DIY Network

Vespa Finale: Mount Turn Signals and Install Headset From "Classic Rides" episode DCLR-113

	Host Kevin Tetz and Greg West, a Vespa restoration expert, have the '74 Vespa Sprint Veloce scooter back on two wheels ready to finish the project.
	Figure A

The '74 Vespa Sprint Veloce project scooter was been stripped down in the first episode, and in the last episode ("Engine Modification and Shock and Brake Replacement" Episode -- DCLR-112) the scooter's engine was modified along with the shock and brake replacement, and now the end of the project is near.

Host Kevin Tetz and guest Greg West, a Vespa restoration expert, finish the project this episode, and in this first segment they mount the turn signals and pull the wires and install the headset.

Installing the Signal Lights

• To begin mount the gasket to the back of the signal light. The gasket acts as a nice cushion between the light and headset.

• Thread the wire getting the blinker light lined up onto the scooter headseat.

• Attach the ground wire to the bolt that holds the signal light assembly to the headset (figure A). The other wire from the signal light goes to the turn signal switch.

  Note: There are several points on Vespas where there needs to be metal-on-metal contact with the body panels because you don't want any weak links in the ground system -- and troubled lights can usually be traced to a ground problem.

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	Figure B
	Figure C
	Figure D
	Figure E

• Tighten the signal light bolt to the headset. Repeat the same process with the other signal light. Mount the lights and attach the ground wires.

• Now it's time for the tubes and hand controls. Apply a bead of white lithium grease to the shifting tube and work it onto the headset. Repeat the same process and install the throttle tube (figure B).

• The next thing you need to do is to put the ends back into the tube to hold them in place, and this is what actually actuates the cables inside the scooter.

• The left end is the gear selector side. It has two spots (figure C) that hold the cables and activates the gears.

• Insert the cable guide into the shifting tube through the headset opening.

• Next, install the spring clip alignment, locking the tube in place.

• Repeat the same process on the throttle side and install the cable guide for the throttle.

• Tighten the mounting screw, which holds the switch assembly to the headset. Snap on the chrome cover and then you can start working on wiring the signal light switch.

• Attach the wire to the turn signal harness (figure D), and feed the harness through the tube while pulling on the wire.

• With the wires out, install the gasket for the turn signal switch.

  Note: For the project scooter there is an "A" and "B" marked on the switch, which matches up with the schematic and the wire color match up. For the turn signal there are three wires that need to be hooked up. According to the schematic, the brown wire, which is one of the turn signal wires, is connected to the A terminal. The other turn signal wire, the blue one, is hooked up to the B terminal. Connect the white wire, the power wire, and tighten it down. While working on the scooter's electrical make sure to reference each appropriate wire with the schematic to avoid any faulty connection.

• Place the metal turn signal cover over the unit and fasten down the screws.

• Using needle-nose pliers, maneuver the wiring harness into the headset. These wires are for the ignition switch and the signal lights.

• Next, run the control cables up into the headset. Feed the last cables through and slide the headset onto the scooter.

• On the front of the headset, place the nut up against the headset bolt opening (figure E). Tap the bolt through the opening and tighten it down. Snug it up and allow proper play to maneuver the headset.

In the next segment the wiring will be completed and the brakes will be hooked up.

RESOURCES :

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Vespa Restoration Parts (Scomo)
Scomo
Website: www.scomo.net

Air Compressor (Bend-Pak)
Bend-Pak, Inc.
Website: www.bendpak.com

Stock Photos, Videos, CD Rom and Timesurfer (Piaggio)
Piaggio, USA, Inc.
Website: www.piaggio.com/

GUESTS :

Greg West
Scooter Restoration Expert
E-mail: wheelsX2@yahoo.com