Vespa Choke Cable
The choke cable on a large
frame Vespa runs from the choke lever in the center of the frame below
the seat to the carburetor on the right side of the engine. The cable
is sold as a single item with a typical outer, but has a wire with
pre-bent ends as the cable itself. When the small choke lever is pulled
out from the frame it simply pulls the cable by about a half inch which
provides a richer mixture for starting.
Unfortunately the cable is
located inside the frame and the fuel tank will need to be removed. On
the Vespa shown in the picture I have a single front seat and a buddy
seat on the standard luggage rack. To remove the front seat, use an
11mm wrench to loosen and remove the three bolts into the frame.
The buddy seat is held to the
luggage rack by two 10mm nuts on the bottom side. They are a little
difficult to see...
...but a look at the underside
of the seat will show them on either side. They hold a small grab bar
in place which clamps the seat to the rack. Loosen the nut only enough
to rotate the clamp so it passes through the slot.
With the rack out of the way
you can remove the last three 11mm bolts holding the rack to the frame,
and the rear of the fuel tank to the frame.
Before you can pull the tank
the fuel lever needs to be turned to the on position so it faces up as
shown. Also the rubber grommet around the fuel lever shaft will need to
be removed by prying it out.
Start to lift the fuel tank up
by lifting at the rear....
As you do the oil sight glass
(if fitted) and the fuel lever will move backwards and into the frame.
Once the fuel lever passes
through the frame hole the tank can be lifted from the frame. Sometimes
it will need a little help and you can peer into the frame area and see
if anything like cables or fuel lines are being caught.
Usually the fuel line will not
need to be disconnected from the tank or the carb. There should be
enough length to it to lift and slightly twist the tank as shown above.
If you have nice paint work, you might want to protect the edges of the
frame opening with a rag.
Now you'll be able to see the
choke cable (shown with a green arrow) and the frame mounted tube and
pin clip in which the small choke plunger fits.
To remove the carb end of the
choke cable you'll need to remove the right hand side engine cowl and
find the carb box mounted on top of the engine. Using a Phillips
screwdriver remove the two screws at either end. Once these are free
the top can be removed although it can sometimes need a little effort.
Using a flathead screwdriver,
remove the air filter element by removing the two screws. The rear
screw is a little weird looking so remember it always goes in the rear
Now you can see where the wire
choke cable attaches to the carb. Using a hook of some sort or a
flathead screwdriver, unhook the cable and push it out through the hole
in the carb box.
Since the carb end is released
you can now pull the choke lever beyond the frame and disconnect it
from the wire.
Remove the old choke cable and
feed it through the hole in the frame. Fit the new choke cable through
the frame hole and make sure the end with a loop in it is outside the
frame. Push the end of the choke outer cable securely into the end of
the frame tube.
Make sure it is fully in the
tube or the next step will be very difficult. There is just enough
length on the wire to allow you to connect the choke cable.
You'll see the end of the wire
poking out of the choke tube on the outside of the frame. The trick is
to grab it with some needlenose pliers and....
..thread the wire through the
end of choke lever. You can see that one side of the choke lever cut
outs is longer than the other (the one on top in this image). Be sure
the wire is threaded as shown above to make sure it doesn't come undone
in the tube.
With the other end of the
cable hanging out through the frame, push the choke lever back into the
frame tube. Thread the choke cable through the carb box, and hook it on
to the carb hook. Test to make sure the carb hook is all the way
released when the choke lever is pushed all the way in, and out when
out. If all is well, replace the filter and the carb top.
The final step is to re-fit
the rubber grommet around the fuel lever so it doesn't rattle around
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