Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
NOTICE TO DEALERS
This manual is provided to ensure that th e sn ow mobile is assembled correctly and given proper presale
preparat ion. Your c ustomer expec ts and dese rves a safe, reliable snowmobile, and performance of the
steps listed here is essential to that end.
The selling dealer assumes sole res ponsibility for an y unauthorized mod ifi cat io ns 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 AWARENESS
WARNING'
lL _______
Table of Contents
Dealer's Assembly and Preparation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly . .. .. . . .. .. .. . . . . . . . .. . . . . . . . . .. . . . . . .... . ... . . . .. . . . . .. . .. .. . . . . . . . . .. . . . . . . . . . . . .. .
Uncrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skis . . . .. . . .. .. . . . ... .. . . . . .... . . .. . . . . . ... ..... .. . . . . . . . . . . . .. .. . . . . . . .. .. .. . . . . . . . . .. . . .
Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle and Brake Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool Kit,Owner Manua l and Safety Handbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Labels .... . ....... ..... . . .... . .... . . .. . ... . . . . . .... . . .. . . ..... ... .. . .... .. . . . . . .. . ..
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Ad ju stmen t (Rear Spri ngs). .. .. .. . . . . .. . . .. . . . . .... . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . .
Handling Ad j ustment (Front Springs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sw in g Arm Adjustmen t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Ski Spring Pre load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering A li gnment .. . .... .. .. . ... . . .. . . .. . .... . . . . . . .. . . . .. ... . . . . . . . ................ .. . . ..
Wi rin g Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal ......... . .. .. ... . ..... ........ ...... .. ... ...... .. . . .... . . . . .. . . . ..... .
Battery Charging ... . . . . . .. . ....... . ......... . . .. ... . ......... . . .. ... .... . . . . . .. .. . . ....
Battery Installat ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Chaincase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Brake Adjustment ...... . . . .. .... ... ... . ... . ..... .. . . .. .. . . .. . . . .. .. . . .. . .... . . . . .. . .. .. . .. .
Engine Coolant Recommendation . ...... ... . . ... . . . ... . . . . . . . . . . . ..... .... . ... . .. . . ... .... . . . .
Fi lli ng Coo li ng System . . . . .... .......... . . ... ... . .. . .. ... . . . . . ... .. . .. ... . ... .. ........ .
Drive and Driven Converter A li gnment . . . . . . ... . . ... . . .. . . . . ...... . . . ... . . . .. . .. . . . . .. . . .... . .. .
CentertoCenter Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Jackshaft Bearing Retainer Shimming ... . .... .... .. .. ... .. ... . .... . . ... . . .. . . ... . .. . . . ....
Converter Offset Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Converter Parallelism. . ... . . . . . . . .. .. . . ... . . . . . .. . . .. .. . .. . . . . ....... . . . .... . .. . . .. . . ...
Eng ine Break-In .... .. .. . . .. ........... .. . .. .... . . ... .... . . . . . .. ......... .. .. . .... . . . .... . ..
Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Oil Tank .. ..... ... .... .. . . .. . . . . ... . ........ . . . .. . .. . . .. . ..... .. . . .. . . ... . ..... . .
Fuel Recommendat ion ........ . ....... . ..... . ... . . .... . . . . . ... .. . . ... . . ........ .. . .. . ...... .
Fuel/Oil Mixture (Break-in Only) ..... ....... ...... .. . ... . ..... . . . . . ... . . . . . . . . .... . . . . ... . .
Fuel/Oil Mixture (Standard) .... .. . . . . .. .. ........ .. ......... .. . . .... ... ... .. . .... . . . .... . .
Ad din g Gasoline Ant ifreeze . . . . .. . .. . .. ... . . ... . .. . . . . .. . . .. . . . . .. . . ... ......... .. ...... .
Fi ll ing Fuel Tank ... ... .... ....... . . . . . .. . . . . . . ... . . . . . .. ... . . ... ... . ...... . .. . ...... ...
Eng ine Gearcase Lubricat ion .... .. . . .. .. . . ... .... . .. . . . . . ... . .. ... . . .... . ... .. .. . . . . . .. ... ...
