Alright, buckle up, because I’m about to spill the beans on my Suzuki Intruder 800 1995 project. It was a wild ride, full of grease, sweat, and a few choice words, but damn, it was worth it!
So, it all started when I stumbled across this Intruder 800. A buddy of mine was looking to offload it. It was sitting in his garage collecting dust. He was practically giving it away. I mean, the price was right, but the bike… let’s just say it had seen better days. The paint was faded, the chrome was rusty, and it sounded like a bag of rocks when it ran. But hey, I saw potential!
First things first, I hauled that beast back to my garage. Then, I spent a good day just assessing the damage. Made a list, checked it twice, and realized I was in for a long haul. But I was determined. This wasn’t just about fixing a bike; it was about bringing a classic back to life.
The engine. Oh, the engine! It was rough. I started by draining all the old fluids. They looked like sludge! Then, I pulled the carburetors. They were gunked up beyond belief. Spent hours cleaning them, replacing jets, and generally making them look like they actually belonged on an engine. The Intruder 800, from what I read, had a decent V-twin – a four-stroke, water-cooled OHC, producing around 50-ish bhp. I wanted to make sure it was purring like a kitten again.
Next up was the fuel system. The tank was rusty inside, so I used some rust remover and gave it a good shake. Worked like a charm! Then, I replaced all the fuel lines and the fuel filter. No point in having clean carbs if the fuel is still full of crap, right?
Spark plugs were next. Popped the old ones out, and they were toast. Replaced them with some fresh ones, and the difference was night and day. While I was at it, I checked the ignition system. Everything seemed in order, so I moved on.
With the engine basics sorted, it was time to tackle the cosmetics. The faded paint job had to go. I stripped the bike down to the bare frame. Sanded everything down, and then applied a fresh coat of paint. Went with a classic black – can’t go wrong with that! The chrome parts got a good polish and a bit of rust removal. They weren’t perfect, but they looked a hell of a lot better than before.
The tires were shot, so I ordered a new set. Got them mounted and balanced. Suddenly, the bike was starting to look like something I could actually ride! Checked the brakes, they were okay but pads were thin so I changed them, flushed the brake fluid. Safety first, always!
Put everything back together, double-checking every bolt and connection. Filled it up with fresh oil and coolant. Then, the moment of truth. Hit the starter button, and… nothing. A few choice words later, I realized I’d forgotten to connect the battery properly. Rookie mistake! Fixed it, tried again, and this time, the engine roared to life! It sounded amazing. Like a completely different machine.
Took it for a test ride, and it was smooth as butter. The engine pulled strong, the brakes worked great, and the handling was surprisingly good for an older bike. I was grinning from ear to ear. I had done it! I had brought this old Intruder back from the brink.
Spent the next few weeks fine-tuning everything. Adjusted the carburetors, checked the timing, and generally made sure everything was running perfectly. And you know what? It was. This Suzuki Intruder 800 1995 was now a reliable, great-looking machine. It’s now my weekend ride and I love every single minute of it.
Reflecting on the project, I’m proud of what I accomplished. It was a lot of hard work, but it was incredibly rewarding. I learned a ton about motorcycles, and I gained a new appreciation for the craftsmanship that goes into building them. Plus, I’ve got a killer bike to show for it! Would I do it again? Absolutely!
