Yamaha EX440D Supplemental Service Manual Download | Manualshive

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Summary of Contents for EX440D

Page 1: ...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 ...

Page 2: ...1980 EX440C CONTENTS 1 NEW SERVICE PROCEDURE 2 2 MAINTENANCE INTERVALS 3 3 SPECIFICATIONS 5 4 SPECIAL TOOLS 11 5 WIRING DIAGRAM 12 6 WIRE AND PIPE ROUTING DIAGRAM 13 1 ...

Page 3: ...n 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 counterclockwise until dial gauge reads approximately 3 1 2 needle re volutions before top dead cente r B T D C 6 Slowly turn flywheel clockwise until dial gauge reads specified ignition tim ing Ignition timing B T D...

Page 4: ...ection and breaks of oil pipes 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 Mixing adjuster pilot screw 0 0 Idling speed adjustment 0 0 Operation and adjustment of oil pump 0 0 Ignition ti ming 0 Cylinder compressions 0 a Muffler joints 0 0 Cylinder head exhaust pipe decarbonize 0 Spark plug condition gap and cleani...

Page 5: ...ICATION INTERVALS Every Lubrication point 20 hrs or 40 hrs or 80 hrs or When Seasonally Oil Grease 400 km 800 km 1 600 km necessary Brand name 250 mil 500mi 1 000mi ENGINE Starter case 0 Oil pump control box 0 0 Aeroshell grease 7 A or Esso Beacon 325 grease Pump drive cover 0 0 Oil in the oil tank 0 YAMALUBE 2 cycle oil l DRIVE Primary sheave weight 0 0 and roller pins Molybdenum disulfide Second...

Page 6: ... cu in Compression chamber type Dome Squish Head gasket thickness 0 5 mm 0 02 in Cylinder Material Cast iron sleeves aluminum Bore size 68 mm 2 677 in Taper limit 0 05 mm 0 0020 in Out of rou nd limit 0 01 mm 0 0004 in Piston Piston skirt clearance Measuring point 0 045 0 050 mm 0 00 18 0 0020 in l 20 mm from piston skirt end Piston oversize 1st 68 25 mm 2 687 in 2nd 68 50 mm 2 697 in 3rd 68 75 mm...

Page 7: ... q ty Labyrinth sea l X 1 pc Right X q ty FWJ 32 48 10 X 1 pc Carburetor Type manufacturer quantity BD44 X 38 KEIHIN X 1 pc I D Mark 8H600 Main jet M J 1 45 Main air jet MAJ 180 Power jet Pw J 150 Power air jet PwAJ 200 Slow jet S J 90 Slow air jet SAJ 100 Pilot screw P S 1 5 8 Starter jet StJ 160 Float height 15 2 mm 0 59 0 08 in 3 0 12 Idling engine speed 1 500 r min Main jet setting chart 30 C ...

Page 8: ...sing oil quantity Chain housing oil grade Brake Type Brake pad thickness Brake pad wear limit Gap between pad and disc V type 0 3 mm 0 012 in 10 4 mm 0 409 in 8 0 cm kg 6 9 in Ib Dark blue 0 20 0 25 mm 0 0079 0 0098 in 1 65 1 87 mm 0 0650 0 0736 in 1 44 0 95 1 19 cc 0 032 1 0 0402 oz 7 84 8 89 cc 0 2651 0 3006 oz 25 1 mm 0 98 0 04 in at idle 2 8 Liter 3 US qt YAMAlUBE 2 cycle V belt automatic cent...

Page 9: ...e 780 at 20 C 68 F White Red Black Charging coil resistance 1130 at 20 C 68 F Brown Black 290 at 20 C 68 F Blue Black Ignition timi ng B T D C 1 6 0 1 mm 0 060 0 004 in Ignition Model Manufacturer CM62 20 H ITACH I Spark gap 9 mm 0 35 in 300 r min 11 mm 0 43 in 3 000 r min Primary winding resistance 0 150 at 20 C 68 F Secondary winding resistance 3 6kO at 20 C 68 F Diode Yes or No No Spark plug Ty...

Page 10: ...ing housing M10 P1 25 6 5 m kg 47 ft Ib Secondary shaft and Bearing collar Socket screw 0 6 m kg 4 ft Ib Brake caliper and Housing chain M10 P1 25 5 0 m kg 36 ft Ib Installation of drive chain sprocket M14 P1 5 6 0 m kg 43 5 ft Ib Nut Installation of driven chain sprocket M10 P1 25 5 0 m kg 36 ft Ib Bolt Chain housing and Frame M8 P1 25 2 5 m kg 18 ft Ib Installation of front axle L H M22 P1 0 8 5...

Page 11: ... M10 P1 25 4 0 m kg 29 ft Ib Use lock washer and wave washer Steering lower bracket MB P1 25 1 5 m kg 11 ft Ib Use lock washer and LOCK TITE Installation of steering column 1 2 M6 P1 0 0 9 m kg 6 5 ft Ib Use lock washer Steering relay ass y M10 P1 25 3 0 m kg 22 ft Ib Use cotter pin Level gauge securing bolt M6 P1 0 0 25 m kg 1 B ft Ib Screw to install the front of seat M6 P1 0 0 5 m kg 3 5 ft Ib ...

Page 12: ... 6 Primary fixed sheave puller 7 Sheave sub assembly tool 8 Bushing tool 9 Sheave gauge 10 Eccentric bearing installer 11 Main switch ring nut tool 12 Pocket tester 13 Electro tester 14 A C Regulator checker 1980 EX440 7 8 13 _3 0 11 Tool No 90890 03097 90890 01195 90890 03098 90890 01803 90890 0 1804 90890 01806 90890 01817 90890 01848 90890 01235 90890 01859 90890 0 1858 90890 0 1877 90890 01875...

Page 13: ...I0 I 16 0 Loo I III 8 l I _It Gy Gy GI y Main switch Headlight beam switch G f y 1 Brake light switch G L _8 1_ G Y o Voltage regulator T I U R C D I unit o 8 I LI 8d IW R Iy oW L C D I magneto Spark plug C1I xJ 2 G C l G xJ l S Ignition coil Color code G Green B Black Y Yeliow L Blue o Orange Br Brown Gy Gray W R White Red G Y Green Yellow B W Black White co CO o m X o o ...

Page 14: ...buretor 20 To engine crankcase 21 To oil pump 22 To tachometer gear unit 23 To carburetor 24 Clamp 25 Clamp 26 Head light lead wire 27 Speedometer cable Gray 28 Tachometer cable Black 29 Spring 30 Shroud stopper u 1 I V8 1t __ J 31 Starter w ire 32 Brake wire r I I I I f l 33 Throttle wire 34 Pump wire 35 Clamp 36 To tachometer gear unit 37 To speedometer 38 To tachometer Tank NOTE Tip of clip sho...

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