Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
SAFETY AWARENESS
I
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 en<;l.
WaRNING
Table of Contents
Dealer's Assembly and Preparat ion Check List............. ....... .... .... ............. .........................
Assembly....... ...... ....................................................... .... ...................................................
Uncrate ................. ............. ........... ...... ....................................... .. ...............................
Skis .......... ... ..... ....... ....................................................................................................
Installation ................................................. ..... ........ .................. ... .........................
Suspension....... .................................................................. ........................ ... .. ............
Windshield........ ........ ................... .. ...... ....................... ........................ ..... .... ................
Handlebar.......................................................................... ........... ................ .. .............
Took Kit/ Owner Manual ............... ........................... ........................... ........................
Safety Labels. ........ ................. ............. .................... ......... ............................ ........ .......
Preparation...... ......... ................ .. .. .................. .. .. ....................... ......... .... .. .. ..... ........... .......
Suspension .... .. ...... ... ................. ........ .......... .. ...... .......... ........... ..... .... .. ................. . ......
R ide Adjustment.. .. ........ ..... ................. .... ........... ...... ...... ..... ... ..............................
Handling Adjustment ...... .............................. .......... .. .. ........ ........... ................ .......
Front Suspension Swing Arm ......... .. ...................................................... .. .............
Ski Spring Preload ......... ... .. ................... ....... ......... .... .. ......... .. ...... ......... ...... .... ............
Steering Alignment........ ....................... ................... .. .................. .......... ..... ... ... ...........
Chaincase ...................... .. ......... ..... ...... .... .. ... ....... .. ......................................... .............
Brake.... ..................................... .............. ....... ... ............ ... ......... ............................ ... ...
Wiring Harness.. ............................................................. .. ................................ ............
Enrichener Cable Adjustment...................... ........... .............. ............... .......... ..............
Fan Belt Tension ............. .. ............. .. ... ................ ......... ....... ............... ... ......... ..... ........
Drive and Driven Converter Alignment.. ...... ............ ...... ..............................................
Center-To-Center Distance .... ............ ............ ........... ............................... ............ ..
Jackshaft Bearing Retainer Shimming ....... ........ ................ .......... .................. .. .... ..
Converter Offset Distan ce ........ ......... ......................... ...... ................... ..................
Parallel ism........... ......................................................................................... .. .......
Oil Tank .......... .. ..........................................................................................................
Bleeding Oil Injection System ........ ........ ........ .... ...................... ............. .... ..................
Engine Gearcase .... ...... ............ .. ......... ..... ... .................. ........... ............... .. ... ............ .. ..
Fuel ....... ... ......................................... .. ........ ...... .... ..... ... .. .... .. ............................ .. ........
Fuel / Oil Mixture (Ratio) .................................................................. .. .........................
Engine Break-In ... .................... .. ............ .... ... .. .................................................. ....... ....
Sy nchronization of Oil Pump and Carburetors ......... ... ..... ..................................... ..... .
Purging Air From Oil Pump Outlet Tubes .. ........... ... .. .............. ................ ............. ... ...
Ignition Timing Check ........ .. .................... ... ............... .......... ......................... .............
Headlight Adjustme nt ....... ... .... ....... ........................ .............. ........ .... ................ ....... ...
Tail / Brake Light Test .................................................. ............ .. ..................................
Track Adjustments .. .............. ...................................... .......... ..... .... ...... ............... .. .. ....
Track Tension ...................... ........... ..... ...... .......... .. ............................................ ...
Track Alignment ...... ........... ......... ... ......................................................... .............
Test Ride (Operational Ch ecks) .... .... .............. ......................................... .... ...... .. ..............
Specificat ions ..... .... ...... ..... .. ..... .............. ................. ... ........... ........ ..... ..................... .. ........
Engin e ...... ......... .... ...... ....... ..... .... ...... ... ... ...... ..... .. .. .. ... .. ....... .......... ...... .. ......... ....... .....
Carbu retor S etti ngs ................. ... ............................. ... ....... ................. .. .......................
Fu el .... ......... ....... .... ...... ........ .... ............ ... .. ......... ......... ..... ....... ........ ......... .. .... .... .... .... .
Drive System .. ... .... ...... ...... ....... .... ...... ........ ...... ........................ .... ...... ........... ...... ....... .
Electrical System .. ... .............. .... ........................ ... .... ........... .. .. ............ ........ ......... .......
Torque Ch art .......... ... .. .......................... ... .............. ......... ..... ...................... ............. ... ... ....
Wiring Diagram ..... ..... .... .... .................... ... ... ..... ......... ............ .. ................. .... ....... ... ... ....... .
