arnoux

Yes it can be purchased through your local S3 dealer. S3 supply the complete kit for all TXT's (horizontal and vertical water pipe heads). We have done quite a few of them. Basically it is a 250 piston with a smaller gudgeon pin and matching head and cylinder.

Can I chip in here from a Gas Gas Importers view point. (Australia) Yes they have had some industrial issues with trying to reduce staff levels. The workers rights are very heavily protected in Spain, and a company cannot just dump employees willy nilly. There is very complex processes in the courts that have to be adhered to if any staff levels are reduced. (not a bad thing for the staff). This seems to be the at the crux of all the rumour mills. I believe Gas Gas are being proactive doing this so they don't end up like a few years ago with a workforce that far outweighs it's current production capability and they end up in debt. They are also in the process of moving everything back to the SALT facility just outside Girona. After the fire at the Salt factory the spare parts department was relocated, and some admin went to Torrot headquarters. They are now centralising everything back to the original premises. There was problems with 19 GP supply, as we had the same issue as the USA. We received far less bikes than our original order, but from talking to the factory they are producing bikes at capacity now. The Gas Gas Factory has one production line, so bikes are produced in "batches". There will be a month of EC enduros produced, then the line will be changed out for a few weeks of CONTACTS, then Kids bikes etc etc. So it is not easy for the Factory to alter future schedules if there has been supply issues. And as we would all be aware, a great majority of the parts that go into producing the finished motorcycle are from third party suppliers (Braktec, NG, Morad, S3 etc etc). If they can't get the parts they can't build the bikes. I have had great parts supply this year, there has been much better processes put in place in the back end for us with new parts ordering software, and better technical support, so I am confident that things are OK with Gas Gas. I know I am at the other side of the world from the Factory, but I see no signs of any mularky that these "rumours" speak of from where I am sitting.

Best method I have found is give it a good rev, and as the revs are falling apply pressure to the lever (either up or down depending on if you are in 1st or 2nd) and it will fall into neutral as the revs are "right".

This is the Gas Gas part number: BT13000CT-CSV-1 If you Google that you will find suppliers.

You say "water" but do you mean coolant? This type of corrosion is caused from the coolant sitting in the bottom of the clutch case. When your water pump seal fails it leaks into the side case. As oil floats on water (or coolant in this case , usually some form of ethylene glycol and water) the coolant ends up pooled under the transmission oil in that area. (it's the lowest point). That is partially why there is a glass oil sight, so you can check oil level, but also oil condition. If it goes the slightest bit milky that is usually a sign of contamination. Some coolants will do this when left in the side case, and also play havoc with the friction material on the clutch plates.

It uses an Gas Gas M01619135 exterior O ring (101.32 x 1.78) and a MT300416065 interior O Ring (82.27 x 1.78)

Sorry Bilko but you are wrong on this one. That is absolutely stock, and most cases of that era are quite "rough" like that. I can see how you may think it is damage, but I can assure you it is nothing to be concerned about. Footnote: I have done many many GG engine rebuilds over the last couple of decades, and seen new cases straight from Spain, as I am Gasser importer in Australia. So I have seen enough to know.

Yes the post 2015 water pump is a direct replacement for the earlier 2003 - 2014 units. Fits straight on.

In relation to chat about main bearings above - There is a gallery in the transmission that basically catches oil "thrown" up by the gears rotating. it feeds this transmission oil into a gallery behind the LHS main bearing and between the seal behind the stator. Centrifugal force from the rotating main bearing forces this oil to lubricate the LHS main bearing and ejects it out through the little hole in the outside of the bearing (that lines up with a hole in the case) and back on top of the transmission sump plug. creating a lubricating system for the LHS Main Bearing. If the main bearing oil seal is shot, or if the hole in the bearing is not aligned with the hole in the case, it allows transmission oil to get into the crank and hence the smoke. If a LHS main bearing it is not set properly in the case, and is "rotating" under revs or load, the evacuation hole may be out of alignment "sometimes" and hence forcing tranny oil past the bearing seal, into the crank, and hence the smoke. This is pretty much why Gas Gas stopped using the magnesium cases. The maggy cases would heat up (and hence expand) much quicker than the steel main bearing, and they could "spin" in there housing if revvved hard in that little window between when the cases swelled as heated, and before the bearing caught up. Also check your flywheel key is not sheared. This can allow random ignition timing as the trigger point moves in relation to the crank angle.

https://drive.google.com/open?id=1-Hwu08MFTAQjuCGlnU-X-5itAWDVVt6N or page 28 of the User Manual.

Looks and sounds like crankshaft main bearing oil seal (LHS)

second that on the crank seals, if there is il coming from the exhaust.

S3 Hardrock Aluminium.

Fans "pull" air from the front of the bike through the radiator, they do not "push" hot air from the engine side through the radiator - so surely you can look at the fan and figure that one out!

No actuating pin or jam nut on that lever.

Are you referring to the Aire (air cooled) or the Delta (water-cooled), both are from 91? The Cylinder head O Rings on the 91 Delta are listed in the original parts book as: M01619115 80mm x 2.62mm and M01619110 125mm x 2.62mm The Aire gasket part number is not listed in the original parts book, but it looks like a paper gasket.

Did you replace the shaft as well as the seal? Usually have to do both at the same time.

TRS supply us a kit with all the homologated parts in it. It comes with the new bikes. It has the bigger headlight, speedo, reflectors, mirrors, proper rear light and number plate hanger etc. Most of the images you see are the "racing" or non homologated version because............. it LOOKS WAY BETTER!

It's available, I have plenty in stock. Must be some suppliers closer to you in the UK that have them too.

Hebo 4 pot calliper repair kits are still available, just google the Gas Gas part number for them, which is BT27922201, and you will find the source.

Here is an explanation of the early chassis numbers. CHASSIS#explanation.pdf

And the sight glass will just press out of the old cover, and transfer into the new one. No need to order that.

The Gas Gas part number for the exhaust O Rings is C290000 - if you google that part number you will find online suppliers who will ship to you.

These two sentences seem to almost contradict each other! Are we looking for shiny or non-shiny tyres? or just shiny black, but not wet tyres! Also check linkage bearing movement. Not a big one to repair, but it is a common wear area. I always look under the bike - the bash plate and rear linkages are a good indiction of the sort of treatment it has had. And check inside the airbox, lots of clean bikes on the outside reveal all sorts of interesting stuff when you pop the airbox cover! it's a good reflection on owner maintenance.