VESPA GTS Super 125 i.e. Service Station Manual Download

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SERVICE STATION MANUAL

677714 EN

Vespa GTS Super 125 i.e.

Summary of Contents for GTS Super 125 i.e.

Page 1: ...SERVICE STATION MANUAL 677714 EN Vespa GTS Super 125 i e ...

Page 2: ...n beforehand to make any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of each model should be checked at the official PIAGGIO sales network Copyright 2013 Piaggio C S p A All rights reserv...

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

Page 4: ......

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

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

Page 7: ...in such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gask...

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

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

Page 10: ... Quantity Fuel tank including a 2 l reserve 9 2 l Cooling system fluid 2 100 2 150 l Engine oil approx 1300 cc Rear hub 250 cc Electrical system ELECTRICAL COMPONENTS Specification Desc Quantity Ignition advance Electronic with inductive discharge and variable advance with three dimensional mapping Spark plug NGK CR8EKB Battery 12V 12Ah Fuses 1 of 30A 2 of 15A 4 of 7 5A Alternator alternating curr...

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

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

Page 13: ...NE TEMPERATURE SENSOR 0 5 900 Ohm 10 3 800 Ohm 20 2 500 Ohm 30 1 700 Ohm 80 300 Ohm MINIMUM OIL PRESSURE SENSOR Normally closed switch Activation threshold 0 3 0 6 BAR With the engine off continuity between muffler and ground HV COIL DIV class O v shape _x0000_s3074 Resistance of the primary 0 5 Ohm 8 Resistance between primary and ground infinite Resistance between primary and H V output 3 1KOhm ...

Page 14: ...th swinging fork articulated to frame by means of an arm with 2 degrees of freedom Pair of double acting hydraulic shock absorbers and coaxial springs with preloading adjust ment in 4 positions Rear shock absorber axial travel 89 5 mm Brakes BRAKES Specification Desc Quantity Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plung ers and hydraulic control lever on the far right end o...

Page 15: ...SSEMBLY Name Torque in Nm Engine swinging arm pin 64 72 swinging arm bolt body shell 76 83 Engine and vehicle side swinging arm junction bolt 33 to 41 Bolt of the Silent block support plate 42 52 Centre stand bolt 32 to 40 Side stand fixing bolt 35 to 40 FRONT SUSPENSION Name Torque in Nm Screw fixing the shock absorber to the shock absorber calliper attachment plate 20 to 27 Wheel axle nut 74 88 ...

Page 16: ... Lambda probe tightening on exhaust manifold 40 50 Exhaust manifold silencer joint tightening 12 to 13 Manifold silencer diaphragm tightening clamp 16 to 18 LUBRICATION Name Torque in Nm Hub oil drainage plug 15 to 17 Oil filter on crankcase fitting 27 33 Engine oil drainage plug mesh filter 24 30 Oil filter 4 6 Oil pump cover screws 7 to 9 Screws fixing oil pump to the crankcase 5 6 Oil pump comm...

Page 17: ...Nm Internal engine crankcase bulkhead transmission side half shaft screws 4 6 Engine crankcase coupling screws 11 13 Starter motor screws 11 13 Crankcase timing cover screws 3 5 4 5 Apply LOCTITE medium type 242 threadlock COOLING Name Torque in Nm Water pump rotor cover 3 4 Thermostat cover screws 3 4 Bleed screw 3 Overhaul data Assembly clearances Cylinder piston assy Calculate the coupling clea...

Page 18: ...ST BE MADE ACCORDING TO THE PISTON AXIS Characteristic Standard clearance 0 001 0 010 mm Check that coating is free from flakes Check that the head coupling surface is not worn or misshapen Characteristic Maximum allowable run out 0 001 over 0 05 mm Pistons and cylinders are classified into categories based on their diameter The coupling is carried out in pairs A A B B C C D D Characteristics Vesp...

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

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

Page 21: ...010 If the crankshaft is within the set limits replace the crankshaft half bearings mounting the crankcase so as to suit the specified couplings The crankcase halves can be mounted with four types of crankshaft half bearings identified by letters B blue C yellow E green CRANKCASE Specification Desc Quantity Category 1 32 959 35 965 Category 2 32 953 to 32 959 CRANKCASE CRANKSHAFT COUPLING CRANKSHA...

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

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

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

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

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

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

Page 28: ...intake 17 130 mm Exhaust 16 310 mm standard axial clearance 0 11 0 41 mm maximum admissible axial clearance 0 42 mm Check that the rocking lever pins exhibit no scores or wear Characteristic Standard diameter Diameter 11 977 11 985 mm Measure the inside diameter of each rocker Characteristic Standard diameter Ø 12 0 011 mm Characteristics Vespa GTS Super 125 i e CHAR 28 ...

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

Page 30: ... the treatment of foam filters AGIP GP 330 Water repellent stringy calcium spray grease R I D A D R 2 10 b 2 R I Na 2 42 I A T A 2 I M D G class 2 UN 1950 Page 9022 EM 25 89 eni i Ride PG 5W 40 Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 AGIP BRAKE 4 Brake fluid Synthetic fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 AGIP PERMANENT...

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

Page 32: ...Bell for bearings OD 39 mm 001467Y014 Calliper to extract ø 15 mm bearings 005095Y Engine support 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch for removing steering bearings from headstock Tooling Vespa GTS Super 125 i e TOOL 32 ...

Page 33: ...0021Y Front suspension service tool 020036Y Punch 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater mounting Vespa GTS Super 125 i e Tooling TOOL 33 ...

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

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

Page 36: ...Description 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35 mm Adaptor 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55 mm Adaptor 020363Y 20 mm guide 020364Y 25 mm guide Tooling Vespa GTS Super 125 i e TOOL 36 ...

Page 37: ... 22 mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band Vespa GTS Super 125 i e Tooling TOOL 37 ...

Page 38: ... 15 mm guide 020423Y Driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting Tooling Vespa GTS Super 125 i e TOOL 38 ...

Page 39: ...441Y 26 x 28 mm adaptor 020444Y Tool for fitting removing the driven pulley clutch 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30 mm guide 020489Y Hub cover support stud bolt kit Vespa GTS Super 125 i e Tooling TOOL 39 ...

Page 40: ... 020922Y Diagnosis Tool 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Bearing housing outside ø 47 mm 020626Y Driving pulley lock wrench 001467Y013 Calliper to extract ø 15 mm bearings Tooling Vespa GTS Super 125 i e TOOL 40 ...

Page 41: ...heel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops 200 250 020622Y Transmission side oil seal punch 020480Y Petrol pressure check kit 020244Y 15 mm diameter punch Vespa GTS Super 125 i e Tooling TOOL 41 ...

Page 42: ...Stores code Description 020115Y Ø 18 punch 020271Y Tool for removing fitting silent bloc Tooling Vespa GTS Super 125 i e TOOL 42 ...

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

Page 44: ...pads I I I I I I I I I I I I I Sliding shoes CVT rollers R R R R R R Tyre pressure and wear I I I I I I I Vehicle road test I I I I I I I Radiator external cleaning I I I I Suspension I I I I I I I Steering A A A A A A A Transmission L L L L Operation Time 60 10 10 0 45 15 0 10 14 0 10 15 0 45 10 0 10 19 0 Spark plug Rest the scooter on its stand Open the saddle and take out the helmet com partmen...

Page 45: ...R THAN THOSE PRESCRIBED CAN SERI OUSLY DAMAGE THE ENGINE Characteristic Electrode gap 0 7 to 0 8 mm Electric characteristic Spark plug NGK CR8EKB Locking torques N m Spark plug 12 14 Hub oil Check Place the vehicle on the centre stand on flat ground Remove the oil dipstick A dry it with a clean cloth and put it back into its hole tightening it completely Remove the dipstick and check that the oil ...

Page 46: ... unscrew the nut B under the body 3 remove the left side fairing 4 remove the helmet compartment 5 unscrew the fixing screws C that can be reached once the helmet compartment has been removed 6 Unscrew the screws D and remove the air fil ter cover Remove the filtering element and clean it with wa ter and shampoo then dry it with a clean cloth and short blasts of compressed air Finally immerse it i...

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

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

Page 49: ...A3 Oil pressure warning light The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the ON position However this light should switch off once the engine has started If the light turns on during braking at idling speed or while turning a corner it is necessary to check the oil level and the lubrication system Cooling system Adding engine coolant The...

Page 50: ...for the front and rear brakes are located on the pumps under the handlebar cover Proceed as follows Remove the brake pump cover Rest the vehicle on its centre stand with the han dlebars perfectly horizontal Check the fluid level through the sight glass as shown in the figure A certain lowering of the level is caused by wear on the pads Top up Position the vehicle on a flat surface and on the centr...

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

Page 52: ...eadlight and check that the boun dary of the light beam projected onto the screen is not higher than 9 10 or lower than 7 10 of the dis tance between the centre of the headlight and the ground 3 Otherwise adjust the right headlight with screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN F...

