Kawasaki SB 340-A2, SB 440-A5 snowmobile Assembly & Preparation Manual
Below you will find brief information for snowmobile SB 340-A2, snowmobile SB 440-A5. This manual outlines the steps required to properly assemble and prepare your new snowmobile for safe and enjoyable operation. It covers topics including uncrating, ski installation, suspension adjustments, engine break-in, and additional preparation steps needed for successful operation.
Advertisement
Advertisement
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 M ODIFICATIONS WHICH MUST BE PERFORMED BEFORE THE S N OWMOBILE IS READY
FOR SALE.
SAFETY A W ARE N E S S
WARNING
I
T h is warning symbol identifies special in·
structions or procedures which, if not cor· r e ctly followed, could result in personalin·
Ju ry , or l o ss of life
()
This caution symbol identifies special in·
structions or procedures which, if not strictly observed, could result in damage
to, or destruction of equipment. u
Table of Contents
DRIFTER
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 ..............
...
....
......
...
..
.......
.
...
..
.
...
..
.. 1 2
Engine Gearcase Lubrication ..............
.
...
..
...
....
........
..
..
....... 12
Oil Injection System ..........
....
..
....
...
...
...
.
..
.
.......
..
..
..
..
..
..
.. 13
Bleeding Oil Pump Supply Tube ....
.
.........
.
......
...
..
.......
...
.
.. 1 3
Oil Pump to Carburetor Synchronization .
.....
.
...
.
.....
......
.
.
..
..
..... 14
Purging Air from Oil Pump Outlet Tubes .
...........
.
....
.............
... 15
Ca rburet or Adjustments .........
.
.....
.
....
..
...
.
....
. _ .
....
.
....
.
..
...
.. 16
Enrichener Cable ....
.
....
....
....
.
.....
.
....
.
..........
.
...
...
.
.
.
.
.. 16
Air Scre w ..
...
.
..............
.
..
.........
.
..........
..
..
..
..
...
...
.. 1 7
Idle Screw ...
...
....
.
..
.....
.
.
...
.
.....
.
............
...
.....
....
.
..
. 17
Throttle Contro l Cable .................
.
.
...
.
...
.
...
....
.
...
.
..
...
...
. 17
Ignition Timing Check .....
..
.
.
....
...
....
...
....
.
...........
.
.
..
..
....... 18
Ignitio n Timin g Adjustment. ...........
.
.
.
..
....
.
..
....
.
...
...
......
.....
. 1 9
Fa n Belt Tension ..
....
..
....
.
...
.
.
...
...
..
...
....
.
..........
..
..
...
...
.
. 20
Headlight Adjustment .....
.
.
.
.
...
...
.
.........
..
..
...
......
..
.
...
.
....... 20
Ta il/ Brake Light Test ......
.
.......
.
.
..
..
...
...
..
............
.
...
.
........ 21
Track Adjustment ....
..
....
..
.........
...
........
.
.......
......
......
.... 2 1
Track Tension .
....
...
.......
.
...
....
.
.
.
.
....
.
...
.......
.
......
..
..
.
. 2 1
Track Alignme nt ...
...
.....
.......
....
...
...
.
..
....
..
..
..
..
....
.....
. 22
Test Ride (Operational Checks ) ..
.
......
.
.....
.
.........
.....
.
.
..........
.. 23
Spec ific a ti ons ......
.
.........
.
....
.
.
..
.....
.
........
. _ ......
..
.
.
.
..
...
.. 25
Engine ..
..
.
...
.
....
....
...
...
...
.........
.
....
..
......
.
......
..
.... 25
Carbu r etor Settings & F ue l ...
.
.
.
....
..............
..
.
.
.
.......
.
...
.
... 25
Drive Syste m ......
.......
.
.
.
..........
.
......
..
.
.
..........
...
...
.
.. 25
Elec tri cal System ........
...
.
.
....
..
.................
..
.
...
.
.....
.... 25
Torque Chart ..
.....
.
....
.
.
.
......
.
.....
.
.....
.
...
...
....
..
....
..
......
.. 26
Wiring Diagram ...
...........
..
.
.
.
...
..........
...
.
.............
.....
.... 27
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 i s completed. Be sure to si.Qn all sections of the form as they are completed.
Retain completed check li s t for your r ecords .
KAWASAKI SNOWMOBILE DEALER'S ASSEMBLY & PREPARATION CHECK LIST
I hereby certify that p rio r to delivery to the first retail purchaser assembly and preparation servicing was performed on the snowmo bile list ed below in accordance with the following check list, and in compliance with the established procedures prescribed by Kawasak i: ( [!it check each it em when completed!.
SNOWMOBilE INFORMATION
MOOEl SERIAL NO. ENGINE NO.
2 0
SKIS· install· torque all bolts.
3 0 SKI SHOCKS · mount and torque bolts.
4
0
WIND S HIELD· mount to hood.
ASSEMBl Y CHECK LIST
, 0 REMOVE CRATE· ch eck for damaged & missing parts .
5 0 HANDLEBARS· adjust to proper position/torque bolts.
6 0 SA FETY DECALS · properl y i nstalled .
