I too am very skeptical with my mileage. I'm not sure what it is currently, but on my last highway trip I was using about a gallon more than another roadi between stops.
I have the Hardchrome 3" big staights and a dyno stage one jet kit installed. The dealership installed the DJ 200 main with the kit; but after about a week of riding, I replaced the main with the DJ 165. However the mileage has not improved.But is does run better.
I was looking at big air kits to see if this might help; but I'm really unsure of which big air kit to purchase. I've looked at Baron, Star cycles, and the Big Suckers from Arlen Ness.
Any advice would be greatly appreciated. If the filters from Arlen Ness are called something else, I apologize in advance.

The dj 165 is too small, and with strait pipes, either a mikuni main jet 170 or 172.5, or DJ equivalent. I wouldn't be surprised if they also replaced the pilot jet, sounds like they did, got back to stock 35 mikuni. start about 2, 2 .25 turns out from a light seat on pilot screw. as far as DJ needle, either 3rd groove or 4th groove for the e-clip.

Really, nothing needed to be done for pipes only, no jetting, a tweak to pilot screw and AIS removal is all that's needed. If you are thinking to go with an after market kit, might as well get it so you only need to open the less times

This may sound stupid but what exactly is the AIS and where is it located.
The pilot has been replaced with a DPJM037, the DJ needle is on groove #4 from the top, and the air screw is 3 turns out.
I took another look at the kits instructions and it recommends between a 170 & 175 main jet with an aftermarket pipes.
Does this sound like a good starting point as is ?



If I go with a high flow intake air filter, would this be close enough as a starting point ?

I might add that this is my 1st V Twin. I'm an old sport bike and dirt bike guy. The characteristics of the Twin seem to be so much different than what I am used to; it's made the jetting a little problematic.

the 170, 175 if dj jets is too small. DJ and Mikuni jets are not the same. mileage is bad because of pilot jet. the pilot screw adjust gas, not air, out is richer. Jetting is not problematic, it's letting the dealer do it, that's the problem. pipes only require a tweak to pilot screw and AIS. ais article removal in tech article section. count needle grooves from blunt end usually 3rd or 4th groove works with DJ needle.

Read ....


Does my bike need to be jetted?

Basic starting point

Doc

Thanks for all the info guys. Hopefully I'll get into it this weekend and get this stuff changed out. I'll let you all know how it turns out. Thanks again.

Just wanted to say thanks to all that had input for my jetting woes. I just replaced my DJ 175 main with the mukini 175 main; took out DJ's needle and replaced it with Barons titanium needle,4th groove from the top(the main jet and needle were recommended by Barons for the Barons Big Air Kit) ; took out the DJ pilot jet and put the stock 35 back in its place; and adjusted the mixture screw to 3 1/2 turns out. And of course I replaced all the spark plugs with new ones.


I'm not sure if it was the plugs or the jetting changes(the old plugs seemed to be in very good shape so I'm thinking it was the jetting)but the bike actually started like it's suppose to. (actually didn't have to turn the choke off right away) I ran the bike at 5, 10,15, & 20 mph several times and it just seemed to run along very smoothly at all these speeds. (slow speeds were giving me problems due to the bike just trying to lurch forward and just running plain running rough) I did not get a chance to ride enough to check to see if my mileage improved (rain) but hopefully that will improve as well.

Although I am very happy with my 1st initial ride after the jetting changes: The only question I have is this.
After the Air intake change (Barons BAK) and the exhaust (3" big straights) how is this carb still supplying enough fuel with the stock pilot. (even Barons recommended changes to only the Main & the Needle, and slight adjustment to the mixture screw. Again thanks too all

Thanks for the pics. I used to set the floats on one of my dirtbikes the same way.
I knew there was a way to do these carbs as well; but I had no idea how till I came across these pics.
Just one question; is 04 and up just for the 1700's. I'm new to RS's so I did not no when and if the 1600 was discontinued.

That correct ....

1600 - 99-03
1700 - 04 to present

Doc