2001 EC200 Riders Beware: Cracked Rocker Arm Support - Other application as well

[mlyle11]

Hey all! I a have been restoring my 2001 EC200 for the last few monts... piece by piece. I was replacing all the bearing in the linkage and swing arm tonight and noticed a crack in the right rocker arm support, part number BE250314006. I am glad I was doing a deep clean or I might have missed this in an annual service. Both the right and left rocker arm supports have z shaped bends in them. The left has a more severe z shape so it has gussets cast into it. The right is not as severe, so they must have assumed no need to gusset it. Not so. The crack is at the beginning of the first bend, at the root of the radius. Exactly where the gussets span on the left support. This part may never break all the way through, and has held up pretty well for 10 years in the woods, but I'm not gonna risk it. I have a parts bike to rob from . Be sure and check this support when you service the bike. The crack is on the outside of the support, so you could see it without dis-assembly. This is the likely location for cracks like this. Happy trails all!!

[jeffs2200]

Here is a pic of mine from my 2011 300. Notice the gussets where you're support is cracked.

[jostby]

Thanks for the heads-up. Although I don't think of myself as being "stuck" with an older bike, I'm not a racer and have no need (only a want) for anything newer and the older they get the more attention they need though our bikes have been extremely trouble free. I think I'll take some time to thoroughly check both bikes in my garage. I have gotten a little complacent about going over them the last few years since we haven't ridden as much. Seems like if the linkage breaks it may not end well for the rider

[mlyle11]

Holy Crap Jeffs2200! That picture made me laugh! Not a funny laugh mind you... Good thing they added gussets!!!! The gussets on the left side extend into the z bend, I wonder why they didn't do the same thing on the new design? I'm thinking that little crack you have around the bolt hole could use a little extra support!!! Did you wipe out when it broke?

jostby - I love my 2001's. I keep rebuilding them and they keep running, and I can keep up with just about anything else in the woods. You should see the guys on the KTM's when they look back and still see me there on my 1980 KDX 175. They have to look way back... but I'm still there!

[jeffs2200]

The only reason I knew it was broken is because I saw it. It was not apparent when riding.

[mlyle11]

It was probably still held pretty securely in the frame, almost half still under the bolt flange, and the other side still intact. I considered putting mine back in, as it may have been cracked for years, but my luck... she aint no lady.

[mlyle11]

I tore my parts bike down to get the rocker arm support. It was ok. No cracks. It's also a 2001 and has had a hard life. I took the assembly to a friend of mine that runs an industrial machine shop, and he agreed that the area in the bend is weak and should have been gusseted. He could have added some weld beads to the part, but I didn't want to wait. I will keep an eye on the area during annual service... aka the winter tear down.