VESPA GTV 125 Service Station Manual
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VESPA GTV 125 Service Station Manual

664619 it-664620 en-664621 fr-664622 de-664623 es-664624 pt-664625 ol-664626 el
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SERVICE STATION MANUAL
664619 IT-664620 EN-664621 FR-664622 DE-664623
ES-664624 PT-664625 OL-664626 EL
Vespa GTV 125

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  • Page 1 SERVICE STATION MANUAL 664619 IT-664620 EN-664621 FR-664622 DE-664623 ES-664624 PT-664625 OL-664626 EL Vespa GTV 125...
  • Page 2 SERVICE STATION MANUAL Vespa GTV 125 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 SERVICE STATION MANUAL Vespa GTV 125 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 SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    Vespa GTV 125 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 9: Vehicle Identification

    Vespa GTV 125 Characteristics Vehicle identification Chassis prefix: ZAPM313010000 ÷ 1001 Engine prefix: M315M1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Total kerb weight 148 ± 5 kg Overall width 770 mm Length 1940 mm Wheelbase 1395 mm Height...
  • Page 10 Vespa GTV 125 Characteristics Engine ENGINE Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Timing system single overhead camshaft chain driven on the left- hand side, three-arm rocking levers set up with threaded set screw Bore 57 mm Stroke 48.6 mm...

  • Page 11: Electrical Components

    Vespa GTV 125 Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circula- tion cooling Capacities CAPACITY Specification Desc./Quantity Engine oil ~ 1000 cm³...

  • Page 12: Wheels And Tyres

    Vespa GTV 125 Characteristics Brakes BRAKES Specification Desc./Quantity Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plungers and hydraulic control (lever on the far right end of the handlebar) Rear Ø 220 disc brake and calliper with two Ø 30 mm...

  • Page 13: Steering Assembly

    Vespa GTV 125 Characteristics Specification Desc./Quantity Petrol inlet hole Starter air jet Ø 1.5 Starter diffuser nozzle Starter jet Diameter of starter pin ~ 20 Ω Starter device resistance Venturi diffuser Ø 29 (47x30.9) Throttle valve Ø 30.5 Diffuser maximum cone N.B.

  • Page 14: Rear Suspension

    Vespa GTV 125 Characteristics Name Torque in Nm Brake pump reservoir screws 15 ÷ 20 REAR SUSPENSION Name Torque in Nm Retainer for left shock absorber to crankcase sup- 20 ÷ 25 port plate Shock absorber upper fitting 20 ÷ 25 Shock absorber lower fitting 33 ÷...

  • Page 15: Crankcase And Crankshaft

    Vespa GTV 125 Characteristics Name Torque in Nm Starter ground screw 7 ÷ 8.5 M5 side screw locking washers on camshaft 7 ÷ 8.5 Tappet set screw lock nut 6 ÷ 8 Inlet manifold screws 11 ÷ 13 Timing chain tensioner slider screw 10 ÷...
  • Page 16 Vespa GTV 125 Characteristics Cylinder - piston assy. ENGINE COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 ÷ 57.018 56.959 ÷...
  • Page 17 Vespa GTV 125 Characteristics Crankcase - crankshaft - connecting rod RANKSHAFT Titolo Durata/Valore Testo Breve (< 4000 Indirizzo Immagine car.) Crankshaft Crankshaft to crankcase axial clearance Crankshaft to crankcase axial clearance CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05...
  • Page 18 Vespa GTV 125 Characteristics Slot packing system Characteristic Compression ratio 12 ± 0.5: 1 Measurement "A" to be taken is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the bigger the base gasket to be used (to recover the compression ratio) and vice versa.
  • Page 19 Vespa GTV 125 Characteristics ENGINE OVERSIZES Name Description Dimensions Initials Quantity Compression ring 57 x 1 0.15 ÷ 0.30 Oil scraper ring 57 x 1 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 0.15 ÷ 0.35 Compression ring 57.2 x 1 0.15 ÷...
  • Page 20 Vespa GTV 125 Characteristics CHAR - 14...

  • Page 21: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 22 Vespa GTV 125 Tooling APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42 mm bearings 001467Y017 Bell for bearings, outside Ø 39 001467Y014 Pliers to extract ø 15-mm bear- ings 005095Y Engine support...
  • Page 23 Vespa GTV 125 Tooling Stores code Description 008564Y Flywheel extractor 020004Y Punch for removing fifth wheels from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch TOOL - 3...
  • Page 24 Vespa GTV 125 Tooling Stores code Description 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip TOOL - 4...
  • Page 25 Vespa GTV 125 Tooling Stores code Description 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cyl- inder 020306Y Punch for assembling valve seal rings 020319Y Immobilizer check tester 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con-...
  • Page 26 Vespa GTV 125 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 6...
  • Page 27 Vespa GTV 125 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 - 7...
  • Page 28 Vespa GTV 125 Tooling Stores code Description 020365Y 22 mm guide 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool...
  • Page 29 Vespa GTV 125 Tooling Stores code Description 020393Y Piston fitting band 020409Y Multimeter adaptor - Peak volt- age detection 020412Y 15 mm guide 020414Y 28-mm guide 020423Y driven pulley lock wrench TOOL - 9...
  • Page 30 Vespa GTV 125 Tooling Stores code Description 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting TOOL - 10...
  • Page 31 Vespa GTV 125 Tooling Stores code Description 020439Y 17 mm guide 020440Y Water pump service tool 020441Y 26 x 28 mm adaptor 020442Y Pulley lock wrench 020444Y Tool for fitting/ removing the driv- en pulley clutch TOOL - 11...
  • Page 32 Vespa GTV 125 Tooling Stores code Description 020455Y 10-mm guide 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020488Y Pin stops fitting tool (200 cm³ en- gines) 020489Y Hub cover support stud bolt set TOOL - 12...
  • Page 33 Vespa GTV 125 Tooling Stores code Description 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser TOOL - 13...
  • Page 34 Vespa GTV 125 Tooling TOOL - 14...

  • Page 35: Index Of Topics

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 36: Maintenance Chart

    Vespa GTV 125 Maintenance Maintenance chart 1000 K FTER Action Engine oil - replacement Hub oil - change Engine oil - change Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
  • Page 37 Vespa GTV 125 Maintenance Action Throttle lever - adjustment Driven pulley roller casing - Greasing Driving belt - replacement Sliding blocks / variable speed rollers - check Coolant level - check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
  • Page 38 Vespa GTV 125 Maintenance Action Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Driven pulley roller casing - Greasing Tyre pressure and wear - check Vehicle and brake test - road test (*) See instructions in «Idle speed adjustment»...
  • Page 39 Vespa GTV 125 Maintenance 72000 FTER Action Engine oil - replacement Hub oil - change Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change valve clearance - check Idle speed (*) - adjustment...
  • Page 40 Vespa GTV 125 Maintenance Carburettor - 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 41: Checking The Spark Advance

    Vespa GTV 125 Maintenance Checking the spark advance - To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire. - Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug).
  • Page 42 Vespa GTV 125 Maintenance Spark advance variation IGNITION ADVANCE VARIATION Specification Desc./Quantity Operation threshold First threshold : 10700 ±50 Second threshold : 11000 ±50 Reactivation threshold First threshold : 10600±50 Second threshold : 10900±50 Spark elimination First threshold : 1 spark on 7...

  • Page 43: Spark Plug

    Vespa GTV 125 Maintenance Spark plug - Rest the scooter on its stand - Open the saddle and take out the helmet com- partment - Disconnect spark plug HV wire hood; - Unscrew the spark plug using the wrench sup- plied;...

  • Page 44: Air Filter

    Vespa GTV 125 Maintenance Check -Stand 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; -Take out the dipstick checking that the oil level reaches the dipstick lower notch;...
  • Page 45 Vespa GTV 125 Maintenance - Dry with short blasts of compressed air and a clean cloth. - Soak with a 50% mixture of gasoline and oil. - Drip dry the filtering element and then squeeze it with your hands without wringing.

  • Page 46: Engine Oil

    Vespa GTV 125 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. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be con- sidered normal, especially if during the run-in period.
  • Page 47 Vespa GTV 125 Maintenance Replacement Replace oil and filter as indicated in the scheduled maintenance table. The engine must be drained by running off the oil from drainage cap "B" of the flywheel side mesh pre-filter; furthermore to facili- tate oil drainage, loosen the cap/dipstick "A". Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter "C"...

  • Page 48: Oil Pressure Warning Light

    Vespa GTV 125 Maintenance Check This operation must be carried out with the engine cold and following the procedure below: 1. Place the vehicle on its centre stand and on flat ground. 2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down completely.

  • Page 49: Cooling System

    Vespa GTV 125 Maintenance indicator on the head, make the crankshaft turn once more. -The TDC reference mark is repeated also be- tween the flywheel cooling fan and the flywheel cover. To use this reference mark, remove the spark plug...

  • Page 50: Level Check

    Vespa GTV 125 Maintenance Level check The brake fluid tanks for the front and rear brakes are located on the pumps under the handlebar cover. Proceed as follows: - Remove the brake pump cover - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal;...

  • Page 51: Headlight Adjustment

    Vespa GTV 125 Maintenance BRAKING CIRCUIT FLUID IS HYGROSCOPIC, WHICH MEANS THAT IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING. CAUTION NEVER USE BRAKE FLUID COMING FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, BRAKE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY 2 YEARS.
  • Page 52 Vespa GTV 125 Maintenance SAS filters inspection and cleaning the SAS for leader engines 125 cm³ - 200 cm³ Euro 2 operates in a similar manner to the SAS for 2T engines. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the dis- charge pipe on the head.
  • Page 53 Vespa GTV 125 Maintenance The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved re- action of the catalytic converter.
  • Page 54 Vespa GTV 125 Maintenance - Remove the 2 fixing screws, the gasket and the pipe connecting the SAS valve to the head. Then remove the pipe. - Release the electrical cable from the flywheel cover clamp as indicated in the photograph...
  • Page 55 Vespa GTV 125 Maintenance - Remove the pump support bracket and fuel filter. - Remove the flywheel cover together with the SAS valve acting on the 4 hexagonal-head screws as indicated in the photograph - Remove the SAS valve two fixing screws and re-...
  • Page 56 Vespa GTV 125 Maintenance - Check that the SAS valve plastic support is not dented or distorted - Check that the gasket is in good conditions - Carefully clean the inside and outside filters. Re- place them if damaged or abnormally distorted.

  • Page 57: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 58: Poor Performance

    Vespa GTV 125 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve...

  • Page 59: Insufficient Lubrication Pressure

    Vespa GTV 125 Troubleshooting Possible Cause Operation Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear- ance - Engine flooded. Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it...
  • Page 60 Vespa GTV 125 Troubleshooting Possible Cause Operation Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level adding the recommended oil...

  • Page 61: High Fuel Consumption

    Vespa GTV 125 Troubleshooting Possible Cause Operation Pressure too low at the end of compression Check the thermal group seals and replace worn components Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit...

  • Page 62: Brakes Overheating

    Vespa GTV 125 Troubleshooting Possible Cause Operation the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc. Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace Brake disc slack or distorted Check the brake disc screws are locked;...

  • Page 63: Noisy Suspension

    Vespa GTV 125 Troubleshooting Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steer- ing even after making the above adjustments, check the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace them.
  • Page 64 Vespa GTV 125 Troubleshooting TROUBL - 8...

  • Page 65: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 66 Vespa GTV 125 Electrical system 1. Electronic ignition device 2. Immobilizer aerial 3. Wiring for the electric pump and the fuel electric pump management device 4. Magneto flywheel - Pick-up 5. Voltage regulator 6. Engine stop switch 7. Automatic starter 8.
  • Page 67 Vespa GTV 125 Electrical system 20. Rear left turn indicator 21. Rear light A. Tail light bulb B. Stop light bulbs 22. Rear right turn indicator 23. Front left turn indicator 24. Asymmetrical headlight assembly A. Tail light bulb B. Headlight bulb 25.
  • Page 68 Vespa GTV 125 Electrical system 40. Saddle opening actuator 41. Spark plug 42. HV coil Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple...
  • Page 69 Vespa GTV 125 Electrical system Headlights and automatic starter section 1. Electronic ignition device 6. Engine stop switch 7. Automatic starter 8. Fuse unit 9. Main fuse 10. Battery 17. Light switch 18. Licence plate lamp 19. Front tail light 21.
  • Page 70 Vespa GTV 125 Electrical system A. Instrument panel bulb E. Headlight warning light F. High-beam warning light 31. Warning light unit with clock F. Lighting F. Lighting 38. Key switch Battery recharge and starting 1. Electronic ignition device 4. Magneto flywheel - Pick-up 5.
  • Page 71 Vespa GTV 125 Electrical system 14. Stop button on rear brake 15. Stop button on front brake 21. Rear light B. Stop light bulbs 38. Key switch Level indicators and enable signals section 1. Electronic ignition device 2. Immobilizer aerial 6.

