VESPA S 50 4T 4V (2008) Manual
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VESPA S 50 4T 4V (2008) Manual

Vespa s 50 4t 4v (2008)
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MANUALE STAZIONE DI SERVIZIO
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Vespa S 50 4T 4V (2008)

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Summary of Contents for VESPA S 50 4T 4V (2008)

  • Page 1 MANUALE STAZIONE DI SERVIZIO ******** Vespa S 50 4T 4V (2008)
  • Page 2 MANUALE STAZIONE DI SERVIZIO Vespa S 50 4T 4V (2008) The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet 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 S 50 4T 4V (2008) Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.

  • Page 5: Index Of Topics

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

  • Page 7: Safety Rules

    Vespa S 50 4T 4V (2008) Characteristics Rules 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; never let the engine run in an enclosed area. Exhaust fumes are toxic.

  • Page 8: Vehicle Identification

    Vespa S 50 4T 4V (2008) Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPC383000001001 Engine prefix C383M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Width 740 mm Length 1755 mm Wheelbase 1290 mm Maximum height 1140 mm Kerb weight 110 ±...

  • Page 9: Oil Filter

    Vespa S 50 4T 4V (2008) Characteristics Specification Desc./Quantity Bore 39 mm Stroke 41.8 mm Cubic capacity 49.93 cm³ Max. Power 3.2 kW at 8250 rpm MAX. torque 3.8 Nm at 7750 rpm Compression ratio 11.5 ÷ 12 : 1...

  • Page 10: Electrical Components

    Vespa S 50 4T 4V (2008) Characteristics ELECTRICAL COMPONENTS Specification Desc./Quantity Ignition advance reference in table Spark plug NGK ER9EH-N Battery 12V - 9Ah Fuses One 15A fuse - Two 7.5A fuses Generator single-phase alternating current CHECKING REMOTE CONTROLS «A» OPER-...
  • Page 11 Vespa S 50 4T 4V (2008) Characteristics KEY SWITCH LIGHT SWITCH STARTER BUTTON HORN BUTTON CHAR - 11...

  • Page 12: Stop Button

    Vespa S 50 4T 4V (2008) Characteristics STOP BUTTON Resistance between green cable and ground con- nection: approx. 170 Ohm - Primary resistance: 0.5 ÷ 0.6 Ohm - Resistance between primary and ground con- nection: infinite - Resistance between primary and HV output: 3 ÷...

  • Page 13: Wheels And Tyres

    Vespa S 50 4T 4V (2008) Characteristics Specification Desc./Quantity Front suspension Single arm suspension with swinging arm articulated to the steering tube. Hydraulic double-acting shock absorber and co- axial spring Front suspension stroke 70 mm Trail (suspension rebounded/compressed) 71/68 mm...

  • Page 14: Front Brake

    Vespa S 50 4T 4V (2008) Characteristics N.B. FOR SAFETY LOCKS, SEE THE «PRE-DELIVERY» CHAPTER. FRONT BRAKE Name Torque in Nm Brake fluid pump-hose fitting 8 ÷ 12 Brake fluid pipe-calliper fitting 20 ÷ 25 Screw tightening calliper to the support 20 ÷...
  • Page 15 Vespa S 50 4T 4V (2008) Characteristics Cylinder - piston assy. COUPLING BETWEEN PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Cylinder 38.993 ÷ 39.000 38.954 ÷ 38.961 0.032 ÷ 0.046 Cylinder 39.000 ÷ 39.007 38.961 ÷ 38.968 0.032 ÷...
  • Page 16 Vespa S 50 4T 4V (2008) Characteristics - Measure the diameter of the bearings on the pis- ton. Characteristic Pin seat diameter 13 +0.005 +0.010 mm - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.

  • Page 17: Piston Rings

    Vespa S 50 4T 4V (2008) Characteristics - Pistons and cylinders are classified into catego- ries based on their diameter. The coupling is car- ried out in pairs (A-A, B-B, C-C, D-D). Characteristic Maximum allowable run-out: 0.05 mm Piston rings...
  • Page 18 Vespa S 50 4T 4V (2008) Characteristics Name Description Dimensions Initials Quantity 2nd Compression ring 39 x 1 0.05 ÷ 0.20 Oil scraper ring 39 x 2 0.20 ÷ 0.70 1st Compression ring 39.2 x 1 0.08 ÷ 0.20 1st Oversize 2nd Compression ring 39.2 x 1...
  • Page 19 Vespa S 50 4T 4V (2008) Characteristics Measure the bearings along X and Y axes Characteristic Crankshaft bearing, transmission side 20 -0.012 -0.025 mm Crankshaft bearing, flywheel side 17 +0.007 0 mm - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.

