Intruder Resurection Thread
 

So, now that I've had my non-running Intruder home for a week or so, I've begun the process of tinkering with it to see what it's going to take to get it back together.

First off, I pulled the carbs. It was a fairly easy job compared to the inline 4s I've done before. The front carb was in the middle of the V and the rear carb was behind the motor.

As I suspected, the carbs will need serious cleaning. The front in particular may be a problem. It had rust on the butterfly and the butterfly is stuck solid. can't budge it even with tapping on it. I've given it a number of liquid wrench baths and let it sit overnight, but still no go.

Front carb:
https://i.postimg.cc/1X1sTv8T/20221130-125846.jpg
https://i.postimg.cc/76VK86hk/20221130-125958.jpg

Rear:
https://i.postimg.cc/fb7KmLx9/20221130-125903.jpg
https://i.postimg.cc/VLTDc2fd/20221130-125919.jpg

having seen how the front carb looked, I decided to buy myself a scope camera for my phone so I could get a glimpse inside.

Here's the intake on the front cylinder and the inside of the cylinder through the spark plug hole. Fortunately, the cylinder itself appears to be ok. It looks like I need to pull the head and clean it.

https://i.postimg.cc/qMd3GTyh/Screen...Scope-ET16.jpg
https://i.postimg.cc/VLBbGVW7/Screen...Scope-ET16.jpg

I'm also going to have to do something with the tank. the bottom of the rear of the tank is rusted through with pinholes. the tank is dry inside, but you can hear the rust jingling around when I shake the tank. I'm not sure at this point if it's salvagable or not at this point. Replacements are hard to come by.

Definitely watching this thread. Looks a little rough but knowing you it will run. :tup:

next up I'm going to turn the motor over by hand and see if I can get any better views of the cylinder walls.

over the weekend I spent some time on the tank. I had to drill the tank lid to get it off. key would not budge even after soaking it multiple times with penetrants. I also got the sander out and scraped off the paint. after using the dremel to open up some of the rust holes, I ended up cutting away sections. I think there's still more to cut away, but I want to talk to someone about repairing it before I got further. some of these are very small holes and could perhaps just be spot welded closed. someone suggested a radiator shop might be able to do the work.


https://i.postimg.cc/P53ZThGz/20221204-154220.jpg

https://i.postimg.cc/yN2Z3P8D/20221204-150402.jpg

so...this week I shipped the carbs off to be refurbished. I also located a radiator shop in the area that also works on gas tanks. they are going to acid wash the tank and then reline it. also weld up a patch on the holes. 250 for the carbs. 160 for the tank. Not bad all things considered.

this weekend I'm working on cleaning up the brake and clutch hydraulics. Attached is a pic of the crud that came from the rear brake system. it was the worst, but I still have work to be done on the clutch. the picture makes it look better than it was. it started out VERY milky. I had some old brake fluid which I used for flushing it, then used some good fresh fluid to finish it off.

Front brake was not too bad. just needed new fluid and bled. cleaned up pretty quickly with my granddaughter helping hold the vacuum pump and bottle.

I tried bleeding the clutch and it was a no-go. I pulled all the lines off and they are clear down to the slave cylinder. it appears the master is not pushing any fluid, so I'm going to take it apart and see if I can clean it out well enough. problem is I don't have a pair of retaining clip pliers that will fit down into the area to remove the circlip to get everything apart. I'll run to an auto parts shop tomorrow and see if I can find a pair that will work.

After I got the front brakes working sufficiently, I was able to put some pressure on the front forks. they are BAD! Gotta tear them apart before I even ride. I was hoping they would be good enough to get the bike running and do some test rides, but they are really bad. I'll at least change the fluid and then go from there.

Wow nice find,good luck with it. Should be parts at a salvage yard, very many of them built.

I fabricated a circlip tool from a nice pair of spring loaded needle nose pliers I found at Lowes. Auto parts stores had nothing to help me.

I was able to disassemble the master cylinder. there wasn't much to see indicating any problem. I was able to clean it well though. I also ordered a rebuild kit for it, so I'll put it back together and see if things are functioning properly.

In the mean time, I pulled the slave cylinder off the bike and got it apart. It's varnished up really bad. I have parts soaking in a bath of Berryman's B12. Hopefully that will loosen the varnish so I can use a toothbrush to clean it up.

last night I decided to tinker a bit. got some 1500 grit sandpaper and polished on the fork tubes. there is one divit in the left tube, but otherwise there were tiny rust spots covering both tubes. Fortunately the sandpaper took them off very nicely.