  • Page 72: Devices And Accessories

    Vespa GTV 125 Electrical system E. Headlight warning light F. High-beam warning light 31.Warning light unit with clock A. Ignition disabled warning light B. Turn signal warning light C. Immobilizer warning light D. ABS warning light E. Water temperature warning light G.Clock...

  • Page 73: Checks And Inspections

    Vespa GTV 125 Electrical system 16. Wiring for antitheft device 20. Rear left turn indicator 22. Rear right turn indicator 23. Front left turn indicator 25. Front right turn indicator 31.Warning light unit with clock B. Turn signal warning light G.
  • Page 74 Vespa GTV 125 Electrical system When the key switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The duration of the flash depends on the electronic control unit program (see figure).

  • Page 75: Diagnostic Codes

    Vespa GTV 125 Electrical system - Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds). - Alternately insert all the available Black keys set- ting each of them to "ON" for 2 seconds.
  • Page 76 Vespa GTV 125 Electrical system 3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised Diagnostic code - 2 flashes Diagnosis code: 2-flashes When the 2-flash code is detected, carry out the following checks: - Check if the failure continues after changing key (MASTER key included).

  • Page 77: Ignition Circuit

    Vespa GTV 125 Electrical system Example with programmed control unit, trans- ponder, programmed key and aerial working prop- erly. Ignition is enabled (regular conditions of use) Ignition circuit Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug.
  • Page 78 Vespa GTV 125 Electrical system - HV coil primary check Disconnect the control unit connector and check that the cable between terminal No. 3 and terminal No. 8 is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals.
  • Page 79 Vespa GTV 125 Electrical system N.B. THE MULTIMETER MUST BE SELECTED TO DETECT CONTINUOUS VOLTAGE. Electric characteristic Resistance value: > 2 Volt - HV coil With the control unit and HV coil connected, meas- ure the voltage of the coil primary during the start-...

  • Page 80: Stator Check

    Vespa GTV 125 Electrical system Stator check - With a tester, check the circuit between connec- tions 5-3 and 5-1 is not interrupted. - Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω...
  • Page 81 Vespa GTV 125 Electrical system Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator.
  • Page 82 Vespa GTV 125 Electrical system Choke Inspection Refer to the engine section to check the resistance and operating conditions of the component. As re- gards voltage supply, keep the connector connec- ted to the system and check that the two terminals receive battery voltage when the engine is on (see figure).
  • Page 83 Vespa GTV 125 Electrical system If no voltage is detected, check the cable harness, the connections and make sure the 15A main fuse is in good conditions; otherwise, proceed as follows: - Jump terminals No.1 (Black/Blue) and No. 4 (Red/Black) (see figure), and set the turn indicator switch alternately to the left and to the right and check that the lights turn on.
  • Page 84 Vespa GTV 125 Electrical system Fuses The electrical system is equipped with: 1. six protection fuses «A» located in the glove compartment to the left 2. one 15A fuse «B» located under the helmet compartment under the saddle hinge latch.
  • Page 85 Vespa GTV 125 Electrical system Specification Desc./Quantity Protected circuits: Voltage regulator, elec- tric fan, key switch, electronic starter device. Dry-charge battery Battery recharge Normal bench charging must be carried out using the special (single or multiple) battery charger, setting the battery charge selector to the type of battery that needs recharging (i.e., at a current equal to 1/10 of the battery rated capacity).
  • Page 86 Vespa GTV 125 Electrical system (-) must be connected to the -negative clamp while the other two red wires marked (+) must be con- nected to the clamp marked with the +positive sign. Checking the electrolyte level The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level.

  • Page 87: Battery Installation

    Vespa GTV 125 Electrical system Battery installation • Remove the battery cover after undoing the 4 screws shown in the photograph. - Remove the strap fastening the battery - Insert the battery breather pipe through the hole shown in the photograph.
  • Page 88 Vespa GTV 125 Electrical system - Fit the battery as shown in the photograph. N.B. IN ORDER TO FIT THE CABLES ON THE BAT- TERY TERMINALS CORRECTLY, REST THE LOWER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.
  • Page 89 Vespa GTV 125 Electrical system - Refit the battery cover ELE SYS - 25...
  • Page 90 Vespa GTV 125 Electrical system ELE SYS - 26...

  • Page 91: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 92 Vespa GTV 125 Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Undo the two exhaust manifold fixings on the head. - Undo the three screws fixing the muffler to the support arm.
  • Page 93 Vespa GTV 125 Engine from vehicle - Disconnect the battery - Remove the helmet compartment - Remove the side fairings Remove the full muffler assembly. - Remove the air cleaner housing acting on the 3 screws indicated in the picture, by removing the...
  • Page 94 Vespa GTV 125 Engine from vehicle - Remove the coolant inlet pipe to the pump as in- dicated in the photograph. - Remove the fuel valve vacuum intake pipe from "T" joint indicated in the photograph - Remove the fuel supply pipe from the carburettor...
  • Page 95 Vespa GTV 125 Engine from vehicle - Remove the spark plug cap - Remove the coolant temperature sensor con- nector indicated in the photo - Remove the throttle control cable from the car- burettor acting on the nut shown in the photo...
  • Page 96 Vespa GTV 125 Engine from vehicle - Remove the positive and negative wires from the starter motor as shown in the photograph - Remove the connector from the flywheel wiring shown in the photograph. - Remove the cable from the retainer clamp on the flywheel cover - Remove the rear shock absorbers.
  • Page 97 Vespa GTV 125 Engine from vehicle - Use a jack to support the vehicle properly. Re- move the engine-swinging arm fixing pin by acting on the nut and the head of the pin indicated in the photograph - The engine is now free.
  • Page 98 Vespa GTV 125 Engine from vehicle ENG VE - 8...
  • Page 99 INDEX OF TOPICS NGINE...

