VESPA 232 L.2 Operation And Maintenance

'!to 'bis 'lRo-eal'bigbness '!tbe IDulleof JE~illburgb

:I;-e'appointment

lI)anufactul'ers of 1I)espaScooters

125 c.c.

232 L.2. MODEL

OPERATION AND MAINTENANCE

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

Telephone 67-1881

DIVISION OF THE WESTINGHOUSE BRAKE AND SIGNAL CO:1PANY LIM,TfD

...

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.

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Fig. I . Vespa 125c.c.

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NOTICE . ,.

To keepyou, VESPA;npeneet ,"nnlng o,d" .nd notto In..lid"e the gu",ntee " ';.'

bythe contract,it isadvisableto entrust repairsonlyto retailersor authorisedservicestations.

Demandoriginal

material, have undergone the same machining steps and inspections as the components of
your VESPA. This means guarantee for long life and normal performance of your machine
and for your personal safety.

Special care should be taken in regard to fuel mixture which should consist of a good

quality petrol and oil of make, grade and in the amount prescribed in this booklet, page18.

Introd uction
Technical data
Identification data

Description: engine

controls

frame

VESPAspare parts exclusively.AllVESPAsparesare madeof the same

INDEX OF MAIN DIRECTIONS

5

page

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Electric wiring
Tool Kit

6
6

Operation

8 Maintenance .

12

Lubrication chart

13

Fault finding

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page 14

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17
18

24

28

31

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The descriptions and illustrations in this booklet are not to be taken as binding on the Manufacturer. The essential fe, "

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out at any moment. without being obliged to bring this booklet up-ta-date in due course, modification that may occu. "iJ

eerning machine units and parts, or delivery of accessories, that the Firm deems to be convenient on improvement PUI .
or for what may concern manufacturing or commercial requirements.

INTRODUCTORY NOTE

We wish to thank you for your choice of this excellent model Vespa and hOFethat it will

satisfy your every desire.

This booklet. in which the simple instructions for operation and maintenance can be

found, will enable you to understand and use your machine in the most advantageous manner.

When referring to this Publication

please quote the following

reference:-

232.L.2./11.63/250/L.B.3708

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TECHN

Fig. 2 - Stamping on frame (I)

Fig. 3 - Stamping on engine (2)

ICAL DATA ".

Fuel con.umpdon (CUNA Standa.._"jJ . ...

120miles per imp. gals approx.

Max speed (CU NA) 75 Kmjh (47 m.p.h)

approx.

Carrying capacity 2 persons and 10Kg.

(22 Ibs.) of luggage.

Range 420 Km (260 miles)
Wheel base 1180mm (46.5")
Handlebars width. 655 mm (25.7")
Max length 1745mm (68.7")
Max height . 985 mm (38.7")
Ground clearance 130mm ( 5.1")
Min. turning circle 1500mm ( 59")
Weight (without fuel) 83 Kg. (183 Ibs.)

IDENTIFICATION DATA

Serial numbers with prefix 4 are stamped
on both frame and engine in the positions
indicated on Figs.2 and 3 respectively.

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Fig. 4. Section of engine

I. Air cleaner and carburettor - 2. Piston - 3.Crankshaft- 4.Clutch - 5. Malnshaftwithgearpinions- 6.Gear shlfter - 7. Fly-

wheel magneto - 8. Kick-starter - 9. Crankcasearm(clutchside), pivoted to the frame.

-7

Fig. 5 - Ignition diagram

I. Ignition coil in flywheel magneto -2. Rotorcam- 3. Breaker-

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

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Such numbers and prefixes ider.. ~-'
Vespa as prescribed by law and. . o.
pe.tod 00 the te" ""d aod ethec d, ~
of the Vespa.

They must be quoted when ordering spares.

ENGINE

Single horizontal cylinder. two-stroke. with
deflector piston and rotary valve. i.e.: fuel
mixture flow to the cylinder is controlled by
the rotation ofa crankweb (see Fig.4).

The engine works on a 2% petrol-oil
mixture.

Bore 52.5 mm (2.06")
Stroke . 57 mm (2.24")
Displacement . 123.4cc (7.53 cu. in)
Compression ratio ° 7.2 to I.

The engine is pivoted to the chassis of
scooter through the swinging arm of the
crankcase half. clutch side. provided with
a spindle and two bushes (see Fig. 4).
Its vibrations are damped by the rear su-

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Fig. 6 - Feeding circuit.

I. Fuel cock lever with sediment trap: (A) Reserve, (8) Open, (C) Closed. 2. Float. 3.

Air cleaner with carburettor

slide - 7. Air vent for main jet - 8. Hole on mixer top - 9. Mixer - 10.Mainjet - 11.Idling
jet - 12.Air vent for idling jet - 13. Plugfor Inlet hole for oil; for laying u

adjuSter - 15. Intake port - 16. Transfer ports - 17. Exhaust duct.

- 4. Choke- S.Setscrewforthrottleslide- 6.Throttle

spension with variable rate coil spring
hydraulic damper (see also page 13).
The rear wheel is secured to the end

mainshaft.
Ignition by a high tension coil in the flywheel

magneto (see Fig.5).
Sparkplug: KLG F.70Gap .023/.026.
Ignition timing with spark advance of26°::l: 1°.

Lubrication of piston, cylinder, gu.:lg=onpin,
connecting rod. crankshaft. main bearings

is attended to by the content of oil in the
fuel mixture.

Both clutch and gear box operate in oil

bath.

Fuel supply by gravity with petrol - oil

mixture.
The carburettor is embodied in the air

cleaner case, has a plate-shaped slide valve

and immersed jets.

10 :...

and

o 0.3 imp. gals).

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Fuel tank with total capacity of 7.7- ,_ c- '
(2.03 USA gals; 1.7 imp. gals) and ' . . _

1 ge",y ,...eve 01 .bout lA I (.037 US.. -4..

Three waytap (" off" - " on "- " reserve ").
Transmission. The engine (see Fig.4) drives

directly the rear wheel through clutch. cush
drive and gear box.

Engine to wheel transmission ratios:

First 12.2 to I
Second: 7.6 to I

Third: 4.85 to I

Clutch. Multiplate. with lining adhering to
the driving discs (see Fig.4).

Control by lever, on left hand side of handle-
bars (see Fig. 8), and adjustable cable.

Gear box. 3-speed drive with mesh gears
in oil bath (see Fig.4).

Its adjustable twistgrip control is coupled

with that of the clutch, on left hand side
of handlebars (see Fig.8).

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Starting. By means of klckstarter, right
hand side of scooter. The multiplate gear
and consequently the engine are set in
motion through a ratchet sector and a gear
by operating the klckstarter.

Cooling effected at all engine speeds by a
centrifugal fan (see Fig.7).

Silencer. Expansion and absorption com-

bined type with very high silencing efficiency.

Air cleaner mounted Inside the body. Air
goes to the carburettor through a large
flexible inlet tube, a silencing chamber and

porous filter, which ensure a very quiet air
Intake.

We recommend not to alter the silencer and the air cleaner

but to keep them in perfect efficiency, in order that the

noise level does not exceed the limits prescribed by law.

Fig. 7 - Engine cooling scheme.

-/I

Fig. 8 . VESPAcontrols

I. Gear changetwlstgrlp with clutch control lever - 2. Front brake lever. 3. Throttle control grip. 4. Lightand dipswitch _5. Front
brake shoes. 6. Rear brake pedal- 7. Klckscarter. 8. Gear shlfter. 9. Rear brake shoes. 10. Clutch. 11.Carburettor, air cleaner.

12. Choke control lever . 13.Fueltap.

F RA ME

Stressed skin body of pressed steel sheet,
(see Fig. I), with streamlined, monocoque

type structure. It gives full protection to the
driver. to the passenger and to the machine
units; it is completed in this function by the
mudguard and, on the two sides. by the
steel sheet engine bonnet and tool box.

