VESPA 152 Operation And Maintenance

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152 L2 MODEL

OPERATION AND MAINTENANCE

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152 L2 MODEL

OPERATION AND MAINTENANCE

_.. _ _:-0.__

-- -- -'- ---

INTRODUCTORYNOTE

In accordance with Douglas(Sales& Service)Ltd. policy of progressiveimprovement,the right is

reserved to alter any details of price, specification, accessories, and equiPment,

without notice, and without incurring any obligation.

BE ~-WISE

To keep your Vespa in perfect running order, it is advisable to entrust repairs only to
authorised Douglas Dealers. We point out that the use of parts other than original "Douglas"
Spares will invalidate your Guarantee.

Specialcare should be taken to ensure that the oil/petrol ratio is always 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 of carrying out repairs when such become necessary.

DOUGLAS (SALES & SERVICE) LTD., KINGSWOOD, BRISTOL.

DIVISION OF THE WESTINGHOUSE BRAKE AND SIGNAL COMPANY LIMITED

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Telephone [phone]

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Fig. I. Vespa 125,

-----

1. Gear change twistgrip with 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.

Fig. 2. Vespa controls.

3. Throttle control grip. 4. Light and dip switch.

9. Rear brake jaws. 10. Clutch. IJ. Carburettor.

IDENTIFICATION DATA

Serial numbers with prefixes are stamped on
both 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

TECHNICAL DATA

Fuel consumption at economic speed

Up to 120miles per imp. gal.

Max. speed
Carrying capacity

and 22 Ibs. of luggage

Range

.ENGINE

Single horizontal cylinder, two-stroke, with

reverse flow scavenge and deflector piston.
Bore 54mm 2.126'
Stroke 54mm 2.126'

Displacement 123.67cc. 7.48cu. in.
Compression ratio . 6.3 to I

The engine is pivoted to the chassisof scooter

46.5 m.p.h.
2 persons

Up to 200 miles

6-

Wheel base

Handlebars width

Scooter length .

Max.height

Min. height of floorboard.
Min. turning circle
Weight (with fuel) .

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 variable rate coil spring and
hydraulic damper (see also page 13).

The rear wheel is secured to the end of
mainshaft.

46.4'

25.7"

68.3"

38.7"

59'

1921bs.

8'

I. Steering column and front suspension. 2. Engine.
case half, clutch side, with swinging arm. 4. Rear
sprinc with hydraulic damper.

FiJ:. 4. Engine installation and suspensions.

3. Crank-

suspension

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.

8

7

6

7. Kickstarter.

Ignition by a high tension coil in the fly-

wheel magneto (see Fig. 6).
Sparkplug: either AC 45 F, KLG F 70,

Lodge HN, or Champion L 86.
Ignition timing with spark advance of

28 :1: 10.

Lubrication by oil in the fuel mixture for
piston, cylinder, gudgeon pin, 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.

Fuel tank

gals. and

Three-waytap ("on" - "off" - "reserve").

T

1;\"

6

3

2

Fig. 6. Ignition diagram.

I. Ignition coil in flywheel magneto. 2. Rotor cam. 3. Breaker.

4. Condenser. S. Sparkplug. 6. Engine cut..out on switch.

-9

Fi&.7. Feedin&circuit.

I. Fuel tank. 2. Fuel cock lever: (A) Reserve,(B) Open,
(C) Closed. 3. Air cleaner. 4. Float. S. Maximum jet.

6. Idlin&jet. 7. Throttle slide. 8. Idlin& adjuster. 9. Adjuster
on throttle control cable. 10.To the cylinder.

10 -

Transmission. The engine (see Fig. 5) drives
directly the rear wheel through clutch. cush

drive and gear box.
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

4.85 to I

Starting by means of kickstarter. right hand

side of scooter (see Fig. 5).

The multiple gear and. consequently, the

engine are set in motion through a ratchet

sector and a gear by operating the kick-

starter.
Cooling effected at all speeds 'by centrifugal

fan (see Fig. 8).
Air cleaner mounted on the engine. Air

goes to the carburettor through a large cone-
shaped inlet 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 maintained in good
condition.

Fig. 8. Cooling system.

-11

FRAME

Stressed skin body of pressed sheet, with
streamlined, monocoque, type structure (see
Fig. I). It gives full protection to the driver,
to the passenger and to the machine units;
it is completed in this function by the mud-
guard and, on the two sides, by the steel
sheet engine bonnet and tool box.

Handlebars consisting of two arms in steel

tube, clamped in a support which is fixed to
the steering column.
The central part of handlebars is completed
with two shells in pressed steel sheet. The

head lamp is installed therein. All control
cables and electric wires, to be connected to
the handlebars, are concealed inside it.

Steering column, suspension and wheels.

The steering column bears the handlebars,

clamped on its top end, and the front wheel
swinging hub, pivoted at its bottom end
through a stub axle.

12-

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 of the nose-pivoted, sprung type

with central spring adjustable to the driver's

weight. Alternatively. a dual seat.

Brakes. Expanding type with cable control.
Front: lever on right hand side of handlebars.
Rear: control pedal on right hand side of

floorboard.

Central stand. A two-leg stand, easy to
operate, is arranged under the floorboard.
A' strong return spring holds it in contact
with the floorboard and keeps it from vI-

brating while the scooter is being ridden.

WIRING

A six pole flywheel magneto (nominal vol-
tage: 6 V) supplies alternating current for
feeding head lamp, tail lamp and horn (see
Figs. 10and 11).

The 105mm dia.head lamp installed on the

handlebars, is provided with a 25/25 double
filament bulb (main and dipped beam) and
with a 3W bulb for parking light.

The tail lamp with red reflector hasa 3W

bulb which also illuminates the 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

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.

- lights off -pilot lamp and tail lamp

Fig.9. Light and dip switch.

M: Engine cut-out.

Switching lever (I): headlight andtail lampon.
0: lights off. (2): pilot lamp and tail lamp on.

Dipping lever (A): dipped beam. (B): main beam.
C: horn button.

- 13

CONNECTOR..

L.T: T.e: ",.,...1o. 04&1&>5."",.

029317.....

171.,....

Fig. I0. Cab le harness.

SWITCH POSITIONS

Position O-No Lights.
Position I-Contacts 1,3 (6 or 7) a and b connected
A.C. current to Hllamp (main or dipped beams)

and Taillight.

Position 2-Contacts I, 2 and 5 connected

D.C. current to Parking and Tail light.

8. H/lamp/parking light to L.T. terminal (White).

9. L.T. terminal to earth (White.). 10. Engine

cut-out (Red) switch contact M to L.T. terminal.

11. Engine cut-out (Red) L.T. terminal to magnetic

coil. 12. D.C. feed (Green) switch contact 2 to
battery. 13. D.C. feed (Pink) switch contact 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
plug. 23. A.C. feed (Violet) switch contact 7 to
H/lamp main beam. 24. A.C. feed (Maroon)
switch contact 6 to H/lamp dipped beam.

THIS IS DIAGRAM

FOR MACHINES UP TO

SERIAL NO. 15240. SEE NEXT

PAGE ABOVE THIS NUMBER

(Page 16).

N~ t IU.TE.kNATO~ Con..

Filt. 11. Connections and electric wiring di"ltram

SWITCH POSITIONS

Position O-No Lights.
Position I-Contacts 1,3 (6 or 7) aand bconnected
A.C. current to Hjlamp (main or dipped beams)
and Tall light.
Position 2-Contacts I, 2 and S connected
D.C. current to Parking and Tail light.

