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Went for a ride today and it is stuttering at 1/4 to 1/2 throttle.

Anyway I have the bike a part a bit so I could get to the needle. I currently have the 162 main 45 pilot. Clip is in the middle at the 3rd position. ( I am in PHX, AZ 1k ft elevation, and 85+ degrees or more today)

Tried the clip at the position from the 2nd from the top. Seemed a bit better but still there. Tried the top position seemed better even more....But started popping. So it is probably too lean.

I am wondering if my exhaust could contribute to this as well. The muffler is bent and damaged, and the header is also dented and bent. Which I was going to replaced in the future, but may replace sooner if it is even a possibility that this could be a factor.

*****Also I noticed that it was hard to start my bike without having to use the hot start....that seemed to be the only way I could get it to start. Is that another issue?

Your initial jetting is perfect. Fuel screw at 1.75 to 2.0 turns out?
Has the bike been sitting for months?
I have never had to use the hot start. Not sure why they were ever needed.

Yes...about 2 I think.

I bought it about 3-4 months ago and have had issues since. I have made it better with adjustments, but just cannot get this sputtering to go away.

I did end up taking it in. We will see what they say I guess.

That makes sense.
The passage at the top of the pilot jet and the fuel screw are quick to get a little layer or chunk of residue, and drastically affect fuel flow.
A metal dental pick to gently scratch it out, some carb cleaner and a blast of air will usually clean it.

Got a call back from the shop. They said everything checks out fine. In fact they said it runs great.

So maybe it is me. I rode street bikes before this and maybe I am just used to a smoother ride at a steady throttle.

Maybe a 450 just doesn't fit my riding style....maybe it just needs a constant increase in throttle that I am not giving it?

I just ride dirt roads and trails and cruise....