VESPA GT 200 Manuals

Manuals and User Guides for VESPA GT 200. We have 4 VESPA GT 200 manuals available for free PDF download: Workshop Manual

Vespa GT 200 Workshop Manual

Vespa GT 200 Workshop Manual (295 pages)

Brand: Vespa | Category: Scooter | Size: 22.5 MB

Table of Contents

Index of Topics
4
Characteristics
5
Safety Rules
6
Maintenance Rules
6
Vehicle Identification
6
Dimensions and Mass
7
Engine Data 125
8
Engine Data 200
8
Transmission
9
Capacities
9
Electrical System
9
Frame and Suspensions
9
Wheels and Tyres
10
Kehin Carburettor 125
10
Tyre Pressure
10
Walbro Carburettor 125
11
Kehin Carburettor 200
11
Tightening Torques
12
Walbro Carburettor 200
12
Steering Assembly
12
Frame Assembly
12
Front Brake
13
Rear Suspension
13
Rear Brake
13
Lubrication
13
Cylinder Head
13
Overhaul Data
14
Assembly Clearances
14
Flywheel
14
Crankcase and Crankshaft
14
Cylinder - Piston Assy.
15
Engine 125 Coupling Categories
15
Crankcase-Crankshaft-Connecting Rod
16
Engine 200 Coupling Categories
16
Slot Packing System
17
Crankshaft/Crankcase Axial Clearance
17
Thickness 125
18
Thickness 200
18
Engine 125 Oversize
19
Engine 200 Oversize
19
Recommended Products
20
Tooling
21
Appropriate Tools
22
Maintenance
34
Maintenance Chart
35
At 1000 Km or 4 Months
35
At 6000 Km or 12 Months
35
At 12000 Km or 24 Months and at 60000 Km
35
At 18000 Km Ad at 54000 Km (125)
36
At 18000 Km and an 54000 Km (200)
36
At 24000 Km and at 48000 Km (125)
36
At 24000 Km and at 48000 Km (200)
37
At 30000 Km and at 42000 Km and at 66000Km
37
At 36000 Km (125)
38
At 36000 Km (200)
38
At 72000 Km
38
Carburettor
39
Checking the Spark Advance
40
Spark Advance Variation
41
Spark Plug
43
Hub Oil Check
44
Hub Oil Replacement
45
Air Filter
45
AGIP Filter Oil
46
Engine Oil Replacement
47
Engine Oil Check
48
Oil Pressure Warning Light
49
Checking the Ignition Timing
49
Cooling System
50
Braking System
50
Level Check
50
Top-Up
51
Headlight Adjustment
52
CO Check
53
SAS Filters Inspection and Cleaning
55
Troubleshooting
60
Engine Poor Performance
61
Rear Wheel Spins at Idle
61
Starting Difficulties
61
Excessive Oil Consumption/Exhaust Smoke
62
Insufficient Lubrication Pressure
62
Engine Tends to Cut-Off at Full Throttle
62
Engine Tends to Cut-Off at Idle
63
High Fuel Consumption
63
Transmission and Brakes
63
Clutch Grabbing or Performing Inadequately
63
Brakes Overheating
64
Battery
64
Turn Signal Lights Malfunction
64
Steering and Suspensions
64
Excessive Steering Play
65
Noisy Suspension
65
Suspension Oil Leakage
65
Conceptual Diagrams
68
Ignition
68
Headlights and Automatic Starter Section
69
Battery Recharge and Starting
70
Level Indicators and Enable Signals Section
71
Turn Signal Lights
71
Checks and Inspections
71
Immobiliser
72
Virgin Circuit
73
Diagnostic Codes
74
Diagnostic Code - 2 Flashes
74
Diagnostic Code - 3 Flashes
75
Ignition Circuit
75
No Spark Plug
75
Battery Recharge Circuit
77
Stator Check
78
Voltage Regulator Check
79
Recharge System Voltage Check
80
Choke Inspection
80
Turn Signals System Check
81
Fuses
82
Dashboard
83
Dry-Charge Battery
84
Battery Installation
86
Engine from Vehicle
89
Exhaust Assy. Removal
90
Removal of the Engine from the Vehicle
90
Engine
96
Automatic Transmission
97
Transmission Cover
97
Air Duct
97
Removing the Driven Pulley Shaft Bearing
98
Refitting the Driven Pulley Shaft Bearing
99
Baffle Roller
99
Metallic Roller Removal
99
Metallic Roller Refitting
99
Removing the Driven Pulley
100
Inspecting the Clutch Drum
100
Removing the Clutch
101
Ispecting the Clutch
102
Pin Retaining Collar
103
Removing the Driven Half-Pulley Bearing
103
Inspecting the Driven Fixed Half-Pulley
104
Inspecting the Driven Sliding Half-Pulley
105
Refitting the Driven Half-Pulley Bearing
106
Refitting the Driven Pulley
107
Inspecting the Clutch Spring
108
Refitting the Clutch
108
Drive-Belt
111
Removing the Driving Pulley
112
Inspecting the Rollers Case
113
Refitting the Driving Pulley
114
Refittingt the Transmission Cover
116
Removing the Hub Cover
117
Removing the Wheel Axle
117
Removing the Hub Bearings
118
Removing the Wheel Axle Bearings
118
Inspecting the Hub Shaft
120
Inspecting the Hub Cover
120
Refitting the Wheel Axle Bearing
120
Refitting the Hub Cover Bearings
121
Refitting the Hub Bearings
122
Refitting the Hub Cover
122
Flywheel Cover
123
Removing the Stator
124
Refitting the Stator
124
Refitting the Flywheel Cover
124
Flywheel and Starting
125
Removing the Flywheel Magneto
125
Inspecting the Flywheel Components
125
Refitting the Flywheel Magneto
126
Refitting the Starter Motor
126
Cylinder Assy. and Timing System
126
Removing the Intake Manifold
127
Removing the Rocker-Arms Cover
127
Removing the Timing System Drive
127
Removing the Cam Shaft
129
Removing the Cylinder Head
130
Removing the Valves
130
Removing the Cylinder - Piston Assy.
131
Inspecting the Small End
133
Inspecting the Wrist Pin
133
Inspecting the Piston
135
Inspecting the Piston Rings
136
Removing the Piston
136
Choosing the Gasket
137
Refitting the Piston Rings
138
Refitting the Cylinder
138
Inspecting the Cylinder Head
139
Inspecting the Timing System Components
140
Inspectig the Valve Sealings
140
Inspectig the Valve Housings
141
Inspectig the Valves
141
Inspecting the Springs and Half-Cones
143
Refitting the Valves
143
Inspecting the Cam Shaft
144
Refitting the Head and Timing System Components
145
Timing System Components Assembly
148
Refitting the Rocker-Arms Cover
149
Refitting the Intake Manifold
149
Crankcase-Crankshaft
149