  • Page 100: Automatic Transmission

    Vespa GTV 125 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 101: Removing The Driven Pulley Shaft Bearing

    Vespa GTV 125 Engine - To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.
  • Page 102 Vespa GTV 125 Engine Metallic roller Removal Belt support roller (200 cm³ models only) - Check that the roller does not show signs of wear and that it turns freely. - Remove the special fixing screw and the roller together with the bearing.

  • Page 103: Removing The Driven Pulley

    Vespa GTV 125 Engine Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.

  • Page 104: Removing The Clutch

    Vespa GTV 125 Engine Characteristic clutch bell inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm Removing the clutch Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position F from the tool internal side.
  • Page 105 Vespa GTV 125 Engine CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD. Characteristic Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it.
  • Page 106 Vespa GTV 125 Engine Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide Inspecting the driven fixed half-pulley - Measure the outer diameter of the pulley bushing.

  • Page 107: Refitting The Driven Pulley

    Vespa GTV 125 Engine Refitting the driven half-pulley bearing - Support the pulley bushing adequately from the threaded side using a wooden surface. - Fit a new roller sleeve as in the figure. - For the fitting of the new ball bearing, follow the example in the figure using a modular punch.
  • Page 108 Vespa GTV 125 Engine - Fit the half-pulley over the bushing using the ap- propriate tool - Check that the pins are not worn and proceed to refitting them in their slots. - Refit the torque server closure collar. Using a curved-spout grease gun, lubricate the driven pulley assembly with approximately 6 g of grease.
  • Page 109 Vespa GTV 125 Engine Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring while it is unloaded. Characteristic Standard length 106 mm acceptable limit after use: 101 mm Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis.
  • Page 110 Vespa GTV 125 Engine - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action until it reaches the pul- leys maximum opening and place the belt on the minimum rolling diameter.

  • Page 111: Removing The Driving Pulley

    Vespa GTV 125 Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width: 21.5 mm Driving belt - standard width: 22.5 ± 0.2 mm During the wear checks foreseen in the scheduled maintenance services at 6,000 km, 18,000 km, etc., check that the rim bottom of the toothing does...
  • Page 112 Vespa GTV 125 Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure.
  • Page 113 Vespa GTV 125 Engine Refitting the driving pulley - Correctly refit the previously removed Bendix back to its position. - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread Loctite 243 Quick Set threadlock on the thread and tighten the nut to the prescribed torque.
  • Page 114 Vespa GTV 125 Engine - Fit the driven pulley/Clutch/belt unit on the en- gine. Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover.
  • Page 115 Vespa GTV 125 Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
  • Page 116 Vespa GTV 125 Engine Removing the wheel axle bearings Hold up the hub cover and take out the bearing. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide With the appropriate tools, remove the oil seal as shown in the figure.
  • Page 117 Vespa GTV 125 Engine Removing the driven pulley shaft bearing When removing the driven pulley shaft, the corre- sponding bearing and oil seal, remove the trans- mission cover and the clutch group as explained above. - Extract the driven pulley shaft from its bearing.
  • Page 118 Vespa GTV 125 Engine Refitting the wheel axle bearing Support the hub cover on a wooden surface. - Heat the cover crankcase with special heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 119 Vespa GTV 125 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 120 Vespa GTV 125 Engine Refitting the ub cover - Fit a new gasket together with the centring dowels. - Seal the gasket of the breather pipe using black silicone sealant. - Fit the gearbox cover, making sure the breather pipe is in the correct position.

  • Page 121: Flywheel Cover

    Vespa GTV 125 Engine Flywheel cover Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover Removing the stator - Remove the electric terminal of the minimum oil pressure switch.
  • Page 122 Vespa GTV 125 Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the prescribed torque. - Place the cable harness as shown in the figure. - Stator screws and Pick-Up N.B.
  • Page 123 Vespa GTV 125 Engine Removing the flywheel magneto - Lock the rotation of the Flywheel with the calliper spanner tool. - Remove the nut. - Take out the flywheel. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS N.B.

  • Page 124: Removing The Intake Manifold

    Vespa GTV 125 Engine Flywheel nut 54 ÷ 60 Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - Fit the starter on the crankcase, locking the two screws to the prescribed torque. Locking torques (N*m) Starter motor screws 11 ÷...
  • Page 125 Vespa GTV 125 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 and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
  • Page 126 Vespa GTV 125 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 127: Removing The Cam Shaft

    Vespa GTV 125 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 128: Removing The Cylinder Head

    Vespa GTV 125 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket.
  • Page 129 Vespa GTV 125 Engine CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. ENG - 31...

  • Page 130: Inspecting The Small End

    Vespa GTV 125 Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAME- TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
  • Page 131 Vespa GTV 125 Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. - Calculate the coupling clearance between pin and connecting rod end. - Measure the capacity diameter on the piston. - Calculate the piston pin coupling clearance.
  • Page 132 Vespa GTV 125 Engine Characteristic Pin diameter Standard diameter 56.997 ÷ 57.025 piston diameter 56.945 ÷ 56.973 mm Pin diameter: Standard clearance 0.015 ÷ 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm Wrist pin seat on the piston: Standard diameter 15.001 ÷...

  • Page 133: Inspecting The Piston

    Vespa GTV 125 Engine Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
  • Page 134 Vespa GTV 125 Engine D = right - Place the wrist pin stop ring into position using a punch - Fit the wrist pin stop using the plug as shown in the figure CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
  • Page 135 Vespa GTV 125 Engine - Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation) - Position the dial gauge on the piston as shown in the figure and measure how much the piston pro- trudes. - By means of the table shown in the specifications chapter identify the cylinder base gasket thickness to be used for refitting.
  • Page 136 Vespa GTV 125 Engine Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.

  • Page 137: Inspecting The Cylinder Head

    Vespa GTV 125 Engine Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
  • Page 138 Vespa GTV 125 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
  • Page 139 Vespa GTV 125 Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
  • Page 140 Vespa GTV 125 Engine CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFUL- LY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
  • Page 141 Vespa GTV 125 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.

