Question about 2005 Kymco People S 200

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After re-building my 150 (08) scootcoupe engine with a 170cc "big bore kit" as well as a new rod-crank assembly (these are not kymco parts, but made to fit the gy6 engine) a hand turn on the crank shows the piston making contact with the head. tried two base gaskets, but still not enough clearence We suspect the rod length or crank throw. any suggestions? maybe a genuine kymco crank assembly?

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Hi! I strongly suggest that you put in a genuine kymco crank assembly. Since you made some modifications, a kymco crank may resolve this. Since it's a trial and error thing for a modified scooter, the genuine crank will be close enough on resolving this. Hope this helps and thank you for using FixYa!

Posted on Sep 01, 2010

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Posted on Jan 02, 2017

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Hi, Muth* I recommend a big bore kit for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Anonymous for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. If necessary transport your vehicle to the dealer or shop and have a professional technician take it for a test drive, if it is in running condition, and give you a written estimate of repairs and answer any specific questions you may have about your issue. For more information about your issue please visit the website below. Good luck and have a nice day.
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To put it in layman's terms it means tat the big end bearings are shot and it will be new bearings and crank shaft grind which leads to engine rebuild which leads to lots of dollars. I do not consider it a stupid question at all as it is a common statement by "shade tree mechanics" looking to make a fast buck at your expense.. It is best if you have a series of tests done to determine the condition of the engine first. Find yourself an accredited ,reputable mechanic and have the following tests done.1--- have a compression test (dry then wet) done to determine the condition of the rings and bores. IT will also find if there are cracks and head gasket problems( minimum psi should be around 120psi). 2--- have the oil pressure tested with a mechanical gauge to find the working oil pressure ( minimum idle pressure around 20psi) reduce the engine idle to as slow as possible and listen to any knocks in the motor. Pull the plug lead of each cylinder in turn and if the knock subsides it can be worn gudgeon (wrist pins) pins in the pistons. When you have the results from all these tests you will have a good guide as to rebuild, replace with a reconditioned engine or get a good unit from the wreckers.

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Hi, Shsnmuk for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. If necessary transport your vehicle to the dealer or shop and have a professional technician take it for a test drive, if it is in running condition, and give you a written estimate of repairs and answer any specific questions you may have about your issue. For more information about your issue please visit the website below. Good luck and have a nice day.
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Hi, Anonymous for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. If necessary transport your vehicle to the dealer or shop and have a professional technician take it for a test drive, if it is in running condition, and give you a written estimate of repairs and answer any specific questions you may have about your issue. For more information about your issue please visit the website below. Good luck and have a nice day.
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How to install a big bor kit on a 50 cc scotter


It's a pretty big job. You need to be competent (and confident) with tools as well as diagnosing and repairing gas engines. Without knowing the details of your scooter, the overview is this: 1) Remove the carburetor (if mounted to the cylinder), exhaust pipe, cylinder head, cylinder and piston. 2) Have the cylinder bored out** to provide the correct clearance between the cylinder and the piston (if different from the scooter manufacturer's clearance this information should be provided by kit manufacturer). 3) Modify the head (more machine work to reshape the combustion chamber to work with the larger bore). 3) Reassemble. 4) Modify the fuel system (usually a carburetor) to correctly fuel the now larger displacement engine. 5) Get the new set up running and then tune it to run properly without damaging itself from an incorrect fuel mixture.


** Some cylinders are aluminum with a steel sleeve that forms the bore that piston runs in. Some are aluminum with a thin nikasil coating on the aluminum bore. These will be much more expensive to bore out as they will need to have the coating replaced after being bored out.

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It's rare that a piston goes bad. So, you need to determine why it failed.
Most times, the cylinder wall is damaged during a piston failure making it impossible to just replace the piston. Check the wall for score marks and out of round condition as well as actual size VS original bore size. (correcting that requires machine work) The new piston must match the cylinder bore as it is now, NOT what it was when manufactured. (same applies to rings).
The old rod can be re-used if it is not bent and providing that the big end (crank end) is still round. Again, the rod needs to be assembled by a machine shop as the wrist-pin is a press-in part.
Most times, you will find that the amount of actual work necessary to replace one piston exceeds what would be necessary to replace the engine in both time, $ and reliability.
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Verify that the valve tappet clearances are set correctly. Insufficient clearance will definately cause valve leakage. Also make sure the carburetor is correctly fitted to the cylinder head with no leakage in between.
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