after two months I've finally got one of my Cosa's back...

Jack broke down on this on the way to Pontedera and it's took eight weeks to get it back here...

it's up on the ramp so let's get the engine stripped...

I already know what's wrong with it as Jack had the sparkplug out of it in Belgium...yes aluminium grey!!..

single cable gear control...it is a late model GS after all...

lunch on the go...

and there is the problem...a beautiful hole where the aluminium on the sparkplug should be...the original aluminium barrel has long since gone...

so far so good...nice homemade tool to pull the gudgeon pin out...

back in the garage for a few days while I wait for a few things to arrive...and it's the weekend...I try not to tat weekends...

besides the big hole there's definitely a few seize marks on it...

ok...more than a few seize marks...

rings are well f*ck*d too...

somehow the Belgian recovery company f*ck*d the seat lock up and as a new lock is just shy of £100 I got a whole (knackered) seat off eBay for thirty quid with a cracking lock and two keys...

there's actually four keys there but only two fit...

weekend's over and I've dived right back into it...

I can see from here that the felt washer needs replacing...I'm also going to have to order new shoes and a cylinder...

since I got the scooter back there's been a pool of two stroke under wherever the scooter's been parked...it's now all over the ramp...I thought the two stroke tank was split but it's a seal on the filter...seal replaced jobs a gud un...

as you can see I got to the point where I thought "f*ck it" let's get the engine out...as I'm not replacing the cylinder just now I've left the brakes in situ...

and there it is...

and it needs a good clean...and as it's out it will be much easier...

carb is cleaned and a new gasket set is fitted...

engine's now looking a lot cleaner...new clutch side bearing fitted...

new hub bearing and felt seal fitted...

better view of the new hub bearing...

new seals and the right tools to do the job properly...

time to stop admiring my work and get them fitted...

both seals in...

once again the right tools for the job...this is the only way to fit the crank...

Cosa clutch for a Cosa engine...

most of the internals in...still have the cruciform to fit then it's let's get the two halves together...

and once the electric petrol tap is fitted there is no room whatsoever in there...

given this a proper clean while it's in bits...

oil tank back in...

this is one hell of a fiddly job...

seat & rack sorted...

much easier than a PX engine...a little more room...

as you could see from earlier pictures the shoes, cylinder and springs needed replacing but as there was no stock here in the UK it had to go back together temporarily just to get it off the ramp...

I didn't do this job while I was rebuilding the engine as I was waiting for VE to get the cylinder in stock...I had to order it from s.i.p. eventually...