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That’s a fantastic heads up thanks so much for that mate

Hi Pat, a tip from doing a tonne of these over the years, you will need to replace the internal bearing that is in the crankcase that supports the kickstart shaft. The GasGas part number is MT2802260067. When this gets worn over time it allows the shaft to move at the furthurest part inboard, and this then cracks the case. If you dont change that it will happen again. There is a huge amount of stress on that bearing and they need replacing over time. It has a "blind" bottom , so it is like a cup. It can be knocked out easily with a drift from the left side of the bike - yes the LEFT side! If you look from the left side just below and behind the carby area on the crankcase right side you will see it's "bum". Once you remove the kickstart shaft you can knock it out to the right with a drift. You MUST do this when replacing the case. Jim Snell's old kickstart video is a help with the technique to get the shaft out: Jim's TXT Pro kickstart video

Let me know what you find, Pat. I’d be really interested. I hope it’s not too serious and good luck!

I have a Caswell-lined fibreglass tank and wondering if I should, or need to, remove fuel mix while storing over the winter (Canadian) and if so, should I replace it with something or okay to leave empty. For my street bikes I just top up tank and add a bit of stabilizer. I asked my neighbour who owns a boat and he says it should be fine if it's treated/lined as it protects from ethanol. Thanks in advance.

Zeez that post is old. Can't believe it has stuck around for all these years since I wrote the article. The fix works Cello.

Hi Ron I’d a feeling I may be at fault but there’s no harm in asking the question. I’ll start ripping into it in the next few days and hopefully all isn’t too bad. Thanks for the reply mate

Hey Pat, I’m no expert but I think the crack in the casing is your problem. It was probably kicked very hard in its life and cracked. Now, it’s my guess, that the kickstarter flexes the shaft just enough so that things are not engaging properly. The kickstart pinion gear and shaft may even be damaged due to the flex. My suggestion would be to open everything up, examine the shaft and gear. I’d also get a new clutch casing or potentially weld the existing crack. Good luck!

Hey Chappo, If you look in the original parts manual from GasGas it states C3 for the bearing.

Evening folks Ive a small issue with my bike , it can be tricky to start, it feels like the kickstart is only engaging at the bottom of the stroke of it. I know this model can have a knack to start but any feedback or help would be great. Also the clutch casing has a crack in it (please see attached photo) where kickstart runs through which I’d assume would not help. What could cause this to crack ? Again any feedback and help would be greatly appreciated Cheers Paddy

Hi folks, I’m just rebuilding the above engine. I’m after a set of 6206 main bearings for her. Im trying to establish if they are C3 or standard bearings that are required. I’d have thought C3 , but just making sure as it’s for a friend. Thanks everyone.

A new Michelin Light arrived this afternoon, too late for this year but I'll be ready for the spring

Don't know how to "repair" the gear lever. I could drill a hole thru and use a passing bolt, maybe, covered with a piece of hose for the time being? Or I could use two metal clamps to keep an L shaped piece attached on it?

Thanks... makes perfectly sense. I don't think I'll be on the hunt for a Pioneer exhaust, it would probably make more power up top but I plan to use it for "semi-trial" stuff at low speed, so it's probably better to keep the Explorer exhaust with the smaller carb. I guess the cylinders are also different on the inside (bigger intake/exhaust ports)? I never worked on Amal carbs, so don't have any jet for it... hopefully the stock setting will work with the actual setup.

If you are using the Explorer exhaust system, there is no advantage in using anything bigger than the 27mm AMAL. The Pioneer uses a bigger carby because it sucks a lot of air when it is on the pipe. The Explorer exhaust will mean that the Pioneer motor will suck about the same amount of air as an Explorer motor at full power.

