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

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

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Summary of Contents for VESPA GTS Super 125 i.e.

  • Page 1 SERVICE STATION MANUAL 677714 EN Vespa GTS Super 125 i.e.
  • Page 2 SERVICE STATION MANUAL Vespa GTS Super 125 i.e. The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &...
  • Page 3 SERVICE STATION MANUAL Vespa GTS Super 125 i.e. This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio 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 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. 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. 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 1170 mm...
  • Page 9 Vespa GTS Super 125 i.e. Characteristics Engine DATA Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Cubic 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 Vespa GTS Super 125 i.e. 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. Characteristics CHECKING RELAYS «A» OPERATING AS CIR- CUIT 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 relay.

  • Page 12: Light Switch

    Vespa GTS Super 125 i.e. Characteristics LIGHT SWITCH STARTER BUTTON IGNITION SWITCH 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 125 i.e. 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 the pins: 100 to 150 Ohm at approx.
  • Page 14 Vespa GTS Super 125 i.e. Characteristics STATOR Power: 450 W Resistance between terminals: 0.2 - 1 Ohm terminal insulation from ground Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Type Unitised body made of stamped plate Front suspension Single arm suspension (cantilever wheel) fitted with a double-...
  • Page 15 Vespa GTS Super 125 i.e. 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 Front tyre pressure (when cold) 1.8 bar...
  • Page 16 Vespa GTS Super 125 i.e. 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 125 i.e. 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. 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...
  • Page 19 Vespa GTS Super 125 i.e. 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). Check the size of the sealing ring opening: Compression ring 0.15 - 0.30 mm.
  • Page 20 Vespa GTS Super 125 i.e. 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 - 56.966...
  • Page 21 Vespa GTS Super 125 i.e. 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. Characteristics Characteristic Axial crankshaft/crankcase clearance: 0.5 - 0.40 mm CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15...

  • Page 23: Cylinder Head

    Vespa GTS Super 125 i.e. 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. 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. 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. Characteristics - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the «V» shaped support. Characteristic Admissible limit: 0.03 mm Measure the valve guide.
  • Page 27 Vespa GTS Super 125 i.e. 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. During the grinding, keep the cylinder head with the valve axes in a horizontal position.
  • Page 28 Vespa GTS Super 125 i.e. Characteristics - Using a gauge, measure the height of the cams. 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. Characteristics - Check that the cam contact sliding block and the articulated register cap 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. 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 - 1.80...

  • Page 31: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...

  • Page 32: Specific Tools

    Vespa GTS Super 125 i.e. 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 005095Y Engine support 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on...
  • Page 33 Vespa GTS Super 125 i.e. 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. 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. 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. Tooling Stores code Description 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35-mm Adaptor 020359Y 42 x 47-mm Adaptor 020360Y 52 x 55-mm Adaptor 020363Y 20-mm guide 020364Y 25-mm guide TOOL - 36...
  • Page 37 Vespa GTS Super 125 i.e. 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 Piston assembly band...
  • Page 38 Vespa GTS Super 125 i.e. 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. 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 kit...
  • Page 40 Vespa GTS Super 125 i.e. Tooling Stores code Description 020428Y Piston position check mounting 020922Y Diagnosis Tool 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Bearing housing, outside ø 47 mm 020626Y Driving pulley lock wrench 001467Y013 Calliper to extract ø...
  • Page 41 Vespa GTS Super 125 i.e. Tooling Stores code Description 020627Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil seal punch 020480Y Petrol pressure check kit 020244Y 15-mm diameter punch...
  • Page 42 Vespa GTS Super 125 i.e. Tooling Stores code Description 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc TOOL - 42...

  • Page 43: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 44: Maintenance Chart

    Vespa GTS Super 125 i.e. 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. Maintenance (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. 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. 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 CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
  • Page 48 Vespa GTS Super 125 i.e. 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. Maintenance Engine oil filter Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the rec- ommended 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 specified torque.

  • Page 50: Braking System

    Vespa GTS Super 125 i.e. 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 AS TO AVOID THE COOLANT ESCAPING FROM THE EXPAN- SION TANK WHEN THE VEHICLE IS IN USE.
  • Page 51 Vespa GTS Super 125 i.e. 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. Maintenance Headlight adjustment Proceed as follows: 1. Position the vehicle in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the ve- hicle is perpendicular to the screen;...

