VESPA 664787, 664795 Service Station Manual

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SERVICE STATION MANUAL

664787-664795 (IT-EN-FR-DE-ES-PT-NL-EL)

Vespa S 50 2T

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SERVICE STATION

MANUAL

Vespa S 50 2T

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/models 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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SERVICE STATION MANUAL

Vespa S 50 2T

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 concerning 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.

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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

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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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 naked 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 solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- 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 sizes. 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.

Vespa S 50 2T Characteristics

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Vehicle identification

Chassis prefix: ZAPC38103

Engine prefix: C381M

Dimensions and mass

Characteristics Vespa S 50 2T

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WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Kerb weight 96 ± 4 kg

Maximum weight allowed 290 kg

Maximum height 1.140 mm

Width 740 mm

Wheelbase 1.290 mm

Length 1.755 mm

Engine

ENGINE

Specification Desc./Quantity

Type single-cylinder, two-stroke

Cubic capacity 49 cm³

Bore x stroke 40 X 39.3 mm Compression ratio 9.9 ± 0.5 : 1 Engine idle speed 1,800 ± 100 rpm

Timing system -

Valve clearance -

Max. Power 3.2 kW at 7,500 rpm

MAX. torque 4.4 Nm at 6,500 rpm

LUBRICATION Engine lubrication carried out by fuel mixture oil.

Lubrication pressure -

Minimum lubrication pressure (100° C) -

Fuel supply Carburettor: DELL'ORTO PHVA 17.5 RD

Cooling Forced-air circulation cooling.

Fuel Unleaded petrol (95 RON)

Exhaust muffler absorption-type exhaust muffler with catalytic converter.

Emissions EURO 2

Transmission

TRANSMISSION

Specification

Desc./Quantity

Transmission Automatic expandable pulley variator with torque server, V belt,

automatic centrifugal dry clutch.

Final reduction Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification

Desc./Quantity

Cooling system fluid -

Transmission oil 80 cm3

Fuel tank (reserve) ~ 8.5 l (2 l)

Mixer oil reservoir (reserve) ~ 1.5 l (0.5 l)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

Start-up Electrical and kick start

Vespa S 50 2T Characteristics

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Specification Desc./Quantity

Ignition Capacitive discharge ignition, with variable advance and sep-

arate HV coil.

Ignition advance 17º at 4,000 rpm

Spark plug CHAMPION RN3C

Alternative spark plug -

Battery 12V/9 Ah

Generator -

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Frame Stamped plate body with welded structural reinforcements.

FRONT SUSPENSION Single arm with helicoidal spring and single double-acting hy-

draulic shock absorber.

Front suspension travel 70.3 mm

Rear suspension Double-acting shock absorber, adjustable to four positions at

preloading.

Rear suspension travel 83 mm

Brakes

BRAKES

Specification

Desc./Quantity

Front brake Ø 200 mm disc brake with hydraulic control activated by han-

dlebar right-side lever.

Rear brake Ø 110 mm drum brake with mechanical control activated by the

handlebar left-side lever.

Wheels and tyres

WHEELS AND TYRES

Specification

Desc./Quantity

Wheel rim type Light alloy rims.

Front rim 11'' x 2.50

Rear rim 10'' x 3.00 Front tyre Tubeless, 110/70 - 11'' 45L Rear tyre Tubeless, 120/70 - 10'' 54L

Front tyre pressure (with passenger) 1.4 bar (-) Rear tyre pressure (with passenger) 2.0 bar (-)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

Characteristics Vespa S 50 2T

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Secondary air

Follow these steps to clean the sponge filters of the secondary air system:

1) Remove the snap-on plastic cover (1) on the transmission cover using a small screwdriver as a lever on the retaining tongues in order to insert one of the three slots found on that cap.

2) Wash the polyurethane sponge with water and soap, dry all components with compressed air and refit to place. Refit the intake cap respecting the angle reference.

3) Undo the two fixing screws (2) on the aluminium cover of the secondary air housing in order to reach the polyurethane sponge inside that housing; clean as indicated in point 2) and refit all elements after checking the steel tab is not deformed and/or does not guarantee correct tightness at its fitting; replace if necessary.

N.B. UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE

TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMINIUM COVERS.

CAUTION WHILE CARRYING OUT OPERATION 3), ALWAYS CHECK

THE TWO RUBBER COUPLINGS (3) ON ONE END OF THE SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND CONTINUITY; IF NECESSARY, REPLACE THEM AND USE NEW CLAMPS TO FIX THEM.

Carburettor

50cc Version

Dell'Orto

DELLORTO CARBURETTOR

Specification

Desc./Quantity

Type PHVA 17.5 RD

Diffuser diameter Ø 17.5

Regulation reference number 8423

Maximum nozzle: 53

Maximum air nozzle (on the body): Ø 1.5

Tapered pin stamped code: A22

Pin position (notches from above): 1

Diffuser: 209 HA

Vespa S 50 2T Characteristics

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Specification Desc./Quantity

