The Suzuki Intruder 1500, also known as the Boulevard C90 in later years, is a classic cruiser admired for its robust engine, comfortable riding position, and distinctive styling. However, like any motorcycle, it’s not without its potential pitfalls. Understanding these common issues can help owners anticipate problems, perform preventative maintenance, and keep their Intruder 1500 on the road for years to come. Let's dive into some of the quirks and potential headaches that can arise with this beloved machine.
So, You're Thinking About an Intruder 1500? Let's Talk Real Talk
Before you jump headfirst into Intruder 1500 ownership (or if you're already there), it's important to be aware of some areas where these bikes can be a little… temperamental. Knowing these issues upfront allows you to be proactive with maintenance and repair, saving you time, money, and frustration down the road. We'll cover some of the most reported problems, from electrical gremlins to mechanical hiccups.
Electrical Issues: The Bane of Many a Cruiser
**Battery Problems:** Let's start with a very common motorcycle problem, the battery. The Intruder 1500, like many cruisers, relies heavily on its electrical system. Weak batteries are a frequent complaint. These bikes require a good, strong battery to start reliably, especially in colder weather. Symptoms include slow cranking, difficulty starting, and potentially even complete electrical failure.
- The Fix: Invest in a high-quality AGM (Absorbed Glass Mat) battery. These batteries are more resistant to vibration and have a longer lifespan. Consider using a battery tender when the bike is not in use, especially during the off-season. Regularly check the battery voltage to ensure it's within the recommended range.
**Charging System Woes:** Beyond the battery itself, the charging system (alternator/stator and rectifier/regulator) can be a source of headaches. A failing stator or rectifier can lead to a battery that doesn't charge properly, resulting in the same symptoms as a weak battery.
- The Fix: Use a multimeter to test the output of the stator and the rectifier. Consult the service manual for the correct voltage and resistance readings. If either component is faulty, replace it with a quality aftermarket or OEM part. Ensure all connections are clean and tight.
**Wiring Harness Gremlins:** Older Intruder 1500s can suffer from wiring harness issues. Wires can become brittle, connectors can corrode, and insulation can crack, leading to shorts, intermittent failures, and general electrical chaos.
- The Fix: Inspect the wiring harness for any signs of damage. Use dielectric grease on all connectors to prevent corrosion. If you find damaged wires, repair them properly with solder and heat shrink tubing. Consider using a wiring diagram to trace circuits and identify potential problem areas.
**Ignition Switch Issues:** The ignition switch can sometimes fail, leading to starting problems or even complete loss of power. This is often due to wear and tear or corrosion within the switch mechanism.
- The Fix: Try cleaning the ignition switch contacts with electrical contact cleaner. If cleaning doesn't resolve the issue, the switch may need to be replaced.
Fuel System Foibles: Keeping the Engine Purring
**Fuel Pump Failures:** The Intruder 1500 utilizes an electric fuel pump to deliver fuel to the engine. These pumps can fail over time, leading to fuel starvation and poor engine performance. Symptoms include hesitation, stalling, and difficulty starting.
- The Fix: Check the fuel pump relay and fuse first. If those are good, test the fuel pump's pressure output. If the pressure is low, the fuel pump may need to be replaced. Consider replacing the fuel filter at the same time.
**Carburetor Complications (Pre-Fuel Injection Models):** Older Intruder 1500 models (pre-fuel injection) rely on carburetors. These can become clogged with debris or develop vacuum leaks, leading to poor idling, hesitation, and overall poor engine performance.
- The Fix: Clean the carburetors thoroughly, paying attention to the jets and passages. Replace any worn or damaged parts, such as O-rings and diaphragms. Ensure the carburetors are properly synchronized.
**Fuel Injector Problems (Fuel Injected Models):** Fuel-injected models can experience clogged or faulty fuel injectors. This results in similar symptoms to carburetor problems: poor idling, hesitation, and reduced power.
- The Fix: Use a fuel injector cleaner to try and clear any blockages. If the problem persists, the injectors may need to be professionally cleaned or replaced.
Mechanical Matters: Engine and Drivetrain Concerns
**Clutch Issues:** The clutch on the Intruder 1500 can experience wear and tear over time, leading to slipping, grabbing, or difficulty engaging.
