honk honk (beep beep?)
As the ride went on I noticed what I can only describe as an "intake honk" appearing. It continued to get more pronounced
The noise isn't something that grows..it's either there or it's not. It does
NOT happen with holes drilled, but does with the cover altogether off. It
ONLY happens to a corresponding twist of the throttle.
If the point was to determine if the noise bothered you (I personally don't like it..others do or don't mind), taking the cover off completely (ty-wrap the electricks box someplace) to see how you like it..or not...would have worked, too.
Things as 'throughout the powerband' makes me think we aren't talking about the same thing. The more the intake is unbaffled, the more you'll hear it ANY time the bike is running, but the 'honk' part is momentary and linked to quick flicks.
Plug indications without specific technique (plug chop for example) is a waste of time. Which is to say checking your plug for color after a period of riding in all sorts of different load conditions and throttle ranges doesn't tell you anything.
re: 'Wasn't prepared to rejet' If you think it runs well now, jet it correctly and you're in for a surprise! 160 for a main is too much. You familiar with the 'plug chop' main jet tuning method? Do that for your main selection. Check:
http://justkdx.dirtrider.net/
..in the 'carb tuning' section to find out the 'how to' of it.
From that same section: (for a 2001 220)
With a performance pipe/expansion chamber, air box mods , the factory or after-market silencer and the stock 33mm carburetor run a 42 pilot, the stock R1173L jet needle in the second from the top clip position, a 145/148 main jet and fine tune the pilot circuit using the air screw.
Note: The R1173L is the stock needle..NOT aftermarket. Note also that 145/148 is a l-o-n-g way from a 160!
Finally...no, it doesn't 'snap' into position. It just sits there.
DO note there is a gasket that runs around the perimeter of the lid.
After all this...the answer to your question? (what you're hearing as a 'developing' intake honk?)
I don't know.
Ha! Would have been MUCH shorter to say that in the
FIRST place, huh?
Good luck!