VESPA GTS 250 I.E. Workshop Manual Download

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- Support the pulley properly using the bell as

shown in the figure.

Specific tooling

001467Y035

Bearing housing outside diameter

47 mm

- Remove the roller bearing using the modular punch.

Specific tooling

020376Y

Adaptor handle

020456Y

Ø 24 mm adaptor

020363Y

20 mm guide

Inspecting the driven fixed half-pulley

Version 250

- Measure the outer diameter of the pulley bushing.

- Check the contact surface with the belt to make

sure there are no flaws.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

Characteristic

Half-pulley minimum diameter

Minimum admissible diameter Ø 40.96 mm

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm

Wear limit

0.3 mm

Engine

Vespa GTS 250 I.E.

ENG - 8

Summary of Contents for GTS 250 I.E.

Page 1: ...WORKSHOP MANUAL 633577 Vespa GTS 250 I E ...

Page 2: ...ny changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all Countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproductio...

Page 3: ...he sections of this manual relating to specific tools along with the specific tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely observe...

Page 4: ......

Page 5: ...OOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 8: ...essed air in such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always us...

Page 9: ... 1001 Engine prefix M451M 1001 Dimensions and mass DIMENSIONS AND MASS Specification Desc Quantity Total loadless weight 151 5 kg Width to hand grips 755 mm Length 1930 mm Wheel base 1370 mm Saddle height 800 mm Vespa GTS 250 I E Characteristics CHAR 3 ...

Page 10: ...ed 120 km h valve clearance intake 0 10 mm discharge 0 15 mm Transmission TRANSMISSION Specification Desc Quantity Transmission Automatic expandable pulley variator with torque server V belt automatic clutch gear reduction unit and transmission housing with forced air circula tion cooling Capacities CAPACITY Specification Desc Quantity Engine oil approx 1300 cc recommended oil Selenia HI Scooter 4...

Page 11: ... Specification Desc Quantity Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plungers and hydraulic control lever on the far right end of the handlebar Rear Ø 220 disc brake and calliper with two Ø 30 mm counteracting plungers and hydraulic control lev er on the far left end of the handlebar Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Front wheels light alloy rims ...

Page 12: ...liper attachment plate 20 27 Wheel axle nut 74 88 Wheel screw 20 25 Screw fixing rear mudguard to steering 5 6 5 shock absorber upper clamp 20 30 FRENO ANTERIORE Name Torque in Nm Brake fluid pump hose fitting 20 25 Brake fluid tube calliper fitting 19 24 Vite serraggio pinza alla piastra attacco ammor tizzatore pinza freno 24 27 Disc tightening screw 6 Apply LOCTITE 242 threadlock medium strength...

Page 13: ...ainage plug 15 17 Oil filter on crankcase fitting 27 33 Engine oil drainage plug mesh filter 24 30 Oil filter 4 6 Oil pump cover screws 7 9 Screws fixing oil pump to the crankcase 5 6 Oil pump control crown screw 10 14 Oil pump cover plate screws 4 6 Oil sump screws 10 14 Minimum oil pressure sensor 12 14 CYLINDER HEAD Name Torque in Nm Spark plug 12 14 Head cover screws 6 7 Nuts fixing head to cy...

Page 14: ...4 102 Nm Pick Up clamping screws 3 4 Screw fixing freewheel to flywheel 13 15 CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead transmis sion side half shaft screws 4 6 Engine crankcase coupling screws 11 13 Starter screws 11 13 Crankcase timing cover screws 3 5 4 5 Apply LOCTITE 242 medium strength threadlock COOLING Name Torque in Nm Water pump rotor cover 3 4 Thermos...

Page 15: ...24 71 960 71 967 0 050 0 064 Piston O 72 024 72 031 71 967 71 974 0 050 0 064 Piston P 72 031 72 038 71 974 71 981 0 050 0 064 Crankcase crankshaft connecting rod CRANKSHAFT Titolo Durata Valore Testo Breve 4000 car Indirizzo Immagine Crankshaft Crankshaft to crankcase axial clearance Crankshaft to crankcase axial clearance Vespa GTS 250 I E Characteristics CHAR 9 ...

Page 16: ...f shaft trans mission side 16 6 0 0 05 A D 0 20 0 50 Flywheel side half shaft 16 6 0 0 05 B D 0 20 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 Slot packing system Characteristic Compression ratio 10 5 11 5 1 Characteristics Vespa GTS 250 I E CHAR 10 ...

Page 17: ... 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 GAUGE EQUIPPED WITH A SUPPORT ON A GROUND PLANE ENGINE 250 SHIMMING Name Measure A Thickness shimming 3 70 3 60 0 4 0 05 shimming 3 60 3 40 0 6 0 05 shimming 3 40 3 30 0 8 0 05 Vespa GTS 250 I E...

Page 18: ...FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AGIP GP 330 Grease for brake levers throttle White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid SPECIAL AGIP PERMANENT fluid coolant Monoethylene gly...

Page 19: ...INDEX OF TOPICS TOOLING TOOL ...

Page 20: ...017 Bell for bearings outside Ø 39 mm 001467Y014 Extraction pliers for ø 15 mm bearings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from the headstock Tooling Vespa GTS 250 I E TOOL 2 ...

Page 21: ... 020021Y Front suspension service tool 020036Y Punch 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank shaft alignment 020150Y Air heater support Vespa GTS 250 I E Tooling TOOL 3 ...

Page 22: ...Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020306Y Punch for assembling valve seal rings 020329Y Mity Vac vacuum operated pump Tooling Vespa GTS 250 I E TOOL 4 ...

Page 23: ...e Description 020330Y Stroboscopic light for timing con trol 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger Vespa GTS 250 I E Tooling TOOL 5 ...

Page 24: ...ode Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42 x 47 mm adaptor 020360Y 52 x 55 mm adaptor 020363Y 20 mm guide 020364Y 25 mm guide Tooling Vespa GTS 250 I E TOOL 6 ...

Page 25: ...Description 020365Y 22 mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Vespa GTS 250 I E Tooling TOOL 7 ...

Page 26: ...code Description 020393Y Piston fitting band 020412Y 15 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork Tooling Vespa GTS 250 I E TOOL 8 ...

Page 27: ...1Y Valve oil seal extractor 020434Y Oil pressure control fitting 020441Y 26 x 28 mm adaptor 020444Y Tool for fitting removing the driv en pulley clutch 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor Vespa GTS 250 I E Tooling TOOL 9 ...

Page 28: ...3Y 30 mm guide 020489Y Hub cover support stud bolt set 494929Y Exhaust fumes analyser 020428Y Piston position check support 020460Y Scooter diagnosis and tester 020621Y H V cable extraction adapter Tooling Vespa GTS 250 I E TOOL 10 ...

Page 29: ...nit interface wiring 001467Y035 Bearing housing outside diame ter 47 mm 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15 mm bear ings 020627Y Flywheel lock wrench 020467Y Flywheel extractor Vespa GTS 250 I E Tooling TOOL 11 ...

Page 30: ...or fitting piston pin stops 200 250 020622Y Transmission side oil guard punch 020480Y Petrol pressure check set 020244Y 15 mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing fitting silent bloc Tooling Vespa GTS 250 I E TOOL 12 ...

Page 31: ...Stores code Description 020638Y 250 I E ENGINE ABS SOFT WARE 020469Y Reprogramming kit for scooter diagnosis tester Vespa GTS 250 I E Tooling TOOL 13 ...

Page 32: ...Tooling Vespa GTS 250 I E TOOL 14 ...

Page 33: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 34: ...000 KM 55 000 KM 65 000 KM 10 Action Engine oil level check top up Brake pads check condition and wear AT 10 000 KM 50 000 KM 70 000 KM 100 Action Safety locks check Throttle lever adjustment Air filter clean Air filter belt compartment check Engine oil change Electrical system and battery check Coolant level check Brake fluid level check Engine oil replacement Brake pads check condition and wear ...

Page 35: ...nd wear check Vehicle and brake test road test Hub oil change Suspensions check Steering check 30 000 KM 140 Action Safety locks check Driving belt replacement Throttle lever adjustment Air filter cleaning Air filter belt compartment check Engine oil change Electrical system and battery check Coolant level check Brake fluid level check Engine oil replacement Brake pads check condition and wear Sli...

Page 36: ...the engine rpm The ignition timing value is detectable any time using the diagnostic tester It is possible to check wheth er the ignition advance determined by the system does in fact correspond with the value actually ac tivated on the engine by means of the strobo scopic light Proceed as follows Remove the spark plug Remove the plastic cover on the flywheel cover shown in the photograph Remove t...

Page 37: ...ition advance match those measured using the diag nostic tester If the values do not correspond check distribution timing revolution timing sensor Injection control unit Specific tooling 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light for timing control 020621Y H V cable extraction adapter Spark plug Rest the scooter on its stand Open the saddle and take out the helmet com partment...

Page 38: ... 20 000 KM THE USE OF NON CONFORMING ELECTRONIC IG NITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SE RIOUSLY DAMAGE THE ENGINE Characteristic Electrode gap 0 7 0 8 mm Electric characteristic Spark plug CHAMPION RG4 PHP Locking torques N m Spark plug 12 14 Hub oil Check Park the vehicle on its centre stand on flat ground Remove the oil dipstick A dry it with a clean cloth and p...

Page 39: ... Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Characteristic Rear hub oil Capacity approximately 250 cc Locking torques N m Hub oil drainage screw 15 17 Nm Air filter Proceed as follows 1 unscrew the fixing screw A 2 unscrew the nut B under the body 3 remove the left side fairing 4 remove the helmet compartment 5 unscrew the fixing screws C that can be reache...

Page 40: ...RY OUT MAINTE NANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGING THE ENGINE Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased ad hesiveness Engine oil In 4T engines the engine oil is used to lubricate the distribution elements the bench bearings and the thermal group An insufficient quantity of oil can cause serious damage to the engin...

Page 41: ...ubri cate the O ring before fitting it Change the engine oil Since a certain quantity of oil still remains in the circuit oil must be filled from cap A Then start up the scooter leave it running for a few minutes and switch it off after five minutes check the level and if necessary top up without exceeding the MAX level The cartridge filter must be replaced every time the oil is changed Use new oi...

