[chuck13637]

Here is the situation. My wifes 03 FXDL was set up from the dealer with SE exhaust, SE air cleaner, and stage 1 set up. This bike has always coughed and sputtered when cold. Lately it has gotten worse, After allowing the bike to warm up and turning the choke off, the engine dies. If you pull the choke out about half way it will run at a higher idle, but when you take off, it starts to cough and sputter. I have not pulled the carb yet to see if they increased the jet sizes when they did the set up. But I think I whould still get it to idle even if they didn't. The plugs show a very light tan color, but the exhaust tips are very sooty.
Any advice would be apprecated.

[hotroadking]

Sounds like an intake leak so you can do a simple test

Start her up, get it warm

Lock the throttle at 1500 RPM with the screw under the throttle

Now take wd-40 with the straw on the can,

Spray some at the rear cyl head/intake port and do the front see if the idle changes

If it does you have an intake leak.

Just would be my first place to look before tossing parts.

[Art_NJr]

I agree with HRK, sounds like an intake leak. The carb jetting may be too "fat" (dealers typically go too big on jets), but the intake leak test is simple & quick.

[chuck13637]

OK
found the intake leak, the seals from the factory were ripped? The manifold was never off as we are the original owners. So I also put in the recomended jets , the stage 1 from dealer had the next size up on pilot, so i just replaced with a new one, the main jet i went one size up due to the recomendation on my carb kit that I purchased from here. i aslo put in the e-z idle screw. The motor will run at a nice idle whith the choke off, but when i take off it wants to stumbel and no power . I rechecked for intake leak, but it tested good. I'm planning on taking carb offand putting the smaller main in, what do you think about the pilot?

[chucktx]

how many turns do you have on the ez screw??? it should be about 2 1/2 turns out from a soft bottoming.........

[chuck13637]

Ok,
I started with 2 1/2 turns, and it still runs like sh*t. So I put the original 190 main jet in, and still running like sh*t. Drove it up and down the street, adjusting the EZ in and out. I tried running with the choke out about 1/4 and that did not help. This is getting frustrating!!
While riding down the street, it sputters and chugs along, sometimes catching and then it wants to cough and die.

Right now i have the 48 pilot and the 190 main. Should I go back to the 46 pilot?

Any other suggestions?

[DynaPat]

Any chance the float got buggered up? Stock petcock? Check the vacuum hose running to it. Make sure the fuel flows good, if you have a Mity-Vac or something like that just apply a vacuum to the hose barb for the vacuum line.

[chucktx]

dont get frustrated......do one thing at a time, usually the easiest first. this is how you will get to know the bike and hopefully cure your problem.........

[chucktx]

some questions...
how do the plugs look?
good voltage at the battery?
charging system ok?
intake system ok?........leaks/clean intake/filter?
good flow of gas from the tank???........tank vented?
gas filter?
plug wires?
good clean electrical connections from the battery?
quality gas???.......clean gas,no water?....or..?

[chuck13637]

OK, I took the carb off and put the original jet needle back in, and I also turned the needle jet around. When i first replaced the main jet, i removed the main jet holder, and for some reason I turned the carb upside down!! the needle jet came out and I was not sure which way it went back in. 50/50 shot and i lost! turned the EZ screw out 1 1/2 turns from soft bottom, reset idle screw to 1000 RPM, took it for a spin down the block, and remembered I had the choke half way out, pushed in, and the bike ran better then it has ever. After letting it warm up with a few trips around block had to reset idle to 1050. Took it for a longer test run, and it performs very well. It only backfired on decel one time. I know it is running a little rich, but will check plugs and then go for a longer ride.

Thanks all for your suggestions.

BTW - I think I will take pictures of the manifold gaskets and send them to Harley...... As if it would matter!!

[chucktx]

glad that things are going your way!!!!!!!!!! have fun with it!!