tag:blogger.com,1999:blog-51715789485723655632024-02-19T02:06:26.989+00:00Lambretta RestorationThe complete guide to stripping down & re-building Lambretta scooters.Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.comBlogger99125tag:blogger.com,1999:blog-5171578948572365563.post-52666636618229861812014-05-12T15:22:00.000+01:002014-05-12T15:22:30.773+01:00Following a rather lengthy break for one reason and another that I won't bore you with, the last of the hold ups preventing me from getting on with the next project is scheduled to be completed later this year. We are having our home extended.<br />
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Because of this, there is limited space to work and limited time to do it.<br />
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However, I promise that as soon as possible, work will begin on my SX150 as previously hinted at. This will be a full strip and restoration with some very intersting (hopefully) custom add-ons.<br />
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Please stay tuned for more helpfull tips and advice from the LCGB.<br />
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Paul SlackPaul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-24480520972294895482013-01-24T20:00:00.004+00:002013-01-24T20:00:37.871+00:00Next Project - Lambretta SX150Coming up from March 2013 will be the next installment of the Lambretta Club Great Britain Restoration Blog. This time, something a little bit different from the standard restoration of the previous scooter. The basis for this project will be a 1967 Lambretta SX150 in Apple Green (Verde Mela). When I say a little different, it's actually going to be quite a bit different.<br />
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There are all kinds of changes going to be made to the scooter to make it very special indeed and hopefully give it a lot more "SX Appeal". For a start, a stock of genuine vintage parts are already waiting to be added, such as a set of genuine Lucas Pathfinder lights, Race Seat (not giving too much away), engine upgrade, braking upgrade and a DC conversion to run all kinds of trick goodies.<br />
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All will be revealed in time. This one is going to be a proper head turner.<br />
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Keep checking back.<br />
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Paul<br />
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<br />Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-73067058714743628572012-01-15T18:33:00.000+00:002014-07-07T16:44:55.816+01:00For Sale. One restored LambrettaWell, just to keep everyone up to date with the story.<br />
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My father and I went in to the garage at 10am this morning to finalise a few bits and bobs on our restoration project. First job was to ensure we snagged her properly, so we went over the earth fixings and made sure they were correct. Then, we added our new rear seat catch, which I collected the previous day. Then, it was time to fire her up. She started on the second kick.<br />
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However, when running, we had no headlight or speedo light. This was fixed because I'd pushed the bullet connectors in the headset at the wrong sides of the main bulb connections and forgotten an earth to the headlight rim. With these issues addressed, everything worked perfectly.<br />
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I took the scooter for a short run in the freezing cold and she ran well, with all the brakes working perfectly as well as selecting gears properly.<br />
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This stunning Lambretta was complete. We spent the next few minutes giving her a final polish and congratulating ourselves.<br />
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Once again, I'd like to thank my dad, who has turned up almost every week to help complete this restoration.<br />
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Here are a couple of pics of him on our finished Lambretta:<br />
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I will be calling Armandos Scooters in Sheffield, to arrange for them to collect the scooter next weekend, where it will be given a final check at the shop. She will also get her number plate and MOT Test Certificate.<br />
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Remember, that this scooter has been restored almost with money no object. Almost all of the parts are factory original and in many cases are vary rare indeed. The engine internals are brand new and all the nuts and bolts have been replaced with exact, or very good match for those that would have been put there by Innocenti. The scooter will come with a warranty to back up our assurance that this is a quality machine.<br />
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We are convinced that the new owner will enjoy many, many happy years of ownership. The purchasor will also be given the certificate of proof this is the restoration scooter as we will sign it off with them on collection.<br />
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<span style="font-size: large;"><b>This Lambretta is SOLD.</b></span></div>
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This is not the end of the restoration blog.<br />
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Keep your bookmark if you are interested in the restoration of Lambretta Scooters as we will be taking on further projects.<br />
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Thank you for reading all these months. I hope you enjoyed it as much as we did.<br />
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<b>Paul Slack - LCGB</b><br />
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Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-41265843416489851582012-01-08T17:06:00.000+00:002012-01-08T17:06:59.569+00:00Just about finished...<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0ww6S-TAp863E3Y-JqVJEGZqGS28HD7dzzFU1fCWfNURuGbycnK1cOOn2_LBRpL2_CZJen5XWW7YBzHHcWR5Opqbe6dNlxO5520t9o4acKHjqfWBlxKkPQok50VQW5yv4LtsUTu087j4/s1600/IMG_1970.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0ww6S-TAp863E3Y-JqVJEGZqGS28HD7dzzFU1fCWfNURuGbycnK1cOOn2_LBRpL2_CZJen5XWW7YBzHHcWR5Opqbe6dNlxO5520t9o4acKHjqfWBlxKkPQok50VQW5yv4LtsUTu087j4/s320/IMG_1970.JPG" width="320" /></a><br />
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Well, it's the first day for a while that it hasn't been raining or sleeting. So I figured that as the scooter is so close to being done, I might as well get her out of the garage and take a few nice shots of her.<br />
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Next week, the plan is to do a good, overall check of the work to make sure I didn't forget anything, get her up and running and play around with the gear selectros to make sure she runs well and goes through teh gears ok. I'll also check the brakes and everything is tight before giving this Lambretta a final clean and polish.<br />
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After that, the scooter will be winging its way back to Armandos in the back of their van and at that point, it will be given a full MOT Test and get its number plate from DVLA. so whoever is fortunate enough to buy this scooter will simply have to bring along a helmet.<br />
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Enjoy looking at her for now. More to follow next week.<br />
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And just to prove she is a genuine 1963 Italian stallion, here's the letter of authentication.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigik32TWKau8AxbJ5k2iZBvD6Ah-Rqcd1xVjeZX343LcnHXmQJoCcBujCcE-noh3V5A58mSwJA7w_s9yYOA6ogU8RnsdCwzlm-FF8UHOf9_tU8j6iizHpyD0BOi80-o-zCzVrRJWk6mS8/s1600/IMG_1981.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigik32TWKau8AxbJ5k2iZBvD6Ah-Rqcd1xVjeZX343LcnHXmQJoCcBujCcE-noh3V5A58mSwJA7w_s9yYOA6ogU8RnsdCwzlm-FF8UHOf9_tU8j6iizHpyD0BOi80-o-zCzVrRJWk6mS8/s320/IMG_1981.JPG" width="320" /></a></div><br />
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In the next few posts for this scooter, I will be advertising the price for her and hopefully showing her off to her new owner. As promised, the new owner will get a certificate for the scooter to proove it was the genuine restoration blog model and it will be signed by all connected to the build.<br />
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Look out for that.<br />
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An advert for the scooter will be posted midweek, with the price. however, if you want to contact me in the meantime, feel free if you are serious about owning this scooter. There is a <b>£250 discount </b>for any LCGB current member.<br />
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Discussions are also underway for the next project. Whatch this space...Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-80267743601823354882012-01-08T16:47:00.000+00:002012-01-08T16:47:32.356+00:00Fitting headset top, headlightHere is our ultra rare Carello unit we described earlier.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPfrNgo2XBwE1kgKW3xdqKJI7sTzK_xnd2sgKsGOZI14Tk-PvuJtlh11e0cl0U1AyKqMSQIQihQ5u1GCNpSuc5A2VG9pN9vZehaDaHLjRztRBMJujM77NAQI86_cfikF5jWv36nCQXTN4/s1600/IMG_1951.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPfrNgo2XBwE1kgKW3xdqKJI7sTzK_xnd2sgKsGOZI14Tk-PvuJtlh11e0cl0U1AyKqMSQIQihQ5u1GCNpSuc5A2VG9pN9vZehaDaHLjRztRBMJujM77NAQI86_cfikF5jWv36nCQXTN4/s320/IMG_1951.JPG" width="320" /></a></div><br />
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And he original block for the wiring. This is inserted in to the rear of the headlamp unit bulb first.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9vA4G_0mi-Fz8DTI35nX43EVnvsZZHUw-_GCYNRqw2DjBMXK8JAqbFc739JFGPKwgRp_YXrYOwbh9w3QdbclOWyvi1MaxOkBKYQfJy0KLXPGzIbG3ZHU0vH9-9hXSyu7SQotVi-wQoHs/s1600/IMG_1952.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9vA4G_0mi-Fz8DTI35nX43EVnvsZZHUw-_GCYNRqw2DjBMXK8JAqbFc739JFGPKwgRp_YXrYOwbh9w3QdbclOWyvi1MaxOkBKYQfJy0KLXPGzIbG3ZHU0vH9-9hXSyu7SQotVi-wQoHs/s320/IMG_1952.JPG" width="320" /></a></div><br />
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And then clip it in place with the wire clip as shown.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioTArGhW3YHLBwHU9-EIGySYf3sLPLIodaZ54A5hp6Evre9dVTLeUQG1ZiCjy83HafF6JiJNeavxtj9M0b14ZZe1pmNsURdYP4U9KGoNBzToeK5gbnSakeZVS_BnJbLHo4Cm5UJ8bS4ps/s1600/IMG_1953.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioTArGhW3YHLBwHU9-EIGySYf3sLPLIodaZ54A5hp6Evre9dVTLeUQG1ZiCjy83HafF6JiJNeavxtj9M0b14ZZe1pmNsURdYP4U9KGoNBzToeK5gbnSakeZVS_BnJbLHo4Cm5UJ8bS4ps/s320/IMG_1953.JPG" width="320" /></a></div><br />
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On the underside of the headset top, you can see the previously installed, NOS speedomoter. There are two holes, one for the speedo bulb and the threaded one for the speedo cable.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgif3Cu76ksOvwOABClNZFh9muaiFKradcxElCwKEqrLw0o4cFvL3TjXzkkZHBV_cfnmi6nOHMIfSulK9y-ZjNivlvTPtpFWczJuakUoJLrMcimAIoKMHLKi-ktIy0TYJwp-kcIMxveg1U/s1600/IMG_1954.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgif3Cu76ksOvwOABClNZFh9muaiFKradcxElCwKEqrLw0o4cFvL3TjXzkkZHBV_cfnmi6nOHMIfSulK9y-ZjNivlvTPtpFWczJuakUoJLrMcimAIoKMHLKi-ktIy0TYJwp-kcIMxveg1U/s320/IMG_1954.JPG" width="320" /></a></div><br />
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The speedo is held in place with the retaining clamp and three screws with washers.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN5Xzw2bUTqEprZz33XWXDA_5-Q2tm0Ym6brU-uNusVESdluXBHQuP1X0OSrXW9_3n7q-h6kwkSOnjeY-HQso7_hIZA-HdL-Zvxnt2Y35VQNOknE3_W_3-Qq1mq-f9zJ4NIYzSV9Wy8lA/s1600/IMG_1955.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN5Xzw2bUTqEprZz33XWXDA_5-Q2tm0Ym6brU-uNusVESdluXBHQuP1X0OSrXW9_3n7q-h6kwkSOnjeY-HQso7_hIZA-HdL-Zvxnt2Y35VQNOknE3_W_3-Qq1mq-f9zJ4NIYzSV9Wy8lA/s320/IMG_1955.JPG" width="320" /></a></div><br />
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Insert the speedo bulb...<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-YOlCfAOd0-2loK1brPsiPoMuzf-MDTOzsBUG9bqXFYGYNek-QjrzuQfgisxqS3U1qVcpejpcXQpBRhez7tGtnWMvJm1JwQJxfkVxvAOC3JQuLMTvs0doJjHLuya2vu9JH0WaqASADG8/s1600/IMG_1956.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-YOlCfAOd0-2loK1brPsiPoMuzf-MDTOzsBUG9bqXFYGYNek-QjrzuQfgisxqS3U1qVcpejpcXQpBRhez7tGtnWMvJm1JwQJxfkVxvAOC3JQuLMTvs0doJjHLuya2vu9JH0WaqASADG8/s320/IMG_1956.JPG" width="320" /></a></div><br />
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...now insert the speedo cable. You may need to remove the cable from the retainer on the foks in order to get enough cable space to have room to get your hand in there.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB16tIgL10N2O3MteVDNOBCw_EPl7YDj8EfW2FezT98TyoMMcai8hk807JUCZTFqeosL6CBi4XP2WcOpngA5qcmRrt5Dvraa1MtNhtydw-B5JTBlvQJXT-xcfXM7Vmy16kHno_MvA1Ky8/s1600/IMG_1957.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB16tIgL10N2O3MteVDNOBCw_EPl7YDj8EfW2FezT98TyoMMcai8hk807JUCZTFqeosL6CBi4XP2WcOpngA5qcmRrt5Dvraa1MtNhtydw-B5JTBlvQJXT-xcfXM7Vmy16kHno_MvA1Ky8/s320/IMG_1957.JPG" width="320" /></a></div><br />
