Author Topic: Gas Tank Removal Question on1981 St440-A4  (Read 257 times)

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Chuck K

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Gas Tank Removal Question on1981 St440-A4
« on: September 19, 2022, 09:29:25 PM »
I just came into possession of the above model intruder with only 892 miles on it. I'm in the process of going through the whole machine.  I'm replacing all the fuel lines and would like to remove the fuel tank to flush, clean, and repaint. I haven't pressed off the handle bars yet but that's next.  Looking at all the manuals for this model including the assembly manual before I do some thing dumb it looks like there are 3 rivets on each side near the foot plates and 2 nylon nuts holding the tank in.  Because of the age of the nylon nuts I'm not sure removing them is a good idea for fear of breaking something off.  But I need to attach those fuel lines to the tank and check those nylon fittings.  Any suggestions from someone who has done this tank removal procedure would be greatly appreciated.  I took a bunch of pre restoration pictures and will post them and the finished machine at a later time.
Thanks in advance,
Chuck K

mswyka

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Re: Gas Tank Removal Question on1981 St440-A4
« Reply #1 on: September 21, 2022, 07:26:52 AM »
Chuck, good morning.  If this is a 81 440 Intruder then the fuel tank will be held in place by a bracket on the top middle of the tunnel under the front of the seat. 

Remove the seat and then there are three rivets that need to be removed to remove the bracket holding the fuel tank.  The tank should then be able to slide rearward away from the handlebar stanchion and be free to lift off of the tunnel.

If the tank is secured any differently, then this is not similar to any of the Intruders that I have worked on.
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

Chuck K

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Re: Gas Tank Removal Question on1981 St440-A4
« Reply #2 on: September 21, 2022, 07:58:48 AM »
Thank you for that advice!  I'll tackle that this weekend and let you know if it comes out as all the others you've worked on in the past.  It shouldn't be any different.  Thanks again for the info.  Cheers!

mswyka

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Re: Gas Tank Removal Question on1981 St440-A4
« Reply #3 on: September 22, 2022, 02:54:13 PM »
Good luck.  You said that you checked the manuals.  Do you have one that says Shop Manual?
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

Chuck K

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Re: Gas Tank Removal Question on1981 St440-A4
« Reply #4 on: September 22, 2022, 06:25:23 PM »
I just got the shop manual last night by PDF.  The gas tank removal is set out perfectly as you mentioned with complete diagrams.  I do have another question though in regards to the skeg.  I will need to weld a new rod that protrudes into the front of the ski as one has been broken off somehow.  Should I make it out of something hard like D2 or just mild rolled steel?  Thanks again for all the help and advice!  Cheers!

mswyka

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Re: Gas Tank Removal Question on1981 St440-A4
« Reply #5 on: September 23, 2022, 06:22:05 AM »
I just got the shop manual last night by PDF.  The gas tank removal is set out perfectly as you mentioned with complete diagrams.  I do have another question though in regards to the skeg.  I will need to weld a new rod that protrudes into the front of the ski as one has been broken off somehow.  Should I make it out of something hard like D2 or just mild rolled steel?  Thanks again for all the help and advice!  Cheers!

I believe that the wear rods are mild steel.  I have never made my own, I normally buy new rods.  Non-carbide are quite inexpensive, but my preference is for the rods with carbide inserts. They last longer and give me better control on ice.  Wear rods are readily available from most outlets.
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: Gas Tank Removal Question on1981 St440-A4
« Reply #6 on: September 23, 2022, 09:09:00 AM »
I will add that the seat bolts will probably break.  For the 20 or 30 Kawasaki sleds that have come into our shop, I have not had a single seat bolt come off correctly.  All the bolts have broken or have stripped out of the seat pan.  There are a few different approaches to fixing this issue, but that is the topic of other threads on this forum.
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