Vespa GT125, GT200 Service manual

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Page 1

WORKSHOP MANUAL

633338

Vespa GT 125-200

Page 2

WORKSHOP

MANUAL

Vespa GT 125-200

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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WORKSHOP MANUAL

Vespa GT 125-200

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

Page 4

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

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INDEX OF TOPICS

CHARACTERISTICS CHAR

Page 6

Characteristics Vespa GT 125-200

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

Vehicle identification

Granturismo 125 Chassis prefix: ZAPM311000000 ÷ 1001

CHAR - 6

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Vespa GT 125-200 Characteristics

Engine prefix: M311M1001

Granturismo 200

Chassis prefix: ZAPM312000000 ÷ 1001 Engine prefix: M312M1001

Dimensions and mass

Specification

Total loadless weight 140 Kg Width (to hand grips) 755 mm

Length 1940 mm

Wheelbase 1395 mm

Saddle height 800 mm

MASS AND DIMENSIONS

Desc./Quantity

CHAR - 7

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Characteristics Vespa GT 125-200

Engine

DATA 125

Specification Desc./Quantity

Type single-cylinder, four-stroke and four liquid-cooled valves

Timing system single overhead camshaft chain driven on the left-hand side, 3-

Bore 125 57 mm

Stroke 48.6 mm

Piston displacement 125 124,015 cm3

Compression ratio 125 12 ÷ 13 : 1

Walbro Carburettor 125 WVF-7G

Keihin Carburettor 125 CVK 30

Engine idle speed 1650 ± 50 rpm

CO value 3,8 ± 0,7 %

Air filter sponge, impregnated with mixture (50% petrol and 50% oil)

Start-up system electric starter motor (engine 200 cc with torque limiter)

Lubrication with lobe pump (inside the crankcase) controlled by a chain and

Fuel supply petrol, with vacuum pump and through carburettor

Max power (shaft) 125 11 kW (15 cv) at 9,700 rpm

Max speed 125 104 Km/h

arm rocking levers set up with set screw

double filter: mesh and paper

DATA 200

Specification

Type single-cylinder, four-stroke and four liquid-cooled valves

Timing system single overhead camshaft chain driven on the left-hand side, 3-

arm rocking levers set up with set screw

Bore 200 72 mm

Stroke 48.6 mm

Piston displacement 200 197,775 cm3

Compression ratio 200 11 ÷ 12 : 1

Walbro Carburettor 200 WVF-7P

Keihin Carburettor 200 CVK 30

Engine idle speed 1650 ± 50 rpm

CO value 3,8 ± 0,7 %

Air filter sponge, impregnated with mixture (50% petrol and 50% oil)

Start-up system electric starter motor (engine 200 cc with torque limiter)

Lubrication with lobe pump (inside the crankcase) controlled by a chain and

Fuel supply petrol, with vacuum pump and through carburettor

Max power (shaft) 200 15.4 kW (21 cv) at 8,500 rpm

Max speed 200 125 Km/h

Desc./Quantity

double filter: mesh and paper

CHAR - 8

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Vespa GT 125-200 Characteristics

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque server, V belt,

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil ~ 1000 cc (recommended oil: Selenia HI Scooter 4 Tech)

Fuel tank (including a ~ 2 l reserve) ~ 9.5 l

Rear hub 150 cc (recommended oil: TUTELA ZC 90)

Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted)

automatic clutch, gear reduction unit and transmission housing

with forced air circulation cooling

Electrical system

Specification

Type of ignition Electronic capacitive discharge ignition, with variable timing

Variable spark advance (before T.D.C.) 125 from 10° ± 1° to 2,000 rpm at 34° ± 1° to 6,000 rpm

Spark plug 125 Champion RG 4 HC

Battery 12V/ 12 Ah

Fuses N° 1 15A, N° 1 10A, N° 3 7,5A, N° 2 5A

Generator alternating current

Specification

Type of ignition Electronic capacitive discharge ignition, with variable timing

Variable ignition advance (before TDC) 200 from 10° ± 1° at 2000 rpm to 32° ± 1° at 6500 rpm

Spark plug 200 CHAMPION RG 6 YC

Battery 12V/ 12 Ah

Fuses N° 1 15A, N° 1 10A, N° 3 7,5A, N° 2 5A

Generator alternating current

Frame and suspensions

ELECTRIC COMPONENTS 125

Desc./Quantity

and separate HV coil

ELECTRIC COMPONENTS 200

Desc./Quantity

and separate HV coil

FRAME AND SUSPENSIONS

Specification

Type Unitised body made of stamped plate

Front suspension Single arm suspension (cantilever wheel) fitted with a double-

acting hydraulic shock absorber with coaxial spring

Front shock absorber axial travel 86.5 mm

Rear suspension Engine with swinging fork articulated to frame by means of an

arm with 2 degrees of freedom Pair of double-acting hydraulic

shock absorbers and coaxial springs with preloading adjust-

Rear shock absorber axial travel 89.5 mm

Desc./Quantity

ment in 4 positions.

CHAR - 9

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Characteristics Vespa GT 125-200

Brakes

BRAKES

Specification Desc./Quantity

Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plung-

Rear Ø 220 disc brake and calliper with two Ø 30 mm counteracting

ers and hydraulic control (lever on the far right end of the

handlebar)

plungers and hydraulic control (lever on the far left end of the

handlebar)

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheels - light alloy rims 3.00x12 Rear wheels - light alloy rims 3.00x12

Front tyres 120/70-12" Tubeless

Rear tyres 130/70-12" Tubeless

TYRE PRESSURE

Specification

Front tyre pressure (when cold) 1.8 bar Rear tyre pressure (when cold) 2 bar

Tyre pressure (when cold) with passenger 2.2 bar

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Desc./Quantity

Carburettor

125cc Version

Kehin

KEHIN CARBURETTOR 125

Specification

Depression carburettor CVEK-30

Body stamping CVEK

CUT-OFF device Not present

Max. jet 98

Minimum jet 38

Max.air jet 150

Minimum air jet 130

Throttle valve spring 100 ÷ 160 g

Minimum mixture set screw initial opening 2 ± ¼

Tapered pin NDVA

Tapered pin notches from top Single-notch pin

Diffuser nozzle Ø 5.0

Petrol inlet hole -

Starter air jet Ø 1.5

Starter diffuser nozzle -

Starter jet 42

Diameter of starter pin -

Starter device resistance ~ 20 Ω

Desc./Quantity

CHAR - 10

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Vespa GT 125-200 Characteristics

Specification Desc./Quantity

Venturi diffuser Ø 29 (47x30.9)

Throttle valve Ø 30.5

Diffuser maximum cone -

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

Walbro

WALBRO CARBURETTOR 125

Specification Desc./Quantity

Depression type WVF-7R*

Printing on the body 7R1

CUT-OFF device Not. pres.

