In this instance the customer has requested a 100% Piaggio Vespa P200 engine but with a variation on final gearing but with the rest of the engine to standard Piaggio specifications




This is a naked Italian made injection, electric start crank case from Piaggio.













The right hand case received genuine ROLF seals and OEM bearings.

All these elements are located with factory tooling but with the exception for extra protection the clutch side seal is seated on a high temp lock adhesive. Especially important if a performance kit is fitted but carried out automatically on all engines by E.B

The 65 tooth ‘input shaft’ or spring gear assy is prepared with the 21 needle rollers. This again is genuine Piaggio OEM equipment.



















At the same time the Left Hand case received its roller bearings, kick shaft quadrant and return spring.

The spring gear group is located and locked, then tested for normal operation




















Here is the view from the other side.

The output or ‘drive shaft’ has its cruciform & gear control rod installed, again in this instance 100% Piaggio OEM



















The twin circlip drive shaft is installed






















The 36 tooth final drive or fourth gear is installed and checked for position

The rest of the gear groups are positioned and the whole shaft ‘shimmed’ to tolerance.



At this stage visual conformation of correct meshing is carried out
















The starter cog is added and correct operation checked once more.




















The new crank shaft is installed & the two halves are joined together and some initial studs hand torqued to check tolerances.

At this stage the two drive shafts again are revolved to check clearances.
















This is a view of the two halves torqued up and the selector box installed. Gear selection is carried out manually



















The drive cogs for the oil injection are installed and lubed.

Next the ‘COSA’ style clutch is installed.

This positions the crank correctly and sequences the build.


















Clutch housing is installed, again genuine Piaggio in this instance.




















Whilst on this side the starter motor is fitted.





















And rear hub assembly
























On the right hand side the stator assy is affected

Now the flywheel is fitted to complete the magneto. This sets the whole crank assy.



















The piston is fitted to the con rod






















And the cylinder matched,



Now the engine is becoming more recognisable.












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