04 ec200 kickstart lock

[warnzie]

Hi there...i have an 04 ec200 and my kickstart is locked. Im hoping its not seized but i rode it 1 month ago fine and no probs..plug is nice no signs of it been lean...Would it be the kickstart gear? Can see how a bike can seize when not in use?

[warnzie]

Update..I pulled the head off and no the engine is not seized..thank goodness. So, basically witht the head off and with the limited slide of the kickstater - about 4cm the piston will move as far as the kickstarter will move? Does this sound like a kickstarter gear?

[2 strokes 4 life]

Possibly a crank bearing, or you starter gear on the clutch is shot.

[Rick]

Sounds like........
With the bike being a 200 you might want to check the crank stuffer bolts. If a crank stuffer bolt backs out, it will keep the engine from turning over. The bolt will "jam" between the rod and crank weights, causing the motor to not turn over, much like a seize.
You will need to pull the topend. Get a bright light and look between the crank weights and look for a small allen head bolt jamed someplace....

My 200 did the same thing, rode the bike one day, shut it off, next time when to start and it turned over 1/2 a turn and was seized.....crank stuffer bolt back out.

[Gasser200UK]

I think I have the same problem - sorry if this is a dumb question, where exactly do the crank stuffer bolts come from or do they go by another name in the manuals available on the GAS GAS Spanish website?

Is a full bottom end rebuild the only option if this is the problem?

[Rick]

On the GasGas USA webiste, looking in the model year 2003 parts, page 102, item #4, it is called plastic counter weight, there is (2) on each side of the crank weights, and a couple of allen head bolts that secure the plastic weights to the crank.

I was kick starting my bike when it locked up, I had very small fragements of black plastic had fallen down into the crank area. I was able to wash out the bottom end and get all the bits out.

TO make this job eaiser, I removed the engine from the bike, and worked on the motor from a work bench. I was able to fish out the bolt, cut down an 90 degree allen wrench and loctie the bolt and reinstall, and secure the bolt tight. I then removed the rest of the bolts and secured them.

Or, you could split the cases, split the crank and go that route....That might be a better route if you were running the motor or riding the bike when it locked up....could be some damage to the rod??? Since I was just kicking it over, I was pretty certain very little damage was caused..if any.

Good luck....If I'm not mistaken, only the 125 and 200 are like this, the 250 / 300 don't have stuffers.