Sat May 14, 2022 11:57 am

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
Sat May 14, 2022 11:57 am linkquote
autojack wrote:
I hate to say this, but I bought a SIP loom for my US Rally 200 with indicators, and ended up having to modify it extensively to match the electronics in the bike. I had thought it would just be minor mods to get the indicators hooked up. But in fact the CDI, horn, and even brake pedal switch wiring were all different between the original harness and the SIP one. In hindsight I felt I would have been better off just making up a whole loom from scratch to match the original.

This may not be an issue for you if you are replacing other electrical components or you have already mapped out the connections and you know you're good. Just a heads up...
I really appreciate this thread. I found it when doing some research, and was about to buy the same loom.

The SIP loom seems fine, as long as you configure it exactly as it's designed, I guess. Using the same switches and such.

It seemed like a big pain to make it adapt to a 1974 American bike, with all the weird/unique things.

I'm just going to make one from scratch instead.
Sat May 14, 2022 2:54 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Sat May 14, 2022 2:54 pm linkquote
There's a screw in the headset for that ground. If memory serves, it's one of the screws that also holds the nylon cable routing piece.
Sat May 14, 2022 5:07 pm

Addicted
1958 Allstate 177VMC, 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 910
Location: Philadelphia
 
Addicted
1958 Allstate 177VMC, 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 910
Location: Philadelphia
Sat May 14, 2022 5:07 pm linkquote
Cdevillasante wrote:
Well I did it, re routed the loom in front of the steering lock. What is this black ground for and where does it go ?
Also I am putting in all new components and the euro style blinkers on the handlebars.
Mine was under a screw where the throttle tube stop is. But I'm on a VNA so yours won't be the same but it should go somewhere on the stem of the headset. The stem being the part that slides onto the fork tube. That chunk of metal. Should be able to attach it to that
Thu May 19, 2022 1:23 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Thu May 19, 2022 1:23 pm linkquote
Cables in and floor mat started but I torqued my back and have to sit out for a bit. So I will order parts. Next up I will do the front forks/ hub and brakes and the rear hub and brakes.



Thu May 19, 2022 1:24 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Thu May 19, 2022 1:24 pm linkquote
Why do my pics keep uploading in portrait direction?
Thu May 19, 2022 5:22 pm

bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
Joined: 26 Sep 2013
Posts: 6434
Location: So Cal
 
bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
Joined: 26 Sep 2013
Posts: 6434
Location: So Cal
Thu May 19, 2022 5:22 pm linkquote
Happens to me too. Try cropping them on your phone before posting.
Mon May 30, 2022 4:10 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Mon May 30, 2022 4:10 pm linkquote
Vinegar and water really do help clean up aluminum! The rear hub was nasty before elbow grease. Here are a couple progress shots. Got the floor Matt and rails in cables and harness in. Front fork is next, it's built so gonna slide in





Mon May 30, 2022 8:48 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
Mon May 30, 2022 8:48 pm linkquote
Looking good!
Sat Jun 11, 2022 3:37 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Sat Jun 11, 2022 3:37 pm linkquote
Thx man! Slow but steady! So next thing is I am working on the front fork. I put in a new shock (wrestled it in) and I am at stuck on the spring. I did a spring for an Allstate but this seems different. I took off the nut holding the spring and removed the hub and the brakes. Do I remove the bolt which holds the breaks and the swing arm?
If so do I take out that 10mm bolt on the other side?







Sat Jun 11, 2022 3:53 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Sat Jun 11, 2022 3:53 pm linkquote
Sorry to say, if I remember right you need to do this in the reverse order. Put the spring on first while everything is loose, then the shock. When I did it, I had the fork already in the bike. I attached the shock at the top, and then had a friend push the front end down repeatedly while I tried to pop the bottom bolt through. That worked better than trying to slowly compress and hold the spring.
Sat Jun 11, 2022 4:02 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Sat Jun 11, 2022 4:02 pm linkquote
Whwn I did the allstate I used straps to compress the spring. I found this, Is it applicable to the rally as well
Sat Jun 11, 2022 4:17 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Sat Jun 11, 2022 4:17 pm linkquote
Well he's doing the spring first as well. I think he has the same problem, figuring out how to compress it enough to line everything up. The spring wants to resist compression, so you either need to tension it manually with straps or something, or you need to force it down all at once like I did. I couldn't get straps or zip ties to work, and I couldn't lever it down with anything either. Maybe if I'd had a larger pry bar.

