Smallframe engine build - 1974 Primavera
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Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Mar 10, 2014 7:31 am quote
Oh yeah.

image.jpg

Molto Verboso
Joined: 24 Jan 2008
Posts: 1909
Location: Santa Margarita,Ca.
Mon Mar 10, 2014 10:11 am quote
Beats my " get behind the scooter in the doggy hump position and stretch right leg up around to brake pedal while reaching with left hand to pull or push a breaker bar or torque wrench" method
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Mar 10, 2014 11:47 am quote
scootermarc69 wrote:
Beats my " get behind the scooter in the doggy hump position and stretch right leg up around to brake pedal while reaching with left hand to pull or push a breaker bar or torque wrench" method
Yeah, I have short legs and arms. I did it missionary style last time but it's hard to read the torque wrench from above .

It was a bent rim with no future, now it's a tool!
Mr. Clean
P,SUPER,V90, 50 Special
Joined: 27 Jul 2010
Posts: 10207
Location: This is't my locker!
Mon Mar 10, 2014 8:31 pm quote
That's cool! I'd like a hib holding tool!!
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Sun Mar 16, 2014 6:56 pm quote
OK I chintzed out today. No pictures.

Finally had some time to button up the final stuff.

1) rear hub nut installed using my schnazzy new tool, torqued to 60 ft-lbs and then turned until I could get the cotter pin through
2) install rear tire, torque nuts
3) realize that I can't get the exhaust bolt in with rear tire installed - remove rear tire
4) install exhaust bolt 1/2 way
5) reinstall rear tire
6) install polini kidney exhaust
7) reconnect battery

My only concern today is the spring on the Polini seems stretched - probably should get a new one as this one isn't tight. Nevertheless, the exhaust bolt and the upper loose fit connection seem to have the pipe pretty solidly in place.

Next up - get some gas . Then try to start this beast.
Addicted
'77 ET3
Joined: 05 Mar 2013
Posts: 564
Location: OC
Mon Mar 17, 2014 4:16 pm quote
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Mar 17, 2014 5:08 pm quote
Ahh the thrill of victory! And the agony of defeat .

Fired on second kick, ran pretty well. Gear cables adjusted OK from the get go. Clutch took a bit of fiddling, then it was in sync too.

Then all of the sudden, the engine stops while I'm puttering in front of my street. Can't turn it over.

Here's where I stand:
-Piston turns freely through most of rotation but stops hard at TDC and BDC
-with clutch in, bottom end turns fine in gear

To me that says:
-bottom end is free
-clutch is working
-lockup is at the crank or primary or in the cylinder

I think I need to:
-pull the clutch cover and inspect
-pull the cylinder head / cylinder and inspect

I'm glad it isn't seized solid but a hard stop at 2 places along the crank rotation isn't exactly something to celebrate.

I'll post my starting video once it's finished uploading - have to love a good first start even if problems happened after.
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Mar 17, 2014 7:45 pm quote
The culprit [/img]

image.jpg

Molto Verboso
Joined: 24 Jan 2008
Posts: 1909
Location: Santa Margarita,Ca.
Mon Mar 17, 2014 8:07 pm quote
OK, so that can't be too bad. Points screw? Misc dirty work bench screw?
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Mar 17, 2014 8:48 pm quote
It's a screw for these wires coming off the ignition coil. Anyone know the size?

image.jpg

Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Mar 17, 2014 8:50 pm quote
It's bunged up so I need to replace. Yeah, lucky break. I wasn't even mad that the clutch cover came off before I found it, the alternatives were so much worse.
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Tue Mar 18, 2014 8:56 am quote
Addicted
'77 ET3
Joined: 05 Mar 2013
Posts: 564
Location: OC
Tue Mar 18, 2014 2:15 pm quote
Is this vid before or after the screw let loose? Almost lost you in the smoky haze!

From Sip: the screw size appears to be a M3x5mm (part 41) and should have a lock washer (part 40)

M3x5mm

lock washer
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Tue Mar 18, 2014 3:20 pm quote
It was before. Yeah, I could have turned the choke off sooner

I found some M3's, and I will grab a lock washer but I plan on a dab of loctite as well after that experience!
Ossessionato
1976 Super (x 2), 1974 Primavera (x 2), 2006 Fly 150
Joined: 26 Sep 2013
Posts: 4905
Location: So Cal
Tue Mar 18, 2014 6:51 pm quote
Glad it's going to be an easy fix.
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Tue Mar 18, 2014 9:07 pm quote
Anyone know where this clip goes on my seat?

image.jpg

Addicted
1990's 50s + DR 85
Joined: 24 Feb 2012
Posts: 558
Location: auckland, new zealand
Wed Mar 19, 2014 12:23 am quote
The only clips I have on my smallframe seat are the 20 or so that hold the edge of the seat cover fabric where it is folded over the metal seat frame?

image.jpg

Molto Verboso
Joined: 31 May 2009
Posts: 1220
Location: NC, USA
Wed Mar 19, 2014 5:42 am quote
While playing the video, my wife came scurrying in with "that sounds like my smallie"! DR with the same pipe. Sounds great.

