2003 – 2008 Vespa Gt200 Granturismo Scooters Workshop Repair Service Manual – PDF DOWNLOAD

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2003 – 2008 Vespa Gt200 Granturismo Scooters Workshop Repair Service Manual

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LANGUAGE:ENGLISH
PAGES:287
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2003 – 2008 VESPA GT200 GRANTURISMO SCOOTERS WORKSHOP REPAIR SERVICE MANUAL – PDF DOWNLOAD:

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2003 – 2008 Vespa Gt200 Granturismo Scooters Workshop Repair Service Manual

FOREWORD:

This manual has been prepared by Piaggio USA, Inc., a subsidiary of Piaggio & C. S.p.A., for use in the workshops of authorized Piaggio® dealers and sub-agents It is assumed that the person utilizing this manual for servicing or repairing Piaggio® vehicles has a knowledge of the principles of mechanics and standard procedures required for general vehicle repair, therefore information regarding routine procedures has been deliberately omitted. Any relevant changes concerning the vehicle characteristics or specific repair operations will be divulged in the form of updates to this manual. Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer to the pages of this manual concerning specific tools and equipment and the special tools catalogue.

Workshop Safety:

• For tests performed with the engine running ensure the work is carried out in a well-ventilated place and, if necessary, using appropriate extractors. Never run the engine in an enclosed space; exhaust gases are toxic. Some types of battery use sulphuric acid as an electrolyte.
• Protect eyes, clothing and skin. Sulphuric acid is highly corrosive; if it comes into contact with the eyes or the skin, rinse thoroughly with water and seek immediate medical attention. The battery produces hydrogen gas, which is extremely explosive.
• Do not smoke and do not allow flames or sparks near the battery, especially whilst it is being recharged. Gasoline is extremely flammable and, under certain conditions, explosive. Do not smoke and do not allow flames or sparks in the work area.

TABLE OF CONTENTS:

2003 – 2008 Vespa Gt200 Granturismo Scooters Workshop Repair Service Manual

Index
1 Vespa GT 200 16
2 Characteristics 17
2.1 Various 17
2.1.1 Workshop Safety 17
2.1.2 Service Recommendations 17
2.2 Vehicle Identification 18
2.2.1 Frame No. 18
2.2.2 Engine No. 18
2.3 Technical Specifications 19
2.3.1 Weight and Dimensions 19
2.4 Engine 20
2.4.1 General 20
2.4.2 Walbro carburetor 21
2.4.3 Kehin carburetor 22
2.5 Transmission 23
2.6 Capacities 23
2.7 Electrical Components 23
2.8 Frame, Suspensions, Brakes and Tires 24
2.8.1 Frame and Suspension 24
2.8.2 Brakes 24
2.8.3 Wheels and Tires 24
3 Tightening Torques 25
3.1 Steering Unit 25
3.2 Frame 25
3.3 Front Suspension 25
3.4 Front Brake 26
3.5 Rear Suspension 26
3.6 Rear Brake 27
3.7 Silencer 27
3
3.8 Hydraulic Components 27
3.9 Cylinder Head 28
3.10 Transmission 29
3.11 Flywheel 29
3.12 Engine Crankcase and Shaft 29
3.13 Cooling 30
4 Assembly Clearances 31
4.1 Piston–Cylinder Mating 31
4.2 O Rings 32
4.3 Compression Ratio Limiting Shimming System: (11-12:1) 33
4.4 Crankshaft End-Play 34
4.5 Crankshaft Alignment 35
5 Recommended Lubricants 36
6 Special Tools 37
6.1 Steering Bearing Seat Installer – 001330Y 37
6.2 Pliers – 001467Y014 37
6.3 Bell – 001467Y017 37
6.4 Steering Column Ball-Cage Bearing Removing Punch – 020004Y 37
6.5 Front Suspension Overhaul Tool – 020021Y 38
6.6 Punch – 020036Y 38
6.7 Punch – 020038Y 38
6.8 Ring Nut Spanner – 020055Y 38
6.9 Crankshaft Aligner – 020074Y 39
6.10 Heat Gun Support – 020150Y 39
6.11 Heat Gun – 020151Y 39
6.12 Oil Pressure Gauge – 020193Y 39
6.13 Crankcase Detacher – 020262Y 40
6.14 Half-Pulley Assembler – 020263Y 40
6.15 Fitting Punch – 020306Y 40
6.16 Vacuum Pump – 020329Y 40
4
6.17 Timing Light – 020330Y 41
6.18 Digital Multimeter – 020331Y 41
6.19 Digital Tachometer – 020332Y 41
6.20 Single Battery Charger – 020333Y 42
6.21 Multiple Battery Charger – 020334Y42
6.22 Dial Gauge – 020335Y 42
6.23 Adapter (42×47 mm) – 020359Y 43
6.24 Adapter (52×55 mm) – 020360Y 43
6.25 Guide (20 mm) – 020363Y 43
6.26 Guide (25mm) – 020364Y 43
6.27 Guide (22 mm) – 020365Y 44
6.28 Adapter (28×30 mm) – 020375Y 44
6.29 Handle – 020376Y 44
6.30 Valve Half-Cone Remover – 020382Y44
6.31 Bushing – 020382Y011 44
6.32 Piston Assembly Band – 020393Y 45
6.33 Multimeter Adapter – 020409Y 45
6.34 Guide (15 mm) – 020412Y 46
6.35 Clutch Drum Lock Wrench – 020423Y46
6.36 Punch – 020424Y 46
6.37 Punch – 020425Y 46
6.38 Piston Fitting Fork – 020426Y 47
6.39 Piston Support – 020428Y 47
6.40 Valve O-Ring Remover – 020431Y 47
6.41 Oil Pressure Gauge – 020434Y 47
6.42 Guide (17 mm) – 020439Y 48
6.43 Water Pump Overhaul Tool – 020440Y 48
6.44 Adapter (26×28 mm) – 020441Y 48
6.45 Stop Wrench – 020442Y 48
6.46 Driven Pulley Spring Tool – 020444Y49
5
6.47 Guide (30 mm) – 020483Y 49
6.48 Pivot Retainers Installer – 020488Y49
6.49 Hub Cover support – 020489Y 49
6.50 Flywheel Wrench – 020565Y 50
6.51 Engine Support – 002095Y 50
6.52 Pliers – 002465Y 50
6.53 Punch – 06029Y 50
6.54 Flywheel Extractor – 08564Y 51
6.55 Gas Analyzer – 494929 51
7 Maintenance 52
7.1 Maintenance Schedule 52
7.2 Carburetor 54
7.3 Checking and Replacing the Spark Plug 55
7.4 Air Filter 56
7.5 Engine Oil 58
7.5.1 Checking the Engine Oil Level 58
7.5.2 Topping-Up the Engine Oil 59
7.5.3 Replacing the Oil and Oil Filter 59
7.6 Hub Oil 61
7.6.1 Checking the Hub Oil Level 61
7.6.2 Replacing the Hub Oil 61
7.7 Topping-Up the Engine Cooling Liquid 62
7.8 Brake Fluid 63
7.8.1 Checking the Brake Fluid Level 63
7.8.2 Topping-Up the Brake Fluid Level 64
