Gasgas MC250F winter refresh - complete

luke11
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luke11
Edited Date/Time 3/22/2022 9:01pm
So I’ve had a few rides on her and she rides perfect but I really want to get it to the condition it should be for a year old bike. Now winters really hitting here I’ve decided to spend the next month or so stripping and rebuilding her from the ground up. This being my first full strip down I got my old
Mechanic out of retirement (my old man) and spent an afternoon taking this bike down to the frame. I’m really hoping I remember how this thing goes back together, the scariest of all is the wiring harness, I labelled as best I could!
Dropped the frame and the rims in for re-anodising and coating this morning and about to order a new set of linkage bearings as noticed a couple of mine were pretty shot. Is it worth going oem over aftermarket?





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Rickyisms
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Rickyisms 1/4/2022 9:46pm
1/4/2022 9:46pm
I put a pivot works linkage kit in my KTM probably 5 years ago? I take the needles out and clean and grease everything every 40 hours so I don’t neglect them. Just about to redo them after about 100 hours. I’m satisfied.
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Ryan625
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Ryan625 1/10/2022 2:53pm
1/10/2022 2:53pm
I always take pictures of wire routing and create a folder in my phone for each bike. Best way I’ve found to route as stock or sometimes actually improve the routing
luke11
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luke11 2/18/2022 6:36am
2/18/2022 6:36am
Frame and wheels back from being refreshed. Steady supply of new parts coming in

luke11
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luke11 2/18/2022 6:41am
2/18/2022 6:41am
A few progress shots, the final picture is how she currently sits. All the labelling with the wiring loom paid off and it went back together smoother than expected.
I bought all new swingarm and linkage bearings but unfortunately the vices I had to hand weren’t big enough so I gave it to the shop to fit for me. Just waiting on getting them back then I’m ready for final assembly.
Managed to do the steering races in the headstock myself though which I was pleased with. Had to buy a bearing race driver set but found one cheap enough on Amazon which did the job.


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luke11
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luke11 2/18/2022 6:44am
2/18/2022 6:44am
Final problem to solve is this wire here. It’s on the wiring loom side of the starter button connector. Looking at it I think easiest will be to just hardwire the starter button into the loom. Someone suggested soldering it into the ‘black loop’ and it would work? I need to have a play around as I’m not the greatest with electrics.

brooklynevans 2/20/2022 12:54am
2/20/2022 12:54am
Guessing the team did most of the mods needed on the GasGas, but in case they didn’t - put a 2 stroke filter cage on, and cut the rib from the inside of the air box panel. Cheap, easy and makes a difference!

If you need any parts, give me a shout - have an online shop so I can supply you with many parts at a good price
Yzf916
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Yzf916 2/20/2022 5:33pm
2/20/2022 5:33pm
I completely did away with that plug with the stupidly thin jumper wires. Think i hardwired blue to black. And orange to brown. But works fine completely eliminating that mess with the jumper wires. Every KTM I know has had those jumper wires break. Hope they fixed that on newer models. My 19 had it. And so does my 2022.
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luke11
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luke11 2/21/2022 12:55pm
2/21/2022 12:55pm
Yzf916 wrote:
I completely did away with that plug with the stupidly thin jumper wires. Think i hardwired blue to black. And orange to brown. But works fine...
I completely did away with that plug with the stupidly thin jumper wires. Think i hardwired blue to black. And orange to brown. But works fine completely eliminating that mess with the jumper wires. Every KTM I know has had those jumper wires break. Hope they fixed that on newer models. My 19 had it. And so does my 2022.
Sweet thank you so much for the heads up. Blue to black and orange to brown.
Yzf916
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Yzf916 2/21/2022 4:08pm
2/21/2022 4:08pm
Verify by following wires. But I think that’s it by memory.
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mikejones202
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mikejones202 2/22/2022 12:06pm
2/22/2022 12:06pm
Yzf916 wrote:
Verify by following wires. But I think that’s it by memory.
Can anyone confirm this? Going to do it to my husky while its apart.....
luke11
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luke11 2/24/2022 1:53am
2/24/2022 1:53am
Yzf916 wrote:
Verify by following wires. But I think that’s it by memory.
mikejones202 wrote:
Can anyone confirm this? Going to do it to my husky while its apart.....
I’ll let you know and get some pictures when I do mine the weekend mate. Check back in here monday
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luke11
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luke11 2/28/2022 11:01pm
2/28/2022 11:01pm
So still haven’t got round to doing the wiring as my soldering iron is on the blink but have made some good progress with wheels, swingarm, seat cover, sprockets some plastics etc etc ..



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Yzf916
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Yzf916 3/21/2022 8:18pm
3/21/2022 8:18pm
Did you ever eliminate the connector and hardwire the starter wires?
luke11
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luke11 3/22/2022 2:09am
3/22/2022 2:09am
Yzf916 wrote:
Did you ever eliminate the connector and hardwire the starter wires?
Sorry mate, yea just hardwired it in. Blue to black, orange to brown. Works a treat now. Just soldered and shrink wrapped the individual wires then shrink wrapped over everything.
luke11
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luke11 3/22/2022 2:11am
3/22/2022 2:11am
So here she is complete, sorry been busy actually riding amongst other things



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Yzf916
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Yzf916 3/22/2022 8:43pm
3/22/2022 8:43pm
Beautiful bike. Looks fantastic. Glad the wiring fix worked out.
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adam8781
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adam8781 3/22/2022 9:01pm
3/22/2022 9:01pm
damn that looks good, i just did one of these for a customer, anodized stock hubs red, rims black, nipples black, swingarm, linkage, triple clamps and bar mounts all black.
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