Yamaha 440 Service Manual

FOREWORDThis Service Manual has beenwrittento acquaint the mechanicwiththedisassembly. reassembly. maintenance. and troubleshooting procedures re-quir

1980SRX4403. Usingtheflywheelpuller, remove theflywheel assembly.F.Oilpump1. Remove the oil delivery pipes.2. Removethebolts andpumpdrive case.E.Prima

1980 SRX440:~1\10 I E:Forthermostatinspection.refer to3-5thermostat.2. Remove the intake manifold.3. Remove the exhaust pipe assembly.4. Remove the cy

1980SRX440b. Check oil seal lips for damage and wear.Replace as required.3. Bearing and oil seal installationa.Wheninstalling or removingleftcrankoil

1980 SRX440Deflection toleranceLeft sideCenter CenterRight side(left)(right)0.03mm0.04mm 0.04mm0.05mm(0.0012in)(0.0016in) 10.0016 in)10.0020 in)FWD<

8. Piston pin and bearing inspectiona. Checkthepinforsignsofwear. If anywearis evident. replace pin and bearing.1980 SRX440Tightening torque:First:10N

1980 SRX440Ring end gap free:Approx.7.0mm(0.28in)Piston clearance:Minimum" ..0.065mm(0.0026in)Maximum0.070mm(0.0028in)e. Wash piston in solvent a

1980 SRX440NOTE:------------Take care during installation to avoid damag-ing the piston skirts againstthecrankcase asthe cylinder is installed.12. Cyl

1980SRX4402/~',--------~/----------3e. Clean cylinder in solvent, then washwithhotsoapy water. Dry. Coatwallswithlightoil film.13. Cylinder insta

1980 SRX440c. Install the intakemanifold.Tighteningtorque:15Nm (1.5m-kg)c.Measurethegapwiththethicknessgaugebetweenthe raised boss on thepumpadjustpul

1980 SRX440Recommended grease:Lowtemperature grease(Esso Beacon325or Aeroshell grease#7A)Pump casetighteningtorque:10Nm(1.0m-kg)3. Installpumpwire, pu

1980 SRX4401. Play2.Adjuster3. Lock nutC.PrimarysheaveRefer to"5-1-B. Primary sheave".D.Flywheelmagento(For inspection. refer to'7-1-G.

.._---_._--1980 SRX4404. By moving thewaterpumphousing upanddown,adjustthebelttension.Adjusttheboltsothatthebeltdeflects4 mm(0.16in)whena force of 4 k

1980 SRX4404. Place the drive pawl, return spring,.ldrive plate spring, drive plate andtighten the thrust washer and nut.NOTE:----~------Grease the p

Intake silencerManualstarter handle1980 SRX440WARNING:-----------,Byturningoutthethrottlelever2or3turns,makesureitoperatescorrectly.V-beltTachometer c

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CHAPTER3.COOLINGSYSTEM3-1. COOLANT3-2A. Coolant level3-2B. Coolanttype3-2C. Draining the coolant3-2D. Replenishingthecoolant3-33-2. COOLING SYSTEM CHE

1980 SRX440CHAPTER3.COOLINGSYSTEM3-1.COOLANTA.CoolantlevelWARNING:-----------.Donotremovetherdiatorcapwhentheengineandradiatorarehot.Checkthecoolantle

1980 SRX440D.ReplenishingcoolantNOTE:----------__Before pouring thecoolantintothe radiator,checkthecooling systemfordamage,loosejointsor leaks.1. Loos

1980 SRX440rail suspensionto"5-3C.Installation1. Install the radiator and coolant hoses.2. Inspect the cooling system. (Refer to"3-2-ACoolin

1980 SRX440D4. Installtheseat and slide rail suspensionassembly.(Referto"5-3SUSPENSION".)5. Fillwiththecoolant. (Referto"3-2-0Replenish

SECTIONINDEXGENERALENGINECOOLINGSYSTEMCARBURETIONPOWERTRAINCHASSIS.~ELECTRICALAPPENDIX

1980 SRX4404. Install the impeller.3. Removethethermostat.Tighteningtorque:25Nm(2.5m-kg)5. Coat thematingsurfacesofwaterpumphousing and coverwithYAMAH

