Modern Vespa

It could just be that the fender is out of shape, or something isn't seated right.

Did you ride the bike before disassembling it?

Not sure how much these will help...

There is about 1 cm of space between the horn cast and the fender. About 5mm between the fender and the legshield at closest point.

Thanks for the pics! They do help! I wonder why the clearance is so small on Rallys. My p has so much more.

I did a thing yesterday because I can't get the fender off the fork now that the dust cover and inner bearing track is on. I decided to try and lift the front of the fender by putting a spacer (well a nut actually) under it. It worked great and I got plenty of clearance on the back but now the top of it rubs the horn cast. I think it may work if I use a smaller spacer. I know it's wonky but just may work!

It should have a pretty decent sized gap

Well if my theory works- I should be able to get a decent gap. The idea is to change the angle of the fender by raising it slightly in the front. Today I'll go down to the hardware store and look for something about half the width of that bolt I used that was a bit too tall. It sounds decent in theory hopefully it works in actuality.

Hopefully you'll find the root cause sooner than later. If it's a bent fork or frame, the steering and straight-line tracking will never be quite right--not necessarily dangerous, but certainly annoying.

If it's play in the bearings, though, that's flat-out dangerous. It'll also be really obvious because it'll shudder when you use the front brake.

Well time to fess up, I made the most amateur of mistakes…….when I was putting in the spacer for my theoretical solution when I realized the holes in the side of the fender no longer line up…..wait where are the bolts that go in there??? DOH …and there was the root cause, the fender wasn't at the right angle! I put those two bolts in, installed the fork and voila it has great clearance. Live and learn eh?

That's great!

Did you have enough room to get the bolts off behind the fender?

Oh I took it off the frame to do these adjustments, is that what you meant?

Yay!

Super-glad to hear you figured out what was going on. It's amazing what happens when you figure out the root cause.

Way better than a bent fork.

Great news!

I am very glad this worked out! Thanks for the update

Yep!

I remember there is little to no room to work with inside the fender.

When something looks or works wrong after putting something together, I automatically start thinking about worst case scenarios and reactions that made the situation worse. I will spare you the stories.

One of the pitfalls of restoring your own machine is that the emotional investment in it can cloud judgement, at least for me. Sometimes I do my best work when I can let go of that feeling and pretend it's a job.

Ok, one story. Spent 18 months building my bus engine and on first start and run in at 2500 rpm while parked it began billowing smoke that smelled awful. I thought I had cooked the engine. Came back the next day and realized it was the fresh paint on the heat exchangers cooking off.

im installing a trail tech and would love to get some advice. I looked through the posts and found some that were further along the process than I am.....basically at the very start.
I was planning on running it through the key hole because the connectors are chunky af.
what did you all do? know any posts that start at square 1?

I put it on a little piece of aluminum on the handle bar using the mirror mounts, like so:

great diagram thanks! gonna try today, did you connect to the spark plug or cylinder bolt? Im thinking spark plug

Got started on the trail tech installation on my lunch break, got it through the wiring harness grommet. It was difficult but finally popped through after cussing and greasing! Next thing is I am ready to put the headset on but don't know what this circular connector is for, and where does it go?

Looks like a ground.

yea I think so too, not sure where to put it

I think there's one that goes to the plate that holds the cable housings. The length looks about right for that. The opening looks too wide, though.

And there's one that goes around the high beam indicator, but looks too short/narrow.

Someone might have a photo.

It will work anywhere it can ground out, though.

That sounds right, I should be able to find somewhere for it

so I am putting the headset back together, and i should have taken pics while disassembling
it, doh! but I cant seem to figure out what part #34 is and I cant find it in my parts trays...

according to the pdf

34. securing plate, part # 100617

cant seem to find info if I search by part #

I need help to figure out how the bottom of the headset goes together.....

#34 is the bracket attached to the speedo under nut #8.

#30 threads into the bracket to hold the speedo in place.

Ahh thanks! makes sense

Forward motion!

Awesome!! Coming together.

Got the headset on phew what am exhilarating pain in the ass! So thinking forward to the ignition Im using femsa/ pinasco flytech. I have no idea what I'm doing but does this look like all the parts (minus the connectors)? Any advice?
I was also toying with the idea of a kit for sip by vape It's tempting cause it's all there shiny new and easy. But is it worth it? Will this femsa be just as good?
https://www.sip-scootershop.com/en/product/ignition-sip-performance-by-vape-road_51007RA0?q=Vape%20for%20rally
I know it's subjective but I need other points of view!

Looking up this one, it looks like it's 12 volt, and uses its own CDI, so don't need the Femsa CDI and and the voltage regulator. Looks like the black coil and smaller regulator replace them.

I've never run one of these, but it looks similar to the one from SIP.

Was the bike running with these prior to disassembly?

No idea. I bought it disassembled

You have a Pinasco kit. Only Pinasco and Vespatronic (basically the same IDM ignition) make kits for the FEMSA crank. SIP's Vape kit isn't compatible, it requires a P crank…

Thanks SaFiS, are you saying I have what I need here? That would be great because it would save sone money...or allocate it to something else!

circled is the Pinasco ignition, looks like you have what you need there.

X marks the original Femsa parts that you would not use with Pinasco.

It looks like all the parts are there.

There's a 12 volt version, and one that doesn't say (I'm guessing it's 6 volt), but they look the same, so not sure which it is.

But comes with these parts.

https://www.scooter-center.com/en/ignition-pinasco-flytech-12v-vespa-rally180-vsd1t-vespa-rally200-vse1t-33996-femsatronic-1600g-pn25356854

https://www.scooter-center.com/en/ignition-pinasco-flytech-slave/master-251ccm-vespa-px-rally-sprint-vna-vnb-vba-vbb-super-ts-gt-gtr-pn26357759

Thanks boyz!

F me wrong way on the engine stand.

You cutting that out rather than remove the back plate? It's got a hefty groove in it.