Two steps forward, one step backwards.
Went out and inspected Brett's handiwork after heading to the Canberra Show last Saturday. Carbs were in etc, but weren't setup.
Come Monday, they'd been dynoed. Muchos power.... but an incredibly nasty flat spot between 1/4 and 3/4 throttle. A flatspot is expected with CRs; the throttles open instantly. But there's a difference between flat but rideable and "wind the thing as rich as possible and it still sucks". Damn.
Turns out no-one's ever really set these up with K&Ns before & a really nice full system, not at least for bottom-end quality too. After supa and I emailed a few places to find out what's recommended, it turns out people accept they have to ride around it. Since Brett thinks things can be made better (with time and lots of tuning), but I want Buzz back soon, we're doing an interim measure: standard carbs tuned to suit exhaust and pod filters.
Note, this is interim only: we'll modify the airbox to run the Keihin supplied velocity stacks which apparently cures most of the bottom-end woes with the CR31s. Woot woot! Problem is it's not easy to run the stacks inside any easily available air filter setup: time for making a big-arsed opening into the airbox, using some air filter foam, and putting the velocity stacks inside the airbox.
Most people run the velocity stacks bare (e.g. see this GPX here:
http://www.kawasakimotorcycle.org/forum/kawasaki-streetbikes-sportbikes/34097-ninja-ex250r-owners-mod-shop-x-e-ryder-5.html). Ugh. Filters are useful on street bikes!
Mike from Power-Barn (the supplier of the carbs) suggests this is the best way to retain something resembling a bottom end (as small as it is in a 250) without losing any top-end.
As I said, two forwards, one backwards. Stay posted for interm results one, and the 'how to mod your airbox to make the damned velocity stacks fit and work awesomely' thread.
We've taken the CR31's off for the moment, still waiting on smaller jets and they're going to be a few weeks away - so the standard carbs have gone back in for the time being and have been jetted and tuned. 29hp with just a bit jetting! WOOHOO! hehe, I didn't care so much about the power gain (as much as it is cool) I just wanted to do something different and working closely with my mechanic, we just wanted to see what we can pump out of it, seeing as most people don't bother because they upgrade after 12 months and it'd be a waste of money to mod a Learner bike!
Anyways the Ninja is going on the back burner for a month or two, preparations on my Suzuki RGV VJ21 for racing in April are now going to be taking up my time!