- The Fix: Adjust the clutch cable to ensure proper free play. If the clutch is slipping, the friction plates may be worn and need to be replaced. Inspect the clutch basket for grooves or damage.
**Transmission Troubles:** While generally reliable, the Intruder 1500 transmission can sometimes experience shifting problems, such as difficulty shifting into gear or popping out of gear.
- The Fix: Check the transmission fluid level and condition. If the fluid is low or contaminated, change it. If the problem persists, the transmission may require internal repairs.
**Shaft Drive Maintenance:** The Intruder 1500 uses a shaft drive, which requires regular maintenance to ensure smooth operation. Neglecting the shaft drive can lead to premature wear and failure.
- The Fix: Change the shaft drive oil according to the manufacturer's recommendations. Inspect the U-joints for wear and play. Grease the splines regularly to prevent corrosion and binding.
**Valve Adjustment:** Regular valve adjustments are crucial for maintaining optimal engine performance and preventing damage. Neglecting valve adjustments can lead to noisy operation, reduced power, and even burnt valves.
- The Fix: Check and adjust the valve clearances according to the service manual. This is a relatively straightforward procedure but requires patience and attention to detail.
Suspension and Handling Hiccups
**Fork Seal Leaks:** Fork seals are prone to leaking over time, especially on older bikes. Leaking fork seals can lead to poor handling and reduced braking performance.
- The Fix: Replace the fork seals and dust wipers. Consider using a higher viscosity fork oil to improve damping.
**Rear Shock Wear:** The rear shock absorber can wear out over time, leading to a bouncy or uncomfortable ride.
- The Fix: Inspect the rear shock for leaks or damage. If the shock is worn, replace it with a new unit. Consider upgrading to an aftermarket shock for improved performance.
Common Quirks and Annoyances
**Neutral Light Issues:** The neutral light can sometimes be finicky, failing to illuminate even when the bike is in neutral.
- The Fix: Check the neutral switch and its wiring. Clean the switch contacts or replace the switch if necessary.
**Speedometer and Odometer Problems:** Speedometers and odometers can sometimes malfunction, providing inaccurate readings.
- The Fix: Check the speedometer cable (if applicable) for damage or kinks. Inspect the speed sensor and its wiring. If the problem persists, the speedometer or odometer may need to be replaced.
Preventative Maintenance: Your Best Friend
The best way to avoid many of these problems is to perform regular preventative maintenance. This includes:
- Regular oil changes
- Checking and adjusting valve clearances
- Cleaning and lubricating the chain (if applicable) or maintaining the shaft drive
- Inspecting and replacing worn brake pads
- Checking tire pressure and tread depth
- Keeping the battery charged
- Cleaning and lubricating all cables and levers
By staying on top of maintenance, you can significantly reduce the likelihood of encountering major problems and keep your Intruder 1500 running smoothly for years to come.
Frequently Asked Questions
**Q: My Intruder 1500 is hard to start in cold weather. What could be the problem?** A weak battery is a common culprit. Also, make sure the choke (if carbureted) or fuel injection system is functioning properly.
**Q: My bike is hesitating when I accelerate. What should I check?** Check the fuel system, including the fuel pump, fuel filter, and carburetors or fuel injectors. A clogged fuel filter or faulty fuel pump can cause hesitation.
**Q: My clutch is slipping. What can I do?** First, adjust the clutch cable to ensure proper free play. If that doesn't solve the problem, the clutch friction plates may be worn and need to be replaced.
**Q: How often should I change the shaft drive oil?** Refer to your owner's manual, but generally, it's recommended to change the shaft drive oil every 12,000 to 15,000 miles.
**Q: Where can I find a service manual for my Intruder 1500?** You can purchase a service manual from online retailers like Amazon or eBay, or directly from Suzuki dealerships.
The Intruder 1500: Still a Great Ride!
Despite these potential issues, the Suzuki Intruder 1500 remains a popular and enjoyable motorcycle. By being aware of these common problems and performing regular maintenance, you can keep your Intruder 1500 running smoothly and reliably for many years to come. Don't let these potential issues scare you; with a little knowledge and care, you can enjoy the open road on your trusty Intruder 1500.