VESPA 152 Installation guide

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152 L2 MODEL
OPERATION AND MAINTENANCE
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152 L2 MODEL
OPERATION AND MAINTENANCE
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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 isalways 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 ofcarrying out repairs when such become necessary.
DOUGLAS (SALES & SERVICE) LTD., KINGSWOOD, BRISTOL.
Telephone [phone]
DIVISION OF THE WESTINGHOUSE BRAKE AND SIGNAL COMPANY LIMITED
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Fig. I. Vespa 125,
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Fig. 2. Vespa controls.
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.
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
46.5 m.p.h.
2 persons
and 22 Ibs. of luggage
Up to 200 miles
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
Wheel base
Handlebars width
Scooter length .
Max.height
Min. height of floorboard.
Min. turning circle
Weight (with fuel) .
46.4'
25.7"
68.3"
38.7"
8'
59'
1921bs.
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.
6-

FiJ:. 4. Engine installation and suspensions.
I. Steering column and front suspension. 2. Engine.
case half, clutch side, with swinging arm. 4. Rear
sprinc with hydraulic damper.
3. Crank-
suspension

8
7
6
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. 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.
Three-waytap ("on" - "off" - "reserve").
Fuel tank
gals. and
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. Maximumjet.
6. Idlin&jet. 7. Throttle slide. 8. Idlin& adjuster. 9. Adjuster
on throttle control cable. 10.To the cylinder.
Transmission. The engine (seeFig.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 meansof kickstarter. right hand
side of scooter (see Fig. 5).
The multiple gear and. consequently, the
10 -

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.
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.
12-

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 -lights off -pilot lamp and tail lamp
on); the other one gives the two light con-
ditions of the head lamp (main and dipped
beam). The switch hasalsotwo push buttons
for cut-out and horn respectively.
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~ tIU.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.
p 8v..e c<.V 2.51-25W'
P4RK''-I<> 8vL.1f1 6v
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.
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- 14and21.22
mm); I double open-ended spanner (8, 14
mm); I single open-ended spanner (J mm);
Iscrewdriver.
These tools are contained in a canvas roll
which is placed in the left wing together with
this booklet.
OPERATION
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