DOUGLAS-VESPA G.L.2. Operation And Maintenance
I
.;.
G.L.2.
Operation and Maintenance
G.L.2.
Operation and Maintenance
""""""
BE VESPA-WISE
Q..
...
..
.
..
-
.
.
.
-
.
..
. . . . .
~
INTRODUCTORYNOTE
Now that you own a DOUGLAS-VESPA,which we trust will afford you great satisfaction, may
we ask you to treat it with pride, and thus, by following a few simple rules of maintenance, help
it to work for youefficiently? .
In this booklet we have tried to set out the principal maintenance operations and procedures
for carrying out minor overhauls. We feel however, that major servicing and particularly
overhauls to the Engine and Gearbox should, whenever possible, be entrusted to Service Agents
who have the necessary facilities to undertake this work.
Whilst the instructions herein are as clear and simple as possible, we realise that at times you
may find yourself in difficulties. We have, therefore, made arrangements with our Service
Agents to handle and answer any queries which may be causing you trouble. They only ask
that you let them have the fullest possible information and details regarding your problem,
with particular mention of the Engine and Frame numbers of your machine.
DOUGLAS (SALES & SERVICE) LTD., KINGSWQOD, BRISTOL.
Telephone 67-1881/9
DireCtors: J. W. G. Kershaw (Chairman). C. McCormack (Managing). J. Grlffith Hall. N. G. Cadman. H. J. Willis. H. R. Ba;ne..
E. F. Brockway. B.C. Owen.
2
Contents
Section
Page
General description of the DOUGLAS.
VESPA with summarised technical data
and accessories "0 ... ... ..0 7
2 ON THE ROAD
Fillingup
... ... ... ... ... 10
Controls ... ... 0" ..0 ..0 13
Starting ... ... ... ... ... 17
Ridingtechnique... "0 ... ... 18
RunningIn... ... ... ... 0.. 20
Enginecut-out ..0 ..0 0.. ... 20
3 LUBRICATION
Engine ... ... ... ... ... 23
Gearbox ... ... ... ... ... 23
FrontHub... ... ... ... ... 24
Hydraulicdamper... ... ... ... 24
Section
Q.
.
.
.
.
.
..
.
.
-
.
'..
..
. ..jJ
Page
4 RUNNING ADJUSTMENTS
General Inspection
Brake Adjustment ...
Front Brake
Rear Brake .. 0
Clutch
Wheel Removal
Tyre Removal
Sparking Plug
Carburettor Filter ...
Decarbonisation
Adjustment of Ignition
Gear Control Cables
Cleaning details
Disuse
2S
2S
2S
26
26
27
27
27
28
28
29
29
30
30
5 FAULT FINDING
31-35
3
Q
4
I
I
I.
LIGHTSWITCH,HORNBUTT,Q
& CUT-OUT.
GEAR SHIFT CONTROL GRIP
& CLUTCH CONTROL LEVER.
HORN.
FOOTST ART.
CARBURETTOR HOUSING COVER.
REAR BRAKE PEDAL.
Fig. 1.
5
Fig.
Controls
2 Electrical wiring system
2a Electrical wiring system
3 Gear change hand grip
4 Security lock ...
S Lubrication diagram
VESPA OWNER PLEASE NOTE
YOUR GUARANTEE IS PRINTED ON THE LAST
PAGEOF THE VESPASPARESBOOK
6
g
' '
.
'
~-.~
. .
c. ,."
Page
23
25
26
28
30
List of Illustrations
Page Fig.
S 6 Gearbox lubrication ...
11
7
Brakeadjustment-front wheel
12
8
Brakeadjustment-rear wheel
14
16
10
Cylinder, cylinderhead and crankcase
21
II
Contact breaker in flywheelmagneto
General description of Machine
and summarised data
The VESPA hasa two-stroke horizontal single-cylinder engine of 125c.c. capacity.
Engine and Gearbox are in a single unit, with direct drive on the rear wheel.
Ignition and lighting are from flywheel magneto supplying H.T. current to the sparking plug,
and L.T. current for lighting and horn, in conjunction with selenium rectifier and battery.
Cooling is ensured at all speeds by centrifugal fan fitted on flywheel.
The frame, of distinctive design, is pressed steel, electrically welded on a central longeron.
Front and rear wheels have spring suspension, while in addition the rear wheel hasa hydraulic
damper.
The wheels themselves are each composed of two flangesof pressedsheet steel. They are inter-
changeable, and being cantilever mounted, are easily removable, in the same manner as those
of a motor car.
