Yamaha SRX440 1980 Service Manual Download

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Summary of Contents for SRX440 1980

Page 1: ...ons are therefore inevitable In light of this fact all specifications within this manual are subject to change without notice Information regarding changes is forwarded to all Authorized Yamaha Dealers as soon as available YAMAHA MOTOR CO LTD SERVICE DEPARTMENT Particularly important information is distinguished in this manual by the fol lowing notations NOTE A NOTE provides key information to mak...

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Page 3: ...SECTION INDEX GENERAL ENGINE COOLING SYSTEM CARBURETION POWER TRAIN CHASSIS ELECTRICAL APPENDIX ...

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Page 5: ...NALVIEW 1 2 1 2 MACHINE IDENTIFiCATION 1 3 A Frame serial number 1 3 B Engine serial number 1 3 1 3 MAINTENANCE INTERVALS CHARTS 1 4 A Periodic maintenance 1 4 B Lubrication intervals 1 5 1 4 HIGH ALTITUDE TUNING 1 6 1980 SRX440 ...

Page 6: ...1980 SRX440 1 1 EXTERNAL VIEW CHAPTER 1 GENERAL 1 2 ...

Page 7: ...TERVALS CHARTS A Periodic maintenance Use this just as guide only Certain conditions may require more frequent inspection of compo nents Every 20 hrs or 40 hrs or 80 hrs or When Seasonally Check point 400km aOOkm 1 600 km necessary 250mi 500 mil 1 000mi ENGINE Tightness of bolts and nuts 0 0 Bends cracks and wear 0 0 Abnormal noise 0 0 Loose connection and breaks of fuel and pulse pipes 0 0 Loose ...

Page 8: ...rive track wheel sprocket 0 0 Drive track adjustment 0 0 Breaks in drive track 0 0 Bends in front and rear axles 0 0 Checking of lock washers 0 0 Drive chain adjustment 0 0 mwe cnam 6if ever Y 0 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...

Page 9: ...YAMALUBE 2 cycle oil DRIVE Primary sheave weight 0 0 and roller pins Molybdenum disulfide Secondary shaft and 0 snowmobile grease Sliding sheave 0 Front axle housing 0 0 Shaft 1 and shaft 2 0 0 light all purpose grease Slide rail Drive chain oil 0 0 Gear oil API Gl 3 replacement SAE 750r 80 BODY Steering column lower 0 0 Light all purpose grease bearing Steering column upper 0 0 Motor oil Steerina...

Page 10: ... the um drive 4 Flywheel puller screw q 8 X 80 mm 90890 01806 cover If it is hand to remove the pump drive case tap it with a soft faced hammer 3 Remove the Phillips head screw and remove the coil plate NOTE When removing the flywheel the key must be removed from the crankshaft Take care so that it is not lost CAUTION The oil pump must not be disassembled because the oil pump is a precision work 3...

Page 11: ... pin hole area 2 5 8 Remove engine bracket 9 Remove crankcase holding bolts Each bolt position is numbered Start with the largest number for disassembly Loosen each bolt 1 4 turns and proceed to the next 10 Split crankcase by lightly striking the upper and lower crankcases 11 Remove crankshaft by tapping the shaft with your hands 2 2 INSPECTION REASSEMBLY AND ADJUSTMENT A Engine components 1 Crank...

Page 12: ...nk pin and big end bear mg Replace defective parts Play after reas sembly should be within specification Rod axial play Maximum 2 0 mm 0 079 in Rod side clearance b Check the connecting rod side clear ance at big end If axial play exceeds tolerance disas semble the crankshaft and replace any worn parts Big end axial play should be within specification CAUTlON When removing pump drive gear re place...

Page 13: ...ide CAUTION The oil seal lip must fit into the crankcase groove UPPER CASE I o FWD CD b Install the crankshaft assembly with oil seal align the bearing punch marks with the crankcase lower and upper mating surfaces c Set the pins of bearing and labyrinth seal in pin holes of crankcase upper by moving the bearings and labyrinth seal 1 Circlip LOWER CASE 2 Sealing surface 3 Knock pin 6 Crankcase ins...

Page 14: ...t installation Install the engine brackets in the correct position 2 8 b Check the pin and bearing for signs of heat discoloration If excessive indenta tion on pin etc replace pin and bear In c Check the bearing cage for excessive wear or damage Check the rollers for signs of flat spots If such wear is found replace pin and bearing d Apply a light film of oil to pin and bear ing surfaces Install t...

