

...

:0

'C

c

0

u

~

10

0

100% J_ - - - ---::0

90%-,---

I

10%

J--

I

o t

!.-10·12

Rise

time

; time between 10%and 90%

of

secondary peak voltage

SECONDARY

VOLTAGE

,

-

2000

ENGINE

3000

SPEED (RPM)

I

.

.1

1000

-'-'-

i

I

- -

--

J.I

second:'

OUTPUT

4000

5000

-

--

'C

<

0

6000

"

u

"

c

co

>

'"

e;,

Z

0

i=

<::

a::

::J

0

IJ

200

u

~

:1.

I

,

100

a

1000

2000

3000

4000

ENGINE SPEED (RPM)

IGNITION

/

TIMING

-

--

CURVE

,

I'

/

f

1000

2000

4000

3000

ENGINE SPEED (RPM)

5000

6000

5000

r-..

........

7

000

6000

r--

8000

1-6 SERVICE

Chassis

SPECIFICATIONS

Converter

Offset

Distance

Converter Center Distance

Drive

Chain

Brake

Lever

Track

Tension Steering Tie

Rod End

Tension

Movement

Alignment.

Adjustment

...

.....

......

Engine Torques

Cylinder

Crankcase-6

Head

-8 mm

mm

size

....

.....

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

. ...

.

. .

. . .

Stud

Jam

. .

...

. .. . .

...

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

....

. ..

....

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

Nut

Dimension ......

LTD

440

19 (2.6

16 (2.2

70 (0 .8

16 (2.2 kg-m)

. .... ....

..

(manual)

It

Ib

kg-m)

It

Ib

kg-m)

in. Ib

kg-m)

It

Ib

....

. . . .. .

.. 0.525

..........

3/4 in.

(19

mm)

. . . . . 1-1 14 in .

. .

.. ......

...

. .... ..

maximum

.

...

to 0.

588

... ... . .. . 12

...........

.

...........

deflection

Skis

parallel

in.

(13.3

or

(32

LTD

19

(2.6

16

(2.2

70 (0.8

16 (2.2

to

14.9

in.

(305

Self

Adjusting

Self

Adjusting

(5 to 8 Ib

118 in.

mm)

maximum

440

(electric)

It

Ib

kg-m)

It

Ib

kg-m)

in. Ib

kg-m)

It

Ib

kg-m)

toe

mm)

pull)

out

Flywheel

Recoil

Carburetor

Gearcase

Starter

Holder

Mounting-6

to

-8

Cylinder

mm

size

mm

size

72

It

Ib

(10.0 kg-m)

70

in. Ib

(0.8

kg-m)

45

in. Ib

(0.5

kg-m)

60

in. Ib

(0 .7

kg-m)

12

It

Ib

(1.7

kg-m)

72 (10

70 (0 .8

45 (0 .5

60

0.7

12 (1

It

.0

in. Ib

kg-m)

It

.7

Ib

kg-m)

Ib

kg-m)

TORQUE CHART

QUANTITY

TORQUE CHART 1-7

CONTROLS

Brake

lever Ignition Throttle

switch

lever

CABLES

Brake

cable -jam Enrichener Enrichener Oil

pump

cable -jam Speedometer Throttle

cable -jam

HOOD

Headlamp Hinge

bracket

Hood

hinge

Hood

latch

SEAT AND

Control Control Fuel Oil Seat

panel panel

level

gauge

to

tunnel -bolts 4

DESCRIPTION

AND

SWITCHES

locking -allen

mounting -face

locking -allen

nuts cable -jam lever

mounting -nut

cable

nut

housing

to

band

holder

to

housing

hood -screws

mounting -nuts

CONSOLE

bracket

to

bracket -screws

gauge

panel

screw

nut

screw

nut

nuts

to

hood -screws

holder -screws

to

chassis -nuts

mounting -screws

LTD

440

1

2 2 1 2 2 1

4 4 6 4 1/ 4

3 1 / 4

2 # 4 # 4 #

SIZE

8mm

-

8mm

5/

16

6 mm

-

6 mm

-

6 mm

#

10

#

10

1/ 4

10 10 10

1/ 4

TORQUE

25

in. Ib (0.3

30

in. Ib (0

25

in. Ib (0.3

50

in. Ib (0.6

20

in. Ib (0.2

Hand

tighten

20

in. Ib (0.2

Hand

tighten

20

in. Ib (0.2

25

in. Ib (0.3

50

in. Ib (0.6 kg-

25

in. Ib (0.3

Compress

95

in. Ib (1.1

20

in. Ib (0.2

20

in. Ib (0.2

20

in. Ib (0.2

35

in. Ib (0.4

kg-m)

.35

kg-m)

kg-m) kg-m)

rubber

kg-m kg-m) kg-m kg-m) kg-m)

m)

) )

STEERING

Handlebar Handlebar Steering Steering

Tie

rod

end -jam

Tie

rod

end

Tie

rod

end

SKI AND

Shock Shock Ski Ski Ski Ski Ski spring

absorber

absorber saddle skeg spring spring

holder -allen

holder arm to column

to

spindle -bolt

mount

nuts

to

steering

to

steering

SPINDLE

to to

to

spindle -nut

to

ski -nuts

to

saddle -nuts

to

ski, front -nut

to

ski, rear -nut

screws

steering

to

chassis -bolt

arm -nuts column -nut

ski -nut ski

saddle -nuts

column -bolt

4

1 2 4 4 3 1

2 2 2 6 4 2 2

1/4

3/8

3/ 8 5/

16 3/ 8 3/ 8 3/ 8

3/ 8 3/ 8 31 ft 3/ 8 5/

16 3/ 8 3/ 8 3/ 8

105

in. Ib (1.2

35

ft Ib (4.8

30

ft Ib (3.9

20

ft Ib (2.8

120

in. Ib (1.4

30

ft Ib (3.9

30

ft Ib (3.9 kg-

31

ft Ib (4.0

Ib (4.0

46

ft Ib (5.7

120

in. Ib (1.4

46

ft Ib (5.7

25

in. Ib (0.3

31

ft Ib (4.0

kg-m)

m)

kg-m) kg-m) kg-m)

kg-m)

