Long story short in chronological order:
- Got the bike used a year and a half ago
- Cleaned and rebuilt carbs
- Installed new UNI replacement filter
- Bike ran lean
- Found that intake boots were leaking, replaced them
- Bike ran healthy after a half turn out of mixture screws, ran great all season
- Fast forward through winter
- #4 carb was overflowing gas, there was some evidence of this towards the end of the first season with it (dark plug on #4)
- This caused the bike to run extremely rich and flood—it would die about ten minutes into riding it
- Replaced the leaky petcock with a new one, rebuilt all carbs, installed new float needles (and adjusted float height to spec), and new pilot jets (and rubber plugs and O-rings) from a K&N rebuild kit
- Now the bike seems to run excessively lean—sometimes dies without choke, dies/comes close to dying when throttle is turned, wacky idle.
- The main point again: is it possible that I should have rejetted the 115 mains to something like 117 mains for the new UNI filter and that somehow the leaky petcock/float needle allowed for the bike to run somewhat healthy?
I'm just trying to narrow down the issue so I don't go out and buy a whole new rebuild kit. Thanks everyone!