Page 2: Table Of Contents
Index Vespa GT 200 Characteristics Various 2.1.1 Workshop Safety 2.1.2 Service Recommendations Vehicle Identification 2.2.1 Frame No. 2.2.2 Engine No. Technical Specifications 2.3.1 Weight and Dimensions Engine 2.4.1 General 2.4.2 Walbro carburetor 2.4.3 Kehin carburetor Transmission Capacities Electrical Components Frame, Suspensions, Brakes and Tires 2.8.1...
Page 3 Hydraulic Components Cylinder Head 3.10 Transmission 3.11 Flywheel 3.12 Engine Crankcase and Shaft 3.13 Cooling Assembly Clearances Piston–Cylinder Mating O Rings Compression Ratio Limiting Shimming System: (11-12:1) Crankshaft End-Play Crankshaft Alignment Recommended Lubricants Special Tools Steering Bearing Seat Installer – 001330Y Pliers –...
Page 4 6.17 Timing Light - 020330Y 6.18 Digital Multimeter - 020331Y 6.19 Digital Tachometer - 020332Y 6.20 Single Battery Charger - 020333Y 42 6.21 Multiple Battery Charger - 020334Y 42 6.22 Dial Gauge - 020335Y 6.23 Adapter (42×47 mm) - 020359Y 6.24 Adapter (52×55 mm) - 020360Y 6.25...
Page 5 6.47 Guide (30 mm) - 020483Y 6.48 Pivot Retainers Installer - 020488Y49 6.49 Hub Cover support - 020489Y 6.50 Flywheel Wrench - 020565Y 6.51 Engine Support - 002095Y 6.52 Pliers - 002465Y 6.53 Punch - 06029Y 6.54 Flywheel Extractor - 08564Y 6.55 Gas Analyzer - 494929 Maintenance...
Page 6 7.12 Spark Advance Variation Curve 7.13 Evaporative emission system Checking the CO Concentration 7.14 SAS (Secondary Air System) 7.14.1 General 7.14.2 Description 7.14.3 Removing the SAS Troubleshooting Engine 8.1.1 Poor Performance 8.1.2 Rear Wheel Spins at Idle 8.1.3 Rich Mixture 8.1.4 Weak Mixture 8.1.5...
Page 7 8.4.3 Noisy Suspension 8.4.4 Suspension Oil Leaking Electrical System Electrical Diagrams 9.1.1 Ignition Section 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 Electrical Equipment 9.2.1 Electronic Ignition (Immobilizer System)
Page 8 9.2.16.5 Cleaning the Battery 9.2.16.6 Installing the Battery Engine 10.1 Disassembling the Engine from the Frame 10.2 Removing the Silencer 10.3 Refitting the Engine onto the Frame 116 10.4 Removing the Rocker Cover 10.5 Refitting the Rocker Cover 10.6 Checking the Compression 10.7 Transmission 10.7.1...
Page 9 10.7.21 Fitting the Clutch 10.7.22 Checking the Moving Driving Half-Pulley 129 10.7.23 Fitting the Fixed Driving Half-Pulley and Bushing Assembly 10.7.24 Fitting the Moving Half-Pulley Assembly 131 10.7.25 Fitting the Clutch Drum 10.7.26 Fitting the Transmission Cover 10.7.27 Removing the Rear Hub Cover 10.7.28 Removing the Rear Wheel Axle 10.7.29...
Page 10 10.10 Lubrication Circuit 10.10.1 Checking the Oil Pressure 10.10.2 Removing the Oil Sump and Pressure Adjusting By-Pass Valve 10.10.3 Checking the By-Pass Valve 10.10.4 Removing the Oil Pump 10.10.5 Checking the Oil Pump 10.10.6 Fitting the Oil Pump 10.10.7 Fitting the Chain Cover Oil Seal 10.10.8 Fitting the By-Pass and the Oil Sump 159 10.10.9...
Page 11 10.10.30 Checking the Valve Spring Plates and Half-cones 10.10.31 Fitting the Valves 10.10.32 Inspecting the Timing Components175 10.10.33 Inspecting the Camshaft 10.10.34 Fitting the Cylinder Head 10.10.35 Fitting the Timing Components 10.10.36 Fitting the Thermostat 10.10.37 Fitting the Intake Manifold 10.11 Crankshaft 10.11.1...
Page 12 10.11.12.2 Walbro WVF-7P Carburetor 10.12 Cooling System 10.12.1 Cooling Circuit 10.12.2 Removing the Water Pump 10.12.3 Checking the Components 10.12.4 Fitting the Water Pump 10.12.5 Checking the Thermostat Suspensions 11.1 Removing and Refitting the Front Wheel 226 11.2 Removing and Refitting the Rear Wheel 226 11.3 Removing the Steering Column 11.4...
Page 13 12.4 Removing the Rear Handlebar Cover251 12.5 Removing the Instrument Panel 12.6 Removing the Glove-box Panel 12.7 Removing the Battery Compartment Cover 12.8 Removing the Side Fairings 12.9 Removing the Footrest 12.10 Removing the Luggage Carrier 12.11 Removing the Taillight 12.12 Removing the Helmet Compartment257 12.13...
Page 14 14.7 Valve Cover 14.8 Chain Tensioner - By-Pass Valve 269 14.9 Oil Filter 14.10 Driven Pulley 14.11 Pump Assembly - Oil Sump 14.12 Rear Wheel Axle 14.13 Driving Pulley 14.14 Electric Starter 14.15 Kick-Starter, Transmission Cover, and Transmission Cooling 272 14.16 Transmission Cooling Air Inlet 14.17...
Page 15 14.37 Saddle and Rear Rack 14.38 Locks and Immobilizer 14.39 Mirrors, Electric Controls, and Instrument Panel 14.40 Lights 14.41 Electrical Devices 14.42 Front Wheel 14.43 Rear Wheel...
Page 16: Vespa Gt
Vespa GT 200 This manual has been prepared by Piaggio USA, Inc., a subsidiary of Piaggio & C. S.p.A., for use in the workshops of authorized Piaggio ® dealers and sub-agents It is assumed that the person utilizing this manual for servicing or repairing Piaggio® vehicles...
Page 17: Characteristics
Characteristics This section describes the general characteristics of the vehicle. Various 2.1.1 Workshop Safety For tests performed with the engine running ensure the work is carried out in a well-ventilated place and, if necessary, using appropriate extractors. Never run the engine in an enclosed space;...
Page 18: Vehicle Identification
Vehicle Identification 2.2.1 Frame No. Vehicle Frame prefix Granturismo 200 cc ZAPM3120000001001 2.2.2 Engine No. Vehicle Engine prefix Granturismo 200 cc M312M1001...
Page 19: Technical Specifications
Technical Specifications 2.3.1 Weight and Dimensions Characteristics Descriptions Dry weight 308 lbs. (140 Kg) Width (at handgrips) 2.48 ft. (755 mm) Length 6.36 ft. (1,940 mm) Wheel base 4.58 ft. (1,395 mm) Saddle height 2.62 ft. (800 mm)
Page 20: Engine
Engine 2.4.1 General Characteristics Descriptions Type Single-cylinder, four-stroke, four-valve, liquid- cooled Timing system Single overhead camshaft driven by chain on L.H., 3-arm rockers with threaded adjuster Bore 2.83 in. (72.0 mm) Stroke 1.91 in. (48.6 mm) Piston displacement 12.06 cu. in. (197.775 cm Compression ratio 11-12: 1 Walbro carburetor...
Page 21: Walbro Carburetor
Lubrication By chain driven lobe pump in crankcase, mesh strainer and cartridge filter Fuel system Gasoline supplied by carburetor with vacuum pump Max power (shaft) 21 hp (15.4 kW) @ 8,500 rpm Max speed 75 mph (120 km/h) 2.4.2 Walbro carburetor Characteristics Descriptions Vacuum type...
Page 22: Kehin Carburetor
2.4.3 Kehin carburetor Characteristics Descriptions Vacuum type CVK 30 Printing on body CUT -OFF device present Max jet Slow running jet Main air jet Idling air jet Throttle valve spring 0.330–0.551 lbs (1.47–2.45 N) Initial opening of idle speed mixture 2¼±¼...
Page 23: Transmission
Transmission Characteristics Descriptions Transmission By automatic variator, with expanding pulleys, torque converter, V-belt, automatic clutch, gear reducer and transmission compartment cooled by forced air circulation Capacities Characteristics Descriptions Engine oil ~1.06 quarts (~1,000 cm (recommended oil: Selenia HI Scooter 4 Tech) Fuel tank ~2.5 gallons (~9.5 liters) (including reserve ~0.5 gal)
Page 24: Frame, Suspensions, Brakes And Tires
Frame, Suspensions, Brakes and Tires 2.8.1 Frame and Suspension Characteristics Descriptions Type Pressed steel, mono-coque type Front suspension Single-arm suspension equipped with dual-effect hydraulic shock absorber with coaxial spring Front shock absorber travel 3.4 in (86.5 mm) Rear suspension Engine mounted on oscillating fork pivoted to the frame by means of an arm with 2 degrees of freedom.
Page 25: Tightening Torques
Tightening Torques Steering Unit Component Torque [lbs· ft (N·m)] 22.1–29.5 Steering upper ring nut (30–40) 5.9–7.4 Steering lower ring nut (8–10) 33.1–36.8 Handlebar clamping screw (*) (45–50) 5.1–7.4 Handlebar control unit U-bolts fixing screws (7–10) Frame Component Torque [lbs· ft (N·m)] 47.1–53.0 Swing arm-engine pivot nut (64–72)
Page 26: Front Brake
Front Brake Component Torque [lbs· ft (N·m)] 13.7–18.4 Pump–oil tube connection (20–25) 13.7–18.4 Caliper-oil tube connection (20–25) 13.7–18.4 Caliper-shock absorber plate fixing screw (20–25) Disk clamping screw (°) 4.4 (6) 8.8–11.8 Oil bleeder screw (12–16) 13.6–18.4 Pad clamping pin (19.6-25) 9.6–13.7 Brake pump basin screw (15–20)
Page 27: Rear Brake
Rear Brake Component Torque [lbs· ft (N·m)] 13.7–18.4 Pipe-oil tube connection (20–25) 13.7–18.4 Caliper–oil tube connection (20–25) 8.1–9.6 Rear disk clamping screw (°) (11–13) 8.8–11.8 Oil bleeder screw (12–16) 13.7–18.4 Caliper–engine fixing screw (20–25) 11.0–14.7 Brake pump basin screw (15–20) 22.1–24.3 Caliper coupling screw (30–33)
Page 28: Cylinder Head
5.9–7.4 Oil filter (8–10) 5.2–6.6 Oil pump cover screw (7–9) 3.7–4.4 Oil pump –crankcase fixing screw (5–6) 7.4–10.3 Oil pump control rim screw (10–14) 2.9–4.4 Oil pump cover plate screws (4–6) 7.4–10.3 Oil sump screw (10–14) 8.8-10.3 Minimum oil pressure sensor (12–14) Cylinder Head Component...
Page 29: Transmission
3.7-4.4 Timing belt tightening central screw (5–6) 2.9–4.4 Camshaft retain plate screw (4–6) 3.10 Transmission Component Torque [lbs· ft (N·m)] 8.1–9.6 Belt support roller screw (11–13) 40.5–44.2 Clutch assy. nut (55–60) 55.2–61.1 Driving pulley nut (75–83) 8.1–9.6 Transmission cover screw (11–13) 39.8–44.4 Driven pulley axle nut...
