VESPA GTS Super 300 ie 2008 Service Station Manual
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VESPA GTS Super 300 ie 2008 Service Station Manual

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MANUALE STAZIONE DI SERVIZIO
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Vespa GTS Super 300 ie (2008)

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  • Page 1 MANUALE STAZIONE DI SERVIZIO ******** Vespa GTS Super 300 ie (2008)
  • Page 2 MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 ie (2008) 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 300 ie (2008) This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.

  • 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 NGINE 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 300 ie (2008) 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 300 ie (2008) 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: Head Lubrication Control Jet

    Vespa GTS Super 300 ie (2008) Characteristics Engine DATA Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Cubic capacity 278.3 cm³ Stroke 63 mm Bore 75 mm MAX. torque 22 Nm at 6500 rpm Max. Power 16.4 kW at 7500 rpm...

  • Page 10: Water Pump

    Vespa GTS Super 300 ie (2008) Characteristics THERMOSTAT Specification Desc./Quantity Type Wax-type, with deviator Starts opening at 85±2°C ELECTRIC VENTILATION Specification Desc./Quantity Electric ventilation starts at 102°C Electric ventilation stops at 96°C WATER PUMP Specification Desc./Quantity Type Centrifugal Control Coaxial to crankshaft...

  • Page 11: Turn Indicator Switch

    Vespa GTS Super 300 ie (2008) 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: Light Switch

    Vespa GTS Super 300 ie (2008) Characteristics LIGHT SWITCH STARTER BUTTON IGNITION KEY FUEL INJECTOR Type: 3 holes Conicity of the nozzle: 20° Resistance at terminals: 13.7 - 15.2 Ohm CHAR - 12...

  • Page 13: Fuel Pump Unit

    Vespa GTS Super 300 ie (2008) 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 SPEED/PHASE SENSOR Resistance between pins 13 and 15: 100 to 150 Ohm at approx.
  • Page 14 Vespa GTS Super 300 ie (2008) 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 - 1 Ohm...
  • Page 15 Vespa GTS Super 300 ie (2008) 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 300 ie (2008) Characteristics REAR SUSPENSION Name Torque in Nm Retainer for left shock absorber to crankcase support plate 20 to 25 Shock absorber lower fitting 40 ÷ 45 Shock absorber upper fitting 20 to 25 Rear wheel axle...

  • Page 17: Crankcase And Crankshaft

    Vespa GTS Super 300 ie (2008) 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 300 ie (2008) Characteristics CYLINDER - PISTON Specification Desc./Quantity Plunger diameter 74.967 +0.014 -0.014 mm Cylinder diameter 75 +0.038 +0.01 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder-piston 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷...

  • Page 19: Piston Rings

    Vespa GTS Super 300 ie (2008) Characteristics - Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
  • Page 20 Vespa GTS Super 300 ie (2008) Characteristics CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD. Characteristic Top piston ring Standard opening: 0.15 to 0.30 mm Middle piston ring Standard opening: 0.20 ÷ 0.40 mm scraper ring Standard opening: 0.20 ÷...
  • Page 21 Vespa GTS Super 300 ie (2008) Characteristics RANKSHAFT Specification Desc./Quantity Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm CHAR - 21...
  • Page 22 Vespa GTS Super 300 ie (2008) Characteristics MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 22...
  • Page 23 Vespa GTS Super 300 ie (2008) Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.43 mm - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR...

  • Page 24: Cylinder Head

    Vespa GTS Super 300 ie (2008) Characteristics COUPLINGS BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING HALVES CATEGORY 29.024 ÷ 29.054 29.024 ÷ 29.054 29.018 ÷ 29.048 29.018 ÷ 29.048 Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2).
  • Page 25 Vespa GTS Super 300 ie (2008) Characteristics - Check the sealing surfaces for the intake and exhaust manifold. - Check that the camshaft and the rocking lever pin capacities exhibit no wear. - Check that the head cover surface is not worn.
  • Page 26 Vespa GTS Super 300 ie (2008) Characteristics - Remove any carbon deposits from the valve seats. - Check the width of the mark on the valve seat «V» with Prussian blue. Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm...
  • Page 27 Vespa GTS Super 300 ie (2008) Characteristics MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Intake: 4.96 mm Exhaust: 4.945 mm - Calculate the clearance between valve and valve guide. - Check the deviation of the valve stem by resting it on a «V» shaped support and measuring the ex- tent of the deformation using a dial gauge.
  • Page 28 Vespa GTS Super 300 ie (2008) Characteristics INTAKE Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm EXHAUST Specification Desc./Quantity Standard clearance: 0.025 to 0.052 mm Admissible limit: 0.09 mm - Check that there are no signs of wear on the mating surface with the set screw articulated terminal.
  • Page 29 Vespa GTS Super 300 ie (2008) Characteristics INIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Camshaft check: Minimum admissible diameter Bearing A Ø: 36.94 mm Camshaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm - Using a gauge, measure the height of the cams.
  • Page 30 Vespa GTS Super 300 ie (2008) Characteristics - Measure the internal diameter of each rocker. Check there are no signs of wear on the slider from contact with the cam and on the jointed adjustment plate. OCKING LEVERS AND PIN DIAMETER Specification Desc./Quantity...
  • Page 31 Vespa GTS Super 300 ie (2008) Characteristics inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa. N.B. MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK- CASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, EQUIPPED WITH A SUP-...

  • Page 32: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...

