TOPIC:

Thanks, though I managed to figure that out on my own this morning

Just an update if some other poor soul is having the same issues as I:

Luck struck upon me and I made friends with a mechanic after getting his reference from someone at Advanced Auto Parts (hooray for conversations!)
Told him my issues, pointed him to this post, we began working together.
He checked out my carbs and said everything looked great and would go through and clean it just in case.

In the meantime I did in fact take my engine apart down to the pistons just for the heck of it even though this wasn't the issue, it was a carb one, but I figured might as well get in the best condition it can be.
Checked a lot of service limits, everything was in order, somehow magically put together the engine correctly (have never messed with this part of DIY before)

Got carbs back from him, same exact issue -> died with throttle
So we found a company that makes jet kits for twin kz440: 6sigma
Appreciated how they go about. Must tell them exact year, make, model, as well as if using aftermarket/custom/OE airbox/mufflers
Then in the instructions for the kit they tell you how to modify and why, etc...

So...the bike runs! I took her around the block
But the mixture is still a little off, so I'll have to get more advice from him.
I always have to crack the throttle a bit to get it to start.
Also the RPM's hang high when using the throttle and drop back down after a couple of seconds which I read indicates a LEAN mixture, but I don't know how that is possible as I just rejetted the thing some pretty huge sizes up (secondary is 72 and main is now 102.5)


I'll update again later.

Hanging revs can also occur if you are getting any air through your carb boots.

SOLVED
Just wanted to update.

Turns out the contact breaker point gap closes over time. I bought a new one a while ago because when I was doing some routine checks, the old one was bent (actually an old post of mine)
So the timing was sh*t because the gap was really close. Only one cylinder was running, and the one that was, well, it was running like crap.
Changed that to specs and oh. my. goodness.

This bike runs amazing. So part of me is happy it took me a long time to figure it out and go through all the other hard stuff. Sometimes it pays off to not check all the easy stuff first haha.
Because I rejetted the system, made that air box, cleaned the engine, checked all those fuel items, closed off vacuum leaks, cleaned the carbs good, this bike is insanely responsive.

Took it to a motorcycle mechanic who specializes in older Kawasaki's and he was surprised at how well it ran, I quote, " In my 30 years of working I have never seen this model run this well"
No bogging, no hesitations, accelerations great, even at 60mph its got jump if you need. Did a plug test, perfect color.

Very very happy...…
Now back to aesthetic items...

Congratulations. Enjoy the ride.