Rieju & GasGas Legacy Riders Club Forum  

Go Back   Rieju & GasGas Legacy Riders Club Forum > GasGas Enduro Technical Forums > Enduro Engine - 2 stroke

Enduro Engine - 2 stroke Cylinder, Piston, Tranny, Bearings, Clutch, Pipes & Silencers, etc.


Reply
 
Thread Tools Display Modes
  #21  
Old 06-22-2020, 05:41 AM
(F5)'s Avatar
(F5) (F5) is offline
Gold Level Site Supporter
 
Join Date: Jul 2006
Location: Wellington New Zealand
Posts: 2,062
Default

Diesel is the business, better than gas for absorbing water.


__________________
'07 EC300 GG
'14 TXT250 GG
'? 496 CPI Cheetah RZ/RGV hybrid
'22 765 Street Triple RS
'21 XTrainer
'69 Stinger T125 Suzuki
'23 TRS 250RR (it's a Trials thing)
Reply With Quote


  #22  
Old 06-22-2020, 07:39 AM
Mikeyx Mikeyx is offline
Senior Member
 
Join Date: Sep 2015
Location: Finland
Posts: 110
Default

So, which parts do I need to get the bike (possibly) running?

- PV triangle (according to an Aussie parts dealer, the tiny stud comes with the triangle)
- according to parts diagram, there are two cyl bottom seals
- according to parts diagram, there are two cyl head seals

Anything else? I was thinking of replacing the piston, but since the bearings are an unknown, I must skip it at this stage.
Reply With Quote
  #23  
Old 06-22-2020, 05:17 PM
swazi_matt swazi_matt is offline
Senior Member
 
Join Date: May 2010
Location: From Swaziland, Now Hamilton New Zealand the “look but don’t touch” enduro heaven
Posts: 2,334
Default

there are multiple thicknesses of base gasket, there are those who are a bit smarter and may take the opportunity to try and improve squish or adjust how the bike performs by changing the thickness, however if you just want it running again i would try to get the same thickness gasket that is already in there

On another note, if the PV assembly had coolant in it there will most likely also be coolant leaked from there into the gearbox, so that will also need flushing. Having drowned my bikes in the past i know that trying to flush the gbox with oil will make you broke before it stops turning white and have always used kerosene (drain oil, fill with same volume of kerosene, ride it around for a minute to mix it all up and then drain it and that will be all the water out. I believe ATF also works)
__________________
2003 txt250 Pro
2013 Ossa 280i
Reply With Quote
  #24  
Old 06-22-2020, 08:14 PM
(F5)'s Avatar
(F5) (F5) is offline
Gold Level Site Supporter
 
Join Date: Jul 2006
Location: Wellington New Zealand
Posts: 2,062
Default

Diesel is the business.
Litre in. Block the bike up super carefully and run it in gear for a minute. Drain repeat.
Drain, tip bike both ways, leave a bit, sew it back up with new oil. Done.
__________________
'07 EC300 GG
'14 TXT250 GG
'? 496 CPI Cheetah RZ/RGV hybrid
'22 765 Street Triple RS
'21 XTrainer
'69 Stinger T125 Suzuki
'23 TRS 250RR (it's a Trials thing)
Reply With Quote
  #25  
Old 06-24-2020, 04:05 AM
Jakobi's Avatar
Jakobi Jakobi is offline
Super Moderator
 
Join Date: Oct 2010
Location: Australia
Posts: 7,994
Default

I've drowned every one of my gassers... never had water in the transmission. Have had them spurting like a whale from the plug hole though!

You'd think I'd have learnt by now.

What others have said.

Head o-rings, base gasket, little gasket at the water intake on the head, and probably some o-rings for the pipe spigot while you're at it.

Pay particular attention when you pull it down to where the gasket has failed.

Make sure all surfaces are flat before reassembling. Make sure all moisture has been removed. Use some sealant on the case joints at the front and rear before putting the gasket down. I'd suggest a 0.5mm gasket too. They are the rubber coated steel ones.. much more resilient than the thinner paper ones.
Reply With Quote
  #26  
Old 06-24-2020, 05:42 PM
swazi_matt swazi_matt is offline
Senior Member
 
Join Date: May 2010
Location: From Swaziland, Now Hamilton New Zealand the “look but don’t touch” enduro heaven
Posts: 2,334
Default

Quote:
Originally Posted by Jakobi View Post
I've drowned every one of my gassers... never had water in the transmission. Have had them spurting like a whale from the plug hole though!

You'd think I'd have learnt by now.

What others have said.

Head o-rings, base gasket, little gasket at the water intake on the head, and probably some o-rings for the pipe spigot while you're at it.

Pay particular attention when you pull it down to where the gasket has failed.

