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Pretty sure the clip is on the leanest setting actually, I put it there thinking it was rich with the blocked pipe then never changed it back. The mixture is still a little rich like I said but I'm over 3 turns out now I think. May need to size the jet down a little, but I don't think I will...

Either that main jet or polishing that needle, my guess is both contributed to solving the problem. The bottom end is probably still a little rich, throttle response is a little sluggish off the mark, might be better off with a slightly smaller pilot jet but I think this bike was always like...

I think that extra time I spent on the main jet is what did it, I can't be sure enough to say but I thiiiink the hole was a little bigger after working it over that wire. My neighbour gave me a sh!tload of tools before he died, was really awesome of him but anyway he had a bunch of gas gear...

Could redrill the pin hole on the lever further in if worse came to worst..?

Craig, it didn't make a difference it still bogged and died with the pipe off. Whatever I did to the carb last night brought it back to life and fixed the problem, I could wind it out again - it was just a bit softer than I remember. So I then took the pipe off and burned it and put it back on...

And just to update, got the pipe back on and the bike is making more power than I ever remember it did haha. Can feel the wheel lifting in second and third gear still.

I got the pipe back on - it has more power than I ever remember it having haha, took it for a ride with the baffle removed - the front wheel lifts in second gear and is still light in third gear, awesome little machines these aye. I rushed putting the pipe back on a bit and put a dent in that...

Well you weren't kidding... That's fun as sh!t :D... That's the torch I was using, probably not an overkill really it was about spot on I think; I got the pipe hot and it started out as a stinking mess as you said it would but it eventually caught fire inside it and blasted it out nicely...

Yep I pulled that clip up to where it was and it is running sweet, got it running down the road full noise! Wooooohoooooo! Thanks so much for your help Craig, Goose, zweb, chronic and everyone else who contributed to this painfully long thread, sorry it took so long. This is the needle after...

That passage doesn't exit where that arrow is exactly, but about half way between that hole and the copper button on the opposite of the passage, bit careless that I missed it though I suppose...

Okaaaaaay I think we're finally getting somewhere!!! I just did a bunch of stuff to it, and got it running quite differently to how it has been. I can hold the throttle against the stop and it won't rev out - but sounds very different, doesn't die, and is flooding the shed with thick smoke...

Well it's a 2 foot propane flame haha. Propane and atmosphere, it's just a lot of it. It will get the pipe glowing, I guess that is hot enough? About spot on is it?

Covering that LHS crank seal did nothing, I don't think that's a very conclusive test anyway it would easily suck the grease through a leak and burn it. But since it held 16 psi for so long I doubt they are the problem... And it looks good, still soft and clean. Do I need to wipe the grease off...

Let me do the grease on the LHS crank first, I'm running new wire from the stator coil to the ignition assy, just because I've got the stator off and it is in sore condition. I will get it running without touching carb just to see if grease makes a difference and if it doesn't, we'll know its...

I've only got propane up here, no bottles for the oxy kit. Dad has a nice big torch for sterilizing our plant grafts, shoots a nice loud 2 foot blue flame - ought to be worth a shot. I'm pretty certain I'm dealing with a mixture problem but this maintenance does sound fun haha... May I'll run it...

Restricting air and getting a gain in performance would imply it was running lean, so I've either got a nasty ass leak somewhere, or not enough fuel getting in. I'll put a drill through both jets and do the grease test on the LHS crank seal... Back later with the results

Interesting ride I just had - I left the air box off it, went riding with the bare carb intake exposed and it produced the same results but I had it going down the road wide open throttle, bogging and surging away as it does and I was able to reach down and stick my hand partially over the...

I can't help but feel like, if I were to cook the pipe on a fire, then take it back to something worth painting on, there would be nothing much left of it lol? do you sand blast it or anything before respraying? Your method does sound fun though. Sorry to hijack the thread!

How do you burn out the expansion chamber exactly? Maybe this is worth doing for my DS80 Goose/67/Chronic...? Sorry if it has come up already but did you try clearing the baffle? Take the bold out from under the end of the flame suppressor and a cap comes out, then baffle, then inner pipe...

I've removed all the wires that aren't neccesary, it has the 3 wires coming from the stator to that harness, then only 2 wires coming from the other side of the harness, I did away with the lighting wires. One goes straight to ground which as far as I understand - is useless as it goes from...