VESPA GTS Super 125 i.e. (2009) Service Manual
  1. Manuals
  2. Brands
  3. VESPA Manuals
  4. Scooter
  5. GTS Super 125 i.e. (2009)
  6. Service manual

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

Hide thumbs
Table of Contents

Advertisement

Quick Links

MANUALE STAZIONE DI SERVIZIO
*******
Vespa GTS Super 125 i.e. (2009)

Advertisement

Table of Contents
loading

Related Manuals for VESPA GTS Super 125 i.e. (2009)

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

  • Page 1 MANUALE STAZIONE DI SERVIZIO ******* Vespa GTS Super 125 i.e. (2009)
  • Page 2 MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 125 i.e. (2009) The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication 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.
  • Page 3 MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 125 i.e. (2009) Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Vespa GTS Super 125 i.e. (2009) Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...

  • Page 8: Vehicle Identification

    Vespa GTS Super 125 i.e. (2009) Characteristics Vehicle identification Chassis prefix: ZAPM45100000 ÷ 1001 Engine prefix: M451M ÷ 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 158 ± 5 kg Maximum weight allowed 340 kg Maximum height...
  • Page 9 Vespa GTS Super 125 i.e. (2009) Characteristics Engine DATA Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Engine capacity 124 cm³ Bore x stroke 57 x 48.6 mm Max. power 11 kW at 9750 rpm MAX. torque 12 Nm at 7500 rpm...

  • Page 10: Water Pump

    Vespa GTS Super 125 i.e. (2009) Characteristics Specification Desc./Quantity Starts opening at 85±2°C ELECTRIC VENTILATION Specification Desc./Quantity Electric ventilation starts at 102°C Electric ventilation stops at 96°C RADIATOR Specification Desc./Quantity Type Made of aluminium in two sections WATER PUMP Specification Desc./Quantity...

  • Page 11: Turn Indicator Switch

    Vespa GTS Super 125 i.e. (2009) Characteristics CHECKING REMOTE CONTROLS «A» OPER- ATING AS CIRCUIT BREAKERS 1) Check that, given regular conditions, there is no continuity between terminals 30 and 87. 2) Apply 12V voltage to power terminals 85 and 86 of the remote control.
  • Page 12 Vespa GTS Super 125 i.e. (2009) Characteristics LIGHT SWITCH STARTER BUTTON KEY SWITCH FUEL INJECTOR Type: 3 holes Conicity of the nozzle: 20° Resistance at terminals: 13.7 to 15.2 Ohm CHAR - 12...
  • Page 13 Vespa GTS Super 125 i.e. (2009) Characteristics FUEL PUMP UNIT Mechanical type pressure regulator operating at a pressure of 2.5 BAR Pump winding resistance: ~ 1.5 Ohm Input current during regular functioning: 1.4 - 1.8 ENGINE SPEED SENSOR Resistance between pins 13 and 15: 100 to 150 Ohm at approx.
  • Page 14 Vespa GTS Super 125 i.e. (2009) Characteristics - Presence of battery voltage between pins 22 and 26 of the interface cable harness upon shifting to ON and for 2 sec. STATOR Power: 450 W Resistance between terminals: 0.2 to 1 Ohm...
  • Page 15 Vespa GTS Super 125 i.e. (2009) Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front wheels - light alloy rims 3.00x12 Rear wheels - light alloy rims 3.00x12 Front tyres 120/70-12" Tubeless Rear tyres 130/70-12" Tubeless TYRE PRESSURE Specification Desc./Quantity...

  • Page 16: Rear Suspension

    Vespa GTS Super 125 i.e. (2009) Characteristics REAR SUSPENSION Name Torque in Nm Retainer for left shock absorber to crankcase support plate 20 ÷ 25 Shock absorber lower fitting 40 ÷ 45 Shock absorber upper fitting 20 ÷ 25 Rear wheel axle 104 ÷...

  • Page 17: Crankcase And Crankshaft

    Vespa GTS Super 125 i.e. (2009) Characteristics Name Torque in Nm Drive pulley nut 75 ÷ 83 Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60 Rear hub cap screws 24 ÷ 27 FLYWHEEL Name Torque in Nm Flywheel cover screw 11 ÷...
  • Page 18 Vespa GTS Super 125 i.e. (2009) Characteristics - Measure the diameter of the bearings on the pis- ton. Characteristic Standard diameter: 15 +0.006 + 0.001mm - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.
  • Page 19 Vespa GTS Super 125 i.e. (2009) Characteristics *Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the port of the rings as shown here. *** Value «A» of the sealing ring inside the cylinder (fitting clearance).
  • Page 20 Vespa GTS Super 125 i.e. (2009) Characteristics ENGINE COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 to 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 to 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 to 57.018 56.959 ÷...
  • Page 21 Vespa GTS Super 125 i.e. (2009) Characteristics Crankcase - crankshaft - connecting rod - Measure the diameter of bushings «A» in the three directions shown in the figure. - Measure the diameter of the crankshaft bearings «B». - Check that the diametral clearance «A-B» is be- tween the pre-set interval.
  • Page 22 Vespa GTS Super 125 i.e. (2009) Characteristics Characteristic Axial crankshaft/crankcase clearance: 0.5 ÷ 0.40 mm CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Transmissionside half- 16.6 +0-0.05 D = 0.20 to 0.50 shaft Flywheel-side halfshaft 16.6 +0-0.05 D = 0.20 to 0.50 Connecting rod 18 -0.10 -0.15...

  • Page 23: Cylinder Head

    Vespa GTS Super 125 i.e. (2009) Characteristics THE CRANKSHAFT is available in two CATEGO- RIES: Characteristic Crankshaft category: CAT. 1 - CAT. 2 CRANKSHAFT CATEGORY IDENTIFICATION: The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
  • Page 24 Vespa GTS Super 125 i.e. (2009) Characteristics - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
  • Page 25 Vespa GTS Super 125 i.e. (2009) Characteristics - In case of excessive wear or damage, replace the head. STANDARD VALVE LENGTH Specification Desc./Quantity Intake 84.5 mm Exhaust 94.5 mm - Measure the diameter of the valve stems in the three positions indicated in the diagram.
  • Page 26 Vespa GTS Super 125 i.e. (2009) Characteristics - Check the concentricity of the valve head by ar- ranging a dial gauge at right angle relative to the valve head and rotate it on a "V" shaped abutment. Characteristic Admissible limit: 0.03 mm...
  • Page 27 Vespa GTS Super 125 i.e. (2009) Characteristics - If no anomalies are found during the above checks, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound.
  • Page 28 Vespa GTS Super 125 i.e. (2009) Characteristics -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity intake 17.382 mm Exhaust 16.563 mm ADMISSIBLE LIMITS Specification Desc./Quantity intake 17.130 mm Exhaust 16.310 mm standard axial clearance 0.11 - 0.41 mm maximum admissible axial clearance 0.42 mm...
  • Page 29 Vespa GTS Super 125 i.e. (2009) Characteristics - Check that the cam contact sliding block and the articulated register plate is free from wear. - In case of wear, replace the component. Slot packing system Characteristic Compression ratio Cr: 11.50 ÷ 13:1 Measurement «A»...
  • Page 30 Vespa GTS Super 125 i.e. (2009) Characteristics (0.3) ODELS WITH METAL HEAD GASKET Name Measure A Thickness Shimming 125 - Cylinder 67.8 - Head 1.40 ÷ 1.60 0.60 ± 0.05 gasket 0.3 - Base gasket 0.6 Shimming 125 - Cylinder 67.8 - Head 1.60 ÷...

  • Page 31: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...

  • Page 32: Specific Tools

    Vespa GTS Super 125 i.e. (2009) Tooling SPECIFIC TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y017 Bell for bearings, OD 39 mm 001467Y014 Pliers to extract ø 15-mm bearings 005095Y Engine support 002465Y Pliers for circlips 006029Y...
  • Page 33 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020021Y 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 TOOL - 33...
  • Page 34 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020151Y Air 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 TOOL - 34...
  • Page 35 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator 020648Y Single battery charger TOOL - 35...
  • Page 36 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020335Y Magnetic mounting for dial gauge 020357Y 32x35-mm Adaptor 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020363Y 20-mm guide 020364Y 25-mm guide TOOL - 36...
  • Page 37 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020365Y 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...
  • Page 38 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020412Y 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 TOOL - 38...
  • Page 39 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020441Y 26 x 28 mm adaptor 020444Y Tool for fitting/ removing the driven pulley clutch 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30-mm guide 020489Y Hub cover support stud bolt set...
  • Page 40 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020428Y Piston position check mounting 020680Y Diagnosis Tool 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Bearing housing, outside ø 47 mm 020626Y Driving pulley lock wrench...
  • Page 41 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bearings 020627Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y...
  • Page 42 Vespa GTS Super 125 i.e. (2009) Tooling Stores code Description 020244Y 15-mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc 020469Y Reprogramming kit for vehicle diagnostic tester TOOL - 42...

  • Page 43: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 44: Maintenance Chart

    Vespa GTS Super 125 i.e. (2009) Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 2 years Km x 1,000 Roller bearing - Driven pulley...
  • Page 45 Vespa GTS Super 125 i.e. (2009) Maintenance -Adjust the distance, if necessary, by bending the side electrode very carefully. In case of anomaly (as described before), replace the spark plug with another of the recommended type; - Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it.

  • Page 46: Air Filter

    Vespa GTS Super 125 i.e. (2009) Maintenance Replacement -Remove the oil filler cap «A». - Unscrew the oil drainage cap «B» and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil.

  • Page 47: Engine Oil

    Vespa GTS Super 125 i.e. (2009) Maintenance ing can be cleaned off by removing the two rubber caps «E». CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NEC- ESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
  • Page 48 Vespa GTS Super 125 i.e. (2009) Maintenance Refit the new cartridge filter being careful to lubri- cate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from cap "A". Then start...

  • Page 49: Engine Oil Filter

    Vespa GTS Super 125 i.e. (2009) Maintenance Engine oil filter The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque.

  • Page 50: Braking System

    Vespa GTS Super 125 i.e. (2009) Maintenance -The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised water- antifreeze solution mix. CAUTION DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO THAT COOLANT DOES NOT SPILL OVER THE EXPAN- SION TANK WHEN THE VEHICLE IS BEING USED.
  • Page 51 Vespa GTS Super 125 i.e. (2009) Maintenance Check the brake fluid level through the sight glass on the pump as shown in the photograph - If the level is below the minimum, fill using the two screws shown in the figure...

  • Page 52: Headlight Adjustment

    Vespa GTS Super 125 i.e. (2009) Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10-m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...

  • Page 53: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 54 Vespa GTS Super 125 i.e. (2009) Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION...

  • Page 55: Brakes Overheating

    Vespa GTS Super 125 i.e. (2009) Troubleshooting Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift of the disc with a dial gauge and with wheel mounted on the scooter.
  • Page 56 Vespa GTS Super 125 i.e. (2009) Troubleshooting Suspension oil leakage IL LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments. TROUBL - 56...

