Complete Rebuild - EC250

[RockefellerGG]

I haven't seen a complete rebuild or walk through on the forum. Maybe I didn't search hard enough. Maybe this will be over-simplified, but I thought it might help someone who needed some motivation or confidence booster.

This EC250 belongs to a friend and fellow forum member. He was riding it a few weeks ago when the engine seized up. While washing it down, he noticed that the carb-to-air boot was disconnected. Here it goes:

Tonight, I'll start with the top end:

I started by removing the water pump cover:


The water pump impeller was seized to the bolt:


Gently pried out the shaft seal:


Remove the clutch cover:


Remove the right side power valve cover:


Removed the kick start lever:


Removed the shifter:


Remove the 6 bolts that hold the right side cover on. Gently pull that cover off:


Removed the lower nut that retains the power valve lever arm:


Removed the upper nut that retains the power valve lever arm: