Vespa GTS300 Service manual
MANUALE STAZIONE DI SERVIZIO
********
Vespa GTS Super 300 ie (2008)
MANUALE
STAZIONE DI
SERVIZIO
Vespa GTS Super 300 ie (2008)
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.
"© 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)
MANUALE STAZIONE DI
SERVIZIO
Vespa GTS Super 300 ie (2008)
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 change 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.
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
Vespa GTS Super 300 ie (2008) Characteristics
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 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.
CHAR - 7
Characteristics Vespa GTS Super 300 ie (2008)
Vehicle identification
Chassis prefix: ZAPM45100000 ÷ 1001
Engine prefix: M451M ÷ 1001
Dimensions and mass
Specification
Kerb weight 158 ± 5 kg
Maximum weight allowed 340 kg
Maximum height 1170 mm
Overall width 755 mm
Overall length 2230 mm
Wheelbase 1370 mm
WEIGHTS AND DIMENSIONS
Desc./Quantity
CHAR - 8
Vespa GTS Super 300 ie (2008) Characteristics
Engine
DATA
Specification Desc./Quantity
Type single-cylinder, four-stroke and four liquid-cooled valves
Cubic capacity 278.3 cm³
Stroke 63 mm
Bore 75 mm
MAX. torque 22 Nm at 6500 rpm
Max. Power 16.4 kW at 7500 rpm
Timing system single overhead camshaft chain driven on the left-hand side, 3-
Compression ratio 10.5 ÷ 11.5
Engine idle speed 1650 ± 50 rpm
Air filter sponge, impregnated with mixture (50% petrol and 50% oil)
Starting system electric starter motor with freewheel
Lubrication with lobe pump (inside the crankcase) controlled by a chain and
Fuel supply Electronic injection with electric fuel pump
valve clearance intake: 0.10 mm - discharge: 0.15 mm
Minimum lubrication pressure (100° C) 0.8 bar
Lubrication pressure 3.5 ÷ 4 bar
Cooling Forced liquid circulation cooling.
arm rocking levers set up with set screw
double filter: mesh and paper
OIL PUMP
Specification
Type Trochoidal
Distance between the rotors Admissible limit clearance: 0.12 mm
Axial rotor clearance Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm
Levelness 0.1 mm
Desc./Quantity
BY-PASS
Specification
Type With piston
Plunger diameter Ø 13.9 - 0.039 -0.057 mm
By-pass check up: Standard length 54.2 mm
Calibration pressure 4.5 bar
Desc./Quantity
OIL FILTER
Specification
Type Paper with pressure relief and anti-drain back by-pass valves
Desc./Quantity
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH
Specification
Calibration 0.3 - 0.6 bar
Desc./Quantity
HEAD LUBRICATION CONTROL JET
Specification
Diameter 1 ± 0.05 mm *
* Tightening torque 5÷7 N·m
Desc./Quantity
COOLING SYSTEM
Specification
Cooling system capacity ~ 2.100 ÷ 2.150 l
Prescribed fluid AGIP PERMANENT SPEZIAL
Sealing pressure Cap calibrated at 0.9 bar
Desc./Quantity
CHAR - 9
Characteristics Vespa GTS Super 300 ie (2008)
THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening 85±2°C
ELECTRIC VENTILATION
Specification Desc./Quantity
Electric ventilation starts at 102°C
Electric ventilation stops at 96°C
WATER PUMP
Specification Desc./Quantity
Type Centrifugal
Control Coaxial to crankshaft
RADIATOR
Specification Desc./Quantity
Type Made of aluminium in two sections
Transmission
Specification
Transmission Automatic expandable pulley variator with torque server, V belt,
Capacities
Specification
Fuel tank (including a ~ 2 l reserve) ~ 9.2 l
Cooling system fluid ~ 2.100 ÷ 2.150 l
Engine oil approx. 1300 cc
Electrical system
Specification
Ignition/advance Electronic, with inductive discharge and variable advance with
Spark plug CHAMPION RG 4 PHP
Generator alternating current
TRANSMISSION
Desc./Quantity
automatic clutch, gear reduction unit and transmission housing
with forced air circulation cooling
CAPACITY
Desc./Quantity
Rear hub 250 cc
ELECTRICAL COMPONENTS
Desc./Quantity
three-dimensional mapping
Battery 12V-12Ah
Fuses One 30A fuse - One 15A fuse - Three 10A fuses - Four 7.5A
fuses - One 3A fuse
CHAR - 10
Vespa GTS Super 300 ie (2008) Characteristics
CHECKING REMOTE CONTROLS «A» OPERATING AS CIRCUIT BREAKERS
1) Check that, given regular conditions, there is no
continuity between terminals 30 and 87.
