Yamaha EX440D User manual

LIT -12618-00-26
• YAMAHA
SNOWMORlll
SUPPlEMENTARY
SERVICE UAl
[Frame serial number: 8J7-036101
~ 8J7-049999 J
Engine serial number: S5433-036101 ~ SS433-049999
8J7-28197-10

1980 EX440C
CONTENTS
1. NEW SERVI CE PROCEDURE .... .... .. .... .... .... .. .. ........ .... .... .. .... .... ...... .... .. ..... 2
2. MAINTENANCE INTERVALS
...... .. .. .................. ...... .... ...... .. ........ .. .. ........... 3
3. SPECIFICATIONS .......................... .. ............ .. .... .. ...................... .. ................. 5
4. SPEC I AL TOOLS............ .. ...... .. .. .. ........ .... .. .... .. .. .. ...... .. .... ........................ .. ... 11
5. WIRING DIAGRAM .............................................. .. ...... .. .......... .. ................ .. 12
6. WIRE AND PIPE ROUTING DIAGRAM ...... .. .. .......................................... 13
( )
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1980 EX440D
1. NEW SERVICE PROCEDURE
(New service procedure applied to the 1980
EX440D)
A. Ignition timing
1. Remove the recoil starter assembly.
2. Remove the ri
ght side spark plug and
screw dial gauge stand i
nto spark plug
hol e.
Tool name Tool No.
Dial gauge stand
90890-0 1195
2. In sert dial gage with needle i nto stand.
Tool name T
oo l No.
Dial gauge
90890-01252
Dial gauge needle
90890-03098
4. Rotate magneto flywheel unti l piston is
at
top -dead-center (T.D.C.)
Set the zero on dial gauge face
to line
up exactly
with a dial gauge needle.
Tighten set
screw on dial gauge stand
to secure dial gauge assembly. Rotate
flywheel back and forth
to be sure that
indicator needle does not go past zero.
5. Starting
at T.D.C., rotate flywheel
counterclockw i se unt il dial gauge
reads approximately 3-1/ 2 needle
re -
volutions before-top - dead -cente r
(B .T.D. C.) .
6.
Slowly turn fl ywheel clockwise until
dial gauge reads specifi
ed ignition tim-
ing.
Ignition timing (B.T.D.C.)
1.6 ±0
.1 mm (0.060 ± 0.004 in)
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7. Check the marks on flywheel and pulser
for a
li gnment.
If not al igned, ad just i gnit ion timing as
follows:
a. Loosen the pulser set screws and turn
the pulser until mark alignment is
achieved.
\
...&. \ ~,
NOTE: -- -- ---- -------- ---- -- ---
If the marks can not be aligned by this ad -
justment. remove the flywheel rotor and
turn the base (stator) assembly.
( )
l )

(
b. Tight en the pulser set screws.
8. Remove the dial gauge and stand. Re-
place the spark p lu g and recoil starter.
Tightening torque
Spark plug: 2.8 m-kg (20 ft-I b)
Sta rt er assemb ly : 0.7 m-kg (5 ft-Ib)
2. MAINTENANCE INTERVAL
[ PERIODIC MAINTENANCE]
1980 EX440D
NOTE: -------------------------
The timing light should be u sed to check if
the marks
on the rotor and base are aligned
when both are replaced with n ew ones. The
marks should a
li gn at any specified timing .
Every
Check point 20 hrs. or
40 hrs. or 80 hrs. or When Seasonally
400 km 800 km 1 .600 km
necessary
(250 mil
(500m i) (1 .000m i)
ENGINE:
Tightness of bolts a nd nuts 0 0
8ends. cracks and wear 0 0
Abnormal noi se 0 0
Loose connection a nd breaks of fuel and pulse pipes 0 0
Loose connection and breaks of oil pip es 0 0
Loose connection and breaks of oil delivery pipe 0 0
Manual rope starter system 0 0
Carburetor
• Operation of starter jet 0 0
•
Mix ing adjuster (p il ot sc rew) 0 0
• Idling speed adjustment 0 0
Operation and adjustment of oil pump 0 0
Ignition ti ming 0
Cylinder compressions 0 a
M uf fler join ts 0 0
Cylinder head/exhaust pipe decarboni ze
0
Spark plug conditio n. gap and cleaning 0 0
Tightening of the cylinder he ad"
0
DR I VE:
Tightness of bolts and nuts 0 0
Wear on s li de runners 0 0
Pr imary drive system 0 0
V-belt 0 0
Secondary dr i ve system 0 0
Sheave distance 0 0
Sheave offset 0 0
Brake pad wear 0 0
Brake operation and ad justment 0 0
Guide wheel rubber 0 0
Wear of drive track wh ee l sprocket 0 0
Drive track adjustment 0 0
Breaks in drive track 0 0
Be nds in front and rear axl es 0 0
Che cking of lock washe rs
0 0
Drive cha in adjus tm ent 0 0
Dri ve chain oil lev el 0 0
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1980 EX440D
Every
Check point
20 hrs. or
40 hrs. or
80 h rs. or When Seasonally
400 km
800 km 1. 600 km necessary
(250 mil
(500mi) (1.000mi)
BODY:
Tightness of bolts and nuts 0 0
Bends and cracks 0 0
Welded riveted. joints
0 0
Ski adjustment 0 0
Ski runner wear 0 0
Breaks in fuel tank 0 0
Cleaning of fuel tank 0 (
Fuel filter 0
Loose connection and breaks in fuel pipe 0 0
Breaks in oil tank 0 0
Oil filter 0
ELECTRICAL:
Wear. breakage of wire covering 0 0
Breaks in high-tension cord 0 0
Vo ltage regulator working voltage 0
Operation of engine stop switch 0 0
Operation of tether switch 0 0
Headlight 0 0
Taillight 0 0
Brake light 0 0
** Retighten every 10 hours from the first use.
[LUBRICATION INTERVALS]
Every
Lubrication
point
20 hrs. or 40 hrs. or 80 hrs. or When Seasonally O
il/ Grease
400 km 800 km 1.600 km necessary Brand name
(250 mil
(500mi) (1.0 00m i)
ENGINE:
Starter case 0
Oi l pump control box
0 0 Aeroshell grease #7A or
Esso Beacon 325 grease
Pump drive cover 0 0
Oi l in the oil tank 0 YAMALUBE 2-cycle oil l
DRIVE:
Pr imary sheave weight
0 0
and roller pins
Mo lybdenum disulfide
Secondary shaft and 0 0 snowmobile grease
sliding sheave
Front axle housing 0 0
Shaft 1 and sha ft 2 0
O·
Light all-purpose grease
(S li de rail)
Dri
ve chain oil 0 0 Gear oil API "
GL-3"
replacement SAE
#75 or #80
BODY:
Steering column
lower
0 0 Light all-purpose grease
bearing
Steering column upper 0 0
Motor oil
bearing
Steering links 0 0
Ski co lumn 0 0
Ski wear plate 0 0 Light all-purpose grease
Ski retaining pin 0 0
Brake wire and stopper 0 0
Esso Beacon 325 grease
and brake lever
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