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Here are the correct bolts and washers to join the two headset halves.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI5fiDGf8stsqetJCYJgqkqV_SOq3zKaLzbg0AHPouDEbB3O-W9Y2VfajiCc1PUoyBP8_mPkasDj26i-QfPAFjagbWsrrRDaRTfT4DB-fwpKiQvJX8JJ9VzOgf2xo6GjZ6KA6JZe3l_L4/s1600/IMG_1958.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI5fiDGf8stsqetJCYJgqkqV_SOq3zKaLzbg0AHPouDEbB3O-W9Y2VfajiCc1PUoyBP8_mPkasDj26i-QfPAFjagbWsrrRDaRTfT4DB-fwpKiQvJX8JJ9VzOgf2xo6GjZ6KA6JZe3l_L4/s320/IMG_1958.JPG" width="320" /></a></div><br />
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With the headset fastened together, push over the rim carefully, and fasten with the correct screws and washers. I use cup washers here for a nice, neat finish.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE75E6v4X8ibl_TXNzS7AF9vjevdbL8cTerks9WazF-xNbjzidek2iGbnluNUxexaCR5ue-PIMTVrAvz0qvcN53QDuA1tsEbN2lxat1QbJmMkVTq0vRXPHQMCGrfO78_xp06mbz1Z4918/s1600/IMG_1959.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE75E6v4X8ibl_TXNzS7AF9vjevdbL8cTerks9WazF-xNbjzidek2iGbnluNUxexaCR5ue-PIMTVrAvz0qvcN53QDuA1tsEbN2lxat1QbJmMkVTq0vRXPHQMCGrfO78_xp06mbz1Z4918/s320/IMG_1959.JPG" width="320" /></a></div><br />
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Now add the bolt to the underside of the headset through the slot for the beam adjustment. Use a flat washer.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPcvo75v05WknuMT_YBA2jkBWuZvnruXJDpo_T_cQg0HHY0DQtpZ4yEaKt1-DwPnRHVanIE2iPU4XLu5M4s60itVhX_x36yvevCAhVlScgRZyZEFntu2ZgZTB-oFJ4iBOTdeECYu1_ht0/s1600/IMG_1960.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPcvo75v05WknuMT_YBA2jkBWuZvnruXJDpo_T_cQg0HHY0DQtpZ4yEaKt1-DwPnRHVanIE2iPU4XLu5M4s60itVhX_x36yvevCAhVlScgRZyZEFntu2ZgZTB-oFJ4iBOTdeECYu1_ht0/s320/IMG_1960.JPG" width="320" /></a></div><br />
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Here is is completed.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtvj90Vm-hZC7Wx2jrrn_ibSKPqXvqycwIZ7mPPqutG1T2SMeh1njdiTE4BN-d79aOq7aMg91FZARedsdSeAR7gglIV5kJq-YFiz3oZFyGeM8dcvO6-C26j1nStjfCtNeHozhDQuEwv5c/s1600/IMG_1961.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtvj90Vm-hZC7Wx2jrrn_ibSKPqXvqycwIZ7mPPqutG1T2SMeh1njdiTE4BN-d79aOq7aMg91FZARedsdSeAR7gglIV5kJq-YFiz3oZFyGeM8dcvO6-C26j1nStjfCtNeHozhDQuEwv5c/s320/IMG_1961.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-90898311849628447462012-01-08T16:27:00.000+00:002012-01-08T16:27:36.386+00:00Adding the horncasting and grilleWe are getting down to the last few bits now.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKJG8OD9oUXnPFzI3Wkbaa-Il667-lWhFQSb80Vg8KagY3N-DRikwHGPEqY5PF00lqaJenqPEnX4mN8YDj2ldvJkOy_k_C_L8gJQVogRdS-8jwCb5KyHF3CpADa-BocA27ftTjJzj0VPg/s1600/IMG_1939.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKJG8OD9oUXnPFzI3Wkbaa-Il667-lWhFQSb80Vg8KagY3N-DRikwHGPEqY5PF00lqaJenqPEnX4mN8YDj2ldvJkOy_k_C_L8gJQVogRdS-8jwCb5KyHF3CpADa-BocA27ftTjJzj0VPg/s320/IMG_1939.JPG" width="320" /></a></div><br />
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Tap out all the threads in the grille and casting to ensure they are free of paint.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOYTXoH-Ec0gsdvXfkgdTnVPcHFWZ3BUoX-x5dAuvpwnYz-ZVlZgF2Z1uliWdqEYhLaf0zqFBIgUv20edPxdJj8hK8fyUbuoj4IBLgtNCd8YL-jFvtM8ghlTjp4Px7ByWXzPYYsx1rPBE/s1600/IMG_1940.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOYTXoH-Ec0gsdvXfkgdTnVPcHFWZ3BUoX-x5dAuvpwnYz-ZVlZgF2Z1uliWdqEYhLaf0zqFBIgUv20edPxdJj8hK8fyUbuoj4IBLgtNCd8YL-jFvtM8ghlTjp4Px7ByWXzPYYsx1rPBE/s320/IMG_1940.JPG" width="320" /></a></div><br />
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Fasten on the grille to the horncasting and then place the lower rubber on top of the mudguard. Offer the horcasting up to the scooter inserting the TOP edge first. The, push in the bottom ensuring is fits snugly on the lover rubber beading. With it in place but not secured with bolts, place the side strip rubbers in to position.<br />
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It can be a bit fiddly, and it is worth stopping and checking when tightening everything up, that none of the beading rubbers have moved. I fasten the top two fittings first, using to bolts with 8mm heads and washers. Make sure you use the correct10mm length bolts as loger ones will break the casting lugs if you tighten them too much to get the fit right.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWEMJa7u44D2Ck5IGnsXJYNvhElDicFsx6StfueiDYd4rNlqfFyFfjT1srErqCHP1iWXRaHsXOnTiKx8aYgrpDAPtA1F7icipcaG72z2xtxwCyBeLeNtujQfV2RPBFPNVkQeF60wr6kTo/s1600/IMG_1941.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWEMJa7u44D2Ck5IGnsXJYNvhElDicFsx6StfueiDYd4rNlqfFyFfjT1srErqCHP1iWXRaHsXOnTiKx8aYgrpDAPtA1F7icipcaG72z2xtxwCyBeLeNtujQfV2RPBFPNVkQeF60wr6kTo/s320/IMG_1941.JPG" width="320" /></a></div><br />
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Next, I fasten the badge plate and casting to the steering bracket on the frame using the correct allen headed bolts as shown.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJGX9MOnmfArIqDBX7-5OSajFDTpBF_rQccGGII4CTqIzkLqEoh04zZKu4j4HqPWfTgMAqLqF6y62kX1ozU09zsFzPSI-LHy7Pmhq2VzxfjPy9NtG-b0sfCpZrukVfdEVjcU8qRrPTW8M/s1600/IMG_1942.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJGX9MOnmfArIqDBX7-5OSajFDTpBF_rQccGGII4CTqIzkLqEoh04zZKu4j4HqPWfTgMAqLqF6y62kX1ozU09zsFzPSI-LHy7Pmhq2VzxfjPy9NtG-b0sfCpZrukVfdEVjcU8qRrPTW8M/s320/IMG_1942.JPG" width="320" /></a></div><br />
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Here it is done. You can see the mouth of the clip, in to which the badge sits.<br />
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Here is the lug on the rear of the badge that goes in to the clip.<br />
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And fitted!<br />
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Now you can continue to add the fastening bolts but keep checking to make sure you have nice, tight fitting beading.<br />
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Don't forget the two 8mm headed bolts and washers that go under the mudguard in to the horncasting.<br />
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And finally, the bolts with slotted, bevel heads and cup washers to finish off the inside of the legshields neatly.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAw7JzRpwdBQj40lHgAY3ubZ1RUpJUb5DGrbTNOnNDZUKF-5n1bCHJDIxzch9jAnB_e_ebieHU5lf5s0ZIwBHnT7Bw8hL1qZX4Iyoimz8n2WEScVYwYSd4KYBFgVBQxHGqyrQN8C3y3fY/s1600/IMG_1949.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAw7JzRpwdBQj40lHgAY3ubZ1RUpJUb5DGrbTNOnNDZUKF-5n1bCHJDIxzch9jAnB_e_ebieHU5lf5s0ZIwBHnT7Bw8hL1qZX4Iyoimz8n2WEScVYwYSd4KYBFgVBQxHGqyrQN8C3y3fY/s320/IMG_1949.JPG" width="320" /></a></div><br />
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Horncasting is completed.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhudFYmIpNTxnKCTp1GJHFh__7KjK6M0EdzEWuU6u26nx0CAx0uMIplXA6nS1y31SZx-9sw7uMRsHtEA9ETtQfyooFK8VZiORmNNcMe04ONMhreXog_dHodYGvXM5UX37WV7efb5ewz2kE/s1600/IMG_1950.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhudFYmIpNTxnKCTp1GJHFh__7KjK6M0EdzEWuU6u26nx0CAx0uMIplXA6nS1y31SZx-9sw7uMRsHtEA9ETtQfyooFK8VZiORmNNcMe04ONMhreXog_dHodYGvXM5UX37WV7efb5ewz2kE/s320/IMG_1950.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-60446431279779828032012-01-08T16:14:00.000+00:002012-01-08T16:14:41.652+00:00Adding lights switch, headset wiring, horn wiringHere is our quality replacement light switch.<br />
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Along with the two screws to attach it to the handlebars. <br />
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The wires behind the switch need to be fed through the apperture in the housing, if you cannot get them to go, you will need to slacken off teh brake, undo the housing bolts and remove the throttle roller in order to pull away the housing a little to get all the wires through. Do NOT pull on the wires.<br />
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With the wires through, fasten the switch to the housing using the bolts in the kit.<br />
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The switch wiring is fed as shown in to the headset.<br />
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And secured under the alloy clip.<br />
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The two wires for the horn brach off and go down as shown in the picture below.<br />
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Feed them down behind the legshield bracket.<br />
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And insert in to the horn connectors. It doesn't matter which way round they go.<br />
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Now connect all the wires from your switch to the headset block floowing the wiring diagram posted earlier. Notice the loom wires are already in from a previous post.<br />
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The lock fits in the hole to the right of the green wire you can see in the pic below.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC6er__HAafm7bFGdbFyCvVsur-NYDTYZGbjm5TMhRn5yE32qhd92Ix2-4OV1QTtiXGMOLRf0bW8DeXRLqaPXhHMnAgEkHoCmvATHgW9WET_3wM2fUKUtbmgdV_j9TzkJQpHd_kZC_jBM/s1600/IMG_1962.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC6er__HAafm7bFGdbFyCvVsur-NYDTYZGbjm5TMhRn5yE32qhd92Ix2-4OV1QTtiXGMOLRf0bW8DeXRLqaPXhHMnAgEkHoCmvATHgW9WET_3wM2fUKUtbmgdV_j9TzkJQpHd_kZC_jBM/s1600/IMG_1962.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC6er__HAafm7bFGdbFyCvVsur-NYDTYZGbjm5TMhRn5yE32qhd92Ix2-4OV1QTtiXGMOLRf0bW8DeXRLqaPXhHMnAgEkHoCmvATHgW9WET_3wM2fUKUtbmgdV_j9TzkJQpHd_kZC_jBM/s320/IMG_1962.JPG" width="320" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC6er__HAafm7bFGdbFyCvVsur-NYDTYZGbjm5TMhRn5yE32qhd92Ix2-4OV1QTtiXGMOLRf0bW8DeXRLqaPXhHMnAgEkHoCmvATHgW9WET_3wM2fUKUtbmgdV_j9TzkJQpHd_kZC_jBM/s1600/IMG_1962.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC6er__HAafm7bFGdbFyCvVsur-NYDTYZGbjm5TMhRn5yE32qhd92Ix2-4OV1QTtiXGMOLRf0bW8DeXRLqaPXhHMnAgEkHoCmvATHgW9WET_3wM2fUKUtbmgdV_j9TzkJQpHd_kZC_jBM/s1600/IMG_1962.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a><br />
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Here is the actual plunger, spring, grub screw and cap to fit the lock.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Lj34i88SArtuhGxetMHuihR7ZCj5AuobR1o6SrmOLYIpvG4jDPkLJZjcgVSDbnvpEV0-ahoyY08NVd3Wl2ebgyUj1VaEElhsPL1ktmiTeLL1Efe9JmIROBkvcDPwGU6QTyxdcncPUGs/s1600/IMG_1963.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Lj34i88SArtuhGxetMHuihR7ZCj5AuobR1o6SrmOLYIpvG4jDPkLJZjcgVSDbnvpEV0-ahoyY08NVd3Wl2ebgyUj1VaEElhsPL1ktmiTeLL1Efe9JmIROBkvcDPwGU6QTyxdcncPUGs/s320/IMG_1963.JPG" width="320" /></a></div><br />
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Make sure the hole for the punger as shown above is clear of paint and that the plunger actually goes up and down in it smoothly. Grease the plunger and spring and offer them in to the hole.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZftiZ5hIWc5k23S2MgS3nzBPABjHEvXZPDMmXj5han8LQ66UU13cKJZsijg9PiaIBTTavJ3cwxeW_2bYhA6zEtjAtw8bqI2FjhbAzASXzArYJ0s7yjIgTqg38IZyz_PiqqoHZ2nL5Plo/s1600/IMG_1964.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZftiZ5hIWc5k23S2MgS3nzBPABjHEvXZPDMmXj5han8LQ66UU13cKJZsijg9PiaIBTTavJ3cwxeW_2bYhA6zEtjAtw8bqI2FjhbAzASXzArYJ0s7yjIgTqg38IZyz_PiqqoHZ2nL5Plo/s320/IMG_1964.JPG" width="320" /></a></div><br />
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The plunger should drop in to the hole and spring back up because of resistance on the spring.<br />
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Below, it is fitted and a glob of grease is added to the upper surface of the plunger.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxO0nCdrPGYvVxXek5xGwrOOQkTomvAYq_NSRqAzTZ9paxw6sDe3bNCW7vrqSxd0Z8QR_0FILLR7h1Ik5ffPf7TJka4IwPGXtG1NhA9PT-73KpmEW0ywC3_YkV8FyaW6Q8WN3b31cHNAE/s1600/IMG_1965.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxO0nCdrPGYvVxXek5xGwrOOQkTomvAYq_NSRqAzTZ9paxw6sDe3bNCW7vrqSxd0Z8QR_0FILLR7h1Ik5ffPf7TJka4IwPGXtG1NhA9PT-73KpmEW0ywC3_YkV8FyaW6Q8WN3b31cHNAE/s320/IMG_1965.JPG" width="320" /></a></div><br />
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The lock itself can only be inserted one way and the giveaway is this hole drilled in to the body of it. This indicated the barrel of the lock which goes uppermost.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXvfPwS94YJlTMHyQJuDUo0kxUDnwK9WwzgI2mNvrJAkGKOBxq29dbsFROjc6nfLD8OhktNURJORTjr-1NUUBEA9-KRwfYW2i78F_lxGHTQp9dyB2LZN545t3SDOWceMxCjjoExmGFNdU/s1600/IMG_1966.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXvfPwS94YJlTMHyQJuDUo0kxUDnwK9WwzgI2mNvrJAkGKOBxq29dbsFROjc6nfLD8OhktNURJORTjr-1NUUBEA9-KRwfYW2i78F_lxGHTQp9dyB2LZN545t3SDOWceMxCjjoExmGFNdU/s320/IMG_1966.JPG" width="320" /></a></div><br />
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Turn the key, so that the lock is OFF. This is indicated by the rounded part of the lock arm being uppermost and adjascent to the hole in the barrel.<br />
