Bump with an update and request for further advice. I am definitely chasing my tail here, and am close to empty on ideas.
I changed the pilots to 17.5s because my old stock pilots looked to be clogged, even after soaking in some dip. Once back together, the bike was really hard to start at first, and then ran rich as hell at idle.
So I picked up some brand new Mikuni 15 pilot jets and put those in. I also changed to some new pilot fuel screws from Z1 that I really like, as they are much easier to adjust. I'll do a quick product review on those in another thread.
Checked the floats again and fine-tuned them to 24mm.
Buttoned her back up and set the pilot fuel screws to 1 turn out and pilot air screws to 2 turns out. Charged the battery to make sure I had good juice after all the starting and testing.
After struggling a bit for the first start-up, I got the bike running and idling at about 1,000. Did my best to adjust the air screws to highest idle, but the idle still wanders/sags. It does not hang after a throttle blip, but when it idles for more than 15-30 seconds, the RPMs will randomly dip and sometimes peter out to zero and die. This happens regardless of where the idle screw is set, and a throttle blip will rev fine and return crisply to a decent idle, or a high idle when I've overcompensated on the idle screw. After a short while, the idle would falter, often after a pod cough or backfire. It also seemed to rattle in the front.
Concerned about that rattling noise, I pulled the valve cover and checked out my clearances. I adjusted them last Fall and re-checked them a few weeks ago, finding all the clearances good and healthy. On this check, the clearances were still excellent, all well above 0.06 mm and most in the 0.08 mm - 0.09 mm range. Cams looked good, showing no wear or rust, etc. Plugs were a bit sooty.
I reset the fuel screws to about 7/8 and checked the floats yet again. Following some of the tips in other threads here, I also checked my choke forks and operation to make sure they were not hanging up anywhere. All good.
Here are all the specs for this last reassembly:
Mains 122.5
Needle - 4th slot but with two of the small rubber spacers on top and the large spacer below to shim them up a bit.
Pilot - brand new Mikuni 15
Fuel screw - 7/8 turn out
Air screw - about 2 turns out
Throttle cables are good, and snap back at all bar positions
No leaky fuel drips from the bowls, pods or overflow tubes.
Valves are in spec.
Carbs fully cleaned, stripped, new o-rings, etc.
Timing confirmed/adjusted with static light per DynaS instructions.
Plugs are new and clean (I have two sets rotating for these tests, one set soaks in dip for scrubbing and spraying before changing out).
Battery is healthy and fully charged.
Choke assemblies are functioning properly.
Petcock is working properly.
Despite all of this, the idle still wanders south randomly, and it still backfires now and then. I took the bike for a couple of laps around the block to test it under load. It pulls away decently and doesn't seem to hesitate or "hunt for power." It also feels pretty smooth through the lower half of the throttle range, with no flat patch between pilot and needle. On decel, however, it pops quite a bit through the exhaust. At a stop, the ADD idle resumes, requiring throttle blips to keep the engine running.
All I can think of next is to check the synch. I vacuum synched the carbs when I changed the needle the other day, but the rattling and erratic idle might indicate something still out of synch. I don't know how the synch might have slipped, since I haven't disrupted the slides or changed any valve gaps.
Other than re-synching the carbs, what other issue should I investigate?