Minimum nozzle: 32

Minimum air nozzle (on the body): Free

Initial minimum mix screw opening: 1 1/2

Starter jet 50

Starter air nozzle (on the body): Ø 1.5

Stroke of starter pin: 11 mm

Gasoline inlet hole Ø 1.5

Tightening Torques

FRONT BRAKE

Name Torque in Nm

Brake fluid pump-hose fitting 8 ÷ 12

Brake fluid pipe-calliper fitting 20 ÷ 25

Screw tightening calliper to the support 20 ÷ 25

Brake disc screws 8 ÷ 10

Circuit bleed calliper fitting 20 ÷ 25

Handlebar pump 7 ÷ 10

FRONT SUSPENSION

Name Torque in Nm

Upper shock absorber fixing nut 20-30

Front wheel axle nut 75 ÷ 90

Shock absorber upper bracket bolts 20 ÷ 25

Wheel rim screws 20 ÷ 25

Lower shock absorber clamping screw 20 - 27

STEERING ASSEMBLY

Name

Torque in Nm

Steering upper ring nut 35 ÷ 40

Steering lower ring nut 8 ÷ 10

Handlebar fixing screw 50 ÷ 55

ENGINE ASSEMBLY

Name

Torque in Nm

Clutch bell nut (**) 40 ÷ 44

Clutch lock ring nut 55 ÷ 60

Nut locking driving pulley on crankshaft (**) 40 ÷ 44 Nm

Start-up lever screw 12 ÷ 13

Flywheel nut (**) 40 ÷ 44

Flywheel fan screws 3 ÷ 4

Half-crank case joint bolts 12 ÷ 13

Bolts holding exhaust pipe to the crankcase 22 ÷ 24

Screws holding the filter box to the crank case 4 ÷ 5

Head nuts 10 ÷ 11

Starter screws 12 ÷ 13

Ignition spark plug 25 ÷ 30 Hub oil drainage cap 3 ÷ 5 Oil hub level dipstick Manual

Rear hub cap screws 12 ÷ 13

Transmission cover screws 12 ÷ 13

Inlet manifold screws 8 ÷ 9

Flywheel hood fixing screws 1 ÷ 2

Cylinder hood fixing screws 3.5 ÷ 5

Stator clamping screws 3 ÷ 4

Pick-Up clamping screw 4 ÷ 5

Mixer clamping screws 3 ÷ 4

Screw fixing brake lever to the journal on the engine 12 ÷ 13

Characteristics Vespa S 50 2T

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FRAME ASSEMBLY

Name Torque in Nm

Swinging arm to engine pin locknut 33 ÷ 41

Swinging arm to chassis pin locknut 44 ÷ 52 Shock absorber to chassis fixing nut 20 ÷ 25 Swinging arm plate to chassis screw 33 ÷ 41

Shock absorber to engine fixing nut 33 ÷ 41

Rear wheel nut 137 ÷ 152

Stand screw torque 18.5 to 19 Nm

Side stand fixing screw 12 ÷ 20

Side stand bracket fixing screw 15 ÷ 20

Overhaul data

Assembly clearances

Cylinder - piston assy.

COUPLING BETWEEN PISTON AND CYLINDER

Name

Initials Cylinder Piston Play on fitting

Standard coupling M 40.005 - 40.012 39.943 - 39.95 0.055 - 0.069 Standard coupling N 40.012 - 40.019 39.95 - 39.957 0.055 - 0.069 Standard coupling O 40.019 - 40.026 39.957 - 39.964 0.055 - 0.069

Standard coupling P 40.026 - 40.033 39.964 - 39.971 0.055 - 0.069 coupling 1st oversize M1 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069 coupling 1st oversize N1 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069 coupling 1st oversize O1 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069 coupling 1st oversize P1 40.226 - 40.233 40.164 - 40.171 0.055 - 0.069

Coupling 2nd oversize M2 40.405 - 40.412 40.343 - 40.35 0.055 - 0.069 Coupling 2nd oversize N2 40.412 - 40.419 40.35 - 40.357 0.055 - 0.069 Coupling 2nd oversize O2 40.419 - 40.426 40.357 - 40.364 0.055 - 0.069 Coupling 2nd oversize P2 40.426 - 40.433 40.364 - 40.371 0.055 - 0.069

Piston rings

SEALING RING

Name

Description Dimensions Initials Quantity

Compression ring 40 A 0.10 to 0.25

Compression ring 1st

oversize

40.2 A 0.10 to 0.25

Compression ring 2nd

Oversize

40.4 A 0.10 to 0.25

Vespa S 50 2T Characteristics

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Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Connecting rod 11.750-0.05 A clearance E = 0.25 to

0.50

shoulder washer 0.5 ± 0.03 G clearance E = 0.25 to

0.50 - clearance F =

0.20 to 0.75

Half-shaft, transmission

side

13.75+0.040 C clearance E = 0.25 to

0.50 - clearance F =

0.20 to 0.75

Flywheel-side half-shaft 13.75+0.040 D clearance E = 0.25 to

0.50 - clearance F =

0.20 to 0.75

Lining between the

shoulders

40.64 H clearance E = 0.25 to

0.50 - clearance F =

0.20 to 0.75

Cage 11.800-0.35 B clearance F = 0.20 to

0.75

Slot packing system

This type of engines foresees the use of one size of basic gaskets.

Characteristics Vespa S 50 2T

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Products

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

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

Characteristic

Transmission oil

80 cm³

Locking torques (N*m)

Hub oil drainage cap 3 ÷ 5

Air filter

-Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter. Cleaning:

-Wash with water and neutral soap.

- Dry with a clean cloth and short blasts of compressed air.

-Saturate with a 50% mixture of gasoline and oil.

-Drip dry the filter and then squeeze it between the hands without wringing.

-Let it dry and refit it again.

CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,

THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Vespa S 50 2T Maintenance

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transmissions

- Adjust the control cables: Mix cable: see procedure indicated in "Mixer timing". Throttle cable: adjust the set screw on the carburettor in such a way that the sheath has no backlash. Splitter control cable: adjust set screw on the throttle control to the handlebar in such a way that there is no backlash on the throttle control. Adjust all transmissions in such a way that their sheathings show no sign of backlash.

