VESPA 946 E4 EMEA 2021 Manual
  1. Manuals
  2. Brands
  3. VESPA Manuals
  4. Scooter
  5. 946 E4 EMEA 2021
  6. Manual

VESPA 946 E4 EMEA 2021 Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
MANUALE STAZIONE DI SERVIZIO
1Q000894
Vespa 946 E4-E5 EMEA-USA-ASIA (2021-)

Advertisement

Table of Contents
loading

Related Manuals for VESPA 946 E4 EMEA 2021

Summary of Contents for VESPA 946 E4 EMEA 2021

  • Page 1 MANUALE STAZIONE DI SERVIZIO 1Q000894 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-)
  • Page 2 STAZIONE DI SERVIZIO Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) The descriptions and images in this publication are given for illustrative purposes only. While the basic features as described and illustrated in this manual remain unchanged, Piaggio & C. S.p.A. reserves the...
  • Page 3 MANUALE STAZIONE DI SERVIZIO Vespa 946 E4-E5 EMEA-USA- ASIA (2021-) Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.

  • Page 5: Index Of Topics

    INDEX OF TOPICS PRE DE DELIVERY ECHNICAL TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS...
  • Page 6 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 7 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.
  • Page 8 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery - Front and rear stop light switches - Turn indicators and their warning lights - Instrument cluster lights - Instrument cluster: fuel gauge - Instrument panel warning lights - Horn - Starter TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
  • Page 9 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery For version EURO 5 Levels check Level check: - Hydraulic braking system fluid level. - Rear hub oil level. - Engine oil level Road test Test ride: - Position the vehicle on the stand and keep it running for at least 5 minutes...
  • Page 10 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery the grip conditions, contributing significantly to the maintenance of stability the vehicle. WARNING THE ASR SYSTEM IS BASED ON THE RECOGNITION OF SPEED DIFFERENCES BETWEEN FRONT AND REAR WHEEL. FOR THE SYSTEM TO PERFORM CORRECTLY IN...
  • Page 11 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery ation of the ASR could actually prevent the move- ment of the vehicle. N.B. AT VEHICLE START-UP THE ASR ICON FLASHES AT THE SAME FREQUENCY AS THE ABS WARNING LIGHT, INDI- CATING A DIAGNOSTIC PHASE OF THE SYSTEM. IF NO...
  • Page 12 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery CATING A DIAGNOSTIC PHASE OF THE SYSTEM. IF NO ERRORS ARE FOUND, THE ASR ICON AND THE ABS IN- DICATOR LIGHT SWITCH OFF AT THE SAME TIME ONCE THE VEHICLE SPEED EXCEEDS 5 Km/h (3 mph).
  • Page 13 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery IN THE EVENT OF MALFUNCTION OF THE BATTERY, THE ABS - ASR SYSTEM TURNS OFF. ASR SYSTEM CALIBRATION PROCEDURE (For the EURO 5 version). In order to maintain the effectiveness of the ASR system following the replacement of one or both tyres a calibration procedure of the system must be performed as follows on a straight flat stretch of road.

  • Page 14: Static Test

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery • Press the ASR on/off button «1» and one of the two brake levers simultaneously for at least 4 seconds. The activation process will be confirmed by the ASR icon «2» turning on with slow flashing.
  • Page 15 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery - Tyre pressure check - Fitting of mirrors and possible accessories Instruments start-up Key: A = Fuel level indicator icons B = Speedometer C = Multifunction indicator D = ASR Icon E = High-beam warning light...
  • Page 16 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery - Total odometer (ODO) - Partial odometer (TRIP) For this indicator «C» and for the speed indicator «B» the unit of measurement can be changed (from Km to Miles and from Kph to mph) with the following procedure: - move the key to «OFF»;...
  • Page 17 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery Specific operations for the vehicle N.B. AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT. ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS- TIC TOOL.
  • Page 18 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery Unscrew the screws that fasten the upper supports of the standard luggage rack. Remove the upper supports and remove the standard rear luggage rack. Fit the accessory luggage rack on the lower sup- ports, together with the side belts.
  • Page 19 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery Screw the fastening screws of the luggage rack upper supports and tighten them using the recom- mended torque. Locking torques (N*m) Luggage rack upper supports fixing screws 6 Nm Place the top case on the luggage rack, inside the mounting brackets.
  • Page 20 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery First the hook must be fastened, without the spe- cific tab (left side). Fasten the hook to the rubber guard on the lug- gage rack crosspiece. Operating on the opposite side of the luggage rack, fasten the hook on the rubber guard, using the specific tab to extend the elastic part.
  • Page 21 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery Using the specific tabs on the hooks of the two side belts, fasten them to the same rubber guards on the luggage rack cross piece. Check that you fitted the two side belts correctly.
  • Page 22 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Pre-delivery Remove the top case from the luggage rack. Refit the transversal belt inside the top case. Wrap the two side belts around the mounting brackets. After wrapping the belts, fasten the hooks to the rubber guards on the luggage rack's cross pieces.

  • Page 23: Index Of Topics

    INDEX OF TOPICS ECHNICAL...

  • Page 24: Safety Rules

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data 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 25: Vehicle Identification

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Vehicle identification Identification registration numbers are made up of a prefix and a number, stamped on the frame and on the engine. The serial number must always be indicated when ordering spare parts. We recommend checking that the frame registration number stamped on the vehicle corresponds with that on the vehicle documentation.

  • Page 26: Vehicle Data

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Engine number The engine number «B» is stamped on the rear part of the engine itself. Vehicle data FOR THE EUROPE-PAP-CHINA VERSION VEHICLE DATA Specification Desc./Quantity Frame Stamped plate body with welded structural reinforcements.

  • Page 27: Engine Data

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Specification Desc./Quantity Rear tire Tubeless 130/70 - 12'' 62P Front tire pressure (with passenger) 1.8 bar (1.8 bar) Rear tire pressure (with passenger) 2.0 bar (2.2 bar) Kerb weight 153 kg Maximum weight limit...
  • Page 28 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Specification Desc./Quantity Exhaust silencer Absorption-type exhaust silencer with catalytic converter. Emissions compliance EURO 5 (*) (*): according to the target market. 125 cm³ ENGINE - FOR THE PAP VERSION ³ ENGINE SPECIFICATIONS Specification Desc./Quantity...

  • Page 29: Engine Specifications

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Specification Desc./Quantity Fuel Unleaded gasoline E10 (95 R.O.N.) Exhaust silencer Absorption-type exhaust silencer with catalytic converter. Emissions compliance EURO 5 (*) (*): according to the target market. 150 cm³ ENGINE - FOR THE USA/LATAM VERSION...
  • Page 30 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data ³ ENGINE SPECIFICATIONS Specification Desc./Quantity Engine Single-cylinder, 4-stroke Piaggio LEM Engine capacity 155 cm³ Bore per stroke 58 x 58.6 mm Max. power 9.0 KW at 8,000 rpm MAX torque 12.0 Nm at 7,000 rpm Compression ratio 10.5: 1...
  • Page 31 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Name Torque in Nm Head blow by 3 to 4 (2.2 to 2.9 lb*ft) FLYWHEEL COVER Name Torque in Nm Pick-up screws 3 to 4 (2.2 to 2.9 lb*ft) Stator fixing screws 5 to 6 (3.7 to 4.4 lb*ft) (Loctite 242) Stator cable plates clamping screws 3 to 4 (2.2 to 2.9 lb*ft)

