Reprinted by permission from Mr Tidy's tech tips

I report this as a last ditch effort for those who may experience extreme situations where their bikes are persistently backfiring through the intake OR exhaust, AND conventional efforts to fix the problem prove fruitless.

It is not a panacea for problems that might be fixed through normal jetting and adjustments. I do want to stress that this is not the best way to fix MOST backfiring problems. Usually the correct fix is performed with alterations to jetting and insurance that the intake and exhaust systems are sealed.

My own Road Star has been plagued with vicious intake backfiring since it was new. The backfiring has frequently been so forceful that stalling the engine was common and at least twice it reversed the engine's rotation.

The Yamaha factory rep couldn't do a thing with it, while it was under warranty and it has largely resisted my efforts as well. I had managed to reduce the intake backfiring a lot by reducing the accelerator pump volume and adjusting the pilot fuel system. That also reduced the stalling by 90% and eliminated the potential for engine reversal.

But the backfiring refused to be fully exorcised. Recently I filled the pilot air correction with solder and then drilled it to .031" (from an original approximate size of .040"). Click image for larger version

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Because the jets are brass, I find it easier to clean them up good and solder them closed. Then drilling the solder to the desired hole diameter is easy with a #1~#80 drill index and a Dremel tool. Some people might be tempted to epoxy the jet closed and then drill, but epoxy is less secure, harder to fill such a small hole and may chip out when the drill is put to it.

It has not popped up the intake even once in the last 200 miles. Again, end of problem.

While they do make alternate air correction jets (as I recall ours is a #100), I've never known a shop that stocks them and, in fact, few would know who to order them from. Sudco ( would probably be the best source, but I don't think they do retail.