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VESPA GTV 250 i.e. 2008 Service Station Manual

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SERVICE STATION MANUAL
633845
Vespa GTV 250 i.e.

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Summary of Contents for VESPA GTV 250 i.e. 2008

  • Page 1 SERVICE STATION MANUAL 633845 Vespa GTV 250 i.e.
  • Page 2 SERVICE STATION MANUAL Vespa GTV 250 i.e. The descriptions and illustrations given in this publication are not binding; While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 SERVICE STATION MANUAL Vespa GTV 250 i.e. This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS 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 COOL SYS OOLING SYSTEM CHAS HASSIS TIME...
  • Page 6 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 7 Vespa GTV 250 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 - Safety locks...
  • Page 8 Vespa GTV 250 i.e. Pre-delivery • instruments: fuel and temperature indicator •Instrument panel lights • Horn • Electric starter • Engine stopping with emergency stop switch • electric saddle opening button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

  • Page 9: Static Test

    Vespa GTV 250 i.e. Pre-delivery - Abnormal noise Static test Static control after the test drive: • 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 10 INDEX OF TOPICS ECHNICAL...

  • Page 11: Safety Rules

    Vespa GTV 250 i.e. 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 12: Vehicle Identification

    Vespa GTV 250 i.e. Technical Data Vehicle identification Chassis prefix: *ZAPM451020000 ÷ 1001* Engine prefix: M451M ÷ 1001 Engine Data ENGINE SPECIFICATIONS Specification Desc./Quantity Engine Single-cylinder, four-stroke Bore x stroke 72 x 60 mm Engine capacity 244.29 cm³ Compression ratio 10.5 - 11.5 : 1...

  • Page 13: Dimensions And Mass

    Vespa GTV 250 i.e. Technical Data Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Length 1930 mm Overall width 770 mm Maximum height 1170 mm Saddle height 800 mm Wheelbase 1370 mm Maximum admitted weight ~ 340 kg Kerb weight 146 ±...

  • Page 14: Electrical Components

    Vespa GTV 250 i.e. Technical Data Transmission TRANSMISSION Specification Desc./Quantity Transmission With continuously variable expandable pulley transmission with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling Capacities CAPACITY Specification Desc./Quantity Engine oil approx.

  • Page 15: Wheels And Tyres

    Vespa GTV 250 i.e. Technical Data Specification Desc./Quantity No. 9 - Live Stop light and 7.5 A Starter key No. 10 - Power to tail light 7.5 A and instrument panel light- Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity...
  • Page 16 Vespa GTV 250 i.e. Technical Data Name Torque in Nm Lower steering ring nut 12 - 14 Handlebar fixing screw 50 - 55 Fixing screws for the handlebar control unit U-bolts 7 - 10 FRAME ASSEMBLY Name Torque in Nm...
  • Page 17 Vespa GTV 250 i.e. Technical Data LUBRICATION Name Torque in Nm Hub oil drainage plug 15 to 17 Oil filter on crankcase fitting 27 - 33 Engine oil drainage plug/ mesh filter 24 to 30 Oil filter 4 - 6...
  • Page 18 Vespa GTV 250 i.e. Technical Data Overhaul data Assembly clearances Cylinder - piston assy. ENGINE COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064...
  • Page 19 Vespa GTV 250 i.e. Technical Data CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Transmissionside half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Flywheel-side halfshaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05...
  • Page 20 Vespa GTV 250 i.e. Technical Data 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 21 INDEX OF TOPICS TOOL OOLING...

  • Page 22: Specific Tools

    Vespa GTV 250 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 on the...
  • Page 23 Vespa GTV 250 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 TOOL - 23...
  • Page 24 Vespa GTV 250 i.e. Tooling Stores code Description 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting plate 020263Y Driven pulley assembly sheath 020306Y Punch valve seal rings fitting TOOL - 24...
  • Page 25 Vespa GTV 250 i.e. Tooling Stores code Description 020329Y Mity-Vac vacuum pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger TOOL - 25...
  • Page 26 Vespa GTV 250 i.e. Tooling Stores code Description 020334Y Multiple battery charger 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 TOOL - 26...
  • Page 27 Vespa GTV 250 i.e. Tooling Stores code Description 020364Y 25-mm guide 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...
  • Page 28 Vespa GTV 250 i.e. Tooling Stores code Description 020393Y Piston fitting ring 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 TOOL - 28...
  • Page 29 Vespa GTV 250 i.e. Tooling Stores code Description 020434Y Union for oil pressure measurement 020441Y 26 x 28 mm adaptor 020444Y Tool for installing/removing clutch on/ from driven pulley 020456Y Ø 24 mm adaptor 020477Y Adapter 37 mm 020483Y 30-mm guide...
  • Page 30 Vespa GTV 250 i.e. Tooling Stores code Description 020489Y Hub cover support stud bolt kit 494929Y Exhaust fumes analyser 020428Y Piston position check mounting 020922Y Diagnosis Tool 020621Y A.T cable pick-up adapter 020481Y Wiring of the control unit's interface TOOL - 30...
  • Page 31 Vespa GTV 250 i.e. Tooling Stores code Description 001467Y035 Bearing housing, external ø 47 mm 021021Y Driving pulley lock wrench 001467Y013 Calliper to extract ø 15-mm bearings 020627Y Flywheel lock tool 020467Y Flywheel extractor 020454Y Tool for fitting the pin snap rings (200 -...
  • Page 32 Vespa GTV 250 i.e. Tooling Stores code Description 020622Y Transmission-side oil seal punch 020480Y Fuel pressure measurement kit 020244Y punch ø 15 020115Y punch ø 18 020271Y Tool for removing-fitting silent bloc 020638Y 250 l ENGINE SOFTWARE E. - ABS...