1-8

TO RQUE

CHART

SUSPENSION

Front

pivot

shaft

Idler

wheel

shaft Limiter Rail Rear axle Rear

Rear Rear Rear Idler

Rear Suspens Front Fr Rear Suspension Suspension Suspension

strap

wear

axle limit pivot

suspension

whee

suspension

spring

ont

spr

spring

strip adjusting

locking -bo

er

strap

shaft

ls to rail

ion

brackets cam

ing

cam

shock

shock brace

DESCRIPTION

to

tunnel -bolt

mounting -bolt

to

swing

arm -nuts

retaining -nut

bolt -jam

lt

to

pivot

to

tunnel -bolt

arm

to

pivot

brackets -nut

arm

to

to rail mounting, mounting, rear

mounting -nuts

absorber absorber

shaft -bolts

TORQUE

nut

arm -nut

arm

assembly -bolt

rail

bracket -bolt

nuts

front -bolt

- b

olt

mounting, mounting, rear -nut

front

- b

CHART

QUANTITY

LTD

olt

(CONTINUED)

440

2 2 4 2 2 2

1 2 2 4 2

38

2 2 4 1 1 2

SIZE

3/ 8 3/ 8 1/4 1/ 4 3/ 8 3/ 8

1/4 3/ 8 3/ 8 3/ 8 3/ 8

1/ 4 3/ 8 3/ 8 5/

16 3/ 8 3/ 8 3/ 8

TORQUE

25

ft Ib (3.5

25

It

Ib (

35

45

in. Ib (0.5

25

in. Ib (0.3

120

in. Ib (1.4 kg-

25

ft Ib (3.5

45

in. Ib (0.5

25

ft Ib (3.5 kg-m)

25

ft Ib

(35

25

ft Ib (3.5

25

ft Ib (3.5

120

in. Ib (1.4

35

in. Ib (0.4

120

in. Ib (1.4

45

in. Ib

(05

25

It

Ib 15 25

(35 kgft Ib (1.9 ft Ib

(35

kg-m) kg-m)

m)

kg-m)

kg-m) kg-m) kg-m)

kg-m)

m) kg-m) kg-m)

DR

IVE SHAFT

Bearing Locking

CHAINCASE

Lower Top Cha Chaincase Chaincase Chaincase Jackshaft Jackshaft Jackshaft Jackshaft Speedometer

housing collar

sprocket

in t

ensioner

bearing bearing bearing bearing

to

tunnel -nuts

- s

et

screw

AND

JACKSHAFT

to

driveshaft

to

jackshalt

moun

cover

mounting

drain

plug -bolt

to

chassis -nuts

retainer retainer retainer retainer

drive

adaptor

BRAKE

B

rake

caliper

to

chaincase -nuts

DRIVEN CONVERTER

Coupling Cover Driven

to

fixed

to

movable

converter

sheave -bolts

sheave

to

jackshaft -bolt

- b

olt

- b

olt

ting -bolts

- b

olts

adjusting bolt -jam housin

g -

to

chassi

to

chassi

- s

crews

nuts

s,

front

s,

rear -bolt

nut

- bolt

3 2

1 1 5/ 8 2

6

1

4 5/

1 3/ 8 2 1/4 1 3/ 8 1

1

2

6

16

1

16

5/ 1/ 4

1/2 1/ 4

1/ 4

-

16

3/ 8

-

3/ 8

6mm 6mm

5/8

12

ft

Ib

(1.7 kg-m

70

in. Ib (0.8

35

ft Ib

(48

50

ft Ib

(69 kg-

70

in.lb 70 Judgement

18ft 20 18ft 19ft

31

120

35

120 50 50

(0.8

in. Ib

(08 kg-

Ib (2.6 kg-

ft Ib (2.8

Ib (2.5 kg-m) Ib

(26 kg-

ft Ib (4.1

in. Ib (1.4

ft Ib (4.8

in. Ib (1.4

in.

lb

(0.6 kg-

It

Ib (6.9

)

kg-m)

m)

kg-m)

m)

kg-m)

m)

kg-m)

m)

kg-m)

TORQUE CHART 1-9

DESCRIPTION

DRIVE CONVERTER

Cover

to

movable

Drive

converter

Ramp

and

Roller

and

Weight

ENGINE

Engine Engine Exhaust mount Mount Exhaust

ramp

MOUNT

mount

to

damper

manifold -nuts

engine

sheave -bolts

to

crankshaft -bolt

assembly

assembly -nut

AND EXHAUST

to

chassis,

mount

damper

to

engine

TORQUE

mounting -bolts mounting -bolts

(special)

recoil

-"

to

side -nuts

allen

screws

bracket -nuts

mount

plate -nuts

CHART

QUANTITY

LTD

440

6 1 6 6 3

2 4 5 6 4

(CONTINUED)

SIZE

6mm 1/2 6mm 6mm 6mm

3/ 8 8mm

16

5/ 1/ 4 8mm

TORQUE

120 in.l 70 96in.lb(1.1 120 in.l 60

35 12ft 60 120 120

b (1.4

ft

Ib (9.7

b (1.4

in. Ib (0.7

ft

Ib (4.8 Ib (1.7

in. lb (0.7

in . Ib (1.4

in. Ib (1.4

kg-m)

kg-m

kg-m kg-m)

kg-m)

kg-m) kg-m)

