VESPA GT 125 Workshop Manual
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VESPA GT 125 Workshop Manual

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WORKSHOP MANUAL
633338
Vespa GT 125-200

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  • Page 1 WORKSHOP MANUAL 633338 Vespa GT 125-200...
  • Page 2 WORKSHOP MANUAL Vespa GT 125-200 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 WORKSHOP MANUAL Vespa GT 125-200 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 4 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    Vespa GT 125-200 Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...
  • Page 7 Vespa GT 125-200 Characteristics Engine prefix: M311M1001 Granturismo 200 Chassis prefix: ZAPM312000000 ÷ 1001 Engine prefix: M312M1001 Dimensions and mass MASS AND DIMENSIONS Specification Desc./Quantity Total loadless weight 140 Kg Width (to hand grips) 755 mm Length 1940 mm Wheelbase...
  • Page 8 Vespa GT 125-200 Characteristics Engine DATA 125 Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Timing system single overhead camshaft chain driven on the left-hand side, 3- arm rocking levers set up with set screw Bore 125 57 mm Stroke 48.6 mm...

  • Page 9: Electrical System

    Vespa GT 125-200 Characteristics Transmission RANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling Capacities CAPACITY Specification Desc./Quantity Engine oil ~ 1000 cc (recommended oil: Selenia HI Scooter 4 Tech) Fuel tank (including a ~ 2 l reserve) ~ 9.5 l...

  • Page 10: Wheels And Tyres

    Vespa GT 125-200 Characteristics Brakes BRAKES Specification Desc./Quantity Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plung- ers and hydraulic control (lever on the far right end of the handlebar) Rear Ø 220 disc brake and calliper with two Ø 30 mm counteracting...
  • Page 11 Vespa GT 125-200 Characteristics Specification Desc./Quantity Venturi diffuser Ø 29 (47x30.9) Throttle valve Ø 30.5 Diffuser maximum cone N.B. * THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE. Walbro WALBRO CARBURETTOR 125 Specification Desc./Quantity Depression type WVF-7R* Printing on the body CUT-OFF device Not.

  • Page 12: Tightening Torques

    Vespa GT 125-200 Characteristics Specification Desc./Quantity Venturi choke Ø 29 (47x30,9) Throttle valve Ø 30,5 Choke maximum cone N.B. THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE Walbro WALBRO CARBURETTOR 200 Specification Desc./Quantity Depression type WVF-7P* Printing on the body...

  • Page 13: Front Brake

    Vespa GT 125-200 Characteristics Name Torque in Nm Wheel screw 20 ÷ 25 Screw fixing rear mudguard to steering 5 ÷ 6.5 FRONT BRAKE Name Torque in Nm Brake fluid pump-hose fitting 20 ÷ 25 Brake fluid hose-calliper fitting 20 ÷ 25 Screw fixing calliper to the shock absorber - calliper plate at- 20 ÷...

  • Page 14: Assembly Clearances

    Vespa GT 125-200 Characteristics Name Torque in Nm Side screw M5 locking the washers on the camshaft (125 cc) 7 ÷ 8,5 Tappet set screw lock nut 6 ÷ 8 Inlet manifold screws 11 ÷ 13 Timing chain tensioner slider screw 10 ÷...
  • Page 15 Vespa GT 125-200 Characteristics Cylinder - piston assy. ENGINE 125 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 ÷...
  • Page 16 Vespa GT 125-200 Characteristics ENGINE 200 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder / piston 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston 72.004 ÷...
  • Page 17 Vespa GT 125-200 Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05...
  • Page 18 Vespa GT 125-200 Characteristics THICKNESS 125 Name Measure A Thickness Gasket thickness 125 2,2 ÷ 2,4 0,4 ± 0,05 Gasket thickness 125 2,4 ÷ 2,6 0,6 ± 0,05 Characteristic Compression ratio, 200 models Cr: 11÷12 :1 Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder.
  • Page 19 Vespa GT 125-200 Characteristics Oversizes ENGINE 125 OVERSIZE Name Description Dimensions Initials Quantity Compression ring 57 x 1 0.15 ÷ 0.30 Oil scraper ring 57 x 1 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 0.15 ÷ 0.35 Compression ring 1st 57.2 x 1...

  • Page 20: Recommended Products

    Vespa GT 125-200 Characteristics Products RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-...
  • Page 21 INDEX OF TOPICS TOOL OOLING...
  • Page 22 Vespa GT 125-200 Tooling APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42-mm bearings 001467Y017 Bell for bearings, OD 39 mm 001467Y014 Pliers to extract ø 15-mm bearings 005095Y Engine support 002465Y Pliers for circlips...
  • Page 23 Vespa GT 125-200 Tooling Stores code Description 008564Y Flywheel extractor 020004Y Punch for removing fifth wheels from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch TOOL - 23...
  • Page 24 Vespa GT 125-200 Tooling Stores code Description 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip TOOL - 24...
  • Page 25 Vespa GT 125-200 Tooling Stores code Description 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cylinder 020306Y Punch for assembling valve seal rings 020319Y Immobilizer check tester 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing...
  • Page 26 Vespa GT 125-200 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 26...
  • Page 27 Vespa GT 125-200 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide TOOL - 27...
  • Page 28 Vespa GT 125-200 Tooling Stores code Description 020365Y 22 mm guide 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool...
  • Page 29 Vespa GT 125-200 Tooling Stores code Description 020393Y Piston fitting band 020409Y Multimeter adaptor - Peak voltage detec- tion 020412Y 15 mm guide 020414Y 28-mm guide 020423Y driven pulley lock wrench TOOL - 29...
  • Page 30 Vespa GT 125-200 Tooling Stores code Description 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting TOOL - 30...
  • Page 31 Vespa GT 125-200 Tooling Stores code Description 020439Y 17 mm guide 020440Y Water pump service tool 020441Y 26 x 28 mm adaptor 020442Y Pulley lock wrench 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 31...
  • Page 32 Vespa GT 125-200 Tooling Stores code Description 020455Y 10-mm guide 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020488Y Pin stops fitting tool (200 cm³ engines) 020489Y Hub cover support stud bolt set TOOL - 32...
  • Page 33 Vespa GT 125-200 Tooling Stores code Description 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser TOOL - 33...
  • Page 34 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 35: Maintenance Chart

    Vespa GT 125-200 Maintenance Maintenance chart EVERY 2 YEARS Action Secondary air filter (external / internal) - Clean Coolant - change Brake fluid - change EVERY 3,000 KM Action Engine oil - level check/ top-up AT 1000 KM OR 4 MONTHS...
  • Page 36 Vespa GT 125-200 Maintenance Action Driving belt - Check / Replacement Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check...
  • Page 37 Vespa GT 125-200 Maintenance Action Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - Check / Replacement Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
  • Page 38 Vespa GT 125-200 Maintenance AT 36000 KM (125) 205' Action Engine oil - replacement Hub oil level - Check / Replace Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil - change Valve clearance - adjustment...
  • Page 39 Vespa GT 125-200 Maintenance Action Engine oil - replacement Hub oil level - Check / Replace Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil - change Valve clearance - check Valve play 200 - recording...

