miner

Parts swap not an option as they are few and far between here… like hens teeth unfortunately. Stator looks OK = visual no signs of damage or overheating, burn up. I’ll have another look on the Hell Team’s website to see if there’s useful values to re-test against. I went through the ignition system before and diagnosed that the Coil/CDI and Rectifier was the problem. Bike has stopped cutting out when hot since, just the hot starting issue persists. Coil Wire = New with the CDI/Coil and integral to it. Plug Cap = Tested it but without a proper reference value it’s hard to tell. Checked against the values in my KTM manual (two stroke, NGK cap), it looked ok. No Visible defects. Easy to swap though. Plug = I’ve tried swapping them about with a couple I had around and same issue. It’s an iridium plug and not that old, within the specified hours. I’ve ordered some more too. I’ve turned it inside out in the process of troubleshooting it… KTMs are much easier, they give you the test resistance values for everything, so you can get down to the extents of primary and secondary coil failures. I think its a carburation issue… I’m going to swap the jets and see how it goes. When it starts its often when you get just the right amount of throttle… but wanted to work backwards through it again in case I had missed anything obvious. Will order a plug cap since I’ve changed the CDI/Coil.

Thanks Alan, a lot to unpick so I left it till I got home and onto my iPad… Didn’t think there was any movement in the pickup, not like they days of offset keys to add/remove advance for old school two stroke tuning. 🤓 Cylinder and piston were all deglazed and decoked when I did the water pump and again when I split the cases there, should be ok. Coolant hose should be ok but its a good point… will double check. Fan is standard 2007 and on its last legs… keep spraying lithium grease into it when its hot, its stopped squawking for now. On the watch list. No issues with spewing coolant with the current set point. Floats were just replaced, one was full of fuel. Not checked the arm setting as it was fine before but will have a look when playing with the jetting. Issue is only this one now… it was cutting out when hot. Rectifier showing signs of burning out from the inside out. I think it is something fairly niggly/poxy that’s causing it… will keep digging. 🦾

Thanks, I’ll check that out… I couldn’t find anything on the fuel screw setting. Clip is at 3rd grove down.

Tried without the vent cap and proved it’s flowing. Not running any vent lines on the carb, it’s never had any on it. 🤪 Carb was fully cleaned and put back together just a few hours ago after rebuilding the bike from its crate. It’s been going on a while but it’s never been fully resolved… just less noticeable until stripped and left in a box. Definitely worse when it’s really hot outside.

I was wondering about that… it’s more of an issue when it’s hot but it can do it when cold starting. Not sure if there is any adjustment on the plate for the pickup coil… it’s just two bolts. No offset on it from what I saw. It’s sometimes blubbering and dying when it sounds like it’s firing, tried cracking it open to rev it and it doesn’t catch either. Sometimes it’s popping and cracking instead of starting. Generally from cold it’ll go in a kick or two. It’ll also run fine when it’s really hot, fan on. It just won’t kick over sometimes when starting it hot. It is rich for the temps here, it was over 40°C last time I took it for a quick play in the evening and was messing about with the carb.

Fast forward some time… 😅 The stripped it down 2yrs ago and it lay in bits for most of that time. Rebuilt it a couple of months ago. I lay the clutch side engine casing on its side and filled it up with gear oil and put some paper towel under it and left it overnight. No leaks. Inside the main bearing ID there’s a viton o-ring which I assume wears over time. Took it out and measured it, got one from a supplier and replaced it. All good. Replaced the gearbox bearings, running a bit quieter now, most of them rough to turn with your finger. Main bearings and the stator side shaft seal ok too. New piston rings and gaskets, running well now.

Still facing issues with this… thinking its too rich… its definitely hot here…. Kicks over ok from a cold start, sometimes when its hot and other times completely not. Could kick it till the cows come home and it wont start. Technique and timing issue sorted. 😅 Ignition (CDI/Coil & Rectifier) changed out for on of the Hell Team’s aftermarket Ducati replacement (discontinued) units. When it starts it runs well. Curve feels a little different but solid, nice to have it back. Stator looks OK, noting obvious. Plug is gapped ok, looks ok, not fouled. Had a play about with the mixture and idle settings the other day, it seemed better… then wouldn’t start eventually. Still getting a fair few kick backs when repeatedly kicking it… no obvious air leaks so could indicate overly rich in the first place? Jetting is stock 35/60/118 combo… might give a leaner jetting setting a go… still got a few months before when it’ll need the stock settings. Thoughts? Part of the fun of owning these things?