Splitting the Crankcase Halves
149
Inspecting the Crankshaft Alignment
152
Inspecting the Crankcase Halves
154
Inspecting the Crankshaft Plain Bearings
155
Lubrication Circuit
157
Oil Pressure Check
159
Crankshaft Oil Seals
160
Refitting
160
Oil Pump
161
Removing the Oil Sump
161
Inspecting the By-Pass Valve
162
Refitting the Oil Sump
162
SAS Valve
163
Inspecting the One-Way Valve
163
Inspecting the Cut-Off
164
Fuel Supply
165
Removing the Carburettor
165
Kehin
165
Walbro
171
Refitting the Carburettor
176
Inspecting the Valve and Needle
184
Inspecting the Automatic Choke Device
188
Adjusting the Idle
191
Suspensions
194
Removing the Front Wheel
195
Front Wheel Hub Overhaul
195
Refitting the Front Wheel
197
Steering Column Removal
197
Steering Column Overhaul
200
Steering Column Refitting
205
Front Shock Absorber Removal
205
Front Shock Absorber Refitting
205
Shock-Absorber - Calliper Bracket
205
Shock-Absorber - Calliper Bracket Overhaul
206
Rear
207
Removing the Rear Wheel
208
Refitting the Rear Wheel
208
Swing-Arm Removal
208
Swing-Arm Overhaul
210
Swing-Arm Refitting
213
Shock Absorbers Removal
214
Shock Absorbers Refitting
214
Exhaust Bracket Removal
215
Exhaust Bracket Refitting
215
Centre-Stand
215
Side Stand
216
Rear Brake Calliper Removal
218
Rear Brake Calliper Overhaul
218
Rear Brake Calliper Refitting
219
Front Brake Calliper Removal
221
Front Brake Calliper Overhaul
221
Front Brake Calliper Refitting
222
Rear Brake Disc Removal
223
Rear Brake Disc Refitting
223
Disc Inspection
223
Front Brake Disc Removal
224
Front Brake Disc Refitting
225
Front Brake Pads
225
Front Brake Pads Removal
226
Rear Brake Pads Removal
227
Rear Brake Pads Refitting
228
Fill Front
228
Brake Fluid Level Check
229
Front Brake Pump Removal
230
Brake Pump Technical Data
230
Front Brake Pump Overhaul
231
Front Brake Pump Refitting
232
Water Pump - Overhaul
234
Water Pump Assembly
234
Water Pump Component Check
235
Water Pump Removal
235
Water Pump Check
238
Chassis
239
Seat
240
Rear Rack
241
Rear Handlebar Cover
242
Instrument Panel
242
Front Handlebar Cover
243
Headlight Assy.
243
Knee-Guard
244
Removing the Ignition Key-Switch When On/Off
245
Removing the Ignition Key-Switch When on "Lock"
246
Front Wheel Housing
247
Taillight Assy.
247
Footrest
248
Side Fairings
249
Rear Mudguard
249
Helmet Bay
250
Fuel Tank
250
Rear Central Cover
251
Front Mudguard
251
Radiator Fan
252
Front Central Cover
253
Pre-Delivery
254
Aesthetic Inspection
255
Tightening Torques Inspection
255
Levels Check
256
Road Test
256
Static Test
256
Functional Inspection
257
Time
258
Crankcase
259
Crankshaft
260
Cylinder Assy.
260
Cylinder Head Assy.
261
Rocker Arms Support Assy.
262
Cylinder Head Cover
262
Chain Tensioner
263
Oil Filter
264