  • Page 40: Checking The Spark Advance

    Vespa GT 125-200 Maintenance 2. Gas valve spring 3. Tapered pin support 4. Tapered pin spring 5. Tapered pin 6. Throttle valve diaphragm 7. Automatic starter 8. Idle speed adjustment screw 9. Accelerating pump rocking lever 10.Idle mixture adjustment screw 11.Float pin...
  • Page 41 Vespa GT 125-200 Maintenance - Operating on the flash corrector displacement of the bulb, make the reference on the flywheel cover coincide with level on the water pump drive. Read the advance degrees indicated by the stroboscop- ic light. - Check that the advance degrees corresponds with the rotation rpm as indicated in the table.
  • Page 42 Vespa GT 125-200 Maintenance VERSION 125 Specification Desc./Quantity Operation threshold First threshold : 10700 ±50 Second threshold : 11000 ±50 Reactivation threshold First threshold : 10600±50 Second threshold : 10900±50 Spark elimination First threshold : 1 spark on 7 Second threshold : 2 sparks on 3...

  • Page 43: Spark Plug

    Vespa GT 125-200 Maintenance Spark plug - Rest the vehicle on the central stand. -Open the saddle and extract the helmet compart- ment - Disconnect the spark plug H.V. cable cap. - Unscrew the spark plug, using the spanners sup- plied.
  • Page 44 Vespa GT 125-200 Maintenance - Adjust the distance, if required, by bending the side electrode carefully. In case of irregularity, re- place the spark plug with one of the recommended type. - Insert the spark plug with the proper inclination, and screw it thoroughly by hand, then tighten it using the special wrench.

  • Page 45: Air Filter

    Vespa GT 125-200 Maintenance Replacement -Remove the oil cap «A». - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil. Recommended products...
  • Page 46 Vespa GT 125-200 Maintenance AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness - Remove the left side panel. - Remove the air cleaner cover after unscrewing the 9 fixing screws. - Take out the filtering element.

  • Page 47: Engine Oil

    Vespa GT 125-200 Maintenance Engine oil In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be con- sidered normal, especially if during the run-in period.
  • Page 48 Vespa GT 125-200 Maintenance Lubricate them and refit the gauze filter and oil drainage tap, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubri- cate the O-ring before fitting it. Change the engine oil.

  • Page 49: Checking The Ignition Timing

    Vespa GT 125-200 Maintenance Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc.

  • Page 50: Cooling System

    Vespa GT 125-200 Maintenance Cooling system Introduction of the engine coolant. The fluid level inspection should be carried out ev- ery 6,000 km when the motor is cold, following the methods indicated below: Place the scooter on its centre stand and on flat ground.
  • Page 51 Vespa GT 125-200 Maintenance Top-up - Position the vehicle on a flat surface and on the centre stand - Remove the brake pump cover as indicated in the photo Check the brake fluid level through the sight glass on the pump as shown in the photograph...

  • Page 52: Headlight Adjustment

    Vespa GT 125-200 Maintenance For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws. CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.
  • Page 53 Vespa GT 125-200 Maintenance CO check Remove the side, then remove the transmission side cooling air inlet so as to easily reach the flow adjustment screw - Remove the gas cap on the exhaust pipe. - Using the original washer, install the exhaust gas collection Kit union.
  • Page 54 Vespa GT 125-200 Maintenance - Disconnect the SAS check valve vacuum pipe from the «T» branch shown in the figure. - Close the branch using a cap or a pipe portion with conical cap. - Connect the Mitivac vacuum pump to the control pipe and to the SAS valve.
  • Page 55 Vespa GT 125-200 Maintenance SAS filters inspection and cleaning the SAS for leader engines 125 cm³ - 200 cm³ Euro 2 operates in a similar manner to the SAS for 2T engines. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the dis- charge pipe on the head.
  • Page 56 Vespa GT 125-200 Maintenance The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved re- action of the catalytic converter.
  • Page 57 Vespa GT 125-200 Maintenance - Remove the 2 fixing screws, the gasket and the pipe connecting the SAS valve to the head. Then remove the pipe. - Release the electrical cable from the flywheel cover clamp as indicated in the photograph...
  • Page 58 Vespa GT 125-200 Maintenance - Remove the pump support bracket and fuel filter. - Remove the flywheel cover together with the SAS valve acting on the 4 hexagonal-head screws as indicated in the photograph - Remove the SAS valve two fixing screws and re-...
  • Page 59 Vespa GT 125-200 Maintenance - Check that the SAS valve plastic support is not dented or distorted - Check that the gasket is in good conditions - Carefully clean the inside and outside filters. Re- place them if damaged or abnormally distorted.
  • Page 60 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 61: Rear Wheel Spins At Idle

    Vespa GT 125-200 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-...
  • Page 62 Vespa GT 125-200 Troubleshooting Possible Cause Operation lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components The carburettor is dirty;...
  • Page 63 Vespa GT 125-200 Troubleshooting Engine tends to cut-off at idle THE ENGINE TENDS TO STOP AT IDLE Possible Cause Operation Air calibrated holes in carburettor blocked Dismantle, wash with solvent and dry with compressed air Defective floating valve Check the proper sliding of the float and the functioning of the...
  • Page 64 Vespa GT 125-200 Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...

  • Page 65: Noisy Suspension

    Vespa GT 125-200 Troubleshooting Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and bottom ring nuts. If irregu- larities in turning the steering continue even after making the above adjustments, check the seats on which the ball bearings rotate: replace them if they are recessed or if the balls are flat- tened.
  • Page 66 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 67 Vespa GT 125-200 Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Front left-hand direction indicator with 2 bulbs Rear stop light switch Light switch Turn indicator switch Horn button Intercom fitting Saddle opening button Thermal switch Electric fan Saddle opening actuator Voltage regulator...
  • Page 68 Vespa GT 125-200 Electrical system Specification Desc./Quantity Key switch Starter button Horn Front right-hand direction indicator with 2 bulbs Instrument group with 9 bulbs, warning lights, fuel re- serve warning light, oil pressure warning light, upper beam indicator, RH flashing light indicator, LH flashing...
  • Page 69 Vespa GT 125-200 Electrical system IGNITION Specification Desc./Quantity Pick - up Magneto flywheel Fuse 15A (No. 7) Electronic ignition device Spark plug HV coil Voltage regulator Battery 12V-12Ah H.T. coil This is to inform you that, starting from frame no. ZAPM3120000022142, a protective cap has been introduced for the H.T.
  • Page 70 Vespa GT 125-200 Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP Specification Desc./Quantity Engine stop switch Key switch contacts Fuse Stop button Start up button Starter motor Remote starter switch No. 8 bulbs for stop light 12V-2,3W Fuse...
  • Page 71 Vespa GT 125-200 Electrical system Level indicators and enable signals section LEVEL INDICATORS AND ENABLE SIG- NALS Specification Desc./Quantity Cooling fluid temperature indicator Fuel gauge Fuel level sender Thermistor Fuel indicator 12V - 1.2W Low oil pressure warning 12V - 2W...
  • Page 72 Vespa GT 125-200 Electrical system Immobiliser The electronic ignition system is realised with di- rect current power supply and is equipped with immobilizer antitheft device built in the control unit. The ignition system is made up of: - control unit...
  • Page 73 Vespa GT 125-200 Electrical system If no faults are found, replace the control unit; oth- erwise, check the wiring and the following compo- nents: - Engine stop remote control switch; - Emergency stop switch; - Side stand switch; - Key switch contacts.
  • Page 74 Vespa GT 125-200 Electrical system high voltage system shielding: In any case it is ad- visable to use resistive spark plugs. Characteristic Shielded cap resistance ~ 5000 Ω. Diagnostic codes The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings.
  • Page 75 Vespa GT 125-200 Electrical system ~ 7 ÷ 9 Ohm Diagnostic code - 3 flashes If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the key switch. - If the failure disappears when the MASTER key is used, encode the service keys (Blue) again.
  • Page 76 Vespa GT 125-200 Electrical system Electric characteristic Pick-up resistance value Pick-up resistance value: 105 ÷ 124 Ohm If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are measured, replace the Pick-Up;...
  • Page 77 Vespa GT 125-200 Electrical system 020409Y Multimeter adaptor - Peak voltage de- tection Electric characteristic Resistance value: ~ 3000 ± 300 Ohm - Pick-Up Disconnect the control unit connector and connect the positive wire to connector No. 2 and the neg- ative wire to connector No.
  • Page 78 Vespa GT 125-200 Electrical system The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.
  • Page 79 Vespa GT 125-200 Electrical system - With a tester, check the circuit between connec- tions 5-3 and 5-1 is not interrupted. - Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω...
  • Page 80 Vespa GT 125-200 Electrical system Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V.
  • Page 81 Vespa GT 125-200 Electrical system check the wiring between starter and control unit, or finally, as last option replace the starter. Turn signals system check - If the turn indicators do not work, proceed as follows: -Disconnect the control unit connector and check that there is battery voltage between terminal No.4 (Red/Black) and the ground lead.
  • Page 82 Vespa GT 125-200 Electrical system Fuses The electrical system is equipped with: 1. six protection fuses «A» located in the glove compartment to the left 2. one 15A fuse «B» located under the helmet compartment under the saddle hinge latch.
  • Page 83 Vespa GT 125-200 Electrical system Specification Desc./Quantity water temperature indica- tor, fuel reserve indicator, oil pressure indicator and fuel reserve light Horn Order on terminal hold- er: 4 Fuse: 7,5A Protected circuits: Horn Intercom fitting, antitheft Order on terminal hold-...
  • Page 84 Vespa GT 125-200 Electrical system Specification Desc./Quantity Right turn indicator Temperature signal Dry-charge battery Battery recharge Normal bench charging must be carried out using the special (single or multiple) battery charger, setting the battery charge selector to the type of battery that needs recharging (i.e., at a current equal to 1/10 of the battery rated capacity).
  • Page 85 Vespa GT 125-200 Electrical system Battery cleaning The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline. CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

  • Page 86: Battery Installation

    Vespa GT 125-200 Electrical system 020334Y Multiple battery charger 1 Hold the vertical tube 2 Look at the level 3 The float must be freed Battery installation • Remove the battery cover after undoing the 4 screws shown in the photograph.
  • Page 87 Vespa GT 125-200 Electrical system - Fit the battery as shown in the photograph. N.B. IN ORDER TO FIT THE CABLES ON THE BATTERY TER- MINALS CORRECTLY, REST THE LOWER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.
  • Page 88 Vespa GT 125-200 Electrical system - Refit the battery cover ELE SYS - 88...
  • Page 89 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 90 Vespa GT 125-200 Engine from vehicle This section describes the operations to be carried out when removing the engine from the vehicle. Exhaust assy. Removal - Undo the two exhaust manifold fixings on the head. - Undo the three screws that fix the muffler to the support arm.
  • Page 91 Vespa GT 125-200 Engine from vehicle - Disconnect the battery - Remove the helmet compartment - Remove the side fairings Remove the full muffler assembly. - Remove the air cleaner housing acting on the 3 screws indicated in the picture, by removing the...
  • Page 92 Vespa GT 125-200 Engine from vehicle - Remove the coolant inlet pipe to the pump as in- dicated in the photograph. - Remove the fuel valve vacuum intake pipe from "T" joint indicated in the photograph - Remove the fuel supply pipe from the carburettor...
  • Page 93 Vespa GT 125-200 Engine from vehicle - Remove the spark plug cap - Remove the coolant temperature sensor con- nector indicated in the photo - Remove the throttle control cable from the car- burettor acting on the nut shown in the photo...
  • Page 94 Vespa GT 125-200 Engine from vehicle - Remove the positive and negative wires from the starter motor as shown in the photograph - Remove the connector from the flywheel wiring shown in the photograph. - Remove the cable from the retainer clamp on the flywheel cover - Remove the rear shock absorbers.
  • Page 95 Vespa GT 125-200 Engine from vehicle - Use a jack to support the vehicle properly. Re- move the engine-swinging arm fixing pin by acting on the nut and the head of the pin indicated in the photograph - The engine is now free.
  • Page 96 INDEX OF TOPICS NGINE...

  • Page 97: Automatic Transmission

    Vespa GT 125-200 Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
  • Page 98 Vespa GT 125-200 Engine - Remove the five screws on two different levels as well as the small casing. - To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.
  • Page 99 Vespa GT 125-200 Engine Refitting the driven pulley shaft bearing - Slightly heat the crankcase from the inside so as not to damage the painted surface. - Insert the bearing in its seat. - Refit the seeger ring. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM- AGING THE COVER PAINT.

  • Page 100: Inspecting The Clutch Drum

    Vespa GT 125-200 Engine - Refit the roller with the special screw. - Tighten to the specified torque. - Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing. Locking torques (N*m) Anti-flapping roller...

  • Page 101: Removing The Clutch

    Vespa GT 125-200 Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft...
  • Page 102 Vespa GT 125-200 Engine - Fit the special driven pulley spring compressor tool with the medium-length pins in position "C" screwed up from the inner side of the tool. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
  • Page 103 Vespa GT 125-200 Engine Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.
  • Page 104 Vespa GT 125-200 Engine - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide Inspecting the driven fixed half-pulley Version 125 - Measure the outer diameter of the pulley bushing.
  • Page 105 Vespa GT 125-200 Engine Inspecting the driven sliding half-pulley 125 - 200 version - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. Characteristic Movable driven half-pulley max. diameter Max. diameter admitted: Ø 41.08 mm Movable driven half-pulley standard diameter Standard diameter: Ø...
  • Page 106 Vespa GT 125-200 Engine MOVABLE DRIVEN HALF-PULLEY DIMENSIONS Specification Desc./Quantity Wear limit 0.3 mm standard diameter Diameter 41.000 - 41.035 mm maximum allowable diameter Ø 41.08 mm - Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling free assembled rollers.

  • Page 107: Refitting The Driven Pulley

    Vespa GT 125-200 Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Insert the new oil guards and O-rings on the mov- able half-pulley.
  • Page 108 Vespa GT 125-200 Engine Specific tooling 020263Y Sheath for driven pulley fitting Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the free length of the mobile driven half- pulley spring.
  • Page 109 Vespa GT 125-200 Engine - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Place the tool in the clamp with the control screw on the horizontal axis.
  • Page 110 Vespa GT 125-200 Engine Version 125 - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position «F» on the inside. - Insert the adapter ring 8 in the pins.
  • Page 111 Vespa GT 125-200 Engine N.B. DURING THE SPRING PRELOADING PHASE, BE CARE- FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. N.B. AN EXCESSIVE QUANTITY CAN DAMAGE THE CLUTCH OPERATION. Specific tooling 020444Y011 adapter ring 020444Y009 46x55 Wrench...

  • Page 112: Removing The Driving Pulley

    Vespa GT 125-200 Engine • Check that the driving belt is not dam- aged. • Check the belt width. Characteristic 125 4T driving belt - standard width: 22.5 ± 0.2 mm 125 4T driving belt - minimum width: 21.5 mm Driving belt standard width 20.5 ±...
  • Page 113 Vespa GT 125-200 Engine Driving pulley removal (125) - With the appropriate tool, remove the nut with the built-in Belleville washer, the drive common to the kick-starter version, and the steel washer. - Remove the fixed driving half-pulley. - Remove the steel washer separating from the bushing.
  • Page 114 Vespa GT 125-200 Engine Ø 26.12 mm roller (200): Standard Diameter Diameter 20.5 - 20.7 mm roller (125): Standard Diameter Ø 18.9 ÷ 19.1 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Movable driving half-pulley bushing: Standard Diameter 26.000 - 26.021 mm...
  • Page 115 Vespa GT 125-200 Engine The lock wrench operates on the start-up crown. - If the torque limiter is worn, the failure can be de- tected when locking the nut on the crankshaft. - The torque limiter cannot be serviced. - In case of failures, replace the start-up crown and the limiter.
  • Page 116 Vespa GT 125-200 Engine - Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Check that the roller contact plate does not have flaws and is not damaged on the grooved edge.
  • Page 117 Vespa GT 125-200 Engine Specific tooling 020423Y driven pulley lock wrench Locking torques (N*m) Transmission cover screws Driven pul- 11 ÷ 13 ley shaft nut 54 ÷ 60 End gear Removing the hub cover - Empty the rear hub through the oil drainage plug.
  • Page 118 Vespa GT 125-200 Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
  • Page 119 Vespa GT 125-200 Engine With the appropriate tools, remove the oil seal as shown in the figure. Specific tooling 020359Y 42x47-mm adaptor Removing the driven pulley shaft bearing When removing the driven pulley shaft, the corre- sponding bearing and oil seal, remove the trans- mission cover and the clutch group as explained above.
  • Page 120 Vespa GT 125-200 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents. Inspecting the hub cover - Check that the fitting surface is not dented or distorted.
  • Page 121 Vespa GT 125-200 Engine - Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal sur- face by means of the appropriate tool used from the 52 mm side. The 52 mm side of the adapter must be turned to- wards the bearing.
  • Page 122 Vespa GT 125-200 Engine - Refit the driven pulley shaft bearing with a mod- ular punch as shown in the figure. N.B. IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN- ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE.
  • Page 123 Vespa GT 125-200 Engine Flywheel cover Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover ENG - 123...

  • Page 124: Removing The Stator

    Vespa GT 125-200 Engine Removing the stator - Remove the electric terminal of the minimum oil pressure switch. - Remove the two Pick-Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure.
  • Page 125 Vespa GT 125-200 Engine Flywheel and starting - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. Removing the flywheel magneto - Lock the rotation of the Flywheel with the calliper spanner tool.
  • Page 126 Vespa GT 125-200 Engine Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut to the prescribed torque - Check that the Pick-Up air gap is between 0.34 ÷ 0.76 mm.
  • Page 127 Vespa GT 125-200 Engine Removing the intake manifold - Remove the flywheel cover completely as de- scribed in the flywheel cover section. - Loosen the 3 crews and remove the intake mani- fold. N.B. TAMPERPROOF SCREWS ARE SUPPLIED WITH 125 CC MODELS.
  • Page 128 Vespa GT 125-200 Engine - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure.
  • Page 129 Vespa GT 125-200 Engine - Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The chain tensioning pad must be removed from the transmission side. As regards the lower chain guide pad, it may only be removed after the head has been removed.

  • Page 130: Removing The Cylinder Head

    Vespa GT 125-200 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket.
  • Page 131 Vespa GT 125-200 Engine Removing the cylinder - piston assy. - Remove the chain guide pad. - Pull out the cylinder. - Remove the cylinder base gasket. - Remove the two stop rings, the wrist pin and the piston. - Remove the piston seals.
  • Page 132 Vespa GT 125-200 Engine ENG - 132...

  • Page 133: Inspecting The Small End

    Vespa GT 125-200 Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
  • Page 134 Vespa GT 125-200 Engine - The cylinder surface must exhibit a roughness of 0.9 micron. - This is required for ensuring a good settling of the sealing rings, thereby ensuring a low oil consump- tion and excellent performance. For engine 125 cc - There are uprated pistons for the cylinder adjust- ment, divided into three categories 1°, 2°, 3°...

  • Page 135: Inspecting The Piston

    Vespa GT 125-200 Engine Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.

  • Page 136: Removing The Piston

    Vespa GT 125-200 Engine Inspecting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge.
  • Page 137 Vespa GT 125-200 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, with- out any base gasket. - Assemble a dial gauge on the specific tool Support to check piston position 020428Y - Set the dial gauge to zero placing the tool on a contrasting surface.
  • Page 138 Vespa GT 125-200 Engine der base gasket thickness to keep the correct compression ratio. - Remove the specific tool and the cylinder. N.B. PISTON PROTRUSION IS MEASURED IN 125 ENGINES WHILE INTRODUCTION IS MEASURED IN 200 ENGINES. See also Slot packing system Refitting the piston rings - Place the oil scraper spring on the piston.

