I pulled in for fuel at Chevron and got my usual 92 octane. A few miles down the road it starts sputtering and choking, limped it back to the garage 2 miles away and put it up on the stands for review.
Video of engine sound:
This is my first bike with FI, but I attack all the usual suspects from past experience.
Jardine slipon and pair valve delete only mods at this time. 54k miles with all interval services but was burning a little oil so I switched rings out with the superceded part.
I pull the engine, tear the top end off, clean the head, cams, journals, valves, seats, and ports, replace battery, fuel pump and strainer, air filter, FPR, secondary injectors, piston rings, replace all gaskets, thermostat, check coil resistances, test primary injectors work and backwash them out anyways, dump tank and refill with new fuel, new iridium plugs, check valve clearances, dielectric grease all connectors, ensure not to kink the fuel or vent hoses when replacing the tank.
Everything is within spec, grounds lashed down tight, good compression, timing is spot on, fuses good, charged just fine when running, every bolt torqued to spec in the appropriate pattern and double checked. Everything looks just perfect.
Start up bike, runs exactly the same as when the issue started. No excessive smoke from exhaust, no strange noises, just a freshly rebuilt Ninja 650 motor sound.
No MIL or error codes shown.
Thoughts? What did I miss?