Rewiring the junction box correctly

Recently I have been working more on my Bajaj Chetak and some body work on my wife's Chetak in an effort to be ready for a Rally ride in three weeks. To see what is happening with the Bajaj's click here. I need to add a post on the Bajaj site to share an interesting thing I found in the oil filter some time in this week.

For info on the rally see the flyer below:



Tonight I replaced the grommets around the junction box to the correct ones. Here's what it looked like first.
Note the incorrect grommets.

Here's what the wiring looks like complete inside the junction box:


To save myself time, I made a diagram to remind myself how to rewire it quickly:


I looked closely at the Technica photo and made sure this time I got it correct. Here's what it looks like:
Note: the only thing I am unhappy is about is the bottom grommet has two holes and I meant to run the wires from the PX HT Coil (mod) through the top hole closest to us so it would be less noticable, but I messed up. In the grand scheme of things, this isn't an issue in any way.

The anoraks may note that my screw for the junction box is also not stock.

Quirky grommets

Just an FYI . . .

Lesson 1:
I am not sure the SS180 requires a "fuel line grommet in air box (113060)". Though talking with David at First Kick Scooters I've learned. . . on most largeframes there is a hole at the bottom of the airbox for the fuel line to go up through (at an angle) to the carb banjo bolt.
I have not found that hole on my SS.

Lesson 2:
The "throttle/choke grommet (48171)" is exactly the same as the "wire harness / frame grommet" so make sure that you order QTY: 2 of one of them. They are the same part with two different names. Note that the spark plug is just in enough for the photo. It is not all the way in. You can see the throttle/choke grommet below.

I believe the wire harness drops through this hole and connects to the HT coil. I need a grommet to go here -- pictured below:

Lessons Learned:
David, from First Kick, just emailed me:
"Jeremy, I talked to the mechanic and he said that someone drilled that hole. It is not suppose to be there." -David

Follow-up from David: 

"Rene from Canada said that the 1st series SS180 did have two holes for the cables and wires." This may apply to some of you, but I own a later SS180.

This is a comment that Paul B. posted, but needs to be on the front page so that you all read it, because it is VERY helpful:
1. No, there is no fuel line grommet for the air box on the SS. The fuel line never enters the airbox like many Vespas; the GS 160/SS180 air filter housing assembly sits ON TOP of the carb.
2. ABSOLUTELY, POSITIVELY, remove that spark plug wire end cap. The clearance between the SS engine cowl and the spark plug is WAY small. The first time your wife hits a good bump in the road, BAM, that cap will come up with the engine and slam the underside of the cowl and put a nice dent in it. Only use the factory item (looks like a bobby pin sort of)with the original soft metal cover. I've seen so many SS's with this damage!
3. The hole you are pointing to is homemade and should have been filled during the restoration. The harness comes through from in the body to the engine area through the throttle cable/choke cable/HARNESS grommet.
Paul B.

Parts order shipped

Partial shipment shipped from Scooter Shop (they're good about having NOS):

Seat Buffers (Part: 56730) NOS $ 5.00

Fuel rod grommet (Part: 47460).New $ 2.00 looks right

Gas Tank Cap Gasket for large frames (Part: 56678). new nice $ 2.50

Qty: 2 -- Cowl hook grommet white nice $ 3.95

QTY: 2 -- Cowl peg buffer (Part: 87488) White nice $ 6.96 each

QTY: 2 -- Cowl hook sheath (Part: 24041) piaggio $ 2.00 each

Gas Tank Cap Gasket for large frames (Part: 56678). new nice $ 2.50

Seal for the fuel assembly – goes beneath the sediment bowl (Part: 26042)NOS $2.00

Fuel assembly gasket for inside gas tank ???? New 2.00

4 hole gasket for fuel cock assembly. Fits GS and Super Sport. (Part: 13836) new Nice $ 3.95

Gasket for air bellow connection (Part: 97493) re made by us $ 15.00

Brake pedal rubber in BLACK italian $ 4.50

Brake Bellow for most 60s and 70s Vespas (Part: 57321) Nice New $ 4.50

Clamshell Speedo glass (Part: 84803). New Nice $ 15.00

Clamshell Speedo gasket (Part:49458?) Nice New grey $ 4.50

Speedo cable SS italian $ 14.95

Grommet Order Placed

Yesterday, I placed the following order along with these prices for my wife's 31st birthday (seeing as the VSC is her bike). We were lucky enough to receive cash from family. We hope to get more . . . we probably need about $200 more.

When possible, I got NOS (and paid for it) and I requested only Italian or German rubber -- no Indian-made. When packaging it, the scooter shop will check everything and replace or not ship/not charge Indian parts. I will pay for the quality. Of course, with 40 year NOS parts, it's possible the lives will not be another 40 years.

Here's the order:

1. Centerstand spring (Part: 47872). New $8.95

2. Seat Buffers (Part: 56730). NOS $5.00 each

3. Fuel rod grommet (Part: 47460). New $2.00

4. Fuel line grommet (Part: 84262). New $2.50

5. Fuel line to airbox rubber. New $2.50

6. Grommet for electrical harness and spark plug wire. Using a Vespa PX HT coil. NOS $2.00

7. Grommet to frame wiring. New $2.00

8. Cable grommet for HT coil wires (Part: 48171). New $4.95

9. Cable Hose (Part: 90541). NOS $5.00

10. Throttle and choke cable grommet. Fits 60s to 80s Vespas. New $2.50

11. Grommet for clutch gears and rear brake. New $3.00

12. Cowl hook grommet (Qty: 2). White nice $3.00

13. Cowl peg buffer (Part: 87488) (Qty:2). White new $6.96/each

14. Fuel line grommet for more most 60s and 70s Vespas. New $3.95

15. Gas Tank Cap Gasket for large frames (Part: 56678). New $2.50

16. Seal for the fuel assembly – goes beneath the sediment bowl (Part: 26042). NOS $2.00

17. Fuel assembly gasket for inside gas tank. New $2.00

18. 4 hole gasket for fuel cock assembly. Fits GS and Super Sport (Part: 13836). New $3.95

