So this weekend I took my first trip to see my gf 120 miles away. One of the reasons I got a motorcycle. My ride there was smooth. Got there friday night and took my gf for a little spin for dinner, very short trip. Didn't ride it saturday and then I left for home sunday.

When I left I had 60 miles on the tank and I normally get 100 to 108 before I hit reserve and I calculated the distance to the next town where I could get fuel and it was about 38 miles away so just before reserve. On my way I just get about 10 miles out of town when my bike starts to lurch like it does when I have to go to reserve. So I switched it and it kept going till it died. Pulled over and saw it was only at 77 miles so I started her back up and thought nothing of it. 2 miles later it does it again! I tried it on prime, res, and on and did it on all. Open gas tank and had plenty of fuel and thought maybe the tank breather was clogged. So i tried running with the tank cracked open and still died. Finally after 45 minutes of a long trip of 7 miles to short trips of 1.1 miles between stops I made it to the gas station. There I filled up 2.1 gallons which is less than I normally have to fill up. So from there I thought she would be fine.

After about 10 more miles it started the surging again. I was in some heavy wind and I had seen a post that said something about some breather tube being pointed the wrong way and when the wind hits it just right it has the same symptoms as low fuel. So I was hoping it was that. I had no problems for the next 30 miles where I stopped to get something to drink and rest after that horrible stop and go ride. So I had 40 miles left to home. I went another ten miles and the bike started surging again but no wind this time! So I pulled off the freeway, drove through town and it seemed fine. So I got back on the road and tried again. On my way back there is a monster hill that my bike always has trouble going up and normally dies once from lack of fuel if I forget to put it on pri. This time i did put it on prime but it still died, twice! Once I got over the hill I thought I was home free but it died going down the hill and then three more times on flat ground before the next off ramp. I pulled off once I got there and let it sit for a few minutes before taking the side roads home.

Has anyone had any similar problems? I have a 2000 with a V&H exhaust, lunchbox and 150 main 40 pilot just like the wiki page says.

You remind me of myself.

Assuming your valve assembly was shimmed correctly since you had it repaired:

1-Pull the carbs.  Clean them better.  Your bowls aren't filling or the mains are plugged.
   Make sure you don't put the bowls in backwards. 
   Re-install with wrong jetting, so you can learn the symptoms of lean/rich instead of asking people and being scared.
2- New float needles and o-rings all over. 
3-Compression test.
4- Flush your tank, get the junk out.  Pull the petcock, clean the screen.  Not with solvent, it will melt. 
5- Clear fuel lines. 
6- inline filter.  Not a plastic one - ethanol will melt it. 
7- Cap the vacuum and modify the petcock. 
8- Iridium plugs.  Better mileage, eases mixture problems.  Timing advance, but that's my personal preference.
9- New clutch and throttle cable, before they break on the highway.  It happened to me.
    I lubed them the week prior. 
10-New brake lines.  Not just a quick bleed. 
11- pull and clean your calipers. 
12- new pads

etc.

Glad you bought such a cheap bike, now? 
And, don't worry - when you fix it up, the resale value is better!   

One possible (and simple/quick) consideration - Use the carb drains. See if a lot of water comes out. You may have a big puddle of watery crud collected in the carbs, with a thin layer of gas on top. If the water gets sucked up into the carb, it doesn't burn like gasoline does...

Sounds like maybe your ignition is cutting out completely or almost, after electonic components get good and hot from sustained high speed running. (assuming you've already made sure of petcock, and carbs are clean etc )

how old is your bike, mileage, were you riding in hot weather ??

It sound like it misfires when the engine is hot.
Buy some new sparkplugs. When you remove the old ones take the spark wire and turn it clockwise into the HT coil to make sure it's tight. Also turn the sparkplug cap the same way so it fits tightly on the wire. Do the same thing in the other side.

Well I'm going to clean the carbs really well. That was my first thought. The spark plugs are fairly new. Only about 800 miles on them. I have had the bike be way too lean because of wrong jets as well as too rich so I know what those feel like. I already cleaned the petcock since having my other major issues such as a broken exhaust valve when i bought the bike. It doesn't have all that many miles. It just hit 30k on this last ride. And the weather went from cold to hot to cold and finished in hot. Happened when it was cold and hot alike. I do have an inline fuel filter. I'll check the spark plug wires and make sure they are perfectly tight. Thx for the help

That's always the dream.  
"Please, let it be the ignition this time.  I'm so tired of getting gas on my hands."

If it's holding idle and puttering along at slow speed, the ignition is firing.  
You do bring up a good point, though:  he should squirt some loctite on the rotor bolt as a precaution.  Add that to the list somewhere.

Not trying to sarcastic or anything, by the way.
If he wants to "distance ride" on a decade-old bike with a previously-busted valve train, he's gonna have to learn a few things himself.  
The magical internet with all the answers disappears on the asphalt.  
Riding around with PRI issues, general unpredictability, AND carrying pretty passengers?  You can tell it scared him, and he doesn't want to admit it.  
Either update/refresh every single system, or learn as each one of them breaks.  And then, update it.  After it's left you stranded (making you look and feel like a fool) or worse.  Much, much worse, especially with a girl on the back.  


Just trying to help.  Hope no one gets all butt-hurt about it.