I want to thank Scott for the information provided on this common Road Star puking problem. I was recently on a ride with about 12 other bikes (mostly Harleys) in West Virginia. The temperatures were 37 and 38 degrees. It was prime puking weather for the Roadie. It didn't fail me either. It always started but only after a puking session and a black smoke display. It was the most embarrassing when we were leaving the Harley dealership.
Well, after receiving your email, I installed the overflow line on the carburetor and threaded it to below the bike. If it wants to puke now, it will be on the ground and not on the hot engine. I also started using premium gasoline. When you take the Ethanol out of the picture you have really solved the problem.
I did opt to make other impovements to the bike at the same time. I have always felt that my Roadie ran way to hot. Last year I installed a Jagg Deluxe oil cooler. It did seem to help it to run a little cooler but I didn't get the big result I was looking for. After reading other information on here, I decided to pull out my wallet and do something about this. I installed a Barrons big air kit, Barrons fuel pump relocation kit and a Barrons AIS
removal kit. It is amazing how this opens up your bike for air flow. The front, left side and right side are totally open now. The bike runs great and there is no more puking. It starts like a bike is supposed to start when it is hot. This is the way it should have come from the factory. You can see the engine now. I couldn't be happier with my Roadie. This is a great forum and thank you for all the information.