  • Page 139: Inspecting The Cylinder Head

    Vespa GT 125-200 Engine N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL. Specific tooling 020393Y Piston fitting band 020287Y Clamp to assemble piston on cylinder Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted.
  • Page 140 Vespa GT 125-200 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
  • Page 141 Vespa GT 125-200 Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
  • Page 142 Vespa GT 125-200 Engine CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COM- POUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
  • Page 143 Vespa GT 125-200 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.
  • Page 144 Vespa GT 125-200 Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft.
  • Page 145 Vespa GT 125-200 Engine Cam shaft check: Maximum admissible axial clearance 0.42 mm Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm Cam shaft check: Standard height Outlet: 29.209 mm Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm...
  • Page 146 Vespa GT 125-200 Engine Assemble the lower timing chain sprocket wheel on the crankshaft, with the chamfer facing the in- sertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the chain tensioner slider from the cylinder head side.
  • Page 147 Vespa GT 125-200 Engine - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que. Locking torques (N*m) Plate screws 4 ÷ 6 Nm Insert the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase.
  • Page 148 Vespa GT 125-200 Engine Set the tensioner cursor to the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the pre- scribed torque. Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque.
  • Page 149 Vespa GT 125-200 Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
  • Page 150 Vespa GT 125-200 Engine - Remove the two retainers indicated in the figure and the starter motor. Before opening the engine crankcase, it is advis- able to check axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
  • Page 151 Vespa GT 125-200 Engine Fitting clearance Connecting rod axial clearance 0.20 - 0.50 Check the radial clearance on the connecting rod. Standard clearance: 0.036 ÷ 0.054 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
  • Page 152 Vespa GT 125-200 Engine Check the diameters of both the driving shaft ends according to the axes and planes shown in the fig- ure. Half-shafts are classified into two categories, Cat. 1 and Cat. 2. The table is shown below.
  • Page 153 Vespa GT 125-200 Engine To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 154 Vespa GT 125-200 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
  • Page 155 Vespa GT 125-200 Engine THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG- GING IMPAIRS THE HEAD LUBRICATION AND THE TIM- ING MECHANISMS.
  • Page 156 Vespa GT 125-200 Engine - The bushing housings in the crankcase are avail- able in two categories, Cat. 1 and Cat. 2, as are the crankshafts. - The main bushings are available in three thick- ness categories, identified by colour markings, as shown in the table below.
  • Page 157 Vespa GT 125-200 Engine LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE) Characteristic Standard driving depth 1.35 ÷ 1.6 Diameter of crankcase without bushing 32.953 ÷...
  • Page 158 Vespa GT 125-200 Engine ENG - 158...

  • Page 159: Oil Pressure Check

    Vespa GT 125-200 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...
  • Page 160 Vespa GT 125-200 Engine Crankshaft oil seals Refitting - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the specified torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, to- gether with the locating dowels.

  • Page 161: Oil Pump

    Vespa GT 125-200 Engine Oil pump - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
  • Page 162 Vespa GT 125-200 Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defective parts.
  • Page 163 Vespa GT 125-200 Engine - When testing the lubrication system, refer to chapter "Crankcase and Crankshaft", regard- ing lubrication of the crankshaft and connect- ing rod Locking torques (N*m) Oil sump screws 10 ÷ 14 SAS valve Inspecting the one-way valve - Remove the SAS valve.
  • Page 164 Vespa GT 125-200 Engine Inspecting the cut-off - Remove the SAS valve. - Connect the MITYVAC pump in low-pressure mode (VACUUM) to the CUT-OFF valve vacuum intake. - Apply a vacuum value higher than 0.5 BAR. - Check that this value is kept all the time.

  • Page 165: Fuel Supply

    Vespa GT 125-200 Engine Fuel supply - To clean the filtering element proceed as follows: remove the 4 filter cover fixing screws indicated in the figure; remove the cover and take out the pa- per filtering element, clean with compressed air and refit.
  • Page 166 Vespa GT 125-200 Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
  • Page 167 Vespa GT 125-200 Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure.
  • Page 168 Vespa GT 125-200 Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
  • Page 169 Vespa GT 125-200 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 169...
  • Page 170 Vespa GT 125-200 Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 171 Vespa GT 125-200 Engine Walbro To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connexion, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, and the intake fitting.
  • Page 172 Vespa GT 125-200 Engine Remove the 4 fixing screws indicated in the figure and the vacuum chamber cover. N.B. DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY. Remove the vacuum valve together with the dia- phragm.
  • Page 173 Vespa GT 125-200 Engine Unscrew the bayonet joint 1/8 of a turn, remove it, take out the spring and vacuum valve plunger Remove the 4 screws shown in the figure. Remove the tank with the intake pump, its control and gasket.
  • Page 174 Vespa GT 125-200 Engine Remove the acceleration pump piston with the ring nut, the hood, the O-Ring and the spring from the tank as shown in the figure. Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side.
  • Page 175 Vespa GT 125-200 Engine Remove the cover of the duct from the carburettor to the starter nozzle as shown in the figure. -Remove the maximum nozzle. -Remove diffuser. Remove the sprayer. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY.
  • Page 176 Vespa GT 125-200 Engine Remove the minimum flow screw with the O-ring, the washer and the spring. -Remove the 2 fixing screws, the cover, the spring, and the cut-off device diaphragm. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE...
  • Page 177 Vespa GT 125-200 Engine Kehin - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
  • Page 178 Vespa GT 125-200 Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear.
  • Page 179 Vespa GT 125-200 Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
  • Page 180 Vespa GT 125-200 Engine - The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position. Walbro - Before refitting, wash the carburettor body accu- rately with petrol and compressed air.
  • Page 181 Vespa GT 125-200 Engine - For the starter circuit, blow the connection pipe properly with the jet.This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. N.B. THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
  • Page 182 Vespa GT 125-200 Engine Level check Kehin - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
  • Page 183 Vespa GT 125-200 Engine - Remove the drainage screw from the tank, wash and blow the tank properly and make sure the ac- celeration pump intake and supply valve are clean. - Being the valves unidirectional, blow them care- fully with compressed air, at the inner side of the tank for the intake valve and at the pump piston housing for the supply valve.
  • Page 184 Vespa GT 125-200 Engine - Prepare the carburettor for adjustment by rotating the screw 3 turns from the close position. - Check that the rocking lever control of the accel- erating pump does not show abnormal wear. - Check that the end of stroke screw of the rocking lever protrudes 3.2 mm.
  • Page 185 Vespa GT 125-200 Engine N.B. THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION. - Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover.
  • Page 186 Vespa GT 125-200 Engine - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Walbro - Check that the pin does not show signs of wear and that the lock is in the 3rd of the 3 notches.
  • Page 187 Vespa GT 125-200 Engine - Check that the diaphragm is not worn or has hardened. If it does, replace it. - Refit the tapered pin on the vacuum valve. - Make sure the spring is in the correct position on the plunger and inserted in its housing.
  • Page 188 Vespa GT 125-200 Engine Inspecting the automatic choke device - Check that the piston of the automatic starter is not deformed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the sealing gasket of the piston is not deformed.
  • Page 189 Vespa GT 125-200 Engine 5 min Electric characteristic Check the automatic starter: Resistance around 30 Ω Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support.
  • Page 190 Vespa GT 125-200 Engine TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNEC- TED TO THE STARTER. Characteristic Check the automatic starter: Kehin: Protrusion value XX ÷...
  • Page 191 Vespa GT 125-200 Engine Characteristic Check the auto starter: Protrusion Value for Walbro 12.5 ÷ 13 mm at approx. 20°C Check the automatic starter: Walbro maximum protrusion 18.5 ÷ 19 mm Check the automatic starter: Walbro max. time 5 min...
  • Page 192 Vespa GT 125-200 Engine loosened the CO value rises (rich mix). Tightening the screw decreases the CO (lean mix). - If the adjustment of the flow screw causes a rpm increase readjust the revs again and if necessary, the flow screw to reach stable values.
  • Page 193 Vespa GT 125-200 Engine CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000 Characteristic Idle adjustment: Pipe sizes Ø 40 mm Idle adjustment: length 500 ÷- 600 mm ENG - 193...
  • Page 194 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 195: Removing The Front Wheel

