This manual covers the Kawasaki 440 Intruder snowmobile models produced between 1978 and 1980. Kawasaki has a strong heritage in powersports, and the Intruder line was designed as a capable machine for trail riding and general use. These snowmobiles feature a two-stroke, twin-cylinder engine with a displacement of approximately 432 cc, air cooling, and dual carburetors. The drivetrain utilizes a Continuously Variable Transmission (CVT) system with a chain drive to the track, and braking is handled by a hydraulic disc brake. The 440 Intruder represents a robust and reliable option for its intended purpose.
This comprehensive repair and workshop manual is designed for owners and independent repair shops of the 1978-1980 Kawasaki 440 Intruder. It provides detailed information on all major systems, including engine mechanicals, fuel and lubrication systems, drivetrain, suspension, steering, and electrical components. The manual covers routine maintenance, lubrication services, engine rebuilds, transmission overhauls, component replacement, and advanced troubleshooting. With its detailed procedures and technical specifications, this manual serves as an essential resource for maintaining the performance, reliability, and longevity of your Kawasaki 440 Intruder snowmobile.
Model Years Covered:
1978, 1979, 1980
Chassis Code Range:
Likely within a specific VIN range for these model years, exact code not provided in product info
Target Audience:
Owners and independent repair shops of 1978-1980 Kawasaki 440 Intruder snowmobiles.
Competitor Manuals:
Original Kawasaki factory service manuals, other aftermarket repair manuals for the era.
Digital Benefit 1:
Instant download after payment.
Digital Benefit 2:
Printable pages for workshop use, preserving the digital copy.
Digital Benefit 3:
Accessible on smartphones for on-trail repairs.
Support:
Lifetime protection policy for lost or damaged downloads.
Primary Coverage:
1978-1980 Kawasaki 440 Intruder Snowmobiles
Additional Coverage:
Not specified, assumes specific to listed models
Estimated Page Count:
Not specified in product information, typical for this era range from 200-500 pages
Type:
Repair Manual / Workshop Manual
Format:
Electronic Downloadable PDF
Engine Mechanical:
Engine Removal and Installation, Engine Specifications, Intake & Exhaust
Lubrication Cooling:
Lubrication and Cooling System
Drivetrain:
Transmission, Drive Chain & Sprockets
Suspension Steering:
Steering System, Shocks
Electrical:
Electrical System
Bodywork Chassis:
Body Work
Maintenance:
Routine Maintenance, Lubrication Service
Repair:
Engine Rebuild, Transmission Overhaul, Component Replacement
Troubleshooting:
Advanced Troubleshooting, Diagnosis of common issues
Depth:
Comprehensive, covering repair, maintenance, and troubleshooting for all major systems.
Searchable Text:
Likely, standard for modern PDF repair manuals.
Printability:
Designed for printing specific pages as needed.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Type:
Two-stroke, twin-cylinder, piston-port induction (typical for this era/model)
Displacement:
432 cc (approximate, derived from '440' designation)
Cooling System:
Air-cooled
Horsepower Range:
Typically in the 40-50 HP range for this engine size and era.
Carburetion:
Dual Mikuni VM series carburetors (common for Kawasaki snowmobiles of this period)
Fuel Type:
Unleaded gasoline mixed with 2-stroke oil
Oil Injection:
Likely automatic oil injection system (KATS - Kawasaki Automatic Oil Injection System)
Type:
CVT (Continuously Variable Transmission) with a primary and secondary clutch system.
Drive System:
Chain drive to the track.
Clutch Service:
Manual will detail clutch inspection, maintenance, and potential roller/spring replacement.
Gear Ratios:
N/A (CVT system)
Track Width:
Typically 15 inches for this class of snowmobile.
Dry Weight:
Likely in the 400-450 lb range (exact figure not provided).
Crash Test Data:
N/A (Snowmobile safety ratings were not standardized in this manner during the era)
Braking System:
Hydraulic disc brake on the drive shaft, operated by handlebar lever.
Ignition Kill Switch:
Standard handlebar-mounted kill switch.
Instrument Cluster:
Basic analog gauges for speedometer, tachometer, engine temperature (or indicator light), and fuel level.
Features:
None; this era of snowmobile predates modern driver assistance systems.
Features:
None; no electronic connectivity features.
Spark Plugs:
Check and clean/replace every 1,000-2,000 miles or annually, depending on usage. Specific plug type (e.g., NGK BR9ES) would be in the manual.
Drive Belt:
Inspect drive belt for wear and damage at seasonal start-up and every 500 miles. Replace if any cords are showing or if wear exceeds specifications.
Chain Case Oil:
Change chain case lubricant annually or every 1,500 miles. Specific lubricant type would be in the manual (e.g., SAE 90 hypoid gear oil).
2 Stroke Oil:
High-quality 2-stroke snowmobile oil, meeting API-TC or JASO FD specifications (manual will specify exact recommendation).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (manual will specify).
Grease:
Lithium-based multi-purpose grease for chassis lubrication points.
Carburetor Icing:
Common issue in cold, humid conditions; manual will offer troubleshooting tips.
Clutch Slippage:
Can occur with worn belts or clutch components; manual provides inspection and service procedures.
Engine Overheating:
Less common with air-cooled engines, but can be due to obstructed cooling fins; manual covers inspection.
Kawasaki Powersports:
Kawasaki has a long history in powersports, including motorcycles and snowmobiles, known for performance and reliability.
Intruder Lineup:
The Intruder model line in Kawasaki's snowmobile history was positioned as a capable trail and general-purpose machine.
Manufacturing Location:
Likely manufactured in Japan or potentially North America by Kawasaki.
Model Specific Awards:
No specific awards for this model are readily available, typical for snowmobiles of this era.