Oil Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Bleed ing Oil Pump Supp ly Tube .. ... . . . ... ... . . .... . . . . .. ....... .. . .. . . . .. . .. .. . . . . .. .. . . ,
Oil Pump to Carburetor Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Synchronization (Mechanical) . .. . . .. .. . . .. . .. . .... . . . . ... . . ... .. . . ... . . ...... .. .
Purg ing A ir From Oil Pump Outlet Tubes ..... .. ... . . .. . .. .... . . .. .... . . .......... . .. . . . ....
Enrichener Cable Adjustmen t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Carburetor Synchronizat ion . . . .. . .. . ....... .. . ... . .............. . . . .. ... ..... . ..... . . .. . . . . ..
Ignition Timing Check . . ....... . .... . .. . . . . . . . . . . . . . . .. . . ... .... . ......... . ..... . . . . . .. . . ... .
Headlight Adjustmen t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tail/Brake Light Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track Ad ju stment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Track Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track Alignment .. .... ..... . . ... .. . ........ . ... . . ... . .. .. . . . .. . .. .... . ... .... . .. . . . .. . ..
Test Ride (Operational Checks) . . . . ........ . . . ... . .... . .. . ..... . .. ...... .. . . . .... ...... . .. ... ,
Specif ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . .. .......... . . . . . . .... ... .. . .. . . .. . . . . ... . . . . . . ... ...... . . .. . .... .... .. .... .. .
Carburetor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Fuel .. ..... . . . ... . ... .. . . . ... . . ... .. . . . .... . .. . ....... . .. . .. . ..... .. .. . ... ... . . . .... . .
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant ........ .. .. ...... .. . ... .. .... . . . . . ..... .... . ........ . .. . ..... . .... . . . .. ... . ...
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Torque Chart ........... . ... . . .. ..... ... ..... . . .. . ... . . . . . ...... . ... . . . .. . .. . . . ...... ... .. . .
Wiring Diagram ..... . . .. . ... .... . .. .... . . .... .... .......... . ... ... ........ . . . . . . .. . . .... . . ..
LTD 440
ii
1
1
1
2
2
3
3
3
4
4
4
5
5
6
7
8
9
9
9
10
11
11
13
13
13
14
15
16
17
18
18
18
18
18
19
19
19
19
21
21
22
23
24
25
25
28
30
31
32
32
33
34
36
36
36
36
36
36
36
36
37
38
TABLE OF CONTENTS
bile listed below in accordance with the following check list, and in compli ance with the established procedures prescribed by Kawasaki : (if check each item when completed).
SNOWMOB IL E INFORMATION
MOD EL
SERIA L NO.
ENGINE NO.
ASSEMBL Y CHECK LIST
ASSEMBL Y BY:
Signature
PREPARATI ON CHECK LIST
1 0 STEERING align skis/components secure.
CLUTCH ALIGNMENT - check / adjust .
CLUTCH CENTER TO CENTER check/adjust.
4 0 CHAI NCASE - add lube if required/check for leaks.
5 0 BRAKE clean disc/ adjust .
6 0 WIRING HARNESS - properly routed/electrical con -
2 0
3 0
secure/properly routed.
nectors secure .
7 0 SUSPENSION check / adjust .
8 0 NUTS, BOLTS. OTHER FASTENERS - checkltighten .
"9 0 ENGINE GEARCASE LUBRICANT - check level/add
recommended oi l as required.
10 0 FUEL PUMP T UBES secure and no kinks
21
22
"23
24
25
PREPARATI ON BY :
Signature
T EST RID E
2 0
3 0
nance/ install.
2 0
3 0
D ELIV ERED BY :
Signature
D EAL ER VE RI FICATI ON
D ler Name _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _
Addr.~
_ _ __ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ __ __ _ _ __ ____ Oat. _ _ __ __ __ __
Applicable models only refer to assembly instruction provided by Kawasaki for specific models.
PIN 4 9007-350 1
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
LTD 440
II
Assembly
Uncrate
Observe this
[:~~~!!~~:]
NOTE: When uncrating vehicle, 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 WAREHOUSE UNITS ..
