Clutch, Cables and Carburetor

I got the new clutch plates in along with a new pressure plate, brass push and 2 new clutch inner cables. While soaking the cork plates in oil, I took out the clutch and took it apart. Then I worked on replacing cables and cable housings.

I first worked on the clutch cable, taking out the old inner and threading through a new inner. Then I took the new inner and threaded it through the new outer cable housing. I took the two loose ends and taped them together with electrical tape. Then up pulled the old cable out which pulled the new one in to place. The cable was tight in the headlight housing, so I used a screwdriver as a 2 toothed gear to help it along. Once the new cable was in place, I separated the 2 cables then threaded new clutch inner cable through the new housing the right direction and replaced the clutch lever.

Then I replaced the speedometer cable. The old cable was wrapped with electrical tape on the bottom half where it came out of the front fork. Speedometers run off a gear on the front wheel on the older Vespas. I could not use the same technique as the clutch cable since the speedo cable housings have threaded end caps that would not feed through the fork. So I removed the inner speedo cable from the housing, then fed a old clutch cable up through the old housing. Then I pulled the old housing out through the headset, leaving the inner cable in place. I threaded the new housing over the inner cable and put a cable stop on the end to keep the housing from sliding off. I pulled on the inner cable from the bottom, but it was being stubborn going through the hole in the fork. I pulled the housing back out, greased the end then pulled it through the hole using pliers for an extra grip on the inner cable. I removed the nipple, ring and gear from the front axle, put in a new brass gear, then cleaned, greased and replaced the ring and nipple. Then I fed the new speed cable through the housing and connected it on both ends. Hopefully that will take care of the bouncing speedo needle.

Next I replaced the front brake cable, housing and lever using the same technique as the clutch cable. Fortunately it fed through the frame and head light housing easier than the clutch cable housing.

I figured that 5 hours was long enough for the clutch corks to soak, I reassembled the clutch and put it back in. The woodruff key kept moving on me so I hit it with a punch a couple time to help snug it in to the slot on the crankshaft. Then the clutch went on ok, followed by the cover and the rear wheel. I then called it a day.

On Sunday, I started on adjusting the clutch cable and rear brake cable. On the test drive the clutch seemed to be working properly.

Next, I worked on finding the right main jets to use in the carburetor. I had a 93, 109, 110, 112 and 116. The 93 was already in the carb, the rest I bought in San Francisco. After much experimentation, the 109 and higher tended to flood the engine at higher rpms, but the 93 seems to run ok. Though this is probably too lean for the engine. So I ordered a range of main jets from 95 to 107 to experiment with when they arrive.

I cleaned up the scooter and the shop and then went home for the evening.