Handlebars in pressed steel. with arrange-
ment for head lamp and speedometer. All
control cables and electric wires, to be con-
nected to the handlebars, are concealed inside

them (see Fig.8).

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 (see Fig. 9).

Front suspension with variable rate coil
spring and double action hydraulic damper.

Rear suspension: swinging bracket for en-

Fig- 9 - Engine and suspension.

I. Steering column and front suspension

2. Engine

3. Pivoting arm of crankcase half, clutch side

4. Rear suspension spring and hydraulic shock-absorber.

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gine and rear wheel, variable rate coil

spring and coaxial, double action hydraulic

damper.

The wheels are interchangeable with rims

of pressed steel sheet (08").

Tyres of dia. 3.50 - 8".

ridden. . ,jJ.

it (cam vlb"tlng wbil. ,b. "00'.' Q

Speedometer. The speedometer is housed

in the central portion of the handlebars,
and adds to the performance and appearance

of the scooter.

Dual Seat of very pleasing appearance in a

range of colours.

Brakes.

trol.

Front: lever on R.H. side of handlebars.
Rear: control pedal on floorboard, R.H.

Drums in light alloy with cooling fins.

Central stand. A two-leg stand, easy to
operate. is arranged under the floorboard.
A strong return spring in the middle holds

it in contact with the floorboard and keeps

14-

Expanding type with cable con-

It is driven by the front wheel, the flex
drive being completely enclosed in the
steering column.

WIRING

Either alternating or direct current for both
horn and lighting system is supplied as

follows (see Fig. 11. page 16).

- Main and dipped beam, tail lamp and
horn are directly fed with a. c. by the
six-pole flywheel magneto (nominalvoltage:
6 V).

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- Parking lights, front and rear, and the

Stop light are with d. c. by a 6V-7Ah
battery which i~re-charged by the flywheel
magneto through a metal rectifier.

- The 6V- 0.6W speedometer bulb is fed
with either a. c. or d. c.

The head lamp, 0 105mm (4.13"), installed

in the handlebars. has a 25/25 W double
filament bulb (main and dipped beam),
and with a 3 W bulb (pilot light and par-

king light).
The tail lamp, with red reflector. has a 3 W

bulb which also illuminates the number

plate. The light and dip switch unit with ,.
levers is installed on the right hand : '/J' ~

of the handlebars (see Fig. 11) ; one
the control levers has th ree positions:

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- pilot light and tail lamp on;

-lights off;

- head lamp and tail lamp on;
the other one gives the two light conditions

of the head lamp (main and dipped beam
with tail light).

The switch has also two push buttons for
cut-out and horn respectively.

- 15

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flYWHEEL MAGI£TO

No~Al:TEI?NA1QR COIL

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DOUBLE F .

ILAMeN I ........

6r~25w

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NoJAtJERNIIiIt:"COIL

Bo\TTERI' 084932M
RfCI1FER Q:J£!;53I.I

TAILU'MP BU..B 0I1907M
!olOPLlGHT EU.B OB3416M
WIRING HARNE!o!o095129M

"" STOP LGiT & S'IOP LIGHT SWlltH OPTIONAL

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POSITION O.

POSITION I.

11 - Electric wiring dIagram

Fig.

SRYUGHT 6--5...

,

SlOP lIGHT SWITCH ..

SWI1t:H P05IIDNS.

1'0 LIGHTS

Lt COIL DISCONNECTED

AC.ClM1RENT. HEAD &TAIL LIGHT ON. LT. COlt. N
CIRCUIT. CONTACTS 1I.3.9,d.6, OR 7,1 CCNIE:TED.

OCCU~T. CllY &TAIL LIGHT ON. lJ. COIL IN
CIRCUIT.CONTACTS 11.3 2,5.1, CONNECTED.

