Kawa-Bunga! A Project Sled for 27

skiroule

Well-known member
My apologies for mangling the classic 60’s surfer expression but it seemed to fit.

I figured I had to decide this spring whether to attempt another project and if so, what kind of project. In the end, I couldn’t shake my fascination with the Kawasaki. It is so different from anything else I have done.

In a different thread I had talked about starting the documentation of a project earlier in the process so I hope you guys are ready for a longer run. All I can promise is that there will be some updates each month throughout the spring, summer, and fall with a target completion date of January 1, 2027. I always expect the unexpected but I don’t see any obvious showstoppers on the sled. I’m a little out of my comfort zone on this sled but maybe that’s not a bad thing.

I’ll post these photos as a visual reminder of the starting point. There are a couple of things I’m thinking about that will change the final look quite a bit, the biggest being color. In 1982, Kawasaki changed the color of the Intruder to red, which I think made it a really sharp sled. Also, I’m debating converting the windshield to an Invader windshield to give it a little lower profile.

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I couldn’t find a photo of an 82 Intruder but I did find a brochure photo that shows the sled in red. My version wouldn’t have the pleated seat but you get the idea.
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skiroule

Well-known member
So it is a 1982 Kawasaki Intruder, is that right?
Looking back at my original post, I did give the impression that it was an 82 and thanks for reminding me to clear things up. The sled is actually a 1980 but I like the color scheme better on the 82 model so I decided to go with that look. I didn’t even know Kawasaki made a red sled but a friend gave me a bare 82 chassis and part of a hood, which is how I found out.

It’s funny, before I even picked up a wrench, I sat and stared at the sled for a long time. I suppose I was trying to gauge my ability to finish it against the work to be done. Once the toolbox opens, it’s a total commitment for me.

I have stuck my toe in the water a little bit and started with some of the easy disassembly items: hood, front bumper, muffler, seat, gas tank.

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As Heckler said, it will definitely make the summer go faster for me. As busy as summers are, I’m sure the sled will get a share of the spare time that’s available.
 

skiroule

Well-known member
Hoping everyone had a good Easter and got to spend it doing the things you like to do on Easter Sunday.

For me, a little shop time was on the list. A few more items are now missing from the chassis: Skis, spindles, steering link, oil tank, handlebars/controls, carbs, and dash.

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In the earlier post that listed the seat as one of the items removed, I didn't mention it but I knew there was something fishy about the seat. It had been recovered but it just didn’t look quite right. I didn’t really like the cover and was going to replace it anyway so I had yanked it off. Sure enough, the seat foam had a crack about where the rider sits. I suspect the original seat cover tore and between moisture and stress, the foam separated before it was recovered. For some reason it wasn't repaired when the seat was recovered. Should be able to repair it now.

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Unlike a lot of manufacturers of the day that used wood for a seat base, Kawasaki used a molded plastic base (or pan, as they call it). The storage compartment can be salvaged but the pan is pretty much toast, all the corners and seat mounting points are broken. It’s kind of funny, the only thing keeping the seat on were the two Phillips screws through the tail light lens. Removed those screws and lens and the seat came right off.

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Luckily, the pans are being reproduced. Not cheap, but at least they’re available.
 
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heckler56

Well-known member
I wonder how much seat foam has evolved? When/if you replace it, do you get your choice of foam density and how does one decide firm vs soft (like picking a mattress which I have been unsuccessful throughout my life).

You got me going online and researching Kaw and wondering how many of the underlying design/sourced materials/perts from Sno Jet carried over to their name branded sleds. I haven’t had this much fun since high school small engines class!
 

euphoric1

Well-known member
I wonder how much seat foam has evolved? When/if you replace it, do you get your choice of foam density and how does one decide firm vs soft (like picking a mattress which I have been unsuccessful throughout my life).

You got me going online and researching Kaw and wondering how many of the underlying design/sourced materials/perts from Sno Jet carried over to their name branded sleds. I haven’t had this much fun since high school small engines class!
"I haven't had this much fun since high school small engine class!" I AGREE!! I have a few resto projects, I wish I had the knowledge and drive Kelly has, another thing is the time to commit. I love classic and vintage stuff and I appreciate the people who preserve it, without them it would just disappear because lets face it there are more of those who could care less than those that do and once its gone its gone. I enjoy Kellys knowledge of what he does, his ability to customize and how he is able to see it in his mind and make it happen. And one thing I really enjoy in following his posts is "I wish I could do that" I appreciate his ability and desire to preserve and as corny as it may sound I picture myself doing it. Again I love the vintage stuff and I'm that guy who's hair stands on end when I go to vintage shows and stuff like thrashoree shows. Two words I have for you Kelly.... THANK YOU!
 
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