PIAGGIO VESPA RALLY 200 Installation guide

INTRODUCTION
The PIAGGIO Co. takes this opportunity of thanking you for your preference for this
excellent model Vespa. We feel sure that this scooter will give you complete
satisfaction.
You will appreciate the matchless performance of the Vespa « RALLY 200both as
regards to its sports and touristic aspects: the engine of 200 cc. with electronicignition
allows to obtain with a very good regularity of functioning high speed andbrilliant pick -
up; very good suspensions and road - holding, quiet engine and elegance are further
characteristics of the vehicle.
Long journeys on your scooter will not fatigue you and you will quickly appreciateits first
class performance and its high average speed on long distances.
This booklet, with its simple instructions on operation and maintenance will furnishyou all the
informations necessary far obtaining a complete working knowledge of your Vespa <
Rally 200 >
Fig. 1 – Vespa Rally 200

CONTENTS
Performance and specifications Page 5
Layout of controls 6
Operating instructions 7
Oil to be used of the fuel mixture 9
Running in 9
Tire pressure 9
Operating and maintenance:
Common operations to cart 11
Maintenance 25
Summary of Instructions for Maintenance 26
Fault finding 28
General specification 29-32
Accessories 31
Electrical equipment 32-34
Identification data 35

PERFORMANCE AND SPECIFICATIONS
Consumption (according to CUNA Standards) : 3 It 100 Km. (78 mls U.S. gals;
94 mls/imp. gals), gasoline-oil
mixture i. e. 2% oil.
Max. speed (CUNA Standards): 110 Km/h (68 mph).
Carrying capacity: 2 persons and 10 Kg. (22 lbs.) of
luggage.
Range 280 Km (174 mls)
Max fuel capacity: 8.2 It. (2.13 U.S. galls
or 1.8 imp. galls)
(incl. 1.8 It. s 0.47 U.S. galls or
0.39 imp.galls of reserve).
Wheel base: 1230 mm (48".4)
Handlebar width: 690 mm (27".6)
Total length 1770 mm (69".6)
Max height 1070 mm (42''.1)
Min. ground clearance: 130 mm ( 5".2)
Turning radius: 1400 mm (55".0)
Total dry weight 103 Kg. (226.5 lbs)
ENGINE: single horizontal cylinder, two
stroke rotary distribution: i. e.,
carburated mixture is regulated
by the crankshaft rotation, with
three transfer ports.
Bore: 66.5 mm (2".62)
Stroke: 57 mm (2". 24)
Cylinder displacement: 197,97 cc. (12.076 cu. in.)
Compression ratio: 1:8.2.
IGNITION: by means of an electronic device that offers many advantages, i. e.,
allowing to produce a higher tension peak reached in a very short time and with a
very limited length of the discharge.

It f o l l o w s :
1) Engine regular running also with spark-plugs very dirty.
2) Starting facility when cold.
3) Light ignition and combustion of thefuel.
4) Higher life of the spark - plugs because of a smaller electrodes wear.
5) Unalterability, during the time, of the ignition advance because the traditional
mechanical devices exposed to the wear (as the contact breaker cam, contact
breaker, sliding block etc.) are not longer present.
Sparking plug types: Marelli CW 7 LTP; Champion N 88: Bosch W 240 T 2; K.L.G.
FE 80; Lodge 2 H LH.
Spark advance: 24-1 before TDC
1. Gear change twist grip and clutch control lever - 2. Front brake lever - 3. Throttle
twist grip - 4. Main switch unit with horn button - 5. Front brake shoes - 6. Rear brake
pedal - 7. Kick starter - 8. Gear selector - 9. Rear brake shoes - 10. Clutch - 11.
Carburettor and air cleaner - 12. Choke control - 13. Fuel cock - 14. Button for tipping
-up the saddle - 15. Fuel tank cap - M: Engine cut-out.
Fig. 2 - Installation of controls and transmissions
Note - In order to gain access to the fuel tank, push on the but-n No. 14 and release
the saddle: then swivel it upwards.

OPERATING INSTRUCTIONS
Operation Instructions
SECURITY LOCK
1. - Steering lock.
a) Locking the handlebars To lock the vehicle, turn the handlebars
anticlockwise up to the limit stop; rotate the key
anticlockwise and push inwards. So that it thrusts
the sliding bar against the steering column
(see fig. 3).
To ease the insertion of the sliding bar into the
hole of the steering column, slightly turn the
handlebars from the limit stop clockwise. When
the handlebars are locked the key will now spring
back to its original position and can then be
withdrawn.
b) Unlocking the handlebars To release the handlebars, insert the key in the lock,
turn it to the left and pull it back; then turn the
handlebars in the normal position.
NOTES
The vehicle is provided with two security locks, the one relates to the steering column
and the other one for locking the front tool box. Both operated by the same key. The key
can be extracted from the lock even if the handlebars a r e free. The security locks should not
be lubricated, eventually use colloidal graphite.
2. Front tool box lock To open the flap door of the front box insert the
key in the lock and turn it fully anticlockwise, then
slide down the external plaque of the lock (fig.
4). In order to close it, close the flap door until
the lock clicks against the tool box; then turn
the key clockwise and withdraw.
BEFORE OPERATING THE VEHICLE Unscrew the plug on the gear box marked
"OLIO" - (fig. 16) and check that the oil is on a
level with the hole when the vehicle is standing
upright.

OPERATING INSTRUCTIONS
Fig. 3 - Steering lock on the steering column Fig. 4 - Front tool box lock
1. Normal position and locking operation – 2. locked position and unlocking operation.
N. B. - The arrow indicates the operation to be carries out for unlocking (1) and for locking
(2) the tool box.

OPERATING INSTRUCTIONS
Operation Instructions
FUEL SUPPLY Use a mixture of gasoline (petrol) and pure
mineral Oil SAE 30 at 2°/°: (Esso 2 - T Motor Oil;
Shell Golden Motor Oil, Shell X - 100 2 T; Total 2
T). The mixture should be at 2% of oil by
volume (1/4 pint of oil to 11/2 gals of gasoline
(petrol). For access to fuel tank pivot the saddle
on its forward edge, after having released the
rear attachment as shown at fig. 2.
NOTES
Ensure that the fuel tank breather Is always clean. Use a mixture 2% by volume
during and after running – in.
For running in first 2000 Km. (1200 mls), do not maintain the throttle fully open for
long periods.
- After first 1000 Km. (600 mls)
change oil in gear box (page 23) and check that all nuts and bolts are tight.
- Check tire pressure: Front: 1.2 Kg/cm' (17 lbs;/sq. in. ); Rear: 1.75 Kg/cm2(25
lbs/sq. in.) with one up; Rear: 2.5 Kg/cm' (35 lbs/sq. in.) with two up.
1. Group carburettor air cleaner - 2. Piston - 3. Crankshaft - 4. Clutch - 5. Drive shaft
and gear pinions assy. - 6. Gear shifter - 7. Flywheel magneto - 8. Kick starter.
Fig. 5 – Engine Section

OPERATING INSTRUCTIONS
Operation Instructions
STARTING Carry out the operations indicated on fig. 6. Do not
use the choke when the engine is warm; as soon as
the engine is running smoothly bring the starter
control back to its normal position.
SETTING THE SCOOTER IN MOTION With the engine running at idling speed declutch
and rotate the gear change twist grip to the position
of first gear (fig. 6). For setting the vehicle in motion
slowly let in the clutch and gradually open the
throttle.
GEAR CHANGE Close the throttle, declutch and rotate the gear
change grip to a higher or lower gear, as the case
may be (fig. 6).
STOPPING THE ENGINE Before stopping the engine change to <neutral>
and then switch off the ignition (Fig. 2).
NOTES
In case of hard starting see page 17. When it is necessary to decelerate do not hesitate
in changing down.
A: Open the fuel tap - B: Selector in neutral C: Pull out the starter control (with cold
engine) - D: Bring throttle twist grip to idling position - E: Operate kick starter.
Fig. 6 – Operation for starting

OPERATING AND MAINTENANCE: Common operations to carry out
REMOVAL OF ENGINE COWLING
- Pull the lever (1) - and turn to release from cowling. Swing the cowling outwards so that
the front locating pin (2) is free of its housing.
- Lift the cowling upwards from the front pivoting on its rear section: so that the clasp (3)
releases from the chassis bracket.
- Pull the cowling outwards on the locating pin (4) so that the latter clears its housing,
thus releasing the cowling.
For reassembly carry out the reverse procedure.
Fig. 7 - Removing engine cowling
1. Lever for locking cowling.
2. Front locating pin.
3. Clasp securing cowling to chassis.
4. Rear hooked pivot pin.

Fig. 8 – Gear Transmission
1. Gear change twist grip - 2. Clutch control lever - 3. Gear change cable - 4. Gear shifter
-5. Selector stem - 6. Selector spider - 7. 1st gear - 8. 2nd gear - 9. 3rd gear - 10. Top
gear - 11. Mainshaft - 12. Spring gear - 13. Clutch. N. B. - The position 1 - 2 - 3 - 4 on the
gear change twist grip correspond to bottom, 2nd, 3rd and top gear respectively; the „0“
indicates neutral.

OPERATING AND MAINTENANCE: Common operations to carry out
ADJUSTMENT ON CARBURETTOR
For adjusting the idling turn the slow running adjuster screw (on the air cleaner
cover) (Fig. 9, n. 5).
- On the carburettor body a set screw is provided for adjusting the throttle cable play;
this screw is to be reset only if necessary or on dismantling and reassembly
operations.
- On the air cleaner case, opposite to said screw, is a plugged hole. When this plug is
removed the spring loaded idler adjusting screw is accessible (Fig. 9, n. 14).
To avoid carburations troubles, we recommend that this adjustment is carried out by a
Vespa dealer.
STARTING UP when the engine is flooded:
In the case of difficulties caused by flooding (presence of unvaporised mixture in the
cylinder), the following methods can be used:
- Attempt push starting: engage the 2nd gear, declutch, push the vehicle to a certain
speed, sharply release the clutch and when the engine fires declutch immediately.
- Close the fuel tap, remove the sparking plug (page 23) and clean; then kick over the
engine several times. Screw in the sparking plug securely, open the fuel tap and start
the engine.

Fig. 9 - Fuel supply and distribution diagram
1. Combined fuel tap and sediment bowl. - A) Reserve; B) Open; C) closed - 2. Float - 3.
Carburettor and air cleaner - 3/1. Air filter - 4. Calibrator for starter - 5. Throttle slide set
screw - 6. Throttle slide - 7. Main jet air calibrator - 8. Air calibrator on mixer - 9. Mixer -
10. Main jet - 11. Slow running jet - 12. Slow running jet air calibrator - 13. Oil filler plug -
14. Slow running adjuster screw - 15. Starter valve - 16. Inlet port. - 17. Transfer ports
(one of the ducts is schematically illustrated) - 18. Exhaust port.

OPERATING AND MAINTENANCE: Common operations to carry out
Operation Instructions
CHANGING WHEELS AND TIRES For dismantling the wheels from the vehicle remove
the nuts as indicated in fig. 10. On reassembly
tighten said screws alternately and progressively.
DISMANTLING THE SPARE WHEEL When a tire has to be removed, first deflate and
INSTRUCTIONS then remove the nuts joining the two wheel rim (fig.
11). Dismantle the spare wheel cowl, following the
instructions given for engine cowl (see pag. 15). To
release the wheel unscrew the bolt securing it to the
lower section of the protective plate, then the two
nuts securing the wheel to the upper part (Fig. 12)
of the bracket.
NOTES
The front and rear wheel are interchangeable o n e with another providing that the tire
pressures are regulated accordingly (page 11).
Fig. 15 - Dismantling spark plug

OPERATING AND MAINTENANCE: Common operations to carry out
Operation Instructions
BRAKE ADJUSTMENT Rotate the adjusting screw indicated in fig. 13 so
that the wheel is completely free to rotate when the
lever and brake pedal are in the resting position.
The braking action should commence immediately
the respective controls are operated.
DISMANTLING AIR FILTER For extracting the air filter «A» (fig. 14) from the air
filter case remove the engine cowl (fig. 7) and air
cleaner case cap. Unscrew the two screws «B»
securing the air filter and extract the latter
component.
NOTES
The air cleaner case cap can be extracted by dismantling the two securing screws.
Fig.11 – Tire removal

Fig. 10 – Removing wheel from vehicle

OPERATING AND MAINTENANCE: Common operations to carry out
Fig. 12 – Dismantling the spare wheel
Operation Instructions
SPARK PLUG REMOVAL Remove engine cowl (Fig. 7), disconnect the H. T.
lead and extract the spark plug using the box
wrench as indicated in Fig. 15.
CHANGING OIL IN GEAR CASE Drain off through hole (Fig. 16). Clean carefully the
plug of said hole. Introduce a small quantity of
flushing oil, run the engine a few minutes to ensure
thorough circulation and cleaning and drain off
again. Afterwards refill gear case with about 250
grs. of new oil (up to level of filling hole).
NOTES
On reassembling the spark plug ensure that it is fitted into the threaded hole, at the
correct inclination. This operation of changing oil should be carried out with warm engine.

Fig. 13 – Front and rear brake adjustment
Fig. 13 (2) – Front and rear brake adjustment

Fig. 14 Dismantling the air cleaner
Note - If the air cleaner case is taken off, it is also possible to gain access to the
carburettor.

OPERATING AND MAINTENANCE: Common operations to carry out
Operation Instructions
DISMANTLING CYLINDER HEAD Strip off engine cowling, (Fig. 7), disconnect the H.
T. lead, dismantle the <Cooling hood> , (fastenings
,<A>-<B>-<C>, fig. 17) and unscrew the four
securing nuts by means of a box wrench.
SUBSTITUTING BULBS Should one of the bulbs fail, before fitting a
replacement, check that the socket contact points
and the general funtioning of the electrical plant are
efficient.
NOTES: For dismantling the cleaner see at page 21.
Fig. 16 – Oil filter hole (1); oil draining hole (2).