Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
I posted this first in projects but figure it will be more useful here since I will have lots of questions! And I am far from done. Here are some pics and I just installed the oil pump injector and gears!

I will also post some pics.






The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1451
Location: PNW from LBC
 
The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1451
Location: PNW from LBC
We do love the old Rally's round the parts. Nice yellow! Looking forward to seeing what you do with this. Fire off those questions, dont be shy. As we say 'round here: pics or it didnt happen.

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
Love it! Another Bay Area rally!

The paint looks nice! Did you get that done locally?

The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1451
Location: PNW from LBC
 
The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1451
Location: PNW from LBC
yeah man...diggin that yellow!

Not So Moderator
VNB VSC o9c VMA vbc VSX
Joined: 28 May 2008
Posts: 6566
Location: Hustletown, TX
 
Not So Moderator
VNB VSC o9c VMA vbc VSX
Joined: 28 May 2008
Posts: 6566
Location: Hustletown, TX
Very cool. That scoot is gonna look great.

Molto Verboso
1958 Allstate 177VMC, 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 1219
Location: Philadelphia
 
Molto Verboso
1958 Allstate 177VMC, 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 1219
Location: Philadelphia
Big fan of the yellow. Needs more pics though.

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Just realized I put this on the wrong thread…oops
So I feel I am making good progress so far. But is there no head gasket on this? One did not come in the kit? Do I need to calculate the squish? Or just put it on?
The pinasco instructions don't mention a gasket or the squish (in English or Italian!)

Oh yea had to figure out those weird clips that hold the cylinder to the crank. Grudgeon?








Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
Love the Series 2!!

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Thx! It's awesome

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
How did you get the engine case so clean? Is that bead blasting?

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Vapor blasting

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
hjo wrote:
Love it! Another Bay Area rally!

The paint looks nice! Did you get that done locally?
Yes I got it painted here in Petaluma at a bodyshop called Rich's, decent price as well

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
Cdevillasante wrote:
Yes I got it painted here in Petaluma at a bodyshop called Rich's, decent price as well
Thanks! I'm getting close to paint. I will check it out!

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Did the squish test today (thanks for the help Derek!) and got an acceptable 1.46

Onwards and upwards!








Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
I got the fuel line grommet and the choke, throttle cables and wiring harness grommet but what's this third hole for?




Ossessionato
79 P200E (Ruby), 62 Allstate (B-62), 2008 Stella (Olive)
Joined: 11 Jan 2006
Posts: 3289
Location: Florence, OR
 
Ossessionato
79 P200E (Ruby), 62 Allstate (B-62), 2008 Stella (Olive)
Joined: 11 Jan 2006
Posts: 3289
Location: Florence, OR
Oil line for autolube?

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Yes! I found an Italian video of the wiring harness install and he pointed that out!

⬆️    About 6w elapsed between posts    ⬇️

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Is this clutch cover modification too much?
I didn't realize that the problem was the input shaft special screw washer blocking the pathway ever so slightly, so I got over enthusiastic with my grinding (and I got new grinding bits for my dremmel that are gnarly)..As soon as I took off the excess in the washer the clutch cover popped into place. So is this still usable? If not anybody have an extra?






Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Wiring harness is in! I went with turn signals but no battery. Keeping it simple




Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Floor rail action! It's finicky but I'm getting it little by little. Decided to go with bolts and nylock nuts. Cap nuts will be in front. Not spec but works for me. The extra holes are from a chrome front rack






The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1451
Location: PNW from LBC
 
The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1451
Location: PNW from LBC
NICE WORK! Coming along bit by bit

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
Looks great!

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Anybody have any tips on getting the floor rail rubber installed? looks easy in the videos but man i have been fighting for every millimeter! I found a little grease helps, also saw a post to dip them in hot water?? what works boys??

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
I haven't specifically done floor rubber, but heat does work miracles to make any kind of rubber easier to work with. A hair dryer or a heat gun may be more helpful and easier to use than hot water. I also wonder if heating the rails themselves to expand them a bit would help.

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Thanks makes sense! Hair dryer it is

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
Cdevillasante wrote:
Anybody have any tips on getting the floor rail rubber installed? looks easy in the videos but man i have been fighting for every millimeter! I found a little grease helps, also saw a post to dip them in hot water?? what works boys??
I've never had problems, though ordered a set, and the rails needed a countersink where the rivets go. They were tapered rivets, but then sit flat.

The rubber fit easily feeding in from the top, though.

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Lucky!

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Well it seems I cheaper out and got the less expensive floor rail set and you get what you pay for! Some rails seem to have one side too compressed so if I raise the angle with a flathead as I go it works. I do have a couple rails where they do slide right in and that's how I realized by comparing the rails that some had one side squished down a bit. Ugggh

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Got the floor rails in, and happy about that. Now I'm wondering what's best to do next, cables? Still have to do the stator and flywheel. Thoughts?




Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1719
Location: San Francisco, CA
If you have the wiring harness in, cables. All the rubber parts at the ends of the cables.

Do you have the fork all reassembled?

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Fork is 90 % there. Wiring harness in. Most grommets in but no cables yet so cables it is

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
So I watched a scooterwest video that said the loom should come out BEHIND the column lock. I brought mine in front of it. Should I fix this or is it ok?




Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
Cdevillasante wrote:
So I watched a scooterwest video that said the loom should come out BEHIND the column lock. I brought mine in front of it. Should I fix this or is it ok?
I made this mistake on my Rally 200 as well. I hoped it wouldn't matter, and pressed on. It mattered. Fix it now while it's easy.

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Thanks man, I thought that was gonna be the answer....shoulda watched the video before installing... live and learn.

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
Yeah, space inside that fork tube is so limited, if you get anything even slightly wrong, it all binds and the headset won't turn fully. You also run the risk of rubbing insulation off the wires and causing a short, which happened with my original loom after 35 years. I hope your wires are sheathed in something in there.

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
They are I have the sip wiring loom, seems good.

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
Cdevillasante wrote:
They are I have the sip wiring loom, seems good.
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...

Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne
 
Addicted
'76 Vespa Rally 200
Joined: 13 Feb 2011
Posts: 608
Location: Melbourne

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
Thanks yea I saw that post but I don't have the skills to make one, so I got the loom without the battery should make it easier. Hopefully haha

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 337
Location: San Francisco Bay Area
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.





Last edited by Cdevillasante on Sat May 14, 2022 9:54 am; edited 2 times in total
   

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