I have an 01 R* 1600. It sat for a couple years and I gave recently gotten back into it. I had a failed oil gear and I was lazy putting her back together. I was having major backfiring thru the carb when I found out the oil gear was gone. So I fixed that recently and she is running ok. Recently I was getting some bad popping on decel and did my homework using a propane torch I found that I have a vacuum leak at the intake manifold. I figured I would do the jets when I took it apart. Ordered my new manifold which had cracks and dry rot. The bike is stock besides long shots,AIS removed, and k&n air filter. I pulled the jets and one was 35 the other 195. I bought 172.5 and 37.5 thinking that was right for this setup. I am assuming that the 195 is DJ. Before I put it back together should I do the 172.5 or get a bigger one? When whoever put in the intake manifold they used a sealant along with the o-rings, do you recommend a sealant?

Thanks for your time... Sorry for the lengthy post.

Mike

Yamaha installs the manifolds with just grease and the orings. Many here have used Hylomar, or Permatex's Permashield. It s a thin blue pasty sealant that doesn't harden for high temps and is fuel resistant.. Surface the flanges before installing the manifold. Some 320 or 400 wet or dry paper laid flat on a hard smooth surface like glass or granite. Work the manifold flanges in figure 8's on the paper until any irregularities are cleaned up.

On a 1600, with less restricted intake and exhaust, the 37.5 Mikuni Pilot, and the 167.5 or 170 Mikuni Main will be good with a multi groove Barons or DJ needle, with the clip in the 4th groove from the top(blunt)end. Set your hot idle to 900rpms, and the PMS at 2 3/8 out from lightly seated.

Just out of curiosity when the dealer does the recall for the clip do they take off that manifold or do they leave it on? They are the only ones that have done anything to this bike besides myself since I've owned it and there was a beige colored sealant that was hard as a rock used on that manifold. I am almost wondering if that was part of my leak issue.

The dealer does take it off. If the sealer was light grey it may have been Yamabond4 case sealer. If so it is some pretty good stuff. It shouldn't have been hard as a rock though. I'm not sure what color other Yamabond products are.