I know a good mechanic in Portland
Lineman, BOSS or Bozarth Offroad Specialty Service is in southeast Portland. Don't have the number-need to 411 it. Rick is racer and has been wrenching on huskys and ktms since the mid 80s. He knows ohlins suspension etc..He is a top Husaberg dealer, straight out of the shop behind his house. He is real meticulous and fair and will tackle most things.
The settings on my 250 are: needle ltr or the proper brass one, pilot 43, main-180 ,mixture screw-1.5 out. Yours should be vary similar. Oh, and I think needle is in middle.
Obviously you are running good gas with proper ratio. is the float parallel with the carb body when upside down? Have you looked at the intake boot or overtightened the clamps on the boot-seen it done. Air leaks downstream from the carb will do weird stuff. Kill switch?(I'm just thinking outloud). Sounds like if its not fuel dilivery it's something shorting out or not getting enough kv to the plug. I think you may be right in your assumption with the electrical.
Rick's shop is at 237 SE 83rd ave Portland Or
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