Well, I learned a few more things about the Rocket today. I have had a couple "quirks" I always thought were just the nature of the beast. For one thing, the transition from off throttle to on has always been a little "abrupt". I pride myself on being a smooth rider, but smooth shifts, especially 1-2, were always a little tricky. I just blamed it on 2300ccs and 164ft lbs. I've also thought I felt very light bit of "surging" at light throttle, steady state. Very mild, and I was never sure it wasn't just a little wind. Also have felt that the bike didn't like to operate at low RPMs. Much under 2000 rpm in top gear and it felt a little "luggy", like it was time to shift down. Not bad, just not what I'd expect with a motor with the bore and stroke of a Cummins diesel.
Friday I took a few minutes before work to hook up TuneECU and do a "reset adaptations". Didn't have time to let it completely cycle-had to get to work. It ran like CRAP. Surging was bad and really bad decel popping/backfiring.
Decided to get into it today. Lifted the tank and checked connections on coils and made sure all vacuum lines were connected (had to replace a cam cover gasket a few weeks ago, wanted to make sure all that was good). One other item I had noticed on this bike was that there was no slack on the throttle. Every other bike had a little play in the twist grip and I couldn't adjust any in at the grip cable adjusters. Decided to tear into it and adjust down at the cable connections by the throttle body. Adjusted per the manual, and ran the ISCV check, in spec in both positions. I then warmed up the bike, did a "reset adaptations" and let her run 12+ minutes-TPS green light came on. Let it sit a few hours and was able to start it without holding the throttle open-did another 12 minute tune.
Went for a ride and what a difference. All signs of surging and decel popping gone. Much smoother operation off-on throttle. And much nicer operation at low RPM. 1500 RPM in top gear (level ground and low load of course) were nice and smooth-none of the "luggy" feeling I had been getting. It is by far the best (smoothest) the bike has ever run. I think a lot of my problems were due to improper adjustment of the throttle cable. Just speculating-but it seems like the ECU would get "confused" when the cables prevent the throttle shaft from operating completely, especially if it wasn't returning to zero properly. Never had an issue with fast idle though.
I'll know in the morning if this fixed the cold start issue. All the specs I checked via TuneECU looked good.