7
0
TOOL KIT · complete /i nstalled.
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 l ube if required/check for leaks.
5 0
BRAKE · clean disc / adjust .
6 0 WIRING HARNESS · properly routed/electrical con· ne ct or s secure.
7 0 SUSPENSION · check / adjust.
80 NUTS, BOLTS, OTHER FASTENERS checkltighten.
·9 0 ENGINE GEARCASE LUBRICANT check level/add recommended oil as required.
'0 0 FUE L PUMP TUBES secure and no kinks
" O ENRICHENER CONTROL -check / adjust .
·'2
DOl L PUMP check synchronization/adjust.
'3 O THROTTLE CABLE · check/adjust
·'5
O
O
CARB
FAN
S YN
BELT
CHRONIZE
· check /
check/adjust adjust (axial fan
(twin modelsl carb
. modelsl
·'6 0 01 L TANK fill with Kawasaki approved oil/check for
. leaks.
"'7 0
OIL LINE TO PUMP · (all oil injection modelsl bleed / secure / properly routed.
"'8 0 ENGINE COOLANT· check level / freeze protection.
'9 0
SPARK PLUGS · check /g ap .
20 O GAS TANK fill with recommended fuel/oil mix {refer to
Owner's Manuall check for leaks.
2' 0 CARBURETOR AI R SCREW · adjust.
22 0 CARBURETOR IDLE SPEED adiust.
"23 O PRIMER -che ck operation .
24 0 IGNITION TIMING - check when engine is warm/adjust.
25 0 ELECTRICAL SYSTEM · check operation· adjust o
Headl ight " 0 Battery Charging System o
Ta illight
0
Brake light
.. 0 Electric Sta rt er · 0 Instr umen ts & Ind i cator
Lights
26 0 TRACK adjust tension/align
PREPARATION BY:
Signature o
CONTROL CAB LES throttle & brake works without bindin~ in any steering position/returns fre e ly .
2 0 ENGINE STOP SWITCH check operation.
3 0 SUSPE NSION· check slider ride adjustment.
4
5
0 STEERING · action is tree lock to lock/no looseness.
0 ENGINE - recoil start€!' works properly/engine starts promptly / good throttle response and return . E xhaust smoke present but n ot excessive (oil injection models).
6 0
CLUTCHES · smooth operation/correct maximum RPM .
7 0 BRAKES adequate· smooth stopping power.
TEST RIDE
8 0
SPEEDOMETE RIT ACHOMETE R check operation.
9 0 NO UNUSUAL NOISES .
·'0
0 NO COOLANT LEAKS.
" 0 NO FUEL OR OIL L EAKS.
"'2 0 COOLANT LE VEL · check / add coolant mix as required.
'3 0 CONTROLS properly positioned/secure/adjusted.
TEST RIODEN BY:
Signature
CUSTOMER DELIVERY o
OWNER'S MANUAL expla in contents/proper mainte nance/install.
2 0
OWNER'S SAFETY HANDBOOK · explain contents/
3 install.
0 WARRANTY CERTIFICATE explain warranty and customer responsibilities thoroughly / install .
4 0
CONTROLS · ex plain location & operation/properly positioned for customer.
DELIVERED BY:
DEALER VERIFICATION
Signature
Dealer Name _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Signature of Dealership Manag er
Addre~
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
Date _ _ _ _ _ _ _ _ _ _
• Applicable models only refer to assembly instruction provided by Kawasak i for specific models.
P I 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 in sert in proper location.
) ii DEALER'S ASSEMBLY & PREPARATION CHECKLIST DRIFTER
Asse mbly
Uncrate
Observe this WARNING' during next step
Bend over all exposed crate fasteners to prevent personal injury or possible vehicle damage.
In a large, clear work area, open crate by separating top and sides. Remove windshield from seat. ( See F i gure 1.)
1. Ski Spindle
2
Observe this
I
WARNING
I during next step
To prevent personal injury, use lifting equipment with approved safety hooks when raising the snowmobile.
1
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 miss ing parts.
Remove plastic bag containing mounting hardware for skis and windshield from storage case.
NOTE: When uncrating v ehic le , in spect for concealed damage that may occur during shipping. If damage i s apparent, STOP uncrating and check your WARRANTY POLICIES & PROCEDURES Section of your Snow Products Binder under RECEIV-
ING WAREHOU SE UNI TS.
Skis
Installation
P l ace 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:
Loosen and remove the nuts that secure the ski spindles to the bottom of the crate. (See Figure 2.)
1. Apply low temperature extreme pressure (ep) grease to the grooved or recessed area on the spindle sleeve, and in sert the sleeve into the spindle. (See Figure 3.)
DRIFTER ASSEMBLY 1
NOTE: During shipping, burrs may form a t the outer edge of the spindle hole making sleeve In sertion difficult. Use a suitable file to remove these burrs.
1. Spindle Sleeve
2. Sp indle
4
1. Flat Washer
3
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.)
