re:
...I can't imagine that it could run any better then it does now.
Ha! Been there.....about 1/2 dozen times! There's always some tweak/upgrade around the corner that makes me think that all over again!
Don't know what 'AS backed way out' means, exactly..but if it's more than two turns out, something else (pilot jet probably) needs to be changed...or fixed.
THAT circuit being primarily responsible for off-idle throttle response, when you get it right, you'll be back to another 'I couldn't imagine.......'
It'll be deja-vu all over again........:)
To say
I am running the stock 200 jet
doesn't mean anything.
THE way to know how it's jetted is to take it apart and look at the numbers. Any advice on what to change without knowing where you're starting from is advice you shouldn't pay attention to.
Note that CDave asked '..exactly what jetting is in the carb right now?' He asked that because it's important..something you need to find out.
Recently was a poster with a 35mm PWK off a 200 that he put on his 220. All other things being normal, he was jetted pretty rich...still showed the kiss of death on his plug (aluminum ash-grey color). In a case like that, telling him to jet richer would be bogus. Something was wrong with that carb or its install. Jetting wasn't going to fix it. KNOWING his jetset from the start indicated a problem other than jetting.
So, post your needle, main, pilot and clip numbers/positions to get any decent, meaningful response.
So, 'am I risking internal damage...?'
Probably not. But maybe so.
re: noticeable power difference
Changing from the stock 33mm 220 carb to the 35mm will certainly be noticeable!!