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

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

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

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

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

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

Page 59: ...r ECU 46 Immobilizer aerial Key Ar Orange Az Light Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU KEY 1 Instrument panel 2 Turn indicator control device 3 Turn indicator switch Vespa GTS Super 125 i e Electrical system ELE SYS 59 ...

Page 60: ...gine stop switch 18 Ignition switch contacts 19 Starter button 20 Starter motor 21 Starter relay 22 Stop light bulb 23 Battery 24 Main fuses 25 Magneto flywheel 26 Voltage regulator 27 Injection load relay 28 Electric fan relay 29 Radiator electric fan 30 Lambda probe 31 Water pump 32 Engine speed sensor 33 HV coil 34 Fuel injector 35 Engine temperature sensor 36 Fuel pump 37 Diagnosis socket 38 I...

Page 61: ...Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Components arrangement 9 Immobilizer aerial Remove the shield back plate to reach it 10 Injection ECU Remove the helmet compart ment to reach it Vespa GTS Super 125 i e Electrical system ELE SYS 61 ...

Page 62: ...to reach it 15 H V coil Remove the battery to reach it to remove the coil first remove the footrest and undo the two screws indicated 20 18 30 38 Horn Solenoids Remove front cen tral cover to reach them Electrical system Vespa GTS Super 125 i e ELE SYS 62 ...

Page 63: ...central cover and the helmet compartment to reach them 22 26 Main fuses Open the front top box and the battery cover to reach them 27 Voltage regulator Remove the shield back plate to reach it Vespa GTS Super 125 i e Electrical system ELE SYS 63 ...

Page 64: ...compartment 40 Key switch contacts Remove the shield back plate to reach them 33 Saddle opening actuator Remove the hel met compartment to reach it undo the two screws indicated and remove the fixing bracket together with the actuator 8 Fuel level transmitter Remove the fuel tank to reach it Electrical system Vespa GTS Super 125 i e ELE SYS 64 ...

Page 65: ...12Ah Battery 7 30A Fuse 8 15A Fuse 10 Key switch contacts 11 Engine stop switch 23 Instrument panel 28 Fuse 7 5A 31 Fuse 7 5A 34 Injection load remote control 40 HV coil 43 Diagnostics socket 45 Injector ECU 46 Immobilizer aerial THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Vespa GTS Super 125 i e Electrical system ELE SYS 65 ...

Page 66: ...s 27 Injection load relay 33 HV coil 38 Injection ECU 39 Immobilizer antenna Battery recharge and starting 1 Magneto flywheel 2 Voltage regulator 3 12V 12Ah Battery 4 Start up remote control switch 5 Starter motor 6 Starter button 7 30A Fuse Electrical system Vespa GTS Super 125 i e ELE SYS 66 ...

Page 67: ... THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU KEY 13 Secondary fuses 16 Stop buttons 17 Engine stop switch 18 Ignition switch contacts 19 Starter button 20 Starter motor 21 Starter relay 22 Stop light bulb 23 Battery 24 Main fuses Vespa GTS Super 125 i e Electrical system ELE SYS 67 ...

Page 68: ...switch 23 Instrument panel 24 Fuel level transmitter 25 Oil pressure sensor 30 Fuse 7 5A 31 Fuse 7 5A 34 Injection load remote control 37 Lambda sensor 39 Engine rpm sensor 41 Fuel injector 42 Coolant temperature sensor 45 Injector ECU 46 Immobilizer aerial THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Electrical system Vespa GTS Super 125 i e ELE SYS 68 ...

Page 69: ...Starter relay 23 Battery 24 Main fuses 35 Engine temperature sensor 38 Injection ECU 39 Immobilizer antenna 40 Fuel level transmitter 41 Oil pressure sensor Devices and accessories 3 12V 12Ah Battery 7 30A Fuse 8 15A Fuse 10 Key switch contacts Vespa GTS Super 125 i e Electrical system ELE SYS 69 ...

Page 70: ...icator control device 23 Instrument panel 28 Fuse 7 5A 29 Fuse 15A 30 Fuse 7 5A 31 Fuse 7 5A 32 Horn button 33 Horn 34 Injection load remote control 35 Electric fan remote control 36 Radiator electric fan 38 Water pump 44 Fuel supply pump 45 Injector ECU THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Electrical system Vespa GTS Super 125 i e ELE SYS 70 ...

Page 71: ...e opening switch 10 Ignition switch contacts 13 Secondary fuses 14 Horn 15 Horn button 18 Ignition switch contacts 23 Battery 24 Main fuses 27 Injection load relay 28 Electric fan relay 29 Radiator electric fan 31 Water pump 36 Fuel pump 38 Injection ECU Vespa GTS Super 125 i e Electrical system ELE SYS 71 ...

Page 72: ...Headlight with twin filament bulb 20 Turn indicator bulbs 21 Turn indicator switch 22 Turn indicator control device 23 Instrument panel 26 Headlight remote control 27 Fuse 7 5A 28 Fuse 7 5A 29 Fuse 15A 30 Fuse 7 5A 31 Fuse 7 5A 45 Injector ECU THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Electrical system Vespa GTS Super 125 i e ELE SYS 72 ...

Page 73: ...t bulb 7 Daylight running light bulbs and license plate light 11 Light switch 12 Headlight relay 13 Secondary fuses 18 Ignition switch contacts 23 Battery 24 Main fuses 38 Injection ECU Checks and inspections This section is dedicated to the checks on the electrical system components Vespa GTS Super 125 i e Electrical system ELE SYS 73 ...

Page 74: ... The diagnosis LED also works as a theft deterrent blinker This function is activated every time the ignition switch is turned to the OFF position or the emergency stop switch is turned to the OFF position It remains activated for 48 hours in order not to affect the battery charge When the key switch is turned to ON it interrupts the function of the immobiliser lamp and a start enable lamp comes O...

Page 75: ...ncy cut out switch in the RUN position If there is no continuity check the con tacts of the latter If no faults are found replace the control unit THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU The electronic ignition system is controlled by the control unit with the integrated Immobilizer system The immobiliser is an antitheft system which allows the vehicle to function o...

Page 76: ... there is battery voltage fuse No 1 fuse No 2 and fuse No 3 efficiency there is power to the control unit as specified below Remove the connector mounting bracket shown in the photograph and disconnect the connector from the control unit Check the following conditions With the key switch set to OFF there is battery voltage between terminals 7 9 and terminal 9 chassis ground fixed power sup ply If ...

Page 77: ...or With the ignition switch at ON check there is bat tery voltage between the Red White and Black cables With MIU connector disconnected check the con tinuity between the Orange White cable and pin 7 of the interface wiring Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Vespa GTS Super 125 i e Electrical system ELE SYS 77 ...

Page 78: ...eg shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base from the connector With the ignition switch at ON check there is bat tery voltage between the Red White and Black cables Electrical system Vespa GTS Super 125 i e ELE SYS 78 ...

Page 79: ...rogrammed control unit provides for the recogni tion of the red key master key as the first key to be stored to memory this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogram med for the memorisation of the service keys The master and service keys must be used to code the system as follows Insert the Master key turn it to ON and ...

Page 80: ...e keys you must re peat the procedure using all the keys you intend to keep using If a service key becomes uncoded the efficiency of the high voltage circuit shielding must be thor oughly inspected In any case it is advisable to use resistive spark plugs Characteristic Shielded cap resistance 5000 Ω Diagnostic codes The Immobilizer system is tested each time the ig nition key is turned from OFF to...

Page 81: ...sh is displayed after which the LED remains off steadily The engine can be started 4 Programmed control unit Master key in a 0 7 sec flash is displayed followed by the LED re maining off for 2 sec and then by short 0 46 sec flashes the same number of times as there are keys stored in the memory including the Master key When the diagnosis has been completed the LED remains permanently OFF The engin...

Page 82: ...se replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Diagnostic code 3 flashes A three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code is repeated even with the Master key replace the control unit If this is not the case reprogram the decoder Batter...

Page 83: ...eplace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing the cover in the footrest 2 Check that the battery does not show signs of losing fluid before checking the output voltage 3 Turn the ignition key to position OFF connect the terminals of the tester between the negative pole of the battery and the black cable and only then disconnect the black cabl...

Page 84: ...iers to the 2 recharge positive poles in output from the regulator Keep the lights on and start the engine bring it to normal speed and read the values on the ammeter With an efficient battery a value must be detected 20A VOLTAGE REGULATOR RECTIFIER Specification Desc Quantity Type Non adjustable three phase transistor Voltage 14 to 15V at 5000 rpm with lights off Starter motor KEY 1 Battery 2 Sta...

Page 85: ...re is not check the cable harnesses 5 Check the start up remote control switch 6 Check that the Red cable between the battery and the start up remote control switch is not interrupted Also check continuity between the latter and the starter motor 7 Check the starter motor ground connection 8 Check that the Orange Blue cable between the start up remote control switch and the control unit pin 24 is ...

Page 86: ...TH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check fuses No 1 2 3 and 4 2 Check ignition switch contacts 3 Check the contacts of the stop buttons and the starter button 4 With the ignition switch set to ON the brake pulled and the starter button pressed check if there is voltage between the Orange White cable of the start up relay and the ground connection If there is not check the cable harness...

Page 87: ...terrupted 9 Check the contacts of the engine stop switch and that the Green Black cable connecting this switch to the control unit pin 4 is not interrupted 10 Check the engine stop switch ground connection Horn control KEY 1 Battery 2 Fuse No 1 3 Key switch contacts 4 Fuse No 4 5 Horn button 6 Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Ch...

Page 88: ...tor control device 6 Turn indicator switch 7 Turn indicator bulbs WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check that bulbs operate properly 2 Check fuses No 1 and 4 3 Check key switch contacts 4 With the key switch set to ON check if there is voltage between the Blue Black cable of the turn indicators switch and the ground connection If the...

Page 89: ...heir ground connection are not interrupted level indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED If faults are detected 1 With a multimeter check resistance values between the White Green cable and the Black cable of the fuel level transmitter under different conditions 2 If the transmitter operates correctly but the indication on the inst...

Page 90: ...k that bulbs operate properly 2 Check fuses No 1 4 and 5 3 Check key switch contacts 4 Check if there is voltage between the Grey cable of the headlight remote control and the ground connection If there is not check the cable harnesses 5 With the key switch set to ON and the engine running check if there is voltage between the Yellow Red cable of the headlight remote control and the ground connect...

Page 91: ...two light bulb 10 Light switch 11 Headlight relay WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED DAYLIGHT RUNNING LIGHT AND LICENSE PLATE LIGHT LINE 1 Check that bulbs operate properly 2 Check fuses No 1 and 7 3 Check ignition switch contacts 4 Check if there is voltage between the Yellow Black cable of fuse No 7 and the ground If not check cable ha...

Page 92: ...Red cable of the light switch and the headlight relay switch is not interrupted 9 Check the light switch contacts 10 Check that the cable harnesses of the bulbs and their ground connection are not interrupted Fuses The electrical system is equipped with 1 six protection fuses A located in the glove compartment to the left 2 of a fuse B located in the battery compart ment The chart shows the positi...

Page 93: ...R TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE CAUTION MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK OF FIRE FUSES Specification Desc Quantity 1 Fuse 1 Current rating 30 A Protected circuits Vehicle main fuse 2 Fuse 2 Current rating 7...

Page 94: ...ry charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE 1 Voltage check Before installing the battery on the vehicle check the open circuit voltage with a standard tester If voltage exceeds 12 60 V the battery can be installed without any renewal recharge If voltage is below 12 60 V a renewal ...

Page 95: ...OF CHILDREN 1 Battery preparation Position the battery on a flat surface Remove the adhesive sheet closing cells and proceed as quick ly as possible to run the subsequent activation phases 2 Electrolyte preparation Remove the container of the electrolyte from the pack Remove and preserve cover strips from the container in fact the strip will later be used as a closing cover Note Do not pierce the ...

Page 96: ...lose to the battery The filling process is now complete Do not remove the strip of caps under any circumstances do not add water or electrolyte Place the battery down for 1 to 2 hours prior to the charging from the battery 7 Recharging the new battery With the above mentioned procedure the battery will have gained around 70 75 of its total electrical capacity Before installing the battery on the v...

Page 97: ...ry recharge Maintenance Free as shown in fig ure f Check the ignition of the green LED indicated with a red arrow in figure g The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place Vespa GTS Super 125 i e Electrical system ELE SYS 97 ...

Page 98: ...ttery charger from the fuel supply grid disconnect the clamps from the battery and proceed to fitting the battery on the vehicle Connectors DIAGNOSTICS CONNECTOR 1 Not connected 2 Ground lead Black 3 Electronic control unit Violet White PICKUP CONNECTOR 1 Control unit positive Red 2 Negative from control unit Brown 3 Not connected FUEL PUMP CONNECTOR 1 Not connected 2 Ground lead Black 3 Not conne...

Page 99: ...k 13 Engine rpm sensor positive Red 14 Injector Red Yellow 15 Engine rpm sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer warning light Red Green 18 To ground Grey Green 19 Low beam lights automatic ignition White Black 20 Injection load remote control Black Purple 21 Not connected 22 HV coil Pink Black 23 Not connected 24 Start up enabling Orange Blue 25 Not connected 26 Ground lead...

Page 100: ...REGULATOR CONNECTOR 1 Battery positive Red Black 2 Ground lead Black 3 Battery positive Red Black 4 Ground lead Black INSTRUMENT PANEL CONNECTOR A 1 Fuel level indicator White Green 2 High beam warning light Violet 3 Left indicator warning light White Blue 4 Right indicator warning light Pink 5 Key powered White 6 Oil pressure sensor Pink White Electrical system Vespa GTS Super 125 i e ELE SYS 100...

Page 101: ...n 2 Battery powered Red Blue 3 Lighting Yellow Black 4 Key powered White H V COIL CONNECTOR 1 Power from relay Black Green 2 Electronic control unit Pink Black ANTITHEFT DEVICE PRE INSTALLATION CONNECTOR 1 Ground lead Black 2 Left indicator White Blue 3 Right indicator Pink 4 Battery powered Red Blue 5 Key powered White 6 Not connected 7 Not connected 8 Not connected Vespa GTS Super 125 i e Electr...

Page 102: ...und lead Black 3 Low fuel warning light Yellow Green COOLANT PUMP CONNECTOR 1 Ground lead Black 2 Injection load relay Black Green 3 Injection load relay Black Green THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU DIAGNOSTICS CONNECTOR 1 Not connected 2 Ground lead Black 3 Electronic control unit Violet White Electrical system Vespa GTS Super 125 i e ELE SYS 102 ...

Page 103: ...Ground Green Black 5 Not connected 6 Key powered Red White 7 Ground No 1 Black 8 Not connected 9 Battery powered Grey Black 10 Start up enabling switch Orange Blue 11 Lambda probe positive Sky blue Black 12 Lambda probe negative White Green 13 Water temperature sensor Sky blue Green 14 Immobilizer aerial Orange White 15 Not connected 16 K serial line Purple White 17 Immobilizer Red Green 18 Not co...

Page 104: ... Not connected 31 Lambda probe heater White 32 Not connected 33 Low beam lights automatic ignition enabling White Black 34 Fuel injector Red Yellow ENGINE TEMPERATURE SENSOR CONNEC TOR 1 Ground lead Grey Green 2 Instrument panel Grey Black 3 Electronic control unit Sky blue Green 4 Ground lead Black INJECTOR CONNECTOR 1 Power from relay Black Green 2 Electronic control unit Red Yellow Electrical s...

Page 105: ... 1 Fuel level indicator White Green 2 High beam warning light Violet 3 Left indicator warning light White Blue 4 Right indicator warning light Pink 5 Key powered White 6 Oil pressure sensor Pink White INSTRUMENT PANEL CONNECTOR B 1 Ground lead Black 2 Injection warning light Brown Black 3 Low fuel warning light Yellow Green 4 Water temperature Grey Black Vespa GTS Super 125 i e Electrical system E...

Page 106: ... control unit Pink Black ANTITHEFT DEVICE PRE INSTALLATION CONNECTOR 1 Ground lead Black 2 Left indicator White Blue 3 Right indicator Pink 4 Battery powered Red Blue 5 Key powered White 6 Not connected 7 Not connected 8 Not connected IMMOBILIZER ANTENNA CONNECTOR 1 Key powered Red White 2 Ground lead Black 3 Electronic control unit Orange White Electrical system Vespa GTS Super 125 i e ELE SYS 10...

Page 107: ...e injection control unit are involved with Pin 10 ELECTRICAL ERRORS Starter command P0170 shorted to positive Error cause Short circuit to positive excessive voltage at PIN 10 of the control unit connector Troubleshooting Short circuit to positive This malfunction is detected with a brake activated and the starter button pressed If the battery voltage does not drop thanks to the absorption of the ...

Page 108: ...tures between PIN 13 and 7 Disconnect the sensor connector Check the continuity of the cable harness between the sensor connector and control unit connector Control unit PIN 13 sensor PIN 3 and control unit PIN 7 sensor PIN 1 If necessary restore the cable harness If the cabling is intact but the sensor resistance value is incorrect this means that the sensor is faulty and must be replaced otherwi...

Page 109: ... the control unit connector and the sensor connector Verify that there is no short circuit with the battery positive on the PIN 1 of the sensor connector corresponding to the PIN 11 of the control unit connector in the presence of short circuit restore the cable harness Verify that there is no short circuit with the battery positive on the PIN 2 of the sensor connector corresponding to the PIN 12 ...

