DIY Network

Vespa Assembly: Engine Removal From "Classic Rides" episode DCLR-110

Now that you know the history of the project 1974 Vespa Sprint Veloce and it's been inspected by host Kevin Tetz and Greg West, a Vespa restoration expert, it's time to get deep into the project by disassembling the scooter so the engine can be inspected as well as mapping out the wiring diagrams.

Getting Started

• Lay out the tools first, which include metric tools since the project scooter is European. Be sure to have a flywheel puller, spark-plug wrench and fuel tap-removal tool (figure A), which is made to get down in the fuel tank to get the nut loose so you can get it out and to replace.

  Note: Vespa specific tools can be purchased from scooter dealers.

• Grab some baggies and have a pen so you can label the parts so you won't lose track of any of the fasteners.

• To remove the seat, lift it up from the frame to access the bolts (figure B). A ratchet wrench makes it easy to remove the fasteners.

Figure A

Figure B

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	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

• To drain the fuel, start by placing a pan under the scooter, and one end of the tube goes into the fuel tank and the other into the catch basin, which should be at a lower height than the tank. To start the flow of gas, pump air (figure C) so the liquid is pushed into the tube by the difference in pressure. Squeeze the siphon bulb, creating the vacuum that starts the siphoning process. Gravity will take it from there.

  Note: Fuel capacity for the project scooter is approximately 1-1/2 gallons.

• With the fuel tank drained it's time to remove the tank. Start by removing the attached gaskets (located on the oil-level site glass) so the parts connected to the gas tank can slide with minimal obstruction. Lift the tank out of the scooter frame from the back, which allows the fuel rod to slide of the frame easily.

• With the tank free, remove the fuel line using a flat screwdriver, and then detach the oil line. The tank can be removed now.

• Next, start on the side cowl (figure D) and get it out of the way so you'll have more access to the engine. To remove the left-side cowl, loosen and remove the fasteners and take the hinged door off. Then remove the fasteners inside the cowl that hold it to the frame.

• Remove the exhaust, which for the project scooter will be replaced with an upgrade: a Sito exhaust, which will give the scooter increased power and better acceleration at top speed. With the exhaust removed, the engine will be lightened a bit, which will make it easier to remove. To remove the old-style exhaust remove the 13mm nut at the barrel stub and the 14mm nut through the swing arm. You might have to deflate the tire to remove the swing arm.

• Remove the muffler clamp.

• With a Phillips-head screwdriver, disconnect the battery, and then get started on the control cables on the engine. Unscrew the bolts that hold the battery to the frame (figure E). Unlatch the battery tie-down strap and remove the battery.

• For access to the choke, throttle cable and fuel line, remove the air filter cover and the filter. Using needle-nose pliers detach the wire clips that hold the choke and throttle cables in place. Pull the fuel line through the bottom of the carburetor and leave it in the scooter.

  Tip: At this point you'll want to take some notes of how the scooter is wired. Yellow wires to yellow. Purple and red wire to green. Black to black. And the white wire is marked with a "V" -- all of this documentation will help with the reinstallation.

• With the wiring diagram mapped out, unhook the junction box wires, and detach the gear-selector cables.

  Note: The junction box (figure F) is where the wiring harness connects to the engine's electrical system.

• Move down to the selector box, use needle-nose pliers and a wrench to loosen the bolts that hold the cables in place. Then detach the cables from the selector box and pull them away from the motor.

• Move down again and get the rear brake-cable loose and pull it out.

• All that's left is the clutch cable. To remove the cable, start by taking off the bolt. This will allow the cable (figure G) to be removed from the operating arm.

• With all the cabling and wiring loose, you're ready to drop the engine.

• Unhook the rear suspension and bring the engine out. To remove the engine, use a socket wrench to remove the pivot bolt. Tap the bolt with a hammer and pull it out. Then remove the engine bolt, which will allow you to remove the engine from the scooter body.

  Note: A motorcycle lift with a platform makes the engine removal process much easier.

In the final segment of this first of four episodes, Kevin and Greg will continue to strip down the Vespa.

RESOURCES :

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

Vespa Restoration Parts (Scomo)
Scomo
Website: www.scomo.net

Air Compressor (Bend-Pak)
Bend-Pak, Inc.
Website: www.bendpak.com

Stock Photos, Videos, CD Rom and Timesurfer (Piaggio)
Piaggio, USA, Inc.
Website: www.piaggio.com/

Vespa Stock Photographs
The National Archives and Records Administration
Website: www.archives.gov

GUESTS :

Greg West
Scooter Restoration Expert
E-mail: wheelsX2@yahoo.com