EC 200 set-up tips needed

[bondo]

Just picked up an '05 EC 200 for my teenage son (apologies to Boomhauer).
i ride orange and was initially looking for same for him, but the more research
I did, the better the GG bikes looked. We finally found the '05 just a few miles from home. This is our first Gas Gas so I could use any advice about setting up the bike for a long, happy life in the tight woods.

This particular bike seems to have fairly low hours on it and mostly needs just a little TLC to sharpen it up. First question, what about the forks? The previous owner has the Ohlins units mounted, but has a set of 'zokes in a box.
I'm well aware of the reputation both units have, but have never ridden either.
He's willing to include either set (but not both, darnit!). I'm planning on trying them both, but could use some input, especially as relates to tunability and
performance in the tight stuff.

Also, what about the spring loaded chain guide on the swingarm?
Should we keep it or replace it with a more traditional block style unit?

Finally, the sag on the rear shock. I was accustomed to running about 90mm of sag on my Ohlins equipped KTM for the riding we do and was planning on starting there for this bike. Comments?

As I said, we ride mostly tight woods. Plenty of rocks, ruts roots etc . . . Lots of elevation change.
If the trail opens up enough to use 4th gear, it's considered a fast section
(for me, anyway), but mostly 2nd and 3rd gear sections.

Any comments or advice about setting up and maintaining this bike would be most welcome.

 

[SpeedyManiac]

I'd go with the Ohlins forks personally, but the Zokes are a good set too.

The stock chain guide works well, but if you're worried, LTR makes a bracket to use a Honda block chain guide.

Sag should be set around 105mm.

Get a LTR powervalve cover for the bike. This really wakes up the bottom end.

For gearing I've been very happy with 13/52, but this is only good in the tight stuff. Sucks on wide open desert riding.

If your son is fairly tall get some bar risers as they really help open up the riding position. I went with a BRP SUB mount as I have a Scotts steering stabilizer as well.

 

[bondo]

Thanks for the input. My son's about 5'8"/5'9", so the rider compartment seems about right. The gearing you suggested is exactly where we're at. The power valve cover suggestion is most helpful. This is just the kind of info I'm hoping to get from this forum. Keep it coming!

 

[SpeedyManiac]

Another tip: If your son has arm pump issues/larger hands, get Spider M1 grips. These suckers are awesome!

 

[Bearman]

Thanks for the input. My son's about 5'8"/5'9", so the rider compartment seems about right. The gearing you suggested is exactly where we're at. The power valve cover suggestion is most helpful. This is just the kind of info I'm hoping to get from this forum. Keep it coming!

Im about his height and have the same bike, just as an '03 not an 05.

I find Reikon bars are good and im pretty sure they are slightly higher than stock.
I find Domino grips work pretty well too, i never get arm pump or anything like that.
The Zokes are great, but if you can get the Ohlins for not much more, go for it. They are great in the roots and rocks and gnarly stuff.
Speedy's right, 13/52's great in the tight stuff, i have 13/50 and i can get around (most of what we ride is tight stuff) but 13/52 would make it easier.

These bikes are great and you can have an absolute ball on them.

 

[bergerhag]

Stick with the spring loaded chain guide. That old Husqvarna invention is THE best. I have now 4 years of tight root/rock infested, rutted trailriding, and have yet to de-rail a chain.

 

[bondo]

All of the feedback so far is great! Can anyone give me some advice regarding what parts of the bike need special attention as far as maintenance is concerned
(for example, KTM kickstarter bolts and kickstand bolts are notorious for getting loose and MUST be Loctited or they disappear).
SpeedyManiac recommended an LTR power valve cover to help the bottom end on the bike. Are there any other aftermarket add-ons that help the bike perform up to it's full potential or make it easier to live with?

 

[widebear]

I would avoid the ohlins forks unless you are able to service them yourself Any tangable differences in performance will be negated by their high maintainence requirments. parts are pricey and they require special tools to work on. I have a set and it has been my experiance that if you dont change the oil every 15 hours your asking for trouble. The ohlins seem to foul the oil very quickly, prob because of the 3 bushings designe and when that happens the performance deteriorates noticably and you can start to blow seals.Also these type of ohlins are an older designe and apart from the bling factor hold little advantage over a well dialed in set of zokes.

 

[Rick]

I've had my 99EC200 for several years and the bike has been bullet proof! Roostafish who posts on this board was the first owner. Messico pipe, FMF Turbine CoreII, suspension redone by LTR. I have added the LTR jet kit. A WER dampner handles front end duties. I really don't think there is much to be changed. I added a skid plate from Uath Cycle Sports. Other than that ride it! I do use loctite blue on my subframe bolts and nuts. Clean airfilter and change the tranny oil always helps. Keep the left side power valve area clean. The 200 hauls my 195 pound frame around through the woods with no problem. The only complant would be the forks. The 45mm Magnum Zokes tend to be a little flexly when pushed. Other than that, The 200 is a solid performer!

