Grenaded GasGas 2 Stroke

slowgti
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Monroe, GA US
12/3/2023 12:25pm
MxAddic wrote:

I would say most likely the metallurgy is not up to Japanese standards but I can't prove it.

I was thinking about the piston to crank contact issue more than the head exploding

edot504_
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Ridgecrest , CA US
12/3/2023 1:15pm
FGR01 wrote:
Does anyone seriously think it would be any different with a Yamaha?   You think they would help anyone out on a blown up 2 yr old...

Does anyone seriously think it would be any different with a Yamaha?   You think they would help anyone out on a blown up 2 yr old YZ250 with over 100 hrs?

I have been around dirt bikes for 50 years and I have never seen a catastrophic failure like this before on a Yamaha, Honda, Kawasaki, or...

I have been around dirt bikes for 50 years and I have never seen a catastrophic failure like this before on a Yamaha, Honda, Kawasaki, or Suzuki. If anyone else has, please post pics. 

SoCalMX70 wrote:

Yeah a YZ ain't gonna blow like that. Even if it did, parts are plentiful and reliable.

We’re actually talking with a dealer right now trying to get a couple YZs now

4

The Shop

mikelindsay
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5/14/2024 10:35pm Edited Date/Time 5/14/2024 10:46pm

Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is not Justin Barcia!!!

3
burn1986
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5/14/2024 10:37pm

We know it won’t happen but GG should replace it all. That head is a casting/manufacturing flaw. Wow

1
mikelindsay
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5/14/2024 10:40pm Edited Date/Time 5/14/2024 10:44pm

I am afraid to put my son back on  this. A 23' was supposed to be bulletproof. If I could unload it I would and get YZ 250 two stroke

2
urbanlift707
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Humboldt, CA US
5/14/2024 11:21pm
Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is...

Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is not Justin Barcia!!!

That horrible, I had my 2020 tc250 blow apart with around 19 hours if I recall and husky paid for everything, parts/labor even bought me a brand new fmf pipe as it had piston chunks inside it. 

1
Richy
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5/14/2024 11:34pm

Some WEIRD (maybe extreme is a more fitting word) failures going on with the recent Austrians

edot504_
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5/14/2024 11:36pm
I am afraid to put my son back on  this. A 23' was supposed to be bulletproof. If I could unload it I would and get...

I am afraid to put my son back on  this. A 23' was supposed to be bulletproof. If I could unload it I would and get YZ 250 two stroke

Yeah my dad was scared to put me back on too, we unloaded all of the GasGas’s and went to YZ250s! Best decision ever

2
burn1986
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5/14/2024 11:45pm Edited Date/Time 5/14/2024 11:53pm

$5000 to fix

$5000?!! Seems like a lot, but when you include brand new parts and labor… 😏

MxAddic
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5/15/2024 4:03am Edited Date/Time 5/15/2024 4:04am

The issue is piston pin beating failure in every one I have seen…

1
wrc777
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5/15/2024 6:08am

$5000 to fix

Probably better off parting it out although I suspect it is closer to $2k in parts or maybe less. Should need head, cylinder, piston, and crank right? $5k sounds like the price of a crate engine. There is a cylinder and piston kit on MX locker for $1015 right now. Crank is $550 on RMATV. There is a rebuilt crank on MX locker for $375. Maybe yours can be rebuilt for less. $60-70 for the head and insert, $800 for new cases if you need them. You might need a better dealer.

1
burn1986
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5/15/2024 6:23am

Heck it’s like a brand new bike. I think I would rebuild it and sell it. If you rebuilt to sell, you could try to do it as reasonably as possible. What a shame since these are such cool looking bikes.

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mikelindsay
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Florham Park, NJ US
5/15/2024 6:27am

@wrc777 yeah it was basically replacing the whole engine.  It also ate the cases, reeds and reed valve, and power valve. Worst nightmare ever! Luckily it grenaded right before gate dropped!

lumpy790
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York, SC US
5/15/2024 7:17am
Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is...

Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is not Justin Barcia!!!

Please Define what corporate means to you. Dealer or factory warranty claim department?

Did you take it back to the dealer you bought it from for them to go to bat for you on a warranty claim?

Ob917
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Carlsbad, CA US
5/15/2024 7:18am

I had a KTM 250sx develop a crack on the side of the cylinder, I caught it before things went bad. KTM sent me a new cylinder Exhaust flange gasket kit and a check for $80. 

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wrc777
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5/15/2024 9:14am
@wrc777 yeah it was basically replacing the whole engine.  It also ate the cases, reeds and reed valve, and power valve. Worst nightmare ever! Luckily it...

@wrc777 yeah it was basically replacing the whole engine.  It also ate the cases, reeds and reed valve, and power valve. Worst nightmare ever! Luckily it grenaded right before gate dropped!

