VESPA 633844 IT Service Manual
  1. Manuals
  2. Brands
  3. VESPA Manuals
  4. Motorcycle
  5. 633844 IT
  6. Service manual

VESPA 633844 IT Service Manual

Vespa gtv 250 i.e.
Hide thumbs
Table of Contents

Advertisement

Quick Links

SERVICE STATION MANUAL
633844 IT - 633845 EN -633846 FR - 633847 DE -
633848 ES - 633849 PT - 633850 NL - 633851 EL
Vespa GTV 250 i.e.

Advertisement

Table of Contents
loading

Related Manuals for VESPA 633844 IT

Summary of Contents for VESPA 633844 IT

  • Page 1 SERVICE STATION MANUAL 633844 IT - 633845 EN -633846 FR - 633847 DE - 633848 ES - 633849 PT - 633850 NL - 633851 EL Vespa GTV 250 i.e.
  • Page 2 SERVICE STATION MANUAL Vespa GTV 250 i.e. The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 SERVICE STATION MANUAL Vespa GTV 250 i.e. This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    Vespa GTV 250 i.e. 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 250 i.e. Characteristics Vehicle identification Chassis prefix: *ZAPM451020000 ÷ 1001* Engine prefix: M451M ÷ 1001 CHAR - 3...

  • Page 10: Dimensions And Mass

    Vespa GTV 250 i.e. Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Length 1930 mm Overall width 770 mm Overall height 1170 mm Saddle height 800 mm Wheelbase 1370 mm Maximum admitted weight ~ 340 kg Kerb weight 146 ± 5 kg...

  • Page 11: Engine Specifications

    Vespa GTV 250 i.e. Characteristics Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V belt, automatic centrifugal dry clutch, gear reduction unit and transmission compartment with forced air circulation cooling. Engine ENGINE SPECIFICATIONS Specification Desc./Quantity Engine single-cylinder four stroke...

  • Page 12: Electrical Components

    Vespa GTV 250 i.e. Characteristics Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Spark plug CHAMPION RG4 Battery 12V - 12 Ah Sealed Battery 14Ah 12V - 14 Ah (mainte- nance free). Generator 380W Rated power 380W at 8000 rpm BULBS Specification Desc./Quantity...

  • Page 13: Wheels And Tyres

    Vespa GTV 250 i.e. Characteristics Specification Desc./Quantity No. 9 - Live Stop light 7.5 A and Starter key No. 10 - Power to tail 7.5 A light and instrument panel lighting Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Type...

  • Page 14: Tightening Torques

    Vespa GTV 250 i.e. Characteristics Tightening Torques GRUPPO STERZO Name Torque in Nm Upper steering ring nut 35 ÷ 40 Lower steering ring nut 12 - 14 Handlebar fixing screw 45 ÷ 50 (The two screws must be tightened to the prescribed torque after having done so with the rear wheel axle nut.

  • Page 15: Freno Posteriore

    Vespa GTV 250 i.e. Characteristics Name Torque in Nm Screws for muffler - shock absorber support arm 20 ÷ 25 (The two screws must be tightened to the on engine prescribed torque after having done so with the rear wheel axle nut. Safety locks: see «Pre-deliv- ery Operations»...

  • Page 16: Crankcase And Crankshaft

    Vespa GTV 250 i.e. Characteristics RANSMISSION Name Torque in Nm Belt support roller screw 11 ÷ 13 Clutch unit nut on driven pulley 45 ÷ 50 Drive pulley nut 75 ÷ 83 Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷...
  • Page 17 Vespa GTV 250 i.e. Characteristics Cylinder - piston assy. ENGINE COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064 Piston 72.024 ÷...
  • Page 18 Vespa GTV 250 i.e. Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side Flywheel-side half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50...
  • Page 19 Vespa GTV 250 i.e. Characteristics Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
  • Page 20 Vespa GTV 250 i.e. Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifi- cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-...

  • Page 21: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 22 Vespa GTV 250 i.e. Tooling APPROPRIATE TOOL Stores code Description 001330Y Tool for fitting steering seats 001467Y017 Bell for bearings, outside Ø 39 001467Y014 Pliers to extract ø 15-mm bear- ings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat...
  • Page 23 Vespa GTV 250 i.e. Tooling Stores code Description 020021Y Front suspension service tool 020036Y Punch 020038Y Punch 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support TOOL - 3...
  • Page 24 Vespa GTV 250 i.e. Tooling Stores code Description 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump TOOL - 4...
  • Page 25 Vespa GTV 250 i.e. Tooling Stores code Description 020330Y Stroboscopic light for timing con- trol 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 5...
  • Page 26 Vespa GTV 250 i.e. 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 - 6...
  • Page 27 Vespa GTV 250 i.e. Tooling Stores code Description 020365Y 22 mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool TOOL - 7...
  • Page 28 Vespa GTV 250 i.e. Tooling Stores code Description 020393Y Piston fitting band 020412Y 15 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork TOOL - 8...
  • Page 29 Vespa GTV 250 i.e. Tooling Stores code Description 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020441Y 26 x 28 mm adaptor 020444Y Tool for fitting/ removing the driv- en pulley clutch 020456Y Ø 24 mm adaptor 020477Y...
  • Page 30 Vespa GTV 250 i.e. Tooling Stores code Description 020483Y 30 mm guide 020489Y Hub cover support stud bolt set 494929Y Exhaust fumes analyser 020428Y Piston position check support 020460Y Scooter diagnosis and tester 020621Y HV cable extraction adaptor TOOL - 10...
  • Page 31 Vespa GTV 250 i.e. Tooling Stores code Description 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bear- ings 020627Y Flywheel lock wrench 020467Y Flywheel extractor TOOL - 11...
  • Page 32 Vespa GTV 250 i.e. Tooling Stores code Description 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y Petrol pressure check set 020244Y 15-mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent...
  • Page 33 Vespa GTV 250 i.e. Tooling Stores code Description 020638Y 250 I. E. ENGINE - ABS SOFT- WARE 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 13...
  • Page 34 Vespa GTV 250 i.e. Tooling TOOL - 14...

