BUILDING THE 2023 GASGAS 500 BRC

[@theprodegypk]

It’s seriously amazing hearing some of these old timers stories, tony working on the old plane and jeffs 40 years of working on bikes is awesome. So much knowledge and talent between the 2. Thanks for the vid!

[@artiexr222]

A pleasure to watch such a master at his craft nice job Manic Mechanic.

[@ricardoguerra9411]

In the Beginning it started with a interest in the Honda XR 75 , fast forward 50 years, its interest in CR 500's and Monsters like this GASGAS . The engineering that goes into our sport machines is remarkable. Watching Jeff work on this Engine makes me appreciate mechanics so much more.

[@matthewchurch1320]

maico 700

[@paulkilmister2223]

Watching a master like Geoff is absolutely fantastic seeing the mighty Gas Gas come alive.

[@adamsmith5913]

Wow he threw that circlip in like a magic trick and he has a built in torque wrench. The way he assembles is like clockwork.

[@MrLorence]

We need more banter from the guy with the Fro...

[@bobbymckinney1264]

I Admire the quality of work he puts into theses engines,master mechanic at its best..

[@whosahberg]

Agree .. he is excellent

[@cleapup2]

Jeff is "The Man" ! An amazing mechanic and a great rider too! Look forward to more content like this!

[@grabir01]

Since it is case reed you can shave the base. If no gasket, make sure to spray some starting fluid around the base when the engine is idling so you will know there are no fresh air leaks. I would spray it around all my seals to make sure there are no fresh air leaks. Fresh air leak can mean certain death for any 2 stoke engine.

[@donniebaker5984]

My hat is off to your mechanic here today as i would have never admitting to the public i hardly use a torque wrench . Im 71 and started wrenching on small two strokes at age 16 at a dealership through the sumer months off from school break ..and by my years in my twenties you could tell when the fasteners are maxed out within a pound or two on the case and side cover screws ..i think it has to do with the pitch of metric threads that split the difference of american course and fine thread pitch. As for me the pull of a wrench us gradual increase and then all of a sudden its like you hit a solid wall and your wrench dosent want to move another fraction on M6x1.0 thread , M8x1.25 thread , and M10x1.25 thread .. years ago harley used 1/4-24 bolts on the lifter blocks cause 1/4-20 wants to loosen up to easy and 1/4-28 is too fine and easy to pull and break threads in sand cast cases of aluminum...today harley uses all 1/4-20 and mostly red lock tight on everything ..i use blue lock tight on harleys so the bolts are not permanently "welded in" and have success keeping my harleys from falling apart.. ...i still like to use a torque wrench on the head bolts and you can still "feel" when that head bolt has had enough right when the torque wrench clicks ..i think the main thing is to follow the sequence numbered in the book on tightening so as not to distort the assembly at all ..you guys are one of the few shops who seem to rehearse the assembly in your heads before you begin any work that is as we both know is an absolute must for a perfect reliable assembly everytime ..and ken jr.my hat is off to you boy for following in his fathers foot steps and then taking it on to the extreme ..there is not that many kids today to carry on their fathers passion ...especially two stroke dirt bikes ..as there are a lot of other ways to invest the kind of money you guys have put into all this ..and it looks like it is paying off to breaking even and that is all you can hope for to feed your addiction that makes this all possible for fan boys like me to see and appreciate ..back in the late 90s when it was announced no more two strokes i was not surprised after i lived through the peak of muscle cars to ho hum grocery gitters ...then when they done away with the two stroke race bikes it was a lost and lonely feeling came over me feeling like a wiped dog ...and now watching you guys just tearing it up for the last year and a half has given me a reason to turn on tube just to see what you bunch of maniacs are doing next . And good time to be alive .thanks for picking up the ball for me boy ..i owe you one ... In respect i was at a drag strip mostly attended by the locals and not too much of rules and standing right next to the cars doing burn outs then staging things can happen ..as this particular day it was a 1970 hemi cuda ..the owner had just rebuilt and installed right before a big weekend of racing ..after his burnout and then staging a rod cap came bouncing my way and landed a quarter inch in front of my left toe of my boot instantly setting the grass on fire . There was an ARP half a rod bolt bent jammed into one of the bolt holes of the rod cap ...the owner jumps out of the cuda and raises the hood and burst into tears sobbing like a baby .. there was dead silence came over the crowd as we all watch a man's spirit being totally busted of one of the sadist experiences you can witness in the sport of racing and walk away from ...ken Sr. And ken Jr. Live long and prosper

