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I have no experience with the 38mm carb. But, 120 pilot, 150 main. popoff around 20 works well on the 44 and 46. I think this may get you started on the 38 as well.

Is your pulse line clear? I know you replaced the hose but what about the fitting? Could be clogged with spiders.

You're not going to like this. First get a repair manual. You need to start over. In the 440, everything needs to be shimmed and aligned properly. First remove engine, pump and driveshaft. You install the driveshaft first, measuring and shimming it to make sure its centered. The book shows you...

You could always remove your 650 impeller and measure it. Is your goal with the switch to have a lanyard? If so, many of the faceplates are inter-changeable. No need to re-wire

Out the head and into head pipe, out the head pipe and into a tee, tee to stinger and pisser. dont forget to plug the extra fitting on the bulkhead

I would do the mikuni. You can go even cheaper and get an adapter for your stock mani. Thats what I have and it works great. You bolt it on and then bore it to match the carb. http://www.watcon.com/Catalog_Pages/Intake%20Manifolds.htm

Looks like a stock 300 handle pole with a custom bracket