Modern Vespa

Hello!

I'm in a service project on a 150 Super from 1978 and I split the case this morning for the first time since I own this bike for 5 years.


There are strange wear marks near the tip at the Christmas tree.






I wonder what caused this. The gear stack on the driveshaft definitely has issues since the 0.65mm feeler gauge slips in behind the circlip. And there's an unusual large gap between the 3rd and 4th gear.


First I thought the input shaft is curved but I can see those marks all around the circumference of the Christmas tree.

Looks like the kick start gear didn't like its presents under the Christmas tree. Got a pic of that kick start gear?

Reason.....something got loose. My uneducated guess would be primary gear bearing is bad, maybe caused by the loose gear stack. If the shaft goes in the bearing easy, it's bad. May need to replace the Christmas tree shaft.

Def need Bearings ALL around including the one inside Christmas tree and some gear shims to get it going.

Did the scoot live a hard life with a bunch of jumps, wheelies, and a lot of fast takeoffs from standing still?

Those grooves look to me more like material removed rather than worn or beaten. There is nothing inside the mating surface of the gear to do that.
The missing material on the gear also looks like it has been ground off. Maybe someone tried to re-profile the ends of the teeth on the first gear ?

This. Looks like small grinder marks, not damage

Lots of pitting on those gears. Marks are definitely from a grinder. Well, I'll say it. I smell a bodge…

^^^Yep. Someone tried to do a fast (bodgy) fixxy.

Those "grind marks" are consistently spaced between each like gear teeth marks.

BTW, you may want to consider not starting a new post each time you come up with an issue on the same project. You're all over the place with different post but no history. Add the fact that you don't provide results of your fix after other's provided suggestions makes it difficult to assist you.

To say all of that it maybe a bodge based on the previous posts and location. Maybe not but not original so anything could have been done to it. My bodge definition maybe different from others because of price, exported, and intentions to unsuspected buyers....like Planet Vespa. If it stays local, cheap, with no negative intentions...its not like the bodges that we see over here.

But still, if you want to get better assistants with everything, keep it all together so others have a history of whats going on.

Front hub corroded...
https://modernvespa.com/forum/post2449038?highlight=#2449038
Bodge wiring..
https://modernvespa.com/forum/post2435780?highlight=#2435780
Painted spring to look copper...
https://modernvespa.com/forum/post2480046?highlight=#2480046
Start of the project...maybe bodgery work with decals and yellow boots but the scoot is local??? This thread maybe the one you should add all your questions, too.
https://modernvespa.com/forum/post2441475?highlight=#2441475



GOOD LUCK!

Looking at the first pic in this post, it sure looks like the distance between the top of the column and the front of the seat bulge is way over the usual 14 1/2" ( +/-) .
https://modernvespa.com/forum/post2441475?highlight=#2441475

It looks like wide angle photo distortion

Excuse me. Obviously, you are correct.

gah! just looking at that I can *feel* my foot slamming into the ground each time I go to kick it and the gear doesn't catch.

you need a new one. and a gear. and judging by that and what else I've seen on that bike you're gonna need a wholllleeeee lot more.

Here are a few pictures of a P200E engine that a shop rebuilt about 8 years ago from mismatch parts. The engine cases were brand new that I purchased, the cylinder kit brand new(Malossi 210) but we used all the internals that were on the original P200E engine before.

My kick start would no longer engage (crank the engine) and second and third gear wanted to skip all the time during hard acceleration.

I did the cruciform and the kickstart gear at the same time about 3 months ago. Note how clean my Christmas tree gear looks like despite the kickstart gear being chewed up.

How did your kickstart felt prior to opening the engine cases? did it missed a lot(skipped/slide freely)?

Whoa! A lot of replies.


The kickstarter cogwheel seems intact but meshes up with the damage marks on the Xmas tree.















So definitely the the kickstarter cogwheel is the one who's fishy but how???

Its obvious the bike has lived a hard knock life and since we don't know the history, its a guess of what happened. Bad bearings, bad build, bad parts, bad spring or a bad life, pick one, it don't matter now. We can tell you how to fix it (unless it's bad cases) for it to may not happen again. My guess is all the above and some...Btw, what does the flyside case look like where the spring sits.

New Xmas tree, bearings all around, new kick start gear, shim the gears, maybe an axle and check gears for wear..there prob bad. Basically, rebuild/replace most of the gearbox to be safe.

Good luck!