  • Page 33: Specific Tools

    Vespa GTS Super 300 ie (2008) Tooling SPECIFIC TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y017 Bell for bearings, OD 39 mm 001467Y014 Calliper to extract ø 15-mm bearings 001467Y035 Bearing housing, outside ø 47 mm 001467Y013 Calliper to extract ø...
  • Page 34 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch for removing steering bearings from headstock 020021Y Front suspension service tool 020036Y Punch 020038Y...
  • Page 35 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020115Y Ø 18 punch 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge...
  • Page 36 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020244Y 15-mm diameter punch 020262Y Crankcase splitting plate 020271Y Tool for removing-fitting silent bloc 020263Y Driven pulley assembly sheath 020306Y Punch for assembling valve seal rings 020329Y Mity-Vac vacuum-operated pump...
  • Page 37 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35-mm Adaptor TOOL - 37...
  • Page 38 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020359Y 42 x 47-mm Adaptor 020360Y 52 x 55-mm Adaptor 020363Y 20-mm guide 020364Y 25-mm guide 020365Y 22 mm guide 020375Y 28 x 30 mm adaptor TOOL - 38...
  • Page 39 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band 020412Y 15-mm guide 020423Y Driven pulley lock wrench...
  • Page 40 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020428Y Piston position check mounting 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting TOOL - 40...
  • Page 41 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020441Y 26 x 28 mm adaptor 020444Y Tool for fitting/ removing the driven pulley clutch 020454Y Tool for fitting piston pin stops (200 - 250) 020456Y Ø 24 mm adaptor...
  • Page 42 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020480Y Petrol pressure check kit 020483Y 30-mm guide 020489Y Hub cover support stud bolt kit 020621Y HV cable extraction adaptor 020622Y Transmission-side oil seal punch 020626Y Driving pulley lock wrench...
  • Page 43 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020627Y Flywheel lock wrench 020648Y Single battery charger 020922Y Diagnosis Tool TOOL - 43...

  • Page 44: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 45: Maintenance Chart

    Vespa GTS Super 300 ie (2008) 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 Safety fasteners...
  • Page 46 Vespa GTS Super 300 ie (2008) Maintenance - Remove the transmission compartment air intake cover shown in the picture. - Rotate the driving pulley fan using a screwdriver until the reference marks between the flywheel and flywheel cover coincide as shown in the pic- ture.

  • Page 47: Spark Plug

    Vespa GTS Super 300 ie (2008) Maintenance Spark plug - Rest the scooter on its stand - Open the saddle and take out the helmet com- partment - Disconnect the spark plug HV wire cap; - Unscrew the spark plug using the wrench sup- plied;...
  • Page 48 Vespa GTS Super 300 ie (2008) Maintenance 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;...

  • Page 49: Air Filter

    Vespa GTS Super 300 ie (2008) Maintenance Locking torques (N*m) Hub oil drainage screw 15 to 17 Nm Air filter Proceed as follows: 1. unscrew the fixing screw «A». 2. unscrew the nut «B» under the body. 3. remove the left side fairing.

  • Page 50: Engine Oil

    Vespa GTS Super 300 ie (2008) Maintenance Engine oil In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.

  • Page 51: Engine Oil Filter

    Vespa GTS Super 300 ie (2008) Maintenance and if necessary top up without exceeding the MAX level. 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.

  • Page 52: Oil Pressure Warning Light

    Vespa GTS Super 300 ie (2008) Maintenance JASO MA, MA2 - API SL - ACEA 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»...

  • Page 53: Braking System

    Vespa GTS Super 300 ie (2008) Maintenance - Top up if the fluid level is near or below the MIN level edge. The liquid level must always be be- tween the MIN and MAX level. -The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised water- antifreeze solution mix.
  • Page 54 Vespa GTS Super 300 ie (2008) Maintenance Top-up - Position the vehicle on a flat surface and on the centre stand - Remove the brake pump cover as indicated in the photo Check the brake fluid level through the sight glass...

  • Page 55: Headlight Adjustment

    Vespa GTS Super 300 ie (2008) 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 vehicle is perpendicular to the screen;...

  • Page 56: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 57 Vespa GTS Super 300 ie (2008) 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 58: Noisy Suspension

    Vespa GTS Super 300 ie (2008) 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 vehicle.
  • Page 59 Vespa GTS Super 300 ie (2008) 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 - 59...

  • Page 60: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 61 Vespa GTS Super 300 ie (2008) Electrical system 1. 12v-10Ah battery 2. Starter relay 3. Starter motor 4. Starter button 5. Voltage regulator 6. Magneto flywheel 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9. Fuse No. 2 - 15A 10.
  • Page 62 Vespa GTS Super 300 ie (2008) Electrical system 20. Radiator electric fan 21. Horn button 22. Horn 23. Lambda probe 24. Engine speed sensor 25. H.V. coil. 26. Fuel injector 27. Engine temperature sensor 28. Fuel pump 29. Diagnosis socket 30.
  • Page 63 Vespa GTS Super 300 ie (2008) Electrical system Components arrangement 9. Immobilizer aerial- Remove the shield back plate to reach it. 10. Injection ECU - Remove the helmet compart- ment to reach it. ELE SYS - 63...
  • Page 64 Vespa GTS Super 300 ie (2008) Electrical system 11. Diagnosis connector - Remove the helmet compartment 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.
  • Page 65 Vespa GTS Super 300 ie (2008) Electrical system 20-23. Remote control switches - Remove the front central cover and the helmet compartment to reach them. 26. Main fuses - Open the front top box to reach them. 41. Secondary fuse - Remove the helmet com- partment to reach it.
  • Page 66 Vespa GTS Super 300 ie (2008) 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 67: Ground Points

    Vespa GTS Super 300 ie (2008) Electrical system 8. Fuel level transmitter - Remove the fuel tank to reach it. 7. Oil pressure sensor - Remove the right side fairing to reach it. 22. Battery - Remove the rear central cover to reach it.

  • Page 68: Electrical System Installation

    Vespa GTS Super 300 ie (2008) Electrical system There is another ground point "B" on the starter motor. Electrical system installation ELE SYS - 68...

  • Page 69: Front Side

    Vespa GTS Super 300 ie (2008) Electrical system Front side 1. Saddle opening switch 2. Pre-installations ELE SYS - 69...
  • Page 70 Vespa GTS Super 300 ie (2008) Electrical system 3. Insert in clamp 4. Fuse box 5. From the wire unit 1. Front left turn indicator connector 2. Front right turn indicator connector 3. Electric fan connector 4. Turn indicator control device...
  • Page 71 Vespa GTS Super 300 ie (2008) Electrical system 1. Right turn indicator connector 2. From regulator 3. Wire unit - regulator connection 4. To the immobilizer aerial 5. Light remote control 6. Electric fan remote control 7. To key switch 8.
  • Page 72 Vespa GTS Super 300 ie (2008) Electrical system 9. Voltage regulator 1. Immobilizer aerial 2. Foldable clamp to hold cables 3. Battery negative terminal ELE SYS - 72...
  • Page 73 Vespa GTS Super 300 ie (2008) Electrical system 4. Battery positive terminal 5. Flywheel - regulator connection 1. To stop switch 2. To turn indicator switch 3. To light switch 4. To horn button 5. To instrument panel 6. To headlight 7.

