·vespa of 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 amendments' under the headings relevant to
Vespa.Rally 200 (VSE1TI.

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

Amendment to Vespa Motorscooter Service Station Manual #153903

• 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 IWARNING 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) Stator Plate 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 P200E Frame Serial #34627 And Later
P125X Frame Serial #82432 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: 12V

Flywheel magneto: Ducati star type, nom inal power - 70W
Head lamp: Seal beam 12V-30/30W (4420)
Electronic regulator: 40W - Ducati
Battery: 12V 5-5 Ah.

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 CAUTION
1 Prolonged use of the vehicle when battery is disconnected may result in severe
.
damage to the electronic regulator.

P200E(VSX1 T) ELECTRONIC IGNITION SYSTEM (DUCATIIGNITION)

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.

Page 2
 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.

\ #1 } Battery
. : - - - - - - #2 Charge Coils

Lighting
IGNITION COIL(I) --=::--:-....::::::::=- } Coils

/
Fig.5
STATOR PLATE ASSEMBLY (P200E)

Page 3
 I. ELECTRICAL
CONTINUED

P200E(VSX1n ELECTRONIC IGNITION SYSTEM (DUCATIIGNITION) Continued

t
YElLOW GREEN

TO {
REGULATOR
YELLOW

TO THE { VIOLET ., ,,
BULBS l. J

Prior to Frame Serial #34627

t
TO THE { YElLOW
REGULATOR

TO THE { .!!.-'RE,-,,-O_+4\/
BATTERY

TO THE { VIOLET
BULBS .
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. Visually inspect ALL ignition related terminals and wiring for possible breaks
and improper connections.
Step#2. Verify engine cut-off switch (@ Fig. 3) is in OFF position.
Step#3. 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 +/- 5 ohms.

REO REO
110± 5 110± 5

GREEN

(
YELLOW

YELLOW REO

Prior to Frame Serial #34627 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 for any 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
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-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. 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.
Step #2. 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 poi nt gap for the P125X(VNX1 T) is 21 0 + 1- 1 0 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).

® CD

Fig.12
NEUTRAL INDICATOR LIGHT SWITCH

If the "NEUTRAL" indicator light is faulty, adjust the position of the switch "G" by acting 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 again the lock nut "''',

NOTE: After every gear cable change, verify that the indicator light is correctly illuminated.

Page 10
·-
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I. ELECTRICAL
CONTINUED
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P125X(VNXH) WIRING SCHEMATIC

Prior To Frame Serial #82432
WHITE GREEN
I
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BLOE I
VIOLET
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I. ELECTRICAL
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P125X(VNX1T) WIRING SCHEMATIC

WHITF
--mnr GREEN i ®- Frame Serle' #82432 And later

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I. ELECTRICAL
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---

-
 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. With T0031760 to stabilize the flywheel assembly, remove the flywheel
retaining nut.
Step #2. With nut removed, thread T0048564 on the internal threads of the flywheel
rotor until secure.
Step#3. 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: To extract use T0014499 with the adapter

halves #23 (refer to Pg. 71 operation #3 of the
Vespa Service Station Manual).

Outer race with bearing removal: To extract use T0021467 with the adapter
halves #18 (refer to Pg. 73 operation #2 of the
Vespa Service Station Manual).

* * * OPERATION COMPLETE

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. Insert T0025127 between crankshaft cams.

Step#2. Heat inner race in oil bath.
Step #3. Fit spacer T0060007 at flywheel shaft base (see Fig. 14).
Step#4. When inner race is sufficiently heated, remove from oil bath and drop over
shaft against spacer T0060007.
Step #5. 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 BEARING RACE INSTALLATION

Page 16
 III. ENGINE REASSEMBLY
CONTINUED

MAIN BEARING INSTALLATION (FLYWHEEL SIDE ONLY) Continued

Outer Race with Bearing Installation:

Step #1. Heat crankcase half (flywheel side) with hot plate.
Step #2. When case half is hot, place greased outer race with bearing over 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,
Fig. 54 of the Vespa Service Station Manual).

Page 17
 IV. MISCELLANEOUS ASSEMBLY
FRONT WHEEL SECURING

• P125X(VNX1T) • P200E(VSX1T)

To properly secure the front wheel assembly in both P125X(VNX1T) and P200E(VSX1T), the
following steps should be performed:

Step#1. Torque tighten new front axle nut to 8.29 kgm (60 ft./lb.).
Step #2. 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.).

• •• OPERATION COMPLETE

Page 18
 V. VEHICLE SPECIFICATIONS

ENGINE: 2-cycle, Single Cylinder, Rotary Valve Induction VNX1T VSXH

Displacement 123.4cc X
197.97cc X
Bore 52.5mm X
66.5mm X
Stroke 57mm X X
Lubrication automatic oil mixture X X
Gas Type premium X
regular X
Oil Type synthetic X X
2-stroke non-detergent X X
Piston/Cylinder Clearance .007" X
.008" X
Compression/Ratio 110/8.2 to 1 X
115/10.5to1 X
Piston Ring End Gap .007" to .009" X X
Head Bolt Torque 156 in. Ibs. X X
Carburetor S120} X
S124 DEL 'ORTO X
S120 Frame Serial #50032 And Later X
Main Jet 95 X
109 X
95 Frame Serial #50032 And Later X
ELECTRICAL SYSTEM: Flywheel Magneto

Point Gap .011" to .019" X

Timing 21 BTDC
0
X
23 0 BTDC X
Spark Plug (Bosch) W5A X
W5C X
Spark Plug Gap .024" X X
Headlight 12V/30/30W X X
Tail Light 12V-5/21W X X

Page 19
 V. VEHICLE SPECIFICATIONS
CONTINUED

TRANSMISSION: 4-speed Manual VNXH VSXH

Gear Ratios 1st 1:14.46 X

2nd 1:10.28 X
3rd 1: 7.31 X
4th 1: 5.36 X

1st 1:13.42 X
2nd1:9.13 X
3rd 1: 6.32 X
4th 1: 4.71 X

CHASSIS TYPE: Pressed Steel X X

WHEELS & TIRE PRESSURE

Tire 3.50 x 10" X X

Front 17 psi X X
Rear 25 psi-one person X X
35 psi·two person X X
Wheels interchangeable X X
Wheel Ring 2.10" X X

DIMENSIONS AND CAPACITIES

Wheel Base 48.62" X X

Fuel Capacity 2.03 gal. X X
Reserve Capacity .37 gal. X X
Dry Weight 2181bs. X
2251bs. X
Max. Speed 90km/h (56 mph) X
11 Okm/h (68 mph) X
Handlebars Width 695mm X X
Total Length 1760mm X X
Maximum Height 1110mm X X
Minimum Ground Clearance 225mm X X
Turning Radius 1650mm X X

Page 20
 V. VEHICLE SPECIFICATIONS
CONTINUED

FUEL CONSUMPTION: (CUNA Standard) VNXH VSXH

Mileage may vary according to up to: 111 mpg X

riding conditions, rider's weight, 78 mpg X
and the condition of the scooter.

RANGE: (CUNA Standard)

Range may vary according to up to: 230 miles X

riding conditions, rider's weight, 165 miles X
and the condition of the scooter.

IDENTIFICATION DATA

The identification data are composed X

by a prefix VNX 1 T on chassis,
VNL 3 M on engine and by a serial
number.

The identification data are composed X

by a prefix VSX 1 T on chassis,
VSE 1 M on engine and by a serial
number.

Page 21