Author Topic: Summer Project  (Read 429 times)

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mswyka

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Summer Project
« on: May 14, 2022, 05:36:49 PM »
Decided to bring one of the project sleds into the shop for a summer project.  We have had this one for several years but had not gotten around to doing anything with it.  At 4,600+ miles this is one of the higher milage sleds that we have picked up and I am sure to a great extent that the high milage is a key contributor to its current condition.  We have a few decisions to make with respect to how much work to put into this particular project - we will have to see as the restoration unfolds.  My initial assessment is that the hood is unusable.  But we have a good 79 hood that will do well as a substitute after a little paint and fresh graphics.  Belly pan too has seen better days and will likely need to be replaced.  It came with no seat.  It is interesting looking at the ski that the former owner really didn't want his wear rod to fall off.  We have a rebuilt suspension skid ready to go in.  And there is a good seat that is just waiting for my sister to fabricate a new cover.  And, if I am remembering correctly there is even a pair of carbs that have been rebuilt and waiting along with a repaired dash panel, and rebuilt airbox.  Now to see if we can find the hundred or so remaining parts necessary to get this machine back on the snow.
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440

Interceptor398

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Re: Summer Project
« Reply #1 on: May 18, 2022, 07:08:47 AM »
I see a couple small issues but a lot of hope.

gixxer6

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Re: Summer Project
« Reply #2 on: May 18, 2022, 09:29:38 AM »
Definitely some potential there... 

I find that the mileage doesn't always correspond to condition.  I have seen sleds with less than 1,000 miles that have been left out in the weather uncovered that are almost completely destroyed.  I have also seen sleds with almost 5,000 miles that have been well cared for and ridden softly that are in pristine condition. 

mswyka

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Re: Summer Project
« Reply #3 on: May 29, 2022, 02:26:33 PM »
Had a few spare minutes on Friday and was able to make some more progress with disassembly.   Looks like there was a problem with the primary as I found a piece of the shive under the footrest.  There is also evidence of extreme heat suggesting at one time that there was a fire in the belly pan.  Belly pan is distorted and the drain plug for the chaincase is melted.

With the broken primary I am making a mental note to check the alignment of the crankshaft.
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440

mswyka

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Re: Summer Project
« Reply #4 on: June 04, 2022, 02:16:56 PM »
Opened up the chaincase today.  All internals look good.  Pucks are hardly worn, spring is bright green and gears and chain look crisp.  I am suspecting that the chaincase internals may have been replaced.
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440

Interceptor398

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Re: Summer Project
« Reply #5 on: June 05, 2022, 09:23:53 PM »
That is a happy place! ;D

gixxer6

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Re: Summer Project
« Reply #6 on: June 06, 2022, 07:03:46 AM »
Opened up the chaincase today.  All internals look good.  Pucks are hardly worn, spring is bright green and gears and chain look crisp.  I am suspecting that the chaincase internals may have been replaced.

With over 4600 miles, they must've been replaced.  Score! 

Interceptor398

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Re: Summer Project
« Reply #7 on: June 06, 2022, 09:24:18 PM »
Perhaps a good sign that the sled was maintained by the previous owner?

mswyka

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Re: Summer Project
« Reply #8 on: June 07, 2022, 07:20:09 PM »
More disassembly this evening.  Looks like some aftermarket heated grips and wiring harness flambé. All of the wires are either scorched, melted or burned.  "X" frame in the bulkhead is in good shape unlike many of  the others that we have seen.  Hood and belly pan are shot.  Tunnel is solid.  Dash needs replacing.  This sled is an interesting combination of good and bad.
« Last Edit: June 08, 2022, 07:13:28 AM by mswyka »
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440

gixxer6

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Re: Summer Project
« Reply #9 on: June 08, 2022, 06:48:19 AM »
Oof, those dash panels can be hard to find in good shape!  Not to mention a decent belly pan...

mswyka

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Re: Summer Project
« Reply #10 on: June 08, 2022, 07:16:56 AM »
Oof, those dash panels can be hard to find in good shape!  Not to mention a decent belly pan...

Well, the good news here is that there is a new belly pan and a new dash (that is new as in a used replacement that is new to this sled) that have been waiting for this project to happen.  The bad news is that I will have to find another dash for the next project.  I also see that I posted the wrong photos last night.  The correct photos have now been inserted.
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440

Interceptor398

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Re: Summer Project
« Reply #11 on: June 08, 2022, 07:35:27 AM »
Stickers look to be in pretty good shape.

mswyka

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Re: Summer Project
« Reply #12 on: June 09, 2022, 07:59:04 AM »
In the process of cleaning up the chassis last night I found this remnant of black/blue decal under the red tunnel decoration.  Thoughts?
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440

gixxer6

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Re: Summer Project
« Reply #13 on: June 09, 2022, 10:54:50 AM »
Interesting.  Looks like a decal from an earlier model.  It looks like the SN's started at 012600 in 82' with the same model identification number stamped on the tunnel (see here:  http://kawasakitrax.com/82models.htm).  This suggests that they had leftover 81's and reworked them into 82's with different color decals. 

Unless someone swapped the decals at some point in it's life?  What is the SN stamped in the tunnel? 

mswyka

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Re: Summer Project
« Reply #14 on: June 09, 2022, 05:10:11 PM »
Interesting.  Looks like a decal from an earlier model.  It looks like the SN's started at 012600 in 82' with the same model identification number stamped on the tunnel (see here:  http://kawasakitrax.com/82models.htm).  This suggests that they had leftover 81's and reworked them into 82's with different color decals. 

Unless someone swapped the decals at some point in it's life?  What is the SN stamped in the tunnel?

I had heard that some sleds were "reissued".  The SN seems to match the 82:  ST440A4-013576
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:  1979 Invader 340, 1980 440, 1980 440 TOC Custom (Green)
Projects:  1980 Invader 340, 1981 Invader 440, 1982 Intruder 440