Page 15: ...ection a Check rings for scoringlany severe scratches are noticed replace ring set b Measure ring end gap in free position If beyond tolerance replace ring set nrme cylindel tbtblelallce 01 bOle to next oversize and fit oversize piston c Carefully remove carbon deposits from ring grooves with filed end of ring d Remove score marks and lacquer de posits from sides of piston using 600 800 grit wet s...

Page 16: ...s a negligeable amount the cylinder may be used Smooth out the edge of the chrome with 400 riLsandpaper to prevent the ring edge from catching the edge of the chrome But if the peeling is present to a considerable degree the cylinder should be replaced NOTE If the cylinder wall has a large amount of scuffing check each piston ring for defects and replace it if necessary 11 Piston installation a In...

Page 17: ...irst 20 Nm 12 0 m kq Makesuretnerings aI e properlvposttionad 8 mm nut Final 25 Nm 12 5 m kg 14 Cylinder head inspection a Remove spark plug b Using a rounded scraper remove carbon deposits from combustion chamber Take care to avoid damaging spark plug threads Do not use a sharp instrument Avoid scratching the al uminum 2 11 NOTE When the cylinder head is installed on the cylinder the D ring may e...

Page 18: ...asket for damage and replace it as required Install the exhaust pipe with gasket B Oil pump 1 Minimum pump stroke checking and ad justment Normally the checking the adjustment of the pump stroke are not required but if any sign of trouble resulting from an incorrect minimum pump stroke is noticed e g excessive engine oil con sumption or engine seizure proceed as follows a Remove the oil pump assem...

Page 19: ...w one b Bleeding the pump distributor and or delivery pipe 1 Start the engine 2 Pull the pump wire all the way out to set the pump stroke to a maximum 1 Pull 2 1 00iipvvile NOTE It is difficult to bleed the distributor com o pletely with the pump stroke at a minimum and therefore the pump stroke should be set to a maximum 3 Keep the engine running at about 2 000 r min for two minutes or so and bot...

Page 20: ...l the drive water pump pulley with water pump belt 3 Install flywheel using rotor holding tool NOTE _ _ Make sure woodruff key is properly seated in keyway of crankshaft Carefully install fly wheel while taking care so it aligns with woodruff key Tool name Rotor holding tool Tool No 90890 01235 3 Install the starter pulley using rotor holding tool Flywheel nut torque 73 Nm 7 3 m kg 4 Adjust igniti...

Page 21: ... to install the spring in a wrong way 3 Hook the loop on the outer end of the spring onto the spring hook in the starter case Then thoroughly grease the s rin 2 Windihe starter rope around the sheave drum and put it into the star ter case Hook the knot on the rope end onto the cut in the sheave drum as il lustrated and wind the rope around the sheave drum in the direction of the arrow leaving abou...

Page 22: ...e that the starter pawl moves out of the drive plate G Engine remounting Install the engine as follows Engine Engine mounting bolts and nuts Magneto lead wire Carburetor 1 Drive plate spring 2 Drive pawl 3 Return spring 6 Install the starter assembly on the crankcase Tightening torque 7 Nm 0 7 m kg NOTE Refer to 5 1 A Sheave adjustment CAUTION Take care not to pinch the wire and pipes between the ...

Page 23: ...olant hoses Fuel pipes pulse pipe Oil pipes Muffler Add the coolant Snowmobile 2 17 NOTE For inspection see 5 1 C V bett CAUTION The oi I pipe in which the oi I filter is in stalled must be correctly connected to the oil pump NOTE After installing oil pipe the autolube system must be bled Refer to 2 2 8 4 Air bleeding NOTE Refer to 3 1 D Replenishing the Coolant ...

Page 24: ...L _ _ _ _ r f ...

Page 25: ...LING SYSTEM CHECK 3 3 A Cooling system check 3 3 B Radiator cap check 3 4 3 3 RADIATOR 3 4 A Removal 3 4 B Inspection 3 4 C Installation 3 4 3 4 HEAT EXCHANGER 3 4 A Removal 3 4 B Inspection 3 4 C Installation 3 4 3 5 WATER PUMP 3 5 A Disassembly 3 5 B Inspection 3 5 C ReasseM bly 3 5 A Removal 3 6 B Inspection 3 6 C Installation 3 6 1980 SRX440 ...

Page 26: ...C 40 F This mixture can be used in almost all snowmobile conditions CAUTION 1 In an area where the temperature is below 40 C 40 F the water jantifreze mixing ratio should be 2 3 40 water 60 antifreeze 2 Do not use water containing im pu rities 0 r oi I 3 2 C Draining coolant 1 When the coolant is still hot slowly loosen the radiator cap to lower the pressure in the radiator Take care not to allow ...

