VESPA GTS Super 300 ie 2008 User Manual
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VESPA GTS Super 300 ie 2008 User Manual

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

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  • Page 1 MANUALE STAZIONE DI SERVIZIO ******** Vespa GTS Super 300 ie (2008)
  • Page 2 MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 ie (2008) The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 ie (2008) This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.

  • Page 5: Index Of Topics

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

  • Page 7: Safety Rules

    Vespa GTS Super 300 ie (2008) Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...

  • Page 8: Vehicle Identification

    Vespa GTS Super 300 ie (2008) Characteristics Vehicle identification Chassis prefix: ZAPM45100000 ÷ 1001 Engine prefix: M451M ÷ 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 158 ± 5 kg Maximum weight allowed 340 kg Maximum height...

  • Page 9: Head Lubrication Control Jet

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

  • Page 10: Water Pump

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

  • Page 11: Turn Indicator Switch

    Vespa GTS Super 300 ie (2008) Characteristics CHECKING REMOTE CONTROLS «A» OPER- ATING AS CIRCUIT BREAKERS 1) Check that, given regular conditions, there is no continuity between terminals 30 and 87. 2) Apply 12V voltage to power terminals 85 and 86 of the remote control.
  • Page 12 Vespa GTS Super 300 ie (2008) Characteristics LIGHT SWITCH STARTER BUTTON KEY SWITCH FUEL INJECTOR Type: 3 holes Conicity of the nozzle: 20° Resistance at terminals: 13.7 ÷ 15.2 Ohm CHAR - 12...

  • Page 13: Fuel Pump Unit

    Vespa GTS Super 300 ie (2008) Characteristics FUEL PUMP UNIT Mechanical type pressure regulator operating at a pressure of 2.5 BAR Pump winding resistance: ~ 1.5 Ohm Input current during regular functioning: 1.4 - 1.8 REVOLUTION TIMING SENSOR Resistance between pins 13 and 15: 100 ÷ 150 Ohm at approx.
  • Page 14 Vespa GTS Super 300 ie (2008) Characteristics HV COIL - Resistance of the primary = 0.5 Ohm ± 8% - Resistance between primary and ground = infin- - Resistance between primary and HV output = 3.1 KOhm ± 9% - Presence of battery voltage between pins 22 and 26 of the interface cable harness upon shifting to ON and for 2 sec.

  • Page 15: Wheels And Tyres

    Vespa GTS Super 300 ie (2008) Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front wheels - light alloy rims 3.00x12 Rear wheels - light alloy rims 3.00x12 Front tyres 120/70-12" Tubeless Rear tyres 130/70-12" Tubeless TYRE PRESSURE Specification Desc./Quantity...

  • Page 16: Rear Suspension

    Vespa GTS Super 300 ie (2008) Characteristics REAR SUSPENSION Name Torque in Nm Retainer for left shock absorber to crankcase support plate 20 ÷ 25 Shock absorber lower fitting 40 ÷ 45 Shock absorber upper fitting 20 ÷ 25 Rear wheel axle 104 ÷...

  • Page 17: Crankcase And Crankshaft

    Vespa GTS Super 300 ie (2008) Characteristics Name Torque in Nm Drive pulley nut 75 ÷ 83 Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60 Rear hub cap screws 24 ÷ 27 FLYWHEEL Name Torque in Nm Flywheel cover screw 11 ÷...
  • Page 18 Vespa GTS Super 300 ie (2008) Characteristics CYLINDER - PISTON Specification Desc./Quantity Plunger diameter 74.967 +0.014 -0.014 mm Cylinder diameter 75 +0.038 +0.01 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder-piston 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷...
  • Page 19 Vespa GTS Super 300 ie (2008) Characteristics - Carefully clean the sealing ring housings. - Measure the coupling clearance between the sealing rings and the grooves using suitable sen- sors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
  • Page 20 Vespa GTS Super 300 ie (2008) Characteristics AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15...
  • Page 21 Vespa GTS Super 300 ie (2008) Characteristics CRANKSHAFT Specification Desc./Quantity Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm CHAR - 21...
  • Page 22 Vespa GTS Super 300 ie (2008) Characteristics MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 22...
  • Page 23 Vespa GTS Super 300 ie (2008) Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.43 mm - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR...
  • Page 24 Vespa GTS Super 300 ie (2008) Characteristics COUPLINGS BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING HALVES CATEGORY 29.024 ÷ 29.054 29.024 ÷ 29.054 29.018 ÷ 29.048 29.018 ÷ 29.048 Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2).
  • Page 25 Vespa GTS Super 300 ie (2008) Characteristics - Check the sealing surfaces for the intake and exhaust manifold. - Check that the bearings of the camshaft and the rocker pins exhibit no wear. - Check that the head cover surface is not worn.
  • Page 26 Vespa GTS Super 300 ie (2008) Characteristics - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm...
  • Page 27 Vespa GTS Super 300 ie (2008) Characteristics MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Inlet: 4.96 mm Outlet: 4.945 mm - Calculate the clearance between valve and valve guide. - Check the deviation of the valve stem by resting it on a "V" shaped abutment and measuring the extent of the deformation with a comparator.
  • Page 28 Vespa GTS Super 300 ie (2008) Characteristics INLET Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm OUTLET Specification Desc./Quantity Standard clearance: 0.025 ÷ 0.052 mm Admissible limit: 0.09 mm - Check that there are no signs of wear on the surface of contact with the articulated register terminal.
  • Page 29 Vespa GTS Super 300 ie (2008) Characteristics Specification Desc./Quantity Cam shaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm -Using a gauge, measure the cam height. TANDARD HEIGHT Specification Desc./Quantity Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Standard height Outlet: 29.209 mm...
  • Page 30 Vespa GTS Super 300 ie (2008) Characteristics Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. OCKING LEVERS AND PIN DIAMETER Specification Desc./Quantity Internal rocker arm diameter: Standard diameter Diameter 12.000 - 12.011 mm...
  • Page 31 Vespa GTS Super 300 ie (2008) Characteristics inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa. N.B. MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK- CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON...

  • Page 32: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...

  • Page 33: Attrezzatura Specifica

    Vespa GTS Super 300 ie (2008) Tooling ATTREZZATURA SPECIFICA Stores code Description 001330Y Tool for fitting steering seats 001467Y017 Bell for bearings, OD 39 mm 001467Y014 Pliers to extract ø 15-mm bearings 005095Y Engine support 002465Y Pliers for circlips 006029Y...
  • Page 34 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020021Y Front suspension service tool 020036Y Punch 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support TOOL - 34...
  • Page 35 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump TOOL - 35...
  • Page 36 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020648Y Single battery charger TOOL - 36...
  • Page 37 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide TOOL - 37...
  • Page 38 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020365Y 22 mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool 020393Y...
  • Page 39 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020412Y 15 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting...
  • Page 40 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020441Y 26 x 28 mm adaptor 020444Y Tool for fitting/ removing the driven pulley clutch 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020489Y Hub cover support stud bolt set...
  • Page 41 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020428Y Piston position check support 020460Y Scooter diagnosis and tester 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench...
  • Page 42 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bearings 020627Y Flywheel lock wrench 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y...
  • Page 43 Vespa GTS Super 300 ie (2008) Tooling Stores code Description 020244Y 15 mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 43...

