Wheelman's ET4 2003 "ISO"
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2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Fri Apr 24, 2020 9:58 pm quote
Greetings:

Accursed Caramba-virus has DMV offices closed to in-person transactions. They tell me I first need to get Safety Inspection - $7. 00 in Tejas. I ride Illegally to my 08:00 appointment - plate expired in 2018. Inspector takes my Proof of Insurance and mistakenly copies my OTHER Vespa's VIN. He didn't ask, I didn't check. Gave him a $5.00 tip and emailed the stuff to the DMV. They call back and say the VIN is wrong, and ISO has not been inspected in their records. Another ride to the Inspector's to obtain an amended form. No tip this time - they didn't even apologize!

Anyway rode back this totally-stock 2003 (tires date-stamped 2004) via the 75MPH bypass. Indicated top speed into a 5-10MPH headwind was 62. Came home to work on the stripped Kickstarter - see other post(s) - and install the Malossi Variator with the white spring. That belt cover was ON there. Plus my clutch bell splines appeared to be nearly seized. Sorted that out and a short down-the-street check ride was a REVelation. This engine can REV! Acceleration from a standstill? No comparison. Have to wait for a plate/sticker to see what happened to Top Speed, but it's feeling better already.



2001 Honda SA 50/72 Flash9. 2010 S50/78 Punkin. 2003 ET150 (ISO). All 3 can run near 60. Which one will soon go faster?



Last edited by Wheelman-111 on Mon May 04, 2020 5:12 am; edited 1 time in total
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GTS 250ie Super, Italjet Velocifero, Scarabeo 150, S50, ET4, ET2
Joined: 22 Nov 2016
Posts: 649
Location: Winston-Salem, NC
Sat Apr 25, 2020 12:10 pm quote
Well done. It's never easy is it.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sat Apr 25, 2020 6:53 pm quote
Greetings:

Perhaps not easy. But once you accept there is no controlling the destination, the fun comes from the journey. Had a wonderful 17 miles slow cruise tonight with Wheel-Boy on the Honda and Ms. Wheel-person around Deepinnaharta this evening.



Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sat Apr 25, 2020 6:54 pm quote
P.S: ISO still on expired plates... added to the fun!
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun Apr 26, 2020 6:47 am quote
Greetings:

It's the Wild West; Texas Governor Greg Abbott has announced the State temporarily waived the requirement for "Current vehicle registration". Woo-hoo!

Greetings:

2003 ET4 purchased with 341 miles on the counter. Lots and lots of Projects. Kicker refurbishing is next.
Update: Typo - the scooter had 541, not 341 miles.

Kickstarter now works perfectly.

Malossi variator and belt make a tangible difference in off-line and rapid acceleration, as it allows engine revs to spool up a little and apply real power instead of Chug-Chug with the stock unit.

Shed scratches fixed with Color-Rite Dragon Red pen. 2 Bigger scuffs will require a different approach.

Still on Pirelli tires date-stamped 3706. This replacement probably needs to be next. I hate watching my own front tire tread fling out in front of the scooter riding at 55 MPH.

FYI any DOT-approved road-going tire has an oval stamp like the one in my pic. 3706 means the tire was minted during the 37th week of 2006. It made me wonder why some previous owner decided to replace the tires when the scooter had less than 500 miles Tires might have been damaged, a desire for better performance or the P.O. was following the same thought process. But tires that are only 3 year-old don't generally don't need replacement



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2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Fri May 01, 2020 5:52 am quote
Centerstand Rubber Buffer
Greetings:

Centerstand rose to horizontal with a CLACK! every time. Easy to spot that the rubber buffer was missing from the two holes in the left leg of the stand. $5.00 part from ScooterParts strore. You'd think installation would be straightforward; push the two little rubber cones protruding from the buffer into the holes. Nope.