[@ronaldspins]

Thanks for clearing this up... I thought GasGas produced the 500 .. I did not realize it had to be retrofitted ..BRC has been doing the CR500 kits for a long time and the kit transforms a CR500 .. this video makes it all understandable ...would GasGas take this BRC kit and factory install it....It would make it more affordable .. the GasGas factory could keep the 300 parts ...now I know why Ken said this would be expensive.

[@Davido50]

It's not making very much power stock..very mild tune stock

[@crashalexander7232]

@@Davido50 sandbagged

[@matthewchurch1320]

maico 700

[@argomotoriders]

Great video!! My favorite part is at 3:51 after the fan was shut off. My dude in the background is talkin about stripping to his undies and had my rolling.

[@Yqsw750001]

Watching him snap in those piston circlips makes me feel like a total novice. I think I spend more time looking for one that shot across the shop than it took for him to build the whole thing. Amazing,

[@doctoreskizo8636]

Buena... Noches, INGENIERÍA de Kaplan America, hermosas manos, hermosas instalaciones... Pasión y trabajo parece ser lo mismo, difícil diferenciar, en todos los componentes, incluso el perrito se da cuenta de la atención prestada a la GASGAS. 500...Vi el video de la concentración - manifestación de motoristas, cuando hablaron con el responsable del asunto... Pero las puertas estaban cerradas... (Tengo que interpretar sus vídeos puesto que no conozco el idioma). Volviendo a las máquina, me preguntaba cuánto rendiria con un sistema de encendido de platinos,??? EL sonido y aceleración... Asemeja a un motor eléctrico... Transmiten seriedad y profesionalidad y amor por lo que hacen... Muy buenos, creo... Los número one. Saludos, gracias, fuerza. 🌞

[@OldestYoungenInGuidePost]

Yes🙌🏼 Installing a gearbox and hearing it's click,seating into place is so satisfying 😋👌🏼👍🏼 I've got an Aprilia RS125 that I've rebuilt a fair few times and it is so easy to do that I timed myself at 28 seconds from a bare cases to having a fully installed gearbox ☺️ I love ❤️ 2 strokes👏🏼 I enjoy watching this 👌🏼 Thanks 🙏 for the upload 👏🏼👏🏼👏🏼

[@romper4444]

I just wanted to let all you guys and gals know in the Kaplan family, STOP BREAKING THE INTERNET! haha, you are producing hands down the best motorcycle content this world has to offer, please don't ever stop! Please know how much your time and efforts are appreciated by all us folk out here watching at home.

[@muckle8]

@Nick well said and couldn’t agree more , to say I’m hooked doesn’t even begin to cover it!

[@ThomasJ.Foolery]

Always enjoy watching a master of their craft.

[@magickennyj]

Rewind back to the 1980's affordable days with this technology and same with my age and I'd be living the dream on a bike like this.

[@danielarney9729]

They usually wont impound if you can get your bike plates, so you basically can go anywhere in the armpit state. You can have your moto bike road legal like they did with WR yzf bike parts swap. Race against 450s at ama nationals if you keep 250/300 labels, remove raised words in covers, get a pipe that looks stock and run a sleeper? What pipe do you use for 500 kit? 300 pipe would keep you under the inspection radar? What would a 500 pipe do for the power?

[@goomtoob8714]

nothing better than an old school mechanic embracing the modern tech, it show's he's still keen to learn.

[@Louis_m9]

i was thinking as they were setting the squish glad they took it off the top and not the bottom/base gasket otherwise it would affect port timing. im sure they already considered this off camera though.

[@randycarpenter3663]

A modern 500. Love it! Preshate the videos and what you guys are doing!

[@322kfunk]

You guys should do more of the wrenching stuff very interesting!!!

[@martycech5844]

17:26… Master Mechanic and a Man of Passion!

[@kodatolppa5401]

I miss having Jeff around he’s such a great guy hope he’s having fun there

[@thevoxofreason8468]

Nice. I could hear that thing pull hard from a relatively low rpm. I could imagine what that feels like out on a trail. Nice.

