VESPA 90 Operation And Maintenance

J£JP~ppointment

~o ~i~ 3lo!,al ~igfJne55 ~~e 3iulte of celJinfJutg~

j!luppIitts of 1:Tespa~tootets

OPERATION AND MAINTENANCE

1Dp %lppointment

~o JIJi5'.nopaI JIJig~ne5'5'~~e ;auke of ~binbutg~

35>lIppIiet5'of 17espa ~tootttS

OPERATION AND MAINTENANCE

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

DIVISION OF THE WESTINGHOUSE BRAKE AND SIGNAL COMPANY LIMITED

Telephone 67-1881

NOTICE

We trust that your Vespawillgive you excellent service, and willsatisfy your every need.
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.

To keep your VESPA in perfect running order and not to invalidate the guarantee offered

by the contract, it is advisable to entrust repairs only to retailers or authorised service stations.

Demand original VESPAspare parts exclusively., All VESPAsparesare madeofthe samematerial,
have undergone the same machining steps and inspections as the components of your VESPA.

This meansguarantee for long life and normal performance of your machine and for your personal
safety.

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

quality petrol and oil of make, grade and in the amount prescribed inthis booklet, page28.

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.

2-

INDEX OF MAIN DIRECTIONS

Introduction ... ... ...

Layout of controls

Technicaldata

... ...

... ... ...

page

Identification detai I ... ...

Operating instruction

Tyre pressures

Running-in
Maintenance

The descriptions and illustrations in this booklet are not to be taken as binding on the Manufacturer. The essential
features of the model described and illustrated herein remaining unaltered, Douglas (Sales & Service) Ltd. reserve
therefore the right to carry out at any moment, without being obliged to bring this booklet up..to..date in due course,
modification that may occur concerning machine units and parts, or delivery of accessories, that the Firm deems to
be convenient on improvement purposes or for what may concern manufacturing or commercial requirements.

... ...

... ... ...

...

... ... ... ..

...

...

2

Lubrication chart ...

5

..

..

10

..

11

..

11

..

13

..

16

Operating instructions:Faultfind-

6

ing

... ...

Engine: description
Chassis: description
Wiring diagram

... ...

Electricalequipment

...

...

... ...

...

...

... ... ..

...

... ... ..

page

28

.. 32

34

..

34
36

..

38

-3

Fig. I - Vespa 90

4-

Fig.2 - Installationofcontrols and transmissions

I. Clutch control (lever) and gear change (twist grip) -2. Front

brake lever - 3. Throttle twist trip. 4. Main switch unit. 5. Front

brake shoes- 6. Rearbrake pedal- 7. Kickstarter - 8. Gear selector
and gear control adjusting screws . 9. Rear brake shoe - 10.
Clutch . 11. Carburettor and air cleaner - 12. Choke control

13. Fuel Tap.

-5

L

TECHNICAL DATA

Consumption: (CUNA Standards) approx.

156 mls.jimp. gal.. petrol-oil mixture i.e.

2% oil.

Max. Speed: (CUNA Standards) 43.5 m.p.h.

Carrying capacity 2 persons

Range 174miles
Max fuel capacity: 1.15 imp galls. incl. 0.15

imp. galls. reserve

DIMENSIONS

Wheel base

Handlebar width

Total length

Note.- The fuel consumption and maximum speed figures must not be accepted as binding.
Manyfactors outside our control can considerably affect them once the machine is in the hands

of the owner and on the road.

6-

1160mm. (45.2")

610 mm. (23.9")

1650mm. (64.9")

Max. height

Min. ground clearance
Turning radius
Total dry weight

Engine: Displacement 88.5 C.c.- 5.4 cu. in. -

995 mm. (39.17")
225 mm. ( 8.85")

1650mm. (64.9")

70 Kg. (157 Ibs.)

(Bore47 mm. - 1.85"- Stroke 51 mm. -

2.0"- Compression ratio I:7.2; Two-stroke

rotary distribution).

H.T. flywheel magneto coil ignition.

Spark advance: 19° :J: 1°before T.D.C.

Sparking plug: Recommendations see p. 38.

I. Group carburettor air cleaner

4. Clutch.. 5. Mainshaft and gear pinion assy. .. 6. Gear shlfter

7. Flywheel magneto.. 8. Kicksurter.. 9. Crankcase swinging arm
clutch side (pivoted to frame).

Fig. 3 .. Engine section

.. 2. Piston .. J. Crankshaft

-7

..

~

... ~

I

I

l

Fig. 4 - Steering lock

I. Normal position - 2. Locked position

Fig.5 - Dual Seat (for pivoting the seat on its forward edge push

thl lever indicated by arrow).

8-

A: Open the fuel tap -B: Select neutral -C: Pull

out the Choke control rod (with cold engine) -D: Bring
throttle twist grip to idling position . E: Depress

the Kickstarter.

Fig. 6 - Starting Instructions

B /-....

.-

.
,

~

'-J

-9

IDENTIFICATION DATA

Each vehicle bears a Serial No. with a specific
production series stamped on the frame and

engine. as indicated in figs. 21 and 22.

Fig. 21 - Serial number stamped on engine. Fig. 22 - Serial number stamped on frame.

10 -

The chassis prefix and serial

the vehicle as prescribed
numbers must be quoted
spare parts.

number identify

by law; these

when ordering

OPERATING INSTRUCTIONS

Before operating the vehicle: unscrew the plug on the gear box marked "aLia"
(fig. 18)and check that the oil is level with the hole when the vehicle isstanding upright.

- Check tyre pressure:
Front (17 p.s.i.): Rear (23 p.s.i.) solo;
Rear (33 p.s.i.): with pillion passenger.

OPERATION

STEERI NG LOCK

INSTRUCTIONS

NOTES

(a) Locking the

scooter.

(b) Unlocking the

scooter.

To lock the vehicle it is necessary to turn the

handlebars in anticlockwise direction up to
the limit stop; rotate the key and push in-
wards, so that it thrusts the sliding bar
against the steering column.
To ease the insertion of the sliding bar into
the hole of the steering column, slightly
turn the handlebars from the limit stop

clockwise.

To release the handlebars, insert the key

in the lock, turn it to the left and pull it

back; then tu rn the hand lebars in the normal

position.

When the handle-
bars are locked the
key will now spring
back to its original
position and can be

extracted.
It can be extracted

from the lock even

if the handlebars are
free.

The steering Jock
should not be lu-
bricated.

-11

OPERATING INSTRUCTIONS

OPERATION

FUEL SUPPLY

STARTING

SETTING THE

SCOOTER IN
MOTION

GEAR CHANGE

12-

INSTRUCTIONS

Ensure that the fuel tank breather is always
clean. Use a mixture 2% by volume
during and after running-in.

- Carry out the instructions indicated on

fig. 6. Do not use the choke when the
engine is warm; as soon as the engine
is running smoothly bring the choke
control back to its normal position.

- With the engine running at idling speed

declutch and rotate the gear change
twist grip to the position of first gear
(fig. 6). For setting the vehicle in motion
slowly let in the clutch and gradually open

the throttle.

- Close the throttle, declutch and rotate
the gear change grip to a higher or lower

gear, as the case may be (fig.7).

NOTES

In case of hard
starti ng see page

32.

Do not attempt to
ride the vehicle un-

less the handlebars
rotate freely.

When It is neces-
sary to slow down

do not hesitate in
changing to a lower

gear.

OPERATING INSTRUCTIONS

OPERATION

STOPPING THE

ENGINE

- Before stopping the engine change to

"neutral" and then operate the cut-out
button on the switch unit.

INSTRUCTIONS

NOTES

RUNNING-IN PERIOD

Up to I,000 miles the machine should never be driven at a speed exceeding 35
m.p.h. It is important of course at all times never to let the engine labour but
during its early life it is doubly important. Use your gear-box freely; never under

any circumstances allow the motor to work hard.
After first 600 miles change oil in gear box (see page 28) and check that all nuts and

bolts are tight.

- 13

~I f:!

\J

I. Gear change twist grip - 2. Clutch control lever - 3. Gear

change cables - 4. Gear shllter - 5. Selector grou p - 6. Ist gear

7. 2nd gear - 8. Top gear - 9. Helical gear - 10. Clutch - 11. Main
shalt - 12. Stirrup lor gear change.

