TGB Sunset 49 Kick starter frozen up

[berg345]

Parked my moped at work the other day.  Came out to drive home.  Kick start is locked up, only moves about an inch, then hits something solid.  Pulled the belt cover off and pulley only turns toward back of bike.  The kick start mechanism (racheting gear) works when not engaged with the end of belt pulley.  Seems the crank is "frozen" or being blocked by something.  Bike was running like a charm until this...suggestions?  Thank you in advance for any advice.

[harry]

hi berg345 welcome to the forum..

so what happens with the electric start?
the sunset is a touchier  scooter as far as starting ,,you have to have
a fully charged battery or no start...
 a seized motor would have given you a sign it was about or had lunched
the piston ,however generally the motor will crank over when it cools down.

i would suspect the starter is jammed or something of the sort..

if you remove the spark plug you can rotate the motor  with a
socket on the variator nut really easily

 oilyhans

[berg345]

Thank you for your quick reply.  No indication by the way it was running of trouble.  Plug is in perfect color.  The electric start has been acting up.  Right now, trickle charging the battery.  With plug removed, pulley won't budge either way.  I don't have the right size deep well socket, but something pretty solid is keeping things from turning.  I thought with the plug out, I would be able to turn it by hand.  It is hitting something solid.  I'll charge the battery all night or get a new one, but this one is only two months old.  Would the electric start "kick out" with enough juice?  Jump start?

Thanks,  Berg345

[berg345]

There seems to be a small gear (about 5:30 on the clock) that is still engaging the teeth of the inside pulley preventing it from moving either way.  I'm pretty sure that is the gear that is on the end of the electric start motor.  There are two screws that hold that gear in place, kind of like the three screws that cover the nut on the end of the crank.  If I pull those screws, am I screwed?

Thanks, Berg345

[harry]

you can remove the 3 allen socket screws with no
problems just put it back the way it came off.

you can jump the scooter BUT do not turn on the car motor

the motor is a bit tight and you can't turn it over unless you use the nut and a socket
it should turn over easily with the kick lever too ,but if its jammed up it might not move.

oilyhans

[berg345]

Oilyhans,

Thanks for your help.  I pulled the gizmo off that is on the end of the starter gear, then tapped the gear lightly and it retracted to free up the motor.  I think that little gear is the problem.  Reassembled, same thing happened...gear caught so motor won't crank.  Repeated the above, but went to the kickstart method.  Started first try.  Guess I use the kickstart instead of electric.

This moped is de-restricted with the shim out of the pulley and did some minor exhaust work.  It will do about 45 mph on the level.  I heard a different jet in the carb would help...do you know anything about changing the jet?  Thanks...

[harry]

perhaps some lithium grease or oil on the shaft would help.
don't let any get on the belt or vairator faces.

so, what did you do to the exhaust system to de-restrict it?
the stock jet is a 60 so a 65 or 67.5  would be a good stab at it,
but  the judge is the throttle and plug color.
#65
http://whidbeyislandmoped.com/cart/index.php?main_page=product_info&cPath=10&products_id=25
#67.5
http://whidbeyislandmoped.com/cart/index.php?main_page=product_info&cPath=10&products_id=179

oilyhans