1978 Invader

[whitley1983]

I've got a 1978 Invader 440 that I picked up last winter, it runs fine and I'm about to tear into it to replace the crank seals. I just ordered the full gasket kit with crank seals and also ordered new carb flanges. Besides the crank seals is there anything else I should just go ahead and replace while I have the motor pulled out of it?

[gixxer6]

Grease the lower bushing on the steering stem.  And I recommend rebuilding the fuel pump if it hasn't already been done. 

[gixxer6]

I always rebuild the recoil on any Kawasaki that I work on. 

[whitley1983]

Hey man thanks for the advice, how do you rebuild the fuel pump? I noticed on DK they don't sell new fuel pumps for them.
-Jake

[Interceptor398]

Might be a few fuel pump rebuild kits floating around on Ebay yet?

[whitley1983]

What all is needed to rebuild the fuel pump? Just started reading it down tonight, didn’t realize I’d have to pull the clutch to pull the motor so now I have to wait for my DK order to come in to go any further. Also it’s so crazy to me how thy designed this sled, the way the chaincase is on the opposite side of the clutches, that’s so far for the power to travel from engine to track.

[whitley1983]

Also, does anyone have any tips for me about doing this year down? Like things to do or not to do? The 440 drifter was the first sled I completely tore down and rebuilt but it was pretty simple, fan cooled and no oil injection so any guidance would be appreciated.

[gixxer6]

Also, does anyone have any tips for me about doing this year down? Like things to do or not to do? The 440 drifter was the first sled I completely tore down and rebuilt but it was pretty simple, fan cooled and no oil injection so any guidance would be appreciated.

See here:  http://kawasakitrax.com/kawiforum/index.php?topic=7.0

[gixxer6]

What all is needed to rebuild the fuel pump? Just started reading it down tonight, didn’t realize I’d have to pull the clutch to pull the motor so now I have to wait for my DK order to come in to go any further. Also it’s so crazy to me how thy designed this sled, the way the chaincase is on the opposite side of the clutches, that’s so far for the power to travel from engine to track.

What sleds are you used to???  The vast majority of modern sleds use a jackshaft and have the chain case on the opposite side of the clutches... 

I used to buy my fuel pump rebuild kits on ebay as Interceptor398 said.  But be careful, there is one spot on one of the gaskets that they forgot to punch a hole in.  So compare the old gaskets to the new ones and make sure you punch that hole, it's necessary. 

If you can't find the fuel pump kit, let me know I think I have a few extra that I could sell. 

[Rollingmenace]

Agree with the guys above.. eBay is a great source for the rebuild kits, heck you can buy complete pumps on there as well and they are not to expensive..

[Interceptor398]

http://kawasakitrax.com/kawiforum/index.php?topic=1908.0

[whitley1983]

Thanks for all the input, so on Ebay I did find someone selling a fuel pump with a new gasket set, I couldn't find the rebuild kit, so my question is what all is needed to rebuild the fuel pump, is it just the gaskets that need to be replaced or are there other troublesome parts that need to be replaced?

[Interceptor398]

Pretty sure I have an extra kit if you are interested. $10.00 + shipping.

[gixxer6]

Agree with the guys above.. eBay is a great source for the rebuild kits, heck you can buy complete pumps on there as well and they are not to expensive..

Careful, they don't sell new complete pumps that are the tall version used on Kaws...You can use the short version, but must install a fuel shutoff. 

[Boomologist]

Fuel shutoff is very important even with the right kit. If the little valve in the pump fails to shutoff fuel for simplest reasons you run the risk of a severely flooded crankcase. Could result in hydro-lock or worse, a fire. I installed fuel shutoff's on every sled I have owned. It also makes it nice to shut fuel off and let engine run out of fuel if it's going to set for a long time. Carbs won't gum up. And if you do have a fuel leak for some reason you can simply just shut it off.