rally 200 owners manual 2.sxw
Contents
1. 1 4 71 Starting see Fig 6 by means of a kickstarter Cooling by means of a certrifugal fan Fig 21 Installation of engine and suspension 1 Steering column and front suspension 2 Engine 3 Crankcase clutch side with swinging arm pivoted to frame 4 Rear suspension spring and hydraulic damper assy FRAME INTEGRAL CHASSIS see fig 1 of pressed sheet steel with streamlined monocoque type structure It is completed for protective means by lateral cowl and mudguard Handlebars Light alloy casting comprising speedometer and headlamp diameter 130 All transmission cables and various controls are concealed therein It is arranged for easy fitting of a windscreen accessory Steering column suspension On the lower end of the steering column is pivoted the front wheel swinging hub Front and rear suspensions with helical spring and double acting hydraulic damper Dual saddle Security lock on the steering column Wheels Interchangeable and made up of 2 10 pressed steel flanges onto which are mounted 3 50 10 Brakes Mechanical expanding type Front brake is operated by hand the rear brake is pedal operated Controls clutch gear box throttle front and rear brake choke provided with flexible and adjustable control cables STANDARD TOOL KIT contained in the front tool box four ended box wrench 11 13 21 22 mm and two double open ended wrench 11 13 and 7 10 mm one single open end2. a soft cloth dipped in oil or turpentine More persistent marks can he removed with a solution of warm water and car shampoo Carry out this procedure periodically to eliminate permanent paintwork damage Polishing If after washing as previously described the original condition is not restored apply evenly a thin coat of good quality wax polish and shine with a soft cloth rubbing gently in a side to side manner FAULT FINDING When the machine does not run properly inspect and rectify as explained below If the suggested remedies are not sufficient in eliminating the trouble consult your Dealer Fault finding 1 Fuel system Carburation Ignition Lack of fuel Filter jets fuel tap carburettor body clogged or dirty Engine flooding Air cleaner chocked or dirty Porcelain of sparking plug cracked Generator device faulty 2 Lack of power Silencer or engine choked Sparking plug loose in the cylinder head Cylinder head loose 3 High fuel consumption a Air filter chocked or dirty or choke control incorrectly set b Other causes carburettor lack in compression etc 4 Noisy engine Defective suspesion Mechanical failures 5 Defective electrical equipment Wire terminals disconnected or carelessly connected Headlamp beam incorrectly set Defective bulbs Remedies Turn to reserve and refil as soon as possible Remove wash in petrol and blow dry See pa
3. hood from engine A and head B OPERATING AND MAINTENANCE Common operations to carry out Operation TIMING CHECKING AND SETTING Instructions Since in this type of ignition there are not as we have said at page 6 mechanical parts exposed to the wear the timing remains during the time practically unalterable Anyway when irregularities of functioning occur remove the flywheel rotor acting on the locking nut lt D gt Fig 17 on the Fig 18 the rotor is already removed and check that the interference between the ignition control cam B and the pick up lt C gt is 0 25 0 30 mm on the position of max radius see Fig 18 If the suggested remedies are not sufficient in eliminating the trouble and specific controls and timing are necessary consult your Dealer OPERATING AND MAINTENANCE Common operations to carry out Operation Instructions SETTING THE HEADLAMP The correct setting of the main beam can be obtained both horizontally and vertically as follows Check that both front and rear tires are inflated to correct pressure i e 1 2 and 2 5 Kg cm2 15 5 and 35 5 p s i Place the scooter on a level floor in front of a white wall as seen in Fig 19 Start the engine hold the throttle control twist grip at about 1 3 and set the switch on lt main beam gt With two persons on the Vespa slacken the screws securing the headlamp then move the latter as required in order that the beam axis coincide
