Modern Vespa

For the few that actually replace the O ring in a smallie clutch cover, does anyone have any clever replacements for the stock folded pin design? Cotter pin? Solid pin?

That is a "ROLL PIN", a cheap and effective way to connect parts just like this. I just measured one and it seems to be 3mm dia x 20mm. You can usually reuse them after you punch or press them out if you are lucky.

You should be able to find metric ones at an industrial fastener store. Not too expensive on Amazon, unless you gotta buy so many that you'll never use.

Ok. One last night I did was mangled from use/me hammering. Figured there's gotta be something on the market that's easier to replace.

this is not the easiest thing to install, getting them out is sometimes just as difficult. Some patience and the help of a vice, using as a press, will go far. There probably is a factory tool for this, never seen one though.

Keep the tricks coming!

Probably was an hour job last night. I added some heat to it which seemed to soften whatever rust/road grime was in there. Then just lots of cursing and whacking.

I tapered the pin to help with install, which honestly kind of wrecked it, but it's through both sides so I'm confident it's not going to break (stock v90 clutch spring).

to put them in and take them out: https://www.mcmaster.com/products/roll-pin-punches/