Finished rejetting with a #128 main and N1TC needle with the clip on the second notch down from the top, fuel screw 2.5 turns out. Drilled the slid hole to 7/64ths and shortened the slide spring a tad to reduce slide opening resistence.

The throttle response seems slow and I'm not getting very good mid range power.

Would changing the needle clip to the third slot help?

Idle when warmed up is set at about 1000 rpm. Should I bump it up a bit.

 

Who told you to cut the spring AND drill the slide? One or the other boss...not both.

Your idle is slow, the manual says around 1250-ish. How did you come to those jet settings? Did you do anything to it to require those? Or did you just stick stuff in?

Hesitation indicates lean, bogging indicates rich. Which one does yours resemble the most?
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MASTURBATION SCHOOL

 

Throttle resoponse seems hesitent but it seems to bog under a load.

The jet settings were recommended as part of opening up the intake and exhaust to richen up the mix. The jet sizes and settings are from multiple sources.

So far the airbox is uncorked and has a hiflow filter. KLX 300 header and muffler are next up.

I've already got a new slide spring because shortening the original was an experiment like all of these tweaks.

 

aaah yes, I see.

You got yourself a 35 pilot in there right? Might want to drop the needle to the 3rd notch.

How is it up top? Still boggy? Or does it pull well?
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ARIZONA DISPENSARY

 

The pilot is the original.

It's been raining here alot so everything is snotty but what top end I've been able to use seems pretty good if I ease into it. If I snap it, it bogs or if I put a load on it, going up a grade, it bogs a bit.

 

the bike comes lean stock, try a 38 pilot. some have used a 40...

 

I see in your signature that you installed a Uni filter, have you also opened the airbox? If not this could be a problem.
Stock exhaust? This also can make it easy to over-jet the bike.

The jetting that you're using may not be ideal but it should be close enough that you should not experience poor throttle response, most people stick with the stock #35 pilot jet.

Depending on the number of coils that you cut this could also be the problem, most people don't mess with the spring.

Your idle speed is set too low as pointed out.

Are you 100% certain that you have got the rubber diaphragm seated back correctly, 90% of the time when the engine doesn't run correctly after the carb has been disassembled the diaphragm is the culprit.

 

I'd drop the clip on the needle one notch to richen up the mid-range.

 

Replaced the slide spring with new original, moved the clip to the 3rd (center) slot, removed some chicken wire while there and she's running MUCH better.

New header and muff are next but it's running well now. I'll worry about final tweaks once the entire flow curcuit is complete.

So far...so good though.

Thank you guys for the unput and help.

 

You could go up to a #132 main jet. The bikes in AUS come with a #132 main from the factory, #35 pilot. Ran fine with all the OE settings.