VESPA 152 Operation And Maintenance Download Page 2 | Manualshive

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Summary of Contents for 152

Page 1: ... p ppointmtnt tiro is t opa i Wntss t Dukt of ellillbllr 1 lIppIitts of Vtspa 6toottts 152 L2 MODEL OPERATION AND MAINTENANCE ...

Page 2: ... S ppointmtnt 11to is l o al i Wntss 11t t ukt of ebillbllrg lIpp1itrs of 1Jtspa coottrs 152 L2 MODEL OPERATION AND MAINTENANCE _ _ _ 0 __ ...

Page 3: ...t the use of parts other than original Douglas Spares will invalidate your Guarantee Specialcare should be taken to ensure that the oil petrol ratio isalways in strict accordance with our recommendations SERVICE EXCHANGE Ask your Dealer for full particulars relating to the Service Exchange Scheme The use of the facilities we offer through this medium ensures an economical speedy and reliable means...

Page 4: ... _ W f Fig I Vespa 125 ...

Page 5: ...ith clutch control lever 2 Front brake lever 5 Front brake iaws 6 Rear brake pedal 7 Kickstarter 8 Gear shifter air cleaner 12 Choke control lever 13 Fuel taD 3 Throttle control grip 4 Light and dip switch 9 Rear brake jaws 10 Clutch IJ Carburettor ...

Page 6: ...engine and frame in the position indi cated on Fig 3 Such numbers and prefixes identify the Vespa as prescribed by law and are r epeated on the test card and other documents of the scooter They must be quoted when ordering spares Fig 3 Stamping on frame I and engine 2 s ...

Page 7: ... 67cc 7 48cu in Compression ratio 6 3 to I The engine is pivoted to the chassisof scooter Wheel base Handlebars width Scooter length Max height Min height of floorboard Min turning circle Weight with fuel 46 4 25 7 68 3 38 7 8 59 1921bs through the cylindric arm of the crankcase half clutch side provided with a spindle and two bushes see Fig 4 Its vibrations are damped by the rear sus pension with...

Page 8: ...FiJ 4 Engine installation and suspensions I Steering column and front suspension 2 Engine case half clutch side with swinging arm 4 Rear sprinc with hydraulic damper 3 Crank suspension ...

Page 9: ...8 7 6 Fig S Section of engine I Piston 2 Crankshaft 3 Clutch 4 Mainshaf 8 Crankcasehalf clutch side with swineinearm 5 Gear shifter 6 Flywheel maeneto 7 Kickstarter ...

Page 10: ...con rod crank shaft main bearings Both clutch and gear box operate in oil bath Feeding Fuel feed to the carburettor is provided for by gravity see Fig 7 with petroil mixture Carburettor with float chamber with total capacity of 1 7 Imp emergency reserve Three way tap on off reserve Fuel tank gals and T 1 6 3 2 Fig 6 Ignition diagram I Ignition coil in flywheel magneto 2 Rotor cam 3 Breaker 4 Conde...

Page 11: ...ox Clutch Multiplate with facings of cork composition applied to the driven discs Control by lever on left hand side of handlebars see Fig 2 and adjustable cable Gear box 3 speed drive with mesh gears in oil bath Its adjustable twistgrip control is coupled with that of the clutch on left hand side of handlebars see Fig 5 Engine to wheel transmission First Second Third ratios 12 2 to I 7 6 to I 4 8...

Page 12: ...et tube and a silencing chamber with filter moistened by fuel mixture which prevents dust and dirt from passing into carburettor Silencer Expansion and absorption com bined type Particular attention has been given to the design of the silencer and air filter in accordance with Ministry of Transport requests to reduce the noise level to an absolute minimum We recom mend that these parts are maintai...

Page 13: ...teering column bears the handlebars clamped on its top end and the front wheel swinging hub pivoted at its bottom end through a stub axle Front suspension with coil spring and double action hydraulic damper Rear suspension with variable rate coil spring and coaxial double action hydraulic damper The 8 0 dia wheels are interchangeable and have rims of pressed steel sheet Tyres of dia 3 50 8 Saddle ...