  • Page 35: Index Of Topics

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 36: Maintenance Chart

    Vespa GTV 250 i.e. Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - change Brake fluid - change AFTER 1,000 KM Action Safety locks - check Throttle lever - adjustment Engine oil - change Electrical system and battery - check...
  • Page 37 Vespa GTV 250 i.e. Maintenance Action Engine oil - level check/ top-up Brake pads - check condition and wear Driving belt - replacement AT 20,000 KM; 40,000 KM; 80,000 KM 150' Action Spark plug - replacement Throttle lever - adjustment...
  • Page 38 Vespa GTV 250 i.e. Maintenance Action Air filter - clean Air filter belt compartment - check Engine oil - change Valve clearance - check Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement...

  • Page 39: Spark Plug

    Vespa GTV 250 i.e. Maintenance - Refit the plastic cap on the flywheel cover. - Adjust the spark gap to the contact position (no reference mark visible) and install it on engine be- tween the spark plug and spark plug cap...
  • Page 40 Vespa GTV 250 i.e. Maintenance -Adjust the distance if necessary by bending the side electrode very carefully. In case of anomaly (as described before) replace the spark plug with another of the recommended type; - Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it.

  • Page 41: Air Filter

    Vespa GTV 250 i.e. Maintenance -Screw up the oil dipstick again and make sure it is locked properly into place. Replacement -Remove the oil cap «A». - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil.

  • Page 42: Engine Oil

    Vespa GTV 250 i.e. Maintenance 6. Unscrew the screws «D» and remove the air fil- ter cover. Remove the filtering element and clean it with wa- ter and shampoo; then dry it with a clean cloth and short blasts of compressed air. Finally, immerse it in a mixture of 50% oil of the recommended type and 50% petrol.
  • Page 43 Vespa GTV 250 i.e. Maintenance Replacement At 1,000 km and after every 10,000 km, the oil and the filter must be changed. The engine must be drained by running off the oil from drainage cap "B" of the flywheel side gauze pre-filter; further- more to facilitate oil drainage, loosen the cap/ dipstick "A".

  • Page 44: Engine Oil Filter

    Vespa GTV 250 i.e. Maintenance 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. 3. Remove the cap/dipstick again and check that the level is between the min and max. marks; top up if necessary.

  • Page 45: Checking The Ignition Timing

    Vespa GTV 250 i.e. Maintenance Checking the ignition timing -Remove the plastic cap on the flywheel cover -Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC). Make...

  • Page 46: Braking System

    Vespa GTV 250 i.e. Maintenance Braking system 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 47: Headlight Adjustment

    Vespa GTV 250 i.e. Maintenance THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, WHICH MEANS THAT IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
  • Page 48 Vespa GTV 250 i.e. Maintenance MAIN - 14...

  • Page 49: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 50 Vespa GTV 250 i.e. 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 Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause...
  • Page 51 Vespa GTV 250 i.e. Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace brake fluid if necessary.
  • Page 52 Vespa GTV 250 i.e. Troubleshooting Possible Cause Operation if they are recessed or if the balls are squashed, replace them. Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: the efficien- cy of the front shock absorbers;...

  • Page 53: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 54 Vespa GTV 250 i.e. Electrical system KEY: 1. Magneto flywheel 2. Voltage regulator 3. Immobilizer aerial 4. Diagnostic socket 5. Revolution sensor 6. Engine stop switch 7. 2 fuse boxes in the helmet compartment 8. Key-switch 9. Saddle opening button 10.

  • Page 55: Electrical System Installation

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

  • Page 56: Front Side

    Vespa GTV 250 i.e. Electrical system Front side 1. Front left turn indicator connector 2. Front right turn indicator connector 3. Electrical fan connector ELE SYS - 4...
  • Page 57 Vespa GTV 250 i.e. Electrical system 1. Immobilizer aerial 2. Foldable clamp to hold cables 3. Battery negative terminal 4. Battery positive terminal 5. Flywheel - regulator connexion ELE SYS - 5...
  • Page 58 Vespa GTV 250 i.e. Electrical system 1. Saddle opening switch 2. Wirings 3. Insert in clamp ELE SYS - 6...
  • Page 59 Vespa GTV 250 i.e. Electrical system 4. Fuse box 5. From the wire unit 1. Right turn indicator connector 2. From regulator 3. Wire unit - regulator connexion 4. To the immobilizer aerial 5. Light remote control ELE SYS - 7...
  • Page 60 Vespa GTV 250 i.e. Electrical system 6. Electric fan starter 7. To key switch 8. Left turn indicator connector 9. Voltage regulator 1. Red sheathing 2. Clamp 3. To headlight 4. To instrument 5. To stop switch 6. To stop switch...

  • Page 61: Back Side

    Vespa GTV 250 i.e. Electrical system Back side 1. Battery positive terminal 2. Battery negative terminal 3. Thermistor 4. Starter motor ground lead 5. Right turn indicator connector 6. Rear headlight assembly connector 7. Left turn indicator connector 8. Starter motor ground lead clamping 9.
  • Page 62 Vespa GTV 250 i.e. Electrical system 1. To flywheel 2. To saddle opening actuator 3. Fuse box 4. Foldable clamp to hold cables 5. Clamp 6. Injector connector 7. To HV coil 8. To front wire unit 9. To rear turn indicators 10.To fuel gauge and fuel tank...
  • Page 63 Vespa GTV 250 i.e. Electrical system 1. Fuse box 2. Remote control switch 3. Ground lead clamping to chassis 4. Oil pressure sensor 5. Lambda probe connector 6. Lambda probe 7. To wire unit 8. To the spark plug 9. H.V. coil...
  • Page 64 Vespa GTV 250 i.e. Electrical system 1. Right rear turn indicator 2. Cableguide 3. To rear light 4. Rear left turn indicator ELE SYS - 12...
  • Page 65 Vespa GTV 250 i.e. Electrical system 1. To HV coil 2. Foldable clamp 3. Foldable clamps to hold the red sheathing 4. Diagnostic socket 5. Starter remote control Conceptual diagrams ELE SYS - 13...
  • Page 66 Vespa GTV 250 i.e. Electrical system Ignition KEY: 7. 2 fuse boxes in the helmet compartment 8. Key-switch 10. Injection load remote control 13. Battery 40. Spark plug 41. High voltage coil 42. Injection ECU ELE SYS - 14...
  • Page 67 Vespa GTV 250 i.e. Electrical system Battery recharge and starting KEY: 1. Magneto flywheel 2. Voltage regulator 6. Engine stop switch 7. 2 fuse boxes in the helmet compartment 8. Key-switch 12. Fuse box for glove box 13. Battery 14. Starter motor 15.
  • Page 68 Vespa GTV 250 i.e. Electrical system Level indicators and enable signals section KEY: 3. Immobilizer aerial 5. Revolution sensor 7. 2 fuse boxes in the helmet compartment 8. Key-switch 10. Injection load remote control 12. Fuse box for glove box 13.