  • Page 32: Front Suspension

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Name Torque in Nm Brake fluid pipe-calliper fitting 20 to 25 (14.7 to 18.4 lb*ft) Rear brake calliper-pipe fitting 20 to 25 (14 to 18 lb*ft) Sensor bracket locking screw 3.4 to 3.8 (2.5 to 2.8 lb*ft) Sensor bracket locking screw 6 to 8 (4.4 to 5.9 lb*ft)
  • Page 33 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Assembly clearances Cylinder - piston assy. VERSION 125 cm³ CYLINDER - PISTON Specification Desc./Quantity Plunger diameter 51.961 (±0.014) mm Cylinder diameter 52 (+0.008 -0.020) mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder - piston 51.980 - 51.987...
  • Page 34 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Code Dimensions Assembly clearance Transmissionside half-shaft 18.1 (+0; -0.05) mm D = 0.20 - 0.50 Flywheel-side halfshaft 18.1 (+0; -0.05) mm D = 0.20 - 0.50...
  • Page 35 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data CRANKSHAFT Specification Desc./Quantity Crankshaft bearings: Standard diameter: Cat. 1 26.998 - 27.004 mm Crankshaft bearings: Standard diameter: Cat. 2 27.004 - 27.010 mm - To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and a good oil flow rate;...
  • Page 36 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data - The main bushings have 2 half-bearings, 1 with and 1 without the lubrication channel. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder.
  • Page 37 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data - The section of the oil feeding channels is also influenced by the driving depth of the bushings. - Visually check the wear of the bushings: in the coupling ends shown in the photo the bushing usu- ally keeps the original look, check in the rest of the bushing if there is evident removal of material.

  • Page 38: Cylinder Head

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data 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 39 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data HEAD BEARINGS Specification Desc./Quantity bearing «A» Ø 10.000 (+0.015) mm bearing «B» Ø 28.000 (+0.007 +0.028) mm bearing «C» Ø 42.000 (+0.009 +0.034) mm Measure the unloaded spring length Characteristic Standard length 35.8 mm - Clean the valve seats of any carbon residues.
  • Page 40 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Intake: 4.030 to 4.015 mm Exhaust: 4.975 - 4.960 mm - Check the deviation of the valve stem by resting it on a «V»...
  • Page 41 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. - Calculate the clearance between the valve and the valve guide. INTAKE Specification Desc./Quantity Standard clearance: 0.10 mm...
  • Page 42 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data - Check that the camshaft bearings exhibit no scores or abnormal wear. - Using a micrometer, measure the camshaft bear- ings. TANDARD DIAMETER Specification Desc./Quantity Camshaft check: Standard diameter Bearing A Ø: 25.002 to 25.015 mm Camshaft check: Standard diameter Bearing B diameter: 12.002 to 12.013 mm...
  • Page 43 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Technical Data Slot packing system Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.

  • Page 44: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 45 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Tooling PECIFIC TOOLS Stores code Description 020937Y Driven pulley lock 020938Y Drive pulley lock 020939Y Flywheel retainer 020940Y Flywheel cover oil seal gasket 020941Y Crankshaft timing adjustment tool 020942Y Piston protrusion check tool TOOL - 45...
  • Page 46 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Tooling Stores code Description 020933Y Flywheel extractor 020922Y Diagnosis Tool 020959Y Spanner for the bag hook 020335Y Magnetic mounting for dial gauge 020329Y Mity-Vac vacuum pump 020376Y Adaptor handle TOOL - 46...
  • Page 47 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Tooling Stores code Description 020441S 26 x 28 mm adaptor 020365Y 22 mm guide 020360S 52 x 55 mm adaptor 020375Y 28 x 30 mm adaptor 001467Y010 Driver for OD 25 mm bearings 001467Y013 Calliper to extract ø 15-mm bearings 001467Y008 Clamp to extract 17 mm ø...
  • Page 48 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Tooling Stores code Description 020271Y Tool for removing-fitting silent bloc 020439Y 17-mm guide 020456Y Ø 24 mm adaptor 020412Y 15-mm guide 020648Y Single battery charger 020331Y Digital multimeter TOOL - 48...
  • Page 49 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Tooling Stores code Description 020965Y ABS sensor bracket positioning pin TOOL - 49...

  • Page 50: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 51: Maintenance Chart

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.

  • Page 52: Recommended Products

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance km x 1,000 or (months) maximum 1 (1) 5 (5) 10 (10) 15 (15) 20 (20) 25 (25) 30 (30) Engine oil filter Valve clearance Clutch assembly Electrical system and battery Braking system Cylinder cooling system...

  • Page 53: Spark Plug

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Spark plug Remove the battery compartment cover. Remove the spark plug cap. Unscrew and remove the spark plug with the sup- plied wrench. Check the spark plug status and the electrode gap Characteristic Electrode gap «A»...
  • Page 54 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance During refitting of the central cover, ensure the correct position of the rubber protection. Refer to para- graph "Battery compartment - Inverter" in the "Bodywork" chapter. Hub oil Check Check oil level with the vehicle placed on the cen- tre stand and on a flat surface.

  • Page 55: Air Filter

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Locking torques (N*m) Hub oil drain screw 15 to 17 Insert through the level check hole the prescribed amount of oil. Recommended products Transmission oil 80W-90 Lubricant for gearboxes and transmissions. SAE 80W-90 API GL-4...

  • Page 56: Engine Oil

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance FILTER MORE OFTEN TO AVOID DAMAGING THE EN- GINE. Recommended products Oil for filter sponges Special product for im- pregnating sponge filtering elements. Engine oil In four-stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the head-engine block-piston assembly.
  • Page 57 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance oil of the recommended type for topping up and changing purposes. N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED. Recommended products Engine oil 5W -40 Synthetic-based lubricant for four-stroke engines. SAE 5W-40; JASO MA, MA2; API SL; ACEA A3...

  • Page 58: Engine Oil Filter

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Engine oil filter Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions.

  • Page 59: Checking The Ignition Timing

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Checking the ignition timing Position the engine at top dead centre (TDC) in compression. To do this, use the appropriate tools. Use the holes on the engine crankcase to secure the tool. Position the specific tool in the window between the flywheel pick-up references as illustrated in the figure.
  • Page 60 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Remove the vapours recovery pipe from the filter box. Remove the lower pin of the steering shock ab- sorber strut. Lower the body until the upper screws of the tappet cover are free. Unscrew the upper screws of the tappet cover and remove the cover to access the valve clearance registers.

  • Page 61: Braking System

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance -To check valve clearance, centre the reference marks of the timing system. - Use a feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clear-...

  • Page 62: Headlight Adjustment

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE LIQUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLU- ID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.
  • Page 63 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Anti-evaporation system Key: 1. Canister MAIN - 63...

  • Page 64: Removing System Components

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance 2. "Roll-over" valve 3. Safety valve 4. Pipe for connecting the fuel tank to the canister 5. Pipe for connecting the canister to the inlet fitting Removing system components After having removed the clamps, unscrew the fastening screw to release the system and bring the components inside the engine compartment.
  • Page 65 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Key: 1. Canister 2. "Roll-over" valve 3. Safety valve 4. Pipe for connecting the fuel tank to the canister 5. Pipe for connecting the canister to the inlet fitting After having installed the components, secure the pipes with new ties.

  • Page 66: Canister Inspection

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance Refit the canister support bracket on the chassis and tighten the fastening screws. Locking torques (N*m) Canister - Frame support bracket 12.0 ± 1.0 Nm Canister inspection The canister is essential to treat the hydrocarbons present in the volume of gas that escapes from the tank when there is an increase in internal pressure (tank heating induced by the cooling radiator, by the motor or by the external environment).
  • Page 67 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance To ensure that the engine works properly, it is necessary that the flow of air is not too intense, this is achieved by means of a restricted section 0.0354in (0.9 mm) formed in the socket on the intake manifold.
  • Page 68 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Maintenance • Prevent pollution of the canister with the liquid fuel (in case of fall of the vehicle, the valve must block the connection with the canister). To control the valve, it is necessary to remove it from the vehicle.

  • Page 69: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 70: Poor Performance

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Troubleshooting N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.

  • Page 71: Brakes Overheating

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Troubleshooting Possible Cause Operation Worn valve guides Check and replace the head unit if required Insufficient lubrication pressure LOW LUBRICATION PRESSURE Possible Cause Operation By-Pass remains open Check the By-Pass and replace if required. Carefully clean the By-Pass area.

  • Page 72: Noisy Suspension

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Troubleshooting Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.
  • Page 73 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Troubleshooting TROUBL - 73...

  • Page 74: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 75 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.
  • Page 76 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ELE SYS - 76...
  • Page 77 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 1. Headlight. (for connector see point 19). 2. Turn indicator control. Remove the leg shield back plate to reach it. 3. Injection load relay. Remove the leg shield back plate to reach it.
  • Page 78 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 5. Voltage regulator. Remove the leg shield back plate, the footrest and the legshield to reach it. 6. Front left turn indicator. Remove the leg shield back plate and the footrest to reach it.
  • Page 79 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system For version EURO 5 9. Fuses. 10. Starter motor relay. 11. Battery. Remove the battery compartment cover to reach 12. Lambda probe. (for connector see point 24). 13. Frame - engine cable harness connector «A».
  • Page 80 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 15. Electrical device right. (for connector see point 21). 16. Immobilizer. Remove the leg shield back plate to reach it. 17. USB socket (pre-installation for accesso- ry). 18. PMP connector (pre-installation for acces- sory).
  • Page 81 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 21. Electronic devices connectors. 22. Instrument panel connectors. Remove the leg shield back plate and the footrest to reach it. 23. Fuel pump connector. Remove the left side fairing to reach it. 24. Lambda probe connector.
  • Page 82 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 28. Rear right turn indicator. To reach it, remove the right side fairing. 29. Licence plate light. Remove the license plate light to reach it. 30. Rear light. To reach it, remove the right side fairing.
  • Page 83 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 32. Electric device left. (for connector see point 21). 33. Ignition switch connector. 34. Voltage regulator connector. 35. Boost. 36. Tip over sensor. Remove the leg shield back plate to reach it. 37. Front speed sensor connector.
  • Page 84 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 39. GPS connector (pre-installation for acces- sory). Remove the leg shield back plate and the footrest to reach it. 40. Engine temperature sensor. 41. Injector. Remove the right side fairing and the left side fair- ing to reach it.

  • Page 85: Instrument Panel

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 44. Rear wheel speed sensor. (for connector see point 27). 45. H.V. coil. Remove the right side fairing, the left side fairing, the air filter and the throttle body to reach it. Instrument panel...
  • Page 86 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system B = Speedometer C = Multifunction indicator D = ASR Icon E = High-beam warning light F = MIL warning light - Injection system failure warning light G = Immobilizer warning LED H = ABS warning light...
  • Page 87 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system IN THIS CASE, THE USER MUST IMMEDIATELY REMOVE FROM THE HEADLAMP ANYTHING THAT MAY INHIBIT COOLING AND STOP THE VEHICLE OR START DRIVING AS SOON AS POSSIBLE TO COOL THE HEADLAMP. N.B. FOR THE ENTIRE TIME THAT THE FAULT PERSISTS, ANY PRESSURES OF THE MODE BUTTON WILL BE IGNORED.

  • Page 88: Ground Points

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Ground points Front ground point - under the footrest on the right part of the vehicle. Engine - frame ground point - under the left spoiler and the left side fairing. Electrical system installation...

  • Page 89: Front Side

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Front side 1. Headlight, electrical devices and instrument panel cable harness 2. Left turn indicator cable harness 3. Right turn indicator cable harness 4. Headlight cable harness 5. Electrical devices cable harness 6. Instrument panel cable harness 7.

  • Page 90: Back Side

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 8. Main wiring harness 9. Battery negative cable harness 10. Engine main cable harness Back side 1. Engine main cable harness ELE SYS - 90...

  • Page 91: Checks And Inspections

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 2. Engine main cable harness 3. H.V. coil cable harness 4. ABS control unit cable harness 5. Rear wheel speed sensor cable harness 6. Engine temperature sensor and injector ca- ble harness 7. CDI control unit cable harness 8.
  • Page 92 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ignition switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process. When the ignition switch is turned to "ON", it inter- rupts the function of the Immobilizer lamp and a start enable lamp comes "ON".
  • Page 93 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Remove the protective base from the connector. With the ignition switch at «ON» check if there is battery voltage between the Red-White and Black cables. Virgin circuit When the ignition system is not codified, any key can operate the engine but it is limited to 2,000 rpm.

  • Page 94: Diagnostic Codes

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system - Insert the MASTER key again switching to ««ON» for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 3 service keys can be programmed at one time.
  • Page 95 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 2. Previously unused control unit - transpond- er absent or cannot be used: the LED is on permanently. In this condition no operations are possible including the start up of the vehicle. 3. Programmed control unit - the service key in (normal condition of use): a single 0.7-second...
  • Page 96 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ground on the serial line. Under normal operating conditions, after switching to «ON», the voltage read with a multimeter has medium values equal to 6-7 V. In case of code 1, the voltage will be about 11V high.

  • Page 97: Stator Check

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system This, in its turn, is connected directly to the ground and the battery's positive terminal passing through the 20A protective fuse. The three-phase alternator provides good recharge power and at low revs a good compromise is ach- ieved between generated power and idle stability.

  • Page 98: Voltage Regulator/Rectifier

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals.. 3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.
  • Page 99 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Fuses The electrical system is protected by fuses located under the central cover. To access them operate as described in the «Battery» paragraph. FUSES Specification Desc./Quantity Fuse no. 1 Capacity: 20 A Protected circuits: vehicle general Fuse no.

  • Page 100: Battery Installation

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system CAUTION PROCEED WITH CAUTION. DO NOT DAMAGE THE TABS AND/OR THEIR CORRESPONDING SLOTS. HANDLE THE PLASTIC AND PAINTED COMPONENTS WITH CARE, DO NOT SCRATCH OR IMPAIR THEM. During refitting of the central cover, ensure the correct position of the rubber protection. Refer to para- graph "Battery compartment - Inverter"...
  • Page 101 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG- ARETTES;...
  • Page 102 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system itself from the battery. Leave the battery to rest, without sealing the six cells, for at least 1 hour before charging. 6) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity.
  • Page 103 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 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: Cdi Control Unit

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note: To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery.

  • Page 105: Abs Control Unit

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 29. Rs - pick up + 30. N.C. 31. BiBL - Lambda heater 32. VeAr - Breather valve 33. BiNe - Lights ignition enabling 34. RsGi - injector ABS CONTROL UNIT 1. Ne - Ground 2.
  • Page 106 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 12. Ro - Left turn lights FRAME WIRING HARNESS CONNECTOR "A"_e5 1. MaNe - Engine management icon 2. RsBi - + key 3. RsVe - + Battery 4. ArBi - Immobilizer antenna 5. VeAr - Breather valve 6.
  • Page 107 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 14. RoRs - CAN H line 15. RoBi - CAN L line 16. Ar - Tip over sensor 17. GrVe - Sensor ground 18. Bi - "ASR" icon 19. Az - Voltage regulator 20.

