Serenity: Ready for Season 2
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As you may have already gathered, Old Blue is up and running again! I want to say thank you again to everyone who chipped in for her rescue, but a few special thanks to:
- Sean at Philadelphia Scooters, for being Sean.
- Pete formerly of Vespa Brooklyn but now of Revolution Moto, for being Pete.
- Denver James, scooter hauler extraordinaire.
- Gwynne and Tom, for scooter storage and support.
- And of course Fred, for many, many reasons.
I daresay Season 2 of Serenity wouldn’t be possible without you guys.
Onward to the resurrection!
Mike sent a photo of old blue at his camp in Galbraith. She made it farther north than I did after all, and hung out there until Mike finished his job and hauled her to his home in Anchorage.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/image1_29976447627_o.jpg)
On August 8, 2017, through the power of uShip, Serenity arrived at the Ballard home of Tom and Gwynne (and Ollie and Cosbee).
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_7652_29976393597_o-800x600.jpg)
After over 5 months of not seeing my bike, Denver James delivered her to Boston on November 12, 2017.
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It was heart-wrenching to take in all the damage up close. This bike was — is home for me for years now, my one constant through ever changing landscapes. However, a closer look revealed much of the damage to be superficial.
Through the scooter network, Fred had already sourced a donor: a 2007 GTS 250 with ~4k on the odometer. Winter lay before us, and I had little else to do (read: under-unemployed). I studied Robot’s videos on how to remove an engine, and his GTS overhaul part 1, part 2, part 3. Below are my notes from the process.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/kbhm5976_31040162268_o-800x800.jpg)
Nov 12, 2017
– Charged battery. Replaced stripped bolt on battery (dammit, Anchorage).
Nov 19, 2017
– Air in tires.
– Removed windscreen (scratched)
– Removed right mirror (smashed).
– Test ride to Harvard Square. Straightened headset and put in gas.
Nov 21, 2017
– Tore into donor.
– Knocked off as much Dalton as possible.
– Removed most crash bar pieces.
– Took off broken spoilers.
– Replaced seat latch dust cover.
– Seat bucket swap (hammered bend straight).
– Replaced bent brake levers with Bagel’s shorties.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0339_44000583255_o-800x600.jpg)
– Replaced entire headlamp unit (scratched to shit). Fred polished new one (only slight scuff).
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0349_44864732612_o-800x600.jpg)
– Taped peeled paint on headset with blue painters tape, replaced metal band (Anchorage again) with ziptie.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0351_44863047162_o-800x600.jpg)
– Replaced left mirror (bent stem).
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0350_44000584035_o-800x600.jpg)
– Inspected temp sensor before realizing it’s the wrong one.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0346_44863046442_o-800x600.jpg)
Dec 6, 2017
– Polished the fuck out of the headlight with NOVUS 3-step kit, thanks Shannon!
– Continued tearing apart donor. Gas drained, floorboard out, seat off, rear rack off.
– Found correct temp sensor and set aside.
– Set aside intact left side trim.
– Prepped headset pieces for paint.
Dec 9, 2017 (first winter snow!)
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2114_43103127240_o-800x600.jpg)
– Removed broken spark plug on donor.
– Donor would not start, determined donor fuel injector was bad/clogged and swapped with Blue.
– Tested compression on donor, only 80 psi? I think Harbor Freight fail.
– Drained fluids and removed donor engine. Mileage: 4701.
– Stripped wiring harness off donor.
– Continued stripping donor.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0618_31040158388_o-800x800.jpg)
Dec 10, 2017
– Dropped fork, set aside mudguard, finished stripping frame.
Dec 12, 2017
– Removed glovebox. Attempted repair of bag hook, but spring is toast. Just reinstalled without.
– Put washers back under gas bracket.
Dec 13, 2017
– Removed floorboard. Hammered out dents on right side of legshield and replaced trim.
– Removed footpegs and internal pieces of crash bars.
Dec 19, 2017
– Fished out stuff rattling around under floorboard, cleaned glovebox.
– Replaced ambient temp sensor.
Winter break in Hong Kong, Nepal, Thailand, and Singapore.
Jan 30, 2018
– Began polishing windscreen, it’s a pain and I need 1600 grit.
– Cheapo Harbor Freight dent puller actually worked on the front dent!
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2170_44912887781_o-800x800.jpg)
Feb 6, 2018
– Began engine swap, 67,107 miles.
– Drained oil and coolant. Removed muffler and rear bracket for cleaning, removed rear brake assembly.
– Dropped T25 hex somewhere in bike.
Feb 10, 2018
– Disconnected all the things.
– Found T25.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_0635_31040216658_o-800x800.jpg)
Feb 11, 2018
– Finished buffing out scratches on windscreen.
