Won't be in the clymer.  Jetting is an art, not a science.  To get it perfect, dyno it, but that's $$$.

Jetting is an art, not a science.  Go to your local bike shop and buy some "Big Round Mikuni Mains," say 140 to 160 sizes.  That is over kill, but, it's an art.  Buy some #3 or 4 SAE sized washers from the hardware stores.  Also, yank out the pilot jet before you go to the bike shop.  buy at least 2, bigger ones than are in there now.  Now go to the tech sect and read and re-read all you can on carbs and jetting, and go to it!  Still got questions?  Post again!  We're all friendly! But learn how to use the search feature!  A lot of us get tired of answering the same ?s over and over agin.  (not to be rude here... just sayin')

Make sure you read the one on the white spacer / midrange and backfires.  

As for the 160, you prolly' won't need it, but a lot of folks are running 155s w/ aftermarket exhaust and modified air intake.

In general:  if you increase airflow, you must rejet up, period. end of story.  There are two basic cheap, easy ways to increase airflow: 1) open up the intake airflow (many, many  ways on this bike) 2) open up the exhaust.  After that, you get into stuff like new carbs, cams, porting the heads, valve clearances...

A lot of folks do 1 at a time to trouble shoot.  I like doing both at once, get the jetting right ONCE, and be done w/ it.

Dude, read, read, read!

Good luck and have fun!

V

Although the DJ kit has a coupon for a free dyno run if that's what you really want to do and know who will accept the coupon.

You won't hurt the engine unless you jet it way lean (to much air comapred to fuel, i.e. too small a jet size) and run it hard, usually on the highway.  Since you will be richening it anyway, this is not a concern.

The only other thing to really worry about is stripping screws.  That can be a pain in the neck.  There are relatively simple ways to ge them out, though.  In general, the screws that hold on the float bowl should be replaced w/ stainless steel allen bolts anyway as the brass ones are soft and tend to strip.

Specific to screwing up the carb, DO NOT:

1) loose parts
2) pinch/tear the rubber flange that goes on top
3) bend the needle
4) screw around with the float level, tabs... unless you are sure this is causing a problem.
5) stretch the big spring too much
6) overtighten the jets when installing them

Also, there is a washer that goes on the main jet that people occasionaly forget to put back in.

Also #2, magnetic tipped screw drivers help a lot when reinstalling the needle plate.

not counting taking out the carb, it should only take about an hour, maybe 1.5 hours for your first time rejetting the carb... if you are lucky (i.e. don't loose stuff...)

When you install the new muffler, try to eliminate exhaust leaks.  I have one, but don't really care.  When you reinstall the carb, make sure the seal is good, you don't want intake leaks either.

No, you drilll them from the outside.  Torque, whose savage does not rest in peace, but pieces in Lancer's garage, punched everything out of his baffle.  You may want to look up his old posts.  Anyway, basically start drilling holes in the back of the pipe until it sounds the way you like it.  This link has instructions for doing this to stock V* 650 pipes.  The 2nd - 4th links are all different ways to go about it.

I do recomend at least re-jeting the midrange, but the whole range is lean from the factory, unless you live at altitude, then it's probably close to right.

Definitly post pics!

V

Yep, started replacing them upon removal too, when possible!

Okay, thanks.  That was a quick response.  From what Ive read, my tuning is right-on.  The initial curve from the headder is gold and I've made no changes.  Bought the bike with only 400 miles on it, so I doubt the previous owner made any changes.  Go figure...

Here's a picture.  The bars were given to me and the grips cost next to nutt'n.  The local Har--- stealership wanted like $75, but a local discount shop had these for a whole lot less.  Gotta' do something with the brake line though.  Yeesh!

God loves a tinker...all of us.