  • Page 74: Back Side

    Vespa GTS Super 300 ie (2008) Electrical system Back side 1. To HV coil 2. Foldable clamp 3. Foldable clamps to hold the red sheathing 4. Diagnostic socket 5. Starter remote control ELE SYS - 74...
  • Page 75 Vespa GTS Super 300 ie (2008) Electrical system 1. Rear right turn indicator 2. Cable guide 3. To rear light 4. Rear left turn indicator ELE SYS - 75...
  • Page 76 Vespa GTS Super 300 ie (2008) Electrical system 1. Fuse box 2. Remote control switch 3. Ground lead clamping to chassis 4. Oil pressure sensor 5. Lambda probe connector 6. Lambda sensor 7. To wire unit 8. To the spark plug 9.
  • Page 77 Vespa GTS Super 300 ie (2008) Electrical system 1. To flywheel 2. To saddle opening actuator 3. Fuse box 4. Foldable clamp to hold cables 5. Clamp 6. Injector connector 7. To HV coil 8. To front wire unit 9. To rear turn indicators 10.To fuel gauge and fuel tank...
  • Page 78 Vespa GTS Super 300 ie (2008) Electrical system 1. Battery positive terminal 2. Battery negative terminal 3. Thermistor 4. Starter motor ground lead 5. Right turn indicator connector 6. Rear headlight assembly connector 7. Left turn indicator connector 8. Starter motor ground lead clamping 9.
  • Page 79 Vespa GTS Super 300 ie (2008) Electrical system Ignition 1. 12v-10Ah battery 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9. Fuse No. 2 - 15A 10. Fuses No. 6 - 7.5A 11. Fuse No. 3 - 15A 12.
  • Page 80 Vespa GTS Super 300 ie (2008) Electrical system Battery recharge and starting 1. 12v-10Ah battery 2. Starter relay 3. Starter motor 4. Starter button 5. Voltage regulator 6. Magneto flywheel 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9.
  • Page 81 Vespa GTS Super 300 ie (2008) Electrical system Level indicators and enable signals section 1. 12v-10Ah battery 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9. Fuse No. 2 - 15A 10. Fuses No. 6 - 7.5A 14.

  • Page 82: Devices And Accessories

    Vespa GTS Super 300 ie (2008) Electrical system Devices and accessories 1. 12v-10Ah battery 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9. Fuse No. 2 - 15A 10. Fuses No. 6 - 7.5A 11. Fuse No. 3 - 15A 12.
  • Page 83 Vespa GTS Super 300 ie (2008) Electrical system 41. Turn indicator switch 43. Pre-installation for anti-theft device Lights and turn indicators Key: 1. 12v-10Ah battery 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9. Fuse No. 2 - 15A 10.
  • Page 84 Vespa GTS Super 300 ie (2008) Electrical system 41. Turn indicator switch 42. 4 bulbs for turn indicators 12v-10w 44. 1 front daylight running light bulb 12v-5w 45. 1 rear daylight running light bulb 12v-5w 46. 1 license plate bulb 12v-5w...

  • Page 85: Checks And Inspections

    Vespa GTS Super 300 ie (2008) Electrical system 25. H.V. coil. 26. Fuel injector 27. Engine temperature sensor 28. Fuel pump 30. Injection electronic control unit 31. Immobilizer antenna 34. Instrument panel Checks and inspections This section is dedicated to the checks on the electrical system components.
  • Page 86 Vespa GTS Super 300 ie (2008) Electrical system The duration of the flash depends on the program- ming of the electronic control unit. If the LED is off regardless of the position of the ignition switch and/or the instrument panel is not initiated, check if: •...
  • Page 87 Vespa GTS Super 300 ie (2008) Electrical system 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 Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm.

  • Page 88: Diagnostic Codes

    Vespa GTS Super 300 ie (2008) Electrical system - Insert the MASTER key again and turn it to «ON» for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys (blue) can be pro- grammed at one time.
  • Page 89 Vespa GTS Super 300 ie (2008) Electrical system 1. Previously unused control unit - key inser- ted: a single 2 second flash is displayed, after which the LED remains off permanently. The keys can be stored to memory, the vehicle can be star- ted but with a limitation imposed on the number of revs.
  • Page 90 Vespa GTS Super 300 ie (2008) Electrical system 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 antenna wiring and change it if nec- essary.

  • Page 91: Stator Check

    Vespa GTS Super 300 ie (2008) Electrical system The three-phase alternator provides good recharge power and at low revs a good compromise is ach- ieved between generated power and idle stability. Stator check Checking the stator windings WARNING THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

  • Page 92: Voltage Regulator/Rectifier

    Vespa GTS Super 300 ie (2008) Electrical system 3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage. Electric characteristic Voltage ranging between 14.0 and 15.0V at 5000 rpm.
  • Page 93 Vespa GTS Super 300 ie (2008) Electrical system 7. Electronic control unit 8. Engine stop switch 9. Stop buttons 10. Fuse No. 6 11. Starter button 12. Starter motor WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

  • Page 94: Horn Control

    Vespa GTS Super 300 ie (2008) Electrical system Horn control 1. Battery 2. Fuse No. 1 3. Key switch contacts 4. Fuse No. 6 5. Horn button 6. Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
  • Page 95 Vespa GTS Super 300 ie (2008) Electrical system Turn signals system check 1. Battery 2. Fuse No. 1 3. Key switch contacts 4. Fuse No. 6 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 96 Vespa GTS Super 300 ie (2008) 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 97 Vespa GTS Super 300 ie (2008) Electrical system Lights list 1. Battery 2. Fuse No. 1 3. Fuse No. 3 4. Key switch contacts 5. Fuse No. 6 6. Fuse No. 7 7. Electronic control unit 8. Daylight running light bulbs and license plate light 9.
  • Page 98 Vespa GTS Super 300 ie (2008) 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, 3 and 6.
  • Page 99 Vespa GTS Super 300 ie (2008) Electrical system FUSES Specification Desc./Quantity Fuse No. 1 Capacity: 30 A Protected circuits: Battery recharge circuit, fuses No. 2-3-4. Live: Fuses No. 5-6-7 Fuse No. 2 Capacity: 15A Protected circuits: Injection load (via remote control), ECU.
  • Page 100 Vespa GTS Super 300 ie (2008) Electrical system Dashboard A = Digital clock B = Odometer C = Speedometer D = Injection warning light E = Engine oil pressure warning light F = Turn indicators G = High-beam warning light...

  • Page 101: Battery Installation

    Vespa GTS Super 300 ie (2008) Electrical system Battery installation VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF) WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL- PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CON- TACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
  • Page 102 Vespa GTS Super 300 ie (2008) Electrical system Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times.
  • Page 103 Vespa GTS Super 300 ie (2008) Electrical system d - Press the red button, as shown in figure. e - Press the "MF" black button to activate the bat- tery recharge Maintenance Free as shown in fig- ure. f - Check the ignition of the green LED indicated with a red arrow in figure.

  • Page 104: Diagnostics Connector

    Vespa GTS Super 300 ie (2008) Electrical system h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge pro-...
  • Page 105 Vespa GTS Super 300 ie (2008) Electrical system ELECTRONIC CONTROL UNIT CONNECTOR 1. H.V. COIL (Pink-Black) 2. Not connected 3. Not connected 4. Engine switch (Grey-Green) 5. Not connected 6. Live supply (Red-White) 7. Ground No. 1 (Black) 8. Not connected 9.
  • Page 106 Vespa GTS Super 300 ie (2008) Electrical system ENGINE TEMPERATURE SENSOR CONNEC- 1. Ground lead (Grey-Green) 2. Instrument panel (Green-Yellow) 3. Electronic control unit (Sky blue - Green) 4. Ground lead (Black) INJECTOR CONNECTOR 1. Power from solenoid (Black - Green) 2.

  • Page 107: Coil Connector

    Vespa GTS Super 300 ie (2008) Electrical system INSTRUMENT PANEL CONNECTOR «A» 1. Fuel level indicator (White-Green) 2. High-beam warning light (Violet) 3. Left indicator warning light (Pink) 4. Right indicator warning light (White-Blue) 5. Live supply (White) 6. Oil pressure sensor (Pink-White) INSTRUMENT PANEL CONNECTOR «B»...

  • Page 108: Diagnostic Instrument

    Vespa GTS Super 300 ie (2008) Electrical system ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. Ground lead (Black) 2. Right arrows (White-Blue) 3. Left arrows (Pink) 4. Battery-powered (Red-Blue) 5. Live supply (White) 6. Helmet compartment button pre-installation (Blue-Black) 7. Not connected 8.
  • Page 109 Vespa GTS Super 300 ie (2008) Electrical system COIL Function Allows generation of the electrical discharge on the spark plug, with an increase of voltage. Pinout: 1. Power from relay 2. Activation by control unit (control unit side PIN ELECTRICAL ERRORS H.V.
  • Page 110 Vespa GTS Super 300 ie (2008) Electrical system INJECTOR Function Provide the correct amount of fuel at the correct time. Operation / Operating principle Injector coil is excited for the petrol passage to open. Pinout: 1. Power from relay 2. Ground from control unit ELECTRICAL ERRORS Injector P0201 - shorted to positive / shorted to negative / open circuit.
  • Page 111 Vespa GTS Super 300 ie (2008) Electrical system Open circuit: circuit interruption. Troubleshooting Short circuit to positive: - Disconnect the injection relay, turn the key to ON and activate the relay through the diagnostics in- strument. - Verify the presence of voltage between relay connector PIN 86 and 85 toward the cabling.
  • Page 112 Vespa GTS Super 300 ie (2008) Electrical system - Carry out the check 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).

  • Page 113: Lambda Probe

    Vespa GTS Super 300 ie (2008) Electrical system Short circuit to negative: - Disconnect the sensor connector. - Check the sensor connector PIN 3 from ground insulation. - If there is no ground insulation restore the cabling. - If PIN 3 is insulated from the ground and the error persists, this means that there is a probable fault in the control unit.
  • Page 114 Vespa GTS Super 300 ie (2008) Electrical system - Check the continuity of the cable harness between the sensor connector and control unit connector: PIN 11 of the control unit - PIN 1 of the sensor and PIN 12 of the control unit - PIN 2 of the sensor. If necessary, restore the cable harness.

  • Page 115: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 116 Vespa GTS Super 300 ie (2008) Engine from vehicle This section describes the operations to carry out when removing the engine from the scooter. Exhaust assy. Removal - Remove the right and left fairings and the spoiler terminals. - Remove the Lambda probe from its support and disconnect it.
  • Page 117 Vespa GTS Super 300 ie (2008) Engine from vehicle - Remove the lambda probe from the manifold. CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle CAUTION SUPPORT THE VEHICLE ADEQUATELY.
  • Page 118 Vespa GTS Super 300 ie (2008) 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 119 Vespa GTS Super 300 ie (2008) 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 120 Vespa GTS Super 300 ie (2008) 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 121 Vespa GTS Super 300 ie (2008) 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 122 Vespa GTS Super 300 ie (2008) 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 123 INDEX OF TOPICS NGINE...

  • Page 124: Automatic Transmission

    Vespa GTS Super 300 ie (2008) Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.

  • Page 125: Removing The Driven Pulley Shaft Bearing

    Vespa GTS Super 300 ie (2008) Engine - Remove the 5 screws, found on two different lev- els, as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.

  • Page 126: Removing The Driven Pulley

    Vespa GTS Super 300 ie (2008) Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indica- ted in the photograph - Check the outer diameter of the roller does not...

  • Page 127: Inspecting The Clutch Drum

    Vespa GTS Super 300 ie (2008) Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic Max. value clutch housing Max. value: Ø 134.5 mm clutch housing standard value Standard value: Ø...