Page 30: Cooling
8.1–9.6 Starter motor screws (11–13) 2.5-3.2 Crankcase timing chain cover screw (°) (3.5-4.5) 3.13 Cooling Component Torque [lbs· ft (N·m)] 2.2–2.9 Water pump impeller cover (3–4) 2.2–2.9 Water pump impeller driving joint screws (3–4) 2.2–2.9 Thermostat cover screws (3–4)
Page 31: Assembly Clearances
Assembly Clearances Piston–Cylinder Mating [in (mm)] Coupling Classes Assembly Part Dimensions Clearance Class Cylinder Piston 2.8342–2.8345 2.8327–2.8330 0 0 0 7 (71.990-71.997) (71.953-71.960) 0 0 0 3 − Cylinder 0.018 2.8345–2.8347 2.8330–2.8333 72.00 0.010 − (71.997-72.004) (71.960-71.967) 0.00118–0.00173 (0.030-0.044) 2.8347–2.8350 2.8333–2.8336 0 0 0 5 ±...
Page 32: O Rings
O Rings [in (mm)] Clearance Assembly Part Dimensions Class Clearance 2.834×0.059 0.005–0.011 Compression ring (72.0×1.5) (0.15-0.30) 2.834×0.039 0.007–0.015 Scraper ring (72.0×1.0) (0.20-0.40) 2.834×0.098 0.007–0.015 Scraper ring (72.0×2.5) (0.20-0.40)
Page 33 Compression Ratio Limiting Shimming System: (11-12:1) 1. Measure «A» (with piston at T.D.C.). Note: Measure «A» must be taken without any gasket installed between the crankcase and the cylinder and after resetting the comparator, complete with support, on a rectified surface. 2.
Page 34: Crankshaft End-Play
Crankshaft End-Play Standard clearance: Crankshaft/crankcase axial clearance 0.005-0.015 in (engine cold) (0.15-0.40 mm) [in (mm)] Clearance Assembly Part Dimensions Class Clearance 0 0 0 0 0 0 1 9 − Half-shaft transmission side 0.000 16.60 0.050 − 0 0 0 0 0 0 1 9 −...
Page 35: Crankshaft Alignment
Crankshaft Alignment Measure the diameters on both X and Y axes Class Standard diameter (mm) 1.1416–1.1418 (28.998-29.004) 1.1418–1.1421 (29.004-29.010) Maximum allowable misalignment: A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm Specific tools and equipment: Support and comparator 020335Y Crankshaft aligning tool 020074Y Crankcase –...
Page 36: Recommended Lubricants
Recommended Lubricants Characteristics Recommended Product SAE 80W/90 oil, exceeding Rear hub TUTELA ZC 90 API GL3 specifications Mineral oil with specific Air filter sponge SELENIA Air Filter Oil additives to increase adhesion ISO VG 150 Complex calcium soap Brake levers, throttle handgrip SYSTEM TW 249 AREXONS grease NLGI 1-2 SAE 5W/40 synthetic oil,...
Page 37: Special Tools
Special Tools Steering Bearing Seat Installer – 001330Y Description Notes Part No. Steering bearing seat installer; to be fitted with parts: 001330Y NECESSARY 001330Y009- For bottom housing 001330Y010- For top housing Pliers – 001467Y014 Description Notes Part No. 001467Y 0.59 in (15mm) Pliers NECESSARY Bell –...
Page 38: Punch - 020038Y
Front Suspension Overhaul Tool – 020021Y Description Notes Part No. Front suspension overhaul tool 020021Y NECESSARY Punch – 020036Y Description Notes Part No. Punch 020036Y NECESSARY Punch - 020038Y Description Notes Part No. Punch 020038Y NECESSARY Ring Nut Spanner - 020055Y Description Notes Part No.
Page 39: Crankshaft Aligner - 020074Y
Crankshaft Aligner - 020074Y Description Notes Part No. Crankshaft aligning tool 020074Y RECOMMENDED 6.10 Heat Gun Support - 020150Y Description Notes Part No. “Metabo hg 1500/2” hot air gun 020150Y RECOMMENDED support 6.11 Heat Gun - 020151Y Description Notes Part No. “Metabo hg 1500/2”...
Page 40: Crankcase Detacher - 020262Y
6.13 Crankcase Detacher - 020262Y Description Notes Part No. Crankcase detachment plate 020262Y RECOMMENDED 6.14 Half-Pulley Assembler - 020263Y Description Notes Part No. Half pulley assembly sheath 020263Y NECESSARY 6.15 Fitting Punch - 020306Y Description Notes Part No. Retaining ring fitting punch 020306Y NECESSARY 6.16...
Page 41: Timing Light - 020330Y
6.17 Timing Light - 020330Y Description Notes Part No. Timing light for two and four- 020330Y RECOMMANDED stroke engines 6.18 Digital Multimeter - 020331Y Description Notes Part No. Digital multimeter 020331Y RECOMMANDED 6.19 Digital Tachometer - 020332Y Description Notes Part No. Digital tachometer 020332Y RECOMMANDED...
Page 42: Single Battery Charger - 020333Y
6.20 Single Battery Charger - 020333Y Description Notes Part No. Single battery charger 020333Y RECOMMANDED 6.21 Multiple Battery Charger - 020334Y Description Notes Part No. Multiple battery charger 020334Y RECOMMANDED 6.22 Dial Gauge - 020335Y Description Notes Part No. Dial gauge (0.001 with...
Page 43: Guide (20 Mm) - 020363Y
6.23 Adapter (42×47 mm) - 020359Y Description Notes Part No. 42×47 mm Adapter 020359Y NECESSARY 6.24 Adapter (52×55 mm) - 020360Y Description Notes Part No. 52×55 mm Adapter 020360Y NECESSARY 6.25 Guide (20 mm) - 020363Y Description Notes Part No. 20 mm guide 020363Y NECESSARY...
Page 44: Guide (22 Mm) - 020365Y
6.27 Guide (22 mm) - 020365Y Description Notes Part No. 22 mm guide 020365Y NECESSARY 6.28 Adapter (28×30 mm) - 020375Y Description Notes Part No. 28×30 mm adapter 020375Y NECESSARY 6.29 Handle - 020376Y Description Notes Part No. Handle for adapters 020376Y NECESSARY 6.30...
Page 45: Piston Assembly Band - 020393Y
020382Y Bushing (for valve removal) NECESSARY 6.32 Piston Assembly Band - 020393Y Description Notes Part No. Piston assembly band 020393Y NECESSARY 6.33 Multimeter Adapter - 020409Y Description Notes Part No. Multimeter adapter (peak voltage 020409Y RECOMMENDED measurement)
Page 46: Guide (15 Mm) - 020412Y
6.34 Guide (15 mm) - 020412Y Description Notes Part No. 15 mm guide 020412Y NECESSARY 6.35 Clutch Drum Lock Wrench - 020423Y Description Notes Part No. Clutch drum lock wrench 020423Y NECESSARY 6.36 Punch - 020424Y Description Notes Part No. Driven pulley-roller housing...
Page 47: Piston Fitting Fork - 020426Y
6.38 Piston Fitting Fork - 020426Y Description Notes Part No. Piston fitting fork 020426Y NECESSARY 6.39 Piston Support - 020428Y Description Notes Part No. Piston projection support 020428Y NECESSARY 6.40 Valve O-Ring Remover - 020431Y Description Notes Part No. Valve o-ring removing tool 020431Y NECESSARY 6.41...
Page 48: Guide (17 Mm) - 020439Y
6.42 Guide (17 mm) - 020439Y Description Notes Part No. 17 mm guide for shock absorber 020439Y NECESSARY support bearing assembly 6.43 Water Pump Overhaul Tool - 020440Y Description Notes Part No. Water pump overhaul tool 020440Y NECESSARY 6.44 Adapter (26×28 mm) - 020441Y Description Notes Part No.
Page 49: Guide (30 Mm) - 020483Y
6.46 Driven Pulley Spring Tool - 020444Y Description Notes Part No. Driven pulley spring compressing 020444Y NECESSARY tool 6.47 Guide (30 mm) - 020483Y Description Notes Part No. 30 mm guide for hub bearing 020483Y NECESSARY assembly 6.48 Pivot Retainers Installer - 020488Y Description Notes Part No.
Page 50: Flywheel Wrench - 020565Y
6.50 Flywheel Wrench - 020565Y Description Notes Part No. Adjustable wrench flywheel 020565Y NECESSARY fixing 6.51 Engine Support - 002095Y Description Notes Part No. Engine support; to be fitted with parts: 002095Y015 – Tube 002095Y RECOMMENDED 002095Y022 – Cross member 002095Y023 –...
Page 51: Flywheel Extractor - 08564Y
6.54 Flywheel Extractor - 08564Y Description Notes Part No. Flywheel removing tool 008564Y NECESSARY 6.55 Gas Analyzer - 494929 Description Notes Part No. Exhaust gas analyzer 494929 RECOMMENDED...
Page 52: Maintenance
Maintenance This section provides information on periodical maintenance. Maintenance Schedule ×625 miles (×1,000 km) Months Check: V Replacement: S Engine oil - Check level/Top up Every 1,875 mile (3,000 km) Engine oil – Replace Hub oil level - Check/Replace Spark plug/Electrodes distance Check...
Page 53 Transmissions- Lubricate Safety locks – Check Suspensions – Check Electrical system and Battery - Check Headlight - Check/Adjust Tires pressure and wear - Check Vehicle and braking system performance - Road test Labor time 70' 130' 135' 140' 150' 90' 245' 90' 150' 140' 135' 90' 260' Safety tightenings: refer to the chapter “Pre-delivery Operations”.
Page 54: Carburetor
Carburetor Disassemble all carburetor components, ac- curately wash them in solvent, and then dry them with compressed air. ensure thorough cleaning, pay particular attention to the passages in the carburetor body. Carefully check conditions each component. The throttle valve must slide freely into the chamber;...
Page 55: Checking And Replacing The Spark Plug
Checking and Replacing the Spark Plug Warning – Remove the spark plug when the engine is cold. Replace the spark plug every 7,500 miles (12,000 km). The use of non- conforming ignition controllers, and spark plugs other than those prescribed seriously damage the engine.
Page 56: Air Filter
Air Filter Note: Every 3,726 miles (6,000 km) it is necessary to check the air filter and blow it, if required. The jet should be directed from the inside outwards of the filter (i.e., opposite to the flow direction during normal engine operation).
Page 57 Note: Every 3,726 miles (6,000 km), during servicing, it is necessary to remove the s tops and the rubber caps located below the filter box, as shown in the figure, and drain any oil accumulation. Cleaning (Every 7,452 miles, or 12,000 km): Wash with water and shampoo.
Page 58: Engine Oil
Engine Oil Engine oil is used in 4-stroke engines to lubricate the valve gear components, the crankshaft bearings and the power plant. An insufficient quantity of oil can cause serious damage to the engine itself. In all 4-stroke engines, oil deterioration and consumption are, to some extent, normal, especially during running-in.
Page 59: Topping-Up The Engine Oil
7.5.2 Topping-Up the Engine Oil The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX mark. Restoring the level between MIN and MAX requires a quantity of oil of ~0.4 quarts (~400 cm Oil pressure warning light The vehicle is equipped with a warning light...
Page 60 Lubricate the O-rings and replace net filter drainage cap; tighten prescribed torque. Install cartridge filter after lubricating the O-ring. Fill with fresh engine oil. Since a certain quantity of oil still remains in the circuit, the fill-up should be carried out with about 0.64 quarts (600-650 cm of oil from cap «A».
Page 61: Checking The Hub Oil Level
Hub Oil 7.6.1 Checking the Hub Oil Level Position the vehicle on its central stand on a flat surface Unscrew the oil dipstick «A», dry it with a clean cloth and reinsert it, screwing it in completely. Pull out the dipstick and check that the oil level reaches the lower notch (see figure);...
Page 62: Topping-Up The Engine Cooling Liquid
Topping-Up the Engine Cooling Liquid Note: The liquid level inspection should be carried out every 3,726 mi. (6,000 km) when the engine is cold. The following steps should be followed: Rest the vehicle on its central stand level ground. Loosen the screw shown in the figure and remove the plastic flap on the right hand side of the vehicle’s leg-shield, in order to access the cooling liquid expansion tank...
Page 63: Brake Fluid
Brake Fluid 7.8.1 Checking the Brake Fluid Level The front and rear brake fluid reservoirs are located pumps installed handlebar. In order to check the brake fluid level in the reservoirs, follow these steps: Rest the vehicle on its central stand on level ground and turn the handlebar to the central position.
Page 64: Topping-Up The Brake Fluid Level
7.8.2 Topping-Up the Brake Fluid Level Caution - Only use brake fluid classified as DOT 4. If the level is below minimum, loosen the two screws shown in the figure. Remove the reservoir cap, remove the gasket only using prescribed fluid and without exceeding the maximum level.
Page 65: Removing The Steering Lock
Removing the Steering Lock 7.9.1 Removing the Steering Lock when on «OFF» Position Remove the leg-shield as described in chapter “Bodywork”. Remove the immobilizer antenna shown in the figure. Disconnect the wiring. Pull out the retaining spring shown in the figure and remove the ignition switch.
Page 66: Removing The Steering Lock When On «Lock" Position
Push the bolt lightly and extract the retainer from the milled part shown in the figure. Extract the bolt assembly from the lock body. To refit, follow the reverse procedure. 7.9.2 Removing the Steering Lock when on «LOCK» Position The bolt retaining spring is not accessible in the «LOCK»...
Page 67: Headlight Adjustment
7.10 Headlight Adjustment Place unloaded vehicle flat surface, 32.8 ft (10 m) from a half lit white screen, with the tires inflated to the prescribed pressure. Ensure that the axis of the vehicle is perpendicular to the screen. Trace a horizontal line on the screen 27.2- 28.3 in (67-70 cm) above ground.
Page 68: Checking The Spark Advance
7.11 Checking the Spark Advance To check the spark advance, use the stroboscopic light with the induction clamp connected toe the spark plug feeder cable. Connect induction clamp paying attention to the polarity (the arrow on the clamp must be facing the spark plug). Set the lamp selector to the central position (1 spark = 1 crankshaft revolution as in 2 stroke engines).
Page 69: Spark Advance Variation Curve
7.12 Spark Advance Variation Curve Rev limiter First threshold First threshold Tripping threshold 9,900±50 rpm 9,900±50 rpm Restore threshold 9,800±50 rpm 9,800±50 rpm Spark suppression 1 spark out of 7 2 sparks out of 3...
Page 70: Evaporative Emission System
7.13 Evaporative emission system A = Canister B = Uni-directional valve C = Air intake membrane D = Cylinder head E = Carburetor F = Air intake float chamber G = Pump H = Fuel output I = Fuel tank L = Plug M = Fuel breather pipe...
Page 71: Checking The Co Concentration
N = Roll-over valve O = Union “T” P = Enviornment Checking the CO Concentration This test may be re quired when engine operation is irregular or while adjusting the idle. The test must be carried out after washing all carburetor components and making sure that the air filter is clean and the spark plug is in good condition.
Page 72 Seal the connection using a cap or a pipe portion with conical a cap. Connect the Mitivac vacuum pump to the control pipe and to the SAS valve. Start the vacuum pump up to a pressure of -8.7 ÷ -11.6 psi (-0.6 ÷ -0.8 bar) so as to close the valve and cut off the SAS system.
Page 73: Sas (Secondary Air System)
7.14 SAS (Secondary Air System) 7.14.1 General The Secondary Air System (SAS) on the 200cc L.E.AD.E.R. engines is similar, in principle, to the SAS employed on PIAGGIO’s 2-stroke engines. Here, however, the secondary air enters directly into the exhaust duct from the head. The bleed valve found on the 2-stroke engine is here replaced by a membrane.
Page 74: Removing The Sas
Flowing through a stiff duct, flanged to the head, the secondary air reaches the exhaust duct thus providing oxygen addition to the unburnt gases just before they enter the catalytic converter. The efficiency of he catalyzing process is therefore increased. 7.14.3 Removing the SAS Warning –...
Page 75 Release electric wiring fixing from flywheel cover as shown in the figure Disconnect the vacuum pipe from the SAS valve Remove the pump support bracket and the fuel filter Remove the flywheel cover with the SAS valve by releasing the 4 hexagon screws as shown in the figure...
Page 76 Remove the two SAS valve fixing screws and remove the valve with the O-ring from the support Remove the plastic support with the gasket Check that the secondary air box valve plastic support is free from cracks and deformations Check the integrity of the gasket Warning - An impaired seal between secondary air box valve and flywheel cover causes an increase of noise of the system.
Page 77: Troubleshooting
Troubleshooting This section provides troubleshooting guidance. All faults are provided with a list of possible causes and remedies. Engine 8.1.1 Poor Performance Symptom Possible Cause Operation Carburetor dirty. Fuel pump or Remove, wash with solvent and dry one-way valve faulty with compressed air, or replace Timing failure or timing system Reset timing phase or replace any...
Page 78: Rear Wheel Spins At Idle
8.1.2 Rear Wheel Spins at Idle Symptom Possible Cause Operation Idle speed too high Adjust the engine idle speed and, if Rear wheel spins necessary, the CO concentration at idle Faulty clutch Check clutch springs/weights 8.1.3 Rich Mixture Symptom Possible Cause Operation Calibrated holes...
Page 79: Weak Mixture
8.1.4 Weak Mixture Symptom Possible Cause Operation Carburetor jets clogged Remove, wash in solvent and dry with compressed air. Float valve faulty Check the proper sliding of the float and the operation of the valve. Level in float bowl too low Restore the level in the float bowl bending the fuel inlet needle thrust blade on the float so that the float is...
Page 80: Starting Problems
8.1.6 Starting Problems Symptom Possible Cause Operation Flat battery Check the battery charge level. If the battery shows any sign of sulphation, replace it with a new one Carburetor dirty or fuel pump Remove, wash with solvent and dry faulty with compressed air, or replace Spark plug...
Page 81: Excessive Oil Consumption/Excessive Smoke From Exhaust
8.1.7 Excessive Oil Consumption/Excessive Smoke from Exhaust Symptom Possible Cause Operation Piston rings worn or broken or Replace cylinder-piston assembly or improperly fitted piston rings Oil leaks from joints or gaskets Check and replace the gaskets or Excessive oil restore the joint seal consumption/ex cessive smoke Oil retainer worn...
Page 82: Engine Tends To Cut Out At Full Throttle
8.1.9 Engine Tends to Cut Out at Full Throttle Symptom Possible Cause Operation Main jet dirty; lean carburetion Wash the jet in solvent and dry with compressed air Water in carburetor Empty the float chamber by using the drain screw Float level incorrect Restore the level in the float chamber Engine tends to...
Page 83: Excessive Fuel Consumption
8.1.11 Excessive Fuel Consumption Symptom Possible Cause Operation Air filter clogged or dirty Remove the sponge, wash it in water and shampoo, and then soak it in a mixture fuel (recommended: Selenia Filter Oil). Squeeze the sponge without twisting, allow it to drip and then replace it.
Page 84: Poor Braking Performance
8.2.2 Poor Braking Performance Symptom Possible Cause Operation Pads or disk excessively worn; Check the pads wear; brake fluid quantity insufficient MIN allowable dimension: or hydraulic system faulty Brake pads wear 0.06 in (1.5 mm) Ensure that the brake disks are not worn, scratched or deformed Check the brake fluid level in the pumps and, if necessary, replace the...
Page 85: Electrical System
Electrical System 8.3.1 Battery Symptom Possible Cause Operation The battery requires regular maintenance. If the vehicle is not used for long periods (1 month or more), the battery Battery must be charged from time to time. Over a period of disuse of 3 months, the battery will discharge completely.
Page 86: Noisy Suspension
8.4.3 Noisy Suspension Symptom Possible Cause Operation Anomalies suspension If the front suspension is noisy, check system the operation of the front shock absorber, the condition of the ball bearings and of the related locknuts, the rubber stops and the sliding Noisy bushes suspension...
Page 87: Electrical System
Electrical System Front left-hand side turn signal light (with 2 bulbs) Rear brake light switch Headlight switch Turn signal lights switch Horn button Radio-intercom fitting Saddle opener button Thermostat Electric fan Saddle opening actuator Voltage regulator Rear left-hand side turn signal light (with bulb) Number plate light (with bulb) Complete tail light (with low beam...
Page 88 Battery 12V 12Ah Anti-theft alarm fitting Immobilizer antenna Key switch Start-up button Horn Front right-hand side turn signal light (with 2 bulbs) Analogue instrument panel with bulbs, warning lights, fuel reserve warning light, oil pressure warning light, upper beam indicator, RH turn signal light indicator, LH turn signal light indicator, LED for immobilizer, 3 bulbs for instrument illumination...
Page 89: Electrical Diagrams
Electrical Diagrams 9.1.1 Ignition Section Pick-up Spark plug Flywheel magneto H.T. coil 15A Fuse (No. 7) Voltage regulator Electronic ignition device (CDI) 12V-12Ah Battery...
Page 90: Turn Signal Lights, Horn, Services And Accessory Pre-Wiring
9.1.2 Turn Signal Lights, Horn, Services and Accessory Pre-Wiring...
Page 91 Direction indicators 12V-2W Ignition switch contact No. 4 Front turn signal light bulbs Ignition switch contact 12V-5W No. 2 Rear turn signal light bulbs 7.5A Fuse 12V-10W Horn 12V Anti-theft alarm pre-wiring Saddle opening button Radio-intercom pre-wiring Horn button 10A Fuse Turn signal lights switch Immobilizer LED Saddle opening actuator...
Page 92: Level Indicators And Safety Switches
9.1.3 Level Indicators and Safety Switches Cooling fluid temperature indicator Oil pressure sensor Fuel level indicator Fuse 7.5A Fuel level transmitter Key switch contacts Thermostat Battery 12V-12Ah Fuel indicator 12V–1.2W Fuse 15A Oil pressure indicator 12V–1.2W Electronic ignition device...
Page 93: Battery Recharge And Starting Section
9.1.4 Battery Recharge and Starting Section Engine stop deviator No. 8 bulbs for stop light 12V–2.3W Key switch contacts Fuse 15A Fuse 5A Battery 12V / 12Ah Stop buttons Electronic ignition device Start-up button Voltage regulator Starter motor Magneto flywheel Starting relay Pick-up...
Page 94: Headlight And Automatic Choke Section
9.1.5 Headlight and Automatic Choke Section Starting relay Fuse 8A Light switch Key switch contacts Dipped beam/upper bulb 12V- Automatic starter 55/60W Upper beam indicator 12V–1.2W Fuse 15A No. 3 bulbs for instrument lighting + Battery 12V-12Ah side/taillights indicator 12V-2W No.
Page 95: Electrical Equipment
Electrical Equipment 9.2.1 Electronic Ignition (Immobilizer System) The electronic ignition system is DC-fed and is equipped with an immobilizer antitheft system built into the electronic control unit. The ignition system consists of: Electronic control unit (CDI) Immobilizer antenna Master service with built-in transponder...
Page 96 Check that battery voltage is present between terminals no. 4 (red/black) and no. 8 (black), as shown in the figure Rs = Red Ne = Black Check that battery voltage is present between terminals no. 5 (green/white) and no. 8 (black) with the ignition switch turned to the «ON»...
Page 97: Un-Coded Electronic Ignition System
9.2.2 Un-Coded Electronic Ignition System When the ignition system is not coded, the engine can be run at a maximum speed of 2,000 rpm. Any attempt to rev up causes the engine to misfire. To code the system, set the emergency cut-off switch to the «RUN» position and use the MASTER (brown) and SERVICE (black) keys as follows: Insert the MASTER key;...
Page 98: Flash Diagnostic Code
9.2.3 Diagnostic Codes After the flash that denotes the switching to the «ON» status, the system may output a number of malfunction codes. The LED stays initially off for 2 seconds, and then the diagnostic codes are displayed in the form of 0.5-second flashes.
Page 99: Flash Diagnostic Code
9.2.5 3-Flash Diagnostic Code If the 3-flash diagnostic code is displayed, check if the anomaly persists even after inserting the MASTER key into the ignition switch. If the malfunction disappears when the MASTER key is used, proceed to a new coding of the SERVICE (black) keys.
