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Ok status update. I ordered a new TEV as suggested (thank you!), which took a while to arrive, and installed it. Yes, the rubber on the old one was not soft and the valve itself was somewhat stuck in the bore. I pulled it out and there was some discoloration along the annular sealing surface. I sprayed out the bore and installed the new one and went for a ride. I was hopeful but . . . no change . . . BANG at lift off! I removed the pilot jet and installed a 55 pilot jet, which I think should be overkill. I was hopeful but . . . no change . . . BANG at lift off! I took an all day motorcycle safety techniques class. During the 30 minute ride there and back, overall, the S40 ran well at all speeds (up to 65 mph) . . . but banging all the way at liftoff. If anything, it may be running a bit rich as it seemed to feel a bit boggy but I am not sure?!
So current config. is stock except Dyna muffler, with 55/152.5 jets, 2 steel washers instead of the plastic piece. So, my next plan, in order is as follows BUT I would like your feedback:
1. Double check for leaks at the carb and exhaust as suggested above. I just bought a propane torch for checking for intake leak. 2. I just bought a KN filter. Try that and see if it feels a bit better which would seemingly indicate that it was actually running rich. But I don't think this will change the core annoyance. But I will assume if banging gets worse, then running more lean because of the KN? I will use whichever filter that makes it run better, if I can tell of any difference. 3. Presuming it is still running well, without much difference, take the top off the carb and remove one washer, which just leaves one washer. 4. If that does not help, I have read some people clipping one loop off the TEV spring to make it weaker as helping the backfire situation. Should I consider this?? The main concern is that I would have to find and buy a new spring if it does not help.
Other options if none of the above works is to: 5a. Just accept the constant backfire, trying to minimize with slower throttle let off ... but I don't think I will be able to accept this. 5b. Just ride the rest of this season with the backfire, and during the winter, take the carb apart and install a full rebuild kit myself or have someone else do it for me. 5c. Give up and buy a replacement carb from Murray's Carbs.- with confirmation from Murray and/or from here that their carb will get rid of the backfire problem. But they are also very expensive. Anyone have experiences with them?
Sorry for the long post but I would appreciate any further thoughts you may have. Thanks, Daniel
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