INTRUDER
11
1
1
1
1
2
2
2
3
3
3
3
3
3
4
4
5
6
6
7
7
8
8
8
9
10
11
12
12
13
14
14
14
15
16
16
18
18
19
19
19
20
22
22
22
22
22
22
23
24
TABLE OF CO NTENTS
bile listed below in accordance with the following check list, and in compliance with the established procedures presc ribed by Kawasaki: Iii? check each item when completedl.
SERIAL NO.
1
2
3
4
5
0
0
0
0
0
'6 0
7
8
ASSEMBL Y BY:
Signature
PR EPARATI ON BY:
Signature
CUSTOMER ~lIVER V
1 0 OWNER'S MANUAL explain contents/ proper mainte
nance . install.
2 0 OWNER'S SAFETY HANDBOOK explain contents
install.
3 0 WARRANTY CERTIFICATE explai n warranty th or
oughly . install.
Dealer Name _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
DELIVERED BY:
Signature
Address
Date
Applicable models only . refer to assembly instruction provided by Kawasaki fo r specific models.
PIN 49007-3501
Printed In U.S.A.
If it js desired to util ize the French portion of this check list, please remove the carbon sheet and insert in proper locatio n.
ii
INTRUDER
Skis
Assembly
Installation
Uncrate
Observe this
1. Ski A ssembly
2. Ski Spindle
Observe this
WARN ING'
INTRUDER
ASSEMBLY
3.
1.
Windshield
Remove the plastic covering and install the
windshield with the o-ring fasteners provided . (See
Figure 4.)
ASSEMBLY
Flat Washer
Suspension
Handlebar
1.
2.
Observe this
INTRUDER
Preparation
Suspension
Ride Adjustment
Safety Labels
WARNING
1. Spring Cam
2. Cam Adjusting Tool
3. Heavy Pre-load Position
4. Light Pre-load Position
Handling Adjustment
The handling adjustment is controlled by changing
spring tension of the front suspension sp rings.
I ncreasing spring tension causes the suspension to
press harder on the ground, resulting in less ski
pressure. Reducing the spring tension, causes th e
front of the suspension to have less pressu re on the
ground and the ski pressure to increase. A change
in ski pressure will affect the vehicle's steering
response.
INTRUDER
PREPARATION
[~~~~~~:]
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. (See
Figure 9. )
The spring arm on each side of the suspension
should be positioned as required, to achieve the
desired steering response and effort for existing
terrain and snow conditions in your area.
1.
WARNING'
1.
2.
3.
Observe this
3.
PREPARATION
INTRUDER
1.
1.
2.
2.
3.
([
2.
3.
4.
Steering Alignment
Check the sk i alignment and handlebar centering.
1.
1.
2.
Locknuts
3.
INTRUDER
PREPARATION
WARNING
5.
Chaincase
4.
WARNING
PREPARATION
1.
2.
Brake
Check to be sure the brake disc can be moved back
and forth with just a very slight drag on the brake
pads. Next, check that the brake lever movement is
less than 3/4 inch (19 mm) when brakes are fully
applied. (See Figure 16.)
INTRUD ER
Wiring Harness
Observe this
WARNING'
1.
2.
3.
4.
INTRUDER
Brake
Brake
Brake
Brake
Adjusting Nut
Disc
Pads
Cable Adjusting Nuts
1.
2.
3.
4.
Plastic Boot
1/ 16 inch (1.5mm)
Locknut
Adjusting Screw
PREPARATION
matter
from
entering
the
enr ichener
Center-To-Center Distance
1.
PREPARATION
INTRUDER
2.
3.
1.
IS
1.
([
2.
INTRUDER
PREPARATION
1.
2.
A luminum Trim
Retaining Bolt
2.
3.
@D@
24
Observe this
4.
5.
6.
10
PREPARATION
AVAILABLE SHIMS
PIN
THICKNESS
92025-3501
92025-3502
92025-3503
INTRUD ER
1.
2.
Driven Converter
Shims
3.
4.
5.
Parallelism
1.
INTRUDER
2.
PREPARATION
11
b.
Observe this
1. Engine Mounting Bracket
2. Shims
3. Engine Mount Bo lt
c.
[~~~
2.
3.
Oil Tank
We recommend using Kawasak i Snowmobile Oil.
This oil is specially formulated to give minimum
piston ring varnish and combustion chamber
deposits along with excellent lubrication qualities.
I n an em ergency situation when Kawasaki
Snowmobile Oil is not available, a B.I.A. certified
TC-W oil may be substituted. All certi fi ed oi ls
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.
12
PREPARATION
INTRUDER
28
1.
2.
Engine Gearcase
NOTE: The carburetor has been removed during
the previous procedure.
Components inside th e gearcase drive the oil
injection pu mp and coo lant pump.
Lubricant level is co rrect when the oil appea rs
above the ce nter of t he sight gauge, but not
higher t han t he t op. (See Figure 29. )
Observe this
1.