4. OPERATION AND MAINTENANCE Allstyles Scooters 02392 655565 VESPA RALLY 200 A ruaa FT D D O O a r es Fig 1 Vespa Rally 200 CONTENTS Performance and specifications Page Layout of controls Operating instructions Oil to be used of the fuel mixture Running in Tire pressure Operating and maintenance Common operations to cart Maintenance Summary of Instructions for Maintenance Fault finding General specification Accessories Electrical equipment Identification data 11 25 26 28 29 32 31 32 34 35 PERFORMANCE AND SPECIFICATIONS Consumption according to CUNA Standards Max speed CUNA Standards Carrying capacity Range Max fuel capacity Wheel base Handlebar width Total length Max height Min ground clearance Turning radius Total dry weight ENGINE Bore Stroke Cylinder displacement Compression ratio 3 It 100 Km 78 mls U S gals 94 mis imp gals gasoline oil mixture i e 2 oil 110 Km h 68 mph 2 persons and 10 Kg 22 lbs of luggage 280 Km 174 mls 8 2 It 2 13 U S galls or 1 8 imp galls incl 1 8 It s 0 47 U S galls or 0 39 imp galls of reserve 1230 mm 48 4 690 mm 27 6 1770 mm 69 6 1070 mm 42 1 130 mm 5 2 1400 mm 55 0 103 Kg 226 5 Ibs single horizontal cylinder two stroke rotary distribution i e carburated mixture is regulated by the crankshaft rotation wit
5. con 3 Shell Retinax A Mobilgrea se MP Total Multis For operations 2 3 4 5 6 Fig 20 Lubrication scheme Notice 2nd detail L H lt S gt indicates the oil draining hole from engine LAYING UP We recommend that the following operations be carried out 1 Clean down the vehicle 2 With the engine stationary and throttle fully opened introduce 40 cc of oil SAE 30 through the appropriate hole in the air cleaner case see page 21 After said operation depress the kickstarter three or four times 3 Drain off all fuel contained in the fuel tank then grease over all unpainted metallic parts next raise the wheel off the ground by placing wooden checks under the footrest 1 2 CLEANING THE VEHICLE Engine For cleaning the exposed surface of the engine use paraffin a brush and clean rags Bodywork Washing Painted parts should be washed down using a low pressure hose Do not use a high pressure system as grit may be forced into the paint When the dirt and grime becomes soft sponge off using one of the lt car type gt shampoos available use a product of the type Rolene and Teepol which are employed in aqueous solution 3 5 by weight First lightly wash the painted surface of the scooter in order to avoid scratching Thoroughly rinse with plenty of water Dry off using a clean chamois leather to eliminate water marks Spots To remove spots caused by tar grease insects etc rub gently with
6. ed wrench 8 mm one screwdriver Accessories A full range of accessories can be supplied and fitted by your dealer A six pole magneto nominal voltage 6 V supplies alternating current to the electrical equipment The controls switching levers horn button are located on the handlebars R H into the main light and dip switch Fig 22 The engine cut out button is located on the frame under the hook for bag see Fig 2 This equipment consists of the following lighting and signaling devices The headlamp Diameter 130 has a 25 25 W bulb main and dipped beam and a 5 W bulb pilot light and front parking light The rear lamp With red reflector is provided with a 5 W bulb red pilot light and light for registration plate and a 10 W bulb Stop light Speedometer light And checking light for headlamp are both 6 V 0 6 bulbs Horn Fig 22 Light and dip switch Switching lever 0 lights off 1 pilot light and tail lamp on 2 head light front parking light and tail lamp on A Switch dipped and main beam B Horn button Notice For the Engine cut out button see Fig 2 on page 7 LOACATION OF ELECTRICAL EQUIPMENT Notice The connector lt A gt for connection of the flywheel cable with the electronic control box is provided with colored reference points which correspond to the cables ete aio arraso Fig 23 Installation of electrical equipment Notice For avoiding damages to the electron
7. ering lock a Locking the handlebars b Unlocking the handlebars NOTES Instructions To lock the vehicle turn the handlebars anticlockwise up to the limit stop rotate the key anticlockwise and push inwards So that it thrusts the sliding bar against the steering column see fig 3 To ease the insertion of the sliding bar into the hole of the steering column slightly turn the handlebars from the limit stop clockwise When the handlebars are locked the key will now spring back to its original position and can then be withdrawn To release the handlebars insert the key in the lock turn it to the left and pull it back then turn the handlebars in the normal position The vehicle is provided with two security locks the one relates to the steering column and the other one for locking the front tool box Both operated by the same key The key can be extracted from the lock even if the handlebars are free The security locks should not be lubricated eventually use colloidal graphite 2 Front tool box lock BEFORE OPERATING THE VEHICLE To open the flap door of the front box insert the key in the lock and turn it fully anticlockwise then slide down the external plaque of the lock fig 4 In order to close it close the flap door until the lock clicks against the tool box then turn the key clockwise and withdraw Unscrew the plug on the gear box marked OLIO fig 16 and check that the oil is on a level with the ho
8. ge 17 See page 21 Check the spark plug or change Disconnect the plug lead Check if sparking occurs between lead and crankcase when the kickstarter is operated Consult your Dealer for eventual repairs Clean see page 31 Screw down with a wrench Set head accurately and tighten nuts Wash in neat petrol gas air blast dry heck choke control mechanism and lubricate Consult your Dealer Consult your Dealer Carefully check and connect Adjust see page 29 See page 25 for substituting GENERAL SPECIFICATIONS Engine see characteristics at pag 5 and fig 5 the engine is pivoted to the chassis of the vehicle fig 21 The rear wheel if fitted on the outer side of the drive shaft Lubrication of engine components piston cylinder crankshaft main bearings is effected by the oil in the fuel mixture Clutch and gear box function in an oil bath Fuel supply see Fig 9 gravity feed with mixture of oil and petrol gasoline Three way tap lt closed gt lt open gt lt reserve gt Carburettor provided with a throttle slide and built into the air cleaner case Ignition by means of an electronic device with a built in H T coil connected to the three flywheel outputs Clutch see fig 5 multiplate Control lever on the handlebars L H and flexible and adjustable control cable Transmission ratio engine to driving wheels Bottom gear 1 13 42 2nd gear 1 9 13 3rd gear 1 6 32 4th gear
9. h three transfer ports 66 5 mm 2 62 57 mm 2 24 197 97 cc 12 076 cu in 1 8 2 IGNITION by means of an electronic device that offers many advantages i e allowing to produce a higher tension peak reached in a very short time and with a very limited length of the discharge tfollows 1 Engine regular running also with spark plugs very dirty 2 Starting facility when cold 3 Light ignition and combustion of thefuel 4 Higher life of the spark plugs because of a smaller electrodes wear 5 Unalterability during the time of the ignition advance because the traditional mechanical devices exposed to the wear as the contact breaker cam contact breaker sliding block etc are not longer present Sparking plug types Marelli CW 7 LTP Champion N 88 Bosch W 240 T 2 K L G FE 80 Lodge 2 H LH Spark advance 24 before TDC 1 Gear change twist grip and clutch control lever 2 Front brake lever 3 Throttle twist grip 4 Main switch unit with horn button 5 Front brake shoes 6 Rear brake pedal 7 Kick starter 8 Gear selector 9 Rear brake shoes 10 Clutch 11 Carburettor and air cleaner 12 Choke control 13 Fuel cock 14 Button for tipping up the saddle 15 Fuel tank cap M Engine cut out Note In order to gain access to the fuel tank push on the but n No 14 and release the saddle then swivel it upwards OPERATING INSTRUCTIONS Operation SECURITY LOCK 1 Ste