19. Gasket for air bellow connection (Part: 97493). Quality/New $15.00

20. Brake pedal rubber in BLACK. Italian new $4.50

21. Brake switch gasket (Part: 82783). New grey $3.95

22. Brake Bellow for most 60s and 70s Vespas (Part: 57321). New $4.50

23. Clamshell Speedo glass (Part: 84803). New $15.00

24. Clamshell Speedo gasket inside glass (Part: 84804) New $5.00

25. Clamshell Speedo gasket (Part: 49458?) New grey $4.50

26. Piaggio Speedo cable. New $14.99

27. Rubber grommet fits around steering lock. New $3.00

The order should arrive a week from Monday at the latest.

Order Placed

I just placed an order with ScooterWest for a few items. I wanted the air bellow, because everyone else sells it for $30 plus. The dang $10 shipping min. meant I needed to get a few more items to make it worth my while.

Here's what I ordered (two of the grommets were badly needed):

- GS/SS air bellow $18.95
- Coil cap & junction box set GS/SS $10.00
- Piaggio Grey Grips 24mm SS/Rally $14.40
- Lever screws $2.28

Total: $55.92

Frame Grommet List

Below is a list of the badly needed rubber grommets I need to proceed with the restoration. I am fine tuning the list, but in its current state it may save you time from needing to create one. I looked for a list that someone else already created, but couldn't find it. Why recreate the wheel, right? I hope this proves helpful for you:

1. Centerstand spring (Part: 47872).
2. Seat Buffers (Part: 56730)
3. Fuel rod grommet (Part: 47460).
4. Fuel line (Part: 93510).
5. Fuel line grommet (Part: 84262)
6. Fuel line to airbox rubber.
7. Grommet for electrical harness and spark plug wire. Using a Vespa PX HT coil.
8. Grommet to frame wiring?
9. Cable grommet for HT coil wires(Part: 48171).
10. Cable Hose (Part: 90541)
11. Throttle and choke cable grommet. Fits 60s to 80s Vespas.
12. Grommet for clutch gears and rear brake.
13. Qty: 2 -- Cowl hook grommet (Qty: 2)
14. QTY: 2 -- Cowl hook sheath (Part: 24041)
15. QTY: 2 -- Cowl peg buffer (Part: 87488)
16. Buffer for cowl latch (Qty: 2)
17. Fuel line grommet for more most 60s and 70s Vespas.
18. Gas Tank Cap Gasket for large frames (Part: 56678).
19. Seal for the fuel assembly – goes beneath the sediment bowl (Part: 26042)
20. Fuel assembly gasket for inside gas tank ????
21. 4 hole gasket for fuel cock assembly. Fits GS and Super Sport. (Part: 13836)
22. Air Bellow (Part: 97366)
23. Gasket for air bellow connection (Part: 97493)
24. Brake pedal rubber
25. Brake switch gasket (Part: 82783)
26. Brake Bellow for most 60s and 70s Vespas (Part: 57321)
27. PX HT Coil cover
28. UPPER -- Coil side insulating cap for VSB1-VSC1 (Part: 57042).
29. LOWER -- Coil side insulating cap for VSB1-VSC1 (Part: 56169).
30. Cable coil grommet.
31. Speedo nut top grommet.
32. Speedo sheath seal.
33. Clamshell Speedo glass (Part: 84803).
34. Clamshell Speedo gasket inside glass (Part: 84804)
35. Clamshell Speedo gasket (Part: 49458?)
36. Rubber grommet fits around steering lock.
37. Handle bar segment grommet. U-shape rubber grommet.
38. Front hub oil seal (Part: 94119).

Grommet Set

American Scooter Center sells a variety of rubber/grommet kits and you can save a pretty penny by buying it in bulk (so to speak) this way.
The set pictured above is for the Sprint/Rally and costs $13. I've gotten mixed messages on Scooter BBS. I'm told that most are correct, but a few aren't. I was also told that most are wrong and won't work and to boot many pieces are the wrong color. So I have emailed Collin for clarification. This is his response:

Hi Jeremy,

Most of the frame type stuff in that kit will work just fine. You will have a number of parts left over that will not work though.

SS/GS bikes have a number of unique rubbers though:

Frame gasket for metal air intake arm

Junction box rubbers (both sides are different)

Coil cover boot (I'm not sure if you're using the correct original bakelite coil or not)

Grommet that goes in the metal clip that holds the spark plug wire to the case

Airbox grommets ( there is a big one and a small one), for the metal SS airbox

The Rubber Air bellow is unique to SS/GS

That's all that I can remember off the top of my head..some of that stuff is available from ASC.

Cheers,

-Collin

ASC also sells grommet kits for the engine as well. These are Indian-made.

I need this kit soon, seeing as the engine is in as is the steering column and it's going to be time connect the cables, which are already run.

Avoid poor quality Indian rubber, which is more likely to dry and crack six months after installation. So always ask first. It will cost you more money/time in the first year if you buy cheap grommets.

SIP sells a kit for $43 made by MeCur -- should have high quality parts. This would be a smart approach. I have been told by a USA scoot shop that the SIP kit they got their client was Indian-made. I find this confusing. I am not that dialed in, but I have not heard that MeCur is outsourcing to India.

You should be safe with German or Italian-made products -- SIP and Pascoli. Don't waste your time with Indian.