)

CHASSIS

Bumper Bumper Bumper Bumper Fuel Outer Outer Rear Snow Passenger

trim and and to

pump

guide guide

stay

flap

clamp hood

guide

hood

hinge

pan -nuts

to

tunnel -nuts

and

brace

and

inner

to

tunnel -bolt

spacer

mounting -nut

handle

to

brace -nuts

to pan to pan -

to pan -

guide

grips -nuts

HEAT EXCHANGER AND

Heat

exchanger Radiator Radiator Radiator Heat

exchanger

duct duct duct

(radiator)

brace

to

brace

to

brace -nut cover

chaincase -bolt chassis -bolts

ENGINE GEARCASE

Gearcase

Gearcase Gearcase Gearcase

ENGINE LIQUID

Thermostat Thermostat

drain

plug -bolt

fill

plug -bolt mounting -bolts mounting -bolts

COOLING

housing housing

mounting -bolts vent

plug -bolt

nuts nuts

nuts

to

pan -nuts

DUCT

to

duct -nuts

SYSTEM

2 4 4

7

2 4 4

2

2 4

4 1/ 4

1

2

4 1/ 4

26

1 1

3

2

3

1

1/4 1/4 1/ 4 1/ 4 1/ 4

# #1

3/ 8

1/ 4

5/

1/ 4 5/

#

6mm

Bmm

6mm

Bmm

6mm

Bmm

10

16

10

70

in. Ib (0.8

70

in. Ib (0.8

70

in. Ib (0 .8

70

in. Ib (0.8

35

in. Ib (0.4

20

0

in. Ib (0 .2

20

in. Ib (0.2

19

ft Ib (2.7

50

in. Ib (0.6

120

45

in. Ib (0.5

60

in. Ib (0.7

18ft

95

in.lb

50

in. Ib (0.6

50

in. Ib (0.6

96

in. Ib (1.1

60

in. Ib (0.7

12

ft Ib (1.7

60

in. Ib (0.7

12ft

in. Ib (1.4

Ib (2.5

Ib (1.7

(1.1

kg-m) kg-m) kg-m) kg-m) kg-m) kg-m) kg-m)

kg-m)

kg-m) kg-m)

kg-m

kg-m)

kg-m

kg-m)

kg-m

kg-m)

)

1- 10 TORQUE

CHART

TORQUE

DESCRIPTION

ENGINE LUBRICATION SYSTEM

Elbow

fitting

to

oil

Oil

pump

inlet

Oil

pump

Oil

mounting -bolts

pump

outlet

CYLINDER HEAD AND CYLINDER

Carburetor Cylinder Cylinder

head mounting -bolts

CRANKCASE

Lower

crankcase

Lower

crankcase

Lower

crankcase

tank

plate

mounting -screws

nozzles

holder

to

cylinder -bolts

mounting -bolts

to

upper -bolt

to

upper -bolt

to

upper -nut

CHART

QUANTITY

LTD

440

3 4 3 3

4

12

B

1 9 4

(CONTINUED)

SIZE

-

4mm 6mm Bmm

Bmm Bmm Bmm

6mm Bmm Bmm

TORQUE

Judgement 13

in.

lb

(015

60

in. Ib (0.7

50

in. Ib (0.6

45

in. Ib

19ft

Ib (2.6

16ft

Ib (2.2

70

in. Ib 16 16ft

(O.B

ft Ib (2.2

Ib (2.2 kg-m)

(05

kg-m) kg-m) kg-m)

kg-m)

PISTON

Flywheel

AND

CRANKSHAFT

mount

ing -

RECOIL STARTER

Pawl retainer

Recoil

assembly

Starter

pulley

to

rope

mounting -bolt

to

flywheel -bolts

MAGNETO

CDI

igniter Ignition Stator

mounting

coil

mounting -screws

plate

mounting -screw

nut

reel -

bolt

1

1 3 3 6 mm

2 1/4 4

2 5 mm

1B mm

Bmm 6mm

6mm

72

ft Ib

11

ft Ib (1.6

70

in. Ib (O.B

70

in. Ib (O.B

60

in.lb

70

in. Ib (O.B

30

in . Ib

(10

(0.7 (0.35

.0

kg-m)

kg-m) kg-m)

kg-m)

GEAR

RATIO CHART 1

-11

I

I-

w

I-

""-

0

a::

w

co

2

::l

z

I

I-

w

~

u

0

a::

0-

(/)

z

w

~

x

0

36

37

38

39

*69

40

*Theoretical NOTE:

GEAR

17

2.18

*75

MPH

64 64 64 66

Red

2.

24

*73

MPH

64

Pink

2.

35

MPH

66

Pink

MPH

All

top

2.06

*79

Pink

2.

*77

Green

2.22

*73

66

Pi

at

speeds

18

MPH

11

MPH

64

MPH

nk

8,200

based

R.P.

RATIO CHART

Drive Sprocket ·

1.90

*86

Red

1.95

*84

Green

2.

*80

66

Red

2.

*77

66

Green

M.

on

.96

19

MPH

64

MPH

05 MPH

11

MPH

overdrive

Numb

*86

*84

*82

er o f Tee

20

1.80

*91 MPH

64

Pink

1.

90

MPH

66

Red

1.95 MPH

66

Pi

nk

2.

00 MPH

66

Green

in

converter

th

21 22

1.76

*93

MPH

Red

1.81

*90

MPH

66

Pink

1.86

*

88

MPH

66

Green

and

engine

1.

68

*97

MPH

66

Pink

73

1.

