VESPA GTS Super 300 ie 2008 Service Station Manual Download

Page: 192 / 317

Remove the gas command fitting as 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 photograph.

Injection

Vespa GTS Super 300 ie (2008)

INJEC - 192

Summary of Contents for GTS Super 300 ie 2008

Page 1: ...MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 ie 2008 ...

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

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

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: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ... 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 use new gasket...

Page 8: ...x 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 Overall length 2230 mm Wheelbase 1370 mm Characteristics Vespa GTS Super 300 ie 2008 CHAR 8 ...

Page 9: ...ooling Forced circulation coolant system 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...

Page 10: ...VT with torque server V belt automatic clutch gear reduction unit and transmission com partment 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 with in...

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 300 ie 20...

Page 12: ...LIGHT SWITCH STARTER BUTTON IGNITION KEY FUEL INJECTOR Type 3 holes Conicity of the nozzle 20 Resistance at terminals 13 7 15 2 Ohm Characteristics Vespa GTS Super 300 ie 2008 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: ... 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 plun...

Page 15: ...EMBLY 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 to 40 Side stand fixing bolt 35 to 40 FRONT SUSPENSION Name Torque in Nm Screw fixing the shock absorber to the shock absorber calliper attachment plate 20 to 27 Wheel axle nut 74 88 Wh...

Page 16: ...Lambda probe tightening on exhaust manifold 40 50 Exhaust manifold silencer joint tightening 12 to 13 Manifold silencer 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 to 9 Screws fixing oil pump to the crankcase 5 6 Oil pump comma...

Page 17: ...w fixing freewheel to flywheel 13 15 CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead transmission side half shaft screws 4 6 Engine crankcase coupling screws 11 13 Starter motor screws 11 13 Crankcase timing cover screws 3 5 4 5 Apply LOCTITE medium type 242 threadlock COOLING Name Torque in Nm Water pump rotor cover 3 4 Thermostat cover screws 3 4 Bleed screw 3 Overh...

Page 18: ... PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS Measure the outer diameter of the gudgeon pin Characteristic Pin outside diameter 16 0 0 004 mm Measure the diameter of the bearings on the pis ton Characteristic Standard diameter 16 0 006 0 001 mm Calculate the piston pin coupling cleara...

Page 19: ...m clearance allowed after use 0 07 mm Check that the head coupling surface is not worn or misshapen Pistons and cylinders are classified according to their diameter The coupling must be made with those of the same type M M N N O O P P Characteristic Maximum allowable run out 0 001 over 0 05 mm Piston rings Sealing rings Alternately insert the three sealing rings into the cylinder in the area where...

Page 20: ...e 4000 car Indirizzo Immagine Crankshaft Axial clearance between crankshaft and connecting rod Axial clearance between crankshaft and connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half shaft transmission 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 Spa...

Page 21: ...SHAFT Specification Desc Quantity Crankshaft bearings Standard diameter Cat 1 28 998 29 004 mm Crankshaft bearings Standard diameter Cat 2 29 004 29 010 mm Vespa GTS Super 300 ie 2008 Characteristics CHAR 21 ...

Page 22: ...MAX ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm Characteristics Vespa GTS Super 300 ie 2008 CHAR 22 ...

Page 23: ...matching surface of the two half bearings must be perfectly orthogonal to the cylinder axis as shown in the figure The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface Check the inside diameter of the main bushings in the three directions indicated in the diagram Repeat the measurements for the other bus...

Page 24: ...THE ENDS ARE RE LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION N B CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY C BUSHINGS YEL LOW Characteristic Crankshaft bushing maximum clearance ad mitted 0 08 mm Diameter of crankcase without bushing CAT 1 32 959 32 965 mm CAT 2 32 953 32 959 mm Cylinder Head Before performing head serv...

Page 25: ...he test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD BEARINGS Specification Desc Quantity bearing A Ø 12 000 12 018 mm bearing B Ø 20 000 20 021 mm bearing C Ø 37 000 37 025 mm Measure the unloaded sp...

Page 26: ...e seats with a 45 milling cutter and then grind In case of excessive wear or damage replace the head STANDARD VALVE LENGTH Specification Desc Quantity Valve check Standard length Intake 94 6 mm Valve check Standard length Exhaust 94 4 mm Measure the diameter of the valve stems in the three positions indicated in the diagram STANDARD DIAMETER Specification Desc Quantity Intake 4 987 4 972 mm Exhaus...

Page 27: ...sing a dial gauge Characteristic Limit values admitted 0 1 mm Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support Characteristic Admissible limit 0 03 mm Measure the valve guide Characteristic Valve guide 5 0 012 mm After measuring the valve guide diameter and the valve stem diameter check clearance between gui...

Page 28: ...tal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE 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 TH...

Page 29: ...ity Camshaft check Standard height Intake 30 285 mm Camshaft check Standard height Exhaust 29 209 mm Check the axial clearance of the camshaft CAMSHAFT AXIAL CLEARANCE Specification Desc Quantity Camshaft check Standard axial clearance 0 11 0 41 mm Camshaft check Maximum admissible axial clearance 0 42 mm Measure the outside diameter of the rocking lever pins Check the rocking lever pins do not sh...

Page 30: ...meter Standard diameter Diameter 12 000 12 011 mm Rocking lever pin diameter Standard diameter Diameter 11 977 11 985 mm Slot packing system Characteristic Compression ratio 10 5 11 5 1 Measurement A to be taken is a value of piston re entry it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder The further the piston falls Characteris...

Page 31: ...er formance four stroke engines JASO MA MA2 API SL ACEA A3 AGIP FILTER OIL Special product for the treatment of foam filters AGIP GP 330 Water repellent stringy calcium spray grease R I D A D R 2 10 b 2 R I Na 2 42 I A T A 2 I M D G class 2 UN 1950 Page 9022 EM 25 89 eni i Ride PG 5W 40 Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 AGIP BRAKE 4 Brak...

Page 32: ...INDEX OF TOPICS TOOLING TOOL ...

Page 33: ...ing steering seats 001467Y017 Bell for bearings OD 39 mm 001467Y014 Calliper to extract ø 15 mm bearings 001467Y035 Bearing housing outside ø 47 mm 001467Y013 Calliper to extract ø 15 mm bearings 005095Y Engine support Vespa GTS Super 300 ie 2008 Tooling TOOL 33 ...

Page 34: ...r circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch for removing steering bearings from headstock 020021Y Front suspension service tool 020036Y Punch 020038Y Punch Tooling Vespa GTS Super 300 ie 2008 TOOL 34 ...

Page 35: ... Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020115Y Ø 18 punch 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge Vespa GTS Super 300 ie 2008 Tooling TOOL 35 ...

Page 36: ...unch 020262Y Crankcase splitting plate 020271Y Tool for removing fitting silent bloc 020263Y Driven pulley assembly sheath 020306Y Punch for assembling valve seal rings 020329Y Mity Vac vacuum operated pump Tooling Vespa GTS Super 300 ie 2008 TOOL 36 ...