  • Page 33: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 34: Maintenance Chart

    Vespa GTV 250 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 Safety fasteners Spark plug...

  • Page 35: Checking The Spark Advance

    Vespa GTV 250 i.e. Maintenance Checking the spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to interpret the reference values based on the engine rpm.

  • Page 36: Spark Plug

    Vespa GTV 250 i.e. Maintenance - Check that the real values of rpm and ignition advance match those measured using the diag- nostic tester. If the values do not match, check: - distribution timing - engine speed sensor - injection control unit...
  • Page 37 Vespa GTV 250 i.e. Maintenance - Insert the cap onto the spark plug and proceed with the reassembly operations. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO- TOR IS COLD.THE SPARK PLUG MUST BE REPLACED EVERY 20,000 KM. THE USE OF NON CONFORMING...

  • Page 38: Air Filter

    Vespa GTV 250 i.e. Maintenance Replacement - Remove the oil filler plug «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 39: Engine Oil

    Vespa GTV 250 i.e. Maintenance 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. Recommended products Oil for filter sponges Special product for im- pregnating sponge filtering elements.
  • Page 40 Vespa GTV 250 i.e. Maintenance Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubri- cate the O-ring before fitting it. Change the engine oil.

  • Page 41: Engine Oil Filter

    Vespa GTV 250 i.e. Maintenance Engine oil top-up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 200 cm³.

  • Page 42: Cooling System

    Vespa GTV 250 i.e. Maintenance Cooling system Adding engine coolant. The fluid level must checked every 10,000 kilome- tres with a cold engine, in the way shown below: Place the vehicle on its centre stand and on flat ground. - Undo the screw shown in the figure and remove the expansion tank cap on RHS.

  • Page 43: Braking System

    Vespa GTV 250 i.e. Maintenance Anti-freeze liquid, ready to use, colour red Eth- ylene glycol antifreeze liquid with organic in- hibition additives. Red, ready to use. ASTM D 3306 - ASTM D 4656 - ASTM D 4985 - CUNA NC 956-16...

  • Page 44: Headlight Adjustment

    Vespa GTV 250 i.e. Maintenance For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws. CAUTION AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING. IN CASE OF ACCI- DENTAL CONTACT, RINSE WITH WATER.
  • Page 45 Vespa GTV 250 i.e. Maintenance TYRE PRESSURE Specification Desc./Quantity Front tyre pressure 1.8 bar Rear tyre pressure 2 bar Rear tyre pressure - driver and passenger 2.2 bar MAIN - 45...

  • Page 46: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 47 Vespa GTV 250 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 Possible Cause...

  • Page 48: Brakes Overheating

    Vespa GTV 250 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 49 Vespa GTV 250 i.e. Troubleshooting Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber. Check the condition of wear of the steering covers and the adjustments. TROUBL - 49...

  • Page 50: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 51 Vespa GTV 250 i.e. Electrical system KEY: 1. Magneto flywheel 2. Voltage regulator 3. Immobilizer aerial 4. Diagnostic socket 5. Revolution sensor 6. Engine stop switch 7. 2 fuse boxes in the helmet compartment 8. Key-switch 9. Saddle opening button 10.

  • Page 52: Electrical System Installation

    Vespa GTV 250 i.e. Electrical system 20. Horn 21. Light switch 22. Rear headlight assembly A. Brake light B. Parking light C. License plate light 23. Low-/high-beam light remote control 24. Front headlight assembly A. Tail light B. High-/low-beam light 25.

  • Page 53: Front Side

    Vespa GTV 250 i.e. Electrical system Front side 1. Front left turn indicator connector 2. Front right turn indicator connector 3. Electric fan connector ELE SYS - 53...
  • Page 54 Vespa GTV 250 i.e. Electrical system 1. Immobilizer aerial 2. Foldable clamp to hold cables 3. Battery negative terminal 4. Battery positive terminal 5. Flywheel - regulator connection ELE SYS - 54...
  • Page 55 Vespa GTV 250 i.e. Electrical system 1. Saddle opening switch 2. Pre-installations 3. Insert in clamp ELE SYS - 55...
  • Page 56 Vespa GTV 250 i.e. Electrical system 4. Fuse box 5. From the wire unit 1. Right turn indicator connector 2. From regulator 3. Wire unit - regulator connection 4. To the immobilizer aerial 5. Light remote control ELE SYS - 56...
  • Page 57 Vespa GTV 250 i.e. Electrical system 6. Electric fan remote control 7. To key switch 8. Left turn indicator connector 9. Voltage regulator 1. Red sheathing 2. Clamp 3. To headlight 4. To instrument 5. To stop switch 6. To stop switch...

  • Page 58: Back Side

    Vespa GTV 250 i.e. Electrical system Back side 1. Battery positive terminal 2. Battery negative terminal 3. Thermistor 4. Starter motor ground lead 5. Right turn indicator connector 6. Rear headlight assembly connector 7. Left turn indicator connector 8. Starter motor ground lead clamping 9.
  • Page 59 Vespa GTV 250 i.e. Electrical system 1. To flywheel 2. To saddle opening actuator 3. Fuse box 4. Foldable clamp to hold cables 5. Clamp 6. Injector connector 7. To HV coil 8. To front wire unit 9. To rear turn indicators 10.To fuel gauge and fuel tank...
  • Page 60 Vespa GTV 250 i.e. Electrical system 1. Fuse box 2. Remote control switch 3. Ground lead clamping to chassis 4. Oil pressure sensor 5. Lambda probe connector 6. Lambda sensor 7. To wire unit 8. To the spark plug 9. HV coil...
  • Page 61 Vespa GTV 250 i.e. Electrical system 1. Rear right turn indicator 2. Cable guide 3. To rear light 4. Rear left turn indicator ELE SYS - 61...
  • Page 62 Vespa GTV 250 i.e. Electrical system 1. To HV coil 2. Foldable clamp 3. Foldable clamps to hold the red sheathing 4. Diagnostic socket 5. Starter remote control Conceptual diagrams ELE SYS - 62...
  • Page 63 Vespa GTV 250 i.e. Electrical system Ignition KEY: 7. 2 fuse boxes in the helmet compartment 8. Key-switch 10. Injection load remote control 13. Battery 40. Spark plug 41. High voltage coil 42. Injection ECU ELE SYS - 63...
  • Page 64 Vespa GTV 250 i.e. Electrical system Battery recharge and starting KEY: 1. Magneto flywheel 2. Voltage regulator 6. Engine stop switch 7. 2 fuse boxes in the helmet compartment 8. Key-switch 12. Fuse box for glove box 13. Battery 14. Starter motor 15.
  • Page 65 Vespa GTV 250 i.e. Electrical system Level indicators and enable signals section KEY: 3. Immobilizer aerial 5. Revolution sensor 7. 2 fuse boxes in the helmet compartment 8. Key-switch 10. Injection load remote control 12. Fuse box for glove box 13.