*94

MPH

66

Gree

n

(Standard)

RPM

at 8,200

G

ear Ratio

S

peed

Chain P

itc

ensioner Sp

ar Ratio

eed

in

Pitch

ensioner Sp

ear Rat

io

Ratio

ain Pitch

Sprin

h

ring

rin

T

Ge Sp Cha T

Gear Ra t io Speed Chain Pitch

Tensioner Spring

G

Speed

Ch ain Pitch

Tensioner Sp

Gear Speed Ch

Tensioner

.

g

Color

Black White Red Orange Pink Ye l

low

Green

Blue

CHAIN

TENSIONER

Length

2.

50

in.

(63.50

2.

50

in.

(63.50

3.

00

in.

(76.20

3.

00

in.

(76.20

3.

38

in.

(85.85

3.

38

in.

(85.85

3.

75

in.

(95.25

3.75 in. (95.

25

SPRINGS

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

0.

049

0.

055

0.

049

0.

055

0.049

0.

055

0.049 i

0.055 i

Wire

Dia.

in. (1.

245

in. (1.

397

in.

(1.245

in. (1

.397

in.

(1.245

in.

(1.397

n.

(1.245

n.

(1.397 mm)

mm) mm)

mm) mm) mm) mm) mm)

1-12 ENGINE PERFORMANCE CURVES

ENGINE PERFORMANCE CURVE

1---

f--

1--

-,-

.-

t--

t--lL

H.

P.

tJ

f-

(/) (J)

..J

"

l-

LL

W

=:l

a

a:

0

I-

40

30

20

10

f--

1----

~-.-

o

o o

cry

../

.-/.

/'

f--

~-

I'\...

1//

V

o

o o

"<t

_.-

,-

~-

17

III

IJ

//

FUEL

b'"

./

CONSUMPTION

'"

o

000000

o

000000

o

l!)

<D <D

ENGINE RPM

r

.-

V

l!)

0

I'- I'-

V

~-I--~-

TORQUE

~

l/

l!)

0

co co

1--

~

l!)

2.2

2.0

1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

a:

I

CL.

I

(/)

"

(J)

..J ..J

w

=:l

LL

I

EXHAUST

PORT

i

B

C

A = B = C = D = 1. E = F = 3. G =

PORT

TOP SURFACE OF CYLINDER

0

INTAKE

BG

1.575

in.

(40

in.

(29.7mm)

in.

(32.6mm)

in.

(50.0mm)

in.

(34.1

in.

(99.6mm)

in.

(14.6mm)

.0mm)

mm)

1.169

1.263 969

1.343 929

0.575

DIMENSIONS

1

P

OR

T j

F

H = 1.

878 in.

I =

1.878

J = 0 .

575

K =

0.650

L =

0.551 in. M=0.441 N =

0.307

(47.7mm)

in.

(47.7mm) in. (1 in. (16

(14.0mm) in.

(11.2mm) in.

(7.8mm)

4.6mm)

L K

.5m

m)

1

NOTE:

Port

width

does

not

incl

ude

the chamfer

. Port hei

ght

and

height

tocat

ion

includes

the

chamfer. Port

Chamfer

= 0.031 in.

(0.8

mm)

MAINTENANCE

MAINTENANCE 2-1

Table

Maintenance ..................

Maintenance

Chart

.....

...

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

of

. .

.........

Contents

. .

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

. .

...

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

2-2

MAINTENANCE

MAINTENANCE CHART

Operation

~

Spark Carburetor -check Throttle ,oil Enrichener F

Ignition

Drive

Plugs -replace

cable -adjust

Pump

cable -adjust

ilt

ers, fuel & oil -

timing -

belt -replace

adjustment

replace

check

Converter alignment -check Converter Converters -clean Drive

bush

converter

ing

wear -check

& i

nspect

mount

bolt

Torque Chain Chaincase Track,

tensioner

guides -check

lubricant -check

tension

& ali

gnment

check

Beginning

of

Each

Season

160

5-10

First

80

Use

to

km

Hours

Every

480

or

Hours

km

20

Use

Every

960

or

Hours

km

40

Use

Every

1450

or

Hours

60

km

Use

End

of

Each

Season

X X X X X X X X X X X X X

X

X X

X

-

X

X X X X

-

X X X

Ski

alignment -check Brake Ski skegs -check Coolant

lubricant level &

adjustmen

t -

pump/gearcase

vent

check

wear

hole

check Coolant pump/gearcase

change Fasteners -check

(Use Suspension Suspension

lubricant

torque

to r

chart as wear

strips -check

spring

cams

que

guide)

replace Headlight -adjust Coolant

level & freeze

protection -check Cylinder

Battery

Battery -charge during

head -check

electrolyte

storage

)

level -

(once a month

-

torque

check

X X

X

X X

X

X X X X

X X X X X

X

X X

Up

Tune

X

BRAKE SYSTEM

BRAKE SYSTEM 3-1

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

Brake Brake Brake Brake Brake Brake

Ad j

ustment. Pad Disassembly ... Inspection Assembly ... Pad

Brake Fixed

Brake

Pad

Wear

Replacement

Disassembly .......

Repl

Assembly

Table

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

...

........

Inspection ...

.. ..

. .

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

. . .

.......

acemen

........

. .

......

t.

.. ..

of

....

. ....

. . .... . . . .

Contents

........ ..

. .

...

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

....

. .... . .

.........

....

...........

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

......

.......

. . .

....

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

. .. . . . .

...

....

...................... 3-10

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

. . .

............. 3-4

......

. . . .... ....

. . .

. ....

...

. . . .

. .

.....

....

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

...

. .

.. ..

. .

........

..........

.....

......

