2004 Gas Gas EC 250 Restoration
 

Wassup GasGas community!

I ride a 2004 Gas Gas EC 250.

Recently I have broken my wrist due to a dirt bike accident In the time of healing up, I got bored. Sooo I decided to entirely rebuild my old bike from ground up and make it like brand new. I bought the bike in fairly decent shape but after I did my dues to it, it became quite a Frankenstein bike.

We went through the whole bike piece by piece, cleaning, painting, rebuilding, any thing and everything I could do to make it look like a brand new bike. I also had help from friends and family to make this bike possible. I am very greatful for their help.

There are plenty of photos of my restoration process if you guys would like to see.

I am still in the process of perfecting the way it looks and rides. It is soooo close to being fully restored. I felt the want to share with yall my process and fun that I encountered as I rebuilt my bike to make it my own custom beautiful bike.

I really hope yall like my restoration.

There will be more post to follow as I make more improvements on the bike!

Thanks

Tripp :)

2004 Gas Gas EC 250
 

Before Restoration:

Disasemble:

Clean up:

Powder Coating:

I powder coated the frame, spring, clutch cover, kick stand, foot pegs, chain guard and kickstand bracket.

Reassembly of bike:

Reasembly:

New Plastics and Decals:
New Seat Cover:
:D

I am awaiting a new headlight unit since mine is busted from a wreck. I wrapped vynal on it and sticker bombed it to make it look good for pictures.

Are yall ready to see the bike all together? :D

All together:

All together #2:

Added some custom stickers to the hand guards:

Added sticker to the swing arm:
Added custom sticker to back of front fender:

This is as far as I am today. I will be uploading more picture as it progresses into a more beautiful bike each day! I hope yall like and enjoy my post! If yall have any questions, comments, or concerns. Feel free to ask me! :)

Looks really good. Well done.

These older GG's are still great bikes, well worth the effort to keep them running. I got my '01 XC 200 out of moth balls the other day, after leaving it sit for 18 months. It fired right up & ran great. Where I live & ride, a plated 4T get ridden more often. In my case that's '17 FE 250 Husky. But I definitely need to plan a off road ride somewhere so I can ride the unplated GG again.

Thanks for posting. Hope the wrist heals up OK.

RB

My head light unit came in! 😁 I have to figure how to match the decaling with the rest of the dirtbike and put it on. I am so excited! Any ideas on the way my decal on my head light could look? The plastic is red now, due to a order mix up. I can wrap it in black vynal though.

nice work!!

Added a new chest pad and the new head light unit! 😁

Added new kill switch and light switch due to both not working anymore. Kill switch might be just a temporary fix.

Looks great, what color is the frame? Nice work!!

Sorry the late late reply. It was tractor supply red powder coat. Unfortunately, they dont sell it anymore... i barely had enough left to get all my parts done.

Im new to the forum. Just bought an 03 EC250. Where did you get the new plastics and decals?

Welcome to the forum! In which part of the world are you located?

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Im in eastern/central Ohio. Took the bike out for the 1st time. I havent ridden since 98. My last bike was an 85 CR 500. I know suspension has changed ALOT from that bike. But I have to figure something out on this GasGas because it is no fun! lol. I went for a ride and the front end felt like I was riding on marbles. No i havent done anything with sag or any personal setup yet, but jeeez I almost dont know where to start with the front end.

Start with servicing the suspension and getting proper springs for your weight. Then set your sag. Adjust all clickers to their mid point and locate the forks at the stock height. Then ride it, see how it does, and adjust from there.

I did all that to the suspension today. seemed like front was 26 clicks rebound/comp and rear was 26 rebound, but damn i counted like 70 clicks on the compression. I think the rear has the high/low speed adjustment with the 17mm nut and screw inside of it. I read post here about setup, but front was for Marzochs, I have the Ohlins. But, i found out that one of the bike previous owners has a suspension shop and he races GNCC, so maybe there are heavier springs in there. Waiting on phone call back to see if he remembers the bike. Anyway, also going to get different front tire, Magnum ex on there now, and push forks all way up in trees. Theyre about 12mm up right now.

You don't know how many hours are on the suspension or the spring weight? Without knowing that all other adjustments are pretty much worthless. Everything starts with that. Get it serviced. Suspension should be freshened up (new fluid, possibly seals and bushings) about every 40 hours of ride time or once a year. Also, while having that done have the springs checked to see if they are right for your weight. Any shop worth dealing with can tell you what springs you have in there once they get them apart.

Replace jet block o ring .Always a cause of bad idling and shitty running.No amount o jetting will overcome this You need to do a plug chop to get an accurate plug reading. 40 or 42 pilot .Throw away original needle ,try the Suzuki rm 250 and 180 main AFTER you check /replace O ring .Good luck

Sorry for the late reply.

I bought the plastic off Ebay https://ebay.com/usr/scrubdesignz_europe

Unfortunately finding the headlight is a real pain. I had to search on my laptop and get it shipped to my cousin in Scottland and have her ship it here... cost me too...

Looks Great!
 

Great job!! I love the old GasGas bikes, seeing them brought back to life is awesome!