Joined: Dec 2011
I Ride: 1996 ZX7R, 1996 ZX7RR (track)
Two months at a shop is ridiculous. To remove, properly clean, set up and reinstall is about 4 hours work. A lot of shops and mechanics do not like/want to work on older bikes. I have made a nice side business of working on older machines that shops refuse to work on. They are correct in the problem being the pilot circuit but it sounds like they were not properly cleaned. All the internal parts need to be removed and every passage needs to be thoroughly cleaned in order for the carbs to function correctly. Then all parts need to be inspected, cleaned and if nevessary, replaced. All o-rings on the pilot screws should be replaced, floats, float valves and seats need to be inspected and possibly replaced and the everything correctly reset to factory settings. Sync and test, tweak settings if required and back riding.