  • Page 20: Cylinder Head

    Vespa S 50 4T 4V (2008) Characteristics - Install the crankshaft on the support and measure the displacement at the 4 points shown in the fig- ure. N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC- TED, TRY STRAIGHTENING THE CRANKSHAFT BY IN-...
  • Page 21 Vespa S 50 4T 4V (2008) Characteristics - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn.
  • Page 22 Vespa S 50 4T 4V (2008) Characteristics Measure the unloaded spring length. • Standard length: 31.3 mm • Admissible limit after use: 29.3 - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V".
  • Page 23 Vespa S 50 4T 4V (2008) Characteristics - Measure the diameter of the valve stems in the three positions indicated in the diagram. TANDARD DIAMETER Specification Desc./Quantity Inlet 3.970 ÷ 3.985 mm drainage 3.960 ÷ 3.975 mm INIMUM DIAMETER PERMITTED Specification Desc./Quantity...
  • Page 24 Vespa S 50 4T 4V (2008) Characteristics Measure the valve guides ALVE GUIDE DIAMETER Specification Desc./Quantity Valve guide Standard diameter: 4 + 0.012 mm Valve guide Maximum admissible diameter: 4 + 0.022 mm - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.
  • Page 25 Vespa S 50 4T 4V (2008) Characteristics - Inspect the cam shaft for signs of abnormal wear on the cams. Characteristic Standard diameter - Bearing A: Ø 12 +0.002 +0.010 Standard diameter - Bearing B: Ø 16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: Ø...
  • Page 26 Vespa S 50 4T 4V (2008) Characteristics Slot packing system Characteristic Compression ratio 11.5 ÷ 12 : 1 PISTON PROTRUSION CHECK Name Measure A Thickness shimming_1 1.7 ÷ 1.95 0.25 shimming_2 1.95 ÷ 2.2 0.35 Products RECOMMENDED PRODUCTS TABLE Product...

  • Page 27: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 28 Vespa S 50 4T 4V (2008) Tooling TOOLS Stores code Description 001467Y008 Pliers to extract 17 mm ø bearings 001467Y029 Bell for bearings, O.D. 38 mm 004499Y Bearing extractor. Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34...
  • Page 29 Vespa S 50 4T 4V (2008) Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Tool to align crankshaft 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y...
  • Page 30 Vespa S 50 4T 4V (2008) Tooling Stores code Description 020288Y Fork to assemble piston on cylinder 020291Y Valve fitting/ removal tool 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y...
  • Page 31 Vespa S 50 4T 4V (2008) Tooling Stores code Description 020332Y Digital rpm indicator 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40-mm Adaptor 020359Y 42x47-mm Adaptor TOOL - 31...
  • Page 32 Vespa S 50 4T 4V (2008) Tooling Stores code Description 020360Y 52x55-mm Adaptor 020362Y 12 mm guide 020363Y 20-mm guide 020364Y 25-mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor TOOL - 32...
  • Page 33 Vespa S 50 4T 4V (2008) Tooling Stores code Description 020432Y Tool to fit the start-up sector spring 020439Y 17 mm guide 020444Y Pin fitting/removal tool 020448Y Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting/removal tool...
  • Page 34 Vespa S 50 4T 4V (2008) Tooling Stores code Description 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 020683Y Valve pressing member TOOL - 34...

  • Page 35: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 36: Maintenance Chart

    Vespa S 50 4T 4V (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 1000 Safety locks...
  • Page 37 Vespa S 50 4T 4V (2008) Maintenance - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condi- tion.

  • Page 38: Checking The Spark Advance

    Vespa S 50 4T 4V (2008) Maintenance Checking the spark advance The vehicle is fitted with a variable advance elec- tronic device. There are two timing references on the flywheel cover in order to ensure a better pre- cision when detecting the reference on the fan.
  • Page 39 Vespa S 50 4T 4V (2008) Maintenance - Fit the spark plug, screw it manually and lock it to the prescribed torque with a spark plug spanner. Electric characteristic Candela NGK ER9EH-6N Distanza elettrodi: 0,6 mm Locking torques (N*m) Candela 8 ÷...

  • Page 40: Air Filter

    Vespa S 50 4T 4V (2008) Maintenance Replacement Remove the oil filler cap/dipstick "A". - Unscrew the oil drainage plug "B" shown in the figure and drain out all the oil. - Screw the drainage plug back and fill up the hub with the required oil (about 100 cm³)

  • Page 41: Engine Oil Filter

    Vespa S 50 4T 4V (2008) Maintenance Replacement Loosen the oil filler plug. - Unscrew the drainage plug from the mesh filter on the flywheel side, and let the oil drain off. - Tighten the drainage plug and refill with ~ 600-650 cm³...

  • Page 42: Recommended Products

    Vespa S 50 4T 4V (2008) Maintenance - After this operation, refit the filter and screw the oil cap at the prescribed torque using a new O- Ring - Refill the engine with oil through the oil filling hole located in the oil sump.

  • Page 43: Checking The Valve Clearance

    Vespa S 50 4T 4V (2008) Maintenance Checking the valve clearance - Remove the spark plug access cover, undo the 4 fixing screws indicated in the figure and remove the tappet cover. - To check valve clearance, centre the reference marks of the timing system point as described above.
  • Page 44 Vespa S 50 4T 4V (2008) Maintenance SAS filters inspection and cleaning Undo the two screws «A» of the side fairing and remove the fairing. Undo the three screws «B» and remove the housing cover of the secondary air system. Detach the housing cover and remove the filtering element «C»...

