Vespa GT125, GT200 Service manual

4 (2)
WORKSHOP MANUAL
633338
Vespa GT 125-200
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
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.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
WORKSHOP MANUAL
Vespa GT 125-200
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-
Gilera 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.
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
INDEX OF TOPICS
CHARACTERISTICS CHAR
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 well-
ventilated, 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
Characteristics Vespa GT 125-200
CHAR - 6
Engine prefix: M311M1001
Granturismo 200
Chassis prefix: ZAPM312000000 ÷ 1001
Engine prefix: M312M1001
Dimensions and mass
MASS AND DIMENSIONS
Specification
Desc./Quantity
Total loadless weight 140 Kg
Width (to hand grips) 755 mm
Length 1940 mm
Wheelbase 1395 mm
Saddle height 800 mm
Vespa GT 125-200 Characteristics
CHAR - 7
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-
arm rocking levers set up with set screw
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
double filter: mesh and paper
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
DATA 200
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-
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
double filter: mesh and paper
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
Characteristics Vespa GT 125-200
CHAR - 8
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque server, V belt,
automatic clutch, gear reduction unit and transmission housing
with forced air circulation cooling
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)
Electrical system
ELECTRIC COMPONENTS 125
Specification
Desc./Quantity
Type of ignition Electronic capacitive discharge ignition, with variable timing
and separate HV coil
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
ELECTRIC COMPONENTS 200
Specification
Desc./Quantity
Type of ignition Electronic capacitive discharge ignition, with variable timing
and separate HV coil
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
FRAME AND SUSPENSIONS
Specification
Desc./Quantity
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-
ment in 4 positions.
Rear shock absorber axial travel 89.5 mm
Vespa GT 125-200 Characteristics
CHAR - 9
Brakes
BRAKES
Specification Desc./Quantity
Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plung-
ers and hydraulic control (lever on the far right end of the
handlebar)
Rear Ø 220 disc brake and calliper with two Ø 30 mm counteracting
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
Desc./Quantity
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. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Carburettor
125cc Version
Kehin
KEHIN CARBURETTOR 125
Specification
Desc./Quantity
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
Characteristics Vespa GT 125-200
CHAR - 10
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
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
KEHIN CARBURETTOR 200
Specification
Desc./Quantity
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
Idle mixture adjustment screw initial opening 2 1/4 ± 1/4
Conical pin NDAA
Conical pin top notches Single notch pin
Diffuser nozzle Ø 5.0
Fuel inlet hole -
Starter air jet Ø 1.5
Starter emulsifier jet -
Starter jet 42
Starter pin diameter -
Starter device resistance ~ 20
Vespa GT 125-200 Characteristics
CHAR - 11
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
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
Torque in Nm
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
Torque in Nm
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
Torque in Nm
Screw fixing the shock absorber to the shock absorber - calliper
attachment plate
20 ÷ 27
Wheel axle nut 75 ÷ 90
Characteristics Vespa GT 125-200
CHAR - 12
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
20 ÷ 25
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» )
REAR BRAKE
Name
Torque in Nm
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
MUFFLER
Name
Torque in Nm
Muffler heat guard clamping screw 5 - 6
Exhaust fumes inlet screw 13 ÷ 15
Screw for fixing muffler to the support arm 20 ÷ 25
LUBRICATION
Name
Torque in Nm
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
CYLINDER HEAD
Name
Torque in Nm
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
Vespa GT 125-200 Characteristics
CHAR - 13
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)
11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5 - 6
Camshaft retention plate screw 4 ÷ 6
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
Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
4 ÷ 6
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)
COOLING
Name
Torque in Nm
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
Characteristics Vespa GT 125-200
CHAR - 14
Cylinder - piston assy.
ENGINE 125 COUPLING CATEGORIES
Name
Initials Cylinder Piston Play on fitting
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
Vespa GT 125-200 Characteristics
CHAR - 15
ENGINE 200 COUPLING CATEGORIES
Name
Initials Cylinder Piston Play on fitting
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
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo
Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Crankshaft to crankcase axial
clearance
Crankshaft to crankcase axial clearance
Characteristics Vespa GT 125-200
CHAR - 16
CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
Name
Description Dimensions Initials Quantity
Half-shaft, transmission
side
16.6 +0-0.05 A D = 0.20 - 0.50
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
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
Vespa GT 125-200 Characteristics
CHAR - 17
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 CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON
A GROUND PLANE
THICKNESS 200
Name
Measure A Thickness
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
Characteristics Vespa GT 125-200
CHAR - 18
Oversizes
ENGINE 125 OVERSIZE
Name
Description Dimensions Initials Quantity
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
57.2 x 1 A 0.15 ÷ 0.30
Oil scraper ring 1st
Oversize
57.2 x 1 A 0.10 ÷ 0.30
Oil scraper ring 1st
Oversize
57.2 x 2.5 A 0.15 ÷ 0.35
Compression ring 2nd
Oversize
57.4 x 1 A 0.15 ÷ 0.30
Oil scraper ring 2nd
Oversize
57.4 x 1 A 0.10 ÷ 0.30
Oil scraper ring 2nd
Oversize
57.4 x 2.5 A 0.15 ÷ 0.35
Compression ring 3rd
Oversize
57.6 x 1 A 0.15 ÷ 0.30
Oil scraper ring 3rd
Oversize
57.6 x 1 A
Oil scraper ring 3rd
Oversize
57.6 x 2.5 A 0.15 ÷ 0.35
ENGINE 200 OVERSIZE
Name
Description Dimensions Initials Quantity
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
Vespa GT 125-200 Characteristics
CHAR - 19
Products
RECOMMENDED PRODUCTS
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GP 330 Calcium complex soap-based grease
with NLGI 2; ISO-L-XBCIB2
Grease (brake control levers, throttle
grip)
AGIP CITY HI TEC 4T Four-stroke engine oil Lubricating oil for flexible shafts (throttle
control)
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP PERMANENT PLUS Coolant Monoethylene glycol antifreeze fluid, CU-
NA NC 956-16
MONTBLANC MOLYBDENUM
GREASE
Grease for driven pulley shaft adjusting
ring and movable driven pulley housing
Grease with molybdenum disulphide
AGIP GREASE PV2 Grease for the steering bearings, pin
seats and swinging arm
White anhydrous-calcium based grease
to protect roller bearings; temperature
range between -20 C and +120 C; NLGI
2; ISO-L-XBCIB2.
Characteristics Vespa GT 125-200
CHAR - 20
INDEX OF TOPICS
TOOLING TOOL
APPROPRIATE TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y009 Driver for OD 42-mm bearings
001467Y017 Bell for bearings, OD 39 mm
001467Y014 Pliers to extract ø 15-mm bearings
005095Y Engine support
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat on steer-
ing tube
Tooling Vespa GT 125-200
TOOL - 22
Stores code Description
008564Y Flywheel extractor
020004Y Punch for removing fifth wheels from
headstock
020021Y Front suspension service tool
020036Y Punch
020037Y Punch
Vespa GT 125-200 Tooling
TOOL - 23
Stores code Description
020038Y Punch
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crankshaft
alignment
020150Y Air heater support
020151Y Air heater
020193Y Oil pressure gauge
020262Y Crankcase splitting strip
Tooling Vespa GT 125-200
TOOL - 24
Stores code Description
020263Y Sheath for driven pulley fitting
020287Y Clamp to assemble piston on cylinder
020306Y Punch for assembling valve seal rings
020319Y Immobilizer check tester
020329Y MityVac vacuum-operated pump
020330Y Stroboscopic light to check timing
Vespa GT 125-200 Tooling
TOOL - 25
Stores code Description
020331Y Digital multimeter
020332Y Digital rev counter
020333Y Single battery charger
020334Y Multiple battery charger
Tooling Vespa GT 125-200
TOOL - 26
Stores code Description
020335Y Magnetic support for dial gauge
020357Y 32 x 35 mm adaptor
020359Y 42x47-mm adaptor
020360Y Adaptor 52 x 55 mm
020363Y 20 mm guide
020364Y 25-mm guide
Vespa GT 125-200 Tooling
TOOL - 27
Stores code Description
020365Y 22 mm guide
020368Y driving pulley lock wrench
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020382Y Valve cotters equipped with part 012 re-
moval tool
020382Y011 adapter for valve removal tool
Tooling Vespa GT 125-200
TOOL - 28
Stores code Description
020393Y Piston fitting band
020409Y Multimeter adaptor - Peak voltage detec-
tion
020412Y 15 mm guide
020414Y 28-mm guide
020423Y driven pulley lock wrench
Vespa GT 125-200 Tooling
TOOL - 29
Stores code Description
020424Y Driven pulley roller casing fitting punch
020425Y Punch for flywheel-side oil seal
020426Y Piston fitting fork
020430Y Pin lock fitting tool
020431Y Valve oil seal extractor
020434Y Oil pressure control fitting
Tooling Vespa GT 125-200
TOOL - 30
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