I have written before about my '96 "cutting off" and bucking like it was out of gas at about 65mph. I have done some other changes while still working on this and encountered a new problem. Thus far: Raptor petcock, Dyna muffler, desmogged (CA bike), white spacer mod, next hotter plug, cone air filter, 150 main jet. When I desmogged it I didn't know what to do with the vacuum and return lines so I just connected the two ports on the carb with a hose. In the original configuration, they actually form a loop through the charcoal cannister so I thought "stick to simple". Didn't work well at all. So last night I simply cut the connecting hose in half. It is now a mother bear to start and seems to take forever to warm up. On this morning's test ride, it started out fine warm with no choke, hit 70 for the first time ever, then started cutting out again and would not exceed 55 mph and ran very poorly. I fiddled with the choke while keeping an eye out for deer, and it will only run well with the choke knob pulled out all the way. Since a choke is an enrichening device, I am thinking I am under-jetted and tonight will try a 155 main. Any thoughts? All else is well, valves, etc. I am pondering buying a non-California carb. This is crazy. I love this bike but won't love it much longer if it keeps this up. Any feedback is appreciated.
Last question: is there a simple way to vent the tank or gas cap to be rid of the hose under the tank on CA emission models?

If you can feel vacuum on a hose that goes to nowhere,that is not good.

Verslagen, you are suggesting to plug those two hoses that formerly went to the charcoal cannister? Or cap them. Neither went to the petcock as I installed a Raptor and capped off that line at the petcock. I had a  large bungee cord rubber tip that fit snugly and cinched it down tight.
I won't get to ride again until possibly Monday as we are forecast for heavy rain next two days. As others have suggested I will check for vacuum and also install the 155 main jet. I also note rom the Haynes manual the CA smog models come with a 47.5 pilot jet and non-CA models have a 52.5. I will order one and let y'all know the results.

I will try capping the old smog canister lines and see what happens. Meanwhile, I will order the richer pilot jet. I'll report back on results. Thanks for the input.

Interestingly, that line from under the fuel tank just goes nowhere. It just trails out to the rear, terminatinng its' open end near the rear frame rail. In the Haynes manual, it is described as the fuel tank vent. I'd still be interested in hearing from anyone about venting the fuel cap and capping that vent line under the tank. Future experiment. . . I am determined to get the ol' '96 running like it should. Today is the one year anniversary of totalling my Road King sidecar outfit. With a rod in my femur, the Savage is easy to horse around  - IF I could get it right. Meanwhile, I still have my 1974 BMW to "play" with. Its' last big excursion was Sep. 2013 from TX to Portland and back - 6,000+ miles.  Still a great bike considering I'm the only one who has ever worked on it except for tire changes.

49Mack,

I don't know if this will be of any help or not.  When I got my bike, it started and idled great.  Wouldn't take throttle for anything. It spit, backfired, afterfired, and died with the opening of throttle.  

If you disassembled the slide assembly, make sure the spring is pushing the needle up against the little screw down plate.  Mine had been put together backwards by the PO and the spring was pushing the needle down.  Once I changed it, everything was great.

I think I finally broke the code on desmogging. Thus far, I have cleaned the carb, removed the air filter and box, added a cone filter, removed the CA emissions box then it wouldn't run except with the choke on. Checked for vacuum leaks, found none. Added a Dyna muffler. Did the white spacer mod (2/3 original size). I upped the main jet to a 155 and pilot jet to 52.5 mm (Sudco.com). Here's a tricky thing. . . I thought perhaps I may have installed the spring etc., in the wrong order after the white spacer mod. But I found the spring had slipped over the washer so I tightened up the diameter of the top coil and it now starts and runs very well up to 70 mph. If you have sudden problem, this could be it. Now it starts to spit and seems to be fuel starved at 70-71 or so. I am thinking it needs the next size main jet (160) or I could also be running rich so I will plan to try the 150 first. Report to follow. Oh, yeah - the two lines that used to go to the airbox are just open as is the 3rd "mystery line" on the right side. With a Raptor petcock installed, the former petcock vacuum port is sealed off.