Sylvie Willis
Removing the fuel tank from a Vespa is a fairly straightforward process, but it can be intimidating for those unfamiliar with the procedure. It is important to gather all the necessary parts before beginning and ensure that any replacement fuel lines are the exact right size. The first step is to remove the seat by taking out the three bolts that hold it in place. Next, the two rear tank bolts need to be removed, followed by the carb airbox top and the air filter, providing access to the carburetor. With the carburetor exposed, the fuel banjo can be removed, allowing for the removal of the fuel hose clamp and the banjo itself. At this stage, the fuel tank can be lifted out, although some manoeuvring may be required for larger tanks.
Removing Vespa Fuel Tank
| Characteristics | Values |
|---|---|
| First Step | Remove the engine |
| Next Steps | Remove the seat by unscrewing the three seat bolts |
| Remove the two rear tank bolts | |
| Remove the carb airbox top, then the air filter, to access the carburator | |
| Remove the bolt holding the fuel banjo | |
| Remove the carb air bellows | |
| Remove the fuel hose clamp, then the banjo | |
| Remove the fuel lever frame grommet | |
| Turn the fuel lever to the middle position and remove the fuel tank by pulling up on the back of the tank | |
| Reinstallation | Attach a string to the end of the fuel rod and feed the free end through the hole in the frame |
| Gently put the tank back into place and reinstall the frame grommets | |
| Feed the fuel line through the hole in the bottom of the airbox | |
| Pull the line to create some slack, then heat the end with a heat gun | |
| Install the hose clamp and carb banjo onto the fuel line | |
| Reinstall the banjo to the carb |
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What You'll Learn
Remove the engine
Removing the engine of a Vespa is a complex task and should not be attempted by a novice. If you are confident in your abilities, the first step is to gather all the parts you will need and ensure you have the correct tools.
Next, you will need to remove the seat by unscrewing the three bolts holding it in place. This will give you access to the fuel tank. If you are only replacing the fuel line, you will only need to pull the tank up slightly to access the fuel tap. If you are also working on the oil tank, pull the tank further up. It is helpful to have an assistant hold the tank while you work.
Once you have access to the fuel tap, remove the old clamp and line. Attach the new clamp to your new line, and fix it to the end of the fuel tap. Feed the new line through the frame to the carb, ensuring it is the correct length. Too short, and it won't reach; too long, and it will kink and block the fuel flow. Loop the fuel line under the fuel control rod and up through the frame hole.
With the tank still out, attach a string to the end of the fuel rod to guide it back through the hole in the frame when you replace the tank. Reinstall the tank and the frame grommets for the fuel control rod and oil tank sight glass. Feed the fuel line through the hole in the bottom of the airbox and pull it through to create some slack. Install the hose clamp and the carb banjo onto the fuel line, and reattach the banjo to the carb.
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Take off the seat
To take off the seat, you will need to remove the three bolts that are holding it in place. This will give you access to the fuel tank. With the seat removed, you can now start working on removing the fuel tank.
Firstly, remove the two rear tank bolts. Then, remove the carb airbox top, followed by the air filter. This will give you access to the carburetor. On the carb, you will find a bolt that holds the fuel banjo in place. Remove this bolt, and then take off the carb air bellows. With these steps completed, you can now loosen and remove the fuel banjo. If the banjo is difficult to remove, you may need to cut the fuel line with a razor.
Now, remove the fuel hose clamp and then take out the banjo itself. The next step is to remove the fuel lever frame grommet. To do this, turn the fuel lever to the middle position to get it through the frame. At this point, you are ready to remove the fuel tank. Pull up on the back of the tank to remove it. If you are working with a Rally Vespa, keep in mind that its tanks are larger than most, so you may need to use a bit more force to get it out.
It is helpful to have an extra pair of hands during this process. Ask a friend to help hold the tank while you work on removing it. If you are working alone, use a towel to protect the frame from getting scraped by the tank.
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Remove rear tank bolts
Removing the rear tank bolts is a crucial step in accessing and working on the fuel system of your Vespa. Here is a detailed guide to help you through the process:
Locate the Rear Tank Bolts: Begin by identifying the rear tank bolts, which are typically located at the back of the fuel tank. These bolts secure the fuel tank in place, and removing them will allow you to lift and remove the tank.
