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GT240 REBUILD

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GT240 REBUILD

Postby Covboy » Mon Sep 08, 2025 1:56 pm

So I blew my GT240 up in the summer. I was pushing along nicely at 70mph ( much faster than I normally go - just ask my riding companions!)…. Then silence …. Seemed to just cut out , no bang or nasty sounds… clutch in , coasted to the hard shoulder to find it seized…

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I’ve had it rebored and gone up to the first oversize piston.
Whilst it’s apart I’ve decided to renew main bearing and flywheel side seals and gaskets, and fit a sluk head cowling and vortex fan for supposedly better cooling ( I’m a sucker for new bling )


So what caused the seize? The plug and piston crown do not indicate a lean issue or air leak judging by the colour. I pressure tested it prior to strip down and it holds pressure with no leaks.
There was a dark black oil stain on the main bearing retention plate. (Sucking air and oil in from crankcase?)
The carb was jetted professionally on a dyno.
Fuel tap is fast flow and measured rate is OK
A club member has suggested looking at the float valve size - I’ve ordered a 3.5mm fast flow valve from MB. Feasibly at that speed the engine may have been using more fuel thank the float bowl could supply and it drained..?

Also I gather that compression ratio will increase too with the rebore - should I add a headgasket to compensate for this - the gt240 kit doesn’t usually need one …

Once rebuilt I’ll get it redyno'd and dialed in
Any thoughts on the cause, or rebuild hints and tips appreciated
Last edited by Covboy on Mon Sep 08, 2025 2:08 pm, edited 1 time in total.
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Re: GT240 REBUILD

Postby Covboy » Mon Sep 08, 2025 2:06 pm

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Re: GT240 REBUILD

Postby nsaints » Mon Sep 08, 2025 2:12 pm

Good thread!
I'll check the pictures when I'm at home, as work blocks the hosting site URL

Any thoughts on the cause, or rebuild hints and tips appreciated


Rich T told me Saturday that the 'squish needs to be between 1.2mm and 1.8mm to aid kicking over'
I'll achieve this by ditching the 0.4mm base gasket, instead using a 1mm packer and Threebond 1215 for gasketing

I've seized on the A34, just at that point before I went onto reserve. what was your fuel level like at that point. were you far from reserve?
Worth checking your fuel cap breather hole to confirm a vacuum wasn't being pulled restricting fuel flow.

On the possible main seal - have you been losing gearbox oil?
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Re: GT240 REBUILD

Postby Covboy » Mon Sep 08, 2025 2:40 pm

Hi Andy - thanks for the reply and suggestions

A: fairly full tank, and breather ok,
I have previously suspected its losing a small amount gearbox oil, however no white exhaust smoke or smells.
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Re: GT240 REBUILD

Postby nsaints » Wed Sep 10, 2025 1:23 pm

Is it known if the ring peg had failed and caused the seize - I'm guessing not 100% known?

I'm only mentioning as I'm aware excessive ring wear can potentially cause the ring peg to fail

I'm only throwing this out there as a possible explanation if nothing obvious is found..
good luck with the rebuild and keep us updated
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Re: GT240 REBUILD

Postby coaster » Tue Sep 16, 2025 12:25 am

That doesnt look like it got hot so possibly not a heat size, maybe just the ring peg comming out and jamming the piston? I think fuel issues would have made it run lean.
Re the squish, I had my GT240 bored to plus 0.5 after severe wear cused by a contaminated tank and didnt change the squish at all, just put it back together as per the build instructions. I've done a few thousand milrs on it since including many at 65-70mph with no trouble at all.
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Re: GT240 REBUILD

Postby Covboy » Tue Sep 16, 2025 7:21 am

Thanks fellas
What exhausts are you using ?
I’ve currently got a TSR EVO which in very happy with
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