Piaggio Vespa WORKSHOP Piaggio Vespa GTS 250 I.E. EN, gts250 workshop, gts250 workshop, gts250 workshop Workshop Manual

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WORKSHOP MANUAL

633577

Vespa GTS 250 I.E.

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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.

in whole or in part is prohibited."

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

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

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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.

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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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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Characteristics Vespa GTS 250 I.E.

Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Rear hub oil

Capacity approximately 250 cc

Locking torques (N*m)

Hub oil drainage screw 15 ÷ 17 Nm

Air filter

Proceed as follows:

1. unscrew the fixing screw «A».

2. unscrew the nut «B» under the body.

3. remove the left side fairing.

4. remove the helmet compartment;

5. unscrew the fixing screws «C» that can be reached once the helmet compartment has been removed;

MAIN - 7

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Maintenance Vespa GTS 250 I.E.

6. Unscrew the screws «D» and remove the air filter cover. Remove the filtering element and clean it with water 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. Then gently squeeze the filter element between your hands, allow it to drip and then refit it. Oil or water deposits in the filter housing can be cleaned off by removing the two rubber caps «E».

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGING THE ENGINE.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

MAIN - 8

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Vespa GTS 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; furthermore to facilitate oil drainage, loosen the cap/ dipstick "A". Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter "C" and remove it. Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the gauze filter and oil drainage tap, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from cap "A". Then start up the scooter, leave it running for a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

N.B.

THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Check

This operation must be carried out with the engine cold and following the procedure below:

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Maintenance Vespa GTS 250 I.E.

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.

The MAX level mark indicates a quantity of around 1300 cc of engine oil. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

Oil top up

The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 200 cc.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before the fitting. Change the engine oil.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light

The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the "ON" position. However, this light should switch off once the engine has been started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

MAIN - 10

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Vespa GTS 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 flywheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference is opposite the indicator on the head, turn the crankshaft once more. For the use of this reference mark, remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a calliper spanner applied to the camshaft command pulley casing.

Cooling system

Introduction of the engine coolant.

The fluid level must checked every 10,000 kilometres with a cold engine, in the way shown below: Place the scooter on its centre stand and on flat ground.

- Undo the screw shown in the figure and remove the expansion tank cap on RHS.

- Top up if the fluid level is near or below the MIN level edge. The liquid level must always be between the MIN and MAX level.

-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% demineralised water- antifreeze solution mix.

CAUTION

DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE.

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Maintenance Vespa GTS 250 I.E.

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 handlebars perfectly horizontal;

- Check the fluid level through the sight glass as shown in the figure. A certain lowering of the level is caused by wear on the pads.

Top-up

- Position the vehicle on a flat surface and on the centre stand

- Remove the brake pump cover as indicated in the photo

Check the brake fluid level through the sight glass on the pump as shown in the photograph

- If the level is below the minimum, fill using the two screws shown in the figure

- Remove the gasket and fill with DOT 4 until the spyglass is completely covered

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Vespa GTS 250 I.E. Maintenance

For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws.

CAUTION

MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN OR CLOTHES. IF THIS HAPPENS ACCIDENTALLY, WASH WITH WATER.

CAUTION

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. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING.

CAUTION

NEVER USE BRAKE FLUID COMING FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, BRAKE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY 2 YEARS.

Locking torques (N*m)

Brake pump reservoir screws 15 ÷ 20

Headlight adjustment

Proceed as follows:

1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10;

MAIN - 13

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Maintenance Vespa GTS 250 I.E.

3. If otherwise, adjust the right headlight with screw «A».

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

MAIN - 14

Page 47

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 48

Troubleshooting Vespa GTS 250 I.E.

This section makes it possible to find the solutions to use in 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 Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace

the valves

Misshapen/worn valve seats Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston

rings

Worn or broken piston rings or piston rings that

have not been fitted properly

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Replace the piston cylinder unit or just the piston

rings

pling seal

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Care-

Oil pump with excessive clearance Perform the dimensional checks on the oil pump

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level using the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch Check that there is no grease on the masses.

Check that the clutch mass contact surface with

the casing is mainly in the centre with equivalent

characteristics on the three masses. Check that

the clutch casing is not scored or worn in an anom-

fully clean the By-Pass area.

components

(Selenia HI Scooter 4 Tech)

alous way

TROUBL - 2

Page 49

Vespa GTS 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. Check there is no air in the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump

seals, replace

Brake disc slack or distorted Check the brake disc screws are locked; measure

the axial shift of the disc with a dial gauge and with

wheel mounted on the scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective sliding of pistons Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial

gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Re-inflated or glued rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

if they are recessed or if the balls are squashed,

replace them.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

TROUBL - 3

Page 50

Troubleshooting Vespa GTS 250 I.E.

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; the condition of

the ball bearings and relevant lock-nuts, the limit

switch rubber buffers and the movement bushings.

In conclusion, check the tightening torque of the wheel hub, the brake calliper, the shock absorber disk in the attachment to the hub and the steering

tube.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Seal fault or breakage Replace the shock absorber Check the condition

of wear of the steering covers and the adjust-

ments.

TROUBL - 4

Page 51

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 52

Electrical system Vespa GTS 250 I.E.

Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578. Per i telai successivi consultare la pagina 2.

ELECTRICAL SYSTEM

Specification Desc./Quantity

1 Flywheel magneto 2 Voltage regulator 3 Immobilizer aerial 4 Diagnostic socket 5 Engine rpm sensor 6 Engine stop switch 7 N° 2 fuse boxes in under helmet compart-

ment 8 Ignition key-switch 9 Saddle opening button 10 Injection load remote control 11 Saddle opening actuator 12 Glove compartment fuse box 13 Battery 12V - 12 Ah 14 Starter motor 15 Starter remote control 16 Starter button 17 Rear stop light switch 18 Stop switch on front brake 19 Horn button 20 Horn 21 Headlight remote control switch

ELE SYS - 2

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Vespa GTS 250 I.E. Electrical system

Specification Desc./Quantity

22 Rear Headlights A Stop light

B Parking light

C License plate light

23 Light switch 24 Front Headlights A Parking light

B High beam/low beam 25 Anti-theft alarm fitting 26 helmet compartment button prewiring 27 Intercom fitting 28 Turn indicator bulbs 29 Turn signal switch 30 Fuel level sender 31 Instrument panel 32 Outside temperature sensor 33 Electric fan 34 Electric fan remote control switch 35 Oil pressure sensor 36 Engine temperature sensor 37 Fuel pump 38 Fuel injector 39 Lambda sensor 40 Spark plug 41 H.V. coil 42 Electronic injection control unit

Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Schema valido dal numero di telaio ZAPM4510000001579 in poi.

ELE SYS - 3

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Electrical system Vespa GTS 250 I.E.

ELECTRICAL SYSTEM

Specification Desc./Quantity

1 Flywheel magneto 2 Voltage regulator 3 Immobilizer aerial 4 Diagnostic socket 5 Engine rpm sensor 6 Engine stop switch 7 N° 2 fuse boxes in under helmet compart-

B Parking light

C License plate light

ELE SYS - 4

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Vespa GTS 250 I.E. Electrical system

Specification Desc./Quantity

23 Light switch 24 Front Headlights A Parking light

Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Electrical system installation

ELE SYS - 5

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Electrical system Vespa GTS 250 I.E.

Front side

1. Saddle opening switch

2. Wirings

ELE SYS - 6

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Vespa GTS 250 I.E. Electrical system

3. Insert in clamp

4. Fuse box

5. From the wire unit

1. Front left turn indicator connector

2. Front right turn indicator connector

3. Electrical fan connector

ELE SYS - 7

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Electrical system Vespa GTS 250 I.E.

1. Right turn indicator connector

2. From regulator

3. Wire unit - regulator connexion

4. To the immobilizer aerial

5. Light remote control

6. Electric fan starter

7. To key switch

8. Left turn indicator connector

ELE SYS - 8

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Vespa GTS 250 I.E. Electrical system

9. Voltage regulator

1. Immobilizer aerial

2. Foldable clamp to hold cables

3. Battery negative terminal

ELE SYS - 9

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Electrical system Vespa GTS 250 I.E.

4. Battery positive terminal

5. Flywheel - regulator connexion

1. Red sheathing

2. Clamp

3. To headlight

4. To instrument

5. To stop switch

6. To stop switch

ELE SYS - 10

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Vespa GTS 250 I.E. Electrical system

Back side

1. To HV coil

2. Foldable clamp

3. Foldable clamps to hold the red sheathing

4. Diagnostic socket

5. Starter remote control

ELE SYS - 11

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Electrical system Vespa GTS 250 I.E.

1. Right rear turn indicator

2. Cableguide

3. To rear light

4. Rear left turn indicator

ELE SYS - 12

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Vespa GTS 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

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Electrical system Vespa GTS 250 I.E.

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

ELE SYS - 14

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Vespa GTS 250 I.E. Electrical system

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. Starter motor positive terminal

Conceptual diagrams

Ignition

Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578. Per i telai successivi consultare la pagina 2.

ELE SYS - 15

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Electrical system Vespa GTS 250 I.E.

IGNITION

7. N° 2 fuse boxes in under helmet compartment

8. Key switch

10. Injection charge contactor

13. Battery

40. Spark plug

41. High voltage coil

42. electronic injection cpu

Schema valido dal numero di telaio ZAPM4510000001579 in poi.

ELE SYS - 16

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Vespa GTS 250 I.E. Electrical system

IGNITION

7. N° 2 fuse boxes in under helmet compartment

8. Key switch

10. Injection charge contactor

13. Battery

40. Spark plug

41. High voltage coil

42. electronic injection cpu

Headlights and automatic starter section

Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578. Per i telai successivi consultare la pagina 2.

ELE SYS - 17

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Electrical system Vespa GTS 250 I.E.

LIGHTS AND TURN INDICATORS

1. Magneto

2. Voltage regulator

7. N° 2 fuse boxes in under helmet compartment

8. Key switch

12. Glove compartment fuse box

13. Battery

21. Light contactor

22. Rear lights A Stop light B Parking light C License plate light

23. High/low beam selector

24. Headlights A Parking light B High beam/low beam

28. Turn indicator bulbs

29. Turn indicator switch

31. Instrument panel

ELE SYS - 18

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Vespa GTS 250 I.E. Electrical system

Schema valido dal numero di telaio ZAPM4510000001579 in poi.

LIGHTS AND TURN INDICATORS

1. Magneto

2. Voltage regulator

7. N° 2 fuse boxes in under helmet compartment

8. Key switch

12. Glove compartment fuse box

13. Battery

21. Light contactor

22. Rear lights A Stop light B Parking light C License plate light

23. High/low beam selector

24. Headlights A Parking light B High beam/low beam

28. Turn indicator bulbs

29. Turn indicator switch

ELE SYS - 19

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Electrical system Vespa GTS 250 I.E.

31. Instrument panel

Battery recharge and starting

Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578. Per i telai successivi consultare la pagina 2.

BATTERY CHARGER AND STARTING

1. Magneto

2. Voltage regulator

6. Engine stop switch

7. N° 2 fuse boxes in under helmet compartment

8. Key switch

12. Glove compartment fuse box

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Vespa GTS 250 I.E. Electrical system

13. Battery

14. Starter motor

15. Starter contactor

16. Starter button

17. Rear brake stop button

18. Front brake stop button

22. Headlights A Stop light B Parking light C License plate light

42. Electronic injection cpu

Schema valido dal numero di telaio ZAPM4510000001579 in poi.

BATTERY CHARGER AND STARTING

1. Magneto

2. Voltage regulator

6. Engine stop switch

7. N° 2 fuse boxes in under helmet compartment

8. Key switch

12. Glove compartment fuse box

ELE SYS - 21

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Electrical system Vespa GTS 250 I.E.

13. Battery

14. Starter motor

15. Starter contactor

16. Starter button

17. Rear brake stop button

18. Front brake stop button

22. Headlights A Stop light B Parking light C License plate light

42. Electronic injection cpu

Level indicators and enable signals section

Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578. Per i telai successivi consultare la pagina 2.

CONSENSUSES AND LEVEL INDICATORS

3. Immobilizer antenna

5. Engine rpm sensor

7. N° 2 fuses boxes in under helmet compartment

8. Key switch

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Vespa GTS 250 I.E. Electrical system

10. Injection charge contactor

12. Glove compartment fuse box

13. Battery

30. Fuel level transmitter

31. Instrument panel

32. External temperature sensor

35. Oil pressure sensor

36. Engine temperature sensor

37. Fuel pump

38. Petrol injector

39. Lambda sensor

42. Electronic injection cpu

Schema valido dal numero di telaio ZAPM4510000001579 in poi.

CONSENSUSES AND LEVEL INDICATORS

3. Immobilizer antenna

5. Engine rpm sensor

7. N° 2 fuses boxes in under helmet compartment

8. Key switch

10. Injection charge contactor

ELE SYS - 23

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Electrical system Vespa GTS 250 I.E.

12. Glove compartment fuse box

13. Battery

30. Fuel level transmitter

31. Instrument panel

32. External temperature sensor

35. Oil pressure sensor

36. Engine temperature sensor

37. Fuel pump

38. Petrol injector

39. Lambda sensor

42. Electronic injection cpu

Turn signal lights

Lo schema sottostante è valido per i telai dal numero ZAPM4510000001007 al ZAPM4510000001578. Per i telai successivi consultare la pagina 2.

DEVICES AND HORN

7. N° 2 fuse boxes in under helmet compartment

8. Key switch 9. Saddle open button

10. Injection charge contactor

11. Actuator for saddle opening

ELE SYS - 24

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Vespa GTS 250 I.E. Electrical system

13. Battery

19. Horn button

20. Horn

33. Electric fan for ventilator

34. Electric fan contactor

42. Electronic injection cpu

Schema valido dal numero di telaio ZAPM4510000001579 in poi.

DEVICES AND HORN

7. N° 2 fuse boxes in under helmet compartment

8. Key switch 9. Saddle open button

10. Injection charge contactor

11. Actuator for saddle opening

13. Battery

19. Horn button

20. Horn

33. Electric fan for ventilator

34. Electric fan contactor

42. Electronic injection cpu

ELE SYS - 25

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Electrical system Vespa GTS 250 I.E.

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 system. The immobilizer is an anti-theft system that allows the scooter to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobiliser system consists of the following components:

- Control unit

- Immobilizer aerial

- master and service keys with built-in transponder

- H.V. coil

- Diagnostic LED The diagnostic LED also works as a deterring blinker. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the key switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check:

•

there is battery voltage

•

that fuse 1 and fuse 8 are in good condition.

ELE SYS - 26

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Vespa GTS 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:

• there is battery voltage between terminals 6-26 and terminal 6-frame earth (fixed power supply). If there is no voltage check that fuse 4 and its cable are in working order.

With the key switch set to ON:

• there is battery voltage between terminals 5-26 and terminal 5-frame earth (fixed power supply). If there is no voltage, check the key switch contacts, that fuse 2 and its cable are in working order.

•

There is continuity between terminals 12-18 and 12-19 with the emergency cut-out switch in the RUN position. If there is no continuity, check the contacts of the latter.

If no faults are found, replace the control unit.

ELE SYS - 27

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Electrical system Vespa GTS 250 I.E.

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 battery voltage between the Red-White and Black cables

With MIU connector disconnected check the continuity between the Orange-White cable and pin 7 of the interface wiring .

Specific tooling

020481Y Control unit interface wiring 020331Y Digital multimeter

ELE SYS - 28

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Vespa GTS 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. The data storage procedure for a previously unprogrammed control unit provides for the recognition of the red key (master key) as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys. The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits 1 to 3 seconds).

- Insert the blue key and set to «ON» for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys (blue) can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.

ELE SYS - 29

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Electrical system Vespa GTS 250 I.E.

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 encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using. If a service key should become un-coded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistive spark plugs.

Characteristic

Shielded cap resistance

~ 5000 Ω.

Diagnostic codes

The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited:

1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. Previously unused control unit - transponder absent or cannot be used: The LED is per-

ELE SYS - 30

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Vespa GTS 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. The engine can be started.

4. Programmed control unit - Master key in: a

0.7 sec. flash is displayed followed by the LED remaining off for 2 sec. and then by short 0.46 sec. flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the LED remains permanently OFF. The engine can be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on permanently. The engine cannot be started. The codes that can be transmitted are:

•

Code 1 flash

•

2 flash code

•

3 flash code

Diagnostic code - 1 flash

The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobiliser aerial wiring and change it if necessary.

ELE SYS - 31

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Electrical system Vespa GTS 250 I.E.

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. If this is not the case, replace the defective key and/or reprogram the control unit. Replace the control unit if the problem continues.

Diagnostic code - 3 flashes

The three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit. If this is not the case, perform a reprogramming.

Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.

Stator check

Stator winding check-up

WARNING

THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Lift the saddle and remove the helmet compartment.

2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the photograph.

3) Measure the resistance between each of the yellow terminals and the other two.

ELE SYS - 32

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Vespa GTS 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 earth.

5) If values that are wrong are noted, replace the stator.

Recharge system voltage check

Look for any leakage

1) Access the battery by removing the cover in the footrest.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.

4) With ignition key still at OFF, the reading detected by the amperometer must be ≤ 0.5 mA.

Check the charging current

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the tester terminals between the battery terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm. 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.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A

ELE SYS - 33

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Electrical system Vespa GTS 250 I.E.

VOLTAGE REGULATOR/RECTIFIER

Specification Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 ÷ 15V at 5000 rpm with lights off

Turn signals system check

The turn indicator circuit is powered from the instrument panel. In the case it does not work, it is necessary to:

1. check light bulb efficiency,

2. check fuse No. 8 efficiency

3. with the key switch set to ON and without disconnecting the instrument panel connector, check frequently for voltage between terminal 20 and the ground lead.

•

If voltage is detected, check if there is also voltage in the turn indicator switch. If it is powered, replace the switch; otherwise, check the cable connecting the switch and the instrument panel.

•

If there is no voltage, disconnect the connector and check if there is voltage between terminals 9-8 and terminal 9-ground lead (check the fixed terminal form the battery) and between terminals 10-8 and terminal 10-ground (check live positive lead). If there is no voltage there, check the circuit wires. If there is, replace the instrument panel.

Fuses

The electrical system is equipped with:

1. six protection fuses «A» placed inside the glove box to the right

2. two fuses «B» located under the helmet compartment below the saddle hinge latch.

3. two fuses «B» located under the helmet compartment on the left fairing. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

BEFORE REPLACING THE BLOWN FUSE, SEARCH AND ELIMINATE THE BREAKDOWN THAT HAS LED TO THE BLOW OUT. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERI-

ELE SYS - 34

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Vespa GTS 250 I.E. Electrical system

AL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).

FUSES

Specification Desc./Quantity

1 General Position on fuse

box: 1

Fuse: 30A

Protected circuits:

General

2 Ignition ECU Fuse box arrange-

ment: 2

Fuse capacity: 7,5 A

Protected circuits:

Ignition ECU

3 Injection loads relay Fuse box arrange-

ment: 3

Fuse capacity: 10 A

Protected circuits:

Injection loads relay

4 Injection ECU Fuse box arrange-

ment: 4

Fuse capacity: 7,5 A

Protected circuits:

Injection ECU

5 Dashboard lighting,

intercom and anti-

theft device pre-wir-

ing

6 High and low-beam

lights, horn

7 High and low-beam

lights, electric seat

opening

8 Dashboard Fuel sup-

ply, intercom and an-

ti-theft device pre-

wiring

9 Starter motor, stop

light

Fuse box arrange-

ment: 5

Fuse capacity: 10 A

Protected circuits:

Dashboard lighting,

intercom and anti-

theft device pre-wir-

ing

Fuse box arrange-

ment: 6

Fuse capacity: 7,5 A

Protected circuits:

High and low-beam

lights, horn

Fuse box arrange-

ment: 7

Fuse capacity: 15 A

Protected circuits:

High and low-beam

lights, electric seat

opening

Fuse box arrange-

ment: 8

Fuse capacity: 10 A

Protected circuits:

Dashboard Fuel supply, intercom and an-

ti-theft device pre-

wiring

Fuse box arrange-

ment: 9

ELE SYS - 35

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Electrical system Vespa GTS 250 I.E.

Specification Desc./Quantity

Fuse capacity: 7,5 A

Protected circuits:

Starter motor, stop

light

10 Front and rear side

lights, dashboard

lighting

Fuse box arrange-

ment: 10

Fuse capacity: 7,5 A

Protected circuits:

Front and rear side

lights, dashboard

lighting

Dashboard

1. Digital instrument panel A. odometer B. coolant temperature indicator C. fuel level indicator D. rpm counter E. external temperature indicator F. digital clock

2. Immobilizer led

3. Engine run lamp and injection fault indication

4. Speedometer

5. Left turn indicator lamp

6. Right turn indicator lamp

7. High beam lamp

8. Light lamp

9. Oil pressure warning lamp

10. Fuel reserve warning lamp

11. Clock setting buttons

INSTRUMENT PANEL CONNECTOR

Specification Desc./Quantity

1. Engine water temperature

2. External temperature positive

3. "K" line not connected

4. Panel lighting

5. High beam indicator lamp

6. Engine rpms (injection)

7. Engine rpms

8. Instrument earth

9. Battery positive

10. Key positive

11. ABS lamp

12. Oil pressure warning lamp

ELE SYS - 36

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Vespa GTS 250 I.E. Electrical system

Specification Desc./Quantity

13. Petrol level indicator positive

14. Petrol level indicator negative

15. Immobilizer lamp

16. Injection lamp

17. External temperature negative

18. Left turn indicator lamp

19. Right turn indicator lamp

20. Turn indicator power

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. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

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 Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

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Electrical system Vespa GTS 250 I.E.

Battery installation

• Remove the battery cover after undoing the 4 screws shown in the photograph.

- Remove the strap fastening the battery

- Insert the battery breather pipe through the hole shown in the photograph.

ELE SYS - 38

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Vespa GTS 250 I.E. Electrical system

- Fit the battery as shown in the photograph.

N.B.

IN ORDER TO FIT THE CABLES ON THE BATTERY TERMINALS CORRECTLY, REST THE LOWER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.

- Using the screwdriver, tighten up the battery terminal cables as far as they will go, placing the special Grover washer between the screw head and the cable terminal.

N.B.

DO NOT USE WRENCHES TO TIGHTEN UP THE SCREWS FOR FIXING THE TERMINALS TO THE BATTERY TERMINALS

- Mount permanently the battery in the battery chamber

- Refit the strap fastening the battery

ELE SYS - 39

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Electrical system Vespa GTS 250 I.E.

- Refit the battery cover

Connectors

ELE SYS - 40

Page 91

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 92

Engine from vehicle Vespa GTS 250 I.E.

This section describes the operations to be carried 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.

Remove the clamp holding the lambda probe cable to the coolant pipe indicated in the photograph

- Undo the two exhaust manifold fixings on the head. To undo the nuts fixing the muffler flange to the head properly, you must use a jointed wrench that enables you to get at the right nut as well, according to the direction of travel, that is difficult to get at with a traditional straight wrench.

- Undo the three screws fixing the muffler to the support arm. Remove the full muffler unit.

ENG VE - 2

Page 93

Vespa GTS 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 REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicle

- Disconnect the battery

- Remove the helmet compartment

- Remove the side fairings and the spoiler terminals. Remove the full muffler assembly.

- Remove the air cleaner housing by unscrewing the 3 screws indicated in the photograph.

CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the clamp off the blow-by pipe and take the pipe out.

- Remove the clamp indicated in the photograph and disconnect the bellows connected to throttle body.

ENG VE - 3

Page 94

Engine from vehicle Vespa GTS 250 I.E.

- 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 retaining clip.

- Disconnect the injector wiring and the throttle body control unit wiring.

- Remove the coolant outlet pipe from the motor as indicated.

- Remove the spark plug caps.

- Remove the coolant temperature sensor connector indicated in the photo.

ENG VE - 4

Page 95

Vespa GTS 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.

- Disconnect the connectors from the flywheel wiring as shown in the photo.

- Remove the cable from the retaining clip on the flywheel cover.

ENG VE - 5

Page 96

Engine from vehicle Vespa GTS 250 I.E.

- Remove the rear shock absorbers.

- Remove the hydraulic piping from the rear calliper by undoing the screw indicated in the photograph. Afterwards remove the retainers fixing the piping to the engine crankcase, indicated in the photograph.

- Use a jack to support the vehicle properly. Remove the engine-swinging arm fixing pin by undoing the nut and the head of the pin as shown in the photograph.

- The engine is now free.

ENG VE - 6

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Vespa GTS 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 register there is a small clearance.

-Check the engine oil level and if necessary top it up with the recommended type.

- Fill the cooling circuit and rear brake circuit.

- Check the functioning of the accelerator and the electrical devices.

- Be specially careful with the clamp fixing the throttle body to the purifier bellows, which must be positioned as shown in the photograph.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY.

ENG VE - 7

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Engine from vehicle Vespa GTS 250 I.E.

ENG VE - 8

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INDEX OF TOPICS

ENGINE ENG

Page 100

Engine Vespa GTS 250 I.E.

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. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.

Specific tooling

020423Y driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling hole.

- Remove the ten screws.

- Remove the transmission cover.

N.B.

WHEN YOU ARE REMOVING THE TRANSMISSION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH BELL.

Air duct

- Remove the transmission compartment air intake cover shown in the photograph.

ENG - 2

Piaggio Vespa WORKSHOP Piaggio Vespa GTS 250 I.E. EN, gts250 workshop, gts250 workshop, gts250 workshop Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual