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Post by lobarrett on Jun 25, 2014 0:07:44 GMT -5
MY STORY - Changing out a bad set of rollers.
My scooter is a 2000’ Vespa ET-2 with a 50cc Piaggio engine. I am strictly a rider and have very limited knowledge of how anything “scoot-wise” works. Over her 14 years she had always been well maintained by “scooter mechanics”.
Due to some economic changes in my world, I was forced to make a decision about my future as a “rider only”. One thing for sure was that if I wanted to ride, I would have to learn how to maintain her myself and if I was going to do the work on her, I would have to learn how it worked. Not a big deal – how complicated could a scooter be anyway?
She had about 5000 miles on her and was running good. So I decided to ride her until something broke.I rode her hard for a couple of months before I got my first opportunity to learn. My scooter’s performance was getting really bad and the little noise that was coming from the general area of the engine was getting much worst. At the time, I did not know what was wrong, but a “scooter buddy” told me that it sounded like the noise was coming from the front pulley – most likely a roller problem in my variator. And, it should be an easy fix.
A few days later, I took the cover off and disassembled the front pulley. I did not know for sure what a “good” roller should look like, but what I saw just did not look right. The variator was slotted for six rollers, but only had five. Of the five one round, the rest were oddly shaped. My “scooter buddy” told me that all I had to do was change the rollers and I would be back on the road.
I wasn’t going to be able to work on her right away so I had it strapped to a wooden pallet and put up on the second floor of my shop. That was about three years ago. During this time, the simple roller change grew to a CVT upgrade, then to a 70cc and exhaust change. As it stands right now, my ET-2 project has turned into a total rebuild project.
Now into the third year of my project, I have been able to actually do some work on my scooter. And, I have made some personal progress in my scooter knowledge base -thanks to the members of 49ccScoot.
I am almost to the point of being able to put some real physical effort into this project – so I thought it was time to start “MY BUILD THREAD”. I am hoping to complete the breakdown of the scooter by the end of this month.
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Post by lobarrett on Jun 25, 2014 0:09:54 GMT -5
MY BUILD PROJECT:
All of the following components are on hand waiting to be installed. I still have a lot of work to-do on the teardown – so I don’t really don’t know when I will start putting her back together.
Components:
1) Engine:
70cc Malossi Cylinder Kit (316926),
upgraded this to a Stage 6 Sport Pro MKII – maybe use the Malossi in a later project,
Top Racing Evolution NG Next Generation crankshaft (had a fitment issue),
upgraded to a Stage 6 HPC crank – maybe use the Top Racing crank in a later project,
Naraku HD crankshaft bearings w/oil seals,
hope the Naraku bearings and seals will work with the Stage 6 crank – will need to look at this
2) Exhaust:
Tecnigas Next R Exhaust,
this probably is not going to be a good choice for the Stage 6 Sport Pro but I am going to give it a try,
3) Fuel/Air:
Malossi/Dellorto PHVA 17.5 (727084),
Malossi Intake Manifold (0257338)
Top Performances V-force3 reed valve (22756),
Plan on using stock air box fitted with a Malossi red sponge air filter foam element (1411425)
4) Drive Train
4a) CVT:
Malossi Multivar 2000 w/ white contrast spring & 7.2 gr rollers (519019),
Upgrade with Malossi Yellow Torque (Contrast) Spring (297042Y0) ( order wrong one will need to reorder), and 3X Bike Equipment Variator rollers adjustment set 19x15.5mm (28337) range from 3.7g up to 11.2g in increments of 0.5g, tune for weight,
Malossi Delta Clutch w/ white spring (5214110,
Upgrade using Malossi Clutch Spring Sport Set (298746) start with green set for clutch engagement of 6500rpm,
Malossi Wing Clutch Bell (77 11207)
Malossi Torque Driver (61 9100),
Malossi Torque Spring Seat (2512828), and
Malossi Special Belt (6111246).
