Question : How can I get the ignition on '99 to '04 200/250/300 water tight?
Answer : So, how does the water get in? The first thing you should know is that there is a vent hole at the bottom of the case that vents to the outside and also lets moisture into the case. In addition, gasgas currently uses a composite cover that can let water into the case at the mating surface.
The seal at the ignition cover can be improved by lapping the mating surface of the cover. Obtain a small and thick piece of plate glass - this will give you a nearly perfect flat surface. Alternatively, the "table" on a drill press or table saw can be used. Lay a piece of extra fine sandpaper on your "very flat surface" and rub the mating surface of the ignition cover against it lightly (in a circular motion) to ensure that the mating surface is completely "flat".
To get a good seal on the gasket, grease the gasket prior to installation along with the rubber plugs. You can also use two gaskets in this location versus one to get a better seal - this will fill voids and give a better seal where the hump is for the counterbalancer (on older models).
As for the hole in the bottom of the case? Some plug it - not sure if this is advised or not. It is a good idea to remove the ignition cover occasionally and spray it down with CRC 2-26 displace the moisture and to combat corrosion. It is not advisable to use WD-40 as components in it have been shown to degrade the insulation in the windings.
On a related topic - dielectric grease can be used to waterproof connections and to avoid corrosion in these connections.
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Input on this one?
thanks,
jeff
Answer : So, how does the water get in? The first thing you should know is that there is a vent hole at the bottom of the case that vents to the outside and also lets moisture into the case. In addition, gasgas currently uses a composite cover that can let water into the case at the mating surface.
The seal at the ignition cover can be improved by lapping the mating surface of the cover. Obtain a small and thick piece of plate glass - this will give you a nearly perfect flat surface. Alternatively, the "table" on a drill press or table saw can be used. Lay a piece of extra fine sandpaper on your "very flat surface" and rub the mating surface of the ignition cover against it lightly (in a circular motion) to ensure that the mating surface is completely "flat".
To get a good seal on the gasket, grease the gasket prior to installation along with the rubber plugs. You can also use two gaskets in this location versus one to get a better seal - this will fill voids and give a better seal where the hump is for the counterbalancer (on older models).
As for the hole in the bottom of the case? Some plug it - not sure if this is advised or not. It is a good idea to remove the ignition cover occasionally and spray it down with CRC 2-26 displace the moisture and to combat corrosion. It is not advisable to use WD-40 as components in it have been shown to degrade the insulation in the windings.
On a related topic - dielectric grease can be used to waterproof connections and to avoid corrosion in these connections.
-----
Input on this one?
thanks,
jeff
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