Plastics Conversion - 2005 x 2011 - Airbox Issue

[Marcão]

Dear All,

I've recently bought in Spain a kit to convert my EC 250 2005 into a 2011. It comes with a full set of plastics and graphics, sub frame and complete seat. However, when started to assembly the new airbox I really didn't understand how to attach the rubber boot to the airbox front cover (parts 2 and 14 in the attachment). Any idea ????

Thanks a lot in advance !

 

[Todd5774]

When I did mine I used the 05 carb boot and drilled holes in the airbox panel so that it still installs the same as your 05 design.

 

[Marcão]

When I did mine I used the 05 carb boot and drilled holes in the airbox panel so that it still installs the same as your 05 design.

That means you keep that metalic parts from the 2005 carb boot ? Because the 2011 doesn't seem to use them (at least in the parts diagram). I woul like to know how the boot is fixed to the front airbox panel in a 2011 bike... But it's really not so simple to find a 2011 to give a quick look here where I live...

 

[Jakobi]

I hav a 2010. Same design. The air boot rubber has 2 lips and push fits into the airbox like a big bad gromet. I've never taken mine out but from what I can see thats how it works.

 

[jhendr3702]

I hav a 2010. Same design. The air boot rubber has 2 lips and push fits into the airbox like a big bad gromet. I've never taken mine out but from what I can see thats how it works.

that is exactly how mine is.. on the 07 with 11 rear fender..

 

[Marcão]

that is exactly how mine is.. on the 07 with 11 rear fender..

Thanks a lot Jakobi and jhendr3702.
Now it makes some sense. I will disassemble the 2005 boot and see how it fits (in the mentioned way) to the new cover. Probably it will be necessary to apply some silicon in the lips...

 

[Jakobi]

Yeah part 2 pushes into the hole in part 14. You might need to lube it up to slide it in, but definately dont need any sealant as the air filter mounts directly to the boot. Parts 8 and 13 I have never seen and are for emissions control.

Looking forward to seeing the finished product!

 

[lonetree]

Dont suppose you would have a link to where you bought your conversion kit from?
Are they actually sold as a conversion kit? or just an order of the required parts?
look forward to seeing photos of your finnished bike.

 

[gasgasman]

Now it makes some sense. I will disassemble the 2005 boot and see how it fits (in the mentioned way) to the new cover.

The 2005 boot won't work with the new air box.

 

[Marcão]

Dont suppose you would have a link to where you bought your conversion kit from?
Are they actually sold as a conversion kit? or just an order of the required parts?
look forward to seeing photos of your finnished bike.

Lonetree,
I live in Brazil but working for a Spanish company, so I travel in a regular basis to Spain. I bought the kit at greenlandmx.com. As far as I know they are shipping overseas. I've paid 359 Euros for the Kit. The link for the kits page : http://www.greenlandmx.com/adhesivos-y-fundas-gas-gas-lp-1-50-familia-45/. Look for the "Kit Transformacion".

 

[Marcão]

The 2005 boot won't work with the new air box.

Gasgasman,

The boot does fit the airbox front panel (inclusive the gasgas part number for the boot is the same for both years - 05 and 11). Lets see if I will find some problem when assembling the new air box to the subframe (which is also supplied with the kit).

 

[gasgasman]

Yes ,you are right.
I was thinking of my 2001 Gas Gas that had the retaining bolt for the air filter.

 

[Jakobi]

Dont suppose you would have a link to where you bought your conversion kit from?
Are they actually sold as a conversion kit? or just an order of the required parts?
look forward to seeing photos of your finnished bike.

http://translate.google.co.uk/transl...ucts_id=2899

 

[Marcão]

Guys,

One more simple question... Is there any rivet linking the front and the bottom cover of the airbox (parts 14 and 15 of the diagram) ? I've mounted them in the subframe and everithing is so tight and firm that I don't see the need of rivets...But would like to know how it's out of crate in the 2011's...

Thanks in advance !!!

 

[Marcão]

Finished...

After roughly 2 months the conversion is ready.
Considering that mechanically my bike was quite ok, the main reason for doing a conversion like this in Brazil is the price for a new bike. A 2012 EC 250 costs here around US$ 14.000 and I would get not much more than US$ 5.000 in my 2005. I spent around US$ 1.500, in this conversion (basically because I've been travelling to Spain several times this year and had the chance for buying the parts there) and the bike looks quite new again.
Follow a few pics...

 

[Jakobi]

That looks fantastic! Top work mate! Now to get some dirt on it

 

[desertgasser300]

That looks great. I love the 11' plastics with the nickel frame.

 

[Diggs345]

By the look of the old plastics it just gets polished lol

 

[Marcão]

Thanks for the comments.

Besides new cosmetics I've added a set of new valve reeds, changed all oils and fluids, the gas of rear shock, new chain and sprocket, new chain slider and TM chain guide, Trimetal sprocket, cleanned the carb, a CCK needle and, most important, a machined head to adjust squish.

But today I've noticed that the rear spring is rubbing tha carb boot. Probably because the boot was slightly deformed by the previous subframe. Must check...

 

[lonetree]

looks great, just like a new one.
did you have any problems getting everything to fit? how about the exhaust?
top job.