EDITED:
In short, I caused the problem by routing my fuel line under the carbs... don't do that...At the start of the week I warmed up the bike a few minutes, then added Seafoam High Mileage Engine Treatment to my tank, in the prescribed amount. Idle immediately dropped and the bike acted like it was about to die, so I had to hold the throttle open a bit for about a minute or 2. (It never does that otherwise)
This is my first time adding any sort of fuel additive to any motorcycle, but it came recommended.
Friday I went out for a ride. I was on the freeway going 60mph or so, and 20 miles into my trip, the bike started sounding and acting like it was out of gas. The trip meter read that I'd only traveled 75miles since last fill up, but I switched to reserve anyway. For a moment it was better, but then a minute or so later, it was sputtering and choking like a fish out of water. I was only 1/4 mile from the exit, so I limped it off the highway, holding that throttle open but barely able to go 50. Got to gas station...bike died at the pump.
It took just 2.2 gallons in to fill the tank, so the odometer hadn't lied. Checked my float bowls, plenty of gas. Bike ran awesome after the fill up, so I rode another 30miles and then came home.
The carbs are spic and span, new fuel lines, new fuel filter as of 100 miles ago. When I got home, I removed the gas and checked my fuel tap. The mesh "sack" filter on the tubes is clean. No tears. I used a telescoping magnet to pull any bits of rust from all over the inside. I collected a bit of rust (fingerprint size), but nothing near the fuel tap. I blasted some compressed air through the tap where it connects to my fuel line with it turned to "On" and "Reserve". Everything is normal. Nothing in there suggests that the fuel tap was clogged when the bike was choking.
100+ miles or so ago I changed the gas cap seal. It seals quite well. I wondered if what I've experienced is something akin to vapor lock. I checked the breather hole at the bottom of the cap, and it is free and clear of muck. I blasted some compressed air through and felt air around the rim of the seal.
I found a discussion about vapor lock from 2015.
http://forums.sohc4.net/index.php?topic=144611.0Katman said, "...on my 75 750k...would be going along and would act like it was running out of gas. Lines, filters everything good. I could open the gas cap for a few seconds and close it and it would start and run like normal. Suspected the vent so I replaced the cap, and no more problems."
Sounded like my problem, but I'd rather not replace something I can fix. So I searched up how to disassemble the gas cap and found this:
http://forums.sohc4.net/index.php/topic,35056.0.html Indeed, I did have a bit of a problem there, but I don't know if it would have affected my ventilation or not. And I won't know until next time I get to half a tank of gas...
Question: Do any of you know, if adding a chemical like Seafoam would alter the air in the tank in such a way that my little stock breather hole wouldn't be enough? It sounds odd to me, but I'm not a chemical engineer or even a good mechanic.