The answer about checking your plug color is WAY WAY WAY off!!!!...those days are LONG GONE!!!......The ONLY way to tell if you are running PROPER is to use an exhaust gas analyzer and air/fuel ratio meter...ON a DYNO.....this will show, at EVERY RPM, what a/f ratio makes the most power. Todays engines run lean on FUELS WITH ADDITIVES THAT GIVE FALSE PLUG COLOR READINGS.
DO NOT....DO NOT......change the HEAT RANGE of the PLUGS!!!!!!......this will affect the performance of the ECM and injection by changing the temp readings by the ECM.
Carbs are ANCIENT technology and no where near as fine tuneable as injection...injection, on a dyno can be dialed in PERFECTLY for max performance....AND....fuel economy combined at EVERY RPM......Carbs can't...PERIOD!!!
"punching" out your baffles will do NOTHING for performance.....one of the BEST performing systems for HD's ...IS....the stock exhaust with the baffles REMOVED. You do this by using a hole saw to cut out the weld at the end end of the muffler and then use a long steel rod to knock out the baffle ASSEMBLY from the housing, leaving a straight through glass pack, the stock headers with the bracket/crossover tube is the key to this system's performance, use Samson Torque Cones and Screamin Eagle Flat-Style Exhaust Gaskets to help increase exhaust gas velocity......Email me through my profile and I can send specific instructions how to do all this...there is a proper squence!!!
The stock ECM is NOT relearn capable, it will only self compensate under the extremely NARROW parameters by which it was programmed...it does this by the use of O2 sensors....NEVER EVER eliminate the O2 sensors!!!!!
V&H Fuel Pack, Ness Fuel Controller....are junk!!!..........Read below........it is answer to another similar question regarding injection tuning, also included is info on oil to help run COOLER...cooler = better performance.......Due to the EXTREMELY LIMITED mounting space for add-on "piggy-back" fuel controllers on a Softail.....I HIGHLY AND STRONGLY recommend the Sreamin Eagle Super Tuner.....it is only software that reprograms the ECM with nothing needing to be mounted to the bike. The Super Tuner will allow for infinite adjustments to the air/fuel ratio, ignition timing, rev-limiter, acellerator pump feature, engine decel enleanment to eliminate exhaust popping, etc.
And to make it run BETTER & COOLER.......here is some info on proper tuning........an answer to a previous question......
DO YOU HAVE A HI-FLO AIR CLEANER AND PIPES ON THE BIKE???.....IF SO, DID YOU HAVE THE ECM REMAPPED BY HD OR HAVE A SUPER TUNER OR POWER COMMANDER ON IT????...........THIS IS VERY VERY IMPORTANT!!!!!!
HD'S ARE SET UP TO RUN VERY VERY LEAN DUE TO EPA REGULATIONS!!!!!!! RUNNING LEAN CAUSES THE ENGINE TO RUN HOT!!!!!!........THERE ARE OIL JETS THAT SQUIRT OIL ON THE BOTTOM SIDE OF THE PISTON TO COOL THE PISTON.....THIS HEATS UP THE OIL..........RICHEN IT UP, THE PISTON WILL RUN COOLER....THE OIL WILL RUN COOLER.
Even if the bike is COMPLETELY STOCK.......have HD do a Stage 1 download to the ECM......if you have a Power Commander or Super Tuner on the bike..........get it dyno TUNED.....it will increase your performance and make the engine run OPTIMALLY..................her... is some info about "downloads compared to the Super Tuner.......
You want the Screamin Eagle SUPER TUNER!!!!.......and have it Dyno TUNED.....don't sttle for just having the base map loaded. The difference between being tuned and a base map is like night and day. The base maps are just that...a base to which to work form. Every engine is as individaul as we are as humans, they each require a little finesse and tuning to make them perform optimally. The Super Tuner will also allow for easier tuning for any future upgrade you may make.
A Stage 1 download is nothing more than a GENERIC map from HD that is "ok" for all bikes....this is CRAP!!!......the Stage 1 download was specifically made for a HD with Screamin Eagle Mufflers and Air Cleaner......not all mufflers (or complete exhaust systems) flow exactly the same and not all Air Cleaners flow exactly the same...meaning, if you change ANYTHING on the exhaust and intake that the Stage 1 was not designed for, it wil not work as well.....like I said every engine is DIFFERENT.
As far as power output goes....it will vary as to what components are used and how well it is tuned....but on an average from completely STOCK to an upgrade of exhaust/air cleaner, super tuner, about 12-15 horsepower........At how many miles did you start running synthetic? You should never run synthetic until at least 2500.
Which Power Commander was installed....the O2 eliminator ( DO NOT USE THIS!!!...THE O2 SENSORS ARE THERE FOR A REASON....O2 eliminators should ONLY be used for RACING applications!!!!) or the new PC 5 w/ wide band O2 sensors? (The WIDE BAND IS THE BEST fuel controller on the market for Big Twins....BUT requires a fair amount of room to install it along with extra room needed for the add-on ign control module), did you have the separate ADJUSTABLE IGNTION MODULE AND/OR AUTO TUNE MODULE (09-newer) installed also....this will HELP ALOT!!!!....the HD Super Tuner is good, but it runs narrow band O2 sensors (i like these for Sportsters because there is no module to install and conceal).....BUT it does have ignition adjustments the PC doesn't have by itself (have to add it extra with the PC5).
Either way, it sounds like you need to have the bike properly tuned....if they just simply loaded a map....that is NO GOOD...a map is just a starting point for proper tuning.
You air cleaner...did you mean BIG SUCKER???...if so good choice.....the Screamin EEagle air cleaner is way better than stock HD.....but does not hold a candle to the DEEPER K&N filter Ness uses......GOOD CHOICE.