VESPA GTS Super 125 i.e. (2009) Service Manual Download

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This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well-

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water

and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed 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 spare parts may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. Using unsuitable

coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

sure the electric connections have been made properly, particularly the ground and battery connections.

Vespa GTS Super 125 i.e. (2009)

Characteristics

CHAR - 7

Summary of Contents for GTS Super 125 i.e. (2009)

Page 1: ...MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 125 i e 2009 ...

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

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

Page 4: ......

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

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

Page 7: ...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 spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new...

Page 8: ... M451M 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Kerb weight 158 5 kg Maximum weight allowed 340 kg Maximum height 1170 mm Overall width 755 mm Maximum length 1930 mm Wheelbase 1370 mm Characteristics Vespa GTS Super 125 i e 2009 CHAR 8 ...

Page 9: ...ooling OIL PUMP Specification Desc Quantity Type Trochoidal Distance between the rotors Admissible limit clearance 0 12 mm Axial rotor clearance Limit values admitted 0 09 mm Distance between the outer rotor and the pump body Admissible limit clearance 0 20 mm Levelness 0 1 mm BY PASS Specification Desc Quantity Type With piston Plunger diameter Ø 13 9 0 039 0 057 mm By pass check up Standard leng...

Page 10: ...ariator with torque server V belt automatic clutch gear reduction unit and transmission compartment with forced air circulation cooling Capacities CAPACITY Specification Desc Quantity Fuel tank including a 2 l reserve 9 2 l Cooling system fluid 2 100 2 150 l Engine oil approx 1300 cc Rear hub 250 cc Electrical system ELECTRICAL COMPONENTS Specification Desc Quantity Ignition advance Electronic wit...

Page 11: ...the remote control powered check that there is continuity between terminals 30 and 87 4 If these conditions are not fulfilled the remote control is damaged and must be replaced To check buttons and switches check that according to their position the continuity of contacts is correct as indicated in the following charts TURN INDICATOR SWITCH ENGINE STOP SWITCH HORN BUTTON Vespa GTS Super 125 i e 20...

Page 12: ...LIGHT SWITCH STARTER BUTTON KEY SWITCH FUEL INJECTOR Type 3 holes Conicity of the nozzle 20 Resistance at terminals 13 7 to 15 2 Ohm Characteristics Vespa GTS Super 125 i e 2009 CHAR 12 ...

Page 13: ...GINE TEMPERATURE SENSOR 0 5900 Ohm 10 3800 Ohm 20 2500 Ohm 30 1700 Ohm 80 300 Ohm MINIMUM OIL PRESSURE SENSOR Normally closed switch Activation threshold 0 3 0 6 bar With the engine off continuity between terminal and ground HV COIL DIV class O v shape _x0000_s3074 Resistance of the primary 0 5 Ohm 8 Resistance between primary and ground infinite Resistance between primary and HV output 3 1 KOhm 9...

Page 14: ...k absorber axial travel 86 5 mm Rear suspension Engine with swinging fork articulated to frame by means of an arm with 2 degrees of freedom Pair of double acting hydraulic shock absorbers and coaxial springs with preloading adjust ment in 4 positions Rear shock absorber axial travel 89 5 mm Brakes BRAKES Specification Desc Quantity Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plu...

Page 15: ...ery Operations Fixing screws for the handlebar control unit U bolts 7 10 FRAME ASSEMBLY Name Torque in Nm Engine swinging arm pin 64 72 swinging arm bolt body shell 76 83 Engine and vehicle side swinging arm junction bolt 33 to 41 Bolt of the Silent block support plate 42 52 Centre stand bolt 32 40 Side stand fixing bolt 35 40 FRONT SUSPENSION Name Torque in Nm Screw fixing the shock absorber to t...

Page 16: ...htening on exhaust manifold 40 to 50 Exhaust manifold muffler joint tightening 12 13 Manifold muffler diaphragm tightening clamp 16 to 18 LUBRICATION Name Torque in Nm Hub oil drainage plug 15 to 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 command crown screw 10 14 ...

Page 17: ... Nm Internal engine crankcase bulkhead transmission 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 to 4 Thermostat cover screws 3 to 4 Bleed screw 3 Overhaul data Assembly clearances Cylinder piston assy Calculate the coupling...

Page 18: ...T BE MADE ACCORDING TO THE PISTON AXIS Characteristic Standard clearance 0 001 0 010 mm Check that coating is free from flakes Check that the head matching surface exhibits no deformations or wear Characteristic Maximum allowable run out 0 05 mm Pistons and cylinders are classified into categories based on their diameter The coupling is carried out in pairs A A B B C C D D Characteristics Vespa GT...

Page 19: ...ting clearance Check the size of the sealing ring opening Compression ring 0 15 0 30 mm Max value 0 5 mm Oil scraper ring 0 10 0 30 mm Max value 0 65 mm Oil scraper ring 0 15 0 35 mm Max value 0 65 mm N B FITTING CLEARANCE VALUES ARE THE SAME FOR BOTH THE STANDARD SEALING RINGS AND THE OVERSIZES Vespa GTS Super 125 i e 2009 Characteristics CHAR 19 ...

Page 20: ...inder 2nd Oversize A2 57 397 to 57 404 57 345 57 352 0 045 0 059 Cylinder 2nd Oversize B 2 57 404 to 57 411 57 352 57 359 0 045 0 059 Piston 2nd Oversize C 2 57 411 to 57 418 57 359 57 366 0 045 0 059 Piston 2nd Oversize D 2 57 418 to 57 425 57 366 57 373 0 045 0 059 Cylinder 3rd Oversize A 3 57 597 to 57 604 57 545 57 552 0 045 0 059 Cylinder 3rd Oversize B 3 57 604 to 57 611 57 552 57 559 0 045 ...

Page 21: ... If the crankshaft is within the set limits replace the crankshaft half bearings mounting the crankcase so as to suit the specified couplings The crankcase halves can be mounted with four types of crankshaft half bearings identified by letters B blue C yellow E green CRANKCASE Specification Desc Quantity Category 1 32 959 35 965 Category 2 32 953 to 32 959 CRANKCASE CRANKSHAFT COUPLING CRANKSHAFT ...

Page 22: ...ANCE Name Description Dimensions Initials Quantity Transmissionside half shaft 16 6 0 0 05 A D 0 20 to 0 50 Flywheel side halfshaft 16 6 0 0 05 B D 0 20 to 0 50 Connecting rod 18 0 10 0 15 C D 0 20 to 0 50 Spacer tool 51 4 0 05 E D 0 20 to 0 50 Characteristics Vespa GTS Super 125 i e 2009 CHAR 22 ...

Page 23: ...t and Crankcase featuring the same category Cylinder Head Before performing head service operations thoroughly clean all coupling surfaces Note the position of the springs and the valves so as not to change the original position during refitting Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum allowable run out 0 09...

Page 24: ...re meter HEAD BEARINGS Specification Desc Quantity Bearing A 37 0 025 Bearing B 20 0 021 Bearing C 12 0 018 Measure the unloaded spring length Characteristic Standard length 40 5 mm Allowable limit after use 39 7 mm Clean the valve seats of any carbon residues Using the Prussian blue check the width of the impression on the valve seat V Characteristic Admissible limit 1 6 mm If the width of the im...

Page 25: ...cification Desc Quantity Intake 4 987 4 972 mm Exhaust 4 975 4 960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc Quantity Intake 4 96 mm Exhaust 4 945 mm Calculate the clearance between valve and valve guide Check the deviation of the valve stem by resting it on a V shaped abutment and measuring the extent of the deformation with a dial gauge Characteristic Limit values admitted 0 1 mm Vespa G...

Page 26: ...fter measuring the valve guide diameter and the valve stem diameter check clearance between guide and stem EXHAUST Specification Desc Quantity Standard clearance 0 025 to 0 052 mm Admissible limit 0 09 mm INTAKE Specification Desc Quantity Standard clearance 0 013 0 04 mm Admissible limit 0 08 mm Check that there are no signs of wear on the surface of contact with the articulated register terminal...

Page 27: ...CE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT Check that the camshaft bearings exhibit no scores or abnormal wear Using a micrometer measure the camshaft bearings STANDARD DIAMETER Specificatio...

Page 28: ...130 mm Exhaust 16 310 mm standard axial clearance 0 11 0 41 mm maximum admissible axial clearance 0 42 mm Check that the rocking lever pins exhibit no scores or wear Characteristic Standard diameter Diameter 11 977 11 985 mm Measure the inside diameter of each rocking lever Characteristic Standard diameter Ø 12 0 011 mm Characteristics Vespa GTS Super 125 i e 2009 CHAR 28 ...

Page 29: ...ston crown protrudes from the plane formed by the upper part of the cylinder The further the piston protrudes from the cylinder the thicker the base gasket to be used to restore the compression ratio and vice versa N B NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PI...

Page 30: ... 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased 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 AGIP PERMANENT SPEZIAL coolan...

Page 31: ...INDEX OF TOPICS TOOLING TOOL ...

Page 32: ...017 Bell for bearings OD 39 mm 001467Y014 Pliers to extract ø 15 mm bearings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer ing tube 020004Y Punch for removing fifth wheels from headstock Tooling Vespa GTS Super 125 i e 2009 TOOL 32 ...

Page 33: ...1Y Front suspension service tool 020036Y Punch 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater mounting Vespa GTS Super 125 i e 2009 Tooling TOOL 33 ...

Page 34: ...eater 020193Y Oil pressure check gauge 020262Y Crankcase splitting plate 020263Y Driven pulley assembly sheath 020306Y Punch for assembling valve seal rings 020329Y Mity Vac vacuum operated pump Tooling Vespa GTS Super 125 i e 2009 TOOL 34 ...

Page 35: ...Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator 020648Y Single battery charger Vespa GTS Super 125 i e 2009 Tooling TOOL 35 ...

Page 36: ... Description 020335Y Magnetic mounting for dial gauge 020357Y 32x35 mm Adaptor 020359Y 42x47 mm Adaptor 020360Y 52x55 mm Adaptor 020363Y 20 mm guide 020364Y 25 mm guide Tooling Vespa GTS Super 125 i e 2009 TOOL 36 ...

Page 37: ...2 mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band Vespa GTS Super 125 i e 2009 Tooling TOOL 37 ...

Page 38: ...5 mm guide 020423Y Driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting Tooling Vespa GTS Super 125 i e 2009 TOOL 38 ...

Page 39: ...1Y 26 x 28 mm adaptor 020444Y Tool for fitting removing the driven pulley clutch 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30 mm guide 020489Y Hub cover support stud bolt set Vespa GTS Super 125 i e 2009 Tooling TOOL 39 ...

Page 40: ...osition check mounting 020680Y Diagnosis Tool 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Bearing housing outside ø 47 mm 020626Y Driving pulley lock wrench Tooling Vespa GTS Super 125 i e 2009 TOOL 40 ...

Page 41: ...tract ø 15 mm bearings 020627Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops 200 250 020622Y Transmission side oil guard punch 020480Y Petrol pressure check set Vespa GTS Super 125 i e 2009 Tooling TOOL 41 ...

Page 42: ...ode Description 020244Y 15 mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing fitting silent bloc 020469Y Reprogramming kit for vehicle diagnostic tester Tooling Vespa GTS Super 125 i e 2009 TOOL 42 ...

Page 43: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 44: ... A A Brake pads I I I I I I I I I I I I I Sliding blocks variable speed rollers R R R R R R Tyre pressure and wear I I I I I I I Vehicle test ride I I I I I I I Radiator external cleaning I I I I Suspension I I I I I I I Steering A A A A A A A Transmissions L L L L MAINTENANCE TABLE TIME Km x 1000 1 5 10 15 20 25 30 35 40 45 50 55 60 Operation Time 60 10 100 45 150 10 140 10 150 45 100 10 190 Spar...

Page 45: ...IC IGNITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERI OUSLY DAMAGE THE ENGINE Characteristic Electrode gap 0 7 to 0 8 mm Electric characteristic Spark plug NGK CR8EKB Locking torques N m Spark plug 12 to 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 put it back into its hole tightening it complet...

Page 46: ...ng 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 reached once the helmet compartment has been removed 6 Unscrew the screws D and remove the air fil ter cover Remove the filtering element and clean it with wa ter and shampoo then dry it with a clean cloth and short blasts of compressed air Finally ...

Page 47: ...should be con sidered normal especially if during the run in period Consumption levels in particular can be influenced by the conditions of use e g oil consumption increases when driving at full throttle Replacement At 1 000 km and after every 10 000 km the oil and the filter must be changed The engine must be drained by running off the oil from drainage cap B of the flywheel side gauze pre filter...

Page 48: ... operation must be carried out with the engine cold and following the procedure below 1 Place the vehicle on its centre stand and on flat ground 2 Undo cap dipstick A dry it off with a clean cloth and replace it screwing down completely 3 Remove the cap dipstick again and check that the level is between the min and max marks top up if required The MAX level mark indicates a quantity of around 1300...

Page 49: ...pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the ON position However this light should switch off once the engine has been started If the light turns on during braking at idling speed or while turning a corner it is necessary to check the oil level and the lubrication system Cooling system Adding engine coolant...

Page 50: ... the front and rear brakes are located on the pumps under the handlebar cover Proceed as follows Remove the brake pump cover Rest the vehicle on its centre stand with the han dlebars perfectly horizontal Check the fluid level through the sight glass 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 s...

Page 51: ...N CASE OF ACCIDENTAL CONTACT WASH WITH WATER CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE THEREFORE WHEN TOPPING IT UP AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE THE BRAKING CIRCUIT FLUID IS HYGRO SCOPIC THAT IS IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE THIS WILL RESULT IN INEFFICIENT BRAKING...

