My kodiak started running lean and needed about1/4 choke to run without popping or stalling. I have completely dissambled, cleaned and reassembled the carb ( I thought it was gumed up after 5 years) and its the same. Im thinking there is an air leak in the carb somewhere. I havent found a manual for this carb so I need some help with trouble shooting. What do you all think?

 

Sounds like you may have some junk in the pilot jet or the idle circuit, the holes in the pilot are super tiny, but any restriction, and it will not idle at all, pluss its hard to blow out the passages in the carb, get that spray straw in there and blow until you see a good solid stream coming out the ports in the carb body. I had to take a single wire strand off a wire brush to clean out a stubborn pilot jet on my son's 300ex, it was that plugged, and would not idle. after that, ran like a charm.

 

Yup dirty carb.
could be as simple as a little water in carb bowl.
Try draining carb bowl by the screw at very bottom of the bowl.
With the fuel tap Open from gas tank , lossen screw.
This should flush out old gas, dirt and water.
You should do this on a semi regularly basis.
If this doesn't help , then you will have to pull carb and clean manuely.