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. 1 . Windshield Mounting Screw
2. Rubber Well Nut
2 . Secure sk i and shock absorber assemb ly to spindle using hardware supp li ed. Be sure nut and large flat washer are instal · led on inward side of the sp indl e and torque 30 ft Ib (4.1 kgm). Torque shock absorber mounting nut 30 ft
I b (4.1 kg-m). (See Figure 4.)
Remove the protec tive film from the windshield and install windshield sea l tri m. ( See Figure 6.)
2 ASSEMBLY DRIFTER
Check th e routing of the control cables a nd wire h a rne sses for prop e r positioning. They must pass through the cutaway section in the hood for adequate free movement wh e n the hood i s closed . Be sure the fuel tank vent tube is not crimped or pinched . (S ee Figures 7 and 8.)
6
1. Windshield
2 . Sea l Trim
Instal l windshield using mounting screws provid ed .
Handlebar
1. Fue l Tank Vent Tube
Observe this
[:~~~~~~~:] during next step
Adjust the handlebar so it does not hit the windshield when turning in either direction.
The h ea dlight instrument wire harn ess an d speedo m e t er cable must be rout e d properly on underside of hood. Clamps are u sed to secure harness and cable in position. (S ee Figure 9.)
Adjust h and l eba r for comfortable driving position and even ly torque four screws 105 in. Ib (1.2 kg-m).
( See Figur e 7.)
DRIFTER
1. Hood Cutaway Section
1. H ead li g ht-In s trument Wire Harn ess
2. Clamps
3. Speedometer Cable
9
ASSEM B LY 3
Throttle and Brake Control Levers
Check throttle and brake control lever position. Be
sure they are comfortable for driving. Torque set
screws 25 in.lb (0.3 kg m). (See Figure 10.)
Tool Kit, Owner Manual, and Safety Handbook
Check the storage box to be sure it contains the
Tool Kit, Owner's Manual and Safety Handbook.
Preparation
1. Set Screw
Safety Labels
I
WARNING'
Insure that all safety labels are properly located and secure. (See Figure 11.)
Suspension
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.
Ride Adjustment
As assemb l ed , the r ear 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 spr ing s to increase their ten s ion . 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 sp rin g can cause spring breakage or excessive wear to one side of the slide wear strips.
To change spring tension:
1. Install spring adjusting tool, PIN 57001-3507 onto the end of the spring arm as shown. (See
Figure 12 .
)
DRIFTER
4 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.
1. Spring Adjusting Tool PIN 57001-3507
2 . Spring Arm
3. Spring Retainer
To ad ju st or change th e handling characteristics of the snowmob il e, tighten the ad ju st ing nuts on each side of the suspension equa lly to incr ease front spring tension or loosen the nuts equally to decrease spring tension. ( See Figure 13.)
Observe this
WARNING t during next step
Rear suspension springs are under heavy spring load and improper adjusting techni· ques may result in personal injury.
Th e standard ad ju s tm en t is 1/4 in. ( 6 .3
5 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.
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 S u spens ion Spring
3. Exposed Threads
Handling Adjustment
The handling characteristics of the snowmobile are controlled by the tension of the front suspen · sian springs. In creasing the spring tension will reduce ski pressure on the ground , resulting in less steering effort and s l owe r response. Less spring tension allows more ski pressure, causing quicker respo nse a nd i nc reased steering effort.
Ski Spring
Preload
Three positions have been provided for the front ski spri ng mounting bolt: (S ee Figure 14 .
)
DRIFTER PREPARATION 5
3. With weight sti ll on front bumper , remove bolt, s li de spring rub strip to a li 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
1. Spring Mounting Position
FRONT HOLE POSITION secures spring to reduce spring arch , increasing spring tension pre l oad , resulting i n a firmer ride with less spring travel for maximum stability during high speed operation.
Check the ski alignment and handlebar centering.
1. 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 spr ing preload, resulting in a softer ride for moderate speeds and trail riding.
REAR HOLE POSITION - provides maximum sprin g arch , further reducing spring preload , r esu lti ng in a much softer ride. This position is recommended for deep snow operation or slow speed trail riding only.
NOTE: Alw a y s mount the front sk i spr in g bolt into the same po s ition on each sk i.
To change the preload of the ski spring , be sure the weight of snowmob il e i s on the skis, and proceed as follow s:
15
1. Straigh t Edge Aga in s t Tr a ck
2. Measure Distance He r e
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.
2. When the sk i cen t er lin e is parall el to the outside edge of th e track, check the steering handlebar for centerin g .
6 PREPARATION 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.)
1. Equal Distance Between Ski Center
Lines· Front and Rear
17
1. Jam Nuts
2. Tie Rod Length Adjusting Stud
3. 1 · 1/4 in . ( 32 mm) Maximum
Wiring Harness
Check wiring harness for proper routing. Be sure wires are not being rubbed or pinched and all con· nectors are secure and fully connected.
3. If handlebar requires centering , support vehi· cle so RH ski is off the ground allowing it t o 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 cente r line remains parallel to straight edge while turning the tie rod adjusting stud.
Chaincase
4. To align RH sk i, move both ski tips towards cen t er of snowmobile to remove the steering li nkage play. Turn the RH tie rod len gth ad· ju s tin g stu d to obtain an equal distance from ski center to ski center when measured at the front a nd rear of the skis. (See Figure 17.)
