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[i] To me, it's acting like a fuel delivery problem, so we're looking for a rebuild kit for the carb, and sometime today we're going to check the in-tank filter.
Oh yeah, we also ran a full bottle of SeaFoam threw 'er and it helped a bit, but still not right.
I'm not sure what other details I can mention, but any other questions, let me know. [/B]
...Thats my next recommendation, especially after making a run to sturgis...Flush the gas tank and fuel bowl and if he dont have a Pingel petcock on it already ('bout 80 bucks online)...get one, especially with the mods ya done. The stock ones dont flow worth a crap, plus, add a inline see-thru filter...its amazing the gunk youll see...sand, dirt and even tank liner. Except for the petcock/filter, it'll only cost ya labor
...Or, just pull the old petcock (if its stock) and remove the tube and screen then add the inline (for the cheap quick fix).
...I wouldnt rebuild it until ya tried this fix first though...save ya a few bucks if ya can.
Are you sure that it is not a timing problem? That's what I would check if it were my truck, but then again, I have never even ridden a harley. (rode a yamaha once, it was a blast!)
I agree with wabikers suggestion, though I suggest getting a plastic Toyota replacement filter (the inlet and outlet are at 90 degrees, so its a natural fit for Harleys) which is an old school mod. The see-through "glass tube with end caps" style filters are leaks waiting to happen.
Since you've tried everything else, I'd reseal the intake manifold to the heads after inspecting the seal rings. Replace them if not perfect.
I use a solid Ram-Jett manifold to dispose of the "compliance fittings" and recommend it highly. I installed it in 1988 and had over 70K miles before I top-ended the engine. I don't even use a carb brace since the manifold is more than adequate.
(If your heads are incorrectly lined up you would have to loosen one to mate them to the manifold, but I didn't need to.)
S&S carbs are dead simple, (if it looks ok it is highly likely it IS ok) but a way to check it out is to temp swap a stock carb and see how it runs.