  • Page 44: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 45: Maintenance Chart

    Vespa GTS Super 300 ie (2008) Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 2 years km x 1,000 Safety locks...
  • Page 46 Vespa GTS Super 300 ie (2008) Maintenance - Remove the transmission compartment air intake cover shown in the photograph. - Rotate the driving pulley fan using a screwdriver until the reference marks between the flywheel and flywheel cover coincide as shown in the pho- tograph.

  • Page 47: Spark Plug

    Vespa GTS Super 300 ie (2008) Maintenance Spark plug - Rest the scooter on its stand - Open the saddle and take out the helmet com- partment - Disconnect the spark plug HV wire cap; - Unscrew the spark plug using the wrench sup- plied;...
  • Page 48 Vespa GTS Super 300 ie (2008) Maintenance 0.7-0.8 mm Electric characteristic Spark plug NGK CR8EKB Locking torques (N*m) Spark plug 12 ÷ 14 Hub oil Check -Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely;...

  • Page 49: Air Filter

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

  • Page 50: Engine Oil

    Vespa GTS Super 300 ie (2008) Maintenance Engine oil In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.

  • Page 51: Engine Oil Filter

    Vespa GTS Super 300 ie (2008) Maintenance and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

  • Page 52: Oil Pressure Warning Light

    Vespa GTS Super 300 ie (2008) Maintenance Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON»...

  • Page 53: Braking System

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

  • Page 55: Headlight Adjustment

    Vespa GTS Super 300 ie (2008) Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...

  • Page 56: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 57 Vespa GTS Super 300 ie (2008) Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION...

  • Page 58: Brakes Overheating

    Vespa GTS Super 300 ie (2008) Troubleshooting Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift of the disc with a dial gauge and with wheel mounted on the scooter.
  • Page 59 Vespa GTS Super 300 ie (2008) Troubleshooting Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Seal fault or breakage Replace the shock absorber Check the condition of wear of the steering covers and the adjustments. TROUBL - 59...

  • Page 60: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 61 Vespa GTS Super 300 ie (2008) Electrical system 1. Pre-installation for anti-theft device 2. Left turn indicator bulbs 3. Right turn indicator bulbs 4. Turn indicator switch 5. Turn indicator control device 6. Instrument panel 7. Oil pressure sensor 8. Fuel level transmitter 9.
  • Page 62 Vespa GTS Super 300 ie (2008) Electrical system 20. Injection load remote control 21. Stop light bulb 22. Battery 23. Start-up remote control 24. Starter motor 25. Starter button 26. Main fuses 27. Voltage regulator 28. Magneto flywheel 29. Radiator electric fan 30.
  • Page 63 Vespa GTS Super 300 ie (2008) Electrical system Components arrangement 9. Immobilizer aerial - Remove the shield back plate to reach it. 10. Injection ECU - Remove the helmet compart- ment to reach it. ELE SYS - 63...
  • Page 64 Vespa GTS Super 300 ie (2008) Electrical system 11. Diagnosis connector - Remove the helmet compartment to reach it. 15. HV coil - Remove the battery to reach it; to remove the coil, first remove the footrest and undo the two screws indicated.
  • Page 65 Vespa GTS Super 300 ie (2008) Electrical system 20-23. Remote control switches - Remove the front central cover and the helmet compartment to reach them. 26. Main fuses - Open the front top box to reach them. 41. Auxiliary fuses - Remove the helmet com- partment to reach them.
  • Page 66 Vespa GTS Super 300 ie (2008) Electrical system 27. Voltage regulator - Remove the shield back plate to reach it. 28. Magneto flywheel - Remove the flywheel cov- er, as described in the «Engine» chapter, to reach it. To get access to the connectors, remove the helmet compartment.

  • Page 67: Ground Points

    Vespa GTS Super 300 ie (2008) Electrical system 33. Saddle-opening actuator - Remove the hel- met compartment to reach it, undo the two screws indicated and remove the mounting bracket to- gether with the actuator. 8. Fuel level transmitter - Remove the fuel tank to reach it.

  • Page 68: Electrical System Installation

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

  • Page 69: Front Side

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

  • Page 74: Back Side

    Vespa GTS Super 300 ie (2008) Electrical system Back side 1. To HV coil 2. Foldable clamp 3. Foldable clamps to hold the red sheathing 4. Diagnostic socket 5. Starter remote control ELE SYS - 74...
  • Page 75 Vespa GTS Super 300 ie (2008) Electrical system 1. Rear right turn indicator 2. Cable guide 3. To rear light 4. Rear left turn indicator ELE SYS - 75...
  • Page 76 Vespa GTS Super 300 ie (2008) Electrical system 1. Fuse box 2. Remote control switch 3. Ground lead clamping to chassis 4. Oil pressure sensor 5. Lambda probe connector 6. Lambda sensor 7. To wire unit 8. To the spark plug 9.
  • Page 77 Vespa GTS Super 300 ie (2008) Electrical system 1. To flywheel 2. To saddle opening actuator 3. Fuse box 4. Foldable clamp to hold cables 5. Clamp 6. Injector connector 7. To HV coil 8. To front wire unit 9. To rear turn indicators 10.To fuel gauge and fuel tank...
  • Page 78 Vespa GTS Super 300 ie (2008) Electrical system 1. Battery positive terminal 2. Battery negative terminal 3. Thermistor 4. Starter motor ground lead 5. Right turn indicator connector 6. Rear headlight assembly connector 7. Left turn indicator connector 8. Starter motor ground lead clamping 9.
  • Page 79 Vespa GTS Super 300 ie (2008) Electrical system Ignition 6. Instrument panel 9. Immobilizer aerial 10. Injection ECU 15. HV coil 20. Injection load remote control 22. Battery 26. Main fuses 31. Engine stop switch 40. Key switch contacts ELE SYS - 79...
  • Page 80 Vespa GTS Super 300 ie (2008) Electrical system Battery recharge and starting 10. Injection ECU 21. Stop light bulb 22. Battery 23. Start-up remote control 24. Starter motor 25. Starter button 26. Main fuses 27. Voltage regulator 28. Magneto flywheel 39.
  • Page 81 Vespa GTS Super 300 ie (2008) Electrical system Level indicators and enable signals section 6. Instrument panel 7. Oil pressure sensor 8. Fuel level transmitter 9. Immobilizer aerial 10. Injection ECU 13. Engine temperature sensor 14. Fuel injector 16. Engine rpm sensor 17.