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The shot above, shows the lock in "locked" position. Turn it off to insert the barrel in to the hole in the headset.<br />
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Push the key and lock barrel in to the headset whilst pushing down the plunger with a screwdriver until the barrel will go no further. You may need to turn the barrel one way or the other until the hole in the barrel can be seen through the threaded hole for the grubscrew which holds the barrel in place.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz2CNMh2-KAsqYZAb5AjhOostpAfdTvoWHbhvEx6oRzWKZd1kBiqrUSdNGyPwEsT6T6rT1L4nP-zsfl8qBgGultHaZd9Q-wJyr-RmaW4SEkePqRWi_r3jWYpbMEvAeh8kNZsArpidSmP0/s1600/IMG_1967.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz2CNMh2-KAsqYZAb5AjhOostpAfdTvoWHbhvEx6oRzWKZd1kBiqrUSdNGyPwEsT6T6rT1L4nP-zsfl8qBgGultHaZd9Q-wJyr-RmaW4SEkePqRWi_r3jWYpbMEvAeh8kNZsArpidSmP0/s320/IMG_1967.JPG" width="320" /></a></div><br />
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When they do line up, insert and tighten the grub screw.<br />
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This simply stops the barrel rotating when you turn the key.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8cWps7yFDxaBuQwdLO0sL_cJTLg8MlFyGrfmbgtOA2-EbE6esMHfYVLkxlXiC-JsE3nb2yGddmc3tgbzaCBJAVQbPuL3O31busQS24YwCg5hWRf1AeKgpSErcUVLJV5zwH6Gh75u_Q4U/s1600/IMG_1968.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8cWps7yFDxaBuQwdLO0sL_cJTLg8MlFyGrfmbgtOA2-EbE6esMHfYVLkxlXiC-JsE3nb2yGddmc3tgbzaCBJAVQbPuL3O31busQS24YwCg5hWRf1AeKgpSErcUVLJV5zwH6Gh75u_Q4U/s320/IMG_1968.JPG" width="320" /></a></div><br />
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Check the lock to ensure it works properly by turning the steering to one side or the other and putting the key to ON position. The steering should be locked. Now push in the alloy protective dust cap over the plunger. Job done.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMx4BCvPKLkcRg2kXuk9ZZgQI_bNsJPk_4_4sO58XWgOFHMctNIyICSnda8yaxU4NaPW7kQGz9K6lsoER8NG3InP-4g7vXTPvYh8Brnmq935kZOvOyJqbUTlwycd_iZD8Zw8GahiAR6VA/s1600/IMG_1969.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMx4BCvPKLkcRg2kXuk9ZZgQI_bNsJPk_4_4sO58XWgOFHMctNIyICSnda8yaxU4NaPW7kQGz9K6lsoER8NG3InP-4g7vXTPvYh8Brnmq935kZOvOyJqbUTlwycd_iZD8Zw8GahiAR6VA/s320/IMG_1969.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-14944070417811028632012-01-08T15:49:00.000+00:002012-01-08T15:49:58.008+00:00Adding seatHere is our seat base back from being stripped of all the original paint and rust etc. It has been painted black, exactly as it should be. Alongside it are the rubber frame buffer and rear catch.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXCP2ApNpZGf7-UFVlA0H5IpnrpUFmcg9bASVf6E-UE7CSI2nnyoufwZZBvicj207E2ohnQ5Gw6YLfYGZX6zz5ansgjzH9gMwK_sjRcq2NFHEaI1zfUnjPY0rWI140LTyHxDfYCtwTSuM/s1600/IMG_1903.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXCP2ApNpZGf7-UFVlA0H5IpnrpUFmcg9bASVf6E-UE7CSI2nnyoufwZZBvicj207E2ohnQ5Gw6YLfYGZX6zz5ansgjzH9gMwK_sjRcq2NFHEaI1zfUnjPY0rWI140LTyHxDfYCtwTSuM/s320/IMG_1903.JPG" width="320" /></a></div><br />
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Original marking for "Giuliari" accross the centre cross member.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjS7fhBrLeZin576Ydr37t5Dhaf6UqpDxrkwgIroTf_4OA7FzspRFfGOiOEJbTxNUs6X_FRfvhqOzjT_EwiVfh8V2EUaG4XVoSt56_mifWqyx3KejECxEtuFlYEWGJACgrb8iVfmYb3a-w/s1600/IMG_1904.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjS7fhBrLeZin576Ydr37t5Dhaf6UqpDxrkwgIroTf_4OA7FzspRFfGOiOEJbTxNUs6X_FRfvhqOzjT_EwiVfh8V2EUaG4XVoSt56_mifWqyx3KejECxEtuFlYEWGJACgrb8iVfmYb3a-w/s320/IMG_1904.JPG" width="320" /></a></div><br />
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Don't forget to put back a new rubber buffer on the end of the seat catch push rod.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji4eGck80Wngl1XCxqiMRT45SbF6W2nHvhAAAGtX7WXvwtMlyYZmarjG-pU2pw32zNE7M200APUzCqE5Nd0gBLqfo4pB3IkeuZZRPGN8TwUMNEl8NkLHoR5jpth8xHaYQL4p4Ntx2Rz8A/s1600/IMG_1905.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji4eGck80Wngl1XCxqiMRT45SbF6W2nHvhAAAGtX7WXvwtMlyYZmarjG-pU2pw32zNE7M200APUzCqE5Nd0gBLqfo4pB3IkeuZZRPGN8TwUMNEl8NkLHoR5jpth8xHaYQL4p4Ntx2Rz8A/s320/IMG_1905.JPG" width="320" /></a></div><br />
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Here is our new seat cover as original spec.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfTshdsJVRPX4LROYdhD7tZIOVftEtOtl4SuS3Sxy4wGJiJTFXbCGsr8o2tGOP3rKybSJdpPt4zP0CzDJ0mFOGSZwF4eOmABhyphenhyphenGgVDYF9ru5scQJdt7H_sL0BabfqCzpOd86NW7y9zhBg/s1600/IMG_1906.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfTshdsJVRPX4LROYdhD7tZIOVftEtOtl4SuS3Sxy4wGJiJTFXbCGsr8o2tGOP3rKybSJdpPt4zP0CzDJ0mFOGSZwF4eOmABhyphenhyphenGgVDYF9ru5scQJdt7H_sL0BabfqCzpOd86NW7y9zhBg/s320/IMG_1906.JPG" width="320" /></a></div><br />
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Note the alloy tabs on the inside, which you will have to turn upright after the seat cover has been put on the base.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVwrxh_hvKqTS3vxA0LUVHrTuh4xMs5tHxzieGAQsdzNDBiCCRM_tSCaAGQjN0ffj2VISpAwaySCobxDwYehJW6GDqbaLuwzPNXe_9V9_4BqKnGKqu8SKogfJkQmwNMXNG08Z7UtDMB8k/s1600/IMG_1907.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVwrxh_hvKqTS3vxA0LUVHrTuh4xMs5tHxzieGAQsdzNDBiCCRM_tSCaAGQjN0ffj2VISpAwaySCobxDwYehJW6GDqbaLuwzPNXe_9V9_4BqKnGKqu8SKogfJkQmwNMXNG08Z7UtDMB8k/s320/IMG_1907.JPG" width="320" /></a></div><br />
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Insert the base in to the cover starting at the rear end first and then push in the front. It might be a bit of a stretch but with effort, it will go.<br />
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Then, start bending the cover tabs over the frame loop by first (with the seat upside down) pushing the top tab down and then the lower tab up and over it.<br />
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This prevents the alloy tabs from scratching or catching on your painted frame when the scooter is in use as it keeps the sharp edges away from the panelwork.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN00nw5vxaTcL5AQ9FKNJsTd8D75LiBn3Fr4pywTMbkShYz_h36YYoQH8OjlGQhPu6cCwiQ1Jkw_s2-2rm4XFoQhTV75DdhwahDZ8F7x-ID6or6mIYMv4fglcf0gFHVGIHPsMZ9x-dSZ0/s1600/IMG_1908.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN00nw5vxaTcL5AQ9FKNJsTd8D75LiBn3Fr4pywTMbkShYz_h36YYoQH8OjlGQhPu6cCwiQ1Jkw_s2-2rm4XFoQhTV75DdhwahDZ8F7x-ID6or6mIYMv4fglcf0gFHVGIHPsMZ9x-dSZ0/s320/IMG_1908.JPG" width="320" /></a></div><br />
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With both tabs bent over, squash them flat using a hand clamp.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxIgO8pTNrKVQGHmG-ubNnkeoDqbIaa9tHtoJcMN5a9bbfVhgd8NiVW29hp-4l8vXtPAXRWbHHyzcz7M69zKTkQBHcFzvsxTxX1nVM8awpuACpLbFXvW1On-BXBU2JOsD-X0urJU-Uk8g/s1600/IMG_1909.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxIgO8pTNrKVQGHmG-ubNnkeoDqbIaa9tHtoJcMN5a9bbfVhgd8NiVW29hp-4l8vXtPAXRWbHHyzcz7M69zKTkQBHcFzvsxTxX1nVM8awpuACpLbFXvW1On-BXBU2JOsD-X0urJU-Uk8g/s320/IMG_1909.JPG" width="320" /></a></div><br />
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Work your way forward, both sides at the same time...<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghmTaAalZdtNd3YOU-BmJigpuMGl8rrfwnMnbt1G_RqvNKImuYvvjtjgsxoahQEq5Y0j75biMF4L6MDg5mfBtJlDQ5kdJ_dgAhiP66LY18rtIHXydfkHlA_-WUHLMQupN4_AXOSMW0Nb0/s1600/IMG_1910.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghmTaAalZdtNd3YOU-BmJigpuMGl8rrfwnMnbt1G_RqvNKImuYvvjtjgsxoahQEq5Y0j75biMF4L6MDg5mfBtJlDQ5kdJ_dgAhiP66LY18rtIHXydfkHlA_-WUHLMQupN4_AXOSMW0Nb0/s320/IMG_1910.JPG" width="320" /></a></div><br />
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Until all the tabs are done.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilAR38sLX9s7087ggOgwslYjnjBU2Ic9lihSObA88jsNOguGGXCp85CwCB4nulhdafyH81EvUgWnO5Qc7vsU8RaIy63dTqCKFpdzs4vffA6GtDxch5X0XslHFaZ0vW7T-lqGRawLkmv_k/s1600/IMG_1911.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilAR38sLX9s7087ggOgwslYjnjBU2Ic9lihSObA88jsNOguGGXCp85CwCB4nulhdafyH81EvUgWnO5Qc7vsU8RaIy63dTqCKFpdzs4vffA6GtDxch5X0XslHFaZ0vW7T-lqGRawLkmv_k/s320/IMG_1911.JPG" width="320" /></a></div><br />
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Your seat should now look like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6cJEOpizRaYKlQ7ENbkrd7CTMg4WtoxjwD8uNivWVHBuaIda8UdkgRDsLT0sd_M4XjjdCFxiUsc3O44WshuNstrvUyXe4Wfb3LiGnhEd_2V78zcgidOOaUW0XA8kVFPGe3AuW7KI8LVw/s1600/IMG_1912.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6cJEOpizRaYKlQ7ENbkrd7CTMg4WtoxjwD8uNivWVHBuaIda8UdkgRDsLT0sd_M4XjjdCFxiUsc3O44WshuNstrvUyXe4Wfb3LiGnhEd_2V78zcgidOOaUW0XA8kVFPGe3AuW7KI8LVw/s320/IMG_1912.JPG" width="320" /></a></div><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgShDyPSwC4NXDClfxGQGkuTPYmhqOCuGcrJ5d3uPduUQVhyphenhyphengL-Xv5Y7sNpfE_uv_ZM0Bqm8SW2gtGH64yWVpoMa2B-tKwcYvxDa7lJY9afFByyueGzdKWGBgBX2fsOTeNbnvCFoDXABZI/s1600/IMG_1913.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgShDyPSwC4NXDClfxGQGkuTPYmhqOCuGcrJ5d3uPduUQVhyphenhyphengL-Xv5Y7sNpfE_uv_ZM0Bqm8SW2gtGH64yWVpoMa2B-tKwcYvxDa7lJY9afFByyueGzdKWGBgBX2fsOTeNbnvCFoDXABZI/s320/IMG_1913.JPG" width="320" /></a></div><br />
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Now, from the inside, push a sharp screwdriver or similar through the threaded hole where indicated to make a guide for the hole in the seat where the strap will be fitted. When you have done both sides, drill out the hole in the seat cover to 5mm.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixi4aUB_SsdZmsp_QQlllmaXyH9UT5uv3gzpyq8T9_Vjgm4_zVqlkNjphGFkg9N8RJm7EJ_gSaHopjZT8Jyo_mvmUKHNfFWZbJcAPfw0IoG-OheGk0ZEzo0KClbyENvLcmEWC7B5H06Yc/s1600/IMG_1914.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixi4aUB_SsdZmsp_QQlllmaXyH9UT5uv3gzpyq8T9_Vjgm4_zVqlkNjphGFkg9N8RJm7EJ_gSaHopjZT8Jyo_mvmUKHNfFWZbJcAPfw0IoG-OheGk0ZEzo0KClbyENvLcmEWC7B5H06Yc/s320/IMG_1914.JPG" width="320" /></a></div><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrnUoel8Wozd9talfJJW6CkOl5vVekfTdKMXRy4WrOi2FxQ5VHztdmhU3kEq_U7iCklnKTe9HrLyUK4MjeL6vkXr8ZWv2UgC-kJznAul4sjHA-noUbo-cMCrO-I2V4N1Cie28gA2zcjaM/s1600/IMG_1916.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrnUoel8Wozd9talfJJW6CkOl5vVekfTdKMXRy4WrOi2FxQ5VHztdmhU3kEq_U7iCklnKTe9HrLyUK4MjeL6vkXr8ZWv2UgC-kJznAul4sjHA-noUbo-cMCrO-I2V4N1Cie28gA2zcjaM/s320/IMG_1916.JPG" width="320" /></a></div><br />
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You can now add the stap by insertign the strap end bolts through the cover and in to the threaded hole in the frame. It should then look like this:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbAW8PRHmWr4DUdCL-iFpeg9cOHbHoXktOkv_cOgkDjVHJPWpcBEk6n9H1t4VrbC-OkmUTw1_QAshQwmogcctVgQqx9s6ySrvLpXosY7Q9T4gOlu67u5iDcYpEQPIS_d1PTVx7iES5qZE/s1600/IMG_1917.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbAW8PRHmWr4DUdCL-iFpeg9cOHbHoXktOkv_cOgkDjVHJPWpcBEk6n9H1t4VrbC-OkmUTw1_QAshQwmogcctVgQqx9s6ySrvLpXosY7Q9T4gOlu67u5iDcYpEQPIS_d1PTVx7iES5qZE/s320/IMG_1917.JPG" width="320" /></a></div><br />
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And be dead centre in the seat pattern as shown below. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh93nTRrZ41eBlTvPc1WnuD44ZFdYN5hyphenhyphenVWkzL8Bhg6IL6z8PblWhv0D6gdOK1rHzNurVd6Jerz8d1lYPDTp27SQvPYQTz1Aow4DiLSknseMSngSeZMA_pJDvc1cVw3RLri3mVr-G7JfFo/s1600/IMG_1918.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh93nTRrZ41eBlTvPc1WnuD44ZFdYN5hyphenhyphenVWkzL8Bhg6IL6z8PblWhv0D6gdOK1rHzNurVd6Jerz8d1lYPDTp27SQvPYQTz1Aow4DiLSknseMSngSeZMA_pJDvc1cVw3RLri3mVr-G7JfFo/s320/IMG_1918.JPG" width="320" /></a></div><br />
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Now insert the rubber buffer block.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdKBlN06GXn7Rj_k2qQ6a177VpHu7hV4QUA0BKCoJDEeAOL8R6YYstyIXmw1Ig-dSDjJH4Sjw45zQbLqNFtkiEnEe9NNJl5gpoaFu9o3PZzh74awlOUgCsJb1Tcd6AFopU7FekqXoy68A/s1600/IMG_1919.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdKBlN06GXn7Rj_k2qQ6a177VpHu7hV4QUA0BKCoJDEeAOL8R6YYstyIXmw1Ig-dSDjJH4Sjw45zQbLqNFtkiEnEe9NNJl5gpoaFu9o3PZzh74awlOUgCsJb1Tcd6AFopU7FekqXoy68A/s320/IMG_1919.JPG" width="320" /></a></div><br />
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You might need to drop it in boiling water and use a bit of soap to get it to go in to the frame holes. It is VERY tight!<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8rI8MBfZcWVKhNQfA4zlIX3rYG-lEynDtmyKAbYatnmxuP2dJmybO44ZWGUbbbly4qdWj9majMVuMh5rHm1ornu9hhCA4Vj8hIeNubuNToskagLPxHIwaWkRtuvNFLp-KMCL3cecQgd4/s1600/IMG_1920.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8rI8MBfZcWVKhNQfA4zlIX3rYG-lEynDtmyKAbYatnmxuP2dJmybO44ZWGUbbbly4qdWj9majMVuMh5rHm1ornu9hhCA4Vj8hIeNubuNToskagLPxHIwaWkRtuvNFLp-KMCL3cecQgd4/s320/IMG_1920.JPG" width="320" /></a></div><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUbAqMMMBWlk6F4scm43x6u5XOcFOR8chAqGg-N0qGRGdIHeJTQCRdLUxXZugl-9kdTGWlxjPak_96HJ-wa6Vkqe-TFVh6yWnOFwc_XxbyGdN9XJzhGEj2REbdMPfSYcENArHKqMKE270/s1600/IMG_1921.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUbAqMMMBWlk6F4scm43x6u5XOcFOR8chAqGg-N0qGRGdIHeJTQCRdLUxXZugl-9kdTGWlxjPak_96HJ-wa6Vkqe-TFVh6yWnOFwc_XxbyGdN9XJzhGEj2REbdMPfSYcENArHKqMKE270/s320/IMG_1921.JPG" width="320" /></a></div><br />
