Douglas Vespa 150 Manuals

Manuals and User Guides for Douglas Vespa 150. We have 1 Douglas Vespa 150 manual available for free PDF download: Service Station Manual

Douglas Vespa 150 Service Station Manual (145 pages)

Brand: Douglas | Category: Scooter | Size: 18 MB

Introduction
5
Technical Data - Description
8
Identification Data
9
Engine
10
Engine Installation
10
Stamping on Frame and Engine
10
Engine Installation and Suspension
11
Ignition Diagram
13
Cylinder
13
Cooling System
14
Section of Engine
15
Vespa Controls
16
Frame
17
Transmission
17
Clutch
17
Gear Box
17
Stressed Skin Body
18
Electric Wiring
19
Security Lock
19
Tool Kit
20
Light and Dimmer Switch Positions
20
Cable Harness
21
Wiring Diagram
22
Accessories
23
Fitting Accessories
23
Spare Wheel and Bracket
23
Operation
24
Running-In
24
Slow Running Adjustment
24
Lubrication Chart
25
Lubrication Scheme
26
Adjustment of Headlamp
27
Setting the Headlamp
27
Tyre Pressure
28
Battery Service
28
Brake Adjustment
28
Laying up
29
Tyre Pressure Chart
29
Tooling
30
Dismantling
38
Removing Engine from Scooter
40
Dismantling the Engine
42
Dismantling Front Part of Scooter
54
Dismantling the Handlebars
55
Removal of Steering Column
56
Dismantling the Steering Column
57
Dismantling Steering Column and Front Suspension
58
Dismantling Front Wheel Hub
59
Removal of Saddle, Luggage Carrier, Tool Box, Battery
60
Removal of Engine Cowling, Tank, Rear Suspension
61
Dismantling the Fuel Tap
62
Removal of Security Lock
62
Removal of Central Stand and Tail Lamp
63
Removal of Rear Brake Pedal
63
Removal of Cable Harness and Control Cables
64
Permissible Tolerances - Unit Overhaul
65
Fault Finding
65
Assembly Tolerances
67
Piston Rings
67
Piston and Gudgeon Pin
68
Con. Rod - Needle Cage - Gudgeon Pin
68
Cylinder and Piston
69
Shoulder Rings
70
Overhauls - Special Assemblies
71
Flywheel Magneto Overhaul
71
Replacing the Cam
71
Re-Magnetising the Rotor
72
Stator Overhaul
73
Rotor Balance Inspection
73
Magnetiser
74
Flywheel Magneto Test Stand
75
Replacing the Coils on the Stator
75
Test Preliminaries
78
Timing Test
79
Timing the Stator
79
Test at Minimum Revs
81
Efficiency Test
81
Checking Current Intensity and Voltage
81
Overspeed Test
82
Timing of Flywheel Magneto with no Test Stand
82
Rectifier Inspection
83
Inspection of Rectifier
84
Replacing the Plates
85
Checking Total Axial Play of Clutch Plates
85
Checking the Transmissible Statical Moment
86
Control Adjustment
86
Gear Shifter
87
Replacement of Internal Operating Lever
87
Cush Gear
88
Replacement of Pawl on Gear Sector of Starter Assembly
88
Components for Attachment of Engine to Frame
88
Dismantling the Cush Gear
89
Assembling Rubber Bushes
91
Engine Test on Stand
93
Description of the Stand
93
Adjustment of Test Propeller
95
Fuel Consumption Test on the Stand
96
Normal Test
96
Replacement of Handlebars Sleeve
98
Replacement of Piaggio Medallion
100
Replacing Twistgrips, Beading of Engine Bonnet, Rubber Mat
100
Steering Column Inspection
101
Alignment of Frame
101
Painting
101
Jig or Frame Inspection
102
Replacement of Shield Protector
103
Fuel Consumption Test on Road
105
Premise
105
Preparing the Scooter
106
Road Test
106
Calculating Fuel Consumption
106
Fault Finding and Remedies
108
Hard Starting
108
Incorrect Running
110
Re-Assembly
118
Notice
119
Mainshaft Ball Bearing
120
Starter Assembly
123
Assembly of Starter Unit
127
Joining the Crankcase Halves
128
Timing the Engine
129
Assembly of Steering Column
130
Assembly of Handlebars and Saddle
132
Assembly of Speedometer
133
Before Starting Operation of the Scooter
134
Alphabetical Index
135
General Index
141

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Douglas Vespa 150 Service Station Manual (145 pages)

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