Treats sent Leon my way to fix his trusty ol' pug 103 SP....can you say basket case? We later found out it had been knocked over in a line of motorcycles and wrecked twice. This explained why the end of the crankshaft had broken off in the flywheel and the axle mount on the front fork was busted off. We replaced the front end of the bike. There were several vacuum leaks from worn seals and a Malossi intake that was not very well cast and had to be milled flat. Oh yeah, the bearings were shot, too. The bike had all the symptoms of coil failure, a very common pug problem (or any moped with original internal ignition coil). However, we had to get the flywheel off to replace the coil, which involved drilling out the bent & broken crankshaft after blowtorch & pullers did nothing except rip the threads off the flywheel (and my puller). Therefore, we had to replace the crank & flywheel....ie, total rebuild of the bottom end of the motor. No problem, except the first crank we got was out of spec. The threads on the variator side were .1 mil off and had to be re-tapped. When we tried to fire it up, it quickly became apparent that something was not right, and turns out the lobes were off by about a mil from being the right width for the case. Although it was properly shimmed & centered when assembled, it quickly wandered under the stress of running. It was replaced with a Gilardoni crank, which worked flawlessly. As the only available internal ignition coil was too small, CDI was the only option for electrics. This CDI was installed. No problem with the CDI, but the flywheel was junk: the glue holding the magnet to the housing didn't, and the timing mark flew off....Treats replaced the defective flywheel with this one and once installed, the bike ran like a champ.
Yikes.
DIY woodruff key (no stock key, remember?)
Chinese
VS.
Gilardoni
Re-assembly!
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