CONTENTS

1. MODIFiCATIONS 22. NEW SERVICE PROCEDURE 53. MAINTENANCE INTERVALS 64. SPECiFiCATIONS 85. SPECIAL TOOLS : 146. WIRING DIAGRAM 157. WIRE AND PIPE ROUTING DIAGRAM 17

-1-

1980 EX440

1980 EX440

1. MODIFICATIONS(Compared with 1979 model EX440)

A. ENGINEThere are no particular changes.

B. DRIVEThere are no particular changes.

C. CHASSIS1. Tune-up label

(8J8-77743-00)

As an aid to service. a tune-up label isattached to the drive belt guard.

2. Throttlea. To keep the throttle cable end, which is

held by the throttle lever, from contact­ing the throttle grip, a collar is mountedand the lever is properly curved.

3. Spark plug holder(8G9-23885-00)For better saleability. the spark plugholder is provided as standard (whichis an option for the 1979 model).

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

8J8-77 541 -00 can be used on both1979 and 1980 models.

D. ELECTRICAL1. Spark plug

(94701-00063 ----> 94701-00046)The spark plug has been changed to atype because it is more easily availablein the market and does not affect engineperformance adversely.

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

Lever (8J5-42138-00) and collar(90387-22726) can be used on both1979 and 1980 models.Lever (8G8-42138-00) can not be usedon the 1980 model.

Collar (90387-22726lLever (8GB-42138-00 ----+

BJ5-42138-00)

-2-

Interchangeability: Yes

2. COl magneto(8E7-85500-10 ----> 8J7-85500-1 0)For better durability and easier service,the number of pulsers is decreased from2 to 1:

Interchangeability: No

For the ignition timing adjustment. referto "2. New service procedure."

1980 EX440

3. COl unit(8H6-85540-10 -+ 8J7-85540-10)Due to change in the COl magneto. thecircuit is modified.

Interchangeability: No

4. Main switch

(898-82508-20 -+ BJ7 -82508-20)For better safety, the circuits of theheadlight, meter light and taillight aremodified so that they are turned on aslong as the engine is in operation, andtheir positions are changed.

'79 model '80 model

Gray

\ Lead wire I"'" Lead wirecolor Gray Orange Red/Blue Blue/White Red/White Blue cclor Black Black/WhitePosition '\.

¢Position -""

OFF OFF

ON ON/LIGHT

LIGHT

~BraCkoran\8. II-. VI- d IS Black/White

>...\... 0 0 II IIBlue __

~T

IRed/Blue Bfue/White

Interchangeability: No

5. Wire harnessFor better safety, the circuits aremodified so that the headlight, meterlight and taillight are turned on, when­ever the engine runs. (Refer to "6. Wir­ing Diagram.")

Wire harness ass'v:8G6-82590-20 -+ 8J7 -82590-20

Wire harness ass'v 2:8G6-82580-20 -+ 8J7-82580-20

Interchangeability: No

-3-

1980 EX440

6. Tether switch(S9S-S2550-00 ---> SJ7-S2550-00)To prevent the switch from coming offeasily, the rubber cap thickness is in-

79 model

creased, by which the durability andstrength of the cap is also increased.The ring is provided with a hook so itcan easily be hooked to the clothes.

'SO model

Increased thicknessE

Interchangeability: Yes

7. Headlight unit(SE7-S4310-40 --->SH7-S4310-41)The headlight is modified so that itmeets the European regulations.

-4-

Hook is added

12V 60/60W ---> 12V 45/40W

. Interchangeability: No

1980 EX440

3. Insert the dial gauge with needle intothe stand.

Tool name Tool No.

Dial gauge 90890-01252

Dial gauge needle 90890-03098

2. NEW SERVICEPROCEDURE

(New service procedure applied to the 1980

EX440)

If not aligned. adjust ignition timing as

follows:

Ignition timing (B.T.D.C.)1.6 ± 0.1 mm (0.060 ± 0.004 in)

7. Check the marks on flywheel and pulserfor alignment.

Tool No.

90890-01195

Tool name

Dial gauge stand

Ignition timing1. Remove the recoil starter assembly.2. Remove the right side spark plug and

screw the dial gauge stand into thespark plug hole.

