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I think that might be causing the bubbles...some sort of heating inside the pump that is mostly inconsequential.
Phil had the answer though (all hail Phil!) the underlying consistent problem was with the SU needles. I've got late HS6s with spring loaded needles...the spring keeps them so that the shoulder of the needle is past flush with the piston, acting as a leaner needle than they should be. I replaced them with old school pistons and KD needles...problem solved, revs out well.
thanks for the suggestions!
Per
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