Let the fun begin!

[12Bravo]

I'm making this post as a running project and a learning tool for me.
I would love advise on where I should go and what is a good practice. Would like to also use this post as a go to for all EC 200 motor rebuild.

I have taken a bunch of pictures of the disassembled motor and already see some issues and don't know what a lot of the parts are or where they go. So this is going to be rough, for me learning. I'm confident I can figure it out, of course with the great advise from this forum and lots of online reading.

There will also be a running video segment on my youtube channel for this build and other issues I may find with my bike.

 

[12Bravo]

I wish I could just put the pictures in the post......I can't figure out how!

Looks like the connecting rod? Has lateral movement, about 1/8" maybe a bit more.

 

[12Bravo]

Video of the table of stuff!

https://youtu.be/xVGODF6MbnE

 

[GGRider01]

I think the connecting rod will always slide side to side. It's the up and down play that should worry you.

Maybe someone knows more.

 

[stabak]

Actually there are tolerances for side to side movement, (by memory 0.8-1mm gap) to be pressed accordingly. Check the rod too if it is needed to be replaced where at this point imo you should do.

Get the service manual, doubt there are major differences for a 200 spec wise.
Jacobi has some rebuild threads too...

If you're planning keeping the bike, there is only one way of doing things, the right way. In other words, specs, tolerances, measurements and new stuff where needed. Don't get lazy or cheap . In doubt ask and don't push things to happen, usually there's a reason they don't.

 

[12Bravo]

Get the service manual, doubt there are major differences for a 200 spec wise.
Jacobi has some rebuild threads too...

Mine is a 99', I have a an expanded view of the motor. But can't find a shop/service manual for my year. What years are the same? Like-99'-04?

The manual I have I got from this sight, it's not a real detailed thing. Just like an owners manual.

 

[12Bravo]

The more I look at this, the more I am seeing parts and more parts I am missing........Oh well you live to learn. So much for a complete motor "Just needs a Piston".....ggrrrr!

Some day's I wish I was made of money, I get tired of having to get older stuff to enjoy anything.