Rally 200 Clutch issues

[bazman]

Well done mate, just get the miles on her and enjoy

[storkfoot]

further more ,dont forget or overlook the fact that the cush drive springs may be shot

Update: Since I last posted the problem has never really gone away. I've done 2000 marvellous miles on her over the Winter (although I've put off going back in the clutch) but this issue is bugging me now

When I pull the clutch in, there's a very audible rattle from the clutch/gearbox area. The clutch doesn't always snatch but when you're pulling away from a standing start, and when your using the engine to brake, say, coming down from 3rd to 2nd, it often does.

From Sean's comment above, and the following Scooterhelp article, is it a reasonable assumption that it may well be the cush drive?

http://www.scooterhelp.com/tips/engine/ ... vespa.html

[paulnobodyimportant]

Storkfoot

Did you ever sort out your problem. I say this as I have put a fully working clutch from my P200 Malossi into a unused Rally 200 engine and get a fairly violent shudder when I let out the clutch. So much so that it is un-drive able. In addition, I have had to seriously adjust the clutch cable trunnion to have the clutch disengage when I fully pull the lever in and no play at the lever end, unlike a lambretta where we tend to leave a 1mm gap/play at the lever. Like you, I know Lambretta's back to front, but the Vespa engine is all new.

Firstly I'm wondering if there was indeed ever a washer spacer in place before I put on the complete clutch assembly. I say this as the original brass clutch center was all askew and the clutch had sheared the woodruff key.

Just for completeness, I did put in a new thrust washer.

Suppose I will have to take the clutch out and have a look and hope its not the cush drive

[storkfoot]

I have bought a genuine piaggio Cush drive kit as, other than this issue, the clutch works fine.

I use the scoot for work at the moment so it'll be later in the year before I drop the engine. Mine is rideable, if you can handle mini wheelspins, just annoying. Sorry, can't give you a definite answer, paul

[GLscoot]

I don't know why I have not been following this thread, but anyway, it sounds to me your basket may have gone. As in, it has spread open at the large cir clip end, very common on vespa clutches and generally over looked. You tend to buy new plates, corks, spacer washers, pressure plate and brass bush, still the problem is there.
I agree the oil cog spacer washers fit far better, tighter the better, than the other ones. Also check the thickness of these washers, unknown to me there are two thicknesses, probably more now. If your clutch is slightly off, its going to be a nightmare. Regarded the weakest point on a Vespa engine, hence the massive range of CNC clutches now. I would look into one of these, the one I have is brilliant.
gary

[storkfoot]

Thanks for that. I have tried the original basket with everything else new. That didn't work. The clutch in now is a complete new SIP one. Plates all separate fine. No slip and no drag. I have also tried 2 different spacer washers. Problem still persists, unfortunately.

Which clutch do you recommend, GLscoot?

[GLscoot]

Im currently using the sip 2 banded clutch with there pressure plate, fcking expensive around £200. You do need the P2 clutch cover or grind the two internal fins away as its a little larger than normal clutches. I do know the bgm clutch needs a spacer between the casing and clutch cover. There are other ones, but most of them are expensive. I will post the parts numbers on here later.
Have you had a look at the primary drive (xmas tree), there may be a knackered spring in there. Nightmare of a job but may be worth a look before any more cash is spent.
gary