Plastics Conversion - 2005 x 2011 - Airbox Issue

[Marcão]

Originally Posted by gasgasman

The 2005 boot won't work with the new air box.

Gasgasman,

The boot does fit the airbox front panel (inclusive the gasgas part number for the boot is the same for both years - 05 and 11). Lets see if I will find some problem when assembling the new air box to the subframe (which is also supplied with the kit).

[gasgasman]

Yes ,you are right.
I was thinking of my 2001 Gas Gas that had the retaining bolt for the air filter.

[Jakobi]

Originally Posted by lonetree

Dont suppose you would have a link to where you bought your conversion kit from?
Are they actually sold as a conversion kit? or just an order of the required parts?
look forward to seeing photos of your finnished bike.

http://translate.google.co.uk/transl...ucts_id%3D2899

[Marcão]

Guys,

One more simple question... Is there any rivet linking the front and the bottom cover of the airbox (parts 14 and 15 of the diagram) ? I've mounted them in the subframe and everithing is so tight and firm that I don't see the need of rivets...But would like to know how it's out of crate in the 2011's...

Thanks in advance !!!

[Marcão]

After roughly 2 months the conversion is ready.
Considering that mechanically my bike was quite ok, the main reason for doing a conversion like this in Brazil is the price for a new bike. A 2012 EC 250 costs here around US$ 14.000 and I would get not much more than US$ 5.000 in my 2005. I spent around US$ 1.500, in this conversion (basically because I've been travelling to Spain several times this year and had the chance for buying the parts there) and the bike looks quite new again.
Follow a few pics...

[Jakobi]

That looks fantastic! Top work mate! Now to get some dirt on it

[desertgasser300]

That looks great. I love the 11' plastics with the nickel frame.

[Diggs345]

By the look of the old plastics it just gets polished lol

[Marcão]

Thanks for the comments.

Besides new cosmetics I've added a set of new valve reeds, changed all oils and fluids, the gas of rear shock, new chain and sprocket, new chain slider and TM chain guide, Trimetal sprocket, cleanned the carb, a CCK needle and, most important, a machined head to adjust squish.

But today I've noticed that the rear spring is rubbing tha carb boot. Probably because the boot was slightly deformed by the previous subframe. Must check...

[lonetree]

looks great, just like a new one.
did you have any problems getting everything to fit? how about the exhaust?
top job.