I just replaced the exhaust pipe on my 2003 700 sportsman with a two piece pipe kit for a 800. Fits great and I thought the header type pipe should work well. Took it out for a test run and the first time I mash the throttle it dies. Now will barely run above idle. It was running good before just had an exhaust leak at the Y pipe. Its like the needle fell off the slide in the carb which I will check tomorrow. Might be just a coincidence that happened right after I put the pipe on. Just wondered if anyone had installed that kit on a 700 and had carb issues. Thanks

 

Check that the intake manifold isn't split,especially under the carb clamp.Can cause one to run lean and bog. If the intake manifold or the carb or fuel supply isn't the problem,could be the troublesome Ducati ignition about to go out.

 

Thanks OPT, I do know about those other issues, been there done that. This is related to the new exhaust pipe that is bigger but still goes into the same muffler. CV carbs are sensitive to air flow changes even on the exhaust side apparently. Was wondering if anyone knew the right combination of needle, jets, springs etc. that would make this work.

 

If you are running the stock silencer you may not need to re-jet.
I was running the Pure Polaris/ White Brothers silencer along with the 800 pipe, airbox snorkle and a K&N air filter...

You should have a 155 main jet in from the factory (model years 2003-2004).
With stock airbox try a 162.5 or a 165 and work down after plug reads at WOT.
Maybe go down one slot on the needle clip.


I have a 162.5 in and its running good with a tan plug in the 50-80 deg. range (0-2k altitude) with the K&N and 800 pipe/snorkel.

I may need to jet up for colder winter weather under 40 deg., maybe a 165 or 167.5.
I bought 165 thru 170 mains at my dealer for $4 each.

Jim

more photos at...
800 Pipe -snorkle Photos by jimmypsp700 | Photobucket