sounds like you have MASSIVE air leaks all over that thing

If I didn't like some challenge... I would put the bike on CL and take the cash to a dealer and get a new one heh.

heheheh well in the end it will be worth the trouble...i think id take everything off thats in the way and toruble shoot all the vac lines before even attampting anything else

OK, so its now a project weekend. New vacuum lines were purchased, I got the air switch actually moving again (Do not know how much force it should take to close the valve tho anyone know?) and some replacement exhaust gaskets for the pipes (also anyone know if it matter what direction they go in as?) I hope this will fix the emissions issue once and for all. THEN I can finally get around to doing what I want with the bike: painting it from red to a nice midnight blue and fixing the scrapes on the body and right side covers from the PO.

hello wraithscrono...i live about 15 min away in peoria...i am very familiar with the az emissions testing...the way to bring that number down will be to turn the fuel srcews out just a little bit...im talkn about 1/2 turn each...now if u are having someone do this for you...make sure they block off the air injection...this will give you a true reading of what the carbs CO and HCs are....if u need any help...hit me up

just to clarify the fuel screw adjustment i recommended....turn them out about 1/2 more from where they are set at now...

Well I think I am going to re-stock the carbs now, found that piston 2 exhaust was MISSING the gasket and the 92027-1142 COLLAR,EXHAUST PIPE, so unless i get lucky with BOBs having some, or someone locally having a set for some reason I shall order them tomorrow good things is with the seals in there it no longer has the Harley sound, the airswitch is also working again so it looks like it may be on the right path quickly. Bike Tech, do you have a carb sync as I do not trust mine any longer.

Update: took the bike in 600/800 hydrocarbons on idle test, seems that it was the missing gasket that fixed it right up, went home, tuned it out to 2 screws out on the carbs to regain power again, now comes time to play with the bike and make it all pretty (ordered a front fender to replace the missing one, then I get to learn how to paint)