Topher,

I believe you may have been pretty close on your previous setup. I ended up with the needle at 3.5 and the PMS at about 2. One other thing I did was to screw the accelerator pump duration adjustment to where it was only about 1 turn out. I wonder if it's possible that the stutter could be cause by a momentary flooding condition caused by the accelerator pump?

I found that my bike was running rich with the clip in the fourth position and my mileage was down under 40. Interestingly, when I had the clip in the fourth position I had to dial the PMS screw out further (richer) than when it was in the 3.5 position. Seems counter intuitive to me that should be the case but I couldn't get the bike to run properly without putting the PMS around 3.

One thing that is different about my setup is the main jet. I put in the 172.5 per Baron's instructions and just never got around to changing it to something smaller. Not sure how much effect it has on the lower end (has to be some) but I don't notice any performance problems through the whole throttle range and mileage is consistently 50 mpg or better.

Good luck to you. Sounds like you're real close to getting it like you want it!