A new bike is probably around $8k maybe less right now. I would part it out or sell it as a mechanics special before I spent $5k to rebuild the engine. 

YZed250
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Costa Mesa, CA US
5/15/2024 9:17am
YZed250 wrote:
You can get cases, crank cylinder from other models .. you just need to put some work in on the part number cross-referencing and spend some...

You can get cases, crank cylinder from other models .. you just need to put some work in on the part number cross-referencing and spend some time looking for used stuff. I think you could get it back for under $2k in parts, in my opinion. 

I'm happy to help, as are the Vitards (Vital forum members). 

I would suggest that there is a lot to learn in this ... laying down a stack of cash ($4k to be exact) is a missed opportunity. 

Edit: part numbers are not going to cross reference too well due to changes in suppliers between 2019 and 2023. But the parts will cross over. You just need to ask the right people about what fits together.

$5k? 

As I said previously, you can piece together one of these motors together for a lot less than $5k, probably less than half of that, even with cases or case fix. There are so many members willing to help with sourcing parts and so many lessons to tuning. I get it, everyone wants everything now/yesterday ... $5k might get you a new motor on a silver platter thru instacart ... I guess that's how we role in 2024. 

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jeffro503
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St Helens, OR US
5/15/2024 10:24am

Haven't read through the whole thread yet , but my guess would be a rod failure, or bottom end bearing failure. I have seen damaged heads before from this scenario.....but never seen one blow the head apart like that. Wow!  I have seen rods blow through the bottom end , just never seen a top end explode like that. 😧😧 Crazy , and sorry to hear man. At least you didn't get hurt. 

mikelindsay
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Florham Park, NJ US
5/15/2024 10:33am

@lumpy790 Warrenty department wouldn't budge. My dealer was great! Warrenty department said my catastrophic failure was from not following the manual instructions and replacing piston at 10 hours. BIKE is fixed now, I am just scared that it can happen again.

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JK BRO
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5/15/2024 10:43am
Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is...

Corporate had no compassion and told me I should have changed the piston after 10 hours (as per Manual) for a 250 #%&@ My son is not Justin Barcia!!!

No surprise. GasGas corporate can suck my ass. I purchased my txt300 new and it was lacking half the graphics when I picked it up from the dealer. They told me to contact gasgas and they'll get it sorted because you know "supply chain issues". Rat bastards led me on with a string of emails and eventually ghosted my responses.

3
burn1986
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5/15/2024 10:48am
@lumpy790 Warrenty department wouldn't budge. My dealer was great! Warrenty department said my catastrophic failure was from not following the manual instructions and replacing piston at...

@lumpy790 Warrenty department wouldn't budge. My dealer was great! Warrenty department said my catastrophic failure was from not following the manual instructions and replacing piston at 10 hours. BIKE is fixed now, I am just scared that it can happen again.

Wow that’s good news. I wonder how many of these GGs we don’t hear about? So what’s your plan now? Go with KTM/Husky or YZs?

mikelindsay
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Florham Park, NJ US
5/15/2024 10:50am

I could and would always use the help and suggestions. Fortunately the way this got paid for was by built up contingency and a God send in high places. But still messes with my confidence in the brand!

burn1986
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bossier city, LA US
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5/15/2024 11:08am Edited Date/Time 5/15/2024 11:10am
I could and would always use the help and suggestions. Fortunately the way this got paid for was by built up contingency and a God send...

I could and would always use the help and suggestions. Fortunately the way this got paid for was by built up contingency and a God send in high places. But still messes with my confidence in the brand!

The KTM/ Husky’s may be okay, since we’ve only seen the GGs grenade like this.

Of course you can’t go wrong with the YZ - reliable and less maintenance, but maybe not as good contingency. 

lumpy790
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York, SC US
5/15/2024 11:19am
@lumpy790 Warrenty department wouldn't budge. My dealer was great! Warrenty department said my catastrophic failure was from not following the manual instructions and replacing piston at...

@lumpy790 Warrenty department wouldn't budge. My dealer was great! Warrenty department said my catastrophic failure was from not following the manual instructions and replacing piston at 10 hours. BIKE is fixed now, I am just scared that it can happen again.

Thank you for clarifying this you definitely went the correct route 

ChiefLPD
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Leesburg, GA US
5/15/2024 12:18pm

I have never owned an Austrian bike, but I have owned/raced/wrenched my share of 2t's. I am leaning with those that suggested bad casting or an air leak as more likely culprits, but one other less-likely theory is a failed water jacket that got thru to the combustion chamber (possibly by a more minor bad casting that split, failed O-ring head seal, etc...). Enough hydraulic pressure could do that.

2

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