  • Page 69: Devices And Accessories

    Vespa GTV 250 i.e. Electrical system Devices and accessories KEY: 1. Magneto flywheel 2. Voltage regulator 7. 2 fuse boxes in the helmet compartment 8. Key-switch 12. Fuse box for glove box 13. Battery 21. Light switch 22. Rear headlight assembly A.
  • Page 70 Vespa GTV 250 i.e. Electrical system 31. Instrument panel Lights and turn indicators KEY: 7. 2 fuse boxes in the helmet compartment 8. Key-switch 9. Saddle opening button 10. Injection load remote control 11. Saddle opening actuator 12. Fuse box for glove box 13.

  • Page 71: Checks And Inspections

    Vespa GTV 250 i.e. Electrical system Checks and inspections This section is devoted to the checks on the electrical system components. Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys- tem. The immobilizer is an anti-theft system that...
  • Page 72 Vespa GTV 250 i.e. Electrical system there is power to the control unit as specified below: Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: •...
  • Page 73 Vespa GTV 250 i.e. Electrical system After removing the shield back plate, remove the electrical connection from the aerial as shown in the photograph Remove the protective base from the connector. With the ignition key switch at ON check there is...
  • Page 74 Vespa GTV 250 i.e. Electrical system Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly.

  • Page 75: Diagnostic Codes

    Vespa GTV 250 i.e. Electrical system Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to en- code new service keys, in the event of losses, replacements, etc.
  • Page 76 Vespa GTV 250 i.e. Electrical system manently ON; in this condition, no operations are possible, including starting of the vehicle. 3. Programmed control unit - the service key in (normal condition of use): a single 0.7 second flash is displayed, after which the LED remains off permanently.

  • Page 77: Stator Check

    Vespa GTV 250 i.e. Electrical system Diagnostic code - 2 flashes Two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary.
  • Page 78 Vespa GTV 250 i.e. Electrical system Electric characteristic Resistance: 0.2 - 1 Ω 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check Look for any leakage 1) Access the battery by removing the cover in the footrest.

  • Page 79: Voltage Regulator/Rectifier

    Vespa GTV 250 i.e. Electrical system Maximum current output check. - With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V. - Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.
  • Page 80 Vespa GTV 250 i.e. Electrical system BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERI- AL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).
  • Page 81 Vespa GTV 250 i.e. Electrical system INSTRUMENT PANEL CONNECTOR Specification Desc./Quantity 1 Power supply 2 Fuel gauge signal 3 Low fuel warning light 4 Oil pressure warning light 5 High-beam warning light 6 Headlight warning light and lighting 7 Ground lead...
  • Page 82 Vespa GTV 250 i.e. Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.

  • Page 83: Battery Installation

    Vespa GTV 250 i.e. Electrical system 2) Constant voltage battery charge mode - Constant voltage charge equal to 14.40 ÷ 14.70V -Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended...
  • Page 84 Vespa GTV 250 i.e. Electrical system - Insert the battery breather pipe through the hole shown in the photograph. - Fit the battery as shown in the photograph. N.B. IN ORDER TO FIT THE CABLES ON THE BAT- TERY TERMINALS CORRECTLY, REST THE...
  • Page 85 Vespa GTV 250 i.e. Electrical system - Mount permanently the battery in the battery chamber - Refit the strap fastening the battery - Refit the battery cover Connectors ELE SYS - 33...
  • Page 86 Vespa GTV 250 i.e. Electrical system ELE SYS - 34...

  • Page 87: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 88 Vespa GTV 250 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the right and left fairings and the spoiler terminals. - Remove the Lambda probe from its support and disconnect it.
  • Page 89 Vespa GTV 250 i.e. Engine from vehicle Remove the lambda probe from the manifold. CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle...
  • Page 90 Vespa GTV 250 i.e. Engine from vehicle - Remove the coolant inlet pipe to the motor as indicated in the photograph. - Disconnect the fuel delivery and return pipes from the injector by removing the screw locking the re- taining clip.
  • Page 91 Vespa GTV 250 i.e. Engine from vehicle - Remove the throttle cable from the throttle body by undoing the nut shown in the photo. - Loosen the clamp indicated in the photograph and remove the throttle body. - Remove the positive and negative wiring from the starter motor as shown in the photo.
  • Page 92 Vespa GTV 250 i.e. Engine from vehicle - Remove the rear shock absorbers. - Remove the hydraulic piping from the rear cal- liper by undoing the screw indicated in the photo- graph. Afterwards remove the retainers fixing the piping to the engine crankcase, indicated in the photograph.
  • Page 93 Vespa GTV 250 i.e. Engine from vehicle When refitting the engine to the scooter, carry out the operations in reverse order from that adopted when removing it and respect the tightening torque shown in the Characteristics Chapter. Check that with valve in abutment against the reg- ister there is a small clearance.
  • Page 94 Vespa GTV 250 i.e. Engine from vehicle ENG VE - 8...
  • Page 95 INDEX OF TOPICS NGINE...

  • Page 96: Automatic Transmission

    Vespa GTV 250 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
  • Page 97 Vespa GTV 250 i.e. Engine - Remove the five screws on two different levels as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by...
  • Page 98 Vespa GTV 250 i.e. Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indica- ted in the photograph - Check the outer diameter of the roller does not...
  • Page 99 Vespa GTV 250 i.e. Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic Max. value clutch bell Max. value: Ø 134.5 mm Clutch bell standard value Standard value: Ø...