Breather Hole
2.
3.
INTRUDER
~J
PREPARATION
13
Fuel
Use regular or premium leaded gasoline with a
minimum PUMP POST OCTANE NUMBER OF
89.
31
WARNING
Fill the fuel tank slowly and pour the fuel into
the tank using a funnel with a fine mesh screen.
14
PREPARATION
Engine Break-In
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. Pre-mixing
gasoline and oil will no longer be required after
the initia l three gallons of gasoline and oil mix
have been consumed.
INTRUDER
33
1.
2.
3.
3.
4.
5.
6.
Turn
the
idle stop screws, on both
carburetors, in until the spring is coil bound.
Then, back off each screw six comp lete turns
(initial adjustment) . Air screw is properly
adjusted when opened 1.5 turns off its seat.
7.
32
1.
2.
3.
Air Screw
4.
INTRUDER
PREPARATION
15
Outlet Tubes
Observe this
I WARNING I
and
engine
damage
will
3.
4.
5.
6.
performance
result.
[:~~~!!~~]
8.
34
' - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- J
1.
2.
3.
4.
2.
16
PREPARATION
INTRUDER
1.
onto the
to attach
than the
with the
2.
3.
4.
b.
Observe this
I WARNING I
PREPARATION
17
[:~!~!!~~]
Observe this
Observe this
during next step
When adjusting the stator plate, take care
not to damage the coil windings.
2.
3.
WARNING
The
high
mm)
(See
Headlight Adjustment
1.
2.
1.
2.
18
Wall
25 Feet (7,620 mm)
Reference Mark (center of headlight to
floor)
2 Inches (51 mm) Below Reference Mark
PREPARATION
INTRUDER
3.
Track Adjustments
WARNING
Track Tension
WARNING'
1.
1.
Raise the rear of the snowmobile so the track
is off the ground for its entire length and
secure the snowmobile so it cannot fall; then
hang a 5 - 8 lb. (2.2 - 3.6 kg) weight from
the mid point of the track.
5.
Observe this
Track Alignment
INTRUDER
PREPARATION
19
Test Ride
(Operational Checks)
Test ride
following:
CONTROL CABLES
Th e throttle and brake controls must operate
without binding and return freely in any
steering position.
1.
2.
3.
4.
Observe this
I WARNING
procedures,
ENGINE
Recoil starter works properly and the engine
starts promptly. Test for good throttle
response and return.
STEERING
SUSPENSION
Adjusted for average
operates smooth ly.
driver
weight
and
20
CONVERTERS
Test for smooth operation and correct engine
R.P.M ., 6,900 - 7,100 at full throttle.
BRAKES
When activated, the brakes should result in
adequate smooth stopping of the track; when
released, there should be no brake drag.
])
INSTRUMENTS
Check for proper indications.
INTRUD ER
of
Test
Ride,
1.
Brake adjustment
2.
INTRUDER
check
3.
Retorque drive converter mounting bolt 65 70 ft. Ibs. (9.0 - 10.0 kg-m)
4.
5.
the
21
Specifications
ENGINE
Type ..... .......... ......... ...... .. ...... .... ........ ......................................................................... ... .. T A440C
Displacement............. ......... .. .. .. ....... ....... .. ..... ...... .. ........ .... .. .... ..... ....... ........ ..... 26.6 C.I. (436 cc)
Bore X Stroke ... .... .. ..... .. ... ...... ............. ... ....... .... ................. 2.677 x 2.362 inches (68 x 60 mm)
Number of Cylinders ............ ............ ..... .. .................................................... .......... .. .... ..... .. ........ 2
Ignition System ..... ........ .... ............. ............................................. ...... . Capacitor Discharge (C. D.)
Ignition Timing ... .. ..................................................................... 0.073 inch B.T.D.C. (1.86 mm)
Spark Plug ..... ......... ... ........ ....... ........ ................. ................. ........... .. ... ................... NGK BR-9 EV
Spark Plu g Gap ............ ........... ...... ... ..... .......... ... .......... .... ..... .... .. .. .... .. .... .... 0.024 inch (0.6 mm)
Carburetor Make and Model ............ .. ... ...... ... .. ... ... ..... ... .......... .......... ... Mikuni VM32 Econo Jet
Engine R.P.M. at Full Throttle .... ........ ..... ..... .... ...... ............. ..... ......... ... ... .. 6,900 - 7,100 R.P.M.
