Modern Vespa

I have a 2024 GTS Super 300 Tech, on which I decided to install some Dr. Pulley sliders (13g). In order to crank on the variator pulley, I purchased the Buzzetti variator tool from Scooter West. I didn't need the tool to get the nut off, but it was pretty important when trying to get the right torque when putting it back on.

The problem is, the Buzzetti tool doesn't seem to fit flushly inside the fan fins on the HPE outer pulley half. No matter the orientation, the butt of the handle would impinge on a fan fin. Because of this, the handle juts off at a slight angle, one that causes a problem when trying to align and secure the included bolt to the transmission housing (and yes, I made sure the belt was loose and not interfering). With the angle, the bolt doesn't even reach to the hole. Check out the attached images to see what I mean.

I ordered a replacement Buzzetti tool from Scooter West in case it was a flaw in the tool, but the new tool sits the same. I also ordered a new HPE outer pulley half which just arrived from Italy on backorder, and the tool doesn't sit flushly in this one either.

Has anyone else experienced this same problem? Could it be that the non-HPE outer pulley half has slightly different inner dimensions inside the fins, but with the HPE outer pulley half, the tool is not actually a proper fit (it appears to have originally been designed for the non-HPE pulley half)?

In the end, I was able to get the torque I needed with the clever application of a PVC pipe and the ground to act as a long arm on the tool, but it's not a great or reliable solution (probably need to get a metal pipe if I do this again, or shell out for the factory tool).

So far, I've been happy with the Dr. Pulley 13g sliders. I'll be monitoring over the next few months for belt and oil pan gasket wear, and will let you know if I see anything.

Why not grind off a bit of the tool handle where it's welded to the 'ring'? Just a slot to accommodate the fin.

I probably can. While I have a number of tools for wrenching on the Vespa, the one thing I haven't gotten is an angle grinder. Nonetheless, they're a dime a dozen at Harbor Freight, so modifying the tool is certainly an option. I just expected the tool to come without requiring custom modification (or additional tools to adjust the tool).

I also figure that if this is a general thing, then having a post here helps point people to solutions (like yours) and this becomes a known thing, hopefully ahead of time.

Use a Dremel (or the HF equivalent!) - much more versatile than a larger angle grinder except for much larger metalwork jobs.

https://www.harborfreight.com/search?q=rotary%20tools

I had to grind on the tool as well to get it to fit. No idea why SW doesn't just have them made differently to accommodate but whatever.

It's something you only have to do once at least. Then it works fine forever.

I've had Buzzetti tools for early 125s and later 300s - both had to be modified slightly to fit, either by lengthening a mounting hole or grinding a smidgen off here and there.

Why they don't make them fit in the first place seems very strange.

where is the long space that came with the tool?

it goes between the tool and the engine case then your long bolt that came with the tool goes thru the tool into the spacer and then threaded into the engine case. this is the way the tool stays in place so you can use the proper sockets to tighten or loosen the nut.

I have the spacer; it came with both of the tools. I didn't show it in the photo because the purpose of that photo was to show how far the bolt reaches, and the spacer doesn't change the length of the bolt. If it were possible to have attached the bolt, then yes, I would have used the spacer to ensure appropriate leveling and to secure the tool.

Where in Colorado are you? If you are anywhere near Central Denver, I'll hook you up.

Northwest Denver metro area, but a frequent visitor to the dealership in your profile picture. In fact, the Vespa is there right now waiting for warranty parts to arrive for a malformed water pump cover that was spraying coolant around.

Yikes!

I got the buzzetti at AF1 earlier in the year. Tried it last month or two, could only get one end or the other to line up. Rode out to AF1, luckily they drilled out the hole in an oval shape for me. I'm 500 miles short of 10000 on this 2021 belt. Wondering if I should push it to 15000 miles.

edit: i ended up grinding the back side. more like file since i dont have a grinding tool.

Nobody wants to hear about boring "Hey I changed my belt today" stories but we love "Belt broke on the interstate at night, in the rain" stories. I say try for 20,000 miles.

You're starting to push your luck with that belt. I would advise you to change it very soon. Or you'll end up pushing the scoot

Isn't that half the fun, hours in the shed fettling your aftermarket scooter component to make it fit.

but I like seeing pics of folks digging out the shredded belts. It'll be alright for them. they get all their moneys worth out if it that way.

i ended up changing the belt at 9943 miles. had a crack in it as shown the manual. gotta find a manual in english however.

manuals at https://manuals.wotmeworry.org.uk/Vespa/

thanks. finally connected the dots. had a rough time deciphering German.