SERVICE STATION MANUAL Vespa GTS Super 125 ie

SERVICE STATION MANUAL Vespa GTS Super 125 ie
SERVICE STATION MANUAL
677714 EN
Vespa GTS Super 125 i.e.
SERVICE STATION
MANUAL
Vespa GTS Super 125 i.e.
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. 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 each
model should be checked at the official PIAGGIO sales network.
© Copyright 2013 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
Vespa GTS Super 125 i.e.
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio 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.
INDEX OF TOPICS
CHARACTERISTICS
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
INJECTION
INJEC
SUSPENSIONS
SUSP
BRAKING SYSTEM
BRAK SYS
COOLING SYSTEM
COOL SYS
CHASSIS
PRE-DELIVERY
TIME
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Vespa GTS Super 125 i.e.
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 well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid 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.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Vespa GTS Super 125 i.e.
Characteristics
Vehicle identification
Chassis prefix: ZAPM45100000 ÷ 1001
Engine prefix: M451M ÷ 1001
Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification
Kerb weight
Maximum weight allowed
Maximum height
Overall width
Maximum length
Wheelbase
CHAR - 8
Desc./Quantity
158 ± 5 kg
340 kg
1170 mm
755 mm
1930 mm
1370 mm
Vespa GTS Super 125 i.e.
Characteristics
Engine
DATA
Specification
Type
Cubic capacity
Bore x stroke
Max. power
MAX. torque
Timing system
Desc./Quantity
single-cylinder, four-stroke and four liquid-cooled valves
124 cm³
57 x 48.6 mm
11 kW at 9750 rpm
12 Nm at 7500 rpm
single overhead camshaft, chain-driven, on the left-hand side,
three-arm rocking levers set up with threaded set screw
12 ± 0.5: 1
1,750 ± 50 rpm
sponge, impregnated with mixture (50% petrol and 50% oil)
electric starter motor with freewheel
with lobe pump (inside the crankcase) chain-driven and double
filter: mesh and paper
Electronic injection with electric fuel pump
intake: 0.10 mm - exhaust: 0.15 mm
0.8 bar
3.5 to 4 bar
Forced-circulation coolant system.
Compression ratio
Engine idle speed
Air filter
Starting system
Lubrication
Fuel system
valve clearance
Minimum lubrication pressure (100° C)
Lubrication pressure
Cooling
OIL PUMP
Specification
Type
Distance between the rotors
Axial rotor clearance
Distance between the outer rotor and the pump body
Levelness
Desc./Quantity
Trochoidal
Admissible limit clearance: 0.12 mm
Limit values admitted: 0.09 mm
Admissible limit clearance: 0.20 mm
0.1 mm
BY-PASS
Specification
Type
Plunger diameter
By-pass check up: Standard length
Calibration pressure
Desc./Quantity
With piston
Ø 13.9 - 0.039 -0.057 mm
54.2 mm
4.5 bar
OIL FILTER
Specification
Type
Desc./Quantity
Paper with pressure relief and anti-drain back by-pass valves
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH
Specification
Calibration
Desc./Quantity
0.3 - 0.6 bar
HEAD LUBRICATION CONTROL JET
Specification
Diameter
Desc./Quantity
1 ± 0.05 mm *
* Tightening torque 5÷7 N·m
COOLING SYSTEM
Specification
Cooling system capacity
Recommended fluid
Sealing pressure
Desc./Quantity
~ 2.100 ÷ 2.150 l
AGIP PERMANENT SPEZIAL
Cap calibrated at 0.9 bar
THERMOSTAT
Specification
Type
Desc./Quantity
Wax-type, with deviator
CHAR - 9
Vespa GTS Super 125 i.e.
Characteristics
Specification
Starts opening at
Desc./Quantity
85±2°C
ELECTRIC VENTILATION
Specification
Electric ventilation starts at
Electric ventilation stops at
Desc./Quantity
102°C
96°C
RADIATOR
Specification
Type
Desc./Quantity
Made of aluminium in two sections
WATER PUMP
Specification
Type
Control
Desc./Quantity
Centrifugal
Electric
Transmission
TRANSMISSION
Specification
Transmission
Desc./Quantity
Automatic expandable pulley CVT with torque server, V-belt,
automatic clutch, gear reduction unit and transmission compartment with forced air circulation cooling
Capacities
CAPACITY
Specification
Fuel tank (including a ~ 2 l reserve)
Cooling system fluid
Engine oil
Rear hub
Desc./Quantity
~ 9.2 l
~ 2.100 ÷ 2.150 l
approx. 1300 cc
250 cc
Electrical system
ELECTRICAL COMPONENTS
Specification
Ignition/advance
Spark plug
Battery
Fuses
Alternator
Desc./Quantity
Electronic, with inductive discharge and variable advance with
three-dimensional mapping
NGK CR8EKB
12V-12Ah
1 of 30A - 2 of 15A - 4 of 7.5A
alternating current
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELECTRICAL COMPONENTS
Specification
Ignition/advance
Spark plug
Battery
Fuses
Alternator
CHAR - 10
Desc./Quantity
Electronic, with inductive discharge and variable advance with
three-dimensional mapping
NGK CR8EKB
Sealed, 12 V / 10 Ah
1 of 30A - 1 of 15A - 5 of 7.5A
alternating current
Vespa GTS Super 125 i.e.
Characteristics
CHECKING RELAYS «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 relay.
3) With the relay powered, check that there is continuity between terminals 30 and 87.
4) If these conditions are not fulfilled, the relay 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
LIGHT SWITCH
STARTER BUTTON
IGNITION SWITCH
FUEL INJECTOR
Type: 3 holes
Conicity of the nozzle: 20°
Resistance at terminals: 13.7 - 15.2 Ohm
CHAR - 12
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
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
SPEED/PHASE SENSOR
Resistance between the pins: 100 to 150 Ohm at
approx. 20°
ENGINE TEMPERATURE SENSOR
0° = 5,900 Ohm
+10° = 3,800 Ohm
+20° = 2,500 Ohm
+30° = 1,700 Ohm
+80° = 300 Ohm
MINIMUM OIL PRESSURE SENSOR
Normally closed switch
Activation threshold: 0.3 - 0.6 BAR
With the engine off: continuity between muffler and
ground
HV COIL
<DIV class=O v:shape="_x0000_s3074">
- Resistance of the primary = 0.5 Ohm ± 8%
- Resistance between primary and ground = infinite
- Resistance between primary and H.V. output = 3.1KOhm ± 9%
CHAR - 13
Vespa GTS Super 125 i.e.
Characteristics
STATOR
Power: 450 W
Resistance between terminals: 0.2 - 1 Ohm
terminal insulation from ground
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification
Type
Front suspension
Front shock absorber axial travel
Rear suspension
Rear shock absorber axial travel
Desc./Quantity
Unitised body made of stamped plate
Single arm suspension (cantilever wheel) fitted with a doubleacting hydraulic shock absorber with coaxial spring
86.5 mm
Engine with swinging fork articulated to frame by means of an
arm with 2 degrees of freedom Pair of double-acting hydraulic
shock absorbers and coaxial springs with preloading adjustment in 4 positions.
89.5 mm
Brakes
BRAKES
Specification
Front
Rear
CHAR - 14
Desc./Quantity
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)
Ø 220 disc brake and calliper with two Ø 30 mm counteracting
plungers and hydraulic control (lever on the far left end of the
handlebar)
Vespa GTS Super 125 i.e.
Characteristics
Wheels and tyres
WHEELS AND TYRES
Specification
Front wheels - light alloy rims
Rear wheels - light alloy rims
Front tyres
Rear tyres
Desc./Quantity
3.00x12
3.00x12
120/70-12" Tubeless
130/70-12" Tubeless
TYRE PRESSURE
Specification
Front tyre pressure (when cold)
Rear tyre pressure (when cold)
Tyre pressure (when cold) with passenger
Desc./Quantity
1.8 bar
2 bar
2.2 bar
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES
Tightening Torques
STEERING ASSEMBLY
Name
Upper steering ring nut
Lower steering ring nut
Handlebar fixing screw
Fixing screws for the handlebar control unit U-bolts
Torque in Nm
35 - 40
12 - 14
50 ÷ 55
7 to 10
CHASSIS ASSEMBLY
Name
Engine-swinging arm pin
swinging arm bolt - body shell
Engine and vehicle side swinging arm junction bolt
Bolt of the Silent block support plate
Centre stand bolt
Side stand fixing bolt
Torque in Nm
64 - 72
76 ÷ 83
33 to 41
42 ÷ 52
32 to 40
35 to 40
FRONT SUSPENSION
Name
Screw fixing the shock absorber to the shock absorber - calliper
attachment plate
Wheel axle nut
Wheel screw
Screw fixing rear mudguard to steering
shock absorber upper clamp
Torque in Nm
20 to 27
74 - 88
20 to 25
5 to 6.5
20 to 30
FRONT BRAKE
Name
Brake fluid pump-hose fitting
Brake fluid pipe-calliper fitting
Screw fixing calliper to the shock absorber - calliper plate attachment
Disc tightening screw
Oil bleed screw
Pad fastening pin
Brake pump reservoir screws
Brake disc screws
Torque in Nm
20 to 25
19 ÷ 24
24 to 27
6 (Apply LOCTITE 242 threadlock, medium strength)
12 - 16
19.6 ÷ 24.5
1.5 ÷ 2
8 ÷ 10
CHAR - 15
Vespa GTS Super 125 i.e.
Characteristics
REAR SUSPENSION
Name
Retainer for left shock absorber to crankcase support plate
Shock absorber lower fitting
Shock absorber upper fitting
Rear wheel axle
Screw fixing wheel to hub
Screws for silencer - shock absorber support arm on engine
Engine- and vehicle-side swinging arm junction bolt
Torque in Nm
20 to 25
40 ÷ 45
20 to 25
104 to 126
20 to 25
20 ÷ 25 (The two screws must be tightened after having done
so with the rear wheel axle nut at the specified torque. Safety
fasteners: see «Pre-delivery Operations»)
40 ÷ 45
REAR BRAKE
Name
Brake fluid pump-hose joint
Brake fluid pipe-calliper fitting
Rear disc tightening bolt
Oil bleed screw
Calliper to engine tightening screw
Brake pump reservoir screws
Calliper coupling screw
Torque in Nm
20 - 25
20 ÷ 25
11 to 13
12÷16
20 to 25
1.5 ÷ 2
30 ÷ 33
SILENCER
Name
Silencer heat guard fixing screw
Screw for fixing silencer to supporting arm
Lambda probe tightening on exhaust manifold
Exhaust manifold-silencer joint tightening
Manifold - silencer diaphragm tightening clamp
Torque in Nm
4 to 5
20 ÷ 25
40 - 50
12 to 13
16 to 18
LUBRICATION
Name
Hub oil drainage plug
Oil filter on crankcase fitting
Engine oil drainage plug/ mesh filter
Oil filter
Oil pump cover screws
Screws fixing oil pump to the crankcase
Oil pump command crown screw
Oil pump cover plate screws
Oil sump screws
Minimum oil pressure sensor
Torque in Nm
15 to 17
27 ÷ 33
24 ÷ 30
4÷6
7 to 9
5-6
10 ÷ 14
4÷6
10 ÷ 14
12 ÷ 14
CYLINDER HEAD
Name
Spark plug
Head cover screws
Nuts fixing head to cylinder
Head fixing side screws
Starter ground screw
Tappet adjustment check nut
Intake manifold screws
Timing chain tensioner slider screw
Starter counterweight support screw
Timing chain tensioner support screw
Timing chain tensioner central screw
Camshaft retention plate screw
Torque in Nm
12 ÷ 14
6÷7
7±1 + 10±1 + 270°
11 - 12
7 ÷ 8.5
6-8
11 ÷ 13
10 ÷ 14
11 to 15
11 ÷ 13
5÷6
4÷6
TRANSMISSION
Name
Belt support roller screw
Clutch unit nut on driven pulley
CHAR - 16
Torque in Nm
11 ÷ 13
45 ÷ 50
Vespa GTS Super 125 i.e.
Characteristics
Name
Drive pulley nut
Transmission cover screws
Driven pulley shaft nut
Rear hub cap screws
Torque in Nm
75 ÷ 83
11 ÷ 13
54 ÷ 60
24 ÷ 27
FLYWHEEL
Name
Flywheel cover screw
Stator assembly screws
Flywheel nut
Pickup fixing screws
Screw fixing freewheel to flywheel
Torque in Nm
11 ÷ 13
3 - 4 (Apply LOCTITE medium type 242 threadlock)
94 - 102
3÷4
13 - 15
CRANKCASE AND CRANKSHAFT
Name
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
Engine-crankcase coupling screws
Starter motor screws
Crankcase timing cover screws
Torque in Nm
4÷6
11 ÷ 13
11 - 13
3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)
COOLING
Name
Water pump rotor cover
Thermostat cover screws
Bleed screw
Torque in Nm
3÷4
3÷4
3
Overhaul data
Assembly clearances
Cylinder - piston assy.
- Calculate the coupling clearance between pin
and connecting rod small end.
Characteristic
Standard diameter:
Ø 14.996 - 15.0 mm
Standard clearance:
0.015 - 0.029 mm
CHAR - 17
Characteristics
Vespa GTS Super 125 i.e.
- Measure the diameter of the bearings on the piston.
Characteristic
Standard diameter:
15 +0.006 + 0.001mm
- 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
- Check that coating is free from flakes.
- Check that the head coupling surface is not worn
or misshapen.
Characteristic
Maximum allowable run-out:
0.001 over 0.05 mm
- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried
out in pairs (A-A, B-B, C-C, D-D).
CHAR - 18
Vespa GTS Super 125 i.e.
Characteristics
*Fit rings «2» and «3» with the word «TOP» facing upwards.
** Position the port of the rings as shown here.
*** Value «A» of the sealing ring inside the cylinder (fitting clearance).
Check the size of the sealing ring opening:
Compression ring 0.15 - 0.30 mm. Max. value 0.5 mm
Oil scraper ring 0.10 - 0.30 mm. Max. value 0.65 mm
Oil scraper ring 0.15 - 0.35 mm. Max. value 0.65 mm
N.B.
FITTING CLEARANCE VALUES ARE THE SAME FOR BOTH THE STANDARD SEALING RINGS
AND THE OVERSIZES.
CHAR - 19
Vespa GTS Super 125 i.e.
Characteristics
ENGINE COUPLING CATEGORIES
Name
Cylinder
Cylinder
Piston
Piston
Cylinder 1st Oversize
Cylinder 1st Oversize
Piston 1st Oversize
Piston 1st Oversize
Cylinder 2nd Oversize
Cylinder 2nd Oversize
Piston 2nd Oversize
Piston 2nd Oversize
Cylinder 3rd Oversize
Cylinder 3rd Oversize
Piston 3rd Oversize
Piston 3rd Oversize
Initials
A
B
C
D
A1
B1
C1
D1
A2
B2
C2
D2
A3
B3
C3
D3
Cylinder
56.997 to 57.004
57.004 to 57.011
57.011 to 57.018
57.018 to 57.025
57.197 to 57.204
57.204 to 57.211
57.211 to 57.218
57.218 to 57.225
57.397 to 57.404
57.404 to 57.411
57.411 to 57.418
57.418 to 57.425
57.597 to 57.604
57.604 to 57.611
57.611 to 57.618
57.618 to 57.625
Piston
56.945 - 56.952
56.952 - 56.959
56.959 - 56.966
56.966 - 56.973
57.145 - 57.152
57.152 - 57.159
57.159 - 57.166
57.166 - 57.173
57.345 - 57.352
57.352 - 57.359
57.359 - 57.366
57.366 - 57.373
57.545 - 57.552
57.552 - 57.559
57.559 - 57.566
57.566 - 57.573
Play on fitting
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
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.
CHAR - 20
Vespa GTS Super 125 i.e.
Characteristics
Crankcase - crankshaft - connecting rod
- Measure the diameter of bushings «A» in the
three directions shown in the figure.
- Measure the diameter of the crankshaft bearings
«B».
- Check that the diametral clearance «A-B» is between the pre-set interval.
Characteristic
Diameter clearance
0.023 - 0.041 mm
If value «A-B» is above the limit, check that value «B» is within the admissible values of the categories.
CRANKSHAFT
Specification
Category 1
Category 2
Desc./Quantity
28.998 to 29.004
29.004 to 29.010
If the crankshaft is within the set limits, replace the crankshaft half-bearings mounting the crankcase
so as to suit the specified couplings. The crankcase halves can be mounted with four types of crankshaft
half-bearings identified by letters- B (blue), C (yellow), E (green).
CRANKCASE
Specification
Category 1
Category 2
Desc./Quantity
32.959 - 35.965
32.953 to 32.959
CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGS
Specification
Crankshaft category 1 - Crankcase category 1
Crankshaft category 2 - Crankcase category 1
Crankshaft category 1 - Crankcase category 2
Crankshaft category 2 - Crankcase category 2
Desc./Quantity
E+E
C+C
C+C
B+B
CHAR - 21
Vespa GTS Super 125 i.e.
Characteristics
Characteristic
Axial crankshaft/crankcase clearance:
0.5 - 0.40 mm
CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
Name
Half-shaft, transmission
side
Flywheel-side half shaft
Connecting rod
Spacer tool
CHAR - 22
Description
Dimensions
16.6 +0-0.05
Initials
A
Quantity
D = 0.20 - 0.50
16.6 +0-0.05
18 -0.10 -0.15
51.4 +0.05
B
C
E
D = 0.20 - 0.50
D = 0.20 ÷ 0.50
D = 0.20 ÷ 0.50
Vespa GTS Super 125 i.e.
Characteristics
THE CRANKSHAFT is available in two CATEGORIES:
Characteristic
Crankshaft category:
CAT. 1 - CAT. 2
CRANKSHAFT CATEGORY IDENTIFICATION:
The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the
package with a drawing number plus FC1/FC2 or (001/002).
If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both
crankcase halves, combining the two components (Shaft and Crankcase) featuring the same category.
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 gauge check that
the cylinder head surface is not worn or distorted.
Characteristic
Maximum allowable run-out
0.09 mm
- In case of faults, replace the head.
- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocking lever pin capacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant seal plug exhibits no oxidation.
CHAR - 23
Vespa GTS Super 125 i.e.
Characteristics
- 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"
Bearing "B"
Bearing "C"
Desc./Quantity
37 +0.025
20 +0.021
12 +0.018
- Measure the unloaded spring length.
Characteristic
Standard length
40.5 mm
Allowable limit after use:
39.7 mm
- Clean the valve seats of any carbon residues.
- Using the Prussian blue, check the width of the
impression on the valve seat "V".
Characteristic
Admissible limit:
1.6 mm
- If the width of the impression on the valve seat exceeds the specified limits, replace the cylinder head.
CHAR - 24
Vespa GTS Super 125 i.e.
Characteristics
- In case of excessive wear or damage, replace the head.
STANDARD VALVE LENGTH
Specification
Intake
Exhaust
Desc./Quantity
84.5 mm
94.5 mm
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification
Intake:
Exhaust:
Desc./Quantity
4.987 - 4.972 mm
4.975 - 4.960 mm
MINIMUM ADMISSIBLE DIAMETER
Specification
Intake:
Exhaust:
Desc./Quantity
4.96 mm
4.945 mm
- Calculate the clearance between the valve and
the valve guide.
- Check the deviation of the valve stem by resting
it on a «V» shaped support and measuring the extent of the deformation using a dial gauge.
Characteristic
Limit values admitted:
0.1 mm
CHAR - 25
Vespa GTS Super 125 i.e.
Characteristics
- Check the concentricity of the valve head by
placing a dial gauge at right angles to the valve
head and rotating it on the «V» shaped support.
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 clearance between
guide and stem.
EXHAUST
Specification
Standard clearance:
Admissible limit:
Desc./Quantity
0.025 to 0.052 mm
0.09 mm
INTAKE
Specification
Standard clearance:
Admissible limit:
Desc./Quantity
0.013 - 0.04 mm
0.08 mm
- Check that there are no signs of wear on the mating surface with the set screw articulated terminal.
CHAR - 26
Vespa GTS Super 125 i.e.
Characteristics
- If no anomalies are found during the above
checks, 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 MATING SURFACE, DO NOT ROTATE 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
Bearing A Ø:
Bearing B diameter:
Desc./Quantity
37 - 0.025 -0.050 mm
19 - 0.020 -0.041 mm
MINIMUM ADMISSIBLE DIAMETER
Specification
Bearing A Ø:
Bearing B diameter:
Desc./Quantity
36.940 mm
19.950 mm
CHAR - 27
Vespa GTS Super 125 i.e.
Characteristics
- Using a gauge, measure the height of the cams.
STANDARD HEIGHT
Specification
intake
Exhaust
Desc./Quantity
17.382 mm
16.563 mm
ADMISSIBLE LIMITS
Specification
intake
Exhaust
standard axial clearance
maximum admissible axial clearance
- Check that the rocking lever pins exhibit no scores or wear.
Characteristic
Standard diameter
Diameter 11.977 - 11.985 mm
- Measure the inside diameter of each rocker.
Characteristic
Standard diameter
Ø 12 +0.011 mm
CHAR - 28
Desc./Quantity
17.130 mm
16.310 mm
0.11 - 0.41 mm
0.42 mm
Vespa GTS Super 125 i.e.
Characteristics
- Check that the cam contact sliding block and the
articulated register cap is free from wear.
- In case of wear, replace the component.
Slot packing system
Characteristic
Compression ratio
Cr: 11.50 - 13:1
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 thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
CHAR - 29
Vespa GTS Super 125 i.e.
Characteristics
MODELS WITH METAL HEAD GASKET (0.3)
Name
Shimming 125 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.6
Shimming 125 - Cylinder 67.8 - Head
gasket 0.3 - Base gasket 0.8
Measure A
1.40 - 1.60
Thickness
0.60 ± 0.05
1.60 - 1.80
0.80 ± 0.05
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP GEAR SAE 80W-90
eni i-Ride PG 5W-40
AGIP FILTER OIL
AGIP GP 330
eni i-Ride PG 5W-40
AGIP BRAKE 4
AGIP PERMANENT SPEZIAL
AGIP GREASE PV2
CHAR - 30
Description
Lubricant for gearboxes and transmissions.
Synthetic based lubricant for high-performance four-stroke engines.
Special product for the treatment of foam
filters.
Water repellent stringy calcium spray
grease.
Synthetic based lubricant for high-performance four-stroke engines.
Brake fluid.
Ethylene glycol-based antifreeze fluid
with organic inhibition additives. Red,
ready to use.
Ivory smooth-textured, slightly-stringy
anhydrous calcium-base grease.
Specifications
API GL-4
JASO MA, MA2 - API SL - ACEA A3
R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 I.A.T.A. 2 - I.M.D.G. class 2 UN 1950
Page 9022 EM 25-89
JASO MA, MA2 - API SL - ACEA A3
Synthetic fluid SAE J 1703 -FMVSS 116
- DOT 3/4 - ISO 4925 - CUNA NC 956
DOT 4
ASTM D 3306 - ASTM D 4656 - ASTM D
4985 - CUNA NC 956-16
TL 9150 066, NATO G 460 symbol
INDEX OF TOPICS
TOOLING
TOOL
Vespa GTS Super 125 i.e.