Page 42: ...200 cc Engine oil filter The cartridge filter must be replaced every time the oil is changed Use new oil of the recommended type for topping up and changing purposes Make sure the pre filter and discharge tap O rings are in good condition Lubricate them and refit the mesh filter and oil drainage plug screwing them up to the specified torque Refit the new cartridge filter being careful to lubricate...

Page 43: ...tion using a cal liper spanner applied to the camshaft command pulley casing Cooling system Introduction of the engine coolant The fluid level must checked every 10 000 kilome tres with a cold engine in the way shown below Place the scooter on its centre stand and on flat ground Undo the screw shown in the figure and remove the expansion tank cap on RHS Top up if the fluid level is near or below t...

Page 44: ...ass as shown in the figure A certain lowering of the level is caused by wear on the pads Top up Position the vehicle on a flat surface and on the centre stand Remove the brake pump cover as indicated in the photo Check the brake fluid level through the sight glass on the pump as shown in the photograph If the level is below the minimum fill using the two screws shown in the figure Remove the gaske...

Page 45: ...VALUE THIS WILL RESULT IN INEFFICIENT BRAKING CAUTION NEVER USE BRAKE FLUID COMING FROM OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDITIONS BRAKE FLUID MUST BE CHANGED EVERY 20 000 KM OR ANYWAY EVERY 2 YEARS Locking torques N m Brake pump reservoir screws 15 20 Headlight adjustment Proceed as follows 1 Place the vehicle in running order and with the tyres inflated to the prescribed ...

Page 46: ... screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS REFER TO THE STATUTORY REGU LATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED Maintenance Vespa GTS 250 I E MAIN 14 ...

Page 47: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 48: ... pling seal Worn valve oil guard Replace the valve oil guard Worn valve guides Check and replace the head unit if required Insufficient lubrication pressure POOR LUBRICATION PRESSURE Possible Cause Operation By Pass remains open Check the By Pass and replace if required Care fully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil...

Page 49: ... Brake disc slack or distorted Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Clogged compensation holes on the pump Clean carefully and blast with compressed air Re inflated or glued rubber gaskets Replace gaskets Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening...

Page 50: ...e ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushings In conclusion check the tightening torque of the wheel hub the brake calliper the shock absorber disk in the attachment to the hub and the steering tube Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Seal fault or breakage Replace the shock absorber Check the condition of w...

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

Page 52: ... 5 Engine rpm sensor 6 Engine stop switch 7 N 2 fuse boxes in under helmet compart ment 8 Ignition key switch 9 Saddle opening button 10 Injection load remote control 11 Saddle opening actuator 12 Glove compartment fuse box 13 Battery 12V 12 Ah 14 Starter motor 15 Starter remote control 16 Starter button 17 Rear stop light switch 18 Stop switch on front brake 19 Horn button 20 Horn 21 Headlight re...

Page 53: ...30 Fuel level sender 31 Instrument panel 32 Outside temperature sensor 33 Electric fan 34 Electric fan remote control switch 35 Oil pressure sensor 36 Engine temperature sensor 37 Fuel pump 38 Fuel injector 39 Lambda sensor 40 Spark plug 41 H V coil 42 Electronic injection control unit Key Ar Orange Az Sky blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple ...

Page 54: ...witch 9 Saddle opening button 10 Injection load remote control 11 Saddle opening actuator 12 Glove compartment fuse box 13 Battery 12V 12 Ah 14 Starter motor 15 Starter remote control 16 Starter button 17 Rear stop light switch 18 Stop switch on front brake 19 Horn button 20 Horn 21 Headlight remote control switch 22 Rear Headlights A Stop light B Parking light C License plate light Electrical sys...

Page 55: ... 31 Instrument panel 32 Outside temperature sensor 33 Electric fan 34 Electric fan remote control switch 35 Oil pressure sensor 36 Engine temperature sensor 37 Fuel pump 38 Fuel injector 39 Lambda sensor 40 Spark plug 41 H V coil 42 Electronic injection control unit Key Ar Orange Az Sky blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Electrical system in...

Page 56: ...Front side 1 Saddle opening switch 2 Wirings Electrical system Vespa GTS 250 I E ELE SYS 6 ...

Page 57: ...3 Insert in clamp 4 Fuse box 5 From the wire unit 1 Front left turn indicator connector 2 Front right turn indicator connector 3 Electrical fan connector Vespa GTS 250 I E Electrical system ELE SYS 7 ...

Page 58: ...onnector 2 From regulator 3 Wire unit regulator connexion 4 To the immobilizer aerial 5 Light remote control 6 Electric fan starter 7 To key switch 8 Left turn indicator connector Electrical system Vespa GTS 250 I E ELE SYS 8 ...

Page 59: ...9 Voltage regulator 1 Immobilizer aerial 2 Foldable clamp to hold cables 3 Battery negative terminal Vespa GTS 250 I E Electrical system ELE SYS 9 ...

Page 60: ...4 Battery positive terminal 5 Flywheel regulator connexion 1 Red sheathing 2 Clamp 3 To headlight 4 To instrument 5 To stop switch 6 To stop switch Electrical system Vespa GTS 250 I E ELE SYS 10 ...

Page 61: ...Back side 1 To HV coil 2 Foldable clamp 3 Foldable clamps to hold the red sheathing 4 Diagnostic socket 5 Starter remote control Vespa GTS 250 I E Electrical system ELE SYS 11 ...

Page 62: ...1 Right rear turn indicator 2 Cableguide 3 To rear light 4 Rear left turn indicator Electrical system Vespa GTS 250 I E ELE SYS 12 ...

Page 63: ...2 Remote control switch 3 Ground lead clamping to chassis 4 Oil pressure sensor 5 Lambda probe connector 6 Lambda probe 7 To wire unit 8 To the spark plug 9 H V coil Vespa GTS 250 I E Electrical system ELE SYS 13 ...

Page 64: ... opening actuator 3 Fuse box 4 Foldable clamp to hold cables 5 Clamp 6 Injector connector 7 To HV coil 8 To front wire unit 9 To rear turn indicators 10 To fuel gauge and fuel tank Electrical system Vespa GTS 250 I E ELE SYS 14 ...

Page 65: ...light assembly connector 7 Left turn indicator connector 8 Starter motor ground lead clamping 9 Starter motor positive terminal Conceptual diagrams Ignition Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 Vespa GTS 250 I E Electrical system ELE SYS 15 ...

Page 66: ...met compartment 8 Key switch 10 Injection charge contactor 13 Battery 40 Spark plug 41 High voltage coil 42 electronic injection cpu Schema valido dal numero di telaio ZAPM4510000001579 in poi Electrical system Vespa GTS 250 I E ELE SYS 16 ...

Page 67: ...3 Battery 40 Spark plug 41 High voltage coil 42 electronic injection cpu Headlights and automatic starter section Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 Vespa GTS 250 I E Electrical system ELE SYS 17 ...

Page 68: ...2 Glove compartment fuse box 13 Battery 21 Light contactor 22 Rear lights A Stop light B Parking light C License plate light 23 High low beam selector 24 Headlights A Parking light B High beam low beam 28 Turn indicator bulbs 29 Turn indicator switch 31 Instrument panel Electrical system Vespa GTS 250 I E ELE SYS 18 ...

Page 69: ... under helmet compartment 8 Key switch 12 Glove compartment fuse box 13 Battery 21 Light contactor 22 Rear lights A Stop light B Parking light C License plate light 23 High low beam selector 24 Headlights A Parking light B High beam low beam 28 Turn indicator bulbs 29 Turn indicator switch Vespa GTS 250 I E Electrical system ELE SYS 19 ...

Page 70: ...ro ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 BATTERY CHARGER AND STARTING 1 Magneto 2 Voltage regulator 6 Engine stop switch 7 N 2 fuse boxes in under helmet compartment 8 Key switch 12 Glove compartment fuse box Electrical system Vespa GTS 250 I E ELE SYS 20 ...

Page 71: ...ght B Parking light C License plate light 42 Electronic injection cpu Schema valido dal numero di telaio ZAPM4510000001579 in poi BATTERY CHARGER AND STARTING 1 Magneto 2 Voltage regulator 6 Engine stop switch 7 N 2 fuse boxes in under helmet compartment 8 Key switch 12 Glove compartment fuse box Vespa GTS 250 I E Electrical system ELE SYS 21 ...

Page 72: ... Electronic injection cpu Level indicators and enable signals section Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 CONSENSUSES AND LEVEL INDICATORS 3 Immobilizer antenna 5 Engine rpm sensor 7 N 2 fuses boxes in under helmet compartment 8 Key switch Electrical system Vespa GTS 250 I E ELE SYS 22 ...

Page 73: ... Engine temperature sensor 37 Fuel pump 38 Petrol injector 39 Lambda sensor 42 Electronic injection cpu Schema valido dal numero di telaio ZAPM4510000001579 in poi CONSENSUSES AND LEVEL INDICATORS 3 Immobilizer antenna 5 Engine rpm sensor 7 N 2 fuses boxes in under helmet compartment 8 Key switch 10 Injection charge contactor Vespa GTS 250 I E Electrical system ELE SYS 23 ...

Page 74: ...9 Lambda sensor 42 Electronic injection cpu Turn signal lights Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 DEVICES AND HORN 7 N 2 fuse boxes in under helmet compartment 8 Key switch 9 Saddle open button 10 Injection charge contactor 11 Actuator for saddle opening Electrical system Vespa GTS 250 I E ELE S...

Page 75: ...aio ZAPM4510000001579 in poi DEVICES AND HORN 7 N 2 fuse boxes in under helmet compartment 8 Key switch 9 Saddle open button 10 Injection charge contactor 11 Actuator for saddle opening 13 Battery 19 Horn button 20 Horn 33 Electric fan for ventilator 34 Electric fan contactor 42 Electronic injection cpu Vespa GTS 250 I E Electrical system ELE SYS 25 ...

Page 76: ...zer aerial master and service keys with built in transponder H V coil Diagnostic LED The diagnostic LED also works as a deterring blinker This function is activated every time the ignition switch is turned to the OFF position or the emergency stop switch is turned to the OFF position It remains activated for 48 hours in order not to affect the battery charge When the key switch is turned to ON it ...

