1981 KAWASAKI INVADER INTRUDER 440 SNOWMOBILE Repair Manual

INVADER/INTRUDER Page i .... Kawasaki PARTS CATALOG MODEL IDE NT IF ICATION Snowmobile models are identified in the parts catalog by Mark et ing Code nu mber s. The chart conta in s the Marketing Cod e alo ng with the Marke ting Name for ident if icat ion cross referenee, M ARKETING N AME MARKETING COD E ENGINE MOD EL INVA DER 440 SS440-A3A TC440A-C201 INTRUDER 440 ST440-A4 TA440C-D20 1 INTRUD ER INVADER © 1980, K aw asak i Mot ors Corp., USA First Pri nted: August 1980 (2m) Snowmobile Product Services- KA L Pr inted in USA

INVADER/INT RUDER P age ii Kaw asa ki CA TALO GUE DES P IECES IDENTI FICATION DES MODELES Les rnodeles de motoneiges sont identifiables dans Ie catalogue des pieces detachees par leurs nurneros de code marchands . On trouvera ces codes dans Ie tableau ainsi que Ie nom marchand du modele correspondant de motoneige. DENOMI NATION MO DELE MOTEUR MODELE INVADE R 440 SS440-A3A TC440A-C20 1 INTRUDE R 440 ST440- A4 TA440C-D201 INV ADER INTRUDER -

