Cosa clutch in 150 engine?

[sime66]

Am I right in thinking it isn’t such a simple job to put a Cosa clutch into a 150 engine? I did a lot of reading last night about swapping to Cosa, and some say there’s mods needed to the casing, or a p200 cover and pressure plate, and some gloss over it, but maybe they’re talking about changing 200 engines to cosa. As I was getting a bit bogged down with info and didn’t know what to trust. I’m still investigating it myself, but I thought it best to just ask the straightforward question:



. What’s involved in putting a Cosa clutch into a 150 casing?



That doesn’t mean I’m going to do it, I’m still weighing up the pros and cons, but if it’s a faff it might help me make my mind up when I get to it.
I'd really like to avoid using one of these castellated nuts again though.


To keep fitting it simple I’m starting to think I’m limited to a 108mm OD clutch.



. Same question applies to larger clutches.


. Same question applies to banded clutches.


This might be a silly question, but i've got myself a bit bogged down with info.

Cheers, Chaps........

[sime66]

Following on from that question above, the list below is the choice as I see it, but without yet knowing the full implications of using a 115mm dia clutch.
In ascending order of price, with pros and cons as I understand it at present:

[glscoot]

VESPA P150X / PX150 E 150 VLX1T 2T AC `78-`85 modify clutch cover or use 200cc cover

Is this your scooter, if so all 115mm diameter clutches will fit with a P2 clutch cover. The reason you need the P2 clutch cover is so the wider/thicker clutch will fit without fouling the two fins on your clutch cover. The diameter has really nothing to do with this. If you think about 115mm - 108mm, difference of 7mm, thats 3.5mm either side of your clutch.
I can't remember how many corks or steels your clutch has but the Cosa has 4 steels and 4 corks, which i know is more than your clutch, this makes it a few mm wider/thicker. The Cosa clutch was excellent, but there are a few now where the basket is very poorly made and is prone to spreading its legs, ending up with the large cir clip being forced out and so the clutch ends up like yours. Hence the reason the clutch basket is banded or now CNC machined making it stronger so all you need to do now is make sure the clutch is built properly and the corks are soaked in oil, of course fitted properly as well. Correct spacer washer and a nice tight woodruff key fitted to the crank.
Check your clutch cover it may already be a P2 cover.

Gary

[pxguru]

In your situation I would buy a banded ready assembled 21 tooth Cosa clutch, nut and washer.

To fit the bigger clutch you just need to dremel that bit of the casing that sticks out (the bit you have already damaged) and reduce the size of the oil way in the clutch cover to clear the clutch at its edge. Sounds a lot more difficult than it is.

[glscoot]

I will try and post a picture of the section you need to remove, if your clutch cover is not a P2 and as guru said none of this is difficult.
gary

[sime66]

Yes that’s my engine. What you’ve said is pretty much as I read it, but I was unsure about the 115mm because I just don’t know what sort of tolerances there are there, and I’d already been catching the casing at some point as we’ve said. I see now the real difference is in the depth, not the diameter, hence the p200 (or modified) cover. I’ll dig mine out and have a look at it there’s a photo somewhere too. It does seem like a banded Cosa will be the way to go, however there are developments on the clutch nut removal that might have moved the goalposts.

Thanks for your help Chaps.

[glscoot]

When you find your clutch cover, it will either say 125 or 200 on the inside and if you have the 125 the two fins that need to be grinded away are pretty obvious and if you make a james hunt of it, you've only lost a clutch cover, but to be honest its pretty easy.
gary

[sime66]

It was bagged and boxed for cleaning, and it’s clear to me the bits you mean. - Already had a few knocks there too.
(pic below to help those that may read this in the future – my 150 left, 200 right -)
I’m weighing up the options now I’ve messed my crank up, but if I’m ever allowed power tools again, I reckon I can handle that little job.

[sbwnik]

There's no other differences. As long as it has the right amount of teeth, there is no other work that needs doing (other than get a Cosa type nut and washer to lock it up... The single best reason for swapping over that there is!)

[sime66]

That's that decision made then.
Cutting for a Cosa it is. 
Now, back to this engine.............

[henri]

sorry if i confused you with talk of spacers for sip cosa clutches ,the standard cosa's fit with a dremelled cover or p2 1.the uprated/billet sip clutches with more plates are the ones that are thicker an need a spacer between the cover an cases to fit.when you mentioned a sip 1 for 200quid i thought you were looking at there uprated clutches ,that you dont really need at your state of tune .if you read glscoots threads about his gs build i think he did a clutch swap on lml cases which are the same as px 1's.H

[sime66]

Love your contributions H, you didn’t confuse me.
I confused myself – greedy for knowledge, sweeping the net in the wee small hours, and not knowing what was right, so I asked you clever blokes.
Clutch choice always confused me, which is why I had it done for me last time.
I reckon I’ve got my head round it now, which is great; also learned to slow it down a bit.
I’m going to get a banded Cosa when I have the cash, but probably a 2nd hand Cosa to get back on the road.
Will go back to glscoots gs build post - (was just looking at lovely shiny scoot before)

[henri]

clever blokes? must be talking about others ,i get called "a right little clever bleeder" sometimes but dont think its a compliment.
i do the same on net aswell,as ive said before "scoots weve all got a opinion on em,but what if were all wrong" ,an with all the forums an shops out there it does help to go old-skool an note it on paper.all round my puter are post-its with cryptic lists an numbers on ,just like ya clutch notes.i always get lost going page to page an trying to remember who said/sold what an how i got to page to start with.
glscoots gs is nice n shiny ,not sure about orange cases tho,not for me ,but gave him a thumbs up as it will have the purists spinning in there parkas/anoraks.always a good thing in my book.
if i remember right gazpx was up to a clutch in his thread "new engine build" but not sure .might be worth a gaze ,
sorry but dont mean to make ya jealous,but rain just stopped an sun came out an ive got errands to run on my "little red-un" ,cheers H

[sime66]

New thread started - 'PX150EFL Engine Strip for Inspection / Repair'