Page 27: ...bleeder bolt located above the thermostat vaIve and let the air out Add coolant to radiator again up to the level line shown in the illustration 6 Repeat steps 4 and 5 above until the coolant level in the radiator becomes stable Tighten bleeder bolt 7 Start the engine and keep it running at 3 000 r min until thermostat valve opens The thermostat valve opens at 60 65 0 C If you look into the radia ...

Page 28: ...olant Refer to 3 1 C Draining coolant 2 Remove the coolant hoses 3 Remove the radiator stay bolts and re move the radiator 3 3 RADIATOR 2 Apply 10 bar 1 0 kg cm2 pressure and observe the gauge to check whether pressure drops or not If the pressure shows a drop the cooling system is leaky Repair as required Refer to 3 3 Radiator or below B Radiator cap check Using a pressure gauge inspect the radia...

Page 29: ... shaft driven water pump pulley and belt 3 5 B Inspection 1 Remove the deposits from the impeller and water pump cover 2 Check the impeller for cracks and damage Replace as required 3 Check the oil seal and bearing for damage and wear Replace as required 4 Check the water pump belt for damage and wear Replace as required C Reassembly 1 Coat the impeller shaft gear with grease 2 Install the housing...

Page 30: ... 60 0 65 C 114G 149 FI rID 7 Install the water pump assembly on the engine and adjust the belt tension Refer to 2 2 F Water purnp 8 Inspect the cooling system Refer to 3 2 A Cooling system check 9 Fill with the coolant Refer to 3 2 0 Replenishing coolant 3 6 THERMOSTAT 1 Thermometer 2 Full open 3 Begin to open 0 i 0 0 4 Water 5 Thermostat 6 Vessel A Removal 1 Drain coolant to below thermostat leve...

Page 31: ...2 Install the coolant hose 3 Inspect the cooling system Refer to 3 2 A Cooling system check 4 Fill with the coolant Refer to 3 2 0 Replenishing coolant 1980 SRX440 3 7 ...

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Page 33: ...CHAPTER 4 CARBURETION 4 1 CARBURETOR 4 2 A Carburetor tuning 4 2 B Overhauling 4 5 C Troubleshooting 4 10 4 2 FUEL PUMP 4 12 1980 SRX440D ...

Page 34: ...ight and left carbure tors Set the throttle cable adjuster SO that both throttle valves to open at the same time Also make certain that the throttle valves reach full throttle position at the same time c Repeat the operation specified in a and b above When the adjustment is com plete be sure to install the intake air silencer WARNING Throttle cable must not be lubricated in any way It must be rout...

Page 35: ... engine by pulling the starter lever and fully warm up the engine c Set the throttle stop screw so that the CD 2 5 2 5 mm 0 06 0 0 in 1 Adjuster 2 Lock nut Free play between outer tube end and adjuster 15 2 5 mm 0 06 0 10 in 4 Oil pump cable adjustment Refer to 2 2 8 5 Pump cable adjust ment 5 Low speed tuning The carburetor is built so that low speed tuning can be done by adjusting the throttle s...

Page 36: ...gine at high speeds and make sure the engine operates smooth ly b Check both spark plugs and depending on the discoloration of each spark plug the main jet should be adjusted on the basis of the following table Refer to spark plug color samples Standard main jet 260 Spare main jet 270 250 240 230 Spark plug color No 1 Good Carburetor is tuned properly Bad Mixture is too rich NO 2 Replace main jet ...

Page 37: ...y from fire After assembling the carbure tor firmly tighten the rubber joint screw Make sure the throttle outer tube is in place and the throttle cable moves smoothly Clean the carburetor and allow it to dry B Overhauling 1 Disassembly a Remove the intake silencer assembly b Remove the carburetor from the engine and disconnect the control cables as follows 1 Loosen the throttle cable holder screw ...

Page 38: ... drop it 2 The fuel valve plays a very important role so special care should be taken so that the rubber part of the needle is not scratched 3 Use care to keep the plastic parts free from shocks because they could be damaged easily 4 Never wash the rubber parts with al cohol or lacquer thinner Use gasoline ...

Page 39: ...2 Inspection CAUTION 1 Before checking thoroughly clean all parts in gasoline and blow the jets float chamber and fuel pas sages in the carburetor body with compressed air so the dust and dirt can be removed 2 When washing the carburetor body and float chamber be sure to use a soft brush 3 When decarbonizing the throttle valve and its adjacent area take special care not to scratch the throt tle va...