2) Apply 12V voltage to power terminals 85 and 86
of the remote control.
3) With the remote control powered, check that
there is continuity between terminals 30 and 87.
4) If these conditions are not fulfilled, the remote
control is damaged and must be replaced.
To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.
TURN INDICATOR SWITCH
ENGINE STOP SWITCH
HORN BUTTON
CHAR - 11
Characteristics Vespa GTS Super 300 ie (2008)
LIGHT SWITCH
STARTER BUTTON
KEY SWITCH
FUEL INJECTOR
Type: 3 holes
Conicity of the nozzle: 20°
Resistance at terminals: 13.7 ÷ 15.2 Ohm
CHAR - 12
Vespa GTS Super 300 ie (2008) Characteristics
FUEL PUMP UNIT
Mechanical type pressure regulator operating at a
pressure of 2.5 BAR
Pump winding resistance: ~ 1.5 Ohm
Input current during regular functioning: 1.4 - 1.8
A
REVOLUTION TIMING SENSOR
Resistance between pins 13 and 15: 100 ÷ 150
Ohm at approx. 20°
ENGINE TEMPERATURE SENSOR
0° = 5900 Ohm
+10° = 3800 Ohm
+20° = 2500 Ohm
+30° = 1700 Ohm
+80° = 300 Ohm
MINIMUM OIL PRESSURE SENSOR
Normally closed switch
Activation threshold: 0.3 - 0.6 bar
With the engine off: continuity between terminal
and ground
CHAR - 13
Characteristics Vespa GTS Super 300 ie (2008)
HV COIL
- Resistance of the primary = 0.5 Ohm ± 8%
- Resistance between primary and ground = infinite
- Resistance between primary and HV output = 3.1
KOhm ± 9%
- Presence of battery voltage between pins 22 and
26 of the interface cable harness upon
shifting to ON and for 2 sec.
STATOR
Power: 450 W
Resistance between terminals: 0.2 ÷ 1 Ohm
terminal insulation from ground
Frame and suspensions
Specification
Type Unitised body made of stamped plate
Front suspension Single arm suspension (cantilever wheel) fitted with a double-
Front shock absorber axial travel 86.5 mm
Rear suspension Engine with swinging fork articulated to frame by means of an
Rear shock absorber axial travel 89.5 mm
Brakes
Specification
Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plung-
Rear Ø 220 disc brake and calliper with two Ø 30 mm counteracting
FRAME AND SUSPENSIONS
Desc./Quantity
acting hydraulic shock absorber with coaxial spring
arm with 2 degrees of freedom Pair of double-acting hydraulic
shock absorbers and coaxial springs with preloading adjust-
ment in 4 positions.
BRAKES
Desc./Quantity
ers and hydraulic control (lever on the far right end of the
handlebar)
plungers and hydraulic control (lever on the far left end of the
handlebar)
CHAR - 14
Vespa GTS Super 300 ie (2008) Characteristics
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front wheels - light alloy rims 3.00x12
Rear wheels - light alloy rims 3.00x12
Front tyres 120/70-12" Tubeless
Rear tyres 130/70-12" Tubeless
TYRE PRESSURE
Specification Desc./Quantity
Front tyre pressure (when cold) 1.8 bar
Rear tyre pressure (when cold) 2 bar
Tyre pressure (when cold) with passenger 2.2 bar
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Tightening Torques
STEERING ASSEMBLY
Name
Upper steering ring nut 35 ÷ 40
Steering lower 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-delivery Operations» )
Fixing screws for handlebar control assembly U-bolts 7 ÷ 10
FRAME ASSEMBLY
Name
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
FRONT SUSPENSION
Name
Screw fixing the shock absorber to the shock absorber - calliper
attachment plate
Wheel axle nut 74 ÷ 88
Wheel screw 20 ÷ 25
Screw fixing rear mudguard to steering 5 ÷ 6.5
shock absorber upper clamp 20 ÷ 30
Torque in Nm
Torque in Nm
Torque in Nm
20 ÷ 27
FRONT BRAKE
Name
Brake fluid pump-hose fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 19 ÷ 24
Screw fixing calliper to the shock absorber - calliper plate at-
tachment
Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium strength)
Oil bleed screw 12 - 16
Pad fastening pin 19.6 ÷ 24.5
Brake pump reservoir screws 1.5 ÷ 2
Brake disc screws 8 ÷ 10
Torque in Nm
24 ÷ 27
CHAR - 15
Characteristics Vespa GTS Super 300 ie (2008)
REAR SUSPENSION
Name Torque in Nm
Retainer for left shock absorber to crankcase support plate 20 ÷ 25
Shock absorber lower fitting 40 ÷ 45
Shock absorber upper fitting 20 ÷ 25
Rear wheel axle 104 ÷ 126
Screw fixing wheel to hub 20 ÷ 25
Screws for muffler - shock absorber support arm on engine 20 ÷ 25 (The two screws must be tightened to the prescribed
Engine- and vehicle-side swinging arm junction bolt 40 ÷ 45
torque after having done so with the rear wheel axle nut. Safety
locks: see «Pre-delivery Operations» )
REAR BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 20 ÷ 25
Rear disc tightening bolt 11 ÷ 13
Oil bleed screw 12÷16
Calliper to engine tightening screw 20 ÷ 25
Brake pump reservoir screws 1.5 ÷ 2
Calliper coupling screw 30 ÷ 33