Mixer Timing

- Using the transmission set screw on the crankcase, with throttle control untwisted, adjust the reference mark on the rotating plate so that it is lined up with the reference mark on the mixer body, as shown in the figure. While doing this, the engine must be fuelled with a 2 % oil mixture (0.5 litre minimum if the reservoir is empty).

CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN

THE RESERVOIR BLEED THE MIXER AS FOLLOWS: REFILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE) UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH THE RELEVANT METAL CLIP.

Recommended products

AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISOL-EGD

Braking system

Maintenance Vespa S 50 2T

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Level check

- Rest the vehicle on its centre stand on flat ground.

- The brake fluid reservoir has a sight glass «A» made of transparent material; the quantity of liquid contained in the sight glass indicates the level of fluid in the reservoir.

- When the sight glass «A» is full, the level inside the reservoir is above the MIN level; when it is partially full, the level has dropped to the MIN level; when it is fully empty, the level of fluid in the reservoir is below the MIN level.

N.B. THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET

WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF REQUIRED. TOP UP THE PUMP TANK, IF REQUIRED, CONSIDERING THAT THE "MAX." LEVEL MUST ONLY BE OBTAINED WITH NEW PADS.

- Under standard climatic conditions, replace fluid as indicated in the scheduled maintenance table.

Top-up

Proceed as follows:

-Remove the rear-view mirrors.

- Undo the two screws «A».

- Undo the screw «B» and remove the front handlebar cover.

Vespa S 50 2T Maintenance

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- Remove the reservoir cover «C» by loosening the two fixing screws «D» and refill with the prescribed brake fluid type only and without exceeding the maximum level.

CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE

SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.

CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS

MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.

N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO

THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

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;

Maintenance Vespa S 50 2T

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

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

SAS filters inspection and cleaning

Remove the right side fairing by undoing the 2 screws marked «B» indicated in the figure. Remove the two screws «A» from the aluminium SAS cover. Release the metal tube from the rubber housing on the cover without extracting the tube from the cover/sleeve. Remove the tab and plastic cover, extract the sponge and wash it in water and soap. Dry it with compressed air before refitting it, making sure to correctly fit the tab in the housing on the two plastic and aluminium covers. Every time you disassemble the filter, replace the O-ring seal located in the cover.

Vespa S 50 2T Maintenance

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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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

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air

Excess of encrustations in the combustion chamber Remove the encrustations

Lack of compression wear of the piston rings or cylinder Check the worn parts and replace them

Exhaust pipe clogged due to excessive encrustations Replace the exhaust pipe and check the carburation and mixer

timer

Air filter blocked or dirty Clean according to the procedure

Starter inefficient (stays on) Check the mechanical sliding, continuity of the circuit, the pres-

ence of power and electrical wiring

Clutch slipping Check the centrifugal brake shoe assembly and /or clutch bell

and replace if necessary

Defective mobile pulley sliding Check all the parts, replace the faulty parts and lubricate only

the driven pulley using recommended grease

Transmission belt worn Replace

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

Fuel filter on vacuum operated cock blocked Clean the cock filter

Roller wear; Presence of oil; Dirt Check the cap with filter is fitted to the transmission cover;

clean the speed variator, replace the rollers if worn out

Rear wheel spins at idle

REAR WHEEL

Possible Cause

Operation

Idling rpm too high Adjust the idle speed

Clutch fault Check the spring/friction mass and the clutch bell

Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged

Starting difficulties

DIFFICULTY STARTING

Possible Cause

Operation

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air

Faulty fuel cock Check that, at ignition and with throttle untwisted, no petrol

flows out the delivery pipe; otherwise, replace the vacuum-op-

erated cock

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

power supply

Defective spark plug or with incorrect electrode gap Check and if necessary replace the spark plug and the elec-

trode gap

Battery flat Check the state of the battery. If it shows signs of sulphation

replace it and bring the new battery into service charging it for

eight hours at a current of 1/10 of the capacity of the battery

itself

- Engine flooded. Start up keeping the throttle fully open alternating approximately five seconds of turning it with five seconds still. If however it does not start, remove the spark plug, the engine over with the

throttle open being careful to keep the cap in contact with the

Vespa S 50 2T Troubleshooting

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Possible Cause Operation

spark plug and the spark plug grounded but away from its hole.

Refit a dry spark plug and start the vehicle.

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill

Faulty spark plug Remove the encrustation, restore the plug gap or replace being

sure to use the types of spark plug recommended at all times.

Bear in mind that many problems engines have, derive from

the use of the wrong spark plug

Intake joint cracked or with a bad seal Replace intake joint and check for correct sealing on the head

Purifier-carburettor fitting damaged Replace

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Excess of encrustations in the combustion chamber Remove the encrustations

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause Operation

Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air

Dirty carburettor Wash the carburettor with solvent and dry with compressed air

Water in the carburettor Empty the tank through the appropriate bleed nipple.