1. Ski Assembly
2. Ski Spindle
Skis
Observe this
WARNING
Place the snowmobile on its side. Be sure to provide a protected surface to prevent marring the
finish of the snowmobile. Then perform the
following:
1.
2.
Remove plastic bag containing mounting hardware for skis and windshield from storage case.
LTD 440
ASSEMBLY
Windshield
Remove th e plastic covering and install the windshield w ith the o-ring fasteners provided . (See
Fi gure 4.)
WARNING
Handlebar
Prior to securing the handlebars, check the lower
hand lebar holder for security to th e steering pole .
Torque the lower hand lebar holder mounting bolt
35 ft Ib (5.0 kg-m). (See Figure 5.)
3.
1. Flat Washer
ASSEMBLY
LTD 440
Observe this
[:~~~~!~~:]
Safety Labels
WARNING'
1. Set Scre w
LTD 440
ASSEMBLY
Preparation
Spring tension (preload) of springs must
be equal on each side of suspension (front
to front, rear to rear). Higher tension ad
justment on one spring can cause spring
breakage or excessive slide wear strip
Suspension
The snowmobile is shipped with the suspension
springs adjusted during production assembly to
provide satisfactory ride and handling
characteristics for average driver weight. Normal
Iy, no adjustments are required.
WARNING
PREPARATION
Ride Adjustment
wear.
1.
2.
3.
4.
5.
6.
LTD 440
II
2.
/.--0
4.
Handling Adjustment
The front springs, located on each side of the
front swing arm, contro l handling or steering
response. Increasing spring tension forces the
front of the suspension to lift more, shifting
weight or pressure from skis to the suspension.
Reducing tension causes less suspension lift, increasing pressure on skis. The amount of
pressure on the skis directly affects steering effort and response. More ski pressure means increased steering response and effort while less
pressure means easier effort but less response.
11
3.
4.
5.
6.
2.
3. Install spring into lower detent to increase ten sion or into upper detent to decrease tension.
4.
LTD 440
PREPARATION
12
2.
3.
14
REAR HOLE POSITION - provides maximum spring arch, further reducing spring preload,
resulting in a much softer ride . This position is
recommended for deep snow operation or slow
speed trail riding only.
13
4.
5.
6.
PREPARATION
LTD 440
2.
16
When the ski center line is parallel to the outside edge of the track, check steering
handlebar for centering. The handlebar holder
shou ld be parallel to lower edge of control
panel.
Steering Alignment
5.
Loosen lock Gam) nuts and turn tie rod adjusting stud in the direction necessary to
center handlebar. (See Figure 17.)
2.
Position the ski so distance measured between ski center line and board edge is the
same at front and rear of ski. (See Figure 16.)
LTD 440
PREPARATION
17
6.
WARNING
7.
Tighten all hardware (nuts, bolts, etc.) in steering system. Torque jam nuts on tie rod
assemblies 120 in. Ib (1.4 kg-m). Refer to Torque Chart for recommended torque values of
other fasteners in the steering system.
PREPARATION
~t'-----0
-3_---"I~
18
Wiring Harness
Check wiring harness for proper routing. Be sure
wires are not being rubbed or pinched and all connectors are secure and fully connected.
LTD 440
2.
3.
Battery Removal
1.
Battery Charging
WARNING
LTD 440
PREPARATION
POISON/DANGER
KEEP OUT OF REACH OF CHILDREN
ANTIDOTE
EXTERNAL Flush with water at least 5 min
utes.
INTER NAL Drink large quantity of water or milk.
Follow with milk of magnesia, beaten egg or
vegetable oil.
CALL PHYSICIAN IMM EDIATELY.
EYES Flush with water for 15 minutes. GET
PROMPT MEDICAL ATTENTION.
1.
2.
5.
3.
Observe this
[:~~~!!~~:]
4.
10
PREPARATION
2.
3.
LTD 440
Observe this
[:~~~!!~:~::J
4.
5.
Connect " BLACK" cable to negative (-) terminal and coat terminal with grease to prevent
corrosion.
Check chaincase fluid level. For proper lubri cation of chain and bearings, fluid level must be
between the center and top of sight gauge.
WARNING
Brake Adjustment
Chaincase Lubrication
23
22
LTD 440
PREPARATION
11
3.
