Problems with my Gilera Cougar 125 :(

scottmaster91 · L Plate Warrior Joined: 01 Apr 2015 Karma :

Hello their, im struggling with my new bike i have just purchased. Ive had the bike around 2-3 weeks and all i have had is problems with it.

Basically the bike starts up and will run for a random amount of time, then just cuts out regardless of throttle position. I can even be riding the bike at 20-30mph and it just cut out. Most of the time it will restart back up, but sometimes its not.

The plug is very black and the bike seems too be over fueling. But i and other garages who have tried too repair the bike cannot gather why.

Does anybody know what size jets are meant for it? One mechanic said 38s?others said 35?

The bike has had a new iridium plug, new coil and lead, compression is good at 160psi, Its had a new battery,a new air filter and valve clearances checked and fuel lines checked.
Any help would be greatly appreciated.
Thanks.

finniee · Spanner Monkey Joined: 03 Jul 2013 Karma :

https://www.bikechatforums.com/viewtopic.php?p=2444094

Could you not buy the carburetor repair set and replace the jets from that into your carb?? or replacing the float needle ?.
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Honda CBF125

StormCrow · Scooby Slapper Joined: 14 Mar 2010 Karma :

'Cuts out' in what way?

Splutters to a halt as if you've run out of fuel, or engine dies completely like you've hit the kill switch? When you say a random amount of time, we talking 30s - 5 minutes or half an hour?

Sounds electrical to me to be honest - I had a Coguar and they're hardly complex machines, although very 'vibey' so something may have worked loose or a fractured wire somewhere?

Mine had a fault with the side stand - the switch was getting 'tetchy' and it made the switch very sensitive - to the point where you'd hit a bump and it'd cut out...

I've got the manuals on a CD somewhere if you want it...?

scottmaster91 · L Plate Warrior Joined: 01 Apr 2015 Karma :

the spark plug gets black very quickly and it will just splutter when cracking the throttle in idle and usually cuts out as soon as you release the throttle its been at a motorcycle garage for the last 3 days but he cant seem to find the issue and its like hitting the kill switch yes, the bike will just die ive checked and cleaned the side stand switch just in case it was that but it wasn't when i first got the bike 3 weeks ago i could ride it for the first day but the second day i set of to a friends and got half way but it cut out i tried to start it again but it wouldn't , it decided to cut out in 4th gear riding along at 40mph and i was left at the side of the road which was a little scary , but seen as a motorcycle mechanic cant find the fault im kinda stuck as ive only got basic knowledge wen it comes to motorcycles -

But he could not work out why the spark plug was getting so black so quickly he had tried everything - ( so im told anyways )

apparently it has a 38 pilot jet in the carb but ive been told it should be a 35 but not 100% sure the guy from the garage told me to look it up

he also told me it could be timing but if its getting 160psi then i dont think it would be an issue would it ?

any help or advice would be great would just like to get back on the road

Ariel Badger · Super Spammer Joined: 02 Dec 2006 Karma :

He has not tried everything otherwise it would be sorted, did the Muppet charge you? First thing I would be looking at is the choke staying on and then air filter.
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Bikers make great organ donors, get 115 on your licence today.

temeluchus · World Chat Champion Joined: 01 Oct 2008 Karma :

scottmaster91 · L Plate Warrior Joined: 01 Apr 2015 Karma :

yes i got charged £55 , and came away with loads of stuff to try felt a little like im coming away doing his job - and has a new filter

finniee · Spanner Monkey Joined: 03 Jul 2013 Karma :

Aye sounds it, did you get a record of what the guy has done?.
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Honda CBF125

scottmaster91 · L Plate Warrior Joined: 01 Apr 2015 Karma :

no i didnt get anything what so ever for what he had done but they are now on holiday for 2 weeks so cant contact anyone

cheeseman · Trackday Trickster Joined: 11 Jun 2014 Karma :

Bet it's something silly like a faulty sidestand switch. Bit of a PITA to test without doing a swap or (shudder) bypassing the thing.
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XJ600S->Sprint ST 955i * ; Now ST1100 + W650

scottmaster91 · L Plate Warrior Joined: 01 Apr 2015 Karma :

ive had a fiddle and its now running for long periods of time after around 10 cut outs in a morning but is still cutting out almost when it cools down compression is 155-160 but when it does cut out you hear like a click or a pop almost then it just dies i tried getting it running and flipping the kill switch to see if it sounds the same but it doesn't do you reckon it could be the relay starter , after a good few times of the bike cutting out , i can ride it around my area and seems to be fine but will just randomly go so dont trust it going anywhere as i dont think i would get back

Ted · World Chat Champion Joined: 26 Mar 2006 Karma :

My Coguar had terrible wiring, which had then been bodged further by the previous keeper.

I'd be tempted to check over all cables, to see if there any broken or rubbed wires. It's a long and boring job, but that might be why the mechanic didn't do it...