It doesn't look like taking off the middle pivot bolt would help that much. I've only done this once so I can only tell you what worked for me - spring first.
Sat Jun 11, 2022 6:21 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
Sat Jun 11, 2022 6:21 pm linkquote
oh yeah. Pain.

No need to take off the pivot.

install the spring first. you can kind of screw down the top mount a bit, so it's easier to fit through. then move it back out.

Should be able to do this with a channel lock, and something that protects the threads from getting chewed.

The shock. attach the bottom part first. It has a key/slot that fits in the swing arm.

Put the hub back on (not super tight), and you can usually get it into place just pushing on it.


Moving this it farther makes it easier to get the top bolt in.


1. Then move the top shock mount back.
2. attach the bottom bolt first.

Sat Jun 11, 2022 6:34 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Sat Jun 11, 2022 6:34 pm linkquote
thanks! I will try it. Was removing the spring difficult? mine doesn't budge. (maybe after I remove the damper)
Sat Jun 11, 2022 7:01 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Sat Jun 11, 2022 7:01 pm linkquote
Totally worked when I did it in the order you laid out! Thx.
Your fork looks so good. Is it new?



Sun Jun 12, 2022 11:58 am

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
Sun Jun 12, 2022 11:58 am linkquote
Oh good!

My fork is original, just all repainted.
Mon Jun 13, 2022 6:15 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Mon Jun 13, 2022 6:15 pm linkquote
I f'n did it! Thx for the tips !



Mon Jun 13, 2022 6:22 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Mon Jun 13, 2022 6:22 pm linkquote
Cdevillasante wrote:
I f'n did it! Thx for the tips !
Yeah boi! That's a tough one, nice job.
Mon Jun 13, 2022 8:51 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
Mon Jun 13, 2022 8:51 pm linkquote
Awesome! That will ride a lot better!
Fri Jun 17, 2022 3:26 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Fri Jun 17, 2022 3:26 pm linkquote
this is a bit un related but my kickstart lever on my p200 just slipped a spline and the bolt underneath is stripped to almost round..... any suggestions how to get it off?
Fri Jun 17, 2022 3:28 pm

Ossessionato
79 P200E (Ruby), 62 Allstate (B-62), 2008 Stella (Olive)
Joined: 11 Jan 2006
Posts: 3033
Location: Florence, OR
 
Ossessionato
79 P200E (Ruby), 62 Allstate (B-62), 2008 Stella (Olive)
Joined: 11 Jan 2006
Posts: 3033
Location: Florence, OR
Fri Jun 17, 2022 3:28 pm linkquote
Vice grips?
Fri Jun 17, 2022 3:54 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Fri Jun 17, 2022 3:54 pm linkquote
tried, made it worse
Fri Jun 17, 2022 5:18 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Fri Jun 17, 2022 5:18 pm linkquote
I've sometimes had luck with wrapping a fastener with tape, to get a better grip on it with a tool. Also, I'd hit it with a penetrating oil just to make sure it's as easy as possible to break free.

Failing that, a grinder or Dremel with a cutoff wheel.
Fri Jun 17, 2022 6:58 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Fri Jun 17, 2022 6:58 pm linkquote
Thanks yea I put some liquid wrench. Hoping it gets in there
Sat Jun 18, 2022 10:37 am

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Sat Jun 18, 2022 10:37 am linkquote
Got it! It was a weird soft brass nut that got all mangled by the visegrips. It was on there when I bought it and I knew it would give me trouble someday…..my kickstart lever was shot inside too but the shaft is perfect so that's a win



Wed Jun 22, 2022 6:55 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Wed Jun 22, 2022 6:55 pm linkquote
Making good progress on the rally but there's a rub….. I mounted the front fork and the fender rubs the leg sheild when turning right. It's not a lot but enough to stop the turn. Left is fine. Any ideas why or what to do? Maybe modify the fender?
Oh and I changed the lock thanks scooterhelp! http://www.scooterhelp.com/tips/body/70s.locks.html







Wed Jun 22, 2022 7:07 pm

Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: 16 Jun 2011
Posts: 5958
Location: Nashville
 
Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: 16 Jun 2011
Posts: 5958
Location: Nashville
Wed Jun 22, 2022 7:07 pm linkquote
Cdevillasante wrote:
Making good progress on the rally but there's a rub….. I mounted the front fork and the fender rubs the leg sheild when turning right. It's not a lot but enough to stop the turn. Left is fine. Any ideas why or what to do? Maybe modify the fender?
Oh noes!

Something is bent, most likely the fork, I hate to have to tell you.

