Are the butterflys square in the hole. Back off on blade shaft adjusters...loosen every blade and tap lightly with a small hammer handle or plastic screwdriver handle to seat the blade. you will hear it seat....do them all ....re tap each and tighten.
Is the idle bypass stuck???
new butterflys set at 0.002", can't see /feel any visible wear in the bores. Slight wear in the front of the throttle shaft where the cable connects so we're looking at bushing it. Also considering getting a sycrometer to check how even they are.
This is a stack system, so in terms of plumbing at the pump we have inlet in, primary bypass, shut off return, main line to BV and secondary bypass off the BV. If by idle bypass you mean the secondary bypass off BV, I'm led to believe this is blocked at anything less than 25 degree throttle opening ?, so should be blocked at idle. In terms of it's operation, coming off the burnout and run, there is no surge or stumble so we assume it's opening at part throttle to reduce the fuel pressure on throttle closure.