125/150/250/300 KTM/HUS/GG jetting thread

gahooligan
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Location
Bethlehem, GA, USA
3/6/2022 3:52pm
Hoping some of you are still around...
I am trying to get my 2022 125xc sorted. Riding woods in GA at about 600-800ft in the 60-70 air temp range.
I installed the jetting from the first page:
Replaced jet block gasket with JD jetting gasket
Set float height parallel to carb body using the side tilt method (should it be upside down)
JD Jetting 5.0 slide, notched as instructed
490 main
End up at 32.5 pilot
1 1/8 on AS
S4 nozzle
42-74 needle position 2
PV 1.75 in from full out
FMF turbine 2 to be legal
93 pump w 40:1 castor 927
(I got my sons 2019 ktm 85sx dialed and it doesnt spooge even with a turbine core 2 so I dont think its the castor 927 see spooge comments below)

This runs SO much better than stock!! I still have a slight unpredictable hesitation on the trails when whacking it to loft a mudhole or root. I tried going to 1.5 on AS and it made it worse. With a 30 pilot i had to run the AS at .5
I tried pos 3 on the needle and a 30 pilot thinking i was making up for a lean needle with the pilot and AS. It was worse. Went back to 32.5 pilot and it was worse. Both of these were now rich on the needle. Best i can get it is position 2 on the 42-74 and either the 30 pilot at .5 on the AS or 32.5 pilot at 1 1/8 on the AS.
Also thinking the 490 Main may be too much as I get spooge out of the turbine core (less than before) and it "speckles" the rear fender just reving on the stand (have read this may be the Turbine core itself).
Should i leave it and try the stock silencer, or do you guys have any advice? To me, The AS settings says something still insn't just right, but its really really close.

Looking for thoughts and suggestions! Thanks guys!
#434
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DE
3/7/2022 1:23am
Hey guys,
I took a lot of advice from here to get the Mikuni on my 2017 125sx to run properly. Different slide with a notch, different needle jet, all kinds of different jets and needles, holes in the float bowl, new seal and so on. I got it to run quite good, especially when I just accelerated hard from turn to turn. What was always not so nice is how the carb handled technical sections with on off throttle. It would load up and run inconsistently.
Now I had the chance to buy a 36 Keihin from a 125 EXC of ebay and what can I say... I took the jetting from the 2016 125SX (with the 38 Keihin) and the bike ran better and much more consistent from the get go than with everything I've tried with the Mikuni. It picks up great and just feels nice and smooth. It’s also less finicky with temperature differences (couldn’t test it in different elevations yet).
So if you've got the chance to get a Keihin and you’re not an expert on jetting Mikunis, buy it! It makes life so much easier.
Cheers!
1
motoman998
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Pensacola, FL, USA
3/13/2022 1:49pm
In reference to the settings in the original/first post, what are the stock settings on a 2020 KTM 250sx? To make my question simple, I'm going to fill a motosport cart with exactly what's in that list and don't want to order a part if that jet or needle etc is already in the carb. Thanks!
AJ565
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San Antonio, TX, USA
3/13/2022 2:09pm
motoman998 wrote:
In reference to the settings in the original/first post, what are the stock settings on a 2020 KTM 250sx? To make my question simple, I'm going...
In reference to the settings in the original/first post, what are the stock settings on a 2020 KTM 250sx? To make my question simple, I'm going to fill a motosport cart with exactly what's in that list and don't want to order a part if that jet or needle etc is already in the carb. Thanks!
You need everything. If it’s cold then you might get away with the stock 35 pilot, but warm out it will hesitate down low out of turns.

Main jet 500
Pilot jet 32.5
Slide 5.75 (Kawasaki part#16025-0003)
Needle 43-75 (KTM part #55431134400)
Clip position #2
Needle jet S4 (KTM part #55431021400)
Air screw 1.5-2.0
Fuel 55:1

The Shop

motoman998
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Pensacola, FL, USA
3/13/2022 2:13pm
motoman998 wrote:
In reference to the settings in the original/first post, what are the stock settings on a 2020 KTM 250sx? To make my question simple, I'm going...
In reference to the settings in the original/first post, what are the stock settings on a 2020 KTM 250sx? To make my question simple, I'm going to fill a motosport cart with exactly what's in that list and don't want to order a part if that jet or needle etc is already in the carb. Thanks!
AJ565 wrote:
You need everything. If it’s cold then you might get away with the stock 35 pilot, but warm out it will hesitate down low out of...
You need everything. If it’s cold then you might get away with the stock 35 pilot, but warm out it will hesitate down low out of turns.

