1980 EX440

CONTENTS

1. MODIFiCATIONS 2
2. NEW SERVICE PROCEDURE 5
3. MAINTENANCE INTERVALS 6
4. SPECiFiCATIONS 8
5. SPECIAL TOOLS : 14
6. WIRING DIAGRAM 15
7. WIRE AND PIPE ROUTING DIAGRAM 17

-1-
1980 EX440

1. MODIFICATIONS 3. Spark plug holder

(Compared with 1979 model EX440) (8G9-23885-00)
For better saleability. the spark plug
A. ENGINE holder is provided as standard (which
There are no particular changes. is an option for the 1979 model).

B. DRIVE
There are no particular changes.

C. CHASSIS
1. Tune-up label
(8J8-777 43-00)
As an aid to service. a tune-up label is
attached to the drive belt guard.

4. Rear bumper
(8E7-77341-00 ----> 8J8-77541-00)
For better strength, the pipe diameter is
rncrease rom . mm 0 . mm.

8J8-77 541 -00 can be used on both

1979 and 1980 models.

D. ELECTRICAL
1. Spark plug
2. Throttle
(94701-00063 ----> 94701-00046)
a. To keep the throttle cable end, which is The spark plug has been changed to a
held by the throttle lever, from contact- type because it is more easily available
ing the throttle grip, a collar is mounted in the market and does not affect engine
and the lever is properly curved. performance adversely.

B-9EV (N.G.K.) ----> B-9ES (N.G.K.)

Interchangeability: Yes

2. COl magneto
(8E7-85500-10 ----> 8J7-85500-1 0)
Lever (8GB-42138-00 ----+
Collar (90387-22726l BJ5-42138-00)
For better durability and easier service,
the number of pulsers is decreased from
2 to 1:
Lever (8J5-42138-00) and collar
(90387-22726) can be used on both Interchangeability: No
1979 and 1980 models.
Lever (8G8-42138-00) can not be used For the ignition timing adjustment. refer
on the 1980 model. to "2. New service procedure."

-2-
 1980 EX440

3. COl unit 4. Main switch

(8H6-85540-10 -+ 8J7-85540-10) (898-82508-20 -+ BJ7 -82508-20)
Due to change in the COl magneto. the For better safety, the circuits of the
circuit is modified. headlight, meter light and taillight are
modified so that they are turned on as
Interchangeability: No long as the engine is in operation, and
their positions are changed.

'79 model '80 model

\ Lead wire
color Gray Orange Red/Blue Blue/White Red/White Blue
I"'" Lead wire
cclor Black Black/White
Position '\. Position -""

OFF ¢ OFF

ON ON/LIGHT

LIGHT

.
oran\8
II ~BraCk
-. VI- d IS Black/White
II
00
Blue __ >...\... II

~T
Red/Blue Bfue/White
I
Gray

Interchangeability: No

5. Wire harness Wire harness ass'v:

For better safety, the circuits are 8G6-82590-20 -+ 8J7 -82590-20
modified so that the headlight, meter Wire harness ass'v 2:
light and taillight are turned on, when- 8G6-82580-20 -+ 8J7-82580-20
ever the engine runs. (Refer to "6. Wir-
ing Diagram.") Interchangeability: No

-3-
1980 EX440

6. Tether switch creased, by which the durability and

(S9S-S2550-00 ---> SJ7-S2550-00) strength of the cap is also increased.
To prevent the switch from coming off The ring is provided with a hook so it
easily, the rubber cap thickness is in- can easily be hooked to the clothes.

79 model

'SO model

Hook is added

Increased thickness
E

Interchangeability: Yes

7. Headlight unit 12V 60/60W ---> 12V 45/40W

(SE7-S4310-40 --->SH7-S4310-41)
The headlight is modified so that it . Interchangeability: No
meets the European regulations.

-4-
 1980 EX440

2. NEW SERVICE Ignition timing (B.T.D.C.)

PROCEDURE 1.6 ± 0.1 mm (0.060 ± 0.004 in)
(New service procedure applied to the 1980
EX440)
7. Check the marks on flywheel and pulser
Ignition timing for alignment.
1. Remove the recoil starter assembly.
2. Remove the right side spark plug and
screw the dial gauge stand into the
spark plug hole.

Tool name Tool No.

Dial gauge stand 90890-01195

3. Insert the dial gauge with needle into

the stand.

Tool name Tool No.