2. Installthecoolanthose.3.Inspectthe cooling system. (Refer to"3-2-ACoolingsystemcheck:")4. Fillwiththecoolant. (Refer to"3-2-0Repleni

CHAPTER4.CARBURETION4-1.CARBURETOR4-2A. Carburetor tuning4-2B. Overhauling ,4-5C. Troubleshooting.4-104-2. FUEL PUMP4-121980 SRX440D

1980 SRX440CHAPTER4.CARBURETION4-1.CARBURETORA.Carburetortuning1. Standard specificationThe carburetor is set atthefactorytorun at temperaturesofO°C t

1980 SRX4403. Starter cableadjustmentPull the starter cableoutertubeupward,and adjust the free playbetweentheoutertube end and adjuster to specifi-cat

1980SRX440DSparepilotjet: #90, #801. Pilot jet2. Turnthepilotscrewin andout1/4turnor less each time, andsetit in a positionwherethe engine idles faste

CAUTION:---------,Whenremovingthestartercable,takecaresothattherubbercap,coilspringandstartercabledonotfallofforarenotlost.AlsousespeciaI ca renottosc

1980 SRX4404-6NOTE:------------1. Hook the clip onto the float arm. andremove the fuel valve while taking carenotto drop it..2. The fuel valve plays a

CAUTION:----------,Neverattempttodisassemblethefol-lowingparts.1)Throttlevalve2)ThrottleshaftReason:1)Thethreadedportionofthescrewisclinchedaftertheth

1980 SRX4404)Blowtheairbentandslowcircuitswithcompressed air.jet3. Pilot air jetSlowcircuit2.MainairjetPe ..erjeteiletlitStarterjet circuit6)Blowthema

3. Reassembly and adjustmentCAUTION:-----------,1)Washallpartsincleangasolinebe-foreassembling.2)Alwaysusenewa-rings.3)Makesuremovingpartsrotateorslid

1980 SRX440(4) If any part is in good conditionbutfloat level isnotwithinthespecified range,correctfloatlevelby bendingthefloatarm tangslightly.r:CAUT

carburetorwithahardtool.Dustshouldbeblownoffwithcom-pressed air.2)Whenreinstallingthethrottlecable,makesu rethethrottleva Ive can befullyopenedandclos

1980 SRX440Trouble CheckpointRemedyAdjustmentCloggedpowerjetCleanClogged fuel pipeClean or replaceDirtyfueltankClean fueltankAir leaking into fuel lin

CHAPTER5.POWERTRAIN5-1. DRIVE5-2A. Sheave adjustment5-2B. Primary sheave :5-3C. V-belt..5-7D. Secondary sheave5-7E.Chain housing5-9F. Front axle5-135-

1980 SRX440CHAPTER5.5-1.DRIVEA.SheaveadjustmentUsethesheave gauge to checkthefollowing:Center to center distancebetweentheprimaryand secondary sheaves

1980 SRX440Tightening torque:7 Nm (0.7 m-kg)2. Sheaveoff-setadjustmenta. Remove the secondary sheave securingboltand washer.b. Placethesheave gauge ov

1980 SRX440NOTE:------------If bushing is installed tightly. remove the bu-shing using the bushing tool.b. Loosen the six bolts securing theprimary sh

1980 SRX440AltitudeSea level (Std.)High altitudeSettingparts(Upto1500m(5000It)) (About1500m(5000It) or morelParts No.90501-60579 90501-55296Color code

CHAPTER1.GENERAL1-1. EXTERNALVIEW.1-21-2. MACHINE IDENTIFiCATION1-3A. Frame serial number.1-3B. Engine serial number1-31-3. MAINTENANCE INTERVALS CHAR

1980 SRX440ShimSlider button-to-guide clearancec. Install thecomponentparts totheslid-ing sheave and the sheave cap.o2.wheninstallingthespacer and col

d. Installthesheave subassemblytoolandtighten the cap.e. Tighten the six primary sheave cap boltsand removethesubassembly tool.Tightening torque:11 Nm

Course Trail and tourLake surfaceSetting factor Position of spring seat TwistPositionof spring seatTwistIce snowStd.Std.No.2600PackedsnowStd.Std. Std.

