SHE IS ALIVE - 2001 EC200 Rebuild/Restore

[mlyle11]

Hello GasGasers!
It is with great joy that I announce my she devil fires. Last year after donning new plastic, she threw a lower rod. Instead of the junk heap, I broke the bank.

Bottom End over haul by Hall's
New Second Gear and Shaft
New piston, port an polish (top half is a 250 jug, piston and head)
New clutch
New Wheel Set and Bearings
New Pirelli Scorpions
New Chain and sprockets
TM Designs Chain Guide
New Rollers and Swing Arm Guide
About 40 hours of hand work cleaning up the swing arm
All Swing Arm and Link Bearings
Repack Exhaust
Rebuild All Brakes, New Disks (rear still needs work - wont lock up)
Forks (Pretty Gold Ohlin 48's) Rebuilt, and tuned by Borelli Suspension
Shock Rebuilt and tuned by Borelli
New Stem Bearings

And today... she fired on first kick!

Attached is picture of my pride and joy, minus the shrouds, as I have a few coolant hose leaks to fix. Also a u-tube link to hear her purr. I was worried on the first two kicks, but gee, it helps to crack the throttle a bit. Once I gave it a touch... ring ning ning ning ning....

http://youtu.be/Bht0-1VFroU

Thanks so much to all the folks here that have helped me along the way!

[mlyle11]

After a few spins around suburbia (and a few dirty looks from the neighbors) to get her nice and warm, I finally called it a night. I can't brink her up on the pipe to much here, but I am happy. I have a new challenge though. There is a severe oil leak from the clutch cover gasket. It was new GG gasket. I have seen some threads where gasket sealer was needed, or just cut a new gasket from better material, such as permatex, Cherrios box, brown paper bag, etc. The rear brake adjusted up nicely, except I am at the limit of travel. I think the problem here is that every piece of the linkage is worn. I will disassemble this week and see what it takes to rebuild the linkage. I see a trick pedal bushing from check point...
http://www.checkpointoff-road.com/store.html

Thanks again to all that helped get me back in the dirt!

[Jakobi]

I thought you said she had all new linkage bearings? Thats all it is to rebuild it! The checkpoint brake pivot is the goods! What do you mean the brake is at the end of its travel? You mean it depresses all the way in without engaging fully? Might need a bleed.

If the gasket surfaces were clean and clear of damage the new gasket should work. I usually use a touch of grease on both surfaces to assist in removal at a later date and reuse of gaskets. Works well. Make sure you tighten the bolts up in a cross pattern. I'd also go back over them one last time to make sure they're all snug before pulling it back off. A bit of liquid gasket will help if it still won't seal.

Shes looking good mate! Would look phat with white shrouds I reccon!

[mlyle11]

I meant to say the swing arm linkage. I didnt get to the brake lever linkage yet. Ah, more money!
- The threaded rod that goes into the rear MC is adjusted out to its max length, any more turns and it would come out of the nut inside the clevis.
- The brake pedal adjusting bolt (goes through a braket welded to frame) is also nearly at its max thread. If I try and put to the middle of the travel (like I suspected new would be?) the lever just rattles around. They spring does not place tension on the lever till the adjusting bolt is near full out. Worn spring too?
- In this condition I get good rear braking. Full lock up. It just seems I am at the end of all the adjustment.

I tore it apart just now and all the bushings are worn out. I have seen some trick levers on line, but the OEM seems to be holding up, just needs new bushings!

Shrouds are blue... but they do have a nice white "Gas Gas" sticker on them!

[Jakobi]

Yeah if the brake pedal bushing is flogged out the thing will flop around more than it should. You should have been able to check the swing arm pivots when you had the linkage out. Grab the swing arm and make sure it moves up and down without binding and a smooth action. I also do the side to side and make sure there is no play that way!

How'd they do the 200 bottom end, 250 top? Keen to hear more about that.

[wheelie]

looks great, congrats on your hard work!

[Moto7man]

Great job! It looks and sounds good!

[Ed Ventura]

Tell me more about the 250 top end on the 200 bottom end

[savage sausage]

Nice 1 .. it's an epic journey rebuilding these gassers getting to know every last nut and bolt, and knowing that you can trust your own work.

Tis looking good squire!!

Enjoy the ride, cant wait to finish mine off now.

[desertgasser300]

Nice thing about doing a complete rebuild. You can sort out the oddball fastener plague with the earlier bikes.