Gather the Necessary Tools: Make sure you have the appropriate tools to remove the bolts. You will likely need a suitable socket wrench or a screwdriver, depending on the type of bolts on your Vespa. Having a tray or container to place the bolts in once removed is also helpful.
Prepare the Work Area: Before starting, it is essential to ensure your safety and protect your work area. Place your Vespa on a flat, stable surface and engage the parking brake to prevent any unintended movement. If there is fuel in the tank, drain it or remove the fuel line to avoid spills.
Remove the Rear Tank Bolts: Using your chosen tool, carefully loosen and remove the rear tank bolts. Some Vespa models may have two rear tank bolts, while others may have more. Take note of their location and keep them organized, as you will need to reinstall them securely later.
Access the Fuel System: With the rear tank bolts removed, you can now lift the back of the fuel tank slightly to access the fuel system. Depending on the work you plan to perform, you may need to lift the tank further or remove it entirely. If you need to remove the tank, remember to support it with your hand or a jack to prevent it from falling.
At this point, you have successfully removed the rear tank bolts and can proceed with your intended maintenance or repair tasks related to the fuel system. Remember to refer to a Vespa repair guide or seek assistance from a qualified mechanic if you need further guidance on specific steps or procedures.
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Access the carburettor
Accessing the carburettor of a Vespa scooter depends on the model of the scooter and the type of carburettor. Vespa scooters are known to use the DELLORTO SI carburettor, which is easily accessible for adjustment and service work. The SI carburettor is positioned above the rotary slide cheek of the crankshaft, which ensures the best lubrication of the connecting rod.
To access the carburettor, you will need to locate it first. The carburettor is usually found near the cylinder, and it is connected to the intake manifold. The intake manifold can be either a direct or double intake manifold. A direct intake manifold sits directly on the cylinder, offering a short intake path and a very direct response. On the other hand, a double intake manifold is used in some engine layouts to ensure optimal filling.
Once you have located the carburettor, you will need to remove any components blocking access to it. This may include the fuel tank, air filters, or any other surrounding parts. Refer to your specific Vespa model's repair manual for detailed instructions on removing these components.
After gaining access to the carburettor, you can proceed with the necessary adjustments, maintenance, or repairs. It is important to note that the carburettor should generally be tuned when the engine is at operating temperature. The first step in tuning the carburettor is to adjust the idle speed by turning the high vertical screw protruding from the top of the air filter.
Additionally, when working with two-stroke engines, it is crucial to use the correct type of oil. Partially or fully synthetic oils are preferable to simple mineral oils.
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Pull up the fuel tank
To remove the fuel tank of a Vespa, you will need to first remove the seat by taking out the three seat bolts. Next, remove the two rear tank bolts. Now, remove the carb airbox top, the air filter, and the bolt holding the fuel banjo to get access to the carburator. With the banjo loose from the carb, pull it up and away from the carb. Remove the fuel hose clamp and the banjo. If the fuel line is old, you may need to use a razor to cut it and get the banjo off.
Now, remove the fuel lever frame grommet. Turn the fuel lever to the middle position to get it through the frame. Finally, pull up on the back of the tank to remove it. Rally tanks are larger than most, so you will need to put in some extra effort to get it out. If you are just replacing the fuel line, pull the tank up just enough to reach the fuel tap. If you are replacing both the fuel and oil, pull the tank further up to access the bottom of the oil tank. It is helpful to have an extra pair of hands to hold the tank while you work on the tap. If you are working alone, use a towel to protect the frame from getting scraped by the tank.
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Frequently asked questions
The first step is to remove the engine. Then, take off the seat by removing the three seat bolts.
Remove the two rear tank bolts. Then, remove the carb airbox top and the air filter to access the carburettor.
Remove the bolt holding the fuel banjo to the carb, then remove the carb air bellows. Pull the banjo up and away from the carb, then remove the fuel hose clamp and the banjo.
Remove the fuel lever frame grommet by turning the fuel lever to the middle position. Now, you can pull up on the back of the tank to remove it.