Page 40: ...ged fuel flow will be hindered and hard starting will result 1 Starter circuit 2 Check the power jet circuit for clogging If clogged blow it with compressed air care not to scratch the seat and blow it with compressed air Check the end of the valve needle and the valve seat for damage If damaged replace the valve needle and valve seat as an assembly a Float chamber 1 Check the starter jet and powe...

Page 41: ...nstall the main nozzle main jet and pilot jet Tightening torque Main nozzle 5 Nm 0 5 m kg Main jet 2 Nm 0 2 m kg Pilot jet 0 8 Nm 0 08 m kg 2 Install the power jet and power jet cover bolt Tightening torque Power jet 1 8 Nm 0 18 m kg Power jet cover bolt 4 Nm 0 4 m kg 3 Install the throttle stop screw and coil spring Adjustment See Low speed tuning 4 Install the pilot screw and coil spring Adjustm...

Page 42: ... 4 Wire holder attached to the throttle valve b Float chamber 1 Screw the main jet cover bolt with O r ing into the float chamber 2 Install the O ring to the float chamber and install it to the carburetor body 4 10 NOTE By turning the throttle lever to the full open position two or three times make sure it op erates correctly 3 Make sure the starter lever isfullv pu shed in and connect the starter...

Page 43: ...ed Throttle stop screw Adjust Tightened to much Engine speed is higher Backed out too much Engine does no idle Damaged pilot screw Replace pilot screw Clogged bypass hole Clean Clogged or loose slow jet Clean and retighten Remove slow jet and blow it out with compressed air Air leaking into carburetor joint Retighten band screw Defective starter valve seat Clean or replace Overflow Correct See Ove...

Page 44: ...while taking care not to Power idleing scratch valve seat Poor performance at low mid range and high Scratched or unevenly worn Clean or replace float valve Valve seat is press fitted to body speeds float valve or valve seat and valve seat So body must be replaced if seat is Excessive fuel consumption damaged Hard starting Broken float Replace float Power loss Poor acceleration Incorrect float lev...

Page 45: ...sing 5 9 F Front axle 5 13 5 2 BRAKE 5 15 A Disassembly 5 15 B Inspection 5 15 C Reassembly 5 16 D Adjustment 5 16 5 3 SUSPENSION 5 16 A Removal 16 B Inspection 5 17 C Slide rail suspension adjustment 5 18 D Installation 5 20 5 4 DRIVE TRACK 5_20 A Removal 5 20 B Inspection 5 20 C Installation 5 21 D Adjustment 5 21 1980 SRX440 ...

Page 46: ...ce and alignment by moving the engine back forth or sideways Tool name Tool No Sheave gauge 90890 01875 Sheave distance 270 mm 10 63 0 0 11 in 1 Sheave distance 2 Sheave off set 0 O 5 5 0 5 mm 0217 0 020 in 270 3 mm 10 63 _O 11m Sheave distance check 1 Sheave gauge Sheave offset alignment check NOTE If sheave distance or alignment is not ad bolts on the bearing housing supporting the secondary sha...

Page 47: ... rotor holding tool Tool name Tool No Tool name Tool No Sheave gauge 90890 01875 Primary fixed sheave puller 90890 01859 2 Disassembly a Install the sheave sub assembly tool to the primary sheave Sheave off set 5 5 0 5 mm 0 217 0 020 in Axial play o 1 0 mm 0 0 04 in l Primary fixed sheave puller Tool name Tool No c Tighten the secondary sheave securing bolt Tightening torque 50 Nm 5 0 m kg 90890 0...

Page 48: ...f scratches are minor burnish with emery cloth b Check the primary sheave cap bushing and sliding sheave bushing for wear If beyond tolerance replace the bushing Bushing clearance limit Small bushing Large bushing Inside 0 25 mm 0 01 in 0 25 mm 0 01 in Outside 0 25 mm 0 01 in 0 25 mm 0 01 in Tool name Bushing tool 1 Bushing too 90890 01877 5 4 c Check the compression spring for igue ex es ive y ig...

Page 49: ...ation using an optional compression spring b By changing the position and quantity of primary weight rivets the thrust of weight can be changed and thus the engine rpm at which the clutch is shifted can also be changed As a re sult the engine rpm at which the clutch is engaged can be changed CAUTION The rivets for three weights must be in the corresponding positions o 5 Reassembly a Adjust the sli...