5. Torque adj usting stud locknuts 120 in. I b (1.4 kg·m). Refer to torque cha rt and tighten a ll hardware (nuts, bolts, etc.) in steering system.
To avoid loss of lubricant, use KAWASAKI
Chain lubricant ONL
to or
Y . whenever filling chaincase. adding
Check chaincase fluid level by r emov ing Fluid
Level Plug. Fluid l eve 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 lev el hole's low er edge. (See Figure 18.)
DRIFTER PREPARATION 7
Install Fill Plug and Fluid Leve l Plug into chaincase.
18
1 . Fill Plug
2. Oil Lev e l Plug
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 l ever movement which should be less than 3/4 in. (19 mm) when brake is fully applied. Perform Brake
Adjustment if required. (See Figure 19 .
)
1.
314 in. (19 mm) Maximum
2. Push Pins
3. Brake Pads
4. Brake Disc
5. Brake Cam
6. Brake Cable Jam Nut
Brake Adjustment
1 . Back both brake cable jam nuts away from bracket about 1/4 in . (6 mm) . Tighten brake adjust i ng nut bottom i ng 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)
Observe this
I
WARNING
I
during next step
DO NOT OVERTIGHTEN the brake because damage to components, or personal injury co uld result.
3. Loosen brake adjusting nut until brake disc can be rotated back and forth easily with brake pads just lightly contacting the disc.
8 PREPARATION DRIFTER
Drive and Dr
Alignment
iv
en Conver
t
e
r 4 . If adjustment of converter center distance is n ec essary; loo s en four chaincase mounting nut s. Position chaincase forward or rearward as r e quired. Torque chaincase mounting nuts
28 ft Ib (3 .
9 kg·m) .
Converter Cente r ·To·Cente r D i s t a n ce
Correc t co n verte r ce nt er· t o·ce nt er d i sta n ce o f
1 0.3 in. ( 262 m m) a n d conve rt e r off se t distance of
0 .
497 in . ( 1 1 .5 m m ) i s ob t a i ne d when a li g nm e nt gauge P IN 5700 1 ·35 1 5 i s co rr ect ly i nsta ll ed b e· twee n dr iv e a nd d riv e n co n ve r ter s h ea v es. ( See
F i g u re 20.
)
NOT E : Driven converter bearing support must be di sc onnect e d by r e moving clevis pin from chassis yok e . Aft e r adju s ting chaincase , loosen support j a m nut a nd a dju s t s upport assembly to proper l e n g th . R e connect support to yoke and torque jam nut 95 in. Ib (1.1 kg-m) . (See Figure 21 .
)
1. A li gnme nt Gauge
2 . Converte r O f fset
3. 1 0.3 i n. ( 262 mm )
2 0
1. Remove be lt guard and remove d r ive belt.
2. Rotate dr i ven co nv erte r mov eab l e shea v e assem bly clockw is e, a n d i nsert a li gnme nt gauge between sheaves. C a r e fully r e l ease mo v eab le sheav e assembly a ll ow i ng spring t ens i on to reta in gauge i n p os i t i on between s t at i o n ary and moveable sheave asse m b l ies.
( See Figu r e 20 .)
3 . Cen t e r di stance is correct i f the notch in the a li g n men t ga u ge fits ove r th e shaft on th e dr iv e converter.
DRIFT E R
1 . D riv e n Conv e rter Support Arm
2 . D riv e n Co nv e rt e r Mov e abl e S he a ve
3 . Ali g nm e nt Ga ug e PIN 5 7 001 · 3515
4 . Drive Co nv e rter
21
PREPARATION 9
Converter Offset Distance
1. Correct off-set distance is obtained when the surface of the shallow notch on the al i gnment gauge touches the base of the fixed sheave of the converter. ( See F igur e 22.)
1. Alignment Gauge PIN 57001-3515
23
1. Alignment Tool PIN 57001-3515
2. Alignment Tool Recess
3. Drive Converter Stationary Sheave
22
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 adjustment is necessary, loosen four engine mounting nuts. Slide engine back and forth until stat ion ary sheave fits into recess in alignment gauge. Tighten all mounting bolts securely.
Converter Parallelism
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. 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.)
1. 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.
NOTE: Never use more than 2 alignment washers per bolt.
"U"
10 PREPARATION
DRIFTER
1. "U" Washer, PIN 92025-3507
Filling Oil Tank
Fill oil tank with r ecommended 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. Proper Routing Sharp bends or kinks in the vent tub e will reduce oil flow to the oil pump.
2. Tie Band In sta llation Tie band may pinch off tub e, reducing oil flow to the oil pump, if in sta lled 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
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.
Oil Re
c
ommendation
We recommend using Kawasaki Snowmobile Oil.
This oil i s specially formulated to give minimum piston ring varnish and combustion chambe r deposits along with excel l ent lubrication qualities.
In an emergency situation when Kawasaki
Snowm obile 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 lubric ants such as "tune-up tonics" and "super oils" is NOT RECOMMENDED.
