Modern Vespa

Hello all,
Second post..

So I’ve been riding my new p200 daily, absolutely love it. While riding I notice it will jump out of 2nd gear and can have a hard time finding 3rd. I’m thinking about replacing with a cosa clutch and had some questions. I’ve never done any type of mechanical work in my life so this is very new to me. I found a good resource on scooterhelp and have a Haynes Manual on the way.

Any other resources you can point a complete beginner to?

What would I need to complete this job? Obviously the clutch but would I need to order anything additional?

Also with the cosa clutch, does it lighten the clutch pull? I have a pre-existing nerve condition that limits my strength; a lighter clutch pull would be awesome.

Thanks!
-justin

Sounds like a cruciform problem, rather than a clutch problem.

Okay, I will read up on it.. thanks for the info!

This ^

^^^^

Or something else... But likely not a clutch problem

Lots of good video from ScooterWest - Robot - Lots to learn there.

Also, the forum is a wealth of knowledge. Learn how to search it well.

Cruciform problem is often caused by a selector box problem, caused by a clutch problem. Once the gears jump, I would change the lot.

+1 on this... the whole train needs to be looked at...

Was diagnosing something similar before...

https://modernvespa.com/forum/post2458118#2458118

Ended up changing the gear selector, gear box, and refurbishing the clutch.

You'll need a list of tools and potentially replacement parts (woodruff key, clutch washer between bearing etc.) to look into taking the clutch off and reinstalling it (clutch holder, puller (depends if its a little stuck), clutch dismantling tool, torque wrench)

Hey Justin!
IMO the Haynes Manual is a coffee table relic. It's like buying a floppy disk, in terms of practicality. Still have mine, staining the sofa with old grease.

There are better clutches out there that will lighten the pull for sure.
The BGM I'm using is a blessing for guys with arthritis and such.

My baby-step advice:
Get one 7mm and two 8mm spanners. The two cables to the selector box might use some adjusting.

Agreed, doesn't sound like your clutch.

That being said: as someone who went through the cosa clutch "upgrade" I wouldn't recommend it.

Pros: much lighter pull than stock.
Cons: finicky. It was very hard to get it set up just right to have no drag, and it was super sensitive to the tolerances of the plates you install. I got sick of futzing with it.

I forked out the "big bucks" for a BGM Superstrong and LOVE it. People will tell you it is overkill for a stock 200 and they are right - however, the build quality is exceptional, the pull is still markedly softer than stock (although not as light as the cosa), and it's a tolerant thrasher. The thing is built to last and easy to dial in and forget about. So IF you choose to ditch your stock clutch (which you probably don't need to, but I was in the same boat needing a softer pull) I feel that is a better upgrade than the cosa.

My 2c

I've been going through a lot of plates lately and the first symptom when wearing out has always been difficult 2nd to third and dragging. I know all my gearbox/selector components are fine as they are on my kitchen table! If your plate wear has been at a normal rate then the other parts may be worn too but you'll lose nothing by just trying plates first.

I'd be worried if you're going through plates quickly... using stock plates?

I used to go through stock plates every 3 months (riding around 20kms daily) on a basic Malossi 210 tune...

Now I'm using the same CR80 plates i first installed 3 years ago... not had any problems with those and ive been test riding the crap out of them... surprised they havent died as i punished the motor during a certain period... about a year ago when i was testing a TMX carb...

The only thing ive had to change, were the in between metal plates and the brass bushing...