Author Topic: My First Kawasaki Sled 78 ?? 440 FC Invader  (Read 210 times)

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gixxer6

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #15 on: October 15, 2020, 02:23:56 PM »
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. 

mswyka

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #16 on: October 15, 2020, 07:27:46 PM »
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.
Intruders:  1978, 1979 X2, 1980, 1981 Custom
Invaders:  1979 340, 1980 440, 1980 440 TOC Custom
Projects:  1981 Invader 440, 1979 Invader 340, 1980 Invader 340, 1979 Intruder 440, 1982 Intruder 440, 1980 Drifter 340 F/C...

Rollingmenace

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #17 on: October 16, 2020, 04:55:12 AM »
Well it just keeps getting better.. but nothing I wasnít 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  Iím 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.

mswyka

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #18 on: October 16, 2020, 09:05:49 AM »
If you need some encouragement, split the case.  The crank seals will thank you - and you will thank yourself later.
Intruders:  1978, 1979 X2, 1980, 1981 Custom
Invaders:  1979 340, 1980 440, 1980 440 TOC Custom
Projects:  1981 Invader 440, 1979 Invader 340, 1980 Invader 340, 1979 Intruder 440, 1982 Intruder 440, 1980 Drifter 340 F/C...

gixxer6

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #19 on: October 16, 2020, 01:15:00 PM »
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. 

Rollingmenace

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #20 on: October 16, 2020, 08:17:10 PM »
Thanks guys.. I was planning on doing the seals for sure.. just wasnít for sure if I needed to split cases to do so... havenít read that far ahead in the manual.. heck it will give me a chance to check main bearings for signs of heat or galling...