Max jet 103

Minimum jet 38

Max air jet 60

Minimum air jet 110

Throttle valve spring 100 g

Idle mixture adjustment screw initial opening 2 7/8 ± 1/2

Conical pin 653

Conical pin top notches 2

Diffuser nozzle Ø 2.7

Gasoline inlet hole Ø 1.5

Starter air jet 200

Starter diffuser jet 130

Starter jet 48

Starter pin diameter Ø 1,78

Starter device resistance ~ 40 Ω

Venturi diffuser Ø 29 (30.3x27)

Throttle valve Ø 33

Choke maximum cone Ø 48,0

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

200cc Version

Kehin

Idle mixture adjustment screw initial opening 2 1/4 ± 1/4

Conical pin top notches Single notch pin

Starter emulsifier jet -

Starter pin diameter -

Starter device resistance ~ 20 Ω

KEHIN CARBURETTOR 200

Specification

Depression type CVEK 30

Body stamping CVK

CUT-OFF device Present

Max jet 92

Minimum jet 38

Max air jet 70

Minimum air jet 115

Gas valve spring 0,150 - 0,250 Kgf

Conical pin NDAA

Diffuser nozzle Ø 5.0

Fuel inlet hole -

Starter air jet Ø 1.5

Starter jet 42

Desc./Quantity

CHAR - 11

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Characteristics Vespa GT 125-200

Specification Desc./Quantity

Venturi choke Ø 29 (47x30,9)

Throttle valve Ø 30,5

Choke maximum cone -

N.B.

THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE

Walbro

WALBRO CARBURETTOR 200

Specification Desc./Quantity

Depression type WVF-7P*

Printing on the body 7P

CUT-OFF device Present

Max jet 95

Minimum jet 33

Max air jet 120

Minimum air jet 55

Gas valve spring 120 gr

Idle mixture adjustment screw initial opening 2 ± 1/2

Conical pin 495

Conical pin top notches 2

Diffuser nozzle Ø 2.7

Gasoline inlet hole Ø 1.5

Starter air jet 200

Starter emulsifier jet 110

Starter nozzle 45

Starter pin diameter Ø 1,78

Starter device resistance ~ 40 Ω

Venturi diffuser Ø 29 (30.3x27)

Throttle valve Ø 33

Choke maximum cone Ø 48,0

N.B.

THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE

Tightening Torques

STEERING ASSEMBLY

Name

Upper steering ring nut 30 ÷ 40 Lower steering ring nut 8 ÷ 10 Handlebar fixing screw 45 ÷ 50 (The two screws must be tightened to the prescribed

torque after having done so with the rear wheel axle nut. Safety

locks: see «Pre-delivery Operations» )

Fixing screws for handlebar control assembly U-bolts 7 ÷ 10

FRAME ASSEMBLY

Name

Engine-swinging arm bolt 64 - 72

swinging arm bolt - body shell 76 ÷ 83

Engine and vehicle side swinging arm junction bolt 33 ÷ 41

Bolt of the Silent block support plate 42 ÷ 52

Centre stand bolt 25 - 30

Side stand fixing bolt 40 ÷ 45

FRONT SUSPENSION

Name

Screw fixing the shock absorber to the shock absorber - calliper

attachment plate

Wheel axle nut 75 ÷ 90

Torque in Nm

20 ÷ 27

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Vespa GT 125-200 Characteristics

Name Torque in Nm

Wheel screw 20 ÷ 25

Screw fixing rear mudguard to steering 5 ÷ 6.5

FRONT BRAKE

Name Torque in Nm

Brake fluid pump-hose fitting 20 ÷ 25

Brake fluid hose-calliper fitting 20 ÷ 25

Screw fixing calliper to the shock absorber - calliper plate at-

tachment

Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium strength)

Oil bleed screw 12 - 16

Pad fastening pin 19.6 ÷ 24.5

Brake pump reservoir screws 15 ÷ 20

REAR SUSPENSION

Name Torque in Nm

Retainer for left shock absorber to crankcase support plate 20 ÷ 25

Shock absorber upper fitting 20 ÷ 25 Shock absorber lower fitting 33 ÷ 41

Rear wheel axle 104 ÷ 126

Screw fixing wheel to hub 20 ÷ 25

Screws for muffler - shock absorber support arm on engine 20 ÷ 25 (The two screws must be tightened to the prescribed

torque after having done so with the rear wheel axle nut. Safety

locks: see «Pre-delivery Operations» )

20 ÷ 25

REAR BRAKE

Name

Brake fluid pump-hose fitting 20 ÷ 25

Brake fluid pipe-calliper fitting 20 ÷ 25

Rear disc tightening bolt 11 ÷ 13

Oil bleed screw 12÷16

Calliper to engine tightening screw 20 ÷ 25

Brake pump reservoir screws 15 ÷ 20

Calliper coupling screws 30 ÷ 33

Torque in Nm

MUFFLER

Name

Muffler heat guard clamping screw 5 - 6

Exhaust fumes inlet screw 13 ÷ 15

Screw for fixing muffler to the support arm 20 ÷ 25

Torque in Nm

LUBRICATION

Name

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 8 ÷ 10

Oil pump cover screws 7 ÷ 9

Screws fixing oil pump to crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

Torque in Nm

CYLINDER HEAD

Name

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts for head fastening to the cylinder 7± 1 + 180° (2x90°) (Fasten nuts in two crossed passes) (Be-

fore fitting the nuts, lubricate them with engine oil.)

