Handle bar tube repair
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Hooked
1955 Allstate 1958 lambretta 1965 Allstate 1968 sprint
Joined: 20 Jul 2017
Posts: 279
Location: Central california
Thu Feb 21, 2019 8:36 pm quote
Hoping someone can help me. I have mid 60ís scooter...the handle bar on the clutch side has a bunch of ďslopĒ in it. My question is Iím not totally sure how to get it apart. If I pull the inner clutch cable out and there is a funky clip that goes through the center of the tube....if I pull that clip out will the tube come out? I took a couple of pictures but Iím not sure how good the pictures are. Thanks for the help scott

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Ossessionato
1976 Super (x 2), 1974 Primavera (x 2), 2006 Fly 150
Joined: 26 Sep 2013
Posts: 4612
Location: So Cal
Fri Feb 22, 2019 6:30 am quote
Yep, pull that clip. It secures the shifter to the tube inside the headset that the gear cables connect to. You might have to twist the pin 45į to pull it. Shine a light on it, youíll figure it out.
Hooked
1955 Allstate 1958 lambretta 1965 Allstate 1968 sprint
Joined: 20 Jul 2017
Posts: 279
Location: Central california
Fri Feb 22, 2019 7:27 am quote
Handle
Thanks socal...thatís what I was thinking. Scott
Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1060
Location: Siam
Fri Feb 22, 2019 7:28 am quote
I'm just curious what your plan is to fix the slop.
Hooked
1955 Allstate 1958 lambretta 1965 Allstate 1968 sprint
Joined: 20 Jul 2017
Posts: 279
Location: Central california
Fri Feb 22, 2019 2:04 pm quote
Handle bar repair.
Iím going to make a bushing on the lathe that will push into the headset with a ID hole for the handle bar pole to slide in. Thatís the plan Iím going with...judging from your question my guess is there is no real fix, other than replacing the headset. Scott
Molto Verboso
Joined: 26 Oct 2015
Posts: 1383

Fri Feb 22, 2019 4:09 pm quote
Re: Handle bar repair.
Sjanuary wrote:
Iím going to make a bushing on the lathe that will push into the headset with a ID hole for the handle bar pole to slide in. Thatís the plan Iím going with...judging from your question my guess is there is no real fix, other than replacing the headset. Scott
Rather than making your own bushing, you might be able to use one from out of a Stella? I'm not sure, but i think most all Vespas use a 7/8" OD tube for the bars on both sides.
Veni, Vidi, Posti
a herd of easy shifty rats
Joined: 22 Nov 2010
Posts: 6798
Location: seattle/athens
Fri Feb 22, 2019 5:08 pm quote
Using a bushing to snug it up is a good idea, but you will need to do something about the worn bores in the headset casting. But rather than make a bushing, I'd try this one because it's self adjusting:



A Thompson Nyliner, which is designed for applications like this. They only come in inch sizes, but Metric may be hard to find, but the 1" size should work. If it's too tight, just open up the spiral groove so it can close a bit further. Your nominal diameter on the throttle/shift tube should be about 24.5mm at the bearing journals. That's .96 inches. The 1" Nyliner specifies a housing bore of 1.0935, so if you bore or ream the headset to 1.0395 - .040, it should work. OK, they also have one 25mm ID calling for a 27.5 housing bore that might be better. Just bore or ream to 27mm.

You'd probably need to source these from a distributor. More here: https://www.specialtyproducttechnologies.com/thomson/products/flanged-bearings
Hooked
1955 Allstate 1958 lambretta 1965 Allstate 1968 sprint
Joined: 20 Jul 2017
Posts: 279
Location: Central california
Fri Feb 22, 2019 6:45 pm quote
Handle bar repait
Thanks....gives me something to think about. I will be sure and take some pictures and post, what I did to fix the problem. Thanks again...Scott
Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1060
Location: Siam
Fri Feb 22, 2019 7:50 pm quote
Re: Handle bar repair.
Sjanuary wrote:
Iím going to make a bushing on the lathe that will push into the headset with a ID hole for the handle bar pole to slide in. Thatís the plan Iím going with...judging from your question my guess is there is no real fix, other than replacing the headset. Scott
No, that's the fix. What you say is how I've had it done as well. A machined steel shim pressed in works well. I'm just glad you didn't say something like JB weld and drill new hole.
Ossessionato
05 Stella, '62 VBB, 76 Sprint V, 63 GL
Joined: 16 Jun 2011
Posts: 2038
Location: Chicago. Well, Evanston, but that's almost Chicago
Sat Feb 23, 2019 5:27 am quote
Re: Handle bar repair.
nomadinsiam wrote:
I'm just glad you didn't say something like JB weld and drill new hole.
Heresy!
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