  • Page 100: Removing The Clutch

    Vespa GTV 250 i.e. Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring No. 11 with the cham- fering facing the inside of the tool.
  • Page 101 Vespa GTV 250 i.e. Engine 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 102 Vespa GTV 250 i.e. Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 103 Vespa GTV 250 i.e. Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws.
  • Page 104 Vespa GTV 250 i.e. Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
  • Page 105 Vespa GTV 250 i.e. Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 123 mm acceptable limit after use:...
  • Page 106 Vespa GTV 250 i.e. Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool.

  • Page 107: Removing The Driving Pulley

    Vespa GTV 250 i.e. Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic 250 4T Transmission belt/minimum width 19.5 mm 250 4T Transmission belt/standard width 21.3 ± 0.2 mm During the wear checks in the scheduled servicing...
  • Page 108 Vespa GTV 250 i.e. Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
  • Page 109 Vespa GTV 250 i.e. Engine 26.000 - 26.021 mm Movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm...
  • Page 110 Vespa GTV 250 i.e. Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
  • Page 111 Vespa GTV 250 i.e. 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 112 Vespa GTV 250 i.e. Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
  • Page 113 Vespa GTV 250 i.e. Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing.
  • Page 114 Vespa GTV 250 i.e. Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 115 Vespa GTV 250 i.e. 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 116: Flywheel Cover

    Vespa GTV 250 i.e. Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the breather pipe using black silicone sealant.

  • Page 117: Removing The Stator

    Vespa GTV 250 i.e. Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the ten fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
  • Page 118 Vespa GTV 250 i.e. Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4...

  • Page 119: Removing The Starter Motor

    Vespa GTV 250 i.e. Engine Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft spline clip...
  • Page 120 Vespa GTV 250 i.e. Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - Remove the flywheel nut with its washer...
  • Page 121 Vespa GTV 250 i.e. Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.

  • Page 122: Removing The Intake Manifold

    Vespa GTV 250 i.e. Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷ 102...

  • Page 123: Removing The Rocker-Arms Cover

    Vespa GTV 250 i.e. Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring...
  • Page 124 Vespa GTV 250 i.e. Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.

  • Page 125: Removing The Cam Shaft

    Vespa GTV 250 i.e. 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 126: Removing The Valves

    Vespa GTV 250 i.e. Engine MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool.
  • Page 127 Vespa GTV 250 i.e. 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 128 Vespa GTV 250 i.e. Engine Inspecting the piston - Measure the diameter of the wrist pin seat on the piston. - Calculate the piston pin coupling clearance. - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis.
  • Page 129 Vespa GTV 250 i.e. 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 head coupling surface is not worn or misshapen.

  • Page 130: Removing The Piston

    Vespa GTV 250 i.e. Engine scraper ring Standard opening: 0.20 ÷ 0.40 mm Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin stop ring onto the appropriate tool...
  • Page 131 Vespa GTV 250 i.e. Engine N.B. MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.
  • Page 132 Vespa GTV 250 i.e. Engine Refitting the piston rings Fitting the sealing 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 133: Inspecting The Cylinder Head

    Vespa GTV 250 i.e. Engine 020393Y Piston fitting band 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 134 Vespa GTV 250 i.e. Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
  • Page 135 Vespa GTV 250 i.e. Engine Inspecting the valves - Measure the width of the sealing surface on the valve seats and on the valves. Sealing surface width: After use: Intake and ex- haust: 1.6 mm - If any of the sealing surfaces on the valves is...
  • Page 136 Vespa GTV 250 i.e. Engine Valve check standard clearance Inlet: 0.013 ÷ 0.040 mm Valve check Minimum admissible diameter Outlet: 4.95 mm Valve check Minimum admissible diameter Inlet: 4.96 mm Valve check Standard diameter: Inlet: 4.972 ÷ 4.987 mm Valve check Standard diameter: Outlet: 4.96 ÷...
  • Page 137 Vespa GTV 250 i.e. Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.

  • Page 138: Inspecting The Cam Shaft

    Vespa GTV 250 i.e. 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 139 Vespa GTV 250 i.e. Engine Diameter 11.977 - 11.985 mm 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...
  • Page 140 Vespa GTV 250 i.e. Engine Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 - Refit the lower timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft.
  • Page 141 Vespa GTV 250 i.e. Engine -Fit the end-stop ring on the automatic valve-lifter cam and fit the automatic valve-lifter cam to the cam shaft. - Fit the automatic valve-lifter return spring. - During this operation the spring must be loaded by approximately 180°.
  • Page 142 Vespa GTV 250 i.e. 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...

  • Page 143: Crankcase - Crankshaft

    Vespa GTV 250 i.e. Engine Refitting the intake manifold Fit the intake manifold and do up the three screws. Locking torques (N*m) Inlet manifold screws 11 ÷ 13 Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft.
  • Page 144 Vespa GTV 250 i.e. Engine either excessive wear or wrong machining on the crankcase. - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfa- ces shown in the figure. The half-shafts are clas- sified in two categories Cat.
  • Page 145 Vespa GTV 250 i.e. Engine Crankshaft bearings: Standard diameter: Cat. 28.994 ÷ 29.000 Crankshaft bearings: Standard diameter: Cat. 29.000 ÷ 29.006 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 146 Vespa GTV 250 i.e. Engine N.B. THE MAIN BEARINGS ARE NOT GRINDABLE Specific tooling 020074Y Support base for checking crankshaft alignment Characteristic Off-line maximum admitted A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm...
  • Page 147 Vespa GTV 250 i.e. Engine - Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and di- mensions.
  • Page 148 Vespa GTV 250 i.e. Engine must be perfectly perpendicular to the cylinder ax- is, as shown in the figure. - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface.
  • Page 149 Vespa GTV 250 i.e. Engine 29.019 ÷ Original 29.034 and spare 29.028 ÷ 29.043 29.022 ÷ Original 29.037 Match the shaft with two category 1 crank webs with the category 1 crankcase (or cat. 2 with cat. 2) Furthermore a replacement crankcase cannot be matched with a crankshaft with mixed catego- ries.
  • Page 150 Vespa GTV 250 i.e. Engine Refitting the crankcase halves - 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. - Position the oil pre-filter element as shown in the photograph.
  • Page 151 Vespa GTV 250 i.e. Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.

  • Page 152: Lubrication Circuit

    Vespa GTV 250 i.e. Engine Conceptual diagrams LUBRICATION CIRCUIT ENG - 58...
  • Page 153 Vespa GTV 250 i.e. Engine ENG - 59...