  • Page 108: Roll-Over Sensor

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ENGINE WIRING HARNESS CONNECTOR "C" 1. Gi - Flywheel 2. Gi - Flywheel 3. Gi - Flywheel PRE-INSTALLATION GPS 1. GiNe - + Key 2. Ne - Ground 3. RsVe - + Battery USB PORT 1.

  • Page 109: Fuel Pump

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system FRONT SPEED SENSOR 1. AzNe - Ground 2. AzRs - Signal REAR SPEED SENSOR 1. MaNe - Ground 2. Ma - Signal AERIAL WITH IMMOBILIZER 1. RsBi - + key 2. Ne - Ground 3.
  • Page 110 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ELECTRICAL DEVICE RIGHT 1. RsBi - Stop button 2. BiNe - Stop button 3. RsBi - STARTER BUTTON 4. Vi - Starter button 5. Ve - MODE button 6. Ne - Ground 7. GrVe - Sensor ground 8.
  • Page 111 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system TAILLIGHT 1. Bi - Daylight running light 2. Ne - Ground 3. BiNe - Stop light LICENCE PLATE LIGHTING 1. Bi - + Key 2. Ne - Ground HORN 1. GrNe - Positive 2.
  • Page 112 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system INSTRUMENT PANEL CONNECTOR «B» 1. BiRs - Headlight diagnostic 2. BiNe - Lights ignition enabling 3. Ro - Oil pressure warning light 4. Bi - + Key 5. BiVe - Fuel level indicator 6.

  • Page 113: Ignition Switch

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system BATTERY NEGATIVE 1. Ne IGNITION SWITCH 1. Ar - Key ON 2. RsNe - + Battery 3. N.C. 4. N.C. VOLTAGE REGULATOR 1. RsNe - + Battery 2. Az - CTRL from the C.D.I. control unit 3.
  • Page 114 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system REAR LEFT TURN INDICATOR 1. Ro - Turn indicator enable control 2. Ne - Ground REAR RIGHT TURN INDICATOR 1. BiBL - Turn indicator enable control 2. Ne - Ground FRONT LEFT TURN INDICATOR 1.

  • Page 115: Magneto Flywheel

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system FRONT RIGHT TURN INDICATOR 1. BiBL - Turn indicator enable control 2. Ne - Ground 3. Bi - Daylight running light FOR USA VERSIONS ONLY 1. BiBL - + 2. Ne - Ground MAGNETO FLYWHEEL 1A.

  • Page 116: Engine Temperature Sensor

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ENGINE TEMPERATURE SENSOR 1. AzVe - Positive 2. Gr Ve - Negative H.V. COIL. 1. RoNe - Negative 2. NeVe - Positive LAMBDA PROBE WITH HEATER 1. VeBL - Lambda + 2. AzNe - Lambda - 3.

  • Page 117: Fuse Holder

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system STARTER MOTOR NEGATIVE 1. Engine/frame ground DIAGNOSIS SOCKET (for China market) 1. Not connected 2. Not connected 3. Ne - Ground 4. Rs - Battery power supply 5. ArNe - K Line FUSE HOLDER 1.

  • Page 118: Breather Valve

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 12. Ar - Ignition switched live power supply 13. Ar - Ignition switched live power supply 14. Ar - Ignition switched live power supply 15. N.C. 16. Rs - Battery power supply 17. Rs - Battery power supply 18.

  • Page 119: Diagnostic Instrument

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system ABS GROUND 1. Ne - Ground Diagnostic instrument STARTER COMMAND Function Commands engine starting through the injection control unit. Operation / Operating principle The starter button, the brake switches, the starter command relay and the injection control unit between PIN 5 and 10 are involved.

  • Page 120: Lambda Probe

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system 1. Injection ECU 2. Control unit ground Engine temperature sensor P0115 - open circuit or shorted to positive / shorted to negative. Error cause Open circuit or short circuit to positive: interruption of the circuit or excessive voltage at PIN 13 of the control unit connector.
  • Page 121 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system reach a high operating temperature: that is why there is a heating circuit inside. Pin-out: 1. Heater supply (1) 2. Heater ground (2) 3. Sensor signal + (3) 4. Sensor signal - (4)
  • Page 122 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Short-circuit to positive: excessive voltage at PIN 31 of the control unit connector. Short circuit to negative: lack of insulation from ground on the sensor connector PIN 1. Open circuit: circuit interruption. Troubleshooting Short-circuit to positive: - Disconnect the control unit connector and the sensor connector.
  • Page 123 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system Troubleshooting Short-circuit to positive: - Disconnect the injector connector, turn ignition switch to ON and activate the component using the diagnostic tool. - Verify the absence of voltage at the injector connector PIN 2; if present restore the wiring harness, otherwise proceed with the following checks.
  • Page 124 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Electrical system COIL Function Allows generation of the electrical discharge on the spark plug, with an increase of voltage. Pin-out: 1. Activation by control unit (control unit side PIN 2. Relay powered (PIN 87 relay side) ELECTRICAL ERRORS H.V.

  • Page 125: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 126 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.
  • Page 127 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle Remove the lambda probe cable from the lock on the bracket. Unscrew the screw of the clamp retaining the lambda probe cable to the crankcase. Unscrew the nuts fixing the silencer to the head.
  • Page 128 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle Removal of the engine from the vehicle - Remove the right and left side fairings. - Remove the battery cover. - Remove the complete silencer. - Remove the air filter. - Remove the rear mudguard.
  • Page 129 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle Free the stator and pick-up connectors from the fittings on the crankcase. Unscrew the screw retaining the clamp of the con- trol unit cable harness to the crankcase. Remove the ECU connector.
  • Page 130 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle Remove the injector connector. Remove the engine temperature sensor connec- tor. Remove the starter motor power supply cable by unscrewing the nut. Remove the ground cable on the starter motor by unscrewing the nut.
  • Page 131 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle Remove the fuel pipe paying attention to possible leaks due to the pressure in the pipes. Disconnect the throttle grip cables from the throttle body Remove the throttle body freeing the main cable harness by loosening the clamp fastening the manifold.
  • Page 132 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine from vehicle - Disconnect the rear ABS sensor connector by freeing it from the retaining clamps. - Remove the rear brake calliper as described in the corresponding chapter. To refit, follow the previous operations but in reverse order, observing the prescribed torques indicated in the SPECIFICATIONS chapter.
  • Page 133 INDEX OF TOPICS NGINE...

  • Page 134: Automatic Transmission

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine This section describes the operations to be carried out on the engine and the tools to be used. N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS"...
  • Page 135 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Unscrew the ten screws fixing the engine and re- move the transmission cover. See also Air duct Air duct - Unscrew the screws indicated and remove the duct. ENG - 135...

  • Page 136: Removing The Driven Pulley Shaft Bearing

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the driven pulley shaft bearing - Remove the Seeger ring. CAUTION PLACE THE COVER ON A SURFACE, REMOVING OR EX- CLUDING THE ALIGNMENT DOWELS. - Support the transmission cover adequately. - Using appropriate tools, remove the bearing.

  • Page 137: Removing The Driven Pulley

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Insert the Seeger ring. - Insert the alignment dowels if removed during disassembly. Removing the driven pulley - Undo the clutch fixing screw, recovering the lin- ing. - Remove the clutch drum. - Remove the driven pulley.

  • Page 138: Inspecting The Clutch Drum

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the clutch drum - Make sure that the clutch housing is not worn or damaged. - Measure the clutch housing inside diameter. Characteristic Clutch housing max. value Max. value: Ø 134.5 mm clutch housing standard value Standard value: Ø...

