Okay, I have a 1999 GS500E and I have already shimmed the needle and added 140 mains (#40 pilots soon too) to make it run run better with my pipe and UNI filter. I was wondering if the only difference between the jet "kit" and just replacing the jets is that some of the jet kits have you drill the slide. If so can't I just drill the slide myself? Dose anyone know what size and where to drill the thing? I'm assuming that the mod is supposed to give better throttle response but don't know exactly why.

Has anyone done this? Dose anyone have the instructions from a jet kit that you could post? Dose anyone know that I'm about to ruin my bike?
Thanks 

The slide drilling ... OK its completely unneccasry to drill it, because you plug it after drilling ... and they give you 10-32 plugs. You can get a 4-40 plastic screw and plug the thing by just tapping it and cutting it flush and sanding it smooth. The reason they have 10-32 is cos the screw is larger dia and they put an allen wrench pocket in it. The 4-40 is harder to do that in cos its smaller. Big freaking deal ... you can cut and sand it instead of putting it in and not sanding it.
Now here is what you even need that thing plugged. Their needles are seriously tapered. So when the slide lifts the mixture gets richer faster than it needs it. Your stock needles are less drastic taper. Your needle actually is tapered with a good estimate of how rapidly your motor can build rpm. They have to have 2 or 3 different tapers in the needle because that are attempting to run a much much smaller main jet. See the DJ kits were designed in the 70's as somehting you can just drop in wihtout taking carbs off the bike. but of course the fac that you ahve to remove the caps on mix screws in the 80's shot that in the ass, but theys till retain their stupidity.
Really you are better off wihtout one hole shut in the slide. if you open throttle slowly and the bike runs fine, and open fast and it falls on its face ... that means your slide is comming up too fast. then plug 1 hole, but I doubt its happening in your case.
In most peoples minds, drilling the slides are the worst thing about jetting.
Cool.
Srinath.

2004+ owners don't need to drill anything do they?

Can't they just buy three new jets for each carb 

dynojet's web site has an instruction sheet in pdf

Thanks guys 

Quote from: seshadri_srinath on September 21, 2006, 10:30:23 AM
The slide drilling ... OK its completely unneccasry to drill it, because you plug it after drilling ... and they give you 10-32 plugs. You can get a 4-40 plastic screw and plug the thing by just tapping it and cutting it flush and sanding it smooth. The reason they have 10-32 is cos the screw is larger dia and they put an allen wrench pocket in it. The 4-40 is harder to do that in cos its smaller. Big freaking deal ... you can cut and sand it instead of putting it in and not sanding it.
Now here is what you even need that thing plugged. Their needles are seriously tapered. So when the slide lifts the mixture gets richer faster than it needs it. Your stock needles are less drastic taper. Your needle actually is tapered with a good estimate of how rapidly your motor can build rpm. They have to have 2 or 3 different tapers in the needle because that are attempting to run a much much smaller main jet. See the DJ kits were designed in the 70's as somehting you can just drop in wihtout taking carbs off the bike. but of course the fac that you ahve to remove the caps on mix screws in the 80's shot that in the ass, but theys till retain their stupidity.
Really you are better off wihtout one hole shut in the slide. if you open throttle slowly and the bike runs fine, and open fast and it falls on its face ... that means your slide is comming up too fast. then plug 1 hole, but I doubt its happening in your case.
In most peoples minds, drilling the slides are the worst thing about jetting.
Cool.
Srinath.

why do you drill the slides?

BTW, got my shaZam! tuned perfectly. Here is the final setup.

142.5 mains, 40 pilot, 2.5 turns out and zero #4 washers. Runs like a champ. Thanks buddy.

If your bike acceletaes perfectly when you open the throttle slowly, but gasps and starts sounding dry when you whack it open under load (AKA 3rd gear and higher) that is a sign you need to block 1 hole in your slide. drilling is needed only if you are planning to put a huge ass screw in it. I block them by tappinh with 4-40 and using a nylon 4-40 machine screw and cutting it flush.
If your needles were drastically tapered, you'd more than likely have to do it. So DJ gives you that with the kit.
Cool.
Srinath.