DIY Network

Vespa Assembly: Front End Disassembled From "Classic Rides" episode DCLR-110

Figure A

In the last segment host Kevin Tetz and Greg West, a scooter-restoration expert, stripped the project '74 Vespa Sprint Veloce and removed the engine, but they are only at the half-way point of disassembling the scooter. In this final segment the front end is tackled.

Continuing the Disassembly

Before you get started, be sure to check the headset of your scooter. The one on the project Vespa is a well-designed unit because Enrico Piaggio wanted this particular scooter to be easy to operate even for the novice rider. All the controls -- gear selector, horn, signal lights -- are within reach and hand operated (figure A).

Note: The leg shields were created to protect the rider from all the elements, and Piaggio wanted them to be different than what's on a motorcycle -- and more like a car.

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	Figure B
	Figure C
	Figure D
	Figure E

• To disassemble the headset, first remove the speedometer. Feed the cable up through the headset to get it loose. Next, detach the speedometer from the cable and remove it.

  Tip: As before, be sure to label the wiring for future reinstallation.

• Once the wires are labeled, it's time to remove the first steering tube. Simply remove the clip (figure B) and the tube should slide out.

• Repeat the same process on the left side of the scooter and remove the other steering tube.

• Loosen the wires and to remove the harness, disconnect it from all points on the scooter. The junction is connected to the taillight, engine, brake switch, headset switches, horn and headlight. Be sure to check the harness for wear and tear.

• With all the wires loosened, it's time to remove the headset. Go ahead and put some penetrating oil on the bolt, which will help prevent corroding down the road. Using a 13mm wrench, loosen the bolt on the backside of the headset -- and remove the bolt (figure C).

• Remove the headset by giving it some gentle pressure upward, working it back and forth. Then work the cables and wires back through the open space in the headset.

• Next you want to remove the front-fork assembly, which looks similar to aircraft landing gear, which may not be such a surprise since Piaggio originally designed and manufactured aircraft. The design included a single-link suspension (figure D), which is extremely efficient. It also leaves the wheel unobstructed for easy removal.

• Begin disassembly by unscrewing the lock nut on the fork tube. Next remove the tension nut and the fork assembly is ready to be removed. Lower the back of the scooter and the steering tube should slide right out.

  Note: Not only is the bodywork attached to the project Vespa, but also the suspension and bearing, the hub, the brake assembly -- all in one removable unit. Talk about amazing construction!

  Part of the restoration plan for the project scooter will include new brakes and shocks for the front-fork assembly, along with a new set of floor rails.

• Now it's time to get started on the floor rails. Drill the rivets out, pull the rubber floor panel strips off, remove the old floor panels, take off the sky hook and pedal -- and remove the control cables.

In this first of four "Vespa Restoration" episodes, Kevin and Greg have managed to take off the body work, remove the entire engine and suspension assembly from the rear, remove the whole front fork assembly with the body work -- and finally the headset and electrical wiring, which has practically stripped down the scooter to nothing (figure E).

In the next episode Kevin begins the body work on the '74 Vespa Sprint Veloce, including some great painting techniques.

RESOURCES :

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

Vespa Restoration Parts (Scomo)
Scomo
Website: www.scomo.net

Air Compressor (Bend-Pak)
Bend-Pak, Inc.
Website: www.bendpak.com

Stock Photos, Videos, CD Rom and Timesurfer (Piaggio)
Piaggio, USA, Inc.
Website: www.piaggio.com/

Vespa Stock Photographs
The National Archives and Records Administration
Website: www.archives.gov

GUESTS :

Greg West
Scooter Restoration Expert
E-mail: wheelsX2@yahoo.com