Page 77: ...age check that fuse 4 and its cable are in working order With the key switch set to ON there is battery voltage between terminals 5 26 and terminal 5 frame earth fixed power supply If there is no voltage check the key switch contacts that fuse 2 and its cable are in working order There is continuity between terminals 12 18 and 12 19 with the emergency cut out switch in the RUN position If there is...

Page 78: ...tor With the ignition key switch at ON check there is battery voltage between the Red White and Black cables With MIU connector disconnected check the con tinuity between the Orange White cable and pin 7 of the interface wiring Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Electrical system Vespa GTS 250 I E ELE SYS 28 ...

Page 79: ... reprogram med for the memorisation of the service keys The master and service keys must be used to code the system as follows Insert the Master key turn it to ON and keep this position for two seconds lower and upper lim its 1 to 3 seconds Insert the blue key and set to ON for 2 seconds If you have copies of the key repeat the operation with each key Insert the MASTER key again and turn it to ON ...

Page 80: ...000 Ω Diagnostic codes The immobiliser system is tested each time the ig nition key switch is turned from OFF to ON During this diagnosis phase a number of control unit sta tuses can be seen and various light codes dis played Regardless of the code transmitted if at the end of the diagnosis the led remains off per manently the ignition is enabled If however the led remains on permanently it means ...

Page 81: ...mes as there are keys stored in the memory including the Master key When the diagnosis has been completed the LED remains permanently OFF The engine can be started 5 Programmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains on permanently The engine cannot be started The codes that can be transmitted are Code 1 flash 2 flash code 3...

Page 82: ...ontrol unit If this is not the case perform a re programming Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel The alternator is directly connected to the voltage regulator This in its turn is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse The three phase generator provides good...

Page 83: ...0 5 mA Check the charging current WARNING BEFORE CARRYING OUT THE CHECK MAKE SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Place the vehicle on its centre stand 2 With the battery correctly connected to the circuit place the tester terminals between the battery terminals 3 Start the engine ensure that the lights are all out increase the engine speed and at the same time measure the voltage Ele...

Page 84: ...isconnect the connector and check if there is voltage between ter minals 9 8 and terminal 9 ground lead check the fixed terminal form the battery and between terminals 10 8 and terminal 10 ground check live positive lead If there is no voltage there check the circuit wires If there is replace the instrument panel Fuses The electrical system is equipped with 1 six protection fuses A placed inside t...

Page 85: ... Fuse box arrange ment 5 Fuse capacity 10 A Protected circuits Dashboard lighting intercom and anti theft device pre wir ing 6 High and low beam lights horn Fuse box arrange ment 6 Fuse capacity 7 5 A Protected circuits High and low beam lights horn 7 High and low beam lights electric seat opening Fuse box arrange ment 7 Fuse capacity 15 A Protected circuits High and low beam lights electric seat ...

Page 86: ...lock 2 Immobilizer led 3 Engine run lamp and injection fault indication 4 Speedometer 5 Left turn indicator lamp 6 Right turn indicator lamp 7 High beam lamp 8 Light lamp 9 Oil pressure warning lamp 10 Fuel reserve warning lamp 11 Clock setting buttons INSTRUMENT PANEL CONNECTOR Specification Desc Quantity 1 Engine water temperature 2 External temperature positive 3 K line not connected 4 Panel li...

Page 87: ...charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN CIRCUIT STORAGE 1 Voltage check up Before installing the battery on the vehicle check the open circuit voltage with a normal 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 r...

Page 88: ... the battery cover after undoing the 4 screws shown in the photograph Remove the strap fastening the battery Insert the battery breather pipe through the hole shown in the photograph Electrical system Vespa GTS 250 I E ELE SYS 38 ...

Page 89: ...sing the screwdriver tighten up the battery ter minal cables as far as they will go placing the special Grover washer between the screw head and the cable terminal N B DO NOT USE WRENCHES TO TIGHTEN UP THE SCREWS FOR FIXING THE TERMINALS TO THE BATTERY TERMINALS Mount permanently the battery in the battery chamber Refit the strap fastening the battery Vespa GTS 250 I E Electrical system ELE SYS 39...

Page 90: ... Refit the battery cover Connectors Electrical system Vespa GTS 250 I E ELE SYS 40 ...

Page 91: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 92: ...a ble to the coolant pipe indicated in the photograph Undo the two exhaust manifold fixings on the head To undo the nuts fixing the muffler flange to the head properly you must use a jointed wrench that enables you to get at the right nut as well ac cording to the direction of travel that is difficult to get at with a traditional straight wrench Undo the three screws fixing the muffler to the supp...

Page 93: ...tment Remove the side fairings and the spoiler termi nals Remove the full muffler assembly Remove the air cleaner housing by unscrewing the 3 screws indicated in the photograph CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the clamp off the blow by pipe and take the pipe out Remove the clamp indicated in the photograph and disconnect the bellows connected to throttle bo...

Page 94: ...jector by removing the screw locking the re taining clip Disconnect the injector wiring and the throttle body control unit wiring Remove the coolant outlet pipe from the motor as indicated Remove the spark plug caps Remove the coolant temperature sensor con nector indicated in the photo Engine from vehicle Vespa GTS 250 I E ENG VE 4 ...

Page 95: ... in the photograph and remove the throttle body Remove the positive and negative wiring from the starter motor as shown in the photo Disconnect the connectors from the flywheel wir ing as shown in the photo Remove the cable from the retaining clip on the flywheel cover Vespa GTS 250 I E Engine from vehicle ENG VE 5 ...

Page 96: ...aph Afterwards remove the retainers fixing the piping to the engine crankcase indicated in the photograph Use a jack to support the vehicle properly Re move the engine swinging arm fixing pin by undo ing the nut and the head of the pin as shown in the photograph The engine is now free Engine from vehicle Vespa GTS 250 I E ENG VE 6 ...

Page 97: ... Check the engine oil level and if necessary top it up with the recommended type Fill the cooling circuit and rear brake circuit Check the functioning of the accelerator and the electrical devices Be specially careful with the clamp fixing the throttle body to the purifier bellows which must be positioned as shown in the photograph CAUTION PAY PARTICULAR ATTENTION TO POSITION ING THE THROTTLE COMM...

Page 98: ...Engine from vehicle Vespa GTS 250 I E ENG VE 8 ...

Page 99: ...INDEX OF TOPICS ENGINE ENG ...

Page 100: ...the clutch bell lock wrench shown in the figure remove the driven pulley shaft locking nut and washer Specific tooling 020423Y driven pulley lock wrench Remove the cap dipstick from the engine oil filling hole Remove the ten screws Remove the transmission cover N B WHEN YOU ARE REMOVING THE TRANSMIS SION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH BELL Air duct Remove the transmission compart...

Page 101: ...adaptor 020412Y 15 mm guide Refitting the driven pulley shaft bearing Slightly heat the crankcase from the inside so as not to damage the painted surface Insert the bearing in its seat Refit the seeger ring CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT N B ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING Specific tooling 020376Y Adaptor handle 020357Y 32 x 35 mm...

Page 102: ...defects that could jeopardise belt functioning For refitting place the roller with the belt contain ment edge on the engine crankcase side Tighten the wrench to the prescribed torque Locking torques N m Anti flapping roller 12 16 Removing the driven pulley Remove the clutch bell housing and the driven pulley assembly N B THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE PULLEY MOUNTED Engine Vespa GTS 2...

Page 103: ...eter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support to check the crankshaft alignment Using a feeler pin gauge and the magnetic base measure the bell eccentricity Repeat the measurement in 3 positions Central internal external If faults are found replace the bell Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magneti...

Page 104: ...place Dismantle the driven pulley components Clutch and spring with its plastic holder CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL EXCESSIVE TORQUE CAN CAUSE THE SPE CIFIC TOOL TO BUCKLE Specific tooling 020444Y011 adapter ring 020444Y009 Wrench 46 x 55 020444Y Tool for fitting removing the driven pulley clutch Inspecting the ...

Page 105: ... IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O RING SEAL Remove the four torque server pins and pull the pulley halves apart Removing the driven half pulley bearing Check there are no signs of wear and or noisi ness Replace with a new one if there are Remove the retaining ring using two flat blade screwdrivers Support the pulley bushing adequately from the threaded side using a wooden surfa...

Page 106: ...mm guide Inspecting the driven fixed half pulley Version 250 Measure the outer diameter of the pulley bushing Check the contact surface with the belt to make sure there are no flaws Check the riveted joints are functional Check the evenness of the belt contact surface Characteristic Half pulley minimum diameter Minimum admissible diameter Ø 40 96 mm Half pulley standard diameter Standard diameter ...

Page 107: ...limit 0 3 mm standard diameter Diameter 41 000 41 035 mm maximum allowable diameter Ø 41 08 mm Refitting the driven half pulley bearing Support the pulley bushing adequately from the threaded side using a wooden surface Fit a new roller sleeve as in the figure For the fitting of the new ball bearing follow the example in the figure using a modular punch Fit the retention ring WARNING N B FIT THE B...

Page 108: ...y unit with approximately 6 gr of grease Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings N B THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED UNDER TAKING THE OPERATION WHEN THE BEAR INGS ARE BEING SERVICED MIG...

Page 109: ...uce the adapter ring 11 with the chamfering facing upwards Insert the clutch on the adapter ring Lubricate the end of the spring that abuts against the servo system closing collar Insert the spring with its plastic holder in contact with the clutch Insert the driving belt into the pulley unit accord ing to their direction of rotation Insert the pulley unit with the belt into the tool Slightly prel...

Page 110: ... position Remove the driven pulley belt unit from the tool N B DURING THE SPRING PRELOADING PHASE BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREAD ING N B FOR DESIGN REASONS THE NUT IS SLIGHT LY ASYMMETRIC THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH Specific tooling 020444Y Tool for fitting removing the driven pulley clutch 020444Y011 adapter ring 02044...

Page 111: ...icing programme you are advised to check the rim bot tom of the toothing does not show signs of inci sions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Removing the driving pulley Turn the crankshaft until the ropes of the pulley are on a horizontal axis Insert the adaptor sleeve of the appropriate tool in the hole shown in the p...

Page 112: ...re outer diameter B of the pulley sliding bushing shown in the figure Check that the rollers are not damaged or worn Check the guide shoes for the variator back plate are not worn Check the wear of the roller housings and of the belt contact surfaces on both pulley halves Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact wit...