4b) Gearbox:
Polini Primary Gear Kit 13/40T #202.1378
Polini Secondary Gear Kit 16/47T #202-1402,
Polini Secondary Gear Kit 14/48T #202-1404 (most likely use this set of secondary gears in this build),
Polini Evolution Gearbox Cover #170-0300, and
Polini Wheel shaft #202-1410.
5) Tires & Rims
Tires mostlikely stay stock
Not much you can do with Piaggio rims maybe powder coat just not sure how that will stand up to tire changing – but working on it. I would like to increase the tire and rim size but think doing so would be nearly imposable -maybe something for a down the road project.
6) Flywheel/Stator
Most likely stay Stock. The stock unit has 6 coils, would like to go to 8 or 11 coils, but there would be a lot of fitment issues to deal with - might put it off to a later project.
7) Ignition - CDI, Ignition Switch, & Spark Plug
Piaggio uses a rev limited (10,000rpm) CDI so that will probably need to go
Plug will most likely change, but have not looked into this issue.
Everything else stock
8) Instrumentation - Gauges & Meters
Working on – just do not have a good solution yet
9) Electrical Wiring, Lights, Voltage Regulator, Solenoids & Switches
Working on
Had to get a new VR – the turn signals flasher is part of the VR in the stock configuration – I had wired around the issue earlier with a std Advanced Auto flasher to keep them working but wanted to go back to stock – will keep the old stuff – just in case the new VR burns out.
10) Frame, Body, Styling, Brake & Suspension
Working on
Most likely do a brake job and replace the front and rear springs. Install a low to med wind screen. And, replace some of the stock trim and lights – with stock components.
About the only thing I have purchased for the suspension is a Polini Torsen Swing Arm #172.0011. Probably going to have an issue with fitting my exhaust pipe around the Polini swing arm – Polini warns that it only works with the Polini exhaust. We will see.
I will post more on what I have done component wise in each group later – for now, I would like to show you some photo’s of my scooter. Wished I had some to show you before I started the teardown – but I don’t have any.
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Post by lobarrett on Jun 25, 2014 0:14:04 GMT -5
My beginning weekend (04/13).
I took my scooter off the wooden pallet that has been her home for the last two plus years and brought her in my shop. After some rigging and blocking, I hoisted her up on a Harbor Freights # 99887 Motorcycle hoist – and that where she is today.
Note: The Harbor Freight #99887 High Position Motorcycle Lift was a great addition to my equipment list. At less than $190.00 and discounted with a 25% off coupon it is a good deal. The straps that came with it sucked but I had a set of their normal straps that did the job.
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Post by lobarrett on Jun 25, 2014 0:21:04 GMT -5
I got back to work on my scooter. (02/14)
Pulled the engine and stripped some of the parts off the frame.
Pictures of the engine before cleaning:
I had removed the flywheel/stator, cylinder head, and gears while it was still on the lift and in the scooter.
So far, I have only stripped the hardware off rear portion and the front kick panels. I was hoping to have all of this done months ago – need to get the frame/body into a body shop. Going to have them strip off the old paint, take out the dents and give her a paint job - most likely Yellow and black or maybe orange and black.
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Post by lobarrett on Jun 25, 2014 0:26:18 GMT -5
There was a little rust under the front kick panel - probably more under the foot panels.
I got to stop and regroup – do some organizing.
When I post again to this thread, I will do a better job of organizing the photo’s, problems and issues.
Thank you for viewing,
Larry
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Post by 2TDave on Jun 25, 2014 5:51:13 GMT -5
Nice build. Glad you got the crank sorted out and are able to start working on her.
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Post by 90GTVert on Jun 25, 2014 6:05:31 GMT -5
When I post again to this thread, I will do a better job of organizing the photo’s, problems and issues. Hardly seems possible. Very well constructed posts. Looking forward to seeing what is better than this as well as the progress on your build. It's going to be one top notch scooter when complete from the parts/labor list and the attention to detail that you seem to have. |
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Post by lobarrett on Jun 25, 2014 21:41:47 GMT -5
Had a good day in the shop yesterday- the GOOD news is that my ET-2 has now been stripped down to just the frame/body. As you can see it is a pressed steel frame with a integral welded on body – think something like the old VW uni-body.
