Best rebuild advice

Technical topics related to machines powered by Kasasaki motors
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phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Best rebuild advice

Post by phishoook »

Rebuilding ASAP.

When I tear this stock 1980 440 trailfire down, where should I start? and go for parts? Looking at Dennis kirk...

with a 30 yr. old sled, I'm guessing I should go all the way to the crank seals?
JDT
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Joined: Wed Nov 21, 2007 1:00 am
Real Name: Todd
Location: Milbank South Dakota

Re: Best rebuild advice

Post by JDT »

You are correct.
Complete engine teardown, cleaning and inspection. New seals and gaskets at a mininum.
Pistons and rings if needed. Careful inspention of crankshaft and bearings. Loads of fun ahead.

But do the rest of the sled also. Steering, suspension, electrical system, skis, ect ect ect.
Todd Schrupp

Milbank SD
phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Re: Best rebuild advice

Post by phishoook »

The steering and clutch will be next. I know I need new buttons on the secondary.

Put an 80' liquifire trac and suspension on when I painted 2 seasons ago. First ride after the new paint, the compression dropped like a rock from 130 to about 90 on the fan side. I didn't have the time or cash to rebuild then.

*also looking for a new backrest, or at the least the back of it.
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phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Re: Best rebuild advice

Post by phishoook »

OK I was wrong, it was the clutch side that had the low compression, and I'm just now getting to the rebuild.

I'm having problems pulling the clutch off. The puller I have is the wrong thread size. Anyone know what size treads are on the clutch to pull it?

Has anyone here heard of using hot water to pull the clutch? Or would some heat be better?
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JD600
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Joined: Thu Jan 29, 2009 1:00 am
Location: Fremont NE

Re: Best rebuild advice

Post by JD600 »

The threads inside of the comet clutches are 3/4 fine thread. I wouldn't recomend putting any heat on the clutch. If you can't get ahold of the proper puller, and you don't have a sled shop close by to pop it off for you, it is possible to pop it off using a 3/4" FINE THREAD GRADE 8 bolt and automatic transmission fluid. Turn the engine on its side with the clutch facing up and the bolt removed. Fill all but about a half inch of the hole with ATF and thread the bolt in. Put your impact gun on it, and presto chango, your clutch will come off. Just be careful because the fluid could be under extreme pressure when the clutch finally pops.

This is kinda messy, but i perfer this method over the puller because nothing metal ever comes in contact with the end of the crankshaft. Good luck and let us know how you make out.

DE
Dustin Elder
Salem, OH


Midmounts.... Lots and lots of midmounts...

"Everyone is entitled to be stupid, but some abuse the privilege."
phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Re: Best rebuild advice

Post by phishoook »

Thank you! That is the same method I heard as using hot water.
______

Next question...
splitting the case, how? Does the whole fan side come off, then split it?
harleysportster
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Joined: Thu Jul 14, 2005 12:00 am
Real Name: Pat Scott
Location: Southeast Pa.

Re: Best rebuild advice

Post by harleysportster »

Yes, you must remove the fan cover in order to remove the flywheel.
Here is a link to the service manual.
http://www.vintagesnow.com/John_Deere_f ... ilfire.pdf
'76 440 cyclone
'76 440 liquifire
'78 440 Cyclone
'75 JDX8 (sold to a member here)
'78 Liquifire(CrossCountry Clone)
'80 Liquifire(sold)
JDT
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Joined: Wed Nov 21, 2007 1:00 am
Real Name: Todd
Location: Milbank South Dakota

Re: Best rebuild advice

Post by JDT »

After the flywheel is off then the stator has to come off before the case can be split.
The stator is bolted to bolt the upper and lower halves.
Todd Schrupp

Milbank SD
phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Re: Best rebuild advice

Post by phishoook »

well the clutch Cyl. is shot. It needs bored and re-chromed.

I do have a 440 kaw motor out of an invader. Do these parts interchange? Or should I just swap motors and rebuild the Kawasaki? Would the electric match up?
phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Re: Best rebuild advice

Post by phishoook »

*lets just say the clutch didn't come off as planned, the jugs for the Invader are not the same, and the clutch on the Invader has a metal band holding it together with self tapping screws. So I'm sure that clutch is junk too.
JDT
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Real Name: Todd
Location: Milbank South Dakota

Re: Best rebuild advice

Post by JDT »

While both engines are Kawasaki the Invader is LC and the T-fire is FC.
No parts will interchange.

Never use a damage clutch. If it has been juryrigged it will be out of balance and may explode at speed.
Having pieces of metal pierce your favorite snow boots will ruin your day not to mention your two-step.

More than likely someone on the board will have a jug for your engine. If not check e-bay or just buy a complete used engine.
Todd Schrupp

Milbank SD
phishoook
Posts: 24
Joined: Fri Jan 01, 2010 5:38 pm
Location: Northern Indiana

Re: Best rebuild advice

Post by phishoook »

It must not have been an Invader, this is a fan cooled 440.

I think I found a complete motor. But I wont have it until next week.
Invader440
Posts: 114
Joined: Sun Sep 07, 2008 12:00 am
Location: Fosston, Mn

Re: Best rebuild advice

Post by Invader440 »

You can also use Drifter jugs if you can't find some for a Trailfire.
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