VESPA 633844 IT, 633845 EN, 633846 FR, 633847 DE, 633849 PT 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

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

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

required for manufacturing or construction reasons.

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

should be checked at the official Piaggio sales network.

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

in whole or in part is prohibited."

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

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

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

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.

Characteristics Vespa GTV 250 i.e.

CHAR - 2

Vehicle identification

Chassis prefix: *ZAPM451020000 ÷ 1001*
Engine prefix: M451M ÷ 1001

Vespa GTV 250 i.e. Characteristics

CHAR - 3

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.

Characteristics Vespa GTV 250 i.e.

CHAR - 4

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

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 approx. 1300 cc (recommended oil Selenia HI

Scooter 4 Tech)

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)

Vespa GTV 250 i.e. Characteristics

CHAR - 5

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

55/60 - 12V (Quantity

1)

2 Front position light 5W - 12V (Quantity

2)

3 Instrument Panel

warning lights

1.2W - 12V (Quantity

5)

4 Front turn indicator

light

5W - 12V (Quantity

4)

5 Rear turn indicator

light

10W - 12V (Quantity

2)

6 Rear tail light 5W - 12V (Quantity

1)

7 Stop Light 16W - 12V (Quantity

1)

8 License Plate Light 5W - 12V (Quantity

1)

FUSES

Specification Desc./Quantity

1 No.1 - Vehicle main

fuse

30A

2 No. 2 - Live injection

ECU

7.5 A

3 No. 3 - Power to in-

jection load

10A

4 No. 4 - Battery-pow-

ered injection ECU

7,5A

5 No. 5 - Live accesso-

ries and instrument

panel

10A

6 No. 6 - Live light re-

mote control and

horn

7.5 A

7 No. 7 - Live Headlight

and Saddle Opening

Switch

15 A

8 No. 8 - Battery-pow-

ered Accessories

and Instrument panel

10A

Characteristics Vespa GTV 250 i.e.

CHAR - 6

Specification Desc./Quantity

9 No. 9 - Live Stop light

and Starter key

7.5 A

10 No. 10 - Power to tail

light and instrument

panel lighting

7.5 A

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 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

Vespa GTV 250 i.e. Characteristics

CHAR - 7

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

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 32 ÷ 40

Side stand fixing bolt 35 ÷ 40

SOSPENSIONE ANTERIORE

Name Torque in Nm

Screw fixing the shock absorber to the shock ab-

sorber - calliper attachment plate

20 ÷ 27

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

24 ÷ 27

Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium

strength)

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

20 ÷ 25

Shock absorber upper fitting 20 ÷ 25

Shock absorber lower fitting 33 ÷ 41

Rear wheel shaft 104 ÷ 126

Screw fixing wheel to hub 20 ÷ 25

Characteristics Vespa GTV 250 i.e.

CHAR - 8

Name Torque in Nm

Screws for muffler - shock absorber support arm

on engine

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

prescribed torque after having done so with the

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

ery Operations» )

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

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

Vespa GTV 250 i.e. Characteristics

CHAR - 9

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

4 ÷ 6

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

Thermostat cover screws 3 ÷ 4

Bleed screw: 3

Overhaul data

Assembly clearances

Characteristics Vespa GTV 250 i.e.

CHAR - 10

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.)

Indirizzo Immagine

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

Vespa GTV 250 i.e. Characteristics

CHAR - 11

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half-

shaft

16.6 +0-0.05 B D = 0.20 - 0.50

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

Slot packing system

Characteristic

Compression ratio

10.5 ÷ 11.5 : 1

Characteristics Vespa GTV 250 i.e.

CHAR - 12

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

Vespa GTV 250 i.e. Characteristics

CHAR - 13

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)

Oil for 4-stroke engines

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

for increased adhesiveness

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

based spray grease with NLGI 2;

ISO-L-XBCIB2

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

JASO MA Synthetic oil

AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid

SPECIAL AGIP PERMANENT

fluid

coolant Monoethylene glycol-based anti-

freeze fluid, CUNA NC 956-16

Characteristics Vespa GTV 250 i.e.

CHAR - 14

INDEX OF TOPICS

TOOLING TOOL

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

Tooling Vespa GTV 250 i.e.

TOOL - 2

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

Vespa GTV 250 i.e. Tooling

TOOL - 3

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

020329Y MityVac vacuum-operated pump

Tooling Vespa GTV 250 i.e.

