The jetting chart is a no go? Thats the best place to start. Thats what I did, from there it has only been needle adjustment or mixture screws. Richer than the chart is safer than going the other way, but it depends on alot. You and your questions will probably be moved to "Jetting again and again", its a good thread to go through. Honestly it sounds like you need to take it aprt anyway to see what you really have. V-force says so on the reed cage and most Kaws are a stock cylinder unless it sleeved. If the jetting chart isn't working, maybe you have something else to look for. You should post the year of your bike, exact problem that has. In the mean time, it'd be a good idea to get the carb apart cleaned, and check the float settings, overflows, jet sizes, clip position.
Pro circuit has jetting recommendations to double check the chart. It will be close unless you are running a modified cylinder, or a worn one. Keep searching, you'd be surprised just how many problems guys have had with jetting which has resulted in lots of great info to find. Good luck.
