Modern Vespa

Man this pinasco stator fits just barely and all weird. The screws don't seem to line up very well with the slots on the stator. Looks like I may have to make one of the slots a bit wider so it sits in place better. Any suggestions? In the pic the screw by the O of pinasco is back from the post about 2mm and the screw on top doesn't go in because the plate is on top of its post by about 2mm. I also noticed that one of the slots is a deeper than the others (further in the plate). Does this positioning look relatively ok like a good place to start? Or does it only go on in one specific position and that's why it's not fitting ? From pics in other posts it seems the coil that's different from the others goes on top…

This site is so good. I was searching and it led back here.

Pinasco flytech timing Rally 200

Yes that's the post I was basing my initial positioning on. Hoping there was another solution than dremmeling….. not opposed but I don't want to mess up the cases…..

the stator plate gets the dremel, not the cases.

if you leave the upper right screw out does it seat down in the tabs like it should with the other two screws?

Stator looks like it's off center. Is it fitted correctly?? Shouldn't the timing marks be at the bottom??

I second that. I have no experience with that stator, but it seems that timing marks should be down where the corresponding mark is on the case on PX models (around 7 o'clock), not up there. From a marketing point of view, it seems like the branding should be read somewhat upright as well.

That is, unless ignition systems are positioned totally differently from P-series on Rallys???

The stator is backwards on the plate. Turn it around and it'll suddenly be fine

That's about the level of quality I expect from the FlyTech based on my experiences with them.

Thanks guys that makes sense! I'll try it later today!

Well fits perfectly like this (with the indicator marks at 7 o'clock). Seems like a good starting point. Also I found a possible marking on the case. Thoughts?

if it doesn't work maybe the stator is mounted 180 out on the plate, it's only 2 bolts holding it and they are apparently 180 apart.

Ultimately, it's all going to come down to marking TDC and seeing where it sparks.

the vespatronic just sparks twice so it makes no difference

Well that's cool

Trying to see what this will be like to install. Is this correct? It feels off, but it's where the extra holes in the frame are. The Plate for the cdi doesn't fit on the case…

I think the one that says Pinasco might be the rectifier, and go on the spare tire side?

But I've never used one of those.

Good to see it coming together!!

I'd recommend you to make a mount for the CDI on the engine. Otherwise there will be constant stress on the ignition cable and wires when the engine moves and CDI stays put on the frame side.

It looks like it's designed to attach to one of these.

https://www.scooterwest.com/bracket-for-cdi-vespa-p200e-164844.html

+1 on mounting the CDI to the motor. I tried out putting the CDI on the frame like that one time and the wiring gave me nothing but headaches.

The Stella/LML and some Bajaj's have the coil mounted to the frame, but they're engineered for it. This electrical system is not.

One day, I'll actually (remember to) spend the money for the proper mount, but I usually just bend a piece of sheet steel or aluminum to fit.

I mounted the coil to the frame so that it matched the look of the rally as much as it could.



there is an extra hole in the rally case for the wires to the coil to pass, this comes out behind the fan. I had to rework some of the wires from the stator to bring them out this way to the coil and then have all the other wires go out the top to the junction box.

in your picture it looks like the wires are already split to the two paths, so should be easy.

the hole you used to mount the regulator is meant to hold a small clip that secures the wires to the coil. I put the regulator on the other side of the frame where the stock one goes.



[img]https://modernvespa.com/forum/post2152760#2152760[/img]

Thanks for the pics! Have you had problems with the coil mounted to the frame? and thanks for the tip about the regulator and other wires, makes a lot more sense now.That would seem to justify mounting the coil on the frame, so the other wires more easily pass to the other side.....

Oh wait I think I mis understood. Are you saying I need to take the red and yellow and white/red wires and pass them through the extra hole in the case (just noticed that!)

In my Rally I have the CDI mounted on the frame as original. The only problem I had with it was early in my ownership, when the spark plug wire kept getting pulled out. I finally realized that the wire not only needs to be long enough, but needs to have a loop that goes down and back up sort of behind the motor. That gives enough slack so the engine can pivot without pulling the wire out. Previously I was giving it a lot of slack, but it was slipping down the side of the motor and getting chopped up by the fan.

After the scooter was shipped over to Australia, I did have the other wires pull out of the stator once. That was right after it got here. I think during transport it might have been strapped down with the rear shock compressed so much that it stretched and pulled those out.

It might be different with the Vespatronic, but on the Femsa, the electrical wires come out the top, and the CDI wires come out the back.




There are two harnesses on that one, though.

There's also this grommet that makes it fit the hole in the back. Scooterwest has this.

exactly! and perfect photo to show it.

on the Vespatronic, as it shipped, all the wires came out the top. I reworked them to split them up so the CDI came out the back.

The Pinasco looks like it has them split up already from what I see in the photo.

