Historical Context:
The 1978 Kawasaki Invader and Intruder models were part of Kawasaki's robust entry into the growing snowmobile market during the late 1970s, known for their performance-oriented twin-cylinder engines and capable chassis for trail riding and general snowmobiling.
Key Competitors:
Arctic Cat El Tigre, Ski-Doo Blizzard, Yamaha SRX, Polaris TX series.
Distinguishing Factors:
Kawasaki's reliable two-stroke engine technology, often featuring reed-valve induction for improved performance, combined with a relatively lightweight and agile chassis for the era.
Target User:
Owners, hobbyists, and professional technicians seeking to maintain, repair, or restore 1978 Kawasaki Invader and Intruder snowmobiles.
Digital Benefit:
Provides instant access to critical repair and maintenance data, allowing for immediate problem diagnosis and repair on the trail or in the workshop, avoiding downtime.
Models Covered:
1978 Kawasaki Invader 340, 1978 Kawasaki Invader 440, 1978 Kawasaki Intruder 340, 1978 Kawasaki Intruder 440
Primary Focus:
Service, Repair, Maintenance, Troubleshooting
Estimated Page Count:
300-500
Manual Type:
OEM Repair Manual / Factory Service Manual
Engine:
General Information, Specifications, Routine Maintenance, Engine Removal/Installation, Top End Overhaul, Bottom End Reassembly, Carburetion, Cooling System, Lubrication System
Fuel System:
Fuel tank, fuel lines, fuel pump (if applicable), carburetor (Mikuni VM series typical), fuel filter maintenance and adjustment.
Lubrication Cooling:
Oil injection system (if applicable), oil type, oil change procedures, cooling system design (air-cooled typically), fan maintenance.
Transmission Drive:
Drive clutch (primary), driven clutch (secondary) maintenance, belt inspection/replacement, chaincase lubrication, chain adjustment, sprocket wear inspection, track drive system.
Steering Suspension:
Handlebar assembly, steering post, tie rods, ski alignment, ski spindle lubrication, front suspension (trailing arm or similar design) components, shock absorber servicing, rear suspension (slide rail or bogie wheel system), track adjustment and alignment.
Electrical System:
Ignition system (CDI typical), stator, flywheel, lighting coils, magneto, wiring diagrams, battery maintenance (if applicable), kill switch, throttle linkage, starter motor (if equipped).
Bodywork Chassis:
Body panel removal/installation, seat, windshield, decals, chassis inspection for damage, frame integrity checks.
Maintenance:
Scheduled maintenance intervals, lubrication points, filter replacements, track tension adjustment, spark plug replacement, carburetor cleaning and adjustment.
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, ignition troubleshooting, fuel system issues, starting problems, track slippage diagnosis.
Repair Rebuild:
Engine component replacement (pistons, rings, crankshaft, bearings), carburetor rebuild, clutch service, suspension component replacement, electrical component diagnosis and repair.
Specifications Data:
Torque specifications for fasteners, engine clearances, ignition timing, carburetor jetting specifications, clutch engagement/disengagement speeds.
Depth Of Information:
Comprehensive factory-level detail, suitable for both experienced mechanics and dedicated DIY enthusiasts. Covers from basic checks to full engine and drivetrain rebuilds.
Print Quality Suitability:
High resolution, suitable for printing individual pages for workshop use, minimizing wear on the digital original.
Binding Type:
N/A (Digital Download)
Paper Type Recommendation:
For printed copies: High-quality, durable paper (e.g., 24 lb bond or higher) to withstand workshop conditions.
Engine Type:
Two-stroke, piston-ported or reed-valve induction (model dependent), air-cooled twin-cylinder
Displacement 340:
Approx. 330-340cc
Displacement 440:
Approx. 430-440cc
Horsepower Estimate 340:
45-55 HP (estimated)
Horsepower Estimate 440:
55-65 HP (estimated)
Carburetor Type:
Dual Mikuni VM Series (e.g., VM30, VM32 - specific size varies by model/displacement)
Fuel Type:
Unleaded gasoline (minimum 87 octane) mixed with 2-stroke engine oil
Oil System:
Oil injection system (typical) or premix (check specific model variant)
Drive System:
CVT (Continuously Variable Transmission) utilizing a primary (drive) clutch and a secondary (driven) clutch.
Clutch Service:
Manual covers inspection, cleaning, replacement of drive belts, clutch spring and roller maintenance, and sheave alignment.
Chaincase:
Gear reduction drive within a sealed chaincase, requiring specific gear oil and periodic checks.
Oil Change Chaincase:
Annually or every 100-150 operating hours; manual specifies exact interval and procedure.
Spark Plugs:
Inspect every 500 miles or annually; replace as needed. Manual specifies correct plug type (e.g., NGK BR9ES or equivalent).
Clutch Inspection:
Inspect primary and secondary clutches annually for wear on rollers, ramps, and sheave surfaces; check belt condition.
Track Tension:
Check and adjust track tension regularly, especially after initial break-in or significant use; manual provides specific tension values and adjustment methods.
Chaincase Oil:
Kawasaki Gear Oil GL-4 or API SF/GL-4, SAE 80W-90 is commonly specified. Manual will list the exact type and capacity.
2-Stroke Oil:
High-quality 2-stroke oil rated for air-cooled snowmobile engines, meeting Jaso FD or API TC specifications. Manual may recommend specific Kawasaki branded oil.
Carburetion Icing:
Common in cold, humid conditions; manual provides troubleshooting and potential remedies.
Clutch Wear:
Wear on clutch weights, rollers, and sheave surfaces can lead to poor performance; regular inspection and service are crucial.
Engine Seizure:
Can occur due to lean fuel mixtures, improper oil/fuel ratio, or overheating; manual details preventative measures and rebuild procedures.
Track Skipping:
Often caused by improper track tension or worn drive sprockets; manual guides on diagnosis and adjustment.
Kawasaki Powersports:
Kawasaki Heavy Industries has a long history in manufacturing powersports vehicles, including motorcycles and snowmobiles, known for engineering prowess and performance.
Invader Intruder Lineage:
These models represent Kawasaki's efforts to compete in the popular trail and performance snowmobile segments of the late 1970s, building upon previous engine designs and chassis innovations.
Manufacturing Era:
Produced primarily for the 1978 model year, with potential carryover into subsequent years with minor revisions.