Page 50: ...ave cap to the primary sliding sheave be sure to align the X marks on the spider and sheave cap with that on sliding sheave X Freefrom oil _ Greasing point b Oil the points shown in the illustration Do not apply the grease on the portion of X mark For other parts greasing is unnecessary CAUTION If the cotter pin is removed for the greasing replace it with new one CAUTION When the bushing is replac...

Page 51: ...d value re place with a new belt f Clean the oil off the tapered portion of crankshaft using a lacquer thinner g Fit the primary sheave assembly to the tapered portion of crankshaft h Apply engine oil to the threaded portion of primary sheave bolt and its contact surface with spring washer i Tighten the primary sheave mounting bolt using the rotor holding tool Next lock the lock washer NOTE Check ...

Page 52: ...condary spring twist 90 0 a Secondary spring position The spring seat is provided with four holes Nos 1 to 4 so that the secondary spring position can be changed as re quired 5 8 b Check torsion spring for fatigue If ex cessively fatigued replace c Check both sheaves for warpage If warped replace 3 Secondary sheave spring adjustment It is advisable to change the secondary sheave setting to corresp...

Page 53: ...sliding sheave boss and se condary shaft and mount the sliding sheave on the shaft Recommended grease Molybdenum disulfide snowmobile grease b Install the sliding sheave to the fixed sheave and set the spring and spring seat as specified See Secondary sheave spring adjustment of above item c Install the circlip secondary fixed sheave boss slit 5 9 NOTE After installation thoroughly clean both fixe...

Page 54: ...ring race and brake disc and key 1 Eccentric bearing installer e Remove the brake caliper assembly Refer to 5 2 Brake section 5 10 2 Inspection a Drive chain Except in case of oil starvation the chain wears very little If the chain has stretched excessively and it is difficult to keep the proper chain tension the chain should be replaced b Drive driven and chain tension sprockets Check sprocket fo...

Page 55: ...7 18 19 20 21 22 P N878 P N878 piN 878 SRX440 PIN 878 P N878 P NoBl8 _ P N 878 Teeth of 17682 50 17682 60 17682 70 Std 17682 90 17693 00 17693 10 17693 20 driven sprocket 29 933 1 813 1 706 1 611 1 526 1 450 1 381 1 318 SRX440 Std 68 68 68 or 70 70 70 70 _70 or 72 72 31 2 067 1 938 1 824 1 722 1 632 1 550 1 476 1 409 PIN 878 47587 00 68 70 70 70 70 or 72 72 72 72 33 2 200 2 063 1 941 1 833 1 737 1...

Page 56: ...eck the gasket and if damaged replace with a new one Tightening torque 16 Nm 1 6 m kg f To add gear oil the filler cap and oil level screw should be removed Fill until oil begins to run out the screw hole Recommended oil Gear oil API GL 3 SAE 75 or 80 Quantity 320 em After adding oil be sure to install and g Chain tension adjustment Remove adjuster bolt clip Tighten ad juster bolt turn clockwise b...

Page 57: ...d front axle housing Lock the front axle by applying the brake 5 13 1980 SRX440 d Remove the chain housing cap Refer to chain housing Drain oil and remove the chain driven sprocket e Loosen the left side guide wheel secur ing collar and slide the guide wheel to the right side f Pullout the front axle g To remove the wheel sprocket from the axle loosen the band and push out using a press 2 Inspecti...

Page 58: ...eth are aligned as shown After positioning tighten the band Tightening torque 5 Nm 0 5 m kg c Apply a low temperature grease to the chain case oil seal and insert the right hand side of front axle into chain case through drive track Tighten the front axle with chain driven sprocket 5 14 Tightening torque 50 Nm 5 0 m kg d Install the front axle housing Next in stall belleville washer and front axle...

Page 59: ...Install the chain housing cap and add oil See 5 1 E 4 Chain housing g Install the slide rail suspension assemb ly See 5 3 D Suspension installation h Fill up the meter housing with a low temperature grease and install it Guide wheel collar tightening torque 5 5 Nm 0 55 m kg Tightening torque 6 Nm 0 6 m kg e Set the left side guide wheel 46 mm 1 81 in from the left sprocket wheel side FWD 5 15 1 Ne...

Page 60: ... adjusting bolt so that the brake inner cable does not touch the brake caliper the brake caliper and brake inner cable must be in a straight ine Then tighten the lock nut 5 16 1 Lock nut 2 Adjusting bolt b Loosen the lock nut and turn the ad justing screw so that the brake cable has a play of approx 5 mm 0 20 in at the brake lever holder Then tighten the lock nut 1 Adjusting screw 2 Lock nut 2 rig...

