Got Any Ideas?

It sounds like you're getting plenty of fuel through the choke circuit but not enough through the pilot circuit to keep the bike running.  

Yea and I’ve blown 90 psi through every port, especially the pilot circuit and felt air coming out of the other end so it would appear they are clear and the jets and have nice clear passages. I even sized the jets up to 34 from 32. 

Everything you said you've done suggests the bike should start just fine.  I'm wondering if that 7 mm spec on the float valves is the issue?  You might want to raise them.  A Mikuni spec is usually around 3 to 4 mm.

Picture of plugs shown below. 

Checked each cylinder and it has enough compression to throw my finger off. 

That 7mm is out of the clymer manual. And 7mm below the mating surface is also listed for the tk26 on loudhvx’s site.

hardrockminer wrote:

Everything you said you've done suggests the bike should start just fine.  I'm wondering if that 7 mm spec on the float valves is the issue?  You might want to raise them.  A Mikuni spec is usually around 3 to 4 mm.

I thought seven seemed too much, but hat is what the fsm calls for.

OK...7 it is then.  

So the engine runs on the choke circuit which means you have fuel and ignition.  But it doesn't run on the primary circuit, which means fuel is not getting from the bowls into the air intake.  This can occur when jets are clogged and we have ruled that out.  It can also occur when the pressure differential between the bowls and the intake is too small because fuel will not be drawn up the jets.  But you said your bowls are properly vented.  

What about the air screws on the primary circuit?  They control air and fuel mixture at low rpm's.

Rechecked fuel service levels. All in spec and actually lean more towards 6mm.

Pilot air/fuel mixture screws are all new. All turned out 1.5 turns. 

My float bowl vents might be a problem. They don’t seat very tight as I replaced the old cracked o rings with some nitrile ones I had of similar size. The float bowls seem to take awhile to fill up and fuel trickles into the carb inlet from the auxiliary tanks. I have a clear tube hooked up between the two. Could this be a problem?  
pictured is the carb bowl vent I’m referring to.

The engine is getting fuel on the choke circuit so I would assume flow to the bowls is OK.  Have you tried taking the bowls off and checking your fuel flow when the float is wide open and then close it manually (with your hand) to see if it works as it should?  Also, and I'm really reaching for this one...is it possible your floats remain stuck closed when the bowls are installed?  I've had a float that remained in closed position because it was touching the side of the bowl, but never had four of them sticking at the same time.

You stated you have a clear tube connecting the bowl vents together.  Does this mean you've linked the two pairs of bowl vents?  Shouldn't the bowl vents (in pairs) be open to the atmosphere to vent properly?  (Maybe I'm misunderstanding your description)

No sorry, the clear tube I’m referring to  connects an auxiliary tank with the fuel inlet to the carbs. The bowls are vented in pairs connected by a T joints as shown in the previous picture. 

I will check the floats. 

This bike really has me stumped. I’ve never went through carbs so meticulously. Never had one give me this much of a fit just to idle on its own. 

It runs intermittently on choke, but only for at most 30 seconds, then dies. I have tried adjusting fast idle and the air/fuel mixture screw in several configurations, but no real improvement. 

Have you done the test to se if it gets to much fuel? i mean to take off the sparkplug caps and turn the engine on starter for a while then take the plugs out to se if they are wet. Also look at the top of pistons if they are wet.
If wet it gets fuel ,but mayby too much.Fuel should not drible into the intake when you have a external tank fitted that may be the reason for it getting too much fuel. To fix that you will have to lower the fuel level a little or it can be that the needlevalveseat gasket/o ring are leaking.

Bowls are slow to fill, but continue to take on fuel after filled? Seems like that could be float valve problems. Are they oem or Keyster? Many aftermarket ones are junk. 
If used, did the needles get mixed up? The needles and seats wear together and need to stay together.