Page 52: ...the headlight and check that the bor derline of the projected light beam on the screen is not higher than 9 10 or lower than 7 10 of the distance from the ground to the centre of vehicle headlamp 3 If otherwise adjust the right headlight with screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATION...

Page 53: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 54: ...ss and replace if required Carefully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level adding the recommended oil type Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operati...

Page 55: ...ing even after making the above adjustments check the seats in which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above adjustme...

Page 56: ...L LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments Troubleshooting Vespa GTS Super 125 i e 2009 TROUBL 56 ...

Page 57: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 58: ...ht bulbs and license plate light 18 Headlight with twin filament bulb 19 Pre installation for anti theft device 20 Turn indicator bulbs 21 Turn indicator switch 22 Turn indicator control device 23 Instrument panel 24 Fuel level transmitter 25 Oil pressure sensor 26 Headlight remote control 27 Fuse 7 5A 28 Fuse 7 5A 29 Fuse 15A 30 Fuse 7 5A 31 Fuse 7 5A 32 Horn button 33 Horn 34 Injection load remo...

Page 59: ...ure sensor 43 Diagnostics socket 44 Fuel supply pump 45 Injector ECU 46 Immobilizer aerial 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 Components arrangement Vespa GTS Super 125 i e 2009 Electrical system ELE SYS 59 ...

Page 60: ...ove the helmet compart ment to reach it 11 Diagnosis connector Remove the helmet compartment to reach it 15 HV coil Remove the battery to reach it to re move the coil first remove the footrest and undo the two screws indicated Electrical system Vespa GTS Super 125 i e 2009 ELE SYS 60 ...

Page 61: ...over to reach them 23 Remote control switches Remove the front central cover and the helmet compartment to reach them 22 26 Main fuses Open the front top box and the battery cover to reach them Vespa GTS Super 125 i e 2009 Electrical system ELE SYS 61 ...

Page 62: ...to flywheel Remove the flywheel cov er as described in the Engine chapter to reach it To get access to the connectors remove the helmet compartment 40 Key switch contacts Remove the shield back plate to reach them Electrical system Vespa GTS Super 125 i e 2009 ELE SYS 62 ...

Page 63: ...remove the fixing bracket together with the actuator 8 Fuel level transmitter Remove the fuel tank to reach it 7 Oil pressure sensor Remove the right side fairing to reach it 22 Battery Remove the rear central cover to reach it Conceptual diagrams Vespa GTS Super 125 i e 2009 Electrical system ELE SYS 63 ...

Page 64: ...recharge and starting 1 Magneto flywheel 2 Voltage regulator 3 12V 12Ah Battery 4 Start up remote control switch 5 Starter motor 6 Starter button 7 30A Fuse 8 15A Fuse 9 Stop light bulb 10 Key switch contacts 12 Stop buttons 30 Fuse 7 5A 31 Fuse 7 5A 45 Injector ECU Level indicators and enable signals section 3 12V 12Ah Battery 7 30A Fuse 8 15A Fuse 10 Key switch contacts 11 Engine stop switch Ele...

Page 65: ...8 15A Fuse 10 Key switch contacts 14 Key switch contacts 15 Saddle opening switch 16 Saddle opening actuator 19 Pre installation for anti theft device 20 Turn indicator bulbs 21 Turn indicator switch 22 Turn indicator control device 23 Instrument panel 28 Fuse 7 5A 29 Fuse 15A 30 Fuse 7 5A 31 Fuse 7 5A 32 Horn button 33 Horn 34 Injection load remote control 35 Electric fan remote control 36 Radiat...

Page 66: ... and inspections This section is devoted to the checks on the electrical system components Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys tem The immobilizer is an anti theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit The code is integrated in a transponder in...

Page 67: ... the flash depends on the program ming of the electronic control unit If the LED is off regardless of the position of the ignition key switch and or the instrument panel is not initiated check if there is battery voltage that fuse 1 and fuse 8 are in good con dition there is power to the control unit as specified below Remove the connector support bracket shown in the photograph and disconnect the...

Page 68: ...There is continuity between terminals 12 18 and 12 19 with the emergency cut out switch in the RUN position If there is no continuity check the con tacts of the latter If no faults are found replace the control unit After removing the shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from the connector Electrical system Vespa GTS ...

Page 69: ... is not encrypted any key will start the engine but limited to 2000 rpm The keys can only be recognised if the control unit has been programmed properly The data storage procedure for a previously un programmed control unit provides for the recogni tion of the red key master key as the first key to be stored to memory this becomes particularly important because it is the only key that enables the ...

Page 70: ...o cedure If you do not start again from the begin ning Once the system has been programmed master key transponder decoder and control unit are strictly matched With this link established it is now possible to en code new service keys in the event of losses replacements etc Each new programming deletes the previous one so in order to add or eliminate keys you must re peat the procedure using all th...

Page 71: ...not be used The LED is per manently ON in this condition no operations are possible including starting of the vehicle 3 Programmed control unit the service key in normal condition of use a single 0 7 second flash is displayed after which the LED remains off steadily The engine can be started 4 Programmed control unit Master key in a 0 7 sec flash is displayed followed by the LED re maining off for...

Page 72: ...he aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Diagnostic code 3 flashes A three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code is repeated even with the Master key replace the ...

Page 73: ...nce 0 2 1 Ω 4 Check that there is insulation between the each yellow cable and the ground 5 If values are incorrect replace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing the cover in the footrest 2 Check that the battery does not show signs of losing fluid before checking the output voltage 3 Turn the ignition key to position OFF connect the termina...

Page 74: ...n the lights and let the battery voltage set to 12V Connect ammeter pliers to the 2 recharge positive poles in output from the regulator Keep the lights on and start the engine bring it to normal speed and read the values on the ammeter With an efficient battery a value must be detected 20A VOLTAGE REGULATOR RECTIFIER Specification Desc Quantity Type Non adjustable three phase transistor Voltage 1...

Page 75: ...e control switch and the ground connec tion If there is not check the cable harnesses 5 Check the start up remote control switch 6 Check that the Red cable between the battery and the start up remote control switch is not interrupted Also check continuity between the latter and the starter motor 7 Check the starter motor ground connection 8 Check that the Orange Blue cable between the start up rem...

Page 76: ...NNECTED 1 Check fuses No 1 and 4 2 Check the key switch and horn button contacts 3 With the key switch set to ON and the horn button pressed check if there is voltage between the Yellow Pink cable of the horn device and the ground connection If there is not check the cable har nesses 4 Check the horn device ground connection Electrical system Vespa GTS Super 125 i e 2009 ELE SYS 76 ...

Page 77: ...contacts 4 With the key switch set to ON check if there is voltage between the Blue Black cable of the turn indicators switch and the ground connection If there is not check the cable harnesses and the con nections of the turn indicator control device 5 Check the turn indicator switch contacts 6 With the turn indicator switch pressed to the right check if there is voltage between the White Blue ca...

Page 78: ...HE CORRESPONDING CONNECTORS DISCONNECTED If faults are detected 1 With a multimeter check resistance values be tween the White Green cable and the Black cable of the fuel level transmitter under different condi tions 2 If the transmitter operates correctly but the in dication on the instrument panel is not exact check that the cable harnesses between them are not interrupted Electric characteristi...