Page 37: ...iption 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35 mm Adaptor Vespa GTS Super 300 ie 2008 Tooling TOOL 37 ...

Page 38: ...res code Description 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55 mm Adaptor 020363Y 20 mm guide 020364Y 25 mm guide 020365Y 22 mm guide 020375Y 28 x 30 mm adaptor Tooling Vespa GTS Super 300 ie 2008 TOOL 38 ...

Page 39: ...tor handle 020382Y Valve cotters equipped with part 012 re moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band 020412Y 15 mm guide 020423Y Driven pulley lock wrench Vespa GTS Super 300 ie 2008 Tooling TOOL 39 ...

Page 40: ...20424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020428Y Piston position check mounting 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting Tooling Vespa GTS Super 300 ie 2008 TOOL 40 ...

Page 41: ...28 mm adaptor 020444Y Tool for fitting removing the driven pulley clutch 020454Y Tool for fitting piston pin stops 200 250 020456Y Ø 24 mm adaptor 020467Y Flywheel extractor 020477Y 37 mm adaptor Vespa GTS Super 300 ie 2008 Tooling TOOL 41 ...

Page 42: ...ol pressure check kit 020483Y 30 mm guide 020489Y Hub cover support stud bolt kit 020621Y HV cable extraction adaptor 020622Y Transmission side oil seal punch 020626Y Driving pulley lock wrench Tooling Vespa GTS Super 300 ie 2008 TOOL 42 ...

Page 43: ...Stores code Description 020627Y Flywheel lock wrench 020648Y Single battery charger 020922Y Diagnosis Tool Vespa GTS Super 300 ie 2008 Tooling TOOL 43 ...

Page 44: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 45: ...and wear I I I I I I I Vehicle road test I I I I I I I Suspension I I I I I I Steering A A A A A A A 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 Checking the spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to i...

Page 46: ...k plug and spark plug cap Connect the induction clamp on the spark gap cable respecting the proper polarity the arrow on the clamp must be pointing at the spark plug Connect the diagnostic tester Start the engine Select the Parameters function in this menu Set the stroboscopic light control to the traditional four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition...

Page 47: ...ending the side electrode very carefully In case of anomaly as described before replace the spark plug with another of the recommended type Fit the spark plug with the correct inclination and manually screw it all the way down then use the special spanner to tighten it Insert the cap onto the spark plug and proceed with the reassembly operations CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO T...

Page 48: ...ing from the lower end if the level is under the MAX mark it needs to be filled with the right amount of hub oil Screw up the oil dipstick again and make sure it is locked properly into place Replacement Remove the oil filler cap A Unscrew the oil drainage cap B and drain out all the oil Screw in the drainage cap again and fill the hub with the prescribed oil Recommended products AGIP GEAR SAE 80W...

Page 49: ...o then dry it with a clean cloth and short blasts of compressed air Finally immerse it in a mixture of 50 oil of the recommended type and 50 petrol Then gently squeeze the filter el ement between your hands allow it to drip and then refit it Oil or water deposits in the filter hous ing can be cleaned off by removing the two rubber caps E CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NEC ESSA...

Page 50: ... be drained by running off the oil from drainage cap B of the flywheel side gauze pre filter further more to facilitate oil drainage loosen the cap dipstick A Once all the oil has drained through the drainage hole unscrew the oil cartridge filter C and remove it Make sure the pre filter and drainage plug O rings are in good conditions Lubricate them and refit the mesh filter and the oil drainage p...

Page 51: ...er the vehicle has been used and therefore with a hot engine the level will be lower in order to carry out a correct check wait at least 10 minutes after the engine has been stopped so as to get the correct level Engine oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX level Restoration of the level from MIN to MAX re...

Page 52: ... in the figure TDC Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure If the ref erence is opposite the indicator on the head turn the crankshaft once more For the use of this reference mark remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a ca...

Page 53: ... THE COOLANT ESCAPING FROM THE EXPAN SION TANK WHEN THE VEHICLE IS IN USE Braking system Level check The brake fluid tanks for 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...

Page 54: ...D CONTACT OF THE BRAKE FLUID WITH YOUR EYES SKIN AND CLOTHING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE THEREFORE WHEN TOPPING 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 EXC...

Page 55: ...e headlight and check that the bor derline of the projected light beam on the screen is no higher than 9 10 or lower than 7 10 of the distance from the ground to the centre of the ve hicle s 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 REGULA...

Page 56: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 57: ...ass 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 Operat...

Page 58: ...eering even after making the above adjustments check the seats in which the ball bearings rotate if they are recessed or if the balls are squashed replace them 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 adjustm...

Page 59: ...IL 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 Vespa GTS Super 300 ie 2008 Troubleshooting TROUBL 59 ...

Page 60: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 61: ...use No 1 30A 8 Fuse No 5 7 5A 9 Fuse No 2 15A 10 Fuses No 6 7 5A 11 Fuse No 3 15A 12 Fuse No 4 7 5A 13 Fuse No 7 7 5A 14 Key switch contacts 15 Engine stop switch 16 N 2 stop buttons 17 Brake lamp 12v 16w 18 Injection load relay 19 Electric fan remote control Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 61 ...

Page 62: ... relay 37 Saddle opening switch 38 Saddle opening actuator 39 Headlight with dual light bulb 12v 55w 60w 40 Turn indicator control device 41 Turn indicator switch 42 4 bulbs for turn indicators 12v 10w 43 Pre installation for anti theft device 44 1 front daylight running light bulb 12v 5w 45 1 rear daylight running light bulb 12v 5w 46 1 license plate bulb 12v 5w Key Ar Orange Az Light Blue Bi Whi...

Page 63: ...Components arrangement 9 Immobilizer aerial Remove the shield back plate to reach it 10 Injection ECU Remove the helmet compart ment to reach it Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 63 ...

Page 64: ...h it 15 H V coil Remove the battery to reach it to remove the coil first remove the footrest and undo the two screws indicated 18 30 38 Horn Remote control switches Re move front central cover to reach it Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 64 ...

Page 65: ...ve the front central cover and the helmet compartment to reach them 26 Main fuses Open the front top box to reach them 41 Secondary fuse Remove the helmet com partment to reach it Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 65 ...

Page 66: ...each it To get access to the connectors remove the helmet compartment 40 Key switch contacts Remove the shield back plate to reach them 33 Saddle opening actuator Remove the hel met compartment to reach it undo the two screws indicated and remove the fixing bracket together with the actuator Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 66 ...

Page 67: ...il pressure sensor Remove the right side fairing to reach it 22 Battery Remove the rear central cover to reach it Ground points On the vehicle there is a ground point on the chassis marked with the letter A Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 67 ...

Page 68: ...There is another ground point B on the starter motor Electrical system installation Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 68 ...

Page 69: ...Front side 1 Saddle opening switch 2 Pre installations Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 69 ...

Page 70: ... Fuse box 5 From the wire unit 1 Front left turn indicator connector 2 Front right turn indicator connector 3 Electric fan connector 4 Turn indicator control device Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 70 ...