  • Page 82: Devices And Accessories

    Vespa GTS Super 300 ie (2008) Electrical system Devices and accessories 1. Pre-installation for anti-theft device 2. Left turn indicator bulbs 3. Right turn indicator bulbs 6. Instrument panel 10. Injection ECU 12. Fuel pump 18. Horn 19. Horn button 20.
  • Page 83 Vespa GTS Super 300 ie (2008) Electrical system 41. Auxiliary fuses Lights and turn indicators 2. Left turn indicator bulbs 3. Right turn indicator bulbs 4. Turn indicator switch 5. Turn indicator control device 6. Instrument panel 10. Injection ECU 22.

  • Page 84: Checks And Inspections

    Vespa GTS Super 300 ie (2008) Electrical system Checks and inspections This section is devoted 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 85 Vespa GTS Super 300 ie (2008) 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 86 Vespa GTS Super 300 ie (2008) Electrical system After removing the shield back plate, remove the electrical connection from the aerial as shown in the photograph. Remove the protective base from the connector. With the ignition key switch at ON check there is...
  • Page 87 Vespa GTS Super 300 ie (2008) Electrical system Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly.

  • Page 88: Diagnostic Codes

    Vespa GTS Super 300 ie (2008) 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 89 Vespa GTS Super 300 ie (2008) Electrical system manently ON; in this condition, no operations are possible, including starting 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 90: Stator Check

    Vespa GTS Super 300 ie (2008) 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 immobiliser aerial or the transponder.
  • Page 91 Vespa GTS Super 300 ie (2008) 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 92: Voltage Regulator/Rectifier

    Vespa GTS Super 300 ie (2008) Electrical system VOLTAGE REGULATOR/RECTIFIER Specification Desc./Quantity Type Non-adjustable three-phase transistor Voltage 14 ÷ 15V at 5000 rpm with lights off Starter motor 1. Battery 2. Start-up remote control 3. Fuse No. 1 4. Fuse No. 3 5.

  • Page 93: Horn Control

    Vespa GTS Super 300 ie (2008) Electrical system 2) Check key switch contacts. 3) Check the contacts of the stop buttons and the starter button. 4) With the key switch set to «ON», the brake pulled and the starter button pressed, check if there is voltage between the Orange-White cable of the start-up remote control switch and the ground connec- tion.
  • Page 94 Vespa GTS Super 300 ie (2008) Electrical system 5. Horn button 6. Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 1 and 5. 2) Check the key switch and horn button contacts.
  • Page 95 Vespa GTS Super 300 ie (2008) Electrical system ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check that bulbs operate properly. 2) Check fuses No. 1 and 4. 3) Check key switch contacts. 4) With the key switch set to «ON», check if there is voltage between the Blue-Black cable of the turn indicators switch and the ground connection.
  • Page 96 Vespa GTS Super 300 ie (2008) Electrical system Lights list 1. Battery 2. Fuse No. 1 3. Fuse No. 6 4. Key switch contacts 5. Fuse No. 5 6. Fuse No. 9 7. Electronic control unit 8. Tail lights and license plate light bulbs 9.
  • Page 97 Vespa GTS Super 300 ie (2008) Electrical system 5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted. HIGH-BEAM /LOW-BEAM LIGHTS LINE 1) Check that bulbs operate properly. 2) Check fuses No. 1; 5 and 6.

  • Page 98: Electrical System

    Vespa GTS Super 300 ie (2008) Electrical system THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE. FUSES Specification Desc./Quantity Fuse No. 1 Capacity: 30 A Protected circuits: Battery recharge circuit, fuses No. 6-7. Live: Fuses No. 4 - 5 - 8 - 9 Fuse No.
  • Page 99 Vespa GTS Super 300 ie (2008) Electrical system Dashboard A = Digital clock B = Odometer C = Speedometer D = Injection telltale light E = Engine oil pressure warning light F = Turn indicators G = High-beam warning light...
  • Page 100 Vespa GTS Super 300 ie (2008) Electrical system Connectors DIAGNOSIS CONNECTOR 1. Not connected 2. Ground (Black) 3. Electronic control unit (Purple-White) PICK-UP CONNECTOR 1. Positive from control unit (Red) 2. Negative from control unit (Brown) 3. Not connected FUEL PUMP CONNECTOR 1.
  • Page 101 Vespa GTS Super 300 ie (2008) Electrical system 11. Lambda probe positive terminal (Sky blue- Black) 12. Engine stop switch (Green-Black) 13. Engine rpm sensor positive (Red) 14. Injector (Red-Yellow) 15. Engine rpm sensor negative (Brown) 16. Diagnosis (Purple-White) 17. Immobilizer warning light (Red-Green) 18.
  • Page 102 Vespa GTS Super 300 ie (2008) Electrical system LAMBDA PROBE CONNECTOR 1. Positive from control unit (Sky blue-Black) 2. Negative from control unit (White-Green) VOLTAGE REGULATOR CONNECTOR 1. +Battery (Red-Black) 2. Ground (Black) 3. Battery positive (Red-Black) 4. Ground (Black) INSTRUMENT PANEL CONNECTOR «A»...
  • Page 103 Vespa GTS Super 300 ie (2008) Electrical system INSTRUMENT PANEL CONNECTOR «C» 1. Immobilizer warning light (Red-Green) 2. Battery powered (Red-Blue) 3. Lighting (Yellow-Black) 4. Power permanent supply (White) HV COIL CONNECTOR 1. Power via remote control (Black-Green) 2. Electronic control unit (Pink-Black)

  • Page 104: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 105 Vespa GTS Super 300 ie (2008) Engine from vehicle This section describes the operations to carry out when removing the engine from the scooter. Exhaust assy. Removal - Remove the right and left fairings and the spoiler terminals. - Remove the Lambda probe from its support and disconnect it.
  • Page 106 Vespa GTS Super 300 ie (2008) Engine from vehicle Remove the lambda probe from the manifold. CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle CAUTION SUPPORT THE SCOOTER ADEQUATELY.
  • Page 107 Vespa GTS Super 300 ie (2008) Engine from vehicle - Get a + 2.5 l container to collect the coolant. - Remove the coolant inlet pipe to the motor as indicated in the photograph. - Disconnect the fuel pipe from the injector and re- move the screw locking the retainer clamp.
  • Page 108 Vespa GTS Super 300 ie (2008) Engine from vehicle - Remove the coolant outlet pipe from the motor as indicated. - Remove the spark plug cap. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle control cables from the throt- tle body by undoing the nuts indicated in the pho- tograph.
  • Page 109 Vespa GTS Super 300 ie (2008) Engine from vehicle - Remove the clamp retaining the starter motor from the sleeve. - Remove the positive and negative wiring from the starter motor as shown in the photograph. - Disconnect the connectors from the flywheel wir- ing as shown in the photo.
  • Page 110 Vespa GTS Super 300 ie (2008) Engine from vehicle - Remove the four retainers of the rear brake pipes from the crankcase. - Remove the rear shock absorbers. - Remove the engine-swinging arm fixing pin by undoing the nut and operating on the head of the pin as shown in the photograph.
  • Page 111 Vespa GTS Super 300 ie (2008) Engine from vehicle - Pay particular attention to the sleeve, be careful to position the throttle body reference marks as in- dicated in the photograph. CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.
  • Page 112 INDEX OF TOPICS NGINE...

  • Page 113: Automatic Transmission

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

  • Page 114: Removing The Driven Pulley Shaft Bearing

    Vespa GTS Super 300 ie (2008) Engine - Remove the five screws on two different levels 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 115: Removing The Driven Pulley

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

  • Page 116: Inspecting The Clutch Drum

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

  • Page 117: Removing The Clutch

    Vespa GTS Super 300 ie (2008) Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring No. 11 with the cham- fering facing the inside of the tool.
  • Page 118 Vespa GTS Super 300 ie (2008) Engine Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.
  • Page 119 Vespa GTS Super 300 ie (2008) Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 120 Vespa GTS Super 300 ie (2008) Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets 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 121: Refitting The Driven Pulley

    Vespa GTS Super 300 ie (2008) Engine Refitting the driven pulley - Insert the new oil guards 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 122 Vespa GTS Super 300 ie (2008) Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 123 mm...
  • Page 123 Vespa GTS Super 300 ie (2008) Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation.

  • Page 124: Removing The Driving Pulley

    Vespa GTS Super 300 ie (2008) Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width 19.5 mm Driving belt - standard width 21.3 ± 0.2 mm...
  • Page 125 Vespa GTS Super 300 ie (2008) Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
  • Page 126 Vespa GTS Super 300 ie (2008) Engine Movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
  • Page 127 Vespa GTS Super 300 ie (2008) Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
  • Page 128 Vespa GTS Super 300 ie (2008) Engine End gear Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket.
  • Page 129 Vespa GTS Super 300 ie (2008) Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
  • Page 130 Vespa GTS Super 300 ie (2008) Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing.
  • Page 131 Vespa GTS Super 300 ie (2008) Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 132 Vespa GTS Super 300 ie (2008) Engine Refitting the hub cover bearings For the fitting of 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 the appropriate tools.

  • Page 133: Flywheel Cover

    Vespa GTS Super 300 ie (2008) Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els.

  • Page 134: Removing The Stator

    Vespa GTS Super 300 ie (2008) Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the 10 fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
  • Page 135 Vespa GTS Super 300 ie (2008) Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4...

  • Page 136: Removing The Starter Motor

    Vespa GTS Super 300 ie (2008) Engine Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft...
  • Page 137 Vespa GTS Super 300 ie (2008) Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - Remove the flywheel nut with its washer...
  • Page 138 Vespa GTS Super 300 ie (2008) Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.

  • Page 139: Removing The Intake Manifold

    Vespa GTS Super 300 ie (2008) Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷ 102...
  • Page 140 Vespa GTS Super 300 ie (2008) Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring...
  • Page 141 Vespa GTS Super 300 ie (2008) Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.

  • Page 142: Removing The Cam Shaft

    Vespa GTS Super 300 ie (2008) Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes.

  • Page 143: Removing The Valves

    Vespa GTS Super 300 ie (2008) Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool. - Remove the lower spring supports.
  • Page 144 Vespa GTS Super 300 ie (2008) Engine Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the wrist pin N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.

  • Page 145: Removing The Piston

    Vespa GTS Super 300 ie (2008) Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin snap ring onto the appropriate...
  • Page 146 Vespa GTS Super 300 ie (2008) Engine - By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres- sion ratio.

  • Page 147: Inspecting The Cylinder Head

    Vespa GTS Super 300 ie (2008) Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure.
  • Page 148 Vespa GTS Super 300 ie (2008) Engine Inspecting the valve sealings N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Inspecting the valves N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.

  • Page 149: Inspecting The Cam Shaft

    Vespa GTS Super 300 ie (2008) Engine Specific tooling 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 150 Vespa GTS Super 300 ie (2008) Engine - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley.
  • Page 151 Vespa GTS Super 300 ie (2008) Engine - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading.
  • Page 152 Vespa GTS Super 300 ie (2008) Engine - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque. N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM- PRESSED AIR JET.

  • Page 153: Crankcase - Crankshaft

    Vespa GTS Super 300 ie (2008) Engine Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
  • Page 154 Vespa GTS Super 300 ie (2008) Engine CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH- INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.
  • Page 155 Vespa GTS Super 300 ie (2008) Engine - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking partic- ular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket be-...
  • Page 156 Vespa GTS Super 300 ie (2008) Engine - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder. - To prevent obstructions in the oil feeding chan- nels, the matching surface of the two half-bearings must be perfectly perpendicular to the cylinder ax- is, as shown in the figure.
  • Page 157 Vespa GTS Super 300 ie (2008) Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.

  • Page 158: Lubrication Circuit

    Vespa GTS Super 300 ie (2008) Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the photograph, re- move the stud bolt from its seat. Clean the threaded seat on the carter thoroughly.
  • Page 159 Vespa GTS Super 300 ie (2008) Engine ENG - 159...

  • Page 160: Oil Pressure Check

    Vespa GTS Super 300 ie (2008) Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check 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 161 Vespa GTS Super 300 ie (2008) Engine Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
  • Page 162 Vespa GTS Super 300 ie (2008) Engine - Orientate the oil guard 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 163 Vespa GTS Super 300 ie (2008) Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
  • Page 164 Vespa GTS Super 300 ie (2008) Engine - Check the clearance between the rotors in the position shown in the diagram using a thickness gauge. Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure.
  • Page 165 Vespa GTS Super 300 ie (2008) Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the belleville washer. Tighten to the prescribed torque. - Fit the oil pump cover by tightening the two screws to the prescribed torque.
  • Page 166 Vespa GTS Super 300 ie (2008) Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal.

