Modern Vespa : Project 1974 Rally

Project 1974 Rally

sdjohn UTC details Johnny Two Tone '15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4 Joined: UTC Posts: 8986 Location: San Diego, CA
sdjohn Johnny Two Tone '15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4 Joined: UTC Posts: 8986 Location: San Diego, CA	UTC quote simple check hang a wrench from each flywheel magnet (just one wrench, move it around). 17mm i think, but you get the idea, it has to hold up the wrench or it's not strong enough. ⚠️ Last edited by sdjohn on UTC; edited 1 time

chandlerman UTC details Lucky 76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 66 Lammy S3 Joined: UTC Posts: 10815 Location: Nashville 255 Days Since Last Explosion
chandlerman Lucky 76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 66 Lammy S3 Joined: UTC Posts: 10815 Location: Nashville 255 Days Since Last Explosion	UTC quote try hanging a 19mm wrench off the flywheel to check the magnetism.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote chandlerman wrote: try hanging a 19mm wrench off the flywheel to check the magnetism. Just on the outside?

sdjohn UTC details Johnny Two Tone '15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4 Joined: UTC Posts: 8986 Location: San Diego, CA
sdjohn Johnny Two Tone '15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4 Joined: UTC Posts: 8986 Location: San Diego, CA	UTC quote on each magnet on the inside, like in this photo (thanks scooterwest):

SoCalGuy UTC details bodgemaster 63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150 Joined: UTC Posts: 7215 Location: So Cal
SoCalGuy bodgemaster 63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150 Joined: UTC Posts: 7215 Location: So Cal	UTC quote Check the gap between the cam and black pickup. Needs to be 0.25mm - 0.30mm. Positive

hjo

UTC

details

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

hjo

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

UTC quote

Ah. I guess I need to pull the flywheel.

I hope it doesn't need to be replaced. Those are not easy to find. And I had it vapor blasted.

I guess I'll get the rest of the bike together.

I also need to rebuild the shifter box, or replace it. It shifts, but has a lot of play in the box itself, so it's a little squishy.

I guess that can be a project at any point, though.

Got the speedo cable to work. That was not easy. But it's very pretty. This was BGM version. Amazing to see it attach to the 50 year old brass thing.

This choke clip thing. How does it attach? It's asymmetrical, and there's a slot, and kind of a sheet metal fin thing close to it.

Some shots in almost done shape.

Forum member supplied image with no explanatory text

⚠️ Last edited by hjo on UTC; edited 1 time

brok3nr0b0t UTC details Hooked '71 Sprint Veloce Joined: UTC Posts: 285 Location: SoCal
brok3nr0b0t Hooked '71 Sprint Veloce Joined: UTC Posts: 285 Location: SoCal	UTC quote You should be able to get the flywheel re-magnetized if that ends up being the issue. I know scooter west has a machine to do it but there might be someone closer to you that can do it also

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote brok3nr0b0t wrote: You should be able to get the flywheel re-magnetized if that ends up being the issue. I know scooter west has a machine to do it but there might be someone closer to you that can do it also I love Scooterwest. They rebuilt my stator. And most of the parts are from there. Positive

Cdevillasante UTC details Addicted 1979 P200, 1960 Lambretta s2, 1975 Rally 200 Joined: UTC Posts: 580 Location: San Francisco Bay Area
Cdevillasante Addicted 1979 P200, 1960 Lambretta s2, 1975 Rally 200 Joined: UTC Posts: 580 Location: San Francisco Bay Area	UTC quote Looks great! that clip is a pain but it slides over the tube where the opening is, you just gotta finagle/ wrastle it. When it finds the right spot it clicks into place. Choke Lever clip https://www.scooterhelp.com/genmaintain/vespa.choke.cable.html

Rallygeek

UTC

details

Hooked

Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special

Joined: UTC
Posts: 462
Location: Melbourne

Rallygeek

Hooked

Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special

Joined: UTC
Posts: 462
Location: Melbourne

UTC quote

hjo wrote:

Spark. No spark.

I disconnected the junction box, tried my spare Femsa. Tried the green/blue/red in forward and reverse order. Checked the ground on the Femsa (it goes to a bare frame post).

Nothing.

Not sure what's going on.

I had the stator checked and rewired by Robot. I'm sure that''s good.

I don't know if I put the stator the right way. But it only seems to fit one way.

And if it was the wrong way, it would probably spark, just at the wrong time, since it's all a circle.

Hm. I guess I could have damaged a wire pulling it through. The grommet was hard to get through. But seemed fine.

The bike is looking great.

Are you sure that the femsa boxes you have are all ok? A check would be to use a Ducati Cdi if you have one lying about and use the conversion method to test if it's the box. FEMSA's can be frustrating.

http://www.vespa-klub.dk/Rally_CDI.HTM I think there were some recent posts on this forum about using the Ducati Cdi.

orwell84 UTC details Ossessionato Joined: UTC Posts: 3623 Location: northern New York
orwell84 Ossessionato Joined: UTC Posts: 3623 Location: northern New York	UTC quote Hang in there, you will get it. What a beauty.

hjo

UTC

details

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

hjo

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

UTC quote

Rallygeek wrote:

Are you sure that the femsa boxes you have are all ok? A check would be to use a Ducati Cdi if you have one lying about and use the conversion method to test if it's the box. FEMSA's can be frustrating.

http://www.vespa-klub.dk/Rally_CDI.HTM I think there were some recent posts on this forum about using the Ducati Cdi.

Thanks. This looks complicated. But I'll try it. I have a Ducati cdi, and a third femsa box I can try.

It's possible that my others are dead.

Seems most likely since the stator was all checked and rewired.

hjo

UTC

details

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

hjo

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

UTC quote

Rallygeek wrote:

Got this wired.

This worked well!

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote I spoke to Scooterwest, who rebuilt the flywheel, and they thought it was probably the gap with the cam/pickup. That would be really the best case.

SoCalGuy UTC details bodgemaster 63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150 Joined: UTC Posts: 7215 Location: So Cal
SoCalGuy bodgemaster 63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150 Joined: UTC Posts: 7215 Location: So Cal	UTC quote SoCalGuy wrote: Check the gap between the cam and black pickup. Needs to be 0.25mm - 0.30mm. Ahem ... ^

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote SoCalGuy wrote: Ahem ... ^ You called it!!

Ray8 UTC details Ossessionato Joined: UTC Posts: 2042 Location: Los Angeles
Ray8 Ossessionato Joined: UTC Posts: 2042 Location: Los Angeles	UTC quote Given your concours level restoration, have you considered sourcing mudguard reflectors? Looks like you filled the holes... But if so, I might have a NOS reflector hack. $50 total, including Claus Studios gaskets.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote Yes! Also the stripes. The silver stripes are only made by Scooterwest, and they're ordering new ones. The reflectors are impossible to find. I did find these ones. They're the same reflectors, but don't have the aluminum frame. I have to drill holes for them. Is there a better fix? I haven't touched the bike this week. Life things.

Birdsnest UTC details Not So Moderator VNB VSC VMA VSX - o9c vmb vse Joined: UTC Posts: 8791 Location: Hustletown, TX
Birdsnest Not So Moderator VNB VSC VMA VSX - o9c vmb vse Joined: UTC Posts: 8791 Location: Hustletown, TX	UTC quote Mark (Poi Dog) may have one. I think he'd sell it… Would get you half way there.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote Birdsnest wrote: Mark (Poi Dog) may have one. I think he'd sell it… Would get you half way there. I have a friend who may have a set. I'll ask him. This was very last step.

Ray8 UTC details Ossessionato Joined: UTC Posts: 2042 Location: Los Angeles
Ray8 Ossessionato Joined: UTC Posts: 2042 Location: Los Angeles	UTC quote hjo wrote: I did find these ones. They're the same reflectors, but don't have the aluminum frame. That's the very same hack. Same number lens. Screw holes match. I see now that the original frame is also wider than these Frame covers the lens edge

hjo

UTC

details

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

hjo

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

UTC quote

Does the aluminum frame wrap around the whole thing? Or just cover the front?