Main jet 500
Pilot jet 32.5
Slide 5.75 (Kawasaki part#16025-0003)
Needle 43-75 (KTM part #55431134400)
Clip position #2
Needle jet S4 (KTM part #55431021400)
Air screw 1.5-2.0
Fuel 55:1
Appreciate the help. One last question (for now anyway haha): Where can I find any instructions or guidance for dremel-ing my stock slide? That kawi part is a little spendy, and that money is probably going to gas for races this spring.
opyguy
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3/13/2022 2:16pm Edited Date/Time 3/13/2022 2:19pm
your 2020 has a 35 pilot, should have also come with a 32.5 and a 30 in the kit.
450 main and mains up to 470
79jz
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Traverse City, MI, USA
3/22/2022 6:00am
AJ565 wrote:
If it was me I’d leave everything the same as you had it and drop the pilot to a 32.5. If you notched the slide then...
If it was me I’d leave everything the same as you had it and drop the pilot to a 32.5. If you notched the slide then the pilot circuit if more efficient and needs a smaller pilot or it will be rich.
AJ with the 125 specs pinned on the 1st page, have you used U4.4 and if so what changes to main, pilot, clip position? I found your 250 jetting with u4.4 but didn’t see any for the 125. Thanks in advance!
AJ565
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3/22/2022 10:59am
AJ565 wrote:
If it was me I’d leave everything the same as you had it and drop the pilot to a 32.5. If you notched the slide then...
If it was me I’d leave everything the same as you had it and drop the pilot to a 32.5. If you notched the slide then the pilot circuit if more efficient and needs a smaller pilot or it will be rich.
79jz wrote:
AJ with the 125 specs pinned on the 1st page, have you used U4.4 and if so what changes to main, pilot, clip position? I found...
AJ with the 125 specs pinned on the 1st page, have you used U4.4 and if so what changes to main, pilot, clip position? I found your 250 jetting with u4.4 but didn’t see any for the 125. Thanks in advance!
You’ll have to read back a few pages. I think those guys are going bigger main and pilot. With u4.4 if it was me I’d try the 32.5 pilot and the 500 main to start and see how it goes. Maybe get a couple sizes both directions on the main and try them.
bdavis354
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Wilmington, NC, USA
3/22/2022 6:20pm Edited Date/Time 3/22/2022 6:21pm
2018 KTM250sx stock motor and exhaust only mod is Vforce 4 and Kreft PV adjuster.

I’m running 50:1 Motorex with non ethanol 93 or T4
Currently jetting is the following, def rich and boggy. Temps are going up here in NC soon (80-90drg with 85%+ humidity…. Basically FL) so I wanna dial this jetting asap. Bike has 35hrs and I don’t race much just love to ride . Mostly track but some
Sprint enduro too requiring crisper low end.

Current jetting:
Stock 4.slow slide
MJ 430
NJ s1
JN is JD Blue on 2.5 clip
PJ 37.5
AS 1.5 out
PV 2in Yellow spring

I’m going to order parts based on knowledge gained from this invaluable thread AJ and so many have dialed. This is what’s in my cart to play with. The slide is the one thing that I’m bouncing between 5.0 and 5.5 I live in the 1/4-2/3 throttle range with MX and Sprint enduro… I’d love to find a setting where I’m just maybe dealing with AS and PJ adj between disciplines if feasible. Also interested in anyone running T2 exclusively and their jetting.

My Cart:
5.5 Slide
43-75 and 42-75 Needles
S4 NJ
480, 485, 490, 500 MJ
35 PJ (I have a 32.5 too already to play with)
Fresh silencer packing
JD Jet block kit

Question is , am I worrying too much about 1mm on the slide leaning it badly in unison with the S4 and needle swap? Everything above is moving in a lean direction other than the MJ which is honestly the least of my concern as I barely touch it.
wrc777
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3/22/2022 7:40pm
If it were me I would try the needle and jet before dropping the money on the slide.
AJ565
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3/22/2022 9:10pm
wrc777 wrote:
If it were me I would try the needle and jet before dropping the money on the slide.
It won’t fix the problem.

My bike currently has the 5.75 slide with humid 100 degree weather.
1
bdavis354
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3/23/2022 3:06am
wrc777 wrote:
If it were me I would try the needle and jet before dropping the money on the slide.
AJ565 wrote:
It won’t fix the problem.

