Hi, John here in Tx. Got an 04 Sporty that started giving me trouble. I knocked out the baffles in the stock mufflers and rejetted the carb ran great, louder and crisp throttle, it ran fine for +/- 6 mos then started to sputter and spit just off idle to about 2000 rpm. It only acts up after the engine is fully warmed up. My puzzle is whether it is electrical or fuel related, I assume it to be electical since it starts after the engine is warm. Its still in warranty but I gotta feeling HD will void it cuz I wrenched it myself. Thanks any ideas, and or suggestions greatly appreciated.

 

Just take it in and try it under warranty. I don't think the motor being warm would equate to the electrical system. Shouldn't matter if the motor is warm. Have you tried changing the plugs, or anything else?

 

So far I checked the plugs they are tan to brownish in color, I also looked at the diaphram no sign of damage or pin holes. Is there a filter above the fuel petcock in the tank? In the carb? I had an 89 Caravan that ran the same way when it warmed up, turned out it had a bad diode in the altenator. Thanks, John

 

Just take it into the dealer and make no mention of your upgrades. If they don't notice there is no need for you to mention it.

Far as I know there should be a mesh filter on the top of the petcock in the tank.