Quote:
Originally Posted by Zman
There was a change in engine mount locations around 2005. There may also be a change in the swingarm shaft size around the 2000 time as well so the cases may be different. If the cases are different you should be able to swap over the transmission gear sets. If you do swap the internals, you may want to consider changing the bearings while you are in there. You can get these at a bearing supply house or dealer. These bearing and seal sizes work for the older 200, 250 and 300 bikes up to 2004. They probably cover newer bikes too, but double check the numbers or sizes to be safe.
GasGas Transmission bearings
Bearing # Grainger #
Counter shaft bearing 6305C3 4ZXJ1
Countershaft Seal 30x40x7
Clutch bearing 6205Zc3E
Trans shafts 6203c3 4zxe8
LHS CRANK SEAL KOK 20x35x6 (VITON) ktm 47030076100 04-14 105 85 65
RHS CRANK SEAL KOK 38x52x7 (VITON) ktm 0760385273 94-14 250 300
COUNTERSHAFT SEAL 30x40x7 Suzuki 09283-30061
Shift Shaft Seal 12x22x7
KICKSTART shaft SEAL 20X30X7
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Thank you very much for all that!
Quote:
Originally Posted by gassergrant
The big nut on the crank clutch side is a reverse thread think , my one went funny after stripping it down and kept coming loose.
I replaced and used red lock tight it's never loosened since lol
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Funny you mention that as I found it lose on mine as well. It was eating in to the side cover right below the sight glass.
Quote:
Originally Posted by desertgasser300
The internals should most if not all swap over. Since your inside put in all new bearings. I ordered my bearing from USA bearing and belt. They will have a crossover chart for the sizes you need. And most of your bearings should be stamped with the size on them somewhere. Pick the best parts between the two motors, check the crank play, throw in some new bearing and hammer it with a piece of mind knowing you did it right. If you need some help let me or another local know. I live in Maricopa and have torn these motors down a few time, really not much to them. I will be off the entire month of November.
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Yeah, whenever I split the cases on any bike everything inside gets replaced. Bearings, bushings, seals, etc. will all be new.
Since I'm in there, it would probably be a good idea to rebuild the crank. I thought I read something about it being a CR250 crank and rod. Is that correct? If not, where can I find a good rod for it? Plus, I have read a few things on doing something with the base gasket(s) and head. Could someone point me to a definitive thread covering all that needs to be done?
I wish there was some way to identify the exact year engine as I suspect it isn't actually an '05 but instead is an earlier model. I just can't afford to buy parts that don't fit or I won't be riding for a long time.