Advertisement

VESPA GT 200 Workshop Manual

VESPA GT 200 Workshop Manual (287 pages)

Brand: VESPA | Category: Scooter | Size: 14.2 MB

Table of Contents

Table of Contents
2
Vespa Gt
16
Characteristics
17
Workshop Safety
17
Service Recommendations
17
Vehicle Identification
18
Technical Specifications
19
- Engine
  20
Walbro Carburetor
21
Kehin Carburetor
22
Transmission
23
Electrical Components
23
Frame, Suspensions, Brakes and Tires
24
Frame and Suspension
24
Tightening Torques
25
Steering Unit
25
Front Brake
26
Hydraulic Components
27
Rear Brake
27
Cylinder Head
28
- Transmission
  29
Engine Crankcase and Shaft
29
Cooling
30
Piston–Cylinder Mating
31
Assembly Clearances
31
O Rings
32
Crankshaft End-Play
34
Crankshaft Alignment
35
Recommended Lubricants
36
- Steering Bearing Seat Installer – 001330Y
  37
- Steering Column Ball-Cage Bearing Removing Punch – 020004Y
  37
Special Tools
37
Front Suspension Overhaul Tool – 020021Y
38
Punch - 020038Y
38
Ring Nut Spanner - 020055Y
38
Crankshaft Aligner - 020074Y
39
Heat Gun Support - 020150Y
39
Oil Pressure Gauge - 020193Y
39
Crankcase Detacher - 020262Y
40
Half-Pulley Assembler - 020263Y
40
Fitting Punch - 020306Y
40
Vacuum Pump - 020329Y
40
Timing Light - 020330Y
41
Digital Multimeter - 020331Y
41
Digital Tachometer - 020332Y
41
Single Battery Charger - 020333Y
42
Multiple Battery Charger - 020334Y
42
Dial Gauge - 020335Y
42
Guide (20 MM) - 020363Y
43
Guide (22 MM) - 020365Y
44
Piston Assembly Band - 020393Y
45
Multimeter Adapter - 020409Y
45
Guide (15 MM) - 020412Y
46
Clutch Drum Lock Wrench - 020423Y
46
Piston Fitting Fork - 020426Y
47
Piston Support - 020428Y
47
Valve O-Ring Remover - 020431Y
47
Oil Pressure Gauge - 020434Y
47
Guide (17 MM) - 020439Y
48
Water Pump Overhaul Tool - 020440Y
48
Stop Wrench - 020442Y
48
Guide (30 MM) - 020483Y
49
Pivot Retainers Installer - 020488Y
49
Hub Cover Support - 020489Y
49
Driven Pulley Spring Tool - 020444Y
49
Flywheel Wrench - 020565Y
50
Engine Support - 002095Y
50
Flywheel Extractor - 08564Y
51
Gas Analyzer
51
Maintenance
52
Maintenance Schedule
52
Carburetor
54
Checking and Replacing the Spark Plug
55
Air Filter
56
Engine Oil
58
Topping-Up the Engine Oil
59
Hub Oil
61
Checking the Hub Oil Level
61
Replacing the Hub Oil
61
Topping-Up the Engine Cooling Liquid
62
Brake Fluid
63
Topping-Up the Brake Fluid Level
64
Removing the Steering Lock
65
Removing the Steering Lock When on «Lock" Position
66
Headlight Adjustment
67
Checking the Spark Advance
68
- Spark Advance Variation Curve
  69
- Evaporative Emission System
  70
Checking the CO Concentration
71
- Sas (Secondary Air System)
  73
- Removing the SAS
  74
- Troubleshooting
  77
- Poor Performance
  77
- Rear Wheel Spins at Idle
  78
- Rich Mixture
  78
- Weak Mixture
  79
- Low Compression
  79
- Starting Problems
  80
- Excessive Oil Consumption/Excessive Smoke from Exhaust
  81
- Insufficient Lubrication Pressure
  81
- Engine Tends to Cut out at Full Throttle
  82
- Excessive Fuel Consumption
  83
- Transmission and Brakes
  83
- Irregular Clutch Operation or Grapping
  83
- Poor Braking Performance
  84
- Brakes Overheating
  84
Electrical System
85
3 Flash Diagnostic Code