Page 79: ...dlight remote control WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED TAIL LIGHTS AND LICENSE PLATE LIGHT LINE 1 Check that bulbs operate properly 2 Check fuses No 1 and 7 3 Check key switch contacts 4 Check if there is voltage between the Yellow Black cable of fuse No 7 and the ground If not check cable harnesses Vespa GTS Super 125 i e 2009 Electri...

Page 80: ... remote control switch 8 Check that the Grey Red cable of the light switch and the headlight remote control switch is not interrupted 9 Check the light switch contacts 10 Check that the cable harnesses of the bulbs and their ground connection are not interrupted Fuses The electrical system is equipped with 1 six protection fuses A located in the glove compartment to the left 2 of a fuse B located ...

Page 81: ...F Turn indicators G High beam warning light H Headlight warning light I Fuel gauge L Low fuel warning light M Coolant temperature gauge N Immobilizer LED Sealed battery If the vehicle is provided with a sealed battery the only maintenance required is checking its charge and recharging when necessary These operations should be carried out before delivering the vehicle and on a six month basis while...

Page 82: ...ant current battery charge mode Charge current equal to 1 10 of the battery rated capacity Charge time Maximum 5 h Connectors DIAGNOSIS CONNECTOR 1 Not connected 2 Ground Black 3 Electronic control unit Purple White PICK UP CONNECTOR 1 Positive from control unit Red 2 Negative from control unit Brown 3 Not connected FUEL PUMP CONNECTOR 1 Not connected 2 Ground Black 3 Not connected 4 Not connected...

Page 83: ...ack 13 Engine rpm sensor positive Red 14 Injector Red Yellow 15 Engine rpm sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer warning light Red Green 18 To ground Grey Green 19 Low beam lights automatic ignition White Black 20 Injection load remote control Black Purple 21 Not connected 22 HV coil Pink Black 23 Not connected 24 Start up enabling Orange Blue 25 Not connected 26 Ground le...

Page 84: ...OLTAGE REGULATOR CONNECTOR 1 Battery Red Black 2 Ground Black 3 Battery positive Red Black 4 Ground Black INSTRUMENT PANEL CONNECTOR A 1 Fuel level indicator White Green 2 High beam warning light Purple 3 Left indicators warning light White Blue 4 Right indicators warning light Pink 5 Power permanent supply White 6 Oil pressure sensor Pink White Electrical system Vespa GTS Super 125 i e 2009 ELE S...

Page 85: ...d Red Blue 3 Lighting Yellow Black 4 Power permanent supply White HV COIL CONNECTOR 1 Power via remote control Black Green 2 Electronic control unit Pink Black ANTI THEFT DEVICE PRE INSTALLATION CONNECTOR 1 Ground Black 2 Left indicators White Blue 3 Right indicators Pink 4 Battery powered Red Blue 5 Power permanent supply White 6 Not connected 7 Not connected 8 Not connected Vespa GTS Super 125 i...

Page 86: ...e FUEL LEVEL TRANSMITTER CONNECTOR 1 Fuel level indicator White Green 2 Ground Black 3 Low fuel warning light Yellow Green COOLANT PUMP CONNECTOR 1 Ground Black 2 Injection load remote control Black Green 3 Injection load remote control Black Green Electrical system Vespa GTS Super 125 i e 2009 ELE SYS 86 ...

Page 87: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 88: ... ble to the coolant pipe indicated in the photograph Undo the two exhaust manifold fixings on the head To unscrew the nuts that fix the muffler flange to the head properly use a jointed wrench that allows according to the travel direction to get also at the right nut That is difficult to do with a traditional straight wrench Undo the three screws that fix the muffler to the supporting arm Remove t...

Page 89: ...ve the side fairings and the spoiler termi nals Remove the rear brake calliper Remove the air cleaner from the housing by un screwing the three screws indicated in the photo graph CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the clamp from the blow by pipe and take the pipe out remove the retainer clamp Remove the clamp indicated in the photograph and disconnect the sl...

Page 90: ... in the photograph Disconnect the fuel pipe from the injector and re move the screw locking the retainer clamp Disconnect the injector wiring and the throttle body control unit wiring Disconnect the cable harnesses from the two clamps indicated Engine from vehicle Vespa GTS Super 125 i e 2009 ENG VE 90 ...

Page 91: ...oolant temperature sensor con nector indicated in the photo Remove the throttle control cables from the throt tle body by undoing the nuts indicated in the pho tograph Loosen the clamp indicated in the photograph and remove the throttle body Vespa GTS Super 125 i e 2009 Engine from vehicle ENG VE 91 ...

Page 92: ...Remove the positive and negative wiring from the starter motor as shown in the picture Disconnect the connectors from the flywheel wir ing as shown in the photo Release the cables from the retainer clamps Engine from vehicle Vespa GTS Super 125 i e 2009 ENG VE 92 ...

Page 93: ...gine onto the scooter carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter Check that there is a small clearance when the valve is in abutment against the set screw Check the engine oil level and if necessary top it up with the recommended type Fill and bleed the cooling circuit Check accelerator and electric devices for corre...

Page 94: ...ve be careful to position the throttle body reference marks as in dicated in the picture CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY Engine from vehicle Vespa GTS Super 125 i e 2009 ENG VE 94 ...

Page 95: ...INDEX OF TOPICS INJECTION INJEC ...

Page 96: ...Injection Vespa GTS Super 125 i e 2009 INJEC 96 ...

Page 97: ... Coolant temperature Intake air temperature Lambda probe The system implements an idle feeding correction with cold engine through a Stepper motor on a by pass circuit of the throttle valve The control unit manages the Stepper motor and the injector opening time thereby ensuring the idle steadiness and the proper combustion In all conditions of use mixture preparation is managed by modifying the i...

Page 98: ...s system connected to an indicator light in the in strument panel Failures are detected and restored by the diag nostic tester In any case when the fault is no longer present the data storage is automatically cleared after 16 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required to adjust the idle mixture Specific tooling 020680Y Diagnosis Tool ...

Page 99: ...cap E Intake circuit a Dirty air filter b Dirty by pass circuit c Faulty Stepper motor F Other a Incorrect timing b 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 connector...

Page 100: ...d 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 problem is detected start the checks from the battery and the injection system connections 9 Before disconnecting the MIU ECU connector perform the following steps in the order shown S...

Page 101: ...sor 10 incomplete 11 lambda probe 12 Engine stop switch 13 engine rpm sensor 14 fuel injector 15 engine rpm sensor 16 Diagnostics socket output 17 Immobilizer LED 18 Pin short circuited with pin 26 19 low beam automatic ignition 20 injection load remote control 21 incomplete 22 HV coil 23 incomplete 24 Start up enabling 25 incomplete Vespa GTS Super 125 i e 2009 Injection INJEC 101 ...

