VESPA 232 L.2 Operation And Maintenance

:I;-e'appointment

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

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

VESPAspare parts exclusively.AllVESPAsparesare madeof the same

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.

INDEX OF MAIN DIRECTIONS

Introd uction

page

5

Electric wiring

page 14

Technical data

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6

Tool Kit

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17

Identification data

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6

Operation

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18

Description: engine

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8 Maintenance .

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24

controls

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12

Lubrication chart

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28

frame

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13

Fault finding

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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, "

m ''mori''''." "' ',m', ,,~.,., Do.,w"~ _ m",.""m ..:..:

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 youfor 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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6-

TECHN

Fig. 2 - Stamping on frame (I)

Fig. 3 - Stamping on engine (2)

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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.

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

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

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

Fig. 5 - Ignition diagram

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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 (7.53cu. 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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A

Fig. 6 - Feeding circuit.

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

Air cleaner with carburettor

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

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. Plug for Inlet hole for oil; for laying u

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

-D

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: KLGF.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 :...

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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..

o 0.3 imp. gals).

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

and

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).

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 bylaw.

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 dip switch _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".

Dual Seat of very pleasing appearance in a

range of colours.

Expanding type with cable con-

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

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

ridden. . ,jJ.

Speedometer. The speedometer is housed

in the central portion of the handlebars,

and adds to the performance and appearance

of the scooter.

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

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plate. The light and dip switch unit with ,.

.

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levers is installed on the right hand : '/J' ~

of the handlebars (see Fig. 11) ; one

the control levers has three positions:

- 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.

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DOUBLE F .

ILAMeN I ........

6r~25w

~R~

flYWHEEL MAGI£TO

No~Al:TEI?NA1QR COIL

NoJAtJERNIIiIt:"COIL

Bo\TTERI' 084932M

RfCI1FER Q:J£!;53I.I

TAILU'MP BU..B 0I1907M

!olOPLlGHT EU.B OB3416M

WIRING HARNE!o!o095129M

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.

11 - Electric wiring dIagram

POSITION O.

POSITION I.

"" STOP LGiT & S'IOP LIGHTSWlltH OPTIONAL

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Fig.

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.

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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 foeItsmaintenance. The,,,h "'" ~ 3'

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

OPERATION

FUEL to be used during and after running-

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

or

* pint oil per It gallons petrol respec-

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.

- 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

18-

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a

.

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

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

enginel

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

the kickstarter and turn grip

..D" opening throttle gradually.

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VESPA 232 L.2 Operation And Maintenance

VESPA 232 L.2 Operation And Maintenance

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