I just completed installing a Kwikset Smart Code deadbolt. the key works without issue but if the key is removed, the unit cannot be locked with either the handle or the electronic method. if the key is reinserted, is works

I presume you figured it out by now, but if the tailpiece is installed wrong in many deadbolts, the key won't come out in one position or the other. It's called a "timing" problem and the way to fix it is to take it off the door, turn the tailpiece a half circle and put it back on the door. Usually Kwikset locks are designed so you can't put it in the wrong way, but it can happen. (If it's not the timing problem, then the deadbolt unit is defective or broken. They are designed to fail in a way that keeps them locked, so this could be a sign that someone tried to break in, or that someone used the extended bolt as a way to stop the door from closing and it hit the door frame too hard.)

The best way to install a deadbolt lock without the instructions handy is to look at the "lazy" cam and see if there is a way to install it wrong and don't install it that way. Example: If there are 2 ways for the tailpiece to fit in the deadbolt unit when the deadbolt is retracted and only one way for the tailpiece to fit in when the deadbolt is extended, then install the lock with the deadbolt extended and you can't install it wrong.

"I have installed your Powerbolt, but when I push the Lock Button, it unlocks? What should I do?"
First remove the cover on the inside of the Powerbolt unit. On the right hand side under the batteries, you will notice that is says "Door Direction Jumper". If the cap is mounted on Prongs 1 & 2, carefully remove it and move it over so that it mounts Prongs 2 & 3. A is right handed, B is left handed.
These instructions will work just fine for you:
http://www.kwikset.com/Customer-Support/Product-FAQs/Faq/50160000000HhhEAAS.aspx

Notice that the above is a .PDF file type. That means that you need to have Adobe Reader or similar installed on your computer to view it. So if you are unable to view the file, download (for free) and install Adobe Reader first. You can get it here:

http://get.adobe.com/reader/

These locks are made to work on a door which, when you stand outside and face it, has its hinges on either the left-hand or right-hand side of the door (= door "handedness").
The jumper controls that for the appropriate installation. Yours is set wrong!

Here is the link to the installation instructions:
http://s7d5.scene7.com/is/content/BDHHI/kwikset-smartcode

Notice that the above is a .pdf filetype. That means that you need to have Adobe Reader or similar installed on your computer to view it. So if you are unable to view the file, download (for free) and install Adobe Reader first. You can get it here:

http://get.adobe.com/reader/

There isn't a whole lot of "programming" to be done with this lock. If it isn't performing correctly, contact Kwikset 1-800-677-5625 USA & CANADA
or visit, www.kwikset.com

Good luck!

Why is my Powerbolt beeping?
http://www.kwikset.com/Customer-Support/Product-FAQs/Faq/50160000000HhhEAAS.aspx

Follow this link to find out how to remove the cover for your Powerbolt:

http://www.kwikset.com/Customer-Support/Product-FAQs/Faq/50160000000HhhEAAS.aspx

This link:

http://s7d5.scene7.com/is/content/BDHHI/40486-02

is the "manual" for the installation of the lock. Programming instructions are found on Page 6.

I'd recommend changing the 4 alkaline AA batteries at the same time.

Good luck--and please provide feedback if this helps!

Kwikset's warranty covers one year electronics defects and lifetime coverage for the mechanical movement and finish.
Here is a link to it:

http://www.kwikset.com/Customer-Support/Warranty-Information.aspx

You can contact them from there for further assistance.

Good luck!

It sounds like the exterior tumbler is bad, it is less expensive to just replace the whole deadbolt than to have the tumbler repaired.

Kwikset Smart Key locks are complete junk. I am a locksmith and I am constantly going from house to house replacing these "dumb key" locks with original kwikset pin tumbler locks. What happens is either your key or the wafers inside the lock wear slightly, slightly enough to cause your keys to not turn, and since these locks cannot be picked due to a side bar system, they must be drilled off and thrown away when this happens Unless you have another access point to get in the house. If you do remove lock from the inside, throw it in the trash, buy original kwikset and replace.

Here is the instructions from kwiksets website

http://www.kwikset.com/Files/PDF/SmartSeries/SmartKeyInsEnglishOnly.pdf

Unfortunatley you need to have the key to remove the cylinder. You can take it to a locksmith that can pick" it to remove the cylinder and make you a key but it may be more cost effective to replace it.

Sorry not to be mre help.

I have the same problem, electronic locking system went dead but still beeps, stuck using keys now...according to the kwikset website though it says "Warranties cover the original residential user of Kwikset Products against defects in material and workmanship as long as the original user occupies the residential premises upon which the product was originally installed." so hopefully they will fix the problem