DOUGLAS-VESPA G.L.2. Installation guide

I.;.
G.L.2.
Operation and Maintenance

G.L.2.
Operation and Maintenance

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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 [phone]
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.
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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.
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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
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4

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LIGHTSWITCH,HORNBUTT,Q
& CUT-OUT.
GEAR SHIFT CONTROL GRIP
& CLUTCH CONTROL LEVER.
HORN.
FOOTST ART.
CARBURETTOR HOUSING COVER. REAR BRAKE PEDAL.
Fig. 1.
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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
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Page
23
25
26
28
30
List of Illustrations
Page Fig.
S 6 Gearbox lubrication ...
11 7Brakeadjustment-front wheel
12 8Brakeadjustment-rear wheel
14
16 10 Cylinder, cylinder head 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 speedsby 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 flanges of pressed sheet steel. They are inter-
changeable, and being cantilever mounted, are easily removable, in the same manner as those
of a motor car.
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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.

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.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
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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
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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.
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ELECTRICALWIRING DIAGRAM.
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SWITCH TO TAIL LAMP.
RECTIFIERTOSWITCH.DC. ISWITCH&HORNBUTTON
BATTERY. 6VOLT.5AMP. I I I SWITCHTOHEADLAMP(BEAM).
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RECTIFIER-RESISTOR.
SWITCH TO EARTH I
FLYWHEEL MAGNETO TO PLUG
RESISTOR TO HORN;
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RESISTOR TO SWITCH.AC.
POSITION C.
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2.
3.
fig. I2.
POSITIONS.
SWITCH
- EARTH. HeAD lAMP
-'OFF: RSPEeDOMETeO~i1~~i &NTAC~~; fO
._, .
TAIL LAM . .._P S l & HEAD .
- DIPPED;ON.~ OM
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ETER LIGHT CONTACTED. C
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P SPEED ONTACTS LAM ~",
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B"~A"P Sp"'e,,b..J!}OOW"'" \i.- _,
-TAIL
GL
iGHT,'ON.,. '.,
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1'0,)
FLYWHEEL MAGNETO. ~
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SPARKING r
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PLUG_
P:
EARTH
TAIL BULB.
BATTERY.
SPEEDOMETER
BULB.
HORN BUTTON.
Fig. 2
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NOTE:-It Is m"h better to mix the pet"i ..d oil in a an before pUtting It intO the g
this cannot be done. put the petrol in first and then add the oil and shake the machine
the petrol and oil are thoroughly mixed, the oil will never.sink to the bottom of the tank.
Details of lubricating oils suitable are given in the lubrication chart on page 22.
CONTROLS
(See figs. I, 2, 20 and 3)
It is advisable before starting the machine to spend some time sitting in the saddle to familiarise
yourself with the position and operation of the various controls and the" feel" of the machine.
The THROTTLE control is the twist grip on the right handlebar, and operates through cable
controls. To open the throttle turn the grip towards you.
Also on the right handlebar is the control lever for the FRONT BRAKE,which operates the
brake by cable control.
Near the right hand twist grip there is the lighting switch Incorporating cut-out (see fig. 2) and
horn push button. 13

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On the left handlebar are the CLUTCH lever
and the GEARCHANGE CONTROL, which are
fitted into the twist grip (see fig. 3). This
shows figures corresponding to the three gears,
and a line indicating neutral. On the handlebar,
at the edge of the twist grip, there is a line.
To engage 1st gear depress the clutch lever and
turn the twist grip until the number of the gear
is opposite the line. Then slowly release the
clutch lever, as described on page 18 under
.. Riding Technique."
On the right hand portion of the footplate is
situated the REAR BRAKE CONTROL PEDAL.
Accustom yourself to operating this pedal.
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fig. 3.
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1st gear.
NEUTRAL.
2nd geap.
3rd gear'.

