LG GTV125 Service Manual

SERVICE STATION MANUAL
664619 IT-664620 EN-664621 FR-664622 DE-664623
ES-664624 PT-664625 OL-664626 EL
Vespa GTV 125
SERVICE STATION
MANUAL
Vespa GTV 125
The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
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)
SERVICE STATION MANUAL
Vespa GTV 125
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. 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 relating to 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 GTV 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 GTV 125 Characteristics
Vehicle identification
Chassis prefix: ZAPM313010000 ÷ 1001 Engine prefix: M315M1001
Dimensions and mass
Specification Desc./Quantity
Total kerb weight 148 ± 5 kg
Overall width 770 mm
Length 1940 mm
Wheelbase 1395 mm
Height 1180 mm
Saddle height 800 mm
WEIGHTS AND DIMENSIONS
CHAR - 3
Characteristics Vespa GTV 125
Engine
ENGINE
Specification Desc./Quantity
Type single-cylinder, four-stroke and four liquid-cooled
valves
Timing system single overhead camshaft chain driven on the left-
hand side, three-arm rocking levers set up with
threaded set screw
Bore 57 mm
Stroke 48.6 mm
Cubic capacity 124 cm³ Compression ratio 12 ± 0.5: 1 Carburettor Keihin CVK 30
Engine idle speed 1650 ± 50 rpm
Air filter sponge, impregnated with mixture (50% petrol and
50% oil)
Starting system electric starter
Lubrication with lobe pump (inside the crankcase) chain-driv-
en and double filter: mesh and paper
Fuel supply petrol, with vacuum pump and through carburettor
MAX. power 10.5 to 9500 rpm
MAX torque 12 Nm at 8,000 rpm
CHAR - 4
Vespa GTV 125 Characteristics
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque
server, V belt, automatic clutch, gear reduction unit
and transmission housing with forced air circula-
tion cooling
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil ~ 1000 cm³
Fuel tank (including a ~ 2 l reserve) ~ 9.5 l
Rear hub 150 cm³
Cooling system fluid ~ 2.100 ÷ 2.150 l
Electrical system
Specification Desc./Quantity
Type of ignition Electronic capacitive discharge ignition, with vari-
Variable ignition advance (before TDC)
Spark plug Champion RG 4 HC
Battery Sealed, 12 V / 10 Ah
Generator alternating current
Frame and suspensions
Specification Desc./Quantity
Type Unitised body made of stamped plate
Front suspension Single arm suspension (cantilever wheel) fitted
Front shock absorber axial travel 86.5 mm
Rear suspension Engine with swinging fork attached to frame by
Rear shock absorber axial travel 89.5 mm
ELECTRICAL COMPONENTS
able timing and separate HV coil
10° ± 1° at 2000 rpm
FRAME AND SUSPENSIONS
with a double-acting hydraulic shock absorber with
coaxial spring
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.
CHAR - 5
Characteristics Vespa GTV 125
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
Carburettor
125cc Version
Kehin
CARBURETTOR KEIHIN
Specification Desc./Quantity
Depression carburettor CVEK-30
Body stamping CVEK
CUT-OFF device Not present
Max. jet 98
Minimum jet 38
Max.air jet 150
Minimum air jet 130
Throttle valve spring 100 ÷ 160 g
Minimum mixture set screw initial opening 2 ± ¼
Tapered pin NDVA
Tapered pin notches from top Single-notch pin
Diffuser nozzle Ø 5.0
CHAR - 6
Vespa GTV 125 Characteristics
Specification Desc./Quantity
Petrol inlet hole -
Starter air jet Ø 1.5
Starter diffuser nozzle -
Starter jet 42
Diameter of starter pin -
Starter device resistance ~ 20
Venturi diffuser Ø 29 (47x30.9)
Throttle valve Ø 30.5
Diffuser maximum cone -
N.B.
* 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
7 ÷ 10
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
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
20 ÷ 27
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
20 ÷ 25
strength)
CHAR - 7
Characteristics Vespa GTV 125
Name Torque in Nm
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
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-
20 ÷ 25
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
CHAR - 8
Vespa GTV 125 Characteristics
Name Torque in Nm
Starter ground screw 7 ÷ 8.5
M5 side screw locking washers on camshaft 7 ÷ 8.5
Tappet set screw lock nut 6 ÷ 8
Inlet manifold screws 11 ÷ 13
Timing chain tensioner slider screw 10 ÷ 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
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
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
4 ÷ 6
Overhaul data
Assembly clearances
CHAR - 9
Characteristics Vespa GTV 125
Cylinder - piston assy.
ENGINE 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
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 D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059
CHAR - 10
Vespa GTV 125 Characteristics
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
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
CHAR - 11
Characteristics Vespa GTV 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
Oversizes
CHAR - 12
Vespa GTV 125 Characteristics
ENGINE OVERSIZES
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
Compression ring
1st oversize
Oil scraper ring 1st
Oversize
Oil scraper ring 1st
Oversize
Compression ring
2nd Oversize
Oil scraper ring
2nd Oversize
Oil scraper ring
2nd Oversize
Compression ring
3rd Oversize
Oil scraper ring 3rd
Oversize
Oil scraper ring 3rd
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
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
57.6 x 1 A 0.15 ÷ 0.30
57.6 x 1 A
57.6 x 2.5 A 0.15 ÷ 0.35
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 Calcium complex soap-based
grease with NLGI 2; ISO-L-
XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,
AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid
SPECIAL AGIP PERMANENT
fluid
coolant Monoethylene glycol-based anti-
Oil for 4-stroke engines
for increased adhesiveness
Grease (brake control levers,
throttle grip)
JASO MA Synthetic oil
freeze fluid, CUNA NC 956-16
CHAR - 13
Characteristics Vespa GTV 125
CHAR - 14
INDEX OF TOPICS
TOOLING TOOL
Tooling Vespa GTV 125
APPROPRIATE TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y009 Driver for OD 42 mm bearings
001467Y017 Bell for bearings, outside Ø 39
mm
001467Y014 Pliers to extract ø 15-mm bear-
ings
005095Y Engine support
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat
on steering tube
TOOL - 2
Vespa GTV 125 Tooling
Stores code Description
008564Y Flywheel extractor
020004Y Punch for removing fifth wheels
from headstock
020021Y Front suspension service tool
020036Y Punch
020037Y Punch
TOOL - 3
Tooling Vespa GTV 125
Stores code Description
020038Y Punch
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crank-
shaft alignment
020150Y Air heater support
020151Y Air heater
020193Y Oil pressure gauge
020262Y Crankcase splitting strip
TOOL - 4
Vespa GTV 125 Tooling
Stores code Description
020263Y Sheath for driven pulley fitting
020287Y Clamp to assemble piston on cyl-
inder
020306Y Punch for assembling valve seal
rings
020319Y Immobilizer check tester
020329Y MityVac vacuum-operated pump
020330Y Stroboscopic light for timing con-
trol
TOOL - 5
Tooling Vespa GTV 125
Stores code Description
020331Y Digital multimeter
020332Y Digital rev counter
020333Y Single battery charger
020334Y Multiple battery charger
TOOL - 6
Vespa GTV 125 Tooling
Stores code Description
020335Y Magnetic support for dial gauge
020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor
020360Y Adaptor 52 x 55 mm
020363Y 20 mm guide
020364Y 25-mm guide
TOOL - 7
Tooling Vespa GTV 125
Stores code Description
020365Y 22 mm guide
020368Y driving pulley lock wrench
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020382Y Valve cotters equipped with part
012 removal tool
TOOL - 8
020382Y011 adapter for valve removal tool
Vespa GTV 125 Tooling
Stores code Description
020393Y Piston fitting band
020409Y Multimeter adaptor - Peak volt-
age detection
020412Y 15 mm guide
020414Y 28-mm guide
020423Y driven pulley lock wrench
TOOL - 9
Tooling Vespa GTV 125
Stores code Description
020424Y Driven pulley roller casing fitting
punch
020425Y Punch for flywheel-side oil seal
020426Y Piston fitting fork
020430Y Pin lock fitting tool
020431Y Valve oil seal extractor
020434Y Oil pressure control fitting
TOOL - 10
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