VS800 Intruder Exhaust Mod

Drill Your Pipes For Maximum Sound & HP

ADDENDUM: In order to drill the 6 holes outlined in step 2, it will be neccessary to angle the drill bit a little. If you can't do this easily, then I recommend you just drill 3 holes in the second baffle instead of 6. There really isn't a noticeable difference either way.

On most modern bikes, the EPA dictates a certain level of exhaust emissions and in order to achieve these low levels, bike manufacturers have to set up the bikes so that they burn very lean (lots of air, and just a little fuel). Consequently, when you replace the stock factory mufflers... or when you drill thru the stock mufflers, the bike breathes a lot better, which means it now can draw even MORE air thru the carbs. The problem with this is that if we start with a lean condition to begin with, and then we add even more air... the bike then runs TOO lean and TOO HOT... and we take a very real chance of destroying the engine in a VERY short length of time unless we immediately take steps to increase the amount of fuel we feed the carbs with all this extra air we are pumping into the engine.

For some reason, the Intruder 800 is exactly the opposite of most bikes though. When we increase the breathing power by opening the exhaust, the bike actually runs richer instead of leaner... and we do not have to do any carb work to the bike to correct a too-lean condition. It turns out that increasing the air flow actually boosts the low end torque and hp of the bike without the need to re-jet.

Some of this information and the Diagram could originally be found @
Miss Vickie's House of Ill Repute
. I've placed it here due to numerous requests.

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