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VESPA 664787, Service Station Manual

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VESPA 664787 Service Station Manual Download Page 10

Specification

Desc./Quantity

Ignition

Capacitive discharge ignition, with variable advance and sep-

arate HV coil.

Ignition advance

17º at 4,000 rpm

Spark plug

CHAMPION RN3C

Alternative spark plug

-

Battery

12V/9 Ah

Generator

-

Frame and suspensions

FRAME AND SUSPENSIONS

Specification

Desc./Quantity

Frame

Stamped plate body with welded structural reinforcements.

FRONT SUSPENSION

Single arm with helicoidal spring and single double-acting hy-

draulic shock absorber.

Front suspension travel

70.3 mm

Rear suspension

Double-acting shock absorber, adjustable to four positions at

preloading.

Rear suspension travel

83 mm

Brakes

BRAKES

Specification

Desc./Quantity

Front brake

Ø 200 mm disc brake with hydraulic control activated by han-

dlebar right-side lever.

Rear brake

Ø 110 mm drum brake with mechanical control activated by the

handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRES

Specification

Desc./Quantity

Wheel rim type

Light alloy rims.

Front rim

11'' x 2.50

Rear rim

10'' x 3.00

Front tyre

Tubeless, 110/70 - 11'' 45L

Rear tyre

Tubeless, 120/70 - 10'' 54L

Front tyre pressure (with passenger)

1.4 bar (-)

Rear tyre pressure (with passenger)

2.0 bar (-)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST
PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

Characteristics

Vespa S 50 2T

CHAR - 10

Summary of Contents for 664787

Page 1: ...SERVICE STATION MANUAL 664787 664795 IT EN FR DE ES PT NL EL Vespa S 50 2T ...

Page 2: ...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 versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reprodu...

Page 3: ...ble to read the sections of this manual concerning special tools along with the special tool catalogue 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 specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to complete...

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: ...ou do not breathe in the dust produced by the wear of the friction 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 spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings an...

Page 8: ...Vehicle identification Chassis prefix ZAPC38103 Engine prefix C381M Dimensions and mass Characteristics Vespa S 50 2T CHAR 8 ...

Page 9: ... lubrication pressure 100 C Fuel supply Carburettor DELL ORTO PHVA 17 5 RD Cooling Forced air circulation cooling Fuel Unleaded petrol 95 RON Exhaust muffler absorption type exhaust muffler with catalytic converter Emissions EURO 2 Transmission TRANSMISSION Specification Desc Quantity Transmission Automatic expandable pulley variator with torque server V belt automatic centrifugal dry clutch Final...

Page 10: ...four positions at preloading Rear suspension travel 83 mm Brakes BRAKES Specification Desc Quantity Front brake Ø 200 mm disc brake with hydraulic control activated by han dlebar right side lever Rear brake Ø 110 mm drum brake with mechanical control activated by the handlebar left side lever Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Wheel rim type Light alloy rims Front rim 11...

Page 11: ...int 2 and refit all elements after checking the steel tab is not de formed and or does not guarantee correct tight ness at its fitting replace if necessary N B UPON REFITTING MAKE SURE TO CORRECTLY FIT THE TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI NIUM COVERS CAUTION WHILE CARRYING OUT OPERATION 3 ALWAYS CHECK THE TWO RUBBER COUPLINGS 3 ON ONE END OF THE SECONDARY AIR PIPE FOR CORRECT TIGHTN...

Page 12: ...SEMBLY Name Torque in Nm Steering upper ring nut 35 40 Steering lower ring nut 8 10 Handlebar fixing screw 50 55 ENGINE ASSEMBLY Name Torque in Nm Clutch bell nut 40 44 Clutch lock ring nut 55 60 Nut locking driving pulley on crankshaft 40 44 Nm Start up lever screw 12 13 Flywheel nut 40 44 Flywheel fan screws 3 4 Half crank case joint bolts 12 13 Bolts holding exhaust pipe to the crankcase 22 24 ...

Page 13: ...0 026 39 957 39 964 0 055 0 069 Standard coupling P 40 026 40 033 39 964 39 971 0 055 0 069 coupling 1st oversize M1 40 205 40 212 40 143 40 15 0 055 0 069 coupling 1st oversize N1 40 212 40 219 40 15 40 157 0 055 0 069 coupling 1st oversize O1 40 219 40 226 40 157 40 164 0 055 0 069 coupling 1st oversize P1 40 226 40 233 40 164 40 171 0 055 0 069 Coupling 2nd oversize M2 40 405 40 412 40 343 40 3...

Page 14: ...rance F 0 20 to 0 75 Half shaft transmission side 13 75 0 040 C clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Flywheel side half shaft 13 75 0 040 D clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Lining between the shoulders 40 64 H clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Cage 11 800 0 35 B clearance F 0 20 to 0 75 Slot packing system This type of engines foresees the use of one s...

Page 15: ...ase 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 AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum disulphide ISO L XBCHB2 DIN KF2K 20 AGIP GP 330 Grease for brake control levers throttle stand White calcium complex soa...

Page 16: ...INDEX OF TOPICS TOOLING TOOL ...

Page 17: ...001467Y006 Pliers to extract 20 mm bearings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings OD 39 mm 002465Y Pliers for circlips Vespa S 50 2T Tooling TOOL 17 ...