Page 113: ...itted Ø 20 mm Refitting the driving pulley Preassemble the movable half pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation Check that the roller contact plate does not have flaws and is not damaged on the grooved edge Mount the complete bushing unit on the driving shaft Fit the dr...

Page 114: ...he 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover Replace the cover tightening the 10 screws at the specified torque Refit the oil loading cap bar refit the steel washer and the driven pulley nut Tighten the nut at the specified torque using the lock wrench and the torque wrench tools Replace the plastic cover Specific tooling 020423...

Page 115: ...through the oil drainage plug Remove the 7 flanged screws indicated in the figure Remove the hub cover and its gasket Removing the wheel axle Remove the wheel axis complete with gear Remove the intermediate gear Vespa GTS 250 I E Engine ENG 17 ...

Page 116: ...over Specific tooling 001467Y013 Pliers to extract ø 15 mm bearings Removing the wheel axle bearings Take out the clip on the outside of the gearbox cover Support the hub cover and expel the bearing By means of the appropriate tools remove the oil guard as in the figure Specific tooling 020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30 mm guide 020359Y 42 x 47 mm adaptor 020489Y Hub cover su...

Page 117: ...move the Seeger ring shown in the figure Remove the driven pulley shaft bearing using the modular punch Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide Inspecting the hub shaft Check the three shafts for wear or distortion of the toothed surfaces the bearing housings and the oil seal housings In case of anomalies replace the damaged com ponents Inspecting the...

Page 118: ... in the figure Fit the Seeger ring Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal sur face by means of the appropriate tool used from the 52 mm side The 52 mm side of the adapter must be turned to wards the bearing Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor 020483Y 30 mm guide Engine Vespa GTS 250 I E ENG 20 ...

Page 119: ...THE COVER SUPPORT THE COVER WITH THE STUD BOLT SET Refit the driven pulley shaft bearing with a mod ular punch as shown in the figure N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm adaptor 020363Y 20 mm guide N B WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE SUPPORT T...

Page 120: ...er pipe using black silicone sealant Fit the gearbox cover making sure the breather pipe is in the correct position Position the shorter screw that can also be rec ognised from the different colour as shown in the figure Fix the breather tube support by means of the lower screw Fit the remaining screws and tighten the seven screws to the prescribed torque Flywheel cover Engine Vespa GTS 250 I E EN...

Page 121: ...inder Remove the ten fixings Remove the flywheel cover Removing the stator Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure Remove the stator and its wiring Vespa GTS 250 I E Engine ENG 23 ...

Page 122: ...e end as shown in the figure Orient the water pump shaft with reference to the transmission gear seat as shown in the photo Refit the cover over the engine and tighten the screws to the prescribed torque Carry out the steps in the reverse order from the dismantling procedure CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR MAKE SURE THE CEN TRING DOWELS ARE PRESENT Locking torques N ...

Page 123: ... of its seat Removing the flywheel magneto Remove the water pump shaft and crankshaft spline clip Line up the two holes in the flywheel as shown in the photo Screw in the guide bushing that is part of the special flywheel stop tool on the flywheel as shown in the photo Vespa GTS 250 I E Engine ENG 25 ...

Page 124: ...otograph Specific tooling 020467Y Flywheel extractor Inspecting the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pick Up control plate Refitting the free wheel S Make sure the free wheel contact surfaces are in good condition Thoroughly clean the free wheel to remove LOCTITE residue Degrease the threading of the holes in the free wheel and the clamp...

Page 125: ... the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitting the flywheel magneto Remove the freewheel retaining plate indicated in the photograph Remove the transmission gear and the freewheel Insert the free wheel on the flywheel as shown in the photo Then refit the flywheel with free wheel and trans mission gear Vespa GTS 250 I E Engin...

Page 126: ... 102 Refitting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the starter on the crankcase locking the two screws to the prescribed torque Locking torques N m Starter screws 11 13 Cylinder assy and timing system Removing the intake manifold Loosen the three screws and remove the air intake manifold When refitting secure to the specified torque Engine Vespa GTS 250 I E...

Page 127: ... spring and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifter retaining cover as shown in the figure Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer Vespa GTS 250 I E Engine ENG 2...

Page 128: ...washer Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioning pad must be removed from the transmission side As regards the lower chain guide pad it may only be removed after the head has been removed N B IT IS ADVISABLE TO MARK THE CHAIN IN OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTATIO...

Page 129: ...ALSO BE REMOVED WITHOUT RE MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER Removing the cylinder head Remove the spark plug Remove the 2 side fixings shown in the figure Loosen the 4 head cylinder fastening nuts in two or three stages and in criss cross fashion Remove the head the two centring dowels and the gasket N B IN CASE OF NEED THE HEAD MAY BE RE MOVED WITH THE CAMSHAFT PINS ROCK ING...

Page 130: ...0382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020431Y Valve oil seal extractor Removing the cylinder piston assy Removing cylinder and piston Remove the chain guide pad Remove the 4 O rings on the stud bolts Pull out the cylinder Remove the cylinder base gasket Remove the two stop rings the wrist pin and the piston Remove the piston seals CAUTION...

Page 131: ... Characteristic Checking the connecting rod small end Maxi mum diameter 15 030 mm Checking the connecting rod small end Stand ard diameter 15 0 015 0 025 mm Inspecting the wrist pin Measure the outer diameter of the gudgeon pin Calculate the coupling clearance between con necting rod end and pin Characteristic Pin diameter Standard clearance 0 015 0 029 mm Pin diameter Standard diameter 14 996 15 ...

Page 132: ...GE FROM THE SECOND SEAL SIDE N B THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS FOR THIS REASON MEASURE MENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PIS TON Characteristic Wrist pin seat on the piston Standard diameter 15 001 15 006 mm Diameter of the wrist pin seat on the piston Standard clearance 0 001 0 010 mm piston diameter 71 953 71 981 mm Fitting clearance Top piston ...

Page 133: ...nto the cylinder in the area where it retains its original di ameter Using the piston insert the rings perpen dicularly to the cylinder axis Measure the opening see figure of the sealing rings using a feeler gauge If any measurements are greater than specified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BE TWEEN THE PISTON RINGS AND THE PISTON RING...

Page 134: ...ition indicated on the tool S left D right Place the wrist pin stop ring into position using a punch Fit the wrist pin stop using the plug as shown in the figure N B THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Specific tooling 020454Y Tool for fitting piston pin stops 200 250 Choosing the gasket Characteristic Compression ratio...

Page 135: ...PLANE FORMED BY THE TOP OF THE CYLINDER THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER THE LESS THE BASE GASKET IS TO BE APPLIED TO RECOVER THE COMPRESSION RATIO AND VICE VERSA ENGINE 250 SHIMMING Name Measure A Thickness shimming 3 70 3 60 0 4 0 05 shimming 3 60 3 40 0 6 0 05 shimming 3 40 3 30 0 8 0 05 Vespa GTS 250 I E Engine ENG 37 ...

Page 136: ...ference mark facing the crown of the piston Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure Lubricate the components with engine oil The top piston ring on the 250 engine has an L cross section N B THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Refitting the cylinder Insert the cylinder b...

Page 137: ...g B Ø 20 000 20 021 mm bearing C Ø 37 000 37 025 mm Inspecting the timing system components Check that the guide shoe and the tensioner shoe are not worn out Ensure that the camshaft drive pulley the chain assembly and the sprocket wheel are not worn If you encounter wear replace the parts or if the chain sprocket wheel and pulley are worn replace the whole assembly Remove the centre screw with th...

Page 138: ...Remove any carbon formation from the valve guides Measure the inside diameter of each valve guide Take the measurement at three different heights in the rocker arm push direction If the width of the impression on the valve seat or the diameter of the valve guide exceed the speci fied limits replace the cylinder head Characteristic Valve seat wear Intake guide limit accepted 5 022 Valve seat wear I...

Page 139: ...ilures you can use the same valves For best sealing results it is advisable to grind the valves Grind the valves gently with a fine grained lapping compound 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 CONTACT SURFA...

Page 140: ...40 mm Valve check Minimum admissible diameter Outlet 4 95 mm Valve check Minimum admissible diameter Inlet 4 96 mm Valve check Standard diameter Inlet 4 972 4 987 mm Valve check Standard diameter Outlet 4 96 4 975 mm Engine Vespa GTS 250 I E ENG 42 ...

Page 141: ...e seals 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 POSI TION FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Specific tooling 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal too...

Page 142: ...e auto matic valve lifter cam or the end of stroke roller or the rubber buffer on the automatic valve lifter retaining cover Check that the valve lifting spring has not yielded Replace any defective or worn components Check the rocker pins do not show signs of wear or scoring Measure the internal diameter of each rocker arm Check there are no signs of wear on the pad from contact with the cam and ...

Page 143: ... shaft check Standard diameter Bearing A Ø 36 95 36 975 mm Refitting the head and timing system components Refit the lower timing chain sprocket wheel on the crankshaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the chain tensioner slider from the cylinder head side Fit the spacer and the screw fastener Tighten the screws to the presc...

Page 144: ...the automatic valve lifter cam to the cam shaft Fit the automatic valve lifter return spring During this operation the spring must be loaded by approximately 180 Fit the automatic valve lifter retaining dish using the counterweight screw fastener as a reference Tighten the clamping screw to the prescribed tor que Set the tensioner cursor in the rest position Fit the chain tensioner on the cylinder...

Page 145: ...4 6 Fit the timing chain guide pad Insert the centring dowel between the cylinder head to the cylinder fit the cylinder head gasket and the cylinder head Lubricate the stud bolt threading Tighten up the nuts to an initial pre torque of 7 1 N m Tighten up the nuts to a second pre torque of 10 1 N m Rotate by an angle of 270 To carry out the operations described above fol low the tightening sequence...

Page 146: ...es N m Timing chain tensioner support screw 11 13 Refitting the rocker arms cover Refit the cylinder head cover tightening the 5 clamping screws to the prescribed torque Make sure the gasket is positioned properly Locking torques N m Tappet cover screws 6 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws Locking torques N m Inlet manifold screws 11 13 Engine Ves...

