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Gas Gas Rebuild

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Nisp
Scooby Slapper



Joined: 31 Oct 2010
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PostPosted: 11:39 - 25 Aug 2012    Post subject: Reply with quote

think you might need bigger washers, just because...

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253709Medium.jpg
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Last edited by Nisp on 16:11 - 25 Aug 2012; edited 1 time in total
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Ichy
World Chat Champion



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PostPosted: 12:22 - 25 Aug 2012    Post subject: Reply with quote

Thanks for the advice but that is the same size as the OEM washer. There is a very good reason why they are that size, want to guess why?

https://i93.photobucket.com/albums/l41/marki_03/bush.jpg
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P.
Red Rocket



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PostPosted: 13:25 - 25 Aug 2012    Post subject: Reply with quote

Filled with grease? Laughing
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Nisp
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PostPosted: 16:08 - 25 Aug 2012    Post subject: Reply with quote

so when doing maintenance you dont need to take to nut off? Laughing
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Ichy
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PostPosted: 17:15 - 25 Aug 2012    Post subject: Reply with quote

Nisp wrote:
so when doing maintenance you dont need to take to nut off? Laughing

Laughing

The washer diameter is about 2mm bigger than the bush. The bush is 1mm thicker than the dog bone.

Anyway. Going in head first I went for the brakes. As ever the pins were seized. Done now and the pistons are clean and moving nicely.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253714Medium.jpg

Next was the tank. It took a bit of time to remove the corroded fixing since I didn't want to risk damaging the tank. I epoxied in a brass insert. A bit of a clean and it'll be fine.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8253717Medium.jpg

I finally worked out where the coil fitted, obvious really when you see it in place. Still can't work out where to mount the CDI and I just realised that there isn't a hole for the horn to mount to the frame.
NEXT!!
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Ichy
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PostPosted: 14:58 - 26 Aug 2012    Post subject: Reply with quote

I ripped the end can apart today. It looks like the actual can will scrub up quite nicely. Not sure what to spray it with once it has all been cleaned? Normal lacquer should be OK shouldn't it?

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8263721Medium.jpg

I'm guessing this needs replacing? Last time I can remember working on a 2 stroke is so far in the past that I haven't got a clue what is good or bad.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8263720Medium.jpg

Any suggestions for stuffing? I don't have any fibreglass lying around so I was considering straw.
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daverwheeler
Renault 5 Driver



Joined: 27 Oct 2009
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PostPosted: 15:00 - 26 Aug 2012    Post subject: Reply with quote

I would leave the packing out and see how it sounds, it's what I've done with all my 2 strokes.
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CHR15
Turbo nutter bastard



Joined: 14 Jun 2008
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PostPosted: 15:02 - 26 Aug 2012    Post subject: Reply with quote

i think ive got a load of left over fibreglass packing if you want to call round mine after work on tuesday.
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stevo as b4
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PostPosted: 15:10 - 26 Aug 2012    Post subject: Reply with quote

daverwheeler wrote:
I would leave the packing out and see how it sounds, it's what I've done with all my 2 strokes.


Bet your neighbour's loved you mate! Laughing
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Ichy
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PostPosted: 15:31 - 26 Aug 2012    Post subject: Reply with quote

Cheers Chris. I'll be in touch Thumbs Up
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daverwheeler
Renault 5 Driver



Joined: 27 Oct 2009
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PostPosted: 16:42 - 26 Aug 2012    Post subject: Reply with quote

stevo as b4 wrote:
daverwheeler wrote:
I would leave the packing out and see how it sounds, it's what I've done with all my 2 strokes.


Bet your neighbour's loved you mate! Laughing


TBH with the bare baffles in they are not too bad. Honest!
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Kickstart
The Oracle



Joined: 04 Feb 2002
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PostPosted: 16:42 - 26 Aug 2012    Post subject: Reply with quote

Hi

Failing that a (not very long lasting) solution is glass fibre loft insulation.

All the best

Keith
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CHR15
Turbo nutter bastard



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PostPosted: 18:50 - 26 Aug 2012    Post subject: Reply with quote

Quote:
Cheers Chris. I'll be in touch


no worries, just dug it out. there's probably just enough to pack that can with.


if your popping round on tuesday, is there any chance i could be cheeky and ask if you've got a rear paddock stand i could borrow for a few days to swap the c+s and rear disk on my new bike?
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Ichy
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PostPosted: 20:05 - 26 Aug 2012    Post subject: Reply with quote

Sorry I sold the stands when I caught the ghey. I do have axle stands and stuff if it is any use?

2T noobie fail time. Crying or Very sad

I can't get it to run. Well not 100% true but here goes. I've filled all the fluids and filled up the carb with premix through a remote tank (pop bottle). Changed the plug and I definately have a spark. Choke has been tried on and off but it won't even back fire/pop/bang/anything. It will run for a couple of seconds if I spray carb cleaner into the carb. I've cleaned the carb twice, it's a real simple design and I cannot see any blockage.

