[Mfidget]

I recently bought my 2003 Intruder 800 and I love it! I do have two questions, though.

1) There is a box mounted to the rear of the passenger seat back that I can't identify. It is about 6 inches high by 4 inches wide by 3 inches deep. It has a Suzuki logo and seems to have brake lines entering the underside at 2 points. Also, it's a California model. Anyone know what this is?

2) The only possible gripe I have is the small fuel tank. Is there a source of an aftermarket tank to fit this bike that's a bit larger?

Thanks!!

----Mike

 

[DrBob]

That ‘box’ is the emissions control evaporator canister for California models. It can be removed, but don’t just yank it off and plug the hoses. I can find the instructions to disable and remove the system if you want.

Several companies make aftermarket tanks, but they are expensive. Seeger Cycles sells a basic 5-gallon tank for the 800 for about $800, or a 5-gallon tank with a cool Harley-style gauge console on it for about $1500. Thunderbike in Germany has an 18-liter (about 4.7 gal) tank for about $600 with shipping. There are others on the market, but these are the only three I know of that keep the original seat, as they are wider rather than longer than stock.

My Intruder 800 goes about 120 miles before it hits the reserve tank, which is about average for a motorcycle, Gold Wing types excluded, so I kept the original tank.

 

[Mfidget]

Dr. Bob, you mentioned you had instructions for removing the emissions control canister from my Intruder. Where do you think you would get that info? Is it something I could get my hands on?

-----Mike

 

[DrBob]

If you pull the hoses and leave them open, the bike will run like crap because it will suck too much air into the system. If you plug the hoses, the bike will run like crap if it runs at all. What you need is vacuum line 'T' fitting, one where the two big ends fit nicely in the hoses going to the evap canister, and the third end of the 'T' is much smaller, say 1/8 inch or so. Try an auto parts store like Pep Boys for a good assortment.
Remove the two hoses from the evap box, and splice them together under the seat with the 'T' fitting, leaving the third, smaller end open. This will provide enough backpreasure in the system to make the motor run right, so you can now remove the box from the back of the seat.