  • Page 45: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 46: Startup Problems

    Vespa S 50 4T 4V (2008) Troubleshooting Engine Poor performance OOR PERFORMANCE Possible Cause Operation Air filter obstructed or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil, then allow to drip dry.
  • Page 47 Vespa S 50 4T 4V (2008) Troubleshooting Possible Cause Operation Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace if necessary. Wrong ignition advance Check flywheel keying on the crankshaft, replace control unit if necessary...

  • Page 48: Excessive Fuel Consumption

    Vespa S 50 4T 4V (2008) Troubleshooting High fuel consumption EXCESSIVE FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.

  • Page 49: Noisy Suspension

    Vespa S 50 4T 4V (2008) Troubleshooting Electrical system Battery BATTERY Possible Cause Operation The battery is the electrical device in the system that requires The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance.
  • Page 50 Vespa S 50 4T 4V (2008) Troubleshooting Possible Cause Operation In conclusion, check the tightening torque of the wheel hub, the brake calliper, the shock absorber disk in the attachment to the hub and the steering tube. Check that the swinging arm connecting the engine to the...

  • Page 51: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 52: Checks And Inspections

    Vespa S 50 4T 4V (2008) Electrical system Instruments and warning lights control board INSTRUMENT BOARD - WARNING LIGHTS AND INSTRUMENT PANEL Specification Desc./Quantity Left turn indicator warning light 12V - 2W High-beam warning light 12V - 1.2W Fuel gauge Instrument panel lighting bulbs 12V - 1.2W...

  • Page 53: Ignition Circuit

    Vespa S 50 4T 4V (2008) Electrical system Disconnect the connector on the flywheel cover and measure the resistance between either con- tact and the earthing. Specific tooling 020331Y Digital multimeter PICK-UP CHECK Specification Desc./Quantity ~ 170 Ω 1) Brown cable and earth...
  • Page 54 Vespa S 50 4T 4V (2008) Electrical system Electric characteristic Pick - up resistance approx. 170 Ohm - HV primary coil check Disconnect the electronic starter connector and check continuity between terminal No. 3 (purple) and terminal No. 1 (black) (see figure).

  • Page 55: Stator Check

    Vespa S 50 4T 4V (2008) Electrical system - Pick-Up Disconnect the ECU connector and connect the positive terminal to connector No. 3 (green) and the negative terminal to connector No. 4 (black). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up.
  • Page 56 Vespa S 50 4T 4V (2008) Electrical system ~ 1 Ω (Stator) Voltage regulator check A malfunction in the voltage regulator might cause the following problems depending on the type of fault: 1) Bulbs burned out (regulator in short circuit).
  • Page 57 Vespa S 50 4T 4V (2008) Electrical system - Voltage supplied at 2000 rpm must be about 25 ÷ 35V. If no value is obtained even with this test, replace the regulator because it is obviously failing. N.B. TO MEASURE THE ABOVE VOLTAGE USE AN ANALOGUE...
  • Page 58 Vespa S 50 4T 4V (2008) Electrical system Start the engine (temporarily connect the red cable to the battery positive terminal in order to avoid damaging the device that measures current). Check that there is a 13V voltage minimum (bat- tery charged) and a recharge current of 1.5 ÷...
  • Page 59 Vespa S 50 4T 4V (2008) Electrical system - If the above tests have positive results, jump con- tacts 5 (blue/black) and 3 (white) on the connector, set the key switch to ON and turn the turn indicator switch to the left and right to see when the lights are steadily on (as they are directly powered by the battery).

  • Page 60: Turn Indicators

    Vespa S 50 4T 4V (2008) Electrical system VOLTAGE REGULATOR 1. LIGHTING SYSTEM POWER SUPPLY (al- ternating) 2. GROUND 3. BATTERY POSITIVE 4. FROM FLYWHEEL (alternating) 5. TURN INDICATORS ELE SYS - 60...
  • Page 61 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 62 Vespa S 50 4T 4V (2008) Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Undo the 2 screws fixing the muffler to the hous- ing; then remove the whole muffler paying atten- tion to the interference between its supporting bracket and the cooling cover.
  • Page 63 INDEX OF TOPICS NGINE...

  • Page 64: Automatic Transmission

    Vespa S 50 4T 4V (2008) Engine Automatic transmission Transmission cover - Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehi- cle, it is necessary to remove the transmission cooling coupling and the air filter housing retain- ers.

  • Page 65: Removing The Driven Pulley Shaft Bearing

    Vespa S 50 4T 4V (2008) Engine Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

  • Page 66: Inspecting The Clutch Drum

    Vespa S 50 4T 4V (2008) Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the inner diameter of the clutch bell. Characteristic Clutch bell diameter/standard value Ø 107+0.2 +0 mm Clutch bell diameter/max.
  • Page 67 Vespa S 50 4T 4V (2008) Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 68 Vespa S 50 4T 4V (2008) Engine Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 69 Vespa S 50 4T 4V (2008) Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø...
  • Page 70 Vespa S 50 4T 4V (2008) Engine 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation...

  • Page 71: Refitting The Driven Pulley

    Vespa S 50 4T 4V (2008) Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...

  • Page 72: Removing The Driving Pulley

    Vespa S 50 4T 4V (2008) Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley.