Does the fact that it will run on carb cleaner mean that the piston timing, reed valves and everything else after the carb is working ok? Am I missing something obvious?
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CHR15
Turbo nutter bastard



Joined: 14 Jun 2008
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PostPosted: 20:11 - 26 Aug 2012    Post subject: Reply with quote

Quote:
Sorry I sold the stands when I caught the ghey. I do have axle stands and stuff if it is any use?


pair of axle stands would be spot on, if you don't mind. i can just sit it on the pegs
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HD
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PostPosted: 20:13 - 26 Aug 2012    Post subject: Reply with quote

Not sure what type of fuel pump it has but if there are two, have you got the fuel going to fuel and vacuum to vacuum? Jets screwed all the way in? Idle not set too low? Mixture screw set right?
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Kickstart
The Oracle



Joined: 04 Feb 2002
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PostPosted: 20:18 - 26 Aug 2012    Post subject: Reply with quote

CHR15 wrote:

if your popping round on tuesday, is there any chance i could be cheeky and ask if you've got a rear paddock stand i could borrow for a few days to swap the c+s and rear disk on my new bike?


I have a paddock stand you can borrow for a bit if you want

All the best

Keith
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Ichy
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PostPosted: 20:32 - 26 Aug 2012    Post subject: Reply with quote

HD wrote:
Not sure what type of fuel pump it has but if there are two, have you got the fuel going to fuel and vacuum to vacuum? Jets screwed all the way in? Idle not set too low? Mixture screw set right?


No fuel pump. I've never run the bike so I'm assuming that the screws are close to where they should be.
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Drake
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PostPosted: 21:21 - 26 Aug 2012    Post subject: Reply with quote

tried popping some 2t in the plug hole to up compression and help it is fuel getting through the reed valve and into the cases?
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woll
World Chat Champion



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PostPosted: 11:58 - 27 Aug 2012    Post subject: Reply with quote

Looking well Mark Thumbs Up
The carb settings should be the same as they've always been. I never fiddled with them. I had a similar problem a time or two. Make sure your getting a good strong blue spark, check that both ends of the ht lead have plenty of good copper there, check the connections to the coil. It was a pain a couple of times the connection to the coil. And check the coil is good. It was replaced not long after i got the bike by blacks.
Give it a kick, then check if the plug is getting wet. If it's not then that points to the carb being wrong. If it is getting wet, then it's possible the compression isn't high enough or spark problems.
I'd give it a try with a small amount of 2t down the bore, to help with compression. If it starts that way keep it running for as long as you can to bed the rings into the bore and up the comp. If that doesn't work it could be possible the crank doesn't have a long enough stroke if you changed it, or that the piston isn't the right size.
The horn IIRC was bolted onto a metal plate that bolted to the coil.
If you need any help give me a ring.
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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
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HD
World Chat Champion



Joined: 16 Dec 2009
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PostPosted: 13:42 - 27 Aug 2012    Post subject: Reply with quote

Marki wrote:
HD wrote:
Not sure what type of fuel pump it has but if there are two, have you got the fuel going to fuel and vacuum to vacuum? Jets screwed all the way in? Idle not set too low? Mixture screw set right?


No fuel pump. I've never run the bike so I'm assuming that the screws are close to where they should be.


Can't remember now but did you clean the carb?
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CHR15
Turbo nutter bastard



Joined: 14 Jun 2008
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PostPosted: 13:46 - 27 Aug 2012    Post subject: Reply with quote

Quote:
Can't remember now but did you clean the carb?


Quote:
I've cleaned the carb twice, it's a real simple design and I cannot see any blockage.




https://i939.photobucket.com/albums/ad233/chris-bracey/Megaman_Derp_1754708_2459276.jpg
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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.
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Ichy
World Chat Champion



Joined: 15 Jul 2005
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PostPosted: 14:00 - 27 Aug 2012    Post subject: Reply with quote

Thanks for the advice guys, especially Woll.

Karma is a bitch! Many posts ago I typed this
Quote:
FWIW the carb was as good as could be expected. Nothing needed to be done.

Turns out I was being a bigger noob than I though. I decided to strip and clean the carb for a third time and finally noticed that the needle valve was jammed shut Rolling Eyes No fuel in carb means no starty. Stripped and cleaned the valve and it started on the second kick. I ran it for a minute just to check. Tickover was very steady.

The kickstart was a bit knackered and I didn't want to spend the stupid amount that gasgas want for a new one so I fitted a small steel plate to take up the slack, works well for now.

https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8273726Medium.jpg

Spent a bit more time on the end can.

It went from this:
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8273750Medium.jpg
to this:
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8273751Medium.jpg
To this:
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8273753Medium.jpg
in a couple of minutes with the help of these:
https://i93.photobucket.com/albums/l41/marki_03/Gas%20Gas/P8273755Medium.jpg

I love the stuff. A 3m pad and Astonish oven cleaner is one of the best abrasive cleaners I've ever used. Best bit is that the cleaner costs just a quid. Not a lot I can do about the pitting but it should look better once it is fitted.
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HD
World Chat Champion



Joined: 16 Dec 2009
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PostPosted: 19:14 - 27 Aug 2012    Post subject: Reply with quote

CHR15 wrote:
Quote:
Can't remember now but did you clean the carb?


Quote:
I've cleaned the carb twice, it's a real simple design and I cannot see any blockage.




https://i939.photobucket.com/albums/ad233/chris-bracey/Megaman_Derp_1754708_2459276.jpg


1. Fhek.

2. I felt/feel so patronising giving someone like Marki advice when he knows so much more than me Laughing
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Drake
World Chat Champion



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PostPosted: 19:56 - 27 Aug 2012    Post subject: Reply with quote

dont then?
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