Rick
99Ec200
AMA
D36

 

[Berkyboy]

I would agree with widebear the ohlins are nice but servicing them can be headache.

 

[bondo]

Excellent feedback on the fork issue, guys!
I had heard that the Marzocchi's tend to dirty the oil quickly, but hadn't heard that about the Ohlins.

Thanks for the tips on where to look for loose bolts and the item about keeping the PV cover clean!

 

[Bearman]

keep and eye on the radiator shroud bolts because they seize up easily. one of mine has just got to spend some time and fix it

 

[GMP]

Bearman,

I noticed in your photos you have a cage type pipe guard. Is that the "Whipps" (sp) made in Austrailia? How do you like it?

 

[barkeater]

I've never had a problem servicing the Ohlins forks on my '03 200... I just stick them in a box and send them to LTR. A week later I thank the UPS driver and stick them back on my bike. The Ohlins are a piece of cake to maintain.

All good recommendations. I love my '03 200. I had a 450 Husaberg for a while, but went back to my EC200.

I've set up narrow Renthal bars (KX80 bars) to sneak between the trees, and a BRP/Fastway/Scotts FIT system. Keeps the cockpit clean and with the mini bike bars, there isn't a lot of room.

LTR power valve cover does help the low end. I also put in the LTR jet kit and after tweaking for air temp, I've been accused of running a 250 with yellow plastic. While we're on LTR, put in the alloy hi-volume impeller too.

You'll want to locktite the kicker... they tend to vanish on the Gassers as well.

Get a wee bit longer throttle cable. Tight turns can get reeaally exciting with the stocker.

I've been running Evans coolant with good results for the last 2 years.

On long rides, you won't get as tired on a 300, but the 200 hops through the tight stuff like a bicycle.

 

[bondo]

Good tips all! I used to run mini-bike bars on my 250 because of the rise.
I usually cut my bars down to about 29" (plus the width of the barkbusters equal 30" total width) and I rarely get hung between trees - but there's not much room to spare for grips, levers, etc. . ., and I usually have to modify the barkbusters to allow the clamps to get a good fit around the bar.

We'll definitely check out the LTR add-ons you suggest. Does everyone agree that LTR is the place to send the Ohlins for service?

I think these may need a fluid change. The service manual I downloaded from the GG site appears to deal with servicing the 'zokes rather than the Ohlins.
Any suggestions on where I can get a manual on the Ohlins units?

Thanks again for all the good input. At this rate, I'll know my way around this bike in no time!

 

[barkeater]

Les used to be active on this site... I haven't talked to him since I dropped my dealership last year. But my forks went out spongy, leaky, and messy and came back set up to the click for my terrain and weight. I just slid them in and went riding.

Somewhere, I have a .pdf manual for the Ohlins... I'm not going to guarantee I will ever find it though.

{edit} Duh, they are on this site in the manuals section. I assume you have the 48's.

http://www.gasgasrider.org/ohlins_48mm_enduro_fork.zip

{/ edit}

 

[Bearman]

Bearman,

I noticed in your photos you have a cage type pipe guard. Is that the "Whipps" (sp) made in Austrailia? How do you like it?

I think it might be, but im not sure. my uncle's mate picked it up for me because i liked the one he had on his 300 (which is the same guard). Ill try and find out if it is the whipps.

I love it, its just a bit of protection against the logs. Definitely cheaper than a new pipe, and it doesnt stick out or look out of place.

 

[bondo]

Thanks for the link to the Ohlins fork manual - I suppose I could have looked it up
under the "manuals" page on this site, but that would have required elementary powers of observation.

On the subject of the forks, I've scanned the manual, but it doesn't appear to
indicate approximately how many cc's of fluid are required in each fork leg (it gives fluid height recommendations, but this doesn't help much when deciding how much fork fluid to buy). Also, any recommendations on what weight fluid for the woods? I usually run 3w or 5w fluid in my WP's and Showa's, but have never used the Ohlins before.

Also, I cleaned the external parts of the power valve behind the left side cover and it made a noticeable difference for the better in the bikes bottom end pull.
Why would a little rudimentary cleaning have such a pronounced effect?

 

[bukwheat]

Yo, bondo! It was good to see ya Sat. nite....are you gonna ride the Gobbler Getter?

 

[bondo]

Re-Post of questions from Monday, 10/23:

Thanks for the link to the Ohlins fork manual - I suppose I could have looked it up
under the "manuals" page on this site, but that would have required elementary powers of observation.

On the subject of the forks, I've scanned the manual, but it doesn't appear to
indicate approximately how many cc's of fluid are required in each fork leg (it gives fluid height recommendations, but this doesn't help much when deciding how much fork fluid to buy). Also, any recommendations on what weight fluid for the woods? I usually run 3w or 5w fluid in my WP's and Showa's, but have never used the Ohlins before.

Also, I cleaned the external parts of the power valve behind the left side cover and it made a noticeable difference for the better in the bikes bottom end pull.
Why would a little rudimentary cleaning have such a pronounced effect?