loss of power and stalling on highway

[cjb1214]

I have a 97 bandit 1200.  I have recently jetted it with 127.5 mains 37.5 pilots and shimmed the needles with 2 radio shack washers.  It was running pretty good.  I bored out the stock exhaust can and rode it and it seemed ok.  Today I took it out for an extended ride and after 20-30 minutes it started acting like it was running out of gas.  I had no power and it surged when I was just crusing.  It would barely excellerate.  When I pulled over it died and wouldn't restart.  I tried using the choke and it started and seemed to run pretty good with the choke on about 1/2.  What is going on??????????????

[Red01]

If it runs better with the choke on, that's a classic example of being set too lean.

[99er]

Sounds like the old case of a pinched gas line. The gen 1 had a long gas line and more than one person that did carb mods (removed tank) reassembled the bike and pinched the line on the tank base. Sometimes it runs well, other times not. Choke helped each time.
Check the gasoline bend and cut it as needed. Open one carb drain and put the tank on prime. If it flows, you're golden. I'd pretty much bank on this one.
Second, it is possible that after carb assembly, #4 does not have its sealing washer and lesser vacuum is reaching the tank. Verify this by running the bike on Prime.

127.5 mains on a stock can is a bit rich. Is this with a 2" hole in the airbox? That mod assumes a performance can. Just nosey.
Marc/Atlanta
'99 2" mod & K&N
early Holeshot system
135main/35 pilot

[cjb1214]

I did the 2" mod and bored out the exhaust can and installed a k&n.

[cjb1214]

It appears you were right about the kinked fuel line.  I took a flashlight and looked up under the tank and it was kinked over pretty bad.  I straightened it out pretty good and took it for a 30 min highway and exceleration ride and it didn't falter at all.  Thank You guys very much for your help.  I love this site.

[99er]

Cool! Enjoy it!
Marc