8. Hjlampjparklng light to L.T. terminal (White).

9. L.T. terminal to earth (White). 10. Engine
cut-out (Red) switch contact M to L.T. terminal.

11. Engine cut-out (Red) L.T. terminal to magnetic
coli. 12. D.C. feed (Blue) switch contact 2 to
battery. 13. D.C. feed (Pink) switch 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 earth. 22. H.T. lead to
plug. 23. A.C. feed (Violet) switch contact 7 to
Hjlamp main beam. 24. A.C. feed (Maroon)
switch contact 6 to Hjlamp dipped beam. 2S.

A.C. feed No. 2 alternator coil to L.T. terminal.

p 8v..e c<.V 2.51-25W'

P4RK''-I<> 8vL.1f1 6v

FOR MACHINES

SERIAL NO. 15241 ONWARDS.

BELOW THIS NUMBER

SEE PAGE 15.

PLUC

Fli. 11. Connections and electric wiring diacram.

TOOL KIT

2 double-ended box spanners(11- 14and 21.22

mm); I double open-ended spanner (8, 14
mm); I single open-ended spanner (J mm);

I screwdriver.

OPERATION

These tools are contained in a canvas roll
which is placed in the left wing together with

this booklet.

For fuel mixture to be used both during

and after running-in, see chart on page 30.

We recommend to use good quality, standard
grade Petrol, and to mix it with 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 19m.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.

Starting the engine. Seeon Fig. 7 the three

positions of the tap: on, off, reserve.
Open the fuel tap, put the gear box In neutral

(see "0", Fig. 13) and the throttle In slow
running position, then depress the starting

lever.

- 17

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~

Fig. 12. Operations 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.

Fig. 13. Drive system.

I. Gear change twistgrip. 2. Clutch control lever. 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

With cold engine, lift the choke rod.

In case of starting troubles due to engine
being flooded (unvaporized fuel mixture has
reached the cylinder and the combustion
becomes therefore very difficult), proceed
according to either one of following methods:

- Push-start the scooter; engage second
gear, depress the clutch and push the machine

to a certain speed; suddenly release the clutch

lever and pull it back as soon as the engine

fires.

- Close the fuel tap, remove the spark-
plug and rotate the engine by means of the

kickstarter; wipe the plug dry and screw it

back. Open the fuel tap and depress the

starting lever.

20 -

Becareful 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 (see

Fig. 13). Now let in the clutch gently, while
opening the throttle gradually to set the

machine in motion.

Gear change. After reaching the required
speed in Ist gear, lift the clutch close quick-
ly the throttle, and turn the gear change
twlstgrip so that the engraved line is oppo-
site figure "2" (2nd gear); let in the clutch
and open the throttle.

Repeat this procedure for changing into 3rd
gear and for changing down (see the drive

system on Fig. 13).

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.

When you reduce the speed of your machine,
change down without delay.

Do not turn the gear change twistgrip while the
engine is not running.

As soon as gear change troubles arise, particu-
larly when t!1e control becomes hard, customers
should have their machines adjusted by a dealer

or authorized service station.

Slow running adjustment. No hand tool

is required for this job. Idling revs. can be
raised or reduced resp. by simply slackening

or tightening the screw on carburettor cover.

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 interchangeable, i.e.
they can be assembled either in front or rear,

provided, of course, that they are inflated to

the pressures subsequently prescribed.
When a flat tyre is to be replaced, unscrew

the four nuts which secure the wheel to the

brake drum, pull the wheel sideways off the
studs, repair the tube or fit the spare wheel

on.

- 21

22 -

Fig. 14. Removing the inner tube.

Make sure that the spring washers are present

when re-assembling the wheel: tighten the nuts

diagonally and evenly.

For removing 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,

Rear 20.
Rear 32.
Rear 24, Sidecar 16.

For Pirelli:

Solo: Front 16,

Pillion: Front 16,

Sidecar: Front 18,

Rear 22.
Rear 32.
Rear 24, Sidecar 16.

Brake adjustment. Brakes are properly

adjusted if:

- the wheel rotates 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

MAINTENANCE

Setting the head lamp. The correct orienta-

tion of the main beam can be obtained on the
vertical plane as follows.