TOOL KIT

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I four-ended box wrench (11-14-21-22mm):
2 double open-ended wrenches (J 1-14 and
7-10 mm); I single open-ended wrench
(8 mm): I screwdriver.

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

with this booklet and the test card.

- 17

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Owing to the simple and rational design of Vespa scooter, no particular experier. ..

q"',ed foeIt, operadon, "o"kUled 'pe"o""el foeIts maintenance. The,,,h "'" ~ 3'

out by any customer, even inexperienced, by following some general rules. .

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OPERATION

FUEL to be used during and after running-

in should be a 2% mixture of oil and petrol,

* pint oil per It gallons petrol respec-

or

tively. (Seelubrication chart).

We recommend to use good quality. standard grade car
petrol, and to mix it with oillhoroughly. Keep the breather

of filling cap clean.

Running-in. Important rules to be followed

while running-in 2000 Km (1200 miles):

- Do not exceed following speeds:

1st gear: 15Km/h (9.5 mph)
2nd gear: 30 Km/h (19 mph)
3rd gear 50 Km/h (31 mph)

- Do not hold these speedsfor long periods
neither use full throttle up-hill.

18-

- Change oil in the gear box and check
that nuts and bolts are not slack after the

first 1000Km (600 miles).

- Check that carburettor is well blocked

on crankcase so that no air infiltrations may
occur.

Starting the engine. See (Fig. 6) the three

positions of the tap: on, off, reserve.

Open the fuel tap, put the gear box in neutral

(Fig. 14-15)and the throttle in slow running

position, then depress the starting lever.

Lift the choke rod when the engine is cold;
push said rod back as soon as the engine

starts.

In case of starting troubles due to engine

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Fig. 14 - Operations to carry out for starting the engine

A: open the fuel tank -B: select" neutral" - C: choke (with cold

- D: throttle control grip in idling position - E: depress

enginel
the kickstarter and turn grip

..D" opening throttle gradually.

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Fig.15- Drive system

I. Gear change twlstgrlp - 2. Clutch control lever - 3. Gear change control cables -

of. Gear shlfter - 5. Selector stem - 6. Selector - 7. 1st gear pinion - 8. 2nd gear P

9. 3rd gear pinion - 10.Malnshaft - 11. Cush gear. - 12. Clutch.

N. B.. Positions 1-2-3 of the gear change twlstgrlp correspond to 1st, 2nd and 3.

respectively; " 0 It Indicates the neutral position. ~,.,. ',' ~

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being flooded (unvaporized fuel mixture
has reached the cylinder, and the combustion
becomes therefore very difficult), proceed

according to either one offollowing 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.

i

- Close the fuel tap, remove sparkplug
and rotate the engine by means of the kick-

starter; wipe the plug dry and 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 the proper angle to avoid damaging

the cylinder; use the box wrench just for the last turns.

the th~ottle g"dually to 'et the mad;'

In motion. ') .iJ ~

Gear change. After reaching the requlrea
speed in 1st gear, close quickly the throttle,

lift the clutch and turn the gear change

twistgrip so that. the engraved line is op-

posite figure .. 2" (2nd gear); let in the

clutch and open the throttle.

Repeat this procedure for changing into

3rd gear and for changing down.
When you reduce the speedof your machine,

changedown without delay.
Seethe drive system

Do not turn the gear change twistgrip while the engine

is not running.
As soon as gear change troubles arise, customers should

have their machines adjusted by a Retailer or authorized

service station.

on Fig. 15.

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Setting the machine in motion. Let the

engine idle, lift the clutch and turn the
gear change twistgrip (L.H.) so that the line
engraved on it coincides with the figure" I ..

(I st gear) engraved on handlebars (seeFig. 15).
Now let in the clutch gently, while opening

Slow running adjustment. Idling revs can
be raised or reduced respectively by simply
tightening or slackening, either with a
screwdriver or by hand, the knurled slotted
screw on air cleaner steel sheet cover (see

-21

Fig. 16 - Removing the inner tube

.-.,

Fig. 6. No. 9). The screw controls.. ~.'

valve of throttle. . . .iJ"

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on the air cleaner case (see Figa 6, No. 11). This screw 15~o
be re-set only if necessary and while dismantling and re-
assembling.

Opposite to said adjuster screw there is on the air cleaner

case a plugged hole for access to another screw (spring-

loaded) with a tapering end (see Fig. 6, No. 7). This screw

controls the now of carburated air through the duct from the
idling jet, and consequently the idling revs. We recommend
to the customer to keep from re-setting this screw, unless

strictly indispensable or during dismantling and re.as.

sembling operations that should, anYW3Y, be entrusted to a

Service Station.

Stopping the engine. Push the earth button;
this will leave the cylinder full of fuel va-
pours, and the next start will be easier.

Tyres. The wheels are interchangeable, i.e.
they can be assembled' either in front or
rear, provided, of course, that they are in-
flated to the pressures subsequently pre-

scribed.
For replacing a flat tyre, unscrew the four

nuts which secure the wheel; pull the latter
sideways off the studs, repair the tube or

fit the spare wheel on.

Make sure that the spring washers are present when ft:.

assembling the wheel: tighten the nuts diagonally and
evenly.

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22 -

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. 16).

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Tyre Pressures

Dunlop

Solofront
Solorear 20 Ib per sq. in
Pillion front 161bper sq. in
Pillion rear 32 Ib per sq. in

16Ib per sq. in

Sidecarfront 161bper sq. in

Sidecar rear 24 Ib per sq. in

Sidecar 16Ib per sq. in

Brake adjustments. Brakes are properly
adjusted if:

Pirelli

16Ib per sq. in

22 Ib per sq. in

16Ib per sq. in

32 Ib per sq. in

18Ib per sq. in

24 Ib per sq. in

161bper sq. in

- the wheel rotates freely when respective

control lever or pedal are in resting position.

- the braking action starts as soon as re-

spective controls are operated.
These conditions are achieved adjusting the
cables by means of screws indicated with
an arrow in Fig. 17.

Fig. 17 . Brake adjustment

- 23

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MAINTENANCE

Setting the head lamp. The correct orien-

tation of the main beam can be obtained
both horizontally and vertically as follows.

Check that both front and
inflated to I and 2.2 atm

psi) respectively.

rear

(14.2

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N. B. - Dimension" 0 11relates to adjustment carried out with driver and passenger on the machine.

Fig. 18 - Adjustment 01 head lamp

24

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Place the scooter on a level floor in front
of a white wall as seen on Fig. 18. Start the

engine, hold the throttle control twistgrip
at about 1/3 and set the switch on .. main

beam...

J

1

With two persons on the Vespa, slacken
the two screws securing the head lamp,
then move the latter as required in order
that the beam axis coincides with point

.. 0 .. on the wall.

Tighten the screws 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 pa-

raffin 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 dam
paint and turns it dull. .,jJ '.~

If necessary, blow the head lamp refle
clean or wipe off dust with a very soft feather
brush. Do not use a cloth and keep your
fingers off the reflector surface.

Before setting the machine in motion

I) - Check oil level in gear box by un-

screwing on the crankcase the level screw
marked .. aLia" (see Fig. 20, No. I).
The scooter standing upright, oil should

just be about to flow out.

2) - Be sure that the positive pole (+)
of the battery is connected to the red cable,
and the negative pole (-) is connected to

the black cable.

A wrong connectiol' will readily turn the rectifier inefficient

and damage the battery entirely.

Screw down the cell caps firmly to avoid
entrance of impurities.

- 25

After the first 1000 Km (600 miles)

Warm up the engine and drain off all oil

through the hole provi Jed.
Pour some fresh cil in and run the engine

for a few seconds. Drain again and refill

with about 0.18 Kg (0.4 Ibs) of
MOTOR Oil 30.

See also page 18.

Every 4000 Km (2500 miles)

I) -Remove the air cleaner

carburettor and agitate it in a

gasoline bath.

2) - Check oil level in the gear box.

3) - Clean the two lubricators of front
wheel hub and refill
greasegun.

4) - Grease all joints on the brake controls.

5) - Grease the felt which lubricates the
cam of flywheel magneto.

6) - Clean the sparkplug electrodes with
a metal brush or very fine emery cloth. and
adjust the gap to 0.6 mm (0.023in).

them by means of a

from the

30% oil-

Inspect the insulation material

plug. replace if the porcelain ISr

Wash with neat petrol. .

Use the sparkplug type prescribed by the Comany. We

remind owners, that the use of an approved sparkplug
will prevent many engine troubles.

7) -lubricate the speedometer drive

pinionandflex drive.

All operations Indicated hereunder should be carried
out by authorized Service Stations.

8) - Clean the

decarbonize the

following notes.

Remove the silencer. the cooling hood.

the cylinder head and the cylinder.
Decarbonize the piston crown, the cylinder

silencer exhaust pipe and

engine as explained in

ports and the inner side of the cylinder
head. Clear carefully the cylinder from
carbon deposits.

Heat the exhaust pipe of the silencer, and

26 -

'-

clean it either by scraping it internally with
a hooked wire or blowing air through from
the opposite end; in both cases the silencer
should be held so that the exhaust pipe is

turned downwards.

Every 8000 Km (5000 miles)

I) - Clean the breaker points.

In order to avoid ignition troubles or abnor-

mal running, have the breaker points adjusted

in a service station: the gap (see Fig. 19,

"A") should be

0.3-0.5mm (0.011" to

0.019"), and the points should begin to open
when the current in the primary ignition
circuit has reached its peak value.

2) - Lubricate the control cables and the

gear shifter.

3) - Change the oil in the gear box (see

page 26).

4) - In case of damper troubles contact

your authorised service station.

Fig. 19 . Breaker points

A - Max gap: 0.3-0.5 mm (0.011-0.019")

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- 27

LUBRICATION CHART

Portto be lubricated

Every2.500

Gear.box

topping-up

Front suspension

Felt pad on flywhee :

cam

Joints on brake

control

Speedo flexible

drive

Engine at each re-fuelling t pint

.Marketed also by National 8enzole Co. Ltd.. by arrangement with Shell-Mex & B.P. Ltd.

Every5,000

I

Gear-box change

oil

I

Control cables
Gear-change

quadrant

Ii

.Shell .8.P.

Shell IT Two-

Stroke Oil Stroke Oil Motor Oil

or or

Shell X-lOO 30

I

Retinax A

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Shell IT Two-
Stroke Oil in Stroke Oil in

ratio of 2 % or ratio of 2% or t pint to It galls t pintto It galls t pintto It galls

to

galls. petrol galls. petrol

After !irst 600 miles change Gearbox Oil.

APPROVED PETROL/OIL MIXTURE

Energol

Energol SAE 30

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Energrease L.2. Multi-purpose

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Energol

It t

pint

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Make

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Two-

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Two- Eosolube 30 in

to

It

Description

Sheli 2T Two-Stroke Mixture
B.P.

National

zole Co. Ltd.

B.P.-Zoom

Ben-IHi-FIi

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Lubrication

£S$O

Essa Extra

lOW /30

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Wokefield

Castrol XL

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Esso

Grease H

ratio of 2 % or ratio of 2% or ratio of 2% or

petrol. Esse petrol. Castrol petrol or Mobil-

Two-Stroke Two-Stroke Oil

Motor 011 in in ratio

ratio of t pint

to I gall. penol

petrol

Castrolease L.M.

Castrol

pint to I gall.

To be used with

eq ual parts of

neat petrol.

I

Mobilgrease M.P.

I

XL in Mobiloil A in

Mix in ratio of

t

pint

gall. petrol

to I

of t

}

28

Hydraulic Dampers When not working efficiently. consult your

Dealer. Ifservicing is required, they should

always be returned to the Works.

Fig. 20 - Lubrication scheme.

A: engine lubricatedby ruel mixture - I: filling hole -2; draining hole.

,0 ~.,

.. < <jJ'

Q

,

~. -:

.

Battery service. Followthe dlrectlons on the
card accompanying each battery for service
and normal re-charge.

Laying up. In such a case, proceed as
follows.

I. Clean the scooter thoroughly (see

page 25).

2. Remove the air cleaner cover and the

cleaner itself.
With engine not running. rotate the throttle

control twlstgrip to its fullest extent. then
pump 40 cc. (2.5 cu.ln) of Motor Oil

30 -

30. by means of an 011can Into 1 ,."
cetto, '"take th,o"gh the hole, ":'"

cleaner cover. .

Depress the kickstarter three or four times.

3. Support the chassis of the machine
on two wooden blocks ensuring that the
tyres are clear of the ground.

4. Empty the fuel tank.

5. Grease all unpainted metal parts.

6. Disconnect the cables from the battery.
clean the terminals ofthe latter and wipe dry.

g

FAULT

Whenthe machinedoes not run properly,makeallinspectionsandrectificationsasexplained below.

If the suggested remedies are not sufficient to eliminate the trouble, the customer should not try to carry out operat Ja

pertaining to the retlllers, who have the necessary facilities to undertake this work.

Locating the trouble

HARD STARTING

FINDING

Remedies

'~_::-~

I.' .,'

.' ::

()

I"~'~

1

I

J

I

I

L......

I. - Fuelsystem - Carburation

Fuel tank empty

Filter on carburettor

Fuel tap body

Carburettor body

Jets

Engine flooding

Air cleaner choked or dirty

}

Clogged,

dirty

2. - Ignition

Sparking plug dirty

Porcelainof sparking plug cracked

Breaker points dirty, worn or pitted; gap between breaker

pointS incorrect.

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

Remove and wash in petrol. Blow dry.

See page 21.

See page 26, No. I.

Disconnect the plug lead. Check if sparking occurs between

lead and crankcase when the kickstarter is operated.

Clean (see page26, No. 6). Correct gapto 0.6 mm (0.023").
Replace the plug (see" Notice ". page 21, and page 26).
Ask the Retailer either to have them cleaned (with very fine

emery paper or suitable flies), or replaced, or to have gap

adiusted.

-'-31

Locating the trouble

INCORRECT RUNNING

I. Lack of power

Muffler outlet pipe carbonise;:l.
Sparkplug not well screwed into cylinder head.
Cylinder head not fitting properly into the spigot on top of

cylinder.

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. - Engine noisy - Clutch troubles. Gear pinions dis-
engage of own accord - Starter assembly not engaging

Controls not operating properly. Steering column
becomes stiff

5. - Poor braking

Stroke of pedal or lever too long.

Brake linings oily or worn down.

Brake drums and linings scratched.

6. . Faulty electric wiring

Leadterminals looseor wronglyconnected
Fuse of rectifier burnt.

Incorrect adjustment of the head lamp.

32 -

-Inefficiency of suspensions.

Remedies

. '.~',

g

Clean (see page 27).

Tighten with 21 mm box wrench.
Set the head properly and tighten the nuts uniformly.

Replace or clean the plug and correct the gap (see page 26,

No. 6) to 0.6 mm (0.023 in.).

Clean with pure petrol and blow dry.

Dip the filter into a 30% petrol-oil bath.

Release and lubricate the choke control lever.
See your Retailer.

Sec your Retailer.

Adjutt (see Fig. 17, page 23).

Wash with petrol and dry in air. or replace.
See your Retailer about oil leakage.

Replace.

Re-connect properly (see Figs. 11-12) or rep:ace and tighten

the screws. .

Replace.
Re-set properly (see page 24).