I can't imagine the case hardened steel rod bearings being softer than the nikasil walls of the cylinder so even though the cylinder looks good it needs to be accurately measured to see if it's still within wear limits.

I agree, I am going to have Eric Gorr check out the cylinder while I get the crank rebuilt.

I took off early from work today and ran the EC200 parts up to Finish Line Engines in Beaver Dam, WI. Ryan Callies (owner) rebuilt the crank, diamond honed the cylinder and ported/polished the cases. Ryan is great to work with, fast and has very fair prices. www.finishlineengines.com I am looking forward to heading back up later this summer to run my big bore XC327 on his Dynojet dynamometer to see how close my jetting is and how much power she makes.

Now I need to order some parts so I can put it back together.

36hrs plus $980 and we have a fresh and clean 2004 EC200 for my youngest son to ride. $1380 bike and parts total invested, minus $400 for the extra parts that came with it including the parts I was getting ready to buy for my bike, (Big Clarke tank, new front rotor and pads).

This bike really runs really well for a 200. With a single ~0.014" base gasket the squish was around 1.7mm. I am sure the polishing of the cases and cylinder helped too.

What was replaced....please provide some insite on the "fresh motor"

I would like to get my 99 rebuilt as well.

Did you replace all tranny bearings as well?

Thanks

I had the connecting rod replaced/crank rebuilt, new crank bearings, cylinder diamond honed (Finishline Engines $200), four new transmission bearings (Grainger $75), crank seals, gaskets and wiseco piston kit (GasGas $350). The prices maybe off a couple bucks one way or another. My output shaft seal, shift shaft sealand kickstart seal looked ok so I left them because they can be replaced later if/when they go bad.

After the fact I found that All Balls has a kit with crank bearings and seals for $80.

I would love to find a second source for GG alcohol friendly crank seals.