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Quick Reference Guide
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SECTION
" ....... .. ...... .... .... .. ................................... "... .. .. ........................... . S peci"f"Icatlons
Maintenance and Theory ........................................................................... .
Repair ...................................................................... .................................. .... .
Appendix ............................................ ......... ..................... .. ............. .. .......... .. .
Using the quick reference guide will assist you in quickly locating a desired topic or procedure contained with in this shop manual. Bend the pages back until you match the desired section above with the black tab on the right hand side of the table of contents for that section. Refer to the table of contents for the exact page(s) to locate the spec ific topic or procedure required.
QUICK REFERENCE GUIDE
ii
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,
Specifications Table of Contents Page Genera I Specifications . . . . . Service Specifications . .. .. Torque Chart. . . . . . . . . . . Gear Ratio Chart .. . . . . . . Port Dimensions. . . . . . . . . Engine Performance Curves .
. . . . . . . . . . . . . . .. 1-2 .. . . . . . . . . . . . , . . 1-5 . . . . . . . . . . . . . . .. 1-7 . . . . . . . . . . . . . . . . 1-10 . . . . . . . . . . . . . . .. 1-11 .. . . . . . . . ... . ... 1-12
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SPECIFICATIONS
1 -1
General Specifications MODEL SA340
SB440
SC340
GENERAL Overall Length .. .. .. . ... . . Overall Width . . . . . . . . . . . .. Overall Height ... . . ... .... Dry Weight (Approximate) ... .
101 in. (2565 mm) 35.5 in . (902 mm) 39.5 in. (1003 mm) 370 Ib (168 kg)
101 in. (2565 mm) 35.5 in. (902 mm) 39.5 in. (1003 mm) 375 Ib (170 kg)
101 in. (2565 mm) 35.5 in . (902 mm) 33 in . (838 mm) 3651b (166 kg)
Type T A 440 B-C20 1 26.6 c.i. (436 cc) 2.677 x 2.362 in. (68 x 60 mm) 2 6600 to 6800 RPM 2500 RPM Manual rewind (Electric option)
Type TB 340 A-A201 20.7 c.i. (338 cc) 2.362 x 2.362 in . (60 x 60 mm) 2 5800 to 6000 RPM 2000 RPM Manual rewind
Capacitor Discharge NGK BZ-9EV
Capacitor Discharge NGK BZ-8ESA
Mikuni VM 32 Econo Jet 32/170 Open Vent 200 None 6FL14-3 0- 6 0.079 in . (2.0 mm) 30 0.055 in. (1.4 mm) 0.031 in. (0.8 mm) 1.5 Turns 0.047 in. (1.2 mm) 0.059 in. (1.5 mm) Special Cable, Dual Position 90 Round Reverse Type
Mikuni VM 32 Econo Jet 32/1 66 Open Vent 250 0.0028 in. (0.7 mm) 6FL 14-3 0- 6 0.079 in. (2.0 mm) 30 0.055 in. (1.4 mm) 0.031 in. (0.8 mm) 1.5 Turns 0.047 in. (1.2 mm) 0.059 in . (1.5 mm) Special Cable, Dual Position 100 Round Reverse Type
Mikuni VM 28 Zinc 28/344 Open Vent 180 None 5DP7 -3 0.098 in. (2.5 mm) 30 0.055 in . (1.4 mm) 0.031 in. (0.8 mm) 1.0 Turns 0.047 in. (1.2 mm) 0.059 in. (1.5 mm) Standard Cab le, Dual Position None
17 teeth 38 teeth 2.24 to 1 90 pitch Se lf Adjusting Green
2 1 teeth 38 teeth 1.81 to 1 92 pitch Se lf Adjusting Green
17 teeth 38 teeth 2.24 to 1 90 pitch Self Adjusting Green
,.
ENGINE Model ..... ..... .... .... Type T A 340 A · D201 Displacement ...... . ...... 20.7 c.i. (338 cc) Bore x Stroke . . . . . . . . . . . . . 2.362 x 2.362 in. (60 x 60 mm) Number of Cylinders .. ...... 2 Engine RPM at Full Throttle . . . 6300 to 6500 RPM Engine RPM at Idle Speed .... 2000 RPM Starter . . . . . . . . . . . . . . . . . Manual rewind (Electric option)
IGNITION Ignition System . . ... . . . . .. Capacitor Discharge Spark Plug . . .. . . ...... . .. NGK BZ-8ESA
CARBURETOR Carburetor Make . .. . . . . . . . . Carburetor Model .... .... .. Identification Marking . . . . . . . Type of Carburetor . . . . . . . . . Main Jet . . . . . . . . . . . . . . . . Air Jet ... . . . . . . . . . . . . .. Jet Needle .. . . . . . . . . . . . . . Needle Jet . . . . . . . . . . . . . .. Throttle Valve (Cut Away) .... Pilot Jet ... .. . . . . . . . . . . . By Pass . . . . . . . . . . . ... . . . Pilot Outlet ..... . ..... . . . Air Screw . . . . . . . . . . . . . . . Float Valve Seat .. . . . . . . . . . Starter Jet . . . . . . . .. ...... Type of Float Chamber . .... . Starter System .... _ . . . . . . . Econo Jet (Power Jet) ... .. ..
P- 0
GEARING Top Sprocket . . . . . . . . . .. . . Lower Sprocket .... ..... .. Sprocket Overall Ratio ... .... Chain - (Silent Type) .... .... Drive Chain Tension ..... ... Chain Tensioner Spring Color ..
1-2
GENERAL SPECIFICATIONS
1
MODEL SC340
SB440
SA340 DRIVE CONVERTER
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Engagement Speed (approximate RPM) . . . . . . . . Drive Converter RPM . .. . . . . . Spring Part Number and Color (Standard) . . . . . . . . .. Spr ing Part Number and Color (Optional) . . . . .... .. .
3500 RPM 6300 to 6500 RPM
3800 RPM 6600 to 6800 RPM
3500 RPM 5800 to 6000 RPM
92081-3553 (Yellow)
92081-3541 (Green)
92081-3553 (Yellow)
92081-3541 (Green) 92081-3561 (Red)
92081-3553 (Yellow) 92081 -3561 (Red)
92081·3541 (Green) 92081-3561 (Red)
4.35 in. (110.4 mm) Green 4.35 in. (110.4 mm) Yellow 4.0 in. (101.6 mm) Red
4.35 in . (11 0.4 mm) Yellow 4.35 in. (110.4 mm) Green 4.0 in . (101 .6 mm) Red
Spr ing Length New with no load* ...... . . 4.35 in. (110.4 mm) Yellow 4.35 in. (110.4 mm) Green 4 .0 in. (101.6 mm) Red Number of Spring Coils (All Colors) .. .. . .. .. . ... 5 Spring Wire Diameter . ... .... 0 .187 ± 0 .005 in. (4 .7 ± 0.1 mm) Yellow 0.192 ± 0 .005 in. (4 .8 ± 0.1 mm) Green 0.176 ± 0.010 in. (4.4 ± 0.2 mm) Red Spring Rate .. . ... ... . ... . 50 in . Ib (0 .89 kg·m) Yellow 64 in. Ib (1.14 kg·m) Gree n 42 in . Ib (0.75 kg-m) Red Spr ing Compress ion .. . ..... . 155 Ib @ 1.25 in. (70.3 kg @ 31.7 mm) Yellow 1981b @ 1.25 in . (89.8 kg @ 31 .7 mm) Green 116 Ib @ 1.25 in . (52.6 kg @ 31.7 mm) Red Spring Outside D ia meter . . . .. 2.375 ±0.125 in . (60.32 ± 3 .1 7 mm) Yellow 2.375 ± 0.125 in. (60.32 ± 3.17 mm) Green 2.375 ± 0.250 in. (60.32 ± 6.3 mm) Red Weight Part Number (Standard) ..... . .... . ... 13042-3502 Ramp Part Number . . .. . . ... 49092-3502 Weight - Total gram weight (Standard) . ... . . .. ... . ... 35.748 grams Weight Markings . .. .. . . .. .. 0146-106
5
5
0.192 ± 0 .005 in . (4.8 ± 0.1 mm) Green 0. 187 ± 0.005 in. (4.7±0.1 mm) Ye ll ow 0.176 ± 0.010 in. (4.4 ± 0.2 mm) Red 64 in . lb (1 .14 kg-m) Green 50 in . Ib (0.89 kg·m) Yellow 42 in . Ib (0.75 kg-m) Red 198 Ib @ 1.25 in. (89.8 kg @ 31.7 mm) Green 1551b @ 1.25 in. (70 .3 kg @ 31.7 mm) Yellow 116 Ib @ 1.25 in. (52.6 kg @ 31.7 mm) Red 2.375 ± 0.125 in . (60.32 ± 3.17 mm) Green 2.375 ± 0.125 in. (60.32 ± 3.17 mm) Yellow 2 .375 ± 0.250 in. (60.32 ± 6.3 mm) Red
0.187 ±0.005 in . (4.7 ± 0.1 mm) Yellow 0.192 ± 0.005 in . (4.8 ± 0.1 mm) Green 0.176 ± 0.0 10in. (4.4 ± 0.2 mm) Red 50 in. Ib (0 .89 kg-m) Yellow 64 in.lb (1.14 kg-m) Green 42 in. Ib (0.75 kg-m) Red 155 Ib @ 1.25 in. (70.3 kg @ 31.7 mm) Yellow 1981b @ 1.25 in. (89.8 kg @ 31.7 mm) Green 116Ib@1.25in. (52.6 kg @ 31.7 mm) Red 2.375 in. ± 0.125 in. (60.32 ± 3.17 mm) Yellow 2.375 ± 0.125 in. (60.32 ± 3.17 mm) Green 2.375 ± 0.250 in. (60.32 ± 6.3 mm) Red
13042-3501 49092-3502
13042-3502 49092-3502
47 .148 grams 0146-1 05
35.748 grams 0146-106
* After approximately 50 miles, the spring will take a set and lose 0.25 (1 /4) of an inch of its total length. No sign ificant loss of spring compression will occur because of the decreased spring length.
GENERAL SPECIFICATIONS
1-3
Optional Weights Part Number
Color
Markings
Gram Weight
13042-3509 13042-3506 13042-3508 13042-3503 13042-3502 13042-3505 13042-3507 13042-3501 13042-3504 050803 050841
Ye llow Black White Black Red Black Yellow Black Red Green White
0146-108 0 146-135 0146-107 0146-279 0146-106 0146-278 0146-123 0146-105 0146-286 0146-136 0146-104
3.058 4.479 4.958 5.457 5.958 6.475 6.992 7. 858 8.800 9.279 9.750
DRIVEN CONVERTER Cam Angle . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Part Number ... . ... . ..... . ... ... Spring Color . . . . . . . . . . . . . . . . . . . . . . . . . Spring Length - New with no load .. .... ... . . Spring Diameter . . . ... .... .. . . . . . ... . .. Spring Wire Diam eter . . . . . . . . . . . . . . . . . . . Spring Pre load - Counterclockw ise . . . . . . . . . . .
. . . . . ..... . . . . . . .... . .. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 0 ... ... .. ... . . . . . . . . . . . . . . . . . . . . . . . 92081 -3535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Black . . ... . . . . . . . . . . .. .. . .. .. . .... . 4 .2 in . (1 07 mm) ... . . . . . . .. . . . . . . . ... . .. .. . 2.880 in . (7 3.15 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.155 in. (3 .94 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ho le - 120 0
BELT Part Number ...... . .. . .... ... . . . . . . . . . . . . . . .. . . ..... .. . . . . ...... . .... .. ... .. 59011-3503 Outside Circu mferen ce .... . . ... ..... . . . . . . . . . . . . . . . . . . . . .. ...... 43.5 ± 0.19 in. (11 04.9 ± 4.8 mm ) Width - Top surface .. .. .. ..... . .. . . . . . . . . . . . . . . . . ..... 1.25 + 0.06 - 0.00 in . (31.7 + 1.55 - 0.00 mm) Thickness - Top of belt to bottom of lug ... . . . . . . . . . . . . . . . . . . .. . .. ... ... 0 .56 ± 0.03 in. (14.2 ± 0.8 mm) Belt Taper An gle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 0 BRAKE Brake Pad replacement required when threads protrud ing through adjusting nut exceed . . . . . . . . . 7/16 in . (11.1 mm) TRACK AND SUSPENS ION Track Type .... . .... ... . .. . . . . . . . . . . . .. .. ... . . .. . . . . . . . . . . . . . . . . . Rubber (Interna l Drive Lug) Track Width . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .... . .. . ... . ...... ... ... 15 in. (381 mm) Track Length . . . . . . . . . .. . . . . . . . . . . . . . . . .. .... . . . . . . . . .... . ..... . ... ... 116 in . (2946.4 mm) Suspe nsion . . ..... .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . .. .. ...... . . . . . . . . . . . . Sli de ra il FUEL/OI L Gasoline . .. . . . . . . . . . . . . . . . . . . . . . Oil .... . ...... .. . . . . . . . . . . . . . . Gasoline / Oil Ratio . . . . . . . . . . . . . . . . . Fuel Tank Capacity ..... ...... . .. ..
1-4
GENERAL SPECIFICATIONS
.. . . Premium or regular leaded (minimum pump posted octane number 89) . .... . . ... ...... . Kawasaki Snowmob il e Oil (B . I.A. certified T.C.w.) (40 to 1) 1 quart (0.946 liters) of oil to 6.25 gallons (23.6 liters) of gasoline . . . . . . . . . . . . . . .... . . . . . . . . . .... . .... . . 9 ga ll ons (34 Iliters)
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MODEL SA340 SB440
SC340
ElECTR ICAl COMPONENTS Type ..... . . . . . . . . . . . . . . . . . . . ...... ... ...... . 12 VAC, 120 W Headlight Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92069·3501 12 V. 60/ 60 W Tail / Brake light . .. .. . . . .... . .. . . . . . . . . . . . . . . . .. G.E.1157 Instrument lights . . ...... . . . . . . . . . ..... . ..... .. . G.E.1816
12 VAC, 120 W 92069·3506, G.E. 4492 G.E.1157 G.E . 1816 (Opt ional)
FRAME Frame ... . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum alloy and HSlA steel construction
Aluminum alloy and HSlA st eel construction
Service Specifications MODEL SA340
SB440
SC340
ENGINE 6.9 to 1 0.008 in. (0.19 mm) 0.008 in. (0 .19 mm) 0.006to 0.014 in . (0.15 to 0.35 mm) Piston Ring End Gap (Bottom) . .. 0.006 to 0.014 in . (0.15 to 0.35 mm) Piston Ski rt Clearance . . . . . . . . . 0.001 to 0.003 in. (0.03 to 0 .06 mm) Connecting Rod Radial Play .. . . . 0.0008 to 0.0012 in. (0.021 to 0.031 mm) 0.016 to 0.020 in. Connecting Rod Side Clearance (004 to 0.5 mm) Connecting Rod Small End Diameter . ..... . . ... . . . . . . 0.787 to 0.789 in. (20.00 to 20.05 mm) Crankshaft End Play (Max) . .... . 0.030 in. (0.77 mm) Crankshaft Run Out (M ax ) .... . . 0.002 in . (TIR) (0 .05 mm) Effect ive Compression Ratio . ... Top Ring/Groove Clearance . . .. Bottom Ring/Groove Clearance . . Piston Ring End Gap (Top) . ... .
. . . .
7.3 to 1 0.009 in. (0.22 mm) 0.008 in. (0.19 mm) 0.008 to 0.0 16 in. (0 .2 to 004 mm) 0.008 to 0.016 in. (0.2 to 0.4 mm) 0.002 to 0.004 in . (0.05 to 0.10 mm) 0 .0008 to 0.0012 in. (0.021 to 0 .031 mm) 0.016 to 0.020 in . (004 to 0.5 mm)
6.9 to 1 0.009 in . (0.22 mm) 0.008 in. (0.19 mm) 0.011 to 0.019 in. (0.28 to 0.48 mm) 0.011 to 0.019 in. (0.28 to 0.48 mm) 0.002 to 0.004 in. (0.06to 0.10 mm) 0.0008 to 0.0012 in. (0.021 to 0.031 mm) 0.016 to 0.020 in. (004 to 0.5 mm)
0.787 to 0.789 in. (20 .00 to 20.05 mm) 0.019 in. (0.048 mm) 0.002 in. (TIR) (0.05 mm)
0.787 to 0.789 in. (20 .00 to 20.05 mm) 0 .030 in. (0.77 mm) 0.002 in . (TIR) (0.05 mm)
0.024 in . (0 .6 mm) 180 @ 6500 RPM 0.073 in. (1 .86 mm)
0.032 in. (0.8 mm) 22 0 @ 6000 RPM 0.108 in. (2.75 mm)
IGNITION Spark Plug Gap .... . . . .... ... 0.032 in. (0.8 mm) Ignition T iming (Dynamic) . . . . . . 22 0 @ 6500 RPM Ignition Timing (BTDC) . ... .. . . 0.108 in. (2.75 mm)
SERVICE SPECIFICATIONS
1-5
MAGNETO RESISTANCE TESTS (SA340, SC340) Item
Ohmmeter Leads Connected Between
Lighting Co il Exciter Coil Pulser Co il
Resistance 0.18 ohm ± 20% 160 ohms ± 20% 17 ohms ± 20%
Yellow-Yellow Red -Ground Red-White
..
IGNITION COIL RESISTANCE TESTS* (SA340, SC340) Item
Ohmmeter Lead s Connected Betwee n
Resistance
Secondary winding
High Tension-High Tension
5,700 ohms ± 15%
MAGNETO COIL RESISTANCE TESTS (S8440) Item
Ohmmeter Leads Connected Between
Lighting Co il Exciter Coi I Pu lser Coil
Resistance 0.18 ohm ± 20% 128 ohms ± 20% 23 ohms ± 20%
Yellow-Yellow Red-Ground Red-White
IGNITION COIL RESISTANCE TESTS* (S8440) Item
Ohmmete r Leads Connected Between
Resistance
Primary winding Secondary winding
Blue-Ground High Tension-H igh Tension
0.37 ohm ± 20% 10,200 ohms ± 20%
*N OTE: Defective coils cannot always be detected using this test alone . Use of a coil tester which simulates operating conditions is the recommended test method.
CARBURETOR Air Screw Sett ing . . .... .... .... . .... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... _ 1.5 turns off seat (SC340, 1.0 turn off seat) Idle Screw Sett ing ... .. .. .. .. . . ..... . . . .. . . . . . . . . . . . . . . . . . . . . . 6 turns open from coil bound-initial (SA340, 2000 RPM-final) (SB440, 2500 RPM-final) (SC340, 2000 RPM-fina l ) CHASSIS Converter Offset Distance . . . . . .. . . . ... .. . . . . . . . . . . ... . . . .. ..... . . . . . . . .. .. 0.454 in . (11.5 mm) Converter Center D istance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .... .... .. . . .. .. . . 10.3 in. (262 mm) Drive Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Self Adjusting Brake Adjustment r equi red when lever movement exceeds . .... . . . . . . . . . . . . . . . . . .. . . . . . . . 3/ 4 in. (19 mm) T rack Tension ... . ...... . .... . . . . . . . . . . 3/4 in. (19 mm) maximum deflection - 5 to 8 Ibs (2.2 to 3.6 kg) pull Steering Alignment . . . . . . . . . . . .. . ..... . . ... ... . ..... . .. . . . .. Sk is parallel or 1/ 8 in. (3.1 mm) toe out Tie Rod End Adjustment Stud Jam Nut Dimension . . . . . . . . .. ... . . . . . . . . . . . . .. 1-1/4 in. (32 mm) maximum GENERAL ENGINE TORQUE SPEC IFICATIONS Cy linder Head Bo lts . .. . Crankcase Bolts and Nuts Flywheel Nut . . . . . . . . Recoil Bolt .. . . . . . . . . Spark Plug ... . ... . . .
1-6
.. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ... . . . . . . . . . . . ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERV IC E SPEC I FICATIO NS
. . . . . . .. . .
. . .. . . . . . .
. . . . 16 ft .... 16 ft . . .. 60 ft . ... 50 in. . . . . 20 ft
Ib Ib Ib Ib Ib
(2 .2 (2.2 (8.3 (0.6 (2.7
kg-m) kg-m) kg-m) kg-m) kg-m)
Torque Chart Descr iption
Quantity
Torque
Size
CONTROLS AND CAB L ES
•
Brake cable lock nuts Brake lever set screw Enrichenercable ja m nut Enrichener mounting nut Ignition switch face nut T hrottle cable jam nut
2 1 1 1 1 1
5 / 16
- -5 /1 6
-- -- 6mm
50 in. Ib (0 .6 25 in. Ib (0.3 20 in . Ib (0.2 Hand tighten Hand tighten 20 in . Ib (0.2
kg-m) kg-m) kg -m)
kg-m)
HOOD Hinge to hood - nuts Rubber retainer to hood - nuts Windshield to hood - screws special
4 4 8
-- -
25 in. Ib (0.3 kg-m ) Compress rubber 1/2 15 in. Ib (0 .2 kg-m)
4 2 2 4 2 1 1 2
1/4 5 /16 3/8 3 /8 3 /8 3/8 3 /8 5/16
105 in. Ib (1.2 kg-m) 18 ft Ib (2 .6 kg-m) 30 ft Ib (3 .9 kg-m) 120 in . Ib (1.4 kg-m) 30 ft Ib (3.9 kg -m) 15 ft Ib (1.9 kg -m) 15 ft Ib (1.9 kg-m) 18 ft Ib (2.5 kg-m)
2 2 6 2 4 2 2
3 /8 3/8 5 /16 3 /8 3/8 3 /8 3/8
30 30 18 30 45 25 30
3/8 1/4 5 / 16 3 /8 3 /8 1/4 5 /16 3 /8 3 /8
30 ft Ib (3.9 kg-m) 100 in. Ib (1.1 kg-m) 45 in . Ib (0 .6 kg -m) 15 ft Ib (1.9 kg-m) 30 ft Ib (3.9 kg-m) 15 ft Ib (1.9 kg-m) 100 in. Ib (1.1 kg -m) 15 ft Ib (1.9 kg-m) 25 ft Ib (3.5 kg-m) 20 ft Ib (2.8 kg-m)
1/4 #10
100 in. Ib (1.1 kg -m) 90 in . Ib (1.0 kg -m)
1/4 1/4
STEERING Handle bar to steering pole - screws, socket head Lower steering mount to front frame - bolts Steering arms to spindle - nuts Tie rod jam nuts Tie rod to steering arm - nuts Tie rod to steering pole - nut Tie rod to steering pole - thin nut Upper steering mount to steering mount - nuts SKI AND SP INDL E Shock absorber to ski - nuts Shock absorber to spindle - nuts Skeg to ski - nuts Ski saddle to sp indle - nuts Ski spring to sadd le - nuts Ski spring to ski, front - nuts Sk i spring to ski, rear - nuts
ft Ib (3.9 kg-m) ft Ib (3 .9 kg-m) ft Ib (2.5 kg -m) ft Ib (3.9 kg-m) ft Ib (5.7 kg -m) in. Ib (0.3 kg -m) ft Ib (3 .9 kg-m)
SUSPENSION Front idler wheels to bracket - bolts Hi-fax to suspension rail - bolts, special Limiter strap to front swing arm - nuts Rear arm idler wheel mount - bolts Rear axle lock ing - bolts Shock absorber mount - nuts Suspension brackets to rail - nuts Suspension swing arm to bracket - nuts Swing arm pivot shafts to tunnel - bolts Track ten sion adjusting bolt jam nuts
2 2 2 2 2 2 20 4 4 2
---
DRIVE SHAFT Bear ing housing to tunnel - nuts Drive shaft locking collar - screws, socket head
3 2
TORQUE CHART
1-7
Description
Quantity
Size
Torque
CHAINCASE Adaptor hole cap to chainca se cover Bearing support jam nut Bearing support to converter shaft - bolt Chaincase cover to chaincase - bolts Chaincase plugs Chaincase to front frame - nuts Lower sprocket to driveshaft - bolt, special Speedometer drive adaptor to ch aincase cover Tensioner arm to chaincase - bolts Top sprocket to converter shaft - bolt
- --
1/4 511 6
Hand tighten 95 in. Ib (1 .0 kg-m) 25 ft Ib (3 .5 kg-m) 50 in. Ib (0.6 kg-m) Judgement 28 ft Ib (3.9 kg-m) 35 ft Ib (4.8 kg-m) 120 in.lb (1.4 kg-m) 70 in. Ib (0.8 kg-m) 25 ft Ib (3.5 kg-m)
2 3 2
5/16 1/4 1/4
25 ft Ib (3.5 kg-m) 95 in. Ib (1 .0 kg-m) 100 in.lb (1.1 kg-m)
3
5/ 16
17 ft Ib (2.4 kg-m)
1 3 3 3 3
1/2 #8 # 10 # 10 #10
60 30 48 48 48
6 8 4 1 2 4 4 2 2
1/4 1/ 4 1/4 #10 1/4 5/ 16 1/4 1/ 4 1/4
100 in. Ib (1.1 kg-m) 100 in. Ib (1.1 kg-m) 100 in. Ib (1.1 kg-m) 20 in . Ib (0.2 kg-m) 100 in. Ib (1.1 kg-m) 120 in. Ib (1.4 kg-m) 100 in. Ib (1.1 kg-m) 35 in. Ib (0.4 kg -m) 35 in. Ib (0.4 kg-m)
1 1 1
- --- ---
Judgement Judgement 40 in. Ib (0.5 kg-m)
4 4
3/8 1/2
30 ft Ib (3 .9 kg-m) 30 ft Ib (3 .9 kg-m)
1 1 1 5 2 4 1 1 2 1
1/4 5/1 6 1/4 -
--
5/1 6
- -- --
BRAKE AND DR IV EN CONVERTER Brake ca liper to bracket - nuts Brake disc to fixed sheave - screws, sock et head Brake support bracket to chaincase - nuts DRIVE CONVERTER Bearing housing to movable sheave - screws, socket head Converter to engine crankshaft - bolt Ramp to movable sheave - screws, soc ket head Roller bearing to spider - nuts, flexlock Spider assembly set screws Spider set screw jam nuts
ft Ib (8.3 kg-m) in. Ib (0.4 kg-m) in. Ib (0.6 kg -m) in . Ib (0 .6 kg-m) in . Ib (0.6 kg-m)
CHASSIS AND SEAT Bumper to nose pan - nuts Hood guide to nose pan - nuts Hood hinge to nose pan - nuts Hood lanyard to front frame - nut Nose pan brace to front frame - nuts Passenger handle to tunnel - nuts Rear bumper to tunnel - nuts Seat to chassis, front - screws Seat to chassis, rear - bolts FU E L SYSTEM Fuel tank pick-up fitting Fuel tank vent fitting Primer pump mount - nut ENGINE MOUNT AND EXHAUST Engine mount plate to front frame - nuts Engine to engine mount plate - bolts
1-8
TORQU E CHART
.
Description
Quantity
Size
Torque
2 4 1 4 2 2 3
# 10 6 mm 14 m m 6 mm 6 mm B mm 6m m
30 in . Ib (0.3 kg-m) Impa ct driver 47 ft Ib (5.S kg-m) 70 in . Ib (O .S kg-m) I mpact driver I mpact driver I mpact driver
2 S 4 4 2
Smm Sm m Smm 6mm
- --
40 in . Ib (0.6 kg-m) 16 ft Ib (2.2 kg-m) 12 ft Ib (1.7 kg-m) 72 in. Ib (O.S kg-m) 20 ft Ib (2. 7 kg-m)
2 2 1 10 4
B mm B mm 6 mm Bmm Bm m
100 in . Ib (1 .1 kg -m) 100 in. Ib (1.1 kg-m) 16 ft Ib (2.2 kg-m) 16 ft Ib (2.2 kg-m) 100 in . Ib (1 .1 kg -m)
3 3 1 3
6 mm 6m m B mm 6mm
60 in. Ib (0.7 kg -m) 60 in. Ib (0.7 kg -m) 120 in . Ib (1.4 kg-m) 60 in. Ib (0.7 kg-m)
2 1 2 1 2 2 2 2 2
6mm 4m m 6 mm 6m m 6 mm 5mm 5 mm 5 mm 6mm
70 in . Ib (O.S kg-m) I mpact driver 70 in . Ib (O.S kg -m) 70 in. Ib (O .S kg -m) 70 in . Ib (O.S kg-m) I mpact driver Impact driver 70 in . Ib (O.B kg-m) 70 in. Ib (O.S kg -m)
2 2 2 1
# 10 #S 1/4 1/4
10 in. Ib (0.1 kg-m) 10 in . Ib (0.1 kg-m) 50 in . Ib (0 .6 kg-m) 100 in . Ib (1.1 kg-m)
ENGINE AIR SHROUD AND FAN CASE Engine air duct to main shroud - nuts Exhaust shroud to main shroud - screws Fan pulley to fan - nut Fan screen to fan housing - screws Intake shrouds to cylinders - screws Main shroud to cylinder head - screws Main shroud to fan housing - screws CYLINDER HEAD AND CYLINDER Carburetor holder to manifold - bolts Cylinder head to cylinder - nuts Exhaust manifold to cylinders - nuts Intake manifold to cylinders - bolts Spark plug to cylinder head CRANKSHAFT AND CRANKCASE Hole cover to crankcase - bolts Hole cover to cranKcase - nuts Lower crankcase boss to upper - bolt Lower crankcase to upper crankcase - bolts Magneto cover to crankcase - nuts RECOIL STARTER Recoil case to fan housing - bolts Reco i l case to magneto cover - bolts Recoil rope reel to recoil case - nut Starter pulley to flywheel - bolts MAGNETO AND CDI SYSTEM CDI igniter to fan housing - screws Coil wire clamp to stator - screw Ignition coil to fan housing - screws Igniter harness clamp to main shroud - screw Igniter to magneto cover - screws Lighting coil to stator plate - screws Pulser coil to stator plate - screws Stator assembly to magneto cover - screws Wiring harness connector to magneto cover - screw INSTRUMENTS, LIGHTS AND WIRING Tail lamp housing to seat - nuts Taillight lens to tail lamp body - screws Voltage regu lator mount, SC340 only - nuts Voltage regulator to upper steering mount - nut
NOTE: Locktite formulas are selected on the basis of the diameter of the fa stener, and th e strength of the bond required. Generally, No. 222 is used on fasteners up to 5/16 in. (S mm) diameter. If a particularly stro ng bond is required , or the fastener diameter is greater than 5/ 16 in. (S mml, No. 242 is specified. Loct ite may signif icantly in crease the torque necessary to remove a fastener. Be careful when applying extra force as this risks damaging th e parts. Use only the specified form ula on each fastener requiring Loctite . Loctite No. 222 and No. 242 are ind ustria l d es ignations. The con sumer equi valent which may be substituted is Loctite "Lock' n Seal,".l:lroduct number 21 , blue.
TORQUE CHART
1-9
Gear Ratio Chart
Drive Sprocket - Number of Teeth 17
36
2.18 * 53 to 60 MPH 90 Red
I
I-
UJ UJ
37
lLL
0
a:
18
19
2.00 *57 to 65 MPH 90 Red
1.89 *61 to 69 MPH 90 Pink
20
21
22 1.64 *70 to 79 MPH 92 Red
2.06 * 56 to 63 MPH 90 Green
1.76 *65 to 74 MPH 92 Red
1.68 * 68 to 77 MPH 92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring Gear Ratio Speed Chain Pitch Tensioner Spring
UJ
al
:2:
::)
z
2.24 * 51 to 58 MPH 90 Green
38
IUJ ~
U
1.90 *60 to 68 MPH 92 Red
0
1.81 *63 to 72 MPH 92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring
STD SB440
a:
a...
CJ)
Z UJ
2.05 * 56 to 63 MPH 92 Red
39
>
a: 0
2.22 *52 to 58 MPH 92 Pink
40
1.95 *59 to 67 MPH 92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring
2.11 *54 to 61 MPH 92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring
*Theoretical MPH at 6000 to 6800 RPM. NOTE: All top speeds based on 1: 1 converter ratio and engine RPM at 6000 to 6800 RPM.
CHAIN TENSIONER SPRINGS Color Red Orange Pink Yellow Green Blue
1-10
GEAR RATIO CHART
Wire Dia. 3.00 3.00 3.38 3.38 3.75 3.75
in. in. in. in. in. in.
(76 .20 (76.20 (85 .85 (85.85 (95.25 (95.25
mm) mm) mm) mm) mm) mm)
0.049 0.055 0.049 0.049 0.049 0.055
in. in. in. in . in. in.
(1.245 (1.397 (1 .245 (1.245 (1.245 (1.397
mm) mm) mm) mm) mm) mm)
Port Dimensions CYLI NDER TOP
r
B
H
- A ------l
c
EXHAUST
PORT
1
SA340 A = 1.41 7 in. B = 1.515 in . C = 0 .925 in. 0 = 1.614 in. E = 1.082 in . F = 3.720 in. G = 0.555 in. H = 1.9 25 in. I = 1.925 in. J = 0.555 in . K = 0.641 in . L = 0.885 in .
(36mm ) (38.5 mm) (23.5 mm) (41 mm) (27.5 mm) (94 .5 mm) (1 4 .1 mm) (48.9 mm) (48.9 mm) (14.1 mm) (16.3 mm) (22.5 mm)
I
:y,:=: : POR~Tr1-
F
I
l
~
I
D
-h'::=TRA==N •
~
I
8Gl
LL
r--L--K -
SC340
SB440 A = 1.575 in. B = 1.358 in . C = 1.063 in. 0 = 1.890 in. E = 1.1 46 in . F = 3.764 in . G = 0.516in. H = 1.906 in. I = 1.906 in. J = 0.516 in. K = 0.787 in. L = 0.787 in .
(40.0 (34.5 (27.0 (48.0 (29.1 (95.6 (13.1 (48.4 (48.4 (13.1 (20.0 (20 .0
mm) mm) mm) mm) mm) mm) mm) mm) mm) mm) mm) mm)
A= B= C= 0= E= F = G= H= I = J = K= L =
1.417 1.51 5 0.925 1.61 4 1.082 3.720 0.555 1.925 1.925 0.555 0.630 0.945
in. in . in. in . in. in. in. in . in. in. in . in.
(36mm ) (38.5 mm) (23 .5 mm) (41 mm) (27.5 mm) (94.5 mm) (14.1 mm) (48.9 mm) (48 .9 mm) (14.1 mm) (16.0 mm) (24.0 mm)
NOTE: Port width does not include the cha mfer. Port height and height location includes the chamfer. Po rt cha mfer = 0.039 in. (1 mm)
PORT DIMENSIONS
1-11
Engine Performance Curves SA340
--1 -- -1- --1-1-
-
I
40 en
co
HORSEPOWER
....J ;::: 30
V
LL W
::l
a
TORQUY
I-
/ L ...........
~ 20
l-//V
10 ~
~ 2.0
r
1.8 a: 1.6 I 1.4 ~
..........
""'-...
""
1.2 tn 1.0 co
V
r--
08 ....J . ....J 0 .6 w 0.4 ~
~
0.2
o o
o
0000000 0000000
C"'l
'<t
o
L!)OL!)O L!) L!) (0
'<t
L!)O
(0
r--
ENGINE RPM
SC340
S8440
--
-
-- -
--1-- -1-1- -1-1-
-1-!-I-
-
-
I
HORSEPOWER
V"f\
40 en
V
co
....J
---l-
30
d
./ ............
/'
10
\
40
"-
f Vjr!
::l
I-
V
TORQUE ~ J/
LL W
a: 20 0
/
~
~
/'
/'
1.6 ~
j
1.4 ~
V
t--
20
1.2 tn d 1.0 ~ a: o 0_8....J I0.6 ~ 0.4 LL
TORQ~
LL
W ::l
I---b.Z ./ ~
10
-
HORSEPOWER
~
/
t7'
1/
-
~~
2.0 1.8 a: 1.6 ~
1\
1.2 tn
../
o o o
o o
C"'l
C"'l
ENG IN E RPM
ENGINE PERFORMANCE CURVES
1.4
0000000 0000000
o
'<t
L!)OlnOL!)O '<t In L!) (0 (0 r--
ENGINE RPM
I
1.0 ~
0.8 ....J 0.6 w 0.4 ~
0.2
0.2
o
1-12
en
co 2.0 ~ 1.8 a: l- 30
Maintenance and Theory
Table of Contents Page Maintenance Chart ... .... ......... ..... .... .. .... .... ... .. ... . 2-3 Lubrication Chart .... .................... ... .. .. .. .. .... .. ...... 2 -4 Engine Theory of Operation .............. .. .. .. ..... ... . 2-5 Carburetor Theory of Operation .. .... ... .... .. ..... 2-1 2 Ignition System Theory of Operation .... .. ..... ..... .. ................ .... ...... ... ... .. ... 2-22 Electrical System Theory of Operation ........ .. ......... .. .. .. ......... .. .. ......... ... .. ... 2-24 Converter Theory of Operation .... .. .... .......... .. 2-26 Track, Suspension, and Steering Operation ... ... .. ..... .. ..... ............... .. ....... ... .. .... .. 2 -27 Engine Inspection ... .. ... .. .... .................. ........ .... 2 -28 Fuel System ..... ... .. .. ... .. ......... ..... .... .. ... ............. 2-29 Ignition System ...... .. ........ .. ........... .. .. .. .... .. .... ... 2 -32 Electrical System .. .... ... .. ...... ................... ..... .... 2-36 Converter Alignment .. ....... ...... .............. ...... .. .. 2-38 Brake .. .. ... ....... .. .. .................. ... ....... .. .... .... ... .. .... 2-42 Cha in Tension .... ...... ..... ............ .. .. ... .. ........... ... 2 -43 Gear Ratio Chart .......... ....... ... .. .. ..... .... ..... ... .. .. 2-44 Steering System .... ..... .... .......... .. ..... ....... .. .... ... 2-45 Suspension Adjustments ...... ... ... .... .. ... .... .. ... .. 2-46 Track Adjustments .. .. .. .......... .. ......... .... ...... ...... 2 -47 Storage ......... ... .. .... ..... .... .... ..... .. ..... ....... .. .. .... .... 2-49
MAINTENANCE AND THEORY
2 -1
.\
Maintenance Chart
~ Operation
Beginning of Each Season
First Ev ery Every Every 50 -100 Miles or 300 Miles 600 Miles 900 Miles End of Page 5 -10 Hours or 20 or 40 or 60 Each ReferUse Hours Use Hours U se Hours Use Season ence x
Install new spark plugs
x
Check carbu retor adjustment
x
x
Check throttle cable adjustment
x
x
2-35 2-29
Replace fuel filter
x
2-31
x
2-29 x
De-carbon engine and exhaust Check axial fan belt
x
2-34
x
x
2-32
x
Check ignition timing Replace drive belt (be sure converter sheaves are clean and dry)
x
Check drive converter and driven converter alignment
x
3 -65
x
2-40
x
x
x
Check drive converter for wear Clean and inspect drive and driven converters
x
Check drive chain tensioner gu ides
x
Adju st track tension and check al ignment
x
Check ski alignment
x
Adjust brake
x
2-43
2-47 2-45
x x
3-83
2 -41
x
x
2-38
2-42
x
Check fasteners for security (use torque chart as a guide)
x
Inspect ski skegs for wear
x
x
2-46
Measure wear of slide rail wear strips
x
x
3 -96
Adjust headl ight
x
x
1-7
2-36
MAINTENANCE CHART
2-3
Lubrication Chart Lubrication Point CONTROL CABLES Inner cab les
Lubricant LPS, WD-40, Dr i-Slide or simil ar low temperature lubricant.
Frequency
Illustration
(
Once a season and every 20 hours of operation.
\
~~
~ Ij/;=~ /~
. ~ .,
DRIVEN CONVERTER Ramp sliding surfaces
Low temperature grease.
Once a season and every 20 hours of operation .
CHAINCASE HOUSING
Kawasaki Chain Lubricant.
Check level every 20 hours of operation.
2-4
LUBRICATION CHART
~
.,~
,
Engine Theory of Operation Introduction to Two-Stroke Engines All internal combustion engines are cha racterized by a four part cycle of operation. The four parts are: 1. Intake, 2. Compression, 3. Combustion, and 4. Exhaust. A fuel / air mixture must be drawn into the engine, compressed, burned, and exhausted. A two-stroke engine uses only two strokes to accomplish all four parts. Each of the four parts can be easily understood by following the path of the fuel / air mixture through the engine. (See Figure 2 -1.) 1. Intake: On the upstroke of the piston a charge of fuel mixed with air is drawn into the engine through an open port in the cylinder. 2. Compression: Near the bottom of the down stroke, the intake port is closed, and the piston starts back up. This upstroke compresses the fuel / air mixture to a fraction of its former volume.
3 . Combustion : When the mixture has been compressed, it is ignited and forces the piston down. This is called the power stroke. 4 . Exhaust: After the power stroke, the burned gases exit through the now open exhaust port, and the cycle is ready to start again. The piston is carried through each step from one power stroke to the next by the rotating inertia of the crankshaft. The intake of a two-stroke engine is perhaps the most complex part of the cycle. After the fuel and air have been mixed in the carburetor, it is drawn into the crankcase . As the piston rises, a hole in the cylinder wall (the intake port) is uncovered by the lower edge of the piston. The rising piston effectively increases the volume of the crankcase, drawing in the mixture. On its return trip, the piston blocks the intake port and lightly compresses the mixture in the crankcase. At about 55°-600 BBDC (before bottom dead center), the upper edge of the piston uncovers ports in the cylinder wall that are connected to the crankcase . The mixture in the crankcase, under pressure, ru shes through these transfer ports into the cyliner.
Figure 2-1
ENGINE THEORY OF OPERATION
2-5
There are two sepa rate intake actions: th e first into the crankcase, and the second into the cylinder. In two -stroke terminology, only the first intake action is called the intake; the second is ca ll ed the tran sfer or scavenging flow. The word scavenge is used because the new mixture flowing into the cylinder helps to clean the exhaust out of the combustion chamber. After the piston passes BOC (bottom dead center) it rises, closing the transfer and exhaust ports, and opening the intake agai n. The mixture trapped above the piston is compressed as the piston nears TOC (top dead center), the spark pi ug is fired and the mixture starts burning. The piston is driven downward by the combust ion until the exhaust port is uncovered by the upper edge of the piston. The two-stroke engine goes through all four basic parts in just two strokes of the piston, and one complete rotation of the crankshaft.
Intake A two-stroke engine's intake tract starts with the carburetor. To get the mixture into the crankcase , there must be an opening from the crankcase to the carbur etor bore. The intake timing is symmetrical, it opens and closes the same number of degrees on either side of TOC. (See Figure 2-2.)
TYPICAL PISTON VALVE ENGINE TOC
76° ATOC
89° ABOC
89° BBOC
The fuel / air mixture in the intake tract has inertia, and takes a certain amount of time to get into the crankcase. The sooner the intake is opened, the more time there is to draw the mixture into the crankcase. If the intake is opened too soon, the crankcase pressure will be higher than atmospheric and the mixture will flow in the wrong direction. The transfers generally close at around 60 0 ABOC, which is the same as 1200 BTOC. It would seem ideal to open the intake at about 115 0 BTOC, just after the transfer ports close . However, on a piston port engine this would require the intake to remain open until 115 0 ATOC as well, and all the crankcase pressure meant to transfer the mixture to the cylinder would be lost back out the open intake.
Transfer Transfer ports are designed to move the fuel / air mixture from the crankcase to the cylinder, and to scavenge the exhaust from the cylinder. Because the exhaust port opens before the transfers do, the exhaust gases are already traveling in the right direction . As th e pressure in the cylinder drops, the exhaust will no longer flow of its own accord . The transfer ports aim the incoming fuel/air mixture in such a way that it will sweep throughout the cyl inder, pushing the exhaust gases toward the exhaust port. The size and shape of the transfer ports are important for efficient scaveng ing . If they are too small, the transfer flow will be restricted. If the port is too large, the flow speed will drop . The lack of inertia of the gases will affect the direction of the flow after it leaves the port, resulting in poor scavenging. The transfer port passage is part of the crankcase volume. The larger the passage, the lower the crankcase pressure. Timing of the transfer ports runs from about 60 0 BBOC to about 600 ABOC. The transfer ports cannot open until after the exhaust does or the exhaust would flow into the crankcase. This would mix the new charge and the exhaust, resulting in less power (or none at all). Transfer port timing is symmetrica l about BOC. The closing point of the transfer port is important to good cylinder filling. If open too long, some of the mixture will flow back into the crankcase.
Compression BOC
Figure 2-2
2 -6
ENGINE THEORY OF OPERATION
Compression occurs as the piston on its upstroke closes the intake and exhaust ports and compresses the fuel/air mixture in the cy linder to a fraction of its original volume. To achieve com pression of any kind, the cylinder must be mechanically sealed .
•
The cylinder head, in most engines, is separate from the cylinder itself. The joining surface between the head and the cylinder is sealed against both compression and combustion by the head gasket. This gasket must be capable of withstanding high temperatures and pressures. Some head gaskets are simply a sheet of copper or aluminum. Others are a sandwich of copper and asbestos sheets. The head must be fastened tightly to the cylinder, squeezing the head gasket with just the right amount of force to keep it from leaking. FLAT The piston is a close fit in the cylinder bore, but the final seal is made by piston rings. These are steel alloy rings which circle the piston in grooves and press outward against the cylinder wall to prevent leakage of compression or combustion past the piston. The piston rings must withstand high temperatures and pressures without deforming while rubbing constantly up and down on the cylinder wall.
Most engines have one or two compression sealing piston rings. Their job is to seal the gap between the piston and cylinder .
RINGS
KEYSTONE RINGS
"DYKES" RING
Figure 2-3
The compress i on ratio may be measured in two different ways . The entire cylinder displacement from BDC to TDC may be used, or just the displacement above the exhaust port. Kawasaki two-stroke engi nes are generally rated by the second method. As an example, imagine the engine in Figure 2-4 with a 60 mm stroke. Its displacement can be figured as shown.
New piston rings must be "broken in." The new rings do not conform exactly to tiny irregularities of the cylinder wall , but they gradually wear to fit. This initial wear is the break-in period.
The cross-section of a ring is an important part of its design. Rings having a rectangular crosssection are called flat rings . The groove for this type of ring has parallel walls . Another type of ring has a wedge-shaped cross-section. (See Figure 23.) This type of ring is called a keystone ring and its groove has nonparallel walls. The shape of the ring and its groove are designed to force the ring outward against the cylinder wall during the combustion stroke for better sealing . Keystone rings should not be installed upside down. Flat rings sometimes also have a top and bottom and should always be installed carefully following the manufacturer's instructions.
A third type of ring is the Dykes pattern ring. This ring is usually used alone on a single-ring piston. It is placed at the upper edge of the piston, so that one side of the L shape protrudes above the edge slightly. The ring is forced against the cylinder wall during the upstroke by the drag of the cylinder wall twisting the ring outward. During the combustion stroke the gas pressure on the inside of the upper leg of the L forces it out against the cylinder wall for a good seal.
o
BORE = 60 mm STROKE = 60 mm
Figure 2-4
ENGINE THEORY OF OPERATION
2-7
v=
TTr2 h
WHERE: V = displacement volume r = 11 2 bore = 30 mm or 3 em h = stroke = 60 mm or 6 em TT = 3.1 416
The further the mixture is compressed before it is burned, the hotter the combustion will be and the more heat will be produced. Greater heat means more expansion of the combustion products, and that means more horsepower for the amount of fuel used and the engine size.
V = (3 .1416) (9) (6) V = 169.6 cc or approximately 170 cc If the engine has a total combustion chamber vol. ume of 20 cc at TDC, then the compression ratio can be figured. V J +V2
R =- - -
V2 WHERE: R = compression ratio V = displacement volume = 170 cc V = volume at TDC = 20 cc 170 +20 R
Combustion Combustion is started by a spark across the electrodes of a spark plug in the combustion chamber. The spark plug receives a timed surge of highvoltage electricity to ignite the mixture at the right instant. If the ignition comes too soon the engine will try to run backward; too late and part of the power stroke will be lost. The ign ition is timed to ignite the mixture at 25° before top dead center. The reason for this lead is to start the mixture burning in time so that peak cylinder pressures will occur just after TDC at high speeds.
20 R
9.5
This is called the "th eoretical " compression ratio . However, if we measure the total volume of the cyl inder at the closing of the exhaust port instead of at BDC, the compression ratio calculations might look like these .
V =71"r 2 h WHERE: V = displacement volume above exhaust port r = 1 12 bore = 30 mm or 3 em h = distance from top of cyl inder to top of exhaust port = 40 mm or 4 em 71"=3.1416
V V R
Normal combustion is a single flame front traveling across the combustion chamber at just the right speed . There are several types of abnormal combustions and all are undesirable. The most common is detonation. Detonation sounds like a hard, metallic, hammering from the engine. The flame front travels almost instantaneously through the mixture resulting in an explosion rather than an even burning of the mixture. Detonation is related to the octane of the gasol ine used .
(3 .1416) (3)2 (4) 113.1 cc or about 113 cc
VI + V2 V2 113 + 20
R 20 R = 6 .7 This is usually called the "actual" compression ratio, and is always lower than the theoretical compression ratio.
2-8
When the spark plug fires, it ignites the mixture that is between its electrodes. That burning mixture ignites the mixture around it, and a "flame front" travels across the combustion chamber. The flame front moves across the combustion chamber, burni ng the mixture as it goes .
ENGINE THEORY OF OPERATION
The "octane" of a gasoline is a number which defines that gasol ine's burning speed under a standard set of laboratory conditions . The higher the octane, the more resistant the gasoline is to detonation. Octane ratings are assigned according to a laboratory procedure which compares a fuel's ability to resist detonation to that of a mixture of two petroleum distillate fuels . Oil companies produce gasoline to meet octane requirements by adding tetra-ethyl of lead or certain high-octane petroleum distillates . The lead in the gasoline makes it burn more slowly, thus avoiding detonation.
When the mixture burns, a chemical reaction takes place. The molecules of fuel combine with oxygen molecules of the air to produce carbon-monoxide, carbon-dioxide, wate r, traces of other various com pounds, and heat. Heat is absorbed by the engine and combustion products. Heat absorbed by the engine is wasted, but heat that goes into the combustion products increases their pressure, forcing them to expand . This expans ion is what produces the actua l power in the engine. The shape of the engine 's combustion chamber is a factor in its ab ili ty to resist detonation. A smooth chamber with few projections and irregu larities is more resistant to detonation . Chambers that induce mixture turbulence are more highly detonation resistant; and chambers with less surface area per unit of volume detonate less than others. Smoothly surfaced combust ion chambers are easily designed. Mixture turbulence can be ind uced by having a squish area: that is a part of the combustion chamber roof that comes very close to th e top of the piston (at TOC), causing the mixture to squirt out from between the piston and the chamber roof as the piston nears TOC. The shape with the lowest surface area per unit of volume is the sphere. An ideal combustion chamber would be a smoothly finished, almost spherical chamber, with a squish area around the edge. This des ign allows a smooth scaveng ing flow across the chamber, especially when scaveng ing flow is lowest. Compression ratio is important to combustion. A high compress ion ratio requires a high octane fuel to avoid detonation. A low compression engine can use a lower octane gasol ine.
should be placed near the center of the chamber so the flame front will have the shortest distance to travel to reach all points of the chamber. If the plug is on one edge of the chamber, the flame front has to travel all the way across. From the center, the flame front only has to travel half as far . Part of the combustion chamber shape is determined by the top of the piston. It becomes the bottom of the chamber at TOC. The top of the piston is generally shaped in a gentle arc to strengthen its center. Some pistons have a raised center to take up space in the combustion chamber and raise the compression ratio. As the piston is forced downward, the angularity of the connecting rod increases. The crankpin moves around its circle, away from the centerline of the cylinder and then back again. This results in the piston's being thrust against one side of the cylinder wall during combustion, and the other side during compression. The piston pin bore is slightly off-set, in the direction opposite the direction of crankpin travel near TDC. This lessens the impact of the piston's sideways motion against the cylinder wall. The piston reaches TOC slightly before the crankpin does, and piston slap at the instant of combustion is minimized. (See Figure 2-5.)
--~~
i-o_----OFFSET
The compression pressure produced by an eng ine is a more accurate measure of its res istance to detonation than its compression ratio. Compression pressure is the pressure in the combustion chamber, before ignition, produced by th e risi ng piston. Another type of abnormal combustion is preignition. If the combustion chamber becomes very hot, or a fleck of carbon on the chamber surface or on the head of the piston heats up, the mixture may be ignited before the plug fires. This starts a flame front traveling across the chamber. When the plug fires, its flame front meets the preignition flame front with a small, sharp sound . The preignition creates advanced timing, and the eng ine will soon overheat. Detonation and preignition can lead to serious engine damage . Another consideration in combustion chamber design is spark plug placement. The spark plug
Figure 2 -5
ENGINE THEORY OF OPERATION
2-9
The piston cannot be made in a perfectly cylindrica l shape or the piston would fit the cylinder only when the engine was cold, and not f it well when the engine was hot. A piston does not expand evenly as it heats up. Near the ring grooves and through the head, the piston walls are thicker for extra strength; the skirt is thin to save weight. (See Figure 2-6.) The upper part of the piston will expand more than the skirt, and must be smaller. The wall thickness near the piston pin bores is greater to handle the stresses of the reciprocating motion of the piston. The piston will expand more across the piston pi n bores and must be made with an elliptical shape . As the piston heats up, it expands into a cylindrica l shape and fits the cylinder.
The last bit of pressure in the cylinder is released into the exhaust system with the opening of the exhaust port. This forces the gases to move in the right direction. The exhaust system consists of a passage from the exhaust port through the cylinder head, an exhaust manifold, and a muffler. It removes the exhaust gases quickly and easily while reducing excessive noise.
Engine Crankcase Design Theory, function, and design of the upper portion of the engine are important, but not complete until the lower end (crankcase) functions are understood. The crankcase contains the crankshaft, and supports the main bearings. Snowmobile engines use ball bearings for the main bearings.
PISTON SHAPE (EXAGGERATED)
These ball bearing s are very strong and consist of two hardened steel races separated by a caged set of steel balls. The crankshaft is fitted to the inner race, and the crankcase carries the outer race. As the crank turns, the inner race rolls on th e balls which rol l on the outer race. The cage keeps the balls from rubbing against each other. (See Figure 2-7.)
Figure 2 -6
The crankcase is designed to totally enclose the crankshaft. In order to install and remove the crankshaft, the crankcase is split horizontally.
The rather odd shape of the piston when cold makes it important to know where to measure when checking piston to cylinder clearances. Usually the piston is measured with a micrometer across the skirt at 90 0 to the piston pin bores, about 3/16 in . (5 mm) up from the bottom edge. The other half of piston clearance is the cylinder diameter. This is measured with a dial -bore gauge (if available) at four different positions, and in two directions at each position. The cylinder is measured not only for size, but for roundness and taper.
The crankcase must be airtight and oiltight. The mating surfaces of the crankcase halves must match perfectly. A sea ling compound is used, rather than a gasket, to insure airtightness on Kawasaki two-stroke engines. The crankshaft oil seals and cylinder base gaskets have to be airtight.
Exhaust The design of the exhaust system and timing has a major effect on the characteristics of the engine. The speed range of the engine increases with the height of the exhaust port. Proportionately, th e useful power rang e of the engine decreases. The exhaust port opens and closes at about 80 0 to 90 0 BBDC. The height of the port determines its timing. The higher the exhaust port, the wider the exhaust angle.
2-10
ENGINE THEORY OF OPERATION
Figure 2-7
To achieve good crankcase compression, the crankwheels are designed to fill the crankcase as completely as possible. Between the crankwheels is the connecting rod. There is very little wasted space inside the crankcase .
¡f
The crankshaft is pressed together from separate parts. A caged needle bearing is used on the crankpin. The crankpin rolls on the needles, and the needles roll on the inside of the large end of the connecting rod. The connecting rod is located sideways, and held by two thrust washers, one on each side of the big end. The crankshaft can twist or loosen and become misaligned because it consists of separate pieces pressed together. The crankwheels must be perfectly aligned on the crankpin. (See Figure 2-8.) There is a specified side and radial clearance for the big end bearing of the connecting rod . (See Figure 2-9.)
ÂŽ RIGHT
WRONG
RIGHTW WRONG
Figure 2 -8
CONNECTING ROD (BIG END)
CRANKPIN
Engine lubrication The lubricating oil for most snowmobile engines is carried entirely in the fuel. Petroil is a mixture of gasoline and oil used as a fuel in these two-stroke engines. The term "petroi!" was probably termed by the British from the two words "petrol" for gasoline, and "oiL" Depending upon the manufacturer's recommendations, the ratio of gasoline to oil in a petroil mix can vary from 16 to 1, all the way to 40 to 1 (and some may be even higher).
Engine Cooling All snowmobile engines need to be cooled. More heat is produced by combustion than the combustion products can absorb in horsepower. This extra heat is absorbed by the piston, cylinder walls, and cylinder head. The piston is cooled by the new fuel / air mixture coming from the bottom, by the new mixture flowing across the top during the scavenging, and by contact with the cylinder walls. The piston is usually hotter than the cylinder walls or the cylinder head, and is the first component damaged by overheating. The most common form of engine damage caused by overheating is piston seizure. This is caused by the overheated piston expanding and pressing against the cylinder wall. Friction adds heat to the piston until it begins to melt. Pieces are rubbed off onto the cylinder wall and welded there by extreme heat. A piston will seize first on the exhaust side because that side runs hotter. Incorrect piston clearances and uneven cylinder expansion can also cause seizure. A mild seizure feels like a sudden loss of power. If the damage is slight, the piston can be cleaned and the cylinder bore may not be damaged. A more severe seizure may lock the engine solid. The damage from a severe seizure re quires fitting a new piston and replacing the cylinder. A severe seizure can damage the connecting rod and crankshaft. These components should always be examined for damage. The cylinder and head may be cooled by air or water. An air cooled engine has fins on the cyl inder and head which increase the area exposed to air. The more area exposed, the more heat given up. If the cooling fins or fan intake system become clogged with foreign material, the engine may overheat.
THRUST WASHERS
A+B+C+D = SIDE CLEARANCE E = RADIAL CLEARANCE
Figure 2 -9
The free air engine is cooled by air flowing over it. A fan cooled engine is cooled by a fan blowing air across the cylinders and cylinder heads. The engine does not cool as effectively at slow speeds or
ENGINE THEORY OF OPERATION
2 -11
idle. Most air cooled snowmobiles gradually overheat if they are operated very slowly or allowed to idle for extended periods of time. The average snowmobile engine contains a high percentage of lightweight aluminum components . Aluminum conducts heat very quickly. An aluminum cylinder or head will run cooler than an identical iron one. The cy linder walls cannot be bare aluminum because they would be too soft and wear quickly. Aluminum cylinders have a chrome plate lining to make them wear acceptably.
The carburetor receives the message from the rider in the form of a pull on a cable. This lifts a valve which uncovers the air passage to the engine. This valve. aided by numerous ports. passages. needles. and jets. regulates the flow of fuel and air into the engine. When the valve is lifted. a greater quantity of fuel/air mixture flows under the valve into the engine. causing it to produce more power. When the valve is lowered. less fuel/air mixture is admitted to the engine. causing it to reduce speed and power. The carburetor controls the amount of fuel / air mixture which reaches the engine. (See Figure 211.)
Carburetor Theory of Operation Introduction The mixing of fuel and air in the amounts required for efficient combust ion is the function of the carburetor. A common method for referring to carburetors is the bore or venturi size. This method is used in snowmobiles. The measurement is the diameter of the smallest part of the venturi. (See Figure 2-10.)
.........................
II
VENTURI MEASUR EMENT
1 Figure 2 - 10 The carburetor is the rider's primary control over the movement of his machine. The carburetor chooses the engine speed that will propel the machine at the desired rate. With a squeeze of the control the rider can choose a speed anywhere from a virtual crawl to flat out. The rider expects that the engine will respond instantly. anywhere within its operating range.
2-12
CARBURETOR THEORY OF OPERATION
Figure 2-11
The fuel/air ratio must be adjusted to meet the changing needs of the engine for particular con ditions of load and speed. The ideal burning ratio of fuel to air is about 1 :15 or one gram of fuel to each 15 grams of air. This is an ideal or theoretical mixing ratio, and is only achieved for a fraction of the time that the engine is running. Due to incomplete vaporization of fuel at low speeds or additional fuel required at high speeds, the actual operational fuel/air ratio is usually richer. Within the acceptable fuel/air ratios that can be burned in the engine, a balance between power and economy must be reached. The amount of air entering the engine for combustion is the limiting factor for maximum performance. To take advan tage of the limited amount of air available for combustion, it is necessary to surround each air molecule with enough fuel molecules to insure that all of the air is utilized. Maximum power is obtained by gaining maximum burning efficiency of the available air. Maximum economy is gained by surrounding each molecule of fuel with several molecules of air to insure maximum use from a given quantity of fuel. Maximum economy is maximum burning efficiency of the available fuel. Somewhere between maximum power and maximum economy is where most snowmobiles are usually ridden. The range of fuel/air ratios that the engine receives at one time or another ranges from an extremely rich 1:6 to a very lean 1: 17. (See Figure 2 - 12.) At very slow engine speeds the flow of air through the carburetor is slow and the fuel is broken up into small droplets. If the engine is cold, these droplets of fuel will not vaporize as they would in a warm engine. It is necessary to provide a very rich mixture to insure that some of the fuel will be burned.
When warmed up, the engine speed at idle is low, and air flow through the carburetor is so low that incomplete atomization of the fuel occurs . The mixture at idle is rich, about 1: 10. Under hard acceleration, when maximum power is being developed, the mixture ratio might be around 1 :12. The actual amounts of fuel and air are much greater for high power operation. This is why fuel economy drops rapidly when a snowmobile is ridden at full throttle much of the time . At cruising speeds, air flow through the carburetor is sub stantial, but the fuel is metered sparingly. This results in a slightly lean mixture. The carburetor must have the ability to meter the fuel and air for extremes of power or economy and somewhere in between. The carburetor responds to the rider's needs by supplying fuel and air to the engine in the exact quantities demanded by speed and load. Carburetor operation is based on the basic prin ciples of fluid dynamics. These principles state that when a fluid (such as air) is flowing through a tube and encounters an area of smaller diameter (known as a venturi or constriction), the fluid will undergo an increase in velocity and a decrease in pressure as it passes through the venturi. (See Figure 2- 13.)
LOW
VENTURI CONSTRUCTION
VELOCITY
I~IGH VELOCIT~I
HIGH
LOW PRESSURE
LOW VELOCITY
lI:;;ggÂŁ : 6
HIGH PRESSURE
PRESSURE
Figure 2-13 LEAN
1: 18 1: 16 1: 14
1 FUEl/AIR
1: 12 1: 10
RATIOS
1 :8 1 :6 1 :4
l
RICH
/'
V ./'
/
Figure 2-12
/
"-
"""
Air is drawn in from the air silencer into the engine. This air flows through the carburetor, both the large entry section and the smaller venturi section, with no loss. If 1000 cc of air flow past a point in the entry of the carburetor in one second, then the same amount of air (1000 cc) must flow past a point in the venturi in the same amount of time (one second). If only 900 cc could flow past the point in the venturi in one second, there would soon be a severe pressure build -up in front of the carburetor. To achieve the same flow volume, the air must flow faster through the venturi. Exactly how much faster depends on how much smaller the constriction or venturi is than the rest of the tube. The smaller the venturi, the faster the air flow.
CARBURETOR THEORY OF OPERATION
2-13
Figure 2-14 shows a carburetor with a maximum entry diameter of 41 mm and a venturi of 26 mm The venturi dimension is the size of the carburetor .
The cross-sectional area of the venturi is: A2 - 3.14 x 13 2 A2 - 3.14 x 169 A2 - 520.66 mm
41 mm
-,-- .--- --..
The ratio of A] to A 2 is: 26mm
A]
=
1319.585 520.66
=
2.53 1
or 2.53:1.
The area of the venturi is about 2-112 times less than the area of the entry. Since the velocity is inversely proportional to the area, the velocity through the venturi is about 2-112 times greater than through the entry tube.
Figure 2-14
The velocity of the air (or a single " particle" in the air) is inversely proportional to the cross-sectional area of the tube. To find the cross-sectional area of the entry and the venturi use the following equations: A] = 7Tr ]2 A2=7Tr22
Where: A] is the area of the entry A2 is the area of the venturi r] is the radius (112 of the diameter) of the entry r 2 is the radius of the venturi 77
is a con stant, 3.14
express A] and A2 in a ratio to find how much larger the entry is than the venturi .
The cross- sectional area of the entry is:
A]
3.14 x 20.5 2
A]
3.14 x 420.25
A]
1319.585 mm
2 -1 4
CARBURETOR THEORY OF OPERATION
Occurring along with the velocity increase is a drop in air pressure in the venturi region. This reduced pressure allows the air flowing through the carburetor to accelerate through the venturi section. Under average conditions, the pressure in the venturi will be approximately 60% of the pressure in the entry (which is approximately the same as atmospheric pressure).
Float Bowl The float bowl (or float chamber) is the source of fuel for all carburetor systems that mix fuel with air as it is needed by the engine. A pressure differential fuel pump supplies fuel from the fuel tank to the float bowl. The float chamber is attached to the bottom of the carburetor. The upper portion of the chamber cavity is vented to the atmosphere, so air pressure inside the bowl is the same as pressure outside the bowl. Fuel level in the float bowl is controlled by floats and a needle valve.The lower end of the needle valve rides on the float arm, and the upper end seals against the needle valve seat. When the level of fuel in the bowl drops, the floats drop slightly, and the needle valve moves down away from the seat. This allows fuel pumped from the tank by the fuel pump to flow into the bowl. As fuel enters the bowl, the floats rise, pushing the needle valve into contact with the valve seat, shutting off the flow of fuel. (See Figure 2-15.) The fuel level affects how rich or lean the engine will run throughout its entire range. The reason for this is the drop in pressure that occurs in the venturi. The float bowl is vented to the atmos phere, so there is a pressure of 14.7 psi (1.03 kgcm 2 ) pushing down on the surface of the fuel in the float bowl. When the engine is stopped, this pressure is on the surface of all the fuel in the float bowl, including the fuel inside the "feed
.
The float level is important at low speeds. If too low, the decreased pressure in the venturi would not be able to pull enough fuel up out of the bowl and into the air stream. This would cause hard starting and lean mixture ratios. If the fuel level is too high, too much fuel is pulled into the venturi and the engine would run too rich. The float level is adjusted by bending the tab. Bending the tab towards the needle valve lowers the fuel level, and bending it away from the valve raises the level. Always set the fuel level at the co rrect level.
Metering System Four separate systems meter the fuel and mix it with the air: The main system for normal running, the pilot system for low speed running, the econo jet system for additional fuel requirements during full throttle operation, and the enrichener system to assist starting a co ld engine.
FLOAT Figure 2-15 tubes" which lead into the venturi. When the engine is running, the pressure in the venturi is less, and the pressure in the feed tubes is also less. The atmospheric pressure acting on the surfa ce of the fuel in the bowl is much greater than the pressure acting on the fuel in the feed tube. Therefore, the level of fuel in the feed tube rises, push ing the fuel in the feed tube up into the venturi where it is relea sed into the air stream as tiny droplets. (See Figure 2-16 .)
..
REDUCED PRESSURE
AIRF
"
FUEL LEVEL
Figure 2-16
Metering the fuel and air in the proper amounts is performed by a number of components . Each component has a range of throttle positions in which it is effective, but the division between where one takes up and another leaves off is gradual. This "overlap" insures the transition from one range to another will be smooth. The metering components are: pilot jet, throttle valve cutaway, jet needle, needle jet, main jet, and econo jet (econo jet- SA340 and SB440 only). Figure 2-17 illustrates the overlap between the components.
Throttle Valve The amount of air entering the carburetor is determined by the throttle valve. The throttle valve rides in a closely fitting bore directly above the venturi in the carburetor body. The movement of the throttle valve is controlled by a cable and spring. In the "fully closed" position, little or no space remains under the throttle valve for the air to flow through the venturi. As the throttle valve is raised higher, more air will flow through the venturi and into the engine. When the throttle valve is in a lower posi tion, it blocks part of the venturi, and the area under the throttle valve becomes a venturi in a venturi. The size of the actual venturi or air passage changes with the position of the throttle valve. This is known as a variable venturi type. It is the most common type found on snowmobiles and is used on all Kawasakis. At lower throttle positions, the cutaway of the throttle valve affects mixture ratios. The effect of the cutaway is felt most from about 1/8 to 1/3 throttle. The higher the cutaway, the leaner the mixture will be at a constant throttle position. The higher cutaway offers less resistance to the incoming air. The fuel supply remains relatively con -
CARBURETOR THEORY OF OPERATION
2-15
THROTTLE VALVE CUTAWAY
MAXIMUM PILOT JET
I JET NEEDLE/ NEEDL E JET
MAIN JET
EFFECT
1/8
MINIMUM 0
1/ 4
3/8
1/2
3/4
FULL
THROTILE POSITION - SC340 THROTTLE VALVE CUTAWAY
MAXIMUM PILOT JET
I
JET NEEDLE/NEEDLE JET
JET EFFECT
MINIMUM
0
1/8
1/4
3/8
1/2
3/4
THROTILE POSITION - SA340 AND SB440
Figure 2 -17 stant at any constant throttle position, and the additional air results in a leaner mixture. The lower the cutaway, the greater air flow resistance, and a richer mixture. The valve cutaway provides for adjustment of the fuel/air ratio as the transition is made from idle to the full venturi action of the carburetor. (See Figure 2 -18.)
Main System The largest portion of the metering is performed by the main system. The components are: The throttle valve, jet needle, needle jet, and the main jet. As soon as there is enough air flow through the venturi to draw fuel up into the main jet/needle jet assembly, the main system takes effect. The main system components meter fuel from 1/8 throttle to full throttle. The throttle valve is part of the main system only in that it carries the jet needle.
2-16
CARBURETOR THEORY OF OPERATION
f t
CUTAWAY
Figure 2-18
FULL
The jet needle rides in the throttle valve and moves up and down with the valve. The needle itself is tapered at its lower end and has grooves at its top end. Figure 2-19 shows a typical double taper jet needle. The needle is tapered in two stages. This double taper needle is used in larger two-stroke engines. The markings on a needle indicate the length of the needle and the taper of both sections. The first number is the overall length of the needle, rounded off to the lowest 10 mm. Thus a 5 indicates that the needle is at least 50 mm but less than 60 mm in length. The letters on the needle indicate the taper of each section. The first letter stands for the taper of the top section (closest to the grooves), and the second letter stands for the bottom taper. The taper ang les are graduated in 15' (15 minute) increments with a taper of 15' indicated by the letter A. a taper of 30' indicated by the letter B and so on . A needle marked 6DH3 would be between 60 and 70 mm with a top taper of 10 and a bottom taper of 20. Refer to chart showing the taper angles of the double taper needles used by Kawasaki . Needles are sometimes referred to with another number which is not actually stamped on the needle. This number indi cates the groove in which the clip belongs. A 6DH3-3 would refer to the needle described, as well as telling that the clip should be in the third groove from the top.
The top of the needle is fastened to the throttle slide, and the tapered end extends into the needle jet. The needle jet fits in the carburetor body in the center of the venturi . Th e lower end of the needle jet is fed fuel from the float chamber by the main j et. The inside diameter of the jet is greater than the non-tapered section of the needle. The inside diameter of the needle jet used is 2.680 mm and the outside diameter of the needle is 2.512 mm. Subtracting the diameter of the needle from the diameter of the jet gives the amount of clearance between them. 2.680 mm -2.512 mm 0.168 mm The clearance is 0.168 mm . As shown in Figure 2 20, the needle blocks the jet when the throttl e valve is closed. When the valve is lifted, the needle rises out of the jet until the tapered section arrives at the upper end of the jet. The effect of the taper is to increase the clearance between the jet and the needle as the needle is lifted.
CLEARANCE
OVERALL LENGTH
FIRST TAPER
SECOND T APER
Figure 2 -19 NEEDLE TAPER ANGLES 0 0 15' {)<l 30' {)<l 45' 10 0' 10 15' F 10 30' G 10 45' H 2 0 0'
A B C 0 E
20 20 20 30 30 N 30 30 P 40
I J K L M
o
15' 30' 45' 0' 15' 30' 45' 0'
Figure 2 -20
CARBURETOR THEORY OF OPERATION
2 -17
With the throttle valve raised, fuel from the float bowl is drawn by reduced pressure, up into the jet and through the clearance area between the jet and the needle. The double taper of the needle serves to accelerate the flow rate of the fuel so the amount of fuel can keep up with increasing amount of air in higher throttle positions. Changing the position of the need le changes the amount of available fu el. The needle is moved by moving the clip up or down in the grooves on the needle. Moving the clip towards the top of the needle delays the fuel flow increase, leaning out the mixture. This is known as lowering the needle (because if the clip goes up, the needle sits lower). Raising the needle (lowering the clip) richens the mixture by advancing the fuel flow increase. (See Figure 2-21.)
LEANER
PRIMARY CHOKE
RESERVOIR
PRIMARY AIR ENTRANCE
PRIMARY NEEDLE JET
Figure 2 -22
2 GROOVE
3
4 5 RICHER
Figure 2 -21
The primary type needle j et has a reservoir which surrounds the point at which the fuel exits past the needle. This reservoir is connected by passages in the carburetor body to a very small air jet in the front (away from the engine) end of the carburetor. Air flows in this jet. through the passages and i nto the reservoir where it mixes with the fuel and is drawn into the venturi. The entrance to this passage is out at a point of near atmospheric pressure and the exit is subject to
PRIMARY CHOKE
Around 3/ 4 throttle, the clearance between the needle and the jet becomes greater than the crosssectional area of the main jet. At this po int, the fuel flow is determined by the size of the main jet. The needle jet pre-atomizes the fuel before it enters the venturi for final atomization into the engine. Fuel enters the venturi in a spray of tiny droplets rather than a flow or dribble. The atomized fuel spray is vaporized by the engine heat. The atomization of the fuel in the needle jet and venturi improves the burning efficiency of the engine. Atomization of the fuel in a snowmobile carburetor is accomplished by use of a primary type needle jet. The primary type tends to flow more fuel, allowing richer mixtures, and is used mostly on larger two -stroke engines . (See Figure 2 -22.)
2-18
CARBURETOR THEORY OF OPERATION
MAIN JET
Figure 2-23
RESERVOIR
NEEDLE JET INSIDE DIAMETERS (MM)
N
0 P Q
0
1
2
3
4
5
6
7
8
9
2.550 2.600 2 .650 2.700
2 .555 2.605 2.655 2.705
2 .560 2.610 2.660 2.710
2.565 2.615 2.665 2.715
2.570 2.620 2.670 2.720
2.575 2.625 2.675 2.725
2.580 2.630 2.680 2.730
2.585 2.635 2.685 2.735
2 .590 2.640 2.690 2.740
2 .595 2.645 2 .695 2 .745
Figure 2 -24 venturi depression. Air flow is aided by pressure differential. The size of the jet is very small, so the air arrives at the reservoir with high velocity. At the reservoir, air helps break up the drops of fuel as they leave the center metering portion of the needle jet. (See Figure 2-23.)
Main jet size is indicated by the number stamped on the jet. There are different types of main jets, each with a different numbering system . Figure 225 shows each type of jet and Figure 2 -26 compares their flow rates in cc per minute to the numbers stamped on the jets.
Surrounding two-thirds of the reservoir is a lip which extends up into the venturi in front of the needle . This lip generates turbulence which creates a greater vacuum behind the lip where the reservoir and needle are located. At high RPM, this extra vacuum effect helps pull more fuel up from the float bowl. The lip on the needle jet is known as a primary choke. The height of the primary choke determines the amount of turbulence, and the amount of extra depression at the venturi exit of the needle jet. A taller primary choke will create more turbulence and suction, leading to a richening of the mixture at higher RPM . Using a taller primary choke allows use of a smaller main jet to achieve approximately the same mixture ratio at full throttle but a decrease in fuel consumption in the medium throttle position.
Use extreme care when changing main jets. Use a replacement of the same type. Matching only the numbers can result in total confusion as to why the engine will not run properly.
AMAL
REVERSE
0.138 in . (3.5 mm) 0.256 in. (6.5) mm)
The needle jet is identified by its diameter. Figure 2-24 is a chart for identifying the Size ' of needle jets of the primary type. The last component of the main system is the main jet and the metering screw (not on all carburetors). The main jet is attached to the inside of the float bowl cover. An O-ring is used to seal the bottom of the needle jet assembly to the float cover to insure that fuel can enter the needle jet only through the main jet. The main jet meters all fuel to the main system. When the main system begins to meter fuel, the throttle valve cutaway, needle, needle jet, and main jet determine the amount of fuel that should be delivered for the amount of air entering the engine. This working relationship continues until approximately 3/4 throttle. At this point, the crosssectional area of the clearance between the needle and the needle jet becomes greater than the crosssectional area of the main jet. When this occurs, there are no restrictions to fuel flow any greater than the restrictions of the main jet; and the size of the main jet determines how much fuel will be available.
Figure 2-2 5
300~---+--~~--~--~~--4----+--~
c
~200~---4~--~~~~---+----4---~~--~ u u
#100 .#150 .#200 it 250 #300 .#350 Figure 2 -26
CARBURETOR THEORY OF OPERATION
2 -19
Econo (Power) Jet System
Pilot System (See Figure 2-27.)
The econo jet system is similar to the ma in system in that it only draws fuel when there is enough air flow through the venturi to draw fuel through the system. The fuel that passes through the system is metered by a reverse type jet. This system has the most effect during wide open throttle position when the engine is operating at engine speeds above 5000 RPM. Use of econo jet gives better engine response at high engine speeds (over 5000 RPM) and better fue l economy at lower engine speeds. At wide open throttle the main jet supplies approximately 70% of the engine fuel requirements while the econo jet supplies 30%. The econo jet stops feeding fuel below 1/2 throttle or 5000 RPM due to the reduced air flow through the carburetor bore at low throttle settings.
Fuel and air supply at low speeds and small throttle openings is controlled by the pilot system, or slow system. The pilot system consists of a series of passageways in the carburetor body, a pilot jet to meter fuel, and a pilot air screw to meter air. At low engine speed and small throttle opening the main system can not provide the proper amount of fuel or air. Fuel is drawn through the pi lot jet which protrudes into the float chamber. The pilot jet has a series of holes drilled in its body at the point where the air is introduced from the passageways. These holes allow fuel to be mixed with air before it enters the venturi through the pilot outlet. (See Figure 2-28.)
o
VENTURI THROTTLE VALVE PILOT BYPASS PI LOT OUTLET
0
[l]
PILOT JET Figure 2-28 Air for the pilot system enters from the front of the carburetor and is metered by the pilot air screw. The pilot air screw is tapered to provide a gradual increase in air flow as the screw is backed out. The taper fits in the center of a passageway, and turning the screw all the way in closes the passageway. The normal air screw setting is from 1 to 1-3/4 turns out from a lightly seated position . If the pilot mixture appears too rich, backing the air screw out further will lean the mixture . Turning the air screw in farther will cut down the amount of air supplied, resulting in a richer mixture . Adjustment of pilot mixtures can also be effected by changing pilot jets.
AIR FL
PILOT OUT LET
///
PILOT BYPASS
~ PILOT JET Figure 2 -27
2 -20
CARBURETOR THEORY OF OPERATION
At idle speeds (very low, closed throttle position) air from the air passage in the front of the carburetor is supplemented by air from the pilot bypass. At these almost closed throttle settings, air enters from the pilot air passage and the bypass. When the throttle is opened, air flow through the venturi increases, and fuel / air mixture now exits from both the outlet and the bypass, where it mixes with the air flowing through the venturi. Fuel / air mixtures metered by the pilot system are somewhat richer than mid-range, partial throttle mixtures. Low engine speed at low throttle posi tion does not promote good atomization of the fuel entering the engine.
â&#x20AC;˘
Enrichener System Starting a cold engine presents problems of low air flow and poor atomization that require a rich mixture. In a cold engine the engine parts are not hot enough to vaporize the droplets of fuel. To overcome these difficulties requires an even richer mixture than that provided by the pilot system . To provide these richer mixtures, an enrichener system is added to the carburetor. This system consists of a jet to meter the fuel, and a plunger which opens air passages from the front of the carburetor and into the venturi. The plunger is lifted by a cable. Lifting the plunger uncovers the air inlet passage and outlet to the venturi . If the throttle valve is closed, the air that goes to the engine must come through the enrichener passageways. This creates enough suction to draw fuel from the bowl into the chamber below the plunger. Here it is mixed with air from the front of the carburetor and drawn into the venturi and the engine. Atomization of fuel for enrichener mixture is aided by an emulsion tube, a long tube which protrudes into the fuel and through which the fuel is drawn. This tube has holes drilled in it, similar to the pilot jet and air bleed needle jet. These holes allow a sma ll amount of air from the float chamber to be mixed with the fuel before it enters the chamber below the enrichener plunger . The atomization of the fuel allows it to flow more easily through small passages. (See Figure 2-29.)
amount of fuel into the carburetor venturi at a point just beyond the throttle valve . (See Figure 230.) For cold starting, pump the primer 2 to 4 strokes. The amount of priming necessary will vary in accordance with temperature and atmospheric conditions. Experience will indicate the correct num ber of strokes required to start your engine. Overpriming will cause engine flooding resulting in hard starting rather than assisting during cold starting. DO NOT overprime the engine.
PRIM ER-----t---"".rc' PUMP
TO FUEL TANK /
Figure 2-30 Should the engine tend to hesitate or die after starting, additional single strokes of the hand pump will be necessary until the motor has attained suffic ient operating temperature. To operate the primer pump:
Figure 2-29
Primer System, SA340 and S 8440 The primer pump is located in the dash panel next to the key switch. This pump is used along with the enrichener for cold starts. It injects a measured
1.
Pull out on the primer knob. Outward movement of the primer shaft draws fuel from the fuel tank to fill the primer pump cavity.
2.
Push in on the primer knob. Inward movement of the primer shaft pumps fuel from pr im er to the fitti ng of each carburetor.
NOTE: Be sure the primer knob is pushed in, and contacting the body of the pump to prevent accidental siphoning of fuel through the primer pump during engine operation.
CARBURETOR THEORY OF OPERATION
2-21
Ignition System Theory of Operation SA340 and SC340 The ignition system consists of the spark plugs, a capacitor discharge ignition (COl) igniter, exciter coi l. and a pulser coil. (See Figure 2-31.) The COl magneto assembly consists of a flywheel with four magnets even ly spaced about the circumference and a stator. The stator serves as a mount for three coils. The exciter coil charges the capacitor in the COl igniter; the pulser coil signals the COl igniter to fire the spark plugs (both spark plugs fire simu ltaneously); and the lighting coil supp lies current to the lights. (See Figure 2-32.) As the flywheel rotates, an alternating current is induced in the coils mounted on the stator. The COl igniter capacitor stores the charge generated by the exciter coil. The amount of charge the exciter coil gives the capacitor effects the in tensity of the spark. Current generated by the pulser coil causes the capacitor in the COl igniter to release its stored charge to the ignition coil. The ignition coil primary induces a high voltage in the secondary winding, and causes a spark to jump across the spark plug electrodes.
1. 2. 3. 4.
Spark PI ug COl Igniter Exciter Coi I Pulser Coil
Figure 2-31
This sequence occurs twice every rotation of the flywheel.
nector which comprise the "stop" circuit. Each switch functions independently of the other and when positioned to "stop" will complete a circuit preventi ng charge of the capacitor in the COl igniter. If no charge is applied to the capac itor, there is no output from the COl igniter to ignition coil resulting in no spark at the plugs.
The pulser coil has no effect on the intensity of the spark. Its sole purpose is to signal the capacitor when to release its charge to the ignition coil. Two switches (emergency stop and key) are connected to COl igniter leads through the engine con -
COl IGNITER & IGNITION COIL WHITE
WHITE
o RED
RED EMERGENCY STOP SWITCH
STATOR ASSEMBLY WHITE
M
t= GRAY
Figure 2 -32
2-22
IGNITION SYSTEM THEORY OF OPERATION
I
S8440 The ignition system consists of the spark plugs, ignition coil, a capacitor discharge ignition (COl) igniter, exciter coil, and a pulser coil. (See Figure 2-33.) The COl magneto assembly consists of a flywheel with four magnets evenly spaced about the circumference and a stator. The stator serves as a mount for three coils. The exciter coil charges the capacitor in the COl igniter; the pulser coil signals the COl igniter to fire the spark plugs (both spark plugs fire simultaneously); and the lighting coil supplies current to the lights. (See Figure 2-34.)
As the flywheel rotates, an alternating current is induced in the coils mounted on the stator. The COl igniter capacitor stores the charge generated by the exciter coil. The amount of charge the exciter coil gives the capacitor effects the in tensity of the spark. Current generated by the pulser coil causes the capacitor in the COl igniter to release its stored charge to the ignition coil. The ignition co il pri mary induces a high voltage in the secondary winding, and causes a spark to jump across the spark pi ug electrodes. 1. Spark Plug 2. Ignition Coil 3. COl Igniter 4. Exciter Coil 5. Pulser Coil
This sequence occurs twice every rotation of the flywheel. The pulser coil has no effect on the intensity of the spark. Its sole purpose is to signal the capacitor when to release its charge to the ignition coil.
Figure 2 -33 Two switches (emergency stop and key) are connected to COl igniter leads through the engine con nector which comprise the "stop" circuit. Each switch functions independently of the other and when positioned to " stop" will complete a circuit
preventi ng charge of the capacitor in the COl igniter. If no cha rge is applied to the capacito r, there is no output from the COl igniter to ignition coil resulting in no spark at the plugs.
STATOR ASSEMBLY
Figure 2-34
IGNITION SYSTEM THEORY OF OPERATION
2-23
Electrical System Theory of Operation
The AC current from the lighting coil is routed to the voltage regulator which adjusts the flow of cur rent according to the demands of the system. Regulator operation is continuous, whenever the engine is running, and is necessary to protect the light bulbs and tachometer from extensive damage wh ich could resu lt from uncontrolled high output potenti al of the lighting coil.
The electrica l system consists of a voltage regulator, key switch, emergency stop switch, headlight dimmer switc h, brake light switch, tail / stop light, headlight, and a speedomete r and / or tachometer when app li cab le.
With the key switch in the RUN position, current from the lighting coil is routed to the regulator, key switch, tachometer, and brake light switch.
In Figures 2-35 and 2-36 schemati c diagrams for each model sho w all component s in the lighting system. Complete elect rical sc hematic diagrams for eac h model are shown in Section 4, Wiring Diagrams.
In the RU N/LIGHTS position, current is routed f rom the key switch to the instrument lights, tail light, and dimmer switch.
AC current to operate the electr ica l lighting components is generated in the lighting coi l on th e stator plate.
The dimmer switch directs current to the appropri ate head light beam or filament.
KEY SWITCH CONNECTIONS KEY SWITCH CIRCUIT COMPLETED POSITIONS BETWEEN CONTACTS MARKED "OFF" G- M "RUN/LIGHTS" B-L "RUN" NONE "ELECTRIC B-S START"
GRAY BLACK
.,.
B!1AKE LIGHT SWITCH
--L
BLUE
BLACK/YELLOW YELLOW/RED STOP-TA L LIGHT B!10WN/YELLOW
BROWN IBRAKE L1GHTJ BLACK ICOMMDN) YELLOW IT AIL LIGHT)
ENGINE MAGNETO RED/YELLOW
ACCESSORY r- - ----- - ----- -,
I I I
I
_ _ _ _ _ _ _ _LIGHT _ _ _ IL SPEEDOMETER
__ _
_
~
VOLT AGE REGULA TOR
r-- - --ACCESSORY - -- - - - -- - - ,
Z
I :
l!5
BROWN WHITE
~
: TACHOMETER LIGHT I I I
SA340 ONLY
â&#x20AC;¢
I I I I I I I I IL. _
_
_ _ __ _ _
_
__ _
_ _
_
Figure 2-35
2 -24
ELECTRICAL SY STE M THEORY OF OPERATION I
KEY SWITCH CONNECTIONS KEY SWITCH CIRCUIT COMPlETEO POSITIONS BETWEEN CaNT ACTS MARKED "OFF" G-M
EMERCEtCY STOP SWITCH ON
OFF
0
OFF
GRAY
WHITE El...ACK
~AKE
LIGHT SWITCH
-L
B-l NO'"'
B-S BlUE
Il.ACKI'fElLOW YEllOW/REO BROWNIYEllOW
g i!
~
iii
ENCINE MACNETO
REOI'fELLOW
S8440 ONLY
'----+-1+--r-~
,- __ _ __A.9Q.E~5..9~ ____ _ ,
z
I [
~
BFtOWN WHITE
I :
: TACI-IOMETER LICHT I I I
: I I I
I
I
~
I I I I
I I I
IL
__________ _____
KEY SW[1CH CONNECTIONS KEY SW[1CH CIRCUIl COMPLETED POSmONS 8ElWEEN CONlAC1S MARKED "OFF" C- III "RUN/UCH1S" 8- L NONE ''RUN'' "ELECTRIC B-S SlART"
EMERCENCY STOP SWITCH
all OFF
0 eJ" OF.:. F_ _ _---,W:;:H.;:,IT;:;E_ __+< BLACK
~
1:1~=+-,
f
8RAKE UCHT SW[1 CH
-L
BlUE
BLACKfYELlOW YEll OW/RED BROWN/YELLOW
ENCINE MAGNETO RED/YELLOW
,- _____A.fg.~S.Q!!! ____ _ , I I I I
~ ~:'E~~~ ~~ ':1~H.2 _____ ~
SC340 ONLY HEADlIGHl
Figure 2 -36
ELECTR ICAL SY STEM THEORY OF OPERATION
2 -25
Converter Theory of Operation A torque sensing, variable ratio, sheave-type torque converter is used to drive the snowmobile. This converter consists basically of a drive converter mounted to the power take-off of the engine, a driven converter which drives the track through the chaincase and gearing, and a V-belt which transmits rotary motion from the drive con verter to the driven converter. (See Figure 2-37.) The method of transmitting power from the drive converter by means of a belt to the driven converter enables multiplication of engine torque as needed by the track to pull the snowmobile through varying snow depths, and up and down hills. The converter automatically shifts to maintain maximum horsepower at all operating conditions. 1. 2. 3. 4. 5. 6. 7.
Roller/Weights Spider Assembly Spring Movable Sheave Ramp Drive Belt Stationary Sheave Figure 2 -38
The primary function of the spring is to control the initial engagement between the movable drive sheave and drive belt. The spring also affects engine RPM throughout the drive converter shift pattern. A weak or light spring will decrease both engagement speed and maximum engine RPM, resulting in speed ing up the shift pattern.
1. Drive Converter 2. V-Be lt 3. Driven Converter
A heavy or strong spring will increase engagement speed and maximum engine RPM, but slows down the shift pattern. The drive spring will take a "set" after approximately 50 miles (80.47 km), and lose 0.25 in. (6.35 mm) of its total length . However, no significant loss of spring tension will occur due to the decreased spring length.
Figure 2-37
Drive Converter The drive converter on the snowmobile is designed to provide maximum performance under all types of snow and load conditions. (See Figure 2-38.) There are three variables that will change the performa nce characteristics of the drive converter. They are as follows: 1. 2. 3.
Spring Weights Ramps
2 -26
CONVERTER THEORY OF OPERATION
The drive converter contains six weights that control engine RPM. A lighter weight will increase engagement RPM, and maintain higher RPM throughout the total shift pattern. Care must be taken not to exceed specified engine RPM or engine damage will occur. By contrast, a heavy weight will decrease engagement RPM , and also lower engine RPM throughout the shift pattern . However, the main function of the weights is to control the engine RPM through the sh ift pattern . The ramp is designed so the shift pattern is within the peak torque curve of the engine. The ramp pro file is the major factor in determining the characteristics of the sh ift pattern.
,.
Driven Converter The power that drives the track is transmitted from the drive converter through the drive belt to the driven converter . The driven converter is held closed by the driven torque converter spring. This positions the belt at idle, or with the engine off at the outside circumference of the driven flanges.
sprocket, drive chain and driven sprocket are housed w ithin the cha incase . The chaincase is a sealed housing which contains lubricant for the drive cha i n. (See Figure 2-40.) The top (drive) sprocket in the chaincase is at tached by splines to the driven converter . The bot tom (driven) sprocket is attached to the track drive shaft by splines. The drive chain transfers power from the driven converter to the track driveshaft.
1. 2. 3. 4.
1. 2.
Spring Torque Bracket Assembly 3. Movable Sheave 4. Drive Belt 5. Stationary Sheave
Chaincase Drive Sprocket Driven Sprocket Drive Chain Figure 2-40
Track, Suspension, and Steering System Operation The suspension system consists of the track and slider and the skis. (See Figure 2-41 .)
Figure 2 -39
As the engine speed increases the driven flanges are spread apart allowing the belt to ride on a smaller diameter of the flanges . This change of flange diameter varies the drive ratio, automatically providing the most favorable ratio between the drive and driven converter for the speed and load at which the machine is operating. (See Figure 2- 39.)
Chaincase and Gearing The chaincase provides a mounting for the driven converter shaft and the front drive shaft. The drive
The track provides flotation and propels the snowmobile. Support for the track and suspension is provided by the sliders. Adjustable spring-loaded arms attached to the sliders allow suspension adjustment for the weight of the rider(s). SuspenSion can also be adjusted for snow conditions and steering control. Two skis are attached to the front of the snow mobile for steering control and flotation. A wear bar at the bottom of the ski protects the ski from wear and aids in steering control. The steering system connected to the ski consists of a spindle, steering arm, t ie rod and handlebars.
TRACK, SUSPENSION AND STEERING OPERATION
2-27
â&#x20AC;˘
Figure 2 -41
Engine Inspection Check the engine for loose or missing hardware, etc .; replace if necessary and tighten hardware as specified on torque chart in Section 1. Carefu lly inspect outside area of engine, paying particular attention to surfaces near mating flanges, seals and gaskets for signs of leakage. If leakage is evident, perform Crankcase Pressure Test and repair as required .
Crankcase Pressure Test 1.
Remove muffler assembly, exhaust manifold, main upper shroud and exha ust side shroud. Discard the exhaust gaskets.
2.
Seal exhaust and intake passages of each cylinder to trap air inside engine assembly during test. a.
Position rubber gasket (cut from old inner tube) on cylinder in place of exhaust gasket. and reinstall manifold.
b.
With carburetor removed, install 1-112 in. (38 .1 mm) wooden plug (cut out of 2 x 4) into rubber carburetor holder and secure in position by tightening clamp screw.
1. 2.
Carburetor Holder Fuel Pump Pulse Tube Nipple Figure 2-42
3.
Connect pressure tester and gauge to fuel pump pulse tube nipple on crankcase. (See Fig ure 2-42.)
2-28
ENGINE INSPECTION
4.
Apply 7 to 10 psi (0.5 to 0.7 kg -cm 2 ) pressure to crankcase and observe gauge. If pressure is maintained for minimum of two minutes, crankcase is okay. Any pressure drop observed within two minutes indicates leakage and must be eliminated.
Spray soapy water mixture along all sealing surfaces of engine to pinpoint leaking gasket or seal and repair as required. 5.
Upon completion of test, reattach shrouds and exhaust system using new exhaust gaskets a nd perform carburetor installation as described in Section 3.
Compression Check A simple compression check is to pull the starter rope slowly. The starter rope shou Id display noticeable resistance on each cylinder as the piston approaches top dead center. Use a compression gauge for accurate measuremerit. A compression reading of 90 to 95 psi (6.33 to 6.68 kg-cm 2 ) pressure per cylinder is minimum. There should be no more than 10 percent difference between the two cylinders. 1. Throttle Cable Adjusting Screw 2. Adjusting Screw Locknut 3. Air Screw 4 . Idle Stop Screw Figure 2-43
Fuel System Carburetor Ajustments The air screw should normally be positioned 112 to 2 turns out from the seated position. An engine may idle smoothly out of these settings; however, problems may occur in the transition to midrange throttle operation. The air screw should be ad justed for best idle within the correct adjustment range. (See Figure 2 -43.)
Fuel Pump Pressure Test 1.
Disconnect fuel pump output (fuel supply) tube from carburetor.
2.
Connect output tube to pressure ga uge . (See Figure 2-44.)
Turn in idle stop screw on the carburetor until spring is coi l bound . Next, back off screw to obtain initial adjustment of 6 turns open.
3.
Start engine and run at idle speed for approximately 15 seconds, then stop engine and observe pressure gauge.
Final adjustment is performed with the engine running; turn screw out until idle speed is:
4.
Gauge should maintain 4 to 7 psi (0.3 to 0.5 kg -cm 2 ) pressure for minimum of one minute. Any pressure drop observed within one minute after test indicates internal fuel pump leak age. Repair fuel pump as required to eliminate leakage.
â&#x20AC;˘
2,000 on DRIFTER 340 MODEL
â&#x20AC;˘
3,000 on DRIFTER 440 MODEL
Fuel Pump Inspect the fuel pump and pulse line clamps for loose fit or leaks.
Fuel Pump Output Test 1.
Perform Fuel Pressure Test to determine condi tion of internal components .
Fuel Filter 2. Disconnect fuel pump output (fuel supply) tube Inspect the fuel filter. If it is dirty or leaking, replace it.
from carburetor and place end of tube into 1 quart (1 liter) container.
FUEL SYSTEM
2 -29
I
I
WARNING
Gasoline fumes are heavier than air and can become explosive if exposed to a pilot light from a furnace, hot water heater, clothes dryer, etc. Perform maintenance only in an area that is well ventilated and free from pilot lights and sparks.
3.
Start engine and run at idle speed for approximately 30 seconds, then stop engine and measure fuel in container.
4.
Fuel pump output is okay if volume measured is: â&#x20AC;˘
6.5 oz. (192 cc) minimum
If amount measured is less, inspect fuel pump, fuel filter, fuel tank fittings and tubes for obstructions.
Primer Pump (SA340 and S 8440 Only) Check all the tube connections in the primer system for loose fits and leaks. Correct as necessary. (See Figure 2-45.)
PRIMER
PUMP--~
TO FUEL TANK
1.
Fuel Filter
Figure 2-44
2-30
FUEL SYSTEM
1. Primer Pump 2. To Fuel Tank Figure 2-45
Fuel Tank and Lines Inspect the fuel tank for leaks . Also check all fuel lines and fuel tank fitting connections for leaks or kinks.
2. To adjust the throttle cable, loosen the adjusting screw lock nut at the carburetor top. Turn the adjusting screw to obtain the proper fr ee play and retighten the lock nut. (See Figure 2-43 .)
r-::~-~~~~-~~]
Throttle Cable Adjustment
I
WARNING
I
While installing air intake silencer, check that rubber seal between silencer and carburetor is properly positioned and fits securely. Failure to comply with this step will cause engine failure.
Do not operate the engine with the air intake silencer removed. Removal will result in engine damage, and may cause carburetor icing and a stuck throttle. 1.
Remove air silencer assembly, hold throttle lever at full throttle position and check that: a.
b.
Throttl e valve inside the carburetor bore opens fully. Be sure rear section of valve does not protrude into carburetor bore to restrict air flow at full throttle. (See Figure 2- 46.) With the throttle lever at idle, there shou ld be approximately 1/16 in . (1.5 mm) free play between the lever and housing.
An excessive gap may cause the inner throttle cable to disconnect from the throttle lever. Too little or no gap can lead to incorrect idle adjustment.
3.
Secure air silencer into position with springs.
Enrichener Cable Adjustment With the enrichener lever down, and boot slid up the cas ing, the Enrichener Cable should have 1/ 16 in. (1.5 mm) free movement when raised as shown. (See Figure 2-47.)
NOTE: Eng ine flooding may occur if the En richener Cable free movement is less than 1/1 6 in . (1.5 mm). If adjustment is required, loosen lock nut and turn adj usti ng screw to obtai n the correct movement. After adjustment, or checking, reposition boot over enrichener fitting to prevent foreign matter from entering the enrichener system.
CORRECT 1. 2. 3.
From Air Silencer To Engine Throttle Valve Figure 2-46
1. 1/ 16 In. (1.5 mm) 2. Adjusting Screw 3. Lock Nut Figure 2-47
FUEL SYSTEM
2-31
Ignition System
4 . Turn the dr ive converter clockwis.e to:
.
Ignition Timing Check
•
0.1 08 in. (2.75 mm ) BTDC (before top dead center) on SA340
Remove the drive belt prior to performing th e following procedure.
•
0 .073 in. (1 .85 mm) BTDC (before top dead center) on SB440
5A340 and 58440 1.
Make a mark on the drive converter fixed sheave corresponding to the tim ing pointer. (See Figure 2-48 .)
Install a fabricated timing pointer onto th e engine . For accuracy it is important to attach the pointer to the engine rather th an to th e chassis, so the pointer can move with th e engine . (See Figure 2 -48.)
Figure 2-49
1. 2.
Dial Indicator Timing Pointer 5. Figure 2-48
Remove the dial indicator. Before installing the spark plugs, check that: a.
When removing spark plugs, carefully rotate plug cap back and forth while pulling cap straight upward. Do not attempt to twist or force plug cap off by pulling on lead wires as this will damage the connection. (See Figure 2 -49.) 2.
3.
Remove both spark plug s and install a dial indicator into the RH cylinder spark plug hole. Rotate the drive converter in th e normal direc tion of rotation (counterclockwi se) to find TDC (top dead center).
2 -32
IGNITION SYSTEM
b.
Plug gap is properly adjusted to: •
0.032 in. (0 .8 mm ) on SA340
•
0.024 in. (0.6 mm) on SB440
The washer is installed on the plug and the cylinder head seat is clear.
Insta ll spark plugs and torque 20 ft Ibs (2.7 kg -mI.
I
WARNING
I
Do not touch the spark plug leads while the engine is running as they will transmit a powerful electrical shock. Do not touch the hot exhaust system, as a severe burn will result.
6.
With the drive belt removed and the converter guard secured in place, run the engine at : •
3.
Rotate drive converter in normal direction of rotation (counterclockwi se) to find TDC (top dead center). Adjust dial indicator to zero .
4.
Turn the drive converter clockwise to:
6,500 RPM
Aim the timing light directly at the pointer and when the mark on the converter aligns with the pointer as the light flashes the timing is correct. (See Figure 2-50.)
•
5.
0.108 in (2.75 mm) BTDC (before top dead center) on SC340.
Check that the "F" mark on flywheel aligns with fixed mark on magneto housing. (See Figure 2-51.)
1. 2.
Magneto Housing Mark Flywheel "F" Mark Figure 2-51
Figure 2-50 If the timing is incorrect, perform Ignition Timing Adjustment.
6.
Remove the dial indicator. Before installing the spark pi ugs, check that: a.
Plug gap is properly adjusted to: •
0.032 in. (0.8 mm) on SC340.
Ignition Timing Check b.
SC340 On SC340 model, remove recoil starter assembly and store in location preventing contact with moving parts when engine is started.
When removing spark plugs, carefully rotate plug cap back and forth while pulling cap straight upward. Do not attempt to twist or force plug cap off by pulling on lead wires as this will damage the connection. (See Figure 2-49.) 2.
Remove both spark plugs and install a dial indicator into the LH cylinder spark plug hole.
The washer is installed on the plug and the cylinder head seat is clear.
Install spark plugs and torque 18 to 20 ft Ibs (2.5 to 2.7 kg-mI.
I
WARNING
I
Do not touch the spark plug leads while the engine is running as they will transmit a powerful electrical shock. Do not touch the hot exhaust system, as a severe burn will result. 7.
Connect strobe type timing light to spark plug lead wire following manufacturer's instructions. Drive belt must be removed and converter belt guard secured in place.
IGNITION SYSTEM
2-33
8.
Wind emergency start rope around starter pulley in direction shown. Be sure knot is positioned in pulley notch. (See Figure 2 -52.)
Figure 2-53
Figure 2 -52 3.
9.
Start engine and allow it to warm up to operating temperature. Then run engine at 6,000 RPM and aim timing light at fixed mark on magneto housing. Timing is correct when mark on flywheel aligns with fixed mark on housing as light flashes. (See Figure 2-51.)
If the timing is incorrect, perform Ignition Timing Adjustment.
Ignition Timing Adjustment 1. On SA340 and SB440 models, the muffler assembly, recoil starter and fan belt pulley must be removed . Twist the belt out of the way.
When adjusting the stator assembly, take care not to damage the coil windings. 2.
Loosen the stator assembly mounting screws through the holes in the flywheel. To correct the ti mi ng, rotate the stator assembly as required (clockwise to retard the timing; counterclockwise to advance the timing). (See Figure 2-53.)
2-34
IGNITION SYSTEM
Tighten the stator assembly mounting screws .
NOTE: On SA340 and SB440 models replace the fan belt pulley and the fan belt . Install the recoil starter assembly and the muffler. 4.
Recheck the timing using the Ignition Timing Check procedure to be sure it is correct.
5.
Install the drive belt and secure the converter guard into proper position with clip pins .
Fan Belt Tension Test fan belt tension with a 11 Ib (5 kg) force applied to the belt, the belt deflection should be 5 / 32 in. (3.5 to 4.5 mm). (See Figure 2-54.)
[~~] To prevent fan belt damage, remove spark plugs and rotate engine crankshaft while torquing outer pulley mounting nun. If adjustment of the fan belt tension is required, remove fan guard and the outer pulley from the fan shaft. To reduce belt deflection, remove a spacer from between the pulley halves, or add a spacer to increase the belt deflection. Re-install the fan guard.
Figure 2-57
Figure 2-58
Burned or blistered insulator and badly eroded electrodes indicate overheating. Improper spark timing, low octane fuel or lean fuel/air mixtures can cause this condition. (See Figure 2-59.)
1. 5/32 In. (3.5 to 4.5 mm) Deflection Figure 2-54 Figure 2-59
Cleaning, Inspecting, and Gapping the Spark Plug Normal plugs have brown to grayish-tan deposits and slight electrode wear. This indicates the correct spark plug heat range. (See Figure 2-55.)
Do not clean old spark plugs with a sandblaster. Grit may be released into the cylinder during engine operation causing severe damage. Inspect spark plugs for cracked porcelain and worn electrodes. Clean the electrodes with a point file. Adj ust the gap to:
Figure 2-55
â&#x20AC;˘
0.032 in. (0.8 mm) on SA340 and SC340
â&#x20AC;˘
0.024 in. (0.6 mm) on SB440
Figure 2-56
Carbon fouled plugs show dry, fluffy black deposits which may be caused by over-rich carburetion, overchoking, weak coil, or worn cables. (See Figure 2-56.) Worn out, eroded electrodes and a pitted insulator are indications of long service. Replace old spark plugs for better fuel economy, quicker starting and smoother engine performance. (See Figure 2-57.) Wet, oily deposits may be caused by the low speed carburetor adj ustment bei ng too rich, prolonged low speed operation, improper fuel-to-oil mixture, or worn breaker points. These plugs can usually be degreased and reinstalled. (See Figure 2-58.)
1. Gap 2. Washer Figure 2-60
IGNITION SYSTEM
2-35
In regapping, adjust only the ground side electrode. Do not attempt to bend the center electrode; the insulation will crack. (See Figure 2-60.)
NOTE: Be sure an operator is seated on the snowmobile while the engine is running to prevent the vehicle from creeping ahead, and to assure proper aiming.
3.
Electrical System Key Switch The key switch should be lubricated with graphite once a year. The graphite will also prevent freezing of the key switch in extremely cold weather. NOTE: Do lubricant.
not
use
an
excessive
amount
.
Always turn headlight adjusting screws to the right (clockwise). Turning screws counterclockwise may back them out of the headlight aI/owing the headlight to become loose or drop out of position.
of
4.
Headlight Adjustment
Turn on the headlight high beam. The head light is properly aimed when the high beam is centered and aimed 2 in. (51 mm) below th e reference mark on the wall. (See Figure 2-61.)
If adjustment is required, turn the adjusting screws as shown. (See Figure 2-62.)
Headlight adjustment is rarely required , but should be checked at least once a year to insure it is properly aimed. The high beam of the headlight is used for aiming, and can be adjusted on both the vertical and horizontal planes as follows:
1. Position the snowmobile on a level floor so the headlight points at a wall 25 feet (7,620 mm) away.
2. Measure the distance from the floor to the center of the headlight and mark the wall at the dimension measured (reference mark). (See Figure 2-61 .)
I
WaRNING
I
If adjusting the headlight indoors, provide proper ventilation to prevent possible carbon monoxide poisioning.
.. .. 1. Wall 2. 3. 4.
25 ft (7,620 mm) Reference Mark (Center of Headlight to Floor) 2 In. (51 mm) Below Reference Mark Figure 2-61
2-36
ELECTRICAL SYSTEM
1. Vertical Adjusting Screws Horizontal Adjusting Screws
2.
Figure 2-62 Check the operation of the headlight low beam.
¡
,
Bulb Replacement Headlight bulb replacement should be performed from the rear of the headlight, from inside the hood. Replacing the bulb from inside the hood does not disturb the aiming of the headlight thus ad justments will not be required. Replace the headlight bulb as follows:
5.
Align the indexing tabs on the retainer with the holes on the mounting plate.
6.
Reinstall the 2 lower screws and secure the headlight by tightening the 4 screws evenly.
SA340 and SB440 1.
Remove the wire harness connector from the headlight.
2.
Push down while turning the retaining ring counterclockwise. The retaining ring is marked top for proper indexing during installation . (See Figure 2-63.)
3.
With the retaining ring removed, the bulb and socket can be pulled out of the headlight. Note that the socket is installed with the wide tab towards the top. (See Figure 2-63 .)
Install the headlight bulb in the reverse order of removal.
1. 2. 3. 4.
Headlight Retainer Screws Headlight Retainer Retainer Indent Figure 2-64
Tail/Brake Light Replace tail and brake light bulb by removing the lens, secured by 2 screws, and then removing the lamp from the socket. (See Figure 2-65.)
1. 2.
Retaining Ring Wide Tab on Socket Figure 2 -63
SC340 1.
Remove the wire harness connector from the headlight.
2.
There are 4 screws and washers that secure the headlight retainer. Remove the 2 lower screws and washers then loosen the 2 upper screws. (See Figure 2-64.)
3.
Remove the retainer and headlamp.
4.
Align tab on rear outside circumference of the headlight with the large indent on the retainer and install headlight and retainer into position under the washers on the 2 upper screws.
Figure 2 -65
Speedometer, SB440 Only The speedometer cable should be lubricated once a year. Remove the cable from the rear of the speedometer and lubricate the cable with graphite .
Voltage Regulator Check the connection on the wiring harness from the voltage regulator. Make sure the connection is clean and tight.
ELECTRICAL SYSTEM
2-37
Converter Alignment Converter Offset Alignment Without Special Tool PIN 57001-3512 The converter alignment (offset) should be 0.454 in. (11.5 mm) as measured from the back face of the fixed sheave on the drive converter to the edge of the driven converter movable sheave. (See Figure 2-66.)
'\
If adjustment of the converter alignment is required: 1.
Loosen bolts that secure the engine mount plate to the chassis.
2.
Slide engine left or right as necessary to obtain the 0.454 in. (11.5 mm) offset. (See Figure 2-66.)
3.
Torque engine mount bolts 30 ft Ib (5.15 kg-m).
4.
Perform Converter Center Distance procedure .
Figure 2-67 If adjustment of the converter center distance is required: 1.
Loosen four mounting nuts on chaincase.
2.
Disconnect driven converter bearing support assembly by remov ing clevis pin from yoke .
3.
Move chaincase to obtain 10.3 in. (262 mm) center distance. (See Figure 2-67.)
4 . Torque chaincase mounting nuts 28 ft Ib (3 .87 kg-m) and install driven converter bearing sup port assembly. 5.
Perform Converter Parallelism procedure .
Converter Alignment Using Special Tool PIN 57001-3512 Correct converter center-to-center distance of 10.3 in. (262 mm), and converter offset distance 0.454 in. (11 .5 mm) is obtained when alignment gauge PI N 57001-3512 is correctly installed between drive and driven converter sheaves. (See Figure 268.) 1. 2. 3.
Fixed Sheave on Drive Converter Movable Sheave on Driven Converter Straight Edge Figure 2-66
Converter Center Distance Using Special Tool PIN 57001-3512 1.
Remove converter guard and drive belt .
2.
Rotate driven converter movable sheave assembly clockwise, and insert alignment gauge between sheaves . Carefully release movable sheave assembly allowing spring tension to retain gauge in position between stationary and movable sheave assemblies . (See Figure 2-69.)
3.
Rotate drive converter assembly until hex shaft is correctly positioned in the alignment gauge.
Converter Center Distance Without Special Tool PIN 57001-3512 The converter center distance should be 10.3 in. (262 mm). (See Figure 2-67.)
2-38
CONVERTER ALIGNMENT
4.
If adjustment of converter center distance is necessary; loosen four chaincase mounting nuts. Position chaincase forward or rearward as required. Torque chaincase mounting nuts 28 ft Ib (3.9 kg-m).
NOTE: On S8440 model, driven converter bearing support must be disconnected by removing clevis pin from chassis yoke. After adjusting chaincase, loosen support jam nut and adjust support assembly to proper length. Reconnect support to yoke and torque jam nut 95 in. Ib (1.1 kg-m). (See Figure 2-69.)
Converter Offset Alignment Using Special Tool PIN 57001-3512 1. Alignment Gauge 2. Converter Offset 3. 10.3 in. (262 mm)
1.
Figure 2-68
Correct off -set distance 0 .454 in. (11 .5 mm) is obtained when drive converter stationary sheave fits into recess of alignment gauge when the gauge is positioned on hex shaft. (See Figure 2-68.)
1. 2. 3.
Alignment Tool PI N 57001-3512 Alignment Tool Recess Drive Converter Stationary Sheave Figure 2-70
1. 2. 3.
Driven Converter Support Arm Driven Converter Movable Sheave Alignment Gauge PIN 57001-3512
4.
Drive Converter Figure 2-69
2.
If adjustment is necessary, loosen four engine mounting nuts. Slide engine back and forth until stationary sheave fits into recess in alignment gauge. Tighten all mounting bolts securely.
CONVERTER ALIGNMENT
2 -39
Converter Parallelism 1.
When checking center-to-center and offset distances, parallelism must be checked by measuring dimensions A and B as shown . (See Figure 2-71.) Compare dimensions A and B against Notes I and II.
1. "U" Washer PI N 92025 -3507 Figure 2-72
Belt Inspect the drive belt for worn areas, cracks between the teeth, or ply separations. Replace the belt when worn 0.125 in. (3.18 mm) from new specifications. Remove the drive belt as follows: NOTE: Prior to removal, observe markings on belt so that it may be installed on converters to rotate in the same direction as original installation. 1.
Remove the safety pin which secures the belt guard at the top, and swing the belt guard forward . (See Figure 2-73 .)
1. Alignment Gauge PIN 57001-3512 Figure 2-71 NOTE I: Dimension A must be more than dimension B. NOTE II: Dimension A must never exceed dimension B by more than 1/16 in . (1.6 mm). 2.
If dimension A is less than B, converter parallelism is not correct. Adjust parallelism by loosening engine mounting nuts, then twisting or rotating engine to correct position. Torque engine mounting nuts 30 ft Ib (4.1 kg -m).
3.
If parallelism is still not correct, loosen chaincase mounting nuts and install alignment "U" washers PI N 92025-3507 as required between chassis and chaincase . (See Figure 272.)
NOTE: Never use more than 2 alignment washers per bolt.
2 -40
CONVERTER ALIGNMENT
1. 2. 3. 4.
Belt Guard Belt Guard Pin Driven Converter Support Arm Clevis Pi n
"U" Figure 2-73
2.
On SB440, disconnect the driven converter support arm from the chassis by removing the clevis pi n from the yoke.
3.
Rotate the movable half of the driven sheave towards the rear of the vehicle while pushing it towards the steering post. Assistance may be required to apply the brake while rotating sheave. (See Figure 2-74.)
1. 2. 3.
Drive Belt Driven Converter Movable Sheave Driven Converter Support Arm Figure 2-75
3.
Roll the drive belt over the top of the movable sheave, being careful not to pinch your fingers. Position the belt into "low gear ratio" by working the belt around the converters until it is fl ush with the outside diameter of the driven converter. This will prevent excessive wear to the belt sides during initial converter engagement.
4.
Install the driven converter support arm to the chassis, and secure the clevis pin with safety clip.
5.
Position the belt guard and secure it with the safety clip.
6.
Close the hood and lock it into position with the hood latches.
Figure 2-74
I
WARNING
I
Use caution when removing the drive belt from the driven converter sheave since it is under a heavy spring load. Keep fingers and hands clear when releasing sheave. 4.
Roll the drive belt up and off the driven converter. Then release the movable sheave. (See Figure 2-75.)
5.
Work the drive belt past the carburetor and air silencer, then remove it from the drive converter.
Converter Lubrication
~ DO
To install the new belt: NOTE: Always reinstall used belt so it will rotate in the same direction as it did originally. 1.
2.
With the drive belt in position around the drive converter, work the belt past the carburetor and around the driven converter support arm. Open the driven converter movable sheave to ease installation of the drive belt.
NO T LUBRICA TE THE DRIVE CONVERTER. Any lubricant applied to the drive converter will drastically change the shifting characteristics, resulting in converter failure and reduced drive belt life. Clean the drive converter sheave surfaces once a year. Use a rag dipped in acetone liquid cleaner to remove water and oil. Remove rust or rubber with No . 260 and No. 320 emery cloth and polish with No. 400 emery cloth.
CONVERTER ALIGNMENT
2-41
Lubricate all driven converter ramp sliding sur faces with low temperature grease. Lubricate the movable sheave sliding surface with a graphite lubricant. Use solvent to remove grease and rubber from the belt contact surfaces .
1.
Back both brake cable jam nuts away from bracket about 1/ 4 in. (6 mm). Tighten brake adjusting nut bottoming cam against push pins.
2.
Pull outer brake cable rearward to remove slack from inner cable and snug rear jam nut to bracket. Tighten forward jam nut against bracket and torque both jam nuts 50 in. Ib (0.6 kg-m).
Brake Check relationship of brake cam detent to brake pad push pins. In the off position the cam detent must be centered over pins. Be sure brake disc can be moved back and forth with very slight drag from brake pads. Measure brake control lever movement which should be less than 3/ 4 in. (19 mm) when brake is fully applied. Perform Brake Adjustment if req uired. (See Figure 2-76.)
WARNING
I
DO NOT OVERTIGHTEN the brake because damage to components, or personal injury could result.
3.
Loosen brake adjusting nut until brake disc can be rotated back and forth easily with brake pads just lightly contacting the disc.
Brake Pad Wear Inspection After adjusting brake, measure amount of threads protruding through the brake adjusting nut. (See Figure 2-77 .) Replacement of brake pads is recommended when the amount of exposed threads measures 7/ 16 in . (11 .1 mm) or more. Remember, excessively worn or excessively tight brake pads will reduce braking action due to overheating, and could damage the brake disc.
1. 2. 3. 4. 5. 6.
3/ 4 in. (19 mm) Maximum Push Pins Brake Pads Brake Disc Brake Cam Brake Cable Jam Nut Figure 2-76
2-42
BRAKE
1. 2.
Brake Adjusting Nut Protruding Threads Figure 2-77
Chain Tension The drive chain is self-adjusting for tension but the plastic chain guides should be inspected for wear. Turn or replace if necessary. (See Figure 2-78.)
1. Chain Guides 2. Tensioner Spring
1. 3. 4. 5.
Figure 2-78
1.
Remove the chaincase cover bolts and cover to allow the oil to drain out of the chaincase and through the hole in lower pan. (See Figure 280.)
NOTE: Be careful not to lose the speedometer key located between the speedometer adapter and the driveshaft. (See Figure 2-80.)
Chaincase
2. Chaincase Cover Speedometer Key Oil Level Check Plug Chaincase Cover O-Ring Figure 2-80
2. The chain guides should be turned 1800 (to use the unworn portion of the guide) when one side is worn to within 0.12 in. (3.0 mm) of the tensioner arm pin . (See Figure 2-79.) When both sides of the chain guides are worn to this dimension they must be replaced.
3.
Clean any plastic sediment and dirt from the chaincase and cover.
4.
Replace the O-ring in the cover if cut or damaged, then reinstall chaincase cover.
5.
Pour Kawasaki Chain Lubricant into the chaincase through the top hole until it is level with the bottom hole lower edge.
1. 0.12 in. (3.0 mm) Figure 2-79
Install the upper and lower plugs into the chai ncase cover.
CHAIN TENSION
2-43
Gear Ratio Chart
Drive Sprocket· Number of Teeth 17
36
2.18 *53 to 60 MPH 90 Red
I
f-
UJ UJ
37
fLL
0 0:
18
19
2.00 *57 to 65 MPH 90 Red
L89 *61 to 69 MPH 90 Pink
20
21
22 1.64 * 70 to 79 MPH 92 Red
2.06 *56 to 63 MPH 90 Green
1.76 *65 to 74 MPH 92 Red
Gear Ratio Speed Chain Pitch Tensioner Spring
1.68 * 68 to 77 MPH 92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring
UJ
co
:2:
=>
z
2.24 *51 to 58 MPH 90 Green
38
f-
UJ ~
L81 * 63 to 72 MPH 92 Green
1.90 * 60 to 68 MPH 92 Red
Gear Ratio Speed Chain Pitch Tensioner Spring
U
0
STD S8440
0: 0-
C/)
z >
UJ
2.05 * 56 to 63 MPH 92 Red
39
0: 0
2.22 * 52 to 58 MPH 92 Pink
40
1.95 * 59 to 67 MPH 92 Green
Gea r Ratio Speed Chain Pitch Tensioner Spring
2.11 * 54 to 61 MPH 92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring
*Theoreti ca l MPH at 6000 to 6800 RPM. NOTE: All top speeds based on 1: 1 converter ratio and engine RPM at 6000 to 6800 RPM.
CHAIN TENSIONER SPRINGS Color Red Orange Pink Yellow Green Blue
2-44
GEAR RATIO CHART
Wire Dia. 3.00 3.00 3.38 3.38 3.75 3.75
in. (76.20 in. (76 .20 in. { 85 .85 in . (85.85 in. (9 5.25 in. (95.25
mm) mm) mm) mm) mm) mm)
0.049 0.055 0.049 0.049 0.049 0.0 55
in. in. in. in. in. in.
(1.245 (1.397 (1.245 (1.245 (1.245 (1.397
mm) mm) mm) mm) mm) mm)
Steering System The steering system components should be checked periodically for excessive wear and secur ity of fasteners (nuts, bolts, etc.). Proper ski alignment cannot be maintained with worn components.
Ski Alignment Alignment shou ld be checked at the beginning of each season, whenever the ski is subjected to a hard side impact. or when steer ing system components are replaced . Check the ski alignment as follows: 1.
Place a long board (or su itable straightedge ) against the left edge of the track, and measure the distance between the board and center line of the ski. Position the ski so that the distance measured between the ski center line and edge of the board is the same at the front and rear of the ski. (See Figure 2-81.)
1. 2. 3.
Locknuts Tie Rod Length Adjusting Stud 1-1 14 In. (32 mm) Maximum Figure 2-82
I
WARNING
I
The dimension shown in Figure 2-82 must not exceed 1-1 1 4 in. (32 mm) and the adjusting stud must remain centered between the two locknuts, to prevent possible steering linkage failure. NOTE: Be sure left hand ski remains parallel to the straightedge while turning the tie rod adjusting stud by placing a support under the bumper to slightly raise right hand ski off ground. To align the other ski, move both ski tips towards the center of the snowmobile to remove the steering linkage play. Turn the tie rod length adjusting stud (located below the muffler) to obtain an equal distance from ski center to ski center when measured at the front and rear of the skis. (See Figure 2-83 .)
4.
1. 2.
Stra ightedge Against Track Measure Clearance Here Figure 2-81
2.
When the ski center line is parallel to th e outside edge of the track, check the stee ring handlebar for centering.
3.
If handlebar requires centering, support vehicle so RH ski is OFF the ground allowing it to move when adjusting handlebar. Loosen jam nuts and turn LH tie rod adjusting stud as necessary to center handlebar.
1.
Equal Distance Between Ski Center Lines Front And Rear Figure 2-83
STEERING SYSTEM
2 -45
5.
Torque the adjusting stud locknuts 100 to 120 in. Ib (1.15 to 1.38 kg-mI. Refer to the torque chart and tighten all the hardware (nuts, bolts, etc.) in steering system.
Ski Skeg Excessively worn ski skegs can greatly reduce the handling of your snowmobile and may result in premature wear to rear portion of ski. The skeg on bottom of each ski should be inspected often, since the wear rate depends on the surface the snowmobile is operated on. Replacement is recommended when skeg is more than 3/4 worn at any point. Refer to Section 3 for Ski Skeg Replacement.
Ski Spring Preload Three positions have been provided for the front ski spring mounting bolt : Center Hole Position - During factory assembly, bolt was installed in center hole in the ski and normally no change is required for general snowmobiling. (See Figure 2-84.)
To change preload of the ski spring , be sure weight of snowmobile is on the skis, and proceed as follows: 1.
Remove nut from front spring mounting bolt .
2.
Open hood and with assistance from another, stand on front bumper to relieve spring tension from mounting bolt.
3.
With weight still on front bumper, remove bolt. slide spring rub strip to align with desired hole position of ski, and insert bolt.
4.
Install nut and torque 25 in . Ib (0.29 kg-m).
Suspension Adjustment The slider suspension is fully adj ustable for rider comfort. The adjustments consist of changing the tension of the suspension springs on each side of the front a nd rear suspension arms.
Ride Adjustment As assembled, rear springs which control ride characteristics are mounted in lowest or softest of three positions available. Ride adjustments can be made by changing position of these springs to increase their tension; this will stiffen the ride and increase load capacity.
The tension pre-load (tension) of the springs on each side of the suspension arm must be equal. Excessive tension of one spring can cause spring breakage or excessive wear to one side of the slide wear strips.
1. Spring Mounting Positions Figure 2-84 Rear Hole Position - Installation of the bolt in rear hole of the ski will reduce spring preload, increase spring arch, and result in a softer ride with greater spring travel. This position is recommended for deep snow operation or slow speed trail riding. Front Hole Position - Placing bolt in front hole of the ski will increase spring preload, reduce spring arch, and result in a stiffer ride with less spring travel. This position should be used for maximum stability during high speed operation.
NOTE: Always mount front ski spring bolt into the same position on each ski.
2-46
SUSPENSION ADJUSTMENTS
To change spring tension : 1.
Install spring adjusting tool, PI N 57001-3507 onto end of the spring arm as shown. (See Figure 2-85.)
WARNING
I
Rear suspension springs are under heavy spring load and improper adjusting techniques may result in personal injury.
1. Adjusting Nut 2. Front Suspension Spring 3. Exposed Threads
1. Spring Adjusting Tool PIN 57001-3507 2. Spring Arm 3. Spring Retainer Figure 2-85
2.
Apply a firm grip on spring adjusting tool with both hands and carefully lift spring arm out of the detent in spring retainer. Be prepared for heavy spring load to be transferred to spring adjusting tool as the spring arm is lifted out of retainer detent.
Figure 2-86
Track Adjustments For optimum performance and for long track life, proper adjustments must be maintained. Since the track is made of rubber and subjected to high torque loads, a certain amount of track stretch is expected. Track tension will compensate for stretch . Once correctly tensioned, the track must be aligned in the chassis to prevent wear to one side of the track.
I
3 . Install spring arm into a higher retainer detent to increase spring tension for the desired ride characteristics.
Handling Adjustment Handling characteristics of the snowmobile are controlled by tension of the front suspension springs. Increasing spring tension will reduce ski pressure on the ground, resulting in less steering effort and slower response. Less spring tension allows more ski pressure, causing quicker response and increased steeri ng effort.
The tension (pre-load) of the front springs on each side of the suspension arm must be equal. Excessive tension of one spring can cause spring breakage or excessive wear to one side of the slide wear strips.
When raising the rear of the snowmobile off the ground place the ski tips against a stationary object and be sure the vehicle is properly secured to prevent personal injury.
Track Tension r-I-W-A-.-N-IN-G--"I
To prevent personal injury, never adjust track tension with the engine running. 1.
Raise rear of the snowmobile so track is off the ground, and secure the snowmobile so it cannot fall; then hang a 5 to 8 Ib (2.2 to 3.6 kg) weight from the mid point of the track.
NOTE: Do not position snowmobile in its side to adjust track tension as it would be impossible to get an accurate adjustment. 2.
To adjust or change handling characteristics of the snowmobile: tighten adjusting nuts on each side of the suspension equally to increase front spring tension or loosen nuts equally to decrease spring tension. (See Figure 2-86.)
WA.NING I
With 5 to 8 Ib (2.2 to 3.6 kg) weight hanging from track, clearance from the bottom of the wear strip to the top edge of the track should be 314 in. (19 mm). Measure this clearance directly below rear suspension pivot arm bolt. (See Figure 2-87 .)
TRACK ADJUSTMENTS
2-47
3.
If adjustment is necessary, loosen rear axle locking bolts, turn the rear axle adjusting bolts as required to obtain the specified wear-strip to track clearance. (See Figure 2-88.)
WARNING
I
To avoid possible personal injury, do not stand behind snowmobile while track is rotating. Remove all tools and foreign matter from track area before starting engine.
5.
Remove the weight from track and start engine. Push throttle lever only enough to turn the track slowly a few revolutions .
6.
Stop engine Check.
and
perform Track Alignment
Track Alignment The track is aligned when the distance between rear idler wheel and edge of track is equal on both sides. (See Figure 2-89.)
1. Rear Suspension Pivot Arm Bolt 2 . 3 / 4 In. (19 mm) Figure 2-87
4.
When proper tension is attained, be sure both adjusting bolts are same length when measured from bolt head to rear axle bracket. (See Figure 2-88.) This is a good starting point for track alignment.
1. 2. 3. 4.
Dimension Equal on Both Sides Rear Axle Locking Bolt Idler Wheel Edge of Track Figure 2-89
If track runs to one side, tighten rear axle adjusting bolt on the same side, approximately 1/2 turn, then restart engine and recheck alignment.
1. 2. 3.
Rear Axle Locking Bolt Rear Axle Adjusting Bolts Lock (Jam) Nuts Figure 2-88
2-48
TRACK ADJUSTMENTS
If track alignment requires considerable adjustment track tension should be rechecked to prevent damage to drive or suspension system.
When track alignment is correct, tighten lock nut on both rear axle adjusting bolts and rear axle locking bolts. NOTE: After rear axle bolts have been tightened, check to be sure that the spacers (tubing) over the rear axle squeeze against slide rail brackets, preventing the spacers from rotating. Loose spacers will permit rear axle to float and proper track alignment cannot be maintained .
Storage
WARNING
To prevent severe personal injury while t~e engine is running, stay clear of moving parts and do not contact the hot exhaust system components.
c.
Start engine and allow it to run at idle. Siphon action will draw oil into the carburetor lubricating the engine internally.
d.
Because fuel tank has been drained, the engine will stop when fuel in the fuel sys tem has been consumed.
e.
Reinstall primer tube onto primer fitting and continue with preparation for storage.
Preparation for Storage 1.
Thoroughly clean the snowmobile by hosing off all dirt and grime from the suspension and the engine compartment.
2.
Remove the drive belt.
3.
Siphon the fuel from the fuel tank.
4.
To prevent rust, internal engine components must be coated with oil. This procedure IS called "Engine Fogging ."
Engine Fogging, SC340 Only NOTE: Because the SC340 model does not have a primer, oil must be injected directly into the carburetor opening. a.
Remove tube from carburetor to the primer pump at the primer pump fitting .
b.
Submerge open end of tube into container of Kawasaki Snowmobile Oil. (See Figure 2-90.)
Remove air intake silencer from carburetor.
I
Engine Fogging, SA340 and SB440 a.
I
I
WARNING
To prevent severe personal injury while t.h e engine is running, stay clear of moving parts and do not contact the hot exhaust system components.
b.
Start engine and allow it to run at idle .
c.
Slowly inject Kawasaki Snowmobile Oil into the carburetor opening. (See Figure 291.)
1. Primer Pump 2. Primer to Carburetor Tube 3. Container of Kawasaki Snowmobile Oil Figure 2-90
Figure 2-91
STORAGE
2-49
d.
e.
5.
Because fuel tank has bee n drained, the engine will stop when fuel in the fu el system has been consumed. Reinstall air intake silencer onto th e carburetor and continue with preparati on for storage.
Position the snowmobil e on its side on a protective surface. Drain th e fuel from th e carburetor through the vent tube as shown. (See Figure 2-92.) Position th e vent tube into the retainer on the carburetor properly after all the fuel has been drained.
DO NOT LUBRICA TE CONVERTER.
THE
DRIVE
9. The driven converter sheaves are steel. To pre vent rusting, apply a light coat of oil to both driven converter sheaves. 10 . Block the rear of the snowmobile off the ground to remove weight from the suspension. 11. Loosen the rear axle adjusting bolts to relieve track tension. 12. If pa int is scratched, use touch - up paint to restore original finish, and wax the hood and c hassis using an automotive type wax. 13. Cover t he snowmobile to protect it from dirt and dust.
Removal From Storage 1.
Fill fuel tank with a fresh fuel mixture (40 to 1 ratio).
2.
Remove the plugs (masking tape or rags) from t he air intake silencer and m uffler outlet.
3.
Using a suitable solvent, remove the oil from the driven converter sheaves. The converter sheaves must be clean and dry.
4.
Install a new drive belt. Use the one removed last year as a spare.
I
WARNING
I
Be sure engine has stopped before checking or adjusting track alignment.
5 . Adjust t he track tension . 6.
Start the engine and rotate the track several revolutions , at low speed only, then stop the engine and check the track alignment.
7.
Lower the vehicle from blocks.
8.
Operate your snowmobile with the old spark pi ugs for the first 11 2 hour of operation. This w ill allow the oil used while storing the snowmobi le to collect on the old spark plugs . Install new spark plugs, refer to the SPECIFICATIONS page for the recommended heat range and gap adjustment.
1. Vent Tube Figure 2-92
6.
With a rag or masking tape, plug the openings of the air intake silencer and muffler.
7 . Check the chainca se lubricant level. 8.
Re pl ace th e fuel filter.
2-50
STORAGE
Repair .
..
Table of Contents Page
Page
General Troubleshooting . .... . . . . . . . . . . ..... 3-2 Ignition Troubleshooting .. . . . . . . . . . . . . . . .... 3 -9 Ignition Test Procedure Using CD Ignition Tester .. . 3-14 Ignition Troubleshooting Using an Ohmmeter ..... 3-24 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Voltage Regulator Tests . . ... . ... . .... . ..... 3-28 Headlight Circuit Test .. .... . . . . . . . . . . . . . .. 3 -29 Dimmer Switch Test . . . . . . . . . . . . . . . . . . . . . . 3-30 Stop/Tail Light Harness Test .. . . . .... .. ... . .. 3-31 Brake Switch Test. . . . . . . . . . . . . . . . . . . . . . . . 3-31 Flow Chart Engine Removal - 340 and 440 Models .. 3-32 Flow Chart - Disassembly - En gine Installed SA340 & SB440 . . . . . . . . . ... . ..... . . . .. 3-33 Flow Chart - Disassembly - Engine InstalledSC340 Only . .. .. . .. . . . . . . . . . . . . ...... 3-34 Flow Chart - Disassembly - Engine Removed SA340 & SB440 . . . . . . . . . . . . . . . . ... . . . . 3-35 Flow Chart Disassembly - Engine Removed SC340 . . . . . . . . . . . . ... . .... . . . . . . . . . . 3-36 Muffler .... .... . . . . . . . . . . ..... ... ..... 3-37 Exhaust Manifold . . . . . . . . . ... . ... . . . . . . .. 3-37 Sil encer . .. ... . . . .... . . . . . . . . . . . . . . . . . 3-38 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . ..... 3 -40 Carburetor ..... . . .. .. .... . . . . . . . . . . . . . 3-41 Intake Manifold . . . . . . . . . . . . .. . .. ...... .. 3-51 Starter Assembly . . . . . . . . . . . . . . . . . . . . . ... 3-52 Air Shrouds . . . . . . . . . . .. . . . . . . . . . . . . . ... 3-56 Fan Housing .. ..... ... .. . .. .... . . . . . . . . 3-57 Magneto Cover, SC340 Only ... . . . . . . . . . . . .. . 3-60 Stator Assembly . . . . . . . . . .. . .. . ... . .. ... . 3-61 Cylinder Heads, Cylinders and Pistons . . . . . . . . . . 3-65 Crankcase Assembly ... .. . . . . . . . . . . . . . . . . . 3-70 Brake Light Switch, Dimmer Switch, or Brake Lever Assembly . . . . . . . . . . . . . . . ..... 3 -75 Emergency Stop Switch or Throttle Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 Speedometer, SB440 Only . . . . . . . . . . . . . . . . . . 3 -78 Tail Lamp .. . . . . . . . . . . . . . . . . . . . . . . ... .. 3-78 Voltage Regulator . .. . . . . . . . . . .... ... . .... 3-79 Throttle Cable . ... ..... .. . . . .. . . . . . . ... . 3-79 Enrichener Cable .. . ... . . . . . . . . . . . . . . .. .. 3 -80 Brake Cable . . . . . . . . ... . .. .. .. .. ..... . .. 3-81 P~imer, SA340 and SB440 Only . . . . . . . . . . .... 3-82 Drive Converter . . . . . . . . . . . . . . . . . . . . . . . .. 3-82 Driven Converter ..... . . . . . . . . . . . . . . . . ... 3-86 Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Chain Replacement . . . . . . . . . . .. ...... . . . .. 3-90 Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90 Suspension .. ..... ..... .. . . .... . . . . . . . . 3-92 Rear Axle and Wheels ... . . . . . . . . . . . . . . . . . . 3-94 Rear Suspension Arm . . . . . . . . . . . . . . . . . . . . . 3-94 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . 3-96 Wear Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96 Front Suspension Arm Springs ..... . .. ... .. . . 3-97 Limiter Straps ... .. . . . . . . . .. . ... . . . . . . . . 3-98 Idler Wheels Front Suspension Arm . . . . . . . . . . . . 3-99 Front Suspension Arm. . . . . . . . . . . . . . . . . . . . . 3-99 Suspe nsion Rails . . . . . . . . . . . . ...... ...... 3-100 Suspension Installation ... . .. ... . . . . . . . . . . 3-101 Driveshaft and Track . . . . . . . . . . . . . . . . . . . .. 3-102 Steering System . . . . . . . . . . . . . . . . . . . . . . . . 3-105 Seat .. .. . . . . . . . . . . . .. . .... . . . .. ..... 3-109 Fuel Tank . . . . . . ... . ... .... . .. . . . . . . . . 3-109
REPAIR
3-1
General Troubleshooting
3.
Isolating a malfunction is as important as correcting the trouble . Use a good systematic approach to locate the problem in the minimum amount of time . All service operations can be solved by following these three steps:
Obtain from the owner an accurate description of the trouble, operating conditions, and main tenance history. In many cases, these will help to isolate the trouble . Sometimes solving the problem is not enough, and the cause has created other un detected problems. Use the Troubleshooting Charts as a guide in solving the problem . If additional in terrelated problems exist, refer to appropriate portion of Section 3 for major repair procedures .
1.
Identify the problem
2.
Determine cause of the problem
Correct the problem
Problem Isolation Chart Condition
Engine Problem Engine does not start - no spark.
1. Key switch not ON or mal functioning.
1. Turn switch ON or replace.
2 . Emergency stop switch in OFF position or malfunctioning.
2. Move switch to ON or replace stop switch .
3. Spark plug(s) fouled, oiled or damaged.
3. Replace spark plug(s).
4 . Plug cap(s) damaged, leaking or shorted.
4. Replace plug cap(s).
5. High tension wire(s) loose, grounded or shorted .
5. Service high tension wire(s) / coil(s).
6. Weak flywheel magnets.
6. Replace the flywheel.
440 MODEL ONLY--- - - - - I 7. Defective ignition coil.
Engine will not start - does not get fuel.
3-2
Remedy
7. Replace ignition coil.
8. Defective exciter coil.
8. Replace exciting coil.
9. Defective CD igniter.
9. Replace CD igniter.
10. Defective pulser coil.
10. Replace pulser coil.
1. Fuel tank empty.
1. Fill fuel tank with fuel.
2. Cracked, broken or pinched fuel line .
2. Replace the fuel line .
3. Obstructed or damaged fuel pump filter .
3. Clean or replace fuel pump filter.
4 . Carburetor jets plugged or fuel pump malfunctioning.
4. Service the carburetor or the fuel pump.
5. Impulse line is cracked, broken or pinched .
5. Replace the impulse line.
6. Carburetor adjusted incorrectly.
6. Adjust the carburetor.
GENERAL TROUBLESHOOTING
Engine Problem (Continued) Engine will not start fuel will not ignite.
Engine does not idle or idle RPM fluctuates.
Engine develops power loss or runs on one cylinder.
Condition
Remedy
1. Air leak between carburetor, silencer seal or intake manifold.
1. Tighten mounting bolt and nuts.
2. Carburetor adjusted incorrectly.
2. Adjust the carburetor.
3. Water in carburetor.
3. Disassemble and clean carburetor .
4. Engine is flooded.
4 . Turn key switch OFF, remove spark plug and dry it crank engine over 5-10 times. Install spark plug and start engine. If engine continues to flood, check carburetor.
5. No compression (worn or broken rings, scored piston, hole in piston or damaged cylinder) .
5 . Check compression, replace worn or damaged parts.
6. Blown head gasket.
6. Replace head gasket.
1. Air screw adjusted incorrectly.
1. Adjust air screw.
2. Idle screw adjusted incorrectly.
2 . Adjust idle screw.
3. Defective fuel pump (check valve).
3. Service the fuel pump (check valve).
4. Belt dust restricting passages in carburetor bore.
4. Disassemble and clean carburetor passages.
5 . Impulse line cracked, kinked or broken.
5. Replace or repair impulse line.
6. Enrichener cable adjusted incorrect Iy.
6 . Adjust enrichener cable.
7. Oil seals leaking.
7. Replace oil seals.
8 Air leak (pressure check engine).
8 . Disassemble and replace worn, defective, or damaged parts.
1. Fouled or defective spark plug(s).
1. Replace the spark plug(s).
2. Obstruction inside of muffler.
2. Remove obstruction or replace muffler.
3 . In-line filter obstructed.
3. Replace in-line filter.
4. Excessive carbon buildup in exhaust portIs).
4. Clean exhaust portIs).
GENERAL TROUBLESHOOTING
3 -3
GENERAL TROUBLESHOOTING (Continued) Engine Problem (Continued) Engine develops power loss or runs on one cylinder (Continued).
Condition
Remedy
5. Damaged or worn rings.
5 . Replace the rings .
6. Low crankcase pressure .
6 . Check crankcase for leaks; rep lace oil sea l or gasket .
7. Damaged piston .
7 . Replace piston and re lated component(s).
Engine overheats.
8. Damaged head gasket.
8. Replace gasket.
9. Broken (shorted) high ten sion leads.
9. Replace complete ignition coil.
10. Defective spark plug cap(s).
10. Replace cap(s).
11. Defective CDI igniter.
11 . Replace CDI igniter.
12. Defective pulser coil.
12. Replace pulser coil.
1. Incorrect spark plug(s).
1 . Install correct spark plug(s).
2. Cooling fins obstructed.
2. Clean cooling f ins.
3. Air leak between carburetor, intake manifold or cylinders .
3. Replace gaskets, tighten mounting hardware.
4. Caburetor adjusted incorrectly.
4 . Adjust carburetor
5. Excessive carbon deposits in combustion chamber, exhaust port or muffler.
5. Clean affected components.
6 . Damaged rings caused by
6. Clean or replace rings .
excessive carbon buildup . Engine backfires; has irregu lar running condition.
1. High tension lead wire shorting out.
1. Replace complete ignition coil.
Note: Engine may eventually overheat.
2. Fouled or incorrect spark plug(s) (heat range too hot).
2 . Replace spark plug(s) or install spark plug(s) having colder heat range.
3. Air leak between carburetor and intake manifold .
3. Check carburetor holder to make sure it is not warped .
4. Air leak between intake manifold and cylinders .
4 . Install new intake manifold gaskets.
1. Carburetor incorrectly ad justed.
1. Adjust carburetor.
2 . Dirt between needle valve and valve seat.
2. Service carburetor.
Engine four-cycles .
3-4
GENERAL TROUBLESHOOTING
.
Engine Problem (Continued ) Engine stops (suddenly) after running.
Engine stops (gradually) after runn ing.
Drive Converter Problem Drive converter engages be fore specified RPM.
Dr ive converter engages after specified RPM.
Remedy
Cond iti on 1. Defective ignit ion coil.
1. Replace ignition coil.
2. Obstruction in fuel tank or f ue l f ilter.
2. Clean or replace filter.
3. Fuel line obstru cted or pinched .
3. Remove obstruction, remove pinched area from fuel line.
4 . Defective exciter coil.
4. Replace exciter coil.
5. Spa rk plug bridged .
5 . Replace spark plug.
6. Se ized pi ston(s).
6. Replace piston and any affected components.
7. Se ized crankshaft.
7. Replace crankshaft and any affected components.
8 . Defective CDI igniter .
8. Replace CDI igniter.
9 . Defective pulser coil.
9. Replace pulser coil.
1. Obst ruction in fuel tank or f uel f ilter.
1. Clean or replace filter.
2. Fue l line obstructed or pinched .
2. Remove obstruction, remove pinched area from fuel line.
3. Damaged head gasket(s).
3. Replace head gasket(s).
4 . Loose cyli nder head.
4. Tighten cylinder head nuts to correct torque.
5. Loose spark plug(s).
5. Tighten spark plug(s) to correct torque.
Remedy
C ond it ion 1. Incorrect spring.
1. Install correct spring .
2. Wea k or da maged spring.
2. Replace spring .
3 . Incorrect wei ghts.
3 . Install correct weights .
1. Incorrect spr ing.
1. Install correct spring.
2 . Incorrect w eights.
2. Install correct weights.
3 . Dirty movabl e sheave.
3 . Clean movable sheave .
4 . Worn (fl at spots) roller s and ramps .
4 . Replace rollers and ramps .
5. Bushi ng in hous ing worn excess ively on in side diameter.
5. Replace components as re quired.
GENERAL TROUBLESHOOTING
3 -5
GENERAL TROUBLESHOOTING (Continued)
Drive Converter Problem (Continued)
Condition
Remedy
1. Incorrect weights.
1. Install correct weights.
2. Incorrect ramps (ramp angle too steep at top).
2. Install correct ramps.
3. Short belt or incorrect center to center distance.
3 . Install new belt and establish correct offset and center to center distance .
1. Incorrect weights (too heavy).
1. Install correct weights .
2 . Incorrect ramps (ramp angle too flat at top).
2. Install correct ramps.
3 . Long belt or incorrect center to center distance .
3. Install new belt and establish correct offset and center to center distance.
1. Incorrect weights (too heavy).
1. Install correct weights .
2. Incorrect ramps (ramp angle too flat).
2. Install correct ramps .
3 . Weak drive spring .
3 . Replace spring .
4. Driven spring preload in correct (too loose).
4. Correct spring preload.
1. Incorrect weights (too light).
1. Install correct weights.
2 . Incorrect ramps (ramp angle too steep).
2. Correct ramps.
3. Spring too strong.
3 . Replace spring .
4. Driven spring preload too tight.
4. Decrease spring preload.
Belt deposits on stationary sheave and movable sheave.
1. Wrong offset and center to center distance.
1. Remove belt deposits and establish correct offset and center to center distance .
Drive converter will not disengage at idle - engine starts hard and stalls because of belt drag.
1. Loose movable sheave bushing setscrews.
1. Stake movable sheave set screws.
2. Drive belt outside circumference below specifications .
2. Replace drive belt.
3 . Thickness of belt on inside diameter exceeds specifica tions.
3. Check drive belt specifications (belt thickness on inside diameter).
Maximum drive converter RPM too high .
Maximum drive converter RPM too low.
Shifting too quickly.
Shifting too slowly .
3 -6
GENERAL TROUBLESHOOTING
Drive Belt Problem
Side of belt glazed or baked not normal, caused by excessive heat buildup.
Lugs worn off inside of belt.
Belt worn in one spot .
Cracks ?t base of belt lug .
Chaincase Problem
Rattle in chaincase .
Chain slippage .
Remedy
Condition
1. Incorrect belt - excessive slippage.
1. Install correct drive belt.
2. Too much throttle applied under heavy load - excessive slippage.
2. Tell driver to dec rease throttle under heavy load con dition ; install new belt.
3. Weak drive converter spring .
3. Perform spring pressure test; install new spring if spring is weak.
4. Drive converter engagement RPM too low.
4. Adjust engagement RPM See Specifications.
5. Improper drive converter operation (sticking, etc .).
5 . Remove and repair drive converter; install new belt if one is needed.
6. Drive converter and driven converter offset / center to center is incorrect .
6. Check and adjust, install new belt if one is needed.
7. Oil or grease on drive con verter or driven converter sheave surface.
7. Clean sheaves; install new belt if one is needed.
1. Drive converter engages suddenly (engagement speed too high).
1. Remove and repair drive converter; install new belt, if one is needed.
2. Center to center distance too far apart or belt too short.
2. Alter center to center distance or install longer belt.
1. Track frozen to suspension, front drive or ground .
1. Free track and install new belt.
2. Incorrect track tension.
2. Adjust track tension and install new belt.
3. Idle speed too high.
3. Reduce idle RPM and install new belt.
4 . Improper operation of drive converter.
4 . Repair or replace drive converter and install new belt.
1. Continuous overrevving when snowmobile is operated.
1. Decrease RPM and install new belt .
Condition
Remedy
1. Incorrect chain tension.
1. Check tensioner guides and spring.
2. Chai n stretched beyond adjust able limit.
2 . Install new chain and sprockets.
1. Incorrect chain tension.
1. Check tensioner guides and spring.
GENERAL TROUBLESHOOTING
3 -7
GENERAL TROUBLESHOOTING (Continu ed ) Chaincase Problem (Continu ed) Chain slippage (Continu ed ).
Chain slips off sprockets.
Condition
Remedy
2. Chain stretched beyond ad justable limit.
2 . Install new chain and sprockets .
3. Sprocket teeth worn.
3 . Install new sprockets and chain .
1 . Incorrect chain tension.
1. Check tensioner gu ides and spring.
2 . Sprocket teeth worn .
2. Install new sprockets and chain .
3 . Sprockets misaligned.
3 . Align top sprocket with bottom sprocket .
Track Problem
Condition
Remedy
1. Track is misaligned.
1. Set track tension and alignment.
2. Track strikes rivets in tunnel, yet alignment is correct.
2. Remove rivets and install correct type rivet.
1. Track tension is too tight.
1. Set track tension and alignment.
2 . Rear idler wheels do not turn or otherwise damaged.
2. Install new rear idler wheels and set track tension and alignment.
Track ratchets or hits on body tunnel (top).
1. Track tension is too loose.
1 . Set track tension and alignment .
Accelerated rail strip wear .
1. Sl ide rail(s) bent.
1. Straighten slide rail(s) or in sta ll new rails.
2. Bad ly worn clip that con tacts sl ide ra i I.
2. Install new rail strip and/or clip .
3. Track is misaligned.
3 . Set track tension and alignment.
Edge of track is frayed.
Track is grooved (worn) or burnt on inside surface.
Condition
Driven Converter Problem
Remedy
Low engine RPM yet belt shifts completely through driven converter operating range.
1. Weak spring or broken spring. 1. Rotate end of spri ng clock wise on driven converter to increase spring tension or install new spring.
High engine RPM yet belt takes too long to sh ift through driven converter range .
1. Incorrect spring - too heavy.
1 . Install correct spring.
2. Dirt on movable or stationary sheave.
2. Clean sheaves.
3. Excessively worn movable or stationary sheave .
3 . Install new components.
3-8
GENERAL TROUBLESHOOTING
Ignition Troubleshooting NOTE: The following tips may help isolate ignition pfOblems quickly . 1.
A defective exciter coil, CD igniter, and / or ignition coil, key switch or emergency stop switch can be the cause of no spark, weak spark or intermittent spark.
2.
A defective pulser coil may cause no spark or intermittent spark but not a weak spark .
â&#x20AC;˘,
Check spring terminal for correct installation to ignition coil lead as follows: 1. Slide cap off lead wire. 2.
Ends of spring terminal must be at 90° angle to insure correct engagement with inner wire . (See Figure 3 - 2.)
"~
Preliminary Procedures
(
.~
l-(
-~
When an ignition problem is present, prior to performing elaborate troubleshooting try to solve problems by performing the easy tests first as follows:
Spark Plug Cap Each ignition coil lead is secured to spark plug tip by a small spring terminal inside the spark plug cap. Incorrect spark plug cap removal will damage the terminal which may result in ignition system malfunction or premature component failure.
[::~~~~~::] Do not twist or force spark plug cap off by pulling on lead wire as this will damage the connection. Twist cap back and forth while pulling straight upward to remove from spark plug. (See Figure 31 .)
Figure 3- 2
3.
Both arms of spring terminal must enter ignition coil lead at centerline to insure contact with inner wire. (See Figure 3 -3.)
01-::::::,-9 ~-g 1.
Lead Wire
2.
Spark Plug Cap Figure 3 - 1
Figure 3-3
IGNITION TROUBLESHOOTING
3 -9
4.
Slide spark plug cap onto ignition coil lead to cover spring term inal. Lubricate spark plug cap with LPS or WD-4D to ease installation .
To prevent ignition system malfunction do not apply oil or grease to spark plug cap during installation.
I
Spark Test Check ignition coil output to performing the following : 1.
spark
plugs
by
Connect test spark plug to each spark plug cap. (See Figure 3-4.)
NOTE: Fabricate test spark plug by removing ground electrode. This increases distance spark must jump from center electrode to ground, working the ignition system harder than jumping standard spark plug gap. 2.
Crank engine and observe spark. a. Blue colored spark jumps gap of test spark plug indicates ignition system should start and run engine if timing is correct. b. No spark observed, shooti ng procedure.
continue
1. Test Spark Plugs 2. Wiring Harness Connector
trouble-
Figure 3-4
Stop Circuit Elimination Test Remove key switch and emergency stop switch circuits from the system by separating wiring harness connector on the engine. (See Figure 3-4.) 1.
Crank engine. If spark occurs with the connector separated, ignition components on the engine are okay, defective component must be key switch, emergency stop switch or the wiring. Refer to Key Switch and Emergency Stop Switch Tests.
2.
If no spark is observed, test ignition components mounted on engine .
Ground Wire Test Check the grounded BROWN and GRAY wires at main engine connector ring terminal for condition and secure mounting. (See Figure 3-5 .) A loose connection will cause intermittent spark while a broken connection will result in no spark.
3-10
IGNITION TROUBLESHOOTING
1. 2.
Main Wiring Connector Brown and Gray Wires Figure 3-5
Ground Wire Test (58440 Only) Check condition of the grounded BROWN wire be tween ring terminal at engine connector and ring terminal on primary of the ignition coil. 1.
Remove screw securing each ring terminal to ground.
2.
Set meter to low ohms scale (XI). Connect one ohmmeter lead to the ring terminal removed from the ground at the ignition coil. Connect the other ohmmeter lead to the ring terminal removed from the ground at the engine connector. (See Figure 3-6.)
3.
If ohmmeter indicates closed circuit (0), BROWN ground wire between the engine connector and the ignition coil is okay.
4.
If ohmmeter indicates open circu it (00) or high resistance, BROWN ground wire is defective . Check BROWN ground wire connection at the ring terminals, the three wire connector between CD igniter and ignition coil. If the wire checks okay, replace the CD igniter .
1. 2.
Ignition Coil Primary Wire COl Igniter to Engine Connector
Ignition Troubleshooting Using CD Ignition Tester PN T56019-201 GENERAL DESCRIPTION The Kawasaki Ignition Tester PI N T56019-201 is an electrical energy measuring device capable of measuring the peak energy output of the CD igniter, magneto exciter, and pulser coils. Ignition energy output pulses occur at a speed of microsecond duration and cannot be accurately measured by a voltmeter . The Kawasaki Ignition Tester PI N T56019-201 is solid state construction capable of measuring energy peaks of less than one microsecond in duration . The Kawasaki Ignition Tester PI N T56019-201 performs as a comparator. The energy output values for all CD Ignition components were derived from tests conducted by Kawasaki . Using this tester, it can be determined if each ignition com ponent is functioning properly. The test results can be compared with the standard values given.
Figure 3-6
High Scale Test: a. Plug the test simulator into a 115 VAC electric outlet for ten seconds. b. Place toggle switch of the tester in the High position. c. Remove the simulator from the outlet, and connect the P and N leads from the tester to the simulator as indicated on the bottom of the simulator. d. Set the tester dial to 50, or below. Depress the button on the simulator. The indicator lamp on the tester should light.
Low Scale Test: a. Place switch in Low position.
Tester Controls and Accessories b. Set tester dial to 50, or below. 1.
High-Low Range Switch The tester has two input ranges selected by a toggle switch. The Low range is sensitive to AC or DC voltages from 0.5 to 27 volts. The High range is sensitive to AC or DC voltages from approximately 75 to 500 volts.
c. Connect yellow lead to negative terminal of 12 volt battery. Connect red lead to positive terminal. Indicator lamp should light. If lamp does not light in either the High or Low scale tests, check tester battery installation.
IGNITION TROUBLESHOOTING
3-11
Check the clip leads for faulty connections. If no faults can be found, refer to the warranty statement for instructions in sending the tester back to Electro-Specialties, Inc. for repair.
2.
Indicator Dial and Light The ignition energy output is referenced against a 0-100 scale on the tester. The greater the energy output, the greater the value indication on the scale. The indication is in the form of an incandescent lamp that lights when the scale dial is set at the position cor responding to the energy output .
5.
MM-1 Clip The MM-1 clip determines the relative amount of energy present in th e spark plug wires. En gines in various stages of wear will indicate a different energy reading than new engines. As the engine compression goes down, the energy necessary to fire the plugs goes down also. Readings lower than standard indicate low coil output (caused by a fault anywhere in the igni tion system, faulty spark plug or ignition wire, or low compression). Readings higher than standard indicate higher coil output or larger than standard spark plug gap .
GENERAL TEST INSTRUCTIONS Indicator Dial Alignment: Check indicator dial alignment by turning the dial to the full clockwise position. The white mark on the dial must line up with the 100 on the face . If the mark does not line up with the 100, loosen the dial setscrew, remove the dial, turn the indicator dial shaft fully clockwise, replace the dial, lining up the mark on the dial with the 100, and tighten the setscrew. Do not force the dial to turn without first loosening the setscrew.
3.
Eng i ne Accessory Circu its Before beginning test procedures, check all primary and secondary ignition wiring, key switches, and engine stop switches to eliminate them as possible causes of ignition failure.
Cranking Engine
Due to manufacturing tolerances, do not be concerned if the white mark on the dial, when turned fully in the counterclockwise direction, does not align exactly with the zero.
Removal of the spark plugs will allow the engine to turn over faster, raising the level of output from the ignition system. Vigorous cranking raises the output over that of cranking without compression. If output results are marginal, output can be mea sured with and without compression. Values listed in the test procedures are taken against compression. Always crank vigorously as in actual starting.
Test Simulator
Analysis of Test Results
The test simulator is used as a source of energy for testing the high range of the ignition tester. It is charged up by being plugged into a 115 VAC outlet.
Indicator Lamp Lights at Specified Setting:
Do not touch the plug pins on the simulator while depressing the button. A mild shock will result. For each test performed by the simulator, it must be recharged. The tester will not be damaged if the test switch is placed in the Low position and high voltage output tests are made.
After every test that lights the indicator lamp, reset the indicator circuit by depressing the Reset button. The Indicator lamp will light at all points downscale from the highest indication. Test results should repeat within five points of the specified setting . If readings do not repeat, output of the ignition system is erratic.
Indicator Lamp Does ~Iot Light Unless Dial Is Turned Downscale From Specified Setting: 4.
Load Coil The CD ignition load coil is used in conjunction with the tester and is designed to provide an output load for the CD igniter unit. The load coil will cause a marginal capacitor to malfunction, but will not effect a good unit .
3-12
IGNITION TROUBLESHOOTING
This indicates that the output is less than that designed to operate the engine in a satisfactory manner. The engine may run at a lower setting , but be subject to hard starting and / or misfiring. Be certain that correct engine cranking conditions were met.
Indicator Lamp Does Not Light: Output of the system is too low to operate the tester indicator c ircu it. Multiple or Intermittent Ignition Problems In dealing with intermittent ignition problems there is no easy way. Problems that occur only during hot engine operation will have to be tested on a hot engine. In some cases of temperature and /or vibration failure, only parts replacement can solve the problem as most of these failures return to normal at engine shut off. Low test readings indicate ideal conditions for engine misfire and hard starting. There is always the possibility of more than one component of the ignition system failing. Careful repeat of the test procedures and troubleshooting of the accessory circuits will uncover any addi tional problems.
WARNING
I
Magneto and COl igniter output voltages are high enough to cause an uncomfortable shock. Always see that clip lead insulators cover the clips so they do not contact the operator or vehicle frame .
Never perform tests on the COl igniter without the ignition coil or the tester connected to the output connections. This will prevent internal damage to the COl igniter.
Never connect the tester directly to the coil secondary output (spark plug). Always use the MM - l clip when testing the ignition coil output.
..
IGNITION TROUBLESHOOTING
3 -13
Test Sequence - Using CD Ignition Tester PIN
SA340 & SC340
T56019-201
TEST
it3
Pulser Coil Output
COl IGNITER & IGNITION COIL WHITE L -_ _~_ _~~_ __ _~~(_ _ _ _ _ _ _ __ __
RED
o
RED OJ
EMERGENCY
STATOR ASSEMBLY
/ S T O P SWITCH
OJ :0
~
0
7'
z
(")
/~
~ TEST #1
BLACK
TEST #2
Ignition Coil Output And Spark Plug Check
G
Exciter Coi l Output
=
TEST #1
TEST #2
TEST #3
RANGE
DIAL SETTING
RANGE
DIAL SETTING
RANGE
DIAL SETTING
Lo w
25
High
35
Low
90
NOTE : Refer to following pages for detailed testing procedure.
3-14
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
i =
Test Sequence - Using CD Ignition Tester PIN T56019 -201 S8440 Only
TEST #4 TEST #3
CD! Igniter Output To Ignition Coil
Pulser Coil Output CD IGNITER
o
o
TEST #2 Exciter Coil Output
ENG INE CONNECTOR
TEST #1 Ignition Coil Output And Spark Plug Check
EMERGENCY STOP SWITCH
TEST #1
TEST #3
TEST #2
TEST #4
RANGE
DIAL SETTING
RANGE
DIAL SETTING
RANGE
DIAL SETT ING
RANGE
DIAL SETTING
Low
25
High
50
Low
90
High
55
NOTE: Refer to following pages for detailed testi ng procedu res.
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
3-15
Test No.1 Ignition Coil Output and Spark Plug Check SA340, SB440 and SC340 CD IGNITER/IGNITION CO IL - SA340 and SC340 IGNITION COIL - SB440
TEST CONNECTIONS 1.
Connect the MM-1 adaptor to the tester N (yel low) lead wire.
2.
Connect the tester P (red) lead wire to a good ground on the engine .
3.
Clamp the MM-1 adaptor around either spark pi ug wire as close to the spark plug as possible. If insulation sleeving is over the spark plug wire, push the sleeving back so that the clip encircles the spark plug wire directly. Do not allow any metal portion of the MM-1 clip to touch the engine.
4.
Before proceeding, be certain that the engine stop switch, ground wires, and all primary and secondary ignition wiring are not contributing to the problem. (See page 3-10.)
1.
Set the toggle switch to the Low range. Set the tester dial to 25.
2.
Pull the recoil starter handle to turn the engine over. If the engine starts, allow it to idle only. Repeat this test three times to verify consistent output.
a. If the lamp lights consistently at or above 25 on the scale, the ignition system up to the spark plugs is operating properly. Remove the spark plugs and replace any plug which is fouled, bridged, or otherwise unfit for service . Consider the possibilities that high heat. vibration, or moisture may be causing ignition problems and repeat Test No. 1 incorporating these factors into the test.
TEST PROCEDURE NOTE: After each test that lights the Indicator Lamp, push the Reset button to turn the lamp off in preparation for the next test.
3-16
b. If the lamp does not light consistently above the specified value or does not light at all, follow the steps on the next page.
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
TEST NO. 1 PROCEDUR E (CONT)
,)rl/
TEST #1 Ignition Coil Output And Spark Plug Check
,
t - - --
Repl ace Spark Plugs
---,
;Q~
Remove spark plugs and replace any plug which is fouled, bridged or otherwi se unfit for service.
I Problem solved or problem not in Ignition System
Proceed to Test #2
Consider the possibi li t ies that high heat, vibration or moisture may be causing ignition prob lems. Retest inj ecting these factors into the test.
,
Proceed to Test #2
,
Problem solved
No Lamp or Low/Inconsistent Read ing
,,\r/,/
--:n~
/'\J'"
Lamp Lights at Specified Value
STANDARD VALUE TEST #1
RANGE
VALUE
Low
25
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
3 -17
Test No.2 Exciter Coil Output
5A340, 58440 & 5C340
2.
Do not turn over the engine unless either coil or tester is connected to the CD igniter. TEST CONNECTIONS 1.
Disconnect the red and white wires between the magneto assembly and the CD igniter.
2.
Connect the tester N (yellow) lead wire to the red wire on the magneto end of the connector.
3.
Connect the tester P (red) lead wire to a good engine ground.
Turn over the engine while observing the Indicator Lamp on the tester. a. If the lamp lights, push the Reset button to turn the lamp off and repeat Test No. 2 three times. If the lamp lights consistently at 35 for SA340 and SC340 and 50 for S8440; the magneto exciter coil is good, proceed to Test No.3. b. If the Indicator Lamp gives inconsistent readings at any dial setting or does not light at all, this indicates, the following:
1. A defective exciter coil (check the ohms). Replace the exciter coil.
2. Defective wiring . Check the wiring . TEST PROCEDURE 1.
Set the toggle switch to the High range. Set the tester dial to 35 for SA340 & SC340; 50 for S8440 model.
3 -18
3. Defective flywheel magnets .
magnets. Replace the
Follow the steps in the chart on the next page.
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
TEST NO. 2 PROCEDURE (CONT)
TEST #2 Exciter Coi l Output
Examine magneto wiring for opens, shorts, or poor ground and repair if possible or replace magneto exciter co il
, Proceed to Test#3
Repeat Test #2
Replace flywheel assembly and repeat Test #2
Proceed to Test#3
No Lamp or Low/Inconsistent Reading
Lamp Lights at Specified Value
STANDARD VALUE TEST #2
SA340
&
S8440
SC340
RANGE
VALUE
RANGE
VALUE
High
35
High
50
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
3 -19
Test No.3 Pulser Coil Output
SA340, S B440, & SC340
â&#x20AC;˘
STATOR ASSEMBLY
TEST CONNECTIONS 1.
2.
With both the red and white wires still discon nected, connect the tester N (yellow) lead wire to the white wire on the magneto end of the connector. Connect the tester P (red) lead wire to a good engine ground.
YELLOW
2.
Turn over the engine while observing the Indicator Lamp on the tester.
a. If the Indicator Lamp lights, push the Reset button to turn the lamp off and repeat Test No. 3 three times . If the lamp lights consistently at 90 the pulser coil is good, proceed to Test No. 4.
TEST PROCEDURE 1.
Set the toggle switch to the Low range. Set the tester dial to 90.
3-20
b. If the Indicator Lamp gives inconsistent readings or does not light at all, follow the steps on the next page.
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
TEST NO. 3 PROCEDURE (CONT)
v'-
",\ 1//
TEST #3 Pulser Coil Output
1---------.
-X
Proceed to Test #4 S8440
Examine magneto wiring for opens, shorts, or poor ground and repair if possible or replace magneto pusler coil
ONLY
Repeat Test #3
Ir Replace flywheel assembly and repeat Test#3
Proceed to Test #4 S8440
ONLY
No Lamp or Low/Inconsistent Reading
",\1/
1/
-:n~
/1\1'"
Lamp Lights at Specified Value
STANDARD VALUE TEST #3 RANGE
VALUE
Low
90
IGNITION TEST PROCEDURE USING CD IGNITION TESTER
3-21
Test No.4 COl Igniter Output To Ignition Coil 58440 Only
,
CD IGNITER STATOR ASSEMBLY
YELLOW ._-----,1
o
P GRAY
TEST CONNECTIONS
TEST PROCEDURE
1.
Disconnect the three-wire connector between the CD igniter and the ignition coil.
1.
Set the toggle switch to the High range. Set the tester dial to 55.
2.
Connect the tester N (yellow) lead to both blue wire terminals in the CD igniter half of the three-wire connector. Form the test jumper into a loop to aid in this connection.
2.
Turn over the engine while observing the Indicator Lamp on the tester.
4.
5.
Connect the tester P (red) lead to the brown wire terminal in the CD igniter half of the three-wire connector. Connect the load coil between the tester P (red) and N (yellow) lead wires.
3-22
a. If the Indicator Lamp lights, push the Reset button to turn the lamp off and repeat Test 4 three times. If the lamp lights consistently at 55 the CD ignitier is good. Replace the ignition coil and repeat Test No.1. b. If the Indicator Lamp gives low/inconsistent readings or does not light at all, replace the CD igniter.
IGNITION TEST PROCEDURE USING CD IGNITION TESTER - S8440 ONLY
,
TEST NO.4 PROCEDURE (CONT)
TEST #4 CDI Igniter Output To Ignition Coil
,
~
". ,\, /,/
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L -_ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _
'-;~~-
Replace ignition coil and repeat Test # 1
No Output replace CDI Igniter and repeat Test # 1
,
No Lamp or Low/Inconsistent Reading
".'\'/'/
-:n ~
/'\1'"
Lamp Lights at Specified Value
STANDARD VALUE TEST #4
RANGE
VALUE
High
55
IGNITION TEST PROCEDURE USING CD IGNITION TESTER - S8440 ONLY
3 -23
Ignition Troubleshooting Using an Ohmmeter
specified in the following illustration. Repair defective wire or replace coil not within specifications. (See Figure 3-8.)
General Description If the Kawasaki CD ignition tester is not available, the exciter coil, pulser coil and on S8440 model the ignition coil may be checked using an ohmmeter. This test is not as accurate or sophisticated as using the Kawasaki CD tester and the results are not 100% conclusive.
NOTE: Exercise care to prevent an electrical shock from the CD igniter. Handle the CD igniter carefully. If you should drop it, the incorporated electronic components will be damaged.
Do not use an improper tester (insulation resistance testers or other testers with a battery of large capacity). The use of a large capacity tester may ruin components during test. SA340 & SC340
The following test procedures are alternate checks designed for locating ignition system malfunction using an ohmmeter. 1.
WIRING CONNECTIONS - Check all wiring connectors to insure connections are clean, secure, and correct. (See Figure 3-7.)
COl I"NlnR & IGNITION COil
STATO H
flSSfMIlLY
SA340 & SC340 PART TO BE MEASURED
EXCITER
OHMMETER LEADS CONNECTED BETWEEN
RED BROWN (GROUND)
WHITE RED
RESISTANCE i1
160i1± 20%
17i1± 20%
*VOLTAGE AC
40 VAC
4 VAC
PULSER
COII(,NITrR & ,,,NIlIUN COIL
~
-t
SB440 SB440 STATOR ASSEMBLY
IGNITION CO i l
EMERGENCY _ STOP SWITCH
WIRING CONNECTIONS Figure 3-7 2.
EXCITER AND PULSER COILS - To locate the cause of trouble (broken wire, short circuit, etc.) measure the resistance of each coil winding and check AC voltage output as
3 -24
PART TO BE MEASURED
EXCITER
OHMMETER LEADS CONNECTED BETWEEN
RED BROWN (GROUND)
PULSER WHITE RED
RESISTANCE i1
128i1± 20%
23i1±20%
*VOLTAGE AC
40VAC
4 VAC
*Measure at cranking speed with spark plugs installed.
IGNITION TROUBLESHOOTING USING AN OHMMETER
Figure 3-8
..
3.
IGNITION COIL S8440 only, measure resistance of ignition coil primary and secondary windings as specified in the follow ing illustration. Repair defective wire or replace coil not within specifications. (See Figure 3 -9.)
c
BLUE
II
BLUE -~
D
'-----I
B*
, I
Do not use an improper tester (insulation resistance testers, or other testers with a battery of large capacity). The use of a large capacity tester may ruin components during test.
OHMMETER LEADS CONNECTED BETWEEN
PRIMARY WIN D I NG C- (G ROUND DI
RESISTANCE"
0.37
SECONDARY WIND IN G A B'
n Âą 20%
10.2K
n Âą 20%
'W lth spark plug caps removed .
. 'Defective coils canno t always be detected usmg thiS test alone. Use of coil tester which Simu lates operating conditiOn is th e most reliable test method.
Figure 3-9
Ignition Troubleshooting Table Condition
Problem No spark is produced
S84400NLy-
-
-
Remedy
1. Defective exciter co il
1. Rep lace exciter coil
2 . Defective pulser coil
2. Rep lace pu lser co il
3. Defective ignition coil primary winding
3. Rep lace ign it ion co il
4. Defective ignition coil secondary winding
4 . Replace ign ition coi l
5. Defective CD igniter
5. Rep lace CD igniter
6 . Spark plug is shorted resistance between electrodes should be 1 M or more
6 . Replace spa rk plug
7. Wrong wire connections
7 . Connect wires correctly
1. Defective exciter coil
1. Replace exciter coil
2. Defective pulser coil
2. Replace pu lser co il
3. Improper timing
3 . Adjust tim ing
4. Defective CD igniter
4. Replace CD ign iter
5. Shorted spark plugs . Resistance between electrodes or more should read 1 M
5. Replace spark plugs
1. Defective exciter coil
1. Replace exciter coil
2 . Defective pulser coil
2. Replace pu lser coil
1. Defective CD igniter
1. Replace CD igniter
---I
n
The engine starts but will not pick up speed
f
n
The engine is cranked again but will not start
The engine tends to kick back
IGNITION TROUBLESHOOTING USING AN OHMMETER
3 -25
Electrical System Key Switch Tests The G and M terminals of the key switch control the RUN and OFF circuit of the ignition system. Lights are operated through terminals marked B and L. (See Figure 3-10.)
Figure 3 - 11
4. Turn the key switch to OFF pos ition. Meter should now indicate closed circuit (0). Replace the switch if the needle does not move to O. 5.
Set the ohmmeter to low ohm scale (Xl) and connect one ohmmeter lead to the key switch B terminal and the other lead to L. (See Figure 3-12.)
Figure 3-10
To test the key switch:
NOTE: Prior to performing key switch tests follow the procedure for Key Switch Removal to obtain access at terminals on switch. 1.
Remove the main wiring harness connector from the key switch terminals.
2.
Set the ohmmeter to high ohm scale (Xl 00) and connect one ohmmeter lead to the key switch G terminal and the other ohmmeter lead to M. (See Figure 3-11.)
3.
With the key switch in the RUN position, the ohmmeter should show open circuit (co). Re place the switch if the needle moves off of in finity (co).
3 -26
ELECTRICAL SYSTEM
Figure 3-12
6.
Turn the key switch to RUN/LIGHTS position. The ohmmeter should indicate a closed circuit (0) . Replace the key switch if the meter does not indicate O.
7.
With the key switch positioned in RUN or OFF, the ohmmeter must indicate an open circuit ( co ). Replace the key switch if (co) is not ob served.
8.
Reconnect the main wIring harness connector to switch terminals and refer to Key Switch Installation.
Emergency Stop Switch Test The emergency stop switch is used to stop the engine quickly in an emergency, and operates in dependent of the key switch. Both the key switch and emergency stop switch must be ON for the engine to operate. To stop the eng ine, turn the emer gency stop switch to STOP. TO TEST THE EMERGENCY STOP SWITCH: 1.
Disconnect the molded connector between the key switch and emergency stop switch.
2. Set the ohmmeter to high ohm scale (X100). Connect one ohmmeter lead to one terminal in the stop switch half of the connector. Connect the other lead to the other terminal in the stop switch half of the connector. (See Figure 3- 13.) 3.
Position the stop switch to ON. The ohmmeter should indicate an open circuit (co). Replace the switch if the ohmmeter needle moves off of infinity (co) .
4.
Position the stop switch to STOP. The ohmmeter should now indicate a closed circuit (0) . If the ohmmeter needle does not indicate to 0, replace the emergency stop switch .
5.
Connect the molded connector between the emergency stop switch and key switch. 1. Emergency Stop Switch Connector Figure 3-13
ELECTRICAL SYSTEM
3 -27
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KEY SWITCH CONNECTIONS KEY SWITCH CIRCUIT COMPLETED POSITIONS BETWEEN CONTACTS MARKED G-M "OFF" "RUN/LIGHTS" B-L "RUN" NONE "ELECTRIC B-S START"
o< ~
l> G'> m :lJ
m
BRAKE LIGHT SWITCH
CO
~
CD
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CD
CO
c:
BLUE
G'> C rl>
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Q)
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o
o...
r+
--' --'
-l
W 0:
:lJ -l
m en
BLACK/YELLOW YELLOW/RED STOP- TAIL LIGHT
o
-l
'" oS
BROWN/YELLOW
gl~l~
--'IO w"'--' >--'
'::l <L
~
",W--'
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'"o
0:
r+
oO:W
--,'>wO'" >---,0
--,""
--' --' W
0:
COIL
'"o
OW--' W>-ID
Z
(BRAKE LIGHT) BLACK (COMMON) YELLOW IT AIL L1GHTl
0:
ID
ENGINE MAGNETO RED/YELLOW
-=-
SWITCH
VOLTAGE REGULATOR
'"
ACCESSORY r---------------~
1 1
~ BROWN ~ WHITE
1 : TACHOMETER LIGHT
1
I
I
1 1 1 1 1 1 1 1 1 1
1 1L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
....
1
'I
h
Zl~
"'~ oz
0:'"
IDO
16
-I en CD
z
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:0; :0;
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ID
0
Voltage Regulator Tests
b.
These tests should be conducted if the bulbs burn out consistently or all the lights are extremely dim (filaments barely light). Bulbs which fail due to over-voltage usually have melted filaments rather than broken ones.
Tachometer shorted - unplug tachometer connector from main wire harness and repeat test.
c.
Main wiring harness shorted - repair shorted wire or replace main wire harness assembly.
1.
Raise the rear of the snowmobile . Make sure the track is free to rotate . WaRNING
I
While raising the snowmobile off the ground, place the ski tips against a stationary object and be sure the vehicle is properly secured, to prevent personal injury. 2.
Set the multi meter to measure 25 volts A.C . and attach one multimeter lead to the yellow wire in the main harness half of the engine connector. DO NOT SEPARATE THE MAIN HARNESS FROM THE ENGINE CONNECTOR .
3.
Connect the other multimeter lead to the other yellow wire in the main harness half of the engine connector.
4.
Turn the key switch to RUN position. Do not activate the brake light during test.
5.
Start the engine . DO NOT RUN OVER 2000 RPM . The multimeter should indicate 8 to 11 volts AC. If the needle indicates 8 to 11 volts, the lighting coil and the voltage regulator are okay. If it reads less than 8 to 11 volts, proceed to step 6.
Headlight Circuit Test Before proceeding with the following tests, be sure the lighting coil and voltage regulator are working properly. 1.
Check to see if the headlight bulb filaments are good. a.
Disconnect the headlight connector.
b.
Set the ohmmeter scale to ohms Xl.
c.
Connect one lead of the ohmmeter to the ground terminal of the headlight. (See Figure 3-14.)
SC340
If the meter indicates higher, the voltage regulator may be open and not working. In crease the RPM slowly. DO NOT EXCEED 3000 RPM. If the voltage reading did not stabilize or exceeded 22 volts, the regulator should be replaced. (Before replacing the regulator, make sure the connector on the regulator to the mai n harness is in good condition and that the case is properly grounded.) 6. With the engine still running at 2,000 RPM, disconnect the voltage regulator from the main wiring harness. With the voltage regulator disconnected, the meter indication should in crease to 14 to 20 volts. If the voltage does not increase, the problem is in the magneto lighting coil circuit. Refer to Section 1 (Magneto Resistence Test) for lighting coil specifications. If voltage does increase,
problem may be: a.
Voltage regulator shorted - replace.
1. 2.
High Beam Low Beam
3.
Ground
Figure 3-14
HEADLIGHT CIRCUIT TEST
3-29
d.
Connect the other lead of the ohmmeter to the high beam terminal.
e.
If the ohmmeter reads infinity (co) or more than 2 ohms, the filament is faulty.
f.
Test the low beam in the same manner by moving the ohmmeter lead from the high beam terminal to the low beam terminal. If the needle indicates infinity (co) or more than 2 ohms, replace the bulb .
g.
If the headlight malfunction still exists, proceed with step 2.
Be sure the key switch is turn ed to RUN/LIGHTS position and that the dimmer switch is set to the proper beam, either high or low. e.
2.
If voltage is not present at either the high or low beam, check the headlight harness for a good connection to the main harness and check for burned or shorted wires in the headlight harness. If the harness is good, proceed to the tests for the dimmer switch.
Dimmer Switch Test
Check to make sure voltage is present at the headlight connector.
1.
Disconnect the dimmer switch from the main harness.
Raise the rear of the snowmobile . Make sure the track is free to rotate.
2.
Set ohmmeter to low ohm scale (X1). Connect one ohmmeter lead to the brown wire terminal in the dimmer switch half of connector. Connect other lead to orange wire terminal in connector. (See Figure 3-16.)
a.
WARNING
I
While raising the snowmobile off the ground, place the ski tips against a stationary object, and be sure the vehicle is properly secured, to prevent personal injury. b.
Run the engine at idle speed.
c.
Set multimeter to measure 25 volts AC.
d.
Check for voltage between brown / yellow and orange wire (low beam) and brown / yellow and green wire (high beam). (See Figure 3-15.)
1. Dimmer Switch Connector Figure 3-16 3.
Turn the dimmer switch to low beam, the ohm meter should indicate a closed circuit (0).
4.
Turn the dimmer switch to high beam, the ohmmeter should indicate open circuit ( co).
5.
Move the ohmmeter lead from the orange wire terminal to the green wire terminal in the dim mer switch half of the connector.
6. Turn the dimmer switch to high beam, the ohmmeter shou ld indicate a closed circuit (0). 1.
Headlight connector 7. Figure 3-15
3-30
DIMMER SWITCH TEST
Turn the dimmer switch to low beam, the ohm meter should indicate an open circuit (co).
,
8.
If any of the tests in steps 3, 4, 6, or 7 were faulty, replace the dimmer switch.
9.
If all of the above tests were okay and there is no power to the headlight, and the headlight harness, lighting coil, voltage regulator, and key switch tests were okay, the problem is in the main harness. The main harness should be removed and repaired or replaced .
Stop / Tail Light Harness Test 1.
2.
3.
Check stop / tail light bulb before testing and make sure it is making a good connection in socket housing. Disconnect tail light connector from the main harness. To check the wIring to the tail light, set the ohmmeter on low ohm scale (Xl). Connect one ohmmeter lead to the black w ire termina l in the tail light half of the connector. Connect the other ohmmeter lead to the yellow wire terminal of the connector. Ohmmeter should indicate 2 to 3 ohms.
Brake Switch Test Before proceeding with this test make sure the brake lever is adjusted so it makes good contact with the brake switch located in the handlebar brake lever assembly. 1.
Disconnect harness.
2.
Set the ohmmeter to low ohms (Xl). Connect an ohmmeter lead to the yellow wire terminal in the brake switch half of the connector. Connect the other ohmmeter lead to the blue wire terminal in the connector. (See Figure 317.)
3.
brake
switch
from
the
main
The ohmmeter should indicate an open circuit (co).
4.
Operate the brake lever. The ohmmeter should indicate a closed circuit (0).
5.
If the readings in steps 3 and 4 are not obtained, replace the brake light switch.
4 . To check the wiring to the stoplight, move the ohmmeter lead from the yellow to the brown wire terminal in the tail light half of the wire terminal connector. Ohmmeter should indicate 1 to 2 ohms. 5.
If the readings in steps 3 and 4 read higher than specified or indicate on open circuit (co), the problem is in the wiring to the tail / stop light. Remove the seat and inspect the wiring to the tail light. (Check the bulb contacts again.)
6.
If the reading in step 3 was okay and the tail light, headlight, and instrument lights do not function proceed to the tests for the lighting coil, voltage regulator and key switch tests. If only the tail light does not function the problem is in the main harness. Remove and repair the main harness or replace .
7.
If the reading in step 4 was okay proceed to the test for the brake light switch.
8.
If the brake light switch tests okay and the other lights function okay the problem is in the main harness. Remove and repair the ma in harness or replace .
1. 2. 3.
Brake Switch Connector Brake Switch Brake Lever Figure 3-17
STOP /TAIL LIGHT HARNESS TEST
3-31
Flow Chart - Engine Removal 340 and 440 Models NOTE: This flow chart is designed to aid in determining the proper sequence for removing various component parts from the engine. Select the component and follow the arrows from the snowmobile box to that point on the chart.
SNOWMOBI LE
I
, ENGINE MOUNT BOLTS
BELT GUARD
MUFFLER TO EXHAUST MANIFOLD SPR INGS
RECOIL STARTER HANDL E
ENGINE TO MAIN WIRING HARNESS CONNECTOR
IMPULSE LINE
AIR SILENCER
DRIVE BELT
CARBURETOR
REMOVE THE ENGINE
3-32
FLOW CHART
I
Flow Chart - Disassembly - Engine Installed, SA340 and S8440 NOTE: This flow chart is designed to aid in determining the proper sequence for removing various component parts from the engine. Select the component and follow the arrows from the snowmobile box to that point on the chart.
I
,
r
STARTER PULLEY CUP
TORQUE CONVERTER
•
,
AIR SHROUD (EXHAUST SIDE)
RECOIL STARTER
UPPER FAN PULLEY HALVES
AIR SHROUD (TOP)
EXHAUST MANIFOLD
MUFFLER
FAN COVER
I
SNOWMOB ILE
PTO OIL SEAL
AIR SILENCER
STARTER PAWLS
t CARBURETOR
LOWER FAN PULLEY
+
RECOIL SPR ING, ROPE PULLEY
INTAKE MANIFOLD
+ FAN HOUSING
+ FAN, FAN BEARINGS
~
AIR SHROUD (INTAKE SIDE)
~
I I
I
• FLYWHEEL
+
HEADS CDI IGNITER
14-
IGNITION COIL S8440 ONLY
14-
~
EXC ITER COIL, PULSER COIL, LI GH TING COIL
STATOR PLATE
r MAG OIL SEAL
• CYLINDERS
Ir LEAD WIRES
* PISTONS, RINGS, WRIST PIN, AND BEARINGS
* Removal, installation, disassembly, or assembly requires use of special tool(s).
FLOW CHART SA340 and S8440
3-33
Flow Chart
Disassembly
Engine Removed, SC340
NOTE: This flow chart is designed to aid in determining the proper sequence for removing various component parts from the engine. Select the component and follow the arrows from the snowmobile box to that point on th e chart.
ENGINE
~
~
RECOIL STARTER
EXHAUST MANIFOLD
CYLINDER HEADS
STARTER PULLEY CUP & FLANGE
CDI IGNITE R
INTAKE MANIFOLD
I
+
STARTER PAWLS
â&#x20AC;¢
r
J
r * CYLINDERS
,
,
RECOIL SPRING & ROPE PULLEY
* FLYWHEEL
* PISTONS. RINGS. WR 1ST PINS, AND BEARINGS
ENGINE MOUNT PLATE
TORQU E CONVERTER
I STATOR PLATE
r CRANKCASE
LEAD WIRES
CRANKSHAFT
~
,
MAG OILSEAL
CRANKSHAFT BEARINGS
" Removal, installation, disassembly, or assembly requ ires use of special tool(s).
3 -36
FlOW CHART SC340
+ PTO SEAL
MAGNETO COVER
Muffler
3.
Removal 1.
Disconnect springs which secure muffler to the exhaust manifold and mounting bracket.
2.
Remove the muffler from the snowmobile, carefu ll y separating from the exhaust manifo ld. (See Figure 3-18.)
Inspect outlet pipe for restrictions and repair as necessary.
Installation Install muffler by reversing removal procedure . Make sure muffler outlet pipe passes through ex haust boot in nose pan.
Exhaust Manifold Removal
1. 2. 3.
1.
Refer to Muffler Removal procedure to remove muffler.
2.
Remove four mounting nuts and spring washers securing exhaust manifold to cylinders. (See Figure 3- 19.)
1. 2.
Springs Exhaust Manifold Muffler
Manifold Mounting Nuts Exhaust Manifold Figure 3 -1 9
Figure 3 - 18 3.
Inspection 1.
2.
Visually check muffler assembly along welds and seams for signs of leakage. Repair any leakage by welding as required. Lightly tap muffler on floor and listen for rattling or ringing inside muffler, indicating loose internal components: Replace muffler if loose internal components are suspected.
Dislodge manifold exhaust gaskets.
from
cylinders.
Remove
Inspection 1.
Check for obstructions inside the manifold using a light. Remove any obstructions.
2.
Scrape off any carbon build-up where mani fold mates to cylinders.
MUFFLER
3-37
5.
Bend cap washer away to unlock enrichener plunger cap. (See Figure 3-29.)
4
1. 2. 3. 4.
1. 2. 3.
Enrichener Plunger Cap Cap Washer Enrichener Plunger Spring Enrichener Plunger
6.
Unscrew enrichener plunger cap and remove plunger assembly from carburetor.
7.
Loose n screw on carburetor holder clamp and remove carburetor from the e.ngine.
Econo Jet Tube Float Chamber Float Chamber Fitting Figure 3 -30
5. Figure 3-29
Carefully pry f loat retainers off from pins and remove floats. (See Fig ure 3 -31 .)
Carburetor Disassembly 5A340 and 58440, VM32 Econo Jet 1.
Select a clean work area for disassembling the carburetor. Most carburetor problems are caused by dirt in the system.
2.
Clean the carburetor with fuel and blow dry with compressed air before disassembling. Do not blow high pressure air through the carburetor until it is disassembled.
3.
Disconnect econo jet tube from float chamber fitting. (See Figure 3 -30.)
4.
Remove screws and separate float chamber from upper carburetor body. Discard float chamber gasket. (See Figure 3 -30.)
3-42
CARBURETOR
CD
1. 2. 3. 4. 5. 6.
Float Retainer Float Main Jet Float Chamber Econo Jet Float Pin Figure 3-31
6.
Unscrew hex main jet and round econo jet from float chamber. (See Figure 3-31.)
7 . Remove needle jet holder and washer then
9 . Rel ease float arm by lightly taping pin out of boss in upper carburetor body. Support boss (on pin head side) to prevent breakage during pin removal. (See Figure 3-33 .)
push the needle jet up through opening in top of carburetor for removal. (See Figure 3-32.)
â&#x20AC;˘
.
1. Pilot Jet Location 2. Pin Head Side Boss
1. Needle Jet
2. Holder Washer 3.
Figure 3-33
Needle Jet Holder
4 . Air Jet
10. Remove float valve assembly, gaskets. (See Figure 3-34.)
baffle
and
Figure 3-32 11. Remove throttle stop screw with spring and pilot air screw with spring. (See Figure 3 -32 .) 8.
Using a thin blade screwdriver, unscrew pilot jet. (See Figure 3-33.)
12. Use a thin blade screwdriver to remove the air jet. (See Figure 3 -32.)
CARBURETOR
3 -43
4
r;=::-
•
"-
\';(:
38
6
J., ,~--7
~:r1 1 ~~I I I
I
29
28
I I ,
I
37--
36
./
~
27 26
I
(;l)
~ ' cb~
26 25
35 --\"~rJ
~ 0
34 17
I
l;>~
I
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v'
15
0 ,24-~ C) II ty
33- B
10 11 12 13 14
I @l~ 0)"
~r' c
il~- 31
32
m
I
16 17 18
I
19 ./ /'
./
22 21 20
VM32 ECONO JET CARBURETOR 1, 2. 3. 4, 5. 6. 7. 8. 9. 10. 11. 12. 13.
Carburetor Assembly Enrichener Plunger Cap Cap Washer Enrichener Plunger Spring Enrichener Plunger Air Screw Spring Pilot Air Screw Float Pin Float Chamber Gasket Pilot Jet Baffle Holder Washer Carb Needle Holder
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Holder O-Ring Float Arm Float Retainer Float Main Jet Float Chamber Special Screw Econo Jet Tube Clamp Tube Retainer Tube Econo Jet Float Valve Assembly Float Valve Gasket Figure 3-34
3-44
CARBURETOR
27. Air Jet 28. Throttle Screw Spring 29. Throttle Stop Screw 30. Primer Tube Fitting 31 . Carburetor Needle Clip 32. Needle Jet 33. Throttle Valve 34. Needle 35. Spring Seat 36. Throttle Valve Spring 37. Mixing Chamber Cap 38. Tube
•
Carburetor Cleaning Thoroughly clean all parts with a mild solvent or fuel/oil mixture. Inspect all drilled holes. openings and fuel passages in the body. Blow compressed air through the passages. Remove any sediment from the fuel bowl. Use of carburetor cleaners may be necessary to remove gum and varnish build-up from the jets and float chamber. DO NOT USE DRILLS OR WIRES to clean the jets or damage to the jets will result. Inspect float valve needle tip for wear or damage in the sealing (tapered) area. Replace float valve assembly if needle shows signs of wear or damage. such as groove or scratches.
Carburetor Reassembly SA340 and S8440, VM32 Econo Jet
ponents are not installed the carburetor cannot be calibrated properly. For location of identification markings refer to Figure 3-35.
1.
Place the spring on the throttle stop screw and install in the carburetor body. (See Figure 334.) Turn in the screw about 10 turns.
2.
Insert spring and pilot air screw in the carburetor body. Turn the screw all the way in. Then turn out 1-3/4 turns for initial adjustment.
3.
Install pilot jet and air jet. (See Figure 3-34.)
4.
Position new gaskets. with baffle plate on the upper carburetor body. Install the float valve assembly. Tighten 25 to 30 in. Ib (0.29 to 0.35 kg-mI. (See Figure 3-34.)
5.
If the float arm was removed. install the float arm and secure with float pin. Be sure the pin is securely seated.
Check carburetor parts for proper identification markings prior to reassembly. If the correct com-
_fl 6
~
8I~ ° °ffi--G)
~
P· 4
~
~
SA340
SB440
1. Throttle Valve 2.0 2. Needle Jet 0 -6 3. Needle 6FL 14 4 . Carburetor Body 321170 5. Econo Jet No. 90 6. Main Jet No. 200 7. Pi lot Jet No. 30
1. Throttle Valve 2.0 2. Needle Jet 0-6 3. Needle 6FL 14 4 . Carburetor Body 32/166 5. Econo Jet No. 100 6. Main Jet No. 250 7. Pi lot Jet No. 30 Figure 3-35
CARBURETOR
3-45
6.
Invert the carburetor and check the alignment between the float arm and the base of the carburetor. The float arm must be parallel to the base. Bend the tab of the float arm to adjust. (See Figure 3-36.)
1. 2. 3. 4.
Econo Jet Main Jet Needle Holder O-ring Float Retainers Figure 3 -37
1. 2. 3. 4.
Float Arm Carburetor Base Surface Parallel to Base Float Arm Tab
12. Place new float chamber gasket in position on mixing chamber and align float chamber to mixing chamber. Gently push castings together keeping them properly aligned.
Figure 3 -36
NOTE: Slight pressure should be felt as needle holder O-ring squeezes into position . 7.
8.
Insert the needle jet down through the top of the carburetor, aligning the needle jet with the guide pin. Hold the needle jet in position while installing the needle jet holder and washer. (See Figure 3-34.) Install new O-ring on needle jet holder and lubricate with oil. (See Figure 3-34.)
NOTE: Effective O - ring seal in econo jet carburetors is absolutely necessary. Damaged 0ring will cause overly rich fuel-to -air mixture resulting in poor engine performance. 9.
Position floats on float chamber pins with the brass rods at the bottom and secure with retainers. (See Figure 3-31 .)
13. Secure float chamber to upper mixing chamber with screws. 14. Connect econo jet tube to float chamber fitting and secure with clamp. 15. Perform Carburetor Installation procedure.
Carburetor Disassembly SC340,
VM28 Zinc 1.
Select a clean work area for disassembling the carburetor. Most carburetor problems are caused by dirt in the system.
2.
Clean the carburetor with fuel and blow dry with compressed air before disassembling. Do not blow high pressure air through the carburetor until it is disassembled .
10. Install round econo jet into hole closest to center of float chamber. (See Figure 3-37.) 11. Install hex main jet into hole farthest away from center of float chamber. (See Figure 3 37 .)
3-46
CARBURETOR
3.
4.
Remove four screws with washers and separate the float chamber body from the upper carburetor body. (See Figure 3-38.) Remove a nd discard the gasket. Release float arm by lightly taping pin out of boss in upper carburetor body. Support boss (on pin head side) to prevent breakage during pin removal. Remove float valve assembly.
6.
Unscrew main jet from upper carburetor body and remove main jet washer.
~
30-
Push needle jet up through opening in top of carburetor for remova I.
8 . Using a thin blade screwdriver, unscrew pilot jet. 9 . Remove throttle stop screw with spring and pilot air screw with spring. 10. If required for cleaning, carefully pry float retainers off from pins and remove floats.
5.
32-~ .1
7.
a-
2
25--~
24-- ~
- C:J
~'~-29 28; --- ~
27-e 26-
--
I '~
b
21-~
W"' -18 ~
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 . 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25 . 26. 27. 28. 29. 30. 31. 32.
Carburetor Assembly Enrichener Plunger Cap Enrichener Cap Washer Enrichener Plunger Spring Enrichener Plunger Pilot Air Screw Air Screw Spring Throttle Screw Spring Throttle Stop Screw Float Pin Float Chamber Gasket Pilot Jet Main Jet Washer Main Jet Float Arm Float Retainer Float Float Chamber Main Jet Cover Cover Gasket Special Screw Float Valve Assembly Float Valve Gasket Special Washer Special Screw Needle Jet Throttle Valve Carb Jet Needle Carburetor Needle Clip Spring Seat Throttle Valve Spring Mixing Chamber Cap
20-CD
19-~
Figure 3-38 VM28 ZINC CARBURETOR
CARBURETOR
3 -47
WARNING
I
4 . The condition may improve slightly when the air silencer is removed.
While ralsmg the snowmobile off the ground, place the ski tips against a stationary object, and be sure the vehicle is properly secured, to prevent personal injury.
5.
Exhaust gases are heavy.
6. Spark plugs become fouled. When fuel / air mixture is too lean,
12. Raise the rear 0 the snowmobile off the ground. Start the engine and perform the carburetor adjustments as described in Section 2.
1.
The engine becomes overheated.
2.
The condition improves when enrichener is opened or the primer pump is operated .
3.
Acceleration is poor.
4.
Spark plugs burn.
5.
The revolutions of the engine fluctuate and lack of power is noticed .
Troubleshooting Carburetor related malfunctions can be identified as too rich or too lean a fuel mixture . Symptoms are as follows: When the fuel / air mixture is too rich: 1.
Engine noise is dull and intermittent.
2.
The condition grows worse when the engine is hot.
3.
The condition grows worse enrichener (choke) is opened.
when
the
If a carburetor is experiencing too rich or too lean fuel mixture problems, first check to see that the throttle is working properly. Then disassemble and clean the carburetor. A rich or lean fuel mixture is usually caused by a clogged air or fuel passage. If cleaning does not improve carburetor performance, carburetor tuning may be necessary.
Tuning MAXIMUM
I
PILOT JET
JET NEEDLE / NEEDLE JET
ECONO
JET SA340 S8440 ONLY
EFFECT
MINIMUM 0
1/ 8
1/ 4
3/ 8
3/ 4
112
FULL
THROTILE POSITION Figure 3 -42 Different fuel metering components function according to the throttle setting. (See Figure 3-42.)
3.
Jet Needle and Needle Jet - one eighth (1 / 8) to seven eighths (7/8) throttle opening .
1.
Pilot Jet - from closed throttle to one half (1 / 2) throttle opening .
4.
Main Jet - one quarter (1 / 4) to full throttle opening.
2.
Throttle Valve Cutaway - from closed throttle to one half (1 / 2) throttle opening.
5.
Econo jet (SA340 and S8440 ONLY) - one half (1/2) to full throttle opening .
3-50
CARBURETOR
Tuning enables adjustment of the fuel/air mixture at any throttle setting by replacing the standard fuel metering devices with parts designed to meter more or less fuel than standard. Because a change in one fuel metering system can affect the performance of other systems, all systems should be checked whenever a change is made to one fuel metering system.
SA340
THE PILOT AIR SCREW - regulates air that mixes with fuel from the pilot jet. Turning the pilot air screw in richens the fuel / air mixture. Turning out leans the mixture. The pilot air screw should be normally positioned 1/2 to 2 turns from full in. Less than 1/ 2 turn indicates the pilot jet is too small. More than two turns out indicates the pilot jet is too large. THE JET NEEDLE SYSTEM - can be tuned by changing the position of the clip on the jet needle. There are five grooves at the top of the needle. The grooves are numbered 1 through 5 from top to bot tom . The clip is normally installed in the No. 3 groove. Moving the clip to a higher position on the needle leans out the fuel / air mixture. Moving the clip to a lower position richens the fuel / air mixture.
SB440
MAIN JET SYSTEM - the main jet meters all of the fuel to the main system. The main fuel system components meter fuel from 1/ 8 throttle to full throttle. ECONO (POWER) JET SYSTEM, SA340 and SB440 models - is similar to the main system in that it only draws fuel when there is enough air flow through the venturi to draw fuel through the sys tem. The fuel that passes through the system is metered by a reverse type jet. This system has the most effect during wide open throttle position when the engine is operating at engine speeds above 5000 RPM. Use of econo jet gives better en gine response at high engine RPM's (over 5000 RPM) and better fuel economy at lower engine RPM. At wide open throttle the main jet supplies approximately 70% of the engines fuel requirements while the econo jet supplies 30%. The econo jet stops feeding fuel below 1/2 throttle or 5000 RPM due to the reduction of air flow through the carburetor bore at reduced throttle-settings.
SC340
Intake Manifold Removal 1.
2.
Refer to Silencer and Carburetor Removal procedures in Section 3 to remove air intake silencer and the carburetor. Remove bolts securing carburetor holder to manifold and remove the holder. (See Figure 3 43.)
1.
Intake Manifold
2. Carburetor Holder 3. Insulator Figure 3-43
INTAKE MANIFOLD
3 -51
3.
Loosen intake manifold mounting bolts. Tap manifold lightly with soft faced hammer if necessary and remove the manifold .
4.
Remove gaskets and insulators.
3.
Disconnect the wIring harness from the engine or circuit board as required.
4.
Remove starter handle from rope guide on steering mount.
5.
Disconnect the fuel impulse tube from the engine. Refer to Carburetor Removal procedure Section 3 to remove carburetor.
Inspection
,;
1.
Clean any gasket residue from manifold or insulators thoroughly.
6.
in
2.
Carefully inspect for cracks or flaws. If evident replace the component.
7.
Using a spring puller tool, locking pliers, or a long wire hook, disconnect th e two muffler mounting springs.
3.
Use straight edge to check flatness of gasket surfaces. If distorted, place No. 400 sandpaper on flat surface and sand the entire surface flat. Unsanded spots indicate low areas or warpage.
8.
Remove the four engine mounting bolts, nuts a nd spacers.
9.
Remove the engine from the snowmobile .
Installation 1.
8e sure all gasket surfaces are clean. Install intake mounting bolts through the manifold. (See Figure 3-43.)
Installation NOTE: Prior to installing engine assembly, per form Crankcase Pressure Test (refer to Section 2) to insure no air leaks are present.
Gaskets and insulators must be installed in proper position and sequence. See Figure 3-43 for proper position and sequence for each model. Failure to do so may lead to restricted fuel low causing poor engine performance and possible failure. 2.
lightly coat new gaskets w ith silicone sealer. Assemble insulators and new gaskets on intake manifold.
3.
Carefully install manifold assembly on engine. Torque mounting bolts 72 in. Ib (0.8 kg-mI.
4.
Coat carburetor holder mounting surface lightly with silicone sealer and install holder on manifold. Torque 40 in. Ib (0.6 kg-mI.
5.
Refer to Carburetor and Silencer Installation in Section 3/ to install carburetor and air intake silencer.
Engine
Install engine by reversing removal procedures along with the following:
D
After step 8, perform Converter Alignment procedure. Refer to Section 2.
D
After step 6, perform Carburetor Adjustments and Throttle Cable Adjustment. Refer to Section 2 .
D
After step 4, secure main wiring harness connector to engine connector. 8e sure connector is clean and secure.
D
After step 1, start the engine and adjust idle speed, then check all light bulbs for operation.
Starter Assembly Removal 1.
On SA340 and S8440 models, refer to Muffler Removal procedure in Section 3 to remove muffler
2.
Unscrew three slotted hex head bolts securing starter assembly to engine and remove starter . (See Figure 3-44.)
Removal 1.
Remove the hood.
2.
Remove the retainer pins, drive belt guard and drive belt.
3-52
ENGINE
Disassembly
1.
1.
Release return spring tension by removing handle from starter rope and allow rope to retract slowly.
2.
Exert slight downward pressure on friction plate, then remove securing nut and washers while slowly removing cover.
3.
Remove the plate return spring, friction spring, pawl springs, pawls and thrust washer from starter assembly. (See Figure 3-46.) Check return spring and pressure spring for breaks, rust, distorted or weakened condition .
Slotted Hex Head Bolts Figure 3-44
3.
WARNING
I
Exercise care when removing recoil reel from starter assembly. All spring tension should be released to prevent spring from accidently disengaging and causing injury. Wear safety glasses when repairing starter assembly components.
Remove starter handle and tie knot in starter rope to prevent rope from suddenly retracting into the recoil case.
Inspection 1.
Pull the starter rope out 3 to 5 in. (76.2 to 127.0 mm) and examine the starter pawls for chips or excessive wear. (See Figure 3-45 .) Lis ten for any grinding noise which might indicate a broken or worn starter spring. Examine the starter rope for excessive wear or frayed condition.
4.
To replace starter rope, remove recoil reel from starter assembly. Untie knot and remove starter rope . Install new starter rope and tie a securing knot.
5.
With recoil reel removed, examine recoil spring for cracks, crystallization or abnormal bends. Exercise care when handling recoil case to prevent recoil spring from accidently disengaging. Spring should remain in the recoil case.
6.
To remove return spring , hold starter housing approximately 2 in. (50.8 mm) above work bench with flat surface of housing towards palm of hand. Slap mounting surface of housing against bench to release spring from housing.
Reassembly 1. 2.
Starter Pawls Starter Rope Figure 3-45
1. Thoroughly clean all parts removed prior to reassembling starter. Reassemble components in sequence shown in Figure 3-46.
STARTER ASSEMBLY
3-53
4
J1/ 8
/~
sJl I
6
5
I
/~ /
/
( I
~
/
I 19
1. 2. 3. 4. 5. 6. 7.
Spacer Flange Starter Pulley Spring Washer Bolt Bolt Pawl Return Spring Pawl
20-
8 . Recoil Reel *9. Slide Plate, Small 00 * 1O. Slide Plate, Large 00 11. Thrust Washer * 12. Nylon Bushing 13. Plate Return Spring 14. Friction Spring *ON 440 MODEL ONLY Figure 3-46
3 -54
STARTER ASSEMBLY
15. Friction Plate 16. Thrust Washer 17. Spring Washer 18. Nut 19. Return Spring 20. Rope 21. Rope Handle
2.
To install spring, insert outside spring hook into housing slot, and carefully wind spring in direction shown, while applying pressure with fingers to prevent spring from jumping out of housing. (See Figure 3-47 .)
1. 2. 3. *4. 5.
5.
Assemble starter pawls, small 00 slide plate, pawl return springs and thrust washer. (See Figure 3-47 .)
6.
Next, position plate return spring onto large 00 slide plate. (See Figure 3-48.)
Spring Hook in Slot Pawl Pawl Return Spring Small 00 Sl ide Plate Thrust Washer
*ON 440 MODEL ONLY * 1. 2. 3. 4. 5. 6.
Figure 3-47
3.
Apply light coat housing .
of
grease to
spring
and
Figure 3-48
NOTE: Use extreme pressure (EP) type grease diluted 50% with Kawasaki Snowmobi le oil to ensure proper operation in cold temperature. 4.
With the rope installed on reel, insert reel assembly into housing. Be sure to engage reel with spring hook near center of housing.
Large 00 Slide Plate Straight End of Spring Hole in Reel End of Spring Through Slot Rotate 1/3 Turn Rotate Until Handle Meets Housing
*ON 440 MODEL ONLY
7.
Insert straight end of plate return spring into hole of reel. (See Figure 3 -48.)
STARTER ASSEMBLY
3 -55
NOTE: Apply grease to dimples in friction plate side of thrust washer prior to performing next step .
8.
Install nylon bushing and friction spring onto stub in recoil housing, then carefully position friction plate onto reel assembly as follows: a.
lower friction plate only until bent end of plate return spring enters slot shown in Figure 3-48.
b.
preload friction plate by turning plate 1/3 turn clockwise. (See Figure 3-48.)
c.
with preload applied to friction plate, lower plate completely into position (guide cutouts in plate over end of pawls) and secure.
,
NOTE: After assembly check to be sure pawl return springs remained properly positioned by moving tip of pawl outward and release. If pawl does not return to disengaged position remove friction plate and repeat steps 5 thru 8. 9.
Fasten handle to rope with knot, then apply preload to return spring by placing rope in notch of recoil reel and rotate reel counterclockwise until handle retracts into housing. (See Figure 3-48.)
1. 2.
Figure 3-49
2.
Remove nuts and lockwashers securing exhaust manifold, gaskets and exhaust air shroud to engine. Discard gaskets. (See Figure 3-50.)
3.
Remove bolts, and washers securing intake manifold, gaskets and intake air shroud to engine. Discard gaskets.
10. Pull starter handle and check starter assembly for proper operation.
Installation
Main Engine Shroud Impact Driver
NOTE: Before bolts are tightened pull slightly on starter rope to engage pawls, then tighten bolts securely. 1.
Secure starter assembly to engine using three hex head bolts.
2.
Insert starter rope through guide in chassis. Pull starter a few times and observe starter operation.
3.
Install muffler. Refer to Muffler Installation.
Air Shrouds, SA340 and S8440 Removal 1.
Using an impact driver, remove screws, and washers securing main shroud to engine. Impact driver should be used to prevent stripping the screw heads because Loctite was applied to screws during assembly. (See Figure 3 -49.)
3-56
AIR SHROUDS
1. 2. 3.
Exhaust Manifold Gaskets Exhaust Air Shroud Figure 3-50
Inspection 1.
Thoroughly clean air shrouds in a solvent and blow dry using compressed air .
2.
Inspect air shrouds for cracks, distortion or rust.
3.
Check intake and exhaust manifolds for cracks. Check gasket surfaces and clean using a scraper .
â&#x20AC;˘
Reassembly 1.
Reassemble air shrouds, intake and exhaust manifolds to engine. Using new gaskets, assemble (2 each per cylinder) one on each side of exhaust and intake air shrouds. Secure using hardware previously removed. Torque exhaust manifold mounting nuts to 10ft Ib (1.38 kg-m) and intake manifold bolts 4 to 5 ft Ib (0.55 to 0 .69 kg-m).
If cylinders or cylinder heads have been removed intake manifold bolts must be secured before torquing nuts securing heads and cylinders.
Figure 3-51
6.
Unscrew four nuts from studs securing fan housing to crankcase and slide fan housing from engine assembly: (See Figure 3-52.)
NOTE: When removing nut from stud on the lower front of the fan housing. Disconnect right side tie rod from the steering arm. Turn handlebars to the left. Insert a short (5-114 to 5-112 in. long) 13 mm twelve point box wrench, under engine from the flywheel end, and remove nut.
NOTE: Apply Loctite to main air shroud screws. Use an impact driver to assure main air shroud screws are tight. 2.
Always use new gaskets during reassembly to ensure proper connections.
Fan Housing, 5A340 & 58440 Removal
â&#x20AC;˘
1.
Disconnect springs securing muffler to exhaust manifold and mounting bracket, then remove muffler.
2.
Remove manual starter. Refer to Starter Assembly Removal procedure in Section 3.
3.
Unscrew bolts securing starter pulley cup and lower fan pulley to flywheel, then remove fan belt with pulley. (See Figure 3-51 .)
4.
Remove screws securing fan housing to intake, top, and exhaust air shrouds.
5.
Disconnect stator assembly wires (lighting coil and ignition system) from connectors on fan housing.
1. 2.
Fan Housing Lower Front Stud Figure 3-52
FAN HOUSING
3-57
Disassembly 1.
2.
Remove fan pulley halves and spacers from fan shaft. (See Figure 3-54.)
Using fan pulley holder tool No. 57001-3506,
remove nut and washer securing fan assembly to fan housing. (See Figure 3-53.)
NOTE: Spacers are used between the fan pulley halves to adjust fan belt tension. Using fewer spacers increases fan belt tension .
â&#x20AC;˘. 3.
Using a heat gun or propane torch, heat aluminum fan housing allowing bearings to be removed from fan housing.
I WARNING' Do not contact heated fan housing with bare hands or severe burn could result.
4.
Using Tru -Arc or circlip pliers remove circlip and two spacers from fan housing. (See Figure 3-54.)
NOTE: Circlip is used to correctly position bear ings. Spacers are installed between bearings to eliminate side loads when shaft nut is tightened.
1. Fan Pulley Holder Tool No. 57001-3506 Figure 3-53
3-58
FAN HOUSING
"
1. 2. 3. 4. 5. 6. 7. 8.
Plain Washer, SB440 Only Spring Washer, SB440 Only Pan Head Screw Fan Screen Nut Fan Pulley Fan Drive Pulley Fan Housing 9. Dowel Pin 10. Seal Plate, SA340 Only 11. Special Washer, SA340 Only 12. Pan Head Screw, SA340 Only
13. 14. 15. 16. 17. 18. 1 9. 20. 21. 22. 23. 24.
Spring Washer, SA340 Only Nut Spring Washer Plain Washer Stud Cooling Fan Woodruff Key Ball Bearing Circiip Shim, 1.0 mm thick Pulley Shim, 0.6 mm thick (AR) Spring Washer
Figure 3-54
FAN HOUSING
3-59
Inspection 1.
Check woodruff key and keyway for damage.
2. Inspect fan housing for cracks or distortion. 3.
Check bearings for discoloration and wear.
4.
Check fan belt for excessive wear.
5.
Check cooling fan assembly for missing or damaged blades .
6.
Check threads damage .
on
all
mounting
studs
• •
for
Reassembly 1.
Install Circiip in fan housing.
2.
Using a heat gun or propane torch heat the aluminum fan housing and insert fan-side bearing. Insert fan shaft through bearing to serve as a pilot for spacers. (See Figure 3-54.)
NOTE: Insert two spacer washers between bearings to eliminate side loads when shaft nut is tightened. 3.
Insert pulley-side bearing in case . Attach pulley half to shaft. Assemble same number of pulley spacer washers to shaft as previously removed and attach remaining pulley half to shaft. Secure pulley halves to shaft using washer and nut, turning nut only hand tight to ease removal when making any necessary adjustments to fan belt tension.
Install fan housing to crankcase. Secure using nuts and washers previously removed. Tighten nuts securely. (See Figure 3-54.)
NOTE: If removed for removing fan housing, reconnect tie rod end . Be sure the rod end spacer is properly positioned between the tie rod end and steering arm. Torque the nut to 35 ft Ib (4,84 kgm). 2.
Connect stator assembly wire to connectors on fan housing. Be sure connections are clean, secure, and wire colors match on each half of connector. (See Figure 3-55.)
I
WARNING
I
When reconnecting the wiring harness, be sure the main wiring harness connector is fully engaged to the engine wiring harness connector to prevent separation during engine operation.
3-60
3.
Install screws to secure fan housing to intake, top, and exhaust air shrouds.
NOTE: Apply Loctite to air shroud screws. Use an impact driver to assure air shroud screws are tight. 4.
Install fan belt, fan drive pulley and starter cup to flywheel. Secure using three bolts and lock washers. Tighten bolts evenly to prevent distortion of pulleys. (See Figure 3-51.)
NOTE: Install fan drive pulley with machined shoulder toward flywheel.
Installation 1.
Figure 3-55
MAGNETO COVER
5.
Check fan belt tension . Refer to Fan Belt Tension procedure in Section 2.
6.
After fan belt tension is correct, install manual starter and muffler.
Magneto Cover, SC340 Only Removal 1.
Refer to Starter Assembly Removal procedure in Section 3 to remove starter.
2.
Unscrew bolts securing starter pulley cup and spacer to flywheel and remove cup.
3.
Remove wiring harness connector from the magneto cover.
•
4.
Unscrew four nuts from studs securing magneto cover to crankcase and slide cover out. (See Figure 3-56.)
Stator Assembly Removal 1.
On SA340 and SB440 models, refer to Muffler Removal procedure in Section 3 to remove muffler.
2.
Refer to Starter Assembly Removal procedure in Section 3 to remove starter.
3
Unscrew flywheel retaining nut from the crankshaft. Use long rod or screwdriver in starter pulley to hold crankshaft from turning . (See Figure 3-57.)
\
1. 2. 3. 4. 5.
Magneto Cover Cover Stud Washer Spring Washer Nut Figure 3-56
NOTE: When removing nut from lower front of cover, disconnect right tie rod from steering arm. Turn handlebars to the left. Insert short (5-1 14 to 5-1/2 in.) 13 mm twelve-point box-end wrench under engine from flywheel end and remove nut.
Installation 1.
Position magneto cover on crankcase. Secure with nuts and washers previously removed. Torque nuts 100 in. Ib (1.1 kg-mI.
2.
Reinstall wiring harness connector and COl Igniter to magneto cover.
Main Wifing harness connector must be fully engaged to engine wiring harness connector to prevent separation during engine operation.
3.
Refer to Starter Assembly Installation procedure in Section 3 to reinstall starter.
Figure 3-57
4.
Remove bolts securing starter pulley cup and lower fan pulley (spacer on SC340) to flywheel. Remove fan belt with pulley.
NOTE: On SA340 and SB440 models, the fan housing must be removed to permit flywheel removal. Refer to Fan Housing Removal procedure in Section 3. The flywheel may be removed with magneto cover in place on SC340 model.
5.
Bolt the flywheel puller (special tool PIN 57001 -3509) to the flywheel with the three flywheel puller bolts (PIN 110P0620). Pull the flywheel and remove the puller, then examine flywheel keyway for damage. (See Figure 3-
58.)
STATOR ASSEMBLY
3-61
3.
Check woodruff key and keyway for damage.
Reassembly Reassemble all components to stator assembly in sequence shown in Figures 3-60 and 3-61.
2.
Be sure wires are properly routed to prevent pinched condition during installation, or rubbing during engine operation.
Installation
Figure 3-58 6.
1.
Prior to removing the stator assembly, scribe a n aligning mark from the stator plate to the crankcase. (See Figure 3-59.) Upon reassembly, the stator plate may be installed with the scribe marks aligned and ignition timing returned to its original setting.
1.
Insert electrical leads through grommet in crankcase and reinstall stator assembly to crankcase. Align mark made during disassembly. Secure stator assembly using two screws and washers previously removed. (See Figure 3-59.)
2.
Install fan drive pulley or spacer (SC340 only) a nd starter cup to flywheel. Secure with bolts and lockwashers. Tighten bolts evenly to pre vent distortion of pulleys.
NOTE: Install fan drive pulley with machined shoulder toward flywheel. 3 . Clean tapered surfaces of flywheel and crank shaft to remove oil and dirt. Surfaces must be clean and dry. Install flywheel on crankshaft and torque nut to 60 ft Ib (8.3 kg-mI. NOTE: On SA340 and SB440 models, install fan housing assembly. Refer to Fan Housing Installa tion procedure in Section 3.
1. Aligning Mark Figure 3-59
4.
7.
Disconnect stator assembly wires (lighting coil and ignition system) from connectors on fan housing.
8.
Remove the two screws and washers securing the stator plate to the crankcase and remove the stator assembly. Remove the stator harness and wires from the rubber grommet.
I WARNING
and
3-61
for
stator 5.
On SA340 and SB440 models, install fan belt and check belt tension. Refer to Fan Belt Ten sion procedure in Section 2.
6.
Perform Ignition Timing Check. Refer to Section 2. Start engine using emergency Starter rope.
7.
When ignition timing is correct, install manual starter and muffler. Refer to Starter and Muffler Installation in Section 3.
Inspection 1.
Inspect all lead wires for cracks or frayed condition.
2.
Check magnets in flywheel assembly. Thoroughly clean magnet area to remove any metal filings or particles that magnets may have attracted.
3-62
STATER ASSEMBLY
I
When reconnecting the wiring harness, be sure the main wiring harness connector is fully engaged to the engine wiring harness connector to prevent separation during engine operation.
Disassembly Refer to Figures 3-60 disassembly sequence.
Connect stator assembly wires to connectors on fan housing. Be sure connections are clean, secure, and wire colors match on each half of connector. (See Figure 3-55.)
SA340 and SC340
tl-
27 --26
c? 6~
~
f
25
29
-3
24
23 21 22
I
\ I /~
(
Y
STATOR ASSEMBLY - SA340 and SC340 Mode ls 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 O.
Screw Spring Washer COl Ign iter Engine Connector Terminal Wiring Harness Connector Plain Washer Spri ng Washer Screw Flywheel Stator Assembly
11. Pu lser Coil 12. Pan Head Screw 13. Lighting Coil 14. Clamp 15. Spring Washer 16. Pan Head Screw 17. Exciter Coil 18. Coil . Collar 19. Pan Head Screw 20. Pan Head Screw
21 . Plain Washer 22 . Spring Washer 23 . Pan Head Screw 24. Spark Plug 25. Plug Cap Boot 26. Spark Plug Cap 27. Spark Plug Cap Terminal 28. Cord Grommet 29. Grommet 30. Igniter Collar
Figure 3-60
STATOR ASSEMBLY
3-63
SB440
1
\
~-2 19-1 ~-2 , 1I
3
24
25
?
26
I
STATOR ASSEMBLY - SB440 Only
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 .
Pan Head Screw Spring Washer Plain Washer Ignition Coil Collar Igniter Harness Clamp Pan Head Screw Spring Washer Plain Washer Wiring Harness Connector Engine Connector Terminal
12. CDI Igniter 13. Stator Assembly 14. Pan Head Screw 15. Pulser Coil 16. Lighting Coil 17. Stator Harness Clamp 18. Spring Washer 19. Pan Head Screw 20. Coil Wire Clamp 21. Exciter Coil 22. Coil Spacer Collar Figure 3-61
3-64
STATOR ASSEMBLY
23. Pan Head Screw 24. Plain Washer 25. Spring Washer 26. Pan Head Screw 27. Flywheel / Ring Gear 28. Spark Plug 29. Plug Cap Boot 30. Spark PI ug Cap 31 . Spark PI ug Cap Terminal 32. Spark Plug Wire Grommet 33. Plug Wire Spacer Grommet
Cylinder Heads, Cylinders And Pistons
INSPECTION 1.
Remove excessive carbon from inside cylinder head using a nonferrous carbon scraper, or cylinder head brush .
2.
Inspect cooling fins for damage. On SC340 model, remove black-rubber head dampers from fins.
3.
Wash cylinder head in solvent and blow dry using compressed air.
4.
Place a straight edge across the gasket surface of the head to detect any warpage. Measure in several spots. If slight distortion is present it can be corrected by placing No. 400 sandpaper on a surface plate and rubbing head in a circular motion on the sandpaper to remove high spots.
Cylinder Heads REMOVAL 1.
Remove spark plugs . Mark heads, cyl inders, and crankcase for reference in reassembly.
2.
Remove eight nuts, lockwashers and washers securing cylinder heads to cylinders, using a 13 mm socket and 3 in. extension . Carefully remove cylinder heads and gaskets. Discard gaskets. (See Figure 3-62 .)
NOTE: Dying the gasket surface before you begin will indicate high spots after some sanding.
Cylinders REMOVAL 1. Gently tap cylinder with a soft mallet to release seal. 2.
Carefully remove cylinders from crankcase studs. Hold piston during cylinder removal to prevent piston from suddenly contacting studs or crankcase . (See Figure 3-63 .)
3.
Remove and discard cylinder base gaskets.
S8440 MODEL 1.
Head Gasket Figure 3-62
Figure 3-63
CYLINDER HEAD, CYLINDERS AND PISTONS
3 -65
INSPECTION
6.
1. Check the cylinder for damaged or broken fins. 2.
Thoroughly clean all carbon deposits from exhaust ports and cylinder walls .
3.
Check cylinder wall for excessive scoring .
4.
Using an inside micrometer check cylinder bore for out-of-round or taper condition. (See Figure 3-64.)
5.
Using an inside micrometer check the cylinder bore for wear. If the cylinder diameter exceeds the dimension shown under Service limit in Figure 3-64, replace the cylinder.
Examine the cylinder wall for excessive wear, scoring or deep lines, and replace cylinder if necessary. The cylinders in th is engine are aluminum with chrome plated bores. They can not be honed or rebored.
NOTE: To check for out of round of the cylinder bore move the micrometer in a circular direction, 90:> at a time. The difference in measurements obtained should not exceed 0.002 in . (0.05 mm).
NOTE: To check for taper of the cylinder bore, move the micrometer from the top to the bottom of the cylinder. The difference in the measurements obtained (between top and bottom) should not exceed 0.002 in. (0.05 mm).
Pistons REMOVAL 1.
Seal crankcase with clean shop rag and using a sharp steel pointer remove piston circlips. Discard circlips . (See Figure 3-65.)
CYLINDER BORE DIAMETER
MODEL
STANDARD (NEW)
SERVICE LIMIT (USED)
SA340 2.3624 - 2.3632 in. (60.005 - 60.025 mm)
2.366 in. (60.10 mm)
SB440
2 .6774 - 2.6781 in . (68.005 - 68.023 mm)
2.681 in. (68.10 mm)
SC340
2.3637 - 2.3645 in. (60.040 - 60.059 mm)
2.3675 in . (60.134 mm)
Figure 3-64
3 -66
CYLINDER HEADS, CYLINDERS AND PISTONS
Figure 3-65
2 . Using piston pin puller tool No. T57001 -910 remove piston pins from pistons and remove piston from connecting rod. (See Figure 3 -66.) NOTE: Keep piston pin bearings together as a set and mark pistons left and right to assure correct reassembly .
..
PISTON SKIRT DIAMETER
MODEL
1. Piston Pin Puller Tool No. T57001-910
STANDARD (NEW)
SERVICE LIMIT (USED)
SA340 2.3607 - 2.3614 in. (59.961 - 59.980 mm)
2.355 in. (59.82 mm)
S8440
2 .6744 - 2.6752 in . (67.929 - 67 .950 mm)
2.670 in . (67 .82 mm)
SC340
2.3607 - 2.3614 in. (59.961 - 59.980 mm)
2 .355 in. (59.82 mm)
Figure 3-66 Figure 3-67 3.
Using a ring expander tool remove rings from piston.
NOTE: Do not interchange rings between pistons.
Should the measured piston skirt diameter be less than the service limit specified in the above table, replace the piston. Measure the skirt diameter of the new piston to be used, and subtract the figure obtained from the measured cylinder bore diameter. Piston skirt-to-cylinder wall clearance must be between: SA340 MODEL - 0 .001 to 0 .003 in . (0.0254 to 0.762 mm)
INSPECTION 1.
Remove all carbon from piston dome, ring grooves a nd piston skirt.
S8440 MODEL - 0 .002 to 0 .004 in. (0.050 to 0.101 mm) SC340 MODEL - 0.001 to 0 .003 in. (0.0254 to 0.762 mm)
NOTE: If piston dome or skirt is scored or pitted from overheating, replace piston and piston rings.
2.
Using a micrometer measure the outside diameter of each piston at right angle to piston pin hole and 3 / 16 in. (4.76 mm) from bottom . (See Figure 3-67.)
If this computed difference is greater than the specified tolerance, a new cylinder will also be needed. 3. Check piston pin for wear or damage. Using a 1 in. outside micrometer measure piston pin diameter. (See Figure 3-68.)
CYLINDER HEADS, CYLINDERS AND PISTONS
3 -67
Should piston pin diameter be less than specified service limit, pin and needle bearing must be replaced.
4.
Measure piston pin bore diameter by inserting a snap gauge approximately 114 in. (6.35 mm) into piston pin bore. Remove snap gauge and measure it using a 1 in. outside micrometer. If measured diameter is greater than service limit given in Figure 3-69, replace piston.
5.
Check needle bearings and needle bearing cage for wear or overheating.
6.
Check piston ring gap by inserting piston ring into cylinder horizontally. Insert a feeler gauge in the opening between the ends of the piston ring. (See Figure 3-70.) If maximum ring gap exceeds the Service Limits when measured at the top and the bottom of the cylinder bore, replace the rings.
PISTON PIN DIAMETER
MODEL ALL
STANDARD (NEW)
SERVICE LIMIT (USED)
0.6297 - 0.6299 in. (15.994 - 16.000 mm)
0.628 in. (15.98 mm)
Figure 3-68
PISTON RING END GAP STANDARD (NEW)
SERVICE LIMIT (USED)
SA340
0.006 - 0.014 in. (0.15 - 0.35 mm)
0.028 in. (0.7 mm)
M ODEL
PISTON PIN BORE DIAMETER
MODEL ALL
STANDARD (NEW)
SERVICE LIMIT (USED)
S 8440
0.008 - 0.016 in . (0.2 - 0.4 mm)
0.028 in. (0.7 mm)
0.6299 - 0.6301 in. (15.999 - 16.005 mm)
0.633 in. (16.08 mm)
S C340
0.011 - 0.019 in . (0.25 - 0.48 mm)
0.028 in. (0.7 mm)
Figure 3 -69
3-68
CYLINDER HEADS. CYLINDERS AND PISTONS
Figure 3-70
7.
With the rings installed in their grooves, take several measurements with a feeler gauge to determine ring to groove clearance. If the clearance exceeds the Service Limit in Figure 3-71 , replace the rings and remeasure ring to groove clearance. If the dimension still exceeds the Service Limit, replace the piston.
3.
Install piston to connecting rod with arrow pointing toward exhaust side . Insert piston pin and secure piston pin using new circlips.
New eirelips must be used to prevent serious engine damage.
4 . Apply a light coat of oil to bearing on each end of rod, inside of cylinders and outside of pistons . Align piston rings with locating pins on piston and using ring compressor tool No. T57001-130 compress the rings and install cylinders over pistons. (See Figure 3 -72 .)
Piston rings must align properly with locating pins located in ring groove to prevent breakage.
TOP RING / GROOVE CLEARANCE STANDARD (NEW)
SERVICE LIMIT (USED)
SA340
0.0010 - 0.0036 in. (0.03 - 0.09 mm)
0.008 in. (0.19 mm)
SB440
0.0020 - 0.0047 in. (0.05 - 0 .12 mm)
0.009 in. (0.22 mm)
SC340
0.0010 - 0.0036 in . (0.03 - 0.09 mm)
0.008 in . (0.19 mm)
MODEL
Figure 3-72 BOTTOM RING / GROOVE CLEARANCE STANDARD (NEW)
SERVICE LIMIT (USED)
0.0020 - 0.0035 in. (0.05 - 0 .09 mm)
0 .008 in . (0.19 mm)
MODEL ALL
Figure 3-71
5.
NOTE: On SA340 and SC340 models, install head gaskets with wide metal section of gasket facing cylinders. 6.
REASSEMBLY 1. Install new cylinder base gaskets on crankcase . 2.
Apply light coat of oil to piston pin needle bearings and insert needle bearings into upper connecting rod.
Install new head gaskets to cylinders.
Set cylinder heads in place on correct cylinders and loosely install the eight nuts, washers and lockwashers. Do not tighten cylinder nuts until intake manifold is installed . Refer to Section 2 for correct torque .
NOTE: On SA340 and SB440 models, install long nuts on outside studs of PTO side cylinder head . 7.
Install spark plugs and torque to 20 ft Ib (2 .77 kg-m).
CYLINDER HEADS, CYLINDERS AND PISTONS
3-69
8.
On SC340 model only, position head and cylinder dampers in place on each cylinder as shown in Figure 3 -73. One cylinder damper is located on the LH rear corner of each cylinder. (See Figure 3-73 .)
Figure 3 -74
1. 2. 3.
Head Damper (4) Head Damper (4) Cylinder Damper (6) Figure 3 -73
Crankcase Assembly
Figure 3 -75
Disassembly 1.
Remove eleven bolts, lockwashers and washers securing crankcase halves . (See Figure 3 -74.)
2.
With a plastic hammer tap on end of lower case half to break seal, and remove lower case. (See Figure 3-75.)
Never pry crankcase halves apart with screwdriver or similar tool. Sealing surfaces will be damaged making crankcase unusable.
3 -70
CRANKCASE ASSEMBLY
3.
Carefully remove crankshaft by lifting the crankshaft assembly straight up and out of the crankcase. Remove oil seals and washers from crankshaft. (See Figure 3 -76.)
To prevent internal crankcase damage lift the crankshaft equally at each end during removal process.
Figure 3-77
1. Oil Seals Figure 3-76
Inspection 1. Wash crankcase halves in cleaning solvent, dry using compressed air. 2.
Inspect crankcase halves for scoring, pitting, scuffing or any imperfection in the castings that may cause a crankcase leak.
3.
Check oil seals for wear, cracks or deteriora tion . Replace seal if damage is suspected . Check washers for damage.
4.
Clean crankshaft in cleaning solvent, dry using compressed ai r.
5.
Check keyway for damage. Inspect magneto external threaded end for damaged threads. Check PTO internal threads for damage. Check taper on both ends of crankshaft for scratches, scoring or signs of excessive wear.
6.
Check rubber damage.
7.
Check crankshaft main outer bearings for discoloration, wear, or skuffing. After oiling, bearings should rotate freely on crankshaft with no binding or grinding noise evident. No notice able play in bearing should exist perpendicular to its axis. Replace bearings if damage is suspected.
a-rings
on
center
seal
New outer main bearings are easily installed on crankshaft after heating inside bearing race with a heat gun or setting bearing on light bulb. After bearing is heated properly, slide bearing into correct position on crankshaft.
Connecting Rod Big End 1.
Check connecting rod side play by inserting a feeler gauge between connecting rod big end and crankshaft flyweight. (See Figure 3-78.) Correct side clearance is 0.016 to 0.020 in . (0.41 to 0 .51 mm).
for
If bearings require replacement, use puller tool No. 57001-158 to remove bearings . (See Figure 3 -77). NOTE: Inner main bearings and labyrinth seal must also show no evidence of bluing, scoring, radial looseness due to wear, or grinding sound, and should turn freely on the shaft after oiling. Any defect found will indicate need for crankshaft replacement.
Figure 3 -78
2.
Check for excessive radial clearance of connecting rod big end by measuring the distance the connecting rod big end is moved up and down . Radial play should not exceed 0.0008 to 0.0012 in. (0.020 to 0.030 mm). See Figure 379.)
CRANKCASE ASSEMBLY
3 -71
Crankshaft Runout After new outer main bearings have been installed, crankshaft runout must be measured. Set the assembled crankshaft in V blocks with outer mains resting in blocks. Attach a dial indicator to read from the converter end of the crankshaft. (See Figure 3-81.) Slowly rotate the crankshaft noting the amount of indicator needle travel. Maximum runout should not exceed 0.002 in. (0.05 mm). Should runout exceed the specified maximum, the crankshaft must be replaced.
Figure 3-79
3.
illilll,
Check that the connecting rod rotates freely on the crank pin through its entire 3600 of movement. Any noticeable drag or gri ndi ng noise i ndicating the presence of foreign particles in the needle rollers or scoring of the rollers and crank pin will necessitate crankshaft assembly replacement.
Connecting Rod Small End -----------------------------Figure 3-81
Crankshaft End Play Adjustment 440 Model Only To check for proper crankshaft end play.
CONNECTING ROD SMALL END DIAMETER
MODEL ALL
STANDARD (NEW)
SERVICE LIMIT (USED)
0 .7875 - 0 .7880 in. (20.003 - 20.015 mm)
0.789 in . (20.05 mm)
Figure 3-80
Check connecting rod small end diameter by in serting a snap gauge into the rod small end bore. (See Figure 3 - 80.) Remove snap gauge and measure it using a 1 in. outside micrometer. Should the measured dimension be greater than the service limit specified, the crankshaft must be replaced.
3 -72
CRANKCASE ASSEMBLY
1.
Position the RH crank shim, RH cranksh aft bearing and RH washer onto crankshaft as shown in Figure 3-82 .
2.
Position the LH crank shim, LH crankshaft inner bearing, smaller LH crank shim, LH crankshaft outer bearing and LH washer onto crankshaft as shown in Figure 3-82.
3.
Measure, where indicated in Figure 3-82, with a micrometer.
4.
Refer to the tables for the correct shims and quantity to use.
Shims C1 are to be placed between the LH crank s him and the inner bearing. (See detail A Figure 3 82.) Shims C2 are to be pl aced between the RH crank shim and the RH crankshaft bearing. (See detail B Figure 3-82.)
â&#x20AC;˘
CRANKSHAFT END PLAY ADJUSTMENT 440 MODEL ONLY LH CRANK SH 1M
RH CRANK SHIM
DIMENSION TO BE MEASURED SHIM C 1 LOCATION
f.--- --
Cl - . . . .. DETAIL A
-
-
-
....I SHIM C2 LOCATION
---I~I ....._ - - -
DETAIL B
Shim Locat ion and Reference Number Measured Dimension
Cl (Detail A)
9.3547 in. (237 .61 mm) 9.3449 - 9.3543 in. (237.36 - 237.60 mm) 9.3390 - 9.3445 in. (237.21 - 237.35 mm) 9.3350 - 9.3386 in. (237.11 - 237.20 mm) 9.3311 - 9.3346 in. (237.01 - 237.10 mm) 9.3271 - 9.3307 in. (236.91 - 237.00 mm) 9.3232 - 9.3268 in. (236.81 - 236.90 mm) 9.3193 - 9.3228 in. (236.71 - 236.80 mm) 9.3153 - 9.3 189 in. (236.61 - 236.70 mm) 9.3114 - 9.3149 in. (236 .51 - 236.60 mm) 9.3075 - 9.3110 in. (236.41 - 236.50 mm) 9.3035 - 9.3071 in. (236.31 - 236.40 mm) 9.2996 - 9.3031 in. (236.21 - 236.30 mm) 9.2957 - 9.2992 in. (236 .11 - 236.20 mm) 9.2917 - 9.2952 in. (236.01 - 236.10 mm) 9.2878 - 9.2913 in. (235.91 - 236.00 mm) 9.2838 - 9.2874 in . (235.81 - 235.90 mm) 9.2799 - 9.2834 in. (235.71 - 235.80 mm) 9.2760 - 9.2795 in. (235.61 . 235.70 mm) 9.2720·9.2756 in. (235.51 ·235.60 mm) 9.2689 · 9.2716 in. (235.43·235.50 mm)
C2 (Detail B)
0 0
0 0 0 0
(1) (2)
(1)
(1)
(2) (2) (3) (3) (3) (3) (2) (4) (2) (4) (2) (1) (5) (5) (5) (5)
( 1) (2) ( 1) (2) (1) + (1) (3) (3) (3) (3) (4) (4) (4) (4) (2) + (3) (1) + (4) (5)
+ (2) + (3) + (3) + (4)
Shim Description Chart Shim Cl Location
Reference Number
Shim C2 Location
92025·535 92025·536 92025·537 92025·538 92025·539
(1) (2) (3) (4) (5)
92025· 515 92025·521 92025·525 92025·528 92025·532
Thickness 0.0079 0.0118 0.0197 0.0276 0.0394
in. in. in. in. in.
(0.2 (0.3 (0.5 (0.7 (1.0
mm) mm) mm) .-mm) mm)
Figure 3-82
CRANKCASE ASSEMBLY
3-73
Crankshaft End Play Adjustment SA340 and SC340 Models measure
men!, the thickness dimension of the bearing yet to be installed . The arrived-at sum of these dimensions will constitute distance A . (See Figure 3-83.)
crankshaft and shim as required to assure correct end play exists when crankshaft is installed in crankcase. Proper end play is to be established by the following procedure :
4 . Refer to Shim Chart (Distance A) and select the appropriate shim(s) required between the two left-hand main bearings .
If
bearings
are
replaced
you
must
1. With a suitable micrometer, measure distance B. (The distance across the outer surfaces of each pair of crankshaft flyweights as shown in Figure 3-83 .)
SHIM(S) REQUIRED FOR DISTANCE A
DISTANCE A
REQUIRED SHIM REFERENCE NUMBER(S)
8.0158 -8.0256 inch (203.61-203 .84 mm)
1. Shim B Location 2. Shim A Location Figure 3-83 2.
Refer to Shim Chart (Distance B) for the appropriate shim to be placed between the bearings and outer flyweights. (See Figure 3-82.)
None
8 .0119 -8.0157 inch (203 .51-203 .60 mm)
1
8.0080-8.0118 inch (203.41-203 .50 mm)
2
8.0040-8.0079 inch (203 .31-203.40 mm)
3
8 .0001 -8.0039 inch (203.21-203 .30 mm)
4
7 .9962 -8.0000 inch (203.11 -203.20 mm)
5
7.9922 -7.9961 inch (203.01 -203.10 mm)
6
7 .9898 -7 .9921 inch (202 .93-203 .00 mm)
6 ... 1, or 5+2, or 4 ... 4
SHIM DESCRIPTION CHART SHIM(S) REQUIRED FOR DISTANCE B
DISTANCE B 1.9551 - 1.9634 inch (49.66-49.87 mm)
REQUIRED SHIM REFERENCE NUMBER(S) None
1.9469 - 1.9547 inch (49.45 -49.65 mm)
2
1.93 78 - 1.9465 inch (49 .22-49.44 mm)
4
3.
After installing the first two bearings, and shims B, distance A is to be computed by measuring the total distance between the outer-most race surfaces of the two bearings already installed, and adding to that measure -
3-74
CRANKCASE ASSEMBLY
SHIM REFERENCE NUMBER
PART NUMBER
1
92025-513
0.0039 in . (0.1 mm)
2
92025 -518
0 .0078 in. (0.2 mm)
3
92025-523
0.0118 in . (0.3 mm)
4
92025-527
0.0157 in. (0.4 mm)
5
92025 -530
0 .0197 in. (0.5 mm)
6,
92025-533
0.0236 in. (0.6 mm)
THICKNESS
.
Reassembly 1.
Oil all bearings .
2. Align crankshaft labyrinth seal aligning pin with reces's in upper crankcase half and carefully insert crankshaft into crankcase. (See Figure 3-84.)
..
Figure 3 -85
Brake Light Switch, Dimmer Switch, or Brake Lever Assembly Removal 1. Aligning Pin
NOTE: Entire brake lever assembly must be removed to replace brake light switch or dimmer switch.
Figure 3-84 1.
Remove brake cable from brake lever assembly.
2.
Insert a screwdriver between handle grip and handlebar to loosen the grip from the bar, and pull handle grip from handlebar, or grasp the handle grip to be removed and hold thumb over end hole. Induce compressed air through end hole of opposite grip, and by twisting grip to be removed, slide it from the handlebar.
3.
Disconnect brake and dimmer switch harness connectors and cable ties from handlebar. Note positioning of cable ties to insure proper location during installation.
4 . Apply crankcase sealer to lower crankcase half and carefully attach crankcase halves.
4.
Loosen lock screw and slide brake lever assembly from handlebar. (See Figure 3-86.)
5.
5.
Remove screw and plate from case; slide switches from case.
6.
Brake lever may be removed by removing pin retainer and washer, and withdrawing pin.
7.
Reassemble reversing order of disassembly.
3.
Install washers in crankcase grooves. Apply a coat of grease to inner section of oil seals and install oil seals to crankshaft.
When replacing bearings, crankshaft surface that oil seal contacts may be scratched which will cause excessive seal wear. Always remove any irregularities on the shaft surfa.ce using No. 400 emery cloth before installing new oil seals.
Secure crankcase halves using eleven bolts, lockwashers and washers. Tighten hardware evenly and in the sequence shown in Figure 385. Torque to 16 ft Ib (2 .21 kg-mI.
NOTE: Apply torque in one third increments to prevent distortion of crankcase halves.
BRAKE LIGHT SWITCH, DIMMER SWITCH OR BRAKE LEVER ASSEMBLY
3 -75
2.
Insert a screwdriver between handle grip and handlebar to loosen the grip from the bar, and pull handle grip from handlebar, or grasp the handle grip to be removed, and hold thumb over end hole. Induce compressed air through end hole of opposite grip, and by twisting grip to be removed, slide it from the handlebar.
3
~
1
\"
-~
1. Dimmer Switch 2. Lock Screw 3 . Pin 4. Washer 5. Retainer 6. Brake Light Switch
ij
2
6 ~~----4
/
5
Figure 3-86 1. 2. 3. 4. 5.
Emergency Stop Switch Lock Screw Pin Washer Retainer Figure 3 -87
Installation 1.
Install brake lever assembly on the handlebar in reverse order of removal. Tighten lock screw to 25 in. Ib (0.278 kg-m).
2.
Check brake lever adjustment as described in Section 2.
Emergency Stop Switch or Throttle Lever Assembly Removal
3.
Disconnect emergency stop connector from main wiring harness. Remove cable tie bands .
4.
Loosen lock screw and slide throttle lever assembly from the handlebar . (See Figure 387.)
5.
Remove screw and switch from case.
6.
Brake lever may be removed by removing pin retainer and washer, and withdrawing pin.
7.
Reassemble reversing order of disassembly.
3-76
slide
1.
Install throttle lever assembly on the handlebar in the reverse order of removal. Tighten lock screw to 25 in . Ib (0.278 kg -m) .
2.
Check throttle lever adjustment as described in Section 2.
moved to replace the emergency stop switch . Remove the throttle cable from throttle lever assembly.
case;
I nsta lIati on
NOTE: Entire throttle lever assembly must be re1.
plate from
EMERGENCY STOP SWITCH OR THROTTLE LEVER ASSEMBLY
..
Headlamp
2.
Removal 1. To remove just the headlamp assembly, dis connect the headlamp harness from the headlamp. (See Figure 3-88.)
SA340 & SB440
Remove the four adjusting screws and springs. The headlamp assembly can now be removed from the hood . Note positioning of short and long adjusting springs for proper location during installation .
Disassemble headlamp as illustrated in Figure 388.
Installation 1.
Reassemble headlamp in reverse order of removal. (See Figure 3 -88.)
2.
Adjust headlamp in accordance with Section 2.
Key Switch Removal 1. SC340
Remove the face nut and wiring harness from the key switch and remove key switch from the console. (See Figure 3-89.)
Installation 1.
Install key switch in the reverse order of re moval. Hand-tighten the face nut.
14
\
(;p
1. Headlamp Harness 2 . Bulb Retainer 3. Bulb 4. Top Spring - Short 5. Lens Assembly 6 . Bottom Spring - Long 7. Rim 8. Adjustment Screw 9. Washer 10. Reta i ner Screw 11. Bulb Retaining Ring 12. Mounting Rim 13. Adjustment Spring 14. Adjustment Screw Figure 3-88
1. 2. 3.
Key Face Nut Key Switch
Figure 3-89
HEADlAMP
3-77
Speedometer, S8440 Only Removal 1.
Open hood for access to the speedometer.
2.
Disconnect speedometer cable and light bulb harness connector.
3.
Remove the speedometer bracket, and remove the speedometer from the panel. (See Figure 390.)
-LLSb==-----=~ II
I
1. Rivets Figure 3-91
Figure 3-90
Installation 1.
With rubber mount positioned in mounting hole, insert speedometer and install the speedometer bracket. Tighten nuts to 11 in. Ib (0.13 kg-m) torque.
2.
Secure the light bulb connector. Connect the speedometer cable and hand-tighten.
3.
Remove rear fuel tank mounting bracket by drilling out the 3 / 16 in. rivets. (See Figure 391.)
4.
Unscrew seat mounting bolts, and while raising fuel tank slightly, remove seat and tail lamp wiring harness from snowmobile.
5.
Separate tail lamp from seat assembly by removing nuts located inside storage compartment. (See Figure 3-92.)
Tail Lamp Removal 1.
Disconnect tail lamp harness from the main harness. Note tie band positioning for proper location during installation .
2.
Remove rear suspension mounting bolts, position snowmobile on its side, (be sure to provide a protective surface to prevent marring finish on snowmobile) then swing track and suspension out of tunnel. (See Figure 3-91.)
3-78
TAIL LAMP
1. Nuts Figure 3-92
Installation 1.
2.
2.
Install tail lamp assembly in the reverse order of remova l.
On SC340 model, remove regulator by remov ing two nuts and special star washer from regulator mounting screws.
To prevent track damage, secure rear fuel tank mounting bracket with rivet heads positioned on underside (track side) of tunnel.
1.
After installing rear suspension mounting bolts, adjust rear suspension springs. Refer to Suspension Ride Adjustment procedure in Section 2.
m).
Voltage Regulator
On SA340 & SB440 models, disassemble mounting nut, brown ground wire and special star washer to remove regulator.
Installation Install voltage regulator in removal. NOTE: On SA340 & SB440 special star washer and brown positioned under nut. Torque nut
Throttle Cable
1.
Removal
1. 2. 3.
Upper Steering Mount Regulator Mounting Nut Voltage Regulator, SC340 Model Figure 3-93
models, be sure ground wire are 100 in. Ib (1.1 kg-
On SC340 model , be sure special star washer is positioned under mounting screw. Torque nuts 50 in . Ib (0.6 kg -m).
Removal Disconnect voltage regulator, located on RH side of upper steering mount, connector from main wiring harness. (See Figure 3-93 .)
reverse order of
1.
Unscrew the mixing body cap assembly, and pull out the throttle valve assembly.
2.
Compress the throttle spring and remove the spri ng seat plate.
3.
Slide the throttle cable tip to the larger hole in the base of the throttle valve and separate the throttle cable from the throttle valve.
4.
Loosen the throttle cable locknut and screw the throttle cable from the mixing body cap assembly. (See Figure 3 -94.)
1. Mixing Body Cap Assembly 2 . Throttle Valve Assembly 3. Spring 4 . Spring Seat Plate Figure 3-94
THROTTLE CABLE
3 -79
5.
Remove snap r ing and disconnect the throttle cable end from the throttle lever. (See Figure 3 - 95 .)
--(3)
7.
Install the throttle valve into the carburetor so the slot in the throttle valve mates with the lo cating pin in the throttle valve bore. Install the mixing body cap assembly and tighten finger tight. Tighten the throttle cable locknut. Per form Throttle Cable Adjustment Procedure . Refer to Section 2.
Enrichener Cable Removal 1.
Unscrew the enrichener mounting nut and separate the enrichener from control console . (See Figure 3-96.)
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Throttle Cable End Snap Ring Throttle Lever Thrott le Cable Tip
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9 1.
1.
Slide the thrott le cable through the throttle lever assembly and install the snap ring. (See Figure 3-95.)
2.
Connect the throttle cable end to the throttle lever.
3.
Screw the mixing body cap assembly to the throttle cable .
4.
Hold the throttle cable and mixing body cap as sembly in one hand. Place the spring in the cap and compress the spring so the throttle cable extends beyond the spring.
5.
Guide the throttle valve over the throttle cable. Insert the end of the cable through the hole in the throttle valve slot.
6.
While keeping the spring compressed, release the throttle va lve and install the spring seat plate. Then release the spring.
3-80
ENRICHENER CABLE
~ 8
2.
Installation
7
3. 4. 5. 6. 7. 8. 9.
Mounting Nut Lever Housing Spring Plunger Cap Lever Pin Cable Assembly Nut Figure 3-96
2.
Unscrew the enrichener plunger cap. (See Fig ure 3-97.) Remove the enrichener plunger assembly from the carburetor.
3.
Unscrew the fitting, compress the enrichener plunger spring and disconnect the enrichener cable from the enrichener plunger assembly.
NOTE: Individual components of enrichener cable assembly are ava ilable if rep lacement is required. A ssemble replacement parts in sequence shown in Figure 3- 96.
Installation 1.
Slide enrichener through hole in control console, and install the enrichener mounting nut.
2.
Slide the enrichener plunger cap , washer and spring over the end of the enrichener cable .
3.
Place hole in the enrichener plunger over the cable end and spring . Insert plunger into car buretor body and tighten the enrichener plunger cap. Bend washer against cap. Perform Enrichener Cable Adjustment Procedure. Refer to Section 2.
.'
4.
Loosen brake cable locknuts and remove the forward nut to disconnect cable from brake support bracket .
5.
Disconnect brake cable from brake lever by removing snap ring and cable end . (See Figure 3-99.)
1. 2. 3. 4.
Brake Return Spring Clevis Retainer Brake Cable Locknuts Hair Pin Figure 3 -98
1. 2. 3. 4.
Enr ichener Plunger Cap Washer Spring Enrichener Plunger Figure 3-97
Brake Cable Removal 1.
Disconnect brake return spring from brake support bracket. (See Figure 3-98.)
2.
Pull out hair pin and remove clevis retainer mounting pin .
3.
Remove brake cable end from clevis retainer.
1. 2. 3. 4.
Brake Snap Brake Brake
Lever Ring Cable End Cable Tip
Figure 3-99
BRAKE CABLE
3 -81
4.
Push the spider down against the movable sheave. If the spider does not sl ide easily, force down with a slight amount of pressure.
4.
Match the alignment marks on the spider assembly and hex shaft and slide the spider assemb ly onto the shaft .
5.
Remove the split ring from the hex shaft .
5.
Place split rings on the hex shaft.
6.
Mark the spider for correct alignment w ith the hex shaft and remove the spider.
6.
7.
Mark the movable sheave for correct alignment with the stationary sheave and remove the movable sheave.
Position the sp ider against the split rings. Tighten the three setscrews on the spider as sembly to 36 to 48 in. Ib (0.41 to 0.55 kg -mI. Tighten the locknuts securely.
7.
Place the cup washer and spring over the hex shaft.
8.
Match alignment marks and place the housing and bearing assembly over the spring. Press down on the housing and bearing assembly to compress the spring. Hold in position while lifting up on the movable sheave. Secure the housing and bearing assembly to the movable sheave with three capscrews and tighten 15 to 17ft Ib (2 .07 to 2.35 kg-mI . (See Figure 3106.)
8.
To service the spider ro l ler arm assembly, remove the capscrew and nut securing the roller arm weights and the roller . Remove the capscrew and ramp from the movable face.
Cleaning 1.
Remove all grease and dirt by placing components in cleaning solvent. Dry parts with compressed air or a clean cloth.
2.
Remove drive belt accumulations from the stationary sheave, movable sheave and hex bearing with cleaning solvent. Do not use steel wool or a wire brush on the hex bearing.
3.
Remove rust and drive belt accumulations from the steel shaft of the stationary sheave with cleaning solvent or a fine grade of steel wool.
Reassembly 1.
Position the ramp in the movable sheave. Secure with the capscrew and tighten capscrew to 24 to 30 in. Ib (0.28 to 0.35 kg-mI. (See Figure 3- 107.)
2.
Place the movable sheave on the hub of the stationary sheave, matching alignment marks on the movable sheave and stationary sheave .
3.
If the spider roller arm assembly was serviced, align the slot in the bushing with the ears on the roller arm. Place the roller and bushing into the roller arm . Slide the weight onto the capscrew and start the capscrew into the roller arm . Slide the remaining roller arm weight on the capscrew and secure with the nut. Tighten the nut to 35 to 48 in. Ib (0.40 to 0.55 kg-mI.
Figure 3- 106
Installation
3 -84
DRIVE CONVERTER
NOTE: Clean taper inside converter and on crankshaft to remove all oil, dust, etc. Tapers must be clean and dry . Install the drive converter on the crankshaft and secure with a bolt and lockwasher. Tighten the bolt to 60 ft Ib (8.3 kg-mI. Insta ll the drive belt.
Roller Bearing Stationary Sheave Movable Sheave and Bearing Assembly Ramp Washer Screw Housing and Bearing Assembly 8 . Washer
1. 2. 3. 4. 5. 6. 7.
9. 10. 11 . 12. 13. 14. 15. 16. 17. 18.
Screw Spring Washer Split Ring Spider Assembly Screw Weight Nut Nut Screw
Figure 3-107
DR IVE CONVERTER
3 -85
Driven Converter
Disassembly
NOTE: When repair of the driven converter is required, remove the chaincase and driven con verter from the snowmobile as an assembly. See Chaincase Removal. Then disassemble the driven converter as follows.
1.
On SB440 only, remove bolt secur ing bearing puller to support to converter shaft. Use remove bearing support and spacer. (See Figure 3- 10B.) On SA340 & SC340 models, remove bolt securing converter assembly to converter shaft, and spacers. (See Figure 3-10B.)
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1. 2. 3. 4. 5. 6. 7. B. 9.
Spacer, SA340 & SC340 Only Bearing Support, SB440 Only Clevis Pin, SB440 Only Bolt, SB440 Only Support Clevis, SB440 Only Retaining Ring Washer Spacer Spring Pin Torque Ramp
10. 11. 12. 13. 14. 15. 1 6. 17. 1 B.
Figure 3- 10B
3-86
DRIVEN CONVERTER
Shoe Ramp Slide Movable Sheave Movable Bush ing Woodruff Key Fixed Sheave Brake Disc Socket Head Screw Converter Key Converter Shaft Spacers
..
2.
Hold stationary sheave while turning movable sheave so shoe ramp slides do not contact the torque ramp.
3.
Force torque ramp down converter shaft until it bottoms. WARNING
a
5.
Align the keyway in the torque bracket with the key . Push the torque bracket onto the shaft just far enough to contact the key. Hold the torque bracket in position . Turn the movable face counterclockwise until there is slight spring tension . Then turn the movable face an additional 120 degrees.
6.
Push the torque bracket down on the shaft, while aligning pin in bracket w ith notch in bearing, until it bottoms. Hold the torque bracket in position and install the retaining ring.
Keep a downward pressure on the torque bracket and release spring tension slowly.
4.
Remove the retaining ring, the torque bracket assembly, and driven spring .
7.
Release the torque retaining ring .
5.
Slide movable sheave from stationary sheave shaft. Remove the key and bushing .
8.
6.
Pull the shoe ramps from the movable sheave.
Install the brake disc and secure with three cap screws. Use Loctite on screws and torque to 95 in. Ib (1.09 kg-mI.
9.
Position the spacers and key on the converter shaft. Install the assembled converter.
7.
hub of the
Remove three capscrews and separate the brake disc from the stationary sheave .
Remove all foreign matter from the shoe ramps with a clean cloth and inspect for wear.
2.
Place remaining components in cleaning sol vent and remove all grease and dirt. Dry components with compressed air or a clean cloth.
3.
Inspect sliding surfaces for wear and damage.
4.
Inspect the fixed and movable faces for broken or loose rivets.
5.
Check the torque bracket for cracks, wear and other damage .
Position the shoe ramps on the movable face and tap into place using a rubber mallet.
2.
Position bearing and movable sheave onto shaft of stationary sheave, then install key.
3.
Position the driven spring over the stationary sheave and hook the turned down end into the hole in the movable face.
4.
Positi on the torque bracket over the spring and hook the turned up end into the second hole of the torque bracket for standard spring tension.
the
On SA340 & SC340 models, position spacers on converter shaft. (See Figure 3 -1 08.) 11 . Install flat washer and bolt, Torque bolt 25 ft Ib (3.5 kg-mI . 12. Refer to Chaincase Installation to chaincase in the snowmobile.
rein sta ll
Chaincase Removal 1.
On 58440 only, remove retainer pin from bearing support clevis.
2.
Remove drive belt .
3.
Remove bolts and nuts securing the" brake caliper bracket to the chaincase, and lift the brake caliper assembly from the chaincase . (See Figure 3 -1 09.)
4.
Remove chain cover and allow oil to drain into a clean conta in er.
Reassembly (See Figure 3-108) 1.
against
10. On 58440 model only, add spacer and press on bearing support. (See Figure 3-108 .)
Cleaning and Inspection 1.
bracket
NOTE: On 58440 model, be sure not to loose the speedometer key when removing the chain cover. 5.
Remove chain tensioner spring from one of the tensioner arms, and the bolts securing sprockets. (See Figure 3-110.) Remove the chain and sprockets from the sp line s on their respective shafts.
CHAINCASE
3-87
6.
Remove the four locking nuts and washers from the through -bolts secu r ing chaincase to chassis. (See Figure 3-110.) Pull the assembled chaincase and dr iven converter outward, disengaging from the track driveshaft and re move the chaincase .
Disassembly of the Chaincase (See Figure 3- 111) 1.
Re move drive n converter and shaft from c haincase as an assem bly by tapping shaft with a soft mall et. Use care not to damage splines.
NOTE: After co nverter and shaft assembly have been removed, chec k to see if spacers are stuck onto ri g ht hand bea r ing race. Install spacers onto driven con verter shaft to insure proper positioning during reassembly and prevent loss during chain ca se cl ea ning.
1. 2.
2.
Cl ea n metal parts in solvent, dry all com ponents except bearings with compressed air. All ow bearings to air dry. Inspect bea r ings for scoring, bind ing during rotat ion, and radial pl ay. Inspect sprocket s and splined shafts for dam aged t eeth or sp lines. Replace damaged parts.
3.
Should bear ings requ ire replacement, they may be removed by the following procedure. Heat the boss area of case w ith a propane torch , a nd remove ri gh t hand bearing by alternately tapp ing on opposite sides of t he inner race. Rem ove th e remain ing spacer. The left bearing m ay now be removed by pressing it out or by placing an appropriately sized drift against the inner race and tapping the bearing from the case w ith a hammer . Remove driveshaft bearing by first removing snap r ing retainer, then pressing or tapping bearing from case.
4.
Inspect cha in and tensioner arm bushings for w ea r; replace if necessary.
Mounting Bolts Support Bracket Figure 3- 109
Reassembly (See Figure 3-111)
1. Upper Sprocket Mou nting Bo lt 2. Chaincase to Ch ass is Nuts 3 . Chain Tens ioner Spring 4 . Lower Sprocket Mounting Bolt Figure 3- 110
3-88
C HAINCASE
1.
Install driveshaft bearing and left converter shaft bearings in case. Assemble snap ring retainer on driveshaft bearing making sure it is properly seated in groove .
2.
Be sure driven converter spacers are installed on shaft, then assemb le right hand bearing onto shaft until bearing contacts spacers.
3.
Next, position inner bearing spacer onto driven converter shaft, then insert assembly through right side of chaincase .
4.
Press shaft assembly through left bearing while right bearing enters chaincase boss .
NOTE: Be sure bearing inner races are seated aga i nst the inner bearing spacer.
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Chain Cover O-Ring Chaincase Cover Fill Plug Special Lock Patch Bolt Speedometer Drive Adapter SB440 Only Adapter Hole Cap, SA340 & SC340 Cap Gasket. SA340 & SC340 Only Oil Level Check Plug Bearing Spacer Bearing Assembly Upper Sprocket Spacer, .50 in . (12.9 mm) Width Upper Sprocket Special Flat Washer
14. 15. 16. 17. 18. 19. 20. 21 . 22 . 23. 24. 25. 26. 27. 28.
Lock Patch Bolt Tensioner Arm Chain Guide Hair Pin Bolt Plain Washer Tensioner Arm Bushing Tensioner Spri ng Chain Speedometer Key Speedometer Key Adapter Spec ial Bolt Special Washer Sprocket Lower Sprocket Spacer .45 in. (11.4 mm) width 29. Snap Ring
30. Bearing 31. Insert Nut 32 . Special Washer 33. Cha incase 34. "U" Washer 35. Plain Washer 36. Bolt 37 . Insert Nut 38. Converter Shaft Spacer 39. Converter Shaft 40. Converter key 41. Washer Spacer, SB440 Only 42. Spacer, SA340 & SC340 Only 43. Bearing Support. SB440 Only 44. Nut. SB440 Only 45. Support Clevis, SB440 Only 46 . Bolt, SB440 Only 47. Clevis Pin, SB440 Only
Figure 3-111
CHAINCASE
3-89
Installation 1.
Loosen track tension. Refer to Track Tension Procedure Section 2.
2.
Install assembled case and converter in snowmobile, sliding driveshaft bearing over driveshaft, and secure case to chassis. As semble four mounting nuts finger tight on throug h bolts .
3.
Remove upper and lower sprocket retaining bolts, then remove sprockets and chain. (See Figure 3-110.)
Installation 1.
Insta ll the upper sprocket, lower sprocket and the chain as a unit. Install the lower sprocket washer and retaining bolt. Torque bolt 35 ft Ib (4.8 kg-mI. Install washer and apply Loctite to upper sprocket retaining bolt. Torque sprocket retaining bolt to 25 ft Ib (3.5 kg-mI. Inspect chain guides, and service as described in Section 2.
3.
Install assembled brake caliper and support bracket to chaincase. Tighten mounting nuts to 100 in . Ib (1.1 kg -mI.
4.
Install chain tensioner arms, and replace chain guides if necessary.
2.
Install chain tensioner spring and retaining pins.
5.
Slide bearing to sprocket space rs onto shafts. Set sprockets in chain, and slide sprockets simu ltaneously onto shafts, rotating sprockets until they align with shaft splines. Apply Loctite and thread bolts with proper washers to shafts. Torque upper and lower sprockets to 25 ft Ib (3.5 kg-m) and 35 ft Ib (4.8 kg-m) re spectively.
3.
Place a -ring gasket properly in cover, applying a light coating of sealer to hold it in place. Install cover to chaincase, and add chain oil until fluid is level with lower edge of hole.
6.
Install chain tensioner spring and retaining hair pin clips.
7.
Place a -ring gasket properly in cover. Apply a thin coating of sealer to the gasket to hold it in place. Install chain cover.
Brake Caliper Removal 1.
Disconnect brake return spring from brake sup port bracket. (See Figure 3- 112.)
NOTE: On SB440 model, position speedometer key into adapter and install drive adapter on chaincase cover. 8.
Add chain oil until fluid is level with lower edge of hole.
9.
Align converters. Refer to Converter Alignment Procedure Section 2.
10. Install drive belt and adjust converter shaft bearing support assembly to install retainer pin through clevis and support brace.
1. 2. 3. 4.
Chain Replacement Removal 1.
Remove the chaincase cover and drain oil from chaincase into a su itable container. Inspect the cover gasket, and discard if damaged.
NOTE: On SB440 model, be sure not to loose the speedometer key when removing the chain cover. 2.
Remove cha in tensioner spring .
3-90
BRAKE CALIPER
Clevis Retainer Brake Support Bracket Hair Pin Brake Return Spring Figure 3-112
2.
Pullout hair pin from pin securing the clevis retainer and remove pin.
3.
Slide brake cable end out of the clevis retainer.
4.
Remove forward brake cable jam nut to release cable from bracket.
5.
Loosen nuts securing brake support bracket to chaincase and remove brake assembly from chaincase. (See Figure 3-113 .)
3.
Repair Inspect the brake pads for wear. If pad B is worn so only 1/ 32 in. (0.79 mm) protrudes from the caliper, replace pad B. Use contact cement to secure the new pad. If pad A is worn to 1/ 8 in . (3.18 mm), replace pad A.
Disassembly 1.
Remove the nut and washer and lift off the cam and spring. (See Figure 3-113 .)
2.
Remove two nuts, bolts, washers and bushings. Remove the brake support bracket.
Separate caliper B from caliper A and remove pad A and backup washer.
Clean all parts in solvent. Be sure to keep oil and grease from the pads. Braking action will be im paired by oily or greasy pads.
3
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1
14
1 . Socket Head Screw 2. Flat Washer 3. Caliper B 4 . Pad B, 5/ 16 in. Thick 5. Pad A , 1/ 2 in. Thick 6. Backup Washer 7. Caliper A 8. Push Pin 9. Pi n
10. 11 . 12. 1 3. 14. 15. 16. 17.
Hair Pin Clevis Retainer Cam Stud Washer Special Nut Bushing Cam Spring Bolt
18. 19. 20. 21. 22. 23. 24. 25 .
Bushing Nut Brake Return Spring Brake Support Bracket Rivet Return Spring Bracket O-Ring Nut
Figure 3- 113
BRAKE CALIPER
3-91
Assembly
2.
Apply coating of NEVER-SEEZ to push pins and inside surface of cam. Assemble and install brake caliper in the reverse order of removal and dis assembly. Then adjust brake as instructed in Section 2.
Position snowmobile on its side on a protective surface and lift suspension out of chassis. Figure 3-115 shows the complete suspension assembly after it has been removed from the snowmobi le.
Suspension Removal 1.
Remove four bolts (two on each side of snowmobile) securing suspension to chassis. (See Figure 3- 114.)
Figure 3-115
Inspection Check wheel bearings, suspension arms and pivot shafts for binding. If the suspension binds, locate the problem and refer to the appropriate repair procedure. Refer to Figure 3-116 for parts location and identification when repairing th e suspension. 1.
Suspension Mounting Bolts Figure 3-114
NOTE: The following repairs are performed with the sl ide rail suspension removed from the snowmobile.
..
3-92
SUSPENSION
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1. Track Assembly 2. Track Clip 3. Track Clip 4. Rear Axle 5. Rear Axle Wheels Spacer 6. Idler Wheel Assembly 7 . Inside Wheel Spa cer 8. Idler Wheel 9. Bal l Bearing 10. Snap Ring 11. Outside Wheel Spacer 12. Rear Axle Wheels Spacer 1.210 in. (30.7 mm) long 13 . Rear Axle Bracket Assembly 14. Rear Axle Wheel Spacer 15. Washer 16. Bolt 17. Nut 18. Nut 19. Bolt 20. Bolt 21. Idler Wheel Shaft 22 . Rear Suspension Idler Wheel Assembly
23. Snap Ring 24. Bearing 25. Wheel 26. Idler Wheel Spacer 27. Rear Suspension Arm 28. Washer 29 . Bolt 30. Suspension Bushing 31. Rear Spring 32. Pivot Shaft 33. Bolt 34. Bolt 35. Rear Suspension Arm Bracket 36. Suspension Rail 37. Rail Wear Strip 38 . Bumper Pin 39. Screw 40. Bolt 41 . Limiter Bracket Assembly 42. Limiter
43. Front Suspension Spring Bushing 44. Limiter Bracket Assembly Washer 45. Cotter Pin 46. Bumper Pin Retainer 47. Rubber Bumper 48. Front Suspension Bracket Assembly 49. Front Idler Wheel Spacer, 0.935 in. (23.7 mm) long 50. Bracket Wear Strip 51. Rear Suspension Bracket Stopper 52. Rivet 53 . Nut 54. Bolt 55. Shock Absorber Bushing 56. Shock Absorber Sleeve 57. Shock Absorber 58 . Nut 59 . Front Spring 60. Eye Bolt 61. Bolt 62. Front Suspension Swing Arm 63. Limiter Strap Washer
Figure 3-116
SUSPENSION
3-93
Rear Axle and Wheels
Reassembly and Installation
NOTE: The following repairs are performed with the slide rail suspension removed from the snowmobile.
1.
Press the new bearings into the wheel s and secure with snap ring, then install the outside and inside (large and small) wheel spacers.
2.
Install idler wheels and spacers onto rear axle in sequence shown . (See Figure 3 - 117.) Be sure plastic spacer 1.210 in. (30.7 mm) long is positioned in side of rear axle bracket.
3.
Secure wheels with bolts previously removed tightened to 30 ft Ib (4.1 kg-m) torque.
4.
Install suspension and check track adjust ments. Refer to Suspension Installation procedure in Section 3 .
Removal and Disassembly 1.
Remove bolts from end of the axle. (See Figure 3-117.)
Rear Suspension Arm NOTE: The following repairs are performed with the slide rail suspension removed from the snowmobile.
1. Rear Axle Mounting Bolt 2. Wheel Assembly 3. Spacers 4. Rear Axle Figure 3-117
2.
Lightly tap rear axle out from wheel assem blies and remove axle spacers.
3.
To remove bearing from wheel, remove out side and inside (large and small) wheel spacers, snap ring, then press the bearing out of the wheel. (See Figure 3 - 116.)
NOTE: To protect against excessive wear, DO NOT allow dirt to enter bearings.
1. 2. 3.
Inspection
Springs Upper Shock Absorber Mount Bolt Rear Arm Mounting Bolts Figure 3 - 118
1.
Replace rear idler cessively worn.
2.
Spin rear idler wheels and check for noise, excessive slop between shaft and bearing, or binding. Replace bearings or spacers if necessary.
Removal and Disassembly 1.
Slide springs off of rear arm . (See Figu re 3 118.)
Inspect the shaft for damage .
2.
Unscrew upper shock absorber mounting bolt.
3.
3-94
wheel
if rubber
REAR SUSPENSION ARM
is ex -
..
3.
Unscrew bolts securing rear arm assembly to slide ra il brackets and lift rear arm from slide rail assembly.
4.
Disassemble rear suspension arm by removing pivot shaft, idler wheels with shaft, spacers and bushings. (See Figure 3- 119.)
Figure 3 - 120
1. 2. 3. 4. 5.
Idler Wheels Idler Shaft Spacers Bushings Pivot Shaft
Figure 3-119
Reassembly and Installation (See Figures 3 - 118 and 3 - 11 9 ) 1.
Assemble idler wheels onto shaft in seq uence shown. (See Figure 3-119.)
2.
Secure idler wheel and shaft assembly to rea r suspension arm by tightening mounting bolts to 15 ft Ib (1.9 kg -m) torqu e.
Inspection (See Figure 3-120) 1.
Measure swing arm as shown. If dimension "X" is different than dimension "Y" by 1 /8 in. (3 .2 mm) or more, replace swing arm. Examine swing arms for distortion, cracks or broken welds. Repair or replace if necessary.
3.
Grease and insert bushings into rear suspen sion arms, position arm assembly into slide ra il brackets, then secure rear arm to rail brackets by tightening mounting bolts and nuts to 15 ft Ib (1.9 kg-m) torque.
2.
Remove and examine bushings and shafts for wear or damage . Replace if necessary.
4.
Secure s hock absorber to rea r arm bracket by tightening mounting bolt and nut to 15 ft Ib (1.9 kg-m) torque.
3.
Examine suspension brackets for bends or cracks. Replace if necessary.
5.
Grease and insert pivot shaft into rea r ar m.
6.
Slide springs onto rear arm as shown. (See Figure 3- 118.)
4.