I dont' know if there were dimensional changes over the years, but these things were not even close to going in without some reaming of the centerstand holes. Ended up needing almost 1/16" enlargement before success.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sat May 02, 2020 5:23 am quote
Greetings:

Clutch pack splines were JAMMED on the transmission input shaft, making it challenging to remove. Spline damage is seldom confined to the male or female components, so installing my Shiny New Delta on that shaft risks transferring the issue to another clutch. Anticipating upgrading power down the road, but thinking new Malossi Primary Gears would give me a new shaft to work with the Malossi clutch.

Question: How much taller than stock will those primaries make the overall gearing? I plan to drop 6 - 12 grams from the variator weights to make up for the difference but can I get by on all-stock power output for a while? I guess I'll find out for myself and post when I have news.

If anyone has experience with this sequence and believes it to be a Colossally Bad Idea, I'm receptive to suggestions.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sat May 02, 2020 6:55 am quote
Speedometer Cable Remnant
Greetings:

Speaking of Caramba-virus with time on our hands, here's a weird one:

The first time I pulled off the headlamp/bar covers, I observed what looked like a second, empty speedometer cable fitting adjacent to the (fully functional) existing cable. Pulled it out to find a segment about 8" (20 cm.) long of speedo cable casing broken off at that point. What??

The 541 mileage indicated on the odometer seems plausible based on the scarcity of belt dust under the cover, but what explains this "extra" cable?
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Granturismo 218
Joined: 04 Feb 2013
Posts: 6620
Location: NWAOK
Sun May 03, 2020 12:04 pm quote
The clutch sticking to the splines is relatively common. Not enough grease inside when the factory installed it. There is a hole on the fixed pulley that is supposed to have a bunch of grease pumped inside before the clutch is assembled and when it is serviced, but it's seldom done. It puts the grease in just the right place so it lubricates the bearing and coats the splines.
As far as the speedometer cable, I suspect either one broke at the factory, and they left it in, or they switched the speedo to US at the factory and broke the cable when making the switch. If they are the same cable, and look about the same age, this is probably what happened. Unless it went bad and someone decided to do a quick drag of the new one through with the old one and just cut the housing.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun May 03, 2020 12:05 pm quote
Garage Therapy
Greetings:

A package is arriving from Scooter shops almost daily lately, affording me some Garage Therapy. Last night a Size 9 battery. Apparently the P.O. installed some random ATV battery in size 14. While it fit the "footprint" of the battery tray, it was almost an inch too tall. This made it impossible to install the tidy battery cover, which at least was present in the pet carrier on purchase.

The CHROME battery arrived featuring an LCD display that gives actual voltage and signals with a Beep when attention is needed. Neatened up the underseat!
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Mon May 04, 2020 5:27 am quote
Greetings:

Thanks MotoVista for your reply. I suspect you are correct, but mysteries abound. Sure is interesting. Previous owner replaced tires in 2005 or 2006, deeply scratching the front rim, especially, in the process. Apparently not ridden much after that...
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Mon May 04, 2020 3:36 pm quote
Greetings:

Parts have started rolling in. Plan to do upgear before 187cc cylinder to avoid spline conflict with Shiny New Delta clutch. Might be a bit tall, will drop weight in variator in an attempt to compensate.


Clutch nut was removed once with inelegant bench vise method. New stuff is always fun!

Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Tue May 05, 2020 6:33 pm quote
Greetings:

Stock pipe and wheel removed, gear oil sure doesn't look 17 years old. 2006 Pirelli removed from rim - whoever worked on it before sure wasn't careful, and Michelin City Grip installed by hand. Stiff 70 profile 10-inch tire was challenging but installed without additional damage. Will install Malossi 17/44 primaries and Delta clutch this weekend.



Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Wed May 06, 2020 8:21 pm quote
Tars
Greetings:

Both Michelin City Grips mounted now. Used all the cuss-words I know, and invented some new. Thick, stiff sidewalls pitted against prodigious Wheel-srtength augmented by The Miracle of Leverage.