Page 110: ... of the injector connector Open circuit circuit interruption Troubleshooting Short circuit to positive Disconnect the injector connector turn ignition switch to ON and activate the component using the diagnostic tool Verify the absence of voltage at the injector connector PIN 2 if present restore the cable harness otherwise proceed with the following checks Short circuit to negative Disconnect the...

Page 111: ...N 22 If necessary restore the cable harness Short circuit to negative Disconnect the injection relay and the control unit Verify ground insulation of the relay connector PIN 86 and 85 toward the cabling if there is no insu lation restore the cabling Open circuit Disconnect the injection relay and the control unit Verify continuity of the cabling between the relay and control unit Relay PIN 85 cont...

Page 112: ... result the coil should be replaced Short circuit to negative Disconnect the control unit connector and the coil connector Verify the coil connector PIN 2 ground insulation or control unit connector PIN 1 If necessary restore the cable harness ELECTRIC FAN CIRCUIT Function Radiator fan and coolant Operation Operation Operating principle The control unit closes the fan control relay excitation circ...

Page 113: ...k procedure of the control unit and relay connectors Verify electrical continuity of the cable between the relay connector PIN 85 and the control unit connector PIN 24 Verify electrical continuity of the cable between the relay connector PIN 30 and the secondary fuse holders Verify continuity between relay PIN 85 and PIN 86 If there is no continuity replace the relay Vespa GTS Super 125 i e Electr...

Page 114: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 115: ...a ble to the coolant pipe indicated in the photograph Undo the two exhaust manifold fixings on the head To unscrew the nuts that fix the silencer flange to the head properly use a jointed wrench that allows according to the travel direction to get also at the right nut That is difficult to do with a traditional straight wrench Undo the three screws that fix the silencer to the supporting arm Remov...

Page 116: ...emove the side fairings and the spoiler termi nals Remove the rear brake calliper Remove the air cleaner from the housing by un screwing the three screws indicated in the photo graph CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD Remove the clamp from the blow by pipe and take the pipe out remove the retainer clamp Remove the clamp indicated in the photograph and disconnect the...

Page 117: ...ed in the photograph Disconnect the fuel pipe from the injector and re move the screw locking the retainer clamp Disconnect the injector wiring and the throttle body control unit wiring Disconnect the cable harnesses from the two clamps indicated Vespa GTS Super 125 i e Engine from vehicle ENG VE 117 ...

Page 118: ... coolant temperature sensor con nector indicated in the photo Remove the throttle control cables from the throt tle body by undoing the nuts indicated in the pho tograph Loosen the clamp indicated in the photograph and remove the throttle body Engine from vehicle Vespa GTS Super 125 i e ENG VE 118 ...

Page 119: ...e Remove the positive and negative wiring from the starter motor as shown in the picture Disconnect the connectors from the flywheel wir ing as shown in the photo Release the cables from the retainer clamps Vespa GTS Super 125 i e Engine from vehicle ENG VE 119 ...

Page 120: ... engine to the vehicle carry out the removal operations but in reverse order and respect the tightening torque shown in the Spec ifications Chapter Check that there is a small clearance when the valve is in abutment against the set screw Check the engine oil level and if necessary top it up with the recommended type Fill and bleed the cooling circuit Check accelerator and electric devices for corr...

Page 121: ...eeve be careful to position the throttle body reference marks as in dicated in the picture CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY Vespa GTS Super 125 i e Engine from vehicle ENG VE 121 ...

Page 122: ...INDEX OF TOPICS INJECTION INJEC ...

Page 123: ...Vespa GTS Super 125 i e Injection INJEC 123 ...

Page 124: ...emperature Intake air temperature Lambda probe The system implements cold engine idle fuel air mixture correction with a stepper motor on a by pass circuit of the throttle valve The control unit manages the Stepper motor and the injector opening time thereby ensuring the idle steadiness and the proper combustion In all conditions of use mixture preparation is managed by modifying the injector open...

Page 125: ... panel Failures are detected and restored by the diagnostic tester In any case when the fault is no longer present the data storage is automatically cleared after 16 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required to adjust the idle mixture Specific tooling 020922Y Diagnosis Tool The MIU injection ignition system carries out checks on the ...

Page 126: ...sensor 2 MIU system faults may be caused by loose connectors Make sure that all connections have been correctly made Check the connectors taking into consideration the following point A check that the terminals are not bent B check that the connectors have been properly connected C Check whether the malfunction can be fixed by shaking the connector slightly 3 Check the entire system before replaci...

Page 127: ... washing the vehicle be careful with the electric components and cable harnesses 8 When an ignition problem is detected start the checks from the battery and the injection system connections 9 Before disconnecting the MIU ECU connector perform the following steps in the order shown Set the switch to OFF Disconnect the battery Failure to respect this norm may damage the control unit 10 Do not inver...

Page 128: ...ensor 10 incomplete 11 lambda probe 12 Engine stop switch 13 engine rpm sensor 14 fuel injector 15 engine rpm sensor 16 Diagnostics socket output 17 Immobilizer LED 18 Pin short circuited with pin 26 19 low beam automatic ignition 20 injection load remote control 21 incomplete 22 HV coil 23 incomplete 24 Start up enabling 25 incomplete Injection Vespa GTS Super 125 i e INJEC 128 ...

Page 129: ...lue 11 Lambda probe positive Sky blue Black 12 Lambda probe negative White Green 13 Water temperature sensor Sky blue Green 14 Immobilizer aerial Orange White 15 Not connected 16 K serial line Purple White 17 Immobilizer Red Green 18 Not connected 19 Side stand Grey Green 20 Engine speed sensor negative Brown 21 Not connected 22 Injection load relay Black Purple 23 Not connected 24 Habilitation el...

Page 130: ...Red 30 Not connected 31 Lambda probe heater White 32 Not connected 33 Low beam lights automatic ignition enabling White Black 34 Fuel injector Red Yellow EMS circuit diagram 1 Battery 12V 12 Ah 2 Rpm sensor Injection Vespa GTS Super 125 i e INJEC 130 ...

Page 131: ...e No 5 15A 14 Starter button 15 Start up remote control switch 16 Electric fan remote control 17 Starter motor 18 Electric fan motor 19 Fuel pump 20 HV coil 21 Injector 22 Lambda sensor 23 Headlight remote control 24 WARNING light 25 IMMOBILIZER led 26 Diagnostics socket output 27 Coolant electric pump THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Vespa GTS Super 125 i e ...

Page 132: ...tacts 21 Starter relay 23 Battery 24 Main fuses 26 Voltage regulator 27 Injection load relay 28 Electric fan relay 29 Radiator electric fan 30 Lambda probe 31 Water pump 32 Engine speed sensor 33 HV coil 34 Fuel injector 35 Engine temperature sensor 36 Fuel pump Injection Vespa GTS Super 125 i e INJEC 132 ...

Page 133: ...ignition Intake air temperature End of compression pressure End of compression pressure Starting difficulties ENGINE STARTER PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Start up speed Starter motor and solenoid Battery Ground connections End of compression pressure End o...

Page 134: ...r Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO IDLING SPEED IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Ignition efficiency Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature senso...

Page 135: ...ition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance TPS reset successful TPS reset successful Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Poor performance at full throttle POOR...

Page 136: ...e air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Fuel supply system The fuel system circuit includes the electric pump the filter the pressure regulat...

Page 137: ...e butterfly valve Remove the helmet compartment Remove the fuel piping clamping screw indicated in the figure Remove the fast release fittings from the injector support Vespa GTS Super 125 i e Injection INJEC 137 ...

Page 138: ...ee screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector Remove the clip fixing the throttle body to the air cleaner bellows Injection Vespa GTS Super 125 i e INJEC 138 ...

Page 139: ...ng the butterfly valve To refit perform the operations in the reverse or der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45 as shown in the photograph Vespa GTS Super 125 i e Injection INJEC 139 ...

Page 140: ...Pump supply circuit 1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts Injection Vespa GTS Super 125 i e INJEC 140 ...

Page 141: ...eck that the injection load 15A fuse No 3 works properly Check that the 7 5A fuse No 2 for live control unit power works properly Check the efficiency of the injection load relay Check the resistance of the energising coil be tween pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the relay Check the power supply line ...

Page 142: ...le between the pin 20 of the control unit and the solenoid base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection Vespa GTS Super 125 i e INJEC 142 ...

Page 143: ...ltage for about two seconds to the Black Green cable of the pump connector and ground with pump connector disconnected Otherwise check the continuity of the Black Green cable between the pump connector and the remote control base Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable system side and the ground If when switching t...

Page 144: ...lack Purple cable pin 20 on the interface wiring is insulated from the ground Specific tooling 020331Y Digital multimeter THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Injection Vespa GTS Super 125 i e INJEC 144 ...

