VESPA GTV 125 Service Station Manual Download

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Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the

threaded side using a wooden surface.

- Fit a new roller sleeve as in the figure.

- For the fitting of the new ball bearing, follow the

example in the figure using a modular punch.

Fit the retention ring

WARNING

N.B.

FIT THE BALL BEARING WITH THE VISIBLE
SHIELD

Specific tooling

020376Y

Adaptor handle

020375Y

Adaptor 28 x 30 mm

020424Y

Driven pulley roller casing fitting

punch

Refitting the driven pulley

- Insert the new oil guards and O-rings on the mov-

able half-pulley.

- Lightly grease the O-rings (A) shown in the figure.

Vespa GTV 125

Engine

ENG - 9

Summary of Contents for GTV 125

Page 1: ...SERVICE STATION MANUAL 664619 IT 664620 EN 664621 FR 664622 DE 664623 ES 664624 PT 664625 OL 664626 EL Vespa GTV 125 ...

Page 2: ...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 shown in this publication are available in all Countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproducti...

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

Page 4: ......

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

Page 6: ......

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

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

Page 9: ...1001 Engine prefix M315M1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Total kerb weight 148 5 kg Overall width 770 mm Length 1940 mm Wheelbase 1395 mm Height 1180 mm Saddle height 800 mm Vespa GTV 125 Characteristics CHAR 3 ...

Page 10: ... 6 mm Cubic capacity 124 cm Compression ratio 12 0 5 1 Carburettor Keihin CVK 30 Engine idle speed 1650 50 rpm Air filter sponge impregnated with mixture 50 petrol and 50 oil Starting system electric starter Lubrication with lobe pump inside the crankcase chain driv en and double filter mesh and paper Fuel supply petrol with vacuum pump and through carburettor MAX power 10 5 to 9500 rpm MAX torque...

Page 11: ... and separate HV coil Variable ignition advance before TDC 10 1 at 2000 rpm Spark plug Champion RG 4 HC Battery Sealed 12 V 10 Ah Generator alternating current Frame and suspensions FRAME AND SUSPENSIONS Specification Desc Quantity Type Unitised body made of stamped plate Front suspension Single arm suspension cantilever wheel fitted with a double acting hydraulic shock absorber with coaxial sprin...

Page 12: ... TYRE PRESSURE Specification Desc Quantity Front tyre pressure when cold 1 8 bar Rear tyre pressure when cold 2 bar Tyre pressure when cold with passenger 2 2 bar N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE REGU LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES Carburettor 125cc Version Kehin CARBURETTOR KEIHIN Specification Desc Quantity Depression carbur...

Page 13: ...ontrol assembly U bolts 7 10 FRAME ASSEMBLY Name Torque in Nm Engine swinging arm bolt 64 72 swinging arm bolt body shell 76 83 Engine and vehicle side swinging arm junction bolt 33 41 Bolt of the Silent block support plate 42 52 Centre stand bolt 25 30 Side stand fixing bolt 40 45 FRONT SUSPENSION Name Torque in Nm Screw fixing the shock absorber to the shock ab sorber calliper attachment plate 2...

Page 14: ...gine tightening screw 20 25 Brake pump reservoir screws 15 20 Calliper coupling screws 30 33 MUFFLER Name Torque in Nm Muffler heat guard clamping screw 5 6 Exhaust fumes inlet screw 13 15 Screw for fixing muffler to the support arm 20 25 LUBRICATION Name Torque in Nm Hub oil drainage plug 15 17 Oil filter on crankcase fitting 27 33 Engine oil drainage plug mesh filter 24 30 Oil filter 8 10 Oil pu...

Page 15: ...crews 11 13 Driven pulley shaft nut 54 60 Rear hub cap screws 24 27 FLYWHEEL Name Torque in Nm Flywheel cover fixing screws 5 6 Stator assembly screws 3 4 Apply LOCTITE 242 medium strength threadlock Flywheel nut 52 58 Pick Up clamping screws 3 4 CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead transmis sion side half shaft screws 4 6 Engine crankcase coupling screws 1...

Page 16: ...7 218 57 159 57 166 0 045 0 059 Piston 1st Over size D 1 57 218 57 225 57 166 57 173 0 045 0 059 Cylinder 2nd Over size A2 57 397 57 404 57 345 57 352 0 045 0 059 Cylinder 2nd Over size B 2 57 404 57 411 57 352 57 359 0 045 0 059 Piston 2nd Over size C 2 57 411 57 418 57 359 57 366 0 045 0 059 Piston 2nd Over size D 2 57 418 57 425 57 366 57 373 0 045 0 059 Cylinder 3rd Over size A 3 57 597 57 604...

Page 17: ...earance Crankshaft to crankcase axial clearance CRANKSHAFT CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft trans mission side 16 6 0 0 05 A D 0 20 0 50 Flywheel side half shaft 16 6 0 0 05 B D 0 20 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 Vespa GTV 125 Characteristics CHAR 11 ...

Page 18: ...ane formed by the upper part of the cylinder The further the piston protrudes from the cylinder the bigger the base gasket to be used to recover the compression ratio and vice versa N B DISTANCE A MUST BE MEASURED WITHOUT ANY GASKET FITTED BETWEEN CRANKCASE AND CYLINDER SHIMMING Name Measure A Thickness Shimming 2 2 2 4 0 4 0 05 Shimming 2 4 2 6 0 6 0 05 Oversizes Characteristics Vespa GTV 125 CHA...

Page 19: ...3rd Oversize 57 6 x 2 5 A 0 15 0 35 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifi cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis sions throttle control Oil for 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for incre...

Page 20: ...Characteristics Vespa GTV 125 CHAR 14 ...

Page 21: ...INDEX OF TOPICS TOOLING TOOL ...

Page 22: ...seats 001467Y009 Driver for OD 42 mm bearings 001467Y017 Bell for bearings outside Ø 39 mm 001467Y014 Pliers to extract ø 15 mm bear ings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube Tooling Vespa GTV 125 TOOL 2 ...

Page 23: ...Stores code Description 008564Y Flywheel extractor 020004Y Punch for removing fifth wheels from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch Vespa GTV 125 Tooling TOOL 3 ...

Page 24: ...ch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip Tooling Vespa GTV 125 TOOL 4 ...

Page 25: ...pulley fitting 020287Y Clamp to assemble piston on cyl inder 020306Y Punch for assembling valve seal rings 020319Y Immobilizer check tester 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light for timing con trol Vespa GTV 125 Tooling TOOL 5 ...

Page 26: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger Tooling Vespa GTV 125 TOOL 6 ...

Page 27: ...s code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47 mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25 mm guide Vespa GTV 125 Tooling TOOL 7 ...

Page 28: ...65Y 22 mm guide 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Tooling Vespa GTV 125 TOOL 8 ...

Page 29: ...ores code Description 020393Y Piston fitting band 020409Y Multimeter adaptor Peak volt age detection 020412Y 15 mm guide 020414Y 28 mm guide 020423Y driven pulley lock wrench Vespa GTV 125 Tooling TOOL 9 ...

Page 30: ...ven pulley roller casing fitting punch 020425Y Punch for flywheel side oil seal 020426Y Piston fitting fork 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting Tooling Vespa GTV 125 TOOL 10 ...

Page 31: ...de Description 020439Y 17 mm guide 020440Y Water pump service tool 020441Y 26 x 28 mm adaptor 020442Y Pulley lock wrench 020444Y Tool for fitting removing the driv en pulley clutch Vespa GTV 125 Tooling TOOL 11 ...

Page 32: ...Description 020455Y 10 mm guide 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020488Y Pin stops fitting tool 200 cm en gines 020489Y Hub cover support stud bolt set Tooling Vespa GTV 125 TOOL 12 ...

Page 33: ...Stores code Description 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser Vespa GTV 125 Tooling TOOL 13 ...

Page 34: ...Tooling Vespa GTV 125 TOOL 14 ...

Page 35: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 36: ...000 KM 10 Action Engine oil level check top up AFTER 6000 KM Action Engine oil replacement Hub oil level check Spark plug electrode gap check Air filter clean Engine oil change valve clearance check Variable speed rollers check or replacement Driving belt check Coolant level check Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear...

Page 37: ...level check Spark plug electrode gap check Air filter clean Engine oil change Variable speed rollers check or replacement Driving belt check Coolant level check Radiator external cleaning check Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AT 24000 KM AND AT 48000 KM Action Engine oil re...

Page 38: ...e and brake test road test Engine oil replacement Oil filter Replacement AFTER 36000 KM Action Engine oil replacement Hub oil level check Air filter clean Engine oil change Spark plug replacement Idle speed adjustment Throttle lever adjustment Variable speed rollers check or replacement Driving belt replacement Coolant level check Radiator external cleaning check Steering adjustment Brake control ...

Page 39: ...adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid hoses replacement Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Driven pulley roller casing Greasing Tyre pressure and wear check Vehicle and brake test road test See instructions in Idle speed adjustment ...

Page 40: ...free valve slide even if it is new replace the carburettor It is advisable to replace the gaskets at every refit WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS RE PLACE THE GASKETS TO AVOID PETROL LEAKS 1 Diaphragm cover 2 Gas valve spring 3 Tapered pin support 4 Tapered pin spring 5 Tapered pin 6 Throttle valve diaphragm 7 Automatic starter 8 Idle speed adjustment screw 9 Accelerating pump rocking lev...

Page 41: ...load on the spark plug power line 10 15 KΩ in series to AT cable Remove the plastic cover from the slot on the fly wheel cover Operating on the flash corrector displacement of the bulb make the reference on the flywheel cover coincide with level on the water pump drive Read the advance degrees indicated by the stroboscop ic light Check that the advance degrees corresponds with the rotation rpm as ...

Page 42: ...esc Quantity Operation threshold First threshold 10700 50 Second threshold 11000 50 Reactivation threshold First threshold 10600 50 Second threshold 10900 50 Spark elimination First threshold 1 spark on 7 Second threshold 2 sparks on 3 Maintenance Vespa GTV 125 MAIN 8 ...

Page 43: ...ully 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 MOTOR IS COLD THE SPARK PLUG MUST BE REP...

Page 44: ...he oil dipstick again and make sure it is locked properly into place Replacement Remove the oil 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 ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Characteristic Rear hub oil Capacity 150 cm L...

Page 45: ...ded products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Remove the left side panel Remove the air cleaner cover after unscrewing the 9 fixing screws Take out the filtering element Replace the air filter with a new one N B EVERY 6 000 KM CHECK THE AIR FILTER AND IF REQUIRED CLEAN IT WITH COMPRESSED AIR THE AIR JET MUST BE DIRECTED FROM T...

Page 46: ...an cause serious damage to the engine In all 4T engines the deterioration of the oil characteristics or a certain consumption should be con sidered normal especially if during the run in period Consumption levels in particular can be influenced by the conditions of use e g oil consumption increases when driving at full throttle Maintenance Vespa GTV 125 MAIN 12 ...

Page 47: ...ilter being careful to lubri cate the O ring before fitting it Change the engine oil Since a certain quantity of oil still remains in the circuit oil must be filled from cap A Then start up the vehicle leave it running for a few minutes and switch it off after five minutes check the level and if necessary top up without exceeding the MAX level The cartridge filter must be replaced every time the o...

Page 48: ...by adding oil without ever exceeding the MAX level The restoration level between the MIN and MAX levels implies a quantity of oil of approx 400 cc Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the ON position However this light should switch off once the engine has been started If the light turns on during b...

Page 49: ...el when the engine is cold as in dicated in the scheduled maintenance table fol lowing the steps below Place the scooter on its centre stand and on flat ground Undo the screw shown in the figure and remove the expansion tank cap on RHS Top up if the fluid level is near or below the MIN level edge The liquid level must always be be tween the MIN and MAX level The coolant consists of an ethylene gly...

Page 50: ...luid level through the sight glass on the pump as shown in the photograph If the level is below the minimum fill using the two screws shown in the figure Remove the gasket and fill with DOT 4 until the spyglass is completely covered For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws CAUTION MAKE...

Page 51: ...te screen situated in a shaded area making sure that the longitudinal axis of the vehicle is perpendicular to the screen 2 Turn on the headlight and check that the bor derline of the projected light beam on the screen is not lower than 9 10 of the distance from the ground to the centre of vehicle headlamp and high er than 7 10 3 Otherwise adjust the headlight operating on the set screw R reached f...

Page 52: ...a diaphragm The unit in dicated by an arrow in the figure has a cut off connected to the depression intake on the inlet manifold that cuts the air inlet in deceleration to avoid explosions in the muffler System description Air is drawn through the opening A goes through the first filter and is channelled through the open ing B Air gets to the second filter B through the opening indicated in the fi...

Page 53: ... converter thus favouring an improved re action of the catalytic converter Remove the muffler Remove the right hand side fairing Remove the coolant inlet and outlet couplings from the pump cover Then drain the system Remove the upper clamp of the SAS valve con nection coupling to the drainage as indicated in the photograph Vespa GTV 125 Maintenance MAIN 19 ...

Page 54: ...d the pipe connecting the SAS valve to the head Then remove the pipe Release the electrical cable from the flywheel cover clamp as indicated in the photograph Disconnect the depression pipe from the SAS valve Maintenance Vespa GTV 125 MAIN 20 ...

Page 55: ...er with the SAS valve acting on the 4 hexagonal head screws as indicated in the photograph Remove the SAS valve two fixing screws and re move the SAS valve together with the O ring from the support Remove the plastic support together with the gasket Vespa GTV 125 Maintenance MAIN 21 ...

Page 56: ... the secon dary air to the head is not dented overheated or distorted If there is replace it Check that the metal pipe does not have any dents CAUTION INADEQUATE TIGHTNESS BETWEEN THE SAS VALVE AND ITS SUPPORT INCREASES NOISE IN THE SAS SYSTEM To refit follow the removal procedure in reverse order being careful to respect the direction of the rubber coupling connecting the SAS valve and the discha...

Page 57: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 58: ...evel Lack of compression parts cylinder and valves wear Replace the worn parts Transmission belt worn Replace Inefficient automatic transmission Check the rollers and the pulley movement re place the damaged parts and lubricate the driven pulley moveable guide with Montblanc Molybde num Grease Clutch slipping Check the clutch system and or the bell and re place if necessary Carburettor nozzles clo...

Page 59: ...y following the instructions shown in the chapter Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tightened Defective floating valve Check the proper sliding of the float and the func tioning of the valve Carburettor nozzles clogged Dismantle wash with solvent and dry with com pressed air Excessive oil consumption Exhaust smoke EXCESSIVE...

Page 60: ...pply Check or replace the fuel pump and check the vacuum intake and the pipe sealing Engine tends to cut off at idle THE ENGINE TENDS TO STOP AT IDLE SPEED Possible Cause Operation Air calibrated holes in carburettor blocked Dismantle wash with solvent and dry with com pressed air Defective floating valve Check the proper sliding of the float and the func tioning of the valve Level in chamber too ...

Page 61: ...it in a mixture of 50 petrol and 50 specific oil Press with your hand without squeezing allow it to drip dry and refit Incorrect float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUT...

Page 62: ...eplace gaskets Electrical system Battery BATTERY Possible Cause Operation Battery This is the device in the system that requires the most frequent attention and the most thorough maintenance If the vehicle is not used for some time 1 month or more the battery needs to be re charged periodically The battery runs down com pletely in the course of 3 months If the battery is fitted on a motorcycle be ...

Page 63: ...e seats in which the ball bearings rotate if they are recessed or if the balls are squashed replace them Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy check the efficien cy of the front shock absorbers the condition of the ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushing...

Page 64: ...Troubleshooting Vespa GTV 125 TROUBL 8 ...

Page 65: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 66: ...p 5 Voltage regulator 6 Engine stop switch 7 Automatic starter 8 Fuse unit 9 Main fuse 10 Battery 11 Starter motor 12 Start up remote control switch 13 Start up button 14 Stop button on rear brake 15 Stop button on front brake 16 Wiring for antitheft device 17 Light switch 18 Licence plate lamp 19 Front tail light Electrical system Vespa GTV 125 ELE SYS 2 ...

Page 67: ...strument panel A Instrument panel bulb B Oil pressure warning light C Low fuel warning light D Fuel gauge E Headlight warning light F High beam warning light 31 Warning light unit with clock A Ignition disabled warning light B Turn signal warning light C Immobilizer warning light D ABS warning light E Water temperature warning light F Lighting G Clock F Lighting 32 Thermoswitch 33 Horn button 34 T...

Page 68: ...e Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Conceptual diagrams Ignition KEY 1 Electronic ignition device 2 Immobilizer aerial 6 Engine stop switch 9 Main fuse 10 Battery 38 Key switch 41 Spark plug 42 HV coil Electrical system Vespa GTV 125 ELE SYS 4 ...

Page 69: ...arter 8 Fuse unit 9 Main fuse 10 Battery 17 Light switch 18 Licence plate lamp 19 Front tail light 21 Rear light A Tail light bulb 24 Asymmetrical headlight assembly A Tail light bulb B Headlight bulb 26 High beam light relay 27 Low beam light relay 30 Instrument panel Vespa GTV 125 Electrical system ELE SYS 5 ...

Page 70: ... Lighting F Lighting 38 Key switch Battery recharge and starting KEY 1 Electronic ignition device 4 Magneto flywheel Pick up 5 Voltage regulator 6 Engine stop switch 8 Fuse unit 9 Main fuse 10 Battery 11 Starter motor 12 Start up remote control switch 13 Start up button Electrical system Vespa GTV 125 ELE SYS 6 ...

Page 71: ...tors and enable signals section KEY 1 Electronic ignition device 2 Immobilizer aerial 6 Engine stop switch 8 Fuse unit 9 Main fuse 10 Battery 28 Oil pressure sensor 29 Fuel level transmitter 30 Instrument panel B Oil pressure warning light C Low fuel warning light D Fuel gauge Vespa GTV 125 Electrical system ELE SYS 7 ...

Page 72: ... Immobilizer warning light D ABS warning light E Water temperature warning light G Clock 32 Thermoswitch 38 Key switch Devices and accessories KEY 1 Electronic ignition device 3 Wiring for the electric pump and the fuel electric pump management device 6 Engine stop switch 8 Fuse unit 9 Main fuse 10 Battery Electrical system Vespa GTV 125 ELE SYS 8 ...

Page 73: ...trical system components Immobiliser The electric ignition system is fed with direct cur rent and is protected by an antitheft immobilizer integrated to the control unit The ignition system consists of Control unit Immobilizer aerial master and service keys with built in transponder H V coil Diagnostic LED The diagnosis LED also works as a blinking light to deter theft This function is activated e...

Page 74: ...nd lead There is battery voltage between the terminal No 4 Red Black and the terminal No 8 Negative as shown in the figure There is battery voltage between terminals No 5 and No 8 with the key switch set to ON and the emergency cut off switch set to RUN If no faults are found replace the control unit oth erwise check the wiring and the following compo nents Emergency cut off switch Key switch cont...

Page 75: ...vice keys in case of loss replacement etc Each new time new data is programmed the previously stor ed one is deleted If a service key should become un coded the efficiency of the high voltage circuit shielding must be thoroughly inspected In any case it is advisable to use resistive spark plugs Characteristic Shielded cap resistance 5000 Ω Diagnostic codes The flash indicating the switching to ON ...

Page 76: ...trol unit CAUTION BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT Electric characteristic immobilizer aerial 7 9 Ohm Diagnostic code 3 flashes If the 3 flash code is detected check if the failure occurs when the MASTER key in inserted into the key switch If the failure disappears when the MASTER key i...

Page 77: ...portant that the engine chassis ground connection bonding is efficient No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited follow this procedure Pick Up check Disconnect the control unit connector and check that the cable between terminal No 2 Green and terminal No 8 Black is not interrupted Check the Pick Up and its power line Electric ...

Page 78: ...p from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal see figure If non conforming values are measured replace the HV coil To carry out a more complete diagno sis check the peak voltage with the multimeter adaptor Specific tooling 020409Y Multimeter adaptor Peak voltage de tection Electric characteristic Resistance value 3000 300 Ohm Pick Up...

Page 79: ...ectric characteristic Resistance value 100 Volt Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel The alternator is directly connected to the voltage regulator In turn the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse This system therefore requires no connection to the key switch Th...

Page 80: ...lues different from the ones stated replace the defective parts N B VALUES ARE STATED AT AMBIENT TEMPER ATURE A CHECK WITH THE STATOR AT OP ERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables Electric characteristic Ohm value 0 7 0 9 Ohm Also check that ...

Page 81: ...ding cable harness Recharge system voltage check Connect an ammeter induction clamp to the volt age regulator positive terminal measure the bat tery voltage and turning on the vehicles lights with engine off wait for the voltage to set at about 12 V Start the engine and measure the current gen erated by the system with lights on and a high running engine In case the generated current value is lowe...

Page 82: ... start up the engine and keep it at idle speed then check whether there is voltage connecting the multimeter with the pos itive probe to terminal No 5 Blue and the nega tive one to terminal No 7 White Black see figure If there is no voltage replace the control unit after making sure that the fuses are not blown other wise check the cable harness between the starter and the control unit and as a la...

Page 83: ...switch alternately to the left and to the right and check that the lights turn on If they do replace the control unit because it is faulty If they do not turn on check the control unit turn indicator switch connection cable harness then repeat the test If the cable harness is in good conditions and the turn indicators still do not turn on replace the turn indicator switch because it is faulty Vesp...

Page 84: ...OF FIRE FUSES Specification Desc Quantity 1 Fuse 1 Current rating 10 A Protected circuits Key switch High Low beam light relay 2 Fuse 2 Current rating 7 5 A Protected circuits Wiring for antitheft de vice immobilizer warning light digital clock 3 Fuse 3 Current rating 7 5 A Protected circuits Fuel gauge low fuel warning light light switch wiring for antitheft device water temperature warning light...

Page 85: ...THAN THAT RECOMMENDED USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE CAUTION DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BAT TERY USE DISTILLED WATER ONLY CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE ...

Page 86: ...g to 30 Bé at a minimum tem perature of 15 C until the upper level is reached Allow to stand for at least 2 hours then top up the level with sulphuric acid Within the following 24 hours recharge with the specific single or multiple battery charger at an intensity approx to 1 10 of the battery rated ca pacity and until the acid density is approximately 1 27 corresponding to 31º Bé and these values ...

Page 87: ...ve the battery cover after undoing the 4 screws shown in the photograph Remove the strap fastening the battery Insert the battery breather pipe through the hole shown in the photograph Vespa GTV 125 Electrical system ELE SYS 23 ...

Page 88: ... Using the screwdriver tighten up the battery ter minal cables as far as they will go placing the special Grover washer between the screw head and the cable terminal N B DO NOT USE WRENCHES TO TIGHTEN UP THE SCREWS FOR FIXING THE TERMINALS TO THE BATTERY TERMINALS Mount permanently the battery in the battery chamber Refit the strap fastening the battery Electrical system Vespa GTV 125 ELE SYS 24 ...

Page 89: ... Refit the battery cover Vespa GTV 125 Electrical system ELE SYS 25 ...

Page 90: ...Electrical system Vespa GTV 125 ELE SYS 26 ...

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

Page 92: ...moval operations but in reverse order and respect the locking torques indicated in the Characteristics 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 Top up the cooling circuit Check the functioning of the accelerator and the electrical devices CAUTION PAY PARTICULAR A...

Page 93: ...oving the clamp from the blow by pipe and disconnecting the bellow connection to the carburettor acting on the clamp as indicated in the photograph CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the air intake manifold on the transmis sion housing acting on the two screws indicated in the photograph and remove the plastic clip Vespa GTV 125 Engine from vehicle ENG VE 3 ...

Page 94: ...raph Remove the fuel valve vacuum intake pipe from T joint indicated in the photograph Remove the fuel supply pipe from the carburettor Remove the coolant outlet pipe from the engine and the bleed pipe indicated in the photograph Engine from vehicle Vespa GTV 125 ENG VE 4 ...

Page 95: ...tor indicated in the photo Remove the throttle control cable from the car burettor acting on the nut shown in the photo Remove the automatic starter connector from the system located inside the protection sheath shown in the photo Vespa GTV 125 Engine from vehicle ENG VE 5 ...

Page 96: ...e photograph Remove the cable from the retainer clamp on the flywheel cover Remove the rear shock absorbers Remove the hydraulic piping from the rear cal liper by undoing the screw indicated in the photo graph Then remove the retainers fixing the piping to the engine crankcase indicated in the photo graph Engine from vehicle Vespa GTV 125 ENG VE 6 ...

Page 97: ...to support the vehicle properly Re move the engine swinging arm fixing pin by acting on the nut and the head of the pin indicated in the photograph The engine is now free Vespa GTV 125 Engine from vehicle ENG VE 7 ...

Page 98: ...Engine from vehicle Vespa GTV 125 ENG VE 8 ...

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

Page 100: ...es Using the clutch bell lock wrench shown in the figure remove the driven pulley shaft locking nut and washer Specific tooling 020423Y driven pulley lock wrench Remove the cap dipstick from the engine oil filling hole Remove the ten screws Remove the transmission cover If this operation is carried out directly on the vehi cle remove the cooling air supply coupling of the transmission housing Air ...

Page 101: ...020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide Refitting the driven pulley shaft bearing Slightly heat the crankcase from the inside so as not to damage the painted surface Insert the bearing in its seat Refit the seeger ring CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT N B ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING Specific tooling 020376Y Adaptor handle...

Page 102: ...together with the bearing Refitting Heat the roller and insert the bearing using the specific punch Appropriate tools Specific tooling 020455Y 10 mm guide Refit the roller with the special screw Tighten to the specified torque Refit the intake throat with the O ring the sump sealing gasket and a the fan housing Locking torques N m Anti flapping roller 12 16 Engine Vespa GTV 125 ENG 4 ...

Page 103: ...134 134 2 mm Checking the bell working surface eccentricity Install the bell on a driven pulley shaft using 2 bearings inner diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support to check the crankshaft alignment Using a feeler pin gauge and the magnetic base measure the bell eccentricity Repeat the measurement in 3 positions Central internal exte...

Page 104: ...wrench component n 9 to remove the nut fixing the clutch in place Separate the driven pulley components Clutch fan and spring with plastic fitting CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL EXCESSIVE TORQUE CAN CAUSE THE SPE CIFIC TOOL TO BUCKLE Specific tooling 020444Y009 46x55 Wrench 020444Y010 adapter ring Inspecting the c...

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

Page 106: ...o make sure there are no flaws Characteristic Half pulley standard diameter Standard diameter Ø 40 985 mm Half pulley minimum diameter Minimum admissible diameter Ø 40 96 mm Inspecting the driven sliding half pulley Remove the two internal grommets and the two O rings Measure the movable half pulley bushing inside diameter Characteristic Movable driven half pulley max diameter Max diameter admitte...

Page 107: ...the example in the figure using a modular punch Fit the retention ring WARNING N B FIT THE BALL BEARING WITH THE VISIBLE SHIELD Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020424Y Driven pulley roller casing fitting punch Refitting the driven pulley Insert the new oil guards and O rings on the mov able half pulley Lightly grease the O rings A shown in the figure Vespa GTV 12...

Page 108: ... out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings N B THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED UNDER TAKING THE OPERATION WHEN THE BEAR INGS ARE BEING SERVICED MIGHT BE EAS IER Specific tooling 020263Y Sheath for driven pulley fitting Recommended products AGIP GREASE SM 2 Gr...

Page 109: ...s A of the mass axis can be seen in full Insert the clutch on the adapter ring Lubricate the end of the spring that abuts against the servo system closing collar Insert the spring with its plastic holder in contact with the clutch Insert the driving belt into the pulley unit accord ing to their direction of rotation Insert the pulley unit with the belt into the tool Slightly preload the spring Mak...

