ciao updates!
November 3, 2013, 4:05 pm
Filed under: belt, brakes, carb, clutch, cosmetic, dellorto, frame, intake, lighting, new parts!, transmission, variator

i did a three parter update about old ciaociao over on did a bunch of maintenance work and a few little things that i’ve been meaning to do for years but never had. go check it out! and stay tuned over there for more ciaociao!


July 21, 2009, 10:03 am
Filed under: belt, carb, dellorto, general, intake, malossi, new parts!

ciaociao is already down in sacramento waiting for me, i left it there after the reno rally.
by the way, my “reliable” bike seized a main bearing at the reno rally, so i did the rest of it on ciao and ciao had no issues whatsoever! it has became my most reliable moped!
the belts i ordered from malossi direct showed up, plus the one from treats i’ve been carrying around with me, i should be good on belts for a little while. those malossi belts are awesome, but the shred apart after a while. the one i’m currently running is starting to fray a little, so i think i’ll be replacing it soon.
i also need to pull the carb off the intake plate and put some loctite on the threads of the mounting bolts, the carb likes to start to wiggle loose after a while. it doesn’t even seem to notice the air leaks, but it’s something that needs to be addressed.
anyway, more to come when i’m in sacramento! goodbye for now, seattle!

pre-rally update!
September 19, 2008, 12:03 am
Filed under: brakes, carb, cdi, dellorto, electronics, fail!, intake, new parts!, port timing

since my last update i’ve gotten a few things taken care of. firstly, i took care of the rear brake.
i have never had a moped with crappy brakes, especially the rear. i know the front does most of the stopping, but all of my bikes have always had awesome rear brakes, like skid worthy. i was a little disappointed in ciaociao’s rear brake hardly slowing me down even.
i pulled the rear end apart to sand the pad and see if there was anything i could do to make it work better, when i remembered i had a kinetic rear hub floating around. i dug it out and discovered the brake pad on it was over twice as wide as the stock ciao pad!
here you can see the stock pad compared to the kinetic pad, which i had already mounted in this picture;

the kinetic one is probably a third bigger than my “large” vespa pad from my si that got saturated in gear oil. totally found another good thing about kinetics! can you believe it?
after mounting it, i got it all sanded and ready to use, and threw a new pedal sprocket on with fewer teeth for good measure.

it works awesome now! skid city!

i also fixed my flywheel fan for the last time, i hope!
i made a new spacer on the lathe, only this time i gave it a cheek for the fan to rest on. i pretty much re-created the same spacer from last time, but left it a super thin shelf for the back of the fan.

then i chucked the fan itself up in the lathe and turned out a step for the spacer’s shelf to fit into.

here they are side by side;

and put together;

poured on the 4000lb test glue and it works perfectly! no more fan falling into my expensive coils!

speaking of expensive coils, after installing the new set and putting the bike back together, i wasn’t getting any spark at all. took the bike all the way apart again to discover my coils were faulty. either they came that way, or i some how broke them while installing them.. at any rate, i thought i was up a creek.
after calling around to literally 20+ ktm dealers in my area, i finally found on that had one in stock! it ended up costing me a good deal more than the other coils, but the ones i got are true made-in-italy ktm50 coils, not after market knock-offs like the last two sets i had and broke. the actual ktm coils are way better quality and totally worth the extra money.

i put the new new coils in last night, cut and bent up a lever choke for my phbg so it would fit, and it fired right up. it was about 11p and i got yelled at by the neighbor, so i put it away for the night. i started in on tuning today and discovered i have an air leak at the intake plate i made, but i have a few ideas to fix that pretty easy. for the meanwhile, i’m going to be slapping on the black rtv and get to tuning!
she’s almost ready to rip!!

carby carb
July 24, 2008, 1:08 am
Filed under: carb, dellorto, intake, new parts!

ok, i’ve been all over the place about my carb issues. this evening i committed to running the 21 phbg like originally planned. why? because it was the quick and easy, i have jets for it, and i love milling the fuck out of things, even if it’s a $150 chunk of aluminum carb body.
oooh, what?

what’s going on here?


yeah, i milled the spigot off the back of the carb! as well as a few hairs of material to make it flat and fit as close to the intake plate as possible. i’m tight for room!
you might also notice i milled the spot for the idle screw flat and installed a block off, and move the idle screw to the other side of the carb. i was going to do the same for the air mixture screw, but that’s more involved.. and i think i can get away with drilling a small hole in the fan shroud and be able to access that on the bike.
i could have just ordered up a right handed phbg, but i don’t have time for that shit.
here you can see where i milled the plate to hold the reed block;

all that’s left for the intake is to drill a couple holes in the carb it self, tap them, and drill a couple countersunk holes in the intake plate. make a gasket and bolt them together! done!
here you can see how nicely the intake plate matches up with the carb;

once i have it bolted solid to the plate, i’ll match them together even better and call it good.
i wish i had gotten pictures of milling on the carb, but i didn’t have my camera handy. oh well, i’m sure you can imagine how fun it was!
tomorrow i’m going to make the gasket, mark where the holes go on both the carb and intake plate and return it all to mikemike to let him finish it off. i think i may have to cut a little chunk out of the frame down at the bottom of the fender (not the actual fender it self, but the support below it) to clear the float bowl, but i’ll have to wait and see once i start putting it together.
ok, that’s enough for one night. it’s time for bed.