Page 102: ... circuit diagram 1 Battery 12V 12 Ah 2 Rpm sensor 3 coolant temperature sensor 4 Immobilizer aerial 5 Stop switches 6 Fuse No 1 30A 7 Key switch contacts 8 Fuse No 4 7 5A Injection Vespa GTS Super 125 i e 2009 INJEC 102 ...

Page 103: ...OES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to the indications of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Fuel system Fuel in the tank Fuel pump activation Fuel pressure low Injector capacity low Power to the spark plug Shi...

Page 104: ... Engine stops at idle ENGINE DOES NOT IDLE IDLING IS UNSTABLE IDLING TOO LOW Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Ignition efficiency Spark plug Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air tempe...

Page 105: ...tle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter box Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold muffler Muffler welding Engine revs irregularly ENGINE IRREG...

Page 106: ...air temperature indicator Ignition advance Fuel system Fuel level in the tank Fuel pressure Fuel filter Injector capacity Engine knocking PRESENCE OF KNOCKING COMBUSTION SHOCKS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Ignition efficiency Spark plug Parameter relia...

Page 107: ...l pump is located in the tank from which the fuel is pumped and sent to the injector through the filter The pressure is controlled by the pressure regulator situated in the pump assembly in the tank Removing the butterfly valve Remove the helmet compartment Remove the fuel piping clamping screw indicated in the figure Vespa GTS Super 125 i e 2009 Injection INJEC 107 ...

Page 108: ...injector support Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector Injection Vespa GTS Super 125 i e 2009 INJEC 108 ...

Page 109: ... indicated in the picture Refitting the butterfly valve To refit perform the operations in the reverse or der 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 picture Vespa GTS Super 125 i e 2009 Injection INJEC 109 ...

Page 110: ...Pump supply circuit 1 Battery 12V 2 Fuse No 3 15A 3 Fuse No 1 30A 4 Key switch contacts Injection Vespa GTS Super 125 i e 2009 INJEC 110 ...

Page 111: ...ck that the injection load 15A fuse No 3 works properly Check that the 7 5A fuse No 2 for live control unit power works properly Check 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 po...

Page 112: ...e between the pin 20 of the control unit 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 Super 125 i e 2009 INJEC 112 ...

Page 113: ... battery voltage for about two seconds to the Black Green cable of the pump connector and ground with pump connector disconnected Otherwise check the continuity of the Black Green cable between the pump connector and the remote control base Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable system side and the ground If when ...

Page 114: ... current is 1 4 to 1 8 A With the battery voltage 12 V check the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool Get a graded burette with a flow rate of approximately 1 L Rotate the pump using the active diagnoses of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabili...

Page 115: ...cture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture Remove the filter from the pump mounting Vespa GTS Super 125 i e 2009 Injection INJEC 115 ...

Page 116: ...g the injector circuit 1 Battery 12V 2 Fuse No 3 15A 3 Fuse No 1 30A 4 Key switch contacts 5 Fuse No 2 7 5A 6 Injection load remote control 7 Fuel pump 8 HV coil Injection Vespa GTS Super 125 i e 2009 INJEC 116 ...

Page 117: ...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 Purple 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...

Page 118: ... and earth If there is none check the continuity of the grey black cable between the fuse box No 3 15 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 Super 125 i e 2009 INJEC 118 ...

Page 119: ...able be tween pin 14 of the interface wiring and the injector connector Switch to ON and check if there is voltage with injector disconnected and control unit connected between the Black Green cable of the injector con nector and the ground lead Vespa GTS Super 125 i e 2009 Injection INJEC 119 ...

Page 120: ...the manifold Install the appropriate tool for checking fuel pres sure and position the manifold over a container graduated by at least 100 cm Connect the injec tor with the cable making up part of the supply for the injection tester Connect the clamps of the ca ble to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within fifteen seconds approximately 40 cm of fuel...

Page 121: ... are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute 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 Super 125 i e 2009 Injection INJEC 121 ...

Page 122: ... unit check continuity between pin 13 and the red cable of the engine speed sensor connector and between pin 15 and the brown ca ble of the engine speed sensor connector With the interface wiring and rpm sensor connec tor disconnected from the control unit check that the Red and Brown cables pin 13 15 are isola ted from each other and insulated from the ground Specific tooling 020481Y Control unit...

Page 123: ...HT coil 1 Battery 12V 2 Fuse No 3 15A 3 Fuse No 1 30A 4 Key switch contacts Vespa GTS Super 125 i e 2009 Injection INJEC 123 ...

Page 124: ... obtain the stabilisation of the speed at 1450 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 phase 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 15A fuse No 3 ...

Page 125: ... 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 2 seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base a...

Page 126: ...Injection Vespa GTS Super 125 i e 2009 INJEC 126 ...

Page 127: ...lack cable between the fuse box No 3 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Coolant temperature sensor TEMPERATURE SENSOR 1 Specification Desc Quantity 1 Water temperature sensor 2 Engine stop switch Vespa GTS Super 125 i e 2009 Injection INJEC 127 ...

Page 128: ...n entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre set reference conditions Pre calibration ensures optimal air flow to control 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 motor and the variation of the ignition advance The throttle bo...

Page 129: ...g point of the mV value corresponding to the pre calibrated position To reset proceed as follows Connect the diagnostic tester Switch to ON Select the functions of the diagnostic tester on TPS RESET Specific tooling 020680Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the stop screw Guaranteeing that this position will be kept send a confirmation for the TPS rese...

Page 130: ...USE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY 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 picture Lambda probe SIGNAL CONTROL 1 Lambda probe Injection Vespa GTS Super 125 i e 2009 INJEC 130 ...

Page 131: ...timeter 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 inside it Vespa GTS Super 125 i e 200...

Page 132: ...Impianto elettroventilatore 1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 Injection Vespa GTS Super 125 i e 2009 INJEC 132 ...

Page 133: ... set to ON check if there is 12 V battery voltage between the RED WHITE cable of the electric fan remote control and the ground connection Check if the RED WHITE cable between the fuse box and the electrical fan remote control base is not interrupted Using a diagnosis hand held computer carry out an active diagnosis for the ELECTRIC FAN Check if there is battery voltage at pins 85 86 of the electr...

Page 134: ... the electric fan remote control base and the ground connection Check if the GREY cable between the fuse box in the glove box compartment and the electric fan remote control base is not interrupted Check if the RED cable between the electric fan remote control base and the electric fan motor is not interrupted Check that the electric fan motor is earthed Injection Vespa GTS Super 125 i e 2009 INJE...

Page 135: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 136: ...xing screws indicated in the pic ture Locking torques N m Wheel fixing screw 20 25 Front wheel hub overhaul Support the vehicle adequately Remove the front wheel Remove the front brake calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub Suspensions Vespa GTS Super 125 i e 2009 SUSP 136 ...

Page 137: ... the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Vespa GTS Super 125 i e 2009 Suspensions SUSP 137 ...

Page 138: ...15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Refitting the front wheel To r...

Page 139: ...el 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 Vespa GTS Super 125 i e 2009 Suspensions SUSP 139 ...