I received the slave cylinder rebuild kit. Right now the parts are still in the Berryman's soak. Not sure if that stuff is going to make the difference or not. if anyone has ideas of a different product to use, I'm open to input.

I'm still waiting on the master cylinder kit. should be here within the next day or two. That'll be something to do this weekend. I might even hook up a battery and see if I can gently crank the motor over.

The guy received my shipment of carbs and has started working on them. Also waiting to hear about the tank.

so, I received rebuild kits for my clutch master and slave cylinders. Put them back together over the weekend. I just need to connect and bleed the lines.

I called today and my tank reconditioning is done and ready. I'll pick it up tomorrow. We'll see what $180 buys me. keep your fingers crossed!

I still need to remove my fuel pump and test it to be sure it works and it's not full of rust/crud.

after that, I'll hook up a battery and see if the bike powers up. no carbs yet, and no fuel involved. I just want to check electricals and see if the motor will turn over.

so....some updates. First.....I got the tank back from the radiator shop. it's not pretty, but cleaned and sealed up as needed. the red sealer is sandable and I'll put some primer of some sort on this to clean it up and make it look at least a little presentable. I just need to get a gas cap and I'll be good to go.

as for my master cylinder, I'm having a heck of a time trying to get the system re-filled with fluid. it really doesn't seem to be passing fluid from the plunger into the system past the last rubber gasket. if anyone has any tricks or ideas, I'm all ears. I have a mity-vac that I use, but I can't even get the system primed to get fluid moving.

my clutch works! my clutch works!

after 2 weeks of tinkering, building and rebuilding both my clutch and slave cylinders, and removing the clutch cover to check out the plates, I FINALLY got it together and working properly. I ended up getting syringes and using them to push fluid in through the SC and backfill the lines up to the MC.

Now I can move on to checking the electrical system.

One of the carbs is still not working. Guy who I have rebuilding them says the slide is stuck and he's tried just about every trick he knows. I'm waiting for final word, but likely will have to buy a replacement.

On a side note....today while looking at a car for my grandson, I noticed some old bikes sitting in the corner of a storage building with lots of dust on them. There was a pair of Moto Guzzi California's. 1997 models, their anniversary models. they were missing a few parts and last time they were plated for the road was 2010. Tanks were rusty but I already have a line on fixing those, right? These might be another candidate for buy/fix/resell. Maybe I've found a fun job for retirement. :)

So....after a long wait and having to replace one of the carbs, this is what I found in my email today. I really haven't gotten anything done on the bike the past two weeks due to crappy weather and a cold.

"Carbs are all set and shipping out!

Everything came out great. All working nice, clean, and smooth.
New float bowl gaskets installed
All New orings throughout
New air fuel screws, washers and orings.
A/F screw are set to 2.5 turns out
New float needles and seats installed.
float levels are perfect at 8mm. Both were at 4mm.
Both new slide diaphragms are in great working condition
carbs are bench synchronized
choke assemblies have been cleaned, polished and oiled. All working great and smooth now.
No adjustments needed."

https://i.postimg.cc/7ZWmwrW0/newcarbs1.jpg
https://i.postimg.cc/1t283JZW/newcarbs2.jpg
https://i.postimg.cc/9QN3wSrY/carbinside.jpg

Looks like Red Kote. Good stuff. Be sure to keep acetone away from it unless you want it to be gone.

carbs are back in place. Right now I'm not happy with the way the clutch is working. it's making a noise when I depress the lever. seems to be coming from the push rod going from the slave cylinder to the clutch basket. I'm going to take it apart once again and see if everything is correct in there.


https://i.postimg.cc/rm3qxWSt/20230131-191448.jpg

Hi.....my name is Dave and I'm a slacker.

("Hi Dave")

it's been a while since I turned a wrench on the project. between crappy cold and rainy weather and a case of covid, I haven't gotten anything further done on the bike. :(

I have to get the fuel lines replaced and then re-install a few electronic pieces that I removed while digging into the left side of the bike. I am also going to take the clutch system apart AGAIN. I am having a weird tick or clunk coming from the system when I engage the clutch lever. it's kinda like the pushrod is moving and then making contact with something before the clutch plates actually separate. I'm going to take everything apart one more time to double check things. I'm also going to bleed the system again, just to be safe. If anyone has any kind of experience with this noise, please let me know. I gotta think it's something stupid cause this entire system is not rocket science and I've had a number of other bikes apart like this before. They were Kawasaki's though. Maybe it's a suzuki thing. :GoneFishin:

Anyway...weather is great here now. The goldwing is getting exercise again, and it's comfortable to work in the garage. Just gotta get past this sluggishness from covid.

