
Getting her back together

Engine Back In
Motor Work:
a. Full strip down!
b. All seals and bearings (FW side – Oil Gallery blocked up and off set, Clutch side – damaged from Cush Gear Plate)
c. Cush kit (springs and plates)
d. Cruciform
e. New Carby
Modifications:1. Machined cases where previously repaired (poor gauging of material to match cases - nice and smooth now)
2. Replacement of all cylinder studs (suspicious threads)
3. Drilled out bearing oil galleries (incorrectly blocked in previous repair - sure to fail eventually)
4. Dremel the seal seats flat internal and external (previous repair had left material that off-set seal seating - nice and flat now)
5. Machined cylinder bead flat (poor fit when cases were matched, needed excess gasket material to work. Also – heaps of ‘crap’ to help seal the ill fitted seal)
6. Machined cylinder head- piston not clear of head (piston would hit head, it had two thin gasket plates to compensate, now fitted without the two gasket - piston is clear of head)
7. Clutch nuts replaces (had normal nuts, not castellated with basket and butchered to remove original nut)
8. FW nut replaced (poor blunt nut replaced)
9. Main drive gear - nuts & retention washer replaced
10. 98mm engine stud added (missing, the long one next to swing arm - bodgey engine stud with nuts used)
11. 14 new X 11mm nuts and stainless steel washers / lock washers and heaps of other crap screws/nuts and bolts
12. Added correctly fitting shim washer on rear axle (leaked and had 3mm play, now nice and tight - and dry!)
Other:
13. All brakes
14. All cables
15. All cable adjusters (most missing or broken)
16. Repaired gear cable control plate / cable holder (had been welded and would not accept correct cable butt end - drilled to correct size, filed clean)
17. Rebuilt brake switch (clean, unbend and solder - removed masking tape)
18. Added cable crimps to all junction box cabling (wire twisted around terminals)
19. Added light to Speedo
20. Front light holder repaired (missing clips, bad connectors and just plain bad)
21. Bulb holder rear light repaired (bad connectors, bare wires and just plain bad)
22. New lights all round
23. Replaced head stem bearings (front end would shudder under braking - now nice and tight)
24. Added mirror
25. Wired in indicators and added switch (poorly added - now works fine, not sure I will keep these on)
26. All wiring joins now soldered, shrink warped or crimped
27. Rebuilt stator plate (Replaced bad wiring)
28. Fitted luggage/tire rack correctly
29. Fitted petrol cap rubber seals
30. Fitted FW points dust cover (Kidney shaped rubber on FW fan cover)
31. Fitted rear shocker (nuts under rear seat had com off!)
32. Renewed control lever bolts (old ones just crap)
33. Added cotter pins to brakes (nails used)
34. Added cotter pins to rear/front axles (nails used)
35. Refit luggage rack
36. Condenser
37. HT Coil
38. Points
39. Set timing
40. Educated myself about all things Zen and Vespa.......
ALL Done – NICE !!
Fingers crossed – starts first kick now, let’s see how reliable she is now.