VESPA P125X Service Station Manual Download Page 1

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vespa

america corporation

PIAGGIO GROUP

P1 25X - P200E

Service Station Manual

Amendment No.1

Revision 1

The Vespa New Line P125X (VNX1D and P200E (VSX1D are equipped with

engines that require similar disassembly procedures as those used for Vespa

Rally 200 (VSE1D vehicles with the exception of a few operations. Listed

herewith is information which pertains to those differences .

Description of all other operations can be found in t

he Vespa Service Station

Manu'al (PIN #153903) and its ame

dme

under the headings relevant to

spa

lly

200 (VSE1TI.

Insert this amendment in Service Manual #153903 for easy reference.

Amendment to Vespa Motorscooter Service Station Manual #153903

Summary of Contents for P125X

Page 1: ...for Vespa Rally 200 VSE1D vehicles with the exception of a few operations Listed herewith is information which pertains to those differences Description of all other operations can be found in t_he Vespa Service Station Manu al PIN 153903 and its amendments under the headings relevant to Vespa Rally 200 VSE1TI Insert this amendment in Service Manual 153903 for easy reference Amendment to Vespa Mot...

Page 2: ... P125X VNX1T P200E V8X1T ...

Page 3: ...IR INSTRUCTIONS SAFETY AWARENESS AND MEANINGS IWARNING This WARNING symbol indentifies special instructions or procedures which if not correctly followed could result in personal injury OR loss of life U IO This CAUTION symbol identifies special instructions or procedures which if not strictly observed could result in damage TOIOR destruction of equipment ...

Page 4: ...ic Prior To Frame Serial 82432 Pg 11 I P1 25X VNX1 T Wiring Schematic Frame Serial 82432 And Later Pg 12 J P200E VSX1 T Wiring Schematic Prior To Frame Serial 34627 Pg 13 K P200E VSX1 T Wiring Schematic Frame Serial 34627 And Later Pg 14 II ENGINE DISASSEMBLY A Flywheel Extraction Pg 15 B Crankcase Separation Pg 15 C Main Bearing Removal Flywheel Side Only Pg 15 III ENGINE REASSEMBLY A Main Bearin...

Page 5: ...ff Engine shut off key is extractable 1 on Ignition and circuit ON key is NOT extractable With keyswitch Fig 3 in position 1 circuit on the following units are fed By A C the flywheel magneto head lamp By D C through the battery tail lamp speedometer lamp neutral indicator lamp front and rear turn signals horn stop lamp NOTE When starting vehicle verify that the lever of switch supplementary engin...

Page 6: ...lator Battery 12V Ducati star type nominal power 70W Seal beam 12V 30 30W 4420 40W Ducati 12V 5 5 Ah Page 2 The charging of the battery is accomplished by current supplied from the flywheel and controlled by the voltage regulator NOTE If batterY is completely discharged voltage regulator will NOT be operational I 1Prolonged use of the vehicle when battery is disconnected may result in severe CAUTI...

Page 7: ...RONIC IGNITION COMPONENTS The STATOR PLATE is fitted with 5 coils see Fig 5 4 for L T circuit feeding 1 2 3 4 and 1 for ignition The ignition and pick up P which when activated by the magneto pole shoes generates the ignition spark pulse to the ELECTRONIC CONTROL BOX IGNITION COIL I 1 Battery 2 Charge Coils Lighting Coils Fig 5 STATOR PLATE ASSEMBLY P200E Page 3 ...

Page 8: ...GNITION Continued YElLOW VIOLET TO REGULATOR TO THE BULBS YELLOW GREEN t l J TO THE REGULATOR TO THE BATTERY TO THE BULBS YElLOW RE O_ 4 VIOLET Prior to Frame Serial 34627 t 1 _ Frame Serial 34627 And Later Fig 6 ELECTRICAL DIAGRAM OFTHE IGNITION UNIT TYPE DUCATI Page 4 ...

Page 9: ...ces on the secondary coil the necessary voltage for the spark plug P200E VSX1 T STATOR PLATE TESTING DUCATIIGNITION If in case of a suspected defective ignition system the following action must be taken in the appropriate steps as listed below Step 1 Step 2 Step 3 Visually inspect ALL ignition related terminals and wiring for possible breaks and improper connections Verify engine cut off switch Fi...