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Here is the fixing kit for the seat. 13mm bolts and nuts, plus washers. Notice, teh rear bracket for the catch has nylon washers.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAl6KENMGiKxSiAc7P1yexmZlRtypUyCCZqt9QISmr4PQE-oq3LmbKzytHCiX9rNHCoeEZfYNgveES0YytXN6AKD9gdEj2U4Vvony93jsbtPFs7Ic4Y0kLNsU8AwQEcqmFPYUPV3kRpUI/s1600/IMG_1922.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAl6KENMGiKxSiAc7P1yexmZlRtypUyCCZqt9QISmr4PQE-oq3LmbKzytHCiX9rNHCoeEZfYNgveES0YytXN6AKD9gdEj2U4Vvony93jsbtPFs7Ic4Y0kLNsU8AwQEcqmFPYUPV3kRpUI/s320/IMG_1922.JPG" width="320" /></a></div><br />
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Fit the front hinge by adding a thicker washer (shown below) under the hinge and a slimmer one under the nut, which goes inside the toolbox.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyqubN-S5YFoHeBpvDlKKeZyB0kgp6dltziIEWuHpJYVxEnTyvN4JXJncTXzg5C2t42gJKC-XiF7yp3HySItErEf9Gi4wWnF1NHjKOB0HgSBvoXZ3q5ufjIXfoP4DKeZ6fKHIQ4K7i6S0/s1600/IMG_1923.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyqubN-S5YFoHeBpvDlKKeZyB0kgp6dltziIEWuHpJYVxEnTyvN4JXJncTXzg5C2t42gJKC-XiF7yp3HySItErEf9Gi4wWnF1NHjKOB0HgSBvoXZ3q5ufjIXfoP4DKeZ6fKHIQ4K7i6S0/s320/IMG_1923.JPG" width="320" /></a></div><br />
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Put the thicker washers in place under the air scoop.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN_LNV0AB0ub7jWmAdjAFVsyAI-h9HYUyi2m2mWn5OIwPJw_HAhKrly2kj0TvCStY9yu8fy53gWNXHasay4BAnHpm1ZFTelW8dxs-wz14YGrJi88YZcIeRVtTEgZB5hpmqA6aHXtD8eJs/s1600/IMG_1924.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN_LNV0AB0ub7jWmAdjAFVsyAI-h9HYUyi2m2mWn5OIwPJw_HAhKrly2kj0TvCStY9yu8fy53gWNXHasay4BAnHpm1ZFTelW8dxs-wz14YGrJi88YZcIeRVtTEgZB5hpmqA6aHXtD8eJs/s320/IMG_1924.JPG" width="320" /></a></div><br />
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Offer up the hinge and push two of the bolts through. This is easily a two man job.<br />
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Fasten these two bolts loosely with a washer and nut on the underside of the frame in the toolbox. Then, slip in the front two thick washers and insert the front bolts and fasten. Don't fasten them all too tightly as we may need to adjust the position of the seat a little when fitting the rear catch.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqW74ragYIHOxl6kfSfvFBfG4Nu7vdbYg4Pow1Ow5CWTvew4nRIQ9FMwV9Pqx2orV_hR-vL8lHAdOiPVI7CcS5NNpS0XWoBfD4PaGyhSaOMNT8IGInQi220ywBOicdYO23jVrMHX3tyNI/s1600/IMG_1925.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqW74ragYIHOxl6kfSfvFBfG4Nu7vdbYg4Pow1Ow5CWTvew4nRIQ9FMwV9Pqx2orV_hR-vL8lHAdOiPVI7CcS5NNpS0XWoBfD4PaGyhSaOMNT8IGInQi220ywBOicdYO23jVrMHX3tyNI/s320/IMG_1925.JPG" width="320" /></a></div><br />
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It was at this point I realised we had picked up the wrong rear catch bracket. So for now, I'm using a sheet of bubble wrap to protect the frame and paint whilst the seat is down.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzOOuFou5y2UPpOlmzvC0G5bw1txCCCZ78iWXtGfBi22VSZ37ABzAETX_fY6_voiQJbN2H5uEM9gk5tkcjSRW_mMBdtD0MfxkRDiIy8B6YyPye_69dbE3jxqlpNaLvT_4W74z8anRUHd0/s1600/IMG_1926.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzOOuFou5y2UPpOlmzvC0G5bw1txCCCZ78iWXtGfBi22VSZ37ABzAETX_fY6_voiQJbN2H5uEM9gk5tkcjSRW_mMBdtD0MfxkRDiIy8B6YyPye_69dbE3jxqlpNaLvT_4W74z8anRUHd0/s320/IMG_1926.JPG" width="320" /></a></div><br />
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But it does look rather good with the seat added.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH9aPZc-M4OjtBkuDkNTQ21TQZbYjsg8qVJ0iNQGmukhFMxKgZUvr8zpKMuZ_jV6CD1f5fdv4o-XaQaOFE3h4s-kpDcwPEsr7AAAh8UXJvRCRz8pa5Uczi_RimrAhCW0lOclRCWHbj_7M/s1600/IMG_1927.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH9aPZc-M4OjtBkuDkNTQ21TQZbYjsg8qVJ0iNQGmukhFMxKgZUvr8zpKMuZ_jV6CD1f5fdv4o-XaQaOFE3h4s-kpDcwPEsr7AAAh8UXJvRCRz8pa5Uczi_RimrAhCW0lOclRCWHbj_7M/s320/IMG_1927.JPG" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3m6zEdAxL2TJfXiwKWwrj4BpA0zhtScFrp3R984TQY83aw6dLYke9nvaQseoVb9PkLjkiNLOVQZOZgNzuA_Z_3N21JFy99qI4y0EGj3qUTJ0SfAhUQ0W0hDA_DuI_XEseEFs1IM5YJGI/s1600/IMG_1928.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3m6zEdAxL2TJfXiwKWwrj4BpA0zhtScFrp3R984TQY83aw6dLYke9nvaQseoVb9PkLjkiNLOVQZOZgNzuA_Z_3N21JFy99qI4y0EGj3qUTJ0SfAhUQ0W0hDA_DuI_XEseEFs1IM5YJGI/s320/IMG_1928.JPG" width="320" /></a></div><br />
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Here is the offending rear bracket. Notice the catch part is central on the bracket. Ours needs to be the type which is very similar, except with the catch to the left a little more. Oh well. I could always have the guys collect the scooter and add this themselves, it's such an easy job now to complete.<br />
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We ALL make mistakes.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbXJLD70gSnUhYQhrPEQwAQnzbm7Mvbp4oSrCtm5hjx6VZR7niRTxzzPxoS8F4T2Pfh4AgLFbFO4_9YeJGDXO57c-malZanUUtxLHutiwUXGVA7LaTTh9YiXNpJsEtL3m2uPogL8deMhU/s1600/IMG_1929.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbXJLD70gSnUhYQhrPEQwAQnzbm7Mvbp4oSrCtm5hjx6VZR7niRTxzzPxoS8F4T2Pfh4AgLFbFO4_9YeJGDXO57c-malZanUUtxLHutiwUXGVA7LaTTh9YiXNpJsEtL3m2uPogL8deMhU/s320/IMG_1929.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com2tag:blogger.com,1999:blog-5171578948572365563.post-70849558091745908972011-12-24T12:51:00.000+00:002011-12-24T12:51:10.875+00:00Christmas UpdateThis post is just to let everyone know what is going on with the restoration Lambretta since it has been a couple of weeks since the last one.<br />
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All the parts required to finish the scooter have arrived at Armandos but I have yet to fetch them. We have a switch for the handlebars as well as a new seat cover to match our newly refurbished seat base and one or two other minor bits. These will be added very early in the new year.<br />
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The reason the parts have not been collected is because Giulio and Guido, from Armandos have been forced to take a break from the shop to travel to Italy following the sudden death of their father and founder of the shop, Armando Pastorelli.<br />
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The news came as a shock to me as Armando was the man who sold me my first ever scooter at the tender age of 18 and his sons, who now manage the shop, have been friends of mine ever since. I want to send them my love and respect and wish them well through this sad time. My thoughts go to the Pastorelli family and all Armandos friends around the world that he made through scootering and beyond. He was one of the most knowlegeable men I have ever had the pleasure of meeting and was generous to a fault. I will personally miss him greatly.<br />
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Hopefully, the next couple of posts on this blog will be the finishing off posts for this particular Lambretta and then it will be going back to the shop for valuation before hopefully being collected by it's new, and VERY lucky owner.<br />
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As mentioned, that will definitely follow after the small Christmas break.<br />
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Merry Christmas and a happy new year to you all.<br />
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Paul Slack.Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-51824205421593639652011-11-27T15:05:00.001+00:002011-11-27T21:14:38.442+00:00Official Dating CertificateJust a quick update.<br />
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There are a couple fo small parts left on order for the scooter to be finished. The first is a handlebar switch, which has been on order a while but is taking a little longer to arrive that we expected. Without it, we cannot run the wires down to the horn and therefor we cannot put on the horn casting or the horn grille. The last item missing is a seat cover. Again, we are waiting for a new leather seat cover to arrive which is remade to original specification to fit on our newly refurbished seat base.<br />
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Next week, we hope to have them and the scooter will be all but finished.<br />
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We can then add the last parts, finish up the wiring and start the scooter for the first time in many, many years. That will be quite a day. The scooter will then go through a few setup stages to ensure starting and running is perfect before it returns to Armandos Scooters in Sheffield for it's MOT.<br />
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This week, the Lambretta Club Great Britain Dating Certificate arrived. This confirms the Lambretta we have was built in 1963 and more importantly, it guarantees that I will be able to have the scooter issued with an age related plate by DVLA.<br />
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So, it is all coming together nicely and we will soon be ready to hand this scooter over to the lucky person who buys it.<br />
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More next week.<br />
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PaulPaul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-81760868913188598482011-11-20T18:38:00.002+00:002011-11-21T12:46:14.492+00:00The wiring loomShown below is the genuine cover for the CDI unit. Passed through it are the green, white and red wires from the stator plate and a green wire from the loom. The yellow wire you can see branches off toward the rectifier.<br />
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Attach the four wires to the CDI.<br />
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And fit the rubber cover as shown.<br />
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This is yet another genuine cover for the regulator. However, it was quite hard due to age and very tight to fit. For the purpose of this work today, I have shown the wiring without it, but it WILL be fitted when the wiring is completed.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjr6ZhZmqpHGtNq0fwlmKoT6fTwtuHxN9-iDsBfOsE_y-CiqbjqkNXijGkMyOng5yY1W0Pl8BGy4UFYoOWsEExj0yUpAsKIOfkgK20CC7w4maRcjuDMSNwuWnt7L2-fry4qPQJQA9iLJqo/s1600/IMG_1844.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjr6ZhZmqpHGtNq0fwlmKoT6fTwtuHxN9-iDsBfOsE_y-CiqbjqkNXijGkMyOng5yY1W0Pl8BGy4UFYoOWsEExj0yUpAsKIOfkgK20CC7w4maRcjuDMSNwuWnt7L2-fry4qPQJQA9iLJqo/s320/IMG_1844.JPG" width="320" /></a></div><br />
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Here we see the yellow wire fitted to the regulator where the yellow dot is. The pink, purple and brown wires from the loom are all joined together and go to the dot marked in grey. The last dot on the regulator is black and indicates earth. Here, you can see the earth braid.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf0VVP7MGdQwvD1LEl1BKN-gCWtv08mXzVowS3S5XjEKSRdcucll4VjGK5CgmEaZj1itZqxFXK15Nyqb6KNWQYxOtdChMiU7Kn3vN4dFBuQRL5Rd2RSNjsVE3v10jYxVYwSHLKRVCzYMM/s1600/IMG_1845.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf0VVP7MGdQwvD1LEl1BKN-gCWtv08mXzVowS3S5XjEKSRdcucll4VjGK5CgmEaZj1itZqxFXK15Nyqb6KNWQYxOtdChMiU7Kn3vN4dFBuQRL5Rd2RSNjsVE3v10jYxVYwSHLKRVCzYMM/s320/IMG_1845.JPG" width="320" /></a></div><br />
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The earth braid travels down and is attached to the legshield strut with a nut and bolt via an inline ring fastener and then down to the top of the flywheel cover, where it is attached at the same point the flywheel cover is fixed uppermost.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVW_7yM-IJx9mYZbxXXUCQDL_JwME34krZdr8uLSDm-UgWewEI4S8Zx2fxeLrxHPK06j9n6ElYIXOzmHQuDPvqgfrzeGWDWjX92U5ar8i0VjxnTvn4xyaEM908E_vYPhSu-M9T6n-k6YY/s1600/IMG_1846.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVW_7yM-IJx9mYZbxXXUCQDL_JwME34krZdr8uLSDm-UgWewEI4S8Zx2fxeLrxHPK06j9n6ElYIXOzmHQuDPvqgfrzeGWDWjX92U5ar8i0VjxnTvn4xyaEM908E_vYPhSu-M9T6n-k6YY/s320/IMG_1846.JPG" width="320" /></a></div><br />
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The headset wiring block is divided in to sections of individual, dual and triple connections. By turning your wiring block over, you can see which ones are linked.<br />
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Using the wiring diagram posted earlier in the build, connect the wires as required. Some wires, like the black ones for example need to be connected in a block that allows 3 to be joined, as long as you allow for this, you can put the wires anywhere as long as they connect together as shown.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkikgrGWWD6Yx8Fv5_13DwWMqfQZV7125srSA6Igdg7ivBSYgrriAgHCIXvG9cUPQFJI1jedIP_9dfEBo0VwoqHz426K4LroCigalI0m8NU-gBkEVW5qvNGnpWabW6RLHCDkcYDXs00zc/s1600/IMG_1849.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkikgrGWWD6Yx8Fv5_13DwWMqfQZV7125srSA6Igdg7ivBSYgrriAgHCIXvG9cUPQFJI1jedIP_9dfEBo0VwoqHz426K4LroCigalI0m8NU-gBkEVW5qvNGnpWabW6RLHCDkcYDXs00zc/s320/IMG_1849.JPG" width="320" /></a><br />
