Hmm, beg to differ on the mileage. I installed my 38's years ago, didn't affect my mileage one iota. What it did affect was I've not experienced any tendency to clog from this lousy fuel now being foisted upon us. Prior to that, I had to either clean or replace the 35's three times. With the 38's I haven't changed my habits except I'm not spending time pulling carbs. One habit I was happy to break.
http://factorypro.com/ the other 3-4 holes are bigger in 38s vs 35s, = worst mpg. its mostly only 1 to 2 mpg difference. most will not notice unless really, keeping great records, on same ride course for a full tank. since I mainly commute on my bike, I can tell u there is a difference esp with my air box and exhaust mods. colder temps I actually need to partially block airflow into the air box. a larger pj would cure the problem but then way too rich on the 3-4 holes during the warmer months.
"As far as the pilot... Look at it this way...
There are 4 outlet holes for the pilot mixture. ~3-4 at the butterfly and one "downstream" of that (for 75% of the idle mixture).
1 hole is controlled by the mixture screw and with the other 3 or 4, max flow is limited by the size of the pilot jet.
At idle, 1 hole (metered by the fuel screw) and 1 un metered hole are open.
At cruise, when the "butterfly" is just "cracked", all 3-4 unmetered holes + the 1 metered one are uncovered -
So.....
At cruise, you get those 3 unmetered holes + the metered hole... So, at least 75% of the fuel delivered at cruise is limited by the size of the pilot jet.
At idle, you get 100% of the trimmed 1 hole + a butterfly valve-trimmed amount of the other 3-4 metered holes.
Rule of thumb....
If you go 1 size larger or smaller on the size of the pilot jet, you will change the fuel screw ~1.5x richer or leaner to retain the original idle mixture -
Example:
You have a #40 pilot jet installed (with the proper main, needle height and fuel level already done) and to get best idle, you are 4.0 turns out (from lightly bottomed out).
Cruise seems lean....
So, I'd expect that I could richen the cruise with 1 size larger (42) pilot jet (size of pj is 75% of cruise mixture) and the "trim" the fuel screw "in" for best mixture for best idle (size of pilot is 25% of idle mixture).
To go back to ~ the same idle mixture, after going from 40 pj/4.0x to the 42........ try 2.5x
40 pj / 4.0x = our reference idle mixture
42 pj / 2.5x = ~ same idle mixture
38 pj /5.5x = ~ same idle mixture (this is a "stretch - after 4.5x, not much changes)
(Using another "rule of thumb", if you have the correct pilot jet, the fuel screw will end up at between 1.5x and 3.0x when set for best idle.)
Marc"
www.factorypro.com