restoring a gilly (gliera) runner 180 sp 1999

[ottootto]

after race on the end of `90/early new millenum on malossi runner cup (europe)


runner cup  ended , cause polluttion law forced gilera to renew the model with 4 stroke engine 
at that time i was also racing in 600 class  , due money situation had to sell all my 3 runner

a little bit of story for how is interested
gilera runner  180 two stroke is famous for:

special frame , without torsion problem (like most of the scooters)

tank is on the middle of the frame , and it s a good quality for center/lower the weight

also the same tank position, just 2 weeks ago  ,in italy was imputed (on court) for broken in case of crash and lost fuel
than piaggio may have to call back /modify 160.000 unit   (but in europe runner are a LOT , just think on 2011 was first place for bike stolen in uk)
here more info (for who want) :click me



engine with 21 hp on original configuration (but a well tuned 200 can be near 40 hp)




it s the favorite on dragster area (some tuner also use to build a twin with those parts)

www.youtube.com/watch?v=fGFZ2t3ZW1Y


and in fact with the same engine italjet built "italjet dragster" (may look a prototype , but is not , was sell between 1999 and 2003)







so when on 2012 i move back in germany  decide to buy some scooters just for hobby/fun

so i found this piece of crap

 for 1475 $ near my town (130 miles)


was original an sp 180 blue and black


the day i went to pick up , and drive home (with test plate) even broken down in the highway
cause the prev owner forgot to tight screw of the muffler and header  broken
not a good start....
was september 2012

18640$ ago....

[ottootto]

most common issue for this scooter are
front fork filled with grease , yes sir grease not oil
after 200 km they bounce like hell , and you can image at 90 mph ...
rear schock...
subframe/sylentblock sistem for vibration reduction on subframe between egine and frame, also this solution let the engine move and after few km ....


first step: special subframe with bearing and special silentblock in vulkollan (45 shra)

[90GTVert]

Interesting stuff. Thanks for taking the time to post it. Cool racing shot too.

[ottootto]

so i broken down on the highway
that s how at 4:00 am my runner arrive at home



than was to time to trow away most of it
and i start to buy/order "ALL"
and when i say all

i mean all.... " style="font-size:10pt;max-width:100%;"] 

here a list 

new parts:

1 cockpit koso

1 navi garmin zumo 550

1 kit malossi

1 kit pm tuning pro street 2

1 kit pm tuning pro street 1

1 kit ngf

2 crankshaft malossi mod for 55 mm stroke 110 rod

1 crankshaft bgm mod for 56 mm stroke 110 rod

8 crank bearing skf

8 polini crankshaft sealing 

2 water pump

1 vario polini

1 malossi delta

1 clutuh bell polini

2 clutch bell pm tuning

1 complete rear pulley assemble

1 cover final trans

1 set of oem 180 gears

1 set bearing and sealing for final trans

8 subframe teflon bush

1 silent 45 shra 

2 silent engine

1 silent rear shock

2 tire raceman schwalbe

2 bearing front wheel

1 front wheel axle

1 fork malossi f 32s

1 fork vespa gt 300

1 brake disc 250 newfren spacer and brake pads

1 brake disk 250 purte1

1 spacer for radial caliper stage 6 on fork vx-vxr

1 spacer for radial caliper stage 6 on malossi f32s

2 radial caliper stage6

1 rear brake pad set

2 red aero brake line(spiegler)

1 red sponge malossi runner 180

2 airbox runner 180

1 red sponge malossi runner 50

1 airbox doppler runner 50

1 reeds valve polini evo 

1 reeds valve vforce tassinari

1 reeds valve v force stage 6 +carbon fiber reeds

1 reeds boyesen double system

1 reeds valve old big polini

1 reeds valve vl 16

15 gaskset reeds valve

6 mm delli jet from 72 to 122

1 Variator rollers polini 14 gr

1 Variator rollers polini 14.6 gr

1 Variator rollers polini 15 gr

12 set malossi 20x17  rolls

1 malossi phvb 22

1 malossi phbl 25

1 exhaust oem no kat

1 exhaust scorpion 

1 sip header 34 mm stainless

1 cable and spark plug connector ngk

3 tacho cable....