Page 61: ...s less than specified value replace slide runner 5 17 2 Check the suspension wheel for damage 3 Shock absorber WARNING Rearshock This shock absorber contains highly pressurized nitrogen gas Read and understand the following in formation before handling the shock ab sorber The manufacturer cannot be held responsible for property damage or personal injury that may result from im proper handling 1 Do...

Page 62: ... gas and or metal chips a Check the rod and if it is bent or dam aged replace the shock absorber b Check for oil leakage If oil leakage is evident replace the shock absorber c By compressing the shock absorber check to see there is no gas leakage C Slide rail suspension adjustment The setting of suspension greatly affects the stability and steering of the machine Therefore it is necessary to adjus...

Page 63: ...s possible unless it impairs the stability of the machine Course Less gap More gap Trail riding with passenger Softer _ 1 Stiffer Suspension wheel Washer Bolt Tightening torque 20 Nm 2 0 m kg 3 Additional wheel installation When the machine is driven on icy sur faces for a prolonged period of time for instance trail riding additional wheels should be installed to protect the slide runners from fas...

Page 64: ... rail in stallation is complete 3 Fit the rear pivot shaft to the frame The rear pivot shaft is being forced toward the rear by the shock absorber 5 20 To assist in rear shaft installation keep the shaft forward by using an iron bar NOTE When installation of slide rail is complete tighten front and rear bolts to proper torque Tightening torque Front pivot shaft mounting bolts 65 Nm 6 5 m kg Rear p...

Page 65: ...ear of the snowmobile to allow the track to turn while the engine is running Stop the engine and prop up the rear with a suitable stand Never stand behind the machine when the track is spinning 4 Never install studs cleats closer than three inches form the edge of the track 5 Replace any track that is damaged to the depth where fabric reinforce ment material is visible Inspect track condition freq...

Page 66: ...runner and edge of track window Track metal Forward Track metal Forward Gap between slide runner and edge of track window When shifted to right Tighten the right track adjusting bolt and loosen the left track adjusting bolt When shifted to left Tighten the left track adjusting bolt and loosen the right track adjusting bolt 5 22 ...

Page 67: ...CHAPTER 6 CHASSIS 6 1 OIL TANK 6 2 6 2 FUEL TANK 6 2 6 3 STEERING 6 2 A Installation 6 2 B Adjustment 6 3 6 4 SKiS 6 4 A Inspection 6 4 B Installation 6 4 1980 SRX440 ...

Page 68: ...t the fuel filter be re placed with a new one each season 1 Fuel filter 6 2 If the filter is faulty obstructing the fuel flow or having a breakage in the ele ment it should be replaced as an assembly unit 6 3 STEERING A Installation 1 Grease the ski column on the frame Position the skis so that they are paral lel to each other Place outside arms on skis L on left ski R on right ski Be sure to inst...

Page 69: ...nd check to see that the skis are parallel If not loosen the steering relay rod lock nut and by turning the steering relay rod in or out adjust the ski toe out to specification see below Ski width agO mm 35 0 in Ski toe out 0 6 mm 0 0 23 in 4 Connect the steering relay rod to the steering column Install a new cotter pin Tightening torque 30 Nm 3 0 m kg 6 3 Steering relay rod tightening torque 25 N...

Page 70: ... 3 B 3 suspension shock absorber a Check the rod and if it is bent or dam aged replace the shock absorber b Check for oil leakage If oil leakage is evident replace the shock absorber c By moving the rod check to see if it has a proper damping effect B Installation 1 After installing the ski assembly grease the wear plate and retaining pin 2 Install the ski column to the ski assem bly 6 4 3 Install...

Page 71: ...n timing 7 3 D Spark gap test 7 4 E Ignition coil 7 5 F Spark plug 7 5 G Pulser and charging coils test 7 6 H C D l unit 7 7 7 2 LIGHTING SySTEM 7 7 A Circuit diagram 7 7 B Headlight beam adjustment 7 7 C Lighting coil resistance check 7 7 D Voltage regulator 7 8 E Oil caution switch 7 9 1980 SRX440 ...

Page 72: ...coil 4 C D I unit 5 Main switch 6 Tether switch 7 Engine stop switch 8 Ignition coil 9 Spark plug B Toubleshooting No spark is produced or weak Check of connections I OK Spark t see 7 1 D Spark gap test l No spark Spark I Plug is falty Charge coil test OK Faulty l Replace Pulser coil test OK l Faulty Replace 7 2 _ _ _ _ _ ...

