Vespa amateur needs gear cable help

[drwols]

I've recently bought myself a Vespa 100 Sport in good shape, but now I want to learn how to do basic maintenance myself to avoid forking out money to a mechanic. at 22 years old, I have little mechanical experience!

One of the gear cables was frayed at the engine end, so I decided to make this my first repair. I succesfully replaced the inner gear cable (the lowermost one in the picture!) but am having difficulty reattaching the cable.



I have searched the internet extensively and found sites that explain how to replace the inner cables. However, when I tighten the little bolt that bites onto the cable at the engine end (sorry I don't know the technical name) it attaches firmly to the cable, and against the metal plate. but when I turn the handle in the direction which should pull the cable, it fails to shift gear. I know that there is no problem with the gears themselves, as the gears worked 100 % fine with the old cable. and I can manually twist the metal plate with my fingers and a little force through the gears with no problem.

Do I just need more patience? does the cable need to be extreme taught? Or am I missing out a crucial step?

Also, is the black disk behind the metal plate supposed to turn? There is a little notch on it, is this supposed to align with the thing on the left? (the thing with the brass middle section, and black plastic end)

Thanks

[nick121170]

that black disc and plunger type thingy looks like a switch for neutral(no wires to it?)
is the outer part of the cable seated correctly in the headset?
does the cable clamp grip the inner cable enough(take it off and tighten the bolt by hand and check the gap where the cable runs through)
the cable has to be reasonably tight and might need a re adjustment.
u could de-adjust the 8mm outer cable adjuster ,then hook up the inner cable to the selector ,then take up any slack with the outer cable adjuster
bit fiddly vespa cables although its all practice
have u tried scooterhelp.com?

[bluebadge]

A "Forth hand tool" comes in handy here.

images.jensonusa.com/large/tl/tl407d00.jpg

[stiltthewilt]

Right, first off make sure you're in neutral and the handlebar gear change is at the neutral setting

Then wind the bolt labelled "1" in the picture in all the way (That's the cable adjuster)

Then slide the trunnion (Little bolt thingy) onto the cable and push it into the gear change mechanism in the correct place (As in "2") and tighten it up.

Next wind the gear cable adjuster ("1") outwards to tighten the cable and you're about done.

Finally trim offthe excess cable and tuck the loose end into the little hook shaped part of the gear change mechanism (labelled "3")

good luck and welcome to the world of smallies

[vinrouge]

Cables you think that they be so straight forward ;D

Welcome, don't forget to give the inner a good greasing, it does make a big difference.

I'm with Nick on the black plastic and brass thingy, its the neutral indicator. There would normally be wires to link back to one of the little lights in the headset. One of the items that was peculiar to the 100 Sport. BTW I've got one and my wires are missing

I normally use masking tape to hold the gear selector at the headset in neutral, before tightening the cables underneath. It can be a pig of a job with out a forth hand tool, plus I think you need a 7 and an 8mm spanners for trunnion (little bolt) just follow Mr Stilts advice and you should get there

[sport100]

on the wifes 100 sport i took the neutral switch off completely and we found it was easier to get into first gear because the brass plunger sits in the indent in the wheel and made it hard to get in to gear hope this makes sense

[breezer]

Another vote for 3rd / 4th hand tool to put the tension in the cable prior to attaching the nipple.

Also another vote for masking taping the handle in place and getting the engine in neutral to start with.

Daft question but you are pulling the clutch lever in when you try to shift aren't you?

Presuming so there's two things I'm thinking:

1 you may not have enough tension in the cable.

2 try rocking the bike backwards and forwards while you try to select gear, it helps to align the sliding dog with the indents on the gears. You often find the gear shifter will just "drop in" when you do this.

Jim

[drwols]

stiltthewilt, thanks for the detailed explanation. I tried what you suggested but it's still not 100 % OK. now I have to turn the gear selector really higher to get it into 1st, and really low to get it into 2nd. Think I'm gonna invest in one of those 4th hand tool and try again

[stiltthewilt]

Yep, your cables aren't tight enough!!

[breezer]

they need to be evenly tensioned as well

[usafstud]

Sept 6, 2011 17:32:25 GMT stiltthewilt said:

Right, first off make sure you're in neutral and the handlebar gear change is at the neutral setting

Then wind the bolt labelled "1" in the picture in all the way (That's the cable adjuster)

Then slide the trunnion (Little bolt thingy) onto the cable and push it into the gear change mechanism in the correct place (As in "2") and tighten it up.

Next wind the gear cable adjuster ("1") outwards to tighten the cable and you're about done.

Finally trim offthe excess cable and tuck the loose end into the little hook shaped part of the gear change mechanism (labelled "3")

good luck and welcome to the world of smallies

Which cable goes with which ends of the gear selector? Which slot (#2 or #3) is used to down shift and up shift?

[bluebadge]

If I'm not mistaken (it's been awhile since I did cables), when you pull up to go into first, it pulls on the one not marked the one with a barrel nut on it already. Then hook up the other. Get them as tight as possible without stressing the cables themselves and then use the adjusters to tighten more if needed and to adjust the shift handle numbers to line up.

[usafstud]

Sept 24, 2011 17:18:35 GMT bluebadge said:

If I'm not mistaken (it's been awhile since I did cables), when you pull up to go into first, it pulls on the one not marked the one with a barrel nut on it already. Then hook up the other. Get them as tight as possible without stressing the cables themselves and then use the adjusters to tighten more if needed and to adjust the shift handle numbers to line up.

I'm going to give it a go with the gear cables its got now but it is pretty frayed. I'll see if I can get it to work before a order new inner cables.

How well does the 4thhand tool work? Does it damage the cables when it holds the cables?

[nicsar]