VESPA GT 200 Instruction manual

Index

1 Vespa GT 200 16

2 Characteristics 17

2.1 Various 17

2.1.1 Workshop Safety 17

2.1.2 Service Recommendations 17

2.2 Vehicle Identification 18

2.2.1 Frame No. 18

2.2.2 Engine No. 18

2.3 Technical Specifications 19

2.3.1 Weight and Dimensions 19

2.4 Engine 20

2.4.1 General 20

2.4.2 Walbro carburetor 21

2.4.3 Kehin carburetor 22

2.5 Transmission 23

2.6 Capacities 23

2.7 Electrical Components 23

2.8 Frame, Suspensions, Brakes and Tires 24

2.8.1 Frame and Suspension 24

2.8.2 Brakes 24

2.8.3 Wheels and Tires 24

3 Tightening Torques 25

3.1 Steering Unit 25

3.2 Frame 25

3.3 Front Suspension 25

3.4 Front Brake 26

3.5 Rear Suspension 26

3.6 Rear Brake 27

3.7 Silencer 27

3.8 Hydraulic Components 27

3.9 Cylinder Head 28

3.10 Transmission 29

3.11 Flywheel 29

3.12 Engine Crankcase and Shaft 29

3.13 Cooling 30

4 Assembly Clearances 31

4.1 Piston–Cylinder Mating 31

4.2 O Rings 32

4.3 Compression Ratio Limiting Shimming System: (11-12:1) 33

4.4 Crankshaft End-Play 34

4.5 Crankshaft Alignment 35

5 Recommended Lubricants 36

6 Special Tools 37

6.1 Steering Bearing Seat Installer – 001330Y 37

6.2 Pliers – 001467Y014 37

6.3 Bell – 001467Y017 37

6.4 Steering Column Ball-Cage Bearing Removing Punch – 020004Y 37

6.5 Front Suspension Overhaul Tool – 020021Y 38

6.6 Punch – 020036Y 38

6.7 Punch - 020038Y 38

6.8 Ring Nut Spanner - 020055Y 38

6.9 Crankshaft Aligner - 020074Y 39

6.10 Heat Gun Support - 020150Y 39

6.11 Heat Gun - 020151Y 39

6.12 Oil Pressure Gauge - 020193Y 39

6.13 Crankcase Detacher - 020262Y 40

6.14 Half-Pulley Assembler - 020263Y 40

6.15 Fitting Punch - 020306Y 40

6.16 Vacuum Pump - 020329Y 40

6.17 Timing Light - 020330Y 41

6.18 Digital Multimeter - 020331Y 41

6.19 Digital Tachometer - 020332Y 41

6.20 Single Battery Charger - 020333Y 42

6.21 Multiple Battery Charger - 020334Y 42

6.22 Dial Gauge - 020335Y 42

6.23 Adapter (42×47 mm) - 020359Y 43

6.24 Adapter (52×55 mm) - 020360Y 43

6.25 Guide (20 mm) - 020363Y 43

6.26 Guide (25mm) - 020364Y 43

6.27 Guide (22 mm) - 020365Y 44

6.28 Adapter (28×30 mm) - 020375Y 44

6.29 Handle - 020376Y 44

6.30 Valve Half-Cone Remover - 020382Y 44

6.31 Bushing - 020382Y011 44

6.32 Piston Assembly Band - 020393Y 45

6.33 Multimeter Adapter - 020409Y 45

6.34 Guide (15 mm) - 020412Y 46

6.35 Clutch Drum Lock Wrench - 020423Y46

6.36 Punch - 020424Y 46

6.37 Punch - 020425Y 46

6.38 Piston Fitting Fork - 020426Y 47

6.39 Piston Support - 020428Y 47

6.40 Valve O-Ring Remover - 020431Y 47

6.41 Oil Pressure Gauge - 020434Y 47

6.42 Guide (17 mm) - 020439Y 48

6.43 Water Pump Overhaul Tool - 020440Y 48

6.44 Adapter (26×28 mm) - 020441Y 48

6.45 Stop Wrench - 020442Y 48

6.46 Driven Pulley Spring Tool - 020444Y49

6.47 Guide (30 mm) - 020483Y 49

6.48 Pivot Retainers Installer - 020488Y49

6.49 Hub Cover support - 020489Y 49

6.50 Flywheel Wrench - 020565Y 50

6.51 Engine Support - 002095Y 50

6.52 Pliers - 002465Y 50

6.53 Punch - 06029Y 50

6.54 Flywheel Extractor - 08564Y 51

6.55 Gas Analyzer - 494929 51

7 Maintenance 52

7.1 Maintenance Schedule 52

7.2 Carburetor 54

7.3 Checking and Replacing the Spark Plug 55

7.4 Air Filter 56

7.5 Engine Oil 58

7.5.1 Checking the Engine Oil Level 58

