How to Restore and Maintain Your Vespa

Your number one Vespa restoration resource! With plants in 15 different countries and sales numbering well into the millions worldwide, Vespa is the make among scooter marques. Return your Vespa to its original glory with this complete guide to restoring your prized scooter to 100% original. This information-packed, authentic restoration guide covers both the mechanical and cosmetic restoration of all Vespa motorscooters from 1946-1996.

Acknowledgments

7

(1)

Introduction

7

(1)

Vespa Scooters: Small Frames, Large Frames, and P-Series

8

(2)

Small Frame

Large Frame

P-Series

History of Piaggio and Motorscooters

10

(11)

Necessity, the Mother of Vespa

Small Changes

Vespa Scooters in the United States

Scooters and More

The British Scooters

The New Breed of Scooter

Vespa Models and Development

21

(14)

The Early Years: 1945--1949

Vespa Scooters Mature: 1950--1953

The Classic Scooter Arrives: 1954

Major Upgrade for the GS

Return of the 125-cc Scooter

The Model in the Middle

Getting Small

A Faster Small Frame

Bigger Displacement for a Small Frame

New Model, New Look: 1964

The Sprint and the Super

Bigger and Faster: 180 and 200 Rally

Electronic Primavera

A New Generation: 1978 P-Series

The Last Vespa Scooters in the United States

Vespa Motorscooter Care and Maintenance

35

(6)

Daily Inspection

Weekly Checks

Monthly Maintenance

Every Three Months

Adjustments and Lubricants

Filling the Glovebox: Helpful Things to Carry with You at All Times

Roadside Repair Tips

Storage

Restoring and Rebuilding

41

(5)

Rebuild or Restore?

Getting Started

The Right Look

Estimating Costs

Engine and Driveline

46

(30)

Crank Seal Inspection and Repair

Two Styles of Fuel Induction

Why Won't It Start?

The Three Basic Systems

Engine Variations

Removing the Motor

Cleaning Up

Checking the Shock Mount

Dismantling the Engine

Checking Engine Wear

Checking the Crankshaft

Inspecting and Rebuilding the Primary Drive

Rebuilding the Gearbox

Rebuilding the Shift Selector

Piston and Cylinder Rebuilds

Oil Injection Gears

Rebuilding the Clutch

Reassembling the Gearbox

Installing the Transmission Gears, Drive Axle, and Clutch

Rebuilding and Installing the Stator Plate and Flywheel

Installing the Piston and Cylinder

Final Assembly

Vespa Carburetors

76

(8)

Carburetor Location

Removing the Carburetor

Carburetor Disassembly

Carburetor Reassembly

Vespa Fuel Tank and Lubrication

84

(4)

Fuel Tank Problems

Removing the Fuel Tank

Cleaning the Fuel Tank

Reinstalling the Fuel Tank

Vespa Front End

88

(14)

Fork Removal

Front Suspension Disassembly

Reassembly of Front Fork, Brake, and Trailing Link

Suspension Reassembly

Headset, Gauges, and Controls

102

(7)

First Cast Headset

Disassembling the Headset

Headset Reassembly

Vespa Rims and Tires

109

(4)

Wheel Disassembly

Choosing Tires

Reassembling the Wheels

Vespa Trim

113

(6)

Renewing Trim

Straightening Bent Levers

Floor Strips

Finishing Trim

Legshield Trim

Reinstalling Floor Strips

Final Reassembly

Vespa Paint and Bodywork

119

(10)

Assessing Chassis Damage

Painting Methods

Preparing the Surface

Painting

Making It Shine

Vespa Electrical Systems

129

(5)

Wiring Harnesses

Electrical Problems

Vespa Performance Tuning

134

(10)

Limited Performance Parts

Carburetors

Exhaust Systems

Engine Modifications

Performance Brakes

Suspension Modifications

Vespa Accessories

144

(3)

Appendices

147

(12)

1: Vehicle Identification Numbers

2: Vespa Specifications

3: Bibliography

4: Vespa Scooter Shops

Index

159

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How to Restore and Maintain Your Vespa Motorscooter

Summary

Table of Contents

Supplemental Materials