Basket case - 2007 Intruder 125 / GN125 - Project Log

CB450DX

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Jun 1, 2024
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Location
Curitiba, Brazil
Went to my mechanic to change the brake hoses and do a few other things. The 2 inferior brake hoses ended up being too long (my fault), and close to 6:30 PM I had the idea to cross them to stretch them.

Well, it was 6:30 PM, they were closing and I just wanted to wash my hands and arms and go home. Worked a lot and learned a lot that day, but I really needed a coffee and a couch.

Mechanic lent me this bike to ride home:
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"Put 1 liter of gas in it just to make sure it doesn't leave you stranded and you'll be good, if you like it, it's yours for R$3500" - those were the conditions I guess. R$3500 amounts to about $660 USD.
Client sold it to him, had documents but they dated back to 2012, and he put in new piston and rings and a cleaned head - didn't look at the head, but he did show me the new piston, cylinder looked good too.
Had new oil, new brake pads, new brake oil as well.
Throttle cable was terrible, but worked, clutch cable and lever were 10/10 though, much due to a new cable as well.
Non-working tachometer (but it is spinning normally on the engine, so it's a panel problem)
All the gear numbers work on the panel, but 2 of them are burned.
Clearly had terrible owners who just did whatever to it. 99% of the stuff was original and OEM, but didn't look too good. You can see on the picture how they just welded the footpeg support to the frame. Still, it's a 125, it should be fine.

VERY FUN bike. I was giving her gas, pulling through gears, even reaching fifth and when I looked at the speedometer, I wasn't even going 60kph (~37mph). I loved it.
Made my girlfriend come and see it, great learner bike for her especially since the seat is so close to the ground. I ended up taking her on a few rides on it around the block and I was also pretty amazed at how this little tractor just didn't care about the extra weight. The torque was just there, it ran completely fine even with her on the back - The difference was curiously smaller than the difference I feel on my CB450 (but then again, the CB enjoys higher RPMs and that's not something I usually do with her on the back)

She ended up buying it, along with a friend who also wanted a weekend bike. I of course, checked all the documents online and confirmed she had nothing illegal or related to insurance tied to it.
And now it's my job to restore this. But both my girlfriend and her friend are kinda short on money. And since last week when I moved out of my mom's house, so am I.

So it'll be a slow one. The first thing I'm going to tackle is of course the throttle cable which is very cheap, and then the rest of the stuff will come later.
I already cleaned out most of the plastics from the 18 years of dust, already put in new screws on the cleaned air filter and now I just gotta fine tune the carb, as it starts wayyyyyyyyy too easy while cold and does not like wide open throttle at idle which leads me to think that it's quite lean.
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During this teardown, I also found that the wiring harness is a unit made by Zouil, so at least it's a good aftermarket one, same brand as the one I'm using on my CB.

Another fun thing I only found out later, it has.. uh.. Pyrex glass on the front? I guess I could say that?

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Yep. It's a plate. A decorated plate.

The rest of the stuff should be pretty easy other than the suspension which I won't bother trying.
Whole front globe is also pretty cheap.
New panels are easy to find from a good brand, can easily find gas tanks or just paint it simple red, or just let it be and put a red gas tank cover.
Sprockets/Chain/etc are also cheap especially since it's just a 125.
I already changed the handlebars to my old CB450 ones, but don't have any pics at the moment.

Will post more. When it happens, if it happens.
 
Dude, you sure find some crazy stuff there! Can't say I've ever seen anyone be creative enough to use a Pyrex dish for a headlight glass. o_O
 
I wrote a whole ******* post and apparently did not click to post it, and I only find out about it months later. Here's what was done:

As I said, I had already put in the CB 450 DX handlebars. She already has/uses the CG125 clutch lever + cable as well - I'll buy new handlebar switches some day, they're pretty cheap but for now it's fine. The clutch deserves a special mention since it's buttery smooth, feels almost hydraulic, even better than my CB450 which I'm already pretty proud of.

New panel (and new cables), everything, including the gear indicator on top, working perfectly now:
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New headlight globe and etcetera - it was missing the wiring harness for the position light, has arrived but I haven't gotten to it yet.
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Replaced the battery as well but didn't take any pics.

I also bought a CG125 carburetor but recently studied a bit more about mechanical carburetors and learned it's normal for it to "burp" if I give it wide open throttle too quick/on very low rpms so I'm not bothering with it for now.
Starter has also stopped working as well, I replaced the brushes when I bought the bike and it seems it failed again.
Brushes cost 1/4 of a new motor, brushes with support cost 1/2 of a new one.

So I'm just gonna go ahead and buy a new one. It starts surprisingly easy, I can start it pulling the wheel on the center stand. Bumping is even easier.

Wife and her friend have been learning on this bike and it's going great so far, wife is aaaaaalmost putting it into 2nd gear, a few more days and she'll get it.
 
I also bought a CG125 carburetor but recently studied a bit more about mechanical carburetors and learned it's normal for it to "burp" if I give it wide open throttle too quick/on very low rpms
Yep, standard slide carbs without accelerator pumps will do that, here's a video I made of my 450 with Mikunis on it to show a guy on Reddit.

Wife and her friend have been learning on this bike and it's going great so far, wife is aaaaaalmost putting it into 2nd gear, a few more days and she'll get it.
That's great, it's always good fun to be able to ride with your partner (way more fun than carrying them around) (y)
 
Yep, standard slide carbs without accelerator pumps will do that
Nice to know, the CL sounds agressive, these dohcs have an awesome roar.

I'm probably going to keep the original Mikuni that is on it. I opened it when I bought it to check and it was pretty clean.
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Looks abused, but clean. The float is floating, and I never saw gas flood out of it, although I'm pretty sure she runs rich as hell since she starts up ridiculously easy no matter how long she's been off (never used choke) and the choke gets the idle a little bit down but kills the bike if I give it throttle.
Not to mention how black the spark plug was, and also the fact she burns a little bit of oil (also going by the spark plug) but she never smoked and even with her steady dripping on my tiles, oil has never gone low. I did put 20w50 on her when the correct one would be 10w30 - I'll change it after I fix the starter motor (so who knows when)
The current oil also has about 120kms on it, I barely ever use her since I love the cb so much.
I replaced the spark plug as well because the old one was bad and old.

And I honestly love the fact that I'm not worried about anything with this bike. Hell, I don't have its documents/title.
Who cares if it burns oil? It only needs 1 liter, and I'm pretty sure she won't mind the cheap semi-synthetic stuff.
Who cares if its running rich? It's a 125, at its richest it's still probably going to do more than 30km/l and I don't think I've ever put more than 4 liters of gas (barely over a gallon) on it.
I also want to remove the PAIR system, emission/crankcase pressure non sense. But who cares, it's running for now.

Also, who cares the tank is all dented, it doesn't leak so I just put a red tank cover on it and now the bike's looking... Maybe decent? It can certainly fool some people.
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Still gotta fix one of the blinkers that stopped working, then figure out why the hell does it have a 6V Blinker Relay/solenoid from a Harley Davidson (????????)
Worst offender now has got to be the front suspension, needs a full rebuild with new oil and of course new seals.

But it's fine, it's a fun little tractor.
And my studio has become a full-on single dude garage, and I've been enjoying it.
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(old pic).
 
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