Inspect wheel bearings for noise, excessive play or binding . Replace defective or questionable bearings. (See Figure 3-116.)
5.
Check springs for worn spots and cracks. Replace if any defects are observed.
7.
Install suspension, and check track adjust ments. Refer to Suspension procedure in Section 3.
Insta llation
REAR SUSPEN S ION ARM
3-95
Shock Absorber Removal (See Figure 3-121) 1.
Unscrew bolts from each end of shock absorber and remove from suspension arms .
2.
Remove bushings and sleeve from upper shock absorber mounting eye.
Short bolt must be installed in upper shock absorber mount or damage to track drive lugs will result. 3.
Secure lower shock absorber mount to front arm bracket assembly by tightening bolt and nut to 30 ft Ib (3 .9 kg-m) torque .
Wear Strips NOTE: The following repairs are performed wi t h the suspension removed from snowmobile.
Hi-Fax (Rail Wear Strip) Inspection 1. Check rail distortion. 2.
1. 2. 3.
Bushings Sleeve Upper Mounting Eye Figure 3-121
Examine shock absorber shaft for warpage.
2.
Inspect shock absorber for leakage and cracked or worn rubber mounts .
3.
Check bush ings and sleeve for wear and damage. Replace defective parts as r~quired .
2.
Install bushings and sleeve into upper shock mounting eye. Position shock absorber upper mounting eye into rear suspension arm bracket, insert short mounting bolt and thin nut, then tighten bolt and nut to 15 ft Ib (1 .9 kg -m) torque .
3-96
WEAR STRIPS
for
cracks,
and
Measure wear strip thickness. If rail strip is worn to 3/8 in. (9.5 mm) or less at any point, it must be replaced .
1. Turn slide rail suspension upside down, and brace it to prevent shifting . 2.
Remove self-tapping screw from bottom of the rail wear strip.
3.
Tap the back of the wear strip with a block of wood and hammer as illustrated in Figure 3 122 to remove it from the suspension rail.
NOTE: To ease removal of wear strip apply silicone spray (or comparable lubricant) between wear strip and slide rail for entire length .
Installation 1.
Lubricate slide rail with silicone spray (or comparable lubricant) then slide wear str ip into position on rail assembly .
2.
Install wear strip mounting screw and tighten to 100 in . Ib (1.1 kg-m) torque.
3.
Install suspension and check track adjustments. Refer to Suspension Installation procedure in Section 3.
Installation (See Figure 3-121) 1.
strips
Removal
Inspection 1.
wear
..
1. 2. 3. 4. 5.
Figure 3-122
Rear Axle Bracket Rear Suspension Arm Wear Strip Rear Suspension Arm Bracket Stopper Rivets Upper Shock Absorber Mount Figure 3- 123
Wear Strip (Rear Suspension Arm) Inspection
Installation (See Figure 3-123) 1. Slide wear strip into position on rails, install rear suspension arm bracket stopper, and se cure components to suspension rails with rivets.
Replace wear strip if damaged or excessive play exists between rear suspension arm and slide rail.
2.
Position rear suspension arm brackets onto wear strips and push assembly forward until brackets contact stoppers.
Removal (See Figure 3-122)
3.
Install upper shock absorber mounting bolt and tighten bolt and nut to 15 ft Ib (1.9 kg-m) torque.
4.
Install rear axle assembly onto suspension rails, then secure rear axle brackets to rails by tightening bolts and nuts to 100 in. Ib (1 .1 kg-m) torque.
5.
Install suspension and check track adjustments. Refer to Suspension Installation procedure in Section 3.
1.
2.
Unscrew bolts securing each rear axle bracket to suspension rails and remove rear axle assembly. Remove outside rear axle wheel for access to bracket mounting bolts. Unscrew upper shock absorber mounting bolt from rear suspension arm.
3 . Slide rear suspension arm assembly towards rear of rails and off from wear strips. 4.
5.
Remove rear suspension arm bracket stopper by drilling 3/ 16 in. (4.7 mm) rivets securing stopper to rails. To simplify removal of rivet, drill off head of rivet, then use punch to push body of rivet downward and out of rail assembly. Tap wear strip rearward until off of suspension rail.
Front Suspension Arm Springs NOTE: The following repairs are performed with the slide rail suspension removed from the snowmobile.
FRONT SUSPENSION ARM SPRINGS
3 -97
Removal (See Figure 3-124) 1.
Disconnect front arm of spr ing from limiter bracket assembly.
2.
Unhook rear arm of spring from eye bolt and slide spring off of front suspension arm .
3.
Remove cotter pin, then slide front suspension spring bushing and washer from limiter bracket assembly.
2.
Slide front springs onto suspension arm and hook rear arm of spring into eye bolt.
NOTE: Springs are different for left and right sides. When properly installed, rear arm of spring is positioned on outside of suspension assembly. 3.
Raise front arm of spring over washer and into position on spring bushing.
4.
Install suspension and check justments. Refer to Suspension procedure in Section 3.
track adInstallation
Limiter Straps Removal (See Figures 3-124 and 3-125)
1. 2. 3. 4.
1.
Disconnect front arm of spring from limiter bracket assembly.
2.
Unscrew bolts and nuts securing limiter straps to front suspension arm, then remove limiters.
Eye Bolt Spring Rear Arm Spring Front Arm Limiter Bracket Figure 3-124
Inspection 1.
Check spr ings for worn spots and cracks. Replace springs if defects are noted.
2.
Replace spring bushing if worn.
3.
Inspect eye bolts for damage and replace if required.
Figure 3- 125
NOTE: If eye bolt replacement is required, observe number of exposed threads protruding through nut. so that same spring tension will be applied during installation of nut and suspension handling adjustment will be unchanged.
Installation (See Figure 3-124) 1.
Install front suspension spring bushing and washer onto limiter bracket assembly, then secure components using cotter pin.
3 -98
LIMITER STRAPS
It
â&#x20AC;˘
Inspection 1.
Inspect limiters for deterioration and damage. Replace as required.
2.
Check the limiter bracket for distortion .
Installation (See Figure 3-125) 1.
2.
Install limiter straps through guides on limiter bracket assembly as shown. Be sure washer is positioned on top of limiter strap, then tighten bolts and nuts to 45 in. Ib (0.6 kg-m) torque. Raise front arm of spring over washer and into position on spring bushing.
3.
Reassembly and Installation (See Figure 3-126) 1.
Press the new bearings into the wheels and secure with snap ring, then install the outside and inside (l arge and sma ll) wheel spacers .
2.
Insta ll idler wheels and spacers onto shaft in sequence shown. Be sure plastic spacer 0.935 in . (23. 7 mm) long is positioned on shaft prior to insta lling wheel assembly.
3.
Secure wheels with bolts previously removed tightened to 30 ft Ib (3.9 kg -m) torque .
Idler Wheels Front Suspension Arm Removal and Disassembly (See Figure . 3-126) 1.
Unscrew bolts securing front idler wheels, then remove wheel assembly and spacer from shaft.
Inspect shaft. If damaged, replace front suspension arm bracket assembly.
Front Suspension Arm NOTE: The following repairs are performed with the slide rail suspension removed from the snowmobile.
Removal (See Figure 3-127) 1.
Remove front suspension arm idler wheels. Refer to Idler Wheel Removal procedure .
Figure 3-126
2. To remove bearing from wheel, remove outside and inside (large and small) wheel spacers, snap ring, then press the bearing out of the wheel. (See Figure 3-116.) NOTE: To protect against excessive wear, DO NOT allow dirt to enter bearings .
f
Inspection 1. Replace front idler shaft wheel if rubber is excessively worn. 2.
Spin wheels on the shaft and check for noise, excessive slop between shaft and bearing, or binding. Replace bearings if necessary. (See Figure 3-116.)
1. Front Suspension Arm Bracket Assemb ly 2. Idler Wheel 3. Bushings 4 . Front Suspension Arm 5. Pivot Shaft Figure 3-127
FRONT SUSPENSION ARM
3-99
2 . Remove front suspension arm springs. Refer to Front Suspension Arm Springs Removal procedure. 3.
Disconnect limiter straps from front suspension arm assembly. Refer to Limiter Strap Removal procedure.
4.
Separate front suspension arm from suspension arm brackets by removing mounting bolts. (See Figure 3-127 .)
5.
Disassemble front suspension arm by removing pivot shaft and bushings.
Inspection (See Figure 3-128) 1.
Measure swing arm as shown. If dimension "X" is different than dimension "Y" by 1 / 8 in. (3.2 mm) or more, replace swing arm. Examine swing arms for distortion, cracks or broken welds. Repair or replace if necessary.
6.
Inspect eye bolts for damage and replace if required .
NOTE: If eye bolt replacement is required, observe number of exposed threads protruding through nut, so that same spring tension will be applied during installation of nut and suspension handling adjustment will be unchanged .
,
Installation (See Figure 3-127) 1. Grease and insert bushings into front suspension arms, position arm assembly into slide rail brackets, then secure by tightening mounting bolts and nuts to 15 ft Ib (1 .9 kg-m) torque. 2.
Install limiter straps. Refer to Limiter Strap Installation procedure .
3.
Install front suspension springs. Refer to Front Suspension Arm Springs Installation procedure.
4.
Secure idler wheels to front suspension arm bracket assembly. Refer to Front Suspension Arm Idler Wheel Installation procedure .
5 . Grease and insert suspension arm . 6.
pivot
shaft
into
front
Install suspension and check track adjustments . Refer to Suspension Installation procedure in Section 3.
Suspension Rails NOTE: The following repairs are performed with the slide rail suspension removed from the Snowmobile.
Inspection
Fig ure 3-128
Inspect suspension rails for distortion and damage. Rails should be parallel for entire length . 2.
Remove and examine bushings and shafts for wear or damage . Replace if necessary.
3.
Examine suspension brackets cracks . Replace if necessary .
4.
5.
for bends or
Inspect wheel bearings for noise, excessive play or binding. Replace defective or questionable bearings. (See Figure 3 - 116.) Check springs for worn spots and cracks. Rep lace if a ny defects are observed.
3-100
SUSPENSION RAilS
Removal (See Figure 3-129) 1.
Remove rail wear strips. Refer to Hi-Fax (rail wear strip) Remova l procedure.
2.
Remove all bolts and nuts, which secure sus pension rails to brackets.
3.
Disconnect front suspension arm spring from limiter bracket assembly.
4.
Remove front and rear suspension arm mounting bolts.
5.
Remove rear bumper.
6.
Remove rear suspension arm wear strip. Refer to Rear Suspension Arm Wear Strip Removal procedure.
7.
Slide suspension rails from brackets.
5.
Measure distance between suspension rails several places along its length, to insure rails are parallel, after performing repairs.
6.
Install suspension and check track adjust ments. Refer to Suspension Installation procedure.
Suspension Installation NOTE: Apply grease to front and rear suspens ion arm pivot shafts prior to installation . 1.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Place the snowmobile on its right side and slide suspension between the track. Be sure I ugs on track are properly mated with drive I ugs on sprockets. (See Figure 3-130.)
Limiter Bracket Assembly Front Suspension Spring Front Suspension Arm Mount Bolt Bumper Rear Suspension Arm Wear Strip Rear Suspension Arm Mount Bolt Suspension Rail Wear Strip Spacer 1.210 in. (30.7 mm) long Spacer 0.935 in. (23.7 mm) long 1. 2.
Figure 3- 129
Pivot Shaft Drive Lugs
Figure 3-130
Installation 1.
2.
3.
4.
Reassemble suspension rails order of removal. Tighten bolts attach rails to the brackets support brackets to 100 in. Ib
in th e opposite and nuts which and rear axle (1.1 kg -m).
2.
Align front pivot shaft with forward holes in side of tunnel. Secure with whiz lock bolts. Torque to 25 ft Ib (3.5 kg-m).
Tighten front and rear suspension arm mounting bolts to 15 ft Ib (1.9 kg-m) torque.
3.
Be sure correct plastic spacer is installed behind front suspension arm idler wheel. (See Figure 3- 129.)
Align rear suspension arm pivot shaft with holes in rear suspension bracket. Install bolts and tighten to 25 ft Ib (3.5 kg-m).
4.
Adjust the track tension and suspension spri ngs. Refer to Track Adjustments and Suspension Adjustment procedures in Section 2.
Install rail wear strips. Tighten screw to 100 in. Ib(l.l kg-m).
SUSPENSION INSTALLATION
3 -10 1
Driveshaft and Track Removal 1.
Remove suspens ion . Refer to Removal procedure in Section 3.
Suspension
2.
Remove the chaincase cover and drain lubri cant into a clean container.
3.
Remove the chain tensioner spring , upper and lower sprocket s and spacers. (See Figure 3131 .)
4.
Remove three bolts, washers, nuts and bearing housing. (See Figure 3-132 .)
5.
Reach between track and slide driveshaft from the chaincase ¡ and remove .
6.
Remove the track.
â&#x20AC;˘
1. Upper Sprocket 2. Lower Sprocket 3. Tensioner Spr ing Figure 3-131
3-102
DRIVESHAFT AND TRACK
5
11
1. 2. 3. 4. 5. 6.
/
Bolt Bearing Housing Plain Washer Insert Nut Socket Head Screw Collar
7. 8. 9. 10. 11.
Sealed Bearing O-Ring Drive Sprocket Sprocket Spacer Track Driveshaft
Figure 3-132
DRIVESHAFT AND TRACK
3-103
Driveshaft Repair 1.
Turn the bearing by hand. If the bear ing binds, has excessive end play or is rough , it must be replaced. Bea r ing is press fit onto shaft.
2.
Check the driveshaft for distortion. Check the splined end for chipped , nicked or broken splines.
3.
Check the drive sprockets for excessive wear . To remove drive sprockets, remove collar assemblies and position driveshaft securely in a press. Activate press to remove sprockets.
NOTE: It is not necessary to drill completely through clip, small indentations are sufficient to permit the clip to split. b.
To install new clip, position it on track and compress with track clip tool assembly (tool No. 57001 -3513) as shown in Figure 3 134.
4 . When assembling drive sprockets, be sure index marks (T) are aligned as shown in Figure 3 - 132.
5.
Position collar assembly on shaft at the dimension shown and tighten 70 in. Ib (0.8 kgmI. (See Figure 3- 133.)
6.
Press sprocket snuggly against collar and install spacer, sprocket and collar in the se quence shown in Figure 3-133 .
1. Track Clip Tool Assembly Figure 3- 134
Installation Driveshaft and Track 1.
Position track into tunnel so angled side of drive ribs rotate toward snowmobile rear. (See Figure 3- 135.)
1. 4.12 ± 0.01 in. (104.6 ± 0 .25 mm) Figure 3-133
NOTE : Advantages direction are:
2.
Check track for cracks, tears and gouges. Rubber portion of track is not repairable . Re place track if rubber damage is observed. Check for broken, worn or missing clips . Re move old clips. a.
3-104
To remove clips from track, drill a series of indentations across top of clip, ' then use hammer and chisel to split clip along indentations.
DRIVES HAFT AND TRACK
installing track
in
this
•
Air turbulence within the tunnel is reduced, requiring less horsepower to turn the track at high speed.
•
Floatation in deep snow is better.
•
Braking action is more positive.
•
Track damage is minimized
Track Repair 1.
of
2. Insert driveshaft bearing end through hole in front frame, then carefully guide splined end of shaft into chaincase.
(- ~"I n ~.;z:'c.l'::=s~~
_____
7.
Install chain guides, tensioner spring and hair pin retainers. (See Figure 3-131.)
8.
Install chaincase cover with new a-ring sea l. Torque cover mounting bolts 70 in. Ib (0.8 kg -
~~
m).
9.
. . . .~-~CD
Fill chaincase as specified in Section 2 .
10. Install suspension , refer to Section 3 for pro cedure. Adjust tra ck as instructed in Section 2 .
Steering System 1. 2.
Direction of Track Rotation Drive Rib Angled Side
Handlebars and Steering Pole Removal (See Figure 3-136)
Figure 3-135
3.
Lubricate a-ring inside bearing housing with grease. Slide housing over bearing with word TOP facing upward. (See Figure 3 - 132.)
1.
Disconnect electri ca l connectors from the main harness so handlebars can be removed .
2.
Disconnect handles.
3.
Remove four mounting screws from the handle holder. (See Figure 3 - 136.) The handlebars can now be removed.
4 . Torque bearing housing mounting bolts 100 in. Ib (1 .1 kg -m). 5.
Install upper and lower sprocket spacers. (See Figure 3-111.) Upper spacer is slightly thicker than the lower spacer.
6.
Install upper and lower sprocket and chain as a unit (lip on lower sprocket toward bearing). Torque upper sprocket mounting bolt 25 ft Ib (3.5 kg-m) . Torque lower sprocket mounting bolt 35 ft Ib (4.8 kg-m).
the
contro l
cables
from
the
NOTE: Engine assembly should be removed for access to steering pole components. 4.
Disconnect tie rods from arms at base of steering pole.
5.
Unscrew bolts and nuts from upper and lower steering pole mounts, then remove steering pole.
STEERING SYSTEM
3 -105
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 . 12. 13.
Handle Grip Cable Tie Band Bolt Mount Block Steering Pole Bushing Handle Pole Assembly Bolt Steering Tie Rod Jam Nut Adjusting Stud Insert Nut Plain Washer Long Steering Arm
14. 15. 16. 17. 18. 1 9. 20. 21. 22. 23. 24. 25. 26.
Figure 3-136
3 -106
STEERING SYSTEM
Bolt Tie Rod End Jam Nut Special Screw Thin Locknut Rod End Spacer Short Steering Arm Bolt Bolt Insert Nut Handle Holder Socket Head Bolt Handlebar
Installation (See Figure 3-136) 1.
Reinstall removal.
steering
pole
reversing
order
2. of
Remove the nuts from the steering arm retaining bolts. Do not remove the bolts, until the tie rods are disconnected.
3. Remove the tie rod end mounting bolts from 2. Apply low temperature grease to bushings and
steering arms and note the numbers and positions of spacers. Rotate the spindle until the steering arm bolt can be removed.
secure bushings and mount blocks to steering mount by tightening bolts 18 ft Ib (2 .5 kg-m).
3. Install handlebars and secure with four mount-
4.
ing bolts. Torque 105 in. Ib (1.2 kg-m). Be sure handlebar is placed in a comfortable driving position.
4.
Reconnect electrical connectors for handlebar controls.
5.
Install the tie rods to the steering pole. Secure with nuts and bolts torqued correctly. Refer to Section 1 Torque Chart.
Position the snowmobile on its side. Force the spindle from the steering arm by tapping with a soft mallet. (See Figure 3-138.)
6. Install engine assembly. Refer to Engine Installation procedure in Section 3.
7.
Align skis as described in Section 2.
1.
Steering Arm and Spindle Removal 1.
Scribe an alignment mark on the steering arm and spindle to aid in installation. (See Figure 3137.)
Spindle
Figure 3-138
5.
Remove one ski spindle bushing from top of snowmobile chassis and one bushing from underneath chassis.
6.
Remove spindle from ski saddle assembly and upper shock absorber mount. (See Figure 3139.)
Installation (See Figure 3-136) NOTE: Prior to installing spindle, lubricate spindle shaft with low temperature (EP) extreme pressure grease.
1.
Slide one bushing onto ski spindle and insert into lower spindle boss of chassis. Slide upper bushing onto spindle from top of chassis.
2.
Install steering arm to spindle, matching index marks made during removal, and tighten mounting bolt and nut to 30 ft Ib (3.9 kg-m) torque.
3.
Attach tie rod ends to steering arms . Install bolts and spacer in sequence shown in Figure 3-136. Refer to Section 1 for proper torque values.
1. Alignment Mark 2.
Nut
3. Steering Arm 4. Tie Rod Figure 3-137
STEERING SYSTEM
3-107
4.
5.
6.
Fill the grease groove or cut away area of the spindle sleeve with a low temperature extreme pressure (EP) grease, and insert sleeve into the spindle. (See Figure 3-139.) Secure the ski assembly to the spindle. Be sure the nut and large flat washer are installed on the inboard side of the ski assembly, then torque the nut 30 ft Ib (3.9 kg -mI. (See Figure 3 - 139.)
Ski Removal (See Figure 3-139) 1.
Remove bolts at each end of spring.
2.
Unscrew bolt securing lower end of shock absorber to ski, and remove ski.
Installation (See Figure 3-139) 1.
Secure upper shock absorber mount to spindle. Refer to Section 1 for proper torque value.
7. Align skis and center described in Section 2.
steering
pole
Position rub strip in ski and install front of ski over shock absorber and spring . Tighten shock absorber mounting bolt to 30 ft Ib (3.9 kg-m) torque, but do not install front spring mount bolt at this time.
as 2.
Install rear spring sleeve and mounting bolt then torque to 30 ft Ib (3 .9 kg -m) to secure spring to ski.
!ยงI-I 3 . Adjust spring preload while installing front spring mounting bolt. Refer to Ski Spring Preload procedure in Section 2.
~I
. .,' -~l
11_Ql .... ~-
,-
12 ~o
I
Ski Spring Removal
......
I I
I
I
I
11-Ql,
I
V-
20-~1
I I I
<...
1.
Remove ski . Refer to Ski Removal procedure.
2.
Unscrew spring mounting bolt nuts to separate spring from saddle. (See Figure 3-140.)
3
4
1 '"~ 5
l
I
0 I~----'------
โ ข
1. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Bushing Spindle Bolt Saddle Bolt Spring Sleeve Plate Bumper Retainer Nut Nut
13. Bolt 14. Ski 15. Skeg 16. Bolt 17. Strip 18. Spacer 19. Shock Absorber 20. Washer 21 . Nut 22. Bolt 23. Sleeve
Figure 3- 139
3-108
STEERING SYSTEM
Spring Mounting Bolts Figure 3-140
Installation (See Figure 3 - 139) 1.
Install spring mounting bolts into saddle.
2.
Next, position spring, back-up plate, bumper and bumper retainer under saddle and secure with nuts. Tighten nuts to 45 ft Ib (5.7 kg -m) torque.
3.
Install ski . Refer to Ski Installation procedure.
,
Skeg Removal (See Figure 3-139) 1.
3.
Remove rear fuel tank mounting bracket by drilling out the 3/16 in. (4.7 mm) rivets. (See Figure 3- 141.)
4.
Unscrew seat mounting bolts, and while raising fuel tank slightly, remove seat and tail lamp wiring harness from snowmobile.
Remove nuts securing skeg to ski and remove skeg.
Installation (See Figure 3-139) 1.
Insert front of skeg into hole near tip of ski.
2.
Align studs on skeg with mounting holes in bottom of ski .
3.
Install nuts and tighten to 18 ft Ib (2.5 kg-m) torque.
Installation NOTE: Check to be sure the rubber pads are properly positioned to protect fuel tank when mounted between tunnel and steering mount. (See Figure 3-142 .) 1.
Seat Removal 1.
Disconnect tail lamp connector from main wIring harness. Note tie band positioning for proper location during installation.
2.
Remove rear suspension mounting bolts, position snowmobile on its side, (be sure to provide a protective surface to prevent marring finish on snowmobile) then swing track and suspension out of tunnel. (See Figure 3-141.)
Position fuel tank onto snowmobile, route tail light harness under fuel tank, then secure fuel tank to tunnel by installing rivets as shown in Figure 3-141 .
To prevent track damage, secure rear fuel tank mounting bracket with rivet heads positioned on underside (track side) of tunnel. 2.
Mount seat to tunnel. Round head screws should be installed at front of seat and hex head bolts at rear of seat.
3.
After installing rear suspension mounting bolts, adjust rear suspension springs. Refer to Suspension Ride Adjustment procedure in Section 2.
4.
Connect tail lamp to main wiring harness and secure wiring with cable tie band.
Fuel Tank Removal 1.
Remove seat assembly. Refer to Seat Removal procedure.
2.
Disconnect fuel tank vent tube from fitting near top of fuel tank.
I 1. 2.
Fuel Tank Bracket Rivet Heads Seat Mounting Bolts (Round Head in Front, Hex Head at Rear) Figure 3-141
WARNING
I
Gasoline fumes are heavier than air and can become explosive if exposed to a pilot light from a furnace, hot water heater, clothes dryer, etc. Perform maintenance only in an area that is well ventilated and free from pilot lights and sparks.
FUEL TANK
3-109
3.
Separate fuel tube from filter and plug end of tube to prevent leakage from tank.
4.
Drill out rivets securing fuel bracket. (See Figure 3-142.)
5.
Remove fuel tank assembly'from snowmobile.
tank
)'15- 4
mount
~-1
)
1. 2. 3. 4.
Fuel Fuel Fuel Fuel
Tank Pads Tank Vent Tube Filter Tank Mount Bracket Figure 3-143
1. 2. 3.
Incorrect vent tube routing may result in fuel spillage within the engine compartment during deceleration or hard braking when the fuel tank is filled to capacity.
Fuel Tank Mount Bracket Bracket Mounting Rivets Fuel Tank Figure 3-142
5.
Mount seat to tunnel. Round head screws should be installed at front of seat and hex head bolts at rear of seat.
6.
After installing rear suspension mounting bolts, adjust rear suspension springs. Refer to Suspension Ride Adjustment procedure in Section 2.
7.
Connect tail lamp connector to main wiring harness and secure wiring harness with a cable tie band.
Installation NOTE: Check to be sure the rubber pads are properly positioned to protect fuel tank when mounted between tunnel and steering mount. (See Figure 3-143.) 1.
Position fuel tank onto snowmobile, route tail light harness under fuel tank, then secure fuel tank to tunnel by installing rivets as shown in Figure 3-141.
To prevent track damage, secure rear fuel tank mounting bracket with rivet heads positioned on underside (track side) of tunnel, 2 . Connect tube between fuel tank and fuel filter . 3.
Install fuel tank vent tube onto tank fitting.
4.
Check vent tube for proper routing . (See Figure 3-144.)
3-110
FUEL TANK
1.
Fuel Tank Vent Tube Figure 3-144
Appendix Table of Contents Page Fuel and Oil Recommendations ... .... .... ... .. ...... 4-2 Engine Break-in ..... ........... .... .......... ........ .... .... ... 4 -3 Conversion Chart ... ..... .. ... ..... .. .... ..... ... ...... ... ... ... 4-4 Drill Sizes ....... ..... ..... ................. ..... .............. .... 4 -5 English to Metric Conversions ... .. ..... ..... ......... 4 -6 Unit Conversion Table ..... ....... ....... ....... .... .. ...... 4 -7 List of Abbreviations .. ... .. ......... .... ... ....... ..... .... 4 -7 Special Service Tools ... ..... ... ....... .... ... .... ... ... ... 4-8 Wiring Diagrams ..... ...... .... ... ..... ....... ... .... ....... 4 -9 Index ..... .... ... .. ....... .. ..... ....... .......... ... .... .... .... .. 4-12
APP ENDIX
4-1
Fuel and Oil Recommendations
I
WARNING
I
Gasoline is extremely flammable and highly explosive under certain conditions. Insure adequate ventilation when fueling the snowmobile and never smoke or allow sparks or open flame near fuel system.
Fuel Use regular or premium leaded gasoline with a minimum PUMP POSTED ANTI-KNOCK INDEX NUM ER of 89.
Fuel/Oil Mixture (Ratio) Fuel Mixture (Break-In Only) )
Your Kawasaki Snowmobile uses a two cycle engine which means oil must be mixed with the gasoline to provide proper internal engine lubrication and cooling .
Oil We recommend using Kawasaki Snowmobile Oil in an emergency use a B.I.A. certified T.C.W. (Two Cycle) oil. These oils are specially formulated to give minimum piston ring varnish and combustion chamber deposits along with excellent lubrication qualities. (See Figure 4-1.)
Fuel and oil MUST be PROPERL Y MIXED or damage to the engine will result. To insu re adequate lubrication of internal engine components during early break-in, a 25 -to - 1 gasoline-to-oil ratio is required for first 6.5 gallons of fuel. To obtain this ratio, thoroughly m ix one quart (0.946 liters) of KAWASAKI SNOWMOBILE OIL with 6.3 gallons (24 .6 liters) of gasoline . After the initi al 6.5 ga llons of the 25 -to- 1 gasolineto-oil ratio have been consumed, the standard recommended 40-to-1 ratio should be used. 25 to 1 Gasoline to Oil Mixture. Break-in Only Oil
Gasoline
1 quart (U. S. )
6 .3 gal. (U.S.) 5.4 gal. (Imp.)
1 quart (Imp.)
6 .3 gal. (Imp.) 7.6 gal. (U.S.)
Fuel Mixture (Standard)
Fuel and oil MUST be PROPERL Y MIXED or damage to the engine will result. 40 to 1 Mixture Ratio Oil
Gasoline
Figure 4 - 1
1 pint (U. S.)
5 gal. (U.S.) 4.3 gal (Imp .)
In an emergency situation when Kawasaki Snowmobile Oil is not available, a B.I.A. certified TC-W oil may be substituted. All certified oils will indicate the TC-W rating on the container. If the B.I.A. certification does not appear on the container, THE OIL MUST NOT BE USED .
1 pint Imp.
5 gal. (Imp.) 6.8 ga l. (U. S. )
The use of fuel additives such as tune-up tonics and "super oils" are NOT RECOMMENDED.
4-2
FUEL AND OIL RECOMMENDATION
The recommended fuel mix rati o is 40 to 1. Add one pint (0.47 liters) of KAWASAKI SNOWMOBILE OIL to 5.0 gal lons (18.9 li ters) of leaded gasoline, with a minimum pump posted anti -knock index number of 89, and tho roughly mix fu el and oil by shaking th e can from side to side.
Adding Gasoline Antifreeze A major brand of Gasoline Antifreeze (such as Heet) should be added to the fuel mix by following the manufacturer's recommendations on the container for proper mix ratio of gasoline with antifreeze. (See Figure 4-2.)
Before removing filler cap from the fuel tank, remove any ice, snow, or water from around the fuel tank opening to prevent contamination of fresh fuel mixture.
Fill the fuel tank slowly and pour the fuel mixture into the tank using a funnel with a fine mesh screen.
(
Engine Break-In To insure adequate lubrication of internal engine components during early break-in, a 25-to-1 gasoline-to-oil ratio is required for the first 6.5 gallons of fuel. To obtain this ratio, thoroughly mix one quart (0.946 liters) of KAWASAKI SNOWMOBILE OIL with 6.3 gallons (24.6 liters) of gasoline. Figure 4 - 2
Filling Fuel Tank
Each time fuel tank is filled. gasoline antifreeze must be added to the fuel mixture. Moisture trapped in fuel system components (fuel tank, lines, fuel pump or carburetors) may freeze causing engine malfunction or damage.
After the initial 6.5 gallons of the 25-to-1 gasolineto-oil ratio have been consumed, the standard recommended 40-to-1 ratio should be used. Fo proper engine break-in, run the machine on hard packed snow at approximately 3/ 8 to 1/ 2 throttle, with occasional bursts to full speed . Limit the full speed operation to 1- 1/2 to 2 minutes, then return to cruising speed for 10 to 15 minute interva ls. After 10 hours of operation or two tanks of gasoline are used, break-in is complete.
ENGINE BREAK-IN
4-3
Conversion Chart / Fraction Inch to Decimal Inch to mm Frac.
Dec.
Inch
Inch
1/ 128 1/64
1/32
3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/1 6 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/1 6 21/64 11/32 23/64 3/8 25/64
4 -4
mm.
Frac.
Dec .
Inch
Inch
.000400 .0100 13/32 .000800 .0200 27/64 .001200 .0300 .001600 .0400 7/16 .002000 .0500 .002400 0600 29/64 .002800 .0700 15/32 .003100 .0800 .003500 .0900 31 /64 .003900 .1000 1/2 .007900 .2000 .011800 .3000 33/64 .015625 .3969 17/32 .015700 .4000 35/64 .01 9700 .5000 .023600 .6000 .7000 9/16 .027600 .031250 .7937 37/64 .031500 .8000 .035400 .9000 19/32 .039370 1.0000 .046875 1.1906 39/64 .050000 1.2700 5/8 .062500 1. 5875 .078125 1. 9844 41/64 .078740 2.0000 .093750 2.3812 21/32 .100000 2.5400 .109375 2.7781 43/64 .11 8 110 3.0000 11/16 .125000 3.1 750 .140625 3.5719 45/64 .150000 3.8100 .156250 3.9687 23/32 .157418 4.0000 47/64 .171 875 4.3656 .187 500 4.7625 3/4 .196850 5.0000 49/64 .200000 5.0800 25/32 .203125 5.1594 .218750 5.5562 51 /64 .234375 5.9531 .236220 6.0000 13/16 .250000 6.3500 .265625 6.7469 53/64 .275590 7.0000 27 /32 .281250 7.1437 .296875 7.5406 55/64 .300000 7.6200 .3 12500 7.9375 7/8 .31 4960 8.0000 57/64 .328125 8.3344 .343750 8.7312 .350000 8.8900 29/32 .354330 9.0000 59/64 .359375 9.1 281 15/16 .375000 9.5250 .390625 9.9219 .393704 10.0000 61/64 .400000 10.1600 31/32
.406250 .421875 .433074 .437500 .450000 .453125 .468750 .472444 .484375 .500000 .511814 .515625 .531250 .546875 .550000 .551184 .562500 .5781 25 .590554 .593750 .600000 .609375 .625000 .629924 .6406 25 .650000 .656250 .669294 .671875 .687500 .700000 .703125 .708664 .7 18750 .734375 .748034 .750000 .765625 .78 1250 .787409 .796875 800000 .812500 .826779 .828125 .8437 50 .850000 .859375 .866149 .875000 .890625 .900000 .905519 .906250 .921875 .937500 .944889 .950000 .953125 .968750
mm .
10.3187 10.7156 11.0000 11 .1125 11.4300 11.5094 11 .9062 12.0000 12.3031 12.7000 13.0000 13.0969 13.4937 13.8906 13.9700 14.0000 14.2875 14.6844 15.0000 15.0812 15.2400 15.4781 15.8750 16.0000 16.2719 16.5100 16.6687 17.0000 17.0656 17.4625 17.7800 17.8594 18.0000 18.2562 18.6531 19.0000 19.0500 19.4469 19.8437 20.0000 20.2406 20.3200 20.6375 21.0000 21.0344 21.4312 21 .5900 21 .8281 22.0000 22.22bO 22.6219 22.8600 23.0000 23.0187 23.4156 23.8125 24.0000 24.1300 24.2094 24.6062
Frac.
Dec.
Inch
Inch
63/64 1 1-1/32 1-1/16 1-3/32 1-1/8 1-5/32 1-3/16 1-7/32 1-1/4 1-9/32 1-5/16 1-11/32 1-3/8 1-13/32 1-7/16 1-15/32 1-1/2 1-17/32 1-9/16 1-19/32 1-5/8 1-21/32 1-11/16 1-23/32 1-3/4 1-25/32
.984259 .984375 1.000000 1.023629 1.031250 1.050000 1.062500 1.062999 1.093750 1.100000 1.102369 1.125000 1.141739 1.150000 1.156250 1.181113 1.187500 1.200000 1.218750 1.220483 1.250000 1.259853 1.281250 1.299223 1.300000 1.312500 1.338593 1.343750 1.350000 1.375000 1.377963 1.400000 1.406250 1.417333 1.437500 1.450000 1.456703 1.468750 1.496073 1.500000 1.531250 1.535443 1.550000 1.562500 1.574817 1.593750 1.600000 1.614187 1.625000 1.650000 1.653557 1.656250 1.687500 1.692927 1.700000 1.718750 1.732297 1.750000 1.771667 1.781250
Frac. Inch
mm.
25.0000 25.0031 25.4001 26.0000 26.1938 26.6699 26.9876 27.0000 27.7813 27.9397 28.0000 28.5751 29.0000 29.2097 29.3688 30.0000 30.1626 30.4797 30.9563 31.0000 31.7501 32.0000 32.5438 33.0000 33.0197 33.3376 34.0000 34.1313 39.2897 34.9251 35.0000 35.5597 35.7188 36.0000 36.5126 36.8297 37.0000 37.3063 38.0000 38.1001 38.8938 39.0000 39.3696 39.6876 40.0000 40.4813 40.6396 41.0000 41.2751 41.9096 42.0000 42.0688 42.8626 43.0000 43.1796 43.6563 44.0000 44.4501 45.0000 45.2438
1-13/16 1·27/32 1-7/8 1-29 /32 1-15/16 1-31/32 2 2-1/32 2-1/16 2-3/32 2-1/8 2-5/32 2-3/16 2-7/32 2-1/4 2-9/32 2-5/16 2-11/32 2-3/8 2-13/32 2-7/16 2-15/32 2-1/2 2-17/32 2-9/16 2-19/32
CONVERSION CHART I FRACTION INCH TO DECIMAL INCH TO mm
Dec. Inch
mm.
1.800000 1.811037 1.812500 1.843750 1.850000 1.850407 1.875000 1.889777 1.900000 1.906250 1.929147 1.937500 1.950000 1.968522 1.968750 2.000000 2.007892 2.031250 2.047262 2.050000 2.062500 2.086632 2.093750 2.100000 2.125000 2.126002 2.1 50000 2.156250 2.165372 2.187500 2.200000 2.204712 2.218750 2.244112 2.250000 2.281 250 2.283482 2.300000 2.312500 2.322852 2.343750 2.350000 2.362226 2.375000 2.400000 2.401596 2.406250 2.437500 2.440966 2.450000 2.468750 2.480336 2.500000 2.519706 2.531250 2.550000 2.559076 2.562500 2.593750 2.598446
45.7196 46.0000 46.0376 46.8313 46.9896 47.0000 47.6251 48.0000 48.2596 48.4188 49.0000 49.2126 49.5296 50.0000 50.0063 50.8001 51.0000 51.5939 52.0000 52.0695 52.3876 53.0000 53. 1814 53.3395 53.97 51 54.0000 54.6095 54.7688 55.0000 55.5626 55.8795 56.0000 56.3564 57 .0000 57.1501 57 .9439 58.0000 58.4195 58.7376 59.0000 59.5314 59.6895 60.0000 60.3251 60.9594 61.0000 61.1189 61.9126 62.0000 62.2294 62.7064 63.0000 63.5001 64.0000 64.2939 64.7694 65.0000 65.0876 65.8814 66.0000
)
Frac. Inch
2-5/8
2-21/32 2-11/16 (
2-23/32 2-3/4 2-25/32 2-13/16 2-27/32 2-7/8 2-29/32 2-15/16
Dec.
mm.
Inch
2.600000 2.625000 2.637816 2.650000 2.656250 2.677186 2.687500 2.700000 2.716556 2.718750 2.750000 2.755930 2.781250 2.795300 2.800000 2.812500 2.834670 2.843750 2.850000 2.874040 2.875000 2.900000 2.906250 2.913410 2.937500 2.950000
66.0394 66.6751 67.0000 67.3094 67.4689 68.0000 68.2626 68.5794 69.0000 69.0564 69.8501 70.0000 70.6439 71.0000 71.1194 71.4376 72.0000 72.2314 72.3893 73.0000 73.0251 73.6593 73.8189 74.0000 74.6126 74.9293
Frac.
Dec.
Inch
Inch
2.952780 2-31/32 2.968750 2.992150 3.000000 3 3-1/32 3.031250 3.031520 3.050000 3-1/16 3.062500 3.070890 3-3/32 3.093750 3.100000 3.110260 3-1/8 3.125000 3.149635 3.150000 3-5/32 3.156250 3-3/16 3.187500 3.189005 3.200000 3-7/32 3.218750 3.228375 3-1/4 3.250000 3.267745 3-9/32 3.281250 3.300000 3.307115
mm.
75.0000 75.4064 76.0000 76.2002 76.9939 77.0000 77.4693 77.7877 78.0000 78.5814 78.7393 79.0000 79.3752 80.0000 80.0093 80.1689 80.9627 81.0000 81.2793 81.7564 82.0000 82.5502 83.0000 83.3439 83.8192 84.0000
Frac.
Dec.
Inch
Inch
mm.
3-5/16 3.312500 84.1377 3-11/32 3.343750 84.9314 3.346485 85.0000 3.350000 85.0892 3-3/8 3.375000 85.7252 3.385855 86.0000 3.400000 86.3592 3-13/32 3.406250 86.5189 3.425225 87.0000 3-7/16 3.437500 87.3127 3.450000 87.6292 3.464595 88.0000 3-15/32 3.468750 88.1064 3-1/2 3.500000 88.9002 3.503965 89.0000 3-17/32 3.531250 89.6939 3.543339 90.0000 3.550000 90.1691 3-9/16 3.562500 90.4877 3.582709 91.0000 3-19/32 3.593750 91.2814 3.600000 91.4392 3.622079 92.0000 3-5/8 3.625000 92.0752 3.650000 92.7092 3-21/32 3.656250 92.8639
Frac.
Dec .
Inch
Inch
3.661449 3-11/16 3.687500 3.700000 3.700819 3-23/32 3.718750 3.740189 3.750000 3-3/4 3.779559 3-25/32 3.781 250 3.800000 3-13/16 3.812500 3.818929 3·27/32 3.843750 3.850000 3.858299 3-7/8 3.875000 3.897669 3.900000 3-29/32 3.906250 3.937043 3-15/16 3.937500 3.950000 3-31/32 3.968750 3.976413 4.000000 4
mm.
93.0000 93.6627 93.9792 94.0000 94.4564 95.0000 95.2502 96.0000 96.0439 96.5192 96 .8377 97.0000 97.6314 97.7891 98.0000 98.4252 99.0000 00.0591 99.2189 100.0000 100.0130 100.3291 100.8060 101.0000 101.6000
Drill Sizes/Inch Decimal Equivalent 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62
.0135 .0145 .0 16 .018 .020 .021 .0225 .024 .025 .026 .028 .02925 .031 .032 .033 .035 .036 .037 .038
61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43
.039 .040 .041 .042 .043 .0465 .052 .055 .0595 .0635 .067 .070 .073 .076 .0785 .081 .082 .086 .089
42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24
.0935 .096 .098 .0995 .1015 .104 .1065 .110 .111 .113 .116 .120 .1285 .136 .1405 .144 .147 .1495 .152
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5
.154 .157 .159 .161 .166 .1695 .173 .1 77 .180 .182 .185 .189 .191 .1935 .196 .199 .201 .204 .2055
4 3 2 1
.209 .213 .221 .228
0 P
A B C D
E F G H I J K
L M N
.234 .238 .242 .246 .250 .257 .261 .266 .272 .277 .281 .290 .295 .302
Q
R S T U V W X y Z
.316 .323 .332 .339 .348 .358 .368 .377 .386 .397 .404 .413
DRILL SIZES / INCH DECIMAL EQUIVALENT
4 -5
English to Metric Conversions METRIC EQUIVALENTS m indicates one meter cm indicat es one hundredth of a meter mm indicates one thousandth of a meter km indicates one thousand meters LENGTH 1 mm . = 0.03937 In. Cm. = 0.3937 In. Meter = 3.28 Ft. Meter = 1.094 Yd. (39.37 In.) Kilom. = 0 .621 Mile In. = 2.54 Cm. Ft. = 0 .3048 Meter Yd . = 0.9144 Meter Mile = 1.61 Kilom . AREA Sq . Cm . = 0.1550 Sq . In. Sq. M . = 10.76 Sq . Ft. Sq . In. = 6.45 Sq . Cm . Sq. Ft . = 0.0929 Sq . M. VOLUME Cu. Cm . 0.061 Cu. In . Cu . M. = 35.315 Cu. Ft.
=
Cu. In. Cu . Ft.
Kilogram = 2.2046 Ibs. Kilogram = 0.0011 Ton (Sht) Met. Ton = 1.1025 Ton (Sht) Gra in = 0.0648 Gram Oz. = 28.35 Gram Lb. 0.454 Kilgm. Ton (Sht) = 907.18 Kilgm. Ton (Sht) = 0.907 Metric Ton Ton (Sht) = 2000 lb.
=
PRESSURE 1 Kilogram per Sq. Cm. = 14. 2233 Lbs. per Sq . In. 1 Lb. per Sq. In. = 0 .070307 Kilgms . per Sq. Cm. 1 Kilogram per Sq . Meter = 0.20482 Lbs. per Sq. Ft. 1 Lb. per Sq. Ft. = 4 .8824 Kilgms . per Sq. Meter 1 Kilgm . per Sq. Cm . = 0.96784 Standard Atmosphere 1 Standard Atmosphere = 1.033228 Kilgm . per Sq. Cm. 1 Metric Atmosphere = 1.033228 Kilgm . per Sq . Cm. 1 Std . Atmosphere = 4.6959 Lbs. per Sq . In . CONVERSION TABLES GA LLON
= 16.38
=
Cu. Cm . 0 .028 Cu . M .
CAPACITY Liter = 0.0353 Cu . Ft . Liter = 0.2642 Gallons (U .S.) Liter = 61.023 Cu. In. Liter 2.202 lb. of fresh water at 62°F. Liter = 1,000 CC Liter = 35. 19 FI. Oz. (Imp .) Liter = 33.82 FI. Oz. (U .S.)
=
Gal. (U.S.) = 3.785 Liters Gal. (Imp.) = 4.546 Liters Cu . Ft. 28.32 Liters Cu . In. 0.0164 Liter FI. Oz: (U .S. ) - 29.57 CC FI. Oz. (Imp.) = 28.41 CC
= =
WEIGHT Gram = 15.432 Grains Gram = 0 .0353 Oz.
U.S.
IMP.
I
1 1/ 4 1/ 8 0.264
= = = =
1 1/ 4 1/ 8 0.220
=4 1 = 112
= =
I
QUART 4 1 112 1.056
0 .880
PINT
= 8 = 2 1 2.113
= = = 82 =1 = 1.760 =
t
LITER
= 3.785 0.946 = 0.473 =1 = 4.546 1.136 = 0.568 =1
=
=
U.S. 1 Ga llon = 128 oz. = 3,785.41 cc 1 Quart = 32 oz. 946.35 cc 1 Pint=160z. =473.18 cc
=
IMP.
=
1 Gal lon = 160 oz. 4,546.09 cc 1 Quart = 40 oz. 1,136.52 cc 1 Pint=20 oz. =568.26 cc
=
CONVERSION FACTORS Inches to centimeters (cm) ... ... .. ....... ... ...... .... .... ... .. ... ....... .. ..... ... ..... ...... ... .... ...... ...... ... ....... Multiply by 2.54 Meters (m) to yards ............ ..... ........ ... ........ ............ .... ...... .. ... ... ... ..... ...... . Multiply by 70 and divide by 64 Kilometers (km) to miles ... .. ..... ... ... .. .. .. .... .. ........ ... ... .... .... .... ... ....... ... ....... ... Multiply by 5 and divide by 8 Cubic inches to cubic centimeters .. .. .................... .. ............ ................... ..... ... .... .. ... ........ Multiply by 16.39 Grams to ounces ...... ... .. ....... ......................... ......... ...... ......... .... .... ....... . Multiply by 567 and divide by 20 Liters to U.S. pints ..... .. ... .......... ....... .. .. ......... ... .... .. ............... ... ............ ... Multiply by 95 and divide by 20 Degrees Centigrade to degrees Fahrenheit .. .... ...... ....... ........... Multiply by 9, divide by 5 and add 32 Degrees Fahrenheit to degrees Centigrade ..... ...... ... ........ Subtract 32, mUltiply by 5 and divide by 9
4-6
ENGLISH TO METRIC CONVERSIONS
)
•
J
Unit Conversion Table
List of Abbreviations
cu .in .
ABOC ............ after bottom dead center
x .03519
fl.oz. (imp.)
ATOC ............. after top dead center
x .03381
fl.oz. (U.S.)
BBOC ............ before bottom dead center
cu. in.
x
16.39
cc
BOC ... ........... bottom dead center
fl. oz.(imp.)
x
28.41
cc
BTOC ............ before top dead center
fl. oz.(U.S.)
x
29.57
cc
cc .................. cubic centimeters
ft-Ibs
x
12
in-Ibs
cu. in ............ cubic inches
ft-Ibs
x
.1383
kg-m
fl. oz ............. fluid ounces
gal. (imp.)
x
4.546
liters
ft .................. foot, feet
x gal. (U.S.) x gal. (U .S. ) x grams x In. x in -Ibs x in-Ibs x kg x kg x kg-m x kg-m x kg/cm2 x km x lb. x Ib/ sq. in. x liter x liter x liter x liter x meter x mile x mm x oz. x qt. (imp.) x
1.201
gal. (U.S.)
ft-Ibs ............. foot-pounds
liters
gal. ............... gallon, gallons
gal. (imp.)
hp ................. horsepower
oz.
in .................. inch, inches
25.40
mm
in-Ibs ............. inch-pounds
.0833
h -Ibs
kg .................. kilogram, kilograms
.0115
kg-m
kg/cm2 ........... kilograms per square centimeter
2.2046
lb.
kg-m .............. kilogram-meters
35.274
oz.
km ................ kilometer
7.233
ft-Ibs
kph ............... ki lometers per hour
86.796
in-Ibs
Ib.,lbs. ......... pound, pounds
14.22
Ibs/ sq .in.
Ibs/sq.in ........ pounds per square inch
.6214
miles
Q •••••••••• •••• •••••
.4536
kg
m .................. meter, meters
.0703
kg/cm 2
mi ................. mile, miles
35 .1 9
fl.oz. (imp.)
mm ............... millimeters
33.81
fl .oz. (U.S.)
mph .............. miles per hour
.8799
qt. (imp.)
oz ................. ounce, ounces
1.0567
qt. (U.S.)
psi ................ pounds per square inch
3.281
ft.
qt ..... ............. quart, quarts
1.6093
km
r.p.m ............. revolutions per minute
.03937
in.
sec ................ second, seconds
28.35
grams
SS ................. standing start
1.1365
liters
TOC .............. top dead center
x
1.201
qt. (U.S.)
qt. (U. S. )
x
.9463
liters
qt. (U. S. )
x .8326 x 1.04
cc
x
cc cc
gal. (imp.)
qt. (imp.)
fl. oz. (U.S.)
.0610
3.7853 .8326 .03527
liter
................... inch, inches
qt. (imp.)
=
fl. oz. (imp.)
LIST OF ABBREVIATIONS
4-7
S pecia l Service Tools
Part No. 57001 -351 2 Concerter A I ignment Gauge Part No. 57001 -3506
Part No. 57001 -3511
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Part No. 57001 -3513 Track Clip T ool Assembly
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Part No . 5700 1-3 509 F lywheel Pul ler
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4 -8
Part No T 56019-201
Part No. 57 001 -983 Mult imeter T ester
SPECIAL SERVICE TOOLS
CD Ign itio n Tester
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Suspension Spring A djuster
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Index Page
Page
Air Shrouds, SA340 and SB440 . . . . . . . . . . . . ... 3-56 Inspection . . . . . . . . . . . . . . . . . . . . . . . . .. 3-57 Reassembly . . . . . . . . . . . . . . . . ... ... ... 3-57 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Belt . . . . . . . . . . . . . . ... . .... .. ..... .. .. 2-40 Belt Specifications '" .. .... ... . . . . . . . . . . . . 1-4 Brake .. . . . . . . . . . . . . . . ..... .. ..... . ... 2-42 Brake Cable .. .. . . . . . . . . . . . . . . . . . . . . . . " 3-81 Installation ... . . . . . . . . . . . . . . . . . . . . . . 3-82 Removal . . . . . . . . . . . . ... . . . . . . . . . . . . 3-81 Brake Cal iper . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-90 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-91 Exploded View . . . . . . . . . . . . . . . . . . . . . . 3-91 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-90 Repair .. . . . . . . . . . . . .. . ...... . . ... . 3-91 Brake Light Switch , Dimmer Switch or Brake Lever Assembly .. . . ..... .... . ...... 3-75 I nsta lIation . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Removal .. . . . . . . . . . . . . . . . . . . ..... " 3-75 Brake Pad Wear Inspection . . . . . . . . . . . . . . . . . . 2-42 Brake Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-4 Brake Switch Test .... '" . . .. . ..... . ... . .. 3-31 Bulb Replacement .... .. . . . . . . . . . . . . . . . . . 2-37 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . ... 3-41 Cleaning . . . . .. . ... . .... ..... .. 3-45 & 3-48 Disassembly SA340 & SB440, VM32 Econo Jet . 3-42 Disassembly SC340, VM28 Zinc . . . . . . . . ... 3-46 Exploded View, VM28 Zinc . . . . . . . . . . . . . . 3-47 Exploded View, VM32 Econo Jet . . . . . . . . . . 3-44 Insta llation . .. . . . . . . . . .... . . . ..... . , 3-49 Reassembly SC340, VM28 Zinc . . . . . . . . .. " 3-48 Reassembly SA340 & SB440, VM32 Econo Jet . 3-45 Removal . . ... . . . . . . . . . . . . . . . . . .. .. . 3-41 Carburetor Adjustments . . . . . . . . . . . . . ... . .. . 2-29 Carburetor Service Specifications . . . . . . . . . . . . . . . 1-6 Carburetor Specifications. . . . . . . . . . . . . . . . . . . . 1-2 Carburetor Theory of Operation .. . . . . . . . . . . . . 2-12 Carburetor Trouble Shooting . . . . . . . . . . . . . ... 3-50 Carburetor Tuning .. . . . . . . . . . . . .... ... . . . 3-50 CDI Igniter Output to Ignition Coil SB440 Only . . . . . . . . . . ..... ... . . . . . . . . . 3-22 Chain Replacement . . . . . . . . . . . . . . . . . . . . . . , 3-90 Installation .. , . . . . . . . . . . . . . . . . . . . . . . 3-90 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-90 Chain Tension .. . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Chain Tensioner Springs .. . . . . . . . . . . . .. ..... 1-10 Chain Tensioner Springs. . . . . . . . . . . . . . . . . . .. 2-44 Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 Disassembly of the Chaincase . . . . . . . . . . . . . 3-88 Exploded View .... . . . . . . . . . . . . . . . . .. 3-89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-90 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 Chaincase and Gearing Operation . . . . . . . . . . . . . . 2-27 Chassis Service Specifications . . . . . . . . . . . . . . . . . 1-6 Cleaning, Inspecting and Gapping the Spark Plug ... 2-35 Combustion Theory of Operation . . . . . . . . . . . . . . 2-8 Compression Check. . . . . . . . . . . . . . . . . . . . . . . 2-29 Compression Theory of Operation . .. ..... .. .. . . 2-6 Conversion Chart . . . . . . . . . . . ... . . . . . . . . 4-4, 4-5 Converter Alignment . . . . . . . . . . . . . . . . . . . . . . 2-38 Converter Alignment Using Special Tool PIN 57001-3512 . . . . . . . . . . . . . . . . . . . . . . . , 2-38 Converter Center Distance Without Special Tool PIN 57001 -3512 .. ...... ... . . . . . . . . . . . . . 2-38 Converter Center Distance Using Special Tool PIN 5700 1-3512 . . . . . . . . . . . . . . . . . . . . . . . , 2-38 Converter Lubrication . . . . . . . . . . . . . . . . . . . . . 2-41 Co nverter Offset Alignment Without Special Tool PIN 57001-3512 ..... . .... .. ... 2-38 Converter Offset Alignment Using Special Tool PIN 57001-3512 . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Converter Parallelism. . . . . . . . . . . . . . . . . . . . . . 2-40 Converter Theory of Operation . . . . . . . . . . . . . . . 2-26 Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . . 3-70 Connecting Rod Big End ... .. . .. . . . . . . . . 3-71 Connecting Rod Small End. . . . . . . . . . . . . . . 3-72 Crankshaft En d Play Adjustment SA340 and SC340 Models . . . . . . . . . ... .. 3-74 Crankshaft En d Play Adjustment 440 Model Only . . . . . . . . .. . . . . . . . . 3-72-3-73 Crankshaft Runout . .. .. . . . . . . . . . . . . . . . 3-72 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Crankcase Pressure Test . . . . . . . . . . . . . . . . . . . . 2-28 Cylinder Heads, Cylinders and Pistons .. . ... .... 3-65 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Cyl inder Heads . . . . . . . . .. .. ..... .. . ... 3-65 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 Reassembly . . . . . . . . . . . . . . . . . . . . . . . .. 3-69 Dimmer Switch Test . . . . . . . . . . . . . . . . . . . . . . 3-30 Dri II Sizes . . . . . . . . . . . .... ... . . . . . . . . . . .. 4-5 Drive Converter . . . . . . . . . . . . . . . . . . . . . . . . . 3-82 Clean ing .. . . . . . . . . . . . . . . . . . . . . . . . . . 3-84 Disassembly ... . . . . . . . . . . . . .. . ... . ... 3-83 Drive Converter Wear Check . . . . . . . . . . . . .. 3-83 Exploded View . . . . . . . . . . . . . . . . . . . . . . 3-85 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-84 Reassembly . . . . . . . . . . . . . . . . . . . . . . . " 3-84 Removal . ... ... . . . . . . . . . ... .... ... . 3-82
4-12
INDEX
Page
Page Drive Converter Component Weight Chart . . . . . . . . . 1-3 Drive Converter Specifications . . .... . ..... .... 1·3 Drive Converter Theory of Operation . . . . . . . . . .. 2-26 Driven Converter . . . . . . . . . . . . . . . . . . . . . ... 3-86 Cleaning and Inspection . . .. .... .... ... " 3-87 Disassembly . . . . . . . ... . . . . . . . . . ...... 3-86 Exploded View . . . . . . . . . . . . . . . . . . . . . . 3-86 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 Driven Converter Specifications. . . . . . . . . . . . . . . . 1-4 Driven Converter T heory of Operation . . . . . . . . .. 2·27 Driveshaft and Track . . . . . . . . . . . . . . . . . . . . , 3-102 Driveshaft Repair . . . . . . . . . . . . . . . . . . . . 3-104 Exploded View . . . . . . . . . . . . . . . . . . . . . 3-103 Installation . .. . . . . . . . . . . . . . . . . . ... . 3-104 Removal ..... . .. . ... . . . " . . . . . . . . . 3-102 Track Repair . . . . . . . . . . . . . . . . . . . . . .. 3·104 Econo (Power) Jet System Theory of Operation. . .. 2-20 Electrical Components Specifications . . . . . . . . . . . . 1·5 Electrical System . . . . . . . . . . . . . . . . . . . . . . " 2-36 Electrical System . ..... . .. ..... . .. .. ... . , 3·26 Electrical System Theory of Operation . . . . . . . . .. 2-24 Emergency Stop Switch or Throttle Lever Assembly . . . . ..... . . . . . . . . . . . ... . 3-76 Installation . . . . . . . . . . . . . . . . . . . . . ... , 3-76 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Emergency Stop Switch Test . . . . . . . . . . . . . . . . 3-27 Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Eng ine Cooling Theory of Operation . . . . . . . . . . . 2-11 Engine Crankcase Design Theory of Operation . . . . . 2-10 Engine Inspection. . . . . . . . . . . . . . . . . . . . . . . . 2·28 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 3-52 Engine Lubrication T heory of Operation. . . . . . . . . 2-11 Engine Performance Curves . . . . . . . . . . . . . . . . . 1·12 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Engine Service Specifications ... . . . . . . . . .. .. .. 1-5 Engine Specifications . . . . .. . . . . . . . . ... . ... . 1-2 Engine Theory of Operation .. . .... .. . . .. . .... 2-5 Engl ish to Metric Conversions .... .. ... . . . . . . . . 4-6 Enrichener Cable .... _ . . . . . . . . . . . . . . . . . . , 3-80 Exploded View .. _ . . . . . . . . . . . . . . . . . . . 3-80 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-81 Removal .... .. . _ . . ... .. .... .... ... , 3-80 Enrichener Cable Adjustment . .... . . . . . . . . . . , 2-31 Enrichener System Theory of Operation . . . . . . . . . 2-21 Exciter Coil Output .. _ . . . . . . . . . . . . . . . . . . . 3-18 Exhaust Manifold .... _ .. ... . .... ...... . " 3-37 Inspection . . . . . . . . ...... . . . . . . . . . ... 3-37 I nsta II ation . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Exhaust Theory of Operation . . . . . . . . . . . . . . . . 2-10 Fan Belt Tension . . . . . . . . . . . . ... . . . . . . . . . 2-34 Fan Housing, SA340 & SB440 . ..... ... ...... 3-57 Disassembly .... ..... .. ... . . . . . . . . . . . 3-58 Exploded View . . . . . . . . . . . . ... . .. . .. . 3-59 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Installation .. . ...... . . . . . . . . ...... . . 3-60 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Float Bowl Theory of Operation " . . . . . . . . . . . . 2-14
Flow Chart Disassembly - Engine Insta ll ed SA340 and SB440 . . . . . . . . . ... .... . ... . . 3-33 Flow Chart Disassembly - Engine Removed SA340 and SB440 . . . . . . . . .. . . . . . . . . .. .. 3-35 Flow Cha rt Disassembly - Engine Installed, SC340 ' .... . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Flow Chart Disassembly - Engine Removed, SC340 ... . .. . . . . . . . . . . . . . . . . . . . ..... 3-36 Flow Chart Engine Removal - 340 a"nd 440 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-32 Frame Specifications. . . . . . . . . . . . . . . . . . . . . . . 1-5 Front Suspension Arm . . .. .. .. ... . . . .. .... . 3-99 Inspection . . . . . . . . .. . . .. . . . . . . . . . " 3- 100 Installation . . . . . . . . . . . . . . .. .. . .... , 3-100 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99 Front Suspension Arm Spri ngs . . . . . . . ... .. . .. 3-97 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98 Installation ... . . .. . .. . ..... " . .. . . .. . 3-98 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-98 Fuel . . . . . . . . . .. .... ...... . .. . . . . . . . . . . 4-2 Fuel and Oil Recommendations . .. .. .. . ..... ... . 4-2 Fuel Filter .. . .... ... .. .. . . . . . . . . . . . . . " 2-29 Fuel Pump ... ... . . . . . . . . . . . . . . . . . . . . . . 2-29 Fuel Pump . . . . . . . . ..... . . . . . . .. . . . .... 3-40 Cleaning . . . . . . . . . . .. .. . . . . . . . . . . ... 3-4 1 Disassembly . . . . . . . . . . . . . . . . . . ... .. . , 3-40 Installation ... .. ... . .... .. . .. .... " .. 3-41 Reassembly .. . .. ... . . . . . . . ..... . .. " 3-4 1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Fuel Pump Output Test . ... . .... . .... . .. .. . 2-29 Fuel Pump Pressure Test . .. . . . . . . . . . . .. .. .. 2-29 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-109 Installation . . .. . . . . . .. . . . . . . . .... . , 3-110 Removal . . . . . . . . . . . . . . . . . . . . . . . . .. 3- 109 Fuel Tank and Lines . . ... . . . . . . . . . . . . . . . .. 2-31 Fuel/Oil Mixture (Ratio) . ... .... . . . . . . . . . . . . 4-2 Fuel/Oil Specifications ... . . . . . . . . .. ... . .... 1-4 Gear Ratio Chart . . . . . . . . .. . . . . . . . . . . . . . . 1-10 Gear Ratio Chart . . . . . . . . .. .. . . .... ". .... 2-44 Gearing Specifications . . . .. .... . . . . .. .. . . . . . 1-2 General Engine Torque Specifications. . . . . . . . . . .. 1-6 General Specifications . . . . . . . . . . . . . . . . . . . . .. 1-2 General Troubleshooting .... . . . .. . .. . . ..... . 3-2 Ground Wire Test . . . . . . . . . . . . . . . . . . . . . . .. 3-10 Ground Wire Test (SB440 Only) . . . . . . . . . . . . . . 3-11 Handling Adjustment .... ..... . ...... ... .. 2-47 Headlamp . . .. .... .. .. . . .. ..... ..... . . . 3-77 Ex ploded View ... . . ... . . .... .. ..... . 3-77 Installation . . . ...... .. .. . . . . . . . . . . . , 3-77 Removal . . . . . . . . . . . . . . . ... . ..... . .. 3-77 Headlight Adjustment . . ..... . ..... .... .... 2-36 Headlight Circuit Test . . . . . . . . . . . . . .. .. .. .. 3-29 Idler Wheel s Front Suspension Arm .. ... .. .... . 3-99 Inspection . . . . . . . . . . .. . ... .. . .. .. . . . 3-99 Reassembly and Installation . . . . . . . . . . .. . . 3-99 Removal and Disassembly . . . . . . . . . . . . . . . 3-99 Ignition Serv ice Spec ifications .. .. ..... . . ... . . . 1-5 Ignition Specifications . . . . . . . . . . . . .... . .... . 1-2
IN DEX
4 - 13
Page
Page
Ignition System . . . . . . . . . . . . . . . . . ... . . . . . 2·32 Ignition System Theory of Operation . ..... . .... 2·22 Ignition Timing Ad justment SC340 Model . . . . . . . . 2·33 Ignition T iming A djustment· 440 Model . . . . ... " 2·34 Ignition Timing Check .. . ... .. . . .... . . . . . . . 2·32 Ignition Trouble shooting . . ...... . . ... ... .. . . 3·9 Ignition Troubleshooting · SB440 Model On ly ... " 3· 14 Ignition Troubleshooting Ta ble · 340 Model On ly . .. 3·14 Igniti on Troubleshooting Ta ble .. . . .. . . . .. . ... 3·25 Ignition Troubleshooting Using C D Ignition Tester PIN T56019·20 1 . . . . . . . . . . . . . . . . . . .. .. . 3·11 Ignition Troubleshooting Using An Ohmmeter ... . . 3·24 Intake Manifold . . . . . . . . . ... ... . ... . .... . 3·5 1 Inspection . .... ...... . ... ... . .. ... " 3·52 Installation ..... .. . ... . . . . . . . . . . . . . . 3·52 Removal ... . . . ... . .. . . ... .. ... . .... 3-51 Intake Theory of Operation .. . . . .. .. . . . . . . . . . 2·6 Introduction to Two Stroke Engines . . . . . . . .. . .. 2·5 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2·36 Key Switch . . . . . . . . .... .... . .. . .. ... .. , 3·77 Installation . . .... . . ... .. ... ..... . . . . 3·77 Remova l . . . . . . . . . . . . . . . . . . . . . . . . . .. 3· 77 Key Switch Tests . ..... . . . . . . . . . . . . . . . . . . 3·26 Limiter Straps ..... . . .. .. . . ..... ... .... . 3·98 Inspection . . . .... . . . . . . . . . . . . . . . ... , 3·98 Installation .... . . . . . . . . . .... . . ...... 3·98 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·98 List of Abbreviations ... . .. ...... . . . .. . .. . .. 4·7 Lubrication Ch art .. .. ... ... . ... . ..... . .... 24 Magneto Cover, SC340 On ly . . . . . . . . . . . . . . . . . 3·60 Installation .. . .. .. .... . . . . . . . . . . . ... 3·61 Removal .... . .. . . . . . . . . . . . ... .. . . . , 3·60 Main System T heory of Operation .. .. . .. .. . . . . 2· 16 Maintenance Chart . . .... . ... . . ... .... .. . .. 2·3 Metering System Theory of Operation ... ... . . .. 2· 15 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3·37 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 3·37 Installation .... . . . .. . . . . . . . . . . . . . . . . 3·37 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·37 Oil .. . . .. ... . .. .... .. .. .. .... ... . . .. . . 4·2 Pilot System Theory of Operation . . . . . . . . . . . . . 2·20 Port Dimens ions . . . . . . . . . . . . . . . . . . . . . . . .. 1· 11 Preparation for Storage ., . . .. .... . .. . .. . . . , 2-49 Primer, SA340 and SB440 Only .. .... ...... . . 3·82 Installation . . . . . . . . . ..... ... . . .. . . " 3·82 Removal . ... .... .. ... . .. . . . . . .... " 3·82 Primer Pump (SA340 and SB440 Only) .. .. . ... . 2·30 Primer System Theory of Operation . .. .. .... . .. 2·21 Problem Isolation Chart .. . . .. . ... ... .. . . . ... 3·2 Pulser Coil Output .... . . . . . . . . . .. . . . . . . . . 3·20 Rear Axle and Wheels . . . . . . . . . . . . . . . . . . . . . 3·94 Inspection ... . . . . . . .... ... . . . . . . . . . , 3·94 Reassembly and Installation .. . . . .... . . ... 3·94 Removal and Disassembly . .. . .. . ... ..... 3·94 Rear Suspension Arm . .. . .... . .... ..... . .. 3·94 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3·95 Reassembly and Installation .. . . .. ... . .. . . 3·95 Removal and Disassembly . . . . .. . . . . . . . . . 3·94 Removal for Storage .. : . . . . . . . . . . . . . . . . . .. 2·50
Ride Adjustment . . . . . . . . . ... ... .. ...... . 2·46 Seat .. .. .. .. . . . ... .. . .. . . . . . . . . . . . .. 3· 109 Installation . . .. ... . ... . . . . . . . . . .. . . 3· 109 Removal. . . . . . . . . . . . . . . . . . . . . . . . .. 3·109 Service Speci fications ..... .. . . .. .. . . . . . .... 1·5 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . 3·96 Inspection . . . . ..... ..... .. . . . ...... . 3·96 Installation .. . .. .. ...... . . . .. . ... . .. 3·96 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 3·96 Silencer . ... .. . . . . . . . . . . . .... .. . . . .. . . 3·38 Assembly . . . . . . . . . .. .. . ..... . . . ... . 3·39 Disassembly . ... . . . . . . . .. . . . .. .. . . .. . 3·39 Inspection .... .. .. . . .... . . .. . .. . ... 3·39 Installation . . . . . . . . . . . ... . .. .. .. .. .. 3-40 Remova I . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·38 Skeg . . . . . . . . . . . . . . ..... . . . . . . . . . . . . . 3·109 Installation ... . . .... ...... . . . . . .. '. 3· 109 Removal . .. ..... .. . . . . . . . . . . . .. . " 3· 109 Sk i . .... .. . .. ... . .. . . . . . . ... . .... . . . 3· 108 Installation . . . . . . . . . . . . . . . . . . . . . . .. 3· 108 Removal . . . . . . . . .... . . . . . . . . .. .. " 3·108 Ski Al ignment . . . . . . . . . . . . . . . . . ... ... .. . 2·4 5 Ski Skeg .. . . . ... . . . . . . .. . ... .. . . . .. .. , 2-46
4-14
INDEX
Sk i Spring .... . . .. . " ... . .... .. '" . .. . 3·108 Installation .... . . .. . ... .. .... . . ... . 3·108 Removal . . . . . . . . . . . . . . . . . . . . . . . . .. 3·108 Ski Spring Preload ... . .. ... . .. . .... . .. . .. 2·46 Spark Plug Gap ..... ..... . . . .... .. ...... . 3·9 Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·1 0 Special Service Tools ...... . .. ... . . ... . ... . . 4·8 Speedometer, SB440 Only .. . .... .. ... . ..... 2·37 Speedometer, SB440 Only ... .. ..... . . . .. . " 3·78 Installation . . . . . . . . . . . . . . .... .... . . . 3·78 Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·78 Starter Assembly .. ..... . ..... .. .. . ..... . 3· 52 Disassembly .. . . .. . . .. .. . . . . . . . . . . .. . 3· 53 Exploded View . . . . . . . . . . . . . . . . . . . . . . 3·54 Inspection . . . . . . . . ... . ... .... . .... . ' 3·53 Installation ...... . . . . .. . . .. . ...... .. 3·56 Reassembly . ... .. . ... . .. ..... . . . . . . . 3·53 Rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . 3·52 Stator A ssembl y . ...... . . . . .. . . . . . . . . . . . . 3· 61 Disassembly . ... . . . . . . . . . . .... . . .... . 3·62 Expl oded View· SA340 & SC340 Models . . . .. 3·63 Exploded View· SB440 Model Only . . .. . ... 3·64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . .. 3-62 Installation . ... . . . . . . . . . . . . . . . . . . . .. 3·62 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3·62 Rem ova l . .. . . . . . . . .... .. .. . .... . .. . 3· 61 Steering Arm and Spindle . . . .. . . ... . .... .. , 3· 107 Exploded View . .. . . . . . . . . . .. . .. . . .. 3· 108 Installation . . . . . . .. .. . . . . . . . . .. .... 3· 107 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3· 107 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . 2·45 Steering System ... .. .. . .. . ...... . . .... , 3·1 05 Ex ploded View .. ... . ... . ... . . . . . . . . 3-106 Handlebars and Steering Pole Remova l . . . .. , 3· 105 Installation . . ... .. . ... . . . . ..... . . .. 3· 107 Stop Circuit Elimination Test ... .. . . . .... .. .. 3·1 0
Page
Page
Stop/ Ta il Light Harness Test .. .. . ..... . . .. .. . 3-31 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Suspension . . . . . . . . . .. ..... .. . .. ... . . .. 3-92 Exploded View .. . . . . ..... ... ... . .... 3-93 Inspection .... ... . . . ... . ... . . . .. ... . 3-92 Removal . . . . . . . . . . . . . . . . . ..... ..... 3-92 Suspension Adjustme nt . . . . . . . . ... . ... ... " 2-46 Suspension Installation ... . . .. . .. . .. . ... .. 3-101 Suspen sion Ra ils ... .. ... ... .. .. . .. .. , .,. 3-100 Inspection . . . . . . . . . . . . . . . . . . . . . . . .. 3- 100 Installation . . . . . . . ...... . . . . . . . . . . . 3-101 Removal . . . . . . . . .... .. ..... . . .. . . . 3- 100 Tail Lam p ... . .... ... . .... . . . .. . ... .. . . 3-78 Installation . . . . ... . . . . . . . . . . ..... ... 3-79 Removal . . . . . . . . ... . .. . .. . ..... . . .. 3-78 Ta il/Brake Light ... ... . .. . . . . . . . . . . .. .... 2-37 Test Sequence Using CD Ignition Tester PI N T56019-20 1 - SB440 Only ...... .. .. ... . 3-14 Throttle Cable Adjustment . . . ... . . . . . .. . .. " 2-31 Thrott le Cable .. . .. .... . . . ...... .. .. .. .. 3-79 Exploded View ... . ..... .. . . .. . ... . .. 3-80 Installati on . ... . . . . . . . . . . . . . . . . . . . . . 3-80 Removal .... . . . .. . ..... . . .... .. .. . , 3-79 Throttle Valve Theory of Operation . ... . . ... . . . 2-15 Torque Chart . .. .. ..... . . . . . . . . . . . . . 1-6 TO 1-9
Track Adjustments . . ... . . . . .. ... ... . . .. .. 2-47 Track A lignment . . ... . ..... .. ..... ... . . . 2-48 Track and Suspension Spec ifi cations ... . .... . . . . 1-4 T rack Suspension and Steering System Operation . " 2-2 7 T rack Tension ..... . .. .. . . . . .. . .. . .. .... 2-47 Transfer Theory of Operation . ..... . ... . . . .. . . 2-6 Troubleshooting Using an Ohmmeter . . . . . .. . . .. 3-24 Unit Conversion Ta ble .. . . . . . .... . .... . . .. . . 4-7 Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . 2-37 Voltage Re gulator . . . . .. . ... . .. . .. .. .... " 3-79 Installation .. . . . . ... . ..... . ... . .... , 3-79 Removal .. .. . . . . . . . .... . . . . . . ... . . , 3-79 Voltage Regulator Tests ..... . .... . .. . . . ... , 3- 28 Wear Strips Hi-Fax (Rail) . .. ... . ... .. .. .. .. . 3-96 Inspection .. ... . .. .. ... .. .. . . . . . . . . ' 3-96 Installation ... . . ... .. . . .... . . . . . . ... 3-96 Removal . . . . . . . . . . . . . . . . . . . . . . . . . " 3-96 Wear Strip (Rear Suspension Arm) . . . . . . . . . . . . . 3-9 7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . .. 3-97 Installat ion . .. .. . . . . . . . ... .. ... .. . .. 3-97 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-97 Wiring Diagram - SA340 Only . . . . . . . ... .. . . . .. 4-9 Wi r ing Diagram - SB440 Only .... . . .. .. . .. ... 4-10 Wiring Di agram - SC340 On ly . ..... . . .. ..... . 4-11
INDEX
4-15
FOREWORD This Drifter SB340-A2, SB440-A5 Shop Manual Supplement is designed to be used in conjunction with the Drifter SA340-A4, SB440-A4, SC340-A 1 Shop Manual (PIN 99963-3511). The maintenance and repair procedures described in this Supplement are only those that are unique to the SB340-A2 and SB440-A5 models. Most service operations for the se models remain identical to those described in the base Shop Manual. Complete and proper servicing of the SB340-A2 and SB440-A5 models therefore requires both this Supplement and the base Shop Manual. The base Shop Manual and this Supplement are designed primarily for use by snowmobile mechanics in a properly equipped shop. However, they contain enough detail and basic information to make them useful to the snowmobi le owner who desires to perform hi s own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactori ly. Whenever the owner has insufficient experience or doubts his ability to do the work, the adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the text, thoroughly familiarize himsel f with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools and equipment are specified, makeshift tools or equipment should not be used. Precision measurements can only be made if the proper instruments are used, and the use of substi tute tools may adversely affect safe operation of the snowmobile. Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.
(
IWARNING I
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment
NOTE: indicates points of particular interest for more efficient and convenient operation.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system , or transmitted in any form or by any means, ele ctronic mechanical photocopy in g, recording or otherwise , without the prior written permission of the Technical Publications Department/Kawasak i Motors Corp. , U.S.A. No liability can be accepted for any inaccuracies or omissions in this publication , although every possible care has been taken to make it as com plete and accurate as possible. All procedures and speC ificat ions subject to change without prior notice or obligation. Illustrations in this publication are intended for reference use only and may not depict actual model component parts.
Š 1981 Kawasaki Motors Corp., U.S.A. FOREWORD
MODEL IDENTIFICATION
SB340·A2 and SB440·A5
ii
MODEL IDENTIF ICATION
TABLE OF CONTENTS
c
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PAGE Specifications .... ... ... . . .. ....... . ... ... .. ..... .. ... ............ ... .. .......... . ... . . 1-1 General .. . .................. . ... . ............ .. . ... ... ..... .... .. ..... ..... . ... ..... 1-1 Serv ice .. . ......................................................... .. ....... .. .. .... 1-4 Torque Chart .................... . ..... . ............... . ........... . ... ......... .. ... 1-6 Gear Ratio Chart .. .. .... ... . . . . .......... .. . .. . ... . ....... . .............. . .. ... . ..... 1-9 Port Dimensions .. . . ....... .......... ....... . . ...... ... . .. . . .. .. ... . .. ........... ... 1-10 Engine Performance Curves .. ..... .. ... ... .. ...... . ...... .. ... . .... .... .......... ... .. 1-10 Maintenance Chart . ... .... ...... ... ..... .. ..... ...... .... .. . ... ...... ... .. ....... ...... 2-1 Lubrication Chart .... ..... . .. . ... . .... ..... ..... ........ .. .... . ......... .. ........... . . 3-1 Oil Injection System .... ............. ..... ... ...... . .... ..... . ....... ................... 4-1 Oil Injection Theory of Operation ... . .. . ......................... ... ....... .......... .. . 4-1 Oil Pump Cable Removal and Installation ... ....... ...... ......... .. ..................... 4-1 Oil Pump Cable Adjustment ....... ... .... . . .. . . ............................... . . . . . ... .4-3 Bleeding Oil Pump Supply Tube ............. . . .......... ....... ....... ..... ... . ........ 4-4 Purging Air From Oil Pump Outlet Tubes ...... ... . .. ...... ................. . . ........... .4-4 Eng ine Gearcase Oil .. . .......... ........ ... ..... . . . ... ............... . ...... .. .... . .. 4-5 Oil Pump Output Test . . . . ........... .... . ..... . .... ...... .. ... .. ...................... 4-6 Oil Pump Nozzle and Check Valve Test . ........ ....... . .. . ......................... . ..... 4-6 Oil Pu mp Removal and Insta llation ... . . . .. . .... . .. . .......... . .......... ...... . ......... 4-7 Eng ine Gearcase Disassembly and Assembly .. . ............. ... . ..... .. ... . .............. 4-8 Oil Tank Removal and In stall ati on ............... . .. ... . ....... . ... . ............. . . ..... .4-9 Oil Fil ter Removal and Install ation ........ .... . . .... ........ . ........... ....... ... .... . 4-10 Fuel System . . . .... . . .. .. ......... . . .. ............. . ...... .. ... . .. ... . . .... ... . . . ... . .. 5-1 Throttle Cable Removal and In stallat ion .... ........ .. . .. ... ... ........ . ........ . ... ... . .. 5-1 Carburetor Adjustments . . . . ............ . . . .. . .... . .. . . ... .. . .... .......... . . . ........ . 5-2 Carburetor Disassembly and Assembly . .. . ............................ . ... .............. 5-3 Fuel Fi lter Clean/Replace ............. ........ ......... . ................... . . ....... .. . 5-4 Ignition System .. . . . .. ... . .. ......... . . ... .... . . ...... .............. .. .......... . . ..... 6-1 Ignition Tim in g Check . . . ..... . ...... .. ............................... . .... ... . .... . . .. 6-1 Ignition Tim in g Adjustment .. . ..... ............ . . .. .... ... . . ... .. ......... . .. . . . ....... 6-2 Ignition Troubleshoot in g Using CD Ignition Tester . .. .. .. .. .... .... . . . . . . .. ............ .... 6-2 Ign iti on Troubleshooting Using Ohmmeter . . ... ...................... ....... ... . . ..... ... 6-9 Torque Converter System ............... ... ............... .. . .... .. ......... . ... ......... 7-1 Drive Converter Theory of Operat ion .. .... ... ... . . . .. .. . . . .. . ......... . .. . ... .. ... . .. .. . . 7-1 Converter Alignment ........ ........ .... .. .. . ........ ...... . .... ........ .............. 7-1 Drive Conve rt er Disassembly and Assembly ............... . .... .......... ... . .... ...... .. 7-3 Drive Converter Cleaning And Inspection . .. .. . . . . ...... ................. . . . ... .......... 7-7 Ramp Weigh t & Bo lt Comb inations ...................................... .. .. ... . . . . ..... 7-9 Driven Converter Disassemb ly and Assembly ....................................... ... .. 7-12 Engine . .... . ..... . ..... .... ................ . .... . ... . . . .. . ....... . .... ...... ......... 8-1 Muffler Removal and In stallati on ..... .... .. . .............. . ....... . ........ ...... ... ... . 8-1 Si lencer Removal and In stallati on ............ . ........ .. .... .. . ........ .. . . . ... ... ...... 8-1 Air Shroud Removal and Installation ....................... . ............ .... ........ ..... 8-1 Fan Housing Removal and In stallati on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . ...... 8-3 Intake Manifold Removal and In sta ll ation .. . . ... . .. . .... . ....... . . .. .. ... .. . .... ......... 8-5 Cyl i nder Removal and In stallation . ............. . ..... .. ........ .. .... .. . . . .... .... ...... 8-6 Piston Removal and Installation .. . ...... . ........................... ... .. ......... . .. . . 8-7 Cylinder Head/Cylinder/Piston Inspection . ........ .. . . .. ........... .. .. ............ .. . ... 8-8 Engine Removal and Installation . ... ........... . .. . . .. . .... . ....... . ... .. ........... ... 8-10 Crankshaft Removal and Install at ion ...... ... . . .... . ........ . . ......................... 8-11 Crankshaft In spection ..... .. .. ..... . . .... ............................ . ..... ..... .... 8-12 Chassis .. . ....... ... ............... .. . . ..... .. ........ .. .... .. .... . .... .. . ....... . .... 9-1 Seat Removal and In stallat ion . ....... . . . .................... .... .... . ........ . . .. ...... 9-1 Taillamp Removal and Installation ... ............ . .. .. . . . .. .... . .. ... ........ ....... .... 9-1 Storage ..... ... ............ . . ... ....... ...... .. .. ................ .... . ............. . . 10-1 General Troubleshooting . ... ..... . ......... .. .......................... .. . ...... ....... 11 -1 Wiring Diagram .............................. .... ........ ... .......... ..... . . ..... . ... 12-1 Fuel and Oil Recommendations ...... . .... . ............................ ..... .... . . .... . . 13-1 Special Tools . .. .. ... ... .. .. ........ . ............ . ..... . ... ........................... 14-1
TABLE OF CONTENTS
iii
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SPECIFICATIONS GENERAL
MODEL SB340·A2
SB440·A5
Dimensions Overall Length . . .. . ... ... . . ... 101 in. (2565 mm) Overall Width ... . . .. . ..... .. .. 35.5 in . (902 mm) Overall Height .. ... .. ......... 43.0 in. (1092 mm) Dry Weight (Approximate) ...... 385 Ib (174.6 kg)
101 in . (2565 mm) 35.5 in. (902 mm) 43.0 in . (1092 mm) 385 Ib (174.6 kg)
Engine Model ... ...... . ... ..... .. . .. TA340C-D203 Displacement . .... . . . .... . . . . 20.7 c.i. (339 cc) Bore x stroke .. . . .. . .. .... . .. . 2.362 x 2.362 in. 60 x 60 mm Number of Cylinders .. . . .... ... 2 Engine RPM at Full Throttle ... . . 6,900 RPM Engine RPM at Idle Speed .. . . . . 2,500 RPM Starter . .. . ... .. . ... . .. .. .... Manual rewind
T A440C-D203 26.6 c.i. (436 cc) 2.677 x 2.362 in. (68 x 60 mm) 2 6,900 RPM 2,500 RPM Manual rewind
Ignition Ignition System ............... Capacitor Discharge Spark Plug ......... . ... ...... NGK BZ·9ES
Capacitor Discharge NGK BZ-9EV
Carburetor Carburetor Make ..... . .... .. . . Mikuni Carburetor Model ..... . .. . .... VM 32 Econo Jet Identification Marking .... .. . . . 32-187 Type of Carburetor .. .. ........ Slide Valve Main Jet .... . .......... ... . .. 180 Air Vent . . _.... . .... .. . . .... . Open Jet Needle ........... . . ...... 6FL14-3 Needle Jet ................... 0 - 6 Throttle Valve (Cut Away) .. . .... 0.079 in . (2 .0 mm) Pilot Jet . .. .. . ... . ...... .. . .. 30 By Pass .. .. . ........... .... . 0.055 in. (1.4 mm) Pilot Outlet . .. ........ ....... 0.031 in. (0 .8 mm) Air Screw . .. . . ... . . .. . ....... 2.0 Turns Float Valve Seat .. . . .. ........ 0.047 in . (1.2 mm) Starter Jet .. ... . .. .. .... . . ... 0.059 in. (1.5 mm) Type of Float Chamber . .. .. . ... Special Starter System . . . . . ... . .. . .. .. Cable, Dual Position Econo Jet (Power Jet) . .. . .. .. .. 120 Round Reverse Type
Mikuni VM 32 Econo Jet 32-186 Slide Valve 250 Open 6FL 14·3 0-6 0.079 in. (2.0 mm) 30 0.055 in. (1.4 mm) 0.031 in. (0.8 mm) 2.0 Turns 0.059 in . (1 .5 mm) 0.059 in . (1.5 mm) Special Cable , Dual Position 110 Rou nd Reverse Type
Gearing Top Sprocket ....... . ......... 18T Lower Sprocket .. . .. . .... . . . .. 37T Sprocket Overall Ratio .. ...... . 2.06 to 1 Chain · (Silent Type) ........... 90 pitch Drive Chain Tension ........... Self Adjusting Chain Tensioner Spring Color .. . Green
21T 38T 1.81 to 1 92 pitch Self Adjusting Green
GENERAL SPECIFICATIONS
1·1
MODEL SB340·A2
SB440·A5
Drive Converter Engagement Speed (approx imate RPM) .. .. .. 3400 to 3600 RPM Drive Co nverter RPM ..... . 6800 to 7000 RPM Sp ring Part Number and Color (Standard ) . . .. . .... 92081·3006 Blue Spring Part Number and Color(Optional) . ..... . .. 92081-3004 Pink 92081 -3005 Red 92081-3001 Ye llow 9208 1-3002 Black 92081-3011 White Spring Length New with no load ±0.25 in. (6.3 mm) ... . ... 4.14 in. (Blu e) (105.2 mm) 3.54 in. (Pink) (89.9 mm) 3.74 in. (Red) (94.9 mm) 3.96 in. (Yellow) (100.5 mm) 4.33 in. (Black) (1 10.1 mm) 4.74 in. (Whi te) (120.4 mm) Number of Spring Co il s (All Co lors) .... . . .... . .. 6 Sp rin g Wire Diameter (All Co lors) ± 0.01 in . (0 .2mm) . .. .. . . 0.197 in . (5.0 mm ) Spring Rate (All Co lo rs) ± 2.8 Iblin. (0.05 kg/mm) . . 56 Iblin. (1 .0 kg/mm ) Sprin g Compress ion ± 5.5 Ib (2.5 kg) .......... Blu e 155 Ib @ 1.36 in. (70.3 kg @ 34.5 mm) Pink 122 Ib @ 1.36 in . (55.3 kg @ 34.5 mm) Red 133 Ib @ 1.36 in. (60.3 kg @ 34.5 mm) Yellow 144 Ib @ 1.36 in. (65.3 kg @ 34.5 mm) Black 166 Ib @ 1.36 in. (75 .3 kg @ 34.5 mm) White 188 Ib @ 1.36 in . (85.3 kg @ 34.5 mm) Sprin g Outside Di ameter (All Colors) ± 0.025 in. (0.63 mm ) ... .. 2.28 in . (57.9 mm) Weight Part Numbers (STD) 110G0620 13042-3001 92019-008 Ramp Part Number and Identification (STD) .. . . .. 39152-3008 " G" Weight-Total (STD) .. . . .. . 56.8 grams
1-2
GENERAL SPECIFICATIONS
3500 to 3700 RPM 6800 to 7000 RPM 92081 -3002 Black 92081-3004 Pink 92081-3005 Red 92081-300 1 Yellow 92081-3006 Blue 92081-3011 White
4.33 3.54 3.74 3.96 4.14 4.74
in . in . in. in. in. in.
