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Rookie carb worker here.... I just rebuilt my old-school horizontal FCR39 (not MX) carb and accelerator pump on my XR440. This carb has no choke or hot start button. Back in the day, they were commonly sold for big bore XR400s through xrsonly web site. They take the old-school FCR pilot/slow jets: This is the exploded view link and photo: http://jetsrus.com/carburetor/carb_keihin_FCR_SINGLE_carb_exploded_view_parts.html The needle has markings on it that read... OC EM R... I know nothing about needle tapering but the clip is in the standard 3rd position. Translation on the markings is here I think: http://jetsrus.com/a_jets_by_carburetor_type/needle_keihin_N427-OC_FCR_35-41mm.html I have a 168 main jet installed and everything is is fine at wide open throttle position. I have a Uni filter, open air box, and supertrapp exhaust with some extra disks in it (open exhaust). I am riding around tierrasanta elevation 350'. (I will worry about Julian altitude later!) Here's the issue. With a #50 pilot jet... the fuel mixture screw has no effect when I turn it all the way in, or all the way out. It has no effect whatsoever on idle. I get a little bit of popping on decel. So, I went down in size to a #45 pilot, which made the fuel mixture screw work better. Now when I turn it all the way in the idle starts to stumble. However, with the #45 pilot I am getting a whole lot of popping on decel like it is running too lean. I have no leaks. I did the flame test on the exhaust. I did the starter fluid test on the intake. So, should I just go with with the bigger pilot jet and ignore the fact that the mixture screw is doing nothing? Or is there something else I am overlooking? Maybe #50 is too small and I need to go bigger on the pilot? Thanks and cheers!

Still have to do an intentional drop to see. Off to Baja Oct 1 with some friends.

A huge thanks to James at JDJetting. He emailed me a long response to some of my questions. His suggestions were spot on. My XR440 is finally dialed in at: EMN needle (4th position) 162 main 45 pilot 1.5 turns out on the mixture screw A couple other things I did -- not sure they actually helped -- but here they are: I added this to the gas tank. It worked wonders to get my wife's Chinese scooter running smooth after multiple failures to clean the carb. This Lucas fuel injector cleaner seems to work great on carbs too: http://www.fuelinjectorcleanerhq.com/lucas-fuel-treatment/ I noticed my spark plug was a bit cross threaded, though I could not hear any air leak I was worried about the seal. I purchased a "back tap" device, which chases the threads from the inside out. It worked great. Spark plug screws in by hand all the way until it seats solid. https://www.amazon.com/Powerbuilt-641148-Back-Tap-Thread-Repair/dp/B001SOHXLQ That's it! Thanks for all the help. Ready for baja now!

I bit the bullet and paid for a dyno run yesterday. He basically ran it three times... at idle, mid-range, and wide open. Idle and wide open was too rich. Mid-range was too lean. Last night I changed my settings to this.... EMN (4th position) 165 main 45 pilot The bike runs better now... pops wheelies much easier... with still a bit of sputtering (it feels like in the mid-range) and a bit of popping on decel still. I may change the EMN needle to the stock 3rd position and see what happens.

Final settings below for elevation of 350 feet about 80 degrees temp. Still a bit of popping on decel but I feel like it's already a bit rich so I am done screwing with it. XR440 FCR 39 (not MX) carb XRsOnly header and muffler UNI air filter with open air box EMP needle with clip in standard 3rd position 170 main jet 48 pilot jet Fuel mixture screw 1.5 turns out Thanks for everyone's help!

I got it running good with a 45 pilot and 168 main. The slow circuit is tunable and fine. I removed two discs from my SuperTrapp exhaust and it has better low end response. Tried removing a 3rd disc and it was no good. Went back and it's fine. Still can't get rid of the popping on decel though.

Thanks.... I will try the 48 slow jet and see if it's tunable. Since I have a supertrapp muffler, I could just keep removing discs until the popping on decel goes away, I suppose. Will post back if and when I get some favorable results.

Since it has an afer market Supertrapp muffler it just slips on with no sleeve. It passes the flame test too. Hold a lighter to the joint and rev the throttle. No flame flicker.

Don't ask me why I needed a new cylinder. The machinist was at a loss to explain how this happened. This is the interior surface of the cylinder after the sleeve was removed. So, somehow this happened between the cylinder and the outside of the sleeve. That cylinder could not be resleeved, so I went this route: http://www.ebay.com/itm/381169859204

THANKS... Just rebuilt the top end. New 440cc cylinder. New valves and cleaned up head. New crush washers on the headers. Valves adjusted to spec.

Headers are from xrsonly: http://www.xrsonly.com/xrs-only-exhaust-header-honda-xr400r Muffler is really old school SuperTrapp with probably too many discs.

Thanks... advice is appreciated! I bought a new spark plug. Did the old spark plug test by killing the engine at WOT. Looks lean??? This is with a 52 pilot and 168 main. Looks like I need to go richer on the pilot. WOT feels fine.

Thanks for the links robertaccio... I don't know if the needle is worn. If I was to replace it, I don't even know what type would be considered standard. http://jetsrus.com/a_jets_by_carburetor_type/needle_keihin_N427-OC_FCR_35-41mm.html

yup, lighter to where the header hits the head... also, i just rebuilt the top end and added headers.

http://www.rvcfire.org/_Layouts/Incident%20Information/IncidentInfoDetail.aspx?2705

https://www.google.com/maps/d/u/0/edit?hl=en&hl=en&authuser=0&authuser=0&mid=1I5a7kH2X32_PuJVxu-AfiT_hp5M

Check for air leaks. It's an easy test.