Page 18: ...eel seat on steer ing tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate Tooling Vespa S 50 2T TOOL 18 ...

Page 19: ...66Y Pin lock fitting tool 020261Y Starter spring fitting 020265Y Bearing fitting base 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing Vespa S 50 2T Tooling TOOL 19 ...

Page 20: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger Tooling Vespa S 50 2T TOOL 20 ...

Page 21: ...tores code Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020359Y 42x47 mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide Vespa S 50 2T Tooling TOOL 21 ...

Page 22: ...Stores code Description 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 001467Y029 Bell for bearings O D 38 mm 020037Y Punch 020036Y Punch Tooling Vespa S 50 2T TOOL 22 ...

Page 23: ...escription 020021Y Front suspension service tool 020038Y Punch 020074Y Support base for checking crankshaft alignment 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring Vespa S 50 2T Tooling TOOL 23 ...

Page 24: ...extractor screw 004499Y007 Half rings 020171Y Punch for driven pulley roller bearing 020340Y Flywheel and transmission oil seals fitting punch 020360Y Adaptor 52 x 55 mm 020358Y 37x40 mm adaptor 020362Y 12 mm guide Tooling Vespa S 50 2T TOOL 24 ...

Page 25: ...tores code Description 020363Y 20 mm guide 020365Y 22 mm guide 020439Y 17 mm guide 020441Y 26 x 28 mm adaptor 020452Y Tube for removing and refitting the driven pulley shaft Vespa S 50 2T Tooling TOOL 25 ...

Page 26: ...Stores code Description 020451Y Starting ring gear lock 020444Y Tool for fitting removing the driven pulley clutch Tooling Vespa S 50 2T TOOL 26 ...

Page 27: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 28: ...ake pads check condition and wear Brake fluid check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AFTER 10 000 KM 50 000 KM 95 Action Hub oil change Spark plug replacement Air filter clean Idling speed adjustment Oil mixer throttle linkage adjustment Variable speed rollers replacement Odometer gear greasing Driving belt checking Steering Check Br...

Page 29: ...sing Brake pads check condition and wear Brake fluid check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Vehicle and brake test road test See the Idle speed adjustment section AFTER 30 000 KM Action Hub oil change Spark plug replacement Air filter clean Idling speed adjustment Oil mixer t...

Page 30: ... section Carburettor Disassemble the carburettor in its parts wash all of them with solvent dry all body grooves with compressed air to ensure adequate cleaning Check carefully that the parts are in good condi tion The throttle valve should move freely in the chamber Replace valve in case of wear due to excessive clearance If there are wear marks in the chamber causing inadequate tightness or a fr...

Page 31: ...iming Spark plug Place the vehicle on its central stand Remove the central cover indicated in the figure by undoing the 2 fixing screws Disconnect the spark plug HV wire cap Undo the spark plug using the socket wrench Examine the condition of the spark plug check that the insulating material is whole and measure the distance between the electrodes using a thick ness gauge Adjust the distance if ne...

Page 32: ...teristic Electrode gap 0 6 to 0 7 mm Locking torques N m Spark plug 25 30 Nm Hub oil Check Do the following to check the correct level Park the vehicle on its centre stand on flat ground Unscrew the oil dipstick A and dry it with a clean cloth then reinsert it screwing it in all the way Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end S...

Page 33: ...ove the cap of the purifier unscrewing the six clamping screws and removing the filter Cleaning Wash with water and neutral soap Dry with a clean cloth and short blasts of com pressed air Saturate with a 50 mixture of gasoline and oil Drip dry the filter and then squeeze it between the hands without wringing Let it dry and refit it again CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOU...

Page 34: ...eference mark on the mixer body as shown in the figure While doing this the engine must be fuelled with a 2 oil mixture 0 5 litre minimum if the reservoir is empty CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS RE FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF UNDO THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN...

Page 35: ...is fully empty the level of fluid in the res ervoir is below the MIN level N B THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN A MINIMUM LEVEL SHOULD NOT BE REACHED IF THE LEVEL IS TOO LOW CHECK AND FIX THE SYSTEM SEALS IF REQUIRED TOP UP THE PUMP TANK IF RE QUIRED CONSIDERING THAT THE MAX LEVEL MUST ONLY BE OBTAINED WITH NEW PADS Under standard climatic conditions replace fluid as indicated in...

Page 36: ...OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDITIONS REPLACE FLU ID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE N B SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Headlight adjustment Proceed as follows 1 Place the vehicle in running order...

Page 37: ... screws marked B indicated in the figure Remove the two screws A from the aluminium SAS cover Release the metal tube from the rub ber housing on the cover without extracting the tube from the cover sleeve Remove the tab and plastic cover extract the sponge and wash it in water and soap Dry it with compressed air before refitting it making sure to correctly fit the tab in the housing on the two pla...

Page 38: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 39: ...of oil Dirt Check the cap with filter is fitted to the transmission cover clean the speed variator replace the rollers if worn out Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpm too high Adjust the idle speed Clutch fault Check the spring friction mass and the clutch bell Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged Start...

Page 40: ... Water in the carburettor Empty the tank through the appropriate bleed nipple Air filter dirty Clean or replace Defective floating valve Check the proper sliding of the float and the functioning of the valve Tank breather hole obstructed Restore the proper tank aeration Engine tends to cut off at idle ENGINE STOP IDLING Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and...

