P200E Engine Build Project Update ! By Kaveman (Read 3,914 times)

[Kaveman]

Hi everyone ! Here is an update on my Vespa P200E engine build project . It has been a while since I last posted . Bit by bit the engine parts are being purchased . A new crankshaft is the last major item needed before I can start tearing into the Stella 2T 's 150cc engine . The Vespa Rally 200 , P200E and PX200 engines were the largest engines Paggio put in their 2 cycle scooters . The actuall stock engine displacement is at 198cc for a stock P200E . There are piston and cylinder upgrades to boost it to 215 cc . My engine will be pretty much a stock P200E but will use my Stella's updated electronic type ignition system and electrical system. Once all the needed parts are here I will be "canibalizing" my 2T engine for the EFL type gear stack-driveshaft assembly and reusing the flywheel and stator assembly . The Vespa and stella's newer stators have 2 different markings on the stator assembly to help with setting the right timing. On a GY6 you set the timing via the cam shaft and timing chain with the help of TDC , for the P(PX) 200 engines and on the newer P PX and Stella 2T engines TDC is critical . There are no timing chains and camshafts on a Vespa 2 cycle scooter engine. The picture I am attaching shows 2 markings on the lower left. one " I.T. "is for the 150 ( 18 degrees off tdc) and the P and PX 200 is the "A" ( 23 degrees). The line on the crankcase is the timing marks. The P and PX 150 and 200 engines timing can vary by 1 to 3 degrees depending if your using a reed valve and if your using a modified race type crankshaft or cylinder and piston . This is my most biggest concern at the moment when the engine is finally installed on my Stella's frame. I hope that will be by the end of the month if funds permit . I'll post again when that time is finally here hopefully with some pictures !! There are still 2 bearings to be installed into the crankcase and the bearing race to be installed onto the crankshaft. If all goes as planned (pending any serious issues once the engine is together ) I'll be back scooting by April . ;D
Cheers ! ,
will c.
P.S.The stock driveshaft for a P200E has a tendency sometimes to have the tranny jump out of gear when at high speed. The EFL type drive shaft found on the later PX series scoots took care of that issue !

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[Kaveman]

Just another quick project update! Earlier today ( Wednesday) I finally started the teardown of the 150cc engine after I pulled it off the scoots frame . LUckily I am doing the dirty work at a friends place so I don't get into extremly hot h2o with the property manager where I live. I'll try and get some pics taken Thursday as I continue my work. After removing the cylinder and cylinderhead I found out that the crankshaft was shot ! The connecting rod was loose bigtime where it mounts into the crankshaft itself. It had too much free movement from side to side . It was why the engine was locking up ! Thursdays mission is to pull the flywheel off , remove the stator assy , split the crankcase without damaging it and then pull the efl driveshaft from the old crankcase . I still have to install 2 bearings and 1 bearing race on the new p200e crankshaft before I can start the final assembly phase of this project. More to come in the next day or two !
will c.
p.s. traitor to the gy6 scoot forum ?
Hell yes !
! Got to love those classy Italian Scoots !! ;D

[Kaveman]

I made more progress this afternoon. Hope to have crankcase together Saturday afternoon after installing the needle bearings on the cluster gear spindle and the drive shaft assembly . The kickstart went in quickly (a/e it was much less of a headache than trying to reinstall the kickstarter with spring on the gy6 I previously has a year and a half ago) . More to come tomorrow evening.

willc.

[Kaveman]

Crankcase is fully bolted up ! I got a lot of work done Saturday afternoon . Cylinder, piston and head are now installed . The rear brakes and rear hub are also now installed on the crankcase . Next on the to do list is the stator , flywheel and reinstalling the engine back onto the frame. Once that is done i'll attach the cables and wiring then put the carb on . I still need to drill 2 holes in the airfilter . More fun to come. The pictures below were taken as I worked away on the engine Saturday afternoon. They are not in any order .
Cheers !
willc.

[Kaveman]

[Kaveman]

[Kaveman]

[Alleyoop]

Very nice Will, nice little motor there.
Alleyoop

[Kaveman]

Not a good afternoon . Ran into a big issue concerning the flywheel and stator assy . The flywheel locks up completely .The teeth from the outer edge of the flywheel are making contact with the cylinder assy . Looks like I'll have to find a stator and flywheel that will work with both the p200e and the stella's electrical system .
willc.

[Kaveman]

Update !! Looks like another 2 weeks of waiting and $100 out of the pocket tomorrow for a new LML made stator and kickstart only flywheel ! The Stella is actually made by LML in India for Genuine Scooter Company in the US . Outside of the US they are known as the LML Star .
willc.

[ridecheap]

Its a hobby fun one. Look forward to updates in the future learning.

[justbuggin]

can you clearance the cylinder for what you have there ?

[Kaveman]

On this engine , no ! Since my last posting I ordered a new flywheel and stator assy combo from a dealer in India ( via Ebay) on April 3rd . It ran me about $96 total with shipping . It is original LML and the wiring off the stator matches up with my Stella's wiring. The Stella is actually made in India by LML for Genuine Scooter Company who sells them here in the USA . In Europe they are sold by LML as the LML Star . The new flywheel I purchased doesn't have the teeth on the outer edges for the electric starter . If I am correct it ( the new flywheel) is also abit smaller in diameter than the one I tried to use ! It is strictly for kickstart only. That means it will not be snagging on the cylinder assy . There are small differences between Vespa kickstart crankcases and the newer electric start versions. There is more clearance for a electric starter and it's larger flywheel . The kickstart version flywheel and crankcase has less clearance and the flywheel area is a tad bit smaller than a electric start flywheel .Unfortunatly I found that out the hardway . Luckily the seller I ordered from had 100% positive feedback on Ebay and the pricing was reasonable with shipping . The seller shipped my purchase by FedEx aswell. Both items ( Flywheel and Stator Assy) should hopefully be here by next Friday pending there is no issues with US Customs ! Thats what FedEx said on the tracking info I got from the seller. Hopefully next weekend when the parts show up, I can get going and try and finish this project !!
will c.

[justbuggin]

hey it was worth a shot good luck getting your parts hope everything gets here like it suppose too

[Kaveman]

We will know soon enough !! How much of a smoke screen the p200e exhaust will put out is yet to be seen. I had a neighbor down the hall last May yell in my face about the smoke the old engine was putting out, while I was in the parkinglot when I was working on the scoots engine.
willc.