I barely prevailed. Gears and Delta clutch must await more time.



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S150, Beo 500ie
Joined: 14 Aug 2019
Posts: 545
Location: Bermuda
Thu May 07, 2020 4:52 am quote
Youíll like those tires but mounting them on the rim is something Iíve been happy to pay a shop to do. It is SO much work for laypeople, but SO easy for the shop.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Thu May 07, 2020 9:39 am quote
Greetings:

After inventing new cusswords for about an hour last night, I succumbed to temptation and ordered THIS.
Addicted
S150, Beo 500ie
Joined: 14 Aug 2019
Posts: 545
Location: Bermuda
Thu May 07, 2020 12:37 pm quote
Youíll be back in the cussword lab before you know it. I am pretty sure the Vespa axle size is too small to fit that tool. But if you figure out a way to use it please post it! I gave up and took it to the shop.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Thu May 07, 2020 1:02 pm quote
Greetings:

Pretty sure the front wheel won't be a problem, but you're right if the tool's stud is larger than the rear axle splines, I'm hosed for the back tire.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Fri May 08, 2020 3:09 pm quote
Greetings:

Getting another day of Garage Therapy. Mounted shiny-new taillamp surround and front suspension cover - now it doesn't rattle!

More serious business to the Malossi clutch and Wing bell. Left the 17/44 primaries off for now - ratio goes from 7.86 (Not "about" 7.75 I assessed by counting spins) might be a bit tall for stock 150cc power, even dropping 10 grams from the current 84-gram variator load. Anybody run this setup feel free to comment.

Peeled the belt cover off easily this time - getting faster. New 46mm Buzetti clutch nut made that part easier than the bench vise. Reassembly resulted in new questions to ponder. No way the cover would sit down over the new clutch using the 5.3mm spacer used with the stock clutch & bell. Took some measurements and found the Wing bell has about 6mm more hub thickness than the stocker. Not sure why the numbers don't add up exactly, but deleting the spacer resulted in perfect fit. (I didn't think to measure the span of the splines on the clutch shaft...)

Anyway, it's buttoned up for now. Saving for the Malossi 187 kit, at which time I may mount the Polini primaries.









Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun May 10, 2020 1:37 pm quote
Gets Easier with Practice
Greetings:

Tires, clutch & vario done. Time for fun!

Wheel-Boy & I installed Tuff tech. Lead wire JUST long enough to reach coil wire. Needed a route from handlebars to main trunk as short as possible. Filed a small notch to suit (pics), behind glovebox & under floor board. Ziptied 5 spins around, buttoned up.


Notch for lead wire.


Wire bedded in



Addicted
S150, Beo 500ie
Joined: 14 Aug 2019
Posts: 545
Location: Bermuda
Sun May 10, 2020 2:59 pm quote
Did you have to do anything special to get the HF wheel tool to work with the Vespa rims? It just did not work for me.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun May 10, 2020 5:08 pm quote
Wheelman Loves Ze Shallenge
Greetings:

I dunno. Haven't yet received the HF tire changer tool. I plan to bolt it to a double layer of Hardwood and mount it to a hitch extender for the Family Truckster. You should know something about me: I get impatient so I tend to tackle a job before I receive the tools ordered to facilitate its completion. ISO tires were mounted entirely by hand, on a piece of cardboard with trusty tire irons and much profanity Once I recveive the HF tool, Punkin's tires are 10 years old and will be replaced using that tool. I will report once I have anything useful to share.
Addicted
S150, Beo 500ie
Joined: 14 Aug 2019
Posts: 545
Location: Bermuda
Sun May 10, 2020 5:37 pm quote
Brute force is my favorite tool too.
Hooked
2016 Sprint 150
Joined: 17 Apr 2020
Posts: 105
Location: NW Washington
Sun May 10, 2020 5:47 pm quote
Leave those tires out in some hot Texas sun seem to reduce the needed brute force.
Nice looking scooters there.