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Here is the wiring diagram posted previously for reference. Print it out if that helps:<br />
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Notice that the block is held in place with a wire clip, I will be removing the block to make life a little easier wiring in the loom and switch etc. clipping it back in to the headlight unit is a very simple job.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZnKB50rIAWWOUI9OKPpCynByF8T5UqKmJRBhNepc6mG3JBhM1szs2E6SZc_zTmriLi5wQU8OR9H6gQ2Rko3ElCAo12vXkMo-qwFK4ogoRyVnM_uMZc1DX-3J3cvusz9iaVGq5wwDFkK0/s1600/IMG_1829.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZnKB50rIAWWOUI9OKPpCynByF8T5UqKmJRBhNepc6mG3JBhM1szs2E6SZc_zTmriLi5wQU8OR9H6gQ2Rko3ElCAo12vXkMo-qwFK4ogoRyVnM_uMZc1DX-3J3cvusz9iaVGq5wwDFkK0/s320/IMG_1829.JPG" width="320" /></a></div><br />
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It was a legal requirement that all scooters used in the UK had a parking light at this time and therefor, all models exported to the UK had a battery tray and battery as standard equipment.<br />
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As this model was made for the Italian market, no battery tray was fitted and thus, we only require two of the water slides.<br />
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Here is the 'running-in' water slide. First, remove the opaque cover from the front of it.<br />
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Then soak in water for around 30 seconds.<br />
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Turn it over carefully and soak for a further 30 seconds on the other side.<br />
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VERY carefully, push the slide upward and off the backing sheet and lay this exposed edge on to the scooter in the position shown.<br />
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Then, slowly slide the backing from the transfer as opposed to the other way around. Gently hold the transfer in place, whilst pulling the backing from underneath.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuRjIIYMoBqED6fMOg5y3aUf26wQNPLBPTkwU3cNbVO0cF5oOUwwCJPvnHHm-uG40aAANFGVDhZd2CirFV6FOH_igTi9JjX7f6uRRwNs7lZOSWQvi8HnrLrfLNfKZAFgr-60bO0UNZMRs/s1600/IMG_1836.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuRjIIYMoBqED6fMOg5y3aUf26wQNPLBPTkwU3cNbVO0cF5oOUwwCJPvnHHm-uG40aAANFGVDhZd2CirFV6FOH_igTi9JjX7f6uRRwNs7lZOSWQvi8HnrLrfLNfKZAFgr-60bO0UNZMRs/s320/IMG_1836.JPG" width="320" /></a></div><br />
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With a very soft clean cloth, carefully dab any excess water from the slide and press out any air bubbles. Minor wrinkles can be left as these will dry out and vanish by thenselves.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0JPWnMB8RW-kFK9yYgxjPxhf0ZhZdsy6VsfKSNWSlgcHsV2hBcSbNLcPDd486JEkxMAoJqbWyt5Kz_iAVtns1xioVd-IR4QzGlc-ZKweXr3suWHXZiI5V4vE1Eqyv3Wk4EIGnFw_y-2Q/s1600/IMG_1837.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0JPWnMB8RW-kFK9yYgxjPxhf0ZhZdsy6VsfKSNWSlgcHsV2hBcSbNLcPDd486JEkxMAoJqbWyt5Kz_iAVtns1xioVd-IR4QzGlc-ZKweXr3suWHXZiI5V4vE1Eqyv3Wk4EIGnFw_y-2Q/s320/IMG_1837.JPG" width="320" /></a></div><br />
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I personally think this is a nice addition to a factory restoration and really looks the part.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYqocw4uM8zGL39vX7o8xntG71XOdsJF9es3apPLzfpYvzPg2r1iZ96b8_EAOI7S_5UxhqU9g26RCH0Oyk58CCQN3EZ2DhC8Qd668Mge4mVjEJ8YrT2XeXzX2DQjOg2AseMWAhpHhwClc/s1600/IMG_1838.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYqocw4uM8zGL39vX7o8xntG71XOdsJF9es3apPLzfpYvzPg2r1iZ96b8_EAOI7S_5UxhqU9g26RCH0Oyk58CCQN3EZ2DhC8Qd668Mge4mVjEJ8YrT2XeXzX2DQjOg2AseMWAhpHhwClc/s320/IMG_1838.JPG" width="320" /></a></div><br />
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Soak the air filter slide as previous.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiVdATYqcWpAkBaJMxb6zf6EyRN_ZS80hHKsGvNuPNvRSAjNtSLmvEHO5Kk31HGSzUeN3JiiyKfxQOtyE4FaGAJIuErxtHgSlT2IIKQSksHtqNPAqUO-nMF6n83rPceS7LiSLEBPDeiXw/s1600/IMG_1839.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiVdATYqcWpAkBaJMxb6zf6EyRN_ZS80hHKsGvNuPNvRSAjNtSLmvEHO5Kk31HGSzUeN3JiiyKfxQOtyE4FaGAJIuErxtHgSlT2IIKQSksHtqNPAqUO-nMF6n83rPceS7LiSLEBPDeiXw/s320/IMG_1839.JPG" width="320" /></a></div><br />
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And apply where shown.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIq49DBxQSLgpXyWVSXK7uq8Q4CiLnc71t5Ejh3C2n9FpkBR5Arzz3pYRg-AR6IwylQlD1OLV__ejn8xXTKLZEuDGrWwSt_mYGI77R7a6ekDz1soctlKk7ZOFzeg31OvfE0Wpqxp2htxA/s1600/IMG_1840.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIq49DBxQSLgpXyWVSXK7uq8Q4CiLnc71t5Ejh3C2n9FpkBR5Arzz3pYRg-AR6IwylQlD1OLV__ejn8xXTKLZEuDGrWwSt_mYGI77R7a6ekDz1soctlKk7ZOFzeg31OvfE0Wpqxp2htxA/s320/IMG_1840.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-29990582497491168122011-11-20T16:05:00.000+00:002011-11-20T16:05:31.311+00:00Installing the speedometerStandard speedos like this are getting increasingly hard to find these days. This one, I know is working 100% although the housing and face are yellowing slightly I am going to use it. It is totally original and quite rare.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguQfEPNEhLR6MpIVtNc-Y9Xq27qe3tzvdor9pkk5zSIXrbIujV1Z3i9PxNf9quIdDHiX6A6w1NIhOU4dwG6exwsGCR_TqKalw0Cbx55UBBPLUNpbOZxfeSAkoVVuKhBVbPFOGB3kFr62c/s1600/IMG_1822.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguQfEPNEhLR6MpIVtNc-Y9Xq27qe3tzvdor9pkk5zSIXrbIujV1Z3i9PxNf9quIdDHiX6A6w1NIhOU4dwG6exwsGCR_TqKalw0Cbx55UBBPLUNpbOZxfeSAkoVVuKhBVbPFOGB3kFr62c/s320/IMG_1822.JPG" width="320" /></a></div><br />
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These are the markings you look for when hunting for a genuine Innocenti Speedometer.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnVfTsiIjhqmB-eiySJLIA1m2Qx2zP5YcaSZA6DCxPKdacM8mNeVQEuVHnLdewZ1Vxlnf4MFSVotexxddkCm_Lt7W4ZxwyB_xMgP4nQXUbIN6t-vjeqCMRB1UYQk3NU-y2gDqnzwpH3FQ/s1600/IMG_1823.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnVfTsiIjhqmB-eiySJLIA1m2Qx2zP5YcaSZA6DCxPKdacM8mNeVQEuVHnLdewZ1Vxlnf4MFSVotexxddkCm_Lt7W4ZxwyB_xMgP4nQXUbIN6t-vjeqCMRB1UYQk3NU-y2gDqnzwpH3FQ/s320/IMG_1823.JPG" width="320" /></a></div><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJrcz2iHhw63iWzEsZYKnioUb0IE8HOp3oTBtZtWxyPEdT9KTMjwhVWNp25UcIyWIyMhpzCZX6K5wwhkhz420UreDw6paJOLzTsqlwZxn3bLOmL041-37_agJEsyClKII0o_Rd3TjKSZ4/s1600/IMG_1824.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJrcz2iHhw63iWzEsZYKnioUb0IE8HOp3oTBtZtWxyPEdT9KTMjwhVWNp25UcIyWIyMhpzCZX6K5wwhkhz420UreDw6paJOLzTsqlwZxn3bLOmL041-37_agJEsyClKII0o_Rd3TjKSZ4/s320/IMG_1824.JPG" width="320" /></a></div><br />
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Insert the speedo into the headset top. It should be quite a snug fit. Make sure your headset top is on a nice soft surface with nothing to scratch it underneath.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEzOUQo4oDRkN_MNisxplJrSxlnRyy4duGkx6Tw1dW-l3er4r0INaMI8Di7SlvgyHPXS4BzASCrA26MpZQgHmwzRiJefLOfhXviRthkdwnzpI07BdKB7ws0uUU0Zxo_2Kjv3NdwZmVjvI/s1600/IMG_1825.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEzOUQo4oDRkN_MNisxplJrSxlnRyy4duGkx6Tw1dW-l3er4r0INaMI8Di7SlvgyHPXS4BzASCrA26MpZQgHmwzRiJefLOfhXviRthkdwnzpI07BdKB7ws0uUU0Zxo_2Kjv3NdwZmVjvI/s320/IMG_1825.JPG" width="320" /></a></div><br />
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Place on the retaining ring as shown.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk89cIm6IGIQtsZlkXtbd7aMBWuDcyFLMugqiSFOILbR4aZzz5h-c5tH943h8vqcs6u3Pag97GuKHrLMrV8R9g4iboXBywy6CeP9xjqrwas0d0JZOlZHcOxTeX8PeTdqF5tPIrJm61ymU/s1600/IMG_1826.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk89cIm6IGIQtsZlkXtbd7aMBWuDcyFLMugqiSFOILbR4aZzz5h-c5tH943h8vqcs6u3Pag97GuKHrLMrV8R9g4iboXBywy6CeP9xjqrwas0d0JZOlZHcOxTeX8PeTdqF5tPIrJm61ymU/s320/IMG_1826.JPG" width="320" /></a></div><br />
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and fasten down with three 5mm long screws which have round slotted heads.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv4RGpml3vJrGalCTwdEhqF9GwPXjVU7Pg6mwEOnVT9ZQ24VmnqLu_tfNQRcE9yDn4-RM95-NFmv7DolTKmO7C_ViGKoiwgfqkaSYOoX6OzRuV4vj-Pv2kmwTmfG1367YvOC9327Ontz8/s1600/IMG_1827.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv4RGpml3vJrGalCTwdEhqF9GwPXjVU7Pg6mwEOnVT9ZQ24VmnqLu_tfNQRcE9yDn4-RM95-NFmv7DolTKmO7C_ViGKoiwgfqkaSYOoX6OzRuV4vj-Pv2kmwTmfG1367YvOC9327Ontz8/s320/IMG_1827.JPG" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWMOrcvtlr3Kp5bb9Le1LJPLEi7dv7PWz_hwJ8EO0qJWNvymx1TsLwhiu_i7yWtLhCqBOAg-FVa2vg92nPKFY_fUatEZ5AiooH-qfl4HuCAdPZToXRVv_iZD0tQ92i0vAmPtxo0pmhfDU/s1600/IMG_1828.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWMOrcvtlr3Kp5bb9Le1LJPLEi7dv7PWz_hwJ8EO0qJWNvymx1TsLwhiu_i7yWtLhCqBOAg-FVa2vg92nPKFY_fUatEZ5AiooH-qfl4HuCAdPZToXRVv_iZD0tQ92i0vAmPtxo0pmhfDU/s320/IMG_1828.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com2tag:blogger.com,1999:blog-5171578948572365563.post-47113162467620916622011-11-20T15:59:00.001+00:002011-11-22T13:23:03.468+00:00Don't forget engine oilEasy to forget, but probably fatal for your engine if you do it.<br />
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Remove the upper oil filler plug.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitMS17269dAOshWoDk1JW-XtapFhbdJmuQlg67730H5h1XlZkymVmW9A2zER5Z6gTzg2bU4QevRA9dH4PKYhx-3NQpczv4plvu8vQ8jXZnnVavBEQmygqE5mCZna4kJEgRvs-trl3cNOo/s1600/IMG_1815.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitMS17269dAOshWoDk1JW-XtapFhbdJmuQlg67730H5h1XlZkymVmW9A2zER5Z6gTzg2bU4QevRA9dH4PKYhx-3NQpczv4plvu8vQ8jXZnnVavBEQmygqE5mCZna4kJEgRvs-trl3cNOo/s320/IMG_1815.JPG" width="320" /></a></div><br />
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Make sure you do not loose the filler plug fibre washer.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmjTlYNsWVZGChyphenhyphenXFGrOlo41AHxqxdf5CSvDoA1E9PSKH7PXYc8NjnsMNsXWwGoMz3vQAbkBtbtk40N_HYmlMggNDmRq14qa_nvPT_oyFTu6euLNxIX3y4_78HbQepDNEGmFPLx_fefiw/s1600/IMG_1816.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmjTlYNsWVZGChyphenhyphenXFGrOlo41AHxqxdf5CSvDoA1E9PSKH7PXYc8NjnsMNsXWwGoMz3vQAbkBtbtk40N_HYmlMggNDmRq14qa_nvPT_oyFTu6euLNxIX3y4_78HbQepDNEGmFPLx_fefiw/s320/IMG_1816.JPG" width="320" /></a></div><br />
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Use a funnel in the engine filler hole.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5H3EEqi0MfoGJTxgp5D7Ntj6zI7E7ozxc1VfEIJC_A1-W5-DfXXxxE4dwvbSDao3clPKuUBB5XRN5vPLTJsb315xQsqm17FWKLQM97st7o4zyWDRs9rdNafVQMN6VwAlgfR1GZIYjMEg/s1600/IMG_1817.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5H3EEqi0MfoGJTxgp5D7Ntj6zI7E7ozxc1VfEIJC_A1-W5-DfXXxxE4dwvbSDao3clPKuUBB5XRN5vPLTJsb315xQsqm17FWKLQM97st7o4zyWDRs9rdNafVQMN6VwAlgfR1GZIYjMEg/s320/IMG_1817.JPG" width="320" /></a></div><br />
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and add 750ml (three quarters of a litre) to a dry engine.<br />
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Remember, we are adding this to a totally dry engine, so after initial running checks and setup, we will be checking the levels again using the level plug as some oil will be lost when circulating the engine and soaking the clutch etc.<br />
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Normally, you will drain the oil using the lower of the two plugs in the bottom of the engine and check the level by filling from the top until it starts to seep from the upper two plugs (the level plug).<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq4jdbnPY3-iApnDf5teg88FbhqPhgOfc7HGgRXWT6OEgBzG8Fx7KQ75lXggHQymyuPxLm0RiA7nsQqRAIgt9sv-wP8PleIVTu3pLdoTfKFEYkXqgVls4YB1yA-9fsk8dApTGgzi-sm_I/s1600/IMG_1819.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq4jdbnPY3-iApnDf5teg88FbhqPhgOfc7HGgRXWT6OEgBzG8Fx7KQ75lXggHQymyuPxLm0RiA7nsQqRAIgt9sv-wP8PleIVTu3pLdoTfKFEYkXqgVls4YB1yA-9fsk8dApTGgzi-sm_I/s320/IMG_1819.JPG" width="320" /></a></div><br />
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The engine is ready to roll.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAYmLeVC2SZGlFO-oLiNPV0F-SgjOcgzoA6441mRVWNYenabD-eSJTrQqjxA_SWjE2CuQJ8D1h7y60Wqwop6xLM3uQBYOy52fElj-tad4SOBDMNaxvNqAGcVF62D0SHI2PTJfx2HE2blA/s1600/IMG_1820.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAYmLeVC2SZGlFO-oLiNPV0F-SgjOcgzoA6441mRVWNYenabD-eSJTrQqjxA_SWjE2CuQJ8D1h7y60Wqwop6xLM3uQBYOy52fElj-tad4SOBDMNaxvNqAGcVF62D0SHI2PTJfx2HE2blA/s320/IMG_1820.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-13183438714222866532011-11-20T15:52:00.000+00:002011-11-20T15:52:38.986+00:00Adding fasteners and supressor cap to HT leadThe HT lead already comes from the CDI Unit as was attached in a previous post.<br />
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Next job is to secure it to the frame en-route to the sparking plug.<br />
