Thanks for the quick response Jon. I just got off the phone with Jim Snell of Rising Sun Imports. He agreed that 99% of bikes run best on the second clip position from the top; only high altitude bikes use the top (leanest) position. All the other settings are close enough not to cause the popping I described. His recommendation was to dismantle and clean out the mid-pipe and repack the muffler as the previous owner was a novice, and likely spent a lot of time running near idle. He said carbon buildup could cause the symptoms. Since it starts first kick, idles strong, and pulls strong, the jetting likely isn't the issue. He also said that in general, some popping is typical on trials bikes.
Stupid question: Will the manifold remove with tearing the gasket, or do I have to replace after checking the reeds?