  • Page 66: Devices And Accessories

    Vespa GTV 250 i.e. Electrical system Devices and accessories KEY: 1. Magneto flywheel 2. Voltage regulator 7. 2 fuse boxes in the helmet compartment 8. Key-switch 12. Fuse box for glove box 13. Battery 21. Light switch 22. Rear headlight assembly A.
  • Page 67 Vespa GTV 250 i.e. Electrical system 31. Instrument panel Lights and turn indicators KEY: 7. 2 fuse boxes in the helmet compartment 8. Key-switch 9. Saddle opening button 10. Injection load remote control 11. Saddle opening actuator 12. Fuse box for glove box 13.

  • Page 68: Checks And Inspections

    Vespa GTV 250 i.e. Electrical system Checks and inspections This section is dedicated to the checks on the electrical system components. 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...
  • Page 69 Vespa GTV 250 i.e. Electrical system • there is power to the control unit as specified below: 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: •...
  • Page 70 Vespa GTV 250 i.e. Electrical system After removing the leg shield back plate, remove the electrical connection from the antenna as shown in the picture. Remove the protective base from the connector. With the ignition switch at ON check there is bat-...
  • Page 71 Vespa GTV 250 i.e. Electrical system Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2,000 rpm. The keys can only be recognised if the control unit has been programmed properly.

  • Page 72: Diagnostic Codes

    Vespa GTV 250 i.e. Electrical system Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to en- code new service keys, in the event of losses, replacements, etc.
  • Page 73 Vespa GTV 250 i.e. Electrical system 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 flash is displayed, after which the LED remains off steadily.

  • Page 74: Stator Check

    Vespa GTV 250 i.e. Electrical system Diagnostic code - 2 flashes A two-flash code shows a system where the con- trol unit does not show the transponder signal. This might depend on the inefficiency of the Immobilizer antenna or the transponder.
  • Page 75 Vespa GTV 250 i.e. Electrical system 3) Measure the resistance between each of the yellow terminals and the other two. Electric characteristic Resistance: 0.2 - 1 Ω 4) Check that there is insulation between the each yellow cable and the ground.

  • Page 76: Voltage Regulator/Rectifier

    Vespa GTV 250 i.e. Electrical system Electric characteristic Voltage ranging between 14.0 and 15.0V at 5,000 rpm. Maximum current output check - With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.
  • Page 77 Vespa GTV 250 i.e. Electrical system BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERI- AL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).
  • Page 78 Vespa GTV 250 i.e. Electrical system INSTRUMENT PANEL CONNECTOR Specification Desc./Quantity 1 Power supply 2 Fuel gauge signal 3 Low fuel warning light 4 Oil pressure warning light 5 High-beam warning light 6 Headlight warning light and lighting 7 Ground lead...
  • Page 79 Vespa GTV 250 i.e. Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.

  • Page 80: Battery Installation

    Vespa GTV 250 i.e. Electrical system - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h Battery installation • Remove the battery cover after undoing the 4 screws shown in the photograph. - Remove the strap fastening the battery - Insert the battery breather pipe through the hole shown in the photograph.
  • Page 81 Vespa GTV 250 i.e. Electrical system - Fit the battery as shown in the photograph. N.B. IN ORDER TO FIT THE CABLES ON THE BATTERY TER- MINALS CORRECTLY, REST THE LOWER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.
  • Page 82 Vespa GTV 250 i.e. Electrical system - Refit the battery cover Connectors ELE SYS - 82...

  • Page 83: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 84 Vespa GTV 250 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the left and right fairing and spoiler terminals. - Remove the Lambda probe from its support and disconnect it.
  • Page 85 Vespa GTV 250 i.e. Engine from vehicle - Remove the lambda probe from the manifold. CAUTION WARNING SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN THE PRIMARY PIPE AND SILENCER. Removal of the engine from the vehicle...
  • Page 86 Vespa GTV 250 i.e. Engine from vehicle - Remove the coolant inlet pipe to the motor as indicated in the photograph. - Disconnect the fuel delivery and return pipes from the injector by removing the screw locking the re- taining clip.
  • Page 87 Vespa GTV 250 i.e. Engine from vehicle - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photograph. - Remove the throttle cable from the throttle body by undoing the nut shown in the photo.
  • Page 88 Vespa GTV 250 i.e. Engine from vehicle - Disconnect the connectors from the flywheel wir- ing as shown in the photo. - Remove the cable from the retaining clip on the flywheel cover. - Remove the rear shock absorbers. - Remove the hydraulic piping from the rear cal- liper by undoing the screw indicated in the photo- graph.
  • Page 89 Vespa GTV 250 i.e. Engine from vehicle When refitting the engine to the scooter, carry out the operations in reverse order from that adopted when removing it and respect the tightening torque shown in the Characteristics Chapter. Check that with valve in abutment against the reg- ister there is a small clearance.
  • Page 90 INDEX OF TOPICS NGINE...

  • Page 91: Automatic Transmission

    Vespa GTV 250 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.

  • Page 92: Removing The Driven Pulley Shaft Bearing

    Vespa GTV 250 i.e. Engine - Remove the 5 screws, found on two different lev- els, as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by...

  • Page 93: Removing The Driven Pulley

    Vespa GTV 250 i.e. Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indica- ted in the picture - Check the outer diameter of the roller does not...

  • Page 94: Inspecting The Clutch Drum

    Vespa GTV 250 i.e. 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 95: Removing The Clutch

    Vespa GTV 250 i.e. Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
  • Page 96 Vespa GTV 250 i.e. Engine 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL- N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.
  • Page 97 Vespa GTV 250 i.e. Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Bearing housing, external ø 47 - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 98 Vespa GTV 250 i.e. Engine Inspecting the driven sliding half-pulley - Remove the two seal rings and the two O-rings - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws.

  • Page 99: Refitting The Driven Pulley

    Vespa GTV 250 i.e. Engine Refitting the driven pulley - Insert the new oil seals and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
  • Page 100 Vespa GTV 250 i.e. Engine Inspecting the clutch spring - Measure the length of the spring when it is re- laxed. Characteristic Standard length 123 mm Acceptable limit after use: 118 mm Refitting the clutch - Support the driven pulley spring compressor spe- cific tool with the control screw in vertical axis.
  • Page 101 Vespa GTV 250 i.e. Engine - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool.

  • Page 102: Removing The Driving Pulley

    Vespa GTV 250 i.e. Engine Drive-belt - Check that the drive belt is not damaged. - Check the width of the belt. Characteristic 250 four stroke Transmission belt - minimum width 19.5 mm 250 four stroke Transmission belt - standard width 21.3 ±...
  • Page 103 Vespa GTV 250 i.e. Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 021021Y Driving pulley lock wrench...
  • Page 104 Vespa GTV 250 i.e. Engine movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 - 25.98 mm Sliding bushing: Minimum diameter permitted Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
  • Page 105 Vespa GTV 250 i.e. Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
  • Page 106 Vespa GTV 250 i.e. Engine End gear Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
  • Page 107 Vespa GTV 250 i.e. Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in...
  • Page 108 Vespa GTV 250 i.e. Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil seal, remove the transmission cov- er as described above. - Extract the driven pulley shaft from its bearing.
  • Page 109 Vespa GTV 250 i.e. Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 110 Vespa GTV 250 i.e. Engine Refitting the hub cover bearings In order to fit the hub box bearings, the engine crankcase and the cover must be heated with the special heat gun. - The three 15-mm bearings must be fitted using...

  • Page 111: Flywheel Cover

    Vespa GTV 250 i.e. Engine Refitting the hub bearings - Assemble the 3 shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the alignment dowels. - Seal the gasket of the breather pipe using black silicone sealant.

  • Page 112: Removing The Stator

    Vespa GTV 250 i.e. Engine Removing the hub cover - Remove the clip fixing the sleeve to the cylinder. - Remove the 10 clamps - Remove the flywheel cover. Removing the stator - Remove the two pick-up screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
  • Page 113 Vespa GTV 250 i.e. Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 - 4...

  • Page 114: Removing The Starter Motor

    Vespa GTV 250 i.e. Engine Removing the starter motor - Remove the two screws indicated in the figure - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft spline clip...
  • Page 115 Vespa GTV 250 i.e. Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the picture Specific tooling 020627Y Flywheel lock tool Remove the plate indicated in the picture. - Remove the flywheel nut with its washer...
  • Page 116 Vespa GTV 250 i.e. Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel Seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.

  • Page 117: Removing The Intake Manifold

    Vespa GTV 250 i.e. Engine - Using the special flywheel lock wrench, tighten up the flywheel fixing nut to the prescribed torque - Refit the retention plate Specific tooling 020627Y Flywheel lock tool Locking torques (N*m) Flywheel nut 94 - 102...
  • Page 118 Vespa GTV 250 i.e. Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: transmission cover, drive pulley with belt, oil sump with spring...
  • Page 119 Vespa GTV 250 i.e. Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.

  • Page 120: Removing The Cam Shaft

    Vespa GTV 250 i.e. Engine Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes. N.B.

  • Page 121: Removing The Valves

    Vespa GTV 250 i.e. Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool - Remove the lower spring supports. CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOG- NISE THEIR ORIGINAL POSITION ON THE HEAD.

  • Page 122: Inspecting The Small End

    Vespa GTV 250 i.e. Engine Inspecting the small end - Measure the internal diameter of the connecting rod small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
  • Page 123 Vespa GTV 250 i.e. Engine - If the clearance is greater than that indicated in the table, replace the piston. N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER THICKNESS GAUGE FROM THE SECOND SEAL SIDE. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.

  • Page 124: Removing The Piston

    Vespa GTV 250 i.e. Engine Inspecting the piston rings Sealing rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpen- dicularly to the cylinder axis.
  • Page 125 Vespa GTV 250 i.e. Engine THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS- ING. Specific tooling 020454Y Tool for fitting the pin snap rings (200 - 250) Choosing the gasket...
  • Page 126 Vespa GTV 250 i.e. Engine THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA. ENGINE 250 SHIMMING Name Measure A...

  • Page 127: Inspecting The Cylinder Head

    Vespa GTV 250 i.e. 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. N.B.
  • Page 128 Vespa GTV 250 i.e. 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 129 Vespa GTV 250 i.e. Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit Max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
  • Page 130 Vespa GTV 250 i.e. Engine - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the faying surface with the articulated set screw terminal. - If no anomalies are found during the above checks, you can use the same valves. For best sealing results, it is advisable to grind the valves.
  • Page 131 Vespa GTV 250 i.e. Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. ENG - 131...

  • Page 132: Inspecting The Cam Shaft

    Vespa GTV 250 i.e. Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seal rings. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
  • Page 133 Vespa GTV 250 i.e. Engine - Measure the internal diameter of each rocking lever. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Rocking lever inside diameter: Standard diam- eter Ø...
  • Page 134 Vespa GTV 250 i.e. Engine - Tighten up the nuts to a second pre-torque of 10 ±1 N·m - Rotate by an angle of 270° - To carry out the operations described above, fol- low the tightening sequence in the figure.
  • Page 135 Vespa GTV 250 i.e. Engine - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley.
  • Page 136 Vespa GTV 250 i.e. Engine Refitting the rocker-arms cover - Refit the cylinder head cover and tighten the 5 clamping screws to the specified torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm...

  • Page 137: Crankcase - Crankshaft

    Vespa GTV 250 i.e. Engine Refitting the intake manifold - Fit the intake manifold and do up the three screws. Locking torques (N*m) Inlet manifold screws 11 to 13 Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft.
  • Page 138 Vespa GTV 250 i.e. Engine not have any defect, the problem must be due to either excessive wear or wrong machining on the crankcase. - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfa- ces shown in the figure.
  • Page 139 Vespa GTV 250 i.e. Engine 28.994 - 29.000 Crankshaft bearings: Standard diameter: Cat. 29.000 - 29.006 Inspecting the crankshaft alignment To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the crankshaft cone, the tab seat, the oil seal capacity, the toothed gear and the threa- ded tangs are in good working order.
  • Page 140 Vespa GTV 250 i.e. Engine N.B. THE MAIN BEARINGS ARE NOT GRINDABLE. Specific tooling 020074Y Support base for checking crankshaft alignment Characteristic Off-line maximum admitted A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm...
  • Page 141 Vespa GTV 250 i.e. Engine oil pressure lubricating the main bushings and connecting rod. - Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and di- mensions.
  • Page 142 Vespa GTV 250 i.e. Engine - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface. - Check the inside diameter of the main bushings in the three directions indicated in the diagram.
  • Page 143 Vespa GTV 250 i.e. Engine matched with a crankshaft with mixed categories. The spare crankshaft has half-shafts of the same category. Crankcase halves Engine half- Bushing shaft Cat. 1 Cat. 1 Cat. 2 Cat. 2 Cat. 1 Cat. 2 Cat. 2 Cat.
  • Page 144 Vespa GTV 250 i.e. Engine - Insert the filter on the engine with the relative cap. Tighten to the prescribed torque. Locking torques (N*m) Internal engine crankcase bulkhead (transmis- sion-side half shaft) screws Engine-crank- 4 - 6 case coupling screws...

  • Page 145: Lubrication Circuit

    Vespa GTV 250 i.e. Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the picture. If it varies significantly from the driving depth indicated, it means that the stud bolt has yielded.
  • Page 146 Vespa GTV 250 i.e. Engine ENG - 146...

  • Page 147: Oil Pressure Check

    Vespa GTV 250 i.e. Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check that the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
  • Page 148 Vespa GTV 250 i.e. Engine Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil seal using the screws provided Specific tooling 020622Y Transmission-side oil seal punch - Screw the threaded bar onto the base of the tool and extract the oil seal.
  • Page 149 Vespa GTV 250 i.e. Engine - Orientate the oil seal by inserting the bracket which is part of the appropriate tool - Tighten the threaded bar onto the crankshaft as far as it will go - Use the nut to move the base of the tool until you...
  • Page 150 Vespa GTV 250 i.e. Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control sprocket. - Block the rotation of the oil pump driving pulley by inserting a screwdriver through one of its holes - Remove the central screw with cup washer, as shown in the diagram.
  • Page 151 Vespa GTV 250 i.e. Engine Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure. Characteristic Axial rotor clearance Limit value admitted: 0.09 mm...
  • Page 152 Vespa GTV 250 i.e. Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the cup washer. Tighten to the prescribed torque. -Fit the oil pump cover, by tightening the two screws to the prescribed torque.
  • Page 153 Vespa GTV 250 i.e. 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 154: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 155 Vespa GTV 250 i.e. Injection MIU injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the crankshaft (24-2 teeth) and pick-up sensor.
  • Page 156 Vespa GTV 250 i.e. Injection - H.V. coil - Injector The control unit is fitted with a self-diagnosis sys- tem connected to a warning light on the instrument panel. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present,...
  • Page 157 Vespa GTV 250 i.e. Injection OMPONENT RANSPOSITION Specification Desc./Quantity Instrument panel Throttle body and injection electronic control unit (MIU) Diagnostics socket con- nector Fuel pump Water temperature sensor Fuel injector H.V. coil Engine speed sensor Lambda probe Injection load relay...
  • Page 158 Vespa GTV 250 i.e. Injection 2 MIU system failure may be caused by loose connectors. Make sure that all connections have been correctly made. Check the connectors taking into consideration the following point: A check that the terminals are not bent.

  • Page 159: Terminal Layout

    Vespa GTV 250 i.e. Injection 13. At the end of every check performed with the diagnostic tester, remember to protect the system connector with its cap. Failure to observe this precaution may damage the MIU control unit. 14. Before reconnecting the quick couplers of the power supply system, check that the terminals are perfectly clean.
  • Page 160 Vespa GTV 250 i.e. Injection Specification Desc./Quantity HV coil ----- ----- Start up enabling ------ ------ Earth connection with engine cut-off switch and engine tem- perature sensor EMS circuit diagram EMS SYSTEM (E LECTRONIC ANAGEMENT YSTEM Specification Desc./Quantity Battery 12V - 12 Ah...

