I know what most of you are thinking right now "here we go again, another SOHC jetting thread". But here me out for a minute because I will show you I have done my requisite research. Hopefully this thread can be referenced to some of the other people who seemingly have this problem.
First, a description of the running condition and the problem,
Bike starts up no problem cold(34 degrees F) with choke. Idle is rock solid at 1200 rpm when warm. Off idle performance is exactly what you'd expect from a small displacement 4 cylinder with round slide carbs. Bike pulls hard through the mid range and very happily all the way to redline(new main jets really woke this bike up above 7k). Cruising at any RPM is very smooth, this bike is such a sewing machine! Now for the problem, when cruising at a constant speed everything is great, until you get on the throttle to accelerate. Upon opening the throttle the bike responds by breaking up slightly for about ¼ second and then clearing up and acting normal. I can only describe this behavior as "choking on your own spit" as that's what the bike feels like it's doing. It exhibits this behavior anywhere from 3k-7k rpm, under that I'm at a stop light, and over that the bike is always happy. I also don't find it does it when accelerating from a stop and rowing through all the gears, only when cruising or decelerating and getting back on the throttle(very annoying coming out of corners).
Second, some background on the current condition of the bike:
It has ~8k original miles.
Lives in SLC, UT, ~ 4300ft elevation.
Stock 4-4 exhausts were shot when I bought it, I welded them back together where the mufflers meet the headers. If I had to guess, Exhausts 1 and 4 probably flow slightly more than 2 and 3 due to being more rusted out.
I replaced the rubber intake boots going to the engine as well as the O-rings that go with them. I also replaced the rubber boots going from the air box to the carbs.
Stock air box, filter, and snorkel all in good condition.
PO clearly had the carbs cleaned/ vapor blasted recently, they are immaculately clean.
Carb body 1 was replaced at some point with a number 3 carb body from another bike. To achieve this they swapped the throttle pivot cap onto the outside hole and epoxied the gas port feed through. They also used a cut off wheel to get the slide to work

, but I ordered the correct slide and replaced it.
Brass looks original, but it's hard to know for sure, at least the idle jet is stamped Kehin.
Main jets have been sized down to #70's to correct for altitude.
Floats set at 22mm not the standard 21mm, this was done using calipers, not the clear tube method.
All vent hoses and drainage lines are in place.
Point, condensers, and ignition coils are all oem (I'm pretty sure they are original).
Points gap was set to 0.014", ignition timing was set with a timing light, and ignition advance showed to be fully working.
Fresh NGK D8EA plugs.
All spark plug wires trimmed back 1cm and boots rescrewed in with care to make good contact with the copper.
Valves all set to proper spec about 50 miles ago, timing chain adjusted as per the manual.
Carbs synced using blue chinese carb sync, I got the cylinders all within 50 mmhg of each other, all of them were sitting at roughly 200 mmhg vacuum when synced, I don't want to dial it in further until I have the current issue figured out.
Idle set screws at 1&¼ out(highest idle), very happy starting hot.
Engine has never blown blue smoke as far as I know. I have not checked the compression yet though
Thirdly, an account of settings tried so far.
1. I replaced the stock main jets(75) for 70's and set the slide needle position to second closest to the needle end(pos #2?). Before the needle was at the stock position third from the needle end(pos #3?). This really helped high rpm performance, I'm assuming due to the main jet, but the stumbling problem was worse than ever.
2. I tried moving the slide needle position to fourth closest to the needle end(pos #4?). This was the best performance I've seen yet, much less stumbling than stock and my first configuration. but still present.
3. I tried the furthest, leanest needle position, fifth from the needle end(pos #5?). This made the bike very unhappy all over, rough cruising, bad acceleration, hard to get moving, ect.
4. I tried using a small washer to set the needles at a position half way between #4 and #3. This has been working okay, but maybe not as good at position number 4.
As a side not I re-synced the carbs after every adjustment as disturbing the throttle linkage to get the needles in and our always threw it out of whack slightly.
Fourthly, a checklist of things from other forum posts and speculation. I have tried to pull from the threads that best match my issue:
http://forums.sohc4.net/index.php/topic,187566.msg2175240.html#msg2175240Suggestion: set float height using clear tube method.
Thoughts: I can do this, but I'm not sure how to measure the gas in the tube. Do you measure the height of the gas against the bottom flange of the carb body? Kind of like you would with the bottom of the floats?
Doesn't seem like this issue got resolved.
http://forums.sohc4.net/index.php/topic,182703.msg2114706.html#msg2114706Suggestion: Make sure carb vent hoses are intact and running to a place with calm air.
Thoughts: Hoses look original, but to be in good shape. I have them running just behind the engine terminating slightly above the swing arm pivot. I think this is good enough?
Suggestion: make emulsifier holes slightly bigger to adjust for modern gas.
Thoughts: I could try doing this with some guitar string, I'm hesitant though because I feel like my problem might be too rich not to lean.
Suggestion: Try lower octane gas.
Thoughts: I would like to try this as I'm curious, however i just filled up with 91 a few days ago so it might take me a second.
Doesn't seem like this issue got resolved.
http://forums.sohc4.net/index.php/topic,189761.50.htmlSuggestion: Switch to Denso 4099 Spark Plug for hotter spark.
Thoughts: Is this worth it? I've always stuck with NGK.
Doesn't seem like this issue got resolved.
Finally, speculation:
I'm inclined to think the next thing to try is adjusting the float height a bit higher. I've had decent success doing this on my CB550. However, the floats are already "statically" set at 22mm. I have a hunch that floats get less "floaty" with age, and needle springs get a little less springy, but I don't have any real evidence to back that up.
How important do y'all find it to do the "clear tube" method? How would I go about it?
How high of float height would be too high? I don't want to lean this thing out at high rpms.
I've also heard tales of people re-shaping slide needles or even slides themselves to fix fueling issues, but that sounds terrifying and I've always had good luck with stock needle shapes.
Please, If you have any other Ideas, or if you've encountered this yourself, please let me know.
Thank you for reading this very long post.