Page 100: Spark Plug Power Supply Failure
9.2.7 Spark Plug Power Supply Failure If no power is supplier to the spark plug and the LED signals that ignition is possible, follow these steps: Run a pick-up check: detach the control unit connector check continuity between terminals no. 2 (green) and no. 8 (black). This check involves the pick up and its supply: Standard resistance: Pick-Up...
Page 101: Battery Charging System
Pick-Up Detach the control unit connector and connect the positive terminal to connector no. 2 and the negative terminal to connector no. 8 (see figure). Crank the engine by operating the starter motor and measure the voltage produced by the pick-up. Standard voltage: Ve = Green Pick-up...
Page 102: Checking The Voltage Regulator
9.2.9 Checking the Voltage Regulator With a fully charged battery and all lights off, measure the voltage at the battery terminals (see figure) with the engine running at high speed. Standard voltage: Voltage regulator <15.2V If a higher voltage is detected, replace the regulator. If the voltage is less than 14 V, check the stator and its wiring.
Page 103: Checking The Regulator
9.2.11 Checking the Regulator Connect the induction nippers of an ammeter to the positive cable of the voltage regulator. Measure the battery voltage and, after turning the lights on without starting the engine, wait until voltage reading settles at about 12V. Start the engine and measure the current supplied by the system with the lights on and the engine running at high speed.
Page 104: Turn Signal Lights Fail To Operate
After disconnecting the choke device, start the engine and keep it idling. Check for the presence of voltage by connecting the multimeter positive terminal to the terminal no. 5 (light blue) and its negative terminal to terminal no. 7 (white/black) (see figure). If no voltage is detected, replace the control unit after verifying the integrity of the fuses, otherwise check...
Page 105: Fuses
9.2.14 Fuses The electrical equipment is protected by: Six fuses (marked as «A» in the picture on the right) located inside the glove-box, on the left hand-side One 15A fuse («B» in the picture below) placed underneath the helmet compartment bucket Warning - Before replacing a blown fuse, always trace and eliminate the fault that caused the blowing.
Page 106: Instrument Panel
9.2.15 Instrument Panel A = Digital clock with calendar B = Coolant temperature C = RH direction indicator switch D = Fuel level indicator E = Light indicator F = Upper beam indicator G = Low oil pressure indicator H = Fuel reserve indicator I = Speedometer L = Odome ter M = Left turn signal indicator...
Page 107: Battery
9.2.16 Battery 9.2.16.1 Preparing the Battery Remove the cap from the bleeder, shown in the figure, and then carefully pour sulphuric acid into each element. Note: the acid must have a density of 78.7 lbs·ft (1,260 kg·m ), equivalent to 30 BE at a minimum temperature of 59°F (15°C) until the upper level is reached.
Page 108: Cleaning The Battery
periodically recharged. Within a period of inactivity of approximately tree months, at standard atmospheric conditions, the battery should be completely discharged. When reinstalling the battery on the vehicle, pay attention not to invert the connections, considering that the ground wire (black and marked with a (-) sign) must be connected to the negative terminal, whereas the two red wires, marked as (+), must be connected to the positive terminal.
Page 109 Remove the battery fixing clamp. Use the hole shown in the figure to insert the battery bleed tube Place the battery onto the tray as shown in the figure, so to attach the wires to the terminals. Note: In order to correctly connect the wires to the battery terminals, pay attention when placing the battery onto the tray and ensure that there are no interferences between the wires and the frame (due...
Page 110 With the aid of a screwdriver fix the wires to the battery terminals placing the supplied beveled washer between the screw head and the wire terminal. Note: Do not use a wrench to tighten the screws. Once the wires are securely fastened, proceed by correctly placing the battery onto the tray.
Page 111: Engine
10 Engine 10.1 Disassembling the Engine from the Frame Caution – The following operations must be performed with the engine cold. Disconnect the battery. Remove the helmet compartment. Remove the side fairings. Disassemble the silencer. Release the three screws fixing the air filter to the crankcase.
Page 112 Remove intake bellows transmission compartment by releasing the two screws shown in the figure and removing the plastic clip. Remove the cooling fluid inlet piping from the pump as shown in the figure. Remove the fuel tap vac uum pipe from the «T» union shown in the figure.
Page 113 Remove the cooling fluid outlet piping from the engine. Also remove the bleeding piping shown in the figure. Remove the spark plug cap. Remove the cooling fluid temperature sensor connector shown in the figure. Remove control cable from carburetor by releasing the nut shown in the figure.
Page 114 Remove automatic connector from system located inside the protective sheath shown in the figure. Remove the positive and negative wirings from the starter motor as shown in the figure. Remove the flywheel wiring connector shown in the figure. Remove the cable from the flywheel cover retain clip.
Page 115 Remove the rear shock absorbers. Remove the hydraulic piping from the rear brake caliper by loosening the screw shown in the figure. Then, remove the pipe attachments to the engine crankcase shown in the figure. Suitably support the vehicle by the jack. Remove the engine–swing arm assembly by loosening the nut and the pin head shown in the figure.
Page 116: Removing The Silencer
10.2 Removing the Silencer Loosen fasteners exhaust manifold from the head. Loosen the 3 screws fixing the silencer to the supporting arm. Remove the complete silencer. 10.3 Refitting the Engine onto the Frame Perform the operations for removal in the reverse order according to the tightening torques indicated in Chapter "Characteristics".
Page 117: Removing The Rocker Cover
10.4 Removing the Rocker Cover Remove the five rocker cover screws and the pipe shown in the figure, after removing the relative strip; remove the tappet cover with decanter and automatic valve. Remove the sealing gasket. Check that the unidirectional valve is in good working order.
Page 118: Transmission
10.7 Transmission 10.7.1 Removing the Transmission Cover Note: To remove the transmission cover it is necessary to remove the plastic cover first, using a screwdriver on the special guides. Using the clutch drum lock wrench shown in the figure, remove the driven pulley axle locking nut and washer.
Page 119: Removing The Transmission Cooling Intake
10.7.3 Removing the Transmission Cooling Intake To remove the transmission cover intake, it is sufficient to remove the 2 screws indicated in the figure. 10.7.4 Removing the Driven Pulley Shaft Bearing Remove the snap ring from the inside of the transmission cover.
Page 120: Removing The Belt Support Roller
10.7.6 Removing the Belt Support Roller Check that the roller is free from wear and that it rotates freely. Remove the special fastening screw and the roller, complete with bearing. Remove the elastic ring and eject the bearing using the following tools. Specific equipment and tools: Handle 020376Y...
Page 121: Removing The Driving Pulley
10.7.8 Removing the Driving Pulley With the pulley stop wrench correctly inserted into the apposite slits, remove the lock nut. Note: The nut has an ‘in-built’ spring washer. Specific equipment and tools: Driving pulley stop wrench 020442Y Remove the starting rim assembly. Remove the driving fixed half-pulley, together with the O-ring and the steel washer on the bushing.
Page 122: Inspecting The Clutch Drum
10.7.10 Inspecting the Clutch Drum Check that the clutch drum is not worn or damaged. Measure the internal diameter, as shown in the figure. Standard dimension: Clutch drum Ø 5.283 in (134.2 mm) Max. allowable dimension: Clutch drum Ø 5.295 in (134.5 mm) 10.7.11 Checking the Clutch Drum Surface Eccentricity...
Page 123: Removing The Clutch
10.7.12 Removing the Clutch Prepare the driven pulley spring compressor (020444Y) with the medium length pins in position «C» tightened on the inside of the tool. Introduce the adapter ring no. 11 with the chamfering facing the inside of the tool. Install the driven pulley assembly onto the tool inserting the three pins into the ventilation holes on the mass holding support.
Page 124: Checking The Fixed Driven Half-Pulley
Rotate the pulley assembly up-side-down, as shown in the figure, and ensure the pulley is suitably supported. Remove the roller bearing using the modular punch. Specific equipment and tools: Handle 020376Y Adapter (24mm) 020456Y Guide (20mm) 020363Y Bell (no. 35) 001467Y035 10.7.14 Checking the Fixed Driven Half-Pulley...
Page 125: Checking The Moving Driven Half-Pulley
10.7.15 Checking the Moving Driven Half-Pulley Remove the two inner sealing rings and the two O-rings. Measure the internal diameter of the bushing, as shown in the figure. Standard dimension: Bushing diameter ∅ 1.599-1.600 in (41.000-41.035mm) Min. allowable dimension: Bushing diameter ∅...
Page 126: Refitting The Driven Pulley
To install the new ball bearing, proceed as shown in the figure using the modular punch. Note: Install the bearing Specific equipment and tools: Handle 020376Y 1.1×1.2 in. (28×30mm) adapter 020375Y 10.7.17 Refitting the Driven Pulley Note: Before proceeding with the assembly ensure the working surface is in good conditions, and shows no signs of abnormal or wear, as described in the previous section.
Page 127: Checking The Moving Driven Half-Pulley Spring
Using a curved-spout grease dispenser, lubricate the driven pulley assembly with approximately ¼ oz. (7 g) of TUTELA MRM2 grease. Apply grease to one of the holes in the bushing until it comes out through the hole on the opposite side. Note: This operation is necessary to avoid the presence of grease beyond the O-rings.
Page 128: Fitting The Clutch
Note: During the wear check (to be performed according to the maintenance table shown at pp. 57-58 of this manual), it is necessary to thoroughly check the bottom of the tooth groove for cracks (see example «A» shown in figure). If cracks are detected the belt must be replaced.
Page 129: Checking The Moving Driving Half-Pulley
Note: An excessive amount could impair the clutch functions. Insert the spring with relevant plastic support in contact with the clutch. Insert the driving belt into the pulley unit according to their direction of rotation. Insert the pulley unit with the belt into the tool. Slightly pre-load the spring.
Page 130: Fitting The Fixed Driving Half-Pulley And Bushing Assembly
Check that the rollers are not damaged or worn. Standard dimension: Ø 0.807-0.815 in Roller diameter (20.5-20.7 mm) Min. allowable dimension: Ø 0.787 in Roller diameter (20.0 mm) Check that the roller contrast plate slide blocks are not damaged. Check the wear of the rolle r housings and of the belt contact surfaces on both half-pulleys.
Page 131: Fitting The Moving Half-Pulley Assembly
Install the group with the bushing on the driving shaft. Install the driven pulley/clutch/belt assembly on the engine. 10.7.24 Fitting the Moving Half-Pulley Assembly Properly reinstall the bendix into its seat, if removed. Install the steel shim in contact with the bushing and the fixed driving half-pulley with the O.R.
Page 132: Fitting The Clutch Drum
Note: Always replace the nut with a new one upon any reassembly. - Turn the engine by hand to obtain a minimum tension of the belt. Tightening torque: Driving pulley screw: 55.3-61.2 lbs·ft (75-83 N·m) Specific equipment and tools: Lock wrench: 020368Y The torque limiter is calibrated at 71.7 lbs·ft (100 N·m).
Page 133: Fitting The Transmission Cover
10.7.26 Fitting the Transmission Cover Check that the locating dowels and the oil seal in the sump are in place. Fit the transmission cover and tighten the ten screws to the specified torque Attach the ground cable to the first screw above the oil sump.
Page 134: Removing The Rear Wheel Axle
10.7.28 Removing the Rear Wheel Axle Remove the wheel axle with the related gear. Remove the reduction gear. 10.7.29 Checking the Hub Casing Bearings Check the condition of the hub casing bearings (wear, play, noise). If any anomalies are found, proceed as described below.
Page 135: Removing The Wheel Axle Bearing From The Cover
10.7.30 Removing the Wheel Axle Bearing from the Cover Remove the Snap ring from the outside of the hub cover. Support the hub cover as shown in the figure. Remove the bearings using the specific tools. Specific equipment and tools: Column kit 020489Y Handle...
