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.

2007 SMOG East Trail Ride (Part 3)

The best part about the SMOG ride is seeing all the old bikes that people have dumped a small fortune into. There were some absolutely beautiful bikes on display and a few of them were even ridden on the trail.


This sweet looking Bultaco Astro flat-tracker wasn't hitting the trails, but it was on display. It had a fantastic air-brushed mural on the back fender that reminded me of a custom van from the 70's. It was like a flashback to my Jr. High School days. I should've taken a photo of that mural, but I was having a mentally-challenged moment.


There was also this very clean and original-looking Ossa MAR (Mick Andrews Replica). It had also been signed by Mick himself. That alone probably doubles the value.


Fellow Stateline and SMOG member Mark B. rode his Bultaco Pursang. Later he hopped on his son's 300 Gasser and we did one hot-lap together. There must've been 20 riders stuck on one hill when we came blasting through. People scattered like teenagers from a keg party when the cops show up.

Of course meeting new Spanish motorcycle enthusiasts is also a highlight. Since most of us suffer from the same affliction (okay, we're nut-jobs) Once again I met a lot of nice people, some from as far away as Iowa, and bench-raced with old familiar faces. Lots of people complimented on how well-behaved my children were. They should've been around when we got home.


Capital Area Trail Riders Assn. (CATRA) showed up in force and we proudly displayed our banner. Left to right - Russ G., Sponge Bob, Dave G. and Trials Pete. Not pictured are Victor and Nina P. (they left early), Kenny (we couldn't find him) and the oaf behind the camera. My kids were tired of having their pictures taken by this point.


We found Kenny! He was about to collapse from trying to start his Ossa Super Pioneer. I don't think he'd started it since the ISDT Reunion Ride in 2003. I snapped this photo of Sponge Bob explaining to Kenny the technique of not kicking like a girl. Kenny was mumbling something about bad gas. Not sure if he was talking about gasoline or something the guy in the yellow Fox jersey was passing.

For me it was another successful SMOG Ride. All my bikes started and two of them were ridden on the trails as a prospective buyer took the 2001 Gasser for a test ride. Nothing was broken on either the bikes or my body. That's three for four.

2007 SMOG East Trail Ride (Part 2)

For October, the weather was unseasonably warm. Don't tell Al Gore, he'll want to make another mockumentary calling for an outright ban on Spanish motorcycles. Before the catch phrase Global Warming/Global Climate Change (or whatever they are calling it these days) people referred to this weather as Indian Summer. I guess that's not a PC term anymore. A couple of EZ-Ups provided shade and, at times, there was a slight breeze.


Here Lauren practices her "Thumbs Up" for the camera. Her favorite part of the day was the group photo. Perhaps she wants to be a model when she grows up?

The ride kicks off at 10:00 a.m. with a group photo. Well, it's supposed to be 10:00 a.m. Around 80 riders were in attendance for the 17th annual ride and the group photo was taken just before 11:00. Ken McGuire, who does a great job organizing the SMOG East Rides and running SMOG, takes the group photo and holds a brief riders meeting. We were told the loop was 10-miles in length. Ken is an attorney... the loop was just over five miles. Maybe it just seems a lot farther on a vintage bike.


I loaded Jacob, Lauren and Kyle onto my Bultaco and pushed them over to where the group photo was taken. None of them fell off and I didn't pull anything important in the process.


Sponge Bob on his 100% original, unrestored, Ossa Super Pioneer. You'd be hard-pressed to find another unrestored '75 enduro bike in this good of shape. However, riding a vintage enduro bike like this makes you glad to get back on a modern enduro bike.


CATRA VP and Sherco dealer, Trials Pete, showed up with this Bultaco model 199 Sherpa T. One of the last models to ever roll out of the original Bultaco factory in Barcelona. He also brought along a Bultaco Alpina and a Bultaco Frontera and not only rode, but completed loops on all three, despite some problems with the Alpina.

After the group photo, everyone hits the trails. Most don't make it around one lap. Lots of vintage bikes were broken down on the trails. Also a few riders were having trouble getting up some of the hills. This is the only time some of these guys ride all year. The trails were bone dry and quite dusty. Sponge Bob and Trials Pete helped keep an eye on my kids while I did two hot-laps on my '03 Gasser.


