EC200 01 vs 06 cases

[Thompo]

Hi Folks,

Working a friends 2006 (ish) EC200 that had the rear section of the casings crack IWO the swingarm pivot bolt, resulting in the engine bobbing around the frame and wrecking all the mounts on the engine.

He got some replacement cases and a gearbox from a 2001 bike, thinking they are the same.

Have both engines out and see a few differences.
Different generator cover and casting around this area.
Different casting IWO the output shaft.

Any other differences to note or that will affect re-assembly?

Cylinder seems to fit ok, we have the gearbox it came with in and working.
Reeds fit.

Havent been able to break the crank bolt yet to see if the crank shaft will swap. Looking at the diagrams, bearings are similar size, just not sure on over all length of the crank.

Any Help appreciated, probably similar issues for 250/300 of similar years.

 

[Anders]

Hi Folks,

Working a friends 2006 (ish) EC200 that had the rear section of the casings crack IWO the swingarm pivot bolt, resulting in the engine bobbing around the frame and wrecking all the mounts on the engine.

He got some replacement cases and a gearbox from a 2001 bike, thinking they are the same.

Have both engines out and see a few differences.

Any other differences to note or that will affect re-assembly?

I'm afraid the engine mounting points moved between 01 and 06. I have never had a 01 engine, but so I have been told. Did you check to see that the 01 engine fits the 06 frame?

 

[Thompo]

Not yet unfortunately, I will check that when I get home today!

 

[Stoby]

different

Don't interchange . the 01 has different size and placement of the rear swingarm mount

 

[Zman]

I do not know if it is possible but maybe you can move the lower frame mounts to fit the other cases. Steel is easier to weld than aluminum.

 

[Gasser Nate]

Quick check are the crankcase gaskets the same? The holes line up all the way through for 250/300?s but the shape of the cases differ slightly.

 

[Zman]

one other consideration is the diameter of the swingarm pivot. GG made a change around 2000/2001 from the small diameter pivot to the larger one they use now.

 

[Thompo]

Bit of an update, Epic battles all around!!

Spent a good while and tried a few things to loosen the widely reported LH threaded hand crank bolt on the clutch side..... after taking to my uncles to use a better impact gun, it isn't a reverse thread on the 200 as per the 250/300 nut. Lefty loosey for the 200 both sides.

Another hr trying to split the cases, wasn't happening, then spent a good hr making a splitter still no luck and convinced myself something wasn't right.. found a bolt still in place inside the generator side lol
Always check for yourself!

Bolt out and it fell apart

The 01 and 06 cases mate except for 1 mismatch before the reed area, mismatch is big enough that gasket wouldn't seal it.
but all mounting points align and are the same dia

So the 01 cases will fit the 06 frame.....

Onto the crank.
01 cases/crank uses 6206 ball bearings both sides 28x68x18

06 uses a 6206 on clutch side and NU206 30x62x16 roller on the stator side....

Balls .... So 01 stator side casing is not compatible with 06 crank.
01 crank is 28mm both sides
06 crank is 30mm stator and 28mm clutch side

Options
Sleeve the case down to 62mm and use the NU206 bearing
Shave the crank to 28mm and use 6206 bearing
Fit a weird ball bearing I managed to find, 30BC07S7N1 C3 30x68x16 and hope it works.

Last option is looking most likely for now depending on availability, cant see any issues with the working of it, roller vs ball bearing any issues?


Cheers

 

[Anders]

Options
Sleeve the case down to 62mm and use the NU206 bearing
Shave the crank to 28mm and use 6206 bearing
Fit a weird ball bearing I managed to find, 30BC07S7N1 C3 30x68x16 and hope it works.

Last option is looking most likely for now depending on availability, cant see any issues with the working of it, roller vs ball bearing any issues?


Cheers

I would also go for the last option (if you can find it). I presume the reason for using roller bearings is that it my be easier to mount without getting sideways stress on the bearings.

 

[Thompo]

Few pictures of the cases.
Some casting differences, crankcase is the same dia. 111mm
Most things seem to fit bar the crank etc mentioned above.

Mounting points will need drilled out.
2001 14mm swing arm and 8mm frame bolts.
2006 18mm swing arm and 10mm frame mounts.


So as an aside, given the gearbox, clutch, powervalve etc is common across the 200/250/300 and cases are supposedly different on the 200, what is the difference? Anyone got 250/300 cases care to measure the crankcase dia?

At this point, its looking like a whole lot hassle to make the 01 cases work. Will probably go the route of welding the re-drilling or sleeving the existing mounts.


Cheers

 

[Zman]

Lots of great info! Thank you! Good luck with the rebuild.