7.5.2 Topping-Up the Engine Oil 59

7.5.3 Replacing the Oil and Oil Filter 59

7.6 Hub Oil 61

7.6.1 Checking the Hub Oil Level 61

7.6.2 Replacing the Hub Oil 61

7.7 Topping-Up the Engine Cooling Liquid 62

7.8 Brake Fluid 63

7.8.1 Checking the Brake Fluid Level 63

7.8.2 Topping-Up the Brake Fluid Level 64

7.9 Removing the Steering Lock 65

7.9.1 Removing the Steering Lock when on «OFF» Position 65

7.9.2 Removing the Steering Lock when on «LOCK» Position66

7.10 Headlight Adjustment 67

7.11 Checking the Spark Advance 68

7.12 Spark Advance Variation Curve 69

7.13 Evaporative emission system 70

Checking the CO Concentration 71

7.14 SAS (Secondary Air System) 73

7.14.1 General 73

7.14.2 Description 73

7.14.3 Removing the SAS 74

8 Troubleshooting 77

8.1 Engine 77

8.1.1 Poor Performance 77

8.1.2 Rear Wheel Spins at Idle 78

8.1.3 Rich Mixture 78

8.1.4 Weak Mixture 79

8.1.5 Low Compression 79

8.1.6 Starting Problems 80

8.1.7 Excessive Oil Consumption/Excessive Smoke from Exhaust 81

8.1.8 Insufficient Lubrication Pressure 81

8.1.9 Engine Tends to Cut Out at Full Throttle 82

8.1.10 Engine Tends to Stop at Idle 82

8.1.11 Excessive Fuel Consumption 83

8.2 Transmission and Brakes 83

8.2.1 Irregular Clutch Operation or Grapping 83

8.2.2 Poor Braking Performance 84

8.2.3 Brakes Overheating 84

8.3 Electrical System 85

8.3.1 Battery 85

8.3.2 Turn Signal Lights Not Working 85

8.4 Steering Controls and Suspension 85

8.4.1 Excessive Steering Stiffness 85

8.4.2 Excessive Steering Play 85

8.4.3 Noisy Suspension 86

8.4.4 Suspension Oil Leaking 86

Electrical System 87

9.1 Electrical Diagrams 89

9.1.1 Ignition Section 89

9.1.2 Turn Signal Lights, Horn, Services and Accessory Pre-Wiring 90

9.1.3 Level Indicators and Safety Switches92

9.1.4 Battery Recharge and Starting Section 93

9.1.5 Headlight and Automatic Choke Section 94

9.2 Electrical Equipment 95

9.2.1 Electronic Ignition (Immobilizer System) 95

9.2.2 Un-Coded Electronic Ignition System97

9.2.3 Diagnostic Codes 98

9.2.4 2-Flash Diagnostic Code 98

9.2.5 3-Flash Diagnostic Code 99

9.2.6 Ignition System 99

9.2.7 Spark Plug Power Supply Failure 100

9.2.8 Battery Charging System 101

9.2.9 Checking the Voltage Regulator 102

9.2.10 Stator check 102

9.2.11 Checking the Regulator 103

9.2.12 Checking the Automatic Choke Section 103

9.2.13 Turn Signal Lights Fail to Operate104

9.2.14 Fuses 105

9.2.15 Instrument Panel 106

9.2.16 Battery 107

9.2.16.1 Preparing the Battery 107

9.2.16.2 Checking the Electrolyte Level 107

9.2.16.3 Checking the Electrolyte Density 107

9.2.16.4 Checking the Battery Charge Level108

9.2.16.5 Cleaning the Battery 108

9.2.16.6 Installing the Battery 108

10 Engine 111

10.1 Disassembling the Engine from the Frame 111

10.2 Removing the Silencer 116

10.3 Refitting the Engine onto the Frame 116

10.4 Removing the Rocker Cover 117

10.5 Refitting the Rocker Cover 117

10.6 Checking the Compression 117

10.7 Transmission 118

10.7.1 Removing the Transmission Cover118

10.7.2 Removing the Fan Case 118

10.7.3 Removing the Transmission Cooling Intake 119

10.7.4 Removing the Driven Pulley Shaft Bearing 119

10.7.5 Fitting the Driven Pulley Shaft Bearing 119

10.7.6 Removing the Belt Support Roller120

