It seems the 2 months since I last set a metering lever is too long for my memory to hold up: I gave you an incorrect instruction. Yes, you have to set the height of the lever arm directly above the spring, not the height of the tip of the needle.

Now, let's run through the process with that correction. The WA model does not require a measuring tool, for the reason you gave: you can just lay the end of a ruler across the surrounding metal and it has to just touch the end of the lever, right above the spring. However that is because the WA has a flat surface lower than the surrounding surface. Here is the instruction from the WA manual:
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Here is the one from the WT manual, which you will notice applies also to the WA:
[Linked Image]

The measuring tool you made is supposed to be the same as the one in the WT manual: it spans all the way across the end of the carburetor. What you may be saying is that the dimension I gave you (1.65 mm) is incorrect.

Here is the Walbro Service Manual's instruction for setting the lever height:
[Linked Image]

So, if you use the 1.65 mm gauge you made, applying it to the lever arm above the spring, not the tip of the needle, does everything suddenly work correctly? Or are you saying I gave you the wrong dimension for the gauge? That 1.65 mm figure did not come from Walbro, it came from a repair technician on the internet, so it could perhaps be wrong - I'd very much like to find out if it is.