  • Page 128: Removing The Clutch

    Vespa GTS Super 300 ie (2008) Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
  • Page 129 Vespa GTS Super 300 ie (2008) Engine Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL- N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.
  • Page 130 Vespa GTS Super 300 ie (2008) Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Bearing housing, outside ø 47 mm - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 131 Vespa GTS Super 300 ie (2008) Engine Inspecting the driven sliding half-pulley - Remove the two seal rings and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the faying surface with the belt to make sure there are no flaws.

  • Page 132: Refitting The Driven Pulley

    Vespa GTS Super 300 ie (2008) Engine Refitting the driven pulley - Insert the new oil seals and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
  • Page 133 Vespa GTS Super 300 ie (2008) Engine Inspecting the clutch spring - Measure the length of the spring when it is re- laxed. Characteristic Standard length 123 mm Acceptable limit after use: 118 mm Refitting the clutch - Support the driven pulley spring compressor spe- cific tool with the control screw in vertical axis.
  • Page 134 Vespa GTS Super 300 ie (2008) Engine - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool.

  • Page 135: Removing The Driving Pulley

    Vespa GTS Super 300 ie (2008) Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width 19.5 mm Driving belt - standard width 21.3 ± 0.2 mm...
  • Page 136 Vespa GTS Super 300 ie (2008) Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
  • Page 137 Vespa GTS Super 300 ie (2008) Engine movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
  • Page 138 Vespa GTS Super 300 ie (2008) Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
  • Page 139 Vespa GTS Super 300 ie (2008) Engine End gear Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket.
  • Page 140 Vespa GTS Super 300 ie (2008) Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
  • Page 141 Vespa GTS Super 300 ie (2008) Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil seal, remove the transmission cov- er as described above. - Extract the driven pulley shaft from its bearing.
  • Page 142 Vespa GTS Super 300 ie (2008) Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 143 Vespa GTS Super 300 ie (2008) Engine Refitting the hub cover bearings In order to fit the hub box bearings, the engine crankcase and the cover must be heated with the special heat gun. - The three 15-mm bearings must be fitted using...

  • Page 144: Flywheel Cover

    Vespa GTS Super 300 ie (2008) Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the alignment dowels. - Seal the gasket of the breather pipe using black silicone sealant.

  • Page 145: Removing The Stator

    Vespa GTS Super 300 ie (2008) Engine Removing the hub cover - Remove the clip fixing the sleeve to the cylinder. - Remove the 10 clamps - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
  • Page 146 Vespa GTS Super 300 ie (2008) Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 to 4...

  • Page 147: Removing The Starter Motor

    Vespa GTS Super 300 ie (2008) Engine Removing the starter motor - Remove the two screws indicated in the figure - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft...
  • Page 148 Vespa GTS Super 300 ie (2008) Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the picture Specific tooling 020627Y Flywheel lock wrench Remove the plate indicated in the picture. - Remove the flywheel nut with its washer...
  • Page 149 Vespa GTS Super 300 ie (2008) Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel Seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.

  • Page 150: Removing The Intake Manifold

    Vespa GTS Super 300 ie (2008) Engine - Using the special flywheel lock wrench, tighten up the flywheel fixing nut to the prescribed torque - Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut...
  • Page 151 Vespa GTS Super 300 ie (2008) Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: transmission cover, drive pulley with belt, oil sump with spring...
  • Page 152 Vespa GTS Super 300 ie (2008) Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.

  • Page 153: Removing The Cam Shaft

    Vespa GTS Super 300 ie (2008) Engine Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes.

  • Page 154: Removing The Valves

    Vespa GTS Super 300 ie (2008) Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool. - Remove the lower spring supports.
  • Page 155 Vespa GTS Super 300 ie (2008) Engine Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the wrist pin N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.

  • Page 156: Removing The Piston

    Vespa GTS Super 300 ie (2008) Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin retainer ring onto the appropriate...
  • Page 157 Vespa GTS Super 300 ie (2008) Engine - By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres- sion ratio.

  • Page 158: Inspecting The Cylinder Head

    Vespa GTS Super 300 ie (2008) Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure.
  • Page 159 Vespa GTS Super 300 ie (2008) Engine Inspecting the valve sealings N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Inspecting the valves N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.

  • Page 160: Inspecting The Cam Shaft

    Vespa GTS Super 300 ie (2008) Engine COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH). Specific tooling 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft N.B.
  • Page 161 Vespa GTS Super 300 ie (2008) Engine - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley.
  • Page 162 Vespa GTS Super 300 ie (2008) Engine - Fit the timing chain guide slider. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading.
  • Page 163 Vespa GTS Super 300 ie (2008) Engine - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque. N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM- PRESSED AIR JET.

  • Page 164: Crankcase - Crankshaft

    Vespa GTS Super 300 ie (2008) Engine Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
  • Page 165 Vespa GTS Super 300 ie (2008) Engine CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH- INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.
  • Page 166 Vespa GTS Super 300 ie (2008) Engine - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking partic- ular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket be-...
  • Page 167 Vespa GTS Super 300 ie (2008) Engine - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposed the cylinder. - To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the figure.
  • Page 168 Vespa GTS Super 300 ie (2008) Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the picture. If it varies significantly from the driving depth indicated, it means that the stud bolt has yielded.

  • Page 169: Lubrication Circuit

    Vespa GTS Super 300 ie (2008) Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the picture, remove the stud bolt from its seat. Clean the threaded seat on the carter thoroughly.
  • Page 170 Vespa GTS Super 300 ie (2008) Engine ENG - 170...

  • Page 171: Oil Pressure Check

    Vespa GTS Super 300 ie (2008) Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check that the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
  • Page 172 Vespa GTS Super 300 ie (2008) Engine Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil seal using the screws provided. Specific tooling 020622Y Transmission-side oil seal punch - Screw the threaded bar onto the base of the tool and extract the oil seal.
  • Page 173 Vespa GTS Super 300 ie (2008) Engine - Orientate the oil seal by inserting the bracket which is part of the appropriate tool. - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you...
  • Page 174 Vespa GTS Super 300 ie (2008) Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control sprocket. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
  • Page 175 Vespa GTS Super 300 ie (2008) Engine - Check the clearance between the rotors in the position shown in the diagram using a feeler gauge. Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure.
  • Page 176 Vespa GTS Super 300 ie (2008) Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the cup washer. Tighten to the prescribed torque. -Fit the oil pump cover, by tightening the two screws to the prescribed torque.
  • Page 177 Vespa GTS Super 300 ie (2008) Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal.