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You will need a rubber grommit like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiuheUtpB6w8e6cw7Ht6LuhajQ6FVl1qgbjBj6fGBreTab4ZWom6Mea8cXEBvheadOz746IxK41MIMnrwIfISK9BfsgWPKCZ2oYt6rEjao2JJ5KONoYY2wjYSStqCNurVWEu2sacangYA/s1600/IMG_1802.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiuheUtpB6w8e6cw7Ht6LuhajQ6FVl1qgbjBj6fGBreTab4ZWom6Mea8cXEBvheadOz746IxK41MIMnrwIfISK9BfsgWPKCZ2oYt6rEjao2JJ5KONoYY2wjYSStqCNurVWEu2sacangYA/s320/IMG_1802.JPG" width="320" /></a></div><br />
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Slip the grommet over the plug end of the HT lead<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1YRBM8o7SLKa8MtRFvBi6ryzhKn5261jquYrJVVWUn7_C-wTXejUXNm9FnlQplr2vWXPoHlmQ04AftdG8xo25s_x5c9Kt1u9yz4N59CYjjJ2plOpRKcZfiYjv3IUDB_Uwyte03wmvY1s/s1600/IMG_1803.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1YRBM8o7SLKa8MtRFvBi6ryzhKn5261jquYrJVVWUn7_C-wTXejUXNm9FnlQplr2vWXPoHlmQ04AftdG8xo25s_x5c9Kt1u9yz4N59CYjjJ2plOpRKcZfiYjv3IUDB_Uwyte03wmvY1s/s320/IMG_1803.JPG" width="320" /></a></div><br />
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Push the grommet right up the lead and then pass the lead down through the tab on the legshield support like so...<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1cbVX28fA91PLgn5WSWqk112xOVDlbu_yllEYQ0D-Wwfb6NDBmxy-CiKE_gB2iIgL4AA12rK0kNpw6jJFMsGclMyQqFHnRHuHpHv-jgObhLHmluUfmtUpm_CqDf93w0iMRJf_Yg31NHw/s1600/IMG_1804.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1cbVX28fA91PLgn5WSWqk112xOVDlbu_yllEYQ0D-Wwfb6NDBmxy-CiKE_gB2iIgL4AA12rK0kNpw6jJFMsGclMyQqFHnRHuHpHv-jgObhLHmluUfmtUpm_CqDf93w0iMRJf_Yg31NHw/s320/IMG_1804.JPG" width="320" /></a></div><br />
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Now, the grommet and lead leed to be secured by the metal tab. If yours will not pass under it, you will need to open up the tab VERY gently. The tab can break off pretty easily.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCz_DDoiDD94ea1tTnsLCgYrvTZySAodK3jlqGyvP1o3jhWhvL8V0DMgDWq4ULhfHHUTGgrp_cm3Wk5llPfxQTezcKPxxCF_KBu4fIpRS-zFMstAeU5LEcwvtK4r5yt3SlbwaQaWCkTCw/s1600/IMG_1805.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCz_DDoiDD94ea1tTnsLCgYrvTZySAodK3jlqGyvP1o3jhWhvL8V0DMgDWq4ULhfHHUTGgrp_cm3Wk5llPfxQTezcKPxxCF_KBu4fIpRS-zFMstAeU5LEcwvtK4r5yt3SlbwaQaWCkTCw/s320/IMG_1805.JPG" width="320" /></a></div><br />
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It should look like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoosaqHhz_xyhwr8KLqJIivamDERp5SpUQZoL7dl66c2QlWbxqCX8M_dsaP2TfLHpgEpPi5O84IM0vRVdATxXOlaa7NRQpb0LuB4VYLokl3V6XLO7edF24DlkFpZJ9slCcQvplltUjSTk/s1600/IMG_1806.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoosaqHhz_xyhwr8KLqJIivamDERp5SpUQZoL7dl66c2QlWbxqCX8M_dsaP2TfLHpgEpPi5O84IM0vRVdATxXOlaa7NRQpb0LuB4VYLokl3V6XLO7edF24DlkFpZJ9slCcQvplltUjSTk/s320/IMG_1806.JPG" width="320" /></a></div><br />
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Whatever model you are working on or whatever CDI, Coil, Regulator setup, your HT Lead should go over the rear shock absorber support like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghfpoCzySjY62IcNZdr3EHZZ224Ap4_6969PzS6aFRe2s4gP5i56L_gvrRMBCrTdEloKrwEITUqHVf_2RwZFh3z0i0C3KlSeyeFoQWcvDMjfQk2DISDiGu38JVhcmJ_56hfFOAXMNmkAw/s1600/IMG_1807.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghfpoCzySjY62IcNZdr3EHZZ224Ap4_6969PzS6aFRe2s4gP5i56L_gvrRMBCrTdEloKrwEITUqHVf_2RwZFh3z0i0C3KlSeyeFoQWcvDMjfQk2DISDiGu38JVhcmJ_56hfFOAXMNmkAw/s320/IMG_1807.JPG" width="320" /></a></div><br />
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Pass a rubber bridge over the HT Lead end.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlpSPYHQ0899o9E4TahwrmuI_gwdhphsP2jc2D8hURXkm68zMZahBXHTAT6n8mgwSVSo9QT3F4BHRLfMNb1PD_SRyfD-ovS5nXbP7tqsJkeGPSaLBdEVX-mLUGTEp694Fc0JUGopfwsgw/s1600/IMG_1808.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlpSPYHQ0899o9E4TahwrmuI_gwdhphsP2jc2D8hURXkm68zMZahBXHTAT6n8mgwSVSo9QT3F4BHRLfMNb1PD_SRyfD-ovS5nXbP7tqsJkeGPSaLBdEVX-mLUGTEp694Fc0JUGopfwsgw/s320/IMG_1808.JPG" width="320" /></a></div><br />
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Attach to the frame using the last of your frame alloy clips as previously shown. It goes just in front of the bracket for the airbox.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipxy6ivtylOjnaV7JfMcWCKjr3XgNP9hWkCSId_KZiB263ck8cT_6yp2zlfCqPNFe6Zpjq9iCv8rppNNyvvUeEAF2h1q7HtdgOylf4K8DSiTG4B5hAnVexWLU4yjc9g3M1Y2MyxQsCGn8/s1600/IMG_1809.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipxy6ivtylOjnaV7JfMcWCKjr3XgNP9hWkCSId_KZiB263ck8cT_6yp2zlfCqPNFe6Zpjq9iCv8rppNNyvvUeEAF2h1q7HtdgOylf4K8DSiTG4B5hAnVexWLU4yjc9g3M1Y2MyxQsCGn8/s320/IMG_1809.JPG" width="320" /></a></div><br />
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This is my favorit kind of supressor cap as they very rarely come off. Insert the HT Lead in to the cap shaft and push home as far as possible.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5ex0zPlJGf2jGreHRAZd6ai1aU00r_wATdpv5M-xfbWffYFqcbl-zQOo8T9CmrcClFs_WVbzZkzvZfncCOzzcGQ3aIH1P2H1jCaD3Wv8O5fzs9QQyCJLqnWUQIUJeSia-46exJyQdtz4/s1600/IMG_1810.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5ex0zPlJGf2jGreHRAZd6ai1aU00r_wATdpv5M-xfbWffYFqcbl-zQOo8T9CmrcClFs_WVbzZkzvZfncCOzzcGQ3aIH1P2H1jCaD3Wv8O5fzs9QQyCJLqnWUQIUJeSia-46exJyQdtz4/s320/IMG_1810.JPG" width="320" /></a></div><br />
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Look in to the cap and you will see it is all the way home. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy9TbEVYmY2R0Y-KyRzw5y_-LOy-Xe6JGdzPr9z8WM0p-W5fI-U0zOVbhbnHWaVykVF8nWSfPW1QX3lejn2RGndKiBsxgTS6XAk3Pw1qk9yME-k83YYYqsKiF4CewrvpiTV2G0Q5iSRAg/s1600/IMG_1811.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy9TbEVYmY2R0Y-KyRzw5y_-LOy-Xe6JGdzPr9z8WM0p-W5fI-U0zOVbhbnHWaVykVF8nWSfPW1QX3lejn2RGndKiBsxgTS6XAk3Pw1qk9yME-k83YYYqsKiF4CewrvpiTV2G0Q5iSRAg/s320/IMG_1811.JPG" width="320" /></a></div><br />
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Now screw in the plug clip. This not only grips the head of the sparking plug, it also pierces and secured the HT Lead.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCkvUQtxmo-8Yq5XmdcqNd7HgLPOUmXZX41QJznpt0vu1fyg5Ye2kND6EE-POxoLKsa6MTX7xkXVwflK6afMdcHBw_JD7KvkIoXLHLbORIZVyxy0kDd8YgB4CXN0RmgCdAS0txh3T82eo/s1600/IMG_1812.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCkvUQtxmo-8Yq5XmdcqNd7HgLPOUmXZX41QJznpt0vu1fyg5Ye2kND6EE-POxoLKsa6MTX7xkXVwflK6afMdcHBw_JD7KvkIoXLHLbORIZVyxy0kDd8YgB4CXN0RmgCdAS0txh3T82eo/s320/IMG_1812.JPG" width="320" /></a></div><br />
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Like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOy4hyphenhypheni_4FsbwlQKel-QkAGWtfam9sRnSvhddyKxdMj872T8LRUhsrgV-J_YgScWkBJL2uzA9rsRw67wMnKLcvcLb3H04EF55CdOxnkVbTjvx5TD1W_UgQ_Cpe7BoEwbVsi6mxzP_IqFI/s1600/IMG_1813.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOy4hyphenhypheni_4FsbwlQKel-QkAGWtfam9sRnSvhddyKxdMj872T8LRUhsrgV-J_YgScWkBJL2uzA9rsRw67wMnKLcvcLb3H04EF55CdOxnkVbTjvx5TD1W_UgQ_Cpe7BoEwbVsi6mxzP_IqFI/s320/IMG_1813.JPG" width="320" /></a></div><br />
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You can remove the alloy cap from the top of the sparking plug and pop on the cap.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh50lD-82NjLD159gZKIIB3dsfMC64TmvPWgmI3GcCDfmYEyjtey0ZUw3urhrIUA-ToOvJ4K71EDhM3JzCw6UVUyA6heAZIzrQNSEgG6wSdjKnaKnHGhBOQQGC6LPeImzLUlCwU8_r03Cw/s1600/IMG_1814.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh50lD-82NjLD159gZKIIB3dsfMC64TmvPWgmI3GcCDfmYEyjtey0ZUw3urhrIUA-ToOvJ4K71EDhM3JzCw6UVUyA6heAZIzrQNSEgG6wSdjKnaKnHGhBOQQGC6LPeImzLUlCwU8_r03Cw/s320/IMG_1814.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com1tag:blogger.com,1999:blog-5171578948572365563.post-22392363456691056322011-11-20T15:40:00.000+00:002011-11-20T15:40:12.625+00:00Installing the kick start pedalIf you have to buy a new one, make absolutely sure it is the correct one for your scooter. There are many different kinds and the wrong one will mean a bad fit, incorrect depth and loss of kick travel or even worse, damage the spline on your kickstart shaft.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4qtkD3GJEbwrh5s7WKMb0WplalPMVtrZOZ3BlE_grHqmNvjx8lcFwji2Z7L7zVt0LXuGTMeZZy9x2Kc-3bFma1Ep6o4psKQ3X4pQzstqznRhHHSaS-nuIgTMRq-6DyeEb_gMRkZim58dJ/s1600/IMG_1797.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4qtkD3GJEbwrh5s7WKMb0WplalPMVtrZOZ3BlE_grHqmNvjx8lcFwji2Z7L7zVt0LXuGTMeZZy9x2Kc-3bFma1Ep6o4psKQ3X4pQzstqznRhHHSaS-nuIgTMRq-6DyeEb_gMRkZim58dJ/s320/IMG_1797.JPG" width="320" /></a></div><br />
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Fit the pedal rubber.<br />
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Push the kickstart pedal on to the engine shaft making sure the tab is as close to being in line with the stopper rubber inserted in the engine. Don't worry if the best spline to fit the pedal means the stopper is very slightly over or under, but more than a few mm is not good.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirXOIERbjlW6mK_Sz_x_JqAgzLp1RSzlWjuIByVFzbbo5ZgEYT1VAz3VoI4yt8E_d3lM-Ydprnsq5IPlX1eZESJ-R1pmJjuM4-hlPXLijqNmZGI9urot5ZqXAirWkAeInYbSM6YiOprnFK/s1600/IMG_1799.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirXOIERbjlW6mK_Sz_x_JqAgzLp1RSzlWjuIByVFzbbo5ZgEYT1VAz3VoI4yt8E_d3lM-Ydprnsq5IPlX1eZESJ-R1pmJjuM4-hlPXLijqNmZGI9urot5ZqXAirWkAeInYbSM6YiOprnFK/s320/IMG_1799.JPG" width="320" /></a></div><br />
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Affix the bolt from above like so...<br />
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And tighten using a split washer on the underside. You don't want this bolt getting loose whilst in use or the pedal WILL go missing.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg49XDWOOIEWlCEXGfBLOZWlnlPjujLxDN6aTNuYSL8sQ2CXNswZnd15pdcs1l0H13jUHz8LDwzqMb5_wC5gfuzN_ED3XIW3-hMJH_qvuPKNQkLKBcy8k9kRo3WrK11jdCXB2tfwfM3hnvI/s1600/IMG_1801.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg49XDWOOIEWlCEXGfBLOZWlnlPjujLxDN6aTNuYSL8sQ2CXNswZnd15pdcs1l0H13jUHz8LDwzqMb5_wC5gfuzN_ED3XIW3-hMJH_qvuPKNQkLKBcy8k9kRo3WrK11jdCXB2tfwfM3hnvI/s320/IMG_1801.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com1tag:blogger.com,1999:blog-5171578948572365563.post-61208824561863070662011-11-20T15:33:00.000+00:002011-11-20T15:33:23.881+00:00Rear footbrake install and setupInstalling the footbrake normally required the footbrake pedal, cable adjuster link, two washers and a circlip.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz6S0tdt1bmx5fipXvsf_B5JNf0lllJo89xNi36dGVFLEXc0aQUvZQwtsPGLXbwuqlf9GP6G6C4uRwL4n70PUp2-aRj8cszJOJb38b-jWtzV0Npl4fUcQKFLyn8vyocC0VKT5R3ZxuL1nk/s1600/IMG_1772.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz6S0tdt1bmx5fipXvsf_B5JNf0lllJo89xNi36dGVFLEXc0aQUvZQwtsPGLXbwuqlf9GP6G6C4uRwL4n70PUp2-aRj8cszJOJb38b-jWtzV0Npl4fUcQKFLyn8vyocC0VKT5R3ZxuL1nk/s320/IMG_1772.JPG" width="320" /></a></div><br />
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Offer the pedal up to the floorboard at and angle thus...<br />
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...if it is tight in the hole, removing the pedal rubber can help, but once through it can be left to sit like this for now.<br />
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Put plenty of of copper grease on the footbrake stub.<br />
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Insert the rear brake return spring in to the hole in the frame. The lever part of the spring will be pointing upward.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd50Tbaib5UQwjmItSGBds1Ph4UPyrtizo0_s7y3TDnvI2SAhDfsYwuOB08y9ueLA4zmut-4HIvFT2hg9wTLScVBSLIa6HSDJ6PBXTACCYSLhV-R8SfRuY4iv38DnFpQO98P7EYRK7n_44/s1600/IMG_1785.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd50Tbaib5UQwjmItSGBds1Ph4UPyrtizo0_s7y3TDnvI2SAhDfsYwuOB08y9ueLA4zmut-4HIvFT2hg9wTLScVBSLIa6HSDJ6PBXTACCYSLhV-R8SfRuY4iv38DnFpQO98P7EYRK7n_44/s320/IMG_1785.JPG" width="320" /></a></div><br />
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Now put on the rear, lerger of the two washers.<br />
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Next, slip the pedal on to the stub and push home as far as possible.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOYdBjwthxPqIwOIHJFdY4i9f6hG9iqT0PZOAUmyHx-zLLwwQEwAYvSK902Cu8B-mOekBpC4HgjetazRKmQAHUDBXmWInRQj2ngfVUwp1yHaWJjixZFCRD0K8f4hhiOsPSTYilH_m2rSIa/s1600/IMG_1787.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOYdBjwthxPqIwOIHJFdY4i9f6hG9iqT0PZOAUmyHx-zLLwwQEwAYvSK902Cu8B-mOekBpC4HgjetazRKmQAHUDBXmWInRQj2ngfVUwp1yHaWJjixZFCRD0K8f4hhiOsPSTYilH_m2rSIa/s320/IMG_1787.JPG" width="320" /></a></div><br />
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Use a spring puller or cable tie in a loop to pull down the return spring leg until it is under the brake pedal.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWHXUNttPpHYUwb3JouEVWrQmmirg9sLFhxSjh91ebmlRioJQDpoH6t7e2uyZ7dzCyawLqqzSqIgLeLw8UvVO47W2x9hIC6_ecd4HFDM6yGUE9cRCUiUZ8oPc_XI3oDP302r15hyphenhyphenkAVVEb/s1600/IMG_1788.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWHXUNttPpHYUwb3JouEVWrQmmirg9sLFhxSjh91ebmlRioJQDpoH6t7e2uyZ7dzCyawLqqzSqIgLeLw8UvVO47W2x9hIC6_ecd4HFDM6yGUE9cRCUiUZ8oPc_XI3oDP302r15hyphenhyphenkAVVEb/s320/IMG_1788.JPG" width="320" /></a></div><br />
