200 Rally P cases

[vespasco]

After pulling apart my engine to change bearings and seals I.noticed a nasty crack in the cases, rendering them useless (unless I get them welded).

I have some '74 Rally cases (Femsa), which is the original engine for my scoot.

For one reason.or another I'd like to use the flywheel side case from the PX200E with the originall Rally clutch side case.

Ideally one should use matching halves but is there any reason why this would not work??



The differences I see are;

Rally case fly side- the stator (upgraded to electronic ignition) would need profiling to fit snuggly. With the P200 case it woyld fit perfectly without mods.

The actual crank case has better lubrication for the crank bearings in the P200 fly side.

The gearbox cover would fit properly using the P200 case (I will be using the late type gearbox)

On the Rally the oil hole is lower (no biggy)

On the Rally there are a couple of extra holes behind the stator that woyld need fillibg. (I guess for extra wires for the Femsa ignition).

I can use standard p200 flywheel bearing using p200 fly side case (no biggy)

There is no spring for the kickstart (the thin flap od metal rivetwd inside the case. Again, thats no biggy.

Also the P200 junction box would fit perfectly on the P200 case.)(the Rally is slightly different)

The oil thrower is fixed on the Rally cases. No biggy.

Im more concerned about the internal bits and pieces lining.up etc. But as most parts are interchangeable with Rally and Px I think it shoyld be ok?

What do you guys reckon?!

[pxguru]

Sounds like you found where the seals were leaking from!

Mixing Rally and PX/E casings is fine. I have done it before with no major issue. Important to check the base gasket surface. Between the halves it will not be exactly level with the crank centre and the barrel will not sit square. Check the lip on the gasket surface and make a thin half base gasket to sit on just one side to level it up

[vespasco]

Thanks.
I just quickly checked this and yeh you're right.

The joint at the top is pretty flush.
The bottom joint has a slight lip on it.

I think I can get away with just lapping the Base.
The px case is very slightly lower than the Rally case.

i1050.photobucket.com/albums/s412/Khalnayak14/Mobile%20Uploads/2014-08/IMG_0005_zpsfvklcle1.jpg

[vespasco]

Aug 25, 2014 16:49:00 GMT pxguru said:

Sounds like you found where the seals were leaking from!

Yes. The leak from the cylinder head - you can see the blow by in the photos

Also you can see where another leak was coming from on fly side seal

The clutch seal also was blown. See the pool of oil in the crankcase.

Then also... is the crack in the cases. Not so easy to spot on the photos but its quite big and visible inside but mainly outside the cases, behind the rear wheel. Although I couldn't actually see any visible oil leak from there. (probably because all the oil was in the crankcase and not the gearbox)!!!

Im suprised I made it home!

[sbwnik]

You should also check for straightness across the crank bearings, even 1mm difference will lead to it shredding seals and/or bearings regularly. This is straight forward though, drop a crank into the clutch side bearing, offer up the flywheel side, pin it with a couple of bolts (they need to be tight, but no need to use all of them) and see if the flywheel spins without feeling like it's hitting a high spot.

[vespasco]

Thanks nik. I think you're right. It would not take much to be out of alignment. And on a kitted motor that I want running perfectly (as poss) its even more crucial.
The more I think about, the more I think its a bad idea. If they were both pxe cases made around the same time then probably/maybe!

So Ive now decided to use a px set of cases. Either by getting my cracked ones welded up, which is quite do-able but will take time.
Or...
Ive also still got the running engine that I replaced with the Pinasco. Thats a stock px200e with late type gearbox upgrade. Luckily no one bought that as its been up for sale for ages!! But once youve had a nice fast tourer then going back to stock speeds will be.highly disappointing
So I must rebuild the Pinasco!!

Ive also got 2 great sets of early Rally 200 cases! (The best of which is still up for sale BTW
(the other set belong with my Rally- same/close serial numbers)
And I have the 'stock' upgrades to go with them.(12v ducati,late gearbox etc)

I have decided that, with a kitted motor at least, I'd much prefer having that fly side bearing lubricated by the px cases. And a matching set too!!
And also the gear selector cover will fit properly. (as im using late gearbox). And the junction box!

Basically im trying to have a good clear out of scooter 'stuff'. Ive even sold my beloved ss180 recently
The plan is to be left with only my Rally/pinasco in full working order and the original Rally cases.
So ill have a few nice bits for sale soonish. All the crap will go in the bin!


I think I need to make myself a long pondering stick and decide what to do!!

[vespasco]

Heres what I ended up doing...


s1050.photobucket.com/user/Khalnayak14/media/output_zpsn7kcp81t.jpg.html

s1050.photobucket.com/user/Khalnayak14/media/output_zpsm3bdrrgg.jpg.html

I think im slowly getting the hang of putting my pics in a bucket Hope it works!