LG GTS250 Service Manual

WORKSHOP MANUAL

633577

Vespa GTS 250 I.E.

WORKSHOP

MANUAL

Vespa GTS 250 I.E.

The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

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.

"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."

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

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

WORKSHOP MANUAL

Vespa GTS 250 I.E.

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio­Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific 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

INJECTION INJEC

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 250 I.E.

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the scooter.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.

- 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 reassembly.

- 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 scooter that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec­tions.

CHAR - 2

Vespa GTS 250 I.E. Characteristics

Vehicle identification

Chassis prefix: ZAPM45100000 ÷ 1001
Engine prefix: M451M ÷ 1001

Dimensions and mass

Specification Desc./Quantity

Total loadless weight 151 ± 5 kg
Width (to hand grips) 755 mm

Length 1930 mm

Wheel base 1370 mm

Saddle height 800 mm

DIMENSIONS AND MASS

CHAR - 3

Characteristics Vespa GTS 250 I.E.

Engine

DATA

Specification Desc./Quantity

Type single-cylinder, four-stroke and four liquid-cooled

valves

Timing system single overhead camshaft chain driven on the left-

hand side, three-arm rocking levers set up with

threaded set screw

Bore 72 mm

Stroke 60 mm

Cubic capacity 249.29 mm

Compression ratio 10.5 ÷ 11.5

Idle speed 1650 ± 50 rpm

Air filter sponge, impregnated with mixture (50% petrol and

50% oil)

Starting system electric starter motor with freewheel

Lubrication with lobe pump (inside the crankcase) chain-driv-

en and double filter: mesh and paper
Fuel supply by electronic injection with electric fuel pump
Max. speed 120 km/h

valve clearance intake: 0.10 mm - discharge: 0.15 mm

Transmission

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

Capacities

Specification Desc./Quantity

Engine oil approx. 1300 cc (recommended oil Selenia HI

Fuel tank (including a ~ 2 l reserve) ~ 9.2 l

Rear hub 250 cc ( recommended oil TUTELA MATRIX)

Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted)

Electrical system

TRANSMISSION

server, V belt, automatic clutch, gear reduction unit

and transmission housing with forced air circula-

tion cooling

CAPACITY

Scooter 4 Tech)

CHAR - 4

ELECTRICAL COMPONENTS

Specification Desc./Quantity

Ignition/advance Electronic, with inductive discharge and variable

advance with three-dimensional mapping

Spark plug CHAMPION RG 4 PHP

Battery 12V-12Ah

Vespa GTS 250 I.E. Characteristics

Specification Desc./Quantity

Fuses 1: 30A - 1: 15A - 3: 10A - 4: 7,5A - 1: 3A

Generator alternating current

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Type Unitised body made of stamped plate

Front suspension Single arm suspension (cantilever wheel) fitted

with a double-acting hydraulic shock absorber with

coaxial spring

Front shock absorber axial travel 86.5 mm

Rear suspension Engine with swinging fork attached to frame by

means of an arm with 2 degrees of freedom Pair

of double-acting hydraulic shock absorbers and

coaxial springs with preloading adjustment in 4

positions.

Rear shock absorber axial travel 89.5 mm

Brakes

BRAKES

Specification Desc./Quantity

Front Ø 220 disc brake and floating calliper with Ø 25

mm twin plungers and hydraulic control (lever on

the far right end of the handlebar)

Rear Ø 220 disc brake and calliper with two Ø 30 mm

counteracting plungers and hydraulic control (lev-

er on the far left end of the handlebar)

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheels - light alloy rims 3.00x12

Rear wheels - light alloy rims 3.00x12

Front tyres 120/70-12" Tubeless

Rear tyres 130/70-12" Tubeless

TYRE PRESSURE

Specification Desc./Quantity

Front tyre pressure (when cold) 1.8 bar
Rear tyre pressure (when cold) 2 bar

Tyre pressure (when cold) 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

CHAR - 5

Characteristics Vespa GTS 250 I.E.

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. 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 32 ÷ 40

Side stand fixing bolt 35 ÷ 40

7 ÷ 10

SOSPENSIONE ANTERIORE

Name Torque in Nm

Screw fixing the shock absorber to the shock ab-

sorber - calliper attachment plate

Wheel axle nut 74 ÷ 88

Wheel screw 20 ÷ 25

Screw fixing rear mudguard to steering 5 ÷ 6.5

shock absorber upper clamp 20 ÷ 30

FRENO ANTERIORE

Name Torque in Nm

Brake fluid pump - hose fitting 20 ÷ 25

Brake fluid tube- calliper fitting 19 ÷ 24

Vite serraggio pinza alla piastra attacco ammor-

tizzatore - pinza freno

Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium

Oil bleed screw 12 - 16

Pad fastening pin 19.6 ÷ 24.5

Viti vaschetta pompa freno 1,5 ÷ 2

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

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

20 ÷ 27

24 ÷ 27

strength)

20 ÷ 25

CHAR - 6

Vespa GTS 250 I.E. Characteristics

Name Torque in Nm

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

ery Operations» )

FRENO POSTERIORE

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

Viti vaschetta pompa freno 1,5 ÷ 2

Vite accoppiamento pinza 30 ÷ 33 Nm

MUFFLER

Name Torque in Nm

Muffler heat guard fixing screw 4 ÷ 5
Screw for fixing muffler to the support arm 20 ÷ 25
Lambda probe clamp on exhaust manifold 40 ÷ 50

Exhaust manifold-muffler joint clamp 12 ÷ 13

Manifold - muffler diaphragm tightening clamp 16 ÷ 18

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 4 ÷ 6

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 fixing head to cylinder 7±1 + 10±1 + 270°

Head fixing side screws 11 ÷ 12 Nm

Starter ground screw 7 ÷ 8.5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Timing chain tensioner slider screw 10 ÷ 14
Start-up counterweight support screw 11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

CHAR - 7

Characteristics Vespa GTS 250 I.E.

Name Torque in Nm

Clutch unit nut on driven pulley 45 ÷ 50

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

FLYWHEEL

Name Torque in Nm

Flywheel cover screw 11 ÷ 13

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

threadlock)

Flywheel nut 94 - 102 Nm

Pick-Up clamping screws 3 ÷ 4

Screw fixing freewheel to flywheel 13 - 15

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

Engine-crankcase coupling screws 11 ÷ 13

Starter screws 11 ÷ 13

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

4 ÷ 6

threadlock)

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

Overhaul data

Assembly clearances

COOLING

CHAR - 8

Vespa GTS 250 I.E. Characteristics

Cylinder - piston assy.

ENGINE COUPLING CATEGORY

Name Initials Cylinder Piston Play on fitting

Cylinder M 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064
Cylinder N 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064

Piston O 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064
Piston P 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 - 0.064

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000

car.)

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

Indirizzo Immagine

CHAR - 9

Characteristics Vespa GTS 250 I.E.

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

16.6 +0-0.05 A D = 0.20 - 0.50

16.6 +0-0.05 B D = 0.20 - 0.50

Slot packing system

Characteristic

Compression ratio

10.5 ÷ 11.5 : 1

CHAR - 10

Vespa GTS 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.

N.B.

MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK­CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON
A GROUND PLANE

ENGINE 250 SHIMMING

Name Measure A Thickness

shimming 3.70 - 3.60 0.4 ± 0.05
shimming 3.60 - 3.40 0.6 ± 0.05
shimming 3.40 - 3.30 0.8 ± 0.05

CHAR - 11

Characteristics Vespa GTS 250 I.E.

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-

sions (throttle control)

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives

AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

SPECIAL AGIP PERMANENT

fluid

coolant Monoethylene glycol-based anti-

Oil for 4-stroke engines

for increased adhesiveness

based spray grease with NLGI 2;

ISO-L-XBCIB2

JASO MA Synthetic oil

freeze fluid, CUNA NC 956-16

CHAR - 12

INDEX OF TOPICS

TOOLING TOOL

Tooling Vespa GTS 250 I.E.

APPROPRIATE TOOL

Stores code Description

001330Y Tool for fitting steering seats

001467Y017 Bell for bearings, outside Ø 39

mm

001467Y014 Extraction pliers for ø 15 mm

bearings

005095Y Engine support

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seat

on steering tube

020004Y Punch for removing fifth wheels

from the headstock

TOOL - 2

Vespa GTS 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

Tooling Vespa GTS 250 I.E.

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

TOOL - 4

020329Y Mity-Vac vacuum operated

pump

Vespa GTS 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

Tooling Vespa GTS 250 I.E.

Stores code Description

020335Y Magnetic support for dial gauge

020357Y 32 x 35 mm adaptor
020359Y 42 x 47 mm adaptor

020360Y 52 x 55 mm adaptor

020363Y 20 mm guide

020364Y 25 mm guide

TOOL - 6

Vespa GTS 250 I.E. Tooling

Stores code Description

020365Y 22 mm guide

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle

020382Y Valve cotters equipped with part

012 removal tool

020382Y011 adapter for valve removal tool

TOOL - 7

Tooling Vespa GTS 250 I.E.

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

Tooling Vespa GTS 250 I.E.

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 H.V. cable extraction adapter

TOOL - 10

Vespa GTS 250 I.E. Tooling

Stores code Description

020481Y Control unit interface wiring

001467Y035 Bearing housing outside diame-

ter 47 mm

020626Y Driving pulley lock wrench

001467Y013 Pliers to extract ø 15 mm bear-

ings

020627Y Flywheel lock wrench

020467Y Flywheel extractor

TOOL - 11

Tooling Vespa GTS 250 I.E.

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

bloc

TOOL - 12

Vespa GTS 250 I.E. Tooling

Stores code Description

020638Y 250 I. E. ENGINE - ABS SOFT-

WARE

020469Y Reprogramming kit for scooter

diagnosis tester

TOOL - 13