  • Page 73: Specific Tooling

    Vespa S 50 4T 4V (2008) Engine 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm Refitting the driving pulley - Manually move the movable driven half-pulley...
  • Page 74 Vespa S 50 4T 4V (2008) Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the re- turn spring. - Remove the damaged components.
  • Page 75 Vespa S 50 4T 4V (2008) Engine Removing the hub cover • Remove the transmission cover • Remove the clutch assembly • Discharge the rear hub oil. • Remove the 5 screws indicated in the figure. • Remove the hub cover with driven pulley shaft.
  • Page 76 Vespa S 50 4T 4V (2008) Engine Removing the driven pulley shaft bearing - Remove the Seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane.
  • Page 77 Vespa S 50 4T 4V (2008) Engine Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the specific tool posi- tioned under the press and insert the driven pulley axle.

  • Page 78: Flywheel Cover

    Vespa S 50 4T 4V (2008) Engine Refitting the ub cover - Refit the whole wheel axle. - Refit the intermediate gear paying attention to the two shim washers. - Apply LOCTITE 510 for surfaces to the hub cov- ers and refit the same with driven pulley shaft.

  • Page 79: Cooling Fan

    Vespa S 50 4T 4V (2008) Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.

  • Page 80: Removing The Starter Motor

    Vespa S 50 4T 4V (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. N.B. THE PICK-UP CABLE MUST BE POSITIONED ADHERING...
  • Page 81 Vespa S 50 4T 4V (2008) Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor.

  • Page 82: Intermediate Gear

    Vespa S 50 4T 4V (2008) Engine Starter gear rim - Check the toothing is level and in good conditions Intermediate gear - Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns ade- quately.
  • Page 83 Vespa S 50 4T 4V (2008) Engine Refitting the starter motor - Install the starter motor in its seating in the crank- case. - Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the pre- scribed torque.
  • Page 84 Vespa S 50 4T 4V (2008) Engine Removing the timing system drive - Temporarily loosen the tensioner central screw and remove it together with the spring. - Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket.

  • Page 85: Removing The Cam Shaft

    Vespa S 50 4T 4V (2008) Engine Removing the cam shaft - Remove the limit screw of the rocking lever pins shown in the figure. - Remove the Seeger ring retaining the camshaft bearing. - Remove pins and rocking levers.

  • Page 86: Removing The Cylinder Head

    Vespa S 50 4T 4V (2008) Engine Removing the cylinder head - Remove the cooling covers, the timing control, the camshaft and the rocking levers. - Remove the spark plug. - Remove the 2 side fixings shown in the figure.

  • Page 87: Inspecting The Small End

    Vespa S 50 4T 4V (2008) Engine Removing the cylinder - piston assy. - Remove the cylinder paying attention to the 2 cylinder centring dowels in the housing. - Remove the cylinder base gasket. To avoid damaging the piston, keep it fixed while removing the cylinder.

  • Page 88: Inspecting The Piston

    Vespa S 50 4T 4V (2008) Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. Characteristic Standard diameter: gudgeon pin 13 -0-0.004mm Minimum admissible diameter gudgeon pin 12.990 mm Inspecting the piston - Measure the diameter of the bearings on the pis- ton.
  • Page 89 Vespa S 50 4T 4V (2008) Engine Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen.

  • Page 90: Removing The Piston

    Vespa S 50 4T 4V (2008) Engine SEAL RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 0.08 ÷ 0.20 2nd Compression ring 39 x 1 0.05 ÷ 0.20 Oil scraper ring 39 x 2 0.20 ÷ 0.70 1st Compression ring 39.2 x 1...
  • Page 91 Vespa S 50 4T 4V (2008) Engine - With the opening in the position indicated on the tool, set the lock ring into position in the tool with the punch. - Rest the tool on the piston paying attention that the 90°chamfered side faces upwards as indicated...

  • Page 92: Inspecting The Cylinder Head

    Vespa S 50 4T 4V (2008) Engine Refitting the cylinder - Insert the cylinder base gasket. - Fit the cylinder as shown in the figure. - The piston can be kept out of the housing plane using the appropriate tool.
  • Page 93 Vespa S 50 4T 4V (2008) Engine Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD CHECK Specification Desc./Quantity Standard diameter (mm) A Ø 32.015 ÷ 32.025 mm Standard diameter (mm) B Ø 16.0 ÷ 16.018 Standard diameter (mm) C Ø...
  • Page 94 Vespa S 50 4T 4V (2008) Engine Inspecting the valve sealings - 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 95 Vespa S 50 4T 4V (2008) Engine - Measure the diameter of the valve stems in the three positions indicated in the diagram. TANDARD DIAMETER Specification Desc./Quantity Inlet 3.970 ÷ 3.985 mm drainage 3.960 ÷ 3.975 mm INIMUM DIAMETER PERMITTED Specification Desc./Quantity...
  • Page 96 Vespa S 50 4T 4V (2008) Engine Inspecting the valve stem guide clearance Measure the valve guides ALVE GUIDE DIAMETER Specification Desc./Quantity Valve guide Standard diameter: 4 + 0.012 mm Valve guide Maximum admissible diameter: 4 + 0.022 mm - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.