  • Page 154: Oil Pressure Check

    Vespa GTV 250 i.e. Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
  • Page 155 Vespa GTV 250 i.e. Engine Removal - Remove the transmission cover and the com- plete driving pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.

  • Page 156: Oil Pump

    Vespa GTV 250 i.e. Engine - Orientate the oil guard by inserting the bracket which is part of the appropriate tool - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you...
  • Page 157 Vespa GTV 250 i.e. Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
  • Page 158 Vespa GTV 250 i.e. Engine Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure. Characteristic Axial rotor clearance Limit values admitted: 0.09 mm...
  • Page 159 Vespa GTV 250 i.e. Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the belleville washer. Tighten to the prescribed torque. - Fit the oil pump cover by tightening the two screws to the prescribed torque.
  • Page 160 Vespa GTV 250 i.e. Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal.

  • Page 161: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 162 Vespa GTV 250 i.e. Injection MIU injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the crankshaft (24-2 teeth) and pick-up sensor.
  • Page 163 Vespa GTV 250 i.e. Injection - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester.
  • Page 164 Vespa GTV 250 i.e. Injection OMPONENT RANSPOSITION Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Fuel pump Water temperature sensor Fuel injector HV coil Engine rpm sensor Lambda sensor Injection load remote control...
  • Page 165 Vespa GTV 250 i.e. Injection b. Wrong idle mixture c.Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors. Make sure that all connections have been correctly made. Check the connections as follows: A check that the terminals are not bent.

  • Page 166: Terminal Layout

    Vespa GTV 250 i.e. Injection 13. At the end of every check performed with the diagnostic tester, protect the system connector with its cap. Failure to do this may damage the MIU control unit. 14. Before reconnecting the quick couplers of the power supply system, check that the terminals are perfectly clean.
  • Page 167 Vespa GTV 250 i.e. Injection Specification Desc./Quantity Cavalletto laterale ---- ---- Injection load remote control Lambda probe heater HV coil ----- ----- Start up enabling ------ ------ Earth connection with engine cut-off switch and en- gine temperature sensor EMS circuit diagram...

  • Page 168: Troubleshooting Procedure

    Vespa GTV 250 i.e. Injection EMS SYSTEM (E LECTRONIC ANAGEMENT YSTEM Specification Desc./Quantity Battery 12V - 12 Ah Engine rpm sensor Water temperature sensor Immobilizer aerial Stop button Fuse 30 A Fuse Key switch contacts Fuse 10 A Engine stop switch Fuse 7.5 A...

  • Page 169: Starting Difficulties

    Vespa GTV 250 i.e. Injection Possible Cause Operation Intake air temperature End of compression pressure End of compression pressure Starting difficulties ENGINE START-UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector...
  • Page 170 Vespa GTV 250 i.e. Injection Possible Cause Operation Intake sleeve Filter box Fuel feed (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH...
  • Page 171 Vespa GTV 250 i.e. Injection Possible Cause Operation Fuel filter Injector capacity Exhaust system sealing (infiltrations) Manifold - head Manifold - muffler Muffler welding Engine revs irregularly ENGINE IRREGULAR PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning...

  • Page 172: Fuel Supply System

    Vespa GTV 250 i.e. Injection Possible Cause Operation Fuel supply Fuel level in the tank Fuel pressure Fuel filter Injector capacity Engine knocking PRESENCE OF KNOCKING (HEAD KNOCKING) Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay...
  • Page 173 Vespa GTV 250 i.e. Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. Remove the snap-on fittings from the injector sup- port INJEC - 13...
  • Page 174 Vespa GTV 250 i.e. Injection Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the MIU connector Remove the clip fixing the throttle body to the pu-...
  • Page 175 Vespa GTV 250 i.e. Injection Remove the gas command fitting as indicated in the photograph Refitting the butterfly valve To refit, perform the operations in the reverse or- der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45°...
  • Page 176 Vespa GTV 250 i.e. Injection OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 16...

  • Page 177: Electrical Data

    Vespa GTV 250 i.e. Injection Specification Desc./Quantity Electric fan starter When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied.
  • Page 178 Vespa GTV 250 i.e. Injection (REMOTE CONTROLS, CONTROL UNIT, FUSES ETC.). INJEC - 18...
  • Page 179 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
  • Page 180 Vespa GTV 250 i.e. Injection control unit disconnected and the injection load re- mote control disconnected, that the Black-Purple cable (pin 20 on the interface wiring) is insulated from the earth. Specific tooling 020331Y Digital multimeter Circuit leak test Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe..
  • Page 181 Vespa GTV 250 i.e. Injection Specific tooling 020480Y Petrol pressure check set Fuel filter check Disconnect the terminals from the electric pump Remove the screw shown in the photograph Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph.
  • Page 182 Vespa GTV 250 i.e. Injection Remove the filter from the pump support INJEC - 22...
  • Page 183 Vespa GTV 250 i.e. Injection Inspecting the injector circuit OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil INJEC - 23...
  • Page 184 Vespa GTV 250 i.e. Injection Specification Desc./Quantity Fuel injector Lambda sensor Electric fan starter Check the resistance at the injector ends: 14.5 ± 5% Ohm Check that the injection load 10A fuse No. 3 is in good conditions. Check that the 7.5A fuse No. 2 for the live control unit is in good conditions.
  • Page 185 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
  • Page 186 Vespa GTV 250 i.e. Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check if there is voltage, with...
  • Page 187 Vespa GTV 250 i.e. Injection With injector disconnected and the injector load remote control disconnected, check the continuity of the Black-Green cable between the injector con- nector and remote control base. Inspecting the injector hydraulics To carry out the injector check, remove the intake...