10. ic control box not disconnect the cables of the low tension socket when the engine is running Giallo Yellow Nero Black Azzurro Sky blue Verde Green Ross Red Blu Blue Grigio Grey Viola Violet Marrone Brown Bianco White WIRING DIAGRAM Speedometer Headlight Bulb light 6V 25W 6V 0 6W Y Pilot light 6V O 6W Brake light 6V 10W Hondlebar Switch 6 Brake switch Fig 24 Wiring diagram NOTICE The loads on the bulbs and horn are connected in series with respect to the flywheel magneto coils whereas the switch units are in parallel to the bulbs the insertion of the lights and horn comes about by opening instead of closing the relative control switches IDENTIFICATION DATA Fig 25 Serial number stamped on frame VSE 1 TXXXXXX and on engine VSE I MXXXXXxX Notice These numbers should be quoted when ordering spare parts PLEASE NOTE SOME INFORMATION MAY VARY AS IT HAS COME FROM GENUINE EDITED LAMBRETTA amp VESPA BOOKS ARCHIVE ETC Allstyles Scooters
11. ine Section OPERATING INSTRUCTIONS Operation STARTING SETTING THE SCOOTER IN MOTION GEAR CHANGE STOPPING THE ENGINE NOTES Instructions Carry out the operations indicated on fig 6 Do not use the choke when the engine is warm as soon as the engine is running smoothly bring the starter control back to its normal position With the engine running at idling speed declutch and rotate the gear change twist grip to the position of first gear fig 6 For setting the vehicle in motion slowly let in the clutch and gradually open the throttle Close the throttle declutch and rotate the gear change grip to a higher or lower gear as the case may be fig 6 Before stopping the engine change to lt neutral gt and then switch off the ignition Fig 2 In case of hard starting see page 17 When it is necessary to decelerate do not hesitate in changing down A Open the fuel tap B Selector in neutral C Pull out the starter control with cold engine D Bring throttle twist grip to idling position E Operate kick starter Na 4 gt 7 l l OPERATING AND MAINTENANCE Common operations to carry out REMOVAL OF ENGINE COWLING Pull the lever 1 and turn to release from cowling Swing the cowling outwards so that the front locating pin 2 is free of its housing Lift the cowling upwards from the front pivoting on its rear section so that the clasp 3 relea
12. irst deflate and then remove the nuts joining the two wheel rim fig 11 Dismantle the spare wheel cowl following the instructions given for engine cowl see pag 15 To release the wheel unscrew the bolt securing it to the lower section of the protective plate then the two nuts securing the wheel to the upper part Fig 12 of the bracket The front and rear wheel are interchangeable o n e with another providing that the tire pressures are regulated accordingly page 11 Fig 15 Dismantling spark plug OPERATING AND MAINTENANCE Common operations to carry out Operation BRAKE ADJUSTMENT DISMANTLING AIR FILTER NOTES Instructions Rotate the adjusting screw indicated in fig 13 so that the wheel is completely free to rotate when the lever and brake pedal are in the resting position The braking action should commence immediately the respective controls are operated For extracting the air filter A fig 14 from the air filter case remove the engine cowl fig 7 and air cleaner case cap Unscrew the two screws B securing the air filter and extract the latter component The air cleaner case cap can be extracted by dismantling the two securing screws Fig 11 Tire removal Fig 10 Removing wheel from vehicle OPERATING AND MAINTENANCE Common operations to carry out Fig 12 Dismantling the spare wheel Operation Instructions SPARK PLUG REMOVAL Remove engine cowl Fig 7 disconnec
13. le when the vehicle is standing upright OPERATING INSTRUCTIONS Fig 3 Steering lock on the steering column Fig 4 Front tool box lock 1 Normal position and locking operation 2 locked position and unlocking operation N B The arrow indicates the operation to be carries out for unlocking 1 and for locking 2 the tool box OPERATING INSTRUCTIONS Operation Instructions FUEL SUPPLY Use a mixture of gasoline petrol and pure mineral Oil SAE 30 at 2 Esso 2 T Motor Oil Shell Golden Motor Oil Shell X 100 2 T Total 2 T The mixture should be at 2 of oil by volume 4 pint of oil to 1 2 gals of gasoline petrol For access to fuel tank pivot the saddle on its forward edge after having released the rear attachment as shown at fig 2 NOTES Ensure that the fuel tank breather Is always clean Use a mixture 2 by volume during and after running in For running in first 2000 Km 1200 mls do not maintain the throttle fully open for long periods After first 1000 Km 600 mls change oil in gear box page 23 and check that all nuts and bolts are tight Check tire pressure Front 1 2 Kg cm 17 Ibs sq in Rear 1 75 Kg cm 25 Ibs sq in with one up Rear 2 5 Kg cm 35 Ibs sq in with two up 1 Group carburettor air cleaner 2 Piston 3 Crankshaft 4 Clutch 5 Drive shaft and gear pinions assy 6 Gear shifter 7 Flywheel magneto 8 Kick starter Fig 5 Eng
14. s with point lt gt on the wall Tighten the screws firmly NOTES Do not wipe down with a cloth or contact with finger the reflector This operation can be carried out also with the driver only sitting on the machine In this case of course the beam alignement should be altered whenever the scooter is beeing riden by both driver and passenger Fig 19 Setting the headlamp N B The point lt gt is valid for setting with one or two persons mounted Note m 5 16 FT approx m 0 95 0 97 3 FT approx MAINTENANCE Though the electronic ignition provides a regular running of the engine also when the spark plug is dirty or the electrodes setting is not correct when difficulties of ignition occur check the spark plug clean in neat gasoline petrol and wire brush or emery cloth the electrodes adjust the gap 0 6 mm 0 023 Check porcelain insulation if cracked or broken change plug It is advisable not to change the type of spark plug as recommended by the manufacturer Every 4000 Km 2400 mls 1 Check oil level in gear box Fig 16 2 De coke the engine cylinder head piston crown and cylinder ports see at page 25 Ensure that not residual carbon deposits remain inside the cylinder Clean the exhaust pipe using a hooked steel wire 3 Grease front hub through the appropriate nipples and lubricate the speedometer drive and transmission the brake lever and gear selector 4 Remove the air filter
15. see page 21 clean by agitating in an oil gasoline petrol bath and if possible air blast dry Every 8000 Km 4800 mls 1 Change oil in gear box see page 23 The oil should be changed also after the first 1000 Km 2 Lubricate control cables transmissions and felt lubricating pad on flywheel Consult your Service Station 3 If the engine runs irregularly or in any case the performances are reduced consult your Service Station SUMMARY OF INSTRUCTIONS FOR MAINTENANCE AND LUBRICATION PRINCIPAL OPERATIONS TO CARRY OUT EVERY 4000 Km 2400 mls Gear box top up Fulcrum points of brake lever and pedal Gear selector Front suspension Speedometer drive and transmission Cleaning air filter in gasoline petrol Decoking cylinder head and piston Cleaning and adjusting sparking plug electrodes Decoking silencer Engine At each refilling lubricated by oil in mixture Front and rear dampers only if defective EVERY 8000 4800 mls Gear box change oil Greasing control cables LUBRICANTS Oil SAE 30 Shell Retinax A Esso Beacon 3 Mobilgrease MP Total Multis 2 by volume pure mi neral Oil SAE 30 Esso Univis J 43 Shell Tellus Oil 13 Mobilfluid 62 Consult your Service Station e g Esso 2 T Motor Oil Shell Golden Motor Oil Shell X 100 2T Total 2T Esso Motor Oil 30 Esso 2 T Motor Oil Shell Golden Motor Oil Shell X 100 2 T Total 2 T For operation 1 I Esso Bea
