LG GTS125 Service Manual

SERVICE STATION MANUAL

664662 IT-664663 EN-664664 FR-664665 DE-664666

ES-664667 PT-664668 OL-664669 EL

Vespa GTS 125

SERVICE STATION

MANUAL

Vespa GTS 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.

Not all versions shown in this publication are available in all Countries. The availability of single versions

should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL

Vespa GTS 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. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Characteristics Vespa GTS 125

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 wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

CHAR - 2

Vespa GTS 125 Characteristics

Vehicle identification

Chassis prefix: ZAPM313000000 ÷ 1001 Engine prefix: M315M1001

Dimensions and mass

Specification Desc./Quantity

Total kerb weight 145 ± 5 kg

Width (to hand grips) 755 mm

Length 1940 mm

Wheelbase 1395 mm

Height 1180 mm

Saddle height 800 mm

WEIGHTS AND DIMENSIONS

CHAR - 3

Characteristics Vespa GTS 125

Engine

Minimum lubrication pressure (90° C) 0.6 ÷ 1.2 bar

ENGINE

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 124 cm³

Bore x stroke 57.0 x 48.6 mm

Compression ratio 12 ± 0.5: 1

Engine idle speed 1650 ± 100 rpm

Timing system 4 valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm

MAX. power 10.5 kW at 9,500 rpm

MAX torque 12 Nm at 8,000 rpm

Lubrication Engine lubrication with lobe pump (inside crank-

case) controlled by a chain with double filter: mesh

and paper.

Lubrication pressure 3 ÷ 4 bar

Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel

pump.

Cooling Forced coolant circulation system.

Fuel Unleaded petrol (95 RON)

CHAR - 4

Vespa GTS 125 Characteristics

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

server, V belt, dry self-ventilating automatic cen-

trifugal clutch and transmission housing with

forced air circulation.

Final reduction Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.10 l

Transmission oil 150 cm³

Cooling system fluid ~ 2 l

Fuel tank (reserve) ~ 10 l (2 l)

Electrical system

Specification Desc./Quantity

Start-up Electric

Ignition Capacitive discharge ignition, with variable ad-

Ignition advance 10° at 2.000 rpm - 29° at 6.750 rpm

Spark plug CHAMPION RG4HC

Alternative spark plug NGK CR8EB

Battery Sealed, 12 V / 10 Ah

Frame and suspensions

Specification Desc./Quantity

Chassis Tubular and sheet steel.

FRONT SUSPENSION Single arm with helicoidal spring and single douFront suspension travel - mm

Rear suspension Two double-acting shock absorbers, adjustable to

Rear suspension travel - mm

ELECTRICAL SYSTEM

vance and separate HV coil.

FRAME AND SUSPENSIONS

ble-acting hydraulic shock absorber.

4 positions at preloading.

CHAR - 5

Characteristics Vespa GTS 125

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 220 disc brake with hydraulic control activated

by handlebar right lever.

Rear brake Ø 200 mm disc brake with hydraulic control acti-

vated by handlebar left lever.

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy rims.

Front rim 12'' x 3.00 Rear rim 12'' x 3.00

Front tyre 120/70 - 12'' 51P Tubeless

Rear tyre 130/70 - 12'' 62P Tubeless

Front tyre pressure (with passenger) 1.8 bar (-)

Rear tyre pressure (with passenger) 2.2 bar (-)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Carburettor

125cc Version

Kehin

CARBURETTOR KEIHIN

Specification Desc./Quantity

Depression carburettor CVEK-30

Body stamping CVEK

CUT-OFF device Not present

Max. jet 108

Minimum jet 38

Max. air jet 70

Minimum air jet 130

Throttle valve spring 100 ÷ 160 g

Minimum mixture set screw initial opening 1 ± ½

Tapered pin NDYB

Diffuser nozzle Ø 5.0

Starter air jet Ø 1.5

Starter jet 42

Starter device resistance ~ 20 Ω

Venturi diffuser Ø 29 (47x30.9)

Throttle valve Ø 30.5

N.B.