~~'-~I&'-~j,.'-'_"'-

A

Jilt.......

"""C

r

I

f

Check that both front and rear tyres conform
to prescribed pressures.

o

, ~

. J

i!J

,j c-l .

24 -

N.B. . The adjuStment muSt be carried out with driver and passenger on the machine.

Fig. 16. Adjustment of head lamp.

Place the scooter on a level floor in front
of a white wall as seen on Fig. 16.

Start the engine, hold the throttle control

twistgrip at about 1/3 and set the switch on

"main beam".

With two persons on the Vespa, slacken
the screw securing the headlamp, then

move the latter as required in order that

the beam axis coincides with point "0"
on the wall.

Tighten the screw firmly.
This operation can be carried out also with

driver only sitting on the saddle.
In such a case, of course, the beam align-

ment should be altered whenever the 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 motion,
check oil level in gear box by unscrewing on

the crankcase the level screw marked "Oil."
When the scooter is upright, oil should just

be about to flow out.

After the first 600 miles. Replace oil in
the gear box by the procedure as explained

in the lubrication chart, page 30. The crank-
case can be drained through drain hole.

-25

Every 1,250 miles. i. Remove the air

cleaner from the carburettor and agitate it

in a 30% oil-petrol bath.

2. Check oil level in the gear box (see

page 31).

3. Clean the Sparking Electrodes with
very fine Emery or suitable files and adjust
the Gap to: '023/.026" for K.L.G. F.70,

.022/.026" for Lodge H.N.,
'022" for A.CA5 F., and

.020" for Champion L.86 Plugs.

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 by authorised
Service Stations.

Inspect the insulation material of sparkplug;

replace the latter if the porcelain is cracked.

Wash with neat petrol.

Use the sparking plug type prescribed by

the Company. We remind owners that the

26 -

5. Clean and adjust the contact breaker
points of the flywheel magneto (see Fig. 17),
to .4 mm gap (.015").

6. Clean the silencer and decarbonise the
engine as explained in following notes.

Removethe silencer,the cooling hood and

the cylinder head. Bring the piston to the
top dead centre 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

Heat and clean the exhaust pipe of the

silencer,either byscraping it internally with

a hooked wire or blowing air through from
the opposite end; in both casesthe silencer
should be held so that the exhaust pipe is

turned downwards.

Every 1.800 miles. Grease the felt which

lubricates the cam of flywheel magneto.
case of damper troubles, contact your

authorised service stations.

28 -

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 the

ground.

In

N.B. Lubricate exclusively with oil and
grease as indicated on lubrication chart,

page 30.

After long lay up, in order to prevent formation
of air bubbles in the fuel system during the first
fuelling, and consequent carburation troubles,
remove the air cleaner (SERVICE STATION),

disconnect the rubber hose from the carburettor
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 should then
visit your dealer.

- 29

LUBRICATION CHART

Part to be lubricated

Every 2,500 Every 5,000

Gear-box

topping-up

Front suspension

Felt pad on fly-

wheel cam

Joints on brake

control

Speedo flexible

drive

Engineat eachre-fuelling t-pint

" Marketed also by National Benzole Co. Ltd., by arrangement with B.P & Shell-Mex Ltd.

Gear-box change

oil Stroke Oil

Control cables

Gear-change

quadrant

"Shell

Shell 2T Two-

or

Shell X-lOO 30

Retinax A

Shell 2T Two-

Stroke Oil in
ratio of 5% or

to

gaUs.petrol galls. petrol

Shell 2T Two-Stroke Mixture
B.P. B.P.-Zoom

National
Benzole

Co. Ltd.

I!

APPROVED PETROL/OIL MIXTURE

Make

"B.P.

Two- Esso

Energol

Stroke Oil Motor Oil

or

Energol SAE 30

Energrease L.2. Multi-purpose

Two-

Energol
Stroke Oil

ratio of 50/0 or t-plntto Ihalls. t-pintto Ihalls.
t-pint

Hi-Ai

in

to

I!

