Damn, worked all day on this bike and got the airfilters on correctly for once, then it started playing up again.
My son came to give me a hand and we hooked up a clear tube full of gas so we could see what happened to the flow, well it scoffed it big time, we couldn't believe that any carb could keep up with that flow. Obviously this was what was happening, the carbs were being overloaded with gas and the motor couldn't keep up with it so was running at idle only, when my boy put his finger over the tube end the gas stopped flowing and after a few moments the engine picked up and ran well.
Tore it all apart again, benched the carbs and found the small "O" rings that surround the copper carb valve casings had perished, guess 14 years against a shed wall didn't help them, they snapped as I removed them, brittle as. I had a swag of new ones I bought for my partner's bike so all good there.
So now I'm too tired to go back out to the shed to put it all back together but tomorrow is another day (and last day of my holidays)