beeaj

Hi Limit is 20kg but I just found out they don't allow things with combustion engines such as chainsaws etc so I doubt they'd allow a 250 2stroke engine, if I remove the top end surely that's less than 20kg (roughly 45 pounds) ?

Hi, does anybody know the approximate weight of a 2003 TXT250 pro engine/ gearbox and weight if top end is removed? I have to put an engine on a flight and don't have it here to weigh but can send gearbox only if it's under weight allowance. Thanks in advance.

Hi Jon I took the clutch basket out and checked the spring which seems to be OK, the bike was meant to stay out in Italy when I return to the UK next week but I guess I will now have a much bigger problem? so I will most likely take the bike back to the uk to work on it. Have you any idea what an engine/ gearbox on a TXT 250 weighs? I could just bring home the engine and fly it back out. I have attached a link to some photographs, there seems to be a hole on the inner casing shown on one photo, is this meant to be like this? hopefully one of these links will show the photos My link http://jalbum.net/en/browse/user/album/1022872/ sorry for so many questions but any advise on what might be wrong now and how much work involved would be appreciated thanks in advance Mike

many thanks, i'll get the clutch out in the next few days and check Mike

Thanks for replies, I hoping it's not a big problem, the gear lever wasn't hit but the problem just started on a run home in 4th?

Jon I am in Italy just now and have limited internet, but I was out riding my other Gas Gas with the local trials club here and told the guys what had happened, I am not fluent but they all seemed to be saying that this is a very common problem but said usually with a 2005?? they also asked if I had hit a rock, I don't speak good enough Italian to have understood much about the problem. The bike did take a real thump on its belly off a rock but ran fine for the rest of the day, I lost the gears on a run back up the village I was going along in 4th and went to change down and nothing, I think I might of heard a small noise just before I discovered the shifter was doing nothing, do you think it would be the shift centering spring and how difficult is it to fix with limited knowledge? many thanks Mike

Jon I am in Italy just now and have limited internet, but I was out riding my other Gas Gas with the local trials club here and told the guys what had happened, I am not fluent but they all seemed to be saying that this is a very common problem but said usually with a 2005?? they also asked if I had hit a rock, I don't speak good enough Italian to have understood much about the problem. The bike did take a real thump on its belly off a rock but ran fine for the rest of the day, I lost the gears on a run back up the village I was going along in 4th and went to change down and nothing, I think I might of heard a small noise just before I discovered the shifter was doing nothing, do you think it would be the shift centering spring and how difficult is it to fix with limited knowledge? many thanks Mike

I was riding my 2003 250txt today when suddenly I lost all gear change, the gear lever doesn't click anymore just moves up and down and the bike is stuck in 4th or 5th. Anyone have a clue what has happened ?? Thanks in advance Mike

I have just changed the oil and seals in my 04 txt250 but the forks are not good at all. They seem to drop a quite a bit with the weight of the bike, if I lift the bars I get about 2inches of lift out of the forks and the weight of the back allows this to drop back down when I let go. Also the rebound is pretty poor and slow. Any suggestions greatly received thanks

Once again Jon Thanks I don't want metal flakes in my engine OR zombie hands helping me out so I'll keep the petrol in the can! I'll give it a flush with some diesel just before I put the new oil in and to be safe I'll change the oil pretty soon after checking all is OK Mike

Jon once again your knowledge will get me out of trouble and hopefully prevent it in future, many thanks What do you think about flushing out the old oil with diesel or petrol? Mike

http://jalbum.net/a/911432/ Can anyone confirm the way these fit on the shaft "4", I assume the bearing 1 goes on first then 2 flat side against the bearing and then washer 3. Also is it safe to put some diesel in my drained gearbox to flush out old oil and any tiny metal flakes that might have dropped into the clutch when I had to helicoil the case threads, I was pretty careful but might have let some small flakes drop in, is this very bad or will a flush out get them to the magnet on the drain plug. Thanks in advance Mike

I was out on riding with my mate and on a more challenging climb he flipped his bike which crushed the aluminium exhaust midsection, this happened to my bike when my nephew decided he was better than he is, I replaced mine with an older steel one. Can anyone tell me if a 2002 section would fit his 2005 250txt pro. Also would the 2002 airbox unit fit his 2005 (it took a bashing too) thanks

Absolutely perfect, thanks so much Mike

I've added some more photo's which hopefully might help?

Hi Jon it's a 2003 250 txt pro

http://mikebiagi.jalbum.net/wires/ Please excuse my ignorance but as a novice when it comes to wiring (and a fool who deleted some of the photos of how it came apart), but should there be two wires to the thermostat and in the photo above am I wiring it up OK? I seem to have got as far as one wire to it and have a yellow and a red left? any ideas

Jon thanks yet again for the quick and perfect info good to know your there Mike

http://mikebiagi.jalbum.net/clutch/ Hopefully this photograph can be viewed I have the clutch case of my txt 250 and have noticed that two or three of the clutch release arms are loose and sit open from the others, they just push back into place but should they be loose like this? The others seem to be held in place? any info greatly appreciated Beeaj

Just had another look and further back in the bottom hole it does look as if it might have had a thread at one time, could it just be really stripped out?

Hi all I have now taken off the clutch casing to find that the bottom water pump mount hole (for the longest bolt ) doesn't seem to have any sign of, or having ever had a thread. It also seems to have a collar which sticks out a bit and the hole is larger than the other 2. Should there be an insert with a thread in here??? It looks like it would be pretty easy to fit a helicoil but I am not sure if this is the best fix. I have a detailed photo of it which I am about to try and attach??? Hope it works and someone has some good info thanks Mike http://jalbum.net/a/895095/

Thanks all great advice

I have just replaced my water pump impellor, seal etc and on putting it back together found that the longest bottom bolt couldn't catch a thread, closer look showed the bolt thread slightly stripped. New set of bolts ordered but when they arrived I was gutted to find that the bottom bolt still wouldn't grip and one other bolt started but only to strip after getting slightly tight. I can only assume that the casing thread has been stripped. Has anyone else had this and how did you fix it? I have heard of HeliCoils but haven't used them, don't know if they come that small and can be fitted easily (if at all) Pretty disappointing stage of an otherwise successful rebuild! Any advice gratefully received Mike

Thanks Dom for replying so quickly with this info Mike (Beeaj)

I ordered a load of parts from Gas Gas UK including a cylinder base gasket. I have just had a look at a parts list which shows there are four sizes available, I assume that Gas`Gas will have sent me the correct size for my TXT 250 pro?? Also does it matter which way up the gasket sits (printed side up / down and should it be fitted dry or lubricated in any way. Thanks Beeaj (thank god for this forum!)