  • Page 139: Removing The Clutch

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the clutch - Prepare the locking tool for the driven pulley with the pins half-screwed in the tool set to «C». - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
  • Page 140 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FACING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 141 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the driven half-pulley bearing - Remove the retainer ring using two flat blade screwdrivers. - Using a hammer and pin, knock the ball bearing out as shown in the figure. - Remove the bearing and the rollers with the spe- cific extractor.

  • Page 142: Refitting The Driven Pulley

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting the driven pulley - Check that the faying surfaces of the 2 half-pul- leys and the belt do not show any signs of wear, scoring or grease. - Insert the new oil seals and O-rings on the mov- able half-pulley.

  • Page 143: Removing The Driving Pulley

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting the driven pulley - Reassemble the clutch housing and spacer. Drive-belt - Make sure the drive belt is not damaged and does not show abnormal wear. - Replace according to the scheduled maintenance table.
  • Page 144 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - remove the flat washer and the cup washer. - remove the stationary half-pulley and the washer. - disengage the belt. - remove the complete roller housing. Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A.
  • Page 145 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt. CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS...
  • Page 146 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting the transmission cover Follow the removal steps but in reverse order; be careful to tighten to the prescribed torques. Locking torques (N*m) Clutch cover retainer screws 10.8 - 12.8 End gear Removing the hub cover - Drain the oil of the final drive as described in the chapter «MAINTENANCE».
  • Page 147 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Remove the breather pipe. - Remove the cover. Removing the hub bearings Removing the clutch shaft bearing - Remove the Seeger ring. - Remove the oil seal from the opposite side. - Remove the bearing working from the external side and using the specific tools.
  • Page 148 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Wheel axle bearing removal - Remove the bearing using the specific tools Specific tooling 001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bear- ings Removing the wheel axle bearings - Support the hub cover properly to avoid damag- ing the sealing surface with the crankcase.
  • Page 149 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the hub shaft - Check the three shafts and the intermediate gear for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of faults, replace the damaged parts.
  • Page 150 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting the driven pulley shaft bearing - Use the heat gun to heat the bearing seat. - Set a new bearing using the specific equipment. - Insert a locking seeger. Specific tooling 020151Y Air heater...
  • Page 151 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting the hub cover bearings Fitting the Wheel axle bearing - Use the heat gun to heat the bearing seat. - Plant a new bearing using the equipment, apply grease on the adapter and guide in order to main- tain the position of the bearing during operation on the vertical axis.

  • Page 152: Flywheel Cover

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Tighten the screws «A» and «B» to the prescri- bed torque. - Restore the hub oil as described in the chapter MAINTENANCE Locking torques (N*m) Hub cover screws 24 - 27 See also...
  • Page 153 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the hub cover - Remove the oil dipstick. - Remove the sensor connector. - Unscrew the eleven fixing screws of the flywheel cover. - Remove the cover. - Remove the gasket. - Pay attention to the alignment dowels.

  • Page 154: Removing The Stator

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the stator - Remove the flywheel cover. - Unscrew the 2 flywheel fixing screws and the four pick-up fixing screws and wiring harness retainer screws. - Remove the flywheel and the pick-up complete with wiring harness.

  • Page 155: Removing The Starter Motor

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Tighten the screws and tighten to the specified torque. CAUTION TO AVOID DAMAGING THE OIL SEAL, USE THE SPECIFIC TOOL PRIOR TO POSITIONING THE FLYWHEEL COVER. Specific tooling 020940Y Flywheel cover oil seal gasket...
  • Page 156 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the flywheel magneto - Undo the screw indicated and remove the plate. - Install the specific tool and unscrew the retainer nut of the flywheel, recovering the washer. Specific tooling 020939Y Flywheel retainer...
  • Page 157 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate. - Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate.

  • Page 158: Removing The Intake Manifold

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Cylinder assy. and timing system Removing the intake manifold - The intake manifold is positioned on the head, loosen the clamps and remove the sleeve con- necting to the throttle body. - Undo the three manifold fixing screws and re- move it.
  • Page 159 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the rocker-arms cover - Remove the protective cover, undoing the three screws. - Remove the engine temperature sensor. - Undo the screw indicated. - remove the upper part of the cover. ENG - 159...
  • Page 160 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Unscrew the four screws and remove the tappet cover. ENG - 160...
  • Page 161 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the timing system drive - Before carrying out operations on the timing sys- tem we recommend positioning the engine at TDC in compression. To do this use the specific tools. - Use the holes on the engine crankcase to secure the tool.
  • Page 162 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Undo the two screws on the timing system gear. - Disengage the timing system gear and remove the camshaft control sprocket. - Remove the cylinder as described in section «Engine/Piston cylinder disassembly» After removing the head the camshaft control com- ponents can be removed: - Remove the inspection cover as described in sec.
  • Page 163 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Remove the control gear. - Remove the seal OR. - Remove the flat washer. CAUTION REMEMBER TO CORRECTLY POSITION THE SEAL OR IN THE REFITTING PHASE. ENG - 163...

  • Page 164: Removing The Cam Shaft

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Release the timing chain from the crankshaft. - Remove the control gear. See also Removal Removing the cylinder - piston assy. Removing the cam shaft - Undo the camshaft lock screw. - Remove the lock.

  • Page 165: Removing The Cylinder Head

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the cylinder head - Gradually loosen the four screws in crossed se- quence and recover the washers. - Undo the two external screws. ENG - 165...
  • Page 166 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Remove the cylinder head. - Remove the chain guide slider and the gasket. - Remove the gasket. N.B. ON ASSEMBLY PAY CLOSE ATTENTION TO THE TWO DOWELS. ENG - 166...

  • Page 167: Removing The Valves

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the valves - Use the specific tool to remove the cotters, cap and spring. CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS. CAUTION DURING ASSEMBLY, POSITION THE VALVE SPRINGS WITH THE GREEN COLOURED COIL FACING UPWARD.
  • Page 168 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Use the specific tool to remove the valve oil seal. Specific tooling 020431Y Valve oil seal extractor - Slide off the valve and remove the lower support. Removing the cylinder - piston assy.
  • Page 169 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) 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 170: Removing The Piston

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the piston - Fit the piston and pin onto the connecting rod, aligning the piston arrow towards the engine di- rection of rotation. CAUTION AT EVERY NEW MOUNTING USE RETAINER RING PINS. Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket.
  • Page 171 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) 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 172: Inspecting The Cylinder Head

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) 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 173 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.

  • Page 174: Valve Clearance Check

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine VALVE CLEARANCE CHECK - Remove the cover. - Position the engine to the TDC in compression. - Using a feeler gauge check the valve clearance. CAUTION - USE THE FEELER GAUGE LATERALLY, IN LINE WITH...
  • Page 175 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Cylinder Head Refitting the valves CAUTION MOUNT THE VALVE SPRINGS WITH THE GREEN COL- OURED COIL FACING UPWARD. - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.

  • Page 176: Inspecting The Cam Shaft

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the cam shaft N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Refitting the head and timing system components - Position the crankshaft to the TDC in compres- sion.
  • Page 177 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine - Tighten the nuts to an initial pre-torque of 9-11 - Tighten up the nuts by rotating 270.0±5.0° with crossed sequence. - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.

  • Page 178: Crankcase - Crankshaft

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Locking torques (N*m) Intake manifold fixing screws 10.8 - 12.8 Crankcase - crankshaft Splitting the crankcase halves - Undo the eight crankcase coupling screws. - Separate the crankcase halves while keeping the crankshaft in one of these two halves.
  • Page 179 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the crankshaft alignment N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts.
  • Page 180 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (3.2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
  • Page 181 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine CAUTION CAREFULLY CHECK THE CLEANING OF THE BY-PASS DUCT. CHECK THAT THE PISTON SLIDES BY HAND, FREELY AND WITHOUT STICKING. CAUTION IT IS ADVISABLE TO INSERT THE CRANKSHAFT IN THE FLYWHEEL SIDE CRANKCASE HALF TO PREVENT, WITH...
  • Page 182 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Lubrication Conceptual diagrams The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the cartridge filter «E» where there is also a safety valve «D».

