Gas Gas Rebuild

[woll]

WOW looks like a totally different engine
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[dangerousdave]

some great work there - looking forward to seeing more progress
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

[Tim..]

Looking good

Keep the faith
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Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[Ichy]

Question time.

Worth repairing or replace?
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P3252125Large.jpg

Any ideas on the cost or if it is even feasible to repair?

What is it?
What does it do?
Is it knackered?
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P3252126Large.jpg

I know Woll had a few electrical problems. Not surprising really.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P3252129Large.jpg

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P3252130Large.jpg

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P3252131Large.jpg

I'll probably rewire the lot. It should be a fairly small loom anyway.
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[mattsprattuk]

Poor electrics? It could be worse... Much worse.
This was on my CRF250

https://img710.imageshack.us/img710/171/38005210151086090095517.jpg
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[Ichy]

[woll]

I may have made the wiring a bit messier I wired in the trailtech killswitch & light controls cos the original was rusted up to buggery. and I put a trailtech regulator in, don't remember changing the wiring for that though.
Was the stator ok? Seem to remember some of the coils being a bit black, not sure if it was just crap or burnt.
____________________
Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[.....]

That "What is it?" bit is a rim lock. Locks the tyre to the rim so you can run very low tyre pressures. That looks like it needs replacing, they're not expensive.

[Ichy]

[Ichy]

[woll]

Probably down to me cleaning it all the friggen time, or the missus cleaning it last time (teaching her slowly) Get a good fuel filter on it, or you may end up doing the same.
____________________
Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Ichy]

Damn! 3 months later. To be fair I have spent the best part of two months out of the UK. I haven't been entirely negligent, things are slowly moving on.

Every single bearing on the bike was finished.
Headstock, knackered.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243080Medium.jpg

The twelve bearings in the rear suspension? Dead.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243081Medium.jpg

I'm pretty glad that I ripped it all apart now. There were several areas of the frame that had suffered damage including half of the sub frame diameter being eaten by the chain, the rear sub frame for the seat was broken on one side and cracked on the other. The sidestand bracket was cracked at least 70% of the way through and the swingarm had been gouged where the chain had eated through the chain guide.

Meh, no point whinging about it, I just welded it all up and cleaned it to make good.

At the moment one pile looks like this.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243087Medium.jpg


BUT......


The other pile looks like this.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243098Medium.jpg

Now this is the good pile. I was going to get the frame powder coated but the problem was that it was chromed. The powder coat was going to cost £100 but he wanted the frame chrome free. The nearest place wanted another £90 to strip it . It was never going to happen.

What did happen is that it ended up painted it with epoxy paint. Very hard wearing and it is more plastic than powder coating which means that it can take knock and bumps far better. I did have to get it sandblasted to give a good surface to prime to and I'm pretty pleased with the results. It isn't perfect, no point really, and I should have spent a bit of time filling in some of the bigger damage to the metal.

Shock spring. Need to clean up the body next.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243088Medium.jpg

Swingarm.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243089Medium.jpg

Ummmmm. I need to source some stickers.

Subframe
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243090Medium.jpg

And the frame.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243091Medium.jpg

I'm really pleased with the finish although being honest I would have prefered a satin finish. Looks good though.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243094Medium.jpg

I'm just waiting on some 'o' rings before I can start assembling. It shouldn't take too long.


In the mean time I decided to make some dog bones. At a guess Woll is at least 9 inches taller than me. The first time I got on the bike I couldn't get off. I could buy 126mm dog bones that will drop the rear by 1 inch for around £70 but where is the fun in that?

First I rough cut them from billet with a hacksaw, drilled them as a pair, reamed to size then clamped and started filing.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243085Medium.jpg

After a short time (yeah right) they started to look like this.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6243086Medium.jpg

Still a fair bit of work involved to shape them. The bigger problem is that they should be 10mm thick and the only material I had was 12mm. I initally thought it would be ok but I now think that I'm going to have to convince someone to remove 2mm from them to get them closer to original. Oh well, could be a fair few hours sanding involved otherwise.

So there it stands. I need to buy a few bits and I'm sure that I will find a few more things wrong but it is moving in the right direction.
____________________
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[woll]

Fair play looking well now mate

It's not that high on the standard dog bones Bit short for me lol
____________________
Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[CHR15]

[Ichy]

Thanks for the offer Chris. The overall shape will be fine, I need the exercise. It is just the thickness that might cause problems.
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[CHR15]

milling isn't an issue
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Ichy]

Well the engine is almost in the frame for the first time in ages.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6293103Medium.jpg

Only problem I can see is that there is a big gap between the engine and swingarm, same both sides.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P6293106Medium.jpg

What's missing? I didn't remove the engine so I'm not sure if there should be a spacer. Nothing is obvious in the parts manual. Any idea Woll?
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[woll]

Got me thinking now lol, was a good while ago that engine came out. If i remember rightly I put the swingarm pivot back through after i took the engine out with anything that was inbetween on the pivot. I always put nuts and bolts back on when i take something off so I don't loose things
____________________
Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Ichy]

Ahhhh but remember you fitted the swingarm back on, with a broken arm, so that I could push it on the trailer. I'll try the gasgas forum. Looks odd though.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[woll]

[Tim..]

Yes! Aww sum. Good update
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[Ichy]

[woll]

Don't leave us on a cliff hanger....
____________________
Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Suntan Sid]

Any progress lately?
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"Everybody needs money, that's why they call it money!"

[Ichy]

Funny you should ask. I actually took a day off work yesterday just to spend time in the garage with this bike.

One problem is that when I picked up the bike it looked like this.

https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/375719_10150459108402079_602342078_10277972_1277511743_n.jpg

There isn't much info out there on these bikes so working out where bits go hasn't been that easy. This is a bike that has had a hard life and the amount of wear means that more parts than expected have needed changing or repairing. This is the first project Enduro that I have owned and it will be the last, they are built to be abused then thrown away.

Carrying on from the last post the dog bones came out ok with the use of an angle grinder and a file

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253709Medium.jpg

Once I got going it didn't take too long to get it to this point. That rear wheel took a hell of a lot of cleaning!

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8233695Medium.jpg

I actually took a video of the bike starting in that condition, no carb slide, loose plug and loose wires, but I forgot to turn the sound on It actually fired up pretty good so at least I know it will start

The front end has been completely rebuilt and does feel quite good. Bars were replaced due to loads of wear on the throttle.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253711Medium.jpg

Thanks to Covdude for the replacement Renthals. Superb condition and a perfect match for the originals.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8243702Medium.jpg

Rear shock is looking pretty good with a bit of carbon wrap for show.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8243700Medium.jpg

I spent a total of about 10 hours in the garage and only got to this point. Rads scrubbed up nicely.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253705Medium.jpg

Every little job was an uphill struggle. Still felt good at the end of the day though. Zorst was only fitted to work out the path. I'm going to give it a good scrub down and paint it with barbecue paint.

Wiring has gone ok other than working out where bits go. I still have no idea where the coil and ECU are supposed to be mounted.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253710Medium.jpg

Still a lot of work to do, brakes being one of the next big ones. They are not in great condition but I have little choice but to work with them.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253712Medium.jpg

Still a fair bit to go. Roughly £50 of spares required to finish the build. Most of it is stupid little stuff, special fixings and clips that I can only get from Gasgas. I then need to get the front wheel sorted. The rim isn't round and I have no idea how to tighten up the spokes to sort it out. Actually I have no idea if it can be sorted. There is a spinning fixing in the fuel tank that is supposed to secure the side panel. I know that is going to be a pain to sort.

No work until Tuesday so lets see if I can get a bit more done.
____________________
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