Page 110: ...t assembly from the tool N B FOR DESIGN REASONS THE NUT IS SLIGHT LY ASYMMETRIC THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH N B DURING THE SPRING PRELOADING PHASE BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREAD ING N B AN EXCESSIVE QUANTITY CAN DAMAGE THE CLUTCH OPERATION Specific tooling 020444Y011 adapter ring 020444Y009 46x55 Wrench Locking torques ...

Page 111: ...ing 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 With the appropriate tool remove the nut with the built in Belleville washer the drive common to the kick starter version and the steel washer Remove the fixed driving half pulley Remove the steel washer separating from t...

Page 112: ...ck that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt Check that the O ring is not pushed out of shape CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS Characteristic Movable driving half pulley bushing Standard Diameter 26 000 26 021 mm Movable driving half pulley bushing Maxi mum allowable diameter Ø 26 12 mm Sli...

Page 113: ...ELY IMPORTANT THAT THE BELT IS PERFECTLY FREE WHEN THE FIXED DRIVING HALF PULLEY IS ASSEMBLED THIS IS TO AVOID CARRYING OUT A WRONG TIGHTENING OF THE DRIVING HALF PULLEY Specific tooling 020368Y driving pulley lock wrench Locking torques N m Drive pulley nut 75 83 Preassemble the movable half pulley with the roller contrast plate by putting the rollers in their housings with the larger support sur...

Page 114: ...lace the cover tightening the 10 screws at the specified torque Refit the oil loading cap bar refit the steel washer and the driven pulley nut Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools Replace the plastic cover Specific tooling 020423Y driven pulley lock wrench Locking torques N m Transmission cover screws 11 13 Driven pul ley shaft nut 54 60 End ge...

Page 115: ...l axis complete with gear Remove the intermediate gear Removing the hub bearings Check the state of the bearings being examined wear clearance and noisiness If faults are de tected do the following Use the specific bearing extractor to remove the three 15 mm bearings 2 in the crankcase and 1 in the hub cover Specific tooling 001467Y013 Pliers to extract ø 15 mm bearings Vespa GTV 125 Engine ENG 17...

Page 116: ...over and take out the bearing Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide With the appropriate tools remove the oil seal as shown in the figure Specific tooling 020359Y 42x47 mm adaptor Engine Vespa GTV 125 ENG 18 ...

Page 117: ...smission side Remove the seeger ring shown in the figure With the sectional punch remove the driven pulley shaft bearing Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide Inspecting the hub shaft Check the three shafts for wear or distortion of the toothed surfaces the bearing housings and the oil seal housings In case of anomalies replace the damaged com ponen...

Page 118: ...oling 020150Y Air heater support 020151Y Air heater 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020483Y 30 mm guide Assemble 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 Engine Vespa GTV 125 ...

Page 119: ...SET Refit the driven pulley shaft bearing with a mod ular punch as shown in the figure N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE Specific tooling 020376Y Adaptor handle 020359Y 42x47 mm adaptor 020363Y 20 mm guide N B WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE SUPPORT THE CRANKCASE PREFERABLY ON A SURFACE TO ALLOW THE...

Page 120: ...ng sure the breather pipe is in the correct position Place the 3 shortest screws identifiable by their different colour as shown in the figure Fasten the breather pipe support bracket with the lower short screw Assemble the remaining 4 screws and tighten the 7 screws to the prescribed torque Locking torques N m Rear hub cover screws 24 27 Engine Vespa GTV 125 ENG 22 ...

Page 121: ...the 4 retainers and the flywheel cover Removing the stator Remove the electric terminal of the minimum oil pressure switch Remove the two Pick Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure Remove the stator and its wiring Vespa GTV 125 Engine ENG 23 ...

Page 122: ... flywheel cover Place the flywheel with the top dead centre mark aligned with the crankcase Place the flywheel cover by aligning the reference marks of the drive and the crankcase cover Reassemble the cover on the engine placing the three connectors in the drive for the water pump Carry out the steps in the reverse order from the dismantling procedure CAUTION TAKE CARE TO CORRECTLY POSITION THE FL...

Page 123: ...l plastic parts of the flywheel and the Pick Up control plate Refitting the flywheel magneto Fit the flywheel being careful to insert the key properly Lock the flywheel nut to the prescribed torque Check that the Pick Up air gap is between 0 34 0 76 mm The air gap cannot be modified when assembling the Pick Up Different values result from deformations visible on the Pick Up support N B A VARIATION...

Page 124: ...screws to the prescribed torque Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the intake manifold Remove the flywheel cover completely as de scribed in the flywheel cover section Loosen the 3 crews and remove the intake mani fold N B SCREWS AGAINST ACCIDENTAL OPERA TION ARE PROVIDED Engine Vespa GTV 125 ENG 26 ...

Page 125: ...th spring and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifter retaining cover as shown in the figure Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer Vespa GTV 125 Engine ENG 27 ...

Page 126: ...s washer Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioning pad must be removed from the transmission side As regards the lower chain guide pad it may only be removed after the head has been removed N B IT IS ADVISABLE TO MARK THE CHAIN IN OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTAT...

Page 127: ...he cam shaft Remove the pins and the rocker arms from the flywheel side holes N B IN CASE OF NEED THE HEAD MAY BE RE MOVED WITH THE CAMSHAFT PINS ROCK ING LEVERS AND FIXING BRACKET THE HEAD CAN ALSO BE REMOVED WITHOUT RE MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER Vespa GTV 125 Engine ENG 29 ...

Page 128: ...lves Using the appropriate tool fitted with an adapter remove the cotters caps springs and valves Remove the oil guards with the appropriate tool Remove the lower spring supports CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD Specific tooling 020382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020306Y Pun...

Page 129: ...CAUTION TO AVOID DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Vespa GTV 125 Engine ENG 31 ...

Page 130: ...ACE THE CRANKSHAFT IF THE DIAME TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING Characteristic Checking the connecting rod small end Maxi mum diameter 15 030 mm Checking the connecting rod small end Stand ard diameter 15 0 015 0 025 mm Engine Vespa GTV 125 ENG 32 ...

Page 131: ... 0 05 mm Pistons and cylinders are classified into catego ries based on their diameter The coupling is car ried out in pairs A A B B C C D D The cylinder rectifying operation should be car ried out with a surfacing that respects the original angle The cylinder surface roughness should be 0 9 micron This is indispensable for a good seating of the sealing rings which in turn minimises oil consump ti...

Page 132: ... 945 56 973 mm Pin diameter Standard clearance 0 015 0 029 mm Pin diameter Standard diameter 14 996 15 000 mm Wrist pin seat on the piston Standard diameter 15 001 15 006 mm Diameter of the wrist pin seat on the piston Standard clearance 0 001 0 010 mm Engine Vespa GTV 125 ENG 34 ...

Page 133: ...gure of the sealing rings using a feeler gauge If any measurements are greater than specified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES AND BETWEEN THE PISTON AND THE CYLINDER IS AS SPECIFIED IN ANY CASE NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDIT...

Page 134: ...UALLY Specific tooling 020430Y Pin lock fitting tool Choosing the gasket Provisionally fit the piston into the cylinder with out any base gasket Assemble a dial gauge on the specific tool Support to check piston position 020428Y Set the dial gauge to zero placing the tool on a contrasting surface Keeping the zero position as semble the tool on the cylinder and lock it with 2 supplied nuts as shown...

Page 135: ...piston pro trudes By means of the table shown in the specifications chapter identify the cylinder base gasket thickness to be used for refitting Correctly identify the cylin der base gasket thickness to keep the correct compression ratio Remove the specific tool and the cylinder N B MEASURE PISTON PROTRUSION See also Slot packing system Vespa GTV 125 Engine ENG 37 ...

Page 136: ...rence mark facing the crown of the piston Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure Lubricate the components with engine oil N B THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Refitting the cylinder Insert the cylinder base gasket with the thickness determined above Using the fork s...

Page 137: ...mum allowable run out 0 05 mm Check that the camshaft and the rocker pin ca pacities exhibit no wear Check that the cylinder head cover surface the intake manifold and the exhaust manifold are not worn Characteristic bearing A Ø 12 000 12 018 mm bearing B Ø 20 000 20 021 mm bearing C Ø 37 000 37 025 mm Vespa GTV 125 Engine ENG 39 ...

Page 138: ...ove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole assembly Inspecting the valve sealings Insert the valves into the cylinder head Alternatively check the intake and exhaust valves The test is carried out by filling the manifold with petrol and checkin...

Page 139: ...ide Accepted limit 5 022 Valve seat wear Exhaust guide Standard diameter 5 000 5 012 mm Inspecting the valves Measure the diameter of the valve stems in the three positions indicated in the diagram Calculate the clearance between valve and valve guide Check that there are no signs of wear on the sur face of contact with the articulated register termi nal If the checks above give no failures you ca...

Page 140: ...length Outlet 94 4 mm Valve check standard length Inlet 94 6 mm Valve check Maximum admissible clearance Outlet 0 072 mm Valve check Maximum admissible clearance Inlet 0 062 mm Valve check standard clearance Outlet 0 025 0 052 mm Valve check standard clearance Inlet 0 013 0 040 mm Valve check Minimum admissible diameter Outlet 4 95 mm Valve check Minimum admissible diameter Inlet 4 96 mm Valve che...