I might be ok with the plastic reflectors. They are so close. The reflector even has the same part number.

It has a plastic back with posts that are melted around the bracket, but in the same place.

I thought I might be able to file those down and thread them with a die, and use a nylon nut.

It's funny. The rarest part of the Rally is little plastic reflectors that cost like 50 cents to make.

Ray8

UTC

details

Ossessionato

Joined: UTC
Posts: 2042
Location: Los Angeles

Ray8

Ossessionato

Joined: UTC
Posts: 2042
Location: Los Angeles

UTC quote

Those plastic nubs dremel off in seconds. Bracket lifts right off.

I drilled plastic epoxy wells in a drill press and used #4 screws.
Considered using zinc came (used to wrap stained glass), rolling one side of the U flat and wrapping it. Something like this:

https://www.amazon.com/Zinc-6ft-Came-Into-Pieces/dp/B00LLVORLU/ref=sr_1_16?crid=7XF446GKDEKM&keywords=5%2F16+round+u+came&qid=1667158377&sprefix=5%2F16+round+u+came%2Caps%2C264&sr=8-16

But the plastic is good enough for my hole covering project.

And yeah, it is funny. Saw a pair on FB for $200+ that sold right away

oopsclunkthud UTC details Banned 3:5 Joined: UTC Posts: 9044 Location: San Francisco
oopsclunkthud Banned 3:5 Joined: UTC Posts: 9044 Location: San Francisco	UTC quote if you don't have holes in the fender I'd use 3M double sided tape. Positive

sdjohn UTC details Johnny Two Tone '15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4 Joined: UTC Posts: 8986 Location: San Diego, CA
sdjohn Johnny Two Tone '15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4 Joined: UTC Posts: 8986 Location: San Diego, CA	UTC quote there's always shoe goo....

Christopher_55934

UTC

details

Ossessionato

2007 Stella 225

Joined: UTC
Posts: 3547
Location: Rochester, Minnesota

Christopher_55934

Ossessionato

2007 Stella 225

Joined: UTC
Posts: 3547
Location: Rochester, Minnesota

UTC quote

Ray8 wrote:

If you don't use some odd metric size like a 4.5mm it's considered a bog fix.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote Life has been a little chaotic, and left this. The wires appear to be working. Attached the switches and the tail and brake lights work. The LEDs are not very bright! The material on this doesn't tap. It's not dense enough. Stripped out. Can I epoxy or super glue this maybe?

GeekLion UTC details The Dude Too Many piles of Junk that need too much work and too much money Joined: UTC Posts: 2221 Location: PNW from LBC
GeekLion The Dude Too Many piles of Junk that need too much work and too much money Joined: UTC Posts: 2221 Location: PNW from LBC	UTC quote I did 2 of those levers to fit the brake switch post. One of them tapped ok, the other barely held the threads; same as you. So this is one rare instance where I would use...JBWeld. Pack some in, thread it and go. Held up fine for the one of mine.

oopsclunkthud UTC details Banned 3:5 Joined: UTC Posts: 9044 Location: San Francisco
oopsclunkthud Banned 3:5 Joined: UTC Posts: 9044 Location: San Francisco	UTC quote Where did you get the reflectors from? think I may need to add them back on mine.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote oopsclunkthud wrote: Where did you get the reflectors from? think I may need to add them back on mine. Treatland, if I remember. They're wheel reflectors from Italian mopeds.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote I got some of this stuff. There store also had JB Weld, but I think this might be less messy. The tap just stripped the metal right out. But it's super soft aluminum. It was very easy to drill. The post is such a hack thing. It's just a screw with a piece of tubing over it.

hjo

UTC

details

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

hjo

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

UTC quote

The harness appears to work.

Though the LED flasher doesn't. It emits a loud tone, and the lights stay on.

In the reverse position with the wires, the lights flash once, and stop.

I'm not sure how the electrical works. There are three positions for the lights. One turns on the tail light. The brake works in all three. And the high beam indicator does too, so I might have put a wire in the wrong place on the switch.

Switches. Working even. The horn isn't. But I think it might need to be adjusted.

But the lights are connected.

