Afternoon everyone,

Having a issue with my bike when it hits about 5-6k rpms it stalls out. I rebuilt the carb, moved needled up and down notches but no luck. Starts fine, idles fine, runs fine till it hits about 5k rpms or trying to go up a hill it stalls out. Any help or thought be appreciated

sounds like your exhaust is plugged up. might need to burn out the pipe and silencer.

Yep, as BIGDOG302 says above. Plus i'd be changing the small Oring on the jet setter where it seals into the bowl. If it's 'not' sealing it'll go rich on open throttle [much like a blocked exhaust]. If that's what you mean by 'Stalls Out' [won't rev beyond that but keeps running?.

even though lot of smoke is coming out exhaust still can be clogged? If so how do you go about burning it out?

Correct it wont rev any higher, but doesn't die either. One thing i noticed if i keep rocking the throttle it does every now and then rev higher but then stalls out again.

Which oring are you referring too? the one that sits under the needle jet? I did replace that one

Yep the one under the needle jet.So should be ok if genuine or if not it must be a good push fit tight seal into the bowl. Anyway--burning the exhaust. Not easy unless you have something to get it hot & excited then blow air through it at speed if you can, & careful where you aim it as don't want to start a grass fire etc. I've mostly just left them overnight in a bonfire & let it smoulder away then wash it out in the morning, or just shake it out. I/m keen to try my leaf blower on one if i can heat it up super hot but don't have oxyacetylene welding plant anymore. I've seen pics or vids on here of a guy who set his paint stripping heat gun in the header pipe i think, & got it all burning but not sure how he followed that up but with compressed air possibly. To prove a point you could give it good ol rev with the header pipe mount loose on the cylinder. Or if ya brave enough just take off the exhaust & rev it to see if it clears then shut it down. Backtracking a bit--Remove the baffle first & try it but might have a spark arresting bit fixed further down in which blocks up. Blimey, sorry about the essay.

It might be too lean. 

Ill double check make sure that tight enough, Ive tried running it without the baffle just was loud but didnt make a difference. I guess i can try and start a fire and let it sit in the pit overnight see if that will help

I have the needle set as low as it will go or closest to the point. I also have the oil pump and mixed oil 50:1 in the tank

Ok so maybe im doing something wrong here cause i went and looked at another carb i had and its main jet you can swap out the end but on this one its one piece.