Page 73: ...1 unit Faulty l Replace 2 Insert dial gauge with needle into stand Tool name Tool No Dial gauge 90890 01252 Dial gauge needle 90890 03098 c Ignition timing 1 Remove the right side spark plug and screw dial gauge stand into spark plug hole Tool No 90890 01195 Tool name 3 Rotate magneto flywheel until piston is at top dead center T D C Set the zero on dial gauge face to line up exactly with a dial g...

Page 74: ...on the rotor and base are aligned when both are replaced with new ones The marks should align at any specified timing 3 Start engine and increase spark gap until misfire occurs misfire and weak spark using the Electro Tester If the ignition system will fire across a sufficient gap the engine ignition system can be considered good If not proceed with in dividual component test until the probelm is ...

Page 75: ...istance resls ICe 0 15Q 10 3 6kn 20 at 20 C 68 F at 20 168 F 7 5 actually economical to install a new plug often since it will tend to keep the engine in good condition and prevent excessive fuel consu mption 1 How to read spark plug condition The spark plug color J1plesare at the end of this manual r CD Good S The insulator normally has a tan color This check should be made after driving the mach...

Page 76: ...ctrodes of carbon and ad just the electrode gap c Besure to use the proper reach plug as a replacement to avoid overheating fouling or piston damage Spark plug type B 9ES NGK Spark plug gap use wire gap gauge 0 7 0 8 mm 0 028 0 031 in Spark plug torque 28 Nm 2 8 m kg G Pulser and charging coil test Check the resistance between terminals If resistance is out of specification coil is broken Check th...

Page 77: ...resistance Black to Yellow leads O 220 1 O 20 C 68 F C Lighting coi I resistance check Check the resistance between yellow lead and ground If resistance is out of specifica tion coil is broken Check the coil connec tions Ifthe coil connections are good then the coil is broken inside and it should be re placed 5 Taillight 6 Meter light 7 Brake light Flywheel magneto 2 Lighting source coil 3 Voltage...

Page 78: ...Set tester at RX position D Voltage regulator 2 Connections Connect two 12V batteries in series using the sub lead wires Connect the red lead wire A for pow er of the regulator checker to the posi 7 8 s 1 1 Instruments required for inspection CD Regulator checker ell Two 12V batteries Sub lead wire CD ...

Page 79: ...needle swings over the black zone and it will not return to 0 from 20V or more s v E Oil caution switch The oil caution light comes on when there is little oil in the oil tank thus warning the rider G I I I i I I S R I __ J Q 5 Oil level switch 6 Brake light 7 011 caution light 1 Flywheel magneto 2 Brake switch 3 Oil caution switch ass v 4 Diode 4 Checking the regulator a Set the right switch to R...

Page 80: ... the slider the tester should read zero If not the switch must be replaced 2 Diode check Check the diode as specified using the pocket tester Pocket tester connecting point Replace Replace Good element element Black shorted opened Black Red Green Yellow 0 0 X 1 I Green Yellow Black Red X 0 X Lead wire color Black Red Green 0 0 X l _ _ Green Black Red X 0 X 0 Continuity X Discontinuity NOTE When ma...

Page 81: ...ECIAL TOOLS 8 2 8 2 SPECIFICATIONS 8 3 A General 8 3 B Engine 8 3 C Drive and track suspension 8 5 D Chassis 8 6 E Electrical 8 6 F Tightening torque 8 7 8 3 WIRING DIAGRAM 8 8 8 4 WIRE AND PIPE ROUTING DIAGRAM 8 9 1980 SRX440 ...

Page 82: ...ment 90890 01804 4 c Flywheel puller screw 90890 01806 4 d Drive handle 90890 01817 4 e Flywheel puller body 90890 01848 5 Rotor holding tool 90890 01235 6 Primary fixed sheave puller 90890 01859 7 Sheave sub assembly tool 90890 01858 8 Bushing tool 90890 01877 9 Sheave gauge 90890 01875 10 Eccentric bearing installer 90890 01851 11 Pocket tester 90890 03104 12 Electro tester 90890 03021 13 A C Re...

Page 83: ...on chamber volume with spark plug 21 0 ern Compression chamber type Dome Squish Cylinder Material Alum inurn cylinder with hard chrome bore Bore size 6S 5 mm Piston Piston skirt clearance measuring point 0 065 0 070 mm 10 mm from piston skirt end Piston pin outside diameter x length 1 20x 56 m Piston ring Piston ring design Top Keystone Piston ring design Znd Rin9 end gap installed Top 0 35 0 55 m...

