Modifying stock air filters

I would say your problem lies within such a big jump in jet size.For changing to pod type filters you shouldnt have to go more than a couple of sizes bigger.Yes upsizing your pilot jets would be a good idea.Since your mains are so large I would go up 2 sizes on the pilots and see what if anything changes.
 
Floats are 1mm below chamber? Not sure what this is but if you have brass floats they should be 26mm and the plastic ones 22mm.
 
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can't post a photo of plugs right now, but by 'fine' I meant dark brown color. I'll post a photo asap.
Also I could've made a mistake, the original main jet was probably 134 or 132, not 128.
I think changing main jets to bigger reduced the choking a little but the difference is so small I may be getting a wrong impression.
By floating level 1mm below floating chamber I meant level of gas in a tube connected to the drain. It's just like some fellows photo in another topic:
full

I have plastic floats set to around 22mm.
Another thing that just came to my mind is that I had to unscrew my mixture screws to 3 full rotations to get my bike to at least run. the manual says 1,25 rotation. But I guess it's crazy, it shouldn't be like that.
 
Plastic floats should be 22mm. The tube test need to be don't with the carbs on the engine and running then off. With it 3mm +-1mmbelow gasket face. 3 turns out with 42.5 pilot jets is about right.
 

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I've read the topic on confusing float height but I didn't find it conclusive, some people suggested 22/21 mm height. to achieve 32mm height I'd have to bend the floats really a lot, should I worry about that?
 
This is how you measure. No gasket and to the top of the float. Remember to do both sides of the float. A plastic float is much thicker than a brass one so 22mm is very achievable.
 

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Thank you xschris. Unfortunately it was as I expected - 32mm is not right for my floats. They were ridiculously bent. I couldn't even remove the gasket once I installed it. There was no point in trying to install the carbs.
I also tried bending them to 26mm. Resulted in carbs overflowing and a puddle of gas on a floor. Also no point starting the engine.

So I'm back to 21mm and the problem remains.

I changed main jets back to the stock, which are 125, but it ran better on 140s.

Here are photos of floats:


I didn't get the chance to check and take a pic of plugs yet, I'll upload them on saturday. I really appreciate your help everyone!
 
It will not run right at 21mm because there is too much fuel in the carbs. You have to measure with the bowl gasket off. You may have something wrong with your float valve or floats. They look like they may be bent out of wack. Take a good pic so we can see it.
 
Yes, these are exactly the ones I have.
By "gasket" you mean a square shaped seal, not the valve needle, am I correct?
Anyhow I measured 32mm as on the picture, without the square shaped seal, and the cover got stuck with the floats when I screwed it on.
Here's one additional picture
http://postimg.org/image/5ejxn2pd7/
 
Those floats don't look right. It looks like where the plastic meets the metal is bent. Look at my pics and you can see it is flat. The adjustment tang should also be almost flat. Take a pic of the float valve needle and seat also because something is not right here. I think 26mm would work with those floats if they where strait. Personally I prefer the brass ones.
 
Here are pictures of my plugs and the rest of stuff. Still can't get it to work.
 

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That one plug is definitely too rich compared to the other. Is the jetting/settings the same between them? (the two carbs) That one plug may be fouled out and not running proper.
 
Yes it's true that the right plug looks different, even though all the settings are the same for both of them. I cleaned both of them 10 km before taking this picture. Any suggestions what to do next?
 
I would replace the plug with a new one and see what happens. Have you synced the carbs with a manometer yet?
 
Yes I did sync them, but maybe I'll do it again.
I remember that when syncing when I added throttle, a pointer of one of manometers was going nice up and down, while the other was kind of lazy. what does that tell you?
 
When syncing carbs you should not give it throttle. If one is not creating vacuum it sounds like there is low compression on that side or is not firing right. I would do a compression test.
 
I did compression test and it was around 10 bar on both cylinders. If it's not firing right do you think I should start with checking the ignition timing?
 
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