charley

I recently purchased a used crossover and thought about cutting it open and reworking it . Has anyone done this and is it going to improve performance.

My brake pedal was also too high . I lowered it as much as possible, but was still too high. Ended up cutting the push rod by about half inch on the threaded side and now its always under foot.

Well I decided to do a front fork oil change and got the forks out of the triple trees and the cap off but cannot disconnect the the cap from the cartridge pipe. Before I undo the allen bolt from the lower, I need to know if this is the right method. I've read all the tech articles but none seem to reference the 43 mm fork design. At this point I just drained the forks and reinstalled but without removing the springs you can't measure the fluid level for proper air gap. I refilled with 400 cc's oil and will try to do this correctly on the next maintenance interval. Any info you can give will be appreciated . My ambassador is so much simpler but doesn't give near the grin factor.

The part number is GU04238300 date 24/02/2010. APE GILERA PIAGGIO VESPA ETC. it says genuine. the old spring measured .o78 thousandths and new spring is .080 thousandths. Hope this helps identify the new parts

Got the new spring in today, and reassembled the shift unit. This was a very easy job after reading all the posting and the only special tools needed were snap ring pliers small size and ball type allen wrench for the bottom bolts. Got an extra spring just incase, but the new spring was a larger diameter than the original. So its my guess that even in 04 there were still faulty springs being installed at the factory. If this happens to you don't be afraid to this repair.

I finally found the broken bit. attached is photo. This bike has had red line shock proof since 500 miles . No sludge in housing at all. Any tricks to reinstalling cover?

My newly acquired 2004 Lemans with 17k has come down with the dreaded broken pawl spring. I've popped the trans cover and found that it has the correct 15 mm arm and I',m wondering why this happened. I also can't seem to find the broken off bit and I'm concerned that it could somehow still be in the gearbox. There was a small amount of metal on the magnetic drain plug , so could it have been ground up? Are there new and improved springs available ,or is 04 23 83 00 my only option. What kind of sealant is used on the cover on reinstall? Also any tips on the this operation will be appreciated.

Looking for a roper plate for my 2004 Lemans . email at farle4@gmail.com