2005 body rebuild

Your bike is going to look fantastic when done and I see you are doing it the right way with all the good parts. I agree that the 11 headlight mask looks better than the 12's. I like the Soumi graphics as well and would have got them if they would have had the subframe. I remodeled my 05 last year but not with the new subframe and newer rear plastic as the subframe was not available. Here is a few before and after on my 05 EC200.
 

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Your bike is going to look fantastic when done and I see you are doing it the right way with all the good parts. I agree that the 11 headlight mask looks better than the 12's. I like the Soumi graphics as well and would have got them if they would have had the subframe. I remodeled my 05 last year but not with the new subframe and newer rear plastic as the subframe was not available. Here is a few before and after on my 05 EC200.

Zrt1200 Woo colossal difference - good job!
I was thinking of such a set as yours, but I managed to buy the last subframe in the motocross center :) so I decided on a full transformation kit.
Nambotin graphics was the second which purchase I was considered :) unfortunately as I bought the set I had to choose only between suomi and cervantes.
I'm pissed because this week I'll get a frame and a swingarm from the paint shop. I've been waiting 2 weeks already. The paint shop had a furnace failure :(
 
Zrt1200 Woo colossal difference - good job!
I was thinking of such a set as yours, but I managed to buy the last subframe in the motocross center :) so I decided on a full transformation kit.
Nambotin graphics was the second which purchase I was considered :) unfortunately as I bought the set I had to choose only between suomi and cervantes.
I'm pissed because this week I'll get a frame and a swingarm from the paint shop. I've been waiting 2 weeks already. The paint shop had a furnace failure :(

Thanks. This is the modification kit I got below. There is a plastic piece you should buy to support the front fender as well. Having to wait for parts stinks being riding season is here. I can feel your pain as I have been there before. There is also a front brake line bracket you have to order. I will see if I can find the PN for you.

http://www.motocrosscenter.com/shop...valido-para-gas-gas-ec-2001-2006-187208.html#

Fender brace....

http://www.motocrosscenter.com/shop...uller-gas-gas-ec-2012-2015-be90000463012.html

And I am thinking this is the front fender that came with the kit...

http://www.motocrosscenter.com/shop...r-polisport-white-gas-gas-01-07-18566805.html

The brake line guide is PN BE215202511

Which can be seen in Post #18 here...

http://www.gasgasrider.org/forum/showthread.php?t=20613&page=2

OR post #5 here...

http://www.gasgasrider.org/forum/showthread.php?t=22372
 
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Zrt1200 - thanks a lot !
I thought I got everything in the "transformation kit" I checked it thoroughly and I do not have that fender holder. Thanks a lot again.
 
Zrt1200 - thanks a lot !
I thought I got everything in the "transformation kit" I checked it thoroughly and I do not have that fender holder. Thanks a lot again.

You are very welcome and that whats this forum is all about. Helping each other. When I did my kit another member told me I needed the fender holder as well. Im looking forward to seeing more pics of your bike.
 
Finally, I picked up my frame and the swingarm :)Scope of work:
- sanding
- welding fixing of footpeg
- powder painting
Price 50 euro :)



I can not wait for the weekend ...
 
Today was the bearings day :)

Lubricated and ready :)

All bearings changed to new and greased.

Begins to resemble a motorcycle :)

Swingarm and engine mounted
 
Yesterday I spent some time in the garage :)
Clean and lubricate the foot brake. I put nicely on new gaskets.

I did not know how to secure these parts of the swingarm so it took me some time to remove it. Now it looks like the original 2011 :)

Brake pump on place.

All nicely mounted on new handles and screws :)


Today I received a shipment so I can install new radiators and hoses :)
Radiator Guards - 62 euro

 
Geco triple clamps mounted
I did a double job :) I installed the bearings for 2005 but forgot that geco need 2006-2011 bearings hehehe

Front fork mounted

Radiator guards and radiator horse mounted

Head lamp and front fender fitted -

I started to check if the plastic air box fit :)

To my surprise everything fits quite well so I started to keep going :)
 
Your bike is starting to look like a bike again, A new bike that is :D Keep up the good work & keep the pics coming.
 
I bought some parts :)

Gear change leve - 27 euro
Swingarm slider - 12 euro
Air filter bolt - 14 euro
Red hoses to carburetor - 5 euro

I refreshed the frame guards
I stick on it a carbon imitation sticker :)
 
Waiting for a package from Motocrosscenter.com I bought a new front tire in Poland
Pirelli Scorpion xc mid soft - 38 euro


I found some time and cleaned the carburetor well , and using the opportunity I put on the red hoses :)
 
I did a job where I'm a little confused. I still believe that the old system was more stable but I want to put it according to 2011 manual.
I cleaned and put on the air filter rubber.

My first doubt is that the rubber has some slack and moves slightly.
It is already quite hard because of age and does not adhere evenly



I wonder if I should buy a new one maybe it will be more flexible. New one will be without these holes?
I'm wondering also whether to not panic :) and just simply seal it with silicone :)
 
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