  • Page 97: Inspecting The Cam Shaft

    Vespa S 50 4T 4V (2008) Engine Refitting the valves - Lubricate the valve guides with graphite grease. - Place the lower caps of the valve spring on the head. - Use the punch to fit the 4 sealing rings one at a time.
  • Page 98 Vespa S 50 4T 4V (2008) Engine - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones. N.B. A BALL BEARING IS FITTED ON BEARING «A»; CONSE- QUENTLY, BEARING «B»...
  • Page 99 Vespa S 50 4T 4V (2008) Engine - Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque. Specific tooling 020450Y Camshaft fitting/removal tool - Fit pins, inlet rocking lever and discharge rocking lever.
  • Page 100 Vespa S 50 4T 4V (2008) Engine Refitting the timing chain - Insert the timing chain pads in their correspond- ing seatings, the screw and the spacer as indica- ted in the figure. - Tighten to the prescribed torque and check the tensioner pad moves adequately.
  • Page 101 Vespa S 50 4T 4V (2008) Engine Camshaft pulley screw Head cover 12 ÷ 14 screw 8 ÷ 10 Nm - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque.

  • Page 102: Crankcase - Crankshaft

    Vespa S 50 4T 4V (2008) Engine Locking torques (N*m) Inlet manifold screw 7 ÷ 9 Nm Crankcase - crankshaft - First remove the following units: Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder-piston-head unit Starter motor with cables.
  • Page 103 Vespa S 50 4T 4V (2008) Engine - Check the axial clearance on the connecting rod. Fitting clearance Standard connecting rod axial clearance 0.15 ÷ Max. connecting rod clearance 0.30 mm 0.5 mm - Check the correct radial clearance of the con-...
  • Page 104 Vespa S 50 4T 4V (2008) Engine Refitting the crankshaft bearings - Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 120° C with a thermal gun (and support).
  • Page 105 Vespa S 50 4T 4V (2008) Engine Inspecting the crankshaft alignment - Install the crankshaft on the support and measure the displacement at the 4 points shown in the fig- ure. N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC-...
  • Page 106 Vespa S 50 4T 4V (2008) Engine - Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully. -Insert the flywheel half casing. - Fit the 10 screws and tighten them to the pre- scribed torque.

  • Page 107: Oil Pump

    Vespa S 50 4T 4V (2008) Engine - Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain.
  • Page 108 Vespa S 50 4T 4V (2008) Engine Removal - Remove the chain compartment cover undoing the 3 fixing screws indicated in the figure. - Take out the cover using the appropriate fusion couplings on the cover with a pair of pliers - Undo the 2 clamping screws in the figure and re- move the cover over the pump control crown gear.
  • Page 109 Vespa S 50 4T 4V (2008) Engine - Measure distance between rotors (inner rotor/ outer rotor) with a thickness gauge in the position shown in the picture. Characteristic Admissible maximum clearance 1 0.15 mm Measure the distance between the outer rotor and the pump body (see figure).
  • Page 110 Vespa S 50 4T 4V (2008) Engine - Fit the pulley on the pump, the central screw to the specified torque and the belleville washer. - Check that there is no seizing and/or friction dur- ing the pulley rotation. N.B.

  • Page 111: Fuel Supply

    Vespa S 50 4T 4V (2008) Engine Fuel supply - Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe.

  • Page 112: Removing The Carburettor

    Vespa S 50 4T 4V (2008) Engine N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING. Removing the carburettor - To detach the carburettor from the engine, re- move the two clamps anchoring the carburettor to the inlet manifold and the air intake coupling to the filter.
  • Page 113 Vespa S 50 4T 4V (2008) Engine - Remove the chamber components following the procedure below. - Undo the 2 screws fixing the intake pump dia- phragm cover. - Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring.
  • Page 114 Vespa S 50 4T 4V (2008) Engine -Remove the minimum nozzle. - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 115 Vespa S 50 4T 4V (2008) Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For the minimum circuit, make sure the following...
  • Page 116 Vespa S 50 4T 4V (2008) Engine - Wash and blow the minimum nozzle properly and reassemble it. - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindric part directed to the diffuser.

  • Page 117: Level Check

    Vespa S 50 4T 4V (2008) Engine - Check the diaphragm is in good conditions and remove the remaining components of the acceler- ating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
  • Page 118 Vespa S 50 4T 4V (2008) Engine - Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve. N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH...
  • Page 119 Vespa S 50 4T 4V (2008) Engine - The starter should disconnect progressively by means of electric heating. - Check the starter resistance when adjusted to the ambient temperature. Characteristic ambient temperature 24° C Electric characteristic Automatic starter resistance 20 Ω ± 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible.

  • Page 120: Adjusting The Idle

    Vespa S 50 4T 4V (2008) Engine - Insert rubber pipes for chamber ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seatings. - Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter.
  • Page 121 Vespa S 50 4T 4V (2008) Engine - Using the rpm indicator in the analyser or a sep- arate one, adjust the idle screw. N.B. THE WASTED SPARK IGNITION SYSTEM OFFERS RE- MARKABLE POWER. READINGS MAY NOT BE ACCU- RATE IF INADEQUATE RPM INDICATORS ARE USED.

  • Page 122: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 123: Removing The Front Wheel

    Vespa S 50 4T 4V (2008) Suspensions Front Removing the front wheel - Remove the five Allen screws that fix the wheel to the hub. N.B. BEFORE REMOVING THE WHEEL HUB, REMOVE THE BRAKE CALLIPER. SUSP - 123...