Page 71: ...2 From regulator 3 Wire unit regulator connection 4 To the immobilizer aerial 5 Light remote control 6 Electric fan remote control 7 To key switch 8 Left turn indicator connector Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 71 ...

Page 72: ...9 Voltage regulator 1 Immobilizer aerial 2 Foldable clamp to hold cables 3 Battery negative terminal Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 72 ...

Page 73: ...nnection 1 To stop switch 2 To turn indicator switch 3 To light switch 4 To horn button 5 To instrument panel 6 To headlight 7 To the position light 8 To starter button 9 To the engine stop switch Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 73 ...

Page 74: ...Back side 1 To HV coil 2 Foldable clamp 3 Foldable clamps to hold the red sheathing 4 Diagnostic socket 5 Starter remote control Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 74 ...

Page 75: ...1 Rear right turn indicator 2 Cable guide 3 To rear light 4 Rear left turn indicator Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 75 ...

Page 76: ...ote control switch 3 Ground lead clamping to chassis 4 Oil pressure sensor 5 Lambda probe connector 6 Lambda sensor 7 To wire unit 8 To the spark plug 9 HV coil Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 76 ...

Page 77: ...ing 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 Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 77 ...

Page 78: ...tarter motor ground lead 5 Right turn indicator connector 6 Rear headlight assembly connector 7 Left turn indicator connector 8 Starter motor ground lead clamping 9 Starter motor positive terminal Conceptual diagrams Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 78 ...

Page 79: ...uses No 6 7 5A 11 Fuse No 3 15A 12 Fuse No 4 7 5A 14 Key switch contacts 15 Engine stop switch 18 Injection load relay 25 H V coil 29 Diagnosis socket 30 Injection electronic control unit 31 Immobilizer antenna 34 Instrument panel Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 79 ...

Page 80: ...r 4 Starter button 5 Voltage regulator 6 Magneto flywheel 7 Fuse No 1 30A 8 Fuse No 5 7 5A 9 Fuse No 2 15A 10 Fuses No 6 7 5A 14 Key switch contacts 16 N 2 stop buttons 17 Brake lamp 12v 16w 30 Injection electronic control unit Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 80 ...

Page 81: ...10 Fuses No 6 7 5A 14 Key switch contacts 15 Engine stop switch 23 Lambda probe 24 Engine speed sensor 27 Engine temperature sensor 30 Injection electronic control unit 31 Immobilizer antenna 32 Fuel level transmitter 33 Oil pressure sensor 34 Instrument panel Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 81 ...

Page 82: ...o 3 15A 12 Fuse No 4 7 5A 14 Key switch contacts 19 Electric fan remote control 20 Radiator electric fan 21 Horn button 22 Horn 30 Injection electronic control unit 34 Instrument panel 37 Saddle opening switch 38 Saddle opening actuator 40 Turn indicator control device Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 82 ...

Page 83: ...5 7 5A 9 Fuse No 2 15A 10 Fuses No 6 7 5A 11 Fuse No 3 15A 12 Fuse No 4 7 5A 13 Fuse No 7 7 5A 14 Key switch contacts 30 Injection electronic control unit 34 Instrument panel 35 Light switch 36 Headlight relay 39 Headlight with dual light bulb 12v 55w 60w 40 Turn indicator control device Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 83 ...

Page 84: ...icense plate bulb 12v 5w Injection Key 1 12v 10Ah battery 7 Fuse No 1 30A 8 Fuse No 5 7 5A 9 Fuse No 2 15A 11 Fuse No 3 15A 12 Fuse No 4 7 5A 14 Key switch contacts 15 Engine stop switch 18 Injection load relay 19 Electric fan remote control 20 Radiator electric fan 23 Lambda probe 24 Engine speed sensor Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 84 ...

Page 85: ...ranspond er in the key block This allows the driver clear operation without having to do anything other than just turning the key The Immobilizer system con sists of the following components Control unit Immobilizer aerial master and service keys with built in transponder HV coil diagnosis LED The diagnosis LED also works as a theft deterrent blinker This function is activated every time the ignit...

Page 86: ...ls 7 9 and terminal 9 chassis ground fixed power supply If there is no voltage check that fuse 2 and its cable are in working order With the key switch in the ON position there is battery voltage between terminals 6 7 and terminal 6 chassis ground fixed power supply If there is no voltage check the key switch contacts that fuse 5 and its cable are in working order There is continuity between termi...

Page 87: ...ides 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 control unit to be wiped clean and 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 ...

Page 88: ...keys you must re peat the procedure using all the keys you intend to keep using If a service key becomes uncoded the efficiency of the high voltage circuit shielding must be thor oughly inspected In any case it is advisable to use resistive spark plugs Characteristic Shielded cap resistance 5000 Ω Diagnostic codes The Immobilizer system is tested each time the ig nition key is turned from OFF to O...

Page 89: ... 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 2 sec and then by short 0 46 sec flashes the same number of times 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 ...

Page 90: ... 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 control unit If this is not the case reprogram the decoder Battery ...

Page 91: ...lace 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 terminals of the tester between the negative pole of the battery and the black cable and only then disconnect the black cable ...

Page 92: ...eter 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 14 to 15V at 5000 rpm with lights off Starter motor KEY 1 Batter...

Page 93: ...mote control switch and the ground connec tion If there is not check the cable harnesses 5 Check the starter relay 6 Check that the Red cable between the battery and the starter relay 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 remote control switch and the cont...

Page 94: ...NNECTED 1 Check fuses No 1 and 6 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 300 ie 2008 ELE SYS 94 ...

Page 95: ...ontacts 4 With the ignition key 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 c...

Page 96: ...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 97: ...tch 11 Headlight relay 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 300 ie 2008 Electri...

Page 98: ...tch 8 Check that the Grey Red cable of the light switch and the headlight relay 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 one fuse B located under the helmet com partment...

Page 99: ...l Live Saddle opening actuator 4 Fuse No 4 Capacity 7 5 A Protected circuits Pre installation for anti theft device instrument panel 5 Fuse No 5 Capacity 7 5 A Protected circuits Electric fan remote control injection load relay immobilizer aerial ECU 6 Fuse No 6 Capacity 7 5 A Protected circuits Horn stop light start up circuit headlight relay antitheft pre installation turn indicators instrument ...

Page 100: ... charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE 1 Voltage check Before installing the battery on the vehicle check the open circuit voltage with a standard tester If voltage exceeds 12 60 V the battery can be installed without any renewal recharge If voltage is below 12 60 V a renewal re...

Page 101: ... CHILDREN 1 Battery preparation Position the battery on a flat surface Remove the adhesive sheet closing cells and proceed as quick ly as possible to run the subsequent activation phases 2 Electrolyte preparation Remove the container of the electrolyte from the pack Remove and preserve cover strips from the container in fact the strip will later be used as a closing cover Note Do not pierce the se...

Page 102: ...e to the battery The filling process is now complete Do not remove the strip of caps under any circumstances do not add water or electrolyte Place the battery down for 1 to 2 hours prior to the charging from the battery 7 Recharging the new battery With the above mentioned procedure the battery will have gained around 70 75 of its total electrical capacity Before installing the battery on the vehi...

Page 103: ...recharge Maintenance Free as shown in fig ure f Check the ignition of the green LED indicated with a red arrow in figure g The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place Vespa GTS Super 300 ie 2008 Electrical system ELE SYS 103 ...

Page 104: ...om the fuel supply grid disconnect the clamps from the battery and proceed to fitting the battery on the vehicle Connectors DIAGNOSTICS CONNECTOR 1 Not connected 2 Ground lead Black 3 Electronic control unit Violet White PICKUP CONNECTOR 1 Control unit positive Red 2 Negative from control unit Brown 3 Not connected FUEL PUMP CONNECTOR 1 Power from solenoid Black Green 2 Fuel level indicator White ...

Page 105: ...hite 15 Not connected 16 K serial line Purple White 17 Immobilizer Red Green 18 Not connected 19 Side stand Grey Green 20 Speed sensor negative Brown 21 Not connected 22 Injection load relay Black Purple 23 Not connected 24 Consent to radiator electric fan Blue Yellow 25 Injection warning light Brown Black 26 Not connected 27 Not connected 28 Not connected 29 Engine speed sensor positive Red 30 No...

Page 106: ...ONNECTOR 1 Power from solenoid Black Green 2 Electronic control unit Red Yellow LAMBDA PROBE CONNECTOR 1 Positive from control unit Sky blue Black 2 Control unit negative White Green VOLTAGE REGULATOR CONNECTOR 1 Battery positive Red Black 2 Ground lead Black 3 Battery positive Red Black 4 Ground lead Black Electrical system Vespa GTS Super 300 ie 2008 ELE SYS 106 ...

Page 107: ...UMENT PANEL CONNECTOR B 1 Ground lead Black 2 Injection warning light Brown Black 3 Low fuel warning light Grey Black 4 Water temperature Green Yellow INSTRUMENT PANEL CONNECTOR C 1 Immobilizer warning light Red Green 2 Battery powered Red Blue 3 Lighting Yellow Black 4 Live supply White H V COIL CONNECTOR 1 Power from solenoid Black Green 2 Electronic control unit Pink Black Vespa GTS Super 300 i...

Page 108: ...rter button the brake switches the starter relay and the injection control unit through PIN 10 are involved ELECTRICAL ERRORS Starter command P0170 shorted to positive Error cause Shorted to positive excessive voltage at PIN 10 of the control unit connector Troubleshooting Short circuit to positive This malfunction is detected with a brake activated and the starter button pressed If the battery vo...

Page 109: ...ge on the coil connector PIN 2 if present restore the cabling otherwise replace the coil Open circuit Carry out the check procedure of the coil and control unit connectors Verify continuity of the cabling between the coil and control unit Coil PIN 2 control unit PIN 1 If there is no continuity restore the cable harness Verify with the key turned ON the presence of voltage on the coil connector PIN...

Page 110: ...e harness otherwise proceed with the following checks Shorted to negative Disconnect the injector connector turn ignition switch to ON and activate the component using the diagnostic tool Verify the presence of voltage at the ends of the injector connector if there is no voltage restore the cable harness otherwise proceed with the following checks Open circuit Perform the check of the injector and...

Page 111: ...le harness ELECTRIC FAN CIRCUIT Function Radiator fan and coolant Operation Operation Operating principle The control unit closes the fan control relay excitation circuit to ground until the temperature drops ELECTRICAL ERRORS Fan relay P0480 shorted to positive shorted to negative open circuit Error cause Shorted to positive excessive voltage at PIN 24 of the control unit connector Shorted to neg...

Page 112: ...t circuit to positive interruption of the circuit or excessive voltage at PIN 13 of the control unit connector Short circuit to negative null voltage between PIN 13 and 7 of the control unit connector Troubleshooting Open circuit Disconnect the connector of the control unit Measure the resistance value of the sensor at different temperatures between PIN 13 and 7 Disconnect the sensor connector Che...

Page 113: ...n signal not plausible for abnormal title correction or probe signal fault Error cause Short circuit to positive excessive voltage to PIN 11 or PIN 12 of the control unit connector Open circuit or short circuit to negative interruption of the circuit or zero voltage between the pins 11 and 12 of the control unit connector Troubleshooting Short circuit to positive Disconnect the control unit connec...

Page 114: ...ecks Short circuit to negative Disconnect the sensor connector and the control unit connector Check the insulation from the ground of PIN 1 of the sensor connector If there is no insulation restore the cable harness Check the insulation from the ground of PIN 2 of the sensor connector If there is no insulation restore the cable harness If PIN 1 and 2 are insulated from ground and the error persist...

Page 115: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 116: ...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 silencer 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 silencer to the supporting arm Remove ...

Page 117: ...ove 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 s...

Page 118: ... 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 300 ie 2008 ENG VE 118 ...

Page 119: ...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 300 ie 2008 Engine from vehicle ENG VE 119 ...

Page 120: ...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 300 ie 2008 ENG VE 120 ...

Page 121: ...ngine to the vehicle carry out the removal operations but in reverse order and respect the tightening torque shown in the Spec ifications 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 correc...

Page 122: ...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 300 ie 2008 ENG VE 122 ...

Page 123: ...INDEX OF TOPICS ENGINE ENG ...

Page 124: ...tch housing 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 TRANSMISSION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH HOUSING Air duct Remove the transmission compartme...

Page 125: ...or 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 DAM AGING 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 Ada...

Page 126: ...ts 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 housing and the driven pulley assembly N B THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED Engine Vespa GTS Super 300...

Page 127: ...r 15 and 17 mm Lock with the original spacer and nut Place the bell shaft unit on the support to check the crankshaft alignment Using a feeler dial 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 Magnetic moun...

Page 128: ... spring with its plastic holder CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CON TACT WITH THE TOOL EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE Specific tooling 020444Y011 adapter ring 020444Y009 wrench 46 x 55 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass friction ...

Page 129: ... O RING SEAL Remove the 4 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 retainer ring using two flat blade screwdrivers Support the pulley bushing adequately from the threaded side using a wooden surface Using a hammer and pin knock the ball bearing out as...

Page 130: ... guide Inspecting the driven fixed half pulley Measure the outside diameter of the pulley bush ing Check the faying surface with the belt to make sure there are no flaws Check the riveted joints are functional Check 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...

Page 131: ...m standard diameter Ø 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 bearing as shown in the figure For the fitting of the new ball bearing follow the example in the figure using a modular punch Fit the retainer ring WARNING N B FIT THE BALL BEARING ...

Page 132: ...ately 6 grams of grease Apply 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 RE PLACED UNDERTAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER Specific ...

Page 133: ...gainst the torque server closing collar Insert the spring with its plastic holder in contact with the clutch Insert the drive belt into the pulley unit according to their direction of rotation Insert the pulley unit with the belt into the tool Slightly preload the spring Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut Place the tool...

Page 134: ... BE CARE FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING N B FOR DESIGN REASONS THE NUT IS SLIGHTLY ASYM METRIC THE FLATTEST SURFACE SHOULD BE MOUN TED IN CONTACT WITH THE CLUTCH Specific tooling 020444Y Tool for fitting removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55 Locking torques N m Clutch unit nut on driven pulley 45 50 Refitting the dr...

Page 135: ...gram you are advised to check that the rim bottom of the toothing does not show signs of incisions 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 picture V...

Page 136: ...ter 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 faying 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 with the belt Chec...

Page 137: ...m 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 crank shaft Fit the driven pulley Cl...

Page 138: ...2 alignment dowels and that the sealing gasket for the oil sump on the trans mission cover is adequately fitted Replace the cover and tighten the 10 screws to the specified torque Refit the oil loading cap bar Refit the steel washer and the driven pulley nut Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools Refit the plastic cover Specific tooling 020423Y D...

Page 139: ...hrough 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 Super 300 ie 2008 Engine ENG 139 ...

Page 140: ...Specific tooling 001467Y013 Calliper to extract ø 15 mm bear ings Removing the wheel axle bearings Take out the clip on the outside of the hub 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 support ...

Page 141: ... 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 If faults are found replace the damaged compo nents Inspecting the hub ...

Page 142: ...he 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 Super 300 ie 2008 ENG 142 ...

Page 143: ...EQUATELY SUPPORT THE COVER WITH THE STUD BOLT KIT 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 RETAIN ER 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 144: ...pe 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 Super 300 ie 20...

Page 145: ...er Remove the 10 clamps 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 Super 300 ie 2008 Engine ENG 145 ...

Page 146: ...t the end as shown in the figure Orient the water pump shaft with reference to the transmission gear seat as shown in the picture Refit the cover over the engine and tighten the screws to the prescribed torque Carry out the removal steps but in the reverse order CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR MAKE SURE THE CEN TRING DOWELS ARE PRESENT Locking torques N m Flywheel co...

Page 147: ...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 picture Screw in the guide bushing that is part of the special flywheel stop tool on the flywheel as shown in the picture Vespa GTS Super 300 ie 2008 Engine ENG 147 ...

Page 148: ...cture Specific tooling 020467Y Flywheel extractor Inspecting the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate Refitting the free wheel Make sure the freewheel faying 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 clamping scre...

Page 149: ...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 picture Remove the transmission gear and the freewheel Insert the free wheel on the flywheel as shown in the picture Then refit the flywheel with free wheel and trans mission gear Vespa GTS Super 300 ie 2008 E...

Page 150: ...itting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the intake manifold Loosen the 3 screws and remove the air intake manifold Upon refitting secure to the specified torque Engine Vespa GTS Super 30...

Page 151: ...g 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 Super 300 ie 2008 Engine E...

Page 152: ...emove the control sprocket wheel and the tim ing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioner slider must be removed from the transmission side As regards the lower chain guide slider it may only be removed after the head has been removed N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION I...

Page 153: ...G THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER 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 alignment dowels and the gasket N B IF NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKER PINS AND FIXING BRACKET THE HEAD CAN ALSO BE RE...

Page 154: ... 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 slider 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 TO AVOID DAMAGING THE PISTON S...

Page 155: ...o Cylinder piston assy Inspecting the piston N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the cylinder N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the piston rings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHA...

Page 156: ... STOPS HOUS ING Specific tooling 020454Y Pin lock fitting tool Choosing the gasket Provisionally fit the piston into the cylinder without any base gasket Assemble a dial gauge on the specific tool Specific tooling 020428Y Piston position check mounting Using an abutment plane reset the dial gauge with a preload of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler...

Page 157: ...p posed to the spring junction and with the writing top facing the piston crown The chamfered side of the oil scraper ring should always be facing the piston crown Fit the second lining with the identification letter or the writing top facing the piston crown In any case the step must be facing opposite the piston crown Install the first compression lining in the direction imposed by the housing I...

Page 158: ...ING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Inspecting the timing system components Check that the guide slider and the tensioner slider are not worn out Ensure that the camshaft control pulley chain as sembly and the sprocket wheel are not worn If you detect wear replace the parts or if the chain sprocket wheel and pulley are worn replace the whole unit Remove the centre...

Page 159: ...al wear Replace a component when worn Measure the unloaded spring length N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Refitting the valves Lubricate the valve guides with engine oil Place the valve spring supports on the head Using the special punch fit the four valve seal rings Fit the valves the springs and the caps Using the appropria...

Page 160: ...rankshaft 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 prescribed torque Fit the pins and rocking levers Lubricate the two rocking levers through the holes at the top Lubricate the 2 bearings and insert the camshaft in ...

Page 161: ...ish 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 using a new gasket and tight the two screws to the pre scribed torque Insert the chain tensioning screw together with the spring and washer tightening it to the prescri bed torque Adjust the valve cleara...

Page 162: ...ket 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 in the figure Engine Vespa GTS Super 300 ie 2008 ENG 162 ...

Page 163: ...Timing chain tensioner support screw 11 to 13 Refitting the rocker arms cover Refit the cylinder head cover and tighten 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 Intake manifold screws 11 13 Vespa GTS Su...

Page 164: ...hown 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 any defect the problem must ...

Page 165: ...MITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly clean all surfaces and oil ducts On the transmission side crankcase half take particular care when handling the oil pump com partment and the oil ducts the by pass duct the main bushings and the cooling ...

Page 166: ...ARE DIFFICULT TO DETECT PISTON TEMPERATURE IN CREASE FAILURE OR LEAKS CAN CAUSE A CONSID ERABLE DROP IN THE LUBRICATION PRESSURE FOR MAIN BUSHINGS AND CONNECTING ROD N B THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET THIS GIVES A LOW PRESSURE HEAD LUBRICATION THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP THE JET CLOG GING IMPAIRS THE HEAD LUBRICATION AND THE TIM ING M...

Page 167: ...he prescribed torque Fit the oil filter fitting and tighten it to the prescri bed torque Position the oil pre filter element as shown in the picture Place a new gasket on one of the crankcase halves preferably on the transmission side to gether with the alignment dowels Lubricate the main bushings and insert the crank shaft in the transmission side crankcase half Reassemble both crankcase halves F...

Page 168: ...seat in the crankcase Check the depth of stud bolt driving with a gauge as indicated in the picture If it varies significantly from the driving depth indicated it means that the stud bolt has yielded In this case replace it Engine Vespa GTS Super 300 ie 2008 ENG 168 ...

Page 169: ... 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 Loctite 270 high strength threadlock Loctite 270 high strength threadlock Lubrication Conceptual diagrams LUBRICATION CIRCUIT Vespa GTS Super 300 ie 2008 Engine ENG 169 ...

Page 170: ...Engine Vespa GTS Super 300 ie 2008 ENG 170 ...

