Gas Gas Rebuild

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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N cee thirty · Banned Joined: 31 Jan 2010 Karma :

cool,look forward to it getting some love
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

woll · World Chat Champion Joined: 01 May 2010 Karma :

Have fun

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.
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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

The Artist · Super Spammer Joined: 06 Jan 2008 Karma :

You need to buy a bike off Chris next Laughing

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

Good luck with it, cracking bikes, looks like it's got some bling yokes Thumbs Up

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

want a newer swing arm of a 2006 one ?
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Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

Why? What difference would it make?
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Welshd1k · World Chat Champion Joined: 03 Oct 2006 Karma :

they all had ohlins and mazurochi forks i thought...
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

Up until 2008ish they had Marzocchi forks and Ohlins rear, unless you got the Ohlins fork version.

reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

basicaly the same just newer looking only want 10 for it as it taking up room
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..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

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.

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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MaybeGuy · Super Spammer Joined: 12 Mar 2007 Karma :

Why do you need to split the casings to check the bearings? Confused

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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!! Mr. Green

Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

the main berings are expensive to replace mightaswell replace the rod while your in there what make is the rod
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Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

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
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Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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woll · World Chat Champion Joined: 01 May 2010 Karma :

Wow can't believe how worn the clutch is. Never has a problem with it Confused

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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

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

It probably wouldn't have made much difference, I personally feel that you lose some of the feedback with hydraulic clutches.
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woll · World Chat Champion Joined: 01 May 2010 Karma :

Yeh i found it a lot sharper than a cable one.
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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

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

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.
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