  • Page 124: Front Wheel Hub Overhaul

    Vespa S 50 4T 4V (2008) Suspensions Front wheel hub overhaul - Remove the ball bearing check Seeger ring indi- cated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings...

  • Page 125: Refitting The Front Wheel

    Vespa S 50 4T 4V (2008) Suspensions - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing - Refit the ball bearing check Seeger ring...

  • Page 126: Steering Column

    Vespa S 50 4T 4V (2008) Suspensions Removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and discon- necting the electrical terminals, remove the termi- nal fixing the handlebar to the steering. - Check all components and replace faulty parts.
  • Page 127 Vespa S 50 4T 4V (2008) Suspensions Overhaul -The front suspension service operation is useful to replace the connecting parts between the steering tube and the swinging hub of the front wheel holder, provided that the steering tube and the wheel holder hub are in excellent conditions.
  • Page 128 Vespa S 50 4T 4V (2008) Suspensions - Fit both dust guard rings «C» on the swinging hub as shown in the detail drawing «A». - Connect the swinging hub to the steering tube with the guide pin, part 5*.
  • Page 129 Vespa S 50 4T 4V (2008) Suspensions * Supplied with the tool Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °...

  • Page 130: Front Shock Absorber

    Vespa S 50 4T 4V (2008) Suspensions Refitting When fitting the fork, lubricate with the steering bearing tracks with the recommended grease. Tighten the lower ring nut "A" and the upper ring nut "B" to the specified torque Recommended products...
  • Page 131 Vespa S 50 4T 4V (2008) 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 132 Vespa S 50 4T 4V (2008) 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 133 Vespa S 50 4T 4V (2008) 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 52x55-mm Adaptor...

  • Page 134: Steering Bearing

    Vespa S 50 4T 4V (2008) Suspensions White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 ° C and +120 °C; NLGI 2; ISO-L-XBCIB2 Steering bearing Removal - Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis.

  • Page 135: Refitting The Rear Wheel

    Vespa S 50 4T 4V (2008) Suspensions Refitting the rear wheel - Fit the wheel, tighten the nut to the prescribed torque. - Refit the cap and the split pin folding it correctly as shown in the figure. Locking torques (N*m) Locking torque 137 ÷...

  • Page 136: Shock Absorbers

    Vespa S 50 4T 4V (2008) Suspensions Refitting For rifting, respect the locking torques Locking torques (N*m) Part C Part B Part A 33 ÷ 41 44 ÷ 52 33 ÷ 41 Shock absorbers SUSP - 136...
  • Page 137 Vespa S 50 4T 4V (2008) Suspensions Removal - To replace the shock absorber remove the bat- tery access flap to reach and remove the shock absorber/ frame anchoring nut. Then remove the shock absorber/engine anchorage nut. - When refitting, tighten the shock absorber/chas- sis anchoring nut and the shock absorber/engine pin to the prescribed torque.

  • Page 138: Braking System

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 139: Front Brake Calliper

    Vespa S 50 4T 4V (2008) Braking system 1. Tank cover. 2 - Pump body. 3 - Brake lever. 4 - Pump plunger. 5- Oil delivery hose. 6 - Protection cap for air bleed screw. 7- Calliper. 8- Dust guard 9- Piston sealing ring.

  • Page 140: Front Brake Disc

    Vespa S 50 4T 4V (2008) Braking system - bed the O-Ring gasket (4) on a calliper body. - Couple the internal body with the external one with assembling bolts. Refitting the pads and purging air (see previous sections). - Place the calliper on the disc and lock it to the support by tightening the bolts.

  • Page 141: Disc Inspection

    Vespa S 50 4T 4V (2008) Braking system tightening torque 5 ÷ 6.5 Nm Disc Inspection Specific tooling 020335Y Magnetic support for dial gauge Characteristic Max oscillation allowed 0.1 mm. Front brake pads Removal - Pads must be replaced when the friction material thickness reaches the wear limit.

  • Page 142: Recommended Products

    Vespa S 50 4T 4V (2008) Braking system The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw. -When the operation is over, tighten up the oil bleed screw to the prescribed torque.
  • Page 143 Vespa S 50 4T 4V (2008) Braking system Removal - Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac- tuate the brake lever until no more fluid flows out. -Remove the oil pump from the handlebar; remove the brake lever and then remove the wheel cylin- der.

  • Page 144: Rear Drum Brake

    Vespa S 50 4T 4V (2008) Braking system 5. Sealing ring. 6. Piston. 7. Gasket. 8. Spring. Rear drum brake Once the muffler and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner.
  • Page 145 INDEX OF TOPICS CHAS HASSIS...
  • Page 146 Vespa S 50 4T 4V (2008) Chassis Seat - Lift the saddle and remove the helmet compart- ment «A». - Undo the two screws indicated. Rear handlebar cover - Remove the front handlebar cover. - Undo the three screws indicated in figure fixing it to the handlebar, the odometer transmission and the electrical connectors.

