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VESPA 946 E4 EMEA 2021, Manual

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WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.

WARNING

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.

N.B.

WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS.

Locking torques (N*m)

Brake fluid pump-hose joint

 

19 to 22

 

Handlebar brake pump nuts

 

7 - 10

Rear brake pump - combined

Removal

- Remove the front handlebar cover.

- Drain the braking system.

- Disconnect the brake oil pipe from the pump,

paying attention to a possible escape of remaining

oil.

- Disconnect the connector of the brake stop but-

ton.

- Unscrew the nuts fixing the pump to the handle-

bar.

- Remove the brake pump with the lever.

Refitting

- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.

- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.

CAUTION

WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.

WARNING

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.

Braking system

Vespa 946 E4-E5 EMEA-USA-ASIA (2021-)

BRAK SYS - 250

Summary of Contents for 946 E4 EMEA 2021

Page 1: ...MANUALE STAZIONE DI SERVIZIO 1Q000894 Vespa 946 E4 E5 EMEA USA ASIA 2021 ...

Page 2: ...nd to make any changes to components parts or accessory supplies which it deems necessary to improve the product or which are required for manufacturing or commercial reasons Not all the versions shown in this publication are available in every country Availability of the individual versions must be verified with the official PIAGGIO sales network Copyright 2021 Piaggio C S p A All rights reserved...

Page 3: ...si 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...

Page 4: ......

Page 5: ... DELIVERY PRE DE TECHNICAL DATA DT TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS ...

Page 6: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 7: ...re is a yellow mark on the following clamps Rear suspension strut fixing Rear shock absorber fixing Rear shock absorber linkage fixing Front ABS sensor Rear ABS sensor Front brake calliper Rear brake calliper Handlebar locking screw Swinging arm pin Frame Swinging arm pin Engine Engine arm pin Frame arm See also System ASR Electrical system Electrical system Battery Main switch Headlamps high beam...

Page 8: ...S IT CONTAINS SUL PHURIC ACID AVOID CONTACT WITH EYES SKIN AND CLOTHING IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP CLEAR OF NAKED FLAMES SPARKS ...

Page 9: ...n efficiency Abnormal noise CAUTION POSITION THE VEHICLE ON THE STAND AND KEEP IT RUNNING FOR AT LEAST 5 MINUTES BEFORE PERFORMING THE TEST RIDE N B PERFORM THE ASR SYSTEM S CALIBRATION PROCEDURE DURING THE ROAD TEST ASR SYSTEM The ASR system is a driving aid that assists the driver in acceleration manoeuvres particularly on low grip surfaces or under conditions that can cause sudden back wheel sl...

Page 10: ...vehicle The system is functioning correctly and is active poor grip con ditions engine power limiting in effect ride with extreme care as the grip limit has been exceeded restore the vehicle safety conditions by gently re ducing the throttle opening Off with the vehicle in gear the system is disa bled and will not intervene in case of loss of grip If the deactivation was voluntary by pressing the ...

Page 11: ...rip con ditions engine power limiting in effect ride with extreme care as the grip limit has been exceeded restore the vehicle safety conditions by gently re ducing the throttle opening Lit with moving vehicle the system is disabled and will not intervene in case of loss of grip If the deactivation was voluntary by pressing the appropriate button 1 for 1 second with the engine running it is recomm...

Page 12: ...TMOST CARE AND IN AC CORDANCE WITH THE REGULATIONS IN FORCE CAUTION AT LOW SPEED LESS THAN 5 Km h 3 mph THE ASR SYSTEM IS NOT OPERATIONAL IT IS RECOMMENDED TO PAY PARTICULAR ATTENTION IN THE EVENT OF ACCELERATION FROM STANDSTILL IN CONDITIONS OF LOW GRIP ESPECIALLY IN THE FIRST METRES N B IN CASE OF ROAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR SYSTEM SUCH EVENT APPEARS UNDER NOR...

Page 13: ...ASR icon 2 switched on steadily Once the procedure is complete it is necessary to turn off the vehicle panel key off and wait 30 seconds before turning the panel on key on If the procedure is not memorised the ASR icon 2 will switch off but the system will stay active until the panel is switched off key off If the system is voluntarily disabled and enabled again the ASR icon will stay switched off...

Page 14: ...rned off key off To restart the ASR it is necessary to turn on vehicle panel key on It is however necessary to repeat the process until it succeeds Static test Static control after the test drive Restarting when warmed up Minimum holding turning the handlebar Uniform turning of the steering Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE CAUTION NEVER EXCEED...

Page 15: ...rning light G Immobilizer warning LED H ABS warning light I Low engine oil pressure warning light L Turn indicator warning light M Miniature VESPA 946 By turning the ignition key to the ON position all the digital display functions will light up for a few seconds MULTIFUNCTION INDICATOR C Acting on the MODE button this indicator displays the following functions in sequence Clock CLOCK Vespa 946 E4...

Page 16: ...ECONDS CLOCK SETTING To set or adjust the clock with the vehicle running or with key inserted in ON position proceed as follows short press the MODE button to the left in se quence until the clock appears on the display long press to the left to enter the hour display adjust the hour by short pressing the MODE but ton to the left with a long press the set value is confirmed or present value if not...

Page 17: ...PDATING THE DIAGNOS TIC TOOL CAUTION AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 5 000 Km 3 106 mi OR 5 MONTHS LUGGAGE RACK AND TOP CASE KIT ACCESSORY FITTING Key for luggage rack and top case kit ACCESSORY 1 Transversal belt 2 Left side belt 3 Rear luggage rack 4 Right side belt 5 Case Vespa 946 E4 E5 EMEA USA ASI...

Page 18: ...ndard rear luggage rack Fit the accessory luggage rack on the lower sup ports together with the side belts WARNING PLACE THE SIDE BELTS ON THE SADDLE DO NOT RE MOVE THE GUARDS FROM THE BELT HOOKS TO AVOID DAMAGING THE BODY Place the upper supports of the luggage rack Pre delivery Vespa 946 E4 E5 EMEA USA ASIA 2021 PRE DE 18 ...

Page 19: ...supports fixing screws 4 6 Nm Place the top case on the luggage rack inside the mounting brackets Check that the top case rests on the lower mount ing bracket First fit the transversal belt The belt is not symmetrical it has an elastic strip only on one side used to facilitate the fastening Vespa 946 E4 E5 EMEA USA ASIA 2021 Pre delivery PRE DE 19 ...

Page 20: ...g on the opposite side of the luggage rack fasten the hook on the rubber guard using the specific tab to extend the elastic part Check that you fitted the transversal belt correctly N B THE TOP CASE HANDLE MUST BE AT THE CENTRE OF THE BELT S SLOT Remove the hook guards of the side belts Pre delivery Vespa 946 E4 E5 EMEA USA ASIA 2021 PRE DE 20 ...

Page 21: ...you fitted the two side belts correctly TOP CASE ACCESSORY REMOVAL First unhook the two side belts placing them tem porarily on the vehicle s saddle WARNING AVOID DROPPING THE HOOKS OF THE BELTS TO AVOID DAMAGING THE BODY Remove the transversal belt first releasing the hook with tab Vespa 946 E4 E5 EMEA USA ASIA 2021 Pre delivery PRE DE 21 ...

Page 22: ...the transversal belt inside the top case Wrap the two side belts around the mounting brackets After wrapping the belts fasten the hooks to the rubber guards on the luggage rack s cross pieces Pre delivery Vespa 946 E4 E5 EMEA USA ASIA 2021 PRE DE 22 ...

Page 23: ...INDEX OF TOPICS TECHNICAL DATA DT ...

Page 24: ...carefully to avoid the risk of inhaling dust produced by worn 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 spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets seal ri...

Page 25: ... parts We recommend checking that the frame registration number stamped on the vehicle corresponds with that on the vehicle documentation CAUTION PLEASE REMIND THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS IMPOUNDING OF THE VEHICLE ETC Frame number To read the chassis number A the saddle must be lifted Vespa 946 E4 E5 EMEA USA ASIA 2021 Technical Data DT 25 ...

Page 26: ...c shock absorber Rear suspension Double acting shock absorber adjustable to four positions at pre loading Front brake Ø 220 mm hydraulically operated disc brake controlled from RH handlebar lever braking assisted by ABS system Rear brake Disc brake Ø 220 mm with hydraulic control operated from the handlebar with the left lever braking assisted by ABS system Wheel rims type Light alloy Front rim 12...

Page 27: ...0 Ah Engine Data 125 cm ENGINE FOR THE EUROPE VERSION 125 CM ENGINE SPECIFICATIONS Specification Desc Quantity Type Single cylinder 4 stroke Engine capacity 124 cm Bore per stroke 52 0 x 58 6 mm Max power for Euro 5 version 8 3 kW at 8500 rpm Max torque for Euro 5 version 10 0 Nm at 7000 rpm Compression ratio 10 5 0 5 1 Idle speed 1 750 100 rpm Valve clearance cold engine intake 0 08 mm outlet 0 0...

Page 28: ...iven with double filter mesh and paper Cooling Forced air circulation cooling Starting Electric Ignition Electronic inductive discharge ignition with variable advance and separate H V coil Ignition advance Three dimensional map managed by control unit Spark plug NGK CR8EB Electrode gap 0 7 0 8 mm Power supply Electronic injection with Ø 28 mm throttle body single injector Fuel Unleaded gasoline E1...

Page 29: ...erter Emissions compliance 40 CFR Part 86 Subpart E 150 cm ENGINE FOR THE PAP VERSION 150 CM ENGINE SPECIFICATIONS Specification Desc Quantity Engine Single cylinder 4 stroke Piaggio LEM Engine capacity 155 cm Bore per stroke 58 x 58 6 mm Max power for Euro 3 version 8 9 kW at 8 000 rpm Max torque for Euro 3 version 11 5 Nm at 6750 rpm Max power for Euro 4 version 9 0 kW at 8 000 rpm Max torque fo...

Page 30: ...ecification Desc Quantity Engine oil quantity 81 7 in of which 7 3 in in the filtering cartridge 1 340 cm of which 120 cm in the filtering cartridge Hub oil quantity 18 3 in 300 cm Fuel tank capacity 2 25 gal of which 0 4 gal reserve 8 5 l of which 1 5 l reserve Tightening Torques HEAD AND CYLINDER Name Torque in Nm Head cover screws 10 8 to 12 7 7 9 to 9 4 lb ft Cylinder head nut PRE TIGHTENING 6...

Page 31: ... to 4 4 lb ft Oil pump command sprocket screw 10 to 14 7 4 to 10 3 lb ft Rotor cover 1 to 1 50 0 7 to 1 1 lb ft Rotor clamp 3 to 4 2 2 to 2 9 lb ft TRANSMISSION AND FINAL REDUCTION Name Torque in Nm Transmission cover screws 11 to 13 8 1 to 9 5 lb ft Final reduction cover screws 24 to 27 17 7 to 20 lb ft Driven pulley fixing nut 53 to 59 40 to 43 5 lb ft Hub oil drain screw 15 to 17 11 to 12 5 lb ...

Page 32: ...t Headlight fixing 11 to 13 N m 8 1 to 9 6 lb ft Headlight frame fixing 1 to 1 5 N m 0 7 to 1 1 lb ft Nut fixing handlebar element 33 to 35 N m 24 3 to 25 8 lb ft Screws fixing front turn indicators USA version 6 to 8 N m 4 4 to 5 9 lb ft FRONT SUSPENSION Name Torque in Nm Screws fastening the shock absorber bracket 20 to 25 14 7 to 18 4 lb ft Shock absorber head nut 19 to 29 14 to 21 4 lb ft Fron...

Page 33: ...026 0 040 VERSION 150 cm CYLINDER PISTON Specification Desc Quantity Plunger diameter 57 947 0 014 mm Cylinder diameter 58 0 008 0 020 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder piston A 57 980 57 987 57 933 57 940 0 040 0 054 cylinder piston B 57 987 57 994 57 940 57 947 0 040 0 054 cylinder piston C 57 994 58 001 57 947 57 954 0 040 0 054 cylinder piston W 58 0...

Page 34: ...ance Transmissionside half shaft A 18 1 0 0 05 mm D 0 20 0 50 Flywheel side halfshaft B 18 1 0 0 05 mm D 0 20 0 50 Connecting rod C 15 0 10 0 15 mm D 0 20 0 50 Spacer tool E 51 4 0 05 0 mm D 0 20 0 50 Diameter of crankshaft bearings Measure the bearings on both axes x y Technical Data Vespa 946 E4 E5 EMEA USA ASIA 2021 DT 34 ...

Page 35: ... diameter Cat 2 27 004 27 010 mm To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and a good oil flow rate the bushings must be correctly positioned so as not to obstruct the oil supply channels Characteristic A AXIS CYLINDER Vespa 946 E4 E5 EMEA USA ASIA 2021 Technical Data DT 35 ...

Page 36: ...anged opposite the cylinder To prevent shutters in the oil feeding channels the matching surface of the two half bearings must be perfectly orthogonal to the cylinder axis as shown in the photo Characteristic A AXIS CYLINDER BEARINGS TYPE IDENTIFICATION CRANKSHAFT HALF BEARING B BLUE 1 971 1 976 C YELLOW 1 974 1 979 E GREEN 1 977 1 982 Technical Data Vespa 946 E4 E5 EMEA USA ASIA 2021 DT 36 ...

Page 37: ...linder using a bore meter at two depths indicated in the figure the diameter of the bushings After measuring the two diameters take the average Characteristic A AXIS CYLINDER The bushings housing hole in the crankcase half is divided into two categories depending on the size Category 1 and Category 2 DIAMETER OF CRANKCASE WITHOUT BUSHING Specification Desc Quantity CAT 1 30 959 30 965 mm CAT 2 30 ...

Page 38: ...n all coupling surfaces Note the position of the springs and the valves so as not to change the original position during refitting Using a trued bar and a feeler gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum allowable run out 0 03 mm In case of faults replace the head Check the sealing surfaces for the exhaust manifold Check that the camshaft and the ro...

Page 39: ...h 35 8 mm Clean the valve seats of any carbon residues Using the Prussian blue check the width of the impression on the valve seat V Characteristic Standard value 1 1 3 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 damage replace the head Vespa 946 E4 E5 EMEA USA ASIA 2021 Technical Data D...

Page 40: ... it on a V shaped abutment and measuring the extent of the deformation with a dial gauge Characteristic Limit value admitted 0 02 mm Check the oscillation 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 Limit allowed 0 3 mm Measure the valve guide Characteristic Valve guide 4 3 0 1 mm Technical Data Vespa 94...

Page 41: ...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 MATING SURFACE DO NOT...

Page 42: ...external diameter of the rocking lev er pins Check the rocker pins do not show signs of wear or scoring Measure the internal diameter of each rocker Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate DIAMETER OF PINS AND ROCKING LEVERS Specification Desc Quantity Rocking lever inside diameter Standard diameter C Ø 10 015 to 10 035 mm Rocking l...

Page 43: ...linder the less the base gasket to be applied to recover the compression ratio and vice versa N B MEASUREMENT A MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK CASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE EQUIPPED WITH A SUP PORT ON A GROUND PLANE ENGINE SHIMMING Name Measure A Thickness Shimming 0 0 1 0 8 0 05 Shimming 0 1 0 3 0 6 0 05 Shimming 0 3 0 4 0 4 0 05 Vespa 946 E4 E5 E...

Page 44: ...INDEX OF TOPICS TOOLING TOOL ...

Page 45: ...937Y Driven pulley lock 020938Y Drive pulley lock 020939Y Flywheel retainer 020940Y Flywheel cover oil seal gasket 020941Y Crankshaft timing adjustment tool 020942Y Piston protrusion check tool Vespa 946 E4 E5 EMEA USA ASIA 2021 Tooling TOOL 45 ...

Page 46: ...020933Y Flywheel extractor 020922Y Diagnosis Tool 020959Y Spanner for the bag hook 020335Y Magnetic mounting for dial gauge 020329Y Mity Vac vacuum pump 020376Y Adaptor handle Tooling Vespa 946 E4 E5 EMEA USA ASIA 2021 TOOL 46 ...

Page 47: ...0365Y 22 mm guide 020360S 52 x 55 mm adaptor 020375Y 28 x 30 mm adaptor 001467Y010 Driver for OD 25 mm bearings 001467Y013 Calliper to extract ø 15 mm bearings 001467Y008 Clamp to extract 17 mm ø bearings Vespa 946 E4 E5 EMEA USA ASIA 2021 Tooling TOOL 47 ...

Page 48: ...ion 020271Y Tool for removing fitting silent bloc 020439Y 17 mm guide 020456Y Ø 24 mm adaptor 020412Y 15 mm guide 020648Y Single battery charger 020331Y Digital multimeter Tooling Vespa 946 E4 E5 EMEA USA ASIA 2021 TOOL 48 ...

Page 49: ...Stores code Description 020965Y ABS sensor bracket positioning pin Vespa 946 E4 E5 EMEA USA ASIA 2021 Tooling TOOL 49 ...

Page 50: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 51: ...ystem and battery I I I I I I I Braking system I I I I I I Cylinder cooling system I I I Brake Fluid I I I I I I I I R Engine oil R I R I R I R R R Hub oil I I I I I Headlight direction adjust ment I I I Brake pads I I I I I I I I Sliding shoes CVT rollers I R I Engine oil pre filter C C C C Tire pressure and wear I I I I I I I I I Vehicle road test I I I I I I Driven pulley roller casings I L I S...

Page 52: ...THE VEHICLE STARTING FROM THE SERVICE OF 5 000 Km 3 106 mi OR 5 MONTHS N B THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES Recommended products Piaggio Group recommends the use of prod ucts from its Castrol official partner for the scheduled maintenance of its vehicles Only use lubricants and fluids which meet or ex ceed the performance character...

Page 53: ...k plug with the sup plied wrench Check the spark plug status and the electrode gap Characteristic Electrode gap A 0 7 0 8 mm Spark plug NGK CR8EB Screw the spark plug again to the prescribed torque Locking torques N m Spark plug tightening 10 to 12 Vespa 946 E4 E5 EMEA USA ASIA 2021 Maintenance MAIN 53 ...

Page 54: ...hole In case of oil leakage carefully clean the trans mission crankcase with a cloth CAUTION REPLACE THE COPPER GASKET EACH TIME THE LEVEL CHECK AND OR HUB OIL DRAINAGE SCREW IS UN SCREWED Replacement Remove the hub oil level check screw Prepare an adequately sized container under the crankcase at the height of the wheel hub Unscrew the oil drainage screw and drain out all the oil Tighten the oil ...

Page 55: ...ted Unscrew the screw indicated in the figure and re move the filter cover complete with air duct Remove the filter element and clean it with water and shampoo then dry it off with a clean cloth and small compressed air jets and immerse it in rec ommended oil Squeeze it between your hands without twisting it let it stand until it stops dripping and then reinstall it CAUTION IF THE VEHICLE IS USED ...

Page 56: ...e table Remove the silencer The engine must be emptied by draining off the oil through the drainage plug of the mesh pre filter flywheel side furthermore to facilitate oil drainage loosen or remove the cap dipstick Once all the oil has drained through the drainage hole unscrew the oil cartridge filter and remove it Make sure the pre filter and drainage plug O rings are in good conditions Lubricate...

Page 57: ...round Remove the right side fairing Undo cap dipstick dry it off with a clean cloth and reinsert it screwing down completely Remove the cap dipstick again and check that the level is between the MIN and MAX reference marks top up if required If the check is carried out after the vehicle has been used and therefore with a hot engine the level will be lower in order to carry out a correct check wait...

Page 58: ...g it Change the engine oil Recommended products Engine oil 5W 40 Synthetic based lubricant for four stroke engines SAE 5W 40 JASO MA MA2 API SL ACEA A3 Characteristic Engine oil 1 340 cm of which 120 cm in the filtering car tridge Oil pressure warning light The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the ON position This warning light wil...

Page 59: ...gure The arrows stamped respectively on the valve frame and sprocket must coincide N B IF THE TIMING UNIT IS NOT IN PHASE CHECK THE COR RECT FITTING OF COMPONENTS As a further verification of the correct distribution timing insert a pin into the hole on the gear of the camshaft and check that it coincides with the spe cial blind hole on the frame of the head Checking the valve clearance Remove the...

Page 60: ... pin of the steering shock ab sorber strut Lower the body until the upper screws of the tappet cover are free Unscrew the upper screws of the tappet cover and remove the cover to access the valve clearance registers Maintenance Vespa 946 E4 E5 EMEA USA ASIA 2021 MAIN 60 ...

Page 61: ...let 0 08 mm Braking system Level check Rest the vehicle onto the centre stand with the handlebar centred Check the level of liquid using the warning lights A and B A certain lowering of the level is caused by wear on the pads Top up Remove the handlebar cover as described in the corresponding chapter For both brakes remove the reservoir cap by loos ening the relative screws remove the gasket and t...

Page 62: ...4925 CUNA NC 956 DOT4 Locking torques N m Brake pump reservoir screw 15 20 Headlight adjustment Position the vehicle in running order and with the tyres inflated to the prescribed pressure onto a flat surface 10 m away from a half lit white screen en sure that the longitudinal axis of the vehicle is perpendicular to the screen Turn on the headlight and check that the border of the projected light ...

Page 63: ...Anti evaporation system Key 1 Canister Vespa 946 E4 E5 EMEA USA ASIA 2021 Maintenance MAIN 63 ...

Page 64: ...ting Removing system components After having removed the clamps unscrew the fastening screw to release the system and bring the components inside the engine compartment Refitting system components Upon reassembling the components use caution when connecting the pipes to the canister Maintenance Vespa 946 E4 E5 EMEA USA ASIA 2021 MAIN 64 ...

Page 65: ... to the canister 5 Pipe for connecting the canister to the inlet fitting After having installed the components secure the pipes with new ties Upon refitting the canister valve observe the di rection of the arrow toward the engine Vespa 946 E4 E5 EMEA USA ASIA 2021 Maintenance MAIN 65 ...

Page 66: ... to regenerate the activated carbon by means of a reversed flow of ambient air sucked by the engine These vacuums of pollution and carbon regeneration take place at each cycle of use of the vehicle To control the canister it is necessary to proceed with its removal while keeping the 2 pipes connec ted Shake the Canister and make sure there is no noise Using a compressed air gun blow al ternately i...

Page 67: ...lve it is preferable to it alterna tively just access the manifold side pipe Connect the MITY VAC pump on the engine side duct Select the pump command on the vac uum position then slowly apply vac uum up to the valve threshold check opening If you detect different pressures replace the valve Note An excessively high opening vacuum value impedes the active carbon regeneration process vice versa an ...

Page 68: ...witch the control of the pump to pres sure and keeping the valve in the ver tical axis check that it is possible to pressurise the valve up to values slightly below 1 45PSI 0 87PSI 10kPa 6kPa 100mbar 60mbar Note The calibration pressure is easily identifia ble as when this pressure is reached the valve vents the air with a small sound Position the valve in the horizontal axis and check that you ca...

Page 69: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 70: ... or just the piston rings Starting difficulties START UP PROBLEMS Possible Cause Operation Flat battery Check the state of the battery If it shows signs of sulphation replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1 10 of the capacity of the battery itself Faulty spark plug Replace the spark plug Incorrect valve sealing or valve adjustm...

Page 71: ...EM Possible Cause Operation Inefficient braking system Check the pad wear 1 5 MIN Check that the brake discs are not worn scored or warped Check the correct level of fluid in the pumps and replace brake fluid if necessary Check there is no air in the circuits if necessary bleed the air Check that the front brake calliper moves in axis with the disc Fluid leakage in hydraulic braking system Failing...

Page 72: ...nts check the seats in which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering clearance Check the tightening of the top ring nut If irregularities continue in turning the steering even after making the above adjust ments check the seats in which the ball bearing...

Page 73: ...Vespa 946 E4 E5 EMEA USA ASIA 2021 Troubleshooting TROUBL 73 ...

Page 74: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 75: ...ER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER Components arrangement Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 75 ...

Page 76: ...Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 76 ...

Page 77: ...emove the leg shield back plate to reach it 3 Injection load relay Remove the leg shield back plate to reach it 4 Front right turn indicator Remove the leg shield back plate and the footrest to reach it Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 77 ...

Page 78: ...ont left turn indicator Remove the leg shield back plate and the footrest to reach it 7 Horn Remove the leg shield back plate the footrest and the legshield to reach it 8 Diagnostics socket Remove the battery compartment cover to reach it Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 78 ...

Page 79: ...compartment cover to reach it 12 Lambda probe for connector see point 24 13 Frame engine cable harness connector A 14 Frame engine cable harness connector B Remove the leg shield back plate and the footrest to reach it Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 79 ...

Page 80: ...ck plate to reach it 17 USB socket pre installation for accesso ry 18 PMP connector pre installation for acces sory 19 Headlight connector 20 Voltage regulator connector Remove the leg shield back plate and the footrest to reach it Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 80 ...

Page 81: ...reach it 23 Fuel pump connector Remove the left side fairing to reach it 24 Lambda probe connector 25 Magneto flywheel connector To reach it remove the right side fairing 26 ABS ECU 27 Rear speed sensor connector To reach it remove the right side fairing Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 81 ...

Page 82: ...right side fairing 29 Licence plate light Remove the license plate light to reach it 30 Rear light To reach it remove the right side fairing 31 Instrument cluster for connector see point 22 Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 82 ...

Page 83: ...tor connector 35 Boost 36 Tip over sensor Remove the leg shield back plate to reach it 37 Front speed sensor connector Remove the leg shield back plate and the footrest to reach it 38 Front wheel speed sensor for connector see point 37 Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 83 ...

Page 84: ... it 40 Engine temperature sensor 41 Injector Remove the right side fairing and the left side fair ing to reach it 42 CDI control unit To reach it remove the right side fairing 43 Rear left turn indicator Remove the left side fairing to reach it Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 84 ...

Page 85: ...r see point 27 45 H V coil Remove the right side fairing the left side fairing the air filter and the throttle body to reach it Instrument panel Key A Fuel level indicator icons Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 85 ...

Page 86: ...tion after about 2 seconds release the MODE button WARNING TO SWITCH FROM km h TO mph THE MULTIFUNCTION INDICATOR C MUST BE SET TO TO TAL ODOMETER ODO N B THE FOLLOWING ARE DEFINED WHEN NAVIGATING THE DISPLAY BRIEF PRESS A PRESS OF THE INDICATED BUTTON FOR A PERIOD OF LESS THAN TWO SECONDS PROLONGED PRESS A PRESS OF THE INDICATED BUTTON FOR A PERIOD OF MORE THAN TWO SECONDS N B THE VEHICLE IS EQUI...

Page 87: ...d The bars are illuminated in relation to the fuel level in the tank according to the following table BAR FUEL CORRESPONDENCE Number of segments switched on Corresponding fuel level litres 7 8 5 7 0 5 7 0 5 8 5 5 8 4 6 4 4 6 3 4 3 3 4 2 4 2 2 4 1 4 1 1 4 1 0 0 1 0 0 0 A possible failure of the fuel level sensor is shown at the level indicator by both flashing the 1st and 7th bar This condition occ...

Page 88: ... point under the footrest on the right part of the vehicle Engine frame ground point under the left spoiler and the left side fairing Electrical system installation Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 88 ...

Page 89: ...le harness 2 Left turn indicator cable harness 3 Right turn indicator cable harness 4 Headlight cable harness 5 Electrical devices cable harness 6 Instrument panel cable harness 7 Frame main cable harness Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 89 ...

Page 90: ...8 Main wiring harness 9 Battery negative cable harness 10 Engine main cable harness Back side 1 Engine main cable harness Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 90 ...

Page 91: ...itheft system which allows the vehicle to function only if it is activated by means of the coded keys that the control unit recognises The code is integrated in a transpond er in the key block This allows the driver clear operation without having to do anything other than just turning the key The Immobilizer system con sists of the following components Control unit Immobilizer antenna master and s...

Page 92: ... below Remove the connector mounting bracket shown in the photograph and disconnect the connector from the control unit Check the following conditions With the key switch set to OFF there is battery voltage between terminals 7 9 and terminal 9 chassis ground fixed power supply If there is no voltage check that fuse 2 and its cable are in working order With the key switch in the ON position there i...

Page 93: ...for the recognition of the MASTER as the first key to be saved this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys To encode the system it is necessary to use the MASTER key and the service keys as described below Insert the MASTER key switch to ON and keep this position for 2 secon...

Page 94: ...the efficiency of the high voltage circuit shielding must be thoroughly inspected In any case it is ad visable to use resistive spark plugs Diagnostic codes The Immobilizer system is tested each time the Ignition switch is turned from OFF to ON During this diagnosis phase a number of control unit statuses can be identified and various light codes displayed Regardless of the code transmit ted if at...

Page 95: ...mmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains on steadily The engine cannot be started The codes that can be trans mitted are 1 flash code 2 flash code 3 flash code Diagnostic code 1 flash DIAGNOSIS CODE 1 FLASH This error is identi fied as a serial failure damaged or shorted to ground With this code proceed with the followin...

Page 96: ... the Immobilizer antenna or the transponder Turn the switch to ON using several keys if the code is repeated even with the Master key check the antenna wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Diagnostic code 3 flashes A three flash code indicates a system where the contro...

Page 97: ...ce 0 2 1 Ω 4 Check that there is insulation between the each yellow cable and the ground 5 If the values are incorrect replace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing the specific cover 2 Check that the battery does not show signs of losing fluid before checking the output voltage 3 Turn the ignition key to position OFF connect the terminals o...

Page 98: ...e engine bring it to normal speed and read the values on the ammeter With an efficient battery a value must be detected 20A VOLTAGE REGULATOR RECTIFIER Specification Desc Quantity Type Non adjustable three phase transistor Voltage 14 15V at 5 000 rpm with lights off Lights list This section lists the bulb types required for the vehicle s equipment BULBS Specification Desc Quantity 1 High beam low ...

Page 99: ... rear daylight running lights front daylight running lights Fuse no 7 Capacity 5A Protected circuits key powered immobilizer antenna tip over sensor starter circuit stop button stop light ABS control unit and engine control unit Fuse no 8 Capacity 7 5 A Protected circuits key powered USB socket pre installation accessory turn indicator control device antitheft pre instal lation Fuse no 9 Capacity ...

Page 100: ...heck Before installing the battery on the vehicle check the open circuit voltage with a standard tester If voltage exceeds 12 60 V the battery can 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 charge equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for Nomin...

Page 101: ...er itself because inside there is sulphu ric acid 3 Procedure for filling the battery with acid Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes Push the container down with enough force to break the seals The electrolyte should start to flow inside the battery Note Do not tilt the container to prevent the flow of electrolyte from p...

Page 102: ...he battery will not be able to exceed 75 charge without jeop ardising its useful life on vehicle The dry charge battery MF like the completely loa ded YTX must have a zero load voltage between 12 8 13 15 V Bring the battery to full charge us ing the 020648Y battery charger a select the type of battery with the red switch on the left of the panel battery charger panel b select NEW on the yellow tim...

Page 103: ...t the clamps from the battery and check the voltage if voltages are detected of less than 12 8 V proceed with a new recharge of the battery starting from point c of the recharge pro cedure of the new battery otherwise go to point i i The battery is now properly activated disconnect the battery charger from the power supply and unplug the terminals from the battery 7 Battery closing Insert the airt...

Page 104: ...rs CDI CONTROL UNIT 1 RoNe H V coil 2 N C 3 Bi ASR icon 4 ViNe Motor cut out switch 5 Vi Starter button 6 RsBi key 7 Ne Ground 1 8 GrNe Stop buttons 9 RsVe Battery 10 ViBi Start enable 11 VeBL Lambda 12 AzNe Lambda 13 AzVe Engine temperature sensor 14 ArBi Immobilizer antenna 15 GrVe Sensor ground 16 N C 17 Gi Immobilizer 18 Ar Signal from the roll over sensor 19 GrVe Sensor ground 20 Ma Pick up 2...

Page 105: ...wheel speed signal 12 MaNe Rear wheel speed ground signal 13 AzNe Front wheel speed ground signal 14 AzRs Front wheel speed signal 15 Ne Ground 16 ArNe K Line 17 N C 18 RsGr Battery PIAGGIO MULTIMEDIA PLATFORM 1 RsBL from the battery 2 GiNe Key 3 ArNe K Line 4 Vi High beam lights 5 N C 6 BiBl Right turn indicators 7 RoBi CAN L line 8 RoRs CAN H line 9 Az Speedometer signal 10 Ne Ground 11 BiVe Fue...

Page 106: ...he injector loads 14 RoRs CAN H line 15 RoBi CAN L line 16 Ar Tip over sensor 17 GrVe Sensor ground 18 Bi ASR icon 19 Az Boost 20 Ro Oil pressure sensor ENGINE CABLE HARNESS CONNECTOR A 1 MaNe Engine management icon 2 RsBi key 3 RsVe Battery 4 ArBi Immobilizer antenna 5 VeAr K line 6 Gi Immobilizer LED 7 BiNe Lights ignition enabling 8 NeVi injection load relay 9 ViBi Start enable 10 ViNe Motor cu...

Page 107: ...nsor ENGINE CABLE HARNESS CONNECTOR B 1 AzBi External temperature sensor 2 BiNe Stop buttons 3 N C 4 N C FRAME CABLE HARNESS CONNECTOR B 1 AzBi External temperature sensor 2 BiNe Stop buttons 3 N C 4 N C FRAME WIRING HARNESS CONNECTOR C 1 Gi Flywheel 2 Gi Flywheel 3 Gi Flywheel Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 107 ...

Page 108: ...el 2 Gi Flywheel 3 Gi Flywheel PRE INSTALLATION GPS 1 GiNe Key 2 Ne Ground 3 RsVe Battery USB PORT 1 GiNe Key 2 Ne Ground ROLL OVER SENSOR 1 N C 2 GrVe Ground 3 RsBi key 4 Ar Signal Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 108 ...

Page 109: ...R SPEED SENSOR 1 MaNe Ground 2 Ma Signal AERIAL WITH IMMOBILIZER 1 RsBi key 2 Ne Ground 3 ArBi Ignition enabling FUEL PUMP 1 BiVe Fuel level indicator 2 Ne Ground 3 NeVe pump 4 GrNe pump Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 109 ...

Page 110: ...ton 2 BiNe Stop button 3 GrNe Horn 4 GiNe Key 5 BiRo Left turn indicator enable control signal 6 GrBL Right turn indicator enable control signal 7 Gr Com 8 Ma Low beam lights 9 Vi High beam lights 10 Bi Horn 11 N C 12 N C HEADLIGHT 1 Ne Ground 2 AzBi External temperature sensor 3 Ma Low beam lights 4 Vi High beam lights 5 BiNe Lights ignition enabling 6 BiRs Headlight diagnostic Electrical system ...

Page 111: ...Ne Ground HORN 1 GrNe Positive 2 Ne Ground INSTRUMENT PANEL CONNECTOR A 1 Gi Immobilizer LED 2 RsVe Battery 3 BL ABS warning light 4 MaNe Engine management icon 5 N C 6 Ve MODE button 7 N C 8 N C 9 Bi ASR icon 10 Vi High beam warning light Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 111 ...

Page 112: ...icator 6 Ne Ground 7 N C 8 BLRo Turn indicator warning light 9 Az Speedometer 10 N C DIAGNOSTIC SOCKET 1 N C 2 Ne Ground 3 ArNe K Line DIAGNOSTIC SOCKET Euro 5 1 GiNe from the key 2 RoRs CAN H line 3 Ne Ground 4 RsBL from the battery 5 RoBi CAN L line 6 ArNe K Line BATTERY POSITIVE 1 Rs Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 112 ...

Page 113: ...I control unit 3 Ne Ground 4 Gi Flywheel 5 Gi Flywheel 6 Gi Flywheel TURN INDICATOR CONTROL 1 BiRo Left indicator input 2 Ne Ground 3 Ro Left indicator output 4 GrBL Right indicator input 5 BLRo Turn indicator warning light 6 N C 7 GiNe Key 8 BiBL Right indicator output Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 113 ...

Page 114: ...R RIGHT TURN INDICATOR 1 BiBL Turn indicator enable control 2 Ne Ground FRONT LEFT TURN INDICATOR 1 Ro Turn indicator enable control 2 Ne Ground 3 Bi Daylight running light FOR USA VERSIONS ONLY 1 Ro 2 Ne Ground Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 114 ...

Page 115: ...light FOR USA VERSIONS ONLY 1 BiBL 2 Ne Ground MAGNETO FLYWHEEL 1A Gi Voltage regulator 2A Ro Oil pressure sensor 1B Ma Pick up 2B Gi Voltage regulator 1C Gi Voltage regulator 2C Rs Pick up FUEL INJECTOR 1 RsGi Positive 2 NeVe Negative Vespa 946 E4 E5 EMEA USA ASIA 2021 Electrical system ELE SYS 115 ...

Page 116: ...e H V COIL 1 RoNe Negative 2 NeVe Positive LAMBDA PROBE WITH HEATER 1 VeBL Lambda 2 AzNe Lambda 3 NeVe Power supply from the injection loads 4 BiBL C D I control unit STARTER MOTOR POSITIVE 1 Rs Electrical system Vespa 946 E4 E5 EMEA USA ASIA 2021 ELE SYS 116 ...

Page 117: ...n switched live power supply from F01 2 RsBi Ignition switched live power supply from F02 3 GiNe Ignition switched live power supply from F03 4 Gr Ignition switched live power supply from F04 5 N C 6 RsNe Battery power supply from fuse F06 7 RsVe Battery power supply from fuse F07 8 RsGr Battery power supply from fuse F08 9 RsBL Battery power supply from fuse F09 10 N C 11 Ar Ignition switched liv...

Page 118: ...ry power supply 20 N C 30R1 Rs Battery power supply for the starter re lay contact 87R1 Rs Battery power supply for the starter re lay contact 85R1 ViBi Ground for starter coil 86R1 RsBi Ignition switched live power supply for the starter coil SHUNT 1 Rs Starter relay contact BREATHER VALVE 1 NeVe Power supply from the injection loads 2 VeAr C D I control unit Electrical system Vespa 946 E4 E5 EME...

Page 119: ...s malfunction is detected with a brake activated and the starter button pressed voltage of 12V read at PIN 5 If the battery voltage does not drop thanks to the absorption of the starter command relay excitation coil the control unit understands that PIN 10 is shorted to battery Restore the cabling if the short is in the cabling or the relay if the short is in the relay ENGINE TEMPERATURE SENSOR Fu...

Page 120: ...ct this means that the sensor is faulty and must be replaced otherwise proceed with the checks Short circuit to positive With the sensor connector and the control unit disconnected verify that the fault is a short with the battery positive of sensor connector PIN 1 or control unit PIN 13 and restore wiring Short circuit to negative Disconnect the sensor connector Check the sensor connector PIN 1 g...

Page 121: ...s no short to battery positive on sensor connector PIN 4 corresponding to control unit connector PIN 12 if there is a short restore the wiring harness Open circuit Disconnect the control unit connector and the sensor connector Check the continuity of the wiring harness between the sensor connector and control unit connector Control unit PIN 11 sensor PIN 3 and control unit PIN 12 sensor PIN 4 If n...

Page 122: ...on relay PIN 3 If necessary restore the wiring harness If the wiring harness is intact and the error persists proceed with the following checks Short circuit to negative Disconnect the sensor connector Check the sensor connector PIN 2 ground insulation If there is no insulation restore the wiring har ness If PIN 2 is insulated from ground and in the absence of other errors fuel pump injector coil ...

Page 123: ...sitive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage at PIN 22 of the control unit connector Short circuit to negative null voltage at PIN 85 of the injection relay Open circuit circuit interruption Troubleshooting Short circuit to positive Disconnect the injection relay turn the key to ON and activate the relay through the diagnostic tool Verify th...

Page 124: ...oil connector PIN 1 if present restore the cabling otherwise replace the coil Open circuit Carry out the check procedure of the coil and control unit connectors Verify continuity of the wiring harness between the coil and control unit Coil PIN 1 control unit PIN 1 If there is no continuity restore the wiring harness Verify with the key turned ON the presence of voltage on the coil connector PIN 2 ...

Page 125: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 126: ...E UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER Exhaust assy Removal 1 Silencer 2 Silencer heat guard 3 Manifold heat guard 4 Lambda probe Remove the right side fairing Disconnect the lambda probe connector Engine from vehicle Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG VE 126 ...

Page 127: ...and remove the silencer CAUTION FREE THE CABLES OF THE LAMBDA PROBE BEFORE REMOVING THE SILENCER PUTTING THIS CABLE HAR NESS UNDER AN EXCESSIVE VOLTAGE MAY DAMAGE IT To refit follow the previous operations but in reverse order observing the prescribed torques Locking torques N m Lambda probe tightening on exhaust manifold 40 50 Screws fixing silencer to the crankcase 24 to 27 Vespa 946 E4 E5 EMEA ...

Page 128: ...T THE VEHICLE ADEQUATELY WARNING CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD Remove the pin connecting the swinging arm to the engine by unscrewing the nut on the left side of the vehicle Lift the rear part of the vehicle as far as possible CAUTION DURING THE LIFTING OPERATIONS PAY ATTENTION THAT THE CABLE HARNESS TRANSMISSIONS AND PIPES ARE NOT TIGHTENED WARNING PAY ATTENTION TO THE STABIL...

Page 129: ... on the crankcase Unscrew the screw retaining the clamp of the con trol unit cable harness to the crankcase Remove the ECU connector Undo the connecting screw on the frame engine ground frame Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine from vehicle ENG VE 129 ...

Page 130: ...the engine temperature sensor connec tor Remove the starter motor power supply cable by unscrewing the nut Remove the ground cable on the starter motor by unscrewing the nut Engine from vehicle Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG VE 130 ...

Page 131: ...re in the pipes Disconnect the throttle grip cables from the throttle body Remove the throttle body freeing the main cable harness by loosening the clamp fastening the manifold Disconnect the HV coil connector Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine from vehicle ENG VE 131 ...

Page 132: ...he previous operations but in reverse order observing the prescribed torques indicated in the SPECIFICATIONS chapter WARNING EACH TIME THAT THE CONNECTOR OF THE CONTROL UNIT IS DISCONNECTED THE LEARN ING OF THE CONTROL UNIT MUST BE PERFORMED AS DESCRIBED IN THE INJECTION FITTING OF THE THROTTLE BODY CHAPTER Engine from vehicle Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG VE 132 ...

Page 133: ...INDEX OF TOPICS ENGINE ENG ...

Page 134: ...IT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER Automatic transmission Transmission cover Remove the air duct Remove the plastic cover that has the vehicle logo on it Insert the specific tools rotate the engine until the driven pulley stops and remove the nut recovering the washer Specific tooling 020994Y Driven pulley stop Engine Vespa 946 E4 E5 EMEA...

Page 135: ... Unscrew the ten screws fixing the engine and re move the transmission cover See also Air duct Air duct Unscrew the screws indicated and remove the duct Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 135 ...

Page 136: ...ndle 020357Y 32 x 35 mm Adaptor 020412Y 15 mm guide Refitting the driven pulley shaft bearing Use the heat gun to heat the inner part of the lid Using the equipment plant a new bearing apply grease on the adapter and guide in order to main tain the position of the bearing during operation on the vertical axis Specific tooling 020151Y Air heater 020376Y Adaptor handle 020358Y 37 x 40 mm Adaptor 020...

Page 137: ...rt the alignment dowels if removed during disassembly Removing the driven pulley Undo the clutch fixing screw recovering the lin ing Remove the clutch drum Remove the driven pulley Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 137 ...

Page 138: ... diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft unit on the support to check the crankshaft alignment Using a dial gauge and the magnetic base meas ure the bell eccentricity Repeat the measurement at 3 positions Central internal external In case of faults replace the bell Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic moun...

Page 139: ...ake contact with a minimum force Using the specific wrench inserted 46 mm from the side remove the clutch central locking nut Separate the components of the driven pulley CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE TIGHTENED WITH EX CESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL Specific tooling 020444Y Tool for installing removing ...

Page 140: ...USE TOOLS TO OPEN THE MASSES TO AVOID VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Simultaneously turn and pull the collar manually to remove it N B USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL TY N B BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O RING SEAL Inspecting the driven fixed half pull...

Page 141: ...rings Refitting the driven half pulley bearing Assemble a new roller bearing using the specific punch fit the bearing with the label facing outward and insert it completely up to the punch on the half pulley N B REST THE DRIVEN PULLEY ON A WOODEN SURFACE TO AVOID DAMAGING ITS THREADED BUSHING ALSO DO THIS UPON REMOVAL Specific tooling 020424Y Driven pulley roller casing fitting punch To assemble t...

Page 142: ... pins and the collar Use a greaser with 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 operation is necessary to avoid the presence of grease beyond the O rings Specific tooling 020263Y Driven pulley assembly sheath Inspecting the clutch spring Meas...

Page 143: ...drive belt is not damaged and does not show abnormal wear Replace according to the scheduled maintenance table Removing the driving pulley using specific tools lock the driving pulley and loosen the nut Specific tooling 020938Y Drive pulley lock Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 143 ...

Page 144: ...ng shown in the fig ure is not abnormally worn and measure inner diameter A Measure outer diameter B of the pulley sliding bushing shown in the figure Check that the rollers are not damaged or worn Check the sliding shoes for the variator back plate are not worn Check the wear of the roller housings and of the belt facing surfaces on both pulley halves Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG...

Page 145: ...ers ø 19 mm Wear limit ø 18 4 mm Refitting the driving pulley perform the operations in reverse order of disas sembly CAUTION INSERT THE ROLLERS WITH THE LARGEST SUPPORT SURFACE ACCORDING TO THE DIRECTION OF ROTA TION tighten the torque using the specific tool to lock the pulley CAUTION DURING THE INSTALLATION PAY SPECIAL ATTENTION TO THE ASSEMBLY OF THE SPRING WASHER AS SHOWN IN FIGURE Specific t...

Page 146: ...to tighten to the prescribed torques Locking torques N m Clutch cover retainer screws 10 8 12 8 End gear Removing the hub cover Drain the oil of the final drive as described in the chapter MAINTENANCE Remove the 3 screws A and the 5 screws B Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 146 ...

Page 147: ...ng working from the external side and using the specific tools Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide 020357Y 32 x 35 mm Adaptor Removing the intermediate gear bearing Remove the bearing using the specific tools Specific tooling 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract ø 15 mm bear ings Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 147 ...

Page 148: ...with the crankcase Remove the Seeger ring from the outside Operating on the inside remove the oil seal Remove the wheel axle bearing using the specific tool Specific tooling 020376Y Adaptor handle 020364Y 25 mm guide 020359S 42 x 47 mm Adaptor Removing the intermediate gear bearing Remove the bearing using the specific tools Specific tooling 001467Y013 Calliper to extract ø 15 mm bear ings 001467Y...

Page 149: ...place the damaged parts Characteristic Driven pulley shaft A 22 0 01 0 02 mm Wheel axle B 15 0 010 0 020 mm C 25 0 007 0 020 mm Intermediate gear D 15 0 01 0 02 mm E 15 0 01 0 02 mm Inspecting the hub cover Check that the fitting surface is not dented or distorted Check the bearing bearings In case of faults replace the damaged components Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 149 ...

Page 150: ...o heat the bearing seat Set a new bearing using the specific equipment Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor For main bear ings and wheel axle 020412Y 15 mm guide Fitting the Wheel axle bearing Use the heat gun to heat the bearing seat Set a new bearing using the specific equipment Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42...

Page 151: ...0364Y 25 mm guide Fitting the transmission gear bearing Use the heat gun to heat the bearing seat Using the equipment set a new bearing Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359S 42 x 47 mm Adaptor 020412Y 15 mm guide Refitting the ub cover Clean the engine crankcase and reduction cover surfaces adequately Working in reverse with respect to the disassem bly inert the comman...

Page 152: ... 27 See also Replacement Flywheel cover Cooling hood Unscrew the five indicated screws and remove the cooling cap Cooling fan By inserting the specific tool in the indicated holes unscrew the nut fixing the cooling fan Remove the cooling fan Recover the wrench Specific tooling 020442Y Pulley lock wrench Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 152 ...

Page 153: ...move the oil dipstick Remove the sensor connector Unscrew the eleven fixing screws of the flywheel cover Remove the cover Remove the gasket Pay attention to the alignment dowels Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 153 ...

Page 154: ...ng harness Refitting the stator Refit the stator and flywheel carrying out the re moval procedure in reverse tightening the retain ers to the specified torque Respect the operation of the pick up Locking torques N m Stator fixing screws 8 to 10 Pickup fixing screws 3 4 Refitting the flywheel cover Fit the gasket and be careful with the two align ment dowels Engine Vespa 946 E4 E5 EMEA USA ASIA 202...

Page 155: ...NG THE FLYWHEEL COVER Specific tooling 020940Y Flywheel cover oil seal gasket FLYWHEEL COVER SCREWS POSITION DIMENSIONS TORQUE Nm A M6x90 11 to 13 B M6x35 11 to 13 C M6x30 11 to 13 Flywheel and starting Removing the starter motor Undo the two fixing screws and remove the start er motor Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 155 ...

Page 156: ...he washer Specific tooling 020939Y Flywheel retainer Before screwing in the flywheel extractor the pro tection tool provided in the specific tool must be positioned Specific tooling 020933Y Flywheel extractor Acting on the extractor remove the flywheel to gether with the starting sprocket and intermediate gear Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 156 ...

Page 157: ...ing the flywheel magneto Perform the procedure in reverse order of disassembly taking care to tighten to specified torque Locking torques N m Flywheel fixing nut 100 110 Refitting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the starter motor on the crankcase and lock the two screws to the prescribed torque Locking torques N m Starter screws 10 8 12 8 Vespa 946 E4 E...

Page 158: ... the intake manifold The intake manifold is positioned on the head loosen the clamps and remove the sleeve con necting to the throttle body Undo the three manifold fixing screws and re move it Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 158 ...

Page 159: ...ocker arms cover Remove the protective cover undoing the three screws Remove the engine temperature sensor Undo the screw indicated remove the upper part of the cover Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 159 ...

Page 160: ... Unscrew the four screws and remove the tappet cover Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 160 ...

Page 161: ...ls Use the holes on the engine crankcase to secure the tool Position the specific tool in the window between the flywheel pick up references as illustrated in the figure Specific tooling 020941Y Crankshaft timing adjustment tool First loosen the tensioner and unscrew the fixing screws Remove the tensioner complete with gasket Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 161 ...

Page 162: ...ter removing the head the camshaft control com ponents can be removed Remove the inspection cover as described in sec Lubrication Main bushing oil seals removal Remove the oil pump command as described in section Lubrication Oil pump Disassembly Undo the chain tensioner pad fixing screw re move the bushing and the slider Remove the chain tensioner pad Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG ...

Page 163: ... Remove the control gear Remove the seal OR Remove the flat washer CAUTION REMEMBER TO CORRECTLY POSITION THE SEAL OR IN THE REFITTING PHASE Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 163 ...

Page 164: ...Remove the control gear See also Removal Removing the cylinder piston assy Removing the cam shaft Undo the camshaft lock screw Remove the lock Remove the two pins and the rockers Remove the camshaft Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 164 ...

Page 165: ...Removing the cylinder head Gradually loosen the four screws in crossed se quence and recover the washers Undo the two external screws Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 165 ...

Page 166: ... Remove the cylinder head Remove the chain guide slider and the gasket Remove the gasket N B ON ASSEMBLY PAY CLOSE ATTENTION TO THE TWO DOWELS Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 166 ...

Page 167: ...ing CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS CAUTION DURING ASSEMBLY POSITION THE VALVE SPRINGS WITH THE GREEN COLOURED COIL FACING UPWARD Specific tooling 020382Y Valve fitting removal tool Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 167 ...

Page 168: ...ON TO PREVENT DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER N B IN ORDER NOT TO DAMAGE THE BASE GASKET WITH THE PISTON LOCK FORK 020426Y DURING THE MOUNT ING PHASE IT IS RECOMMENDED TO INSERT THE ALIGNMENT DOWELS OF THE CYLINDER CRANKCASE UNDER THE CYLINDER DURING THE ASSEMBLY Remove the base gasket Remove the retainer rings and remove the piston N B BE CAREFUL NOT TO DAMAGE THE SEALI...

Page 169: ...S AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the piston N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the piston rings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Piston rings Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine EN...

Page 170: ...ic tool Specific tooling 020942Y Piston protrusion check tool Using an abutment plane reset the dial gauge with a pre load of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Install the tool on the cylinder without changing the dial gauge position Lock the tool using the original head fixing nuts Rotate the crankshaft up to the TDC the inver sion point of t...

Page 171: ...and D and must be fitted so that the reference arrow faces the exhaust duct The letter is found at the centre of the piston Fit the sealing rings with the word TOP or the identification letter facing upwards In any case the step must be facing opposite the piston crown Sealing rings are manufactured with a cylinder contact conical cross section and piston gaps must be offset by 120 in order to obt...

Page 172: ...W OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL Specific tooling 020426Y Piston fitting fork 020427Y Piston assembly band Recommended products Engine oil 5W 40 Synthetic based lubricant for four stroke engines SAE 5W 40 JASO MA MA2 API SL ACEA A3 Inspecting the cylinder head N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Engine Vesp...

Page 173: ...ove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole unit Inspecting the valve sealings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Inspecting the valves N B TO MEASURE WEAR LIMITS AND COUPLIN...

Page 174: ...ADE THAT MAY AFFECT THE MEAS UREMENTS Characteristic Valve clearance cold engine intake 0 08 mm outlet 0 08 mm Inspecting the springs and half cones Check that the upper and lower supporting spring washers the cotters and the oil seal show exhibit no signs of abnormal wear Replace a component when worn N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Engi...

Page 175: ... valve seal rings alternately Fit the valves the springs and the caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats N B DO NOT CHANGE THE VALVE FITTING POSITION FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Specific tooling 020382Y Valve fitting removal tool 020431Y Valve oil seal extractor Vespa 946 E4 ...

Page 176: ... Head Refitting the head and timing system components Position the crankshaft to the TDC in compres sion Insert the head gasket and check the correct operation of the alignment dowels Insert the chain guide slider Insert the head Lubricate the stud bolt threads with engine oil Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 176 ...

Page 177: ...T CAUTION ALWAYS USE A NEW HEAD GASKET UPON REFITTING Locking torques N m Cylinder head nut TIGHTENING 9 11 Tighten to the prescribed torque and then proceed with 270 0 5 0 rotation Screws fixing cylinder to crankcase 10 8 12 7 Refitting the rocker arms cover Remove the cylinder head cover and tighten the four clamping screws to the prescribed torque Pay attention to the integrity of rubber gasket...

Page 178: ...SHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT ACCIDENTALLY FALL Remove the gasket and be careful with the align ment dowels Inspecting the crankshaft components N B TO...

Page 179: ...th the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase coupling gasket between the crankcase halves or the mating surfaces shown in the diagram could cause a drop in the oil pressure lubricating the main bushings and connecting rod Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear The dimension between these seats...

Page 180: ...ft axial clearance of the limiting surface N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Coupling chart N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Refitting the crankcase halves Follow the removal steps but in reverse order be carefu...

Page 181: ...earance Using specific tools to support the dial gauge verify that the fitting clearance is within the limits Higher clearances are signs of wear of the crankshaft crankcase supporting surfaces Characteristic Crankshaft crankcase axial clearance 0 2 0 5 mm Studs Using two nuts fitted as nut and lock nut type remove and then drive from the seat Proceed with a thorough cleaning of the threaded seat ...

Page 182: ... the main bearings are lubricated and the big end with high pressure the piston pin and connecting rod small end via spray H Subsequently the oil arrives at the timing system where it lubricates the camshaft A and from this valves and rockers The oil passes through the timing chain duct and returns to the sump B by gravity In the system there is a minimal oil pressure sensor I and a spray that ser...

Page 183: ...riate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the flywheel cover If the oil pressure is not within the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FILTER IN...

Page 184: ...screw the three screws and remove them complete with the copper gaskets Using pliers remove the door by acting on the appendices Remove the spacer and the O ring Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 184 ...

Page 185: ... reverse order taking care to tighten to torque WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE WE RECOM MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH Locking torques N m Crankcase timing cover screws 3 5 4 5 Oil pump Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 185 ...

Page 186: ...e the oil shield Preventing rotation unscrew the water pump command screw and collect the washer Remove the oil pump command sprocket com plete with chain Unscrew the two screws and remove the oil pump Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 186 ...

Page 187: ...n the rotors in the position shown in the figure Check the distance between the outer rotor and pump body see figure Check the axial clearance of the rotors using a trued bar as shown in the figure Characteristic Axial rotor clearance Limit value admitted 0 09 mm Distance between the outer rotor and the pump body Admissible limit clearance 0 20 mm Distance between the rotors Admissible limit clear...

Page 188: ...T THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY MAKE SURE THAT THE PUMP TURNS FREELY Recommended products Loctite 243 Medium strength thread locking sealant Blue Locking torques N m Screws fixing oil pump to the crankcase 5 to 6 Preventing rotation tighten the water pump com mand screw complete with washer Engine Vespa 946 E4 E5 EMEA USA ASIA 2021 ENG 188 ...

Page 189: ...th belt and the sprocket wheel as described in the Transmis sion chapter Drain the oil as described above Remove the seven screws indicated in the figure with the two rear brake transmission retainer brackets Remove the washers the spring and the by pass piston Vespa 946 E4 E5 EMEA USA ASIA 2021 Engine ENG 189 ...

Page 190: ...al Refit the sump taking care to locate the spring in the appropriate recess machined into the inside of the sump Refit the rear brake transmission mounting brack ets and the screws in the reverse order from which they were removed Tighten the screws to the prescribed torque Refit the driving pulley assembly the drive belt the sprocket wheel and the transmission cover as described in the Transmiss...

Page 191: ...INDEX OF TOPICS INJECTION INJEC ...

Page 192: ...c Faulty shielded cap E Intake circuit a Air filter dirty b b Dirty by pass circuit c Faulty stepper motor F Other a Wrong timing system b Wrong idle mixture c Wrong reset of the throttle valve position sensor 2 Failures in the system may be caused by loose connectors Make sure that all connections are properly implemented Check the connectors taking into consideration the following point A check ...

Page 193: ...e vehicle not in use fill the tank to at least the halfway mark This will ensure the pump will be covered by fuel 7 When washing the vehicle do not spray excessive water on electric components and wiring har nesses 8 In the event of ignition problems begin troubleshooting from the battery and the injection system connections 9 Before disconnecting the ECU connector perform the following steps in t...

Page 194: ...mobilizer antenna 15 Sensors ground 16 K Line 17 Immobilizer 18 External temperature sensor 19 Sensors ground 20 Pick up 21 NC 22 Injection load relay 23 Ground 2 24 Tyre pressure sensor 25 Injection warning light 26 CAN H line 27 CAN L line 28 NC 29 Pick up 30 NC 31 Lambda probe heater 32 ASR warning light 33 Lights ignition enabling 34 Injector Injection Vespa 946 E4 E5 EMEA USA ASIA 2021 INJEC ...

Page 195: ... 18 Rear ground node 51 engine stop switch 56 Engine temperature sensor 57 Pick up 58 Lambda probe 59 Lambda probe heater 60 Engine control unit 63 Injector 64 H V coil 65 Fuel pump 66 Injection load relay Troubleshooting procedure Vespa 946 E4 E5 EMEA USA ASIA 2021 Injection INJEC 195 ...

Page 196: ...agnosis Pump relay H V coil Injector Engine speed timing sensor Air temperature Engine temperature Starter speed Starter motor and relay Battery Ground connections End of compression pressure End of compression pressure Power to spark plug Spark plug Shielded cap H V coil Engine speed timing sensor Ignition advance Fuel system Fuel pressure low Injector flow low Injector sealing poor Correctness o...

Page 197: ...ctness of the parameters Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter housing Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector flow Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause Opera...

Page 198: ... by self diagnosis Pump relay H V coil Injector Engine speed timing sensor Air temperature Engine temperature Lambda probe Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER ENGINE IRREGULAR PERFORM ANCE ON PICKUP Possible Cause Operation Faults detected by self diagnosis Pump relay H V coil Injector Engine speed timing sensor Air temperature Engine temperature Lambda probe Po...

Page 199: ...ng TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector flow Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Fuel supply system The fuel supply circuit includes the electric pump the filter the pressure regulator the electro injector and the fuel delivery pipes The electrical pump is located in the tan...

Page 200: ...n cause seri ous malfunction it must be observed that the pin of the spring is placed inside the recess in the in jector body as shown in figure Removing the butterfly valve Preventively remove Left side fairing Right side fairing Air filter Rear suspension strut Slightly lift the rear part of the vehicle CAUTION Injection Vespa 946 E4 E5 EMEA USA ASIA 2021 INJEC 200 ...

Page 201: ... Unscrew the screw locking the clamp retaining the crankcase to the control unit cable harness Loosen the adjustment nut and remove the throttle grip cables Disconnect the control unit connector Loosen the clamp fastening the throttle body to the manifold Vespa 946 E4 E5 EMEA USA ASIA 2021 Injection INJEC 201 ...

Page 202: ...itting proceed as follows Turn the ignition switch ON Wait 10 seconds Turn the ignition switch OFF Turn the ignition switch ON Wait 30 seconds Turn the ignition switch OFF Start the vehicle on the stand and keep it running for at least 5 minutes Pump supply circuit Injection Vespa 946 E4 E5 EMEA USA ASIA 2021 INJEC 202 ...

Page 203: ... load relay 7 Electronic control unit 8 Fuel pump Fuel filter check Disconnect the terminals of the electrical pump Remove the screw shown in the picture Remove the clamp fixing the piping to the filter shown in the photograph Vespa 946 E4 E5 EMEA USA ASIA 2021 Injection INJEC 203 ...

Page 204: ...he pump mounting FITTING For the fitting proceed in reverse order paying attention to the fitting angle of the pump flange in the tank CAUTION DURING THE FITTING OF THE FUEL PUMP IN THE TANK PAY ATTENTION TO THE FITTING ANGLE OF THE FLANGE Injection Vespa 946 E4 E5 EMEA USA ASIA 2021 INJEC 204 ...

Page 205: ...Ohm Check function of fuses No 1 2 and 7 for the ECU and injection load relay Check functionality of the injection load relay also located behind the front grille check the resistance of the energising coil between pins 86 and 85 40 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the relay WARNING Vespa 946 E4 E5 EMEA USA ASIA 2021 Injec...

Page 206: ...Check the presence of fixed voltage between the Red White cable of the relay base and ground Otherwise check the continuity of the Red White cable between the fuse box No 02 10 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC See also Fuses Check on switching to ON that there is battery voltage for about two seconds to the...

Page 207: ...the injector to the wire supplied with the injection tester Connect the clamps of the cable to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within fifteen seconds approximately 40 cm of fuel is dispensed with an adjustment pressure of approximately 2 5 Bar Specific tooling 020480Y Fuel pressure measurement kit Tachometer Disconnect the fuel pipe connector Start ...

Page 208: ...ck that the pins 20 and 29 of the control unit are insulated from each other and insulated from the ground Specific tooling 020331Y Digital multimeter Injection Vespa 946 E4 E5 EMEA USA ASIA 2021 INJEC 208 ...

Page 209: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 210: ...R TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER Front Removing the front wheel Remove the plastic cover levering in the appropri ate slit Undo the screws fixing the wheel to the wheel hub Front wheel hub overhaul WHEEL HUB REMOVAL Remove the front wheel Remove the front brake calliper Remove the cotter pin Suspensions Vespa 946 E4 E5 EMEA U...

Page 211: ...the wheel axle Remove the wheel hub WHEEL HUB SERVICE If due to an excessive clearance it is necessary to replace the bearings proceed as follows Remove the retainer ring of the bearing Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensions SUSP 211 ...

Page 212: ...ings Remove the oil seal of the bearing on brake disc side Remove the bearing using the guide the adaptor and the handle Specific tooling 020363Y 20 mm guide 020456Y Ø 24 mm adaptor 020376Y Adaptor handle With a specific gun heat the seat of the bearing on the brake disc side Specific tooling 020151Y Air heater Suspensions Vespa 946 E4 E5 EMEA USA ASIA 2021 SUSP 212 ...

Page 213: ... Adaptor handle Heat the seat of the bearing from the opposite side of the brake disc Specific tooling 020151Y Air heater Drive the bearing in the seat as far as it will go using the guide the adaptor and the handle Specific tooling 020412Y 15 mm guide 020357Y 32 x 35 mm Adaptor 020376Y Adaptor handle Insert the retainer ring Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensions SUSP 213 ...

Page 214: ... X 0 9 1 2 mm Locking torques N m Front wheel axle nut 74 88 Front wheel to hub fixing screws 20 25 Handlebar Removal Preventively remove the leg shield back plate The footrest The mirrors The connectors of the instrument panel head lights and electrical devices Release the cable harness of the instrument pan el headlights and electrical devices Undo the screws indicated Remove the front handlebar...

Page 215: ...aying at tention to the correct passage of the cables the piping and the cable harness THE FIXING SCREW OF THE HANDLEBAR ON THE STEERING PIPE 1 AND THE NUT 2 MUST BE RE PLACED AT EVERY REMOVAL Locking torques N m Handlebar locking screw 40 45 Steering column Removal Remove the handlebar Remove the front wheel Remove the piping of the front brake calliper Remove the front speed sensor Remove the up...

Page 216: ...0004Y Punch for removing steering bearings from headstock Insert the new lower steering bearing Refitting For the removal operations proceed in reverse order Locking torques N m Lower steering bearing 12 14 Upper steering bearing 35 40 Front shock absorber Removal Support the vehicle adequately Remove the wheel hub Loosen the shock absorber lower clamps and re move the brake calliper shock absorbe...

Page 217: ...carry out the removal operations in reverse order observing the prescribed tightening torques Locking torques N m Lower shock absorber clamp 19 to 26 Upper shock absorber retainer 20 25 Shock absorber calliper bracket Removal Remove the front wheel hub Remove the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensi...

Page 218: ...b sorber attachment side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441S 26 x 28 mm adaptor 020365Y 22 mm guide Remove the oil seal on the wheel hub side 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 020360S 52 x 55 mm adaptor Suspensions Ve...

Page 219: ...the specific tool Specific tooling 020365Y 22 mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 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 tooling 020036Y Punch 020037Y Punch Recommended products Calcium based grease Calcium gr...

Page 220: ...lcium based grease Calcium grease Smooth textured appearance Ivory coloured Specification TL 9150 066 symbol NATO G 460 Rear Removing the rear wheel Remove the silencer Remove the cover of the wheel pin nut CAUTION FREE THE CABLES OF THE LAMBDA PROBE BEFORE REMOVING THE SILENCER PUTTING THIS CABLE HAR NESS UNDER AN EXCESSIVE VOLTAGE MAY DAMAGE IT Unscrew the indicated screws and remove the rear wh...

Page 221: ...the operations in the reverse order ob serving the prescribed tightening torques Check the distance between the front speed sen sor and the tone wheel in the event that it is not correct insert a washer of 0 3 0 05 or 0 6 0 05 between ABS sensor and support until reaching the correct value Characteristic Tone wheel distance Sensor X 0 9 1 2 mm Locking torques N m Rear wheel hub nut 104 126 Vespa 9...

Page 222: ...m Removal Support the vehicle adequately Unscrew the nut of the engine swinging arm pin and remove the pin Unscrew the nut of the engine swinging arm chassis swinging arm pin and remove the pin Unscrew the nut of the chassis swinging arm pin and remove the pin Suspensions Vespa 946 E4 E5 EMEA USA ASIA 2021 SUSP 222 ...

Page 223: ...d remove the bracket Overhaul Proceed with the service if there is an excessive clearance of the motor regarding the body Remove the plastic thickness of the swinging arm on the chassis side Remove the axis of the swinging arm on the frame side Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensions SUSP 223 ...

Page 224: ...mm bear ings Remove the plastic thickness of the swinging arm on the engine side Remove the axis of the swinging arm on the en gine side Remove the bearings from both sides of the swinging arm using an extractor and bell Specific tooling 001467Y010 Driver for OD 25 mm bearings 001467Y008 Clamp to extract 17 mm ø bear ings Suspensions Vespa 946 E4 E5 EMEA USA ASIA 2021 SUSP 224 ...

Page 225: ...t Place the silentblock in the bracket using the specific tool Specific tooling 020271Y Tool for removing fitting silent bloc For both bearings of the swinging arm on the engine side proceed as follows Use handle and guide to drive the bearing into its seat Specific tooling 020439Y 17 mm guide 020456Y Ø 24 mm adaptor 020376Y Adaptor handle Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensions SUSP 225 ...

Page 226: ...the thickness Insert the axis into the swinging arm on the frame side and then insert the thickness Grease in the points indicated by arrows Refitting Proceed the removal operations but in the reverse order observing the prescribed tightening torques Locking torques N m Silent block bracket screw 42 to 52 swinging arm to engine frame pin locknut 76 to 83 Swinging arm to frame pin locknut 40 45 Eng...

Page 227: ...o the bracket Unscrew the fixing screw of the shock absorber to the linkage Unscrew the screw fixing the strut to the linkage of the shock absorber Unscrew the lock nut of the linkage pin and slide the pin from the opposite side Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensions SUSP 227 ...

Page 228: ... screw 67 73 Lock nut of the linkage 81 90 Strut to linkage fixing screw 67 73 Strut to bracket fixing screw 67 73 Screws fixing bracket to crankcase 20 25 Centre stand REMOVAL CENTRE STAND Support the vehicle adequately Remove the two stand return springs Unscrew the nut fixing the stand to the engine and remove the pin from the opposite side FITTING CENTRE STAND To refit proceed in reverse order...

Page 229: ...Locking torques N m Centre stand axis nut 40 45 Vespa 946 E4 E5 EMEA USA ASIA 2021 Suspensions SUSP 229 ...

Page 230: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 231: ...am 1 Front brake calliper 2 Rear brake master cylinder 3 Front brake master cylinder 4 Right joint 5 Left joint 6 ABS Modulator 7 Rear brake calliper 8 Vehicle centre Guide to diagnosis At each key ON if at least one current or memorised system error is not identified the ABS warning light flashes When exceeding 5 km h if no errors are detected the ABS warning light turns off Vespa 946 E4 E5 EMEA ...

Page 232: ...ATE NO go to 3 YES go to 4 3 PERFORM THESE CHECKS A Ground PIN 7 and PIN 23 B 12V at PIN 9 C 12V at PIN 6 with key ON 4 ARE THERE ANY ERRORS YES go to point 5 NO go to point 6 5 CONSULT THE ERRORS DISPLAY TABLE 6 ABS WARNING LIGHT ACTIVATION IS IT ACTIVATED YES go to point 7 NO go to point 8 7 CONTACT TECHNICAL SERVICE 8 PERFORM THESE CHECKS A Continuity cable between PIN 8 of the ABS control unit...

Page 233: ... tubes in sequence 1 2 4 3 N B PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING THE REMOVAL OF THE PIPING FROM THE MODULATOR USE A SMALL CONTAINER AND A CLOTH MODULATOR INSTALLATION When installing the ABS modulator repeat the operations described in the removal in reverse order paying close attention when inserting the pipes Before installing the side fairings bleed the brake system in order to re...

Page 234: ...M THE ASR SYSTEM S CALIBRATION PROCEDURE DURING THE ROAD TEST ASR SYSTEM The ASR system is a driving aid that assists the driver in acceleration manoeuvres particularly on low grip surfaces or under conditions that can cause sudden back wheel slippage The ASR in these situations automatically intervenes by re ducing engine output within the limit imposed by the grip conditions contributing signifi...

Page 235: ...engine running it is recommended to reactivate the system as soon as possible If the system was NOT deactivated vol untarily this indicates an ASR system fault To ensure maximum safety of the vehicle it is ad visable to keep the system active Deactivation may be necessary only in case of starting with very low grip surfaces mud snow on which the oper ation of the ASR could actually prevent the mov...

Page 236: ...th the engine running it is recommended to reactivate the system as soon as possible If the system was NOT deactivated vol untarily this indicates an ASR system fault To ensure maximum safety of the vehicle it is ad visable to keep the system active Deactivation may be necessary only in case of starting with very low grip surfaces mud snow on which the oper ation of the ASR could actually prevent ...

Page 237: ...OAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR SYSTEM SUCH EVENT APPEARS UNDER NORMAL OPERATION CONDI TIONS OF THE VEHICLE N B THE DEVICE PREVENTS IMPRESSING ON THE REAR HIGH SPEED ROTATION WHEEL WITH THE VEHICLE ON THE CENTRE STAND IT IS RECOMMENDED NOT TO IN SIST WITH THE THROTTLE GRIP IN THIS PARTICULAR CONDITION CAUTION A POOR STATE OF MAINTENANCE OF THE TYRES CAN RESULT IN ABN...

Page 238: ...gine start key on the ASR system will return to the standard operation with the previ ously memorised value It is however necessary to repeat the process until it succeeds For the EURO 3 EURO 4 version ASR SYSTEM CALIBRATION PROCEDURE In order to maintain the effectiveness of the ASR system following the replacement of one or both tyres a calibration procedure of the system must be performed as fo...

Page 239: ...HE BRAKE CALLIPER BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM INED Refitting Follow the removal procedures but in reverse order and tighten to the prescribed torques with the recommended product Locking torques N m Rear brake calliper fixing screws 20 25 If the calliper was repla...

Page 240: ...ightening calliper to support 20 25 If the calliper was replaced bleed the system CAUTION ALWAYS USE NEW COPPER WASHERS CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM Locking torques N m Brake fluid pipe calliper fitting 20 25 Rear brake disc Removal Remove the rear wheel hub Unscrew the indicated nuts Refitting For removal proceed in reverse order paying attention to the prescribed torques C...

Page 241: ...Loosen the screw of the speed sensor bracket Loosen the fixing nut of the speed sensor brack et Insert the special tool in the speed sensor hous ing and tighten the contact plane Specific tooling 020965Y ABS sensor bracket positioning pin Vespa 946 E4 E5 EMEA USA ASIA 2021 Braking system BRAK SYS 241 ...

Page 242: ...ixing nut of the speed sensor bracket to the prescribed torque Locking torques N m Lock nut of the sensor bracket 3 5 4 5 Tighten the screw of the speed sensor bracket to the prescribed torque Locking torques N m Sensor bracket locking screw 6 8 Braking system Vespa 946 E4 E5 EMEA USA ASIA 2021 BRAK SYS 242 ...

Page 243: ...0 9 1 2 mm Disc Inspection Remove the rear wheel Use a calliper to check the disc thickness as shown in the photograph Repeat the measurement at no fewer than six points on the disc Remove the rear brake calliper Place the dial gauge on the disc outer edge Make the wheel hub turn and check the disc de viation Specific tooling 020335Y Magnetic mounting for dial gauge Characteristic STANDARD THICKNE...

Page 244: ...r paying attention to the prescribed torques Check the gap between tone wheel and front speed sensor Locking torques N m brake disc screws 8 10 Disc Inspection Remove the rear wheel Use a calliper to check the disc thickness as shown in the photograph Repeat the measurement at no fewer than six points on the disc Braking system Vespa 946 E4 E5 EMEA USA ASIA 2021 BRAK SYS 244 ...

Page 245: ...c mounting for dial gauge Characteristic STANDARD THICKNESS 4 0 2 0 2 MM MINIMUM THICKNESS 3 5 MM Max deviation allowed 0 1 mm Front brake pads Removal Remove the brake calliper Undo the indicated screws and remove the brake pads Refitting Follow the process in reverse order to refit Rear brake pads Vespa 946 E4 E5 EMEA USA ASIA 2021 Braking system BRAK SYS 245 ...

Page 246: ... pin Remove the pin Remove the spring Remove the pads Check that there are no faults or warping If there are replace them Check that the thickness of the friction material is more than 1 5 mm Otherwise proceed with re placement Braking system Vespa 946 E4 E5 EMEA USA ASIA 2021 BRAK SYS 246 ...

Page 247: ... calliper tightening screw 20 25 Nm Fill Rear combined Remove the rubber cap from the bleed screw Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered With the brake lever load the system and bring it up to the required pressure Keeping the brake lever pulled loosen the bleed screw to purge the air in the system Then tighten the bleed screw Repeat the operation until o...

Page 248: ...ed screw to permit the brake fluid to be recovered With the brake lever load the system and bring it up to the required pressure Keeping the brake lever pulled loosen the bleed screw to purge the air in the system Then tighten the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recovery pipe and refit the rub ber cap over the bleed screw Top up...

Page 249: ...ough the sight glass A and B A certain lowering of the level is caused by wear on the pads Front brake pump Removal Remove the front handlebar cover Drain the braking system Disconnect the brake oil pipe from the pump paying attention to a possible escape of remaining oil Disconnect the connector of the brake stop but ton Unscrew the nuts fixing the pump to the handle bar Remove the brake pump wit...

Page 250: ...ying attention to a possible escape of remaining oil Disconnect the connector of the brake stop but ton Unscrew the nuts fixing the pump to the handle bar Remove the brake pump with the lever Refitting Upon refitting perform the operation but in reverse order Tighten the hydraulic line to the prescribed torque and purge the system When the operation is over tighten the brake fluid bleed screw to t...

Page 251: ...THEIR FITTINGS Locking torques N m Brake fluid pump hose joint 19 to 22 Handlebar brake pump nuts 7 10 Brake pipes 1 Front brake pump pipe 2 Rear brake pump pipe 3 Front brake calliper pipe Vespa 946 E4 E5 EMEA USA ASIA 2021 Braking system BRAK SYS 251 ...

Page 252: ...4 Rear brake calliper pipe Braking system Vespa 946 E4 E5 EMEA USA ASIA 2021 BRAK SYS 252 ...

Page 253: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 254: ...N POLLUTE WATER THE VEHICLE MUST BE WASHED AT A WASH STATION EQUIPPED WITH A SPECIAL WATER PURIFICATION SYSTEM CAUTION DO NOT USE A HIGH PRESSURE WATER JET MACHINE TO CLEAN THE ENGINE AND OR VE HICLE HOWEVER IF NO OTHER MEANS ARE AVAILABLE IT IS THEN NECESSARY TO ONLY USE A FAN LIKE SPRAY JET DO NOT PLACE THE NOZZLE CLOSER THAN 60 CM DO NOT USE WATER AT TEMPERATURES OVER 40ºC DO NOT USE HIGH PRESS...

Page 255: ...L OF DUST OR FOR MANUAL DRYING AFTER CLEANING DO NOT USE SILICON WAX OR POLISHING AGENTS DO NOT USE ALCOHOL FOR CLEANING IT IS STRONGLY RECOMMENDED TO MANUALLY WASH WITH SPONGE AND NEUTRAL SHAMPOO AVOIDING EX CESSIVE RUBBING THAT COULD AFFECT THE HAZE DE GREE OF THE PAINTING DO NOT USE ABRASIVE CLEANERS FAILURE TO FOLLOW THE ABOVE GIVEN ADVICE COM PROMISES THE HAZE OF THE PAINTING DO NOT APPLY ADH...

Page 256: ...he seat with commercial products to avoid staining the clothing If stained allow the area to dry and possibly wash it with warm water and neutral shampoo do not use alcohol or solvent based products Pay special attention when refuelling Suggestions for cleaning the fabric To clean the fabric use a cotton wipe soaked in water without applying too much pressure In case of exposure to rain even if it...

Page 257: ... Disconnect the cable from the saddle lock Remove the 6 MY13 4 MY14 indicated screws and remove the saddle with the support Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 257 ...

Page 258: ... removing the seeger ring and the indicated pin Remove the 4 screws fixing the saddle to the support and separate the saddle from the support BAG HOOK REMOVAL Using the appropriate tool lock the two nuts in side the body Specific tooling 020959Y Spanner for the bag hook Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 258 ...

Page 259: ...or this procedure see section Misc documents Side fairings Remove the leg shield back plate Remove the footrest For both sides of the vehicle remove the 9 re tainer screws of the upper bumpers Remove the 5 retainer screws of the lower bump ers Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 259 ...

Page 260: ...ntrol Disconnect the front and rear stop connectors Remove the front and rear brake pump Remove the front and rear brake pipes Remove the right and left controls Disconnect the right and left controls connectors Remove the screw fixing the handlebar cover to the steering pipe and remove the handlebar cover WARNING THE SCREW AND THE NUT TIGHTENING THE HANDLE BAR MUST BE REPLACED AFTER EACH REMOVAL ...

Page 261: ... refitting pay attention to the correct cable channels in the rear handlebar cover A Front brake pipes B Instrument panel cable harness electric devi ces cable harness headlight cable harness C Rear brake pipes throttle grip cables Front handlebar cover Remove the leg shield back plate Remove the footrest Disconnect the connectors of the light assembly and the instrument panel and free the cables ...

Page 262: ...rip cables HANDLEBAR Name Torque in Nm Right control fixing screws 3 to 4 Headlight cover fixing 1 to 1 7 Instrument panel fixing 1 to 1 7 Handlebar electrical device fixing 1 to 1 7 Headlight support fixing 4 5 to 7 Upper handlebar body fixing 6 8 Handgrips terminals fixing 4 6 Headlight fixing 11 13 Headlight frame fixing 1 to 1 5 Nut fixing handlebar element 33 to 35 Chassis Vespa 946 E4 E5 EME...

Page 263: ...bles from the retaining clamps Remove the headlight frame by unscrewing the 2 indicated screws Remove the headlight cover by unscrewing the indicated screws on both sides of the headlight Remove the front handlebar cover Undo the 2 screws indicated Remove the screw indicated on both sides of the headlight Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 263 ...

Page 264: ...e Remove the footrest Disconnect the connectors of the turn indicators Unscrew the 2 indicated screws and remove the turn indicators NOTE The following procedures refer to the vehicle with USA market destination The front turn indicators A are under the han dlebar Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 264 ...

Page 265: ...ows undo the transparent glass fixing screw Remove the transparent glass Remove the coloured semi transparent glass In order to remove the bulb press it slightly and turn anticlockwise Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 265 ...

Page 266: ... back plate Remove the footrest Remove the piaggio clip on badge Undo the screw indicated Undo the screw indicated on both sides of the vehicle Knee guard Undo the screws indicated Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 266 ...

Page 267: ... the ignition key switch when on off Remove the leg shield back plate Remove the footrest Disconnect the ignition switch contacts connec tor Disconnect the immobilizer connector Remove the locking spring of the ignition switch contacts connector Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 267 ...

Page 268: ...f the locking Remove the lock Remove the steering lock Removing the ignition key switch when on lock Remove the leg shield back plate Remove the switch of the ignition switch Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 268 ...

Page 269: ... the cylinder to get into the lock body now turn the key leftwards to OFF and at the same time press until the cylinder is completely in See also Knee guard Taillight assy Unscrew the pin fixing the rear suspension strut to the bracket on the crankcase Pay attention that the cable of the ABS sensor and the rear brake pipe are not tensed lift the rear part of the vehicle Disconnect the rear light a...

Page 270: ... the side fairings Disconnect the connectors of the turn indicators Remove the 2 screws indicated NOTE The following procedures refer to the vehicle with USA market destination The rear turn indicators A are on the rear of the vehicle Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 270 ...

Page 271: ...ows undo the transparent glass fixing screw Remove the transparent glass Remove the coloured semi transparent glass In order to remove the bulb press it slightly and turn anticlockwise Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 271 ...

Page 272: ...icated Remove the license plate light by sliding it from the support Footrest Remove the leg shield back plate Undo the 3 screws indicated Remove the battery cover Undo the screw indicated Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 272 ...

Page 273: ... external footrest strips Remove the 5 screws under each footrest strip Remove the spoilers from both sides of the ve hicle Unscrew the screws under the spoilers Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 273 ...

Page 274: ...hicle Pay attention not to damage the bodywork Side fairings Remove the spoilers Undo the screw indicated Undo the indicated screw License plate holder Remove the license plate light Undo the 2 screws indicated Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 274 ...

Page 275: ...r filter Remove the left side fairing Undo the 2 screws indicated Loosen the hose clamp indicated and remove the filter box Rear mudguard Remove the side fairings Remove the silencer Undo the 2 screws indicated Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 275 ...

Page 276: ...R PROTECTION AGAINST WEATHERING AND OTHER IMPURITIES ON THE ROAD DURING COVER ASSEMBLY INSERT THE PROTECTION IN THE COMPARTMENT BETWEEN BODY AND FOOT REST IN FRONT OF THE SWINGING ARM THEN PRESS IT AGAINST THE FRONT PART OF THE VEHICLE IN OR DER TO SUPPORT THE BODY AS SHOWN IN THE FIG URE Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 276 ...

Page 277: ...uel tank Remove the tank cover Remove the engine Remove the fuel pump connector on the upper part of the engine housing Unscrew the rear tank fixing screw Remove the locking by unscrewing the 3 screws indicated Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 277 ...

Page 278: ...the 3 screws indicated Unscrew the tank fixing screw Slide off the tank towards the rear part of the ve hicle Front mudguard Remove the front handlebar cover Remove the rear handlebar cover Remove the upper steering bearing Chassis Vespa 946 E4 E5 EMEA USA ASIA 2021 CHAS 278 ...

Page 279: ...move the front ABS sensor Adequately support the vehicle and remove the front wheel Slide off the steering pipe Undo the 3 screws indicated Slide off the mudguard from the steering pipe Vespa 946 E4 E5 EMEA USA ASIA 2021 Chassis CHAS 279 ...

Page 280: ...ANCE WITH REGULATIONS IN FORCE CAUTION ELECTROLYTE CONTAINS SULPHURIC ACID AVOID CONTACT WITH EYES SKIN AND CLOTHES IN CASE OF ACCIDENTAL CONTACT RINSE WITH ABUNDANT WA TER AND CONSULT A DOCTOR CAUTION IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYS TEM NEVER DISCONNECT THE WIRING WHILE THE EN GINE IS RUNNING DO NOT TIP THE VEHICLE TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF THE BATTERY ELECTROL...

Page 281: ...OMPLIANCE WITH REGULATIONS IN FORCE Place the support band by tightening the previ ously removed fixing screws Refit the central cover and lock it by tightening the relative fixing screws N B THE CENTRAL COVER HAS A RUBBER PROTECTION AGAINST WEATHERING AND OTHER IMPURITIES ON THE ROAD DURING COVER ASSEMBLY INSERT THE PROTECTION IN THE COMPARTMENT BETWEEN BODY AND FOOT REST IN FRONT OF THE SWINGING...

Page 282: ...e fluid 249 Bulbs C Checks 91 E Engine oil 56 F Fuel 199 203 277 Fuses 99 206 H Headlight 62 263 Hub oil 54 I Identification 25 Instrument panel 85 261 M Maintenance 24 51 Mirrors 260 O Oil filter 58 R Recommended products 52 S Shock absorbers 226 Spark plug 53 Start up 15 Suspension 72 ...

Page 283: ...T Tank 277 Technical Data 24 Transmission 71 134 146 V Vehicle 17 25 26 126 128 ...

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