4.
5. Apply brake firmly and turn the manual adjuster until the correct measurement of 3/4 In.
(19 mm) is achieved. (See Figure 26.) Do not
1.
26
1. Brake Adjuster
25
1.
2.
3.
4.
2.
12
Brake Cable
Upper Brake Cable Jam Nut
Lower Brake Cable Jam Nut
Brake Actuation Lever
Remove cable slack by pulling brake cable upward I without moving brake cam lever and
snug upper jam nut to bracket.
PREPARATION
LTD 440
WARNING
WARNING
Observe this
1.
Observe this
[:~~~~~~~:]
3.
28
LTD 440
1. Drive Converter
2. Alignment Gauge PIN 57001-3503
3. Driven Converter
PREPARATION
13
CentertoCenter Distance
3.
1.
30
1.
2.
3.
4.
5.
29
1.
2.
3.
4.
14
PREPARATION
2.
LTD 440
WARNING
Observe this
WARNING
1.
Observe this
[:~~~~~~:]
3.
28
LTD 440
1. Drive Converter
2. Alignment Gauge PIN 57001-3503
3. Driven Converter
PREPARATION
13
Center-to-Center Distance
3.
1.
Center distance is correct if notch in alignment gauge fits over shaft on the drive converter.
NOTE: Drive belt will not be reinstalled until running tests on engine are completed.
30
1.
2.
3.
4.
5.
29
1.
2.
3.
4.
14
PREPARATION
2.
LTD 440
3.
Move the jackshaft bearing retainer and chaincase forward or rearward, as required, to ob-
4.
To insure correct center distance is maintained, turn adjusting bolt so head of the bolt contacts jackshaft bearing retainer flange, and
tighten locknut. (See Figure 30.)
5.
LTD 440
1. Aluminum Trim
2. Retaining Bolt
PREPARATION
15
Engine Breakln
For proper engine break-in, run machine on hardpacked snow at approximately 3/8 to 1/2 throttle,
with occasional bursts to full speed. Limit 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.
2.
3.
Vent Tube Position - To prevent siphoning action possible under certain conditions, position end of vent tube higher than top of oil tank
and away from brake components (disc and
pads).
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.
Fuel Recommendation
WARNING
1.
18
PREPARATION
LTD 440
25 to 1 Gasoline to Oil
Mixture. Break-in Only
Oil
Gasoline
1 pint U.S.)
3 gal. (U .S.)
2.6 gal. (Imp.)
1 pint (Imp.)
3 gal. (Imp.)
3.75 gal. (U.S.)
Each time fuel tank is filled, gasoline antifreeze must be added to fuel system.
Moisture trapped in fuel system components (fuel tank, lines, fuel pump or carburetors) may freeze, causing engine
malfunction or damage.
The fuel-to-oil ratio required is automatically controlled at the engine oil pump.
Observe this
WARNING
Fill fuel tank slowly and pour fuel into the tank using funnel with a fine mesh screen .
37
LTD 440
PREPARATION
19
Observe this
Fill or add lubricant to th e gearcase as follows:
[:~:~~~~~::]
Failure to remove obstructions from gearcase breather hole may cause excessive
oil consumption resulting in extensive
engine damage. (See Figure 38.)
1.
2.
NOTE: The air silencer assembly should not be installed until Purging Air from Oil Pump Outl et
Tubes procedure is completed .
20
PREPARATION
LTD 440
Observe this
[~~~:~~~:]
After filling the oil tank, bleed air from oil pump
supply tube as follows:
a~r
5.
1.
Remove the
2.
6.
3.
7.
8.
4.
silencer assembly.
Hold oil supply line and filter in a vertical position, as the oil fills the line and filter, make sure
all air in filter has been forced out.
LTD 440
PREPARATION
21
1.
Back off throttle cable jam nut 114 in. (6.4 mm)
and loosen throttle cable until there is slack in
the inner cable.
2.
41
1.
2.
3.
4.
Air
Oil
Oil
Oil
Bubble
Pump Supply Tube
Pump
Pump Bleed Screw
42
1.
2.
3.
4.
5.
6.
7.
8.
9.
