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Post by Rebel on Sept 24, 2011 15:51:53 GMT -5
Ted dropped his scooter off for me to fiddle with for him.
Most of the body panels are off so that makes it easier to dig into. We hit the starter and it spins freely, the motor is not turning over. I'm figuring that means I'll be pulling the right side off the motor and looking at the reduction gear and the clutch. I suggested replacing the oil pump at the same time. This scooter is showing 45,000 plus on the odometer, if that is kilometers and not miles it is still a lot of riding on this 2002 scooter.
So for you guys with similar scooters, do you think the parts for a regular gy6 will work in this? He left me money to buy parts, I hate to spend more than it needs, he thinks they will work but I know things like the variator are totally different.
I tried to join the Kymco forum and ask there but it must have something against me, it wouldn't let me join. I think my reputation preceded me and I'm on their block member list. just kidding but really I couldn't get in there.
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jmkjr72
contributing staff
Commander 132nd Northern Cav. Division
Posts: 2,779
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Post by jmkjr72 on Sept 24, 2011 16:58:34 GMT -5
kymcos record kilometers they do use a few odd parts and im not sure what ones as i just get kymco parts from my firends shop
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Post by Rebel on Sept 24, 2011 22:54:39 GMT -5
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Post by Rebel on Sept 25, 2011 15:29:05 GMT -5
Hoping for something easy, I pulled the starter out, it looks OK. Ted told me it started dripping oil after a valve adjustment was done. I don't think it was the valve adjustment that did it, I pulled the fan cover off, then the fan. looks like a leak on that side of the motor, it is caked pretty badly with oil and dirt. So now I have to wait for a flywheel puller to get to me to break it on apart.
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Post by Rebel on Sept 25, 2011 16:41:35 GMT -5
Another problem it had was that the kick start stopped working. It was frozen up, I could not move it so I popped the cvt cover off, it only had three bolts holding it on. The kickstart is totally different than the regular gy6. The problem looked pretty obvious after I took this gear out. PartsPitStop.com has this for $19.54, a few bucks cheaper than some other places, has anybody here ever ordered from them? www.partspitstop.com/pages/OemParts#%2fKymco_USA%2fMongoose_90%2fCrank_Case%2f2K01080005%2f01080003
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jmkjr72
contributing staff
Commander 132nd Northern Cav. Division
Posts: 2,779
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Post by jmkjr72 on Sept 25, 2011 17:40:22 GMT -5
my only concern with ordering kymco parts online is that even when you order the part right from kymco they have made so many changes to part numbers over the years that many times you get the wrong part
as for the oil leak with the cooling shroud still on it looks like maybe a crank seal is going
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Post by fox on Sept 25, 2011 19:59:01 GMT -5
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Post by Rebel on Sept 25, 2011 23:34:17 GMT -5
Well, I am doing this for the fun of helping a guy out. I'm willing to fix a few things and get it going but tearing it all down and doing an overhaul is not going to happen.
I didn't take the cover off the cylinder but looked around the valve cover and didn't see any dripping.
And yup, I registered on the Kymco forum.
Regarding the compression, I was turning it over with a ratchet and it seems to have pretty decent compression, that is just going on the feel of how it turns over, I didn't use a tester.
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Deleted
Deleted Member
Posts: 0
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Post by Deleted on Sept 26, 2011 11:13:36 GMT -5
REBEL
I would not fool with lessor/cheaper parts for a kymco, even if something fits it may be inferior metals-NOT GOOD
boy i wish i had you for a neighbor
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Post by Rebel on Sept 26, 2011 12:05:25 GMT -5
REBEL
I would not fool with lessor/cheaper parts for a kymco, even if something fits it may be inferior metals-NOT GOOD
boy i wish i had you for a neighbor Except Ted mentioned using them to me. It would be nice to know if regular parts would fit, the guys on the Kymco forum make no mention of using them. I just wish I had more time. I'm now wondering if the messed up kick start was keeping the starter from turning the motor over. I'm going to check that out. I'll post that question on the kymco forum.
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Post by Rebel on Sept 26, 2011 20:30:52 GMT -5
Got home hooked the battery back up and nope, the kick start removal didn't help. So I'm back to waiting for a flywheel puller.
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Post by tedsride on Oct 1, 2011 9:47:24 GMT -5
I am guilty of riding this scoot like I stole it It still runs like a champ. I just plain wore out the starter... It has never wanted to start with the kick starter, always felt like it had waaaay toooo much compression, almost hurt my ankle while trying to kick start it, so I just used the Elect. starter motor to start it, plus had to install that EXTRA battery in the rear storage box... A lawn and garden battery from Wally Mart, only $19.92, the cost of a scooter battery was way out of sight, as far as my thinking goes... I had the side cover off to see how things were looking inside, and only put it back on to carry it up to you, so all the starter parts would be there, as I know it needed a new bushing in that housing, at the least... Those broken teeth are probably from trying to kick start it with a bad bushing and so much compression, at least that is what it felt like, like the timing needed to be backed off during the start process, like the old Model Ts used to do.. ?? as far as that oil leak goes, it has been leaking almost from the start, after a visit to the scooter shop here in Bako, it has leaked ever since... I rode the H#!! out of that scoot, best way to get all around town, for riding thru heavy traffic and use not much gas, like 70 MPG, love it really, but I needed a younger fellow to work on it as my back says no... These Golden years suck in that department...
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Post by Rebel on Oct 1, 2011 13:54:19 GMT -5
Ted, I'm headed out to work some more on it just now. I'll check on that bushing and since I have to halfway remove what is in the way for the rear wheel to come off, I'm going to order brake shoes for that, you really do have it adjusted to the end of the adjustment for it and very little pedal left, I'm hoping it didn't go metal on metal.
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Post by Rebel on Oct 2, 2011 0:25:52 GMT -5
The side of the case is off and I tried to get the starter clutch off but the nut is not budging. This is a left handed nut and the manual says that if you do not have the special tool to just use a hammer and a chisel to back it out.
I didn't want to use a chisel, figured it would cut into the metal too easily so I was trying some more blunt things like a screw driver at fist then a punch, no luck.
Fox, jmkjr72, got any suggestions? Anybody else have a suggestion?
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Post by fox on Oct 2, 2011 8:52:40 GMT -5
I'm rebuilding a GY6 150 right now and that nut had me cussing for a while. No hammer and chisel is gonna loosen it. I had the piston off the engine so I put my super larger Phillips screwdriver through the connecting rod and used a couple of wood blocks so it didn't dig into the case to immobilize the crank. Then I used a pipe wrench on the nut. It wasn't easy but the nut came off. I had to use a ratchet strap to hold the engine down to the bench. The nut got some chew marks from the pipe wrench but it lived. You probably still have the engine in the scooter with the top end still installed on it right? Maybe you can make a crank immobilizer tool to use on the variator side. I've see one guy use a piece of 2x4 a couple of feet long with two holes drilled in it and a couple bolts, with flat washers on both sides and a nut. The bolts were sticking out an inch or so. It worked just like this tool: totalruckus.com/phpBB2/viewtopic.php?t=27461The issue I have with a tool like that is that's a lot of force on the cast aluminum drive face. It can warp the entire piece or the part the bolt fits into can break off causing an imbalance and put you back to square one. I think the best option is to have Ted order this and be done with it: cgi.ebay.com/ebaymotors/Freeshipping-GY6-50CC-clutch-remover-tool-88384-/290612050297?pt=Other_Vehicle_Parts&hash=item43a9d3f979 It says it's for a 50cc but i think it will work on the 150 as well. Have to measure the nut.
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