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.

It's not recommended that this method be used on the VS1400 Intruder. The VS1400 Intruder is set up differently than the VS800 Intruders when it comes to air/fuel ratio's and exhaust restrictions. (See NOTE below)

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.

NOTE: If you choose to drill the exhaust on the VS1400, do not perform Step 3 or Step 4 from the above diagram as the bike will not run correctly.

In Step 1 on the VS1400 Intruder I used 4 holes between the rivets and then drilled 4 more holes straight through for my Step 2. Rejetting may or not be needed on the VS1400 Intruder if you drill the stock exhaust. Minimun recommendation is the turn the carb adjustment screws for each carb so they are min 2 & 1/4 to 2 & 1/2 turns out to decrease the possibility of a lean condition. If popping on decel persists re-jetting is recommended.

Some of this information and the Diagram could originally be found @ Miss Vickie's House of Ill Repute, most notably the VS800 Intruder Info. I've placed it here due to numerous requests. The Information on the VS1400 Intruder is based on my personal experience, your experiences may not perfectly match mine. As usual judge the risks you are willing to take & exercise your own judgement before performing any modification.

If You Attempt Modifications & Ruin Your Motorcycle
It Is Your Problem.
If You Are Not Mechanically Inclined,
Get Help From Someone Who Is

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Use @ Your Discretion

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