Guess it is a cheap way of putting a scooter together – only thing is living near salt water could be a problem. Since I am about a 100ft away from a large body saltwater – I though rust was going to be a major issue – lucky for me frame rust is not going to be that big of an issue.
The next step for the frame and body is to bring it over to the powder coaters. Hope to have it over there by this Saturday. They are going to sandblast the body inside and out. When they are done with the paint & rust stripping, it will come back to my shop and I will take it over to the body shop.
The guys at the body shop will repair the rusted areas – especially around the main support – they will also remove the dents and get it ready to go back to the powder coaters. Again at this point it will come back to my shop and I will take it back to the powder coaters.
The powder coaters are going to do the outside of the body and under frame. They will also do the inside of the engine area. Right now, the plan is to do the entire body inside and out in YELLOW. The wheel rims are going to be done in BLACK. When they are done, it will come back to my shop.
Once I get it back I will meet with the air brush guy and we will plan out the work he will do. Right now, he will air brush in shades (darker and lighter) of the body YELLOW. He will also be responsible for re-painting the plastic trim (black) and front fender (yellow). And, when he gets the air brushing done, he will clear coat everything.
Getting all of this done is going to be a logistic nightmare – lot of shops and different people. I have a close (anti-scoot) friend that owns a custom motorcycle shop that is going to handle getting all the people & work done on it. And, I will be able to control the process at each step so I feel comfortable with getting it done to my liking.
Anyway, that is where I am at with the body and frame. Now on to some things I can do myself.
I will POST the progress and the changes in the plan as this part of the project continues.
Thanks for viewing,
Larry
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Post by 2TDave on Jun 26, 2014 5:39:35 GMT -5
Nice progress. I could see where it would be nice to work with metal versus all the plastic.
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Post by lobarrett on Jun 26, 2014 14:23:15 GMT -5
Nice progress. I could see where it would be nice to work with metal versus all the plastic. I got my first scooter in the late 50's, it was an all steel Vespa. I was to young to drive it on the road, but I had fun running up and down alleys. Crashed it into a wall one day and my dad took it away. Don't remember what he did with it. Wished I had it now - but it is probably a pile of rust now.
So when I bought my second scooter it was a Vespa-I bought it to remember my childhood not because it was steel.
Got a Venus scooter - trashed it but saved the JOG engine. Picked up a 2005 CPI runner 50 without a title-striped it down. Saved the engine, some of the body panels, rims and the steel frame. Not sure what I am going to do with all the parts - most likely save the engine and trash the rest. All the body parts were plastic.
So my only riding experience has been on all steel scooters. Other than the salt/rust issues you have living near the ocean, I am OK with steel. Guess the main drawback is the weight. My ET-2 weighs in at 216 lbs. Add my body weight and you end up with a lot of mass or crap to push around with a little 50cc engine.
I think my next scooter is going to be a MadAss 125. It's about 209 lbs - look like the majority of it is steel. It looks like it would be fun to ride. And, I think the "fun to ride" is the big issue - which is better plastic or steel - is just something riders can disagree on.
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Post by 90GTVert on Jun 26, 2014 16:04:37 GMT -5
Nice "wishlist". I've wanted a MadAss since I first saw one online.
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Post by 2TDave on Jun 26, 2014 16:30:43 GMT -5
Me too!
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Post by vlatx on Jun 26, 2014 16:31:34 GMT -5
he MadAss can bee updated whit nice tuning parts  Here is one frome my friend   |
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Post by Sitticuss on Jun 26, 2014 17:53:47 GMT -5
I would want one also
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Post by scooterpimp on Jun 26, 2014 18:15:26 GMT -5
Madass , there I said it too! Cool , but they
cost quite a bit for what they are.
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Here is one frome my friend