Page 145: ...1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts 5 7 5A fuse No 2 Vespa GTS Super 125 i e Injection INJEC 145 ...

Page 146: ...t the injection load 15A fuse No 3 works properly Check that the 7 5A fuse No 2 for live control unit power works properly Check the efficiency of the injection load relay Check the resistance of the energising coil be tween pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the relay Check the power supply line of the ...

Page 147: ...FUSES ETC Check the presence of fixed voltage between the grey black cable of the relay base and ground If there is none check the continuity of the grey black cable between the fuse box No 3 15 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Vespa GTS Super 125 i e Injection INJEC 147 ...

Page 148: ...ing the continuity between the pump connector black cable system side and the ground If when switching to ON the pump continues to turn after two seconds of activation check with the control unit disconnected and the injection load re lay disconnected that the Black Purple cable pin 22 on the interface wiring is insulated from the ground Specific tooling 020331Y Digital multimeter Circuit leak tes...

Page 149: ...re gauge of the appropriate tool Make a graded burette available with a flowrate of approximately 1 L Rotate the pump using the active diagnosis of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at approx 2 5 BAR Check that in fifteen seconds the pump has a flowrate of around 110cc Specific tooling 020480Y Petrol pressure check ...

Page 150: ... clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture Remove the filter from the pump mounting Injection Vespa GTS Super 125 i e INJEC 150 ...

Page 151: ...ecting the injector circuit 1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts 5 7 5A fuse No 2 6 Injection load relay 7 Fuel pump 8 HV coil Vespa GTS Super 125 i e Injection INJEC 151 ...

Page 152: ...en pins 30 and 87 of the relay Check the power supply line of the injection load remote control energising coil after switching to ON make sure there is battery voltage for two seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box under the saddle hinge and the remote control base and o...

Page 153: ...y base and ground If there is none check the continuity of the grey black cable between the fuse box No 3 15 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Vespa GTS Super 125 i e Injection INJEC 153 ...

Page 154: ... cable be tween pin 14 of the interface wiring and the injector connector Switch to ON and check if there is voltage with injector disconnected and control unit connected between the Black Green cable of the injector con nector and the ground lead Injection Vespa GTS Super 125 i e INJEC 154 ...

Page 155: ...jector load relay disconnected check the continuity of the Black Green cable between the injector connector and relay base THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Vespa GTS Super 125 i e Injection INJEC 155 ...

Page 156: ...1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts 5 7 5A fuse No 2 Injection Vespa GTS Super 125 i e INJEC 156 ...

Page 157: ...86 and 85 make sure that there is continuity between pins 30 and 87 of the relay Check the power supply line of the injection load relay energising coil after switching to ON make sure there is battery voltage for 2 seconds be tween the Red White cable and Black Purple ca ble of the relay base If there is not check the continuity of the Red White cable between the fuse box and the relay base and o...

Page 158: ...y base and ground If there is none check the continuity of the grey black cable between the fuse box No 3 15 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection Vespa GTS Super 125 i e INJEC 158 ...

Page 159: ... cable be tween pin 34 of the interface wiring and the injector connector Switch to ON and check if there is voltage with injector disconnected and control unit connected between the Black Green cable of the injector con nector and the ground lead Vespa GTS Super 125 i e Injection INJEC 159 ...

Page 160: ...ifold Install the appropriate tool for checking fuel pres sure and position the manifold over a container graduated by at least 100 cm Connect the injec tor with the cable making up part of the supply for the injection tester Connect the clamps of the ca ble to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within fifteen seconds approximately 40 cm of fuel is dis...

Page 161: ...ere are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute Tachometer With wiring disconnected from the control unit and connected to the system check that the sensor resistance between pins 13 15 is between 100 and 150 Ohm at an engine temperature of approx imately 20 Vespa GTS Super 125 i e Injection INJEC 161 ...

Page 162: ...n 13 and the red cable of the engine speed sensor connector and between pin 15 and the brown ca ble of the engine speed sensor connector With the interface wiring and rpm sensor connec tor disconnected from the control unit check that the Red and Brown cables pin 13 15 are isola ted from each other and insulated from the ground Specific tooling 020481Y Control unit interface wiring 020331Y Digital...

Page 163: ...e between pins 20 and 29 is around 2 8 V With the interface wiring disconnected from the control unit check continuity between pin 29 and the red cable of the engine speed sensor connector and between pin 20 and the brown cable of the engine speed sensor connector With the interface wiring disconnected from the control unit and engine speed sensor connector check that the Red and Brown cables pin ...

Page 164: ...HT coil 1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts Injection Vespa GTS Super 125 i e INJEC 164 ...

Page 165: ...btain the stabilisation of the speed at 1450 50 R 1 Magnetisation time The coil magnetisation time is controlled by the control unit The ignition power is increased during the engine start up phase The injection system recognises the 4 stroke cycle so ignition is only commanded in the compression phase Specific tooling 020331Y Digital multimeter Check that the injection load 15A fuse No 3 works pr...

Page 166: ...re that there is continuity between pins 30 and 87 of the relay Check the power supply line of the injection load solenoid energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and Black Purple cable of the solenoid base If there is not check the continuity of the Red White cable between the fuse box and the solenoid base and of the Blac...

Page 167: ...Vespa GTS Super 125 i e Injection INJEC 167 ...

Page 168: ...heck the continuity of the grey black cable between the fuse box No 3 15 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Injection Vespa GTS Super 125 i e INJEC 168 ...

Page 169: ...1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts 5 7 5A fuse No 2 Vespa GTS Super 125 i e Injection INJEC 169 ...

Page 170: ...l unit The ignition power is increased during the engine start up phase The injection system recognises the 4 stroke cycle so ignition is only commanded in the compression phase Specific tooling 020331Y Digital multimeter Check that the injection load 15A fuse No 3 works properly Check that the 7 5A fuse No 2 for live control unit power works properly Check there is voltage between pins 1 and 7 of...

Page 171: ...ay energising coil after switching to ON make sure there is battery voltage for 2 seconds be tween the Red White cable and Black Purple ca ble of the relay base If there is not check the continuity of the Red White cable between the fuse box and the relay base and of the Black Pur ple cable between the pin 22 of the control unit and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE ...

Page 172: ...y base and ground If there is none check the continuity of the grey black cable between the fuse box No 3 15 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection Vespa GTS Super 125 i e INJEC 172 ...

Page 173: ...the coolant temperature sensor connector connected check the resistance between pins 9 and 26 in relation to the engine temperature 20 2500 100 Ω 80 308 6 Ω With the control unit side connector disconnected and the coolant temperature connector discon nected check the insulation between the two light blue green and pink yellow cables Vespa GTS Super 125 i e Injection INJEC 173 ...

Page 174: ...THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU TEMPERATURE SENSOR Specification Desc Quantity 1 Water temperature sensor Injection Vespa GTS Super 125 i e INJEC 174 ...

Page 175: ...flow to control idling This regulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance The throttle body after the pre calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve p...

Page 176: ...tic tester on TPS RESET Specific tooling 020922Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the stop screw Guaranteeing that this position will be kept send a confirmation for the TPS reset procedure Injection Vespa GTS Super 125 i e INJEC 176 ...

Page 177: ...ECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE CALIBRATION Given that the TPS resetting is also done when the control unit is replaced place the control unit filter box bellows at 45 during the refitting operation as shown in the picture Lambda probe SIGNAL CONTROL 1 Lambda probe Vespa GTS Super 125 i e Injection INJEC 177 ...

Page 178: ...e is approx 1V During the closing phase the voltage is approx 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits inside it SIGNAL CONTROL THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU 1 Lambda probe Install the electronic control unit interface wiring Start the engine and warm up until the elec...

Page 179: ...th the throttle valve completely open the volt age is approx 1V During the closing phase the voltage is approx 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits inside it Vespa GTS Super 125 i e Injection INJEC 179 ...

Page 180: ...Impianto elettroventilatore 1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 Injection Vespa GTS Super 125 i e INJEC 180 ...

Page 181: ...ith the ignition switch set to ON check if there is 12 V battery voltage between the RED WHITE cable of the electric fan relay and the ground con nection Check if the RED WHITE cable between the fuse box and the electric fan relay base is not interrup ted Using a diagnosis Palmtop carry out an active di agnosis for the ELECTRIC FAN Check if there is battery voltage at pins 85 86 of the electric fa...

Page 182: ...ay base and the ground connection Check if the GREY cable between the fuse box in the glove box compartment and the electric fan relay base is not interrupted Check if the RED cable between the electric fan relay base and the electric fan motor is not inter rupted Check that the electric fan motor is earthed THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU Injection Vespa GT...

Page 183: ...1 Battery 12V 2 15A fuse No 3 3 30A fuse No 1 4 Ignition switch contacts Vespa GTS Super 125 i e Injection INJEC 183 ...