LH Carburetor
RH Carburetor
LH Carburetor Idle Stop Screw
Oil Pump Cable
Throttle Cable
RH Carburetor Idle Stop Screw
Upper Carburetor Bracket
Throttle Cable Jam Nut
PREPARATION
LTD 440
WARNING
5.
1.
2.
3.
4.
5.
6.
7.
Oil
all
Oil
Oil
Oil
Oil
Oil
45
44
LTD 440
1.
2.
3.
4.
PREPARATION
23
2.
With carburetor throat facing downward, slowly turn idle speed screw in until the drill falls
out. (See Figure 45)
3.
4.
5.
Remove air silencer assembly, drive belt and perform the following procedure.
46
1.
2.
3.
4.
Observe this
WARNING
2.
24
PREPARATION
Observe this
[~~~~~~~=:J
3.
4.
LTD 440
Carburetor Synchronization
Enrichener Cable Adjustment
With Enrichener lever down, and protective boot
slid up casing, the enrichener cable should have
1/16 in. (1.6 mm) free movement when raised as
shown. (See Figure 47.)
1.
2.
3.
4.
LTD 440
Protective Boot
1/16 in. (1.6 mm)
Jam Nut
Adjusting Screw
PREPARATION
25
1.
Observe this
WARNING
3.
48
1. Screw Plugs
26
PREPARATION
4.
5.
LTD 440
6.
INCORRECT
INCORRECT
CORRECT
CORRECT
51
LJ
7.
50
LTD 440
8.
9.
PREPARATION
27
Observe this
[:~~~~!~~:]
53
2.
52
1. Fabricated Pointer
2. Drive Converter Fixed Sheave
I WARNING I
To avoid possible severe burns or a paten
tial fire hazard, NEVER attempt to start or
turn over engine with only one of the two
spark plugs removed from a cylinder.
28
PREPARATION
3.
LTD 440
4.
Observe this
WARNING
54.)
54
55
1. Dial Indicator
2. Dial Indicator Adaptor PIN 99970-3543
8.
5.
a.
(0.66 mm).
b.
6.
7.
LTD 440
1. Timing Light
2. Mark on Drive Converter
3. Timing Pointer
PREPARATION
29
2.
5.
6.
57
1. Flywheel
Observe this
[:~~~~~~~:]
Headlight Adjustment
3.
4.
30
PREPARATION
1.
2.
LTD 440
+~
4.
If headlight adjustment is requ ired, turn adjusting screws to the right (clockwise) as required. (See Figure 59.)
------------- ------
58
1. Wall
2. 25 ft. (7,620 mm)
3. Re ference Mark (center of headlight to floor)
4. 2 in. (51 mm) Below Referen ce Mark
Observe this
WARNING
3. Turn on headlight high beam. Headlight is properly aimed when the high beam is centered
and aimed 2 in. (51 mm) below reference mark
on the wall. (See Figure 58.)
Observe this
[::~~!!~:~:]
LTD 440
PREPARATION
31
3.
Track Adjustments
To adjust track tension, loosen rear axle locking bolts. Back off rear axle adjusting bolt jam
nuts from rear axle bracket. (See Figure 61.)
Track Tension
Observe this
WARNING
1.
1. Adjusting Bolts
2. Adjusting Bolt Jam Nuts
3. Rear Axle Locking Bolts
4.
5.
2.
WARNING
6.
1.314 in. (19 mm)
32
PREPARATION
LTD 440
Track Alignment
1.
2.
3.
62
1.
2.
3.
4.
4.
After performing Track Tension procedures, adjust track alignment as follows:
Observe this
[:~~~~!~~:]
LTD 440
Torque rear axle locking bolts 25 ft Ib (3.5 kgm). Tighten jam nuts on adjusting bolts.
PREPARATION
33
Test Ride
" , TRACK
(Operational Checks)
Improper engine warmup could result in
extensive engine damage.
Engine WarmUp To warm up the eng ine, idling is
not recommended. It is better to drive snowmobile
about five minutes at slow speeds before any sus
tained full throttle operation . Liquid cooled
engines need time to warm up th e coolant, all ow
ing pistons and cylinders to obtain proper
clearances.