(Black) (110.1 mm) (Pink) (89.9 mm) (Red) (94.9 mm) (Yellow) (100 .5 mm) (Blue) (105.2 mm) (White) (120.4 mm)
6
0.197 in . (5.0 mm)
56 Iblin . (1.0 kg/mm) Black 166 lb. @ 1.36 in. (75.3 kg @ 34.5 mm) Pink 122 Ib @ 1.36 in. (55.3 kg @ 34.5 mm) Red 133 Ib @ 1.36 in. (60.3 kg @ 34.5 mm) Yellow 144 Ib @ 1.36 in. (65.3 kg @ 34.5 mm) Blu e 155 Ib @ 1.36 in . (70.3 kg @ 34.5 mm) White 188 Ib @ 1.36 in. (85.3 kg @ 34.5 mm)
2.28 in. (57.9 mm) 110G0628 13042-3002 92019-008 39152-3008 "G" 61.1 grams
Drive Converter Component Weight Chart PART NUMBER
COMPONENT
GRAM WEIGHT
13042-3001 13042-3002 92019-008 92001 -3009 92001-3003 92001 -3015 110G0620 110G0628 39152-3008
Weight, 0.031 in. (0.8 mm) thick Weight, 0.062 in. (1.6 mm) thick Nut, special 6 mm Bolt, aluminum, 6 x 15 mm Bolt, aluminum, 6 x 20 mm Bolt, steel, 6 x 16 mm Bolt, steel, 6 x 20 mm Bolt, steel, 6 x 28 mm Weight Assembly "G"
0.5 1.0 2.3 1.8 2.1 5.3 6.0 7.3 47.5
Driven Converter Cam Angle .. . . . ............ . ................ . . ... ... ... .. . .. . .. ............................. . 30· Spring Part Number .. .. . ... ... . ... . .. .. ..... . ...................................... ..... 92081-3535 Spring Color ... . .. .. . ..................... . ............ . . ............ . .... ............. .... Black Spring Length - New with no load ...... ... . ... . .......... ....................... ..... . . 4.2 in. (107 mm) Spring Diameter ............. . ......... ......... .... ....... ........... . . ........ 2.880 in. (73.15 mm) Spring Wire Diameter ............................... . .... . ........... .... ......... 0.155 in. (3.94 mm) Spring Preload - Counterclockwise ...... ........ .. ........ . . ... . .. . .. . . ......... ............ 3rd hole
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Belt Part Number ... . .... .. ......... . ....... .. .................... ... .. .. ................. .. 59011-3503 Outside Circumference .......... .. ..... . . . ..... ..... ..... .. ... . .. . .. .43.5 ± 0.19 in. (1104.9 ± 4.8 mm) Width - Topsurface ......... . . .. ..... ... ... . ...... . . ...... 1.25 + 0.06-0.00in.(31.7 + 1.55-0.00mm) Thickness - Top of belt to bottom of lug ... . . . . . .... .. . .... . .. . .. ....... ... . 0.56 ± 0.03 in. (14.2 ± 0.8 mm) Belt Taper Angle .... .... ... .. ...... . ... .. ... ... ........ . ... . .. . . ......... . .................... 30·
Brake
I
Brake Pad replacem ent required when threads protruding through adjusting nut exceed . . .... 7/16 in . (11 .1 mm)
Track and Su spension Trac k Type ............... . . ...... . ..... ... . . . .. . . . .... . . . ..... . . . ........ Rubber (Internal Drive Lug) Track Width .. . . . .................... . . . ..... .. . .. .................................. 15 in. (381 mm) Track Length .... . ....... .. ........ . .. . . ......................................... 116 in. (2946.4 mm) Suspension .. . ....... . . ...... . .. . ....... .. ... . .............. . ............. . .... . ... .. .. . Slide rail
Fuel/Oil Gasoline ........ .... ...... . . . .. . . .. .. ... . ... . . . . Leaded with minimum pump posted octane number89 Oil . . ......... . .. . . . . . .. ... . ........... . ..... . ..... . .. Kawasaki Snowmobile Oil (B.I.A. certified T.C.W.) Gasoline/Oil Ratio .. . .. Oil injection (approx. fuel/oil ratio of 110 to 1 at idle and 25 to 1 at top engine speed) Fuel Tank Capacity .. . . . .. . .................................................... . .. 9 gallons (34 liters) Oil Tank Capacity ..... . ..... . ........ ........ .. . .. . ... . ............ . ........... 2.5 quarts (2.37 liters)
GENERAL SPECIFICATIONS
1-3
I
MODEL SB440-A5
SB340-A2 Electrical Components Type ....... . . .... ..... ... ............ . . .. .. .. . 12 VAC , 120W Headlight Part Number . .. .. . .. . ... . ....... .. . .... 92069-3501 12 V 60/60 W Tail/Brake Light . . . .... .. .. . ... .. .. . . .. .. ...... .. G.E. 1157 Instrument Lights ... ... .. ..... .. . ... ... . . .... . .. G.E . 1816 (optional)
12 VAC, 120 W 92069-3501 12V 60/60W G.E. 1157 G.E. 1816
Frame Frame . .. ............ .. . .. .. . .... . ... . . ... .. ... Aluminum alloy and HSLA steel construction
Aluminum alloy and HSLA steel construction
SERVICE MODEL SB340-A2
SB440-A5
Engine Effective Compression Ratio . . . .. . . . ... . . ... .. .. .. 7.1 to 1 Piston Ring/Groove Clearance (Top and Bottom) ... ... 0.0010 - 0.0036 in. (0.03 - 0.09 mm) Piston Ring End Gap (Top and Bottom) ..... .. .. ... .. 0.006 to 0.014 in. (0.15 to 0.35 mm) Piston Skirt Clearance . . ... .. . . .. ... . .. .. .. ...... 0.001 to 0.003 in. (0.03 to 0.06 mm) Connect ing Rod Radial Play . . .. . .... . . . . ... . . ... . 0.0008 to 0.0012 in. (0.021 to 0.031 mm) Connecting Rod Side Clearance .. . .... .. .. .. . . ... . 0.016 to 0.020 in. (0.4 to 0.5 mm) Connecting Rod Small End Diameter . ... ... .... ... . 0.787 to 0.789 in. (20.00 to 20.05 mm) Crankshaft End Play (Max) . .. . . ..... .. . .. ... . . ... . 0.015 in. (0.38 mm) Crankshaft Run Out (Max) .. .... . .. .. .. .. ... . . ... . 0.002 in. (TIR) (0 .05 mm)
7.3 to 1 Keystone 0.008 to 0.016 in. (0.2 to 0.4 mm) 0.002 to 0.004 in. (0.05 to 0.10 mm) 0.0008 to 0.0012 in . (0 .021 to 0.031 mm) 0.016 to 0.020 in. (0.4 to 0.5 mm) 0.787 to 0.789 in . (20.00 to 20.05 mm) 0.015 in. (0 .38 mm) 0.002 in . (TIR) (0.05 mm)
Ignition Spark Plug Gap ... ... . .. . . ... ... .. ... . ... . . . . ... 0.024 in. (0.6 mm) Ignition Timing (Dynamic) .. ..... . ... ....... ...... 18 ° @ 6500 RPM Ignition Timing (BTDC) .. . . . . . .. . .. ...... . . . .. . . .. 0.073 in . (1.86 mm)
1-4
GENERAL SPECIFICATIONS
0.024 in. (0.6 mm) 18° @ 6500 RPM 0.073 in. (1.86 mm)
Magneto Resistance Tests ITEM
OHMMETER LEADS CONNECTED BETWEEN
0.18 ohm ± 20 % 160 ohms. ± 20 % 17 ohms ± 20 %
Yellow-Yellow Red-Ground Red-White
Light ing Coil Exciter Co il Pulser Coil
RESISTANCE
COl Igniter Ignition Coil Resistance Tests· ITEM
OHMMETER LEADS CONNECTED BETWEEN
RESISTANCE
Secondary winding
High Tens ion-High Tension
5,700 ohms ± 15 %
* NOTE : Faulty coils cannot be detected using this test alone. Use of a coil tester which simulates operating condi tions is the recommended test method .
Carburetor Air Screw Setting ... . .... .... . . . . .. _.. . _... .. . ... . .. . .. . . . . . . . . . . . . . .. .. . . . .... .. . . 2.0 turns off seat Idle Screw Setting ....... .. .. ... .. . . . ........... _.... . .. . .. _....... 6 turns open from coil bound -initial 2,500 RPM-final
Chassis Converter Offset Distance . ... . . . ... . . .. ...... . . .. . . .. .. . . .... . .... . .. . ... .. _... . .. 0.497 in . (12.6 mm) Conve rter Center Distance . . . . . . .. . .. .. . . ... . . . ..... .. .... .. . .. .. ... .. . . . . . .. . . .. . .. 10.3 in . (262 mm) Drive Chain Tens ion . ... . .. ... .. .. . .. .. . .. . . . . .. .. . .. .. . . . . . .. .. . . . . .. . . ... . . .. .. . . . . Self Adjusting Brake Adjustment required when lever movement exceeds . .. .. .. .. . . . ... ............ . ..... 314 in . (19 mm) Track Tension ....... .. . .. . . .. . ... . . .. ... . . 314 in. (19 mm) max imum deflection - 5 to 8 Ibs (2 .2 to 3.6 kg) pull Steering A l ignment ....... . ..... . . . ... .. .. .. .. .. ... ... . . . .. ... . . . Skis parallel or 1/8 in. (3.1 mm) toe out Tie Rod End Adjustment Stud Jam Nut Dimensions .... . .. .... . . .. . .. .. .. .. . ... . 1-1/4 in . (32 mm) maximum
General Engine Torque Specifications Cylinder Head Nuts .. . . . . . . .. .. . . . .. .. ... . . . . . . . .. .. .. . .. . ..... ... . .. . . . . ... .. ... . . 16 ft Ib (2.2 kg-m) Crankcase Bolts . . .. .. . . .. . ........ . . .. . . . . . . .. . . . . . . ..... . .. . . .. . .. . . . . . . . ..... . .. 16 ft Ib (2 .2 kg-m) Flywheel Nut . .. .. . . . ... . . . . . .. .. . . . .. .. .. . . . .. .. . . .. . . . . . . . . ... ... ... .. . . . ... .. . . 60 ft Ib (8.3 kg-m) Recoil Case Bolts . .. . .. . . .... . .. . . .. .. .. .. ... . . .. .. .. . . .. . . . . . . .. . .. . .. . . . .. . . . . .. 50 in . lb (0.6 kg -m) Spark Plug . . . . .... . . ... . .. . . ... . . . . . . . ... . .... .. . . . .. . . . ...... . . .. .. .. . ... ... .. . . 20 ft Ib (2.7 kg -m)
SERVICE SPECIFICATIONS
1-5
TORQUE CHART DESCRIPTION
QUANTITY
SIZE
TORQUE
- --
Hand tighten 50 in. Ib (0.6 kg -m) 25 in. Ib (0.3 kg-m) 20 in. Ib (0.2 kg-m) Hand tighten Hand tighten 20 in. Ib (0.2 kg-m) 25 in . Ib (0.3 kg-m) 20 in. Ib (0.2 kg -m)
Controls and Cables Speedometer cable nuts Brake cable lock nuts Brake lever set screw Enrichener cable jam nut Enrichener mounting nut Ignition switch face nut Throttle cable jam nut Throttle lever set screw Oil pump cable jam nuts
2 2 1 1 1 1 1 1 2
5/16 8mm 6 mm
- --
- -6 mm 8mm 6mm
Hood Hinge to hood - nuts Rubber retainer to hood - nuts Windshield to hood - screws special
4 4 8
1/4 1/4
---
25 in . Ib (0.3 kg-m) Compress rubber 1/2 15 in. Ib (0.2 kg -m)
Steering Handle bar to steering pole - screws , socket head Lower steering mount to front frame - bolts Steering arms to spindle - nuts Tie rod jam nuts Tie rod to steering arm - nuts Tie rod to steering pole - nut Tie rod to steering pole - thin cut Upper steering mount to steering mount - nuts
4 2 2 4 2 1 1 2
1/4 5/16
3/8 3/8 3/8 3/8 3/8 5/16
105 in . Ib (1 .2 kg-m) 18 ft Ib (2.6 kg-m) 30 ft Ib (3.9 kg -m) 120 in. Ib (1.4 kg-m) 30 ft Ib (3 .9 kg-m) 15 ft Ib (1.9 kg-m) 15 ft Ib 1.9 kg -m) 18 ft Ib (2.5 kg -m)
Ski and Spindle Shock absorber to ski - nuts Shock absorber to sp indle - nuts Skeg to ski - nuts Ski saddle to spindle - nuts Ski spring to saddle - nuts Ski spring to ski, front - nuts Ski spring to ski, rear - nuts
2 2 6 2 4 2 2
3/8 3/8 5/16
3/8 3/8 3/8 3/8
30 30 18 30 45 25 30
ft Ib (3.9 kg-m) ft Ib (3.9 kg-m) ft Ib (2.5 kg -m) ft Ib (3.9 kg -m) ft Ib (5.7 kg-m) in . Ib (0.3 kg -m) ft Ib (3 .9 kg-m)
Suspension Front idler wheels to bracket - bolts Hi-fax to suspension rail - bolts, special Limiter strap to front swing arm - nuts Rear arm idler wheel mount - bolts Rear ax le locking - bolts Shock absorber mount - nuts Suspension brackets to rail - nuts Suspension swing arm to bracket - nuts Swing arm pivot shafts to tunnel - bolts Track tension adjusting bolt jam nuts
2 2 2 2
2 2 20 4 4 2
3/8
3/8 3/8
30 ft Ib (3.9 kg-m) 100 in. Ib (1.1 kg -m ) 45 in. Ib (0.6 kg -m) 15 ft Ib (1.9 kg-m) 30 ft Ib (3.9 kg-m) 15 ft Ib (1.9 kg -m) 100 in. Ib (1.1 kg-m) 15 ft Ib (1.9 kg-m) 25 ft Ib (3.5 kg -m) 20 ft Ib (2.8 kg-m)
1/4 #10
100 in. Ib (1.1 kg -m) 90 in. Ib (1.0 kg -m)
- -1/4 5/16
3/8 3/8 1/4 5/16
Drive Shaft Bearing housing to tunnel - nuts Drive shaft locking collar - screws , socket head
1~
TORQUE CHART
3 2
TORQUE CHART (CONT.)
DESCRIPTION
QUANTITY
SIZE
TORQUE
Adaptor hole cap to chaincase cover Bearing support jam nut Bearing support to converter shaft· bolt Chaincase cover to chaincase - bolts Chaincase plugs Cha incase to front frame - nuts Lower sprocket to driveshaft - bolt, special Speedometer drive adaptor to chaincase cover Tensioner arm to chaincase - bolts Top sprocket to converter shaft - bo lt
1 1 1 5 2 4 1 1 2 1
. ..
1/4 5/16
Hand tighten 95 in. Ib (1.0 kg·m) 25 ft Ib (3.5 kg-m) 50 in. Ib (0.6 kg-m) Judgement 28 ft Ib (3.9 kg -m) 35 ft Ib (4.8 kg -m) 120 in . Ib (1.4 kg-m) 40 in. Ib (0.4 5 kg -m) 25 ft Ib (3 .5 kg-m)
2 3 2
5/16 1/4 1/4
25 ft Ib (3 .5 kg -m) 95 in. Ib (1 .0 kg-m) 100 in . Ib (1 .1 kg-m)
1 6 6 6 3 1
1/2 6 6 6 6
72 ft Ib (10.0 kg-m) 120 in. Ib (1.4 kg -m ) 120 in. Ib (1.4 kg-m) 120 in. Ib (1.4 kg-m) 60 in . Ib (0 .7 kg-m) 160 ft Ib (2 2 kg-m)
Chaincase 1/4 5/16 1/4
- --
5/16
- -- --
Brake and Driven Converter Brake caliper to bracket - nuts Brake disc to fixed sheave - screws, socket head Brake support bracket to chaincase - nuts
Drive Converter Drive converter to crankshaft - bolt Cover to movable sheave - bolt Roller and pin asse mbly in movable sheave - bo lt Weight ramp and pin assembly to spide r - bolt Weight ramp - nut Sp ider to fixed sheave (use Loctite #271)
mm mm mm mm
- --
Chassis and Seat Bumper to nose pan - nuts Hood guide to nose pan - nuts Hood hinge to nose pan - nuts Hood lanyard to front frame - nut Nose pan brace to front frame - nuts Passe nger handle to tunnel - nuts Rear bumper to tunnel - nuts Seat to chassis, front - screws Seat to chassis, rear - bolts
6 8 4 1 2 4 4 2 2
1/4 1/4 1/4 #10
1/4 5/16 1/4 1/4 1/4
100 in. Ib (1 .1 kg -m) 100 in. Ib (1 .1 kg -m) 100 in . Ib (1 .1 kg -m ) 20 in. Ib (0 .2 kg-m) 100 in. Ib (1.1 kg -m ) 120 in. Ib (1.4 kg -m) 100 in. Ib (1 .1 kg-m) 35 in . Ib (0 .4 kg-m) 35 in . Ib (0.4 kg-m)
Fuel System Fuel t an k pick-up fitting Fue l tank vent fitting Primer pump mount - nut
1 1 1
-- --
-
. --
Judgement Judgement 40 in. Ib (0.5 kg·m)
Engine Mount and Exhaust Eng ine mount pl ate to front frame - nuts Engine to engine mount plate - bolts
4 4
3/8
1 4 2 2 2
- --
1/2
30 ft Ib (3.9 kg-m) 30 ft Ib (3.9 kg-m)
Engine Lubrication System
c
Elbow fitting to oil tank Oi l pump inl et plate sc rews Oil pump mounting bolts Oi l pump nozzles Oil tank bracket bolts
4 mm 6 mm 8 mm
1/4
Judgement 13 in. Ib (0.1 kg -m ) 60 in. Ib (0 .7 kg-m) 10 in . Ib (0.1 kg -m ) 100 in. Ib (1.1 kg-m)
TORQUE CHART
1-7
TORQUE CHART (CONT.) DESCRIPTION
QUANTITY
TORQUE
SIZE
Engine Air Shroud and Fan Case Air shroud mounting bolts Engine exhaust duct mounting screws Fan housing to crankcase mount ing nuts Fan scree n to fan housing Fan pu lley to fan mounting nut .
12 2 4 4 1
6 mm #10 B mm 6 mm 14 mm
60 15 11 70 47
in. Ib (0.69 kg -m) in . Ib (0.17 kg-m) ft Ib (1 .5 kg-m) in. Ib (O.B kg-m) ft Ib (6.5 kg-m)
2 B 4 4 2
B mm Bmm B mm 6 mm
-- -
40 16 12 72 20
in . Ib (0.6 kg-m) ft Ib (2.2 kg-m) ft Ib (1 .7 kg-m ) in. Ib (O.B kg-m) ft Ib (2.7 kg-m)
1 3 4 1 1 2 B 1
B mm 6 mm B mm 6 mm B mm 6 mm B mm 1B mm
96 60 12 50 12 70 16 60
in. Ib (1 .1 kg -m) in . Ib (0 .7 kg-m ) ft Ib (1 .7 kg-m) in . Ib (0 .6 kg-m) ft Ib (1 .7 kg-m) in. Ib (O .B kg-m) ft Ib (2.2 kg-m) ft Ib (B .3 kg-m)
3 1 3
6 mm B mm 6mm
60 in . Ib (0 .7 kg-m) 120 in . Ib (1.4 kg-m) 60 in . Ib (0 .7 kg-m)
2 2 2 2 2 2
6 4 5 5 5 4
70 in. Ib (O.B kg-m) Hand tighten 35 in. Ib (0.4 kg-m) 35 in . Ib (0.4 kg-m) 30 in . Ib (0.35 kg-m) Hand tighten
2 2 1
#10 #B 1/4
Cylinder Head and Cylinder Carburetor holder to manifold - bolts Cy lin der head to cylinder - nuts Exhaust manifold to cylinders - nuts Intake manifold to cylinders - bolts Spa rk plug to cylinder head
Crankshaft, Crankcase and Gearcase Gearcase fill plug Gearcase cover mounting bolts Gearcase cover mounting bolts Gearca se drain plug Oil pump gear nut Crankcase bolts Crankcase bo lt s Crankshaft (flywheel) nut
Recoil Starter Reco il case to fan housing - bolts Recoil rope ree l to recoil case - nut Starter pulley to flywheel - bolts
Magneto and COl System CO l igniter to fan housing screws Wire clamps to stator screws Lighting coil to stator screws Pu lsing coil to stator screws St ator assembly mounting screws Wiring harness connector to fan housing screw
mm mm mm mm mm mm
Electrical Taill ight hous in g to storage case cover nuts Taillight lens to body screws Vo ltage regu lator mounting nut
10 in. Ib (0.1 kg-m) 10 in. Ib (0.1 kg-m) 100 in. Ib (1 .1 kg-m)
NOTE: Loctite formulas are selected on the basis of the diameter of the fastener, and the strength of the bond re quired. Generally, No. 222 is used on fasteners up to 5/16 in. (B mm) diameter. If a particularly strong bond is required, or the fastener diameter is greater than 5/16 in . (B mm), No. 242 is specified. Loctite may significantly increase the torque necessary to remove a fastener. Be careful when applying extra force as this risks damaging the parts. Use only the specified formula on each fastener requiring Loctite. Loctite No. 222 and No. 242 are industrial designations. The consumer equivalent which may be substituted is "Lock N' Seal ," product number 21 , blue. The drive converter requires the use of Loctite No. 271 (PIN 49075-3612).
1~
TORQUE CHART
GEAR RATIO CHART DRIVE SPROCKET - NUMBER OF TEETH 17
36 I I-
w w
ILL
37
0
a:
z
38
I-
w ~
2.00 67 MPH
1.89 71 MPH
1.64 82 MPH
90 Red
90 Pink
92 Red 1.76 76 MPH
1.68 80 MPH
90 Red
90 Green STD SB340
92 Red
92 Green
2.24 60 MPH
1.90 71 MPH
1.81 74 MPH
90 Green
92 Red
92 Green STD SB440
()
0
a:
a..
(J)
z > -
22
2.06 65 MPH
w ~
21
19
2.18 62 MPH
III
::J
20
18
39
w
a: 0
40
2.05 66 MPH
1.95 69 MPH
92 Red
92 Green
2.22 61 MPH
2.11 64 MPH
92 Pink
92 Green
Gear Ratio Speed Chain Pitch Tensioner Spring Gear Ratio Speed Chain Pitch Tensioner Spring
Gear Rat io Speed Chain Pitch Tensioner Spring Gear Ratio Speed Chain Pitch Tensioner Spring Gear Ratio Speed Chain Pitch Tensioner Spring
"Theoretical MPH at 6,900 RPM . NOTE: All top speeds based on 0.98 converter ratio and engine RPM at 6,900 RPM.
Chain Tensioner Springs COLOR
LENGTH
Red Orange Pink Yellow Green Blue
3.00 3.00 3.38 3.38 3.75 3.75
in. in. in . in . in. in .
(76.20 (76.20 (85.85 (85.85 (95.25 (95.25
WIRE DIA. mm) mm) mm) mm) mm) mm)
0.049 0.055 0.049 0.049 0.049 0.055
in. in. in. in. in. in.
(1.245 (1.397 (1 .245 (1 .245 (1.245 (1 .397
mm) mm) mm) mm) mm) mm)
GEAR RATIO CHART
1-9
PORT DIMENSIONS CYLINDER TOP
f B H
f--- - A --~
-y
~
EXHAUST
II I
PORT
~
F C
r . - - -- D
~
nil! L:J L::J !
SB340路A2 A B C D E F
G H I
J K L
= = = = = = = = = = = =
1.378 1.378 1.083 1.732 1.161 3.740 0.555 1.906 1.906 0.555 0.669 0.669
---~
-+-L- -+- K -
SB440路A5
in. (35.0 in. (35 .0 in. (27.5 in . (44.0 in. (29.5 in. (95.0 in . (14.1 in. (48.4 in. (48.4 in. (14.1 in. (17.0 in . (17.0
mm) mm) mm) mm) mm) mm) mm) mm) mm) mm) mm) mm)
A B C D E F
G H I
J K L
= 1.575 in . (40.0 mm) = 1.358 in. (34.5 mm) = 1.102 in . (28.0 mm) = 1.890 in . (48.0 mm) = 1.185 in. (30.1 mm) = 3.764 in. (95.6 mm) = 0.555 in. (14.1 mm) = 1.906 in. (48.4 mm) = 1.906 in. (48.4 mm) = 0.555 in . (14.1 mm) = 0.787 in . (20 .0 mm) = 0.787 in. (20.0 mm)
NOTE: Port width does not include the chamfer. Port height and height location includes the chamfer. Port chamfer = 0.039 in. (1 mm)
ENGINE PERFORMANCE CURVES SB440路A5
SB340路A2
-- - -
- - - - - -- -- -
-- -- -- -- - - - -
-- -- - - -- - -- - - -
--
-- -- -- -- - -- -- -- -- -- - - - -HP- -- -
- - -- - - - - - -- - - (j)
40
HP
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V
30
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--... V" .#
20
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1"\
F UEL
CfNriMrIIO, 0 0 0
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0 0 0
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000000 000000
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ENGINE RPM
1-10
PORT DIM ENSIONS
It)
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<0<01'-1'-0000
2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4
(j)
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20 10 0 0 0 cry
0 0 0
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0 0 0
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FUEL fOilUMnlOi000000 000000
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ENG INE RPM
2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4
a::
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MAINTENANCE CHART
~ Operation
Beginning of Each Season
First 80·160 Kilometers or 5·10 Hours Use
Every 480 Kilometers or 20 Hours Use
Every 960 Kilometers or 40 Hours Use
Every 1450 Kilometers or 60 Hours Use
End of Each Season
x
Install new spark plugs
x
Check carburetor adjustment
x
x
Check throttle and oil pump cab le adjustment
x
x
x
Check enrichener cable adjustment
x
x
x x
Replace fuel and oil filters Torque cyl inder head nuts
x
x
Check fan belt tension
x
x
x
x
Check ignition timing Rep lace drive belt (be sure converter sheaves are clean and dry)
x
Check drive converter and driven converter alignment
x
x
x
x
x
Check drive converter for wear Clean and inspect drive and driven converters
x
Torque drive converter mount bolt
x
Check chaincase lubricant level
x
Check engine gearcase oi l level and gearcase breather hole
x
Replace eng ine gearcase lubricant
x
x x
x
x
x
x
Check drive chain tensioner guides
x
Check brake adjustment
x
x
x
x
Adjust track tension and check alignment
x
Check ski alignment
x
x
Check fasteners for security (use torque chart as a guide)
x
x
Inspect ski skegs for wear
x
x
Measure wear of slide rail wear strips
x
x
Adjust headlight
x
MAINTENANCE CHART
x
2·1
LUBRICATION CHART LUBRICATION POINT CONTROL CABLES Inner cables
LUBRICANT LPS, WD-40, Dri-Slide or similar low temperature lubricant.
FREQUENCY Once a season and every 20 hours of operation
ILLUSTRATION
~
StfJ
/~r DRIVEN CONVERTER Low temperature Ramp sliding grease. surfaces
Once a season and every 20 hours of operation.
CHAINCASE HOUSING
Kawasaki chain lubricant
Check level every 20 hours of operation and change lubricant every 60 hours of operation.
ENGINE GEARCASE
Kawasaki engine gearcase oil or 10W40 motor oil that meets or exceeds API service SE specifications, such as Shell Fire and Ice. Level should be above center of sight glass but not higher than the top.
Change after initial 5-10 hours of operation. Check every 20 hours of operation. Drain and refill at end of each season.
LUBRICATION CHART
3-1
OIL INJECTION SYSTEM
3-2
Kawasaki Fill oil tank each Snowmobile Oil or a time gas tank is filled BIA certified TC-W oil.
LUBRICATION CHART
OIL INJECTION SYSTEM OIL INJECTION THEORY OF OPERATION
(
This snowmobi le engine is automatically lubricated by a variable pump which may change the fuel/oil mixture from about 110 to 1 to about 25 to 1, depending on engine speed and throttle opening. When the engine needs less oil, as at an idl e, it gets less oil.
The oil pump outout is controlled partially by the number of plunger strokes per minute. The number of plunger strokes is determined by the speed of oil pump shaft rotation. Since crankshaft rotation is transmitted directly to the oil pump shaft, the oil pump output changes in direct proportion to engine RPM.
Under full throttle, the engine receives more oil. Automatic oiling is economical because it gives the engine only as much oil as it needs. This also cuts down on vi sib le exhaust emissions. In the Kawasaki oil injection system, oil is kept in a tank separate from the engine and pumped by an oil pump to the engine. It is then mixed with the fuel/air mixture from the carburetor. The rate at which the oil is pumped is controlled by both throttle opening and engine speed. The quantity of oil will vary with the engine's requirements. With the ideal lubrication that results, engine performance and durability are vastly improved.
1. 2. 3. 4. 5.
Outlet Ports Plunger Plunger Tip Control Arm Pump Shaft
The other factor that controls oil pump output is the plunger stroke length. This length is determined by the oil pump cam position, which is controlled by the throttle lever, through the oil pump cable. As the cam is turned by its cable, the plunger stroke increases. When the cam is turned from the maximum flow to the minimum flow posi tion, the plunger tip will strike the cam after less travel, thereby pumping less oil. Since there are two high points on the plunger cam face, there are two comp lete pumping cycles for each revolution of the plunger. A greater plunger stroke will pump more oil.
OIL PUMP CABLE REMOVAL AND INSTALLATION
The oil pump for the engine lubrication system is a plunger type . In this system, th e oil pump output is controlled to regulate the ratio of oil to fuel/air mixture so that proper lubrication is achieved at all engine speeds and loads.
On the Drifter the throttle lever cable con nects to a junction block through which it operates both the carburetor cable and oil pump cable.
OIL INJ ECTION THEORY OF OPERATION
4-1
I WARNING
I ~ny
dirt or other contaminants the carburetor may cause faulty carburetor operation and possibly an accident. In
1. Throttle Lever Cable 2. Junction Block 3. Carburetor Cable 4. Oil Pump Cable To remove the oil pump cable: 1. Remove snap ring from throttle lever cable casing at throttl e case. 2. Disconnect inner throttle lever cable from throttle lever and pul l cable casing out of throttl e case.
1. Snap Ring 2. Throttle Case 3. Throttle Lever Cable
1. 2. 3. 4.
Carburetor Cap Throttle Valve Sp ring Sp ring Seat
6. Loosen oil pump cable jam nuts. Slip cable out of oil pump inlet plate and disconnect cable end from oil pump control lever.
1. 2. 3. 4.
Jam Nuts Oil Pump Inlet Plate Control Lever
3. Loosen carburetor cable jam nut at carburetor cap and turn adjuster clockwise to create more cable free play.
7. Pry cap out of junction block housing and pull throttle lever cable to remove junction block from housing.
4. Unscrew carburetor cap and pull throttle valve out of carburetor.
8. Disconnect oil pump cable from junction block. Pry end of housing open slightly and pull cable casing out of housing.
5. Pu ll spring towards cap and disconnect carburetor cable end from throttle valve. Push clean shop towel into carburetor and wrap throttle valve in clean towel.
4-2
OIL PUMP CABLE REMOVAL
7. Continue with Oil Pump Cable Adjustment
OIL PUMP CABLE ADJUSTMENT Synchronizat ion of the oi l pump and carburetor is extremely important to assure adequate engine lubrication and peak performance. Remove drive belt and air silence r assembly, then perform following procedure: 1. Loosen idle stop screw so that the throttle valve bottoms out in carburetor bore.
1. Cap 2. Junction Block 3. Oil Pump Cab le
NOTE: Check to be sure throttle valve has bottomed -out. If not, loosen jam nut and turn throttle cable adjuster to all ow valve to bottom out.
To install the oil pump cable: 1. Push oil pump cable casing into junction block housing until it snaps into position. Connect cable end to junction block. 2. Slide junction block into housing and push cap into housing until it snaps into position. 3. Connect oil pump cable end to oil pump control lever. Slip cable into inlet plate and loosely install jam nut.
1. 2. 3. 4.
Throttle Cable Adjuster Adjuster Jam Nut Air Screw Idle Stop Screw
2. Push oil pump lever forward until it contacts the stop pin; this insures the oi l pump is at dead idle position.
1. Control Lever 2. Cable End 3. Inlet Plate 4. Compress throttle valve spring into carburetor cap. Fit carburetor cable end in throttle valve. Install spring seat and release spring . 5. Slide throttle valve into carburetor. Install cap and tighten securely.
6. Push throttle lever cable through throttle case and hook it into throttle lever. Push snap ring onto end of cable casing.
1. Lever Stop Pin 2. Slack Removed 3. Cable Locknuts OIL PUMP CABLE INSTALLATION
4-3
3. Adjust cable on carburetor so that all slack is removed. The throttle valve should begin to rise as soon as the throttle lever on handlebar is advanced.
1. Fill oil tank with Kawasaki Snowmobile Oil. 2. Remove oil pump bleed screw. This allows oil to fill the filter and flow through oil supply tube to oil pump.
4. Loosen locknuts on oil pump cable and, while holding oil pump lever against the stop pin, remove all slack. Adjustment is correct when the lever on the oil pump and throttle valve in the carburetor move simultaneously as the throttle control lever is activated.
4. Visually check oil filter and oil supply tube to be sure that all air has been removed.
5. Turn idle stop screw in until spring is coil bound. Then, back off screw six complete turns (initial adjustment). Air screw is properly adjusted when opened 2.0 turns off its seat.
5. Air trapped inside the oil pump assembly can be removed by squeezing (pulsing) oil pump supply tube with pliers. This process causes air to exit the oil pump nipple and enter the supply tube.
3. Replace oil pump bleed screw when supply tube is filled.
6. Reinstall air silencer assembly. 7. Adjust idle speed and check throttle control cable adjustment as described in Carburetor Adjustments. BLEEDING OIL PUMP SUPPLY TUBE
Failure to bleed out air trapped in the oil line can cause severe engine damage.
The Drifter is equipped with an in-line oil fil ter to prevent foreign particles from entering the oil injection system. After filling oil tank, bleed air from oil pump supply tube as follows: 1. 2. 3. 4.
Air Bubble Oil Supply Tube Oil Pump Bleed Screw
Continue squeezing (pulsing) oil pump supply tube until bubbles no longer exit the pump assembly. 6. Remove bleed screw from top of oil pump and allow to drain until all air bubbles are removed from inlet tube. Visually check entire length of tube to be sure that all air has been removed, then reinstall bleed screw. PURGING AIR FROM OIL PUMP OUTLET TUBES
Remove drive belt and perform the following procedure. Any air bubbles in the oil pump outlet tubes will cause serious internal damage. Purge air from these tubes as follows:
1. Oil Tank 2. Oil Supply Line Filter 3. Oil Supply Tube
4-4
OIL PUMP CABLE ADJUSTMENT
1. The oil pump inner control cable must be disconnected from the control lever on the oil pump to prevent damage to cable. Do not disturb cable locknuts when removing the inner cable.
IWAR NI NG I lhi~
Failure to disconnect oil pu!"p control cable when performing
Fill or add lubricant to the gearcase as follows:
/lrocedure will damage the cable. The
1. Remove gearcase fill plug (located on top of
damaged oil pump control cable will prevent the throttle from returning to idle position, resulting in automatic clutch engagement when engine is started, which may lead to per· sonal injury.
1. 2. 3. 4.
gearcase) and pour Kawasaki engine gearcase oil, Shell Fire and Ice 10W40 or an equivalent viscosity motor oil that meets or exceeds API service SE specifications. Gearcase capacity is about 0.84 02 (25 cc). Reinstall fill plug and torque to 96 in. Ib (1.1 kg-m).
Oil Pump Inner Control Cable Oil Pump Control Lever Rubber Band Mount Bolt
2. Attach rubber band to hold oil pump control lever in the wide open position. This will cause the maximum flow of oil through the outlet tubes. 3. Start engine and adjust idle stop screw to obtain engine idle speed of 2,500 RPM. Stop engine after it has idled for one minute. This is ample time to purge all air from the oil pump outlet tubes.
~ ~f:~~e~u~e.::~~!~e f~~h t~~ carburetor. Poor engine performance and damage will result.
4.
~elease rubber band and reconnect oil pump Inner control cable to lever. Be sure to check operation of oil pump control lever and cable by activating throttle control lever on the handlebar.
5. Reinstall drive belt. ENGINE GEARCASE OIL
Components inside gearcase drive the oil injection pump.
1. Oil Level Sight Gauge 2. Engine Gearcase Drain Plug 3. Gearcase Breather Hole E~g.i~e gearcase oil should be changed after the In.ltlal 80-160 kilometers of operation, every 480 kilometers, and at the beginning of each season, to re~ove any impurities or foreign matter present In the gearcase cavity. To com· pletely drain the gearcase:
center but not higher than the top of the
Re~ove gearcase fill plug and drain plug. Raise rear of snowmobile to drain oil com· pletely.
Sight gauge. The sight gauge is located on the engine front, below left·hand cylinder assembly.
2. Reinstall drain plug and torque to 50 in. Ib (0.6 kg·m).
1. Lubricant level is correct when oil appears a~ove
PURGING AIR FROM OIL PUMP OUTLET TUBES
4-5
3. Pour in spec ified type and amount of oil. Reinstall fill plug and torque to 96 in . Ib (1.1 kg-m).
NOTE: Use separate container and length of test tubing for each oil pump outlet fitting. 4. Secure oil pump lever at WIDE OPEN position, then start engine and adjust idle speed to 3,000 RPM. Run engine long enough to purge test tubes (oil is discharged from outlet of tubes). 5. After purging the test tubes and securing the oil pump lever WIDE OPEN, start engine and operate at 3,000 RPM for ONE MINUTE then stop engine and measure output from pump. 6. Oil pump output should be 1.8 to 2.2 cc from each tube. 7. Replace oil pump not meeting these specifications. See Oil Pump Removal and Installation.
1. Container of Oil 2. Gearcase Fill Hole
8. Connect outlet tubes to oi l pump and purge air from outlet tubes. See Purging Air From Oil Pump Outlet Tubes.
4. To insure proper operation of oil seal between the engine gearcase and crankcase, check for obstructions in the gearcase breather hole, located above gearcase sight gauge.
OIL PUMP NOZZLE AND CHECK VALVE TEST
[~~!Iill
ir~i~r~!~:cea~~v~~~~~~rct~oo~:
may cause excessive oil consumption resulting in extensive engine damage. OIL PUMP OUTPUT TEST
The check valve is needed to prevent oil from bleeding back to the pump when the engine stops. The check valve retains oil in the hose between the oil pump and cylinder so it is instant ly available when the engine restarts. A small capacity, hand held pressure tester is recommended for testing the check valves. Only 3 to 6 PSI is required to move the check valve off its seat.
@tIiIill
~~:~du:~ ~~~h~r~~:~~e v~~::
1. For this test it is necessary to run engine using premixed fuel and oil at a 40 to 1 ratio. To obtain the 40 to 1 ratio, thoroughly mix 1 pint (0.47 liter) of Kawasaki Snowmobile Oil with 5 gallons (18.9 liters) of gasoline.
High pressure air will damage the valve which will result in engine failure.
2. Disconnect oil pump outlet tubes from oil pump fittings.
2. Disconnect oil pump outlet tubes from oil pump.
3. Install one end of 14 in. (610 mm) length of test tubing on oil pump fitting and insert other end into calibrated container capable of measuring approximately 5 cc.
3. Remove carburetor from holder.
4-6
ENGINE GEARCASE OIL
1. Remove intake s il encer.
4. Connect pressure tester to each outlet tube. Check that oil begins to flow through each nozzle when 3 to 6 psi is applied.
5. If pressure is out of specif ication or oil does not flow, replace outlet tube or nozzle as required. 6. Re install carburetor in holder and tighten clamp securely.
7. Install intake silencer. Check that silencer spring washer on right side of carburetor holder is pointing down. If silencer spring washer points toward oil tank, vibration may cause it to rub against tank_ Eventually, this may cause a hole in tank and subsequent loss of oil.
1. F ill Plug
2. Drain Plug 3. Gearcase Cover 4. Bolts
5. Remove idler gear. NOTE: One spacer is installed in front of idler gear and one spacer is installed behind gear. Set spacers aside with gear. The front spacer may come off with gearcase cove r.
1. Silencer Spring Washer 2. Oil Tank
8. Connect outlet tubes to oil pump and purge air from outlet tubes. See Purging Air From Oil Pump Outlet Tubes. OIL PUMP REMOVAL AND INSTALLATION NOTE: To remove oil pump, you must remove engine gearcase cover and oil pump drive gear.
1. Spacer 2. Idler Gear 3. Spacer
To remove oil pump:
1. Remove drive belt. 2. Remove drive converter. See Drive Converter Disassembly and Assembly.
6. Install fan puller holder tool into two holes in oil pump gear. Remove nut securing gear to pump shaft and remove gear.
3. Remove gearcase fill plug and drain plug. Raise rear of snowmobile to drain oil completely.
4. Remove bolts securing gearcase cover to crankcase and remove cover.
1. Fan Puller Holder 2. Nut OIL PUMP REMOVAL
4-7
7. Disconnect oil pump outlet tubes from oil pump fittings. Disconnect oil supply tube from oil pump inlet plate and plug or crimp tube. Remove two bolts securing oil pump to crankcase and remove pump.
5. Install gearcase cover. Torque 6 mm gearcase cover mounting bolts to 60 in. Ib (0.7 kg-m) and 8 mm bolts to 12 ft Ib (1.7 kg-m).
CD---.....!
1. Outlet Tube 2. Supply Tube 3. Mounting Bolt To install oil pump: 1. Install new a-ring into oil pump flange and apply thin coat of silicone sealer. Install oil pump into crankcase. Install two oil pump mounting bolts and torque them to 60 in. Ib (0.7 kg-m).
1.6 mm Bolts 2.8 mm Bolts
6. Install gearcase drain plug and torque to 50 in. Ib (0.6 kg-m). 7. Fill gearcase to just above center of sight glass but not higher than top of glass with Kawasaki engine gearcase oil, Shell Fire and Ice 10W40 or an equivalent viscosity motor oil that meets or exceeds API service SE specifications. Gearcase capacity is about 0.84 oz (25 cc). Install fill plug and torque to 96 in. Ib (1.1 kg -m). NOTE: Check the gearcase vent hole directly above the sight glass to be sure it is free from obstruction to ensure proper seal operation. If this hole is plugged, it could permit the gearcase oil to be sucked into the crankcase through the seal between the gearcase and crankcase. Loss of this oil would result in gear and bearing failure.
8. Reinstall drive converter. See Drive Con verter Disassembly and Assembly.
1. a-ring 2. Mounting Bolts
2. Install oil pump gear on pump shaft. Install nut and torque to 12 ft Ib (1 .7 kg -m).
9. Connect oil pump outlet tubes and supply tube to oil pump. Bleed oil pump supply tube and purge air from outlet tubes . See Bleeding Oil pump Supp ly Tube and Purging Air From Oil Pump Outlet Tubes. 10. Reinstall drive belt.
3. Position one spacer, idler gear and second spacer on idler shaft.
ENG INE GEARCASE ASSEMBLY
4. Install new a-ring into gearcase cover and coat gasket surface lightly with silicone sealer. The outer seal in gearcase cover is double-lip type. Fill area between two lips with grease before installing cover.
NOTE: This section covers special procedures required only when gearcase cover bearing or crankshaft is replaced. For general gearcase disassembly and assembly refer to Oil Pump Removal and Installation.
4-8
OIL PUMP INSTALLATION
DISASSEMBLY
AND
1. To remove bearing from gearcase cover, heat cover in oven to 212 °F (1 00 °C).
OIL TANK REMOVAL AND INSTALLATION To remove oil tank and bracket assembly:
2. Remove old bearing and press in new bearing .
(
3. When gearcase cover has coo led , measure from gasket surface of cover to face of bearin g inner race. Also measure from gasket surface of crankcase to face of crankshaft drive gear. Su btrac t dimens ion B from dimension A for clearance.
1. Remove intake silencer. 2. Disconnect upper oil supp ly tube from oil filter and plug or crimp tube. 3. Release tank hold down band and lift tank off bracket assembly. 4. Remove bo lts from brackets and remove bracket assemb ly.
CRANKCASE (GEARCAS E) COVER
A
BEARING (GEARCASE) B
CRANKS HA FT (PTa)
4. Dete rmin e appropriate shims us ing following tables and in sta ll them on end of crankshaft between crankshaft drive gear and gearcase cover bearing. NOTE: With correct sh im s installed there should be an axial clearance of 0.004 to 0.016 in. (0.15 to 0.39 mm).
Clearance 0.0052-0.0156 0.0157-0.0232 0.0236-0.0312 0.0315-0.0390 0.0394-0.0469 0.0472-0.0537 0.0551-0.0626 0.0629-0.0705 0.0709-0.0783 0.0787-0.0862 0.0866-0.0931 0.0945-0.1020 0.1024-0.1 076
= Dimension in. in. in. in. in. in. in . in. in. in. in . in . in .
B-A
(0.1 35-0.39 mm) (0 .4-0.59 mm) (0.6-0.79 mm) (0.8-0.99 mm) (1 .0-1.19 mm) (1 .2-1.39 mm) (1.4-1.59 mm) (1.6-1.79 mm) (1.8-1.99 mm) (2.0-2 .1 9 mm) (2.2-2.39 mm) (2.4-2.59 mm) (2.6-2.735 mm )
Shim No. Required None (1 ) (1) + (1) (2) (1) + (2) (3) (2) + (2) (4) (2) + (3) (2) + (2) + (2) (3) + (3) (2) + (2) + (3) (3) + (4)
1. Oil Filter 2. Bracket Assembly 3. Bolts To install oil tank and bracket assemb ly: 1. Position oi l tank bracket assemb ly so the in side of each U-shaped bracket contacts frame bracket as shown. In sta" mounting bolts and torque to 100 in.lb (1.1 kg -m). Do not position outside surface of U-shaped bracket against frame bracket. The bracket assembly may shift and possibly disconnect oil supply tube.
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SHIM NUMBER DESCRIPTION No.
Th ickness
Part No.
2 (1 )
(2) (3) (4)
0.00787 in. (0 .2 ± 0.015 mm) 0.02362 in . (0.6 ± (0.030 mm) 0.03937 in. (1 .0 ± 0.040 mm) 0.05512 in. (1 .4 ± 0.050 mm)
92025-3007 92025-3008 92025-3009 92025-3010
1. Frame Bracket 2. U-shaped Bracket
ENGINE GEARCASE DISASSEMBLY AND ASSEMBLY
4-9
2. Position oil tank on bracket assembly and secure w ith hold down band. 3. Reconnect oil supp ly tube to oil filter. 4. In stal l intake silencer. 5. Bleed oil pump supply tube and purge air from oil pum p outlet tubes. See Bleeding Oil Pump Supply Tube and Purging Air From Oil Pump Outlet Tubes . OIL FILTER REMOVAL AND INSTALLATION
To remove the oil filter: 1. Disconnect oil supply tubes from oil filter. Plug or c ri mp tube ends to prevent oil drainage. 2. Replace filter w ith new one at end of each season , if filter shows any signs of leakage or if foreign particles are trapped in screen . To install the oil filter: 1. Attach oi l supply tubes to correct fittings on filt er. Supp ly tube from oil tank must attach to filter fitting marked IN.
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inail~~: t~:~~~~ta~li:e~~~~ fi~~~
cau se oil pump failure. Any foreign particles trapped in the filter screen will be picked up by the oil flowing through the filter in the opposite direction and be carried into the oil pump.
I
1
2. Bleed oil pump supply tube . See Bleeding Oil Pump Supply Tube. 4-10
OIL TANK REMOVAL AND INSTALLATION
FUEL SYSTEM THROTTLE CABLE REMOVAL AND INSTALLATION
3. Loosen carburetor cable jam nut at carburetor cap and turn adjuster c lockwise to create more cable free play.
On the Drifter there are actually two throttle cables. The throttle lever cable connects to a junction block through which it operates the carburetor cable and oil pump cable.
4. Unscrew carburetor cap and pu ll throttle valve out of carburetor. 5. Pull spring towards cap and disconnect carburetor cable end from throttle valve. Push clean shop towel into carburetor and wrap throttle valve in clean towel.
IWARNING I
Any dirt or other contaminants _ in the carburetor may cause faulty carburetor operation and possibly an accident.
1. 2. 3. 4.
Throttle Lever Cable Junction Block Carburetor Cable Oil Pump Cable
To remove the throttle lever cable and carburetor cable: 1. Remove snap ring from throttle lever cable cas in g at throttle case. 2. Disconnect inner throttle lever cable from throttle leve r and pull cable casing out of throttle case.
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1. Snap Ring 2. Throttle Case 3. Throttle Lever Cable
1. Carburetor Cap 2. Throttle Valve 3. Spring 4. Spring Seat
6. Loosen oil pump cable jam nuts. Slip cable out of oil pump inlet plate and disconnect cable end from oil pump control lever.
1. 2. 3. 4.
Jam Nuts Oil Pump Inlet Plate Control Lever
THROTTLE CABLE REMOVAL
5-1
7. Pry cap out of junction block housing and pull throttle lever cable to remove junction block from housing.
4. Compress throttle valve spring in carburetor cap. Fit carburetor cable end in throttle valve. Install spring seat and release spring.
8. Disconnect throttle lever cable end and carburetor cable end from junction block. Pry
5. Slide throttle valve into carburetor. Install
ends of junction block housing and cap open s lightly and pull cable casings out of housing and cap.
cap and tighten securely.
6. Push throttle lever cable through throttle case and hook it into throttle lever. PlJsh snap ring onto end of cable casing.
7. Synchronization of the oil pump and carburetor is extremely important to assure adequate engine lubrication and peak performance. Remove drive belt and air silencer assembly, then see Oil Pump Cable Adjustment for synchronization procedure. CARBURETOR ADJUSTMENTS Enrichener Cable
1. Cap 2. Junction Block 3. Carburetor Cab le 4. Throttle Lever Cable
With the enrichener lever down, and plastic boot slid up the casing, the enrichener cable should have 1/16 inch (1.5 mm) free movement when raised as shown. NOTE: Engine flooding may occur if the enrichener cable free movement is less than 1/16 inch (1.5 mm).
To install the throttle lever cable and carburetor cable: 1. Push carburetor cable casing into junction block housing and throttle lever cable casing into hou sing cap until they snap into position. Connect cable ends to junct ion block.
2. Slide junction block into housing and push cap into housing until it snaps into position .
3. Connect oil pump cable end to oil pump control leve r. Slip cable into inl et plate and loosely install jam nut.
1. Plastic Boot 2. 1/16 in. (1 .5 mm) 3. Locknut 4. Adjusting Screw
If adjustment is required, loosen jam nut and turn adjusting screw to obtain correct movement. Torque jam nut to 20 in. Ib (0.2 kg-m). 1. Control Lever 2. Cable End 3. Inlet Plate 5-2
THROTILE CABLE INSTALLATION
After adjustment or check, position boot over fitting to prevent dirt from entering the enrichener system .
Air Screw The carburetor air screw is properly adjusted when opened 2.0 turns off its seat. Refer to the specifications page.
With the throttle lever at the idle position there should be 1/16 in. (1.6 mm) free play between the lever and its housing. Remove air silencer and check that carburetor slide is raised completely above carburetor venturi at full throttle. Adjust throttle cable by loosening adjusting screw jam nut. Turn adjusting screw to obtain proper adjustment and torque jam nut 20 in. Ib (0. 2 kg-m).
Correct 1. 2. 3. 4.
Throttle Cable Adjuster Adjuster Jam Nut Air Screw Idle Stop Screw
Idle Screw The idle speed screw initial adjustment is 6 turns open from coil bound, (screw turned in tig ht).
I WARNING I
If ~he engine idles too fast, the . _ drive converter may not disengage when the throttle lever is released, or the converter may engage automatically. Either condition could result in personal injury. Make sure the fuel pump pulse line and all fuel lines are secure and free of kinks and bends.
Start the engine and run it at low speed for 3 to 5 minutes for proper warm·up, and adjust the idle speed using a portable tachometer. Throttle Control Cable
CARBURETOR DISASSEMBLY AND ASSEMBLY The SB340·A2 and SB440-A5 carburetors are nearly identical to the VM32 Econo Jet car· buretors used on the SA340-A4 and SB440-A4 models. Refer to pages 3·41 through 3-51 in the SA340-A4, SB440-A4, SC340-A 1 Shop Manual for removal, disassembly, assembly and in· stallation procedures. Cleaning Thoroughly clean all parts in nonflammable or high flash point solvent.
I. WAR NI NGI_
Ne.ver use gasoline or lo~ flash pomt solvents for cleanmg the carburetor. A fire or explosion could result.
In spect all drilled holes, openings and fuel passages in the body. Blow compressed air through the passages. Remove any sediment from the fuel chamber. Use of automotive carburetor cleaners may be necessary to remove gum and varnish build ·up from the jets and fuel chamber.
throttle cable to disconnect from lever. Too lit· tie or no free movement may lead to incorrect idle adjustment.
• Do not use automotive car· buretor cleaners for cleaning the carburetor body. The plastic fittings may be damaged making it necessary to replace the carburetor. • Do not use drills or wires to clean the jets or damage to the jets will result.
NOTE: Check synchronization of the oil pump and carburetor cables before adjusting the throttle control cable to ensure adequate engine lubrication.
In spect float valve needle tip for wear or damage in the sealing (tapered) area. Replace float valve assembly if needle shows signs of wear or damage, such as groove or scratches.
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c
Incorrect
CARBURETOR ADJUSTMENTS
5-3
Be su re arrow on new f ilter points toward fuel pump.
Parts Identification Check carburetor parts for proper iden t ifi cation markings prior to reassembly. If th e co rrect components are not installed th e car-
buretor cannot be calibrated properly. FUEL FILTER CLEAN/R EPLACE Th e Drifter fuel system uses two fu el filters . On e fu el filt er screen is in corporated in t he fue l pick-up tube weight in sid e th e fu el tank and th e other in -line filter is located in th e fu el t ube be tween th e fuel tank and fu el pump.
IWARN ING I
Gasoline fumes are heavier . - than air and can become explosive if exposed to a pi lo t light from a furnace, hot water heater, clothes dryer, etc. Per· form maintenance only in an area that is well ventilated and free from pilot lights and sparks.
1. In-l ine Filter 2. Arrow 3. Filter Screen 3. Check fue l filter and tubes for leaks and replace as required.
In-line Fue l Filter Rep lace the in-line fu el filter at the end of each season.
Fuel Filter Screen
1. Cri mp fu el tube between fuel tan k and fue l fi Iter.
If excessive fuel tank contaminants block the flow of fuel through the screen, it must be cleaned.
2. Pu ll fu el lin es off fil ter and in stall new fi lter.
1. Remove fuel tank cap.
IDENTIFICATION MARKIN GS
P· 4
~----® SB340·A2
1. 2. 3. 4. 5. 6. 7. 5-4
Throttl e Va lve 2.0 Needl e Jet 0-6 Needl e 6FL 14-3 Carburetor Body 32-187 Econo Jet No. 120 Main Jet No. 180 Pilot Jet No. 30
SB440-AS
1. Throttl e valve 2.0 2. Needle Jet 0-6 3. Needle 6FL 14-3 4. Carbu retor Body 32-186 5. Econo Jet No. 110 6. Main Jet No. 250 7. Pilot Jet No. 30
CARBURETOR DISASS EMB LY A ND ASSEMBLY
VM32 ECONO JET CARBURETOR
~ -
B- 2
/ /
1-
---3
/
/
(
--- ---
---5
I
/'
38 - - - - - - - - l
I
I
I
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(
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I
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I I
---4
/
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31
®
1
I
II I I
1 36---1~~
I I I
28
l'
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8
27 I
35 ~
10 11
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12 13 14
r~ b
25-----1
~~~-31
34
..
26-----
I I
I
2 6 - - - - - -<h 1 G
15
0
~
0 ' 24-tr.0
16
17-----
I I' I I
17 18
I 1 I
23---\ 19
22----, 21------"-~1J1
I
20-----
1. Carbu retor Assemb ly En ri chener Plu nger Cap Cap Washer En ri c hener Plu nger Spring Enri chener Plunger Air Screw Spring Pilot Air Screw Float Pin 9. Float Chamber Gasket 10. Pi lot Jet 11 . Baffle 12. Ho lder Washer 13. Carb Need le Holde r
2. 3. 4. 5. 6. 7. 8.
14. 15. 16. 17. 18. 19. 20. 21 . 22. 23. 24. 25. 26.
Holder a-Ring Float Arm Float Retainer Float Main Jet Float Chamber Special Screw Econo Jet Tube Clamp Tube Retainer Tube Econo Jet Float Valve Assembly Float Valve Gasket
-
-
27. 28. 29. 30. 31. 32. 33. 34.
35. 36. 37. 38.
__ __ J Air Jet Throttle Sc rew Sp rin g Throttle Stop Screw Primer Tube Fittin g Carburetor Needle Clip Needle Jet Throttle Valve Needle Spring Seat Throttle Valve Spri ng Mixing Cham ber Cap Tube
CARBURETOR DISASSEMBLY AND ASSEMBLY
5-5
2. Pull free end of fuel tube out of fuel tank using piece of wire.
1. Fuel Filter Screen 3. Remove fuel filter screen/weight assemb ly from tube. Clean screen and reinstall on tube . Drop end of tube into tank and install cap .
5-6
FUEL FILTER CLEAN/REPLACE
IGNITION SYSTEM IGNITION TIMING CHECK Remove the drive belt prior to performing the following procedure. 1. In stall fabricated timing pointer onto engine. For accuracy, attach pointer to engine rather than chassis so pointer moves with engine.
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3. Rotate drive converter in normal direction of rotation (counter-clockw ise) to find TDC (top dead center). Adjust dial indicator to zero. 4. Turn drive converter clockwise to 0.073 in . (1.86mm). 5. Make a mark on drive converter fixed sheave corresponding to timing pointer. 6. Remove the dial indicator. Before installing the spark plugs, check th at: a. Plug gap is properly adjusted. Gap: 0.024 in. (0.6 mm) b. Compression washer is installed on spark plug and cylinder head seat is clean. c. Spark plugs are torqued to 20 ft Ib (2.7 kgm).
7. Connect strobe type timing light to spark plug lead wire following manufacturer's in structions. Drive belt must be removed and converter belt guard secured in place.
1. Dial Indicator 2. Converter Fixed Sheave 3. Fabricated Pointer
IWARNING I
Do not touch the spark plug leads while the engine is running as they will transmit a powerful elec¡ trical shock. Do not touch the hot exhaust system, as a severe burn will result.
2. Remove both spark plugs and install a dial in dicator into the LH cylinder spark plug hole.
§ITill ':a~:~ulI~~o~:~~g PI~a~a:~agcSk and forth whi le pulling cap straight upward_ Do not attempt to twist or force plug cap off by pulling on lead wires as this will damage the connection.
1. Timing Light 2. Mark on Drive Converter 8. Start engine and allow it to warm up to operating temperature. Then run engine at 6,500 RPM and aim timing light, through converter guard, directly at timil)g pointer. Timing is correct when mark aligns with pointer as light flashes.
IGNITION TIMING CHECK
6-1
5. Recheck timing using Ignition Timin g Check procedure to be sure timing is correct.
IGNITION TIMING ADJUSTMENT 1. Remove recoil starter assembly and fan belt pulley. Twist fan belt out of the way.
6. In stall recoil starte r assemb ly. Drive be lt may now be insta lled and belt guard secured into position with clip pins .
2. Loosen
the stator assembly mounting screws through the holes in the flywheel. To correct the timing, rotate the stator assemb ly as required (cl ockwise to retard t im ing; counterclockwise to advance ti mi ng).
IGNITION TROUBLESHOOTIN G USING CD IGNITION TESTER Refer to pages 3-9 through 3-13 in the SA340A4, SB440-A4, SC340-A 1 Shop Manual for preliminary ign ition test procedures and a general description of the CD ign it ion tester operat ion.
When adjusting the stator assembly, take care not to damage the coil windings.
The ground wire terminal on the SB340 and SB440 is located at the lower COl igniter mounting screw .
1. Flyw hee l 3. Tighten stator mounting screws . Torque to 30 in. Ib (0.35 kg-m). 4. Replace fan belt pulley, starter pulley and fan belt. Torque bolts to 60 in. Ib (0.7 kg-m ).
1. Brow n and G ray Wi res
Test Sequence - Using CD Ignition Tester PIN T56019-201
CDI IGN ITER & IGNITION COIL
EME RGE NCY STOP SWITCH
/
TEST # 1
BLACK
Ignit ion COil
Output And
G
Spark Plug Check
KEY SWITCH
TEST #1
T EST #3
TEST #2
RANGE
DIAL SETTING
Low
25
RANGE
DIAL SETTING
RANGE
DIAL SETTING
High
35
Low
90
NOTE: Refer to follo",:,ing pages for detailed testing procedure. 6-2
IGNITION TIMING ADJUSTMENT
Test No.1 Ignition Coil Output and Spark Plug Check
CO l IGNITER & IGN ITION CO I L WH ITE
RED
ST ATOR ASSEMBL Y
EMERGENCY STOP SWITCH
KEY SW ITCH
TEST CONNECTIONS 1. Connect the M M-1 adaptor to the tester N (yellow) lead wire. 2. Connect the tester P (red) lead wire to a good ground on the engine. 3. Clamp the MM-1 adaptor around either spark plug wire as close to the spark plug as possi ble. If insulation sleeving is over the spark plug wire, push the sleeving back so that the clip encircles the spark plug wire direct ly. Do not allow any metal portion of the MM-1 clip to touch the engine. 4. Before proceeding, be certain that the engine stop switch, ground wires, and all primary and secondary ignition wiring are not cont ributing to the problem.
=
TEST PROCEDURE NOTE: Afte r each test t hat li ghts t he Indicator Lamp, push the Reset button to t urn t he lamp off in preparat ion fo r the next test. 1. Set the toggle switch to the Low range. Set the tester dial to 25. 2. Pull the reco il starter handle to t urn the engine over. If the eng ine starts , allow it to idle only. Repeat th is test three times to verify consistent output. a. If the lamp lights consistently at or above 25 on the scale, the ignition system up to the spark plugs is operating properly. Remove the spark plugs and replace any plug which is fouled , bridged , or otherwise unfit for service. Consider the possibilities that high heat, vibrat ion , or moisture may be causing ignition problems and repeat Test No.1 incorporating these factors into the test. b. If the lamp does not li ght consistently above the specified value or does not light at al l, fo ll ow the steps on t he next page. IGNITION TROUBLES HOOTING
6-3
Test No.1 Procedure (Cont.)
, ) 1///
t-------,-;/J~-
TEST #1 Ignition Coil Output A nd Spark Plug Check
r
,
Replace Spark Plugs
Remove spark plugs and replace any plug which is fouled, bridged or otherwise unfit for service.
I Problem solved or problem not in Ignition System
Proceed to Test #2
Cons ider the possibilities that hi gh heat , vibration or moisture may be causing ignition problems . Retest i njecti ng these factors into the test.
,
, Proceed to Test #2
,
No Lamp or Low/Inconsistent Reading
,,-,\'/1/
--:n ~
/I'J'"
Lamp Lights at Specified Value
STANDARD VALUE TEST #1
6¡4
RANGE
VALUE
Low
25
IGNIT IO N TROUBLESHOOTING
Problem solved
Test No.2 Exciter Coil Output
STATOR ASSEMBLY COl IGNITER & IGNITION COIL WHITE
o
II
RED OJ
OJ
:t>
0
r
()
7<
:D ::-;:
Z
EM ERGENCY STOP SWITCH
2. Turn over the engine while observing the Indicator Lamp on the tester.
TEST CONNECTIONS 1. Disconnect the red and white wires between the mag neto assemb ly and the CD igniter. 2. Connect the tester N (yellow) lead wire to th e red wire on the magneto end of the connector. 3. Connect the tester P (red) lead wire to a good engine ground.
a. If the lamp lights, push the Reset button to turn the lamp off and repeat Test No. 2 three times. If the lamp lights consistently at 35, the magneto exciter coil is good, proceed to Test No.3. b. If the Ind icator Lamp gives in consistent readings at any dial setting or does not light at all, this indicates th e following: 1. A faulty exciter coil (ch ec k the ohms). Replace the exc iter coil. 2. Fau lty w iring. Check the wiring .
TEST PROCEDURE 1. Set the toggle sw itch to the High rang e. Set the tester dial to 35.
3. Faulty flywheel mag nets. Replace the magnets. Follow the steps in the chart on th e next page. IGNITION TROUBLESHOOTING
6-5
Test No.2 Procedure (Cont.)
TEST #2 Exciter Coil Output
Examine magneto wiring for opens, shorts, or poor ground and repair if possible or replace magneto exciter coil
, Proceed to Test#3
Repeat Test # 2
, Replace flywheel assembly and repeat Test #2
Proceed to Test#3
No Lamp or Lowllnconsistent Reading Lamp Lights at Specified Value
STANDARD VALUE TEST #2 RANGE High
6-6
IGNITION TROU BLESHOOTING
VALUE
35
Test No.3 Pulser Coil Output
STATOR ASSEMBLY COl IGNITER & IGN ITION COIL WHITE
o RED OJ
OJ
l>
0
r
:ll
(")
~
A
Z
EMERGENCY STOP SWITCH
KEY SW ITCH
TEST CONNECTIONS
TEST PROCEDURE
1. With both the red and white wires still disconnected, connect the tester N (yellow) lead wire to the white wire on the magneto end of the connector.
1. Set the toggle switch to the Low range. Set the tester dial to 90.
2. Connect the tester P (red) lead w ire to a good engine ground .
2. Turn over the engine while observing the Indicator Lamp on the tester. a. If the Indicator Lamp lights, push the Reset button to turn the lamp off and repeat Test No.3 three times. If the lamp lights consistently at 90 the pulser coil is good , repeat Test NO.1. b. If the Indicator Lamp gives inconsistent readings or does nQt light at all, follow the steps on the next page. IGNITION TROUBLESHOOTING
6-7
Test No.3 Procedure (Cont.)
"'\, /,/
TEST #3 Pulser Coil Output
~----., -XJ;: Repeat Test # 1
Examine magneto wiring for opens, shorts, or poor ground and repair if possible or repl ace magneto pulser coil
Repeat Test #3
Replace flywheel assembly and repeat Test#3
Repeat Test # 1
,
No Lamp or Lowllnconsistent Reading
"'\'/'/
-:n-:- Lamp Lights at Specified Value /''\1'"
STANDARD VALUE TEST #3
6·8
RANGE
VALUE
Low
90
IGNITION TROUBLESHOOTING
IGNITION TROUBLESHOOTING USING OHMMETER
If the Kawasaki CD ignition tester is not available, the exciter and pulser coils can be tested using an ohmmeter. This test is not as accurate as using the Kawasaki CD ignition tester. NOTE: Exercise care to prevent an electrical shock from the CD igniter. Handle the CD igniter carefully. If you should drop it, the in corporated electronic components will be damaged.
The following test procedures are alternate checks designed for locating ignition system malfunction using an ohmmeter. 1. WIRING CONNECTIONS - Check all wiring connectors to insure connections are clean, secure, and correct
COllloNITI R & Il,NITIONCOIL
STATOII ASStM8LV
PART TO BE MEASURED
EXCITER
PULSER
OHMMETER LEADS CONNECTED BETWEEN
RED BROWN (GROUND)
WHITE RED
RESISTANCE
160r2±20% 17r2±20%
·VOLTAGE AC
40 VAC
4 VAC
• Measure at cranking speed with spark plugs installed.
COl I(;NlllH & IGNITION COIL
2. EXCITER AND PULSER COILS - To locate the cause of trouble (broken wire, short circuit, etc.) measure the resistance of each coil winding and check AC voltage output as specified in the following illustration. Repair defective wire or replace coil not within specifications.
ff~!ii'£~ ~~s~~tti~~e ~;s::.~~~~ert~:~~~: or other testers with a battery of large capacity). The use of a large capacity tester may ruin com· ponents during test.
IGNITION TROUBLESHOOTING
6-9
)
)
)
TORQUE CONVERTER SYSTEM DRIVE CONVERTER THEORY OF OPERATION
The drive converter contains three ramp weights that control engine RPM . Lighter ramp weight will increase engagement RPM, and maintain higher RPM throughout the total sh ift pattern. Care must be taken not to exceed specified engine RPM or engine damage will occur. By contrast, heavier ramp weights will decrease engagement RPM, and also lower engine RPM throughout the shift pattern . However, the main function of the ramp weights is to control the engine RPM through the shift pattern.
The drive converter on the snowmobile is designed to provide max imum performance under all types of snow and load conditions. There are three variables that will change the performance characteristics of the drive co nverter. They are as fo ll ows: 1. Spring 2. Weights 3. Ramps The primary function of the sprin g is to con trol the ini tial engagement between th e movable drive sheave and T.C. belt. The spring also affects engine RPM throughout the drive converter shift pattern. A weak or light sprin g will decrease both engagement speed and maximum engine RPM, resu lting in speed ing up the shift pattern. A heavy or stro ng spring will in crease engagement speed and maximum engine RPM, but slows down the shift pattern.
The ramp is designed so the shift pattern is within the peak torque curve of the engine. The ramp profile is the major factor in determining the characteristics of the shift pattern. CONVERTER ALIGNMENT Three separate checks are required to ensure correct drive and driven converter alignment. Use alignment gauge PIN 57001 -3515 to make checks No.1 and 2. 1. Converter center-to-center distance 2. Converter offset distance 3. Converter parallelism Converter Center-To-Center Distance The distance from the center of the drive converter to the center of the driven converter should be 10.3 in. (262 mm).
1. Alignment Gauge 2. 10.3 in. (262 mm) 1. Roller 2. Spider Assem bly 3. Spring 4. Movable Sheave 5. Weight Ramp 6. Drive Be lt 7. Stationary Sheave
1. Remove belt guard and remove drive belt. 2. Rotate driven converter moveable sheave assem bly clockwise, and insert alignment gauge between sheaves. Carefully release moveable sheave assembly allowing sprin g tension to retain gauge in position between stationary and moveable sheave assemblies. DRIVE CO NVERTER THEORY OF OPERATION
7-1
3. Center distance is correct if the notch in the alignment gauge fits over the shaft on the drive converter.
1. Drive Converter Stationary Sheave 2. Driven Converter Movable Sheave 3. 0.497 in. (11.5 mm)
1. Correct offset distance is obtain ed wh en the surface of the alignment gauge touch es t he base of th e drive converter fixed sheave . 1. 2. 3. 4.
Driven Converter Support Arm Driven Converter Moveable Sheave Alignment Gauge Drive Converter
4. If adjustment of converter center distance is necessary; loosen four chaincase mounting nuts. Position chaincase forward or rearward as required. Torque chaincase mounting nuts 28 ft Ib (3.9 kg-m). NOTE: Driven converter bearing support must be disconnected by removing clevis pin from chassis yoke. After adjusting chaincase, loosen support jam nut and adjust support assembly to proper length. Reconnect support to yoke and torque jam nut to 95 in. Ib (1.1 kg-m). Converter Offset Distance
The distance from the back face of the drive converter stationary sheave to the edge of the driven converter moveable sheave should be 0.497 in . (11.5 mm).
1. Alignment Tool 2. Alignm ent Tool Surface 3. Drive Converter Stationary Sheave 2. If adjustment is necessary, loose n four engine mounting nuts. Slide engine bac k and forth until stationary sheave tou c hes alignment gauge. Tighten all mounting bo lts securely.
7-2
CONVERTER ALIGNMENT
Converter Para llelism 1. When checking center-to-center and offset distances, parallelism must be checked by measuring dimensions A and B as shown. Compare dimensions A and B against Notes I and II. NOTE I: Dimension A must be more than dimens ion B. NOTE II: Dimension A must never exceed dimens ion B by more than 1/16 in. (1 .6 mm). 2. If dimension A is less than B, converter parall eli s m is not correct. Adjust parallelism by looseni ng engin e mounting nuts, then twisting or rotating eng ine to correct position. Torq ue engine mounting nuts to 30 ft Ib (4.1 kg -m).
1. "U" Washer, PIN 92025-3507
DRIVE CONVERTER DISASSEMBLY AND ASSEMBLY To disassemble the drive con verter: 1. Remove the drive belt. 2. Remove the drive converter mounting bolt and lockwasher whil e holding the end of the fixed sheave with an open end wrench.
3. Install the drive converter puller and screw it in until the drive converter pops off th e cranks haft taper.
1. A li gnment Gauge 3. If parall elism is sti ll not correct, loosen chaincase mounting nuts and intall ali gnment "U" washers PIN 92025-3507 as required between chassis and chaincase. NOTE: Never use more than 2 alignment " U" washers per bo lt.
CONVERTER ALIGNMENT
7-3
4. Place the drive converter on a rubber mat or piece of cardboard on the floor. With your knee or foot on the cover, remove the boits securing the cover to the converter. Remove the cover slowly.
I WARNING
I
Do not let go of the cover sud路 denly. It can pop up and cause
personal injury.
5. Remove the spring. 6. Remove each wear guide by rocking the bot路 tom of the fingers in towards the center of the spider and lifting it out.
NOTE: The wear guides cannot be removed by pulling them straight off the spider.
1. Drive Converter Holder 2. Holder Pin 3. Sp ider 8. Separate the spider, movable sheave and fixed sheave. 9. Remove the three ramp weight assemblies from the spider by removing the bolts and retainer washers.
7. Clamp the drive converter holder in a bench vise. Slip the end of the fixed sheave through the center of the holder and engage the holder pin s with the sides of the spider. Fit the drive converter socket onto the end of the fixed sheave and turn it in the direc路 tion shown to separate the fixed sheave from the spider. Be sure the holder pins are forced against the spider and not the movable sheave when separating the fixed sheave from the spider or damage to the movable sheave may occur. 7路4
DRIVE CONVERTER DISASSEMBLY
1. Retainer Washer 10. Remove the roller assemblies from the movable sheave by removing the bolts and retainer washers.
1. Retain er Was her To asse mble t he drive converter: 1. Assemb le th e ro ll er assembli es, pin s, and spacers and pl ace them into th e movab le sheave w it h the pi ns in th e pin grooves. Install the retaine r was hers and bo lts. Torque the bolts to 120 in. Ib (1 .4 kg-m). 2. Afte r torquing th e bolts, chec k th at th e rollers rotate free ly.
1. Weight Ramp Assembly 2. Pin 3. Spacers
5. Apply a non-permanent locking agent such as Loctite No. 271 (PIN 49075-3612) to the thread s of the fixed sheave. Place the fixed sheave on a work bench with the shaft up.
@ยงill
Do not allow the locking agent to get on any sliding surfaces
of the sheave_
1. Loctite 1. Ro ller Assembl y 2. Pin 3. Spacers
6. Align the arrows on the spider and movable sheave, then place the spider inside the movable sheave.
3. Assemb le the weight ramp assembli es, pin s and spacers and place t hem in t he sp ider w ith t he pins in t he pin grooves. Install the retainer washers and bo lts. Torque the bo lts to 120 in. Ib (1.4 kg-m ). 4. After torqu ing t he bo lts , chec k that the weight ramps move free ly.
1. Arrow
1. Arrow
DRIV E CONVERTER ASSEMBLY
7-5
DRIVE CONVERTER
19
I 18
4
I 5
(/ L%
12 9
I
~ I ' 9
~~~1 14
r 'f~
13
12 11
1. Bolt 2. Cover Assembly 3. Bushing 4. Movable Sheave Assembly 5. Bushing 6. Fixed Sheave 7. Retainer Washer 8. Pin 9. Spacer 10. Roller Assembly 7·6
DRIVE CONVERTER ASSEMBLY
6
(
11. 12. 13. 14. 15. 16. 17. 18. 19.
Nut Weight Ramp Weight Assembly Bolt Spring Spider Wear Guide Bolt Lockwasher
7. Lower th e movable sheave and spider onto th e shaft of th e fi xed sheave. Screw the sp id er onto th e fixed sheave until it is hand tight.
9. Insert the wear guides between the spider and movable sheave in the same manner as they were removed. 10. In stall the spring.
8. Clamp the drive converter holder in a bench vise. Slip the end of th e fi xed sheave through the center of the hold er and engage the hold er pins with the sid es of th e sp ider. Fit the drive converter socket onto th e end of th e fixed sheave and by turning it in the direction show n, tighten the sp id er and fixed sheave to 160 ft Ib (22 kg-m) of torque.
11. Align the arrow on th e converter cover with the arrow on the sp ider. Slide the cover down over the shaft of the fixed sheave. Squeeze th e cover and movable sheave together and install the six cover bolts. Torque the bolts to 120 in. Ib (1 .4 kg-m). NOTE: After the drive c lutch is assembled, allow 30 minutes for the locki ng agent to cure before operating the snowmob il e. 12. Clean oi l and dirt off the end of the crankshaft and the mating taper in the drive clutch with lacquer thinner or other cleaning agent which leaves no residue. 13. Position the drive c lutch on the crankshaft end. Install the bolt and lockwasher. Torque the bolt to 72 ft Ib (10.0 kg-m) wh il e holding the end of the fixed sheave with an open end wrench. 14. Install the drive belt. DRIVE CONVERTER CLEANING AND INSPECTION To clean the drive converter: NOTE: Accumu lation of foreign matter on s li ding surfaces or moving components w ithin converter will alter the sh ifting characteristics, which will aff ec t vehicle p e rform ance throughout the sh iftin g range. Contamination of converter components may cause the vehicle to display any of the following symptoms: a. Bog (hesitation) during acceleration. b. Poor back shift. c. Low top speed .
MOVING COMPONENTS
SLIDING SURFACES
DRIVE CONVERTER ASSEMBLY
7-7
1. Remove all grease and dirt by WiPing the components with a rag dipped in cleaning solvent. Dry parts with compressed air or a clean cloth.
2. Inspect the wear guides for wear, cracks or other damage. Replace as required.
DO NOT soak components with bushings in cleaning solvents, since some solvents can damage the bushing resulting in converter failure. 2. Remove drive be lt accumulations from th e stationary sheave and movable sheave with cl eaning so lvent. 3. Remove rust and drive belt acc umulat ions from th e steel shaft of the stat ionary sheave with cleaning solvent or a fine grade of stee l wool. 4. Thoroughly clean pins and bushings for ro ll er and ramp weight assembl ies. To inspect th e drive converter: 1. Check the cover bushing for excessive wear. A quick check can be made by placing the cover over the fixed sheave and rocking it on th e shaft. If excess ive wobbling is noticed, th e bushing shou ld be replaced . For an ac curate check, measure the outs id e diameter o f the fixed sheave shaft and the inside diameter of the bush ing. If the difference between the two reading s is 0.02 in . (0 .5 mm) or larger, replac e the bushing.
-~ 3. Slide the movable sheave onto the fixed sheave and check the bushing for excessive wear by wobbling the sheave from side to side. If movement is excessive, replace the bushing. For an accurate measurement, measure the diameter of the shaft on the fixed sheave and the inside diameter of the bushing in the movable sheave. If the difference between the two readings is 0.02 in. (0.5 mm) or larger, replace the bushing. NOTE: Bushings used in the converter are th e sp lit type. During in spect ion do not mistake the bus hing li ne as a crack.
NOTE: Bush ings used in the converter are the split type. During inspection do not mistake the bushing lin e as a crack.
1. Removing Bush in g
1. Removing Bushing
1. Installing Bushing
7-8
DRIVE CONVERTER CLEANING AND IN SPECTION
1. Installing Bushing
4. Inspect the moveable sheave retainer washers, pins, spacers and rollers. Replace any part that shows signs of excessive wear or damage.
5. Inspect the sp id er assemb ly retainer washers, pins, spacers and ramp weights. Replace any part that shows signs of excessive wear or damage.
a. Spacers - Measure thickness with a micrometer. They should measure 0.032 ± 0.004 in. (0.8 ± 0.1 mm). Replacement is required when they measure 0.016 in. (0.4 mm) or less.
a. Spacers - Measure thickness with a micrometer. They shou ld measure 0.032 ± 0.004 in. (0.8 ± 0.1 mm). Replacement is required when they measure 0.016 in. (0.4 mm) or less.
b. Pins and Rollers - Maximum clearance allowed between pin and roller is 0.02 in. (0.5 mm).
b. Pins and Ramp Weights - Maximum clearance allowed between pin and ramp bushing is 0.02 in. (0.5 mm).
RAMP WEIGHT AND BOLT COMBINATIONS RAMP WEIGHT POSITIONING
~ ~~\ \
~ ~.
NUT
~
~ ~ BOLT , ~Rl ~ WEIGHTS
\ y~~)
RAMP
~ ~WEIGHTS
CORRECT
INCORRECT
~,
~~
~
~ BOLT
,
NUT
~
Rl
~~
~
WEIGHT
RAMP
WEIGHTS
DRIVE CONVERTER CLEANING AND INSPECTION
7-9
DRIVE CONVERTER RAMP WEIGHT COMBINATIONS USING BOLT PART NUMBER 92001·3015 (6 x 16 mm STEEL)
Total Ramp Weight·Grams
Number of Weights Installed
Weight (0.5 gram each) 0.031 in. (0.8 mm) thick Part Number 13042·3001
55.1 grams 55.6 grams 56.1 grams
0 1 2
0 0.5 gram 1.0 gram
Bolt 6 x 16 mm Part Number 92001·3015
Nut Special Part Number 92019·008
Ramp Weight Part Number 39152-3008
5.3 grams 5.3 grams 5.3 grams
2.3 grams 2.3 grams 2.3 grams
47.5 grams 47.5 grams 47.5 grams
lE:~ill To permit proper installation and security of n~t, do not exc.eed a maximum of 2 in· stalled weights Part Number 13042·3001 (0.031 In., 0.8 mm thick) on 6 x 16 mm bolts. NOTE: In stalled weight positioning must not exceed 0.5 gram difference on each side of ramp as shown in illustration.
DRIVE CONVERTER RAMP WEIGHT COMBINATIONS USING BOLT PART NUMBER 110G0620 (6 x 20 STEEL)
Total Ramp Weight-Grams
Number of Weights Installed
55.8 56.3 56.8 57.3 57.8 58.3 58.8 59.3
0 1 2 3 4 5 6 7
Weight (0.5 gram each) 0.031 in . (0.8 mm) thick Part Number 13042-3001 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
gram gram grams grams grams grams grams
Bolt 6 x 20 mm Part Number 110G0620 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
grams grams grams grams grams. grams grams grams
Nut Spec ial Part Number 92019-008 2.3 grams 2.3 grams 2.3 grams 2.3 grams 2.3 grams 2.3 grams 2.3 grams 2.3 grams
Ramp Weight Part Number 39152-3008 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5
grams grams grams grams grams grams grams grams
[~§illTO permit proper installation and security of n~t, do not exc.eed a maximum of 7 in· stalled weights Part Number 13042·3001 (0.031 In., 0.8 mm thick) on 6 x 20 mm bolts. NOTE: One weight Part Number 13042·3002 (0.062 in., 1.6 mm thick) may be substituted for two weights Part Number 13042·3001 (0.031 in., 0.8 mm thick) providing that installed w eight positioning does not exceed 0.5 gram difference on each side of ramp as shown in illustrat ion.
DRIVE CONVERTER RAMP WEIGHT COMBINATIONS USING BOLT PART NUMBER 92001·3003 (6 x 20 mm ALUMINUM)
Total Ramp Weight-Grams
Number of Weights Installed
51 .9 grams 52.4 grams 52.9 grams 53.4 grams 53.9 grams 54.4 grams 54.9 grams 55.4 grams
0 1 2 3 4 5 6 7
Weight (0.5 gram each) 0.031 in. (0.8 mm) thick Part Number 13042-3001 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
gram gram grams grams grams grams grams
Bolt 6 x 20 mm Part Number 92001-3003 2.1 grams 2.1 grams 2.1 grams 2.1 grams 2.1 grams 2.1 grams 2.1 grams 2.1 grams
Nut Special Part Number 92019·008 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3
grams grams grams grams grams grams grams grams
Ramp Weight Part Number 39152-3008 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5
grams grams grams grams grams grams grams grams
[~1f!I[[}TO permit proper installation and security of n~t, do not exc~ed a maximum of 7 in· stalled weights Part Number 13042·3001 (0.031 In., 0.8 mm thick) on 6 x 20 mm bolts. NOTE: One weight Part Number 13042·3002 (0.062 in., 1.6 mm thick) may be substituted for two weights Part Number 13042·3001 (0.031 in ., 0.8 mm thick) providing that installed weight positioning does not exceed 0.5 gram difference on each side of ramp as shown in illustration.
7-10
RAMP WEIGHT AND BOLT COMBINATIONS
DRIVE CONVERTER RAMP WEIGHT COMBINATIONS USING BOLT PART NUMBER 110G0628 (6 x 28 mm STEEL)
(
Total Ramp Weight-Grams
Number of Weights Installed
57.1 grams 57.6 grams 58.1 grams 58.6 grams 59.1 grams 59.6 grams 60 .1 grams 60.6 grams 61.1 grams 61 .6 grams 62.1 grams 62.6 grams 63.1 grams 63.6 grams 64.1 grams 64.6 grams 65.1 grams 65.6 grams
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Weight (0.5 gram each) 0.031 in. (0.8 mm) thick Part Number 13042-3001 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5
gram gram grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams
Bolt 6 x 28 mm Part Number 110G0628 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3 7.3
grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams
Nut Special Part Number 92019-008 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3
grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams
Ramp Weight Part Number 39152-3008 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5 47.5
grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams grams
~[] To permit proper installation and security of m.~t, do not exc~ed a maximum of 17 in· stalled weights Part Number 13042·3001 (0.031 m., 0.8 mm thick) on 6 x 28 mm bolts.
NOTE: One weight Part Number 13042-3002 (0.062 in ., 1.6 mm thick) may be substituted for two weights Part Number 13042-3001 (0.031 in., 0.8 mm thick) providing that installed weight positioning does not exceed 0.5 gram difference on each side of ramp as shown in illustration.
RAMP WEIGHT AND BO LT COMB IN ATIONS
7-11
DRIVEN CONVERTER DISASSEMBLY AND ASSEMBLY
Refer to pages 3-86 and 3-87 in t he SA340-A4, SB440-A4, SC340-A 1 Shop Manual for driven converter disassemb ly, clean ing , inspection and reassembly procedures.
Use the illustration below, however, and not the illustration in the base shop manual when assembling a 1981 Drifter driven converter. The 1981 models include a washer (No. 13) which is not used in prior Drifter models.
DRIVEN CONVERTER
._____11
17
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
7-12
Spacer, SB340 only Bearing Support, SB440 only Clevis Pin , SB440 only Bolt, SB440 only Support Clevis, SB440 only Retaining Ring Washer Spacer, SB440 only Spring Pin Torque Ramp Shoe Ramp Slide
11. 12. 13. 14. 15. 16. 17. 18. 19.
Movable Sheave Movable Bushing Washer Woodruff Key Fixed Sheave Brake Disc Socket Head Screw Converter Key Converter Shaft Spacers
DRIVEN CONVERTER DISASSEMBLY AND ASSEMBLY
ENGINE MUFFLER REMOVAL AND INSTALLATION
2. Disconnect bracket.
rubber
band
from
oil
tank
To remove the muffler: 3. Twist si lencer and seal off carburetor. 1. Disconnect two long springs securing muffler to muffler bracket. 2. Disconnect three short spri ngs securing muffler to exhaust manifold.
[ยง]ill ~~;~~ r~i~e~~:r e~eg~noeve~it~roa~ the carburetor_ Poor engine performance and engine damage will result
4. Check that si lencer spring washer on righ t s ide of carburetor holder is pointing down.
{I~ !~:~~~c~rl sr:~~~ ~~~=~~~o~~~ cause it to rub against tank_ Eventually, this may cause a hole in tank and subsequent loss of oil.
To install air intake silencer reverse the removal procedure. NOTE: Be sure the plastic adapter is in sta lled on the carburetor before installing the silencer to prevent breakage of the econo jet fitting.
1. Long Springs 2. Short Springs
~~!~ ~1~i~~ei~S~~~~~gt~=~ t~~ r~~~~~
3. Pull exhaust pipe out of boot and remove muffler.
seal between the intake silencer and carburetor is properly positioned and secure_
To install the muffler reverse the removal procedure. NOTE: Apply silicone sealant to the muffler and exhaust manifold mating surfaces to prevent exhaust leakage. SILENCER REMOVAL AND INSTALLATION
To remove the air intake s il encer: 1. Disconnect spring from silencer washer on left side of carburetor.
spring
1. Plastic Adapter AIR SHROUD REMOVAL AND INSTALLATION
1. Spring 2. Left Spring Washer 3. Right Spring Washer
On the drifter the main upper air shroud is rubber. The intake and e~haust side ai r shrouds are metal. MUFFLER REMOVAL AND INSTALLATION
8-1
To remove the main upper shroud: 1. Remove spark plug caps. Open converter belt guard.
@~!1m ~~:~u~~;~::~~ S~~u~ p~~~ ~~Sk
and forth while pulling cap straight upward. Do not attempt to twist or force plug cap off by pulling on lead wires as this will damage the connection.
1. Exhaust Manifold 2. Exhaust Air Shroud To remove in take s ide shroud:
2. Remove bolts, washers and shroud plates securing upper shroud to engine. Note that each mounting hole in shroud has a collar. 3. Remove air shroud.
1. Upper Shroud 2. Shroud Plate To remove exhaust side shroud: 1. Remove muffler. Remove four nuts and spring washers from exhaust manifold studs. Remove exhaust manifold, and exhaust air shroud. Discard gaskets. 8-2
AIR SHROUD REMOVAL
1. Remove air intake s il ence r. See Si lencer Remova l and In sta ll at ion. 2. Loosen carb uretor holder c lamp and pu ll carburetor out of ho lder. 3. Remove oil inject ion nozzles and check va lves from intake man ifo ld.
1. Oil Injection Nozzles 2. Check Valves 4. Remove four bo lts from intake manifold and remove intake air shroud , insulator blocks and manifold . Discard gaskets. NOTE: Cover the nozzles with a plastic bag or other suitable cover to prevent fore ign matter from entering t he system.
To install the air shrouds:
rEI~!Jill
~a~:I~~~~~e~o~!~~~n~~k~e:~~
exhaust manifold bolts must be torqued before torquing the cylinder head nuts. NOTE: Always use new gaskets when installing the exhaust manifold, intake manifold and oil injection nozzles to prevent leakage. 1. Position exhaust air shroud on studs with exhaust gaskets on both sides. Install exhaust manifold and torque mounting nuts to 12 ft Ib (1.7 kg -m). Reinstall muffler.
2. Push mounting ¡ bolts through intake manifold. Stack gaskets, insulator blocks and intake air shroud on bolts as shown and install all parts as an assembly on cylinders. Torque mounting bolts to 72 in. Ib (0.8 kg-m). 3. Install oil injection nozzles and check valves on intake manifold. Torque nozzles to 10 in. Ib (0.1 kg-m). 4. Install carburetor in holder and tighten clamp securely. Reinstall air intake silencer. 5. Install upper air shroud. Fit internal shroud dampers into cylinder head and cylinder fins. Position collars in shroud mounting holes and install bolts, washers and shroud plates. Torque bolts to 60 in. Ib (0.69 kg-m). NOTE: Apply Loctite or other non-permanent locking agent to the main upper air shroud bolts to prevent them from loosening.
1. Exhaust Gasket
1. Upper Shroud 2. Shroud Plate 6. Reinstall spark plug caps. Close and latch converter belt guard. FAN HOUSING REMOVAL AND INSTALLATION To remove the fan housing: 1. Remove oil tank and bracket assembly. See Oil Tank Removal and Installation. 2. Remove manual starter. See Starter Assembly Removal and Installation in Section 3 of SA340-A4, SB440-A4, SC340-A 1 Shop Manual. 1. Insulator Block 2. Intake Gasket
3. Unscrew bolts securing starter pulley cup and lower fan pulley to flywheel, then remove cup and fan belt pulley. AIR SHROUD INSTALLATION
8-3
NOTE: When removing nut from stud on the lower front of the fan housing, turn handlebars to the left. Insert a short (5 -1/4 to 5-112 in. long) 13 mm twelve point box wrench, under engine from the flywheel end , and remove nut.
4. Remove bolts securing fan housing to intake, top, and exhaust air shrouds. 5. Remove screws securing COl igniter unit and wiring harness connector to fan housing. 6. Unscrew four nuts from studs securin g fan housing to crankcase and slide fan housing from engine assembly.
1. Fan Housing
FAN HOUSING
1. 2. 3. 4. 5. 6. 7.
8-4
Plain Washer Spring Washer Pan Head Screw Fan Screen Nut Fan Pulley Fan Drive Pulley
8. 9. 10. 11 . 12. 13. 14.
FAN HOUSING REMOVAL
Fan Housing Dowel Pin Nut Spring Washer Plain Washer Stud Cooling Fan
15. Woodruff Key 16. 17. 18. 19. 20.
Ball Bearing Circlip Shim, 1.0 mm thick Pulley Shim , 0.6 mm thick (AR) Spring Washer
To install the fan housing: 1. Install fan housing on crankcase. Secure using nuts and washers previously removed. Torque nuts to 11 ft Ib (1.5 kg-m). 2. Install CDI igniter unit and wiring harness connector on fan housing and tighten screws securely. 3. Install bolts to secure fan housing to intake, top , and exhaust air shrouds. NOTE: Apply Loctite to air shroud bolts. 4. Install fan belt, fan drive pulley and starter cup to flywheel. Secure using three bolts and lock washers. Tighten bolts evenly to prevent distortion of pulleys . NOTE: Install fan drive pulley with machined shoulder toward flywheel. 5. Check fan belt tension. Refer to Fan Belt Tension Adjustment in Section 2 of base Shop Manual.
