Dead 02 EC 200

[markwoodlief]

out riding today about 1/2 way down a burly single track my bike started hissing a bit out of the overflow, got out to the flats and opened it up a bit hit third gear and the bike died, like someone pulled the plug, no bang, nothing...

I tried to kick it over once and heard some pretty bad grinding noise, not at all smooth like it was an hour earlier. Got her back to a friends shop who has now taken the top end off, piston looks brand new, everything up top looked great..

thougths on this? Not being totally familiar with the engines not sure where to look. Crank bearings? anyone have a clue?

 

[PEB]

Was any coolant in or around tha crank area. Should be easy to spot with the topend off. How does tha crank feel? It should rotate easily by hand with the piston off. If the crank and top end seem fine the next area to look at would be under the right cover. Take the water pump cover and impeller off, you may find the impeller is all buggered up. Next the kickstart and then the side cover can come off. Then take a good look see around. The manual for these biikes can be found here, any of the newer model shop manuals will work for any older model, assuming thats what you have. Good luck I'm sure you will figure it out. These 2t bikes are pretty straight forward and nothing special about the GG to know about .

I had been eyeing your bike on Craigslist. If you got a good deal on it and you don't feel like messing with it I could part it out for you, but you will get it running. Were you at Reiter?

Paul from Everett

 

[markwoodlief]

Was any coolant in or around tha crank area. Should be easy to spot with the topend off. How does tha crank feel? It should rotate easily by hand with the piston off. If the crank and top end seem fine the next area to look at would be under the right cover. Take the water pump cover and impeller off, you may find the impeller is all buggered up. Next the kickstart and then the side cover can come off. Then take a good look see around. The manual for these biikes can be found here, any of the newer model shop manuals will work for any older model, assuming thats what you have. Good luck I'm sure you will figure it out. These 2t bikes are pretty straight forward and nothing special about the GG to know about .

I had been eyeing your bike on Craigslist. If you got a good deal on it and you don't feel like messing with it I could part it out for you, but you will get it running. Were you at Reiter?

Paul from Everett

No coolant in there.. that looked ok, but turning the crank by hand, doesnt feel right at all... not smooth.. I was at little local riding spot, not reiter. thanks for the tip, not interested in parting it out, rather rebuild the whole engine.

 

[PEB]

If i remember corectly with the ignition still on the crank will have a somewhat notchy feeling. Get some more input than my shadetree inclanations. Gofasters can be an awesome resource if you catch them when they are not to busy. The full rebuild is not to bad, In fact it's kind of fun. I would definately pull the side covers and look around before you tear the case out of the frame. Keep posting observations and questions here, I am sure someone else will chime in.

 

[markwoodlief]

If i remember corectly with the ignition still on the crank will have a somewhat notchy feeling. Get some more input than my shadetree inclanations. Gofasters can be an awesome resource if you catch them when they are not to busy. The full rebuild is not to bad, In fact it's kind of fun. I would definately pull the side covers and look around before you tear the case out of the frame. Keep posting observations and questions here, I am sure someone else will chime in.

thats exactly what it feels like, a bit notchy.. hmm...the powervalve was gunked all up, black sludge oozed out of it when we took that off.. normal? Ill ride my Adventure up there today and try to get some pics, etc. Thanks for the all the help so far.. kind of lame, only had the bike a week..

 

[PEB]

The pover valve cover has goo in it normally esp. if if it does not have a drain. Do you have the Side covers off yet? I am guessingf your problem lies in one of them. If the crank keyway that holds the ignition on were to let loose it could cause a scenario similar to yours. I have lots of gaskets if you need any let me know. Several years ago I was riding some good stuff of Ben Howard road, I have been thinking of checking it out again, same stuff?

 

[markwoodlief]

The pover valve cover has goo in it normally esp. if if it does not have a drain. Do you have the Side covers off yet? I am guessingf your problem lies in one of them. If the crank keyway that holds the ignition on were to let loose it could cause a scenario similar to yours. I have lots of gaskets if you need any let me know. Several years ago I was riding some good stuff of Ben Howard road, I have been thinking of checking it out again, same stuff?

man, that just may be it..
this happend at machias orv, a very very small orv place north of Monroe.. but.. I do ride where you speak of.. its a gray area.. but I get there from my backyard.. behind the house there are hundreds of acres that i can ride in that backs right into Hancock and DNR land, so I dont officially go around any gates.. as there are trails from my backyard to those places..

thanks for the tips soo far, got the right side cover off.. the clutch side.. the bikes up in Lake Stevens right now or Id go shoot some pics.. ill get up there today..

 

[PEB]

I have a small ignition you could use for awhile if yours is buggered up. Funny thing is I just went to machias a couple weeks ago for the first time. I found some fun, yet short sections of good trail out there.

 

[markwoodlief]

I have a small ignition you could use for awhile if yours is buggered up. Funny thing is I just went to machias a couple weeks ago for the first time. I found some fun, yet short sections of good trail out there.

man.. that sounds great!!!!.. yep, its small, but definately fun, there are some really fun technical stuff.. I rode with another gasgasrider that belongs to another forum and a local that rides out there as well.. its fun for a few hour local get away..

ps.. working out a deal with that gasgas on cl right now in clinton as well.. 02 ec200 same as my bike but with ohlins.. may pick it up.. saw it yesterday, it wouldnt idle, i was scared off because of recent gasgas issues..be nice to have 2 exact same bikes though..