", CONVERTERS
Test for smooth operation and correct engine
RPM, 8,200 at full throttle.
" , BRAKES
Test ride the snowmob il e and check for the
following:
", STEERING
Steering should be smooth and free from lock
to-lock with no excessive looseness or
tightness in the steering linkage.
" , ENGINE
Recoil starter works properly and the eng ine
starts promptly. Test for good throttle
response and return.
" , SUSPENSION
Adjusted for average
operates smoothly.
34
TEST RIDE
driver
weight
and
v' INSTRUMENTS
Check for proper indications.
LTD 440
1.
Brake adjustment.
2.
3.
4.
5.
6.
LTD 440
TEST RIDE
35
Specifications
ENGINE
Type .. . ..... ... ..... ... . .... . ..... . .... . ..... . ..... ... ... TC440D-A201
. ..... . ..... .. . .. . ... . .. . ... . ..... . ....... . ........ .. .... TC440D-A204
Di spl ace ment ...... .. ... . .. .... .................... . .... 26.6 C.1. (436cc)
Bore X Stroke .. . .. ... .. .. ................. . ... 2.677 x 2.362 in. (68 x 60 mm)
Number of Cylind ers . .. ... ................ .. ... .. ................. . ... 2
Ignition System . . . .. .. ... ............ .. . .. . Dual Capacitor Discharge (C. D.)
Ignition Timing (engine co ld) . ...... . 21 @ 6500 RPM, 0.102 in. (2.61 mm) BTDC
Spark Plu g .. ..... .. .. ... ....................... . ......... . NGK BZ-9EV
Spark Plu g Gap ... ......... . . . . . . . ..... ... . . ......... . .. 0.024 in. (0.6 mm)
Carburetor Make and Mode l . ... Keihin BD 40-36 x 2 (twin) with accelerator pump
Engine RPM at Fu ll Thrott le . .. . . ............................... 8200 RPM
Engine Gearcase Capac ity ... . . . . . ... . ...................... 1.35 oz. (40 cc)
FUEL
Gasoline ... .. .... ........ . . . ................. Regular or Premium Leaded
minimum pump posted anti-knock number 89
Oil .. . .. ... . .... .... . ... Kawasak i Snowmobile Oil or B.I.A. certified TC-W oil
Gasoline/Oil Rati o . . ... . .. . .. ........ . ....... . . . .. . ........ . Oillnjection
LUBRICANTS
Engine Gearcase .. . ...... ... . ............... Kawasaki Gearcase Lubricant
(10W40 oil that meets or exceeds API service SE specifications)
Chaincase . .. ... . . ... . . . . .. ... .... DEXRON II Automatic Transmission Fluid
COOLANT
Engine Cooling System . . . 55% ETHYLENE GLYCOL base antifreeze/45% water
protection to -50 F (-45C)
Cooling System Capac ity . .. ... ............. . .. .. ..... 1.2 Gallons (4.5 liters)
DRIVE SYSTEM
Drive Belt Width . ...... .. .. ........... . ........ . ....... . 1-1/4 in. (31.7
Drive Belt Outside Circ umference ......... . ...... .. ..... 46-5/8 in. (1,184
Converter Offset .. ... .... .. ........ .. ....... . 0.525 - 0.588 in. (13.3-14.9
Converter Center Di stance . . .. .. .. .. . ..................... 12 in. (304.8
mm)
mm)
mm)
mm)
ELECTRICAL SYSTEM
Type ................... . ..... ....... . ........ . . .. ... 12 Volts - 160 Watts
Headlight . . . ... . .... . ....... .. . 12V 60/55 W Quartz, PH ILIPS No. 12342-PH4,
TUNGSRAM No. 50440-PH3T-38
Tail/Brake Light. .......... ............ ... .. ... . .. ..... ... .. G.E. No. 1157
Instrument Lights ....... . . ................. ...... . .. .. .. ... G.E. No. 1816
Temperature Gauge Light . ....... . .. . ... . ....... . ..... . .. . ... G.E. No. 363
36
SPECIFICATIONS
LTD 440
TORQUE CHART
DESCR IPTION
TORQUE
TORQUE
DESCRIPTION
CAB LES
Brake cable jam nuts (5/1 6)
Enrichener cable jam nuts (6 mm)
Enrichener lever mtg .. nut
Oil pump cable jam nuts (6 mm)
Speedomete r cable
Throttle cable jam nut (6 mm)
HOO D
Headlamp housing holder to hood screws (NIO)
Hi nge bracket to hood housing holder screws (NIO)
Hood hinge to hood screws (1/4)
Hood lat ch band mtg .. nuts (1/4)
STEERI NG
Handlebar holder allen sc rews (1/4)
Handlebar holder to steering col umn bolt (318)
Steering arm to spindle bolt (3/8)
Steering col umn mount to chass is bolt (5/16)
Tie rod end jam nuts (318)
Tie rod end to steering arm nuts (3/8)
T ie rod end to steering column nut (3/8)
31 ft Ib (4.0 kgm)
31 ft Ib (4.0 kgm)
~ ft Ib (6.4 kgm)
120 In.lb (1.4 kgm)
~ ft Ib (6. 4 kgm)
25 In.lb (0.3 kgm)
31 ft Ib (4.0 kgm)
SUSPENSION
Front pivot shaft to t unnel bolt (3/8)
Fron t swing arm to suspensi o n bracket bolt (3/8)
Idler wheel sha ft mtg .. bol t (3/8)
Limiter st rap to sw ing arm nuts (1/4)
Rail wear strip retaining nut (1/4)
Rear axle adjustin g bolt jam nut (3/8)
Rear axle lock ing bolt (3/8)
Rear limiter st rap to pivot arm nut (1/4)
Rea r pivot shaft to tunne l bolt (3/8)
Re ar pivot arm to rear suspension arm bolt (3/8 Gr. 8)
Suspensio n brackets to slide rail nuts (3/8)
Suspension front spring cam mtg ., front bolt (3/8)
Suspension front spring cam mtg. rear bolt (3/8)
Suspension rear arm to pivot arm bolts (3/8)
Suspension shock absorber mtg., front nut (318)
Suspension shcok absorber mtg ., rear nut (t hin)
Su spension rear sp rin g cam mtg .. nu ts (5116 )
Top idler shaft bolt (3/8)
25 ft Ib (3.5 kgm)
25 ft Ib (3.5 kgm)
25 ft Ib (3.5 kgm)
45 in.lb (0.6 kgm)
25 i n.lb (0.3 kgm)
120 in.tb (1.4 kgm)
25 ft Ib (3.5 kgm)
45 i n.lb (0.6 kgm)
25 ft Ib (3.5 kgm)
25 ft Ib (3.5 kgm)
105 in.lb (1. 2 kgm)
35 in.lb (0.4 kgm)
10 ft Ib (1.4 kgm)
25 ft Ib (3.5 kgm)
25 ft Ib (3.5 kgm)
15 ft Ib (1. 9 kgm)
45 in.lb (0. 6 kgm)
25 ft Ib (3.5 kgm)
DRIVES HAFT
Bearing housing to tun ne l nuts (5/16)
Locking collar set screw (1/4)
18 ft Ib (2.6 kgm)
70 in.lb (0.8 kgm)
LTD 440
18 ft Ib (2.6 kgm)
20 ft Ib (2.8 kgm)
18 ft Ib (2.6 kgm)
19 ft Ib (2.6 kgm)
31 ft Ib (4.1 kgm)
120 in.lb (1.4 kgm)
BRAKE
35 ft Ib (4.8 kgm)
DRIVEN CONVERTER
120 in. Ib (1.4 kgm)
50 in.lb (0.6 kgm)
50 ft Ib (6.9 kgm)
DRIVE CONVERTER
120 in.tb (1.4 kgm)
70 ft Ib (9.7 kgm)
96 in.lb (LI kgm)
120 in.tb (1.4 kgm)
60 in.lb (0.7 kgm)
25 ft Ib (3.5 kgm)
90 in.lb (1.0 kgm)
