2005 ec250 --> 2011

[RockefellerGG]

The fit of the rear subframe is off. Looks like they did a bit too much welding on it at once or too much on one side first. It isn't square and needs some massaging to fit into the frame.

The Polisport plastics are close, but there are a few areas that needed trimming to fit. Here, I trimmed the fins down to clear the cross-brace.



I also couldn't keep the front of the airbox attached. I drilled the 4 little tabs and put a nut/bolt through. I'll probably add a dab of silicone to these or replace them with a rivet. In this pic, I have just one of the tabs drilled and secured.

 

[RockefellerGG]

I can't believe I missed this! The kit comes with a new airfilter cage that has a lip inside and keeps the airfilter from rotating. DUH!

 

[RockefellerGG]

New hoses from MotoHose arrived today. They are listed as GasGas 2012-2015, but a couple trims and they fit my 2005 just fine. I also added an inline cooler that I picked up last year from Checkpoint Offroad and never got around to installing.

Link to the hoses: http://motohose.com/epages/a63cd3c7-4c1b-4f87-864e-06f1ef9212ba.sf/en_US/?ObjectPath=/Shops/a63cd3c7-4c1b-4f87-864e-06f1ef9212ba/Products/24-78

 

[RockefellerGG]

Picked up some new-to-me wheels from Mcnut:


Triple clamps and forks installed. I added the new hose organizer clip. I may drill and tap a new hole to relocate it.

 

[RockefellerGG]

Found a home for the CDI.

 

[RockefellerGG]

Added some braided loom to protect the wiring connectors:



I broke the locating tabs on the right side panel. I've added some JB weld and washers to reinforce them. I'm not so sure it will hold. I'll have to order a new side panel.

 

[RockefellerGG]

 

[RockefellerGG]

Some learnings:

1. I thought the bolt in the center of the airbox bottom was supposed to line up with the seat mount hole. They aren't supposed to.
I needed to keep pushing the airbox toward the rear to make everything line up.




2. The flimsy plastic anchor insert are very flimsy. I'll probably tap the aluminum holes or add a rivet that will be semi permanent.

 

[RockefellerGG]

The rubber tank strap was disintegrated. I made this from a bungee and some bailing wire:

 

[Jakobi]

She's coming up a treat mate! Would love to hear a rough amount that she owes you when all is said and done.

 

[RockefellerGG]

To do the update, the only thing I needed was the kit:
Transformation Kit: 387.60 ? + 66.00 ? Shipping (Motocrosscenter.com)

These were all optional, I needed to do some preventative maintenance and changed the hoses for "looks"

Hoses: $129.00 (Motohose.com)
Chain Slider: $39.00 (T.M. Designworks)
Chain Guide Block and Bracket: $108.00 (T.M. Designworks)
Upper and Lower Chain Roller: $26.00 (ebay)
Swing Arm Bearings: $60.00 (ebay)

Paint and Primer: $25
Stripper: $14

 

[RockefellerGG]

 

[booth]

Looking really good Rockefeller, has inspired me to start my own thread, though its not as comprehensive as yours as I have not taken as many photos as you...

 

[RockefellerGG]

Thanks. I did this for my last off road rig build, and enjoy the documentation. Keeps me busy while waiting for parts.

1. Th JB Weld didn't work on the airbox side cover. I rebuilt the little holes using an old soldering iron and scrap plastic from an old black front fender. Plastic welding it seems to be the ticket.

2. When I bolted on the radiator covers, the screw in the gas tank pulled out, bringing with it the plastic that held the screw in. I used plast-aid to fill the hole and sanded it flush. I drilled a pilot hole in the original spot for the self-tapper.

 

[RockefellerGG]

The left side airbox to fender plastics fit perfectly:


The right side doesn't. I gave up when I got it this close:


Added yellow to all the number plates. I need to wire up the headlight still, but couldn't resist taking a couple pics:

 

[booth]

What sump guard combo do you use?

Ha ha that's quite an assortment of welding helmets you have there.

Looking really good, luckily my bike is a 2011, so hopefully the Polisport plastics bolt on without to much hassle.

I am battling with my header pipe at the moment, its catching on the frame.. Always small issues that hamper projects

 

[nknudsen]

The left side airbox to fender plastics fit perfectly:


The right side doesn't. I gave up when I got it this close:


Added yellow to all the number plates. I need to wire up the headlight still, but couldn't resist taking a couple pics:

Give it a try again on the right side cover. It's just not snapped/positioned correctly. The fender needs to fit on the other side of that thin black plastic tab of the side cover if I remember correctly. I think it gives most people fits on the install. The bike looks nice!

 

[RockefellerGG]

Since I had to re-form the plastic tabs on the side cover, I'm hoping that the locations are just off slightly, causing the issue. I've got a new side cover coming from Hall's Cycles here soon. They had to order the part, so I'll just live with this for a week or two.

I can't ride anyway... I'm still healing from Surgery and have the holidays coming up. I'll just be patient.


On a bright note, I had my o-ring chain soaking in degreaser since the tear down. A quick once over with a tooth brush and some fresh chain wax has it looking great. There was a ton of grime in the bottom of the bin it was soaking in. I was very happy to see the results and scared to see how much crap was in the chain.

 

[gump147]

Great looking bike who made the graphics maybe I read through to quick and missed it thanks

 

[RockefellerGG]

These are the GasGas 2012 Six Days graphics. They came with the transformation kit from Motocrosscenter.com


They fit all of the 2011 plastics except for the headlight. I cut apart the sections and trimmed them to make it work.