  • Page 53: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 54 Vespa GTS Super 125 i.e. 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: Noisy Suspension

    Vespa GTS Super 125 i.e. 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. Brakes overheating...
  • Page 56 Vespa GTS Super 125 i.e. 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. 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. 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: Light Blue Bi: White Bl: Blue Gi:...
  • Page 60 Vespa GTS Super 125 i.e. Electrical system 4. Bulbs for turn indicators 5. Pre-installation for anti-theft device 6. Headlight with twin-filament bulb 7. Daylight running light bulbs and license plate light 8. Saddle opening actuator 9. Saddle opening switch 10. Ignition switch contacts 11.
  • Page 61 Vespa GTS Super 125 i.e. Electrical system Ar: Orange Az: Light Blue Bi: White Bl: Blue Gi: Yellow Gr:Grey Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple Components arrangement 9. Immobilizer aerial- Remove the shield back plate to reach it.
  • Page 62 Vespa GTS Super 125 i.e. 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 63 Vespa GTS Super 125 i.e. Electrical system 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 64 Vespa GTS Super 125 i.e. Electrical system 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. 40. Key switch contacts - Remove the shield back plate to reach them.
  • Page 65 Vespa GTS Super 125 i.e. Electrical system 7. Oil pressure sensor - Remove the right side fairing to reach it. 22. Battery - Remove the rear central cover to reach it. Conceptual diagrams Ignition 3. 12V-12Ah Battery 7. 30A Fuse 8.
  • Page 66 Vespa GTS Super 125 i.e. Electrical system 1. Instrument panel 13. Secondary fuses 18. Ignition switch contacts 23. Battery 24. Main fuses 27. Injection load relay 33. HV coil 38. Injection ECU 39. Immobilizer antenna Battery recharge and starting 1. Magneto flywheel 2.
  • Page 67 Vespa GTS Super 125 i.e. Electrical system 8. 15A Fuse 9. Stop light bulb 10. Key switch contacts 12. Stop buttons 30. Fuse 7.5A 31. Fuse 7.5A 45. Injector ECU THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
  • Page 68 Vespa GTS Super 125 i.e. Electrical system 25. Magneto flywheel 26. Voltage regulator 38. Injection ECU Level indicators and enable signals section 3. 12V-12Ah Battery 7. 30A Fuse 8. 15A Fuse 10. Key switch contacts 11. Engine stop switch 23. Instrument panel 24.

  • Page 69: Devices And Accessories

    Vespa GTS Super 125 i.e. Electrical system 1. Instrument panel 13. Secondary fuses 17. Engine stop switch 18. Ignition switch contacts 21. Starter relay 23. Battery 24. Main fuses 35. Engine temperature sensor 38. Injection ECU 39. Immobilizer antenna 40. Fuel level transmitter 41.
  • Page 70 Vespa GTS Super 125 i.e. Electrical system 14. Key switch contacts 15. Saddle opening switch 16. Saddle opening actuator 19. Pre-installation for anti-theft device 20. Turn indicator bulbs 21. Turn indicator switch 22. Turn indicator control device 23. Instrument panel 28.
  • Page 71 Vespa GTS Super 125 i.e. Electrical system 4. Bulbs for turn indicators 5. Pre-installation for anti-theft device 8. Saddle opening actuator 9. Saddle opening switch 10. Ignition switch contacts 13. Secondary fuses 14. Horn 15. Horn button 18. Ignition switch contacts 23.
  • Page 72 Vespa GTS Super 125 i.e. Electrical system 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. Headlight with twin-filament bulb 20.

  • Page 73: Checks And Inspections

    Vespa GTS Super 125 i.e. Electrical system 1. Instrument panel 2. Turn indicator control device 3. Turn indicator switch 4. Bulbs for turn indicators 6. Headlight with twin-filament bulb 7. Daylight running light bulbs and license plate light 11. Light switch 12.
  • Page 74 Vespa GTS Super 125 i.e. Electrical system Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys- tem. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit.
  • Page 75 Vespa GTS Super 125 i.e. Electrical system Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: • there is battery voltage between terminals 6-26 and terminal 6-frame earth (fixed power supply).
  • Page 76 Vespa GTS Super 125 i.e. Electrical system - diagnosis LED The diagnosis led also works as a blinking light to deter theft. This function is activated every time the ignition switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process.
  • Page 77 Vespa GTS Super 125 i.e. Electrical system After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture. Remove the protective base from the connector. With the ignition switch at ON check there is bat-...
  • Page 78 Vespa GTS Super 125 i.e. Electrical system THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture. Remove the protective base from the connector.
  • Page 79 Vespa GTS Super 125 i.e. Electrical system With MIU connector disconnected, check the con- tinuity between the Orange-White cable and pin 14 of the control unit. Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm.

