KawasakiTrax Community
Tech Information => So you got a "New to you Kawasaki snowmobile" => Topic started by: whitley1983 on November 04, 2019, 12:19:52 PM
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Hey, brand new to this community but just want to say I'm really happy I found it. I recently acquired a 1980 440 Kawasaki Drifter that is in decent shape, the left cylinder had low compression so I pulled the top end off and the left piston had a ring that part of it broke off and scarred the inside of the cylinder. I am going to send the cylinder off to be re-plated, am ordering new pistons, rings, needle bearings and a new top end gasket set for it. Additionally I am going to put new slide rails on the rear suspension. I was just curious if anyone could suggest any other major maintenance things I should go ahead and do since I have it all torn apart. This is my first vintage sled rebuild and would love any input I can get. Thanks in advance
-Jake
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Welcome to the site!! From the way is sounds the things you are working on will have you in the places you need to looking at. Keep us up to date and we will do what we can to help you thru it as best we can.
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Welcome, Jake!
1) You didn't mention changing the crank seals in your post. You definitely should do that while you are working on the engine....fairly simple job with the Drifter engine.
2) When you replace the sliders, make sure you really clean the suspension cross shafts and the tubes they go through, then lubricate ALL pivot points..not just the cross shafts..with low temp grease or copper based Never Seize. I think a lot of people complain about rough riding sleds because they never take the time to do this.
3) Check out the chaincase for 40 year old crud....it may never have been looked at, then refill.
4) If you need a shop manual, I can PM you with a downloadable one from another site.
Ask away with any questions.... 8)
Rick
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Hey, thanks for the replies. I found the shop manual online already! I'm def going to open up the chain case and clean it out, and I'm getting ready to pull out the rear suspension and I'll def clean and grease the cross shafts. As for the crank seals, how hard is is to split the crank shaft case? And any tips on splitting the case? Thanks in advance
Jake
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Splitting the case is not hard, it just takes some time. We can help!
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Go to the "Tips and tricks" section on here and go down to the 4th post...."Crank seals for dummies"...good info.
You will have to get 4 things....
1) Proper clutch puller....here is one place that carries them; https://www.mfgsupply.com/725-068.html
2) A decent flywheel puller.
(if the clutch and flywheel have never been removed, they can be stuck on the crankshaft really tight.)
3) A torque wrench. The shop manual will show the proper torque and tightening sequence for the bolts that hold the crankcase halves together. Doesn't have to be a fancy one, I continue to use an old Craftsman beam type.
4) A good crankcase sealant. As is mentioned in the "Crank seals for dummies" post, don't ever try any type of RTV Silicone, I don't care what color. That stuff will start to dissolve in the presence of gas or oil and turn to jelly. I use Threebond 1184....pretty widely available. I think Yamaha and Kawasaki still make good sealants for this also and dealers would probably have it.
8) 8)
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Here's my progress so far, hopefully soon will start putting it all back together. Does anyone have any leads on how to either repair or where I can buy a new base for the seat? It's the only thing I haven't been able to find online that I need. Thanks in advance
-Jake
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more pics
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Great progress! Seat bases are a problem and new ones seldom show up for sale.
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I've only ever worked on seats for the Liquid sleds...Could you make a base out of some treated plywood for the Drifter? Otherwise you're basically stuck trying to repair what you have.
I think I have an extra trunk door. PM me if you're interested.
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Any seat bases I have seen needed to be repaired.
Those are fun sleds. I have one the same that I got brand new.
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Well I got it all torn down as far as I'm going to. Now a lot of prep work to do, painting, and then re-assembly. I'm still waiting on the cylinder to come back from being replaced and them I'm gonna split the case, replaces the seals and re-assemble the engine. Any suggestions on what to use for the crank case cover? I know someone suggested Yamabond for the case but I don't think I saw any crank case cover gaskets online. Here's some updated pictures.
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Looks good!
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It does look like it is in good shape and that you are doing some impressive work. Should be a good sled when done.
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Just an update, pretty close to putting it all back together
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Wow! ;D
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Looking good.