New to me 2002 EC250

[toadl]

[ QUOTE=pscook;128639]Those are labeled PRO-09, not PSR 21 or PRO 21 (If I remember correctly). You might have the wrong reeds. I believe that the GasGas reeds that cross with Yamaha reeds only appeared on the Yam for one year. I'll see if I can dig up the number from my posts on this.[/QUOTE]

You are correct. I figured it out later. The PSR-09 are for the 1996 yz250 with the Rad reed block. I emailed Boyesen and if they have a reed specifically made for the gasgas I'll get that unless its $$$$$$$.

 

[toadl]

11 OZ fly wheel weight is what you have .

Whow! I totally missed this post. It was at the bottom of the page. Thanks for the info. May I ask how you know?

So I took the forks apart. I don't know if I mentioned earlier, but when I took the old fork springs out I measured the oil level. At 150mm from the top I gave up and decided the forks needed to be rebuilt. I ordered All Balls Fork Bushings, because I got a good deal ($23), but after looking them over I wish I would have gone with stock bushings. I did get the expensive SKF seals and wipers. I am really happy with the purchase. You can see the difference in quality, they really seal up tight, and there is hardly any friction.
Here is a pic of the old bushings. You can see the wear.


The bike is getting back together. I got the rear wheel on and noticed the rear caliper isn't letting go. It's cold outside so it's hard to find time to work on the bike. But in the next couple days I will compress the caliper on the rotor and release the pressure through the bleed valve. If the caliper stays tight I'll have to rebuild it.
So many little things wrong with this bike.

 

[toadl]

Cleaned the radiator out with distilled water and vinegar. Which obviously means I had to fire her up. Bike is pretty much complete.

This is what I cleaned out of the radiator, not including the stuff I spilt on the garage floor.


I haven't done anything cosmetically yet, but it sure looks better knowing all those parts are working as they should.
When I put some hours on the bike and fall in love with her. I'll give her the beauty treatment and post pics.

 

[toadl]

Two months later

Well, nothing has been finalized with this bike, but are you ever done working on your bike. I got the bike all put together and rode it at an indoor MX track and then at a gravel pit while there was still snow on the ground. I have to say I was still kind of neutral about my feelings toward the bike. At the Gravel pit I was having clutch problems, which ended up being just clutch adjustment. That was just frustrating.
My last ride was two weekends ago, a weekend before the first race of the year. It was my first chance to ride it on single track. Let me be frank, I hated it, It wouldn't turn, the ergo's where really low, and it just tired me out. I posted the bike on craigslist, but some friends saw it and convinced me to give it some more time. After a couple days, I kind of figured every bike needs some adjustment and tuning.
On Saturday I measured the Sag, 116mm and changed it to 106mm. I also had 10mm of preload on my new fork springs. I took out one 5mm spacer in each fork and raised the forks in the clamps about 5 mm. I installed a much higher handle bar bend, adjusted the rear brake position (I wasn't sure how I wanted it adjusted because it has that built in slop. I needed to lower it because on the trail I was having a hard time finding the rear brake lever), I also loosened up the suspension, and I installed the racing numbers.
So, now I have to wait to ride this thing again and really spend some time getting used to it and tuning the chassis.

 

[bowhunter007]

It's a good lookin' machine. I've only had one bike...ever, that I liked as I purchased it. My 03 Gasser was close, but not the one. I learned how to set up a bike(for me), the hard way...(trial & error, spending money). I've calculated the cost of a new machine + setup...expensive. I've almost given up "that" dream, while I finish rebuilding my 03 GG, & my old KX for a lot less money. I guess it's entirely possible that your Gasser just doesn't suit your particulars. All 3 of my GGs were excellent bikes...once I learned what I needed from them, and spent the money to get 'em that way. Good luck with your GG, I hope it works out, in your favor.

sent from my Sony Experience Z1s

 

[toadl]

It's a good lookin' machine. I've only had one bike...ever, that I liked as I purchased it. My 03 Gasser was close, but not the one. I learned how to set up a bike(for me), the hard way...(trial & error, spending money). I've calculated the cost of a new machine + setup...expensive. I've almost given up "that" dream, while I finish rebuilding my 03 GG, & my old KX for a lot less money. I guess it's entirely possible that your Gasser just doesn't suit your particulars. All 3 of my GGs were excellent bikes...once I learned what I needed from them, and spent the money to get 'em that way. Good luck with your GG, I hope it works out, in your favor.

sent from my Sony Experience Z1s

I think the racing numbers are really going to make an improvement. My next race, hopefully, is an enduro on June 1st. I plan on racing the Gas Gas.

