New (to us) 2007 EC200 Seize - what to do?

[CMSTAJ]

Hello everyone (my first post). First, thanks for this site and info.

We had been looking for a bike for trails that both me and my 15 yr son could ride on trails. About a week and half ago, we found a 07 EC200 in our price range and after doing some research decided to get it. The bike looked to be in nice shape. The only thing I noticed was a lot of spooge on the pipe and also around the exhaust/head springs. The owner said he mixed the gas at 30-32:1 with non-syn. oil and liked to see that. Another thing was the carb. dripped when we got back from riding in the yard, but only when leaned on the kickstand. Owner said it did this until warmed up.

I should say that we don't ride much, but I have been on bikes and atvs since a young kid and done medium repairs over the years.

My son was really ready to ride, so I took a vacation day, mix 40:1 (syn.) oil/gas and loaded up. My plan was to ride it easy and us check it out on the trails, then see what was up with the carb. drip.

I did my normal warm up (~4-5 min) on it, but then had an issue with another bike, so shut it off. After about 15 min's, started it back up for a couple of mins and my son was took it out to head to the trail. He said he was in 3rd gear and wide open and it just stopped (no sounds or sputtering, etc.), when I got to him the kick starter was locked, but I could move it in N. It has a Rekluse clutch, which allowed him to coast to a stop.

I will make some more posts to show what we are doing and trying to figure out. This pic is the most telling I think, but will post others.

Any help or advise will be appreciated very much.

 

[CMSTAJ]

More pics of what we have seen so far.

What we are trying to figure out:
1. what caused this (too cold, ran too long at high rpm not fully warmed up, 40:1 syn. mix, something from the leaky carb., etc.???)
2. whether we should break into the engine on our own or take it to someone (there is a service shop local, but haven't talked to them yet) or should we go ahead and removed the head, then decide whether to take it or not
3. what else should we check as we go

4. Last, but not least, what is this going to cost us?


thanks again

 

[CMSTAJ]

Also, looking for any advice on the best service manual that might help us if we go into the engine.

(more pics)

 

[Enduroger]

Sounds like it could be one of the bolts holding the counterweights on the crankshafts that might have backed out and locking the crank.

Take the topend off and look for a M6 allen head bolt between the crankweights.

This happened to my 2004 EC200 a couple of years ago. I stopped the engine and the next time i tried to kickstart it the crank was locked. Heard it have happened on some other 200's too.

 

[CMSTAJ]

I will look for any backed out bolts, but thinking it was the piston/rings since we saw metal shavings on the plug.

After we got the plug out we were able to un-seize it by turning the back wheel backwards.

Thinking we may drain the coolant and start removing the head today.

 

[john r b]

200

Post a photo of the pipe, my bet is was heavily damaged (bent) , The Oil looks like it hasn't been changed in a while. Everything else looks ok so far, read up on removing the lock nut on the right side power valve prior to removing. my bet its a hung ring.

 

[(F5)]

You won't know what it will cost until you pull it apart. It could just be bad timing and no maintenance on an old bike. They are reliable bikes but 2007 was a long time ago.

That said I've only just done the crank on my 07.

Very easy to pull apart. Read up, watch some YouTube and give it a go.

It does absorb time so a bakeshop will have to charge for that time if you give them a complete engine. Better to give them a crank to rebuild for example.

 

[CMSTAJ]

Spent some more time on it today and got the top off.

More pics of what we saw.

 

[CMSTAJ]

I was thinking it might be the piston or rings, but they and cylinder look ok.

Then we found that the bottom is still bound, shown in the second pic below.

Not sure what we are going to do from here, getting to this point is pretty good for us.

 

[Ghostrider]

That?s a Bummer. Without hearing it run before the failure it?s hard to say. Definitely a lot of heat on that crank at some point. The excessive oil all over is not exactly a crisp running machine. That engine oil was pretty dirty also. Probably all still original parts and like stated 07 was a long time ago. You guys may be able to tear down the motor completely to save some money and have it built back up by a professional. That way you?ll know it was done correctly.
Good luck.

Ghost

 

[Neels]

I was thinking it might be the piston or rings, but they and cylinder look ok.

Then we found that the bottom is still bound, shown in the second pic below.

Not sure what we are going to do from here, getting to this point is pretty good for us.

Evening sir. I hate to break it to you but your crankshaft is toast. Thrust washers are chewed up and one can see where there was excessive heat on that crank.
I'm not here trying to take your money please understand that, however I am a mechanic and would be happy to help you with the engine if you'd like me to. I see your in middle Tennessee? Is that correct? I'm in Franklin just south of Nashville.
My name is Neels and my number is 307 seven six three 317four. Text or call me and we could work something out.

 

[(F5)]

Been riding my 07 today. What a fantastic machine. Worth preserving.

 

[RBrider]

My '01 XC 200 seized like yours . It turned out to be a bad left (or mag)side crank bearing. The cage for the ball bearings came apart and wedged between the crank & the cases.

It's a pretty easy & straightforward engine to work on, imo. Also, if you do a search on this forum, there's a very good step by step engine rebuild report posted. It's for a 250, I believe, but , except for using a different right side crank bearing, the same as your 200. I used it when going thru my 200. It was a great help.

Or, pull the engine and take it to Neels .

One other point. My GG owners manual says to use syn oil with prem. fuel at 50;1. That's what I use and it has worked fine.

RB

 

[Harry]

My 300 seized under similar circumstances. Turned out to be corroded main crank bearings, the result of long term storage.

 

[Jakobi]

Here are a couple links to rebuild threads. Good spread of pics through both. Lots of tips thrown in by the knowledgeable folk.

http://www.gasgasrider.org/forum/showthread.php?t=21160
http://www.gasgasrider.org/forum/showthread.php?t=14730

 

[CMSTAJ]

Thanks for the help so far from everyone.

We are going to keep studying and post what we come up with for next steps.

 

[CMSTAJ]

We talked to a local shop here who works on gasgas (performance supercycle) close to Cookeville and they are doing some checking to see if the can find a total rebuild kit & the cost if they did it for us. Hope to get some info back next week.

We'll $ee...