Kawasaki 550 Interceptor #246

[Letthegoodtimesroll62]

Hello, New Member here. I own Interceptor # 246. Previous owner in their wisdom tried to remove primary using pry bar and damaged case / seal boss. Currently being tigged and surfaced. Crankshaft good, need clutch & mag side seals ? As well as all engine gaskets ?
It may be necessary to nicasil jugs, but I’ll get to that in due process. For now want to get lower end back together. Then determine COA for top end. Engine was running , but sucking air on pto side.
As stated new member , just starting to feel my way around here. Lots of Unfo !!! If someone can give me a lead on seals and gaskets , muchly appreciated. Thank you
Also have 2- 440 intruders , 2- 440 invaders, 2-340 invaders , 1-LTD

[Ameritude]

Oooooh another interceptor has surfaced! Welcome to the site, I personally can't help in this department lol but someone definitely can! Let the good times roll!

[Interceptor398]

Welcome to the site!!

The gasket sets between the 440 LTD and Interceptors are nearly identical except for the fire rings.

  LTD set can be found here   https://www.mfgsupply.com/710118.html

I will make sure #246 is in the registry.

[Letthegoodtimesroll62]

Thank You very much for the good lead on Gasket Set . I work remote and do not always have access to internet or wifi
If anyone has a cross reference or supplier for pto & mag side crank seals , I sure would appreciate the lead.
Question: is the lower end on the 550 the same as an LTD ?
If this were so then (just perhaps) there may be seals
Listed for the LTD , somewhere
Thanks again the site is awesome and so very much reading

[Interceptor398]

Bottom ends are the same.

[Letthegoodtimesroll62]

Thank you
For all responses.
Things are progressing well. Crank case repaired .
Crankshaft reset and sealed .
Jugs honed. One piston serviceable , the other ( from pto side)
NOT . Appears to have had a 4 point seize . A result of the
B/O case seal boss and sucking air .
Bottom line , need a piston or would prefer a set .
Any suggestions for New 550 (530) Interceptor pistons
Was thinking perhaps their might be an option from an
Alternate engine , but rings would need to be pinned
To same (oem) location

[gixxer6]

550 pistons are extremely hard to find.  There are a few options:

1.  Find NOS, which is near impossible
2.  Use the Kaw jet ski pistons, which are really close but the wrist pin is smaller
3.  A 583 ski doo piston is fairly close, but you’ll need to enlarge the bores
4.  There are a few guys that have had small runs of aftermarket pistons made, these are usually quite expensive.  There are none available that I’m aware of right now. 

[Interceptor398]

In the short term the 440 LTD top end would get you on the trails.