  • Page 161: Troubleshooting Procedure

    Vespa GTV 250 i.e. Injection Specification Desc./Quantity Ignition switch contacts Fuse 10 A engine stop switch Fuse 7.5 A Fuse Fuse 7.5 A Starter button Injection load relay Start-up solenoid Electric fan relay Starter motor Electric fan Fuel pump H.V. coil...
  • Page 162 Vespa GTV 250 i.e. Injection Possible Cause Operation H.V. coil Engine speed timing sensor Ignition advance Fuel system Fuel pressure (low) Injector flow (low) Injector sealing (poor) Correctness of the parameters Coolant temperature Intake air temperature Stepper throttle valve position (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve;...
  • Page 163 Vespa GTV 250 i.e. Injection Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause Operation Faults detected by self-diagnosis Pump relay H.V. coil Injector Engine speed timing sensor Air temperature Coolant temperature Lambda probe Correctness of the parameters Throttle valve position sensor...

  • Page 164: Fuel Supply System

    Vespa GTV 250 i.e. Injection Possible Cause Operation Air temperature Coolant temperature Lambda probe Power to spark plug Spark plug Shielded cap H.V. cable H.V. coil Intake system Air filter Filter box (sealing) Intake sleeve (sealing) Parameter reliability Throttle valve position signal...
  • Page 165 Vespa GTV 250 i.e. Injection Removing the butterfly valve Remove the fuel piping fixing screw as indicated. Remove the fast-release fittings from the injector support. INJEC - 165...
  • Page 166 Vespa GTV 250 i.e. Injection Remove the injector connector. Remove the 3 collector fixing screws on the big end and the throttle body fixing clamp on the col- lector. Remove the MIU control unit connector. Remove the clip fixing the throttle body to the air intake sleeve.
  • Page 167 Vespa GTV 250 i.e. Injection Remove the throttle control fastening as shown in the photo 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 168 Vespa GTV 250 i.e. Injection OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe Electric fan relay INJEC - 168...

  • Page 169: Electrical Data

    Vespa GTV 250 i.e. Injection 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. ELECTRICAL DATA •...
  • Page 170 Vespa GTV 250 i.e. Injection INJEC - 170...
  • Page 171 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
  • Page 172 Vespa GTV 250 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 Circuit leak test Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe..
  • Page 173 Vespa GTV 250 i.e. Injection 020480Y Fuel pressure measurement kit Fuel filter check Disconnect the terminals of the electrical pump Remove the screw shown in the picture Remove the clamp fixing the piping to the filter shown in the photograph Separate the lower part of the pump mounting as shown in the picture.
  • Page 174 Vespa GTV 250 i.e. Injection Remove the filter from the pump mounting INJEC - 174...
  • Page 175 Vespa GTV 250 i.e. Injection Inspecting the injector circuit OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe...
  • Page 176 Vespa GTV 250 i.e. Injection Specification Desc./Quantity Electric fan relay Checking the resistance at the injector ends: 14.5 ± 5% Ohm Check that the injection load 10A fuse No. 3 is in good conditions. Check that the 7.5A fuse No. 2 for the live control unit is in good conditions.
  • Page 177 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
  • Page 178 Vespa GTV 250 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 that, with the injector...
  • Page 179 Vespa GTV 250 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 180: Components Location

    Vespa GTV 250 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 181 Vespa GTV 250 i.e. Injection Tachometer With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
  • Page 182 Vespa GTV 250 i.e. Injection With the interface cable harness disconnected from the control unit, check continuity between pin 13 and the red cable of the engine speed sensor connector and between pin 15 and the brown ca- ble of the engine speed sensor connector...
  • Page 183 Vespa GTV 250 i.e. Injection HT coil OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe INJEC - 183...
  • Page 184 Vespa GTV 250 i.e. Injection Specification Desc./Quantity Electric fan relay The system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
  • Page 185 Vespa GTV 250 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 - 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 186 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
  • Page 187 Vespa GTV 250 i.e. Injection Coolant temperature sensor INJEC - 187...

  • Page 188: Engine Temperature Sensor

    Vespa GTV 250 i.e. Injection ENGINE TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor 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 189 Vespa GTV 250 i.e. Injection The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance. The throttle body after the pre-calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself.

  • Page 190: Lambda Probe

    Vespa GTV 250 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 191 Vespa GTV 250 i.e. Injection high temperatures, it has an electric preheating element inside it, controlled by the control unit, to take it quickly to the functioning state. Specific tooling 020481Y Wiring of the control unit's interface 020331Y Digital multimeter Check that the injection load 10A fuse No.
  • Page 192 Vespa GTV 250 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 - 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 193 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.

  • Page 194: Signal Control

    Vespa GTV 250 i.e. Injection SIGNAL CONTROL INJEC - 194...
  • Page 195 Vespa GTV 250 i.e. Injection OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition switch contacts Fuse 7.5 A Injection load relay Fuel pump H.V. coil Fuel injector Lambda probe Electric fan relay INJEC - 195...
  • Page 196 Vespa GTV 250 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 multimeter probes between pins 4 (-)

  • Page 197: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 198: Removing The Front Wheel

    Vespa GTV 250 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 199 Vespa GTV 250 i.e. Suspensions - Remove the oil seal on the roller bearing side using a screwdriver - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide...

  • Page 200: Refitting The Front Wheel

    Vespa GTV 250 i.e. Suspensions ISO L-X-BCHA 3 - DIN 51 825 K3K -20 Refitting the front wheel - To refit, carry out the removal operations but in reverse order and comply with the specified locking torque. Locking torques (N*m)
  • Page 201 Vespa GTV 250 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 202 Vespa GTV 250 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 - Remove the steering tube ring nut cover...
  • Page 203 Vespa GTV 250 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 204 Vespa GTV 250 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 on the steering tube - Use the specific tool to fit the fifth wheel fitting on...
  • Page 205 Vespa GTV 250 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 BEARINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING. Specific tooling...