Fuel Mixture (Break·ln Only)
To insure adequate lubric atio n of internal e ngin e components during early break-in, a 25-to 1 gasoline-to o il ratio is recommended for the first three (3) gallons of gasoline. This ratio can be ob tained by thoroughly mixing 1 pint (0.47 liter) of
Kawasaki Snowmobi le Oil with three (3) gallons
(11.4 lit ers) o f gaso lin e. Pre-mixing gasoline and oil wi ll no l onger be required after the initial three gallons of gasoline and oil mix have been consumed .
PREPARATION 11 DRIFTER
Filling Fuel Tank
25 to 1 Gasoline to Oil
Mixture. Break-in Only
Oil
Gasoline
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.
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
.
)
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.
Adding Gasoline Antifreeze
A major brand of Gasoline Antifreeze (such as
Heet) should be added to the fu e l mix by following the manufacturer's recommendations on the container for a proper mix ratio of fuel with antifreeze.
(See Figure 25.)
Fill the fuel tank slowly and pour the fuel mixture into the tank using a funnel with a fine mesh screen.
Engine Gearcase Lubrication
25
Components in side gearcase drive the oil injec tion pump.
Lubricant l evel 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.)
Each time fuel tank is filled, gasoline an-
tifreeze 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
Fill or add lubri cant to the gearcase as follows:
1. Remove gearcase fill plug (locat ed on top of gearcase) and pour Kawasaki engine gearcase oil or Shell Fire and Ice 10W40 or an equ iv elant viscosity motor oil that meets or exceeds API service SE specifications. Gearcase capacity is about 1.35 oz. (40 cc). (See Figur e 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, loc ated above gearcase sight gauge.
1. Oil Level Sight Gauge
2. Engine Gearcase Drain Plug
3. Gearcase Breather Hole
Engine gearcase oil should be changed after the initial 100 miles of engine operation, and at the end of each se a son, 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.)
Oil Injection System
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 in jection system. After filling oil t a nk, bleed a ir fr om 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 u eez ing (pul s in g ) oil pump supp ly tube until bubb l es no long er exit th e pump asse mbly.
6. Remove bleed screw from top o f oi l pump and a ll ow to drain until a ll air bubb l es are removed from inlet tu be . Visually check entire l ength of tu be to be sure that all air has been removed , then reinstall bleed screw.
1 . Oil Tank
2. Oil Supply Line Filter
3. Oil Supp ly Tu be
1. Fill oil tank with Kawas a ki Snowmobi l e Oil.
2. Remove oil pump bl eed screw. This a llow s oil to fill the filter and flow through oil supply tub e to oil pump . (S ee Figure 29.
)
3. Replace oil pump bleed screw when s upply tub e i s fill ed.
4. Visu a lly check oil filter and oil supp ly tu be to be sure that all air has been removed .
5 . Air trapp ed inside the oil pump assemb ly can be remov ed by sq u eez ing (pul sing ) oil pump su pply tube with pliers. This process causes air to e xit the oil pump nipple a nd enter the s upply tube . (Se e Figure 29.
)
Oil Pump to Carburetor Synchroniza tion
Synchronization ex
1 . tr lubri belt s eme cat lid i e
Figur l y on and
Loosen e import and ai r idl
30.) s of an the oil pump t to e stop screw bottoms out ass in ure so and carbure adequate peak performance. il e following procedur nc e: e r assemb th a t eng
Remove ly, then tor i in s e drive perform the throttle carburetor bore. ( See
NOT E: Check to be sure throttle s lid e has bottomed-out. If not, loosen jam nut a nd turn throttl e cab l e adjuster to a llow s lid e to bottom out.
14 PREPARATION DRIFTER
])
1. Throttle Cable Adjuster
2. Adjuster Jam Nut
3. Air Screw
4. Idle Stop Screw
30
3. Adjust throttle cable on carburetor so that all slack i s 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 idl e 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.
2. 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 int erna l damage. Purge air from these tubes as follows:
DRIFTER
1. Lever Stop Pin
2. Slack Removed
3. Cable Locknuts
31
Observe this 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 inn e r cable. (S ee 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
1. Oil Pump Inner Control Cable
2. Oil Pump Control Lever
3. Rubber Band
4 . Mount Bolt
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 rais ed as shown . ( See Figure 33.
)
32
NOTE: Engine flooding may occur if the enrichener cab le free movement i s l ess than 1/16 inch (1 .
5 mm) .
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. (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
DRIFT ER
If adjustment is required, loosen jam nut and turn ad justing que jam nut 20 in. Ib (0.2
After adjustment or kg-m). check, position boot over fit ting to prevent dirt from entering the enrichener system. screw to obtain correct movement. Tor 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.
Air Screw
The carburetor air screw is properly adjusted when opened 1 .5 turns off its seat. Refer to the s pecifications page. (See Figure 34.)
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 m i nutes 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. Throttle Cab l e Adjuster
2. Adjuster Jam Nut
3. Air Screw
4. Idle Stop Screw
To prevent cable end breakage, throttle lever must contact handlebar grip at full throttle position.