  • Page 167: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 168 Vespa GTS Super 300 ie (2008) Injection INJEC - 168...
  • Page 169 Vespa GTS Super 300 ie (2008) Injection OMPONENT RANSPOSITION Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Fuel pump Water temperature sensor Fuel injector HV coil Engine rpm sensor Lambda sensor Injection load remote control...
  • Page 170 Vespa GTS Super 300 ie (2008) Injection - Spark plug The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only in the compression phase) at the same time. The MIU injection-ignition system controls engine functions by means of a pre-set program.
  • Page 171 Vespa GTS Super 300 ie (2008) Injection The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide further safety for the scooter. Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults.
  • Page 172 Vespa GTS Super 300 ie (2008) Injection c. Remote controls d. Connectors B: Chassis earthing C: Fuel supply a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c. Broken shielded cap E: Intake circuit a.
  • Page 173 Vespa GTS Super 300 ie (2008) Injection Terminals setup 1. Injection warning light 2. incomplete 3. incomplete 4. (-) lambda probe 5. (+) live battery 6. (+) battery 7. Immobilizer aerial 8. Electric fan remote control 9. Water temperature sensor 10.incomplete...
  • Page 174 Vespa GTS Super 300 ie (2008) Injection 26.Ground lead EMS circuit diagram 1. Battery 12V - 12 Ah 2. Rpm sensor 3. coolant temperature sensor 4. Immobilizer aerial 5. Stop switches 6. Fuse No. 1; 30A 7. Key switch contacts 8.

  • Page 175: Troubleshooting Procedure

    Vespa GTS Super 300 ie (2008) Injection 9. Fuse No. 3; 15A 10.Engine stop switch 11.Fuse No. 2; 7.5A 12.Injection load remote controls 13.Fuse No. 6; 15A 14.Starter button 15.Start-up remote control switch 16.Electric fan remote control 17.Starter motor 18.Electric fan motor 19.Fuel pump...
  • Page 176 Vespa GTS Super 300 ie (2008) Injection Starting difficulties ENGINE START-UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Start up engine speed Starter motor and remote control...
  • Page 177 Vespa GTS Super 300 ie (2008) Injection Possible Cause Operation HV coil Injector revolution timing sensor Air temperature Coolant temperature Ignition efficiency Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor...
  • Page 178 Vespa GTS Super 300 ie (2008) Injection Possible Cause Operation Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PROGRESS ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis...

  • Page 179: Fuel Supply System

    Vespa GTS Super 300 ie (2008) Injection Fuel supply system The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector and the fuel delivery pipes. The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through the filter.
  • Page 180 Vespa GTS Super 300 ie (2008) Injection Remove the fast-release fittings from the injector support. Remove the injector connector. Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold.
  • Page 181 Vespa GTS Super 300 ie (2008) Injection Remove the clip fixing the throttle body to the air cleaner bellows. Remove the gas command fitting as indicated in the photograph Refitting the butterfly valve To refit, perform the operations in the reverse or-...
  • Page 182 Vespa GTS Super 300 ie (2008) Injection Pump supply circuit 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump 8.

  • Page 183: Electrical Data

    Vespa GTS Super 300 ie (2008) Injection 9. Fuel injector 10.Electric fan remote control When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied.
  • Page 184 Vespa GTS Super 300 ie (2008) Injection CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (REMOTE CONTROLS, CONTROL UNIT, FUSES ETC.). INJEC - 184...
  • Page 185 Vespa GTS Super 300 ie (2008) Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none, check the continuity of the grey/black cable between the fuse box (No. 3 15 A) and the remote control base.
  • Page 186 Vespa GTS Super 300 ie (2008) Injection mote control disconnected, that the Black-Purple cable (pin 20 on the interface wiring) is insulated from the earth. Specific tooling 020331Y Digital multimeter Circuit leak test Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
  • Page 187 Vespa GTS Super 300 ie (2008) Injection Remove the screw shown in the photograph Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph.
  • Page 188 Vespa GTS Super 300 ie (2008) Injection Inspecting the injector circuit 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump 8.
  • Page 189 Vespa GTS Super 300 ie (2008) Injection 9. Fuel injector 10.Electric fan remote control Check the resistance at the injector ends: 14.5 ± 5% Ohm Check that the injection load 15A fuse No. 3 works properly. Check that the 7.5A fuse No. 2 for live control unit power works properly.
  • Page 190 Vespa GTS Super 300 ie (2008) Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none, check the continuity of the grey/black cable between the fuse box (No. 3 15 A) and the remote control base.
  • Page 191 Vespa GTS Super 300 ie (2008) Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to «ON» and check if there is voltage, with...
  • Page 192 Vespa GTS Super 300 ie (2008) Injection With injector disconnected and the injector load remote control disconnected, check the continuity of the Black-Green cable between the injector con- nector and remote control base. Inspecting the injector hydraulics To carry out the injector check, remove the intake...
  • Page 193 Vespa GTS Super 300 ie (2008) Injection Proceed with the injector seal test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector.
  • Page 194 Vespa GTS Super 300 ie (2008) Injection Components location INJEC - 194...

  • Page 195: Component Layout

    Vespa GTS Super 300 ie (2008) Injection COMPONENT LAYOUT Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostic socket Fuel pump Water temperature sensor Fuel injector HV coil Flywheel - rpm timing sensor Lambda sensor Injection load remote control...
  • Page 196 Vespa GTS Super 300 ie (2008) Injection Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring con- nected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2.8 V...
  • Page 197 Vespa GTS Super 300 ie (2008) Injection HT coil 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump 8. HV coil...
  • Page 198 Vespa GTS Super 300 ie (2008) Injection 9. Fuel injector 10.Electric fan remote control The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two important parameters: - Ignition advance This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ±...
  • Page 199 Vespa GTS Super 300 ie (2008) Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected.
  • Page 200 Vespa GTS Super 300 ie (2008) Injection INJEC - 200...
  • Page 201 Vespa GTS Super 300 ie (2008) Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none, check the continuity of the grey/black cable between the fuse box (No. 3 15 A) and the remote control base.

  • Page 202: Coolant Temperature Sensor

    Vespa GTS Super 300 ie (2008) Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor Engine stop switch With the connector on the control unit side discon- nected, and the coolant temperature sensor con- nector connected, check that the resistance val- ues between pins 9 and 18 correspond to the engine temperature.
  • Page 203 Vespa GTS Super 300 ie (2008) Injection With the control unit side connector disconnected, and the coolant temperature sensor connector dis- connected, check the continuity between pin 9 of the interface wiring and the light blue-green cable of the connector, and between pin 26 of the inter- face wiring and the grey-green cable of the con- nector.
  • Page 204 Vespa GTS Super 300 ie (2008) Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw.