16. ses from the chassis bracket Pull the cowling outwards on the locating pin 4 so that the latter clears its housing thus releasing the cowling For reassembly carry out the reverse procedure Fig 7 Removing engine cowling 1 Lever for locking cowling 2 Front locating pin 3 Clasp securing cowling to chassis 4 Rear hooked pivot pin Fig 8 Gear Transmission 1 Gear change twist grip 2 Clutch control lever 3 Gear change cable 4 Gear shifter 5 Selector stem 6 Selector spider 7 1st gear 8 2nd gear 9 3rd gear 10 Top gear 11 Mainshaft 12 Spring gear 13 Clutch N B The position 1 2 3 4onthe gear change twist grip correspond to bottom 2nd 3rd and top gear respectively the 0 indicates neutral OPERATING AND MAINTENANCE Common operations to carry out ADJUSTMENT ON CARBURETTOR For adjusting the idling turn the slow running adjuster screw on the air cleaner cover Fig 9 n 5 On the carburettor body a set screw is provided for adjusting the throttle cable play this screw is to be reset only if necessary or on dismantling and reassembly operations On the air cleaner case opposite to said screw is a plugged hole When this plug is removed the spring loaded idler adjusting screw is accessible Fig 9 n 14 To avoid carburations troubles we recommend that this adjustment is carried out by a Vespa dealer STARTING UP when the engine is flooded In
17. t the H T lead and extract the spark plug using the box wrench as indicated in Fig 15 CHANGING OIL IN GEAR CASE Drain off through hole Fig 16 Clean carefully the plug of said hole Introduce a small quantity of flushing oil run the engine a few minutes to ensure thorough circulation and cleaning and drain off again Afterwards refill gear case with about 250 grs of new oil up to level of filling hole NOTES On reassembling the spark plug ensure that it is fitted into the threaded hole at the correct inclination This operation of changing oil should be carried out with warm engine Fig 13 2 Front and rear brake adjustment Fig 14 Dismantling the air cleaner Note If the air cleaner case is taken off it is also possible to gain access to the carburettor OPERATING AND MAINTENANCE Common operations to carry out Operation Instructions DISMANTLING CYLINDER HEAD Strip off engine cowling Fig 7 disconnect the H T lead dismantle the lt Cooling hood gt fastenings lt A gt lt B gt lt C gt fig 17 and unscrew the four securing nuts by means of a box wrench SUBSTITUTING BULBS Should one of the bulbs fail before fitting a replacement check that the socket contact points and the general funtioning of the electrical plant are efficient NOTES For dismantling the cleaner see at page 21 Fig 16 Oil filter hole 1 oil draining hole 2 17 A Fig 17 Dismantling cooling
18. the case of difficulties caused by flooding presence of unvaporised mixture in the cylinder the following methods can be used Attempt push starting engage the 2nd gear declutch push the vehicle to a certain speed sharply release the clutch and when the engine fires declutch immediately Close the fuel tap remove the sparking plug page 23 and clean then kick over the engine several times Screw in the sparking plug securely open the fuel tap and start the engine Cea NA gs pe O D Nn Fig 9 Fuel supply and distribution diagram 1 Combined fuel tap and sediment bowl A Reserve B Open C closed 2 Float 3 Carburettor and air cleaner 3 1 Air filter 4 Calibrator for starter 5 Throttle slide set screw 6 Throttle slide 7 Main jet air calibrator 8 Air calibrator on mixer 9 Mixer 10 Main jet 11 Slow running jet 12 Slow running jet air calibrator 13 Oil filler plug 14 Slow running adjuster screw 15 Starter valve 16 Inlet port 17 Transfer ports one of the ducts is schematically illustrated 18 Exhaust port OPERATING AND MAINTENANCE Common operations to carry out Operation CHANGING WHEELS AND TIRES DISMANTLING THE SPARE WHEEL INSTRUCTIONS NOTES Instructions For dismantling the wheels from the vehicle remove the nuts as indicated in fig 10 On reassembly tighten said screws alternately and progressively When a tire has to be removed f
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