  • Page 188: Components Location

    Vespa GTV 250 i.e. Injection Proceed with the injector seal test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector. Slight oozing is normal.
  • Page 189 Vespa GTV 250 i.e. Injection Tachometer With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
  • Page 190 Vespa GTV 250 i.e. Injection With the interface cable harness disconnected from the control unit, check continuity between pin 13 and the red cable of the rpm sensor connector and between pin 15 and the brown cable of the rpm...
  • Page 191 Vespa GTV 250 i.e. Injection HT coil OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil INJEC - 31...
  • Page 192 Vespa GTV 250 i.e. Injection Specification Desc./Quantity Fuel injector Lambda sensor Electric fan starter The ignition system is integrated with the injection and is of the inductive high efficiency type. The control unit manages two important parameters: - Ignition advance This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ±...
  • Page 193 Vespa GTV 250 i.e. Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected.
  • Page 194 Vespa GTV 250 i.e. Injection INJEC - 34...
  • Page 195 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.

  • Page 196: Coolant Temperature Sensor

    Vespa GTV 250 i.e. Injection Coolant temperature sensor ENGINE TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor With the control unit side connector disconnected and the coolant temperature sensor connector connected, check the resistance between pins 9 and 26 in relation to the engine temperature.
  • Page 197 Vespa GTV 250 i.e. Injection With the control unit side connector disconnected and coolant temperature sensor connector dis- connected, check the continuity between pin 9 of the interface wiring and the light blue-green cable of the connector, and between pin 26 of the inter- face wiring and the grey-green cable of the con- nector.
  • Page 198 Vespa GTV 250 i.e. Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw.

  • Page 199: Lambda Probe

    Vespa GTV 250 i.e. Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
  • Page 200 Vespa GTV 250 i.e. Injection Check that the injection load 10A fuse No. 3 is in good conditions. Check that the 7.5A fuse No. 2 for the live control unit is in good conditions. Check there is voltage between pins 21 and 26 of the interface wiring, for around two seconds, when switching to «ON».
  • Page 201 Vespa GTV 250 i.e. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
  • Page 202 Vespa GTV 250 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.

  • Page 203: Signal Control

    Vespa GTV 250 i.e. Injection SIGNAL CONTROL INJEC - 43...
  • Page 204 Vespa GTV 250 i.e. Injection OMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 44...
  • Page 205 Vespa GTV 250 i.e. Injection Specification Desc./Quantity Electric fan starter Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V.
  • Page 206 Vespa GTV 250 i.e. Injection INJEC - 46...

  • Page 207: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 208: Removing The Front Wheel

    Vespa GTV 250 i.e. 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 209 Vespa GTV 250 i.e. Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide...

  • Page 210: Refitting The Front Wheel

    Vespa GTV 250 i.e. 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 211 Vespa GTV 250 i.e. Suspensions - Remove the retainer fixing the odometer cable to the mudguard indicated in the photograph - Remove the retainer fixing the brake piping to the front shock absorber upper plate - Remove the retainer fixing the brake piping to the...
  • Page 212 Vespa GTV 250 i.e. 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 213 Vespa GTV 250 i.e. Suspensions Overhaul Carry out this operation only if strictly necessary and in any case remove and replace the old part with a new one. - Remove the steering tube - Use a special tool remove the upper disk of the...
  • Page 214 Vespa GTV 250 i.e. Suspensions - Use the specific tool to fit the fifth wheel fitting on the headstock as indicated in the figure Specific tooling 001330Y Tool for fitting steering seats - Remove the steering tube - Remove the attachment bracket...
  • Page 215 Vespa GTV 250 i.e. 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 216: Front Shock Absorber

    Vespa GTV 250 i.e. Suspensions Handlebar to steering tube 45 ÷ 50 Nm Upper steering ring nut 35 ÷ 40 Lower steering ring nut 12 - 14 Front shock absorber Removal - Remove the steering tube - Remove the shock absorber lower clamps...
  • Page 217 Vespa GTV 250 i.e. Suspensions - Before refitting the bracket in the wheel axle, place the O-ring as shown in the photograph so that it is correctly placed after fitting the bracket. - Refit the washer and the Seeger ring.
  • Page 218 Vespa GTV 250 i.e. Suspensions - Suitably hold the brake calliper - shock absorber attachment bracket - Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm...

  • Page 219: Removing The Rear Wheel

    Vespa GTV 250 i.e. Suspensions Removing the rear wheel - Remove the bracket supporting the rear shock absorber and the muffler; - Remove the rear wheel by unscrewing the 5 screws indicated in the photograph Refitting the rear wheel To refit, carry out the removal operations but in reverse order, observing the prescribed torques.
  • Page 220 Vespa GTV 250 i.e. Suspensions - Remove the two screws fixing the buffer support bracket to the frame - Remove the left and right caps located under the footrest to reach the pin fixing the swinging arm to the body.
  • Page 221 Vespa GTV 250 i.e. Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension. Overhaul - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side.
  • Page 222 Vespa GTV 250 i.e. Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - Using a suitable pin remove the roller casings as...
  • Page 223 Vespa GTV 250 i.e. Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in...
  • Page 224 Vespa GTV 250 i.e. Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the...

  • Page 225: Shock Absorbers

    Vespa GTV 250 i.e. Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 - 72 Body shell - Swinging arm pin 76 ÷...
  • Page 226 Vespa GTV 250 i.e. Suspensions Lower shock absorber clamping screw 33 ÷ 41 Nm Upper shock absorber fixing screws 20 ÷ 25 Exhaust bracket Removal Remove the full muffler assembly. - Remove the two fixing screws of the bracket to...

  • Page 227: Side Stand

    Vespa GTV 250 i.e. Suspensions Side stand REMOVAL - Uncouple the centre stand return spring; Remove the screw shown in the photograph FITTING To refit, carry out the removal operations in re- verse order and comply with the specified torque.
  • Page 228 Vespa GTV 250 i.e. Suspensions SUSP - 22...

  • Page 229: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 230: Rear Brake Calliper

    Vespa GTV 250 i.e. 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 231 Vespa GTV 250 i.e. Braking system - Check that the pistons and relevant seats exhibit 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 232: Front Brake Calliper

    Vespa GTV 250 i.e. Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the crankcase with the two screws with elastic washer at the prescribed tor-...
  • Page 233 Vespa GTV 250 i.e. Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the two front brake calliper devices fas- tening them to the support as shown in the photo- graph.

  • Page 234: Rear Brake Disc

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

  • Page 235: Disc Inspection

    Vespa GTV 250 i.e. Braking system Removal - Remove the rear brake calliper. - Remove the brake disc and the hub from the wheel axle - To remove the brake disc from the hub, hold the unit firmly with a vice and operate on the 5 fixing...

  • Page 236: Front Brake Disc

    Vespa GTV 250 i.e. 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 237: Front Brake Pads

    Vespa GTV 250 i.e. Braking system Refitting - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.
  • Page 238 Vespa GTV 250 i.e. Braking system Removal - Remove the front wheel - Pre-loosen the two fixing pins of the brake pads - Remove the brake calliper - Remove permanently the two pad fixing screws - Check that there are no flaws or warping. If there is, replace it.

  • Page 239: Rear Brake Pads

    Vespa GTV 250 i.e. Braking system - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the 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 240 Vespa GTV 250 i.e. Braking system See also Removal Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the clip on the pin - Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque.

  • Page 241: Brake Fluid Level Check

    Vespa GTV 250 i.e. Braking system BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND...

  • Page 242: Front Brake Pump

    Vespa GTV 250 i.e. Braking system VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING. CAUTION - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SUR- ROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN VAL- UE, BRAKING EFFICIENCY WILL BE RE- DUCED.
  • Page 243 Vespa GTV 250 i.e. 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 244 Vespa GTV 250 i.e. Braking system 3. Diaphragm. 4. Bellows. 5. Sealing ring 6. Piston. 7. Gasket. 8. Spring. 9. Reservoir Refitting To refit, carry out the removal operations but in reverse order, observing the specified torques. Locking torques (N*m) Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handle bar: 7 ÷...

  • Page 245: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 246 Vespa GTV 250 i.e. Cooling system System bleed - Start up the engine until the operating tempera- ture is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to...
  • Page 247 Vespa GTV 250 i.e. Cooling system TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER. Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check: Opening start temperature 69.5 ÷ 72.5°C COOL SYS - 3...
  • Page 248 Vespa GTV 250 i.e. Cooling system COOL SYS - 4...
  • Page 249 INDEX OF TOPICS CHAS HASSIS...
  • Page 250 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 251 Vespa GTV 250 i.e. Chassis Remove the four screws shown in the figure and the rear seat from the chassis saddle. - Free the electric cables form the retaining clamps indicated in the photograph Unscrew the two screws of saddle fixing hook cover.
  • Page 252 Vespa GTV 250 i.e. Chassis To remove the cable and the sheath: - Remove the elastic ring and unscrew the cable end from the seat on the saddle fixing hook. - Remove the other end of the cable from the fixing seat on the locking block.

  • Page 253: Instrument Panel

    Vespa GTV 250 i.e. Chassis - Remove the two screws, indicated in the figure, that fix the luggage rack to the body Instrument panel - Remove the two screws indicated in the figure. -Remove the instrument panel by slightly pulling it upwards.
  • Page 254 Vespa GTV 250 i.e. Chassis - Remove the bulb holder by turning it anticlock- wise and take out the failing bulb. - To fit, insert the new bulb and turn the bulb holder clockwise. Headlight assy. - Operate the screw indicated in the figure to re-...
  • Page 255 Vespa GTV 250 i.e. Chassis - Remove the expansion tank cover and then its - Remove the central screw inside the glove-box, indicated in the photograph - Remove the two screws indicated in the photo- graph and located below the expansion tank cover...
  • Page 256 Vespa GTV 250 i.e. Chassis - Remove the electric saddle opening switch, the fuse box and the manual saddle opening cable as shown in the photograph Taillight assy. - Operate the screw indicated in the figure to re- move the rear turn indicator Remove screw «A»...
  • Page 257 Vespa GTV 250 i.e. Chassis WATER IS INFILTRATING. CONTACT THE PIAGGIO AFTER-SALES SERVICE NETWORK. Footrest - Remove the shield back plate - Remove the battery compartment cover - Remove the side fairings - Remove the central screw located under the bat-...

  • Page 258: Side Fairings

    Vespa GTV 250 i.e. Chassis - Remove the screws under the non-slip rubber mat of the footrest as indicated in the photograph Side fairings Unscrew the fixing screw "A" Unscrew the nut "B" under the body. Helmet bay - Lift the saddle and remove the helmet compart-...
  • Page 259 Vespa GTV 250 i.e. Chassis - Remove the screw indicated in the figure that fixes the tank to the body after removing the rear head- light assembly - Remove the two turn indicators - Use a jack to lift the body so that there is enough...

  • Page 260: Front Mudguard

    Vespa GTV 250 i.e. Chassis Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard - Remove the three mudguard-steering tube clamps indicated in the figure...
  • Page 261 Vespa GTV 250 i.e. Chassis - The same procedure also applies to the left ra- diator for which it is necessary to remove the elec- trical fan first by undoing the 3 screws indicated in the photograph. To refit, perform the removal operations but in reverse order being careful when positioning the news clips for the fluid hoses and when filling the cooling system.
  • Page 262 Vespa GTV 250 i.e. Chassis CHAS - 14...
  • Page 263 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 264 Vespa GTV 250 i.e. 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 Lock check...

  • Page 265: Road Test

    Vespa GTV 250 i.e. Pre-delivery •Instrument panel lights • Horn • electric start up • Engine stopping with emergency stop switch • electric saddle opening button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

  • Page 266: Static Test

    Vespa GTV 250 i.e. Pre-delivery - Abnormal noise Static test Static control after the test ride: • Hot engine restart • Minimum seal (turning the handlebar) • Uniform steering rotation • Possible losses • electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 267 INDEX OF TOPICS TIME...
  • Page 268 Vespa GTV 250 i.e. 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 269 Vespa GTV 250 i.e. Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 3...

  • Page 270: Cylinder Assy

    Vespa GTV 250 i.e. Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replace- ment 001154 Pin ring piston unit - Service 001129 Chain tightener - Overhaul and replacement TIME - 4...

  • Page 271: Cylinder Head Assy

    Vespa GTV 250 i.e. Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 001083 Thermistor - Replacement 001057 Thermostat - Replacement TIME - 5...

  • Page 272: Cylinder Head Cover

    Vespa GTV 250 i.e. 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 273: Head Cover

    Vespa GTV 250 i.e. 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 Oil filter OIL FILTER Code...
  • Page 274 Vespa GTV 250 i.e. Time Flywheel cover LYWHEEL COVER Code Action Duration 001087 Flywheel cover - replace 001150 Flywheel cover gasket - Re- placement 007007 Water pump rotor cover 007017 Water pump cover - Replace- ment 007003 Coolant delivery and return...

