Too embarrassed to even say this....but my initial re-teardown has led me to believe I didnt have the carbs all the way down and in their boots. Will get the tank off tonight and confirm.
ARRRRGH - and I've been riding and wrenching bikes for....hmm over 30 years
2011 KTM 300 XC-W, 2002 KTM Duke II, 2011 KTM 250 XC-W, 2010 KTM 530 XCW Six Days, 1998 Superhawk
2012 KTM 500 EXC - sold, 950 SER-sold (regret)
Prior: BMW XC, TE610, KLR 650, 07 KTM 990 Adv, and many more ...BMWs, Ducs, KTMs, Harleys