Page 140: ...n 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 Pre loosen the 3 nuts fixing the mudguard to the suspension Suspensions Vespa GTS Super 125 i e 2009 SUSP 140 ...

Page 141: ...cific 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 Overhaul Carry out this operation only if strictly necessary and in any case remove and replace the old part with a new one Vespa GTS ...

Page 142: ...e the lower disk of the fifth wheel operating from the up per part Specific tooling 020004Y Punch for removing fifth wheels from headstock Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing fifth wheels from headstock Suspensions Vespa GTS Super 125 i...

Page 143: ... pin and the Nadella opposite the tool thrusting direction To extract the second Nadella use the tool with the part 2 instead of part 1 on opposite side to the one indicated in the figure Specific tooling 020021Y Front suspension service tool Fit both dust guard rings C on the swinging hub as shown in the detail drawing A Connect the swinging hub to the steering tube with the guiding pin part 5 Us...

Page 144: ...mineral oil and half fill the roller casings with recommended grease Insert the sealing ring on the pin and the roller bushing with wedging washers at the same time Remove the specific tool and then the part 5 guide partially ejected in the previous assembly stage part 4 must be always fitted Replace part 3 with part 16 on the stem Push from the handgrip the wedging washer roller casing sealing ri...

Page 145: ... spacers part 17 fill with recommen ded grease the area between the steering tube and the swinging hub and place the dust guard rings in that place Recommended products AGIP GREASE PV2 Grease for steering bear ings pin seats and swinging arm Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 of the swinging arm Refitting To refit carry out the removal operations but in revers...

Page 146: ...clamps and re move the brake calliper shock absorber mounting Loosen the screws fixing the front brake pipe re tainer clamp and the odometer cable in order to reach the upper clamps Unscrew the upper fixing nuts Remove the front shock absorber Suspensions Vespa GTS Super 125 i e 2009 SUSP 146 ...

Page 147: ... the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Before refitting the bracket in the wheel axle place the O ring as shown in the photograph so that it is correctly placed after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Locking torques ...

Page 148: ...side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph Suitably hold the brake calliper shock absorber attachment bracket Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y 52x55...

Page 149: ...pecific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Grease for steering bear ings pin seats and swinging arm Soap based lithium and zinc oxide...

Page 150: ...he removal operations but in reverse order observing the prescribed torques Locking torques N m Wheel fixing screws 20 25 Swing arm Removal Place the vehicle on its centre stand Remove the engine housing Remove the swinging arm engine fitting shown in the picture Move the engine back remove the spring anchoring the swinging arm to the chassis as shown in the picture Suspensions Vespa GTS Super 125...

Page 151: ...fer support bracket to the chassis 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 Vespa GTS Super 125 i e 2009 Suspensions SUSP 151 ...

Page 152: ...eeler gauge Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm To check the clearance on the chassis side arm mount the retainer using the pin fixing the swinging arm to the chassis and two adaptor rings of the appropriate 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 sticking...

Page 153: ... 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 Chassis side swinging arm plastic bushing shim 3 5 0 05 mm Length of the interna...

Page 154: ...st protruding part pointing towards the silent block side as shown in the picture Recommended products AGIP GREASE PV2 Grease for steering bear ings 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 it is replace the coupling Remove the Seeger ring shown in the picture Remove the full s...

Page 155: ...all 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 picture Refitting To refit perform the removal operations in reverse Grease the bearings and the rolling parts with the recommended grease Vespa G...

Page 156: ...ove 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 unscrew the two upper nuts one on each side fixing the shock absorber spring assembly to the frame and remove the shock...

Page 157: ...ration 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 Shock absorber lower fitting 40 45 Wheel axle clamping 104 126 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 figure Remove th...

Page 158: ... 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 Suspensions Vespa GTS Super 125 i e 2009 SUSP 158 ...

Page 159: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 160: ...R BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM INED 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 compr...

Page 161: ... at the specified torque Locking torques N m Calliper coupling screw 30 33 Nm Refitting Follow the removal steps but in reverse order and tighten to the prescribed torque Locking torques N m Calliper fixing screw 24 27 If the calliper is replaced CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM CAUTION ALWAYS USE NEW COPPER WASHERS Locking torques N m Screw fixing the oil connection to the call...

Page 162: ...E BRAKE CALLIPER Overhaul Proceed as follows 1 remove the two male hexagonal screws 1 and take out the two pads 10 2 remove 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 expulsio...

Page 163: ... plate 5 floating body 6 piston 7 piston sealing rings 8 guide protection rubbers 9 brake pad check spring 10 pads Refitting Insert 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...

Page 164: ...t disc in the wheel axle Locking torques N m Disk to the hub 11 13 Disc Inspection Remove the rear brake calliper Check the disc thickness with a micrometer Characteristic Standard thickness 3 5 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 th...

Page 165: ... 0 1 mm If you detect incorrect values replace the disc If the anomaly persists 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 Vespa GTS Super 125 i e 2009 Braking system BRAK SYS 1...

Page 166: ...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 mounting f...

Page 167: ...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 Vespa GTS Super 125 i e 2009 Braking system BRAK SYS 1...

Page 168: ...crew tightening calliper to support 24 to 27 Pad fixing pin 19 6 24 5 Rear brake pads Removal Remove the rear brake calliper Remove the snap ring slide off the pad retention pin and the clip Remove the brake pads and check there are no faults or warping Otherwise replace them 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 ...

Page 169: ...ert a rubber pipe in the bleed screw to permit the brake fluid to be recovered 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 tighten the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recovery ...

Page 170: ...cific tooling 020329Y Mity Vac vacuum operated pump Locking torques N m System bleed calliper fitting 12 16 Nm Brake fluid level 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 up ...

Page 171: ...DING AIR IF THE LEVEL OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN VALUE BRAKING EFFICIENCY WILL BE REDUCED Never use brake liquid in open or partially used containers Under standard climatic conditions replace coolant as indicated in the scheduled maintenance table For refitting purposes carry out the removal operations but in reverse order and respect the tightening torques of the tank cover s...

Page 172: ...he 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 1 Reservoir cap screw 2 Reservoir cap 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8 Spring 9 Tank Braking system Vespa GTS Super 125 i e 2009 BRAK...

Page 173: ...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 to 10 Nm Vespa GTS Super 125 i e 2009 Braking system BRAK SYS 173 ...

Page 174: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 175: ...Circuit diagram 1 Coolant electric pump 2 Three way thermostat 3 Electric fan Vespa GTS Super 125 i e 2009 Cooling system COOL SYS 175 ...

Page 176: ...4 Expansion tank 5 Radiator 6 coolant temperature sensor Cooling system Vespa GTS Super 125 i e 2009 COOL SYS 176 ...

Page 177: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 178: ...crews 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 Super 125 i e 2009 CHAS 178 ...

Page 179: ...graph 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 Super 125 i e 2009 Chassis CHAS 179 ...

