craigrevo

Aparently there are 2 diffrent types of 40mm Marzocchi forks for the gasgas 2005. So the springs are wrong.

Is that how to bodge the wrong part on, or just what you must do to fit stiffer springs? I would rather have the right parts to be honest.

I ordered some Jitsie springs for my 2005 Gas gas Raga 300 but when I came to fit them they are about 1" shorter, but more importantly they are 5mm narrower. This makes them to narrow for the plastic spacer tube. Has anyone incountered this problem or are they the wrong part for my forks? Link to the springs numbers on my fork leg.

It's a 2005 300 raga. I removed the top hat from the slave so I could paint the inside of the case. I've done loads of work on bikes in the past including bleeding clutches but this one is having none of it. So if it's a normal bleeding system it must have a problem. I'm leaning towards the bleed nipple as it is a little loose.

Is there a special procedure to bleeding the Gasgas clutch? So far I've tried standard on off bleeding, reverse bleeding with a syringe, suction bleeding with a syringe, and vacuum bleeding with a mates kit. I'm using atf mineral oil as I use in my KTMs. I've now ordered a new bleed nipple and some LHM fluid to try and rule everything out. The clutch has feel but no engagement.

Cheers Biff, Im going to just ride it now and see how it is.

Yes!!! finaly a result. Im still going to change the clutch basket as it doesnt sound perfect and Ive had to order a thermostat as it still overheated.

Ive sprayed the inside of the clutch cover now so I will know for sure if the marks are old or fresh.

At least now I know the engine is good with all the new parts, and I know what to look for in the future. Ive ordered some new shims for the gearbox to take out the slop and hopfully I will get to ride it a bit.

This was the dent in the tooth!!

Inspect your gears as the tinyest bit of damage to them can cause huge knocking!! This was my bike with a little dent in the clutch basket gear.

Got it!! There was a tiny dent on one tooth of the clutch basket. So I have used a dremel to reshape it. Now it sounds loads better!! Thanks for all your help and advise guys.

You were right lineaway there was a tiny dent in the clutch basket tooth that was not meshing with the primary gear properly. But there is signs of rubbing on the clutch cover. I'm getting excited now because it's nearly fixed but I don't want to rush it back together if there is still an issue with to much end float.

Are there any Gasgas experts on here who can tell me if this movement is normal? If not do you know what might be causing it?

Now this peace of crap is annoying me!! So far I've spent £400 on parts and still it's knocking. I've replaced Kickstart gear Idle gear Clutch basket bearings Clutch main case bearing 3rd gear half bearings Output shaft bearing Flywheel keyway Crank case main bearings. There is about 2mm of out and in play in the clutch basket but i don't know if that is normal or how to fix it if it isn't normal. I've removed the water pump and the knock is still there, so that can be ruled out totally now. This thing is driving me mad.