Tales of Piaggio Vespa Tuning

The only red Italian two-seater that I will be able to afford has been in my garage, it seems, forever. But I’ve never written about it. My Piaggio Vespa PX200E was purchased new in Hong Kong, in 2002, and has been a quiet (cough, ahh not really) and simple pleasure for all of that time.

Whilst I may not ride it so often, just knowing that it is in the garage patiently waiting to whisk me away from my cares is a comfort and is a calming pressure-valve.

DSC00318

In Hong Kong the Vespa PX200 was used far longer than in most other countries, because automatic scooters were often unable to manage the extreme inclines prevalent on the Island. The geared PX200 allows the rider to manually manage the clutch and not stall or burn out on the hills. I rode mine with friends and we were able to get into places that were closed to cars on the weekend because of vehicle volume, and with public transport packed to overflowing. Reaching the beach or country park on a scooter is the best way possible.

There is a strong scooter tuning culture in Hong Kong, and my bike was built by Tom L who also ran a civil engineering company in his spare time.

One highlight of the Hong Kong stay, was using it as my “wedding car”. There’s nothing like riding off with the bride on the back of your bike. Ride it like you stole it.

DSC00320

In England, the registration approval process was complicated by the difficulties in achieving the required noise emission levels. Fortunately the helpful DVLA assessor was unable to maintain the required engine RPM and check his sound level meter at the same time. The lack of a flywheel makes the engine difficult to hold at a fixed RPM. Standing back, I noted that instead of achieving 99 dBA required by legislation, the actual reading was around 115 dBA. Finally the assessor asked me to assure him that there would be only 1 bike of this type imported (yes Sir), and that I would not ride about in town making a nuisance of myself (no Sir, of course not), and we were compliant and free to go.

Despite the short 4th gear and a speedometer only marked to 120 km/h,  I could hold 135 km/h on the motorway, at least until the fuel ran out. Running out of fuel was a constant worry when travelling at a reasonable speed.

DSC00319

After bringing it to Australia, I found I needed to ride it from Melbourne to Sydney. It was a long and fairly uneventful ride. The only real excitement was managing fuel usage. Cruising at 110-115 km/h meant that I wasn’t worried about being rear-ended by a massive semi-trailer, but that meant I needed to stop and use the 5 litre reserve can on every leg. Slowing down to 95 km/h allowed me to get between rest stops without stopping to fill up from the reserve can, but then trucks overtaking was a real concern.

Riding in Sydney with the Gasoline crew was a highlight. Buzzing the CBD like a swarm of angry bees, on the way to the watering hole, was a weekly fixture in my social calendar.

For the past few years, not much has happened. But that feisty red Italian still patiently waits in the garage, for that time when I just have to get away and recapture my freedom and youth (at a conservative speed, and with minimal expenditure).

Tuning Aspects

The standard PX200 engine produces 12 hp @ 5,700 rpm. This is enough to get it to a maximum of about 105 km/h, with a tail wind. But tuning the PX200 motor to generate far MOAR POWR is simply a matter of selecting the right components, and making choices about drive-ability, reliability, and ease of use.

DSC00324

Horsepower is generated by a Malossi 210 cc cylinder and piston kit, with the transfer airways ground open and polished, together with a SIP cylinder head and Mazzucchelli PX200 racing crankshaft. The exhaust is fed into a SIP stainless steel polished cross-over pulse tuned exhaust. Using the cross-over exhaust means that a spare tire will no longer fit, so a can of puncture repair lives in the glove box.

The choice of carburetor has a large bearing on the maximum horse power produced, but also affects how the fuel / oil mixture is prepared. I elected to stay with the standard 24 mm Dellorto, but with jets appropriate to the revised performance levels.

The Malossi / SIP / Dellorto trim is a path well travelled, and this combination produces upwards of 27 hp @ 7,500 rpm.

To get this additional power to the rear wheel, a strengthened COSA type clutch with a closed basket was used, together with racing clutch material. Never the less, in just a few thousand Hong Kong km I had to do three clutch replacements. Not sure whether this was due to the hill starts, or simply having too much fun.

A short 4th gear from the PX150 is fitted. This reduces the top speed (down to 135 km/h), but it makes carrying a pillion passenger a more enjoyable experience.

The cast metal flywheel and ring gear has been removed, and replaced by a HP4 fan wheel. Removing the  flywheel dead-weight contributes greatly to engine responsiveness. Having the plastic fan flywheel means that that the electric starter motor was redundant, and was simply more weight to be removed.

DSC00322

The standard PX200 dampers were replaced by a pair of Bitubo adjustable dampers. These contribute greatly to stability at speed, and reduce rocking under acceleration and braking.

To further improve the handling a wide rim kit spacer kit is fitted to the rear wheel. The rear wheel rubber is a 130/70 Continental Zippy. A wider rim is also fitted to the front, with 100/80 Continental Zippy rubber.

Finally, to dress up the package a little a set of SIP brushed stainless steel laser-cut floor-boards was fitted. Also a Daytona tachometer was mounted into the top of the glove box.

