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I'm mostly an arm-chair tuner so take this with a huge grain of salt...

OE style filter or foam? makes a tiny difference.

I'm guessing you'll end up with 140 or 145 mains, maybe start at 150-155

This is fantastic, thanks for sharing. It's great that you and the family are having so much quality time, and that this machine is back where it belongs! It looks like you weren't even really trying on that lap, so smooth and drama free. Good luck with the next steps!

Not mine, looks pretty clean and complete...

https://austin.craigslist.org/mcy/d/san-antonio-1971-suzuki-500-titan-tween/7356214466.html

You've got to jet to the bike, not the book.

That said, a less restrictive air filter would indicate the need for bigger jets.

Is the rest of the machine stock?

I wouldn't change the pilots until you see how the mains are working, the pilots have a little adjustability with the air screws.

So yeah, start in the 150-160 range.

Looks like my pile of spares is doing better than my 401K...

Only $595 for a Daytona side cover...

https://www.ebay.com/itm/164816899497?hash=item265fda4da9:g:nh4AAOSwo49geL9a

It's apparently SWSX is also that weekend...50K+ people heading to town for music...

Circuit of the Americas is back on the calendar Oct 1-3!

Yep, and hotel rates are already ridiculous, many are sold out.

EDIT: while I was researching rates I went back to select one that I liked and it was sold out (this happened in less than an hour)

Sweet! I love originality and the simplicity... no power brakes, maybe no power steering... tell me it has disc brakes in front at least?! I dig the air blast horn too.

That looks FUN!

My guess is puttering around town is leaving a little gas/oil in the crank case and when you really get going you clear out the reside in the motor, thus the extra smoke.

I'm far from an expert but I stayed at a Holiday Inn once.

sorry RD400

I did some googling... probable low voltage at the bulb due to old wires and possibly a dodgy connection. I'll check it out and look wiring in a relay for better voltage to the bulb. They sell some sort of capacitor but it looks too big to fit in the bucket.

I installed the Auxito LED H4 9003 bulb recently and it flickers at idle, once revs approach 2000 it stops flickering. Test meter on the battery indicates the charging system is working properly. I read something about a diode or something that will suppress the flicker. The bulb creates an impressive amount of light, I just wish it didn't flicker. Any ideas?

I think it was 5900

Try fiddling with the air screws, once idle is set you shouldn't need to mess with it. I used to carry a long screwdriver with me and I'd try 1/8th turn increments, it can make a noticeable difference is the 'crispness' of the motor. It's also help figure if your jetting is too lean or rich based on how far in or out the screw is.

Also you shouldn't need to use the choke more than a couple minutes on a cold start.



PS your bike sounds really good

not mine...

https://austin.craigslist.org/mcy/d/pflugerville-1973-suzuki-gt250k-1500-obo/7323014588.html

My dusty memory is 66mm is the max overbore on RD400's, Wiseco offers a 66mm piston, which may be about right for your 66.1 cylinders. The 64.9mm cylinders are probably too loose for a 64.75mm piston and will probably need to be bored to 65.25, as a 65mm bore may not get all the cylinder wall

2¢