  • Page 142: Inspecting The Cam Shaft

    Vespa GTV 125 Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft.
  • Page 143 Vespa GTV 125 Engine Cam shaft check: Maximum admissible axial clearance 0.42 mm Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm Cam shaft check: Standard height Outlet: 29.209 mm Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm...
  • Page 144 Vespa GTV 125 Engine Fit the pins and rocking levers. - Lubricate the two rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers.
  • Page 145 Vespa GTV 125 Engine Assemble the limiting bell using the counterweight fixing screw as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Limiting bell screw 11 ÷ 15 Nm Set the tensioner cursor to the rest position.
  • Page 146 Vespa GTV 125 Engine Name Torque in Nm Counterweight screw 7 ÷ 8.5 Plate screws 4 ÷ 6 Nm Slider screw 10 ÷ 14 Nm - 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.

  • Page 147: Crankcase - Crankshaft

    Vespa GTV 125 Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
  • Page 148 Vespa GTV 125 Engine Before opening the engine crankcase, it is advis- able to check axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge. Higher clearances are signs of wear on the sup- porting surfaces of the crankshaft casing.
  • Page 149 Vespa GTV 125 Engine Fitting clearance Connecting rod axial clearance 0.20 - 0.50 Check the radial clearance on the connecting rod. Standard clearance: 0.036 ÷ 0.054 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
  • Page 150 Vespa GTV 125 Engine The crankshaft can be reused when the width is within the standard values and the surfaces show no signs of scoring. Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure.
  • Page 151 Vespa GTV 125 Engine RANKSHAFT ALIGNMENT Titolo Durata/Valore Testo Breve (< 4000 Indirizzo Immagine car.) Crankshaft alignment Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean the all surfaces and oil ducts. - On the transmission-side crankcase half, take...
  • Page 152 Vespa GTV 125 Engine cylinder head and the oil drainage duct at the fly- wheel side oil seal. - 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.
  • Page 153 Vespa GTV 125 Engine Inspecting the crankshaft plain bearings o obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (3,2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
  • Page 154 Vespa GTV 125 Engine TYPE IDENTIFICATION BLUE YELLOW Type "A" Type "B" Type "C" - RED - BLUE - YEL- Main half- 1.970 ÷ 1.9703 ÷ 1.976 ÷ bearing 1.973 1.976 1.979 Bush- Crank- Internal bush- Possible ing cat- case...
  • Page 155 Vespa GTV 125 Engine N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED...
  • Page 156 Vespa GTV 125 Engine ENG - 58...

  • Page 157: Oil Pressure Check

    Vespa GTV 125 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electrical connexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...

  • Page 158: Crankshaft Oil Seals

    Vespa GTV 125 Engine Crankshaft oil seals Refitting - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the specified torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, to- gether with the locating dowels.

  • Page 159: Oil Pump

    Vespa GTV 125 Engine Oil pump - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
  • Page 160 Vespa GTV 125 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. - If not, eliminate any impurities or replace defective parts.
  • Page 161 Vespa GTV 125 Engine ing lubrication of the crankshaft and connect- ing rod Locking torques (N*m) Oil sump screws 10 ÷ 14 SAS valve Inspecting the one-way valve - Remove the SAS valve. - Provisionally assemble the rubber coupling of the SAS valve outlet to ensure tightness.
  • Page 162 Vespa GTV 125 Engine Inspecting the cut-off - Remove the SAS valve. - Connect the MITYVAC pump in low-pressure mode (VACUUM) to the CUT-OFF valve vacuum intake. - Apply a vacuum value higher than 0.5 BAR. - Check that this value is kept all the time.

  • Page 163: Fuel Supply

    Vespa GTV 125 Engine 020329Y MityVac vacuum-operated pump Fuel supply - To clean the filtering element proceed as follows: remove the 4 filter cover fixing screws indicated in the figure; remove the cover and take out the pa- per filtering element, clean with compressed air and refit.
  • Page 164 Vespa GTV 125 Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
  • Page 165 Vespa GTV 125 Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure.
  • Page 166 Vespa GTV 125 Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
  • Page 167 Vespa GTV 125 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 69...
  • Page 168 Vespa GTV 125 Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 169 Vespa GTV 125 Engine Kehin - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
  • Page 170 Vespa GTV 125 Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear.
  • Page 171 Vespa GTV 125 Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
  • Page 172 Vespa GTV 125 Engine - Wash and blow the flow screw properly. - Check that screw is not deformed and/or rusty. - Assemble the spring on the screw. - Screw the flow screw on the carburettor body. - The screw final position should be determined by an exhaust fume analysis.
  • Page 173 Vespa GTV 125 Engine Kehin - Check that the tapered pin of the vacuum valve does not show wear. - Check that the depression valve does not show threads on the external surfaces. - Check that the vacuum intake hole is not clogged.
  • Page 174 Vespa GTV 125 Engine - Wash and blow dry the filter sponge of the am- bient pressure intake. - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws.
  • Page 175 Vespa GTV 125 Engine Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the piston sealing gasket is not de- formed.

  • Page 176: Adjusting The Idle

    Vespa GTV 125 Engine Starter device resistance ~ 20 Ω Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow cer- tain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to re-...

  • Page 177: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 178: Removing The Front Wheel

    Vespa GTV 125 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 ÷ 25...
  • Page 179 Vespa GTV 125 Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide...

  • Page 180: Refitting The Front Wheel

    Vespa GTV 125 Suspensions Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 Refitting the front wheel - To refit, carry out the removal operations but in reverse order and comply with the specified locking torque. Locking torques (N*m) Wheel fixing screw 20 ÷...
  • Page 181 Vespa GTV 125 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 182 Vespa GTV 125 Suspensions - Pre-loosen the 3 nuts fixing the mudguard to the suspension - Remove the rear handlebar cover. - Remove the screw fixing the handlebar to the steering tube - Tilt the handlebar towards the shield back plate...
  • Page 183 Vespa GTV 125 Suspensions To refit, carry out the removal operations but in reverse order; grease the fifth wheel fittings and tighten to the prescribed torques. Locking torques (N*m) Upper ring nut 30 ÷ 40 Nm Lower ring nut 30 ÷ 40 Nm Handlebar to steering tube 45 ÷ 50 Nm...
  • Page 184 Vespa GTV 125 Suspensions - Use the specific tool to fit the fifth wheel fitting on the headstock as indicated in the figure Specific tooling 020037Y Punch - Remove the steering tube - Remove the attachment bracket - Use the specific tool with the part 1 and operate the handgrip until removing temporarily the pin and the Nadella opposite the tool thrusting direction.
  • Page 185 Vespa GTV 125 Suspensions To fit sealing rings, roller casings and wedging washers proceed as follows - Lubricate the sealing rings with mineral oil and half fill the roller casings with Z2 grease. - Insert the seal ring on the pin and the roller bush- ing with wedging washers at the same time.
  • Page 186 Vespa GTV 125 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. Afterwards remove the...