Page 136: Removing The Driven Pulley Shaft
10.7.31 Removing the Driven Pulley Shaft In order to remove the driven pulley shaft, its bearing and oil seal, it is necessary to remove the transmission cover and the clutch assembly as previously described. Pull the driven pulley shaft off the bearing. Remove the oil seal from inside the bearing and expel it on the transmission side taking care no to damage its seat.
Page 137: Fitting The Wheel Axle Bearing On The Cover
Install the three 15mm bearings using the specific tools. Specific equipment and tools: Handle 020376Y (42×47mm) adapter 020359Y 0.585 in (15mm) guide 020412Y Note: The 42mm side of adapter 020359Y must face the bearing. Note: Before installing the bearings onto the cover, ensure that this is suitably supported by means of the recommended column kit.
Page 138: Checking The Hub Shafts
Install the Snap ring, as shown in the figure. Install the oil seal with the sealing lip facing the inside of the hub and aligned to the edge of the seat. Specific equipment and tools: Handle 020376Y 2.047×2.165 in (52×55mm) adapter 020360Y Note: The 2.047 in (52mm) side of adapter 020360Y must face the bearing.
Page 139: Fitting The Hub Gears
10.7.36 Fitting the Hub Gears Install the three shafts in the engine crankcase as shown in the figure. 10.7.37 Fitting the Hub Cover Install a new gasket with centering dowels. Carefully seal the vent pipe gasket using black silicone sealant. Install the cover ensuring that the breather pipe is correctly positioned.
Page 140: Flywheel
10.8 Flywheel 10.8.1 Removing the Flywheel Cover Assembly Remove the two clamps and sleeves shown in the figure and then drain the cooling system. Remove the two clamps fixing the SAS valve connection sleeve to the drainage pipe. Remove the two fastening screws, the secondary air connection pipe and the relevant copper gasket.
Page 141 Note: If needed, it is possible to remove the complete flywheel cover by releasing the four hexagonal-head screws shown in the figure. Remove the two screws fixing the SAS valve to the flywheel cover. Remove the SAS valve, complete with the gasket Remove the three screws fixing the SAS valve support to the flywheel cover as shown in the...
Page 142 Remove the SAS valve support complete with its gasket Remove the external filter shown in the figure. Remove flywheel cover with centering dowels as shown in the figure. Remove the inside filter cover shown in the figure.
Page 143: Removing The Flywheel
Remove the inside filter shown in the figure. Check that the two internal and external sponge filters are clean and efficient. Check that the plastic support for the secondary air box is free from cracks and deformations. Check the integrity of the gasket. Warning - an impaired seal between secondary air box valve and flywheel cover may cause an increase of noise.
Page 144: Removing The Stator
Using specific extractor, remove flywheel. Specific tools and equipment: Flywheel extractor 008564Y 10.8.3 Removing the Stator Removing the electric terminal of the low oil pressure switch. Remove the two pick-up screws (indicated by two black arrows in the figure), the wiring clip screw and the two stator fixing screws (white arrows).
Page 145: Checking The Low Oil Pressure Switch
10.8.5 Checking the Low Oil Pressure Switch Using a multimeter, check for continuity between connector 4 and ground (with engine off). 10.8.6 Checking the Pick-Up Check that the resistance between connection 2 and ground is approximately 105-124 O at 68°F (20°C).
Page 146: Fitting The Flywheel
10.8.9 Fitting the Flywheel Fit the flywheel taking care to correctly insert the woodruff key. Tighten the flywheel lock-nut with the prescribed torque. Tightening torques: Flywheel fixing nut 38.2-42.6 lbs·ft (52-58 N·m) Check that the pick-up clearance gap ranges between 0.013-0.029 in (0.34-0.76mm). No adjustment of the clearance gap is necessary when fitting the pick-up.
Page 147 Prepare the flywheel cover by aligning the reference marks between the drive and the cover casing. Fit the cover on the engine. Insert the three studs in the water pump drive. Follow the operations for the removal in the reverse order. Warning –...
Page 148: Checking The Secondary Air Box Valve
Tighten the two SAS piping screws at the prescribed torque. Tightening torques: SAS piping screw 7.4±8.8 lbs·ft (10±12 N·m) 10.9 Checking the Secondary Air Box Valve Remove the SAS valve. Temporarily install the rubber sleeve at the outlet of the SAS valve ensuring its seal. Connect the mityvac vacuum pump to the rubber sleeve as shown in the figure.
Page 149: Checking The One-Way Valve
10.9.1 Checking the One-Way Valve Remove the SAS valve. Connect the mityvac vacuum pump to cut-off valve vacuum inlet as shown in the figure. Set the pump onto vacuum mode. Operate the pump until a vacuum pressure of 0.5 bar is reached. Check that this value is maintained does not decrease with time.
Page 150 In standard operating conditions, the pressure undergoes a drop and then settles. A slow and gradual gain of pressure, up to about 0.4 bar, then occurs. At this point, the valve opens and vacuum suddenly resets. A seal failure or an opening at inconsistent pressure values is not to be considered as acceptable.
Page 151: Lubrication Circuit
10.10 Lubrication Circuit...
Page 152: Checking The Oil Pressure
Oil vapors to the air filter Oil filler Rocker cover Oil level in sump Crankshaft Oil pump Oil blow-by valve Oil filter cartridge Low oil pressure sensor Net oil filter 10.10.1 Checking the Oil Pressure After removing the flywheel cover as described in the “Flywheel”...
Page 153: Removing The Oil Sump And Pressure Adjusting By-Pass Valve
10.10.2 Removing the Oil Sump and Pressure Adjusting By-Pass Valve Remove the oil filler cap, the transmission cover, the driving pulley assembly (with belt), and the pinio n as described in chapter “Transmission”. Drain the oil from the sump as previously described.
Page 154: Removing The Oil Pump
10.10.4 Removing the Oil Pump Remove the chain transmission cover and the complete driving pulley assembly. Install the base of the specific tool on the oil guard, using the supplied screws. Specific equipment and tools: Transmission-side oil seal punch 020662Y Screw the threaded bar at the base of the tool and remove the oil seal.
Page 155: Checking The Oil Pump
Remove the central screw with the Belleville washer; see figure. Remove the chain with its pulley. Remove the control pinion with the O-ring. After loosening the two fastening screws, shown in the figure, remove the oil pump. Remove the seal. Note: The chain should be suitably marked in order to ensure that the original direction of rotations is maintained when refitted.
Page 156: Fitting The Oil Pump
Check the rotor axial clearance using a rectified bar as shown in the figure. Max. allowable clearance: Rotor axial clearance 0.0035 in (0.09 mm) 10.10.6 Fitting the Oil Pump Check that the pump shaft body is not worn. Check that the pump cover exhibits no wear or superficial imperfections.
Page 157: Fitting The Chain Cover Oil Seal
with the prescribed torque. Tightening torques: Oil pump cover screw 0.5-0.6 lbs·ft (0.7-0.9 N·m) Note: Fit the Belleville washer so that its outer rim is in contact with the pulley. Ensure that the pump can rotate freely. 10.10.7 Fitting the Chain Cover Oil Seal Check that the chain tightening shoe is not worn.
Page 158 Insert the tool, with the oil seal onto the crankshaft, and make it slide until it is in contact with the crankcase. Warning – Orientate the oil seal by positioning the chain housing channel facing downwards. When the seal is in place, do not pull it back outwards. Failure to comply with this rule can cause a wrong positioning of the oil seal sheath.
Page 159: Fitting The By-Pass And The Oil Sump
Place the cover onto the engine crankcase and, by tightening the three screws (with copper washers) with the prescribed torque, fix the cover to its seat. Tightening torques: Chain cover fixing screw 2.6-3.3 lbs·ft (3.5-4.5 N·m) 10.10.8 Fitting the By-Pass and the Oil Sump Fit the by-pass piston in its seat.
Page 160: Thermostat Removal
10.10.10 Thermostat Removal Loosen the two screws shown in the figure and remove the thermostat cover. Remove the thermostat and its gasket. 10.10.11 Removing the Timing Chain Sprockets Before removing cylinder head, necessary remove following components: transmission cover, driving pulley (and belt), starter Bendix, oil sump with spring and blow-by piston, lower oil pump sprocket cover, O-ring on crankshaft and oil pump...
Page 161: Removing The Camshaft And Rockers
Remove the Allen screw, shown in the figure, and the counterweight. Remove timing chain sprocket associated washer from the camshaft. Remove the timing chain drive sprocket from the camshaft. Remove the screw fastener indicated by the arrow in the figure, the stator and the chain guide.
Page 162: Removing The Cylinder Head
Remove the camshaft. Remove the rocker pin by pushing it through from the flywheel side. Remove the rockers, together with their spring washers. Note: Mark the position of the rockers in order to prevent the reversal of the inlet and outlet rockers on reassembly.
Page 163: Removing The Valves
10.10.14 Removing the Valves Using the appropriate special tool, fitted with the adapter shown in the figure, remove the split cones, the valve spring retainer caps, the valve springs and the valves themselves. Special tools and equipment: Valve removing tool 020382Y Adapter 020382/11Y...
Page 164: Inspecting The Small End
Remove the two wrist pin spring clips, the wrist pin and the piston. Remove the piston rings. Note: Take care to avoid damaging the piston rings whilst removing them. 10.10.16 Inspecting the Small End Measure the internal diameter of the small end using an internal micrometer.
Page 165: Inspecting The Wrist Pin Diameter
10.10.17 Inspecting the Wrist Pin Diameter Measure the external diameter of the wrist pin. Standard dimension: Wrist pin diameter ∅ 0.5904-0.5906 in (14.996-15.000 mm) Min. allowable diameter: Wrist pin diameter ∅ 0.5903 in (14.994 mm) Estimate the clearance between the wrist pin and piston.
Page 166: Inspecting The Piston
Using a bore measuring instrument, measure the cylinder bore, in different directions and at different heights, as shown in the figure. Check that there is no wear or deformation on the surface of the cylinder that mates with the cylinder head. Max.
Page 167: Checking The Piston Ring Gap
Standard Clearance Wear limit: max. clearance Top ring 0.0006-0.0024 in 0.0028 in (0.015-0.060 mm) (0.070 mm) Middle ring 0.0006-0.0024 in 0.0028 in (0.015-0.060 mm) (0.070 mm) Oil scraper ring 0.0006-0.0024 in 0.0028 in (0.015-0.060 mm) (0.070 mm) 10.10.20 Checking the Piston Ring Gap Insert each of the three piston rings in turn, in a part of the cylinder that still maintains its original diameter, making sure they are square...
Page 168: Fitting The Piston
10.10.21 Fitting the Piston Assemble the piston and wrist pin onto the connecting rod, with the arrow in the piston crown pointing towards the exhaust port. Insert the wrist pin spring clips, using the appropriate special three-part tool, as described below.
Page 169 Choose the base gasket thickness according to the difference between the two dial gauge readings obtained, referring to the table below. Choosing the correct base gasket thickness will give the correct compression ratio. Remove the dial gauge and support from the cylinder.
Page 170: Fitting The Cylinder
10.10.23 Fitting the Piston Rings Place the oil scraper ring spring on the piston. Install the scraper ring keeping the opening opposed to the spring junction and with the word “TOP” facing upwards. In any case, the chamfering must be arranged towards the piston.
Page 171: Inspecting The Cylinder Head
Note: Before installing the cylinder blow out the lubrication ducts thoroughly and lubricate the bore of the cylinder with engine oil. Warning – Always use a new base gasket. 10.10.25 Inspecting the Cylinder Head Using a bar with a ground flat surface, check the surface of the cylinder head that mates with the cylinder is not worn.
Page 172: Inspecting The Valve Seats
If the valve sealing surface is wider than the prescribed limit, interrupted in one or more points, or bent, replace the valve. Warning – Do not change the valve assembly position. 10.10.27 Inspecting the Valve Seats Clean any carbon build-up from the valve guides.
