Hello Lads,
Yes Paul moved house, back on the coast again. Though i liked the highlands ( "high" in Aussie terms

). Warmer in the day, which is nice. Thanks for the warm welcome back.
Re the 65 pilot jet on the RGS, the 180 series 1 1000 factory seting is 55 however the 1200 is listed at 65. The 1200 jetting is for the restricted air box though you wonder at the apparant going the wrong way on the pilot when the air flow is reduced. Possibly the reduced air flow also reduced the helmholtz ( venturi ) effect that enables fuel to be drawn up the emulsifier tube at low rpm.
Thus a bigger pilot jet may have been required.
Of all the Breganze triples the RGS was most afflicted with off idle/low rpm stumbles and almost incurable pilot jet to needle transistion variation in correct fueling ie it is either too rich or to lean or the 25 degree step on the ignition made it appear so. If you try to adjust the pilot on a BTZ the motor will pink in hot conditions and stumble dangerously in slow hairpin turns especially uphill, i know after nearly droping a Corsa!
The factory solution was to "smoother" the horrendous step of the ignition by gross overjetting on the pilot. Theory easly proved by fitting a decent ignition like mine or the Witt DMC, fitting the 55 or 60 pilots, reset the carby balence at cruise rpm of about 4000rpm ( forget balencing at idle rpm as whom rides around at idle rpm?? ). 80% of my riding is done on the pilots ( misnomer the phrase "idle pilot" as if that was so why does the fuel idle screw have an adjustment? ) it is the ever important pilot jet and transistion onto the needle/emulsifier that is soooo much more important than main jet size.
Paul B, that point number 2 low throttle opening can be hard to diagnose. Though with some clever ideas like the one from Chris Pritt you can diagnose it very quickly on the road. Find a straight low traffic area, warm the engine up and start riding, get the engine to "hunt" then pull the choke on slowly at first, if the condition worsens then you are rich on that phase of the throttle if it gets better then worsens most likely your lean. Over rich low throttle can feel like a lean out in the way the engine surges, though normaly you get other indicators for lean outs like carby spit backs and poping on the overrun ( provided the exhaust system is sealed against leaks ). Make sure your air flow through the air box is adequate and near standard ( no snorkel! ).
One word of warning should you go for the 55 pilot, on the 180's here i find the closed or trailing throttle transistion to needle results on some engines, a pronounced over rich on closed throttle to correct fueling when re opening the throttle. This results if riding close to the guy in front a "boost" of about 10hp and i find myself right on the front mans rear wheel in short order, bit disconcerting at first however i think it is great fun. The reason i can only guess at however obviously the transistion phase is markedly effected.
HTH John