Head fixing side screws 11 ÷ 13

Starter ground screw 7 ÷ 8.5

Torque in Nm

CHAR - 13

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Characteristics Vespa GT 125-200

Name Torque in Nm

Side screw M5 locking the washers on the camshaft (125 cc) 7 ÷ 8,5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Timing chain tensioner slider screw 10 ÷ 14

Start up mass bell screws (200 cc) 11 ÷ 15

Central screw M6 locking the washers on the camshaft (125

cc)

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

11 ÷ 15

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch assembly nut on driven pulley 55 ÷ 60

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

FLYWHEEL

Name Torque in Nm

Flywheel cover fixing screws 5 - 6

Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength threadlock)

Flywheel nut 52 ÷ 58

Pick-Up clamping screws 3 ÷ 4

CRANKCASE AND CRANKSHAFT

Name

Internal engine crankcase bulkhead (transmission-side half

shaft) screws

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength threadlock)

Name

Water pump rotor cover 3 ÷ 4

Screws of the water pump rotor driving link 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Overhaul data

Assembly clearances

Torque in Nm

4 ÷ 6

COOLING

Torque in Nm

CHAR - 14

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Vespa GT 125-200 Characteristics

Cylinder - piston assy.

ENGINE 125 COUPLING CATEGORIES

Name

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059

Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059 Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059 Cylinder 1st Oversize B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059

Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059

Piston 1st Oversize D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059 Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059 Cylinder 2nd Oversize B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059

Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 2nd Oversize D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059 Cylinder 3rd Oversize A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059 Cylinder 3rd Oversize B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059

Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059 Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

Initials Cylinder Piston Play on fitting

CHAR - 15

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Characteristics Vespa GT 125-200

ENGINE 200 COUPLING CATEGORIES

Name

Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044 Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044

Initials Cylinder Piston Play on fitting

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo

Crankshaft Crankshaft to crankcase axial

Crankshaft to crankcase axial clearance

Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

clearance

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Vespa GT 125-200 Characteristics

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name

Half-shaft, transmission

side

Flywheel-side half-shaft 16.6 +0-0.05 B D = 0.20 - 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

Description Dimensions Initials Quantity

16.6 +0-0.05 A D = 0.20 - 0.50

Slot packing system

Characteristic

Shimming system for limiting the compression ratio 125

Rc = 12 ÷ 13 : 1

Measurement "A" to be taken is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the bigger the base gasket to be used (to recover the compression ratio) and vice versa.

N.B.

DISTANCE "A" MUST BE MEASURED WITHOUT ANY GASKET FITTED BETWEEN CRANKCASE AND CYLINDER

CHAR - 17

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Characteristics Vespa GT 125-200

THICKNESS 125

Name Measure A Thickness

Gasket thickness 125 2,2 ÷ 2,4 0,4 ± 0,05 Gasket thickness 125 2,4 ÷ 2,6 0,6 ± 0,05

Characteristic

Compression ratio, 200 models

Cr: 11÷12 :1

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.

N.B.

MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE

THICKNESS 200

Name

Gasket thickness 200 1,7 ÷ 1,6 0,4 ± 0,05 Gasket thickness 200 1,6 ÷ 1,4 0,6 ± 0,05 Gasket thickness 200 1,4 ÷ 1,3 0,8 ± 0,05

Measure A Thickness

CHAR - 18

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Vespa GT 125-200 Characteristics

Oversizes

ENGINE 125 OVERSIZE

Name

Compression ring 57 x 1 A 0.15 ÷ 0.30

Oil scraper ring 57 x 1 A 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35

Compression ring 1st

oversize

Oil scraper ring 1st

Oversize

Oil scraper ring 1st

Oversize

Compression ring 2nd

Oversize

Oil scraper ring 2nd

Oversize

Oil scraper ring 2nd

Oversize

Compression ring 3rd

Oversize

Oil scraper ring 3rd

Oversize

Oil scraper ring 3rd

Oversize

Description Dimensions Initials Quantity

57.2 x 1 A 0.15 ÷ 0.30

57.2 x 1 A 0.10 ÷ 0.30

57.2 x 2.5 A 0.15 ÷ 0.35

57.4 x 1 A 0.15 ÷ 0.30

57.4 x 1 A 0.10 ÷ 0.30

57.4 x 2.5 A 0.15 ÷ 0.35

57.6 x 1 A 0.15 ÷ 0.30

57.6 x 1 A

57.6 x 2.5 A 0.15 ÷ 0.35

ENGINE 200 OVERSIZE

Name

Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40 Oil scraper ring 72 x 1 A 0.20 ÷ 0.40

Compression ring 72 x 1.5 A 0.15 ÷ 0.30

Description Dimensions Initials Quantity

CHAR - 19

Page 20

Characteristics Vespa GT 125-200

Products

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Characteristic

Engine oil top-up

600 ÷ 650 cc

Check

This operation must be carried out with the engine cold and following the procedure below:

1. Place the vehicle on its centre stand and on flat ground.

2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down completely.

3. Remove the cap/dipstick again and check that the level is between the min and max. marks; top up if necessary.

The MAX level mark indicates a quantity of around 1100 cc of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

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Page 49

Vespa GT 125-200 Maintenance

Oil top up

The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc.

Oil pressure warning light

The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

Checking the ignition timing

-Remove the 4 fixing screws and move away from the engine the flywheel cover fitted with a water pump and cooling manifolds.

-Rotate the flywheel until the reference matches the crankcase operation end as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once more.

-The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover. To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction using a calliper spanner applied to the camshaft command pulley casing.

N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

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Page 50

Maintenance Vespa GT 125-200

Cooling system

Introduction of the engine coolant.

The fluid level inspection should be carried out every 6,000 km when the motor is cold, following the methods indicated below: Place the scooter on its centre stand and on flat ground.

- Undo the screw shown in the figure and remove the expansion tank cap on RHS.

- Top up if the fluid level is near or below the MIN level edge. The liquid level must always be between the MIN and MAX level.

-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.

CAUTION DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS

TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE.

Braking system

Level check

The brake fluid tanks for the front and rear brakes are located on the pumps under the handlebar cover. Proceed as follows:

- Remove the brake pump cover

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the fluid level through the sight glass as shown in the figure. A certain lowering of the level is caused by wear on the pads.

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Page 51

Vespa GT 125-200 Maintenance

Top-up

- Position the vehicle on a flat surface and on the centre stand

- Remove the brake pump cover as indicated in the photo

Check the brake fluid level through the sight glass on the pump as shown in the photograph

- If the level is below the minimum, fill using the two screws shown in the figure

- Remove the gasket and fill with DOT 4 until the spyglass is completely covered

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Page 52

Maintenance Vespa GT 125-200

For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws.

CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

CAUTION

THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING.

