VESPA 2008 S 50 4T 4V Manual Download Page 121

Page: 121 / 199

- Using the rpm indicator in the analyser or a sep-

arate one, adjust the idle screw.

N.B.

THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE IF INADEQUATE RPM INDICATORS ARE USED.

Specific tooling

020332Y

Digital rpm indicator

Characteristic

Idle speed

about 1900/2000 rpm

Vespa S 50 4T 4V (2008)

Engine

ENG - 121

Summary of Contents for 2008 S 50 4T 4V

Page 1: ...MANUALE STAZIONE DI SERVIZIO Vespa S 50 4T 4V 2008 ...

Page 2: ...make any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of single models should be checked at the official Piaggio sales network Copyright 2008 PIAGGIO C S p A Pontedera All rights reserved ...

Page 3: ...dispone degli impianti e delle attrezzature necessarie ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to sp...

Page 4: ......

Page 5: ...ARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...riction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and split pins upon refitting After removal clean the co...

Page 8: ... C383M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Width 740 mm Length 1755 mm Wheelbase 1290 mm Maximum height 1140 mm Kerb weight 110 5 kg Engine ENGINE Specification Desc Quantity Type single cylinder four stroke and four valve air cooled engine Characteristics Vespa S 50 4T 4V 2008 CHAR 8 ...

Page 9: ... depression type KEIHIN NCV ø 20 Cooling forced air circulation OIL PUMP Specification Desc Quantity Type Trochoidal Distance between the rotors Admissible limit clearance 0 15 mm Axial rotor clearance Limit values admitted 0 09 mm Distance between the outer rotor and the pump body Admissible limit clearance 0 20 mm Levelness 0 1 mm OIL FILTER Specification Desc Quantity Type mesh plastic and cent...

Page 10: ...PER ATING AS CIRCUIT BREAKERS 1 Check that given regular conditions there is no continuity between terminals 30 and 87 2 Apply 12V voltage to power terminals 85 and 86 of the remote control 3 With the remote control powered check that there is continuity between terminals 30 and 87 4 If these conditions are not fulfilled the remote control is damaged and must be replaced TURN INDICATOR SWITCH Char...

Page 11: ...KEY SWITCH LIGHT SWITCH STARTER BUTTON HORN BUTTON Vespa S 50 4T 4V 2008 Characteristics CHAR 11 ...

Page 12: ...y and ground con nection infinite Resistance between primary and HV output 3 3 6 kOhm Shielded cap 5000 Ohm Power 120 W resistance between BLUE cable and GROUND CONNECTION 1 Ohm Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc Quantity Type Unitised body made of stamped plate Characteristics Vespa S 50 4T 4V 2008 CHAR 12 ...

Page 13: ... rims Front rim 2 50 x 11 Light alloy rims rear rim 3 00 x 10 N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES Tightening Torques STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut 30 40 Steering lower ring nut 8 10 Handlebar locking 50 55 Nm FRAME ASSEMBLY Name Torque in Nm Engine swinging arm bolt 33 41...

Page 14: ...l nut 40 to 44 N m Stator screws 3 4 Pick up screws 3 4 Oil pump bulkhead screw 4 5 Timing chain oil pump compartment cover screws 4 5 Oil decantation labyrinth sheet screws 7 8 Oil pump crown screw 8 10 Screws fixing oil pump to the crankcase 5 6 Oil sump screws 8 10 Nm Inlet manifold screw 7 9 Carburettor manifold clamp screw 1 2 1 5 Screws fixing cables to starter motor 1 5 2 5 Starter screws 1...

Page 15: ...32 0 046 Cylinder 2nd oversize B2 39 400 39 407 39 361 39 368 0 032 0 046 Piston 2nd oversize C2 39 407 39 414 39 368 39 375 0 032 0 046 Piston 2nd oversize D2 39 414 39 421 39 375 39 382 0 032 0 046 Cylinder 3rd oversize A3 39 593 39 600 39 554 39 561 0 032 0 046 Cylinder 3rd oversize B3 39 600 39 607 39 561 39 568 0 032 0 046 Piston 3rd oversize C3 39 607 39 614 39 568 39 575 0 032 0 046 Piston ...

Page 16: ...he piston N B MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER THICKNESS GAUGE FROM THE SECOND SEAL SIDE Fitting clearance Top piston ring standard coupling clearance 0 03 0 065 mm Top piston ring maximum clear ance allowed after use 0 07 mm Middle piston ring standard coupling clearance 0 02 0 055 mm Middle piston ring maximum clearance al lowed after use 0 06 mm oil scraper ring stand ...

Page 17: ...e the opening see figure of the sealing rings using a thickness gauge If any measurements are greater than specified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES AND BETWEEN THE PISTON AND THE CYLINDER IS AS SPECIFIED IN ANY CASE NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE D...

Page 18: ...2nd Oversize 39 4 x 2 A 0 20 0 70 1st Compression ring 3rd Oversize 39 6 x 1 A 0 08 0 20 2nd Compression ring 3rd Oversize 39 6 x 1 A 0 05 0 20 Oil scraper ring 3rd Oversize 39 6 x 2 A 0 20 0 70 Crankcase crankshaft connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE Name Description Dimensions Initials Quantity Half shaft transmission side 14 0 0 005 A Flywheel side half shaft 16 0 0 ...

Page 19: ...ing flywheel side 17 0 007 0 mm Check that the driving shaft cone the tab seat the oil seal capacity the toothed gear and the threaded tangs are in good working order In case of failures replace the crankshaft Specific tooling 020074Y Support base for checking crankshaft alignment Vespa S 50 4T 4V 2008 Characteristics CHAR 19 ...

Page 20: ...sing a bore gauge measure the connecting rod small end diameter N B IF THE CONNECTING ROD SMALL END DIAMETER EX CEEDS THE STANDARD DIAMETER EXHIBITS WEAR OR OVERHEATING PROCEED TO REPLACE THE CRANK SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER Characteristic Rod small end diameter 13 0 015 0 025 mm Max diameter admitted check the small end 13 030 mm Calculate the coupling clearance be...

Page 21: ...un out 0 1 mm Insert the valves into the cylinder head Alternatively check the intake and exhaust valves The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD CHECK Specification Desc Quantity Standar...

Page 22: ...e seat V Characteristic Standard value 1 1 3 mm Admissible limit 1 6 mm If the impression width on the valve seat is larger than the prescribed limits true the seats with a 45 mill and then grind In case of excessive wear or damages replace the head STANDARD VALVE LENGTH Specification Desc Quantity Inlet standard length 74 9 mm Outlet standard length 74 35 mm Characteristics Vespa S 50 4T 4V 2008 ...

Page 23: ... Calculate the clearance between valve and valve guide Check the concentricity of the valve head by ar ranging a dial gauge at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 03 mm Check the deviation of the valve stem by resting it on a V shaped abutment and measuring the extent of the deformation with a dial gauge Characteristic Limit...

