of
• P125X(VNX1T)
• P200E (V8X1T)
SAFETY
SAFETY AWARENESS SYMBOLS are inserted in
this
manual
to
alert you
to
possible
SAFETY
HAZARDS. When you see these symbols,
[:~AU!i?N]
OR
I
WARNING
I HEED THEIR 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.
TABLE OF CONTENTS
I.
ELECTRICAL
A.
Electrical Switch Operations
Pg.
1
-2
B.
Electrical Equipment Specifications
Pg.
2
C.
P200E
(VSX1
T)
Electronic System (Ducati Ignition)
Pg.
2-5
D.
P200E
(VSX1
T)
StatorPlate Testing (Ducati Ignition)
Pg.
5-8
E.
P200E
(VSX1
T)
Engine Timing (Ducati Ignition)
Pg.
8
F.
P125X
(VNX1
T)
Engine Timing (Ducati Ignition) Pg. 9
G.
Neutral Indicator Lamp Pg.
10
H.
P125X
(VNX1
T)
Wiring Schematic 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 Bearing Installation (Flywheel Side Only)
Pg.
16
B.
Crankshaft Installation
Pg.
17
IV.
MISCELLANEOUS ASSEMBLY
A.
Front Wheel Securing
Pg.
18
B.
Rear Wheel Securing
Pg.
18
V.
VEHICLE SPECIFICATIONS
Pg.
19-21
I.
ELECTRICAL
ELECTRICAL SWITCH OPERATIONS
• P125X(VNX1T)
•.
P200E(VSX1T)
Prior to
P200E
Frame Serial
#34627
P125X
Frame Serial
#82432
P200E
Frame Serial
#34627
And
Later
P125X
Frame Serial
#82432
And
Later
Fig.3
Switch Operations
® IGNITION KEY SWITCH
"P" Engine Shut-off and taillight on (key is extractable)
"O"-"off"
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
engine stop) is in
position"
RUN".
® HEAD LAMP HI-LO BEAM SWITCH
"1"
Lo-Beam position
"2"
Hi-Beam
position
Page 1
I.
ELECTRICAL
CONTINUED
ELECTRICAL SWITCH OPERATIONS Continued
• P125X(VNX1T) • P200E(VSX1T)
© HORN
PUSH
BUnON
@ TURN SIGNAL SWITCH AND SUPPLEMENTAL ENGINE STOP
"0"
Turn signals non-operational
"L"
Left hand turn signals on
"R"
Right hand turn signals on
"OFF"
High tension coil
to
ground
"RUN"
Engine is operational
® NEUTRAL INDICATOR LAMP
® HIGH BEAM INDICATOR LAMP
@ TURN SIGNAL INDICATOR LAMP
ELECTRICAL EQUIPMENT SPECIFICATIONS
• P125X(VNX1T) • P200E(VSX1T)
Voltage output:
Flywheel magneto:
Head lamp:
Electronic regulator:
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
CAUTION
.
damage
to
the electronic regulator.
P200E(VSX1 T) ELECTRONIC IGNITION SYSTEM (DUCA
TIIGNITION)
Shown on the next page (Fig.
4)
are all main components
of
the
electronic
ignition
circuit.
The
FLYWHEEL
MAGNETO
incorporates 6 magnetic
induction
poles
similar
to
the style
of
the
traditional ignition.
I.
ELECTRICAL
CONTINUED
P200E(VSX1T) ELECTRONIC IGNITION SYSTEM (DUCATIIGNITION) CONT.
STATOR PLATE
ASSEMBLY
------+
ELECTRONIC
REGULATOR
----
(COl
UNID
FLYWHEEL
;---'-------'----
MAGNETO
Fig.4
ELECTRONIC 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
I.
ELECTRICAL
CONTINUED
P200E(VSX1n ELECTRONIC IGNITION SYSTEM (DUCATIIGNITION) 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
I.
ELECTRICAL
CONTINUED
P200E(VSX1
T)
ELECTRONIC IGNITION SYSTEM
(DUCATIIGNITION)
Continued
The flywheel generates on
ignition
coil
(B),
and alternating current that when
rectified
by the
diode
(02) charges the condenser
(C1).
The pick-up
unit
(P)
supplies
immediately
the
control
signal
to
the
thyristor
(SCR);
Thyristor
(SCR)
feeds the discharge
of
condenser
(C1)
on the high
tension
coil
(primary side) and hence produces 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
(@
Fig.
3)
is in
OFF
position.
At the
electronic
box (COl) unit)
disconnect
the
white
lead (ground) red lead
(pick-up), and
inside green lead
(ignition
coil) from the box. (Fig.
7)
Fig.7
ELECTRONIC CONTROL BOX LEADS
Page 5
I.
ELECTRICAL
CONTINUED
P200E(VSX1T) STATOR PLATE TESTING (DUCATIIGNITION)
Continued
With
an
ohmeter
that can measure up
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
+/-
5ohms.
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
I.
ELECTRICAL
CONTINUED
P200E(VSX1T) STATOR PLATE TESTING (DUCATIIGNITION)
Continued
With the same procedure, test the IGNITION COIL by
connecting
the
tester
between the GREEN
LEAD
and the 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 forany visible damage. If none is found,
REPLACE the
defective
component.
Page 7
I.
ELECTRICAL
CONTINUED
P200E (VSX1
T)
STATOR PLATE TESTING (DUCATIIGNITION) CONT.
If ignition coil and pick-up testing
DOES
NOT
show any
ohmic
irregularities then:
Step#4.
Replace electronic control box (COl unit).
All testing operations which involve the
ignition
circuit
should
be carried
out
with the supplemental engine stop
switch
(@ Fig.
3)
in
OFF
position
to
avoid damage to electronic control box.
