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Ack! Choke not seating! Didn't register 'til I read it again. Any chance one of the choke cables got pulled out of its stop socket? If so it will hold the choke open on that side. Easy to do on the left by just pushing it aside to install the left pod because on that side it seats on the outside of the carb.
finally have a minute to get in the garage. checked o-ring on idle adjust and air/fuel adjust screws and they both seemed a little tired so I replaced them. cleaned out the screen from fuel hose inlet and there where some fine particles trapped there so not sure if finer particles made their way through. checked the floats and, if I'm reading this correctly, they are at 25mm(!). manual says between 17.5-18.5. so (a) did I read them correctly in the pics attached and (b) what is the method to bend the tab to get them to the proper height?
my floats are connected so I measured them according to the method laid out in the Dell'orto manual (and also thisoldtractor.com) by lying the carb on its side, not its top. did I get that wrong?
That's the way I measure mine (vertical float arm), but, after looking at a lot of floats, I think the 18mm float height is wrong if you are running newer floats and the spring loaded needles.Don't mess with your float level. Check the other things (choke plunger) first - Certainly if the problem is only on one side. My floats measure about 25mm with no compression of the spring-loaded plunger and about 20mm with a vertical float arm.I have new spring loaded needles. I bought new white plastic floats (not adjustable) and they measure 20-21mm and they are lighter (they close the needle at a lower fuel level for the same measurement) than the black plastic floats. I've tried brand new black plastic floats and they measure about 20mm or so on their OD. I can make the black plastic floats give an 18mm measure, but the new float arms need to be bent A LOT and then the needle only seats at nearly full upward travel (where it bangs into the chamber roof). The bent float arm looks wrong and the bike doesn't run as well. The source of the 18mm measure may be the design of the original PHF brown plastic floats. They have a chamber with a raised seam around it. They measured about 20mm on their OD, but if you ignore the raised seam and measure the outside of the chamber they measure 18mm without bending the crap out of the arm.
Check the o ring on the pilot jet screw first. Might save some work.
This was the culprit. Changed out the o-rings and the bike starts, runs and idles better than ever. Great info, thanks!