Modern Vespa

I posted this first in projects but figure it will be more useful here since I will have lots of questions! And I am far from done. Here are some pics and I just installed the oil pump injector and gears!

I will also post some pics.

We do love the old Rally's round the parts. Nice yellow! Looking forward to seeing what you do with this. Fire off those questions, dont be shy. As we say 'round here: pics or it didnt happen.

Love it! Another Bay Area rally!

The paint looks nice! Did you get that done locally?

yeah man...diggin that yellow!

Very cool. That scoot is gonna look great.

Big fan of the yellow. Needs more pics though.

Just realized I put this on the wrong thread…oops
So I feel I am making good progress so far. But is there no head gasket on this? One did not come in the kit? Do I need to calculate the squish? Or just put it on?
The pinasco instructions don't mention a gasket or the squish (in English or Italian!)

Oh yea had to figure out those weird clips that hold the cylinder to the crank. Grudgeon?

Love the Series 2!!

Thx! It's awesome

How did you get the engine case so clean? Is that bead blasting?

Vapor blasting

Yes I got it painted here in Petaluma at a bodyshop called Rich's, decent price as well

Thanks! I'm getting close to paint. I will check it out!

Did the squish test today (thanks for the help Derek!) and got an acceptable 1.46

Onwards and upwards!

I got the fuel line grommet and the choke, throttle cables and wiring harness grommet but what's this third hole for?

Oil line for autolube?

Yes! I found an Italian video of the wiring harness install and he pointed that out!

Is this clutch cover modification too much?
I didn't realize that the problem was the input shaft special screw washer blocking the pathway ever so slightly, so I got over enthusiastic with my grinding (and I got new grinding bits for my dremmel that are gnarly)..As soon as I took off the excess in the washer the clutch cover popped into place. So is this still usable? If not anybody have an extra?

Wiring harness is in! I went with turn signals but no battery. Keeping it simple

Floor rail action! It's finicky but I'm getting it little by little. Decided to go with bolts and nylock nuts. Cap nuts will be in front. Not spec but works for me. The extra holes are from a chrome front rack

NICE WORK! Coming along bit by bit

Looks great!

Anybody have any tips on getting the floor rail rubber installed? looks easy in the videos but man i have been fighting for every millimeter! I found a little grease helps, also saw a post to dip them in hot water?? what works boys??

I haven't specifically done floor rubber, but heat does work miracles to make any kind of rubber easier to work with. A hair dryer or a heat gun may be more helpful and easier to use than hot water. I also wonder if heating the rails themselves to expand them a bit would help.

Thanks makes sense! Hair dryer it is

I've never had problems, though ordered a set, and the rails needed a countersink where the rivets go. They were tapered rivets, but then sit flat.

The rubber fit easily feeding in from the top, though.

Lucky!

Well it seems I cheaper out and got the less expensive floor rail set and you get what you pay for! Some rails seem to have one side too compressed so if I raise the angle with a flathead as I go it works. I do have a couple rails where they do slide right in and that's how I realized by comparing the rails that some had one side squished down a bit. Ugggh

Got the floor rails in, and happy about that. Now I'm wondering what's best to do next, cables? Still have to do the stator and flywheel. Thoughts?

If you have the wiring harness in, cables. All the rubber parts at the ends of the cables.

Do you have the fork all reassembled?

Fork is 90 % there. Wiring harness in. Most grommets in but no cables yet so cables it is

So I watched a scooterwest video that said the loom should come out BEHIND the column lock. I brought mine in front of it. Should I fix this or is it ok?

I made this mistake on my Rally 200 as well. I hoped it wouldn't matter, and pressed on. It mattered. Fix it now while it's easy.

Thanks man, I thought that was gonna be the answer....shoulda watched the video before installing... live and learn.

Yeah, space inside that fork tube is so limited, if you get anything even slightly wrong, it all binds and the headset won't turn fully. You also run the risk of rubbing insulation off the wires and causing a short, which happened with my original loom after 35 years. I hope your wires are sheathed in something in there.

They are I have the sip wiring loom, seems good.

I hate to say this, but I bought a SIP loom for my US Rally 200 with indicators, and ended up having to modify it extensively to match the electronics in the bike. I had thought it would just be minor mods to get the indicators hooked up. But in fact the CDI, horn, and even brake pedal switch wiring were all different between the original harness and the SIP one. In hindsight I felt I would have been better off just making up a whole loom from scratch to match the original.

This may not be an issue for you if you are replacing other electrical components or you have already mapped out the connections and you know you're good. Just a heads up...

Replacing Rally 200 wiring loom

Thanks yea I saw that post but I don't have the skills to make one, so I got the loom without the battery should make it easier. Hopefully haha

Well I did it, re routed the loom in front of the steering lock. What is this black ground for and where does it go ?
Also I am putting in all new components and the euro style blinkers on the handlebars.