Public comment is open for planned improvements to Three Sisters Falls trail, parking lot, restrooms, etc. The draft impact assessment is posted here: http://tinyurl.com/zth6fug A quick read and I cannot find any info on whether this would affect public access to CEDAR CREEK RD, the trail that goes west from the area of the planned improvements to the Cedar Creek Falls trail head. Hopefully it will not. Cool YouTube drone video of Three Sisters Falls from Feb 2016: https://youtu.be/YB7AKRGA7TM UT article below: Print page Big plans for Three Sisters Falls trail in forest Paths to Three Sisters, Eagles Peak summit will be realigned By J. Harry Jones | 5:36 a.m. June 16, 2016 Three Sisters Falls as seen from space. Google Earth CLEVELAND NATIONAL FOREST — The U.S. Forest Service is working on a plan to realign and create safer trails leading to the Three Sisters Falls and the Eagle Peak summit near Julian where dozens of hikers have been rescued over the past several years. The plan also calls for the construction of a trailhead and parking lot off Boulder Creek Road near the intersection of Cedar Creek Road where only a small makeshift parking lot now exists. For years, hikers have been moving along steep paths forged through the area by determined visitors heading to the picturesque spots. The Cleveland National Forest is proposing to upgrade the trails and make them official, both to protect the environment and to improve safety. If things move ahead as scheduled, crews will start cutting the new trails in October, said Lee Hamm, a recreation and lands officer for the Cleveland National Forest and the project manager. Total cost for the trail construction is a bit more than $700,000, said Chris Dowling, Palomar District Ranger for the forest service. Building a parking lot and restrooms at the trailhead will cost about $1 million, but that project hasn’t been funded. Like other trails all over the county, the Three Sisters and Eagles Peak trails have seen an explosion in popularity in recent years as more and more people have become familiar with hiking opportunities via the Internet and social media sites. Forest officials estimate that during recent winter and spring months, roughly 50 to 150 hikers use the trails on weekdays, and that skyrockets to as many as 400 on weekends. The numbers drop by about two-thirds in the hot summer months, but rescues during that time increase. Most of the rescues involve hikers who are injured or overcome by extreme heat. On June 3, five helicopter rescues were made either at Three Sisters or at Cedar Creek Falls further to the west, said Sgt. Mark Johnston of the Sheriff’s Department Aviation unit. This year, countywide sheriff’s helicopters have made 55 rescues, including 12 that came out of The Three Sisters and Cedar Creek areas. “Almost all the rescues in that area are heat-related,” Johnston said. Sometimes hikers must be hoisted into a large fire helicopter; other times a small law enforcement helicopter will suffice. The copter will land in the valley, deputies will give water to those in distress, and then fly them to the Cal Fire station in the San Diego Country Estates in southern Ramona for treatment. And those are just the most serious situations. Many more calls from distressed hikers are made every week leading to other types of help being rendered. In just about every case, officials say, the problem can be traced back to hikers not bringing enough water with them and/or not wearing proper footwear. The unofficial trails begin on an abandoned road and then split, with one descending about 1,000 feet in elevation into a valley toward the falls while the other heads up a hill to the top of Eagle Peak. The Three Sisters hike is the more popular of the two. Hikers are rewarded at the end of the 2.5-mile hike with a three-tiered waterfall. “When you start working your way down into the valley, its very over-steep and narrow,” said Dowling. Hamm, the Forest Service land officer, said “some areas are so steep that some people will bring in ropes they have to use to climb down and back up.” The hikers can also cause damage to the area. “We have a lot of concern about erosion with sediment being washed down into the water way down there,’ said Dowling. Trash has become more prevalent as well, he said. The new trails will make the hikes much easier by creating switchbacks and using other methods of slope management. It will still be a difficult hike, Dowling said, but the actual walking should be much better. Back at the trailhead, a new parking lot with room for 60 to 80 cars will be built. Cars currently use only a small lot and then spill over to both sides of Boulder Creek Road making it difficult, and at times impossible, for emergency vehicles to get by which is important, since so many rescues take place every year and because people live farther down the road. Dowling said there are no plans to require hiking permits like those instituted a few years ago for Cedar Creek. Crowds were getting so large there in the early part of the decade that extreme measures had to be taken. The number of hikers going to Three Sisters constitutes just a small fraction of the thousands that were hiking to the Cedar Creek Falls each day. The plan is currently going through the review process, and the public is being asked to comment on the proposal by July 5. The plan can be viewed by accessing the Cleveland National Forest websitehttp://tinyurl.com/jktpvrc"> here. Comments can be sent to: comments-cleveland@fs.fed.us. © Copyright 2016 The San Diego Union-Tribune. All rights reserved.

1980s University City

Anybody done this leg? Any gates? https://drive.google.com/open?id=1CWYzmNH03EE_duSFHqo61vX7xRw&usp=sharing

Yes that's the side trail. We had to turn around further down. Not shown in the photos are a couple rutted washouts and a rock slide. It's a lot steeper than it looks in those photos above. Not saying it ain't do-able, just risky and a lot of (kick starting) work. The blue is our track and you can see the leg where we turned around. There's also a side spur that goes up to a peak:

Come to think of it, there was a gate as you ride through those houses but it was open (today anyway).

Marker 250

Here's our entire 133 mile loop. Proctor Valley Rd, over Otay Mtn. Border run to Campo. Then up to I-8.