Rebuilding An Aging GasGas, Worth It???

[BLD]

In my case a well used 2013 300. Since buying it used I have racked up a lot of hours and raced in my first hare scramble. At this point I would rather rebuild this bike than buy new, especially for the low price I paid for the bike. It is a bit rough, and the frame, swingarm and wheels have plenty of scratches, gouges and missing paint.

My concern is finding some of the parts. Wheels seem to be hard to come by and mine are bent and well worn. I also have no idea which engine and trans parts may be hard to source beyond the top end kits I can find. What about springs and parts for the Marzochi forks? The only real change I would like to make is stiffer springs front and rear. I understand 2013 was a rocky time and many changes were made right before and after my model year...

Do you think it is worth the headaches to go for a rebuild? I am not too worried about getting things like the frame powder coated, plastics, cylinder replated, or the Ohlins rear shock rebuilt, but some of the important items seem to be tough to source. If I pull the engine out to have the frame powdercoated, and swingarm fixed/replaced I would like to be able to replace all the little bushings, bearings and seals while I am at it. If the bottom end needs a rebuild I would like to be able to find those parts as well. Is it still possible with all the changes in available parts for the older bikes?

 

[Moto7man]

It depends on how much you are going to ride it. You might just need to clean and regrease a lot of your suspension and swing arm bearings and just add new seals.A lot of the GasGas parts are very durable, the cylinders are very tough and wossner make a forged piston kit. An exception is usually the steering head bearings are just toast. Parts are available now in North America but they are very overpriced. I am still riding my 2011 300 without any problems and the bottom end and crank have never been apart.

 

[BLD]

It depends on how much you are going to ride it. You might just need to clean and regrease a lot of your suspension and swing arm bearings and just add new seals.A lot of the GasGas parts are very durable, the cylinders are very tough and wossner make a forged piston kit. An exception is usually the steering head bearings are just toast. Parts are available now in North America but they are very overpriced. I am still riding my 2011 300 without any problems and the bottom end and crank have never been apart.

Funny you say that. Looking at moving to the deep south very soon, and with the exception of cross country and enduro races, it may be a bit much for the motocross tracks and flat quad trails near where I am moving. I have no reason to believe that it needs anything more than a fresh top end, suspension rebuild/re-spring, wheels, rubber parts, plastics, and some new bearings... but to do all that and re-pack the exhaust, I may as well tear it all the way apart and make it look as pretty as it runs again...

Wheels are discouraging me, 2 months ago I found new Warp 9s complete in red/black for a good price at Rocky Mountain ATV, and now they list nothing for my bike. Anything on Marzochi forks seems to be hard to find as well...

 

[SS109]

Price out buying a new bike. Now, price out buying a used bike and the possible unknown issues and things that will have to be serviced at some point. Lastly, consider costs to rebuild your current bike, a bike that you already have an idea on what it needs.

Personally, I've always found it a better deal to rebuild what I have. Unless I just want a change, I always choose to rebuild.

 

[risk74]

If you can do the work yourself and have the time, you might come out ahead (well, as ahead as you can come out throwing money at toys!!). I just completely rebuilt this 2011 300. Purchased for $1,600 burning transmission oil. Now it has a KYB swap valved/sprung for my weight/skill, 270mm front brake rotor, new brake lines, House of Horsepower Pipe, Lectron carb, S3 head, newly plated cylinder, new piston, rebuilt crank, Barnett basket and lots of other stuff. Cost all in (including purchase) is about $4,500 USD. The thing rips and other than being a little heavier than new bikes and lacking electric start, it's all I could ask for.

I could have done it a lot cheaper, sticking with the stock pipe and carb, not replating the cylinder (it was decent), and keeping the stock front end/brakes, but what fun would that have been?

 

[BLD]

If you can do the work yourself and have the time, you might come out ahead (well, as ahead as you can come out throwing money at toys!!). I just completely rebuilt this 2011 300. Purchased for $1,600 burning transmission oil. Now it has a KYB swap valved/sprung for my weight/skill, 270mm front brake rotor, new brake lines, House of Horsepower Pipe, Lectron carb, S3 head, newly plated cylinder, new piston, rebuilt crank, Barnett basket and lots of other stuff. Cost all in (including purchase) is about $4,500 USD. The thing rips and other than being a little heavier than new bikes and lacking electric start, it's all I could ask for.

I could have done it a lot cheaper, sticking with the stock pipe and carb, not replating the cylinder (it was decent), and keeping the stock front end/brakes, but what fun would that have been?

Thanks and nice looking bike! I bought mine for $1800 OTD and have already added a Lectron, and Fixed the e-start. Definately worth rebuilding to me. It is not the lightest or best steering bike, but I like the quirks and it always gets me back to the truck!

Been wondering about a KYB fork swap. I prefer changing fork seals on my Marzochis over my friends KYB forks, but they can get parts anywhere... Good to know you were able to source parts for the crank rebuild. GGparts guy has been good so far for most of my parts.

 

[risk74]

Thanks and nice looking bike! I bought mine for $1800 OTD and have already added a Lectron, and Fixed the e-start. Definately worth rebuilding to me. It is not the lightest or best steering bike, but I like the quirks and it always gets me back to the truck!

Been wondering about a KYB fork swap. I prefer changing fork seals on my Marzochis over my friends KYB forks, but they can get parts anywhere... Good to know you were able to source parts for the crank rebuild. GGparts guy has been good so far for most of my parts.

http://www.kenoconnorracing.com/

Ken O'Connor Racing was recommended to me on this forum a few months ago for the crank rebuild. He did two cranks for me this fall. Price is very good, work is impeccable and he does it in the time frame specified.

I have two 2011s, one that was already converted to KYB and the other with WER valved Marzocchis. After riding the KYB front end, I converted the other one as soon as I could. Just refreshed one set with new seals/bushings/oil and it was not a tough job.

 

[Idahocharley]

I would rebuild - 2011 bike is not that old. Parts are readily available just check ebay: Zoke forks bushings/seals/springs/shims or contact MxTech for suspension parts Jeremy is very good or LTR. The engine hasn't changed very much in the bottom end or clutch area - power valve adjustment external added in about 2015 connecting rods and pistons haven't changed. So more of a side case change and minor change to water pump. If your looking for built wheels then maybe that could shock be a problem but you could just buy rims and rebuild with new spokes using your hubs. Plastics I think would be your only problem coming up with … some have updated with 2015 plastic I believe. The 2011 handles fine if it is set-up correctly for trail riding 2-4 gear stuff.

 

[SS109]

Plastics are readily available on Ebay as well.

 

[BLD]

I would rebuild - 2011 bike is not that old. Parts are readily available just check ebay: Zoke forks bushings/seals/springs/shims or contact MxTech for suspension parts Jeremy is very good or LTR. The engine hasn't changed very much in the bottom end or clutch area - power valve adjustment external added in about 2015 connecting rods and pistons haven't changed. So more of a side case change and minor change to water pump. If your looking for built wheels then maybe that could shock be a problem but you could just buy rims and rebuild with new spokes using your hubs. Plastics I think would be your only problem coming up with ? some have updated with 2015 plastic I believe. The 2011 handles fine if it is set-up correctly for trail riding 2-4 gear stuff.

Thanks! You guys rock! I?ll check out MXTech and Ken O? Connor. Hoping to be tearing into it within the next couple months. May make 1 more race first, my front wheel still turns

 

[(F5)]

Haha. . Aging. . . I saw this thread and assumed that you meant a 99.
My 07 is still going strong.

Wheels are expensive. Rims aren't. YouTube a wheel rebuild. I learnt by just doing it. Piece of Piss. Spokes are rugged if you haven't let them rust.
Penetrating oil and electric screwdriver makes it even easier.

 

[Moto7man]

Haha. . Aging. . . I saw this thread and assumed that you meant a 99.
My 07 is still going strong.

Wheels are expensive. Rims aren't. YouTube a wheel rebuild. I learnt by just doing it. Piece of Piss. Spokes are rugged if you haven't let them rust.
Penetrating oil and electric screwdriver makes it even easier.

If your spokes are shot, order a set from Buchannans, they are the strongest spokes that you will ever find and you can get them with a stainless finish. Good stuff.

 

[hadfield4wd]

Haha. . Aging. . . I saw this thread and assumed that you meant a 99.
My 07 is still going strong.

Wheels are expensive. Rims aren't. YouTube a wheel rebuild. I learnt by just doing it. Piece of Piss. Spokes are rugged if you haven't let them rust.
Penetrating oil and electric screwdriver makes it even easier.

No kidding. I have a '99 and '00. I am doing the '99 top end now. no problems. Getting a full grease on all the bearings as well as new silicone hoses.

The cheapest bike to have is the one you already own.

If your spokes are shot, order a set from Buchannans, they are the strongest spokes that you will ever find and you can get them with a stainless finish. Good stuff.

I relaced my front last fall with buchannans'

 

[BLD]

Haha. . Aging. . . I saw this thread and assumed that you meant a 99.
My 07 is still going strong.

Wheels are expensive. Rims aren't. YouTube a wheel rebuild. I learnt by just doing it. Piece of Piss. Spokes are rugged if you haven't let them rust.
Penetrating oil and electric screwdriver makes it even easier.

Haha, no its not that old... In this case its more of a matter of how hard the miles were as opposed to how many miles. Judging by the spare parts it came with, and how chewed up the swingarm and linkage guard are, someone had a good time with this bike!

 

[BLD]

Well now I did it! Think I blew the rings on my last ride. Started to sound lean on the way back to camp, and eventually died. It sounds terrible when I kick it, but it still turns over! Now I have an excellent excuse to tear into the bike!

I will wait until I get moved to the new house before I start dissasembly, and I think I will remove the engine to give me full access to everything. Ill document the process if anyone is interested and make a few youtube videos too.

Now to find a nice YZ 250 to ride for the summer while I gather all the parts and get the dull bits powder coated! I want this bike to look as cherry as it will run, and if I buy a backup bike it will be something I can find parts for anywhere... I only have the patience for 1 exotic at a time!

 

[Moto7man]

One exotic or one old bike at a time is a good rule. Otherwise

 

[Zman]

Old GGs never die! We have nine of them in our riding group between the years of 98 and 04. They are the most reliable bikes we have owned. There are plenty of new and used parts available.

Although, presently we are in search of a frame for a 2000 EC200. My nephew often confuses his GG with a jet ski watercraft and the frame is severely rusted.

One more thought on the comparison between the rebuild and a new bike. Both comparisons need to include the cost of additional guards, suspension and other personal fitment items to suit the rider. Those bits add up quickly.

 

[(F5)]

Bet it will be the left crank bearing and everything else will be fine.

 

[Moto7man]

The GGs are actually very tough.

 

[RBrider]

Bet it will be the left crank bearing and everything else will be fine.

+ 1

That's what happened to my '01 XC 200.