Tooling
SPECIFIC TOOLS
TOOL - 32
Stores code
001330Y
Description
Tool for fitting steering seats
001467Y017
Bell for bearings, OD 39 mm
001467Y014
Calliper to extract ø 15-mm bearings
005095Y
Engine support
002465Y
Calliper for circlips
006029Y
Punch for fitting steering bearing seat on
steering tube
020004Y
Punch for removing steering bearings
from headstock
Vespa GTS Super 125 i.e.
Tooling
Stores code
020021Y
Description
Front suspension service tool
020036Y
Punch
020038Y
Punch
020055Y
Wrench for steering tube ring nut
020074Y
Support base for checking crankshaft
alignment
020150Y
Air heater mounting
TOOL - 33
Vespa GTS Super 125 i.e.
Tooling
TOOL - 34
Stores code
020151Y
Description
Air heater
020193Y
Oil pressure check gauge
020262Y
Crankcase splitting plate
020263Y
Driven pulley assembly sheath
020306Y
Punch for assembling valve seal rings
020329Y
Mity-Vac vacuum-operated pump
Vespa GTS Super 125 i.e.
Tooling
Stores code
020330Y
Description
Stroboscopic light to check timing
020331Y
Digital multimeter
020332Y
Digital rpm indicator
020648Y
Single battery charger
TOOL - 35
Vespa GTS Super 125 i.e.
Tooling
TOOL - 36
Stores code
020335Y
Description
Magnetic mounting for dial gauge
020357Y
020359Y
32 x 35-mm Adaptor
42 x 47-mm Adaptor
020360Y
52 x 55-mm Adaptor
020363Y
20-mm guide
020364Y
25-mm guide
Vespa GTS Super 125 i.e.
Tooling
Stores code
020365Y
Description
22 mm guide
020375Y
28 x 30 mm adaptor
020376Y
Adaptor handle
020382Y
Valve cotters equipped with part 012 removal tool
020382Y011
adapter for valve removal tool
020393Y
Piston assembly band
TOOL - 37
Vespa GTS Super 125 i.e.
Tooling
TOOL - 38
Stores code
020412Y
Description
15-mm guide
020423Y
Driven pulley lock wrench
020424Y
Driven pulley roller casing fitting punch
020426Y
Piston fitting fork
020431Y
Valve oil seal extractor
020434Y
Oil pressure check fitting
Vespa GTS Super 125 i.e.
Tooling
Stores code
020441Y
Description
26 x 28 mm adaptor
020444Y
Tool for fitting/ removing the driven pulley
clutch
020456Y
020477Y
Ø 24 mm adaptor
37 mm adaptor
020483Y
30-mm guide
020489Y
Hub cover support stud bolt kit
TOOL - 39
Vespa GTS Super 125 i.e.
Tooling
TOOL - 40
Stores code
020428Y
Description
Piston position check mounting
020922Y
020621Y
Diagnosis Tool
HV cable extraction adaptor
020481Y
Control unit interface wiring
001467Y035
Bearing housing, outside ø 47 mm
020626Y
Driving pulley lock wrench
001467Y013
Calliper to extract ø 15-mm bearings
Vespa GTS Super 125 i.e.
Tooling
Stores code
020627Y
Description
Flywheel lock wrench
020467Y
Flywheel extractor
020454Y
Tool for fitting piston pin stops (200 - 250)
020622Y
Transmission-side oil seal punch
020480Y
Petrol pressure check kit
020244Y
15-mm diameter punch
TOOL - 41
Vespa GTS Super 125 i.e.
Tooling
TOOL - 42
Stores code
020115Y
Description
Ø 18 punch
020271Y
Tool for removing-fitting silent bloc
INDEX OF TOPICS
MAINTENANCE
MAIN
Vespa GTS Super 125 i.e.
Maintenance
Maintenance chart
SCHEDULED MAINTENANCE TABLE
I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Replace every 2 years
Km x 1,000
Roller bearing - Driven pulley
Safety fasteners
Spark plug
Drive belt
Throttle control
Air filter
Oil filter
CVT Filter
Valve clearance
Electrical system and battery
Brake levers
Brake fluid *
Coolant *
Engine oil
Hub oil
Headlight direction adjustment
Brake pads
Sliding shoes / CVT rollers
Tyre pressure and wear
Vehicle road test
Radiator (external cleaning)
Suspension
Steering
Transmission
Operation Time
1
I
A
R
I
L
I
I
R
R
I
I
I
I
I
R
I
I
I
A
I
A
60' 10'
- Rest the scooter on its stand
- Open the saddle and take out the helmet compartment
- Disconnect the spark plug HV wire cap;
- Unscrew the spark plug using the wrench supplied;
- Check the conditions of the spark plug, make
sure the insulation is intact, that the electrodes are
not excessively worn or sooty, the conditions of the
washer, and measure the distance between the
electrodes using the appropriate feeler thickness
gauge.
-Adjust the distance, if necessary, by bending the
MAIN - 44
I
10
L
I
R
I
A
C
R
C
A
I
L
I
I
R
I
15
R
I
A
I
20
L
25
R
I
A
C
R
C
I
L
I
I
R
R
I
R
I
I
I
I
I
Spark plug
side electrode very carefully. In case of anomaly
5
10
0'
I
A
L
45'
15
0'
10'
30
L
I
R
R
A
C
R
C
A
I
L
I
I
R
I
A
I
R
I
I
I
I
A
L
14
0'
35
40
L
R
I
A
C
R
C
I
I
I
L
I
I
R
R
I
R
I
I
45
R
I
A
I
50
L
I
R
I
A
C
R
C
A
I
L
I
I
R
I
55
I
R
I
I
I
I
I
I
A
10'
15
0'
I
A
L
45'
10
0'
10'
60
L
I
R
R
A
C
R
C
I
L
I
I
R
R
A
I
R
I
I
I
I
A
L
19
0'
Vespa GTS Super 125 i.e.
Maintenance
(as described before), replace the spark plug with
another of the recommended type;
- Fit the spark plug with the correct inclination and
manually screw it all the way down, then use the
special spanner to tighten it.
- Insert the cap onto the spark plug and proceed
with the reassembly operations.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUST BE REPLACED
EVERY 20,000 KM. THE USE OF NON CONFORMING
ELECTRONIC IGNITION CONTROL UNITS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap
0.7 to 0.8 mm
Electric characteristic
Spark plug
NGK CR8EKB
Locking torques (N*m)
Spark plug 12 ÷ 14
Hub oil
Check
-Place the vehicle on the centre stand on flat
ground;
- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
Remove the dipstick and check that the oil level is
slightly over the second notch starting from the
lower end; if the level is under the MAX. mark, it
needs to be filled with the right amount of hub oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.
MAIN - 45
Maintenance
Replacement
-Remove the oil filler cap «A».
- Unscrew the oil drainage cap «B» and drain out
all the oil.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions.
API GL-4
Characteristic
Rear hub oil
Capacity approximately 250 cc
Locking torques (N*m)
Hub oil drainage screw 15 to 17 Nm
Air filter
Proceed as follows:
1. unscrew the fixing screw «A».
2. unscrew the nut «B» under the body.
3. remove the left side fairing.
4. remove the helmet compartment;
5. unscrew the fixing screws «C» that can be
reached once the helmet compartment has been
removed;
6. Unscrew the screws «D» and remove the air filter cover.
Remove the filtering element and clean it with water and shampoo; then dry it with a clean cloth and
short blasts of compressed air. Finally, immerse it
in a mixture of 50% oil of the recommended type
and 50% petrol. Then gently squeeze the filter element between your hands, allow it to drip and
then refit it. Oil or water deposits in the filter hous-
MAIN - 46
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Maintenance
ing can be cleaned off by removing the two rubber
caps «E».
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF
THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE
ENGINE.
Recommended products
AGIP FILTER OIL Special product for the treatment of foam filters.
-
Engine oil
In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and
the thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should
be considered normal, especially if during the run-in period. Consumption levels in particular can be
influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Replacement
At 1,000 km and after every 10,000 km, the oil and
the filter must be changed. The engine must be
drained by running off the oil from drainage cap
"B" of the flywheel side gauze pre-filter; furthermore to facilitate oil drainage, loosen the cap/
dipstick "A". Once all the oil has drained through
the drainage hole, unscrew the oil cartridge filter
"C" and remove it.
Make sure the pre-filter and drainage plug O-rings
are in good conditions.
Lubricate them and refit the mesh filter and the oil
drainage plug, screwing them up to the prescribed
torque.
MAIN - 47
Maintenance
Vespa GTS Super 125 i.e.
Refit the new cartridge filter being careful to lubricate the O-ring before fitting it.
Change the engine oil.
Since a certain quantity of oil still remains in the
circuit, oil must be filled from cap "A". Then start
up the scooter, leave it running for a few minutes
and switch it off: after five minutes check the level
and if necessary top up without exceeding the
MAX level. The cartridge filter must be replaced
every time the oil is changed. Use new oil of the
recommended type for topping up and changing
purposes.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Recommended products
eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
Check
This operation must be carried out with the engine cold and following the procedure below:
1. Place the vehicle on its centre stand and on flat ground.
2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down completely.
3. Remove the cap/dipstick again and check that the level is between the min and max. marks; topup, if required.
The MAX level mark indicates a quantity of around 1300 cc of engine oil. If the check is carried out after
the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out
a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
Engine oil top-up
The oil should be topped up after having checked
the level and in any case by adding oil without
ever exceeding the MAX. level.
Restoration of the level from MIN to MAX requires
approximately 200 cc.
MAIN - 48
Vespa GTS Super 125 i.e.
Maintenance
Engine oil filter
Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the recommended type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the specified torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
Recommended products
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
Oil pressure warning light
The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to
the «ON» position. However, this light should switch off once the engine has started.
If the light turns on during braking, at idling speed or while turning a corner, it is necessary to
check the oil level and the lubrication system.
Cooling system
Adding engine coolant.
The fluid level must checked every 10,000 kilometres with a cold engine, in the way shown below:
Place the scooter on its centre stand and on flat
ground.
- Undo the screw shown in the figure and remove
the expansion tank cap on RHS.
- Top up if the fluid level is near or below the MIN
level edge. The liquid level must always be between the MIN and MAX level.
MAIN - 49
Maintenance
-The coolant consists of an ethylene glycol and
corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS
TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE VEHICLE IS IN USE.
Braking system
Level check
The brake fluid tanks for the front and rear brakes
are located on the pumps under the handlebar
cover. Proceed as follows:
- Remove the brake pump cover
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the fluid level through the sight glass as
shown in the figure. A certain lowering of the level
is caused by wear on the pads.
Top-up
- Position the vehicle on a flat surface and on the
centre stand
- Remove the brake pump cover as indicated in the
photo
MAIN - 50
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Maintenance
Check the brake fluid level through the sight glass
on the pump as shown in the photograph
- If the level is below the minimum, fill using the two
screws shown in the figure
- Remove the gasket and fill with DOT 4 until the spyglass is completely covered
For refitting purposes carry out the operations in
the reverse order from the removal operation and
respect the tightening torque of the tank cover
screws.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR
EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE.
THEREFORE, WHEN TOPPING UP, AVOID LETTING IT
COME INTO CONTACT WITH THE PAINTED PARTS OF
THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE
SURROUNDING AIR. IF MOISTURE CONTAINED IN THE
BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL
RESULT IN INEFFICIENT BRAKING.
CAUTION
NEVER USE BRAKE FLUID COMING FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC
CONDITIONS, BRAKE FLUID MUST BE CHANGED EVERY
20,000 KM OR ANYWAY EVERY 2 YEARS.
Locking torques (N*m)
Brake pump reservoir screws 15 - 20
MAIN - 51
Maintenance
Headlight adjustment
Proceed as follows:
1. Position the vehicle in running order and with
the tyres inflated to the prescribed pressure, onto
a flat surface 10 m away from a half-lit white
screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen;
2. Turn on the headlight and check that the boundary of the light beam projected onto the screen is
not higher than 9/10 or lower than 7/10 of the distance between the centre of the headlight and the
ground;
3. Otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
MAIN - 52
Vespa GTS Super 125 i.e.
