General impressions after 3 days and 3/4 tank of gas:
The bike is loud. Not "people cover their ears when I drive by" loud, but loud enough that I'm self-conscious about it. Aside from the sheer volume, the sound is frikken awesome. I used a Cone Engineering "Performance" muffler because I liked the additional length aesthetically. The standard core mufflers are 4" shorter. They do make a "Quiet Core" in the longer length, and given the bike's performance, I think I might be okay with potentially sacrificing some (if any) pep for less volume.
Warm starts generally a one-kick affair; no throttle, no choke. Cold starting is more painful... choke on, hold the kill switch and decompression thinger, then kick through several times. Release kill & thinger, wind idle adjustment up 2-3 turns, and 5-17 hard kicks from TDC and it's generally good to go. Let her settle for a moment, then wind idle back down under 2kRPM. Put on my hard hat, and release the choke... certainly cold-blooded. I'm trying for a 1300RPM warm idle, as per the Honda manual. 158 main jet, 45 pilot, NCVT needle @ third clip, mixture 2-3/4 turns out from closed. From the cold-starting behavior and mixture setting, I'm guessing that I could stand to try a larger pilot.
Accelerator pump is an overachiever; timing is okay, but the squirt length is >1.5sec. I have a 55 leak jet, which is almost certainly too small. May also dick around with the "o-ring mod", but I'm a fairly strong believer in optimizing all the jettings and settings provided for by the carb manufacturer before modding anything. The FCR-MX makes all sorts of entertaining whistles and clatters, which the interwebz tell me are A) coming from the air jet and vacuum-release slide, and B) a normal part of the FCR experience, especially without a stock rubber boot/airbox to mute them.
Oh, and that performance: Stock bore/compression (as far as I can tell), 41mm FCR-MX jetted as above, short/wide/streamlined intake with very non-restrictive air filter, FMF PowerBomb exhaust with very non-restrictive muffler, Hot Cams Stage 1 camshaft, Rick's Electric HotShot CDI, 200watt RickyStator, new OEM coil, and NKG DPR8EIX-9 Iridium plug... Just the basic mellow bolt-on mods, but with the stock 14-48 cogs, the bike is just tractor-pull stupid; 3/4-throttle powershifts make for a fight to keep the front wheel down through the first three gears. In more capable hands than mine, this retro-styling exercise would be completely assholic.
The rear shock is charged with 120psi of air, which needs to be replaced with the appropriate ~300psi of Nitrogen asap. Shock could use a turn or two more preload, and none of the damping at either end has been touched (it's all either wound off or in an arbitrary midline setting). Brakes are sufficient, but require some mental technique adjustment after riding my cafe.
The cheapo "I used 'em because I had 'em" bar-end turn-signals are junk; Motogadget is calling... The bike needs a mirror (in the works). XR's Only case-saver is inbound. I really need to try a 44- or 40-tooth chainring. A larger tail-light would probably be advisable (there's a DOT Acerbis one available that bolts into the same pattern under the fender). I'd like to add an additional rear inner fender; I don't intend to ride this bike through tons of muck, but I do want to be able to ride in otherwise shitty weather. Needs a proper decompression activation device (not a lever/cable on the bar, but something better than just twisting the thinger on the cam cover with my thumb). The time-delay reg/rec and the headlight are not agreeing with one another; the LED light only draws 3.7amps, but when switched on, the rec/reg intermittently cuts the charge to the battery... puzzling, but all the electrics are happily under warranty, and answers will be found once tech support(s) open on Monday.
Altogether a very entertaining ride! I'm looking forward to continued testing/tuning/tweaking...