[@craigcolburn8016]

Kick ass guys. I'm guessing that fuel injected 500 package should produce around 55 horsepower. It's been a big four fanatic since the late 70s love to see you guys still doing that kind of stuff

[@MegaSkypes]

Lovely lunch time viewing! Always impressed with the content and finishing touches and full time coverage of this build! Beer o’clock after 5! Cheers 🍻

[@jasoneardley2202]

You guys are reeling me in for one of these big bore ec 500 gas gas no replacement for displacement hats off to Yamaha for still building 2 strokes but gas gas definitely has a leg up on advancement Jeff is class act🇺🇸🤙🏻

[@matthewchurch1320]

there are still a lot making them but more for enduro then motocross motocross is more the japanese big 4 now enduro is more europen brands like ktm Beta Gas Gas Husqvarna Motorcycles

[@MC0386]

I would love to work besides Jeff, what a awesome mechanic

[@SnowBikeNation]

We're about to have this as a Snowbike in the Rental fleet this season. People can book a tour with us on it this season! Gonna be sick.

[@patrickstenkilsson5676]

Your blessed to have such an awesome crew of guys. Love your videos, keep them coming. God bless you and your family and crew. God bless America 🇺🇸 👍😇

[@mfitzgerald130]

Good quality engine that also looks great , Good to see the quality piston compared to other brands. 👍🙂

[@lenhannaford8718]

I also was a mechanic from the 70s. I was taught to cross torque bolts, not just tighten them as you go clockwise around the cases?

[@kevfinn8232]

Maybe some more workshop vids, this a so satisfying to watch how things go together. Maybe one of the wizards mastery carb rebuilds.

[@ericandrews1251]

That is absolutely the best weapon money can buy today. 😮

[@reidspeed77]

⚙solid spanners ,the GG5 sounds crisp, got the numbers, Seriously good

[@gjalie]

It's a pleasure to watch the guys working on the bikes! Question: does polishing the transmission reduce friction and increase horsepower?

[@rickstrom6097]

Quality! That would be a fun job putting together the piece. I forgot what BRC charges for it i think it was 900 bucks. I think week end warriors can do it with a press minus the shaved heat. Thanks for sharing. Awesome!

[@Goose-it]

I believe BRC kits are $5000-$7000

[@rickstrom6097]

@@Goose-it Talking about putting it together 900 bucks. Take your old engine out and putting in the kit.

[@rickstrom6097]

Saying that Kaplan Cycles probably can do for less then that or equal and you don't have to ship your bike to Canada. There have been plenty that have and always thought that was crazy.

[@panic-revv85]

My buddy has a BRC yzm 500 on order for his 2022 YZ 250x. Interesting to see how the tpi system will work on the BRC, as most guys who do anything faster than trail riding don't seem to like the tpi system, hense the lack there of on the MX models. Keep posting on this build. Good luck.

[@FeatheredDino]

Gas Gas is good.... but Beta revolutionized 2 strikes in dirt bikes with the RR300, and still have the best 300cc smoker on the market

[@sbam4152]

Awesome to watch this 👏 The master at work. Would be cool to see a long term review of this build and see how she holds up over time 🤘

[@atrain882]

The counter balance shaft is amazing on that bike or any bike that you can have that done to leave with the BRC to come up bigger big bore kit

[@edwardthompson3213]

I bet Jeff's talk rench built in to his elbow is more accurate than most . Cant beat experience you jest know that engine will be spot on . We all need a manic mechanic to build our engines . What he doesn't know. Ant worth knowing 👍👍👍👍👍👍

[@gotdirt66]

I would like to see this done on ktm 500 exc-F. Build break down with the mechanic and understand what to do without the oil system on the 500 exc-F?

[@gotdirt66]

Is it for sale?

[@Cr-24-r]

Build a supermoto with some 450-500cc bike,that’s can be cool

[@ThePurePlayaz]

If those thumbs could talk.. :) Thanks for sharing the greatness of Gas Gas new tech. That piston is massive!

