Modern Vespa

So I finished the rebuild of the P200 and it runs great, Starts up great. Shifting was rough at first but I adjusted the selector cables and can row through the gears nicely when it is moving. However, When I come to stop and put it in 1st gear with the clutch lever fully pulled, it's not engaging and releasing properly and the bike is popping into first with the clutch engaged and upon release lurching forward and then the engine dies. In other words I can't slowly release the clutch lever and move into1st smoothly, it's just popping straight into gear and popping the front wheel, so I have to be very careful not to give it too much gas or it will pop a wheelie ;o)

The engine was totally tuned up in the 90s by Moto Strada in MD, 2k original miles, and it runs great but the bike has sat since like 2000. I put in 80W gear oil as recommended until it was flowing out of the top fill hole. Do I need to lube the clutch or do I need to tear the engine down. Trying to avoid that as I just installed it, but these things happen. Anyone have any advice on steps I could take to fix this prior to pulling the engine? Thanks in advance. PS. When I had the clutch tension higher I had more spring in the clutch but then I could not shift it through the gears.

I would remove the clutch and inspect.

Is the basket turrets in good shape or have they been "ate" by the friction plate ears?

What condition are the clutch plates in? Both steel and cork?

The drive cog is revited. Any okay there?

Is your brass bushing and brass washer on good shape?

You could make sure the clutch cable isn't too tight. Adjust the pinch bolt so that most of the slack in the clutch arm on the engine is taken up, but not all of it.

Good advice from Gick and Orwell -- that's what I would do. Clutches can get worn out with lots and lots of miles.

You started off with saying you just finished the rebuild. Am I correct in the assumption that you didn't go through the engine, since you mentioned engine work from the 90s? If that's the case, so to speak, it's possible that there's other component wear in addition to the clutch.

Sometimes the shifting cross aka cruciform in the gear stack needs replacing after wearing out, causing lurching into gear (usually 2nd gear, for me) or the cush drive/xmas tree stops working correctly after its internal springs break.

I had the same problem…lurching when moving off from first unless I let it out really slowly. I went through the whole clutch, but I'm certain I had it adjusted too tight and just kept adjusting it tighter. When I put it all back together with a lot less tension on the clutch arm, it was great. A Vespa usually has a forgiving clutch.

Thanks all. The bike has 2k original miles, so other than sitting a long time I doubt the clutch is worn out, but possible. I am playing around with the clutch cable first to see if that helps. It definitely improved a little and I also think I had the Clutch Lever pin screwed in a little too tight, I backed off that a bit so it can return more easily.

It's real possible your cork plates are sticking to the steel plates.

That's also a possibility too. There are some quick fixes for that, but I wouldn't spend too much time on it trying out the quick and easy stuff. Just rebuild it and start fresh.

The hardest part for me was getting that stupid castle nut off and on. Get a modern flanged nut. It will make the job a lot easier.