  • Page 178: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 179 Vespa GTS Super 300 ie (2008) Injection INJEC - 179...
  • Page 180 Vespa GTS Super 300 ie (2008) 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 181 Vespa GTS Super 300 ie (2008) 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 182 Vespa GTS Super 300 ie (2008) Injection Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults. 2. The fuel system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release fitting of the fuel supply pipe, check that there are no naked flames.
  • Page 183 Vespa GTS Super 300 ie (2008) Injection C: Fuel system a. Faulty fuel pump b.Dirty fuel filter D: Ignition system a. Faulty spark plug b.Faulty coil c.Faulty screened cap E: Intake circuit a. Air filter dirty b.Dirty by-pass circuit c.Faulty stepper motor F: Other a.
  • Page 184 Vespa GTS Super 300 ie (2008) Injection 2. Not connected 3. Not connected 4. Engine switch (Grey-Green) 5. Not connected 6. Live supply (Red-White) 7. Ground No. 1 (Black) 8. Not connected 9. Battery-powered (Grey-Black) 10. Start-up signal (Orange-Blue) 11. Lambda probe positive (Sky blue-Black) 12.
  • Page 185 Vespa GTS Super 300 ie (2008) Injection EMS circuit diagram 1. Battery 12V - 12 Ah 2. Starter relay 3. Starter motor 4. Starter button 5. Voltage regulator 6. Magneto flywheel 7. Fuse No. 1 - 30A 8. Fuse No. 5 - 7.5A 9.

  • Page 186: Troubleshooting Procedure

    Vespa GTS Super 300 ie (2008) Injection 20. Radiator electric fan 23. Lambda probe 24. Engine speed sensor 25. H.V. coil. 26. Fuel injector 27. Engine temperature sensor 28. Fuel pump 29. Diagnosis socket 30. Injection electronic control unit 31. Immobilizer antenna 34.
  • Page 187 Vespa GTS Super 300 ie (2008) Injection Possible Cause Operation Shielded cap HV coil Speed-timing sensor Ignition advance Fuel system Fuel pressure (low) Injector capacity (low) Injector sealing (poor) Correctness of the parameters Coolant temperature Stepper throttle valve position intake air temperature (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve;...
  • Page 188 Vespa GTS Super 300 ie (2008) Injection Possible Cause Operation Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature...

  • Page 189: Fuel Supply System

    Vespa GTS Super 300 ie (2008) Injection Possible Cause Operation Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Spark plug power supply Spark plug Shielded cap HV cable HV coil Intake system Air filter Filter box (sealing) Intake sleeve (sealing)
  • Page 190 Vespa GTS Super 300 ie (2008) Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. Remove the fast-release fittings from the injector support. INJEC - 190...
  • Page 191 Vespa GTS Super 300 ie (2008) Injection Remove the injector connector. Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the MIU ECU connector. Remove the clip fixing the throttle body to the air cleaner bellows.
  • Page 192 Vespa GTS Super 300 ie (2008) Injection Remove the gas command fitting as indicated in the picture Refitting the butterfly valve To refit, perform the operations in the reverse or- der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45°...
  • Page 193 Vespa GTS Super 300 ie (2008) Injection Pump supply circuit 1. Battery 12V 2. Fuse No. 2 of 15A 3. 30A fuse No. 1 4. Key switch contacts 5. Fuse No. 5 of 7.5A 6. Injection load remote control 7. Fuel pump 8.

  • Page 194: Electrical Data

    Vespa GTS Super 300 ie (2008) Injection 9. Fuel injector 10.Electric fan solenoid When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied.
  • Page 195 Vespa GTS Super 300 ie (2008) Injection CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (RELAYS, CONTROL UNIT, FUSES ETC.). 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.
  • Page 196 Vespa GTS Super 300 ie (2008) Injection pump circuit6 Check, on switching to "ON", that there is battery voltage, for about two seconds, to the Black-Green cable of the pump connector and ground with pump connector disconnected. Otherwise, check the continuity of the Black-Green cable between the pump connector and the remote control base.
  • Page 197 Vespa GTS Super 300 ie (2008) Injection Check during regular operation by placing the ap- propriate tool between the pump and the injector. With the battery voltage> 12 V check that the fuel pressure is 2.5 BAR and that the input current is 1.4 to 1.8 A...
  • Page 198 Vespa GTS Super 300 ie (2008) Injection Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture. Remove the filter from the pump mounting...
  • Page 199 Vespa GTS Super 300 ie (2008) Injection Inspecting the injector circuit 1. Battery 12V 2. Fuse No. 2 of 15A 3. 30A fuse No. 1 4. Key switch contacts INJEC - 199...
  • Page 200 Vespa GTS Super 300 ie (2008) Injection 5. Fuse No. 5 of 7.5A 6. Injection load relay 7. Fuel pump 8. H.V. coil. 9. Fuel injector 10.Electric fan solenoid 11.Coolant electric pump Check the resistance at the injector ends: 14.5 ± 5% Ohm Check that the injection load 15A fuse No.
  • Page 201 Vespa GTS Super 300 ie (2008) 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. 2 15 A) and the remote control base.
  • Page 202 Vespa GTS Super 300 ie (2008) Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 34 of the interface wiring and the injector connector Switch to «ON» and check if there is voltage, with...
  • Page 203 Vespa GTS Super 300 ie (2008) Injection With injector disconnected and the injector load relay disconnected, check the continuity of the Black-Green cable between the injector connector and solenoid base. Inspecting the injector hydraulics To carry out the injector check, remove the intake...
  • Page 204 Vespa GTS Super 300 ie (2008) 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 205 Vespa GTS Super 300 ie (2008) Injection Components location INJEC - 205...

