Hi there,

Looking for some info to help with the rebuild of my gasser after doing a few repairs in the gearbox.

Wondering:

• What thickness of gasket to use under the barell
  
• Tthe spark plug gap (manual says 0.6mm but trialspartsusa.com says 0.9mm)
  
• The tightening torque for the barell bolts
  
• The volume of gear oil, manual says 550cc but this seems to be too much
  

Cheers,

Ben

Ben,

1) Measure the old gasket and add a little extra for material compression or use the thickest if not sure.

2) .6mm seems to work well, it's what I run with an NGK BPR5EIX.

3) 25 Nm.

4) Usually about 425cc's will do it. I like to keep the oil about 2/3rds up the window on

the clutch sidecover. Change it often for best results.

Jon

• What thickness of gasket to use under the barell
  
• There is a video on trialspartsusa.com how to measure up the 'Squish'
  
• Tthe spark plug gap (manual says 0.6mm but trialspartsusa.com says 0.9mm)
  
• I set mine to 0.7mm
  
• The tightening torque for the barell bolts
  
• Owners manual says;
  
• Cylinder stud bolt fasteners 25 N-m.
  
• and Cylinder head screws 11.5 -13 N-m.
  
• The volume of gear oil, manual says 550cc but this seems to be too much
  
• Yes it is too much, fill it half to two thirds in the sight window.
  

Edited June 20, 201214 yr by richt

Thanks guys. I'll stick some photos up I've been taking of the strip and rebuild if anyone is interested.

I didn't get a manual with the bike, and the manual that is downloadable on the gas gas website doesn't have these tightening torques, any idea where to get a manual that does? Already been conned out of a couple of quid on the net for a 'workshop manual' which was just the owners manual

Cheers, Ben

I've still got the manual for my 2010 bike that got stolen, there is a table with all the torque figures.

You should be able to down load a copy from Trialspartsusa.

Thanks, I checked the gas gas website and it seems like pretty much only the 2004 manual doesn't have torques! Most of the others do, sorted. Thanks.