4. Rotate the magneto flywheel unit pistonis at top-dead-center (T.D.C.)Set the zero on dial gauge face to lineup exactly with a dial gauge needle.Tighten the set screw on the dial gaugestand to secure the dial gauge assemb­ly. Rotate the flywheel back and forth tobe sure that the indicator needle doesnot go past zero.

5. Starting at T.D.C., rotate the flywheelcounterclockwise until the dial gaugereads approximately 3-1/2 needle re­volutions before-top-dead -cente r(B.T.D.C.).

6. Slowly turn the flywheel clockwise untilthe dial guage reads specified ignitiontiming.

a. Loosen the pulser set screws and turn

achieved.

NOTE: --------------'If the marks can not be aligned by this ad­justment. remove the flywheel rotor andturn the base (stator) assembly.

-5-

1980 EX440

b. Tighten the pulser set screws.

8. Remove the dial gauge and stand. Re­place the spark plug and recoil starter.

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]

NOTE:-----------­The timing light should be used to check ifthe marks on the rotor and base are alignedwhen both are replaced with new ones. themarks should align at any specified timing.

Every

20 hrs. or 40 hrs. or 80 hrs.or When ICheck point Seasonally

400km BOO km 1.600 km necessary

{250mi} (500mi) (1.000 mil

ENGINE:

Tightness of bolts and nuts a aBends. cracks and wear a a

Loose-connection and-break f , ..

Looseconnection and breaks of oil pipes a aLoose connection and breaks of oil delivery pipe a aManual rope starter system a . aCarburetor .

• Operation of starter jet a a

• Mixing adjuster (pilot screw) a a

• Idlil)g speed adjustment a aOperation and adjustment of oil pump a aIgnition timing . aCylindercompressions a aMuffler joints a aCylinder head/exhaust pipe decarbonize aSpark plug condition, gap and clea-ning a aTightening of the cylinder head .... a

DRIVE:

Tightness of bolts and nuts a aWear on slide runners a aPrimary drive system a . aV-belt a aSecondary drive system a aSheave distance a aSheave offset a aBrake pad wear a aBrake operation and adjustment a aGuide wheel rubber a aWear of drive track wheel sprocket a aDrive track adjustment a aBreaks in drive track a aBends in front and rear axles a aChecking of lock washers a aDrive chain adjustment a aDrive chain oil level a a

-6-

1980 EX440

Every

Check point 20 hrs. or 40 hrs. or 80 hrs. or When Seasonally4QOkm 800km 1.600 km necessary(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

Lubrication point 20 hrs. or 40 hrs. or 80 hrs. or when Seasonally Oil/Grease400km BOOkm 1.6'00 km necessary Brand name

(250 mt} (500 mil (1.000 mil

ENGINE:

Starter case 0

Oil pump control box 0 0Aeroshell grease #7 A orEsso Beacon 325 grease

Pump drive cover 0 0

Oil in the oil tank 0 YAMALUBE 2-cycle oil

DRIVE:

Primary sheave weight0 0and roller pins Molybdenum disulfide

Secondary shaft and0 0

snowmobile greasesliding sheave

Front axle housing 0 0

Shaft 1 and shaft 20 0

Light all-purpose grease(Slide rail)

Drive chain oil0 0

Gear oil API "GL-3"replacement SAE #75 or #BO

BODY:

Steering column lower0 0 Light all-purpose greasebearing

Steering column upper0 0 Motor oilbearing

.Steering links 0 0

Ski column 0 0

Ski wear plate 0 0light all-purpose grease

Ski retaining pin 0 0

Brake wire and stopper 0 0 Esso Beacon 325 greaseand brake lever

-7-

1980 EX440

4. SPECIFICATIONSGeneral

NOTE: * ..... New specification

(Compared with 1979 EX440)

Model:Model (I.B.M. No.l * EX4401'BO)18J8)Frame 1.0. & starting number * BG6-050101Engine 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 55433Displacement 433 em' (26.42 eu.in)Bore X Stroke 68 X 59.6 mm (2.68 X 2.35 in)Effective compressionratio 7.0: 1Starting system Recoil hand starterIgnition 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 aluminumBore 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)

IF) +0 ( +0 in)56 -0.05 mm 2.205 -0.002

Crankshaft deflection (D) 0.03 mm (D-1) 0.04 mm (D-2)0.04 mm (D-3) 0.05 mm (D-4)

-8-

Connecting rod large end side clearance (C)Connecting rod small end deflection (PI

0.25 - 0.75 mm 10.010 - 0.030 in)2.0 mm (0.079 in)

1980 EX440

r

DA

I

(M.J.)(MAJ.)