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Normally, the brake pedal can now be pushed right on to the stub, but if your spring is brand new, they can be very tight and prevent the pedal from seating all the way back. If this is the case, it may be necessary to compress the spring, which in effect, opens the centre hole and allows you to push the pedal right on to the stub until it is protruding out from the front edge.<br />
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I use stilsons to compress the spring upward and at the same time, tap the pedal home with a small hammer. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0urbVPhrV5sR4GASTLq7sD6snK5ODmNJQR8PG0zjUVUSVVrex_thlP7zjfOApYy-eFdUMP-lC7R5cTyOJ58wKdeuw3iMneE6Aypr81MPYhic22qKiMvv98ZvYaIgmAr0AqTQcbeDzNwpe/s1600/IMG_1790.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0urbVPhrV5sR4GASTLq7sD6snK5ODmNJQR8PG0zjUVUSVVrex_thlP7zjfOApYy-eFdUMP-lC7R5cTyOJ58wKdeuw3iMneE6Aypr81MPYhic22qKiMvv98ZvYaIgmAr0AqTQcbeDzNwpe/s320/IMG_1790.JPG" width="320" /></a></div><br />
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Now you can add the second, thin washer and your circlip. don't worry if there is no room for the second washer, sometimes it won't fit, so the circlip is added flush against the copper bush in the pedal hole.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvhXoopuTZ24VwOgNcMDzhLEE9gvOTphN_ukuSRKRaXUVOWLx4ECfjerGM5FpE7UJUWBOsyjFQYsrOemBY27SrZkObOdTIc5zFeGRnBqTY1VQVU-taJXJpZJXrud8UuKNzEYRn2BuiI6Mp/s1600/IMG_1791.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvhXoopuTZ24VwOgNcMDzhLEE9gvOTphN_ukuSRKRaXUVOWLx4ECfjerGM5FpE7UJUWBOsyjFQYsrOemBY27SrZkObOdTIc5zFeGRnBqTY1VQVU-taJXJpZJXrud8UuKNzEYRn2BuiI6Mp/s320/IMG_1791.JPG" width="320" /></a></div><br />
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Make certain the circlip is snug in the groove on the stub and that the pedasl stop is touching the frame. Also note that the switch is depressed by the block on the pedal. The switch is actuated by being released, rather than depressed.<br />
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Check that the adjuster, previously added in another post, is actually wound off as much as possible.<br />
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Insert the inner cable through the hole in the adjuster trunnion, pull on it with pliers and tighten the 14mm nut to secure it.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0mrFbETdxnFq3obmHAq15-_eZ1Pawf_qw9AuqEQS41VLFEhAWbq3RCWUzJUd3Se2-090bvq5CUq0YlY9KJ8302cu1rF_PzqnVdBtYFOM50c_cvhn5wj5k9Jm1xTtGi7ls3thCu1V2BCm-/s1600/IMG_1795.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0mrFbETdxnFq3obmHAq15-_eZ1Pawf_qw9AuqEQS41VLFEhAWbq3RCWUzJUd3Se2-090bvq5CUq0YlY9KJ8302cu1rF_PzqnVdBtYFOM50c_cvhn5wj5k9Jm1xTtGi7ls3thCu1V2BCm-/s320/IMG_1795.JPG" width="320" /></a></div><br />
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Only a minor adjustment should be required at the rear adjuster to ensure the brake activates correctly and the rear wheel spins when released.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCGHeQcZza27KCqqs1l7Pq8d-ZL0C_-uJ9cLJkIuXWSujuRMjtlseuV_vCL8OLgXv7ch2ZpJdZLOAYrYt9cllioB_og94lzTMkyqCsnimxnuL2IwHx5INQd-xtW3Q_i1_8tkz9Wq4Z81qk/s1600/IMG_1796.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCGHeQcZza27KCqqs1l7Pq8d-ZL0C_-uJ9cLJkIuXWSujuRMjtlseuV_vCL8OLgXv7ch2ZpJdZLOAYrYt9cllioB_og94lzTMkyqCsnimxnuL2IwHx5INQd-xtW3Q_i1_8tkz9Wq4Z81qk/s320/IMG_1796.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-3539396104231101102011-11-13T18:35:00.000+00:002011-11-13T18:35:29.058+00:00Badges and stickersA few finishing touches to the days work for today.<br />
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Here is an original petrol flap sticker, which is actually a very thin sheet of aluminium foil. These were factory fitted items and it would have been sold in the UK with a sticker like this. So ours is having one.<br />
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Lift the petrol flap.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkXbm0CsITta-MpJ27KDEoSKyjB3BToJxmI2s6_aAtGSDxkL5t7NroixCv2vsY1FWDkS-Atga0u99k2aVyv2-CiMRl2_n05eVBPMydH37TZRSKEoJxHlT5oYfrxYLY9NT9g4gxPbasjj6d/s1600/IMG_1769.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkXbm0CsITta-MpJ27KDEoSKyjB3BToJxmI2s6_aAtGSDxkL5t7NroixCv2vsY1FWDkS-Atga0u99k2aVyv2-CiMRl2_n05eVBPMydH37TZRSKEoJxHlT5oYfrxYLY9NT9g4gxPbasjj6d/s320/IMG_1769.JPG" width="320" /></a></div><br />
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And if you buy a remade sticker, make certain that you peel the backing OFF the sticker and not the other way around. If you try to peel the sticker off, it will curl or crease.<br />
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No great amount of care was taken when the original stickers were fitted and you often see them at all kinds of strange angles. Just for the sake of it, I've put ours on as straight as possible.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx3QNMOqXrf3JQ7W4siD4g4E2-b14sp2DMZlc-gUhsaq1luxVRLR5McLsmIRllPtEp-lZxa3sjzJKqnS0fsapdSgRKLSG4OeH_WRKbFsp1jBoc1Jp8J0ZVM8Fspv6kTr6hGyjNcrtAbtOq/s1600/IMG_1770.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx3QNMOqXrf3JQ7W4siD4g4E2-b14sp2DMZlc-gUhsaq1luxVRLR5McLsmIRllPtEp-lZxa3sjzJKqnS0fsapdSgRKLSG4OeH_WRKbFsp1jBoc1Jp8J0ZVM8Fspv6kTr6hGyjNcrtAbtOq/s320/IMG_1770.JPG" width="320" /></a></div><br />
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For adding the legshield badges, please see the post on the sidepanels. Fitting these badges is carried out in exactly the same way.<br />
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Starting to look like a proper Lambretta now.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6EonnKBQ7-I0FuAzp5hDADdQtFQlsFnYF7lPHTXQjo6Z7YHUJsW7YRUhJ1m23wz94RPkf9Ob1PGKujbpp0bDcpmVytsyTOpnEwLb8k5EP_g0Sja2-Av1LJWNug2W58DFN0jUK2ofjtfvp/s1600/IMG_1771.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6EonnKBQ7-I0FuAzp5hDADdQtFQlsFnYF7lPHTXQjo6Z7YHUJsW7YRUhJ1m23wz94RPkf9Ob1PGKujbpp0bDcpmVytsyTOpnEwLb8k5EP_g0Sja2-Av1LJWNug2W58DFN0jUK2ofjtfvp/s320/IMG_1771.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-12176316085641059812011-11-13T18:29:00.000+00:002011-11-13T18:29:10.569+00:00Installing cut out button (kill switch)Very simple job.<br />
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Notice the kill switch has a bracket attached to the rear, inner section of the housing. It is held in place with a small grub screw, which passes through the bracket and in to the rear body of the switch. Remove the screw, being careful not to lose the small flat washer underneath.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2DDq3urQr5i4fN9OqCNxWvkE7dBWgEtByvf6XHfETwXlWGYFx9B7cvtu_TiixiCMAfV-y6pp2MpNBmD6jQR_Asa3zjWyBPYlXczSOcdZG_k9_d2TPkSU2t-UsfHHgrR35DPln6YEHhAMa/s1600/IMG_1763.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2DDq3urQr5i4fN9OqCNxWvkE7dBWgEtByvf6XHfETwXlWGYFx9B7cvtu_TiixiCMAfV-y6pp2MpNBmD6jQR_Asa3zjWyBPYlXczSOcdZG_k9_d2TPkSU2t-UsfHHgrR35DPln6YEHhAMa/s320/IMG_1763.JPG" width="320" /></a></div><br />
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The kill switch has a slotted upper section in the housing, this is designed so that the peg sticking down from the hole in the headset can fit into it. So the switch can only go in one way around and the peg will help to prevent it from swivelling around during use.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKxQ7ViVyFNJR2jI12P8kpb-NIWPeN6KYz19v9ZIZ8ESzsU-J6b0OTmfO_nspQDsWit1LV2sySTnjLYoeJKqsN03z9LpXP0MQfk_4ZMiVkIPnIo5KMCYpLqiL2sxpT7G4JVUMnq6EE3wx9/s1600/IMG_1764.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKxQ7ViVyFNJR2jI12P8kpb-NIWPeN6KYz19v9ZIZ8ESzsU-J6b0OTmfO_nspQDsWit1LV2sySTnjLYoeJKqsN03z9LpXP0MQfk_4ZMiVkIPnIo5KMCYpLqiL2sxpT7G4JVUMnq6EE3wx9/s320/IMG_1764.JPG" width="320" /></a></div><br />
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Push the green earth wire through the hole in the headset and then the switch itself.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6cqkkjAmtVtHPwv1YwjitKRNKTwrHXW4abz9BwDvRy0e6cK1_R_9xemKoXOELnGukxEID_ewzAuaFkYpBojGP5OJBDSRNrkIr0uQK7OMtGIj9W6ed9_6XoUUJZ8c9_lWSKsZ3mZKw6kom/s1600/IMG_1765.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6cqkkjAmtVtHPwv1YwjitKRNKTwrHXW4abz9BwDvRy0e6cK1_R_9xemKoXOELnGukxEID_ewzAuaFkYpBojGP5OJBDSRNrkIr0uQK7OMtGIj9W6ed9_6XoUUJZ8c9_lWSKsZ3mZKw6kom/s320/IMG_1765.JPG" width="320" /></a></div><br />
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Whilst holding the switch in place, insert the bracket over the inside as shown so that it is level with the ground. See picture below.<br />
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Tighten the grub screw but don't overdo it.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMNnBfCtgZnGlShB9uhREepyMfoMTr9MJlmI73Gu3boH9psBWuG5t3SW8AIz6sHUJvNKeVJgotb4HqMrztZA98eZaxLNQ4yqUAaUSSxyKts8ASsSYLamM5mJSSlpbIuEV4EeYvGd7gEq7U/s1600/IMG_1766.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMNnBfCtgZnGlShB9uhREepyMfoMTr9MJlmI73Gu3boH9psBWuG5t3SW8AIz6sHUJvNKeVJgotb4HqMrztZA98eZaxLNQ4yqUAaUSSxyKts8ASsSYLamM5mJSSlpbIuEV4EeYvGd7gEq7U/s320/IMG_1766.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com1tag:blogger.com,1999:blog-5171578948572365563.post-21223260860494446242011-11-13T16:25:00.000+00:002014-07-07T16:46:38.505+01:00Adding bridge pieceBridge piece, two rubber strips, 2 25mm countersunk bevel head bolts, 2 8mm nuts, 2 countersunk washers, 2 washers.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4m4m5X7glVFo8Udv77GOH7c548iD3qTUwjXjOzbbQR4o-UDjg9tJqxEbhjSJuh2mf1_6xaV5cz6bk2YpsOklvcaHarvzakdgpymdlAzOH6Ljo2oOovqai2ryl1Vn3Z9Hv9BjkxcRBsYZ/s1600/IMG_1761.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4m4m5X7glVFo8Udv77GOH7c548iD3qTUwjXjOzbbQR4o-UDjg9tJqxEbhjSJuh2mf1_6xaV5cz6bk2YpsOklvcaHarvzakdgpymdlAzOH6Ljo2oOovqai2ryl1Vn3Z9Hv9BjkxcRBsYZ/s320/IMG_1761.JPG" height="240" width="320" /></a></div>
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The pre-shaped rubber gasket obviously goes at the back. You may need to use super glue but be very careful, it WILL effect your paintwork.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitFGs41FDzvic0yzhVQM6d7qP8UdhPICCgnOIvkxgL8dg6Gc1cQuRv-07dFSqNWO-dCalbP_moXcv8OyAmczU8iRUwp3Oy9AJgtDArQY3QVbxLn0dmrlh6uuX3xqvo_imOLj394J0tXpkK/s1600/IMG_1762.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitFGs41FDzvic0yzhVQM6d7qP8UdhPICCgnOIvkxgL8dg6Gc1cQuRv-07dFSqNWO-dCalbP_moXcv8OyAmczU8iRUwp3Oy9AJgtDArQY3QVbxLn0dmrlh6uuX3xqvo_imOLj394J0tXpkK/s320/IMG_1762.JPG" height="240" width="320" /></a></div>
Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com1tag:blogger.com,1999:blog-5171578948572365563.post-47872103890487717082011-11-13T16:19:00.003+00:002012-01-09T11:13:58.596+00:00Adding sidepanel handles and badgesCheck first of all that the panels actually fit. It isn't unusual for them to get a little out of shape whilst being worked on in prep for paint. Especially if repairs have had to be made.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA0ejXfneR_FMWJR6s1oevquxHBgPNRx2mZRUoELtoEU9bT6HTl8px4Pf7C1TejJQIY0_lVCeWmIcdtxfpMp0p2vH1q5ZvprNU4kvkrVgU_CmbOrXzjq3D744Swz8dCzXj4okOdOaz7hJz/s1600/IMG_1742.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA0ejXfneR_FMWJR6s1oevquxHBgPNRx2mZRUoELtoEU9bT6HTl8px4Pf7C1TejJQIY0_lVCeWmIcdtxfpMp0p2vH1q5ZvprNU4kvkrVgU_CmbOrXzjq3D744Swz8dCzXj4okOdOaz7hJz/s320/IMG_1742.JPG" width="320" /></a></div><br />
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Put grease on the shaft of the panel roller.<br />
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Place on a wavey washer.<br />
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Push the roller under the clip inside the frame as if the legshields were fitted for use. The portion sticking out of the side panel should now look like the image below.<br />
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If it doesn't and is pointing in the wrong direction entirely, you have used the wrong roller. Swap them over.<br />
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The panel handle has a hole for the bolt on one side only. This faces downward.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBaoLOtxbHAHywjSKQP_JNBfeMKJC0jWQAECT4ozBhxFZL3Rkk_6rbqlALpogp1EvocwOpocaGXcoAt8bIYsgUEY2tZBISLrDdbo7rnvqLBdjpP6jOMP8yLNcPN48lxfP0GHMsCcNasMS9/s1600/IMG_1749.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBaoLOtxbHAHywjSKQP_JNBfeMKJC0jWQAECT4ozBhxFZL3Rkk_6rbqlALpogp1EvocwOpocaGXcoAt8bIYsgUEY2tZBISLrDdbo7rnvqLBdjpP6jOMP8yLNcPN48lxfP0GHMsCcNasMS9/s320/IMG_1749.JPG" width="320" /></a></div><br />
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The correct grub screw and star washer hold the handle on to the roller shaft.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1SawV0vpz7_z8pBtJkwXzaGf3393sgeyLhTNk0jycykvomh18WBLl4ikX8iF0OW-w37z0Dpu-FWH_rr_teUCd4m8YeAa4o8S-toBjztE7UZ2W6YPZW86YzNT422bIOA8ijQSq3k6YC9wg/s1600/IMG_1750.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1SawV0vpz7_z8pBtJkwXzaGf3393sgeyLhTNk0jycykvomh18WBLl4ikX8iF0OW-w37z0Dpu-FWH_rr_teUCd4m8YeAa4o8S-toBjztE7UZ2W6YPZW86YzNT422bIOA8ijQSq3k6YC9wg/s320/IMG_1750.JPG" width="320" /></a></div><br />
