Modern Vespa

Hi there!
I bought this 1987 Vespa PK 50 Nuova a few years ago for really low money.
Condition you can see on photos.

In that times my mate was at the finish line in the restoration of his PK50XL but he lacked many little things. So I gave him what he want from this Nuova. And then a lot of other guys got some parts of what they need from it.
I also put hubs and front fork form it on my 50 Special.

Then scooter was left alone near year in cold and dark basement.
But I sometimes thought about Nuova and thought that it would be nice to rebuild it.
Restore it full is worth too much money for me and also it have no papers.

So I looked here and there in my garage and in garages of my mates and figured out that I have lot of used parts for rebuild Nuova. I decide that it will be low price off-road fun rider. Offcourse I need to buy some parts as hubs and fork(it was great luck) new bearings, seals, gaskets etc.

Works began. Today I matched ports for Polini 102cc.

Also stripped down engine what my mate gives to me to take from it 4 speed gear box. As my Nuova have 3 speed.
But it didn't work out - someone put a 3 speed gearbox in this motor too
In addition, the loose gears were installed incorrectly.

Today cleaned crankcase and put in few bearings. And e-start plug made of myself. Slowly but surely.

very clean porting work! nicely done!

Was just going to mirror this sentiment. Tidy port work.

Thanks guys.
I hope that porting gives some more power for this cylinder. Because when it was on my non-ported 50 Special crankcase there is no difference with DR 102cc.

This evening I assembled rear wheel. It is 90/90-10 Mototech 6024 tyre. And it seems too big.
I grinded out some material from swing arm but don't want go too deep and it is not enough.
I have few ideas. Maybe someone can help me to find right way?

1. Put some spacers on wheel shaft between hub and bearing. I have few shims the height of all together is 1.8 mm. And this is enough for tyre not rubs anywhere. Yes I know about this spacers kit from SIP but its pricey and need to be ordered. Can I use only hub-bearing spacers?

2. Put spacers between rim and hub. As for me it is bad idea.

3. Put rim on hub in reversed position. I mean wide part to the left. Its give a lot of clearance but make huge problem with exhaust fitting. And I also need to put front rim in that way to align both wheels. As for me it is bad idea too.

since you're riding off road, I wouldn't really concern myself with alignment that much. I mean, you're already going to be manhandling the bike so an adjustment in riding style isn't much more to ask.

the extra washers on the studs I think is fine. you've got plenty of meat and the securing nuts look as though they're fully done up. I wouldn't worry there.

I wouldn't go much more on that case.

if anything, shave the tire down a little more.

Thanks again Greasy
I have time to think what to do. Maybe put one shim between hub and bearing and also put shims between rim and hub.

Today worked on exhaust. As it for V-range so need to match lower bracket with PK cases. It looks not pretty but it works for sure. Now all clearances are sorted. Also painted weld places and rusty places.

That is badass! Fun to see this unfold

This evening I have a little free time so I decided to change engine rubber bushes. Nothing special - slowly but surely.
This Vespa will be weird looking but technically I try to do all the best what I can in low budget.

I spent this evening trying to fit an engine with an exhaust on the chassis and cut some pieces off the chassis.
Now I can easily take off/put on exhaust and rear wheel. Nothing rubs nowhere.

I also tried to mount rear shock with PX upper silent block but it seems too much - in that case I need to modify hole on body for carburetor. So I decided to put rear PK shock with suitable silent blocks. Maybe later I go back to this problem.

I already like how this Vespa looks

Some of today progress. Installed all bearings, shimmed gear box loose gears, install primary DRT Cobra 19/60 and Mazzucchelli Super Competizione crankshaft with small cone.
Also put handmade copy of MD Racing gear selector link.
Pity but noticed that I have no primary basket circlip.

Well I got hold of ratty PK XL 75 last year, same sort of boat at you, how do you tidy up the bodywork to make it semi presentable. Having got the engine, lighting, brakes, lenses, busted toolbox (most of it sorted out now) and registered for the UK and MOT, What was letting it down was the large dink in fairing horn, front bumper and the side panels. i used a dolly kit for £15.00 as best i could do get out the major dinks and then gave it a polish and used some touch up paint. If i had these resprayed would be obvious and not in keeping with the rest of the scooter which has original paint which is pretty good, still shines and looks glossy. So headed for ebay and looked at vinyl stickers. So for about 25 quid the results are shown below; going to add a few more. So you could sticker everything over on your panels along the lines of offroad rallying theme maybe? Will hide all the war damage. Im sure it will be a great little scooter for you, good luck with your project.

Nice PK mate!

And I don't really worry about the appearance of the chassis, the maximum that I will do is wash it thoroughly. I don't care about scratches, dents and rust.
This is the cheapest build.

I'm not sure what carb you intend to run-- unless stock? but cutting will be most necessary.

that shifting cross is roached. knock a new one in while you got it all apart.

good work all around though! it's looking awesome!

I have SHB 19.19. The problem is if I put PX upper bushing on shock absorber the intake manifold seats too deep in frame and its no possible to put carb on it.
So I decide to use stock PK upper bushing. In that case no cutting needed.

Yes shifting cross not in perfect condition, but I really don't want to order new one - really pricey(you remember this is a budget build ) including postage and a lot of time waiting.