Got it yesterday and installed today… never fun getting all the wiring into the cavity… 😑 but it actually goes in better than OE. Tidy kit, bike fired up after a few kicks and is running like a champ. 🦾 Happy days. 😎 https://imgur.com/gallery/nxUgmNS

Yes, just ordered from this from Hell Team in Oz… will revert when installed. 🤞 https://www.thehellteam.com/cdi-regulator-rectifier-external-ignition-coil-gas~182025

Sadly the market for these bikes is beyond niche here even though there is some great terrain for it… mostly enduro riding but even that’s niche compared to shredding the dunes on MX bikes… https://imgur.com/gallery/HU9PfQD

Luckily indeed… I saw that old thread and contacted them. Their response was that they have a full Hidira kit option… not keen on the cost of full replacement to be honest. 🥴💸

Always worth a swatch… discontinued doesn’t mean it’s not in active licence somewhere else. 😁

The above Ducati ignition fitted to the 04-07 250 and other capacity bikes is obsolete… anyone replaced theirs fairly recently and have any recommendations on what to do / which parts? I have seen so far… Trials Bike Breakers UK have a full Hidira kit (inc flywheel) Hell Team (Oz) have CDI and Rectifier plus full kit options Full kit on a couple of other websites I am going to keep looking for other options… nothing on Ali Express… confirmed obsolete by John Shirt Motorcycles (Gas Gas UK). Replacement costs seem to be either an arm/leg for the rectifier and CDI, or an arm and a leg for the full kit… full kit really not in the budget for now. Would ideally just like to fire a coil in the bike but it looks like that’s not happening. 😣 A bit annoyed after getting the bike up and running again after two years in two boxes… it’s been plagued with hot starting issues since I got it though… found my old threads researching the issues. It died on me today again, had to push it 1.2km home today in +40’c heat. Three times in three rides. Been having a look through the electrical info threads too… not as straightforward as working on the KTMs unfortunately. All the testing is clearly laid out with the ranges and the wiring is a lot more straight forward. Tried measuring the resistance from the coil wire to the earth wire, open circuit. Going to have another check but fairly certain its that. Thanks for your help and hopefully money saving advice… 🤞🤪

Pic of the stator up on IMGUR for reference… Gas Gas 07 250 TXT Pro Stator Was looking at the kits… OEM kit only comes with the whole kit and caboodle… expensive. 🤪💸 So may be an aftermarket stator? Same as the OP’s either way… My issue may have been related to the clutch basket coming loose… we shall see… will test all the electrical stuff and check too.

The rubbing was something else… put some pics on IMGUR (only use it for here and a few others 🤪)… good news is that I found the vented bolt… it was holding the stator in. 🤦‍♂️ I was looking at the parts manual including the stator… then I saw the black bolts listed there… I knew there and then it was the most likely place it had been put. 🤪 My next question is around the first two images above which I replicated… Pic 1 shows the clutch and vented bolt… does the bolt go straight in? Or is it missing the bush which is the washer? Pic 2 shows the back of the basket… in the centre, is that the bush? Therefore the vented bolt is purely an axial retainer? I’ve ordered a nut and bush from Lings GG… will probably take 7-10d via Shop & Ship though… wasn’t paying £50 to FedEx it to me in Abu Dhabi 🇦🇪🙅‍♂️😅… if only that bolt then all good for now anyway. 🤞🙏 There’s a few pics on there showing the clutch casing damage… some dunce may have put a washer under the longer stator black bolt and it all went sideways on the second ride. Last pics are what I was practicing on instead of riding the Gas Gas… made some changes to the setup for the better though… plus fixed the broken fan mount. Just need to do the water pump seal kit now… 🫠😅 GG 250 TXT Pro Clutch 07