Gas Gas ec 2006 1st gear problems

[Munch]

I had a quick look today and I noticed this thing was bent and one f the wires were showing, I don't think it used to be like this. I did crash from around 5ft in the air the last time I rode it so I think it's from then but it was already spluttering so I doubt it's this causing it but what is it called as I would like to make sure it's all working fine. Pics below.

[Neil E.]

That is your AC voltage regulator. Measure between the yellow and ground as you increase the RPM. If your AC voltage does not exceed about 14-15 volts, it's working fine. Cover the exposed strands with silicone seal if they bother you. If your lightbulbs are blowing out, it's definitely not working and needs to be replaced.

[Munch]

Well, I feel really annoyed at myself.

When I took the bike out and it was spluttering originally the first thing I checked was the powervalve, I took the cover off and put the exhaust back on and revved the bike and the powervalve opened fine, I checked the nut on the stud that keeps the arm onto the plate and it seemed ok, I gave it a little turn and it seemed tight and not loose so I guessed the weld I had previously done was still working.

My buddy was certain it was powervalve related so we had another look today and instantly I could see a lot of play in the plate, I turned the nut and it was just turning - the weld had come off! Previously when it happened though I lost the powerband completely and it just felt different so I didn't think it was the issue but took it to be re-welded again. Put it back on and the bike runs perfect again.

Time to order a new plate since I don't trust the weld!

[barossi73]

Good to know its a simple fix!
You will finally get some decent ride time,let us know how she goes

[Munch]

Originally Posted by barossi73

Good to know its a simple fix!
You will finally get some decent ride time,let us know how she goes

If I can find the plate It seems like the normal places seem to be out of stock. Hopefully someone in the UK has stock.

[Jakobi]

Have the old one welded mate.

Don't just tack it together best you can. Drop past someone who welds professionally. They'll likely do it for free, but worst case it'll probably still be quicker, easier, cheaper, and STRONGER than an OEM one.

When you put the nyloc nut back on it doesn't need to be cranked super tight. When you take them off be gentle and use a little heat to soften the nylon if required.

[Munch]

Originally Posted by Jakobi

Have the old one welded mate.

Don't just tack it together best you can. Drop past someone who welds professionally. They'll likely do it for free, but worst case it'll probably still be quicker, easier, cheaper, and STRONGER than an OEM one.

When you put the nyloc nut back on it doesn't need to be cranked super tight. When you take them off be gentle and use a little heat to soften the nylon if required.

That's the thing - it was previously welded! I have had it welded again hopefully this time it holds up. I think before the person I had weld it made it really nice and tidy and made it nice and flat meaning only a tiny bit of weld existed if that makes sense. We will see if this weld holds up though if not maybe I'll take it to someone else to get welded.

[barossi73]

Most likely he was just trying to avoid blowing a hole right through and got a very superficial surface weld.sometimes its a very fine line!