Page 180: ...necting the wiring remove the rear handlebar Instrument panel Remove the rear handlebar cover Remove the four screws indicated in the figure Remove the instrument panel Front handlebar cover Remove the rear view mirrors Remove the front central cover Remove the front screw indicated in the figure Chassis Vespa GTS Super 125 i e 2009 CHAS 180 ...

Page 181: ... handlebar cover Disconnect the front headlamp connectors Headlight assy Remove the front handlebar cover Undo the four screws indicated Operate the screw indicated in the figure to re move the front turn indicator Vespa GTS Super 125 i e 2009 Chassis CHAS 181 ...

Page 182: ... its cap Remove the central screw inside the glove box indicated in the photograph Remove the two screws indicated in the photo graph and located below the expansion tank cover and the 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 Chassis Vespa GTS Super 125 i e 2009 CHAS 182 ...

Page 183: ...op light bulb and license plate bulb To reassemble repeat the operation but in reverse order N B IF MISTING IS NOTICED ON THE INSIDE OF THE HEAD LAMP GLASS THIS DOES NOT INDICATE A FAULT AND IS ATTRIBUTABLE TO HUMIDITY AND OR TO LOW TEM PERATURES THE PHENOMENON SHOULD QUICKLY DISAPPEAR WHEN THE LIGHT IS SWITCHED ON THE PRESENCE OF DROPS OF WATER ON THE OTHER HAND COULD INDICATE THAT WATER IS INFIL...

Page 184: ...ted under the bat tery compartment cover as indicated in the figure Remove the passenger footrests undoing the two screws indicated in the 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 Chassis Vespa GTS Super 125 i e 2009 CHAS 184 ...

Page 185: ...nut B under the body Helmet bay Lift the saddle and remove the helmet compart ment Fuel tank Remove 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 Vespa GTS Super 125 i e 2009 Chassis CHAS 185 ...

Page 186: ...he two turn indicators Use a jack to lift the body so that there is enough space between the vehicle rear side and the en gine to slide off the tank To refit perform the steps in the reverse direction to disassembly Rear central cover Remove the four screws indicated in the figure Chassis Vespa GTS Super 125 i e 2009 CHAS 186 ...

Page 187: ...y operation on the radiator unit flow out the coolant in the coolant delivery pipe in the pump indicated in the photograph Remove the shield back plate Remove the coolant feed and return hoses from the right radiator Unscrew the 4 screws fixing the radiator to the body Detach the radiator Detach the pipe from the plastic duct by removing the plastic clip shown in the photograph Then re move the du...

Page 188: ...graph and afterwards disconnect the connector To refit perform the removal operations but in reverse order being careful when positioning the news clips for the fluid hoses and when filling the cooling system Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Chassis Vespa GTS Super 125 i e 2009 CHAS 188 ...

Page 189: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 190: ...ews 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 beam lights low beam lights taillights front and rear and relevant warning lights Headlight adjustment according to the regulations curren...

Page 191: ...IDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES 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 FUS...

Page 192: ...AUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check chassis and engine number check tools and equipment licence plate fitting lock check tyre pressure check rear view mirror and any acce...

Page 193: ...INDEX OF TOPICS TIME TIME ...

Page 194: ...and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine from chassis Removal and refit 2 003064 Engine oil change Crankcase CRANKCASE Code Action Duration 1 001153 Crankcase halves gasket Replace ment 2 001133 Engine crankcase Replacement Time Vespa GTS Super 125 i e 2009 TIME 194 ...

Page 195: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Vespa GTS Super 125 i e 2009 Time TIME 195 ...

Page 196: ...sy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 3 001129 Chain tensioner Service and Re placement Time Vespa GTS Super 125 i e 2009 TIME 196 ...

Page 197: ...Code Action Duration 1 001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves adjust 4 001056 Head gasket change 5 001083 Thermistor Replacement 6 001057 Thermostat Replacement Vespa GTS Super 125 i e 2009 Time TIME 197 ...

Page 198: ...Rocker arms support assy CAMSHAFT Code Action Duration 1 001148 Rockers valves Replacement 2 001044 Camshaft Replacement Cylinder head cover Time Vespa GTS Super 125 i e 2009 TIME 198 ...

Page 199: ...lacement 3 001088 Head cover gasket Replacement 4 001074 Oil vapour recovery pipe Replace ment Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor change 3 001102 Net oil filter change Cleaning Vespa GTS Super 125 i e 2009 Time TIME 199 ...

Page 200: ... 001087 Flywheel cover Replacement 2 001150 Flywheel cover gasket change 3 007007 Water pump rotor Replacement 4 007017 Water pump cover Replacement 5 007003 Coolant delivery and return pipe change Driven pulley Time Vespa GTS Super 125 i e 2009 TIME 200 ...

Page 201: ...Replacement Oil pump OIL PUMP Code Action Duration 1 001125 Chain guide pads Replacement 2 001051 Belt Timing chain Change 3 001042 Oil pump overhaul 4 001112 Oil pump change 5 001122 Oil pump chain Replacement 6 001130 Oil sump change 7 001172 Chain cover flap change 8 001124 Lubrication by pass Replacement Vespa GTS Super 125 i e 2009 Time TIME 201 ...

Page 202: ...DUCTION GEAR Code Action Duration 1 001010 Reduction gear Replacement 2 003065 Gear box oil Replacement 3 001156 Reduction gear cover Replacement 4 004125 Rear wheel axle Replacement Time Vespa GTS Super 125 i e 2009 TIME 202 ...

Page 203: ...001086 Driving half pulley Replacement 2 001011 Driving belt Replacement 3 001066 Driving pulley Removal and refitting 4 001177 Variator rollers shoes Replace ment 5 001141 Belt anti flapping roller Replace ment Vespa GTS Super 125 i e 2009 Time TIME 203 ...

Page 204: ...Action Duration 1 001135 Transmission cover bearing Re placement 2 001096 Transmission crankcase cover Re placement 3 001131 Transmission air intake Replace ment 4 001065 Transmission cover Replacement Time Vespa GTS Super 125 i e 2009 TIME 204 ...

Page 205: ...TART UP Code Action Duration 1 001020 Starter motor Replacement 2 001104 Start up freewheel Replacement 3 001151 Starter driven gearing Replacement 4 001017 Start up pinion Replacement Vespa GTS Super 125 i e 2009 Time TIME 205 ...

Page 206: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001067 Stator Removal and Refitting 2 001173 Rotor Replacement 3 001058 Complete flywheel change Time Vespa GTS Super 125 i e 2009 TIME 206 ...

Page 207: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Replacement 2 001047 Injector Replacement 3 001013 Intake manifold change Vespa GTS Super 125 i e 2009 Time TIME 207 ...

Page 208: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 005138 Lambda probe Replacement Time Vespa GTS Super 125 i e 2009 TIME 208 ...

Page 209: ...ction Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Air cleaner carburettor union Re placement 4 001027 Body air cleaner union Replace ment Vespa GTS Super 125 i e 2009 Time TIME 209 ...