  • Page 205: Lambda Probe

    Vespa GTS Super 300 ie (2008) Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING 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 206 Vespa GTS Super 300 ie (2008) Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V.
  • Page 207 Vespa GTS Super 300 ie (2008) Injection Impianto elettroventilatore 1. Battery 12V 2. Fuse No. 3; 15A 3. Fuse No. 1; 30A 4. Key switch contacts 5. Fuse No. 2; 7.5A 6. Injection load remote control 7. Fuel pump INJEC - 207...
  • Page 208 Vespa GTS Super 300 ie (2008) Injection 8. HV coil 9. Fuel injector 10.Electric fan remote control 11.Fuse No. 6; 15A 12.Electric fan motor Check that the 7.5A fuse No. 2 works properly With the key switch set to ON, check if there is +12...
  • Page 209 Vespa GTS Super 300 ie (2008) Injection Check the 15A Fuse No. 6 Check if there is +12 V voltage between the GREY cable of the electric fan remote control base and the ground connection. Check if the RED - BLACK cable between the fuse box under the seat and the fuse box in the glove- box compartment is not interrupted.

  • Page 210: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 211: Removing The Front Wheel

    Vespa GTS Super 300 ie (2008) Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pho- tograph. Locking torques (N*m) Wheel fixing screw 20 ÷...
  • Page 212 Vespa GTS Super 300 ie (2008) Suspensions - Remove the wheel hub. - Remove the ball bearing check seeger ring indi- cated in the photograph Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings...

  • Page 213: Refitting The Front Wheel

    Vespa GTS Super 300 ie (2008) Suspensions - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide - Heat the roller bearing seat with a heat gun...

  • Page 214: Steering Column

    Vespa GTS Super 300 ie (2008) Suspensions Steering column Removal - Remove the front wheel - Remove the brake calliper - Loosen the screw fixing the odometer cable plate and take out the cable. - Remove the suspension arm housing by un- screwing the three screws indicated in the photo- graph.
  • Page 215 Vespa GTS Super 300 ie (2008) Suspensions - Remove the retainer fixing the odometer cable to the mudguard indicated in the photograph - Remove the retainer fixing the brake piping to the front shock absorber upper plate - Remove the retainer fixing the brake piping to the...
  • Page 216 Vespa GTS Super 300 ie (2008) Suspensions - Remove the rear handlebar cover. - Remove the screw fixing the handlebar to the steering tube - Tilt the handlebar towards the shield back plate being careful not to scratch the plastic parts...
  • Page 217 Vespa GTS Super 300 ie (2008) Suspensions - Remove the steering tube - Use a special tool remove the upper disk of the fifth wheel fitting seat on the headstock by operat- ing form the lower part of the headstock as indica- ted in the photograph.
  • Page 218 Vespa GTS Super 300 ie (2008) Suspensions - Refit the fifth wheel fitting and the dust guard on the steering tube until they stop, using the specific tool. Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube...
  • Page 219 Vespa GTS Super 300 ie (2008) Suspensions - Once the pin has been fitted, insert the two spacers part 17 slightly hitting with a mallet (see next figure). CAUTION USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING.

  • Page 220: Front Shock Absorber

    Vespa GTS Super 300 ie (2008) Suspensions To position roller casings on the pin (pin end in contact with the internal bottom of the roller cas- ings) proceed as follows: - Use the tool with part 20 and 21 fitted to the stem as indicated in the figure.
  • Page 221 Vespa GTS Super 300 ie (2008) Suspensions Removal - Support the scooter adequately. - Remove the wheel hub. - Loosen the shock absorber lower clamps and re- move the brake calliper shock absorber support. - Loosen the screws fixing the front brake pipe re- tainer clamp and the odometer cable in order to reach the upper clamps.
  • Page 222 Vespa GTS Super 300 ie (2008) Suspensions Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques. Locking torques (N*m) shock absorber lower clamp 20 - 27 shock absorber upper clamp 20 ÷ 30...
  • Page 223 Vespa GTS Super 300 ie (2008) Suspensions Overhaul - The bracket for the shock absorber -calliper at- tachment has two roller bearings separated one from the other as shown in the photograph - Remove the two roller bearings from the bracket...
  • Page 224 Vespa GTS Super 300 ie (2008) Suspensions - Assemble a new roller bearing on the shock ab- sorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch - Suitably hold the brake calliper - shock absorber...

  • Page 225: Removing The Rear Wheel

    Vespa GTS Super 300 ie (2008) Suspensions Removing the rear wheel - Remove the bracket supporting the rear shock absorber and the muffler; - Remove the rear wheel by unscrewing the 5 screws indicated in the photograph Refitting the rear wheel To refit, carry out the removal operations but in reverse order, observing the prescribed torques.
  • Page 226 Vespa GTS Super 300 ie (2008) Suspensions - Remove the two screws fixing the buffer support bracket to the frame - Remove the left and right caps located under the footrest to reach the pin fixing the swinging arm to the body.
  • Page 227 Vespa GTS Super 300 ie (2008) Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension.
  • Page 228 Vespa GTS Super 300 ie (2008) Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - Using a suitable pin remove the roller casings as...
  • Page 229 Vespa GTS Super 300 ie (2008) Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in...
  • Page 230 Vespa GTS Super 300 ie (2008) Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the...

  • Page 231: Shock Absorbers

    Vespa GTS Super 300 ie (2008) Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine- and vehicle-side swinging arm junction bolt 40 ÷ 45 Swinging arm pin - Engine 64 - 72 Body shell - Swinging arm pin 76 ÷...
  • Page 232 Vespa GTS Super 300 ie (2008) Suspensions Shock absorber lower fitting 40 ÷ 45 Upper shock absorber fixing screws 20 ÷ 25 Nm Exhaust bracket Removal Remove the full muffler unit. - Remove the two fixing screws of the bracket to...

  • Page 233: Side Stand

    Vespa GTS Super 300 ie (2008) Suspensions Side stand REMOVAL - Uncouple the centre stand return spring; Remove the screw shown in the photograph FITTING To refit, carry out the removal operations in re- verse order and comply with the specified torque.

  • Page 234: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 235: Rear Brake Calliper

    Vespa GTS Super 300 ie (2008) Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the rear wheel. - Remove the pad retention pin snap ring. - Using a pin partially remove the brake pad re- tention pin.
  • Page 236 Vespa GTS Super 300 ie (2008) Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to...

  • Page 237: Front Brake Calliper

    Vespa GTS Super 300 ie (2008) Braking system Front brake calliper Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the two front brake calliper devices fas- tening them to the support as shown in the photo- graph.
  • Page 238 Vespa GTS Super 300 ie (2008) Braking system - that the cylinder and the floating body of the cal- liper do not show signs of scratches or erosion, otherwise replace the entire calliper; - that the guides of the fixed plate are not scratched or eroded, otherwise replace the entire plate;...

