Gas Gas Maintenance - 3

Following my DNF at the Snow Run Enduro, I removed the subframe from my '03 Gas Gas. It had broken in two places. One place looked like it had been broken for some time and the other break was fresh. Additionally I found two more cracks in the subframe. Three of the four fractures were in the heat-affected zone near a weld. After consulting with an experienced aluminum welder, I decided it was not feasible to repair the broken subframe.

These three pieces were once a complete subframe.

Unfortunately a new, aftermarket, subframe is $220. As you probably know by now, I'm cheap. So I hit up the internet looking for a used subframe. After a couple days I came across a couple leads. One was for an '03 aluminum subframe, for $125 + shipping. The other was for a '97 steel subframe for $50 + shipping. Have I ever mentioned that I'm 1/4 Scottish? Well If I haven't, and you know how tight a Scotsman can be with money, it doesn't take a genius to figure out which subframe I bought. Although heavier, steel is stronger than aluminum. However, I knew it would not be an exact fit as there were quite a few changes between the '97 and '03 models.


Here is the '97 subframe with most of the parts bolted back up. Excuse the dirt as I didn't do a great job cleaning up after the Snow Run Enduro.

The first problem was bolting up the seat. The mounts on the back of the seat base would not line up with the holes in the subframe. I knew somewhere there was a change made as the seat from my '01 Gas Gas would not fit on the '03 either.


This was as close as I could get the '03 seat to align with the mounting holes in the subframe.

Luckily I had a spare seat from my '01 Gas Gas still laying around (actually it was at a friends house). A quick test fit showed it would bolt up. However the '01 seat did not have the tall seat foam that I need.


The spare seat from my '01 Gas Gas lines up almost perfect with the subframe holes.

Looking at the seat mounting tabs, it is obvious why the '03 seat does not line up. They are different. Since the '03 seat has the tall foam, needed for anyone over 6-feet tall, I decided to drill out the rivets and swap the '01 tabs onto the '03 seat.

With the '03 seat on the left and the '01 seat on the right, you can see the difference in the mounting tabs.

It took about 15-minutes to swap the mounting tabs over. Now the seat fits perfectly. The next project to tackle is the silencer.

2008 NETRA Snow Run Enduro

After taking most of last season off, I decided to get back in the saddle, so to speak, and chase points in the NETRA B-Senior Enduro Class for 2008. I actually started my quest early this year going to they gym 3 days a week working on cardio and strength training. Additionally I've been skiing at least one day a week, getting my legs in shape. For two Sundays prior to the Snow Run Enduro I went riding, getting use to riding in snow and getting the bike dialed in. I was ready... or so I thought.


At the start of the 2008 NETRA Snow Run Enduro. That's me, second from the left in the blue & red outfit. It started raining just after this picture was taken and things went from bad to worse.

Because the Snow Run takes place in February, conditions are very unpredictable. This year, above normal temperatures left little in the way of actual snow on the trails. What was left was a mixture of mud and rocks. Combine an outside air temperature just above freezing with moisture falling from the sky and you've got rain. In fact it started pouring just after the above photo was taken, while we were riding down a paved transfer section, to the first test section. Now I don't mind the cold so much as I dislike being cold and wet. It took me a while to get into a groove and I ended up dropping 6 minutes in the first test section. Not a spectacular start, but I figured things could only get better. How wrong I was.

Following the first test section was an off-road transfer section. It was here that my front wheel decided to tag a tree and send me over the bars. I hit the ground with a thud followed by an ouch as I cracked a rib. However, not wanting to be a called a pussy, I continued on. At the second test section I zeroed the check-in and started getting into a good groove, despite the pain. In fact I was really doing good until I arrived at the swamp. This place was full of mud holes and bikes buried up to their handlebars. I was doing a pretty good job navigating around some of the deep stuff until my front tire got buried in a deep rut. I used up a lot of energy getting the bike unstuck. When I finally got going I tried making up for lost time, but tagged a rock with my foot and broke a toe. In all I dropped another 13 minutes and 3 seconds in this section.

At the gas stop I decided to mess with my bikes idle since it was idiling way too fast. I left gas and proceeded through a couple more transfer sections before getting to the third test section. Once again I zeroed the check-in and started riding balls-to-the-wall. I was getting into a good groove when suddenly, without warning, the bike made a loud noise and quit. I attempted to re-light the motor, but the loud noise told me something wasn't right. Major Joe pulled up next to me and said: "Look at your seat!" Crap, the seat was sticking up in the air. Turns out the subframe snapped in two places, pulling the carburetor boot off the reed block and shutting off the fuel supply to the motor. Using a couple zip-ties I redneck-engineered the bike back together and decided to call it a day, riding back to the pits standing on the pegs. By now the temperature had dropped and I was soaking wet and freezing.


My pitiful score, 22 points to check 6. A firm grip on last place in B-Senior. Probably could've beaten a couple guys had the bike not told me I'm too fat.

I had a solid lock on last place in B-Senior. Only made six of the 13 checks. Not even 50%, so I won't get any championship points. Time to fix the bike and let my body heal.