This is the follow-up to this post where I discovered the dead piston in my friend Andrew's P200.
It took me a bit of time, but I got a new top end shipped in. I also figured that I should just tear the motor apart and inspect everything. I'm glad I did.
This is a shot of the motor when I got it most of the way apart. As you can see, the gears are out. At this point, next steps were to take out the crank and work on the shift cross.
Here you can see the shifting cross. Boy-howdy is it worn out. This scooter supposedly had around 6,000 miles on the clock. I'm thinking that either the odometer wasn't accurate, or the previous owners really hammered it. Literally all of the wear components in this motor were toast.
For comparison, here is the new shifting cross in position. Yeah, you can really see how bad the old one was!
After I got the crank off, I replaced the clutch side seal. I figured I should just do it all while I had it apart. The cases were in good shape, so that was a good thing. Ultimately, I replaced the following on this motor: carb, piston, cylinder, seals, clutch, second gear, shifting cross, gaskets. Lots of fun on this project. No joke. After I was done, it drove fantastic. What was crazy was that it actually ran before I did all this stuff. Not great, but it did run. That sure is a testament to these things. Even when virtually everything is wrong, they will still run!