Lambretta Engine Rebuild Part 5

Ready to fit

In all its glory

Newfren shoes

Well that's the engine done. Not pictured is the hub, unfortunately the original serveta one had been taken off and replaced with a completely nackerd one before I bought the scooter, apparently the genuine serveta one's are the best there is so it's no surprise it vanished. The best I found was made by uni but be careful there are a lot of dodgy hubs out there that can let go at any time.

Lambretta Engine Rebuild Part 4

Af kit, bgm 120w stator and lightened gp flywheel fitted

timing marks made

Dial gauge to find tdc

Asso Piston 

Something I noticed when matching the base gasket to the barrel was that a standard gasket isn't up to the job, so after looking around I found that scooter restorations listed thicker better fitting ones for the sr kit's. After fitting the barrel I used a dial gauge to find tdc and a timing disc to set up the timing as described in stickys book (This book is the first thing you should buy if you are planning on building a Lambretta) One more thing I think you should buy for any top end build you are doing are longer barrel studs. The ones I used were from mb development's, they are tapped further on both sides so they go all the way in to the casings and you still have ample on top

AF Rayspeed 175

Fiber gasket matched to port

Freshly honed

The casing were matched to barrel

Looking up the inlet port

skimmed head

This is a great kit. They start out as a scooter restoration Indian sourced kit which has a much superior asso werke piston supplied, and finally the factory stage 4 tuning is improved and polished.

Lambretta Engine Rebuild Part 3

This took a good few hours polishing 

All oiled up and ready to go

Home made tools doing there job

This is the way i soak clutch plates

When it comes to soaking clutch plates I have found it easier and cleaner to put them in a sealable food bag with a bit of oil and leave them for a couple of day's. It would have been easier to buy or even borrow all the services tools that were required but I thought I'd give making them myself a go

Lambretta Engine Rebuild Part 2

I had all intentions to use a 16 tooth front sprocket  

ScootRS chain tensioners were fitted 

The clutch spider was welded

With the gearbox in it was time to fit the clutch housing, chain, tensioners and front sprocket. The original plan was to fit a 16 tooth front sprocket but when I tried to fit the original 80 link chain that I thought must have stretched enough over It came apparent I was wrong, so on went the 15 tooth instead. The thing is that turned out to be the right decision in retrospect as I'm not the 11 stone lad I was age 17 and the engine is setup to be much higher revving so if I had got it to fit I now believe it would have made the scooter slower

A long time coming

Wow time fly's, it's been to long since I did an update. Well the lambretta has been finished and on the road for 10 months so it's about time to get on and do this blog. So I shall endeavour to get my arse in to gear over the next few months and catch up

Lambretta Engine Rebuild Part 1

I will not go into depth telling you how to build a lambretta engine because i no more about vespa engines, so all i did was use (Sticky's Book on Lambrettas) and asked for help from my friends anyway. As i was going to replace the crank it was decided that i would use a GP one as it means i can use a stonger GP flywheel, this was fitted with F.A.G bearings and good quality seals. I have been very lucky with the gear box as it was fitted with an italian ratio one and not the usual spanish one that have a bad third to fourth difference, again new bearings and seals were fitted

More Things Painted

The hub was stripped then blasted before painting then new bearing, seals and shoes were fitted. The brake lever is away with some other parts at the the chrome platers. The tank and other stuff were also blasted before painting

Lambretta Forks And Dampers

Right the plan was easy it was buy a Escort damper kit off ebay and weld on the top brackets, beadblast the lot and paint and put all the bits back together. So i striped the forks and waited for the kit . What a disapointment, when it did arrive the dampers chrome was crap and starting to go rusty, the welding looks bad and worse they had different damping from side to side. Anyway i did use the top brackets and paint them all up. The internals were in very good nick so they were just cleaned up and put back in with new bumper stops and new chrome bolts and cable guide. I have ordered some scootrs s.steel dampers

Sand And Fill

All the body panels have been sand blasted or beed blasted and welded up. The legshealds were in a bit of a state around the bottom edge so i have decided to use a stainless steel trim to add strength plus it also looks nice. I then panel beated all the dents out and skimmed them with filler

About Time

Its been a long time but i have eventually got on with updating this blog. I have been working on it inbetween the other stuff like the frogeye sprite, and the rally frame ( Pixs on my other blog see listing on side bar). I shall now try to catch up. The frame and body parts have all been sand blasted, there was a bit of rot on the hoop of the frame that we brazed up. The ignition key hole was also welded up as i do not like the keys on the side. This scooter may not be to the liking of the puritans as i will be making lots of small modifications

Old Skool Stage 4 175

I have been buying lots of new parts for the engine. The plan is to build the most reliable but a little faster block that i can afford. I did think of buying a new indian 200 engine but as the cheepst one that i could find was £650 and they probably need rebuilding and i'm not a good saver there for i went this way.Engine Spec:

Electronics: BGM 120watt stator with lightened indian shortfin GP flywheel and ducati cdi
Crank: Mazzucchelli GP taper 58mm
Bearins & Seals: Fag+INA with GP flywheel side. Rolf seals and a new mag housing
Gearbox: Italian Li 150
Clutch: ScootRS 46 lightened bell sprocket with surflex plates
Chain & Sprocket: 80 link with ever 15 or 16 front (Not sure yet) and ScootRS chain guides
Cylinder: AF Rayspeed ali stage 4 175 ports polished with asso piston
Carburettor: Dellorto phbh 28mm (not shown)
Exhaust: ScootRS stainless steel
I just have to get a couple of small bits and then i can bulid it!

Casings

The casings have now been cleaned and inspected, one of the barrel stud threads had gone which has been helycoiled. I have also found a snapped stud which holds the mag housing on luckily i managed to get it out without damaging the thread. One of the things i have noticed is that the casings were fitted with Russian bearings, seems a bit odd maybe this is common on Spanish lambrettas, these will all be replaced anyhow along with a new mag housing as there is a crack running around the circlip slot.

Start And Stop

I should have got on with this blog ages ago but with the bad winter and the problems with my p2 its just not happend. O well this is where i am with the lammy
As you can see i have got on stripping her down and have also striped the engine ( sorry some of the pix are off my phone) . The idea that the scooter had only done a 1000k was wrong, more like 10.000k by the state of the engine so i have decided to replace a lot of it, also i have bust the headset trying to free up the gear shaft though this wasn't just my fault as there was already a crack on it