Air filter dirty Clean or replace

Defective floating valve Check the proper sliding of the float and the functioning of the

valve

Tank breather hole obstructed Restore the proper tank aeration

Engine tends to cut-off at idle

ENGINE STOP IDLING

Possible Cause

Operation

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

Starter that stays open Check: electric wiring, circuit continuity, mechanical sliding and

power supply

Reed valve does not close Check / replace the reed pack

Wrong idling adjustment Adequately adjust the engine idle speed

Spark plug defective or faulty Replace the spark plug with one with the specified degree and

check the plug gap

Excessive exhaust noise

INCREASED NOISINESS

Possible Cause

Operation

Secondary metal air pipe deteriorated Check there are no leaks on the hoses on the crankcase and

the housing, check that there is a cap with filter and it is correctly

fitted to the transmission cover

Good condition of the missing secondary air circuit components Check the individual components and the piping, check the

precision of the fitting. Replace the damaged components

Troubleshooting Vespa S 50 2T

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High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause Operation

Air filter blocked or dirty. Clean according to the procedure

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

power supply

SAS malfunctions

SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-

FLER

Possible Cause Operation

Secondary air reed blocking Replace Secondary air filter clogging Clean the filter and the housing

Blockage of the secondary air fitting on the muffler Remove the encrustations from the joint being careful not to let

the debris fall into the muffler

Transmission and brakes

Clutch grabbing or performing inadequately

CLUTCH BRAKES

Possible Cause

Operation

Slippage or irregular functioning Check that the masses open and return normally

Check that there is no grease on the masses

Check that the clutch masses' contact surface with the clutch

bell is mainly in the middle with characteristics equivalent on

the three masses

Check that the clutch bell is not scored or worn abnormally

Never operate the engine without the clutch bell

Check the cap with filter is fitted to the transmission cover

Insufficient braking

BRAKING SYSTEM MALFUNCTION

Possible Cause

Operation

Poor braking The rear (drum type) brake is adjusted by regulating the special

adjustment (on the wheel) bearing in mind that, with the control

levers in the rest position, the wheels must turn freely.

The braking action should begin when the brake levers are

pressed by about a third.

Check the brake pad wear. If it is not possible to remove any problems by simply adjusting the transmissions, check the brake pads and front brake disc, the brake shoes and the rear drum. If you encounter excessive

wear or scoring, make the necessary replacements.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be

no flexible movement of the brake lever).

Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump breakdown, replace

The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in

the pump

Defective sliding of the cables in their sheathes Lubricate or substitute

Brake noise Check the wear of the brake pads and/or shoes

Vespa S 50 2T Troubleshooting

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Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective sliding of pistons Replace the calliper.

Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the

wheel correctly fitted or the concentricity of the rear drum.

Electrical system

Battery

BATTERY

Possible Cause Operation

Battery The battery is the electrical device in the system that requires

the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery

needs to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keep-

ing in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM

chapter for the recharging of the batteries.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause

Operation

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

If irregularities continue in turning the steering even after mak-

ing the above adjustments, check the seats in which the ball

bearings rotate: replace if they are recessed.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

Operation

EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts.

If irregularities continue in turning the steering even after mak-

ing the above adjustments, check the seats in which the ball

bearings rotate: replace if they are recessed.

Noisy suspension

NOISY SUSPENSION

Possible Cause

Operation

NOISY SUSPENSION If the front suspension is noisy, check: the efficiency of the front

shock absorbers; the condition of the ball bearings and relevant

Troubleshooting Vespa S 50 2T

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Possible Cause Operation

lock-nuts, the limit switch rubber buffers and the movement

bushings.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Oil leakage from suspension Service the pumping members and check the sleeves and

sealing rings are in good conditions. Replace the damaged

parts

Vespa S 50 2T Troubleshooting

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

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KEY

1. Electronic ignition device

2. Magneto flywheel - Pick-up

3. Key switch

4. Voltage regulator

5. 7.5A Fuse

6. 12V - 9Ah Battery

7. Starter motor

8. Start-up remote control switch

9. Horn button

10. Horn

11. Starter button

12. Stop button on rear brake

13. Stop button on front brake

14. Turn indicator switch

15. Light switch

16. Rear left turn indicator

17. Rear light

18. Rear right turn indicator

19. Front left turn indicator

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20. Front light A. Tail light bulb B. High-/low-beam light bulb

21. Front right turn indicator

22. Fuel level transmitter

23. Instrument panel A. Turn indicator warning light B. Headlight warning light C. Instrument panel lighting bulbs D. Fuel gauge E. Low fuel warning light F. Oil warning light G. High-beam warning light

24. Automatic starter

25. Heater

26. Heater control device

27.Oil reserve warning light

28. Spark plug

R = Red - B = White - Bl = Blue - N = Black - V = Green - Rs = Pink -Mr = Brown - Gr = Grey - Az = Sky Blue G = Yellow Vi = Purple A = Orange

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Components arrangement

1 / 2 / 5 / 6 / 7 / 8 / 24 / 25 / 28 - Electronic ignition device / Magneto flywheel - Pick-Up / 7.5A Fuse/

12V-9Ah Battery / Starter motor / Start-up remote control / Automatic starter/ Heater / Spark plug.

3 / 4 / 10 / 26 - Key switch / Voltage regulator / Horn / Heater control device.