Idle Screw
The idle speed screw initial adjustment is 6 turns open from coil bound, (screw turned in tight).
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.)
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.)
DRIFTER PREPARATION 17
INCORRECT CORRECT
35
1. Dial Indic ator
2. Converter Fixed Sheave
3. Fabricated Pointer
36
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.
(See Figure 36.)
3. Rotate drive converter in normal direction of rotation (counter·clockwise) to find TDC (top dead center ) . Adjust dia l indicator to zero.
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.)
Observe this
[:~~~~!~~:] during next step
When removing spark plugs, carefully rotate plug cap back and forth while pull· 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· tion. (S ee Figure 37.)
2 . Remove both spark plug s and in sta ll a dial in · 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:
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 timing pointer. Timing is correct when mark aligns with pointer as light flashes. (See Figure 38.) 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 i s clean. c . Spark plugs are torqued kg-m).
20 ft Ib (2.7
Ignition Timing Adjustment
1 . Remove recoil starter assemb ly and fan belt pulley. Twist fan belt out of the way.
Observe this WARNING' 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
[=~~~!~~:~:] during next step
When adjusting the stator assembly, take
care not to damage the coil windings.
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.
2 . 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.
)
DRIFTER
1. Timing Light
2. Mark on Drive Converter
38
39
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 i s correct.
6. In sta ll 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 (refer ence mark).
( See Figure 41.)
WARNING
I
If adjusting the headlight Indoors, provide proper ventilation to prevent possible car· bon mon oxide poisoning.
20 PREPARATION
1.5/32 in. (3 .8 mm)
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 . Wall
2
3
.
.
25
4. 2 ft (7,620 mm)
Reference Mark (center in. (51 mm) below of headlight to floor) reference mark
3. Turn on the headlight high beam. The headlight is properly aimed when the high beam is centered and aimed 2 in. (51 mm) below the reference mark on the wall. (See
Figure 41.)
The taillight will operate on ly when the key switch is in the "Run/Light s" position.
The brake light i s act ivat ed by a switc h mounted in the brake l ever housing on the handlebar. Brake light operation is ind ependent of the other light s and the key switch .
Track Adjustments
Observe this
Always turn headlight adjusting screws to the right (clockwise). Turning screws counterclockwise may back them out of the headlight, allowing the headlight become loose or drop out of position. to
I
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 jury. to prevent personal In·
DRIFTER
1. Vertical Adjusting Screws
2. Horizontal Adjusting Screws
Track Tension
WARNING'
To prevent personal Injury, never adjust track tension with the engine running.
1. 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 it s sid e to adjust track ten s ion as it would be impo ss ibl e to g e t an accurate adjustment.
2 . With the 5 Ib (2.2 kg) weight h a n g in g fr o m t h e track , the clearance from the bott o m o f th e wear strip to the top e dge of th e tr ac k s h o ul d be 3/4 in. (19 mm). M e a s ure thi s c l ea r a n ce directly b e low the re a r s u s p e n s i o n piv o t a r m bolt. (See Figure 43 .
)
1. Rea r Ax l e L ock in g Bo lt
2. Rea r Ax l e Adju s tin g Bo lt s
3 . L o ck (Jam) Nut s
Ffll
£ ' /
Observe this
I
WARNING
I during next step
NEVER raise rear of snowmobile by hand or stand behind the vehicle when engine is
-,, ---_ .
_~
,
_ .
_ .
__
.
...
_-running or track i s r otating. A r otating track can fling debris rearward at great velocity. This may cause severe personal injury. Remove all tools and foreign matter
I I
43 from track area before starting engine .
1.314 in. (19 mm)
5. Re m ove th e we i g ht fr o m the track and start th e e n g in e . P u s h t h e throttle l e v e r o nly eno u g h to turn the track slowly a f e w revolution s .
6 . S top th e engin e and perform T rack A l ignment
Chec k .
3. If adjustment is necessary, loosen rear axle locking bolts and rear axle adjusting bolt jam nuts. Turn adjusting bolt s r e quir e d to obtain specified clearance. ( See Fi g ur e 44 .
)
Tr ac k A l ign ment
The track i s align e d when th e di s tan ce betw ee n th e r e ar id l er wheel and edge o f the track i s eq u al on both sides. (See Figure 45.)
4. When proper tension is attained, b e sur e both adjusting bolts are same l e ngth when measured from bo l t end to r e ar axle bracket.
(See F i gure 44.) This is a good s tarting p o int for track alignment.
If tr ac k runs to one side, tighten rear axle a djusting b o lt 1/2 turn on s i de with greater m e asurm en t fr o m rea r wh ee l to e dg e o f track. Re s tart engine and re c h ec k alignment.
22 PREPARATION DRIFT ER
Tes
t Ride
Ope
r
a
tional Checks
Test ride the snowmobi le and check for the following:
1. Dimens ion Equa l on Both Sides
2 . Rear Axle Locking Bolt
3. Idler Wheel
4. Edge of Track
If track alignment requires considerable ad ju s tm ent, track tension should be rechecked to prevent damage to drive or suspens ion system.