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Vespa GTS Super 125 i.e.
Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.
Engine
Excessive oil consumption/Exhaust smoke
EXCESSIVE CONSUMPTION
Possible Cause
Operation
Wrong valve adjustment
Adjust the valve clearance properly
Overheated valves
Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats
Replace the head unit
Worn cylinder, Worn or broken piston rings
Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been
Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets
Check and replace the gaskets or restore the coupling seal
Worn valve oil guard
Replace the valve oil seal
Worn valve guides
Check and replace the head unit if required
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE
Possible Cause
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Perform the dimensional checks on the oil pump components
Replace the cartridge filter
Restore the level adding the recommended oil type
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Faulty clutch
Operation
Check that there is no grease on the masses. Check that the
clutch mass faying surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch housing is not scored or worn in an anomalous way
Insufficient braking
INEFFICIENT BRAKING SYSTEM
Possible Cause
Inefficient braking system
Fluid leakage in hydraulic braking system
TROUBL - 54
Operation
Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Failing elastic fittings, plunger or brake pump seals, replace
Vespa GTS Super 125 i.e.
Troubleshooting
Possible Cause
Brake disc slack or distorted
Operation
Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle.
Brakes overheating
BRAKE OVERHEAT
Possible Cause
Defective plunger sliding
Brake disc slack or distorted
Clogged compensation holes on the pump
Swollen or stuck rubber gaskets
Operation
Check calliper and replace any damaged part.
Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial deviation
of the disc.
Clean carefully and blast with compressed air
Replace gaskets.
Steering and suspensions
Heavy steering
STEERING HARDENING
Possible Cause
Steering hardening
Operation
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: if they are recessed or if the balls are squashed, replace
them.
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
Torque not conforming
Operation
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flattened.
Noisy suspension
NOISY SUSPENSION
Possible Cause
Faults in the suspension system
Operation
If the front suspension is noisy, check: the efficiency of the front
shock absorber; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers; and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disc in the
attachment to the hub and the steering tube.
TROUBL - 55
Vespa GTS Super 125 i.e.
Troubleshooting
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION
Possible Cause
Faulty or broken seals
TROUBL - 56
Operation
Replace the shock absorber Check the condition of wear of the
steering covers and the adjustments.
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
1. Magneto flywheel
2. Voltage regulator
3. 12V-12Ah Battery
4. Start-up remote control switch
5. Starter motor
6. Starter button
7. 30A Fuse
8. 15A fuse
9. Stop light bulb
10. Key switch contacts
11. Engine stop switch
12. Stop buttons
13. Light switch
14. Key switch contacts
15. Saddle opening switch
16. Saddle opening actuator
17. Front and rear daylight bulbs and license plate
light
18. Headlight with twin-filament bulb
19. Pre-installation for anti-theft device
20. Turn indicator bulbs
21. Turn indicator switch
22. Turn indicator control device
23. Instrument panel
24. Fuel level transmitter
25. Oil pressure sensor
26. Headlight remote control
27. Fuse 7.5A
28. Fuse 7.5A
29. Fuse 15A
30. Fuse 7.5A
31. Fuse 7.5A
32. Horn button
33. Horn
34. Injection load remote control
35. Electric fan remote control
36. Radiator electric fan
37. Lambda sensor
ELE SYS - 58
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
38. Water pump
39. Engine rpm sensor
40. HV coil
41. Fuel injector
42. Coolant temperature sensor:
43. Diagnostics socket
44. Fuel supply pump
45. Injector ECU
46. Immobilizer aerial
Key
Ar: Orange Az: Light Blue Bi: White Bl: Blue Gi:
Yellow Gr:Grey
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green
Vi: Purple
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
KEY
1. Instrument panel
2. Turn indicator control device
3. Turn indicator switch
ELE SYS - 59
Electrical system
4. Bulbs for turn indicators
5. Pre-installation for anti-theft device
6. Headlight with twin-filament bulb
7. Daylight running light bulbs and license plate light
8. Saddle opening actuator
9. Saddle opening switch
10. Ignition switch contacts
11. Light switch
12. Headlight relay
13. Secondary fuses
14. Horn
15. Horn button
16. Stop buttons
17. Engine stop switch
18. Ignition switch contacts
19. Starter button
20. Starter motor
21. Starter relay
22. Stop light bulb
23. Battery
24. Main fuses
25. Magneto flywheel
26. Voltage regulator
27. Injection load relay
28. Electric fan relay
29. Radiator electric fan
30. Lambda probe
31. Water pump
32. Engine speed sensor
33. HV coil
34. Fuel injector
35. Engine temperature sensor
36. Fuel pump
37. Diagnosis socket
38. Injection ECU
39. Immobilizer antenna
40. Fuel level transmitter
41. Oil pressure sensor
ELE SYS - 60
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
Key
Ar: Orange Az: Light Blue Bi: White Bl: Blue Gi: Yellow Gr:Grey
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
Components arrangement
9. Immobilizer aerial- Remove the shield back
plate to reach it.
10. Injection ECU - Remove the helmet compartment to reach it.
ELE SYS - 61
Electrical system
11. Diagnosis connector - Remove the helmet
compartment to reach it.
15. H.V. coil- Remove the battery to reach it; to
remove the coil, first remove the footrest and undo
the two screws indicated.
20-18-30-38 Horn - Solenoids Remove front central cover to reach them.
ELE SYS - 62
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
23. Remote control switches - Remove the front
central cover and the helmet compartment to
reach them.
22-26. Main fuses - Open the front top box and
the battery cover to reach them.
27. Voltage regulator - Remove the shield back
plate to reach it.
ELE SYS - 63
Electrical system
28. Magneto flywheel - Remove the flywheel cover, as described in the «Engine» chapter, to reach
it. To get access to the connectors, remove the
helmet compartment.
40. Key switch contacts - Remove the shield
back plate to reach them.
33. Saddle-opening actuator - Remove the helmet compartment to reach it, undo the two screws
indicated and remove the fixing bracket together
with the actuator.
8. Fuel level transmitter - Remove the fuel tank
to reach it.
ELE SYS - 64
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
7. Oil pressure sensor - Remove the right side
fairing to reach it.
22. Battery - Remove the rear central cover to
reach it.
Conceptual diagrams
Ignition
3. 12V-12Ah Battery
7. 30A Fuse
8. 15A Fuse
10. Key switch contacts
11. Engine stop switch
23. Instrument panel
28. Fuse 7.5A
31. Fuse 7.5A
34. Injection load remote control
40. HV coil
43. Diagnostics socket
45. Injector ECU
46. Immobilizer aerial
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELE SYS - 65
Electrical system
KEY
1. Instrument panel
13. Secondary fuses
18. Ignition switch contacts
23. Battery
24. Main fuses
27. Injection load relay
33. HV coil
38. Injection ECU
39. Immobilizer antenna
Battery recharge and starting
1. Magneto flywheel
2. Voltage regulator
3. 12V-12Ah Battery
4. Start-up remote control switch
5. Starter motor
6. Starter button
7. 30A Fuse
ELE SYS - 66
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
8. 15A Fuse
9. Stop light bulb
10. Key switch contacts
12. Stop buttons
30. Fuse 7.5A
31. Fuse 7.5A
45. Injector ECU
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
KEY
13. Secondary fuses
16. Stop buttons
17. Engine stop switch
18. Ignition switch contacts
19. Starter button
20. Starter motor
21. Starter relay
22. Stop light bulb
23. Battery
24. Main fuses
ELE SYS - 67
Electrical system
Vespa GTS Super 125 i.e.
25. Magneto flywheel
26. Voltage regulator
38. Injection ECU
Level indicators and enable signals section
3. 12V-12Ah Battery
7. 30A Fuse
8. 15A Fuse
10. Key switch contacts
11. Engine stop switch
23. Instrument panel
24. Fuel level transmitter
25. Oil pressure sensor
30. Fuse 7.5A
31. Fuse 7.5A
34. Injection load remote control
37. Lambda sensor
39. Engine rpm sensor
41. Fuel injector
42. Coolant temperature sensor:
45. Injector ECU
46. Immobilizer aerial
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELE SYS - 68
Vespa GTS Super 125 i.e.
Electrical system
KEY
1. Instrument panel
13. Secondary fuses
17. Engine stop switch
18. Ignition switch contacts
21. Starter relay
23. Battery
24. Main fuses
35. Engine temperature sensor
38. Injection ECU
39. Immobilizer antenna
40. Fuel level transmitter
41. Oil pressure sensor
Devices and accessories
3. 12V-12Ah Battery
7. 30A Fuse
8. 15A Fuse
10. Key switch contacts
ELE SYS - 69
Electrical system
Vespa GTS Super 125 i.e.
14. Key switch contacts
15. Saddle opening switch
16. Saddle opening actuator
19. Pre-installation for anti-theft device
20. Turn indicator bulbs
21. Turn indicator switch
22. Turn indicator control device
23. Instrument panel
28. Fuse 7.5A
29. Fuse 15A
30. Fuse 7.5A
31. Fuse 7.5A
32. Horn button
33. Horn
34. Injection load remote control
35. Electric fan remote control
36. Radiator electric fan
38. Water pump
44. Fuel supply pump
45. Injector ECU
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELE SYS - 70
Vespa GTS Super 125 i.e.
Electrical system
KEY
4. Bulbs for turn indicators
5. Pre-installation for anti-theft device
8. Saddle opening actuator
9. Saddle opening switch
10. Ignition switch contacts
13. Secondary fuses
14. Horn
15. Horn button
18. Ignition switch contacts
23. Battery
24. Main fuses
27. Injection load relay
28. Electric fan relay
29. Radiator electric fan
31. Water pump
36. Fuel pump
38. Injection ECU
ELE SYS - 71
Electrical system
Vespa GTS Super 125 i.e.
Lights and turn indicators
3. 12V-12Ah Battery
7. 30A Fuse
8. 15A Fuse
10. Key switch contacts
13. Light switch
17. Front and rear daylight bulbs and license plate
light
18. Headlight with twin-filament bulb
20. Turn indicator bulbs
21. Turn indicator switch
22. Turn indicator control device
23. Instrument panel
26. Headlight remote control
27. Fuse 7.5A
28. Fuse 7.5A
29. Fuse 15A
30. Fuse 7.5A
31. Fuse 7.5A
45. Injector ECU
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELE SYS - 72
Vespa GTS Super 125 i.e.
Electrical system
KEY
1. Instrument panel
2. Turn indicator control device
3. Turn indicator switch
4. Bulbs for turn indicators
6. Headlight with twin-filament bulb
7. Daylight running light bulbs and license plate light
11. Light switch
12. Headlight relay
13. Secondary fuses
18. Ignition switch contacts
23. Battery
24. Main fuses
38. Injection ECU
Checks and inspections
This section is dedicated to the checks on the electrical system components.
ELE SYS - 73
Electrical system
Immobiliser
The electronic ignition system is controlled by the
control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that
allows the vehicle to be operated only when it is
started with coded keys recognised by the control
unit. The code is integrated in a transponder in the
key block. This allows the driver clear operation
without having to do anything other than just turning the key. The Immobilizer system consists of the
following components:
- Control unit
- Immobilizer aerial
- master and service keys with built-in transponder
- HV coil
- diagnosis LED
The diagnosis LED also works as a theft-deterrent
blinker. This function is activated every time the
ignition switch is turned to the "OFF" position, or
the emergency stop switch is turned to the "OFF"
position. It remains activated for 48 hours in order
not to affect the battery charge.
When the key switch is turned to "ON", it interrupts
the function of the immobiliser lamp and a start
enable lamp comes "ON".
The duration of the flash depends on the programming of the electronic control unit
If the LED is off regardless of the position of the
ignition-key switch and/or the instrument panel is
not initiated, check if:
•
there is battery voltage
•
that fuse 1 and fuse 8 are in good condition.
•
there is power to the control unit as
specified below:
ELE SYS - 74
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
Remove the connector support bracket shown in
the photograph and disconnect the connector from
the control unit. Check the following conditions:
With the key switch set to OFF:
• there is battery voltage between terminals 6-26
and terminal 6-frame earth (fixed power supply). If
there is no voltage check that fuse 4 and its cable
are in working order.
With the key switch set to ON:
• there is battery voltage between terminals 5-26
and terminal 5-chassis ground (fixed power supply). If there is no voltage, check the ignition key
contacts, that fuse 2 and its cable are in working
order.
•
There is continuity between terminals
12-18 and 12-19 with the emergency
cut-out switch in the RUN position. If
there is no continuity, check the contacts of the latter.
If no faults are found, replace the control unit.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
The electronic ignition system is controlled by the control unit with the integrated Immobilizer system.
The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means
of the coded keys that the control unit recognises. The code is integrated in a transponder in the key
block. This allows the driver clear operation without having to do anything other than just turning the
key. The Immobilizer system consists of the following components:
- Control unit
- Immobilizer antenna
- master and service keys with built-in transponder
- H.V. coil
ELE SYS - 75
Electrical system
Vespa GTS Super 125 i.e.
- diagnosis LED
The diagnosis led also works as a blinking light to deter theft. This function is activated every time the
ignition switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging
process.
When the ignition switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start
enable lamp comes "ON".
The duration of the flash depends on the programming of the electronic control unit.
If the LED is off regardless of the position of the ignition switch and/or the instrument panel is not
initiated, check if:
•
there is battery voltage
•
fuse No. 1, fuse No. 2 and fuse No. 3 efficiency.
•
there is power to the control unit as specified below:
Remove the connector mounting bracket shown in the photograph and disconnect the connector from
the control unit. Check the following conditions:
With the key switch set to OFF:
• there is battery voltage between terminals 7-9
and terminal 9-chassis ground (fixed power supply). If there is no voltage check that fuse 3 and its
cable are in working order.
With the key switch in the ON position:
• there is battery voltage between terminals 6-7
and terminal 6-chassis ground (fixed power supply). If there is no voltage, check the ignition switch
contacts, that fuse 2 and its cable are in working
order.
ELE SYS - 76
Vespa GTS Super 125 i.e.
Electrical system
After removing the leg shield back plate, remove
the electrical connection from the aerial as shown
in the picture.
Remove the protective base from the connector.
With the ignition switch at ON check there is battery voltage between the Red-White and Black
cables
With MIU connector disconnected, check the continuity between the Orange-White cable and pin 7
of the interface wiring.
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
ELE SYS - 77
Electrical system
Vespa GTS Super 125 i.e.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
After removing the leg shield back plate, remove
the electrical connection from the aerial as shown
in the picture.
Remove the protective base from the connector.
With the ignition switch at ON check there is battery voltage between the Red-White and Black
cables
ELE SYS - 78
Vespa GTS Super 125 i.e.
Electrical system
With MIU connector disconnected, check the continuity between the Orange-White cable and pin 14
of the control unit.
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
Virgin circuit
When the ignition system is not encrypted, any key
will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has
been programmed properly.
The data storage procedure for a previously unprogrammed control unit provides for the recognition of the red key (master key) as the first key to
be stored to memory: this becomes particularly
important because it is the only key that enables
the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code
the system as follows:
- Insert the Master key, turn it to «ON» and keep
this position for two seconds (lower and upper limits 1 to 3 seconds).
- Insert the blue key and set to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation
with each key.
ELE SYS - 79
Electrical system
- Insert the MASTER key again and turn it to «ON»
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys (blue) can be programmed at one time.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, master
key transponder, decoder and control unit are
strictly matched.
With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc.
Each new programming deletes the previous one
so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to
keep using.
If a service key becomes uncoded, the efficiency
of the high voltage circuit shielding must be thoroughly inspected. In any case it is advisable to use
resistive spark plugs.
Characteristic
Shielded cap resistance
~ 5000 Ω.
Diagnostic codes
The Immobilizer system is tested each time the ignition key is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit statuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the LED remains off
permanently, the ignition is enabled. If, however,
the LED remains on permanently, it means the ignition is inhibited:
ELE SYS - 80
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be started but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transponder absent or cannot be used: the LED is on
permanently. In this condition no operations are
possible including the start up of the vehicle.
3. Programmed control unit - the service key in
(normal condition of use): a single 0.7-second
flash is displayed, after which the LED remains off
steadily. The engine can be started.
4. Programmed control unit - Master key in: a
0.7-sec flash is displayed followed by the LED remaining off for 2 sec and then by short 0.46-sec
flashes, the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
LED remains permanently OFF. The engine can
be started.
5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:
•
1-flash code
•
2-flash code
•
3-flash code
ELE SYS - 81
Electrical system
Vespa GTS Super 125 i.e.
Diagnostic code - 1 flash
A one-flash code indicates a system where the serial line is not present or is not detected. Check the
Immobilizer antenna wiring and change it if necessary.
Diagnostic code - 2 flashes
A two-flash code shows a system where the control unit does not show the transponder signal. This
might depend on the inefficiency of the immobilizer
antenna or the transponder.
Turn the switch to ON using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. If this
is not the case, replace the defective key and/or
reprogram the control unit. Replace the control unit
if the problem continues.
Diagnostic code - 3 flashes
A three-flash code indicates a system where the
control unit does not recognise the key. Turn the
switch to ON using several keys: if the error code
is repeated even with the Master key, replace the
control unit. If this is not the case, reprogram the
decoder.
Battery recharge circuit
The charging circuit consists of three-phase alternator and a permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive terminal passing through
the 30A protective fuse.
ELE SYS - 82
Vespa GTS Super 125 i.e.
Electrical system
The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.
Stator check
Checking the stator windings
WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Lift the saddle and remove the helmet compartment.
2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the
picture.
3) Measure the resistance between each of the yellow terminals and the other two.
Electric characteristic
Resistance:
0.2 - 1 Ω
4) Check that there is insulation between the each
yellow cable and the ground.
5) If values are incorrect, replace the stator.
Recharge system voltage check
Look for any leakage
1) Access the battery by removing the cover in the footrest.
2) Check that the battery does not show signs of losing fluid before checking the output voltage.
3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole
(-) of the battery and the black cable and only then disconnect the black cable from the negative pole
(-) of the battery.
4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.
Charging current check
WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.
1) Place the vehicle on its centre stand
2) With the battery correctly connected to the circuit, place the multimeter leads between the battery
terminals..
ELE SYS - 83
Vespa GTS Super 125 i.e.
Electrical system
3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time
measure the voltage.
Electric characteristic
Voltage ranging between 14.0 and 15.0V at 5000 rpm.
Maximum current output check.
- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.
- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.
- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter.
With an efficient battery a value must be detected: > 20A
VOLTAGE REGULATOR/RECTIFIER
Specification
Type
Voltage
Starter motor
KEY
1. Battery
2. Start-up remote control switch
3. Fuse No. 1
4. Fuse No. 3
5. Key switch contacts
6. Fuse No. 2
ELE SYS - 84
Desc./Quantity
Non-adjustable three-phase transistor
14 to 15V at 5000 rpm with lights off
Vespa GTS Super 125 i.e.
Electrical system
7. Electronic control unit
8. Engine stop switch
9. Stop buttons
10. Fuse No. 4
11. Starter button
12. Starter motor
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1,2,3 and 4.
2) Check key switch contacts.
3) Check the contacts of the stop buttons and the starter button.
4) With the key switch set to «ON», the brake pulled and the starter button pressed, check if there is
voltage between the Orange-White cable of the start-up remote control switch and the ground connection. If there is not, check the cable harnesses.
5) Check the start-up remote control switch.
6) Check that the Red cable between the battery and the start-up remote control switch is not interrupted.
Also check continuity between the latter and the starter motor.
7) Check the starter motor ground connection.
8) Check that the Orange-Blue cable between the start-up remote control switch and the control unit
(pin 24) is not interrupted.
9) Check the contacts of the engine stop switch and that the Green-Black cable connecting this switch
to the control unit (pin 12) is not interrupted.
10) Check the engine stop switch ground connection.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELE SYS - 85
Electrical system
Vespa GTS Super 125 i.e.
KEY
1. Battery
2. Starter relay
3. Fuse No. 1
4. Fuse No. 3
5. Ignition switch contacts
6. Fuse No. 2
7. Electronic control unit
8. Starter motor
9. Stop buttons
10. Fuse No. 4
11. Starter button
12. Engine stop switch
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1, 2, 3 and 4.
2) Check ignition switch contacts.
3) Check the contacts of the stop buttons and the starter button.
4) With the ignition switch set to «ON», the brake pulled and the starter button pressed, check if there
is voltage between the Orange-White cable of the start-up relay and the ground connection. If there is
not, check the cable harnesses.
ELE SYS - 86
Vespa GTS Super 125 i.e.
Electrical system
5) Check the starter relay.
6) Check that the Red cable between the battery and the starter relay is not interrupted. Also check
continuity between the latter and the starter motor.
7) Check the starter motor ground connection.
8) Check that the Orange-Blue cable between the starter relay and the control unit (pin 10) is not interrupted.
9) Check the contacts of the engine stop switch and that the Green-Black cable connecting this switch
to the control unit (pin 4) is not interrupted.
10) Check the engine stop switch ground connection.
Horn control
KEY
1. Battery
2. Fuse No. 1
3. Key switch contacts
4. Fuse No. 4
5. Horn button
6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1 and 4.
2) Check the key switch and horn button contacts.
ELE SYS - 87
Electrical system
Vespa GTS Super 125 i.e.
3) With the key switch set to «ON» and the horn button pressed, check if there is voltage between the
Yellow-Pink cable of the horn device and the ground connection. If there is not, check the cable harnesses.
4) Check the horn device ground connection.
Turn signals system check
KEY
1. Battery
2. Fuse No. 1
3. Key switch contacts
4. Fuse No. 4
5. Turn indicator control device
6. Turn indicator switch
7. Turn indicator bulbs
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check that bulbs operate properly.
2) Check fuses No. 1 and 4.
3) Check key switch contacts.
4) With the key switch set to «ON», check if there is voltage between the Blue-Black cable of the turn
indicators switch and the ground connection. If there is not, check the cable harnesses and the connections of the turn indicator control device.
ELE SYS - 88
Vespa GTS Super 125 i.e.
Electrical system
5) Check the turn indicator switch contacts.
6) With the turn indicator switch pressed to the right, check if there is voltage between the White-Blue
cable of the switch and the ground connection. If there is not, check the cable harnesses.
7) With the turn indicator switch pressed to the left, check if there is voltage between the Pink cable of
the switch and the ground connection. If there is not, check the cable harnesses.
8) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values between the White-Green cable and the Black cable of
the fuel level transmitter under different conditions.
2) If the transmitter operates correctly but the indication on the instrument panel is not exact, check that
the cable harnesses between them are not interrupted.
Electric characteristic
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω
Lights list
ELE SYS - 89
Electrical system
Vespa GTS Super 125 i.e.
KEY
1. Battery
2. Fuse No. 1
3. Fuse No. 5
4. Ignition switch contacts
5. Fuse No. 4
6. Fuse No. 7
7. Electronic control unit
8. Daylight running light bulbs and license plate light
9. High/low beam two-light bulb
10. Light switch
11. Headlight relay
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
TAIL LIGHTS AND LICENSE PLATE LIGHT LINE
1) Check that bulbs operate properly.
2) Check fuses No. 1 and 7.
3) Check key switch contacts.
4) Check if there is voltage between the Yellow-Black cable of fuse No. 7 and the ground. If not, check
cable harnesses.
5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
HIGH-BEAM /LOW-BEAM LIGHTS LINE
1) Check that bulbs operate properly.
2) Check fuses No. 1, 4 and 5.
3) Check key switch contacts.
4) Check if there is voltage between the Grey cable of the headlight remote control and the ground
connection. If there is not, check the cable harnesses.
5) With the key switch set to «ON» and the engine running, check if there is voltage between the YellowRed cable of the headlight remote control and the ground connection. If there is not, check the cable
harnesses.
6) Check that the White-Black cable connecting the headlight remote control switch and the control unit
(pin 19) is not interrupted.
7) Check the headlight remote control switch.
8) Check that the Grey-Red cable of the light switch and the headlight remote control switch is not
interrupted.
9) Check the light switch contacts.
10) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
ELE SYS - 90
Vespa GTS Super 125 i.e.
Electrical system
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
KEY
1. Battery
2. Fuse No. 1
3. Fuse No. 5
4. Ignition switch contacts
5. Fuse No. 4
6. Fuse No. 7
7. Electronic control unit
8. Daylight running light bulbs and license plate light
9. High/low beam two-light bulb
10. Light switch
11. Headlight relay
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
DAYLIGHT RUNNING LIGHT AND LICENSE PLATE LIGHT LINE
1) Check that bulbs operate properly.
2) Check fuses No. 1 and 7.
3) Check ignition switch contacts.
4) Check if there is voltage between the Yellow-Black cable of fuse No. 7 and the ground. If not, check
cable harnesses.
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Electrical system
5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
HIGH BEAM/LOW BEAM LIGHTS LINE
1) Check that bulbs operate properly.
2) Check fuses No. 1, 4 and 5.
3) Check ignition switch contacts.
4) Check if there is voltage between the Grey cable of the headlight relay and the ground connection.
If there is not, check the cable harnesses.
5) With the ignition switch set to «ON» and the engine running, check if there is voltage between the
Yellow-Red cable of the headlight relay and the ground connection. If there is not, check the cable
harnesses.
6) Check that the White-Black cable connecting the headlight relay and the control unit (pin 33) is not
interrupted.
7) Check the headlight relay.
8) Check that the Grey-Red cable of the light switch and the headlight relay switch is not interrupted.
9) Check the light switch contacts.
10) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
Fuses
The electrical system is equipped with:
1. six protection fuses «A» located in the glove
compartment to the left
2. of a fuse «B», located in the battery compartment.
The chart shows the position and specifications of
the fuses in the vehicle.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE
THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).
CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT
ATTENTION TO THE TECHNICAL SPECIFICATIONS OF
THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK
OF FIRE.
FUSES
1
ELE SYS - 92
Specification
Fuse 1
Desc./Quantity
Current rating: 30 A
Vespa GTS Super 125 i.e.
Electrical system
Specification
2
Fuse 2
3
Fuse 3
4
Fuse 4
5
Fuse 5
6
Fuse 6
7
Fuse 7
Desc./Quantity
Protected circuits: Vehicle main fuse
Current rating: 7.5A
Protected circuits: Running lights and instrument panel
illumination power
Current rating: 7.5A
Protected circuits: Live services circuit
Current rating: 7.5A
Protected circuits: Live injection ECU
Current rating: 7.5A
Protected circuits: Battery power for accessories and
instrument panel
Current rating: 15A
Protected circuits: Battery power for headlight and saddle release system.
Current rating: 15A
Protected circuits: Injection load power supply.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
The electrical system is equipped with:
1. six protection fuses «A» located in the glove compartment to the left
2. of a fuse «B», located in the battery compartment.
The chart shows the position and specifications of the fuses in the vehicle.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO
BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF
ELECTRIC WIRE).
CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR
WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN
CAUSE MALFUNCTIONING AND RISK OF FIRE.
FUSES
1
Specification
Fuse 1
2
Fuse 2
3
Fuse 3
4
Fuse 4
5
Fuse 5
6
Fuse 6
7
Fuse 7
Desc./Quantity
Current rating: 30 A
Protected circuits: Vehicle main fuse
Current rating: 7.5A
Protected circuits: Key powered ECU, immobilizer aerial, electric fan relay, injection load relay.
Current rating: 15A
Protected circuits: Battery-powered load and injection
control unit.
Current rating: 7.5A
Protected circuits: Key powered to headlight relay
switch, pre-installation for anti-theft device , turn indicator control device, instrument panel, horn, stop.
Current rating: 7.5 A
Protected circuits: Battery power for headlight, electric
fan and saddle release.
Current rating: 7.5A
Protected circuits: Battery power for pre-installation for
anti-theft device and instrument panel.
Current rating: 7.5A
Protected circuits: Key powered to daylight running
light and instrument panel lighting.
ELE SYS - 93
Electrical system
Vespa GTS Super 125 i.e.
Dashboard
A = Digital clock
B = Odometer
C = Speedometer
D = Injection warning light
E = Engine oil pressure warning light
F = Turn indicators
G = High-beam warning light
H = Headlight warning light
I = Fuel gauge
L = Low fuel warning light
M = Coolant temperature gauge
N = Immobilizer LED
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 to 14.70V
- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
ELE SYS - 94
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Electrical system
Battery installation
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES
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.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation
phases.
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphuric acid.
3) Procedure for filling the battery with acid.
Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.
4) Control the flow of electrolyte
ELE SYS - 95
Electrical system
Vespa GTS Super 125 i.e.
Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Now, gently pull the container out from the battery, only do this when the
container is completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.
Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 to 2 hours prior to the charging from the battery.
7) Recharging the new battery
With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeopardising its useful life on vehicle.
The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between
12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger:
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).
ELE SYS - 96
Vespa GTS Super 125 i.e.
Electrical system
d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.
f - Check the ignition of the green LED indicated
with a red arrow in figure.
g - The activation cycle of the new battery lasts for
30 minutes after the ignition of the recharge LED
has taken place
ELE SYS - 97
Electrical system
Vespa GTS Super 125 i.e.
h - Disconnect the clamps from the battery and
check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge procedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
Connectors
DIAGNOSTICS CONNECTOR
1. Not connected
2. Ground lead (Black)
3. Electronic control unit (Violet - White)
PICKUP CONNECTOR
1. Control unit positive (Red)
2. Negative from control unit (Brown)
3. Not connected
FUEL PUMP CONNECTOR
1. Not connected
2. Ground lead (Black)
3. Not connected
4. Not connected
5.Power from relay (Black - Green)
ELE SYS - 98
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Electrical system
ELECTRONIC CONTROL UNIT CONNECTOR
1. Injection telltale light (Brown-Black)
2. Not connected
3. Not connected
4. Lambda probe negative terminal (White-Green)
5. Live supply (Red-White)
6. Battery powered (Grey-Black)
7. Immobilizer Aerial (Orange-White)
8. Electric fan remote control (Blue-Yellow)
9. Water temperature sensor (Sky blue-Green)
10. Not connected
11. Lambda probe positive (Sky blue-Black)
12. Engine stop switch (Green-Black)
13. Engine rpm sensor positive (Red)
14. Injector (Red-Yellow)
15. Engine rpm sensor negative (Brown)
16. Diagnosis (Purple-White)
17. Immobilizer warning light (Red-Green)
18. To ground (Grey-Green)
19. Low-beam lights automatic ignition (WhiteBlack)
20. Injection load remote control (Black-Purple)
21. Not connected
22. HV coil (Pink-Black)
23. Not connected
24. Start-up enabling (Orange-Blue)
25. Not connected
26. Ground lead (Black)
ENGINE TEMPERATURE SENSOR CONNECTOR
1. Ground lead (Grey-Green)
2. Instrument panel (Grey-Black)
3. Electronic control unit (Sky blue - Green)
4. Ground lead (Black)
ELE SYS - 99
Electrical system
INJECTOR CONNECTOR
1. Power from relay (Black - Green)
2. Electronic control unit (Red - Yellow)
LAMBDA PROBE CONNECTOR
1. Positive from control unit (Sky blue - Black)
2. Control unit negative (White - Green)
VOLTAGE REGULATOR CONNECTOR
1. Battery positive (Red-Black)
2. Ground lead (Black)
3. Battery positive (Red-Black)
4. Ground lead (Black)
INSTRUMENT PANEL CONNECTOR «A»
1. Fuel level indicator (White-Green)
2. High-beam warning light (Violet)
3. Left indicator warning light (White - Blue)
4. Right indicator warning light (Pink)
5. Key powered(White)
6. Oil pressure sensor (Pink-White)
ELE SYS - 100
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
INSTRUMENT PANEL CONNECTOR «B»
1. Ground lead (Black)
2. Injection warning light (Brown-Black)
3. Low fuel warning light (Yellow-Green)
4. Water temperature (Grey-Black)
INSTRUMENT PANEL CONNECTOR «C»
1. Immobilizer warning light (Red-Green)
2. Battery-powered (Red-Blue)
3. Lighting (Yellow - Black)
4. Key powered (White)
H.V. COIL CONNECTOR
1. Power from relay (Black - Green)
2. Electronic control unit (Pink - Black)
ANTITHEFT DEVICE PRE-INSTALLATION
CONNECTOR
1. Ground lead (Black)
2. Left indicator (White - Blue)
3. Right indicator (Pink)
4. Battery-powered (Red-Blue)
5. Key powered (White)
6. Not connected
7. Not connected
8. Not connected
ELE SYS - 101
Electrical system
Vespa GTS Super 125 i.e.
IMMOBILIZER ANTENNA CONNECTOR
1. Key powered (Red-White)
2. Ground lead (Black)
3. Electronic control unit (Orange-White)
FUEL LEVEL TRANSMITTER CONNECTOR
1. Fuel level indicator (White - Green)
2. Ground lead (Black)
3.Low fuel warning light (Yellow-Green)
COOLANT PUMP CONNECTOR
1. Ground lead (Black)
2. Injection load relay (Black-Green)
3. Injection load relay (Black-Green)
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
DIAGNOSTICS CONNECTOR
1. Not connected
2. Ground lead (Black)
3. Electronic control unit (Violet - White)
ELE SYS - 102
Vespa GTS Super 125 i.e.
Electrical system
PICK-UP CONNECTOR
1. Control unit positive (Red)
2. Negative from control unit (Brown)
3. Oil pressure sensor (Pink-White)
FUEL PUMP CONNECTOR
1. Not connected
2. Ground lead (Black)
3. Not connected
4. Not connected
5.Power from relay (Black - Green)
ELECTRONIC CONTROL UNIT CONNECTOR
1. H.V. COIL (Pink-Black)
2. Not connected
3. Not connected
4. Ground (Green-Black)
5. Not connected
6. Key powered(Red-White)
7. Ground No. 1 (Black)
8. Not connected
9. Battery-powered (Grey-Black)
10. Start-up enabling switch (Orange-Blue)
11. Lambda probe positive (Sky blue-Black)
12. Lambda probe negative (White-Green)
13. Water temperature sensor (Sky blue-Green)
14. Immobilizer aerial (Orange-White)
15. Not connected
16. K serial line (Purple-White)
17. Immobilizer (Red-Green)
18. Not connected
19. Side stand (Grey-Green)
20. Engine speed sensor negative (Brown)
ELE SYS - 103
Electrical system
21. Not connected
22. Injection load relay (Black-Purple)
23. Not connected
24. Habilitation electric fan (Blue-Yellow)
25. Injection warning light (Brown-Black)
26. Not connected
27. Not connected
28. Not connected
29. Engine speed sensor positive (Red)
30. Not connected
31. Lambda probe heater (White)
32. Not connected
33. Low beam lights automatic ignition enabling
(White-Black)
34. Fuel injector (Red-Yellow)
ENGINE TEMPERATURE SENSOR CONNECTOR
1. Ground lead (Grey-Green)
2. Instrument panel (Grey-Black)
3. Electronic control unit (Sky blue - Green)
4. Ground lead (Black)
INJECTOR CONNECTOR
1. Power from relay (Black - Green)
2. Electronic control unit (Red - Yellow)
ELE SYS - 104
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Vespa GTS Super 125 i.e.
