Great advice, Lizard.One thing to point out here:
First, all these suggestions as to sag #s and gearing are what each rider "feels" is the best.
Second, not everyone is going to have the best answer for you. The problem with the internet is that you ask a question, you get 15 different answers. In between those answers, you get guys going back and forth as to what is better - their way or the other person's...
So, try this. Set-up to use 6th gear is it has a long straight. If you don't like shifting a whole lot, gear for 5th and try it.
As far as sag goes, 35mm front and back is a great start. I set my stuff to be around 30mm and will even go as far as 38mm max. Basically, no one on here can tell you that you need a set sag number. We don't know how hard you are on the front, we don't know what your riding style is, etc.
Novices to AMA privateers all have different opinions. What works for a novice, ain't gonna cut it for an AMA privateer and vice versa.
Start out with a few things. Most guys in the paddock running 190 anything are running flush fronts with a lowered rear. The old days of raising the rear to the moon to turn these things is long gone. Ask around. Ask the top guys and see where they are. Don't conceed and run what they do and "live" with it. Change it. Remember, that guy you asked may be running 5 seconds a lap faster than you. His chasis numbers may be a great start and his gearing may be too aggressive for your speed, but it all is a great starting point.
Make sure of one constant - TAKE NOTES. Wanna run "track A"? Ask Tray, Jensen, Frankenfield, whatever fast guys what they do. They have the top times at those tracks and therefore, what they are doing is a great place to start. Work from there down and get yourself to the point you can use those settings with a bit of confidence. If they don't work, start going down. Change the rear sprocket by adding a tooth or two. Lower the front 1-2mm and see what happens.
You get the idea... Whatever you do, do it for what you need - not what everyone else runs and just sit there and wonder why it doesn't work... For you.
One common denominator seems to be to flush the forks (especially if running a 190).
My plan is to put the d209 back on, flush the forks, set the sag to 35/30 for starters...and go from there.
My bike has been pretty dialed since January, so to have it suddenly be completely f-ed up is quite discouraging. But, although posting a ? to this board and getting 15 different answers can be a bit confusing, there are some common themes plus it stimulates thought on my part (which is great). The other cool thing is that I am actually beginning to "feel" these things (front pushing, rear breaking loose, etc.) on the track and under what conditions (turn entry/mid corner/exit, on the gas/brakes, track conditions). I'm learning and I'll figure all out.
Thanks again to everyone.