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2005 ec250 --> 2011
Time to update the look of my 2005 EC250. I'll update with some pics as I go.
As she was: http://i71.photobucket.com/albums/i1...psmmnrk9zi.jpg http://i71.photobucket.com/albums/i1...pseqobnuoq.jpg My update kit arrived from Motocrosscenter.com http://i71.photobucket.com/albums/i1...pswecbvodh.jpg 2012 Graphics on 2011 Plastics The headlight graphics didn't fit since the 2012 headlight is bigger. I did some major surgery and made them fit. http://i71.photobucket.com/albums/i1...psh3c20sv8.jpg |
Started the tear down
http://i71.photobucket.com/albums/i1...ps4m8mhp1d.jpg I had shoulder surgery 1 month ago, so I won't be able to ride for a few more months. I can't ride, so, I might as well go all the way. This is where I stopped tonight: http://i71.photobucket.com/albums/i1...psn9khsty1.jpg |
Nice Rockefeller,
I am totally a sucker for the 2012 Six Days graphics, I am busy having the following printed for my 2011 300: http://i242.photobucket.com/albums/f...ps2wjhwt3h.jpg Hopefully turns out as good as your kit, I also redid my bike completely from the ground up, redid the frame, motor, everything. |
That's going to look great!
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2 applications of chemical stripper and the powerwasher took off 90% of the old paint and primer. A wire wheel on an angle grinder took off the rest.
http://i71.photobucket.com/albums/i1...psfjbu1kqd.jpg A couple hours of prep work and I was able to lay down 2 coats of primer: http://i71.photobucket.com/albums/i1...psx3no0ohf.jpg Treating the radiator guards to come color as well... primer: http://i71.photobucket.com/albums/i1...psa75eflja.jpg |
Great thread, stoked to see what's next! <Where's that popcorn eating emoticon?>
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3 coats of engine enamel and a clear coat on the radiator guards:
http://i71.photobucket.com/albums/i1...psr7x8urzd.jpg Shock Spring coating was cracking and rusting: http://i71.photobucket.com/albums/i1...psnxtvmb5l.jpg My Helpers: http://i71.photobucket.com/albums/i1...psgdkuak7w.jpg 4 coats of white paint and 2 coats of clear: http://i71.photobucket.com/albums/i1...pslxhs6qm2.jpg The carbon fiber pipe guard trapped a lot of mud and crud up against the pipe. I'll need to do some polishing on this while I wait for the paint to fully cure. http://i71.photobucket.com/albums/i1...pslcbg0cgi.jpg The pipe guard only has a top layer of carbon fiber. The rest appears to be ordinary fiberglass chop behind it. I think I will add a layer of fiberglass over the whole thing: http://i71.photobucket.com/albums/i1...pstu3djbdh.jpg |
The pipe was quite pitted and had some rust:
http://i71.photobucket.com/albums/i1...psxrq4xi0y.jpg http://i71.photobucket.com/albums/i1...psqk7xx0jx.jpg Step 1: WD40 with 400 grit sand paper Step 2: Mothers Mg and Alu polish: http://i71.photobucket.com/albums/i1...ps095jolq2.jpg |
That's really something how you made that pipe shine, the whole project is looking good.
Cannot wait to see the end result! |
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Thanks. I found this video on youtube, and decided to give it a try: https://www.youtube.com/watch?v=oqGLErwkLFQ |
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Spent day wiring up new switches and fixing wiring on my bike. How did your frame turn out? |
I'm very pleased with the frame. I'm just letting it sit for a couple more days to fully cure.
The subframe that came in the kit doesn't match up perfectly and will take some massaging to get it lined up. I just want to be sure that I don't do too much damage to the new paint. I know nickel coatings are durable, but I wouldn't sand too deep! I had to go pretty deep on the rust pitting. I'm hoping that I wont see new rust spots where I went deeper. |
Great posts and pictures. Keep them up. I'm planning on doing the same to my 05. I have the transformation kit on order now from motocrosscenter.com
Sent from my iPhone using Tapatalk |
Taped up the frame. I don't want to destroy all the hard work that went into the frame.
http://i71.photobucket.com/albums/i1...psckrdofoe.jpg Engine back in: http://i71.photobucket.com/albums/i1...psfd5drvoo.jpg I tried dying a few parts black using RIT dye. It worked on swing arm brake line clips, but not on the chain slider: http://i71.photobucket.com/albums/i1...psjzq0j5d5.jpg I'm waiting on new hoses, a pipe o-ring, and a new chain slider from T.M. |
I apologize for hi-jacking your thread Rockefeller,
How my "2012 Six Days Kit" turned out: [IMG]http://i242.photobucket.com/albums/f...pspuv3dzka.jpg[/IMG] [IMG]http://i242.photobucket.com/albums/f...psmocjtkoc.jpg[/IMG] http://i242.photobucket.com/albums/f...psqqurjzny.jpg http://i242.photobucket.com/albums/f...psvf8rf4cl.jpg http://i242.photobucket.com/albums/f...psvafpas7a.jpg http://i242.photobucket.com/albums/f...pszttej07u.jpg http://i242.photobucket.com/albums/f...pst9rilnix.jpg http://i242.photobucket.com/albums/f...psmukcazn7.jpg |
Booth - That turned out great! I love this color combination. It really does something for me. Especially, the radiator and headlight plastics!
Who did you have do them? |
So a question about the airbox and quick release for the airfilter.
The 2005 had a metal ring behind the airbox that had an index pin and a notch for the post to sit in. I don't see this on the 2011. I can install the ring, but I don't see it on the diagrams for a 2011. What prevents the air filter cage from rotating? Just the pressure from the spring? Here's a quick video to describe what I am looking at: https://www.youtube.com/watch?v=d1xQhEX40hU |
I am also searching for some other answers:
White hook: be215202511 is a brake hose guide and bolts into the upper triple clamp. Red Aluminum Washer: Looks like it is used under the bolt that holds the seat down. I'm guessing the longer bolt is used to go through the seat. But not really sure about the rest. I'll probably post this in the updated plastics thread too. http://i71.photobucket.com/albums/i1...psfjtdjnqz.jpg |
The black brackets are headlight holders. I found a part number on them, I can't believe I missed that earlier.
Still not sure about the little split anchor bolts. I'm guess the silver spacer is used on the rear: perhaps it is part #49? http://www.motocrosscenter.com/shop/...-plastic-parts |
silver spacer is part of the seat bolt mounting.
Plastic anchor bolts are for the plastic to subframe |
The fit of the rear subframe is off. Looks like they did a bit too much welding on it at once or too much on one side first. It isn't square and needs some massaging to fit into the frame.
The Polisport plastics are close, but there are a few areas that needed trimming to fit. Here, I trimmed the fins down to clear the cross-brace. http://i71.photobucket.com/albums/i1...psihub2nlo.jpg I also couldn't keep the front of the airbox attached. I drilled the 4 little tabs and put a nut/bolt through. I'll probably add a dab of silicone to these or replace them with a rivet. In this pic, I have just one of the tabs drilled and secured. http://i71.photobucket.com/albums/i1...psnzl3ssa0.jpg |
I can't believe I missed this! The kit comes with a new airfilter cage that has a lip inside and keeps the airfilter from rotating. DUH!
http://i71.photobucket.com/albums/i1...psozqxvd4m.jpg |
New hoses from MotoHose arrived today. They are listed as GasGas 2012-2015, but a couple trims and they fit my 2005 just fine. I also added an inline cooler that I picked up last year from Checkpoint Offroad and never got around to installing.
Link to the hoses: http://motohose.com/epages/a63cd3c7-...Products/24-78 http://i71.photobucket.com/albums/i1...pszb3jpqwn.jpg |
Picked up some new-to-me wheels from Mcnut:
http://i71.photobucket.com/albums/i1...ps62c3y1ei.jpg Triple clamps and forks installed. I added the new hose organizer clip. I may drill and tap a new hole to relocate it. http://i71.photobucket.com/albums/i1...psaqbs3ens.jpg |
Found a home for the CDI.
http://i71.photobucket.com/albums/i1...psygrprz6t.jpg http://i71.photobucket.com/albums/i1...psfo0tbtno.jpg |
Added some braided loom to protect the wiring connectors:
http://i71.photobucket.com/albums/i1...psubpjoyk7.jpg I broke the locating tabs on the right side panel. I've added some JB weld and washers to reinforce them. I'm not so sure it will hold. I'll have to order a new side panel. http://i71.photobucket.com/albums/i1...psinajuvo8.jpg |
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Some learnings:
1. I thought the bolt in the center of the airbox bottom was supposed to line up with the seat mount hole. They aren't supposed to. I needed to keep pushing the airbox toward the rear to make everything line up. http://i71.photobucket.com/albums/i1...psasx6on2u.jpg 2. The flimsy plastic anchor insert are very flimsy. I'll probably tap the aluminum holes or add a rivet that will be semi permanent. http://i71.photobucket.com/albums/i1...ps2sbw0nox.jpg |
The rubber tank strap was disintegrated. I made this from a bungee and some bailing wire:
http://i71.photobucket.com/albums/i1...psuwtuwyzo.jpg |
She's coming up a treat mate! Would love to hear a rough amount that she owes you when all is said and done.
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To do the update, the only thing I needed was the kit:
Transformation Kit: 387.60 ? + 66.00 ? Shipping (Motocrosscenter.com) These were all optional, I needed to do some preventative maintenance and changed the hoses for "looks" Hoses: $129.00 (Motohose.com) Chain Slider: $39.00 (T.M. Designworks) Chain Guide Block and Bracket: $108.00 (T.M. Designworks) Upper and Lower Chain Roller: $26.00 (ebay) Swing Arm Bearings: $60.00 (ebay) Paint and Primer: $25 Stripper: $14 |
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Looking really good Rockefeller, has inspired me to start my own thread, though its not as comprehensive as yours as I have not taken as many photos as you...
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Thanks. I did this for my last off road rig build, and enjoy the documentation. Keeps me busy while waiting for parts.
1. Th JB Weld didn't work on the airbox side cover. I rebuilt the little holes using an old soldering iron and scrap plastic from an old black front fender. Plastic welding it seems to be the ticket. 2. When I bolted on the radiator covers, the screw in the gas tank pulled out, bringing with it the plastic that held the screw in. I used plast-aid to fill the hole and sanded it flush. I drilled a pilot hole in the original spot for the self-tapper. http://i71.photobucket.com/albums/i1...ps7zhxrm5t.jpg http://i71.photobucket.com/albums/i1...psw4hp1vv6.jpg |
The left side airbox to fender plastics fit perfectly:
http://i71.photobucket.com/albums/i1...psqi9pzmpk.jpg The right side doesn't. I gave up when I got it this close: http://i71.photobucket.com/albums/i1...psooutvlfx.jpg Added yellow to all the number plates. I need to wire up the headlight still, but couldn't resist taking a couple pics: http://i71.photobucket.com/albums/i1...psr6wuahu6.jpg http://i71.photobucket.com/albums/i1...pspc90hcqt.jpg |
What sump guard combo do you use?
Ha ha that's quite an assortment of welding helmets you have there. Looking really good, luckily my bike is a 2011, so hopefully the Polisport plastics bolt on without to much hassle. I am battling with my header pipe at the moment, its catching on the frame.. Always small issues that hamper projects |
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Since I had to re-form the plastic tabs on the side cover, I'm hoping that the locations are just off slightly, causing the issue. I've got a new side cover coming from Hall's Cycles here soon. They had to order the part, so I'll just live with this for a week or two.
I can't ride anyway... I'm still healing from Surgery and have the holidays coming up. I'll just be patient. On a bright note, I had my o-ring chain soaking in degreaser since the tear down. A quick once over with a tooth brush and some fresh chain wax has it looking great. There was a ton of grime in the bottom of the bin it was soaking in. I was very happy to see the results and scared to see how much crap was in the chain. |
Great looking bike who made the graphics maybe I read through to quick and missed it thanks
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These are the GasGas 2012 Six Days graphics. They came with the transformation kit from Motocrosscenter.com
They fit all of the 2011 plastics except for the headlight. I cut apart the sections and trimmed them to make it work. |
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