98
- Diagnostic Codes
  98
2 Flash Diagnostic Code

99
- Ignition System
  99
- Spark Plug Power Supply Failure
  100
- Battery Charging System
  101
- Checking the Voltage Regulator
  102
- Stator Check
  102
- Checking the Automatic Choke Section
  103
- Checking the Regulator
  103
- Turn Signal Lights Fail to Operate
  104
- Fuses
  105
- Instrument Panel
  106
- Battery
  107
- Cleaning the Battery
  108
  - Engine
    111
  - Disassembling the Engine from the Frame
    111
  - Removing the Silencer
    116
  - Refitting the Engine Onto the Frame
    116
  - Removing the Rocker Cover
    117
  - Refitting the Rocker Cover
    117
  - Checking the Compression
    117
  - Transmission
    118
  - Removing the Transmission Cover
    118
  - Removing the Transmission Cooling Intake
    119
  - Removing the Driven Pulley Shaft Bearing
    119
  - Fitting the Driven Pulley Shaft Bearing
    119
  - Removing the Belt Support Roller
    120
  - Refitting the Belt Support Roller
    120
  - Removing the Driving Pulley
    121
  - Removing the Driven Pulley
    121
  - Inspecting the Clutch Drum
    122
  - Checking the Clutch Drum Surface Eccentricity
    122
  - Removing the Clutch
    123
  - Disassembling the Fixed Driven Half-Pulley Bearings
    123
  - Checking the Fixed Driven Half-Pulley
    124
  - Checking the Moving Driven Half-Pulley
    125
  - Fitting the Fixed Driven Half-Pulley Bearings
    125
  - Refitting the Driven Pulley
    126
  - Checking the Moving Driven Half-Pulley Spring
    127
  - Checking the Drive Belt
    127
- Fitting the Clutch
  128
  - Checking the Clutch Friction Material
    128
- Checking the Moving Driving Half-Pulley
  129
- Fitting the Fixed Driving Half-Pulley and Bushing Assembly
  130
- Fitting the Moving Half-Pulley Assembly
  131
- Fitting the Clutch Drum
  132
- Fitting the Transmission Cover
  133
- Removing the Rear Hub Cover
  133
- Removing the Rear Wheel Axle
  134
- Removing the Wheel Axle Bearing from the Cover
  135
- Checking the Hub Cover
  136
- Fitting the Hub Casing Bearings
  136
- Removing the Driven Pulley Shaft
  136
- Fitting the Wheel Axle Bearing on the Cover
  137
- Checking the Hub Shafts
  138
- Fitting the Hub Cover
  139
- Fitting the Hub Gears
  139
- Flywheel
  140
- Removing the Flywheel Cover Assembly
  140
- Removing the Flywheel
  143
- Checking the Stator
  144
- Removing the Stator
  144
- Checking the Flywheel
  145
- Checking the Low Oil Pressure Switch
  145
- Checking the Pick-Up
  145
- Fitting the Stator Assembly
  145
- Fitting the Flywheel
  146
- Fitting the Flywheel Cover Assembly
  146
- Checking the Secondary Air Box Valve
  148
- Checking the One-Way Valve
  149
  - Lubrication Circuit
    151
  - Checking the Oil Pressure
    152
  - Removing the Oil Sump and Pressure Adjusting By-Pass Valve
    153
  - Removing the Oil Pump
    154
  - Checking the Oil Pump
    155
  - Fitting the Oil Pump
    156
  - Fitting the Chain Cover Oil Seal
    157
  - Fitting the By-Pass and the Oil Sump
    159
  - Removing the Intake Manifold
    159
- Removing the Timing Chain Sprockets
  160
- Thermostat Removal
  160
- Removing the Camshaft and Rockers
  161
- Removing the Cylinder Head
  162
- Removing the Cylinder and Piston Assembly
  163
- Removing the Valves
  163
- Inspecting the Small End
  164
- Inspecting the Piston and Cylinder Diameters
  165
- Inspecting the Wrist Pin Diameter
  165
- Inspecting the Piston
  166
- Checking the Piston Ring Gap
  167
- Choosing the Base Gasket Thickness
  168
- Fitting the Piston
  168
- Fitting the Cylinder
  170
- Fitting the Piston Rings
  170
- Checking the Valve Seals
  171
- Inspecting the Cylinder Head
  171
- Inspecting the Valve Seats
  172
- Checking the Valve Spring Plates and Half-Cones
  174
- Fitting the Valves
  174
- Testing the Valve Seals
  174
- Inspecting the Timing Components
  175
- Inspecting the Camshaft
  176
- Fitting the Cylinder Head
  177
- Fitting the Timing Components
  178
- Fitting the Intake Manifold
