Target Audience:
Owners of the 1979 Kawasaki Intruder 440 snowmobile seeking to perform maintenance, diagnostics, and repairs.
Value Proposition:
Empowers owners with factory-level knowledge to maintain and repair their snowmobile, saving on labor costs and ensuring optimal performance.
Alternative Resources:
Generic repair guides, online forums (often unreliable or incomplete), dealer-only service information.
Instructional Style:
Step-by-step guidance with easy-to-read text and supporting illustrations.
Customer Support:
Guaranteed quality service manual with excellent customer service follow-up.
Additional Resources:
Link provided for download; website (johnsmanuals.com) for other service manuals.
Coverage Description:
Comprehensive service and repair for the 1979 Kawasaki Intruder 440 snowmobile, covering all nuts, bolts, and operational aspects. Includes diagnostics and repair procedures for common and complex issues.
Estimated Pages:
Hundreds (exact number not specified, but stated as 'hundreds of pages')
Manual Classification:
Factory Service Repair Manual / Shop Manual
Language Proficiency:
English
Delivery Format:
Digital Download (PDF)
Engine System:
Detailed breakdown of the 440cc engine, including disassembly, assembly, timing, lubrication, cooling, and fuel delivery.
Drivetrain System:
Coverage of the drive clutch, driven clutch (secondary clutch), chaincase, and drive shaft mechanisms. Includes adjustment and replacement procedures.
Suspension System:
Information on front and rear suspension components, including shock absorbers, springs, sliders, and track alignment.
Electrical System:
Wiring diagrams, ignition system diagnosis and repair, lighting, and starter motor components.
Fuel System:
Carburetor identification, adjustment, cleaning, and rebuild procedures. Fuel tank and line maintenance.
Brake System:
Disc or drum brake system inspection, service, and adjustment.
Chassis And Body:
Frame inspection, seat, handlebar, and body panel removal and installation.
Routine Maintenance:
Oil changes, lubrication points, track tension adjustment, spark plug replacement, air filter service.
Troubleshooting:
Diagnostic flowcharts and step-by-step guides for identifying and resolving common and uncommon issues.
Engine Repair:
Piston and ring replacement, cylinder head service, gasket replacement, valve adjustment (if applicable).
Transmission Repair:
Drive and driven clutch disassembly, belt replacement, clutch calibration, and chaincase gear inspection.
Electrical Diagnostics:
Testing ignition coils, stators, rectifiers, and lighting circuits.
Carburetor Rebuild:
Complete disassembly, cleaning, reassembly, and jetting adjustments.
Depth Of Information:
Factory-level diagnostic and repair procedures, suitable for both novice DIY mechanics and experienced technicians. Covers everything from basic adjustments to complete engine and drivetrain overhauls.
Diagnostic Capabilities:
Detailed symptom-based troubleshooting guides and specific component testing procedures.
Rebuild Instructions:
Comprehensive instructions for rebuilding major components like the engine and clutches.
File Size:
Approximately 100MB
Searchability:
Searchable text enabled
Printable Pages:
Yes, individual pages or sections can be printed.
Illustration Quality:
Hundreds of illustrations provided to aid in understanding procedures.
Binding Method:
N/A (Digital PDF, not physically bound)
Paper Composition:
N/A (Digital PDF, not printed on paper)
Engine Displacement:
440cc (Cubic Centimeters)
Engine Type:
Two-stroke, Twin-cylinder (common configuration for this era and displacement)
Cooling System:
Air-cooled (typical for 1970s snowmobiles)
Horsepower Estimate:
Approx. 40-55 HP (estimated based on typical engines of this displacement and era)
Torque Estimate:
Not specified, but would be torque-optimized for snowmobile operation.
Carburetor Configuration:
Dual carburetors (common for twin-cylinder engines of this size and era)
Fuel Type:
Gasoline (typically leaded or unleaded regular)
Ignition Type:
CDI (Capacitor Discharge Ignition) likely
Transmission Type:
Continuously Variable Transmission (CVT) - Drive and Driven Clutch System
Optional Gearbox:
N/A (CVT is standard for this application)
Clutch System:
Includes primary (drive) clutch and secondary (driven) clutch with belt drive.
Chaincase:
Chaincase transmission for reverse gear and potentially reduction gearing.
Track Width:
Not specified, but typical for the era (e.g., 15-20 inches)
Track Length:
Not specified, but typical for the era.
Dry Weight:
Estimated 400-500 lbs (typical for a snowmobile of this size and era)
Oil Change Interval:
Refer to manual for specific interval; typically based on mileage or operating hours, or annually for two-stroke oil.
Spark Plug Replacement:
Refer to manual; typically every 1000-2000 miles or as needed based on performance.
Clutch Maintenance:
Regular inspection of clutch sheaves, rollers, and spring tension; belt inspection and replacement as per manual recommendations.
2 Stroke Oil:
Kawasaki 2-stroke engine oil or equivalent API-TC certified oil. Refer to manual for specific viscosity and blend.
Chaincase Oil:
Refer to manual for specific gear oil type and viscosity (e.g., SAE 80W-90).
Carburetor Clogging:
Common issue with older snowmobiles due to fuel degradation; requires regular cleaning and carburetor rebuilds.
Clutch Wear:
Wear on clutch weights, rollers, and buttons can affect performance and require replacement.
Track Tension:
Improper track tension can lead to excessive wear on the track, slides, and bearings.
Ignition Coil Failure:
Aging ignition coils can lead to weak spark or complete failure, causing misfires or no-start conditions.
Common Part Numbers:
Not provided in product description, but the manual will contain specific OEM part numbers.
Kawasaki Motorsports:
Kawasaki has a long history in motorsports, including motorcycles and jet skis, bringing engineering expertise to their snowmobile division.
Intruder Series:
The Intruder name was used across various Kawasaki product lines. The 440 designation typically refers to its engine displacement.
Production Period:
1979 model year, likely produced in the late 1970s.
Manufacturing Location:
Likely Japan or North America (Kawasaki has global manufacturing capabilities).
