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Enduro Engine - 2 stroke Cylinder, Piston, Tranny, Bearings, Clutch, Pipes & Silencers, etc. |
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Thread Tools | Display Modes |
#11
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I've never replaced gearbox bearings. They live in oil and turn slowly.
Left bearings on crank don't last forever.
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'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) |
#12
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Case Splitting Seals and Bearings
This is a series of three videos (see link below)that show you how to do a bottom end rebuild. It includes tools needed and inspection tips.Go slow, split the bottom end, replace the gaskets, main bearings and seals as you go along.As I remove each assembly,I place it in a clear sandwich bag and mark it with a felt pen and put the bags in the order they were removed.
If you can't find an oem gasgas bearing or seal just post a picture and someone on the should be able to help you find a replacement. For the most part main bearings and seals should be easy to find. Replace any old seals, gaskets or bearings now and you won't have to go back into the bottom end for a long time. Don't monkey with the transmission but you can post a few pictures and the transmission gurus here on the board should be able give you an opinion on any wear or needed parts. https://www.youtube.com/watch?v=kYX-bOG9vR4
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2011 GG EC 300E, 1994 CR 250R, 1984 RM 250 E, 2022 Ranger 300 "If you stop eating donuts you will live 3 years longer. It's just 3 more years that you want a donut." ―Comedian Lewis Black "I think best when I have a wrench in my hands." Soichiro Honda "Dreams are messages from the deep." -Unknown Sardaukar |
#13
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Quote:
Quote:
I haven't confirmed all of them, but it looks like I can get all the bearings & seals through CPD. If they don't have the OEM part, they usually have an equivalent. There's a very strong possibility that I'll be posting a lot of pictures and asking silly questions I guess my next step is working out the specialty tools I need, and finding them.
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2001 Gas Gas EC250 (or 300?) 2006 KTM 950 Adventure S 1985 Hobie Cat 16' |
#14
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I have another question regarding parts in the diagrams that I'm missing.
I seem to be missing the reed valve spacer, part 3 here ...and of course one of the 4's: Is the diagram right that I should have that spacer? ...is it important? ...I assume so, or why would they add it? Maybe the previous owner was even more inept than I thought and lost/left it out; ...or maybe it's only a 200 (apparently that part is only for the 250 and 300 bikes). I was told it's a 250 with a 300 top end. I guess I'll find out more when I open it up.
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2001 Gas Gas EC250 (or 300?) 2006 KTM 950 Adventure S 1985 Hobie Cat 16' |
#15
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another missing part, the cylinder head brace.
It appears to be a couple of lengths of flat bar that bolt through either side of the frame at the top end and the cylinder head at the bottom. Part 18 in this low quality CPD diagram: Is this something everyone else has? I assume it would be very good to have them. They're $10 each.
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2001 Gas Gas EC250 (or 300?) 2006 KTM 950 Adventure S 1985 Hobie Cat 16' |
#16
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Weird they aren't there. Have you got a length of metal to make new ones?
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'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) |
#17
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Quote:
I'm sure I can make some. I have a sheet aluminium that should do it, it's fairly thick. ...I won't even have to worry about painting them, I don't want to end up with a rusty mess. I haven't got far in the engine rebuild yet. I got it out of the bike, but the stupid block that the kick starter arm fastens to won't come off the shaft, ...and I sent the tools I ordered to my old address so I have to go get them tomorrow.
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2001 Gas Gas EC250 (or 300?) 2006 KTM 950 Adventure S 1985 Hobie Cat 16' |
#18
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My home made kick start puller worked a treat....
...and yes, I put a washer on the end of the shaft to avoid damaging it with the bolt. =) I now have the full clutch cover removed. ...is the nut for the clutch basket, the one with the fold-over lock washer, supposed to only be finger tight?
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2001 Gas Gas EC250 (or 300?) 2006 KTM 950 Adventure S 1985 Hobie Cat 16' |
#19
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I got the full clutch cover off and have been having fun removing the various parts in order to split the engine. I'm glad I had my father-in-laws pneumatic impact driver because my electric one wasn't able to undo the crank nut. ...I wasn't sure the air one is was going to get it either, it struggled! I suspect a lot of thread lock may have been used, as there was a lot of something in the threads. There was also a lot of what appeared to be broken plastic behind the nut, I'm hoping it's just excess thread lock....
My 27mm LH flywheel puller hasn't arrived yet, it's still in transit somewhere this side of Las Vegas apparently, but I'm not sure it's going to help. Upon closer inspection the thread appears to have been flattened. I'm guessing someone using a socket to drive the flywheel on got it into the threads and destroyed them. Fingers crossed, but I'm anticipating making another custom puller.
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2001 Gas Gas EC250 (or 300?) 2006 KTM 950 Adventure S 1985 Hobie Cat 16' |
#20
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You may very well be right, but there should never be a need for drive the flywheel onto its taper with anything but your own fingers. It is a loose fit until it is onto the taper.
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Anders "So you know, that you're over the hill when your mind makes a promise that your body can't fill" (Little Feat: Old Folks Boogie) 2015 EC200 Racing: TE bars, Rekluse Core Exp 3.0, 38mm Lectron & Ohlins S3 steering damper 2006 EC200: 2011 plastics, Rekluse Z-Start, revalved KYB forks & Scotts steering damper 1998 Bimota Supermono 1986 Duc Mille S2 1975 Guzzi sidecar hack 1961 Morini Corsaro 125 etc |
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