Thanks Mason. I've been trying to get to the bottom of this for a few days now. I posted the same question on the Roland forums and received no answer. Go figure!
I posted another question a recently about bad contour cuts on a few forums, everyone suggested adding "all the pinch rollers", even though I added the details of my printer being the SP-300v. I think everyone who has the SP-540v assumes the SP-300v is the same. Unfortunately it isn't...
Thanks again,
Gene