Page 10: ...to 1 000 ohms test the PICK UP by connecting the tester between the RED LEAD and the WHITE LEAD ground Fig 8 The tester should show CONTINUITY and and OHMIC VALUE OF 110 5 ohms GREEN REO 110 5 REO 110 5 YELLOW YELLOW Prior to Frame Serial 34627 REO Frame Serial 34627 And Later Fig 8 PICK UP OHMIC VALUE TESTING Page 6 ...

Page 11: ...e WHITE LEAD ground Fig 9 The tester should show CONTINUITY AND OHMIC VALUE OF 500 20 ohms Prior to Frame Serial 34627 Frame Serial 34627 And Later Fig 9 IGNITION COIL OHMIC VALUE TESTING If after having checked the ignition coil and pick up ohmic irregularities are found remove the flywheel and inspect for any visible damage If none is found REPLACE the defective component Page 7 ...

Page 12: ...SX1 T ENGINE TIMING DUCATIIGNITION To achieve proper engine timing it is necessary that THE NOTCH ON THE BACKPLATE IS PERFECTLY IN LINE WITH THE CORRESPONDING NOTCH ON THE CRANKCASE As indicated with arrow in Fig 10 Fig 10 MECHANICAL TIMING P200E VSX The timing is correct when the flash from an ignition timing light stroboscopic gun is SYNCHRONOUS with the alignment of the white trace on the pick ...

Page 13: ... arm is at a distance of 23mm 0 90 from the respective magnet shoe Rotate the flywheel again The MAXIMUM opening of the breaker points A should be 0 3 0 5mm 0 011 0 019 The proper procedure for setting the spark advance of the vehicle remains the same as for the 125 Primavera The following special tools should be used when spark advance is to be checked refer to Pg 168 of the Vespa Service Station...

Page 14: ...ng as follows If with gear selector engaged with any gear the neutral light REMAINS ON Unloose the lock nut I Turn clockwise the switch G until the indicator light is off in this position tighten again the locK nut If with gear selector in N EUTRAL the neutral Iight does not light Unloose the lock nut I Turn counter elockwise the switch G until the indicator light is on in this position tighten ag...

Page 15: ...t d t SIQO tch onlY It ll4 l 1 I 15 YU s q 8 u_lllAI 11 8 1I 1 1V55 l lI HI AII OI Ilywf leet eo tc q SN o UO XJ Ovt of T coil 11 l T junell bt _ 12 A oul O 13 N ICh 2 A IUO n o AH 111V tWi n h oP1V Y11W1 1 8 Re lum lo lH It7 W I ELECTRICAL CONTINUED WHITE I BLOE I P125X VNXH WIRING SCHEMATIC Prior To Frame Serial 82432 vIm FT IVElLcrN I I GREEN VIOLET IIGHT RI liE GREEN It I PINK a 5 c a a 1 W I ...

Page 16: ...111 0 Ill 111 1 Y I IJ C _oboat d l IQO l1c IOflbt et d l T o n I uMIS 1 11 M1 t17Y I t I 1l11 o ft t G I I So no UCl M OuI HT C I 11 L T Ivroc tlorobo n Aevu atO 1 U lll_tum to AH 111Yl W1 I_ll1Y HWI 11 A_ 1Uf lg LM ItN 11OW I ELECTRICAL CONTINUED I e Cl I I P125X VNX1T WIRING SCHEMATIC Frame Serle 82432 And later L Rnux GREEN i J r TI 1 VIOl 14 J r mnr WHITF 1 LIGHT BLUE I I N BlACK I II I 3 c a...

Page 17: ...NIl lIeJ 1l11 C1 O4 l4 WotJ 10 S l en Ol cl W d pu l ullon II onlh LH I12V lW1 12 rOl UII IIn 9t M A H t 1V 2 11 Cl no tICloanI SlOO I nlonor r n 1 1 11 N11 112 S AI II I lI IOf 1l AiM6 I SOoM_PlUQ lO oICUO WCoqntllOl l 21 L f l ncllOl tIOl 12 I Of 13 U ICJ 24 1 n K llNllW 1 is r IWtloPlV It IW I R tUfn L Il rv 21Wl Q QO 0 o m oVl iil i 3 I VI I Z Q ltVl 0 0 Olm I 0 i i ...

