I had the same problem with my '95 Hurricane. The bike started with full choke, ran for a few seconds, then died.

Check the manifold vacuum plug under the carbies. Sometimes the plug pops off when the bike back fires. If it comes off, too much air is being sucked in.

 

Just wondering, because I've got the exact same problem, bike ran fine, I left the petcock on reserve, which is a big no no for my bike. Figured no problem, just got some trash in the carbs. Now I've had them off and on 3 times and still have an issue with #2. Cylinder fills up with gas everytime!!!! What did I miss?

 

Can you please tell me where the vacume plug is? is it on the carbs or the motor?

 

There is a vacuum plug on each carb. Look on top of the runner between the carb body and the cylinder head. You should find a small rubber cap on a nipple. Mine has a small wire clip on each rubber cap.

If you are looking for the spot where the vacuum hose for your petcock attaches, that one runs to the left front side of your number one carb.

 

ok those are still on there. now i seem to have a cal. model and i removed all vacume lines and plugged all ports. is that ok or do i need to have them hooked up or just some of them?

 

KilgoreTrout has the most experience on that stuff

 

I also have a Cali model with the pair removed. You may have to hook some stuff back up. I had a few glitches along the way while I was ripping mine out, too.
Do you happen to have any pics? I'm not sure if they set the '91 up like the '95, but mine has a ton of chit on it.

The small vac line closest to the rear on the right side of the bike should be connected directly to the small one that runs between the two sets of carbs. You can link them and plug them, or link them directly together.

The rest of the small lines all need to be connected together.

The larger lines between 1&2 and 3&4 should also be linked.

Here is a pic to show you what I mean:

 

I'd like to add that there are other ways to do it. However, I found that it ran perfect with it set up like this.
All the other stuff (PAIR valves, injection lines, etc.) are all gone. I did this so that all I have to do to pull the valve cover is disconnect a couple lines and pull it. Before, it was a major PITA because (believe it or not) there was a lot more chit in the way.

I hope this helps a little bit.

 

Did you get it fixed? Finally took mine to my mechanic, and badabing-badaboom, $600 later, she runs like a champ. The culprit was the float valves, got 4 new ones, #2 cylinder no longer fills up with fuel, and quite frankly, I don't think its ever run so well for me!!!!

 

It sucks that it cost that much, but I'm glad you got it sorted out, Racer!
(and thanks for the update!)