  • Page 80: Diagnostic Codes

    Vespa GTS Super 125 i.e. 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 81 Vespa GTS Super 125 i.e. 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 82 Vespa GTS Super 125 i.e. 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 83: Stator Check

    Vespa GTS Super 125 i.e. 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 84: Voltage Regulator/Rectifier

    Vespa GTS Super 125 i.e. 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 85 Vespa GTS Super 125 i.e. Electrical system 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 86 Vespa GTS Super 125 i.e. Electrical system 1. Battery 2. Starter relay 3. Fuse No. 1 4. Fuse No. 3 5. Ignition switch contacts 6. Fuse No. 2 7. Electronic control unit 8. Starter motor 9. Stop buttons 10. Fuse No. 4 11.

  • Page 87: Horn Control

    Vespa GTS Super 125 i.e. Electrical system 5) Check the starter relay. 6) Check that the Red cable between the battery and the starter relay is not interrupted. Also check continuity between the latter and the starter motor. 7) Check the starter motor ground connection.
  • Page 88 Vespa GTS Super 125 i.e. Electrical system 3) With the key switch set to «ON» and the horn button pressed, check if there is voltage between the Yellow-Pink cable of the horn device and the ground connection. If there is not, check the cable har- nesses.
  • Page 89 Vespa GTS Super 125 i.e. Electrical system 5) Check the turn indicator switch contacts. 6) With the turn indicator switch pressed to the right, check if there is voltage between the White-Blue cable of the switch and the ground connection. If there is not, check the cable harnesses.
  • Page 90 Vespa GTS Super 125 i.e. Electrical system 1. Battery 2. Fuse No. 1 3. Fuse No. 5 4. Ignition switch contacts 5. Fuse No. 4 6. Fuse No. 7 7. Electronic control unit 8. Daylight running light bulbs and license plate light 9.
  • Page 91 Vespa GTS Super 125 i.e. Electrical system THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. 1. Battery 2. Fuse No. 1 3. Fuse No. 5 4. Ignition switch contacts 5. Fuse No. 4 6. Fuse No. 7 7.
  • Page 92 Vespa GTS Super 125 i.e. 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 93 Vespa GTS Super 125 i.e. Electrical system Specification Desc./Quantity 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 Protected circuits: Live services circuit Fuse 4 Current rating: 7.5A...
  • Page 94 Vespa GTS Super 125 i.e. 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 H = Headlight warning light...

  • Page 95: Battery Installation

    Vespa GTS Super 125 i.e. 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 96 Vespa GTS Super 125 i.e. 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 97 Vespa GTS Super 125 i.e. 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 98: Diagnostics Connector

    Vespa GTS Super 125 i.e. 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 99 Vespa GTS Super 125 i.e. 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 100 Vespa GTS Super 125 i.e. Electrical system INJECTOR CONNECTOR 1. Power from relay (Black - Green) 2. Electronic control unit (Red - Yellow) LAMBDA PROBE CONNECTOR 1. Positive from control unit (Sky blue - Black) 2. Control unit negative (White - Green) VOLTAGE REGULATOR CONNECTOR 1.

