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I'm sorry if I missed this before but what engine are these Webers on? From my little experience with Webers (but the learning curve is steep!) I could be an exhaust leak as you have already noted, an over rich mixture which doesn't seem to make sense due to your smallish mains or maybe possibly improperly adjusted floats? Yes that last one is a question more than an answer. Sorry for the lack of direction but hopefully somone with more experience will chime in! Best wishes!
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