Xj900 Problems

Having some issues with my 1983 xj900. The idle speed seems to be all over the place and I keep needing to adjust it to compensate. There's also a bad hesitation off idle sometimes but not all the time. And I'm leaking fuel from the #1&2 carb. Recently replaced gas tank with a cleaner one, Broke carb rack cleaned them in a ultrasonic, wet set floats, synced carbs, set mix at 2.5 turns, replaced and gapped spark plugs, checked for air leaks, replaced head and camshaft and adjusted valves last year.
Im at my wits end with this thing if someone can give me an idea of the problem that would be great.

 

Sounds like my bike!
That doesn't help. Sorry.
I have 2 X 900 engines. Exactly the same.
One does this and I've gone to the nth degree to solve it.
Hesitation ended up being a whopping pain in the backside to solve and In my case it ended up being the tci and a faulty regulator. Although low compression didn't help either... Drilling out the slide holes fixed that but obviously fixing the compression issue would have been more ideal.
The rambling idle from cold to hot seems to be associated to sync and everytime I do a sync it needs adjusting just a smidge. So I set the idle so it is right for hot and struggle with nearly stalling when cold.

So. Everything you have done sounds perfect but... Have a look at electrical just to make sure.

 

Oh... Leaking from the carbs probably indicate the floats are stuck. Had that a few times also after a rebuild. Give em a few raps with the handle of a screw driver and see if they fall into line. Otherwise the levels are way out.

 

Would polishing the float pins help, I don't know just an idea.

 

As said, solve the leaking fuel (float valve issues) first. If the problem persists you may need to replace throttle shafts seals, but this is a full stripdown. Check for air leaks with a gas torch first.

 

Would the leaking float valves cause the hesitation and idle issues? I have new shaft seals installed, and have checked for leaks by spraying starting fluid anywhere i think there could be an air leak. I do have a map torch somewhere if that would work better.

 

Only way to test tci and regulator is by replacing with known good parts right?

 

Definitely the most effective way without being an electronics engineer.