. .

......... 3-10

....

. . .

...

33-3

.

3-4 3-6 3-6

3-10 3-10

1

3-2

BRAKE SYSTEM

BRAKE

1 BOLT, 2 BRACKET, 3 SPACER, 4 RIVET 5 PAD 6 CALIPER 7 NUT, insert, 8 SPRING, pad return 9 PAD,

10

RING

3/8-24 x 2.00

brake

caliper

3/8-24

movable

cable

11

RING, retaining 1 2 SHAFT, 13

STATOR

14

PLUG,

15

SCREW,

16

SPRING, torsion

17

BALL

18

ROTOR

19

BEARING,

20

WASHER,

brake

friction

thrust

plug

21-

21

DISC ASSY, 22 WASHER, 23

LEVER, 24

RING, 25

PIN, 26 PIN, 27 RETAINER, 28

SPRING, 29

GUARD,

brake

snap

clevis

hair

brake

special

clevis

brake

neoprene

return

disc

BRAKE SYSTEM

3-3

BRAKE

Braking

a

mechanically

and

hub

assembly ment) on men t

the jacksha

between movement vehicle

Brake

I

WARNING

...,.

____

ing

operation which

Adjustment

to

possible

snowmobile

This

model

disc

brake.

1.

Apply

lever

movement

than

3/4 i

action

is

operated

float

the

may

cause a rattling

Ilmproper

.. _ may

personal

or

its

components.

is

equipped

To

check

the

brake

n.

(19mm).

applied

to

the

caliper. The

(free

left

ft

to

mainta

brake caliper

is

norma

brake

cause

brake

injury

with a self-adjusting

for

proper

firmly

which

and

should

brake

disc

brake

to right

in

proper

sound

pads

move. This

dur

l.

adjustment failure

and

damage

adjustment:

measure

be

no

greater

disc

ali

gn-

ing

lead-

the

by

to

If n

ecessary,

1.

Back bracket

1. Brake Cable Bracket.

2.

Upper

3.

4.

5.

Jam

Lower

Jam Adjusting Brake Lever

both br

about 1/

Nut. Nut.

Screw

adju

ake

st brake

cable

as

jam

follow

nuts awa

4 in. (6.4 mm).

s:

y from

1.

2.

3/4

in.

(19

Release tance

.

•

This

1/8

in. (3.2 mm).

mm)

Brake

the

brake

dimension

Applied.

handle

should

and

be

measure

no

greater

dis-

than

2.

Remove cable slac

• Pull

bra brake cam lever to brac

3. Turn bot

4. Ch

ec

h jam

ket.

low

er jam

nuts to

k hand

dimension

5. Ap

ply

brake

until

correct

mm) at bra

k .

ke

cable

and snug

nut

up

50 in.lb (0.6 kg-m).

leb

ar

brake lever

with

brake

firmly

and

measurement

ke

lever

upward

to

bracket

released.

turn

is

achieved.

without

upper

and

for

manual

of

3/4

moving

jam

nut

torque

correct

adjuster

in.

(19

1.

1/8

in.

(3.2

mm)

Brake

Released

NOTE increases men decreases

.

6. Perform

: Cl

ockwise rotation

the ha

ndleb

t, a nd count

the m

easu

Brake

e r -

rement.

Pad

of

ar

brak

clockwi

Wear

th e

adjuster

e lever meas

se

rotati

Inspection.

screw

ure

o n

-

3-4

BRAKE SYSTEM

Brake

1.

Pad

Wear

Measure movable

•

Apply Measure pad

• face

114 in.

(6.4

brake

of

brake

mm)

Minimum

Inspection

firmly

pad tab to

2. If measurement is l replace

both

brake

• Refer to Brake Pad

ur

e.

ced

brake

pad

.

thickness

.

ess

than

pads.

Replacement

thickness.

from

outer

brake

disc

11

4 in. (6.4 mm)

.

sur-

pro-

3.

Unfasten remove

1.

Speedometer

2.

Key

.

3.

Chaincase

4. Drain

speedometer

key

.

Adapter.

Cover.

chaincase

• Place oil drain pan pan .

•

Unscrew

chaincase

and remove

5.

Unhook

cha

in

lubricant.

cover

.

tensioner

drive adapter

under

hole in low

mounting

spring .

and

er

bolts

Brake NOTE: Before di

brake, Pad Wear

1. Remove

Disassembly

sass

embling

check

Refer to Battery Removal procedur

•

brake

Inspection

batt

ery (e

pad

wear

procedure

lectric

self

. Refer to Brake

.

start

2. Remove lower battery bracket.

• Unfasten

1.

Lower

Battery

mounting

Bracket

bolts.

adjusting

mod els only).

e.

1.

Top Sprocket

2.

Chain

.

Tensioner

3.

4.

Lower

Sprocket.

6.

Remove

• Unfasten

•

Pu

ll spr

space

7. Remove

•

Refer to

8. Remove

• Refer to Be

.

Spring

.

upper

sprocke

ocke

rs found

air

silencer

Silencer

drive

sprocket

and

space

t bolt.

ts

off shaft

behind

and

sproc

.

Removal procedure.

belt.

lt

Removal procedure.

ket.

r.

slide

off

9.

Unfasten le

provide

removal.

1.

Trim

.

ft

side

clearance

trim from lower pan to

for driven

converter

1.

Return

2.

Retainer

3.

Brake

4.

Brake

5.

Brake

Spring

. Cable. Cable Lever

.

Bracket.

.

BRAKE

SYSTEM

3-5

10

. Remove

• Unfasten

•

Slide enough to remov e

1.

Bearing

2.

Beariri

3.

O-Ring.

4.

Bearing.

5.

