Vespa GTV125 Service manual

SERVICE STATION MANUAL

664619 IT-664620 EN-664621 FR-664622 DE-664623

ES-664624 PT-664625 OL-664626 EL

Vespa GTV 125

SERVICE STATION

MANUAL

Vespa GTV 125

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

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

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

required for manufacturing or construction reasons.

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

should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

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

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

SERVICE STATION MANUAL

Vespa GTV 125

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to special tools, along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Characteristics Vespa GTV 125

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

CHAR - 2

Vespa GTV 125 Characteristics

Vehicle identification

Chassis prefix: ZAPM313010000 ÷ 1001 Engine prefix: M315M1001

Dimensions and mass

Specification Desc./Quantity

Total kerb weight 148 ± 5 kg

Overall width 770 mm

Length 1940 mm

Wheelbase 1395 mm

Height 1180 mm

Saddle height 800 mm

WEIGHTS AND DIMENSIONS

CHAR - 3

Characteristics Vespa GTV 125

Engine

ENGINE

Specification Desc./Quantity

Type single-cylinder, four-stroke and four liquid-cooled

valves

Timing system single overhead camshaft chain driven on the left-

hand side, three-arm rocking levers set up with

threaded set screw

Bore 57 mm

Stroke 48.6 mm

Cubic capacity 124 cm³ Compression ratio 12 ± 0.5: 1 Carburettor Keihin CVK 30

Engine idle speed 1650 ± 50 rpm

Air filter sponge, impregnated with mixture (50% petrol and

50% oil)

Starting system electric starter

Lubrication with lobe pump (inside the crankcase) chain-driv-

en and double filter: mesh and paper

Fuel supply petrol, with vacuum pump and through carburettor

MAX. power 10.5 to 9500 rpm

MAX torque 12 Nm at 8,000 rpm

CHAR - 4

Vespa GTV 125 Characteristics

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque

server, V belt, automatic clutch, gear reduction unit

and transmission housing with forced air circula-

tion cooling

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil ~ 1000 cm³

Fuel tank (including a ~ 2 l reserve) ~ 9.5 l

Rear hub 150 cm³

Cooling system fluid ~ 2.100 ÷ 2.150 l

Electrical system

Specification Desc./Quantity

Type of ignition Electronic capacitive discharge ignition, with vari-

Variable ignition advance (before TDC)

Spark plug Champion RG 4 HC

Battery Sealed, 12 V / 10 Ah

Generator alternating current

Frame and suspensions

Specification Desc./Quantity

Type Unitised body made of stamped plate

Front suspension Single arm suspension (cantilever wheel) fitted

Front shock absorber axial travel 86.5 mm

Rear suspension Engine with swinging fork attached to frame by

Rear shock absorber axial travel 89.5 mm

ELECTRICAL COMPONENTS

able timing and separate HV coil

10° ± 1° at 2000 rpm

FRAME AND SUSPENSIONS

with a double-acting hydraulic shock absorber with

coaxial spring

means of an arm with 2 degrees of freedom Pair

of double-acting hydraulic shock absorbers and

coaxial springs with preloading adjustment in 4

positions.

CHAR - 5

Characteristics Vespa GTV 125

Brakes

BRAKES

Specification Desc./Quantity

Front Ø 220 disc brake and floating calliper with Ø 25

mm twin plungers and hydraulic control (lever on

the far right end of the handlebar)

Rear Ø 220 disc brake and calliper with two Ø 30 mm

counteracting plungers and hydraulic control (lev-

er on the far left end of the handlebar)

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheels - light alloy rims 3.00x12

Rear wheels - light alloy rims 3.00x12

Front tyres 120/70-12" Tubeless

Rear tyres 130/70-12" Tubeless

TYRE PRESSURE

Specification Desc./Quantity

Front tyre pressure (when cold) 1.8 bar

Rear tyre pressure (when cold) 2 bar

Tyre pressure (when cold) with passenger 2.2 bar

N.B.

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

Carburettor

125cc Version

Kehin

CARBURETTOR KEIHIN

Specification Desc./Quantity

Depression carburettor CVEK-30

Body stamping CVEK

CUT-OFF device Not present

Max. jet 98

Minimum jet 38

Max.air jet 150

Minimum air jet 130

Throttle valve spring 100 ÷ 160 g

Minimum mixture set screw initial opening 2 ± ¼

Tapered pin NDVA

Tapered pin notches from top Single-notch pin

Diffuser nozzle Ø 5.0

CHAR - 6

Vespa GTV 125 Characteristics

Specification Desc./Quantity

Petrol inlet hole -

Starter air jet Ø 1.5

Starter diffuser nozzle -

Starter jet 42

Diameter of starter pin -

Starter device resistance ~ 20 Ω

Venturi diffuser Ø 29 (47x30.9)

Throttle valve Ø 30.5

Diffuser maximum cone -

N.B.

* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.

