Gas Gas Maintenance - 2

There's nothing like a component failure to make one get off their butt and do some long overdue preventive maintenance. Such had been the case when my 2003 Gas Gas EC300 died at the Rocktoberfast Enduro.


New Wiseco forged piston, wrist pin and bearing installed on the connecting rod.


Once the piston was installed all I had to do was slip the jug (cylinder) over the piston. Even though it was stamped "A", the Nikasil plated cylinder does not require honing, but was worn enough, ~0.0005" to fit a "B" piston. Prior to installation I cleaned the cylinder and exhaust power valve assembly.


Here you can see the engine is all back together. All that's left is to install the expansion chamber, silencer, gas tank, seat and side panel.
But first...


I pulled the carburetor and reed block. Then installed new Boyesen Power Reed valves in the block.
And then...


I pulled apart the silencer and cleaned about 10 lbs. of carbon out of the screen, spark arrestor and end cap before repacking it. Note the budget packing. High temperature fiberglass insulation courtesy of Lowes. Sure you can buy fancy motorcycle silencer packing for $20, or spend $5 and repack your silencer 5 times. Hmmmm tough decision. Remember I'm a member of the Budget Racing Team.