Page 147: ...move the oil filter fitting shown in the diagram Check the axial clearance on the connecting rod Check the radial clearance on the connecting rod Check the surfaces that limit the axial free play are not scored and measure the width of the crank shaft between these surfaces as shown in the diagram If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have...

Page 148: ...RE THAT THE MEAS UREMENTS ARE NOT MODIFIED BY THE RAD IUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Axial crankshaft crankcase clearance Stand ard clearance 0 15 0 40 mm when cold Axial connecting rod crankshaft clearance Standard clearance 0 20 0 50 mm Radial connecting rod crankshaft cleara...

Page 149: ...be replaced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the lubrication duct with compressed air Make sure that the 2 pads on the crank button are properly mounted A wrong installation of a buffer can seriously af fect the bushing lubrication pressur...

Page 150: ...duct at the fly wheel side oil seal Inspect the coupling surfaces on the crankcase halves for scratches or deformation taking partic ular care with the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase coupling gasket be tween the crankcase halves or the mating surfaces shown in the diagram could cause a drop in the oil pressure lubricating the main bearings an...

Page 151: ...e positioned properly so that the oil feed channels are not choked The main bushings are comprised of two half bearings one containing holes and channels for lubrication and the other solid The solid half bearing must withstand the thrusts due to combustion and is therefore positioned op posite the cylinder So as not to choke the oil feed channels it is es sential for the coupling surfaces of the ...

Page 152: ...our markings as shown in the table below TYPE IDENTIFICATION A RED B BLUE C YELLOW Type A RED Type B BLUE Type C YEL LOW Main half bearing 1 970 1 973 1 9703 1 976 1 976 1 979 Bush ing cat egory Crank case halves category Internal bush ing diameter after fitting Possible fitting A 1 29 025 29 040 Original B 1 29 019 29 034 Original and spare 2 29 028 29 043 C 2 29 022 29 037 Original Match the sha...

Page 153: ...GORY AND ARE FITTED WITH CATEGORY B BUSHINGS BLUE Characteristic Standard driving depth 1 35 1 6 Diameter of crankcase without bushing 32 953 32 963 Refitting the crankcase halves Fit the internal bulkhead by locking the two screws to the prescribed torque Fit the oil filter fitting and tighten it to the specified torque Position the oil pre filter element as shown in the photograph Place a new ga...

Page 154: ...e filter on the engine with the relative cap Tighten to the specified torque Locking torques N m Internal engine crankcase bulkhead transmis sion side half shaft screws 4 6 Engine crankcase coupling screws 11 13 Oil filter on crankcase fitting 27 33 Engine oil drainage plug mesh filter 24 30 Engine Vespa GTS 250 I E ENG 56 ...

Page 155: ...lace it By working on two fitted cylinder head fixing nuts nut and lock nut as shown in the photograph re move the stud bolt from its seat Clean the threaded seat on the carter thoroughly Refit a new stud bolt and apply the special product on the threading crankcase side Tighten up to the depth of the driving indicated Recommended products Loctite Quick Set Strong 270 threadlock Strong 270 threadl...

Page 156: ...Engine Vespa GTS 250 I E ENG 58 ...

Page 157: ...ure Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the fan cover If the oil pressure is outside 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 ...

Page 158: ...the oil guard Specific tooling 020622Y Transmission side oil guard punch Refitting Use a new oil guard for the refitting Prepare the new oil guard lubricating the sealing lip Preassemble the oil guard with the appropriate tool positioning the screws Insert the sheath over the crankshaft Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase Insert the ad...

Page 159: ...BRICATE THE SURFACE FOR KEY ING ONTO THE ENGINE CRANKCASE CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL GUARD FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL GUARD SHEATH CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIO...

Page 160: ...the oil pump by unscrewing the two screws in the figure Remove the oil pump seal N B IT IS ADVISABLE TO MARK THE CHAIN IN OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the clip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Reassemble the rotors in the pump b...

Page 161: ...limit clearance 0 12 mm Refitting Check there are no signs of wear on the oil pump shaft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the unit Fit the pump cover in the position that permits the crankcase fixing screws to be aligned Make sure the gasket is positioned properly and refit the...

Page 162: ... N m Screws fixing oil pump to the crankcase 5 6 Oil pump control crown screw 10 14 Oil pump cover screws 0 7 0 9 Removing the oil sump Remove the oil filler plug the transmission cover the complete drive pulley assembly with belt and the sprocket wheel as described in the Trans mission chapter Drain the oil as described previously Remove the seven screws shown in the dia gram and the two rear bra...

Page 163: ...fit the two centring dowels Refit the sump taking care to locate the spring in the appropriate recess machined into the inside of the sump Refit the rear brake cable brackets and the screws in the reverse order from which they were removed Tighten the screws to the prescribed torque Refit the drive pulley assembly the drive belt the sprocket wheel and the transmission cover as de scribed in the Tr...

Page 164: ...Engine Vespa GTS 250 I E ENG 66 ...

Page 165: ...INDEX OF TOPICS INJECTION INJEC ...

Page 166: ...essure is kept constant based on the ambient pressure The feed circuit consists of Fuel pump Fuel filter Injector Pressure regulator Pump filter and regulator are placed into the fuel tank using a single support The injector is connected by two pipes provided with quick couplings This allows obtaining a continuous circulation thereby avoiding the risk of fuel boiling The pressure regulator is situ...

Page 167: ...is also required for adjusting the idle mixture Specific tooling 020460Y Scooter diagnosis and tester The MIU injection ignition system carries out checks on the rpm counter and the electric fan for radiator cooling The MIU control unit has a decoder for the anti theft immobiliser The MIU control unit is connected to a diagnostic LED on the instrument panel that also carries out the deterrent flas...

Page 168: ...Injection Vespa GTS 250 I E INJEC 4 ...

Page 169: ...wo litres of fuel in the tank Failure to respect this norm will damage the fuel pump 6 If the scooter is expected to remain unused for a long time refill the tank up to a little over half the level This will ensure the pump will be covered by fuel 7 When washing the vehicle be careful with the electric components and wiring 8 When an ignition fault is detected start the checks from the battery and...

Page 170: ... Wrong idle mixture c Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors Make sure that all connections have been correctly made Check the connections as follows A check that the terminals are not bent B check that the connectors have been properly connected C see whether the malfunction can be fixed by shaking the connector slightly 3 Check...

Page 171: ...M sensor 14 Fuel injector 15 R P M sensor 16 Diagnostics socket output 17 Immobilizer LED 18 Side stand short circuited on pin 19 19 Earth Connected with water temperature sensor engine stop side stand 20 Injection load remote control 21 Lambda probe heater 22 HV coil 23 24 Start up enabling 25 26 Ground lead EMS circuit diagram Lo schema sottostante è valido per i telai dal numero ZAPM45100000010...

Page 172: ...12 Ah 2 Engine rpm sensor 3 Water temperature sensor 4 Immobilizer aerial 5 Stop button 6 Fuse 30 A 7 Fuse 3 A 8 Key switch contacts 9 Fuse 10 A 10 Engine stop switch 11 Fuse 7 5 A 12 Fuse 15A 13 Fuse 7 5 A 14 Starter button Injection Vespa GTS 250 I E INJEC 8 ...

Page 173: ...Electric fan starter 18 Starter motor 19 Electric fan 20 Fuel pump 21 HV coil 22 Fuel injector 23 Lambda sensor 24 Rpm indicator 25 WARNING light 26 Immobilizer LED 27 Diagnostics socket connector Schema valido dal numero di telaio ZAPM4510000001579 in poi Vespa GTS 250 I E Injection INJEC 9 ...

Page 174: ...6 Immobilizer LED 27 Diagnostics socket connector Troubleshooting procedure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to the indi cations of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Fuel suppl...

Page 175: ...ctness of the parameters Coolant temperature Stepper throttle valve position intake air tempera ture steps and actual opening Cleaning of the auxiliary air pipe and air filter effi ciency gas valve Engine stops at idle ENGINE DOES NOT HOLD IDLING IDLING IS UNSTABLE IDLING TOO LOW Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timin...

Page 176: ...Intake system seal infiltrations Intake manifold head throttle body manifold Intake manifold Filter box Fuel feed low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature ...

Page 177: ...set successful TPS reset successful Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER IRREGULAR ENGINE PROGRESS ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector ...

Page 178: ...Ignition advance Intake system seal Intake manifold Filter box TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the thickness of the cylinder base liner Fuel supply system The fuel supply circuit includes the electric pump the filter the pressure regulator the electro injector...

Page 179: ...Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the snap on fittings from the injector sup port Vespa GTS 250 I E Injection INJEC 15 ...

Page 180: ...the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU connector Remove the clip fixing the throttle body to the pu rifier bellows Injection Vespa GTS 250 I E INJEC 16 ...

Page 181: ...er from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45 as shown in the photograph Pump supply circuit Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 Vespa GTS 250 I E Injection INJEC 17 ...

Page 182: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injection Vespa GTS 250 I E INJEC 18 ...

Page 183: ...eck the efficiency of the injection load remote control Check the resistance of the energising coil between pins 86 and 85 40 to 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 remote control Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for t...

Page 184: ... REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection Vespa GTS 250 I E INJEC 20 ...

Page 185: ... switching to ON that there is battery voltage for about two seconds to the Black Green cable of the pump connector and earth with pump connector disconnected Otherwise check the continuity of the Black Grey cable between the pump connector and the base of the remote con trol Check the efficiency of the earth line of the fuel pump by measuring the continuity between the pump connector black cable ...

Page 186: ...mote control disconnected that the Black Purple cable pin 20 on the interface wiring is insulated from the earth Specific tooling 020331Y Digital multimeter Schema valido dal numero di telaio ZAPM4510000001579 in poi Injection Vespa GTS 250 I E INJEC 22 ...

Page 187: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Vespa GTS 250 I E Injection INJEC 23 ...

Page 188: ...4 to 1 8 A With the battery voltage 12 V check the capacity of the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool Make a graded burette available with a flow rate of approximately 1 L Ro tate the pump using the active diagnosis of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pr...

Page 189: ... from the electric pump Remove the screw shown in the photograph Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph Vespa GTS 250 I E Injection INJEC 25 ...

Page 190: ...the pump support Inspecting the injector circuit Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pagina 2 Injection Vespa GTS 250 I E INJEC 26 ...

Page 191: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Vespa GTS 250 I E Injection INJEC 27 ...

Page 192: ...inuity between pins 30 and 87 of the remote control Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box under the saddle hinge and the remo...

Page 193: ...l base and earth If there is none check the continuity of the grey black cable between the fuse box No 3 10 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Vespa GTS 250 I E Injection INJEC 29 ...

Page 194: ...llow cable be tween pin 14 of the interface wiring and the injector connector Switch to ON and check the presence of voltage with injector disconnected and control unit con nected between the Black Green cable of the in jector connector and the earth Injection Vespa GTS 250 I E INJEC 30 ...

Page 195: ...jector load remote control disconnected check the continuity of the Black Green cable between the injector con nector and remote control base Schema valido dal numero di telaio ZAPM4510000001579 in poi Vespa GTS 250 I E Injection INJEC 31 ...

Page 196: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injection Vespa GTS 250 I E INJEC 32 ...

Page 197: ...le making up part of the supply for the injection tester Connect the clamps of the cable to an auxiliary battery Activate the fuel pump with the active diagnosis Check that in fifteen sec onds approximately 40 cc of fuel is dispensed with a regulation pressure of approximately 2 5 BAR Specific tooling 020480Y Petrol pressure check set Proceed with the injector seal test Dry the injector outlet wit...

Page 198: ...Components location Injection Vespa GTS 250 I E INJEC 34 ...

Page 199: ...injector 7 HV coil 8 Flywheel rpm timing sensor 9 Lambda sensor 10 Injection load remote control 11 Battery 12V 12 Ah 12 Electric fan starter Tachometer With wiring disconnected from the control unit and connected to the system check that the sensor resistance between pins 13 15 is between 100 and 150 Ohm at an engine temperature of approx imately 20 Vespa GTS 250 I E Injection INJEC 35 ...

Page 200: ...of the rpm sensor connector and between pin 15 and the brown cable of the rpm sensor connector With the interface wiring disconnected from the control unit and rpm sensor connector check that the red and brown cables pin 13 15 are isolated from each other and insulated from the earth Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter HT coil Lo schema sottostante è v...

Page 201: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Vespa GTS 250 I E Injection INJEC 37 ...

Page 202: ... 50 R 1 Magnetisation time The coil magnetisation time is controlled by the control unit The ignition power is increased during the engine start up The injection system recognises the 4 stroke cycle and therefore ignition is only controlled during compression Specific tooling 020331Y Digital multimeter Check that the injection load 10A fuse No 3 is in good conditions Check that the 7 5A fuse No 2 ...

Page 203: ...ontinuity between pins 30 and 87 of the remote control Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box under the saddle hinge and the r...

Page 204: ...Injection Vespa GTS 250 I E INJEC 40 ...

Page 205: ...one check the continuity of the grey black cable between the fuse box No 3 10 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Schema valido dal numero di telaio ZAPM4510000001579 in poi Vespa GTS 250 I E Injection INJEC 41 ...

Page 206: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injection Vespa GTS 250 I E INJEC 42 ...

Page 207: ...de connector disconnected and the coolant temperature sensor connector connected check the resistance between pins 9 and 19 correspond with the engine temperature 20 2500 100 Ω 80 308 6 Ω With the control unit side connector disconnected and the coolant temperature connector discon nected check the insulation between the two light blue green and grey green cables Vespa GTS 250 I E Injection INJEC ...

Page 208: ...ol of the idling This regulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper and the variation of the ignition advance The throttle body after the pre calibration has an opened valve with angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor ...

Page 209: ...nostic tester on TPS RESET Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve is supporting the stop screw Guaranteeing that this position will be kept give the confirmation for the TPS reset procedure Vespa GTS 250 I E Injection INJEC 45 ...

Page 210: ...INIMUM OPENING MAKE THE AIR FLOW DIFFERENT FROM THAT OF PRE CALIBRATION Given that the TPS resetting is also done when the control unit is replaced place the control unit filter box bellows at 45 during the refitting operation as shown in the photograph Lambda probe Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578 Per i telai successivi consultare la pag...

Page 211: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Vespa GTS 250 I E Injection INJEC 47 ...

Page 212: ...nsor only works at high temperatures it has an electric preheating element inside it controlled by the control unit to take it quickly to the functioning state Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Check that the injection load 10A fuse No 3 is in good conditions Check that the 7 5A fuse No 2 for the live control unit is in good conditions Check the pres...

Page 213: ...ng coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box under the saddle hinge and the remote control base and of the Black Violet cable between pin 20 of the control unit and the remote control base N B CONTINUITY T...

Page 214: ...l base and earth If there is none check the continuity of the grey black cable between the fuse box No 3 10 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection Vespa GTS 250 I E INJEC 50 ...

Page 215: ...Schema valido dal numero di telaio ZAPM4510000001579 in poi Vespa GTS 250 I E Injection INJEC 51 ...

Page 216: ...tion Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injection Vespa GTS 250 I E INJEC 52 ...

Page 217: ... down to 2 V Place the tips of the multimeter between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between 0V and 1V With the throttle valve completely open the volt age is approx 1V During the closing phase the voltage is approx 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits...

Page 218: ...Injection Vespa GTS 250 I E INJEC 54 ...

Page 219: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 220: ...n the pho tograph Locking torques N m Wheel fixing screw 20 25 Front wheel hub overhaul Remove the ball bearing seeger ring indicated in the photograph Extract the ball bearing using the specific tool Specific tooling 001467Y014 Extraction pliers for ø 15 mm bear ings 001467Y017 Bell for bearings outside Ø 39 mm Suspensions Vespa GTS 250 I E SUSP 2 ...

Page 221: ...s with the shielded side facing out Refit the ball bearing locking seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 x 47 mm adaptor 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch...

Page 222: ...he specified locking torque Locking torques N m Wheel fixing screw 20 25 Wheel axle nut 74 88 Steering column Removal Remove the front wheel Remove the brake calliper Loosen the screw fixing the odometer cable plate and take out the cable Remove the suspension arm housing by un screwing the three screws indicated in the photo graph Suspensions Vespa GTS 250 I E SUSP 4 ...

Page 223: ...er cable to the mudguard indicated in the photograph Remove the retainer fixing the brake piping to the front shock absorber upper plate Remove the retainer fixing the brake piping to the suspension arm Vespa GTS 250 I E Suspensions SUSP 5 ...

Page 224: ...e being careful not to scratch the plastic parts Remove the steering tube ring nut cover Use a specific tool to remove the counter ring nut the spacer washer and the ring nut of the upper disk of the fifth wheel fitting Slide off the steering tube and remove perma nently the mudguard from the suspension Specific tooling 020055Y Wrench for steering tube ring nut Suspensions Vespa GTS 250 I E SUSP 6...

Page 225: ... wheel operating from the up per part Specific tooling 020004Y Punch for removing fifth wheels from the headstock Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing fifth wheels from the headstock Refit the fifth wheel fitting and the dust guard on th...

Page 226: ...oling 020021Y Front suspension service tool Fit the two dust guard rings C on the swinging hub as shown in drawing A Connect the swinging hub to the steering tube with the guiding pin part 5 Use the specific tool fitted with part 3 on the stem and part 4 on the tool base Lubricate the pin with Z2 grease and insert it temporarily on the swinging hub move the tool handgrip until part 3 is fully inse...

Page 227: ...e shown in the figure to refit the second wedging washer roller casing sealing ring unit To position roller casings on the pin pin end in contact with the internal bottom of the roller cas ings proceed as follows Use the tool with part 20 and 21 fitted to the stem as indicated in the figure Push the two roller casings with the handgrip until their bottoms make contact with the pin end Use the spec...

Page 228: ...mps Refitting To refit carry out the removal operations in reverse order observing the prescribed tightening torques Locking torques N m shock absorber lower clamp 20 27 Nm shock absorber upper clamp 20 30 Shock absorber calliper bracket Remove the front wheel hub with the brake disc Remove the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Suspensions...

Page 229: ...ower clamp 20 27 Overhaul The bracket for the shock absorber calliper at tachment has two roller bearings separated one from the other as shown in the photograph Remove the two roller bearings from the bracket with the specific tool operating on the shock ab sorber attachment side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Rem...

Page 230: ... mm adaptor Assemble a new roller bearing on the shock ab sorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch Suitably hold the brake calliper shock absorber attachment bracket Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch Rear Suspensions Vespa GTS 250 I E SUSP 12 ...

Page 231: ...y out the removal operations but in reverse order observing the prescribed torques Locking torques N m Wheel fixing screws 20 25 Nm Swing arm Removal Place the scooter on its centre stand Remove the engine housing Remove the swinging arm engine fitting shown in the photo Move the engine back remove the spring anchoring the swinging arm to the frame as shown in the photo Vespa GTS 250 I E Suspensio...

Page 232: ...the buffer support bracket to the frame Remove the left and right caps located under the footrest to reach the pin fixing the swinging arm to the body Remove the pin Then remove the swinging arm Suspensions Vespa GTS 250 I E SUSP 14 ...

Page 233: ...sing a feeler gauge Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm To check the clearance on the frame side arm mount the retainer using the pin fixing the swinging arm to the frame and two adaptor rings of the ap propriate tool 020229Y Alternatively use two washers with inner diameter for 12 mm pins min outer diameter 30 mm min thickness 4 mm Check there is no sti...

Page 234: ...ion the bearings with the O rings facing outwards Specific tooling 020244Y 15 mm diameter punch 020115Y Ø 18 punch Characteristic Length of the swinging arm tube on the engine side L 175 3 0 3 0 Length of the internal swinging arm spacer on the engine side L 183 0 3 0 Engine side swinging arm plastic bushing shim 3 5 0 05 mm Frame side swinging arm plastic bushing shim 3 5 0 05 mm Length of the in...

Page 235: ...the most protruding part pointing towards the silent block side as shown in the photograph Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 of the swinging arm Make sure the silent bloc is not broken If there is replace it Remove the seeger ring shown in the photograph Remove th...

Page 236: ...rt Install a new silent bloc making sure it aligns properly with the reference tooth Fit the silent blocs making sure the chamfered part of the silent bloc matches the chamfered part of the bracket Using the appropriate tool fit the silent bloc as shown in the photo Refitting To refit perform the removal operations in reverse Grease the bearings and the rolling parts with the recommended grease Su...

Page 237: ...nd remove the luggage rack lift the engine a little with a jack so as to free the two shock absorbers remove the muffler assembly undo the shock absorber spring assembly clamp ing screw from the support fixed to the engine on the one side and from that fixed to the muffler on the other undo the two upper nuts one on each side fixing the shock absorber spring assembly to the frame and remove the sh...

Page 238: ...emoval operation being careful to respect the torques indicated and the spacer assembly layout as shown in the photo Locking torques N m Bracket fixing screws to the engine crankcase 20 25 Nm Shock absorber lower clamp 33 41 Wheel axle clamping 104 126 Nm Centre stand REMOVAL Use a jack to support the vehicle properly Remove the two return springs from the centre stand Undo the nut shown in the fi...

Page 239: ...return spring Remove the screw shown in the photograph FITTING To refit carry out the removal operations in re verse order and comply with the specified torque Locking torques N m Side stand fixing bolt 35 40 Vespa GTS 250 I E Suspensions SUSP 21 ...

Page 240: ...Suspensions Vespa GTS 250 I E SUSP 22 ...

Page 241: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 242: ...R BEFORE REMOV ING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMP TIED THE SYSTEM OF THE CIRCUIT BEING EXAMINED Overhaul Remove the rear brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupling screws as shown in the photo Remove the two pistons from the calliper body with the aid of short blasts of comp...

Page 243: ...torque Locking torques N m Calliper coupling screw 30 33 Nm Refitting Insert the brake pads in the calliper Insert the pad fixing pin and the retention screw being careful to position the terminals of it pointing towards the bleed screw as shown in the photo Insert the clip on the pad fixing pin N B FAILURE TO RESPECT THE PAD POSITION ING REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COUL...

Page 244: ...h elastic washer at the prescribed tor que as shown in the photograph Fix the brake pipe joint to the calliper and tighten at the prescribed torque Bleed the system and refit the rear wheel Locking torques N m Brake calliper support clamping 20 25 Nm Brake pipe connection 20 to 25 N m Front brake calliper Braking system Vespa GTS 250 I E BRAK SYS 4 ...

Page 245: ...ove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons 6 5 Check that the plates and the body are whole and in good condition that the cylinder and the floating b...

Page 246: ...ert the following on the front brake body The sealing rings and the pistons 1 Refit the plate 2 Arrange the pad holding clamp 3 Refit the pads and bleed air Place the calliper on the disk and lock it to the support by tightening the bolts at the prescribed torque Lock the pipe joint to the calliper at the prescribed torque Follow the same procedure for the rear brake cal liper Locking torques N m ...

Page 247: ...alliper Check the disc thickness with a micrometer Characteristic Minimum thickness allowed after use 3 5 mm Standard thickness 4 0 2 0 2 mm Repeat the measurement at no fewer than six points on the disc Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed onto the brake calliper as shown in the photo In order to be able to anchor the appropriate too...

Page 248: ...sts replace the hub Front brake disc Removal Remove the front wheel Remove the front brake calliper Remove the hub and the disc operating on the wheel axle nut Hold the hub and the disc firmly and remove the brake disc undoing the six screws indicated in the photograph Braking system Vespa GTS 250 I E BRAK SYS 8 ...

Page 249: ... the photograph Repeat the measurement in at least 6 points on the disk Remove the front brake calliper In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it to one of the two front brake calliper attachment points Place the dial gauge on the disk outer edge Make the wheel hub turn and check the disk de viation Specific tooling 020335Y Magnetic suppo...

Page 250: ...there is replace it Check the thickness of the friction material is more than 1 5 mm If it is not replace it The replacement must be made with greater re sidual thickness if the pad has not worn evenly A 0 5 mm thickness difference in the residual friction material is permitted Refitting To fit proceed as follows Insert the two pads in the callipers Braking system Vespa GTS 250 I E BRAK SYS 10 ...

Page 251: ...e 243 threadlock Locking torques N m Screw tightening calliper to the support 24 27 Pad fastening pin 19 6 24 5 Rear brake pads Removal Remove the rear brake calliper Remove the brake pad and check there are no faults or warping If there is replace it Check the thickness of the friction material is more than 1 5 mm If it is not replace it The replacement must be made with greater re sidual thickne...

Page 252: ...ered With the left had brake lever load the system and bring it up to the required pressure Keeping the left hand brake lever pulled loosen the bleed screw to permit the air in the system to escape Then do up the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recovery pipe and refit the rubber hood over the bleed screw Top up the brake fluid t...

Page 253: ...vel check Position the vehicle on a flat surface and on the centre stand Remove the brake pump cover as indicated in the photo Use the appropriate spyglass on the pump to check the level of the brake fluid as shown in the photograph If the level is below the minimum fill using the two screws shown in the figure Remove the gasket and fill with DOT 4 until the spyglass is completely covered CAUTION ...

Page 254: ...ng torques N m Brake pump reservoir screws 1 5 2 Never use brake liquid in open or partially used containers Under normal climatic conditions the fluid must be changed every 20 000 km or anyway every two years For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws Front brake pump Removal Remove the...

Page 255: ...cap 4 and take out the internal parts in order 3 Check that The pump body shows no signs of internal damage or corrosion The plunger shows no sign of damage or abnormal wear The plunger return spring is in good condition CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED Vespa GTS 250 I E Braking system BRAK SYS 15 ...

Page 256: ... 7 Gasket 8 Spring 9 Reservoir Refitting To refit carry out the removal operations but in reverse order observing the specified torques Locking torques N m Oil pipe joint to the pump 20 25 Brake pump fixing screws to the handle bar 7 10 Nm Braking system Vespa GTS 250 I E BRAK SYS 16 ...

Page 257: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 258: ...les inside the circuit Tighten the bleed valve respecting the maximum torque Bring the coolant up to the correct level inside the expansion tank Locking torques N m Bleed screw 3 Check 1 Look to see that the thermostat is not damaged 2 Fill a metal container with approx 1 litre of wa ter Immerse the thermostat and keep it in the centre of the container Immerse the multimeter temperature probe and ...

Page 259: ...NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check Opening start temperature 69 5 72 5 C Vespa GTS 250 I E Cooling system COOL SYS 3 ...

Page 260: ...Cooling system Vespa GTS 250 I E COOL SYS 4 ...

Page 261: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 262: ...e two screws shown in the photograph Remove the saddle Remove the helmet compartment Remove the 2 nuts indicated in the photograph Free the electric cables form the retaining clamps indicated in the photograph Remove the saddle opening transmission cable Remove the saddle manual opening transmis sion cable Chassis Vespa GTS 250 I E CHAS 2 ...

Page 263: ...e photograph Remove the clip from the transmission Remove the actuator from the supporting bracket Rear rack Remove the helmet compartment Remove the 4 screws indicated in the figure Remove the two screws indicated in the figure that fix the luggage rack to the body Vespa GTS 250 I E Chassis CHAS 3 ...

Page 264: ...e Remove the rear handlebar cover after detaching the electrical wires Instrument panel Remove the rear handlebar cover Remove the four screws indicated in the figure Remove the instrument panel Front handlebar cover Remove the front grille Remove the front screw indicated in the figure Chassis Vespa GTS 250 I E CHAS 4 ...

Page 265: ...indicated in the figure to re move the front turn indicator Knee guard Remove the rear handlebar cover Remove the two screws indicated in the photo graph and located on the shield under the grille Remove the expansion tank cover and then its cap Remove the central screw inside the glove box indicated in the photograph Vespa GTS 250 I E Chassis CHAS 5 ...

Page 266: ...he left cover respectively Remove the shield back plate lower screws to the right and left side of the shield back plate as indicated in the photograph Remove the electric saddle opening switch the fuse box and the manual saddle opening cable as shown in the photograph Chassis Vespa GTS 250 I E CHAS 6 ...

Page 267: ... THIS DOES NOT IN DICATE A FAULT AND IS RELATED TO THE HUMIDITY AND OR TO LOW TEMPERATURES THE PHENOMENON SHOULD QUICKLY DIS APPEAR WHEN THE LIGHT IS SWITCHED ON THE PRESENCE OF WATER DROPS ON THE OTHER HAND COULD INDICATE THAT WA TER IS INFILTRATING CONTACT THE PIAG GIO AFTER SALES SERVICE NETWORK Footrest Remove the shield back plate Remove the battery compartment cover Remove the side fairings ...

Page 268: ...figure Remove the right and left screws fixing the foot rest indicated in the figure Remove the right and left lower covers as shown in the figure Remove the screws under the non slip rubber mat of the footrest as indicated in the photograph Chassis Vespa GTS 250 I E CHAS 8 ...

Page 269: ...the helmet compartment Remove the side fairings Remove the muffler Remove the luggage rack Remove the shock absorber upper clamps Remove the two screws indicated in the figure that fix the tank to the body Remove the screw indicated in the figure that fixes the tank to the body after removing the rear head light assembly Vespa GTS 250 I E Chassis CHAS 9 ...

Page 270: ... perform the steps in the reverse direction to disassembly Rear central cover Remove the four screws indicated in the figure Front mudguard First remove the steering tube and uncouple the front brake pipes from the calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Chassis Vespa GTS 250 I E CHAS 10 ...

Page 271: ... body Detach the radiator Detach the pipe from the plastic duct by removing the plastic clip shown in the photograph Then re move the duct The same procedure also applies to the left ra diator for which it is necessary to remove the elec trical fan first by undoing the 3 screws indicated in the photograph To refit perform the removal operations but in reverse order being careful when positioning t...

Page 272: ...Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Chassis Vespa GTS 250 I E CHAS 12 ...

Page 273: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 274: ...wheel screws Front and rear wheel hub nut Front and rear brake calliper clamping screws Frame swinging arm bolt Swinging arm bolt Engine Engine arm pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Main switch Lights high beams low beams side taillights front and rear and relevant warning lights Regulating the headlights according to the regulations...

Page 275: ...SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION THE BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH ...

Page 276: ...ATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check frame and engine number check tools and equipment licence plate fitting lock check tyre pressure check rear view mirror and a...

Page 277: ...INDEX OF TOPICS TIME TIME ...

Page 278: ...n code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine from frame Removal and refit 2 003064 Engine oil change Crankcase CRANKCASE Code Action Duration 1 001153 Crankcase halves gasket Replacement 2 001133 Engine crankcase Replace ment Time Vespa GTS 250 I E TIME 2 ...

Page 279: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Vespa GTS 250 I E Time TIME 3 ...

Page 280: ...linder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replace ment 2 001154 Pin ring piston unit Service 3 001129 Chain tightener Overhaul and replacement Time Vespa GTS 250 I E TIME 4 ...

Page 281: ...D Code Action Duration 1 001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves Adjustment 4 001056 Head gasket Replacement 5 001083 Thermistor Replacement 6 001057 Thermostat Replacement Vespa GTS 250 I E Time TIME 5 ...

Page 282: ...Rocker arms support assy CAM SHAFT Code Action Duration 1 001148 Rocking lever valve Re placement 2 001044 Camshaft Replacement Cylinder head cover Time Vespa GTS 250 I E TIME 6 ...

Page 283: ...placement 3 001088 Head cover gasket Replace ment 4 001074 Oil vapour recovery pipe Re placement Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor Re placement 3 001102 Net oil filter Replacement Cleaning Vespa GTS 250 I E Time TIME 7 ...

Page 284: ...ion 1 001087 Flywheel cover replace 2 001150 Flywheel cover gasket Re placement 3 007007 Water pump rotor cover 4 007017 Water pump cover Replace ment 5 007003 Coolant delivery and return pipe Replacement Driven pulley Time Vespa GTS 250 I E TIME 8 ...

Page 285: ...ll Replacement Oil pump OIL PUMP Code Action Duration 1 001125 Chain guide pads Replace ment 2 001051 Belt Timing chain Change 3 001042 Oil pump Service 4 001112 Oil pump change 5 001122 Oil pump chain Replace ment 6 001130 Oil sump Replacement 7 001172 Chain cover flap change 8 001124 Lubrication by pass Re placement Vespa GTS 250 I E Time TIME 9 ...

Page 286: ...L REDUCTION Code Action Duration 1 001010 Reduction gear Replace ment 2 003065 Gear box oil Replacement 3 001156 Geared reduction unit cover Replacement 4 004125 Rear wheel axle Replace ment Time Vespa GTS 250 I E TIME 10 ...

Page 287: ...tion 1 001086 Driving half pulley Replace ment 2 001011 Driving belt Replacement 3 001066 Drive pulley Removal and refitting 4 001177 Variator rollers shoes Re placement 5 001141 Belt anti flapping roller Re placement Vespa GTS 250 I E Time TIME 11 ...

Page 288: ... Code Action Duration 1 001135 Transmission cover bearing Replacement 2 001096 Transmission crankcase cov er Replacement 3 001131 Transmission air intake Re placement 4 001065 Transmission cover Re placement Time Vespa GTS 250 I E TIME 12 ...

Page 289: ...AL START UP Code Action Duration 1 001020 Starter motor Replacement 2 001104 Start up freewheel Replace ment 3 001151 Start up driven gearing Re placement 4 001017 Start up pinion Replace ment Vespa GTS 250 I E Time TIME 13 ...

Page 290: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001067 Stator Removal and Refit ting 2 001173 Rotor Replacement 3 001058 Complete flywheel Replace ment Time Vespa GTS 250 I E TIME 14 ...

Page 291: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Replacement 2 001047 Injector Replacement 3 001013 Intake manifold change Vespa GTS 250 I E Time TIME 15 ...

Page 292: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 005138 Lambda probe Replace ment Time Vespa GTS 250 I E TIME 16 ...

Page 293: ...Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Air cleaner carburettor fitting Replacement 4 001027 Body air cleaner union Re placement Vespa GTS 250 I E Time TIME 17 ...

Page 294: ...placement 2 004085 Fairing 1 Replacement 3 004149 Shield central cover Re placement 4 004053 Spoiler Replacement 5 004015 Footrest Removal and Re fitting 6 004023 Shield rim Replacement 7 004159 Plates Stickers Replace ment Time Vespa GTS 250 I E TIME 18 ...

Page 295: ...Centre stand STAND Code Action Duration 1 004102 Side stand Replacement 2 004004 Stand Replacement Footrests Vespa GTS 250 I E Time TIME 19 ...

Page 296: ...nt 2 004071 Battery compartment re placement 3 004078 Front rear footrest rubber Replacement 4 005046 Battery cover change Rear cover REAR SHIELD Code Action Duration 1 004083 Glove box Replacement 2 004081 Glove box door Replace ment Time Vespa GTS 250 I E TIME 20 ...

Page 297: ...Underseat compartment UNDERSADDLE Code Action Duration 1 004016 Helmet compartment Re moval and Refitting 2 004011 Central chassis cover re place Vespa GTS 250 I E Time TIME 21 ...

Page 298: ...Plate holder LICENCE PLATE HOLDER Code Action Duration 1 004136 License plate support re place 2 005048 Licence plate holder Re placement Time Vespa GTS 250 I E TIME 22 ...

Page 299: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replace ment 2 004009 Rear mudguard Replace ment 3 003044 Shock absorber cover Re placement Vespa GTS 250 I E Time TIME 23 ...

Page 300: ...Code Action Duration 1 004005 Fuel tank Replacement 2 005010 Tank float Replacement 3 004109 Fuel tank breather change 4 004073 Fuel pump Replacement 5 004137 Injector pump pipe Replace ment Time Vespa GTS 250 I E TIME 24 ...

Page 301: ...mplete with support Replacement 3 007001 Expansion tank Replace ment 4 001052 Coolant and air bleed Re placement 5 007013 Expansion tank radiator connecting hose Replace ment 6 007003 Delivery line and coolant re turn Replacement 7 001170 Air duct Replacement Vespa GTS 250 I E Time TIME 25 ...

Page 302: ...Rear shock absorber REAR SHOCK ABSORBERS Code Action Duration 1 003007 Rear shock absorber Re moval and Refitting 2 003077 muffler rear shock absorber support arm Service Time Vespa GTS 250 I E TIME 26 ...

Page 303: ...Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheel Re placement 2 003073 Steering clearance Adjust Vespa GTS 250 I E Time TIME 27 ...

Page 304: ...Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004018 Front handlebar covers Re placement 2 004019 Rear handlebar covers Re placement Time Vespa GTS 250 I E TIME 28 ...

Page 305: ...ump Removal and refitting 4 005017 Stop switch Replacement 5 002059 Right hand knob change 6 002071 Left hand grip Replacement 7 003059 Counterweight Replace ment 8 002060 Throttle grip Replacement 9 002063 Throttle control transmission Replacement 10 003061 Accelerator transmission adjust 11 002037 Brake or clutch lever Re placement Vespa GTS 250 I E Time TIME 29 ...

Page 306: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chas sis connection Replacement 2 004058 Silent block Replacement Time Vespa GTS 250 I E TIME 30 ...

Page 307: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Instrument panel Vespa GTS 250 I E Time TIME 31 ...

Page 308: ...ght switch or turn indicators Replacement 6 005040 Horn button Replacement 7 005121 Saddle opening button Re placement 8 005039 Headlight switch replace 9 005078 Odometer glass Replace ment 10 005038 Instrument panel warning light bulbs Replacement 11 005076 Clock battery Replacement Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement Time Vespa GTS 250 I E TIME 32 ...

Page 309: ...er hook transmission Replacement 3 004158 Saddle opening splitter Re placement 4 005072 Immobilizer aerial Replace ment 5 005099 Electric saddle opening de vice Replacement 6 004054 Saddle lock catch Replace ment 7 004010 Anti theft lock Replacement 8 005016 Key switch Replacement Vespa GTS 250 I E Time TIME 33 ...

Page 310: ...5139 Tail light bulb Replacement 5 005008 Front headlamp bulbs Re placement 6 005012 Front turn indicator Re placement 7 005090 Stop light bulb Replacement 8 005140 Front light Replacement 9 005022 Rear turn indicators replace 10 005068 Rear turn indicator bulb Re placement 11 005066 Rear light bulbs Replace ment 12 005028 Rear light assembly glass Replacement Time Vespa GTS 250 I E TIME 34 ...

Page 311: ...EL Code Action Duration 1 003047 Front tyre replace 2 003037 Front wheel rim Replace ment 3 004123 Front wheel Replacement 4 003033 Front wheel hub Replace ment 5 002041 Brake disc Replacement Vespa GTS 250 I E Time TIME 35 ...

Page 312: ...n Duration 1 004126 Rear wheel tyre Replace ment 2 001071 Front wheel rim Removal and refitting 3 001016 Rear wheel Replacement 4 002028 Rear wheel hub Replace ment 5 002070 Rear brake disc Replace ment Time Vespa GTS 250 I E TIME 36 ...

Page 313: ...005052 Fuse 1 Replacement 6 005007 Battery Replacement 7 005120 Control unit power supply re mote control Replacement 8 005035 Headlight remote control Replacement 9 005117 Electrical fan remote control Replacement 10 005011 Start up remote control switch Replacement 11 005054 Fuse block 1 Replacement 12 005001 Electrical system Removal and refitting Vespa GTS 250 I E Time TIME 37 ...

Page 314: ...Transmissions TRANSMISSIONS Code Action Duration 1 002051 Odometer transmission as sembly Replacement Time Vespa GTS 250 I E TIME 38 ...

Page 315: ... absorber Re moval and Refitting 2 003045 Steering tube Replacement 3 003010 Front suspension Service 4 003035 Shock absorber support and brake calliper Replacement 5 003034 Front wheel hub bearing Re placement 6 001064 Odometer reel Replace ment Vespa GTS 250 I E Time TIME 39 ...

Page 316: ...eplace ment 3 002021 Front brake piping Replace ment 4 002047 Front brake fluid and air bleeding system Replace ment 5 002020 Rear brake disc piping Re placement 6 002080 Rear brake oil bleeding sys tem Replacement 7 002002 Rear brake pads replace 8 002048 Rear brake calliper Re placement Time Vespa GTS 250 I E TIME 40 ...

Page 317: ...Stickers TRANSFERS Code Action Duration 1 004159 Plates Stickers Replace ment Vespa GTS 250 I E Time TIME 41 ...

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VESPA GTS 250 I.E., Workshop Manual

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