I've got an 03' 1300S that I have put some V&H bigshots on and rejetted with a dynajet kit using the 195 jet and the replacement spring. It was running a little lean. It was popping and backfiring slightly when cold and seemed like it took too long to warm up. As per recommendations I turned the mixture screw out about an 1/8th. Seemed to help a little so I just left it til another day. Today I took off the PAIR valve, took the reed valves out and used the same reed plate with the rubber gasket, replaced the reed covers with some Baron's block off plates. I then richened up the mixture one more 1/8th. It seems like it is running leaner now than before. If I pull the choke out a little it defenitely runs better. I stuck a screw in the vac hose. Checked all of my other hoses and don't think I have any vacuum lines off. I'm perplexed! Any suggestions?
+1 Scar; BigT, you're DJ 195 is slinging less fuel than your stock Keihin 195 main. Put that back in there and try shimming the stock needle, with the stock Keihin Main Jet by the link Scar provided (and authored).
Why they tell you that....who knows. The Stage 1 kits for our bike all have a smaller main jet than what comes in it stock (the DJ jets and Keihin Jets are measured differently--if you take a Keihin 195 main, which is stock, and calc. it out to a DJ, it comes out to be a DJ 208), and that doesn't make any sense to me if you're letting more air in and/or out.
Yes, the stage III kit will have a 210 DJ main, which is what you'll need. But, I run a BAK and didn't like the DJ kit in there---leaves something to be desired as far as I'm concerned and runs good on bottom end, didn't like the top end "feel." I've actually got a Keihin 198 and 200 MJ on the way, I'm putting those in unshimmed to start (I'll actually use the 200 to start, only getting the 198 as a safety measure in case it acts too rich) with and moving up to a 58 pilot to start as well.
If you decide to put the BAK on with your stock parts, 3 shims on the needle, stock main and stock pilot (keihin 55). It will get you running and you'll notice a difference. I'm lean with my BAK and this method (don't get me wrong, bike runs good but I think it can take more fuel and run even better).
I'll be happy to post back with my final jetting once I get it all done.
The stock Keihin needle doesn't have a clip settting/grooves in it. It is smooth. If you're shimming a needle "up", then you put them between the top of the needle and where it sits in the hole in the slider tube.