Page 184: ...tween the RED WHITE cable of the electric fan relay and the ground con nection Check if the RED WHITE cable between the fuse box and the electric fan relay base is not interrup ted Using a diagnosis Palmtop carry out an active di agnosis for the ELECTRIC FAN Check if there is battery voltage at pins 85 86 of the electric fan relay Check if the blue yellow cable between the control unit pin 24 and ...

Page 185: ...nnection Check if the GREY cable between the fuse box in the glove box compartment and the electric fan relay base is not interrupted Check if the RED cable between the electric fan relay base and the electric fan motor is not inter rupted Check that the electric fan motor is earthed Vespa GTS Super 125 i e Injection INJEC 185 ...

Page 186: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 187: ... fixing screws indicated in the pic ture Locking torques N m Wheel fixing screw 20 to 25 Front wheel hub overhaul Support the vehicle adequately Remove the front wheel Remove the front brake calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub Vespa GTS Super 125 i e Suspensions SUSP 187 ...

Page 188: ...n the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract ø 15 mm bear ings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Suspensions Vespa GTS Super 125 i e SUSP 188 ...

Page 189: ... 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch Recommended products AGIP GREASE MU3 Yellow brown lithium base medium fibre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 Refitting the front wheel To refit...

Page 190: ...wheel Remove the brake calliper Loosen the screw fixing the odometer cable plate and take out the cable Remove the suspension arm housing by un screwing the three screws indicated in the photo graph Suspensions Vespa GTS Super 125 i e SUSP 190 ...

Page 191: ... 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 Pre loosen the 3 nuts fixing the mudguard to the suspension Vespa GTS Super 125 i e Suspensions SUSP 191 ...

Page 192: ...pecific tool to remove the counter ring nut the spacer washer and the ring nut of the upper disk of the fifth wheel fitting Slide off the steering tube and remove perma nently the mudguard from the suspension Specific tooling 020055Y Wrench for steering tube ring nut Overhaul Carry out this operation only if strictly necessary and in any case remove and replace the old part with a new one Suspensi...

Page 193: ...e lower disk of the fifth wheel operating from the up per part Specific tooling 020004Y Punch for removing steering bearings from headstock Remove the fifth wheel fitting and the dust gaiter on the steering bearing as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing steering bearings from headstock Vespa GTS Super 125 i e...

Page 194: ...rily the pin and the Nadella opposite the tool thrusting direction To extract the second Nadella use the tool with the part 2 instead of part 1 on opposite side to the one indicated in the figure Specific tooling 020021Y Front suspension service tool Fit both dust guard rings C on the swinging hub as shown in the detail drawing A Connect the swinging hub to the steering tube with the guiding pin p...

Page 195: ...ll the roller casings with recommended grease Insert the sealing ring on the pin and the roller bushing with wedging washers at the same time Remove the specific tool and then the part 5 guide partially ejected in the previous assembly stage part 4 must be always fitted Replace part 3 with part 16 on the stem Push from the handgrip the wedging washer roller casing sealing ring unit placing part 16...

Page 196: ...the swing ing hub Remove the spacers part 17 fill with recommen ded grease the area between the steering tube and the swinging hub and place the dust guard rings in that place Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 NATO G 460 symbol Refitting To refit carry out the removal operations but in reverse order grease the fift...

Page 197: ...er clamps and re move the brake calliper shock absorber mounting Loosen the screws fixing the front brake pipe re tainer clamp and the odometer cable in order to reach the upper clamps Unscrew the upper fixing nuts Remove the front shock absorber Vespa GTS Super 125 i e Suspensions SUSP 197 ...

Page 198: ...ve the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Before refitting the bracket in the wheel axle place the O ring as shown in the photograph so that it is correctly placed after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Locking torque...

Page 199: ...t side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph Suitably hold the brake calliper shock absorber attachment bracket Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y 52 ...

Page 200: ...ps using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base ...

Page 201: ... the removal operations but in reverse order observing the prescribed torques Locking torques N m Wheel fixing screws 20 25 Swing arm Removal Place the vehicle on its centre stand Remove the engine housing Remove the swinging arm engine fitting shown in the picture Move the engine back Remove the spring anchoring the swinging arm to the chassis as shown in the picture Vespa GTS Super 125 i e Suspe...

Page 202: ...uffer support bracket to the chassis Remove the left and right caps located under the footrest to reach the pin fixing the swinging arm to the body Remove the pin Then remove the swinging arm Suspensions Vespa GTS Super 125 i e SUSP 202 ...

Page 203: ...e Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm In order to check the clearance of the swinging arm on the frame side prepare a retainer using the fixing pin of the swinging arm on the frame and two rings from the special tool 020229Y Alternatively use two washers with 12 mm inside diameter for pins minimum 30 mm outside diameter and 4 mm thick at least Check ther...

Page 204: ...e bearings with the seal rings facing outwards Specific tooling 020244Y 15 mm diameter punch 020115Y Ø 18 punch Characteristic Length of the swinging arm tube on the engine side L 175 3 0 3 0 Length of the internal swinging arm spacer on the engine side L 183 0 3 0 Engine side swinging arm plastic bushing shim 3 5 0 05 mm Chassis side swinging arm plastic bushing shim 3 5 0 05 mm Length of the int...

Page 205: ... side swinging arm with the most protruding part pointing towards the silent block side as shown in the picture Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 NATO G 460 symbol Make sure the silent bloc is not broken If it is replace the coupling Remove the Seeger ring shown in the picture Remove the full silent bloc bracket Un...

Page 206: ...nstall a new silent bloc making sure it aligns properly with the reference tooth Fit the silent blocs making sure the chamfered part of the silent bloc matches the chamfered part of the bracket Using the appropriate tool fit the silent bloc as shown in the picture Refitting To refit perform the removal operations in reverse Grease the bearings and the rolling parts with the recommended grease Susp...

Page 207: ...emove the luggage rack lift the engine a little with a jack so as to free the two shock absorbers remove the muffler assembly undo the shock absorber spring assembly clamp ing screw from the support fixed to the engine on the one side and from that fixed to the muffler on the other unscrew the two upper nuts one on each side fixing the shock absorber spring assembly to the frame and remove the sho...

Page 208: ...eration being careful to respect the torques indicated and the spacer assembly layout as shown in the photo Locking torques N m Bracket fixing screws to the engine crankcase 20 25 Shock absorber lower fitting 40 45 Wheel axle clamping 104 126 Centre stand REMOVAL Use a jack to support the vehicle properly Remove the two return springs from the centre stand Undo the nut shown in the figure Remove t...

Page 209: ...n spring Remove the screw shown in the photograph FITTING To refit carry out the removal operations in re verse order and comply with the specified torque Locking torques N m Side stand fixing bolt 35 to 40 Vespa GTS Super 125 i e Suspensions SUSP 209 ...

Page 210: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 211: ...PER BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM INED Overhaul Remove the rear brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupling screws as shown in the photo Remove the two pistons from the calliper body with the aid of short blasts of com...

Page 212: ...ews at the specified torque Locking torques N m Calliper coupling screw 30 33 Nm Refitting Follow the removal steps but in reverse order and tighten to the prescribed torque Locking torques N m Calliper fixing screw 24 27 If the calliper is replaced CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM CAUTION ALWAYS USE NEW COPPER WASHERS Locking torques N m Screw fixing the oil connection to the c...

Page 213: ... THE BRAKE CALLIPER Overhaul Proceed as follows 1 remove the two male hexagonal screws 1 and take out the two pads 10 2 remove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expul...

Page 214: ...ed plate 5 floating body 6 piston 7 piston sealing rings 8 guide protection rubbers 9 brake pad check spring 10 pads Refitting Insert the following on the front brake body The sealing rings and the pistons 1 Refit the plate 2 Arrange the pad holding clamp 3 Refit the pads and bleed air Place the calliper on the disk and lock it to the support by tightening the bolts at the prescribed torque Lock t...

Page 215: ...nit disc in the wheel axle Locking torques N m Disk to the hub 11 13 Disc Inspection Remove the rear brake calliper Check the disc thickness with a micrometer Characteristic Standard thickness 3 5 mm Repeat the measurement at no fewer than six points on the disc Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed onto the brake calliper as shown in ...

Page 216: ...wed 0 1 mm If you detect incorrect values replace the disc If the anomaly persists replace the hub Front brake disc Removal Remove the front wheel Remove the front brake calliper Remove the hub and the disc operating on the wheel axle nut Hold the hub and the disc firmly and remove the brake disc undoing the six screws indicated in the photograph Braking system Vespa GTS Super 125 i e BRAK SYS 216...

Page 217: ... photograph Repeat the measurement in at least 6 points on the disk Remove the front brake calliper In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it to one of the two front brake calliper attachment points Place the dial gauge on the disk outer edge Make the wheel hub turn and check the disk de viation Specific tooling 020335Y Magnetic mounting ...

