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@nolascooter avatar
UTC

Addicted
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
 
Addicted
@nolascooter avatar
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
UTC quote
anybody have any advice on how to reset this spring? Its the spring for the kickstart lever. not sure how it came out, but it did. All of my attempts to fix it have been thwarted. I am puzzled.
red line points to nub on spring that fits in groove on plate
red line points to nub on spring that fits in groove on plate
plate in place
plate in place
arrow shows where nub needs to bee with hook in place and gear in place
arrow shows where nub needs to bee with hook in place and gear in place
@caschnd1 avatar
UTC

Grumpy Biker
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
 
Grumpy Biker
@caschnd1 avatar
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
UTC quote
This is virtually impossible to correct without a special tool. I had to make my own tool to reload the spring on Debbie's ET4. Also the spring gets pulled around counter clockwise until it hooks on the notch you did not point to in your photo.

To make a tool, start with a large washer about the size of the spring...
External inline image provided by member with no explanatory text

Trim it down to fit into the spring recess area like this...
External inline image provided by member with no explanatory text

Drill a hole to capture the end of the spring...
External inline image provided by member with no explanatory text

Then weld on a T shaped handle. The tool drags the spring under the kickstart gear until the end can be captured in the notch.
External inline image provided by member with no explanatory text

Hope that helps.

-Craig
@brown_beret7 avatar
UTC

Veni, Vidi, Posti
1975 Vespa GTR 125, 1976 Vespa V90 (Resto), 2001 Vespa ET4 125 (Sold), 2009 Vespa GTS300 Super
Joined: UTC
Posts: 6064
Location: Northants UK
 
Veni, Vidi, Posti
@brown_beret7 avatar
1975 Vespa GTR 125, 1976 Vespa V90 (Resto), 2001 Vespa ET4 125 (Sold), 2009 Vespa GTS300 Super
Joined: UTC
Posts: 6064
Location: Northants UK
UTC quote
IIRC JimC once told me that one needs a spring compressor to reset it...
OP
@nolascooter avatar
UTC

Addicted
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
 
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@nolascooter avatar
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
UTC quote
haynes manual
I looked at my haynes manual and realized the mistake I had made with orientation. The solution in the haynes manual is a steel tube over the end of the nub and work it around that way. I will give it a shot tomorrow and let ya know. If that doesn't work, looks like I will be making a should be patented et4 spring tool per caschnd1's concept. thanks for the replies. I thought I was going nuts....looks like I was.
@caschnd1 avatar
UTC

Grumpy Biker
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
 
Grumpy Biker
@caschnd1 avatar
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
UTC quote
I didn't come up with this tool. Piaggio's tool is basically the same design. I just had everything needed to make my own so I went that route. I'd like to see the Haynes tool and how it works.

-Craig
OP
@nolascooter avatar
UTC

Addicted
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
 
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@nolascooter avatar
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
UTC quote
done, what a pain
so it was a PITA, but is done. The haynes manual said to take a steel rod a drill a hole in the end. I used a screwdriver that had interchangeable bits as seen below, The hardest part was keeping enough downward pressure on it to keep the spring in the recessed area. Kept sneaking up under the plate before I could push it through. Took a few attempts but I got it.
this is the nub that fits in the groove on the plate and needs to be pushed down on
this is the nub that fits in the groove on the plate and needs to be pushed down on
another view
another view
close up
close up
I used a screwdriver that uses hex bits
I used a screwdriver that uses hex bits
like this.
From there its a constant downward pressure and twist the plate into place and push it through. was not easy.
like this. From there its a constant downward pressure and twist the plate into place and push it through. was not easy.
@jimc avatar
UTC

Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: UTC
Posts: 43907
Location: Pleasant Hill, CA
 
Moderaptor
@jimc avatar
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: UTC
Posts: 43907
Location: Pleasant Hill, CA
UTC quote
Well done - those kick-start springs are right buggers!
@caschnd1 avatar
UTC

Grumpy Biker
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
 
Grumpy Biker
@caschnd1 avatar
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
UTC quote
Ingenious! The reason for the half-moon shape of my tool is to keep the spring down in the recessed area. But it's good to know there is a way to load the spring without a fancy tool.

This thread should go into the wiki for future reference. I'll find a few minutes in the next day or so to do that.

-Craig
UTC

Member
Vespa ls
Joined: UTC
Posts: 11
Location: USA
 
Member
Vespa ls
Joined: UTC
Posts: 11
Location: USA
UTC quote
Had the same problem before, didn't know how to fix it, lucky a pal of mine helped me out and let me borrow is special tool. But anyone knows where or how to get one? I would like to have one for myself for future use.
OP
@nolascooter avatar
UTC

Addicted
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
 
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@nolascooter avatar
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
UTC quote
Yeah, as I struggled to keep that spring in place, the shape of the tool caschnd1 fashioned made perfect sense. I will be making one when I have some time. Not that I ever plan on having to do that again.
@caschnd1 avatar
UTC

Grumpy Biker
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
 
Grumpy Biker
@caschnd1 avatar
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
UTC quote
Yeah, I made my tool for virtually $0. I will probably use it very rarely. But I like tools that make a painful job easy. I have a drawer full of "special" tools that just do one thing really well. Mostly old Harley-Davidson tools. My pride and joy is a set of HydraGlide fork slider rebuild tools that date back to around 1950.

-Craig
@caschnd1 avatar
UTC

Grumpy Biker
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
 
Grumpy Biker
@caschnd1 avatar
1980 Vespa P200e (sold), 2002 Vespa ET4 (sold), 1949 Harley-Davidson FL
Joined: UTC
Posts: 5450
Location: Sparks, Nevada, USA
UTC quote
nolascooter,

I created a Wiki article for this. I placed it in the DIY Repairs section. I think it has to be added by one of the moderators before it will show up on the Wiki page. But here is a direct link. I used a combination of your photos and my photos. Feel free to edit the article and add any information you think would be helpful. It's been 3+ years since I had to do this job so you might remember some details I've left out.

ET2/ET4/LX150 Kickstart Spring Reloading

-Craig
@fleece avatar
UTC

Ossessionato
1991 Vespa T5 Pole Position, 2008 Vespa S 125, 2023 Piaggio MP3 300HPE Sport
Joined: UTC
Posts: 4197
Location: Staffordshire England
 
Ossessionato
@fleece avatar
1991 Vespa T5 Pole Position, 2008 Vespa S 125, 2023 Piaggio MP3 300HPE Sport
Joined: UTC
Posts: 4197
Location: Staffordshire England
UTC quote
glad someone has solved this, it cost me 3 knuckles last time i tried to re-set the spring (on a Zip 50)
OP
@nolascooter avatar
UTC

Addicted
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
 
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@nolascooter avatar
2005 piaggio typhoon 50, and 2008 gt 200, 2003 et4 150.....
Joined: UTC
Posts: 513
Location: new orleans, louisiana u.s.a.
UTC quote
nice write up
Great write up.
Thanks Craig for putting that together.
UTC

Member
Vespa ls
Joined: UTC
Posts: 11
Location: USA
 
Member
Vespa ls
Joined: UTC
Posts: 11
Location: USA
UTC quote
caschnd1 wrote:
nolascooter,

I created a Wiki article for this. I placed it in the DIY Repairs section. I think it has to be added by one of the moderators before it will show up on the Wiki page. But here is a direct link. I used a combination of your photos and my photos. Feel free to edit the article and add any information you think would be helpful. It's been 3+ years since I had to do this job so you might remember some details I've left out.

ET2/ET4/LX150 Kickstart Spring Reloading

-Craig
Many thanks for sharing this to all of us... Its very helpful.
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