  181
  - Crankshaft
    182
  - Preparing the Engine for Crankcase Separation
    182
  - Separating the Crankcase Halves
    183
  - Checking the Crankshaft
    184
  - Checking the Crankcase Halves
    186
  - Checking the Main Bearings
    187
  - Assembling the Crankcase Halves
    188
  - Fitting the Starter Motor
    190
  - Removing the Carburetor
    191
- Fitting the Thermostat
  181
- Walbro WVF-7P Carburetor
  197
  - Re-Assembling the Carburetor
    204
- Walbro WFV-7P Carburetor
  206
- Checking the Float Height
  208
- Walbro WVF-7P Carburetor
  210
- Checking the Vacuum Valve and the Needle
  212
- Walbro WVF-7P Carburetor
  214
- Checking the Automatic Choke Device
  215
- Walbro WVF-7P Carburetor
  217
  - Cooling Circuit
    219
  - Cooling System
    219
  - Removing the Water Pump
    220
  - Checking the Components
    221
  - Fitting the Water Pump
    222
  - Checking the Thermostat
    224
  - Suspensions
    225
  - Removing and Refitting the Front Wheel
    226
  - Removing and Refitting the Rear Wheel
    226
  - Removing the Steering Column
    227
  - Front Wheel Hub Overhaul
    230
  - Removing the Front Wheel Hub
    230
  - Removing the Front Brake Caliper-Shock Absorber Bracket
    232
  - Front Brake Caliper-Shock Absorber Bracket Overhaul
    233
  - Front Swing Arm Overhaul
    235
  - Removing the Front Shock Absorber
    235
  - Steering Column Ball-Cage Bearings Overhaul
    237
  - Removing the Rear Shock Absorber-Silencer Bracket
    240
  - Rear Shock Absorbers
    241
  - Refitting the Rear Shock Absorbers
    242
  - Swing Arm Overhaul
    245
  - Silent-Block Overhaul
    247
  - Bodywork
    250
  - Removing the Front Handlebar Cover
    250
  - Removing the Seat
    250
  - Removing the Steering Column Cover
    250
  - Removing the Instrument Panel
    251
  - Removing the Rear Handlebar Cover
    251
  - Removing the Glove-Box Panel
    252
  - Removing the Battery Compartment Cover
    254
  - Removing the Footrest
    254
  - Removing the Side Fairings
    254
  - Removing the Luggage Carrier
    256
  - Removing the Helmet Compartment
    257
  - Removing the Taillight
    257
  - Removing the Front Fender
    258
  - Removing the Fuel Tank
    258
  - Removing the Radiators and the Cooling Fan
    260
  - Removing the Rear Mudguard
    261
  - Removing the Turn Signal Lights
    261
  - Removing the Electrical Opening Seat System
    262
  - Checking the Electrical Circuit
    264
  - Checking the Tightening Torques
    264
  - Checking the Vehicle Appearance
    264
  - Pre- Delivery Inspections
    264
  - Checking the Levels
    265
  - Road Test
    265
  - Static Test
    265
  - Functional Check
    266
- Time Sheets
  267
  - Piston-Cylinder Assembly
    268
  - Cylinder Head and Valves
    268
- Valve Cover
  269
- Driven Pulley
  270
- Pump Assembly - Oil Sump
  270
- Driving Pulley
  271
- Rear Wheel Axle
  271
- Electric Starter
  272
- Kick-Starter, Transmission Cover, and Transmission Cooling
  272
- Transmission Cooling Air Inlet
  272
- Flywheel Magneto
  273
- Air Filter
  274
- Frame
  275
- Footrest and Battery
  276
- Front Fender and Rear Mudguard
  277
- Fuel Tank
  277
- Helmet Compartment and Rear Fender
  277
- Cooling System
  278
- Fuel Pump
  278
- Steering Column
  279
- Handlebar Covers
  280
- Rear Suspension
  280
- Handlebar, and Brake and Throttle Controls
  281
- Swing Arm
  281
- Brakes
  282
- Locks and Immobilizer
  283
- Saddle and Rear Rack
  283
- Mirrors, Electric Controls, and Instrument Panel
  284
- Lights
  285
- Electrical Devices
  286
- Front Wheel
  287
- Rear Wheel
  287

VESPA GT 200 Workshop Manual

VESPA GT 200 Workshop Manual (295 pages)

Brand: VESPA | Category: Scooter | Size: 21.96 MB

Table of Contents

Advertisement

VESPA GT 200 Workshop Manual

VESPA GT 200 Workshop Manual (308 pages)

Brand: VESPA | Category: Scooter | Size: 54.03 MB

Advertisement

Related Products

VESPA Categories

Scooter Motorcycle Toy

More VESPA Manuals