Page 210: ...ement 2 004085 Fairing 1 Replacement 3 004149 Shield central cover Replacement 4 004053 Spoiler Replacement 5 004015 Footrest Removal and Refitting 6 004023 Shield rim Replacement 7 004159 Plates Stickers Replacement Time Vespa GTS Super 125 i e 2009 TIME 210 ...

Page 211: ...Centre stand STAND Code Action Duration 1 004102 Side stand Replacement 2 004004 Stand Replacement Footrests Vespa GTS Super 125 i e 2009 Time TIME 211 ...

Page 212: ... 004071 Battery compartment replacement 3 004078 Front rear footrest rubber Replace ment 4 005046 Battery cover change Rear cover REAR SHIELD Code Action Duration 1 004083 Glove box Replacement 2 004081 Top box lid Replacement Time Vespa GTS Super 125 i e 2009 TIME 212 ...

Page 213: ...Underseat compartment HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Removal and Refitting 2 004011 Central chassis cover Replacement Vespa GTS Super 125 i e 2009 Time TIME 213 ...

Page 214: ...Plate holder LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate holder support Re placement 2 005048 number plate holder Replacement Mudguard Time Vespa GTS Super 125 i e 2009 TIME 214 ...

Page 215: ...t 3 003044 Shock absorber cover Replace ment Fuel tank FUEL TANK 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 Replacement Vespa GTS Super 125 i e 2009 Time TIME 215 ...

Page 216: ...lete with support Re placement 3 007001 Expansion tank Replacement 4 001052 Coolant and air bleed Replacement 5 007013 Expansion tank radiator connecting hose Replacement 6 007003 Delivery line and coolant return Re placement 7 001170 Air deflector Replacement Time Vespa GTS Super 125 i e 2009 TIME 216 ...

Page 217: ...shock absorber REAR SHOCK ABSORBERS Code Action Duration 1 003007 Rear shock absorber Removal and Refitting 2 003077 muffler rear shock absorber support arm Service Vespa GTS Super 125 i e 2009 Time TIME 217 ...

Page 218: ...Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheels Replacement 2 003073 Steering clearance Adjustment Time Vespa GTS Super 125 i e 2009 TIME 218 ...

Page 219: ...Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004018 Front handlebar covers Replace ment 2 004019 Rear handlebar covers Replace ment Vespa GTS Super 125 i e 2009 Time TIME 219 ...

Page 220: ...al and re fitting 4 005017 Stop switch Replacement 5 002059 Right hand knob Replacement 6 002071 Left hand grip Replacement 7 003059 Counterweight Replacement 8 002060 Throttle grip Replacement 9 002063 Throttle control transmission Re placement 10 003061 Accelerator transmission adjust 11 002037 Brake or clutch lever Replacement Time Vespa GTS Super 125 i e 2009 TIME 220 ...

Page 221: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine chassis connection swinging arm Replacement 2 004058 Silent block Replacement Vespa GTS Super 125 i e 2009 Time TIME 221 ...

Page 222: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Instrument panel Time Vespa GTS Super 125 i e 2009 TIME 222 ...

Page 223: ...or turning indicator switch Re placement 6 005040 Horn button Replacement 7 005121 Saddle opening button Replace ment 8 005039 Lights switch Replacement 9 005078 Odometer glass Replacement 10 005038 Instrument panel warning light bulbs Replacement 11 005076 Clock Cell Replacement Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement Vespa GTS Super 125 i e 2009 Time TIME 22...

Page 224: ...ok transmis sion Replacement 3 004158 Saddle opening splitter Replace ment 4 005072 Immobilizer aerial Replacement 5 005099 Electric saddle opening device Re placement 6 004054 Saddle lock catch Replacement 7 004010 Anti theft lock Replacement 8 005016 Key switch Replacement Time Vespa GTS Super 125 i e 2009 TIME 224 ...

Page 225: ...ail light bulb Replacement 5 005008 Headlight bulbs Replacement 6 005012 Front turn indicator Replacement 7 005090 Stop light bulb Replacement 8 005140 Front light Replacement 9 005022 Rear turning indicators Replace ment 10 005068 Rear turning indicator bulb Re placement 11 005066 Rear light bulbs Replacement 12 005028 Rear light assembly glass Replace ment Vespa GTS Super 125 i e 2009 Time TIME ...

Page 226: ... Action Duration 1 003047 Front tyre Replacement 2 003037 Front wheel rim Replacement 3 004123 Front wheel Replacement 4 003033 Front wheel hub Replacement 5 002041 Brake disc Replacement Time Vespa GTS Super 125 i e 2009 TIME 226 ...

Page 227: ...ation 1 004126 Rear wheel tyre Replacement 2 001071 Front wheel rim Removal and Re fitting 3 001016 Rear wheel Replacement 4 002028 Rear wheel hub Replacement 5 002070 Rear brake disc Replacement Vespa GTS Super 125 i e 2009 Time TIME 227 ...

Page 228: ...5 005052 Fuse 1 Replacement 6 005007 Battery change 7 005120 Control unit power supply remote control Replacement 8 005035 Headlight remote control Replace ment 9 005117 Electric fan contactor Replacement 10 005011 Start up remote control switch Re placement 11 005054 Fuse block 1 Replacement 12 005001 Electrical system Removal and re fitting Time Vespa GTS Super 125 i e 2009 TIME 228 ...

Page 229: ...Transmissions TRANSMISSIONS Code Action Duration 1 002051 Odometer transmission assembly Replacement Vespa GTS Super 125 i e 2009 Time TIME 229 ...

Page 230: ...r Removal and Refitting 2 003045 Steering tube Replacement 3 003010 Front suspension Service 4 003035 Shock absorber mounting and brake calliper Replacement 5 003034 Front wheel hub bearing Replace ment 6 001064 Odometer sprocket Replacement Time Vespa GTS Super 125 i e 2009 TIME 230 ...

Page 231: ...eplacement 3 002021 Front brake piping Replacement 4 002047 Front brake fluid and air bleed sys tem Replacement 5 002020 Rear brake disc piping Replace ment 6 002080 Rear brake oil bleed system Change 7 002002 Rear brake pads Replacement 8 002048 Rear brake calliper Replacement Vespa GTS Super 125 i e 2009 Time TIME 231 ...

Page 232: ...Stickers TRANSFERS Code Action Duration 1 004159 Plates Stickers Replacement Time Vespa GTS Super 125 i e 2009 TIME 232 ...

Page 233: ...C Checks 66 Coolant 127 E Electric 228 Engine oil 47 F Fuel 107 114 185 215 Fuses 80 H Headlight 52 181 Horn 76 Hub oil 45 I Identification 8 Instrument panel 180 222 L Luggage rack M Maintenance 7 44 O Oil filter 49 199 R Recommended products S Saddle Shock absorbers 156 Spark plug 44 ...

Page 234: ...Stand 158 Start up Suspension 55 56 230 Switch T Tank 185 215 Transmission 10 54 204 Turn indicators 66 Tyre pressure Tyres 15 V Vehicle 8 88 89 ...

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VESPA GTS Super 125 i.e. (2009), Service Manual

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