Thanks mate, I've found these from DHZ
NEW MIKUNI CARBURETOR SLOW & MAIN JET KIT - eBay Other Makes, Bike Parts, Motorcycle Parts, Accessories, Cars, Bikes, Boats. (end time 08-Aug-09 11:23:55 AEST)
And they should do the trick, but the question remains... To go larger, or smaller...!? Or do I reset everything and try again?
With the symptoms present, does anyone have any idea?
Mate contact Ken at DHZ directly, (can be done through ebay site) and explain to him your problem. He is absolutely brilliant to deal with, and very quick to help. If you let him know the problems your facing, and enquire about a jet kit, he may be able to help with jets on the higher and lower than what you already have. This will allow you to try both, and this should give you an idea of which way to go... richer or leaner..
The gasket on your float bowl "shouldnt" suck any air if it's not aligned properly. you will soon know if it isnt right, as fuel will seep out of the bowl.. a bit of a trick for them in the future, if it gets fuel on it, they expand, which sounds like what you experienced... so if it happens again, dry it out a bit, and it will shrink back.. Dont dry it out with a cigarette lighter though.. ha ha
The other thing i thought, is that the carby itself may have coughed in it's nappy.. i experienced similar problems with the mikuni in my Thumpstar Hunge-ten.. ran great for ages, then one day just decided not to work anymore. Nothing on the bike had been changed, the jetting was as delivered and was jetted perfectly.. but something died in the carby, it's been cleaned, rebuilt, rejetted, all the tricks, and is still shagged.. Just a case of a cheap copy item failing... which may be the case with yours if jetting still doesnt fix it... keep in mind you did set fire to it...
... and no disrespect taken.... it helps if other people offer more ideas, more chance of finding the answer.