Plastic removal

[dalbertog]

Guys, I have a new (to me) '10 EC250 that I want to take apart and clean up for this season, however I am stuck on taking the rear plastic off. Its a three piece system (including the fender) that I can't figure out. Can someone PLEASE let me know how to get those plastics off without me destroying them, thanks for the help.

Looking for a push in the right direction.

 

[gasgasman]

Remove the seat.
Remove the bolts at the front of the side number plates and the two at the rear of the number plates that screw into the subframe.
Then slide the fender/number plate assembly off.

 

[swazi_matt]

The gasgas web site has parts manuals that you can download for all years. It will help see how everything goes together/comes apart

 

[poelinca]

The gasgas web site has parts manuals that you can download for all years. It will help see how everything goes together/comes apart

Here it is, manuals for 2010 http://www.gasgasmotos.es/en/manuals/models-2-2010.html

 

[dalbertog]

Guys, thanks a million, that parts list is something I could really use, however, I am not sure, but (i think) it does not show the airbox cover/plastic. I found the screws, but it looks like the airbox cover somehow fits into the fender shroud and I still can't figure out how to dislodge the middle/airbox cover to be able to undo the rest of the plastics. I have the radiator shroud and gas tank off (piece 'o cake), but I still cant figure out the last two pieces. Maybe its just me...

Help

 

[JP4]

It's a bit of a dose to get it apart - worse trying to reassemble - as you have to push and pull at the same time. You have to remove the plastic rivet thingys that secure the side covers to the airbox. I just drilled them out, cut an M8 or M10 thread into the aluminum subframe and replaced with big button head screws and a washer. To get the side covers off, you have to push them forward to clear the pins on the front of the airbox, while at the same time working them free where they interlock with the tails of the fender that form the other half of the number plate. Then you can tackle the rear fender which takes a quite a bit force to get free. Good luck mate.

 

[dalbertog]

JP4, thanks for that insight. Its been a while, but I've managed to get to/at most of the bike and repair, clean, and inspect 95% of it. However, I am still stuck on getting that ?#$@ air box cover off. You mentioned taking the rivets out and replacing them (you said "cutting in") with an M8, or M10. Could you walk me through how you did that. I am at the point where the carb and new exhaust are ready to go back in. I would like to replace some of the plastics also, especially around the air box. If I can just get those plastics off ...

Thanks.
Dalbertog
'10 EC250

 

[poelinca]

Have you considered to take the sub-frame off for easier access ? That's what i did on my '14, i took the sub-frame off with the air box in. After that it's very easy as you can twist and turn the whole thing as you please to get access on any screw you need (you need to remove all the back plastics, rear fender, etc off).