  • Page 183: Oil Pressure Check

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1,750 rpm and the oil temperature at ~90°C, check that the oil pressure...
  • Page 184 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removal - Unscrew the three screws and remove them, complete with the copper gaskets. - Using pliers remove the door by acting on the appendices. - Remove the spacer and the O-ring. ENG - 184...

  • Page 185: Oil Pump

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting - Insert the components making sure to thoroughly grease the O-ring and the oil seal. - Follow the steps in reverse order taking care to tighten to torque. WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF...
  • Page 186 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removal - Remove the oil sump and the by-pass. - Remove the oil shield. - Preventing rotation, unscrew the water pump command screw and collect the washer. - Remove the oil pump command sprocket com- plete with chain.
  • Page 187 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Inspection - Remove the two screws and remove the oil pump cover. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible.
  • Page 188 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Refitting - Follow the steps in reverse order to the removal, tightening the screws to the specified torque. - Insert the oil pump. - Insert the control sprocket and the chain. N.B. FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY.
  • Page 189 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmis- sion chapter. - Drain the oil as described above.
  • Page 190 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) 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 191: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 192 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.
  • Page 193 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection 4. For troubleshooting, use a multimeter with an internal resistance of more than 10KW/V. Improper instruments may damage the control unit. The instruments to be preferred have a definition over 0.1V and 0.5W and an accuracy over 2%.
  • Page 194 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Terminals setup 1. H.V. coil 2. Boost 3. Tilting sensor 4. engine stop switch 5. Starter button 6. + Key 7. Ground 1 8. Stop buttons 9. + Battery 10. Start enable 11. Lambda + 12.

  • Page 195: Troubleshooting Procedure

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection EMS circuit diagram 1. Battery 6. Fuse no. 2 8. Fuse No. 1 9. Ignition switch 11. Fuse No. 7 18. Rear ground node 51. engine stop switch 56. Engine temperature sensor 57. Pick-up 58.
  • Page 196 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Engine does not start ENGINE DOES NOT START EVEN IF PULLED Possible Cause Operation Immobilizer enabling signal System not encoded System not efficient, repair according to the indications of the self-diagnosis Faults detected by self-diagnosis Pump relay H.V.
  • Page 197 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Possible Cause Operation Correctness of the parameters Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing (infiltrations)
  • Page 198 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Possible Cause Operation Exhaust system sealing (infiltrations) Manifold - head Manifold - silencer silencer welding Engine revs irregularly ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve...

  • Page 199: Fuel Supply System

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Engine knocking PRESENCE OF KNOCKING (COMBUSTION SHOCKS) Possible Cause Operation Faults detected by self-diagnosis Pump relay H.V. coil Injector Engine speed timing sensor Air temperature Engine temperature Lambda probe Ignition efficiency Spark plug Parameter reliability...
  • Page 200 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Refitting the injector - The injector on this vehicle is a twin head injector with angle different to 90°, an incorrect positioning of the injector in the throttle body can cause seri- ous malfunction; it must be observed that the pin of the spring is placed inside the recess in the in- jector body as shown in figure.
  • Page 201 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection DURING THE LIFTING OPERATIONS, PAY ATTENTION THAT THE CABLE HARNESS, TRANSMISSIONS AND PIPES ARE NOT TIGHTENED. Unscrew the screw locking the clamp retaining the crankcase to the control unit cable harness. Loosen the adjustment nut and remove the throttle grip cables.
  • Page 202 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Remove the throttle body. Refitting the butterfly valve - To refit, perform the removal operations in reverse. After the refitting proceed as follows - Turn the ignition switch "ON" - Wait 10 seconds - Turn the ignition switch "OFF"...
  • Page 203 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection 1. Battery 2. Fuse 2 - 10 A 3. Fuse 1 - 20 A 4. Ignition switch 5. Fuse 7 - 5 A 6. Injection load relay 7. Electronic control unit 8. Fuel pump...
  • Page 204 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Separate the lower part of the pump mounting as shown in the picture. Remove the filter from the pump mounting FITTING For the fitting proceed in reverse order paying attention to the fitting angle of the pump flange in the...
  • Page 205 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Inspecting the injector circuit 1. Battery 2. Fuse 2 - 10 A 3. Fuse 1 - 20 A 4. Ignition switch 5. Fuse 7 - 5 A 6. Injection load relay 7. Electronic control unit 8.
  • Page 206 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection TO INDICATE THE RELAY OF THE DESIRED FUNCTION, REFER TO THE PIN-CABLE COLOUR RELATIONSHIP WITH THE ATTACHED ELECTRIC SYSTEM DIAGRAM. Check the power supply line of the injection load relay energising coil: after switching to "ON", make...
  • Page 207 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection Switch to «ON» and check that, with the injector disconnected and the control unit connected, there is a voltage present between the Black-Green ca- ble of the injector connector and earth. With injector disconnected and the injector load relay disconnected, check the continuity of the Black- Green cable between the injector connector and relay base.
  • Page 208 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Injection - Check that the pins 20 and 29 of the control unit are insulated from each other and insulated from the ground. Specific tooling 020331Y Digital multimeter INJEC - 208...

  • Page 209: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 210: Removing The Front Wheel

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions Sospensioni anteriore This section is dedicated to operations that can be carried out on the suspensions. N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS"...
  • Page 211 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Remove the nut cover. - Remove the nut of the wheel axle. - Remove the wheel hub. WHEEL HUB SERVICE If, due to an excessive clearance, it is necessary to replace the bearings, proceed as follows.
  • Page 212 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - With the extractor and the bell remove the bear- ing on the outside. Specific tooling 001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bear- ings - Remove the oil seal of the bearing on brake disc side.
  • Page 213 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Use guide, adaptor and handle to drive the bear- ing into its seat as far as it will go and insert the oil seal. Specific tooling 020363Y 20-mm guide 020357Y 32 x 35-mm Adaptor...

  • Page 214: Refitting The Front Wheel

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions Refitting the front wheel - Proceed with the operations in the reverse order, paying attention to the tightening torques and check the distance between front speed sensor and tone wheel. In the event that it is not correct, insert a washer of 0.6 ±...

  • Page 215: Steering Column

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Remove the brakes piping paying attention to the brake fluid drainage. - Remove the front and rear brake pumps. - Undo the screw indicated and remove the rear handlebar cover. Refitting - Proceed with the operations in the reverse order,...

  • Page 216: Front Shock Absorber

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Remove the lower ring and the upper ball bearing - Slide off the steering pipe from the headstock. Overhaul If you have to replace the bearings, due to an excessive clearance, proceed as follows: - Remove the lower steering bearing using the extractor.
  • Page 217 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Loosen the screws fixing the front brake pipe re- tainer clamp and the front speed sensor cable in order to reach the upper clamps. - Unscrew the upper fixing nuts and remove the shock absorber.
  • Page 218 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) 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 219 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Assemble a new roller bearing on the shock ab- sorber side and move it until it stops using the specific tool. Specific tooling 020365Y 22 mm guide 020375Y 28 x 30 mm adaptor...

  • Page 220: Removing The Rear Wheel

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Refit the parts in reverse order of the removal operation. CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK, LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch...