Page 171: ...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 flywheel cover If the oil pressure is not within the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL...

Page 172: ...al Specific tooling 020622Y Transmission side oil seal punch Refitting Always use a new oil seal upon refitting Prepare the new oil guard by lubricating the seal ing lip Preassemble the oil seal with the appropriate tool by 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 adapt...

Page 173: ...T LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL SEAL FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONIN...

Page 174: ...heel with relative O ring Remove the oil pump by undoing the two screws in the figure Remove the oil pump seal N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the circlip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Rea...

Page 175: ...mm Distance between the rotors Admissible 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 clamping screws to be aligned Make sure the...

Page 176: ...g oil pump to the crankcase 5 6 Oil pump command sprocket screw 10 to 14 Oil pump cover screws 0 7 0 9 Removing the oil sump Remove the oil filler plug the transmission cover the complete driving pulley assembly with belt and the sprocket wheel as described in the Trans mission chapter Drain the oil as described above Remove the 7 screws shown in the diagram and the 2 rear brake fluid pipe fixing ...

Page 177: ...o 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 driving pulley assembly the drive belt the sprocket wheel and the transmission cover as described in the Transmissio...

Page 178: ...INDEX OF TOPICS INJECTION INJEC ...

Page 179: ...Vespa GTS Super 300 ie 2008 Injection INJEC 179 ...

Page 180: ...rs Coolant temperature Intake air temperature Lambda probe The system implements cold engine idle fuel air mixture correction with 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 181: ...anel Failures are detected and restored by the diagnostic 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 020922Y Diagnosis Tool The MIU injection ignition system carries out checks on the rp...

Page 182: ...om the battery and the injection system connections 9 Before disconnecting the MIU ECU connector perform the following steps in the order shown Set the switch to OFF Disconnect the battery Failure to respect this norm may damage the control unit 10 Do not invert the poles when fitting the battery 11 To avoid causing any damage disconnect and reconnect the MIU system connectors only if re quired Be...

Page 183: ...heck that the terminals are not bent B check that the connectors have been properly connected C Check whether the malfunction can be fixed by shaking the connector slightly 3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU install the original control unit again and check if the fault occurs again 4 Use a multimeter with an internal resistance of more tha...

Page 184: ...6 K serial line Purple White 17 Immobilizer Red Green 18 Not connected 19 Side stand Grey Green 20 Speed sensor negative Brown 21 Not connected 22 Injection load relay Black Purple 23 Not connected 24 Consent to radiator electric fan Blue Yellow 25 Injection warning light Brown Black 26 Not connected 27 Not connected 28 Not connected 29 Engine speed sensor positive Red 30 Not connected 31 Lambda p...

Page 185: ...6 Magneto flywheel 7 Fuse No 1 30A 8 Fuse No 5 7 5A 9 Fuse No 2 15A 10 Fuses No 6 7 5A 11 Fuse No 3 15A 12 Fuse No 4 7 5A 14 Key switch contacts 15 Engine stop switch 16 N 2 stop buttons 17 Brake lamp 12v 16w 18 Injection load relay 19 Electric fan remote control Vespa GTS Super 300 ie 2008 Injection INJEC 185 ...

Page 186: ...Revolution timing sensor Fuel system Fuel in the tank Fuel pump activation Fuel pressure low Injector capacity low Power to the spark plug Shielded spark plug cap HV coil secondary insulation Parameter reliability Coolant temperature Distribution timing injection ignition Intake air temperature End of compression pressure End of compression pressure Starting difficulties ENGINE STARTER PROBLEMS Po...

Page 187: ...or Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper 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 Engine does not rev down ENGINE DOES NOT RETURN TO IDLING SPEED IDLING SPEED TOO HIG...

Page 188: ...lencer welding Engine revs irregularly ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing Intake sleeve Filter box Ignition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperatu...

Page 189: ...t temperature Lambda probe Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Sel...

Page 190: ...Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the fast release fittings from the injector support Injection Vespa GTS Super 300 ie 2008 INJEC 190 ...

Page 191: ... screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector Remove the clip fixing the throttle body to the air cleaner bellows Vespa GTS Super 300 ie 2008 Injection INJEC 191 ...

Page 192: ... 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 photograph Injection Vespa GTS Super 300 ie 2008 INJEC 192 ...

Page 193: ...upply circuit 1 Battery 12V 2 Fuse No 2 of 15A 3 30A fuse No 1 4 Key switch contacts 5 Fuse No 5 of 7 5A 6 Injection load remote control 7 Fuel pump 8 H V coil Vespa GTS Super 300 ie 2008 Injection INJEC 193 ...

Page 194: ...it power works properly Check the efficiency of the injection load solenoid Check the resistance of the energising coil be tween 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 relay Check the power supply line of the injection load solenoid energising coil after switching to ON make sure there is battery voltage...

Page 195: ...between the grey black cable of the remote control base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Vespa GTS Super 300 ie 2008 Injection INJEC 195 ...

Page 196: ...easuring the continuity between the pump connector black cable system side and the ground If when switching to ON the pump continues to turn after two seconds of activation check with the control unit disconnected and the injection load re mote control disconnected that the Black Purple cable pin 20 on the interface wiring is insulated from the ground Specific tooling 020331Y Digital multimeter Ci...

Page 197: ... gauge of the appropriate tool Make a graded burette available with a flowrate of approximately 1 L Rotate 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 pressure stabilise at approx 2 5 BAR Check that in fifteen seconds the pump has a flowrate of around 110cc Specific tooling 020480Y Petrol pressure check ki...

Page 198: ...lip 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 Injection Vespa GTS Super 300 ie 2008 INJEC 198 ...

Page 199: ...Inspecting the injector circuit 1 Battery 12V 2 Fuse No 2 of 15A 3 30A fuse No 1 4 Key switch contacts Vespa GTS Super 300 ie 2008 Injection INJEC 199 ...

Page 200: ... and 85 make sure that there is continuity between pins 30 and 87 of the relay Check the power supply line of the injection load solenoid energising coil after switching to ON make sure there is battery voltage for two sec onds between the Red White cable and Black Purple cable of the solenoid control base If there is not check the continuity of the Red White cable between the fuse box under the s...

Page 201: ... base and earth If there is none check the continuity of the grey black cable between the fuse box No 2 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Vespa GTS Super 300 ie 2008 Injection INJEC 201 ...

Page 202: ...able be tween pin 34 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 Injection Vespa GTS Super 300 ie 2008 INJEC 202 ...

Page 203: ...ifold 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 is dis...

Page 204: ...njector outlet with a blast of compressed air Activate the fuel pump Wait for one minute making sure there are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute Injection Vespa GTS Super 300 ie 2008 INJEC 204 ...

Page 205: ...Components location Vespa GTS Super 300 ie 2008 Injection INJEC 205 ...

