Looking for information to split case

[RayGas]

Have to split cases on an 04 200ec can someone point me in the right direction to splitting the cases.

Also it appears that the nylon counter balance pieces unbolted and siezed the lower end is this common?

Ray

 

[Rick]

I know of 2 EC200's that this has happend to both being 1999's. 1 being mine and the other being my riding buddy. In his case the crank stuffer bolt came out and jammed between the rod and crank while riding. He split the cases and rebuilt the lower end.

On my bike, the same thing happended, I was starting my bike in the shop and it locked up. I was kicking it over I knew right away what had happend. I removed the topend, and bolt the bolt back in. I was able to fish out the bolt, I put loctite on the threads and re-install. I did the same to the rest of the stuffer bolts.

 

[RayGas]

splitting case

Mine is a little different, there was plastic everywhere???
I could not figure out where the plastic came from until I found a
crankshaft breakdown apparently the counterbalance is made of
a nylon derivative. I did not find any bolts (three bolts are supposed to hold it on) so I assume that they are in the bottom of the case somewhere.

I found a manual to split the cases on the GasGas USA site and hope to
split the cases this week. I will post when I split the cases and determine the extent of the damage.

Ray