Okay, rebuilt the top-end of the 1987 KX500C-1:
New piston & rings, clearances perfect, LOTS of compression.
New KIPS valves timed correctly.
Everything spotless, carb, airbox, pipe, you name it, its been cleaned and assembled correctly.
Cleaned the UNI air filter and lightly oiled it with 30wt engine oil.
New spark plug, correct one. Gapped at .025
Ohm Tested coil = good
Ohm Tested CDI = good
Ohm Tested Stator windings = good
Removed flywheel = perfect /keyway aligned/not slipping.
Removed stator plate, cleaned everything for perfect ground.
Keihin PWK with 168 main / 55 pilot / Screw out 1-1/2 / 2nd clip on needle. (tried many settings)
Idle screw set to many different settings, makes no difference.
Brand new Boysen SuperStock reed valves. New gaskets.
Float height set to 16mm.
Fresh 92 gas at 36:1 Castrol A747
Will only start if I pull the bike with a rope and a truck, engage he clutch in 5th gear she will fire in approx. 1/8 mile of pulling. She will then run, but really boggy & poorly. Feels like it is missing, etc.
Runs crappy. Cannot adjust anything on the carb to make it idle, but I guess you can say it does run???If I rev the engine, it does rev well, but will not idle at all, and tries to die if not always holding the trottle open somewhat.
Is not "crisp" at all.
Biggest problem is: Stop bike, try to start with kickstarter: All I get is massive (LOUD!!) backfires out the tailpipe every 10 or 15 kicks, but will not run.
Tried every starting technique on this website and some of my own, lay bike over, flood it, fuel pouring out tubes, etc. Nothing.
Any advice???