Carb/idle issues, stumped...need help
Okay guys, I've run into an issue with my 2010 KLR650 with 1850 miles on it. I disassembled it for a good cleaning and lots of cosmetic changes and all. I pulled the airbox off, removed the snorkel, installed an FMF exhaust, I swapped the main jet to a 148, turned fuel screw out 2.5 turns, put in a new iridium plug, had all the controls off, etc.. The bike ran perfect before this. The tank was almost empty on gas when I pulled it, tried running it with the little left in there and it was acting up so put some fresh gas and a little seafoam in. Something is definitely off, here's what it's doing.
Started off would only start and idle with the choke on, would die when I turn choke off. It would rev fine just idle issues.
After running a little while it idled fine with no choke, when I gave it gas at first it bogged and I let it idle and it eventually died.
Choke on it started, then choke off it idled for a little after idling a little longer it bogged/hesitated a little when giving gas, also backfired a few times.
It will start up without the choke and idle now but it will idle a little erratic and die eventually
I played around with the air fuel screw a little and didn't really get much improvement.
All vaccuum lines are connected, checked airbox and tried it with the filter off and door off and still about the same.
My plastic choke housing cracked a little at the outer half, not near the threaded part, I removed it, epoxied it, wiped a little RTV over that, and put it back on and it's still the same. It didn't look like it was at any location that would cause any issues but I'm gonna order a new one anyways.
When I finally gave up it was idling without the choke and needed choke to get it to fire up but still would eventually die.
I'm kinda stumped here as to what could be going on here. My problems are all at idle, other than a little popping when giving it gas. I might try swapping back in the original main jet but I'm not worried about that at this point, just trying to get it to idle right. Any help would be greatly appreciated.
Any help would be GREATLY appreciated.