Dial gauge 90890-01252 If not aligned. adjust ignition timing as
Dial gauge needle 90890-03098 follows:

a. Loosen the pulser set screws and turn

achieved.

4. Rotate the magneto flywheel unit 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. NOTE: - - - - - - - - - - - - - - '
Tighten the set screw on the dial gauge If the marks can not be aligned by this ad-
stand to secure the dial gauge assemb- justment. remove the flywheel rotor and
ly. Rotate the flywheel back and forth to turn the base (stator) assembly.
be sure that the indicator needle does
not go past zero.
5. Starting at T.D.C., rotate the flywheel
counterclockwise until the dial gauge
reads approximately 3-1/2 needle re-
volutions before-top-dead -cente r
(B.T.D.C.).
6. Slowly turn the flywheel clockwise until
the dial guage reads specified ignition
timing.

-5-
1980 EX440

b. Tighten the pulser set screws. NOTE: - - - - - - - - - - - -

The timing light should be used to check if
8. Remove the dial gauge and stand. Re- the marks on the rotor and base are aligned
place the spark plug and recoil starter. when both are replaced with new ones. the
marks should align at any specified timing.
Tightening torque
Spark plug:
28 Nm (2.8 rn-kq. 20 ft-lb) ,
Starter assembly:
7 Nm (0.7 m-kq, 5 ft-lb)

3. MAINTENANCE INTERVAL
[PERIODIC MAINTENANCE]

Every
20 hrs. or 40 hrs. or 80 hrs. or When I
Check point Seasonally
400km BOO km 1.600 km necessary
{250mi} (500mi) (1.000 mil
ENGINE:
Tightness of bolts and nuts a a
Bends. cracks and wear a a

Loose-connection and-break f ,..

Loose connection and breaks of oil pipes a a

Loose connection and breaks of oil delivery pipe a a
Manual rope starter system a . a
Carburetor .

• Operation of starter jet a a

• Mixing adjuster (pilot screw) a a
• Idlil)g speed adjustment
Operation and adjustment of oil pump a
a a
a
Ignition timing .a
Cylinder compressions a a
Muffler joints a a
Cylinder head/exhaust pipe decarbonize a
Spark plug condition, gap and clea-ning a a
Tightening of the cylinder head .... a
DRIVE:
Tightness of bolts and nuts a a
Wear on slide runners a a
Primary drive system a . a
V-belt a a
Secondary drive system a a
Sheave distance a a
Sheave offset a a
Brake pad wear a a
Brake operation and adjustment a a
Guide wheel rubber a a
Wear of drive track wheel sprocket a a
Drive track adjustment a a
Breaks in drive track a a
Bends in front and rear axles a a
Checking of lock washers a a
Drive chain adjustment a a
Drive chain oil level a a

-6-
 1980 EX440

Every
20 hrs. or 40 hrs. or 80 hrs. or When
Check point
necessary
Seasonally
4QOkm 800km 1.600 km
(250 mil (500 mil (1,000 mil
BODY:
Tightness o~ 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
Voltage 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

•• ReLigliteli eve,y 16 !lOUiS fiUllitlie fiiSl ase.

[LUBRICATION INTERVALS]

Every
20 hrs. or 40 hrs. or 80 hrs. or when Oil/Grease
Lubrication point
necessary
Seasonally Brand name
400km BOOkm 1.6'00 km
(250 mt} (500 mil (1.000 mil
ENGINE:
Starter case 0
Aeroshell grease #7 A or
Oil pump control box 0 0 Esso Beacon 325 grease
Pump drive cover 0 0
Oil in the oil tank 0 YAMALUBE 2-cycle oil
DRIVE:
Primary sheave weight
and roller pins 0 0
Molybdenum disulfide
Secondary shaft and snowmobile grease
0 0
sliding sheave
Front axle housing 0 0
Shaft 1 and shaft 2 Light all-purpose grease
(Slide rail) 0 0

Drive chain oil Gear oil API "GL-3"

0 0
replacement SAE #75 or #BO
BODY:
Steering column lower
bearing 0 0 Light all-purpose grease

Steering column upper

0 0 Motor oil
bearing
.
Steering links 0 0
Ski column 0 0
light all-purpose grease
Ski wear plate 0 0
Ski retaining pin 0 0
Brake wire and stopper
0 0 Esso Beacon 325 grease
and brake lever

-7-
1980 EX440

4. SPECIFICATIONS NOTE: * ..... New specification

General (Compared with 1979 EX440)

