Scooterotica

Ok cheers, I will strip down the clutch and inspect the components. Basically, the clutch is stuck "off", so kick start engages and so do gears. But, no matter if I push on the lever direct or the handle bar lever does it disengage the gearbox.

What's the best way of preventing the woodruff key falling into the engine? Is it just a matter of removing the clutch slowly?

I am fairly clued up in lammy engines, but have no experience with vespa engines as I have had no problems with it.

To protect the woodruff key falling in the engine, a piece of white paper arced underneath the clutch. When you feel the clutch coming out just pull very carefully and slowly. The key should be ok, just be aware of it. I would not replace the key as it should be a very tight fit and normally doesnt wear down.
Over the winter months its worth starting the scooter as often as possible to keep the clutch basket well oiled and taking it for a run when ever you can, even if its just a couple of miles.

I rode it for a couple of weeks ago, but my attention has mainly my been with my lambretta.

Cheers for the suggestions. I will strip down and see what I find. Maybe the clutch problem has caused the excessive rattle?

not if its got a malossi 172 kit m8

When you do the clutch you will need a holding tool and a tool to undo the castellated nut. To avoid the key falling out turn the clutch so that the keyway is at 12 o'clock and use two long screwdrivers to lever the clutch off the crank slowly. You can either use a bolt and washers to compress the clutch or trap it in a vice to remove the circlip. Thoroughly examine all parts on the clutch, they can even split along the keyway boss .

I sorted it last night, plunger and pressure plate had come loose and were rattling around like mad. So put a new one on and touch wood it seems ok now...

That's strange, I've had a lot of things go wrong on my scooters, but never that. What happened to the clip, was it still there and in tact.

I couldnt find it, but, I have heard of people using silicone or glue to hold them in place... So maybe some one has doen that in the past?

I've never heard of that. I would drain my engine oil and check for any fragments of metal. If you have the magnetic type oil bolts it should crab some of the clip's debris. I'm not saying it won't be ok, but it may damage your internal seals, so best to remove the oil and hopefully the clip won't have done any damage.

I have already checked the oil and couldnt see any fragments or damage. I also tried fishing arounf with a magnet and could not find any debris or metallic particles...