SOURCE: backfiring
when you replaced the exaust you should of had the jetting changed they have to be rejetted.
there is your problem
SOURCE: battery location for a 2004 suzuki intruder 800
Hi ...... Find where the battery is, under the seat or behind a side panel. Disconnect the black (negative lead usually with a 10mm spanner then disconect the red (positive) lead. The battery will be held in place with a 'rubber' strap or a bracket and depending on type of battery there may be a vent hose from the battery to the lower half of the bike, this just pulls off and remains in place until you replace the battery. Installation is reverse except you connect red (positive) first.
Let us know how you get on.
SOURCE: battery removel for a 2004 suzuki 800 intruder
I know for the models till 2002 where the battery is located in front of the rear wheel.
Place the bike on her side stand
remove the negative battery lead at the left side, just below the transmission tube ( cone ) 10mm socket wrench
On the right side remove the security cap on the positive lead ( cross screwdriver ), then remove the positive lead.
The battery is hold in place with a 'floor plate'. remove both bolts of the floorplate ( on each side ) while holding the palte into place.
gently lower the plate and the battery.
I hope the 2004 model has the same assembly!
SOURCE: My suzuki intruder is missing backfiring on the
Did you sync the two carbs? If not the rear may be getting all the gas from the rear carb and none to the front. Twist throttle engine off and see if front carb cable is pulling the carb open.
Also unscrew the spark plug boot from the front spark plug wire and trim 1/8th inch off the wire and screw the boot back in. The plug wire end may be corroded on that wire.
SOURCE: 2004 Suzuki VL1500 Intruder LC Motorcycle backfire
If they cant duplicate it your good.Usualy with backfiring i would make sure to eliminate any exhaust leaks. The dealer is inexperienced at solving compound problems,(sorry) not picking a fight, but sometimes cleaning is not goog enough,I went through this with a 1400 Intruder.several attempts were needed to get the two carbs level on the same line with each other.so the floats would work properly together,then set fuel flow and the air flow through the ventouri in the carbs.Also i had to make these adjustments while level (not on side stand) The floats were very sencitve to needle valve to seat adjustment(bent to open or close some of the flow)
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