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Feb 15, 2018
– Finished removing engine.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2394_31040278658_o-800x600.jpg)
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– Replacement engine lined up for connection.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2373_44912914781_o-800x600.jpg)
– Dropped fuel tank, waiting on dollies to bump out dent on right cowl.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2381_31040279868_o-800x600.jpg)
Feb 16, 2018
– Banged out right side dent slightly.
– Inspected tear near footpegs. They are symmetrical and backed by subframe, decided not to weld.
– Replaced fuel tank and lines. Mudguard and taillight back in place.
– Replacement engine bolted in. Reconnected everything but intake manifold, coolant, and large hoses (out of hose clamps).
– Rear brake caliper in place, but it’s grabbing. Will adjust tomorrow.
Feb 17, 2018
– Torqued rear shocks to spec.
– Reconnected coolant lines with hose clamps.
– Cables cleaned up under the seat.
– Reconnected intake manifold and coolant sensor with RTV silicone.
– Replaced rear brake caliper. Original pads were grabbing, so Fred put the brake pads from donor to match brake disc from donor.
– Replaced rear tire with original tire (donor tire has cracks).
![](https://250superhero.com/wp-content/uploads/2019/04/img_2402_44863255832_o-800x800.jpg)
Feb 19, 2018
– Attached spark plug cap.
– Inspected CVT/belt, decided to use donor CVT and belt. Cover on.
– Air filter tightened down.
– Picked up overpriced exhaust gasket, Fred installed muffler.
– Added engine and gear hub oil.
– Flushed coolant and bled.
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– Reinstalled battery.
– SHE RUNS!
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April 11, 2018
– Plastic parts are in from the painter! Plus extra blue paint for touch up.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2693_44000821485_o-800x800.jpg)
April 12, 2018
– Brushed anti-rust and blue paint on body.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2695_29976805677_o-800x600.jpg)
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April 13, 2018
– Swapped buttons over from old headset. Starter button is a bit broken.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2699_44914852071_o-800x600.jpg)
April 16, 2018
– Removed front rack, disconnected brake line and speedo cable. Dropped fork and cleaned. Lubricated bearings.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2740_31040429198_o-800x600.jpg)
– Replaced front mudguard, reconnected brake line and speedo. Replaced collar dust cover.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2742_44193499874_o-800x600.jpg)
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– Out of brake fluid, will restock and flush and bleed front brake later.
– Attached left and right spoilers, rear mudguard, floorboard end caps.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2757_29976838907_o-800x800.jpg)
April 19, 2018
– E6000’ed some tiny dinosaurs and a lucky cat to my dash.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2702_44913041821_o-800x600.jpg)
April 21, 2018
– Restocked brake fluid, flushed and bled front brake.
April 23, 2018
– Realized the reason the headset doesn’t fit: throttle assembly on 07s are different from 09s. Dremeled off some plastic, headset still doesn’t fit.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2772_31042270708_o-800x600.jpg)
– Perhaps handlebars were slightly bent in crash? Replaced handlebars with donor, moved throttle assembly over. Headset on.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2773_31042271568_o-800x600.jpg)
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2803_29976838327_o-800x800.jpg)
– Still waiting for new starter button, so it’s dangling, but we’re nearly there.
– Front rack back on.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_2809_29976851587_o-800x600.jpg)
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May 1, 2018
– Felt like belt slip on ride. Need to address rattle from CVT.
May 7, 2018
– Replaced belt with old belt 4537 miles. Odo at 67241.
– Replaced rollers with flat spots with new ones (4701 + 67241 – 67107 = 4835 on old belt)
– Noticed ridge on variator.
– Noticed clutch-side bearing is loose.
– Cleaned oil out of bulbs on filter.
May 11-13, 2018
– Long distance test run to Whiskey Dick 7!
June 7, 2018
– Finally installed the footpegs.
June 8, 2018
– Replaced broken starter button, had to file down paint on headset otherwise the button won’t depress and bike won’t start.
June 9, 2018
– Took out old 12v charger, replaced with 2 USB ports. Much fance.
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_3318_29976898177_o-800x800.jpg)
– Replaced broken bag hook with new aluminum one.
And that’s about it for now!
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_8665_29976893807_o-800x600.jpg)
She survived her run to the Poconos for Whiskey Dick 7 (after a new belt), alongside Fred’s black GTS! This was great news, because we had plans for the summer…
![](https://250superhero.jellycity.com/wp-content/uploads/2019/04/img_3398_31040508938_o-800x600.jpg)
If you recognize a Cannonball bike in Boston greater area, you would be correct.
Thanks for the write up. I'm following your adventures with interest. Good luck. 🙂
Wow, what a lot of successful work to rebuild an old friend. Well done. Next gig after books are completed…support world travels as a roving Vespa mechanic/trainer? I finally sold our BMW 1200GT and bought a Honda 500GT. Love it. Looking forward to your future posts.