10.7.7 Refitting the Belt Support Roller 120

10.7.8 Removing the Driving Pulley 121

10.7.9 Removing the Driven Pulley 121

10.7.10 Inspecting the Clutch Drum 122

10.7.11 Checking the Clutch Drum Surface Eccentricity 122

10.7.12 Removing the Clutch 123

10.7.13 Disassembling the Fixed Driven Half-Pulley Bearings 123

10.7.14 Checking the Fixed Driven Half-Pulley 124

10.7.15 Checking the Moving Driven Half-Pulley 125

10.7.16 Fitting the Fixed Driven Half-Pulley Bearings 125

10.7.17 Refitting the Driven Pulley 126

10.7.18 Checking the Moving Driven Half-Pulley Spring 127

10.7.19 Checking the Drive Belt 127

10.7.20 Checking the Clutch Friction Material128

10.7.21 Fitting the Clutch 128

10.7.22 Checking the Moving Driving Half-Pulley 129

10.7.23 Fitting the Fixed Driving Half-Pulley and Bushing Assembly 130

10.7.24 Fitting the Moving Half-Pulley Assembly 131

10.7.25 Fitting the Clutch Drum 132

10.7.26 Fitting the Transmission Cover 133

10.7.27 Removing the Rear Hub Cover 133

10.7.28 Removing the Rear Wheel Axle 134

10.7.29 Checking the Hub Casing Bearings134

10.7.30 Removing the Wheel Axle Bearing from the Cover 135

10.7.31 Removing the Driven Pulley Shaft136

10.7.32 Checking the Hub Cover 136

10.7.33 Fitting the Hub Casing Bearings 136

10.7.34 Fitting the Wheel Axle Bearing on the Cover 137

10.7.35 Checking the Hub Shafts 138

10.7.36 Fitting the Hub Gears 139

10.7.37 Fitting the Hub Cover 139

10.8 Flywheel 140

10.8.1 Removing the Flywheel Cover Assembly 140

10.8.2 Removing the Flywheel 143

10.8.3 Removing the Stator 144

10.8.4 Checking the Stator 144

10.8.5 Checking the Low Oil Pressure Switch 145

10.8.6 Checking the Pick-Up 145

10.8.7 Checking the Flywheel 145

10.8.8 Fitting the Stator Assembly 145

10.8.9 Fitting the Flywheel 146

10.8.10 Fitting the Flywheel Cover Assembly 146

10.9 Checking the Secondary Air Box Valve 148

10.9.1 Checking the One-Way Valve 149

10.10 Lubrication Circuit 151

10.10.1 Checking the Oil Pressure 152

10.10.2 Removing the Oil Sump and Pressure Adjusting By-Pass Valve 153

10.10.3 Checking the By-Pass Valve 153

10.10.4 Removing the Oil Pump 154

10.10.5 Checking the Oil Pump 155

10.10.6 Fitting the Oil Pump 156

10.10.7 Fitting the Chain Cover Oil Seal 157

10.10.8 Fitting the By-Pass and the Oil Sump 159

10.10.9 Removing the Intake Manifold 159

10.10.10 Thermostat Removal 160

10.10.11 Removing the Timing Chain Sprockets 160

10.10.12 Removing the Camshaft and Rockers 161

10.10.13 Removing the Cylinder Head 162

10.10.14 Removing the Valves 163

10.10.15 Removing the Cylinder and Piston Assembly 163

10.10.16 Inspecting the Small End 164

10.10.17 Inspecting the Wrist Pin Diameter165

10.10.18 Inspecting the Piston and Cylinder Diameters 165

10.10.19 Inspecting the Piston 166

10.10.20 Checking the Piston Ring Gap 167

10.10.21 Fitting the Piston 168

10.10.22 Choosing the Base Gasket Thickness168

10.10.23 Fitting the Piston Rings 170

10.10.24 Fitting the Cylinder 170

10.10.25 Inspecting the Cylinder Head 171

10.10.26 Checking the Valve Seals 171

10.10.27 Inspecting the Valve Seats 172

10.10.28 Inspecting the Valves 172

10.10.29 Testing the Valve Seals 174

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