GT200 Stator Replacement
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Hooked
2006 GT 200
Joined: 28 May 2010
Posts: 180
Location: SF inner sunset
Sun Aug 17, 2014 11:57 pm quote
This post is dedicated to other who have contributed and helped others (and me) in the community. Thank you TB, Jimc, Greasy, Miguel and many others for being awesome making this forum great.

Tools and Parts Needed
Voltmeter____________________________Required
Flywheel nut/key_______________________Required
Puller________________________________Required
http://www.scooterwest.com/items/?_pageCCS=t#page=/item_details/Tool-Fly-Wheel-Puller-(Vespa-Piaggio)/2083
Small tie wrap_________________________Required
Hose clamps__________________________Required
____________________________________3/8-7/8 and - 1
Mallet_______________________________ Helpful
Motorcycle Jack________________________Helpful
Torque wrench_________________________Required
Coolant______________________________Required

Setup
1) on center stand or lifted
2) pet carrier out, seat open and resting as shown
3) battery disconnected and battery cover left open

Before replacement
1) idling at 12.1V
2) riding at 45 mph 12.2V
3) after a few rides battery at 11.9V and needs recharging

After replacement
1) idling = 12.40V
2) rev until the rear wheel just starts to rotate on centerstand = 12.76V
3) after a few rides battery at 12.96V

stator8-17-2014-8.03.55 PM.png
Setup: muffler and side cover removed, battery disconnected, seat up to let light in from top

stator8-17-2014-8.36.00 PM.png
remove these 2 clamps, loosen hoses and tuck them out of your way. you will need a bucket to catch coolant.

stator8-17-2014-8.43.39 PM.png
After draining, remove these 3 and remove the black cover, then tuck the lose hoses out of the way

stator8-17-2014-8.45.47 PM.png
should look like this once removed and hoses tucked away

stator8-17-2014-8.58.27 PM.png
remove these 2 screws, the other is behind the unit. Let the unit hang, if you lifted your bike, then you don't need to remove these, will see why later

stator8-17-2014-10.44.59 PM.png
remove the SAS valves with 3 screws (screws already removed in picture), the top arrow is screw is hidden, which you can get to, if you loosen in the previous step (look at next picture)

stator8-17-2014-10.49.50 PM.png
the arrow points to the deep screw, and half circle is a screw driver, you need to remove that fuel thingy if you didn't lift your bike

stator8-17-2014-11.01.34 PM.png
looks like this once removed, the right screw needed loosening, the missing left screw can actually stay, detached the small hose, and the bottom rubber hose from pipe. (and remove the pipe from engine block, *see supplemental picture 1 in follow up)

stator8-17-2014-11.28.05 PM.png
Remove these 4 allen bolts, 4mm, (fourth not circled but should be at 6 oclock) then work the housing out, a friend help pull the bottom while I worked the top. wiggle and tap

stator8-17-2014-11.24.01 PM.png
notice the 2 centering dowels, don't loose them

stator8-17-2014-11.39.11 PM.png
I used a puller to remove the flywheel, look at Hachi's post below to get official puller around $15

stator8-17-2014-11.49.24 PM.png
now the coils are exposed, see hand removing the second of 2 screws holding stator. the second, ignore the flywheel, I used this picture to show all the screws and plug to be removed. but before you do, take a picture for reference. now remove

stator8-17-2014-11.57.22 PM.png
install new stator: notice the blue zip in the last picture, replacing the one we cut off. Now put back the flywheel with the new flywheel nut. use 42-43 ftlb of torque for GT200. It is keyed and can only go on one way. no picture shown for this. ne

stator8-18-2014-12.32.03 AM.png
should also check this before putting back the housing

stator8-18-2014-12.14.16 AM.png
fitting the housing back, the idea is to match these rubber studs with the holes in the impeller. grease the holes to make life easier on fitting.

stator8-18-2014-12.04.27 AM.png
now prepare for reinstallation of the housing, take out the plug in first picture, then align the fan to housing as in second picture

stator8-18-2014-12.08.52 AM.png
now, align the TDC mark, the manual align it to that little lip in the smaller circle, but I find that the fan holes align better with the TDC pointing to white dot. this will get you close to alignment, use your judgment for minor adjustment alignment.



Last edited by sixstitches on Mon Aug 18, 2014 3:35 pm; edited 16 times in total
Hooked
2006 GT 200
Joined: 28 May 2010
Posts: 180
Location: SF inner sunset
Mon Aug 18, 2014 12:27 am quote
Finishing Up and Additional Info
Finishing Up

-Reseat your 5 prong connector, before tightening the housing.
-When putting the housing back on, thread the 4mm bolts in lightly, and wiggle and tap if you need to get the housing to line backup, be mindful of the centering dowels.
-Keep tighten a little more, work in star pattern, then wiggle and tap.
-You are done. put everything back, reconnect hoses, battery etc. add coolant.

Supplemental Pictures:

stator8-18-2014-7.58.59 AM.png
Supplemental 1: removing SAS Valve, remove the two hose clamps, the clamp and tube in circle, bottom arrow remove this metal tube completely



Last edited by sixstitches on Mon Aug 18, 2014 3:29 pm; edited 4 times in total
Hooked
2006 GT 200
Joined: 27 Feb 2014
Posts: 206
Location: Green Valley Az.
Mon Aug 18, 2014 4:35 am quote
Excellent write-up sixstiches many thanks for taking the time on this! Hoping I won't have to do this of course, but these pictures should take some of the terror out of the job.
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 37250
Location: Pleasant Hill, CA
Mon Aug 18, 2014 6:04 am quote
Excellent write-up.
Hooked
2006 GT 200
Joined: 28 May 2010
Posts: 180
Location: SF inner sunset
Mon Aug 18, 2014 9:03 am quote
question came in about what could have cause the stator going bad. I don't clearly know.

-my vespa is 2006 and had about 8600 miles on it, bought in 2010 with 3400 miles on it
-i do have an upgrade headlamp from sylvania ultra silverstar 55w, that's the only thing that I have changed in electrical system
-when charging system started failing, i replace the battery with OEM, but problem didn't go away
-after a full charge, I have maybe 12 starts before it dies, i use a solar panel to help mitigate this issue for many months. with a 5w solar panel I can charge from 12.1 to 12.4 in just a few sunny hours. and 12.8 if all day in a full sunlight.
-after removal i notice metal filing on the coils (picture below), i didn't attempt to clean this up and reused the old coil, 1) it may not work then i have to do this again 2) i can't return the coil i bought because it's an electrical component

stator8-18-2014-10.01.47 AM.png
the bad stator

Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 37250
Location: Pleasant Hill, CA
Mon Aug 18, 2014 10:19 am quote
Did you check the flywheel magnets? They can crack and bits can break off. Just a small sharp shard of magnet can rip through the enamel insulation or tear open a poorly-soldered joint. This is what happened to mine in Italy while riding home from Greece:

DSC01171sm.jpg
Torn stator

DSC01172sm.jpg
Buggered magnets

Sponsor
Granturismo 218
Joined: 04 Feb 2013
Posts: 5209
Location: South Carolina
Mon Aug 18, 2014 11:40 am quote
sixstitches wrote:
question came in about what could have cause the stator going bad. I don't clearly know.
8 Years, as much as anything else. Stators, Starters, and cables are all starting to wear out on these bikes. By the way, the puller you are using is a very bad idea.
Hooked
2006 GT 200
Joined: 28 May 2010
Posts: 180
Location: SF inner sunset
Mon Aug 18, 2014 12:01 pm quote
Hi Jimc, The flywheel was in great condition.
Sergeant at Arms
Weird 80's Vespas & Cool Vintage Lambrettas
Joined: 21 Oct 2005
Posts: 7263
Location: The state of insanity, SoCal
Mon Aug 18, 2014 12:07 pm quote
Motovista wrote:
sixstitches wrote:
question came in about what could have cause the stator going bad. I don't clearly know.
8 Years, as much as anything else. Stators, Starters, and cables are all starting to wear out on these bikes. By the way, the puller you are using is a very bad idea.
this. so much this.

yes, your 06 GT200 only has 3200mi on it but do you realize that the original tires on that thing were probably produced in 05? c'mon now...

but yeah, after so many years, regardless of mileage components are starting to go into failure mode.

-g
Hooked
2006 GT 200
Joined: 27 Feb 2014
Posts: 206
Location: Green Valley Az.
Mon Aug 18, 2014 1:37 pm quote
Motovista wrote:
sixstitches wrote:
question came in about what could have cause the stator going bad. I don't clearly know.
8 Years, as much as anything else. Stators, Starters, and cables are all starting to wear out on these bikes. By the way, the puller you are using is a very bad idea.
Motovista, my GT200 is an '06 also and except for the fuel pump has been perfect. But anticipating more issues, such as stator repair, which gear puller is recommended for this job? Google images has many of course, but all seem similar without big differences.

Thanks
Hooked
'81 P200E, '80 P200E, '64 V90 and 3 Ciaos
Joined: 27 Mar 2014
Posts: 136
Location: Tucson, AZ
Mon Aug 18, 2014 1:53 pm quote
LapinAgile wrote:
Motovista, my GT200 is an '06 also and except for the fuel pump has been perfect. But anticipating more issues, such as stator repair, which gear puller is recommended for this job? Google images has many of course, but all seem similar without big differences.

Thanks
Lapin,

The puller for the flywheel is the same as the one used on the PX Vespas. I have a few of them and I'm just up the road in Tucson. You're welcome to borrow one if you want.
Hooked
2006 GT 200
Joined: 28 May 2010
Posts: 180
Location: SF inner sunset
Mon Aug 18, 2014 2:08 pm quote
For the extractor for GT200, it's 008564Y, about $90 from scooterwest, I didn't buy one.

the spanner wrench is 020565Y, I dont know how much it cost.

when i get home, i will add some pictures, but they are also in the manual for GT200 pages 143 and 144
Ossessionato
2005 GT 200
Joined: 19 Jun 2010
Posts: 2083
Location: Montgomery,Alabama
Mon Aug 18, 2014 2:28 pm quote
sixstitches wrote:
For the extractor for GT200, it's 008564Y, about $90 from scooterwest, I didn't buy one.
I bought this one to use on my GT200 and it worked fine. Only $15

http://www.scooterwest.com/items/?_pageCCS=t#page=/item_details/Tool-Fly-Wheel-Puller-(Vespa-Piaggio)/2083
Sponsor
Granturismo 218
Joined: 04 Feb 2013
Posts: 5209
Location: South Carolina
Mon Aug 18, 2014 2:31 pm quote
Flywheel pullers are about $10, and one does fit just about every Vespa.
Hooked
2006 GT 200
Joined: 28 May 2010
Posts: 180
Location: SF inner sunset
Mon Aug 18, 2014 2:34 pm quote
I would have bought it for $15, but I did a phone order, and the guy said it was $89 dollars.

I just didn't know.
Hooked
2006 GT 200
Joined: 27 Feb 2014
Posts: 206
Location: Green Valley Az.
Mon Aug 18, 2014 3:30 pm quote
az_slynch wrote:
LapinAgile wrote:
Motovista, my GT200 is an '06 also and except for the fuel pump has been perfect. But anticipating more issues, such as stator repair, which gear puller is recommended for this job? Google images has many of course, but all seem similar without big differences.

Thanks
Lapin,

The puller for the flywheel is the same as the one used on the PX Vespas. I have a few of them and I'm just up the road in Tucson. You're welcome to borrow one if you want.
Great az_slynch! Many thanks. Looks like you've got some really good classic models, congrats. I'll get in touch as soon as symptoms start. I like the guys at Renaissance, but costly of course and far for me.
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