Gas Gas EC250 Project...

[woll]

Finally got the gas gas home from work. The tart up has begun...
This is how it started out...
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/264583_10150279353097079_602342078_8904433_1939530_n.jpg
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/264902_10150279353362079_602342078_8904437_3551894_n.jpg

My original plan was to clean the carb, wack a new coil on, comp test to check if it needed a rebuild, possibly rebuild and then polish the frame and clean and polish wheels and swingarm.

But i started the strip down (got the missus to help ). Took the tank and panels off. Took the carb off, the missus cleaned the outside. I thought i'd have a peek at the reeds and found this:
https://i649.photobucket.com/albums/uu211/whalley1992/37b598b5.jpg
Of course this means I needed to find it in the engine. Strip down it is then
Swing arm out :
https://i649.photobucket.com/albums/uu211/whalley1992/13b990ea.jpg
Then the f-ing and blinding began lol disconnected everything had an absolute mare getting the mounting bolts out, eventually brute force and ignorance prevailed and they were removed. Next problem getting the engine out, i got it so far then it got jammed on the kick starter. I was pissed off so my size twelve dealer boot made it leave the frame.
https://i649.photobucket.com/albums/uu211/whalley1992/734d9ef8.jpg
Quickly whipped the head off and found the peace of reed valve i was looking for. You can see it melted onto the top of the piston.
https://i649.photobucket.com/albums/uu211/whalley1992/885e754a.jpg
Might as well rebuild the engine while im in there. The piston has some movement in the barrel, so I think it's due lol.

so my next job is try and find the letter stamp so i know what size piston kit to buy. Whip the barrel off all together.

does anybody have a workshop manual for a '98 EC250? not sure how the power valve works on one of these and don't want to knacker it taking the barrel off.
____________________
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

[woll]

Going to have to put it on hold for a while, flat mate told me the other night i've got a month to find somewhere else to live because he has got himself a job down south.
____________________
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

[woll]

Moved back to mothers... everything is a go go.
Top end off the engine...
https://i649.photobucket.com/albums/uu211/whalley1992/5a1aab9e.jpg
https://i649.photobucket.com/albums/uu211/whalley1992/4b54ba0a.jpg
https://i649.photobucket.com/albums/uu211/whalley1992/aa525544.jpg

Measured the piston & bore with a very near caliper got 66.11 bore and 65.89 piston. Remeasured both with another and got the same again. Not a piston size you can buy off ebay or bike shops as standard gas gas sizes.
Took the number off the top of the piston, 614ps. It should be 66.4mm piston size and it's a standard cr250 piston so i haven't got a clue wtf has gone on there. Can only presume the bore measurement is slightly out and the piston has worn down. It does look like it's been badly polished so i think piston slap has worked it down a bit lol.
Going to go gas gas uk on saturday and getthem to check it out and see what they think to it.
____________________
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

[garth]

Why's there a drawing of a schlong on your reeds?
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You ain't a has been if you never was

[Moo.]

[fezza612]

nice reeds!
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Previous: '02 Honda CG125, '03 yamaha enticer
Current: '98 Kawasaki GPZ500S

[chris-red]

[SuzukiTom]

excellent, i had one of those! really good bike, mine was the 300 but every part is pretty much the same other than bore size.

i had a really good experience with Gas Gas UK, really good bunch. Also the hold music is stand up sketches from the 80s which is quite funny!

[woll]

I'm not far from them so it's an excuse to go up the c&f on t weekend
____________________
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