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Conceptual diagrams

Ignition

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KEY

1. Electronic ignition device

2. Magneto flywheel - Pick-up

3. Key switch

5. 7.5A Fuse

6. 12V - 9Ah Battery

28. Spark plug

Headlights and automatic starter section

KEY

2. Magneto flywheel - Pick-up

3. Key switch

4. Voltage regulator

5. 7.5A Fuse

6. 12V - 9Ah Battery

15. Light switch

17. Rear light

20. Front light A. Tail light bulb B. High-/low-beam light bulb

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23. Instrument panel B. Headlight warning light C. Instrument panel lighting bulbs G. High-beam warning light

24. Automatic starter

Battery recharge and starting

KEY

2. Magneto flywheel - Pick-up

3. Key switch

4. Voltage regulator

5. 7.5A Fuse

6. 12V - 9Ah Battery

7. Starter motor

8. Start-up remote control switch

11. Starter button

12. Stop button on rear brake

13. Stop button on front brake

17. Rear light

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Level indicators and enable signals section

KEY

2. Magneto flywheel - Pick-up

3. Key switch

4. Voltage regulator

5. 7.5A Fuse

6. 12V - 9Ah Battery

22. Fuel level transmitter

23. Instrument panel D. Fuel gauge E. Low fuel warning light F. Oil warning light

27.Oil reserve warning light

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Devices and accessories

KEY

2. Magneto flywheel - Pick-up

3. Key switch

4. Voltage regulator

5. 7.5A Fuse

6. 12V - 9Ah Battery

9. Horn button

10. Horn

14. Turn indicator switch

16. Rear left turn indicator

18. Rear right turn indicator

19. Front left turn indicator

21. Front right turn indicator

23. Instrument panel A. Turn indicator warning light

25. Heater

26. Heater control device

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Checks and inspections

All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irreparably damaged.

Ignition circuit

1) Check the condition of the spark plug (clean it with a metal brush, remove deposits, apply short blasts of compressed air and, if necessary, replace it).

2) Without removing the stator, carry out the following checks: After visually checking the electrical wiring, use a specific tester to measure the loading reel, the pick-up (see chart) and cable continuity.

- If checks on the loading boil, the pick-up and cable continuity show irregularities, replace the stator; otherwise replace the control unit.

- Remember that the engine must be off to disconnect any connections in order to replace the central unit.

Specific tooling

020331Y Digital multimeter

PICK - UP CHECK (FIGURE A)

Specification

Desc./Quantity

1 Red cable (1) and White cable (2) 90 ÷ 140 Ohm

RECHARGING COIL CHECK (FIGURE B)

Specification

Desc./Quantity

1 Red cable (3) and Green cable (4) 800 ÷ 1100 Ohm

CONTINUITY CHECK

Specification

Desc./Quantity

1 White cable - Engine Continuity 2 White cable - Frame Continuity

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Voltage regulator check

Voltage regulator

The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault:

1) Lighting system bulbs burn out.

2) Lighting system is not working.

3) Battery overcharges (the main fuse blows).

4) Battery not recharging.

5) Turn indicators not working.

6) Oil and fuel check warning light not working. Remedies FAULT 1

Check that the control voltage is between 13V and

14.5V at 5000 rpm with the lights on. Check that the control voltage is 16V at 5000 rpm with the lights off. Replace the voltage regulator if control voltages are over >16V.

FAULT 2 a) Check that voltage to stator is correctly sup-

plied: disconnect the regulator connector and place the tester to detect alternating voltages between the connection of the grey-blue cable (2) and the black cable (6) to check that the voltage supplied at 3000 rpm is within 25-30 V (FIG. A). If faults are detected, replace the stator. b) If no faults are detected with these controls, replace the regulator. c) If functioning is still not correct even when the regulator has been replaced, check the connections of the electrical system.

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FAULT 3

After checking that there are no short circuits in the system towards earthing with the engine off and the regulator connector detached, replace the regulator because it is certainly inefficient, and replace the protection fuse. Following the replacement, measure the current and the recharging voltage on the battery ends (FIG. B). The values detected must be 1.5 ÷ 2 A and 13 V at 3000 rpm.

FAULT 4 a) Place the tester that detects alternating voltages

between the connection of the yellow cable (8) on the regulator and the black cable (6) (FIG. D) to check that the voltage supplied by the generator at 3000 rpm is within 26 ÷ 30 V (the battery should be disconnected to measure this). If faults are detected, replace the stator; otherwise, proceed to point b). b) Yellow/black cable (1) connected to the regulator. Insert an ammeter between the grey/blue cable (2) of the stator and the battery and use the tester to check that the current supplied at 3000 rpm is approx. 1.5 ÷2 Ampere (FIG. C). If the values detected are lower than those specified, replace the regulator. Before carrying out the checks on the regulator and the corresponding system, it is always good practice to check that there is continuity between the black cable and the earthing.

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FAULT 5

(FIG. E) If the turn indicators do not work, proceed as follows:

- Remove the regulator connector, and insert the tester probes between the contact 5 (yellow-red) and the ground lead.

- Turn the key switch to ON and check that the battery is getting voltage. If no voltage is detected, check the wiring and the contacts on the key switch and on the battery.

(FIG. F) Repeat the procedure now placing the tester probes between contacts 5 (yellow/ red) and 6 (black), and check the presence of the battery voltage with the key switch set to ON. If there is no voltage, check the regulator ground wiring.

(FIG. G) If the above tests have positive results, jump the contacts 5 (yellow/red) and 7 (blue/black) on the connector, set the key switch to ON and shift the turn indicator switch to the right and left to see when the lights are steadily on (as they are powered directly from the battery). If even after this operation the turn indicators fail to turn on, check that the wiring is not damaged and the switch works properly. If these last two tests have a positive result, replace the regulator because it is certainly not functioning properly.

FAULT 6 Oil reserve check warning light not working

(FIG H) - Disconnect the voltage regulator connector.

- Supply 12V to the terminal marked with number 5; with a digital tester check that the terminal number 4 has a similar output (12V) for about 5 seconds.

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- If no voltage is detected for terminal number 4, replace the regulator.

- If there is voltage for terminal number 4, check both the installation and the bulb of the oil warning light.

Specific tooling

020331Y Digital multimeter

level indicators

- Check resistance between Pin 4 and the ground connection on the 5-way connector in the instrument panel to check the efficiency of the fuel gauge.

