Keywest died while running!

[maharaja88]

I have '09 Keywest, started sounding rough on the right side of the motor the other night, rode about a mile and it just shut off on me like I'd hit the kill switch. Started it again went a few hundred yards, same thing, smelt funny, like hot metal. Waited 10 mins til it cooled and made it another 500 yards, died again, pushed it the rest of the way home (uphill, of course!) Tore it apart the next day, took off muffler, air intake cover, white plastic fan/pulley, til I got to the brass coloured, round pulley, noticed that inside it are 4 transistor/resistor looking things (magnets wrapped in copper wire) 1 of the 3 has no wire wrapped around it, is that normal? Anyway, seems like I need another person to hold the pulley on the other side of the bike whike I take off the nut that is holding that assembly on. Is there a danger to removing that pulley? Whatr does it do? And is there an internal safety sensor that is shutting the bike off? Every fiber of my being tells me that if I continue to run it there will be permanent damage (not that it will go more than a few hundred yards without dying anyway!) When it dies, there is a slight smell of hot metal, melting copper/electrical heat! Is this something I can fix myself?

[harry]

the stop running thing could also be a soft seized piston~
no oil or bad pump.

as for removal of the flywheel  best to use a impact wrench
you can buy a cheapy electric one at harbor freight

 the service manuals and parts manuals(good for the exploded view)
links are located at the bottom of the forum home page.

 let me know if you want or need  any genuine TGB parts.
 oilyhans

[maharaja88]

I dont like the sound of that! When I had it idling the other day I disconnected the oil hoses from the pump to the carb and there was oil coming out...So you think it's not an electrical problem?n What about those 4 coils, one w/o copper wrapped around it?

Thanks for your time!

[harry]

the coils behind the flywheel is the stator  .
see if  the battery is being charged , use a meter .
the stator  makes the power for the scooter to recharge the battery ,
and it gives the 'fire signal'  & power to the cdi .
 
sometimes if you have soft seized a couple of times
you start to lose needle bearings in the wrist pin
and you can/will hear a rattling sound  before the
real damage is done to the cylinder~ but it toasts the piston,
wrist pin , and sometimes the head as the bearings
get sucked up into the combustion chamber  and they get
pounded into the top of the piston , the head or both.

i have a piston that a needle was rammed all the way down to
the first ring on the edge of the piston.

for a soft seize check, (but not always the tell all but its no doubt if present)
pull the plug and look very closely  .
check the electrode and the ground strap for tiny balls
that are fused to them ,if you see any its the piston burning up.

oilyhans
 

[maharaja88]

Thanks Oilyhans!
 
   So, I'll check it when I get home. If it is the piston, rings etc. whats my next step? Any hope of doing it my self? Probably need air tools, which I don't have. Whats a ballpark on what a mechanic would charge me to fix that?

 Thanks again,

Ian.

[harry]

hey Ian,
a cylinder swap is easy  you only need a 10mm socket and a
set of long nose pliers , maybe a razor blade or something to remove
any gasket material left at the cylinder base.
a stock kit will run around $150 and $185 for a 70cc kit.

let me know what you would want and i get it for you.

 guessing at what some other shop wants for labor & parts is hard
but somewhere around $300 or more plus parts.

 you can check the condition of the piston  (look for deep scratches)
by removing the exhaust pipe and and looking at the piston.
you may have to turn the crank or use the kick lever(its easier if you
remove the plug).
 
oilyhans

[maharaja88]

Hey OH,
  Been busy (mostly riding damn mountain bike everywhere!)...So I tried to take out the spark plug, but it's not the standard SP socket size, seems to be bigger and longer?? Also I had a guy recommended to me to take a look at my scooter, first thing he did was to crank it up and then rev the motor, there was a depressingly unpleasant sound, a big puff of white smoke and then it died, pretty sure he made the situation worse!! I'm afraid to try to start it again. So you think switching to a 70cc cylinder(head?) is my best bet? And that just involves replacing the old with the new? Sounds a little to good to be true, what if he broke the piston when he revved it? Coundn't it of damaged the "block" (for lack of a more appropriate scooter term!) Any way to verify that? What's my next step?

                Thanks again,
                                      Ian.

[maharaja88]

Also, while I've got the tools out and time on my hands, I read in another thread where you told someone about removing the brass restrictor to increase speed. If I'm looking at the tgb parts manual correctly, under "Part 6 CVT" are you referring to Part#13, directly behind the flywheel?

[harry]

yeah there are 2 sizes of plugs used on scooters
small like ch8a and the bigger ones like bpr7hs in the TGB's
here's a link to a cylinder kit ;
http://whidbeyislandmoped.com/cart/index.php?main_page=product_info&cPath=37&products_id=5
look at the picture  on the page for a close up. but its got all you need.
cylinder , head ,piston & rings, pin & clips, gaskets. the only slightly tricky part is
putting the rings on the piston

the case will be fine and so should the crank & connecting rod.

HOWEVER ,you will need to verify that the oil pump is working!!!!
and that is what caused the failure ...

removing the wedding ring is a easy deal.. and yes its #13
just remember that the nut (#6) is reverse threads!

oilyhans

[uziXwraith]

Did you happen to check for spark after it died? im working on a 2009 key west, and it loses spark after it warms up to operating temperature
as for the puff of white smoke, sounds like you need a new oil pump a light blue smoke is normal running 2 stroke did you fix the bike? this post seems a little dead im going to repost with my problem