Page 14: ... numberplate The light and dip switch unit with two levers is installed on the right hand side of the handlebars see Fig 9 one of the control levers hasthree positions head light and tail lamp on lights off pilot lamp and tail lamp on the other one gives the two light con ditions of the head lamp main and dipped beam The switch hasalso two push buttons for cut out and horn respectively Fig 9 Light...

Page 15: ...CONNECTOR L T T e 1o 04 1 5 029317 171 Fig I0 Cab le harness ...

Page 16: ...tact 5 to parking light 14 Tail lamp lead Black switch contact I to tail light IS A C feed Yellow switch contact 3 to horn 16 A C feed Yellow horn to L T terminal 17 A C feed Yellow L T terminal to No 1 alternator coil 18 A C feed Yellow No 2 alternator to L T terminal 19 A C feed Yellow L T terminal to rectifier 20 Horn to horn button White switch contact 4 21 Battery lead to earth 22 H T lead to...

Page 17: ...itch contact S to parking lIiht 14 Tail lamp lead Black switch contact I to tail light IS A C feed Yellow switch contact 3 to horn 16 A C feed Yellow horn to L T terminal 17 A C feed Yellow L T terminal to No I alternator coli 18 A C feed Yellow No 2 alternator to L T terminal 19 A C feed Green L T terminal to rectifier 40 7 P c UP 20 Horn to horn button White switch contact 4 21 Battery lead to e...

Page 18: ... oil thoroughly Keep the breather on filling cap clean Running in Important rules to be followed while running in 1200 miles Do not exceed following speeds Ist gear 9 5 m p h 2nd gear 19 m p h 3rd gear 31 m p h Do not hold these max speeds for long periods neither use full throttle opening up hill Change 011in the gear box and check that nuts and bolts are not slack after the first 600 miles Start...

Page 19: ...ions to carry out for starting the engine A open the fuel tap B select neutral C choke with cold engine D throttle control grip in idling position E depress the kickstarter and turn grip D opening throttle gradually ...

Page 20: ...3 Gear change control cables 4 Gear shifter S Selector stem 6 Selector 7 1st gear 8 2nd gear 9 3rd gear 10 Mainshaft 11 Cush gear 12 Clutch N B Position 1 2 3 of the gear change twistgrip correspond to 1st 2nd and 3rd gear respectively 0 indicates the neutral position ...

Page 21: ...d screw it back Open the fuel tap and depress the starting lever Be careful while re assembling the sparking plug start screwing it by hand at he proper angle and use the box spanner just for the last turns Setting the machine in motion Let the engine idle lift the clutch and turn the gear change twistgrip so that the figure 1st gear engraved on it coincides with the line engraved on handlebars se...

Page 22: ...ackening or tightening the screw on carburettor cover Near the screw for slow running adjustment there is a screw for adjusting the throttle control cable It is to be used only if necessary and while dismantling and re assembling Stopping the engine Close throttle and push the earth button This will leave the cylinderfull offuel vapours and the next start will be much easier Tyres The wheels are i...

Page 23: ...oving the inner tube deflate it first then unscrew the six nuts on the wheel so that the two halves of the rim will fall apart see Fig 14 Tyre pressures Ibs to be For Dunlop Solo Front 16 Pillion Front 16 Sidecar Front 16 For Pirelli Solo Front 16 Pillion Front 16 Sidecar Front 18 Rear 20 Rear 32 Rear 24 Sidecar 16 Rear 22 Rear 32 Rear 24 Sidecar 16 22 ...

Page 24: ...freely when respective control lever or pedal are in resting position the braking action starts as soon as respective controls are operated These conditions are achieved adjusting the cables by means of screws indicated with arrows In Fig 15 Fig IS Brake adjustment 23 ...

