Jet Set Scooterlab
Things I Learned Restoring my GS160
Here are just a few notes on things you might run into working on a Vespa GS160.
- The clutch cable outer housing that comes with most modern cable kits is not long enough for the GS160 or SS180. This can be a real pain in the ass if you don't realize this until you bolt the engine in and have to re-thread the outer.
- For a GS or SS that starts first kick, but isn't completely original, use a PX125 HT coil instead of the original brown/orange style coil. Just attach the red lead to the coil and the black to ground. Works great.
- For more powerful engine you can bore out a GS 160 cylinder to 180cc and use an SS piston, or you can bolt on an SS180 barrell. You will need to change either the conrod or the crank in order to use the SS piston: it takes a larger gudgeon pin with needle bearings rather than the GS brass bushing. I rebuilt my original GS crank with an SS conrod. GS cranks are full circle and are a bit smoother than SS cranks.
- For a higher gear ratio put in an SS gearbox. I left the GS gearbox for better acceleration.
- I replaced the flywheel bolts - the one's that stick out and destroy the engine cowl if you're not careful - with dome head allen bolts. Look sharp too.
- You can use a Sito Plus exhaust with some minor modifications. I haven't done this but it will give about 5 mph more on the top end.
- The GS column lock is unique among vespas: you remove it by screwing IN the tiny set screw on the top of the lock that is accessed through the top of the body with the headset off. Don't lose the little round barrell that actually locks the fork, or the spring. Both may fall down into the body when you remove the lock.
- SS forks are identical to the GS except for the slot for the column lock. Both of them seem prone to bending. If you have a bent fork, Vespa Supershop (I have heard) has a jig that straightens forks, or you can track down a PK125 fork and have a modern front end . (More here.)
- GS parts that used to be hard to find, but are now available. I found most at Scooters Originali, but try your local shop:
- Floor rails: Mauro Pascoli finally makes some rails that fit the curves and have the correct rubber.
- Legshield trim: the original is stainless, and can be straightened and polished without too much difficulty if you have it. Mauro Pascoli makes some nice chromed stainless trim that fits and is almost as good as the original. You can get some nice chrome double trim from Scootopia.
- Seat covers: excellent repros with the correct fasteners.
- Electrical junction box rubber.
- Small diameter light grey grips.
- Exhausts: Sito repros that are better flowing than the original items.
- Glove box locks - not original looking but work.
- Floorstrip rubber: the correct stuff is trapezoidal with a slot down the middle.
- GS parts that as far as I know are impossible to find (let me know if you know otherwise):
- MK1 airboxes: look like a coke can ray gun. You can use a MK2, which is similar to an SS and a bit easier to track down.
- Fan shroud. Same as the SS and very scarce. For some reason, cylinder shouds are easier to find.
- Front shocks: there are Sebac aftermarket shocks, but they don't look right, and I have heard they can break.
- Body parts: expect to pay a ton, but Scooters RS in Vietnam is considering making them new. Let them know if you are interested.
Feel free to email me if you wanna talk GS's. Other sites that are rich with Vespa GS and SS info are:
