Lunchbox + Rejet = Help with idle (is anyone in San Diego?)

[speeder2k]

I need some ideas on what to check.

I disassembled my '08 GS500F, took off the airbox, the carbs, removed the valve cover and checked for clearance - it was OK (and there was some oil pooled up under the lobes, assuming it's okay). Re-attached the valve cover & breather cover. Removed the tensioner - OK, reattached.
I then removed the lower carb covers, replaced the jets with 20/65/142.5, and reassembled the covers. Screwed the air mixture screws all the way, and screwed back 3 full turns.
Attached K&N and 'simplified' some PAIR routing. Also, blocked off PAIR block connectors with the hayabusa ones.

Red = connected directly, no tee. Black = removed.

I left the tank connector vent to atmo. Also, the valve breather & top carb hose are both venting to atmo.

When trying to start the bike = it needs some throttle, and choke needs to be pulled out, but not all the way. It doesn't idle without choke or add'l throttle.
Also, more worryingly, there's smoke coming out, from what seems to be the valve cover breather hose. It's hard to tell with tank in the way (ps. any thoughts on getting the bike some gas w/o the tank in place for easy troubleshooting?

What could be happening?

Thanks!

Edit: updated 2nd reply

[Kerry]

any thoughts on getting the bike some gas w/o the tank in place for easy troubleshooting?

Here's the setup I use. ( I just used it again today!)  Note the white "coupler" joining the clear hose with the GS500 RES hose.  I found that at an auto parts dealer.

[speeder2k]

I've got the battery recharged, and tried adjusting the idle screws today, but i'm not having much luck.

I tried following this procedure - http://www.angelfire.com/mt2/mikesgs500/rejetting/

Turned the screw one turn out on both carbs. Warmed up the bike, lowered rpms around 1k (right around when the bike died).
I then tried watching the RPMs as i undescrewed the air screws but it didn't really do much. Anywho, i can't really get the RPMs to come down quickly (between 2-4k rpm is where it slows) with any setting it looks like which means the bike is running lean in idle right? I left the screws at 2.5 turns, and the bike sometimes dies when shifting into first gear, and died on me once or twice while idling. I set the idle RPMs around 1.2k

Also, i'm still having smoke/smell issues out of the valve cover breather. I re-checked the oil level and it's a bit above the full line, could that be causing it? The bike has 16.5k miles and i havn't really noticed that when the breather was going into the airbox.

[ctjacket]

I have somewhat of a similar issue.  When I rejetted to 40,140, 1 washer, and about 3 turns on the idle screw my bike will start to hang at 3k after about 30 min of riding.  Also after it warms up (which takes about 2 miles or so to turn the choke all the way off), the rpms drop slowly.  And I have to have my idle set at about 1100, or else the bike runs either too lean or dies out.

My floats are good, and I have been through my carbs twice.  Have you checked your valves?  That is my next step because I don't know what else it could be at this point.  I also have 0 vacuum leaks.

[speeder2k]

I checked the valves (first time doing it) and they were all under .08. I realized that the bottom purge canister ports became uncapped, so i re-capped them today and rode around. Seemed okay, i may try the idle adjustment game again to see if my results are better with that capped.

Also, choke is behaving differently. It doesn't rev up like it used to until the bike warms up a bit...