  • Page 187: Front Shock Absorber

    Vespa GTV 125 Suspensions - Remove the steering tube - Remove the attachment bracket - Use the specific tool with the part 1 and operate the handgrip until removing temporarily the pin and the Nadella opposite the tool thrusting direction.
  • Page 188 Vespa GTV 125 Suspensions Shock-absorber - calliper bracket - Remove the front wheel hub with the brake disc - Remove the front shock absorber lower clamps - Remove the bracket locking Seeger ring - Unscrew the bracket - 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.
  • Page 189 Vespa GTV 125 Suspensions - Remove the two roller bearings from the bracket with the specific tool operating on the shock ab- sorber attachment side as shown in the photo- graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor...

  • Page 190: Removing The Rear Wheel

    Vespa GTV 125 Suspensions - Suitably hold the brake calliper - shock absorber attachment bracket - Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch...
  • Page 191 Vespa GTV 125 Suspensions Removal - Place the scooter on its centre stand; - Remove the engine housing - Remove the swinging arm/engine fitting shown in the photo - Move the engine back - remove the spring anchoring the swinging arm to...
  • Page 192 Vespa GTV 125 Suspensions - Remove the left and right caps located under the footrest to reach the pin fixing the swinging arm to the body. - Remove the pin. Then remove the swinging arm. - Check the entire swinging arm assembly.
  • Page 193 Vespa GTV 125 Suspensions - To check the clearance on the frame-side arm, mount the retainer using the pin fixing the swinging arm to the frame and two adaptor rings of the ap- propriate tool 020229Y. Alternatively use two washers with inner diameter for 12-mm pins, min.
  • Page 194 Vespa GTV 125 Suspensions - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the O-rings facing outwards Specific tooling 020244Y 15-mm diameter punch 020115Y Ø 18 punch Characteristic Length of the swinging arm tube on the engine side: L 175.3 + 0.3 0...
  • Page 195 Vespa GTV 125 Suspensions - Make sure the silent bloc is not broken. If there is, replace it. - Remove the seeger ring shown in the photograph - Remove the full silent bloc bracket - Undo the silent bloc ring shown in the photograph...

  • Page 196: Shock Absorbers

    Vespa GTV 125 Suspensions - Install a new silent bloc, making sure it aligns properly with the reference tooth. - Fit the silent blocs, making sure the chamfered part of the silent bloc matches the chamfered part of the bracket...
  • Page 197 Vespa GTV 125 Suspensions the one side and from that fixed to the muffler on the other; - undo the two upper nuts (one on each side) fixing the shock absorber spring assembly to the frame and remove the shock absorbers themselves.

  • Page 198: Side Stand

    Vespa GTV 125 Suspensions Locking torques (N*m) Bracket fixing screws to the engine crankcase: 20 ÷ 25 Nm Shock absorber lower clamp 33 ÷ 41 Wheel axle clamping 104 ÷ 126 Nm Centre-stand REMOVAL - Use a jack to support the vehicle properly.

  • Page 199: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 200: Rear Brake Calliper

    Vespa GTV 125 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. - Using a pin partially remove the brake pad re- tention pin.
  • Page 201 Vespa GTV 125 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 202: Front Brake Calliper

    Vespa GTV 125 Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the crankcase with the two screws with elastic washer at the prescribed tor-...
  • Page 203 Vespa GTV 125 Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the two front brake calliper devices fas- tening them to the support as shown in the photo- graph.

  • Page 204: Rear Brake Disc

    Vespa GTV 125 Braking system - that the brake pad check spring works properly. CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED. The brake pad check spring 1. pad fixing screws 2. reaction plate fixing screws 3.

  • Page 205: Disc Inspection

    Vespa GTV 125 Braking system Removal - Remove the rear brake calliper. - Remove the brake disc and the hub from the wheel axle - To remove the brake disc from the hub, hold the unit firmly with a vice and operate on the 5 fixing...

  • Page 206: Front Brake Disc

    Vespa GTV 125 Braking system Characteristic Max. deviation allowed: 0.1 mm - If you detect incorrect values, replace the disc. If the anomaly persists, replace the hub. Front brake disc Removal - Remove the front wheel - Remove the front brake calliper...

  • Page 207: Front Brake Pads

    Vespa GTV 125 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 208 Vespa GTV 125 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 209: Rear Brake Pads

    Vespa GTV 125 Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B. IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT- TING, GENTLY EXPAND THE PADS.
  • Page 210 Vespa GTV 125 Braking system See also Removal Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the clip on the pin - Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque.

  • Page 211: Brake Fluid Level Check

    Vespa GTV 125 Braking system BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND...
  • Page 212 Vespa GTV 125 Braking system HICLE. THE BRAKING CIRCUIT FLUID IS HY- GROSCOPIC, WHICH MEANS THAT IT ABSORBS MOISTURE FROM THE SUR- ROUNDING AIR. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING.
  • Page 213 Vespa GTV 125 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 214 Vespa GTV 125 Braking system 1. Reservoir cap screw 2. Reservoir cap. 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.