1 series clutch spings malossi

1 intake mainfold oem

1 straight intake mainfold malossi

1 360 intake mainfold malossi

all lamps

2 rear mirrors

1 battery yuasa

1 air filter tube airbox-frame

1 air filter tube lamby (for use with straight mainfold)

10 fairing screws

10 spring plate fairing

5 spring plate m6

5 screw m6 fairing

1 oem contrast sping

1 oem vario v belt

1 hand grip right

1 hand grip left

1 pump belt

5 screw (m6x60)

5 screw (m6x35)

1 rear center cover

1 front center cover

1 front turn signal vxr right

1 front turn signal vxr left

1 rear handlebar cover

1 temp sensor

1 rubber gaskset belt carter cover

1 inf foot rest right

1 inf foot rest left

1 fuel filler flap

1 complete vxr rear light

10 fairings screw

1 rear plate holder /mudguard

1 front shock rs 24

1 rear shock de carbon

1 rear shock bitubo

2 rear shock rs 24

2 series head steering bearing

1 series Dust protection + oil seal vx-vxr fork

1 front air intake right 

1 front air intake left 

1 rubber under fuel cap

1 rubber under oil cap

1 switch light

trans oil , liquid cooling , brake fluid

20 liter oli motul 710

all tools i need (buzzetti)

used stuff:

1 cockpit koso with 4468 km

1 seat purejet2004

1 sebac fork gold cap

1 v belt trans cover

1 airbox runner 180

1 rear right fairing runner 125 sp black

1 front left fairing runner 180 black

1 front wheel

1 rear wheel

1 rear wheel vxr

1 fron mudguard vespa lx

1 mudguard runner 50

1 crankcase with trans from 180 disc 

1 cranckase with trans 180 rolling nut

1 cranckase with trans 125 rolling nut

1 cranckase complete tph 125 rolling nut

1 stage6 mina am6 intake mainfold
and other 3 complete engine

if i remeber all well

and  JUST few random pictures


polini vario and malossi spring for malossi delta clutch


koso dashboard (with rev conter)


all inner fairing /screw and other oem parts

[ottootto]

[aeroxbud]

I love your builds Otto
Those gilly forks are a real known weak point in the handling
Lots of people have trouble with play in the silent block

[Aaron420e]

Holy crap... that is a ton of parts. Did you just hit the lottery?

[ottootto]

was really in bad shape...

random pictures
nice rear pulley.... aka how to destroy your belt in bunch of km



but i had no dubt about mental condition of prev owner (with a nice "hitler motorrad" sticker fit on the dashboard....)
as you can see mental was able to detroy it in less than 10000 km (6215 miles)


after cleaning


 start with restoring plan
(frame was clean , and wiring rewrap and fix)
here a little slideshow of the condition between 21 of september and 18 of dicember

[ottootto]

sort to find a new left front fairing in oem black

new 28 mm dellorto carb/malossi 35x30 mainfold
new complete rear gear
out of 180
125 with secondary malossi
180 with primary polini
180 with secondary malossi
few set of rolls
few belts
a new clutch bell

and a nice jim lomas ltd edition pipe in stainless steel


i m also waiting few other parts for fr4 vario so i can go on with test

[aeroxbud]

That is one nice pipe. I wish there were more stainless steel pipes for scooters

[ottootto]

j.l. exhaust


28 phbh dellorto

[90GTVert]

Love the exhaust. That pipe is badass.

[ottootto]

[aeroxbud]

Those stage 6 over size disc and radial caliper are so nice. But so expensive

[ottootto]

cnc support for polini reeds , with 28 mm mainfold for minarelli am6