  • Page 239: Rear Brake Disc

    Vespa GTS Super 300 ie (2008) Braking system Rear brake disc Removal - Remove the rear brake calliper. - Remove the brake disc and the hub from the wheel axle - To remove the brake disc from the hub, hold the...

  • Page 240: Front Brake Disc

    Vespa GTS Super 300 ie (2008) Braking system N.B. SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC. Specific tooling 020335Y Magnetic support for dial gauge Characteristic Max. deviation allowed: 0.1 mm...

  • Page 241: Front Brake Pads

    Vespa GTS Super 300 ie (2008) Braking system Refitting - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.
  • Page 242 Vespa GTS Super 300 ie (2008) Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the brake calliper - Remove permanently the two pad fixing screws - Check that there are no flaws or warping. If there is, replace it.

  • Page 243: Rear Brake Pads

    Vespa GTS Super 300 ie (2008) Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B.
  • Page 244 Vespa GTS Super 300 ie (2008) Braking system Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the lock on the bolt and then the protection cover N.B.

  • Page 245: Brake Fluid Level Check

    Vespa GTS Super 300 ie (2008) Braking system N.B. DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS.
  • Page 246 Vespa GTS Super 300 ie (2008) Braking system AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE.
  • Page 247 Vespa GTS Super 300 ie (2008) Braking system Overhaul Proceed as follows: 1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take out the dia- phragm (3); 2) remove the cap (4) and take out the internal parts in order;...
  • Page 248 Vespa GTS Super 300 ie (2008) Braking system 3. Diaphragm. 4. Bellows. 5. Sealing ring 6. Piston. 7. Gasket. 8. Spring. 9. Reservoir Refitting To refit, carry out the removal operations but in reverse order, observing the specified torques. Locking torques (N*m) Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handle bar: 7 ÷...

  • Page 249: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 250: Circuit Diagram

    Vespa GTS Super 300 ie (2008) Cooling system Circuit diagram COOL SYS - 250...
  • Page 251 Vespa GTS Super 300 ie (2008) Cooling system COOL SYS - 251...
  • Page 252 Vespa GTS Super 300 ie (2008) Cooling system System bleed - Start up the engine until the operating tempera- ture is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to...
  • Page 253 Vespa GTS Super 300 ie (2008) Cooling system - Bring the coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleed screw Thermostat Removal - Remove the helmet compartment. - Place a + 2.0 l container under the vehicle to col- lect the coolant.
  • Page 254 Vespa GTS Super 300 ie (2008) Cooling system Check the temperature at which the thermostat starts to open: Heat up until the thermostat is completely open. 3) Replace the thermostat if it is not working prop- erly. CAUTION TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI- THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER.
  • Page 255 INDEX OF TOPICS CHAS HASSIS...
  • Page 256 Vespa GTS Super 300 ie (2008) Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Remove the helmet compartment - Remove the two screws shown in the photograph - Remove the saddle...

  • Page 257: Rear Rack

    Vespa GTS Super 300 ie (2008) Chassis - Remove the electric connector from the saddle opening actuator - Remove the two screws shown in the photograph - Remove the clip from the transmission - Remove the actuator from the supporting bracket...

  • Page 258: Instrument Panel

    Vespa GTS Super 300 ie (2008) Chassis Rear handlebar cover - Remove the front handlebar cover - Undo the 5 screws indicated in the photograph -Disconnect the odometer cable -After disconnecting the wiring remove the rear handlebar. Instrument panel - Remove the rear handlebar cover;...
  • Page 259 Vespa GTS Super 300 ie (2008) Chassis -Undo the 2 screws indicated in the figure; - Remove the front handlebar cover - Disconnect the front headlamp connectors Headlight assy. - Remove the front handlebar cover. - Undo the four screws indicated.
  • Page 260 Vespa GTS Super 300 ie (2008) Chassis Knee-guard - Remove the rear handlebar cover. - Remove the two screws indicated in the photo- graph and located on the shield under the grille - Remove the expansion tank cover and then its...
  • Page 261 Vespa GTS Super 300 ie (2008) Chassis - Remove the electric saddle opening switch, the fuse box and the manual saddle opening cable as shown in the photograph Taillight assy. - Operate the screw indicated in the figure to re- move the rear turn indicator Remove screw «A»...
  • Page 262 Vespa GTS Super 300 ie (2008) Chassis Footrest - Remove the shield back plate - Remove the battery compartment cover - Remove the side fairings - Remove the central screw located under the bat- tery compartment cover as indicated in the figure...

  • Page 263: Fuel Tank

    Vespa GTS Super 300 ie (2008) Chassis - Remove the screws under the non-slip rubber mat of the footrest as indicated in the photograph Side fairings Unscrew the fixing screw "A" Unscrew the nut "B" under the body. Helmet bay...
  • Page 264 Vespa GTS Super 300 ie (2008) Chassis - Remove the screw indicated in the figure that fixes the tank to the body after removing the rear head- light assembly - Remove the two turn indicators - Use a jack to lift the body so that there is enough...

  • Page 265: Front Mudguard

    Vespa GTS Super 300 ie (2008) Chassis Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard - Remove the three mudguard-steering tube clamps indicated in the figure...
  • Page 266 Vespa GTS Super 300 ie (2008) Chassis - The same procedure also applies to the left ra- diator for which it is necessary to remove the elec- tric fan first by undoing the three screws indicated in the photograph and afterwards disconnect the connector.
  • Page 267 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 268 Vespa GTS Super 300 ie (2008) Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection...
  • Page 269 Vespa GTS Super 300 ie (2008) Pre-delivery •Instrument panel lights • Horn • electric start up • Engine stopping with emergency stop switch • electric saddle opening button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

  • Page 270: Static Test

    Vespa GTS Super 300 ie (2008) Pre-delivery - Abnormal noise Static test Static control after the test ride: • Hot engine restart • Minimum seal (turning the handlebar) • Uniform steering rotation • Possible losses • electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 271 INDEX OF TOPICS TIME...
  • Page 272 Vespa GTS Super 300 ie (2008) Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit.
  • Page 273 Vespa GTS Super 300 ie (2008) Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 273...

  • Page 274: Cylinder Assy

    Vespa GTS Super 300 ie (2008) Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001154 Pin-ring-piston assembly - Service 001129 Chain tightener - Overhaul and re- placement TIME - 274...

  • Page 275: Cylinder Head Assy

    Vespa GTS Super 300 ie (2008) Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 001083 Thermistor - Replacement 001057 Thermostat - Replacement...

  • Page 276: Cylinder Head Cover

    Vespa GTS Super 300 ie (2008) Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rocking lever valve - Replacement 001044 Camshaft - Replacement Cylinder head cover TIME - 276...