Make sure the two sections are both parallel to each other and that viewed front-on, it's all straight and in line. The easiest way to do it is to take some good photos from each angle and then draw lines on it on the computer.
Wed Jun 22, 2022 7:20 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Wed Jun 22, 2022 7:20 pm linkquote
Noooooo! Is a bent fork fixable? Or do I need a new fork?
Wed Jun 22, 2022 8:15 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Wed Jun 22, 2022 8:15 pm linkquote
Looks close to me?



Wed Jun 22, 2022 8:38 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Wed Jun 22, 2022 8:38 pm linkquote
I know you don't need me to tell you how to use the search function, but I was curious myself...

Front fork / fender installed right? suggests among other things you may have a bearing or spacer wrong/missing/etc. If you think about it, basically getting the fork to sit slightly lower in the tube might be all you need.

(Full disclosure: I have never dropped the fork in a Vespa.)
Wed Jun 22, 2022 8:43 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Wed Jun 22, 2022 8:43 pm linkquote
Thanks for that. I was looking at a couple others but didn't see that one. I do have an extra spacer… might be worth a try. But I will do lots more research too
Thu Jun 23, 2022 12:14 am

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1412
Location: San Francisco, CA
Thu Jun 23, 2022 12:14 am linkquote
Could be a bent fork. Did it sit correctly before?

Could be that something isn't seated right.

There should be some space there.
Thu Jun 23, 2022 8:10 am

Hooked
1968 VBB150
Joined: 04 Nov 2015
Posts: 432
Location: OC
 
Hooked
1968 VBB150
Joined: 04 Nov 2015
Posts: 432
Location: OC
Thu Jun 23, 2022 8:10 am linkquote
Is there a bearing cup on that fork? I may just not be seeing it in the pics.
Thu Jun 23, 2022 9:21 am

Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: 16 Jun 2011
Posts: 5958
Location: Nashville
 
Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: 16 Jun 2011
Posts: 5958
Location: Nashville
Thu Jun 23, 2022 9:21 am linkquote
definitely no dust shield or bearing cup on that photo. It's pretty obvious if you put a fork in without them (or even the bearings).

You get a lot worse misalignment that that if you stick a bare fork in the frame, though.

OP will have to let us know current state to be sure, though.
Thu Jun 23, 2022 9:41 am

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Thu Jun 23, 2022 9:41 am linkquote
yes that was before assembling everything
Thu Jun 23, 2022 10:15 am

Hooked
1968 VBB150
Joined: 04 Nov 2015
Posts: 432
Location: OC
 
Hooked
1968 VBB150
Joined: 04 Nov 2015
Posts: 432
Location: OC
Thu Jun 23, 2022 10:15 am linkquote
Cdevillasante wrote:
yes that was before assembling everything
Ok, then I am going to go with you need to shim it.
Thu Jun 23, 2022 11:46 am

Ossessionato
2007 Stella 225
Joined: 02 Nov 2019
Posts: 2672
Location: Rochester, Minnesota
 
Ossessionato
2007 Stella 225
Joined: 02 Nov 2019
Posts: 2672
Location: Rochester, Minnesota
Thu Jun 23, 2022 11:46 am linkquote
How much clearance should be between horn mount and fender? Maybe someone with same model can give you an idea what that clearance should be. So you have an idea of how much you need.

What about how fender mounts? Does it have front and back mounts? Could you put a washer under a front mount to give it a bit more angle to help with clearance?

Did you do any metal work to fender? Could you have bent fender so it rubs in one direction?
Thu Jun 23, 2022 2:07 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Thu Jun 23, 2022 2:07 pm linkquote
Quote:
What about how fender mounts? Does it have front and back mounts? Could you put a washer under a front mount to give it a bit more angle to help with clearance?
I cant get anything under the dust cover because it would be super hard to move that at this point, the inner track for the lower bearing was a bitch to get on and is tight tight tight.

I am attaching the parts diagram that I am following[/quote]

I will take it out again later today and look at the fender, also check that all parts are there (using the Rally 200 parts book) then install it again. I haven't done anything to the fender but I suspect it may be out of shape a bit.....heres hoping I just installed it wrong the first time, but I did look at new forks....



Thu Jun 23, 2022 3:38 pm

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 596
Location: Melbourne
Thu Jun 23, 2022 3:38 pm linkquote
Let me know if some pictures from my 76 Rally would help.
Thu Jun 23, 2022 5:09 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 140
Location: San Francisco Bay Area
Thu Jun 23, 2022 5:09 pm linkquote
I would love some pics! Thx man
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