TOOL - 4

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

Vespa GTV 250 i.e. Tooling

TOOL - 5

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

Tooling Vespa GTV 250 i.e.

TOOL - 6

Stores code Description

020365Y 22 mm guide

020375Y Adaptor 28 x 30 mm

020376Y Adaptor handle

020382Y Valve cotters equipped with part

012 removal tool

020382Y011 adapter for valve removal tool

Vespa GTV 250 i.e. Tooling

TOOL - 7

Stores code Description

020393Y Piston fitting band

020412Y 15 mm guide

020423Y driven pulley lock wrench

020424Y Driven pulley roller casing fitting

punch

020426Y Piston fitting fork

Tooling Vespa GTV 250 i.e.

TOOL - 8

Stores code Description

020431Y Valve oil seal extractor

020434Y Oil pressure control fitting

020441Y 26 x 28 mm adaptor

020444Y Tool for fitting/ removing the driv-

en pulley clutch

020456Y Ø 24 mm adaptor
020477Y Adaptor 37 mm

Vespa GTV 250 i.e. Tooling

TOOL - 9

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

Tooling Vespa GTV 250 i.e.

TOOL - 10

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

Vespa GTV 250 i.e. Tooling

TOOL - 11

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

Tooling Vespa GTV 250 i.e.

TOOL - 12

Stores code Description

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

WARE

020469Y Reprogramming kit for scooter

diagnosis tester

Vespa GTV 250 i.e. Tooling

TOOL - 13

Tooling Vespa GTV 250 i.e.

TOOL - 14

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

EVERY 2 YEARS

60'

Action

Coolant - change
Brake fluid - change

AFTER 1,000 KM

60'

Action

Safety locks - check
Throttle lever - adjustment
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - change
Steering - Check

AFTER 5,000 KM; 25,000 KM; 35,000 KM; 55,000 KM; 65,000 KM

10'

Action

Engine oil - level check/ top-up
Brake pads - check condition and wear

AT 10,000 KM 50,000 KM 70,000 KM

100'

Action

Safety locks - check
Throttle lever - adjustment
Air filter - clean
Air filter belt compartment - check
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - check
Suspensions - check
Steering - Check

AT 15,000 KM 45,000 KM 75,000 KM

45'

Maintenance Vespa GTV 250 i.e.

MAIN - 2

Action

Engine oil - level check/ top-up
Brake pads - check condition and wear
Driving belt - replacement

AT 20,000 KM; 40,000 KM; 80,000 KM

150'

Action

Spark plug - replacement
Throttle lever - adjustment
Air filter - clean
Air filter belt compartment - check
Engine oil - change
Valve clearance - check
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - change
Suspensions - check
Steering - Check

30,000 KM

140'

Action

Safety locks - check
Driving belt - replacement
Throttle lever - adjustment
Air filter - clean
Air filter belt compartment - check
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - check
Suspensions - check
Steering - Check

60,000 KM

190'

Action

Spark plug - replacement
Driving belt - replacement
Throttle lever - adjustment

Vespa GTV 250 i.e. Maintenance

MAIN - 3

Action

Air filter - clean
Air filter belt compartment - check
Engine oil - change
Valve clearance - check
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - change
Suspensions - check
Steering - Check

Checking the spark advance

The ignition advance is determined electronically
on the basis of parameters known by the control
unit. For this reason it is not possible to declare the
reference values based on the engine rpm. The
ignition timing value is detectable any time using
the diagnostic tester. It is possible to check wheth­er the ignition advance determined by the system
does in fact correspond with the value actually ac­tivated on the engine, by means of the strobo­scopic light.
Proceed as follows:

- Remove the spark plug.

- Remove the plastic cover on the flywheel cover
shown in the photograph.

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

- Rotate the driving pulley fan using a screwdriver
until the reference marks between the flywheel
and flywheel cover coincide as shown in the pho­tograph.

- Bring the reference mark onto the transmission
side between the fan and the transmission cover
as shown in the photograph.

- Refit the spark plug.

Maintenance Vespa GTV 250 i.e.

MAIN - 4

- Refit the plastic cap on the flywheel cover.

- Adjust the spark gap to the contact position (no
reference mark visible) and install it on engine be­tween the spark plug and spark plug cap

- Connect the induction calliper on the spark gap
cable respecting the proper polarity (the arrow on
the calliper must be pointing at the spark plug).

- Connect the diagnostic tester.

