After years of chasing jetting problems, I finally yanked the manifolds and found the problem. The previous owner decided that finding the right o-rings was too difficult, so he simply used silicone. Needless to say, it didn't do the job very well. Big air leak, that got worse as it got hot. I had a spare pair of Malossi manifolds that did have the o-rings, and it made all the difference. For your future reference, o-rings come in 1.0 mm increments for the ID, and 0.5mm thickness increments. Search the internet for o-ring stores near you. They are generally cheap, less than a dollar a piece. No reason not to put the right ones in. Viton is best for intake as it can take the heat, and also the gasoline exposure. Silicone degrades with exposure to gasoline, which is why it should never be used for intakes.

Oh, and thanks to Skins for the article to balance the carbs. Did the cuddle and she loves it. Runs great.

Still going to make a two bottle manometer just to get a finer balance.
Here's the two bottle method.
http://faq.ninja250.org/wiki/How_do_I_s ... uretors%3F
http://www.youtube.com/watch?v=2PiQBr20 ... re=related

Cheers,

Never made the two bottle manometer. A buddy of mine had a Twin Max that he uses to tune his Ducati's. Works great.
The odd thing is that I started with the cuddle, and a new pair of slides, and I had to make a big adjustment in the cables at open throttle. To be frank, I don't like the cable setup that I have and will be changing them, so I'll report back on how much tuning after new cables are installed and I do the 'cuddle'.

Bike runs great. Best ever.

http://www.aerostich.com/twinmax-synchronizer.html

Cheers,

I made it by my own in a very easier way. Have a look to 750paso/faq to my post (vacuum carb balancing)