 

[markwoodlief]

I have a small ignition you could use for awhile if yours is buggered up. Funny thing is I just went to machias a couple weeks ago for the first time. I found some fun, yet short sections of good trail out there.

bored today by any chance? feel like taking a peak at the gasser up in Lake Stevens?

 

[PEB]

If I wasn't watching my kids I would perhaps this week.

 

[fury1]

alot of the older gasgas bikes if not properly jetted will never idle! dont be scared,its normal for them not to idle

 

[markwoodlief]

bought it today, so now have 2 ec 200's, no word on the broke one today, i was out picking this up. this one has a wierd knocking when i lift the bike from the rear, think its coming from the top of the shock, this fix is more up my alley though so dont mind..

 

[PEB]

I like your style and soon you will have two running 200's. Your new likely has a clunk coming from the lower shock mount. Be sure not to overtighten the bolt as it gabbing only about 4-5 aluminum threads on the shock clevis.

 

[markwoodlief]

I like your style and soon you will have two running 200's. Your new likely has a clunk coming from the lower shock mount. Be sure not to overtighten the bolt as it gabbing only about 4-5 aluminum threads on the shock clevis.

just rode the piss out of it today, instead of researching all day.. So heres one for you.. my other one is all tore apart and there is nothing the matter with it, we can not find a bad bearing or marked up metal any freaking where, the noise it was making is not there at all, when turning the crank by hand.. it feels perfectly normal now.. this is going to sound ridiculous but could it be that things were just jammed up and by taking it apart inadvertantly unbind out? that makes no sense at all, but grasping here... the only bearing that even may be close is we can get about 1/4 mm or so of movenment from the crank bearing.. you can not tell by the eye but if you put your finger on it you can feel it move just a super fraction..

the mystery remains,

 

[markwoodlief]

alot of the older gasgas bikes if not properly jetted will never idle! dont be scared,its normal for them not to idle

after wringing its neck on some technical stuff today, it all seemed to work itself out, well the shocks still a bit screwy, but fresh gas and loads of hammering on her for a few hours, she actually purrs like a kitten now.. surprisingly so..

 

[markwoodlief]

Update

Its all back together now. Went to the shop and was there when it was started up, started up first kick.. but something is wrong.. there is a growling noise in the engine somewhere.. or a deep whirring noise.. gets louder as you rev the engine. My mechanic working on the bike thinks it may be the crank bearings.. when we had it apart everything looked great though.. we found one ball bearing in the water pump that was stuck.. tough to explain but the centrifugal attachment that lets the ball bearings move the faster the engines reving.. but thats it.. no metal shavings.. nothing.. he says it may be infact the crank bearings.. although they looked great.. any suggestions? Good thing is it fired right off, bad thing is it looks like it needs to come out again..

Our next thought is to run it down to Tasky's Metric Cycle in the form it is now and fire it off and let him have a listen.

any suggestions are welcome!

 

[Skidad]

Gotta be the crank or lower connecting rod bearings with that noise (both maybe). I think pull it apart and replace everything...crank bearings, upper and lower con rod bearings, crank seals and check piston and rings very carefully as well. Clean the heck out of the PV assy and also check reed condition while apart.

 

[markwoodlief]

bout done with them both.. bought 2 2002 ec 200's this month, and both are screwed up.. first one this threads all about, the second one the previous owner buggered up the top shock mount, i knew something was up but couldnt see in there until today. I took teh rear subframe off with the airbox to get a good look,

so.. heres my history with gas gas..

bought an 03 450 FSE, blew crank at 700 miles.. that was brand new out the door about 9500 bucks..

bought the first 200 for 2000 bucks, got about 3 hours on it, blown up

bought the second for around 1800, got about 3 hours on it, top shock mount is wasted..

Anyone want a couple of gassers for a ktm?

 

[markwoodlief]

Was any coolant in or around tha crank area. Should be easy to spot with the topend off. How does tha crank feel? It should rotate easily by hand with the piston off. If the crank and top end seem fine the next area to look at would be under the right cover. Take the water pump cover and impeller off, you may find the impeller is all buggered up. Next the kickstart and then the side cover can come off. Then take a good look see around. The manual for these biikes can be found here, any of the newer model shop manuals will work for any older model, assuming thats what you have. Good luck I'm sure you will figure it out. These 2t bikes are pretty straight forward and nothing special about the GG to know about .

I had been eyeing your bike on Craigslist. If you got a good deal on it and you don't feel like messing with it I could part it out for you, but you will get it running. Were you at Reiter?

Paul from Everett

may part out the yellow one.. still interested in handling that? Think Im going to keep the black/yellow one. The motor runs right now, runs great actually, but there is a loud growling noise that is not right.. the rest of the bikes in pretty decent shape, plastics arent bad, i have 2 sets..suspension etc is all dialed in on the yellow one..