More to come.

Although no covid here, I know the feeling. The Diesel Project and the Bronda have both ground to a halt. There's a possibility that they both may go away if we get the second Ural.

I've gotten pretty good at looking at future projects on FB Marketplace and just saying "No".

I have problems saying no. :D

I'm getting better.

I failed at that one today. Approximately 300 pcs of HO slot car track, 10 controllers, 6 transformers, and a whack of pylons and guardrails for $50. Even though everything said it should work, Blackberry Raceway never did. Plan B.

Mr. Moderator. Please move this to the appropriate thread. You are way off topic. :lmao:

Well, it was an extension of this bit of the thread. ;) I failed.

I'll have to put you on probation until you get more training. :hehe:

is the training in Mexico? :)

my work has now been officially sidetracked by this. Goldwing rear tires are apparently a curse to me. :o

https://i.postimg.cc/ZqKn6ZH5/20230228-171145.jpg

https://i.postimg.cc/SQ8S2J4G/FB-IMG-1677633832066.jpg

so I'm going to go to a CT on this GW just like the last one. I had to order it from england and surprisingly, it arrived today. shipping was far quicker than I expected. I'm going to proceed with the tire install, but first.....a spring break trip to South Beach. :D

so, spring break in Miami was absolutely perfect. I'd post pictures, but y'all would just be jealous. :)

I have the rear tire changed out on the GW. turns out it was a valve failure. I've got new ones installed. I still have the front tire to change out. CT on the back and reverse-rear on the front. Double Dark. and new valve for the front just for security. Hopefully that will all be finished up by the weekend. Then back to the Intruder resurrection!

haven't updated for a while....

I got all the bits and pieces back on the bike and purchased a new battery for it as well. At this point, it's cranking. I still have two fuel lines from the tank to the petcock to install before I can try firing up the bike....but at least it's cranking and acting like a bike should.

here's a walk-around of where she stands now. don't get too excited. she's a 20 footer. if you get close you can see the wrinkles. :D

I still need to get new tires, but the ones that are on it are ok for a test run. Forks are bad, for sure. again...ok for a test run, but need fixed badly. I have started the process of getting a bonded title for it. Note the rear brake rotor is pretty rusty. I'd like to get that and a few other pieces that are rusty cleaned up to make it look presentable.

https://i.postimg.cc/XJXKyBd2/20230505-150013.jpg

https://i.postimg.cc/2yQ1qCcc/20230505-150022.jpg

https://i.postimg.cc/VL4N2G3C/20230505-150029.jpg

https://i.postimg.cc/ZndMpMpD/20230505-150036.jpg

so...good news and bad. got the remaining fuel lines in the mail. got them installed and gave the old girl a try. rear carb was spewing gas out of the overflow tube. I shut it down and had to put it away before I could do much troubleshooting. Likely it's a stuck float, so next step will be to beat on the carb a few times to see if I can free it up. if that doesn't work, I'll need to remove the carb and inspect in the float bowl. if no luck there, I'll ship it back to the guy that rebuilt them and ask him to take a deeper look.

More to come!

Tap test epic fail. Moving on to carb removal. <sigh>

You knew you weren't going to get away that easy. lol

I always just. Pull the carbs on anything that has sat. It's very rare for.the carb to be in good working order after sitting.

it's only sat for about a month. carbs were just rebuilt. this is just the first time flowing gas thru to fire the bike up.

Inline fuel filters? Lord only knows what may have left the tank and took the big trip down to a needle seat.

I hate carbs! any ideas from the masses why this carb would be puking fuel?


https://i.postimg.cc/qBDd5J9q/20230512-130537.jpg

https://i.postimg.cc/CL4bg2sR/20230512-130522.jpg

https://i.postimg.cc/CLCdTV78/20230512-130445.jpg

https://i.postimg.cc/wTr4pSB6/20230512-130518.jpg

Puking fuel out of the throat or the bowl? Throat, stuck float or crap betwixt the needle and seat. Bowl, possibly a cracked overflow tube.

from overflow tube. if I plug the overflow, out the throat of the carb into the air box.