rally read?
July 16, 2008, 1:35 am
Filed under: bars, carb, cdi, dellorto, electronics, fork, intake, motor

well, it’s crunch time again. i decided it was time to prioritize what i had left to do for ciaocioa to finish her. i decided the most important, at the top of the list thing that needs to happen, is to get the electronic system and the intake finished. these are things that absolutely need to happen before she’s on the road.
last sunday i went down to mikemike’s and did some work on the mill to make the stator plate we are using fit. all i really had to do was drill some holes in it, and mill it down to be half as thick as it was. then we had to turn the inner hole out a bit larger to clear the bearing seal and it was golden.
here it is sitting in the motor.

notice all the extra holes everywhere. this plate originally went to something else, we used it because it took little to make it fit proper. we’ll only be using the three holes that bolt the plate to the motor, the rest will go unused.
here it is with the rotor and coil set on it something like it will be when it’s all mounted up proper.

you can see how small the rotor is. the little holes in it will be drilled out a bit more and tapped for the alum fan adapter plate to bolt on, which will allow use of the plastic fan i stole from a parted out kinetic.
i hope this weekend to go in and bust out the intake for it. i’ll be using the dellorto si carb to start with.

it uses crazy car-carb-like press-in jets, but they are readily available at pretty much any serious scooter shop. i can also order up what ever i need at the shop, so that’s good.
these carbs are found stock on the old, bigger vespa scooters, so there’s a bit of novelty using it on my vespa ciao.
i chose it for a few reasons; flat slide, down draft (makes building an intake much easier), novelty, availability of jets and parts, and best of all, it was free! thanks jeb!
ok, so those are the things i am going to focus on until they are done.
however, a running engine is no good if you don’t have a bike to put it in..
since my time at mikemike’s shop is reserved for those two bits for now, i’m going to put off the fork swing arms until i get them done.
even if i had the swing arms done, i’d still have to lathe out the stem adapter before i could use that for.. so for now i am going to just use the heavier bravo forks that i was rocking on the orange ciao for so long. i’m also using orange ciao’s handle bars, controls and grips.
tonight i bolted the fork on and threw a too-small axle in the front wheel just to put everything together to see how it looked, and it’s going to be awesome. i forgot my camera here today, so no pictures. i’ll get some tomorrow.

March 26, 2008, 10:25 am
Filed under: carb, dellorto, wheels

well, as some of you know, i quit my job last friday, and will be working at seattle mopeds come april 1st.
this has me super excited! no more 9 hours of sitting in front of a computer in a dark office with depressed coworkers all day! even if i end up doing a fair amount of sitting in front of the computer at the shop doing the ebay thing and keeping the seattle mopeds facebook and myspace updated and stuff like that, at least it won’t be tedious boring work, and it won’t be in such a depressing environment.
anyway, i was just about to order the carb when i noticed my bank is down to the >300 mark, so now i’m torn between holding out till i get another paycheck in the bank, or just saying screw it and ordering the thing. i reaaaallly want to get that thing in my hands asap.
i think i’m going to mikemike’s later today to machine the brake plate for the front wheel to get it to fit proper. this will be a big step too, as it’ll allow me to get the wheels bolted up and have a rolling chassis laying around rather than a pile of parts.
ok, i’m going to go put some things on craigslist and see if i can’t generate some bucks. anyone interested in a seriously like-new roland alpha juno 2 in hard shell case? $200 + shipping!

March 2, 2008, 12:09 am
Filed under: carb, dellorto, electronics, frame, intake, malossi, paint, performance, transmission

sorry to you guys that follow this. i have been lame about updating. it’s been busy around here! i feel like i need to update more mostly because other than jon’s blog, this is pretty much the only moped build blog that ever gets any updates. at least as far as i know.
well, i have paid for another set of the malossi gears, and they should be on their way soon. i’m going to be buying up a third set as soon as i can too. one set for orange ciao, another set for ciaociao. i was so impressed by the performance gain the gears gave me in la on orange ciao, that i really hate to go back to stock on that bike. that’s why i’m still running around on the broken malossi gears!
speaking of broken malossi gears, i think i should update my installation guide to inform everyone of what i think went wrong, and what i think i need to do to avoid it a second time. i’ll do that soon.
as far as the rest of ciaociao goes, i haven’t made much progress. i need to get on mikemike more about getting with me to machine the remaining electronic parts, and also to weld up the seams on the frame, and get that cross bar in there.
jeb said he has a dellorto si kicking aorund that i can check out to see if it will work for me. the carb for me is either a 20mm si, or a 21 phbg. once i figure out what i’m doing there, then i need to make an intake. that shouldn’t be hard/take long. i hope.
anyway, my goal is to have this bike done (sans powder coating) for the puddle cutter rally in june. i will be riding it in it’s rough and raw stage for that rally. i think i’ll be back in reno (at least for a bit) some time between that rally and creature rally, which means i’ll be able to strip ciaociao down and drive it to sac to have it coated by nate and rafter. save on shipping, and i’ll be able to test ride and tune the crap out of the bike before pumping more money into it for powder coating.
anyway, that’s my update for tonight. there’s more that i could go into, but i’ll save it for another post.