Back at it

[mswyka]

We are back at sorting out why the 1979 Intruder starts so well but runs so poorly.  So yesterday the sled came into the shop and we are going to start over at the beginning.

To recap the sled starts and idles well.  On the last outing back in March the sled flew down the lake and then lost power.  We were able to limp back to the barn.  Off the ice the sled seemed to perk up a bit.  But another run a week later confirmed that it had no power.

Compression is good.

Fuel Line is clear and flowing.  5 psi from fuel pump.  Clunk not obstructed.

Secondary was frozen the prior year.  Secondary freed and working properly.

I did not check primer.  So this is still on the list.

After that I am going to need to pull and disassemble the engine.

[mswyka]

Engine is out and apart.  Looks quite good.  Some evidence of bearing chatter.  Cylinders are clean and measure on the low end of acceptable range.  Pistons show some wear and measure  towards the high end of acceptable range.  I will likely replace some bearings and get new pistons and rings.

[Interceptor398]

Your off to a better start to winter than I am.  I'm still working on the winter wood pile but getting close to enough.

[mswyka]

Your off to a better start to winter than I am.  I'm still working on the winter wood pile but getting close to enough.

I am thinking that you have made the wiser choice. 

[Ameritude]

If a coil gets hot or "saturated" due to being old, it can cause a loss of power aswell. If you have a spare, I would throw it on just to be safe. Happy sledding 

[mswyka]

If a coil gets hot or "saturated" due to being old, it can cause a loss of power aswell. If you have a spare, I would throw it on just to be safe. Happy sledding 

Definately a possibility.  Good thing that we have spares.

[mswyka]

Making progress

[Interceptor398]

Which sealer are you using?

[mswyka]

On this engine I am using Permatex Motoseal.  This is the first time I have used this product.  In the past I have used Permatex aircraft sealant.  On one engine I used Permatex anaerobic flange sealant - jury is still out on this last one as I have never run this particular engine.

[mswyka]

Reassembled and ready for a test ride.

[Interceptor398]

Good work!  Smoked up the garage yet??

[mswyka]

Ah yes, the garage now has that intoxicating aroma of two stroke that just makes me itch to climb on and pull the throttle!

[Interceptor398]

That is a good feeling!

[mswyka]

Three weeks ago we recieved a good storm - enough to do some riding at the house - so I was able to take the Intruder out for a test ride.  Everything seemed to work - not great, but not bad - until I tried to pull a steep hill and ended up running alongside the sled thinking it was about to die and didn't want it to die in the middle of the hill. 

Ray sent me a link to a thread describing a similar problem that was posted here on the site where the filter in the fuel pump seemed to be starving the engine of fuel.  http://kawasakitrax.com/kawiforum/index.php?topic=1930.0    So with that information I pulled the pump, and even though the filter did not appear to be obstructed, I removed the filter and buttoned the pump back up and re-installed in the sled.  Last night I was able to take another test ride and the sled performed remarkably better.  We need some fresh snow for a full test, but for the moment I am encouraged.

[mswyka]

Finally got some snow and took the Intruder out for a test.  It is running like a new sled.  It has not run so well in years.  Hard to believe that the filter in the pump would have that great an impact on operation.