Page 41: ...he engine without the clutch bell Check the cap with filter is fitted to the transmission cover Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause Operation Poor braking The rear drum type brake is adjusted by regulating the special adjustment on the wheel bearing in mind that with the control levers in the rest position the wheels must turn freely The braking action should begin when ...

Page 42: ... terminal marked Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts If irregularities continue in turning the steering even after mak ing the above adjustments check the seats in which the ball beari...

Page 43: ...ovement bushings Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Service the pumping members and check the sleeves and sealing rings are in good conditions Replace the damaged parts Vespa S 50 2T Troubleshooting TROUBL 43 ...

Page 44: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 45: ...tarter motor 8 Start up remote control switch 9 Horn button 10 Horn 11 Starter button 12 Stop button on rear brake 13 Stop button on front brake 14 Turn indicator switch 15 Light switch 16 Rear left turn indicator 17 Rear light 18 Rear right turn indicator 19 Front left turn indicator Vespa S 50 2T Electrical system ELE SYS 45 ...

Page 46: ...t warning light C Instrument panel lighting bulbs D Fuel gauge E Low fuel warning light F Oil warning light G High beam warning light 24 Automatic starter 25 Heater 26 Heater control device 27 Oil reserve warning light 28 Spark plug R Red B White Bl Blue N Black V Green Rs Pink Mr Brown Gr Grey Az Sky Blue G Yellow Vi Purple A Orange Electrical system Vespa S 50 2T ELE SYS 46 ...

Page 47: ...nic ignition device Magneto flywheel Pick Up 7 5A Fuse 12V 9Ah Battery Starter motor Start up remote control Automatic starter Heater Spark plug 3 4 10 26 Key switch Voltage regulator Horn Heater control device Vespa S 50 2T Electrical system ELE SYS 47 ...

Page 48: ...Conceptual diagrams Ignition Electrical system Vespa S 50 2T ELE SYS 48 ...

Page 49: ...9Ah Battery 28 Spark plug Headlights and automatic starter section KEY 2 Magneto flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 15 Light switch 17 Rear light 20 Front light A Tail light bulb B High low beam light bulb Vespa S 50 2T Electrical system ELE SYS 49 ...

Page 50: ...ic starter Battery recharge and starting KEY 2 Magneto flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 7 Starter motor 8 Start up remote control switch 11 Starter button 12 Stop button on rear brake 13 Stop button on front brake 17 Rear light Electrical system Vespa S 50 2T ELE SYS 50 ...

Page 51: ...o flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 22 Fuel level transmitter 23 Instrument panel D Fuel gauge E Low fuel warning light F Oil warning light 27 Oil reserve warning light Vespa S 50 2T Electrical system ELE SYS 51 ...

Page 52: ...V 9Ah Battery 9 Horn button 10 Horn 14 Turn indicator switch 16 Rear left turn indicator 18 Rear right turn indicator 19 Front left turn indicator 21 Front right turn indicator 23 Instrument panel A Turn indicator warning light 25 Heater 26 Heater control device Electrical system Vespa S 50 2T ELE SYS 52 ...

Page 53: ...ng use a specific tester to measure the loading reel the pick up see chart and cable continuity If checks on the loading boil the pick up and ca ble continuity show irregularities replace the sta tor otherwise replace the control unit Remember that the engine must be off to dis connect any connections in order to replace the central unit Specific tooling 020331Y Digital multimeter PICK UP CHECK FI...

Page 54: ...ol voltage is 16V at 5000 rpm with the lights off Replace the voltage regulator if control voltages are over 16V FAULT 2 a Check that voltage to stator is correctly sup plied disconnect the regulator connector and place the tester to detect alternating voltages be tween the connection of the grey blue cable 2 and the black cable 6 to check that the voltage supplied at 3000 rpm is within 25 30 V FI...

Page 55: ...6 FIG D to check that the voltage supplied by the generator at 3000 rpm is within 26 30 V the battery should be disconnected to measure this If faults are de tected replace the stator otherwise proceed to point b b Yellow black cable 1 connected to the regula tor Insert an ammeter between the grey blue ca ble 2 of the stator and the battery and use the tester to check that the current supplied at ...

Page 56: ...sts have positive results jump the contacts 5 yellow red and 7 blue black on the connector set the key switch to ON and shift the turn indicator switch to the right and left to see when the lights are steadily on as they are powered directly from the battery If even after this operation the turn indicators fail to turn on check that the wiring is not damaged and the switch works properly If these ...

Page 57: ...lue with empty tank and low fuel warning light on 90 Ω 13 Ω 3 Ω Lights list BULBS Specification Desc Quantity 1 High low beam light bulb Type Spherical Power 12V 35 35W Quantity 1 2 Front tail light bulb Type All glass Power 12V 5W Quantity 1 3 Front turn indicator bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 LHS 4 Rear turn indicator light bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 ...

Page 58: ...he vehicle check the open circuit voltage with a normal tester If the voltage exceeds 12 60 V the battery may be installed without any renewal recharge If voltage is below 12 60 V a renewal recharge is required as explained in 2 2 Constant voltage battery charge mode Constant voltage equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for nominal capacity Duration of the charge 10 to 12 ...

Page 59: ...es are 1 Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level Only use distilled water to restore this level If it is necessary to add water too frequently check the vehicle s electrical system the battery works overcharged and is subject to quick wear 2 Load status check After restoring the electrolyte level check its den sity using an...

Page 60: ...mes or sparks when charging Remove the battery from the vehicle removing the negative clamp first CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED USING A FUSE OF UNSUITABLE RATING MAY SERIOUS LY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE CAUTION DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BATTERY USE DISTIL LED WATER ONLY CAUTION TO ENSURE MAXIMUM PERFOR...

Page 61: ...MINAL WITH THE CORRE SPONDING LONG TUBE WITH OPEN END THAT YOU FIND FITTED TO THE VEHICLE TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Connectors HEATER CONTROL DEVICE CONNECTOR 1 Positive from voltage regulator Yellow 2 Ground Black 3 Heater Sky Blue 4 Heater Orange Black 5 Not connected 6 Positive from the...

Page 62: ...EVICE CONNECTOR 1 Pick up Red 2 Ground Black and White 3 Magneto flywheel Green 4 Not connected AUTOMATIC STARTER CONNECTOR 1 Positive from voltage regulator Yellow Black 2 Ground Black OIL LEVEL INDICATOR CONNECTOR 1 Positive from voltage regulator Orange 2 Oil reserve warning light Orange 3 Positive from voltage regulator Yellow 4 Live Positive White Electrical system Vespa S 50 2T ELE SYS 62 ...

Page 63: ... light Pink 3 Positive from voltage regulator Yellow Black 4 Ground Black INSTRUMENT PANEL CONNECTOR B 1 Live Positive White 2 Low fuel warning light Yellow Green 3 Oil reserve warning light Orange 4 Fuel level indicator White Green 5 High beam warning light Purple Vespa S 50 2T Electrical system ELE SYS 63 ...

Page 64: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 65: ...nnect the battery Remove the muffler assembly Remove the rear wheel Remove the rear brake mechanical transmission Disconnect the electric terminals Remove the throttle grip and mixer transmissions Disconnect the hoses petrol oil Remove the engine side swinging arm and remove the entire engine WARNING Be very careful when handling fuel CAUTION When installing the battery first attach the positive c...

Page 66: ...INDEX OF TOPICS ENGINE ENG ...

Page 67: ... charging of the spring as shown in the figure Refit the seeger ring after checking that it is in good condition Specific tooling 020261Y Starter spring fitting Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Remove the seeger ring located on the exterior of the crankshaft Dismantle the dog gear from its ...

Page 68: ...t from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing N B IN CASE OF DIFFICULTY A STANDARD 8MM INSIDE DI AMETER EXTRACTOR CAN BE USED Refitting the driven pulley shaft bearing Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the cra...

Page 69: ...e clutch bell is not worn or damaged Measure the inner diameter of the clutch bell Characteristic Clutch bell diameter standard value Ø 107 0 2 0 mm Clutch bell diameter max value allowed after use Ø 107 5 mm Eccentricity measured max 0 20 mm Removing the clutch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and put the central sc...

Page 70: ...aterial The masses must not show traces of lubricants otherwise check the driven pulley unit seals 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 TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pi...

Page 71: ...e the ball bearing retention snap ring Expel the ball bearing from the side of the clutch housing by means 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 the...

Page 72: ...ed products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Mo lybdenum disulphide ISO L XBCHB2 DIN KF2K 20 Make sure the pins and collar are not worn reassemble the pins and collar Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr of grease This operation must be done through one of the holes inside the bus...

Page 73: ...r 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring Check that the contrast spring of the driven pulley does not show signs of deformation Measure the free length of the spring Characteristic Standard length 118 mm Minimum length allowed after use XXXX Refitting the clutch Preassemble the driven pulley group with spring sheath and clutch Position the spring wit...

Page 74: ...ues N m Clutch lock ring nut 55 60 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 Clutch bell nut 40 44 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 Transmissi...

Page 75: ...SE THIS COULD BREAK SUD DENLY DURING OPERATION CAUTION ON REFITTING MAKE SURE THAT DIRT DOES NOT GET INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN N B REPLACE THE BELT AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE Inspecting the rollers case 1 Check that the bushing and the sliding rings of the mobile pulley do not show signs of scori...

Page 76: ...HE BUSHING Characteristic Driving pulley Maximum diameter 20 12 mm Driving pulley Standard diameter 20 021 mm Driving pulley bushing Diameter maximum XXX mm Driving pulley bushing Standard diameter 20 0 020 0 041mm Refitting the driving pulley Manually move the movable driven half pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first...

Page 77: ...E DRIVING PULLEY UNIT IT IS OF UT MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSE QUENTLY DAMAGING THE CRANKSHAFT KNURLING Specific tooling 020451Y Starting ring gear lock Locking torques N m Crankshaft pulley nut 18 to 20 90 Nm For 25 km h engine type versions the limit washer is 5 5 mm thick End gear Removing the hub cover Remove the transmission cover R...

Page 78: ...ompartment using the appropriate punch Specific tooling 020363Y 20 mm guide 020376Y Adaptor handle 020358Y 37x40 mm adaptor Removing the driven pulley shaft bearing Remove the seeger ring inside the cover Remove the oil seal from the outside Remove the centring dowels and position the cover on a plane Position the special tool on the internal track of the bearing and remove said bearing with the a...

Page 79: ...acity A of the transmission gear wear deformations etc Check the pulley shaft seating Superficial wear B may indicate irregularities in the crankcase seatings or in the pulley shaft capacities Inspecting the hub cover Check that the fitting surface is not dented or distorted If faults are found replace the hub cover Refitting the driven pulley shaft bearing Support the inner track of the bearing f...

Page 80: ...the special adapter with the aid of a hammer Refit the seeger ring and the oil seal using the 42 x 47 mm adapter and the handle Specific tooling 020151Y Air heater 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42x47 mm adaptor Refitting the ub cover Refit the whole wheel axle Refit the intermediate gear paying attention to the two shim washers Apply LOCTITE 510 for surfaces to the hub cov ers...

Page 81: ...b cap screw 12 13 Flywheel cover Cooling hood Remove the four fixings shown in the figure Remove the fan cover Remove the oil piping retention band from the hood Remove the 2 screws shown in the figure Vespa S 50 2T Engine ENG 81 ...

Page 82: ...the wiring Refitting the stator Refit the stator and flywheel carrying out the removal procedure in reverse tightening the retainers to the specified torque N B THE PICK UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM BLY Locking torques N m Stator clamping screws 3 4 Pick Up clamping screw 4 5 Flywheel and ...

Page 83: ...E USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS Extract the flywheel with the extractor Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor Inspecting the flywheel components Check the condition of the flywheel and any dis tortions that might cause rubbing on the stator and on the Pick Up Vespa S 50 2T Engine ENG 83 ...

Page 84: ...NCE SUCH AS TO CAUSE PINGING KNOCKING ETC Locking torques N m Flywheel nut 40 44 Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter on the crankcase locking the two screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD TIMING LUBRICATION FLYWHEEL AND TRANSMISSION CHAPTERS Locking torques N m Starter screws 12 13 Cy...

Page 85: ...4 screws shown in the figure Removing the cylinder piston assy Remove the cylinder very carefully Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN RETENTION SNAP RINGS Vespa S 50 2T Engine ENG 85 ...

Page 86: ...Rod small end standard diameter 17 0 011 0 001 Rod small end maximum allowable diameter 17 060 mm Inspecting the wrist pin Check the wrist pin external diameter using a mi crometer Characteristic Wrist pin standard diameter 12 0 005 0 001 mm Inspecting the piston Measure the bearings on the piston using a bore meter Calculate the piston pin coupling clearance Characteristic Wrist pin housing stand...

Page 87: ...ylinder with a bore meter according to the directions given in the figure Check that the fitting surface with the head is not dented or distorted To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy Inspecting the piston rings Alternatively insert the two sealing rings in the cylinder Using the piston insert the seals perpendicularly to the cylinder ax...

Page 88: ...RSE ORDER FROM THE REMOVAL OPERATIONS Specific tooling 020166Y Pin lock fitting tool Locking torques N m Cylinder head nuts 10 11 Use new wrist pin snap rings Use new cylinder base gasket Before refitting carefully clean all the surfaces Use oil to be mixed during the fitting of the piston and the cylinder CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING THE WRIST...

Page 89: ...em components CAUTION CHECK THE CORRECT REED UNIT SEAL NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA Crankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners Vespa S 50 2T Engine ENG 89 ...

Page 90: ...he crankshaft from the transmission side half crankcase Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft bearings The bearings can stay on either the half crankcase or the crankshaft indifferently Using the special tool remove any bearings that have been left on the crankshaft N B The half rings must be inserted on the bearings with a few mal let blows Specific tooling 00...

Page 91: ...Inspecting the crankshaft alignment With the specific tool shown check that the eccen tricity of the surfaces of diam A B C are within 0 03 mm reading limit on the dial gauge in addition check the eccentricity of diam D for which a maximum reading of 0 02 mm is permitted In the case where eccentricity is not much above prescribed levels straighten the shaft by acting on the counterweights with a s...

Page 92: ...ature of the crankshaft Again install the special crankcase separation plate NOT installing the crankshaft protection During the assembly phase keep the central thrust screw loose Take the four clamping screws to the end of the stroke and loosen them again with the same angle e g 90 When the temperature has settled preload the thrust screw of the tool manually until the ball bear ing clearance is ...

Page 93: ...dly Insert the other 5 screws and tighten them to the specified torque Locking torques N m Half crank case joint bolts 12 13 Move the crankcase separation plate in a position back from the one indicated in the figure Install the special magnetic support with dial gauge at the end of the crankshaft Check the axial clearance of the crankcase If this is not within the maximum limit allowed re peat th...

Page 94: ...T COMPATIBLE WITH THE FITTED WRENCH Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Install a new transmission side oil seal using the special tool with adapter ring The transmission side oil seal is recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump Removal Remove the 2 screws shown in the figure Engine ...

Page 95: ...uel supply Completely empty the gas tank Remove the petrol delivery tube and the suction tube Loosen the clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent Refit the tap making sure that there is an O Ring Turn the tap to the direction it had before it was removed and block the clip N B THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING Vespa S ...

Page 96: ...f the tap Turn the engine by using the starter for five sec onds with the carburettor at minimum Take up the fuel by means of a graded burette N B THE MEASUREMENT 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 PURPO...

Page 97: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 98: ...eel Support the scooter adequately Loosen the five screws fixing the wheel to the hub Front wheel hub overhaul Support the scooter adequately Remove the front wheel Remove the front calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub Suspensions Vespa S 50 2T SUSP 98 ...

Page 99: ...ted in the photograph Extract the ball bearing using the specific tool 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 Vespa S 50 2T Suspensions SUSP 99 ...

Page 100: ...20357Y 32 x 35 mm adaptor 020412Y 15 mm guide Use the specific tool to fit 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...

Page 101: ...he electrical terminals remove the termi nal fixing the handlebar to the steering Check all components and replace faulty parts N B IF THE HANDLEBAR IS BEING REMOVED 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 fixi...

Page 102: ...LY THEN IS THE SERVICE JUSTIFIABLE MOREOVER REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE WHEN DEFORMED a Ø 12 Punch b Sharp edged end Use a suitable punch with the dimensions indica ted on the figure hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end Repeat the operation for the second washer using the punch on the side opposite...

Page 103: ...the steering tube After fitting the pin insert the two spacers slightly hitting them with the mallet N B BEFORE PROCEEDING WITH THE DESCRIBED FITTING PLACE THE TWO DUST GUARD RINGS ON THE SWING ING HUB AS SHOWN IN THE FIGURE Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum d...

Page 104: ... XBCHA3 DIN K3K 20 Use the tool fitted with part 20 on its stem and part 21 on the tool base as shown in the figure By moving the tool handgrip push the two NA DELLA bushings until their internal bottoms make contact with the pin end Use the tool fitted with parts 3 and 4 to fit the pin and press moving the tool handgrip until wedging the washers on the swinging hub Now remove the two spacers part...

Page 105: ...t A and the upper ring nut B to the specified torque Recommended products AGIP GREASE 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 Steering upper ring nut 35 40 Front shock absorber Vespa S 50 2T Suspensions...

Page 106: ...r lower clamps and re move the brake calliper shock absorber support Loosen the screws fixing the front brake pipe re tainer clamp and the odometer cable in order to reach the upper clamps Unscrew the upper fixing nuts Remove the front shock absorber Suspensions Vespa S 50 2T SUSP 106 ...

Page 107: ...ke disc Remove the front shock absorber lower clamps Remove the bracket locking seeger ring Unscrew the bracket Before refitting the bracket in the wheel axle place the O ring as shown in the photograph so that it is correctly placed after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Lo...

Page 108: ...chment side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph Suitably hold the brake calliper shock absorber attachment bracket Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360...

Page 109: ...oval operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Steering...

Page 110: ...be 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 Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube Rear Removing the rear wheel Remove the muffler Remov...

Page 111: ...and collect the washer Refitting the rear wheel To refit follow the removal steps but in reverse order be careful to tighten to the prescribed tor que Locking torques N m Locking torque 137 152 Nm Swing arm Vespa S 50 2T Suspensions SUSP 111 ...

Page 112: ...entral tunnel inspection door To remove the upper clamp from the chassis proceed as follows Unscrew the pin and collect the washer Remove the cap from the lower part Collect the lower fixing nut and collect the wash er Suspensions Vespa S 50 2T SUSP 112 ...

Page 113: ...g on the right side unscrew the side fixing nut to the chassis and collect the washer Working on the left side remove the pin Remove the spoiler terminal from both sides Working on the right side unscrew the fixing nut Vespa S 50 2T Suspensions SUSP 113 ...

Page 114: ...ine and collect the spacer Now the swinging arm is free Remove the swinging arm from the vehicle first release it from the engine side and then from the chassis side Overhaul Check that the silent blocks are in good condi tions Otherwise replace the swinging arm Suspensions Vespa S 50 2T SUSP 114 ...

Page 115: ...ng arm to chassis pin locknut 44 52 Swinging arm plate to chassis screw 33 41 Shock absorbers Removal Adequately support the rear part of the scooter Remove the battery cover Undo the indicated upper fixing screw to the frame Unscrew the lower fixing pin to the transmission crankcase Vespa S 50 2T Suspensions SUSP 115 ...

Page 116: ... complete stand Work on the screws shown in the figure When refitting secure to the prescribed torque Locking torques N m Stand screw torque 18 5 to 19 Nm Side stand REMOVAL Uncouple the centre stand return spring Remove the screw shown in the photograph FITTING To refit carry out the removal operations in re verse order and comply with the specified torque Locking torques N m Side stand fixing bo...

Page 117: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 118: ...be careful to tighten to the prescribed torques N B ONCE REFITTING IS FINISHED BLEED THE SYSTEM Locking torques N m Screw tightening calliper to the support 20 25 Brake pipe connection 20 to 25 N m Front brake disc Removal Remove the front wheel Remove the front brake calliper Remove the hub and the disc operating on the wheel axle nut Adequately support the hub with the disc and op erating on the...

Page 119: ...sc Inspection Remove the front wheel Use a micrometer to check the disc thickness as shown in the photograph Repeat the measurement in at least 6 points on the disk Remove the front brake calliper In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it to one of the two front brake calliper attachment points Place the dial gauge on the disk outer edge ...

Page 120: ...front calliper Remove the cotter pin and slide off the pin that locks the two pads Remove the pads being careful with the pad spring clamp Check the thickness of the friction material of the pads Replace the pads if the thickness is below the minimum value The replacement must be made with greater re sidual thickness if the pad has not worn evenly A 0 5 mm thickness difference in the residual fric...

Page 121: ... 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 Refitting Insert the brake pads Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo Insert the lock on the bolt and then the protection cover Fill Vespa S 50 2T Braking system BRAK SYS 121 ...

Page 122: ... BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM Specific to...

Page 123: ...ake pump Removal Remove the front and rear handlebar covers Remove the two screws fixing the brake pump to the handlebar indicated in the photograph Remove the oil pipe joint from the pump Remove the connector to the stop light switch Overhaul Proceed as follows 1 Remove the brake lever by loosening the retaining screw open the cover 2 and take out the dia phragm 3 2 remove the cap 4 and take out ...

Page 124: ...Reservoir Refitting To refit carry out the removal operations but in reverse order observing the specified torques N B USE NEW COPPER GASKETS ON THE JOINTS CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM Locking torques N m Oil pipe joint to the pump 20 25 Brake pump fixing screws to the handle bar 7 10 Nm Pipe brake calliper coupling 20 25 Braking system Vespa S 50 2T BRAK SYS 124 ...

Page 125: ...specific pliers Remove the shoes with the help of a lever Refit the new shoes with a few taps with the mal let Attach the spring using the specific spanner CAUTION REPLACE THE SHOES BEFORE THE FRICTION MATERI AL IS FULLY WORN Specific tooling 020325Y Brake shoe spring calliper Vespa S 50 2T Braking system BRAK SYS 125 ...

Page 126: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 127: ...rt ment 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 Vespa S 50 2T Chassis CHAS 127 ...

Page 128: ... fixing 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 Chassis Vespa S 50 2T CHAS 128 ...

Page 129: ...crews 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 Vespa S 50 2T Chassis CHAS 129 ...

Page 130: ...do the 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 Chassis Vespa S 50 2T CHAS 130 ...

Page 131: ... 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 Vespa S 50 2T Chassis CHAS 131 ...

Page 132: ...ng on 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 Chassis Vespa S 50 2T CHAS 132 ...

Page 133: ...nnect the fuel outlet pipe Undo the two fixing screws to the chassis and collect the fuel pipe supporting plate Remove the turn indicators 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 Vespa S 50 2T Chassis CHAS 133 ...

Page 134: ...ing tube and uncouple the front brake pipes from the 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 Chassis Vespa S 50 2T CHAS 134 ...

Page 135: ... Undo the two screws indicated Remove the front central cover sliding it up wards Vespa S 50 2T Chassis CHAS 135 ...

Page 136: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 137: ...arm Engine bolt Engine arm Frame arm bolt Handlebar lock nut Steering lower ring nut Steering upper ring nut Electrical system Electrical System Main switch Headlamps high beam lights low beam lights tail lights and their warning lights Adjusting the headlights according to the regulations currently in force Rear lights and stop light Front and rear stop light switches Turn indicators and their wa...

Page 138: ...BOUT 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 BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO EN SURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP O...

Page 139: ...ER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the frame and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors and a...

Page 140: ...INDEX OF TOPICS TIME TIME ...

Page 141: ...Engine ENGINE Code Action Duration 1 001001 engine from frame removal and re fitting Vespa S 50 2T Time TIME 141 ...

Page 142: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Time Vespa S 50 2T TIME 142 ...

Page 143: ...CRANKSHAFT Code Action Duration 1 001118 Main bearings Replacement 2 001100 Oil seal clutch side Replacement 3 001099 Oil seal flywheel side Replacement 4 001117 Crankshaft Replacement Vespa S 50 2T Time TIME 143 ...

Page 144: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Inspection clean ing Time Vespa S 50 2T TIME 144 ...

Page 145: ...ssy HEAD Code Action Duration 1 001097 Cooling hood Replacement 2 001093 Spark plug Replacement 3 001126 Head Replacement 4 001013 Intake manifold Replacement 5 001178 Disc pack Replacement Vespa S 50 2T Time TIME 145 ...

Page 146: ...ulley DRIVEN PULLEY CLUTCH Code Action Duration 1 001012 Driven pulley Service 2 001110 Driven pulley Replacement 3 001022 Clutch Replacement 4 001155 Clutch bell housing Replacement Time Vespa S 50 2T TIME 146 ...

Page 147: ...Oil pump OIL PUMP Code Action Duration 1 001028 Mix movement gear socket Re placement 2 001019 Mixer belt replacement 3 001018 Mixer Replacement Vespa S 50 2T Time TIME 147 ...

Page 148: ... REDUCTION GEAR Code Action Duration 1 001010 Geared reduction unit Service 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement Time Vespa S 50 2T TIME 148 ...

Page 149: ...ING PULLEY Code Action Duration 1 001066 Driving pulley Removal and refitting 2 001086 Driving half pulley replace 3 001011 Driving belt Replacement 4 001177 Variator rollers shoes Replace ment Vespa S 50 2T Time TIME 149 ...

Page 150: ...on cover TRANSMISSION COVER Code Action Duration 1 001087 Flywheel cover Replacement 2 001135 Transmission cover bearing Re placement 3 001096 Transmission crankcase cover Re placement Time Vespa S 50 2T TIME 150 ...

Page 151: ...020 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 Vespa S 50 2T Time TIME 151 ...

Page 152: ...TO FLYWHEEL Code Action Duration 1 001109 Cooling fan Replacement 2 001173 Rotor Replacement 3 001067 Stator Fitting and Refitting 4 001058 Flywheel Replacement 5 001087 Flywheel cover Replacement Time Vespa S 50 2T TIME 152 ...

Page 153: ...pection 2 001063 Carburettor Replacement 3 007020 Carburettor heating tubing replace ment 4 001081 Automatic choke Replacement 5 001082 Carburettor heating resistor Re placement 6 003058 Carburettor Adjustment 7 004177 Heating hood Replacement Vespa S 50 2T Time TIME 153 ...

Page 154: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement Time Vespa S 50 2T TIME 154 ...

Page 155: ...ir cleaner 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 Vespa S 50 2T Time TIME 155 ...

Page 156: ...hassis 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 Time Vespa S 50 2T TIME 156 ...

Page 157: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004102 Side stand Replacement 3 004179 Stand buffer Replacement Vespa S 50 2T Time TIME 157 ...

Page 158: ...Footrests FOOTREST Code Action Duration 1 004178 Footrest Replacement 2 004078 Front rear footrest rubber Replace ment Time Vespa S 50 2T TIME 158 ...

Page 159: ...Rear cover SHIELD BACK PLATE Code Action Duration 1 004065 Front shield rear part Removal and refitting Vespa S 50 2T Time TIME 159 ...

Page 160: ... HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover change 3 004011 Central chassis cover Replacement 4 004071 Battery compartment replacement Time Vespa S 50 2T TIME 160 ...

Page 161: ...older LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate support Replacement 2 005048 Licence plate holder Replacement 3 005032 Licence plate light glass Replace ment Vespa S 50 2T Time TIME 161 ...

Page 162: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement Time Vespa S 50 2T TIME 162 ...

Page 163: ... 1 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 Replacement Vespa S 50 2T Time TIME 163 ...

Page 164: ...Code Action Duration 1 005018 Oil reservoir float Replacement 2 004017 Oil reservoir Replacement 3 004095 Oil reservoir cock Replacement 4 004091 Oil reservoir hose Replacement Rear shock absorber Time Vespa S 50 2T TIME 164 ...

Page 165: ...absorber Removal and Refitting Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheel Replacement 2 003073 Steering clearance Adjustment 3 004119 Bearing upper steering fifth wheel Replacement Vespa S 50 2T Time TIME 165 ...

Page 166: ...R COVER Code Action Duration 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 Time Vespa S 50 2T TIME 166 ...

Page 167: ...lacement 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002054 Throttle or splitter transmission com plete Replacement 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 Vespa S 50 2T Time TIME 167 ...

Page 168: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chassis con nection Replacement Time Vespa S 50 2T TIME 168 ...

Page 169: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement Vespa S 50 2T Time TIME 169 ...

Page 170: ...Front turn 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 turn indicators Replacement 8 005068 Rear turn indicator bulb Replace ment Time Vespa S 50 2T TIME 170 ...

Page 171: ...1 004123 Front wheel Replacement 2 003047 Front tyre replace 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 Vespa S 50 2T Time TIME 171 ...

Page 172: ...Rear wheel REAR WHEEL Code Action Duration 1 004126 Rear wheel tyre Replacement 2 001071 Rear wheel rim Removal and Refit ting 3 001016 Rear wheel Replacement Time Vespa S 50 2T TIME 172 ...

Page 173: ...placement 2 005011 Start up remote control switch Re placement 3 005009 Voltage regulator Replacement 4 005007 Battery Replacement 5 005052 Fuse 1 Replacement 6 001023 Control unit Replacement 7 001094 Spark plug cap Replacement 8 005054 Fuse block 1 Replacement Vespa S 50 2T Time TIME 173 ...

Page 174: ...eplacement 2 005006 Light switch or turn indicators 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 Anti theft lock Replacement Time Vespa S 50 2T TIME 174 ...

Page 175: ...12 Splitter Replacement 3 002057 Carburettor splitter transmission complete Replacement 4 002058 Mix splitter transmission complete Replacement 5 002053 Rear brake transmission complete Replacement 6 002049 Odometer cable Replacement 7 003061 Accelerator transmission Adjust ment Vespa S 50 2T Time TIME 175 ...

Page 176: ...g 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 6 003011 Front shock absorber Removal and Refitting Time Vespa S 50 2T TIME 176 ...

Page 177: ...t brake 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 bleeding system Replacement 5 002002 Shoes Rear brake pads Replace ment Vespa S 50 2T Time TIME 177 ...

Page 178: ...164 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 2T TIME 178 ...

Page 179: ...2 C Carburettor 11 30 153 E Engine stop F Fuel 41 95 133 163 Fuses 58 H Headlight 36 129 Hub oil 32 I Identification 8 Instrument panel 128 M Maintenance 7 28 O Odometer S Saddle Shock absorbers 115 Spark plug 31 Stand 116 Start up T Tank 133 163 164 Transmission 9 41 67 150 Tyres 10 ...

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