Jetting and spark plug experts please help

[Jakobi]

Do you have a used spark plug to put in there and check?

What oil, at what ratio are you using? Have you set the float height?? (possibly too low, starving for fuel at extended WOT). Have you checked the intake (carb boot, reed block, and manifold?) Consider inspecting the stator side seal too.

Does it feel lean? Sound tinny? Make the hestitating starving gasping bwaaaah *cough* sound when you whack the throttle open? If you ride with steady throttle and then roll the throttle back does the bike surge forward before the revs drop?

 

[gg3]

Apart from the plug colour ,how did the bike run?Noticeably different?

 

[nestz]

Using motul 800, 50:1. Why try a used spark plug? I will have another look for air leaks. Not sure about how to set the float height - is that not set correct from factory? It does feel lean, very very tinny, sounds like a 125. I didnt really notice the other symptoms you mentioned though.

 

[Jakobi]

Used plug - it's easier to stick an old oily plug in, do a run and inspect it than it is to try and get some clean porcelain to colour up. If it's really lean it'll turn an old oily plug white and ashy.

In saying that, I'd be looking into the things I've mentioned prior.

 

[nestz]

Apart from the plug colour ,how did the bike run?Noticeably different?

Yeh the power was broader - probably from the nedw needle. Its hard to know how its meant to feel. My last bike was a ktm sx250 and this 300 feels so weak compared to that - is that normal, are they quite tame bikes?

 

[memphis2857]

Ditch the Motul! That oil is lack molasses and the flash point is too high. The flash point on Motul is like 550* where as all other quality synthetic oils is around 200*. This was another issue I went through. What will happen is the oil will load up in the crankcase during slow riding and then when it comes time to WOT the bike will suck all the extra oil out of the crankcase and make it run like crap. That being said I don't think it has anything to do with your lean condition.


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[memphis2857]

Yeh the power was broader - probably from the nedw needle. Its hard to know how its meant to feel. My last bike was a ktm sx250 and this 300 feels so weak compared to that - is that normal, are they quite tame bikes?

It's not going to have the big hit of the sx250. But it should still pull nearly as hard. It's just going to explode into the powerband like you are use to.


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[memphis2857]

Just had a thought. Check to make sure your airfilter is installed properly.


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[gg3]

Hi Nestz,this is a mystery?
As memphis said it won't have the hard hit of the sx250. You should be able to easily lift the front using the throttle though?
Does it idle nicely or does the idle hang. ie. after giving it a burst of throttle it idles at high revs & then comes down gradually?
+1 on the air filter.It is easy to not seat it properly at the bottom.
That jetting is near enough to being right for testing purposes so we need to eliminate 2 problems.
Too much air - Check filter.You have checked everything else except crank/case seals ,unlikely on a new bike so work through the easy stuff first.
Not enough fuel- Jetting is ok so check float height (+1 jakobi),plenty of info here on how to do it.While doing it look for a piece of swarf or plastic that may be jamming it or rough aluminium casting that may be contacting the floats & stopping them rising.There will be visible contact marks on the top of the plastic floats.Wrong float height is common on new bikes but usually too high not too low?
Try running it with the choke on & see if it is better.Choke on will make it richer.

 

[nestz]

Have you checked the intake (carb boot, reed block, and manifold?) Consider inspecting the stator side seal too.

What am I looking for around the reed block, maniford? Just that the bolts are tight, or am I pulling apart and looking for something? Also what am I looking for on the stator seal?

Is there anyway to have them pressure tested or something? If so how is that done?

 

[hamilton]

All good advice here for you, but if your not so sure what to look for why not take it back to the dealer? You said it's brand new right?

 

[nestz]

Good news! I think I've found the problem. See attached. Thats the air leak right?

 

[nestz]

I just took the cover off and the gasket wasn't even put on properly, totally crooked and missed a screw hole. Sloppy workmanship. Ive got to say I'm not overly impressed with gasgas so far, ive had bolts fall out all over the show, the brace the holds the regulator thing under the tank ( think that's what's its called) has snapped off, tail light snapped out of its screw... and the bike is only 2hrs old. I hope I haven't made a mistake, the reason I bought a new bike was to avoid this sort of stuff.
Are these bikes normally pretty good? Sorry for the rant. On a positive note the support from this forum has been amazing!

 

[Jakobi]

That won't be the source of your air leak. It'll be pulling air into the stator but it still has to get past the main seal in order to affect the engine. In saying that though, any dust and crud pulled in won't be doing any good in there. At this stage based on the low hours, new bike, and issues you have already identified I'd be working closely with my dealer.

I've had a couple bits and pieces replaced under warranty, and never a question asked.

These bikes in the past have been known for some 'odd' build quality. My experience is that they do need a good going over to get setup (but what bike doesn't - they just have a few more quirks). Once done, will be as reliable as a stone.

 

[nestz]

damn really? I was hoping that's what it was. Is that not what you meant by "Consider inspecting the stator side seal too"?

The dealer is hours from where I live and its past the 30 days warranty.

 

[Jakobi]

Here in Australia its 12months warranty. You may find it worth while at least giving them a call.

The main seal sits behind the stator and flywheel. Means you need to remove the cover in your picture, plus a few more bits and pieces, and have the right tools to do so.

 

[memphis2857]

Yeah it should be at least 6 months. Maybe send Rod Overstreet a message and see what he can do for you


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[nestz]

True, the manual says 6mth factory warranty. I will find a local gas gas dealer and see what they say.

 

[Moto7man]

This is a link to my build thread from a few months ago. Go to post 19 on the thread which will show the basics of a leak down test for cylinder air leaks. It would be advisable to have someone experienced to help you perfrom the test. I ride in deep sand here in Florida and I am running a 178 main, 42 pilot.

http://www.gasgasrider.org/forum/showthread.php?t=19892&page=2

 

[nestz]

Update: I called the dealer today but he is unwilling to help because he said that a 'pre delivery inspection' was not done on my bike because it was a cheap deal - therefore he feels they are not responsible.

Is that fair? The warranty states:

"GG with this document guarantees the consumer in accordance with the
conditions set out below, the repair, free of charge, of any defect in materials or that might result from faulty manufacture that is detected
in a new motorcycle within the period covered by this Warranty and with no limit on number of kilometres covered or hours of use." "For
countries outside the European Community, the Warranty Period will be determined by the existing regulations in those countries. Nevertheless,
should the fault appear during the first six months after the delivery of the motorcycle, it will be presumed that the said fault existed
at the time of delivery" "Should the purchaser resell the product within the Warranty Period, the duration and conditions of the present Warranty will remain"

What do you guys think? I'm in New Zealand is there anyone I can talk to further up the GG chain who can help my case?

I asked him what he recommend I should do (given I mainly ride sand) he said, check air screw, put main jet back to 175, move needle to clip #4, and change oil ratio to 40:1, change radiator fluid. He said he wouldn't be too worried about how my plug appeared.

Do you guys agree with his recommendations? Also should I not be too worried about how my plug is snow white?

But aside from all that, I triple checked that the air filter is installed properly and it is.

I also checked the air screw as he suggested and discovered its 3 turns out - could that be producing a white spark plug right through the rev range or only on idle?

My next step is checking the float height but I doubt it will be on the lean side because it leaks fuel when on the side stand - is my thinking right with that theory?