CAUTION NEVER USE BRAKE FLUID COMING FROM OPEN OR PAR-

TIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, BRAKE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY 2 YEARS.

Locking torques (N*m)

Brake pump reservoir screws 15 ÷ 20

Headlight adjustment

- Position the unloaded vehicle, in running conditions and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a white screen in a half-lit room, and make sure the vehicle longitudinal axis is perpendicular to the screen.

- Draw a horizontal line on the screen at a height of 67 ÷ 70 cm from the ground.

- Remove the front radiator grille working on the screw indicated in the photograph

- Switch on the low-beam headlight and check that the horizontal borderline between the projected light beam and the dark area is not higher than the horizontal line drawn on the screen. To remove the headlight, act on the screw indicated in the figure.

MAIN - 52

Page 53

Vespa GT 125-200 Maintenance

CO check

Remove the side, then remove the transmission side cooling air inlet so as to easily reach the flow adjustment screw

- Remove the gas cap on the exhaust pipe.

- Using the original washer, install the exhaust gas collection Kit union.

- Suitably orientate the components.

- Close the gas outlet terminal of the tool.

- Start the engine and let it warn until the electric fan starts.

- Stop the engine.

MAIN - 53

Page 54

Maintenance Vespa GT 125-200

- Disconnect the SAS check valve vacuum pipe from the «T» branch shown in the figure.

- Close the branch using a cap or a pipe portion with conical cap.

- Connect the Mitivac vacuum pump to the control pipe and to the SAS valve.

- Start the vacuum up to - 0.6 - 0.8 Bar so as to close the valve and cut off the SAS system.

Remove the exhaust gas collection Kit closing cap and connect the analyser properly pre-heated. Check the conditions displayed by the analyser and the engine rpm and adjust the CO value at 3.8 ±

0.7 at 1,650 ± 50 rpm

N.B.

CHECK THAT THE RESULT IS OBTAINED WITH THE GAS VALVE IN THE CLOSEST POSITION. ALSO CHECK THAT THE CARBURETION ADJUSTMENT IS OBTAINED WITH THE FLOW SCREW OPEN BY 2 TO 4 TURNS. IF NOT, CHECK THE FUEL LEVEL ADJUSTMENT IN THE BASIN AND CHECK THE FUEL CIRCUIT. IN CASE OF UNSTEADY CO, CHECK THE CARBURETTOR CLEANING, THE FEEDING SYSTEM EFFICIENCY AND THE VACUUM SEALS. IN CASE OF UNBURNT HYDROCARBONS (HC) > OF 1,000 P.P.M., CHECK THE IGNITION SYSTEM, THE TIMING, THE VALVE CLEARANCE AND THE DRAINAGE VALVE SEAL.

Specific tooling

020329Y MityVac vacuum-operated pump 020332Y Digital rev counter 494929Y Exhaust fumes analyser

MAIN - 54

Page 55

Vespa GT 125-200 Maintenance

SAS filters inspection and cleaning

the SAS for leader engines 125 cm³ - 200 cm³ Euro 2 operates in a similar manner to the SAS for 2T engines. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge pipe on the head. The 2T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut-off connected to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions in the muffler.

System description:

Air is drawn through the opening "A", goes through the first filter and is channelled through the opening "B"

Air gets to the second filter "B" through the opening indicated in the figure. Now, the filtered air enters the diaphragm device, and then is channelled to the head.

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Page 56

Maintenance Vespa GT 125-200

The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reaction of the catalytic converter.

- Remove the muffler.

- Remove the right-hand side fairing

- Remove the coolant inlet and outlet couplings from the pump cover. Then, drain the system

- Remove the upper clamp of the SAS valve connection coupling to the drainage as indicated in the photograph

MAIN - 56

Page 57

Vespa GT 125-200 Maintenance

- Remove the 2 fixing screws, the gasket and the pipe connecting the SAS valve to the head. Then remove the pipe.

- Release the electrical cable from the flywheel cover clamp as indicated in the photograph

- Disconnect the depression pipe from the SAS valve

MAIN - 57

Page 58

Maintenance Vespa GT 125-200

- Remove the pump support bracket and fuel filter.

- Remove the flywheel cover together with the SAS valve acting on the 4 hexagonal-head screws as indicated in the photograph

- Remove the SAS valve two fixing screws and remove the SAS valve together with the O-ring from the support

- Remove the plastic support together with the gasket

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Page 59

Vespa GT 125-200 Maintenance

- Check that the SAS valve plastic support is not dented or distorted

- Check that the gasket is in good conditions

- Carefully clean the inside and outside filters. Replace them if damaged or abnormally distorted.

- Make sure the coupling connecting the secondary air to the head is not dented, overheated or distorted. If there is, replace it.

- Check that the metal pipe does not have any dents

CAUTION INADEQUATE TIGHTNESS BETWEEN THE SAS VALVE

AND ITS SUPPORT INCREASES NOISE IN THE SAS SYSTEM.

To refit, follow the removal procedure in reverse order being careful to respect the direction of the rubber coupling connecting the SAS valve and the discharge system

MAIN - 59

Page 60

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 61

Vespa GT 125-200 Troubleshooting

This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given.

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

Automatic starter failure Check: mechanical movement, electric connection and fuel

supply, replace if required.

Oil level exceeds maximum Check for causes and fill to reach the correct level

Lack of compression: parts, cylinder and valves worn Replace the worn parts

Transmission belt worn Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the driven pulley moveable guide with

Montblanc Molybdenum Grease

Clutch slipping Check the clutch system and/or the bell and replace if neces-

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

place

sary

Rear wheel spins at idle

REAR WHEEL TURNING WITH IDLE ENGINE

Possible Cause

Idling rpms too high Adjust the engine idle speed and the CO%, if necessary.

Clutch fault Check the springs / clutch masses

Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-

Operation

ened

Starting difficulties

DIFFICULT STARTING

Possible Cause

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill

Rpm too low at start-up or engine and start-up system dam-

aged

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance

- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to

Automatic starter failure Check: mechanical movement, electric connection and fuel

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

Check the starter motor, the system and the torque limiter

start, remove the spark plug, dry it and before refitting, make

the motor turn so as to expel the fuel excess taking care to

connect the cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

soak it in a mixture of 50% petrol and 50% of specific oil (Se-

Operation

supply, replace if required.

TROUBL - 61

Page 62

Troubleshooting Vespa GT 125-200

Possible Cause Operation

lenia Air Filter Oil), then hand dry without squeezing, allow to

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-

Battery flat Check the charge of the battery, if there are any sulphur marks,

replace and use the new battery following the instructions

Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-

Defective floating valve Check the proper sliding of the float and the functioning of the

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

drip dry and then reassemble.

place

shown in the chapter

ened valve

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not been

fitted properly

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level using the recommended oil type (Selenia HI

Engine tends to cut-off at full throttle

THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE

Possible Cause

Level in tank too low Restore the level in the tank by bending on the float the thrust-

Tank breather hole obstructed Restore the proper tank aeration

Fuel supply pipes choked or clogged Restore the adequate fuel supply

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air

Water in the carburettor Empty the tank through the appropriate bleed nipple.

Incorrect float level Restore the level in the tank by bending on the float the thrust-

Faulty fuel supply Check or replace the fuel pump, and check the vacuum intake

Operation

By-Pass area.

Scooter 4 Tech)

Operation

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

and the pipe sealing

TROUBL - 62

Page 63

Vespa GT 125-200 Troubleshooting

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE

Possible Cause Operation

Air calibrated holes in carburettor blocked Dismantle, wash with solvent and dry with compressed air

Defective floating valve Check the proper sliding of the float and the functioning of the

Level in chamber too high Restore the level of the float chamber bending on the float the

thrusting reed of the petrol inlet pin so as to have the float par-

allel to the float chamber level, with the carburettor inverted.

The starter remains on Check the electric connection, fuel supply and mechanical

movement. Replace if required.

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

Incorrect timing Time the system and check the timing system components

Cut off device failure Check that the following parts work properly: valve; diaphragm;

spring; and that the air calibration elements are clean; check if

the sponge filter is clean too

Incorrect idle adjustment Adjust using the rpm indicator

Pressure too low at the end of compression Check the thermal group seals and replace worn components

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

The starter remains on Check: electric wiring, circuit not interrupted, mechanical

movement and power supply; replace if necessary

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

valve

High fuel consumption

HIGH CONSUMPTION

Possible Cause

Loose nozzles Check the maximum and minimum nozzles are adequately

Fuel pump failure Check the low-pressure duct sealing

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

Air filter obstructed or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

Incorrect float level Restore the level in the tank by bending on the float the thrust-

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause

Faulty clutch Check that there is no grease on the masses. Check that the

clutch mass contact surface with the casing is mainly in the centre with equivalent characteristics on the three masses.

Check that the clutch casing is not scored or worn in an anom-

Operation

fixed in their fittings

power supply

drip dry and then reassemble.

Operation

alous way

TROUBL - 63

Page 64

Troubleshooting Vespa GT 125-200

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

of the disc with a dial gauge and with wheel mounted on the

scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective sliding of pistons Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or stuck rubber gaskets Replace gaskets.

a wheel mounted on the vehicle to measure the axial shift of

the disc.

Electrical system

Battery

Possible Cause

Battery This is the device in the system that requires the most frequent

Turn signal lights malfunction

TURN INDICATOR NOT WORKING

Possible Cause

Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue -

BATTERY

Operation

attention and the most thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 3 months. If the battery is fitted on a motorcycle,

be careful not to invert the connections, keeping in mind that

the black ground wire is connected to the negative terminal

while the red wire is connected to the terminal marked+.

Operation

Black) and 5 (Red/Blue) on the control unit connector. If by

operating the turn indicator control the lights are not steadily

on, replace the control unit; otherwise, check the cable harness

and the switch.

Steering and suspensions

TROUBL - 64

Page 65

Vespa GT 125-200 Troubleshooting

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

larities in turning the steering continue even after making the above adjustments, check the seats on which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

larities in turning the steering continue even after making the above adjustments, check the seats on which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

Noisy suspension

Possible Cause

Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause

Seal fault or breakage Replace the shock absorber Check the condition of wear of the

NOISY SUSPENSION

Operation

shock absorbers; the condition of the ball bearings and relevant

lock-nuts, the limit switch rubber buffers and the movement

bushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disk in the

attachment to the hub and the steering tube.

Operation

steering covers and the adjustments.

TROUBL - 65

Page 66

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 67

Vespa GT 125-200 Electrical system

ELECTRICAL SYSTEM

Specification

1 Front left-hand direction indicator with 2 bulbs 2 Rear stop light switch 3 Light switch 4 Turn indicator switch 5 Horn button 6 Intercom fitting 7 Saddle opening button 8 Thermal switch 9 Electric fan 10 Saddle opening actuator 11 Voltage regulator 12 Rear left-hand direction indicator with bulb 13 Number plate light with bulb 14 Complete tail light with position light with 8 stop bulbs 15 Rear right-hand direction indicator with bulb 16 Fuel level sender 17 Engine earth 18 Starter motor 19 Oil pressure sensor 20 Flywheel magneto 21 Automatic starter 22 Thermistor 23 HV coil 24 Starter remote control 25 Fuse holder with 2 fuses 26 Battery 12V - 4Ah 27 Anti-theft alarm fitting 28 Immobilizer aerial

Desc./Quantity

ELE SYS - 67

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Electrical system Vespa GT 125-200

Specification Desc./Quantity

29 Key switch 30 Starter button 31 Horn 32 Front right-hand direction indicator with 2 bulbs 33 Instrument group with 9 bulbs, warning lights, fuel re-

34 Remote control switch 35 Complete right or left-hand asymmetric headlight with

36 Fuse holder box 37 Anti-theft alarm fitting 38 Electronic ignition device 39 Engine stop switch 40 Front brake stop button

serve warning light, oil pressure warning light, upper

beam indicator, RH flashing light indicator, LH flashing

light indicator, LED for immobilizer, 3 bulbs for instru-

ment illumination

bulb for headlight and 1 bulb for position

Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Conceptual diagrams

Ignition

ELE SYS - 68

Page 69

Vespa GT 125-200 Electrical system

IGNITION

Specification Desc./Quantity

1 Pick - up 2 Magneto flywheel 3 Fuse 15A (No. 7) 4 Electronic ignition device 5 Spark plug 6 HV coil 7 Voltage regulator 8 Battery 12V-12Ah

H.T. coil

This is to inform you that, starting from frame no. ZAPM3120000022142, a protective cap has been introduced for the H.T. coil cable; this is aimed at preventing the cable from rubbing against other components.

Headlights and automatic starter section

HEADLIGHTS AND AUTOMATIC START-

Specification Desc./Quantity

1 Remote control switch 2 Light switch 3 Dipped beam/upper bulb 12V-55/60W 4 Upper beam indicator 12V-1,2W 5 No. 3 bulbs for instrument

lighting + side/taillights in-

dicator

6 No. 3 number plate posi-

tion bulbs 7 Fuse 8A 8 Key switch contacts 9 Automatic starter 10 Fuse 15A 11 Battery 12V-12Ah 12 Electronic ignition device

12V-2W

12V - 5W

ELE SYS - 69

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Electrical system Vespa GT 125-200

Battery recharge and starting

BATTERY RECHARGE AND START-UP

Specification

1 Engine stop switch 2 Key switch contacts 3 Fuse 5A 4 Stop button 5 Start up button 6 Starter motor 7 Remote starter switch 8 No. 8 bulbs for stop light 12V-2,3W 9 Fuse 15 A 10 Electronic ignition 11 Battery 12V-12Ah 12 Electronic ignition device 13 Voltage regulator 14 Magneto flywheel 15 Pick - up

ELE SYS - 70

Desc./Quantity

Page 71

Vespa GT 125-200 Electrical system

Level indicators and enable signals section

LEVEL INDICATORS AND ENABLE SIG-

NALS

Specification Desc./Quantity

1 Cooling fluid temperature 2 Fuel gauge

3 Fuel level sender 4 Thermistor 5 Fuel indicator 12V - 1.2W 6 Low oil pressure warning

7 Oil pressure sensor 8 Fuse 7,5A 9 Key switch contacts 10 Battery 12V-12Ah 11 Fuse 15A 12 Electronic ignition device

Turn signal lights

indicator

12V - 2W

light

DIRECTION INDICATORS

Specification Desc./Quantity

1 Direction indicators 12V- 2W 2 4 Turn indicator bulbs 12V-10W 3 No. 2 rear flashing light

bulbs 4 Horn 12V 5 Saddle opening button 6 Horn button 7 Turn indicator switch 8 Saddle opening actuator 9 7.5A 10 Fuse 7,5A 11 Anti-theft alarm fitting 12 Key switch contacts 13 Key switch contacts 14 Fuse 7.5 A 15 Anti-theft alarm fitting 16 Intercom fitting 17 Fuse 10A 18 Immobilizer LED 19 Battery 12V-12Ah 20 Fuse 15A 21 Immobilizer aerial 22 Electronic ignition device

12V - 10W

Checks and inspections

This section is devoted to the checks on the electrical system components.

ELE SYS - 71

Page 72

Electrical system Vespa GT 125-200

Immobiliser

The electronic ignition system is realised with direct current power supply and is equipped with immobilizer antitheft device built in the control unit. The ignition system is made up of:

- control unit

- immobilizer antenna

- master and service key with built-in transponder

- H.V. coil

- diagnostic LED The diagnostic LED also has the function of deterrent flashing. This function is obtained every time the key switch is set to «OFF» or if the emergency stop switch is set to «OFF» and it stays on for 48 hours to avoid discharging the battery. When the key switch is set to «ON» the deterrent flash stops and there is a confirmation flash of the switching to «ON». This flash lasts according to the control unit programming (see figure).If the led stays off even when switching to «ON», proceed to the following checks:

- battery voltage presence

- main fuse 15A (No 7) efficiency If the led remains off, check the control unit power supply as follows:

- Disconnect the control unit connector and check the following conditions:

- Presence of battery voltage between terminal no. 4 (Red/Black) and earth

- Presence of battery voltage between terminal no. 4 (Red/Black) and no. 8 (Negative) as shown in the figure.- Presence of battery voltage between terminal no. 5 and no. 8 with the key switch set to «ON», the side stand raised and the emergency stop switch set to «RUN».

ELE SYS - 72

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Vespa GT 125-200 Electrical system

If no faults are found, replace the control unit; otherwise, check the wiring and the following components:

- Engine stop remote control switch;

- Emergency stop switch;

- Side stand switch;

- Key switch contacts.

Virgin circuit

When the ignition system is not coded, it allows the engine operation but with a limit of 2,000 rpm; miss is evident when trying to accelerate To code the system, besides having the side stand raised and the emergency stop switch set to «RUN» it is necessary to use the MASTER (brown) and SERVICE keys (black) as follows:

- Insert the MASTER key, set to «ON» and keep this position for 2 seconds (limit values: 1 - 3 seconds).

- Alternately introduce all black keys available switching each key to «ON» for 2 seconds.

- Insert the MASTER key again and set to «ON» for 2 seconds. The maximum time to change keys is of 10 seconds. Three service keys (Black coloured) can be programmed within the same storage operation. Sequence and times must be respected; otherwise, repeat the procedures from the beginning. Once the control unit has been coded, an inseparable matching between control unit and the transponder of the MASTER key is created.This matching allows performing further service key storage in case of loss, replacement, etc. Each storage deletes the former one. In case of loss of the service key storage, carefully check the

ELE SYS - 73

Page 74

Electrical system Vespa GT 125-200

high voltage system shielding: In any case it is advisable to use resistive spark plugs.

Characteristic

Shielded cap resistance

~ 5000 Ω.

Diagnostic codes

The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings. That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial. Ignition disabled-Vehicle immobilised

3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised

Diagnostic code - 2 flashes

Diagnosis code: 2-flashes When the 2-flash code is detected, carry out the following checks:

- Check if the failure continues after changing key (MASTER key included). If the failure persists with any key, disconnect the aerial connector from the control unit and check the aerial continuity with the 020331Y multimeter. If non-conforming values are measured, replace the aerial. If no failures are found in the aerial, replace the control unit.

CAUTION

BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT

Electric characteristic

immobilizer aerial

ELE SYS - 74

Page 75

Vespa GT 125-200 Electrical system

~ 7 ÷ 9 Ohm

Diagnostic code - 3 flashes

If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch.

- If the failure disappears when the MASTER key is used, encode the service keys (Blue) again.

- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to "ON", only a 0.7-second flash is detected (see diagram). In this case, the engine can be started. Example with programmed control unit, transponder, programmed key and aerial working properly.

Ignition is enabled (regular conditions of use)

Ignition circuit

Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug

Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure:

- Pick-Up check. Disconnect the control unit connector and check that the cable between terminal No. 2 (Green) and terminal No. 8 (Black) is not interrupted. Check the Pick-Up and its power line:

ELE SYS - 75

Page 76

Electrical system Vespa GT 125-200

Electric characteristic

Pick-up resistance value

Pick-up resistance value: 105 ÷ 124 Ohm

If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness. In case conforming values are measured, try replacing the control unit (without programming) and make sure the failure has been solved by checking sparks are produced in the spark plug; only then program the control unit.

- HV coil primary check Disconnect the control unit connector and check that the cable between terminal No. 3 and terminal No. 8 is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If non-conforming values are measured, repair the cables or replace the HV coil.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Electric characteristic

Resistance value:

0.4 ÷ 0.5 Ohm

- HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.

Specific tooling

ELE SYS - 76

Page 77

Vespa GT 125-200 Electrical system

020409Y Multimeter adaptor - Peak voltage detection

Electric characteristic

Resistance value:

~ 3000 ± 300 Ohm

- Pick-Up Disconnect the control unit connector and connect the positive wire to connector No. 2 and the negative wire to connector No. 8 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up. Replace Pick-Up if non-conforming values are measured.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Electric characteristic

Resistance value:

> 2 Volt

- HV coil With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the ground one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.

N.B. THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE

HV COIL PRIMARY IS BLACK AND THE NEGATIVE TERMINAL ONE IS GREEN.

Electric characteristic

Resistance value:

> 100 Volt

Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse. This system therefore requires no connection to the key switch.

ELE SYS - 77

Page 78

Electrical system Vespa GT 125-200

The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Stator check

Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic

Ohm value:

0.7 ÷ 0.9 Ohm Also check that all yellow cables are insulated from

the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.

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Vespa GT 125-200 Electrical system

- With a tester, check the circuit between connections 5-3 and 5-1 is not interrupted.

- Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω Minimum oil pressure switch check

- With a tester, check the circuit between connections 4 and ground (with engine off) is not interrupted. Pick-Up check

- Check that there is a resistance of about 105 ÷ 124 Ω at 20° C between connection 2 and ground.

- In case of values different from the ones stated, replace the defective parts.

N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A

CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.

Voltage regulator check

With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

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Electrical system Vespa GT 125-200

Recharge system voltage check

Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine. In case the generated current value is lower than 10A, repeat the test using a new regulator and/ stator alternatively.

Choke Inspection

For the component resistive and functional check, see the engine section. As regards its power supply, keep the system connector connected and check the presence of battery voltage at the two terminals with engine running (see figure). If there is no voltage, connect the multimeter negative terminal to earth and the positive terminal to the orange wire of the automatic starter device; with key switch set to «ON» check the presence of battery voltage; in case of negative result, check the wiring to the key switch and the functionality of the 15° fuse (N° 8).If voltage is present, repeat the check from the ignition control unit connector. After disconnecting the starter, start the engine and keep it idle then check the presence of voltage connecting the multimeter with positive terminal to the terminal no. 5 (light blue) and negative to terminal no. 7 (white-black) (see figure). If there is no voltage, replace the control unit after checking the integrity of the fuses; otherwise,

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Vespa GT 125-200 Electrical system

check the wiring between starter and control unit, or finally, as last option replace the starter.

Turn signals system check

- If the turn indicators do not work, proceed as follows:

-Disconnect the control unit connector and check that there is battery voltage between terminal No.4 (Red/Black) and the ground lead.

-Check that the same happens between terminal No. 4 and terminal No. 8 (Black).

-Repeat the check between terminal No. 5 (Sky blue) and terminal No. 8 (Black) with the key switch set to "ON", with the emergency switch set to "RUN".

If no voltage is detected, check the cable harness, the connections and make sure the 15A main fuse is in good conditions; otherwise, proceed as follows:

- Jump terminals No.1 (Black/Blue) and No. 4 (Red/Black) (see figure), and set the turn indicator switch alternately to the left and to the right and check that the lights turn on. If they do, replace the control unit because it is faulty. If they do not turn on, check the control unit-turn indicator switch connection cable harness; then, repeat the test. If the cable harness is in good conditions and the turn indicators still do not turn on, replace the turn indicator switch because it is faulty.

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Electrical system Vespa GT 125-200

Fuses

The electrical system is equipped with:

1. six protection fuses «A» located in the glove compartment to the left

2. one 15A fuse «B» located under the helmet compartment under the saddle hinge latch. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).

FUSES

Specification

1 Rear side/taillight, number

plate holder, instrument

lighting and instrument

light indicator.

2 Stop light bulb, remote

control start switch enable

signal

3 Intercom fitting, antitheft

fitting, water temperature

indicator, fuel reserve indi-

cator, oil pressure indica-

tor and fuel reserve light

Desc./Quantity

Order on terminal hold-

er: 1

Fuse: 5A

Protected circuits: Rear

side/taillight, number plate

holder, instrument lighting

and instrument light indi-

cator.

Order on terminal hold-

er: 2

Fuse: 5A

Protected circuits: Stop

light bulb, remote control

start switch enable signal

Order on terminal hold-

er: 3

Fuse: 7,5A

Protected circuits: Inter-

com fitting, antitheft fitting,

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Vespa GT 125-200 Electrical system

Specification Desc./Quantity

water temperature indicator, fuel reserve indicator,

oil pressure indicator and

fuel reserve light

4 Horn Order on terminal hold-

Protected circuits: Horn

5 Intercom fitting, antitheft

fitting, immobilizer led

6 Electric saddle opener,

dipped/full headlights, full

headlight indication light

7 General Order on terminal hold-

Order on terminal hold-

Protected circuits: Inter-

com fitting, antitheft fitting,

Order on terminal hold-

Protected circuits: Elec-

tric saddle opener, dipped/

full headlights, full head-

Protected circuits: Gen-

er: 4

Fuse: 7,5A

er: 5

Fuse: 7,5A

immobilizer led

er: 6

Fuse: 10A

light indication light

er: 7

Fuse: 15A

eral

Dashboard

A = Digital clock with calendar B = Cooling liquid temperature gauge C = Right turn indicator warning light D = Fuel gauge E = Headlight warning light F = High-beam warning light G = Low oil pressure warning light H = Low fuel warning light I = Speedometer L = Odometer M = Left turn indicator warning light N = Antitheft device LED (immobilizer)

Specification

1 Fuel gauge signal 2 High-beam warning light 3 Oil warning light 4 Fuel supply (+) 5 Low fuel warning light 6 Lighting

Desc./Quantity

Specification

1 Ground lead 2 Left turn indicator

Desc./Quantity

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Electrical system Vespa GT 125-200

Specification Desc./Quantity

3 Right turn indicator 4 Temperature signal

Dry-charge battery

Battery recharge

Normal bench charging must be carried out using the special (single or multiple) battery charger, setting the battery charge selector to the type of battery that needs recharging (i.e., at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ).

