Top End Rebuild on EC200: In search of experts...

Rien Deau

New member
So I recently seized my '05 EC200 and am in the process of rebuilding the top end. I ordered a new top end kit from Bob Piper at North Tahoe Motorsports (I would recommend anyone rebuilding a Gasgas to use him) and was going to send out the cylinder for re-plating when I ran into a few problems that I could use some answers to:

1) How do you remove the bearings that are on the power valve assembly? They're tiny bearings tucked into a blind hole and no ordinary puller/extractor seems to get a hold? Is there a specific tool or is this just one of those "smash and replace" kind of deals?

2) Is re-plating even my best option or should I start looking for another used cylinder and head? (the cylinder I have has some pretty nasty gouges from a piece of the old ring getting chewed up)

TLDR--Has anyone removed the power valve assembly from an EC 200 and how did you do it?
 
please post a picture, I rebuilt mine in 06 same thing and I can't remember off the top of my head but it is doable and the shop you send your cylinder to will advise you if you need to bore and plate or if you need to sleeve etc. but doubtful you will need to replace unless its toast.
 
Here are some shots of the problem. I tried to get a good shot of the gouge in the cylinder, its about 1 mm x 4mm and deep enough to catch a fingernail in. I would like to re-plate as I've heard that sleeving is a bit on the sketchier side and I'd like to do this right. The other two pictures are of the let and right sides of the case. The bearing I'm trying to pull is on the left side ,I believe its the second picture.
 

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Nasty gouge for sure! just let whomever is going to do the work on it advise you and don't worry about sleeving and re-plating it'll work just fine and should be cheaper than a new cylinder. I looked at Gofasters site and new cylinder is $718.65.

Follow link below for exploded view of your cylinder and you need to remove your power valve first before you can remove the bearings.

http://partsfinder.onlinemicrofiche...=22&c=0&d=2005 DE200 CYLINDER - CYLINDER HEAD
 
The major replate companies can fix that cylinder. If that one can not be fixed let me know as I have a used 200 cylinder that I will sell. The one I have needs a replate.
 
Thanks for all the help guys. The link that Moto7man put up is way more helpful than the user manual. I shopped around a bit for re-plate options and I think I'm gonna go with Powerseal. It seems like they do a pretty high quality job for the price. I'll be sure to give them a call and get their advice on honing and re plating. Hopefully I can get back out there by the end of the month!
 
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