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The p",h-pe 11leel oook I, ,',""ed In'lde the ",bncetto, oompmment. To teen the ~.. '-.":~ ,. .,
press the button in to its full extent and to turn it off, pull the button out to its full exte . .
push it forward from behind).
A small lever projects from the body of the cock just above the button. See that this lever s
always over to the left as far as it will go. Ifthe reserve fuel is required then the lever must be
moved over to the right as far as it will go.
The control for the choke is situated under and to the rear of the saddle, and consists of a rod
which on being lifted closes the choke valve of the carburettor. It is not recommended that ths
should be used unless difficulties are encountered in starting from cold.
On the right hand side of the rear part of the chassis is the footstart.
You will observe that the engine is covered by a cowling. Ifyou have occasion to examine t"e
engine, place the machine on the stand, then, with the gear control twist grip at neutral, a~d
the fuel cock closed, depress the footstart to its full extent. Keeping it depressed, release tf-e
cowling catch and raise the cowling, after which, allow the footstart to return to its norma;
posItion. When closing the-cowling, reverse the procedure.
The left hand rear wing holds the selenium rectifier and provides accommodation for the
battery, but has space also for the tool kit.
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The tool kit consists of:-
I single ended flat spanner
9m.m.
I single ended flat spanner
IOm.m.
double ended flat span-
ner I1 and 14m.m.
double ended flat span-
ner 7 and 8 m.m.
Tommy Bar.
I double ended box
spanner I1 and 14 m.m.
double ended box
spanner 21 and 22 m.m.
I Screwdriver, also,special
carburettor spanner:-
double ended flat
spanner !" Xfs-"
all contained in a canvas
tool roll. Finally, you have
a SECURITYLOCK on the
main Longeron just below
the handlebar (see fig. 4).
This enables you to lock the
machine up when necessary.

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with the handleb., In ,"th a p"'ltlon that whlbt the lock f"netlon, the maohloe j. ',. ,~- 'C
moved in a straight line. To lock the machine, turn the key in an anti-clockwise I!
then turn the handlebars to the left to their full extent and they will lock automatically.
BEFOREATTEMPTINGTORIDETHEMACHINE,MAKESURETHATIT IS UNLOCKED.
STARTING
FIRSTMAKE SURETHAT THEMACHINE ISNOT STILLON THE STAND
Ensure that the gear change control is in neutral and that the petrol is turned on.
Operate the footstart, with the twist grip throttle control slightly open.
You will find it most convenient to stand facing the right hand side of the machine, holding the
throttle twist grip in your right hand, and operating the footstart with the left foot, the whole
time steadying the machine by holding the saddle with your left hand.
Do not close the choke valve (by lifting the rod beneath the saddle) unless you have difficulty in
starting the normal way. 17

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Ifthe ",bocetto, I' floodedto ,"oh '" extent that the enginetannot be""ted, It.g
to turn off the petrol supply, remove the sparking plug and turn the engine OVE .
start several times while holding the throttle fully open. After completing this operation, cl
the sparking plug. refit it and start the engine in the normal way, but do not flood the carburet1
RIDING TECHNIQUE
To set the machine in motion, engage first gear. To do this pull the clutch lever on the
handlebar towards you to its fullest extent and turn the gear control twist grip upwards
towards you so that the line is oppositethe figure I. (Seefig.3). Now let the clutchin \
gently by gradually releasing the lever. At the same time increase the engine speed by gradl
opening the throttle, when the machine will pass smoothly into motion.
For the best results it is necessary for all movements to be carried out firmly and gradually.
N.B.- The throttle should not be opened to its fullest extent until the machine has completed 1,200 It
(See section on running-in).
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Once having satisfactorily set the machine in motion for the first time, we urge you to ."" ,. .
bOttomgm 10'" leu' ,e" m;"u'e"'0 giveyou"ell to"fide",eI"b,I'"d"g ,he ma<bi"e.'~ ..,~
attemptingto changeinto a highergear.
To develop a neat gear change technique may take you, if you are a beginner, some little time.
To change up into a higher gear, accelerate until the required speed is reached. As a guide only
to the beginner, the following speeds are suggested for changing up:-
First to second gear
Second to third gear
10 m.p.h.
20 m.p.h.
The throttle should then be closed and the gearchange twist grip turned so that the line is oppo-
site the figure 2. Now open up the throttle again.
The machine will now be in second gear. Repeat this procedure for changing Into third gear.
The suggested speeds for gear changing given above are of course only approximate and. after a
time experience will tell you the speeds at which changes should be effected.
Aboveall, try to avoid placingunduestrain on the engineduringIts first 300 miles. 19