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
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 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
Torque in Nm
CYLINDER HEAD
Name
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
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
Torque in Nm
CHAR - 16
TRANSMISSION
Name
Belt support roller screw 11 ÷ 13
Clutch unit nut on driven pulley 45 ÷ 50
Torque in Nm
Vespa GTS Super 300 ie (2008) Characteristics
Name Torque in Nm
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
Pick-Up clamping screws 3 ÷ 4
Screw fixing freewheel to flywheel 13 ÷ 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
Engine-crankcase coupling screws 11 ÷ 13
Starter motor screws 11 ÷ 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength threadlock)
4 ÷ 6
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Bleed screw 3
Overhaul data
Assembly clearances
Cylinder - piston assy.
COOLING
CHAR - 17
Characteristics Vespa GTS Super 300 ie (2008)
CYLINDER - PISTON
Specification Desc./Quantity
Plunger diameter 74.967 +0.014 -0.014 mm
Cylinder diameter 75 +0.038 +0.01 mm
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder-piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064
cylinder-piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064
cylinder-piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064
cylinder-piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Measure the outside diameter of the gudgeon
pin.
Characteristic
Pin outside diameter
16 +0 -0.004 mm
- Measure the diameter of the bearings on the piston.
Characteristic
Standard diameter
16 +0.006 +0.001 mm
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 ÷ 0.010 mm
CHAR - 18
Vespa GTS Super 300 ie (2008) Characteristics
- Carefully clean the sealing ring housings.
- Measure the coupling clearance between the
sealing rings and the grooves using suitable sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
Fitting clearance
Top piston ring - standard coupling clearance
0.015 - 0.06 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance allowed after use 0.07 mm oil scraper ring - standard coupling clearance 0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm
- Check that the head coupling surface is not worn
or misshapen.
- Pistons and cylinders are classified according to
diameter. The coupling must be made with those
of the same type (M-M, N-N, O-O, P-P).
Characteristic
Maximum allowable run-out:
0.05 mm
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo
Crankshaft Crankshaft to crankcase axial
Crankshaft to crankcase axial clearance
Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
clearance
CHAR - 19
Characteristics Vespa GTS Super 300 ie (2008)
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Half-shaft, transmission
side
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
Diameter of crankshaft bearings.
Measure the bearings on both axes x-y.
Description Dimensions Initials Quantity
16.6 +0-0.05 A D = 0.20 - 0.50
CHAR - 20
Vespa GTS Super 300 ie (2008) Characteristics
CRANKSHAFT
Specification
Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm
Desc./Quantity
CHAR - 21
Characteristics Vespa GTS Super 300 ie (2008)
MAX. ADMISSIBLE DISPLACEMENT
Specification
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
Desc./Quantity
CHAR - 22
Vespa GTS Super 300 ie (2008) Characteristics
Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm
- Using a bore gauge, measure the connecting rod
small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.
Characteristic
Standard diameter
16 +0.025 +0.015 mm
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings must
be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- There are three crankcase versions: with BLUE bushings, with YELLOW bushings and with GREEN
bushings.
- There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter
after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
- The main bushings are available in three thickness categories, identified by colour markings, as shown
in the table below.
BUSHINGS
TYPE
B BLUE 1.973 ÷ 1.976
C YELLOW 1.976 ÷ 1.979
E GREEN 1.979 ÷ 1.982
IDENTIFICATION CRANKSHAFT HALF-BEARING
CHAR - 23
Characteristics Vespa GTS Super 300 ie (2008)
COUPLINGS
BUSHING CATEGORY CRANKCASE
HALVES CATEGORY
B 2 29.024 ÷ 29.054
C 1 29.024 ÷ 29.054
2 29.018 ÷ 29.048
E 1 29.018 ÷ 29.048
Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2).
Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare
crankshaft has half-shafts of the same category.
BUSHING INSIDE DIAMETER AFTER FITTING
CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
N.B.
