Oil pump gears - check 'em.

[Areomyst]

Hi guys,

Last night I helped my friend fix his Agility 50.  He had 29,000+ KM on the clock, an noticed his engine making a funny noise.  Both valves were not sealing up well, but worse, was that the oil wasn't being pumpped into the top of the engine so the cam, valves, etc went a short while with no lubrication...

The plastic gears on the oil pump were completely worn out.  I highly recommend that you pay particular attention to the oil screen when you start getting high miles on the scooter.  You'll see chunks of gear in it.  Might be worth just replacing as preventative maintenance around 20,000 kilometers or so.

I have detailed photos, and will upload them when I get a chance.

My friend's engine was not badly damaged.  We replaced the oil pump gear and the valves.  I also threw in a new piston, but only because it was faster/easier than cleaning up the old one.

~Josh

[wordslinger]

..i bet that's what happened to my 08....i've never opened it up yet...

..died with 55,000kms....

[zombie]

Where is the oil pump! A new one came with the 50mm kit I just installed, and I didn't want to go that far. Scoot has 697 miles on it, Just sat in a shed for 4 years... so I'm not stressin' Just curious.

[zombie]

Wait for it... Wait... Just a minute more...
And now for your tuning pleasure... The NEW TSG How to On Oil Pumps video!

Thanks in advance J.!

You are one busy guy!!!!!!!!!

[Areomyst]

Wait for it... Wait... Just a minute more...
And now for your tuning pleasure... The NEW TSG How to On Oil Pumps video!

Thanks in advance J.!

You are one busy guy!!!!!!!!!

Pfft.  Videos on 4-stroke stuff?  No way!

...

Acutally, I've made a Ruckus valve adjustment video but... don't tell anyone.

Anyway, here are those photos:

[zombie]

oooowwwwwweeeeeeeoooooowwwwwweeeeeeeeeoooooooooo! Spooky how I knew that!

More sound effects...
Dowchicha dow wow..dowchica dow wow (porn music)

[wordslinger]

Anyway, here are those photos

..wowww...i gotta open that o8....

[axy]

Hi guys,

Last night I helped my friend fix his Agility 50.  He had 29,000+ KM on the clock, an noticed his engine making a funny noise.  Both valves were not sealing up well, but worse, was that the oil wasn't being pumpped into the top of the engine so the cam, valves, etc went a short while with no lubrication...

The plastic gears on the oil pump were completely worn out.  I highly recommend that you pay particular attention to the oil screen when you start getting high miles on the scooter.  You'll see chunks of gear in it.  Might be worth just replacing as preventative maintenance around 20,000 kilometers or so.

I have detailed photos, and will upload them when I get a chance.

My friend's engine was not badly damaged.  We replaced the oil pump gear and the valves.  I also threw in a new piston, but only because it was faster/easier than cleaning up the old one.

~Josh

1. What did you have to remove to see oil pump gear? Was the gasket intact or did you install a new one?

2. When you say that you have replaced the valves, are you referring to cylinder intake/exhaust valves or something else?

Incredible that they make such a crucial part of the engine of plastic material.
I would be willing to bet (even though I am not keen on conspiracy theories...) that this could be a part of "programmed engine failure". I cannot explain this in any other way.

Gf's A125 has 30.000 kms and I wonder if it should be replaced...

[Areomyst]

1. What did you have to remove to see oil pump gear? Was the gasket intact or did you install a new one?

2. When you say that you have replaced the valves, are you referring to cylinder intake/exhaust valves or something else?

Incredible that they make such a crucial part of the engine of plastic material.
I would be willing to bet (even though I am not keen on conspiracy theories...) that this could be a part of "programmed engine failure". I cannot explain this in any other way.

Gf's A125 has 30.000 kms and I wonder if it should be replaced...

I removed the exhaust, fan shroud, flywheel/fan, stator, drained the engine oil, and removed the right side engine casing.  After you do this, you'll see what I have taken photos of.  Some of the Agility scooters use a retaining clip to hold the gear onto the oil pump.  Some use a nut.

The valves replaced were the intake and exhaust valves, yes.  It was not a required part of the repair, but it was a good measure to take.  The old valves could have been cleaned, lapped, and re-installed.

There has to be a weak link somewhere.  If the gear were metal, and something got jammed between the gears at high RPM, it could literally crack the engine casing, lock the engine up while riding, or worse.  Don't get me wrong, it sucks that this happened but it was a relatively cheap fix since it was caught in time.

~Josh

[axy]

I removed the exhaust, fan shroud, flywheel/fan, stator, drained the engine oil, and removed the right side engine casing.  After you do this, you'll see what I have taken photos of.  Some of the Agility scooters use a retaining clip to hold the gear onto the oil pump.  Some use a nut.

The valves replaced were the intake and exhaust valves, yes.  It was not a required part of the repair, but it was a good measure to take.  The old valves could have been cleaned, lapped, and re-installed.

There has to be a weak link somewhere.  If the gear were metal, and something got jammed between the gears at high RPM, it could literally crack the engine casing, lock the engine up while riding, or worse.  Don't get me wrong, it sucks that this happened but it was a relatively cheap fix since it was caught in time.

~Josh

Jesus Christ. (called His name in vain!) I thought this was something more simple that could be easily done.

Don't get me wrong, I am all for DIY, but I live in an appartment, do not have a garage, and to do this, I have to spend half a day on the parking, with exquisit selection of nosy and stupid neighbors who come by to give handy advices (and never saw internal combustion engine before...) 

I guess this one will be job for the mechanic, next time...

I wonder if those gears are made of metal in cars and motorcycles. 

[zombie]

In almost all production engines they use a sacrificial component in the drive line. Some are aluminum riding against hardened steel, or "fiber composit" against alum.. High out put or performance engines replace the sacrificial component for durability.
Some are installed on cam/crank, some on distributer/cam, some on oil pump ect. The only down side is long term wear, or  a misfire could shear a few teeth.
Another example would be the use of a timing "belt" vs timing chain.

[Areomyst]

Jesus Christ. (called His name in vain!) I thought this was something more simple that could be easily done.

Don't get me wrong, I am all for DIY, but I live in an appartment, do not have a garage, and to do this, I have to spend half a day on the parking, with exquisit selection of nosy and stupid neighbors who come by to give handy advices (and never saw internal combustion engine before...) 

I guess this one will be job for the mechanic, next time...

I wonder if those gears are made of metal in cars and motorcycles. 

You don't have to take the top end of the engine apart - just the right side engine cover.  I'll bet you can get it done in 2.5 hours.

~Josh

[zombie]

Axy has not developed thumbs yet so it may take a bit longer.

GOOD BOY!

[zombie]

I know "Repeated personal affront. Reported to moderator" Yeah Yeah Yeah...

[axy]

I know "Repeated personal affront. Reported to moderator" Yeah Yeah Yeah...

Now I could probably find a funny video of Deliverance inbred playing banjo in North Georgia implying he is you, but I will not.

Personally, I am all for videos if they are of mechanical nature, and witty videos could be a part of General/Chat thread, but not all over the place.

Actually, I have never reported anybody anywhere, but I think that you are a bit overusing videos here, slowly turning the forum into illegible junk. Furthermore, you have to understand that humor you are using is not well understood by people outside of USA, and here you have quite a few people from all over the world.

Of course, this is just my opinion.

Anyway, it would be great if Kymco supplied us with a list of plastic crucial parts of Kymco engines that could fall apart just like that, in programmed or not programmed manner.