First off, sorry this is so long but I don't know how else to explain it all.
I am at the end of the rope and don't know which way to turn. Since installing a Hardchrome 2 into 1 Xcellerator I have had nothing but trouble and problems getting the jetting correct, all done at the local Yamaha shop, except once in Fargo. Including the cost of the exhaust, I have spent a ton of money for dyno runs, rejetting, jetting kits and most recently another dyno run and rejetting at a different shop for a little over $163. Here is what I have, 2000 Silverado, ported manifold, BAK, AIS removed, Xcellerator with HP baffles in the down tubes, 167.5 main, 40 pilot, clip on 3.5 and no cue where they set the PMS. I also installed new Autolight plugs and rapped the coiuls with fusion tape. Prior to this I was at 180 main and a 50 pilot, don't know where the clip was or what the PMS was set to before this last session. I knew I was way to rich because the plugs would foul out and they were very carboned up and black smoke was very evident when I cranked it. One other thing, last year either the local shop or the guy in Fargo pinched one of the wires reinstalling the tank which caused one of the coils to fry (installed two new ones). Now, when cruising at 30 mph in 3rd the exhaust changes tone like one or more of the plugs aren't firing and I have to twist the trottle a couple of times to get it to run. Also running at 70 - 75 in 5th its kinda doggy, in fact a new sportster walked away from me like I was slowing down, not trying to excellerate. This morning, I started it up, enricher half way out, pushed it in after starting and the bike wouldn't stay running unless I feathered the throttle. I took off after a minute or two and the bike would not stay running for more than a block. It almost acted like it was running out of gas as it missed real bad, backfired and coughed threw the exhaust and carborator then quit. It was a bear to restart and when I did it would last for another block and do the same thing. The engine felt very hot, more so than ever before so I left it off and trailered it home. Anybody ever hear of anything like this? Any thoughts on what I should try? I am not going back to the shop, I'll buy a different bike before I do that again (but not from them)! But before I do that, I'll put my stock stage three pipes back on and rejet back to stock. Does anybody know what the clip is suppose to be at for stock and I believe the stock main is 165 and the pilot is 35. Any help or suggestions would be deeply appreciated.<br><br>Post edited by: Loobie, at: 2005/05/30 21:20

Assuming you are using Mikuni jets, I believe you are vey close on the jetting.

With different aftermarket pipes, I have used the 170 main, either the 35 or 40 pilot and the needle at 4 to 4.5.

First .... do the simple things.

- you ported you manifold .... check for leaks. A leak here will mean a no-go anywhere else.

- you removed the AIS .... check to see that the nipple is still on tight on the manifold.

- check to see that the PMS has not fallen out. A good starting point for now is to turn it in until it seats lightly and then out 3 turns.

- remove each spark plug and check for spark (make sure to ground the plug).

- drain gas tank, fuel lines and carb and put fresh gas in tank.

The symptoms you describe are also common if you stored you bike over the winter and did not put stabilizer in the tank or drained the carb. The carb and its jets may be gummed up. If it's not too badly gummed up you may be succesfuul by running a tankful of gas with carb/injector cleaner in it. It may also help to spray carb cleaner in the carb throat play particular attention to the visible holes. However, the best thing to do for this is to take the carb apart and clean.

Let's start here before we try the jetting but you should make sure you have a 170 or 172 main as I think you're probably too lean with the 167.5.

Doc

This is a duplicate post Loobie, so I am locking it down to keep all responses in the same thread.

The other thread is at:
http://roadstarclinic.com/index.php?option=com_simpleboard&amp;func=view&amp;catid=12&amp;id=2349#2349

Doc has some great suggestions (as usual).

GRAM