INTRODUCTION INVADER/INTRUDER Page iii GENERAL .~ ·r 'i' " .. . '. -_.. - ._...... m ."... : .'b, lO ' •• '• ----- _ _ o Locate the system or component that requires replacement pa rts in the pictorial i ndex , and t urn to the p age number indicated fo r the exploded view and parts list . Use the Parts Cat alog by following the expla nati ons listed below. This cat alog cont ain s the exploded views and repl acemen tp arts li st s f o r servicea ble components of Kawasaki snowmobiles. Always use GENUINE K AWASAKI parts for replace ment to maintain the standards of r eliabilitv, performance, an d safety that was designed into K awas aki snowmobiles . o IN DEX ... " • EXP LODED VIEW Each serviceable pa rt in the exploded v iew is identified by a reference number . Use th e reference number to locate necessary part informati on in the PARTS LIST BR E AKDOWN. Parts not shown disassembled in the exploded view are no t sold sep arat ely, but are included in the complete uni t or ne xt higher assembl ies as shown in the illustration. Reference numbers conn ected to broken lines indicate assembly part numbers. All of the co mpo nents inside the broken lines are included w hen the assembly pa rt number is ordered . Jl ~ -, {)- 1 " I/Y ~ : ' .'~ ~ ,I~K,/ . ~. ~ ,.-Sfj r- r "'~" r · n-e 1~ I -J . , ~ Parts drawn with dotted l ines are reference components used to show loca tion of assemblies or proper positioning of replacement parts. Refer to th e pictorial i nde x to find the page nu mber and exploded view for the reference components. • PAR TS LIST BR E AK DOWN Always use the complete Kawasaki part number to order parts. Avoid shi p ping error s by ensuring the entire part number is leg ibl e. Items in the descri ptio n col umn preceded by a black d ot i ndicate that thi s part is i ncl uded in the above assembl y. ::: ~,~ ~~ _'HG._ •. _, "'''D1.~.,'' .- 5U ( .... [._ ~~- DA_R 11""":/0 • . .. ,~ ,..... ,~ -otT.l/S14 .]$G -~, .....-Il._ •. ~ _'NG._o< ._- S&.uvl.. ...... " ~ O'UoTE ._ " _.- ~. ~ " .. _.- ..... ,._.~)O ~M_ HUT.--.li/" " , ...... ,JM .oI.T.)jW. loI .]5G " . 'n -n o. .. . ' ao- :MO:l "" .. •. ~ $T~"._ . '~.3Ul /' f---- -- ,. r;, _,,-, _ r..... s..- ..._ Go_!. __ ._ It It4l NAn ll Dil ~. ~ 561020· 071 " " 11O JoC· 3Slli6 eo , 561020-1131 " .. 11034- 3598 ~ , 156019· 201 " : 11034-3605 · T56019-011 " lUeoe::lS " · TS1001-IJO " 1 l:=:: " e B7001 -9 10 :: ., · 8 11(8)610 118llA0814 .. · 11011lJ61S ~ , :::m :: :: , 11l1lO6lZ . ~ """" , 11"'1116 :; 110106)0 .. l lleaAlnt1 , m= :: 11"'1236 '" : , 119lWlf101l , :~= :: . ll=~g '" l ~ .. '''''''' , 1198A0812 ~: " 110Gt1628 a '" 1I9llA0816 e 110G086J se l 1l91lAOll1 6 " l 1loP06lO " 1I91lAll816 .. l1oo1-lOl 4 " ~ 1I 91lAll818 ~ ! ll 004 -J01 O 1: 119aAll1l22 1I 004 · 1015 , "..... , 11005-)015 " ~ \1Q ." ~. 11ClOt-lOOl .. 11009-JOO5 .. , l::: == .. When Right Hand and Left Hand d escriptions are used , t h ese position s are identifi ed whe n lookin g from t he back to the front of the snowmob ile . (EX AMPL E: T he manual starter is on the Right Hand side of the sno wmo bite.) The q uanti ty colum n indicates whic h snowmobile model the part is used on and the total qua nt it y req ui red for r epai r of the snowmobile . ( EX AMPLE : The exploded view of the ski shows one ski, however, the q uantity column contains t he amo u nt required to re pai r both skis.l Each part nu mber is listed numerically in the index located at th e rear of this catalog. It cont ai ns th e page nu mber, for pa rt location refere nce, along with q uantit y u sed per m od el. U se t he nu merica l index to determ ine co mponent location wh en o nly the par t number is k nown . e NUMERICAL PARTS INDEX ABBREVIATIONS m ... .. .. Pounds Square Inch Power Take Off . .. Right-H and _. .Reference _.. St andard .. .. .. ... .. .Tee _.. .. .. . . .. Vo lt .. ...... ... ......... Width or Watt s PSI PTa RH Ref Std . T V W . .. . Left -Hand . Mi les Per Ho ur . Meter .Mill imeter _. Number ........... .. Natio nal Coarse __ Outsi de Circumference _ _Outside D iame te r Op tional mm No NC OC 00 .... OPt LH MP H AR . .. .. _ ...... .. •.. .. A s Req uired A ssy .. ........ • ... . A ssem b ly CA Cut Away Carb . . Carbu retor CO l .. Capac itor D isch ar ge Ig ni t ion GE .. _ _. .. . General Electr ic hex .. Hexagonal 10 .. _.... . In tern al Diameter K PI-l _Kilnmet ers Per Ho ur

