Suzuki Katana 600 getting choked at 6k RPM.. any clues ?

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j s

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Hi folks..
My '99 Suzuki Katana recently got a problem with the carbs due to some dust under the float needle, due to which the fuel overflowed and filled up the air filter, and even got into the engine apparently..
But anyways, now, I got it all cleaned and put back together, and the bike seems to be running smooth in the low rpm range..
However, there's 2-3 problems that now I'm resolve.
1. It still takes quite a while in the morning to startup (with couple of long self-starts)
2. It gives a whole lot more of smoke through the exhaust than it was earlier.
3. The acceleration and running is absolutely flawless in the initial range, but right at 6k rpm, the bike apparently seems to choke and doesn't push beyond that point... This is what I'm majorly concerned about..!

So help folks!! HELP!!!

Regards,
J.
Apparently the Air filter box was choked due to an object in front of it.. sucked onto the main hole.
Removed it and the bike pushes sweetly now.. though the smoke is still there, and it's apparently WHITE..
Also, after drive for 15-20 minutes at good speed today, when I parked it back, and checked after few hours, it leaked fuel on the ground.. apparently coming through the air filter..! and the bike won't start that easily now. :(
 
I'm not fmailiar with the specifics of a Suzuki Katana, but you should look at the following items when you are troubleshooting.

1. proper float level, choke sealing properly, gas-air mixture, choke linkage, compression, ignition timing, spark plugs

2. blue smoke? Cylinder, rings, or valves could have been damaged when dirt got in the cylinders. Black smoke? Not enough air- check choke, air filter, gas-air mixture.

3. dirty air filter, bad plugs, incorrect timing, choke not releasing, spark advance mechanism, valve lash, valve springs
 
As far as the high speed problem, remove the air filter and try it. If it runs ok, that's the problem. As far as as being cold natured, make sure the enriching plungers are extending completely. If the floats were set slightly lower than before, that would lean out both the idle and main jet. Try adjusting the pilot screws in or out to richen up the idle circuit. I'm not sure which way you need to go because some Mikuni pilot screws control air while others control fuel. Try turning all four in a half turn and try it. If it runs worse, turn them out one half turn from the original position and see if that helps.

The color of the exhaust is going to determine where it's coming from. Unless your bike is water cooled and it's poofing out damp, white, funny smelling smoke, I wouldn't worry about it, especially at this point. Get the other stuff right first, then see if the smoke problem still exists.
 
Make sure you have air tight seals at the carb boots. Make sure choke is hooked up properly. Install fresh plugs. Check the easy stuff first. But I agree with the other guy. You missed something in the rebuild.

edit: Fuel running out when parked tells me the needle is sticking open, or the floats are set too high. White smoke is an indication of oil burning or antifreeze is getting into the combustion chamber. What does the smoke smell like? Play the wait and see game. If the initial problem is corrected, the smoke may dissipate.
 
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