Page 84: ...AJ Power jet IPw J Power air jet Pw A J J Pilot jet IP J Pilot air jet IPAJ Pilot screw P S Starter jet ISt J Float height Idling engine speed 1 0 6 115 1 1 3 85 1 0 8 2 0 turns out 1 2 0 30 1 mm 1 500 r min Jet setting chart Temperature Altitude 30 C 1 22 FI Sea level MJ 260 PJ 85 MJ 250 PJ 85 MJ 240 PJ 85 Up to 1000 m 13000 hi MJ 240 PJ 85 MJ 230 PJ 85 MJ 220 PJ 85 Up to 2000 m 6000 ft MJ 210 PJ...

Page 85: ...e Damper type Spring color code Front Spring color code Rear Slide runner wear limit Track width Track deflection Length on ground Wheel sprocket material and number of teeth Stopper band length Secondarv drive Type Reduction ratio Chain pitch x Number of links Free play Chain housing oil quantity Chain housing oil grade Brake Type Brake pad thickness Brake pad wear limit Brake cable free play 8 5...

Page 86: ...e Ignition timing B T D C Ignition coil Model Manufactu ret One ntity Spark gap Primary winding resistance Secondary winding resistance Diode IYes or No Spark p1U9 Type quality Spark plug gap Spark plug cap Type Noise suppressor resistance C D I unit Model Manufacturer Lighting system Lighting output Lighting coil resistance Headlight type Bulb wattaqe q tv Tail Brake light wattage A C requlator M...

Page 87: ...hain Ml0P1 25 50 Nm 5 0 m kg Installation of drive chain sprocket Ml0P1 25 50 Nm 5 0 m kg Nut Installation of driven chain sprocket Ml0 Pl 25 50 Nm 15 0 m kq Bolt Chain housing and frame M8 Pl 25 23 Nm 2 3 m kg Installation offront axle L H M22 Pl 0 85 Nm 8 5 m kg Front axle housing and frame M8 Pl 25 23 Nm 12 3 m kg Wheel sprocket and front axle 5 5 Nm 0 55 m kg Front pivot shaft Ml0Pl 25 65 Nm 6...

Page 88: ...ight LI r 12V 3 4Wl I XION3ddlt 8 3 WIRING DIAGRAM I r Ln Tail brake light 12V 8W 23W 1 G Y f I L LJ I I B W 8 1 tl I II I T GI I 1 I r I B W II l i U lv Ii lDIF tlli Hlil LIGlv o T h r switch UNtlFF co 00 rrrt 8 y wlBr R RI8 11 t 81 18 W 1 2 C D 1 unit 4Wtt L C D I magnetol Voltage regulator TIC 1 160 L Onlever l wn 11 ...

Page 89: ...oint of C O arneS5 and other ad 15 magneto lead wire wire wire ter hose wire harness d Clamp the we d C OJ unit lead 16 Ban mecnetc lead wire an C O 1 wires I 17 C D 1 uM wire C D 1 magneto le d 18 dometer cable 19 Spee ad wire 20 Speedometer Ie meter lead wire 21 W tertemperature 22 Tachometer lead w re 23 Tether sWitch lead Wire harness assembly 25 Ignition coil wire 26 Voltage regulat r 1 9hten...

Page 90: ...encer 41 Fuel pipe 42 Oil tank breather pipe 43 Fuel tank breather pJpe 44 To fuel pump 45 Fuel pipe 46 Speedometer cable 47 Fuel pipe 48 Fuel level pipe 49 Wire harness protector 50 Bend cable allarge curve 51 Voltage regulator lead wire 52 Brake light switch coupler 53 Headlight beam switch Goupler 54 Couple Molder 55 Tether switch coupler 56 Engine stop switCh coupler 57 Wir harness ...

Page 91: ...5 High tension cord 66 Oil pump cable 67 Fuel pipe ITo leffcarburetor 68 Oilpump cable 69 Oil pump 70 Starter cable for left carburetor 71 Fuel pump 72 Throttle cable for right carburetor 73 Starter cable cylinder 74 Throttle cable for left carburetor 75 High tension cord 76 Oil pump cable 77 Fuel pipe To right carburetor 78 Oil pipe To upper nozzle of oil pump 79 Oil pipe ITo lower nozzle of oil ...

Page 92: ...1980SRX440 MEMO ...

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Yamaha SRX440 1980, Service Manual

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Summary of Contents for SRX440 1980

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