55 in.lb (0.6 kgm)
105 in.lb (1.2 kgm)
CH ASSIS
Bumper & brace to pan nuts (1/4)
Bum per & hood guide to pan nuts (1/4)
Bumper & hood hinge to pan nuts (1/4)
Bumper to pan nuts (1/4)
Fuel pump to tunnel nuts (1/4)
Outer guide & brace to pan nut s (1/4)
Outer guide & inner guide to pan nuts (1/4)
Outer gu ide & inner gu ide to pan nuts (NIO)
Rear stay to t unnel bolt (3/8 )
Snow flap spacer mtg .. nut (1/4)
Judgement
35 ft Ib (4.8 kgm)
50 ft Ib (6.9 kgm)
50 in .l b (0.6 kgm)
70 in.lb (0.8 kgm)
Judgement
Judgement
40 in .lb (0.5
60 in.lb (0.7
45 in.lb (0.6
45 in .lb (0.6
kg.m)
kgm)
kgm)
kgm)
45
16
18
16
70
20
60
60
16
70
CRANKCASE
Gearcase fill plug bolt (8 mm)
Gearcase fill plug bolt (8 mm)
Lower crankcase to upper bolt (8mm)
Lower c rankcase boss bolts (6 mm)
RECOIL STARTER
II ft Ib (1.6 kgm)
70 in.lb (0.7 kgm)
18 ft Ib (2.5 kgm)
MAGNETO
CDI igniter mounting (1/4)
Ignition co il mount ing - screw (6 mm)
Stator plate mounting screw (5 mm)
Voltage regulato r nut (1/4)
Wiring harness connector mounting - screw (4 mm)
60 in.lb (0.6
70 in.lb (0.8
70 in.lb (0.8
105 in.lb (1.2
40 in.tb (0.5
kgm)
kgm)
kgm)
kgm)
kgm)
ELECTRIC START
Battery cable to solenoid nut (6 mm)
Battery cables to battery bolt (6 mm)
Battery case to chassis nut (114)
Rear starter motor bracket to starter motor bolt (6 mm)
Rear starter bracket to engine nut (5 mm)
Starter motor to engine cap screw (8 mm)
Starter motor cable to solenoid nu t (6 mm)
Starter solenoid to duct assy .. bolt (5/16)
55
40
70
50
32
12
55
'0
TORQUE CHART
37
:!!
z
c:>
)0
c:>
:JJ
:.-
i:
BLACK
-=
WHITE
BLACK
lit
WI'"
'" '"
::>::>
-' -'
TO SPA;K PLUGS
>-
BLACK
t:J
'"
a:
-=
-'
BLACK
-L
BLUE
~-wO
I a::OI GI a:~
I
OFF
KEY SW IT CH CONNECTIONS
KEY SW ITCH
CIRCUIT COMPLETE D
WHEN CONTACTS MARKED
POSITIONS
"O FF "
G-M
"RUN / LIGHTS"
BL
"RUN "
NONE
"ST ART"
B-S
'"
OF F
...J
TACHOMETER
"''''
~o
0-,
w-,
a:",
BROWN
>BLACK / YE LLOW
YELLOW/ RED
STOP-TAI L LIGHT
BROWN / YELLOW
PULSER COIL
-'
Q.
a:
::>
-=-
Q.
BROWN / YELLOW
RED / YELLOW
-=
o-1 -
:=-0
...JZ I...J
wO - >-~ Z
-- ~
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LU
l:J
~o ~ ~
o~ t9 a::
a:
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r-
-1
C
~
HEADLIGH T
:)
,....
-I
o
o
IGNITION COIL
BLACK
WHITE
BLACK
IGNITION COIL
W
~ IW
~
--' --'
>-
BLACK
a:> a:>
':'
<1:
a:
""<1:
t:l
a:>
OFF
OFF
--'
BLACK
BLUE
;;
TACHOMETER
-0--,
0
w --'
a: w
BROWN
>BLACKIYELLOW
YELLOW / RED
;;l wl~
BROWN / YELLOW
g,::::~
PULSER COIL
--'IO
w
--'
>-
~
Q.
~~j
w
EXC ITER COIL
Q.
a:
':"
r:: ,,,\
RED/ YELLOW
RED
REGULA TOR /
RECT IFIER
-:-
PURP LE
T EMP.
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o--,_",0
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a:
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a:
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3:
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CD
RED
HEADLIGHT