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Your method for determining pilot size is close to mine. I have always aimed to have a bike that will just barely try to start cold with no choke. That usually indicates to me that the idle mixture is set fairly close. From the size ranges you are describing, and the obvious differences in displacement power, and airflow between the TTR250 and the CG250 engines, I think a 40 pilot is a perfect starting point. Main jet, with all mods, minus the head work, I think a safe starting point would be a 140 would be a safe (likely rich) starting point.
I just got the carb in today. I must say, for the money, this is a rather well built carburetor. The idle mixture screw is an air metering type and the screw is on the left side as well as the idle speed screw, which is both thumb turn or flathead. The only thing in kind of an awkward place is the choke pull, which is also on the left side but is rather high up. It might be awkward to get to installed on the bike, so I may look into doing a simple choke cable setup for it.
Honestly, the only thing kind of less than spectacular with the quality is just the finish on it, which is just a bit discolored and dirty looking. Nothing a little time with some steel wool and WD40 couldn't fix. That said, the bore machining is beautiful. While I wait for my laundry I am going to take the carb apart and clean it really well and try to shine it up a bit.
Went ahead and ordered an intake for it as well as an angled Uni filter for now. I will try to sort out a better air filter/intake solution in the future, but this will get it up and running. I don't plan on crossing any bodies of water any time soon, so the pod filter will be fine. Likely I am going to find a piece of 2 inch aluminum mandrel tubing that will relocate the pod to where the airbox used to be, or mod the airbox so that the pod sits inside of it. I will cross that bridge when I get to it though.
I will say this, and I agree with Pete and his many assertions in other threads, the PWK/OKO/KOSO flat side carbs are going to definitely offer a performance increase over the VM26/PZ30. The lack of reduction down to 26mm like you find in the VM26 is going to make a big difference in airflow. The real question is, how much of a difference will it make.
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