- Start the engine.

- Select the menu on the "parameter" function.

- Select the stroboscopic light command in the tra­ditional four-stroke engine position (1 spark 2
revs).

- Check that the real values of rpm and ignition
advance match those measured using the diag­nostic tester.

If the values do not correspond, check:

- distribution timing

- revolution-timing sensor

- Injection control unit

Specific tooling

020460Y Scooter diagnosis and tester
020330Y Stroboscopic light for timing control
020621Y HV cable extraction adaptor

Spark plug

- Rest the scooter on its stand

- Open the saddle and take out the helmet com­partment

- Disconnect spark plug HV wire hood;

- Unscrew the spark plug using the wrench sup­plied;

- Check the conditions of the spark plug, make
sure the insulation is intact, that the electrodes are
not excessively worn or grimy, the conditions of the
washer, and measure the distance between the
electrodes using the appropriate feeler gauge.

Vespa GTV 250 i.e. Maintenance

MAIN - 5

-Adjust the distance if necessary by bending the
side electrode very carefully. In case of anomaly
(as described before) replace the spark plug with
another of the recommended type;

- Fit the spark plug with the correct inclination and
manually screw it all the way down, then use the
special spanner to tighten it.

- Insert the cap onto the spark plug and proceed
with the reassembly operations.

CAUTION

THE SPARK PLUG MUST BE REMOVED WHEN
THE MOTOR IS COLD.THE SPARK PLUG
MUST BE REPLACED EVERY 20,000 KM. THE
USE OF NON CONFORMING ELECTRONIC IG­NITION CONTROL UNITS OR SPARK PLUGS
OTHER THAN THOSE PRESCRIBED CAN SE­RIOUSLY DAMAGE THE ENGINE.

Characteristic

Electrode gap

0.7-0.8 mm

Electric characteristic

Spark plug

CHAMPION RG4 PHP

Locking torques (N*m)

Spark plug 12 ÷ 14

Hub oil

Check

- Park the vehicle on its centre stand on flat
ground;

- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
Remove the dipstick and check that the oil level is
slightly over the second notch starting from the
lower end; if the level is under the MAX. mark, it
needs to be filled with the right amount of hub oil.

Maintenance Vespa GTV 250 i.e.

MAIN - 6

-Screw up the oil dipstick again and make sure it
is locked properly into place.

Replacement

-Remove the oil cap «A».

- Unscrew the oil drainage cap "B" and drain out
all the oil.

- Screw in the drainage cap again and fill the hub
with the prescribed oil.

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;

Vespa GTV 250 i.e. Maintenance

MAIN - 7

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".

Maintenance Vespa GTV 250 i.e.

MAIN - 8

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:

Vespa GTV 250 i.e. Maintenance

MAIN - 9

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 drainage plug O-rings are in good conditions. 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.

Maintenance Vespa GTV 250 i.e.

MAIN - 10

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.

Vespa GTV 250 i.e. Maintenance

MAIN - 11

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

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

Maintenance Vespa GTV 250 i.e.

MAIN - 12

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 vehicle 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;

3. Otherwise, adjust the headlight operating on the
set screw «R» reached from under the front mud­guard.

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.

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

Vespa GTV 250 i.e. Maintenance

MAIN - 13

Maintenance Vespa GTV 250 i.e.

MAIN - 14

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

This section makes it possible to find what solutions to apply when 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

Replace the piston cylinder unit or just the piston

rings

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

pling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

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

fully clean the By-Pass area.

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

components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level using the recommended oil type

(Selenia HI Scooter 4 Tech)

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-

alous way

Troubleshooting Vespa GTV 250 i.e.

TROUBL - 2

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

Swollen 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:

Vespa GTV 250 i.e. Troubleshooting

TROUBL - 3

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.

Troubleshooting Vespa GTV 250 i.e.

TROUBL - 4

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

KEY:

1. Magneto flywheel

2. Voltage regulator

3. Immobilizer aerial

4. Diagnostic socket

5. Revolution sensor

6. Engine stop switch

7. 2 fuse boxes in the helmet compartment

8. Key-switch

9. Saddle opening button

10. Injection load remote control

11. Saddle opening actuator

12. Fuse box for glove box

13. Battery 12V - 12Ah

14. Starter motor

15. Starter remote control

16. Starter button

17. Stop button on rear brake

18. Stop button on front brake

19. Horn button

Electrical system Vespa GTV 250 i.e.

