blomster

Amazing how a question like "My front brake disk is loose" gets so many views and some replies, yet I get no reply lol. No offence to the loose brake disk op.

Ok so I sorted my stripped threads out by helicoiling. Now I have a new problem, according to the frame number my bike is a 1993 model, yet looking at the diagrams here http://www.gasgasmotos.es/en/manuals/5.html my barrel and cylinder head match the diagrams for the 1992 model, but mine has a hydraulic clutch not the manual one. According to the diagram the hydraulic clutch is on the 93 onwards. Anyone know if I have a model that is somewhere inbetween or has a previous owner been mixing engine parts ?. And are there gasket kits available for my engine ?. Thanks.

Any suggestiond on the threadlock i should use ? I would use studlock unless anyone has better Idea.

Helicoiled both holes today. Looking good so far. Next job is to grind away the protruding part of the helicoil as per Peter's suggestion.

I am hoping that crack isn't going to be a problem. Not sure why there would be a crack there in the first place. All I can think is the last person to build the engine was a bit heavy handed when assembling.

Yes that is a small crack. The hole has already been drilled for a helicoil and part of the bearing outer race is exposed in the hole, but only a small part so I think the PeterB's Idea of carefully grinding back the protruding part of the helicoil could work.

Here is the photo. http://i1019.photobucket.com/albums/af312/barcelonablom/crankcase.jpg

Looking at those manuals I think the 92 and 93 are piston ported. O at least the 93 contact-t is. The number on the engine is p248432.

Thanks for the replies, and cheers for that link gasgas249uk. After looking at the diagrams it seems I got it wrong. The front forks appear to be identical to the 1993 model. And the carb input is on the barrel. I am just charging my phone, I will post a pic soon as I can. The stripped threads are the ones that hold the clutch actuator to the casing. The bottom one is too close to a bearing to helicoil. Although the previous owner obviously was going to do that as it had already been drilled and has cut away a small portion of the bearing housing. If it cannot be helicoiled I was thinking I could just bolt it through with a nut on the inside of the casing providing theres room inside for the nut. only problem being you would need to split the case if you needed to remove the clutch actuator. But how often would you need to remove it anyway ? Maybe thats the solution if there is no other option. Cheers.

Hi, Bought a Gas Gas 93/94/95 model cheap as it was in bits. Started doing her up, everything, sweet then came across some stripped threads in left crankcase. Thread is too close to a bearing to be helicoiled. I feel I have been ripped off, since the guy who sold it to me never mentioned it, I thought I would overlook it and have been trying to find a way to repair it. However it seems it is not possible to repair. I found what I thought was the right crankcase half on fleabay but on comparing it is obviously not the right one. The one for sale has the carb port on the crankcase yet mine is on the barrel. According to the frame number mine is a 94 model. Can anyone cofirm this this ? Are the engines from 93 to 95 interchangeable ?. Thanks.