When track alignment i s correct, tight en the l ock nut on both r ear axle adjus ting bolts and torque re ar ax le locking bolts 25 ft Ib (3.4 kg-m).
NOTE: After the rear ax l e bolts h ave been tighten ed, c heck to be su re th at the space rs (tubi ng) over the r ear 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.
~
CONTROL CABLES
The thr ott l e and brake controls must operate without binding and return fr ee ly in any s t ee r in g position.
NOTE: With engine running at idle, turn handlebars lo ck to lo ck . If any change in engine speed occurs, check cables for proper routing.
~
STEER IN G
S t ee ring should be smooth and free from lock to-lock with no excessive loo se ne ss or tighteness in the s teering linkage.
~
INE
Recoil s tarter works properly and the engine sta rts promptly. Test for good throttle response and return.
~
SUSPE NSION
Adjusted for average driver weight and operates s moothly.
~
TRACK
Track run s true with little vibration or drag. If ratcheting ( s lippage or jumping between drive lu gs on track and drive sprockets ) during hard acceleration or braking occurs, tighten track t ens ion s lightly .
~
EMER GENC Y STOP SWITCH
Check op e ration in al l switch positions .
.,I
CONVERT ERS
Tes t for s mooth operation and correct eng in e
RPM at full throttle.
~
BRAKES
When activated, the brakes shou ld result in adequate smooth stopping of the track; when released, ther e s hould be no brake drag.
DR IFT ER TEST RIDE (OPERATIONAL CHECKS) 23
t/
INSTRUMENTS
Check for proper indic at ion s.
2. 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 l eaks and repair as required.
Upon completion of the test ride, open the hood and check the following:
1. Brake adjustment.
4 . Fastner check perform a general inspection to check fasteners for security. Use torque chart as a guide for tightening hardware when required.
24 TEST RIDE (OP ERAT IONAL CHECKS) 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 ....................................... BZ-9ES ............... NGK BZ-9EV
Spark Plug Gap ................................ .
.
.......
.. 0.024 in . (0.6 mm)
Carburetor Make ....................................... .................... Mikuni
Carburetor Model ................
.......
........ VM32 Econo Jet ....
......
.
. VM 32 Econo Jet
Engine RPM at Full Throttle ...
....................... ...............
. 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 ...........
..
........................................
........
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 ....
...
....
.........
...
.
.....
...
.........
......... in. (262 mm)
ELECTRICAL SYSTEM
Type .
.
..
......
.........................
...
...................
......... Volts 120 Watts
Headlight ........................
....
......
.
...............................
Tail/Brake Light ..............
..
.
....................
......
...............
....
Instrument Lights .........
...
................
..
................
.......
.......
DRIFTER SPECIFICATIONS 25
DESCRIPTION
CONTROLS & SW IT CHES
Brake lever locking · allen screw
Enrichener lever mig .. nut
Ignition 5 witctl mig . nul
Primer pump mi g. nut
Throttle lever allen screw
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)
HOOD
Hinge to h ood - nuts (1/4)
Hood latch band mtg. - nut
Lanyard mtg. nut ((#10)
Windshield mig .
. screws
STEERING
Handlebar clamp screws (114)
Steering a rm 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 r od to steering post nuts (3/8)
SKI & SPINDLE
Fro nt spring to ski nuts (3/8)
Rear sp ring 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)
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)
SUSPENS ION
Bra cket 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)
DRIVESHAFT
Bearing housing mtg . nuts (1/4)
Locking colla r set screw (114)
CHAINCASE & DRIVEN
CONVERTER SHAFT
Chaincase leve l 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
25 in .
lb (0 .
3 kg m)
Handtighten
Handlighten
40 in.lb (0.4 kg m)
25 in.lb (0.3 kg m)
50 in .
lb (0.6 kg-m)
20 in .l
b (0.2 kg m)
20 in .
l b (0.2 kg m)
Handtighten
20 in .
lb (0 .
2 kg m)
25 in.lb (0.3 kg m)
Compo Rubber
20 in .
lb (0.2 kg m)
15 i n .
l b (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)
25 in .
lb (0 .
3 kg m)
31 It Ib (4 .
2 kg m)
30 It Ib (4.1 kg m)
18 It Ib (2.5 kg-m)
30 It Ib (4.1 kg-m)
30 It Ib (4 .
1 kg m)
45 It Ib (6.4 kg -m)
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
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 -m l
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
Torque Chart
TORQUE DESCRIPTION
100 in .
lb ( 1.2 kg-m)
95 in .
lb (1 .
1 kg m)
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.
l b (0.
