Jacob 'Berg
Member
I was able to confirm that the 04 transmission parts will work in the 2011. I will know for sure once I have split the cases on the 04 bottom end. Hopefully everything matches up.
Last edited:
Tranny Failure
- Thread starter Jacob 'Berg
- Start date
Jacob 'Berg
Member
While you're there you might as well put crank bearings in. Check the trans bearings too, and clean them very carefully if you decide you're going to keep them. Add a shift fork or two to your list and check the math.
I wouldn't trust the parts fiche () - give Mark a call to make sure you're getting the right pieces, part numbers be damned.
Crank bearings seem in order and have only 50 hours on them, so I may leave them. I will take a good look at the transmission bearings and will most likely replace, although the failure was immediate and I doubt that any debris was likely to make it's way into the bearings.
Jacob 'Berg
Member
Trying to find a bottom end gasket kit and some seals. I was quoted 3 months from the Gas Gas dealer for the gasket kit and two months for one of the seals. Any help would be greatly appreciated.
https://www.amazon.com/gp/product/B00IRWLXRM/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
I've bought two of these. Complete set, everything you need. Not the toughest gaskets, so be careful. Use a very small amount of RTV to keep them stuck in place for assembly. As far as seals go, I would get measurements and start looking for alternative sources.
I've bought two of these. Complete set, everything you need. Not the toughest gaskets, so be careful. Use a very small amount of RTV to keep them stuck in place for assembly. As far as seals go, I would get measurements and start looking for alternative sources.
pscook
Platinum Level Site Supporter
Bob Piper at North Tahoe Motorsports. His ebay store only lists top ends for the 300, but he has complete gasket kits in stock. Plus he is a wealth of information.
Jacob 'Berg
Member
I tried, sent a message via his ebay store, but got no response.
Jacob 'Berg
Member
Thanks for the head's up. I purchased a similar kit from Great Britain, as I could not find any on ebay from the states, but still 3 weeks out. I may be able to get the gaskets I need a little quicker as some of the members that make this site great have offered some help.
I am going to take ID, OD, and depth measurements and try to source the seals locally. The only one that may be an issue will be the water pump seal. Not a big deal though, as this is easy to get to when replacing.
Zman
Platinum Level Site Supporter
Here is a list of seals minus the water pump. I believe the seals are the same from year to year but you should double check to make sure these look correct in size for your engine.
1 x LHS CRANK SEAL KOK 20x35x6 ? VITON ktm 47030076100 04-14 105 85 65
1 x RHS CRANK SEAL KOK 38x52x7 - VITON ktm 0760385273 94-14 250 300
1 x COUNTERSHAFT SEAL 30x40x7 Suzuki 09283-30061
Shift Shaft Seal 12x22x7
KICKSTART shaft SEAL 20X30X7
1 x LHS CRANK SEAL KOK 20x35x6 ? VITON ktm 47030076100 04-14 105 85 65
1 x RHS CRANK SEAL KOK 38x52x7 - VITON ktm 0760385273 94-14 250 300
1 x COUNTERSHAFT SEAL 30x40x7 Suzuki 09283-30061
Shift Shaft Seal 12x22x7
KICKSTART shaft SEAL 20X30X7
Jacob 'Berg
Member
From the parts fiche it looks like there are two seals on the counter shaft, one covering the bearing, and another that is accessible from outside the case.
Jacob 'Berg
Member
Got the bottom end buttoned up today. Transmission gears from the 2004 bottom end looked flawless and mated up perfectly. Glad I did not drop the extra coin for a few new parts, as I have a spare crank and cases for both bikes now. New piston went in as well. Motor will go back into the bike next weekend. Thank you for all the help. Bob from NTMS did a great job setting me up with bearings, gaskets, and seals. I did and will try to support the dealer network as GasGas gets back onto it's feet in the coming months.
Jacob 'Berg
Member
Oh, I forgot to purchase/replace the kick shaft seal. Can this be removed/installed without removing the inner cover again?
Jacob 'Berg
Member
Sage advice on the RTV. It was necessary, as each of the two dowels were in opposite sides of the cases, which makes keeping the gasket in place a little tricky. I kept the RTV near the motor mounts and away from where the cases need to seal.
Batman Bailey
New member
gears
I had a gear break a tooth and lock up trans. I had to replace three gears.
I had a gear break a tooth and lock up trans. I had to replace three gears.
A bit belated, but the common method seems to be to run a course thread screw into the seal, not very deep, and pull out with pliers. Then use an appropriately sized socket to hammer a new one in.
Similar threads
