Clip on needle jet set way too low like 5th slot from top/blunt end will also make it run way rich because at low tyhrottle setting it will be runing almost on full main jet that would explain using 3 gals fuel in 55 miles .

Choke/cold enrichment could also not be returning to off position when pushed in or is stuck.

Yes incorrect float lvl or dirt in needle & seat could also cause his less then 20 mpg but you would think there would be some fuel exiting carb at times if float lvl adj was that far off or if dirt was stuck in needle and seat and he said thats not happening at all which is why i think its more a carb tuning/maybe choke issue .

But as already suggested the flaot lvl still needs to be checked to ensure its right before moving on to checking/tuining carb and ensuring choke returns to full off position.

Also,Could accell pump possibly be stuck in some way /not returning allowing fuel to be sucked from its small discharge shoot into carb killing fuel mileage?

scott

Youve probably already checked but make sure your choke knob is pushed all the way in. If the tension adj on the back works loose it can make it stay out more than it should.

it'nt there a little tiny o-ring gasket at the tip of the PMS? or not.

"I had the bike professionally tuned, took it back 3 times now and they have given it a look over, but they are so busy they claim it would be 3 weeks out."

There-in lies your problem....as had been said around here numerous times, usually if you go back to the last thing that was fixed (Engine Tuned by Professionals) you will find your problem

Need to make sue choke is closing. Need to make sure pilot screw is no more than 3 turns out at utmost. Need to make sure they did not change pilot jet from stock size 35 mikuni

well DISASTER struck today, I filled the bike up with fuel, and it was sitting in the sun and started venting out the gas tank, and I wasnt aware this was happening, so after awhile I went outside and noticed all the clear coat / paint was coming off the side of my tank from fuel. BUMMER!!!

So, I was riding it home, when all of a sudden it started bogging down, and fuel was just spraying out the carb all over my leg / exhaust pipe until it died and came to a stop.

I got it home and finally decided to pull it apart, I havent had much time lately so I havent been able to work on it.

Anyway, after pulling it all apart. I checked all the jets (all clean), needle and float were working properly... and nothing clearly visible wrong.

I am located in morris, IL... The elevation here is about 525 above sea level.... and My bike is a 99 roadstar silverado, 1602

Barons Big Air Kit (BAK) and pipes... (not 100% sure what kind they are)

Pilot Jet 40
Mid 57.5 ( I think... Hard to read)
Main 170

Air screw was about 2 turns out

No idea what is going on.. the only thing I can see going wrong is the accelerator pump may be leaking a little when you crack the throttle.. This pisses me off because that was one of my original complaints when I took it into the bike shop to be tuned.

Any idea's? I need help and I am really losing faith in my roadie, Im starting to feel like its no longer reliable but I know that is not true. Its still basically new, only 13k miles!

trying to post pics, not working so well.

You cannot use a 40 pilot jet with the Barons needle, there lies your biggest issue, a 40 is way too big, the Barons runs with the stock 35 pilot jet. the 170 is fine, needle set-up would be clip on 4th groove counting from the blunt end, spacer 1 washer.

Pilot screw at 2 to 2.5 turns out from a light seat. after fully warmed, then re-adjust the idle. the pilot screw and idle adjuster kind of work hand in hand, Idle should be final adjustment on a fully warmed engine

That may be part of the issue, but when I got the bike back from the shop it was running fine and started acting up. I will change the pilot tommorow and see what happens.

Going from a 40 to a 35 really make that big of a differance?

I went on a long ride this weekend which was mostly all highway speeds, about 95 miles... none of which was stop and go traffic, and I got about 32 mpg which seems very low even for running on the main.

I should get at least 40-45, some guys ive seen have been getting 50+

you might have to change your plugs too, they may be fouled as well. probably a good idea to check float level too. yes, on the Barons needle a 40 to a 35 is 1 full size, big difference. the diameter of the Barons needle is very thin compared to the stock needle, a lot of fuel goes thru when in the cruise portion of the needle.