Well I finally "attempted" it today. It really does take awhile. The 100% humidity was swell to work in too!!!
So anyway I bought an assortment of stones for my dremel. They don't last long! The most time I spent was with a cone shaped stone on the top bolt bump. Took forever to get it down. But it's pretty much gone. There was more thickness there than what I thought. I opened up the carb side more & tried to spend time also "straightening" the bends on the sides. The metal drums seemed to work best for that. I didn't go all the way to the head side though. I left the last 1/4-1/2" untouched. I tried my best to keep the vein but I didn't do a real good job on it. In fact it's misaligned in the middle. I tried my best to straighten it & take it to the ends but couldn't. The finish is smoother than stock but not super smooth. I used 60 grit paper on my finger to finish it & "deburr" some ridges I made.
I did not cut the rubber carb to intake flange at all. The rubber ledge in the middle people tend to trim seemed about inline with the carb so I didn't tinker. (Some of it was me being tired). I don't see how you guys can use a razor blade to trim it & not hack it up bad.
I drilled the mounting holes just BARELY bigger. It has just a slight misaligned when fitted now. Less than 1/32 I'm guessing. On the upper right side of the ports.

Well since it has been raining lots my test ride is somewhat skewed maybe. It fired right up, that made me feel relived.
On the wet grassy trail.....
It does seem more responsive down low. But the lack traction makes it hard to tell. I really can't get a good feel for it yet.

On the road. (I know, I know) Low end felt somewhat better. However on the top end it felt maybe like it was choking. Maybe it's just me? Sometimes on the road with nothing close to you it feels slower because of the distance from things. Maybe the better bottom end makes the top only "feel" like less?
I'm only running a 170 main, needle richest setting & a 45 pilot. Maybe I need a 172.5 now with the needle in the 4th notch???

Who knows.... Need to ride more to be sure. I did an OK job on it, Wish I would have done better, just couldn't seem to straighted the vein out good & show it off more.
I did take some pics. I can email or post later.

c-ya

 

Seen the pictures looks real good! I told you it was a peice of cake.

Did Zulu reorder the correct jets for you or should I order some from Columbus Grove's Full Throttle?
The 172.5 main jet with needle in the 4th stock position seems to work great with the quite core and spark arrester both in.

I had the DS out today checking it out since my flywheel key was replaced and you know what,
The guys at Zulu left my left side coil disconnected. I could only get her up to 55 mph, She was only running on one plug.
When i picked her up and test rode it and it backfired a little once I left off the throttle. I told them before I left and they kind of blew it off like it was my pilot jet, being to lean. Once I put the coil wire back on under my front cowl she ran like a top with no backfiring.
They also cut all my wire ties under the front cowl and didnt replace them. When I unloaded the ds today at home she did want to start, it was like the kill switch was on. I rechecked the plugs and wire connections under the front cowl and tried to start her again and she fired right up.... Kind of disappointed in there finish up and put back together process.

Though im still happy with the great deals they gave me on the ridding gear and how they covered the less than $5.00 in parts and .60 hrs of the 2.5 hrs of labor under warranty, specialy since my 1 year warranty ended 6 months after my purchase date.....

 

Yeah one time when they adjusted my valves they had my breather line on the gas tank ran wrong. I had ro rerun it when I got home. I worry about things like that. Funny they mention your pilot jet. They told me they same. Mine was running fine, They just mentioned it.
I thought it was odd. I mean not once at Lima or the dunes did I hear the X pop off throttle. And I was behind you alot!

R/T keeps ordering the large head Mukuni's. I looked through their book & that is all their book shows. So yes if full throttle can order a SMALL HEAD 172.5 Mukuni, please order one for me. It's the only one I'm missing.

You make me feel alot better about my work. Ever see the pic of Sams intake? His work looks awesome. Mine looks like some 3rd world country made it[img]i/expressions/face-icon-small-sad.gif[/img] I just hope it helps, need more evaluation time.

No test riding today more rain.


ps> I told RT that are bikes were real close. I mentioned maybe leaving the left coil unhooked to so I have a good chance in our next race! j/k

 

Ill get the jet ordered.

PS left coil ROF LOL!

 

01ds650, A trick for matching up the rubber intake boot is to clamp it to the intake and then use a dremel sanding drum to smooth it. Then clamp it to the carb and do the same. Mark the position of the boot and when you install it, put in on exactly they same way you had it when porting it. The sharp edges and mismatches are usually much more important than the enlarging that gets done.
Needles aren't really made to be run in the richest setting so you probaly already needed a larger jet. I'd buy a 175 and a 180 and try both out., clip in the middle.
Net time you work on aluminum, get the carbide bits and a couple cans of wd-40. You can port all day long just keep your work wet with the wd-40.

 

Thanks for the tips.
I tried a 175 jet with needle on the 3rd clip. It was rich, ( It would miss on low rpm acceleration) so I figure I at least need a 172.5.

As far as the boot I may try that. It looked like it matched the carb good. Does it really help to take that ridge out if it matches the carb so close & sits right against it anyway?

 

I trimmed the boot as described by mystereid. The sanding drum is much easier then a razor.

As far as making a difference one way or another I couldn't answer. It was however recommended by Mr HP who did my port job. I wonder if anyone has actually checked it on a dyno????

 

mystereid,
If I match the boot to the intake, I really wouldn't need to match it to the carb though right? I made the intake bigger in diameter so the boot would already be bigger than the carb. Know what I mean? I may try & match it to the intake though.