Hi all, just getting started on a rebuild for my smallframe engine. The trans keeps popping out of gear when I select 2nd or 3rd, so I'm suspecting worn cruciform / selector spring.
I pulled the engine out the other day and got it on the bench. All the write-ups I see start with pulling the head and cylinder, but I don't have an impact, so I decided to use the rope trick to hold the piston and get off the flywheel, clutch nut, and primary gear nut before pulling the head.
First up, the flywheel came off. Make note of where the stator is in case the marks get cleaned off. In this case, a previous owner has marked 20 degrees BTDC with the marker marks. I think a photo with the casting numbers is a good reference to have:
I made a diagram of the stator connections before pulling it out. The helpful folks at Piaggo or some previous owner used 3 of the same color wires, so I marked them with a Sharpie and dots to be able to put them back later. The wiring insulation is cracking apart near the junction box on more than one wire. I may opt to have the stator rewired or just get all soldery on it myself.
I pulled the clutch cover. I recently changed this clutch. I was surprised to find kind of a brassy mess under here. I wonder if I had the plunger adjusted too tight or if there is a fitment issue? Comments are welcome. I usually adjust so there is about 1/4" free play at the clutch lever before you feel something happen. I might have got it wrong but I didn't think so.
Here's a closeup after they are cleaned up:
I used the clutch puller tool to grab out the clutch since the top end was still locked. Then I pulled the primary gear as well.
I took a pic to remember which way the gear goes on:
Last edited by sdjohn on Mon Jan 20, 2014 11:05 pm; edited 2 times in total