Newbie with clutch problem on EC 125 - 2002

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Newtogasgas

New member
Hello

First post on here. Thanks

So recently our family got a ?02 or 03 gas gas 125 ec. Not new to bikes but first GG I?ve had, interesting bike and look forward to getting it running for the kid.. Haven?t started it yet, changed all fluids and then came to addressing the clutch, empty, no handle.

So after losing some brake fluid into the gearbox, and having to drain the new good oil out, we have discovered both O rings on the clutch slave are bad ,the one on the piston and the one around it?s housing.

I am not coming up with much info, on these. So anyone know where to get such Orings?

Thanks
 

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Hello, and welcome!
Where are you located?

I guess any decent gasgas dealer should be able to source them, but also bearing shops, as long as you know what type of o-ring you need. And the dimension of course.

Just a word of caution: You wrote "brake fluid". Not all Gasgas clutch cylinders use brake fluid, some use mineral oil. I presume your clutch master's resevoir cover has a text about what type of fluid to use.
 
That is a very clean GG 125! How does the inside of the slave cylinder look where the O-rings ride? Those O-rings look horrible. Is it possible the previous owner put the wrong fluid in the master cylinder? If so disassemble the master too and clean it out.
 
That looks in great condition for a 02 or 03 bike, I'm sure you'll have great fun on it once you get your clutch problem sorted. :D

All the best, Dave.
 
Thanks guys. Ya the bike is in great shape, just need to find these dang o rings

Sorry I?m located in US- Wa state

Inside of the Soave area there is mint, either whoever replaced them boogered them up or that way from factory, this bike has been sitting for years.

Any idea on the o rings? I don?t need the piston , it?s still mint, and there was no spring in it, so literally just need those 2 o rings to get it back together and see if all is well there and the master cylinder.

Yes it says dot 4 on the reservoir cap.
 
Hey there

Ya not having much luck finding just the orings.

Yes that kit is all I?m finding also, and I emailed go faster , and they say there dealers had that kit and outer o ring, and was checking on if just the o ring is available

Dang it..this dumb little thing is holding up the show
 
Do you have any industrial areas near you?

Not sure how things are in the USA but here in UK/Europe there is normally a 'Bearings and Seals' shop in most industrial areas. If you take the parts to them and explain what they're for they should be able to supply suitable size O rings made of the correct material.

Probably much cheaper than buying original parts too! :)

All the best, Dave.
 
Davehuge said:
Do you have any industrial areas near you?

Not sure how things are in the USA but here in UK/Europe there is normally a 'Bearings and Seals' shop in most industrial areas. If you take the parts to them and explain what they're for they should be able to supply suitable size O rings made of the correct material.

Probably much cheaper than buying original parts too! :)

All the best, Dave.
Click to expand...

Same here in Australia..
 
You should confirm if this bike has any aluminum clutch plates and replace them with steel plates if it does. It may be specific to the MC 125, but the aluminum plates do not last. There were usually a mix of steel and aluminum plates in the MC 125 clutch pack.
 
This is a 125 ec

Ya , nothing real close as far as bearing shops go, big places are within a hour but not sure how much help there gonna be for a few bux in o rings..

I?m surprised this isn?t already figured out somewhere..
 
I suspect the clutch was designed by Magura and therefore you could use a KTM oring on the piston. Slaven sells one for 5 bucks and might be worth a shot.

https://slavensracing.com/shop/slave-cylinder-o-rings-ktm-husqvarna/

I have a 02 MC125 and the bike is a hoot. Basically a copy of the 98-01 YZ125 motor. I'd suggest a smaller carb as the 38mm on mine was overkill for sure and made it tough to get the jetting dialed for a wide range of conditions. I ended up with a 95 KX125 35mm PWK and the bike is sooo much better now. I also found the head squish to be big and having the head cut made it run smooth and clean..
 
The Orings have a small cross section and may be difficult to find. The mfr of the slave cylinder could be Magura but I would have guessed AJP to match the master cylinders.

I agree on the 35mm PWK from the KX125. I had a post a while back that provided the proper Boyesen coupler from the carb to the reed cage. The 35mm has a smaller output diameter. It ran much better on the bottom and still screamed on top. You can also add some ignition timing to help bottom end too.
 
Zman said:
The Orings have a small cross section and may be difficult to find. The mfr of the slave cylinder could be Magura but I would have guessed AJP to match the master cylinders.

I agree on the 35mm PWK from the KX125. I had a post a while back that provided the proper Boyesen coupler from the carb to the reed cage. The 35mm has a smaller output diameter. It ran much better on the bottom and still screamed on top. You can also add some ignition timing to help bottom end too.
Click to expand...

Boyesen coupler RB-10
 
Hey thanks a lot for the replies.

So didn?t hear back from gofasters, so not sure.. there the only one that replied saying they could probably find it..

Ya I?m tempted to hit the bearing place a few towns over and see if any luck.

The outer , thinner one I suspect will be easier, but the main one on the piston , as said above wider then a usual o ring and not sure if it?s possible to find one or, if a regular one will work..
 
... but the main one on the piston , as said above wider then a usual o ring and not sure if it?s possible to find one or, if a regular one will work..[/QUOTE]

Interesting. I never had need to work on the clutch slave cylinder of our 125s. I assumed it was similar to the 200-300 bikes that have small cross section orings on the slave cylinder piston.

Good luck with the search and please let us know what you find.
 
It's probably a X profile that seals in both directions. Also known as a quad ring seal. The KTM one is a single oring profile as the piston has a groove in it.

Matto Cycle in PA is a big GasGas dealer too. In a quick search for the part number it looks like it is a 40-50 for the whole unit and still available.
 
Who has it available?

The guy I was talking to , his dealers ?said? they had it but after checking are having a problem locating the kit, as sold only that way.

Drove to a few bearing shops and none had the right size or kind..

This is ridiculous
 
125 clutch slave

I found what appeared to be a piece of "welding slag" in my slave over a year ago. Brand new,with about an hour on it since new. After dressing the inside sealing surface of slave housing, I tried to replace the piston with new. It didn't work well. I went ahead and purchased a new slave cylinder assy from Bud Mattos. Problem solved, after another lesson in bleeding the system multiple times...
In short, the seals are only available with the piston assy, which is at least $50.+... unless someone else has sourced the seal elsewhere, that's the best info I have at this point.
The one you have pictured for your 02 model, looks like my '15 model also.
The truth of the matter is, these are quite underrated 125s imho, I like mine a lot !
Best wishes with yours
 
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