I'm sure you don't want to hear this, and I'm guessing you've been through this but here goes.
First find a wire small enough to fit in the passages of the carb, a wire from a wire brush or a single strand of wire from a piece of automotive wire. You need to hit everything,the emultion tube cross holes, the idle and mid bypass holes in the throat of the carb,don't just soak in carb cleaner, it won't work. after you are sure you got all the passages do it again, then use brake clean and with the tube on the can, spray through all passages and make sure you see it coming out.
Now double check the acv for pin holes, a small LED light run around the backside while you look for light works well,a rubbed or worn spot is most likely a leak even if you can not see through it.
If the carb is absolutly clean and acv is good it will run. From there it's just tunning to your preference.
Took a couple times to get mine to work correctly, patience.

I went through that carb too many times I'm done wasting time on it.

Also I managed to break Muddaholics fuel screw off due to it being seized and lost a piece of brass from my carb. Since that would be throwing $45 towards new parts I just bought a 40mm FCR carb for $150 instead.

Thanks for all the ideas and help,
Kell

k5kell, on 09 February 2012 - 09:24 PM, said:

You'll be very happy with the FCR, they really wake up the XRL's. Best mod I've done.

zx12r, on 10 February 2012 - 12:08 PM, said:

Hey ZX12 .... Could you please tell me / us the parts you used for the conversion to the FCR ? The cables / manifold etc...

thanx

Muddaholic, on 13 February 2012 - 08:52 AM, said:

Do a search on here of ( XR650L FCR ) 8 pages come up. Heres my post.

http://www.thumperta..._1#entry8356129