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I have a 92 600, and it will not start even with starting fluid after cleaning the rubber diaphragms that are under the top caps on the carbs. I inspected them to check for any cracks, tearing, or dryness and replaced one that was slightly torn. When looking at them there were a lot of tiny particles and fabric on them. So I sprayed a little carb cleaner on them and wiped them down to the best I could. When I reassambled them the bike would no longer start up even with starting fluid.
Now before I cleaned those diaphragms the bike was not running normal at all. It would idle at around 4k and above; sometimes the rpms would even jump to 10k and I would have to hit the kill switch. Also it would sometimes idle below 4k and stall out, but all 4 pipes were getting hot and it sounded good as long as rpms were past 4k. The bike also seemed to be running lean because the spark plugs kept getting wet with gas and a little black. This was after buying a new set of carbs, replacing all the floats except one, cleaning everything out except the pilot jets because I could not get them out, and setting float height and a/f screws to 2.25 out.
So the reason I cleaned the diaphragms was because when I opened the tops back up I saw that they looked like they could be cleaner, and maybe this would help something. Well, once I did that it no longer wanted to start, and I KNEW I had to get to those pilot jets eventually so I then took those out and replaced them with new ones. Upon attempting to remove the one pilot jet with an easy out I broke a peice off of where the pilot jet screws into. I then replaced that carb body with one of the old carbs that used to be on the bike.
Whenever I replaced the body I saw that there is supposed to be a plug that goes where the pilot jet is screwed into. So I then got all new plugs and fitted them all in, saw that there were no o-rings where the vaccuum ports are, and got new o-rings as well.
I then clean every part again, after already taking all the carbs apart and cleaning them 1000 times before and make sure everything fits right. Well I noticed the one float did not sit tight anymore so I replaced it with one that did fit, and checked the float height on it. I finally reassembled everything hoping that now everything should be 100%, but it still refuses to start. Even with starting fluid all it does is cough and put out a little smoke from the exhaust. It also now leaks gas from the carbs when turning over. So I will check the float heights again and see if the float needles are getting stuck.
I am pretty much at a stand still right now except needing to check float height again, and would greatly appreciate some input as to what I should try next! I also bought a new battery and 4 new spark plugs. And sorry for the huge wall of text!
tldr; cleaned and replaced parts on carbs except pilot, idled at 4k and above, had spark, all 4 pipes heating up the same. Then cleaned the rubber diaphgragms and will no longer start even with starting fluid, cleaned carbs again, replaced another diaphragm, bought new pilot jets and plugs, and vaccuum o-rings; now it leaks gas and won't start.
Now before I cleaned those diaphragms the bike was not running normal at all. It would idle at around 4k and above; sometimes the rpms would even jump to 10k and I would have to hit the kill switch. Also it would sometimes idle below 4k and stall out, but all 4 pipes were getting hot and it sounded good as long as rpms were past 4k. The bike also seemed to be running lean because the spark plugs kept getting wet with gas and a little black. This was after buying a new set of carbs, replacing all the floats except one, cleaning everything out except the pilot jets because I could not get them out, and setting float height and a/f screws to 2.25 out.
So the reason I cleaned the diaphragms was because when I opened the tops back up I saw that they looked like they could be cleaner, and maybe this would help something. Well, once I did that it no longer wanted to start, and I KNEW I had to get to those pilot jets eventually so I then took those out and replaced them with new ones. Upon attempting to remove the one pilot jet with an easy out I broke a peice off of where the pilot jet screws into. I then replaced that carb body with one of the old carbs that used to be on the bike.
Whenever I replaced the body I saw that there is supposed to be a plug that goes where the pilot jet is screwed into. So I then got all new plugs and fitted them all in, saw that there were no o-rings where the vaccuum ports are, and got new o-rings as well.
I then clean every part again, after already taking all the carbs apart and cleaning them 1000 times before and make sure everything fits right. Well I noticed the one float did not sit tight anymore so I replaced it with one that did fit, and checked the float height on it. I finally reassembled everything hoping that now everything should be 100%, but it still refuses to start. Even with starting fluid all it does is cough and put out a little smoke from the exhaust. It also now leaks gas from the carbs when turning over. So I will check the float heights again and see if the float needles are getting stuck.
I am pretty much at a stand still right now except needing to check float height again, and would greatly appreciate some input as to what I should try next! I also bought a new battery and 4 new spark plugs. And sorry for the huge wall of text!
tldr; cleaned and replaced parts on carbs except pilot, idled at 4k and above, had spark, all 4 pipes heating up the same. Then cleaned the rubber diaphgragms and will no longer start even with starting fluid, cleaned carbs again, replaced another diaphragm, bought new pilot jets and plugs, and vaccuum o-rings; now it leaks gas and won't start.
The jetting is on the other end duder. 
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