Vespa Rally 200, disc brake and PX ignition conversion
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Enthusiast
1978 P200E
Joined: 07 Sep 2015
Posts: 78
Location: Ohio
Wed Nov 29, 2017 9:11 pm quote
Bike in question: Vespa Rally 200, 1974, Femsatronic





The plan:

- Rebuild the engine
- Replace the Femsatronic with a PX Ducati ignition
- PK fork disc brake conversion
- Powdercoat a bunch of stuff, incl shrouds, hubs, headlamp ring, etc.

Step 1:

I went ahead and dropped the engine, tore it down and cleaned it up.




https://www.youtube.com/watch?v=lD8xQ_M4gHo

Step 2:

After everything was taken apart, I gave it a glass bead blast, mounted Clauss Studio engine mounts and new bearings all around. I took the chance to also rebuild the cush drive and the clutch.






https://www.youtube.com/watch?v=9IYSM5RU6KI
https://www.youtube.com/watch?v=c47x8Yqo2cE



Step 3:
I put the engine back together but left the ignition off. Over that weekend I built a Pinasco 9TX engine for a friend and he left me his crank and ignition. So we decided to go ahead and put the Mazzuchelli PX crank into the Rally and run a lightened Ducati ignition.







https://www.youtube.com/watch?v=5PjxIZOUkZI
https://www.youtube.com/watch?v=QHMjwuBek1k



Step 4:

Finally, off to the fork! Using a modified PK fork, fitted for Sprint, Rally, etc. the bike was meant to get some good stopping power. I painted the fork black (after priming it of course). On the fork a Grimeca hub was fitted with Grimeca caliper. As a shock, we came across a very gently used, 195mm BGM PK shock, perfect for this!

Fitting the fender in was quite an endeavour as I didnít want to scratch up the paint, but also not repaint. A set of new holes were drilled and in meticulous trial & error the fender was offset with washers to assure the best possible position. With all new bearings it was then mounted into the frame.

This kit was not to be used as semi-hydraulic. A custom-made bracket kit uses a Piaggio Typhoon master cylinder, hidden underneath the handlebar. There were no instructions, it was quite a learning experience! Run on a set of Pinasco tubeless in black with Heidenau K80ís, to be replaced however by K47, as those were going on my P.










https://www.youtube.com/watch?v=OcIZjxueISQ

Step 5:
I mounted the rear suspension, which is a modified PK shock, mostly because I am an idiot and ordered the wrong one. The engine went in like butter and the bike was ready to be put together, cleaned and test ridden.



(Almost) Final result:

Still missing a headlamp glass, some minor adjustments, the proper tires and new levers in full black. I removed the misses in the front and ran two white stripes. Quite happy how it turned out!










https://www.youtube.com/watch?v=Ld5ok4hhO40

Feel free to leave some feedback, really would love to hear some!
bodgemaster
1963 GL, 1976 Super (x 2), 1974 Primavera (x 2), 2006 Fly 150
Joined: 26 Sep 2013
Posts: 5294
Location: So Cal
Thu Nov 30, 2017 9:20 am quote
Nice work, very clean.
Veni, Vidi, Posti
T5s
Joined: 19 Feb 2009
Posts: 17006
Location: The West Of Yorkshire ... Gods Country
Thu Nov 30, 2017 3:42 pm quote
tidy
Put clause mounts in me orange bastard. .... vibrates like a fucker ..... rubbed the powder coating off me mats
Ossessionato
09 190s taormina
Joined: 08 Apr 2010
Posts: 2080
Location: Googleville
Thu Nov 30, 2017 8:13 pm quote
Needs a pipe.
Molto Verboso
Honda elite
Joined: 19 Jun 2007
Posts: 1028
Location: California
Mon Dec 04, 2017 7:46 am quote
great job and report!
Mr. Clean
P,SUPER,V90, 50 Special
Joined: 27 Jul 2010
Posts: 10207
Location: This is't my locker!
Tue Dec 05, 2017 6:26 pm quote
Great looking bike... Love the front hub/disc... nice work..

P.S... nice documentation (pics) and writeup.
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7646
Location: Victoria, Australia
Wed Dec 06, 2017 12:59 am quote
Looks great! But if I'm being picky, I would pack the front mudguard a little higher at the rear to A. reduce the gap between the mudguard and legshield, and B. help to align the stripes front and rear. I think it'll look much closer to stock that way.

Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7646
Location: Victoria, Australia
Wed Dec 06, 2017 1:01 am quote
Also, have you got anywhere with your write-up of the GSF (Micro Dyno) app?
Enthusiast
1978 P200E
Joined: 07 Sep 2015
Posts: 78
Location: Ohio
Thu Dec 07, 2017 1:01 pm quote
Not yet, I am trying to build the little testing box instead of using a mic.

Also i do not have a proper engine to test right now, building one currently though

And you are right, the fender could come up in the rear. Adjusting that was suuuuuuch a hassle, it was hard to get a full clear image too.

Thanks, i am sure the owner and I will raise it this winter
Hooked
P200,Rally180, 100 sport , SuperCub50
Joined: 14 May 2009
Posts: 177

Fri Dec 08, 2017 2:19 pm quote
disc reservoir mount kit
Hey, - love the bike, where did you get the reservoir brake lever mount kit ? I've never seen one.
Hooked
P200,Rally180, 100 sport , SuperCub50
Joined: 14 May 2009
Posts: 177

Mon Jan 08, 2018 10:15 pm quote
brake master
So where did you find that master brake that works with the stock handlebar?
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7646
Location: Victoria, Australia
Tue Jan 09, 2018 12:20 am quote
Re: brake master
spielawieler wrote:
So where did you find that master brake that works with the stock handlebar?
https://www.sip-scootershop.com/en/products/brake+master+cylinder+crimaz+_56375300

Pretty sure someone else makes them as well, just can't think who.
Addicted
64 allstate, 66 sprint, 74 primavera, 79 P125x
Joined: 10 Mar 2013
Posts: 788
Location: Maine
Sun Jan 21, 2018 1:05 pm quote
Did you buy the fork already modified, or did you do the modification?
Enthusiast
1978 P200E
Joined: 07 Sep 2015
Posts: 78
Location: Ohio
Mon Jan 29, 2018 9:18 am quote
october wrote:
Did you buy the fork already modified, or did you do the modification?
SIP sells the fork modified.
Lurker
VLB1T
Joined: 01 Apr 2020
Posts: 4
Location: Indonesia
Tue Apr 21, 2020 6:19 am quote
Question: I've just installed the grimeca kit on my px fork - what surprised me was the front wheel pulls slightly right under braking. Is this a common issue or something is wrong with my setup? Cheers bud!
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