replacing the light and horn switch on a puch moped

I had forgotten how difficult it was to work around the legshield. Removed the flywheel to have it re-magnetised. When he had his replaced with thicker spokes locally, I had my spokes replaced as well. Also, Gary had nothing but problems with the 3 mm spokes on his new VS rear wheel which continued to break. Despite having never been fitted to the bike, the chrome is already starting to pit. Since the rear tyre needed replacing I also decided to fit the new wheel I bought from RBO in 2012. No wonder Puch only used the early type of leg shield for two years (1957 to 1958). Replaced the cylinder head which for the VS50K means: Will definitely fit that in-line filter and look at coating the tank. I also had to re-fit a second exhaust gasket, as it was blowing oil, but in the meantime the engine stopped working and runs just with cold start spray. Better now but still can reach the bottom when pressing hard. Refilled the front shocks as they were bottoming out. Stupid! Also, will need to match the transfer ports of the crankcase to the wider ports of the new cylinder. Have now ordered a piston with 12 mm pin. I had ordered a kit with 10 mm gudegeon pin but had forgotten that I must have fitted a new 12 mm crankshaft. I can still re-fit the old exhaust, and maybe reduce the advance a bit.įinally removed the cylinder and piston in order to fit the new RBO aluminium cylinder. But it is early days, and the engine still needs to be run in. If anything the bike runs worse than before. The first test drive was a bit disappointing: The cylinder is supposed to deliver 5 HP, but I knew this was wishful thinking because of the small exhaust. The exhaust interfered with the foot brake lever, so I hat to grind off a piece of the exhaust seam.

The exhaust has a welded 28 mm manifold, so I had to juggle the legshield, the exhaust and the subframe to get everything fitted – but only just. The rubber connecting the carb to the air filter is even harder to fit with the 15 mm carb.

In fact, I had to file a notch off the frame’s seam to make the carb fit. The 15 mm carb is so close to the frame that the engine needs to be dropped at the front to fit the carb. The rear wheel needs to be removed to get to the rear bolt fastening the legshield subframe to the frame. It is absolutely no joy working on these bikes using the first of series of legshields:įor pretty much any work on the engine, the legshield needs to be removed. Johan kindly rebuilt the engine for me, and I fitted it back to the bike, together with the small MS exhaust which is also used under the VS50K floor boards (but with 28mm manifold and larger pipes), and the 15 mm carb with adjustable jet. It took a while but I finally received the correct piston with the 12 mm gudgeon pin. Fitted the RBO aluminium cylinder to the VS50K

Replacing the light and horn switch on a puch moped