Resend my activation email : Register : Log in 
BCF: Bike Chat Forums


Gas Gas Rebuild

Reply to topic
Bike Chat Forums Index -> Show & Tell Goto page 1, 2, 3, 4, 5, 6, 7  Next
View previous topic : View next topic  
Author Message

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 16:18 - 26 Nov 2011    Post subject: Gas Gas Rebuild Reply with quote

I'll start with these.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PB260778-1.jpg

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PB260779-1.jpg

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PB260780-1.jpg

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PB260781-1.jpg

I picked up this EC250 from Woll earlier today. The overall condition is better than expected and this 'might' be an easy project to work on over the next few months.

The plan is to first put it all back together and get it running. It definately needs new reeds, a gasket set and possibly a new piston. Once I start building it I should get a good idea of any parts than are missing or need replacing. I'll then strip it back down and start tarting it up. The main task will be cleaning it all, the main frame could use new powdercoat and the loom needs replacing to tidy it up.

Cheers Woll, should be fun.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/


Last edited by Ichy on 11:43 - 26 Aug 2012; edited 1 time in total
 Back to top
View user's profile Send private message You must be logged in to rate posts
N cee thirty This post is not being displayed because the poster is banned. Unhide this post / all posts.

woll
World Chat Champion



Joined: 01 May 2010
Karma :

PostPosted: 20:05 - 26 Nov 2011    Post subject: Reply with quote

Have fun Thumbs Up have to bob up on it when it's going again, be good to see it running again.
N rob it did get loved, up until it broke 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
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

The Artist
Super Spammer



Joined: 06 Jan 2008
Karma :

PostPosted: 21:27 - 26 Nov 2011    Post subject: Reply with quote

You need to buy a bike off Chris next Laughing
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

.....
Quote Me Happy



Joined: 15 Jan 2005
Karma :

PostPosted: 21:29 - 26 Nov 2011    Post subject: Reply with quote

Good luck with it, cracking bikes, looks like it's got some bling yokes Thumbs Up
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 22:24 - 26 Nov 2011    Post subject: Reply with quote

According to the previous owner it has some special parts on it. Ohlins rear shock, excel rims, billet yokes, and the front forks are 'something' but I don't know what Laughing. Most of this means very little to me to be honest.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

reggie
Spanner Monkey



Joined: 22 Dec 2009
Karma :

PostPosted: 23:06 - 26 Nov 2011    Post subject: Reply with quote

want a newer swing arm of a 2006 one ?
____________________
when the shit hits the fan make sure its facing the other way.
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 23:42 - 26 Nov 2011    Post subject: Reply with quote

Why? What difference would it make?
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

Welshd1k
World Chat Champion



Joined: 03 Oct 2006
Karma :

PostPosted: 03:55 - 27 Nov 2011    Post subject: Reply with quote

they all had ohlins and mazurochi forks i thought...
____________________
Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<
 Back to top
View user's profile Send private message You must be logged in to rate posts

.....
Quote Me Happy



Joined: 15 Jan 2005
Karma :

PostPosted: 13:57 - 27 Nov 2011    Post subject: Reply with quote

Up until 2008ish they had Marzocchi forks and Ohlins rear, unless you got the Ohlins fork version.
 Back to top
View user's profile Send private message You must be logged in to rate posts

reggie
Spanner Monkey



Joined: 22 Dec 2009
Karma :

PostPosted: 18:23 - 27 Nov 2011    Post subject: Reply with quote

basicaly the same just newer looking only want 10 for it as it taking up room
____________________
when the shit hits the fan make sure its facing the other way.
 Back to top
View user's profile Send private message You must be logged in to rate posts

.....
Quote Me Happy



Joined: 15 Jan 2005
Karma :

PostPosted: 08:18 - 28 Nov 2011    Post subject: Reply with quote

One thing I've remembered, there's some parts from other bikes that fit and there's a list here

https://www.gasgasrider.org/html/parts_crossover.html

It came in useful a couple of times.

For spare parts I've used Gas Gas UK but they have sent me the wrong bits before. I used https://www.biketechuk.co.uk/ - very helpful as well, whenever I ordered stuff he always gave me tips on how to go about fitting etc.
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 13:10 - 28 Nov 2011    Post subject: Reply with quote

Thanks Joe, I've already joined the gasgas forum. Very Happy

What is surprising is the general lack of info and part suppliers. I guess that's the price of having a smallish brand.