Page 218: ...re is replace it Check the thickness of the friction material is more than 1 5 mm If it is not replace it The replacement must be made with greater re sidual thickness if the pad has not worn evenly A 0 5 mm thickness difference in the residual friction material is permitted Refitting To fit proceed as follows Insert the two pads in the callipers Braking system Vespa GTS Super 125 i e BRAK SYS 218...

Page 219: ...crew tightening calliper to support 24 to 27 Pad fastening pin 19 6 to 24 5 Rear brake pads Removal Remove the rear brake calliper Remove the snap ring slide off the pad retention pin and the clip Remove the brake pads and check there are no faults or warping Otherwise replace them Check the thickness of the friction material is more than 1 5 mm If it is not replace it The replacement must be made...

Page 220: ...nsert a rubber pipe in the bleed screw to permit the brake fluid to be recovered With the left had brake lever load the system and bring it up to the required pressure Keeping the left hand brake lever pulled loosen the bleed screw to permit the air in the system to escape Then tighten the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recover...

Page 221: ...ecific tooling 020329Y Mity Vac vacuum operated pump Locking torques N m System bleed calliper fitting 12 to 16 Nm Brake fluid level check Position the vehicle on a flat surface and on the centre stand Remove the brake pump cover as indicated in the photo Use the appropriate spyglass on the pump to check the level of the brake fluid as shown in the photograph If the level is below the minimum fill...

Page 222: ...NDING AIR IF THE LEVEL OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN VALUE BRAKING EFFICIENCY WILL BE REDUCED Never use brake liquid in open or partially used containers Under standard climatic conditions replace coolant as indicated in the scheduled maintenance table For refitting purposes carry out the removal operations but in reverse order and respect the tightening torques of the tank cover ...

Page 223: ...t The pump body shows no signs of internal damage or corrosion The plunger shows no sign of damage or abnormal wear The piston return spring is in good condition CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED 1 Reservoir cap screw 2 Reservoir cap 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8 Spring 9 Tank Vespa GTS Super 125 i e Braking system BRAK SY...

Page 224: ...he removal operations but in reverse order observing the specified torques Locking torques N m Oil pipe joint to the pump 20 25 Brake pump fixing screws to the handlebar 7 to 10 Nm Braking system Vespa GTS Super 125 i e BRAK SYS 224 ...

Page 225: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 226: ...Circuit diagram 1 Coolant electric pump 2 Three way thermostat 3 Electric fan Cooling system Vespa GTS Super 125 i e COOL SYS 226 ...

Page 227: ...4 Expansion tank 5 Radiator 6 coolant temperature sensor Vespa GTS Super 125 i e Cooling system COOL SYS 227 ...

Page 228: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 229: ...wo screws shown in the photograph Remove the saddle Remove the helmet compartment Remove the 2 nuts indicated in the photograph Free the electric cables form the retaining clamps indicated in the photograph Remove the saddle opening transmission cable Remove the saddle manual opening transmis sion cable Vespa GTS Super 125 i e Chassis CHAS 229 ...

Page 230: ...otograph Remove the clip from the transmission Remove the actuator from the supporting bracket Rear rack Remove the helmet compartment Remove the 4 screws indicated in the figure Remove the two screws indicated in the figure that fix the luggage rack to the body Chassis Vespa GTS Super 125 i e CHAS 230 ...

Page 231: ...connecting the wiring remove the rear handlebar Instrument panel Remove the rear handlebar cover Remove the four screws indicated in the figure Remove the instrument panel Front handlebar cover Remove the rear view mirrors Remove the front central cover Remove the front screw indicated in the figure Vespa GTS Super 125 i e Chassis CHAS 231 ...

Page 232: ...ont handlebar cover Disconnect the front headlamp connectors Headlight assy Remove the front handlebar cover Undo the four screws indicated Operate the screw indicated in the figure to re move the front turn indicator Chassis Vespa GTS Super 125 i e CHAS 232 ...

Page 233: ...en its cap Remove the central screw inside the glove box indicated in the photograph Remove the two screws indicated in the photo graph and located below the expansion tank cover and the left cover respectively Remove the shield back plate lower screws to the right and left side of the shield back plate as indicated in the photograph Vespa GTS Super 125 i e Chassis CHAS 233 ...

Page 234: ... stop light bulb and license plate bulb To reassemble repeat the operation but in reverse order N B IF MISTING IS NOTICED ON THE INSIDE OF THE HEAD LAMP GLASS THIS DOES NOT INDICATE A FAULT AND IS ATTRIBUTABLE TO HUMIDITY AND OR TO LOW TEM PERATURES THE PHENOMENON SHOULD QUICKLY DISAPPEAR WHEN THE LIGHT IS SWITCHED ON THE PRESENCE OF DROPS OF WATER ON THE OTHER HAND COULD INDICATE THAT WATER IS IN...

Page 235: ...cated under the bat tery compartment cover as indicated in the figure Remove the passenger footrests undoing the two screws indicated in the figure Remove the right and left screws fixing the foot rest indicated in the figure Remove the right and left lower covers as shown in the figure Vespa GTS Super 125 i e Chassis CHAS 235 ...

Page 236: ...Unscrew the nut B under the body Helmet bay Lift the saddle and remove the helmet compart ment Fuel tank Remove the helmet compartment Remove the side fairings Remove the luggage rack Remove the shock absorber upper clamps Remove the two screws indicated in the figure that fix the tank to the body Chassis Vespa GTS Super 125 i e CHAS 236 ...

Page 237: ...e the two turn indicators Use a jack to lift the body so that there is enough space between the vehicle rear side and the en gine to slide off the tank To refit perform the steps in the reverse direction to disassembly Rear central cover Remove the four screws indicated in the figure Vespa GTS Super 125 i e Chassis CHAS 237 ...

Page 238: ...any operation on the radiator unit flow out the coolant in the coolant delivery pipe in the pump indicated in the photograph Remove the shield back plate Remove the coolant feed and return hoses from the right radiator Unscrew the 4 screws fixing the radiator to the body Detach the radiator Detach the pipe from the plastic duct by removing the plastic clip shown in the photograph Then re move the ...

Page 239: ...tograph and afterwards disconnect the connector To refit perform the removal operations but in reverse order being careful when positioning the news clips for the fluid hoses and when filling the cooling system Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Vespa GTS Super 125 i e Chassis CHAS 239 ...

Page 240: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 241: ...Front and rear wheel hub nut Front and rear brake calliper clamping screws Frame swinging arm bolt Swinging arm bolt Engine Engine arm pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Main switch Lights high beam lights low beam lights taillights front and rear and relevant warning lights Headlight adjustment according to the regulations currently ...

Page 242: ...ENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES...

Page 243: ...E CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check chassis and engine number check tools and equipment licence plate fitting lock check tyre pressure check rear view mirror and any a...

Page 244: ...INDEX OF TOPICS TIME TIME ...

Page 245: ...de and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine from chassis Removal and refit 2 003064 Engine oil change Crankcase CRANKCASE Code Action Duration 1 001153 Crankcase halves gasket Replace ment 2 001133 Engine crankcase Replacement Vespa GTS Super 125 i e Time TIME 245 ...

Page 246: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Time Vespa GTS Super 125 i e TIME 246 ...

Page 247: ... assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 3 001129 Chain tensioner Service and Re placement Vespa GTS Super 125 i e Time TIME 247 ...

Page 248: ...D Code Action Duration 1 001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves adjust 4 001056 Head gasket change 5 001083 Thermistor Replacement 6 001057 Thermostat Replacement Time Vespa GTS Super 125 i e TIME 248 ...

Page 249: ...Rocker arms support assy CAMSHAFT Code Action Duration 1 001148 Rockers valves Replacement 2 001044 Camshaft Replacement Cylinder head cover Vespa GTS Super 125 i e Time TIME 249 ...

Page 250: ...Replacement 3 001088 Head cover gasket Replacement 4 001074 Oil vapour recovery pipe Replace ment Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor change 3 001102 Net oil filter change Cleaning Time Vespa GTS Super 125 i e TIME 250 ...

Page 251: ... 1 001087 Flywheel cover Replacement 2 001150 Flywheel cover gasket change 3 007007 Water pump rotor Replacement 4 007017 Water pump cover Replacement 5 007003 Coolant delivery and return pipe change Driven pulley Vespa GTS Super 125 i e Time TIME 251 ...

Page 252: ...ing Replacement Oil pump OIL PUMP Code Action Duration 1 001125 Chain guide pads Replacement 2 001051 Belt Timing chain Change 3 001042 Oil pump overhaul 4 001112 Oil pump change 5 001122 Oil pump chain Replacement 6 001130 Oil sump change 7 001172 Chain cover flap change 8 001124 Lubrication by pass Replacement Time Vespa GTS Super 125 i e TIME 252 ...