    Vespa GT 125-200 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pho- tograph. Locking torques (N*m) Wheel fixing screw 20 ÷...
  • Page 196 Vespa GT 125-200 Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide...

  • Page 197: Steering Column

    Vespa GT 125-200 Suspensions Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 Refitting the front wheel - To refit, carry out the removal operations but in reverse order and comply with the specified locking torque. Locking torques (N*m) Wheel fixing screw 20 ÷...
  • Page 198 Vespa GT 125-200 Suspensions - Remove the retainer fixing the odometer cable to the mudguard indicated in the photograph - Remove the retainer fixing the brake piping to the front shock absorber upper plate - Remove the retainer fixing the brake piping to the...
  • Page 199 Vespa GT 125-200 Suspensions - Pre-loosen the 3 nuts fixing the mudguard to the suspension - Remove the rear handlebar cover. - Remove the screw fixing the handlebar to the steering tube - Tilt the handlebar towards the shield back plate...
  • Page 200 Vespa GT 125-200 Suspensions To refit, carry out the removal operations but in reverse order; grease the fifth wheel fittings and tighten to the prescribed torques. Locking torques (N*m) Upper ring nut 30 ÷ 40 Nm Lower ring nut 30 ÷ 40 Nm Handlebar to steering tube 45 ÷ 50...
  • Page 201 Vespa GT 125-200 Suspensions - Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure, using the specific tool. Proceed giving a few taps with the mallet. Specific tooling 020004Y Punch for removing fifth wheels from...
  • Page 202 Vespa GT 125-200 Suspensions - Fit both dust guard rings «C» on the swinging hub as shown in the detail drawing «A». - Connect the swinging hub to the steering tube with the guiding pin, part 5. - Use the specific tool fitted with part 3 on the stem and part 4 on the tool base.
  • Page 203 Vespa GT 125-200 Suspensions 4 on the stem, on the side opposite the one shown in the figure to refit the second wedging washer - roller casing - sealing ring unit. To position roller casings on the pin (pin end in...
  • Page 204 Vespa GT 125-200 Suspensions - Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure, using the specific tool. Proceed giving a few taps with the mallet. Specific tooling 020004Y Punch for removing fifth wheels from...

  • Page 205: Front Shock Absorber

    Vespa GT 125-200 Suspensions Refitting To refit, carry out the removal operations but in reverse order; grease the fifth wheel fittings and tighten at the specified locking torques Locking torques (N*m) Handlebar to steering tube 45 ÷ 50 Upper steering ring nut 30 ÷ 40 Lower steering ring nut 8 ÷...
  • Page 206 Vespa GT 125-200 Suspensions - Remove the bracket locking seeger ring - Unscrew the bracket - Before refitting the bracket in the wheel axle, place the O-ring as shown in the photograph so that it is correctly placed after fitting the bracket.
  • Page 207 Vespa GT 125-200 Suspensions - Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph - Suitably hold the brake calliper - shock absorber attachment bracket - Fit a new oil seal and move it until it stops using...

  • Page 208: Removing The Rear Wheel

    Vespa GT 125-200 Suspensions Removing the rear wheel - Remove the bracket supporting the rear shock absorber and the muffler; - Remove the rear wheel by unscrewing the 5 screws indicated in the photograph Refitting the rear wheel To refit, carry out the removal operations but in reverse order, observing the prescribed torques.
  • Page 209 Vespa GT 125-200 Suspensions - Remove the two screws fixing the buffer support bracket to the frame - Remove the left and right caps located under the footrest to reach the pin fixing the swinging arm to the body. - Remove the pin. Then remove the swinging arm.
  • Page 210 Vespa GT 125-200 Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension. Overhaul - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side.
  • Page 211 Vespa GT 125-200 Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - Using a suitable pin remove the roller casings as...
  • Page 212 Vespa GT 125-200 Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in...
  • Page 213 Vespa GT 125-200 Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the...

  • Page 214: Shock Absorbers

    Vespa GT 125-200 Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 - 72 Body shell - Swinging arm pin 76 ÷...
  • Page 215 Vespa GT 125-200 Suspensions Lower shock absorber clamping screw 33 ÷ 41 Nm Upper shock absorber fixing screws 20 ÷ 25 Exhaust bracket Removal Remove the full muffler unit. - Remove the two fixing screws of the bracket to the engine crankcase...

  • Page 216: Side Stand

    Vespa GT 125-200 Suspensions Side stand REMOVAL - Uncouple the centre stand return spring; Remove the screw shown in the photograph FITTING To refit, carry out the removal operations in re- verse order and comply with the specified torque. Locking torques (N*m)
  • Page 217 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 218: Rear Brake Calliper

    Vespa GT 125-200 Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the rear wheel. - Remove the pad retention pin snap ring. - Using a pin partially remove the brake pad re- tention pin.
  • Page 219 Vespa GT 125-200 Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to...
  • Page 220 Vespa GT 125-200 Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the crankcase with the two screws with elastic washer at the prescribed tor-...
  • Page 221 Vespa GT 125-200 Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the two front brake calliper devices fas- tening them to the support as shown in the photo- graph.
  • Page 222 Vespa GT 125-200 Braking system - that the brake pad check spring works properly. CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED. The brake pad check spring 1. pad fixing screws 2. reaction plate fixing screws 3.
  • Page 223 Vespa GT 125-200 Braking system Removal - Remove the rear brake calliper. - Remove the brake disc and the hub from the wheel axle - To remove the brake disc from the hub, hold the unit firmly with a vice and operate on the 5 fixing...

  • Page 224: Front Brake Disc

    Vespa GT 125-200 Braking system 020335Y Magnetic support for dial gauge Characteristic Max. deviation allowed: 0.1 mm - If you detect incorrect values, replace the disc. If the anomaly persists, replace the hub. Front brake disc Removal - Remove the front wheel...