  • Page 206: Front Shock Absorber

    Vespa GTV 250 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 207 Vespa GTV 250 i.e. Suspensions Removal - Remove the steering tube - Remove the shock absorber lower clamps - Remove the shock absorber upper clamps Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
  • Page 208 Vespa GTV 250 i.e. Suspensions - Before refitting the bracket in the wheel axle, place the O-ring as shown in the photograph so that it is correctly placed after fitting the bracket. - Refit the washer and the Seeger ring.
  • Page 209 Vespa GTV 250 i.e. Suspensions - Suitably hold the brake calliper - shock absorber attachment bracket - Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor...

  • Page 210: Removing The Rear Wheel

    Vespa GTV 250 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 211 Vespa GTV 250 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 212 Vespa GTV 250 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 - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the chassis side.
  • Page 213 Vespa GTV 250 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 214 Vespa GTV 250 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 215 Vespa GTV 250 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 216: Shock Absorbers

    Vespa GTV 250 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 33 ÷ 41 Nm Swinging arm pin - Engine 64 -...
  • Page 217 Vespa GTV 250 i.e. Suspensions Lower shock absorber clamping screw 33 - 41 Nm Upper shock absorber fixing screw 20 to 25 Exhaust bracket Removal Remove the complete silencer. - Remove the two fixing screws of the bracket to the engine crankcase...

  • Page 218: Side Stand

    Vespa GTV 250 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 219: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 220: Rear Brake Calliper

    Vespa GTV 250 i.e. Braking system This section is dedicated to the description of the brake system components. Rear brake calliper Removal - Remove the rear wheel. - Remove the brake pad retention pin snap ring. - Using a pin partially remove the brake pad re- tention pin.
  • Page 221 Vespa GTV 250 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 222: Front Brake Calliper

    Vespa GTV 250 i.e. Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the crankcase with the two screws with elastic washer at the prescribed tor-...
  • Page 223 Vespa GTV 250 i.e. Braking system 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 224: Rear Brake Disc

    Vespa GTV 250 i.e. Braking system - that the brake pad check spring works properly. CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED. The brake pad check spring 1. pad fixing screws 2. reaction plate fixing screws 3.

  • Page 225: Disc Inspection

    Vespa GTV 250 i.e. Braking system 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 unit firmly with a vice and operate on the 5 fixing...

  • Page 226: Front Brake Disc

    Vespa GTV 250 i.e. Braking system 020335Y Magnetic mounting for dial gauge Characteristic Max. deviation allowed: 0.1 mm - If incorrect values are measured, replace the disc. If the anomaly persists, replace the hub. Front brake disc Removal - Remove the front wheel...

  • Page 227: Front Brake Pads

    Vespa GTV 250 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 228 Vespa GTV 250 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 229: Rear Brake Pads

    Vespa GTV 250 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 specified torque. N.B. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS.
  • Page 230 Vespa GTV 250 i.e. Braking system See also Removal 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 clip on the pin - Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque.

  • Page 231: Brake Fluid Level Check

    Vespa GTV 250 i.e. Braking system 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. CONTACT WITH BRAKE FLUID WILL COMPROMISE THE PERFORMANCE AND EFFICA- CY OF THE BRAKING SYSTEM.
  • Page 232 Vespa GTV 250 i.e. Braking system BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CON- TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. Never use brake liquid in open or partially used containers.
  • Page 233 Vespa GTV 250 i.e. Braking system 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 234 Vespa GTV 250 i.e. Braking system Locking torques (N*m) Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handlebar: 7 - 10 Nm BRAK SYS - 234...
  • Page 235 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 236: Circuit Diagram

    Vespa GTV 250 i.e. Cooling system Circuit diagram COOL SYS - 236...
  • Page 237 Vespa GTV 250 i.e. Cooling system COOL SYS - 237...
  • Page 238 Vespa GTV 250 i.e. Cooling system System bleed - Start up the engine until the operating tempera- ture is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to...
  • Page 239 Vespa GTV 250 i.e. Cooling system - Bring the coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleeder screw Check 1) Look to see that the thermostat is not damaged. 2) Fill a metal container with approx. 1 litre of wa- ter.
  • Page 240 INDEX OF TOPICS CHAS HASSIS...
  • Page 241 Saddles fitted to this scooter are upholstered in Authentic Leather, and are a stylish accessory to em- phasise an already exclusive product such as your Vespa. As leather is a natural and vivid material, it tends to get "very opaque" aspect as time goes by, an aspect typical of Authentic Leather. This product may also show characteristic undertones and strains.
  • Page 242 Vespa GTV 250 i.e. Chassis Remove the four screws shown in the figure and the rear seat from the chassis saddle. - Free the electric cables form the retaining clamps indicated in the photograph Unscrew the two screws of saddle fixing hook cover.
  • Page 243 Vespa GTV 250 i.e. Chassis To remove the cable and the sheath: - Remove the elastic ring and unscrew the cable end from the seat on the saddle fixing hook. - Remove the other end of the cable from the fixing seat on the locking block.