Tightening Torques

STEERING ASSEMBLY

Name Torque in Nm

Upper steering ring nut 30 ÷ 40 Lower steering ring nut 8 ÷ 10

Handlebar fixing screw 45 ÷ 50 (The two screws must be tightened to the

prescribed torque after having done so with the

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

ery Operations» )

Fixing screws for handlebar control assembly U-

bolts

7 ÷ 10

FRAME ASSEMBLY

Name Torque in Nm

Engine-swinging arm bolt 64 - 72

swinging arm bolt - body shell 76 ÷ 83

Engine and vehicle side swinging arm junction bolt 33 ÷ 41

Bolt of the Silent block support plate 42 ÷ 52

Centre stand bolt 25 - 30

Side stand fixing bolt 40 ÷ 45

FRONT SUSPENSION

Name Torque in Nm

Screw fixing the shock absorber to the shock ab-

sorber - calliper attachment plate

Wheel axle nut 75 ÷ 90

Wheel screw 20 ÷ 25

Screw fixing rear mudguard to steering 5 ÷ 6.5

20 ÷ 27

FRONT BRAKE

Name Torque in Nm

Brake fluid pump - hose fitting 20 ÷ 25 Brake fluid hose-calliper fitting 20 ÷ 25

Screw fixing calliper to the shock absorber - cal-

liper plate attachment Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium

Oil bleed screw 12 - 16

Pad fastening pin 19.6 ÷ 24.5

20 ÷ 25

strength)

CHAR - 7

Characteristics Vespa GTV 125

Name Torque in Nm

Brake pump reservoir screws 15 ÷ 20

REAR SUSPENSION

Name Torque in Nm

Retainer for left shock absorber to crankcase sup-

port plate

Shock absorber upper fitting 20 ÷ 25

Shock absorber lower fitting 33 ÷ 41

Rear wheel shaft 104 ÷ 126

Screw fixing wheel to hub 20 ÷ 25

Screws for muffler - shock absorber support arm

on engine

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

prescribed torque after having done so with the

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

20 ÷ 25

ery 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 15 ÷ 20

Calliper coupling screws 30 ÷ 33

MUFFLER

Name Torque in Nm

Muffler heat guard clamping screw 5 - 6

Exhaust fumes inlet screw 13 ÷ 15

Screw for fixing muffler to the support arm 20 ÷ 25

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 8 ÷ 10

Oil pump cover screws 7 ÷ 9

Screws fixing oil pump to the crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name Torque in Nm

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts for head fastening to the cylinder 7± 1 + 180° (2x90°) (Fasten nuts in two crossed

passes) (Before fitting the nuts, lubricate them with

engine oil.)

Head fixing side screws 11 ÷ 13

CHAR - 8

Vespa GTV 125 Characteristics

Name Torque in Nm

Starter ground screw 7 ÷ 8.5

M5 side screw locking washers on camshaft 7 ÷ 8.5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Timing chain tensioner slider screw 10 ÷ 14

M6 central screw locking washers on camshaft 11 ÷ 15

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 4 ÷ 6

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch assembly nut on driven pulley 55 ÷ 60

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 fixing screws 5 - 6

Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength

threadlock)

Flywheel nut 52 ÷ 58

Pick-Up clamping screws 3 ÷ 4

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmis-

sion-side half shaft) screws

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength

threadlock)

COOLING

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

Screws of the water pump rotor driving link 3 ÷ 4

Thermostat cover screws 3 ÷ 4

4 ÷ 6

Overhaul data

Assembly clearances

CHAR - 9

Characteristics Vespa GTV 125

Cylinder - piston assy.

ENGINE COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059 Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059

Cylinder 1st Over-

size

Cylinder 1st Over-

size

Piston 1st Over-

size

Piston 1st Over-

size

Cylinder 2nd Over-

size

Cylinder 2nd Over-

size

Piston 2nd Over-

size

Piston 2nd Over-

size

Cylinder 3rd Over-

size

Cylinder 3rd Over-

size

Piston 3rd Over-

size

Piston 3rd Over-

size

A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059 B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059 C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059 D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059

A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059 B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059 C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059 D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059 A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059 B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059 C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059 D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

CHAR - 10

Vespa GTV 125 Characteristics

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000

car.)

Crankshaft Crankshaft to crankcase

axial clearance

Crankshaft to crankcase axial clearance

Indirizzo Immagine

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

Flywheel-side half-

shaft

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

16.6 +0-0.05 A D = 0.20 - 0.50

16.6 +0-0.05 B D = 0.20 - 0.50

CHAR - 11

Characteristics Vespa GTV 125

Slot packing system

Characteristic

Compression ratio

12 ± 0.5: 1

Measurement "A" to be taken is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the bigger the base gasket to be used (to recover the compression ratio) and vice versa.

N.B.

DISTANCE "A" MUST BE MEASURED WITHOUT ANY GASKET FITTED BETWEEN CRANKCASE AND CYLINDER

SHIMMING

Name Measure A Thickness

Shimming 2.2 ÷ 2.4 0.4 ± 0.05 Shimming 2.4 ÷ 2.6 0.6 ± 0.05

Oversizes

CHAR - 12

Vespa GTV 125 Characteristics

ENGINE OVERSIZES

Name Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 ÷ 0.30

Oil scraper ring 57 x 1 A 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35

Compression ring

1st oversize

Oil scraper ring 1st

Oversize

Oil scraper ring 1st

Oversize

Compression ring

2nd Oversize

Oil scraper ring

2nd Oversize

Oil scraper ring

2nd Oversize

Compression ring

3rd Oversize

Oil scraper ring 3rd

Oversize

Oil scraper ring 3rd

Oversize

57.2 x 1 A 0.15 ÷ 0.30

57.2 x 1 A 0.10 ÷ 0.30

57.2 x 2.5 A 0.15 ÷ 0.35

57.4 x 1 A 0.15 ÷ 0.30

57.4 x 1 A 0.10 ÷ 0.30

57.4 x 2.5 A 0.15 ÷ 0.35

57.6 x 1 A 0.15 ÷ 0.30

57.6 x 1 A

57.6 x 2.5 A 0.15 ÷ 0.35

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