maybe your TCI has gone. have you ensured the earths are clean from the battery and to the engine.
Switching on and off is the work of a simple contact set, that's why I'm looking at the TCI having issues.
If you look on the TCI there is a TID number, try and borrow one of the same type to see if its that
good look with the build
lube your cable if its not a slinky coated one, or just replace it.
Readjust the cable and check the run is not near an exhaust pipe where it will burn
it also depends on the handle bar shape. American bars tend to have higher, curvier bars so there are shaped to meet those curves.
TBH so long a the bore size is the same, you should be ok. try xs650 stuff off mikes XS
I never forget undoing a cam cover bolt on the FZ using a ratchet ring spanner.
going great till it hit the frame with no where else to go. had to cut the spanner with an angle grinder.
I feel your pain
I'm suprised its finicky then.
I'd still check timing, fuel height, valve clearance . before you start on different jets.
BTW fuelling the top end still applies, get that right (over 3k) there' usually a transition around there from pilot
check timing if its adjustable first.
check 2 stroke oil as too much weakens the mix
you need a jet kit, allens or NRP, you need to ensure mains set first for WOT, do plug chops to check mix.
I assume the carb is set up and cleaned throughout?
on the carpe-tdm site, one really tall guy has slightly modified his controls and this helped http://www.carpe-tdm.net/ipb/index.php?showtopic=37015&hl=tall#entry376858
hard luggage for me too, when I went to spain etc, just unhook them at destination and walk in like a suitcase.
they are safer like Cynic says so brew stops are less fraught .
Say hello on http://www.carpe-tdm.net/ipb/index.php loads of info for you there too