  • Page 57: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 58 Vespa GTS Super 125 i.e. (2009) Electrical system 1. Magneto flywheel 2. Voltage regulator 3. 12V-12Ah Battery 4. Start-up remote control switch 5. Starter motor 6. Starter button 7. 30A Fuse 8. 15A fuse 9. Stop light bulb 10. Key switch contacts 11.
  • Page 59 Vespa GTS Super 125 i.e. (2009) Electrical system 38. Water pump 39. Engine rpm sensor 40. HV coil 41. Fuel injector 42. Coolant temperature sensor: 43. Diagnostics socket 44. Fuel supply pump 45. Injector ECU 46. Immobilizer aerial Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi:...
  • Page 60 Vespa GTS Super 125 i.e. (2009) Electrical system 9. Immobilizer aerial- Remove the shield back plate to reach it. 10. Injection ECU - Remove the helmet compart- ment to reach it. 11. Diagnosis connector - Remove the helmet compartment to reach it.
  • Page 61 Vespa GTS Super 125 i.e. (2009) Electrical system 20-18-30-38 Horn - Solenoids Remove front cen- tral cover to reach them. 23. Remote control switches - Remove the front central cover and the helmet compartment to reach them. 22-26. Main fuses - Open the front top box and the battery cover to reach them.
  • Page 62 Vespa GTS Super 125 i.e. (2009) Electrical system 27. Voltage regulator - Remove the shield back plate to reach it. 28. Magneto flywheel - Remove the flywheel cov- er, as described in the «Engine» chapter, to reach it. To get access to the connectors, remove the helmet compartment.
  • Page 63 Vespa GTS Super 125 i.e. (2009) Electrical system 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.
  • Page 64 Vespa GTS Super 125 i.e. (2009) Electrical system Ignition 3. 12V-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.

  • Page 65: Devices And Accessories

    Vespa GTS Super 125 i.e. (2009) Electrical system 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.

  • Page 66: Checks And Inspections

    Vespa GTS Super 125 i.e. (2009) Electrical system 45. Injector ECU Lights and turn indicators 3. 12V-12Ah Battery 7. 30A Fuse 8. 15A Fuse 10. Key switch contacts 13. Light switch 17. Front and rear daylight bulbs and license plate light 18.
  • Page 67 Vespa GTS Super 125 i.e. (2009) Electrical system - Control unit - Immobilizer aerial - master and service keys with built-in transponder - HV coil - diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ignition switch is turned to the "OFF"...
  • Page 68 Vespa GTS Super 125 i.e. (2009) Electrical system With the key switch set to ON: • there is battery voltage between terminals 5-26 and terminal 5-chassis ground (fixed power sup- ply). If there is no voltage, check the key switch contacts, that fuse 2 and its cable are in working order.
  • Page 69 Vespa GTS Super 125 i.e. (2009) Electrical system With the ignition key switch at ON check there is battery voltage between the Red-White and Black cables With MIU connector disconnected, check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring.
  • Page 70 Vespa GTS Super 125 i.e. (2009) Electrical system The master and service keys must be used to code the system as follows: - Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3 seconds).

  • Page 71: Diagnostic Codes

    Vespa GTS Super 125 i.e. (2009) Electrical system Diagnostic codes The Immobilizer system is tested each time the key switch is turned from «OFF» to «ON». During this diagnosis phase a number of control unit sta- tuses can be identified and various light codes displayed.
  • Page 72 Vespa GTS Super 125 i.e. (2009) Electrical system • 3 flash code Diagnostic code - 1 flash A one-flash code indicates a system where the se- rial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessa-...

  • Page 73: Stator Check

    Vespa GTS Super 125 i.e. (2009) Electrical system This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. The three-phase generator provides good recharge power and at low revs, a good compromise is ach- ieved between generated power and idle stability.

  • Page 74: Voltage Regulator/Rectifier

    Vespa GTS Super 125 i.e. (2009) Electrical system 2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals.. 3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.
  • Page 75 Vespa GTS Super 125 i.e. (2009) Electrical system 5. Key switch contacts 6. Fuse No. 2 7. Electronic control unit 8. Engine stop switch 9. Stop buttons 10. Fuse No. 4 11. Starter button 12. Starter motor WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

  • Page 76: Horn Control

    Vespa GTS Super 125 i.e. (2009) Electrical system Horn control 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.
  • Page 77 Vespa GTS Super 125 i.e. (2009) Electrical system Turn signals system check 1. Battery 2. Fuse No. 1 3. Key switch contacts 4. Fuse No. 4 5. Turn indicator control device 6. Turn indicator switch 7. Turn indicator bulbs WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
  • Page 78 Vespa GTS Super 125 i.e. (2009) Electrical system 7) With the turn indicator switch pressed to the left, check if there is voltage between the Pink cable of the switch and the ground connection. If there is not, check the cable harnesses.
  • Page 79 Vespa GTS Super 125 i.e. (2009) Electrical system Lights list 1. Battery 2. Fuse No. 1 3. Fuse No. 5 4. Key switch contacts 5. Fuse No. 4 6. Fuse No. 7 7. Electronic control unit 8. Tail lights and license plate light bulbs 9.
  • Page 80 Vespa GTS Super 125 i.e. (2009) Electrical system 5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted. HIGH-BEAM /LOW-BEAM LIGHTS LINE 1) Check that bulbs operate properly. 2) Check fuses No. 1, 4 and 5.
  • Page 81 Vespa GTS Super 125 i.e. (2009) Electrical system FUSES Specification Desc./Quantity Fuse 1 Current rating: 30 A Protected circuits: Vehicle main fuse Fuse 2 Current rating: 7.5A Protected circuits: Running lights and instrument panel illumination power Fuse 3 Current rating: 7.5A...
  • Page 82 Vespa GTS Super 125 i.e. (2009) Electrical system - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode - Constant voltage charge equal to 14.40 to 14.70V - Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity...
  • Page 83 Vespa GTS Super 125 i.e. (2009) Electrical system ELECTRONIC CONTROL UNIT CONNECTOR 1. Injection telltale light (Brown-Black) 2. Not connected 3. Not connected 4. Lambda probe negative terminal (White-Green) 5. Live supply (Red-White) 6. Battery powered (Grey-Black) 7. Immobilizer Aerial (Orange-White) 8.
  • Page 84 Vespa GTS Super 125 i.e. (2009) Electrical system INJECTOR CONNECTOR 1. Power via remote control (Black-Green) 2. Electronic control unit (Red-Yellow) LAMBDA PROBE CONNECTOR 1. Positive from control unit (Sky blue-Black) 2. Negative from control unit (White-Green) VOLTAGE REGULATOR CONNECTOR 1.
  • Page 85 Vespa GTS Super 125 i.e. (2009) Electrical system INSTRUMENT PANEL CONNECTOR «B» 1. Ground (Black) 2. Injection telltale light (Brown-Black) 3. Low fuel warning light (Yellow-Green) 4. Water temperature (Grey-Black) INSTRUMENT PANEL CONNECTOR «C» 1. Immobilizer warning light (Red-Green) 2. Battery powered (Red-Blue) 3.
  • Page 86 Vespa GTS Super 125 i.e. (2009) Electrical system IMMOBILIZER AERIAL CONNECTOR 1. Live supply (Red-White) 2. Ground (Black) 3. Electronic control unit (Orange-White) FUEL LEVEL TRANSMITTER CONNECTOR 1. Fuel level indicator (White-Green) 2. Ground (Black) 3. Low fuel warning light (Yellow-Green) COOLANT PUMP CONNECTOR 1.

  • Page 87: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 88 Vespa GTS Super 125 i.e. (2009) Engine from vehicle Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo. Exhaust assy. Removal - Remove the right and left fairings and the spoiler terminals. - Remove the Lambda probe from its support and disconnect it.
  • Page 89 Vespa GTS Super 125 i.e. (2009) Engine from vehicle Remove the lambda probe from the manifold. CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle CAUTION SUPPORT THE VEHICLE ADEQUATELY.
  • Page 90 Vespa GTS Super 125 i.e. (2009) Engine from vehicle - Get a + 2.5 l container to collect the coolant. - Remove the coolant inlet pipe to the motor as indicated in the photograph. - Disconnect the fuel pipe from the injector and re- move the screw locking the retainer clamp.
  • Page 91 Vespa GTS Super 125 i.e. (2009) Engine from vehicle - Remove the coolant outlet pipe from the engine as indicated. - Remove the spark plug cap. - Remove the 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.
  • Page 92 Vespa GTS Super 125 i.e. (2009) Engine from vehicle - Remove the clamp retaining the starter motor from the sleeve. - 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.
  • Page 93 Vespa GTS Super 125 i.e. (2009) Engine from vehicle - Remove the four retainers of the rear brake pipes from the crankcase. - Remove the rear shock absorbers. - Remove the engine-swinging arm fixing pin by undoing the nut and operating on the head of the pin as shown in the photograph.
  • Page 94 Vespa GTS Super 125 i.e. (2009) Engine from vehicle - Pay particular attention to the sleeve, 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.
  • Page 95 INDEX OF TOPICS INJEC NJECTION...
  • Page 96 Vespa GTS Super 125 i.e. (2009) Injection INJEC - 96...
  • Page 97 Vespa GTS Super 125 i.e. (2009) Injection OMPONENT RANSPOSITION Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Fuel pump Water temperature sensor Fuel injector HV coil Engine speed sensor Lambda probe Injection load remote control...
  • Page 98 Vespa GTS Super 125 i.e. (2009) Injection - Spark plug The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only in the compression phase) at the same time. The MIU injection-ignition system controls engine functions by means of a pre-set program.
  • Page 99 Vespa GTS Super 125 i.e. (2009) Injection The MIU control unit power supply is furthermore controlled by the emergency switch; to allow further safety of the scooter. Precautions Troubleshooting hints 1 A MIU failure is more likely to be due to the connections than to the components.
  • Page 100 Vespa GTS Super 125 i.e. (2009) Injection 4 When troubleshooting use a multimeter with an internal resistance over 10 Ohm /V. Instruments that are not suitable might damage the MIU control unit. Instruments must be used with definitions over 0.1V and 0.5 W , the precision must be greater than 2%.
  • Page 101 Vespa GTS Super 125 i.e. (2009) Injection Terminals setup 1. Injection warning light 2. incomplete 3. incomplete 4. (-) lambda probe 5. (+) live battery 6. (+) battery 7. Immobilizer aerial 8. Electric fan remote control 9. Water temperature sensor 10.incomplete...
  • Page 102 Vespa GTS Super 125 i.e. (2009) Injection 26.Ground lead EMS circuit diagram 1. Battery 12V - 12 Ah 2. Rpm sensor 3. coolant temperature sensor 4. Immobilizer aerial 5. Stop switches 6. Fuse No. 1; 30A 7. Key switch contacts 8.

  • Page 103: Troubleshooting Procedure

    Vespa GTS Super 125 i.e. (2009) Injection 9. Fuse No. 3; 15A 10.Engine stop switch 11.Fuse No. 2; 7.5A 12.Injection load remote controls 13.Fuse 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...
  • Page 104 Vespa GTS Super 125 i.e. (2009) Injection Starting difficulties ENGINE START-UP 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 remote control...
  • Page 105 Vespa GTS Super 125 i.e. (2009) Injection Possible Cause Operation 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 sensor Intake air temperature sensor...
  • Page 106 Vespa GTS Super 125 i.e. (2009) Injection Possible Cause Operation Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM- ANCE ON PICKUP Possible Cause Operation...

  • Page 107: Fuel Supply System

    Vespa GTS Super 125 i.e. (2009) Injection Fuel supply system The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector and the fuel delivery pipes. The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through the filter.
  • Page 108 Vespa GTS Super 125 i.e. (2009) Injection Remove the fast-release fittings from the injector support. Remove the injector connector. Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold.
  • Page 109 Vespa GTS Super 125 i.e. (2009) Injection Remove the clip fixing the throttle body to the air cleaner bellows. Remove the gas command fitting as indicated in the picture Refitting the butterfly valve To refit, perform the operations in the reverse or-...
  • Page 110 Vespa GTS Super 125 i.e. (2009) Injection Pump supply circuit 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts INJEC - 110...

  • Page 111: Electrical Data

    Vespa GTS Super 125 i.e. (2009) Injection 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan remote control 11.Coolant electric pump When switched to "ON", the fuel pump starts to rotate for two seconds and then stops.
  • Page 112 Vespa GTS Super 125 i.e. (2009) Injection and of the Black-Purple cable between the pin 20 of the control unit and the remote control base. N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (REMOTE CONTROLS, CONTROL UNIT, FUSES ETC.).
  • Page 113 Vespa GTS Super 125 i.e. (2009) Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none, check the continuity of the grey/black cable between the fuse box (No. 3 15 A) and the remote control base.
  • Page 114 Vespa GTS Super 125 i.e. (2009) Injection mote control disconnected, that the Black-Purple cable (pin 20 on the interface wiring) is insulated from the ground. Specific tooling 020331Y Digital multimeter Circuit leak test Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
  • Page 115 Vespa GTS Super 125 i.e. (2009) Injection Remove the screw shown in the picture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture.
  • Page 116 Vespa GTS Super 125 i.e. (2009) Injection Inspecting the injector circuit 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump 8.
  • Page 117 Vespa GTS Super 125 i.e. (2009) Injection 9. Fuel injector 10.Electric fan remote control Check the resistance at the injector ends: 14.5 ± 5% Ohm 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.
  • Page 118 Vespa GTS Super 125 i.e. (2009) Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none, check the continuity of the grey/black cable between the fuse box (No. 3 15 A) and the remote control base.
  • Page 119 Vespa GTS Super 125 i.e. (2009) Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to «ON» and check if there is voltage, with...
  • Page 120 Vespa GTS Super 125 i.e. (2009) Injection With injector disconnected and the injector load remote control disconnected, check the continuity of the Black-Green cable between the injector con- nector and remote control base. Inspecting the injector hydraulics To carry out the injector check, remove the intake...
  • Page 121 Vespa GTS Super 125 i.e. (2009) Injection Proceed with the injector seal test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector.
  • Page 122 Vespa GTS Super 125 i.e. (2009) Injection Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring con- nected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2.8 V...
  • Page 123 Vespa GTS Super 125 i.e. (2009) Injection HT coil 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts INJEC - 123...
  • Page 124 Vespa GTS Super 125 i.e. (2009) Injection 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan remote control 11.Coolant electric pump The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
  • Page 125 Vespa GTS Super 125 i.e. (2009) Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected.
  • Page 126 Vespa GTS Super 125 i.e. (2009) Injection INJEC - 126...

  • Page 127: Coolant Temperature Sensor

    Vespa GTS Super 125 i.e. (2009) Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none, check the continuity of the grey/black cable between the fuse box (No. 3 15 A) and the remote control base.
  • Page 128 Vespa GTS Super 125 i.e. (2009) Injection With the control unit side connector disconnected and the coolant temperature sensor connector connected, check the resistance between pins 9 and 26 in relation to the engine temperature. 20° = 2500 ± 100 Ω...
  • Page 129 Vespa GTS Super 125 i.e. (2009) Injection To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to match the throttle body with the control unit following the procedure known as TPS resetting.

  • Page 130: Lambda Probe

    Vespa GTS Super 125 i.e. (2009) Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
  • Page 131 Vespa GTS Super 125 i.e. (2009) Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V.
  • Page 132 Vespa GTS Super 125 i.e. (2009) Injection Impianto elettroventilatore 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 INJEC - 132...
  • Page 133 Vespa GTS Super 125 i.e. (2009) Injection 4. Key switch contacts 5. 7.5A fuse No. 2 6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan remote control 11.Coolant electric pump 12.Fuse No. 5; 15A 13.Electric fan motor...
  • Page 134 Vespa GTS Super 125 i.e. (2009) Injection Check if the BLUE - YELLOW cable between the control unit pin 8 and the electric fan remote con- trol base is not interrupted Check the 15A Fuse No. 5 Check if there is +12 V voltage between the GREY cable of the electric fan remote control base and the ground connection.

  • Page 135: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 136: Removing The Front Wheel

    Vespa GTS Super 125 i.e. (2009) Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pic- ture. Locking torques (N*m) Wheel fixing screw 20 ÷...
  • Page 137 Vespa GTS Super 125 i.e. (2009) Suspensions - Remove the wheel hub. - Remove the ball bearing check Seeger ring indi- cated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings...

  • Page 138: Refitting The Front Wheel

    Vespa GTS Super 125 i.e. (2009) Suspensions - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the...

  • Page 139: Steering Column

    Vespa GTS Super 125 i.e. (2009) Suspensions Steering column Removal - Remove the front wheel - Remove the brake calliper - Loosen the screw fixing the odometer cable plate and take out the cable. - Remove the suspension arm housing by un- screwing the three screws indicated in the photo- graph.
  • Page 140 Vespa GTS Super 125 i.e. (2009) Suspensions - Remove the retainer fixing the odometer cable to the mudguard indicated in the photograph - Remove the retainer fixing the brake piping to the front shock absorber upper plate - Remove the retainer fixing the brake piping to the...
  • Page 141 Vespa GTS Super 125 i.e. (2009) Suspensions - Remove the rear handlebar cover. - Remove the screw fixing the handlebar to the steering tube - Tilt the handlebar towards the shield back plate being careful not to scratch the plastic parts...
  • Page 142 Vespa GTS Super 125 i.e. (2009) Suspensions - Remove the steering tube - Use a special tool remove the upper disk of the fifth wheel fitting seat on the headstock by operat- ing form the lower part of the headstock as indica- ted in the photograph.
  • Page 143 Vespa GTS Super 125 i.e. (2009) Suspensions - Refit the fifth wheel fitting and the dust guard on the steering tube until they stop, using the specific tool. Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube...
  • Page 144 Vespa GTS Super 125 i.e. (2009) Suspensions - Once the pin has been fitted, insert the two spacers part 17 slightly hitting with a mallet (see next figure). CAUTION USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING.