Bearing

Cap

'g R

Cap

brake

jack

jackshaft

Nut.

etainer:

.

disc.

shaft bearing retainer cap.

out

of

chaincase

brake

disc.

far

12. Unbolt

•

13

. Remove movable pad.

caliper

Remove

brake

spacer, and

from

disc

• Place a rag

1.

2.

Top Peg.

brake should

•

Unhook chaincase

Brake

mechanism

be

dropped

movable

pegs and remove pad .

Pad

Spring

chaincase.

cable

guard.

behind

to

.

brake

.

bracket, cal

chaincase

catch

pad

parts

springs

iper

under

if

they

from

11. Disconnect Unhook

•

• Pull

• Remove

•

Unf

brake

hair

pin from

clevis

aste n jam

cable

.

return

spring

clevis pin.

pin.

nut

s and remove

bracket.

.

cable

from

14. Remove

• Unfasten

•

Slide

NOTE

: Be

balls

when removing se

1

5.

Remove self-adj

• As

an

chaincase

16

. Slide

thrust

rotor.

brake

lever and

careful

lever and neoprene washer.

snap

ring.

washer

from rotor shaft.

not to lose the three steel

lf-adjusting

usting

mechanism .

mechanism.

assembly, push mec hanism

.

bearing and

thrust

washer

out

off

of of

3-6

BRAKE

1.

Thrust

Washer Thrust Rotor Brake

tator.

Steel

Bearing.

.

Shaft.

Ball.

2.

3.

4.

5. S

6.

17. Separate

18.

stator Remove

and

• Remove

SYSTEM

.

rotor

shaft.

brake

shaft

retaining

and

thr

from stator. ring

ee

stee

s from

l balls from

shaft.

• Remove

•

1.

Stator.

2.

Friction

3. Set

•

Thread

Plug.

Screw.

Use a scr push

friction

set

shaft

ibe

screw

from stator.

out

of

stator

or

another suitable

plug

out

of

(LH

stato

thread).

tool

r.

to

1.

Stator.

2.

Torsion

3.

Brake

4. Retaining

Shaft.

• Remove turning springs.

1.

Torsion

2.

Brake

3.

Shaft.

Stator.

Springs.

Rings

as

Springs.

.

torsion

shown.

springs

Be

careful

from

not

shaft by to

distort

Brake

I

....

action

Inspection

WARN

____

will

ING

I

Do

...

solvent,

be

impaired

1. Clean all metal

2.

3.

4.

5.

6.

Inspect thrust

• If replace

Check

• If ball and

Inspect

• If

Examine

• If

Check

•

If

steel

washer

any

parts

them.

stator

pockets

rotor.

brake

threads

tors

springs

brake

pads

are

set.

• If

movable in . (6.3 mm) metal

back

Brake

1.

Assembly

Thread

•

Screw thirds

stator

of

brake

tor.

not

subject

oil,

or

by

oily

parts

in cl

eaning

balls,

thrust

.

show pitting

and

rotor

.

are

worn, replace

shaft.

damaged, replace

ion

spr

ings.

distorted, replace

pad

wear.

worn

unevenly,

pad

measures

overa

ll

thickness

ing),

replace

onto

brake

until

shaft

shaft.

approximately

extends

brake

grease.

or

pads Braking

greasy

pads.

solvent.

bearing, and

or discoloration

stator

shaft.

them.

replace

less

than 0.25

(including

pad

set.

two-

through

to

,

pad

sta-

BRAKE

SYSTEM 3-7

NOTE:

I

WARNING

'"-

installation braking.

2.

Parts have LH thread .

_____

Position torsion

• Eyes on end of

ITorsion

.installed

of

springs

spring

brake

shaft.

springs

as

will

ends

shown.

result

on

brake

must

Incorrect

in

loss

be

of

shaft.

face slotted

1.

Ring

(Full

2. Ri

ng

NOTE:

(C-

Type).

Brake

Circle).

shaft

turning

to the operation of the

i~m.

If set

self

adjust. If set

screw

is too loose, the

screw

not release properly,

brake

overheating

and the

on.

resistance

self-adjusting

brake

is too tight, the

which

will

brake

result

light

is

critica

mechan-

will not

brake

in the

staying

l

will

1.

Brake

Shaft

2.

Torsion

Slot.

Spring

3. Test torsion and tension.

1.

Spr

ings

2.

Springs

Turn. Won't

Turn

"Eyes".

springs

.

for

correct

installation

5. Install

Use one

set screw.

• Torque

• Turn set tion turn.

1.

Tighten

2.

Stator

.

friction

of

the

set

plug

follow

screw

and set

ing

to

1.9

methods

or

screw

in until it bottoms on

plug, then tighten an

DO

NOT overtighten set screw.

1/8

Turn.

screw

in.lb.

additional

into stator.

to

adjust

fric

1/8

-

• Hold

• Turn torsion

brake

shaft

springs

1. The torsion

in vice.

by hand in

springs

shaft.

•

Attempt

tion

to turn

2.

If torsion springs will turn, replace

springs

them.

4.

Position rings on

• Install full

•

Slide

C-type

circle

ring

brake

ring first.

into

shaft.

groove on shaft.

direction

should turn on

by

hand in

direc-

6.

Test for

•

proper Temporarily without

the steel

set

screw

install

balls

torque.

rotor on

.

• While holding the stator, turn rotor

alternating

• When shaft screw

directions.

turning

must

the rotor in

not turn. If the

is too loose.

direction

shaft

brake

turns, set

shaft,

in

1,

the

3-S BRAKE SYSTEM

1.

Shaft

Must

Not

Turn

2.

3.

4.

5.

Shaft Stator Rotor. Brake

Must .

