Hesitation, surging and crap mpg.

[darrsi]

You're doing long trips so this is a long shot, but we are in the carb icing season. Worth a check of the carb heating circuit? At least it should be possible to blow through them without taking them off, they're a bugger to refit in cold weather.
Beyond that it is pointing to an ignition problem I guess.
Flooding carbs would make it hard to start, as would low compression. Fuel starvation would explain a lack of power, but that doesn't tally with high consumption and an exhaust full of soot.
Have you gone round all the electrical connections making sure they're clean and tight?
Make a careful inspection of the wiring harness too: check where flexes with the steering and look for places where it can vibrate and chafe against things... particularly near the ignitor box in the tail unit, that was where I had a wire break in the immobiliser wiring.
Failing that, I'd try a swap of ignitor box and, it pains me to say, the regulator/rectifier. (I have no idea how that caused Red98's problem!)

This problem started when it was in really warm weather so i think carb icing can safely be ruled out.
When i had it the bike virtually came to a stop anyway, whereas his bike is still running, albeit roughly.


He's still describing symptoms of a faulty TPS to me........rough running, bad fuel consumption, misfiring, etc.