8 kg m)
19 It Ib (1.2 kg ml
TORQUE
BRAKE
Brake cable jam nuts (5/ 16 1
Brake disc to converter screws (1/ 4 )
Brake bracket to chaincase . nuts (1/ 4 )
Caliper assy mtg . nuts (5/16)
DRIVE & DRIVEN CONVERTERS
Support t o driven converter jam nut (114)
Support to dr iven shalt bolt (5/161
Drive converte r mtg . bolt (112)
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)
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
E n gine to plate bolt (1/21
30 It Ib (4 .
2 kg-m)
30 II Ib (4.2 kg ml
ENGINE LUBRICATION SYSTEM
E lb ow litti ng to oil tank
Oil pump inlet plate mtg . - screws (4 mm)
Oil pump mounting bolts (6 mm)
Oil pump outlet nozz l e to crankcase bolt (8 mm)
Oil pump outlet nozzle to cylinder bolt (8 mm)
ENGINE GEARCASE
Gearcase drain p lug bolt (6 mml
Gearcase to crankcase allen bolts ( 8 mm )
Gearcase to crankcase boss bolt (6 mml
Oil pump gear to pump nut (8 mm )
Judgemenl
40 in.lb (0 .
5 kg ml
60 in .
lb (0.7 kg ml
10 i n .
lb (0 .
1 kg-ml
10 in .
lb (0 . t kg-m)
50 in.lb (0 .
6 kg ml
12 It Ib (1 .7 kg-ml
60 in .
lb (0.7 kg-ml
12 II Ib (1.7 kg-ml
CYLINDER HEAD AND CY LI NDER
Ca rburet o r holder 1 0 intake manifold· bolts (8 mm)
Cylinder head nuts (8 mml
Exhaust manil old nuts (8 mm)
In take manilold to cy linder (6 mm)
Spark plugs (14 mm)
45 in .
lb (0 .
6 kg-ml
16 It Ib (2.2 kg-ml
12 It Ib (1.7 kg-m)
70 It Ib (0.8 kg-ml
20 It Ib (2 .
7 kg-ml
FAN CASE AND AIR SHROUD
Engine air du ct t o main shroud nuts (#10)
Exhaust shroud to main shroud · bolts (6 mm)
Fan p ull ey to Ian nut (1 4 mml
Fan sc r een t o fan hous i ng· screws (6 mm)
Intak e s hroud s t o cy linders bolts (6 mm)
Main s hroud 1 0 cy l i nder head bolts (6 mml
Main s hroud to Ian housing boilS (6 mm )
CRANKCASE
Gear case lill plug boll (8 mm)
Lower c rankcase boss to upper (6 mm)
Lower c rankcase to upper crankcase (8 mml
PISTON & CRANKSHAFT
Flywheel mtg. nut (18 mm)
RECOIL STARTER
Friction plale to rope real nut (8 mm)
Recoil assemb ly mig . bolts (6 mml
Starter pulley 10 Ilywheel bolls (6 mm)
MAGNETO
C.D.I. igniter mig . - screws (6 mml
I gn ition harne ss · screw (4 mm)
Sta t o r plate mtg . screws (5 mm)
30 in .l
b (0.3 kg-m l
70 in .
lb (0.8 kg-ml
47 II Ib (6 .
5 kg ml
70 in .lb (0 .
8 kg-ml
70 in.lb (0.8 kg m)
70 in .
lb (0 .
8 kg m)
70 in.lb (0 .
8 kg-m)
16 It Ib (2.
2 kg m)
16 It Ib (2 .
2 kg-ml
60 It Ib (8 .
3 kg-m)
10 It Ib (1.
4 kg-m)
70 in.lb (0.8 kg-ml
70 in .
lb (0.8 kg-m)
60 in .
lb (0 .
7 kg ml
Jud gement
70 in.lb (0 .
8 kg-m)
DRIFT ER
~
:II
Z
C)
C
:;
C)
:II
»
3:
I\,) .... c
~
."
-4 m
:II
"--
J
LJ
IGNlTION
COIL
AND COl
J-
TO SPARK PLUGS
Wiring Diagram
EMERGENCY STOP SWITCH
ON
OfF 0 OFF WHITE
BLACK
~
~
D
'"
<
.,j
KEY SWITCH CONNECTIONS
KEY SWITCH
POSlTIONS
"OF,
"RUN/LIGHTS"
"RUN"
CIRCUIT
BETWEEN
COMPLETEO
CONTACTS
G-M
8-L
NONE
MARKEO
8-S
BLUE
~I~
~
P\A.5ER COIL
EXCITER COIL
~
ENGINE MAGNETO
L1GHTINC COIL
~IWI~
- ' I O
~~g
W
~
BLACK/YEllOW
YELLO W
BROWN/YELLOW
REO/YELLOW
~ a
_ g
~
!Ii
~
0 - ,
-J a ~ ~ gga
...... ~<
~
!O' .,j
I
I
I r----~~£~~~-----,
I
L~~~!:~~
________ "
VOL T AGE REGULA TOR
ACCESSORY r---------------~
BROWN I p
WHIIt.
TACHO M ETER LIGHT
I
I
I
I
I
I
I
~
Zl~ fil
TACHOMETER
\
__ _
ER REO ~:
BRAKE LIGHT SWITCH
- L
BROWN (BRAKE L
~HTl
BLACK (CO MMON ]
YELLO W IT AIL L1GHTl
SWIT CH
~
Download
Public link updated
The public link to your chat has been updated. You may view and manage your chat links after registration here.
Document public link
Advertisement
Key features
- Installation
- Suspension adjustments
- Engine break-in
- Safety
- Preparation steps
- Proper assembly