[@dennisoven9259]

1.3mm (50/1000) is quite tight squish for big bore for EURO standards. 60 is better but still tight. We use more in the range of 80-85/thou squish and a tad higher comp ratio. Tight squish is generally not recommended for elastic throttle response for enduro riding, heat wise, impact on internals and overall longevity. It is used primarily for MX or cart engines. I do notice that "USAans" like it tight overall and also use higher octane fuel to compensate for higher heat. Also, rather than milling bottom of cyl, we mill the head, and also cut some dome material out, to compensate for compression increase. By no means a critic, just comparison. That is an animal on its own, thanks for the video, I'd really like to test it.

[@JCMTNUT]

Love it! So cool you guys take the time to do these.

[@arcosaojorge4061]

True mecanic !! ❤💪💪👍

[@raoulwoodruffbecker1518]

why didn't you mill the head? wouldn't milling the cylinder down affect porting?

[@bloomerb4162]

The kit doesn't come with new ecu? I would use torque wrench if squish reading off. But I trust manic mechanics judgement. A little beer helps sometimes.

[@SnowBikeNation]

Sick video guys! Awesome watching putting it all together and the dyno runs.

[@ziruk-king4466]

I also did not know it did not come factory 5. I gas ken and the guys expect to be busy this summer with upgrades to to 5. Please send one to Wyoming thank you -- lol

[@4R1P5R]

The dip in power is mapping - for sure Try a new header and exhaust with the correct ecu map that dip will disappear

[@250wrecks]

i love the vibe of the shop and the guys over all i work at bettencourts in west bridgewater ma same family own n relaxed

[@mariuszbros2806]

Pozdro dla Kaplan America robisz extra filmy. Pozdrawiam z Polski 🇵🇱💪🏿💪🏿

[@saltonearth.3650]

I wonder why you don't use sealant on the casing, because all casing that I have done needed sealant, or you would see dirt collect were the leaked through the case.

[@waltcomotorsports3994]

Mils is the term your lookin for jeff! Love that xr650 you built its killer!!

[@mikestowe6136]

only thing that sucks about this kit is im sure it isnt cheap then ya gotta find somebody to put it together that knows what thier doing then the biggest thing that sucks ya gotta have the cyl milled down for it to work n finally i bet money the cost to make this a 500 cc cost more then half of what the bike cost but hey if ya got the money to piss away more power to ya i guess now we need to see someone beat the shit out of the bike to see how long the motor last and if its reliable

[@Davido50]

You guys should *bypass* the oil injection for engine safety reasons & PRE-MIX that fuel

[@crashalexander7232]

why?

[@shauncry1917]

@@crashalexander7232 for engine safety reasons

[@crashalexander7232]

@@shauncry1917 please explain

[@crashalexander7232]

@@shauncry1917 what safety reasons?

[@crashalexander7232]

@@shauncry1917 what isn't safe?

[@christopheribarra28]

we need more engine build videos like these! on all types of bikes

[@whosahberg]

The mechanic who is manic is a good operator , I would let him work on my bike . A question for SEEN ~ YER .. , if you had only 2 bikes to choose from , no others available. CR500RR or BRC500 ? .. your choice SIR

[@douglasnorman8748]

why was the squish wrong though? was it the cases or the cylinder?

[@bobg1219]

The 300 had a smooth power curve

[@offgridliving4128]

Surprised a new 2023 has case reeds like an old gamma motor. Will not changing base gaskets raise or lower port timing? Also filters are measured in microns.

[@acek1605]

This is the real treat really enjoy watching some of that favorite wizard tune..... Also would like to add look at the size of that piston you can knock a hole in the wall with that..... that's what I'm talking about 👍 I was about to say that it's right up there with the XR650R way lighter GasGas 500 🙏

[@kananisA75]

The gasgas are known to have restrictive airboxes , maybe do another run with a vented side panel or no side panel just to see! Maybe the bike will gain 1-2hp maybe none.

[@stopibeastin]

Thank you for this video it really clears things up! God bless America 🇺🇸!!!!

[@Davido50]

My '20 Yamaha YZ250F makes 45hp or more stock! Hope you guys get more power esp for 500cc. Love the channel.

[@brendanhickey9771]

Not to the wheel

[@keithpeterson3447]

🤣

[@danieltopp7298]

Nope that's at the crank like 35 rear wheel max my gf has one my yz 250 2 stroke smokes Evry 250 f and it's 10 years old

[@KaplanCycles]

Lmao.

