1980-1985 Yamaha SS440, SS440D, SS440E, SS440H Snowmobile Service Manual

Comprehensive service manual for Yamaha SS440, SS440D, SS440E, and SS440H snowmobiles (1980-1985). Includes diagrams, specifications, and troubleshooting for all major systems.

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Document Details

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Document Number / Seller:
29624 / Walter Hicks
File Size:
31.75 MB
File Type:
PDF
Language:
English
Pages:
128
Printable:
Yes
Category:
Snowmobile
Last updated / verified
Jan 1, 2026

Models Covered & Key Technical Specifications

Yamaha SS440, SS440D, SS440E and SS440H (1980-1985) Service Manual

Official Factory Service Manual | Technical Reference Unit.

  • General Specifications: Includes overall length, width, and height measurements, providing baseline dimensional data.
  • Engine Specifications: Details engine type, displacement, bore x stroke, and compression ratio of 6.2:1 for optimal performance.
  • Ignition System Testing: Provides resistance values for primary and secondary coils, ensuring proper ignition function.
  • Carburetor Adjustments: Outlines procedures for main jet, pilot screw, and throttle stop screw adjustments for optimal tuning.
  • Suspension Settings: Details stopper band settings for front and rear suspension, allowing adjustment based on course and rider preference.
  • Track Tension: Specifies a deflection of 25-30 mm/10 kg for correct track tension, ensuring optimal handling and performance.

Professional Workshop Service Manual & Technical Specifications

Yamaha SS440, SS440D, SS440E and SS440H (1980-1985) Service Manual: Technical Reference

Component-Focus: Engine Specifications // Technical-Scope: Full Coverage / System Logic // System-Identifier: Official Factory Documentation.

Identifier System-Path Calibration-Data
Engine Specifications 6.2:1 Compression Ratio
Carburetor Tuning Pilot Screw 1-1/2 Turns Out
Drive Sheave Adjustment 270 mm Sheave Distance
Ignition Timing 1.4 mm BTDC
Suspension Stopper Band 3rd Hole from Bottom Setting
Track Tension 25-30 mm/10 kg Deflection

Integrated service sections encompass engine inspection, carburetor tuning, drive and track suspension adjustments, electrical system diagnostics, and chassis maintenance. This manual documents torque specifications for critical engine components to ensure proper thread engagement security.

The troubleshooting chapter addresses common issues like no spark or weak spark, poor idling, and performance issues at various speeds. Cooling system maintenance is addressed in detail, including fan belt tension adjustments. Testing requirements are specified for ignition coils and charging coils, with resistance values provided for diagnostics. Clearance measurements are addressed for various components to ensure correct assembly and operation.

FAQ

What is the **required** fluid capacity for the chain housing? keyboard_arrow_down

250 cc (8.5 oz) of Gear oil API "GL-3" SAE #75 or #80 is required for the chain housing.

Calculate the **specified** idle engine speed for the carburetor. keyboard_arrow_down

1,500 r/min is the specified idle engine speed for the carburetor.

What values are **essential** for the brake cable adjustment? keyboard_arrow_down

A play of approximately 5 mm (0.20 in) at the brake lever holder is essential for brake cable adjustment.

Assess the **correct** spark plug gap for the ignition system. keyboard_arrow_down

0.7 - 0.8 mm (0.028 - 0.031 in) is the correct spark plug gap measurement.

What components have **documented** torque specifications for the primary sheave installation? keyboard_arrow_down

The primary sheave bolt has documented torque specifications, with an initial tightening to 120 Nm (12 m-kg, 85 ft-lb) and a final torque of 65 Nm (6.5 m-kg, 47 ft-lb).

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Reviews (4)

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Rated 5 out of 5 stars
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This manual made restoring my Yamaha SS440E a breeze! The step-by-step instructions are clear and easy to follow. Highly recommended!
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The detailed sections on engine and carburation were particularly helpful. Downloading the manual was smooth and the support team was quick to respond to my questions!
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The electrical troubleshooting section saved me a lot of time! The email with the download link arrived promptly. Excellent service!