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  • #41
    Originally posted by davej View Post
    Install the dj pilot and see if it helps. If not install a Mikuni 37.5 pilot. I'd be curious to know. As Said I would never put out that type of info based on my assumption, It was from research and talking to DJ tech support to obtain that info. I guess the only assumption on my part was assuming that the tech support guy knew what he was talking about. lol
    Also there should only be 1 washer Under the clip. Putting 2 under the clip only richens the fuel mixture at cruising speed by about a 1/2 groove on an adjustable needle. In the stock configuration the cruising speed AFR does not need to be richened at all. The 2nd washer should be placed on top of the clip for the little spring to set on.
    I finally got around to installing DJ 37 pilot jet. I also removed 1 of the washers from under the needle clip and placed it on top. I had the PMS screw out 3.5 turns with the Mikuni 35, I took a guess and moved it back to 2-3/4 turns for initial setting. I tried starting the bike with the enrichener in (running position) to check if pilot circuit might be to rich, but wouldn't start. I pulled out the enrichener, and it started right up. I was going to take it for a long test run, but I got a mile or 2 away and it started pouring, so I turned around and came back. I had let it warm up enough before I left, and I think it's really close to where it needs to be, no hesitation, blipping throttle seemed crisp, and bike seemed to accelerate nicely. Throttle returned to idle quickly when letting off. I have to check the idle rpm, may try turning PMS back another 1/4-1/2 a turn to see how it compares, than take it for a longer run to verify it running well.

    I did take measurements of all the holes in both Mikuni and DJ jets for comparison. I have full set number drills to #80. I used the shank end of bits to test until I found one that fit snugly and the next size wouldn't fit. One thing I noticed, and I ran into this recently on aftermarket jets for a 72 Honda CB500 I recently restored, the DJ jet didn't do a good job of cleaning burrs off the back of holes. When I was trying to measure the id of the emulsion end of the DJ pilot, there were burrs on the back of some of the 8 perpendicular through holes. I had to use the drill end to clean the burrs off. The Mikuni jet was well machined with all sharp edges de-burred and the 8 holes on emulsion are chamfered (see attachment) Click image for larger version

Name:	20201017_PilotJets resized.jpg
Views:	108
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ID:	111093 . Keeping all holes clean from burrs will give the max flow it can. Burrs obviously can impede the flow. Anyway if you want dimensions, I can give them to you, I just didn't want to give you my scribble, I'd make a little nicer sketch.

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    • #42
      I put a follow up question here: for my 2003 XV1600 I have K&N airbox and plan to go for Cobra HP 2-1, carb is stock now. I have Barons jet kit coming + plus mikuni 37,5 pilot jet on top. Shall I go with 167,5 main, the 37,5 pilot and clip on the 4th groove in Barons needle, PMS 2,5 turns out? This is what I’m picking up here but would that fit with the K&N - Cobra -combo?

      Any other tips / things I should consider? Many thanks!!

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      • #43
        yes that will be the jetting for your bike with those mods. You may have to play with the PMS just a little with the weather being colder this time of year. you may need to turn it out 1/4 turn or so

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        • #44
          Thanks, davej, yes it’s off season for us here now...garage months ahead and back out riding hopefully in April again. (Yes, we know, the weather here in Nordics suck!

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