  • Page 145: Front Shock Absorber

    Vespa GTS Super 125 i.e. (2009) Suspensions To position roller casings on the pin (pin end in contact with the internal bottom of the roller cas- ings) proceed as follows: - Use the tool with part 20 and 21 fitted to the stem as indicated in the figure.
  • Page 146 Vespa GTS Super 125 i.e. (2009) Suspensions Removal - Support the vehicle adequately. - Remove the wheel hub. - Loosen the shock absorber lower 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.
  • Page 147 Vespa GTS Super 125 i.e. (2009) Suspensions Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques. Locking torques (N*m) shock absorber lower clamping 20 - 27 shock absorber upper clamp 20 to 30...
  • Page 148 Vespa GTS Super 125 i.e. (2009) Suspensions Overhaul - The bracket for the shock absorber -calliper at- tachment has two roller bearings separated one from the other as shown in the photograph - Remove the two roller bearings from the bracket...
  • Page 149 Vespa GTS Super 125 i.e. (2009) Suspensions - Assemble a new roller bearing on the shock ab- sorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch - Suitably hold the brake calliper - shock absorber...

  • Page 150: Removing The Rear Wheel

    Vespa GTS Super 125 i.e. (2009) Suspensions Removing the rear wheel - Remove the bracket supporting the rear shock absorber and the muffler; - Remove the rear wheel by unscrewing the 5 screws indicated in the photograph Refitting the rear wheel To refit, carry out the removal operations but in reverse order, observing the prescribed torques.
  • Page 151 Vespa GTS Super 125 i.e. (2009) Suspensions - Remove the two screws fixing the buffer 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.
  • Page 152 Vespa GTS Super 125 i.e. (2009) Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension.
  • Page 153 Vespa GTS Super 125 i.e. (2009) Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the picture. - Using a suitable pin remove the roller casings as...
  • Page 154 Vespa GTS Super 125 i.e. (2009) Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in...
  • Page 155 Vespa GTS Super 125 i.e. (2009) Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the...

  • Page 156: Shock Absorbers

    Vespa GTS Super 125 i.e. (2009) Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine- and vehicle-side swinging arm junction bolt 40 ÷ 45 Swinging arm pin - Engine 64 ÷ 72 Body shell - Swinging arm pin 76 ÷...
  • Page 157 Vespa GTS Super 125 i.e. (2009) Suspensions Shock absorber lower fitting 40 ÷ 45 Upper shock absorber fixing screws 20 ÷ 25 Nm Exhaust bracket Removal Remove the full muffler unit. - Remove the two fixing screws of the bracket to...

  • Page 158: Side Stand

    Vespa GTS Super 125 i.e. (2009) Suspensions Side stand REMOVAL - Uncouple the centre stand return spring; Remove the screw shown in the photograph FITTING To refit, carry out the removal operations in re- verse order and comply with the specified torque.

  • Page 159: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 160: Rear Brake Calliper

    Vespa GTS Super 125 i.e. (2009) Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the rear wheel. - Remove the pad retention pin snap ring. - Using a pin partially remove the brake pad re- tention pin.
  • Page 161 Vespa GTS Super 125 i.e. (2009) Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to...

  • Page 162: Front Brake Calliper

    Vespa GTS Super 125 i.e. (2009) Braking system Front brake calliper Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the two front brake calliper devices fas- tening them to the support as shown in the photo- graph.
  • Page 163 Vespa GTS Super 125 i.e. (2009) Braking system - that the cylinder and the floating body of the cal- liper do not show signs of scratches or erosion, otherwise replace the entire calliper; - that the guides of the fixed plate are not scratched or eroded, otherwise replace the entire plate;...

  • Page 164: Rear Brake Disc

    Vespa GTS Super 125 i.e. (2009) Braking system Rear brake disc Removal - Remove the rear brake calliper. - Remove the brake disc and the hub from the wheel axle - To remove the brake disc from the hub, hold the...

  • Page 165: Front Brake Disc

    Vespa GTS Super 125 i.e. (2009) Braking system N.B. SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC. Specific tooling 020335Y Magnetic mounting for dial gauge Characteristic Max. deviation allowed: 0.1 mm...

  • Page 166: Front Brake Pads

    Vespa GTS Super 125 i.e. (2009) Braking system Refitting - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.
  • Page 167 Vespa GTS Super 125 i.e. (2009) Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the brake calliper - Remove permanently the two pad fixing screws - Check that there are no flaws or warping. If there is, replace it.

  • Page 168: Rear Brake Pads

    Vespa GTS Super 125 i.e. (2009) Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B.
  • Page 169 Vespa GTS Super 125 i.e. (2009) Braking system Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the lock on the bolt and then the protection cover N.B.

  • Page 170: Brake Fluid Level Check

    Vespa GTS Super 125 i.e. (2009) Braking system N.B. DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS.
  • Page 171 Vespa GTS Super 125 i.e. (2009) Braking system AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE.
  • Page 172 Vespa GTS Super 125 i.e. (2009) Braking system Overhaul Proceed as follows: 1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take out the dia- phragm (3); 2) remove the cap (4) and take out the internal parts in order;...
  • Page 173 Vespa GTS Super 125 i.e. (2009) Braking system Refitting To refit, carry out the removal operations but in reverse order, observing the specified torques. Locking torques (N*m) Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handle bar: 7 to 10 Nm...

  • Page 174: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 175: Circuit Diagram

    Vespa GTS Super 125 i.e. (2009) Cooling system Circuit diagram 1. Coolant electric pump 2. Three-way thermostat 3. Electric fan COOL SYS - 175...
  • Page 176 Vespa GTS Super 125 i.e. (2009) Cooling system 4. Expansion tank 5. Radiator 6. coolant temperature sensor COOL SYS - 176...
  • Page 177 INDEX OF TOPICS CHAS HASSIS...
  • Page 178 Vespa GTS Super 125 i.e. (2009) Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Remove the helmet compartment - Remove the two screws shown in the photograph - Remove the saddle...
  • Page 179 Vespa GTS Super 125 i.e. (2009) Chassis - Remove the electric connector from the saddle opening actuator - Remove the two screws shown in the photograph - Remove the clip from the transmission - Remove the actuator from the supporting bracket...

