What Musky said, the 180 or the 185 main jet, pilot jet back to stock 35,needle on 5th slot and set the PMS to 2 1/2 turns out. Do the WOT to see if the main needs to be changed. You may have to move the needle up to the 4th slot. To fine tune the PMS screw it in till the engine start to stumble then slowly screw it out counting the turns till it starts to stumble, screw the PMD back in half the turns that you counted. Ride and note the way the bike runs then tweak the PMS in or out 1/8 to 1/4 turns until it runs the way you think it should. The DJ 185 is closer to the Mu 172.5 that I am running but the 180 my be where you need to be. I suggest you go to Radio Shack and buy a package of phono plugs and take the rubber boot off one and place it on your PMS tower. I had my PMS out 4 1/2 turns and did a lot of adjusting and the PMS viberated out on the highway and went Bye Bye. It is hard to get home with no PMS. BTW carry a small screwdriver with you at all times.

thanks Musky, I'll reinstall the original pilot and go from there. I have done the WOT and everything seems fine. I would like to get the settings correct before I do the other air filter mod that I mentioned. I want to keep things simple if I have to trouble shoot. One thing at a time I can go back to the original place if I know where that was.

I put the stock pilot jet back in and with the BAK (stock air box with six 1" holes) I adjusted to no back fire after a hard accelerate, wot was fine, I used 4th gear for that and everything was good. I had the pms about 3 1/2 turn out. Did all this to get everything as correct as I could before going forward.
Now I have installed the air filter that Mr. Cancilla has the posts on, I haven't had a chance to test drive yet, but when I started the bike I did not have to use the choke ! It is in the 40's and that (starting with out the choke) is not normal. I tweeked around with the pms with the bike cold, just to see if I could make it need the choke, no success in that. What is the next step, more or different jetting? the next size main jet I have is the stock, 170 or 195?

Is the needle still in the #5 location? If so , try #4. That'll lean it out some. BB

Did you have the needle on the 5th for the WOT? If so did you drop it back to the 4th after? Float level OK? Sure the choke is working right? Any tweaking you do should be on a fully warmed up motor.

I'll move the needle and see how that works, also let it warm up before I make adjustments. Maybe I'm jumping the gun, it just seems strange that it didn't need the choke to start, that has never happened before.

Welcome to tinkerville This kinda stuff happens cuz we can't leave stuff alone.

yeah, I didn't fool around with it that much prior to getting on this web site. Now by wife says "I didn't know anything was wrong with it". My silent answer was "not til I got to working on it".

We'll everyone keep up the posts I'm waiting on parts now DJ kit is coming and new filter is here Mr Cancilla's setup I'll be making mounting brackets tomorrow. I'm gonna need all the info I can get to put it all together LOL.

Sundance have you tried Musky's choke knob trimming yet? Never mind I miss read your last post DAAAAAAAAAAA