ELE SYS - 2

20. Horn

21. Light switch

22. Rear headlight assembly
A. Brake light
B. Parking light
C. License plate light

23. Low-/high-beam light remote control

24. Front headlight assembly
A. Tail light
B. High-/low-beam light

25. Wiring for antitheft device

26. Wiring for helmet compartment switch

27. Wiring for intercom

28. Turn indicator bulbs

29. Turn signal switch

30. Fuel level transmitter

31. Instrument panel

32. External temperature sensor

33. Electrical fan

34. Electrical fan remote control

35. Oil pressure sensor

36. Engine temperature sensor

37. Fuel pump

38. Fuel injector

39. Lambda probe

40. Spark plug

41. high voltage coil

42. Injection ECU

43. Turn signal command device
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

Vespa GTV 250 i.e. Electrical system

ELE SYS - 3

Front side

1. Front left turn indicator connector

2. Front right turn indicator connector

3. Electrical fan connector

Electrical system Vespa GTV 250 i.e.

ELE SYS - 4

1. Immobilizer aerial

2. Foldable clamp to hold cables

3. Battery negative terminal

4. Battery positive terminal

5. Flywheel - regulator connexion

Vespa GTV 250 i.e. Electrical system

ELE SYS - 5

1. Saddle opening switch

2. Wirings

3. Insert in clamp

Electrical system Vespa GTV 250 i.e.

ELE SYS - 6

4. Fuse box

5. From the wire unit

1. Right turn indicator connector

2. From regulator

3. Wire unit - regulator connexion

4. To the immobilizer aerial

5. Light remote control

Vespa GTV 250 i.e. Electrical system

ELE SYS - 7

6. Electric fan starter

7. To key switch

8. Left turn indicator connector

9. Voltage regulator

1. Red sheathing

2. Clamp

3. To headlight

4. To instrument

5. To stop switch

6. To stop switch

Electrical system Vespa GTV 250 i.e.

ELE SYS - 8

Back side

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

Vespa GTV 250 i.e. Electrical system

ELE SYS - 9

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

Electrical system Vespa GTV 250 i.e.

ELE SYS - 10

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

Vespa GTV 250 i.e. Electrical system

ELE SYS - 11

1. Right rear turn indicator

2. Cableguide

3. To rear light

4. Rear left turn indicator

Electrical system Vespa GTV 250 i.e.

ELE SYS - 12

1. To HV coil

2. Foldable clamp

3. Foldable clamps to hold the red sheathing

4. Diagnostic socket

5. Starter remote control

Conceptual diagrams

Vespa GTV 250 i.e. Electrical system

ELE SYS - 13

Ignition

KEY:

7. 2 fuse boxes in the helmet compartment

8. Key-switch

10. Injection load remote control

13. Battery

40. Spark plug

41. High voltage coil

42. Injection ECU

Electrical system Vespa GTV 250 i.e.

ELE SYS - 14

Battery recharge and starting

KEY:

1. Magneto flywheel

2. Voltage regulator

6. Engine stop switch

7. 2 fuse boxes in the helmet compartment

8. Key-switch

12. Fuse box for glove box

13. Battery

14. Starter motor

15. Start up remote control switch

16. Starter button

17. Stop button on rear brake

18. Stop button on front brake

22. Rear headlight assembly
A. Brake light
B. Parking light
C. License plate light

42. Injection ECU

Vespa GTV 250 i.e. Electrical system

ELE SYS - 15

Level indicators and enable signals section

KEY:

3. Immobilizer aerial

5. Revolution sensor

7. 2 fuse boxes in the helmet compartment

8. Key-switch

10. Injection load remote control

12. Fuse box for glove 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. Fuel injector

39. Lambda probe

42. Injection ECU

Electrical system Vespa GTV 250 i.e.

ELE SYS - 16

Devices and accessories

KEY:

1. Magneto flywheel

2. Voltage regulator

7. 2 fuse boxes in the helmet compartment

8. Key-switch

12. Fuse box for glove box

13. Battery

21. Light switch

22. Rear headlight assembly
A. Brake light
B. Parking light
C. License plate light

23. Low-/high-beam light remote control

24. Front headlight assembly
A. Tail light
B. High-/low-beam light

28. Turn indicator bulbs

29. Turn signal switch

Vespa GTV 250 i.e. Electrical system

ELE SYS - 17

31. Instrument panel

Lights and turn indicators

KEY:

7. 2 fuse boxes in the helmet compartment

8. Key-switch

9. Saddle opening button

10. Injection load remote control

11. Saddle opening actuator

12. Fuse box for glove box

13. Battery

19. Horn button

20. Horn

33. Radiator electrical fan

34. Remote control for electric fan

42. Injection ECU

43. Turn signal command device

Electrical system Vespa GTV 250 i.e.

