I’m Rebuilding My Vespa P200E All By Myself… Part 4
Whoever worked on this Vespa before me should buy new tools. Seriously, every nut, bolt, screw was stripped. This took lots of creativity (and a whole bottle of penetrating oil) to disassemble. I was bracing tools with my feet, using two breaker bars at a time, cutting new slots in screw-heads by hand… every freed fastener was a triumph.
Because I knew I was going to get confused, I put the pieces to each system or big part in a separate little aluminum tray. Airbox parts here, stator screws there, electrical pieces in another one. I’m pretty pleased with myself for coming up with that. I also zip-tied parts and fasteners together to keep them organized and in order. Took pictures of a few things hoping that would help later. Because who would remember that the purple wire goes to the red wire? Also, was purple wire on sale and they were out of red wire? Because who mixes up colors like that?
I did get help on one part. The clutch nut is castellated (basically it has a weird top on in that needs a special tool). The clutch also rotates, so:
moves around + special tool + worn-out nut + on there pretty good = impact wrench
I didn’t have one of those. Tim from Trophy Motorcycles. was nice enough to free this up for me.