  • Page 147: Instrument Panel

    Vespa S 50 4T 4V (2008) Chassis Instrument panel - Remove the rear handlebar cover. - Undo the three screws indicated fixing the rear handlebar cover. Front handlebar cover Proceed as follows: -Remove the rear-view mirrors. - Undo the two screws «A».
  • Page 148 Vespa S 50 4T 4V (2008) Chassis Headlight assy. - Remove the front handlebar cover. - Undo the four screws indicated fixing the front handlebar cover. Knee-guard - Undo the five screws indicated. - Remove the rubber strip from both sides and un- do the indicated screw.
  • Page 149 Vespa S 50 4T 4V (2008) Chassis Taillight assy. - Undo the two fixing screws and remove the rear light unit. - Undo the screw indicated and disconnect the connector. Footrest - Remove the shield back plate. - Remove the side fairings.
  • Page 150 Vespa S 50 4T 4V (2008) Chassis - The fixing screw at the front. - Remove the footrest. Side fairings - Undo the screw «A» and the smaller screw «B». - Detach the seats on the fairing. CHAS - 150...
  • Page 151 Vespa S 50 4T 4V (2008) Chassis License plate holder - Remove the side fairings. - Working on both sides, undo the two screws in- dicated. - Remove the license plate light. Air filter - Remove the helmet compartment. - Remove the side fairings.
  • Page 152 Vespa S 50 4T 4V (2008) Chassis Fuel tank CHAS - 152...
  • Page 153 Vespa S 50 4T 4V (2008) Chassis - Adequately support the rear part of the scooter. - Remove the wheel and the rear mudguard. - Remove the battery compartment. - Disconnect the fuel outlet pipe. - Undo the two fixing screws to the chassis and collect the fuel pipe supporting plate.
  • Page 154 Vespa S 50 4T 4V (2008) Chassis - Remove the turn indicators. - Remove the rear light unit and undo the indicated screw. - Unscrew the closing cap. - Lower the fuel tank and disconnect the bleed pipes and the level indicator connector.

  • Page 155: Front Mudguard

    Vespa S 50 4T 4V (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 Front central cover - Remove the "Piaggio"...
  • Page 156 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 157: Safety Locks

    Vespa S 50 4T 4V (2008) Pre-delivery Aesthetic inspection - Paintwork - Fitting plastics parts - Damage - Dirt Tightening torques inspection Lock check - All tightening torques - External screw of covers SAFETY LOCKS Name Torque in Nm Handlebar locking 40 ÷...

  • Page 158: Functional Inspection

    Vespa S 50 4T 4V (2008) Pre-delivery NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE. WARNING KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
  • Page 159 Vespa S 50 4T 4V (2008) Pre-delivery CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. PRE DE - 159...
  • Page 160 INDEX OF TOPICS TIME...
  • Page 161 Vespa S 50 4T 4V (2008) Time Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit. 003064 Engine oil - Change TIME - 161...
  • Page 162 Vespa S 50 4T 4V (2008) Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement Crankshaft TIME - 162...

  • Page 163: Cylinder Assy

    Vespa S 50 4T 4V (2008) Time CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement 001100 Oil seal, clutch side - Replacement 001118 Main bearings - Replacement Cylinder assy. CYLINDER- PISTON Code Action...

  • Page 164: Cylinder Head Assy

    Vespa S 50 4T 4V (2008) Time Cylinder head assy. HEAD Code Action Duration 001056 Head gasket - Replacement 001045 Valves - Replacement 001126 Head - Replacement TIME - 164...
  • Page 165 Vespa S 50 4T 4V (2008) Time Rocker arms support assy. CAMSHAFT SUPPORT Code Action Duration 001049 Valve clearance - Adjustment 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 165...

  • Page 166: Cylinder Head Cover

    Vespa S 50 4T 4V (2008) Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement 001097 Cooling hood - Replacement 001089 Head cover - Replacement TIME - 166...

  • Page 167: Driven Pulley

    Vespa S 50 4T 4V (2008) Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001110 Driven pulley - Replacement 001012 Driven pulley - Overhaul 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 167...
  • Page 168 Vespa S 50 4T 4V (2008) Time Oil pump IL PUMP Code Action Duration 001051 Belt/Timing chain - Change 001112 Oil pump - change 001042 Oil pump - Service 001121 Chain cover oil seal - Replacement 001122 Oil pump chain - Replacement...
  • Page 169 Vespa S 50 4T 4V (2008) Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 004125 Rear wheel axle - Replacement 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 001010 Gear reduction unit - Inspection...

  • Page 170: Driving Pulley

    Vespa S 50 4T 4V (2008) Time Driving pulley PULLEY REAR VIEW Code Action Duration 001177 Variator rollers / shoes - Replace- ment 001086 rear-view half-pulley - Replacement 001066 Driving pulley - Removal and refitting 001011 Driving belt - Replacement...

  • Page 171: Transmission Cover

    Vespa S 50 4T 4V (2008) Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - re- place 001132 Transmission air inlet pipe - Replace- ment 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re-...

  • Page 172: Starter Motor

    Vespa S 50 4T 4V (2008) Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Re- placement 001017 Starter sprocket wheel - Replace- ment 001021 Kick starter - Inspection 008008...