I'm weighing up the idea of splitting the cases and changing the main bearings. There doesn't appear to be a problem but it would be good to know that they were right and to also inspect the gearbox. We'll see.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 19:06 - 11 Dec 2011    Post subject: Reply with quote

Slow but sure. I decided to strip the engine.
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PC110799Copy.jpg

Pretty worn out clutch plate.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PC110798Copy.jpg

Interesting, a loose crank stopper. I can only assume that it became dislodged when the bike was transported. It looks like it has come into contact with the con rod a few times.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PC110801Copy.jpg

I've messed around a bit looking for a reliable spares supplier. Just waiting for the fly wheel puller so I can split the case and check the main bearings.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

mattsprattuk
Super Spammer



Joined: 12 Mar 2007
Karma :

PostPosted: 20:12 - 11 Dec 2011    Post subject: Reply with quote

Why do you need to split the casings to check the bearings? Confused
____________________
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!! Mr. Green
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 20:20 - 11 Dec 2011    Post subject: Reply with quote

Bad wording.
I want to paint the cases and change the bearing and seals while I have it open. Cost is less than a tenner and it gives me something to do.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

reggie
Spanner Monkey



Joined: 22 Dec 2009
Karma :

PostPosted: 10:48 - 12 Dec 2011    Post subject: Reply with quote

the main berings are expensive to replace mightaswell replace the rod while your in there what make is the rod
____________________
when the shit hits the fan make sure its facing the other way.
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 12:02 - 12 Dec 2011    Post subject: Reply with quote

reggie wrote:
the main berings are expensive to replace mightaswell replace the rod while your in there what make is the rod


I get the bearing online. Working from the fiche I get a size of 30x72x19. SKF 6306C3 are around £8 +vat. The C4 version is £20.

Not something I'm planning at the moment but the con rod is the same as fitted to the earlier CR250 as is the piston, total cost is around £130 for parts although I would have to get a price for spliting the crank, I think it was around £25 last time.

My budget for the bike is going to be around £300. Doesn't seem a lot but the majority is superficial, more labour intensive. That said, parts are expensive and I've already spent £100 on just the reeds and gaskets. I'll see how it goes.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

reggie
Spanner Monkey



Joined: 22 Dec 2009
Karma :

PostPosted: 12:53 - 12 Dec 2011    Post subject: Reply with quote

getting the rod pressed in is 75 quid INC THE ROD

seem silly not to do it now as a fullgasket set is over 30 and risk having to do it in the future
____________________
when the shit hits the fan make sure its facing the other way.
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 13:11 - 12 Dec 2011    Post subject: Reply with quote

You are probably right about the con rod and that's better than I expected, where did you get that price from? The quotes I got for an oem gasket set were around £70+ Shocked . I finally found a copy for £30. I have a lot of gasket paper in the garage so I'll copy a couple of the useful ones just in case.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

woll
World Chat Champion



Joined: 01 May 2010
Karma :

PostPosted: 20:02 - 12 Dec 2011    Post subject: Reply with quote

Wow can't believe how worn the clutch is. Never has a problem with it Confused
____________________
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
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 20:16 - 12 Dec 2011    Post subject: Reply with quote

It probably wouldn't have made much difference, I personally feel that you lose some of the feedback with hydraulic clutches.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

woll
World Chat Champion



Joined: 01 May 2010
Karma :

PostPosted: 21:17 - 12 Dec 2011    Post subject: Reply with quote

Yeh i found it a lot sharper than a cable one.
____________________
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
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 22:08 - 14 Dec 2011    Post subject: Reply with quote

Clutch cover off. Looking fine in there.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PC140823Small.jpg

The puller arrived so off with the bits on the other side.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PC140815Small.jpg

I guess this might be the reason for oil on the generator side.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/PC140812Small.jpg

No play in the crank so I guess it was just not fitted correctly at some point.
All being well I should be able to measure up the barrel, piston, and rings tomorrow to find out if I need to replace anything.
So far the costs are.

£32 gasket set
£11 puller

Parts to replace.
Clutch plate or complete clutch kit £10 - £60
Reed valves £30 - £80
Powervalve bearing - £3

I guess the list is only going to get longer.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts

Ichy
World Chat Champion



Joined: 15 Jul 2005
Karma :

PostPosted: 14:29 - 15 Dec 2011    Post subject: Reply with quote

Everything measured.

Barrel first. Average is around 66.41 against a spec of 66.38 - 66.5 so that is fine.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/SDC10982.jpg

Some ovality but nothing significant.

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

Piston next.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/SDC10985.jpg

it was looking a bit rough so I wasn't surprised that it measured quite a bit undersized. It should be around 66.33mm, but measures on average around 66mm. The limit between bore and piston is only 0.1mm.

Piston rings are good but they will be scrapped since I'll get a piston kit.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/
 Back to top
View user's profile Send private message You must be logged in to rate posts
Old Thread Alert!

The last post was made 12 years, 107 days ago. Instead of replying here, would creating a new thread be more useful?
  Display posts from previous:   
This page may contain affiliate links, which means we may earn a small commission if a visitor clicks through and makes a purchase. By clicking on an affiliate link, you accept that third-party cookies will be set.

Post new topic   Reply to topic    Bike Chat Forums Index -> Show & Tell All times are GMT + 1 Hour
Goto page 1, 2, 3, 4, 5, 6, 7  Next
Page 1 of 7

 
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You cannot download files in this forum

Read the Terms of Use! - Powered by phpBB © phpBB Group
 

Debug Mode: ON - Server: birks (www) - Page Generation Time: 0.12 Sec - Server Load: 0.05 - MySQL Queries: 17 - Page Size: 136.44 Kb