It has them split, but in the same harness. The cdi ones are longer so I'll try to put them out the other hole. As you can see in the photo there are already two attached wires on my cdi, would those be extra? Sorry this part baffles me! I will get better pics later its like 100 degrees in my garage now!

found this great thread about the flytech
https://modernvespa.com/forum/topic168761

I've started trying to follow the directions red/black to cdi
Blue to ground.
I have a yellow leftover
and the red/white stays unconnected since I am AC.

Where does the yellow go and am I doing this right? Do the harness wires go in the junction box too?

I am thinking the red/black and blue go through that extra hole in the case to the stator, but where on the stator do they connect (if that's the case….no pun intended haha)

If it's like the Vespa rally harness.

The wiring harness would go to the front of the junction box.

Any longer wires to the CDI would go out the back of the case.

The wires that go out the junction box from the stator have ring connections and end there.

The regular would go behind the spare tire, and have wires from the harness coming out that side of the frame.

So what I cant figure out:
The wires are in one single harness and I cant see how the yellow and white /red wire to the regulator would go behind the spare tire, on the other side of the frame, they are like 5-6 inches long.
I see the cdi has the red/black and blue wires coming from it and the stator also has these colors coming from it, do these get put together in the junction box?

The cdi has the red/black and blue wires coming from it and there is no room for the yellow/ red white cables. do they go to the regulator on the other side of the bike? How can they possibly reach? Are these the cables meant to come out the extra hole in the junction box?

It all just seems so counter intuitive....
Thanks for all your help on this, I am very appreciative sorry if it sounds whiny

It might be set up like P style, where the CDI wires come out of the top, and the junction box is right there.

But the power wires just connect to the bike's wiring harness, they run through that to the regulator, then up to the headset switches, lights, etc.

If this is made to just replace the stator and CDI/regulator components, I expect it would just keep those components where the old ones were. So the junction box does its thing, the CDI is right there at the engine, and the main harness is more or less the same.

Did this also come with a wiring harness that connects to the switches and lights, but keeps the same number of wires and their colors? I don't see in your photos.


P style CDI and junction box. All comes out of the junction box.



Then on the other side of the frame, there's this harness, that connects to the regulator, fuses, battery, etc.

So this is mine.

The wires that come from the stator to power the lights all just end here. Then there's another harness that comes out in front of the engine and connects to these.

It looks like yours is simpler, and has fewer wires.

I do have a split in the harness with a red wire and black wire that go (I think ) to the regulator on the other side. (I have to push it back through the body).

can you lay out all the wires and components so they are not overlapping and take a picture? Really hard to know what should go where only seeing half of things.

I suspect that the small harness with the red and blue goes from the coil on the frame, into the cases at the hole in the back, then up the hole in the top with the wires from the stator.

So the green, yellow, blue, red, go to the junction box, the other two go out the other side... And there's one stray orange one?

The orange one is for my blinkers, got it separately from sip and added it to the harness. Hopefully the pic is better.
1 cdi with blue (forks To blue ground too) and red/black wire attached

2. Regulator with blue ground wire attached.

3. From stator:short blue and red/black wires with round connectors and longer yellow and red/ white wires with square connectors and a red wire coming back off the yellow with a round connector
(probably to replace attach at the junction box)

The good pic keeps getting posted upside down no matter what.

I'll get a better pic with everything off the rally

Here it is that's all of it still have to get a spark plug wire

If this is right.

The CDI has one wire that's a ground. Yours is blue, which is odd. It's usually black.

And another that's red/black, and that splits and goes back to the junction box and connects to the kill switch on the main harness.

On your regulator, you also have a blue ground (why?)

And on this diagram, it has just the red/white and yellow wires going through the regulator, a ground, and a fourth one going to the battery (there might be a non-battery version, too?

So those two blue wires with the large rings loop around and ground on the bolts that mount them.

These two diagrams are the same, except one has the CDI ground out, and one has the CDI ground from the stator. Yours has both.

It looks like (and I could be wrong)
Regulator:
- yellow
- red/white
- one red wire goes back to the junction box as the power to everything.

the ones that connect to the frame harness are
- red/black (kill)
- red (lights)
- blue (just connects to the CDI ground)
- Black (another ground? I guess to the main wiring harness.)

Do you have a wiring harness that connects to red/black, red, and black, then goes to all the switches and lights?

Was looking at this.

Without seeing a diagram of it, I'm guessing:
- blue ground to blue ground
- black ground to black ground
- green to red/black
- red to red

Then you have another yellow wire left over.

Either that, or the red/yellow run to the other side of the frame, in which case the regulator is on that side, and
- Red/white to red
- yellow to yellow

The red/black wires. I am now sure about those. They could be the flasher unit?

They don't make this easy!

right?! quite the puzzle! since I am running AC I think the red/white gets left unplugged

Here is what I have from sip although it doesn't say rally It's what I have. I have no battery but yes key switch and blinkers