OK. I spent about 10 hours today on my carbs. Got the clymer manual, pulled the carbs from the bike. The floats were nice and clean with no signs of rust, or built up residue. I took out the the 37.5 pilots, and put in my fresh shiny 40 pilots. Closed up the air screws, then turned them out to 3 turns.
Ok I put the carbs back on the bike, made sure no hoses were pinched, and double-checked hoses, and routing. There is sufficient slack in the throttle cable, and the carb boots are seated without air leaks.

After adjusted the idle speed back to 1200 the bike runs weird. It's idle is really incosistent, and I'm getting surging at 1/8 throttle opening. After that bike pulls really nice, much better then it did with the old 37.5 pilots. When I'm cruising on partial throttle (no load), the bike wants to buck, and surge, which is annoying since that is about 90% of my riding.

So I spent an hour dremeling a screwdiver down so I can reach the air adjustment screws (grrrrr). and turned them down to 2 turns out. Now the bike is running lean and slowing coming down from revs.... which isnt right. But if I go with 3 turns out then I get the surging problem, and poor idle. At 4 turns out the surging get worse, and there is a %50 chance that the bike will die while idling.

My current settings are:
Everything stock except 40 pilots.
3 turns out on the air adjustment.
idling at 1200 RPM

So any suggestions. Looking at the rejetting matrix it suggested that the air adjustment screw be 3 turns out. am I missing something here. I'm really tempted right now to soak the 37.5 pilots in in carb cleaner, and stick that back in with 2.25 turns out... which was the setting before I started this whole mess.


sigh...

After searching throught the forum for carb issues I found out that I got #40 *bleeder* jets, as opposed to non-bleed. This is probably cuasing my rough idle, and 1/8 throttle buck/surge condition. I'm off the order some *non-bleed* 40 pilots now.

*sigh*

stupid details.... and stupid dealers

Looks like you found the answer to your problem. When you have the carbs apart again you may want to check your float height.