NOTE: Cover the nozzles with a plastic bag or other suitab le cover to prevent foreign matter from entering the system. 4. Remove four bolts from intake manifold and remove manifold. 5. Clean gaskets and gasket material from oil injection nozzles and check valves, manifold, insulator blocks and intake side air shroud. To install the intake manifold: If cylinders or cylinder heads have been removed, the intake manifold bolts must be torqued before torquing the cylinder head nuts. NOTE: Always use new gaskets when installing the intake manifold and oil injection nozzles to prevent leakage. 1. Push mounting bolts through intake manifold. Stack gaskets and insulator blocks on bolts as shown. Install assembly on cylinders. Torque mounting bolts to 72 in. Ib (0.8 kg-m).
6. After fan belt tension is correct, install manual starter. 7. Reinstall oil tank and bracket assembly. INTAKE MANIFOLD REMOVAL AND INSTALLATION To remove the intake manifold: 1. Remove air intake silencer. See Silencer Remova l and Installation. 2. Loosen carburetor holder clamp and pull carburetor out of holder. Remove two bolts securing carburetor holder to in take manifold.
1. Insulator Block 2. Intake Gasket 3. Intake Gasket
2. Install oil injection nozzles and check valves on intake manifold . Torque nozzles to 10 in. Ib (0.6 kg-m).
1. Oil Injection Nozzles 2. Check Valves
3. Install carburetor holder on intake manifold and torque bolts to 40 in. Ib (0.6 kg-m). Be sure to position silencer spring washer on right side of carburetor holder so it points down.
FAN HOUSING INSTALLATION
8-5
5. Carefully remove cylinders from crankcase studs. Hold piston during cylinder removal to prevent piston from suddenly contacting studs or crankcase.
NOTE: Before lifting the cylinder off the piston, raise it just enough to push a shop towel into the crankcase opening. This will prevent any foreign material from .falling into the crankcase.
1. Silencer Spring Washer 2. Oil Tank
6. Remove and discard cylinder base gaskets. Scrape any gasket material from crankcase and cylinder.
[~:~[l !~~~~~C~rl Sr:~~? ~~~:t~~~o::~~ cause it to rub against tank. Eventually, this may cause a hole in tank and subsequent loss of oil.
4. Install carburetor in holder and tighten clamp securely. 5. Install air intake silencer. CYLINDER REMOVAL AND INSTALLATION NOTE: To service the cylinders and pistons, engine removal is not required.
To install the cylinders: To remove the cylinders: 1. Remove main upper air shroud, intake side air shroud and exhaust side air shroud. See Air Shroud Removal and Installation. 2. Remove spark plugs. Mark heads, cylinders, and crankcase for reference in reassembly. 3. Remove eight nuts, lockwashers and washers securing cylinder heads to cylinders. Carefully remove cylinder heads and gaskets. Discard gaskets.
1. Install new crankcase.
cylinder
base
8¡6
INTAKE MANIFOLD INSTALLATION
on
2. Apply a light coat of oil to bearing on each end of rod, inside of cylinders and outside of pistons. Align piston rings with locating pins on piston and using ring compressor tool No. T57001¡130 compress the rings and install cylinders over pistons.
@~:illm :ii~~07~~~~~n~u:i~~Ii~~t:~:cr:~ ring groove to prevent breakage.
4. Gently tap cylinder with a soft mallet to release seal.
gaskets
3. Install new head gaskets on cylinders. 4. Set cylinder heads in place on correct cylinders and loosely install the eight nuts, washers and lockwashers. Do not tighten cylinder nuts until intake and exhaust manifolds have been installed. 4. Install air shrouds.
I
5. Install spark plugs and torque to 20 ft Ib (2.77 kg-m). PISTON REMOVAL AND INSTALLATION
To remove the pistons: 1. Remove cylinders. See Cylinder Removal and Installation. 2. Make sure crankcase is sealed with shop towel. Then remove piston pin circlips. Discard circlips.
4. Using a ring expander tool remove rings from piston. NOTE: Do pistons.
not
interchange rings
between
To install the pistons: 1. Install piston rings with markings upward.
3. USing piston pin puller tool No. T57001-910 remove piston pins from pistons and remove piston from connecting rod. NOTE: Keep each piston, piston pin and bearing together as a set. Mark pistons left and right to assure correct reassembly.
S8340
S8440
2. Apply light coat of oil to piston pin needle bearings and insert need le bearings into upper connecting rod. 3. Install piston to connecting rod with arrow pointing toward exhaust side. In sert piston pin and secure piston pin using new circlips.
CCB:~
New circlips must be used to prevent serious engine
damage_
4. Reinstall cylinders.
CYLINDER INSTALLATION
8-7
CYLINDER HEAD/CYLINDER/PISTON INSPECTION Cylinder Head 1. Remove excessive carbon from inside cylinder head using a nonferrous carbon scraper, or cylinder head brush. 2. Inspect coo li ng fins for damage.
3. Wash cylinder head in so lvent and blow dry using compressed air. 4. Place a straight edge across the gasket surface of the head to detect any warpage. Measure in several spots. If slight distortion is present it can be corrected by placing No. 400 sandpaper on a surface plate and rubbing head in a c ircular motion on the sandpaper to remove high spots. NOTE: Dying the gasket surface before you begin will indicate high spots after some sanding. Cylinder
1. Check the cy lin der for damaged or broken fins. 2. Thoroughly clean all carbon deposits from exhaust ports and cylinder walls. 3. Check cy linder wall for excessive scoring.
4. Using an inside micrometer check cylinder bore for out-of-round or taper condition. NOTE: To check for out-of-round of the cylinder bore move the micrometer in a circular direction 90 at a time. The difference in mea'surements obtained should not exceed 0.002 in. (0.05 mm).
5. Using an inside micrometer check the cylinder bore for wear. If the cylinder diameter exceeds the service limit, replace the cylinder. 6. Examine the cylinder wall for excessive wear, scoring or deep lines, and replace cylinder if necessary. The cylinders in this engine are aluminum with chrome plated bores. They cannot be honed or rebored . CYLINDER BORE DIAMETER
0
NOTE: To check for taper of the cylinder bore, move the micrometer from the top to the bottom of the cylinder. The difference in the measurements obtained (between top and bottom) should not exceed 0.002 in. (0.05 mm).
STANDARD (N EW)
SERVICE LIMIT (U SED)
S8340
2.3624 - 2.3632 in. (60.005 - 60.025 mm)
2.366 in. (60.10 mm)
S8440
2.6774¡2.6781 in. (68.005 - 68.023 mm)
2.681 in. (68.10 mm)
MODEL
Piston 1. Remove all carbon from piston dome, ring grooves and piston skirt. NOTE: If piston dome or skirt is scored or pitted from overheating , replace piston and piston rings. 2. Using a micrometer measure the outside diameter of each piston at right angle to piston pin hole and 3/16 in. (4.76 mm) from bottom.
8-8
CYLINDER HEAD INSPECTION
I
PISTON PIN DIAMETER
PISTON SK IRT DIAMETER
MODEL
SERVICE LIMIT (U SED)
STANDARD (NEW)
S8340
2.3607 - 2.3614 in. (59.961 - 59.980 mm)
2.355 in . (59.82 mm)
S8440
2.6744 - 2.6752 in. (67.929 - 67.950 mm)
2.670 in . (67.82 mm)
( Should the measured piston skirt diameter be less than the service limit specified in the above table, replace the piston . Measure the skirt diameter of the new piston to be used, and subtract the figure obtained from the measured cylinder bore diameter. Piston skirt-to-cylinder wall clearance must be between:
MODEL ALL
STANDARD (NEW) 0.6297 - 0.6299 in. (15 .994 - 16.000 mm)
SERVICE LIMIT (USED)
I
0.628 in. (15.98 mm)
4. Measure piston pin bore diameter by insert ing a snap gauge approximately 1/4 in. (6.35 mm) into piston pin bore. Remove snap gauge and measure it using a 1 in. outside micrometer. If measured diameter is greater than serv ice limit, replace piston.
PISTON SKIRT CLEARANCE S8340 MODEL
0.001 to 0.003 in. (0.0254 to 0.0762 mm)
S8440 MODEL
0.002 to 0.004 in. (0.050 to 0.101 mm)
If this computed difference is greater than the specified tolerance, a new cylinder w ill also be needed.
(
3. Check piston pin for wear or damage. Using a 1 in . outside micrometer measure piston pin diameter. Should piston pin diameter be less than specified service limit, pin and needle bearing must be replaced.
PISTON PIN BORE DIAMETER
MODEL ALL
STANDARD (NEW)
SERVICE LIMIT (USED)
0.6299 - 0.6301 in. (15.999 - 16.005 mm)
0.633 in. (16.08 mm)
PISTON INSPECTION
8-9
5. Check needle bearings and needle bearing cage for wear or overheating. 6. Check piston ring gap by inserting piston ring into cylinder horizontally. In se rt a feeler gauge in the opening between the ends of the piston ring. If maximum ring gap exceeds the service limit wh en measured at the top and the bottom of the cylinder bore, repl ace the rings.
PISTON RING/GROOVE CLEARANCE TOP AND BOTTOM MODEL S8340
STANDARD (NEW)
SERVICE LIM IT (U SED)
0.0010 - 0.0036 in. (0.03 - 0.09 mm)
0.008 in. (0 .19 mm)
NOTE: Th is procedure app li es only to the SB340 pistons which use a Dykes top ring and a rectangu lar second ring. This procedure does not apply to the SB440 pistons whi c h use keystone rings. ENGINE REMOVAL AND INSTALLATION Remova l
1. Remove the hood.
PISTON RING END GAP
MODEL
STANDARD (NEW)
SE RVIC E LIMIT (U SED)
S8340
0.006¡0.014 in . (0 .15 - 0.35 mm)
0.028 in . (0 .7 mm)
S8440
0.008 - 0.016 in. (0 .2 - 0.4 mm)
0.028 in. (0 .7 mm)
7. On th e SB340, install the piston rings in their grooves. Take several measurements with a f ee ler gauge to determine ring to groove clearance. If the clearance exceeds the servic e limit, replace the ring s and remeasure ring to groove clearance. If th e dimension still exceeds the service limit, replace the piston. 8-10
PISTON IN SPECTION
2. Remove th e retainer pins, drive belt guard and drive belt. 3. Remove the muffler. 4. Remove the intake s ilence r. Loosen th e carburetor holder c lamp and pull the carburetor out of the holder. 5. Remove th e oil tank and bracket assemb ly. Disconnect the oil pump cab le and oil supply tube from th e oil injection pump . 6. Remove the spark plug caps. Remove the CD I igniter unit and wire harn ess conn ector from the fan housing. Unplug the wire harness connecto r. 7. Remove the starter handle from the rope gu ide on the steering mount. 8. Disconnect the fue l impulse tube from the engine crankcase.
9. Remove the four engine mounting bolts securing the engine mount plate to the front frame. Remove the washers, rubber mounts and spacers.
~~~:ITill
~~:;~:enltif!nt~~~al C~~a~kk~~:f~
equally at each end during removal process_
10. Remove the engine and mount plate from the snowmobile. Installation NOTE: Prior to installing the engine, make a crankcase pressure tes t to be sure there are no air leaks. Install the eng ine by reversing the removal procedures along with the following :
o
After step 9 check converter center-tocenter distance, offset and parallel ism before tightening engine mounting bolts. See Converter Alignment.
o
After step 3 bleed the oil pump supply tube, sychronize the oil pump and carburetor and purge air from the oil pump outlet tubes. See Bleeding Oil Pump Supply Tube, Oil Pump Cable Adjustment, and Purging Air From Oil Pump Outlet Tubes.
NOTE: Adjust the id le speed after purging air from the oil pump outlet tubes. CRANKSHAFT REMOVAL AND INSTALLATION To remove the crankshaft: 1. Remove the engine. See Engine Removal and Installation .
To install the crankshaft: 1. Place the crankshaft assembly into the crankcase. Be sure the dowel pin on labyrinth seal is properly located in the notch of the upper crankcase half. Apply a liberal amount of oil to all the bearings on the crankshaft assembly. Be sure that the lips of the oil seals and the thrust washers near the center main bearings are properly seated in the grooves in the upper crankcase half.
2. Remove the fan housing. See Fan Housing Removal and Installation. 3. Remove the oil injection pump. See Oil Pump Removal and Installation. 4. Remove the pistons. See Piston Removal and Installation. 5. Remove the flywheel and stator assembly. Refer to Section 3 in the SA340-A4, SB440A4. SC340-A 1 Shop Manual. 6. Remove the two bolts and the hole cover from the crankcase. 7. Remove the bolts securing the crankcase halves together. Remove the lower crankcase from the upper crankcase.
1. Dowel Pin 2. Labyri nth Seal
8. Use a mallet or a soft hammer to break the crankcase seal and separate the two halves. 9. Lift the crankshaft assembly straight up and out of the crankcase.
ENGINE REMOVAL AND INSTALLATION
8-11
2. Apply a continuous thin bead of Kawasaki Sealer to th e upper crankcase half.
\
3. In stall the lower half of the crankcase. Torque the bolts in a criss-cross pattern as shown. Bolts numbered one through eight torque to 16 ft Ib (2.2 kg -m). Bolts numbered nine and ten torque to 70 in. Ib (0.8 kg -m ).
3. To check the connecting rod radial clearance, set up the crankshaft as shown with a dial indicator. With the connecting rod perpendicular pull the connecting rod up toward the dial indicator. Then push the connecting rod down towards the crank pin . The difference between these two readings is the radial c learance . The allowable radial clearance is 0.0008 to 0.0012 in. (0.021 to 0.031 mm), if the radial clearance exceeds these dimens ions replace the crankshaft assembly.
I'
4. To comp lete engine assembly and in stallation in the frame, reverse steps 1 through 6 in Crankshaft Removal. CRANKSHAFT INSPECTION
4. If the outer bearings, seals or oil pump drive gear require replacement, remove these parts with a bearing puller. Never hammer on the bearings or crankshaft to remove these parts. When installing the bearing or gear, heat the parts with a heat gun or place on top of a light bulb. The parts will expand for easy installation.
1. With a feeler gauge check the side clearance of th e connect ing rods . The correct tol erance is 0.016 to 0.020 in. (0.4 to 0.5 mm). If the clearance is greater than thi s replace the crankshaft assembly. 2. Chec k the crankshaft cen ter bearings for wear or rough spots. If th e center bearings show wear or have rough spots replace the cranks haft assembly.
8-12
CRANKSHAFT REMOVAL AND INSTALLATION
5. If the outer bearings on either end have been replaced or a new oil pump drive gear has been pressed onto the crankshaft, the crankshaft must be checked for alignment. Place the crankshaft on V-blocks and use a dial indicator as shown to check the alignment. Maximum run out permissable is 0.002 in. (0.05 mm) TIR (Total Indicated Reading). If the run out exceeds this dimension replace the crankshaft assembly.
6. When reinstalling crankshaft into crankcase measure crankshaft end play. The end play can be measured with a feeler gauge between the center bearing and the thrust washer at the magneto end . The end play can also be measured by placing a dial indicator against one end of the crankshaft and moving it to one end of the crankcase and then back to the other end of the crankcase. The difference in the two readings is end play. Select a shim from the chart below to permit 0.003 to 0.005 in. (0.08 to 0.13 mm) end play. Maximum allowable end play is 0.015 in. (0.38 mm). Install the selected shim between the thrust washer and the crankshaft center bearing on the magneto end. Use only one shim to control crankshaft end play.
" SHIM " TO BE USED
I
Part No.
Thickness 0.0276 ± 0.0012 0.0315±0.0012 0.0354 ± 0.0016 0.0393±0.0016 0.0472 ± 0.0020
in . in. in . in. in.
(0.7t ± 0.03 (0.8t±0.03 (0.9t ± 0.04 (1 .0t±0.04 (1.2t ± 0.05
mm) mm) mm) mm) mm )
92025-3001 92025-3002 92025-3003 92025-3004 92025-3005
1. Shim 2. Insert Shim Here 3. Magneto End
CRANKSHAFT INSPECTION
8-13
)
CHASSIS SEAT REMOVAL AND INSTALLATION
TAILLAMP REMOVAL AND INSTALLATION
To remove the seat:
To remove the taillamp:
1. Open hood and disconnect taillamp wire con nector located in front of fue l tank beneath air intake silencer.
1. Remove seat. 2. Disconnect bunjie cords from storage case cover.
2. Remove two bolts from under frame at rear corners of seat. 3. Remove two round head screws from under frame at front corners of seat.
3. Remove two nuts from inside of cover. Pull taillamp wires through cover to remove taillamp. To install the taillamp reverse the removal procedure.
1. Round Head Screw 2. Bolt 4. Lift off seat. NOTE: Guide taillamp wires under fuel tank so connector does not become caught and possibly damage w ires. To install the seat: 1. Position seat on frame so you can feed taillamp wires under fuel tank. 2. Shift seat into proper position. Install two round head screws at front corners of seat. 3. Install bolts at rear corners of seat. 4. Torque screws and bolts to 35 in. Ib (0.4 kg-m). 5. Reconnect taillamp wire connector and make sure taillamp operates correctly.
SEAT REMOVAL AND INSTALLATION
9-1
..D
)
STORAGE PREPARATION FOR STORAGE
1. Thoroughly clean the snowmobile by hosing off all dirt and grime from the suspen sion and the engine compartment.
5. Position th e snowmobile on its sid e on a protec tive surface. Drain the fuel from th e carbure tor through the vent tube as show n. Pos it io n th e vent tube into the retaine r on th e carburetor properly after all the fu el has been drained.
2. Remove the drive belt. 3. Siphon the fuel from the fuel tank. 4. To prevent rust, internal eng ine components must be coated with oil. This procedure is called " Engine Fogging." a.
Remove tube from carburetor to the primer pump at the primer pump fitting .
b.
Submerge open end of tube into container of Kawasaki Snowmob ile Oil.
~
~e~~~;r:~r~~;~~~e~:;~~~::ab:~
may cause restrictions in carbur e t or passageways and jets. This can lead to lean fuel-to-air intake mixtures that may cause severe engine damage.
1. Vent Tube 1. Primer Pump 2. Primer to Carburetor Tube 3. Container of Kawasaki Snowmobile Oil c. Start eng ine and allow it to run at idle. Siphon action will draw oil into the carburetor lubricating the engine internally.
I
WARNING â&#x20AC;˘ !o prev~nt severe ~ers~nal in-
. ~ JUry while the engme IS running, stay clear of moving parts and do not contact the hot exhaust system components.
6. With a rag or mask ing tape, plug the openings of the air intake silencer and muffl er. 7. Check the chaincase lubricant level. 8. Replace th e fuel filter. 9. Drain and refill engine gearcase. 10. The driven converter sheaves are steel. To prevent ru st ing, apply a light coat of oil to both driven converter sheaves.
d.
Because fuel tank has been drained, the engine will stop when fuel in the fuel system has been consumed.
DO NOT LUBRICATE THE DRIVE CONVERTER.
e.
Reinstall primer tube onto primer fitting and continue with preparation for storage.
11 . Block the rear of the snowmobile off the ground to remove weight from the suspension.
PREPARATION FOR STORAGE
10-1
12. Loosen the rear axle adjusting bolts to relieve track tension. 13. If paint is scratched, use touch-up paint to restore original finish, and wax the hood and chassis using an automotive type wax. 14. Cover the snowmobile to protect it from dirt and dust. 15. Protect track clips from rusting and extend slide wear strip service life by applying a moisture remover or anti-rust product (such as WD-40, LPS or equivalent) to all exposed areas of each track clip. REMOVAL FROM STORAGE 1. Fill the fuel tank with fresh fuel. 2. Fill the oil tank with Kawasaki Snowmobile Oil. 3. Check the oil tube connecting the oil tank to oil pump for air bubbles. If any air is present, bleed the oil tube and pump.
6. Using a suitable solvent, clean the converter sheaves. The converter sheaves must be clean and dry. 7. Install a new drive belt. Use the one removed last year as a spare. 8. Adjust the track tension. 9. Start the engi ne and rotate the t rack severa l revolutions, at low speed only, then stop engine and check the track alignment.
IWARNING I
To avoid possible personal injury, never allow anyone to stand behind snowmobile while track is rotating. Be sure engine has stopped before checking or adjusting track alignment. Remove all tools and foreign matter from track area before starting engine.
10. Lower the vehicle from blocks. 4. Check and fill engine oil pump gearcase. Use KAWASAKI ENGINE GEARCASE OIL. Level should be above center of sight gauge but not higher than the top. 5. Remove the plugs (masking tape or rags) from the air intake silencer and muffler outlet.
10-2
PREPARATION FOR STORAGE
11. Operate the snowmobile with the old spark plugs for the fi rs t 1/2 hour of operation. This will allow the oil used while storing the snowmobile to collect on the old spark plugs. Install new spark plugs, refer to the Specifications page for the recommended heat range and gap adjustment.
GENERAL TROUBLESHOOTING ENGINE 2. Idle screw adjusted incorrectly. Engine does not start - no spark_
3. Faulty fuel pump (check valve). 1. Key sw itch not ON or malfunctioning.
2. Emergency stop switch in OFF position or malfunctioning.
4. Belt dust restricting passages in carburetor bore.
5. Impulse line cracked, kinked or broken. 3. Spark plug(s) fouled, oiled or damaged. 6. Enrichener cable adjusted incorrectly.
4. Plug cap(s) damaged , leaking or shorted. 7. Oil seals leaking. 5. High tension wire(s) loose, grounded or shorted.
6. Weak flywheel magnets.
8. Air leak (pressure check engine). Engine develops power loss or runs on one cylinder.
7. Faulty exciter coil. 1. Fouled or faulty spark plug(s).
8. Faulty CD igniter. 2. Obstruction inside of muffler.
9. Faulty pulser coil. 3. In-line filter obstructed. Engine will not start - does not get fuel. 1. Fuel tank empty.
4. Excessive port(s).
carbon
buildup
2. Cracked , broken or pinched fuel line.
5. Damaged or worn rings.
3. Obstructed or damaged fuel pump filter.
6. Low crankcase pressure.
4. Carburetor jets plugged or fuel pump malfunctioning.
7. Damaged piston.
in
exhaust
8. Damaged head gasket.
5. Impulse line is cracked, broken or pinched. 6. Carburetor adjusted in correctly. Engine will not start - fuel will not ignite. 1. Air leak between carburetor, silencer seal or intake man ifold .
9. Broken (shorted) high tension leads. 10. Faulty spark plug cap(s). 11. Faulty COl igniter. 12. Faulty pulser coil. Engine overheats.
2. Carburetor adjusted incorrectly. 1. Incorrect spark plug(s). 3. Water in carburetor. 2. Cooling fins obstructed. 4. Engine is flooded . 5. No compression (worn or broken rings , scored piston, hole in piston or damaged cylinder). 6. Blown head gasket.
3. Air leak between carburetor, manifold or cylinders.
intake
4. Carburetor adjusted incorrectly. 5. Excessive carbon deposits in combustion chamber, exhaust port or muffler.
Engine does not idle or idle RPM fluctuates. 1. Air screw adjusted incorrectly.
6. Damaged rings caused by excessive carbon buildup.
GENERAL TROUBLESHOOTING - ENGINE
11-1
Engine backfires; has irregular running condi· tion.
2. Incorrect weights. 3. Dirty movable sheave.
NOTE: Engin e may eventually overheat. 4. Worn (flat spots) rollers and ramps . 1. High tension lead wire shorting out. 2. Fouled or incorrect spark plug(s) (heat range too hot).
5. Bushing in housing worn excessively on inside diameter. Maximum drive converter RPM too high.
3. Air leak between carburetor and intake manifold.
1. Incorrect weights.
4. Air leak between intake manifold and cylinders .
2. Short belt or incorrect center·to·center distance.
Engine four·cycles.
Maximum drive converter RPM too low.
1. Carburetor incorrectly adjusted.
1. Incorrect weights (too heavy).
2. Dirt between needle valve and valve seat.
2. Long belt or incorrect center·to·center distance.
Engine stops (suddenly) after running. Shifting too quickly. 1. Obstruction in fuel tank or fuel filter. 1. Incorrect weights (too heavy). 2. Fuel line obstructed or pinched. 2. Weak drive spring. 3. Faulty exciter coil.
3. Driven spring preload incorrect (too loose).
4. Spark plug bridged . Shifting too slowly. 5. Seized piston(s). 6. Seized crankshaft.
1. Incorrect weights (too light). 2. Spring too strong.
7. Faulty CDI igniter. 3. Driven spring preload too tight. 8. Faulty pulser coil. Engine stops (gradually) after running. 1. Obstruction in fuel tank or fuel filter.
Belt deposits on stationary sheave and movable sheave. 1. Wrong offset distance.
and
center·to·center
2. Fuel line obstructed or pinched. 3. Damaged head gasket(s).
Drive converter will not disengage at idle . engine starts hard and stalls because of belt drag.
4. Loose cylinder head. 5. Loose spark plug(s). DRIVE CONVERTER
1. Drive belt outside circumference below specifications. 2. Thickness of belt on inside diameter ex· ceeds specifications.
Drive converter engages before specified RPM. 1. Incorrect spring .
DRIVEN CONVERTER
2. Weak or damaged spring.
Low engine RPM yet belt shifts completely through driven converter operating range.
3. Incorrect weights . 1. Weak spring or broken spring . Drive converter engages after specified RPM. 1. Incorrect spring. 11·2
GENERAL TROUBLESHOOTING· ENGINE
High engine RPM yet belt takes too long to shift through driven converter range.
1. Incorrect spring - too heavy.
CHAINCASE
2. Dirt on movable or stationary sheave.
Rattle in chaincase.
3. Excessively worn movable or stationary sheave .
1. Incorrect chain tens ion. 2. Chain stretched beyond adjustable limit. Chain slippage.
DRIVE BELT
1. Incorrect chain tension .
Side of belt glazed or baked . caused by ex· cessive heat buildup. 1. Incorrect belt · excessive slippage. 2. Too much throttle applied under heavy load· excessive slippage . 3. Weak drive converter spring.
2. Chain stretched beyond adjustable limit. 3. Sprocket teeth worn . Chain slips off sprockets. 1. Incorrect chain tension. 2. Sprocket teeth worn.
4. Drive converter engagement RPM too low.
3. Sprockets misaligned.
5. Improper drive converter operation (stick· ing , etc .). 6. Drive converter and driven converter off· set/center·to·center is incorrect. 7. Oil or grease on drive converter or driven converter sheave surface .
TRACK Edge of track is frayed. 1. Track is misaligned.
Lugs worn off inside of belt. 1. Drive converter engages (engagement speed too high).
suddenly
2. Center·to·center distance too far apart or belt too short.
2. Track strikes rivets in tunnel , yet align· ment is correct. Track is grooved (worn) or burnt on inside sur· face. 1. Track tension is too tight.
Belt worn in one spot. 1. Track frozen to suspension , front drive or ground .
2. Rear idler whee ls do not turn or otherwise damaged. Track ratchets or hits on body tunnel (top).
2. Incorrect track tension. 1. Track tension is too loose. 3. Idle speed too high. Accelerated rail strip wear. 4. Improper operation of drive converter. 1. Slide rai I(s) bent. Cracks at base of belt lug. 2. Badly worn clip that contacts slide rail. 1. Continuous overrevving when snowmobile is operated.
3. Track is misaligned.
GENERAL TROUBLESHOOTING - DRIVEN CONVERTER
11 ·3
)
EMERGENCY STOP SWITCH ON WHITE il.ACK TO SPARK PLUGS
gl ~I
IGNITION COIL AND GOI
0
OFF
KEY SWITCH CONNEC TIONS KEY SWITCH CIRCUIT COMPLETED POSITIONS BETWEEN CONTACTS MARKED "OFF" G-M "RUN/LIGHTS" 8-L "RUN" NCNE
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IIlAKE LIGHT SWITCH
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ENGINE MAGNETO
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IIlOWN IINPUTI
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VOL TAGE REGULA TOR ~
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HEADLIGHT
)
FUEL AND OIL RECOMMENDATIONS OIL RECOMMENDATION We recommend using Kawasaki Snowmobile Oil. This oil is specially formulated to give minimum piston ring varnish and combustion chamber deposits along with excellent lubrication qualities. In an emergency situation when Kawasaki Snowmobile Oil is not available, a B.I.A. certified TC-W oil may be substituted. All certified oils will indicate the TC-W rating on the container. If the B.I.A. certification does not appear on the container, the oil MUST NOT BE USED. The use of lubricants such as "tune-up tonics" and "super oils" is NOT RECOMMENDED. Filling Oil Tank Fill oil tank with recommended oil. DO NOT ALLOW DIRT TO ENTER WHILE FILLING. Oil tank capacity is 2-1/2 quarts (2.37 liters).
quired after the initial three gallons of gasoline and oil mix have been consumed. 25 to 1 Gasoline to Oil Mixture. Break-in Only Oil
Gasoline
1 pint (U.S.)
3.0 gal. (U.S.) 2.6 gal. (Imp.)
I
1 pint (Imp.)
3.0 gal (Imp.) 3.8 gal. (U.S.)
Fuel Mixture (Standard) The fuel¡to-oil ratio required is automatically controlled at the engine oil pump. Adding Gasoline Antifreeze A major brand of Gasoline Antifreeze (such as Heet) should be added to the fuel mix by following the manufacturer's recommendations on the container for a proper mix ratio of fuel with antifreeze.
Check oil tank vent tube for: 1. Proper Routing - Sharp bends or kinks in the vent tube will reduce oil flow to the oil pump. 2. Tie Band Installation - Tie band may pinch off tube, reducing oil flow to the oil pump, if installed too tight. 3. Vent Tube Position - To prevent siphoning action, possible under certain conditions, position end of vent tube higher than top of oil tank. FUEL RECOMMENDATION Use leaded gasoline with a minimum PUMP POSTED ANTI-KNOCK INDEX NUMBER OF 89. DO NOT USE GASOHOL.
I WARNING
I
Gasoli~e fumes are heavier
than air and can become explosive if exposed to a pilot light from a furnace, hot water heater, clothes dryer, etc. Mix fuel or fill fuel tank only in an area that is well ventialted and free from pilot lights and sparks. Fuel Mixture (Break¡ln Only)
To insure adequate lubrication of internal engine components during early break-in, a 25-to-1 gasoline-to-oil ratio is recommended for the first three (3) gallons of gasoline. This ratio can be obtained by thoroughly mixing 1 pint (0.47 liter) of Kawasaki Snowmobile Oil with three (3) gallons (11.4 liters) of gasoline. Premixing gasoline and oil will no longer be re-
Each time fuel tank is filled, gasoline antifreeze must be added to fuel mixture. Moisture trapped in fuel system components (fuel tank, lines, fuel pump or carburetors) may freeze causing engine malfunction or damage_ Filling Fuel Tank Before removing filler cap from the fuel tank, remove any ice, snow, or water from around the fuel tank opening to prevent contamination of fresh fuel mixture.
I WARNING I-
Gasoline fumes are heavier than air and can become explosive if exposed to a pilot light from a furnace, hot water heater, clothes dryer, etc. Fill the fuel tank only in an area that is well ventilated and free from pilot lights and sparks.
Fill the fuel tank slowly and pour the fuel mixture into the tank using a funnel with a fine mesh screen . FUEL AND OIL RECOMMENDATIONS
13-1
)
)
)
SPECIAL TOOLS
Part No. 5700 1-3509 Flywhee l Pull er
iii Part No. 57001-3519 Track Clip Tool Assembly
Part No. 110P0620 Flywheel Puller Bolt
Part No. T56019-201 CD Ignition Tester
-
SEALER -
-
LIQUID GASKET
Part No. 92104-002 Liquid Gasket Sealer
Part No. 57001-983 Multimeter Tester
.----q Part No. 57001-3507 Suspens ion Spring Adjuster
SPECIAL TOOLS
14-1
II II " II II Part No. 57001-3506 Fan Pulley Holder Part No. T57001-130 Piston Ring Compressor Set
Part No. T57001-910 Piston Pin Puller
Part No. 57001-3515 Converter Alignment Gauge
NET ( M" )
Part No. 49075-3612 Loctite No. 271
Part No. 57001-3516 Drive Converter Holder
14-2
SPECIAL TOOLS
liII\ll l l l l llg Part No. 57001-3517 Drive Converter Pu IIer
Part No. 57001-3518 Drive Converter Socket
NOTICE TO DEALERS This manual is provided to ensure that the snowmobile is assembled correctly and given proper presale preparation. Your customer expects and deserves a safe, reliable snowmobile, and performance of the steps listed here is essential to that end. The selling dealer assumes sole responsibility for any unauthorized modifications prior to sale. REFER TO YOUR SNOW PRODUCTS BINDER FOR ANY SERVICE BULLETINS SPECIFYING FACTORY DIRECTED MODIFICATIONS WHICH MUST BE PERFORMED BEFORE THE SNOWMOBILE IS READY FOR SALE.
SAFETY AWARE N ESS
WARNING
I
()
This warning symbol identifies special in路 structions or procedures which, if not cor路 rectly followed, could result in personalin路 Jury, or loss of life
This caution symbol identifies special in路 structions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment.
u
Table of Contents Dealer's Assembly and Preparation Check List ..... .. ... .. ...... . ... ....... ... ... ii Assembly ................... . ...... . ...... ....... .......... .. ............ . .. 1 Uncrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Skis ............ . ........................ . ................ . .. ........ . . 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 Handlebar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Throttle and Brake Control Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tool Kit/Owner Manual and Safety Handbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Safety Labels.... .... . .. ....... . .... . .. .. ... ....... .. . . . ... . .. .. ... . .... 4 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Ride Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Handling Adjustment ... . ...... . . . . ... .. ... . ......... .. .. . . . .... ... . .. 5 Ski Spring Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 Steering Alignment . ... .. ... .. ... .. . . . .......... . .. .. ..... .. ....... . ..... 6 Wiring Harness .... . .. ... .. .. . .... .... ......... . . .... .............. . ..... 7 Chaincase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brake .. . .... ....... .. . ........ . .... . ...... . ... . ... . ... ... .. ............ 8 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Drive and Driven Converter Alignment . .. . . . . .................... . .... . ...... 9 Converter Center-to-Center Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Converter Offset Distance .. .. . . . . .. .. ..... . .. ..... .. ..... .. . . .... .. ... 10 Converter Parallelism ... .. . . ... ... .... . ........ . ...... ... . . . .......... 10 Engine Break-In ................... .... . . ..................... . ... .. ... .. 11 Oil Recommendation ... .. .. .... ................... ... ... .. . ..... . .... .. . . 11 Filling Oil Tank .. . ...... . ..... .. .............. . ......... . ... ... ... . 11 Fuel Recommendation .. .. . ..... .. ................. ... .. . ... .. . ..... . . .. . 11 Fuel/Oil Mixture (Break-In Only) ... .... .......... . ...................... 11 Fuel/Oil Mixture (Standard) .......... . . .... . ... . ....... . .... . . ... ... . .. 12 Adding Gasoline Antifreeze .... .. ..... . ... . .... .. .... ........... . ... .. 12 Filling Fuel Tank .............. ... .... ...... ... .. ....... . ... .. . ... .. .. 12 Engine Gearcase Lubrication .............. . ... .. ... .... ........ .. .. ....... 12 Oil Injection System .......... .... .. .... ... ... ... . .. . ....... .. .. .. .. .. .. .. 13 Bleeding Oil Pump Supply Tube .... . ......... . ...... ... .. ....... ... . .. 13 Oil Pump to Carburetor Synchronization . ..... . ... . ..... ...... . . .. .. ..... 14 Purging Air from Oil Pump Outlet Tubes . ........... . .... ............. ... 15 Carburetor Adjustments ......... . ..... . .... .. ... . .... . _. .... . .... . .. ... .. 16 Enrichener Cable .... . .... .... .... . ..... . .... . .......... . ... ... . . . . .. 16 Air Screw .. ... . .............. . .. ......... . .......... .. .. .. .. ... ... .. 17 Idle Screw ... ... .... . .. ..... . . ... . ..... . ............ ... ..... .... . .. . 17 Throttle Control Cable ................. . . ... . ... . ... .... . ... . .. ... ... . 17 Ignition Timing Check ..... .. . . .... ... .... ... .... . ........... . . .. .. ....... 18 Ignition Timin g Adjustment. ........... . . . .. .... . .. .... . ... ... ...... ..... . 19 Fan Belt Tension .. .... .. .... . ... . . ... ... .. ... .... . .......... .. .. ... ... . . 20 Headlight Adjustment ..... . . . . ... ... . ......... .. .. ... ...... .. . ... . ....... 20 Tail/Brake Light Test ...... . ....... . . .. .. ... ... .. ............ . ... . ........ 21 Track Adjustment .... .. .... .. ......... ... ........ . ....... ...... ...... .... 21 Track Tension . .... ... ....... . ... .... . . . . .... . ... ....... . ...... .. .. . . 21 Track Alignment ... ... ..... ....... .... ... ... . .. .... .. .. .. .. .... ..... . 22 Test Ride (Operational Checks) .. . ...... . ..... . ......... ..... . . .......... .. 23 Spec ificati ons ...... . ......... . .... . . .. ..... . ........ . _...... .. . . . .. ... .. 25 Engine .. .. . ... . .... .... ... ... ... ......... . .... .. ...... . ...... .. .... 25 Carbu retor Settings & Fue l ... . . . .... .............. .. . . . ....... . ... . ... 25 Drive Syste m ...... ....... . . . .......... . ...... .. . . .......... ... ... . .. 25 Electri cal System ........ ... . . .... .. ................. .. . ... . ..... .... 25 Torque Chart .. ..... . .... . . . ...... . ..... . ..... . ... ... .... .. .... .. ...... .. 26 Wiring Diagram ... ........... .. . . . ... .......... ... . ............. ..... .... 27 DRIFTER
TABLE OF CONTENTS
Dealer's Assembly and Preparation Check List Remove the Assembly & Preparation Check List from storage case. Complete each item of the check list following the procedures outlined in this manual. Verify compliance by placing a check ( ..... ) in box preceeding each item as it is completed. Be sure to si.Qn all sections of the form as they are completed. Retain completed check li st for your records .
KAWASAKI SNOWMOBILE DEALER'S ASSEMBLY & PREPARATION CHECK LIST I hereby certify that prio r to delivery to the first retail purchaser assembly and preparation servicing was performed on the snowmo bile listed below in accordance with the following check list, and in compliance with the established procedures prescribed by Kawasak i: ([!it check each item when completed!. SNOWMOBilE INFORMATION MOOEl
SERIAL NO.
ENGINE NO. ASSEMBl Y CHECK LIST
60
, 0 REMOVE CRATE· ch eck for damaged & missing parts .
SA FETY DECALS · properl y installed . 7 0 TOOL KIT · complete /i nstalled.
2 0 SKIS· install· torque all bolts.
30 0 50
4
SKI SHOCKS · mount and torque bolts. WIND SHIELD· mount to hood. HANDLEBARS· adjust to proper position/torque bolts.
ASSEMBl Y BY: Signature
PREPARATION CHECK LIST
, 0 STEERING · align skis/components secure. 2 0 CLUTCH ALIGNMENT · check/adjust. 3 0 CLUTCH CENTER TO CENTER · check /adj ust. 4 0 CHAINCASE . add lube if required/check for leaks. 5 0 BRAKE · clean disc/ adjust .
6 0
"'7 0
OIL LINE TO PUMP · (all oil injection modelsl bleed /
"'8 0 '9 0
ENGINE COOLANT· check level / freeze protection. SPARK PLUGS · check /gap . GAS TANK - fill with recommended fuel/oil mix {refer to Owner's Manuall check for leaks. CARBURETOR AI R SCREW · adjust. CARBURETOR IDLE SPEED - adiust. PRIMER -check operation . IGNITION TIMING - check when engine is warm/adjust. ELECTRICAL SYSTEM · check operation· adjust Headl ight " 0 Battery Charging System Ta illight 0 Brake light .. 0 Electric Starter · 0 Instr umen ts & Ind icator Lights TRACK - adjust tension/align
secure /properly routed.
20 O
WIRING HARNESS · properly routed/electrical con·
nectors secure.
2' 0
7 0 SUSPENSION · check / adjust. 80 NUTS, BOLTS, OTHER FASTENERS - checkltighten. ·9 0 ENGINE GEARCASE LUBRICANT - check level/add
22 0 "23 O
24 0 25 0
recommended oil as required.
'0 0 FUE L PUMP TUBES - secure and no kinks "
O ENRICHENER CONTROL -check /adjust . DOl L PUMP - check synchronization/adjust. '3 O THROTTLE CABLE · check/adjust O CARB SYN CHRONIZE - check/adjust (twin carb modelsl . O FAN BELT · check / adjust (axial fan modelsl . ·'6 0 01 L TANK - fill with Kawasaki approved oil/check for leaks.
·'2 ·'4 ·'5
26 0
o o
PREPARATION BY: Signature
TEST RIDE
o CONTROL CAB LES - throttle & brake works without bindin~ in any steering position/returns freely .
2 0 3 0 4 0 5
0
60 70
ENGINE STOP SWITCH - check operation. SUSPE NSION· check slider ride adjustment. STEERING · action is tree lock to lock/no looseness. ENGINE - recoil start€!' works properly/engine starts promptly / good throttle response and return . Exhaust smoke present but not excessive (oil injection models). CLUTCHES · smooth operation/correct maximum RPM . BRAKES - adequate· smooth stopping power.
8 0 9 0
·'0 0
" 0 "'2 0 '3 0
SPEEDOMETE RIT ACHOMETE R - check operation. NO UNUSUAL NOISES . NO COOLANT LEAKS. NO FUEL OR OIL L EAKS. COOLANT LE VEL · check / add coolant mix as required. CONTROLS - properly positioned/secure/adjusted.
TEST RIODEN BY: Signature
CUSTOMER DELIVERY
o OWNER'S MANUAL - expla in contents/proper mainte2 0 3
0
nance/install. OWNER'S SAFETY HANDBOOK · explain contents/ install. WARRANTY CERTIFICATE - explain warranty and customer responsibilities thoroughly / install .
4 0
CONTROLS · ex plain location & operation/properly positioned for customer.
DELIVERED BY: Signature
DEALER VERIFICATION Dealer Name _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Addre~
Signature of Dealership Manager
_ _ _ _ _ __ _ _ _ _ _ _ _ __ _ _ __ __ _ __ _ _ __ _ __ ___
Date _ __ _ _ _ __ _ _
• Applicable models only - refer to assembly instruction provided by Kawasak i for specific models. PI N 49007-3501
white copy · dealer file/canary copy - owner
Printed in U.S.A.
)
If it is desired to utilize the French portion of this check list, please remove the carbon sheet and insert in proper location.
ii
DEALER'S ASSEMBLY & PREPARATION CHECKLIST
DRIFTER
Assembly Uncrate
Observe this
WARNING'
during next step
Bend over all exposed crate fasteners to prevent personal injury or possible vehicle damage.
2
1. Ski Spindle
In a large, clear work area, open crate by separating top and sides. Remove windshield from seat. (See Figure 1.) Observe this
I
WARNING
I
during next step
To prevent personal injury, use lifting equipment with approved safety hooks when raising the snowmobile.
With assistance, or the use of a hoist, carefully lift the snowmob ile from the crate. Thoroughly inspect snowmob ile for sh ippin g damage and missing parts.
1
Remove plastic bag containing mounting hardware for skis and windshield from storage case.
Skis NOTE: When uncrating vehic le, inspect for concealed damage that may occur during shipping. If damage is apparent, STOP uncrating and check your WARRANTY POLICIES & PROCEDURES Section of your Snow Products Binder under RECEIVING WAREHOU SE UNITS.
Installation
Place the snowmobile on its side. Be sure to provide a protected surface to prevent marring the finish of the snowmobi le. Then perform the following:
1. Loosen and remove the nuts that secure the ski spindles to the bottom of the crate. (See Figure 2.)
DRIFTER
Apply low temperature extreme pressure (ep) grease to the grooved or recessed area on the spindle sleeve, and insert the sleeve into the spindle. (See Figure 3.)
ASSEMBLY
1
NOTE: During shipping, burrs may form at the outer edge of the spindle hole making sleeve Insertion difficult. Use a suitable file to remove these burrs.
4 1. Flat Washer
Windshield Install the well nuts by threading a windshield mounting screw part way in and using the screw as a handle, push the wel l nut into position and remove the screw. (See Figure 5.)
3 1. Spindle Sleeve 2. Sp indle
Observe this
WARNING'
during next step
Improper tightening of spindle to saddle bolt will result in excessive steering system play. This negatively effects vehicle handling and could result in loss of control and possible personal injury to the operator.
2. Secure sk i and shock absorber assembly to spindle using hardware supp li ed. Be sure nut and large flat washer are instal¡led on inward side of the sp indle and torque 30 ft Ib (4.1 kgm). Torque shock absorber mounting nut 30 ft Ib (4.1 kg-m). (See Figure 4.)
2
ASSEMBLY
1. Windshield Mounting Screw 2. Rubber Well Nut
Remove the protec tive film from the windshield and install windshield seal tri m. (See Figure 6.)
DRIFTER
Check th e routing of the control cables and wire harnesses for proper positioning. They must pass through the cutaway section in the hood for adequate free movement wh en the hood is closed . Be sure the fuel tank vent tube is not crimped or pinched . (See Figures 7 and 8.)
6 1. Windshield 2. Seal Trim Instal l windshield using mounting screws provid ed .
Handlebar
Observe this
1. Fue l Tank Vent Tube
[:~~~~~~~:]
during next step
Adjust the handlebar so it does not hit the windshield when turning in either direction.
The headlight-instrument wire harn ess an d speedo meter cable must be routed properly on underside of hood. Clamps are used to secure harness and cable in position. (See Figure 9.)
Adjust hand lebar for comfortable driving position and even ly torque four screws 105 in. Ib (1.2 kg-m). (See Figure 7.)
9
1. Hood Cutaway Section
DRIFTER
1. Head li ght-Instrument Wire Harness 2. Clamps 3. Speedometer Cable
ASSEM BLY
3
Throttle and Brake Control Levers
Check throttle and brake control lever position. Be
Tool Kit, Owner Manual, and Safety Handbook
sure they are comfortable for driving. Torque set screws 25 in.lb (0.3 kg -m). (See Figure 10.)
Check the storage box to be sure it contains the Tool Kit, Owner's Manual and Safety Handbook.
Preparation Suspension 1. Set Screw
Safety Labels
I
The snowmobile is shipped with the suspension sp ring s adjusted during production assembly to provide satisfactory ride and handling characteristics for average driver weight. Normally, no adjustments are required.
WARNING'
Insure that all safety labels are properly located and secure. (See Figure 11.)
Ride Adjustment
As assemb led , the rear springs which control the ride characteristics are mounted in the lowest or softest of the three positions available. Ride adjustments can be made by changing the position of the se spring s to increase their ten sion. This will stiffen the ride and increase load capacity.
The tension (pre-load) of the springs on each side of the suspension arm must be equal. Excessive tension of one sprin g can cause spring breakage or excessive wear to one side of the slide wear strips.
To change spring tension: 1.
4
PREPARATION
Install spring adjusting tool, PIN 57001-3507 onto the end of the spring arm as shown. (See Figure 12.)
DRIFTER
The tension (pre·load) of the front springs
on each side of the suspension arm must be equal. Excessive tension of one spring can cause spring breakage or excessive wear to one side of the slide wear strips.
1. Spring Adjusting Tool PIN 57001-3507 2. Spring Arm 3. Spring Retainer
Observe this
WARNING
t
during next step
To adju st or change th e handling characteristics of the snowmob il e, tighten the adju st ing nuts on each side of the suspension equally to increase front spring tension or loosen the nuts equally to decrease spring tension. (See Figure 13.)
Th e standard adju stm en t is 1/4 in. (6.35 mm) of ex· posed threads from th e adjusting nuts. This is recommended for the best overall handling over a wide range of cond ition s and terrain.
Rear suspension springs are under heavy spring load and improper adjusting techni· ques may result in personal injury.
2. Apply a firm grip on the spring adjusting tool with both hands and carefully lift the spring arm out of the detent in the spring retainer. Be prepared for the heavy spring load to be transferred to the spring adjusting tool as the spring arm is lifted out of the retainer detent. 3.
Install the spring arm into a higher retainer de· tent to increase spring tension for the desired ride characterist ics. 1. Adjusting Nut 2. Front Suspension Spring 3. Exposed Threads
Handling Adjustment
The handling characteristics of the snowmobile are controlled by the tension of the front suspen· sian springs. Increasing the spring tension will reduce ski pressure on the ground, resulting in less steering effort and slowe r response. Less spring tension allows more ski pressure, causing quicker respo nse and inc reased steering effort.
DRIFTER
Ski Spring Preload Three positions have been provided for the front ski spri ng mounting bolt: (See Figure 14.)
PREPARATION
5
3.
With weight sti ll on front bumper, remove bolt, s li de spring rub strip to ali gn with desired hole position of sk i, and in sert bolt.
4.
Install nut and torque 25 in. Ib (0.3 kg-m).
Steering Alignment 14 Check the ski alignment and handlebar centering. 1. Spring Mounting Position 1.
FRONT HOLE POSITION - secures spring to reduce spring arch , increasing spring tension pre load , resulting in a firmer ride with less spring travel for maximum stability during high speed operation.
Place a long board (or suitable straightedge) against the left edge of the track, and measure the distance between the board and center line of the ski. Position the ski so that the distance measured between the ski center line and edge of the board is the same at the front and rear of the ski. (See Figure 15.)
CENTER HOLE POSITION - allows more spring arch , reducing spring preload, resulting in a softer ride for moderate speeds and trail riding.
REAR HOLE POSITION - provides maximum sprin g arch , further reducing spring preload , resu lti ng in a much softer ride. This position is recommended for deep snow operation or slow speed trail riding only.
NOTE: Always mount the front sk i spring bolt into the same po sition on each sk i. To change the preload of the ski spring , be sure the weight of snowmob il e is on the skis, and proceed as follow s:
15 1. Straigh t Edge Aga in st Track 2. Measure Distance Here
1.
Remove nut from front spring mounting bolt.
2. Open hood and with assistance from another, stand on front bumper to relieve spring tension from mounting bolt.
6
PREPARATION
2.
When the sk i cen ter line is parall el to the outside edge of th e track, check the steering handlebar for centerin g.
DRIFTER
Observe this
WARNING
I
during next step
To prevent possible steering linkage failure adjusting stud must remain centered between two jam nuts and measurement between jam nuts must not exceed 1·114 in. (32 mm). (See Figure 16.)
17 1. Equal Distance Between Ski Center
Lines· Front and Rear
1. Jam Nuts 2. Tie Rod Length Adjusting Stud 3. 1·1/4 in. (32 mm) Maximum
Wiring Harness 3.
If handlebar requires centering , support vehi· cle so RH ski is off the ground allowing it to move when adjusting handlebar. Loosen jam nuts and turn LH tie rod adjusting stud as necessary to center handlebar.
NOTE: Be sure the sk i center line remains parallel to straight edge while turning the tie rod adjusting stud.
4.
5.
To align RH sk i, move both ski tips towards cen ter of snowmobile to remove the steering li nkage play. Turn the RH tie rod length ad· ju stin g stud to obtain an equal distance from ski center to ski center when measured at the front and rear of the skis. (See Figure 17.)
Torque adj usting stud locknuts 120 in. Ib (1.4 kg·m). Refer to torque chart and tighten all hardware (nuts, bolts, etc.) in steering system.
DRIFTER
Check wiring harness for proper routing. Be sure wires are not being rubbed or pinched and all con· nectors are secure and fully connected.
Chaincase
To avoid loss of lubricant, use KAWASAKI Chain lubricant ONL Y . whenever adding to or filling chaincase.
Check chaincase fluid level by removing Fluid Level Plug. Fluid leve l must be even with level hole's lower edge. If add itional fluid is required, remove fill plug and pour KAWASAKI Chain Lubri · cant into fill hole until fluid level is even with fluid level hole's lower edge. (See Figure 18.)
PREPARATION
7
Install Fill Plug and Fluid Leve l Plug into chaincase.
18
1. Fill Plug 2. Oil Level Plug
1. 2. 3. 4. 5. 6.
Brake Check relationship of brake cam detent to brake pad push pins. In the off position the cam detent must be centered over pins. Be sure brake disc can be moved back and forth with very slight drag from brake pads. Measure brake control lever movement which should be less than 3/4 in. (19 mm) when brake is fully applied. Perform Brake Adjustment if required. (See Figure 19.)
Observe this
Back both brake cable jam nuts away from bracket about 1/4 in. (6 mm). Tighten brake adjusting nut bottom ing cam against push pins.
2.
Pull outer brake cable rearward to remove slack from inner cable and snug rear jam nut to bracket. Tighten forward jam nut against bracket and torque both jam nuts 50 in. Ib (0.6 kg -m)
8
PREPARATION
I
WARNING
I
during next step
DO NOT OVERTIGHTEN the brake because damage to components, or personal injury could result.
Brake Adjustment
1.
314 in. (19 mm) Maximum Push Pins Brake Pads Brake Disc Brake Cam Brake Cable Jam Nut
3.
Loosen brake adjusting nut until brake disc can be rotated back and forth easily with brake pads just lightly contacting the disc.
DRIFTER
Drive and Driven Converter Alignment
4. If adjustment of converter center distance is necessary; loosen four chaincase mounting nuts. Position chaincase forward or rearward as required. Torque chaincase mounting nuts 28 ft Ib (3.9 kg·m).
Converter Center·To·Center Distance
Correc t converte r center·to·center distance of 10.3 in. (262 mm) and converter offset distance of 0.497 in. (11.5 mm) is obtained when ali gnment gauge PIN 57001·3515 is correct ly installed be· twee n drive and driven converter sheaves. (See Figure 20.)
NOTE: Driven converter bearing support must be di sconnected by removing clevis pin from chassis yoke. After adjusting chaincase, loosen support jam nut and adju st support assembly to proper length . Reconnect support to yoke and torque jam nut 95 in. Ib (1.1 kg-m). (See Figure 21 .)
20
1. Alignment Gauge 2. Converter Offset 3. 10.3 in. (262 mm)
1.
Remove be lt guard and remove drive belt.
2.
Rotate driven converter moveable sheave assem bly clockw ise, and insert ali gnment gauge between sheaves. Carefully release moveable sheave assembly allowing spring tension to retain gauge in posit ion between stationary and moveable sheave assemblies. (See Figu re 20.)
3. Cen ter di stance is correct if the notch in the ali gnment gauge fits over the shaft on the drive converter. DRIFTER
21 1. Driven Converter Support Arm 2. Driven Converter Moveabl e Sheave 3. Ali gnment Gauge PIN 57001 ·3515 4. Drive Converter
PREPARATION
9
Converter Offset Distance
1.
Correct off-set distance is obtained when the surface of the shallow notch on the al ignment gauge touches the base of the fixed sheave of the converter. (See Figure 22.)
23 1. Alignment Gauge PIN 57001-3515
22 1. Alignment Tool PIN 57001-3515 2. Alignment Tool Recess 3. Drive Converter Stationary Sheave
2.
If adjustment is necessary, loosen four engine mounting nuts. Slide engine back and forth until stat ionary sheave fits into recess in alignment gauge. Tighten all mounting bolts securely.
NOTE I: Dimension A must be more than dimension B.
NOTE II: Dimension A must never exceed dimension B by more than 1/16 in. (1.6 mm).
2.
If dimension A is less than B, converter parallelism is not correct. Adjust parallelism by loosening engine mounting nuts, then twisting or rotating engine to correct position. Torque engine mounting nuts 30 ft Ib (4.1 kgm).
3. Converter Parallelism
1.
10
When checking center-to-center and offset distances, parallelism must be checked by measuring dimensions A and B as shown. (See Figure 23.) Compare dimensions A and B against Notes I and II.
PREPARATION
If parallelism is still not correct, loosen chaincase mounting nuts and install alignment "U" washers PIN 92025-3507 as requi red between chassis and chaincase. (See Figure 24.)
NOTE: Never use more than 2 alignment "U" washers per bolt.
DRIFTER
Filling Oil Tank Fill oil tank with recommended oil. DO NOT ALLOW DIRT TO ENTER WHILE FILLING. Oil tank capacity is 2-1/2 quarts (2.37 liters). Check oil tank vent tube for:
1. "U" Washer, PIN 92025-3507
1.
Proper Routing - Sharp bends or kinks in the vent tube will reduce oil flow to the oil pump.
2.
Tie Band In stallation - Tie band may pinch off tube, reducing oil flow to the oil pump, if installed too tight.
3. Vent Tube Position - To prevent siphoning action, possible und er certain conditions, position end of vent tube higher than top of oil tank.
Engine Break-In For proper engine break-in, run the machine on hard packed snow at approximately 3/8 to 1/2 throttle, with occasional bursts to full speed. Limit the full speed operation to 1 1/2 to 2 minutes, then return to cruising speed for 10 to 15 minute intervals. After 10 hours of operation or two tanks of gasoline are used, break-in is complete.
Fuel Recommendation Use regular or premium leaded gasoline with a minimum PUMP POSTED ANIT-KNOCK INDEX NUMBER OF 89. DO NOT USE GASAHOL.
I
Oil Recommendation We recommend using Kawasaki Snowmobile Oil. This oil is specially formulated to give minimum piston ring varnish and combustion chamber deposits along with excel lent lubrication qualities. In an emergency situation when Kawasaki Snowmobile Oil is not available, a B.LA. certified TC-W oil may be substituted. All certified oils will indicate the TC-W rating on the container. If the B.LA. cer1ification does not appear on the container, the oil MUST NOT BE USED. The use of lubricants such as "tune-up tonics" and "super oils" is NOT RECOMMENDED.
DRIFTER
WARNING
I
Gasoline fumes are heavier than air and can become explosive if exposed to a pilot light from a furnace, hot water heater, clothes dryer, etc. Mix fuel or fill fuel tank only in an area that is well ventilated and free from pilot lights and sparks.
Fuel Mixture (Break¡ln Only) To insure adequate lubrication of internal engine components during early break-in, a 25-to-1 gasoline-to-oil ratio is recommended for the first three (3) gallons of gasoline. This ratio can be obtained by thoroughly mixing 1 pint (0.47 liter) of Kawasaki Snowmobi le Oil with three (3) gallons (11.4 liters) of gaso lin e. Pre-mixing gasoline and oil wi ll no longer be required after the initial three gallons of gasoline and oil mix have been consumed .
PREPARATION
11
Filling Fuel Tank
25 to 1 Gasoline to Oil Mixture. Break-in Only
Oil
Gasoline
1 pint (U.S.)
3.0 gal. (U.S.) 2.6 gal. (Imp.)
1 pint (Imp.)
3.0 gal. (Imp.) 3.8 gal. (U.S.)
Before removing filler cap from the fuel tank, remove any ice, snow, or water from around the fuel tank opening to prevent contamination of fresh fuel mixture.
WARNING
I
Gasoline fumes are heavier than air and can become explosive if exposed to a pilot light from a furnace, hot water heater, clothes dryer, etc. Fill the fuel tank only In an area that is well ventilated and free from pilot lights and sparks.
Fuel Mixture (Standard) The fuel -to-oil ratio required is automatically controlled at the engine oil pump.
Fill the fuel tank slowly and pour the fuel mixture into the tank using a funnel with a fine mesh screen.
Adding Gasoline Antifreeze A major brand of Gasoline Antifreeze (such as Heet) should be added to the fuel mix by following the manufacturer's recommendations on the container for a proper mix ratio of fuel with antifreeze. (See Figure 25.)
Engine Gearcase Lubrication Components in side gearcase drive the oil injection pump.
25
Lubricant level is correct when oil appears above center but not higher than the top of the sight gauge. The sight gauge is located on the engine front, below left-hand cylinder assembly. (See Figure 26.)
Fill or add lubri cant to the gearcase as follows:
Each time fuel tank is filled, gasoline antifreeze must be added to fuel mixture. Moisture trapped in fuel system components (fuel tank, lines, fuel pump or car¡ buretors) may freeze causing engine malfunction or damage.
12
PREPARATION
1.
Remove gearcase fill plug (located on top of gearcase) and pour Kawasaki engine gearcase oil or Shell Fire and Ice 10W40 or an equ ivelant viscosity motor oil that meets or exceeds API service SE specifications. Gearcase capacity is about 1.35 oz. (40 cc). (See Figure 27.)
DRIFTER
1. Container of Oil 2. Gearcase Fill Hole
To insure proper operation of oil seal between the engine gearcase and crankcase, check for accumulated obstructions in the gearcase breather hole, located above gearcase sight gauge.
1. Oil Level Sight Gauge 2. Engine Gearcase Drain Plug 3. Gearcase Breather Hole
Oil Injection System
Engine gearcase oil should be changed after the initial 100 miles of engine operation, and at the end of each season, to remove any impurities or foreign matter present in the gearcase cavity. To completely drain gearcase, remove drain plug and raise rear of snowmobile. (See Figure 26.)
The oil pump is a variable ratio pump; at idle, the fuel/oil ratio is approximately 110 to 1 increasing with throttle position to approximately 25 to 1 at maximum power.
Bleeding Oil Pump Supply Tube
Observe this Failure to remove obstructions from gearcase breather hole may cause excessive oil consumption resulting In extensive engine damage. (See Figure 26.)
DRIFTER
Observe this
[~~~:~~~:]
during next step
Failure to bleed out air trapped In the 011 line can cause severe engine damage.
PREPARATION
13
The Drifter is equipped with an in-line oil filter to prevent foreign particles from entering the oil injection system. After filling oil tank, bleed air from oil pump supply tube as follow s: (See Figure 28.)
1. Ai r Bubble 2. Oil Supp ly Tube 3. Oi l Pump
Con tinue sq ueezing (pul sin g) oil pump supp ly tube until bubb les no long er exit th e pump asse mbly. 6.
1. Oil Tank 2. Oil Supply Line Filter 3. Oil Supp ly Tu be
Remove bleed screw from top of oi l pump and all ow to drain until all air bubb les are removed from inlet tu be. Visually check entire length of tu be to be sure that all air has been removed , then reinstall bleed screw.
Oil Pump to Carburetor Synchronization 1.
Fill oil tank with Kawasaki Snowmobi le Oil.
2.
Remove oil pump bl eed screw. This allows oil to fill the filter and flow through oil supply tube to oil pump. (See Figure 29.)
3.
Replace oil pump bleed screw when supply tube is fill ed.
Synchronization of the oil pump and carburetor is ex treme ly importan t to assure adequate eng ine lubri cat ion and peak performance. Remove drive belt and ai r sil encer assemb ly, then perform following procedure:
Visu ally check oil filter and oil supp ly tu be to be sure that all air has been removed .
1. Loosen idl e stop screw so that the throttle slide bottoms out in carburetor bore. (See Figure 30.)
5. Air trapped inside the oil pump assemb ly can be removed by sq ueez ing (pul sing) oil pump su pply tube with pliers. This process causes air to exit the oil pump nipple and enter the supply tube. (See Figure 29.)
NOTE: Check to be sure throttle slide has bottomed-out. If not, loosen jam nut and turn throttl e cab le adjuster to allow slide to bottom out.
4.
14
PREPARATION
DRIFTER
])
3.
Adjust throttle cable on carburetor so that all slack is removed . The throttle slide should begin to rise as soon as the throttle lever on handlebar is advanced. (See Figure 30.)
4.
Loosen locknuts on oil pump cable and, while holding oil pump lever against the stop pin, remove all slack. Adjustment is correct when the lever on the oil pump and throttle slide in the carburetor move simultaneously as the throttle control lever is activated. (See Figure 31.)
5.
Turn idle stop screw in until spring is coil bound. Then, back off screw six complete turns (initial adjustment). Air screw is properly adjusted when opened 1.5 turns off its seat.
6.
Reinstall air silencer assembly.
7.
Perform steps under Purging Air from Oil Pump Outlet Tubes.
30 1. 2. 3. 4.
2.
Throttle Cable Adjuster Adjuster Jam Nut Air Screw Idle Stop Screw
Push oil pump lever forward until it contacts the stop pin; this insures the oil pump is at dead idle position. (See Figure 31.) Purging Air from Oil Pump Outlet Tubes
Remove drive belt and perform the following procedure. Any air bubbles in the oil pump outlet tubes will cause serious internal damage. Purge air from these tubes as follows:
Observe this
31 1. Lever Stop Pin 2. Slack Removed 3. Cable Locknuts
DRIFTER
WARNING'
during next step
Failure to disconnect oil pump control cable when performing this procedure will damage the cable. The damaged 011 pump control cable will prevent the throttle from returning to Idle position, resulting In automatic clutch engagement when engine is started, which may lead to personal injury.
PREPARATION
15
1.
The oil pump inner control cable must be disconnected from the control lever on the oil pump to prevent damage to cable. Do not disturb cable locknuts when removing the inner cable. (See Figure 32.)
4.
Release rubber band and reconnect oil pump inner control cable to lever. Be sure to check operation of oil pump control lever and cable by activating throttle control lever on the handlebar.
Carburetor Adjustments
Enrichener Cable With the enrichener lever down, and plastic boot slid up the casing, the enrichener cable shou ld have 1/16 inch (1.5 mm) free movement when raised as shown . (See Figure 33.)
32
1. 2. 3. 4.
2.
NOTE: Engine flooding may occur if the enrichener cable free movement is less than 1/16 inch (1 .5 mm).
Oil Pump Inner Control Cable Oil Pump Control Lever Rubber Band Mount Bolt
Attach rubber band to hold oil pump control lever in the wide open position. This will cause the maximum flow of oil through the outlet tubes. (See Figure 32.)
Observe this
[:~~~~~~~:]
during next step
Never run engine with air silencer removed from the carburetors. Poor engine perfor¡ mance and damage will result.
3. Start engine and adjust idle stop screw to obtain engine idle speed of 2,500 RPM . Stop engine after it has idled for one minute. This is ample time to purge all air from the oil pump outlet tubes.
16
PREPARATION
1. Plastic Boot 2.1/16 in. (1.5 mm) 3. Locknut 4. Adjusting Screw
DRIFTER
If adjustment is required, loosen jam nut and turn adjusting screw to obtain correct movement. Torque jam nut 20 in. Ib (0.2 kg-m). After adjustment or check, position boot over fitting to prevent dirt from entering the enrichener system.
WARNING'
If the engine idles too fast, the drive converter may not disengage when the throttle lever is released, or the converter may engage automatically. Either condition could result in personal injury.
Make sure the fuel pump pulse line and all fuel lines are secure and free of kinks and bends. Air Screw The carburetor air screw is properly adjusted when opened 1.5 turns off its seat. Refer to the specifications page. (See Figure 34.)
Start the engine and run it at low speed for 3 to 5 minutes for proper warm-up, and adjust the idle speed using a portable tachometer.
Throttle Control Cable
Excessive free movement of throttle lever may cause inner throttle cable to disconnect from lever. Too little or no free movement may lead to incorrect idle adjustment.
With the throttle lever at the idle position there should be 1/16 in . (1.6 mm) free play between the lever and its housing.
34 1. 2. 3. 4.
Throttle Cab le Adjuster Adjuster Jam Nut Air Screw Idle Stop Screw
To prevent cable end breakage, throttle lever must contact handlebar grip at full throttle position.
Be sure throttle lever contacts handlebar grip at full throttle position. Remove air silencer and check that carburetor slide is raised completely above carburetor venturi at full throttle. (See Figure 35.) Idle Screw The idle speed screw initial adjustment is 6 turns open from coil bound, (screw turned in tight).
DRIFTER
Adjust throttle cable by loosening adjusting screw jam nut. Turn adjusting screw to obtain proper adjustment and torque jam nut 20 in. Ib (0.2 kgm). (See Figure 35.)
PREPARATION
17
INCORRECT
CORRECT
36 1. Dial Indicator 2. Converter Fixed Sheave 3. Fabricated Pointer
35
Ignition Timing Check
3.
Rotate drive converter in normal direction of rotation (counter路clockwise) to find TDC (top dead center). Adjust dial indicator to zero.
Remove the drive belt prior to performing the following procedure.
4.
Turn drive converter clockwise to 0.073 in. (1.85 mm).
5.
Make a mark on drive converter fixed sheave corresponding to timing pointer. (See Figure 36.)
1.
In stall fabricated timing pointer onto engine. For accuracy, attach pointer to engine rather than chassis so pointer moves with engine. (See Figure 36.)
Observe this
[:~~~~!~~:]
during next step
When removing spark plugs, carefully rotate plug cap back and forth while pull路 ing cap straight upward. Do not attempt to twist or force plug cap off by pulling on lead wires as this will damage the connec路 tion. (See Figure 37.)
2.
Remove both spark plug s and install a dial in路 dicator into the LH cylinder spark plug hole. (See Figure 36.)
18
PREPARATION
DRIFTER
6.
Remove the dial indicator. Before installing the spark plugs, check that:
a.
Plug gap is properly adjusted to 0.024 in. (0.6 mm).
b.
Compression washer is installed on spark plug and cylinder head seat is clean.
c.
Spark plugs are torqued 20 ft Ib (2.7 kg-m).
8.
Ignition Timing Adjustment 1.
Observe this
WARNING'
Remove recoil starter assemb ly and fan belt pulley. Twist fan belt out of the way.
during next step
Do not touch the spark plug leads while the engine is running as they will transmit a powerful electrical shock. Do not touch the hot exhaust system, as a severe burn will result.
Observe this
Connect strobe type timing light to spark plug lead wire following manufacturer's instructions. Drive belt must be removed and converter belt guard secured in place.
[=~~~!~~:~:]
Loosen the stator assembly mounting screws through the holes in the flywheel. To correct the timing, rotate the stator assembly as required (clockwise to retard timing; counter¡ clockwise to advance timing). (See Figure 39. )
39
38 1. Timing Light 2. Mark on Drive Converter
DRIFTER
during next step
When adjusting the stator assembly, take care not to damage the coil windings.
2. 7.
Start engine and allow it to warm up to operating temperature. Then run engine at 6,500 RPM and aim timing light, through converter guard, directly at timing pointer. Timing is correct when mark aligns with pointer as light flashes. (See Figure 38.)
1. Flywheel
PREPARATION
19
3.
Tighten stator mounting screws. Torque to 6 ft Ib (0.83 kg-m).
4.
Replace fan belt pulley, starter pulley and fan belt. Torque bolts to 70 in.lb (0.8 kg-m).
5.
Recheck timing using Ignition Timing Check procedure to be sure timing is correct.
6.
In stall recoil starter assembly. Drive belt may now be installed and belt guard secured into position with clip pins.
If adjustment of fan belt tension is required, remove outer pulley half from fan shaft. Add or remove spacers between pulley halves as required for proper belt tension. Adding spacers will decrease belt tension and removing spacers will increase tension.
To prevent fan belt damage, remove spark plugs and rotate engine crankshaft while tightening outer pulley mounting nut.
Use Fan Pulley Holder Tool PIN 57001-3506 to hold pulley and torque nut 47 ft Ib (6.5 kg-m).
Fan Belt Tension
Remove fan guard to test fan belt tension. With 11 Ib (5 kg) force applied to belt, tension should be 5/32 in. (3.8 mm). (See Figure 40.)
Headlight Adjustment
1.
Position the snowmobile on a level floor so the headlight points at a wall 25 feet (7,620 mm) away.
2.
Measure the distance from the floor to the center of the headlight and mark the wall at the dimension measured (reference mark). (See Figure 41.)
WARNING
I
If adjusting the headlight Indoors, provide proper ventilation to prevent possible car¡ bon monoxide poisoning.
1.5/32 in. (3.8 mm)
20 PREPARATION
NOTE: Be sure an operator is seated on the snowmobile while the eng ine is running to prevent the vehicle from creeping ahead, and to assure proper aiming.
DRIFTER
4.
If headlight adjustment is required, turn the adjusting screws as required. (See Figure 42.)
Check the operation of the headlight low beam.
Tail/Brake Light Test 1. 2. 3. 4.
3.
Wall 25 ft (7,620 mm) Reference Mark (center of headlight to floor) 2 in. (51 mm) below reference mark
Turn on the headlight high beam. headlight is properly aimed when the beam is centered and aimed 2 in. (51 below the reference mark on the wall. Figure 41.)
The high mm) (See
The taillight will operate on ly when the key switch is in the "Run/Lights" position. The brake light is act ivated by a switc h mounted in the brake lever housing on the handlebar. Brake light operation is independent of the other lights and the key switch .
Track Adjustments Observe this
I
Always turn headlight adjusting screws to the right (clockwise). Turning screws counterclockwise may back them out of the headlight, allowing the headlight to become loose or drop out of position.
WARNING'
When raising the rear of the snowmobile off the ground, place the ski tips against a stationary object and be sure the vehicle Is properly secured to prevent personal In¡ jury.
Track Tension
WARNING'
To prevent personal Injury, never adjust track tension with the engine running.
1.
1. Vertical Adjusting Screws 2. Horizontal Adjusting Screws
DRIFTER
Raise the rear of the snowmobile so the track is off th e ground for its entire length and secure th e snowmob ile so it cannot fall; then hang a 5 Ib (2.2 kg) weight from the mid¡point of th e track.
PREPARATION
21
NOTE: Do not position the snowmobile on its sid e to adjust track ten sion as it would be imposs ible to get an accurate adjustment.
2. With the 5 Ib (2.2 kg) weight hangin g from t he track , the clearance from the bottom of th e wear strip to the top edge of th e trac k should be 3/4 in. (19 mm). Measure thi s c learance directly below the rear suspension pivot arm bolt. (See Figure 43.)
1. Rear Ax le Lock ing Bo lt 2. Rear Ax le Adju stin g Bolts 3. Lock (Jam) Nuts
Observe this
Ffll ,ti7 __
~ -Z
_._.
...
_----
II
WARNING
I
during next step
NEVER raise rear of snowmobile by hand or stand behind the vehicle when engine is running or track is rotating. A rotating track can fling debris rearward at great velocity. This may cause severe personal injury. Remove all tools and foreign matter from track area before starting engine.
ÂŁ'/
--,,- --_._-
I
43
1.314 in. (19 mm)
5.
Remove th e we ight from the track and start th e engine. Push the throttle lever only enough to turn the track slowly a few revolution s.
6. Stop th e engine and perform Track A lignment Chec k.
3.
4.
22
If adjustment is necessary, loosen rear axle locking bolts and rear axle adjusting bolt jam nuts. Turn adjusting bolts required to obtain specified clearance. (See Fi g ure 44.)
When proper tension is attained, be sure both adjusting bolts are same length when measured from bolt end to rear axle bracket. (See Figure 44.) This is a good starting point for track alignment.
PREPARATION
Track Alignment The track is aligned when th e di stan ce betwee n th e rear id ler wheel and edge of the track is eq ual on both sides. (See Figure 45.)
If trac k runs to one side, tighten rear axle adjusting bo lt 1/2 turn on side with greater measurmen t from rear wh ee l to edge of track. Restart engine and rec hec k alignment.
DRIFTER
Tes t Ride Operational Checks Test ride the snowmobi le and check for the following:
~ CONTROL CABLES The thrott le and brake controls must operate without binding and return free ly in any st eering position.
1. 2. 3. 4.
Dimens ion Equal on Both Sides Rear Axle Locking Bolt Idler Wheel Edge of Track
NOTE: With engine running at idle, turn handlebars lock to lock . If any change in engine speed occurs, check cables for proper routing.
~ STEERIN G Stee ring should be smooth and free from lockto-lock with no excessive looseness or tighteness in the steering linkage.
~ ENG INE Recoil starter works properly and the engine sta rts promptly. Test for good throttle response and return.
~ SUSPENSION Adjusted for average operates smoothly.
If track alignment requires considerable adju s tm ent, track tension should be rechecked to prevent damage to drive or suspension system.
~
When track alignment is correct, tighten the lock nut on both rear axle adjusting bolts and torque rear ax le locking bolts 25 ft Ib (3.4 kg-m).
~
DR IFTER
weight
and
TRACK Track run s true with little vibration or drag. If ratcheting (slippage or jumping between drive lu gs on track and drive sprockets) during hard acceleration or braking occurs, tighten track tens ion s lightly. EMERGENC Y STOP SWITCH Check operation in al l switch positions .
.,I NOTE: After the rear ax le bolts have been tighten ed, c heck to be su re th at the space rs (tubi ng) over the rear axle sq ueeze against the slide rail brackets , preventi ng the spacers from rotating. Loose spacers will permit the rear axle to fl oat and proper track alignment cannot be maintained.
driver
CONVERTERS Tes t for smooth operation and correct eng ine RPM at full throttle.
~
BRAKES When activated, the brakes shou ld result in adequate smooth stopping of the track; when released, there should be no brake drag.
TEST RIDE (OPERATIONAL CHECKS)
23
t/
INSTRUMENTS
2.
Check for proper indicat ion s.
Retorque drive converter mounting bolt 55 to 60 ft Ib (7.6 to 8.3 kg-m).
During the test ride, listen for any unusual noises (rattles, squeaks, ets.) that may warrant inspection and correction .
3. Thoroughly inspect the engine compartment for fuel or oil leaks and repair as required.
Upon completion of the test ride, open the hood and check the following:
4.
1.
Brake adjustment.
24
TEST RIDE (OP ERATIONAL CHECKS)
Fastner check - perform a general inspection to check fasteners for security. Use torque chart as a guide for tightening hardware when required.
DRIFTER
Specifications ENGINE DRIFTER 340
DRIFTER 440
Type ................... . ........................ TA340C-D203 .............. TA440C-D203 Displacement .................................. 20.7 c.L (339 cc) ............. 26.6 c.L (436 cc) Bore X Stroke ......................... 2.362 x 2.362 in. (60 x 60 mm) .... 2.677 x 2.362 (68 x 60 mm) Number of Cylinders .... .... ............................. . ... 2 ......................... 2 Ignition System ............................ Capacitor Discharge ........ Capacitor Discharge Ignition Timing ............... . ... ..... . . 0.073 in. (1.85 rnm)BTDC ..... 0.073 in. (1.85 mm)BTDC Spark Plug ....................................... NGK BZ-9ES ............... NGK BZ-9EV Spark Plug Gap ................................ 0.024 in. (0.6 mm) . . ....... .. 0.024 in. (0.6 mm) Carburetor Make ....................................... Mikuni .................... Mikuni Carburetor Model ................ ....... ........ VM32 Econo Jet .... ...... . . VM 32 Econo Jet Engine RPM at Full Throttle ... ....................... 6,700-6,900 ............... . 6,700-6,900 Engine RPM at Idle Speed ........................... . ..... 2,500 ............. ........ 2,500
CARBURETOR SETTINGS & FUEL Air Screw ............................. .. ................................. 1.5 turns off seat Idle Screw. . . . . .. . .......... 6 turns open from coil bound initial (adjust to specified idle speed) Gasoline ...... Regular or Premium Leaded, minimum pump posted anti-knock index number of 89 Oil ....... . ............................... Kawasaki Snowmobile Oil or B.I.A. certified TC-W oil Gasoline/Oil Ratio ........... .. ........................................ ........ Oillnjection
DRIVE SYSTEM Drive Belt Width .............................................. . .......... . 1-114 in. (31.7 mm) Drive Belt Circumference ............................ ... .... .......... " .43-1/2 in. (1,105 mm) Converter Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.497 in. (11.5 mm) Converter Center Distance .... ... .... ......... ... . ..... ... ......... ......... 10.3 in. (262 mm)
ELECTRICAL SYSTEM Type . . .. ...... ......................... ... ................... ......... 12 Volts - 120 Watts Headlight ........................ .... ...... . ............................... Stanley A5988 Tail/Brake Light .............. .. . .................... ...... ............... .... G.E. No. 1157 Instrument Lights ......... ... ................ .. ................ ....... ....... G.E. No. 1816
DRIFTER
SPECIFICATIONS
25
Torque Chart DESCRIPTION
TORQUE
Brake lever locking · allen screw Enrichener lever mig .. nut Ignition 5witctl mig . - nul
25 in .lb (0.3 kg -m) Handtighten
Primer pump mi g. - nut
40 in.lb (0.4 kg -m) 25 in.lb (0.3 kg -m)
Handlighten
50 in .lb (0.6 kg-m) 20 in .l b (0.2 kg -m) 20 in .lb (0.2 kg -m) Handtighten 20 in.lb (0.2 kg -m)
HOOD Hinge to hood - nuts (1/4) Hood latch band mtg. - nut Lanyard mtg. - nut ((#10) Windshield mig . . screws
25 in.lb (0.3 kg -m) Compo Rubber 20 in .lb (0.2 kg -m) 15 i n.lb (0.2 kg -m)
105 in .lb (1.2 kg -m) 30 It Ib (4 .1 kg -m) 18 It Ib (2.5 kg -m) 18 It Ib (2.5 kg -m) 120 in .lb (1.4 kg -m) 15 It Ib (20 kg -m) 15 It Ib (2.0 kg -m)
SKI & SPINDLE Front spring to ski - nuts (3/8) Rear spring to ski - nuts (3/8) Ski assembly - nuts (3/8) Ski skeg mtg. - nuts (5/16) Spindle to shock - nuts (3/8) Spindle to ski - bolts (3/8) Sp ring to saddle - bolts (3/8)
25 31 30 18 30 30 45
in .lb (0.3 kg -m) It Ib (4.2 kg -m) It Ib (4.1 kg -m) It Ib (2.5 kg-m) It Ib (4.1 kg-m) It Ib (4 .1 kg -m) It Ib (6.4 kg -m)
CHASSIS Brace to nose pan - nuts (114) Bumper to pan· nuts (1/4) Hinge to pan - nuts (1/4 ) Passenger grip mtg . - nuts (5/16) Rear bumper mtg . - nuts (1/4) Seat to chassis - bolts (1/4) Seat to c hasses - screws (114) Tail light lens mtg. - screws (#8) Tail light body to rear door - nut (#10) Voltage regulator mtg. - nuts (114)
100 in.lb (1.2 kg -m) 100 in.lb (1.2 kg-m) 100 in .lb (1.2 kg-m) 10 It Ib (1.4 kg-m) 100 in .l b (1.2 kg -m) 35 in .lb (0.4 kg -m) 35 in.lb (OA kg -m) 10 in.lb (0.1 kg -m) 20 i n.lb (02 kg-ml 100 in .lb (1.2 kg -ml
SUSPENSION Bracket to rail - nuts (114) Hi -fax to rail · screws Idler wheel shalt mtg. - bolts (3/8) Idler wheels to rear arm - bolts (5/16) Limiter strap mtg . - nuts (114) Rear axle locking - bolts (5/16) Shock absorber mtg . - nuts (3/8) Swing arm pivot shalt - bolt (318) Swing arm to bracket - nut s (5/16) Track adjusting bolt - jam nuts (3/8)
100 in.lb (1.2 kg -m) 100 in.lb (1.2 kg-m) 30 It Ib (4.1 kg -ml 15 It Ib (2.0 kg -ml 45 in .lb (0.5 kg -m) 25 It Ib ((3.5 kg -ml 15 It Ib (2.0 kg -ml 25 It Ib (3.5 kg -m) 15 II Ib (2.0 kg-ml 20 It Ib (0.2 kg-ml
DRIVESHAFT Bearing housing mtg . - nuts (1/4) Locking colla r - set screw (114)
100 in .lb (1.2 kg-m) 95 in.lb (1 .1 kg -m)
CHAINCASE & DRIVEN CONVERTER SHAFT Chaincase level plug Chaincase lill plug Chaincase mtg. - nuts (5/16) Cover to chai ncase - bolts (114) Driveshalt collar (#10) Lower drive sprocket - bol t (1/2) Speedometer adaptor to chaincase Tensioner arm - bolt (114) Top drive sprocket - bolt (5/16)
26
TORQUE CHART
50 in.lb (0.6 kg -m) 95 in.lb (1.1 kg-m) 100 in.lb (1 .2 kg -m) 18 It Ib (1.2 kg-m)
Support to driven converter - jam nut (114) Support to driven shalt - bolt (5/161 Drive converte r mtg . - bolt (112)
95 in.lb (1 .1 kg-m) 25 II Ib (3.5 kg-ml 60 It Ib (8.3 kg-ml
ENGINE MOUNT & EXHAUST BRACKET Engine mounl - nut (3/81 Engine to plate - bolt (1/21
30 It Ib (4.2 kg-m) 30 II Ib (4.2 kg -ml
ENGINE LUBRICATION SYSTEM
STEERING Handlebar clamp - screws (114) Steering arm to spindle - nuts (3/8) Steering block mtg. - bolts (5/16) Steering block mtg. - nuts (5/16) Tie rod - jam nuts (3/8) Tie rod to steering arm - nuts (3/8) Tie rod to steering post - nuts (3/8)
Brake cable - jam nuts (5/ 161 Brake disc to converter - screws (1/4 ) Brake bracket to chaincase . nuts (1/ 4 ) Caliper assy mtg . - nuts (5/16)
DRIVE & DRIVEN CONVERTERS
CABLES Brake cable - jam nuts (5/16) Enrichener cable - jam nut (6 mm) Oil pump ca ble - jam nuts (6 mm) Speedometer ca ble Throttle cable - jam nut (6 mm)
TORQUE
BRAKE
CONTROLS & SWITCHES
Throttle lever - allen screw
DESCRIPTION
Elbow litti ng to oil tank Oil pump inlet plate mtg . - screws (4 mm) Oil pump mounting - bolts (6 mm) Oil pump outlet nozz le to crankcase - bolt (8 mm) Oil pump outlet nozzle to cylinder - bolt (8 mm)
Judgemenl 40 in.lb (0.5 kg -ml 60 in.lb (0.7 kg -ml 10 in.lb (0.1 kg-ml 10 in .lb (0. t kg-m)
ENGINE GEARCASE Gearcase Gearcase Gearcase Oil pump
drain p lug - bolt (6 mml to crankcase - allen bolts (8 mm) to crankcase boss - bolt (6 mml gear to pump - nut (8 mm)
50 12 60 12
in.lb (0.6 It Ib (1 .7 in .lb (0.7 II Ib (1.7
kg -ml kg-ml kg-ml kg-ml
45 16 12 70 20
in.lb (0.6 kg-ml It Ib (2.2 kg-ml It Ib (1.7 kg-m) It Ib (0.8 kg-ml It Ib (2.7 kg-ml
CYLINDER HEAD AND CYLI NDER Carburet or holder 10 intake manifold· bolts (8 mm) Cylinder head - nuts (8 mml Exhaust manilold - nuts (8 mm) In take manilold to cy linder (6 mm) Spark plugs (14 mm)
FAN CASE AND AIR SHROUD Engine air du ct to main shroud - nuts (#10) Exhaust shroud to main shroud · bolts (6 mm) Fan pulley to Ian - nut (1 4 mml Fan sc reen to fan housing· screws (6 mm) Intake shroud s to cy linders - bolts (6 mm) Main shroud 10 cy linder head - bolts (6 mml Main shroud to Ian housing - boilS (6 mm)
30 in.l b (0.3 kg-m l 70 47 70 70 70 70
in.lb (0.8 kg-ml II Ib (6.5 kg -ml in.lb (0.8 kg-ml in.lb (0.8 kg -m) in .lb (0.8 kg -m) in.lb (0.8 kg-m)
CRANKCASE Gearcase lill plug - boll (8 mm) Lower crankcase boss to upper (6 mm) Lower c rankcase to upper crankcase (8 mml
16 It Ib (2. 2 kg -m) 16 It Ib (2.2 kg-ml
PISTON & CRANKSHAFT Flywheel mtg. - nut (18 mm)
60 It Ib (8.3 kg-m)
RECOIL STARTER Friction plale to rope real - nut (8 mm) Recoil assemb ly mig . - bolts (6 mml Starter pulley 10 Ilywheel - bolls (6 mm)
10 It Ib (1. 4 kg-m) 70 in.lb (0.8 kg-ml 70 in .lb (0.8 kg-m)
MAGNETO Judgement Judgement 28 It Ib (3.8 kg -m) 50 in. Ib (0.6 kg-m) 90 in.lb (1 .0 kg-m) 35 It Ib (4.8 kg-ml 10 It Ib (1.4 kg -m) 70 in. lb (0. 8 kg -m) 19 It Ib (1.2 kg -ml
C.D.I. igniter mig . - screws (6 mml Ign ition harness · screw (4 mm) Sta tor plate mtg . - screws (5 mm)
60 in.lb (0.7 kg -ml Judgement 70 in.lb (0.8 kg-m)
DRIFTER
~
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Wiring Diagram
m :II
EMERGENCY STOP SWITCH
ON WHITE BLACK TO SPARK PLUGS
LJ
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u
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OFF
BRAKE LIGHT SWITCH
-L
8-S
J-
BLUE
~I~
BLACK/YEllOW
~
YELLOW/RED
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P\A.5ER COIL
EXCITER COIL
0
KEY SWITCH CONNECTIONS KEY SWITCH CIRCUIT COMPLETEO POSlTIONS BETWEEN CONTACTS MARKEO "OF, G-M 8-L "RUN/LIGHTS" NONE "RUN"
IGNlTION COIL AND COl
~Iolul~ ~~~i
OfF
-=-
'-.:/
ENCINE CONNECTOR
~IWI~ -'-~
~~g
L1GHTINC COIL
STOP-~A L LIGHT
0-,
o~-
-'IO
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BROWN/YELLOW ~
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W
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W
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~ ~
g _
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ENGINE MAGNETO
REO/YELLOW
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BROWN (BRAKE L BLACK (COMMON] YELLOW IT AIL L1GHTl
r----~~£~~~-----,
I I I I
L~~~!:~~
________ " SWIT CH
VOL TAGE REGULA TOR ~
ACCESSORY r---------------~
p
BROWN
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WHIIt.
TACHOMETER LIGHT
I I I
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DRIFTER
Page i
Kawasaki PARTS CATALOG MODEL IDENTI F ICAT IO N Snowmobile models are identified in t he parts catalog by Market ing Code numbers. The chart con tains the Marke t ing Code alo ng with the Marke ting Name for identification cross ref erence.
MA RK ETING NAM E DR IFTE R 340
MA RK ETING CODE
ENGINE MODEL
SA340-A4
T A 340A -D 201
DR IHER 440
SB440 -A4
T A440B -C20 1
DR IFT ER 340 F/A
SC34 0-Al
TB340A-A20 1
DRIFTER
© 1979 Kawasaki Motors Corp., USA First Printed : Aug. 1979 (2.5m) Rapid Design Service, Inc. LJF
Printed in U. S.A.
-
DRI FTER
Page ii
Kawasaki
CATALOGUE DES PIECES IDENT I FICATI ON DES MOD ELES
MOT EUR
Les rnode les de moto neiges so nt identifiab les dans Ie cat a logue de s pieces det achees par leurs nurneros de co de marcha nds. On t ro uvera ces co des da ns Ie tabl eau ainsi que Ie nom mar ch and du modele corresponda nt de moto neige.
DRIFTER
DENOMINAT IO N
MOD ELE
MODE LE
D RI FT ER 340
SA3 40-A4
TA340A-D201
DRIFTE R 440
SB440 -A4
T A440B-C20 1
DR I FT ER 34 0 F/A
SC340 -A 1
TB340A-A 20 1
DRIFTER Page iii
INTRODUCTION
GE NERAL
e
Th is catal og co ntai ns the ex p lo ded views and rep lacement parts lists f o r ser viceabl e componen t s o f K aw asak i snowmobiles . Alway s use GENUINE K AW A SAKI part s f or r ep lac eme nt to m aintain the standards of reliability, perf o r mance, an d safety t hat was desi gned into K awasaki snowmobi les.
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Use t he Parts Cat alog by foll owing the explanations listed bel ow .
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IND E X
Locate the sy st em or co m ponent th at req uires repl acemen t parts in t he pictori al index, and t u r n to the page numbe r indicated for the expl od ed view and par t s l ist .