  • Page 244: Instrument Panel

    Vespa GTV 250 i.e. Chassis - Remove the two screws, indicated in the figure, that fix the luggage rack to the body Instrument panel - Remove the two screws indicated in the figure. -Remove the instrument panel by slightly pulling it upwards.
  • Page 245 Vespa GTV 250 i.e. Chassis - Remove the bulb holder by turning it anticlock- wise and take out the failing bulb. - To fit, insert the new bulb and turn the bulb holder clockwise. Headlight assy. - Operate the screw indicated in the figure to re-...
  • Page 246 Vespa GTV 250 i.e. Chassis - Remove the expansion tank cover and then its - Remove the central screw inside the glove-box, indicated in the photograph - Remove the two screws indicated in the photo- graph and located below the expansion tank cover...
  • Page 247 Vespa GTV 250 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 248 Vespa GTV 250 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 249 Vespa GTV 250 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 250 Vespa GTV 250 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 251: Front Mudguard

    Vespa GTV 250 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. - Then remove the three mudguard-steering tube clamps indicated in the figure.
  • Page 252 Vespa GTV 250 i.e. Chassis - The same procedure also applies to the left ra- diator for which it is necessary to remove the elec- trical fan first by undoing the 3 screws indicated in the photograph. To refit, perform the removal operations but in reverse order being careful when positioning the news clips for the fluid hoses and when filling the cooling system.
  • Page 253 INDEX OF TOPICS TIME...
  • Page 254 Vespa GTV 250 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 255 Vespa GTV 250 i.e. Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 255...

  • Page 256: Cylinder Assy

    Vespa GTV 250 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 - 256...

  • Page 257: Cylinder Head Assy

    Vespa GTV 250 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 - 257...

  • Page 258: Cylinder Head Cover

    Vespa GTV 250 i.e. Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rockers valves - Replacement 001044 Camshaft - Replacement Cylinder head cover TIME - 258...

  • Page 259: Oil Filter

    Vespa GTV 250 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 Action...
  • Page 260 Vespa GTV 250 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 261: Driven Pulley

    Vespa GTV 250 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 262 Vespa GTV 250 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 - 262...

  • Page 263: Driving Pulley

    Vespa GTV 250 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Drive belt - Replacement 001066 Drive pulley - Removal and refitting 001177 CVT rollers / sliders - Replacement 001141 Belt anti-flapping roller - Replace-...

  • Page 264: Transmission Cover

    Vespa GTV 250 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 - 264...

  • Page 265: Starter Motor

    Vespa GTV 250 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 - 265...

  • Page 266: Flywheel Magneto

    Vespa GTV 250 i.e. Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - change TIME - 266...

  • Page 267: Butterfly Valve

    Vespa GTV 250 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 267...

  • Page 268: Exhaust Pipe

    Vespa GTV 250 i.e. Time Exhaust pipe MUFFLER Code Action Duration 001009 Silencer - Replacement 001095 Silencer heatshield - Replacement 005138 Lambda probe - Replacement TIME - 268...

  • Page 269: Air Cleaner

    Vespa GTV 250 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 270 Vespa GTV 250 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 271: Centre-Stand

    Vespa GTV 250 i.e. Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 271...

  • Page 272: Rear Cover

    Vespa GTV 250 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 004083...

  • Page 273: Underseat Compartment

    Vespa GTV 250 i.e. Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 004011 Central chassis cover - Replacement TIME - 273...
  • Page 274 Vespa GTV 250 i.e. Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder mounting - Re- placement 005048 number plate holder - Replacement TIME - 274...
  • Page 275 Vespa GTV 250 i.e. Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - change 004009 Rear mudguard - Replacement 003044 Shock absorber cover - Replace- ment TIME - 275...
  • Page 276 Vespa GTV 250 i.e. Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - change 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 276...
  • Page 277 Vespa GTV 250 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 278: Rear Shock Absorber

    Vespa GTV 250 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 - 278...
  • Page 279 Vespa GTV 250 i.e. Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering bearing - Replacement 003073 Steering clearance - Adjustment TIME - 279...

  • Page 280: Handlebar Covers

    Vespa GTV 250 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar covers - Replace- ment 004053 Spoiler - Replacement TIME - 280...

  • Page 281: Handlebar Components

    Vespa GTV 250 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 Right-hand knob - Replacement...

  • Page 282: Swinging Arm

    Vespa GTV 250 i.e. Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-chassis connection swinging arm - Replacement 004058 Silent block - Replacement TIME - 282...
  • Page 283 Vespa GTV 250 i.e. Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement TIME - 283...
  • Page 284 Vespa GTV 250 i.e. Time Instrument panel 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 285 Vespa GTV 250 i.e. Time Rear rack UGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement TIME - 285...
  • Page 286 Vespa GTV 250 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 antenna - Replacement 005099 Electric saddle opening device - Re-...

  • Page 287: Turn Signal Lights

    Vespa GTV 250 i.e. Time Turn signal lights NDICATORS AND LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005067 Front turn indicator bulb - Replace- ment 005031 Licence plate light - Replacement 005139 Tail light bulb - Replacement 005008...

  • Page 288: Front Wheel

    Vespa GTV 250 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 - 288...

  • Page 289: Rear Wheel

    Vespa GTV 250 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 Rear brake disc - Replacement...

  • Page 290: Electric Devices

    Vespa GTV 250 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 291 Vespa GTV 250 i.e. Time Transmissions RANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement TIME - 291...

  • Page 292: Front Suspension

    Vespa GTV 250 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 293 Vespa GTV 250 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 294 Vespa GTV 250 i.e. Time Stickers RANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 294...
  • Page 295 Air filter: 38 Battery: 64, 74, 79, 80 Brake: 220, 222, 224, 226, 227, 229, 231, 232 Brake fluid: 231 Bulbs: Checks: 68 Coolant: 187 Electric: 290 Engine oil: 39 Fuel: 164, 173, 249, 276 Fuses: 76 Headlight: 44, 245 Hub oil: 37 Identification: 12 Instrument panel: 244, 284...
  • Page 296 Stand: 218 Start-up: Suspension: 48, 49, 292 Tank: 249, 276 Technical Data: 11 Transmission: 14, 47, 91, 105, 264 Turn indicators: 67 Tyre pressure: Tyres: 15 Vehicle: 12, 84, 85...

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