  • Page 101: Coil Connector

    Vespa GTS Super 125 i.e. Electrical system INSTRUMENT PANEL CONNECTOR «B» 1. Ground lead (Black) 2. Injection warning light (Brown-Black) 3. Low fuel warning light (Yellow-Green) 4. Water temperature (Grey-Black) INSTRUMENT PANEL CONNECTOR «C» 1. Immobilizer warning light (Red-Green) 2. Battery-powered (Red-Blue) 3.
  • Page 102 Vespa GTS Super 125 i.e. Electrical system IMMOBILIZER ANTENNA CONNECTOR 1. Key powered (Red-White) 2. Ground lead (Black) 3. Electronic control unit (Orange-White) FUEL LEVEL TRANSMITTER CONNECTOR 1. Fuel level indicator (White - Green) 2. Ground lead (Black) 3.Low fuel warning light (Yellow-Green) COOLANT PUMP CONNECTOR 1.
  • Page 103 Vespa GTS Super 125 i.e. Electrical system PICK-UP CONNECTOR 1. Control unit positive (Red) 2. Negative from control unit (Brown) 3. Oil pressure sensor (Pink-White) FUEL PUMP CONNECTOR 1. Not connected 2. Ground lead (Black) 3. Not connected 4. Not connected 5.Power from relay (Black - Green)
  • Page 104 Vespa GTS Super 125 i.e. Electrical system 21. Not connected 22. Injection load relay (Black-Purple) 23. Not connected 24. Habilitation electric fan (Blue-Yellow) 25. Injection warning light (Brown-Black) 26. Not connected 27. Not connected 28. Not connected 29. Engine speed sensor positive (Red) 30.
  • Page 105 Vespa GTS Super 125 i.e. Electrical system LAMBDA PROBE CONNECTOR 1. Positive from control unit (Sky blue - Black) 2. Control unit negative (White - Green) VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Black) 2. Ground lead (Black) INSTRUMENT PANEL CONNECTOR «A»...
  • Page 106 Vespa GTS Super 125 i.e. Electrical system INSTRUMENT PANEL CONNECTOR «C» 1. Immobilizer warning light (Red-Green) 2. Battery-powered (Red-Blue) 3. Lighting (Yellow - Black) 4. Key powered (White) H.V. COIL CONNECTOR 1. Power from relay (Black - Green) 2. Electronic control unit (Pink - Black)

  • Page 107: Diagnostic Instrument

    Vespa GTS Super 125 i.e. Electrical system FUEL LEVEL TRANSMITTER CONNECTOR 1. Fuel level indicator (White - Green) 2. Ground lead (Black) 3.Low fuel warning light (Yellow-Green) COOLANT PUMP CONNECTOR 1. Ground lead (Black) 2. Injection load relay (Black-Green) 3. Injection load relay (Black-Green) Diagnostic instrument THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
  • Page 108 Vespa GTS Super 125 i.e. Electrical system ENGINE TEMPERATURE SENSOR Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
  • Page 109 Vespa GTS Super 125 i.e. Electrical system THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. LAMBDA PROBE Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle...
  • Page 110 Vespa GTS Super 125 i.e. Electrical system - Check the insulation from the ground of PIN 2 of the sensor connector. If there is no insulation, restore the cable harness. - If PIN 1 and 2 are insulated from ground and the error persists, it means that there is a probable defect in the control unit.
  • Page 111 Vespa GTS Super 125 i.e. Electrical system THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. FUEL PUMP ELECTRICAL ERRORS Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit. Error cause Short circuit to positive:excessive voltage at PIN 22 of the control unit connector.
  • Page 112 Vespa GTS Super 125 i.e. Electrical system Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 1 of the control unit connector. Troubleshooting Short circuit to positive: - Disconnect the coil connector, turn the key to ON and activate the component through the diagnostics instrument.
  • Page 113 Vespa GTS Super 125 i.e. Electrical system - Disconnect the fan control relay and the control unit. - Verify ground insulation of the cable between the fan control relay (PIN 85) and the control unit (PIN 24). Restore the cabling if necessary.