  • Page 173: Flywheel Magneto

    Vespa S 50 4T 4V (2008) Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Fitting and Refitting 001173 Rotor - Replacement 001102 Net oil filter - Replacement / Cleaning 001109 Cooling fan - Replacement 001087 Flywheel cover - Replacement...
  • Page 174 Vespa S 50 4T 4V (2008) Time Carburettor CARBURETTOR Code Action Duration 001063 Carburettor - Replacement 001008 Carburettor - Inspection 003058 Carburettor - Adjustment 001081 Automatic choke - Replacement 001082 Carburettor heating resistor - Re- placement 001013 Intake manifold - change...

  • Page 175: Exhaust Pipe

    Vespa S 50 4T 4V (2008) Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 175...

  • Page 176: Air Cleaner

    Vespa S 50 4T 4V (2008) Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Re- placement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 176...
  • Page 177 Vespa S 50 4T 4V (2008) Time Frame RAME Code Action Duration 004001 Frame - Replacement 004023 Shield rim - Replacement 004149 Shield central cover - Replacement 004159 Plates / Stickers - Replacement 004012 Rear side panels - Replacement 004059...

  • Page 178: Centre-Stand

    Vespa S 50 4T 4V (2008) Time Centre-stand TAND Code Action Duration 004004 Stand - Replacement 004171 Stand support plate - Replacement TIME - 178...
  • Page 179 Vespa S 50 4T 4V (2008) Time Footrests OOTREST Code Action Duration 004178 Footrest - Replacement 004078 Front/rear footrest rubber - Replace- ment TIME - 179...

  • Page 180: Rear Cover

    Vespa S 50 4T 4V (2008) Time Rear cover HIELD BACK PLATE Code Action Duration 004174 Trunk levers - Replacement 004065 Legshield, rear part - Removal and refitting 004081 Glove box door - Replacement 004082 Top box gasket - Replacement...

  • Page 181: Underseat Compartment

    Vespa S 50 4T 4V (2008) Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005046 Battery cover - change 004011 Central frame cover - Replacement 004071 Battery compartment - replacement TIME - 181...
  • Page 182 Vespa S 50 4T 4V (2008) Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder support - Re- placement 005048 Licence plate holder - Replacement 005032 number plate light glass - Replace- ment TIME - 182...
  • Page 183 Vespa S 50 4T 4V (2008) Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 183...

  • Page 184: Fuel Tank

    Vespa S 50 4T 4V (2008) Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Replace- ment 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement...

  • Page 185: Rear Shock Absorber

    Vespa S 50 4T 4V (2008) Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 185...
  • Page 186 Vespa S 50 4T 4V (2008) Time Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheels - Replacement 003073 Steering clearance - Adjustment 004119 Bearing / upper steering fifth wheel - Replacement TIME - 186...

  • Page 187: Handlebar Covers

    Vespa S 50 4T 4V (2008) Time Handlebar covers ODOMETER - HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs...

  • Page 188: Handlebar Components

    Vespa S 50 4T 4V (2008) Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Replacement 005017 Stop switch - Replacement...

  • Page 189: Swinging Arm

    Vespa S 50 4T 4V (2008) Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-frame connection swinging arm - Replacement TIME - 189...
  • Page 190 Vespa S 50 4T 4V (2008) Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004131 Luggage rack support - Replacement TIME - 190...

  • Page 191: Turn Signal Lights

    Vespa S 50 4T 4V (2008) Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - change 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement...

  • Page 192: Front Wheel

    Vespa S 50 4T 4V (2008) Time Front wheel FRONT WHEEL Code Action Duration 004123 Front wheel - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Replacement 003033 Front wheel hub- Replacement 002041 Front brake disc - Replacement...

  • Page 193: Electric Devices

    Vespa S 50 4T 4V (2008) Time REAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Removal and Refit- ting 001016 Rear wheel - Replacement 002002 Rear brake pads/shoes - Repl. Electric devices...

  • Page 194: Electronic Controls

    Vespa S 50 4T 4V (2008) Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement...
  • Page 195 Vespa S 50 4T 4V (2008) Time Transmissions TRANSMISSIONS Code Action Duration 002053 Rear brake transmission complete - Replacement 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement TIME - 195...

  • Page 196: Front Suspension

    Vespa S 50 4T 4V (2008) Time Front suspension FRONT SUSPENSION Code Action Duration 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber support and brake calliper - Replacement 001064 Odometer reel - Replacement 003044 Shock absorber cover - Replace-...

  • Page 197: Braking System

    Vespa S 50 4T 4V (2008) Time Braking system BRAKING SYSTEM Code Action Duration 002021 Front brake hose - Remov. and Re- fitt. 002007 Front brake shoes/pads - Remov. and Refitt 002039 Front brake calliper - Removal and Refitting 002047...
  • Page 198 Vespa S 50 4T 4V (2008) Time Secondary air box SECONDARY AIR HOUSING Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001163 Muffler secondary air connection -...
  • Page 199 Air filter: 40, 151 Battery: 49 Brake: 139–142, 144 Carburettor: 36, 112, 115, 174 Engine oil: 40 Engine stop: Fuel: 48, 111, 152, 184 Headlight: 43, 148 Hub oil: 39 Identification: 8 Instrument panel: 147 Maintenance: 7, 36 Odometer: Oil filter: 41 Saddle: Shock absorbers: 136 Spark plug: 38, 53...

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2008 s 50 4t 4v

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