Page 173 (4.960 mm) Min. allowable dimension: Valve stem diameter (exhaust) ∅ 0.1949 in (4.950 mm) Estimate the clearance between valve stem and valve guide. Standard clearance: Valve stem-guide (intake) 0.0005 -0.0016 in (0.013-0.040 mm) Standard clearance: Valve stem-guide (exhaust) 0.0010-0.0020 in (0.025-0.052 mm) Max.
Page 174: Testing The Valve Seals
10.10.29 Testing the Valve Seals Fit each of the valves, alternatively, into the head. For each valve, fill the appropriate manifold chamber with fuel and check that no petrol leaks out, whilst holding the valve shut with just the force of a finger. 10.10.30 Checking the Valve Spring Plates and Half-cones Check that the spring upper support plates and half-cones are free from irregular wear.
Page 175: Inspecting The Timing Components
Fit the valves, the springs and the spring retaining caps. Using the appropriate special tool and adapter, compress the spring and insert the split cones in their seats. Specific tools and equipment: Valve installation tool 020382Y Adapter 020382/11Y Note: Do not change the valve assembly position. Fit the valves with the reference color on the half- cones side.
Page 176: Inspecting The Camshaft
10.10.33 Inspecting the Camshaft Inspect the camshaft for signs of abnormal wear on the cams. Measure diameter bearing surfaces (“A” and “B” in the figure) and the height of the height of the intake and exhaust cams. Standard dimension: Diameter (A) ∅...
Page 177: Fitting The Cylinder Head
Check the rocker pin for excessive wear or scoring. Standard dimension: Rocker pin diameter ∅ 0.4715-0.4719 in (11.977-11.985 mm) Measure the internal diameter of both rockers. Standard dimension: Rocker diameter ∅ 0.4724-0.4729 in (12.000-12.011 mm) Check there are no signs of wear on the cam followers or the tappets.
Page 178: Fitting The Timing Components
Fit the two screw fasteners on the outside of the timing chain side of the cylinder head and tighten them to the specified tightening torque. Tightening torque: Timing side screws 8.1-9.6 lbs·ft (11-13 N·m) Note: Before fitting the cylinder head, check the lubricating channels are clean, using compressed air, if necessary, to remove any residues.
Page 179 Fit the spacer on the camshaft. Rotate the engine so that piston is at TDC, using the reference marks on the flywheel and the crankcase. Holding the engine in this position, loop the chain over the camshaft timing chain sprocket, making sure the reference mark “4V”...
Page 180 Tightening torque: Tensioner cap 3.7-4.4 lbs·ft (5-6 N·m) Adjust the valve clearances according to the instructions given in the previous chapters. Fit the spark-plug. Tightening torque: Spark plug 8.9-10.3 lbs·ft (12-14 N·m) Recommended spark plug: Champion RG 6YC Fit the rocker cover gasket. The projections on the timing chain side provide a reference for its orientation.
Page 181: Fitting The Thermostat
10.10.36 Fitting the Thermostat Place the thermostat with the drainage hole in the highest point. Check that rubber gasket properly positioned. Install the thermostat cover with the carburetor heating connection facing the flywheel. Tighten the two screws at the prescribed torque. Tightening torque: Thermostat screw 2.1-2.8 lbs·ft...
Page 182: Crankshaft
10.11 Crankshaft 10.11.1 Preparing the Engine for Crankcase Separation Following the instructions previously described, remove the following components/assemblies: Transmission cover, driving pulley, drive belt, driven pulley, reduction gearbox cover, gears bearings and oil seals (“Transmission” chapter). Oil sump, oil blow-by valve, oil pump and cover (“Lubrication”...
Page 183: Separating The Crankcase Halves
10.11.2 Separating the Crankcase Halves Remove the eleven screw fasteners securing the crankcase halves together. Separate the crankcase halves, taking care to leave the crankshaft supported by one of the two halves. Warning – Failing to observe this rule can lead to damage of the crankshaft.
Page 184: Checking The Crankshaft
10.11.3 Checking the Crankshaft Check the connecting rod axial clearance, before removal. Standard clearance: Connecting rod (axial) 0.008-0.020 in (0.20-0.50 mm) Check the radial clearance on the connecting rod. Standard clearance: Connecting rod (radial) 0.0014-0.0021 in (0.036-0. 054 mm) Check that the surfaces that limit the axial free- play are not scored and measure the width, as shown in the figure.
Page 185 Note: Provided none of the specified crankshaft tolerances are exceeded, any non- acceptable axial play found on the crankshaft must be due to either excessive wear or wrong machining on the crankcase. Measure the diameters on both X and Y axes Class Standard diameter (mm) 1.1416–1.1418...
Page 186: Checking The Crankcase Halves
10.11.4 Checking the Crankcase Halves Before proceeding check crankcase halves, thoroughly clean all the surfaces and oil ducts. On the transmission side crankcase half, take particular care cleaning the housing and oil ducts for the following components: the oil pump, the oil blow-by valve, the main bearings and the cooling jet on the transmission side, see picture.
Page 187: Checking The Main Bearings
following the procedure previously described for measuring crankshaft axial play dimensions. 10.11.5 Checking the Main Bearings Proper lubrication of the main bearings depends them being seated correctly their housings, which will avoid obstructing lubrication ducts. Not only will this ensure proper flow of oil, but also proper oil pressure values 58 psi (4 bar), on which lubrication of the main bearings depends.
Page 188: Assembling The Crankcase Halves
during the bedding. A = Matching surface The main bearings are chosen from a selection of standard sizes that give certain internal diameters once driven into the bearing housings in the crankcase, so as to obtain a match with the crankshaft. Bearing housings are available in two categories as are the crankshafts (cat.
Page 189 Fit the oil filter union and tighten it to the specified tightening torque. Tightening torque: Oil filter union 19.9-24.3 lbs·ft (27-33 N·m) Place a new gasket on one of the crankc ase halves, preferably on the transmission side, together with the locating dowels. Lubricate the main bearings and insert the crankshaft in the transmission side crankcase half.
Page 190: Fitting The Starter Motor
10.11.7 Fitting the Starter Motor Fit a new O-ring on the starter motor and lubricate it. Fit the starter motor to the crankcase and tighten the two screw fasteners to the specified tightening torque. Tightening torque: Half crankcase coupling screws 8.1-9.6 lbs·ft (11-13 N·m) Note: Re-fit the remaining engine components as...
Page 191: Removing The Carburetor
10.11.8 Removing the Carburetor 10.11.8.1 Kehin CVK 30 Carburetor To disconnect the carburetor from the engine, it is necessary to move the air filter and remove throttle cable, automatic choke connection, the clamps fastening the carburetor to the filter box and the intake manifold, the pipe supplying air to the membrane, and the inlet connection.
Page 192 Remove the clamp and the cap with the membrane chamber filter. Remove the four fixing screws shown in the figure and the vacuum chamber cover. Caution - The spring can suddenly jump out during the operation of removal. Take care to contain it.
Page 193 Remove the vacuum valve with the membrane. Turn the coupling by ? turn and remove it. Remove the spring and the vacuum valve pin. Remove the four screws shown in the figure.
Page 194 Remove the float bowl, the accelerator pump and its gasket. Remove the sealing gasket. Remove the accelerator pump inlet and outlet valves from the bowl. Note: Pay particular attention when handling the valves, since they consist of nozzles, springs and metallic spheres.
Page 195 Remove the main jet. Loosen the emulsion jet. Tilt the carburetor and remove the emulsion jet.
Page 196 Remove the atomizer. Note: This operation is necessary to avoid loosing the atomizer while cleaning the carburetor body. If the atomizer is jammed in its housing, do not attempt to remove it, or it may get damaged. Remove the idling jet. Remove the idle-speed flow screw and spring.
Page 197: Walbro Wvf-7P Carburetor
10.11.8.2 Walbro WVF-7P Carburetor To disconnect the carburetor from the engine, it is necessary to move the air filter and remove throttle cable, automatic choke connection, the clamps fastening the carburetor to the filter box and the intake manifold, the pipe supplying air to the membrane, and the inlet connection.
Page 198 Remove the four fixing screws shown in the figure and the vacuum chamber cover. Caution - The spring can suddenly jump out during the operation of removal. Take care to contain it. Remove the vacuum valve with the membrane.
Page 199 Turn the coupling by ? turn and remove it. Remove the spring and the vacuum valve pin. Remove the four screws shown in the figure.
Page 200 Remove the float bowl, the accelerator pump and its gasket. Remove the sealing gasket. Remove the accelerator pump inlet and outlet valves from the bowl. Note: Pay particular attention when handling the valves, since they consist of nozzles, springs and metallic spheres.
Page 201 Using a hammer, and with the carburetor suitably supported, remove the float pin from the throttle valve side. Remove the float. Remove the cap conveying fuel to the starting jet, shown in the figure. Remove the main jet.
Page 202 Loosen the emulsion jet. Remove the atomizer. Note: This operation is necessary to avoid loosing the atomizer while cleaning the carburetor body. If the atomizer is jammed in its housing, do not attempt to remove it, or it may get damaged. Remove the idling jet.
Page 203 Remove the idle-speed flow screw with O-ring, washer and spring. Remove the two fixing screws, the cover, the spring and the cut -off device membrane. Warning - Do not attempt to remove components pressed into the carburetor body. These include the fuel feed duct, the needle valve seat, the starter jet, the emulsion tube plug, the accelerator jet, the air adjuster (minimum and maximum), the butterfly valve and the butterfly valve control arm.
Page 204: Re-Assembling The Carburetor
10.11.9 Re-assembling the carburetor 10.11.9.1 Kehin CVK 30 Carburetor Clean carburetor thoroughly before reassembly, using petrol and compressed air. Take particular care in cleaning the fuel feed duct and the float valve seat. Clean the main air jet shown in the figure. Carefully clean slow-running...
Page 205 Check that on the carburetor there are five ball bearing seals pressed into the holes machined in the carburetor body. Check that the two mating surfaces, between the float bowl and the diaphragm, are unblemished. Check the butterfly valve and control arm. Check that the float valve housing channel shows no signs of scoring.
Page 206: Walbro Wfv-7P Carburetor
Check there are no signs of wear on the sealing surface of the float needle, the softened pin or the return spring. If there are any signs of wear, replace the needle with a new one. Check that the float shows no signs of wear on the hinge, or the metal tab in contact with the float needle and check that fuel has not infiltrated the float.
Page 207 Carefully clean the air holes shown in the figure. Carefully clean the slow-running circuit, concentrating in the following points: the air screw, the passage within the slow-running screw mechanism and the auxiliary channel openings around the butterfly valve. Note: The slow-running is controlled by two calibrations. That of the cut-off is obtained directly in the carburetor.
Page 208: Checking The Float Height
emulsifier. Re-fit the emulsion jet, ensuring the atomizer is correctly located, and tighten. Re-fit the main jet. Check there are no signs of wear on the sealing surface of the float needle, the softened pin or the return spring. If there are any signs of wear, replace the needle with a new one.
Page 209 Replace the accelerator pump valves in the following sequences: Intake valve (A): Spring Sphere Nozzle Delivery valve (M): Sphere Spring Nozzle Note: The delivery valve nozzle is provided with a milling. Check the seal on the screw by introducing a small amount of fuel into the float bowl.
Page 210: Walbro Wvf-7P Carburetor
10.11.10.2 Walbro WVF-7P Carburetor Holding the carburetor upside-down, check that the float is parallel to the plane of the bowl. If found to be out of alignment, adjust by bending the metal tab that controls the needle, until corrected. When making adjustments to the metal tab, ensure it remains parallel to the pin on which the float hinges.
Page 211 Check the seal on the screw by introducing a small amount of fuel into the float bowl. Re-fit the float bowl to the carburetor body, using a new gasket and tightening the four screws to the specified torque. Check that the throttle rocker arm rotates freely onto its seat.