Electrical system
LAMBDA PROBE CONNECTOR
1. Positive from control unit (Sky blue - Black)
2. Control unit negative (White - Green)
VOLTAGE REGULATOR CONNECTOR
1. Battery positive (Red-Black)
2. Ground lead (Black)
INSTRUMENT PANEL CONNECTOR «A»
1. Fuel level indicator (White-Green)
2. High-beam warning light (Violet)
3. Left indicator warning light (White - Blue)
4. Right indicator warning light (Pink)
5. Key powered(White)
6. Oil pressure sensor (Pink-White)
INSTRUMENT PANEL CONNECTOR «B»
1. Ground lead (Black)
2. Injection warning light (Brown-Black)
3. Low fuel warning light (Yellow-Green)
4. Water temperature (Grey-Black)
ELE SYS - 105
Electrical system
INSTRUMENT PANEL CONNECTOR «C»
1. Immobilizer warning light (Red-Green)
2. Battery-powered (Red-Blue)
3. Lighting (Yellow - Black)
4. Key powered (White)
H.V. COIL CONNECTOR
1. Power from relay (Black - Green)
2. Electronic control unit (Pink - Black)
ANTITHEFT DEVICE PRE-INSTALLATION
CONNECTOR
1. Ground lead (Black)
2. Left indicator (White - Blue)
3. Right indicator (Pink)
4. Battery-powered (Red-Blue)
5. Key powered (White)
6. Not connected
7. Not connected
8. Not connected
IMMOBILIZER ANTENNA CONNECTOR
1. Key powered (Red-White)
2. Ground lead (Black)
3. Electronic control unit (Orange-White)
ELE SYS - 106
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Electrical system
FUEL LEVEL TRANSMITTER CONNECTOR
1. Fuel level indicator (White - Green)
2. Ground lead (Black)
3.Low fuel warning light (Yellow-Green)
COOLANT PUMP CONNECTOR
1. Ground lead (Black)
2. Injection load relay (Black-Green)
3. Injection load relay (Black-Green)
Diagnostic instrument
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
STARTER COMMAND
Function
Commands engine starting through the injection control unit.
Operation / Operating principle
The starter button, the brake switches, the starter command relay and the injection control unit are
involved with Pin 10.
ELECTRICAL ERRORS
Starter command P0170 - shorted to positive.
Error cause
Short circuit to positive: excessive voltage at PIN 10 of the control unit connector.
Troubleshooting
Short circuit to positive:
- This malfunction is detected with a brake activated and the starter button pressed.
- If the battery voltage does not drop (thanks to the absorption of the starter command relay excitation
coil) the control unit understands that PIN 10 is shorted to battery.
- Restore the cabling (if the short is in the cabling) or the relay (if the short is in the relay).
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
ELE SYS - 107
Electrical system
Vespa GTS Super 125 i.e.
ENGINE TEMPERATURE SENSOR
Function
Serves the purpose of communicating the engine
temperature to the control unit in order to optimise
performance.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Pin-out:
1. Ground lead
2. Instrument panel
3. Electronic control unit
4. Ground lead
Engine temperature sensor P0115 - open circuit or shorted to positive / shorted to negative.
Error cause
Open circuit or short circuit to positive: interruption of the circuit or excessive voltage at PIN 13 of the
control unit connector. Short circuit to negative: null voltage between PIN 13 and 7 of the control unit
connector.
Troubleshooting
Open circuit:
- Disconnect the connector of the control unit.
- Measure the resistance value of the sensor at different temperatures between PIN 13 and 7.
- Disconnect the sensor connector.
- Check the continuity of the cable harness between the sensor connector and control unit connector:
Control unit PIN 13 - sensor PIN 3 and control unit PIN 7 - sensor PIN 1. If necessary, restore the cable
harness.
- If the cabling is intact but the sensor resistance value is incorrect, this means that the sensor is faulty
and must be replaced, otherwise proceed with the checks.
Short circuit to positive:
- With the sensor connector and the control unit disconnected, verify that the fault is shorted with the
battery positive of sensor connector PIN 3 (or control unit PIN 13) and restore the cabling.
Short circuit to negative:
- Disconnect the sensor connector.
- Check the sensor connector PIN 3 from ground insulation.
- If there is no ground insulation restore the cabling.
- If PIN 3 is insulated from the ground and the error persists, this means that there is a probable fault
in the control unit.
ELE SYS - 108
Vespa GTS Super 125 i.e.
Electrical system
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
LAMBDA PROBE
Function
In charge of telling the control unit whether the
mixture is lean or rich.
Operation / Operating principle
Based on the difference of oxygen in the exhaust
fumes and the environment, this generates voltage which is read and interpreted by the injection
control unit.
Pin-out:
1. Positive from control unit
2. Negative from control unit
ELECTRICAL ERRORS
Check the air-fuel ratio / Lambda probe P0130 - Shorted to positive / open circuit, shorted to negative
or carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault.
Error cause
Short circuit to positive: excessive voltage at PIN 11 or PIN 12 of the control unit connector.
Circuit open or short circuit to negative: interruption of the circuit or null voltage between control unit
connector PIN 11 and 12.
Troubleshooting
Short circuit to positive:
- Disconnect the control unit connector and the sensor connector.
- Verify that there is no short circuit with the battery positive on the PIN 1 of the sensor connector
(corresponding to the PIN 11 of the control unit connector); in the presence of short circuit, restore the
cable harness.
- Verify that there is no short circuit with the battery positive on the PIN 2 of the sensor connector
(corresponding to the PIN 12 of the control unit connector); in the presence of short circuit, restore the
cable harness.
Open circuit:
- Disconnect the control unit connector and the sensor connector.
- Check the continuity of the cable harness between the sensor connector and control unit connector:
PIN 11 of the control unit - PIN 1 of the sensor and PIN 12 of the control unit - PIN 2 of the sensor. If
necessary, restore the cable harness.
- If the cable harness is intact and the error persists, proceed with the following checks.
Short circuit to negative:
- Disconnect the sensor connector and the control unit connector.
- Check the sensor connector PIN 1 ground insulation. If there is no insulation, restore the cable harness.
ELE SYS - 109
Electrical system
Vespa GTS Super 125 i.e.
- Check the insulation from the ground of PIN 2 of the sensor connector. If there is no insulation, restore
the cable harness.
- If PIN 1 and 2 are insulated from ground and the error persists, it means that there is a probable defect
in the control unit.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJECTOR
Function
Provide the correct amount of fuel at the correct
time.
Operation / Operating principle
Injector coil is excited for the petrol passage to
open.
Pinout:
1. Power from relay
2. Ground from control unit
ELECTRICAL ERRORS
Injector P0201 - short circuit to positive / short circuit to negative / open circuit.
Error cause
Short circuit to positive: excessive voltage to PIN 34 of the control unit connector.
Short circuit to negative: zero voltage to the PIN 1 of the injector connector.
Open circuit: circuit interruption.
Troubleshooting
Short circuit to positive:
- Disconnect the injector connector, turn ignition switch to ON and activate the component using the
diagnostic tool.
- Verify the absence of voltage at the injector connector PIN 2; if present restore the cable harness,
otherwise proceed with the following checks.
Short circuit to negative:
- Disconnect the injector connector, turn ignition switch to ON and activate the component using the
diagnostic tool.
- Verify the presence of voltage at the ends of the injector connector; if there is no voltage, restore the
cable harness, otherwise proceed with the following checks.
Open circuit:
- Perform the check of the injector and control unit connectors.
- Verify continuity of the cable harness between the control unit connector and the injector connector
(control unit PIN 34 - injector PIN 2). If there is no continuity, restore the cable harness.
ELE SYS - 110
Vespa GTS Super 125 i.e.
Electrical system
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
FUEL PUMP
ELECTRICAL ERRORS
Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit.
Error cause
Short circuit to positive:excessive voltage at PIN 22 of the control unit connector.
Short circuit to negative: null voltage at PIN 86 of the injection relay.
Open circuit: circuit interruption.
Troubleshooting
Short circuit to positive:
- Disconnect the injection relay, turn the key to ON and activate the relay through the diagnostics instrument.
- Verify the presence of voltage between relay connector PIN 86 and 85 toward the cabling.
- If no voltage is read, disconnect the control unit and verify insulation from battery positive of the relay
PIN 85 (or control unit PIN 22). If necessary, restore the cable harness.
Short circuit to negative:
- Disconnect the injection relay and the control unit.
- Verify ground insulation of the relay connector PIN 86 and 85 toward the cabling: if there is no insulation, restore the cabling.
Open circuit:
- Disconnect the injection relay and the control unit.
- Verify continuity of the cabling between the relay and control unit: Relay PIN 85 - control unit PIN 22.
If necessary, restore the cable harness.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
COIL
Function
Allows generation of the electrical discharge on
the spark plug, with an increase of voltage.
Pin-out:
1. Power from relay
2. Activation by control unit (control unit side PIN
1)
ELECTRICAL ERRORS
H.V. Coil P0351 - shorted to positive / open circuit or shorted to negative.
Error cause
Short circuit to positive: excessive voltage at PIN 1 of the control unit connector.
ELE SYS - 111
Electrical system
Vespa GTS Super 125 i.e.
Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 1 of the control unit
connector.
Troubleshooting
Short circuit to positive:
- Disconnect the coil connector, turn the key to ON and activate the component through the diagnostics
instrument.
- Verify the presence of voltage on the coil connector PIN 2: if present, restore the cabling, otherwise
replace the coil.
Open circuit:
- Carry out the check procedure of the coil and control unit connectors.
- Verify continuity of the cabling between the coil and control unit: Coil PIN 2 - control unit PIN 1. If there
is no continuity, restore the cable harness.
- Verify, with the key turned ON, the presence of voltage on the coil connector PIN 1. If no voltage is
detected, check that the cable harness between the coil and injection relay is not interrupted: Coil PIN
1 - relay PIN 87.
- If the above tests provided a positive result, the coil should be replaced.
Short circuit to negative:
- Disconnect the control unit connector and the coil connector.
- Verify the coil connector PIN 2 ground insulation (or control unit connector PIN 1). If necessary, restore
the cable harness.
ELECTRIC FAN CIRCUIT
Function
Radiator fan and coolant - Operation.
Operation / Operating principle
The control unit closes the fan control relay excitation circuit to ground until the temperature drops.
ELECTRICAL ERRORS
Fan relay P0480 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to positive: excessive voltage at PIN 24 of the control unit connector.
Shorted to negative: null voltage at PIN 24 of the control unit connector.
Open circuit: circuit interruption.
Troubleshooting
Short circuit to positive:
- Disconnect the fan control relay and, turning the key to ON position, measure the voltage read at PIN
85 of the relay connector to the cable harness: if the voltage is 12V restore the cabling. If the voltage
is zero replace the relay.
Short circuit to negative:
ELE SYS - 112
Vespa GTS Super 125 i.e.
Electrical system
- Disconnect the fan control relay and the control unit.
- Verify ground insulation of the cable between the fan control relay (PIN 85) and the control unit (PIN
24). Restore the cabling if necessary.
Open circuit:
- Carry out the check procedure of the control unit and relay connectors.
- Verify electrical continuity of the cable between the relay connector (PIN 85) and the control unit
connector (PIN 24).
- Verify electrical continuity of the cable between the relay connector (PIN 30) and the secondary fuse
holders.
- Verify continuity between relay PIN 85 and PIN 86. If there is no continuity replace the relay.
ELE SYS - 113
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Vespa GTS Super 125 i.e.
Engine from vehicle
Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.
Exhaust assy. Removal
- Remove the right and left fairings and the spoiler terminals.
- Remove the Lambda probe from its support and disconnect it.