Page 25: ... beam can be obtained on the vertical plane as follows Check that both front and rear tyres conform to prescribed pressures I j _ o i J J j c l A Jilt C r I f Fig 16 Adjustment of head lamp N B The adjuStment muSt be carried out with driver and passenger on the machine 24 ...

Page 26: ...e scooter is being ridden by both driver and passenger Cleaning the scooter Brushing with paraffin and wiping dry with clean rags is advisable for outside cleaning of engine All painted surfaces should be washed with water cleaned by means of a sponge and wiped dry with chamois leather Do not use paraffin on such surfaces since it damages paint and turns it dull Before setting the machine in motio...

Page 27: ...orcelain is cracked Wash with neat petrol Use the sparking plug type prescribed by the Company We remind owners that the use of an approved sparking plug will prevent many engine troubles 4 Clean the two lubricators of front wheel hub and refill them by means of a grease gun Lubricate the speedometer drive pinion and cable if necessary N B All operations indicated hereunder should be carried out b...

Page 28: ... to decarbonise its crown and clean all carbon deposits from the mouth of the cylinder then bring the piston to the bottom dead centre and clean the cylinder ports Decarbonise the inner side of the cylinder head ensure that the cylinder barrel is free of all carbon Fig 17 Breaker poin gap 0 015 27 ...

Page 29: ...magneto In case of damper troubles contact your authorised service stations Laying up Clean the Vespa thoroughly Drop 60 c c mineral oil into the engine through the sparking plug hole and turn the engine over a few times to ensure that a thin oil film spreads all over the Internal surfaces to prevent rusting Support the chassisofthe machine on two wooden blocks ensuring that the tyres are clear of...

Page 30: ...tor and let some fuel drip out to expel air Then with the fuel tap open reconnect the hose to the carburettor Follow this procedure also when refuelling after running out of fuel In case of long storage the carburation may become faulty though said above precautions have been taken because of oil deposits in the idling jet due to the evaporation of the petrol con tained in the fuel mixture You sho...

Page 31: ...y Control cables wheel cam Esso Joints on brake Gear change Retinax A Energrease L 2 Multi purpose Castrolease L M Mobilgrease M P control quadrant Grease H Speedo flexible drive Shell 2T Two Energol Two Essolube 30 in Castrol XL in Mobiloll A in Stroke Oil in Stroke Oil in ratio of 50 0 or ratio of 5 or ratio of 5 or ratio of 5 or ratio of 50 0 or t plntto Ihalls t pintto Ihalls t pintto Ihalls E...

Page 32: ...ENGINE LUBRICATED BY MIXTURE OIL LEVEL GEAR BOX LUBRICATION SCHEME 31 ...

Page 33: ...gged dirty Main jet and atomizer Float needle valve sticking in its seating Engine flooding air cleaner choked or dirty 2 Ignition Sparkingplug dirty porcelain of sparking plug cracked Breaker points dirty worn or pitted gap incorrect Remedies Turn to Reserve Refill as soon as possible a Unscrew and remove the main jet If the fuel system is efficient fuel will come out b Blow through jet orifice t...

Page 34: ...ion b Other troubles faulty carburettor poor compression etc 4 Enginenoisy Clutch troubles Gear pinions disengage of own accord Starter assembly not engaging Controls not operating properly Steering column becomes stiff Inefficiency of suspensions Remedies Clean see page 27 Tighten with 21 mm box spanner Set the head properly and tighten the nuts Replace or clean the plug and correct the gap see p...

Page 35: ...e this Reference 152 L 2 jlM j6 67 LB 8119 34 Locating the trouble Remedies S Poor braking Stroke of pedal or lever too long Adjust see Fig IS page 23 Brake linings oily or worn down Wash with petrol and dry in air or replace See your dealer about oil leakage Brake drums and lining scratched Replace 6 Faulty electric wiring Lead terminals loose or wrongly connected Re connect properly see Figs 10 ...

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