Page 24: ...bove checks you can use the same valves To obtain better sealing performance grind the valve seats Grind the valves gently with a fine grained lapping com pound During the grinding keep the cylinder head with the valve axes in a horizontal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SU...

Page 25: ... N B A BALL BEARING IS FITTED ON BEARING A CONSE QUENTLY BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM Characteristic Standard height Inlet 24 397 mm Standard height Outlet 23 996 mm Fitting clearance Maximum admissible axial clearance 0 5 mm Measure the outside diameter of the rocking lever pins Check the rocker pins do not show signs of wear or scoring Measure the in...

Page 26: ...AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid MONTBLANC MOLYBDENUM GREASE Grease for driven pulley shaft adjusting ring and movable driven pulley housing Grease with Molybdenum disulphide AGIP G...

Page 27: ...INDEX OF TOPICS TOOLING TOOL ...

Page 28: ...9 Bell for bearings O D 38 mm 004499Y Bearing extractor Fitted with 1 Bell 2 Sleeve 3 Screw 6 Ring 27 Half rings 34 Half rings 005095Y Engine support 008119Y009 Tube to assemble shafts and axles 020004Y Punch for removing fifth wheels from headstock Tooling Vespa S 50 4T 4V 2008 TOOL 28 ...

Page 29: ... steering tube ring nut 020074Y Tool to align crankshaft 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y Bearing fitting base Vespa S 50 4T 4V 2008 Tooling TOOL 29 ...

Page 30: ...le piston on cylinder 020291Y Valve fitting removal tool 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter Tooling Vespa S 50 4T 4V 2008 TOOL 30 ...

Page 31: ...ital rpm indicator 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40 mm Adaptor 020359Y 42x47 mm Adaptor Vespa S 50 4T 4V 2008 Tooling TOOL 31 ...

Page 32: ...Stores code Description 020360Y 52x55 mm Adaptor 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25 mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor Tooling Vespa S 50 4T 4V 2008 TOOL 32 ...

Page 33: ...mm guide 020444Y Pin fitting removal tool 020448Y Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting removal tool 020451Y Driving pulley lock wrench 020452Y Tube for removing and refitting the driven pulley shaft Vespa S 50 4T 4V 2008 Tooling TOOL 33 ...

Page 34: ...Stores code Description 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 020683Y Valve pressing member Tooling Vespa S 50 4T 4V 2008 TOOL 34 ...

Page 35: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 36: ... I I I Hub oil level R I R I R I R I R I R Engine oil R I R I R I R I R I R I R I R I R I R I R Brake Pads Shoes I I I I I I I I I I I Tyre pressure I I I I I I I I I I I Headlight A A A A A Vehicle test drive I I I I I I I I I I I Idle speed A A A A A A Odometer gear L L L L L Variable speed rollers I R I R I R I R I R Suspensions I I I I I Steering A A A A A A Transmissions L L L L L Carburettor...

Page 37: ...learance If there are wear marks in the chamber causing inadequate tightness or a free valve slide even if it is new replace the carburettor It is advisable to replace the gaskets at every refit WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS 1 Needle valve 2 Idle speed adjustment screw 3 Max jet 4 Accelerating pump 5 Tapered pin 6 Jet holder 7 Float 8 Chamber 9...

Page 38: ...ESISTIVE CABLE CONNECTED IN SERIES TO AN HV CA BLE IF THE IRREGULAR READING CONTINUES AFTER THIS OPERATION CHECK THE COMPONENTS OF THE IGNITION SYSTEM When the advance check is carried out with a stroboscopic gun add 10 flywheel keying to the table below Spark plug Disconnect and remove the spark plug tube Examine it carefully and replace it if the insulator is chipped or cracked Measure electrode...

Page 39: ... dry it with a clean cloth and reinsert it screwing it in thoroughly Pull out the dipstick and check that the oil level is above the middle notch dipstick with 3 notches For dipsticks with 2 notches the oil level must re main in the lower half of the dipstick Screw up the oil dipstick again and make sure it is locked properly into place Recommended products AGIP ROTRA 80W 90 rear hub oil SAE 80W 9...

Page 40: ...he 2 knobs they can be reached by tipping the saddle and remov ing the helmet compartment afterwards remove the filtering element Cleaning Wash with water and car shampoo Dry with a clean cloth and short blasts of com pressed air do not wring Immerse it in a mixture of 50 oil and 50 petrol Allow the filtering element to drip dry and then press it in your hands but without squeezing CAUTION NEVER R...

Page 41: ...0 cm in the engine If the oil level is close to the MIN mark top up by adding oil but do not exceed the MAX level Recommended products AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brakes throttle control and od ometer Oil for 4 stroke engines Engine oil filter Change oil when the engine is hot Place a container under the oil sump and remove the oil drainage cap After draining the oi...

Page 42: ...Y HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the require ments of API SL ACEA A3 JASO MA specifica tions Locking torques N m Engine oil pre filter cover 25 28 Nm Checking the ignition timing Turn the flywheel clockwise until its 2nd notch coincides with the Pick up reference mark as shown in the figure Make sure that the reference point on the camshaft command crown is aligned with t...

Page 43: ...s follows 1 Place the vehicle in running order and with the tyres inflated to the prescribed pressure on a flat surface 10 m away from a white screen situated in a shaded area making sure that the longitudinal axis of the scooter is perpendicular to the screen 2 Turn on the headlight and check that the bor derline of the projected light beam on the screen is not lower than 9 10 of the distance fro...

Page 44: ... Wash the sponge with water and neutral soap then dry with a clean cloth and short blasts of compressed air While cleaning the filter check the condition of the reed valve D and fit it back in place on the housing Before closing the cover of the SAS housing check the good condition of the sealing O ring re place it if damaged or deformed N B The reed valve can be inserted in only one direction on ...

Page 45: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 46: ...ust the valve clearance properly Valve seat distorted Replace the head assembly Worn cylinder Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpm too high Check the idling speed and if necessary adjust the C O Clutch fault Check the spring friction mass and the clutch bell Air filter housi...

Page 47: ...he upper cover contact plane that is the throttle valve membrane cover Fuel supply pipes choked or clogged Restore the adequate fuel supply Tank breather hole obstructed Restore the proper reservoir aeration Level in chamber too low Restore the correct level in the chamber the float must be par allel to the upper cover contact plane that is the throttle valve membrane cover Engine tends to cut off...

Page 48: ...ads or shoes Replace the brake pads or shoes and check for brake disk or drum wear conditions Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the wheel correctly fitted and the concentricity of the rear drum check th...

Page 49: ... indicators device and or wiring as described in the Electrical system chapter Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation STEERING HARDENING Check the tightening of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above adjustments check the seats in which the ball bearings rotate replace them if they ar...

Page 50: ...in the attachment to the hub and the steering tube Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper Troubleshooting Vespa S 50 4T 4V 2008 TROUBL 50 ...

