Modern Vespa

Help.... Clunky gear change and bike creaping when in gear. Replaced the springs , steels and plates, twice ... Had advice in assembly and ensured I put in correctly with 'notch' steel in second etc. Adjusted so only 1-2mm play on kick start etc........
Should be a smooth clutch by now but certainly not the case.
Any advice would help as pulling my hair out lol.

Sounds like its your clutch not being adjusted properly. Start again so....Loosen the nipple at the clutch arm.
Screw in the adjuster screw to the start.
Push clutch arm with finger force to as far as it will go.
Lock in with nipple.
With adjuster, release by perhaps 2 to 3 turns and lock in place with other nut.
Test drive.
If still creeping or not going into gears smoothly turn adjuster again.
Trial and error. You'll get there.

Good luck buddy.

So aftermarket Cosa style clutch in a PX125? Not stock, but did it ever work properly? No experience here, just a random memory about maybe needing a different clutch cover. Do a search or others can advise on that. Explain exactly what clutch you're running for best results.

Meanwhile, consider doing this for smooth, buttery clutch action: Honda CR80 clutch disk page, what have you got?

Thanks matey. Done it and seems better so will run for a day or so and adjust and see where I go but optimistic. 1st gear significantly better would think other gears would be a bit smoother ??will keep fine tuning.

Check the turrets for depth. You need 22mm for everything to work just so and many baskets only had 21mm or so.

I had a similar problem lately with my original Cosa clutch not long after replacing the plates. I had soaked them overnight (mistake) and they swelled up such that no amount of adjusting could get them to let go sufficiently.

At least I think that's what happened. They could've also just been a bad set of plates.

Regardless, replacing them once again and this time only lightly oiling them during assembly seems to have fixed it. Also, if the clutch is going to sit around before reinstalling, store it on edge so any excess oil can run out, just like it would installed.