Motor Problems on 2004 EC 200
 

I shut my bike off when it was running fine. I went to start it and the started locked. The startermis not the problem, I can turn the crank approximately almost all the way around but it seems as if the piston is hitting something. It will not go to bottom dead center. Are there any common problems similar to this and any one else have any problems like this?
Thanks.

Sounds like a "crank stuffer" bolt backed out and has jammed the rod.
The crank stuffers are plastic plugs that bolt into the crank weights to increase volume in the case area.

There are 6 allen bolts that hold these plastic inserts in place. They have been know to back out and jam up the rod.

It has happned to my bike, same thing, I was warming it up one day, hit the kill button, then wanted to start it again, bam, locked up.

I was able to pull the topend off, I pulled the motor out of the frame so I could work on it on the bench.

I was able to "fish out " the little bolt, I had to cut down a " L" shaped allen wrench so it would fit between the weights. A drop of loctite and threaded it back in.

The other way is to split the cases pull the crank, have the crank seperated and install the bolts.

http://partsfinder.onlinemicrofiche....&d=-CRANKSHAFT

Make sure the rod is not damaged.

Good Luck

Thanks, it makes sense, the cranks turns perfectly smooth until it approaches Bottom Dead Center. Thanks for the luck, I need it.