Description

Lubrication

Esso

Extra Castrol XL Mobillol A

20W /30

Esso

Grease H

Essolube 30 in

ratio of 50/0 or

petrol.

Motor Oil in
ratio of f-pint

to

Esso

Two-Stroke Two-Stroke Oil

I! galls.

petrol

Wake field

Castrolease L.M.

Castrol XL in Mobiloll

ratio of 5% or ratio of 5% or

petrol. Castrol petrol or Mobil-
in ratio of i-pint i-pint

to

1* galls.

petrol

Mobil

Mobilgrease M.P.

A in

t-pintto Ihalls.

Mix in ratio of

to

galls. petrol

I!

Hydraulic Dampers

When not working efficiently, consult your
Dealer: If servicing is required, they should
always be returned to the Works.

ENGINE LUBRICATED BY MIXTURE.

OIL LEVEL.

GEAR BOX.

LUBRICATION SCHEME.

-31

FAULT FINDING

When the machine does not run properly. make all inspections and rectifications as explained below.

If the suggested remedies are not sufficient to eliminate the trouble, the customer should not

try to carry out operations pertaining to the dealers, who have the necessary facilities to undertake

this work.

Locating the trouble

HARD STARTING
I. '. Fuel system

Fuel tank empty.
Fuel does not flow to the carburettor although

the fuel tap is open or in position "reserve."

Filter on carburettor

Fuel tap body .

Carburettor body Clogged. dirty
Main jet and atomizer
Float needle valve sticking in its seating.

Engine flooding; air cleaner choked or dirty.

.Carburation

}

2. . Ignition

Sparkingplug dirty; porcelain of sparking plug

cracked.

Breaker points dirty, worn or pitted: gap incorrect.

32 -

Remedies

Turn to "Reserve." Refill as soon as possible.

(a) Unscrew and

system is efficient. fuel will come out.

(b) Blow through jet orifice to ensure that. it is

clear.

Remove and wash in petrol. Blow dry.

Release

pages 21 and 26.

See

Disconnect the plug lead. Check if sparking occurs

between lead and crankcase when the kick-

starter is operated.

Have the points cleaned (with very fine emery

paper or suitable files), or replaced, or the gap
adjusted to 0.4 mm

remove the main jet. If the fuel

See page 26.

(0.015') by a dealer.

Locating the trouble

INCORRECT RUNNING

I. . Lack of power

Silencer exhaust pipe carbonised.

Sparkplug not well screwed into cylinder head.
Cylinder head not fitting properly into the spigot

on top of cylinder.

--

Remedies

Clean (see page 27).

Tighten with 21 mm box spanner.

Set the head properly and tighten the nuts.

2. - Explosions at silencer and carburettor.

3. . High fuel consumption.

(a) Air cleaner choked or dirty; flap of choke

valve sticking in closed or partially closed
position.

(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.

Replace or clean the plug and correct the gap

(see page 27).

Clean witt. pure petrol and blow dry.
Dip the metal war!ding into a 30% petrol-oil bath.

Release and lu bricate the choke lever.
See your dealer.

See your dealer.

- 33

Locating the trouble

S. -Poor braking

Stroke of pedal or lever too long.
Brake linings oily or worn down.

Brake drums and lining scratched.

6. - Faulty electric wiring.

Lead terminals loose or wrongly connected.

Incorrect adjustment of the head lamp.

NOTICE - When observing through the red indicator that the pilot
light and consequently the tail lamp are off, set the switch to the
position "Dipped beam," so that the tail lamp goes on again. Then check

the two bulbs and replace the damaged one.

When referring to this Publication

it is essential to quote this Reference:-

34-

Remedies

Adjust (see Fig. IS, page 23).
Wash with petrol and dry in air, or replace.
See your dealer about oil leakage.
Replace.

Re-connect properly (see Figs. 10-11) or replace

and tighten the screw.

Reset properly (see page 24).

152.L.2.jlM.j6.67./LB.8119