I just recleaned/soaked the carb again, cleaned all jets, and entire carb,,,,everything looks good, the bike won't run without almost full choke, turn the throttle and it bogs out/ off or hesitates then revs up into the rpms, the throttle response is aweful and only idles with choke 3/4 on.
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My money is on a partial blockage of the main jet or the passageway to it. You're having to force it to run through the idle jet by fully choking the incoming air. There's not enough gas coming in with the choke open to allow it to run.
I'm thiniking total carb disassembly, carb cleaner and an air compressor combined with a ton of patience will take care of the issue.
Lindsey... your problem is the classic issue with plugged jets. Specifically the low speed speed (pilot) jets are clogged. With the carb removed and the float bowl removed, and the float also removed, you'll see generally two sets of jets. Usually the one in the center is the main jet and has a larger hole and that jet doesn't usually clog but to be sure remove it and inspect the opening. If you can't see light then it's clogged. The more suspect issue is the pilot (low speed jet), usually off to the side. This jet, once removed has a longer body and this is the jet that is clogged. Perform the same "look thru" and you'll see no light or very little. When this jet clogs it displays the symptoms you mention. As you give the bike throttle, transition from idle thru low speed and then to main jet occurs, based on rpm and throttle demand. The pilot jet doesn't allow transition and the bike falters from about 2000 to 5/6 k rpm.
So how to clean. I've tried acetylene torch tip cleaners but most are too big. If you have an air compressor, try blowing high pressure air thru the jet and it may clear. The ultimate fall back is a chemical clean. Place the jet in a ultrasonic tank or purchase Berryman's carb cleaner in a small tank (1 gallon) (Auto Zone or internet)http://www.amazon.com/Berryman-0996-Chem-Dip-Carburetor-Cleaner/dp/B00DSMEL2A/ref=sr_1_1?s=automotive&ie=UTF8&qid=1419804749&sr=1-1&keywords=berrymans+carb+cleaner
and soak the jets in it. Here's another potential problem... the pilot hole in the body of the carb may also be plugged so while at it disassemble the soft parts from the carb and treat the carb body (no soft parts) also in the carb cleaner. Usually about 1 - 2 hrs soak removes the clog. Best to clean all holes in the carb body with high-pressure air. Since you have a four cylinder then you must perform the same exercise 4x. This will solve your problem...
If you need to use choke and there has been a recent clean and/or rebuild. It would be a good idea to check the fuel mixture screw setting. It sounds like it is running a fuel/air mix that is too thin, (lean mixture).
Remove Seat, Gas tank, side covers, and airbox.
Loosen throttle cable adjuster to give free play to cable.
Loosen intake boot clamp and pick up on carbs so you can get then throttle cables off the carb.
Loosen choke cable holder and remove choke cable from carb.
twist the carbs and pull out left side of bike.
turn carbs upside down and remove the bowl screws.
Remove float pin and float and float needle.
remove all the jets, and set them in the carb bowl
turn the air fuel mixture screw in until it stops, counting the turns, remove it and place it in the bowl.
Remove the diaphram, and set aside.
Submerge the bowl with all the jets and screws in it into a carb cleaning solution.
Submerge the carburetor body in the solution.
Let set for minimum 2 hours. Depending on the corrosion it may take 24+ hours.
after soaking, wash all parts with water, and blow everything out with air compressor.
Make sure you can see through every jet and through the little holes in the sides of the jets.
make sure you can blow through every orfice in the carb body.DO NOT stick wires in the jets.
If the jets are still clogged just soak them overnight. Trust me, i've done hundreds.
Reassemble the carb and put it back on the bike.
Your carb will work like brand new.
NOTE: If you are not familiar with any of this but you still want to do it yourself. WRITE everything down and label every hose, vacuum line, throttle cable, choke cable, ONE AT A TIME.
This is very important to be successful. Take notes
It still sounds like your pilot jets in the carburetor are clogged. Just soaking will not clear plugged jets. The jets need to be removed, and manually cleared out. If you take a single strand from a piece of wire, it is usually small enough to pass through the pilot jet without damaging the orifice. After you have passed the wire through the jet, soak it again to remove any remaining deposits. Then blow the jet clear with compressed air. You should be able to see light through the jet orifice if it is clear.
this is very tipical. when bikes are stored the fuel varishes up the jets & needles. soak the carb. moving it back and forth in the soak solution. then blow every jet and orfice with a controlled air source. note: any speck of rust or dirt can plug these jets. pay attention to detail and do every thing twice. then install the carb and adjust it to your riding style. later Spike
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