ELE SYS - 18

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.

Vespa GTV 250 i.e. Electrical system

ELE SYS - 19

•

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.

Electrical system Vespa GTV 250 i.e.

ELE SYS - 20

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

Vespa GTV 250 i.e. Electrical system

ELE SYS - 21

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.

Electrical system Vespa GTV 250 i.e.

ELE SYS - 22

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-

Vespa GTV 250 i.e. Electrical system

ELE SYS - 23

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.

Electrical system Vespa GTV 250 i.e.

ELE SYS - 24

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 magneto 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.

Vespa GTV 250 i.e. Electrical system

ELE SYS - 25

Electric characteristic

Resistance:

0.2 - 1 Ω

4) Check that there is insulation between the each
yellow cable and the ground.

5) If values are incorrect, 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.

Electrical system Vespa GTV 250 i.e.

ELE SYS - 26

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

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

Il circuito degli indicatori di direzione viene alimentato dal quadro strumenti. In caso di non funziona­mento è necessario:

1. verificare efficienza lampade

2. verificare efficienza del fusibile n° 10

3. con commutatore a chiave in ON e senza disconnettere il connettore Gruppo spie , verificare la
presenza di tensione ad intermittenza fra il terminale 8 e massa.

•

In caso di tensione presente verificare la presenza di tensione anche sul commutatore
lampeggiatori. Se questo è alimentato sostituire il commutatore, altrimenti verificare il ca­blaggio del collegamento commutatore-quadro strumenti.

•

In caso di tensione assente disconnettere il connettore e verificare la presenza di tensione
fra i terminali 4-8 (alimentazione da batteria e massa) e fra i terminali 10-8 (alimentazione
sotto chiave e massa ). Qualora non vi fosse tensione verificare il cablaggio del circuito. In
caso contrario sostituire il quadro strumenti.

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

Vespa GTV 250 i.e. Electrical system

ELE SYS - 27

BEFORE REPLACING THE BLOWN FUSE,
SEARCH AND SOLVE THE PROBLEM THAT
CAUSED IT TO BLOW.
NEVER TRY TO REPLACE A BLOWN FUSE
WITH A FUSE OF A DIFFERENT RATING THAN
THAT SPECIFIED OR USING OTHER MATERI­AL (FOR EXAMPLE, A PIECE OF ELECTRICAL
WIRE).

FUSES

Specification Desc./Quantity

1 No.1 - Vehicle main

fuse

30A

2 No. 2 - Live injection

ECU

7.5 A

3 No. 3 - Power to in-

jection load

10A

4 No. 4 - Battery-pow-

ered injection ECU

7,5A

5 No. 5 - Live accesso-

ries and instrument

panel

10A

6 No. 6 - Live light re-

mote control and

horn

7.5 A

7 No. 7 - Live Headlight

and Saddle Opening

Switch

15 A

8 No. 8 - Battery-pow-

ered Accessories

and Instrument panel

10A

9 No. 9 - Live Stop light

and Starter key

7.5 A

10 No. 10 - Power to tail

light and instrument

panel lighting

7.5 A

Dashboard

A = Fuel gauge B = Headlight warning light C =

High-beam warning light D = Speedometer E =
ABS Warning light (wiring) F = Coolant tempera­ture warning light G = Antitheft device Led (immo­bilizer) H = Engine control telltale light and
injection system failure warning light I = Turn indi­cator warning light L = Odometer M = Low oil
pressure warning light N = Low fuel warning light

Electrical system Vespa GTV 250 i.e.

ELE SYS - 28

INSTRUMENT PANEL CONNECTOR

Specification Desc./Quantity

1 Power supply

2 Fuel gauge signal

3 Low fuel warning light

4 Oil pressure warning light

5 High-beam warning light

6 Headlight warning light and lighting

7 Ground lead

WARNING LIGHT UNIT CONNECTOR

Specification Desc./Quantity

1 1 Ground lead (-)
2 2 Clock light
3 3 Immobilizer
4 4 Power from battery
5 5
6 6
7 7 Turn indicator warning light
8 8 Turn indicator warning light
9 9 Live
10 10 Engine temperature warning light
11 11 Injection telltale light
12 12 ABS warning light

Vespa GTV 250 i.e. Electrical system

ELE SYS - 29

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 regular 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).

Electrical system Vespa GTV 250 i.e.

ELE SYS - 30

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

Battery installation

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

- Remove the strap fastening the battery

Vespa GTV 250 i.e. Electrical system

ELE SYS - 31

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

- 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

Electrical system Vespa GTV 250 i.e.

ELE SYS - 32

- Mount permanently the battery in the battery
chamber

- Refit the strap fastening the battery

- Refit the battery cover

Connectors

Vespa GTV 250 i.e. Electrical system

ELE SYS - 33

Electrical system Vespa GTV 250 i.e.

ELE SYS - 34

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

This section describes the operations to carry 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.

Engine from vehicle Vespa GTV 250 i.e.

ENG VE - 2

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.

Vespa GTV 250 i.e. Engine from vehicle

ENG VE - 3

- 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.

Engine from vehicle Vespa GTV 250 i.e.

ENG VE - 4

- 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.

Vespa GTV 250 i.e. Engine from vehicle

ENG VE - 5

- 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.

Engine from vehicle Vespa GTV 250 i.e.

ENG VE - 6

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.

Vespa GTV 250 i.e. Engine from vehicle

ENG VE - 7

Engine from vehicle Vespa GTV 250 i.e.

ENG VE - 8

INDEX OF TOPICS

ENGINE ENG

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

Version 250

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

Engine Vespa GTV 250 i.e.

ENG - 2

- Remove the five screws on two different levels
as well as the small casing.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by
means of:

Specific tooling

020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020412Y 15 mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as
not to damage the painted surface.

- Insert the bearing in its seat.

- Refit the seeger ring.

CAUTION

USE AN APPROPRIATE REST SURFACE TO
AVOID DAMAGING THE COVER PAINT.

N.B.

ALWAYS REPLACE THE BEARING WITH A
NEW ONE UPON REFITTING.

Specific tooling

020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide

Baffle roller

Vespa GTV 250 i.e. Engine

ENG - 3

Plastic roller

- Check that the roller does not show signs of wear
and that it turns freely.

- Remove the special clamping screws as indica­ted in the photograph

- Check the outer diameter of the roller does not
have defects that could jeopardise belt functioning

- For refitting, place the roller with the belt contain­ment edge on the engine crankcase side

- Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Removing the driven pulley

- Remove the clutch bell housing and the driven
pulley assembly.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE
DRIVING PULLEY MOUNTED.

Engine Vespa GTV 250 i.e.

ENG - 4

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristic

Max. value clutch bell

Max. value: Ø 134.5 mm

Clutch bell standard value

Standard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to
check the crankshaft alignment.

- Using a feeler pin gauge and the magnetic base,
measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central,
internal, external).

- If faults are found, replace the bell.

Specific tooling

020074Y Support base for checking crankshaft
alignment

020335Y Magnetic support for dial gauge

Characteristic

clutch bell inspection: Limit eccentricity.

Admissible limit eccentricity: 0.15 mm

Vespa GTV 250 i.e. Engine

ENG - 5

Removing the clutch

Fit the driven pulley spring compressor specific
tool with medium length pins screwed in position
«C» on the tool internal side.

- Introduce the adapter ring No. 11 with the cham­fering facing the inside of the tool.

- Fit the driven pulley unit on the tool with the in­sertion of the 3 pins in the ventilation holes in the
mass holder support.

- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tight­en the clutch nut.

- Use the special 46x55 wrench component No. 9
to remove the nut fixing the clutch in place.

- Dismantle the driven pulley components (Clutch
and spring with its plastic holder)

CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE
CLAMP AND THE CENTRAL SCREW MUST BE
BROUGHT INTO CONTACT WITH THE TOOL.
EXCESSIVE TORQUE CAN CAUSE THE SPE­CIFIC TOOL TO BUCKLE.

Specific tooling

020444Y011 adapter ring
020444Y009 46x55 Wrench
020444Y Tool for fitting/ removing the driven

pulley clutch

Inspecting the clutch

- Check the thickness of the clutch mass friction
material.

- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EX­HIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE AN­OTHER.
VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.

CAUTION

Engine Vespa GTV 250 i.e.

ENG - 6