Eng ine Gearcase Capacity ................ .. .... ... ... .. ..... ..... .......................... ... .. ...... .. .... 1.35 oz. (40 cc )
CARBURETOR SETTINGS
Ai r Screw .......... ........... ..... .... ....... .......... ... ........... .. ...... .. .... ... .. .... ... ........ ....... .... 1.5 turns off seat
Idle Screw ... ... ... ....... ... .. ..... .. .. .. ......... 6 turns open from coil bound initial (3,000 R.P.M. final)
FUEL
Gaso line .... .... ... .......... Regula r or Premium Leaded, minimum pump posted octane num ber 89
Oi!. ... .. .... .. .... ...... ....... .. .... .. ... ... ... ......... ... Kawasaki Snowmobile Oil or B.I.A. cert ified TC-W o il
Gasol ine/Oil Ratio ............. ...... ... ..... ....................... .... ... ....... .. ............. ..... .... .. .......... Oil Injection
DRIVE SYSTEM
Drive Belt Width ... ....... ...... ..... .. ... .. .... .... .......... ........ ....... .... ............. ... .... 1-1/ 4 inches (3 1.7
Drive Belt Outside Circumference ........ .. ... .... ....... ... ... ..... ........ .... .. .... .46-5/8 inches (1 ,184
Converter Offset .... .... ... .. .......... ... .. ... ..... ...... .. ......... ..... ... 0.525 - 0.588 inches (1 3.3 - 14.9
Converter Center Distance ....... .......... ...... .... ... .. ......... ..... ........ ....... .... ..... .. 12 inches (304.8
mm)
mm)
mm)
mm)
ELECTRICAL SYSTEM
Type ......... ...... ... ............. ....... .......... ......... .. .... ...... ......... ........ .. ... ... .. ........ .... 12 Volts - 120 Watts
Headl ight ..................... .. .... .... ..... ...... ....... ~ .... ............. .... ..... .... ...... .... .. .. .. .. .. .. ...... ... ... Sta nl ey 5988
Tail/Brake Light ... ..... ... .... .............. ... ....... ..... ........... ..... ...... ... .... ... ... ............. .. .... .. G.E. No. 11 57
Instrument Lights .... .. .... ...... .... ... .................................................... ......... .... ........ ... G.E. No. 363
22
INT RUDER
Torque Chart
TORQUE
DESCRIPTION
TORQUE
DESCRIPTION
EXHAUST
Exhaust man ifold - nuts
HOOD
Hood hinge - nuts
INSTRUMENT PANEL
& INSTRUMENTS
Gauges to panel - nuts
Instrument panel - screws
RECOIL STARTER
CHASSIS
Hood guide and trim mounting screws
Hood guide, front bumper and
hood hinge attaching - nut
Passenger handle attaching - nuts
Pan brace attaching - screws
Trim attaching - screws
Seat attach i ng bolts
(0.8
(2.5
(0.8
(0.2
(0.4
kg-m)
kg-m)
kg-m)
kg-m)
kg-m)
DRIVE CONVERTER
Drive converter to crankshaft - bolt
Cover to movable sheave - bolt
Roller and pin assembly in movable
sheave - bolt
Weight ramp and pin assy to
spider - bolt
Weight ramp - nut
8-10ft.lb. (1 .1-1.3kg-m)
16-18 ft.lb. (2.2 -2.5 kg -m)
5-6 ft.lb. (0.6-0 .8 kg-m)
STEERING
Handle holder - bolt
Steering arm to spindle - bolt
Steering column to t ie rod - nut
Steering arms to tie rods - nuts
Upper steering post mounting - nuts
Lower steering post mounting - nuts
Tie rod jam - nut (LH)
Tie rod jam - nut (RH)
R H tie rod to steering arm - nut
Handlebar to holder clamp
mounting - screws
35 ft.lb.
30 ft.lb.
30 ft .lb.
30 ft.lb.
18 ft.lb.
20 ft.lb.
100-120
100-120
30 ft.lb.
(4.8 kg-m)
(4 .1 kg-m)
(4 .1 kg-m)
(4.1 kg-m)
(2. 5 kg-m)
(2.7 kg-m)
in.lb. (1.1 -1.3 kg-m)
in.lb. (1.1-1.3 kg-m)
(4.1 kg-m)
SUSPENSION
ENGINE, GENERAL
Cylinder head bolts
Flywheel nut
Spark plug
Holder (carb.) bolts
Gear case bolts (socket head)
INTRUDER
16
60
20
45
12
ft.lb.
ft.lb.
ft.lb.
in.lb.
ft.lb.
(2.2
(8.3
(2.7
(0.5
(1.6
kg-m)
kg-m)
kg-m)
kg-m)
kg-m)
30
25
25
35
25
25
25
ft.lb.
ft.lb.
ft.lb.
ft.lb .
ft.lb.
ft.lb.
ft.lb.
(4.1
(3.4
(3.4
(4.8
(3.4
(3.4
(3.4
kg-m)
kg-m)
kg-m)
kg -m)
kg-m)
kg-m)
kg-m)
TORQUE CHART
23
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