At the three previous SMOG rides I attended this was the bike I rode, back when it was in Alpina trim. I'm older and wiser now. This year I rode it around the field and had the kids sit on it during the group photo. Trailer Queen much?

Click here for part 3.

2007 SMOG East Trail Ride (Part 1)

Once a year SMOG, the Spanish Motorcycle Owners Group (you really didn't think I was talking about air pollution, did you?), holds a trail ride near the town of Ravena in Upstate NY. This years trail ride was Saturday October 6th, followed by a road ride on Sunday. I've been attending the SMOG Ride since 2004. Finally I brought a camera and, instead of using it to keep paper plates from blowing away, took some photos.


See, I told you SMOG doesn't stand for pollution. Next year is the SMOG 20-year anniversary. The SMOG World Rally is planned to take place in Jonesboro, IL. Wonder if the wife will let me go?


Friday night, after rebuilding the top-end in my 2003 Gas Gas EC300, I loaded my Spanish armada into the trailer. Imagine that, three Spanish motorcycles and all three run. Left to right - 2001 Gas Gas XC300 (For Sale), 1973 Bultaco "Sherpina" 250, 2003 Gas Gas EC300.


Actually it was more like wedging all three bikes into the trailer. That's a tight fit. I hope the trailer can handle the load.

Ravena is less than an hour from my house, depending on which road you take. You know you're getting close when you see pickups and trailers full of old dirt bikes. Most caravan over from the Ravena Diner, but being a thrifty individual, I stopped at Dunkin' Donuts, grabbed a dozen and some coffee before heading over to the ride. Occasionally you'll see someone driving around in circles because they are lost.


Our destination, once again, was Dave Flach's farm outside of Ravena. Fellow CATRA and SMOG member Sponge Bob was in attendance. He brought three Spanish motorcycles as well. A Bultaco Frontera, a Montesa Cota and an Ossa Super Pioneer (not pictured). He rode all three around.


For the second year in a row my wife had something planned for that weekend, so I brought along all three of our kids (three kids, three motorcycles, coincidence?). Here Jacob is demonstrating to Lauren and Kyle the proper way to do the "Thumbs Up" Bultaco trademark (shhh, don't tell Hugh). This was Jacob's fourth SMOG Ride.

Click here for part 2.

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.

Gas Gas Maintenance - 1

Piston from my 2003 Gas Gas EC300. Some carbon dragging, from the power valve, on the exhaust side of the skirt.

Buying a used bike is always a gamble unless you know the previous owner. Even then you might know them, chances are good you'll find a hidden surprise or two. The previous owner of my 2003 Gas Gas EC300 was one Doug S., whom I've known for a few years. In fact Doug was the original owner of my 2001 Gas Gas XC300 (I'm the third owner of that bike). I'd been warned that Doug's mechanical skills are on par with those of an 8th grader who sniffed too much gasket remover in shop class. While I have yet to confirm this warning, I will say that Doug never did any mechanical work to the engine in the four years he owned the '03 Gasser.

I should have listened to my inner voice when it told me to do a top-end. Actually I should've listened to a lot of things my inner voice was telling me. However, with limited time to perform preventive maintenance I ignored my inner voice. The result of this misfortune can be seen in these pictures.

Here you can see the main culprit. The compression rings are stuck in the ring grooves on the exhaust side of the piston.

I'm not going to make any excuses or blame the previous owner or the bike. This failure, and my subsequent DNF at the Rocktoberfast Enduro, was the result of my laziness. Prior to the Newark Enduro I should've changed the main jet from a 175 to a 178. While the 175 was fine for short full-throttle bursts, running WFO in top-gear through open fields and back roads was a big NO-NO. When the air filter became clogged with dust, this actually prevented air flow into the engine. Less air meant the engine ran hotter. The combination of all three caused the rings to stick in the grooves.

This week I'l be putting in a new piston, cleaning the exhaust power valve, installing new reed valves on the intake and repacking the silencer. In case you're thinking I'm forgetting something, I already installed a 178 main jet in the carburetor.