  • Page 206: Component Layout

    Vespa GTS Super 300 ie (2008) Injection COMPONENT LAYOUT Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostic socket Fuel pump Water temperature sensor Fuel injector HV coil Flywheel - rpm timing sensor Lambda Probe Injection load remote control...
  • Page 207 Vespa GTS Super 300 ie (2008) Injection HT coil 1. Battery 12V 2. Fuse No. 2 of 15A 3. 30A fuse No. 1 4. Key switch contacts 5. Fuse No. 5 of 7.5A 6. Injection load remote control 7. Fuel pump 8.
  • Page 208 Vespa GTS Super 300 ie (2008) Injection 9. Fuel injector 10.Electric fan solenoid The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
  • Page 209 Vespa GTS Super 300 ie (2008) Injection Check the power supply line of the injection load solenoid energising coil: after switching to "ON", make sure there is battery voltage, for two sec- onds, between the Red-White cable and Black- Purple cable of the solenoid control base. If there...
  • Page 210 Vespa GTS Super 300 ie (2008) 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. 2 15 A) and the remote control base.
  • Page 211 Vespa GTS Super 300 ie (2008) 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 212 Vespa GTS Super 300 ie (2008) Injection Impianto elettroventilatore 1. Battery 12V 2. Fuse No. 2 of 15A 3. 30A fuse No. 1 4. Key switch contacts 5. Fuse No. 5 of 7.5A 6. Injection load relay 7. Fuel pump...
  • Page 213 Vespa GTS Super 300 ie (2008) Injection 8. H.V. coil. 9. Fuel injector 10.Electric fan solenoid 11.15A fuse No. 3 12.Electric fan motor Check that the 7.5A fuse No. 5 works properly With the key switch set to ON, check if there is +12...
  • Page 214 Vespa GTS Super 300 ie (2008) Injection Check the 15A Fuse No. 3 Check if there is +12 V voltage between the GREY cable of the electric fan remote control base and the ground connection. Check if the RED - BLACK cable between the fuse box under the seat and the fuse box in the glove- box compartment is not interrupted.

  • Page 215: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 216: Removing The Front Wheel

    Vespa GTS Super 300 ie (2008) Suspensions This section is dedicated to operations that can be carried out on the suspensions. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pic- ture. Locking torques (N*m)
  • Page 217 Vespa GTS Super 300 ie (2008) 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 Calliper to extract ø 15-mm bear-...

  • Page 218: Refitting The Front Wheel

    Vespa GTS Super 300 ie (2008) 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 219: Steering Column

    Vespa GTS Super 300 ie (2008) 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 220 Vespa GTS Super 300 ie (2008) 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 221 Vespa GTS Super 300 ie (2008) 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 222 Vespa GTS Super 300 ie (2008) 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 223 Vespa GTS Super 300 ie (2008) Suspensions - Refit the fifth wheel fitting and the dust gaiter on the steering bearing until they stop, using the spe- cific tool. Specific tooling 006029Y Punch for fitting steering bearing seat on steering tube...
  • Page 224 Vespa GTS Super 300 ie (2008) 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 225: Front Shock Absorber

    Vespa GTS Super 300 ie (2008) 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 226 Vespa GTS Super 300 ie (2008) 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 227 Vespa GTS Super 300 ie (2008) 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 228 Vespa GTS Super 300 ie (2008) 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 229 Vespa GTS Super 300 ie (2008) 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 230: Removing The Rear Wheel

    Vespa GTS Super 300 ie (2008) 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 231 Vespa GTS Super 300 ie (2008) 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 232 Vespa GTS Super 300 ie (2008) 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 233 Vespa GTS Super 300 ie (2008) 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 234 Vespa GTS Super 300 ie (2008) Suspensions Length of the swinging arm tube on the chas- sis 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 235 Vespa GTS Super 300 ie (2008) 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 236: Shock Absorbers

    Vespa GTS Super 300 ie (2008) 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 237 Vespa GTS Super 300 ie (2008) 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 238: Side Stand

    Vespa GTS Super 300 ie (2008) 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 239: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 240: Rear Brake Calliper

    Vespa GTS Super 300 ie (2008) Braking system This section è is dedicated to the description of the brake 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 241 Vespa GTS Super 300 ie (2008) 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 242: Front Brake Calliper

    Vespa GTS Super 300 ie (2008) 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 243 Vespa GTS Super 300 ie (2008) 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 244: Rear Brake Disc

    Vespa GTS Super 300 ie (2008) 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 245: Front Brake Disc

    Vespa GTS Super 300 ie (2008) 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 246: Front Brake Pads

    Vespa GTS Super 300 ie (2008) 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 247 Vespa GTS Super 300 ie (2008) 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 248: Rear Brake Pads

    Vespa GTS Super 300 ie (2008) 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 249 Vespa GTS Super 300 ie (2008) 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 250: Brake Fluid Level Check

    Vespa GTS Super 300 ie (2008) 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 251 Vespa GTS Super 300 ie (2008) 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 UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE.
  • Page 252 Vespa GTS Super 300 ie (2008) 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 253 Vespa GTS Super 300 ie (2008) 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 handlebar: 7 to 10 Nm...

  • Page 254: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 255: Circuit Diagram

    Vespa GTS Super 300 ie (2008) Cooling system Circuit diagram COOL SYS - 255...
  • Page 256 Vespa GTS Super 300 ie (2008) Cooling system COOL SYS - 256...
  • Page 257 Vespa GTS Super 300 ie (2008) Cooling system System bleed - Start up the engine until the operating tempera- ture is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to...
  • Page 258 Vespa GTS Super 300 ie (2008) Cooling system - Bring the coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleed screw Thermostat Removal - Remove the helmet compartment. - Place a + 2.0 l container under the vehicle to col- lect the coolant.
  • Page 259 Vespa GTS Super 300 ie (2008) Cooling system Check the temperature at which the thermostat starts to open: Heat up until the thermostat is completely open. 3) Replace the thermostat if it is not working prop- erly. CAUTION TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI- THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER.
  • Page 260 INDEX OF TOPICS CHAS HASSIS...
  • Page 261 Vespa GTS Super 300 ie (2008) Chassis This section è is dedicated 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 262 Vespa GTS Super 300 ie (2008) 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 263: Instrument Panel

    Vespa GTS Super 300 ie (2008) 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 264 Vespa GTS Super 300 ie (2008) 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 265 Vespa GTS Super 300 ie (2008) 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 266 Vespa GTS Super 300 ie (2008) 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 267 Vespa GTS Super 300 ie (2008) 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 268 Vespa GTS Super 300 ie (2008) 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 269 Vespa GTS Super 300 ie (2008) 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 270: Front Mudguard

    Vespa GTS Super 300 ie (2008) 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 271 Vespa GTS Super 300 ie (2008) 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 272 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 273 Vespa GTS Super 300 ie (2008) Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Handle fuel with care. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check...
  • Page 274 Vespa GTS Super 300 ie (2008) 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 275: Static Test

    Vespa GTS Super 300 ie (2008) 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 276 INDEX OF TOPICS TIME...
  • Page 277 Vespa GTS Super 300 ie (2008) Time This section is dedicated 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 278 Vespa GTS Super 300 ie (2008) Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 278...

  • Page 279: Cylinder Assy

    Vespa GTS Super 300 ie (2008) 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 - 279...

  • Page 280: Cylinder Head Assy

    Vespa GTS Super 300 ie (2008) 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 281: Cylinder Head Cover

    Vespa GTS Super 300 ie (2008) Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rockers valves - Replacement 001044 Camshaft - Replacement Cylinder head cover TIME - 281...

  • Page 282: Oil Filter

    Vespa GTS Super 300 ie (2008) 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 283: Driven Pulley

    Vespa GTS Super 300 ie (2008) 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 284: Oil Pump

    Vespa GTS Super 300 ie (2008) Time DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001155 Clutch housing - Replacement Oil pump OIL PUMP Code Action Duration 001125 Chain guide pads - Replacement...
  • Page 285 Vespa GTS Super 300 ie (2008) 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 - 285...

  • Page 286: Driving Pulley

    Vespa GTS Super 300 ie (2008) Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Drive belt - Replacement 001066 Driving pulley - Removal and refitting 001177 CVT rollers / sliders - Replacement 001141 Belt anti-flapping roller - Replace-...

  • Page 287: Transmission Cover

    Vespa GTS Super 300 ie (2008) 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 288: Electrical Start-Up

    Vespa GTS Super 300 ie (2008) 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 - 288...

  • Page 289: Flywheel Magneto

    Vespa GTS Super 300 ie (2008) Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - change TIME - 289...

  • Page 290: Butterfly Valve

    Vespa GTS Super 300 ie (2008) Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 290...

  • Page 291: Exhaust Pipe

    Vespa GTS Super 300 ie (2008) Time Exhaust pipe MUFFLER Code Action Duration 001009 Silencer - Replacement 001095 Silencer heatshield - Replacement 005138 Lambda probe - Replacement TIME - 291...

  • Page 292: Air Cleaner

    Vespa GTS Super 300 ie (2008) 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 293 Vespa GTS Super 300 ie (2008) 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 294: Centre-Stand

    Vespa GTS Super 300 ie (2008) Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 294...

  • Page 295: Rear Cover

    Vespa GTS Super 300 ie (2008) 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 296: Underseat Compartment

    Vespa GTS Super 300 ie (2008) Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 004011 Central chassis cover - Replacement TIME - 296...
  • Page 297 Vespa GTS Super 300 ie (2008) Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder mounting - Re- placement 005048 number plate holder - Replacement Mudguard TIME - 297...
  • Page 298 Vespa GTS Super 300 ie (2008) 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 299 Vespa GTS Super 300 ie (2008) 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 300: Rear Shock Absorber

    Vespa GTS Super 300 ie (2008) Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Removal and Refitting 003077 silencer/rear shock absorber support arm - Service TIME - 300...
  • Page 301 Vespa GTS Super 300 ie (2008) Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering bearing - Replacement 003073 Steering clearance - Adjustment TIME - 301...

  • Page 302: Handlebar Covers

    Vespa GTS Super 300 ie (2008) Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar covers - Replace- ment TIME - 302...

  • Page 303: Handlebar Components

    Vespa GTS Super 300 ie (2008) 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 304: Swinging Arm

    Vespa GTS Super 300 ie (2008) Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-chassis connection swinging arm - Replacement 004058 Silent block - Replacement TIME - 304...
  • Page 305 Vespa GTS Super 300 ie (2008) Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement Instrument panel TIME - 305...
  • Page 306 Vespa GTS Super 300 ie (2008) 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 307 Vespa GTS Super 300 ie (2008) 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 308: Turn Signal Lights

    Vespa GTS Super 300 ie (2008) 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 309: Front Wheel

    Vespa GTS Super 300 ie (2008) 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 310: Rear Wheel

    Vespa GTS Super 300 ie (2008) 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 311: Electric Devices

    Vespa GTS Super 300 ie (2008) 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 312 Vespa GTS Super 300 ie (2008) Time Transmissions RANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement TIME - 312...

  • Page 313: Front Suspension

    Vespa GTS Super 300 ie (2008) Time Front suspension FRONT SUSPENSION Code Action Duration 003011 Front shock absorber - Removal and Refitting 003045 Steering tube/Fork tube - Replace- ment 003010 Front suspension - Service 003035 Shock absorber mounting and brake...
  • Page 314 Vespa GTS Super 300 ie (2008) 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 315 Vespa GTS Super 300 ie (2008) Time Stickers RANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 315...
  • Page 316 Air filter: 49 Battery: 80, 90, 100, 101 Brake: 240, 242, 244–246, 248, 250, 251 Brake fluid: 250 Checks: 85 Electric: 311 Engine oil: 50 Fuel: 189, 197, 268, 298 Fuses: 98 Headlight: 55, 264 Horn: 94 Hub oil: 48 Identification: 8 Instrument panel: 263, 305 Luggage rack:...
  • Page 317 Start-up: Suspension: 58, 59, 313 Switch: Tank: 268, 298 Transmission: 10, 57, 124, 138, 287 Turn indicators: 83 Tyre pressure: Tyres: 15 Vehicle: 8, 116, 117...

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