I did mention that I've been working with these engines for about 8 years now right? If this was caused by something obvious I'd have figured it out.
I can barely get it to run at all with muffler cap on. 4-stroking at 10mph. so something other than oversized jets is going on. Piston and cylinder have no scratches and no sigh of blow by, compression can lock up rear wheel, remove spark plug and engine spins freely, no change in RPMs when starter fluid is sprayed on bearings, crank case and lower cylinder gasket, head gasket shows no signs of leak, carb now runs extremely lean on my friends engine and still rich on mine.
Tried about 6 different spark plug gaps from .018 to .040 no difference, tried new magneto and CDI, no difference, tried about 4 different spark plugs, no difference, swapped cylinder head with my friends engine, no difference, flushed crank case with carb cleaner and drained completely, no difference, removed choke and air filter and swapped intakes again, no difference.
What am I missing!?! Could port timing do this?
If I turn fuel off, it runs great for about 2 seconds before running out of fuel.