I got some time with the project this afternoon. Much tweaking settings and test driving.
The first thing I did was swap out the stock return spring for something a little more wrist friendly. Original spring on left, replacement on right.
Huge difference in comfort and it still closes the throttle fine.
I am now running the idle jet drilled to 0.60 mm. The idle mix screw is at 3.5 turns. The accelerator pump is set at 3/4. The main jet is now a 142 Keihin.
I tried to measure the original main jet. If you remember it had no markings on it at all. Using my micro drill bits, I found the original main jet to be somewhere larger than my 1.30mm bit but smaller than the 1.40mm. I don't have any way to measure any closer than that. I wanted to try a larger jet to get more pull at bigger throttle inputs. I had a Keihin 142 so I put that in. Oh baby! That caused me to get bugs in my teeth, if you know what I mean.
I have learned to adjust one thing at a time until you are not getting any improvement and then move on to the next adjustment. It still needs to be done in order: first idle, then midrange, then top end. On this carb, midrange is an overlap of idle and top end with the accelerator pump helping to fill in the gap.
I did experiment with the accelerator pump today also. It was factory set at the 1/2 point. I first moved it to 1/4. I didn't get any changes, good or bad that were noticeable. Then I moved it up to 3/4.
That was a big help. When riding along at steady cruise, then twisting hard, like you need to pass a car quickly, the bike would begin to pull then stop pulling hard, like it was getting too much air and wanting more gas. If I backed off the throttle a little bit it would pull harder again. This pump adjustment took almost all of that away. I am going to go another step up in main jet to see if I get any more power in that "car passing" range.
One other note. My stock exhausts were cut when I bought the bike. This might explain why DKL and I are ending up with different settings. You can kind of see them in the next picture.
I am really pleased at how this project is coming along. Another time or two of testing and tuning and it will be ready to go, carb wise anyway. I still have more lighting and misc stuff to take care of before it will be complete.
Thanks again for all the help, guys.