  • Page 275: Driven Pulley

    Vespa GTV 250 i.e. Time DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement Oil pump OIL PUMP Code Action Duration 001125 Chain guide pads - Replace-...

  • Page 276: Final Reduction

    Vespa GTV 250 i.e. 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 277: Driving Pulley

    Vespa GTV 250 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001066 Driving pulley - Removal and Refitting 001177 Variator rollers / shoes - Re- placement 001141 Belt anti-flapping roller - Re-...

  • Page 278: Transmission Cover

    Vespa GTV 250 i.e. 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 001065 Transmission cover - Re- placement TIME - 12...

  • Page 279: Starter Motor

    Vespa GTV 250 i.e. Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001104 Start-up freewheel - Replace- ment 001151 Start-up driven gearing - Re- placement 001017 Start-up pinion - Replace- ment TIME - 13...

  • Page 280: Magneto Flywheel

    Vespa GTV 250 i.e. Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refit- ting 001173 Rotor - Replacement 001058 Complete flywheel - Replace- ment TIME - 14...

  • Page 281: Butterfly Valve

    Vespa GTV 250 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 15...

  • Page 282: Exhaust Pipe

    Vespa GTV 250 i.e. Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 005138 Lambda probe - Replace- ment TIME - 16...

  • Page 283: Air Cleaner

    Vespa GTV 250 i.e. Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor fitting - Replacement 001027 Body / air cleaner union - Re-...
  • Page 284 Vespa GTV 250 i.e. 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 285: Centre-Stand

    Vespa GTV 250 i.e. Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement Footrests TIME - 19...

  • Page 286: Rear Cover

    Vespa GTV 250 i.e. Time MATS AND COVERS Code Action Duration 004079 Footrest - replacement 004071 Battery compartment - re- placement 004078 Front/rear footrest rubber - Replacement 005046 Battery cover - change Rear cover REAR SHIELD Code Action Duration 004083...
  • Page 287 Vespa GTV 250 i.e. Time Underseat compartment NDERSADDLE Code Action Duration 004016 Helmet compartment - Re- moval and Refitting 004011 Central chassis cover - Re- placement TIME - 21...
  • Page 288 Vespa GTV 250 i.e. Time Plate holder LICENCE PLATE HOLDER Code Action Duration 004136 License plate support - re- place 005048 Licence plate holder - Re- placement TIME - 22...
  • Page 289 Vespa GTV 250 i.e. Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replace- ment 004009 Rear mudguard - Replace- ment 003044 Shock absorber cover - Re- placement TIME - 23...
  • Page 290 Vespa GTV 250 i.e. Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replace-...
  • Page 291 Vespa GTV 250 i.e. Time Radiator RADIATOR Code Action Duration 007002 Water cooler - Replacement 007016 Fan complete with support - Replacement 007001 Expansion tank - Replace- ment 001052 Coolant and air bleed - Re- placement 007013 Expansion tank / radiator...

  • Page 292: Rear Shock Absorber

    Vespa GTV 250 i.e. Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Re- moval and Refitting 003077 muffler/rear shock absorber support arm - Service TIME - 26...
  • Page 293 Vespa GTV 250 i.e. Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Re- placement 003073 Steering clearance - Adjust TIME - 27...

  • Page 294: Handlebar Covers

    Vespa GTV 250 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Re- placement 004019 Rear handlebar covers - Re- placement 004053 Spoiler - Replacement TIME - 28...

  • Page 295: Handlebar Components

    Vespa GTV 250 i.e. 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...

  • Page 296: Swinging Arm

    Vespa GTV 250 i.e. Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chas- sis connection - Replacement 004058 Silent block - Replacement TIME - 30...
  • Page 297 Vespa GTV 250 i.e. Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement TIME - 31...
  • Page 298 Vespa GTV 250 i.e. Time Instrument panel INSTRUMENT PANEL Code Action Duration 004066 Driving mirror - Replacement 005014 Odometer - Replacement 005041 Starter button - Replacement 005077 Emergency stop switch - Re- placement 005006 Light switch or turn indicators - Replacement...
  • Page 299 Vespa GTV 250 i.e. Time Rear rack UGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement TIME - 33...
  • Page 300 Vespa GTV 250 i.e. 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 301: Turn Signal Lights

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

  • Page 302: Front Wheel

    Vespa GTV 250 i.e. Time Code Action Duration 005028 Rear light assembly glass - Replacement Front wheel RONT WHEEL Code Action Duration 003047 Front tyre - Replacement 003037 Front wheel rim- Replace- ment 004123 Front wheel - Replacement 003033 Front wheel hub- Replace-...

  • Page 303: Rear Wheel

    Vespa GTV 250 i.e. Time Rear wheel EAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replace- ment 001071 Front wheel rim - Removal and refitting 001016 Rear wheel - Replacement 002028 Rear wheel hub - Replace- ment 002070...

  • Page 304: Electric Devices

    Vespa GTV 250 i.e. Time Electric devices LECTRICAL DEVICES Code Action Duration 001094 Spark plug cap - Replace- ment 001069 HV coil - replace 005003 Horn - Replacement 005009 Voltage regulator - replace 005052 Fuse (1) - Replacement 005007 Battery - Replacement...
  • Page 305 Vespa GTV 250 i.e. Time Transmissions RANSMISSIONS Code Action Duration 002051 Odometer transmission as- sembly - Replacement TIME - 39...

  • Page 306: Front Suspension

    Vespa GTV 250 i.e. 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...
  • Page 307 Vespa GTV 250 i.e. Time Braking system RAKE SYSTEM Code Action Duration 002039 Front brake calliper - Re- placement 002007 Front brake pads - Replace- ment 002021 Front brake piping - Replace- ment 002047 Front brake fluid and air bleeding system - Replace-...
  • Page 308 Vespa GTV 250 i.e. Time Stickers RANSFERS Code Action Duration 004159 Plates / Stickers - Replace- ment TIME - 42...

This manual is also suitable for:

633845 en633846 fr633847 de633849 pt633848 es633850 nl ... Show all

Table of Contents