2004 Suzuki VS 1400 Intruder - Answered Questions & Fixed issues

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.

Could be contaminated fuel, or bad spark plugs.

No, backfiring is almost always the mixture, not the plug and probably not the wires unless they are getting crossed. I would assume that in this case it is probably from the mixture being too rich. I would say the choke may be staying on too long.

337mls buddy each leg

The Intruder does handle fairly well compared to its' counterparts of the cruiser class, by handling I would assume your talking about how well it behaves in turns...since this class of machine IS the cruiser type do not expect to keep up with the current or past generations of sportbikes as you will fall behind. The best scenario is SMOOTH sweeping turns, the suspension in its' current form cannot deal with irregularities in the road...sportbikes' suspensions are meticulously calibrated for these real world curcumstances...cruisers cannot do this. The raked out front forks of cruisers make for a very stable platform but are not designed to be turned hard. A simple modification that I would myself do if I had a cruiser, would be the addition of a fork brace...a chunk of aluminum that strengthens the two front fork tubes..so that they don't flex (As much!). In addition I would pay attention to the exaust setup, footpegs and any other hard parts that would interfere with agressive cornering(Lean angle).Some exausts hang SO far down on cruisers that they really limit how far you can bend er over...all that stuff needs to be removed, changed or modified so you can corner good up to the suspensions limit.

The most likely thing is a sticking clutch. With the ignition off, can you drop it into second gear and push it with the clutch pulled in? You say you put 'new petrol' in, so it sounds like it has been stored for a while. Clutches will often stick as the clutch plates have been under pressure for so long. Fully warm the engine before moving off until the plates free up.And it looks like you probably mean VS1400 not VS400!There is help herehttps://www.google.com/search?q=suzuki+intruder+vs1400+stalls+when+put+in+gear..

I would look to the main inline fuse

Yes it is easier to work if you do. The caliper will easily slide off the disc if left in place, but not quite so easy putting the wheel and disc back in. Here is the VS1400 Service Manual

Suzuki Intruder VS1400 Service Manual

ManualsLib https://www.manualslib.com > ... > Intruder VS1400 View and Download Suzuki Intruder VS1400 service manual online. Intruder VS1400 motorcycle pdf manual download. ‎Engine - Tightening Torque · ‎Wiring Diagram (The Others) · ‎Balancing Carburetors https://www.google.com/search?q=2000+Suzuki+Intruder+GS1400%2C+removing+the+front+wheel&

Probably a course thread metric sized.

This sounds like an issue with your clutch. It looks like you have a hydraulic clutch, so it may just need to be bled. As long as it is something in the clutch actuation, like the master or slave cylinders, it is not all that expensive. However, if it is a problem with the clutch itself, it can be an expensive fix. First thing to check is to see if the clutch fluid reservoir has fluid or not.

3.7 quarts

check the fuses!

i do my hayabusa to about 20ft lb and the lock nuts do the rest.

have to purge air from the system

First check all battery cables and connections, no one may look loose , heated or oxydated. Jump the starter relay with a big diameter cable, if startermotor runs normally, replace the relay. Check the amperage starter takes when starting. if it's over 100A, then your starter or your engine is stuck.

check main fuse

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The carby butterflies or the carby levers to open and close the butterflies are stuck.

remove the battery cover and then you can get to the 2 battery cables. remove those I do the ground first then the positive. pull the battery out and replace and install reverse order. before installing the covers. check the bike starts and the 2 battery cables are tight. those should be about 15 pounds of torque. which is not a lot. since it does not do anything but hold the wires it does not need the same tightness as a tire lug nut.

unfortunately not unless you want to do a tremendous amount of fabrication, welding and rechroming