Need a little help here guru's. '04 Roadie with ported manifold, stage III on the pipes and self-drilled BAK (FATBAK). I jetted the carb with a Dynojet kit. 190 main, 4th on the clip and 3.25 turns on the pms. Rode about 100 miles yesterday and she runs a great deal better. The problem is when cold and first cranked w/choke (10 seconds max then 1/2 choke). She was pumping black smoke and would hardly run. (rich to say the least). After warming up she ran better than she ever has but the baffling part is I have popping on decel indicating a lean condition. I am almost positive I have no leaks intake or exhaust. The head pipes were never off. Today I turned the PMS to 2.25 turns out and went for a ride. She still is spewing the black smoke when cold but after warming up runs like a champ. I did the WOT test and she doesn't speed up abnormally when backing off 1/4 on the throttle but is still popping hard on decel. I do believe the DJ 190 to be a little big but the next size in the kit is a DJ165. Should I try the 165? Drop the needle to the 3rd groove or just play with the PMS, turning her in another 1/4 to 1/2? Being rich and decel popping has me stumped but I know from past experience with the help of the great folks here that I'll get her dialed in. I must say that the stage III on the pipes sound awesome. Thanks in advance!!!

Alan
SCRC Chapter 102
Huntsville, Alabama

I need to ask the obvious .... is the AIS removed?

Popping out the carb is a lean condition. Popping out the exhaust is usually an exhaust leak.

But then agiain my exhaust 'pops' somewhat but does not backfire and I know it's dialed in.

Doc

Doc,

Appreciate the reply. The AIS was the first thing to go. I have the insistent carb cough but have gotten it to subside somewhat with the acc. pump adjustment. Thinking about soldering up and redrilling the pilot air jet to see if that completely eliminates the cough. The popping I described on decel isn't to bad unless I really hammer it and then shut the throttle all the way. If I open it back up an 1/8 to 1/4 turn it disappears. I am concerned that I am way rich with the main and needle clip position BUT on the other hand it runs great after warming it up and cleaning the plugs off. I had the problem of fouling the plugs after porting the manifold, before doing the pipes and air box. I had to run my PMS all the way down to 7/8 of a turn to eliminate this problem. After doing the rejet I went back to 3.25 out and then to 2.25. I believe I'll take it to 1.5 (factory setting) and see if that helps with the plug issue. What do you think????

Thanks!!!!!!!

Gram is the resident carb guru.

I sounds like you have things well in hand.

I'm not familiar with the DJ equivalents of a Mikuni and don't have my chart here at work. As a comparison, I have the Nasties but with very restrictive baffles, Nemesis manifold and BAK. I'm running a 170 Mikuni, 4 on the clip, 35 pilot and about 1.5 on the PMS and it's just about right. I may have leak in exhaust pipes which I need to check. If I hammer it and back off I may get some popping but rarely a backfire in the pipes.

Without the baffles, I was running the 170. 4 1/2 on the clip, 40 pilot and 2 on the PMS.

On the other hand, if I'm at a red light and blip the throttle it's not uncommon for me to pop through the carb or stall it.

So .... incomparison to mine, I would say you are a bit rich. Why not try what you suggest. First move then needle to 3.5 or pop in the DJ 165 at 4.5 and see how the WOT test works.

Sorry I can't help much.

Doc

Doc,

You have indeed been a help. By comparison the Mikuni 170 is equal to a DJ 181.3 according to the chart posted by Mr. Tidy. The DJ190 would by comparison be equivalent to a Mikuni 178/179 or thereabouts. I see that you are running your PMS at 2 with a #40. Do you know if the '04 is stock with the #35 or was it changed to a #40? For some reason I think I read that somewhere.....memory isn't what it used to be..LOL. I am fixing to turn the PMS to 1.25 and go for a ride. I'll let you know the results. BTW.....Beautiful Bike, I love the color.

Alan
SCRC Chapter 102
Huntsville, Alabama

FYI:
My '04 came stock with a Mikuni 182.5 main and 35 pilot. With mods I am at 172.5 main and 37.5 pilot and appx 2 turns on pms.

Running very nicely now.
David

David,

I noticed that you now have a smaller main than stock. With mods are you running a Mikuni main and pilot? What was your factory setting on the PMS? I love my '04 and can't think of a bike I would prefer other than this beauty. It has its own personality which makes it special.
How many miles do you have on her? I just clicked 7900 tonight!!!!

Alan
SCRC Chapter 102
Huntsville, Alabama

Alan,

I don't know what the stock pms was set to. When the dealer installed my pipes, airkit, ignition, etc., they used a Dynajet jet kit. They installed a 165 main jet and left the 35 pilot. It was so lean it would hardly pull itself. Plugs were totally white. I have since switched to Mikuni jets in the main and pilot. I also removed the ais and that helped. I am also considering filling and drilling the pilot air jet in the throat of the carb. It doesn't cough, so I am not to worried about it.

I have about 6700 miles on it. I want to get 10k before the snow flys here in Minnesota, but I have the sinking feeling that it will happen in October this year. Usually happens in November.

David

Doc,

I dropped the needle to the third clip position, turned my PMS to 1.25 and put about 40 miles on her last night. She pulls harder than she ever has. I won't know for sure until I crank and ride her cold but the plug problem seems to have disappeared. I had already ridden and the motor was still hot when I adjusted yesterday. Thanks for your help!!

Alan
SCRC Chapter 102
Huntsville, Alabama

My impression from most post is that most guys are concerned about running too lean and 'ruining' the motor, thus run their bikes too rich. However, running rich on these bikes seems to cause valve problems.

One way to easily know if you're too rich .... if the bike starts without the choke. You should have to choke the bit to start it. Once started, you should be able to push the choke partway in, and depending on the air temp, push it all the way in within a few 'blocks'.

Sounds like you guys have the jetting well in hand.

Gram is the expert. At my lever of expertise, I find that changing one thing at a time, going for a ride will usually tell me how I'm doing.

doc