1977 Invader 440 conversion to electric starter "how to"

[Mbalsup@gmail.com]

Would like to convert my 440 repurposed to grand kids dirt buggy to electric start but having difficulty identifying correct parts and sources


I have aquire a ring gear. Found a reference here to Hitachi 108-34 starter brushes. Assume I can source solenoid and rectifier at Dennis Kirk. Anyone want to help me out?

[Interceptor398]

Welcome to the site!!!  Someone on here has an Intruder with the parts you are looking for.  An Invader motor on a dirt buggy must go pretty good.

[Mbalsup@gmail.com]

It flies,or would if it had wings.

[Lloyd (ljm)]

 Does the engine case have the hole for the starter?

 If not (most likely does not) You have to do some machining to do on the engine case

[Lloyd (ljm)]

What are you using for a clutch?

 Can a ring gear be put on your clutch?

[rminier]

 Well, I messed that up ....I posted an entire old post that includes a good regulator/rectifier for an electric start Kawi. Other sources may be tough to find. I think you're right, a universal solenoid from Dennis Kirk, or your local auto store should work great.

[gixxer6]

I have some cases that have the starter hole and I think I have a good starter motor.  Lmk if you need them. 

[Mbalsup@gmail.com]

I'll bore my case once I get a starter so I can take some measirements. I could use your starter offer. however. Let me know how much. Thanks.

[Mbalsup@gmail.com]

UPDATE - I now have the ring gear thanks to Ebayer Cyr in Quebec. Measuring I find the ring gear to be .0053 smaller than the outside of the flywheel. I'm assuming Kawasaki intended the gear to be held in place by an interference fit.

My experience tells me that .0053 is an awful lot for the flywheel to shrink (freezer overnight) and the heat-treated ring gear to expand (oven at 400 degrees). I am almost certain that proceeding in this manner will result in the ring gear failing. PLEASE, ANYONE CARE TO DIFFER?

Anyhow, my immediate thought is to turn .0043 from the flywheel shoulder (since it's not hardened), then proceed with a .0010 interference fit. Lastly, I see where the ring gear has two (2) provisions for staking - which I will utilize.

Please, if anyone sees me heading in the wrong (catastrophic) direction - STOP ME.

[jimvw57]

Might be less work to find a Intruder flywheel..

[Mbalsup@gmail.com]

I was, somehow, of the opinion that the intruder and invader 440 were the same. Is that incorrect? As far as your suggestion to replace flywheel - I'm retired and have invested in the equipment so I like to use it and my time on my project is virtually worthless anyhow.

[gixxer6]

I have a flywheel with ring gear from an 80' 4/6 Invader.  I'm not sure if they are the same?

[Mbalsup@gmail.com]

I'll keep that in mind
 Thanks Gixxer6.

[Lloyd (ljm)]

 I have never measured them. But I have pressed many ring gears off and on the flywheels. I don't think there is any difference in the outside diameter of the Kawasaki flywheels