DSC00321

All of the initial custom fitting, build and, engineering was done by Thomas L in Hong Kong.

In 2007, Gasoline in Sydney did an engine, clutch, and gearbox rebuild.

VW Jetta Mk5 hacking – 5 year report

Well my peoples’ car has turned 5 years old. Manufactured in May 2007, and purchased in December 2007 for the express purpose of ferrying MissNow9 to school, it has performed admirably during its tenure as a shuttle bus.

Got it cleaned today, so perhaps it is time to write a review of its performance over the past years and to catalogue some of the minor improvements it has received.

Now, as a project, I think it is complete. So, it should get us to school in style for quite a few years to come.

Update September 2017
In September 2017 the car finally passed 100,000km, and is approaching its 10th anniversary. Over the past 3 years it has seen fairly light usage (no school run, no track days), so the annual mileage has been fairly low. Perhaps because of this light usage, or because of the VW engineering capability, there have been no issues to speak of since this report was originally written, 5 years ago.

Input

This car started out as a VW Jetta MkV FSi 2.0 with DSG gearbox, leather seats, and alarm.

It looks very boring. It has a huge 527 litre boot. Largest of almost any car sold in Australia.

It is easy to park, and it is easy to drive. Cheap to own.

P1020938

But, it is actually a Golf GTI in disguise. It has a very nice turbo petrol motor producing 147 kW (200 hp) for motivation, and something like 47 controllers on its CAN bus to manage everything electrical.

Design specification

  1. Always remain reliable – to get to school on time.
  2. Look completely boring – stay inside OEM visual envelope.
  3. Rock on the race track – be very surprising for drivers of track-day sports cars.

Outcome

Jetta – 260kW – 470Nm – 1430kg – 5.5kg/kW

versus

Cayman R – 239kW – 370Nm – 1340kg – 5.6kg/kW

HSV R8 Clubsport – 317kW – 550Nm – 1760kg – 5.6kg/kW

BMW 335i – 225kW – 400Nm – 1510kg – 6.7kg/kW

Some sample (wet / dry track) video from Sandown

Ingredients

Building this result is a combination of a number of subtle improvements to the motor, suspension, transmission, brakes, and work space.

A lot of things were purchased from ECS Tuning.

Audvolks is my current garage. Raymond & James fitted the K04 Turbo upgrade. James goes out of his way to help customers with special cars. Take the time to find them.

Pedders South Melbourne people are continually helpful. Ben and Reid, have been great with the car, building the special solutions and fixing all my issues as needed.

Motor

The Turbo FSi motor is an enormously tunable engine, that can produce up to 340kW with the right additional components.

My design specification indicated that there should be no obvious variation from the OEM visual signature. Open the bonnet… nothing to see here.

P1020948

Every necessary improvement has been made to achieve 260kW and, as a side benefit, the highway fuel economy has improved over standard by 1litre/100km to just under 7litre/100km.

Suspension

Handling of the Jetta / GTI Mk5 is very good, and doesn’t need much to make it better. So we just need to lower the body a little, reduce some on-limit under steer, and deliver a lot more traction (negative camber and reduced unsprung weight).

P1020944
P1020942P1020943Photo_3PhotoPhoto_2Photo_4Photo_5
  • KW Variant 1 coil-over springs, and dampers, to tighten the cornering response.
  • Whiteline rear sway-bar to reduce slight under-steer. Also at the rear, -1.5 degrees of negative camber has been set.
  • Audi TT Mk2 lower control arm, reduces unsprung weight, improves wheel positioning, improves traction, and adds adjustable negative camber which has been set to -2.4 degrees.

Transmission

260kW through front wheel drive. How can that work? Well, with a little moderation and understanding it can work very well.

The combination of a Torsen differential, stiffened engine mountings, significant negative camber, and very sticky rubber provides necessary grip and control whenever the vehicle is in motion.

However, a standing start using more than about 25% throttle is pretty noisy, smokey, and fruitless. So, we just don’t do it. Wide Open Throttle; only on a race track please!

Qdf19r

Brakes

Ok, we’re doing over 200 kmh at the end of the straight. How do we slow down? We need a pretty good braking solution. Fortunately, the Golf R32 has a good solution, with appropriate improvements of course. And, it all hides behind OEM 17″ wheels.

P1020945P1020941P1020940P1020934

Golf R32 345mm front brake conversion including

Electrical

Adding HID inserts into the headlamps was a great improvement, and converting all exterior and interior lamps to LED keeps the feeling fresh.

Workspace

Unfortunately, the Jetta missed out on DSG flappy paddles. Adding a R32 steering wheel, with appropriate CAN controller keying, provides this functionality.

And a touchscreen DVD/GPS system was also needed.

P1020933

Detailed Discussion (done better, done again)

Ditched the DBA 4000 rear rotors. They were discoloured (rusted), and didn’t do much.

This bad thing happened with the Racingbrake two piece rotor. Keep those special bolts torqued.