Page 18: ... f Stoet ilc IO bo o d l l fu I1 llln tiS uU fl j 11 B II II1YSS t8 1l IOf lo 19 o nDfuG 1 N vt ol IOfII7YJW g 1117 I JWl fll _10 1 0 00 to 5_11 0 0 cl oo DV bullo 11 O l lH 111V11W U 0 1 h on R It7V tWl H ed OU It fNo 10 t1V JOWI 3 1I y llCfI SIGIP ftC fO lrorolbo S fU l d e IOfI onlfl1V 7W l H vtt c IOI fl1VlWl Fr e S rl 1 34627 And La ler t 5 ...

Page 19: ...rawhide mallet in rotating manner the flywheel case half until the crankcase separates NO SPECIAL TOOLS NEEDED FOR CRANKCASE SEPARATION OPERATION COMPLETE MAIN BEARING REMOVAL FLYWHEEL SIDE ONLY P125X VNX1T P200E VSX1T The flywheel side main bearing is a needle bearing When the crankcase is split the bearing will separate with the inner race remaining on the crankshaft and the outer race with bear...

Page 20: ... Step 5 Insert T0025127 between crankshaft cams Heat inner race in oil bath Fit spacer T0060007 at flywheel shaft base see Fig 14 When inner race is sufficiently heated remove from oil bath and drop over shaft against spacer T0060007 Remove spacer when race is cool NOTE Clearance between top of inner race and crankshaft lobe is to be 16mm se e Fig 15 D OPERATION COMPLETE T 0060007 0 Fig 15 INNER B...

Page 21: ...ver the crankcase bearing seat Immediately tap bearing with rawhide mallet until bearing sits against the crankcase bearing retaining lip NOTE Outer race of crankcase half and inner race on crankshaft must belong to the same bearing OPERATION COMPLETE CRANKSHAFT INSTALLATION P125X VNX1T P200E VSX1T The crankshaft is installed in the crankcase by the use of T0018119 with adapter 6 refer to Pg 164 F...

Page 22: ...w front axle nut to 8 29 kgm 60 ft lb Spot punch nut collar where key way is present on front axle designated by arrow on Fig 16 NOTE It is recommended always to complete assembly with replacement of a new axle nut OPERATION COMPLETE Fig 16 FRONT AXLE SECURING DIAGRAM REAR WHEEL SECURING P125X VNX1T P200E VSX1T Rear wheel axle nut to be torque tightened at 8 29 kgm 60 ft lb to 9 0 kgm 70 ft lb OPE...

Page 23: ...c oil mixture Spark Plug Gap Headlight Tail Light Spark Plug Bosch Main Jet Compression Ratio Piston Ring End Gap Head Bolt Torque Carburetor Piston Cylinder Clearance Point Gap Timing Bore Oil Type Displacement Stroke Lubrication Gas Type premium regular synthetic 2 stroke non detergent 007 008 110 8 2 to 1 115 10 5to1 007 to 009 156 in Ibs S120 S124 DEL ORTO S120 Frame Serial 50032 And Later 95 ...

Page 24: ...andlebars Width Total Length Maximum Height Minimum Ground Clearance Turning Radius Page 20 1st 1 14 46 2nd 1 10 28 3rd 1 7 31 4th 1 5 36 1st 1 13 42 2nd1 9 13 3rd 1 6 32 4th 1 4 71 3 50 x 10 17 psi 25 psi one person 35 psi two person interchangeable 2 10 48 62 2 03 gal 37 gal 2181bs 2251bs 90km h 56 mph 11 Okm h 68 mph 695mm 1760mm 1110mm 225mm 1650mm VNXH VSXH X X X X X X X X X X X X X X X X X X...

Page 25: ...ry according to riding conditions rider s weight and the condition of the scooter IDENTIFICATION DATA The identification data are composed by a prefix VNX 1 T on chassis VNL 3 M on engine and by a serial number The identification data are composed by a prefix VSX 1 T on chassis VSE 1 M on engine and by a serial number up to 111 mpg 78 mpg up to 230 miles 165 miles VNXH VSXH X X X X X X Page 21 ...

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