•
EXPL O D ED VIEW
Each ser v iceab le p art in t h e exploded view is ident if ied by a referen ce nu m b er . Use the re fer ence number to l ocate necessary part inf o rmat ion in t he PARTS LIST BREAKD OW N. Parts not sh o w n di sassemb led in the ex p loded vi ew are no t so ld sepa ratel y , bu t ar e in cluded in t he co m p let e un i t or ne x t high er assem b l ies as shown in the illu strati on. Referen ce numbers co n nected to br ok en l ines indi cate assemb ly pa rt numbers. A ll of t he co m po nent s inside the broken lines ar e included w he n t he assembly par t number is ordered .
....
Parts drawn w i th dotted l ines are refe ren ce components used t o sho w location of assemblies o r proper posit ioning o f replacemen t parts . R efer to the p ictorial ind ex to f ind the p age number and expl od ed view f o r the refe rence componen t s.
- -- - - - - -( ~~~" .f -- - - - Tl)Il_
.(G.I)
Ilt Gu &I QOl _
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PAR T S LI ST B R EAKDOWN
Alway s use t he co m p le t e Ka w asak i p art numb er to order par t s. A voi d sh ip ping errors by ensu r ing t he en tire par t number is legible.
WASHf _ ........
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"' 45Ht: II -....
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c._s _ c:._ _ .- ..._
SC1I,,,'014 .I: t ...... .. $ l y _ ,
U N$..
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Items in t he descripti on column preceded by a bl ack d o t ind icate that t h is par t is included in the abo ve assem b l y . When Righ t Hand and Le ft H and de scri p ti on s ar e used , t he se po siti o ns are identified w hen l o o k ing f r om the back to the front o f t he sno w m obi le. (EXAMPL E : T he m anu al sta rter is o n th e Right H and side o f th e snowmob il e. ) 39091.)501
The q ua n ti t y col u m n indica tes which sno wmob il e m od el t he part is used o n and the tota l q ua nti t y requ ired f or repair o f t he sno w mob ile . (EXA MPLE : The ex p lo ded vi ew o f th e sk i show s one ski, however , t he q ua n t i t y co lu m n c ontains t he am o u n t requi red t o rep air bo t h skis .)
e
J9091-)!)Ol
39092-3503 19092.lSOJ
J9O'tl .JS03 )9(l'M-3502 39 1 00-~
39105·)503 39 1(15.3504
3'.1106-3501 3911 1-3510 3911Z· 3S06 39120-350 1
3'.l112-)SOS
N U M E RI CAL PARTS I N D EX
Each p art nu mber is li st ed numeri cally in t he index l oc ated at t he rear of t hi s ca ta log . It contain s th e p age numbe r , f or part locat io n reference , alo ng with q ua ntit y used per m odel. U se t he numerica l index to determin e compon ent l ocati on wh en o nly t he part number is kn own .
391Z5-JSOli 39117- )50 1 39\ 30·350 1 3'1134- 3502 39134-3503 39134.350 4 39134- 3505 39134 -3 506 39134-3508 3913S- 1S09 39135-35 10 39135-35 11
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22 11 12 11 12 12 12
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.. Z Z PT OPT OPT PT IOPT PTOPTOP T PT I1PTOP1 101'1 1 a r l on o n I
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)i lS6-)!iU l'.l1S6-J!it5 J91S6-J5o«i 391S6·J5041 39159-J5O') :5110-3501 J9111-J5OJ J9112_JS02 J911 Z-J503 J9 118-J5Q<l 39118 _3S06 J9 118·J501 41080600 41080600 41080600 41OllO6OO 41080600 410BOBOO
41080000 4101lOSOO 41025_3501
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A B BR EV I ATI ON S
AR A ssy CA
Carb . COl GE hex 10
. A s R equi red . A ssembly .C ut Away . Carburet o r Capaci to r Disch ar ge Ignition . G ener al Ele ct r ic Hex agonal Ins ide Diameter
LH m mm No NC OC 00 . Opt
. . . . . . . . ..
.
. . . L eft -H and . Meter .M ill im ete r N umbe r N ati o n al Co arse . O~tside Ci rc umference . O utside D iame ter . Optio nal
PSI . . . . PTO RH R ef Std . T V W
. . Pounds Sq uare I nch . . Powe r T ake O ff .. Righ t -Ha nd . Referen ce
.S ta nd a rd . Tee . V ol t . Wi dth or Wa tts . f .
..... .. . ...
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DRIFTE R Page iv
INTRO0 UCTI ON
...
DAIHEIl
GE NER ALI TE S Le present cat alogu e co n t ient les vues de tai llees des p ieces int ern es et les li stes de pieces detachess po ur I'e n t ret ien des motoneiges Kawasaki. N'uti lissz que des p ieces de rem plac ement d'ORIGI N E KAWASAKI af in de maintenir les standa rds de f iab il it e. de p erf o rm ance et de secutite qui sont Ie prop re des moto neiges Kaw asak i. Pou r u t il iser Ie cat alogue de p ieces d et achees, suivez les instructi on s ci-de sso us.
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RE PERT OI R E
Loca l isez Ie svste rne ou I'ele men t necess ita nt des p ieces de remp lacem ent da ns Ie la page indiqu ee laqu ell e vo us t rouverez la vue rep ert oire illu stre et t ou rnez detai lee et la l iste de p ieces co rrespondante s.
a
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.." VU E DETA ILLEE MONT RANT L EUR POS ITION CORR ECTE
L ES DI FFERENTES PI ECE S DANS
Chaq ue pi ece rem pl acab le est id ent if iee par un nurn ero de ref erence Uti lisez ce nurnero de refe rence po ur reper er les renseignem ent s se rappo rtan t cette p iece dans la NO M ENCLA TURE DES PI ECES DET A CHE ES.
a
e
Les p ieces n'app araissant pas d e rno n te es dans la vue de tail lee ne so nt pas vendues separernen t mais fo nt parti e d' un b loc co mp let ou de I'ensem b le su ivant Ie plu s proche . co m me indi q ue sur I' illus t rat io n.
a
des l ignes brisees ind iquent les nurnero s de Les nurne ros de reference reli es pieces d ' u n ensem b le. T ous les eleme nt s sit ues lin t eri eur des li gnes brisees sont compr is dans la com ma nde po rta nt Ie nurn ero de pi eces de I'e nsem b le.
a
...
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L es p ieces dessin ees en poi nt i l le sont des elem ent s de referenc e servant mo ntrer I'emp lacemen t des ensem b les ou Ie p laceme nt correct des pi eces de rechange. Hefe rezvo us au rep er to ire i llust re p ou r t rou ver la page po rtan t la vue deta il lee des elem ent s de refe rence.
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ONOM ENCLAT U R E DES PIECES DETACHEES
91\l11 3S3l1 9:/ll11~ J ~ "' AA8OQ
:" , a.0.0600 1'!QD_'O
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9100II3_
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Go_ I. . ... .......
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Indiq uez t o ujo u rs Ie nurn ero de p iece co m p let Kaw asak i pour vos co m mandes de p ieces. A ssurez-vous qu e Ie nurnero ent ier est parfai tem ent l isib le af in d' eviter toute erreur l' exp ed it io n .
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"Descr ip ti on " ind ique nt qu e
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Les artic les precedes d 'u n po i nt no ir ces pieces font part ie d 'un ensembl e.
'
Quan d il ex iste des desc r ip t ions pou r la Dro ite et la Gauc he, ces positions sont iden ti fi ees en regarda nt la mo t oneige de l' arri er e vers l'avaru. I E X E M P L~ I Ie de rnarreur ma in se t rouv e du cot e Dro it de la m ot on eige.)
a
La colo nne q uan ti te ind iqu e Ie modele de moton eige sur lequ el la p iece est la reparat io n de la motoneige. (EX EM PL E! L a vue det ai ll ee du ski . rnontre un seul sk i, t outefo is, la colon ne qua nti te i ndi que to ut ce qu i est necessaire la reparati on des deu x skis.)
uti lisee et Ie nombre to t al de p ieces necessaires
a
8
39&. n.3S01
a
8
12
39092-350) ) g()92-3503 »092- 3503
26 32 36
39094- 3502 J9100 · 35¢S 39105 -l!>O3 3910 5- 3S<l4 39106-350 1
22 Z4 16 16 ZZ
~m ~:r~
~:
J9l ZO-3S01 39 1Zl-3% 39125 -3506 39121 - 350 1 391) 0 -3501 J91l4 -350 Z 39134-3S0 3 39134- 3504
NOM ENCL A T U R E D ES PIE CES DETACH EES
10
3909243501
ZZ
ea 16 2'~
22 12 , 12 ;,. 12
e
2 2 PT OPT OPT PT 1 OPT PTOPT OPT
r:m:~s~ HP~ ga ::~
Chaque nurne ro de p iece fa it parti e d'u ne li ste par ordre de grand eur nurneriq ue. , dans la nom encl atu re qui se t rouv e la f in du catal ogue'. Elle co m prend Ie ''1 nurnero de la page. la ref erence pour I'em placem ent des pieces. ai nsi que la quant ite necessair e par m odele. L ors qu'onl ne co n nai t qu e Ie nurn ero de la p iece, ut il iser la nomenc lature pou r det erm iner I' em p lacem ent de I'element
a
39135- 3m-
39135-3 510
11
1
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1
1
39156.:35 44 39156 -3545 39156-3546 39156_3 541 39159- 3S05 39170- 3501 39111·3503 )9172 -3S02 39172 _3503 39178-3504 39178- 3!lO6 19178- l S07 410B0600 410 80600 41080600 41080600 41(180600 410B08OO 41080000 410 BOllO(l 41025 . 3501 4WSO-350 2 41066 -350 2
J6 J6 J6 J2
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12
"" 16
2 2 2 52
"se "se 62 62
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1
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6
1
1
13 12 2
2
1 1 1
:
1
A B REV IAT IONS AR Assy CA .. Car b CDI .. GE hex ID .
.Comm o Requ is Ensembl e . . . . . . . .Cou pe . . . . . Carb u rate ur .. : . . A llu m age Elect rosta t iq ue . . . . Gener al Electri c . .. . ... . . . Hex ago nal Diarn etre Int erie ur
LH .Gauche . m . . Met re mm . . . . . . . . . . . . . . . . . M illirnet res No Nurn ero National Co arse NC .. . .. Circonference Exter ieu re OC 00 IDE) . . . . . Diarnet re Exterieu r .Optionne l Opt .
f
PSI L ivre -Mesure -Ponce PTO (POM) .Prise De Mouvement RH Or o ite Ref erence Ref . . Std .S tand a rd T . . . . . • . . . . . . . . .. . . . . .Ferrue ente V ... . . V ol t W L argeur or Watts
DRIFTER Page v
INDEX 1. E ngine Mou nt & Exh au st
Page 1
4 . Dr ive Co nve rt er
Page 7
2. Instr u ment s, Light s & Wirin g
Page 3
5. Drive n Co nve rt e r & Bra ke
Page 9
3. Co nt ro ls & Sw it c hes
Page 5
6 . Chaincase
Pag e 11
DRIFTER Page vi 7. Susp ension
INDEX Page 15
10. Steering
Page 23
.',~~.
"'
8. Drive Shaft
Page 19
11. Chassis (1/ 3 )
Page 25
9. Sk i & Sp ind le
Page 21
12. Chass is (2/ 3)
Page 27
DRIFTER
INDEX
Page vii . . Page 29
14. Hood (SA 34 0 & S844 0 )
15. Hood (SC340 )
16. Seat
17. Fu el Syst em
. . . . Page 3 5
18. Cables
Page 37
. . . .. . Page 39
. . . . Page 43
DRIFTER
INDEX
Page viii
19. Carburetor (SA340 & SB440)
Page4 5
22. Cylinder Head, Cy linder (SC340)
Page 53
t
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~
20. Carburetor (SC340)
Page 49
21. Cy linder Head, Cyl ind er (SA 34 0 & SB440 ) . Page 51
23. Cran kcase
24. Piston & Crank shaft
Page 55
Page 57
DRIFTER Pageix
INDEX 25. Engin e Air Shroud (SA340 & SB440) . .... Page 6 1
28. Magnet o (SA 340 & SC340)
Page 6 7
26. Fan Case (SA340 & SB440)
Page 63
29. Recoil St art er
Page 69
27. CD I Sy stem (SB440)
Page 65
30. T ool Ki t & Lubr icants
Page 7 1
."
DRIFTER
INDEX
Page x
3 1. Spec ial Service Tools .. .. . . ... . .. .. .. Page 73
en -
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32 . Engine A ssembl ies and Manuals
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ASSEMB LY &
MOD EL
ENG IN E
OWNER'S
PREPARATION
MANUA L
MANUA L 999 64-3 514
SA34 0·A4
70340 -3014 99974-3505
SB440-A4
70440-3017 99974-3505
99964 -3514
SC340-A 1
70340-30 10 999 74-3509
99964-3514
SHOP
FL A T RA TE
MODEL
MANUAL
MANUAL
SA340 -A4
99963-3511
99990-350 1
SB440 -A4
99963-3511
99990-3501
SC340-A 1
99963-3 5 11
9999 0-3501
--------
DRIFTER
Page 1
1. ENGINE MOUNT & EXH AU ST
3
DRIFTER
1. ENG INE MOU NT & EXHA UST Page 2
/ Ref . No.
Kawasaki Part No .
Oese r:pt Ion
,,:>b<
2
MUFFLER
49070 -3506
MUFF LER
490 70-35 10
MUFFL ER
39 178-3506
MANI FOLD, exhaust
39 178-3504
MANIFOL D, exhaust
39 178-35 07
MANIFO LD, exhaust
\:)'?'
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7 Remarks
\Str-
~
C:Jv
C:J«j
49006 -3505
BOOT , exhaust pipe
1
1
4
9208 1-35 02
SPRING, exhaust
4
4
2
Short
5
350BA1 200
NUT, insert, 3 /8 -24
4
4
4
Grade 5, zinc plated
6
92022-3549
WA SH ER, engine moun t
4
4
4
7
92075-3509
MOUNT , rubber engine
8
8
8
92026-3536
SPACER, mount
4
4
92026-3548
SPACE R, mou nt
9
92022-3555
WA SH ER, special
4
10
92001-3506
BO LT, carriage, 3/8 -24 x 2.00
4
13 169-353 1
PLATE, engine moun t
1
13169-352 7
PLAT E, engine moun t
46 5FA1600
WA SH ER, spring lock, 1/ 2"
3
8
11
12
•
490 70-3509
'W
\:)'?' C:Jtr-
Quant it y
13
118BA 16 20
SCREW, 1/ 2-13 x 1.25
14
32069-35 11
BRACK ET , muffl er
15
9208 1-354 7
SPRING, exhaust
1.03 lon g 4
1.13 1ong
4
4
Internal square
4
4 1
1 4 4
4
4
St eel, zinc plated
4
4
Grade 5, zinc plat ed
1 2
2
2
Long
DRIFTER
Page 3
_
_
=E: N~TS" LIGHTS LI & WIRING _2. INSTRUM _
_
-
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I
31
28
27
I'~PDJ 17
[] ~ -1 6
15
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I
iii
18
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DRIFTER 2. INSTRUMENTS, LIG HTS & WIRING
Page 4
/ Ref. No .
Kawasaki Part No .
Description
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c:;~
SPEEDOM ET ER HEAD ASSY
opt
opt
2
92069-3505
•
opt
op t
3
21066-3504
REGULATOR, voltage
2 1066-3505
REGULATOR, voltage
4
92022 -3538
WASHER , special
92022-355 0
WASHER, special
35 1BA0 800
NUT,1 /4-20
5
Remarks
n.,l>'
c:;V
25005-3505
BUL B, 12V, 3AW
/
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c:;~
r
Quant it y
1.
Inc ludes mounting stud
2 Grade 5, zinc plat ed
35 1BA 0600
NUT, insert, 10-24
2
Grade 5, zin c pl at ed
6
250D A0610
SCREW, 10-24 x .62
2
Grade 60M , zin c plated
7
23025-3 501
LAMP ASSY, tail
• •
8
23026-3503
9
244DA0506
10
11009-3505
11
LENS, tail lamp
1
1
1
2
2
Grade 60 M, zinc plated
SCREW, #8-3_2 x .38
2
GASKET, tai l lamp
1
92069- 3502
• •
BU LB, 12V tail lamp
1
1
1
GE #1157
12
2302 7-3501
•
BODY A SSY, t ail lamp
1
1
1
Inclu des wiring - no bulb
13
412E A0600
WAS HER, pla in, # 10
2
2
2
St eel, zinc plated
14
350BA0600
NUT, insert, #10- 32
2
2
2
Grade 5, zinc plated
15
2600 1·35 0 7
HARNE SS A SSY, main wir ing
1
1
1
16
2 1169-350 1
•
T ERMINAL
5
5
5
Main harness to engine
17
131 59-3503
•
CONNECTOR
1
1
1
Main harness to engine
18
26001 -3506
HARN ESS, headlamp & instrument
26001-3 509
HA RN ESS, headlamp & instrumen t BA N D, cable t ie
2
3
3
19
92072-3501
20
92009-3549
SCREW, adjustm ent
4
21
92081-3557
SPRING, adjustment
4
22
23006-3 501
RIM , mounting
1 1
23
92069-3506
BU LB , 12V 60 /6 0W
24
23006-3502
RIM, bulb ret aining
1
25
92022-3552
WASH ER: bulb retaining
4
Special
26
92009- 3550
SCREW, b,!lb retaining
4
Special
GE #4492
27
92009-354 6
SCREW, special adjustment
28
41025-3501
RIM, headlamp lens
29
9208 1,!t4 9
SPRI NG, top adjustment
2
2
Short
9208 1-354 8
SPR lNG, bottom adjust ment
2
2
Lo ng
31
2300 7-35 0 1
LE NS
1
32
92069-3501
BU L B, 12V 60 / 60W
1
St anley 00 1-1763-2
92069- 3504
BU LB, special quartz
opt
Phillips 1234 2-PH4
140 20-3505
RETAINER, bulb
30
33
I'
4
4 1
opt
Includes spring
DRIFTER
Page 5
3. CONTROLS & SWITCHES
~
~--~
i~ 10 I 9
11
._ - - - - - -
~-14
12
13
I
I -: 'I I l---
~,
"
2.s»: 0 -J~:~
~
~
-J.
11
---
I
19
I 18
DRIFTER 3. CONT RO LS & SWITCHES
Page 6
/
Ref. No.
':>~
39074-350 5
LE VER ASSY, throttle , 32 mm
390 74-3506
L EV ER A SSY, throttle, 28mm
270 10-3507
1
rf
~
0"?' 1
0«}
0°
1 1
9
13 169 -3510
PLATE , throttle case
1
1
1
10
92009-3524
• • • • • • • • • •
SCREW, plate
1
1
1
11
430 77-350 2
L EV ER ASSY, brake
1
1
1
12
270 10-3508
•
SWIT CH, dimmer
1
1
1
13
92009-35 20
• • • •
SCREW, lock
1
1
1
PIN, lever
1
1
1
LEVE R, brak e
1
1
1
WA SHER, pin
1
1
1
RETA INER , pin
1
1
1
CASE, brake
1
1
1
PLA TE , brake case
1
1
1
SCREW, plate
1
1
1
2 3
92009 -3 520
4
9204 3-3504
5
390 75-3506 390 75-35 07
6
92022-3517
7
920 33-3505
8
320 99 -3502
14
9204 3-3504
15
43001 -350 1
16
92022-35 17
17
9203 3-3505
SWITCH, emergency st op
1
1
1
SCREW, lock
1
1
1
PIN, lever
1
1
1
LE V ER, t hrottle, 32 mm
1
1
WA SHE R, pin
1
1
1
RETA INER, pin
1
1
1
CASE, t hrottle
1
1
1
L EV ER, thro ttle , 28mm
21
270 10-3505
• • • • •
22
27005-350 1
SWITCH ASSY, key
18
32099-350 1
19
13 169-3509
20
92009 -3524
1
1
1
1
K EY NUM BER
AR
AR
AR
Set of 2
• • • • • • • • • • •
KEY 20
AR
AR
AR
Set of 2
KEY 21
AR
AR
AR
Set of 2
KEY 22
AR
AR
AR
Set of 2
K EY 23
AR
AR
AR
Set of 2
27008-3506
•
27008-3507
27008-3511
• • • • •
2700 8-3512
• •
9201 5-3509
•
27008 -3502 2700 8-3503 27008 -3504
27008 -3508 27008-3509 27008 -3 510
24
1
27008-350 5
27008-350 1
1
1
SWITC H, brake light
• • • • • •
23
/
~f{~
Description
Kawasaki Part No.
Quant it y
K EY 24
AR
AR
AR
Set of 2
K EY 25
AR
AR
AR
Set of 2
KE Y 26
AR
AR
AR
Set of 2
K EY 27
AR
AR
AR
Set of 2
K EY 28
AR
AR
AR
Set of 2
K EY 29
AR
AR
AR
Set of 2
KE Y 30
AR
AR
AR
Set of 2
K EY 3 1
AR
AR
AR
Set of 2
1
1
1
NUT, face
Remarks
JA4i¥ •
DRIFTER
Page 7
4. DR IVE CO NVERTER
.....:;::;.
.>
;:-/
/
.>
~~':::'--'" \" \ \ \\\ \ \
\\
;:
"
-
II
I
::
I
/I
I
11
/
/
/
II
/1
/
I I. II
I I
/
/
/
.-
/ / /
/
,/
' ~,-:- - - -:--: //~ ~ .-;,. /
/ ,
l
/ /
/
/ / /
II
I:
DRIFTER
4. DRIVE CONVE RTER Page Ouantit y
/ Ref. No.
Kawasaki Part No.
/
%fj(~
Descrip tion
Remarks
'?~ ~~ ~ S'?" s<O SO
49093-3501
CONVERT ER A SSY, dr ive
49093-3502
CONVERTER ASSY, driv e
2
59296-3502
•
STAT IONAR Y SHEAVE
1
1
1
3
59301-3502
1
1
1
4
49092-3502
RA MP, 0146·294
3
3
3
Replace as set· 3 ramps
5
465FA0500
• • •
MOVA BL E SHEAVE ASSY
WA SH ER, spring lock, #8
3
3
3
Steel, zin c plated
6
92009-3541
•
SCREW, socket , #8-32 x .88
3
3
3
7
13095-3501
1
1
8
465FA 1000
WASHER, spring lock, 5/16"
3
3
3
9
92009-3542
• • •
HOUS ING & BEAR ING ASSY
SCREW, socket , 5/ 16-18 x .88
3
3
3
10
9208 1-354 1
~
SPRING, green
1
opt
64l bs/ inch
9208 1-3553
•
SPRING, yellow
4 2 lbs/inch
SPRING, red
9208 1-356 1
opt
opt
Steel, zinc plated
50 lbs/ inch
opt
opt
opt
WA SHER, cup
1
1
1
RING, split
2
2
2
14
920 43 -35 16
• • • • •
15
13042-350 1
•
WEI GHT, black 0 146-10 5
1304 2-3502
•
WEI GHT, red 0146-106
6
opt
6
5.95 8 grams
WEI GH T, red 014 6-286
opt
opt
opt
8.800 grams
11
92022-3554
12
43058-3505
13
490 50-3502 49050-3504
1304 2-3 504
SPID ER ASSY
1
SPID ER A SSY
1
1
BOL T, special
3
3
3
opt
6
opt
7.858 grams
Install with head of bolt on side of arm with tabs
1304 2-3 507
WEI GHT, yell ow 0146-123
opt
opt
opt
6.992 grams
13042 -35 05
WEI GHT, black 0 146-278
opt
opt
opt
6.4 75 grams
1304 2-3503
, WEIGH T , black 0146-279
opt
opt
opt
5.457 grams
13042-3508
WEIGH T, wh ite 0146 -107
opt
opt
opt
4.958 grams
13042 -3506
WE IGHT, black 0146-135
4.479 grams
16
920 15-3524
17
346AA0600
18
92009-3540
19
99970-3520
• • • •
opt
opt
opt
NU T, flex lock, #10-32
3
3
3
NUT, # 10-24
3
3
3
SCREW, set, # 10-24 x 1.25
3
3
3
ROLLER -BEAR ING KIT
Grade 2, zinc plated
1
3 roller-bearing assvs Steel, zinc plated
- 20
465FA 1600
WA SHE R, spring lock, 1/ 2"
1
21
9200 1-3532
BOL T, 1/2- 20 x 5.00
1
Grade 5
22
590 11-3503
BE LT , convert er
1
43 .5 OC x 1.2 50 W
.
8
DRIFTER 5. DRIV EN CO NVERTER & BRAKE
Page 9
13
I 36 - ~ ",
37-~ ~
-, a -38 <, ./
./
,
29
DRIFTER 5. DRIVEN CO NVERTER & BRAKE Page 10
Ref No.
Remarks
Descripti on
1
490 94-3501
CONVERTER ASSY, driven
1
1
2
92033 -3509
•
RING, ret aining
1
1
3
49092-3501
RA MP, t orque
1
1
4
9208 1-3535
SPRING, dri ven
1
1
1
SLI DE, shoe ramp
3
3
3
SHEAVE ASSY, movable
1
1
1
BUSH ING, movable
1
1
1
SHEAV E ASSY, fi xed
1
1
1
12
9204 3-3523
• • • • • • • • • •
1
1
1
13
39044 -3503
CA LIPE R ASSY, brak e
1
1
1
14
92009-3537
SCREW, special sock et-head
2
2
2
15
41 2EA 1000
WASHER, f lat, 5/ 16':
2
2
2
5
49048-3501
6
5930 1-350 1
7
92028-3512
8
59296 -350 1
9
41080-3503
10
92009-3536
11
92038-3503
30° ramps
D ISC, brake
1
1
1
SCREW, 1/4-20 x .62
3
3
3
K EY, woodruff
1
1
1
PIN, spring, 3/32 x 1.00
16
4304 2-350 2
17
43050-350 2
18
43050-3503
19
92022-3 545
• • • • • •
20
4304 2-3503
•
CALIP ER A
1
1
1
21
92043-350 1
2
2
2
22
41050-3502
CAM,22°30'
1
1
23
92022-3504
• • •
PIN, push
WASHER, stud
1
1 1
1
1
1
1
1
1
Metall ic
PA D A , 1/2" t hick
1
1
1
Met allic
WASHER, back up
1
1
1
920 15-3523
•
NUT, special, 5/16-24
1
130 70-350 1
1
26
92081-3511
• • • •
BUSHING SPRING, , cam
1
1
1
2
2
2
2
2
2
1
1
28
92028-3511
St eel, zinc plated
CALI PER B
24
92015-3522
Socket head
PAD B, 5/ 16" thi ck
25
27
f-
Kawasaki Pa rt No.
NUT
t,
,"'" BUSH ING
Lube with "Never-Seez "
29
92081 -350 1
SPRING, brake ret urn
1
30
11034-3569
BRACKET, brake support
1
1
1
31
534YY0603
RIV ET,3/ 16;;-
2
2
2
32
11034-3593
BRACK ET, ret urn spring
1
1
1
33
92055-3507
RING, " 0 "
1
1
1
Prevents ratt le
34
119BA0820
BOLT, 1/4-28 x 1.25
2
2
2
Grade 5, zinc plated
35
350BA0800
NUT , insert, 1/4-28
2
2
2
Grade 5, zinc plated
36
39092-3501
PIN, hair
1
1
1
~7
92043-3512
1
1
1
,,'38
14020-3515
PIN / RETA INER, clevis
1
1
1
Stain less steel
DRIFTER
Page 11
6. CHAINCASE
Ip t
I
36~
35 -@~
I
34 ~,,------:;:/
<,
32- 0 @
I
31
DRIFTER
6. CHAINCASE
Page 12
/ Ref . No .
Kawasaki Part No.
Description
1
92055·3 505
RIN G, " 0," chain cover
2
39039·3 502
COVE R, chaincase
3
92066·3502
PLU G, fill
/
~«~
t? C;#
~
Ouant ity
Remarks
v~
C;
1
4
9200 1·350 3
BOLT, 1/4 ·20 x 1.00
5
41077·3504
AD APTER, speedometer dr ive
6
1101 2·35 02
CAP, adapter hole
1
1
7
11009·3514
GA SKE T, cap
1
1
5
5
5
Special lock pat ch
1
8
920 66-3505
PLU G, oi l level check
1
1
1
9
92026-3529
SPACER , bearing
1
1
1
10
9204 5-3 502
BEA RIN G ASSY, ball
2
2
2
11
92026-3530
SPACER, upper sprocket
1
1
1
12
39134-3503
SPROCKE T, 21 teeth
1
opt
391 34-3506
SPROCKE T, 17 teeth
39 134 -3502
SPROCK ET, 18 teet h
opt
opt
opt
39134-350 5
SPROCKET, 19 teet h
opt
opt
opt
391 34 -3504
SPROCK ET, 20 teeth
opt
opt
opt
391 34-350 8
SPROCK ET, 22 teeth
opt
opt
opt
13
9202 2-3542
WASHE R, special fl at
2
2
2
14
92001 -351 7
BOLT, lock pat ch, 5/ 16-24 x .75
2
2
2
15
39 170-35 0 1
TEN SION ER A RM
2
2
2
16
12053-3501
GU ID E, chain
2
2
2
17
39092-3501
PIN, hair
2
2
2
18
119BA0816
BOLT, 1/4-28 x 1.00
2
2
2
Grade 5, zinc plated
19
412EA0800
WASHE R, plain , 1/4"
2
2
2
St eel, zinc plated
20
420 36-3501
BUSH ING, ten sioner arm
2
2
2
21
92081 -3508
SPRING, green tensioner
1
1
1
.049 wire dia. x 3.75 long
920 81·3503
SPRING, blue tensioner
opt
opt
opt
.0 55 w ire dia. x 3.75 long
92081-3 506
SPRING, pink t ensioner
opt
opt
opt
.049 wire di a. x 3.38 long
92081-3507
SPRING, yellow t ensio ner
opt
opt
opt
.055 wire dia. x 3.38 long
92057-3505
CHA I N, 90 pitch silent
92057·3 504
CHAI N, 92 pi t ch silent
22
23
-
390 72-3 502
KE Y, speedometer
24
41077-3502
A DAPTER, speedometer key
25
92001 -3525
BO LT, special
26
92022-3502
WA SH ER, special
opt
opt
Tensioner wear block
Speedomet er key adapt er not included
39 135-3 509
SPROCK ET, 38 teet h
3913 5-3510
SPROCKET, 36 teet h
opt
opt
opt
39 135-3513
S P ~OCKE T,
37 t eeth
opt
opt
opt
39 135-35 12
SPROCKE T, 39 t eeth
opt
opt
opt
39 135-35 11
SPROCKE T, 40 teeth
opt
opt
opt
28
92026-353 1
SPACER, lower sprocket
29
92033·35 10
RIN G, snap
27
Grade 5, zi nc plated
DRIFTER Page 13
6. CHAIN CASE (CONTINUED)
'
'.
,
,
"
' .~
'' ' ... ,
·~····,j:;t~~~
'~"{~ /: : Q':j t
36~ 35-
@«l\
I
34
DRIFTER
6. CHAINCASE (CONTINU ED) Page 14
/ Ref . No.
Description
Kawasaki Part No.
/ Remarks
(f(#'f #"
,:?"":J
':i
Quant it y
':i
0nf
':)
30
92045-3506
BEAR ING, ball
1
1
1
31
350B A 1000
NUT, insert, 5/ 16-24
4
4
4
32
92022-354 6
WASHER, special
4
4
4
33
360 14-3502
CASE, chain
34
92025·3507
WASHER, "U"
35
41 2EA1 000
36
9200 1-3523
Grade 5, zinc plated
1
1
1
AR
AR
AR
WA SHER, plain, 5/ 16"
4
4
4
Steel, zinc plated
BOL T, 5/1 6-24 x 5.00
4
4
4
Grade 8, zinc plated
Convert er alignment
37
350BA080 0 '
NUT, insert, 1/4 -28
2
2
2
Grade 5, zinc plated
38
92026-3528
SPA CER, clutch shaf t
3
3
3
1.0 1 x 1.25 x .073
39
13107 -3505
SHA FT, converter
1
40
9203 8-3504
KEY, convert er, 3/1 6 x 1/4 x 3.00
1
41
92022-3544
SPA CER, washer
42
92026-3530
SPA CER
43
39 171-3503
BEA RING SUPPORT ASSY
44
343 BA0800
NUT,1 /4 -20
45
11034-3570
CLE V IS, support
46
9200 9-3559
BOLT, 1/4 -20 x 3.00
47
92043-3518
PIN, clevis
*
S61020- 14 1
OI L, chaincase (case of 24 )
1
Grade 5, zinc plated Grade 8, zinc plated Contains sea lant
"Not shown
I
DRIFTER
7. SUSPENSION
Page 15
17
I
61
63-'f>
,
41 A
I â&#x20AC;¢
DR IFTER
7. SUSPE NSION Page 16
·w /
Ref . No.
Descript ion
Kawasaki Pa rt No.
Quantity
7 Remarks
-r. -r -r. ~t>'
"Jt>'
C:J'Y'
~
C:J0
C:J«)
1
1
1
CLIP, track
46
46
46
With guide tab
CLI P, track
46
46
46
With out guide tab
AXLE, rear
1
1
1
92026-3534
SPACER, rear axle wheels
1
1
1
41073-3506
WHEEL ASSY, idler
.6
6
6
7
92026·3509
6
6
6
8
39 153-3511 ,
• •
SPACER, inside wheel WHEE L, idler
6
6
6
9
92045 -3502
BEAR ING, ball
6
6
6
10
92033-3504
• •
RING, snap
6
6
6
SPACER, outside wheel
6
6
6
1
39 125-3506-
TRACK ASSY
2
49048-3502
•
3
49048-3503
•
4
32032-3530
5 6
.-
~-
11
92026 ·3508
•
12
92026-3532
SPACER, rear axle wheels
2
2
2
13
39 172-3503
BRACK ET ASSY, RH rear axle
1
1
1
5.88"
aD
1.21" long
39172-3502
BRACKET ASSY, LH rear axle
1
1
1
14
92026 -3535
SPACER, rear axle wheel
2
2
2
15
413EA 1200
WASHER, plain, 3/8"
4
4
4
Steel, zinc plated
16
9200 1-3529
BOL T, 3/8 -16 x 1.00
4
4
4
Special lock patch
17
351 BA0800
NUT, insert, 1/4 -20
22
22
22
Grade 5, zinc plated
2
2
Grade 5, zinc plated
18
343BA1200
NUT, 3/8 -16
2
19
9200 1-3527
BOLT, 3/8-16 x 3.75
2
2
2
Grade 5, zinc plated
20
118BA0814
BOLT, 1/4-20 x .87
16
16
16
Grade 5, zinc plated
21
13107-3507
SHAFT, idler wheel
1
1
1
22
41073-3505
WHEEL ASSY, rear suspension idler
2
2
2
•
2
2
.2
24
92033 ~ 92045-3513
RING, snap BEAR ING
2
2
2
25
3915 3-3510
• •
WHEEL
2
2
2
2
2
23
26
3203 2-3 540
SPACER, idler wheel
2
27
3300 1-3504
AR M, rear suspension
1
1
1
28
465FA1000
WASHER, spring lock, 5/ 16"
2
2
2
BOL T, 5/16 -18 x .75
118BA1012
29
; f
4.25"
aD
St eel, zinc plated
2
2
2
Grade 5, zinc plat ed
4
4
Apply grease AR
30
32032-3543
BUSH ING, suspension
4
31
92081 -3538
SPRING, rear RH
1
1
1
92081-3537
SPRING, rear LH
1
1
1
13107-3506
SHAFT, pivot
2
2
2
A pply grease
4
4
Whiz lock Grade 5, zinc plated
32
9200 1-3508
BOLT, special, 3/8-16 x 1.00
4
34
118BA1032
BOLT, 5/16 -1 8 x 2.00
4
4
4
35
39020-3504
BRA CKET, rear suspension arm
2
2
2
36
39105-3 504
RA I L, suspension
1
1
1
RH side
RAI L, suspensi on
1
1
1
LH side
STRIP, rail wear
2
2
2
Hi-Fax
PIN, bumper
4
4
4
Special
SCREW, 1/4 -20 x .75
4
4
4
Grade 60M , zinc plated
33 '.
3910 5-3503
•
37
39139-3504-
38 ""'-.;l2043-3 515 ,. 244DA081~ 39
-
.
,
r
DRIFTER
7. SUSPENSI ON (CONTIN UED) Page 17
17
I
a
63-~
62 -
i I
I
I.
Jl
·r
DRIFTER
7. SUSPE NSION (C ONTINUED) Page 18
/
t(<<er
Descript ion
Ref. No.
Kawasaki Part No.
40
92009·3538
BOLT, special
2
2
2
41
23062 ·3517
BRACKET ASSY, li miter
1
1
1
42
39076·3503
LIMI T ER
2
2
2
/ Remark s
fJll' ~ t>J C:J"?' C:J<O C:JV
43
92028-35 15
BUSHING, front suspension spring
2
2
2
44
92022-355 1
WASHER , li miter bracket assy
2
2
2
45
92041 -350 1
PIN, cotter
2
2
2
46
14020 -3517
RETAINER, bumper pin
4
4
4
4
4
4
47
59201-3504
BUMPER, rubber
48
39020·3 505
BRACKET ASSY, f ront suspension
1
1
1
49
92026·3533
SPACER, fr ont idler wheel
2
2
2
50
39 139·3503
STR IP, brack et wear
2
2
2 2
Special
0.94" long
51
11034 -3584
STOPPER, rear suspension bracket
2
2
52
534YW0612
RIVE T,3/16"
4
4
4
Steel, zinc plated
53
351 BA 1000
NUT , insert, 5/ 16-18
4
4
4
Grade 5, zinc plated
54
118BA1232
BOLT, 3/8 -16 x 2.00
2
2
2
Grade 5, zinc plated
55
92028·3502
BUSHlNG , shock absorber
2
2
2
56
42036-3502
SLE EVE, shock absorber
1
1
1
57
45014-3503
SHOCK ABSORBER
1
1
1
58
92015-352 7
NUT, insert , 3/8- 16
2
2
2
1
1
1
59
»<
Quant ity
92081 -3539
SPRING, front RH
92081 ·3540
SPRING , front LH
1
1
1
60
390 10-3502
BOLT, eye
2
2
2
61
118BA0816
BOLT, 1/4·20 x 1.00
2
2
2
Special
62
3300 1·3503
ARM , f ron t suspension swing
1
1
1
63
413EA0800
WASHER, plain, 1/4"
2
2
2
Steel, zinc plated
64
35 1BA1200
NUT, insert 3/8- 16
2
2
2
Grade 5, zinc plated
DRIFTER Page 19
8. DRIVE SHAFT
DRIFTER
8. DR IVE SHAFT Pa ge 20
/
Ref. No.
Kawasaki Part No.
Quantity
~«~
Descript ion
/ Remarks
':>~ tf nJ" '?'?" ,?«j ,?V
1
118BA0816
BOL T, 1/4-20 x 1.00
2
41066-3502
HOUSING, bearing
3
412EA0800
4 5
3
3
3
Grade 5, zinc plated
WASHER , plain, 1/4"
3
3
3
St eel, zinc plated
351 BA0800
NUT, insert, 1/4 -20
3
3
3
Grade 5, zinc plat ed
92055-3506
RING , " 0 "
1
1
1
6
92045-3514
BEARING
1
1
1
Sealed
7
92027-3505
COL LAR ASSY
2
2
2
Includes screw
8
92009-3563
•
2
2
2
Socket head
9
12046 -3504
SPROCKET, drive
2
2
12046-3 50 5
SPROCKET, dr ive
2
10
32032-3527
SPACER , sprock et
1
11
39 159-3505
SHAFT, tr ack drive
SCREW, # 10-32 x .62
DRIFTER
Page 21
9. SKI & SPINDLE
ยง- l
a2 1 - ~ <,
1
Q
<,
22 ~
I I I
21 - ~,
I ~-3
20-~ G?<-. I o
.
<. -
4
:~ 5
I J.
_ --
6 -
---l.-
7
~
DRIFTER
9. SKI & SP INDLE Page 22
/
Ref. No.
Kawasaki Part No.
t/j(~
Descript ion
/
Quant it y
~t><
t:?-
0?'
0<0
0°
1
92028-351 8 /
BUSH ING , spindle
4
4
4
2
391 27·3501
SPIND LE , ski
2
2
2
3
119CA 1220
BO LT , 3/8 -24 x 1.25
4
4
4
4
390 15-3503
SADDLE, ski spring
2
2
2
5
118BA 125 2
BOL T, 3 /8 -16 x 3.25
2
2
2
2
2
/ Remarks
r>J
Grade 8, zinc plated
Grade 5, zinc plated
6
39 130 -3501
SPRING, monol eaf
2
7
42036-3503
SL EEVE , spring
2
2
2
8
39094-3502
PLATE, spr ing backup
2
2
2
9
59201 -3502
BUMPER, ski spring sa ddl e
2
2
2
10
39 106-350 1
RET AINE R, bumper
2
2
2
11
350BA 1200
NU T, insert , 3/ 8-24
10
10
10
12
351 BA 1000
NUT, insert, 5/ 16-18
6
6
6
Grade 5, zinc plated
2
Grade 5, zinc plated
A pply grease
Grade 5, zinc plated
13
119BA 1244
BO LT , 3 /8-24 x 2.75
2
2
14
39 122-3505
SK I
2
2
2
15
39 120 -350 1
SKEG , ski
2
2
2
Sk i wear runn er
16
119BA 1248
BO LT, 3/ 8-24 x 3.00
4
4
4
Grade 5, zinc plat ed
2
2
17
39138-3503
STR IP, rub
2
18
920 26-35 10
SPACER, shock
4
4
4
19
4 5014 -3 504
SHOCK ABSORBER
2
2
2
20
92022 -352 8
WA SH ER, special
2
2
2
4
4
Grade 5, zinc plat ed
21
351 BA 1200
NUT, insert , 3/ 8-16
4
22
118 BA 1244
BOL T, 3/8 -16 x 2.75
2
2
2
Grade 5, zinc plated
23
42036-3508
SLEE VE , spin dle
2
2
2
A ppl y grease
DRIFT ER
Page 23
10. STEER ING
1
~
2 -~
~- 2
DRIFTER
10. STEE RING Page 24
7
Ref No.
Kawasaki Part No.
w:;y
Descript ion
'?~
\>.~
s<O
S'?"
2
Quant it y
/ Remarks
r:,l>'
SV
4607 5-3501
GRI P, handl e
2
2
2
92072· 3501
BA ND , cable t ie
3
3
3
2
2
Grade 5, zinc plated
3
119 BA1 040
BOLT, 5/ 16-24 x 2.50
2
4
39009-3501
BLOC K, moun t
4
4
4
5
9202 8·3 510
BUSHIN G, steer ing pol e
4
4
4
6
39100·3 505
POL E ASSY , handle
7
119B A 1224
BOL T, 3/ 8-24 x 1.50
2
2
2
Grade 5, zinc plated
8
39111 -3510
ROD, steeri ng t ie
2
2
2
RH & LH wel dment
9
344BA 1200
NU T, jam, 3 / 8-24 RH
2
2
2
Grade 5, zinc plated
10
92004-3502
ST U D, adj usting
2
2
2
11
350BA 1200
NUT, insert , 3/8-24
5
5
5
Grade 5, zin c pl ated
12
4 12 EA 1200
WA SHER, plain, 3/8"
4
4
4
St eel, zinc pl ated
13
3900 6-3508
ARM , lon g st eering
1
1
1
LH
1
119B A 1236
BO LT, 3/8 -24 x 2.25
2
2
2
Grade 5, zinc plated
15
39112-3506
ROD END, ti e
2
2
2
Female
16
9201 5-3510
NUT, jam, 3/8 -24 L H
2
2
2
Special
17
92009-3539
SCREW, special, 3/8 -16 x 1.38
1
Grade 8, blac k
18
9201 5-3527
NUT, t hin lock, 3/8 -16
1
19
9202 6-3537
SPACER, rod end
1
20
39006-3509
ARM, short steering
RH
21
119BA1 228
BOL T, 3/8 -24 x 1.75
Grade 5, zinc plated
22
92001 -3528
BOL T, 5/ 16-24 x 2.50
2
2
2
Grade 8, lock pat ch
2
2
Grade 5, zinc plated
14
23
350B A 1000
NUT, inser t, 5/16 -24
2
24
46012-3504
HOLDER , hand le
1
1
1
25
92009-3510
BOL T, socket head, 1/ 4-20 x 1.00
4
4
4
26
46003-3503
BAR, handl e
RH on ly
DRIFTER 11. CHASSIS (1/3)
Page 25
1
1
I
r.
' -Tl _-=-.J
3
J'->
4
~6n26-~
25
J , i
24
8
d-)-7
~-7 1
~ /
»>
I ------ ~~
i:J9 ---
I
24-"-
~~
/
.-A
2)- 7
;-
T 6
~-
~7
I
I a a ."- 'i'~r>
7 7
(i' .
,,-
VJ
8
- 10
~"
23- ,
1~
1
DRIFTER 11. CHASSIS (1/3)
r
r
Page 26
/ Ref No.
/
?ff fr
Descn pt Ion
Kawasaki Par t No .
Quant it y
"J~
\>.~
c}-
Remarks
~
0<0
00
1
390 73-3506
LAN Y A RD ASSY
1
2
39092-3503
•
2
3
56040 -350 1
LAB EL, warning
French/ Engli sh
4
39056-3503
GUARD ASSY, convert er belt
Weldment
39056-3504
GUARD A SSY, converter bel t
PIN, hair
1
5
92043-35 19
PIN, convert er guard
2
2
2
6
39092-3503
PIN, hair
2
1
2
7
35 1BA0800
NUT, insert , 1/4-20
24
24
20
Grade 5, zi nc pl ated
8
41 2EA 0800
WASHER, pl ain, 1/4"
20
20
16
St eel, zinc plated
9
39145-3508
TRIM -SEAL, hood guide
2
2
2
10
13070-35 11
GU ID E, hood
2
2
2
11
118BA 08 12
BOLT, 1/4-20 x .75
16
16
16
12
3903 1-3503
CA P, bumper end
2
2
2
Grade 5, zinc plated
13
92009-3543
SCREW, self tap, #6-32 x .38
2
2
2
14
5602 7-3533
D ECA L, bumper
1
1
1
15
35009-3509
BRACE, nose pan
2
2
2
16
39027-350 2
BUMPER, fron t
17
92037-35 11
CLA MP, harness
18
35034-352 1
PLAT E, hin ge back ing
2
2
19
244DA0812
SCREW, mach ine, 1/4-20 x .75
8
8
Grade 60M, zin c plated
20
53044-3503
TR 1M, pan, 22.50"
1
1
(See note . )
21
3909 0·35 05
PANEL, nose vent
1
Black gri ll
22
53009-35 17
HING E, low er LH
1 1
23
53009-35 15
HING E, lower RH
24
92009·3552
SCREW, 1/4-20 x .75
25
53009-352 1
HINGE
26
92022-3539
27
1
1 4
Special
WA SH ER, special
2
St eel, zin c pl ated
390 12-3503
CASE, storage
1
28
535YW0604
R IV ET, 3/ 16"
2
29
14025-35 13
COV ER, storage case
.
NOT E: Bulk t rim is available by orderi ng t he fo llowing part num ber . •
53044-3506
TRI M, 25 ft . ro ll
~
Steel, z inc pla ted
DRIFTER 12. CH ASSIS (2/3)
Page 27
f
1
~
3
I V
- 10 -
11
DRIFTER
12. CHASS IS (2/3) Page 28
/
([
Ref . No
Kawasaki Part No.
(f(<<~
Descript ion
/ Remarks
~~ ~ ~ 0"<" 0<0 0°
1
39 156·3524
PAD, RH foot gri p
1
2
39 156·35 25
PAD , LH foot grip
1
3
118 BA 0824
BOLT , 1/4 ·20 x 1.50
4
4
4
920 09·3547
SCR EW, truss head, 5/ 16·24 x 1.00
4
4
5
413EA 1000
WA SHER, p lai n, 5/ 16"
4
4 4
4
Grade 5, zinc plated
4
4
Steel, zinc plated
6
35 1BA 08 00
NUT, insert, 1/ 4·20
4
7
39028· 3503
BUMP ER, rear
1
8
13 169·3526
PLATE , snow flap
9
535YW0608
RIV ET,3/ 16:
4
4
10
390 47·350 2
FLA P, snow
1
1
1
2800 1·3502
REF LECTO R, red
2
2
2
12
9201 5·3507
NUT , lock, 5/ 16·24
4
4
13
92022 ·35 05
WA SH ER, cupped
4
4
14
9202 6·35 02
SPACE R, hand le grip
4
4
15
39053·35 02
HAND L E, passenger
2
2
16
560 18·3518
MARK,3 40
2
17
560 18·35 09
MA RK ,4 40
18
53044·3504
TRIM , pan, 8.18 "
NOTE:
•
Bulk t rim is avail able by ordering th e follow ing part num ber.
53044 ·3506
TR IM , 25 ft . ro ll
Grade 5, zinc plated
St eel, zinc plated
11
If
r
Quanti ty
Ny lon cap
2 2
2
2
(See note. )
DRIFTER
Page 29
13. CHASSIS (3/3)
~~ 3
~-2 I I I )
o
1: I
0
I I I
I I I I I I I
~-9
r- "
~I
14--~j
°
I " I
I I I I
I II
I' , I I--J • I J •
~ 0 0_
~I
:
• 13- - . .
0
I"
•
~15 J • -
•
• - •
1
DRIFT ER
13. CH ASS IS (3/3) Page 30
/
r
J
r I I
Ref . No.
7
~f{ r
Descn ptron
Kawasaki Part No .
Quant it y
':l~
\>.~
'J~
Remarks
':l~
'J<{j
'Jv
1
39 048-3503
FOOTREST, RH
1
2
534YW0604
RI V ET, 3/1 6 x .4 5
6
3
92059-3544
T UBE , special
4
390 84 -3509
MOUNT, upper st eeri ng
39084 -3505
MOUN T , up per steering
39084 -35 08
MOUNT , upper steer ing
5
534YY0602
RI V ET , 3/16 x .33
87
87
87
6
534 Y Y0 604
RIVET, 3/16 x .45
6
8
6
7
39048-35 04
FOOT REST, L H
1
1
1
8
534YW0603
RI V ET, 3/ 16 x .37
10
10
10
Steel, zinc plated
9
534YW0602
RIVET, 3/ 16 x .33
42
42
42
St eel, zinc plated
10
3902 6-3505
BU LK HE A D, rear
1
1
1
11
534 XW0604
RIVET, 3/ 16 x.45
8
8
8
A lumi num, black anod ize
12
39149 -3509
TU NN EL
39 149-35 11
T U NN EL
13
390 20-3503
BRA CKET , LH rear suspension
14
39020-3502
BRAC KET , RH rear suspension
15
99970-3529
PA N A SSY , nose
1
Includes rivets
16
535 YW0604 534XW0602
• •
18
11034-356 6
BRA CKET, LH f ron t suspension
19
11034-35 67
BRACKET , RH front suspension
20
32002-35 10
FRAM E, fr ont
32002-3503
FRA ME, fr ont
32002-35 11
FRAME, f ront
17
RIVE T , 3/16 x .45 RIVET , 3/16 x .33
6
6
St eel, zi nc plated
1
1
Prot ect s fu el t ank
1 Stainless steel, small head
1
39 4
39 4
39 4 1
St eel, zinc plated , large head Alum inum, black anod ize
DRIFTER 14. HO OD (SA340 & SB440)
Page 31
43
~ ~ 42 38
I
~-41
39
..,- 44
~
2-~
37
1 \
)
/ 32- '\
29- ( 33-
"V / /
~./,Ci-
29 ll
30-
\\ : - 29
31-~ :@~-28 \
I
~-11
27 15
6- 15
i - 26
~-1 6
f- 17
I fL/ .-----/J~-25
@
17- '24 -
6
23-~ I
21
DRIFTER 14. HOOD (SA340 & SB440)
Page 32
/
1
Ref . No.
1
/ Remarks
"?t>< ~ r>J <::>'?' <::><Q <::>0
39 154-3508
WIN DSHI EL D, smoke tinted
39 154-35 13
WIN DSH IE LD, h igh
2
92009-3544
3
In cludes tr im opt
opt
SCREW, special b lack
8
8
92055-3503
a -R ING , w indsh ield
1
1
4
56040-350 4
LABEL, warnin g
1
1
5
53044-3505
T R 1M, hood rear edge
1
6
4
4
Windshie ld mount ing
4 1.4 lon g
250DH081 6
SCREW, 1/4-20 x 1.00
7
13169-3528
PLATE, reta iner back up
2
2
8
9 2072 -3508
RETA INER, ru bber hood
2
2
9
270 12-350 1
HOOK retainer
2
2
10
412EA0800
WAS HER , p lain, 1/4 "
4
4
11
351BA0800
NUT, insert , 1/4 -20
12
12
12
560 27-35 3 5
PA TI ER N, LH side
56027-3534
PATTERN, RH side
1
1
Kawasaki red, w h ite and bl ue str ipes
PATTER N, bo ttom edge
2
2
Black stripe
14
. 2801 2-350 1
REF LECTOR, amber
2
2
15
92022-353 9
WA SHE R, backup
3
3
Clamp and hood lanyard
13
r
~f{P
Descrip t ion
Kawasak i Part No.
Quantity
560 27-35 36
Grade 60M, black chrom e
St eel, zinc p lated Grade 5, zinc plated Kawasak i red, white and blue str ipes
16
92037 -3511
CLAMP, headli ght harness
2
2
.28 " hol e x .44 " clamping d iamet er
17
535YW0606
RIVET,3 / 16
3
3
Clamp and hood lanyard mo unting
18
92093-35 14
SEAL, engine air outl et duct
92093-3513
SEAL, engine air out let duct
19
39156-3530
PAD , top left
20
39156-3547
PAD , LH side
21
391 56-3 531
PA D , RH side
22
391 56-3532
PAD, top right
23
92081 -3529
SPRI NG, hood lany ard
1
24
35 1BA0600
NU T , insert, #1 0-24
25
39073-3503
LA NYARD , hood
1
26
244DA0608
SCREW, # 10-24 x .50
1
1
27
92043-3522
PIN, clevis
2
2
28
92037 -35 17
CLAMP , headl ight harn ess
1
1
29
92022-352 7
WASHER , rubber
16
16
30
53009 -3520
H I NGE, L H upper
1
31
39092-3503
PIN, hair
2
2
32
250DH08 12
SCREW, 1/4-20 x .75
8
8
33
53009 -35 19
H ING E, RH upp er
34
594 56 -3505
HOOD
Grade 5, zinc plated
Grade 60M , zinc plated
.28 " ho le x .62" clamp ing d iameter
Gr ade 60M , black chrome
No decals applied
DRIFTER 14. HOOD (SA340 & SB440) (CONTINUED)
Page 33
]
~
40
I
~b I 39
38
43
~ 42 ~
I
,
! ! 41 ~ ~
-«
I
2-~ 3- ~
37
! / •
I
,
#
, A
1 \
\
).,- 29
30- b
31- '" {7~¥9P -28 ~\
I
27
i - 26
15
I @ flL/ ~-25 17- '
~-11 ~-1 5
~-1 6
- 17
24-6
"'"
23-~
J
DRI FTER 14. HOOO (SA340 & S84 40 ) (CONT INU ED ) Page 34
/
Ref. No .
Kawasak i Part No .
~l>'
n}' 0?-
/
0«j
n}'
92015-35 14
NUT, rubber well
8
8
36
560 18-35 10
M A RK, drif ter
1
1
37
560 27-35 38
PATTE RN, windshield LH
Black stripe
38
56027·35 37
PA TTER N, windshie ld RH
Black strip e
PA NE L , RH vent
39
39090·3507
40
140 20-3519
RET AINER, vent panel
4
41
39090 -3508
PA NE L, LH vent
1
42
5602 7·35 39
PA TT ERN, dash
560 27-3561
PATT ERN, dash
1
43
39090·3 506
VEN T, hood
2
2
44
140 20-35 18
RETA INER, push nut
12
12
50275-35 12
PAI NT , light blu e
AR
AR
1
,
Remarks
0°
35
*No t sho wn
]
Quant ity
~fI;Y
Description
Windsh ield mount ing
4
Hood vent
DRIFTER 15. HO 0 D (SC340)
Page 35
~-- 2
~-----
"
3
)
I
-
-
4
33 - - - /
32- , 31 --~ // ,/
/
/
/
\
~:>---- 31
\ \
30
0'· \ \
.
28
\ ",,,-
L~ tX" '",
29
~-- 2 7
\
I
11
26-17--
-l,
-"
18
25
~-- 1 9
" ~ f~ -20
24-"
l j, _
r.,;
21
'1--
22
'€I,
I 23
<,
f
DRIFTER 15. HO 0 0 (SC340)
Page 36
rf
cr
/ Ref, No ,
Descripti on
Kawasaki Part No,
Quantity
>t:~ v
\J'?' '?t'
cY
\J'?'
\)<t'
0<0
/
\JY'-
Remark s
r;j>'
0
1
Safety
1
56040-3 505
LABEL, warning
2
56 040-3506
LA BEL, warni ng
3
56 027 -3564
PATTERN, windshield moun t slot s
4
5602 7-3562
PAT TE RN, speedometer hole
1
5
56027-35 63
PATTERN, w indshie ld moun t holes
4
Rou nd
6
920 09-3551
SCREW, 1/4-20 x 1.00
4
Special
7
131 69-3528
PLATE
2
8
920 72-3508
BAND , hood ho ld down
2
9
27 0 12-35 0 1
HOOK
2
10
4 12EA0800
WASH ER, pla in, 1/4 "
4
St eel, zinc plated
11
351 BA0800
NUT, insert , 1/4-20
8
Grade 5, zinc plat ed
12
560 27-3559
PATTERN , left side
1
Red & white
56027 -3560
PATTERN, ri ght side
1
Red & wh ite
13
56 0 18-3520
MARK, Kawasaki
2
Drifter F/ A
14
280 12-350 1
REF LE CTOR, amber
2
No passengers 4
Oval
15
39 156-3542
PAD, t op cent er
2
16
39 156-3543
PAD, top rear
1
17
391 56-3 545
PAD , left side
18
39156-3544
PA D, top cent er
19
244 DA 0608
SCREW, 10-24 x .50
1
20
39073-35 03
LANYARD
1
21
351BA 0600
NUT, insert , 10-24
1
22
92081 -3529
SPRING , lanya rd
1
23
920 22-35 39
WASHER , special
2
Steel, zinc plated
24
9203 7-3511
CLAMP , headlight h arness
1
.28 ho le x .44 clampi ng d iamet er
25
535X W06 04
RIVET,3/16"
Clamp t o duct
535XX0606
RIVET,3/16"
Lanyard to duct
1 Grade 60M , zinc plated
Gr ade 5, zinc plated
26
39156-3546
PAD , ri ght side
1
27
92043-3520
PIN, ho od h inge
2
28
11034 -3592
BRACKET, h inge
2
29
39092-3503
PIN, hair
2
30
390 90 -3509
PAN EL, nose vent
1
31
9202 2-3 527
WASHER , rubber
8
32
92009 -3552
SCREW, 1/4 -20 x .75
4
Specia l
33
594 56 -35 10
HOOD , pl ain
1
No decals applied
50275-35 12
PAINT , l igh t blue
1 "No t sh o wn
AR
DR IFTER 16. SEAT
Page 37
1
/
/
1/
I /
,/
~
7
I
I
I
@- 16
!
18
DRIFTER 16. SEAT
Page 38 Quantity
/
I
Ref . No.
Descrip tion
Kawasaki Part No.
#fiY "'JI>'
5300 1-3505
SEAT A SSY
1
2
4903 1-3505
•
LATCH , sto rage case
3
3901 2-350 1
4
92037-3512
• • • •
5
4 12 EA 0 700
Remark s
r>J
1).1>'
0'?' 1
/
0<0
0G
1
Less storage case cover
2
2
Bungee cord
CASE , stora ge
1
1
CLAMP , latch
2
2
WA SH ER , plain, # 12
2
2
Steel, zi nc plated
11
11
Steel, zi nc plated
1
1
11
11
1
1
1
1
6
92022-3539
WA SHE R, special
7
53002-3503
8
92039-3520
9
53006-350 1
• • •
10
11009-3503
GAS K ET , storage co ver
SEA T ,RIVET,3 / 16 FRA ME ASSY
11
14025-3502
COVE R, storag e case
12
92043-3506
PIN
1
13
92033-350 7
RI NG, snap
2
2
14
53009-35 14
HI NGE, storage case cover
2
2
15
92039-3503
RIVET,3/ 16
6
6
Include s special mounting nuts
16
4 12EA0800
WA SH ER, plai n, 1/4"
4
4
4
Steel, zi nc plated
17
118BA 0814
BO LT , 1/4 -20 x .87
2
2
2
Grade 5, zinc plated
18
250DA08 14
SCREW, 1/4 -20 x .88
2
2
2
Grade 60M, zin c plated
19
5300 1-35 13
SEAT A SSY
1
20
53002-3505
•
SEA T
1
21
53006-3502
•
F RA ME ASSY
Inc ludes specia l mounting nuts
J
DRIFTER 17. FUEL SYSTEM
Page 39
(J~ L7oooo{)JOO -
1
~ -- 2 47
~
J~=:
1
_
--1-
ffLJ- 7 8 9
[ 13
I
<
~
'<,
<, <,
<,
, 18----:/"9 <,
<,
<,
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14
c
DRIFTER
17. FUEl SYSTEM
Page 40
/ Ref . No.
Descript ion
Kaw asaki Pa rt No .
".:>t>'
~t>'
e,<O
1
1
1
1
1
3
3
3
Remar ks
".:>t>'
e,v
Gasket required
5 1049-350 1
CA P, f uel t ank
1
2
11009-3502
GA SK ET, cap
3
14020-35 16
RETAI NE R, fuel level gauge
4
52005-3503
GAUG E, fuel level
1
1
1
5
534YW0604
RIV ET, 3/16"
4
4
4
6
11034-3534
BRACKET , fu el t ank
1
1
7
39085-350 1
PAD, bracket
1
1
1
8
5 1004 -3503
TA N K , f uel
1
1
1
9
32032-3504
WEI GHT , fuel pick up
1
1
1
10
39 156-3522
PAD , f uel t ank side
2
2
2
8 .00" long
11
92072-350 4
BAN D
1
1
1
Silencer to support
12
560 40-3502
MA R K, w arning
1
1
1
A ir silen cer
13
9208 1-3555
SPRING , exte nsion, 18.25"
1
1
1
Silencer t o carb
13227 -35 14
HOU SING , intake silencer
1
13227-3526
HOUS IN G, intake sile ncer
Carb side
13227-3522
HOUS ING, inta ke silencer
Carb side
15
32032 -3549
PIPE, int ake, 3. 25"
16
92022-353 1
WA SH ER, special
17
180 20-3508
BA FF L E, intake guard
1
1
18
92039-3 532
RIVE T , special, 5/32"
3
3
19
13227-3 527
HOU SING, intak e
Elbow end
13227-35 16
HOUSI N G, intake
Elbow end
20
39 156-3527
PAD, f uel tan k LH
21
92059-35 22
TU BE, 7/32 x 12.00
22
92005 -35 10
FITT ING , fue l tank
23
9209 3-3510
SEA L, silencerlcarb
92093-35 11
SEAL , silencer/carb
24
410 77 -350 6
A DAP TE R, carb to seal
1
1
25
534XV0806
RIV ET, 1/4 x .62
2
2
26
4904 0-3506
FUEL PUMP ASSY
27
43028-3504
28
43028-3503
14
]
/
#fiY
e,'?'
1
Oua nt it v
29
11009-351 3
30
92009-3548
• • • •
31
92059 -3542
32
St eel, zinc plated
Carb side
1 3
3
3
3
Closed type
Pick up to f itting (See note e)
2
A lu m inum, small head DF 44-202 -00 1
MEMBRANE , pump D IAP HRAGM, pu mp GAS KET, pump SCREW!WASHER
4
4
4
T U BE, 3/ 32 x 15.00
2
2
Pr imer pump (See note e )
920 59-3524
T U BE, 7 /32 x 1.25
2
2
(See note _)
33
39 156-3535
PA D, fu el tank RH
1
1
34
92005-3503
F ITT ING, tank vent
35
92072-35 01
BAND , cable ti e
V ent t ube to steering mo unt
36
9205 9-353 1
TUBE , 118 x 15.00
F uel tank vent (See note
37
490 19-350 2
F I LTER , fuel
1
+)
DRIFTER 7. FUEL SY I VI (CONTINU ED) Page 41 _ _ _ _ _ 1 __ =ST~EM
ij~ IJOODomoO43~ ~
42
Ivt
~ ---- 2
44 45----"{1~~46 -
-41
\;.
47
"
/"
47
31 ~
I
1
~
~
f f
I
8 9
[ 13
I
<
~
<,
<, <,
----..'-1 8-~ <,
<,
<,
<,
<,
<,
<,
<,
<, '-
/ <,
'-..
~/
/'
/
/
\2
I
14
l
DRIFTER
17. FUEl SYSTEM (CONTINUED)
Page 42 /
Ref . No .
Kaw asaki Part No .
Quantity
·<t~ ·<t~ rf :~'·
M
Oeser i ption
')t><
c}'
/ Remark s
~t>< S«j SV
f - - - --
-
-
- --
- - --
(See note . )
92059 -352 4
T U BE , 7/ 32 x 1.25
92059-3545
T UBE , 7/32 x 3.00
39
92005 -3506
F ITTI NG , T
40
92059 -3526
T UBE, 7/ 32 x 18. 00
Fuel pump to carb (See note.)
41
92059-354 1
T U BE, 7/ 32 x 13.00
Fuel pump to pulse (See note. )
42
92037-350 1
CLA MP, pulse tube
Engine end
43
92066 -3506
PLUG , primer hole
44
92015-35 15
NUT , primer pump
45
920 22 -352 1
WAS HE R, primer pu mp
46
49043-3502
PUMP, pr imer
1
47
391 56 -3523
PAD , fu el tank top
2
38
1
NOTE : Bul k tub ing is available by orde ring t he f o llo w ing part num bers:
•
92059-3520
TUBE , 7/ 32 in. x 100 ft .
•
920 59-3518
T UB E, 3/32 in. x 100 ft .
•
92059-3 519
TUBE, 1/8 in. x 100 ft.
Filter to fuel pump (See not e .)
Internal star Hardware not includ ed
2
2
3.00" long
-
-
DRIFTER
18. CABLES
Page 43
/ .'
,
,, \ \
..........., \ :
,
"
t,'
...........\~ .:'
L
I
oRifl ER 18. CAB LES Page 44
/
Ref . No.
(f(<<~
Descri pt ion
Kawasaki Part No .
~~
540 12-352 7
CABL E, thr ott le
2
920 15-3 512
•
0«)
0°
NUT, jam, 5/ 16024
3
92033-350 2
R lN G, cable snap
2
2
2
4
5400 5-3502
CAB LE ASSY , brake
1
1
1
5
344BA 1000
•
NU T, j am, 5/1 6-24
2
2
2
6
39030-3504
CA BLE A SSY, enr ichener
1
1
1
7
92015-3525
1
1
13 168-3501
• • •
NUT , pal
8
LEVER
1
1
HO US ING
1
1
• •
SPRI NG
1
1
CAP, hou sing
NU T, jam , 5/16 -24
~.
9
1322 7-35 13
10
9208 1-3542
11
16016-3501
/
nJ
~
0'?1
Quant it y
PLU NGER
12
1402 5-35 11
13
92043-35 17
14
39030-3505
• • •
15
920 15-35 12
•
16
54001-3503
CAB LE , speedomete r
PIN , lever CABLE A SSY
Th rottl e & brake
Brake
Remark s
DRIFTER
Page 45
_ __ _ _9_oC_ARBURETOR (SA340 & SB440)
1
_
1
L
e
./
/
'
I
I
@
~ ~
I I
2
I
3 4
5 6
38
I
__ ~
~
-
7
8 9
26
10 11
36 ---~~
26
12 13 14
25
35
I
15
34 -
16
17 -
17 33
18
\
23 32-
-
19
22 21 -
I I-
-
- L--
20 -
L
DRIFTER
19. CARBURETOR (SA340 & SB440) Page 46
/ Ref . No.
/
(f(1(r'
Descrip tio n
Kawasak i Part No.
Quant it y
,)1>'
1).1>'
0?-
0«j
nJ"
0(,
16001 -3522
CARBURETOR ASSY, 3 2mm
Marke d 32 /166
16001 -3528
CARBURETOR ASSY, 32mm
Mark ed 32/1 70
2
16012-3501
3
9202 2-3529
4
160 13-003
• • •
SPRI NG , enri chener pl unger
5
160 16-002
•
PLU NGER , enr ichener
6
160 22-007
SPRI NG, air screw
7
160 14 -0 06
• • • • •
8
1603 2-008
9
11009 -3509
10
92064-022
CAP, enr ichener p lun ger WA SH ER, cap
SCREW, p ilot air PIN, f loat GASKET , f loat chamber PI LOT JET, #30
92064-049
PILOT JET, # 15
opt
opt
Leaner
9 2064-021
PILOT JET, #20
opt
opt
Leaner
92064-032
PILOT JET, #25
opt
opt
Leaner
11
180 20-3 505
•
BAF FLE
12
16034-001
•
WASH ER, ho lder
1
13
1606 5-0 08
HOLDER , carb needle
1
14
920 55-044
• •
O-RI NG , hol der
1
15
16055-004
•
AR M, fl oat
16
140 20-3 508
2
2
17
16031 -021
• •
RETA INER , float FLOAT
2
2
18
9 2063- 0 22
•
MA IN JET, #200
9206 3-0 27
•
MAI N JET, #250
op t
920 63 -017
MAIN JET, # 160
opt
opt
Long hex -Am al
920 63 -0 19
MAIN JET, # 170
opt
opt
Long hex -Am al
920 63 -02 0
MAIN JET, # 180
op t
opt
Long hex -Am al
92063-02 1
MAI N JET, # 190
opt
opt
Long hex-A mal
MAIN JET, #2 10
opt
op t
Long hex -A mal
920 63-023
s-
1
opt
Long hex-Amal Long hex-Amal
920 63-0 24
MAI N JET, #220
opt
opt
Long hex -Amal
92063-025
MAIN JET, #230
op t
opt
Long hex -Am al
920 63-026
MA IN JET, #240
opt
opt
Long hex -Am al
920 63-028
MAIN JET, #260
op t
opt
Long hex -Am al
Includ es washer
SCREW, special
4
4
9203 7-078
• • •
CLA M P, econo jet tube
2
2
22
14020 -3 509
•
RET AIN ER, tube
3
3
23
9 20 59 -35 15 161 59-3 515
• • •
T U BE, 3.5 x 98
24
19
160 20-3503
20
16033-0 13
21
16 159-35 13
Remarks
CHAMBER, fl oat
Econ o jet
ECONO JET, #90
op t
Round - reverse jet
ECONO JET, # 100
opt
161 59-3 525
ECONO JET , #70
opt
opt
Round - reverse jet
16 159-3524
ECONO JET, # 75
opt
opt
Rou nd - reverse jet
Rou nd - reverse jet
DRIFTER 19. CARBURETOR (SA340 & SB44 0) (CO NTIN UED)
Page 47
1
L 2
3 4
5
-~ 38':--~ - / 38
- --
U(
6
- -
/
I
_ ~') ~ -
I
iI
I 1 I
27
I
2
- ,~
-W '' ,
36 ---~'Q2
Q 35
r
-----31
34
i
15
33
32
15
I
c>
0 0° 0
17
24
I
~
/
,- -
b~:~
I
I
j
.,, '
89
-- 12
i i
-' -
6 § ~ --- ~~ I~ _ _
I
16
.
'
6
:
7
13
_
~
1 .
I I ~: ir
I
-
-
16 17
18 19
//
.>
./
22 21 ---..!:::..-.-..."lln ~~
20 - -
L
DR IFTER 19. CARB URETOR (SA340 & SB440) (CONTINUED) Page 48 Quant it y
/
Ref No.
Kawasaki Part No .
~#r
Des crip t ion
" t'
':J'?"
'\>.t '
':Jqj
/ Remark s
rf
':Jv
16 159-35 17
ECONO JET , #80
opt
opt
Round - reverse jet
16159-3516
ECONO JET, #85
opt
opt
Rou nd - reverse jet
16 159-35 14
ECONO JET, #9 5
opt
opt
Rou nd - reverse jet
16159-35 12
ECONO J ET , #10 5
opt
opt
Round - reverse jet
16159-3501
ECONO JET , # 110
opt
opt
Round - reverse jet
16 159-3502
ECON O JET, # 115
opt
opt
Round - rever se jet
16159 -3503
ECONO JET , # 120
opt
opt
Round - reverse jet
27
16035-350 1
• • •
28
16022-005
•
SPRING, t hrott le screw
29
16021- 3501
•
SCREW, throttle stop
30
92005 -3509
•
F ITTI NG , pri mer tube
31
160 08-0 10
CLI P, carb ur et or need le
32
16017 -350 6
33
16025 -350 4
34
16009-3503
35
16007-022
36
92081 -355 6
37
16004-022
38
92059-35 16
• • • • • • • •
25
16030-3 503
26
11009-35 10
FLOA T VA LVE ASSY , 1.2
1
GA SK ET , f loat valve
2
A IR JET
1 1
2
.
I .I ....
NEEDLE JET, 0-6
;,
VA LV E, CA2 .0 NEEDL E, 6 FL 14-3
CIip in 3rd groov e
SEAT, spring SPR lNG , thrott le valve
1
CAP, mix ing cham ber
1
Includes gasket
2
A ir vent
TUBE , 3.5 x 240
.."
'~1
2
DR IFTER
20. CARBUR ETOR (SC340)
Page 49
I -:
{(JE))
32.~
-:
(
25
I
24
B-2
-:
I I I
I I I I I II
31
30
-~ "@
-
29
28
:
L
I
I I
I I
27
1 1~ ~ 1 1-
23
22-----1
I
-~
YI~
13 14
l1J~
I
26
lr
12
~- 15
I
///)
~/ u
I
I~~_W
.9
21 -b
1J 20-
CD
19- 9
- -18
DRIFTER 20. CARB URETOR (SC340)
Page 50
/
Ref. No.
Descripti on
Kawasaki Pa rt No.
r;tJi
16001-3531
CAR BURET OR ASSY , 28mm
2
16012-3502
•
CAP, enr ichener plunger
3
9202 2-3556
•
WA SHER, enr ichener cap
4
16013-003
SP RlNG, enr ichener plunger
5
16016-002
6
16014 -006
7
1602 2-00 7
8
92081-3558
9
160 21-100 5
• • • • • • •
10
16032-008
11
11009-3508
12
92064-0 22
• •
7
1}(#7
e,'?' 1
Quant it y
t>tJi
e,«;}
nJ'
e,v
Marked 28/3 44
PL UNGER, enrichener SCREW, p ilot air SPRING, air screw SPR ING, throttle screw SCREW, throttle st op PIN, float GAS K ET , f loat chamber PI LOT JET, #30
920 64-02 1
PILOT JET, #20
opt
Leaner
92064-03 2
PI LOT JET, #2 5
opt
Leaner
13
16034-001
• WA SHER, main jet
14
92063-020
•
opt
Long hex -Amal
9206 3-015
MAIN JET, #140
opt
Long hex -Ama l
92063-0 16
MAIN JET, #1 50
opt
Long hex -Amal
92063 -017
MAIN JET, #16 0
opt
Long hex -Amal
92063-0 19
MAIN JET, # 170
opt
Long hex -Amal
92063-3508
MAIN JET, # 175
opt
Long hex -Ama l
MAIN JET, # 190
opt
Long hex-Amal
92063-021
23
16029-004
24
92022-3557
• • • • • • • • • •
25
92009-352 3
•
SCREW, special
1
26
160 17-3507
•
NEEDLE JET , P-O
1
27
16025-3506
V ALVE, throttle, CA 2.5
1
NEEDLE , carb jet, 5DP7-3
1
CLIP, carburetor needle
1
SEA T , spring
1
CAP, mixing chambe r
15
160 55-3501
16
140 20-3508
17
16031-029
18
160 20-350 2
19
1604 9-006
20
160 38-009
21
16033-009
22
16030 -3504
28
16009-031
29
16008-010
30
16007-3501
31
92081-3559
• • • • •
32
16004-3501
•
I J
Long hex-Amal
MAIN JET, #180 MAIN JET, # 130
92063-0 14
Remarks
ARM, float
1
RETAINER , float
2
FLOAT
2
CHAMBER , f loat
1
COVER, main jet GA SKET, cover
1
SCREW, special
4
FLOAT VALVE A SSY, 1.2
1
GAS K ET , float valve
1
WA SHER, special
1
Include s washer
Clip in 3rd groove
SPR ING, throttle valve Includes gasket
DR IFTER
Page 51
_
CYLINDER HEA D CYLIND ER (SA340 & SB440)
21. =~
1-;-' 2 --3-
r
G:::l--4 \Oi 2
~ ---
G£)_ 3
I 18 - - ,' . -e-
/
III
17 ---
2
1 6 -(J~_1 5 S4J1(J
DR IFTER 21. CYLINDER HEAD, CYLINDER (SA340 & SB440)
/"
Ref. No.
Kawasa ki Par t No.
~
\><~
00
NUT, lon g, 8mm
920 15-502
NUT , long, 8mm
2
46 1F080 0
WASHER, spring, 8mm
10
10
3
92022-503
WA SH ER, plain , 8mm
8
8
5
6
31 1G0800
NUT, 8mm NU T, 8mm
11001-3004
HEAD , cy linder
1100 1-514
HEA D, LH cy linder
11004 -513
GAS KET, head
6 6 2
2 2
11004-507
GASKET , head CY LI NDER , RH
11005 -300 4
CYLI ND ER, RH
11009-3001
GASKET , intake
16062-51 0
GAS KET, intake
16073-3002
INSU LATOR
1606 1-517
INSU LATO R
59076-3004
MA NIFOL D, inta ke
59076-300 1
MA N IF OLD, intake
11
4 10B0600
WA SHER, plain, 6mm
6
6
12
46 1F0600
WA SHER, spring, 6mm
6
6
13
110 B066 7
BOL T, 6 x 67mm
110B0 678
BOLT, 6 x 78mm
14
110B064 2
BOLT , 6 x 4 2mm
110B0653
BOLT , 6 x 53mm
4
15
114B0825
SO LT , 8 x 25m m
2
2
16
92022-300 7
WASH ER, silencer spr ing
2
2
17
92037 -30 13
CLA MP, carbur etor holde r
1
1
18
16065-3011
HO LDE R, carburetor
11009-507
GAS KET , cylinder base
11009-505
GASK ET, cyl inder base
11005-3005
CYLI NDE R, LH
11005-3003
CY LINDER , LH
11009-30 13
GASKET , exhaust 4
8
9
10
19
20
21
6 8 2 2
2 2 4
1 2 2
4
18067-501
GAS KE T, exhaust
22
172G0820
STU D, 8 x 20mm
4
4
23
46 150800
WASHE R, spring, 8mm
4
4
24
31 1R0800
NUT , 8mm
310M0800A
NUT ,8mm
4
11001-30 08
HEAD , RH cylinder
1
25
,,~
0°
2
11005-3006
7
/
2
92015-50 1
3 10B0800
Quant it y
fj{f( ~
Descri pt ion
0'?-
4
Page 52
4
RH or LH
Remark s
DR IFTER
Pag_ e 53_ _ _
:(SC~34~O) _ _
22. CYLINDER HEA _ __ _ D,_CY__ lIN=DE:R
26-~
25-~
~-9 20 19
18
15
14
DRIFTER
22. CYLI NDE R HEAD, CYLINDER (5C340) Page 54
7
Descript ion
Quant it y
~ff/
Ref . No.
Kawasaki Pa rt No.
1
31180800
NUT , 8mm
8
2
92022·302 7
WASHER , spring, 8mm
8
3
41180800
WASHER, plain, 8mm
8
4
92075-3003
DA MPER, head
4
5
92075·3002
DAMPER , head
4
6
11001·30 12
HEAD , cylinder
2
7
11004·3009
GASKET , head
2
8
11005·301 4
CY LI NDER
2
9
92075·3004
DA MPER, cy li nder
6
,,\:>0 'iJ<\:>O ~ ~"?" ~«j ~v
10
18067 ·50 1
GAS KET, exhaust
2
11
172G0820
STUD , 8 x 20 mm
4
12
46 1S080 0
WA SH ER, spring, 8mm
4
13
3 11R0800
NUT, 8mm
4
14
11009·505
GASKET , cyl inder base
2
15
16062·520
GAS K ET , intake
4
16
16073·3005
INSULAT OR
2
17
59076·3008
MAN I FO LD , int ake
18
41080600
WASHER , plain , 6mm
19
461 F0600
WASHER , spr ing, 6mm
6
20
11080640
BO LT , 6 x 40mm
4
21
11080660
BO LT , 6 x 60mm
2
22
16065·301 2
HOLDE R, carbu retor
1
23
92037·30 15
CLAMP, carburetor ho lder
1
6
24
92022·3007
WA SHE R, spring clamp
2
25
461 F08 00
WAS HER, spring , 8mm
2
26
220B0820
SCREW, 8 x 20mm
2
/ Remarks
DRIFTER
23. CRA NKCASE
Page 55
/
r I
- -2
DR IFTER
23. CRAN KCASE Pa ge 56
/ Ref. No.
Descript ion
Kawasaki Pa rt No.
"J':>l
14031-3004
COVER , magneto
2
92004-504
STUD , crankcase
92004 -3005
STUD, crankcase
14001-3007
CRANKCASE SET ASSY
14001-3012
CRAN KCASE SET ASSY
3
14001-3001
CRA NKCASE SET ASSY
4
32032 -300 1
5
551A0816
6
92104 ·002
7 8
.~ nJ
(;:S"?"
c.}"' 1
Quant it y (;:S"?"
00
8 8
1
•
PIPE, pu lse
1
1
1
•
PIN, dow el, 8 x 16mm
2
2
2
SEALER, liqu id gasket
AR
AR
AR
410B0800
WASHER, p lain 8mm
13
12
14
461 F0800
WASHER, spring, 8mm
12
12
14
9
110G0863
BOLT , 8 x 63mm
10
6
10
10
92001 -3010
BOLT,8 x 7 1mm
4
11
110B0 640
BOLT, 6 x40mm
1
12
461 F0600
WASHER , sprin g, 6mm
1
13
410B0600
WASHER, plain, 6mm
1
14
110B0812
BO LT , 8 x 12mm
2
15
14025-3013
COVER, hole
1
16
311B0800
NUT, 8mm
2
17
172B0820
ST UD, 8 x 20mm
1
172G0820
STUD , 8 x 20mm
110 B0868
BOLT , 8 x 68mm
18
(;:S'?'
t;..':>l
0<0
8
7
4 4
100g tube
Remarks
DRIFTER
24. PISTON & CRANKSHAFT
Page 57
-
I
1-1@ i L _~ ~
I
c,
24
3 I
-
-
~
5
I~
if
<,"'~
I
12
~ ~~~ I
" '. ,~
~' .il ~ 19I 8
11/ ~( I
1
13
I 10 10 ,,/
'''b-22
oRiflER 24. PISTO N & CRANKSHAFT Page 58 Quantity
/ Ref . No.
~#r
Descrip t ion
Kawasa ki Pa rt No.
nf
,:>'?"
13008-300 7
PISTON RING SET
13008-3001
PISTO N RING SET
13001 -3007
PISTON
1300 1-3008
PISTON
2
3
13033-3001
BEARIN G, pist on pi n
2
4
13002 -504
PIN, pi ston
1300 2-505
PIN, pi ston
2
92036-507
CI RCL IP
4
6
13031-3002
CRAN KSHAFT ASSY
1
7
49035-3001
PIN, spr ing
1
8
92050-509
SEAL, L H crank
1
9
920 22-3022
• • •
2
5
2 2 2 2
2 4
1.6mm
2
BEAR l NG, ball
2
11
92025-531
SH 1M, LH crank, 35 x 45 x 0.8mm
1
12
92025-535
• •
SHIM, LH crank, 40 x 47 x 0.2mm
AR
SHIM, LH crank , 40 x 47 x 0.3mm
AR
SHIM, LH crank, 40 x 47 x 0.5mm
AR
SH IM, LH crank, 40 x 4 7 x 0.7mm
AR
SHIM , LH crank, 40 x 47 x 1.0mm
AR
SHIM, LH crank, 40 x 47 x 1.0mm
1 2
13
92025 -539
• • • • •
14
92055-3002
•
O-R ING, crankshaft
15
92025-3017
1
92025-5 15
SH IM, RH crank, 35 x 42 x 0.2mm
AR
SH IM, RH crank, 35 x 42 x 0.3mm
AR
SH IM, RH crank, 35 x 42 x 0.5mm
AR
SH IM, RH crank, 35 x 42 x 0.7mm
AR
92025 -3017
• • • • • •
SHIM , RH crank, 35 x 42 x 1.0mm
16
SHIM, RH crank, 35 x 42 x 1.0mm
AR
17
92045-3002
•
BEA R lNG, ball
18
92022-30 21
•
WA SHER, RH crank , 50 x 65.7 x
92025-539
92025-52 1 92025 -525 92025-5 28
4
T CY357210
WA SHER, LH crank , 58 x 75.7 x
•
92025 -538
2
2
92045-507
920 25-537
nJ'
,:>0
2
2
10
92025 -536
~
':>«}
/
1
1.6mm
1
SEA L, RH crank o il
1
19
92050-507
•
20
3 15B1800A
NUT ,1 8mm
1
21
92022 -30 19
WASHER, lock, 18mm
1
22
510A5200
KEY , wood ruff
1
23
13031-3001
CRA NKS HAF T ASSY
6207 -9C4
6206-9 RT-C4
T CY 3062 10
Remarks
DRIFTER 24. PISTON & CRANKSHAFT (CONT INUED)
Page 59
-
I
1-1§ I L _~ 2-
3
,
.
'
-
~
I
I~
!if
·'b-22
DRIFTER 24. PISTON & CRANKSHAFT (CONTINUED) Page 60
/
Ref . No.
Kawasaki Part No.
55 1A04 1O
25
92055-504
,,\);
26
92045-50 5
27
92025-513 92025 -518 92025-523 92025 -52 7
• • • • • • •
tf- nJ
e,«:}
e,v
PIN, dowel, 4 x lO mm O-RING , crankshaft
7
7
BEAR lN G, BA LL
3
3
SH IM, crank, 0.1mm
AR
AR
SH 1M, crank, 0. 2mm
AR
AR AR
SHIM, crank, 0.3m m
AR
SH 1M, crank , OAm m
AR
AR
SH IM, crank, 0 .5mm
AR
AR
SH IM, crank , 0 .6mm
AR
AR
92025-533
• •
28
92022-531
WA SH ER, crank , 50 x 65.7 x 1.6mm
2
2
29
920 50-507
SEA L, crank oi l
2
2
92025 -530
/
~«CY
Descrip tion
e,'?'
24
Quant it y
6206N C3
T CY 306210
Remarks
DRIFTER
25. ENGINE AIR SHROUD (SA340 & SB440)
Page 61
7
~
DRIFTER
25. ENG INE AIR SHROUD (SA340 & SB440)
Page 62 Quant it y
/
Ref . No.
Kawasaki Part No .
(f(# r
Descript ion
,,~
~~
e,"?'
nJ
SCREW, pan head, 6 x 12mm
21460610
SCREW, pan head, 6 x 10mm
9
2
461 F06 00
WASHER, spring, 6mm
9
3
411B0600
WASHER, plain, 6mm
410B0600
WASHER , plain 6mm
4
49089-3010-9H
SHROUD, main upper
Sem i gloss black
49089-3001 -9H
SHROUD, main upper
Semi gloss black
49089-3012
SH RO UD , intake side
Sem i gloss black
49089-3020
SHROUD, intake side
Sem i gloss black
6
49089-3018
SH ROU D, crankcase/intake
Sem i gloss black
7
92093-3011
DAMPER , shroud
92093-3012
DAMPER, shro ud
49089-3011-9H
SHROUD, exhaust side
Semi gloss black
49089-3002 -9 H
SHROUD, exhaust side
Sem i gloss black
8
Remarks
e,v
220B0612
5
r
e,«3
/
10
10 9
9
9
410B0800
WASHER, plain, 8mm
2
2
10
461 F0800
WA SHER, spring, 8mm
2
2
11
214B0812
SCREW, pan head, 8 x 12mm
2
2
12
39145-3509
TRIM / SEAL
2 1
13
56030-3001
LABEL, Kawasaki
14
92009-3533
SCREW, # 10-32 x 2.50
2
2
15
412EA0600
WA SHER, flat, #1 0
4
4
16
14073-3516
DUCT, air outlet
1
1
17
350B A0600
NUT , #10-32
2
2
Steel, zinc plated
Grade 5, zinc plated
DRIFTER 26. FAN CASE (SA340 & S8440)
Page 63
1
23
II
>
-
4
1
10
1,%8/ I
~
II
9 8
7
1
DRIFTER
26. FAN CASE (SA340 & SB440)
Page 64 Quantity
/
1
Ref . No.
Desc ription
Kawasaki Pa rt No.
-r
".>b'
14037-503
SCREEN, fan
2
410B0600
WASHER, plain, 6mm
4
3
461 F0600
WASHER, spring, 6mm
4
220B0622 234B0420A
SCREW, pan head, 4 x 20mm
4907 9-3002
PULL EY, fan dr ive
59091-515
PULLEY, f an dri ve
59066 -3002
HOUSING, fa n
59066-3006
HOUSING, fan
1
7
13190 -502
PLAT E, sea l
1
8
92022-54 5
WASHER , special
3
9
461 F0400
WASHER, spring, 4mm
3
10
220B0410A
SCREW, pan head, 4 x 10mm
3
11
551A0608
PIN, d owel, 6 x 8mm
551A 0612
PIN, dowe l, 6 x 12mm
311B0800
NUT ,8mm
3 10B0800
NUT,8mm
4
5
6
12
4
2 2 4
13
461 F0800
WASHER , spr ing, 8mm
4
4
410 B0800
WASH ER, plain, 8mm
4
4
15
92004-1008
STUD, 8 x 25mm
172B0820
ST UD, 8 x 20mm
59041 -3003
FAN ASSY, cool ing
4 4
5904 1-50 1
FA N ASSY, coo ling
17
510A32 00
KEY, wood ruff
1
18
92045-300 1
BEARING, ball
2
92045 -501
BEAR lNG, ball
92033-3001
CIRCLl P, 4 7mm
1
1
20
92025-52 9
SHIM, 1.0mm thick
2
2
21
59091-3001
PULL EY, f an
2
2
22
59011-3001
BELT, fa n BELT, fan
6204 RU 6204C3 ZZ
2
19
590 11-3002
~ ,?V
5
14
16
~
,?«j
SCREEN, f an
SCREW, pan head, 6 x 22mm
'?{r
-r -r v.
14037-3001
4
/
1 1
23
92025 -50 1
SH IM, pu lley
AR
AR
24
461 F1400
WASHER , spring , 14mm
1
1
25
315B 1400
NUT, 14mm
1
1
0.6mm th ick
Remarks
DRIFTE R
27. COl SYSTEM (SB440)
Page 65
1 (1-31
~-30 ~-29
Â¥
e-
28
. J 24
25
P I
26
I
27
DRIFTER
27. COl SYSTEM (SB440)
Page 66
/
Ref. No .
Kawasaki Pa r t No .
