Poor top end power?

No amount of re-jetting will compensate for a restricted exhaust.
Only a larger volume muffler can reduce decibels whilst retaining performance.

i'm thinking that the packing itself may be part of the problem, possibly the packing or rewelding has caused the problem. if this can be confirmed and rectified, it may just need rejetting.

zed1015 wrote: No amount of re-jetting will compensate for a restricted exhaust.
Only a larger volume muffler can reduce decibels whilst retaining performance.

While you are correct he will not gain any lost performance by re-jetting he will make the bike run better by re-jetting for the baffle.

Packing and baffle are out. Actually damaged the baffle getting it out to remove the packing so it's now running wide open megaphone exhaust (quite loud).

I guess I'll know that exhaust restriction isn't the problem now, just have to see if I can still hear when I get to work!

You cannot re-jet for a partially blocked exhaust.
It is a gas flow issue not a fuelling issue.
That muffler will only flow a specific amount of gasses before backing up.
The engine pumps a fixed amount of air per revolutuion no matter what the fuel/air mixture.
There will always come a point where the engine puts out more volume of gas than the restricted muffler can flow.
If that point is 6500 rpm it will always be 6500 rpm no matter what size jets.

Well, I made it to work. The bike doesn't run any better, but it certainly is more deafening!

Seems it will rev pretty freely in 1st gear all the way up. 2nd isn't bad. After that, it gets sluggish (may be due to approaching 80-90 mph) above 6500 rpm's.

I'll certainly be repairing that baffle and re-installing. I'm pretty sure I'll get pulled over and/or go deaf if I don't get it quieted back down a bit. May use a little less packing this time around, but performance didn't really seem much different.

Anything else that can cause trouble? Do these bikes normally bog below 3k rpm's in 5th? It isn't terrible, just a little weak. Smooths out around 4k rpm's.

Seems this is about where it's transitioning from pilot circuit to primary? Just a funny spot between 3500 and 4000. Too lean/rich? Is that a needle height adjustment needed?

I'll be pulling the carbs anyway to make sure I don't have any crud in there. I'll get my jet sizes while I'm at it.

I would say you are lean on the big jet. Roy

To avoid BOG Add Nitrous

If it bogs/stumbles when you give it gas it is to rich on the main. Go down one size and try again. Also, rpm's play no role in jetting throttle position is the judging factor for which circuit you're on.

andy9802gt wrote: If it bogs/stumbles when you give it gas it is to rich on the main. Go down one size and try again. Also, rpm's play no role in jetting throttle position is the judging factor for which circuit you're on.

Only bogs under load below 3000 rpm's in 5th gear. Doesn't have same issue in lower gears.

I'll post up my jet sizes once I get it apart. Stock air-box and filter, unknown 4-into-1 exhaust. I think everything else is stock.