Carb tuning no idle

[waycrazy]

Here is the deal . My 03 EC300 doesn't Idle. Originally it was thought that my Pilot jet was to rich. And it ran like it was to. So I took the carb off and the first thing I found was the intake boot was torn. The jetting was #45 pilot #178main and #7 slide. The carb for the most part was clean as a whistle but there was a bit of crud stuck in the Pilot jet. So I blew out the Idle circuit and seemed ok . Replaced the the Pilot jet with a #38 and slapped it all back together. Thinking something of the above was the problem. Well the bike screams now.But still no idle and seems to be getting hot fast. Idle screw has no effect. And the idle/air has little effect . But if you screw out the throttle cable adjustment on the Throttle it idles fine. But I know this isn't right.So I am wondering if my needle is wrong or set wrong? Any other ideas?
Other info. I ride from 2000'-6600' elevation. I repacked the silencer when I changed jets.(It was plugged up )

[stainlesscycle]

been there.

either:
go to #8 slide
go to needle with thicker diameter

when you went to 38 pilot you probably got too lean. hence the hot and no air screw effect.

when you use the throttle cable adjuster you are bypassing the pilot completely.

if you go to a thicker needle (what needle are you on now?) you will need a much richer pilot...

[waycrazy]

Stainless to answer your question about the needle I had to pull the slide out. I have never inspected that part because I had found other things that I thought would cause the issues. Anyways my findings. The clip that holds the needle in position was broke. The 3rd notch that the clip was in is damaged. The needle was wore on the tip and there was a small ledge just above the tip.And I still have no idea what size needle this is. No markings and I don't have a micrometer.
So I am in need of a new needle and clip. I have seen weird things break on my jeep .But nothing on a bike like I have found on this one... Previous owner was really mean to this thing.
You can see the busted clip and the worn 3rd notch.

The worn tip and small ledge just above tip

[stainlesscycle]

that doesn' look good. if it has no markings, it's probably a ddk (it doesn't have a red or blue top right?). try a ddk or leaner (ddl/ddm) or cck/ccl/ccm you roughly need to go up a pilot size per each other step leaner needle. the dd/cc are straight taper needles with very linear power delivery and are pretty easy to jet. others have had good success with n1/n3 series needles and jd jetting needles.. the jd needles give a nice mid hit.


if it was my bike, i would get a ddk, cck, and either ddm or ccm. put the ddk in first, and try about 40 or 42 pilot. see how that works at 2000'.

178 and 45 are probably way too rich for those ddk/cck needles at 6000', but start rich, see where it burbles, then work down.

if it still refuses to idle, put the ddm in with 42 or 45 pilot...

[waycrazy]

Thank you for the suggestions . I had thought about getting the JD kit.But for about $80 more I can have RB designs work it over. All though I might pick up a needle for my main and call it good until the snow fly's. Decisions,decisions. It seems no matter which route a guy goes it isn't cheap and full of testing . I think the multiple R&R on the jets is what will drive me nuts!

[biggstr6]

I was thinking the same. I was spending all this money on jets and needles on my 36mmm carb (ktm needles were $19.00 each,YZ needles $12.00 each) . I finally said I can get RB to fix it up right and be not too far off on the price , and have a better carb.

I should be getting it back in a day or so.

[waycrazy]

I would like to thank everyone for posting up help. I do appreciate the knowledge.But I decided to send my carb of to RB designs. Let them bear the headache.

[waycrazy]

Well got a reply back from RB designs . I dont feel so bad now . No matter what I had done at home I would have never got this thing to tune. They said everything that could be bad was. So I am on the hunt for a carb...

[waycrazy]

Just a update to let everyone know How my problems were solved. I bought a new carb from RB designs and they did the mods . I emailed Ron to check what settings worked best for a base because at first my bike would instantly wet the plug and no spark. Ron called about a hour later and spent 20min. Making sure everything was ok. I was really impressed with his service . I only expected a return email . I have nothing but praise for his business now.The bike now pulls like a freight train!!! And of course idles well.