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Charging status check

After topping-up the electrolyte level, check the density using special densimeter When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.

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Vespa GT 125-200 Electrical system

Battery cleaning

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BATTERY: USE DISTILLED WATER ONLY.

CAUTION

TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

Checking the electrolyte level

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.

- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of

1.26, corresponding to 30 Bé at a minimum temperature of 15°C until the upper level is reached.

- Allow to stand for at least 2 hours, then top up the level with sulphuric acid.

- Within the following 24 hours, recharge with the specific (single) or (multiple) battery charger at an intensity approx. to 1/10 of the battery rated capacity and until the acid density is approximately

1.27, corresponding to 31º Bé, and these values are stabilised.

- After charging, level the acid (adding distilled water). Close and clean carefully.

- Once the above operations have been performed, install the battery in the vehicle ensuring that it is wired up properly.

Specific tooling

020333Y Single battery charger

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Electrical system Vespa GT 125-200

020334Y Multiple battery charger

1 Hold the vertical tube 2 Look at the level 3 The float must be freed

Battery installation

• Remove the battery cover after undoing the 4 screws shown in the photograph.

- Remove the strap fastening the battery

- Insert the battery breather pipe through the hole shown in the photograph.

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Vespa GT 125-200 Electrical system

- Fit the battery as shown in the photograph.

N.B. IN ORDER TO FIT THE CABLES ON THE BATTERY TER-

MINALS CORRECTLY, REST THE LOWER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.

- Using the screwdriver, tighten up the battery terminal cables as far as they will go, placing the special Grover washer between the screw head and the cable terminal.

N.B. DO NOT USE WRENCHES TO TIGHTEN UP THE SCREWS

FOR FIXING THE TERMINALS TO THE BATTERY TERMINALS

- Mount permanently the battery in the battery chamber

- Refit the strap fastening the battery

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Electrical system Vespa GT 125-200

- Refit the battery cover

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

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Engine from vehicle Vespa GT 125-200

This section describes the operations to be carried out when removing the engine from the vehicle.

Exhaust assy. Removal

- Undo the two exhaust manifold fixings on the head.

- Undo the three screws that fix the muffler to the support arm.

- Remove the full muffler unit.

Removal of the engine from the vehicle

-Carry out the removal operations but in reverse order and respect the locking torques indicated in the

Characteristics Chapter. Check that there is a small clearance when the valve is in abutment against the set screw.

-Check the engine oil level and if necessary top it up with the recommended type.

- Top-up the cooling circuit.

- Check the functioning of the accelerator and the electrical devices.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

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Vespa GT 125-200 Engine from vehicle

- Disconnect the battery

- Remove the helmet compartment

- Remove the side fairings Remove the full muffler assembly.

- Remove the air cleaner housing acting on the 3 screws indicated in the picture, by removing the clamp from the blow-by pipe and disconnecting the bellow connection to the carburettor acting on the clamp as indicated in the photograph

CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the air intake manifold on the transmission housing acting on the two screws indicated in the photograph and remove the plastic clip

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Engine from vehicle Vespa GT 125-200

- Remove the coolant inlet pipe to the pump as indicated in the photograph.

- Remove the fuel valve vacuum intake pipe from "T" joint indicated in the photograph

- Remove the fuel supply pipe from the carburettor

- Remove the coolant outlet pipe from the engine and the bleed pipe indicated in the photograph

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Vespa GT 125-200 Engine from vehicle

- Remove the spark plug cap

- Remove the coolant temperature sensor connector indicated in the photo

- Remove the throttle control cable from the carburettor acting on the nut shown in the photo

- Remove the automatic starter connector from the system located inside the protection sheath shown in the photo

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Engine from vehicle Vespa GT 125-200

- Remove the positive and negative wires from the starter motor as shown in the photograph

- Remove the connector from the flywheel wiring shown in the photograph.

- Remove the cable from the retainer clamp on the flywheel cover

- Remove the rear shock absorbers.

- Remove the hydraulic piping from the rear calliper by undoing the screw indicated in the photograph. Then remove the retainers fixing the piping to the engine crankcase, indicated in the photograph.

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Vespa GT 125-200 Engine from vehicle

- Use a jack to support the vehicle properly. Remove the engine-swinging arm fixing pin by acting on the nut and the head of the pin indicated in the photograph

- The engine is now free.

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INDEX OF TOPICS

ENGINE ENG

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Vespa GT 125-200 Engine

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.

Specific tooling

020423Y driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling hole.

- Remove the ten screws.

- Remove the transmission cover. If this operation is carried out directly on the vehicle, remove the cooling air supply coupling of the transmission housing.

Air duct

Version 125

- Remove the 4 screws and the housing.

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Engine Vespa GT 125-200

- Remove the five screws on two different levels as well as the small casing.

- To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by means of:

Specific tooling

020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide

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Vespa GT 125-200 Engine

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as not to damage the painted surface.

- Insert the bearing in its seat.

- Refit the seeger ring.

CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM-

AGING THE COVER PAINT. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE

UPON REFITTING.

Specific tooling

020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide

Baffle roller

Metallic roller

Removal

Belt support roller (200 cm³ models only)

- Check that the roller does not show signs of wear and that it turns freely.

- Remove the special fixing screw and the roller together with the bearing.

Refitting

- Heat the roller and insert the bearing using the specific punch:

Specific tools:

Specific tooling

020455Y 10-mm guide

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Engine Vespa GT 125-200

- Refit the roller with the special screw.

- Tighten to the specified torque.

- Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Removing the driven pulley

- Remove the spacer, the clutch bell and the whole driven pulley unit.

N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING

PULLEY MOUNTED.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristic

Max. value clutch bell

Max. value: Ø 134.5 mm

Clutch bell standard value

Standard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2 bearings (inner diameter 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to check the crankshaft alignment.

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Vespa GT125, GT200 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual