I downloaded the instructions they are saying 170 main #5 clip with a spacer and one washer under the clip one washer on top and the PMS 3.5 turns out no mention of the pilot jet
And I did get Baron's adjustable PMS needle
do i leave the needle and seat alone i was reading one of the tech articles about the bike runs of of gas at wot
I have an 01. When I did this recently, I went with the 170 main, needle in the 4th, and the PMS is currently about 3.5 turns out. I have the V&H
long shots, and a modified stock air box(added a 1 3/8 inch hole, with a K&N(YA-1699)filter). I did, change my pilot to a 37.5 from the 35, because I couldn't get my idle right without it.
Since Barons is happy with the 170, it'd be a good place to start. Leave the pilot at 35. I have all the power I'm comfortable dealing with, with my set up.
I only suggested the 172.5 originally, because you have an after market airbox, 'and' a ported manifold, as well as the freer flowing exhaust. I was also thinking that was what they told me to use(so much for gray hair brain cells)
With the 170, in the 5th, you'll still have either a half step with a second washer under the plastic spacer, or a whole step, by moving the clip to the 6th, if you need to go richer.
I'm actually thinking about dropping back to the 167.5 main in the future on mine, just to see how it works. The 170 should be plenty for you. You could probably be in the 4th and still be fine.
If you set the float level properly, so that it is according to what the 04's and later are, you should have plenty of fuel with the stock needle and seat. The only reason people have been going bigger(2.5 suzuki, or yamaha grizzley 3.0)is because they went "pumpless".
If the float is still set at the original 99-03 spec, you could experience some fuel starvation under heavy throttle(when your using gobs of fuel). Set it right, and you should be fine. I wouldn't mess with the needle and seat, unless you think you might ditch the pump in the future.
In the WOT
article, where it is discussing a lean condition,..ie, the bike seems to want to increase speed, when your not giving it throttle...., this is what the richer main(170, clip in the 5th) will take care of.
All the needle and seat valve does, is open and close according to the float level, to maintain the proper amount of fuel in the carb
bowl. It's just a gate, to let the gas from the tank, into the carburetor. As long as the float level is set correctly, the 170 main will have all the fuel it needs.
If....I say "If", you experience a lean condition with the 170 main, and clip in the 5th(which I seriously doubt will happen), when doing the WOT test after rejetting, that is when you move the clip to the 6th groove, or add a second washer under the white plastic spacer(for a half step, to get more fuel.
The kit your ordering will have the 170, 172.5, and a couple of other main jets in it, so that you can experiment if needed.