[@tommodobbo3475]

@@danieltopp7298 💯💪

[@brandonvarney7258]

Good to see Jimmy! Miss seeing him on Yellowbullet!

[@team_1j_jont-179]

Ken jr has a voice similar to Jason weigandt. Awesome commentator!! You could easily have a career in broadcast buddy...

[@patrickstenkilsson5676]

You guys need to build same kit but in ex model gas gas and race them against your other 500s

[@generalsixty2133]

Great mechanic has the experience. No base gasket with Loctite 2 non hardening gasket sealant.

[@chadjohnson2853]

Amazing work. I love bikes two strokes more than anything. Love the videos. Even love the ones you involved your family 🥰

[@ianreed4636]

They say that kit turns that engine into the smoothest 500 money can buy .

[@shawnslaunwhite2085]

Love the detail in the build video. Thank you for sharing the process.

[@peaceprayer595]

how much does the bike weigh once this motor is in the bike?

[@MichaelForrestChnl]

that pre-powerband power dip is due to the power valve opening too late in the RPM

[@daylemackintosh9966]

They have started selling gas gas up at drysdales in Perth Scotland proper nice bikes

[@Briank-ef5iq]

When are the 2023 strokes coming in ?

[@clayboi6939]

I thought you had to pull the crank into the case rather than press the case onto the crank to avoid distorting the crank. Not trying to question Jeff's skillz cuz they far exceede mine, but did I just buy a crank puller for no reason??😆

[@Scissors69]

I would also pull the crank to assemble

[@keithpeterson3447]

Jeff's awesome but when I saw that, I cringed. It is a bigger pin so harder to distort but still a risky move. So absolutely use a puller. The smaller the crank pin, all the more you want to pull it in. When ypu deck the top of a nickel plated cylinder, you want to use a diamond cutter as well. A regular carbide cutter can chip the plating as it hits the plating from behind.

[@bobg1219]

The Magnum Eagle LIVES!!!!

[@Extremegaz25]

Great video, loved the intricate detail of the motor rebuilding, your professional mechanics need to pass on their knowledge to a good apprentice who will hopefully carry on the good work, I should know, I've got less than 10 years left in the motor trade, and there isn't enough young blood interested. All the best guys and keep up the good work.

[@MiamiJato]

how much for this bike, the way it is, with the BRC. Thanks....

[@kbishop94]

what happened to the sound at the end?

[@ronaldtartaglia4459]

Junior, I am 3 minutes into this video and I'm completely blown away by the awesome edit. Did you hire a new video editor or are you doing this yourself? I love this format I can't believe I have a 1/2 hour of full build action to sit back and watch!

[@Davido50]

Jr Is excellent for a 21yr old right?

[@KaplanCycles]

All jrs work. The shifty vids are all sr cell phone

[@sonnyseabury4051]

Jr. could work in Hollywood!

[@cat-im4vv]

this building videos are the best...

[@johnrickey5631]

I dont understand how dynos are done this bike should make like max 63hp not 53 please explain.

[@bones6554]

What is out the door price on one of these vs the stock 300?

[@randycarpenter3663]

Long live 2 strokes!

[@rajanrairealty8979]

Maico does. At engine it's 70plus

[@jasonkennedy1670]

4 stroke dirt bike motors are the answer to the question that nobody ever asked

[@lucapecorari8801]

I'd love to see an honda xr650r on that dyno to compare the 450s and 500s to it

[@cm-oo1td]

Gasket sealer for the cases ????

[@allenhodges5448]

I want one of those so bad. Got to get one. How much does it cost

[@KaplanCycles]

7k for the kit in a box +++

[@alex2_035]

Why did he not use a gasket for the bottom end?

[@AAs-vb7pv]

Do you sell just the 500 engine case s and use the gears and that from the 300?

[@keithpeterson3447]

Yes

[@stewartmackay8537]

Wow what a machine wat a upgrade really enjoyed the manic mechanics way in which he works just a kick ass bike I'm gonna get 1💚💚👌👍✌🤙🤘🖖😄

[@stewartmackay8537]

How is actually replying 2 my messages is it a worker from the i.t. side or family