Page 51: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 52: ...ailure or malfunction cannot be easily identified at sight first of all re place the control unit by another one in operating conditions Remember that the engine must be off to discon nect and replace the control unit If after replacement the vehicle starts properly the control unit is failing and must be replaced If the failure persists check the generator and the stator components as follows Aft...

Page 53: ...ignition circuit must be done with the engine off if this is not done the controls might be irretrievably damaged No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited follow this procedure Check the Pick Up Disconnect the electronic starter connector and check continuity between terminal No 3 Green and terminal No 4 Black The check includ...

Page 54: ...ns otherwise replace the HV coil Electric characteristic HV coil primary resistance 0 5 0 6 Ohm HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal see figure If non conforming values are measured replace the HV coil To carry out a more complete diagnosis check the peak voltage with the m...

Page 55: ...ring the start up test with the voltage peak adaptor and by connecting the positive ter minal to the ground lead and the negative terminal to the coil positive connector If non conforming values are measured replace the control unit THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK Electric characteristic High voltage coil voltage value High voltage coil voltage value 100 Volt Stator check Usi...

Page 56: ...eep running it at idle speed Connect the tester positive probe to terminal No 1 yellow cable and the negative probe to terminal No 2 black cable check if there is voltage If there is voltage check that the light remote con trol and its excitation line coming from the elec tronic starter sky blue PIN 7 purple PIN 3 work properly Check the cable harness from the light switch to the remote control an...

Page 57: ...quently the battery fails to recharge b Battery fails to recharge regulator interrup ted Measures a Protection fuse blows regulator in short circuit Check that the cable harness going from the pro tection fuse to the key switch is not damaged which may cause a short circuit to ground thus preventing damaging the regulator Afterwards measure the resistance between con tact 3 Orange and contact 2 Bl...

Page 58: ...oltage can be found If values other than those above are detected replace the regulator contrariwise check the cable harness and the connections Electric characteristic Voltage regulator resistance 8 MΩ Turn signals system check 4 TURN INDICATORS NOT WORKING If the turn indicators do not work do the following Remove the regulator connector and place the tester probes between the orange cable 3 and...

Page 59: ...at the wiring is not damaged and the switch works properly If these last two tests have a positive result replace the regulator because it is certainly not functioning properly Specific tooling 020331Y Digital multimeter Connectors ELECTRONIC STARTER SECTION A 1 HV COIL CONTROL 2 KEY SWITCH CONTACTS TO GROUND 3 HV COIL POSITIVE SECTION B 1 KEY POSITIVE 2 STARTER POWER SUPPLY 3 PICK UP SIGNAL 4 GRO...

Page 60: ...VOLTAGE REGULATOR 1 LIGHTING SYSTEM POWER SUPPLY al ternating 2 GROUND 3 BATTERY POSITIVE 4 FROM FLYWHEEL alternating 5 TURN INDICATORS Electrical system Vespa S 50 4T 4V 2008 ELE SYS 60 ...

Page 61: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 62: ...he muffler assembly Remove the rear wheel Remove the rear brake mechanical transmission Disconnect the electric terminals Remove the throttle grip transmission Disconnect the tubing petrol vacuum operated cock control Disconnect the swinging arm on the engine side Disconnect the rear shock absorber lower clamping WARNING Be very careful when handling fuel CAUTION When installing the battery first ...

Page 63: ...INDEX OF TOPICS ENGINE ENG ...

Page 64: ...ROPRIATE COUPLINGS TO REMOVE THE COVER Kickstart To remove the start up pinion push the starter lever to facilitate extracting the pinion Remove the kick start screw and lever Remove the Seeger ring and the washer indica ted in the figure Pull out the toothed sector WARNING THE SECTOR KEEPS THE SPRING SET BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS Air duct To remove the intake throat on the trans...

Page 65: ...h the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside N B WHEN REFITTING ALWAYS REPLACE THE BEARING WITH A NEW ONE CAUTION WHEN REMOVING REFITTING THE BEARING TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE Removing the driven pulley Lock the clutch bell housing with the specific tool Remove the nut the clutch bell housing and the whole of ...

Page 66: ...tch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and have the central screw make con tact CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR Using a 34 mm socket wrench remove the clutch locking nut Loosen the central screw by undoing spring of the driven pulley unit Separate the components Specific t...

Page 67: ... A CEN TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Remove the collar with the aid of 2 screwdrivers Remove the three guide pins and the mobile half pulley Vespa S 50 4T 4V 2008...

Page 68: ...of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the work surface of the belt If there are replace the half pulley Make sure the bearings do not show signs of un usual wear Measure the extern...

Page 69: ... a curved spout to lubricate the driven pulley unit with around 6 g of grease This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole This procedure is necessary to prevent the presence of grease beyond the O ring Recommended products AGIP GREASE SM 2 Grease for the C ring of the tone wheel Soap based lithium grease containing NLGI 2 Moly...

Page 70: ...ck the driven pulley unit N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFER ENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Minimum thickness permitted 1 mm Refitting the clutch Preassemble the driven pulley group with spr...

Page 71: ... clutch unit on pulley 55 60 Nm Refitting the driven pulley Refit the driven pulley assembly the clutch bell and the nut using the specific tool Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Driven pulley shaft nut 40 to 44 Nm Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Characteristic...

Page 72: ... deformation 2 Check the roller running tracks on the contact pulley there must not be signs of wear and check the condition of the contact surface of the belt on the half pulleys mobile and stationary 3 Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders 4 Check the integrity of the sliding...

Page 73: ...he components of the assembly roller con tainer assembly with bushing limiting washer sta tionary half pulley cooling fan belt with drive washer and nut With the specific tool tighten the lock nut to 20 Nm and then perform a final 90 locking in order to prevent the rotation of the driving pulley N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF...

Page 74: ...and the Kick start lever Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Insert the pinion in its seating by pushing the starter lever Fit the intake throat and tighten the 3 screws Make sure the oil sump presents centring dowels and sealing gaskets Replace the cover tightening the 12 screws to the prescr...

Page 75: ...move the intermediate gear and the complete gear wheel axle When removing the intermediate gear pay atten tion to the various shim adjustments Removing the wheel axle bearings Remove the oil seal and the Seeger ring Remove the bearing by pushing from the outside towards the inside of the gear compartment using the appropriate punch Specific tooling 020363Y 20 mm guide 020376Y Adaptor handle 020358...

Page 76: ...e Expel the driven pulley shaft with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Inspecting the hub shaft Check the three shafts for wear or distortion of the toothed surfaces the bearing housings and the oil seal housings In case of anomalies replace the damaged com ponents Check capacity A of the transmission gear wear deformations etc Chec...

Page 77: ... radial part on the bearing side N B FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40 mm Adaptor Refitting the wheel axle bearing Heat the half crankcase on the transmission side using a thermal gun After lubricating its outer strip insert the bearing with the special adapter with the aid of a hamm...