7
The tyres are low pressure and interchangeable, giving long service; they are remo' ...
unusual simplicity, owing to the form of the wheels themselves. ..
A tool kit neatly stowed away in one of the rear wings, is supplied as standard equipment. A
luggage carrier is fitted, as well as a speedometer. Two keys are issued, with the serial number
of the lock stamped on them.
ACCESSORIESare not sold with the machine as standard equipment but you may consider their
usefulness merits the additional expenditure:-
Pillion seat, dual seat, 2 types of windscreens, spare wheel (which provides for an
extra reserve of petrol), bracket for spare wheel, bumpers, seat cover, pillion foot-
rests, shopping basket, luggagecarriers front and rear, front suspension damper, etc.
Petrol tank capacity
Emergency reserve
1.1 Imperial Gallons
.2 Imperial Gallons
Bore
Stroke
Capacity
Compression ratio
Fuel -
Max. Brake Power
Sparking Plug electrodes gap
8
2.12 inches
2.12 inches
7.65 cu. ins.
6.4 to I
Petrol-Oil mixture
5 h.p. at 5,000 r.p.m.
.018 ins. Maximum
54 m.m.
54 m.m.
123.67c.c.
-
.012ins.
12.2to I (Solo) 14.7(Sidecar)
7.6 to I (Solo) 8.18 (Sidecar)
4.85 to I (Solo) 5.84 (Sidecar)
6 cu. ins. (approx. 1/6th pint)
3tx8 inches
Michelin (Solo)
14/15Ibs. per sq. inch
20121Ibs. per sq. inch
(29/30Ibs.with 2 persons)
67t inches
38t inches
31t inches
44.5 inches
185Ibs. approx.
59 inches
g
.
..
.
.
:.
,-
liJ
Flywheel Magneto contact breaker gap, fully
open
Gear ratios: First Gear
Second Gear -
Third Gear
Gear box oil capacity
Tyre size, front and rear
Tyre pressure, Front -
Tyre pressure, Rear -
Overall length
Overall height, unloaded
Overall handlebar width
Wheel base
Dry weight without accessories
Minimum turning circle
Battery
Headlamp bulbs (two beam)
Parking light bulb
Tail lamp bulb
Speedometer bulb
6 volts,S. A.h.
24X24 watts
3 watts
3 watts
3 watts
9
g
--.
,
.. ..~- .
...iJ'
SECTION TWO
ON THE ROAD
FILLING UP
On the chassisjust behind the saddle you will find the fuel-tank cap.
The fuel tank holds slightly more than a gallon, and you must remember never to fillwith petrol
alone, but always with the addition of oil in the fuel tank at the same time as the petrol.
It is very important that the correct quantity of lubricating oil should be added. This is t
pint of oil Grade SAE30 to I gallon of petrol both during and after the running in period.
10
ELECTRICALWIRING DIAGRAM.
~~~~~
SWITCH TO TAIL LAMP.
RECTIFIERTOSWITCH.DC. I SWITCH&HORNBUTTON
BATTERY. 6VOLT.5AMP. I I I SWITCHTOHEADLAMP(BEAM).
'.
,
:,
~~..t\~':' - \~\"\.
~:\. \ t' \
/! ,-1.." . .11i
.1' t~b.)!\ !ijj
'~A~~,., /. .~..
~. \ "..' . .4 1.1/
'. ' '::.:;/ ./.~/
"""""::;- .'.;c;,&-/'
RECTIFIER-RESISTOR.
SWITCH TO EARTH
I
FLYWHEEL MAGNETO TO PLUG
RESISTOR TO HORN;
I
RESISTOR TO SWITCH.AC.
POSITION C.
o.
J.
2.
3.
fig. I 2.
POSITIONS.
SWITCH
- EARTH. HeAD lAMP
-'OFF:
R SPEeDOMETe
O
~i1~~i &NTAC~~;
fO
. _, .
TAIL LAM . .._P S l & HEAD .
- DIPPED;ON.~
OM
.
ETER LIGHT CONTACTED.
C
,..".
.
P SPEED ONTACTS LAM ~",
- "'''~.~.,~.f,",.",", ยท ",["0::.,,,- . \ .
B"~A"P Sp"'e,,b..J!}OOW"'" \i.- _ ,
-TAIL
GL
iGHT,'ON.,. '.,
P,"". , ,__f5"""
Loading...