Modern Vespa

Anyone else dumb enough to do this?

I've got a 135 kit on a '70s v100 engine in my '64 v90 now. Heat cycled it a few times last night then decided to retorque everything. Ain't no way to pull the cylinder shroud with the engine in place.

I got it all apart but before putting it back together I'm thinking about cutting up the shroud so it comes off in two or maybe three pieces. I'm wondering if anyone else has done anything like that and may be kind enough to share pictures or at least a description of how they approached it?

I'm damn tempted to take a hole saw to the cowl so I can pull the plug without playing contortionist, lol.

Anything to do with anything beyond the stock cylinder in those early bikes is a complete pain-in-the-ass.

I have a solution that you don't want to hear.

Yeah?

One way ppl deal with this is to have a setup to raise the back and then pull the shock bolt to swing the engine down some. Some ppl have to loosen the carb too I think...

Here's a good way to raise the back w/ nothing in your way, this lift works for largeframes too : Voodoo Smallie Lift

I have a sneaking suspicion that it may involve a hole saw….

Voodoo's idea is the best solution vs cutting the cylinder cowl. After setup removing the cowl may not be an issue but checking/changing the spark plug will be.

Invest in something like what Voodoo is using or buy a scissor lift and you will not need to remove the tire to change a spark plug. https://www.amazon.com/ZENY-Motorcycle-Center-Scissor-Scooter/dp/B01860HLCU/ref=sr_1_8?crid=3CY0JE6R5XNUJ&keywords=motorcycle+scissor+lift&qid=1638645927&sprefix=motorcycle+sci%2Caps%2C340&sr=8-8

Lifting the bike ain't the problem. It's having to disconnect the carb and shock and pipe just to get at the top end, that's why I'm thinking of modifying the cowl. Maybe not the pipe…. I didn't actually try with it on because I had to pull the wheel to get that rear cowl screw.

I have a awful relationship with the smallframe carb attachment. I try all the tricks and still am plagued with air leaks there so once I get it right I hate having to take it off.

throw it on its side in the grass.. so much easier to access everything that way!

Lots of ways to skin a cat...

If I still had a small door bike that wasn't too perfect or precious, I'd be tempted to cut the opening bigger and fit a repop newer style door. That's only $34 and some clever labor if you don't mind some chopping.

How much can you get away with cutting? Would it be feasible to cut the whole side cowl off and make it go on like a large frame?

How much time are you planning on spending in purgatory?

Ugliness fine, not being able to ride no.

don't do that. please. just... don't do that.

One of the suggestions from the link below. https://vespasmallframeforum.proboards.com/thread/9696/spark-plug-access-problem-cure

This is Ebeth territory. He just went ahead and put a large frame engine into a small frame making it the Not So Small Smallie if my memory serves me correctly.

I love riding my V90, but I'd rather go to the dentist than have to work on it.

leave the 10 mm bolt around the back of the shroud permanently off. This will allow you to lift and rotate the shroud enough to get access to four head bolts (still helps to drop shock bolt)

I have also cut down a plug socket shorter and drilled a hole so you can use a screwdriver in the side to turn it instead of of the ratchet above (where there is no space)

So, of course I wasn't clever enough to take photos of it before putting the bike together. I cut the top off the shroud, zip tied some aluminum tabs in to make it go back on, have a nylon strap holding it back together. I can get to my head studs without dropping the engine now.

Maybe you could market something whereby the cowl splits in two with plastic tabs that pop and hold together firmly thus keeping the integrity of the air flow for cooling head. You could be on a winner $$$$$$$$$$$$$