Pilot Mixture Screw Setting

[penningpd]

Maybe. I don’t know. Gonna try the 37.5 pilot and see where that gets me. I will go from there. To quote a movie “never give up. Never surrender!”

[penningpd]

37.5 pilot is on order…..now we wait.

[Lug Nut]

Like Dave J said...if your bike runs good with stock everything AND PMS out 4.5 turns better spray some starting fluid around the intake manifold area and see if idle changes...inspect rubber intake manifold carefully...could be cracked through or not sealed properly or the nipple on top where the hose attaches could have crack in that hose

[penningpd]

I will check those things. It’s supposed to be 48 here on Monday. That will be a good day to get out in the shop.

[penningpd]

Ok. After checking for leaks I believe I found one at the intake manifold and rear cylinder. What’s the best way to fix a leak there?

[Lug Nut]

Order new manifold. I always use OEM but recently had 3 Road Stars that all needed new manifolds in past couple months....so I tried a different one from eBay and they worked fine (like $55).

You can hand port if you want extra power (very slight increase and don't over do it or you will hurt performance)...

Make sure you also get new orings and you will want to get 1 or 2 large sheets of 400_500ngrit sandpaper to sand the mating surfaces smooth. Make tontonus a very smooth surface for the sandpaper...use WD-40 oil on paper and sand mating surfaces nice and flat (a greenish coating is on those surface sand till gone). Make sure to use some pressure and keep manifold surface very flat as you sand (figure 8's work best). Takes about 20 min. Then clean manifold with soap and water and dry. Then install new orings (I use a little grease on o rings.

When installing make sure you clean head surface with paper towel and brake cleaner good...

Install by putting 4 screws in finger tight and use 1/4 in torque wrench, 5mm hex head socket, short extension, swivel...

Final torque is 105 inch pounds...start at about 30 and go 60 then 90 and finally 105 and go in criss cross pattern.
Kind of a pain in the ass but won't have any problems then.

Also while manifold is off bike you can seal the top nipple (I use a rubber cap and gorilla glue...works well. Some braze over the little metal tube. Assuming you have removed AIS and aren't using stock air box you need to block off this nipple or you will have nasty leak (bike run terrible).

[Shores]

Why get a new manifold if the original one isn't cracked? Sounds like he just has a leak at the flange which could be flattened with your sandpaper suggestion.

[penningpd]

Ok. I get everything but the AIS part. How do I remove it from the bike?

[Brad_G]

Ok. I get everything but the AIS part. How do I remove it from the bike?

http://web.archive.org/web/20170402105616/http://roadstarclinic.com/content/view/47/105/

[penningpd]

Do I NEED to remove the AIS?

[Lug Nut]

Do I NEED to remove the AIS?

If you change to aftermarket exhaust it greatly help decel popping. It cleans up the front of the engine and removes weight. If your all stock you don't need to remove.

[penningpd]

Ok good. I will
leave it and ensure there are no cracks in the hoses.

[brianmac]

use grease on intake manifold NEW O rings

[Lug Nut]

I would buy new manifold for $55 and not try and work with old manifold that may not be sealing well....all the work to get it apart, sand, reinstall....I'd spend $55 and out a new one in there that will last 15+ years. I messed with re sanding and sealing cracks on one bike and 2 months later had the same leak.

[penningpd]

How is this for flange preparation?

[Lug Nut]

How is this for flange preparation?

Looks good...I may spray brake cleaner on the O ring area and scrub with a tooth brush real quick....then when dry use some heavy grease on the orings and put in the slot.

[penningpd]

So you really just coat the o-rings in a thin layer of high temp grease - right. “Don’t use too much”?

[Lug Nut]

So you really just coat the o-rings in a thin layer of high temp grease - right. “Don’t use too much”?

Yes just a thin layer..keeps them pliable and aids in sealing

[penningpd]

Ok. Two questions. Does the image look like I have stock exhaust? I assumed it was but don’t know for sure. Also, what size main jet should be installed - 165? There are no modifications all stock with a 37.5 pilot jet. 2001 1600

[Brad_G]

Looks like stock Yamaha pipes to me.

[penningpd]

Good! Now I just need to know the size of the main jet and what size the vacuum tube from the intake manifold to the AIS is.

[Lug Nut]

Good! Now I just need to know the size of the main jet and what size the vacuum tube from the intake manifold to the AIS is.

165 main jet stock (167.5 if you do open air cleaner and aftermarket exhaust).

Not sure if there would be any harm in using a 167.5 main along with your 37.5 pilot.....Dave J or Duke may have info on this?? If you did this now (resetting) you wouldn't have to do it again IF you ever went to pipes/air cleaner...