Finally figured out the 2002 Montesa carb problem. Actually, there were a combination of adjustments & problem resolutions:

1) Round, black cap bolts on top of carb. were loose. Torqued them down accordingly.
2) Float arms were way out of tolerance. They were at 23mm. I adjusted them down to 18.5 mm as per spec.
3)Moved the Needle clip down 1 slot.
4) Set air screw at 2 turns out.
5) Thoroughly cleaned entire carb w/carb cleaner & blew out w/compressed air.
6) Replaced throttle cable w/new stock cable and re-routed as per Owner's manual.
7) Installed new, slow (black) bushing in throttle housing.

The stalling out condition in tight turns was due to the Kill Switch wires tightening up under load that activating the Kill Switch (not fun in the middle of a jam).

Rode for 2 hours out back. It was a great feeling!

John / Gordon / Chad / Rick - let me know when you go riding at TNT, again.

Gordon - if you need anything in regards to the move, just let me know. I'm not too far away.

Thanks All,
Doug

Doug glad to hear your bike is running good again ! I am moving as we speak!! You can reach me at 803-315-6034 Cell,I will not be close to my pc for a while & don't have a home phone yet .I may take up your offer to help on some of the heavy stuff ( my wife had back surgery so she can only do so much) I plan to bring my bike with me today so I can plan a trip to TNT soon .Cheers Gordon

good job, Doug.

I had a air leak problem one time (sensitive connection between carb and air boot) which caused a crazy idle.

it sounds like you went through and got all the pieces good to go.

see you soon

Gordon,

I will catch up with you soon. I've been real busy with coaching my son's basketball team & getting things in order at work.

btw - I just purchased one of those Radio-controlled nitro fuel vehicles. These things are really cool - super-tiny, 2-stroke motors that can move the truck up to 40 mph. Sort of funny to see.

What's your direct e-mail?

Mine is below.

Doug
skeetzy@msn.com

Doug,
I have those r/c vehicles as well. I have a r/c planes. You wanna talk about expensive!!!!

Yeah, I know, they are really pricey. Kind of finicky at least for breaking in - the temp. needs to be 70 degrees. I'll wait & break in when the temp. goes up. I bought a Traxxas Monster Truck. I didn't want to get an airplane because they are really hard to fly & I can't imagine wrecking one at such an expense.

I had a buddy who got into RC helicopters...
After his fourth good crash , his wife took his credit cards away !!!! (to save the marrige!).

Make sure if you are breaking the engine in, you have a temp gun. After years of racing cars and trucks, that is a must. You dont want to exceed 225 degrees. Tuning those can be a bit tricky, more so than what you were dealing with on your cota.


Raytech makes a nice one for about 70 bucks.
T-maxx is notorius for tuning problems, revo is much easier.

I'll take the bait, I'm looking at one of those
nitro Ducuti rc bikes! Way cool! Other than that,
I'll go with an electric RC rock crawler!

Micky,
get the softer compound tires if you get the ducati. It makes a world of difference in handling. However they do wear out , just like real bikes. You can smoke'em down.