Page 141: ...lve seals Fit the valves the springs and the caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats N B DO NOT CHANGE THE VALVE FITTING POSI TION FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Specific tooling 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal t...

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

Page 143: ... shaft check Standard diameter Bearing B diameter 19 959 19 98 mm Cam shaft check Standard diameter Bearing A Ø 36 95 36 975 mm Refitting the head and timing system components Assemble the lower timing chain sprocket wheel on the crankshaft with the chamfer facing the in sertion side Loop the timing chain around the sprocket on the crankshaft Fit the chain tensioner slider from the cylinder head s...

Page 144: ...ing this position insert the chain on the cam shaft control pulley Insert the pulley on the cam shaft while keeping the reference 4V in correspondence with the ref erence mark on the head Assemble the counterweight with the corre sponding fixing screw and tighten to the prescribed torque Locking torques N m Counterweight screw 7 8 5 Fit the end of stroke ring on the valve lifting mass and fit the ...

Page 145: ...ug Electrode distance 0 8 mm Locking torques N m Spark plug 12 14 Refit the cylinder head cover tightening the 5 screws to the prescribed torque Make sure the gasket is positioned properly Remove the flywheel cover completely as already described in the flywheel chapter Reassemble the oil pump control the chain compartment cover the by pass and the oil sump as described in the lubrication chapter ...

Page 146: ...ten up the nuts to a pre torque of 7 1 N m Rotate by a 180 angle 2 rotations of 90 each To carry out the operations described above fol low the tightening sequence in the figure Fit the two screws on the outside of the timing chain side and tighten them to the prescribed tor que N B BEFORE INSTALLING THE HEAD MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET Locking torque...

Page 147: ...onary remove the following units transmission cover driving pulley driven pulley and belt rear hub cover gears bearings and oil seals as described in the transmission chapter Remove the oil sump the by pass the chain compartment cover and the oil pump as in the lubrica tion chapter Remove the flywheel cover together with the water pump the flywheel and the stator as described in the magneto flywhe...

Page 148: ...case Remove the crankshaft CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPA RATING IT IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT ACCIDENTALLY FALL Remove the coupling gasket of the crankcase halves Remove the two screws and the internal cover shown in the diagram CAUTION WHILE OPENING THE CRANKCASES AND RE MOVING THE DRIVING SHAFT CHECK THAT THE THREADED SHAFT ENDS ...

Page 149: ... NOT MODIFIED BY THE RAD IUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS If the axial clearance between crankshaft and crankcase exceeds the standard and the crankshaft does not have any defect the problem must be due to either excessive wear or wrong machining on the engine crankcase Check the diameters of both bearings of the crank shaft according to the axes and surfaces shown in the figure The ...

Page 150: ... may not be replaced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the lubrication duct with compressed air Make sure that the 2 caps on the crankpin are properly fitted A wrong installation of a cap can seriously affect the bushing lubrication pressur...

Page 151: ... the oil pump com partment and the oil ducts the by pass duct the main bushings and the cooling jet on the trans mission side see diagram Take particular care also that there are no signs wear in the oil by pass valve housing see Chapter Lubrication as this could prevent a good seal in the valve which regulates the oil pressure On the flywheel side crankcase half take partic ular care cleaning the...

Page 152: ...ats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and di mensions N B THE JET IS FED THROUGH THE MAIN BUSH INGS PROPER OPERATION OF THIS COMPO NENT IMPROVES THE PISTON TOP COOLING CLOGGING HAS EFFECTS THAT ARE DIFFI CULT TO DETECT PISTON TEMPERATURE INCREASE FAILURE OR LEAK CAN CONSID ERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD LUBRIC...

Page 153: ...ax is 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 bushing half see diagram There are three crankcase versions with RED main bushings with B...

Page 154: ...37 Original Match the shaft with two category 1 crank webs with the category 1 crankcase or cat 2 with cat 2 Furthermore a replacement crankcase cannot be matched with a crankshaft with mixed catego ries The replacement crankshaft has half shafts of the same category Crankcase halves Engine half shaft Bushing Cat 1 Cat 1 B Cat 2 Cat 2 B Cat 1 Cat 2 A Cat 2 Cat 1 C N B TO KEEP THIS POSITION OF THE ...

Page 155: ...N N B CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS BLUE Characteristic Standard driving depth 1 35 1 6 Diameter of crankcase without bushing 32 953 32 963 Refitting the crankcase halves Lubrication Conceptual diagrams LUBRICATION CIRCUIT Vespa GTV 125 Engine ENG 57 ...

Page 156: ...Engine Vespa GTV 125 ENG 58 ...

Page 157: ... between 3 2 4 2 atm Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the fan cover If the oil pressure is outside the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT L...

Page 158: ...e pre scribed torque Lubricate the flywheel oil seal Using the appropriate tool assemble the oil seal Fit a new O ring on the pre filter and lubricate it Insert the filter on the engine with the relative cap Tighten to the specified torque N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING Specific tooling 020425Y Punch for...

Page 159: ...e washer Tighten to the prescribed torque Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY MAKE SURE THAT THE PUMP TURNS FREELY Locking torques N m Screws fixing oil pump to the crankcase 5 6 Oil pump control crown screw 10 14 Oil pump cover screws 0 7 0 9 Removing the oil sump Remove the oil filler ...

Page 160: ...pressure regulating spring Fit a new sump seal Refit the two centring dowels Refit the sump taking care to locate the spring in the appropriate recess machined into the inside of the sump Refit the rear brake cable brackets and the screws in the reverse order from which they were removed Tighten the screws to the prescribed torque Refit the driving pulley assembly the drive belt the sprocket wheel...

Page 161: ...ure position VAC UUM Operate the pump slowly Check that the one way valve allows the air to pass through causing a slight vibration Switch the pump to pressure mode PRES SURE Operate the pump slowly and check if there is an increase of pressure A small leakage is consid ered to be normal If anomalies are detected replace the pump N B A MALFUNCTIONING ONE WAY VALVE CAN RESULT IN RUBBER COUPLING AND...

Page 162: ...n 0 5 BAR Release the hose and check how the vacuum re acts Under normal functioning conditions the vacuum undergoes a slight fall and then readjusts There follows a slow and continuous loss of de pression up to approximately 0 4 BAR At this point the valve opens and the depression is suddenly set to zero Lack of tightness or the fact that the valve opens at different vacuum values should be regar...

Page 163: ...E TO OBSERVE THESE INSTRUC TIONS MAY RESULT IN WRONG VACUUM IN SIDE THE FILTER HOUSING WHICH IN TURN MAY PRODUCE VARIATIONS IN CARBURET ION Removing the carburettor Kehin To detach the carburettor from the engine it is necessary to move the air filter and remove the transmission throttle control the automatic starter connection the clamps anchoring the carburettor to the filter housing and to the ...

Page 164: ... starter support with the gasket Remove the clamp and cover with the airing filter of the diaphragm chamber Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING THE REMOVAL OF THE CARBURET TOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Engine Vespa GTV 125 ENG 66 ...

Page 165: ...e vacuum valve together with the di aphragm Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Remove the 4 screws indicated in the figure Vespa GTV 125 Engine ENG 67 ...

Page 166: ... the tank N B CAUTION THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES SPRING AND BALL N B AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle Engine Vespa GTV 125 ENG 68 ...

Page 167: ... Remove the maximum nozzle Remove diffuser Vespa GTV 125 Engine ENG 69 ...

Page 168: ...flow set screw and the spring CAUTION DO NOT ATTEMPT REMOVING PARTS EM BEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PLUNGER HOUSING STARTER NOZZLE PIT COVER FOR PRO GRESSIONS AND INLET NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Refitting ...

Page 169: ...tion controlled by flow screw progression holes near the throttle valve For the starter circuit blow the connection pipe properly with the jet This is necessary because the nozzle support hides other inaccessible internal calibrations Blow the intake nozzle properly N B THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE NOZZLE INCORRECT ORIENTATION RESULTS IN I...

Page 170: ...he minimum nozzle properly and reassemble it Properly wash and blow the components of the sprayer maximum circuit the diffuser and the noz zle Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser Assemble the diffuser making sure the sprayer is being adequately inserted and lock it Assemble the maximum nozzle Check that the tapered pin does not ...

Page 171: ...ump valves fol lowing this order INTAKE VALVE A Spring Ball Nozzle IN VALVE M Ball Spring Nozzle N B THE IN VALVE NOZZLE CORRESPONDING TO THE ACCELERATION PUMP IS MILLED Check the screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is free to rotate in its ow...

Page 172: ...aust fume analysis Adjust the carburettor by turning the screw twice from the close position Level check Kehin Place the carburettor inclined as shown in the figure Check that the float reference is parallel to the tank coupling surface If different positions are detected change the plunger control metal plate direction to obtain the position described above Inspecting the valve and needle Engine ...

Page 173: ...herwise replacement the whole valve Insert the tapered pin into the vacuum valve housing Reassemble the vacuum valve on the carburettor body taking care that the tapered pin is inserted into the sprayer N B THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION Reassemble the spring with the pin lock Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place ...

Page 174: ... am bient pressure intake Reassemble the filter with its clamp Wash and blow dry the starter support Assemble a new gasket on the carburettor body and tighten the 2 fixing screws Inspecting the automatic choke device Engine Vespa GTV 125 ENG 76 ...

