Dyno runs and cold starting 01 650

For anyone interested I ran my 01 fe650e on the dyno yesterday. Engine has been rebuilt and has a ported head but otherwise totally stock.

MJ 190,PJ 35 (now 56),NJ DR266,Needle K51 pos #3,Start jet 45 Idle mixture 2 1/2 turns out

52hp is about what I expected and it's a nice smooth curve with plenty of midrange. Tuner suggested going up in pilot to a 56 based on the A/F ratio and past experience with huskys. This got rid of the loud popping on the overrun and throttle response is improved, but hasn't really helping with my problem - cold starting.

Once it's warmed up it starts first or second kick. Start procedure is as other's have posted:
Choke on, 5 or 6 kicks with the decomp on. Decomp off 3-4 kicks until it briefly fires, then choke off and it will normally start in 3-4 kicks.

Only change since it started easily when cold was repairing the kickstart as the engagement sledge got chewed up and bent. When starting after this it kicked back and just about broke my ankle. I double checked the cam timing after this but it's spot on. It still kicks back a bit every now and then, but possibly this is only when my left leg is getting a bit weak and I'm not kicking it firmly enough.

I have cleaned out the carb, valve clearance are right (but I will double check them again). I could try changing the ignition timing, new plug mayybe? It is a little cooler now (15-20C). Any suggestions?

Attached are the dyno charts
Adam

Simon wrote:

While jetting is a pretty geographical thing, I'm extremely surprised by the pilot size 56, that is simply huuuuuge

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Yeah you're right Simon, I'll try a 40 or 45, the 56 was the only one
available, just a test to see if it helped.

Using a DR272 may even out the slight dip you have in the midrange.

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Yeah might try one, that's the stock needle for that model. Previous
owner may have changed it.

I've rechecked the valves and it's still a prick to start when cold, and still
kicks back, damn thing! I think I'll remove the kickstart decomp cable,
and just ease it past TDC with the manual decomp before kicking.
Seem to have more success that way, allowing it get spinning quick
before it hits the compression.

Adam