  • Page 180: Instrument Panel

    Vespa GTS Super 125 i.e. (2009) Chassis Rear handlebar cover - Remove the front handlebar cover - Undo the 5 screws indicated in the photograph -Disconnect the odometer cable -After disconnecting the wiring remove the rear handlebar. Instrument panel - Remove the rear handlebar cover;...
  • Page 181 Vespa GTS Super 125 i.e. (2009) Chassis -Undo the 2 screws indicated in the figure; - Remove the front handlebar cover - Disconnect the front headlamp connectors Headlight assy. - Remove the front handlebar cover. - Undo the four screws indicated.
  • Page 182 Vespa GTS Super 125 i.e. (2009) Chassis Knee-guard - Remove the rear handlebar cover. - Remove the two screws indicated in the photo- graph and located on the shield under the grille - Remove the expansion tank cover and then its...
  • Page 183 Vespa GTS Super 125 i.e. (2009) Chassis - Remove the electric saddle opening switch, the fuse box and the manual saddle opening cable as shown in the photograph Taillight assy. - Operate the screw indicated in the figure to re- move the rear turn indicator Remove screw «A»...
  • Page 184 Vespa GTS Super 125 i.e. (2009) Chassis Footrest - Remove the shield back plate - Remove the battery compartment cover - Remove the side fairings - Remove the central screw located under the bat- tery compartment cover as indicated in the figure...
  • Page 185 Vespa GTS Super 125 i.e. (2009) Chassis - Remove the screws under the non-slip rubber mat of the footrest as indicated in the photograph Side fairings Unscrew the fixing screw "A" Unscrew the nut "B" under the body. Helmet bay...
  • Page 186 Vespa GTS Super 125 i.e. (2009) Chassis - Remove the screw indicated in the figure that fixes the tank to the body after removing the rear head- light assembly - Remove the two turn indicators - Use a jack to lift the body so that there is enough...

  • Page 187: Front Mudguard

    Vespa GTS Super 125 i.e. (2009) Chassis Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard - Remove the three mudguard-steering tube clamps indicated in the figure...
  • Page 188 Vespa GTS Super 125 i.e. (2009) Chassis - The same procedure also applies to the left ra- diator for which it is necessary to remove the elec- tric fan first by undoing the three screws indicated in the photograph and afterwards disconnect the connector.
  • Page 189 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 190 Vespa GTS Super 125 i.e. (2009) Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection...
  • Page 191 Vespa GTS Super 125 i.e. (2009) Pre-delivery •Instrument panel lights • Horn • Electrical start up • Engine stopping with emergency stop switch • electric saddle opening button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

  • Page 192: Static Test

    Vespa GTS Super 125 i.e. (2009) Pre-delivery - Abnormal noise Static test Static control after the test ride: • Hot engine restart • Minimum seal (turning the handlebar) • Uniform steering rotation • Possible losses • electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 193 INDEX OF TOPICS TIME...
  • Page 194 Vespa GTS Super 125 i.e. (2009) Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from chassis - Removal and refit.
  • Page 195 Vespa GTS Super 125 i.e. (2009) Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 195...

  • Page 196: Cylinder Assy

    Vespa GTS Super 125 i.e. (2009) Time Cylinder assy. CYLINDER - PISTON Code Action Duration 001002 Cylinder / Piston - Replacement 001154 Pistonsrings-pin assembly - Service 001129 Chain tensioner - Service and Re- placement TIME - 196...

  • Page 197: Cylinder Head Assy

    Vespa GTS Super 125 i.e. (2009) Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - adjust 001056 Head gasket - change 001083 Thermistor - Replacement 001057 Thermostat - Replacement...

  • Page 198: Cylinder Head Cover

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

  • Page 199: Oil Filter

    Vespa GTS Super 125 i.e. (2009) Time EAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment Oil filter OIL FILTER...

  • Page 200: Flywheel Cover

    Vespa GTS Super 125 i.e. (2009) Time Flywheel cover LYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001150 Flywheel cover gasket - change 007007 Water pump rotor - Replacement 007017 Water pump cover - Replacement 007003 Coolant delivery and return pipe -...

  • Page 201: Oil Pump

    Vespa GTS Super 125 i.e. (2009) Time DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001155 Clutch bell - Replacement Oil pump OIL PUMP Code Action Duration 001125 Chain guide pads - Replacement...
  • Page 202 Vespa GTS Super 125 i.e. (2009) Time Final gear assy. FINAL REDUCTION GEAR Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Reduction gear cover - Replacement 004125 Rear wheel axle - Replacement TIME - 202...

  • Page 203: Driving Pulley

    Vespa GTS Super 125 i.e. (2009) Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001066 Driving pulley - Removal and refitting 001177 Variator rollers / shoes - Replace- ment 001141...

  • Page 204: Transmission Cover

    Vespa GTS Super 125 i.e. (2009) Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement 001131 Transmission air intake - Replace- ment 001065 Transmission cover - Replacement...

  • Page 205: Electrical Start-Up

    Vespa GTS Super 125 i.e. (2009) Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001104 Start-up freewheel - Replacement 001151 Starter driven gearing - Replacement 001017 Start-up pinion - Replacement TIME - 205...

  • Page 206: Flywheel Magneto

    Vespa GTS Super 125 i.e. (2009) Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - change TIME - 206...

  • Page 207: Butterfly Valve

    Vespa GTS Super 125 i.e. (2009) Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 207...

  • Page 208: Exhaust Pipe

    Vespa GTS Super 125 i.e. (2009) Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 005138 Lambda probe - Replacement TIME - 208...

