Stevie wrote:
change the exhaust gaskets


I agree, if you tune a carb till its perfect and still have a pop, its the gaskets letting fresh air in and causing unburned gasses to explode in the pipe.

If the bike throttles up without stumbling, and runs fine other then the popping, and issues with maintaining a steady idle, I think the carb may be fine. Although Seafoam isn't considered to be a mechanic in a can, as long as the fuel is going where it is supposed to, it'll clean.
If the bike is stumbling and struggling off idle as you add throttle, then I'd agree, it is time to do a thorough carb clean.

I'll say again, that checking for manifold leaks, isn't always conclusive. Some have done it repeatedly, and until they have removed the manifold, surfaced the flanges, replaced the orings if they look bad, and then replaced the manifold, they have been unhappy.
The factory considered the orings to be a good enough seal, and didn't worry to much about the flange faces. Surfacing guarantees, that there isn't a high spot, letting air past.
Several have mentioned the exhaust gaskets also. Once they start leaking, replacing them with the high $ OEM's is your best fix. If you pull the exhaust loose far enough to remove the gaskets, and they have carbon tracks from the inside to the outside edges instead of a nice copper ring, then they need to be replaced.

+1 on making sure you get the exhaust gaskets with the copper...I bought a cheap set and they were worse than the old gaskets..

Johnrocks wrote:
I did what that little diagram showed.#1 looped hose from one AIS tube to the other #2 connected the two tubes that lead to each jug with hose #3 I used a 1/2'' stubby extention since I couldn't find a big enough bolt to block off the tube that runs off the top of AIS. This hose was the same size as the others. I suppose I could have a leak in one of the hose connections. I used the hose's that I disconnected. All three hoses were the same size.

Get rid of the entire AIS and plug the small hose or cap it at the manifold. Guys, wouldn't soldering it closed prevent you from using it later on for some other component?

Shores wrote:
Johnrocks wrote:
I did what that little diagram showed.#1 looped hose from one AIS tube to the other #2 connected the two tubes that lead to each jug with hose #3 I used a 1/2'' stubby extention since I couldn't find a big enough bolt to block off the tube that runs off the top of AIS. This hose was the same size as the others. I suppose I could have a leak in one of the hose connections. I used the hose's that I disconnected. All three hoses were the same size.

Get rid of the entire AIS and plug the small hose or cap it at the manifold. Guys, wouldn't soldering it closed prevent you from using it later on for some other component?

There is a certain attraction for those wanting a vacuum gauge to fill a hole in their Fairing, or seeking one more teensy bit of info about vacuum in the manifold. Beyond that, it is just an invitation for bewilderment, when the cap or whatever is sealing it, cracks, and leaves one wondering why going pumpless, makes his bike run like crap.

Shores wrote:
Johnrocks wrote:
I did what that little diagram showed.#1 looped hose from one AIS tube to the other #2 connected the two tubes that lead to each jug with hose #3 I used a 1/2'' stubby extention since I couldn't find a big enough bolt to block off the tube that runs off the top of AIS. This hose was the same size as the others. I suppose I could have a leak in one of the hose connections. I used the hose's that I disconnected. All three hoses were the same size.

Get rid of the entire AIS and plug the small hose or cap it at the manifold. Guys, wouldn't soldering it closed prevent you from using it later on for some other component?


Heat it back up with the soldering iron, hit it with a Solder Sucker, turkey baster, or some other squeeze bulb thingy, and the port is clear again!

ok, I got the AIS system disabled. I finally found the 1/8th vacuum line and plugged it with a golf tee. bike runs much better, still pops on decel but not as often or as intensly. I ran it up hill at 85-90mph in 5th, wot then shut her down. Started popping around 60mph on down to 50, downshift to 4th, a couple of pops, same in third and second. Sprayed the intake from the fuel pump side with starter fluid to avoid the carb intake, the rpms increased for 2-3 secs. I did this several times and got the same result. Guess the manifold does have a leak. Is it rebuildable or should I invest in a Barons ported manifold. I'm going to order the AIS kit from them but want to hold off until I get some opinions on the manifold situation.
Since the carb is gonna have to come off I should probably at least get the extended PMS screw and at least take a look inside so I know what jets are in it, clean it etc...
Gonna check the exhaust gaskets tomorrow (don't have a torx that fits in those tight crevices). Thought I read somwhere to use the Yamaha gaskets along with a Felpro homemade gasket???

That's good news. I think Curt sells ported intake manifolds.

Get one of Curts ported manifolds. He does all the work. It'll be ready to install.
Look in the classifieds here on the forum for ordering info.

If I do the ported manifold should I do anything to the carb besides maybe clean it and check to see what jets are in it. I do want to put a Barons PMS in it while I'm at it. This seems like it would be a good time to do a BAK mod and a rejet but I sure don't want to open up another can of worms. Not sure which way to go right now. I'm thinkin KISS.
Besides I still gotta get a new seat, that stocker is killin me.