Shaft

Turn.

.

1.

2.

Brake Pad

Pad

Radius.

.

• When shaft the set

turning

must

screw

• If nece ssary, above requirements.

Slide rotor

7.

S.

Thread

9.

Lubricate

•

Lightly

off

stator

rotor and stator.

coat

grease.

10. Position steel

11.

Mount

•

rotor

Guide

torsion

• Turn rotor of

ball

pockets

NOTE:

beneath the

catch

12. Position

Place a rag

any

parts

• Align

brake

rotor/stator

tabs

case.

•

Slide

rotor/stator

the rotor in

turn. If the

is too tight. adjust

of

brake

complete

ball

balls

in

onto

stator

spring

until

balls

.

behind

mounting

that

may

on stator

assembly

direction

shaft

does not turn,

set

screw

2, the

to meet

shaft. ly

onto

brake

shaft.

pockets

stator

assemb

with

ball

pockets

ly.

lithium

.

tab into slot of rotor.

fit

into

deepest

the

chaincase

part

area. The rag wil l

drop

during

assembly

assemb ly in chaincase.

with

slots in

into pl

chain-

ace

.

1.

Return

Spring

.

14. Install neoprene

washer, brake

lever, and

snap ring.

• Note

correct

position

of

brake

lever.

, .

1.

Chaincase Slot

2.

Stator

Tabs

13. Assemble movable

s

.

brake

pad and

as shown.

springs

1.

Neoprene

2.

Brake

3.

Snap

15.

Mount cable

•

16

. Install bear ing retainer

17.

Slide jackshaft

•

• Position

•

Washer.

Lever

Ring

.

brake

bracket

Torque

Apply disc

splines

Slide

jackshaft

.

caliper, caliper

, and

bolts to

through

coat

ing of NEVER-SEEZ to

.

brake

• Fit bear in g retainer bearing retainer.

disc

35

disc

into

ft

O-ring

between

posit

O-ring

spacer, brake

guard to

cha

Ib (4.S kg-m).

on bearing.

disc

into chai

brake

ion.

into

groove of

incase.

ncase

brake

pads.

.

1.

Bearing

2.

Bearing

3.

O-Ring

4.

Bear

Bearing

5.

18. In

Cap

.

ing

.

stall top

•

Torque

(6.9 kg-m

Nut

Retainer.

Cap

.

sprocke

sprocket bolt

).

t and spacer.

to

50

ft Ib

1.

Chaincase

2. Sight

3.

4.

I

.....

reduce plug

Gauge. Speedome Drive

Adapter.

WARNING

____

braking

with

disc.

Fill

Plug.

ter

Key.

Iprevent

••

vent

brake

actio

hole

BRAKE

oil

mist

components,

n,

by

installing

pointed

away

SYSTEM

from

coating

which

from

3-9

may

the

brake

fill

1.

Top Sprocket Chain.

2.

3.

Tensioner

4.

Lower

Sprocket

19.

Mount

• Fit

O-r

•

Torque

20. Install l 21

. In

stall tensioner retainers. Mount

22.

• Use new

•

Torque

23. Add

chaincase lubr

• Use Dexron fluid .

•

Add center

.

Spring

.

jackshaft

ing into

nuts

to

eft

side

trim on lower pan.

chaincase

O-ring

bol ts

to

lubricant

and top of

bearing retainer cap.

cap

groove.

70

in. Ib (0.8 kg-m).

spring

and

hair

cover.

sea

l.

70

in. Ib (0.8 kg-m).

icant.

II

automatic

until level is

sight

transmission

between

gauge.

24. Insert cover square

NOTE: within

speedometer hole

hole in lower

Speedometer

chaincase rotated when sprocke

25.

t mount bo lt.

Connect

• Hold drive on cha

• Inse rt end of adapter.

• Slid e

not use f components adapter

26.

Mount

brake

• Thread one l

• Insert

• Install

I

WARNING

,

____

pin,

and

clevis

27.

Install

clevi s

retainer.

•

Mount is toward

• Insert clevis.

• Install

while

rotating key to align with

key

cover

proper

ly

speedometer

adapte

inca

se cover.

of

flexible

adapter

into position on cover.

orce

during

are

will

slide

cab

le in

ock

nut

cable

through bracket.

seco

nd lo

cknu

I

To

avoid

••

function,

retainer

pin, hair

clevis

retainer

chaincase

clevis

hair

pin from

pin in

key

through

sprocke

should be

hole and

chaincase

t mount bolt.

centered

cannot

engaged with lower

drive

r near

key

adapter

mounting

into

.

threads

square

assembly. When

properly

easily

brake

onto

into

cable.

position

cable

aligned,

bracket.

t on cable.

possible

install as

follows:

so

brake

clevis

pin,

and

that slott

pin,

clevis

ed side

.

clevis

chaincase

pin.

side

be

hole

Do

.

mal

hair

-

of

3-10

1.

2.

3.

28.

BRAKE SYSTEM

Retainer Hair

Clevis

.

Pin.

Mount

•

Secure

heat

ware installed in

.

lower

shield

batt

battery

brack

ery bracke

bracket

et

with

sequence

t. to footrest

mounting

shown .

and

hard-

FIXED PAD REPLACEMENT

1. Drill

1.

Fixed

2. Rivet.

2.

3.

out

brake

• Use a 5

Brake

Position new

pad rivet.

/32

in. (4 mm) drill.

Pad.

brake

Rive t new pad to ca

• Use a

drift

to s

upport

pad on

liper

rivet.

• Spread the rivet

with

caliper

as shown.

.

the head of a new

a punch.

29.

Install battery.

• Refer to Battery Install ation procedure.