  • Page 225: Front Brake Pads

    Vespa GT 125-200 Braking system Refitting - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.
  • Page 226 Vespa GT 125-200 Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the brake calliper - Remove permanently the two pad fixing screws - Check that there are no flaws or warping. If there is, replace it.
  • Page 227 Vespa GT 125-200 Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS.
  • Page 228 Vespa GT 125-200 Braking system See also Removal Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the clip on the pin - Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque.
  • Page 229 Vespa GT 125-200 Braking system BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND...
  • Page 230 Vespa GT 125-200 Braking system SCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING. CAUTION THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT AB- SORBS MOISTURE FROM THE SURROUNDING AIR.
  • Page 231 Vespa GT 125-200 Braking system Overhaul Proceed as follows: 1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take out the dia- phragm (3); 2) remove the cap (4) and take out the internal parts in order;...
  • Page 232 Vespa GT 125-200 Braking system 3. Diaphragm. 4. Bellows. 5. Sealing ring 6. Piston. 7. Gasket. 8. Spring. 9. Reservoir Refitting To refit, carry out the removal operations but in reverse order, observing the specified torques. Locking torques (N*m) Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handle bar: 7 ÷ 10 Nm...
  • Page 233 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 234 Vespa GT 125-200 Cooling system Water pump - overhaul Water pump assembly With a hot air gun heat the inner side of the fly- wheel cover. AVOID OVERHEATING AS THIS MAY ALTER THE PAIN- TED SURFACE. Specific tooling 020151Y Air heater - Place the flywheel cover on the ring base following the same procedure as for removal.
  • Page 235 Vespa GT 125-200 Cooling system - Insert the flywheel cover with bearings on the ap- propriate tool. - Insert the shaft together with the mechanical gas- kets on the bearings. - With the appropriate punch and socket, insert the shaft in the bearings and the drive until the end of stroke of the appropriate tool cannot be seen.
  • Page 236 Vespa GT 125-200 Cooling system -Place the flywheel cover on the ring base which is part of the tool N.B. TO AVOID DAMAGING THE COVER SURFACE THAT SEALS THE COOLANT, USE THE RING BASE WITH THE ACCURATELY MACHINED SURFACE FACING THE FLYWHEEL COVER.
  • Page 237 Vespa GT 125-200 Cooling system - Use a screwdriver to remove the static part of the ceramic seal from the flywheel cover. - Place the flywheel cover below the socket making sure it is perfectly levelled. - Use the punch in the inverted position to extract the two ball bearings.
  • Page 238 Vespa GT 125-200 Cooling system Check 1) Look to see that the thermostat is not damaged. 2) Fill a metal container with approx. 1 litre of wa- ter. Immerse the thermostat, and keep it in the centre of the container.
  • Page 239 INDEX OF TOPICS CHAS HASSIS...
  • Page 240 Vespa GT 125-200 Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Remove the helmet compartment - Remove the two screws shown in the photograph - Remove the saddle...

  • Page 241: Rear Rack

    Vespa GT 125-200 Chassis - Remove the electric connector from the saddle opening actuator - Remove the two screws shown in the photograph - Remove the clip from the transmission - Remove the actuator from the supporting bracket Rear rack...

  • Page 242: Instrument Panel

    Vespa GT 125-200 Chassis Rear handlebar cover - Remove the front handlebar cover - Undo the 4 screws indicated in the photograph -Disconnect the odometer cable -After disconnecting the wiring remove the rear handlebar. Instrument panel - Remove the rear handlebar cover;...
  • Page 243 Vespa GT 125-200 Chassis Front handlebar cover - Remove the front grille - Remove the front screw indicated in the figure -Undo the 2 screws indicated in the figure; - Remove the front handlebar cover - Disconnect the front headlamp connectors Headlight assy.
  • Page 244 Vespa GT 125-200 Chassis Knee-guard - Remove the rear handlebar cover. - Remove the two screws indicated in the photo- graph and located on the shield under the grille - Remove the expansion tank cover and then its - Remove the central screw inside the glove-box,...
  • Page 245 Vespa GT 125-200 Chassis - Remove the electric saddle opening switch, the fuse box and the manual saddle opening cable as shown in the photograph Removing the ignition key-switch when on *off* - Remove the shield back plate. - Remove the immobilizer aerial as shown in the figure.
  • Page 246 Vespa GT 125-200 Chassis - Lightly push the master-cylinder and extract the lock from the notch shown in the figure. - Hence extract the master-cylinder complete with the key-switch. - For the reassembly proceed in the reverse order. Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the...
  • Page 247 Vespa GT 125-200 Chassis Front wheel housing • Remove the front fork; • Unscrew the central stud of the wheel well at the frame; • Disconnect the brake pipe to the pump and pull it out;; • Remove the odometer transmission..
  • Page 248 Vespa GT 125-200 Chassis Footrest - Remove the shield back plate - Remove the battery compartment cover - Remove the side fairings - Remove the central screw located under the bat- tery compartment cover as indicated in the figure - Remove the passenger footrests undoing the two...

  • Page 249: Rear Mudguard

    Vespa GT 125-200 Chassis - Remove the right and left lower covers as shown in the figure - Remove the screws under the non-slip rubber mat of the footrest as indicated in the photograph Side fairings - Remove side fairings, right and left, by undoing...

  • Page 250: Fuel Tank

    Vespa GT 125-200 Chassis Helmet bay - Lift the saddle and remove the helmet compart- ment Fuel tank - Remove the helmet compartment - Remove the side fairings - Remove the muffler - Remove the luggage rack - Remove the shock absorber upper clamps...

  • Page 251: Front Mudguard

    Vespa GT 125-200 Chassis Rear central cover - Remove the four screws indicated in the figure Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard...
  • Page 252 Vespa GT 125-200 Chassis Radiator fan - In order to carry out any operation on the radiator unit, flow out the coolant in the coolant delivery pipe in the pump, indicated in the photograph. - Remove the shield back plate;...
  • Page 253 Vespa GT 125-200 Chassis Front central cover - Remove the "PIAGGIO" clip-on badge - Unscrew the screw indicated in the figure - Remove the grille CHAS - 253...
  • Page 254 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 255 Vespa GT 125-200 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection • Safety Locks • Cover retaining screws...
  • Page 256 Vespa GT 125-200 Pre-delivery WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE LEAD. WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL- PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
  • Page 257 Vespa GT 125-200 Pre-delivery • Electrical radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Functional check up: • Hydraulic braking system: lever travel •...
  • Page 258 INDEX OF TOPICS TIME...
  • Page 259 Vespa GT 125-200 Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit.
  • Page 260 Vespa GT 125-200 Time Crankshaft CRANKSHAFT Code Action Duration 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement Cylinder assy. TIME - 260...
  • Page 261 Vespa GT 125-200 Time CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001154 Pin-ring-piston assembly - Service Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement...

