650 Carb problems, I'm at a loss
I have an '04 650 that's been parked for two years, now it's having idling problems. Here's the rundown; I drained the gas, pulled the carbs and thoroughly cleaned them, cleaned pilot jets (numerous times through this process), scrubbed every piece, looked through every manual and website I can find. Still don't think I've fixed it properly.
Before I parked it, I installed a Baron's Big Air Kit. Followed instructions, installed 130 main jets, 22.5 pilot jets, new needles with clip in 4th slot, mixture screws 3.5 turns out. Everything precisely per instructions. But, I never rode it to get it set properly. Now after sitting, I went to start it, and couldn't get it to idle without choke. Yesterday, I pulled the needles and moved the clip to the 6th space, then messed with mixture screws until it idled good, and until popping disappeared, as per Mikuni website. Now the screws are 7.5 (front) and 8 turns (rear) out. Since I see everyone else is fine at 3.5 turns, I can't help but think that something else is screwed up, and the mixture screws are simply compensating for it. But at least now it runs without the choke. After a short test ride, I hit the brakes, and it stalls out. (since it's not registered anymore, all I can do is end of street and back, but up to 30 mph) When I went to park it, lean it over on the kickstand, and it stalls. I believe that shows a float level problem, but I'm 100% positive I didn't alter the floats or the little tab that connects to the needle in any way.
What the heck is goin on!?!?!?!?!
One other point, I noticed a vacuum hose that ran from the carbs to near the rear of the air cleaner. For some reason I can't find this hose adressed anywhere, but I plugged it, and made it run better, so I left it plugged. AIS has been removed.