Scooter Upkeep, Part 2

Well, finally some follow-up for you guys. Thanks again everyone for the tips, tricks and advice.

Over the past little while, parts have filtered in and this morning that last little bit came together.

On my last post, you may have read that I was going to leave the clutch in and worry about it later. Maybe you didn’t read it though, because I just read it and it’s not in there. What am I thinking?

Well the clutch came out since it’s not much more work once the rear end is all apart. Look closely in this picture and you might see where a clutch would hide amongst the 36 years of grime, oil slop, exhaust condensation and other unknown detritus:

I did a lot of scraping and cleaning to make sure all the loose stuff was knocked free and clear of the cover before I opened it. Somehow I managed to not pull the entire lump and give it a good scrubbing, even though it clearly needs it.

Perhaps I’m used to motorcycle parts prices, specifically BMW and KTM, but the kit and tools to rebuild the clutch were dirt cheap. I got stumped briefly by the wire retaining clip that holds the disc that covers the clutch nut on, but thankfully I figured it out before breaking or bending it. The clutch rebuild itself went so quickly I forgot to take pictures. The clutch compressor tool is slick. I’m gonna keep that around, even if it is another 36 years until I use it again.

Here’s the clutch installed and ready to go:

I gave the clutch cover a thurough cleaning and marveled at it’s simple engineering to get oil on the brass button. I made sure the vent worked properly and didn’t even get all three of the bolts tightened down before I realized that I forgot to put the brass button back in.

The rest of the assembly was just cleaning the old parts and installing the new ones:

I love the details of old machinery:

I got talked into some fancy-ass synthetic 30w gear oil. It’s supposed to make the scoot shift better and all that stuff. For the life of me though, all my fancy funnels and hoses and proven-over-time methods of getting oil into their proper places couldn’t help me here. I had to fabricate something new. I love it!

This morning, I finally get home from work and get a chance to run over to a local machinist. I got references for this guy from some of my VW friends and he said he could do my out-of-round front hub so that brakes wouldn’t shudder. His garage is one of those places… Shavings on the ground, mills, lathes, drill presses and other stuff I’ve never seen before surrounded by engine blocks, con rods, heads, crank shafts and buckets of old burnt valves. He tells me “it wasn’t too bad but it’s perfect now.” I shell out $20 for a 36 year old front hub that has been cleaned and turned to the point where it might pass for new, go home pop it on, make some minor adjustments and set up for a test ride.

I took a couple spins around the neighborhood to bed the brake shoes and see if I needed to adjust the clutch. Let me say, it shifts like a dream. I don’t know if it’s just because of the clutch work or some of it is the new oil, but I have to say that I don’t even remember it being so good… and I’ve been riding this scooter off-and-on since 1985. The new brake shoes and turned hub on the front give me linear lever action and improved stopping power without all the shudder that used to accompany the typical front-end-dive. And the rear? Well, no oil where it shouldn’t be yet.

I gave it good wash and scrubbed off all of my greasy fingerprints then propped it back up on the stand for a quick wax. There are sections on this bike that still shine like new, it’s too bad it’s seen some fairly poor care along the way, there’s no way to clean up a lot of the rust.

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