CHAR - 6

Vespa GTS 125 Characteristics

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

Tightening Torques

STEERING ASSEMBLY

Name Torque in Nm

Upper steering ring nut 30 ÷ 40 Lower steering ring nut 8 ÷ 10

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. Safety locks: see «Pre-deliv-

ery Operations» )

Fixing screws for handlebar control assembly U-

bolts

FRAME ASSEMBLY

Name Torque in Nm

Engine-swinging arm bolt 64 - 72

swinging arm bolt - body shell 76 ÷ 83

Engine and vehicle side swinging arm junction bolt 33 ÷ 41

Bolt of the Silent block support plate 42 ÷ 52

Centre stand bolt 25 - 30

Side stand fixing bolt 40 ÷ 45

7 ÷ 10

FRONT SUSPENSION

Name Torque in Nm

Screw fixing the shock absorber to the shock ab-

sorber - calliper attachment plate

Wheel axle nut 75 ÷ 90

Wheel screw 20 ÷ 25

Screw fixing rear mudguard to steering 5 ÷ 6.5

FRONT BRAKE

Name Torque in Nm

Brake fluid pump - hose fitting 20 ÷ 25 Brake fluid hose-calliper fitting 20 ÷ 25

Screw fixing calliper to the shock absorber - cal-

liper plate attachment

Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium

Oil bleed screw 12 - 16

Pad fastening pin 19.6 ÷ 24.5

Brake pump reservoir screws 15 ÷ 20

REAR SUSPENSION

Name Torque in Nm

Retainer for left shock absorber to crankcase sup-

port plate

Shock absorber upper fitting 20 ÷ 25

Shock absorber lower fitting 33 ÷ 41

Rear wheel shaft 104 ÷ 126

Screw fixing wheel to hub 20 ÷ 25

20 ÷ 27

20 ÷ 25

strength)

20 ÷ 25

CHAR - 7

Characteristics Vespa GTS 125

Name Torque in Nm

Screws for muffler - shock absorber support arm

on engine

20 ÷ 25 (The two screws must be tightened to the

prescribed torque after having done so with the

rear wheel axle nut. Safety locks: see «Pre-deliv-

ery Operations» )

REAR BRAKE

Name Torque in Nm

Brake fluid pump - hose fitting 20 ÷ 25

Brake fluid pipe-calliper fitting 20 ÷ 25

Rear disc tightening bolt 11 ÷ 13

Oil bleed screw 12÷16

Calliper to engine tightening screw 20 ÷ 25

Brake pump reservoir screws 15 ÷ 20

Calliper coupling screws 30 ÷ 33

MUFFLER

Name Torque in Nm

Muffler heat guard clamping screw 5 - 6

Exhaust fumes inlet screw 13 ÷ 15

Screw for fixing muffler to the support arm 20 ÷ 25

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 8 ÷ 10

Oil pump cover screws 7 ÷ 9

Screws fixing oil pump to the crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name Torque in Nm

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts for head fastening to the cylinder 7± 1 + 180° (2x90°) (Fasten nuts in two crossed

passes) (Before fitting the nuts, lubricate them with

engine oil.)

Head fixing side screws 11 ÷ 13

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 ÷ 14

M6 central screw locking washers on camshaft 11 ÷ 15

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

CHAR - 8

Vespa GTS 125 Characteristics

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch assembly nut on driven pulley 55 ÷ 60

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

FLYWHEEL

Name Torque in Nm

Flywheel cover fixing screws 5 - 6

Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength

threadlock)

Flywheel nut 52 ÷ 58

Pick-Up clamping screws 3 ÷ 4

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength

4 ÷ 6

threadlock)

COOLING

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Screws of the water pump rotor driving link 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Overhaul data

Assembly clearances

CHAR - 9

Characteristics Vespa GTS 125

Cylinder - piston assy.

COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059 Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059

Cylinder 1st Over-

size

Cylinder 1st Over-

size

Piston 1st Over-

size

Piston 1st Over-

size

Cylinder 2nd Over-

size

Cylinder 2nd Over-

size

Piston 2nd Over-

size

Piston 2nd Over-

size

Cylinder 3rd Over-

size

Cylinder 3rd Over-

size

Piston 3rd Over-

size

A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059 B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059 C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059 D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059

A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059 B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059 C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059 D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059 A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059 B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059 C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059

CHAR - 10

Vespa GTS 125 Characteristics

Name Initials Cylinder Piston Play on fitting

Piston 3rd Over-

size

Piston rings

D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

ENGINE SEALING RINGS

Name Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 ÷ 0.30

Oil scraper ring 57 x 1 A 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35

ENGINE SEALING RINGS (1ST OVERSIZE)

Name Description Dimensions Initials Quantity

Compression ring

1st oversize

Oil scraper ring 1st

Oversize

Oil scraper ring 1st

Oversize

57.2 x 1 A 0.15 ÷ 0.30

57.2 x 1 A 0.10 ÷ 0.30

57.2 x 2.5 A 0.15 ÷ 0.35

ENGINE SEALING RINGS (2ND OVERSIZE)

Name Description Dimensions Initials Quantity

Compression ring

2nd Oversize

Oil scraper ring

2nd Oversize

Oil scraper ring

2nd Oversize

57.4 x 1 A 0.15 ÷ 0.30

57.4 x 1 A 0.10 ÷ 0.30

57.4 x 2.5 A 0.15 ÷ 0.35

ENGINE SEALING RINGS (3RD OVERSIZE)

Name Description Dimensions Initials Quantity

Compression ring

3rd Oversize

Oil scraper ring 3rd

Oversize

Oil scraper ring 3rd

Oversize

57.6 x 1 A 0.15 ÷ 0.30

57.6 x 1 A

57.6 x 2.5 A 0.15 ÷ 0.35

CHAR - 11

Characteristics Vespa GTS 125

Crankcase - crankshaft - connecting rod

Fitting clearances Crankshaft/crankcase axial clearance (H):

0.15 ÷ 0.40 mm (when cold)

CHAR - 12

Vespa GTS 125 Characteristics

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

Flywheel-side half-

shaft

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

CRANKSHAFT HALF-BEARINGS

Name Description Dimensions Initials Quantity

Crankshaft half-

bearing

Crankshaft half-

bearing

Crankshaft half-

bearing

16.6 +0-0.05 A D = 0.20 - 0.50

16.6 +0-0.05 B D = 0.20 - 0.50

Category B - blue 1.973 ÷ 1.976

Category C - yel-

low

Category E - green 1.979 ÷ 1.982

1.976 ÷ 1.979

CRANKCASE - CRANKSHAFT COUPLINGS

Name Description Dimensions Initials Quantity

Crankshaft catego-

ry 1 - Crankcase

category 1

Crankshaft catego-

ry 1 - Crankcase

category 2

Crankshaft catego-

ry 2 - Crankcase

category 1

Crankshaft catego-

ry 2 - Crankcase

category 2

E - E

C - C

B - B

CRANKSHAFT - CRANKCASE

Name Description Dimensions Initials Quantity

Crankshaft Category 1 28.998 ÷ 29.004 Crankshaft Category 2 29.004 ÷ 29.010 Crankcase Category 1 32.959 ÷ 32.965 Crankcase Category 2 32.953 ÷ 32.959

CHAR - 13

Characteristics Vespa GTS 125

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.

N.B.

DISTANCE "A" MUST BE MEASURED WITHOUT ANY GASKET FITTED BETWEEN CRANKCASE AND CYLINDER

SHIMMING

Name Measure A Thickness

Shimming 2.2 ÷ 2.4 0.4 ± 0.05 Shimming 2.4 ÷ 2.6 0.6 ± 0.05

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