N.B. -The position I - 2 - 3 on the gear change twist grip corres-

pond respectively co bottom, 2nd and 3rd gear: the" 0 .,
indicates neutral.

Fig.7- Gear Operation

~Fig.8 - Fuel supply_anddistribution diagram

I. Fuel Tap: (A) Reserve; (B) Open; (C) Closed. 2. Throttle

slide set screw. 3. Slow running adjuster screw - 4. Slow running
jet - S. Starter valve - 6. Slow running jet air Bleed - 7. Air filter

8. Main let air Bleed. 9. Starter jet. 10. Float. 11. Main jet

12. Throttle slide. 13. Inlet port. 14. Transfer ports. 15. Exhaust

port.

14

7

8

11 10

- 15

OPERATING AND MAINTENANCE INSTRUCTIONS

STARTING UP when the engine is

flooded:

In the case of difficulties caused by flooding

(presence of unvaporised mixture in the

cylinder), the following methods can be

used:

- Attempt push starting: select the 2nd

gear, declutch, push the vehicle to a

certain speed, sharply release the clutch
and when the engine starts declutch.

- Close the fuel tap. remove the sparking

plug (fig. 13) and clean; then kick over
the engine several times. Screw in the
sparking plug securely, open the fuel
tap and kick over the engine.

16-

ADJUSTMENTS ON CARBURETTOR

For adjusting the idling speed turn the slow
running adjuster screw (fig. 8 No. 2).

- On the carburettor body a set screw is

provided for adjusting the throttle cable
play; this screw is to be reset only if

necessary or on dismantling and re-
assembly operations.

- On the carburettor body is a spring
loaded volume control screw (fig.8,No. 3).
In order not to influence the engine
running at idle speed, we recommend

that owners should avoid resetting
this screw. Any alteration should

preferably be entrusted to a Service

Station.

Fig. 9 - Removing wheel from vehicle

Fig. 10 - Brake adjustment

- 17

18 -

Fig. 11 . Tyre removal

OPERATING AND MAINTENANCE INSTRUCTIONS

OPERATION

CHANGING

WHEELS AND
TYRES

BRAKEADJUST-

MENT

INSTRUCTIONS

- For dismantling the wheels from the

vehicle remove the bolts as indicated
in fig. 9.

On reassembly tighten said bolts altern-
ately and progressively.

- When a tyre has to be removed, first
deflate and then remove the nuts joining
the two wheel rims (fig. 11).

- Adjust set screws indicated in fig. 10,

keeping in mind that when the brake lever
or pedal are in the off position the wheels
should rotate freely; the braking action
should begin immediately on operating

the respective controls.

NOTES

The front and rear
wheel are inter-
changeable one with
another on condition
that the tyre pressures
are regulated accord..

ingly (page 11).

- 19

20 -

Fig. 12 - Installation of engine and suspension

I. Steering column and (ront suspension -2. Engine- 3. Crankcase
dutch side with sWinging arm pivoted to frame.. 4. Rear supsension

spring and hydraulic damper assy. .. S. Bolt securing carburettor

6. Bolt securing damper of rear suspension -7. Nut securing

engine.

OPERATING AND MAINTENANCE INSTRUCTIONS

OPERATION

SPARKPLUG

REMOVAL

CHANGING OIL

IN GEAR CASE

DISMANTLI NG

AIR FILTER

INSTRUCTIONS

- To remove the spark-plug. rotate the knob

and remove the panel; disconnect the H.T.
lead and extract the spark-plug using the
box wrench as indicated in fig. 13.

- Drain offthrough hole (fig. 18).

- Introduce a small quantity of flushing
oil. run the engine a few minutes to ensure
thorough circulation and cleaning and
drain off again.

- Afterwards refill gear case with new oil
(up to level of the filling hole).

- For dismantling the air filter (fig. 14),
pivot the seat on its forward edge (fig. 5).

remove the tool kit. and the control cable

ofthe choke mechanism (the cable end ring
can be seen on Fig. 14).then disconnect the

NOTES

On reassembling the

spark-plug ensure that
it is screwed into the
threaded hole at the

correct angle.

This operation of
changing oil should

be carried out with
warm engine.

