OK so this one was driving me up the wall. I went in and re-soldered some of the dodgy connections in the wiring loom, replaced ALL of the rubber parts in the carbs, verified jet sizes and reinstalled stock 152.5 main jets. Replaced the carb slider diaphragms and verified all passages were clear. Reassembled the bike this morning and the problem has gone away. Bike pulls strong. It had us fooled for a long time. There is not one single item we can say was definitely the problem but I no longer care, just glad it is fixed. Thanks for all the help on this forum, much appreciated!
Did you do the 'crimp-fix?' "Get a jolt, from your electrode! He did the fix, the crimp-fix."-apologies to Bobby 'Boris' Pickett. ☠
Where it is in the wire harness:
More 'juice,' better charging.
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