Electric characteristic

Resistance value when the tank is full

< = 7Ω

Resistance value when the tank is half-full

38 Ω ±4 Ω

Resistance value with empty tank and low fuel warning light on

90 Ω +13 Ω -3 Ω

Lights list

BULBS

Specification

Desc./Quantity

1 High/low beam light bulb Type: Spherical

Power: 12V 35/35W

Quantity: 1

2 Front tail light bulb Type: All glass

Power: 12V 5W

Quantity: 1

3 Front turn indicator bulb Type: Spherical

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

4 Rear turn indicator light bulb Type: Spherical

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

5 Stop and tail light bulb Type: Spherical

Power: 12V 21/5W

Quantity: 1

6 Warning light bulbs: turn indicators, low-beam lights,

high-beam lights, low fuel, low oil

Type: All glass

Power: 12V - 1.2W

Quantity: 5

7 Instrument panel lighting bulbs Type: All glass

Power: 12V 1.2W

Quantity: 3

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Fuses

The electrical system is protected by a plug fuse «B» located to the left of the battery compartment. The ignition system, headlight and the rear light are not fuse-protected. Before replacing a blown fuse, find and solve the problem that caused it to blow. Do not replace the fuse with any alternative form of conductor

CAUTION

IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BATTERY ELECTROLYTE.

Electric characteristic

Fuse

7.5 A

Sealed battery

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check

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

- If the voltage exceeds 12.60 V, the battery may 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 equal to 14.40÷14.70V

-Initial charge voltage equal to 0.3÷0.5 for nominal capacity

-Duration of the charge: 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 nominal capacity of the battery

-Duration of the charge: 5 h

WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

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Dry-charge battery

WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN

The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are:

1) Check the level of the electrolyte

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.

2)Load status check

After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. After charging the battery, check each element electrolyte level and density. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months.

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If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the earth wire (black) marked (-) must be connected to the - negative terminal while the other two red wires marked (+) must be connected to the terminal marked with the + positive sign. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

4) Cleaning the battery

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

WARNING

- Before recharging the battery, remove the plugs of each cell. Keep the battery away from naked flames or sparks when charging. Remove the battery from the vehicle removing the negative clamp first.

CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN

THAT RECOMMENDED. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION DRINKING WATER CONTAINS MINERALS THAT CAN BE

EXTREMELY HARMFUL TO THE BATTERY: USE DISTILLED WATER ONLY.

CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY

MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

1)- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries, with a specific gravity of 1.26, corresponding to 30° Bé, at a minimum temperature of 15°C until the upper level is reached.

2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.

Electrical system Vespa S 50 2T

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3)- Within the following 24 hours, recharge with the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corresponding to 31º Bé, and these values are stabilised.

4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.

5)- Once the above operations have been performed, install the battery in the vehicle ensuring the connections between the wiring and the battery terminals are correct.

WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Connectors

HEATER CONTROL DEVICE CONNECTOR

1. Positive from voltage regulator (Yellow)

2. Ground (Black)

3. Heater (Sky Blue)

4. Heater (Orange-Black)

5. Not connected

6. Positive from the voltage regulator (Yellow-

Black)

VOLTAGE REGULATOR CONNECTOR

1. Lights power, instrument panel lighting, heater

control device and automatic starter (YellowBlack)

2. Magneto flywheel (Grey-Blue)

3. Not connected

4. Oil reserve indicator power (Orange)

5. Oil reserve indicator power, start-up circuit and

heater control device (Yellow-Red)

6. Ground (Black)

7. Turn indicator switch power (Blue-Black)

8. Magneto flywheel (Yellow)

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MAGNETO FLYWHEEL CONNECTOR

1. Pick-up (Red)

2. Voltage regulator (Yellow)

3. Battery positive (Blue)

4. Voltage regulator (Yellow-Blue)

5. Ground (White)

6. Electronic ignition device (Green)

ELECTRONIC IGNITION DEVICE CONNECTOR

1. Pick-up (Red)

2. Ground (Black and White)

3. Magneto flywheel (Green)

4. Not connected

AUTOMATIC STARTER CONNECTOR

1. Positive from voltage regulator (Yellow-Black)

2. Ground (Black)

OIL LEVEL INDICATOR CONNECTOR

1. Positive from voltage regulator (Orange)

2. Oil reserve warning light (Orange)

3. Positive from voltage regulator (Yellow)

4. Live Positive (White)

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INSTRUMENT PANEL CONNECTOR «A»

1. Right turn indicator warning light (White-Blue)

2. Left turn indicator warning light (Pink)

3. Positive from voltage regulator (Yellow-Black)

4. Ground (Black)

INSTRUMENT PANEL CONNECTOR «B»

1. Live Positive (White)

2. Low fuel warning light (Yellow-Green)

3. Oil reserve warning light (Orange)

4. Fuel level indicator (White-Green)

5. High-beam warning light (Purple)

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 65

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the head

- Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.

Removal of the engine from the vehicle

- Support the scooter adequately.

- Disconnect the battery.

-Remove the muffler assembly.

- Remove the rear wheel.

- Remove the rear brake mechanical transmission.

-Disconnect the electric terminals.

- Remove the throttle grip and mixer transmissions.

- Disconnect the hoses (petrol-oil).

- Remove the engine-side swinging arm and remove the entire engine.

WARNING

Be very careful when handling fuel.

CAUTION

When installing the battery, first attach the positive cable and then the negative cable.

WARNING

Wear safety goggles when using hitting tools.

