KawasakiTrax Community
General Category => Kawasaki Owners => Topic started by: Rollingmenace on October 04, 2020, 09:36:06 PM
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Did some trading and I acquired my first Kawasaki Sled.. I believe it’s a 78 440 FC Invader.
I’m planning on running it In a vintage stock 440 FC Class Oval Ice Races here in Colorado.
The numbers on the tunnel read ST440A - 001308
Motor turns free and has good Blue spark . Unable to test compression as my tester is out on loan lol. I did try and hit it with a little ether and it popped a bit but didn’t really run. The plugs kept coming out wet . The carbs are dry and the oil tank is off . So I’m guessing there is a bit of oil or something in the bottom end Fouling the plug.. I’m planning on pulling motor and at a min disassembling topend and taking a look...
It appears someone installed some homemade brackets to raise the rear of the tunnel. Also it appears the rear shock is some sort of coil over is this normal for this sled??
I’ll attach some pics as soon as I get to my laptop.
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Welcome to the site!
ST440A1 = 1978 Intruder 440
ST440A2 = 1979 Intruder 440
ST440A3 = 1980 Intruder 440
All nice sleds...Which do you have?
You'll want to change the crank seals while you have the motor out.
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I believe it’s still a 78 A1 from all the research I have done it is the model with the headlight inset on top of hood to drivers right side . I believe 79 had a pop up similar to the intruders..
I planned on doing crank seals already ordered a complete gasket set with the seals.. may even throw new bearings in it when apart I’ll just have to inspect .
Like I said It’s my first Kawasaki sled but I’ve been on Kawasaki dirt bikes for about 36 years. I recently got into sleds and ride Arctic Cats in the mountains here.. I just got a wild hair and decided I wanted to race some ovals on a sled that was different than the typical Polaris and Doos you see everywhere .. I’m no stranger to wrenching on my stuff this sled will be the 6th Green Machine in my stable and the only thing I’ve ever had in a shop was my Polaris utility quad...
Once my clutch puller gets here the fun will begin!!!!!!!!!!!
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welcome to the site!! You found the right sled to race as it is the lightest of the Intruders if I remember correctly.
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The "ST" in the model number tells us that it is an Intruder, not an Invader.
None of the Intruders had a pop-up headlight, all of the Invaders did. The 78' Intruder is unique in that the headlight is inset in the hood, 79-82' Intruders all had a non-popup headlight that protruded from the hood.
http://kawasakitrax.com/models.htm
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Well I got my compression tester back today and just out of curiosity I pulled compression..
Clutch side about 90 and mag side between 75-80...
As soon as the clutch puller gets here motor is coming out..
Also got my gasket kit today there appears to be 3 oil seals I’ll have to figure out what the third seal is for...
What are you guys using to pull your flywheels off.. the manual calls out for a puller with a part number.. are you using another type of puller or should I try and find a oem one
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There are two oil seals on the PTO side of the engine. One between the crankcase and the oil/gear case and the second on the outside of the gear case.
I use a three pronged harmonic balancer puller for the flywheel. I had to buy 8mm x 60mm hardened (10.9) bolts. Be careful how far the bolts are threaded into the flywheel. If they go too far they can damage the coils. A photo of my puller is attached.
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Now is a good time to invest in a factory service manual
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Thanks guys I have a balancer puller .. just wanted to confirm beforehand I could use it....
My factory service manual arrived yesterday...
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Added a photo
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Definitely a 78 Intruder hood. Looks to be in very nice shape. We have a 78 Intruder that has proven to be one of our most used sleds - it has also given us more than its fair share of interesting stories.
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It is for sure a 78 intruder.. Only issue with it is at some point someone cut and raised the running boards on the tunnel . And they made brackets to hold the rear suspension. I’m on the fence about leaving it as is or trying to lower back to stock and repairing tunnel ... I am in the process of pulling and rebuilding the motor as it is a bit low on compression.
This sled will be used strictly for a fan motor stock class vintage oval ice racer.
I will add more pics here shortly. It’s just a pain converting them to jpeg off my I Pad
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More pics
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Under the hood
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Pulled the motor this evening and started the disassembly process... it is going well .. on a side note the belly pan is in almost perfect shape only like 3 small and very repairable cracks...
Now i just got to finish up pulling carbs, fuel pump and secondary then ill degrease and pressure wash everything..
On crack repair do you guys recommend overlaying the crack with an additional piece of pan and pvc gluing or or will taping off bottom and just filling crack with glue be sufficient???
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I've riveted thin aluminum sheet to the belly pan to repair cracks and other damage. This method has worked well and held up great for me.
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We have used the patch approach. PVC solvent works well. The challenge is always to find a way to apply pressure. When close to the edge "c" clamps work well. In the middle we have used a block of wood and drywall screws. Then patch the outside with body filler. Then paint.
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Well it just keeps getting better.. but nothing I wasn’t expecting.. I tore down the motor and found the following...
Had 2 different pistons in it correct but just different manufacturers.. the older piston had a stuck ring...
cylinders both scarred up and need repaired and replated I’m going to try and source some useable ones before sending to millennium..
Also for some reason there was no head gasket on pto side.
On a good note crank felt real good and had no excessive play in the rods...still on the fence about splitting cases.
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If you need some encouragement, split the case. The crank seals will thank you - and you will thank yourself later.
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If you need some encouragement, split the case. The crank seals will thank you - and you will thank yourself later.
Yes, this is a must. Imagine buying new pistons, plating your cylinders or sourcing used, new gaskets, all the work putting it together, then the first ride out you melt one of those shiny new pistons and wreck the cylinder. I've seen it happen, these crank seals can be ruthless.
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Thanks guys.. I was planning on doing the seals for sure.. just wasn’t for sure if I needed to split cases to do so... haven’t read that far ahead in the manual.. heck it will give me a chance to check main bearings for signs of heat or galling...
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Following all your recommendations and knowing from experience I decided to go for it.
I’m splitting the cases and doing seals and addressing anything else I come across...
So far so good goth cases split and apart found a fair amount of crud in there settled at bottom..
Cases are apart and my piston kits arrived along with a near perfect set of heads and a pair of very good shape cylinders near perfect themselves...
Now I wait as apparently I loaned out my good puller that I need to pull the pump gear off the crank.. I ordered a new proto puller to replace my MIA one...
The crank is in nice shape all the Bering appear tight so I plan on no crank work other than a good cleaning and seals..
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And here’s where we are at today... cases cleaned up , still need a little bit of time in the washer then onto a good water rinse and air dry to get and residue off..
I will clean up cylinders and heads while waiting for puller to arrive ..
As far as cases upon reassembly what do you guys recommend for sealer I have yamabond 4 and 5. The book calls for a kawasaki sealer but I’m guessing the yamabond should work.
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I have used the Yamabond and have had no issues with it.
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Awesome. Thanks for the Advice...Well hopefully my puller gets here and I can start reassembly this weekend.
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Motor is back together and sitting in the sled now. I’m hoping to fire it this weekend ..
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I feel the suspense building
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Thanks for all of the information Rollingmenace. I also just purchase a 1978 Intruder yesterday and can't wait to get it back to original condition.
JB
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Thanks for all of the information Rollingmenace. I also just purchase a 1978 Intruder yesterday and can't wait to get it back to original condition.
JB
Welcome to the site!!