Naked Jugs for Dummies

The Complete Reference

Note: removed dead links due to volusiaowners.com going down

INTRODUCTION:

This page is designed to be a fill in the gaps resource for people wishing to sport naked jugs on your Intruder Volusia VL 800. Including the COMPLETE shopping list to get this project done. I will attempt to ASSUME NOTHING, making this a plain and simple step by step guide.

STEP 1 (left side):

Pair Valve removal: Order the kit from Mocc's Place and get on good terms with your wife or one of your kids 12 years or older, their hands will be helpful during this project. Pair Valve removal is a standalone project and I recommend doing it first because it won't effect anything else.

THINGS YOU NEED:

  • Gasket sealer
  • 8 mm box wrench
    • (I mention this because my metric set went down to 9 mm, and I had to run out to buy an 8 mm in the middle of the project).
  • Another pair of hands is most helpful.

    • SIDE NOTES to Step 1:

    Mike takes Paypal, the kit is $20 including shipping, he stocks the kits and ships fast. The kit comes with the same instructions posted on his web site. Dealing with Mike was one of the most pleasurable aspects of this project. The bike loses some down throttle noise while engine breaking, also loses the pinging sound of air being injected into the exhaust, which many people probably don't notice anyway. All side effects of this project are positive.

    STEP 2 (right side):

    Removal of air cleaner, installing a uni filter and rejeting the bike: This is where the confusion begins, and why I decided to make this page. The purpose of this page is to fill the gaps, and bring all resources into one location.

    If you are uncertain about your future mods to exhaust, or want a full array of main jets for your personal inventory, then the (dead link removed) DYNO JET KIT #VL800-DJ3195 for $52 (2004 pricing) is for you. Besides 8 main jet sizes, the kit also comes with a couple of springs, a needle valve, washers, e-clips, a screw, and a drill bit. IT DOES NOT INCLUDE A PILOT JET.

    A can also be bought at Oneida Suzuki for $12 (2004 pricing), and it doesn't weigh anything, so if you're already getting the DYNO KIT, get the filter with it to save on shipping.

    There may be several places to get the pilot jet, but www.motorcyclecarbs.com is definitely one of them, they probably could save money over the DYNO #3195 option too, I found out about this place too late for myself. I paid $6.95 for the jet and $6.95 (2004 pricing) for priority mail (I feel I could have found a better deal then this but got caught off guard on this aspect of the project and didn't have time to shop it)

    Also see Briman's (dead link removed) to get an idea of what jets you might need.

    SHOPPING LIST:

  • UNI Filter
  • Main Jet
  • Pilot Jet
  • Air breather for hose on 2nd Jug* (See Parts pic below)
  • Vacuum connector (See Parts pic below)
  • Air filter oil (Spray can)**
  • Small Hose Clamp

    • THINGS YOU NEED:

  • Vise grips (to break loose bottom carb screws)***
  • Drill (to remove plug to access mixture screw, drill bit in DYNO kit)

  • Briman's rejetting Instructions

  • Sock or rag to stuff into venturi (IMPORTANT)


    SIDE NOTES to Step 2:

    I didn't know the DYNO KIT didn't include the pilot jet until the day I received the kit, but decided to do the rejet anyway, even though I found posts saying pilot jet must be at least 35 with a main jet of 150 or it won't run. I installed the 150 main and left the stock pilot, mixture at 3 turns, and it runs fine, I did still have to use choke to start, and my understanding is the pilot is low-end throttle response. I got the idea a pilot jet is like a pilot flame on a gas appliance, it helps get it started... On my little test run, full throttle felt more powerful, and the sucking air sound isn't as bad as I expected. My 35 pilot arrived, Installed it and turned the mixture screw 1/2 turn clockwise to 2-1/2 total turns from closed position, she RUNS GREAT.

    FOLLOWUP: Decided it was running a little rich based on gas mileage, so set the mixture to 2 turns, still runs great, and just got 40 mpg on my last tank of REGULAR gas. I was getting about 42 mpg on premium gas before the rejet, so do the math, this project will pay for itself over time, and puts more power at your command too!

    * The breather I bought for the 2nd jug is Autozone part#: 3998 (chrome) for $9. Cheaper filters will fit, I actually bought a $3 one, but didn't like so exchanged it for this. See my (dead link removed) for installed picture of filter, it comes in one size and four colors, I bought CHROME!

    ** I bought a K&N air filter recharge kit from Autozone which includes cleaner, spray oil, and instructions $12. (another area where I over paid, but now I'm set for a while)

    *** The vise grips only helped me on two of the carb screws, I used an impact driver to remove the 3rd screw, I suspect a smaller vise grip could have helped, but my impact driver was closer at the time.

    Breather Parts


    This is a work in progress, and I will update with new resources as people bring them to my attention.
    I hope this page helps take the mystery out of the NAKED JUGS modification.