Page 175: ... ambient temperature With a 12V battery power the automatic starter and check that the piston protrudes as much as possi ble The correct warm up time depends on the ambi ent temperature If protrusion resistance or timing values are dif ferent from the ones prescribed replace the start er Assemble the starter to the carburettor being careful to position the O Ring correctly insert the plate with th...

Page 176: ...nning it at least 5 mi nutes at approximately 50 kph Connect a millimetre thermometer 020331y on the sump using a cover with oil expressly pre pared for probes Start the engine and before adjusting the idle speed make sure that the oil temperature is be tween 70 80 C Using the rpm indicator of the analyser or an in dependent one 020332y adjust the idle set screw until 1600 1700 rpm is obtained N B...

Page 177: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 178: ...ted in the pho tograph Locking torques N m Wheel fixing screw 20 25 Front wheel hub overhaul Remove the ball bearing seeger ring indicated in the photograph Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings outside Ø 39 mm Suspensions Vespa GTV 125 SUSP 2 ...

Page 179: ...tops with the shielded side facing out Refit the ball bearing locking seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42x47 mm adaptor 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punc...

Page 180: ...omply with the specified locking torque Locking torques N m Wheel fixing screw 20 25 Steering column Removal Remove the front wheel Remove the brake calliper Loosen the screw fixing the odometer cable plate and take out the cable Remove the suspension arm housing by un screwing the three screws indicated in the photo graph Suspensions Vespa GTV 125 SUSP 4 ...

Page 181: ...eter cable to the mudguard indicated in the photograph Remove the retainer fixing the brake piping to the front shock absorber upper plate Remove the retainer fixing the brake piping to the suspension arm Vespa GTV 125 Suspensions SUSP 5 ...

Page 182: ...ate being careful not to scratch the plastic parts Remove the steering tube ring nut cover Use a specific tool to remove the counter ring nut the spacer washer and the ring nut of the upper disk of the fifth wheel fitting Slide off the steering tube and remove perma nently the mudguard from the suspension Specific tooling 020055Y Wrench for steering tube ring nut Suspensions Vespa GTV 125 SUSP 6 ...

Page 183: ...perat ing form the lower part of the headstock as indica ted in the photograph Afterwards remove the lower disk of the fifth wheel operating from the up per part Specific tooling 020004Y Punch for removing fifth wheels from headstock Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific t...

Page 184: ...1Y Front suspension service tool Fit the two dust guard rings C on the swinging hub as shown in drawing A Connect the swinging hub to the steering tube with the guiding pin part 5 Use the specific tool fitted with part 3 on the stem and part 4 on the tool base Lubricate the pin with Z2 grease and insert it temporarily on the swinging hub move the tool handgrip until part 3 is fully inserted on the...

Page 185: ...m on the side opposite the one shown in the figure to refit the second wedging washer roller casing sealing ring unit To position roller casings on the pin pin end in contact with the internal bottom of the roller cas ings proceed as follows Use the tool with part 20 and 21 fitted to the stem as indicated in the figure Push the two roller casings with the handgrip until their bottoms make contact ...

Page 186: ... fifth wheel fitting and the dust guard on the steering tube as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing fifth wheels from headstock Refit the fifth wheel fitting and the dust guard on the steering tube until they stop using the specific tool Specific tooling 006029Y Punch for fitting fifth wheel seat on steering ...

Page 187: ...carry out the removal operations but in reverse order grease the fifth wheel fittings and tighten at the specified locking torques Locking torques N m Handlebar to steering tube 45 50 Nm Upper steering ring nut 30 40 Lower steering ring nut 8 10 Front shock absorber Removal Remove the steering tube Remove the shock absorber lower clamps Remove the shock absorber upper clamps Refitting To refit car...

Page 188: ... 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 N m Shock absorber lower clamp 20 27 Overhaul The bracket for the shock absorber calliper at tachment has two roller bearings separated one from the other as shown ...

Page 189: ...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 Adaptor 52 x 55 mm Assemble a new roller bearing on the shock ab sorber side and move it until it stops using the specific tool Specific too...

Page 190: ... Punch Rear Removing the rear wheel Remove the bracket supporting the rear shock absorber and the muffler Remove the rear wheel by unscrewing the 5 screws indicated in the photograph Refitting the rear wheel To refit carry out the removal operations but in reverse order observing the prescribed torques Locking torques N m Wheel fixing screws 20 25 Nm Swing arm Suspensions Vespa GTV 125 SUSP 14 ...

Page 191: ...using Remove the swinging arm engine fitting shown in the photo Move the engine back remove the spring anchoring the swinging arm to the frame as shown in the photo Remove the two screws fixing the buffer support bracket to the frame Vespa GTV 125 Suspensions SUSP 15 ...

Page 192: ...ent block rubber buffers Replace the work components that cause exces sive clearance on the rear suspension Overhaul Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side Check the axial clearance between the two swinging arms using a feeler gauge Characteristic Standard clearance 0 40 0 60 mm Allowable limit after...

Page 193: ...mm min thickness 4 mm Check there is no sticking in the rotation Check the axial clearance of the swinging arm on the frame side Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm Separate the swinging arm on the engine side from the vehicle side arm Remove the plastic bushings and the internal spacer shown in the photo Using a suitable pin remove the roller casings as...

Page 194: ...nal swinging arm spacer on the frame side 290 0 1 mm Length of the swinging arm tube on the frame side 283 0 1 mm Lubricate roller casings and the plastic bushings with grease Insert the spacers Assemble the two arms with the relative bolt in the position shown in the photograph Adjust the bolt as shown in the photograph Position the frame side swinging arm with the most protruding part pointing t...

Page 195: ...t bloc bracket Undo the silent bloc ring shown in the photograph Hold the full silent bloc bracket in the clamp Using the appropriate tool remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle This is to guarantee the tool is centred properly on the support Vespa GTV 125 Suspensions SUSP 19 ...

Page 196: ...y tightening the nuts on the relative bolts to the proper tightening torque Locking torques N m Engine and vehicle side swinging arm junction bolt 33 41 Nm Swinging arm pin Engine 64 72 Body shell Swinging arm pin 76 83 Screw fixing the silent block support plate to the body 42 52 Shock absorbers Removal Proceed as follows place the scooter on its centre stand remove the luggage rack lift the engi...

Page 197: ...sorber clamping screw 33 41 Nm Upper shock absorber fixing screws 20 25 Nm Exhaust bracket Removal Remove the full muffler assembly Remove the two fixing screws of the bracket to the engine crankcase Remove the split pin the cover and the fixing nut of the rear wheel axle and its spacer Remove the shock absorber lower clamp Refitting The refitting procedure is in the reverse order of the removal o...

Page 198: ...the figure Remove the bolt from the right side Remove the centre stand FITTING On refitting tighten the nut to the specified torque Locking torques N m Centre stand fixing bolt 25 30 Nm Side stand REMOVAL Uncouple the centre stand return spring Remove the screw shown in the photograph FITTING To refit carry out the removal operations in re verse order and comply with the specified torque Locking t...

Page 199: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 200: ...IPER BEFORE REMOV ING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMP TIED THE SYSTEM OF THE CIRCUIT BEING EXAMINED Overhaul Remove the rear brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupling screws as shown in the photo Remove the two pistons from the calliper body with the aid of short blasts of c...

Page 201: ... torque Locking torques N m Calliper coupling screw 22 27 Refitting Insert the brake pads in the calliper Insert the pad fixing pin and the retention screw being careful to position the terminals of it pointing towards the bleed screw as shown in the photo Insert the clip on the pad fixing pin N B FAILURE TO RESPECT THE PAD POSITION ING REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COULD ...

Page 202: ...ith elastic washer at the prescribed tor que as shown in the photograph Fix the brake pipe joint to the calliper and tighten at the prescribed torque Bleed the system and refit the rear wheel Locking torques N m Brake calliper support clamping 20 25 Nm Brake pipe connection 20 to 25 N m Front brake calliper Braking system Vespa GTV 125 BRAK SYS 4 ...

Page 203: ...emove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons 6 5 Check that the plates and the body are whole and in good condition that the cylinder and the floating...

Page 204: ...rt the following on the front brake body The sealing rings and the pistons 1 Refit the plate 2 Arrange the pad holding clamp 3 Refit the pads and bleed air Place the calliper on the disk and lock it to the support by tightening the bolts at the prescribed torque Lock the pipe joint to the calliper at the prescribed torque Follow the same procedure for the rear brake cal liper Locking torques N m S...

Page 205: ...calliper Check the disc thickness with a micrometer Characteristic Minimum thickness allowed after use 3 5 mm Standard thickness 4 0 2 0 2 mm Repeat the measurement at no fewer than six points on the disc Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed onto the brake calliper as shown in the photo In order to be able to anchor the appropriate to...

Page 206: ...sists replace the hub Front brake disc Removal Remove the front wheel Remove the front brake calliper Remove the hub and the disc operating on the wheel axle nut Hold the hub and the disc firmly and remove the brake disc undoing the six screws indicated in the photograph Braking system Vespa GTV 125 BRAK SYS 8 ...

Page 207: ...in the photograph Repeat the measurement in at least 6 points on the disk Remove the front brake calliper In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it to one of the two front brake calliper attachment points Place the dial gauge on the disk outer edge Make the wheel hub turn and check the disk de viation Specific tooling 020335Y Magnetic sup...