  • Page 114: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 115 Vespa GTS Super 125 i.e. 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 116 Vespa GTS Super 125 i.e. 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 117 Vespa GTS Super 125 i.e. 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 118 Vespa GTS Super 125 i.e. 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 119 Vespa GTS Super 125 i.e. 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 120 Vespa GTS Super 125 i.e. 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 121 Vespa GTS Super 125 i.e. 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 122 INDEX OF TOPICS INJEC NJECTION...
  • Page 123 Vespa GTS Super 125 i.e. Injection INJEC - 123...
  • Page 124 Vespa GTS Super 125 i.e. Injection OMPONENT LAYOUT Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Fuel pump Water temperature sensor Fuel injector H.V. coil Engine speed sensor Lambda probe Injection load relay...
  • Page 125 Vespa GTS Super 125 i.e. 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 126 Vespa GTS Super 125 i.e. Injection Precautions Troubleshooting tips 1 A MIU failure is more likely to be due to the connections than to the components. Before troubleshooting the MIU system, carry out the following checks: A: Electrical power supply a.
  • Page 127 Vespa GTS Super 125 i.e. Injection 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 128 Vespa GTS Super 125 i.e. 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 11.(+) lambda probe...
  • Page 129 Vespa GTS Super 125 i.e. Injection 26.Ground lead THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. ELECTRONIC CONTROL UNIT CONNECTOR 1. H.V. COIL (Pink-Black) 2. Not connected 3. Not connected 4. Ground (Green-Black) 5. Not connected 6.
  • Page 130 Vespa GTS Super 125 i.e. Injection 28. Not connected 29. Engine speed sensor positive (Red) 30. Not connected 31. Lambda probe heater (White) 32. Not connected 33. Low beam lights automatic ignition enabling (White-Black) 34. Fuel injector (Red-Yellow) EMS circuit diagram 1.
  • Page 131 Vespa GTS Super 125 i.e. Injection 3. coolant temperature sensor 4. Immobilizer aerial 5. Stop switches 6. Fuse No. 1; 30A 7. Key switch contacts 8. Fuse No. 4; 7.5A 9. Fuse No. 3; 15A 10.Engine stop switch 11.Fuse No. 2; 7.5A 12.Injection load remote controls...
  • Page 132 Vespa GTS Super 125 i.e. Injection 1. Instrument panel 12. Headlight relay 13. Secondary fuses 17. Engine stop switch 18. Ignition switch contacts 21. Starter relay 23. Battery 24. Main fuses 26. Voltage regulator 27. Injection load relay 28. Electric fan relay 29.

  • Page 133: Troubleshooting Procedure

    Vespa GTS Super 125 i.e. Injection 37. Diagnosis socket 38. Injection ECU 39. Immobilizer antenna Troubleshooting procedure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient, repair according to the indications of the...
  • Page 134 Vespa GTS Super 125 i.e. Injection Engine stops at idle ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature...
  • Page 135 Vespa GTS Super 125 i.e. Injection Possible Cause Operation Coolant temperature Lambda probe Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system sealing (infiltrations) Intake manifold - head Throttle body - manifold...

  • Page 136: Fuel Supply System

    Vespa GTS Super 125 i.e. Injection Possible Cause Operation Intake air temperature indicator Ignition advance Fuel system Fuel level in the tank Fuel pressure Fuel filter Injector capacity Engine knocking PRESENCE OF KNOCKING (COMBUSTION SHOCKS) Possible Cause Operation Presence of faults detected by the self diagnosis...
  • Page 137 Vespa GTS Super 125 i.e. Injection Removing the butterfly valve Remove the helmet compartment. Remove the fuel piping clamping screw indicated in the figure. Remove the fast-release fittings from the injector support. INJEC - 137...
  • Page 138 Vespa GTS Super 125 i.e. 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 139 Vespa GTS Super 125 i.e. 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 140 Vespa GTS Super 125 i.e. Injection Pump supply circuit 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts INJEC - 140...

  • Page 141: Electrical Data

    Vespa GTS Super 125 i.e. Injection 5. 7.5A fuse No. 2 6. Injection load relay 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan relay 11.Coolant electric pump 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 142 Vespa GTS Super 125 i.e. Injection Purple cable between the pin 20 of the control unit and the solenoid base. N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (RELAYS, CONTROL UNIT, FUSES ETC.). INJEC - 142...
  • Page 143 Vespa GTS Super 125 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the relay base and ground. If there is none, check the continuity of the grey/ black cable between the fuse box (No. 3 15 A) and the relay base.
  • Page 144 Vespa GTS Super 125 i.e. 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 THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
  • Page 145 Vespa GTS Super 125 i.e. Injection 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts 5. 7.5A fuse No. 2 INJEC - 145...
  • Page 146 Vespa GTS Super 125 i.e. Injection 6. Injection load relay 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan relay 11.Coolant electric pump 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 147 Vespa GTS Super 125 i.e. Injection ple cable between the pin 22 of the control unit and the relay base. N.B. 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 relay base and ground.
  • Page 148 Vespa GTS Super 125 i.e. Injection 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 relay base.
  • Page 149 Vespa GTS Super 125 i.e. 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 150 Vespa GTS Super 125 i.e. 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 INJEC - 150...
  • Page 151 Vespa GTS Super 125 i.e. Injection Inspecting the injector circuit 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts 5. 7.5A fuse No. 2 6. Injection load relay 7. Fuel pump 8. HV coil...
  • Page 152 Vespa GTS Super 125 i.e. Injection 9. Fuel injector 10.Electric fan relay 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 153 Vespa GTS Super 125 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the relay base and ground. If there is none, check the continuity of the grey/ black cable between the fuse box (No. 3 15 A) and the relay base.
  • Page 154 Vespa GTS Super 125 i.e. 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 155 Vespa GTS Super 125 i.e. Injection With injector disconnected and the injector load relay disconnected, check the continuity of the Black-Green cable between the injector connector and relay base. THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
  • Page 156 Vespa GTS Super 125 i.e. Injection 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts 5. 7.5A fuse No. 2 INJEC - 156...
  • Page 157 Vespa GTS Super 125 i.e. Injection 6. Injection load relay 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan relay Check the resistance at the injector ends: 14.5 ± 5% Ohm Check that the injection load 15A fuse No. 3 works properly.
  • Page 158 Vespa GTS Super 125 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the relay base and ground. If there is none, check the continuity of the grey/ black cable between the fuse box (No. 3 15 A) and the relay base.
  • Page 159 Vespa GTS Super 125 i.e. 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 160 Vespa GTS Super 125 i.e. Injection With injector disconnected and the injector load relay disconnected, check the continuity of the Black-Green cable between the injector connector and relay base. Inspecting the injector hydraulics To carry out the injector check, remove the intake...
  • Page 161 Vespa GTS Super 125 i.e. 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. Slight oozing is normal.
  • Page 162 Vespa GTS Super 125 i.e. 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 163 Vespa GTS Super 125 i.e. Injection With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 20 - 29 is between 100 and 150 Ohm at an engine temperature of approxi- mately 20°...
  • Page 164 Vespa GTS Super 125 i.e. Injection HT coil 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts INJEC - 164...
  • Page 165 Vespa GTS Super 125 i.e. Injection 5. 7.5A fuse No. 2 6. Injection load relay 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan relay 11.Coolant electric pump The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
  • Page 166 Vespa GTS Super 125 i.e. Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load solenoid base with the control unit disconnected and the solenoid discon- nected.
  • Page 167 Vespa GTS Super 125 i.e. Injection INJEC - 167...
  • Page 168 Vespa GTS Super 125 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the relay base and ground. If there is none, check the continuity of the grey/ black cable between the fuse box (No. 3 15 A) and the relay base.
  • Page 169 Vespa GTS Super 125 i.e. Injection 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts 5. 7.5A fuse No. 2 INJEC - 169...
  • Page 170 Vespa GTS Super 125 i.e. Injection 6. Injection load relay 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan relay 11.Coolant electric pump The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
  • Page 171 Vespa GTS Super 125 i.e. Injection Check the efficiency of the injection load relay. Check the resistance of the energising coil be- tween pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the relay.
  • Page 172 Vespa GTS Super 125 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the relay base and ground. If there is none, check the continuity of the grey/ black cable between the fuse box (No. 3 15 A) and the relay base.

  • Page 173: Coolant Temperature Sensor

    Vespa GTS Super 125 i.e. Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor engine stop switch 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.
  • Page 174 Vespa GTS Super 125 i.e. Injection THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. EMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor INJEC - 174...
  • Page 175 Vespa GTS Super 125 i.e. Injection With the connector on the control unit side discon- nected, and the coolant temperature sensor con- nector connected, check that the resistance val- ues between pins 13 and 7 correspond to the engine temperature.
  • Page 176 Vespa GTS Super 125 i.e. Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020922Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the stop screw.

  • Page 177: Lambda Probe

    Vespa GTS Super 125 i.e. 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 178 Vespa GTS Super 125 i.e. 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. Place the tips of the multimeter between pins 4 (-)
  • Page 179 Vespa GTS Super 125 i.e. Injection With the engine running at idle speed, check that the voltage oscillates between 0V and 1V With the throttle valve completely open, the volt- age is approx. 1V. During the closing phase, the voltage is approx.
  • Page 180 Vespa GTS Super 125 i.e. Injection Impianto elettroventilatore 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 INJEC - 180...
  • Page 181 Vespa GTS Super 125 i.e. 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 182 Vespa GTS Super 125 i.e. 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 relay base and the ground connection.
  • Page 183 Vespa GTS Super 125 i.e. Injection 1. Battery 12V 2. 15A fuse No. 3 3. 30A fuse No. 1 4. Ignition switch contacts INJEC - 183...
  • Page 184 Vespa GTS Super 125 i.e. Injection 5. 7.5A fuse No. 2 6. Injection load relay 7. Fuel pump 8. HV coil 9. Fuel injector 10.Electric fan relay 11.Coolant electric pump 12.Fuse No. 5 of 7.5A 13.Electric fan motor Check that the 7.5A fuse No. 2 works properly...
  • Page 185 Vespa GTS Super 125 i.e. Injection Check the 7.5A Fuse No. 5 Check if there is +12 V voltage between the GREY cable of the electric fan relay base and the ground connection. Check if the GREY cable between the fuse box in the glove-box compartment and the electric fan relay base is not interrupted.

