[Gene563]

I'm aware that it is louder with the modified filter box; that was part of the allure ... it sounded much better than stock. My issue is beyond that, almost annoyingly loud.
As to the emissions gear, the evap canister was removed during my PDI and the PAIR system a while later.

Update: I have discovered that it is the muffler causing my problems. I re-adjusted the valves, played with the idle mixture, and took her for a test ride. This time I was wearing my half helmet and I could hear the hissing from the exhaust. As i would get on the throttle and build speed, I would hear the exhaust release pressure, like a tea kettle. I could ride that as well ... meaning I could sustain that pressure, but once I let off the throttle, it would dissipate, like taking a kettle off heat.
I returned home and a short while later, removed the muffler and went back out for a short ride. Although loud as heck, it seemed to run well.
Does anyone have a recommendation for a replacement muffler?