Same thing this past Saturday, Labor day weekend, swapped out the ignitech with my spare, splitting the rack, cleaning carbs, checking float heights. 3 and four where not firing! I could hear ignition when holding the boot near the plug and see spark when the plug was out and connected!
I soaked the carb bodies in Gunk carb cleaner, probed what I could with guitar string and blew them out after a good rinse out, reassemble, synced, fired up and sounding Goood! A day of good riding ended when I blew away a guy on his twin cam Harley with no shirt on. Stopped at a light, he rode up to bump fists and the max starts that thup thup thup sound ,NOOOOOOO!!!! FU#@KKKKK its doing it again! Why only 3 and 4, never 1 and 2???? I spent Sunday in the garage, same thing, determined to beat this ****** gremlin out of my bike and salvage some of the weekend. I split everything again,(I can do it in my sleep and quick by now.) I thought I would dump each carb over my clean white heavy shop towel and Bam! a tiny bit of black grit out of each carb. I think the fuel level sending unit in my tank may have some corrosion, I dont know, but the grit was really fine. Mod monkey scheduled tank service for this fall. I drainded the tank through the low level sensor hole, flushed it, added two new fram inline fuel filters. Reassembled the rack AGAIN, refueled ,synced the carbs, all four@ 2.5 turns idle is SICK @ 1k! She sounds GREAT!! I go down the alley and its starting to stumble, I remember it has to purge air out if the fuel system right? No the bike is barely able to limp back the block to the garage. I let it die and cycle the run/off switch, the fuel pump runs the 5 or so seconds every time and never pressurizes! WTF!!!!! FUEL PUMP, yup, took it out and after 10 quick minutes of open pump surgery the little rubber diaphragms each had the grit on both sides! Finally about 7p.m. and no issues after a short ride. I took the max out this evening and she's crisp and strong...ITs about frickin time!!!!!!