[jbctochip2]

My bike sat for just over 1 year. Float needle was gooped up a little, the bowl was clean and the jets were not plugged. Got a carb kit and cleaned out parts. I took off the TPS and read if this comes off it must be reset. Attempted to reset and could not get it within spec so I replaced it. Got the new one set within specs but the bike still will not run right. it is missing the mid range, took carb off again and made sure all passages were clear, still same issue. while riding I can get past the no mid range without choke but when it hits the main it really launches. the only thing I haven't replaced yet is the ICM. need assistance. john

[JimDirt]

Welcome to the site !!

You did not mention anything about putting FRESH Premium in it ...... if it sat for more than a couple months with old gas , it is not going to run well ........ with that said ....... What was the reasoning for taking off the TPS ??? , there should be no need to do so unless you were soaking the entire carb in dip , other than that , usually if the bowl is taken off and the jets removed and soaked or replaced and carb cleaner and air is used , it is usually sufficient to clear most blockages ....... Also , how did you determine the pilot was "clear" , the hole is very small and even a slight blockage would effect how it worked as far as flow goes ,I use a bright pen light with a magnifying glass to view the orifice , and I also use a Carb Cleaning Tool , like K&L has......... Also , is it popping thru the muffler when running poorly ?? , or does it sound fine/normal , except for the performance ??? , if you are having to run it with the choke that would confirm a lean condition on the pilot circuit end of things ......

[jbctochip2]

Gas is fresh, light is through the pilot jet, when I rebuilt carb the only thing that had varnish was the float needle. Pulled the idle screw and the rubber o-ring cracked so I ordered a complete kit. I have been a mechanic for years and carbs were my specialty. All ports are clear. Took off the TPS because I soaked the carb in Berrymans carb dip. I have tried several different locations for the TPS outside of specs still no mid range. Might this be the ICM? It will idle without choke but falls on it's face when open throttle. If I am riding I can get past mid range but launches when it hits the main.

[JimDirt]

Did you soak the pilot as well ??? , light thru it is not a 100% indicator it is "clear" , I personally look thru mine with a penlight , and a magnifying glass , that way I can see if anything is even slightly restricting the passage , if you see a light with a cross in it , it is partially clogged , it should be a round light ............. If it was a ignition issue you would most likely have less spark or intermittent spark , so richening should actually make the issue worse , and leaning the mixture should make it better , so maybe try messing with the needle position and see if it improves by lowering the needle which would lean the mixture in the mid range area , or if you have different size jets , try them , if it is leaner and runs better then ignition could be the issue , I would think ..... not saying it is not a ICM issue , but it could be stator as well ........

What is the fuel screw set at ???? , this will give a good indication as to a fuel or ignition issue , as will the plug ... speaking of plug , the spark plug cap may be a issue , there is a resistance test for it , as it has a resistor in it , and they have been known to go bad from time to time , it would be nice to rule that out as a culprit ...... , I have never had a ignition issue with my 06 , and aside from the initial valve issue , which I solved with Stainless Intakes , I have not really had a "mechanical" issue with mine , it can sit for a year and fire right up (I have a mix of Av gas and Non Ethanol Premium in it) and it has never failed to to start and run well , except when the Intakes went bad , I can literally leave it sit for a year , and take it to the MX track or the woods and never have it even so much as sputter , it will fire right up and run like a top ....... but the claim that after soaking the carb , and the issue did not change , has me wondering , if it was fuel related you should have seen a improvement , whether complete or partial improvement , which was not noticed , and that would indicate a electrical issue .....

Just as another item to check , have you checked the stator output ?? , and checked to see if the battery is charging ?? , just because it runs , does not mean the stator is working as it should ....

[jbctochip2]

New jets came with the rebuild kit although I am using a larger main for the FMF. Ran great when I parked it and that was at sea level and at 7k feet., I did have a rewound stator to run a baja light but since went back to the stock stator and light. Battery is charging. Adjusting the needle clip just dials in the main. I have no off idle circuit, thought it might have been the fuel pump, replaced it and no help. When I did replace the TPS it did get better although still no off idle.

I'm stumped

[JimDirt]

Maybe Leardriver can chime in , as he is the resident intake guru here ..... if it is a fuel related issue , he can figure it out or point you in the right direction .. , if it is not , then the only other option is electrical ... I am not a carb expert , but everything you describe sounds fuel related to me ....