The so-called sealed beam in your picture looks similar to the ones on some USA Vespas. Yours looks like the oddball 120mm with the backwards facing three tabs. It's as if the Italians got a chuckle out of the US requirement for a sealed beam by making a homemade one, and the US inspectors let it slide. It looks as though they soldered a bulb in a reflector base, then attached a lens with goo to make it look like a sealed beam. The only vacuum in that assembly is in the bulb. It must be about fixed tabs on the bulb for connection. I was ready to butcher a burned out one to try to fit a bulb, but fortunately found a used original. I was unable to find an original 120mm replacement from parts vendors. It would be nice to find one before the butchery begins. Is the trim ring a CEV 10973? I need one in good shape. The 120mm setup seems to be scarce.

Thanks for the detailed report. Riding a smallframe is more fun than working on it!
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Wed Mar 19, 2014 7:27 am quote
Thanks Blackbart! I'll grab a picture of the trim ring, the number you posted sounds correct, I was just looking at it last night.

I will have to do some more research on the headlight situation. There's a spare bulb in my toolbox from PO but I'm not sure it could possibly be made to fit given the situation you described (which seems accurate given my look at it). There are 3 spade connectors in a plastic square on the back of the light.

I fixed the stator situation last night and buttoned it back up. Cleaned off my workbench, threw away bad spares (I still keep a good amount, but who needs worn cruciforms?) and organized my parts pile. Feels good to be wrapping up.

On the seat thing, I'm not sure this seat really belongs on a smallie but I like the worn brown leathery appearance and it's comfy so I'm keeping it for now. I think the clip was somewhere near the lever mechanism? I saw it before but it popped off the other day. The seat post has not been installed because the nut isn't welded to the body. When I reassembled this time I used it, and so it probably hit the catch in some way and popped off.
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Sat Mar 29, 2014 6:17 pm quote
First ride today, about 20 miles.

I like it! The combo seems to have good pulling power, and I still don't even have the lightened flywheel back on yet after diagnosing my no spark issue. Way more go in 4th than before, which was one of my primary goals. It pulls strong, and while I thought an 82 main would be fat, it doesn't really feel fat at all. Not lean either, but I'll be reading the plug before I spend any time at WOT. Nice torquey build that seems to pull the hills around the house with about as much ease as my Lambretta 175, which is about the performance mark I was shooting for - not a rocket but a solid usable bike for my roads.
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Sun Mar 30, 2014 10:06 am quote
Apparently my new old tank has a crack in the top.

image.jpg

Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Sun Mar 30, 2014 10:09 am quote
Also maybe a new exhaust spring and copper RTV are in order.

image.jpg

Ossessionato
73 Rally, 74 Rally, 76 ET3, 80 P200, 63 Li125, 65 Li225 Silver Special, 86 Elite 80, 2015 HD Road Glide Special, 2011 Ural Tourist
Joined: 18 Jan 2012
Posts: 3305
Location: Oceanside/ SF
Sun Mar 30, 2014 1:51 pm quote
Whats the mark on the top of the exhaust where the P in Polini is? Rub marks?
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Sun Mar 30, 2014 3:29 pm quote
Yes, rub marks that were there when I got it, it's got clearance now.
Ossessionato
Joined: 22 Oct 2011
Posts: 4074
Location: Tega Cay, SC
Sun Mar 30, 2014 5:28 pm quote
Got a crack in the tank
Isn't that the vent for a small frame tank? I know I am a wiseass. Would some silver solder work? Sucks, 1 step forward.......
Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Sun Mar 30, 2014 5:56 pm quote
I'd be mad if I hadn't had that great ride yesterday but now, it's no biggie. This thing is going to be a hoot once I can open it up.

How many miles break in for a DR kit?
Member
2 Vespa 90 V9A1T US Model's
Joined: 05 Sep 2019
Posts: 34
Location: Brooklyn, New York
Tue Sep 10, 2019 11:39 am quote
Looking good mate!
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