Jetting help needed

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Take a look at the slide diaphragm. I just fixed an issue that was exactly like you are describing. It ended up being a small hole in the rubber diaphragm.

I guess we will have to take your word for it that the diaphragm is good. Stop buying parts and the start looking elsewhere. Any fuel filters? Vacuum operated fuel valves?

Here is a better question. When you get to the point that it starts to act up, does it feel like the clutch is slipping but there is no rpm increase or winding up?

It does this in all gears?

I find it curious that you make no mention of any kind of coughing or popping during all of these jet changes. Observe the jet nozzle as Kenfused directs and go from there.

Jmo, but this is beginning to sound like a non-fuel issue.

Deceleration pop usually means too lean

The stock ignition modules have built in rev limiters set near 5500 rpm.
The slide could be the problem, filling hole with JB weld and re-drilling doesn't necessarily make it good as new. Before you get mad at CVP try a new slide they come with a new diaphragm, Or try ebay for a new or different CV carb, often you can get takeoffs for a reasonable price. Then you have a carb for parts, CV's are one the best all around carburetors out there.
Having used the CVP kit in several different sizes and models of Harley engines with great success I'd say the problem is probably operator malfunction. JMO

One thing he hasn't mentioned is if he even looked at the accelerator pump to make sure the diaphragm in there is good.

Cool

I agree with HarleysLR. JB Weld is not a good fix. $40 for a new slide. At this point, what for have to lose?

Maybe it wasn't the carb to start with, check your local Craigslist for a carb. They really are pretty bullet proof,

I have a little stash of carb parts here is what I'm willing to let go of,
1. stock cv 40 slide NO rubber diaphragm. pic attached
2. 1 complete CV carb with a dyno jet kit in it, I ran this for a couple of months then I bought a complete carb from Ken @ CV Performance. It hasn't been used for about 8 or 9 years. If I remember right it worked ok.
Kens carbs are top shelf stuff polished and all. I'm running one on my stroker 103".
If your interested send me a private message, I'm leaving town for the weekend tomorrow morning and will be home on Monday.
I looked on ebay and there isn't much, you can get a new rubber diaphragm for about $15.00. I didn't like the dynojet stuff and didn't want to change it all back to stock so I got a different carb. If nothing else this is a good parts carb. I'll throw in a Turblator for the throat of the intake manifold.

Good eye, I just checked it, 1/8" that slide came out of a used bike I bought back on 01, it was a 1996 softail,

I had good luck with my CVP parts, bike (04 1200 Sportster), runs much smoother after getting the Dynojet crap out. I did replace my slide as the old one was drilled. I would think JB weld would throw off the overall weight of the slide a bit, making it not perform as expected. Also check (replace) the intake manifold gaskets, and be sure to tighten the collars evenly as they are tapered and will leak if not careful. Use some lube (vaseline) to make sure all fits well.

Clean your existing plugs as well as you can monitor it from there. If it is coughing off idle it is in your pilot circuit. Drop down to a 44 pilot. Almost three turns out? Sounds a bit far to me.jmo

Indication that the pilot is still too big.