1980SRX440b. Secondary spring tensionThe secondary spring tension can bechanged bymoving the spring positionfromthe free position in order to resetthe

1980 SRX440c. Loosenthechain tensioner and removethedrive, driven sprockets and chain.d. Removethebearing inner race securingscrew, and loosen the inn

Manyrough surfaces or unfavorablesnowconditions; the driven/drivesprocket ratio should be made larger.Few rough surfaces or bettersnowcon-ditions; the

1980 SRX440d. Install the drive and driven sprocketswithchain.Place the collarintothedrive sprocket.Tighten the drivesprocketnutanddriven sprocketbolt

1. Eccentric bearing installerI. Tighten the bearing inner race securingscrew.Tightening torque:6 Nm (0.6 m-kg)1',Frontaxle1. Removala. Remove th

1980 SRX4403. Insta lIationa.Wheninstallingthewheel sprocket tothefrontaxle. positionthewheelsprockets on thefrontaxle as shown.Use a press.115.6 mm (

1980 SRX4405-2.BRAKE.(?J'9.5 mm 10.37 ;nl ..,...~III:IIICD13.5mm(O.68inl~3. Removethebrake pads.Wearlimit:9.5mm(0.37 in)A.Disassembly1. Remove

1980 SRX4401-1.EXTERNALVIEWCHAPTER1.GENERAL1-2

1980 SRX440C.Reassembly1,Applyalowtemperature grease totheback up plateshaftandscrewcam,2, Installthebrake caliperwithbrake'padsto the chain hous

5-3.SUSPENSIONA.Removal1. Remove thetwofrontpivotshaftmounting bolts and four rear pivot shaftmounting bolts.1980 SRX440Wear limit: 10 mm (0.4 in)Slid

1. Stopper band settingThe height of thefrontsuspension canbe properly adjusted by changing thelength of the stopper band..1980 SRX4403) Donotdeformor

1980 SRX440NOTE:------------The rear stopper bandnormallydoesnotre-quire adjustment.Rear stopper band setting:3rdhole frombottom2. Rear springThe rear

1980 SRX440O. InstalIationGrease the slide rail suspension as indicatedby arrows in the illustration.For easy installationofthe slide rail suspen-sion

C.InstallationInstall drive track assembly as illustrated.(See5-1-F.Front axle and5-3.Suspensionsection)1980 SRX440The track tension should be so adju

1980 SRX4401. Rear.axlenutNo goodSlide runner1.AdjustingnutGoodSlide runnerNogoodSlide runnerorwarGapbetweenslide runnerand edge oftrackwindow.Track m

CHAPTER6.CHASSIS6-1. OIL TANK6-26-2. FUELTANK6-26-3. STEERING6-2A. Installation6-2B.Adjustment6-36-4. SKiS6-4A. Inspection:.6-4B. Installation6-41980

1980SRX440CHAPTER6.CHASSIS6-1.OILTANK1. Check the hose fromthetankto the oilpumpfor obstructions such as pinchingor other damage.2.It is advisablethat

3. Install the steering column on the frame.Before this operation. coat the steeringlowerand upper bearingwithgrease.Tightenthe nuts. and bend the loc

1980 SRX4401-2.MACHINEIDENTIFICATIONA.FrameserialnumberThe frame serialnumberis located on therighthand side of frame (justbelowthefrontof seat). The

1980 SRX4406-4.SKISA.Inspection1. Check the ski runner. ifwornexcessive-ly. replace.Tighten theboltuntil tight. then backout1/4turn.Then tighten the s

CHAPTER7. ELECTRICAL7-1. IGNITION SySTEM7-2A. Circuit diagram7-2B. Troubleshooting :7-2C. Ignition timing7-3D. Spark gap test7-4E.Ignition coil ,7-5F.