Art
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun May 10, 2020 5:51 pm quote
I Like O'Rhea
Greetings:

Thanks Tweetie! Juan: Mine too. Wheelman gots Gorilla hands. So Here's the Tach Readout from my Top Speed run over the Copano Bay Bridge. About 68 upwind and 72 back. Indicated speeds are Italian Propaganda.



Hooked
2016 Sprint 150
Joined: 17 Apr 2020
Posts: 105
Location: NW Washington
Sun May 10, 2020 6:17 pm quote
I don't know if I want to continue in blissful ignorance or check mine with the GPS.

Art
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Mon May 11, 2020 3:59 pm quote
Greetings:

So HERE
is the clip of the tach in operation.
Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Wed May 13, 2020 2:58 pm quote
CUPPINI Wind-a Screenie
Greetings:


Wish it were a bit smaller and less... Nerdy I thought as I completed the installation of my newly-arrived "Flyscreen". Sure is a lot bigger than the Vespa one on Punkin, and what's up with that straight-up angle? Maybe Clark Griswold would like it, but pretty m'eh to me. Something had to be done!

I get ahead of myself, sometimes. The "Instructions" were a poorly-drawn trajedy. (Pic1) Eventually tried all 7 wrong ways you can assemble the pieces before stumbling into the right one. But then... there-s that angle. Something a meter maid might enjoy, perhaps?

Recruited the assistance of trusty Bench Vise and a 4-foot long jack handle to provide Leverage, and bent the mounting struts as shown in Pic2.

Better, I think, but it's a matter of taste.









Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Thu May 14, 2020 11:59 am quote
Rim Job
Greetings:

Scored a pretty-nice used 11" rim last night for $15 - couldn't resist. Before ordering tires - Punkin's are 10 years old! - I decided to see if it would work on the 2003 ET4 ISO. The rim fits the hub perfectly, although the 2003 wheel bolts are several mm shorter than the 2010 S50. Torqued on, rode a short way down the street. Suspension compression didn't allow the tire to foul the fender , nor did hard stopping. However...

The steering felt Ö Weird. The larger-diameter rim/tire left an uncertain feeling on glide - not super-scary, but then again I didn't exceed 25MPH. The pic tells the story of certain alteration of the rake/trail numbers that explain the weird feeling. Not sure if I can get used to it or not, and a higher-speed run might reveal further steering misbehavior. I didn't search if anyone else has tried this, but reporting my impressions.

If all else fails, I may custom-paint the new rim and install Punkin's new tire on it.



Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun Jun 21, 2020 9:01 am quote
ISO Turns 700
Greetings:

Infrequent rides, dry cleaners, grocery-getting, all shared between 3 scooters, ISO has lived with us for 2 months now. Purchased with 540 miles, here's a pic at the Post Office.



Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Thu Mar 04, 2021 6:28 pm quote
ET4 Battery Thread
Greetings:

Opened a new thread with that title to help any future ET4 owners. The TX12 BS battery fits the battery tray perfectly, and still allows the battery cover to be mounted. The #14 size fits without the tray but is too tall for the cover. Malossi cylinder needs as many CCAs as possible. 12 seems to work.


Same footprint and still short enough to mount the cover!

Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun Apr 18, 2021 12:57 pm quote
Greetings:

Updated pic added.



Addicted
2010 S50 Modified "Punkin"; 2003 ET4 Malossi 187 "ISO"
Joined: 18 Feb 2017
Posts: 730
Location: Deepinnaharta, Texas
Sun May 02, 2021 5:57 am quote
Great Guru Greasy Influence
Greetings:

Greasy Shamed me into it. His off-hand remark about the caramel grips and kneepads stung me as a swarm of angry bees. ET4's saddle appeared black but is in fact a tobacco brown. Enter ScooterWest, which happened to have the grips matching and (pricey) replacement kneepads pictured below.

While I was at it, I relented and got the (really pricey) European headlamp replacement for the anemic US unit.





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