Vespa S 50 2T Engine from vehicle

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INDEX OF TOPICS

ENGINE ENG

Page 67

Automatic transmission

Transmission cover

- Loosen the 15 screws and remove the transmission cover with the aid of a mallet.

N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT

FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.

Kickstart

- Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector.

- Use the special tool for the charging of the spring, as shown in the figure.

- Refit the seeger ring after checking that it is in good condition.

Specific tooling

020261Y Starter spring fitting

Recommended products

AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20

- Remove the seeger ring located on the exterior of the crankshaft.

- Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).

CAUTION

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WHILE REMOVING THE TOOTHED SECTOR, BE VERY CAREFUL OF THE SPRING TENSION: IT COULD CONSTITUTE A HAZARD FOR THE OPERATOR.

- Remove the screws shown in the figure and remove the engine starting lever.

- For the assembly, work in reverse and tighten the screws to the prescribed torque..

Locking torques (N*m)

Starter lever fixing screw 12 ÷ 13

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

N.B. IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-

AMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE.

Engine Vespa S 50 2T

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Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the whole of the driven pulley assembly.

N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE

PULLEY MOUNTED.

Specific tooling

020565Y Flywheel lock calliper spanner

Inspecting the clutch drum

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

- Measure the inner diameter of the clutch bell.

Characteristic

Clutch bell diameter/standard value

Ø 107+0.2 +0 mm

Clutch bell diameter/max. value allowed after use

Ø 107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and put the central screw under stress.

CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW

IS TIGHTENED UP TOO FAR.

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- Using a 34 mm socket wrench remove the clutch locking nut.

- Loosen the central screw thereby undoing the driven pulley unit

- Separate the components.

Specific tooling

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 CEN-

TRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT

A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

Engine Vespa S 50 2T

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- Remove the three guide pins and the mobile half pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley.

CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-

ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.

Specific tooling

001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch housing by means of the special tool.

N.B. PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO

DEFORM THE SLIDING SURFACE OF THE DRIVING BELT

Specific tooling

020376Y Adaptor handle 020363Y 20 mm guide

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work surface of the belt. If there are, replace the halfpulley..

- Make sure the bearings do not show signs of unusual wear.

- Measure the external diameter of the pulley bushing.

Characteristic

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Stationary driven half-pulley/Standard diameter

Ø 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diameter admitted after use

Ø 33.96 mm

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two Orings.

- Measure the inside diameter of the mobile halfpulley bushing.

Characteristic

Mobile driven half-pulley/ Maximum diameter allowed

Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile half-pulley.

- Fitting the half-pulley on the bushing.

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel revolving ring

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products

AGIP GREASE SM 2 Grease for the tone wheel revolving ring

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Engine Vespa S 50 2T

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Page 73

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible from the outside.

CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT

DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley does not show signs of deformation

- Measure the free length of the spring

Characteristic

Standard length

118 mm

Minimum length allowed after use

XXXX

Refitting the clutch

- Preassemble the driven pulley group with spring, sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar.

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- Reassemble the nut securing the clutch and tighten to the prescribed torque.

CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-

ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE

NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)

Clutch lock ring nut 55 ÷ 60

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell and the nut, using the specific tool.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Clutch bell nut 40 ÷ 44

Drive-belt

- Make sure the driving belt is not damaged and does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

Transmission belt/Minimum width

17.5 mm

Engine Vespa S 50 2T

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Page 75

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer, then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.

Specific tooling

020451Y Starting ring gear lock

Mixer gears and belt

- Remove gear and belt.

CAUTION PAY PARTICULAR ATTENTION TO NOT TOUCHING OR

BENDING THE BELT BECAUSE THIS COULD BREAK SUDDENLY DURING OPERATION.

CAUTION ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET

INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN.

N.B. REPLACE THE BELT AS INDICATED IN THE SCHEDULED

MAINTENANCE TABLE.

Inspecting the rollers case

1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation.

2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of marked facetting on the sliding surface and that

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the metallic insert does not come out of the plastic shell borders.

4) Check the integrity of the sliding blocks of the contact plate.

- Check that the internal bushing shown in the figure is not abnormally worn and measure inside diameter «A».

- Measure outside diameter «B» of the pulley sliding bushing shown in the figure.

CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.

Characteristic

Driving pulley / Maximum diameter:

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

Refitting the driving pulley

- Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.

N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO

THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.

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- Refit the particular components of the assembly (roller container assembly with bushing, limiting washer, stationery half-pulley, cooling fan belt with drive, washer and nut).

- With the specific tool tighten the lock-nut to the prescribed torque and then perform a final 90° lock in order to prevent the rotation of the drive pulley.

N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-

MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.

Specific tooling

020451Y Starting ring gear lock

Locking torques (N*m)

Crankshaft pulley nut 18 to 20 + 90° Nm

For 25 km/h engine type versions, the limit washer is 5.5 mm thick

End gear

Removing the hub cover

• Remove the transmission cover

• Remove the clutch assembly

• Discharge the rear hub oil.

• Remove the 5 screws indicated in the figure.

• Remove the hub cover with driven pulley shaft.

Recommended products

AGIP CITY TEC 2T Oil

Recommended oil

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Inspecting the timing system components

CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT

MUST PASS BETWEEN THE SUPPORT AND LAMELLA.

Crankcase - crankshaft

Splitting the crankcase halves

Remove the eight crankcase union fasteners.

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Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side

Specific tooling

020163Y Crankcase splitting plate

Removing the crankshaft

- Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length.