  • Page 221: Refitting The Rear Wheel

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions WHEEL HUB REMOVAL - Remove the rear brake calliper. - Remove the cotter pin. - Remove the cover of the wheel hub nut and un- screw the nut. - Remove the wheel hub paying attention to the present thickness.
  • Page 222 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Tighten the screws fixing the wheel to the hub. Locking torques (N*m) Rear wheel to hub fixing screws 20 - 25 Swing-arm Removal - Support the vehicle adequately. - Unscrew the nut of the engine swinging arm pin and remove the pin.
  • Page 223 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Remove the seeger ring locking the silentblock. - Undo the fixing screw of the silentblock bracket and remove the bracket. Overhaul Proceed with the service if there is an excessive clearance of the motor regarding the body.
  • Page 224 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Remove the bearings from both sides of the swinging arm using an extractor and bell. Specific tooling 001467Y010 Driver for OD 25 mm bearings 001467Y013 Calliper to extract ø 15-mm bear- ings - Remove the plastic thickness of the swinging arm on the engine side.
  • Page 225 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Remove the silentblock from the bracket using an appropriate extractor. Specific tooling 020271Y Tool for removing-fitting silent bloc - Insert the silentblock with the chamfering facing the bracket. - Place the silentblock in the bracket using the specific tool.

  • Page 226: Shock Absorbers

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions For both bearings of the swinging arm on the frame side proceed as follows: - Use handle, adaptor and guide to drive the bear- ing into its seat. Specific tooling 020412Y 15-mm guide 020456Y Ø 24 mm adaptor 020376Y Adaptor handle - Insert the axis into the swinging arm on the engine side and then insert the thickness.
  • Page 227 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions Removal - Support the vehicle adequately. - Undo and remove the screw fixing the strut to the bracket. - Unscrew the fixing screw of the shock absorber to the linkage. - Unscrew the screw fixing the strut to the linkage of the shock absorber.

  • Page 228: Centre-Stand

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions - Unscrew the screws fixing the shock absorber to the body. Refitting Proceed the removal operations but in the reverse order, observing the prescribed tightening torques. REAR SHOCK ABSORBER TIGHTENING TORQUES Name Torque in Nm...
  • Page 229 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Suspensions Locking torques (N*m) Centre stand axis nut 40 - 45 SUSP - 229...

  • Page 230: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 231: Operating Diagram

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. TO REFER TO THE UNIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO-SAXON SYSTEM, SEE THE "CHARACTERISTICS" CHAPTER.
  • Page 232 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system -if at least one malfunction is detected, the ABS warning light turns on permanently. The ABS system is disabled! The system is still fully functional like any other brake system without ABS. The detection of malfunctions may require more or less time depending on the type of fault.
  • Page 233 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system MODULATOR REMOVAL - Remove the right side fairing and the left side fairing. - Disconnect the connector of the ABS control unit. - Undo the screws fixing the control unit to the bracket.

  • Page 234: System Asr

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system ODULATOR TIGHTENING TORQUES Name Torque in Nm Bracket screw ABS control unit 6 - 8 Bracket nuts ABS control unit 20 - 25 Screws fixing ABS control unit to bracket 8 - 10...
  • Page 235 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system For version EURO 5 • BUTTON «1» (with the engine run- ning): activation / deactivation. • ICON «2»: operating indication icon. Flashing mode: - Lit with moving vehicle: the system is working, but is not active (normal condition).
  • Page 236 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system • BUTTON «1» (with the engine run- ning): activation / deactivation. • ICON «2»: operating indication icon. Flashing mode: - Off with the vehicle in gear:: the system is work- ing, but is not active (normal condition).
  • Page 237 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system THE ASR SYSTEM IS ACTIVATED AT EVERY "ON" POSI- TIONING OF THE IGNITION SWITCH. IF DISABLED BY THE USER, THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF THE VEHICLE IS OFF, BY USING THE ENGINE STOP SWITCH;...
  • Page 238 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system Please note that the request for activation of the procedure (steps 1 to 4) must be completed within 60 sec from ignition on the engine. • It is necessary that the diagnostic phase of the ASR systems and ABS is complete: for this purpose, after the key ON, ride a short distance above 5 km/h and wait for the flashing of the ABS indicator light to stop;...
  • Page 239 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system • In case of failure to complete the procedure within 2 minutes the ASR icon «2» will stay on steady and the ASR will remain off until the panel is turned off (key off).
  • Page 240 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system Removal - Adequately support the vehicle and remove the front wheel. - Undo the screws indicated. N.B. SHOULD IT BE NECESSARY TO REPLACE THE CALLIP- ER, FIRST LOOSEN THE JOINT CONNECTING THE PIPE TO THE BRAKE CALLIPER.
  • Page 241 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system Locking torques (N*m) Brake disc screws 8 to 10 SPEED SENSOR BRACKET FITTING - Remove the speed sensor. - Loosen the screw of the speed sensor bracket. - Loosen the fixing nut of the speed sensor brack- - Insert the special tool in the speed sensor hous- ing and tighten the contact plane.
  • Page 242 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system - Insert the special tool with the arrow facing up- wards in one of the holes of the tone wheel. - Tighten the fixing nut of the speed sensor bracket to the prescribed torque.

  • Page 243: Disc Inspection

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system - Insert the speed sensor and tighten the locking screw. Locking torques (N*m) Sensor bracket locking screw 3.4 - 3.8 - Check that the distance «X» between brake disc and sensor is correct; otherwise insert the calibra- ted washers between the sensor and bracket.

  • Page 244: Front Brake Disc

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system 3.5 MM Max. deviation allowed: 0.1 mm Front brake disc Removal - Remove the front wheel hub. - Undo the screws indicated. Refitting - Carry out the removal steps but in the reverse order, paying attention to the prescribed torques.
  • Page 245 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system - Remove the rear brake calliper. - Place the dial gauge on the disc outer edge. - Make the wheel hub turn and check the disc de- viation. Specific tooling 020335Y Magnetic mounting for dial gauge...
  • Page 246 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system Removal - Remove the rear wheel. - Remove the brake calliper. - Remove the locking spring of the pin. - Remove the pin. - Remove the spring. - Remove the pads. - Check that there are no faults or warping. If there are, replace them.
  • Page 247 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system - The replacement must be made with greater re- sidual thickness if the pad has not worn evenly. A 0.5 mm thickness difference in the residual fric- tion material is permitted Refitting - Insert the brake pads.
  • Page 248 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system CAUTION THE BLEEDING OPERATIONS OF THE BRAKING SYS- TEM, EVEN FOR THE VERSION EQUIPPED WITH ABS SYSTEM, DO NOT ALLOW THE USE OF DIAGNOSTIC TESTER, AND ARE THEREFORE EQUAL TO THOSE DE- SCRIBED FOR THE STANDARD BRAKE SYSTEM.

  • Page 249: Brake Fluid Level Check

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system THE BLEEDING OPERATIONS OF THE BRAKING SYS- TEM, EVEN FOR THE VERSION EQUIPPED WITH ABS SYSTEM, DO NOT ALLOW THE USE OF DIAGNOSTIC TESTER, AND ARE THEREFORE EQUAL TO THOSE DE- SCRIBED FOR THE STANDARD BRAKE SYSTEM.
  • Page 250 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.