Descr ipt ion
~f(r .,,1>'
c}"
I
Quant it y
1
220B0625
SCREW, pan head, 6 x 25mm
5
2
46 1F0600
WA SHER, sprin g, 6mm
5
3
92022-554
WASHER , plain, 6mm
5
4
21121-3005
COIL, ign ition
1
5
92027 -291
COLLAR , 6 .5 x 8 .5 x 14mm
1
6
92037-3003
CLAMP, ignit er harn ess
1
7
220B0410A
SCREW, pan head, 4 x 10mm
2
8
461 F0400
WASHER, spr ing, 4mm
2
9
92022-558
WASHER , plain , 4mm
2
10
5922 1-3001
CONNEC TOR , wiring harn ess
1
11
21169-3001
TER MINAL, engine connecto r
5
12
21119-3001
IGN ITER , COl
1
13
21003-3004
STATOR ASSY
14
920 11-532
•
SCREW, pan head, 5 x 34mm
2
15
59026-3002
COIL, pulser
1
16
21047 -3002
• •
COI L , lighting
1
17
92037-5 18
CLA MP, stator harness
1
18
46 1F0400
WA SHER, spr ing, 4m m
2
19
220B0408A
• • •
SCREW, pan head , 4 x 8m m
2
20
92037-5 17
•
CLAMP, coil w ire
1
21
21049-3001
•
COI L, exciter
1
22
92027-52 1
•
COLLAR, coil space r
2
23
92009-3002
•
SCREW, pan head, 5 x 38mm
2
24
92022-544
WASHER, plain, 5mm
2
25
461 F0500
WASHER , spr ing, 5mm
2
26
220B0520A
SCREW, pan head, 5 x 20mm
2
27
21050-3008
FLYWHEE L/RI NG GEAR
1
28
92070-3004
PLUG, spark
2
29
49006-3002
BOOT, pl ug cap
2
30
21130-3004
CAP, spark p lug
2
31
92101-00 1
TE RM INAL, spark plug cap
2
32
92071 -517
GROMMET, spark plug w ire
2
33
9207 1-529
GRO MMET, plu g w ire spacer
1
'0<1>'
~«j
/
nJ
~v
Modul e
NGK BZ -9EV
Remarks
DRIFTER
Page 67
28. MAGNETO (SA340 & SC340)
I r?-~-21
U --~-26
~
23 21 22
I
~~
/--~
(
J
I
DRIFTER
28. MAGN ETO (SA340 & SC340)
Page 68
/
Ref . No .
f
",tl'
220B06 4 5
SCREW, 6 x 45mm
220B062 5
SCREW, 6 x 25mm
2
2
461 F0600
WASH ER, spring, 6mm
3
21119-3006
IGNITE R
2 1119-3005
IGN IT ER
4
21169 -300 1
5
5922 1-3001
6
""tl'
<:-,,<0
2
T ERMINAL, engine connector
5
5
CONNECTO R, wiring harness
1
1
92022 -558
WA SHER, plain , 4mm
2
2
7
461 F0400
WASHER, spring, 4mm
2
2
8
220B0 410A
SCREW, 4 x 10mm
2
2
I 9~
3 fJ/ ).
-
21050-30 10
F L YWH EEL, with ring gear
2 1050-3009
FLYWHE EL, withou t r ing gear
1
10
21003-3005
STAT OR A SSY
1
11
59026-3003
1
12
9201 1-532
• •
9
COIL, pulsing SCREW, pan head, 5 x 34
2
21047 -3003
•
COl L, lighting
1
1
14
•
CLAMP
2
2
15
461 F04 00
•
WASHER, spring, 4mm
3
3
16
220 B0408A
•
SCREW, pan head, 4 x 8
2
2
17
2 1049 -3002
• •
CO I L, exciting
1
1
CO LLA R, coil
2
2
SCREW, pan head , 5 x 36
2
2
SCREW, pan head, 4 x 6
1
-1
2
2
18
920 27-30 08
19
92009-3006
20
220B0 406A
• •
21
411 B0500
WA SHER, plain , 5m m
22
461 F0 500
WA SH ER, spring, 5mm
2
2
23
220B05 20A
SCR EW, pan head, 5 x 20
2
2
24
9207 0-300 5
PL UG, spark
2
2
25
490 06-3004
BOOT , plug cap
2
26
21130-30 04
CA P, spark plug
2
2
27
92 10 1-00 1
T ERMIN AL, spark plug cap
2
2
28
9207 1-5 17
G ROMM ET, cord
3
3
29
9207 1-3002
GROMM ET
30
92027-3006
COLLAR, igniter
2 2
Ifj//'~:J";'.J
2
92037-518
. 13
~ <:-,,0
2 2
;); I (
/
~#~
c}' I
rr
Description
Kaw asa ki Pa rt No .
Quantity
NGK BZ -8ESA
Remarks
DRIFTER
Page 69
29. RECOil STARTER
r 2 3
I~
~
J
4
I
"
~
1 r--
5
DRIFTER 29. RECOil STARTER
Page 70
/
Ref . No.
(f:«cY
Description
Kawasaki Pa rt No.
n}'
':J"?' 1
5909 1-510
PUL L EY, starter
1
2
461F060 0
WA SHER, spring, 6mm
3
3
110B0622
BO LT , 6 x 22m
110 B0618
BO LT , 6 x 18mm
3
4
92001 -30 16
BO LT,6 x 16mm
3
5
49088-3005-9H
STARTER A SSY, recoil
49088 -3004-9H
STA RTE R ASSY, recoil
6
46075-3002
7
59106-505
SPRlNG, spiral rope return
8
9208 1-517
• • • •
9
5902 1-508-9H
•
CA SE, recoil
59106-506
92029-503
• •
WASHER, spr ing, 8mm
12
92022-564
•
WA SHER, thrust
13
13169-3003
• •
PLA T E, friction
14
92081-508
15
9208 1-512
• •
SPR lNG , fr iction
16
92028-3007
17
92095-503
23
41086-504
FLA NGE
59101 -506
21
...92081-503 ~
".
1
3
3 3 3
3 Semi gloss black
1
Semi gloss black
Order start er assy for SB440
1.6mm t hick
SPRING, plate return
13069 -504
20
3
PLA T E, fr iction
22 '~
13169-3002
1
NUT ,8mm
• • • • • • •
13169-3001
~ t>J ':J<O ':Jv
ROPE, recoil
920 15-513
18
Remarks
ROPE, recoil
10
19
/
HANDLE, recoi l rope
11
23072-506
Quant it y
BU SHING , nylon WA SHER , thrus t
1
1.2mm th ick
PLAT E A , recoil slide
1
Large oo
PLATE B, reco il slide
1
Small aD
REEL, recoil rope
1
1
1
SPR lN G, pawl return
3
3
3
PAWL, recoil
3
3
3
DRIFTER 30. TOOL KIT & LUBRICANTS
Page 71
I •
•
III--C K awa s aki
560073504
I 3
I 4
I
2[fl)C00!20CiUU@~~~ ~ngine
oil
•
.... CAUTIONI Combultlblf rP e....ay trom ope n spart
I...
(II
","~ENTIONI Infl"mm~";"""" 101 flamme fl ue au
:1
DRIFT ER 30. TOOL KIT & LUBRICANTS
Page 72
/
Ref . No.
Kawasaki Part No.
~«C;Y
Descript ion
"?t><
e,'?' 56007 -3504
1
Quant it y ~t><
/ Remark s
~
e,«3
e,0
TOOL KIT ASSY
1
•
BA G, tool
1
•
WREN CH , box , 10mm-1 2mm
1
1
•
WR ENCH, box , 17mm-21mm
1
1
• •
GR IP, driver
1
1
BL ADE, driver
1
1
1
•
PUL L ROPE ASSY
1
1
1
1
1
1
24 ( 1/ 2 pint U.S.) cans
2
S6 102 D- 14 1
OIL, case of chaincase
3
S61020 -101
O IL, case of engine
AR
AR
AR
24( 1 pint U.S.) cans
4
S6102 0-07 1
OIL, case of engine
AR
AR
AR
12(1 qt. U.S.) cans
DR IFTER 31. SPEC IAL SERVICE TOOLS
Page 73
~
LnL-----------JA L--I
12
I
1
-2
3 I
10-
-
SEAL ER-
LIQUI D GASKET
:1 -5
9-1l'
8
I
i.'. 6
01 '0
DR IFTER 31. SPECIAL SE RVIC E TOO LS Page 74
/
q~
Ref . No.
Kawasaki Part No .
'?~
l><~
",q)
",'?"
If
/
(f(~r
Description
5700 1-3506
HOL D ER, fan pull ey
1
1
2
T5700 1-910
PULLER , piston pin
1
1
3
5700 1-3507
AD JUSTER, suspension spring
1
1
4
92 104-002
SEA LER , liqu id gasket
1
1
5
570 0 1-983
MULT IMETER
1
1
6
T5700 1-130
COMPRESSOR SET, pisto n r ing
1
1
7
T56019 -201
T ESTE R, C.D. igniti on
1 1 3
8
5700 1-3509
PULLE R ASSY, flywhee l
1
9
110P0620
â&#x20AC;¢
3
10
57001 -35 13
T RAC K CLIP TOOL ASSY
1
11
57001- 3511
PU L LER, dri ve convert er
1
12
5700 1-3512
GA UG E, convert er alignment
1
BOLT, pulle r
Quantity
Remarks
nJ
",0
100g tube
Use with 3 each 11OP0620 3
6 x 20mm
DRIFTER Page i
Kawasaki PARTS CATALOG MODEL IDENTIFICATION
MA RKETI NG NAM E MARKETIN G CODE
Snowmobile mode ls are ident ified in the pa rts catalog by Marketing Code numbers. The char t conta ins the Marketing Code along with t he Marketing Name for ident ificat ion cro ss reference.
DRIFTER 340
SB340-A2
TA340C -D203
DRIFTER 440
SB440-A5
T A440C-D203
I
/
© 1980 Kawasak i Mot ors Corp., USA
-. .•
ENG INE MODEL
._:_- f\ocinn Service, Inc. JPN
Printed in U.S.A.
DRIFTER Page ii
CATALOGUE DES PIE C ES IDENTI FICATI ON DES MOD ELES Les modeles de moto neiges sont identifia bles dans Ie cata logue des pieces detachees par leurs nurneros de code ma rchands. On trouvera ces codes dans Ie tab leau ain si que Ie nom marc hand du modele correspondant de motoneige.
DENOMINATION
MODELE
MOTEUR MODELE
DRIFT ER 340
SB340-A 2
T A340C-D 203
DRI FT ER 440
SB440-A5
T A440 C-D203
I
/
.
.
\
)
DRIFTER Page iii
INTRODUCTION
GENERAL _lOl a ...... . ,
This cat alo g contains t he exploded views and rep lacement parts li sts for servi ceabl e comp o nents of K aw asaki snowmobi les. Always use GENUINE K A WA SA KI parts for rep lacem ent t o m aintain the sta ndards of reliabi li tv. performance. and sate tv t hat w as designed into Kawasak i snowmobiles.
o
U se the Parts Catalog by f o ll o w ing the explan ati ons li st ed below.
o
.-. ,-,.,..
INDEX
c ......~.,...
•
<tlo -,
"'. ,.
L ocate the system o r componen t t hat r eq ui res replacement pa rts in t he p ic torial in d ex . and t u rn to the p age n um b er indi cat ed for the exploded view and pa rts li st .
----------
EXPLODED V IEW
Each servi ceable pa rt i n t he exploded view is identified by a reference nu m b er . Use t he ref eren ce number t o l ocat e necessary par t inf or ma t io n in the PA R T S LI ST BREAKDOWN. Parts not sho w n d isassemb led in t he exploded view are not sold separate ly. bu t are in cl uded in t he complete un i t o r ne x t h ighe r assemblies as sho wn in t he i ll ust rati on .
•
Re fere nce numbers connected to broken lines ind icate assembly pa rt • numbers. All of t he components inside t he b r o k en lines are included whe n t he assemb ly p ar t number is ordered . Parts drawn with dotted l ines are reference components used t o show lo cat io n o f assem blies or proper posi tioning o f replacement parts . Refe r to the pi ctorial ind ex t o fi nd t he page number and exploded view f or the referenc e componen ts.
-..-
- - - - - --
'/f - -- - -
-{'
$PlNou. .
o
PARTS LIST BREAKDOWN
A lways use the co m pl et e Kawasak i pa rt number to order parts. Avo id shipping er ro rs by ensu ring the en t ire pa rt number is legible.
•
S~UVl . _
~"
_T .""" .,.3
.'11..." n .... ':rtt
•
.
am..-:l7
-,z,~ ~,
U
1iIIlaO'-3IlO2
z,~
II
)6 , .... _
.'Z2.-
n
" . ':l1»lllXl
Items in t he desc r iption column preceded by a black dot indicate t hat t hi s part is included in the above assembly .
It
.......
z_
Wh en Right Hand and Left Hand d escri pt ion s are used. these positions are id entified w hen look ing from the back to t he front of the snowmobi le. (E X AMPL E: . The m anual sta rter is on the Right Ha nd side of the snowrnobi le. l The qu an t ity col u m n ind icates wh ich snowmobile model the part is used on and t he t o t al q uant ity requ ired f or repa ir of the snowmobile. (E X AM PL E : The ex pl o d ed view o f the ski shows one ski. however. t he qu an t i ty col umn contains t he amount required to repai r both sk is.)
•
_11._ ~.~
tolT.", :;M .3~
_ I!'IG._ SUlVC. . ....
",-",n._.. ~ .~
III:1'AlIOCII . _
.. .."
HUT. - " W""
,.
Go_ ...... _
...,...-.. ,
.
-" . _
Go_ .. . - ...... Go_Il _ _
1'11.3 .111
..r ~
. ~1lt CAl ""'Tl I. OI .
..,,,
-~
"~ n
•
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.."... ., .. . ::.
.
NUM ERICAL PARTS IN DEX
11CnlS 118M082'
lI 8lW!8lt \l88Alle 14
3
1l8llA10 16
3
1I8lA1216 11.,.1216
l
118Boli 1221
11.,,1236 'l9aAOl108
58
z
1l'lN)IIll0 1198A0810
58
":3
11' 1A0816
n
58 56 56 56
....
Each part number is li sted numerically in th e ind ex located at t h e rear of t h is catalog. It conta ins the page number. for part locat io n reference. along with q ua n titv used per model. Use t he n umerical i ndex to de te rm ine componen t l oca t io n wh en only the part number is k nown .
IIOlol.l§.8I6 11O:M-JS9I 11Olol-:II605
3
,,e , :
1l9SA0812 119lAOlll6
1191A0816 119.-0818
,,"""" l1, LWl84O 11""'~ '
.
"" .,"" ~
.. " "" '.1 :: ..'""1
ee
··:,, , ,,l l
", ]
a
:
ABBREVIATIONS AR . . . . . . . . . . . . . . . As Requ ired Assy Assembly CA . . .. . . .. . .. . .. . Cut Away Carb . . . . Carb u retor COl Capac itor Discha rge Ignition GE General Elec tric Hp.x aaon al
LH MPH m . .... mm No NC OC
..
. . . . L eft-Han d . M iles Per Hour . Meter . Millime te r Number National Co ar se .. Ou t side Circu m fe rence
PSI PTO RH . Ref Std.
'.'
T V \1\1
_.
Pounds Square Inch Power-T ake Off . . . . . . . •. . . . .Righ t -Hand . .~ _ Re fe rence . _ Standard . Tee . . •. . . .. . .. . .. Vol t . • •. . . . . . • . . . Width or Watts
DRIFTER INTRODUCTION
Page iv
GENE RALIT ES Le present catal ogue cont ient les vues det a illees des pieces internes et les listes de pieces detachees pour I'entret ien des motoneiges Kawasak i. N' util isez que des pieces de remplacement d'ORIGINE KAWASAKI afin de mai nte nir les standards de fiabilite , de performance et de secutite qu i sont Ie propre des motoneiges Kawasaki. Po ur utiliser Ie cat alogue de pieces detachees, suivez les instructions ci-dessous.
o
o
R EPERTO IR E
Locali sez Ie svste rne ou l'elernent necess ita nt des pieces de remplacement dans Ie repertoire illustre et to urnez a la page ind iquee a laq uelle vous trouverez la vue detailee et la liste de p ieces correspondantes.
•
VUE DETA ILLE E MONT RANT LES DIFFER ENT ES PIECES DANS LEU R POS IT ION CORR ECT E Chaq ue p iece remp lacab le est identifies par un nurnero de reference. Utilisez ce nurnero de refe re nce pour reperer les renseign ements se rapportant a cette piece dan s la NOMENC LATURE DES PI ECES DETACH EES. Les pieces n'appara issant pas dernontees dans la vue deta illee ne sont pas vendu es separe rnent mais font pa rtie d'un bloc complet ou de I'ensem ble suivant Ie plus proche , comme indique sur I'i llustration. Les nu mer os de reference relies a de s lignes brisees ind ique nt les num ero s de pieces d ' un ensemb le. Tous les elem ents situes l' interieur des lignes br isees sont co m pris dans la commande portant Ie nurnero de piece s de I'ensemble.
a
Les pie ces dessin ees en pointille so nt des elements de reference servant a montrer I'emplacement des ensembles ou Ie placement co rrect des pieces de rechange. Refe rez-vous au reperto ire iltustre pour trouver la page porta nt la vue detai tlee des elem ents de reference.
.....ING._
~
. ._
,
", .. Dl.L...... $lU VE. _
• 10».1lI;05
O
o
NOMENCL AT URE DES PIECES DETA CHEES
f2lI~
DMII'li Il "U .~ :IO . , .3 ~. ~ .oU .~ " . )'1IO
_EII. ___
_ rHG,_ sU rYt . _ .......T l.-...
..-iI ....
II[T"'NE,, _ NVT.-.. ........
Ind iq uez toujours Ie numero de piece complet Kawasaki pou r vos com mandes de pieces. Assurez-vou s que Ie nu rnero entier est parfaitement lisible af in d 'evit er tout e erreur a l'expeditio n.
"
100_ 1. _ _
1OltT.-" ~:IO
~a.._I1.
llOI.T. )Ia.;JoO . J .1ll
_
..
~,
~"
STIlI' . .....
Les arti c les precedes d' un point no ir ces pie ces font partie d 'u n en semble.
a la co lonne
" Descript io n " indiquent que
Qua nd il exi ste des descript ions pour la Dro it e et la Gauche, ces pos it ion s so nt
. ~IIlc.u '
identifiees en rega rdant la motoneige de l' arr iere vers I'ava nt . (EX EMPLE! Ie dernarre ur main se trouve du cote Droit de la motoneige .)
a
La co lonn e quan tite indique Ie mo del e de moto neige sur leq uel la p iece est utili see et Ie no mbre total de pieces nece ssaires a la reparation de la motone ige. (EXEMP LEI La vue det aillee du sk i,montre un seul ski, toutef ois, la colonne qua nt ite indiq ue to ut ce qui est necessa ire la reparation des de ux skis.)
a
"- ,
....
,. ,.
561020.011 561020 ·10 1
TYOl' . 201 TS60I,-olZ fS7001.UO
8
11,*,,10
11010li11
11010lS22 n-..
m..."
:::= """" u.....
" I I
u.......
1l0lZla6 J
NOMENCL ATUR E DES PIECES DETAC HEES
1l0f062l) 11004-:1115
11ms.301S 1l0000-:lODt 110D9-J005
a
! ! ~- ~
.':
, ,,
,
: : :, 3
3
"" '"a~ "" ,az, 50
ll llOl-JD1 4 1l 0l)l..30 10
Chaque nurnero de piece fait partie d'une liste par o rdre de gran dey r nurnerique. dans la no me nclatu re qu i se trouve la fin du catalogue . Elle comprend Ie nurnero de la page , la reference po ur I'emplacement des pieces, a insi q ue la quantite necessaire par mod e le. Lorsq u'onlne co nnait que Ie nurnero de la piece, uti liser la nom enclature pour determiner I'emplacement de l 'elemen t .
....""" ." "
'B 1Oll1-91 0
11010812
8
~~
..lIn l. Du
..
50
!
11 0J01· ~
110lt· )§M 110)4 _)6()5
11'1OIlS
::= : \1"" -
11. ,0 16 118U.1216 II _Ill, 1l 1lllA122ll
11" '12)6 II'BA08CI8 lIHA01l 10
119SIOI10 1l9llAClllIl 119UOl116
119S1011 6
n'aAOIl6 11'&108 11
u...... """"" l "llAl 0 ' 4
!! ~!~28
... ...l:" "" :, .... .."l" n
~: ~~
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··:, ·:,, ,
·: " e
:,
,
l
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ABREVI ATI ONS AR , Cornrno Requ is Assy Ensemble CA Coupe Carb .. . . •. . . . . . . ... . . . Carbu rat eur CD I Allumaqe Electrostatique GE , General Electric hex . . . . . . . . . . . . . . . . . . . . Hexagona l ID Oiarnetre Int erieur KPH Kilome t re a I ' tlp v r p
LH MPH . . . . . . . . . . . . ..
m '"
. . . Gauche Milles iJ L'hevre : . M ~e
mm . . . . . . • . . . Millimetres No Nu rnero NC ... Natio nal Coa rse OC Circonf erence Ext er ieur e OD (DE) Diarnetre Ext erieur /""'In.
PSI PTO (PDM) RH Ref Std T
Livre-Mesure-Po nce Prise De Mouvement Dro ite Ref erence Standard Ferrue ente V ... ... . .. .•. .. .. ... . . .. . . . Vo lt W Laraeur or W~tt.
DRIFTER INDEX
Page v 1.
.. . . .
Page 1
. Co n verter 4. Drive
......
Page 3
. n Co nverte r & Bra ke 5. Drive
c "'=~*=n-
-
. Page 5 .
6. Chaincase . .. .
........
Page 11
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C
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DRIFTER
INDEX
Page vii
14. Hood
15. Seat
Page 31
_ . Page 35
16. Fuel System
Page 37
17. Lubrication System
Page 41
18. Cables
Page 43
DRIFTER INDEX
Page viii 19. Carburetor
Page 45 22. Piston & Crankshaft
Page 53
20. Cylinder Head, Cylinder
Page 49
23. Engine Gearcase
Page 55
21 . Crankcase
Page 51
24. Fan Cooling Syst em
Page 57 i
'" ~
DRIFTER JNDEX Page ix
""'
25. Magneto . . . . . . . . . . . . . . . . . . . . . . . .
Page 59
27. To ol Kit & Lubricants I
0
0 '
Page 63
I
(:.: · l
26. Recoil Starter
Page 61
.
~ .:~ S"
... ,
I
'1 I
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Engine Assemb lies and Manua ls
ASSEMBLY & OWNER'S
PREPARATION
MODEL
ENGINE
MANUAL
MANUAL
SA340-A4
70340-3019
99974-3505
99964-35 14
SB440-A4
70440-3033
99974-3514
99964-3 514
SC340-A 1
70340-3010
99974-3509
99964-35 14
SHOP
FLAT RATE
MODEL
MANUAL
MANUAL
SA340-A4
99963-3511
99990-350 1
SB440-A4
99963-3511
99990-3501
SC340-A1
99963-3511
99990-3501
28. Special Service Tools
Page 6 5
DRIFTER 1. ENGINE MOUNT & EXHAUST Page 1
14
I 15
~
1--17
-18
DRIFTER
-
1. ENGINE MOUNT & EXHAUST
Page 2 /Ouantity/ Ref. No.
Kawasaki Part No.
Description
t(~
~
e,<Q
1
r:
32069-3513
BRACKET, muffler
1
1 2
2
92015-3538
NUT, special thin
2
3
92022-3549
WASHER, engine mount
4
4
4
92075-3509
MOUNT, rubber engine
8
8
Remarks
t?
e,~
5
92026-3554
SPACER, muffler bracket
2
2
6
350BA1200
NUT, insert, 3/8-24
2
2
Grade 5, zinc plated
7
92026-3536
SPACER, rear mount
2
2
1.03 long
8
92022-3555
WASHER, special
4
4
Internal square
9
92001 -3506
BOLT, carriage, 3/8-24 x 2.00
4
4
10
465FA1600
WASHER, spring lock, 1/2"
4
4
Steel, zinc plated
11
118BA1620
SCREW, 1/2-13 x 1.25
4
4
Grade 5, zinc plated
12
13169-3534
PLATE, engine mount
1
1
13
92026-3548
SPACER, front mount
2
2
1.13 long
14
92081-3547
SPRI NG, exhaust
2
2
Long
15
92081-3502
SPRI NG, exhaust
3
3
Short
16
39178-3511
MANIFOLD, exhaust
1
1
17
49070-3511
MUFFLER
1
1
18
49006-3505
BOOT, exhaust pipe
1
1
â&#x20AC;¢
DRIFTER
2. INSTRUMENTS, LIGHTS &WIRING Page 3
'"
~'"
-'
.; ' -
18
17
~ []-16
I
J
~-15 14
DRIFTER 2. INSTRUMENTS, LIGHTS & WIRING
Page 4
ee:
/Quantity/
Ref. No.
Kawasaki Part No.
Description
~
e:,<Q
1
Remarks
~
e:,q.)
Calibrated in KPH
1
25005-3507
SPEEDOMET ER HEAD ASSY
opt
2
92069-3505
•
BULB, 12V, 3.4W
opt
1
3
21066·3504
REGUL A TOR , voltage
1
1
Includes mounting stud
1
Grade 5, zinc plated
4
35 1BA0800
NUT,1/4·20
1
5
92022·3538
WASHER, special
1
1
6
244DA0506
SCREW, #8-32 x .38
2
2
7
23026 ·3503
LENS, tail lamp
1
1
1
1
Grade 60M, zinc plated
8
11009·3505
GASK ET, tail lamp
9
92069·3502
BULB, 12V taillamp
1
1
10
2302 7-3502
BODY ASSY, tail lamp
1
1
Includes wiring - no bulb
GE #1157
11
412EA0600
WASHER, plain , #10
2
2
Steel, zinc plated
12
350BA0600
NUT, insert, #10-32
2
2
Grade 5, zinc plated
13
2600 1-3514
HA RNESS, headlamp & instrument
1
1
14
2600 1·350 7
HA RNESS ASSY , main wiring
1
1
15
21 169-350 1
•
TER MINA L
10
10
Main harness to engine
16
13159-3503
•
CONNECTOR
2
2
Main harness to engine
17
92009 -3546
SCREW, special adjustment
4
4
18
41025-350 1
RIM , headlamp lens
1
1
19
92081 -3548
SPRING, bottom adjustment
2
2
Long
20
92081 -3549
SPRING, t op adjust ment
2
2
Short
21
23007 -350 1
LE NS
1
1
22
92069·3501
BULB, 12V 60/60W
1
1
92069 -3507
BULB , special quartz
opt
opt
23
14020-3505
RET A INER , bulb
1
1
Includes spring
24
92072 -3505
BA ND, cable tie
1
1
Main harness to engine connector
25
92072 -3501
BA ND, cable tie
2
3
Stanley 001-1763-2 Phillips 12342/99-PH4
DRIFTER 3. CONTROLS & SWITCHES Page 5
~-3
..
®-5
J-®
T9
7
8
~-3
10
11
I
I
...
I
~-5 6-®
~
15
~~ 17
1.6
I
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~~ I~
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I I
DRIFTER
3. CONTROLS &SWITCHES Page 6 /Quantity/ Ref. No.
Description
Kawasaki Part No.
~~ ~
r?
e;,<Q
e;,<J:}
1
27010-3507
SWITCH, emergency stop
1
1
2
92009-3520
SCREW, lock
2
2 2
3
92043-3504
PIN, lever
2
4
39075-3506
LEVER, throttle, 32mm
1
1
5
92022-3517
WASHER, pin
2
2
6
92033-3505
RETAINER, pin
2
2 1
7
32099-3502
CASE, throttl e
1
8
13169-3510
PLATE, throttle case
1
1
9
92009-3524
SCREW, plate
2
2
10
27010 -3508
SWITCH, dimmer
1
1 1
11
43001-3501
LEVER, brake
1
12
32099-3501
CASE, brake
1
1
13
13169-3509
PLATE, brake case
1
1
14
27010-3505
SWITCH, brake light
1
1
27005 -3501
SWITCH ASSY, key
1
1
• KEY NUMBER • • KEY 20 • • KEY 21 • • KEY 22 • • KEY 23 • • KEY 24
AR
AR
AR
AR
Set of 2
AR
AR
Set of 2
• • • •
AR
AR
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
1
1
15 16
27008-3501 27008-3502 27008-3503 27008-3504 27008-3505 27008-3506 27008-3507 27008-3508 27008-3509 27008-3510 27008-3511 27008-3512 17
92015-3509
• KEY 25 • KEY 26 • KEY 27 • KEY 28 • • KEY 29 • • KEY 30 • • KEY 31 • NUT, face
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
AR
AR
Set of 2
Remarks
DRIFTER ____ Page 1
4. DRIVE CONVERTER
5
\
V·
-2~- - ------
DRIFTER 4. DRIVE CONV ERTER
Page 8 / Ref. No.
~
,:><Q
49093·3013
CONV ERTE R ASSY, drive
49093·3014
CONVERTER ASSY, drive
92001· 30 20
•
3
14025·3016
4
92028·3011
5
5930 1·3001
2
BOLT, flanged, 6 x 20mm
6
92028·3001
7
59302·3002
8
920 22·3016
9
92043 ·3001
• • • BUSHIN G, 30 x 34 x 20mm • SHEA VE ASSY, movable • • BUSHING, 40 x 44 x 20mm • SHEA V E, fixed • WASHER, spider and roller • PIN, 6. 5 x 10 x 38mm COVER ASSY
Ouantity/
?: ~
Descript ion
Kawasaki Part No.
Remarks
~
':>~
1 18
18
1
1
1
1
1
1
1
1
1
1
6
6
6
6
12
12
10
92026-3001
•
SPAC ER, 10 x 16 x 0.8mm
11
921 22·3011
ROLLER ASSY
3
3
12
92019 -008
NUT, special lock, 6mm
3
3
2.3 grams
13
13042· 3001
• • • • •
WEIGHT, 0.8mm thick
6
opt
0.5 gram
WEI GHT, 1.6mm thick
opt
2
1.0 gram
WEI GHT ASSY, ramp
3
3
Replace as set (Marked G)
BO LT, st eel, 6 x 20mm
3
opt
Silver, 6.0 grams
BOLT, st eel, 6 x 28mm
opt
3
Silver, 7.3 grams
BOLT, steel, 6 x 16mm
opt
opt
Black, 5.3 grams
opt
155 pounds @34.5mm
1304 2·3002 14
391 52·3008
56.6 grams ± 1.0 gram 15
110G0620 110G0628
• •
92001·301 5 16
92081· 300 6
• •
SPRI NG, blue, 105.2mm
166 pound s @34.5mm
SPRING, black, 110.l mm
opt
92081 ·3004
SPRING, pink, 89.9mm
opt
opt
9208 1-3005
SPRING, red, 94.9 mm
opt
opt
92081·3 002
92081·300 1
SPRING, yellow, 100.5mm
92081· 3011
SPRlN G, white, 120Amm
opt
SPID ER
1
1
GU I DE, wear
3
3
1
1
490 50·300 5
18
13070· 300 2
• •
19
92001·3531
BOLT, 1/ 2-20 x 7.00"
133 pounds @34.5mm 144 pounds @34. 5mm
opt
17
122 pounds @34 .5mm
20
9202 2·3560
WASHER, special lock
1
21
590 11·3503
BELT, converter
1
188 pounds @34.5mm
Special 43.5" OC . 1.25" W
DRIFTER
5. DRIVEN CONVERTER & BRAKE Page 9
~ 33 I
I I
~"":'32
DRIFTER 5. DRIVEN CONV ERTER & BRAKE Page 10 /Ouantity/
~~
Ref. No.
Kawasaki Part No.
1
49094-3502
CONVE RTER ASSY, driven
1
1
2
92043-3523
PIN, spring, 3/3 2 x 1.00
1
1
3
920 33-3509
RIN G, retaining
1
1
4
49092·3 501
Description
~ t}i~<Q ~~
5
9208 1-3535
6
49048-3501
7
59301-3501
• • • • • •
8
920 28-3512
•
BUSHING, movable WASHER , special
RA MP, torque
1
1
SPRING, driven
1
1
SLI DE, shoe ramp
3
3
SHEA V E ASSY, movable
1
1
1
1
AR
AR
K EY, woo druff
1
1
SHEAV E ASSY, fixed
1
1
DI SC, brake
1
1
SCREW, 1/4 -20 x .62
3
3
12
41080-3503
13
92009-3536
• • • • •
14
4304 1-3503
CALIPER ASSY, brake
1
1 2
9
92022-3566
10
92038-3503
11
59296-350 1
Remarks
30° ramps
Socket head
15
92009-3537
SCREW, special socket-head
16
412 EA 1000
• •
2
WASHER, flat, 5/16"
2
2
17
43042- 3502
•
CA LI PER B
1
1
18
43050-3502
PAD B, 5/ 16 " t hick
1
1
Metall ic
PA D A, 1/2" thick
1
1
Met all ic
1
1
19
43050-3503
• •
20
92022-354 5
•
WASHER, back up
21
4304 2-3503
CALI PER A
1
1
22
9204 3-3501
PIN, push
2
2
23
410 50-3502
CA M, 22°30'
1
1
24
920 22-3504
• • • •
WASHER, stud
1
1
25
9201 5-3523
•
NUT, special, 5/ 16-24
1
1
26
13070-3501
St eel, zinc plated
Lube wit h "Never-Seez"
27
9208 1-3511
28
92015-3522
29
92028-3511
• • • •
30
920 81-3501
SPRING, brake return
1
1
31
11034-3569
BRAC KET, brake support
1
1
32
534YW0604
RIV ET, 3/16"
2
2
33
11034-3593
BRACKET, return spring
1
1
34
920 55·350 7
RING, " 0 "
3
3
Prevents rattle
35
119BA08 20
BOLT , 1/4 -28 x 1.25
2
2
Grade 5, zinc plated
36
350BA0800
NUT, insert, 1/4-28
2
2
Grade 5, zinc plated
1
BUSH ING
1
1
SPRING, cam
1
1
NUT
2
2
BUSH ING
2
2
37
39092-350 1
PIN, hair
1
38
92043-35 12
PIN
1
1
39
14020-3515
RETA INER, clevis
1
1
St ainless steel
DRIFTER
6. CHAIN CASE
Page 11
2
3~
j~:' -@tAl I 34
DRIFTER 6. CHAINCASE Page 12
« /
Ref. No.
Kawasaki Part No.
Description
~
e:,<C
Quanti t y /
.".
e:,~
1
92055-3505
RING, " 0," chain cover
1
2
39039-3502
COVER, chaincase
1
3
92066·3502
PLUG, fill
1
1
5
5
Special lock patch
1
Calibrated in KPH
1
1
4
9200 1-3503
BOLT, 1/4-20 x 1.00
5
41077·3511
AD APT ER, speedometer drive
6
110 12-3502
CAP, adapter hole
1
7
11009-3514
GASK ET, cap
1
8
92066-3505
PLUG, oil level check
1
1
9
92026·3529
SPACER, bearing
1
1
10
92045-3502
BEARIN G ASSY, ball
2
2
11
92026-3530
SPACE R, upper sprocket
1
1
39134·3502
SPROCK ET, 18 teeth
1
opt
39134·3503
SPROCK ET, 21 teeth
opt
39134-3506
SPROCK ET, 17 teeth
opt
opt
39134-3505
SPROCK ET, 19 teeth
opt
opt
39134-3504
SPROCKET, 20 teeth
opt
opt
39134-3508
SPROCKET, 22 teeth
opt
opt
12
Remarks
13
92022-3542
WASHER, special fl at
2
2
14
92001 -3517
BOL T, lock patch, 5/ 16-24 x .75
2
2
15
39170-3501
TEN SION ER A RM
2
2
16
12053-3501
GUIDE , chain
2
2
Grade 5, zinc plated
Tensioner wear block
17
39092-3501
PIN, hair
2
2
18
119BA0816
BOLT, 1/4·28 x 1.00
2
2
Grade 5, zinc plated
19
412EA0800
WASHER, plain, 1/4"
2
2
St eel, zinc plated
20
42036·3501
BUSHIN G, tensioner arm
2
2
92081 -3508
SPRI NG, green tensioner
1
1
.049 wire dia. x 3.75 long
92081 -3503
SPRING, blue t ensioner
opt
opt
.05 5 wire dia. x 3.75 long
92081 -3506
SPRI NG, pink t ensioner
opt
opt
.049 w ire dia. x 3.38 long
92081 -3507
SPRING, yellow tensioner
opt
opt
.055 wire dia. x 3.38 long
21
92057-3 505
CHA IN, 90 pitch silent
92057·3 504
CHA IN, 92 pitch silent
23
39072·3502
KEY, speedometer
24
41077-3502
A DA PTER , speedometer key
25
92001 ·3525
BOLT, special
26
92022-350 2
WASHER, special
27
3913 5-3513
SPROCK ET, 37 teet h
22
opt opt
Speedomet er key adapter not inclu ded
opt
39135-3 509
SPROCK ET, 38 teeth
opt
3913 5-3510
SPROCK ET, 36 teeth
opt
opt
39135-3512
SPROCK ET, 39 t eet h
opt
opt
39135-3511
SPROCKET, 40 teeth
opt
opt
28
92026·3531
SPACER, lower sproc ket
29
92033·3510
RING, snap
-
DRIFTER Page 13
6. CHAIN CASE (CONTINUED)
47
~A er ~l ~ 4&
t t;J
~
y@
43
13' @ ~_ 42
I
41
~~ -40
~-31
31
@J~ ~
DRIFTER 6. CHAINCASE (CONTINUED) Page 14
-
/Ouant it y / Ref. No.
Kawasaki Part No.
«~
Descri pt ion
n?
~<Q
30
9204 5-3506
BEAR ING, ball
1
1
31
350BA1000
NUT, insert , 5/1 6-24
4
4
32
920 22-3546
WASHER, special
4
4
33
360 14-3502
CASE, chain
1
1
Remark s
t}'-
~~
Grade 5, zinc plated
34
92025-3507
WASHER, "U"
AR
AR
35
412EA1000
WASHER, plain, 5/ 16"
4
4
Steel, zinc plated
36
92001- 3523
BOLT, 5/ 16-24 x 5.00
4
4
Grade 8, zinc plated
37
350B A0800
NUT, insert, 1/4 -28
2
2
Grade 5, zinc plated 1.01 x 1.25 x .073
38
92026 -3528
SPACER, clut ch shaf t
3
3
39
13 107-3 505
SHA FT, converter
1
1
40
92038-3 504
KEY, converter, 3/ 16 x 1/4 x 3.00
1
1
41
92022- 3544
SPACER , washer
1
42
92026 -3530
SPACER
43
39171 -3503
BEA RI NG SUPPORT ASSY
1
44
343B A0800
NUT,1/4-20
1
45
11034-3570
CL EVI S, support
1
46
92009-3559
BOLT, 1/4 -20 x 3.00
1
47
92043-3518
PIN, clevis
1
*
S61020-141
0 1L, chaincase (case of 24)
1
"Not sho wn
Converter alignment
Grade 5, zinc plated Grade 8, zinc plated Cont ains sealant
DRIFTER Page 15
7. SUSPENSION
_
17
!
63- i o
.I~zzz:-
.!.
62 -
i
i J1
41
I
I
~
DRIFTER
-
7. SUSPE NSION
Page 16 /Quantity7 Ref. No.
Kawasaki Part No.
Description
W ~
~<Q
1
39125-3506
TR A CK ASSY
2
49048-3502
3
49048-3503
• •
4
32032-3530
5
1
~
~q;
1
CLIP, tr ack
46
46
With guide tab
CLI P, tra ck
46
46
Without guide tab
AX LE, rear
1
1
92026-3534
SPACER, rear axle wheels
1
1
6
41073-3510
WHEEL ASSY, idler
6
6
7
92026 -3509
SPA CER, inside wheel
6
6
8
39153-3514
6.08" 0 D
9
92045-3502
• • •
10
92033 -3504
•
RING, snap
6
6
11
92026-3508
•
SPACER, outside wheel
6
6
12
92026 -3532
SPACER, rear axle wheels
2
2
13
39172-3503
BRAC KET ASSY, RH rear axle
1
1
39172-3502
BRACKET A SSY, LH rear axle
1
1
92026-3535
SPACER, rear axle wheel
2
2 4
Steel, zinc plated Special lock patch
14
Remarks
WHEEL, idler
6
6
BEAR I NG, ball
6
6
1.21" long
15
413EA1200
WA SHER, plain, 3/8"
4
16
9200 1-3529
BOLT, 3/8 -16 x 1.00
4
4
17
351 BA0800
NUT, insert, 1/4- 20
22
22
Grade 5, zinc plated
18
92015-3536
NUT, 3/8- 16
2
2
Grade 5, zinc plated
19
9200 1-3527
BOLT, 3/8 -16 x 3.75
2
2
Grade 5, zinc plated
20
118BA0814
BOLT , 1/4-20 x .87
16
16
Grade 5, zinc plated
21
13107-3507
SHAFT, idl er wheel
1
1 4.25" 0 D
22
41073-3505
WHEEL ASSY, rear suspension idler
2
2
23
92033-3511
•
RING, snap
2
2
24
92045-3513
•
BEA RING
2
2
25
39153 -3510
•
WHEEL
2
2
26
32032-3540
SPACER, idler wheel
2
2
27
33001 -3504
AR M, rear suspension
1
1
28
465FA1000
WASHER, spring lock, 5/ 16"
2
2
29
118BA1012
BOLT ,5/ 16-18x .75
2
2
Grade 5, zinc plated
30
32032 -3543
BUSHI NG, suspension
4
4
Apply grease AR
31
92081 -3538
SPRING , rear RH
1
1
92081-3537
SPRING , rear LH
1
1
32
13107-3506
SHAFT, pivot
2
2
Apply grease
33
92001 -3508
BOLT, special, 3/8- 16 x 1.00
4
4
Whiz lock
34
118BA1032
BOLT, 5/16 -18 x 2.00
4
4
Grade 5, zinc plated
35
39020-3504
BRACKET, rear suspension arm
2
2
39105-3504
RAI L, suspension
1
1
RH side
39 105-3503
RAI L, suspension
1
1
LH side
37
39139-3504
STR IP, rail wear
2
2
Hi-Fax
38
92043 -3515
PI N, bump er
4
4
Special
4
4
Grade 60M, zinc plated
36
39
244DA0812
SCREW, 1/4-20 x .75
Steel, zinc plated
DRIFTER Page 17
/'
/'
/'
.>
/'
17
I
~
63-'f> !(~-
.i.
62- ;
,,
I
J,
/'
<~-31 "" ()
,~-64
32
~~-33
DRIFTER 7. SUSPENSION (CONTINUED) Page 18
-e:
/Ouantity/
Ref. No.
Kawasaki Part No.
Description
#
t?
C:>~
c:><o
40
92009 -3538
BOLT, special
2
41
23062-3517
BRACKET ASSY, limiter
1
42
39076-3503
LIM ITER
2
2
43
92028-3515
BUSHING, front suspension spring
2
2
44
92022-3551
WASHER, li mite r bracket assy
2
2
45
92041·3501
PIN, cot t er
2
2
46
14020-3517
RETAINER, bumper pin
4
4
47
59201 -3504
BUMPER, rubber
4
4
48
390 20-3505
BRACKET ASSY, fr ont suspension
1
1
49
92026 -3533
SPACER, f ront idl er wheel
2
2
50
39139-3503
STRIP, bracket wear
2
2
51
11034-3584
STOPPER, rear suspension bracket
2
2
52
534YW061 2
RIV ET,3/16"
4
4
53
351BA1000
NUT, insert, 5/16 -18
4
4
Grade 5, zinc plated Grade 5, zinc plated
2
1
54
118BA1232
BOLT, 3/8-16 x 2.00
2
2
55
92028-3502
BUSHING, shock absorber
2
2
56
42036-350 2
SLE EVE , shock absorber
1
1
57
45014-3503
SHOCK ABSORBER
1
1
58
92015 -3527
NUT, insert, 3/8-16
2
2
59
92081 -3539
SPRING, front RH
1
1
92081 -3540
SPRING, front LH
1
1 2
Special
0.94" long
St eel, zinc plated
Special
60
39010- 350 2
BOLT, eye
2
61
118BA0816
BOLT, 1/4-20 x 1.00
2
2
62
33001-3503
ARM, front suspension swing
1
1
63
413EA0800
WASHE R, plain, 1/4 "
2
2
Steel, zinc plated
351 BA1200
NUT, insert 3/8 -16
2
2
Grade 5, zinc plated
64
Remarks
DRIFTER
Page 19
8. DRIVE SHAFT
DRIFTER 8. DRIVE SHAFT
Page 20 /Ouantity/ Ref. No.
Kawasaki Part No.
~~
Descript ion
~
#
~<Q
BOLT, 1/4-20 x 1.00
3
~<?j
3
Grade 5, zinc plated
1
118BA0816
2
4 1066-3502
HOUSIN G, bearing
1
1
3
412 EA0800
WASHER, plain, 1/4"
3
3
Steel, zinc plated
4
35 1BA0800
NUT, insert, 1/4-20
3
3
Grade 5, zinc plated
5
92055-3506
RING, "0"
1
1
6
9204 5-3514
BEA RING
1
1
Sealed
7
92027·3505
COLLA R ASSY
2
2
Includes screw
8
92009-3563
•
2
2
Socket head
9
12046-3505
SPROCKET, drive
2
2 1 1
SCREW, #10-32 x .62
10
32032-3 527
SPACER , sprocket
1
11
39 159·3505
SHA FT, tra ck drive
1
Remarks
DRIFTER
9. SKI &SPINDLE Page 21
ยง-t
e-
t
2 22 -~ <,
r-
~
23~
~-3 I '~- 4
6 7
i~
I
I I
I I I I I I
DRIFTER 9. SKI &SPINDLE
-
Page 22 /Quantity Ref. No.
Kawasaki Part No.
W
Descript ion
~
e;,<O
Remarks
~
e;,q)
1
92028-3518
BUSHING, spindle
4
4
2
39127-3501
SPINDLE, ski
2
2
3
119CA1220
BOLT, 3/8-24 x 1.25
4
4
4
39015-3503
SADDLE, ski spring
2
2
5
118BA1252
BOLT, 3/8-16 x 3.25
2
2
6
39130-350 1
SPRING, monoleaf
2
2
7
42036 -3503
SLEEVE, spring
2
2
8
39094 -3502
PLATE, spring backup
2
2
9
59201-3502
BUMPER, ski spring saddle
2
2
10
39106-3501
RETAINER, bumper
11
350BA1200
NUT, insert, 3/8 -24
12
351 BA1000
13
119BA1244
14
39122-3507
SKI
2
2
15
39120-3501
SKEG, ski
2
2
Ski wear runner
16
119BA1252
BOLT, 3/8-24 x 3.25
2
2
Grade 5, zinc plated
17
119BA1248
BOLT, 3/8 -24 x 3.00
2
2
Grade 5, zinc plat ed
2
Grade 8, zinc plated Grade 5, zinc plated Apply grease
2
2
10
10
Grade 5, zinc plated
NUT , insert , 5/16-18
6
6
Grade 5, zinc plated
BOLT, 3/8-24 x 2.75
2
2
Grade 5, zinc plated
18
39138-3503
STRIP, rub
2
19
92026-3510
SPACER, shock
4
4
20
450 14-3504
SHOCK ABSORBER
2
2
21
92022 -3528
WASHER, special
2
2 4
Grade 5, zinc plated
22
351BA1200
NUT , insert, 3/8 -16
4
23
118BA1244
BOLT, 3/8-16 x 2.75
2
2
Grade 5, zinc plat ed
24
420 36-3 508
SLEEVE, spindle
2
2
Apply grease
DRIFTER 10. STEERING
Page 23
2-~
1
~
DR IFTER 10. STEERING
Page 24
«:
/Ouantity/
Ref. No.
1
Kawasaki Part No.
Description
Remarks
~ r}4 e:,<O e:,q)
2
46075-350 1
GR IP, handle
2 3
3 2
2
92072-350 1
BAND, cable t ie
3
119BA1040
BOLT, 5/ 16-24 x 2.50
2
4
39009 -350 1
BLOCK, mount
4
4
Grade 5, zinc plated
5
92028-3510
BUSHING, steering pole
4
4
6
39 100-3505
POLE A SSY, handle
1
1
7
119BA 1224
BOLT, 3/8- 24 x 1.50
2
2
8
39 111-3510
ROD, steering t ie
2
2
RH & LH weldment Grade 5, zinc plat ed
Grade 5, zinc plated
9
344BA1200
NUT , jam, 3/8-24 RH
2
2
10
92004 -3502
STUD, adjusting
2
2
11
350BA1200
NUT, insert, 3/8 -24
5
5
Grade 5, zinc plat ed
12
4 12EA1200
WASHER, plain, 3/8 "
4
4
Steel, zinc plated
13
39006-3508
ARM, long steering
1
1
LH
14
119BA1 236
BOLT, 3/8 -24 x 2.25
2
2
Grade 5, zinc plated
15
391 12-3506
ROD END, t ie
2
2
Female
16
92015-3510
NUT , jam, 3/8-24 LH
2
2
Special Grade 8, black
17
92009-3539
SCREW, special, 3/8-16 x 1.38
1
1
18
920 15-3527
NUT, t hin lock, 3/8-16
1
1
19
92026 -3537
SPACER, rod end
1
1
20
39006 -3509
ARM, short steering
1
1
RH
1
1
Grade 5, zinc plated
RH only
21
119BA1228
BOLT, 3/8-24 x 1.75
22
92001 -3528
BOLT, 5/16 -24 x 2.50
2
2
Grade 8, lock pat ch
23
350BA1000
NUT, insert, 5/ 16-24
2
2
Grade 5, zinc plated
1
24
46012-3504
HOLDER , handle
1
25
92009 -3510
BOLT, socket head, 1/4-20 x 1.00
4
4
26
46003-3503
BAR, handle
1
1
DRIFTER
11. CHASSIS (113) Page 25
~-
C-;j
l -i 1"--
I
I
L-_ ~
25
3- %
~7
' , 11
~ I ~ 'I _~~ -10 _ ...-"..
r2?11
24 -~-10 1
5
{ 6-
"'"
~~7 .. -_
I
18
.
DRIFTER
11 . CHASSIS (1/3) Page 26
ee:
/Ouant ity /
Ref. No.
Kawasaki Part No.
Descripti on
~
~<c
1
39073·3506
LANYARD A SSY
2
3909 2-3503
•
3
56040 -3501
LABEL, warning
1
1
4
39056·3504
GUA RD ASSY, convert er belt
1
1
2
2
Tf
~q;
1
PIN, hair
2 French/E nglish
5
92043-3519
PIN, converter guard
6
39092-3503
PIN, hair
2
1
7
39 156-3566
PAD, converter
2
2
8
39090 -3512
PAN EL, vent
1
1
9
39145-3 512
T RIM-SEA L, hood guide
2
2
10
35 1BA0800
NUT, insert, 1/4-20
24
24
Grade 5, zinc plated
11
412 EA0800
WASHER, plain, 1/4"
22
22
Steel, zinc plated
12
13070-3518
GUIDE , hood
2
2
13
118BA0812
BOLT, 1/4 -20 x .75
16
16
14
3903 1-3503
CAP, bumper end
2
2
15
92009-3543
SCREW, self tap, #6-32 x .38
2
2
16
56027-3533
DECAL, bum per
1
17
35009-3 509
BRA CE, nose pan
2
2
18
39027·3502
BUMPER, front
1
1
19
92037 -3511
CLA MP, harness
1
1
Prevents rattle
Grade 5, zinc plated
Grade 60 M, zinc plated
20
244DA0812
SCREW, machine, 1/4- 20 x .75
8
8
21
35034-3521
PLATE, hinge backing
2
2
22
53044-3503
TR IM, pan, 22.50 "
1
1
(See note .
23
39090-3505
PANEL, nose vent
1
1
Black grill
24
53009 ·3517
HIN GE, lower LH
1
1
25
53009-35 15
HIN GE, lower RH
1
1
NOTE: Bulk trim is available by orderin g t he f oll owing part number. • 53044-3506
TR IM 25 ft. roll
Remarks
DRIFTER 12. CHASSIS (2/3) Page 27
I I
I
I
- 10
DRIFTER 12. CHASSIS (2/3) Page 28 /Quant ity7 Ref . No.
Kawasaki Part No.
W
Description
~
C;)<Q
~
C;)~
1
39 156-3524
PAD, RH foo t grip
1
1
2
39156-3525
PAD, LH foo t grip
1
1
3
118BA0 824
BOLT, 1/4-20 x 1.50
4
4
4
92009 -3547
SCREW, t russ head, 5/16- 24 x 1.00
4
4
5
41 3EA1 000
WASHER, plain, 5/16"
4
4
Steel, zinc plated
6
351BA0800
NUT, insert, 1/4-20
4
4
Grade 5, zinc plated
7
39028-3 503
BUMPER, rear
1
1 1
8
13 169-3526
PLAT E, snow f lap
1
9
535YW0608
RIV ET, 3/16 :
4
4
10
39047-3502
FL AP, snow
1
1
11
28012-3504
REFLECTOR , red
2
2 4
Grade 5, zinc plated
Steel, zinc plated
Nyl on cap
12
9201 5-3 507
NUT, lock, 5/ 16-24
4
13
920 22-3505
WASHER, cupped
4
4
14
92026-3502
SPACER, handle grip
4
4
15
39053-3502
HA NDLE, passenger
2
2
5602 7-3587
PATTE RN, tunne l right side
1
Blue st ripes
56027-3588
PATTE RN, t unnel left side
1
Blue stripes
56027-3585
PATT ERN, t unnel right side
1
Blue str ipes
56027-3586
PATT ERN, t unnel lef t side
1
Blue st ripes
53044 -3504
T RIM, pan, 8.18"
2
(See note .
16
17
NOTE : Bulk t rim is available by ordering the f oll owin g part number . â&#x20AC;¢
53044-3506
T RI M 25 ft. roll
2
Remarks
DRIFTER
13. CHASSIS (3/3)
Page 29 ~- 2
7
I
. .. .t-
. ~ . .'1 .: 1: . I
I I I
I
I I
I I I I I I
~6 11 _
I'
I: I
~@ •
.
.:~.
s: »
10 _
1 ' , 1 11 I I I r- , I I . ~ I I--J . . I .. • J
-.»
. l' .
~15
s
DR IFTER 13. CHASSIS (3/3) Page 30 -7 0u ant it y/ Ref . No.
Kawasaki Part No.
?f(~
Descript ion
nJ'
C;)<Q
39048-3503
FOOTREST,RH
1
1
2
9205 9-3544
TU BE, special
1
1
3
39084-3510
MOUNT, upper steering
1
1
4
534YW0602
RIVET, 3/ 16 x .33
81
81
5
39048 -3504
FOOTREST, LH
1
1
1
66
66
Remarks
tf'
C;)'<J
Protects fue l tank Steel, zinc plat ed Steel, zinc plated
6
534YW0604
RIV ET, 3/16 x .45
7
39026-3505
BU LKHEAD, rear
1
1
8
534X W0604
RIVET, 3/16 x .45
8
8
9
39 149-3509
T UN NEL
1
1
10
39020 -3503
BRACKET, LH rear suspension
1
1
11
39020-3502
BRACKET, RH rear suspension
1
1
12
11034-3566
BRACKET, LH fr ont suspension
1
1
13
11034-3 567
BRACKE T, RH front suspension
1
1
14
32002-3514
FRAM E, front
1
1
15
99970-3529
PAN ASSY, nose
1
1
16
535YW0604
• • • •
RIVET, 3/ 16 x .45
35
35
RIVET, 3/ 16 x .33
4
4
Alum inum, bl ack anodize
RIV ET, 3/ 16 x .45
6
6
Steel, zinc plated
RIVET, 3/ 16 x .57
4
4
Steel, zinc plated, large head
17
534WW0602
18
534YW0604
19
535Y W0606
Aluminum, black anodize
Includes rivet s Steel, zinc plated, large head
DRIFTER 14. HOOD Page 31
/' -
- -9 // /
/
/
33-~
/
34
/ /35..1
$
.-
- 12
~-13
/
-,..... , - - -33 --..:~ 31 6- 16 32-.' I 17-~
30 -~~· ~ ~~ I
29
j-
I~
.----/j.
18 --~,
8-
@
~:-11 .
\
1/ c» 33 ~-15
16
/
28
~-27
~-25
26
~-1 5
f--18
1 21
10
DRIFTER 14. HOOD
Page 32 / Ref. No.
Kawasa ki Part No.
Description
W
~
e,<Q
2
CkJantity/
39 154-3513
WIND SHIELD, high
39154-3508
WIND SHI ELD, smoke tinted, low
opt
opt
56027-3620
PATTER N, windshield right side
1
1
Remarks
tf-
e,~
Includes trim Includes trim
3
92009-3544
SCREW, special black
8
8
4
39 145-3513
T RIM, seal
1
1
5
56027-3618
PATT ERN, windshield fr ont
1
1
6
56027-36 19
PATTE RN, wind shield left side
1
1
7
5602 7-3539
PATTE RN, dash
5602 7-356 1
PATTER N, dash
1
56040-3507
LA BEL, warnin g
1
9
53044-3509
T RIM, hood rear edge
1
1
43.9 long (See note • )
10
92009-3551
SCREW, 1/4 -20 x 1.00
4
4
Grade 60M, black chrome
11
13169-3528
PLA T E, retainer backup
2
2
12
92072-3508
RETAIN ER, rubber hood
2
2
8
Windshield mounting
1 1
13
270 12-350 1
HOOK retainer
2
2
14
412EA0800
WASHER, plain, 1/4"
4
4
15
35 1BA0800
NUT, insert, 1/4 -20
12
12
16
92022-3539
WASHER, backup
7
7
Clamp, hood lanyard and vent panel
17
92037-3511
CLAMP, headlight harness
2
2
.28" hole x .44" clamping diameter
18
535YW0604
RIVET,3/ 16"
3
3
Clamp and hood lanyard mounting
19
56027 -3579
PATTER N, LH side
1
1
Kawasaki blue and silver stripes
56027 -3580
PATTERN, RH side
1
1
Kawasaki blue and silver stripes
20
56027-3536
PATTE RN, bottom edge
2
2
Black stripe
21
280 12-3503
REF LECTO R, amber
2
2
22
39156-3562
PAD , top
2
2
23
39156-3547
PAD, LH side
1
1
24
39156 -3563
PAD, RH side
1
1
25
92081 -3529
SPRI NG, hood lanyard
1
1
26
351BA0600
NUT , insert , #10-24
1
1
27
39073-3503
LAN YA RD, hood
1
1
28
244DA0608
SCREW, #10-24 x .50
1
1
29
92043-3522
PIN, clevis
2
2
30
39092·3503
PIN, hair
2
2 1
31
92037-3517
CLAMP, headlight harness
1
32
53009-3520
HING E, LH upper
1
1
33
92022·3527
WASHER, rubber
16
16
34
53009 ·3519
HI NGE, RH upper
1
1
NOTE : Bulk trim is available by ordering the f ollowing part number. •
53044-3506
T RIM, 25 ft . roll
Steel, zinc plated Grade 5, zinc plated
Grade 5, zinc plated Grade 60M, zinc plated
.28" hole x .62" clamping diameter
DRIFTER 14. HOOD (CONTINUED)
Page 33
42 ~ ~ ,
; i
40-t
\ I
41
I
/ ~ - 1O /
-9
././ / /
//
~ . .-11
.-12
SJ----13
) /
33-~
-r / ,~,----// ~-----
//35...i..
/
/
34
D 33 ~~-15
\ 33-)"
31
17-~
30'--,; (/~ ~
f-18
32-61 I ~\
I
29 '(-28
16
I
@rL/~-27 18-~
8-26
~-25
6-16
~-15
1 21
DRIFTER 14. HOOD (CONTINUED) Page 34 / Ref. No.
Descript ion
Kawasaki Part No.
Ouanti t y /
~~ ~
e:,</J
Remarks
tf
e:,<JJ
8
Grade 60M, black chrome
1
1
No decals applied, painted. blue
GROMM ET, headli ght harness
1
1
920 15-3514
NUT, rub ber well
8
8
39
39090-35 11
PANEL, vent
1
1
40
534VV0606
RIVET,3/ 16"
4
4
41
14020-3518
RETA INER , push nut
12
12 2
35
250DH08 12
SCREW, 1/4 -20 x .75
8
36
59456-3514
HOOD
37
92071 -3508
38
39090-3506
V ENT, hood
2
43
56027 -3582
PATTER N, to plef t
1
44
56027 -358 1
PATTER N, rocker
1
45
56027 -3583
PATTER N, to p ri ght
42
*
Windshield mounting
Aluminum, black anodize Hood vent Blue and silver stripes
1
Blue and silver stripes Blue and silver stripes
1
1 AR
2.0 oz. bottle with brush
50275-3516
PA INT, dark blue
AR
50275 -3517
PAI NT , dark blue
AR
AR
12.5 oz. spray can
50275·3518
PA INT, dark blue
AR
AR
16.0 oz. can (bulk)
"Not sho wn
DRIFTER
Page 35
15. SEAT
I
I
(.!..~/'1 ty
I
I
I
+-15 ~-16
I
I
~-15
1-17
DRIFTER 15. SEAT
-
Page 36 /Ouantity/ Ref . No.
Kawasaki Part No.
t:~
Description
~
~
~<o
,....
Remarks
~<J:J
Less storage case cover
1
5300 1-3518
SEAT ASSY
1
1
2
5300 2-3509
SEAT
1
1
3
53006-3 503
FRAME ASSY
1
1
Includes special mounti ng nuts
4
49031-3505
Bungee cord
5
5300 9-3 524
6
534XX0606
7
920 22-3539
8
412EA0700
9
92037-3512
• • • • • • • •
CLA MP, latch
2
2
10
14025-3517
COVER, storage case
1
1
11
39 156-3557
PAD
2
2 1
LATCH, storage case
2
2
HIN GE, storage case cover
2
2
RIVET,3/16"
4
4
WASHER, special
4
4
Steel, zinc plated
WASHER, plain, #12
2
2
Steel, zinc plated
12
391 56-3556
PA D
1
13
92033-3507
RING, snap
2
2
14
92043-3524
PIN
2
2
15
412 EA0 800
WASHER, plain, 1/4"
4
4
Steel, zinc plated
16
118BA0 814
BOLT, 1/4-20 x .87
2
2
Grade 5, zinc plated
250 DA0814
SCREW, 1/4 -20 x .88
2
2
Grade 60M, zinc plated
17
DRIFTER 16. FUEL SYSTEM
Page 37
~-38
42
~ I I
~4
- t
5
-
6
~ II
~7 8
9
DRIFTER 16. FUEL SYSTEM
Page 38 /Quantity/ Ref. No.
Kawasaki Part No.
~~
Description
~
~<¢
1
1
1
51049-350 1
CAP, fuel tank
2
11009-3502
GASKET, cap
1
1
3
14020-3516
RETAINER, fuel level gauge
3
3
4
52005-3503
GAUG E, fuel level
1
1
5
534YW0604
RIV ET , 3/ 16"
4
4
Remarks
~
~~
Gasket required
Steel, zinc plat ed
6
3205 2-3505
BRACK ET, fuel tank
1
1
7
3908 5-350 1
PAD, bracket
1
1
8
51004-3503
TANK, fuel
1
1
9
490 19-3503
WEIGH T, fuel pick up
1
1
10
39 156-3522
PAD, fuel t ank side
2
2
8.00" long
11
92072-512
BAND
1
1
Silencer to support
12
56040-3502
MARK, warning
1
1
Air silencer
13
92081 -3555
SPRING, exten sion, 18.25"
1
1
Silencer to carb
14
1322 7-3 529
HOUSING, intake silencer
1
1
Carb side
15
32032-3549
PIPE, intake, 3.25"
1
1
16
92022-3531
WASHER, special
3
3
17
18020-3 508
BAFFL E, intake guard
1
1
18
92039-3 532
RIVET, special, 5/3 2"
3
3
Closed type
19
13227- 3533
HOUSING, intake
1
1
Elbow end
20
39 156-352 7
PAD, fuel tank LH
1
1
21
92059-3522
TU BE, 7/32 x 12.00
1
1
22
92005-3510
FITTIN G, fuel tank
1
1
23
92093 -3504
SEA L, silencer/ carb
1
1
24
41077 -3506
ADAPT ER, carb to seal
1
1
25
534X V0806
RIV ET, 1/4 x .62
2
2
Aluminum, small head
26
49040-3509
FU EL PUMP ASSY
1
1
DF-44-211
27
50289-3503
PART GROUP, rebuild kit
1
1
Diaphragm/Gasket
28
92009-3548
• •
SCREW/WASHER
4
4 2
Primer pump (See note • ) (See note. )
Pick up to fitting (See note. )
29
92059-3542
TUBE, 3/32 x 15.00
2
30
92059 -3524
TU BE, 7/32 x 1.25
3
3
31
39 156-353 5
PAD, f uel tank RH
1
1
32
9200 5-3503
FITTI NG, t ank vent
1
1
33
92059-3531
TUBE, 1/8 x 15.00
1
1
Fuel tank vent (See note. )
34
92072 -350 1
BA ND, cable tie
1
1
Vent tube to steering mount
35
49019-3502
FILTER, fuel
1
1
36
92005-3506
FI TTIN G, T
1
1
37
92059-3526
T UBE, 7/32 x 18.00
1
1
Fuel pump to carb (See note. )
DRIFTER 16. FUEL SYSTEM (CONTINUED)
Page 39
~-38
8 9
13
~
DRIFTER 16. FUEL SYSTEM (CONTINUED)
-
Page 40 /Ouantity/ Ref. No.
Kawasaki Part No.
~~
Description
~
C:J<Q
~
C:J~
Fuel pump to pulse (See note.
38
92059-3541
TUBE, 7/32 x 13.00
1
1
39
92015-3 515
NUT, primer pump
1
1
40
920 22-3521
WASHER, primer pump
1
1
Internal star
1
Hardware not included
2
3.00" long
41
49043 -350 2
PUMP, primer
1
42
39156 -3523
PAD, fuel tank top
2
NOTE: Bulk tubing is available by ordering the foll owing part numbers: 920 59-3520
TUB E, 7/3 2 in. x 100ft.
•
92059-3518
TUBE, 3/32 in. x 100 ft.
•
920 59-3519
TU BE, 1/8 in. x 100 ft.
•
--
Remarks
DRIFTER Page 41
17. LUBRICATION SYSTEM
-
-
10
30 /
-:
./
~
I
29
'~
~I 28 27
13
I
~
15
.J
DRIFTER 17. LUBRICATION SYSTEM
Page 42 /Quantity/ Ref. No.
Kawasaki . Part No.
~~
Description
~ ':J«:J
n)'
':J~
1
51049-3502
CAP, oil tank
1
1
2
92072 -350 1
BAND, cable tie
1
1
Vent t ube
3
92059-3529
TUBE , 3/32 x 24.00"
1
1
Oil tank vent (See note .
1
4
92005-3503
FITTI NG, vent
1
5
5200 1-3503
TA NK , oi l
1
1
6
39085-3502
PAD, oil tank
1
1
7
32052 -3504
BRACKE T ASSY, oil tank
1
1
8
32032 -3518
PIPE, pick up
1
1
9
92005-3512
FIT T ING, straight
1
1
10
92059·355 1
TUBE ,7/32x3.00 "
1
1 1
11
49065-3501
FILTER
1
12
92059-3532
TUBE , 7/32 x 16.00"
1
1
13
92038 -300 1
KEY , woodruff
1
1
14
92055-3005
a -RI NG, oil pump
1
1
1
1
Filter to oil pump (See note * )
15
49042-3012
16
13169-300 5
•
PLA TE, inlet
1
1
17
9208 1-3008
•
SPRING, cont ro l lever
1
1
18
13168-3004
•
LEVER , cont rol
1
1
White
19
92059 -3027
TUB E, 3 x 6 x 100mm
1
1
LH cyl inder t o pump
20
92037-3002
CLA MP, oil t ube
4
4
21
92062 -503
NOZZL E
2
2
22
92065-534
GASKET, 6.2 x 12 x 1.0mm
4
4
23
16087-3001
VA LVE, check
2
2
24
92059-3028
TUBE,3 x 6 x 160mm
1
1
25
11009-3026
GASK ET, 6.2 x 12 x 2.0mm
2
2
26
130B0630
BOL T, fl anged, 6 x 30mm
2
2
27
351BA0800
NUT, insert , 1/4-20
2
2
Grade 5, zinc plated
28
412EA0800
WASHER, plain, 1/4"
2
2
Steel, zinc plated
29
118BA0812
BOLT, 1/4-20 x .75
2
2
Grade 5, zinc plated
92072-512
BAND, tank hold down
1
1
NOTE: Bulk tubing is available by ordering the following
part numbers :
*
92059-3520
TUBE, 7/32 in. x 100 ft .
•
920 59-3518
TUB E, 3/32 in. x 100 ft .
)
Tank t o f ilter (See note * )
0 1L PUMP ASSY
30
c
Remarks
RH cy linder t o pump
DRIFTER 18. CABLES
Page 43
~- 1
-
-
6
2
~
@-5
f
9
~~
II
8 8
~
I
5
DRIFTER
18. CABLES
Page 44 /Quant ity/ Ref. No.
Kawasaki Part No.
~~
Descript ion
~
C:J<O 1
92033-3502
RING, cable snap
2
2 1
2
5401 2-353 2
CAB LE, throttle lever
1
3
13227-3 535
HOUSI NG ASSY
1
1
4
54012-3531
CA BLE, carburetor
1
1
5
92015- 3512
NUT, jam
2
2
6
54012-3 533
CA BLE A SSY, oil pump
1
1
7
54005-350 2
CA BLE ASSY, brake
1
1
8
344B A 1000
•
2
2
9
92015- 3525
NUT, pal
1
1
10
13227-354 5
HOUSING ASSY
1
1
11
39030-3505
CAB LE ASSY
1
1
12
54001-3503
CA BLE, speedometer
NUT, jam, 5/1 6-24
1
b<~
C:J«>
Throttle & brake
Brake
Remarks
DRIFTER Page 45
19. CARBURETOR
_
1
----IL
B-2
38 -
37
-
~
3
~
4
~
5
-----1
8 9
~
...
I
26 - --
- 'ch
26 -
--"
~
36 ---1..~~
-
:m
rar;
-
12 13 14
I~ b
35~
10 11
15
E;l
17-
-
-
24
O· :9/l2 I I I
I
23 -~
22-
- -'
20-
--'
21 -----!::~:ll~m
I I
I
16 17
18
DRIFTER 19. CAR BUR ETOR
-
Page 46
,..
r 1
Description
Kawasa ki Part No.
~ e;,<¢
1600 1-3550
CARBUR ETOR A SSY, 32mm
16001-3549
CARBUR ETOR ASSY, 32mm
2
16012-3501
3
92022-3529
• •
4
16013-003
5
16016-00 2
6
16022-007
7
16014 -006
8
16032-008
9
11009-3509
10
'-
ee:
/Ouantity/
Ref. No.
92064-022
~
e;,~
Marked 32/187 Marked 32 /186
CAP, enrichener plunger WASHER, cap
• •
SPRl NG, enric hener plunger
• • • • •
SPRING, air screw
PLU NGER, enrichener SCREW, pilot air PIN, f loat GASKET, floa t chamber PI LOT JET , #30
92064-049
PILOT JET, #1 5
opt
opt
Leane r
92064 -021
PI LOT JET, #20
opt
opt
Leaner
92064-032
PI LOT JET, #25
opt
opt
Leaner
1
1
13
16065-008
14
920 55-044
• • • •
15
16055-004
•
ARM, fl oat
1
1
16
14020-3 508
•
RETAINER, floa t
2
2
17
1603 1-021
•
FLOAT
2
2
18
92063-020
•
MAIN JET, #180
1
opt
Long hex-Amal
92063-027
•
MAIN JET, #250
opt
1
Long hex-Amal
92063-0 17
MA l N JET, #160
opt
opt
Long hex-Amal
92063 -019
MA IN JET, #170
opt
opt
Long hex-Amal
92063 -021
MAIN JET, #190
opt
opt
Long hex-Amal
92063 -022
MAIN JET, #200
opt
opt
Long hex-Amal
9206 3-023
MAIN JET, #210
opt
opt
Long hex-A mal
92063 -024
MAIN JET, #220
opt
opt
Long hex-Am al
92063 -025
MAIN JET, #230
opt
opt
Long hex-A mal
92063-026
MAI N JET, #240
opt
opt
Long hex-A mal
92063 -028
MAIN JET, #260
opt
opt
Long hex-Amal
11
18020-3505
12
16034-001
BA FFL E WASHER, holder
1
1
HOLDER, carb needle
1
1
O-RING , holder
1
1
19
16020-3 503
•
CHAMBER, float
1
1
20
16033-0 18
SCREW, special
4
4
CLAMP, econo jet tube
2
2
RETAINER, t ube
3
3
21
92037 -078
22
14020-3509
• • •
23
92059-351 5
•
TU BE, 3.5 x 98
1
1
24
16159-3503
• •
ECONO JET #120
1
opt
ECONO JET, #110
opt
161 59-3 525
ECONO JET , #70
opt
opt
Round - reverse jet
161 59-3524
ECONO JET , #75
opt
opt
Round - reverse jet
161 59-3501
Includes washer
Econo jet Round - reverse jet Round - reverse jet
Remarks
DRIFTER Page 47
19. CARBURETOR (CONTINUED)
'I
a
/ /
(g)
1
I
.> 30 I .> X/ ...-.-.--. ./
-
(
5
- --
./
38 ----~
4
~
--
---
3
;
./
38 ----- - /
2
./
6
I
_-- ~- 7 I I
37
I
~
I I I
I I
I I
36 ---~~
I
28
~27
./
~
~
8 9 I
26 - - - - + : 8- - - -10 ~
3 1 34- r-
35~
I
r "---~~
25 _ _---.JI ~O
!
17 -
-
-
-
I
I
33 -----l
24
I
I
v
A fh "01 Q-
: ~IIl~I
I
I
I
-
----
16
17
18
I I
23 -~
I
19
./J ./
./ 1 . /. /
15
I I'
I
32~
14
b
I
I
11
26 - - - - - '
I I
...
22 -
-
- '
21-----l:::....::::.:l.'Lrll 20 --~
I
DRIFTER 19. CARBURETOR (CONTINUED)
Page 48
1
ee:
/Quantity /
Ref. No.
Kawasaki Part No.
Description
~
~<o
opt
Round - reverse jet
opt
opt
Round - reverse jet
opt
opt
Round - reverse jet
ECONO JET, #95
opt
opt
Round - reverse jet
16159-3513
ECONO JET #100
opt
opt
Round - reverse jet
16159-3512
ECONO JET, #105
opt
opt
Round - reverse jet
16159-3502
ECONO JET, #115
opt
opt
Round - reverse jet
16159-3517
ECONO JET, #80
opt
16159-3516
ECONO JET, #85
16159-3515
ECONO JET, #90
16159-3514
FLOAT VALVE ASSY, 1.2
16030-3501
• •
26
11009-3510
•
27
16035-3501
28
16022-005
• • • •
25
t}i-
~«j
16030-3503
29
16021-3501
30
92005-3509
31
16008-010
32
16017-3506
opt opt
1
GASKET, float valve
2
2
AIR JET
1
1
SPRING, throttle screw
1
1
SCREW, throttle stop
1
1
FITTING, primer tube
1
1
CLIP, carburetor needle
1
1
NEEDLE JET, 0-6
1
1
VALVE, CA2.0
1
1
FLOAT VALVE ASSY, 1.5
33
16025-3504
• • •
34
16009-3503
•
NEEDLE,6 FL 14-3
1
1
35
16007-022
•
SEAT, spring
1
1
36
92081-3556
1
1
37
• •
SPRING, throttle valve
16004-022
CAP, mixing chamber
1
1
Includes gasket
38
92059-3516
•
TUBE, 3.5 x 240
2
2
Air vent
Series 159 Clip in 3rd groove
Remarks
DRIFTER
20. CYLINDER HEAD, CYLINDER Page 49
-
4
DR IFTER 20. CYLINDER HEAD, CYLINDER Page 50 /Quantity/ Ref. No.
fY~
Description
Kawasaki Part No.
~
e:,<Q
8
8
WASHER, spring, 8mm
10
10
WASHER , plain, 8mm
8
8
1100 1-3020
HEAD , cyl inder
2
11001-3004
HEA D, cylinder
11004-5 15
GASKE T, head
11004-513
GASKE T, head
1100 5-3020
CYLI NDER , RH
11005-3006
CYLI NDER , RH
7
11009-3001
GASKET, int ake
6
6
8
16073-3002
INSULATOR
2
2
59076 -3010
MAN IFOLD, intake
1
1
10
130B0665
BOLT, f langed, 6 x 65m m
2
2
11
130B0640
BOLT, f langed, 6 x 40mm
4
4
12
9203 7-3013
CLAMP , carbureto r holder
1
1 1
1
311G0800
NUT,8mm
2
46 1F0800
3
92022-503
4 5 6
9
,.-
2 2 2 1
13
16065 -3011
HOLDER , carburetor
1
14
114 B0825
BOL T, 8 x 25mm
2
2
15
92022-3007
WASHER, silencer spring
2
2
16
11009 -507
GASKE T, cy linder base
2
2
17
11005-3019
CYLINDER, LH
1
11005-3005
CYLINDER, LH
1
18
11009-3013
GASKET, exhaust
4
4
19
172G0820
STUD , 8 x 20mm
4
4
20
46 1S0800
WASHER, spring, 8mm
4
4
21
311R0800
NUT,8mm
4
4
~
e:,<l)
Remarks
DRIFTER 21. CRAN KCASE
Page 51
16 G)
-
12
13
I
14
I
I f@~ ~
-
11
I
(II
I
10
I
9
i
'I~ ~
1
,
<.
8-
-
7
2
DRIFTER 21. CRANKCASE Page 52
-
7
-/Ouantity Ref. No.
1
.--
(I •
Description
Kawasaki Part No.
~~
~?"
~ <?<o
92004 -3005
STUD, crankcase
8 1
PIPE, pulse
1
1
PIN, dowel, 8 x 14mm
2
2
t::;"?' ~
<?q)
8
2
14001-3021
CRANKCASE SET ASSY
3
32032-3001
4
92042 -007
• •
5
92001-3004
BOLT, oil filler, 8 x 14mm
1
1
6
11009-3008
GASKET,8mm
1
1
7
130B0640
BOLT, flanged, 6 x 40mm
2
2
8
130G0860
BOLT, flanged, 8 x 60mm
8
8
9
92065-534
GASKET,6mm
1
1
10
130B0612
BOLT, f langed, 6 x 12mm
1
1
11
52005-3001
GAUGE, oil
1
1
12
110B0812
BOLT, 8 x 12mm
2
2 2
13
461 F0800
WASHER, spring, 8mm
2
14
410B0800
WASHER, plain 8mm
2
2
15
14025-3013
COVER, hole
1
1
16
92104-002
SEALER, liquid gasket
AR
AR
100g tube
Remarks
DRIFTER _ _Page 53
â&#x20AC;¢
_
_
K SHAFT 2_2._PIST=DN:&:CRA:N
DR IFTER
22. PISTO N & CRAN KS HAFT Page 54
]
/Quant it y / Ref. No.
Kawasaki Part No.
W
Descript io n
~
~<Q
2
r
13008-3010
RIN G SET, piston
13008-3009
RING SET, piston
1300 1-3014
PISTO N
13001-3012
PISTO N
~
~qj
Top & bottom
2 2
Top & bottom
2 2
3
13031-3014
CRA NKS HAF T A SSY
1
4
49035-3001
•
PIN, spring
1
5
92055-3002
•
O-RING, crankshaft
2
2
6
92050-507
•
SEAL, RH crank oil
1
1
TCY306 210
7
92045-3002
•
BEAR ING, ball
1
1
6206-9 RT-C4
8
92025-3017
•
SHIM, RH crank, 35 x 42 x 1mm
1
1
9
92025-539
SH IM, LH crank , 40 x 47 x 1mm
1
1
10
92045 -507
BEAR ING, ball
1
1
620 7-9C4
SEAL, L H crank oil
1
1
Y4272 10
COLLAR , LH crank
1
1
GEAR , 26 tooth drive
1
1
11
92049·3003
12
92027 -3002
13
5905 1-300 1
• • • • •
14
510A5200
KEY, wood ruff
15
Remarks
1
1 AR AR
92025·30 15
SHI M,0 .5mm
AR
92025-30 16
SH IM, 0.6mm
AR
92025-300 1
SHIM, 0.7mm
AR
AR
92025-3002
SH IM,0.8mm
AR
AR
92025-3003
SHIM,0.9mm
AR
AR
92025-3004
SHIM, 1.0mm
AR
AR
92025-3005
SHIM,1.2mm
AR
AR
16
315B 1800A
NUT, 18mm
1
1
17
92022-30 19
WASHER, claw, 18mm
1
1
18
92036-50 7
CI RCLIP
4
4
13002-505
PIN, piston
2
13002·504
PIN, pist on
13033·300 1
BEARING, pisto n pin
';.
~.
19
20
2 2
2
DRIFTER 23. ENGINE GEARCASE
Page 55
15 14
DRIFTER 23. ENGINE GEAR CASE
Page 56 /Ouantity / Ref. No.
Kawasaki Part No.
Descrip t ion
W ~
C;)<Q
1
5905 1-3002
GEAR , 27 t ooth idler
1
2
92026 -3005
SPACER, idler gear
2
~
C;)<?i
1
2
1.0mm thi ck
92025-3007
SHIM, gear case, 0.2 mm
AR
AR
92025·3008
SHIM, gear case, 0.6mm
AR
AR
92025-3009
SHIM, gear case 1.0mm
AR
AR
92025-3010
SHIM, gear case 1.4mm
AR
AR
4
92045-507
BEARI NG, ball
1
1
5
92055-3003
O-RING , gear case
1
1
6
14055-3002
CASE, gear
1
1
7
92099 ·001
SCREW, rivet
1
1
8
130B0625
BOLT, f langed, 6 x 25mm
3
3
9
92049-3002
SEAL, oil
1
1
TB 35508
10
120P0 83 5
BOLT, 8 x 35mm
4
4
Socket head
3
Remarks
11
46 1F0800
WASHER , spring, 8mm
4
4
12
410B0800
WASHER, plain, 8mm
4
4
13
5905 1-3003
GEAR , 32 t ooth oil pump
1
1
14
4 11B0800
WASHER, plain, 8mm
1
1
15
312B0800
NUT ,8mm
1
1
16
39115-3001
SHAFT, idler gear
1
1
6207 ·9C4
.-
DRIFTER Page 57
24. FAN COOLI NG SYSTEM
-
I~ .,.; -
3&
DRIFTE R 24. FAN COOLING SYSTEM
Page 58 /Ouantity/ Ref. No.
Kawasaki Part No.
~~
Description
~
e:,Q;}
1
130B0 6 14
BOLT, f langed, 6 x 14mm
2
92022-30 13
WASHER, plain, 6m m
3
92027-30 11
COLLAR, shroud
4
49089-3022
12
5
5
11
11
SHROUD, main upp er
1
1 1
5
13169-3010-YP
PLATE, int ake side
1
6
220B0622
SCREW, pan head, 6 x 22m
4
4
7
46 1F0 600
WASHER , spring, 6mm
4
4
8
410B0600
WASHER, plain, 6m m
4
4
14037-3001
SCREEN, fan
1
1
10
46 1F1400
WASHER , spring, 14mm
1
1
11
315B 1400
NUT , 14mm
1
1
9
"--
12
12
59091 -300 1
PULLEY, f an
2
2
13
92025-50 1
SHIM, pulley , 0.6 mm
AR
AR
14
49089-30 26-9H
SHROUD, int ake side
1
1
15
590 11-3001
BEL T, fan
1
1
16
92045-3001
BEAR ING , ball
2
2
17
92025-529
SHIM, 1.0mm thick
2
2
18
92033 -3001
CIRCLlP, 47mm
1
1
19
59066 -3009
HOUSI NG, fan
1
1
20
49079-3002
PULLEY, f an drive
1
1
21
551A0612
PI N, dowe l, 6 x 12mm
2
2
22
46 1F0 800
WASHER , spring, 8mm
4
4
23
311 B0800
NUT,8mm
4
4
24
410B0800
WASHER, plain, 8m m
4
4
25
172G0 825
STUD , 8 x 25mm
4
4
26
59041 -3003
FA N ASSY, cool ing
1
1
27
510A3200
KEY, woodru f f
1
1
28
49089-3023-9H
SHROUD, exhaust side
1
1
29
13169-3 009- Y P PLATE, exhaust shroud
1
1
30
13169-3011 -YP
PLATE, side
1
1
31
92009-3567
SCREW, special
2
2
32
4 12EA0600
WASHER, plain, # 10
4
4
33
14073-3520
DUCT, engine exhaust
1
1
34
350BA0600
NUT, insert, 10-32
2
2
35
92026-354 1
SPACER, duct
2
2
36
92093-3512
SEA L, engine exhaust duct
1
1
~
e:,<Q
Rub ber
Semi gloss black 6204 Ru
Semi gloss black
Steel, zinc plated Grade 5, zinc plated
Remarks
DRIFTER Page 59
25. MAGNETO
")
I
I
~
I
r
I I
DR IFTER 25. MAGNETO Page 60 7Quant ity/ Ref. No.
Kawasaki Part No.
»» ~~
Description
~
0<0
1
220B06 25
SCREW, 6 x 25mm
2
2
2
461 F0600
WASHER, spring, 6mm
2
2
3
410B0600
WASHER, plain, 6mm
2
2
4
21119-30 12
IGNITER
J
~~
#()01~ ,
1
1 1
5
21050·3012
FL YWHEEL, with ring gear
1
6
21169· 300 1
T ERMINA L, engine connector
5
5
7
59221·3001
CONNECTOR, wi ring harness
1
1
8
461 F0400
WASHER, spring, 4mm
2
2
220B0 410A
SCREW, 4 x 10inm
2
2
10
92022-558
2
2
11
21003· 300 7
WASHER, plai n, 4~ ST ATOR A SSY
1
1
• • • • • • • • • •
COl L, pulsing
1
1
SCREW, pan head, 5 x 34
2
2
1
1
9
12
59026-3003
13
92011-53 2
14
21047-3003
15
92037·518
16
220B0408A
17
461 F0 400
18
21049·3002
' I6·;J ,--"
COIL,l ight ing CLAMP
2
2
SCREW, pan head, 4 x 8
2
2
WASH ER, spring, 4mm
3
3
/11'0
1
1
COLLAR, coil
2
2
SCREW, pan head, 5 x 36
2
2
SCREW, pan head, 4 x 6
1
1
COl L, exciter
hlo)~
,
19
9.2027-3008
20
92009 -3006
21
220B0 406A
22
92022 -544
WASHER, plain, 5mm
2
2
23
461 F0500
WASHER, spring , 5mm
2
2
24
220B0520A
SCREW, pan head, 5 x 20
2
2
25
92070·3004
PLUG , spark
2
2
26
21130-3004
CA P, spark plug
2
2
2
2
27
92101-001
TE RMINA L, spark plug cap
28
9207 1-517
GROMMET, cord
2
2
29
92071-529
GROMMET, cord
1
1
r
"I
Remarks
0~ "
!1?ff~
3tJ~q Ii)!IJ~O
....--
NGK BZ-9EV
DRI FTER
26. RECOIL STARTER Page 61
/'
(// I,
4 J
~
~.~ 9 10 11
I
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12 5
, I)
DR IFTER
26. RECOIL STARTER Page 62 /Oua nt it y / Ref. No.
~.,y
Description
Kawasa ki Part No.
~
~<Q
1
49080-300 1
PULLEY, starter
1
1
2
46 1F0600
WA SHER, spring, 6mm
3
3
3
110B0622
BOLT, 6 x 22mm
3
3
BOLT , 6 x 16mm
3
3
1
1
HANDLE, recoil rope
1
1
ROPE, recoi l
1
1
SPRING, spir al rope return
1
1
NUT,8mm
1
1
WASHER , spring, 8mm
1
1
WASHER, th rust
1
1
4
92001 -3023
5
49088-3005-9 H STARTER ASSY, recoil
6
460 75-3002
•
7
59106-505
8
9208 1-517
9
92015-513
10
92029 -503
~
~«)
Semi gloss black
11
92022 -564
• • • • •
12
13169-3003
•
PLATE, fri cti on
1
1
13
9208 1-508
•
SPRING, f ri cti on
1
1
14
9208 1-512
• •
SPRING, plate return
1
1
BUSHING, nylon
1
1
WASHER, thrust
1
1
PLATE A, recoil slide
1
1
Large aD
1
Small aD
15
92028-3007
16
9209 5-503
17
13 169-3002
• •
18
13169-300 1
•
PLATE B, recoi l slide
1
19
5910 1-506
•
REEL, recoi l rope
1
1
20
9208 1-503
•
SPRING, paw l ret urn
3
3
21
13069-504
•
PAWL, recoil
3
3
1.6mm t hick
1.2mm t hick
Remarks
DRIFTER
27. TOOL KIT &LUBRICANTS Page 63
•
I
~~n~
~~·ollW engine 9il
I
III---K K awa s aki
4
3
5
--'
DR IFTER 27. TOOL KIT & LUBR ICANTS
Page 64
ee:
/Ouantity /
Ref . No.
Kawasaki Part No.
Descript ion
~
0<0 56007·3 504
TOOL KIT ASSY
1
•
BAG, t ool
1
1
•
WRENCH, box , 10m m-12mm
1
1
•
WRENCH, box, 17mm·21 mm
1
1
• •
GR IP, driver
1
1
BLAD E, driver
1
1
•
PULL ROPE ASSY
1
1
Remarks
b<~
0<:?)
1
2
S6 10 20-13 1
0 1L, case of engine gearcase
AR
AR
24 (1-1/2 ounce U.S.) bot t les
3
S6 1020-071
01 L, case of engine
AR
AR
12 (1 qt . U.S.) can s
4
S6 1020-101
0 1L, case of engine
AR
AR
24 (1 pint U.S.) cans
5
S6 1020·14 1
01 L, case of chai ncase
1
1
6
S61020· 111
01 L, case of engine
AR
AR
24( 1/2 pint U.S. ) cans 2 (2·1 /2 gallons U.S.) jugs
DRIFTER 28. SPECIAL SERVI CETOOLS Page 65
f\ _
I
14
I IIIi(j
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1 13
_
6 7
11
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I~
9- 1 I
DRIFTER 28. SPECIAL SERVICE TOOLS Page 66 / Quant ity / Ref. No.
Kawasaki Part No.
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Description
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~<Q
C
c
1
5700 1·3506
HOLDER , fan pulley
1
Remarks
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1
2
T57001-910
PULLER, piston pin
1
1
3
5700 1-3507
AD JUSTE R, suspension spring
1
1
4
57001-3 516
HO LD ER, convert er
1
1
5
5700 1-3518
SOCKET, convert er
1
1
For drive converte r maintenance
6
92 104-002
SEA LER, liqu id gasket
1
1
100g tube
7
49075-36 12
LOCTITE , #271
AR
AR
10cc t ube
8
5700 1-983
MULTIM ET ER
1
1
For drive convert er maintenance
9
T57001-130
COMPRESSO R SET , piston ring
1
1
10
T 56019 -201
T ESTER, C.D. igniti on
1
1
11
5700 1-3509
PU L LER ASSY, f lywhee l
1
1
Use with 3 each 11OP0620
12
110P0620
•
3
3
6 x 20mm
13
57001·3 519
TRACK CLI P TOOL ASSY
1
1
14
5700 1·35 17
PUL L ER, drive converter
1
1
15
5700 1-3515
GA UGE, converter alignment
1
1
SOLT, pulle r