I'm based on my first motor rebuild experience from my 50 Special - the cross was worse there, but it still worked and I drove it for 5000 km without any issues. So I think that PK cross is enough good for day-off fun ride Vespa.

oh I see where you're at. use the PK bush and maybe see if you can source a longer shock. might get you where you want to be.

I get you on the cross. it's not ideal but it'll work. just shim the gears up tight and it'll be okay for the fun times here and there.

Today I decide to sort of front end.
And was very surprised when found in my garage front shock.
I can't remember from where I got it. I assume it is from PX but it is bit shorter than original PX front shock. And its a bit longer than original PK one and bigger in diameter.
And it is really work.
Really happy with this find, exactly what I need.

Today I received missing primary circlip and finally closed the crankcase.

Today I received Newfren 3 corks and 2 plates clutch kit, without spring.
Start to assembly clutch and got a problem.

I have used original clutch basket and few used baseplates. And I have on the shelf few used clutch springs - Polini, Newfren, Surflex and RMS. And a lot of used but still in good conditions corks and steel plates, more of them is from 4 corks kits. When I put all together with Newfren used spring there is not enough space to put circlip in. With force added I finally put circlip on its place but there is no clutch play when I push on pressure plate. And spring looks fully compressed.
Then I put two thin steel plates(Newfren, 0.8mm) instead new thick plates, but its still hard to put in circlip and clutch have a very little play.

Is clutch springs length is different for 3 and 4 corks kits? Or what I'm doing wrong?
Since my first touch for smallie engine near 5 year ago I never had problems with build up a clutch. But today it really nightmare.

Maybe make a 4 cork 3 plate stack from your spare parts and the same with your new 3 cork 2 plate stuff, then and measure both for total thickness? That should be an easy clue to chase without removing the basket.

I continue fight with clutch tomorrow. Measured all as you said and try fit used 4 cork 3 plate on the engine.
But this situation really confuses me. I assembled my friend's motor 2 times. And at first I put there a clutch with 4 corks, and in the second I put 3 corks in same basket and baseplates and everything works fine... But both times there was a springs in the kits. I did not pay attention and put everything as it was out of the box

Seems the problem with clutch is sorted.

I measured height both clutch packets and what I got:
3 corks, 2 plates(new Newfren kit) - 10.6 mm
4 corks, 3 plates(used kit) - 10.0 mm
So, obviously problem is not there...Thanks Voodoo for advice!

And then I think about upper baseplate. It sits too tight on the clutch basket. I look it more closer and noticed that there is no space to put in reinforced circlip. Old original circlip is jump on its place perfect.
So I grind down a bit from upper baseplate and then it sits as it should and I can easily put reinforced circlip.

This evening I put cylinder on. It's Polini 102cc, run near 2000-2500 km and have two seizes but nothing scary. Also put intake manifold and its bushing.

Decided to add a bit of juicy colors.

Today I thought that I will finish the engine. Very close but have a problem.

No spark.

I have two stators plates, two CDI and three flywheels. All from PKs.
Not works in any combinations.
Tried both CDI on my daily rider P150X - works ok.
Tried to put CDI from P on Nuova engine and nothing.
Then I measured with multimeter both stators plates.

Nuova original stator have:
GREEN and WHITE - 523(seems ok as manual say 500 +/- 20 Ohms)
RED and WHITE - 521(seems wrong as manual say 110 +/- 5 Ohms)

Stator plate from another Vespa PK is:
GREEN and WHITE - 502 Ohms
RED and WHITE - 110 Ohms

But nothing work.

Could you snap couple photos of the CDIs and the stator plates?

Tomorrow I will do.

Here it is.

I thought I had pictures of mine but could not find them. It's been a while since I worked on my HP4 ignition.

Have you tried to measure the voltage between ignition coil wires (green and white) when spinning the flywheel with a drill or kickstarter? There should be around 50V AC present. If that's the case, you are missing the pickup signal which can be tested by measuring between red and green wire. Should give you under 10V AC.

I like the spinning with a drill test, gives actual readings under use, dynamic testing.

Thanks for help. I tried to measure this and that. All four stators plates shows results near manual and what you said.
But both original Piaggios is dead.
And then I got another two ignitions from my friends. One from HP4 and other from PK 50 XLS. Both is Ducati marked and both is working. So I put one on my Nuova engine.
And this evening I finished engine.

Little progress here...
Since my mate taked his recently bought XL2(white one on photos) to me for full rebuild I have no time for my Nuova.
Now XL2 99% ready and I find some time for my PK.
My other friend renew original Nuova's seat. He also lowered it a little.
And I sort a bit handlebar and decided to buy new handlebar cover.

Good progress this evening and I happy with it.
I put in all cables, fork, engine, wheels, handlebar, ignition lock...

the ride height looks good for the job, what did you end up doing on the rear shock? from what I can see in your earlier posts, you were using some long shock extensions, did you find a longer shock? I was looking thinking it seemed like a weak point for the usage.

I tried to use PX upper rubber bushing, but with it I need to cut frame where intake manifold goes thru it. I don't want do it.
I have few used original used PK rear shocks and I compared them and one was longer than others for 1.5 cm.
I also put all new rubbers in suspension.
Front shock is also longer than original PK shock but shorter than PX one.
Tires is 90/90 and I think because all of it I have bit more ride height.

it looks like so much more ride height than 1.5cm, where does the rest come from? - 90/90 tire is close to 3x10, so I'm confused but I like the result