blomster Posted August 24, 2011 Report Share Posted August 24, 2011 Hi, Bought a Gas Gas 93/94/95 model cheap as it was in bits. Started doing her up, everything, sweet then came across some stripped threads in left crankcase. Thread is too close to a bearing to be helicoiled. I feel I have been ripped off, since the guy who sold it to me never mentioned it, I thought I would overlook it and have been trying to find a way to repair it. However it seems it is not possible to repair. I found what I thought was the right crankcase half on fleabay but on comparing it is obviously not the right one. The one for sale has the carb port on the crankcase yet mine is on the barrel. According to the frame number mine is a 94 model. Can anyone cofirm this this ? Are the engines from 93 to 95 interchangeable ?. Thanks. Quote Link to comment Share on other sites More sharing options...
gasgas249uk Posted August 24, 2011 Report Share Posted August 24, 2011 It would be useful to see a picture so we can see what your up against. There must be a way to sort the existing one.Which bolt is it and what does it hold? Heres a link to compare part numbers if you can translate the Spanish http://www.gasgasmotos.es/en/manuals/5.html Quote Link to comment Share on other sites More sharing options...
peterb Posted August 25, 2011 Report Share Posted August 25, 2011 Hi blomster, The piston ported model is 1992, have a look for the engine number to correctly ID the motor. From 1993, the motor was case reed induction. As mentioned, a photo of the problem would help. It may be possible to use a helicoil and maybe carefully grind back the part of the helicoil that would protrude through the bearing housing, using a Dremmel or similar die grinder. Sounds a bit odd for a stud to be located so close to a bearing housing. Crank area or gearbox? Bye, PeterB. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 25, 2011 Author Report Share Posted August 25, 2011 Thanks for the replies, and cheers for that link gasgas249uk. After looking at the diagrams it seems I got it wrong. The front forks appear to be identical to the 1993 model. And the carb input is on the barrel. I am just charging my phone, I will post a pic soon as I can. The stripped threads are the ones that hold the clutch actuator to the casing. The bottom one is too close to a bearing to helicoil. Although the previous owner obviously was going to do that as it had already been drilled and has cut away a small portion of the bearing housing. If it cannot be helicoiled I was thinking I could just bolt it through with a nut on the inside of the casing providing theres room inside for the nut. only problem being you would need to split the case if you needed to remove the clutch actuator. But how often would you need to remove it anyway ? Maybe thats the solution if there is no other option. Cheers. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 25, 2011 Author Report Share Posted August 25, 2011 Looking at those manuals I think the 92 and 93 are piston ported. O at least the 93 contact-t is. The number on the engine is p248432. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 25, 2011 Author Report Share Posted August 25, 2011 Here is the photo. http://i1019.photobucket.com/albums/af312/barcelonablom/crankcase.jpg Quote Link to comment Share on other sites More sharing options...
blomster Posted August 25, 2011 Author Report Share Posted August 25, 2011 Quote Link to comment Share on other sites More sharing options...
gasgas249uk Posted August 25, 2011 Report Share Posted August 25, 2011 I recon youve got enough space to use a helicoil. It looks like there is a crack from the hole your worried about to the bearing , or is it my eyes. It's probably just a surface mark. I've been helicoiling today and they don't use much space , only 2 mm on each side of the hole. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 26, 2011 Author Report Share Posted August 26, 2011 I recon youve got enough space to use a helicoil. It looks like there is a crack from the hole your worried about to the bearing , or is it my eyes. It's probably just a surface mark. I've been helicoiling today and they don't use much space , only 2 mm on each side of the hole. Yes that is a small crack. The hole has already been drilled for a helicoil and part of the bearing outer race is exposed in the hole, but only a small part so I think the PeterB's Idea of carefully grinding back the protruding part of the helicoil could work. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 26, 2011 Author Report Share Posted August 26, 2011 I am hoping that crack isn't going to be a problem. Not sure why there would be a crack there in the first place. All I can think is the last person to build the engine was a bit heavy handed when assembling. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 27, 2011 Author Report Share Posted August 27, 2011 Helicoiled both holes today. Looking good so far. Next job is to grind away the protruding part of the helicoil as per Peter's suggestion. Quote Link to comment Share on other sites More sharing options...
blomster Posted August 27, 2011 Author Report Share Posted August 27, 2011 Any suggestiond on the threadlock i should use ? I would use studlock unless anyone has better Idea. Quote Link to comment Share on other sites More sharing options...
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