Page 206: ...nic injection control unit MIU 3 Diagnostic socket 4 Fuel pump 5 Water temperature sensor 6 Fuel injector 7 HV coil 8 Flywheel rpm timing sensor 9 Lambda Probe 10 Injection load remote control 11 Battery 12V 12 Ah 12 Electric fan remote control Injection Vespa GTS Super 300 ie 2008 INJEC 206 ...

Page 207: ...HT coil 1 Battery 12V 2 Fuse No 2 of 15A 3 30A fuse No 1 4 Key switch contacts 5 Fuse No 5 of 7 5A 6 Injection load remote control 7 Fuel pump 8 H V coil Vespa GTS Super 300 ie 2008 Injection INJEC 207 ...

Page 208: ...by the control unit The ignition power is increased during the engine start up phase The injection system recognises the four stroke cycle so the ignition is only commanded in the com pression phase Specific tooling 020331Y Digital multimeter Check that the injection load 15A fuse No 2 works properly Check that the 7 5A fuse No 5 for live control unit power works properly Check the efficiency of t...

Page 209: ... the solenoid 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 Purple cable between pin 22 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Vespa GTS Super 300 ie 2008 Injection INJEC ...

Page 210: ...m 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 body after the pre calibration ha...

Page 211: ...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 reset procedure Reset should be performed in the following cases on first fitting if the injection control unit is replaced N B THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR ...

Page 212: ...Impianto elettroventilatore 1 Battery 12V 2 Fuse No 2 of 15A 3 30A fuse No 1 4 Key switch contacts 5 Fuse No 5 of 7 5A 6 Injection load relay 7 Fuel pump Injection Vespa GTS Super 300 ie 2008 INJEC 212 ...

Page 213: ...nd connection Check if the RED WHITE cable between the fuse box under the saddle and the electric 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 electric fan remote control Check if the BLUE YELLOW cable between the control unit pin 8 and the electric fan remot...

Page 214: ...at and the fuse box in the glove box compartment is not interrupted 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 300 ie 2008 I...

Page 215: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 216: ...ixing screws indicated in the pic ture Locking torques N m Wheel fixing screw 20 to 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 300 ie 2008 SUSP 216 ...

Page 217: ...the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract ø 15 mm bear ings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Vespa GTS Super 300 ie 2008 Suspensions SUSP 217 ...

Page 218: ...20412Y 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 Yellow brown lithium base medium fibre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 Refitting the front wheel To refit c...

Page 219: ...eel 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 300 ie 2008 Suspensions SUSP 219 ...

Page 220: ...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 300 ie 2008 SUSP 220 ...

Page 221: ...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 222: ...lower disk of the fifth wheel operating from the up per part Specific tooling 020004Y Punch for removing steering bearings from headstock Remove the fifth wheel fitting and the dust gaiter on the steering bearing as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing steering bearings from headstock Suspensions Vespa GTS Sup...

Page 223: ...ly the 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 par...

Page 224: ... 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 ring unit placing part 16 u...

Page 225: ...e swing ing hub Remove the 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 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 NATO G 460 symbol Refitting To refit carry out the removal operations but in reverse order grease the fifth ...

Page 226: ... 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 300 ie 2008 SUSP 226 ...

Page 227: ... 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 228: ...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 52 x ...

Page 229: ... using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base gr...

Page 230: ...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 300...

Page 231: ...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 300 ie 2008 Suspensions SUSP 231 ...

Page 232: ...Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm In order to check the clearance of the swinging arm on the frame side prepare a retainer using the fixing pin of the swinging arm on the frame and two rings from the special tool 020229Y Alternatively use two washers with 12 mm inside diameter for pins minimum 30 mm outside diameter and 4 mm thick at least Check there ...

Page 233: ...bearings with the seal 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 inter...

Page 234: ...ide swinging arm with the most protruding part pointing towards the silent block side as shown in the picture Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 NATO G 460 symbol 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 silent bloc bracket Undo...

Page 235: ...tall 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 ...

Page 236: ...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 237: ...ation 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 the...

Page 238: ...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 to 40 Suspensions Vespa GTS Super 300 ie 2008 SUSP 238 ...

Page 239: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 240: ...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 241: ...s 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 cal...

Page 242: ...HE 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 expulsi...

Page 243: ... 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 244: ...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 245: ...d 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 300 ie 2008 Braking system BRAK SYS 2...

Page 246: ...hotograph 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 fo...

Page 247: ... 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 300 ie 2008 Braking system BRAK SYS 2...

Page 248: ...ew tightening calliper to support 24 to 27 Pad fastening pin 19 6 to 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 w...

Page 249: ...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 250: ...ific tooling 020329Y Mity Vac vacuum operated pump Locking torques N m System bleed calliper fitting 12 to 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 u...

Page 251: ...ING 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 sc...

Page 252: ...The pump body shows no signs of internal damage or corrosion The plunger shows no sign of damage or abnormal wear The piston 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 300 ie 2008 BRAK ...

Page 253: ... 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 handlebar 7 to 10 Nm Vespa GTS Super 300 ie 2008 Braking system BRAK SYS 253 ...

Page 254: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 255: ...Circuit diagram Vespa GTS Super 300 ie 2008 Cooling system COOL SYS 255 ...

Page 256: ...Cooling system Vespa GTS Super 300 ie 2008 COOL SYS 256 ...

Page 257: ...ank Place one end of the pipe on the bleed valve and the other in the expansion tank Loosen the screw by two turns until the commu nication hole is revealed with the head as shown in the picture Wait until only coolant comes out of the rubber pipe so as to eliminate any air bubbles inside the circuit Tighten the bleed valve respecting the maximum torque Vespa GTS Super 300 ie 2008 Cooling system C...

Page 258: ...the two screws indicated lift the cover and remove the thermostat Check 1 Visually inspect that the thermostat is not dam aged 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 keep it close to the thermostat Heat up the container using the thermal gun Cooling system Vespa GTS Super ...

Page 259: ...20331Y Digital multimeter 020151Y Air heater THERMOSTAT Specification Desc Quantity Type Wax type with deviator Starts opening at 85 2 C Refitting Follow the removal steps but in reverse order be careful to tighten screws to the prescribed torque Locking torques N m Thermostat cover screws 3 4 Once the cooling circuit is restored refill using the recommended product and purge the circuit as expres...

Page 260: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 261: ... 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 Vespa GTS Super 300 ie 2008 Chassis CHAS 261 ...

Page 262: ...ograph 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 Chassis Vespa GTS Super 300 ie 2008 CHAS 262 ...

Page 263: ...nnecting 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 Vespa GTS Super 300 ie 2008 Chassis CHAS 263 ...

Page 264: ...t 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 Chassis Vespa GTS Super 300 ie 2008 CHAS 264 ...

Page 265: ... 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 Vespa GTS Super 300 ie 2008 Chassis CHAS 265 ...

Page 266: ...top 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 INFI...

Page 267: ...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 Vespa GTS Super 300 ie 2008 Chassis CHAS 267 ...

Page 268: ...screw the 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 luggage rack Remove the shock absorber upper clamps Remove the two screws indicated in the figure that fix the tank to the body Chassis Vespa GTS Super 300 ie 2008 CHAS 268 ...