  • Page 215: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 216 Vespa GTV 125 Cooling system Water pump - overhaul Water pump assembly With a hot air gun heat the inner side of the fly- wheel cover. AVOID OVERHEATING AS THIS MAY ALTER THE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the flywheel cover on the ring base following the same procedure as for removal.
  • Page 217 Vespa GTV 125 Cooling system - Insert the flywheel cover with bearings on the ap- propriate tool. - Insert the shaft together with the mechanical gas- kets on the bearings. - With the appropriate punch and socket, insert the shaft in the bearings and the drive until the end of stroke of the appropriate tool cannot be seen.
  • Page 218 Vespa GTV 125 Cooling system -Place the flywheel cover on the ring base which is part of the tool N.B. TO AVOID DAMAGING THE COVER SURFACE THAT SEALS THE COOLANT, USE THE RING BASE WITH THE ACCURATELY MACHINED SURFACE FACING THE FLYWHEEL COVER.
  • Page 219 Vespa GTV 125 Cooling system - Use a screwdriver to remove the static part of the ceramic seal from the flywheel cover. - Place the flywheel cover below the socket making sure it is perfectly levelled. - Use the punch in the inverted position to extract the two ball bearings.
  • Page 220 Vespa GTV 125 Cooling system Check 1) Look to see that the thermostat is not damaged. 2) Fill a metal container with approx. 1 litre of wa- ter. Immerse the thermostat, and keep it in the centre of the container.
  • Page 221 INDEX OF TOPICS CHAS HASSIS...
  • Page 222 Saddles fitted to this scooter are upholstered in Authentic Leather, and are a stylish accessory to em- phasise an already exclusive product such as your Vespa. As leather is a natural and vivid material, it tends to get "very opaque" aspect as time goes by, an aspect typical of Authentic Leather. This product may also show characteristic undertones and strains.
  • Page 223 Vespa GTV 125 Chassis Remove the four screws shown in the figure and the rear seat from the chassis saddle. - Free the electric cables form the retaining clamps indicated in the photograph Unscrew the two screws of saddle fixing hook cover.

  • Page 224: Rear Rack

    Vespa GTV 125 Chassis To remove the cable and the sheath: - Remove the elastic ring and unscrew the cable end from the seat on the saddle fixing hook. - Remove the other end of the cable from the fixing seat on the locking block.

  • Page 225: Instrument Panel

    Vespa GTV 125 Chassis - Remove the two screws, indicated in the figure, that fix the luggage rack to the body Instrument panel - Remove the two screws indicated in the figure. -Remove the instrument panel by slightly pulling it upwards.
  • Page 226 Vespa GTV 125 Chassis - Remove the bulb holder by turning it anticlock- wise and take out the failing bulb. - To fit, insert the new bulb and turn the bulb holder clockwise. Headlight assy. - Operate the screw indicated in the figure to re-...
  • Page 227 Vespa GTV 125 Chassis - Remove the expansion tank cover and then its - Remove the central screw inside the glove-box, indicated in the photograph - Remove the two screws indicated in the photo- graph and located below the expansion tank cover...
  • Page 228 Vespa GTV 125 Chassis - Remove the electric saddle opening switch, the fuse box and the manual saddle opening cable as shown in the photograph Removing the ignition key-switch when on *off* - Remove the shield back plate. - Remove the immobilizer aerial as shown in the figure.
  • Page 229 Vespa GTV 125 Chassis - Lightly push the master-cylinder and extract the lock from the notch shown in the figure. - Hence extract the master-cylinder complete with the key-switch. - For the reassembly proceed in the reverse order. Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the...
  • Page 230 Vespa GTV 125 Chassis Front wheel housing • Remove the front fork; • Unscrew the central stud of the wheel well at the frame; • Disconnect the brake pipe to the pump and pull it out;; • Remove the odometer transmission..
  • Page 231 Vespa GTV 125 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 - Remove the passenger footrests undoing the two...

  • Page 232: Rear Mudguard

    Vespa GTV 125 Chassis - Remove the right and left lower covers as shown in the figure - Remove the screws under the non-slip rubber mat of the footrest as indicated in the photograph Side fairings - Remove side fairings, right and left, by undoing...

  • Page 233: Fuel Tank

    Vespa GTV 125 Chassis Helmet bay - Lift the saddle and remove the helmet compart- ment Fuel tank - Remove the helmet compartment - Remove the side fairings - Remove the muffler - Remove the luggage rack - Remove the shock absorber upper clamps...

  • Page 234: Front Mudguard

    Vespa GTV 125 Chassis Rear central cover - Remove the four screws indicated in the figure Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard...

  • Page 235: Radiator Fan

    Vespa GTV 125 Chassis Radiator fan - In order to carry out any operation on the radiator unit, flow out the coolant in the coolant delivery pipe in the pump, indicated in the photograph. - Remove the shield back plate;...
  • Page 236 Vespa GTV 125 Chassis Front central cover - Remove the "PIAGGIO" clip-on badge - Unscrew the screw indicated in the figure - Remove the grille CHAS - 16...
  • Page 237 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 238: Safety Locks

    Vespa GTV 125 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance checks: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection • Safety Locks • Cover retaining screws...
  • Page 239 Vespa GTV 125 Pre-delivery CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE LEAD. WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL- PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.

  • Page 240: Functional Inspection

    Vespa GTV 125 Pre-delivery • Electrical radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Functional check up: • Hydraulic braking system: lever travel •...
  • Page 241 INDEX OF TOPICS TIME...
  • Page 242 Vespa GTV 125 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 refit.
  • Page 243 Vespa GTV 125 Time Code Action Duration 001133 Engine crankcase- Replace- ment Crankshaft CRANKSHAFT Code Action Duration 001099 Oil seal, flywheel side - Re- placement 001117 Crankshaft - Replacement TIME - 3...

  • Page 244: Cylinder Assy

    Vespa GTV 125 Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replace- ment 001154 Pin ring piston unit - Service TIME - 4...

  • Page 245: Cylinder Head Assy

    Vespa GTV 125 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 TIME - 5...

  • Page 246: Cylinder Head Cover

    Vespa GTV 125 Time Rocker arms support assy. CAM SHAFT Code Action Duration 001148 Rocking lever valve - Re- placement 001044 Camshaft - Replacement Cylinder head cover TIME - 6...

  • Page 247: Chain Tensioner

    Vespa GTV 125 Time HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replace- ment 001074 Oil vapour recovery pipe - Re- placement Chain tensioner CHAIN TIGHTENER Code Action...

  • Page 248: Oil Filter

    Vespa GTV 125 Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Re- placement Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement...
  • Page 249 Vespa GTV 125 Time Code Action Duration 001155 Clutch bell - Replacement Oil pump OIL SUMP PUMP Code Action Duration 001125 Chain guide pads - Replace- ment 001051 Belt/Timing chain - Change 001042 Oil pump - Service 001112 Oil pump - change...

