I forgot that a buddy took some good pics of the bike for me yesterday.  Here's one that shows the headers discoloration and also how the new emgo muffler is starting to discolor as well.

"- Tried #47.5, #50 and #55 pilot jets.  No change at all.  Idle mix screw produces highest idle when fully seated regardless if using #47.5, 50, 55 pilot jets.  Even so, idle is very rough.  Idle mix screw has no affect on idle right now with the exception that the idle increases slightly when the screw is fully seated"

Everything you report indicates that your mixture is grossly rich at idle but OK above idle. Yet your pilot jet and idle mixture screw seem to have zero effect on your idle mixture.  You may have a problem with obstructed pilot air bleeds, or your enricher may not be seating properly.  The float is a possibility but you would think that a messed up float level would affect the mixture across the board (idle, mid range, etc.).

The easiest component to check is the enricher.  Remove the enricher assembly.  Make sure the plunger moves freely from detent to detent.  Make sure the plunger shaft isn't bent.   Verify that it closes completely and that the rubber seal in the face of the plunger is in good condition.  The rubber seal must firmly contact the raised seat in the body of the carb.

This is the plunger.  Note the black rubber seat in the face of the plunger.

If your enricher is functioning properly, and you are sure that it closes off the enrichment fuel completely, check your pilot air bleeds.  

There are two pilot air jets in the dome of the carburetor, a #45 and a #230.  These air jets are below the rubber diaphragm.  Make sure they are not obstructed (especially the #230).  Also make sure the passages associated with these air jets are not obstructed.

These are the two pilot air jets.

Test Results for Test #1 : Float Test

Test Setup: Standard Wal-mart aquarium air line heated and expanded to fit on bottom drain spout of carb.  Airline routed up alongside carb and taped to top of tank.

Test Procedures:
1. Ensure Raptor petcock is on normal "down" position
2. Attach one end of airline to carb drain spout
3. Tape open end of airline above carb, on gas tank with blue painters tape
4. Unscrew drain screw on carb drain spout until fuel starts filling airline
5. Observe fuel level in airline (I used my finger to push the line to be very close and parallel up the side of the carb)
6. Change raptor petcock to "reserve" position.
7. Observe fuel level in airline

Results:
With raptor petcock in normal position, the fuel line is well above gasket line.  I switched the raptor petcock to the "reserve" position and didn't see any change (although I wouldn't expect too).  Not sure if this was needed or not, but I remember something about putting the petcock in reserve as well.

Conclusion:
I think my float is out of alignment and the tang needs to be adjusted, or it has a hole and is filling with fuel.  I'll inspect/adjust tang and make sure the floats actually float in a bowl of fuel.  Since I have to remove the carb to do that, I'll check the enrichment system and air jets with the carb on the bench.

I think this may be one of my issues.  I'll run through the next two tests to be sure I don't have more than one issue going on.  But, it looks like either the tang needs adjusting or the floats ain't floatin.

Sound right?

Pics of test and test setup below:

Test Setup Pic 2

B-Will wrote on 12/18/21 at 14:20:53:


Adjust your float level.

Ok sounds good.  FYI, the enrichment knob looks fine and the idle air bleed jets look good as well (and are the correct size).

I'll do the tang adjustment / float test the floats, batten it all back up, and post results.

Thanks again,
Bwill