You are too hung up on the spacer thing. There is no stock spacer, so you do not need a spacer, period. Just reset the e-clip to the 4th spot and you will be fine. The spacers they mention go on top of the needle and have nothing to do with the needle height, this is a spacer for the clip and spring.

 

i couldnt get the bike to run good on low end with the lid off... so as do i have the lid on with no snorkel in it.

 

I'm running a 128 main DJ and stock pilot out 2.5 turns and with the same header but with an FMF powercore 4 silencer.....mine runs perfect.
#1 check the caps that you used to plug the smog crap on removal...An air leak at one of them will do this instantly.
#2 i'm not using any spacers at all on my needle either as it didn't have them stock.I put one small washer (from the DJ kit) under the clip (3rd position from the top,non pointy end) and it shows a darn good plug reading and runs great with no hesitation or decel pop.
also check to make sure (i know it sounds stupid ) that the carb boot clamps are tightened up good......It almost sounds like your pilot circuit isn't providing fuel .....hence the no start.
The needle could be in whatever clip position you want and it will start and idle and run fine till you go past 1/4 throttle.....
Read the FMF description of carb jetting and you'll quickly see this.
also welcome to posting.....have fun and good luck.

 

also no lid on my airbox.

 

Truckman, what made you try the shim under the e-clip? It sounds like you are running it at say at the 2 1/2 clip position. Was the third position too lean at 3/4 to WOT? Are you running a quiet core and or spark arresstor on your exhaust? (trying to gauge restricton)

 

That's exactly what it is for...it's a 1/2 position i guess you could say.That's what seem to work best after all my test and tune.
I am running a QC on the FMF but i wasn't on my initial setup and a few weeks later i installed the QC with O difference in power or plug reading.
The 3rd position i'm running with the shim is really like a 3 1/2 position (neddle is raised higher).I also tried the #40 pilot jet which was great in the fact that i never had to use the choke to start the bike but it drank fuel like a pig and there was NO noticable gain in the bottom end power....

 

you guys are being very helpful, and I think I maybe understanding my mistake now, i hope. I see where I totally goofed about the spacer thing. If it was on the bottom (pointy side) it would matter, but marc11 is right, on the top, it is just a spacer for the spring and holder. I feel so retarded now. I'm going to go back to fuel injection, lol

I'll change that tonight, I doubt it would fix the hard starting. To get the bike to start, I have to use the "lean the bike" method with the choke on. This bike always started fine stock, so maybe Truckman is correct that I have a vacume leak.

I'll check this all out tonight and report back. You guys are awesome!!

 

sometimes if the bladder on top isnot in perfect; you can get this same thinghappening with the clip on pos. 3-4. Take your time-
it can be frustrating [&:]to get that rubber back in just right.

I guess what I'm trying to say...... if you change the needle and still have the same problem [] don't get too pissed
it could be the darn rubber! [:@]

sounds like you got it handled!

 

[quote]ORIGINAL: wedge

"sometimes if the bladder on top isnot in perfect;"

That would be a Diaphragm.The bladder is farther in and seldom gets "Installed." As far as I know, anyway...

 

...LOL...yeah the diaphragm could also be your culprit too.....forgot to mention that one as well.