Newer Plastic on Older GasGas show your bike

[MNKeith]

More questions. Been through this thread and not finding a clear answer.

I have an '08. Bought the '11 Polisport kit through motocross center. I received the back half of the black air box. I mounted the '08 front panel of the air box on the new one which was an exact fit. Put it on the bike and things don't seem right, even after a little shaving. The rear fender plastics are lined up with the subframe bolt holes, but the outer plastics are not lining up with the mounting points of the inner fender/air box piece. The right hand side air box cover does not match up at all with the air box, there's quite a gap at the front.

Do I need the '11 front air box piece as well?

I looked at the '08 vs '11 on the microfiche and the part #s are the same which leads me to thing the answer is no - however the fitment leads me to believe otherwise.

Part 14, I believe.
http://partsfinder.onlinemicrofiche...asgasdb&a=90&b=19&c=0&d=2011 EC250 AIR FILTER

Long story short. Back half '11 plastics are not lining up well at all.

 

[stay_upright]

Side panel bolts

To anyone who has fitted the upgrade kit, what bolts or screws did you use for the bottom of the side panel plastics? There is a 6 or 8 mm hole untapped in the subframe but the plastics look like a 5 or 6 mm bolt at the biggest.

Also if the red anodised washer is for the seat what bolt are you supposed to use? The washer looks like it is for an 8mm bolt but the subframe tapping is for a 6 mm??

 

[stay_upright]

Keith, the '11 or 12 plastics require a little settling but fit reasonably well its obvious they are the correct parts. If yours obviously look wrong I would guess they are but maybe you can post some pics to tell for sure.

 

[nknudsen]

To anyone who has fitted the upgrade kit, what bolts or screws did you use for the bottom of the side panel plastics? There is a 6 or 8 mm hole untapped in the subframe but the plastics look like a 5 or 6 mm bolt at the biggest.

Also if the red anodised washer is for the seat what bolt are you supposed to use? The washer looks like it is for an 8mm bolt but the subframe tapping is for a 6 mm??

In your limited hardware bag from GG, look for the plastic screws with the expandable thread inserts. That is what lightly holds the lower air box side panels to the lower struts of the sub frame. Use a 6mm flanged bolt with the red seat washer. I used a smaller diameter rubber washer on the bottom side of the seat that the bolt goes thru to keep the bolt always with the seat.

 

[nknudsen]

More questions. Been through this thread and not finding a clear answer.

I have an '08. Bought the '11 Polisport kit through motocross center. I received the back half of the black air box. I mounted the '08 front panel of the air box on the new one which was an exact fit. Put it on the bike and things don't seem right, even after a little shaving. The rear fender plastics are lined up with the subframe bolt holes, but the outer plastics are not lining up with the mounting points of the inner fender/air box piece. The right hand side air box cover does not match up at all with the air box, there's quite a gap at the front.

Do I need the '11 front air box piece as well?

I looked at the '08 vs '11 on the microfiche and the part #s are the same which leads me to thing the answer is no - however the fitment leads me to believe otherwise.

Part 14, I believe.
http://partsfinder.onlinemicrofiche...asgasdb&a=90&b=19&c=0&d=2011 EC250 AIR FILTER

Long story short. Back half '11 plastics are not lining up well at all.

You should have all of the right parts, can you show a few pics of the issue?

 

[MNKeith]

Here are some pics of my issues. I added notes to them which should explain it. I've tried pulling and bending and stretching and not getting very close. Something is not right.

 

[nknudsen]

Keith,
Show a photo of looking down at the air filter area / rear of tank. What's keeping the whole air box/inner fender assembly from moving further back?

 

[stay_upright]

Here are some pics of my issues. I added notes to them which should explain it. I've tried pulling and bending and stretching and not getting very close. Something is not right.

It 100% looks like the wrong part. From the kit I have the Suomi which i think is 2011 or 12 that front panel has 2 aluminium 'prongs' that stick forward and the tabs from the side panels fit over them - also the front face of the airbox site a good inch behind the shock - yours is very close.

 

[MNKeith]

Won't be able to until tonight - but the whole air box assembly is sitting in the subframe very tight. It has little to no wiggle room against all sides.

 

[nknudsen]

Won't be able to until tonight - but the whole air box assembly is sitting in the subframe very tight. It has little to no wiggle room against all sides.

Check out this item on E-Bay, it shows a complete assembled air box & sub frame assembly for reference. Item # 251850656392

 

[MNKeith]

Well I'm not sure what to say. That bastard was in there and not moving, I had fought with it numerous times. Tonight, it just "snapped" back into place and now all is well.



But happy. Thanks!

 

[nknudsen]

Well I'm not sure what to say. That bastard was in there and not moving, I had fought with it numerous times. Tonight, it just "snapped" back into place and now all is well.



But happy. Thanks!

I had to study mine and try it a few times before I got it.

 

[MNKeith]

It's finally all back together and running. Complete motor rebuild, suspension refresh, new parts, powdercoat and a lot of other junk.

Huge thanks to this forum for the resources.

On topic...'11 plastics on '08.

 

[Rick]

It's finally all back together and running. Complete motor rebuild, suspension refresh, new parts, powdercoat and a lot of other junk.

Huge thanks to this forum for the resources.

On topic...'11 plastics on '08.

Looks awesome!!!

 

[HonayBadgerRy]

Are you sure you need to change the airbox on the 00 to fit 04 rear number plates?

 

[BigAl]

Here it is

Untitled by boardrider247, on Flickr

I have just received The 2013 Racing Kit for my 2005 EC300. my kit seems to contain way less parts than the above, do the kits normally contain the updated tail light assembly or not.

Also do I need to use part off my air box ? eg the airboot

Thanks in advance

Alan

 

[Jim Cook]

Are you sure you need to change the airbox on the 00 to fit 04 rear number plates?

Yes. The 2000 model didn't have the airbox door. That came on the 2001 models.

 

[gasgasman]

Here's my 2007 MC250 with the '10 plastic.

 

[Rick]

Here's my 2007 MC250 with the '10 plastic.

That a sano!!!

 

[dalbertog]

All of this refurbishing is making me jealous, where can I get new plastics for a '10 EC250. That's what I need, and I'm ready to do the work. I'd love to do '11-'12 plastics on my '10, does anyone know if can be done????