Page 208: ...f there is replace it Check the thickness of the friction material is more than 1 5 mm If it is not replace it The replacement must be made with greater re sidual thickness if the pad has not worn evenly A 0 5 mm thickness difference in the residual friction material is permitted Refitting To fit proceed as follows Insert the two pads in the callipers Braking system Vespa GTV 125 BRAK SYS 10 ...

Page 209: ...um strength threadlock Locking torques N m Screw tightening calliper to the support 20 25 Pad fastening pin 19 6 24 5 Rear brake pads Removal Remove the rear brake calliper Remove the brake pad and check there are no faults or warping If there is replace it Check the thickness of the friction material is more than 1 5 mm If it is not replace it The replacement must be made with greater re sidual t...

Page 210: ...ed With the left had brake lever load the system and bring it up to the required pressure Keeping the left hand brake lever pulled loosen the bleed screw to permit the air in the system to escape Then do up the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recovery pipe and refit the rubber hood over the bleed screw Top up the brake fluid to ...

Page 211: ...and Remove the brake pump cover as indicated in the photo Use the appropriate spyglass on the pump to check the level of the brake fluid as shown in the photograph If the level is below the minimum fill using the two screws shown in the figure Remove the gasket and fill with DOT 4 until the spyglass is completely covered CAUTION MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN...

Page 212: ...in open or partially used containers Under normal climatic conditions the fluid must be changed every 20 000 km or anyway every two years For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws Front brake pump Removal Remove the rear handlebar cover Remove the two screws fixing the brake pump to the...

Page 213: ...e cap 4 and take out the internal parts in order 3 Check that The pump body shows no signs of internal damage or corrosion The plunger shows no sign of damage or abnormal wear The plunger return spring is in good condition CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED Vespa GTV 125 Braking system BRAK SYS 15 ...

Page 214: ...on 7 Gasket 8 Spring 9 Reservoir Refitting To refit carry out the removal operations but in reverse order observing the specified torques Locking torques N m Oil pipe joint to the pump 20 25 Brake pump fixing screws to the handle bar 7 10 Nm Braking system Vespa GTV 125 BRAK SYS 16 ...

Page 215: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 216: ...he bearings on the housing up to the stop Assembly the ceramic ring and the correspond ing rubber gasket The ceramic ring chamfering should always face towards the gasket Lubricate the rubber gasket and insert the unit on the flywheel cover Use the punch of the appropriate tool manually if necessary ALWAYS USE NEW CERAMIC RING AND GAS KETS ASSEMBLING THE CERAMIC SEALING RING IN A MANNER OTHER THAN...

Page 217: ...que below N B DO NOT LUBRICATE THE O RING FAILURE TO RESPECT THIS RULE RESULTS IN RING DISTORTION Locking torques N m Water pump cover screws 3 4 Component check Check that the rotor does not show abnormal wear or dents Check that the rotor shaft is not rusty Check that there is no rust on the bearing seats or the ceramic seal Check that the drive does not show dents and that it is perfectly integ...

Page 218: ...OLANT USE THE RING BASE WITH THE ACCURATELY MACHINED SURFACE FACING THE FLYWHEEL COVER Specific tooling 020440Y Water pump service tool With an appropriate socket and punch forming part of the specific tool 020440y extract the shaft together with the rotor from the drive and the bearings Cooling system Vespa GTV 125 COOL SYS 4 ...

Page 219: ... they are fitted in any case ceramic seals are subjected to a running in period During this period 1 000 1 500 km there may be small leaks through draining holes which remain visible on the aluminium crankcase This phenomenon is particularly visible there where the hole is more exposed Quasar and Master In such cases we recommend cleaning the casing in order to be able to check again for leaks aft...

Page 220: ...ner using the thermal gun Check the temperature when the thermostat starts to open Heat up until the thermostat is completely open 3 Replace the thermostat if it is not working prop erly CAUTION TO EXECUTE THE TEST CORRECTLY MAKE SURE NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check Openi...

Page 221: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 222: ... tips Do not expose it to weather changes when the scooter is parked protect it with the waterproof cover supplied and stored under the saddle Periodically especially during rainy seasons apply commercially available waterproofing products footwear spray Do not apply shoe polish or wax on the saddle so as not to stain your clothes In case of forced and prolonged exposure to water dry the saddle fa...

Page 223: ...chassis saddle Free the electric cables form the retaining clamps indicated in the photograph Unscrew the two screws of saddle fixing hook cover Remove the saddle opening transmission cable Remove the saddle manual opening transmis sion cable Vespa GTV 125 Chassis CHAS 3 ...

Page 224: ...cable from the fixing seat on the locking block Remove the electric connector from the saddle opening actuator Remove the two screws shown in the photograph Remove the clip from the transmission Remove the actuator from the supporting bracket Rear rack Remove the helmet compartment Remove the 4 screws indicated in the figure Chassis Vespa GTV 125 CHAS 4 ...

Page 225: ...screws indicated in the figure Remove the instrument panel by slightly pulling it upwards Press the two side fins and remove the odometer transmission A from the instrument panel Remove the seven way connector B from the instrument panel by pressing the central fin and slightly pulling it Vespa GTV 125 Chassis CHAS 5 ...

Page 226: ...new bulb and turn the bulb holder clockwise Headlight assy Operate the screw indicated in the figure to re move the front turn indicator Knee guard Remove the rear handlebar cover Remove the two screws indicated in the photo graph and located on the shield under the grille Chassis Vespa GTV 125 CHAS 6 ...

Page 227: ...ated 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 GTV 125 Chassis CHAS 7 ...

Page 228: ...as shown in the photograph Removing the ignition key switch when on off Remove the shield back plate Remove the immobilizer aerial as shown in the figure Detach the electrical wiring Remove the ignition key switch by removing the spring retainer shown in the figure Chassis Vespa GTV 125 CHAS 8 ...

Page 229: ...ition key switch when on lock In position Lock it is not possible to access the cylinder retaining spring The spring must then be removed as shown in the figure allowing the lock spring to be pressed out N B FOR REASSEMBLY FROM THIS POSITION RELEASE THE STEERING WHEEL AND SET THE LOCK BODY INSIDE AND OUTSIDE PART TO OFF THEN PROCEED AS DE SCRIBED IN PARAGRAPH REMOVAL LOCK IN OFF POSITION Vespa GTV...

Page 230: ...pipe to the pump and pull it out Remove the odometer transmission Taillight assy Operate the screw indicated in the figure to re move the rear turn indicator Remove the two screws fixing the license plate light shown in the figure Loosen the two fixing screws and remove the rear light unit Chassis Vespa GTV 125 CHAS 10 ...

Page 231: ... fairings Remove the central screw located 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 Vespa GTV 125 Chassis CHAS 11 ...

Page 232: ... non slip rubber mat of the footrest as indicated in the photograph Side fairings Remove side fairings right and left by undoing the 2 screws shown in the figure Rear mudguard Remove the air filter Remove the screw indicated in the photograph Remove the mudguard Chassis Vespa GTV 125 CHAS 12 ...

Page 233: ...move the connector from the fuel gauge Remove the screw indicated in the figure that fix es the tank to the body after removing the rear headlight assembly Remove the straps retaining the pipes to the fuel valve as shown in the figure Remove 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...

Page 234: ... in the figure Front mudguard First remove the steering tube and uncouple the front brake pipes from the calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Chassis Vespa GTV 125 CHAS 14 ...

Page 235: ...he body Detach the radiator Detach the pipe from the plastic duct by removing the plastic clip shown in the photograph Then re move the duct The same procedure also applies to the left ra diator for which it is necessary to remove the elec trical fan first by undoing the 3 screws indicated in the photograph To refit perform the removal operations but in reverse order being careful when positioning...

Page 236: ...Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Chassis Vespa GTV 125 CHAS 16 ...

Page 237: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 238: ... bolts 45 50 Nm Upper steering ring nut 30 40 Lower steering ring nut 8 10 Electrical system Main switch Lights high beams low beams side taillights front and rear and relevant warning lights Regulating the headlights according to the regulations currently in force Front and rear stop light buttons and relative light Turn indicators and relative telltales Instrument lighting instruments fuel and t...

Page 239: ... TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Level check Hydraulic brake system liquid level Rear hub oil level Engine coolant level Engine oil ...

Page 240: ...BURST Functional inspection Functional check up Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check frame and engine number check tools and equipment licence plate fitting lock check tyre pressure check rear view mirror and any accessory fitting Pre delivery Vespa GTV 125 PRE DE 4 ...

Page 241: ...INDEX OF TOPICS TIME TIME ...

Page 242: ...Duration 1 001001 Engine from frame Removal and refit 2 003064 Engine oil change 3 003057 Engine retainer Tighten nuts ENGINE Code Action Duration 1 001001 Engine from frame Removal and refit 2 003064 Engine oil change 3 003057 Engine retainer Tighten nuts Crankcase CRANKCASE Code Action Duration 1 001153 Crankcase halves gasket Replacement Time Vespa GTV 125 TIME 2 ...

Page 243: ...de Action Duration 2 001133 Engine crankcase Replace ment Crankshaft CRANKSHAFT Code Action Duration 1 001099 Oil seal flywheel side Re placement 2 001117 Crankshaft Replacement Vespa GTV 125 Time TIME 3 ...

Page 244: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replace ment 2 001154 Pin ring piston unit Service Time Vespa GTV 125 TIME 4 ...