INVADER/INTRUDER Pa ge iv INTRODUCTION GENERA LITES .., Le present catalogue contient les vues det aillees des pi eces internes et les list es de pieces detachees pour I' entretien des mot oneiges Kaw asaki . N'u t ilisez que des pieces de remplacement d 'OR IGI NE KAWASAK I af in de maintenir les standards de fiabili te, de perfo rmance et de secutite qui sont Ie pro pre des moto neiges Kawasak i. Pou r uti liser Ie catalogue de pieces detac hees, suivez les instructions ci-dessous. o REPERTO IR E Loca lisez Ie svste rne ou l'elernent necessit ant des pieces de remp lacement dans Ie reperto ire illustre et to urnez a la page ind iqu ee a laqu ell e vous trouverez la vue deta ilee et la liste de pieces correspon dantes. o -~.,... • ,or .•iJ-:-" ~ -=' !:!...... , l ," 8 VUE DE T AILL EE MONT RANT L ES D IFF ERE NTES PI EC ES DANS LEU R POSITION CO RREC TE Chaque piece remplacable est identif iee par un nurnero de refer ence. Util isez ce nurn ero de reference pour reperer les renseignements se rapportan t a cett e pie ce dans la NOM ENCL ATUR E DES PIECES DETAC HEES. Les p ieces n'appa raissant pas dernontees dans la vue detainee ne sont pas vendues separernent ma is font part ie d' un bloc comp let ou de I'ensemble suivant Ie plus proc he, comme ind ique sur I'ill ustrat io n. Les nurneros de reference relies a des lignes brisees indiquent les nurneros de p ieces d'u n ensemble. Tous les elements situes a li nter ieu r des lignes brisees sont comp ris dans la commande porta nt Ie nu rnero de piec es de I'ensemble. !:}-, L es p ieces dessin ees en po i nti l le sont des elem ents de reference servant a montrer I'emplacement des ensemb les ou Ie placement cor rect des pieces de rechange. Referez-vous au repertoire illustre pour tro uver la page port ant la vue detaill ee des elem ent s de reference, . NOMENCL ATU RE DES PIECES DETACHEES Indiq uez toujo urs Ie nurnero de piece comp let Kawasaki pour voscommandesde pieces. Assurez-vous que Ie nurnero entier est par faite ment lisible afin d'eviter toute erreur a l'expedit ion. Les articles precedes d' un point noi r a la colonne " Descri pt io n" indique nt que ces pieces f ont part ie d'un ensemb le. · • . '. '-3rI02 " lIoC:Al1!11 • P1On ·Jti,31 • 3I ':IO-3W1 10 ' »:lI·J!IOl ,,~ , ...... ,~ U . '".MOO .,~ .,""'" M/Sf<'NG. _ P'lIl OU . .... SUIVI._ ~" _' .:L-. )< . ,-"5 IOll.~":M . J.SO WA$H EIl • .-"" _ ING._' st. U V( . ...... .......,E. _._ -.-.;11. .... IInA!HllI._ .....'.-..14,. ... .n .-.. .....'. ... , .w.)< . )!iO ~" /f- ' --- - ,. 0. _ '-- - c._ !io. _ _ c._ ....... _ Quand il existe des descri ptions pour la Droite et la Gauche, ces positi ons sont ide ntifi ees en regardant la motone ige de l'arriere vers I'avant. (EX EM PL EI Ie dernarreur a main se trouve du cote Droit de la moton eige.l La co lonne q uan t it e indique Ie modele de mot oneige sur lequel la piece est ut ilisee et Ie nombre tota l de pieces necessaires a la reparatio n de la motoneige. (EXEMPLEI La vue detai nee du sk i .rn on tre un seul ski, toutefois, la co lon ne quant ite indique tout ce qui est necessaire a la rep aratio n des deux skis.) • NO ME NCLATURE DES PIECES DETACHE ES Ch aqu e nurn ero de p iece f ait part ie d' une list e par ordre de grande ur nu rnerique, dans la nome nclatu re qui se trou ve a la fi n du catalogue. Elle 'com prend Ie nurnero de la page, la refere nce pou r l'ernplacernent des pieces, ainsi que la qua ntite necessaire par modele. Lorsqu'onlne co n nait que Ie nurnero de la piece, utiliser la nomenclatu re pou r deter miner I'e mplacement de l'elernent. tUllt IllUl .Alln '.DU ~, ~ S6102'll-Oll " " 110:M-lS86 20 : S61112'll-llll " ': 1JOlt · 359S 20 ~=:::~~ ~~ 110)4_3605 " . : l1CBOB35 56 . 157001. 1)0 " ll 8AA08Zl aa : • T57lX11-9111 " : 1l8llol1081C " 1I0ll06 10 56 118llAll8\4 56 1l0e0r; 18 .. : tl8lA1 Ol6 :: , 110Kl622 :: I!lU I2!6 ! ,,-.. a 11 ....1216 " I I0000lO :: , IllllA12Z8 ::: 11010635 . 118llA1Zll> : ,, -., 56 : ",..,.. , ,,-., :: ll 9lAQe1O " : 1l l*llll 12 , 1198AOll lO .. """"" . , 119flAO(l 12 :: " 1I0G0628 . '" 1198AOll16 z 11llGlle6J ~ l 1191lA0811i " : 110P0620 11'BAOlll li .. 1l 00 1- lO14 56 a 119llA0818 ': e 11004~30'0 56 a 1198A082Z I 1I004·11 15 56 z 1198A0840 ~: ~ 11005-3015 56 ~ 119llA10 14 ll009~JOOZ .. :l!~!~Z8 ll009~300S ~ ! !!~-:m> ABR£VI ATI ONS PSI . _ Livre-Mes ure-Ponce PTO (PDM ) __ .Prise De Mouvement RH .._ _. _.. ...... Dr oite Ref _. Reference Std .... • _. . . • _ Standard T .._ , _.F errue ente V . . _. _ _. _. . . _. Volt W . . _. ... . .. . .•.. .Largeur or Watts .. ....... . Gauche ............ Milles iJ L' hevre Metre .. .. Mi lli rnetre s Nurn ero Nati on al Coarse . . Circonference Ext erieure ... Di arnetre Ext er ieur . Opt io nne l m mm .. _.. . . . _. _ ._. No NC OC OD (DE) Opt .. LH MPH AR _. ..• ..... __.. Commo Requis Assy . . _........... . _. __ Ensemble CA _. _. •. _ _.. _ Coupe Carb _............ Carburateur CDI _ _. . Allumaqe El ectrost atique GE _.. ... General Elec tr ic hex . _ Hexagonal ID . . •_.. _ Di arne tr eI nter ieu r KPH . __ . Ki lo metre a L'nevre

