i cut about a 2 5/8" hole in my stock cap. put needle in richest position and used a 175main. problem is, above 1/2 to 3/4 throttle, it just chokes or bogs. i can't rev the machine to higher rpms. i tryed a 170 main too, checked my float level, and the air hose for the fuel tank. any thoughts on what is causing this?

 

You cut a giant hole in the stock endcap? I'd probably shop for a new endcap
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i believe mr. hp end cap has 2 1/4" opening and it looks very simple. trying to save a few bucks here, my end cap looks like it does the same thing except with a 3/8" bigger hole. which should be better if anything right? bigger hole, even more air flow.. i definetly feel more low end and mid.

 

10 000 th post

 

oh sorry..thats a reply not post

 

Cutting a hole in the stock endcap is just the first step. Find a piece of 2 & 1/4" muffler pipe about 8 or 10 inches long, stick it into the hole you've cut in your end cap and weld it in place with about 2" sticking out, and 6" sticking into the muffler itself. Cutting lots of slots in the side wall will help with the noise. Get crazy, check out my endcap in the photo section of my profile. I am using a reverse cone and a spark arrestor from a Yamaha.

A modified endcap will not alter the jetting very much, it sounds to me like you have overdone it on the jetting. Too rich. Also remember that as soon as you do anything to the stock exhaust on a DS you start hitting the rev limiter right away. And that makes it seem like it is running like crap too.
Finish building your endcap, put the stock mainjet back in and raise the needle 2 clips from stock.

A lot of guys talk about the pilot screw too,,,,Is it 2 & 3/4 turns out??? Somebody want to clear us up here?