Fixing Luigi, Day 2

If talking about scooter maintenance bores you, skip down to the pictures.

Today, Matt and I aimed to split the case, blowtorch old clutch-side and flywheel-side bearing out and new ones in, swap out the full set of transmission clutch plates, replaces all the seals and gaskets, piston rings, front brakes and some other miscellaneous things.  

I have learned that when dealing with a vintage scooter that is (literally) older than you are, things never go to plan. 

What didn't go to plan:

1.

It turns out that the original seize was NOT caused by the bearings (we think).  Once we split the case, we found the clutch-side oil seal had a large piece missing.  A big piece fell out of the case and was probably lodged in the bearings, causing them to catch.  The remaining missing pieces are probably what got into the cylinder in the first place, caused the seize and some (very minor) scoring on the piston.  So - we decided not to swap out the bearing.

2. 

While trying to replace the clutch-side oil seal that had busted, the new one got damaged during install.  Effectively, this stalls everything until that part arrives next week.  Lame.

3. 

With the engine dismantled, we found that the rear brake pads looked almost new - so they didn't need replaced and just needed cable adjustments.  When we opened up the front brakes (which recently had been almost useless) we found they too were in almost perfect shape.  So, we adjusted cables.  Looks like I will have some brake shoes to return to scooterworks.

What went right:

1.

We replaced the cruciform.  This is a problem Luigi has had since day 1.  VERY rough shifting, which we had always assumed was due to a worn out cruciform.  When, last year, it started to literally slip out of gear while driving and then popping back in - we were certain it was shot.  Sure enough, it was VERY worn.  So - new one is in and that should make things run smoother.

2.

Got some random seals replaced.

3. 

Replaced piston rings.  This took a whole of 20 seconds, but I did manage to cut my thumb.

4. 

Used carb cleaner to cleaner the engine.  WOW.  That stuff is amazing.  Just don't get it into cuts - it hurts.

So, now we have to wait until next week and hopefully can finish up.  If Matt can get this thing back together (necessary) and running again (optional, but fingers crossed) I will owe him some HUGE favors.

Fly wheel shrowd, rear hub, clutch, etc...

Gears=cool

 Dirty, but surprisingly not worn rear brake shoes

Stator 

 Poor Mr. Piston.  He misses Mrs. Cylinder.  They have been apart for this long since they got married.