Hey, heres a great video of how the slide should operate. Its normal for some gas vapors to come towards the airbox i have seen that in many vids.

 

I am more suspect of the .433 and then .334 measurement.

When you removed the main jet and its holder, did the needle jet below make it back into place? The needle jet is a brass collared bushing (gets held in place when you install the main jet holder on top of it) that protrudes slightly into the throat of the carb and the needle on the slide slides in and out of it when the slide moves.
If you cant see the brass needle jet protruding into the throat a little, it may be missing and explain why the holder screwed in to the carb body farther than before you disassembled it...

Just a possibility that would explain a burbly rich condition and fuel spitting out of the carb???

No offense intended if you paid careful attention to the neddle jet and reinstalled it properly. But installed in the same "hole" goes 1) the needle jet, 2) the main jet holder, 3) the main jet.

TC

 

I took the diaphragm apart and confirmed that it was all put together properly. I was thinking perhaps there was an alignment issue with the spring guide to the slide indentations, but after putting everything back together with known alignment, I'm comfortable saying that was not the issue.

Manually assisting the slide and it runs. Sorta. Backfires something fierce and the exhaust (even further back than the carb) gets almost instantly hot. I had it running for less than 30 seconds and it would have burnt me.

Granted, I've never examined the exhaust before to this extent, so it's quite likely that those results are typical

Once I've assisted the slide, it goes up and down with the throttle, but it dies if I let it get to lower rpms. All the while, backfiring and popping

 

No offense taken whatsover!

Truth be told, I was not aware that those two components actually came apart. Yes, I saw the slit for a screwdriver, but I also saw the hex and attacked that instead, knowing how soft brass can be. I figured if it needed any coaxing, I was safer on the hex. So, the whole thing came out as one unit, cleaned as one unit, and then put back in as one unit.
Now, that being said...
When I was spraying the bejeezus out of the threaded hole and through hole in the carb (where the main jet goes) I had a distinct impression that an o-ring flew out, but I automatically attributed it to the crud (the main bore of the carb was rather nasty with green goop). I looked around the ground and also at schematics and saw nothing that would have filled that role in that spot (although, where does #16017 come into play?)

 

Sounds exactly like the symptoms I had when I re-installed without the needle jet by mistake... just to be clear, as I didn't know when I did it, there is the main jet, that screws into the holder, or emulsion tube (which in turn screws into the carb), but also an additional "needle jet" that goes in first, and is held in by the main jet and holder. So, three components all together, the needle jet having no threads, and being easy to lose.

Below are a few quotes that could be helpful if that WAS the case....

"Well... I had a sneaking su****ion after reading this.....

"There is a brass "collar" sitting above the Emulsion Tube. This is the Needle Jet. It protrudes into the carb bore and it is the first item the needle slides in and out of below the slide. It will likely fall out after you remove the Emulsion Tube. If you leave it out or install it upside down, it's "game over" until you go back in and do it right."...... -Klxster, CVK34 list of issues, problems, fixes, post #14

And sure enough......

After I went ahead and removed the carb, (instead of trying to twist), there it was...I picked up my needle jet, dropped it in and re-assembled.
Now it starts AND runs past 1/4 turn, imagine that!!!! I haven't gotten out for a real ride but I putted around the property with no seat or plastic, and all seems good."

CVK34 list of issues,problems,fixes

 

I can say for certain that part is not where it should be. Now to find it......

Thanks, I think that got me on my way to a running bike.

One question though; I see the phrase often "1/4 turn out" or something along those lines, and I honestly have no clue what it means. I'm guessing it's the tuning screw (which I could only guess as to it's location)

 

Maybe referring to the pilot screw (idle mixture). Start at 2 1/2 turns out from being gently seated.

Ride on
Brewster

 

glad you got it!!

 

any luck finding your needle jet?

 

Negative. I've looked all over my bench and work area and no luck. I took the carb body outside to spray it down with carb cleaner, I suspect that's where it fell out. It's a gravel driveway, so...needle in a haystack...

I've got a new one (and other parts) coming. Probably should have called the Kawasaki dealer (an hour away) to see if they could have gotten it quicker than next weekend