ENGINE REBUILD:
We were a bit bored with the standard PX engine, BUT bearing in mind we wanted an oil injection system we couldn't stray to far from a standard engine. We have installed a new BGM (12BHP) top end, cosa clutch, long stroke crank, T-5 forth gear, bearings seals etc. PM tuning exhaust and 24mll carb.
All our engines are stripped, cleaned (yes the outer cases as well) with brand new components where needed, everything went in nice and smooth and now this engine is ready for installation.
Another problem when carring out this type of conversion is the choke. Originally it was a fixed lever system located under the seat, so we purchased a ''pull up'' choke originally for Mini's converted the cable, a lift of the seat, quick pull and twist into position and it works perfectly everytime.
FRONT FORK REBUILD :
We took a set of second hand PKXL forks and got them straightened, then we removed the fork stop from the forks and repostioned them on the forks to suit the VNA frame, also a small metal bar was welded near the top again to suit the steering lock (such as it is) of the VNA.The forks were then powder coated satin black and every thing was assembled with an uprated Malossi RS24 front shock.
The front mudgaurd was also modified to fit the PKXL forks, there sometimes is a need to trim underneath the horn cover, but this was not the case in this instance. The disc brake was assembled, then the froks ''offered up'' we had to use the original sized VNA lower ball bearings (slightly larger) as the forks rocked back and forth with standard p-range bearings. We also had to modify the speedo cable, with an ''old timer outer'' and PX inner.
OIL INJE
CTION & FUEL TANK :
Now the problem of the autolube (oil injection), we didnt like the idea of the sight glass on the classic scooter for a couple of reasons, first was cosmetic, we just dont like the look, the next practical, we didnt think it would fit in the slightly smaller frame!!
We took a standard oil tank from the PX, removed the sight glass, then plastic welded the hole and sourced a oil gauge from an Italjet Dragster 180, drilled a hole in the highest point at the top fitted the gauge then plastic weld the gauge to the tank and hope it all works, because we wont know until we go live!!
After a little bit of jiggery-pokery the fuel and oil tanks slotted in nicely, it had to come back out again the for the wiring of the oil gauge, which was connected to the loom and then onto a warning light along with a petrol warning light located on the tool box
ASSEMBLY :
We have all the idea's, now we have the small problem of assembly and seeing if it all works!!The stand was fitted first and was moved forward slightly to comensate for the PM exhaust, then all the floor runners, centre mat and easy bits were fitted. We modified a PX disc loom to fit all the extra goodies we have, basically chopped it halve and connected all the wires.
Forks were fitted next, then the complete p-range engine where we stumbled across a wee problem, originally the VNA engine is piston ported so the carb sat a bit forward than the p-range carb, so out came the axle grinder and the frame was cut around the engine so that everything fitted nicely with a standard rear shock.
With the front and rear wheels on we then set about bleeding the brakes and connecting the loom with all the little lights, front stop switch and electric start button installed in the same place as the PX disc on the headset.
Sorry i forgot to mention it has electric start as well! We purchased a modified switch for 12 volt systems, but forgot to tell Roy but in hindsight what a great mistake to make as Roy set about modifing the original switch, i now have 3 light settings, horn and kill switch. The (red) fuel warning light & (amber) oil warning lights were now connected on the top of the toolbox along with the ignition switch, which also has 3 settings, also an added bonus with the oil gauge coming from the Italjet, it has a little circuit board on top and the amber light lights up every time i switch the ignition key to the on position, pukka.
ROAD TEST, MOT & REGISTRATION :
OK then cables connected, loom connected, lights all work so here goes, switch the key to the on postion and hey bingo it starts!!
Horn works, so do the lights and floating mechanisms for the oil and fuel, lights ok, rear brake light operated from the front stop switch is working fine as well. The VNA was a budget model and did not have light switches fitted at the rear brake pedal, so we fitted one any way.
Of the scooter went for an MOT, passed and then armed with my Veteren Vespa Club document, insurance certificate, and MOT of i go to the DVLA this is where the real nightmare begins!! i sat in the que for an hour they then took £55.00 of me, then told me they would be in contact within 3 days. well 4 days later i get a letter explaining they want to view the scooter 7 days later!! How the hell did we win 2 world wars, thank god the civil service were not fighting, because it would take 2 weeks before battle would commence!!
Ok just an update, ive changed a couple of things on the scooter, first of all i was a bit worried about not haveing a spare wheel, so i bought and installed a spare wheel carrier for the rear, which will be well handy for rally season (well that's my excuse and i'm sticking to it!!) Secondly ive fitted a right hand JL exhaust, as the PM pipe looked and sounded good, but i felt there was something missing performance wise, Where we are situated, we have what we call a bluebell hill test (more on that on another page), as we turn out of our yard we join blubell hill southbound, we then go round the first roundabout and then head up bluebell hill, which for those of you who dont know it is a steady incline of around 2 miles and with that set up i had to change down to 3rd gear 3/4's of the way up.
Out of interest the right hand JL goes all the way up in 4th, as does a Simonini, scorpion and standard (*) exhaust.
I run the engine in carefully for around 500 miles, then went for a dyno at JB Tuning in essex, and it reached an impressive 12.8 BHP with a top speed of 78MPH, considering thats more or less standard i was well chuffed.
As of 23/06/2009 i have done 767 miles with no major hang ups, autolube works well as does the fuel sensor. Look out for it at a rally near you soon.