Model:
Model (I.B.M. No.l * EX4401'BO)18J8)
Frame 1.0. & starting number
* BG6-050101
Engine 1.0. & starting number 55433-050101
*
Dimension:
Overall length * 2,550 mm (100.4 in)
Overall width (std) 980 mm (38.6 in)
Overall height (w/windshield) 995 mm (39.2 in)

Engine

Description:
En~ine type Fan cooled two-stroke 7-port torque
induction. twin cylinders
Engine model 55433
Displacement 433 em' (26.42 eu.in)
Bore X Stroke 68 X 59.6 mm (2.68 X 2.35 in)
Effective compression ratio 7.0: 1
Starting system Recoil hand starter
Ignition system C.D.1.
, "A,
-" "

,A,

Combustion chamber volume {with spark plug) 24.6 em' (1.50 eu.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 round limit 0.01 mm (0.0004 in)
Piston:
. Piston skirt clearance (Measuring point) 0.045 ~ 0.050 mm (0.0018 ~ 0.0020 in)
(20 mm from piston skirt end)
Piston oversize 1st 68.25 mm 12.687 in)
2nd 6B.50 mm 12.697 in)
3rd 68.75 mm 12.707 in)
4th 69.00 mm (2.717 in)
Piston pin outside diameter X length ,p18 X 55 mm (,p0.709 X 2.17 in)
Piston ring:
Piston ring design (Top) Keystone
(2nd) Keystone
Ring end gap Iinstalledl I'Fop) 0.35 ~ 0.55 mm (0.014~ 0.022 in)
(installed) (2nd) 0.35 ~ 0.55 mm (0.014 ~ 0.022 in)
Small end bearing:
Type Needle bearing
Big end bearing:
Type Needle bearing
Crankshaft:
Crankshaft assembly width (A) 174 ± 0.1 mm (6.85 ± 0.004 in)
+0 ( +0
IF) 56 -0.05 mm 2.205 -0.002 in)
Crankshaft deflection (D) 0.03 mm (D-1) 0.04 mm (D-2)
0.04 mm (D-3) 0.05 mm (D-4)

-8-
 1980 EX440

Connecting rod large end side clearance (C) 0.25 - 0.75 mm 10.010 - 0.030 in)
Connecting rod small end deflection (PI 2.0 mm (0.079 in)

DA

r I

Crank pin outside diameter X length 24 X 55 mm (0.945 X 2.165 in)

Crank pin type Solid shaft assembly type with serration
Crank bearing type (Left) X q'tv #6306 special X 2 pes.
(Center) X q'tv #6206 special X 2 pcs.
IRight) X q'tv #6206 special X 1 pc.
Crank oil seal type ILeft) X q'tv FWJ-32 78 9.5 X 1 pc.
(Center) X q'tv Labyrinth seal X 1 pc.
(Right) X q'tv FWJ-32 48 10 X 1 pc.
Carburetor:
I"y"eBl'manUTaciurerTquantlty 8D44 X 38 KEIHIN X 1 pc.
I.D. Mark 8H500
Main jet (M.J.) #145
Main air jet (MAJ.) #180
Power jet (Pw.J.) #150
Power air jet (PwAJ.) #200
Slow jet IS.J.) #90
Slow air jet ISAJ.) #100
Pilot screw (P.S.) 1-5/8
Starter jet (St.J.) #150
Float height 15 +2 mm 10.59 +0.08 in)
-3 -0.12
Idling engine speed 1.500 r/min
Main jet setting chart:

__________ Tempe;~;~re - 30°C -czo-c '0 C 20e

Altitude ______________ (-22°Fl 1-4"F) (50' F) 168'- F)

Sea level #140

- 600m (2000 Itl #140

-- 1200m (4000 ft) #135

- , 800m (6000 ft) #130

/,/135

-- 2400m (8000 ftl

#130

-- 3000m (10000 ftl or more

#125·

• Change the starter jet to #95 or /,1100.

-9-
1980 EX440

Intake reed valve:

Type V type
Bending limit 0.3 mm 10.012 in)
Valve lift lOA mm IOA09 in)
Tightening torque 0.8 Nm 18.0 cm-kq. 6.9 in-Ib)
Lubrication:
Autolube pump - Color code Dark blue
- Minimum stroke 0.20 ~ 0.25 mm 10.0079 ~ 0.0098 in]
- Maximum stroke 1.65 ~ 1.87 mm 10.0650 ~ 0.0736 inl
- Reduction ratio 1/44
- Output Min./200 strokes 0.95 ~ 1.19 em' (0.0321 ~ 0.0402 oz)
- Output Max./200 strokes 7.84 ~ 8.89 em' (0.2651 ~ 0.3006 oz]
Autolube pump wire tree play 25 ± 1 mm (0.98 ± 0.04 inlat idle
Oil tank capacity 2.8 Q
Oil grade YAMAlUBE 2-eyele

Drive and track suspension

Transmission:
Type V-belt automatic centrifugal engagement
Drive ratio 3.5: 1 ~ 1 : 1
Engagement rpm 2,900 ~ 3,300 r/min
Primary spring:
Part No. 90501-45534
Color code Blue/Green
___________ 0_-

. ,~",,~.

Part No. 90508-45286

Color code Yellow
Secondary spring pre-load (twist) 150 0 (Hole No. 11
Sheave distance 270 +0 mm 110.6 +0
-3 -0.12 in)
Sheave off-set 5.5 ± 0.5 mm 10.22 ± 0.02 inl
V-belt width and outer line length 31.6 x 1,099 mm (1.24 x 43.3 in)
V-belt wear limit 26 mm 11.02 in)
Track suspension:
Type Slide rail suspension
Damper type Oil and gas damper
Spring color code No. painted
Slide runner wear limit 10 mm lOA in)
Track width 380 mm 115 inl
Track deflection 25 ~ 30 mm/1 0 kg 10.984 ~ 1.18 in/22 lb)
Lnegth on ground 850 mm (33.5 in)
Wheel sprocket material and number of teeth Polyethylene BT
Stopper band lenqth 214 mm (8.4 inl 13rd hole from the bottom I
Secondary drive:
Type Chain (#35-3)
Reduction ratio 29/17 (1.706)
Chain pitch X Number of links 9.525 mm 10.375 in) X 68l
Free play 10 +5 mm 104 +0.2
. -0.08 in)
-2
Chain housing oil quantity 320 em' (10.82 oz]
Chain housing oil grade Gear oil API "Gl3" ISAE #75 or 80)
Brake:
Type Floating pad type disc brake
Brake pad thickness 13.5 mm (0.53 in)
Brake pad wear limit 9.5 mm (0.37 in)
Gap between pad and disc 0.15 mm (0.006 in)

-10-
 1980 EX440

Chassis

Frame:
Frame design & material Aluminum + Steel
Steering system:
Caster (ski column) 25'
Camber A'
Ski length X width X thickness 9S0 X 140 X 2.6 mm (3S.6 X 5.5 X 0.10 in)
Ski stance sao mm (31.5 in)
Ski Toe-out 0- 6 mm (0 - 0.23 in)
Steering linkage type Tie-rod
Lock to lock angle [ski} Right ski. t. 20.2' R: 27.6'
Left ski, L: 27.6' R: 20.2'
Lock to lock angle (steering column) Right: 46.5'
Left: 46.5'
Front suspension:
Type Leaf spring
damper type Oil damper
Fuel tank:
Capacity 30 Litre
Fuel grade Regular gasoline

Electrical
..
'0" -,-
Model/manufacturer • F2S0-7S/HITACHI
Voltage 12V
Pulsarcoil resistance • 7Sn at 20'C (6S'F)IWhite/Red - Slack)
Charging coil resistance • 113n at 20'C 16S'F)ISrown - Slack)
• 29n at 20'C 16S'F) (Blue - Black)
Ignition timing:
B.T.D.C. 1.6 ± 0.1 mm 10.060 ± 0.004 in)
Ignition:
Model/Manufacturer CM62-20/HITACHI
Spark gap 9 mm 10.35 in)/300 r/min
11 mm (0.43 in)/3,000 r/min
Primary winding resistance 0.15n at 20'C 168' F)
Secondary winding resistance 3.6kn at 20'C (6S'F)
Diode (Yes or No) No
Spark plug:
Type & Quantity • NGK S-9ES X 2 pes.
Spark plug gap • 0.7 ~ O.S mm 10.02S ~ 0.031 in)
Spark plug cap:
Type Rubber type with noise suppressor IT-112)
Noise suppressorresistance 5kn at 20'C (6S'F)
C.D.1. unit:
Model/Manufacturer • TIAOl-30/HITACHI
Lighting system:
Lighting output 12V/l00W
.
Lighting coil resistance • 0.22n at 20'C (6S'F) (Yellow - Black)
Headlight type Semi shield
Bulb wattage/q'ty • 12V 45/40W X
1 pc.
Tail/brake light wattage 12VSW/23W
Meter light wattage 12V3.4W

-11-
1980 EX440

A.C. regulator:
Model/Manufacturer TRIZ-24B/HITACHI or S8516B/TOSHIBA
Voltage 13.8 ± 0.5V

Tightening Torque
.

Part to be tightened Thread size Tightening torque Remarks

Engine:
Spark plug M14 P1.25 28 Nm 12.8 m-kg. 20 ft-Ibl
Cylinder head M8 Pl.25 25 Nm 12.5 m-kg. 18 ft-Ib] Special nut-s-
Stud bolt
Cylinder head M8 Pl.25 25 Nm (2.5 m-kg, 18 ft-lb) Nut-Stud bolt
Flywheel magneto M16 Pl.0 73 Nm (7.3 m-kg, 53 ft-lb)
Crankcase upper and lower M8 Pl.25 First: 10 Nm (1.0 m-kg, 7.5 ft-lb)
Final: 20 Nm (2.0 m-kg, 15 ft-lb)
Tightening sequence

~g 0 0 0"0
14 10
7 6 3 2
.
- _.
8 5 1 4 9
00 11 0 0 13 0
0 0/0

Starter pulley M8 Pl.25 11 Nm 11.1 m-kg, 8 ft-lb)

.ra,
Crankcase and engine bracket Ml0 Pl.25 40 Nm 14.0 m-kg, 29 ft-lb] Special nut-
Stud bolt
Cylinder and exhaust pipe M8 Pl.25 20 Nm 12.0 m-kg, 15 ft-lb)
Drive and track suspension:
Primary sliding sheave and cap M6 Pl.0 11 Nm (1.1 m-kg, 8 ft-Ib)
Installation of primary sheave UNF 1/2" Initial: Use motor oil
120 Nm 112 m-kg, 87 ft-Ibl
.
Loosen once and
retighten:
60 Nm 16.0 m-kg, 43.5 ft-lb)
Installation of secondary sheave Ml0 Pl.25 50 Nm 15.0 m-kg, 36 ft-lb]
Bearing housing Ml0 Pl.25 65 Nm 16.5 m-kg, 47 ft-lb)
Secondary shaft and Bearing collar Socket
screw 6 Nm (0.6 m-kg, 4 ft-lb)
Brake caliper and Housing chain Ml0 Pl.25 50 Nm (5.0 m-kg, 3.6 ft-tb)
Installation of drive chain sprocket M14 Pl.5 60 Nm (6.0 m-kg, 43.5 tt-lb) Nut
Installation of driven chain sprocket Ml0 Pl.25 50 Nm (5,0 m-kg, 36 tt-lb) Bolt
Chain housing and Frame M8 Pl.25 25 Nm (2.5 m-kg, 18 ft-lb)
Installation of front axle L.H. M22 Pl.0 85 Nm (8.5 m-kg, 61.5 ft-Ib)
Front axle housing and Frame M8 Pl.25 25 Nm (2.5 m-kg, 18 tt-lb)
Wheel sprocket and Front axle 5 Nm (0.5 m-kg, 3.5 ft-lb)
Shaft 1 and Frame Ml0 Pl.25 65 Nm 16.5 m-kg, 47 ft-lb) Use LOCK- TITE
Shaft 2 and Rear bracket Ml0 Pl.25 65 Nm 16.5 m-kg, 47 tt-lb) Use LOCK-TITE
Rear bracket and Frame M8 Pl.25 30 Nm 13.0 m-kg, 21.5 ft-lb) Use LOCK-TITE
Installation of suspension wheel M6 Pl.0 10 Nm 11.0 m-kg, 7 ft-lb) .

Installation of rear guide wheel M8 Pl.25 25 Nm 12.5 m-kg, 18 ft-lb) Use LOCK- TITE
Installation of runner sliding 1 M6 Pl.0 3 Nm (0.3 m-kg, 2 ft-lb) Use LOCK- TITE
Installation of runner sliding 2 M6 no 10 Nm (1.0 m-kg, 7 tt-lb) Use LOCK- TITE
Pivot arm and Frame sliding 1 M6 P1.0 13 Nm (1.3 m-kg, 10 ft-Ib) Use LOCK- TITE

-12-
 1980 EX440

Part to be tightened Thread size Tightening torque Remarks

Bracket 5 & 6 and Frame sliding 1 M6 Pl.0 13 Nm (1.3 m-kg, 10 ft-lb) Use LOCK-TITE
Frame sliding 1 and 2 & 3 M8 Pl.25 25 Nm (2.5 rn-kq. 18 ft-Ibl
Installation of stopper 1 M6 Pl.0 4 Nm (0.4 m-kg. 3 ft-Ib)
Chassis:
Engine mounting bolt Ml0 Pl.25 38 Nm 13.8 m-kg, 27.5 ft-Ib) Nylon nut
Ski runner M8 Pl.25 14.5 Nm (1.45 m-kg, 10 ft-lb) Use plain washer
and LOCK-TITE
Steering column and Gate M6 Pl.0 9 Nm (O.g m-kg, 6.5 ft-lb]
Steering relay rod adjusting nut Ml0 Pl.25 25 Nm (2.5 m-kg, 18 ft-Ib)
Outside arm and Ski column Ml0 Pl.25 40 Nm (4,0 m-kg, 29 ft-Ib) Use lock washer
';"and wave washer
Steering lower bracket M8 Pl.25 15 Nm (1.5 m-kg, 11 ft-lb) Use lock washer
and LOCK-TITE
Installation of steering column 1,2 M6 Pl.0 9 Nm 10.g m-kg, 6.5 ft-Ibl Use lock washer
Steering relay ass'y Ml0 Pl,25 30 Nm 13.0 m-kg, 22 ft-lb) Use cotter pin
Level gauge securing bolt M6 P1.0 2.5 Nm 10.25 m-kg, 1,8 ft-lb)
.
Screw to install the front of seat M6 Pl.0 5 Nm (0.5 m-kg, 3.5 ft-Ibl
Nut to install the rear of seat M8 Pl.25 9 Nm (O.g m-kg, 6.5 ft-Ib]
Brake level holder M5 PO.8 4 Nm (0.4 m-kg, 3.0 ft-Ib)
Throttle lever M6 Pl.0 3.5 Nm (0.35 m-kg, 2.5 ft-Ib)

-13-
1980 EX440

5. SPECIAL TOOLS

No. Description Tool No.

1 Dial gauge 90890-03097
2 Dial gauge stand No.2 90890-01195
3 Dial gauge needle (56 mm) 90890-03098
4-a Flywheel puller bolt 90890-01803
4-b Flywheel puller attachment 90890-01804
4-c Flywheel puller screw 90890-01806
4-d Drive handle 90890-01817
4-. 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 Main switch ring nut tool 90890-01857
12 Pocket tester 90890-03104
13 Electro tester 90890-03021
14 A.C. Regulator checker 90890-03090

-14-
 Speedometer light Tachometer light
112V3.4W) 112V3.4W)
en
Lgj
Head light (12V 60W/60W)
!BJ :E
-
:JJ
-2
OJ .<---, G)
B

_G

-OCJ-..r.
---t>D- B
Iml'
.~
""1rYG
I!LJ LL 8 B
-»o
c;')
:JJ
»
...h...
GIY

o
s:
G.r - G G'

o o B/W WIR

B
B'
L Spark plug
.!.. 81 LI GI'1t laM , y
h
•
~
y
(J1
I G
rf---Y,:::'::::::::::::::::

...=J -""'\...

-
B LI BrI IWiR Iv

)010
r
sr y
1'1:
,
e-wt 01 la I"":'lelr IL B

~
.::::::::::::::::::'.

Ignition coil
Headlight beam switch t, GIY L B c.nh. urlit

~ . . .__ , j :0:
...L
Color code
G Green
nG Y II Y
- B Black
t,
Y Yellow
C.D.1. magneto
L Blue
0 Orange
i >, Voltage Br Brown
y .R GIY
regulator Gy Gray
G
G IWI W/R White/Red
-1.- G/Y
B/W
Green/Yellow
Black/White
to
00
o
m
X
t
o
1980 EX440 1980 EX440

7. WIRE AND PIPE ROUl

20. To engine crankcase
21. To oil pump
(1)-- 22. Totachometergearunit
23. To carburetor
@-- 24. Clamp
25. Clamp
26. Head light lead wire
27. Speedometer cable rGrav)
@-- 28. Tachometer cable (Black)
29. Spring
30. Shroud stopper
31. Starter wire
32. Brake wire
33. Throttle wire
34. Pump wire
35. Clamp
36. To tachometer gear unit
37. To speedometer
38. To tachometer

@---i
®

Tank

Note :P~~h:~': bepes

tlcned on the opposite
side of the tank.

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,/
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