You just need a little washer, doesn't have to be brass. I think the idea is to separate the E-clip from the nylon fitting, so the E-clip does not dig into the nylon over time..

 

Moved the spacer on top of the clip, the slight hesitation is gone now. At least I only had to pull the seat and tank off and not the carb. This bike is so much fun!

 

Glad the picture helped, here's some more:

Vacuum Slide 1

Vacuum Slide 2

Carb Parts

How I plugged the air valve 1

How I plugged the air valve 2

The plugs I used - 3 total

The sealant

Snorkel Removed

Tire Changing (found this somewhere)

I ended up performing the following mods:

• removed the air valve and plugged air box and carb

• drilled crankcase hole to 3/8�

• removed the snorkel (high-flow on backorder – I may not use it)

• drilled the exhaust 1/2"

• changed main jet to 125

• changed to adjustable needle w/clip in position two

• drilled slide 7/64"

• reset suspension settings to stock specs (they were NOT correct, front forks weren’t even set the same),

• set fuel screw 2 1/2 turns out

• and as always, running premium fuel.

 

i have to agree with giacoman on this one i have no brass washer in my carb (we got ripped off)so i have washers that fit on the out side dia. just wondering on the inside sizing. does it set on top of the needle or fit down over and rest on the eclip i guess i would rest on the e clip but i know that guess work in carbs is not a good idea thanks again guys.

 

After reading the other replies, I pulled out the carb again and added a washer between the needle and the plastic clip just to be safe. After all this, the bike started fine and seems to be running pretty smoothly. Although, I have seen increased performance with the modifications, I am not popping wheelies like others have reported.

 

I was wondering about that brass washer too. When I did my carb i too didn't have the washer in there, I figured maybe it was something 300 specific and didn't hassle with it. I guess I should go get one, though I haven't really felt any problem with out it in there.