2002 Gas Gas XC250 REbuild info/specs ?

[motorhead]

My sons 2002 EC250 was locked up tight on Memorial day, kickstarter would not move, rear wheel elevated/in gear only slightly. Teardown revealed that a crank stuffer screw has backed out, wreaking havoc, ending a fine ride before it began, although the end result could have been much worse.
Looking up the crank stuffers on GF parts site, does not show a reference number for the screws, shot them an Email, to which they responded "are not included with "counterweight nylon's" But we have them. Can anyone tell me of an equivalent source?
Also I have no manual for this bike, is there a link for crank width specs? I searched manuals and only came up with a very generic 03' "Owners manual" that had no relevant specs- Such as piston to cylinder clearance.
Have .004"learance now with Wiseco piston which has 66.35 stamped on dome, Wossner piston site shows a "D" piston @ 66.43. Anyone have real world values on these?
Also opinions on rod kits needed. My 05' 300 and my sons 02' 250 have Vesrah rod kits in them, does anyone prefer the Wossner rod? and if so why?
Main bearing numbers? Can I get equivalents from bearing distributor?
Gasket kits? Which brand fits good?
Thanks!

 

[GGRider01]

Crank bearings

1 x LHS CRANK BEARING SKF NJ206ECP - C3 62x30x16
1 x RHS CRANK BEARING SKF 63/28 - C3 28X68X18
1 x LHS CRANK SEAL KOK 20x35x6 - VITON
1 x RHS CRANK SEAL KOK 38x52x7 - VITON

This information is stickied somewhat conspicuously in the Chassis & Body section.

No other information for you, sorry.

 

[hadfield4wd]

As far as gasket kits I like Athena. Good quality and customer service. I've had an issue and it was resolved quickly.

 

[motorhead]

Thank you GGrider01 and hadfield4wd!
Once again
anyone else chime in with crankshaft stuffer bolt info?
Still cannot find a "service manual" online
Looking for piston clearance
crank width
big end side clearance
specifications

 

[jostby]

Unfortunately I don't think you'll find a service manual for '02. I have one for '06 if you need. The only change is the crank bearing type and yours might be new enough to have the newer style bearings, I don't remember when they changed. All other specs remain the same. PM me with your email address if you want it. In a few hours I'll be off-line until Monday because of travel.

 

[RBrider]

I used .002 clearance measured at the skirt (bottom) of the piston. I didn't have a bore gauge, so I measured bore below ports with piston installed normally, then turned piston upside down to measure clearance above the ports. This was on a '01 XC 200 with B piston/cyl.

There is a Gas Gas repair manual online. I found it when doing the top end on my bike. That's where I got the piston clearance specs from.

I found a Athena top end gasket kit online. It was inexpensive, very complete and worked well for me.

I used a Wossner piston kit, just because of their good reputation. Someone on this forum recommended Niks Industries online for Wossner kits. Lowest price I had seen and quick free shipping. It was a good tip, imo, so I'm passing it on.

No info on the screws you need, sorry.

RB