I did rebuild the carb already with a kit, but it did not include the 2 o rings for the jet block. I will set the float height again and see what happens.

 

Float height is 13-14mm (.51-.55 inches) as the carb is turned to where the float tab barely touches the float needle. Doesn't even show o-rings in the parts break down on the jet block.Usually not necessary to even take the jet block out. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

We fixed the float. We also installed the 145 main jet and set the needle to the middle position, 3. Had to change the oil it was filled with gas. Got it running, then we changed the oil again just to be sure it was flushed clean. It still seems to be cutting out over half throttle. It was raining yesterday so we didn't run it after the 2nd oil change. Could it be possible the cam timing is off? i read in the manual that if it was off it would idle but not rev up. I feel 100% that the timing is good because i took it apart after the rebuild just to be certain and it looked right. But it does rev up good in neutral, just not under a load in gear. We checked the compression and got a reading of 90 psi, manual says 70-90 is good. Also the boot from the carb to cylinder head, if this had a small leak would it cause it to run like it is?

 

If it runs good in neutral with good acceleration and no cutting out,still think problem still lies either in the carb,clutches/belt or electrical break down. Under loads either one can cause problems also.Just a process of elimination. You have to just start eliminating things one at a time.If you're still unsure about the cam timing just recheck it,then cross it of the list,move on the next item. You'll eventually find the problem.Plus if you haven't downloaded the pdf manual I listed that shows better electrical tests also,I'd do that.

 

Yes i did download the manual and will have a look. Appreciate your help with this. Will report back when we find something.