My bike currently has the 5.75 slide with humid 100 degree weather.
So I’m hearing don’t stress the 5.5 slide? And the rest is good to have for tuning. It’s only $90 for the slide, I’ve blown more on dumber purchases. Ultimate goal is cleaner more linear power. Eventually I’ll go to a 300kit too for this reason so a lot of this should transfer to dialing that. Stay tuned. I’m hitting the $ button.

Thanks for feedback!

Brandon🤙
AJ565
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3/23/2022 4:04am
bdavis354 wrote:
So I’m hearing don’t stress the 5.5 slide? And the rest is good to have for tuning. It’s only $90 for the slide, I’ve blown more...
So I’m hearing don’t stress the 5.5 slide? And the rest is good to have for tuning. It’s only $90 for the slide, I’ve blown more on dumber purchases. Ultimate goal is cleaner more linear power. Eventually I’ll go to a 300kit too for this reason so a lot of this should transfer to dialing that. Stay tuned. I’m hitting the $ button.

Thanks for feedback!

Brandon🤙
You very much need the slide.
1
bdavis354
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3/23/2022 9:26am
bdavis354 wrote:
So I’m hearing don’t stress the 5.5 slide? And the rest is good to have for tuning. It’s only $90 for the slide, I’ve blown more...
So I’m hearing don’t stress the 5.5 slide? And the rest is good to have for tuning. It’s only $90 for the slide, I’ve blown more on dumber purchases. Ultimate goal is cleaner more linear power. Eventually I’ll go to a 300kit too for this reason so a lot of this should transfer to dialing that. Stay tuned. I’m hitting the $ button.

Thanks for feedback!

Brandon🤙
AJ565 wrote:
You very much need the slide.
I was referring to it being too lean. I ordered the 5.5 seems to be the major game changer in the process
mxstate
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3/23/2022 1:21pm
bdavis354 wrote:
I was referring to it being too lean. I ordered the 5.5 seems to be the major game changer in the process
22 GasGas MC250, Central FL so weather conditions very close and elevation not that much more above on your side)

AJ's specs (I got PV set differently but that's personal pref.
MJ 490
PJ 32.5
AS ~ 1.5 turns out
Needle jet S4
Needle 42-75 on the 2nd clip
Slide 5.5
Fuel mix 50:1

Runs crisp, clean, no bog.
I had a 19 TC250 with same setup minus a 5.0 slide as I couldn't get a 5.5.
It was running great too (full disclosure/ Slow Vet C level)
I would not worry about the slide but if you feel more comfortable doing so get a 5.0, try then re-cut it to 5.5

Once set, it's only A/S adjustment if the temp/humidity change radically
The TMX works fine...
1
gahooligan
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3/23/2022 1:39pm
Just curious guys, how does a 250 run a leaner slide and the same jetting as a 125? I assume it is the richer fuel mix at 50:1 vs the 125s 40:1 and the additional vacuum the 250 pulls to pull more fuel through the jets?
riv187
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Lakeland, FL, USA
3/23/2022 3:27pm
gahooligan wrote:
Just curious guys, how does a 250 run a leaner slide and the same jetting as a 125? I assume it is the richer fuel mix...
Just curious guys, how does a 250 run a leaner slide and the same jetting as a 125? I assume it is the richer fuel mix at 50:1 vs the 125s 40:1 and the additional vacuum the 250 pulls to pull more fuel through the jets?
I own both a TC125 and TC250. The 250s always need smaller jets from my experience with these and others models because of the vacuum/draw is greater on the larger bike. Both my bikes have slides cut on the mikuni carbs.The main jet is 30-40 smaller on 250. If you do a big bore other brand like a RM144 or RM265 (had both) requires a similar drop in main jet from past experience. Those both liked bigger pilots to start,,,then reducing mains on top.
bdavis354
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3/23/2022 4:40pm
gahooligan wrote:
Just curious guys, how does a 250 run a leaner slide and the same jetting as a 125? I assume it is the richer fuel mix...
Just curious guys, how does a 250 run a leaner slide and the same jetting as a 125? I assume it is the richer fuel mix at 50:1 vs the 125s 40:1 and the additional vacuum the 250 pulls to pull more fuel through the jets?
The vacuum from the piston has more force on induction so it pull more fuel mixture into chamber per stroke essentially.
bdavis354
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3/23/2022 4:48pm
bdavis354 wrote:
I was referring to it being too lean. I ordered the 5.5 seems to be the major game changer in the process
mxstate wrote:
22 GasGas MC250, Central FL so weather conditions very close and elevation not that much more above on your side) AJ's specs (I got PV set...
22 GasGas MC250, Central FL so weather conditions very close and elevation not that much more above on your side)

AJ's specs (I got PV set differently but that's personal pref.
MJ 490
PJ 32.5
AS ~ 1.5 turns out
Needle jet S4
Needle 42-75 on the 2nd clip
Slide 5.5
Fuel mix 50:1

Runs crisp, clean, no bog.
I had a 19 TC250 with same setup minus a 5.0 slide as I couldn't get a 5.5.
It was running great too (full disclosure/ Slow Vet C level)
I would not worry about the slide but if you feel more comfortable doing so get a 5.0, try then re-cut it to 5.5

Once set, it's only A/S adjustment if the temp/humidity change radically
The TMX works fine...
Out of curiosity what’s your premix and fuel you use for the 50:1? Otherwise that’s exactly what I’m going to start with for baseline. Parts should be here Friday/Sat 🤘
AJ565
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San Antonio, TX, USA
3/23/2022 6:31pm
bdavis354 wrote:
I was referring to it being too lean. I ordered the 5.5 seems to be the major game changer in the process
mxstate wrote:
22 GasGas MC250, Central FL so weather conditions very close and elevation not that much more above on your side) AJ's specs (I got PV set...
22 GasGas MC250, Central FL so weather conditions very close and elevation not that much more above on your side)

AJ's specs (I got PV set differently but that's personal pref.
MJ 490
PJ 32.5
AS ~ 1.5 turns out
Needle jet S4
Needle 42-75 on the 2nd clip
Slide 5.5
Fuel mix 50:1

Runs crisp, clean, no bog.
I had a 19 TC250 with same setup minus a 5.0 slide as I couldn't get a 5.5.
It was running great too (full disclosure/ Slow Vet C level)
I would not worry about the slide but if you feel more comfortable doing so get a 5.0, try then re-cut it to 5.5

Once set, it's only A/S adjustment if the temp/humidity change radically
The TMX works fine...
bdavis354 wrote:
Out of curiosity what’s your premix and fuel you use for the 50:1? Otherwise that’s exactly what I’m going to start with for baseline. Parts should...
Out of curiosity what’s your premix and fuel you use for the 50:1? Otherwise that’s exactly what I’m going to start with for baseline. Parts should be here Friday/Sat 🤘
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve run C12, T2, u4.4 (all straight and 50/50), and avgas. All work very well, u4.4 and t2 are a noticeable increase in throttle response and power.
2
wrc777
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3/23/2022 6:38pm
I bought a used 150sx that had been run for 20 hours at 60:1 and ridden easy enough that the original sprockets were almost new looking and the tires were less than 1/4 worn. Despite this it needed rings. I run 32:1.
bdavis354
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3/23/2022 7:06pm
AJ565 wrote:
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve...
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve run C12, T2, u4.4 (all straight and 50/50), and avgas. All work very well, u4.4 and t2 are a noticeable increase in throttle response and power.
This is all on same jetting I’m about to try, with possible air screw adj!?!
AJ565
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3/23/2022 8:01pm
AJ565 wrote:
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve...
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve run C12, T2, u4.4 (all straight and 50/50), and avgas. All work very well, u4.4 and t2 are a noticeable increase in throttle response and power.
bdavis354 wrote:
This is all on same jetting I’m about to try, with possible air screw adj!?!
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol free is mixed is 55:1 so I end up around 47:1 when mixed. Noticeable everywhere and not much of a noticeable change between straight T2 and u4.4. It’s the best bang for the buck overall.
mxstate
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3/24/2022 3:25am
AJ565 wrote:
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve...
I’ve only run amsoil dominator at 55:1 in my bike since the day I bought it. 90 octane ethanol free as well from the pump. I’ve run C12, T2, u4.4 (all straight and 50/50), and avgas. All work very well, u4.4 and t2 are a noticeable increase in throttle response and power.
bdavis354 wrote:
This is all on same jetting I’m about to try, with possible air screw adj!?!
AJ565 wrote:
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol...
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol free is mixed is 55:1 so I end up around 47:1 when mixed. Noticeable everywhere and not much of a noticeable change between straight T2 and u4.4. It’s the best bang for the buck overall.
Outlaw Racing fuel - 96 or 110 and Maxima K2
Pump gas is loaded with ethanol here.
bdavis354
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3/24/2022 9:14am
bdavis354 wrote:
This is all on same jetting I’m about to try, with possible air screw adj!?!
AJ565 wrote:
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol...
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol free is mixed is 55:1 so I end up around 47:1 when mixed. Noticeable everywhere and not much of a noticeable change between straight T2 and u4.4. It’s the best bang for the buck overall.
mxstate wrote:
Outlaw Racing fuel - 96 or 110 and Maxima K2
Pump gas is loaded with ethanol here.
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving to Dominator at 50:1 w/T4

Itching to get these parts to get testing/tweaking! Should be a good weekend for it 70's and sunny here on the coast with humidity ~70%
AJ565
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3/24/2022 9:48am
AJ565 wrote:
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol...
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol free is mixed is 55:1 so I end up around 47:1 when mixed. Noticeable everywhere and not much of a noticeable change between straight T2 and u4.4. It’s the best bang for the buck overall.
mxstate wrote:
Outlaw Racing fuel - 96 or 110 and Maxima K2
Pump gas is loaded with ethanol here.
bdavis354 wrote:
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving...
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving to Dominator at 50:1 w/T4

Itching to get these parts to get testing/tweaking! Should be a good weekend for it 70's and sunny here on the coast with humidity ~70%
You could just run T2 and not mess with mixing. The extra oil in it makes up for the oxygen content instead of having to richen the jetting up.
1
DuroTools
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3/24/2022 11:40am
AJ565 wrote:
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol...
It is (the 5.75 slide and 500 main specs.) My favorite fuel combo so far is T2/ethanol free. The T2 is mixed 40:1 and the ethanol free is mixed is 55:1 so I end up around 47:1 when mixed. Noticeable everywhere and not much of a noticeable change between straight T2 and u4.4. It’s the best bang for the buck overall.
mxstate wrote:
Outlaw Racing fuel - 96 or 110 and Maxima K2
Pump gas is loaded with ethanol here.
bdavis354 wrote:
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving...
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving to Dominator at 50:1 w/T4

Itching to get these parts to get testing/tweaking! Should be a good weekend for it 70's and sunny here on the coast with humidity ~70%
I just compared Motorex 2T with Dominator and with the same jetting I had zero spooge drips with Dominator and alot with Motorex. Gonna try Klotz R50 after seeing pics of a Piston in a 150 mixed at 28:1 for 50 hrs and it looks almost new with a tiny black spot. Not sure how thats possible cause it has such a high flash point but apparently it burns super clean if your jetting is proper.
1
bdavis354
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3/24/2022 3:27pm
mxstate wrote:
Outlaw Racing fuel - 96 or 110 and Maxima K2
Pump gas is loaded with ethanol here.
bdavis354 wrote:
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving...
Yeah same here in NC that why I've been mixing T4 at 50:1 with Motorex 2T but after this bottle of premix I think i'm moving to Dominator at 50:1 w/T4

Itching to get these parts to get testing/tweaking! Should be a good weekend for it 70's and sunny here on the coast with humidity ~70%
AJ565 wrote:
You could just run T2 and not mess with mixing. The extra oil in it makes up for the oxygen content instead of having to richen...
You could just run T2 and not mess with mixing. The extra oil in it makes up for the oxygen content instead of having to richen the jetting up.
That’s the end goal
bdavis354
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3/26/2022 7:39pm
Alright we got it all in tonight just in time to watch the heat races in Seattle! Looking fwd to tomorrow and seeing what all the hype is on the AJ/Digger jetting 🤙
gahooligan
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3/27/2022 8:56am
I still cannot get my 2022 125xc to pull clean from closed throttle at lower-ish revs. Initial pull away is fine but a 1st or 2nd gear crusing to a snap open throttle does not respond and clutch or throttle play is needed. I am running the notched JDR 5.0 slide with jetting and PV settings from the first page, and thinking it is just a bit lean in that situation only. I have played with pilot and air screw as well as needle and cannot find a setting that works. Maybe the bike is just geared too tall?? It sucks because it runs great otherwise. My sons 85sx rips in comparison with ZERO hesitation even with me on it (140lbs is t saying much lol). Anyone end up here and have any suggestions?

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