1980 SRX440CHAPTER7. ELECTRICAL7-1.IGNITIONSYSTEMA.CircuitdiagramI.'7,77®1f.1. C,D.I,"magneto2. Pulser coil3. Charging coil4. C.D.I.unit5.Ma

1980 SRX440Ignition coiltest1OKtI Ignition coil test (See 7-1-E."Ignitioncoil")lFaulty~-----tlReplace.C.D.1.unit1 · See7-1-H."C.D.1.uni

1980 SRX4404. Starting at T.D.C., rotate flywheel coun-terclockwise until dial gauge reads ap-proximately3-1/2needle revolutionsbefore-top-dead-center

1980 SRX440E.Ignitioncoil1. Coil spark gaptesta. Removetheignition coil from frame.b. Connect Electro Tester as shown.c. Connectfullychargedbatteryto

1980 SRX440will result in premature ignition orpower loss.@) Bad (Piston holed or seized)The metal shell end and insulatorshowsignsofoverheating. If m

1980 SRX440H. C.D.1.unitIn caseofignition failurewithall the abovesystem check-ups proving .in good order. re-place the C.D.I.unitassembly.I------£-~-

1980 SRX440I~'~IofA.0-V®t.Yellow5. Red2. Brown6.Flywheelmagneto3. Black7.Pocket tester4. White8.Set tester at"RX,"positionD.Voltageregu

1980 SRX440tive sideofoneofthe batteries. andconnecttheblack leadwire(B) to thenegative sideoftheotherbattery.Connect the red leadwire(C) (for test)of

1980 SRX440EveryCheckpoint20hrs. or40hrs. or 80 hrs. orWhenSeasonally400km800 km1,600kmnecessary(250mi)(500mi)(1.000milCoolantleakage0 0Operationofthe

1980 SRX440Theoilcaution circuit can be checked bysqueezing the brake lever.1. Oil level switch checka. Connect the pocket tester leads to theoil caut

CHAPTER8.APPENDIX8-1.SPECIAL TOOLS8-28-2.SPECIFICATIONS8-3A. General8-3B. Engine8-3C. Drive and track suspension8-5D. Chassis8-6E. Electrical8-6F.Tigh

1980 SRX4408-1.SPECIALTOOLS_____nu_---No. DescriptionTool No.1 Dial gauge90890-030972 Dial gauge standNo.290890-011953Dial gauge needle (56 mm)90890-0

8-2.SPECIFICATIONSA. GeneralNOTE: *...Newspecification(Comparedwith1979SRX440)19S0SRX440ModelSRX440DModel:Model(I.8.M.No.) •SRX440('SO) (SK6)F

1980SRX440P02031 J115 mm~1041[JjA~F__Crank pin outsidediameterx lengthCrank pintypeCrank bearing type (Left) xq'tvCrank bearing type (Center) xq&

1980SRX440•Autolubepumpwirefree play23±1 mm at idle•Oiltankcapacity2.5LiterOil gradeYAMALU8E2-cycleCooling system:ThermostatOpen-Close temperature60~6

1980SRX440D. ChassisFrame:MaterialAluminum+ SteelSteering system:Caster (skicolumn)25"Camber0"Ski length xwidthx thickness980x120x 2.0 mmSki

F. Tightening torquePart to be tightened[Engine]Spark plugCylinder headCylinder headFlywheelmagnetoCrankcaseupperandlowerTightening sequence8 511Threa

coCOoen;;UX..."Watertemperaturemeter lightTachometer light112V3.4WI(12V3.4W).~4~L~IO"_.'"'~8 L(12V34W)BIB/RSpeedometer light

1980 SRX4408-4.WIREANDPIPEROUTINGDIAGRAMCDWaler temperaturemetercable~.Wire harnessassembly3Speedometer4Watertemperaturemeter5 Tachometer te, pump dri

B.Lubricationintervals1980 SRX440EveryCheckpoint20hrs. or40hrs. or80hrs. orWhenSeasonallyOil/Grease40Qkm800km1,600kmnecessaryBrandname(250mil(500mil{1

1980 SRX4408-1034. Throttle cable35.Watertemperature meter cable36 Tachometer cable37. Towaterpump driven gear38 Brake cable39. Steering pad40. Route

r\~B---A641980 SRX440®8-1158 Throttle lever59. Left carburetor throttle cable (Upper,ide)60. Right carburetor throttle cable (Lower aidel61.Steeringpa

1980SRX440-MEMO-