Spent the last few weeks just lurking about here, as for the honest to god truth, don't seemed to be real welcome here by some of you. Fortunately for us, the folks a Cannondale do indeed seemed very enthusiastic about our special project. It is because of that I decided to post this thread. We took our Cannondale engined Superkart to Laguna Seca recently for the World Superkart Challenge. We were one of two 4-stroke karts entered. Thursday, we discoverd the engine produces more heat then the trx250R we had run previously and only got a few laps in each session before hitting 220+F. FInally with an additional radiator plumbed in and some ducting, got it down to the 170-180 range, right where Mark S said we should shoot for. According to the Air/fuel meter we installed, we were rich at idle, but lean across the board above that. No more practice that day, so back to the hotel with the laptop. Decided to just alter the base X440s fuel map wiht a universal 10% increase above a TP of 10%. And set teh rider trim for digital jetting, so he can tuen it with teh help of the A/F gauge while out on the track. Up unitl this point the two times we had the thing out, it started everytime and ran fine. Got to the track the next day,hooked up the lap top and downloaded the modified map. Wouldn't start. No other changes made. Noticed teh fuel pump was running on. Finally, just pulled the plug on the fuel pump. It quit of course and when plugged back in it was not running. Still wouldn't start. Switched to the D&M program. no faults registering. Checked the engine cal file. WHAT the H??? It had both throttle values at 5.0 The Injector flow was at 20,000 and the offset was 1.99. Gee, no wonder it wouldn't run!! THought I must have screwedit up with my 1st map creation attempt, so went and downloaded the standard base map. AFter a fair amount of cranking to clear it out, it started right up and seemed to be running fine on the stand in the pits. Shut it down. Get ready for our one practice of the day ( sharing the track wiht ALMS, Formula Mazda, SpeedVision Challenge). Get teh signal to fire up and hit the track. No go, fuel pump also running on again. Run and grab laptop and plug in and check cals. Its back to teh 5.0-20,000-1.99 settings. Was running fine when we shut it down. Reload map, but it is flooded and runs the battery down trying to clean it out. Charge the battery, check all the connectors, etc. Everything looks fine. After a while, it fires up after charging the battery and reloading the map again. Get ready to go out for qualifying. Won't start and pump is running on. Check cals again. Throttle values ok, but injector flow is back to 20,000 and offset 1.99. ???? reload map, but again flooded and won't fire. No qualifying. If able to get it going will start 32nd. Can't figure this out. Get back to hotel and get online and go to the Cannondale website. Find there is a dealer in Salinas, about 10 miles from the track! Get to track Saturday am. Check and the cal file is all corrupted again. Send Stephanie to call the dealer and see if she can get directions. The dealer is Pinit Motorsports. She talks to a gentleman named Steve and tells him we have a Cannondale Superkart ( he already knew we were there from his friend Wayne Rainey, who told him there was a Cannondale on the entry list!), and tells him what it is doing. This dealer, who doesn't know us from Adam, who didn't sell us a thing, and who doesn't care that this is a kart and not a bike or quad, volunteers to come out to Laguna and help out. We rush around to get him the proper pit credentials and meet him at the gate. He rides in on his bike with his laptop and all...and a spare ECU!!! We, well mostly Steve, tried everything with the unit. WOuld still kick out those bizarre engine cals once in a while. Fuel pump would also run on at times. Once while the fuel pump was running, we unplugged the GP control harness and it quit. Plugged it back in and the pump started running again. Steve checked the wiring harness and all.... fuel pump wiring was ok at teh pump and wasn't grounding itself out. (We are running the completely stock harness) Everything was fine. Plugged in his ECU. Wouldn't communicate with my software, but also wouldn't with his dealer software. ?? Back to the original ECU. Finally got some settings in it that it would start and run.....just minutes before the cal to teh grid for the pre-final het race. Start teh single cylinder ICE class in 32nd. Comes around after one lap in about 16th. Comes around the 2nd lap and pulls into the pits, engine still running. This was the first time we had the chance to run it at 100+% effort in racing conditions. The motor bent teh 1/2 in steel rod used as a chain tensioner/engine stop, and twisted the bearing hanger it was attached to to the point it pulled some of the bolts right out of the axle cassette. A little bit of torque there!! The set-up had worked fine on the 250 2-stroke singles we ran. Disappointed to drop out, but passing about 15 karts in one lap showed some potential there. Spent what time we had Sunday welding braces on teh bearing hangers and strengthening the rear assembly. Got it done about 15 minutes before race time for the final. Gremlins crept in again over night and when we hit the green button, there went the fuel pump again and a quick hookup showed the cal file corrupted. Reload the map, but it is flooded. Battery getting weak as we crank it. Hook up a charger. finally get it to fire and try to run, but when we disconnect the charger, it quits. Don't make the grid for the race. Get back to Michigan. Call Cannondale, Call Scooter at GP, call the dealer we got it thru, Team Highland. Scooter has us send him the complete GP controls wiring harness, as he wants to check that out for any shorts. Also has us send him the ProCal disc, as when we go it, it loaded fine on the desk top, but wouldn't load on the laptop. Had to burn a CD from off the desk top to get it to load. SO he wants to check CD. Scooter says he has seen this once or twice before. The Engine cal files we kept defaulting to are the maximum values for those parameters. Never did figure out what had happened to the other units that did this. THinks the hex files got corrupted somehow. Marc also wasn't real sure just what was going on. Steve from Pinit called Mark also and told him what he had experienced wiht the system when he came out to check it. Dennis from Highland also called and talked to the C'dale office. Conclusion, the are sending us a new ECU. Whether it was Pinit, Highland, GP Control, or Cannondale itself, we have had nothing but impressive service to say the least from these folks. Don't think I would have gotten it from Honda or Yamaha. Sure it was disappointing to travel nearly 6,000 miles round trip and then not get to race, but with the response we have had from all these folks, I don't feel so bad about it. I do not feel like I am on my own I would have likely been with some other brands. BTW, the crowds loved the Cannondale kart. When not working on it and setting it at the end of our pit, wasn't unusual to have 5-10 people gathered around, more than around any other single kart. Firing it up in the pits always drew a crowd. People came by after hearing it run out on the track and the consensus opinion seemed to be that it sounded like a Ducati Superbike! If/When I here as to the cause of this corruption of teh system, will let you guys know if anybody is interested. OBTW, for those with the GP control system, know how you can nickname your ECU...well, when we got our set-up, we nicknamed the ECU "Christine"!