Advise required

[Martin-EC300]

Can someone tell me what the purpose of this nipple is? It appears to be blanked inside? Should it be hollow?

It locates in front, next to the exhaust outlet

 

[Martin-EC300]

More questions to follow... I'll keep them all in this thread

 

[poelinca]

It's a hose connection, and yes it should be hollow. A hose should connect to it and run down to under the skid plate. The "gunk" from the exhaust should leak thru it.

There should be another one on top of the RHS PV cover.

The picture bellow is taken from the manual of EC300 2014 model, codes may not apply to your year model.

 

[Martin-EC300]

Thanks, I've been using the 08 diagram to help with the rebuild, this one item has caused me a bit of head scratching... The natural assumption was that it's supposed to be hollow.. But I've even tried knocking the blockage out.. Time for the drill

 

[poelinca]

I think it should work with a heater ? i may be wrong tough. Don't drill it out till others come in and help, i'm not the most mechanically inclined around there nor do i have the experience.

 

[Martin-EC300]

Ok job done! It was completely blocked with carbon!

Next question:

The illustration shows 2 base gaskets, is this just to show more than one is available or do I need to use 2? Also do you guys use gasket paste/sealant

Thanks in advance

 

[swazi_matt]

there are about 3 or 4 base gasket thicknesses

I bought a whole collection before my rebuild hoping to adjust the squish slightly, but then discovered a slight lip at the top of my cylinder so decided to keep the base the same thickness to avoid contact with the lip

I only use a bit of grease on the gaskets that may need to be opened from time to time, eg water pump, clutch and rhs engine cover, this is just to stop them sticking and tearing (very common around the water parts.

OH and i use a fairly generous amount of grease to keep the o-rings in place on the cylinder head

 

[Martin-EC300]

That's great, thank you!!

Ok break time over.. Back to the garage!!

 

[imsimon]

stick as many pics in as u want Martin, I like watching things progress

this was my attempt in the link ures should be up and running in no time




http://www.gasgasrider.org/forum/showthread.php?t=20924

 

[Martin-EC300]

Sorry not got much to post, nothing anyone can learn from I'm afraid, just random progress

 

[Martin-EC300]

These O-ring are a real PITA .. Currently having a time-out otherwise I'm gonna put an angle grinder to the bike!!!!

Can't find grease strong enough to hold them in place

 

[Zman]

I gently stretch the orings before install.

 

[Martin-EC300]

Makes sense! now the blind rage has subsided I'll apply some logic and give it another go..lol

 

[Capz85]

I think you get 2 sets of o rings with those gaskets one set is slightly larger than the other

 

[Martin-EC300]

Yeah, I guessed the smaller ones were for the 250??? Anyway it's done

 

[Martin-EC300]

 

[Martin-EC300]

This is all being done in real time, so those of you that have offered advice along the way, you have my gratitude

 

[Martin-EC300]

The engine mounts are looking pretty sorry for themselves, so gonna rub em down, zinc prime and paint

 

[Capz85]

The nut in the powervalve arm looks tight, usually want to leave it slightly loose so the arm can move freely.

It's caught me out before

 

[Martin-EC300]

Ok I'll back it off slightly, that explains why it's a nyloc .. Thanks