 

[Moto7man]

Its tough getting use to a new bike. Initially, I struggled with the suspension on my 2011. Then I sent the forks and shock to Drew Smith at Works Enduro Rider for a revalve and skf seals. That was the best dollar for dollar investment that I have ever made. Before the revalve, the suspension was decent in the front and good in the rear. Afterwards, both ends were awesome! Proper setup makes a huge difference.

 

[toadl]

Its tough getting use to a new bike. Initially, I struggled with the suspension on my 2011. Then I sent the forks and shock to Drew Smith at Works Enduro Rider for a revalve and skf seals. That was the best dollar for dollar investment that I have ever made. Before the revalve, the suspension was decent in the front and good in the rear. Afterwards, both ends were awesome! Proper setup makes a huge difference.

I believe you. I hate to send the suspension in to someone until I do my best to adjust the screws. Who knows who/if/what for the suspensions been done before.
I installed SKF seals on this bike and can't wait to put them on my other bikes. They really are a step above the others.

 

[toadl]

I rode a little this weekend, mostly just riding up and down a steep hill. I'll I can say is riding a 250 two stroke up a hill is a lot different the a 250 four stroke. No worries about power, just trying to keep the front wheel on the ground or steer with out it.

 

[1RobAusdemore]

I just bought a 2003 EC250 this weekend, unfortunately I do not know very much about these bikes. I appreciate your thread because I learned a lot already. Mine is just going to the cabin and be ridden on whatever trails I come across, so I don't think I am going to dive into the bike the way you did. From what I can tell everything is working as it should. It is in very nice shape and clean. Now for the question. What did you end up doing about the reeds ? And how much were they?

 

[toadl]

I just bought a 2003 EC250 this weekend, unfortunately I do not know very much about these bikes. I appreciate your thread because I learned a lot already. Mine is just going to the cabin and be ridden on whatever trails I come across, so I don't think I am going to dive into the bike the way you did. From what I can tell everything is working as it should. It is in very nice shape and clean. Now for the question. What did you end up doing about the reeds ? And how much were they?

Sorry, I didn't see your ? until now. I bought Boyesen carben fiber reeds PSR-21. Boyesen replied after about a week and told me they are for the Gas Gas. I bought them for $50 on Amazon. Enjoy the bike.

Finally had a real trail ride to test the bike on. 2 days and about 120 miles of trails. Bike handled really well after I adjusted the fork preload, raised the forks in the clamps, and adjusted the sag to 107mm. I really messed a lot with the compression and rebound adjustments. I set the compression a lot softer then what was recommended in the owners manual. It still handled some pretty big whoops in 6th gear really well. I've never messed with rebound adjustment much until this weekend and so that added to the learning curve. It helps I don't need any tools to adjust rebound. I leaned up the carburation. I went down a size in the main (178), dropped the DKK needle to the 2nd slot from top, and I'm going to replace the 45 pilot with a 42 (I have the air screw all the way out.) Throttle is crisper, but the biggest issue was I ran out of gas a lot quicker then 3 other riders all on Gas Gas dirt bikes. It's going to take a while to get used to this power. The first turn I made the rear tire swung out on me and the first jump I almost flipped over backwards.
Rode a friends 2013 xc200. A few things I noticed was that his suspension is really smooth or another way of putting it is better, the 200 power is so much easier to control, and I came to the realization my Gas Gas ended up being set up a lot like my WR250F.
I'm planning on racing the EC250 in the next Enduro. Before I do that I'm going to adjust a little less sag. I want the steering a little quicker. I'm also going to install that 42 pilot. I'm hoping the quicker acceleration and having to use my brakes (no engine braking) will help my times.

 

[toadl]

Just an update. I got 3rd in my class at the last endure. Best ever. I also did some test riding and on a 6 mile loop I was 30 seconds to a minute faster on the Gas Gas then my WR250F. I did two laps with each. Not a big difference but if the results are accurate in a 60 mile enduro that's possibly 10 minutes.

I eventually went with a 38 pilot. Front end lifts easily now for log crossings and bike idles much better. Also the Sag is set at 104mm and seems to work pretty good.

I'm starting to grow fond of this bike.

 

[1RobAusdemore]

Where was it at?

 

[xcracer440]

Hello fellow GG riders. Earlier this week I purchased what I believe is this bike. It still has the 241 on the sides and its still in the ND/MN area. If the owner of this thread could PM me I would love to learn more about this bike's history. I'll also be sticking around here for a while as I really like this bike!