  • Page 250: Final Reduction

    Vespa GTV 125 Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Reduction gear - Replace- ment 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Replacement 004125 Rear wheel axle - Replace- ment TIME - 10...

  • Page 251: Driving Pulley

    Vespa GTV 125 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001066 Driving pulley - Removal and Refitting 001006 driving pulley - Service TIME - 11...

  • Page 252: Transmission Cover

    Vespa GTV 125 Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Replacement 001096 Transmission crankcase cov- er - Replacement 001131 Transmission air intake - Re- placement TIME - 12...

  • Page 253: Starter Motor

    Vespa GTV 125 Time Starter motor ELECTRICAL START UP Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replace- ment 001141 Belt anti-flapping roller - Re- placement TIME - 13...

  • Page 254: Magneto Flywheel

    Vespa GTV 125 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - replace 001113 Water pump / Pump rotor - Replacement 001067 Stator - Removal and Refit- ting 001058 Complete flywheel - Replace- ment 001161 Secondary air filter - Replace-...
  • Page 255 Vespa GTV 125 Time Carburettor CARBURETTOR Code Action Duration 001013 Intake manifold - change 007020 Carburettor heating tubing - replacement 001008 Carburettor - Inspection 001063 Carburettor - Replacement 001081 Automatic choke - Replace- ment 003058 Carburettor - Adjustment 001136 Exhaust emissions - Adjust-...

  • Page 256: Exhaust Pipe

    Vespa GTV 125 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 16...

  • Page 257: Air Cleaner

    Vespa GTV 125 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor fitting - Replacement TIME - 17...
  • Page 258 Vespa GTV 125 Time Frame FRAME Code Action Duration 004001 Chassis - Replacement 004085 Fairing (1) - Replacement 004149 Shield central cover - Re- placement 004053 Spoiler - Replacement 004015 Footrest - Removal and Re- fitting 004023 Shield rim - Replacement...

  • Page 259: Centre-Stand

    Vespa GTV 125 Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 19...

  • Page 260: Rear Cover

    Vespa GTV 125 Time MATS AND COVERS Code Action Duration 005007 Battery - Replacement 004079 Footrest - replacement 004071 Battery compartment - re- placement 005046 Battery cover - change 004078 Front/rear footrest rubber - Replacement Rear cover REAR SHIELD Code...

  • Page 261: Underseat Compartment

    Vespa GTV 125 Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004136 License plate support - Re- placement 004016 Helmet compartment - Re- moval and Refitting 005048 Licence plate holder - Re- placement TIME - 21...
  • Page 262 Vespa GTV 125 Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replace- ment 004009 Rear mudguard - Replace- ment 003044 Shock absorber cover - Re- placement TIME - 22...
  • Page 263 Vespa GTV 125 Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment 004007 Fuel valve - Replacement TIME - 23...

  • Page 264: Expansion Tank

    Vespa GTV 125 Time Expansion tank EXPANSION TANK Code Action Duration 007002 Water cooler - Replacement 007016 Fan complete with support - Replacement 007001 Expansion tank - Replace- ment 007014 Radiator thermal switch - Re- placement 007013 Expansion tank / radiator...

  • Page 265: Rear Shock Absorber

    Vespa GTV 125 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting Steering column bearings TIME - 25...

  • Page 266: Handlebar Covers

    Vespa GTV 125 Time STEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Re- placement 003073 Steering clearance - Adjust Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Re- placement 004019 Rear handlebar covers - Re-...

  • Page 267: Handlebar Components

    Vespa GTV 125 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Removal and re- fitting 002067 Rear brake pump - Replace- ment 002024 Front brake pump - Removal and refitting 005017 Stop switch - Replacement 002059 Right-hand knob - change...

  • Page 268: Swinging Arm

    Vespa GTV 125 Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chas- sis connection - Replacement 004058 Silent block - Replacement TIME - 28...

  • Page 269: Brake Hoses

    Vespa GTV 125 Time Brake hoses CALLIPER BRAKE PIPING Code Action Duration 003071 Rear brake pads/shoes - Check wear 003070 Front brake pads / Shoes - Check wear 002040 Front brake calliper - Check 002048 Rear brake calliper - Re-...
  • Page 270 Vespa GTV 125 Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement TIME - 30...
  • Page 271 Vespa GTV 125 Time Instrument panel INSTRUMENT PANEL Code Action Duration 004066 Driving mirror - Replacement 005014 Odometer - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Re- placement 005006 Light switch or turn indicators - Replacement...
  • Page 272 Vespa GTV 125 Time Rear rack UGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement TIME - 32...
  • Page 273 Vespa GTV 125 Time Locks LOCKS Code Action Duration 002083 Saddle opening transmission - Replacement 002092 Transmission splitter/ hook transmission - Replacement 004158 Saddle opening splitter - Re- placement 005072 Immobilizer aerial - Replace- ment 005099 Electric saddle opening de-...

  • Page 274: Turn Signal Lights

    Vespa GTV 125 Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - change 005005 Taillight - Replacement 005032 Transparent licence plate cover - replace 005067 Front turn indicator bulb - Re- placement 005008 Front headlamp bulbs - Re-...

  • Page 275: Front Wheel

    Vespa GTV 125 Time Front wheel FRONT WHEEL Code Action Duration 002041 Brake disc - Replacement 003033 Front wheel hub- Replace- ment 004123 Front wheel - Replacement 003037 Front wheel rim- Replace- ment 003047 Front tyre - Replacement 003063 Tyre pressure - Check...

  • Page 276: Rear Wheel

    Vespa GTV 125 Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replace- ment 001071 Front wheel rim - Removal and refitting 002070 Rear brake disc - Replace- ment 003077 muffler/rear shock absorber...

  • Page 277: Electric Devices

    Vespa GTV 125 Time Electric devices ELECTRIC DEVICES Code Action Duration 001094 Spark plug cap - Replace- ment 001069 HV coil - replace 005003 Horn - Replacement 002049 Odometer cable - Replace- ment 001023 Control unit - Replacement 005009 Voltage regulator - replace...

  • Page 278: Front Suspension

    Vespa GTV 125 Time Front suspension FRONT SUSPENSION Code Action Duration 003011 Front shock absorber - Re- moval and Refitting 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber support and brake calliper - Replacement 003034...

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