  • Page 186: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 187: Removing The Front Wheel

    Vespa GTS Super 125 i.e. 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) Wheel fixing screw...
  • Page 188 Vespa GTS Super 125 i.e. 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 189: Refitting The Front Wheel

    Vespa GTS Super 125 i.e. 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 190: Steering Column

    Vespa GTS Super 125 i.e. 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 191 Vespa GTS Super 125 i.e. 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 192 Vespa GTS Super 125 i.e. 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 193 Vespa GTS Super 125 i.e. 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 194 Vespa GTS Super 125 i.e. 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 195 Vespa GTS Super 125 i.e. 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 196: Front Shock Absorber

    Vespa GTS Super 125 i.e. 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 197 Vespa GTS Super 125 i.e. 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 198 Vespa GTS Super 125 i.e. 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 Shock-absorber - calliper bracket...
  • Page 199 Vespa GTS Super 125 i.e. 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 200 Vespa GTS Super 125 i.e. 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 201: Removing The Rear Wheel

    Vespa GTS Super 125 i.e. 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 202 Vespa GTS Super 125 i.e. 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 203 Vespa GTS Super 125 i.e. 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. Overhaul...
  • Page 204 Vespa GTS Super 125 i.e. 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 205 Vespa GTS Super 125 i.e. 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 206 Vespa GTS Super 125 i.e. 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 207: Shock Absorbers

    Vespa GTS Super 125 i.e. 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 208 Vespa GTS Super 125 i.e. 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 209: Side Stand

    Vespa GTS Super 125 i.e. 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 210: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 211: Rear Brake Calliper

    Vespa GTS Super 125 i.e. 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 212 Vespa GTS Super 125 i.e. 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 213: Front Brake Calliper

    Vespa GTS Super 125 i.e. 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 214 Vespa GTS Super 125 i.e. 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 215: Rear Brake Disc

    Vespa GTS Super 125 i.e. 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 216: Front Brake Disc

    Vespa GTS Super 125 i.e. 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 217: Front Brake Pads

    Vespa GTS Super 125 i.e. 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 218 Vespa GTS Super 125 i.e. 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 219: Rear Brake Pads

    Vespa GTS Super 125 i.e. 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. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS.
  • Page 220 Vespa GTS Super 125 i.e. 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 221: Brake Fluid Level Check

    Vespa GTS Super 125 i.e. 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 222 Vespa GTS Super 125 i.e. 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 223 Vespa GTS Super 125 i.e. 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 224 Vespa GTS Super 125 i.e. 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 225: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 226: Circuit Diagram

    Vespa GTS Super 125 i.e. Cooling system Circuit diagram 1. Coolant electric pump 2. Three-way thermostat 3. Electric fan COOL SYS - 226...
  • Page 227 Vespa GTS Super 125 i.e. Cooling system 4. Expansion tank 5. Radiator 6. coolant temperature sensor COOL SYS - 227...
  • Page 228 INDEX OF TOPICS CHAS HASSIS...
  • Page 229 Vespa GTS Super 125 i.e. 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 230 Vespa GTS Super 125 i.e. 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 231: Instrument Panel

    Vespa GTS Super 125 i.e. 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 232 Vespa GTS Super 125 i.e. 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 233 Vespa GTS Super 125 i.e. 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 234 Vespa GTS Super 125 i.e. 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 235 Vespa GTS Super 125 i.e. 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 236 Vespa GTS Super 125 i.e. 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 - Lift the saddle and remove the helmet compart-...
  • Page 237 Vespa GTS Super 125 i.e. 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 238: Front Mudguard

    Vespa GTS Super 125 i.e. 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 239 Vespa GTS Super 125 i.e. 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 240 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 241 Vespa GTS Super 125 i.e. 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 242 Vespa GTS Super 125 i.e. 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. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

  • Page 243: Static Test

    Vespa GTS Super 125 i.e. 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 244 INDEX OF TOPICS TIME...
  • Page 245 Vespa GTS Super 125 i.e. 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 246 Vespa GTS Super 125 i.e. Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 246...

