JIM SNELL - TOTAL REBUILD 1993 GASGAS TRIALS GT25-T DUCADOS
Channel: TRIALS PARTS USA
Date: 2020-02-03

Over the years, I continue to tinker with my 'baby' known to many as "Old Smokey" - My 1993 GasGas DUCADOS Amos Bilbao/Jordi Tarrés Replica THE ORIGIN OF THIS STORY - In 1997 a boy was playing with matches in the alley behind my friend’s home. He started a fire that destroyed my friend Doug’s garage and his 1993 GasGas GT25-T was extensively damaged. It was properly insured so my friend was paid for his loss. I purchased the bike from his insurance company. 

At first I thought it would be simply for spare parts, but it was winter, I was not too busy, so I tore it completely down and rebuilt it from the ground up. Over the years it has been extensively modified to what it is today. HOW "SMOKEY" GOT THAT NAME - Because of its history of having been previously “destroyed by fire” we many years ago started referring to this specific machine as “Old Smokey” – Everyone in my group of area trials friends knows Old Smokey as it has been a favorite of mine for more than 20 years now.

THE SETUP ON SMOKEY NOW 

- ENGINE - The front exhaust is from the GT32 model (longer and larger in diameter) with a hand-made KEVLAR "Python Protector Series" heat shield circa 1992. The silencer is from the 1996 JTR370 model with a machined bushing to mount it to the center expansion box. Carburetor is Keihin PWK28 with a very special air filter box with an enlarged top intake cover and larger connection snout to improve air flow into the carburetor, all scratch-built by me. The kick-starter pedal is from the GG Enduro model. The engine has been enlarged from 238cc to 256cc with a modified cylinder head to adapt the chassis to head stay mount. The clutch is Hoerbiger from the GG Skunk Works, the water-pump is the final version circa 2003 with a hardened shaft, high-speed bearings and double-spring double-lip Viton seal. The stator is the original Motoplat that has been rewound with larger wire and controlled by a solid state Motoplat '404' CDI from the GT16 model for a faster and more modern curve mapping. The coil is Nippon Denso and the spark plug is NGK BPR5EV. The rapid response thermostat is from Gustavo Pütz and the cooling fan motor is Mitsuba. 

THE STORY OF THE KEIHIN PWK28 CARBURETOR - The first time I played with a Keihin PWK28 was back in 1995. I put one on my 1995 JT35 (327cc) and it was incredible! But, part of the performance gain was the modifications to the air-box that allowed more air into the intake tract feeding into this Japanese carburetor. Chuck Ellis at Kawtown Kawasaki is the guy who helped me with that first carburetor. We used one from a KX80 MX bike, then I had to fiddle with jets and slides and needles... As Old Smokey is punched-out to 256cc and I had been contemplating this Keihin PWK carburetor update for for Smokey for some years. In my mind, were the mods I did to my 1995 bike 20 years ago and this is almost the exact same air-box. So it was easy for me to fabricate the new nose for the box and put this all together. Especially as I have some more modern Keihin parts for the reed cage area that made this one even better than my original conversion back then.

- CHASSIS - The fuel tank, radiator side shrouds and rear fender are GasGas "Replica" parts used by the factory team. The handlebars are 'Purple' HEBO like Amos Bilbao used for years. Front brake M/Cyl is vintage Brembo GG circa 1991. Clutch M/Cyl is GG Enduro model DOT4. Front caliper and wave rotor are from Galfer circa 1999. Front and rear wheel hubs are AJP 1997 straight-pull type, 36 spoke. The throttle is vintage NOS AMAL aluminum trials model with bronze bushing cable wheel and aluminum housing and grip tube. SMOOTH! The footrests are from the GG racing department with a kick-start pedal cut-out on the right peg. SUSPENSION - Forks are 1997 GG JTX with a billet top tree and bar clamps with Timkin roller bearings. The front fender support is Beta Techno, the front fender is 1998 TX270 - The rear shock is a circa 1999 HEBO Racing brand with aluminum body made by Olle. 

 2020 REBUILD - January 2020 Smokey gets her first tear-down and refurbishment since the build in the winter of 1997-98. Including a NOS chassis! THE STORY CONTINUES...