Yes, twenty years ago you would have to start pretty much from scratch unless some magazine or local riders did the work and learned what was needed. Now you can do a thorough search and make a seriously educated decision when multiple sources give similar feedback.

In my cam chain tensioner side line the internet and forums made it possible both for riders to find what they needed and me to sell what I made. I've never actually advertised, because it would jack up the cost to the riders, in turn they put out reviews, videos, and feedback. Plus, as in the case with the KLX250, they contacted me to make the part they needed. I did not have a KLX250 when I made the first part, TNC did. I still do new ones based on rider needs and requests. The most recent ones are a Husky TE630, Yam;aha XS400 and a Suzuki GS500. The GS happens to be the same as the DRz, but the TE was new as is the Yamaha XS. I like doing ones like the XS, because it keeps another old bike running right.

I think the same reward could exist if a good proven jetting kit was worked up with more positive background research rather than just throwing a bunch of brass in a bag as it seems to be to an extent with the DynoJet. If KLXter would get "in the middle" with a jetting set up I think riders would support it. He wouldn't be looking for a vacation home in the Bahamas, but he'd have some help supporting his bike habit along with new research.

 

I appreciate all you fellas - and your support..
You know klx678, if I end up having to create a needle to properly fuel the FMF system - which would likely work well with any larger-than-stock header and midpipe system - I might consider packaging it all up as a kit.. It is very surprising how different the fueling requirements are, compared to using a stock header + slip-on..

DynoJet: Yes I have been in contact with one of the jetting specialists numerous times. They are no help. They always advised to "put the lid back on".. That is all they know..
I had to research and learn about the CVK circuitry and operation so I could understand why removing the lid was such a "radical" thing to do - Turns out, it's really just because our MAJ and PAJ are not replaceable. And removing the lid sets the AFR in the pilot jet and needle jet all askew (which can be allowed for with retuning) - there are other less important items that are altered, like the vacuum / diaphragm vent port pressure gradient that lifts our slides...etc..

Anyway, I could go on and on.. Hey wouldn't it be nice to roll your stock KLX in some place and come back the next day to pick up a full-on 22-23HP bike for, maybe, $700..? That'd be exhaust, MCM, and a lidless carb setup..

 

Like I said and you clearly understand, it would be great to compare to the KLX stuff, get the best, bag it and sell it. If you can get a break from a dealer/independent shop you could pick up some money as well as make a quality kit for a rider with little to no guess work. THAT would be nice.

Key thing with all you're doing - you may want perfect, but in general darn close is good. We used to have a joking comment when it came to some work we'd do for ourselves and close friends - "good enough for who it is for". Sometimes I'd go too far in pursuit of perfection and screw up the work I had done that was darn good. You know the good range for jetting versus perfect, also knowing what will work 95% of the time for 95% of the riders. That has value.

I know it is an expense, but if you consider this, you may consider getting the Kawasaki KLX300 parts and do your magic with them to see how it compares and what can be done. Which does best.

By the way, I called Orient Express about a tensioner for my Zephyr 550, which was not listed, asking them to measure the adjuster bolt on the GPz550 tensioner so I'd know if it would work. They just said they didn't have a part number for my bike. I emailed APE asking if they could make a GPz550 body with a longer bolt - no response. The guys on the Zephyr zone goaded me into making my own and I made 5. No problem selling the other 4 when mine worked. Another rider said if I made them for the 750 he'd buy 3 - in the UK. He did. That was about 7000 tensioners ago now. APE now makes a Zephyr 550 kit.

 

You might also look into what the EX500 carb uses too

 

EX500, got it..

 

I might be able to help with that. I have my old EX collecting dust. The carb's are stock.
I even have the manual somewhere...