INDEX 1. Engine Mount & Exhaust Page 1 2. Instruments , Lights & Wiring Page 3 3. Controls & Switches Page 5 INVADER/INTRUD ER Pagev 4. Drive Converter Page 7 5. Driven Converter ................... Page 9 6. Chaincase & Jac kshaft Page 11

INVADER/IN TRUD ER '-.. vi INDEX 7. Brake (SS440) Page 15 8. Brake (ST440) Page 17 9. Suspension 1/2 (SS440) Page 19 10. Suspension 2/2 (SS440) Page 23 11. Suspension 1/2 (ST440) .............. Page 25 12. Suspension 2/2 (ST440) " Page 29

INVADER/INTRU DER INDEX Page vii 13. Drive Shaft Page 3 1 16. Chassis 1/3 ....................... Page 37 14. Sk i & Sp ind le Page 33 17. Chassis 2/3 ..................... .. Page 41 15. Steering ......................... Page 35 18. Chassis 3/3 ....................... Page 43 -

INVADE R/INTRUD ER INDEX Page viii 19. Hood (SS440) Page 45 22. Seat & Console (ST440) Page 55 20. Hood (ST440) Page 49 23. Fuel System Page 51 ." 21. Seat & Console (S5440) Page 53 24. Lubrication System Page 61

INVADER/INTRUDER INDEX P age ix 25. Chassis Coolant System Page 63 28. Carburetor Page 71 26. Cables Page 65 29. Cylinder Head & Cylinder (SS440) Page 75 27. Electric Start (ST440) Page 67 30 . Cylinder Head & Cylinder (ST440) Page 77

INVADER/INTRUDER INDEX Page x 31. Crankcase , Page 79 34. Fan Cooling System (ST440) Page 85 (j) I,• 32. Piston & Crankshaft Page 8 1 35. Engine Coolant System (SS440) Page 87 L J ~ 33. Engine Gear Case Page 83 36. Magneto 1/2 (SS440) ................ Page 89

1981 KAWASAKI INVADER INTRUDER 440 SNOWMOBILE Repair Manual

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