  • Page 277: Head Cover

    Vespa GTS Super 300 ie (2008) Time HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment Oil filter OIL FILTER...

  • Page 278: Driven Pulley

    Vespa GTS Super 300 ie (2008) Time Flywheel cover LYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001150 Flywheel cover gasket - Replace- ment 007007 Water pump rotor - Replacement 007017 Water pump cover - Replacement 007003 Coolant delivery and return pipe - Re-...

  • Page 279: Oil Pump

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

  • Page 280: Final Reduction

    Vespa GTS Super 300 ie (2008) Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Re- placement 004125 Rear wheel axle - Replacement...

  • Page 281: Driving Pulley

    Vespa GTS Super 300 ie (2008) Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001066 Driving pulley - Removal and refitting 001177 Variator rollers / shoes - Replace- ment 001141...

  • Page 282: Transmission Cover

    Vespa GTS Super 300 ie (2008) Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement 001131 Transmission air intake - Replace- ment 001065 Transmission cover - Replacement...

  • Page 283: Electrical Start-Up

    Vespa GTS Super 300 ie (2008) Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001104 Start-up freewheel - Replacement 001151 Start-up driven gearing - Replace- ment 001017 Start-up pinion - Replacement TIME - 283...

  • Page 284: Magneto Flywheel

    Vespa GTS Super 300 ie (2008) Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - Replacement TIME - 284...

  • Page 285: Butterfly Valve

    Vespa GTS Super 300 ie (2008) Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - Replacement TIME - 285...

  • Page 286: Exhaust Pipe

    Vespa GTS Super 300 ie (2008) Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 005138 Lambda probe - Replacement TIME - 286...

  • Page 287: Air Cleaner

    Vespa GTS Super 300 ie (2008) Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement 001027 Body / air cleaner union - Replace-...
  • Page 288 Vespa GTS Super 300 ie (2008) Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004085 Fairing (1) - Replacement 004149 Shield central cover - Replacement 004053 Spoiler - Replacement 004015 Footrest - Removal and Refitting 004023 Shield rim - Replacement...

  • Page 289: Centre-Stand

    Vespa GTS Super 300 ie (2008) Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 289...

  • Page 290: Rear Cover

    Vespa GTS Super 300 ie (2008) Time MATS AND COVERS Code Action Duration 004079 Footrest - replacement 004071 Battery compartment - replacement 004078 Front/rear footrest rubber - Replace- ment 005046 Battery cover - change Rear cover REAR SHIELD Code Action...

  • Page 291: Underseat Compartment

    Vespa GTS Super 300 ie (2008) Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 004011 Central chassis cover - Replacement TIME - 291...
  • Page 292 Vespa GTS Super 300 ie (2008) Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder support - Re- placement 005048 Licence plate holder - Replacement Mudguard TIME - 292...
  • Page 293 Vespa GTS Super 300 ie (2008) Time MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement 003044 Shock absorber cover - Replace- ment Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement...
  • Page 294 Vespa GTS Super 300 ie (2008) Time Radiator RADIATOR Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan complete with support - Re- placement 007001 Expansion tank - Replacement 001052 Coolant and air bleed - Replacement 007013...

  • Page 295: Rear Shock Absorber

    Vespa GTS Super 300 ie (2008) Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Removal and Refitting 003077 muffler/rear shock absorber support arm - Service TIME - 295...
  • Page 296 Vespa GTS Super 300 ie (2008) Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment TIME - 296...

  • Page 297: Handlebar Covers

    Vespa GTS Super 300 ie (2008) Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar cover - Replacement Handlebar components TIME - 297...

  • Page 298: Handlebar Components

    Vespa GTS Super 300 ie (2008) Time 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 299 Vespa GTS Super 300 ie (2008) Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement Instrument panel TIME - 299...
  • Page 300 Vespa GTS Super 300 ie (2008) Time INSTRUMENT PANEL Code Action Duration 004066 Driving mirror - Replacement 005014 Odometer - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Replace- ment 005006 Light switch or turn indicators - Re-...
  • Page 301 Vespa GTS Super 300 ie (2008) Time Locks LOCKS Code Action Duration 002083 Saddle opening transmission - Re- placement 002092 Transmission splitter/ hook transmis- sion - Replacement 004158 Saddle opening splitter - Replace- ment 005072 Immobilizer aerial - Replacement 005099...

  • Page 302: Turn Signal Lights

    Vespa GTS Super 300 ie (2008) Time Turn signal lights NDICATORS AND LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005067 Front turn indicator bulb - Replace- ment 005031 Licence plate light bulb - Replace- ment 005139 Tail light bulb - Replacement...

  • Page 303: Front Wheel

    Vespa GTS Super 300 ie (2008) Time Front wheel RONT WHEEL Code Action Duration 003047 Front tyre - replace 003037 Front wheel rim- Replacement 004123 Front wheel - Replacement 003033 Front wheel hub- Replacement 002041 Brake disc - Replacement TIME - 303...

  • Page 304: Rear Wheel

    Vespa GTS Super 300 ie (2008) Time Rear wheel EAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Front wheel rim - Removal and refit- ting 001016 Rear wheel - Replacement 002028 Rear wheel hub - Replacement...

  • Page 305: Electric Devices

    Vespa GTS Super 300 ie (2008) Time Electric devices LECTRICAL DEVICES Code Action Duration 001094 Spark plug cap - Replacement 001069 HV coil - Replacement 005003 Horn - Replacement 005009 Voltage regulator - Replacement 005052 Fuse (1) - Replacement 005007...
  • Page 306 Vespa GTS Super 300 ie (2008) Time Transmissions RANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement TIME - 306...

  • Page 307: Front Suspension

    Vespa GTS Super 300 ie (2008) Time Front suspension FRONT SUSPENSION Code Action Duration 003011 Front shock absorber - Removal and Refitting 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber support and brake calliper - Replacement...
  • Page 308 Vespa GTS Super 300 ie (2008) Time Braking system RAKE 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 bleeding system - Replacement...
  • Page 309 Vespa GTS Super 300 ie (2008) Time Stickers RANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 309...
  • Page 310 Air filter: 49 Battery: 80, 90, 99 Brake: 235, 237, 239–241, 243, 245, 246 Brake fluid: 245 Coolant: 202 Engine oil: 50 Fuel: 179, 186, 263, 293 Fuses: 97 Headlight: 55, 259 Horn: 93 Hub oil: 48 Identification: 8 Instrument panel: 258, 299 Light switch: Luggage rack: Maintenance: 7, 45...
  • Page 311 Tank: 263, 293 Transmission: 10, 57, 113, 127, 282 Turn indicators: 83 Tyre pressure: Tyres: 15...

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