You got baffles in those pipes? What are you pipe sizes inside the heat shields? My HK's were 1 3/4 all the way inside the heat shields. You can try the 172.5 main clip on 5 and do WOT. If the WOT is OK with the 172.5 move the clip to 4 and see how it runs. If it still idles rough the try a 37 pilot. You should count your needle notches from the blunt (top)or (Spring) end of the needle. Let me know how it goes.

Oh CRAP ...that might explain the occasional carb backfire when cracking the throttle (changing the accelerator pump settings didn't help so I put it back the way it was)...got to recheck the needle setting. But does this explain the one cylinder misfire???

Yep start clean with the 172.5 and the needle 5 slot from the spring end and 35 pilot do the WOT and we can go from there. What PMS screw do you have?

Yea, I put V&H quiet baffles in last weekend...didn't seem to change the way it runs, but it sounds much better without any "puffing" sounds at decel. Also removed the AIS 6 mos ago.

Check the needle and see how it runs. Your setting except for the needle look OK. It might be the one cylider will stop acting up. Ya never know. You don't want to change more than 1 thing at a time.

Stock PMS screw. I'll have some time Wednesday to poke with it...I'll let you know. Thanks for your help

Yep you got the puffing sound I'll bet it is the pilot mine was and it ran for 16000 miles and gave me fits till I switched the pipes and the pilot. The pipe switch is what made it show up so go ahead and do just the 172.5 main and wot first.

OK, here's how it went...a friend of mine opened his own mobile motorcycle repair. He came by today to diagnose what could be wrong. (By the way, he used to work for a dealer and has personally rebuilt 70 or so 1600 motors due to the tranny recall) He listens to it run, pulls the plugs and says "Hey, this thing's running a little fat". So he pulled the carb, moved the needle from the 5th to the 4th clip from the blunt end and changed the main to 167.5 from 170. Runs perfect!!!!! Also the problem a few of us know about the choke cable somtime not closing all the way is caused by the cable sleeve pulling out of the crimp by the knob. He pushed the sleeve back in all the way and now the choke pulls out farther (and closes all the way too). He also told me the the plastic retaining nut also has a tendency of breaking after a few years and that the dealer only sells the cable as a kit .... Just have a hard time believing that jetting was causing the problem but I'm glad she's purring the way she should.

Glad ya got your smile back

Yeah , what Musky said. BB