  • Page 209: Air Cleaner

    Vespa GTS Super 125 i.e. (2009) Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement 001027 Body / air cleaner union - Replace-...
  • Page 210 Vespa GTS Super 125 i.e. (2009) Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004085 Fairing (1) - Replacement 004149 Shield central cover - Replacement 004053 Spoiler - Replacement 004015 Footrest - Removal and Refitting 004023 Shield rim - Replacement...

  • Page 211: Centre-Stand

    Vespa GTS Super 125 i.e. (2009) Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 211...

  • Page 212: Rear Cover

    Vespa GTS Super 125 i.e. (2009) Time MATS AND COVERS Code Action Duration 004079 Footrest - replacement 004071 Battery compartment - replacement 004078 Front/rear footrest rubber - Replace- ment 005046 Battery cover - change Rear cover REAR SHIELD Code Action...

  • Page 213: Underseat Compartment

    Vespa GTS Super 125 i.e. (2009) Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 004011 Central chassis cover - Replacement TIME - 213...
  • Page 214 Vespa GTS Super 125 i.e. (2009) Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder support - Re- placement 005048 number plate holder - Replacement Mudguard TIME - 214...
  • Page 215 Vespa GTS Super 125 i.e. (2009) Time MUDGUARDS Code Action Duration 004002 Front mudguard - change 004009 Rear mudguard - Replacement 003044 Shock absorber cover - Replace- ment Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement...
  • Page 216 Vespa GTS Super 125 i.e. (2009) Time Radiator RADIATOR Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan complete with support - Re- placement 007001 Expansion tank - Replacement 001052 Coolant and air bleed - Replacement 007013...

  • Page 217: Rear Shock Absorber

    Vespa GTS Super 125 i.e. (2009) Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Removal and Refitting 003077 muffler/rear shock absorber support arm - Service TIME - 217...
  • Page 218 Vespa GTS Super 125 i.e. (2009) Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheels - Replacement 003073 Steering clearance - Adjustment TIME - 218...

  • Page 219: Handlebar Covers

    Vespa GTS Super 125 i.e. (2009) Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar covers - Replace- ment TIME - 219...

  • Page 220: Handlebar Components

    Vespa GTS Super 125 i.e. (2009) Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Removal and refitting 002067 Rear brake pump - Replacement 002024 Front brake pump - Removal and re- fitting 005017 Stop switch - Replacement...

  • Page 221: Swinging Arm

    Vespa GTS Super 125 i.e. (2009) Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-chassis connection swinging arm - Replacement 004058 Silent block - Replacement TIME - 221...
  • Page 222 Vespa GTS Super 125 i.e. (2009) Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement Instrument panel TIME - 222...
  • Page 223 Vespa GTS Super 125 i.e. (2009) Time INSTRUMENT PANEL Code Action Duration 004066 Driving mirror - Replacement 005014 Odometer - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Replace- ment 005006 Light or turning indicator switch - Re-...
  • Page 224 Vespa GTS Super 125 i.e. (2009) Time Locks LOCKS Code Action Duration 002083 Saddle opening transmission - Re- placement 002092 Transmission splitter/ hook transmis- sion - Replacement 004158 Saddle opening splitter - Replace- ment 005072 Immobilizer aerial - Replacement 005099...

  • Page 225: Turn Signal Lights

    Vespa GTS Super 125 i.e. (2009) Time Turn signal lights NDICATORS AND LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005067 Front turn indicator bulb - Replace- ment 005031 number plate light bulb - Replace- ment 005139 Tail light bulb - Replacement...

  • Page 226: Front Wheel

    Vespa GTS Super 125 i.e. (2009) Time Front wheel RONT WHEEL Code Action Duration 003047 Front tyre - Replacement 003037 Front wheel rim - Replacement 004123 Front wheel - Replacement 003033 Front wheel hub- Replacement 002041 Brake disc - Replacement...

  • Page 227: Rear Wheel

    Vespa GTS Super 125 i.e. (2009) Time Rear wheel EAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Front wheel rim - Removal and Re- fitting 001016 Rear wheel - Replacement 002028 Rear wheel hub - Replacement...

  • Page 228: Electric Devices

    Vespa GTS Super 125 i.e. (2009) Time Electric devices LECTRIC DEVICES Code Action Duration 001094 Spark plug cap - Replacement 001069 HV coil - Replacement 005003 Horn - Replacement 005009 Voltage regulator - Replacement 005052 Fuse (1) - Replacement 005007...
  • Page 229 Vespa GTS Super 125 i.e. (2009) Time Transmissions RANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement TIME - 229...

  • Page 230: Front Suspension

    Vespa GTS Super 125 i.e. (2009) Time Front suspension FRONT SUSPENSION Code Action Duration 003011 Front shock absorber - Removal and Refitting 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber mounting and brake calliper - Replacement...
  • Page 231 Vespa GTS Super 125 i.e. (2009) Time Braking system BRAKING SYSTEM Code Action Duration 002039 Front brake calliper - Replacement 002007 Front brake pads - Replacement 002021 Front brake piping - Replacement 002047 Front brake fluid and air bleed sys-...
  • Page 232 Vespa GTS Super 125 i.e. (2009) Time Stickers RANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 232...
  • Page 233 Air filter: 46 Battery: 64, 72, 81 Brake: 160, 162, 164–166, 168, 170, 171 Brake fluid: 170 Checks: 66 Coolant: 127 Electric: 228 Engine oil: 47 Fuel: 107, 114, 185, 215 Fuses: 80 Headlight: 52, 181 Horn: 76 Hub oil: 45 Identification: 8 Instrument panel: 180, 222 Luggage rack:...
  • Page 234 Stand: 158 Start-up: Suspension: 55, 56, 230 Switch: Tank: 185, 215 Transmission: 10, 54, 204 Turn indicators: 66 Tyre pressure: Tyres: 15 Vehicle: 8, 88, 89...

Table of Contents