CRANKCASES FOR REPLACEMENTS ARE SELECTED
WITH CRANKCASE HALVES OF THE SAME CATEGORY
AND ARE FITTED WITH CATEGORY C BUSHINGS (YELLOW)
Characteristic
Crankshaft-bushing maximum clearance admitted:
0.08 mm
Diameter of crankcase without bushing
CAT. 1: 32.959 ÷ 32.965 mm
CAT. 2: 32.953 ÷ 32.959 mm
Cylinder Head
Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting
- Using a trued bar and a feeler thickness gauge
check that the cylinder head surface is not worn or
distorted.
Characteristic
Maximum allowable run-out:
0.1 mm
- In case of irregularities, replace the head.
CHAR - 24
Vespa GTS Super 300 ie (2008) Characteristics
- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the bearings of the camshaft and the rocker pins exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant sealing pad exhibits no oxidation.
- Insert the valves into the cylinder head.
- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Measure the camshaft bearing seats and rocking
lever support pins with a bore meter
HEAD BEARINGS
Specification
bearing «A» Ø 12.000 - 12.018 mm
bearing «B» Ø 20.000 ÷ 20.021 mm
bearing «C» Ø 37.000 - 37.025 mm
Measure the unloaded spring length
Characteristic
Standard length
40.2 mm
Desc./Quantity
Allowable limit after use:
38.2 mm
CHAR - 25
Characteristics Vespa GTS Super 300 ie (2008)
- Clean the valve seats of any carbon residues.
- Using the Prussian blue, check the width of the
impression on the valve seat "V".
Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damages, replace the head.
STANDARD VALVE LENGTH
Specification Desc./Quantity
Valve check standard length Inlet: 94.6 mm
Valve check standard length Outlet: 94.4 mm
- Measure the diameter of the valve stems in the
three positions indicated in the diagram.
STANDARD DIAMETER
Specification
Inlet: 4.987 - 4.972 mm
Outlet: 4.975 - 4.960 mm
CHAR - 26
Desc./Quantity
Vespa GTS Super 300 ie (2008) Characteristics
MINIMUM ADMISSIBLE DIAMETER
Specification Desc./Quantity
Inlet: 4.96 mm
Outlet: 4.945 mm
- Calculate the clearance between valve and valve guide.
- Check the deviation of the valve stem by resting
it on a "V" shaped abutment and measuring the
extent of the deformation with a comparator.
Characteristic
Limit values admitted:
0.1 mm
- Check the concentricity of the valve head by arranging a comparator at right angle relative to the
valve head and rotate it on a "V" shaped abutment.
Characteristic
Admissible limit:
0.03 mm
Measure the valve guide.
Characteristic
Valve guide:
5 +0.012 mm
- After measuring the valve guide diameter and the
valve stem diameter, check the clearance between guide and stem.
CHAR - 27
Characteristics Vespa GTS Super 300 ie (2008)
INLET
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm
OUTLET
Specification Desc./Quantity
Standard clearance: 0.025 ÷ 0.052 mm
Admissible limit: 0.09 mm
- Check that there are no signs of wear on the surface of contact with the articulated register terminal.
- If the checks above give no failures, you can use
the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the
lapping compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
- Check that the camshaft bearings exhibit no scores or abnormal wear.
- Using a micrometer, measure the camshaft bearings.
STANDARD DIAMETER
Specification
Cam shaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm
Cam shaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm
Desc./Quantity
MINIMUM DIAMETER PERMITTED
Specification
Cam shaft check: Minimum admissible diameter Bearing A Ø: 36.94 mm
CHAR - 28
Desc./Quantity
Vespa GTS Super 300 ie (2008) Characteristics
Specification Desc./Quantity
Cam shaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm
-Using a gauge, measure the cam height.
STANDARD HEIGHT
Specification Desc./Quantity
Cam shaft check: Standard height Inlet: 30.285 mm
Cam shaft check: Standard height Outlet: 29.209 mm
Check the axial clearance of the camshaft
CAMSHAFT AXIAL CLEARANCE
Specification
Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm
Cam shaft check: Maximum admissible axial clearance 0.42 mm
- Measure the outside diameter of the rocking lever pins
- Check the rocking lever pins do not show signs of wear or scoring.
- Measure the inside diameter of each rocking lever.
Desc./Quantity
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Characteristics Vespa GTS Super 300 ie (2008)
Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment
plate.
ROCKING LEVERS AND PIN DIAMETER:
Specification Desc./Quantity
Internal rocker arm diameter: Standard diameter Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm
Slot packing system
Characteristic
Compression ratio
10.5 ÷ 11.5 : 1
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
CHAR - 30
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