Headset Control Roll Pins Help Needed

[phil23fair]

I'm in the process of restoring a GP and have come to reassembling the headset controls. I have got all new control rods, roll pins and nylon bushes bought from a reputable supplier who deals in mainly SIL parts, so everything should fit.
My problem is getting the roll pins in. I have started by trying to fit a shaft end bush to the control rod. The roll pin goes through the bush with a few light taps of a hammer but is so tight it won't go through the rod. At least I don't think it would without a great deal more force than I am prepared to give it. Even if I got the shaft end bushes fitted I don't see how the throttle and gear wheel can be fitted without risking damage to at the least my new paint or at the worst the headset itself because these have to be done in situ. Stickys manual does not give a lot of advice on fitting these pins except to say they are press in. Do they need to be fitted with a special tool? Any advice on how to get the control rods assembled without any damage greatfully received.
Phil

[storkfoot]

Sounds like holes in your bushes are 5mm (Indian spec) and the holes in the rods are 4mm (Italian spec). You're not the first person who's had this problem, believe me

[Weston-scooterist]

Mine tapped in nice and snugly, however after a few hundred miles the throttle one worked its way out, I used a machine screw and nyloc instead, no problem since.

[phil23fair]

Storkfoot,
Thanks for the reply but no, the holes are both 4mm, I've just checked with a drill bit, a 4mm bit will go through both but a 4.5mm won't. The roll pin verniers at 4.5mm

[phil23fair]

Mine tapped in nice and snugly, however after a few hundred miles the throttle one worked its way out, I used a machine screw and nyloc instead, no problem since.

Do you mean you pinned the shaft end bushes and screwed and nylocked the throttle and gear wheels?

[storkfoot]

Storkfoot,
Thanks for the reply but no, the holes are both 4mm, I've just checked with a drill bit, a 4mm bit will go through both but a 4.5mm won't. The roll pin verniers at 4.5mm

In which case, just pinch the end of the roll pin in a vice, and knock it in. They are, deliberately, a tight interference fit

[phil23fair]

In the end I have fitted the roll pins throught the shaft bushes and used alloy gear and throttle rollers. I have drilled and tapped the holes in the end of the control rods for the gear and throttle rollers M5 and drilled the holes in the gear and throttle rollers M5. I have used an M5 socket screw with a spring washer to attach the roller to the control rod (the socket screw has the last bit of the shank under the head unthreaded).The result is I now have a system similar to earlier series 3 Lambrettas where I can remove the rollers and withdraw the control rods should I need to easily.