Did you re-route your throttle and idle cable so they weren't putting the carburetor in a bind? I had that problem until I read the manual and did it right. My cables were pushing the carburetor crooked and didn't get a good seal at the manifold.

 

Mine is a 80" bored .020 with 10.5 SE pistons, Andrews EV27 tour cam, 2 into 1 pipe, ported heads.

I had to go up 1 size with pilot and to 165 main, was still a hare lean in cold temps at high way speed so I aquired a 1 step richer(smaller diameter) needle and have that set at the leanest groove. No hesitation or popping unless it's 40 degrees of colder and pull an average 40 mpg under 80 mph.

 

EvoFatboy:

A 30 pilot seems awful fat.

When you adjust the airscrew how many turns out are you?

If you are more than 2 1/2 turns out your pilot is too big. You should be between 1 and 2 1/2 turns out.

 

I have a 2001 FLHT with a mikuni 42, big sucker, vance &amp\\; hines. I live in&nbsp\\;Boise Idaho (2400 ft elevation).&nbsp\\;I was getting 27 to 36 mpg depending on wind conditions.
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I did the Minton Mikuni rejet (American Rider).
17.5 idle jet,
98 needle wiith clip in middle notch,
50 accellerator pump and uses the stock main jet (I did install a 152 main)
Accelertor pump comes on almost right away and shuts off at 1/2 throttle.
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Now I get 32 to 43 mpg depending on wind conditions and the bike performs much better.
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Still, no matter how far I back out the air flow I can't get the engine to cough. So the bike is still running rich.
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The parts guy at *** Distributing also sent me a 15 pilot because of my altitude.
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I need advice though. Do you carb experts think the 15 could be a problem if I decide to take the bike to the coast? Might I burn up the engine or will the bike just run rough if it gets too lean? I'm willing to install the 15, but only if it's safe.
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Opinions?

 

How are those intake seals......

 

mikuni says to be sure that you don't use a Harley choke assembly. Good idea on the intake seals .. get some wd40 and with the engine at idle spray around the intake close to the heads. if it slows down you have a leak.. I recently helped a friend with a similar problem and it turned out that he used the Harley enricher and cable from his CV carb.. ( big bummer the choke never is completely off ).. Don't give up! I see a lot of excellent responses. In my experience the SS carb is not better ( but it is good ).. Good luck