Page 253: ... REDUCTION GEAR Code Action Duration 1 001010 Reduction gear Replacement 2 003065 Gear box oil Replacement 3 001156 Reduction gear cover Replacement 4 004125 Rear wheel axle Replacement Vespa GTS Super 125 i e Time TIME 253 ...

Page 254: ...ion 1 001086 Driving half pulley Replacement 2 001011 Drive belt Replacement 3 001066 Driving pulley Removal and refitting 4 001177 CVT rollers sliders Replacement 5 001141 Belt anti flapping roller Replace ment Time Vespa GTS Super 125 i e TIME 254 ...

Page 255: ...de Action Duration 1 001135 Transmission cover bearing Re placement 2 001096 Transmission crankcase cover Re placement 3 001131 Transmission air intake Replace ment 4 001065 Transmission cover Replacement Vespa GTS Super 125 i e Time TIME 255 ...

Page 256: ...L START UP Code Action Duration 1 001020 Starter motor Replacement 2 001104 Start up freewheel Replacement 3 001151 Starter driven gearing Replacement 4 001017 Start up pinion Replacement Time Vespa GTS Super 125 i e TIME 256 ...

Page 257: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001067 Stator Removal and Refitting 2 001173 Rotor Replacement 3 001058 Complete flywheel change Vespa GTS Super 125 i e Time TIME 257 ...

Page 258: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Replacement 2 001047 Injector Replacement 3 001013 Intake manifold change Time Vespa GTS Super 125 i e TIME 258 ...

Page 259: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Silencer Replacement 2 001095 Silencer heatshield Replacement 3 005138 Lambda probe Replacement Vespa GTS Super 125 i e Time TIME 259 ...

Page 260: ...e Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Air cleaner carburettor union Re placement 4 001027 Body air cleaner union Replace ment Time Vespa GTS Super 125 i e TIME 260 ...

Page 261: ...lacement 2 004085 Fairing 1 Replacement 3 004149 Shield central cover Replacement 4 004053 Spoiler Replacement 5 004015 Footrest Removal and Refitting 6 004023 Shield rim Replacement 7 004159 Plates Stickers Replacement Vespa GTS Super 125 i e Time TIME 261 ...

Page 262: ...Centre stand STAND Code Action Duration 1 004102 Side stand Replacement 2 004004 Stand Replacement Footrests Time Vespa GTS Super 125 i e TIME 262 ...

Page 263: ...t 2 004071 Battery compartment replacement 3 004078 Front rear footrest rubber Replace ment 4 005046 Battery cover change Rear cover REAR SHIELD Code Action Duration 1 004083 Glove box Replacement 2 004081 Top box lid Replacement Vespa GTS Super 125 i e Time TIME 263 ...

Page 264: ...Underseat compartment HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Removal and Refitting 2 004011 Central chassis cover Replacement Time Vespa GTS Super 125 i e TIME 264 ...

Page 265: ...Plate holder LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate holder mounting Re placement 2 005048 number plate holder Replacement Mudguard Vespa GTS Super 125 i e Time TIME 265 ...

Page 266: ...ent 3 003044 Shock absorber cover Replace ment Fuel tank FUEL TANK Code Action Duration 1 004005 Fuel tank Replacement 2 005010 Tank float Replacement 3 004109 Fuel tank breather change 4 004073 Fuel pump Replacement 5 004137 Injector pump pipe Replacement Time Vespa GTS Super 125 i e TIME 266 ...

Page 267: ...mplete with support Re placement 3 007001 Expansion tank Replacement 4 001052 Coolant and air bleed Replacement 5 007013 Expansion tank radiator connecting hose Replacement 6 007003 Delivery line and coolant return Re placement 7 001170 Air deflector Replacement Vespa GTS Super 125 i e Time TIME 267 ...

Page 268: ...r shock absorber REAR SHOCK ABSORBERS Code Action Duration 1 003007 Rear shock absorber Removal and Refitting 2 003077 silencer rear shock absorber support arm Service Time Vespa GTS Super 125 i e TIME 268 ...

Page 269: ...Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering bearing Replacement 2 003073 Steering clearance Adjustment Vespa GTS Super 125 i e Time TIME 269 ...

Page 270: ...Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004018 Front handlebar covers Replace ment 2 004019 Rear handlebar covers Replace ment Time Vespa GTS Super 125 i e TIME 270 ...

Page 271: ...oval and re fitting 4 005017 Stop switch Replacement 5 002059 Right hand knob Replacement 6 002071 Left hand grip Replacement 7 003059 Counterweight Replacement 8 002060 Throttle grip Replacement 9 002063 Throttle control transmission Re placement 10 003061 Accelerator transmission adjust 11 002037 Brake or clutch lever Replacement Vespa GTS Super 125 i e Time TIME 271 ...

Page 272: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine chassis connection swinging arm Replacement 2 004058 Silent block Replacement Time Vespa GTS Super 125 i e TIME 272 ...

Page 273: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Instrument panel Vespa GTS Super 125 i e Time TIME 273 ...

Page 274: ...t or turning indicator switch Re placement 6 005040 Horn button Replacement 7 005121 Saddle opening button Replace ment 8 005039 Lights switch Replacement 9 005078 Odometer glass Replacement 10 005038 Instrument panel warning light bulbs Replacement 11 005076 Clock Cell Replacement Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement Time Vespa GTS Super 125 i e TIME 274 ...

Page 275: ...hook transmis sion Replacement 3 004158 Saddle opening splitter Replace ment 4 005072 Immobilizer aerial Replacement 5 005099 Electric saddle opening device Re placement 6 004054 Saddle lock catch Replacement 7 004010 Anti theft lock Replacement 8 005016 Key switch Replacement Vespa GTS Super 125 i e Time TIME 275 ...

Page 276: ...9 Tail light bulb Replacement 5 005008 Headlight bulbs Replacement 6 005012 Front turn indicator Replacement 7 005090 Stop light bulb Replacement 8 005140 Front light Replacement 9 005022 Rear turning indicators Replace ment 10 005068 Rear turning indicator bulb Re placement 11 005066 Rear light bulbs Replacement 12 005028 Rear light assembly glass Replace ment Time Vespa GTS Super 125 i e TIME 27...

Page 277: ...de Action Duration 1 003047 Front tyre Replacement 2 003037 Front wheel rim Replacement 3 004123 Front wheel Replacement 4 003033 Front wheel hub Replacement 5 002041 Brake disc Replacement Vespa GTS Super 125 i e Time TIME 277 ...

Page 278: ...Duration 1 004126 Rear wheel tyre Replacement 2 001071 Front wheel rim Removal and Re fitting 3 001016 Rear wheel Replacement 4 002028 Rear wheel hub Replacement 5 002070 Rear brake disc Replacement Time Vespa GTS Super 125 i e TIME 278 ...

Page 279: ...Replacement 5 005052 Fuse 1 Replacement 6 005007 Battery change 7 005120 Control unit power supply remote control Replacement 8 005035 Headlight solenoid Replacement 9 005117 Electric fan remote control Replace ment 10 005011 Starter relay Replacement 11 005054 Fuse block 1 Replacement 12 005001 Electrical system Removal and re fitting Vespa GTS Super 125 i e Time TIME 279 ...

Page 280: ...Transmissions TRANSMISSIONS Code Action Duration 1 002051 Odometer transmission assembly Replacement Time Vespa GTS Super 125 i e TIME 280 ...

Page 281: ...emoval and Refitting 2 003045 Steering tube Fork tube Replace ment 3 003010 Front suspension Service 4 003035 Shock absorber mounting and brake calliper Replacement 5 003034 Front wheel hub bearing Replace ment 6 001064 Odometer sprocket Replacement Vespa GTS Super 125 i e Time TIME 281 ...

Page 282: ...s Replacement 3 002021 Front brake piping Replacement 4 002047 Front brake fluid and air bleed sys tem Replacement 5 002020 Rear brake disc piping Replace ment 6 002080 Rear brake oil bleed system Change 7 002002 Rear brake pads Replacement 8 002048 Rear brake calliper Replacement Time Vespa GTS Super 125 i e TIME 282 ...

Page 283: ...Stickers TRANSFERS Code Action Duration 1 004159 Plates Stickers Replacement Vespa GTS Super 125 i e Time TIME 283 ...

Page 284: ...1 C Checks 73 Coolant 173 E Electric 279 Engine oil 47 F Fuel 136 149 236 266 Fuses 92 H Headlight 52 232 Horn 87 Hub oil 45 I Identification 8 Instrument panel 231 273 L Luggage rack M Maintenance 7 44 O Oil filter 49 250 R Recommended products S Saddle Shock absorbers 207 Spark plug 44 ...

Page 285: ...Stand 209 Start up Suspension 55 56 281 Switch T Tank 236 266 Transmission 10 54 255 Turn indicators 72 Tyre pressure Tyres 15 V Vehicle 8 115 116 ...

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VESPA GTS Super 125 i.e., Service Station Manual

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