Picked up the scooter for a good price. Was "assembled" by seller who had bought it years earlier in boxes after nice paint job. Scoot looks great and seems very original/unmolested, but seller admitted it needed a good going through before hitting the road. Coil was cracked, had no spark and cables all needed adjustment.
As I was turning the engine over to work on spark issue, it started binding up every few rotations. Seemed strange, I rotated forward, backward and it would just stop randomly and I could hear a scratching sound coming from inside the case. Finally decided to split the case to see what was going on. Inside, I found some mangled wire lodged in the crank and piston area. Was able to extract the wire, and everything spins fine now, but the piston and cylinder were gouged pretty good. Piston is a 57.8, it's already on 4th oversize, so I guess they are toast.
The wire had me concerned as I have no idea where it would come from. Too thin to be from clutch or Cush springs it seemed. Pulled the clutch, driveshaft and cush assembly and couldn't find the source of the wire, any idea where it could have come from?
On inspecting the gears, I found that the driveshaft play was a bit too loose and the cross was pretty hammered so will order thicker shim and a new cross. I also found some marks on the smallest cog of the driveshaft and smallest cog of the cush assembly (see pics). I can't tell if these marks are supposed to be there, they are pretty uniform in size/shape and I don't have new gears I can use as reference. Thoughts? Are these trash or good to go? [/img]