Page 269: ...the 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 Vespa GTS Super 300 ie 2008 Chassis CHAS 269 ...

Page 270: ...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 271: ...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 Vespa GTS Super 300 ie 2008 Chassis CHAS 271 ...

Page 272: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 273: ...ont 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 currently in...

Page 274: ...TALLY 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 FUSES W...

Page 275: ...CAUTION 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 acc...

Page 276: ...INDEX OF TOPICS TIME TIME ...

Page 277: ... 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 Vespa GTS Super 300 ie 2008 Time TIME 277 ...

Page 278: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Time Vespa GTS Super 300 ie 2008 TIME 278 ...

Page 279: ...ssy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 3 001129 Chain tensioner Service and Re placement Vespa GTS Super 300 ie 2008 Time TIME 279 ...

Page 280: ...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 Time Vespa GTS Super 300 ie 2008 TIME 280 ...

Page 281: ...Rocker arms support assy CAMSHAFT Code Action Duration 1 001148 Rockers valves Replacement 2 001044 Camshaft Replacement Cylinder head cover Vespa GTS Super 300 ie 2008 Time TIME 281 ...

Page 282: ...placement 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 Time Vespa GTS Super 300 ie 2008 TIME 282 ...

Page 283: ... 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 Vespa GTS Super 300 ie 2008 Time TIME 283 ...

Page 284: ...g 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 Time Vespa GTS Super 300 ie 2008 TIME 284 ...

Page 285: ...EDUCTION 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 Vespa GTS Super 300 ie 2008 Time TIME 285 ...

Page 286: ...n 1 001086 Driving half pulley Replacement 2 001011 Drive belt Replacement 3 001066 Driving pulley Removal and refitting 4 001177 CVT rollers sliders Replacement 5 001141 Belt anti flapping roller Replace ment Time Vespa GTS Super 300 ie 2008 TIME 286 ...

Page 287: ... 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 Vespa GTS Super 300 ie 2008 Time TIME 287 ...

Page 288: ...START 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 Time Vespa GTS Super 300 ie 2008 TIME 288 ...

Page 289: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001067 Stator Removal and Refitting 2 001173 Rotor Replacement 3 001058 Complete flywheel change Vespa GTS Super 300 ie 2008 Time TIME 289 ...

Page 290: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Replacement 2 001047 Injector Replacement 3 001013 Intake manifold change Time Vespa GTS Super 300 ie 2008 TIME 290 ...

Page 291: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Silencer Replacement 2 001095 Silencer heatshield Replacement 3 005138 Lambda probe Replacement Vespa GTS Super 300 ie 2008 Time TIME 291 ...

Page 292: ...Action 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 Time Vespa GTS Super 300 ie 2008 TIME 292 ...

Page 293: ...cement 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 Vespa GTS Super 300 ie 2008 Time TIME 293 ...

Page 294: ...Centre stand STAND Code Action Duration 1 004102 Side stand Replacement 2 004004 Stand Replacement Footrests Time Vespa GTS Super 300 ie 2008 TIME 294 ...

Page 295: ...2 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 Vespa GTS Super 300 ie 2008 Time TIME 295 ...

Page 296: ...Underseat compartment HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Removal and Refitting 2 004011 Central chassis cover Replacement Time Vespa GTS Super 300 ie 2008 TIME 296 ...

Page 297: ...Plate holder LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate holder mounting Re placement 2 005048 number plate holder Replacement Mudguard Vespa GTS Super 300 ie 2008 Time TIME 297 ...

Page 298: ...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 Time Vespa GTS Super 300 ie 2008 TIME 298 ...

Page 299: ...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 Vespa GTS Super 300 ie 2008 Time TIME 299 ...

Page 300: ...shock absorber REAR SHOCK ABSORBERS Code Action Duration 1 003007 Rear shock absorber Removal and Refitting 2 003077 silencer rear shock absorber support arm Service Time Vespa GTS Super 300 ie 2008 TIME 300 ...

Page 301: ...Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering bearing Replacement 2 003073 Steering clearance Adjustment Vespa GTS Super 300 ie 2008 Time TIME 301 ...

Page 302: ...Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004018 Front handlebar covers Replace ment 2 004019 Rear handlebar covers Replace ment Time Vespa GTS Super 300 ie 2008 TIME 302 ...

Page 303: ...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 Vespa GTS Super 300 ie 2008 Time TIME 303 ...

Page 304: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine chassis connection swinging arm Replacement 2 004058 Silent block Replacement Time Vespa GTS Super 300 ie 2008 TIME 304 ...

Page 305: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Instrument panel Vespa GTS Super 300 ie 2008 Time TIME 305 ...

Page 306: ...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 Time Vespa GTS Super 300 ie 2008 TIME 306...

Page 307: ...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 Vespa GTS Super 300 ie 2008 Time TIME 307 ...

Page 308: ...Tail 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 Time Vespa GTS Super 300 ie 2008 TIME ...

Page 309: ... 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 Vespa GTS Super 300 ie 2008 Time TIME 309 ...

Page 310: ...ration 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 Time Vespa GTS Super 300 ie 2008 TIME 310 ...

Page 311: ...placement 5 005052 Fuse 1 Replacement 6 005007 Battery change 7 005120 Control unit power supply remote control Replacement 8 005035 Headlight solenoid Replacement 9 005117 Electric fan remote control Replace ment 10 005011 Starter relay Replacement 11 005054 Fuse block 1 Replacement 12 005001 Electrical system Removal and re fitting Vespa GTS Super 300 ie 2008 Time TIME 311 ...

Page 312: ...Transmissions TRANSMISSIONS Code Action Duration 1 002051 Odometer transmission assembly Replacement Time Vespa GTS Super 300 ie 2008 TIME 312 ...

Page 313: ...oval and Refitting 2 003045 Steering tube Fork tube Replace ment 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 Vespa GTS Super 300 ie 2008 Time TIME 313 ...

Page 314: ...Replacement 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 Time Vespa GTS Super 300 ie 2008 TIME 314 ...

Page 315: ...Stickers TRANSFERS Code Action Duration 1 004159 Plates Stickers Replacement Vespa GTS Super 300 ie 2008 Time TIME 315 ...

Page 316: ...250 C Checks 85 E Electric 311 Engine oil 50 F Fuel 189 197 268 298 Fuses 98 H Headlight 55 264 Horn 94 Hub oil 48 I Identification 8 Instrument panel 263 305 L Luggage rack M Maintenance 7 45 O Oil filter 51 282 R Recommended products S Saddle Shock absorbers 236 Spark plug 47 Stand 238 ...

Page 317: ...Start up Suspension 58 59 313 Switch T Tank 268 298 Transmission 10 57 124 138 287 Turn indicators 83 Tyre pressure Tyres 15 V Vehicle 8 116 117 ...

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VESPA GTS Super 300 ie 2008, Service Station Manual

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Summary of Contents for GTS Super 300 ie 2008

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