90s Kawasaki bayou 220 carb rebuild/problems

[Tubecatgs]

A friend of mine has this Bayou 220 that started running bad and parked it a few years ago. I foolishly volunteered to take a look at it. I noticed right away the choke plunger on the carb was broken and probably the reason it was running bad but now the old gas was evaporated and like turpentine. Before i even tried to start it, i drained/ thoroughly washed the tank out, new fuel filter, new fuel lines. Blew air through the petcock etc. Changed the oil and filter and air filter and new choke plunger and cable. I disassembled the carb and rebuilt it with a kit. I cleaned the main jet with solvent and poked a wire through it to make sure it is clean.. the engine now fires right up with the choke on and dies when i take the choke off. I adjusted the air/fuel screw to about 1.5 turns out and the idle screw about 2.5 turns out. The rubber boot between the carb and head does not have any cracks in it so I don't think it is leaking air. I originally had the clip on the needle on the second from the top ring... when i moved it all the way to the bottom it starts, runs and idles really fast and will idle eeally high with the choke off but if i adjust the throttle cable and/or idle screw to a slower idle it will sometimes stall but the idle will go up and down every few seconds and when you give it gas there is a hesitation... i tried moving the clip down to rhe second from bottom and same problem... i replaced all the parts in the pic to the top right. However, there appears to be a small o ring, washer and spring left over from the kit... i did not see these get removed..... a) any idea if where these extra parts go and if i need them and b) any other ideas on why i cant get it to idle right or carb adjustment ideas?

Thanks

[Frank Angerano]

Welcome to Quadcrazy! Nice job on the carburetor. I like to blow all the jets/ports out with air to be sure they are all clear.  The o ring and washer  is most likely for the air fuel screw. 

I set my carb at 1-3/4 turns out and it was perfect. But it was also varnished inside and had to go at it three times before it was properly free of junk.  

I never went near the main jet/needle clip setting because it was not needed since the bike was running good before it was stored. So go back to where it was.  

Then go back and triple check your cleaning of the carburetor and make sure it’s good.  

   

[Frank Angerano]

FYI fuel air mixture screw.

Screw, washer, o ring, spring should be the right order.