Intruders-Alert

Hey guys new to the forums. About 1.5 years ago I bought my 01 Intruder 800. The original owner said it ran great just needed a battery and carbs cleaned. After I purchased the bike I bought a new battery but was able to run it with choke pulled out. It did run very well. Shortly after I threw on some straight pipes and a pod filter on the rear only...no difference in performance. This past winter I wanted to bob it. So I removed the carbs and cleaned them. Removed the fuel pump for a holley (1.5-2.5 psi) threw the straights back on and both carbs got pod filters. I then synced carbs at idle and above 2k. Took it out and it ran like pure shit. I then purchased a sigma6 jet kit with the 145-150 jets. Still ran like shit. Took the carbs back off and threw in the 160-155 jets. Alittle better but still shit. At Idle and off its snappy. Soon as I go for half throttle plus it sounds like it ran out of gas. Back off the throttle and under 1/2 runs great. I tried about everything as far as the pods. I put 2 socks on each and doubled them up to the point where it ran like shit even right off idle(dead rich). I kept taking layers off down to just the filter itself. I have absolutely no idea. Im new to these bikes.

If you still have the parts, I'd put them all back on, just to see if it comes back. All the changes to the carbs and filter will add little power to the stock bike, and the filter and carb changes just make it harder to get adjusted. These engines were tuned very near their best from the factory.

Go back to the original jetting then wrap 1/2" filter foam around the pods. AF adjust and carb synch. Now you will have a good base line for fine tuning.

Put the old fuel pump back on.

hillsy wrote: ↑

Fri May 14, 2021 3:09 pm

Put the old fuel pump back on.

You think thats what it is?

Fuel pump wasn't the problem

Could it be the needles? Do they make an actual adjustable needle. In the sigma kit you have to use your stock needles. They give you a few washers but how does the needle move up when the round plate inside the slide limits it? Idk if I'm getting this right but the c clip stops at the plate so how does the needle actually move up enough to Richen it?

at around half throttle and above it feels like someone shut the gas off. It has fresh gas and is definitely on

As mentioned, the VS800 is optimal in stock configuration.
Jetting, pods, straight pipes, etc...will just mung it up.
The 1400 has room to move, the 800, not so much.
If you have the stock parts, go back.
JMO.

Jonnylightening wrote: ↑

Fri May 14, 2021 4:18 pm

Fuel pump wasn't the problem

Did you change back to the original to check?

What's the flow rate of the new pump? Is it correct for this application?

You've changed a lot of stuff - you should maybe backtrack a bit to rule some things out.

navigator wrote: ↑

Fri May 14, 2021 5:29 pm

As mentioned, the VS800 is optimal in stock configuration.
Jetting, pods, straight pipes, etc...will just mung it up.
The 1400 has room to move, the 800, not so much.
If you have the stock parts, go back.
JMO.

I dont have the stock stuff. I sold most of it. I honestly didn't think these bikes couldn't be modded. At this point wish I would have started with a better base bike

hillsy wrote: ↑

Fri May 14, 2021 5:45 pm

Jonnylightening wrote: ↑

Fri May 14, 2021 4:18 pm

Fuel pump wasn't the problem

Did you change back to the original to check?

What's the flow rate of the new pump? Is it correct for this application?

You've changed a lot of stuff - you should maybe backtrack a bit to rule some things out.

I did throw the stock pump on and hooked it up the way it was. The Holley I purchased has a flow rate of 1.5-2.5 psi. I asked on other forums but typical no response. I honestly don't know what else to do. Im kind of at the point of maybe just selling it and getting something else. Not to sound d like a dick but I wish I would have spent the extra $$$ and bought a Harley. The aftermarket is crazy for them and they seem to be a simpler design. The whole dual carb thing is killing it for me. I never in my life would have guessed that these things are that picky

Fit a pair of 5D22 needles, centre groove for the front carb, 4th groove down for the rear carb. When installing the retainer plate make sure that the orifice is not covered. The earth from battery to frame causes a lot of problems which seem to be carb related but are not. It would be a good idea to make up and replace this cable making sure that all mating surfaces are well clean. Also fit star washers to the lug screws. The fuel pump pressure should be 3 psi with a discharge rate of better than 600 ml/min.

Lechy wrote: ↑

Fri May 14, 2021 8:35 pm

Fit a pair of 5D22 needles, centre groove for the front carb, 4th groove down for the rear carb. When installing the retainer plate make sure that the orifice is not covered. The earth from battery to frame causes a lot of problems which seem to be carb related but are not. It would be a good idea to make up and replace this cable making sure that all mating surfaces are well clean. Also fit star washers to the lug screws. The fuel pump pressure should be 3 psi with a discharge rate of better than 600 ml/min.

Where would I find those needles? Is there a part #?

Jonnylightening wrote: ↑

Fri May 14, 2021 5:53 pm

The Holley I purchased has a flow rate of 1.5-2.5 psi.

Just to be picky, that is not flow rate, but output pressure. Flow rate would be measured as volume per time, like gpm. Spec on the stock pump is more than 600ml in one minute, or >0.16gpm.

WintrSol wrote: ↑

Sat May 15, 2021 12:31 pm

Jonnylightening wrote: ↑

Fri May 14, 2021 5:53 pm

The Holley I purchased has a flow rate of 1.5-2.5 psi.

Just to be picky, that is not flow rate, but output pressure. Flow rate would be measured as volume per time, like gpm. Spec on the stock pump is more than 600ml in one minute, or >0.16gpm.

25gal/hr (95L/hr)

This might be a long shot
check the wires and connections at and for the coils

Could also be the pods. The cheaper ones have a massive lip where they seat against the carb intake which blocks the air intake for the diaphram on CV type carbs.

5D22 is the number, there is a place in the US that specializes in carb parts maybe someone in here knows of it.

Had my cousin follow me with his bike and he said when it starts sputtering he can smell raw fuel. Throughout the short trip I grabbed the clutch and went WOT. Even with the clutch pulled in it seemed as though I was hitting rev limiter but the revs were nowhere near high enough for that to be possible. At this point I'm kind of clueless