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").
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 (http://www.sudco.com/) would
probably be the best
source, but I don't think they do retail.
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