Page 212: Checking The Vacuum Valve And The Needle
Check that the rocker arm return spring is not slackened. Pre-assemble the spring and the rocker as shown in the figure. Install the rocker on the carburetor keeping the throttle valve open. Tighten the rocker fixing screw. Make sure that the gear works properly. 10.11.11 Checking the Vacuum Valve and the Needle 10.11.11.1 Kehin CVK 30 Carburetor...
Page 213 Fit the spring with the pin lock. After ensuring that the spring is properly positioned into the housing, fit the vacuum chamber cover. Clean and blow the ambient pressure inlet filter sponge. Fit the filter and its clamp as shown in the figure.
Page 214: Walbro Wvf-7P Carburetor
Clean and blow out the choke device support. Install a new gasket onto the carburetor body and tighten the two fixing screws. 10.11.11.2 Walbro WVF-7P Carburetor Ensure the vacuum valve float pin is free from wear and the lock is positioned at the third notch.
Page 215: Checking The Automatic Choke Device
Fit the spring with the pin lock. After ensuring that the spring is properly positioned into the housing, fit the vacuum chamber cover. Clean and blow the ambient pressure inlet filter sponge. Check that the cut-off valve is in good condition and that the membrane is not broken or hardened.
Page 216 Measure the projection of the piston as shown in the figure, and check the corresponding value. Ensure that the starter settles at ambient temperature. Standard dimension: Piston length @ 68°F (20 ° C) XX-XX in (XX-XX mm) The choke should gradually disengage as it is being heated electrically.
Page 217: Walbro Wvf-7P Carburetor
10.11.12.2 Walbro WVF-7P Carburetor Check that the piston (picture) exhibits no scratches or oxidation and that it slides freely into the seat. Check the unloaded length of the spring. Check that the piston sealing gasket exhibits no deformations. Measure the projection of the piston as shown in the figure, and check the corresponding value.
Page 218 Install the choke onto the carburetor checking the proper positioning of the O- Ring, insert the plate with the knurling resting against the choke and tighten the fixing screw. Orientate the choke device as shown in the figure. Install the safety casing...
Page 219: Cooling System
10.12 Cooling System 10.12.1 Cooling Circuit 1 = Expansion tank 4 = Carburetor heating circuit 2 = LH radiator with electric fan 5 = Electric fan switch 3 = Thermostat with by-pass 6 = RH radiator...
Page 220: Removing The Water Pump
10.12.2 Removing the Water Pump If the bearings are noisy or any liquid leaks from the drain hole inside the cover, proceed to overhaul the water pump. Remove the flywheel cover with the water pump from the engine. Remove the impeller cover after unscrewing the three fastenings shown in the figure.
Page 221: Checking The Components
With the aid of a flat screwdriver, carefully remove the static part of the ceramic seal from the flywheel body. Place the flywheel cover under the press. Ensure that the cover is perfectly horizontal. Using the drift in inverted position, eject the two ball bearings.
Page 222: Fitting The Water Pump
10.12.4 Fitting the Water Pump Using the hot air gun, heat the flywheel cover from the inside. Specific tools and equipment: Hot air gun 020151Y Note: To prevent damage to the painted surface, avoid overheating the cover. Place the flywheel cover on the ring-shaped base as during the pump removal.
Page 223 Fit the flywheel cover, complete with bearings, onto the specific tool. Fit the shaft, comp lete with the mechanical seal, on the bearings. Using the specific drift and the press, insert the shaft into the bearings and the drive until the specific tool is felt to have reached its abutting end.
Page 224: Checking The Thermostat
10.12.5 Checking the Thermostat Visually check that the thermostat is not damaged. Prepare a metal container with ~¼ gallon (1 liter) of water. Immerse the thermostat and keep at the center of the container. thermometer probe next thermostat. Specific tools and equipment: 1 = Thermostat Digital multime ter 020331Y...
Page 225: Suspensions
11 Suspensions This section provides information on the operations that may be carried out on the suspensions. Lubricate with oil Clean carefully Caution: handle with care Lubricate with grease Always replace Apply product Torque 73-88 63-77 18-21 lbs·ft 104-126 90-110 25-30 (N·m)
Page 226: Removing And Refitting The Front Wheel
11.1 Removing and Refitting the Front Wheel Remove the five Allen screws shown in the figure, fastening the wheel to the hub. For re-assembly, properly place the wheel onto the front hub, and tighten the five screws at the prescribed torque. Tightening torque: Wheel fixing screws 14.0-17.5 lbs·ft...
Page 227: Removing The Steering Column
11.3 Removing the Steering Column Remove the front wheel. Remove the front caliper. Loosen the odometer fixing plate screw to remove the cable. Remove the suspension arm cover by releasing the three screws shown in the figure.
Page 228 Remove the odometer cable clamp from the front mudguard, as shown in the figure. Remove the brake tube clamp from the top plate of the shock absorber. Remove brake tube fixing from suspension arm. Pre-loosen the three nuts fixing the mudguard to the front suspension bracket.
Page 229 Remove the rear handlebar cover. Remove the screw fixing the handlebar to the steering column. Carefully rest the rear handlebar cover against the leg-shield, paying attention not to scratch any plastic parts. Remove the steering column ring nut cover. Remove the counter ring nut, the spacing washer and the top steering column ball-cage bearing seat ring nut.
Page 230: Removing The Front Wheel Hub
11.4 Removing the Front Wheel Hub Remove the front wheel. Remove the front brake caliper. Remove the split pin and the wheel axle nut cap shown in the figure. Remove the wheel axle nut. Extract the wheel hub, complete with brake disk, from its axle.
Page 231 Using specific tool, remove ball bearing. Specific tools and equipment: 15mm pliers 001467Y014 Bell 001467Y017 Using a flat screwdriver, remove the oil seal on the roller bearing side. Using the specific tool, remove the roller bearing. Specific tools and equipment: Handle 020376Y Adapter...
Page 232: Removing The Front Brake Caliper-Shock Absorber Bracket
Using the specific tool, insert the roller case and push it home. Refit the oil seal on the roller bearing side. Apply grease JOTA 3 FS between ball and roller bearings. Specific tools and equipment: Punch 020038Y 11.6 Removing the Front Brake Caliper-Shock Absorber Bracket Remove the wheel hub and the brake disk.
Page 233: Front Brake Caliper-Shock Absorber Bracket Overhaul
Before replacing the bracket into the wheel axle, place the O-ring as shown in the figure, in order to keep it properly positioned after the bracket assembly. Refit the washer and the snap ring. Replace the screws fixing the shock absorber to the bracket and tighten at the prescribed torque.
Page 234 Remove the oil guard on the wheel hub side using a screwdriver, as shown in the figure. Suitably support the shock absorber-brake caliper bracket. Using the specific tool, install a new oil seal and push it home. Specific tools and equipment: Handle 020376Y 2.0×2.2 in (52×55 mm) adapter...
Page 235: Removing The Front Shock Absorber
11.8 Removing the Front Shock Absorber Remove the steering column. Remove shock absorber lower fixing screws. Remove the top shock absorber attachments. For re-assembly, perform the operations for removal in the reverse order and tighten at the specified torque. Tightening torque: Shock absorber top fixing screw 14-21 lbs·ft (20-30 N·m)
Page 236 Warning - Reassemble with new roller cases, pins, oil seals and dust covers. Install dust covers «C» oscillating hub as shown in detail "A". Connect the oscillating hub to the steering column using the guide pin indicated as part 5. Fit the specific tool with the bearing, part 3, onto the shaft and part 4 at its base.
Page 237: Steering Column Ball-Cage Bearings Overhaul
Use the tool fitted with parts 20 and 21 on its shaft, as shown in the figure. Using the handle exert pressure until the bottom of the two needle casings is brought into contact with the pin end. Use the tool fitted with parts 3 and 4, as for fitting the pin, and operate the handle to exert pressure until the washers are wedged onto the oscillating hub.
Page 238 Remove the steering column. Using the specific tool, remove the top steering column bearing seat from underneath the steering head, as shown in the figure. Then, from the top, remove the lower steering bearing seat. Specific tools and equipment: Steering bearing removing punch 020004Y Using the specific tool, remove the steering column ball-cage bearing seat and the dust...
Page 239 Using the specific tool, replace the dust cover and the steering column ball-cage bearing seat on the steering tube to abutment. Specific tools and equipment: Steering bearing removing punch 006029Y Using the specific tool, install the steering column ball-cage bearing seats on the head as shown in the figure.
Page 240: Removing The Rear Shock Absorber-Silencer Bracket
11.11 Removing the Rear Shock Absorber-Silencer Bracket Remove the silencer. Remove the two screws fixing the bracket to the engine crankcase. Remove the split pin, the key cap, and the rear wheel axle fixing nut with spacer. Remove the lower shock absorber fixing. For re-assembly, perform the operations for removal in the reverse order, tightening each fastener at the specified torque value.
Page 241: Rear Shock Absorbers
11.12 Rear Shock Absorbers 11.12.1 Removing the Rear Shock Absorbers Rest the vehicle on its central stand. Remove the rear rack. Using a jack, slightly lift the engine off the ground so to unload the rear suspensions. Remove the silencer. Loosen both lower shock absorber fastening bolts (on crankcase and crankcase-silencer bracket).
Page 242: Refitting The Rear Shock Absorbers
11.12.2 Refitting the Rear Shock Absorbers Perform the operations for removal in the reverse order, and tighten all fasteners according to the prescribed tightening torques. Tightening torques: Shock absorber lower fixing bolt 23-29 lbs·ft (33-41 N·m) Shock absorber top fixing screw 14-18 lbs·ft (20-25 N·m) 11.13 Central Stand...
Page 243 Remove the spring anchoring the swing arm to the frame, as shown in the figure. Remove the two screws fixing the pad support bracket to the frame.
Page 244 Remove the RH and LH caps located under the footrest to access the pin fixing the swing arm to the body. Carefully inspect the whole of the swing assembly.
Page 245: Swing Arm Overhaul
Carefully inspect centering bushes, rubber pads, and silent block. Replace worn components found to exhibit excessive play, resulting in unsatisfactory riding characteristics. For reassembly, perform these operations in the reverse order. Apply TUTELA Z2 grease on all bearings and revolving components. Complete the assembly tightening the nuts onto the relevant pins at the correct tightening torques.
Page 246 Suitably support the bracket and the silent- block in a vice. Using the specific tool, extract the silent-block from the bracket on the frame side. This is to ensure that the tool is centered with respect to the support. Install silent-block ensuring alignment with the reference tooth.
Page 247: Silent-Block Overhaul
11.16 Silent-Block Overhaul Check that there are no dents on the joint connecting the swing arm on the engine side to the swing arm on the frame side. Check the axial clearance between the two swing arms using a thickness gauge. Standard clearance: 0.016-0.024 in (0.40-0.60 mm)
Page 248 Separate the swing arm on the engine-side from the swing on the frame -side. Remove the plastic bushes and the internal spacer shown in the figure. Using a suitable pin, remove the roller cases as shown in the figure. Using the specific tool, fit new cases being careful to position bearings with sealing rings facing outwards.
Page 249 Standard dimensions: 0.20 0 0 8 175.3 Engine-side swing arm tube length 0 0 0 0.00 − 0.00 0 0 0 0 0 8 0.20 Engine-side internal swing arm spacer length − − 0 0 2 0.05 Engine-side swing arm plastic bushes diameter ±...
Page 250: Bodywork
12 Bodywork 12.1 Removing the Seat Remove the helmet compartment. Loosen the two screws shown in the picture. Remove the seat. 12.2 Removing the Steering Column Cover Remove the “PIAGGIO” badge. Loosen the screw shown in the picture. Carefully pull the cover. 12.3 Removing the Front Handlebar Cover Remove the steering column cover.
Page 251: Removing The Instrument Panel
Loosen the two screws shown in the figure. Remove the front handlebar cover. Carefully detach the headlight connections. 12.4 Removing the Rear Handlebar Cover Remove the front handlebar cover. Loosen the four screws shown in the picture. Detach the speedometer cable. Detach all electrical connections and remove the rear handlebar cover.