Make sure all surfaces are flat before reassembling. Make sure all moisture has been removed. Use some sealant on the case joints at the front and rear before putting the gasket down. I'd suggest a 0.5mm gasket too. They are the rubber coated steel ones.. much more resilient than the thinner paper ones.
never had water in gearbox with the gasser, but had it on a cr250 - didn't even drown it, although i must have been very close to it, must have a different venting system

Reason i say it may have happened here is that his coolant had leaked into the PV assembly and as far as i know the PV rod goes strait through a hole into the gearbox compartment
__________________
2003 txt250 Pro
2013 Ossa 280i
Reply With Quote
  #27  
Old 06-25-2020, 12:07 AM
Jakobi's Avatar
Jakobi Jakobi is offline
Super Moderator
 
Join Date: Oct 2010
Location: Australia
Posts: 7,994
Default

Quote:
Originally Posted by swazi_matt View Post
never had water in gearbox with the gasser, but had it on a cr250 - didn't even drown it, although i must have been very close to it, must have a different venting system

Reason i say it may have happened here is that his coolant had leaked into the PV assembly and as far as i know the PV rod goes strait through a hole into the gearbox compartment
It certainly does!
Reply With Quote
  #28  
Old 07-24-2020, 02:49 PM
Mikeyx Mikeyx is offline
Senior Member
 
Join Date: Sep 2015
Location: Finland
Posts: 110
Default

She's alive!

Now the bike is back in one piece with a new stator (most likely unnecessarily replaced) and a new piston (gives more grunt).

When the piston was removed, I did not feel any radial play in the bearings. The conrod could be moved +/- 2 mm sideways; dunno if that's allowable or not.

Having emptied the coolant and flushed the crankcase with 2-stroke gas, I filled the crack with gas and let it evaporate over time to leave an oil film on the surfaces. Time will tell if there's any damage...

Thank you for help and information!
Reply With Quote
  #29  
Old 10-11-2020, 08:08 AM
Mikeyx Mikeyx is offline
Senior Member
 
Join Date: Sep 2015
Location: Finland
Posts: 110
Default

Time to wrap this ordeal up...

With a new piston and stator installed, I managed to ride the a few times until it died. No spark.

Had it towed to a nearby dirtbike workshop. They found that I had routed the wiring loom the wrong way and the flywheel had frayed the wiring and caused also melting on the windings.

So I purchased a new stator and had them install it. While riding back home from the workshop, a few km's at steady speed (6th gear, 6000 rpm, 85 km/h), the engine died. While waiting for the tow truck I noticed that there was no compression - so nothing to do with the previous repair at the workshop. At home I opened the engine and found that the plug and piston had melted. My jetting: 38/175/N3CJ. I'd been using the past year Denso W22 plug which is one notch hotter than recommended.

Took the cylinder to the workshop. It could have been repaired by just cleaning the aluminum with acid, but they found a crack between the channels. So I chose to purchase a refurbished cylinder from gasgas-outlet.de (180EUR+50EUR for welding job+ sending the old cylinder).

If the bike were a KTM I would have put it into pieces and sold the parts. Unfortunately GG is a rare make back here, and hence there is no market for GG parts...
Attached Images
File Type: jpg Ec300 piston top.jpg (120.5 KB, 20 views)
File Type: jpg ec300 piston.jpg (118.6 KB, 20 views)
File Type: jpg ec300 plug.jpg (116.6 KB, 14 views)
Reply With Quote
  #30  
Old 10-11-2020, 07:00 PM
(F5)'s Avatar
(F5) (F5) is offline
Gold Level Site Supporter
 
Join Date: Jul 2006
Location: Wellington New Zealand
Posts: 2,062
Default

Gee you've had a bad run.

On mine the stator came with an oval washer to fix the ignition timing in the correct place. Is this fitted? Also what is Octane of gas there? There are 2 main stds. Ron and Mon. Can never remember which is which and have to Google.

I'd say the ignition is too advanced for the petrol being used. Would be interesting to know compression ratio. I closed my squish up but machine a wad out of the head as it was too high once closed gap.
__________________
'07 EC300 GG
'14 TXT250 GG
'? 496 CPI Cheetah RZ/RGV hybrid
'22 765 Street Triple RS
'21 XTrainer
'69 Stinger T125 Suzuki
'23 TRS 250RR (it's a Trials thing)
Reply With Quote
Reply



Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Engine block hole Oystein00 Trials Engine 2 03-18-2017 06:44 PM
Setting Squish on an off centred plug hole head savage sausage Enduro Engine - 2 stroke 8 08-11-2016 12:30 AM
Extra spark plug hole? 12Bravo General Discussions & Announcements 10 10-20-2015 11:09 PM
Block (coolant) Heater.....anyone tried one?? McGuiver Enduro Engine 4 stroke (including EFI & Exhaust) 8 12-07-2011 05:19 PM
hole in engine????? lonetree Enduro Engine - 2 stroke 2 10-19-2011 08:43 PM




All times are GMT -5. The time now is 03:32 PM.


Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.
Copyright 2009 - GasGasRider.org