Page 245: ...EAD Code Action Duration 1 001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves Adjustment 4 001056 Head gasket Replacement 5 001083 Thermistor Replacement 6 001057 Thermostat Replacement Vespa GTV 125 Time TIME 5 ...

Page 246: ...Rocker arms support assy CAM SHAFT Code Action Duration 1 001148 Rocking lever valve Re placement 2 001044 Camshaft Replacement Cylinder head cover Time Vespa GTV 125 TIME 6 ...

Page 247: ...d cover Replacement 3 001088 Head cover gasket Replace ment 4 001074 Oil vapour recovery pipe Re placement Chain tensioner CHAIN TIGHTENER Code Action Duration 1 001129 Chain tightener Overhaul and replacement 2 001124 Lubrication by pass Re placement Vespa GTV 125 Time TIME 7 ...

Page 248: ... 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor Re placement Driven pulley DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley Service 3 001110 Driven pulley Replacement Time Vespa GTV 125 TIME 8 ...

Page 249: ...UMP Code Action Duration 1 001125 Chain guide pads Replace ment 2 001051 Belt Timing chain Change 3 001042 Oil pump Service 4 001112 Oil pump change 5 001122 Oil pump chain Replace ment 6 001130 Oil sump Replacement 7 001172 Chain cover flap change Vespa GTV 125 Time TIME 9 ...

Page 250: ...NAL REDUCTION Code Action Duration 1 001010 Reduction gear Replace ment 2 003065 Gear box oil Replacement 3 001156 Geared reduction unit cover Replacement 4 004125 Rear wheel axle Replace ment Time Vespa GTV 125 TIME 10 ...

Page 251: ...DRIVING PULLEY Code Action Duration 1 001086 Driving half pulley Replace ment 2 001011 Driving belt Replacement 3 001066 Driving pulley Removal and Refitting 4 001006 driving pulley Service Vespa GTV 125 Time TIME 11 ...

Page 252: ...over TRANSMISSION COVER Code Action Duration 1 001135 Transmission cover bearing Replacement 2 001096 Transmission crankcase cov er Replacement 3 001131 Transmission air intake Re placement Time Vespa GTV 125 TIME 12 ...

Page 253: ...Starter motor ELECTRICAL START UP Code Action Duration 1 001020 Starter motor Replacement 2 001017 Start up pinion Replace ment 3 001141 Belt anti flapping roller Re placement Vespa GTV 125 Time TIME 13 ...

Page 254: ...ver replace 2 001113 Water pump Pump rotor Replacement 3 001067 Stator Removal and Refit ting 4 001058 Complete flywheel Replace ment 5 001161 Secondary air filter Replace ment 6 001162 Secondary air filter box Re placement 7 001173 Rotor Replacement Time Vespa GTV 125 TIME 14 ...

Page 255: ...anifold change 2 007020 Carburettor heating tubing replacement 3 001008 Carburettor Inspection 4 001063 Carburettor Replacement 5 001081 Automatic choke Replace ment 6 003058 Carburettor Adjustment 7 001136 Exhaust emissions Adjust ment Vespa GTV 125 Time TIME 15 ...

Page 256: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement Time Vespa GTV 125 TIME 16 ...

Page 257: ...Air cleaner AIR CLEANER Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Air cleaner carburettor fitting Replacement Vespa GTV 125 Time TIME 17 ...

Page 258: ...Replacement 2 004085 Fairing 1 Replacement 3 004149 Shield central cover Re placement 4 004053 Spoiler Replacement 5 004015 Footrest Removal and Re fitting 6 004023 Shield rim Replacement 7 004159 Plates Stickers Replace ment Time Vespa GTV 125 TIME 18 ...

Page 259: ...Centre stand STAND Code Action Duration 1 004102 Side stand Replacement 2 004004 Stand Replacement Footrests Vespa GTV 125 Time TIME 19 ...

Page 260: ...ootrest replacement 3 004071 Battery compartment re placement 4 005046 Battery cover change 5 004078 Front rear footrest rubber Replacement Rear cover REAR SHIELD Code Action Duration 1 004083 Glove box Replacement 2 004081 Glove box door Replace ment Time Vespa GTV 125 TIME 20 ...

Page 261: ...mpartment HELMET COMPARTMENT Code Action Duration 1 004136 License plate support Re placement 2 004016 Helmet compartment Re moval and Refitting 3 005048 Licence plate holder Re placement Vespa GTV 125 Time TIME 21 ...

Page 262: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replace ment 2 004009 Rear mudguard Replace ment 3 003044 Shock absorber cover Re placement Time Vespa GTV 125 TIME 22 ...

Page 263: ...uel tank FUEL TANK Code Action Duration 1 004005 Fuel tank Replacement 2 005010 Tank float Replacement 3 004109 Fuel tank breather Replace ment 4 004007 Fuel valve Replacement Vespa GTV 125 Time TIME 23 ...

Page 264: ...mplete with support Replacement 3 007001 Expansion tank Replace ment 4 007014 Radiator thermal switch Re placement 5 007013 Expansion tank radiator connecting hose Replace ment 6 007003 Delivery line and coolant re turn Replacement 7 001052 Coolant and air bleed Re placement Time Vespa GTV 125 TIME 24 ...

Page 265: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Steering column bearings Vespa GTV 125 Time TIME 25 ...

Page 266: ...g fifth wheel Re placement 2 003073 Steering clearance Adjust Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004018 Front handlebar covers Re placement 2 004019 Rear handlebar covers Re placement 3 004053 Spoiler Replacement Time Vespa GTV 125 TIME 26 ...

Page 267: ... pump Removal and refitting 4 005017 Stop switch Replacement 5 002059 Right hand knob change 6 002071 Left hand grip Replacement 7 003059 Counterweight Replace ment 8 002060 Throttle grip Replacement 9 002063 Throttle control transmission Replacement 10 003061 Accelerator transmission adjust 11 002037 Brake or clutch lever Re placement Vespa GTV 125 Time TIME 27 ...

Page 268: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chas sis connection Replacement 2 004058 Silent block Replacement Time Vespa GTV 125 TIME 28 ...

Page 269: ...liper Re placement 5 002068 Rear brake calliper Check 6 002021 Front brake piping Replace ment 7 002020 Rear brake pipes Removal and refitting 8 002007 Front brake pads shoes re moval and installation 9 002002 Rear brake pad s shoes re moval and refitting 10 002047 Front brake fluid and air bleeding system Replace ment 11 002080 Rear brake oil bleeding sys tem Replacement Vespa GTV 125 Time TIME 2...

Page 270: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Time Vespa GTV 125 TIME 30 ...

Page 271: ...witch Re placement 5 005006 Light switch or turn indicators Replacement 6 005040 Horn button Replacement 7 005121 Saddle opening button Re placement 8 005039 Headlight switch replace 9 005078 Odometer glass Replace ment 10 005038 Instrument panel warning light bulbs Replacement 11 005076 Clock battery Replacement 12 005129 Warning light group Re placement Vespa GTV 125 Time TIME 31 ...

Page 272: ...Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement Time Vespa GTV 125 TIME 32 ...

Page 273: ...tter hook transmission Replacement 3 004158 Saddle opening splitter Re placement 4 005072 Immobilizer aerial Replace ment 5 005099 Electric saddle opening de vice Replacement 6 004054 Saddle lock catch Replace ment 7 004010 Anti theft lock Replacement 8 005016 Key switch Replacement Vespa GTV 125 Time TIME 33 ...

Page 274: ...dicator bulb Re placement 5 005008 Front headlamp bulbs Re placement 6 005066 Rear light bulbs Replace ment 7 005031 Licence plate light bulb Re placement 8 005090 Stop light bulb Replacement 9 005068 Rear turn indicator bulb Re placement 10 005022 Rear turn indicators Re placement 11 005012 Front turn indicator Re placement 12 005091 Turn indicator glass Re placement Time Vespa GTV 125 TIME 34 ...

Page 275: ...ement 6 003063 Tyre pressure Check Grease tone wheel or drive Please take note that the code has been intro duced 900001 Grease tone wheel drive 15 Remember to not mistake the codes 002011 drive replacement and 005089 tone wheel replace ment in the event of noise of the indicated com ponents In the following points we indicate with an arrow the area to be greased 1 Drive 2 Tone wheel Vespa GTV 125...

Page 276: ...t 2 004126 Rear wheel tyre Replace ment 3 001071 Front wheel rim Removal and refitting 4 002070 Rear brake disc Replace ment 5 003077 muffler rear shock absorber support arm Service 6 002028 Rear wheel hub Replace ment 7 003063 Tyre pressure Check Time Vespa GTV 125 TIME 36 ...

Page 277: ...e regulator replace 7 005001 Electrical system Removal and refitting 8 005114 Electrical system Service 9 005035 Headlight remote control Replacement 10 005011 Start up remote control switch Replacement 11 005054 Fuse holder Replacement 12 005019 Fuse terminal block Re placement 13 002051 Odometer transmission as sembly Replacement 14 005024 Battery fuse Replacement 15 002025 Brake piping Replacem...

Page 278: ...ck absorber Re moval and Refitting 2 003045 Steering tube Replacement 3 003010 Front suspension Service 4 003035 Shock absorber support and brake calliper Replacement 5 003034 Front wheel hub bearing Re placement 6 001064 Odometer reel Replace ment Time Vespa GTV 125 TIME 38 ...

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VESPA GTV 125, Service Station Manual

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