Brake

I

~

require replace braking

Pad

WARN

____

Replacement

ING

IThe

._

pads

replacement

brake

pads

action.

fixed

have

at

the

as a set

and

been

same

movable

designed time.

to

insure

BRAKE PAD DISASSEMBLY

1.

Refer to Brake

• Perform

Disassembly

steps 1 thr

procedure.

ough 13.

brake

to

Always

good

1. Rivet.

BRAKE PAD ASSEMBLY

1.

Refer to Brake

• Perform

Assembly

steps

13

procedure.

through 29.

CABLES

BRAKE CABLE 4-1

Brake

Enrichener

Oil

Thrott

Cable ... Brake Brake Brake

Enrichener Enrichener Enrichener Enrichener

Pump

Cable ...

Oil

Pump Cable Oil Pump Oil

Pump Oil Pump Cable

le

Cable .........

Throttle Throttle Throttle Throttle

Table

...

. ..... .. . . .

Cable Cab le Cable Insta lla tion

Removal .... ..

Inspection

Cab le . . .. . .. .

Cable Cable

Cable Inspection ... .. .

Cable

.......

Cable Cable

Cable Cable Cable Cable

Adjustment Remova l .

Inspection .......

Installation

.......

Adjustment. Removal . .

Installation

......

Adjustment ....

Removal ......

Inspection

Installation ....

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

of Contents

...

.......

. .

.....

...

......

.....

....

. ......

.....

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

.....

......

.....

.. ..

..........

. .....

...

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

......

. ..

...

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

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

.......

. . .

......

...... .

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

...

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

. ..

.........

. ..

...........

...

.............................. 4-7

..

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

. .

....

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

......

....

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

.. ..

.......

....

.....

. ..

....

. .. . . . .... .

......

. ....

......

.......

........

. ..

..

................ 4-5

.

......

...

. .....

......

.

............... 4-7

.......

......

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

.........

...

..

...

.

....

..

....

. ......

..

....... 4-4

....

. .

.. .. .. 4-4

.......

. .. . ..... .. 4-5

..........

......

...........

..... ......

. .

. . .....

....... 4-6

. 4- 1

..

4-3 4-3 4-3 4-3 4-3

4-4

..

4-5

. . 4-6

4-6

. .

4-6 4-7

4-2 BRAKE CABLE

CABLES

3

~

I

4

1

I

©J

6

I

/

r

9

r

9

)0

10

1 NUT, 2 3 CABLE, 4 CABLE, LH 5 NUT, 6 7 CABLE,

enrichener

HOUSING ASSY,

RH

carb

RING,

special

snap

jam

throttle

mounting.

enrichener

8 CABLE, oil

9 PIN, 10 11 12 13

hair

PIN,

cable

CABLE ASSY,

NUT, jam, BAND,

pump

5/16-24

cable

brake

tie

BRAKE

Brake

1.

Separate

• Remove

• Slide cl

•

Unhook

2.

Unscrew

3.

Disconnect

•

Remove

•

Unhook

CABLE

Cable

Removal

cable

end from clevis retainer.

hair

pin.

evis

pin out.

cab

le end from

locknuts

cable

snap

cab

from cable.

end from brake lever.

ring.

le end from lever.

clevis

retainer.

2.

Mount

cable

• Thread

• Insert

• Install

I

WARNING

L,.

____

pin,

3.

and

Connect

•

...

clevis retainer

Mount

is toward

• Insert clevis.

• Install

4.

Check

cable

• Cable handl eba r in

• Be certain bends

•

Secure prevent may lead to malfun

5.

Adjust

brake.

• Refer to Brake

ENRICHENER

ENRICHENER CABLE

in

brake

one

locknut

cable

through bracket.

second

ITO

function,

clevis

locknut

avoid

assembly.

retainer so that slotted side

chaincase

clevis

hair

pin from

pin in

routing.

must

apply

any

cable

or

kinks.

cable

with tie

chafing

Adjustment

CABLE

cable

onto

bracket.

cable.

on cable.

possible

install

as

follows:

brake

clevis

maI-

pin,

.

clevis

chaincase

pin.

side

and return freely with

steering position.

casing

of

outer

ction

bands

.

has no

sharp

as needed to

cas in

g,

which

procedure.

4-3

hair

of

•

1.

Snap

2.

4.

Ring.

Cable

End.

Note routing snowmobile

Brake

1.

Cable

Check

• Cable not,

2.

Inspect

• If there are replace

3.

Examine

• If

protective

is kinked,

Brake

Cable

1. Attach Hook

•

• Insta ll

.

Inspection

cable

operation.

should

replace

cable

any

cable.

cable

replace

Installation

cable

to

cab

le end

snap

of

cable

move freely

cable.

ends

.

signs of fraying

casing.

coating

is damaged

cable.

brake

lever.

onto

brake

ring.

and remove from

within

casing. If

or

kinking,

or

casing

lever.

Enrichener

1.

Check

•

Cable

enrichener

Set

enrichener lever

(down).

•

Slide

boot

• Cable mm)

casing

free

shown.

1.

Boot.

2.

Free

3.

4.

2.

Movement

Adjuster Lock

.

Nut.

If necessary,

•

Loosen

• Turn

adjuster

free movement.

• Tighten locknut.

3.

Reposition boot prevent

enr

foreign

ichener

Adjustment

up

cab

should

movement

.

adjust

locknut.

to

over

system .

cab

le free movement.

in

off

le, off of adjuster.

have

1/16

when

enrichener

obtain

enr

ich

material

1/16

ener

from

cab

in. (1.5 mm)

adjuster

position

in. (1.5

raised

le.

entering

as

to

Kawasaki LTD 440 Shop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual