LG GTV250 Service Manual

SERVICE STATION MANUAL
633844 IT - 633845 EN -633846 FR - 633847 DE -
633848 ES - 633849 PT - 633850 NL - 633851 EL
Vespa GTV 250 i.e.
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
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 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. 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
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 GTV 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 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 250 i.e. Characteristics
Vehicle identification
Chassis prefix: *ZAPM451020000 ÷ 1001* Engine prefix: M451M ÷ 1001
CHAR - 3
Characteristics Vespa GTV 250 i.e.
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
GENERAL SPECIFICATIONS
Specification Desc./Quantity
Electronic ignition inductive, high efficiency integrated with the injec-
tion system, with variable timing and separate HV
coil. Fuel supply throttle valve dia. 32 mm and single injector Lubrication Engine lubrication with lobe pump (inside crank-
case) controlled by a chain with double filter: mesh
and paper.
Cooling Forced fluid circulation, with engine driven pump;
3-way thermostat to pump intake.
Exhaust muffler absorption-type exhaust muffler with catalytic con-
verter.
CHAR - 4
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
Bore x stroke 72 x 60 mm
Cubic capacity 244.29 cm³
Compression ratio 10.5 - 11.5 : 1
Idle speed 1700 +/- 100 rpm
Ignition advance (before TDC) variable (integrated into the ignition system)
Spark plug CHAMPION RG 4 PHP
Valve clearance intake: 0.10 mm discharge: 0.15 mm Maximum power 15.7 kW at 8500 rpm (EC Standard). Maximum torque 20.1 Nm at 6500 rpm (EC Standard).
Max. speed 120 km/h
Transmission
Capacities
Fuel tank (including a ~ 2 l reserve) ~ 9.2 l
Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted)
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
CAPACITY
Specification Desc./Quantity
Engine oil approx. 1300 cc (recommended oil Selenia HI
Scooter 4 Tech)
Rear hub 250 cc ( recommended oil TUTELA MATRIX)
CHAR - 5
Characteristics Vespa GTV 250 i.e.
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
1 Spark plug CHAMPION RG4
PHP 2 Battery 12V - 12 Ah 3 Sealed Battery 14Ah 12V - 14 Ah (mainte-
nance free).
4 Generator 380W Rated power 380W
at 8000 rpm
BULBS
Specification Desc./Quantity
1 Low-/ high-beam
light
2 Front position light 5W - 12V (Quantity 3 Instrument Panel
warning lights
4 Front turn indicator
light
5 Rear turn indicator
light
6 Rear tail light 5W - 12V (Quantity 7 Stop Light 16W - 12V (Quantity 8 License Plate Light 5W - 12V (Quantity
55/60 - 12V (Quantity
1)
2)
1.2W - 12V (Quantity
5)
5W - 12V (Quantity
4)
10W - 12V (Quantity
2)
1)
1)
1)
FUSES
Specification Desc./Quantity
1 No.1 - Vehicle main
fuse
2 No. 2 - Live injection
ECU
3 No. 3 - Power to in-
jection load
4 No. 4 - Battery-pow-
ered injection ECU
5 No. 5 - Live accesso-
ries and instrument
panel
6 No. 6 - Live light re-
mote control and
horn
7 No. 7 - Live Headlight
and Saddle Opening
Switch
8 No. 8 - Battery-pow-
ered Accessories
and Instrument panel
30A
7.5 A
10A
7,5A
10A
7.5 A
15 A
10A
CHAR - 6
Vespa GTV 250 i.e. Characteristics
Specification Desc./Quantity
9 No. 9 - Live Stop light
and Starter key
10 No. 10 - Power to tail
light and instrument
panel lighting
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
7.5 A
7.5 A
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.
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 wheel Alloy rims: 12" x 3.00" Rear wheel Alloy rims: 12" x 3.00"
Front tyre Without inner tube 120/70-12" 51P
Rear tyre Without inner tube: 130/70-12" 62P
TYRE PRESSURE
Specification Desc./Quantity
Front tyre pressure 1.8 bar
Rear tyre pressure 2 bar
Rear tyre pressure - driver and 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 - 7
Characteristics Vespa GTV 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
20 ÷ 27
24 ÷ 27
strength)
20 ÷ 25
CHAR - 8
Vespa GTV 250 i.e. Characteristics
Name Torque in Nm
Screws for muffler - shock absorber support arm
on engine
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
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
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» )
MUFFLER
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
Starter ground support screw 11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5 - 6
Camshaft retention plate screw 4 ÷ 6
CHAR - 9
Characteristics Vespa GTV 250 i.e.
TRANSMISSION
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 ÷ 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 motor screws 11 ÷ 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Bleed screw: 3
Overhaul data
Assembly clearances
4 ÷ 6
threadlock)
COOLING
CHAR - 10
Vespa GTV 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 - 11
Characteristics Vespa GTV 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 - 12
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.
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 - 13
Characteristics Vespa GTV 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 DOT4 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 - 14
INDEX OF TOPICS
TOOLING TOOL
Tooling Vespa GTV 250 i.e.
APPROPRIATE TOOL
Stores code Description
001330Y Tool for fitting steering seats
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
020004Y Punch for removing fifth wheels
from headstock
TOOL - 2
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
Tooling Vespa GTV 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 MityVac vacuum-operated pump
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
Tooling Vespa GTV 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 HV cable extraction adaptor
TOOL - 10
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
Tooling Vespa GTV 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 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
Tooling Vespa GTV 250 i.e.
TOOL - 14
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