I live in the pyrenees at 650m say 2000 feet or so.My 2004 ttr blue came with the carb box cut open, all snorkels etc. cut off and an after market exhaust, it never ran right. The previous owner had not re jetted. I changed the jets to run with the after market exhaust and it ran great but far too noisy for the villages and country side here. I purchased a second hand exhaust and put back the original jets because it was too noisy and she boggs a bit at the low and mid range, frustrating. I love the quieter drive but its not smooth. First there is a wealth of info here which helps thanks. My? Do I need to replace the airbox as it was originally or should i be able to get the ride smooth with just jets/needle adjustment? Also in passing I have a broken tower for the float chamber so if anyone has a spare carb to sell on.....thanks for any help or advice. ian
Regarding the airbox, why not tape it up to make the air openings as near to standard as possible and see if your TTR runs OK then? If it runs better then the mixture is too lean - if it runs worse then it indicates the mixture is too rich.
A simple and cheap (no cost!) adjustment is to adjust the needle up (to richen the mixture) or down (to lean out the mixture) to see what changes that makes.
If you have the original jetting, airbox opening and exhaust then the mixture can't be too far out
See Jarrah's guide here to repairing the float support post. I have successfully used epoxy resin in the past but the parts to be joined have to be totally grease free.