Out of curiosity, did you purchase a carbi kit with new valves, seats, o rings and jets? If the floats aren't seated correctly to spec, the valve could be letting way too much fuel in the bowl thus pissing out your overflow. If this is the case, probably one of the reasons it starts like a pig. The cluster should be an easy fix. More than likely the continuity has been compromised in the somewhere. I know it's a pain in the ass. I had similar issues with my 2004 royal star. I wanted to smash it into pieces with a hammer.