  • Page 262: Cylinder Head Cover

    Vespa GT 125-200 Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rocking lever valve - Replacement 001044 Camshaft - Replacement Cylinder head cover TIME - 262...
  • Page 263 Vespa GT 125-200 Time HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment Chain tensioner CHAIN TIGHTENER Code Action Duration...

  • Page 264: Oil Filter

    Vespa GT 125-200 Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Replacement Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement...
  • Page 265 Vespa GT 125-200 Time Oil pump OIL SUMP PUMP Code Action Duration 001125 Chain guide pads - Replacement 001051 Belt/Timing chain - Change 001042 Oil pump - Service 001112 Oil pump - change 001122 Oil pump chain - Replacement 001130...
  • Page 266 Vespa GT 125-200 Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Re- placement 004125 Rear wheel axle - Replacement TIME - 266...
  • Page 267 Vespa GT 125-200 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001066 Driving pulley - Removal and refitting 001006 rear-view pulley - Service TIME - 267...

  • Page 268: Transmission Cover

    Vespa GT 125-200 Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement 001131 Transmission air intake - Replace- ment TIME - 268...

  • Page 269: Starter Motor

    Vespa GT 125-200 Time Starter motor ELECTRICAL START UP Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement 001141 Belt anti-flapping roller - Replace- ment TIME - 269...

  • Page 270: Flywheel Magneto

    Vespa GT 125-200 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump / Pump rotor - Replace- ment 001067 Stator - Removal and Refitting 001058 Complete flywheel - Replacement 001161 Secondary air filter - Replacement...
  • Page 271 Vespa GT 125-200 Time Carburettor CARBURETTOR Code Action Duration 001013 Intake manifold - Replacement 007020 Carburettor heating tubing - replace- ment 001008 Carburettor - Inspection 001063 Carburettor - Replacement 001081 Automatic choke - Replacement 003058 Carburettor - Adjustment 001136 Exhaust emissions - Adjustment...
  • Page 272 Vespa GT 125-200 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 272...

  • Page 273: Air Cleaner

    Vespa GT 125-200 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement TIME - 273...
  • Page 274 Vespa GT 125-200 Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004085 Fairing (1) - Replacement 004149 Shield central cover - Replacement 004053 Spoiler - Replacement 004015 Footrest - Removal and Refitting 004023 Shield rim - Replacement 004159...
  • Page 275 Vespa GT 125-200 Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 275...
  • Page 276 Vespa GT 125-200 Time MATS AND COVERS Code Action Duration 005007 Battery - Replacement 004079 Footrest - replacement 004071 Battery compartment - replacement 005046 Battery cover - change 004078 Front/rear footrest rubber - Replace- ment Rear cover REAR SHIELD Code...
  • Page 277 Vespa GT 125-200 Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004136 License plate support - Replacement 004016 Helmet compartment - Removal and Refitting 005048 Licence plate holder - Replacement Mudguard TIME - 277...
  • Page 278 Vespa GT 125-200 Time MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement 003044 Shock absorber cover - Replace- ment Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement...
  • Page 279 Vespa GT 125-200 Time Expansion tank EXPANSION TANK Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan complete with support - Re- placement 007001 Expansion tank - Replacement 007014 Radiator thermal switch - Replace- ment 007013 Expansion tank / radiator connecting...
  • Page 280 Vespa GT 125-200 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock ab- sorber - Removal and Refitting Steering column bearings TIME - 280...

  • Page 281: Handlebar Covers

    Vespa GT 125-200 Time STEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar cover - Replacement...
  • Page 282 Vespa GT 125-200 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Removal and refitting 002067 Rear brake pump - Replacement 002024 Front brake pump - Removal and re- fitting 005017 Stop switch - Replacement 002059 Right-hand knob - Replacement...
  • Page 283 Vespa GT 125-200 Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chassis con- nection - Replacement 004058 Silent block - Replacement TIME - 283...
  • Page 284 Vespa GT 125-200 Time Brake hoses CALLIPER BRAKE PIPING Code Action Duration 003071 Rear brake pads/shoes - Check for wear 003070 Front brake pads / Shoes - Check wear 002040 Front brake calliper - Check 002048 Rear brake calliper - Replacement...
  • Page 285 Vespa GT 125-200 Time Seat SADDLE Code Action Duration 004136 License plate support - Replacement 004016 Helmet compartment - Removal and Refitting 005048 Licence plate holder - Replacement TIME - 285...
  • Page 286 Vespa GT 125-200 Time Instrument panel INSTRUMENT PANEL Code Action Duration 004066 Driving mirror - Replacement 005014 Odometer - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Replace- ment 005006 Light switch or turn indicators - Re-...
  • Page 287 Vespa GT 125-200 Time Locks LOCKS Code Action Duration 002083 Saddle opening transmission - Re- placement 002092 Transmission splitter/ hook transmis- sion - Replacement 004158 Saddle opening splitter - Replace- ment 005072 Immobilizer aerial - Replacement 005099 Electric saddle opening device - Re-...

  • Page 288: Turn Signal Lights

    Vespa GT 125-200 Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005005 Taillight - Replacement 005032 Licence plate light glass - Replace- ment 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement...

  • Page 289: Front Wheel

    Vespa GT 125-200 Time Front wheel FRONT WHEEL Code Action Duration 002041 Brake disc - Replacement 003033 Front wheel hub- Replacement 004123 Front wheel - Replacement 003037 Front wheel rim- Replacement 003047 Front tyre - replace 003063 Tyre pressure - Check...

  • Page 290: Rear Wheel

    Vespa GT 125-200 Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replacement 001071 Front wheel rim - Removal and refit- ting 002070 Rear brake disc - Replacement 003077 muffler/rear shock absorber support...

  • Page 291: Fuel Pump

    Vespa GT 125-200 Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004089 Tank / petrol pump pipe - Replace- ment 004072 Fuel filter - Replacement 004086 Petrol pump depression tube - Re- placement 004086 Petrol pump depression tube - Re-...
  • Page 292 Vespa GT 125-200 Time Electric devices ELECTRIC DEVICES Code Action Duration 001094 Spark plug cap - Replacement 001069 HV coil - Replacement 005003 Horn - Replacement 002049 Odometer cable - Replacement 001023 Control unit - Replacement 005009 Voltage regulator - Replacement...

  • Page 293: Front Suspension

    Vespa GT 125-200 Time Front suspension FRONT SUSPENSION Code Action Duration 003011 Front shock absorber - Removal and Refitting 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber support and brake calliper - Replacement 003034 Front wheel hub bearing - Replace-...
  • Page 294 Air filter: 45 Battery: 64, 70, 77, 84, 86 Brake: 218, 220, 222, 224, 225, 227, 229, 230, 284 Brake fluid: 229 Carburettor: 10, 39, 165, 176, 271 Engine oil: 47 Fuel: 63, 165, 250, 278, 291 Fuses: 82 Headlight: 52, 243 Hub oil: 44 Identification: 6 Instrument panel: 242, 286...

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