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About zippy

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    Advanced Member

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  • Bike
    '15 GG300 - Karen

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    Redneck Hell
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  1. this video shows the new style crank bearing (w/ seals) and how to retro fit to older Pro engines. more videos; https://www.youtube.com/c/TRIALSPARTSUSA/videos there used to be a good video by Jim of tearing down a GasGas pro engine, I am unable to locate at this time good resource for parts diagragms https://www.thehellteam.com/technical-support/gas-gas-parts-and-service-manuals.html click parts books and find your year.
  2. You should be able to purchase a matched cylinder / piston set. with a return of your cylinder for a "core". easier than finding a place to replate etc. I recommend new crank bearings and seals if you feel vertical play. (you are halfway torn down anyway) Pro crank bearings are lubricated with transmission oil, so be sure the hole in the races match the hole in the case. My 0.02
  3. That is the "kickstart stop" Credit Hell Team: https://www.thehellteam.com/technical-support/gas-gas-parts-and-service-manuals.html
  4. yep, get some feeler gauges, and tap that electrode on something solid. I always check the gap of my plugs and adjust as necessary.
  5. YAY!!!!!! Easy fixes are the best fixes
  6. Remove linkage and attach shifter direct to shift shaft, first, Rule out the cheap easy stuff first. Let us know how it goes.
  7. No shame in knowing your limits. You think the top guys spin wrenches on the bikes they ride? There are many websites that offer parts, be advised some parts have been discontinued but many are still available. a few possible options: https://www.rockymountainatvmc.com/ https://www.bikebandit.com/ https://www.hondapartshouse.com/ https://www.partzilla.com/ https://www.hondapartsnation.com/honda-motorcycle-parts
  8. Some information and some opinion. First the opinion, I used to own a tLR200 Reflex. Fun bike, I had the gear shift lever attached direct to the shift shaft. It was mounted vertically, forward for down shift, backward to upshift. This kept it up out of the way and mostly protected, and reduced possible accidental shifts. Question: does the shift lever need moved back to horizontal with every downshift or just when shifting into first? Information, Parts schematics are available on most online parts suppliers for the major Japanese manufacturers. I suspect you have an issue with the shift shaft and return mechanism. Possible 1 "side" of the return spring (#12) is broken off. This will be located under the clutch cover. front of bike in picture would be on the left. Hope you find the issue
  9. The center bolt for holding the clutch basket on is not exactly necessary to have in there, you can leave the bolt and washer out. I am running mine without it. If the basket does move outward it will move a minimal amount before the clutch plunger touches the fingers. which will keep it from moving any farther out. but I am afraid you may need to split the cases. there may be an issue internal of the transmission
  10. No clue what that piece is that fell out when you took the cover off. The Hell Team has much Tech support information. click on "Parts Books" and then click on the year of your bike, and viola!! parts diagrams. I could not find anything that would be under the clutch cover that looked like that piece. https://www.thehellteam.com/technical-support/gas-gas-parts-and-service-manuals.html
  11. I believe you are correct. Here's one. All credit to the Hell Team: https://www.thehellteam.com/technical-support/gas-gas-parts-and-service-manuals.html Number 19
  12. zippy


  13. zippy


    Investigate the locked up kickstart first, check the top hat for gear change. Top Hat has a break away bar in it to protect the other bits of the shifting mechanism. (photos below) Starting procedure: have bike on a stand/leaning on something. get on the pegs, set foot on kickstart, slowly lower kickstart until slack is taken up and kickstart engages. at this point kick downwards with smooth authoritative force. DO NOT "stab" at the kickstart this could cause the quadrant and idle gears to chip. if a piece gets lodged between the two gears, it could (most often does) push the two gears apart placing stress on the clutch cover and breaking the clutch cover at the kickstart shaft. credit: Hell Team Website https://www.thehellteam.com/technical-support/gas-gas-parts-and-service-manuals.html Kickstart quadrant gear highlighted Top Hat highlighted; notice the cross bar. If the bar is broken it will be rotated inside the bore of the top hat. the ends of the bar will remain in place in the wall of the top hat. Google searched this photo, source says Trials Central - Added text - Clutch basket has been removed - there should be a hollow allen head bolt in the center of the clutch basket. 4mm I think, not positive
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