Pilot Jet Mod 

Description Pilot Jet Mod
Author Matthew Date Wed Nov 28, 2007 12:43 am Type Type 1
Category Fix It / Mods
Comments [18 - Post your comments]
Views 3127  [Rate Article]

Pilot Jet Mod

Following " Vitalizing the Virago article
[or see below]

I found a Tool & Supply shop and got me a No. 76 drill bit.
90 cents and very tiny.

I used a pair of needle nose vise grips to hold it vertical.
The pliers have groves or teeth that hold it nice and straight.

I use a Bic metal point pen to hold the pilot jets.
I just removed the plug in the end and jammed the jet inside till flush.

It was very easy and you just need to be careful,
but the pen trick really helps hold everything straight.
Along with the vise grips.


User comments 
ff/medic Posted: Sat Oct 07, 2006 10:40 pm    Post subject

I am going to do this mod. anything to add or any other tips & tricks before I dive right in?
Matthew Posted: Sat Oct 07, 2006 10:57 pm    Post subject

For me it was the best mod ever, over jardines and the maxim front end mod.

Even with a stage 1 K&N jet kit, the pilot jet mod was the finaly ticket to ride the rocket.
ff/medic Posted: Mon Oct 09, 2006 1:12 am    Post subject

okay thanks.
club_c Posted: Mon Oct 09, 2006 11:48 am    Post subject

Medic, keep us posted, I want to do this also in the next couple of weeks...

sbrogden Posted: Mon Oct 09, 2006 1:19 pm    Post subject

Matt - does the pilot jet mod affect gas mileage?
Matthew Posted: Mon Oct 09, 2006 2:38 pm    Post subject

Gas mileage was never a concern or problem.
geo Posted: Tue Oct 10, 2006 5:12 pm    Post subject

i have no regrets for doing mine. gas mileage may be down a mile or two. starts easier and smoother throttle control.
vroomvroom Posted: Thu Oct 12, 2006 8:18 pm    Post subject Re: [ KB ] Pilot Jet Mod

Just to make sure I completely understand, you do not use a drill or anything but rather just the actual drill bit as a sort of a screw? So that you just spin the jet or the drill bit through the existing hole to widen it?
Matthew Posted: Fri Oct 13, 2006 2:15 am    Post subject

Yea dude, you have no idea how small it is. But you do need something to hole the bit firmly in place. They sell pin vises for them small suckers.

Just be careful and go straight and slow. Don't wanna rock it around.
Timbox3899 Posted: Tue Nov 21, 2006 9:50 pm    Post subject Great fix for mine thanks!!!

This is my fist Virago, and I started with a broken rear cam. After I got her running she was popping and making all kinds of backfires. So, this little mod was just what my bike needed. Yes the .020 or #76 drill is small but if your careful you can pull it off the fist time and have it running in a mater of 20 mins. Good luck to all and thanks for a great mod illustration.
orpheus Posted: Wed Nov 22, 2006 7:27 am    Post subject

I drilled to only .46mm at first just to be cautious. It ran a little better at low rpms but nothing major. The other day I drilled them again to .50 and it is noticeably better in those ranges and accelerates to higher rpm faster, too. I have stock air cleaner but aftermarket pipes.

Drilling is very easy. I recommend the pin vise method.
ttraczyk Posted: Thu May 10, 2007 3:14 pm    Post subject

I did this recently to my 81 XV750. The results were great. It took a minor bit of adjustment on the idle screws. It starts easily, and warms up quickly.
joestacey06 Posted: Mon May 14, 2007 6:56 pm    Post subject Re: [ KB ] Pilot Jet Mod

I have an 86 1100. Would this be worthwhile for me to do while I have my carbs out rebuilding them?
Matthew Posted: Wed Nov 28, 2007 12:43 am    Post subject [ KB ]

[ Article updated...Matthew ]

Category: Fix It / Mods
Type: Type 1

Article Name: Pilot Jet Mod
Author: Matthew
Description: Pilot Jet Mod

>>Read Full Article
srinath Posted: Mon Dec 03, 2007 12:09 pm    Post subject Re: [ KB ] Pilot Jet Mod

Holee cow, you guys running 46 and 50 pilots. Yikes. I got something amiss in mine.
I am running 40's. I believe 37.5's are stock on the 87 1100. I went to 40's 2 years ago. I didn't drill mine, I just put them off the GS500 parts pile. Now its run great till clogging up earlier this year. I am thinking I'll take a set of 37.5's and drill it. I have 100's of 37.5's I liberted off GS500 carbs.
r3830 Posted: Thu May 08, 2008 2:41 am    Post subject

This is simply a GREAT mod! Has virtually done away with cold choke starting - and saved a hard working starter motor .... not to mention the battery that supports it.
Many, Many Thanks!!!
club_c Posted: Thu May 08, 2008 2:14 pm    Post subject

Yeah, I'm still doing final adjustments/synching of carbs but also do not use choke at all with .50 pilots
hardcorerider1 Posted: Tue Jun 02, 2009 9:20 pm    Post subject

when doing this do you use the same pilot screw or do you get a new one

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