Page 78: ...king torque 11 to 13 Nm Flywheel cover Cooling hood Remove the manifold and the carburettor undo ing the 2 fixing screws on the head Remove the fastening clamp of the secondary air pipe and disconnect it Remove the 4 front coupling screws 1 of them is a knob and the side fixing screw at the crankcase base Remove the 4 side screws Extract the 3 covers Remove the cover sealing gaskets on the head Fo...

Page 79: ...ng the fan pay attention that the screw holes in the fan and the rotor coincide then tighten screws at the specified torque Removing the stator Remove the 2 Pick Up screws and the 2 stator fixing screws indicated in the figure Remove the stator and its wiring Vespa S 50 4T 4V 2008 Engine ENG 79 ...

Page 80: ...THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COV ER ASSEMBLY Locking torques N m Pick up screws 3 4 Stator screws 3 4 Flywheel and starting Removing the starter motor Undo the screw on the power positive contact and disconnect the cable Undo the 2 screws fixing the starter motor to the crankcase and recover the power wiring Engine Vespa S 50 4T 4V 2008 ENG...

Page 81: ...ific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor Inspecting the flywheel components Check that the flywheel internal magnets are in good conditions Check that the flywheel splines exhibit no loos ening Check there are no deformations that may cause rubbing on the stator and the Pick Up Check that the stator winding its ferromagnetic support and the pick up are in good...

Page 82: ...being careful to pass the wiring through the appropriate crankcase couplings Refit the flywheel to the crankshaft being careful to respect the keying then lock rotation with the specific tool and tighten the nut to the prescribed torque N B A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING KNOCKING ETC Specific tooling 020565Y Flywheel loc...

Page 83: ...ontact N B REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD TIMING LUBRICATION FLYWHEEL AND TRANSMISSION CHAPTERS Locking torques N m Starter screws 11 13 Cylinder assy and timing system Removing the rocker arms cover Remove the cooling covers Remove the 4 retainers of the tappet cover Remove the cover and the O ring Remove the 3 screws and then remove the Blow by cover Clean the nozzle...

Page 84: ...tral screw and the belleville washer indicated in the figure and lock the cam shaft crown with the specific tool N B TO FACILITATE REMOVING THE HEAD COMPONENTS SET THE CRANKSHAFT TO THE TIMING POINT TDC OF THE COMPRESSION END Specific tooling 020565Y Flywheel lock calliper spanner Remove the camshaft control pulley and the washer below Remove the pinion of the crankshaft timing control To remove t...

Page 85: ...ft with bearing using the specific tool shown in the figure Take out the camshaft bearing with the aid of the specific tool being careful to mount a screw on the camshaft in order to protect its thread N B IF A BEARING SEPARATES FROM THE CAMSHAFT IT IS ESSENTIAL TO FIT A NEW BEAR Specific tooling 020450Y Camshaft fitting removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor ...

Page 86: ...D THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS AND ROCKING LEVERS WITHOUT RE MOVING THE DRIVING PULLEY UNIT REMEMBER TO HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE FITTING Removing the valves Using the specific tool fitted with the part shown in the figure remove cotters caps and valve springs Remove the oil seals with the appropriate tool Specifi...

Page 87: ...B BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR ING REMOVAL Inspecting the small end Measure the internal diameter of the small end using an internal micrometer N B IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANK SHAFT CHAPTER Characteristic Max diameter admitted check the sm...

Page 88: ...sors as shown in the diagram If the clearance is greater than that indicated in the table replace the piston N B MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER THICKNESS GAUGE FROM THE SECOND SEAL SIDE Fitting clearance Top piston ring standard coupling clearance 0 03 0 065 mm Top piston ring maximum clear ance allowed after use 0 07 mm Middle piston ring standard coupling clearance 0 ...

Page 89: ... the three sealing rings into the cylinder in the area where it retains its original di ameter Using the piston insert the rings perpendicularly to the cylinder axis Measure the opening see figure of the sealing rings using a thickness gauge If any measurements are greater than specified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BETWEEN THE PISTO...

Page 90: ...ersize 39 4 x 1 A 0 08 0 20 2nd Compression ring 2nd Oversize 39 4 x 1 A 0 05 0 20 Oil scraper ring 2nd Oversize 39 4 x 2 A 0 20 0 70 1st Compression ring 3rd Oversize 39 6 x 1 A 0 08 0 20 2nd Compression ring 3rd Oversize 39 6 x 1 A 0 05 0 20 Oil scraper ring 3rd Oversize 39 6 x 2 A 0 20 0 70 Removing the piston Install piston and wrist pin onto the connecting rod aligning the piston arrow the ar...

Page 91: ... not superim pose Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned Fit the 2nd sealing ring with the identifying letter T facing towards the piston crown Fit the 1st sealing ring with the reference letter T facing towards the piston crown Misalign the lining openings at 120 as shown in the figure Lubricate the components with engine oil N B IN ORDER TO...

Page 92: ...g the procedure below The procedure is different from that indicated in the vehicle manuals Head tightening nut only to replace stud bolts 6 7 N m 135 90 The 45 rotation reduction of the key is necessary to avoid stud bolt stretching Inspecting the cylinder head Using a trued bar check that the cylinder head surface is not worn or distorted Check that the camshaft and rocking lever pin bearings sh...

Page 93: ... the guide shoe and the tensioner shoe are not worn out Ensure that the camshaft drive pulley the chain assembly and the sprocket wheel are not worn If sings of wear are found replace the parts if the chain pinion or pulley are worn replace the whole assembly Remove the central screw and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring I...

Page 94: ... with a 45 mill and then grind In case of excessive wear or damages replace the head Insert the valves into the cylinder head Alternatively check the intake and exhaust valves The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers Inspecting the valves STANDARD VALVE LENGTH Specification D...

Page 95: ...45 mm Calculate the clearance between valve and valve guide Check the concentricity of the valve head by ar ranging a dial gauge at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 03 mm Check the deviation of the valve stem by resting it on a V shaped abutment and measuring the extent of the deformation with a dial gauge Characteristic ...

Page 96: ... Maximum admissible diameter 4 0 022 mm After measuring the valve guide diameter and the valve stem diameter check clearance between guide and stem INLET Specification Desc Quantity Standard clearance 0 015 0 042 mm Admissible limit 0 06 mm OUTLET Specification Desc Quantity Standard clearance 0 025 0 052 mm Admissible limit 0 07 mm Engine Vespa S 50 4T 4V 2008 ENG 96 ...

Page 97: ...ess the springs and insert the cotters in their seats Inspecting the cam shaft Inspect the cam shaft for signs of abnormal wear on the cams Characteristic Standard diameter Bearing A Ø 12 0 002 0 010 mm Standard diameter Bearing B Ø 16 0 015 0 023 mm Minimum diameter allowed Bearing A Ø 11 98 mm Minimum diameter allowed Bearing B Ø 15 96 mm Using a gauge measure the cam height Check the axial clea...

Page 98: ...Check the rocker pins do not show signs of wear or scoring Measure the internal diameter of each rocking lever Check that the pad in contact with the cam is not worn ROCKING LEVERS AND PIN DIAMETER Specification Desc Quantity Rocking levers Inside diameter 11 015 11 035 mm Rocking levers Pins diameter 10 977 10 985 mm Refitting the head and timing system components Fix the head on a workbench Scre...

Page 99: ... Locking torques N m Rocking lever shafts screw 3 4 Finish the head tightening following the proce dure below screw the four head nuts to an initial torque at two crossed passes Afterwards tighten the nuts with 2 turns of 90 each to be done at two crossed passes Finish the tightening of the head to the crankcase with the 2 side screws N B SHOULD THE CRANKCASE OR THE CYLINDER STUD BOLTS BE REPLACED...

Page 100: ...reference marks on the flywheel and the crankcase With this operation insert the chain on the cam shaft control pulley and make the reference notch coincide with the point on the head Fit the pulley onto the camshaft Fit the belleville washer so that the outer rim touches the pulley Bring the screw closer but without reaching its final locking point Push the tensioner pad lightly so as to check th...

Page 101: ...iming chain tensioner central screw 5 6 Ignition spark plug 10 15 Nm Refitting the rocker arms cover Carry out the removal procedure but in reverse order and tighten the four fixing screws to the specified torque N B FIT A NEW O RING ON THE TAPPET COVER Refitting the intake manifold Fit the cover sealing gaskets on the head Fit the 2 covers Fit the inlet manifold and do up the 2 screws to the spec...

Page 102: ...or Splitting the crankcase halves Remove the ten crankshaft coupling screws Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side Remove the crankshaft CAUTION IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT AC CIDENTALLY FALL Remove the oil guard on the flywheel side CAUTION THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE SHAFT CONSEQUENTLY DO NOT WAS...

Page 103: ...Connecting rod radial standard clearance 0 006 0 018 mm Connecting rod max radial clearance 0 25 mm Check that the half shaft surfaces are not scored and with the aid of a gauge check the driving shaft width as indicated in the figure Characteristic Standard measure 45 mm Removing the crankshaft bearings Remove the flywheel bearing fitted on the driving shaft using the specific tool Specific tooli...

Page 104: ...ine crankcase limit stop Specific tooling 020359Y 42x47 mm Adaptor 020364Y 25 mm guide 020376Y Adaptor handle 020360Y 52x55 mm Adaptor Heat a new main bearing in an oil bath at 120 Place the driving shaft on the support base and insert the bearing with the aid of an adequate piece of tube if necessary N B USE A NEW BEARING WHEN REFITTING WARNING THE CENTRIFUGAL OIL FILTER IS IN THE FLYWHEEL AXLE S...

Page 105: ...tic Off line maximum admitted A 0 15 mm Off line maximum admitted B 0 02 mm Off line maximum admitted C 0 02 mm Off line maximum admitted D 0 10 mm Check that the driving shaft cone the tab seat the oil seal capacity the toothed gear and the threaded tangs are in good working order In case of failures replace the crankshaft Specific tooling 020074Y Support base for checking crankshaft alignment Re...

Page 106: ...THREA DED TANGS Recommended products Loctite 510 Liquid sealant Gasket Locking torques N m Half casing joint bolts 8 10 Nm Fit a new O Ring on the mesh oil filter and on the filling cap lubricate the rings Insert the filter on the engine and lock the cap to the prescribed torque Locking torques N m Engine oil pre filter cover 25 28 Nm Lubrication Crankshaft oil seals Removal Extract the flywheel o...

Page 107: ...ace the oil seal fully down until it reaches the bottom of the seating in the crankcase N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE IN INADEQUATE OIL SEALING Fit a new oil seal on the outer rim with the help of the specific tools below Fit a new O ring and lubricate it with grease Install the cover on the engine crankcase insert the three sc...

Page 108: ...nd the belleville washer Remove the chain with the crown gear Remove the crankshaft control pinion Remove the oil pump by undoing the 2 screws indicated in the figure Remove the oil pump seal IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the clip retaining the innermost rotor...

Page 109: ...TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY Characteristic Admissible maximum clearance 3 0 09 mm Refitting Check there are no signs of wear on the oil pump shaft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the assembly Fit the cover on the pump being careful to al...

Page 110: ...pulley assembly with belt and pinion Unscrew the oil drainage plug A shown in the figure and drain out all the oil from the sump Remove the 6 screws indicated in the figure Refitting the oil sump Clean and grease the faying surfaces Apply LOCTITE 510 on the sump surface and tighten the 6 fixing screws to the specified torque Refit the driving pulley assembly the belt the pinion and the transmissio...

Page 111: ...ENT MAY BE FALSIFIED BY THE INCOR RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE IN THIS CASE THE TENDENCY IS TO OB TAIN A REDUCED FUEL FLOW RATE THE SUCTION OUT LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUC TION PULSATION AND THEREBY GUARANTEE A CON STANT TAP FLOW RATE Specific tooling 020329Y MityVac vacuum operated pump Characteristic Min...

Page 112: ... undoing the screw shown in the figure CAUTION THE CARBURETTOR FEATURES AN ANTI VIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY UPON REFITTING THE CARBURETTOR ON THE ENGINE MAKE SURE THIS BUFFER IS PRESENT SO THAT THE PETROL IN THE TANK DOES NOT EMULSIFY Remove the 2 fixing screws indicated in the fig ure the vacuum chamber cover and the spring Remove the vacuu...

Page 113: ... the spring below then remove the spring take out the rubber protection and the diaphragm together with the pipe O Ring Remove the accelerating pump jet together with the ball spring Remove the screw indicated in the figure fixing the float pin Remove the float and the plunger Remove the maximum nozzle Remove diffuser Vespa S 50 4T 4V 2008 Engine ENG 113 ...

Page 114: ... TO REMOVE IT AS THIS WILL ONLY DAM AGE IT Remove the idle flow screw with the O ring and the spring CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PIN SEATING STARTER NOZZLE THROTTLE VALVE CONTROL VALVE SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Engine Ve...

Page 115: ...t hides other inaccessible inter nal calibrations Blow the intake nozzle properly The acceleration nozzle outlet is extremely small and is oriented to the throttle valve Check that the carburettor body has the closing ball for the idle circuit pipe Check that the coupling surfaces the chamber and the diaphragm are not dented Check that the depression valve housing pipe is not scratched Check that ...

Page 116: ...hock ab sorber pin and the return clamp Replace the rod if worn out Check that the float is not worn on the pin housing or on the contact plate with the rod and that there are no fuel infiltrations Replace it in case of anomalies Fit the float together with the pin and rod in its position and lock it with its screw N B INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY Insert the ball in th...

Page 117: ...itioned Fit the rubber bellows protecting the pin in the upper part of the accelerating pump Level check Tilt the carburettor so that the needle valve at the fuel supply is closed and the float weight does not affect it Check that the diaphragm closing line and the float central line are parallel as shown in the figure Blow air in to the tank and then assembly it and its gasket on the carburettor ...

Page 118: ...ention to the spring Inspecting the automatic choke device Check that the automatic starter piston is not de formed or rusty Check that the piston slides freely in its seating Check that the piston sealing O Ring is not de formed The starter must be more or less functional de pending on the ambient temperature Measure the protrusion of the piston as shown in the figure and check its corresponding ...

Page 119: ...ttery to power the automatic starter and check that piston protrudes as much as possible The correct warm up time depends on the ambi ent temperature If protrusion resistance or timing values are dif ferent from the ones prescribed replace the start er Characteristic Battery 12V 9Ah max protrusion 15 mm max time 15 min Fit the starter the support bracket and the pro tection with the screw indicate...

Page 120: ...idle The engine does not require frequent idle speed adjustments but it is essential to strictly follow certain rules when adjusting the idle speed Before adjusting the carburettor make sure to respect requirements on lubrication valve clearance and complying timing spark plug should be in optimum conditions air filter clean and sealed and the exhaust system tight Connect the tester thermometer to...

Page 121: ... idle screw N B THE WASTED SPARK IGNITION SYSTEM OFFERS RE MARKABLE POWER READINGS MAY NOT BE ACCU RATE IF INADEQUATE RPM INDICATORS ARE USED Specific tooling 020332Y Digital rpm indicator Characteristic Idle speed about 1900 2000 rpm Vespa S 50 4T 4V 2008 Engine ENG 121 ...

Page 122: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 123: ...Front Removing the front wheel Remove the five Allen screws that fix the wheel to the hub N B BEFORE REMOVING THE WHEEL HUB REMOVE THE BRAKE CALLIPER Vespa S 50 4T 4V 2008 Suspensions SUSP 123 ...

Page 124: ...Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide Suspensions Vespa S 50 4T 4V 2008 SUSP 124 ...

Page 125: ...t and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Refitting the front wheel When refitting tighten the 5 screws to the ...

Page 126: ...ED TO REMOVE THE STEERING TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting Carry out the removal operations but in the reverse order observing the prescribed tightening torque Locking torques N m Handlebar lock nut 45 50 Steering column Removal After removing the upper seat lean the vehicle on one side and extract the steering tube completely from the fork Specific tooli...

Page 127: ...A Ø12 Punch B Sharp edged end Use the specific tool fitted with part 1 and op erate the handgrip until the pin and the Nadella are simultaneously ejected in the direction opposite the tool thrusting force To eject the second Nadella use the tool fitted with part 2 instead of part 1 on the side opposite the one shown in the figure Supplied with the tool Specific tooling 020021Y Front suspension ser...

Page 128: ...sed grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Lubricate the sealing rings with mineral oil and half fill the roller casings with grease Insert the sealing ring on the pin and the roller bushing with wedging washers at the same time Remove the specific tool then the part 5 guiding partially ejected in the previous assembly stage leave part 4 alwa...

Page 129: ...swinging hub Remove the spacers part 17 fill with grease the area between the steering tube and the swinging hub and place the dust guard rings in that place Supplied with the tool N B ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAME TER Specific tooling 020021Y Front suspension service tool 001330Y Tool for fitting steering seats Recommended products AGIP GR...

Page 130: ...SE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m Steering lower ring nut 8 10 Upper steering ring nut 35 40 CAUTION USE NEW ROLLER CASINGS PIN SEALING RINGS AND DUST GUARDS FOR REFITTING Front shock absorber Suspensions Vespa S 50 4T 4V ...

Page 131: ...se order observing the prescribed tightening torques Locking torques N m shock absorber lower clamp 20 27 shock absorber upper clamp 20 30 Shock absorber calliper bracket Removal Remove the front wheel hub with the brake disc Remove the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Vespa S 50 4T 4V 2008 Suspensions SUSP 131 ...

Page 132: ...er clamp 20 27 Overhaul The bracket for the shock absorber calliper at tachment has two roller bearings separated one from the other as shown in the photograph Remove the two roller bearings from the bracket with the specific tool operating on the shock ab sorber attachment side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remov...

Page 133: ...hold the brake calliper shock absorber attachment bracket Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific t...

Page 134: ...ng 020004Y Punch for removing fifth wheels from headstock Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing fifth wheels from headstock Refit the fifth wheel fitting and the dust guard on the steering tube until they stop using the specific tool Spec...

Page 135: ...cribed torque Refit the cap and the split pin folding it correctly as shown in the figure Locking torques N m Locking torque 137 152 Nm Swing arm Removal Remove the swinging arm acting on the three clamps shown in the figure Vespa S 50 4T 4V 2008 Suspensions SUSP 135 ...

Page 136: ...Refitting For rifting respect the locking torques Locking torques N m Part C 33 41 Part B 44 52 Part A 33 41 Shock absorbers Suspensions Vespa S 50 4T 4V 2008 SUSP 136 ...

Page 137: ... Then remove the shock absorber engine anchorage nut When refitting tighten the shock absorber chas sis anchoring nut and the shock absorber engine pin to the prescribed torque Locking torques N m Shock absorber engine pin torque 33 to 41 N m Shock absorber frame nut torque 20 to 25 Nm Vespa S 50 4T 4V 2008 Suspensions SUSP 137 ...

Page 138: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 139: ...iper tightening screw 20 25 Nm Brake fluid tube calliper 20 25 Overhaul Remove the calliper assembling bolts and take out the internal bodies and components If necessary in order to make it easier to take out the plungers inject shorts blasts of compressed air through the brake fluid pipe Check that the cylinders of the internal and external body of the calliper do not show scratches or signs of e...

Page 140: ...lerated CAUTION RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH Locking torques N m Screw tightening calliper to the support 20 25 Attachment to the calliper 25 30 Nm 1 DUST GUARDS 2 SEALING RINGS 3 PLUNGERS 4 O RING GASKET Front brake disc Removal Should the brake disc be replaced when ...

Page 141: ...ds and replace them once the plungers are down Carry out these operations in reverse order to fit CAUTION BEFORE USING THE BRAKE OPERATE THE LEVER A FEW TIMES Front Once the bleed valve is closed fill the system with brake liquid to the maximum level Undo the bleed screw Apply the tube of the special tool to the bleed screws When bleeding it is necessary to fill the oil tank in continuation while ...

Page 142: ...SORBS HUMIDITY FROM THE SURROUNDING AIR IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX CEEDS A GIVEN VALUE BRAKING EFFICIENCY WILL BE REDUCED THEREFORE ALWAYS USE FLUID FROM SEALED CON TAINERS UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS IF THE BRAKES ARE USED INTENSELY AND OR IN HARSH CONDITIONS CHANGE THE FLUID MORE FRE QUENTLY CAUTION WHEN CARRYIN...

Page 143: ...T CONTACT WITH BRAKE FLUID WILL DAMAGE PAINTED SURFACES RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH THE SEALING RINGS MUST BE IMMERSED IN THE OPER ATING LIQUID Refitting Before fitting the parts must be perfectly clean and free of traces of oil diesel fuel grease etc They should be w...

Page 144: ...w these steps 1 Remove the shoe spring using the specific span ner 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mallet 4 Attach the spring using the specific pliers Specific tooling 020325Y Pliers for brake shoe springs Braking system Vespa S 50 4T 4V 2008 BRAK SYS 144 ...

Page 145: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 146: ...ent A Undo the two screws indicated Rear handlebar cover Remove the front handlebar cover Undo the three screws indicated in figure fixing it to the handlebar the odometer transmission and the electrical connectors Chassis Vespa S 50 4T 4V 2008 CHAS 146 ...

Page 147: ...ing the rear handlebar cover Front handlebar cover Proceed as follows Remove the rear view mirrors Undo the two screws A Undo the screw B and remove the front han dlebar cover Disconnect the electrical terminals and remove the turn indicator bulb Vespa S 50 4T 4V 2008 Chassis CHAS 147 ...

Page 148: ...s indicated fixing the front handlebar cover Knee guard Undo the five screws indicated Remove the rubber strip from both sides and un do the indicated screw Remove the shield back plate bringing it to the rear part of the scooter Chassis Vespa S 50 4T 4V 2008 CHAS 148 ...

Page 149: ...he screw indicated and disconnect the connector Footrest Remove the shield back plate Remove the side fairings Remove the central tunnel inspection door From both sides unscrew The fixing screw at the back The fixing screw on the central part Vespa S 50 4T 4V 2008 Chassis CHAS 149 ...

Page 150: ... The fixing screw at the front Remove the footrest Side fairings Undo the screw A and the smaller screw B Detach the seats on the fairing Chassis Vespa S 50 4T 4V 2008 CHAS 150 ...

Page 151: ...n both sides undo the two screws in dicated Remove the license plate light Air filter Remove the helmet compartment Remove the side fairings Undo the two indicated clamps to the crankcase Undo the two clamps indicated Vespa S 50 4T 4V 2008 Chassis CHAS 151 ...

Page 152: ...Fuel tank Chassis Vespa S 50 4T 4V 2008 CHAS 152 ...

Page 153: ... the scooter Remove the wheel and the rear mudguard Remove the battery compartment Disconnect the fuel outlet pipe Undo the two fixing screws to the chassis and collect the fuel pipe supporting plate Vespa S 50 4T 4V 2008 Chassis CHAS 153 ...

Page 154: ...tors Remove the rear light unit and undo the indicated screw Unscrew the closing cap Lower the fuel tank and disconnect the bleed pipes and the level indicator connector Remove the tank Chassis Vespa S 50 4T 4V 2008 CHAS 154 ...

Page 155: ...calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Front central cover Remove the Piaggio clip on badge Undo the two screws indicated Remove the front central cover sliding it up wards Vespa S 50 4T 4V 2008 Chassis CHAS 155 ...

Page 156: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 157: ...6V minimum otherwise recharge the battery following the specifications indicated on the battery itself Check the following devices Key switch Low beam light high beam light light warning lights position light Headlight adjustment Rear light Stop light front and rear brake if required Turn indicators and relevant warning lights Speedometer and instrument panel lighting Horn Starter button CAUTION I...

Page 158: ...SKIN RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION Levels check Brake oil level Hub oil level Engine oil level Road test Cold start Speedometer activation check Throttle control operation Riding stability Front and rear brake efficiency Front and rear...

Page 159: ...ST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST WARNING BE VERY CAREFUL WHEN HANDLING FUEL Vespa S 50 4T 4V 2008 Pre delivery PRE DE 159 ...

Page 160: ...INDEX OF TOPICS TIME TIME ...

Page 161: ...Engine ENGINE Code Action Duration 1 001001 Engine from frame Removal and re fit 2 003064 Engine oil Change Vespa S 50 4T 4V 2008 Time TIME 161 ...

Page 162: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Crankshaft Time Vespa S 50 4T 4V 2008 TIME 162 ...

Page 163: ... seal flywheel side Replacement 3 001100 Oil seal clutch side Replacement 4 001118 Main bearings Replacement Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder Piston Inspection Clean ing Vespa S 50 4T 4V 2008 Time TIME 163 ...

Page 164: ...Cylinder head assy HEAD Code Action Duration 1 001056 Head gasket Replacement 2 001045 Valves Replacement 3 001126 Head Replacement Time Vespa S 50 4T 4V 2008 TIME 164 ...

Page 165: ...cker arms support assy CAMSHAFT SUPPORT Code Action Duration 1 001049 Valve clearance Adjustment 2 001148 Valve rocking levers Replacement 3 001044 Camshaft Replacement Vespa S 50 4T 4V 2008 Time TIME 165 ...

Page 166: ...ad cover HEAD COVER Code Action Duration 1 001093 Spark plug Replacement 2 001088 Head cover gasket Replacement 3 001097 Cooling hood Replacement 4 001089 Head cover Replacement Time Vespa S 50 4T 4V 2008 TIME 166 ...

Page 167: ... DRIVEN PULLEY CLUTCH Code Action Duration 1 001110 Driven pulley Replacement 2 001012 Driven pulley Overhaul 3 001022 Clutch Replacement 4 001155 Clutch bell housing Replacement Vespa S 50 4T 4V 2008 Time TIME 167 ...

Page 168: ...1112 Oil pump change 3 001042 Oil pump Service 4 001121 Chain cover oil seal Replacement 5 001122 Oil pump chain Replacement 6 001125 Chain guide pads Replacement 7 001130 Oil sump Replacement 8 001129 Chain tightener Overhaul and re placement Time Vespa S 50 4T 4V 2008 TIME 168 ...

Page 169: ...N GEAR ASSEMBLY Code Action Duration 1 004125 Rear wheel axle Replacement 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 001010 Gear reduction unit Inspection Vespa S 50 4T 4V 2008 Time TIME 169 ...

Page 170: ...LLEY Code Action Duration 1 001177 Variator rollers shoes Replace ment 2 001086 rear view half pulley Replacement 3 001066 Driving pulley Removal and refitting 4 001011 Driving belt Replacement Time Vespa S 50 4T 4V 2008 TIME 170 ...

Page 171: ... Action Duration 1 001096 Transmission crankcase cover re place 2 001132 Transmission air inlet pipe Replace ment 3 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement Vespa S 50 4T 4V 2008 Time TIME 171 ...

Page 172: ...Starter motor Replacement 2 005045 Starter motor cable harness Re placement 3 001017 Starter sprocket wheel Replace ment 4 001021 Kick starter Inspection 5 008008 Starter spring pack Replacement 6 001084 Starter lever Replacement Time Vespa S 50 4T 4V 2008 TIME 172 ...

Page 173: ...ation 1 001067 Stator Fitting and Refitting 2 001173 Rotor Replacement 3 001102 Net oil filter Replacement Cleaning 4 001109 Cooling fan Replacement 5 001087 Flywheel cover Replacement 6 001058 Flywheel Replacement Vespa S 50 4T 4V 2008 Time TIME 173 ...

Page 174: ...01063 Carburettor Replacement 2 001008 Carburettor Inspection 3 003058 Carburettor Adjustment 4 001081 Automatic choke Replacement 5 001082 Carburettor heating resistor Re placement 6 001013 Intake manifold change Time Vespa S 50 4T 4V 2008 TIME 174 ...

Page 175: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001136 Exhaust emissions Adjustment Vespa S 50 4T 4V 2008 Time TIME 175 ...

Page 176: ...leaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting Re placement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement Time Vespa S 50 4T 4V 2008 TIME 176 ...

Page 177: ...e Replacement 2 004023 Shield rim Replacement 3 004149 Shield central cover Replacement 4 004159 Plates Stickers Replacement 5 004012 Rear side panels Replacement 6 004059 Spark plug inspection flap Replace ment Vespa S 50 4T 4V 2008 Time TIME 177 ...

Page 178: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004171 Stand support plate Replacement Time Vespa S 50 4T 4V 2008 TIME 178 ...

Page 179: ...Footrests FOOTREST Code Action Duration 1 004178 Footrest Replacement 2 004078 Front rear footrest rubber Replace ment Vespa S 50 4T 4V 2008 Time TIME 179 ...

Page 180: ...CK PLATE Code Action Duration 1 004174 Trunk levers Replacement 2 004065 Legshield rear part Removal and refitting 3 004081 Glove box door Replacement 4 004082 Top box gasket Replacement Time Vespa S 50 4T 4V 2008 TIME 180 ...

Page 181: ...LMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover change 3 004011 Central frame cover Replacement 4 004071 Battery compartment replacement Vespa S 50 4T 4V 2008 Time TIME 181 ...

Page 182: ...ICENSE PLATE HOLDER Code Action Duration 1 004136 License plate holder support Re placement 2 005048 Licence plate holder Replacement 3 005032 number plate light glass Replace ment Time Vespa S 50 4T 4V 2008 TIME 182 ...

Page 183: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement Vespa S 50 4T 4V 2008 Time TIME 183 ...

Page 184: ... 004168 Fuel tank cap Replacement 2 005010 Tank float Replacement 3 004112 Cock carburettor hose Replace ment 4 004005 Fuel tank Replacement 5 004007 Fuel valve Replacement 6 004109 Fuel tank breather change Time Vespa S 50 4T 4V 2008 TIME 184 ...

Page 185: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Vespa S 50 4T 4V 2008 Time TIME 185 ...

Page 186: ...ings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheels Replacement 2 003073 Steering clearance Adjustment 3 004119 Bearing upper steering fifth wheel Replacement Time Vespa S 50 4T 4V 2008 TIME 186 ...

Page 187: ...uration 1 004018 Handlebar front section Replace ment 2 004019 Handlebar rear section Replace ment 3 005014 Odometer Replacement 4 005038 Instrument panel warning light bulbs Replacement 5 005078 Odometer glass Replacement Vespa S 50 4T 4V 2008 Time TIME 187 ...

Page 188: ...Replacement 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002063 Throttle control transmission Re placement 8 002060 Complete throttle control Replace ment 9 004162 Mirror support and or brake pump fit ting U bolt Replacement 10 002059 Right hand grip Replacement Time Vespa S 50 4T 4V 2008 TIME 188 ...

Page 189: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame connection swinging arm Replacement Vespa S 50 4T 4V 2008 Time TIME 189 ...

Page 190: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004131 Luggage rack support Replacement Time Vespa S 50 4T 4V 2008 TIME 190 ...

Page 191: ... indicator Replacement 3 005067 Front turn indicator bulb Replace ment 4 005008 Front headlamp bulbs Replacement 5 005005 Taillight Replacement 6 005066 Rear light bulbs Replacement 7 005022 Rear turning indicators Replace ment 8 005068 Rear turning indicator bulb Re placement Vespa S 50 4T 4V 2008 Time TIME 191 ...

Page 192: ...ont wheel Replacement 2 003047 Front tyre Replacement 3 003037 Front wheel rim Replacement 4 003033 Front wheel hub Replacement 5 002041 Front brake disc Replacement 6 003034 Front wheel hub bearing Replace ment Rear wheel Time Vespa S 50 4T 4V 2008 TIME 192 ...

Page 193: ...Repl Electric devices ELECTRICAL COMPONENTS Code Action Duration 1 005001 Electrical system Replacement 2 005011 Starter remote control switch Re placement 3 005009 Voltage regulator Replacement 4 005007 Battery change 5 005052 Fuse 1 Replacement 6 001023 Control unit Replacement 7 001094 Spark plug cap Replacement 8 001069 HV coil Replacement Vespa S 50 4T 4V 2008 Time TIME 193 ...

Page 194: ...ent 2 005006 Light or turning indicator switch Re placement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005016 Key switch Replacement 7 004096 Lock series Replacement 8 004010 Antitheft lock Replacement Time Vespa S 50 4T 4V 2008 TIME 194 ...

Page 195: ...s TRANSMISSIONS Code Action Duration 1 002053 Rear brake transmission complete Replacement 2 002051 Odometer transmission assembly Replacement 3 002049 Odometer cable Replacement Vespa S 50 4T 4V 2008 Time TIME 195 ...

Page 196: ...ation 1 003045 Steering tube Replacement 2 003010 Front suspension Service 3 003035 Shock absorber support and brake calliper Replacement 4 001064 Odometer reel Replacement 5 003044 Shock absorber cover Replace ment Time Vespa S 50 4T 4V 2008 TIME 196 ...

Page 197: ...rake hose Remov and Re fitt 2 002007 Front brake shoes pads Remov and Refitt 3 002039 Front brake calliper Removal and Refitting 4 002047 Front brake fluid and air bleed sys tem Replacement 5 002002 Shoes Rear brake pads Replace ment Vespa S 50 4T 4V 2008 Time TIME 197 ...

Page 198: ...Crankcase secondary air connection Replacement 2 001161 Secondary air filter Replacement Cleaning 3 001162 Secondary air housing Replace ment 4 001163 Muffler secondary air connection Replacement 5 001165 Secondary air reed Replacement Time Vespa S 50 4T 4V 2008 TIME 198 ...

Page 199: ...74 E Engine oil 40 Engine stop F Fuel 48 111 152 184 H Headlight 43 148 Hub oil 39 I Identification 8 Instrument panel 147 M Maintenance 7 36 O Odometer Oil filter 41 S Saddle Shock absorbers 136 Spark plug 38 53 Stand Start up T Tank 152 184 Transmission 9 48 64 74 171 Tyres 13 ...

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