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If you have taken the Baffles out you need to also install a high flow air filter and adjust and/or re-jet the carb to match. if you have done this, it may be electrical, possible the coil. If it only started this after taking the baffles out try putting baffles back in. if you change the exhaust flow you must also change the intake to match.

If the problem is electrical , I believe your pickup sensor " behind cover that used to have points" , is going bad .You ,can check this by starting the bike and point hair dryer at point cover. If your engine pops and goes dead within 3 or 4 minutes with hair dryer on high you will need to change the sensor.

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Q: 2003 harley sportster 1200 without baffles in stock pipes will run for about 30 35 min then backfires and dies in one hour it will start back up?
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