Zman
Platinum Level Site Supporter
Last autumn my Godson had his 2002 EC200 scream (high RPM) itself to death. He noticed that its throttle revved while going over whoops. He was playing in a big mud puddle/pond prior, but the issues stopped after he left the whoops. Then he went back to the mud pond and the engine revved and it would not stop. He was soaked and the single wire kill switch was shocking him so much he could not press it to kill it. He ultimately pulled the gas line to stop it but it melted the top end and crank bearings.
I inspected the bike immediately after the melt down and the throttle was fine. I rebuilt the entire engine but never found a cause. The crank seals were fine, the intake gaskets were fine, the throttle cable was fine. The carb to intake boot had some minor dry cracking but none went all the way through, but I replaced it anyway.
I checked the carb float bowl and it was clean. I did not have one of the Motion Pro cables with the threaded ends so I applied a little JB weld epoxy to the cable sheath end to secure the sheath in the throttle adjuster screw. I drove the bike for a few miles over some hills and trails but no whoops and it ran great!
The first ride for the rebuilt ec200 was a local enduro. The first mile of the enduro had a whoops section. My Godson's father was riding the 200 this time and was lagging behind so I waited for him to see what was up. He told me that the bike went wide open on the whoops. I was shocked. I spent several minutes to double check the throttle cable and it was still rigidly secure at both ends and the cable sheath was routed correctly. It was not binding and the throttle worked perfectly.
I started the bike and it rode fine across the flat corn field. I normally ride a big bore XC300 and the 200 runs well but it is not an unmanageable amount of power. I took it on the same whoops section again and I was riding with a constant 1/3rd to 1/2 throttle in 3rd gear. The bike acted normal for the first three whoops and all of a sudden the bike the bike revved like it went WFO and it shot out from between my legs and looped itself down the trial in front of me. It happened very fast. I know this sounds silly but it happened. I did not open the throttle to WOT (where it could get stuck) it went WOT or revved on its own.
I just got through riding it hard across the field and the engine did not seem ti have the same amount of power I just witnessed on the whoops.
Again the throttle, cable and ends were fine. Prior to the whoops section the bike had not seen water for 8 months.
I started thinking that maybe the bumps caused enough force to bounce the slide up so I am going to replace the throttle spring but I think that is wishful thinking.
This does not make sense to me and I am starting to wonder if this event could be related to the carb being a little rich in the 1/3 to 1/2 throttle range and if it went leaner over the bumps and had a surge of power.
Another possible option may be that the float level is slightly low and it could similarly cause it to go lean over bumps.
I have not found a good answer for this event and I would appreciate your thoughts. I will install the new spring soon, check the float height and record all of the jetting details.
Entertaining side note- My friend was standing 200 ft away watching the event. When he came over to help, I could not help myself so I told him, " I don't know what you are talking about. The bike runs fine!" I was wearing my GoPro and the video is rather interesting.
I inspected the bike immediately after the melt down and the throttle was fine. I rebuilt the entire engine but never found a cause. The crank seals were fine, the intake gaskets were fine, the throttle cable was fine. The carb to intake boot had some minor dry cracking but none went all the way through, but I replaced it anyway.
I checked the carb float bowl and it was clean. I did not have one of the Motion Pro cables with the threaded ends so I applied a little JB weld epoxy to the cable sheath end to secure the sheath in the throttle adjuster screw. I drove the bike for a few miles over some hills and trails but no whoops and it ran great!
The first ride for the rebuilt ec200 was a local enduro. The first mile of the enduro had a whoops section. My Godson's father was riding the 200 this time and was lagging behind so I waited for him to see what was up. He told me that the bike went wide open on the whoops. I was shocked. I spent several minutes to double check the throttle cable and it was still rigidly secure at both ends and the cable sheath was routed correctly. It was not binding and the throttle worked perfectly.
I started the bike and it rode fine across the flat corn field. I normally ride a big bore XC300 and the 200 runs well but it is not an unmanageable amount of power. I took it on the same whoops section again and I was riding with a constant 1/3rd to 1/2 throttle in 3rd gear. The bike acted normal for the first three whoops and all of a sudden the bike the bike revved like it went WFO and it shot out from between my legs and looped itself down the trial in front of me. It happened very fast. I know this sounds silly but it happened. I did not open the throttle to WOT (where it could get stuck) it went WOT or revved on its own.
I just got through riding it hard across the field and the engine did not seem ti have the same amount of power I just witnessed on the whoops.
Again the throttle, cable and ends were fine. Prior to the whoops section the bike had not seen water for 8 months.
I started thinking that maybe the bumps caused enough force to bounce the slide up so I am going to replace the throttle spring but I think that is wishful thinking.
This does not make sense to me and I am starting to wonder if this event could be related to the carb being a little rich in the 1/3 to 1/2 throttle range and if it went leaner over the bumps and had a surge of power.
Another possible option may be that the float level is slightly low and it could similarly cause it to go lean over bumps.
I have not found a good answer for this event and I would appreciate your thoughts. I will install the new spring soon, check the float height and record all of the jetting details.
Entertaining side note- My friend was standing 200 ft away watching the event. When he came over to help, I could not help myself so I told him, " I don't know what you are talking about. The bike runs fine!" I was wearing my GoPro and the video is rather interesting.