Page 252: Removing The Glove-Box Panel
12.6 Removing the Glove-box Panel Remove the rear handlebar cover. Loosen the two screws shown in the picture, from the front leg-shield. Remove the expansion tank cover and its cap. Loosen screw shown picture, positioned inside the glove-box compartment. Loosen the two screws shown in the picture, positioned underneath the two side covers.
Page 253 Loosen the four screws shown in the picture, positioned at the bottom of the glove-box panel. Detach the seat opening electrical connection, the fuse holder, and the seat opening cable.
Page 254: Removing The Battery Compartment Cover
12.7 Removing the Battery Compartment Cover Loosen the four screws shown in the picture. 12.8 Removing the Side Fairings Loosen the two screws shown in the picture and remove the fairing. Follow the same operation for both left and right hand-side. 12.9 Removing the Footrest Remove the glove-box panel.
Page 255 Remove both pillion pegs by loosening the two screws (on each side) shown in the picture. Loosen the two (LH and RH) footrest fixing screws. Remove the two (LH and RH) lower plastic covers by loosening the screw as shown in the picture.
Page 256: Removing The Luggage Carrier
12.10 Removing the Luggage Carrier Remove the helmet compartment. Loosen the two screws shown in the picture and remove the luggage carrier cover. Loosen the six fixing screws shown in the figures and remove the luggage carrier.
Page 257: Removing The Taillight
12.11 Removing the Taillight Loosen the two license plate light fixing screws shown in the figure, and remove the plastic flap. Loosen the two fixing screws shown in the picture and remove the taillight. 12.12 Removing the Helmet Compartment Open the seat and lift the helmet compartment bay.
Page 258: Removing The Fuel Tank
12.13 Removing the Front Fender In order to remove the front fender, it is necessary to remove the steering column and disconnect the front brake tube from the caliper. The fender can then be removed by loosening the three fixing screws shown in the picture. 12.14 Removing the Fuel Tank Remove the helmet compartment.
Page 259 After removing the taillight, loosen the fuel tank-frame fixing screw shown in the figure. Remove the fuel tap clamps shown in the figure. Remove the rear turn signal lights. Lift the vehicle in order to obtain enough clearance between frame and engine such to remove the fuel tank from underneath the frame.
Page 260: Removing The Radiators And The Cooling Fan
12.15 Removing the Radiators and the Cooling Fan Before acting on the radiators, drain the cooling circuit by disconnecting the liquid inlet tube from the pump. Remove the glove-box panel. Disconnect the inlet and outlet tubes from the RH radiator. Loosen the radiator fixing screws shown in the figure.
Page 261: Removing The Rear Mudguard
Follow the same procedure for the LH radiator, although, in this case, it is necessary to remove the electric fan by loosening the three screws shown in the figure. When reassembling the radiators, follow the operations described above in the reverse order, paying particular attention in using new clamps for all the cooling liquid piping connections and in properly refilling the cooling circuit.
Page 262: Removing The Electrical Opening Seat System
Loosen the screw shown in the figure and remove the rear turn signal light. 12.18 Removing the Electrical Opening Seat System Remove the helmet compartment. Loosen the two nuts shown in the figure. Detach the electrical cable from the clamps shown in the figure.
Page 263 Remove the seat opening cable. Remove the seat opening cable manual control. Detach the electrical connector from the seat opening actuator. Loosen the two screws shown in the figure. Remove the return spring. Remove the actuator from the support bracket.
Page 264: Pre- Delivery Inspections
13 Pre-Delivery Inspections Before deliverying the vehicle, carry out the following checks: Caution – Handle gasoline with the utmost care. 13.1 Checking the Vehicle Appearance Paintwork Plastic fairing joins Scratches or dents Dirtiness 13.2 Checking the Tightening Torques Check all tightening torques Check external fairing screws 13.3 Checking the Electrical Circuit...
Page 265: Checking The Levels
In case of ingestion of electrolyte, drink water or vegetable oil and seek immediate medical attention. Batteries produce explosive gases; keep the battery well away from open flam es, sparks or cigarettes. Ensure there is adequate ventilation when charging batteries in closed areas. Protect the eyes when working with batteries or in their immediate vicinity.
Page 266: Functional Check
13.7 Functional Check Brake lever travel and braking circuit Clutch Engine Other: documents inspection, toolkit, license plate, locks, tires inflation pressure, mirrors and accessories Warning – Check and adjust the tire inflation pressure only when the tires are at ambient temp erature.
Page 267: Time Sheets
14 Time Sheets 14.1 Engine Description Code Time Engine from the frame - Dismantling and 001001 Reassembling Engine oil - Replacement 003064 Engine fixing - Nut 003057 tightening 14.2 Crankcase Description Code Time Half crankcase gasket - 140' 001153 Replacement Engine crankcase - 200' 001133...
Page 268: Piston-Cylinder Assembly
14.4 Piston-Cylinder Assembly Description Code Time Piston-cylinder assy. - 130' 001002 Replacement Piston-Rings-Wrist Pin 130' 001154 Assembly - Overhaul 14.5 Cylinder Head and Valves Description Code Time Cylinder Head Assembly 001126 130' - Replacement Valves - Replacement 001045 130' Valves - Adjustment 001049 Head Gasket - 001056...
Page 269: Valve Cover
14.7 Valve Cover Description Code Time Spark plug - 001093 Replacement Head cover - 001089 Replacement Head cover gasket - 001088 Replacement Oil vapor recovery pipe - 001074 Replacement 14.8 Chain T ensioner - By-Pass Valve Description Code Time Chain tensioner - Overhaul and 001129 Replacement...
Page 270: Driven Pulley
14.10 Driven Pulley Description Code Time Clutch - Replacement 001022 Driven pulley - Overhaul 001012 Driven pulley - 001110 Replacement Clutch drum - 001155 Replacement 14.11 Pump Assembly - Oil Sump Description Code Time Chain guide shoe - 140' 001125 Replacement Timing belt/chain - 140'...
Page 271: Rear Wheel Axle
14.12 Rear Wheel Axle Description Code Time Reduction gear assy. - 001010 Overhaul Reduction gear cover - 001156 Replacement Gearbox oil - 003065 Replacement Rear wheel axle - 004125 Replacement 14.13 Driving Pulley Description Code Time Driving half-pulley - 001086 Replacement Driving belt - 001011...
Page 272: Electric Starter
14.14 Electric Starter Description Code Time Starter motor - 001020 Replacement Starter pinion - 001017 Replacement Belt support roller - 001141 Replacement 14.15 Kick-Starter, Transmission Cover, and Transmission Cooling Description Code Time Transmission cover 001135 bearing - Replacement Transmission cover - 001096 Replacement Transmission air inlet -...
Page 273: Flywheel Magneto
14.17 Flywheel Magneto Description Code Time Flywheel cover - 001087 Replacement Water pump, pump 001113 impeller - Replacement Stator - Removal and 001067 reassembly Complete flywheel - 001058 Replacement Secondary air filter - 001161 Replacement Secondary air filter box - 001162 Replacement Rotor - Replacement...
Page 274: Air Filter
14.19 Air Filter Description Code Time Air filter - 001014 Replacement/Cleaning Air filter box - 001015 Replacement Carburetor-air box 004122 bellow - Replacement 14.20 Silencer Description Code Time Silencer - Replacement 001009 Silencer protection- 001095 Replacement...
Page 275: Frame
14.21 Frame Description Code Time Frame - Replacement 240' 004001 Fairing (1) - 004085 Replacement Horn - Replacement 004149 Spoiler - Replacement 004053 Passenger footrest - 004015 Removal and reassembly Shield edge - 004023 Replacement Badges - Replacement 004159 14.22 Central Stand Description Code Time...
Page 276: Footrest And Battery
14.23 Footrest and Battery Description Code Time Battery - Replacement 005007 Footrest - Replacement 004079 Battery compartment - 004071 Replacement Battery cover - 005046 Replacement Footrest rubber - 004078 Replacement 14.24 Glove-Box Description Code Time Glove-box - Replacement 004083 Glove-box flap - 004081 Replacement...
Page 277: Helmet Compartment And Rear Fender
14.25 Helmet Compartment and Rear Fender Description Code Time Rear fender - 004136 Replacement Helmet compartme nt - 004016 Removal and reassembly Plate holder - 005048 Replacement 14.26 Front Fender and Rear Mudguard Description Code Time Front fender - 004002 Replacement Rear mudguard - 004009...
Page 278: Cooling System
14.28 Cooling System Description Code Time Radiator - Replacement 007002 Fan with support - 007016 Replacement Expansion tank - 007001 Replacement Thermo -switch - 007014 Replacement Tank-radiator pipe - 007013 Replacement Coolant pipe - 007003 Replacement Coolant and air vent - 001052 Replacement 14.29 Fuel Pump...
Page 279: Steering Column
14.30 Steering Column Description Code Time Steering column ball- cage bearings - 003002 Replacement Steering column play - 003073 Adjustment 14.31 Front Suspension Description Code Time Front shock absorber - 003011 Removal and reassembly Steering column - 003045 Replaceme nt Front suspension - 100' 003010...
Page 280: Rear Suspension
14.32 Rear suspension Description Code Time Rear shock absorber - 003007 Removal and reassembly 14.33 Handlebar Covers Description Code Time Handlebar cover, front 004018 side - Replacement Handlebar cover, back 004019 side - Replacement...
Page 281: Handlebar, And Brake And Throttle Controls
14.34 Handlebar, and Brake and Throttle Controls Description Code Time Handlebar - Removal 003001 and reassembly Front brake pump - 002024 Replacement Rear brake pump - 002024 Replacement Brake light switch - 005017 Replacement LH handgrip - 002059 Replacement RH handgrip - 002071 Replacement Counterweight -...
Page 282: Brakes
14.36 Brakes Description Code Time Rear brake pads - Wear 003071 check Front brake pads - Wear 003070 check Front brake caliper - 002040 Overhaul Front brake caliper - 020039 Removal and reassembly Rear brake caliper - 002048 Removal and reassembly Rear brake caliper - 002068 Overhaul...
Page 283: Saddle And Rear Rack
14.37 Saddle and Rear Rack Description Code Time Saddle - Replacement 004003 Rack - Replacement 004008 Rack cover - 004062 Replacement 14.38 Locks and Immobilizer Description Code Time Saddle opening cable - 002083 Replacement Lock cable for saddle 002092 opening - Replacement Lock for saddle opening - 004158 Replacement...
Page 284: Mirrors, Electric Controls, And Instrument Panel
14.39 Mirrors, Electric Controls, and Instrument Panel Description Code Time Rearview mirror - 004066 Replacement Instrument panel - 005014 Replacement Start button - 005041 Replacement Engine cut-off switch - 005077 Replacement Turn signal switch - 005006 replacement Horn button - 005040 Replacement Saddle opening button -...
Page 285: Lights
14.40 Lights Description Code Time Headlight - Replacement 005002 Taillight - Replacement 005005 License plate light - 005032 Replacement Front turn signal bulb - 005067 Replacement Headlight bulb - 005008 Replacement Taillight bulb - 005066 Replacement Plate light bulb - 005031 Replacement Brake light bulb -...
Page 286: Electrical Devices
14.41 Electrical Device s Description Code Time Spark plug cap - 001094 Replacement H.T. coil - Replacement 001069 Horn - Replacement 005003 Odometer/Speedometer 002049 cable - Replacement Electronic ignition device 001023 - Replacement Voltage regulator - 005009 Replacement Electrical circuit - 120' 005001 Replacement...
Page 287: Front Wheel
14.42 Front Wheel Description Code Time Front brake disk - 002041 Replacement Front wheel hub - 003033 Replacement Front wheel - 004123 Replacement Front wheel rim - 003037 Removal and reassembly Front tire - Replacement 003047 Front tire - Check 003063 14.43 Rear Wheel Description...

VESPA GT 200 Workshop Manual

3 Flash Diagnostic Code

2 Flash Diagnostic Code

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