(Pw.J.)(PwAJ.)

IS.J.)

ISAJ.)(P.S.)(St.J.)

Crank pin outside diameter X lengthCrank pin type

Crank bearing type (Left) X q'tv

(Center) X q'tv

IRight) X q'tvCrank oil seal type ILeft) X q'tv

(Center) X q'tv

(Right) X q'tv

Carburetor:

I"y"eBl'manUTaciurerTquantltyI.D. MarkMain jet

Main air jetPower jetPower air jet

Slow jetSlow air jet

Pilot screw

Starter jet

Float height

Idling engine speed

Main jet setting chart:

24 X 55 mm (0.945 X 2.165 in)

Solid shaft assembly type with serration#6306 special X 2 pes.

#6206 special X 2 pcs.#6206 special X 1 pc.FWJ-32 78 9.5 X 1 pc.

Labyrinth seal X 1 pc.FWJ-32 48 10 X 1 pc.

8D44 X 38 KEIHIN X 1 pc.8H500

#145#180#150

#200

#90#1001-5/8#150

15 +2 mm 10.59 +0.08 in)-3 -0.12

1.500 r/min

__________ Tempe;~;~re

Altitude ______________

Sea level

- 30°C(-22°Fl

-czo-c1-4"F)

'0 C(50' F)

#140

20e168'- F)

- 600m (2000 Itl

-- 1200m (4000 ft)

- , 800m (6000 ft)

-- 2400m (8000 ftl

-- 3000m (10000 ftl or more

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

#140

#135

#130/,/135

#130

#125·

-9-

1980 EX440

Intake reed valve:

Type V typeBending 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 idleOil 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 : 1Engagement rpm 2,900 ~ 3,300 r/minPrimary spring:

Part No. 90501-45534Color code Blue/Green

___________ 0_-

. ,~",,~.

Part No. 90508-45286Color code Yellow

Secondary spring pre-load (twist) 150 0 (Hole No. 11

Sheave distance 270 +0 mm 110.6 +0 in)-3 -0.12

Sheave off-set 5.5 ± 0.5 mm 10.22 ± 0.02 inlV-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 inlTrack 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 BTStopper band lenqth 214 mm (8.4 inl 13rd hole from the bottomI

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 +5 104 +0.2 in)-2 mm . -0.08

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-

Chassis

1980 EX440

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-rodLock to lock angle [ski} Right ski. t. 20.2' R: 27.6'

Left ski, L: 27.6' R: 20.2'Lockto lock angle (steering column) Right: 46.5'

Left: 46.5'

Front suspension:Type Leaf springdamper type Oil damper

Fuel tank:Capacity 30 LitreFuel grade Regular gasoline

Electrical

..'0" -,-

Model/manufacturer • F2S0-7S/HITACHIVoltage 12VPulsarcoil 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/HITACHISpark gap 9 mm 10.35 in)/300 r/min

11 mm (0.43 in)/3,000 r/minPrimary 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 shieldBulb wattage/q'ty • 12V 45/40W X1 pc.Tail/brake light wattage 12VSW/23WMeter light wattage 12V3.4W

-11-

1980 EX440

A.C. regulator:

Model/ManufacturerVoltage

Tightening Torque

TRIZ-24B/HITACHI or S8516B/TOSHIBA13.8 ± 0.5V

.

Part to be tightened Thread size Tightening torque Remarks

Engine:Spark plug M14 P1.25 28 Nm 12.8 m-kg. 20 ft-IblCylinder head M8 Pl.25 25 Nm 12.5 m-kg. 18 ft-Ib] Special nut-s-

Stud boltCylinder head M8 Pl.25 25 Nm (2.5 m-kg, 18 ft-lb) Nut-Stud boltFlywheel 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"07 6 3 2 14 10

- _. .