  • Page 251: Brake Pipes

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system N.B. WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS. Locking torques (N*m) Brake fluid pump-hose joint 19 to 22 Handlebar brake pump nuts 7 - 10 Brake pipes 1 - Front brake pump pipe...
  • Page 252 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Braking system 4 - Rear brake calliper pipe BRAK SYS - 252...
  • Page 253 INDEX OF TOPICS CHAS HASSIS...
  • Page 254 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Use a low pressure jet of water to soften the caked dirt and mud deposited on the painted surfaces. Once softened, sponge off mud and dirt using a car body sponge soaked in a car body shampoo and water solution (2-4% of car shampoo in water).
  • Page 255 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis CLEAN YOUR SCOOTER FREQUENTLY SO AS TO AVOID POSSIBLE DIRT OR MUD DEPOSITS THAT COULD CAUSE MALFUNCTIONING IN THE THROTTLE GRIP TRANSMISSION AND/OR OTHER COMPONENTS. CAUTION DURING VEHICLE CLEANING, WITH WATER JET UNDER PRESSURE, KEEP THE SADDLE CLOSED, AVOIDING TO DIRECT THE JET IN THE HELMET COMPARTMENT.
  • Page 256 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Seat The Authentic Leather seat constitutes a style element designed to enhance an already exclusive product. Leather is a natural material, so the seat will tend to acquire an "aged" look over time, the typical quality of Authentic Leather, as well as possible shades of colour and graining are characteristics of the product.
  • Page 257 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Disconnect the cable from the saddle lock. - Remove the 6 (MY13) - 4 (MY14) indicated screws and remove the saddle with the support. CHAS - 257...
  • Page 258 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the gas spring from the saddle by un- screwing the indicated nut. - Remove the gas spring from the saddle support by removing the seeger ring and the indicated pin. - Remove the 4 screws fixing the saddle to the support and separate the saddle from the support.
  • Page 259 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Unscrew the screws on the front part of the hook and remove this hook. N.B. PASSENGER SADDLE For this procedure, see section «Misc. documents». Side fairings - Remove the leg shield back plate.
  • Page 260 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Driving mirrors - Undo the screw indicated to remove the mirror. Locking torques (N*m) Rear-view mirrors 24 - 27 Rear handlebar cover - Remove the leg shield back plate. - Remove the footrest - Remove the front handlebar cover.
  • Page 261 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Instrument panel - Remove the leg shield back plate. - Remove the footrest. - Disconnect the connectors of the light assembly and the instrument panel and free the cables from the retaining clamps. - Remove the front handlebar cover.
  • Page 262 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - When removing the front light assembly pay at- tention to the correct cable channels. A- Front brake pipes B - Instrument panel cable harness, electric devi- ces cable harness, headlight cable harness. C - Rear brake pipes, throttle grip cables.
  • Page 263 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Headlight assy. - Remove the leg shield back plate. - Remove the footrest. - Disconnect the connectors of the light assembly and the instrument panel and free the cables from the retaining clamps. - Remove the headlight frame by unscrewing the 2 indicated screws.

  • Page 264: Turn Indicators

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the instrument panel by freeing the headlight cable harness. TURN INDICATORS - Remove the leg shield back plate. - Remove the footrest. - Disconnect the connectors of the turn indicators. - Unscrew the 2 indicated screws and remove the turn indicators.
  • Page 265 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis To replace the bulb, proceed as follows: - undo the transparent glass fixing screw. - Remove the transparent glass. - Remove the coloured semi-transparent glass. In order to remove the bulb, press it slightly and turn anticlockwise.
  • Page 266 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Legshield - Remove the leg shield back plate. - Remove the footrest. - Remove the piaggio clip-on badge. - Undo the screw indicated. - Undo the screw indicated on both sides of the vehicle.
  • Page 267 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the leg shield back plate and pay atten- tion to the clips in the indicated area. Removing the ignition key-switch when on *off* - Remove the leg shield back plate. - Remove the footrest.
  • Page 268 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the lock spring of the locking. - Remove the lock. - Remove the steering lock. Removing the ignition key-switch when on *lock* - Remove the leg shield back plate. - Remove the switch of the ignition switch.
  • Page 269 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Make a hole on the block using a drill as shown in the figure. - Insert the wheel cylinder with the key and with the anchoring tab facing down halfway on the lock body taking care that the insertion phase of the key is oriented matching "ON"...
  • Page 270 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Unscrew the 3 screws indicated and remove the light assembly. TURN INDICATORS - Remove the side fairings. - Disconnect the connectors of the turn indicators. - Remove the 2 screws indicated. NOTE: The following procedures refer to the vehicle with USA market destination The rear turn indicators «A»...
  • Page 271 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis To replace the bulb, proceed as follows: - undo the transparent glass fixing screw. - Remove the transparent glass. - Remove the coloured semi-transparent glass. In order to remove the bulb, press it slightly and turn anticlockwise.

  • Page 272: License Plate Light

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis License plate light - Undo the screws indicated. - Remove the license plate light by sliding it from the support. Footrest - Remove the leg shield back plate. - Undo the 3 screws indicated.
  • Page 273 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the external footrest strips. - Remove the 5 screws under each footrest strip. - Remove the spoilers from both sides of the ve- hicle. - Unscrew the screws under the spoilers. CHAS - 273...
  • Page 274 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the footrest, sliding it from the front part of the vehicle. Pay attention not to damage the bodywork. Side fairings - Remove the spoilers. - Undo the screw indicated. - Undo the indicated screw License plate holder - Remove the license plate light.

  • Page 275: Rear Mudguard

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Undo the 2 screws indicated on both sides of the vehicle. Air filter - Remove the left side fairing. - Undo the 2 screws indicated. - Loosen the hose clamp indicated and remove the filter box.
  • Page 276 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Undo the screw indicated and remove the mud- guard. Vano portabatterie - inverter - Undo the 4 screws indicated. N.B. THE CENTRAL COVER HAS A RUBBER PROTECTION AGAINST WEATHERING AND OTHER IMPURITIES ON THE ROAD.
  • Page 277 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis spoiler - Remove by turning the spoilers towards the out- side. Fuel tank - Remove the tank cover. - Remove the engine. - Remove the fuel pump connector on the upper part of the engine housing.

  • Page 278: Front Mudguard

    Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the tank fixing screw. - Unscrew the right side cover by unscrewing the 3 screws indicated. - Unscrew the tank fixing screw. - Slide off the tank towards the rear part of the ve- hicle.
  • Page 279 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis - Remove the front brake calliper. - Remove the front ABS sensor. - Adequately support the vehicle and remove the front wheel. - Slide off the steering pipe. - Undo the 3 screws indicated.
  • Page 280 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis Battery To access the battery the central cover «A» must be removed, undoing the retaining screws. Then remove the support clamp «B» undoing the retaining screws «C». The battery is the electrical device requiring the closest monitoring and most diligent maintenance.
  • Page 281 Vespa 946 E4-E5 EMEA-USA-ASIA (2021-) Chassis CAUTION MAKE SURE THAT THE CONNECTING CABLE TO THE NEGATIVE POLE OF THE BATTERY FOLLOWS THE PAS- SAGE SHOWN IN THE FIGURE IN ORDER TO AVOID POS- SIBLE FAILURES. CAUTION DO NOT REVERSE THE POLARITY: RISK OF SHORT CIR- CUIT AND DAMAGE TO THE ELECTRICAL SYSTEM.
  • Page 282 ABS: 231 Air filter: 55, 275 Battery: 72, 96, 100, 280 Brake: 239, 240, 244, 245, 249–251 Brake fluid: 249 Bulbs: Checks: 91 Engine oil: 56 Fuel: 199, 203, 277 Fuses: 99, 206 Headlight: 62, 263 Hub oil: 54 Identification: 25 Instrument panel: 85, 261 Maintenance: 24, 51 Mirrors: 260...
  • Page 283 Tank: 277 Technical Data: 24 Transmission: 71, 134, 146 Vehicle: 17, 25, 26, 126, 128...

This manual is also suitable for:

946 e5 emea 2021946 e4 usa 2021946 e5 usa 2021946 e4 asia 2021946 e5 asia 2021

Table of Contents