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With the stock airbox and filter properly in place and a full exhaust system, even with no baffle, the factory jetting should be really close. Are you sure that the factory jets are in place, including the factory needles? I would be very wary of any jet kits except those from Dynojet, Factory Pro, Ivan’s, Dale Walker, or Keyster. 

I wish I had written down the jet sizes when I cleaned them last. As far as the needles go, they are K&L. I used them before on an old suzuki and didn't have a problem.

I torn down the carbs again, cleaned them (little bit off crap came out), verified what jets I had (88 for secondary & 65 for the primary), and installed the exhaust baffle tonight. She runs the smoothest ever, since 2011. Can't wait to take another test ride because I thing she's fixed.

Good deal. Do you have a good fuel filter installed? There may be more bits of crap on the way to your newly cleaned carbs.

I do not have one for her. I've been debating on that for a while. Part of me wants to keep the screen on the peacock and the other wants to remove it and just have the inline filter.
Here's my Instagram account that has the videos of her first fire-up last year to the most recent fire-up with the baffle installed.

I would keep the screen on the fuel valve and add a Golan super mini to the fuel line.

wrote:

I would keep the screen on the fuel valve and add a Golan super mini to the fuel line.

 

Exactly!  That's what I put on my KZ650.  It's made of metal and its internal screen can be easily cleaned so it will last forever.  Not cheap, but really nice!  Ed

 

I thought y'all ment $35 expensive but not $50 expensive (damn!). I just grabbed a wallet friendly $4 mini filter from Auto Zone. This week looks like crap (rain all week) so I won't be able to take a test ride.

Yes, they are pricy, but it will never need replacing and filters out much finer trash than the less expensive ones.

Glad she's running better for you.

Most, if not all, I've read about carb kits, is to not use the needles in the kit, and stick with the stock needles.
This may be different for CV carbs though.

As long as she is running fine, then great.
A bit of tuning here and there for better performance may be possible.
I'm in a similar situation with the carb swap (VM24 to CVK32) on my KZ650.
She's running great, but I'm sure some fine tuning will help get her running even better.
Been a lot of rain here lately, and only have 200 kms on the KZ650 since sitting 5 years.

On today's episode of "As we tune the carbs" I think my 440 is running too lean. I fired her up with the tank installed, new fuel line, fuel filter and clamps. She idles kinda smooth, pops slightly on decel, and still stumbles on acceleration. So for sh!ts and giggles I put my hand over the snot box holes and she PURRED LIKE A KITTEN! Her idle was perfect and while rolling the throttle (slowly and fast) there was no popping! 

So now the question is:
1- Do I re-jet & to what?
2- Do I turn the pilot screws out more?

What exactly do you mean by snot box holes? If there are random holes in the air filter box, or there are factory holes that are supposed to have something connected to them that is not connected, then the mixture can be too lean. Some factory boxes have an intake silencer, sometimes referred to as a snorkel. If it is missing, you will have mixture problems.