Well, here I go, first time trying a help forum, I'm pretty good at making silly mistakes and then spending lots of time trying to get back to square one ...
I own a 2004 Roadstar with approx. 6,000 miles, and have recently added a set of speedstar drag pipes, speedstar (k&n) open element air filter and installed a dynojet kit. Then my problems began, I've not included some of the dumb ___
mistakes , like stuffing the new main jet into the choke jet hole originally, oops, was that out loud? Now that I've lost all respect... I'll start

Originally did not have the open element filter.

Followed the stage 1 instructions (pipes only),because the kid behind the counter said I had to have a jet kit if I add pipes. (wish I knew about the forum back then)
dynojet needle, clip on groove #4 & dj175 main
dpjm037 pilot jet
3 turns out on pms screw
plugged canister hose (no idea what that is supposed to do)

I live in CT basically at sea level

Bike seemed to run pretty good, but very rich, blowing black smoke out exhaust when hitting throttle and gas mileage from approx. 45 mpg to 35 mpg. Adjusted pms screw and ran slightly better.

Added open element filter, hoping this would semi straighten out rich condition, but made no noticeable change.

After reading quite a few forums I decided to put the stock pilot jet back in and leave the dj needle and main jet (175) alone. Set pms at 3 turns out.
Bike seems to run better, quicker response, does not blow any black smoke out exhaust at all and will probably get alot better mileage, don't know yet.
Although bike may be running hotter (might be overanalyzing) and pops slightly on decel.

Sorry about another long winded jetting question, but I don't want to run an excessively lean condition where I might do serious damage.

Any advice on this would be appreciated.
Thanks in advance

Welcome to the Clinic top

Sea level is the leanest. You get richer as you gain altitude. Set the clip on the 5th notch ( from blunt end of needle) and do the WOT - http://roadstarclinic.com/content/view/94/96/ After you have the main right put the clip in the 4th notch and dial in the needle and PMS. As long as you are doing the jetting I would port the maifold too. that will give you the most bang for your buck. My 2 cents anywho.

We won't talk about your mistakes if you don't talk about ours.

With your current setting, try the WOT test (it's in the Tech Tips section).

If it's OK, oops .... just see Musky replied as I'm typing ....

Put the #35 pilot jet back in and set the PMS to about 3.

Musky suggested the 4 th clip, but for the DJ needle I'd recommend you go to the third clip from the top (washer, clip, white spacer, two sliver washers).

If you blow black smoke when hitting the throttle I suspect you're probably rich on the needle but it's also the #37 pilot.

Doc

Wish I could figure out why DynoJet couldn`t have added 2 friggin brass jets to give you a full kit.(180&185).I have the DJ 195 main in and the 35 pilot.PMS at
3 1/2 turns,and needle on the 3rd clip.ALWAYS have to start with choke.Alone I
get 39 to 42 MPG`s and 2up and loaded 36 to 40.I also found the 175 alittle lean.One of these days I`m gonna order the 180&185 and try them out.

VegasDave--

I too have the Dynojet kit, and while I haven't looked at it in DAYS now , I'm pretty sure mine came with the 180 & 185. I think I have all the way from the 170 to the 205? I guess I really should go look...

I'm at 5600 ft. elevation, have the DJ175 main, stock 35 pilot, clip on 4th down from the blunt end & PMS at 2.75 out, ported manifold, with HK 3" pipes and the Speedstar air cleaner. I still think I'm a bit rich (altitude), and am pretty confident I could get down to the DJ170 main (which is what DJ recommends for over 3000 ft elevation) and clip on 3rd groove.

The one thing I don't get about these DJ needles...why are there more grooves below the 5th one? Who the hell runs with the clip on the 6th groove? And I need to count again, but I think there's even one below that...?

I should have purchased a Baron's needle kit...

RK

Morning RK

I think the Barons needle has 6 grooves too. Not positive though. I haven't looked at it for quite a while.

For your elevation that sounds about right RK.I`m at just under 2000.
But on any given day riding here you go up or down in elevation .
Mt.Charleston is only 48 mile from home and it rises to 9000 Ft.
Man I love ridin my bike And in my DJ kit the 180&185 are not even
listed in the contents.

Just wanted to thank you guys for info, I guess I'm close with the dj 175 main and stock pilot. Glad to see RK 1962 is running the same set up and no problems. I did a quick halfast WOT test before I wrote in and didn't feel much difference when I cut back the throttle, a little tied up with other things and waiting for the rain to end before I give it a good test run.
Only other small problem is occaisionally off idle, carb will spit and stumble slightly. Can't remember bike doing this with stock set up.
It does seem funny that dj doesn't supply 180 & 185 jets, I guess that extra $.35 would be a deal breaker.

topjimy wrote:
Only other small problem is occaisionally off idle, carb will spit and stumble slightly.

First try the PMS out 1/4 turn.

Might need to adjust the accelerator pump.

Doc