-21

!iJo...

! I

~

I

-

I

I

22 -

Fig.13 Dismantling spark-plug

$ \

I

Fig. 14 . To approach the carburettor and air cleaner O$sy.(see Instructions at page 24).

- 23

....

OPERATING AND MAINTENANCE INSTRUCTIONS

OPERATION

INSTRUCTIONS

NOTES

fuel tap rod (see Fig. 14); next unscrew
the two wing nuts securing the air filter

case and extract it.

DISMANTLING

CYLINDER HEAD

- Remove the carburettor (screw No. 5,

fig. 12). Remove silencer, loosen bolt
connecting engine to bearer bracket (fig.

12, No. 7), detach rear damper (fig. 12,

No. 6) and swivel down the engine on its
own bearer bracket.

The cylinder head can then be eased away
from the unit by unscrewing the 4 securing

It is advisable when

carrying out this

operation to place a

wooden platform

underneath the rear

end of the chassis

foot-board, so as to
obtain greater rear
wheel lift than is

possible by the use of

the stand and, at the
same time. adequate

stability.

bolts by means of a box wrench.

Note -When re.assembling the carburettor should be mounted in such a way as to ensure that the float is located vertically.

14 -

J

MAINTENANCE

Should difficulties of starting or running
occur. check the spark plug:

- Clean the spark plug electrodes with a

wire brush or emery cloth and adjust
the gap (see Plug recommendations page

38). Check porcelain insulation: if cracked

or broken change the plug.

Clean in neat petrol.
It is advisable to use the types of spark

plug prescribed by factory.
Every 4000 km (2400miles):

(I) -Check oil level in gear case (see lubri-

cation chart).

(2) - De-coke the engine (see page 24)
cylinder head, piston crown and cylinder
ports). Ensure that residual carbon deposits
do not remain inside the cylinder. Clean the
exhaust pipe using a suitable scraper.

Every 8000 Km (4800 miles):

(I) -Change oil in gear case (see lubrication

chart).

(2)- Remove the rubber plug on front
suspension (No. 3 - fig. 18)and refill with

grease the housing of the front wheel axle

bearingand speedometer drive gear.

(3)- Remove the air filter (see page 21).
clean by agitating in an oil petrol bath and
ifpossibleair blastdry.

(4)- Lubricate control cables transmissions
andfelt lubricatingpad on flywheel.

(5) - Clean. and if necessary. set the contact

breaker points (fig. 17).

Incase of difficultyconsult your Dealer.

- 25

3

Fig. 16 - Ignition circuit

I. Flywheel coU - 2. Flywheel cam - 3. Contact breaker - 4. Con-

denser - 5. Sparking plug - 6. Engine cut-out switch.

26 -

Fig. 17 - Setting contact breaker points.

A -(Point gap) = (0.011" to 0.019").

LAYING UP

We recommend that the following operations
be carried out:

(I) -Clean down the vehicle.

(2) - With the engine stationary, piston

at the bottom dead centre position, remove
the spark plug. Next, introduce through

the plug hole 10 to 15 cc. of 30 SAE Oil.
After said operation depress the kickstarter

three or four times.

(3) - Drain off all fuel contained in the fuel

tank; then grease over all unpainted metallic

parts; next raise the wheels off the ground

byplacingwooden chocks under the footboard.

CLEANING THE MACHINE

For cleaning the exposed surface of the
engine use paraffin, a brush and clean rags.

The painted surfaces of the machine should

be sponged down with water and dried off
with a chamois leather. Do not use paraffin
for washing down painted surfaces.

- 27

LUBRICATION CHART

Parttobelubricated

Every 2,500

Gear-box

topping-up

Front suspension

Felt pad on flywheel

cam Essa

Joints on brake

control

Speedo flexible

drive

Every 5,000

Gearbox change

oil Stroke Oil Stroke Oil Motor Oil

Control cables

Gear.change

quadrant

Engineat eachre-fuelling t pint

.Marketed a:so by National Benz,le Co. Lt.:!.. by arrangement with Shell-Mex & B.P. Ltd.

28 -

I

.Shell .B.P. Esso

Shell 2T Two-

or

Shell X-lOO 30

Retinax A

Shell 2T Two-

Stroke

Oil in

ratio of 2% or

to

galls. petrol galls. petrol

11

After first 600 miles change Gearbox Oil.

APPROVED PETROL/OIL MIXTURE

Moke

Shell 2T Two-Stroke Mixture

B.P.
National Ben- Hi-FIi

zole Co. Ltd.

Hydraulic Dampers

Stroke Oil in

It

t pint

B.P.-Zoom

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

Energol

Energol SAE 30

Energrease L.2. Multi-purpose

Energol
ratio of 2% or t pint to Ihalls. t pint to It galls t pint to Itgal

Two- EsseExtra Castrol XL Mobiloil A

or

Essolube 30 in Castrol XL in Mobiloil A

Two-

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

to

It petrol.

Two-Stroke Two-Stroke 011 Mix in ratio

Motor 011

ratio of t pint

DescriPtion

Lubrication

20W /30

Grease H

to I gall.

petrol

Castrolease L.M.

Essa

petrol.

in

in
pint to I

TO be used with

equal parts of
neat petrol.

}

Wokefie/d

Castrol

ratio of

gall. gall. petrol

petrol

MobilgreaseM.

petrol or Mot)

t t

Mobi/

pint to.

J

Fig. 18 . Lubrication scheme

A: Engine lubricated by fuel mixture (2% by volume) -I. Oil filler hole - 2. Oildrain-

ing hole - 3. Rubber plug of speedometer drive gear housing.

MOTOR OIL 30 SAE

GREASE

SEE CHART

- 29

MAINTENANCE

Setting the head lamp. The correct orienta- Check that both front and rear tyres are

tion of the main beam can be obtained both inflated to correct pressures. See Chart, page
horizontally and vertically asfollows. 11.

30 -

- - --

The horizontal distance equivalent is 16' 6. and the vertical equivalent is 2' 10"'-2' 11.

N.B... Dimension110" corresponds to adjustment carried out with driver and passenger on the machine.

Fig. 19- Adjustment of head lamp

- - -

Place the scooter on a level floor in front of
a white wall as seen in Fig. 19. Start the

engine, hold the throttle control twistgrip
at about 1/3 and set the switch on "mai n

beam."

Tighten the screw firmly.

This operation can be carried out also with the

driver only sitting on the seat.

\1

With two persons on the Vespa, slacken the
set screw securing the head lamp, then move

the latter as required in order that the beam
axis coincides with point "0" on the wall.

In this case, of course, the beam alignment
should be altered whenever the scooter is

being ridden by both driver and passenger.

- 31

FAULT FINDING

If the machine does not run properly, inspect and rectify as explained below. Ifthesuggestedremedies are not sufficient
to eliminate the trouble, the customer should not try to carry out operations but approach an authorised Vespa Dealer.

who has the necessary facilities to undertake this work.

Fault finding

HARD STARTING

I.. - Fuel system - Carburation. Ignition
Lack of fuel.

Filter, jets. fuel tap, carburettor body dogged or dirty.
Engine flooding. Air cleaner choked or dirty.
Sparking plug dirty a Porcelain of sparking plug cracked.

Breaker points dirty. worn or pitted; gap between breaker points Consult your Dealer.

incorrect.

VARIOUS RUNNING DEFECTS

I. - Lack of power

Silencer choked.
Cylinder head joint or sparkplug loose.

2. .. Silencer or carburettor.
Back-firing. (see page 38).

Turn to Reserve and refill as soon as possible.
Remove, wash in petrol and blow dry.

See page 16.
Disconnect the plug lead. Check if sparking occurs between lead

and crankcase when the kickstarter is operated.

Clean (see page 25).
Position head correctly and tighten nuts uniformly; tighten spark

plug with plug spanner.
Check the sparking plug, clean, change or set the electrode gap

32 -

Remedies

Fault finding

3. - High fuel consumption
(a> Air filter choked or dirty or choke control set in closed

or partially closed position.

(b) Other causes (carburettor, lack in compression etc).

4. . Noisy engine - Defective clutch - Gear pinions
disengage of own accord. Kickstarter a55Y. not mesh-

ing . Defective operation of controls and steering-

Defective suspension -Defective braking.

5. - Defective electrical equipment.

Wire terminals disconnected or incorrectly connected.

Headlight beam incorrectly set.

Remedies

Washin pure petrol, airblastdry.

Free off choke control and lubricate.
Consult your Dealer.

Consult you Dealer.

Carefully check and connect.

Adjust (see page 30).

- 33

GENERAL SPECIFICATION

Installation of engine (see fig. 12): The

engine is pivoted to the chassisof the vehicle
through the crankcase swinging arm (clutch

side). The rear wheel is fitted on the outer
side of the main shaft.

Lubrication of engine (piston, cylinder,

crankshaft, main bearing - flywheel side)

is effected by the oil in the fuel mixture.

The clutch, the main bearing - clutch side,

-and gear box function in an oil bath.

Fuel supply (see fig. 8): gravity feed with
mixture of oil and petrol. Carburettor pro-

vided with a throttle slide.

Three way tap ("closed", "open", "re-

serve ").
Clutch (see fig. 3): multiplate on the lay-

shaft. The unit is operated by lever located
on L.H. handlebars and adjustable cable.

34 -

Gear box (see fig. 7): three speed drive
with constant mesh gears. Operated by the

twist grip on L.H. handlebar which functions
in conjunction with the clutch control lever.

Transmission ratio engine to driving wheel:

Bottom gear I : 17.18
2nd gear I: 9.66
3rd gear I: 6.12

Starting (see fig. 6): by means of a kick-
starter on the R.H. side of the vehicle.

Cooling: at all speeds by means of a cen-
trifugal fan.

Air intake: situated inside the frame.

Exhaust silencer: combined expansion and

absorption type.
Chassis (see fig. I): of pressed sheet stee

with streamlined monocoque type structure,

Handlebars: Light alloy casting incorporat-

ing speedometer. All transmission cables
and various controls are enclosed.

Parking stand: a two legged stand with a

central return spring.

Steering column, suspension: On the
lower end of the steering column is pivoted
the front wheel swinging hub: front and
rear suspensions with helical spring and
hydraulic damper.

Wheels: Interchangeable and made up of

10"dia. pressedsteel flanges.fitted with 3.00-
10"tyres.

Brakes: cable operated expanding type.
Front brake is operated by hand-lever
(R.H. handlebars); the rear brake is pedal
operated on R.H. footboard.

Steering lock: the locking device operates

by mean of a sliding bar engaging in the

steering column.

STANDARD TOOL KIT
Wrenches: I box wrench (11-17-21 mm.);

2 single open-ended wrenches (7-8 mm.).

Screwdriver: I item.

These tools are contained in a canvas roll
together with this booklet which is placed

in a tool box located under the saddle.

- 35

36 -

WIRING DIAGRAM

~~

.

.

6 1 1 85

7.
9

I. Black- 2. White - 3. Green - 4. Red- 5. Violet- 6. Brown

7. Blue- 8. Pink- 9. Yellow.

9

9

3

1,

.,

Fig. 19- Installation of electrical equIp-

ment . see

trical connections ... see Fig. at
the present page

page 36 and elec-

Fig. 20 - Light and dip switch

0... I - 2: Switching lever posir.ions. ...O. Lights off; - I. Pilot light

and tail lamp on; -2. Head light. front parking light and tail :amp

on A: Main and dipped beam switch -8: Horn button -M: Engine

cut-out.

- 37

ELECTRICAL EQUIPMENT

Asixpoleflywheelmagneto-nominal voltage

6 V -supplies alternating current to the

electrical equipment.
The main switch unit is installed on the

handlebars (fig. 20).

Following groups are fed:

- The headlamp, dia. 105 mm. (4.15")

SPARK PLUG RECOMMENDATIONS

Make

KLG
A.c.
LODGE

CHAMPION

BOSCH

38 -

has a 25/25 W bulb (main and dipped
beam) and a 5 W (Pilot light bulb).

- The rear lamp is provided with a 5 W

bulb (red pilot light and white light

for registration plate) and a Stop light

(10 W).

- Horn.

Type

FaO

M42F
2HN
L.SI

W.240T.I.

Gap

0.023

0.022

0.023

0.023

0.023