Everything but the speedo wire, which was upstairs.

The high beam indicator is red, for some reason. It's so funny how this works. It's a bulb that lights up the whole inside of the headset.

ok. the switch just pushed the post out. This did not work. But the epoxy takes a day to set, so hopefully it's better tomorrow.

The switch cover is the only thing with original patina.

Christopher_55934 UTC details Ossessionato 2007 Stella 225 Joined: UTC Posts: 3547 Location: Rochester, Minnesota
Christopher_55934 Ossessionato 2007 Stella 225 Joined: UTC Posts: 3547 Location: Rochester, Minnesota	UTC quote hjo wrote: Life has been a little chaotic, and left this. The wires appear to be working. Attached the switches and the tail and brake lights work. The LEDs are not very bright! Is there enough material to insert a helicoil or thread repair kit? I've done that previously in aluminum when I had this issue.

hjo

UTC

details

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

hjo

Molto Verboso

Scattered remnants of (two!) 1974 Rallys

Joined: UTC
Posts: 1847
Location: San Francisco, CA

UTC quote

Christopher_55934 wrote:

Is there enough material to insert a helicoil or thread repair kit? I've done that previously in aluminum when I had this issue.

Not for this size screw.

My tap set didn't seem to work, partly because the taper before it threads is too deep, but also the material is so soft, when it got to the threads, it just stripped right away.

It might work better to make like a dowel in a lathe that is the same shape.

This is such a hacky thing. Just a screw tapped in.

Ray8 UTC details Ossessionato Joined: UTC Posts: 2042 Location: Los Angeles
Ray8 Ossessionato Joined: UTC Posts: 2042 Location: Los Angeles	UTC quote Pretty sure you'd have better luck with this setup. With epoxy thread repair and some under the plate it'll outlast us all. Works

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote All the lights work. I must have wired the switch wrong. The taillight comes on in one position, but the headlight is on when the key is on. I think the headlight should only come on when the taillight is on. But I am not sure what the three switch positions are. 0 miles. I hope this isn't a problem registering it.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote This thing is such an ordeal. It will eventually get there. Something seemed strange about my back wheel, and it looks like it is warped, somehow. It's an original Piaggio rim, but a vintage one. Also, I tried to bold down the exhaust, and the caged nut is stripped. It's like every single thing. ::

chandlerman UTC details Lucky 76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 66 Lammy S3 Joined: UTC Posts: 10815 Location: Nashville 255 Days Since Last Explosion
chandlerman Lucky 76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 66 Lammy S3 Joined: UTC Posts: 10815 Location: Nashville 255 Days Since Last Explosion	UTC quote It could be worse. It could be the axle. Frustrating, I know, but comes with the territory. Replacing the caged nut isn't a big deal. It's a great concept when it works, but that's a maddeningly low percentage of the time.

Jack221

UTC

details

Jet Eye Master

PX221 MHR, PX200 O tuned, PX181 M1XL, PX125 O tuned and some motorbikes

Joined: UTC
Posts: 4801
Location: London UK

Jack221

Jet Eye Master

PX221 MHR, PX200 O tuned, PX181 M1XL, PX125 O tuned and some motorbikes

Joined: UTC
Posts: 4801
Location: London UK

UTC quote

hjo wrote:

This thing is such an ordeal. It will eventually get there.

Something seemed strange about my back wheel, and it looks like it is warped, somehow.

It's an original Piaggio rim, but a vintage one.

Also, I tried to bold down the exhaust, and the caged nut is stripped.

It's like every single thing. ::

Not much to worry about on a stock build. However, that clicking sounds like gear misalignment. If it is, extra gaskets under the selector box usually fix it.

OP hjo UTC details Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA
OP hjo Molto Verboso Scattered remnants of (two!) 1974 Rallys Joined: UTC Posts: 1847 Location: San Francisco, CA	UTC quote Jack221 wrote: Not much to worry about on a stock build. However, that clicking sounds like gear misalignment. If it is, extra gaskets under the selector box usually fix it. I think it's the selector box. When I shift, the selector gear has a lot of play. It moves up and down where the cables attach

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