Author Topic: My First Kawasaki Sled 78 ?? 440 FC Intruder  (Read 4540 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, 1981 Custom (Pink)
Invaders:   1980 440
Projects:    1981 Invader 440

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, 1981 Custom (Pink)
Invaders:   1980 440
Projects:    1981 Invader 440

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...

Rollingmenace

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Re: My First Kawasaki Sled 78 ?? 440 FC Invader
« Reply #21 on: October 25, 2020, 05:39:44 PM »
Following all your recommendations and knowing from experience I decided to go for it.
Iím 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..

Rollingmenace

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #22 on: October 25, 2020, 05:50:46 PM »
And hereís 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 Iím guessing the yamabond should work.

Interceptor398

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #23 on: October 27, 2020, 08:22:03 PM »
I have used the Yamabond and have had no issues with it.

Rollingmenace

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #24 on: October 29, 2020, 10:10:28 PM »
Awesome. Thanks for the Advice...Well hopefully my puller gets here and I can start reassembly this weekend. 

Rollingmenace

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #25 on: December 11, 2020, 10:43:33 PM »
Motor is back together and sitting in the sled now. Iím hoping to fire it this weekend ..

mswyka

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #26 on: December 12, 2020, 08:19:31 AM »
I feel the suspense building
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:   1980 440
Projects:    1981 Invader 440

jbenjamin

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #27 on: January 21, 2024, 08:25:56 AM »
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
1978 Kawasaki 440 Intruder

Interceptor398

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Re: My First Kawasaki Sled 78 ?? 440 FC Intruder
« Reply #28 on: January 21, 2024, 12:29:44 PM »
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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