P200E(VSX1
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
MECHANICALTIMING 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-up with the
two
traces marked on
the flywheel inspection slot.
If timing is found irregular and adjustment is not possible, refer
to
P200E
Stator
Plate Testing, Pgs.
4-6
for proper test procedures.
Page
8
I.
ELECTRICAL
CONTINUED
P125X(VNX1
T)
ENGINE TIMING (DUCATIIGNITION)
The operations listed below
must
be carried
out
to
properly check and set the engine timing:
Step#1.
Step
#2.
Place gear selector in
"NEUTRAL"
and remove spark plug. Extract rubber
flywheel plug and rotate by hand until breaker
points
are
visible
(see Fig.
11).
The breaker
points
"A"
should start
to
open when the breaker
point
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 Manual #153903).
T0023465 - Graduated Disc
T0030259 - Indexing Figure
T0027533 - Timing Light
NOTE: The breaker point gap for the P125X(VNX1
T)
is
21
0 +
1-
10 BTDC.
Fig.11
FLYWHEEL TIMING
Page9
I.
ELECTRICAL
CONTINUED
NEUTRAL INDICATOR LAMP
• P125X(VNX1l) • P200E(VSX1l)
The illumination
of
the neutral
indicator
light
(®Fig.
3)
is controlled by a
switch
located at the
gear selector box
(@ Fig.
12).
®
Fig.12
NEUTRAL INDICATOR LIGHT SWITCH
CD
If the "NEUTRAL" indicator
light
is faulty, adjust the position
of
the
switch
"G"
by acting as
follows:
If with gear selectorengaged 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 again the
lock
nut
"''',
NOTE:
Afterevery gear cable change, verify that the indicator
light
is correctly illuminated.
Page
10
·-
2'
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I""O"'~""~"'"
IN
JO'JOW1
]
_..,._lIc'"
•
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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
~)
I===t-I
c:
PINK
--
-'
I\LW
I
WAil
E
-IiREEN[JIF.
I
I I
C\J
rl
,
-..
1
104..,'...-
.....
11
rto+o"'lif'>CIto-~_I7YJl)t)OW'l
,
........
Ic.h
•
SIQO,.Ilc.
...
IO"t""."bt
....
~
,
'uno
',0"
..
1~10I'
"01'1'
PlY
1W'I
•
"IO'le.-lt>dol",I'1Y7WI
1
~,"ettlO4"'d~.IO'I11YJWI
•
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, rVf
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.....
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....
,'lloQ
10
S_lcfl
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~
....
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Poot"D'V,"b<lIIOft
TI
,.'0"'"
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LH
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11 ,..0"111
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IJ
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C~I
11
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n Aevu'atO"
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..,
'
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LM
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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
~-y~/
O@
12
~
I I
PINK
'
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•
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,
......
z..~W'l'
truonal'4
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n~~llOf'l4t'zY,l'NI
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Ar.K
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PlIo4It'1mCaiCll'lllV·,.,.,.
'.S~.1oOf\11INJW'l
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lIeJ'1l11'C1
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10.
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"-,,
pu-"
l)ullon
II.
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I12V·~lW1
12.
'rOl'UII,IIn
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I.
ELECTRICAL
CONTINUED
:lO
(LecI'O"lclo"Uq,
" l T
jvftctioftbo.
n
"-0'11,100
1]
H'
u
l
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AH
'l1VllW)
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h"'""OII'"
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fu
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11
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t8
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19 !>o-nDfuG
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to
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fNo
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.-ftC
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fU"'l.~
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"'d-e.IOfI,onlfl1V
7W'l
•
H+vtt~""'+c.IOI'fl1VlWl
~
-Fr~;;;e
S~rl~1
#34627
And La
.
ler
t·
~
5
---
-
II. ENGINE DISASSEMBLY
All engine disassembly operations for the P125X(VNX1T) and P200E (VSX1T) are
the
same as
specified for Vespa Rally
200
in Vespa Service Station manual #153903
with
the
following
exceptions:
FLYWHEEL EXTRACTION
Step #1.
Step #2.
Step#3.
With
T0031760 to stabilize the flywheel assembly, remove
the
flywheel
retaining nut.
With nut removed, thread
T0048564 on the internal threads
of
the
flywheel
rotor until secure.
Hold puller
with
adjustable wrench and turn
center
bolt
clockwise
with
17
mm
open end wrench
until
flywheel is extracted.
*** OPERATION COMPLETE
CRANKCASE SEPARATION
Step
#1.
With all crankcase securing
bolts
removed, tap
with
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
bearing
to
remain
seated in flywheel side
of
crankcase. To properly REMOVE the bearing
components,
the
procedures
listed below must be followed:
Inner race removal:
Outer race with bearing removal:
*** OPERATION COMPLETE
To
extract
use T0014499
with
the
adapter
halves #23 (refer
to
Pg.
71
operation #3
of
the
Vespa Service Station Manual).
To extract use
T0021467
with
the adapter
halves #18 (refer
to
Pg.
73 operation #2
of
the
Vespa Service Station Manual).
Page 15
ilL ENGINE REASSEMBLY
MAIN BEARING INSTALLATION (FLYWHEEL SIDE ONLY)
• P125X(VNX1D • P200E(VSX1D
The proper
INSTALLATION
of
the main bearing (flywheel side) should be performed as follows:
Inner Race Installation:
Step#1.
Step#2.
Step
#3.
Step#4.
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
innerrace and crankshaft lobe is to be 16mm
(se.e
Fig.
15
(D)).
***
OPERATION
COMPLETE
T.0060007
(0)
Fig.15
INNER BEARING RACE INSTALLATION
Page
16
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VESPA P200E Service Station Manual
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