Modern Vespa

While I was working through my Rally 200 engine with significant case issues, I built an engine with all new parts. . . Every single one of them. I left nothing on the table and used the very best that is in the market today that I thought appropriate for a Rally with stock brakes and suspension.

My German market Rally 200 is non oil injected, so I left out the oiler gears and used a machined plug to fit the oiler hole.

A few specs:

Malossi V-one cases
Malossi 210, Sport version
BGM 57mm crankshaft
SIP PX output shaft & gearset
DRT Long 3rd gear
65 primary/piaggio PX Xmas tree
BGM primary repair
23t VMC clutch
BGM clutch cover
SIP Vape ignition- static timing
Scootopia rear drum
sprint/rally kickstart quadrant

Over 4K to build it out.

Good lord. So fine that gave me the vapors.

Just ace all around.

Any fitment issues among all the different suppliers?

None.

Wow that's sexy!

What exhaust are you going to use with the 210 Mark 3? Just built one last week, and the exhaust manifold Allen bolts hit the exhaust clamps I was using.

i would most likely mount a ceramic coated Polini Box.

Damn, a 10/10 job it looks like w/ no stone left unturned - our dream build w/ max power & reliability in mind that most of us can only dream of....

But just to keep on dreaming, can you share about how much is invested just in the BOM, and also if you wanna take a guess - how much for such an engine all built up, tested and ready to ship out the door?

Edit: Looks like you have now added 1st answer, over 4K , but you get what you pay for here.

Bench tested, boxed, and shipped for $4600 to your door. if anyone is interested, PM me.

My goal was an engine replacement for this Rally 200 that would be P&P. I wanted to build something that was high quality, but not radical to the point you have to special order the simplest part. An engine that any mechanic in the USA could work on and most likely have parts in the shop to do any maintenance.

You certainly could build a much higher Hp engine, no doubt. but that was not my goal. I just wanted something i can run 55-65 mph all day long and NOT have to fuck with anything, P&P with cables and air bellow. for the most part, appears stock sitting in the chassis. KISS-keep it simple stupid.

That is a very reasonable premium over just the parts. It seems a good option for someone w/ a decent bike but no good motor and limited time who mainly just wants to ride reliably when they can and little chance of breakdowns.

I suppose the price for desired exhaust would have to be added. So ideally the testing & jetting with it installed could be done.

Nice little touch w/ a sprint/rally kickstart quadrant available! Tell all your buddies that your roundtail AllState is mostly stock 😁

Which reminds me, could you estimate the HP just for fun?

That's a hell of a build. I'm jelly.

As much as I love my high-strung builds, I also love my nice, reliable, mildly tuned 210 that I couldn't kill if I tried.

Great piston work..!

any port work on the cases or straight P&P on the kit?

beautiful work all around

Boost ports seemed to have been enlarged "worb5" style…

That 0.8-1mm base gasket will be pretty much perfect for the Polini.

Not sure if you would need to take anything off the top of the cylinder to balance the squish. 1.3mm to be riding all day. Lower compression head maybe too?

Looks too shiny. Shame to start and dirty it up. Will make a lovely touring motor.
If on an SI carb, it's going to need some big jets. Right up on the limit of the carb, I would guess.

i widened the exhaust port to .68 x bore, then polished. Top transfer in the cylinder is opened up as it's constricted there. The piston is opened up. Nothing radical.

Fantastic! I'm building a similar engine and contemplating getting the Malossi cases and selling my virgin Piaggio cases. Going the 221 Sport route, already have a crank.

Nice build Gickspeed.

I'm building similar at the moment... can you guide me to the correct installation of the block off plug for the autolube? The Malossi instructions aren't very helpful

that is the correct orientation. there is a little o-ring that is added to it.

Okay, I probably have it right then, o-ring on the second groove... the top of the bung sticks out, thought maybe the carb box might "cap" it down and seal it off nicely. There's nothing really holding it in place.

If you're not worried about using it as an oiler you can epoxy the plug in.

Hey Jon, why did you choose to use a Vape static instead of a variable?

Thanks for sharing. I like it. Looks like a solid touring engine. That clutch cover is super slick.

Wondering whether your choice of a 57mm crank (instead of a 60mm) was part of keeping it simple or a performance/reliability consideration.

Thanks!

A thing of beauty and purpose, that engine looks like it will run forever and a day with minimum fuss. Kudos!

What a beautiful built, I love it.

plenty of power with the standard 57mm crankshaft. nothing exotic.

What carb are you planning on using? Thanks

24.24e SI.

What mpg are getting with this motor?
Thanks for posting your build.

I don't have a great answer. Maybe 45-55 gallons/mile? I have never calculated it.

Are you running an internal seal only with your Scootopia drum or doing both seals? The outer surface is rough. Thinking about smoothing mine up in the lathe and running both seals.

external only.

Hey, I've got two questions about this excellent looking build.

1. What is achieved with ceramic coating (cerakoteing?) the box exhaust, beyond a nice rustproof finish? Does it suppress noise at all?

2. That BGM clutch cover - does it offer any additional clearance with the tire compared to stock? I'm running 10/90-10s and when they heat up they do tend to rub.

Just gives you a nice looking exhaust for years to come instead of a rusty one. Always hated having a nice looking bike with a rusty exhaust bolted to the engine. Now in theory, ceramic coating gives benefits to 2-stroke engines, but I will let you google that bad boy and you can go down the rabbit hole of information out there.


No idea on the tire; I run stock size, traditional tread pattern tires.

Did you happen to polish your ports on the case before it got assembled or does it make any difference? I only have one mold line. Looks the same as yours.

Thanks GickSpeed. I've already been down the rabbit hole of what different exhaust coatings do and there's so much conflicting opinion out there. I'd tinkered with exhaust wrapping the manifold on a Polinibox last summer and found that all it did was 1) lodge thousands of fibreglass shards in my skin; 2) lead to a gradual CHT climb, over the course of a long cruise, where none existed before; and 3) absolutely nothing to deaden the exhaust noise. So, out came the scissors and the whole expensive prickly mess ended up in a Slovak dumpster.

About the BGM clutch cover, I'm normally pretty leery of shiny things from BGM, but the flat angled shape of it made me wonder if it might have a mm or 2 more clearance than the stock cover, right there at the widest point of the tire. I seem to remember even stock 3.5x10 tires rubbing on the stock clutch cover, however slightly. I wish they didn't do that.

Absolutely not needed. Ports must be bit rough.

Thanks Roland! Didn't know if I was overdoing it.

So, a thirsty beast...

that should read 45-55 miles to the gallon.

it's purely a guess on my end, i never calculated it and never cared to.