Hello, could you tell me what could be the problem with starting a cold engine? I have to put the bike on a stand and kick it as hard as I can about 20 times. After starting, the bike starts right after turning off the engine, but if it sits for 2 minutes, it is very difficult to start again, sometimes even impossible. The bike has a lot of mileage (about 1000 engine hours). After purchasing it from the previous owner, I replaced the fuel filter, fuel pump, injector, hose clamps in the gas tank, ignition coil and condenser in an attempt to find the problem. After that, everything got better, but the problem remains. Direct fuel injection into the intake manifold helps; in this case, it starts every time. I read all the threads on the forum and came to the conclusion that the problem could be in the crankshaft seals or sensors. I have seen people installing small batteries in the filter block, but I'm not sure which wires to connect them to? To the capacitor or to the battery connector, which should be under the seat? I think this option should help, I'd be grateful for any help.

Ok guys, managed to find a Motoplat coil and the right kickstarter lever for this engine. Also got a tank with petcock, but they're both pretty much trash. I poured some pretty rich premix inside the spark plug hole and the engine came to life, with huuuuge surprise. Started but died after 1 second. The second time I started it, lasted maybe 2 seconds. In the meantime I tried to put the tank in place with a hose going to the carb, but ended up badly with my cursing and fuel everywhere. Today it started at first kick (!) and for maybe 8 seconds... I managed to twist the throttle a couple of times before the fuel into the bowl finished and it died... but it's aliiiive! As you can see the carb is the Amal from the Explorer engine... should I get something more modern and better for the Pioneer engine? I read it had a 32mm. The guy I got coil, kickstarter lever and tank from, kindly sent me for free a rear brake cable and a broken gear lever (I'll have to find a way to make it work).

Seen the top riders motorcycle get stolen at a 2-day national, had two nefarious individuals attend one of my events purely for the purpose of delaying and disrupting the event, now I have security at events to stop that nonsense.

Local events in my State in the US do not have pre-entry. Just roll up the day of 2 hours before start of event and sign up is open. You can sign up for AMA at the event, but honestly that is a P.I.T.A for everyone involved. Sign up for AMA on-line and either bring the new card to the event or some sort of electronic verification on your phone if the card has not arrived. Security at a local Trials event??? that's nuts. we could leave a $20 bill on the sign up table and people would think it was a collection to help somebody out and add to it. As far as I know we have only had 1 theft in MOTA in 25yrs. A set of handlebars was taken from a mobile dealer.

I've just had a stator for a Fantic rewound at West Country Windings and they seemed very efficient, not fitted it yet but my brother had the same done some years ago and its still working

Yeah, you guys are talking about two different types of events. Our local event does have pre entry, but you can sign up at the trials for the same costs. We have had portable toilets at local events for about 2 decades as the total people count is about a hundred. We are having a National next May. Already working on the sections. The Nationals thrive on having a real number of pre-entries, you can enter on site the day of the event, but costs a hundred dollars more! Security? You guys don`t live in the states. Even our Pastor at Church carries a gun under his Robe.

Under 50 riders and ease of access lol Canadian trials events rarely reach that number of riders, hard enduro no problem attracting 100 riders and 70% of those riders can't complete an event. Long distance travel is also a reality in Canada that most people living on an island can not relate to, nothing is easy access here other than wildlife. Yep living in the past you are, back in the days when you didn't even need security at an event, those days are done.

No I totally agree. My problem is it's more and more common for small club trials with expected entrants <50 now requiring pre entries. To me that goes against the ease of access trials is renowned for. Or maybe im living in the past

Maybe here https://ricksmotorsportelectrics.com/l/aftermarket-stators?srsltid=AfmBOooPHVWzz3Ug93MZ2_SBhLpL4CSpiGre4s0rPjAvfj3MdIMHyP4V

I prefer to host 2-day nationals if I go to the bother of doing a sanctioned event under CMA/FIM, nationals see better participation and support, yes to likely much different level to anything you ride, I own a 400 acre world class trials venue and have hosted events for 30 years 🤣 casual riders consider it too rough to ride a lot of it. If you don't want to pre-enter my events out of principal, believe I would prefer you stay home anyway, it would be much easier for everybody.

Portable toilets and parking spaces. We are obviously talking about completely different level of trials events. Haven't seen a portaloo at a club trial in my country in 30 years 🤣