DogHouse

Yesterday, I changed the rollers and drive belt on Stacy’s 2004 Vespa Gran Turismo 200L.  Her Vespa has 10, 518 miles on it.  Her belt and rollers looked as good as new.

 Getting Ready

Pretty Scooter

Work Space

Remove Plastic Cover

The 2004 has a different air cooling intake.  Also, It has no filter.

Loosen the Air Box and Remove the Dip Stick.

Insert Clutch Holding Tool and Remove the Nut.

Remove the Housing and Tape the Oil Fill Hole. 

Remove the Fly Wheel and the Clutch Bell.

I have a tool for holding the fly wheel.  A philips head screw drive wedged between the bottom of the fly wheel and the oil compartment will work in a pinch but is not recommended.

Remove Outside Half of the Variator.

Notice the shim/washer.  At full speed this shim prevents the belt from riding to the top.  Notice how dirty the tape over the oil fill hole is.  That is why I tape the hole closed.

Remove the Clutch Assembly and the Drive Belt.

Remove the Inside Half of of the Variator.

 Notice How One of the Yellow Plastic Guides Fell Off. 

Rollers and Variator Shaft Bushing.

New Rollers.

Re install Bushing, Inside Half of the Variator, Belt, Shim, and Clutch Assembly.

Another View.  Notice Placement of the Shim/Washer.

Install Outside Half Of the Variator.

Install Fly Wheel, Tighten the Nut, and install the Clutch Bell.

Get another beer.

Finished.  Wipe off all the grease smudges. 

I washed, dried, and Oiled the Foam Air Filter Before I Reinstalled the Air Filter Box.

Tomorrow, I will change the oil and oil filter.  Then I will install the Stebel horn.