Originally Posted by
Barrett
Sir: You have no base-line established to commence basic trouble-shooting. In simplest terms: If you have fuel...spark...compression...timing....your XB has no choice. It must and it will start. One or more of those ingredients missing.
YOUR BASELINE:
OIL-remove lower cowling...oil filter...swingarm drain plug. Allow several hours for bike to fully drain. After several hours, simply remove 10A fuel pump fuse or disconnect pump wiring harness and crank engine for 5-7 approx seconds to evacuate most oil from crankcase to drain. Appears your engine has "wet-sumped". This will be mostly resolved by cranking over. Refill with new filter and 2.5 quarts of quality 20W50 oil. There's your oil capacity baseline.
OIL CHECK: Your procedure for checking swingarm oil level is incorrect. The 2003-only oil fill cap dipstick wildly inaccurate. Your procedure also incorrect.
PLUGS AND WIRES: Replace whatever is in there with NGK DCPR8EIX. Best XB plug. 9 is one heat range colder if you like. NGK supplied gap is fine. OHM the plug wires. If they appear incorrect as you stated then simply replace. Probably garbage.
AIRBOX BASE ATTACHMENT BOOT: Your so-called "velocity stack" connects the airbox base plate to throttle body assembly. It must be installed and fitted correctly for your XB to run properly. If missing or improperly installed your XB will run horribly.
FUEL PUMP: The 2003 pump is unique. Design was decent but longevity wasn't. It will need to be removed and either fully rebuilt by competent tech or replaced with 2004-newer design.
Good luck.