  • Page 247: Cylinder Assy

    Vespa GTS Super 125 i.e. 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 - 247...

  • Page 248: Cylinder Head Assy

    Vespa GTS Super 125 i.e. 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 TIME - 248...

  • Page 249: Cylinder Head Cover

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

  • Page 250: Oil Filter

    Vespa GTS Super 125 i.e. 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 Code...

  • Page 251: Flywheel Cover

    Vespa GTS Super 125 i.e. 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 252: Driven Pulley

    Vespa GTS Super 125 i.e. 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 253 Vespa GTS Super 125 i.e. 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 - 253...

  • Page 254: Driving Pulley

    Vespa GTS Super 125 i.e. 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 255: Transmission Cover

    Vespa GTS Super 125 i.e. 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 TIME - 255...

  • Page 256: Electrical Start-Up

    Vespa GTS Super 125 i.e. 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 - 256...

  • Page 257: Flywheel Magneto

    Vespa GTS Super 125 i.e. Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - change TIME - 257...

  • Page 258: Butterfly Valve

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

  • Page 259: Exhaust Pipe

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

  • Page 260: Air Cleaner

    Vespa GTS Super 125 i.e. 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 261 Vespa GTS Super 125 i.e. 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 262: Centre-Stand

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

  • Page 263: Rear Cover

    Vespa GTS Super 125 i.e. 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 Duration...

  • Page 264: Underseat Compartment

    Vespa GTS Super 125 i.e. Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 004011 Central chassis cover - Replacement TIME - 264...
  • Page 265 Vespa GTS Super 125 i.e. Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder mounting - Re- placement 005048 number plate holder - Replacement Mudguard TIME - 265...
  • Page 266 Vespa GTS Super 125 i.e. 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 005010...
  • Page 267 Vespa GTS Super 125 i.e. 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 Expansion tank / radiator connecting...

  • Page 268: Rear Shock Absorber

    Vespa GTS Super 125 i.e. 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 - 268...
  • Page 269 Vespa GTS Super 125 i.e. Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering bearing - Replacement 003073 Steering clearance - Adjustment TIME - 269...

  • Page 270: Handlebar Covers

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

  • Page 271: Handlebar Components

    Vespa GTS Super 125 i.e. 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 002059...

  • Page 272: Swinging Arm

    Vespa GTS Super 125 i.e. Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-chassis connection swinging arm - Replacement 004058 Silent block - Replacement TIME - 272...
  • Page 273 Vespa GTS Super 125 i.e. Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement Instrument panel TIME - 273...
  • Page 274 Vespa GTS Super 125 i.e. 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 275 Vespa GTS Super 125 i.e. 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 Electric saddle opening device - Re-...

  • Page 276: Turn Signal Lights

    Vespa GTS Super 125 i.e. 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 277: Front Wheel

    Vespa GTS Super 125 i.e. 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 TIME - 277...

  • Page 278: Rear Wheel

    Vespa GTS Super 125 i.e. 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 002070...

  • Page 279: Electric Devices

    Vespa GTS Super 125 i.e. 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 Battery - change...
  • Page 280 Vespa GTS Super 125 i.e. Time Transmissions RANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement TIME - 280...

  • Page 281: Front Suspension

    Vespa GTS Super 125 i.e. 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 calliper - Replacement...
  • Page 282 Vespa GTS Super 125 i.e. 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- tem - Replacement...
  • Page 283 Vespa GTS Super 125 i.e. Time Stickers RANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 283...
  • Page 284 Air filter: 46 Battery: 66, 82, 94, 95 Brake: 211, 213, 215–217, 219, 221, 222 Brake fluid: 221 Checks: 73 Coolant: 173 Electric: 279 Engine oil: 47 Fuel: 136, 149, 236, 266 Fuses: 92 Headlight: 52, 232 Horn: 87 Hub oil: 45 Identification: 8 Instrument panel: 231, 273 Luggage rack:...
  • Page 285 Stand: 209 Start-up: Suspension: 55, 56, 281 Switch: Tank: 236, 266 Transmission: 10, 54, 255 Turn indicators: 72 Tyre pressure: Tyres: 15 Vehicle: 8, 115, 116...

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