OK so knowing that it did run with that carb setup I would have to say you are getting too much air(lean) with the choke off. I would reset the carb to original factory settings on the screws and try it there. Also agree with texashillcountry about checking the carb to intake seal as if there is a poor seal then you are getting unmetered air which will cause a lean condition. If everything is sealed up good and you start with factory settings it should start. Then you can adjust it from there. That is unless you have issues inside the carb still.

 

Also check the seals btw the intake and heads... 5 years is a long time! Had that problem on my 91 when I got it.. Fixed that, rejetted and it ran like a top! Good luck! Gary

 

Thanks for the help, the seal between the carb and intake is brand new, just replace a few days ago. Going to rebuild the carb and start off with all stock settings and replace the intake gaskets and exhaust gaskets. Will update when I get it done. Thanks for the help!

 

when installing any of the intake gaskets, use dish soap and water to make sure they seal real good. Very important! or spit works in a pinch too.. I do it to the glad hands on the truck if they have a little air leak. Hate to see you do it twice. Trucker Gary

 

Is that gasket the only thing that holds the carb on?

 

No, actually what holds the carb on is the air cleaner breather bolts. go into the heads. sandwiches the carb btw the intake and A/C.

 

See the bracket going from the head to the carb? Thats what holds it in. Trucker Gary

 

If you don't have a bucket with carb cleaner to dunk it in, go to lowes(etc) and get a clean one gallon paint can and some lacquer thinner. Put the lacquer thinner in the paint can and submerge the disassembled carb in it at least overnight. Be sure to have all the rubber parts removed. The idle air screw has a needle with a small spring, washer, and little o-ring and all those parts have to go back in the same order. Also where the needle that is in the slide goes into the carb there is a silver colored needle jet. The inside of it has a square end and a radiused end. The radiused end goes up so the needle can go into it. Do not put it in the other way or the carb will not work properly. Do not put the slide in the cleaner. Do not cut the spring or drill holes in the slide for street use. Use high pressure compressed air to blow out all the passages. When you reinstall the idle air screw make sure the spring, washer, and o-ring are installed in the proper order and gently screw the needle all the way in and back it out two full turns.
The overflow is probably caused by a bad float needle, they have rubber (viton) tips that get hard over time with today's fuel.
Hope this helps.
John

 

Thanks for all the help! I kinda feel like a moron with the what holds the carb on question...I haven't had air box on with all the adjustments to the carb. Once you said that I clicked!

 

What!

Ok...let us know how she acts with everything back on the bike.