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Like so.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7GXDHIZQovJ2PBUASu2HqakvtGkzjwCBsb_c6C6Nf18cA5oJl7yan1-FT5_OD1gIN_vnYnDMmWEDr8y-p96xmvyd-hoOM1zf99SB0Bs7annthRvwNVhcIpgbLl9sXmMevT43bBQq4c5FI/s1600/IMG_1751.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7GXDHIZQovJ2PBUASu2HqakvtGkzjwCBsb_c6C6Nf18cA5oJl7yan1-FT5_OD1gIN_vnYnDMmWEDr8y-p96xmvyd-hoOM1zf99SB0Bs7annthRvwNVhcIpgbLl9sXmMevT43bBQq4c5FI/s320/IMG_1751.JPG" width="320" /></a></div><br />
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If you are lucky, your painter will be educated enough to have left the holes for your badges visible. They may need to be cleaned out a little, we used a rivet, but if yours are fairly blocked, use a drill in a Dremmil.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7Ka1Wwy5wY9RFk5dSBwPwPtDqopYbuQmd3rneYFKPORpaMyM8NfYmMFLi8hiL80aFlXtVY6hneRw4dVUeWQU35bEGkGhP8yNUCtQ05PDU_FAuj-zxjqftiEGGqNmRz-cDJnILTf0U7X7y/s1600/IMG_1752.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7Ka1Wwy5wY9RFk5dSBwPwPtDqopYbuQmd3rneYFKPORpaMyM8NfYmMFLi8hiL80aFlXtVY6hneRw4dVUeWQU35bEGkGhP8yNUCtQ05PDU_FAuj-zxjqftiEGGqNmRz-cDJnILTf0U7X7y/s320/IMG_1752.JPG" width="320" /></a></div><br />
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Pop all the badge studs through the panel.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTUpPPy8R_ugISBH9a1c4E2tKEI5kFMqPVFT-k_R4t5CE8rKNvxTpSNAkLVcFlU9sNNmXtl-n5X2v8RSVN6Fjp_hEf8addPyzZ5-1MWOIXW1H9uinkZrMsaI7MtJ66g69C0vFxD0IOWcmf/s1600/IMG_1753.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTUpPPy8R_ugISBH9a1c4E2tKEI5kFMqPVFT-k_R4t5CE8rKNvxTpSNAkLVcFlU9sNNmXtl-n5X2v8RSVN6Fjp_hEf8addPyzZ5-1MWOIXW1H9uinkZrMsaI7MtJ66g69C0vFxD0IOWcmf/s320/IMG_1753.JPG" width="320" /></a></div><br />
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And tape it down.<br />
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Now either put the panel on it's side or face down and get help for this bit.<br />
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You need to have a hard rubber mallet pressed against the badge over the area of the stud you are working on. Press fairly hard against the badge and tap ofer the stud. You don't need to hit hard as the stud alloy is quite soft.<br />
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Move the mallet to the correct position under the next stud, and work along like that.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaWqwClmTPVdKEXlaKjJvR0PDJVb_GdP2QdvnK5NYhF8-Fe8oYe3jfbz-ki82W3sPlSiAgdrqWAA4_DtNB6-DV_mtETyMVeO5hRKdLLvdew5yXJ8zpj1j82qLM1Uf4mesl09w-AhzK1VmW/s1600/IMG_1755.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaWqwClmTPVdKEXlaKjJvR0PDJVb_GdP2QdvnK5NYhF8-Fe8oYe3jfbz-ki82W3sPlSiAgdrqWAA4_DtNB6-DV_mtETyMVeO5hRKdLLvdew5yXJ8zpj1j82qLM1Uf4mesl09w-AhzK1VmW/s320/IMG_1755.JPG" width="320" /></a></div><br />
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Until they are all peined over like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-F5S_Qqqei-cBGyetCV5pl0kKR044DPVPjKfG7QodY01311mD26WIMTHtv0r1rNCnJq9fKbwjwnEWTxQtuk_RmXYJ_EbSQvjZvG-S_jIFJbRdift6YwW3Yh1ZyeW1lI2UY2raOxunssE2/s1600/IMG_1757.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-F5S_Qqqei-cBGyetCV5pl0kKR044DPVPjKfG7QodY01311mD26WIMTHtv0r1rNCnJq9fKbwjwnEWTxQtuk_RmXYJ_EbSQvjZvG-S_jIFJbRdift6YwW3Yh1ZyeW1lI2UY2raOxunssE2/s320/IMG_1757.JPG" width="320" /></a></div><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK9oSPrbBrqSRjhwBdu6y0inLAMaXrbmt6jLJPocCOnh7vFSmeqD6YEC-OoI8LkdO_EorRK7On6GTBlQejmdo4FVtzW4s_fSlZEvqx3qRgJxWcdThZGZJ1kVqmWvv64_3JjYdRCdGWJlf_/s1600/IMG_1760.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK9oSPrbBrqSRjhwBdu6y0inLAMaXrbmt6jLJPocCOnh7vFSmeqD6YEC-OoI8LkdO_EorRK7On6GTBlQejmdo4FVtzW4s_fSlZEvqx3qRgJxWcdThZGZJ1kVqmWvv64_3JjYdRCdGWJlf_/s320/IMG_1760.JPG" width="320" /></a></div>Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-59429565283410375102011-11-13T16:03:00.002+00:002015-05-07T14:11:40.894+01:00Adding toolbox door<div class="separator" style="clear: both; text-align: center;">
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To add the toolbox door, you must first insert the two rubber buffers.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsJd9j9PrVUQrud1fkBN9nOQFE4yb1VlMe13uzST_Ln2efdDWe-Yt49Wvp6i_sswHwlrBylsMoIZU2-U_92Cxm33yCqwgxD-MKv3AruBOvD3fLOmu9DKTNfgx6cPEc-35ek7CnaNbbJQUN/s1600/IMG_1725.JPG" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsJd9j9PrVUQrud1fkBN9nOQFE4yb1VlMe13uzST_Ln2efdDWe-Yt49Wvp6i_sswHwlrBylsMoIZU2-U_92Cxm33yCqwgxD-MKv3AruBOvD3fLOmu9DKTNfgx6cPEc-35ek7CnaNbbJQUN/s320/IMG_1725.JPG" width="320" /></a><br />
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This is the correct way around. Try poking them through with a small bladed screwdriver until there is enough visible to get hold of with pliers. Then pull it through until it pops in to place.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUp2doN0PPLTicyaZP88XYZCO7mJi1IVpkKttvjCWXMwd5PZyHtxD_lX-6Ro8IZD2uG27RrlYz8jAhmgolR_FPZd96qM2PXQo2ibu2C8Iq4g1l3Bs3RcFamHfvcpcdAt3JNDIJQubCbXc2/s1600/IMG_1726.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUp2doN0PPLTicyaZP88XYZCO7mJi1IVpkKttvjCWXMwd5PZyHtxD_lX-6Ro8IZD2uG27RrlYz8jAhmgolR_FPZd96qM2PXQo2ibu2C8Iq4g1l3Bs3RcFamHfvcpcdAt3JNDIJQubCbXc2/s320/IMG_1726.JPG" width="320" /></a></div>
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Like this.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG5phSFc-c6jusCh7RuLPth7bQpKFKBn4omxZcw2JyJJUB50fe0aMd2b6GvYmyvfvQ-a9dedSQ_wKUC3AmNUBugfVdQFhMVxpI0fTNZb6t_507EBW_e-khx00RimwZKqi0iZXUF2G6KEcs/s1600/IMG_1727.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG5phSFc-c6jusCh7RuLPth7bQpKFKBn4omxZcw2JyJJUB50fe0aMd2b6GvYmyvfvQ-a9dedSQ_wKUC3AmNUBugfVdQFhMVxpI0fTNZb6t_507EBW_e-khx00RimwZKqi0iZXUF2G6KEcs/s320/IMG_1727.JPG" width="320" /></a></div>
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When both are fitted, the hinge should look similar to this.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ2ofiyK-eCmbn0JjOxWMupqliFYepm7OsJWn6WUdm3LBWYMH3sOy9wwmfF1kmrVQuHSzjajOcEwcI6qwTGbCOQ3WJoQV2gR0noEGsLKPL7JxWfhNZvorlQ-kH9dxvJffXH__PUiFeSo4y/s1600/IMG_1728.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ2ofiyK-eCmbn0JjOxWMupqliFYepm7OsJWn6WUdm3LBWYMH3sOy9wwmfF1kmrVQuHSzjajOcEwcI6qwTGbCOQ3WJoQV2gR0noEGsLKPL7JxWfhNZvorlQ-kH9dxvJffXH__PUiFeSo4y/s320/IMG_1728.JPG" width="320" /></a></div>
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Now remove the circlip from the rear of the lock barrel.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8G8kZGeIXdhVFNjYOn9116hiYydH4Ly9jOy-kZhRYrNOU9tGKnooYUuhb0gUtAUbhzRHJtYgim21JewlSA5kVUqe4CgiUUWI8C6DZBXutHw_9dYqjU-PLH41VXRv2IxPb3G5ERz5PI0Vw/s1600/IMG_1729.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8G8kZGeIXdhVFNjYOn9116hiYydH4Ly9jOy-kZhRYrNOU9tGKnooYUuhb0gUtAUbhzRHJtYgim21JewlSA5kVUqe4CgiUUWI8C6DZBXutHw_9dYqjU-PLH41VXRv2IxPb3G5ERz5PI0Vw/s320/IMG_1729.JPG" width="320" /></a></div>
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Push the outer barrel through the lock hole in the door so that the slot in the end facing is downward.<br />
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PLEASE NOTE: THIS IS AN ERROR. THE FLAT PLATE, WITH TWO HOLES SHOULD HAVE GONE ON THE <b>INSIDE</b> OF THE TOOLBOX DOOR AND NOT ON THE OUTSIDE AS SHOWN HERE. THE ONLY PART THAT SHOULD BE SEEN FROM THE FRONT, IS THE TOOLBOX LOCK HANDLE AND THE PLATE IS RIVETED TO THE <b>INSIDE</b>.<br />
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SORRY ABOUT THAT. I MUST HAVE DOZED OFF WHEN ATTACHING THIS ONE.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5ITaYfOsFeXd8yhmhiPHmnfy3n25o2E-tq988fST6wCqqZ-6WJoR9SbwHjNEJddsnBTwL-NeBU8mZYOyGcB0qTrAvEGRKbunyw8F_S4OWuSFk6xyJ30Om_W6SqKCgBR3wM49B8OG9HFDI/s1600/IMG_1730.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5ITaYfOsFeXd8yhmhiPHmnfy3n25o2E-tq988fST6wCqqZ-6WJoR9SbwHjNEJddsnBTwL-NeBU8mZYOyGcB0qTrAvEGRKbunyw8F_S4OWuSFk6xyJ30Om_W6SqKCgBR3wM49B8OG9HFDI/s320/IMG_1730.JPG" width="320" /></a></div>
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Adjust to line up the holes at the front.<br />
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You now require two soft alloy blind rivets.<br />
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Push the rivets through from the front and tape in place to hold them temporarily.<br />
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<b>PLEASE NOTE: THE FLAT PLATE OF THE HANDLE SHOWN IN THE IMAGE BELOW SHOULD GO ON THE INSIDE OF THE TOOLBOX DOOR AND NOT ON THE OUTSIDE AS SHOWN HERE. I MADE A MISTAKE ATTACHING IT LIKE THIS. SORRY.</b><br />
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THE REST OF THE PROCESS HOWEVER, IS CORRECT. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy8Bd8EsCmSDrcsrMNona63aT_2D8uPM5LFnly9LaqFO8gxgIrbs8sSXqHupz9efvxXXwCM7KBK8vWKzfzo2FsrJ44krzqa4nmNOyIykp-FBMNI24-wc-DGKnMNr9LZhkFu8QdPcGXtbg7/s1600/IMG_1733.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy8Bd8EsCmSDrcsrMNona63aT_2D8uPM5LFnly9LaqFO8gxgIrbs8sSXqHupz9efvxXXwCM7KBK8vWKzfzo2FsrJ44krzqa4nmNOyIykp-FBMNI24-wc-DGKnMNr9LZhkFu8QdPcGXtbg7/s320/IMG_1733.JPG" width="320" /></a></div>
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To flatten the rivets, I placed my toolbox on top of a clean and flat piece of hardwood. Get somebody to hold it in the correct position and use a centre punch with a wide and flat head to pein over the rivet shank.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXiQJiDy3A1HxTXe2LpsdIipLl1VxnR1WCjjms1eAeqGn2oiL3E8MW9hj5r_oyrJD-w8VyP38WMadg4RWFZLIZbau3P3YCTHZN7VG9rZinJCSwSQLEqZn49yHoxOx6xNtRJjU3SpDQuKgM/s1600/IMG_1735.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXiQJiDy3A1HxTXe2LpsdIipLl1VxnR1WCjjms1eAeqGn2oiL3E8MW9hj5r_oyrJD-w8VyP38WMadg4RWFZLIZbau3P3YCTHZN7VG9rZinJCSwSQLEqZn49yHoxOx6xNtRJjU3SpDQuKgM/s320/IMG_1735.JPG" width="320" /></a></div>
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Re-attach the lock barrel and clasp.<br />
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Using the correct hinge pin, first make sure it will pass through the loops of the hinge on both the door and the frame.<br />
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Hold the door in alignment...<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaMDPJshxLi7ibc_eDNoWNZNHsqWHMdz91IVUU7dFd1RXk3d7K30NKuGVqa_UnlRcqlKsiQ6vCFBiQEww_9_YfWlrFINtyaj98BK1yOwCPBRYy-V6XYZUoEzq0WFonJBVZe6thBCXHLBeP/s1600/IMG_1739.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaMDPJshxLi7ibc_eDNoWNZNHsqWHMdz91IVUU7dFd1RXk3d7K30NKuGVqa_UnlRcqlKsiQ6vCFBiQEww_9_YfWlrFINtyaj98BK1yOwCPBRYy-V6XYZUoEzq0WFonJBVZe6thBCXHLBeP/s320/IMG_1739.JPG" width="320" /></a></div>
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And push the pin through, you may need to use pointed pliers to hold the pin as you push. It makes the job easier. When it is right through, split the opposite end of the pin to prevent it working itself out.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQo1Ut9Z8qZ1259wq0CPnAytkJ02hlqaqK-JRuiLMve7qKbD-LiQTtxGoDv-tYzQ8BRe4c8ojTkK8JBG8B40-wqdYiyL9LjARjCG3TM7kURM6yN37xVcm07RmYKzuba6DS0Of34BbkPKDq/s1600/IMG_1740.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQo1Ut9Z8qZ1259wq0CPnAytkJ02hlqaqK-JRuiLMve7qKbD-LiQTtxGoDv-tYzQ8BRe4c8ojTkK8JBG8B40-wqdYiyL9LjARjCG3TM7kURM6yN37xVcm07RmYKzuba6DS0Of34BbkPKDq/s320/IMG_1740.JPG" width="320" /></a></div>
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Job done.<br />
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Paul Slackhttp://www.blogger.com/profile/05650798074652169361noreply@blogger.com0tag:blogger.com,1999:blog-5171578948572365563.post-84802803578512204162011-11-06T20:46:00.000+00:002011-11-06T20:46:08.130+00:00Adding front brake adjusterInsert top-hat stop in to the lug of the front wheel<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-2tawLYExX5-fzfnZ6-N8HiPTEJPPrbrH6nZjqlgajrTp9jfepYtYsesVVcIJY7XAeKlqQGb-TZ7OSKV_GcIWJrXNr7NTse0eVYwUiux9_-ALTQ28AIDBqphDirvmkR0l2pPKnS-iAFv3/s1600/IMG_1717.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-2tawLYExX5-fzfnZ6-N8HiPTEJPPrbrH6nZjqlgajrTp9jfepYtYsesVVcIJY7XAeKlqQGb-TZ7OSKV_GcIWJrXNr7NTse0eVYwUiux9_-ALTQ28AIDBqphDirvmkR0l2pPKnS-iAFv3/s320/IMG_1717.JPG" width="320" /></a></div><br />
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Push through the inner and outer cable.<br />
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Unwind the adjuster almost completely and slot in to the arm as shown.<br />
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Remove the adjuster top clamp and pushing on the arm, mark the length of the cable and bend at that point with pliers.<br />
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Re-attach the top clamp and tighten.<br />
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Test the front brake by spinning the wheel and applying the brake via the lever. Adjust as required or pull through more cable if too much adjustment is needed.<br />
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There should be around 3mm of play before the brake begins to be actuated.<br />
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