7.9 Removing the Steering Lock 65
7.9.1 Removing the Steering Lock when on «OFF» Position 65
7.9.2 Removing the Steering Lock when on «LOCK» Position66
7.10 Headlight Adjustment 67
7.11 Checking the Spark Advance 68
6
7.12 Spark Advance Variation Curve 69
7.13 Evaporative emission system 70
Checking the CO Concentration 71
7.14 SAS (Secondary Air System) 73
7.14.1 General 73
7.14.2 Description 73
7.14.3 Removing the SAS 74
8 Troubleshooting 77
8.1 Engine 77
8.1.1 Poor Performance 77
8.1.2 Rear Wheel Spins at Idle 78
8.1.3 Rich Mixture 78
8.1.4 Weak Mixture 79
8.1.5 Low Compression 79
8.1.6 Starting Problems 80
8.1.7 Excessive Oil Consumption/Excessive Smoke from Exhaust 81
8.1.8 Insufficient Lubrication Pressure 81
8.1.9 Engine Tends to Cut Out at Full Throttle 82
8.1.10 Engine Tends to Stop at Idle 82
8.1.11 Excessive Fuel Consumption 83
8.2 Transmission and Brakes 83
8.2.1 Irregular Clutch Operation or Grapping 83
8.2.2 Poor Braking Performance 84
8.2.3 Brakes Overheating 84
8.3 Electrical System 85
8.3.1 Battery 85
8.3.2 Turn Signal Lights Not Working 85
8.4 Steering Controls and Suspension 85
8.4.1 Excessive Steering Stiffness 85
8.4.2 Excessive Steering Play 85
7
8.4.3 Noisy Suspension 86
8.4.4 Suspension Oil Leaking 86
Electrical System 87
9.1 Electrical Diagrams 89
9.1.1 Ignition Section 89
9.1.2 Turn Signal Lights, Horn, Services and Accessory Pre-Wiring 90
9.1.3 Level Indicators and Safety Switches92
9.1.4 Battery Recharge and Starting Section 93
9.1.5 Headlight and Automatic Choke Section 94
9.2 Electrical Equipment 95
9.2.1 Electronic Ignition (Immobilizer System) 95
9.2.2 Un-Coded Electronic Ignition System97
9.2.3 Diagnostic Codes 98
9.2.4 2-Flash Diagnostic Code 98
9.2.5 3-Flash Diagnostic Code 99
9.2.6 Ignition System 99
9.2.7 Spark Plug Power Supply Failure 100
9.2.8 Battery Charging System 101
9.2.9 Checking the Voltage Regulator 102
9.2.10 Stator check 102
9.2.11 Checking the Regulator 103
9.2.12 Checking the Automatic Choke Section 103
9.2.13 Turn Signal Lights Fail to Operate 104
9.2.14 Fuses 105
9.2.15 Instrument Panel 106
9.2.16 Battery 107
9.2.16.1 Preparing the Battery 107
9.2.16.2 Checking the Electrolyte Level 107
9.2.16.3 Checking the Electrolyte Density 107
9.2.16.4 Checking the Battery Charge Level108
8
9.2.16.5 Cleaning the Battery 108
9.2.16.6 Installing the Battery 108
10 Engine 111
10.1 Disassembling the Engine from the Frame 111
10.2 Removing the Silencer 116
10.3 Refitting the Engine onto the Frame 116
10.4 Removing the Rocker Cover 117
10.5 Refitting the Rocker Cover 117
10.6 Checking the Compression 117
10.7 Transmission 118
10.7.1 Removing the Transmission Cover118
10.7.2 Removing the Fan Case 118
10.7.3 Removing the Transmission Cooling Intake 119
10.7.4 Removing the Driven Pulley Shaft Bearing 119
10.7.5 Fitting the Driven Pulley Shaft Bearing 119
10.7.6 Removing the Belt Support Roller 120
10.7.7 Refitting the Belt Support Roller 120
10.7.8 Removing the Driving Pulley 121
10.7.9 Removing the Driven Pulley 121
10.7.10 Inspecting the Clutch Drum 122
10.7.11 Checking the Clutch Drum Surface Eccentricity 122
10.7.12 Removing the Clutch 123
10.7.13 Disassembling the Fixed Driven Half-Pulley Bearings 123
10.7.14 Checking the Fixed Driven Half-Pulley 124
10.7.15 Checking the Moving Driven Half-Pulley 125
10.7.16 Fitting the Fixed Driven Half-Pulley Bearings 125
10.7.17 Refitting the Driven Pulley 126
10.7.18 Checking the Moving Driven Half-Pulley Spring 127
10.7.19 Checking the Drive Belt 127
10.7.20 Checking the Clutch Friction Material128
9
10.7.21 Fitting the Clutch 128
10.7.22 Checking the Moving Driving Half-Pulley 129
10.7.23 Fitting the Fixed Driving Half-Pulley and Bushing Assembly 130
10.7.24 Fitting the Moving Half-Pulley Assembly 131
10.7.25 Fitting the Clutch Drum 132
10.7.26 Fitting the Transmission Cover 133
10.7.27 Removing the Rear Hub Cover 133
10.7.28 Removing the Rear Wheel Axle 134
10.7.29 Checking the Hub Casing Bearings134
10.7.30 Removing the Wheel Axle Bearing from the Cover 135
10.7.31 Removing the Driven Pulley Shaft 136
10.7.32 Checking the Hub Cover 136
10.7.33 Fitting the Hub Casing Bearings 136
10.7.34 Fitting the Wheel Axle Bearing on the Cover 137
10.7.35 Checking the Hub Shafts 138
10.7.36 Fitting the Hub Gears 139
10.7.37 Fitting the Hub Cover 139
10.8 Flywheel 140
10.8.1 Removing the Flywheel Cover Assembly 140
10.8.2 Removing the Flywheel 143
10.8.3 Removing the Stator 144
10.8.4 Checking the Stator 144
10.8.5 Checking the Low Oil Pressure Switch 145
10.8.6 Checking the Pick-Up 145
10.8.7 Checking the Flywheel 145
10.8.8 Fitting the Stator Assembly 145
10.8.9 Fitting the Flywheel 146
10.8.10 Fitting the Flywheel Cover Assembly 146
10.9 Checking the Secondary Air Box Valve 148
10.9.1 Checking the One-Way Valve 149
10
10.10 Lubrication Circuit 151
10.10.1 Checking the Oil Pressure 152
10.10.2 Removing the Oil Sump and Pressure Adjusting By-Pass Valve 153
10.10.3 Checking the By-Pass Valve 153
10.10.4 Removing the Oil Pump 154
10.10.5 Checking the Oil Pump 155
10.10.6 Fitting the Oil Pump 156
10.10.7 Fitting the Chain Cover Oil Seal 157
10.10.8 Fitting the By-Pass and the Oil Sump159
10.10.9 Removing the Intake Manifold 159
10.10.10 Thermostat Removal 160
10.10.11 Removing the Timing Chain Sprockets 160
10.10.12 Removing the Camshaft and Rockers161
10.10.13 Removing the Cylinder Head 162
10.10.14 Removing the Valves 163
10.10.15 Removing the Cylinder and Piston Assembly 163
10.10.16 Inspecting the Small End 164
10.10.17 Inspecting the Wrist Pin Diameter165
10.10.18 Inspecting the Piston and Cylinder Diameters 165
10.10.19 Inspecting the Piston 166
10.10.20 Checking the Piston Ring Gap 167
10.10.21 Fitting the Piston 168
10.10.22 Choosing the Base Gasket Thickness168
10.10.23 Fitting the Piston Rings 170
10.10.24 Fitting the Cylinder 170
10.10.25 Inspecting the Cylinder Head 171
10.10.26 Checking the Valve Seals 171
10.10.27 Inspecting the Valve Seats 172
10.10.28 Inspecting the Valves 172
10.10.29 Testing the Valve Seals 174
11
10.10.30 Checking the Valve Spring Plates and Half-cones 174
10.10.31 Fitting the Valves 174
10.10.32 Inspecting the Timing Components175
10.10.33 Inspecting the Camshaft 176
10.10.34 Fitting the Cylinder Head 177
10.10.35 Fitting the Timing Components 178
10.10.36 Fitting the Thermostat 181
10.10.37 Fitting the Intake Manifold 181
10.11 Crankshaft 182
10.11.1 Preparing the Engine for Crankcase Separation 182
10.11.2 Separating the Crankcase Halves 183
10.11.3 Checking the Crankshaft 184
10.11.4 Checking the Crankcase Halves 186
10.11.5 Checking the Main Bearings 187
10.11.6 Assembling the Crankcase Halves 188
10.11.7 Fitting the Starter Motor 190
10.11.8 Removing the Carburetor 191
10.11.8.1 Kehin CVK 30 Carburetor 191
10.11.8.2 Walbro WVF-7P Carburetor 197
10.11.9 Re-assembling the carburetor 204
10.11.9.1 Kehin CVK 30 Carburetor 204
10.11.9.2 Walbro WFV-7P Carburetor 206
10.11.10 Checking the Float Height 208
10.11.10.1 Kehin CVK 30 Carburetor 208
10.11.10.2 Walbro WVF-7P Carburetor 210
10.11.11 Checking the Vacuum Valve and the Needle 212
10.11.11.1 Kehin CVK 30 Carburetor 212
10.11.11.2 Walbro WVF-7P Carburetor 214
10.11.12 Checking the Automatic Choke Device 215
10.11.12.1 Kehin CVK 30 Carburetor 215
12
10.11.12.2 Walbro WVF-7P Carburetor 217
10.12 Cooling System 219
10.12.1 Cooling Circuit 219
10.12.2 Removing the Water Pump 220
10.12.3 Checking the Components 221
10.12.4 Fitting the Water Pump 222
10.12.5 Checking the Thermostat 224
11 Suspensions 225
11.1 Removing and Refitting the Front Wheel 226
11.2 Removing and Refitting the Rear Wheel 226
11.3 Removing the Steering Column 227
11.4 Removing the Front Wheel Hub 230
11.5 Front Wheel Hub Overhaul 230
11.6 Removing the Front Brake Caliper-Shock Absorber Bracket 232
11.7 Front Brake Caliper-Shock Absorber Bracket Overhaul 233
11.8 Removing the Front Shock Absorber235
11.9 Front Swing Arm Overhaul 235
11.10 Steering Column Ball-Cage Bearings Overhaul 237
11.11 Removing the Rear Shock Absorber-Silencer Bracket 240
11.12 Rear Shock Absorbers 241
11.12.1 Removing the Rear Shock Absorbers 241
11.12.2 Refitting the Rear Shock Absorbers242
11.13 Central Stand 242
11.14 Inspecting the Rear Swing Arm 242
11.15 Swing Arm Overhaul 245
11.16 Silent-Block Overhaul 247
12 Bodywork 250
12.1 Removing the Seat 250
12.2 Removing the Steering Column Cover 250
12.3 Removing the Front Handlebar Cover250
13
12.4 Removing the Rear Handlebar Cover251
12.5 Removing the Instrument Panel 251
12.6 Removing the Glove-box Panel 252
12.7 Removing the Battery Compartment Cover 254
12.8 Removing the Side Fairings 254
12.9 Removing the Footrest 254
12.10 Removing the Luggage Carrier 256
12.11 Removing the Taillight 257
12.12 Removing the Helmet Compartment257
12.13 Removing the Front Fender 258
12.14 Removing the Fuel Tank 258
12.15 Removing the Radiators and the Cooling Fan 260
12.16 Removing the Rear Mudguard 261
12.17 Removing the Turn Signal Lights 261
12.18 Removing the Electrical Opening Seat System 262
13 Pre-Delivery Inspections 264
13.1 Checking the Vehicle Appearance 264
13.2 Checking the Tightening Torques 264
13.3 Checking the Electrical Circuit 264
13.4 Checking the Levels 265
13.5 Road Test 265
13.6 Static Test 265
13.7 Functional Check 266
Time Sheets 267
14.1 Engine 267
14.2 Crankcase 267
14.3 Crankshaft 267
14.4 Piston-Cylinder Assembly 268
14.5 Cylinder Head and Valves 268
14.6 Camshaft 268
14
14.7 Valve Cover 269
14.8 Chain Tensioner – By-Pass Valve 269
14.9 Oil Filter 269
14.10 Driven Pulley 270
14.11 Pump Assembly – Oil Sump 270
14.12 Rear Wheel Axle 271
14.13 Driving Pulley 271
14.14 Electric Starter 272
14.15 Kick-Starter, Transmission Cover, and Transmission Cooling 272
14.16 Transmission Cooling Air Inlet 272
14.17 Flywheel Magneto 273
14.18 Carburetor 273
14.19 Air Filter 274
14.20 Silencer 274
14.21 Frame 275
14.22 Central Stand 275
14.23 Footrest and Battery 276
14.24 Glove-Box 276
14.25 Helmet Compartment and Rear Fender 277
14.26 Front Fender and Rear Mudguard 277
14.27 Fuel Tank 277
14.28 Cooling System 278
14.29 Fuel Pump 278
14.30 Steering Column 279
14.31 Front Suspension 279
14.32 Rear suspension 280
14.33 Handlebar Covers 280
14.34 Handlebar, and Brake and Throttle Controls 281
14.35 Swing Arm 281
14.36 Brakes 282
15
14.37 Saddle and Rear Rack 283
14.38 Locks and Immobilizer 283
14.39 Mirrors, Electric Controls, and Instrument Panel 284
14.40 Lights 285
14.41 Electrical Devices 286
14.42 Front Wheel 287
14.43 Rear Wheel 287

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]