- Remove the crankshaft from the transmission side half crankcase

Specific tooling

020163Y Crankcase splitting plate

Removing the crankshaft bearings

The bearings can stay on either the half crankcase or the crankshaft indifferently

- Using the special tool, remove any bearings that have been left on the crankshaft

N.B.

The half rings must be inserted on the bearings with a few mallet blows.

Specific tooling

004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings

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- Using the specific tool remove any bearings left on the half crankcase

Specific tooling

001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings

Refitting the crankshaft bearings

Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track

Specific tooling

020265Y Bearing fitting base

Inspecting the crankshaft alignment

With the specific tool shown check that the eccentricity of the surfaces of diam. «A»-«B»-« C» are within 0.03 mm. (reading limit on the dial gauge); in addition, check the eccentricity of diam. «D», for which a maximum reading of 0.02 mm is permitted. In the case where eccentricity is not much above prescribed levels, straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp (with an aluminium bushing) as required..

Specific tooling

020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft

alignment

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Refitting the crankshaft

- Position the transmission side half crankcase on two wooden supports

- Using a thermal gun, heat the bearing seat to about 120°

- Firmly insert the crankshaft until the bearing reaches the end-of-stroke stop

- Let the temperature of the half crankcase settle at the temperature of the crankshaft.

- Again install the special crankcase separation plate NOT installing the crankshaft protection

- During the assembly phase keep the central thrust screw loose.

- Take the four clamping screws to the end of the

stroke and loosen them again with the same angle

(e.g. 90°)

- When the temperature has settled, preload the

thrust screw of the tool manually until the ball bear-

ing clearance is cancelled out.

Specific tooling

020163Y Crankcase splitting plate

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Refitting the crankcase halves

- Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the surface using a suitable solvent (e.g. trichloroethylene)

- Heat the flywheel-side half crankcase with a thermal gun.

Recommended products

Loctite 510 Liquid sealant

Gasket

- Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement

- Insert at least three clamping screws and tighten up rapidly

- Insert the other 5 screws and tighten them to the specified torque.

Locking torques (N*m)

Half-crank case joint bolts 12 ÷ 13

- Move the crankcase separation plate in a position back from the one indicated in the figure

- Install the special magnetic support with dial gauge at the end of the crankshaft

- Check the axial clearance of the crankcase If this is not within the maximum limit allowed, repeat the crankcase coupling procedure

Specific tooling

020335Y Magnetic support for dial gauge

Characteristic

Axial clearance with warm crankcase

0.10 ÷ 0.12 mm

Axial clearance with cold crankcase

0.06 to 0.08 mm

Limit value with cold crankcase

0.02 ÷ 0.03 mm

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Lubrication

Crankshaft oil seals

Refitting

- Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter

N.B. THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE

WITH THE FITTED WRENCH

Specific tooling

020340Y Flywheel and transmission oil seals fitting punch

- Install a new transmission side oil seal using the special tool with adapter ring. The transmission-side oil seal is recognised by the larger diameter

Specific tooling

020340Y Flywheel and transmission oil seals fitting punch

Oil pump

Removal

- Remove the 2 screws shown in the figure

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Remove the tube passage seal from the crankcase shown in the figure

Refitting

To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure

Fuel supply

- Completely empty the gas tank.

- Remove the petrol delivery tube and the suction tube.

- Loosen the clip and remove the tap.

- Clean the tank and the filter of the tap with a specific solvent.

- Refit the tap making sure that there is an O-Ring.

- Turn the tap to the direction it had before it was removed and block the clip.

N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO

FACILITATE CLEANING.

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- Disconnect the fuel supply and the suction taking pipe from the carburettor.

- Check that there are no fuel leaks between the two tubes.

- Close the fuel outlet pipe.

- By means of the MITIVAC pump apply 0.1 bar of suction to the tap.

- Make sure that the suction is kept stable and that and that there are no fuel leaks.

- Reconnect the suction pipe to the manifold.

- Position the fuel pipe with the outlet at the point of the tap.

- Turn the engine by using the starter for five seconds with the carburettor at minimum.

- Take up the fuel by means of a graded burette.

N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-

RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUTLET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.

Specific tooling

020329Y MityVac vacuum-operated pump

Characteristic

Minimum flow rate

20 cc

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INDEX OF TOPICS

SUSPENSIONS SUSP

Page 98

This section is devoted to operations that can be carried out on the suspension.

Front

Removing the front wheel

- Support the scooter adequately.

- Loosen the five screws fixing the wheel to the hub.

Front wheel hub overhaul

- Support the scooter adequately.

- Remove the front wheel.

- Remove the front calliper.

- Remove the cotter pin and remove the cap.

- Unscrew the nut fixing the front wheel hub.

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- Remove the wheel hub.

- Remove the ball bearing check seeger ring indicated in the photograph

Extract the ball bearing using the specific tool

Specific tooling

001467Y014 Pliers to extract ø 15-mm bearings 001467Y017 Bell for bearings, OD 39 mm

- Remove the oil seal on the roller bearing side using a screwdriver.

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- Remove the roller bearing using the specific tool

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide

- Heat the roller bearing seat with a heat gun

- Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing out

- Refit the ball bearing check seeger ring

Specific tooling

020151Y Air heater 020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide

- Use the specific tool to fit and push the roller casing until it stops

- Refit the oil seal on the roller bearing side

- Lubricate the area between the roller bearing and the ball bearing

Specific tooling

020038Y Punch

Recommended products

AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20

- To refit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torque.

Locking torques (N*m)

Front wheel axle nut 75 ÷ 90

Suspensions Vespa S 50 2T

SUSP - 100

VESPA 664787, 664795 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual