Should I fit this Malossi Top end

[paulwaite]

Should I fit this Malossi top end to my Rally 200 engine that has starred in the "Heavy ball bearing when turning engine off."

This engine is now in a Vespa 160GS, or in reality, a Spanish version of a GS, but with the GS headset, rather than the rectangular spanish one. Anyway, never really used this scooter and may sell next year, so just making sure everything is running OK. Now that I have solved the ball bearing sound, I'm going to check the rest of the bearings and replace the oil seals.

However, I bought this Malossi 210 barrel and piston a few years ago that looks like it has been tuned even higher than the standard Malossi. And like a fool, I'm tempted to put this barrel and piston  on this engine, without opening up the transfer ports on the case, without putting in a T5 fourth gear and using the original Rally cylinder head.


So, the question is, with these limitations, will I see any benefit over the standard Rally 200 top end, or would it make it worse












Original Rally barrel on left

[henri]

it depends on what exhaust ya thinking off , stock one you'll see a marginable increase in performance ,stock looking but big box ,sip road/tsr/bgm a better increase .but if like you suspect its been worked on it will probably only come "alive" with a expansion chamber ,an will probably def need a short/t5 4th .
if keeping i'd say stay stock, but if selling it being a "mallosi 210" is a def selling point, but without being to name the tuner an work done not a really big 1 . H

[pxguru]

If you have no other use for that kit then you might as well use it. Doesn't look like much has been done to it. That hole in the boost port won't make much difference from a standard 210 but the good news is that the transfer and exhaust ports look fairly untouched. Raising the exhaust port on an old 210 is usually not a good idea. Piston has some nice home work done, looks like it has the 60mm crank mods too.

On an old GS frame you are not looking for speed really, so just to go better like a touring set up (assuming you have a 57mm crankshaft)fit the kit without a base gasket, just a smear of gasket sealer. And run standard exhaust and carb if that's whats on it. As the 210 bore is 2.0 mm bigger, the standard head might just touch the piston a little bit depending on which head you have.This must not happen. If your standard head is already not touching (or you can just Dremel the edge off it all the way round to clear) then it will be better suited to a touring set up with the higher compression. Timing at 20 degrees and carb set up properly (see other threads). Do it like this and it will go really fine even without the correct head, exhaust, port matching, T5 4th, etc.
Edit; One of those Malossi copper head gaskets will get round the issue of using the standard head on a 210, if the compression is too much or you dont want to Dremel the head.

A little worrying how that clutch was assembled, let's hope that's the last of it.