8 5 1 4 900 11 0 0 13 0

0 0/0

Starter pulley M8 Pl.25 11 Nm 11.1 m-kg, 8 ft-lb)Crankcase and engine bracket Ml0 Pl.25 40 Nm 14.0 m-kg, 29 ft-lb] Special nut-

.ra,

Stud boltCylinder 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) NutInstallation of driven chain sprocket Ml0 Pl.25 50 Nm (5,0 m-kg, 36 tt-lb) BoltChain 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-TITEShaft 2 and Rear bracket Ml0 Pl.25 65 Nm 16.5 m-kg, 47 tt-lb) Use LOCK-TITERear bracket and Frame M8 Pl.25 30 Nm 13.0 m-kg, 21.5 ft-lb) Use LOCK-TITEInstallation 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-TITEInstallation of runner sliding 1 M6 Pl.0 3 Nm (0.3 m-kg, 2 ft-lb) Use LOCK-TITEInstallation of runner sliding 2 M6 no 10 Nm (1.0 m-kg, 7 tt-lb) Use LOCK-TITEPivot 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-TITEFrame sliding 1 and 2 & 3 M8 Pl.25 25 Nm (2.5 rn-kq. 18 ft-IblInstallation 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 nutSki runner M8 Pl.25 14.5 Nm (1.45 m-kg, 10 ft-lb) Use plain washer

and LOCK-TITESteering 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 washerSteering lower bracket M8 Pl.25 15 Nm (1.5 m-kg, 11 ft-lb) Use lock washer

and LOCK-TITEInstallation of steering column 1,2 M6 Pl.0 9 Nm 10.g m-kg, 6.5 ft-Ibl Use lock washerSteering relay ass'y Ml0 Pl,25 30 Nm 13.0 m-kg, 22 ft-lb) Use cotter pinLevel 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-IblNut 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 90890-011953 Dial gauge needle (56 mm) 90890-03098

4-a Flywheel puller bolt 90890-01803

4-b Flywheel puller attachment 90890-018044-c Flywheel puller screw 90890-01806

4-d Drive handle 90890-01817

4-. Flywheel puller body 90890-01848

5 Rotor holding tool 90890-012356 Primary fixed sheave puller 90890-01859

7 Sheave sub-assembly tool 90890-018588 Bushing tool 90890-018779 Sheave gauge 90890-01875 .

10 Eccentric bearing installer 90890-0185111 Main switch ring nut tool 90890-0185712 Pocket tester 90890-03104

13 Electro tester 90890-03021

14 A.C. Regulator checker 90890-03090

-14-

Iml'"1rYG.~ I!LJ LL 8

Speedometer light

112V3.4W)

LgjHead light (12V 60W/60W)

OJ _G

-OCJ-..r.---t>D- B

B.<---,

"

Tachometer light

112V3.4W)

!BJ

...h...GIY

B

en

:E-:JJ-2G)

o-»c;'):JJ»s:

G.ro

- G

o

G'

B/W WIR

o

. .__. ,

nG Y II Y

i >,

to00omXto

-

~

Spark plug

•rf---Y,:::'::::::::::::::::~

.::::::::::::::::::'.

Color code

G GreenB BlackY Yellow

L Blue

0 Orange

Br Brown

Gy GrayW/R White/RedG/Y Green/Yellow

B/W Black/White

Ignition coil

-

C.D.1. magneto

LI BrI IWiR Iv

B

B

hy

B'

...L

rI"":'lelr IL,)010

c.nh. urlit

1'1:e-wt 01 la

y

:0:

B

B

t,

L

-1.-

Voltage

regulator

,L

81 LI GI'1t laM

GIY

s r y

j

t,

G

.R GIY

Gy

G IWI

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

Headlight beam switch

~

.!..(J1

I

1980 EX440 1980 EX440

7. WIRE AND PIPE ROUl

(1)-­

@--

@--

@---i®

Tank

Note :P~~h:~': be pestlcned on the oppositeside of the tank.

7-

20. To engine crankcase21. To oil pump22. Totachometergearunit23. To carburetor24. Clamp25. Clamp26. Head light lead wire27. Speedometer cable rGrav)28. Tachometer cable (Black)29. Spring30. Shroud stopper31. Starter wire32. Brake wire33. Throttle wire34. Pump wire35. Clamp36. To tachometer gear unit37. Tospeedometer38. To tachometer

/',/{J