G.S. V.S.B.I MODEL SERIES I and II (160 c.c.) SERVICE STATION MANUAL T G.S. V.S.B.I MODEL SERIES I and II (160 c.c.) SERVICE STATION MANUAL DOUGLAS (SALES & SERVICE) LTD., KINGSWOOD, BRISTOL A DIVISION OF THE WESTINGHOUSE BRAKE AND SIGNAL COMPANY LIMITED INDEX General Specification. Page 5 Assembly tolerances on: Cylinder - piston Page 43 General maintenance and lubrication Piston rings 45 instructions 9 Piston gudgeon pin 45 Con-rod-gudgeon pin 46 Gear wheel spacer washers 46 Electrical wiring diagrams 13 Overhauls: Fault finding Flywheel mag. timing test 47 Engine 15 Rectifier check 47 Electrical eqUipment 16 Gear change cable control adjustment . 51 Braking system 16 Clutch (inspection and cable adjustment) .. 51 of Controls - Steering column - Suspension 17 Crankshaft: substitution of small end bush 51 Notes on elimination of specific faults. 20 Multiple gear overhaul 54 Carburettor (description and tuning) 55 Replacement of handlebar sleeve . 56 List of tools for: Road running consumption tests 57 Normal use 21 Re-assembly: Dismantling: Engine 59 Engine 25 Engine and magneto timing 68 i Steering column 37 Steering column and chassis parts . .. 70 Chassis components 39 Instructions for re-assembly of speedometer 74 Cable harness 42 Final operations to vehicle before use. .. 74 J ~-. ,.~ VESPA G.S. VSB. I IDENTIFICATION DATA In the positions indicated on the figures 3 and 4 are the vehicle in the eyes of the law and are reproduced stamped the prefix (VSB) and production serial on all other documents relative to the vehicle. On numbers of both engine and frame. requesting spares said numbers should always be These prefixes and serial numbers serve in identifying quoted. Fig. 3-Engine identification Fig. -4-Frame identification 7 ~ , _:"-" . ." ~ ~ -' ~.~" ..::. ''; .-•• _._~ •."-.i. :"0#0 ..'~'.; "1:.': -.1. ''',.... ~ ::~:" ,~iEl i • Consumption 95 miles/Imp. gal. approx. Engine-wheel transmission ratio: Max. speed with one up 62 m.p.h. Ist Gear 14·72: I Max. speed with two up 53 m.p.h. 2nd Gear 10·28 I B.H.P. 8 at 6,500 r.p.m. 3rd Gear 7·61 I MAIN SPECIFICATIONS 4th Gear 5·84: 1 Wheel base 1,220 mm. (48") Overall handlebar width 7/0 mm. (28") Overall length 1,795 mm. (70-7") Overall height 1,045 mm. (41·2") Particular attention has been given to the design Min. footboard height 220 mm. (8·7") of the silencer and air filter in accordance with Min. turning circle 1,400 mm. (55") Ministerial requests to reduce the noise level to Total weight, dry plus spare wheel an absolute minimum. We recommend that 110 Kg. (242Ibs.) these parts are maintained in good condition. Engine Model Year Stroke Bore Capacity Mixture CarburetCor Timing Sparking Plug Prefix mm. mm. em. Dell'orto Tyre Pressure ± 1° F. R. VSB I 1962 60 S8 IS8'63 S% S127/23 26· Champion NA8 Pure mineral oil Dunlop 16 Dunlop Solo 20 KLG F.E80 Pirreli 16 Pirreli n Lodge 2 KLN Dunlop with (-:\ . '; i Speed gear box See lubricnion Pillion 32 Chart Pirreli 32 Tyro. - 3'50-10' 8 , . ~:.:-:.--- -~.~~ :~ ~ ._~: ~-.- -.~ ;..;. ..r....<;. ...:-: .:; G_ ~;....,...:.....~~ ~~-'-'=- LUBRICATION CHART Part to be lubriated Lu briation Evory 2,500 Every 5.000 'Shell ·B.P. Es.o Wakefield Mobil Shell 2T Two- Energol Two- E.sso Extr.l Castrol XL Mobiloil A See over Stroke Oil Stroke Oil Motor Oil or or 20W/30 Shell X-loo 30 Energol SAE 30 Front suspension Felt pad on fly- Control abIes wheel cam Essa Joinu on brake Gear-change Retinax A Energrease L.2. Hulti~purpose Castroleue L.M. Mobilgreilse M.P. control quadrant Grease H Speedo flexible drive Shell 2T Two~ Energol Two- Essolube 30 in Castrol XL in Mobiloil A in Stroke Oil in ratio Stroke Oil in ratio ratio of S% or ratio of 5% or ratio of S% or Engine ilt each re-fuelling of 5% or t~pint to of 5% or t~pint to 1-pint to Ii- galls. t~pint to I! galls. t~pint to It-gall•. It-gall•. petrol I t~gal1s. petrol petrol. Esso petrol. Castrol petrol or Mobil- Two~Stroke Two-Stroke Oil Mix in ratio of Motor Oil in in ratio of t·pint i-pint to It-galls. ratio of j-pint to to Ii-galls. petrol petrol It-g.II•. petrol • Marketed also by National Benzole Co. Ltd., by arrangement with B.P. & Shell·Mex Ltd. APPROVED PETROL/OIL MIXTURE Make Description Shell 2T Two·Stroke Mixture B.P. 8.P.-Zoom National Benzole Hi-Fli Co. Ltd. Hydraulic Dampers When not working efficiently, consult your . Dealer. If servicing is required, they should always be returned to the Works. 9 GENERAL INSTRUCTIONS FOR MAINTENANCE AND LUBRICATION OPERATIONS TO CARRY OUT Group Lubricant NOTES After first 600 mls. Every 2,'!OO mis, Every ",800 mis, During overhauls Gear·box Oil change (00) Oil change (..) Oil change (..) Oil change (..) Check and top up Esso Motor Oil 30 (••) Operation to be every 1,200 mls. Shell X·IOO Motor carried out with Oil2 T Shell X·IOO Motor warm engine. Oil 30 Mobiloil A Clean magnetic drain plug. Gear Selector Grease Grease Grease Esso Multi Purpose Bnke lever and Grease "H" or pedal fulcrum Gre3se 2 points - Shell RetinOlx A - Grease Gruse Front suspension - Shell Alvani... Felt. of mag. am. Grea.se 3 Mobilgreue MP Hobilgrease Special Air Filter Clean in petrol Clean in petrol Clean in pecrol and dry in air jet and dry in air jet - The filter should be and dry in air jet cleaned more regu- larly when running on dusty roads. Speedometer drive Esso Multi Purpose (00) system - Grease (00) Grease (00) Use 7S% of Control cables - Grease "H II or ESSO SAE 30 plu. Grease 2 25% Esso Multi- ~ Shell Retinax A Pu rpose Grease 2 for Shell Alvania lubricating control Grease 3 cables. Mobilgreue HP Mobilgrease Special More important bolts and nuts Check tightness - - Check tightness Sparking plug Clean, decoke and Fit new sparking - a.djust electrode pluZ - gap to 0'6 mm (0"023) - 10 ~ ,;.:,. f ...•• j.:-._- OPERATIONS TO CARRY OUT I Group Lubriunt NOTES After first 600 mls. Every 2.400 mls. Every 4.800 mls. During overhauls Q --t-------I--;---I Silencer - Clean exhaust pipe Clean exhaust pipe - (+ +) Clea.n using "' (+-'-) (- +) hooked wire or by I blowing through Engine Check carburettor Decoke piston. Decoke engine compressed a.ir from nuts -and bolts cylinder head. parts. To be the inlet end after for tightness cylinder ports re-assembled having previously a.nd external heated the unit cylinder surfaces externally. Flywheel - - Clean contact Repb,ce contact The out-let section breaker points breaker arm (if of the pipe is at leut 2nd adjust gap necessary) or 10 mm (0-"') wide, toO'-019); check clean and set timing points: check timing Main bearing Introduce 6 cc. of Esso Multi Purpose housing, flywheel greue after Grease 2 side cleaning out the Shell Alvania. housing with . Grease 3 petrol J Mobilgrease Special Bearings and area Grease Esso Multi Purpose of speedometer Grease" H .. or bearing on front Grease 2 wheel a.xle Shell Retinax A Shell Alvani;a, Grease 3 Mobilgreue MP Mobilgrease Special Battery PeriodiC2lly add distilled water (once a. month or depending on distance of runs and seuonal 1- I -:-te_m_p_e_ra_t-:-u_'_es_)_S_O_t_h:-,,_t_h_e_p_1a-:t_es_ar_e_a_l_w_.y_s_i_m_m_e_'_s_ed_, --:-::- --: 1 1 When the vehicle is to be left inactive over 3. long period carry out the following instructions: I. Cle<tn the vehicle - 2.. With engine stationary and throttle open, introduce 40 cc, Esso Motor Oil 30 (Shell X·lOO Motor Oil 2T, Shell X·IOO Motor Oil 30 or Mobiloil A); action kickstil,rter 3 or ~ times - 3. Dnin off all fuel - 4. Grease all unpainted metallic pUts - S. Disconnect battery abies. clean poles and dry - 6. Raise the vehicle wheels from the &round. II Setting the headlamp beam: A correct orientation With two persons on the Vespa, slacken the two can be obtained by adjusting the three screws which screws securing the headlamp, then move the latter secure the head lamp in its housing. Before carrying as required in order that the beam axis coincides with point" 0 .. on the wall. out this operation ensure that the tyre pressures con­ Tighten the screws firmly. form to the recommendations and then place the This operation can be carried out also with the driver scooter on a level floor in front of a white wall as seen only sitting on the saddle. in Fig. 21. Start the engine, hold the throttle control In this case, of course, the beam alignment should be twistgrip at about 1/3 and set the switch on " main altered whenever the scooter is being ridden by both beam." d river and passenger. Fig. 21-Hudlamp adjustment N.B.-The height of the point" 0 .. is c.onsunt for solo or driver and pillion passenger adjustment. 12 Vespa G. S. Mod. VSB 1 ~ L ---------$J! CONNECTIONS ON SWITCH UNIT Terminal connection 1.2: H.T. coil termin.1 _): Black - 4: Yellow - 5: Green - 6: Red - 7: White Positions 8: Pink - 9: Violet - 10: Brown - II: Sky-blue. .. Parking light on ., ~. S· I •• Light off •• Bulbs: 6V. 2S/25 W (He.dl.mp); 6V-JW (Pilot light); 6V.JW (T.il I.mp); ~.7 .. Day.time runninz: ". .. t. ~.7·1-5·8 6V-IOW (StOP light); 6V-0·6W (Speedo. lIght). oo n~ght w~th 0".. Running by pilot I!ghu ~.7;2-5-6-8 .. Running by night With head light on Battery: 6V.12Ah; Fuse: 8A; Rectifier: 6V-J·7A.