Remove the clamp holding the lambda probe cable to the coolant pipe indicated in the photograph
- Undo the two exhaust manifold fixings on the
head. To unscrew the nuts that fix the silencer
flange to the head properly, use a jointed wrench
that allows, according to the travel direction, to get
also at the right nut. That is difficult to do with a
traditional straight wrench.
- Undo the three screws that fix the silencer to the
supporting arm.
- Remove the full silencer unit.
ENG VE - 115
Engine from vehicle
Vespa GTS Super 125 i.e.
- Remove the lambda probe from the manifold.
CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.
Removal of the engine from the vehicle
CAUTION
SUPPORT THE VEHICLE ADEQUATELY.
- Disconnect the battery.
- Remove the helmet compartment.
- Remove the side fairings and the spoiler terminals.
- Remove the rear brake calliper
- Remove the air cleaner from the housing by unscrewing the three screws indicated in the photograph.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE
ENGINE IS COLD.
- Remove the clamp from the blow-by pipe and
take the pipe out; remove the retainer clamp.
- Remove the clamp indicated in the photograph
and disconnect the sleeve connecting it to the
throttle body.
ENG VE - 116
Vespa GTS Super 125 i.e.
Engine from vehicle
- Get a + 2.5 l container to collect the coolant.
- Remove the coolant inlet pipe to the motor as
indicated in the photograph.
- Disconnect the fuel pipe from the injector and remove the screw locking the retainer clamp.
- Disconnect the injector wiring and the throttle
body control unit wiring.
- Disconnect the cable harnesses from the two
clamps indicated.
ENG VE - 117
Engine from vehicle
- Remove the coolant outlet pipe from the engine
as indicated.
- Remove the spark plug cap.
- Remove the coolant temperature sensor connector indicated in the photo.
- Remove the throttle control cables from the throttle body by undoing the nuts indicated in the photograph.
- Loosen the clamp indicated in the photograph
and remove the throttle body.
ENG VE - 118
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Engine from vehicle
- Remove the clamp retaining the starter motor
from the sleeve.
- Remove the positive and negative wiring from the
starter motor as shown in the picture.
- Disconnect the connectors from the flywheel wiring as shown in the photo.
- Release the cables from the retainer clamps.
ENG VE - 119
Engine from vehicle
- Remove the four retainers of the rear brake pipes
from the crankcase.
- Remove the rear shock absorbers.
- Remove the engine-swinging arm fixing pin by
undoing the nut and operating on the head of the
pin as shown in the photograph.
- The engine is now free.
Upon refitting the engine to the vehicle, carry out
the removal operations but in reverse order, and
respect the tightening torque shown in the «Specifications» Chapter.
- Check that there is a small clearance when the
valve is in abutment against the set screw.
- Check the engine oil level and if necessary, top
it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct
functioning.
ENG VE - 120
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Engine from vehicle
- Pay particular attention to the sleeve, be careful
to position the throttle body reference marks as indicated in the picture.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE
THROTTLE CONTROL TRANSMISSION PROPERLY.
ENG VE - 121
INDEX OF TOPICS
INJECTION
INJEC
Vespa GTS Super 125 i.e.
Injection
INJEC - 123
Vespa GTS Super 125 i.e.
Injection
COMPONENT LAYOUT
1
2
3
4
5
6
7
8
9
10
11
12
Specification
Instrument panel
Throttle body and electronic injection control unit (MIU)
Diagnostics socket connector
Fuel pump
Water temperature sensor
Fuel injector
H.V. coil
Engine speed sensor
Lambda probe
Injection load relay
Battery
Electric fan relay
Desc./Quantity
MIU injection system
This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature
- Intake air temperature
- Lambda probe
The system implements cold engine idle fuel/air mixture correction with a stepper motor on a by-pass
circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time,
thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel system pressure is kept constant in relation to ambient pressure.
The fuel system circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by a pipe with fast-release fittings. The pressure regulator is located at the
beginning of the circuit.
The fuel pump is controlled by the MIU; this ensures safety of the vehicle.
The ignition circuit consists of:
- HV coil
- HV cable.
- Shielded cap
- MIU control unit
INJEC - 124
Vespa GTS Super 125 i.e.
Injection
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector
The control unit is provided with a self-diagnosis
system connected to an indicator light in the instrument panel.
Failures are detected and restored by the diagnostic tester.
In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles
of use (cold start, running at regular engine temperature, stop).
The diagnostic tester is also required to adjust the idle mixture.
Specific tooling
020922Y Diagnosis Tool
The MIU injection-ignition system carries out
checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the antitheft immobilizer system.
The MIU control unit is connected to a diagnostic
LED on the instrument panel, that also carries out
the deterrent flashing functions.
The MIU control unit power supply is furthermore controlled by the emergency switch; to allow further
safety of the vehicle.
INJEC - 125
Vespa GTS Super 125 i.e.
Injection
Precautions
Troubleshooting tips
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b.Burnt fuse
c.Remote control switches
d.Connectors
B: Chassis ground
C: Fuel system
a. Faulty fuel pump
b.Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b.Faulty coil
c.Faulty screened cap
E: Intake circuit
a. Air filter dirty
b.Dirty by-pass circuit
c.Faulty stepper motor
F: Other
a. Wrong distribution timing
b.Incorrect idle speed carburetion
c.Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connectors taking into consideration the following point:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C - Check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU, install the
original control unit again and check if the fault occurs again.
4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instruments that are not suitable might damage the MIU central control unit. Use instruments with definitions
over 0.1V and 0.5 W , the precision must be greater than 2%.
INJEC - 126
Vespa GTS Super 125 i.e.
Injection
1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release fitting of
the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to avoid
spraying fuel to your eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the
tank. Failure to respect this norm will damage the fuel pump.
6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and cable harnesses.
8. When an ignition problem is detected, start the checks from the battery and the injection system
connections.
9. Before disconnecting the MIU ECU connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the poles when fitting the battery.
11. To avoid causing any damage, disconnect and reconnect the MIU system connectors only if required. Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, remember to protect the system
connector with its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
INJEC - 127
Injection
Terminals setup
1. Injection warning light
2. incomplete
3. incomplete
4. (-) lambda probe
5. (+) live battery
6. (+) battery
7. Immobilizer aerial
8. Electric fan remote control
9. Water temperature sensor
10.incomplete
11.(+) lambda probe
12.Engine stop switch
13.(+) engine rpm sensor
14.(-) fuel injector
15.(-) engine rpm sensor
16.Diagnostics socket output
17.Immobilizer LED
18.Pin short-circuited with pin 26
19.(-) low-beam automatic ignition
20.(-) injection load remote control
21.incomplete
22.(-) HV coil
23.incomplete
24.Start up enabling
25.incomplete
INJEC - 128
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
26.Ground lead
THE FOLLOWING INFORMATION REFER TO
THE VERSION EQUIPPED WITH MIU G3 ECU.
ELECTRONIC CONTROL UNIT CONNECTOR
1. H.V. COIL (Pink-Black)
2. Not connected
3. Not connected
4. Ground (Green-Black)
5. Not connected
6. Key powered(Red-White)
7. Ground No. 1 (Black)
8. Not connected
9. Battery-powered (Grey-Black)
10. Start-up enabling switch (Orange-Blue)
11. Lambda probe positive (Sky blue-Black)
12. Lambda probe negative (White-Green)
13. Water temperature sensor (Sky blue-Green)
14. Immobilizer aerial (Orange-White)
15. Not connected
16. K serial line (Purple-White)
17. Immobilizer (Red-Green)
18. Not connected
19. Side stand (Grey-Green)
20. Engine speed sensor negative (Brown)
21. Not connected
22. Injection load relay (Black-Purple)
23. Not connected
24. Habilitation electric fan (Blue-Yellow)
25. Injection warning light (Brown-Black)
26. Not connected
27. Not connected
INJEC - 129
Injection
28. Not connected
29. Engine speed sensor positive (Red)
30. Not connected
31. Lambda probe heater (White)
32. Not connected
33. Low beam lights automatic ignition enabling (White-Black)
34. Fuel injector (Red-Yellow)
EMS circuit diagram
1. Battery 12V - 12 Ah
2. Rpm sensor
INJEC - 130
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
3. coolant temperature sensor
4. Immobilizer aerial
5. Stop switches
6. Fuse No. 1; 30A
7. Key switch contacts
8. Fuse No. 4; 7.5A
9. Fuse No. 3; 15A
10.Engine stop switch
11.Fuse No. 2; 7.5A
12.Injection load remote controls
13.Fuse No. 5; 15A
14.Starter button
15.Start-up remote control switch
16.Electric fan remote control
17.Starter motor
18.Electric fan motor
19.Fuel pump
20.HV coil
21.Injector
22.Lambda sensor
23.Headlight remote control
24."WARNING" light
25."IMMOBILIZER" led
26.Diagnostics socket output
27.Coolant electric pump
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJEC - 131
Injection
KEY
1. Instrument panel
12. Headlight relay
13. Secondary fuses
17. Engine stop switch
18. Ignition switch contacts
21. Starter relay
23. Battery
24. Main fuses
26. Voltage regulator
27. Injection load relay
28. Electric fan relay
29. Radiator electric fan
30. Lambda probe
31. Water pump
32. Engine speed sensor
33. HV coil
34. Fuel injector
35. Engine temperature sensor
36. Fuel pump
INJEC - 132
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
37. Diagnosis socket
38. Injection ECU
39. Immobilizer antenna
Troubleshooting procedure
Engine does not start
ENGINE DOES NOT START IF ONLY PULLED
Possible Cause
Immobiliser enabling signal
Presence of faults detected by the self diagnosis
Fuel system
Power to the spark plug
Parameter reliability
End of compression pressure
Operation
System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Pump relay
HV coil
Injector
Revolution timing sensor
Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Shielded spark plug cap HV coil (secondary insulation)
Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure
Starting difficulties
ENGINE STARTER PROBLEMS
Possible Cause
Presence of faults detected by the self diagnosis
Start-up speed
End of compression pressure
Power to the spark plug
Fuel system
Correctness of the parameters
Operation
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Starter motor and solenoid
Battery
Ground connections
End of compression pressure
Spark plug
Shielded cap
HV coil
Speed-timing sensor
Ignition advance
Fuel pressure (low)
Injector capacity (low)
Injector sealing (poor)
Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter efficiency
INJEC - 133
Vespa GTS Super 125 i.e.
Injection
Engine stops at idle
ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Correctness of the parameters
Intake system cleaning
Intake system sealing (infiltrations)
Fuel system (low pressure)
Operation
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Spark plug
Ignition timing
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Engine does not rev down
ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Correctness of the parameters
Intake system sealing (infiltrations)
Fuel system (low pressure)
Operation
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition timing
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Exhaust backfires in deceleration
EXHAUST BACKFIRES WHEN DECELERATING
Possible Cause
Presence of faults detected by the self diagnosis
INJEC - 134
Operation
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Vespa GTS Super 125 i.e.
Possible Cause
Correctness of the parameters
Intake system sealing (infiltrations)
Fuel system (low pressure)
Exhaust system sealing (infiltrations)
Injection
Operation
Coolant temperature
Lambda probe
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Manifold - head
Manifold - silencer
silencer welding
Engine revs irregularly
ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN
Possible Cause
Intake system cleaning
Intake system sealing
Ignition system
Parameter reliability
TPS reset successful
Presence of faults detected by the self diagnosis
Operation
Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake sleeve
Filter box
Spark plug wear check
Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Poor performance at full throttle
POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORMANCE ON PICKUP
Possible Cause
Presence of faults detected by the self diagnosis
Spark plug power supply
Intake system
Parameter reliability
Operation
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Spark plug
Shielded cap
HV cable
HV coil
Air filter
Filter box (sealing)
Intake sleeve (sealing)
Throttle valve position signal
Coolant temperature indicator
INJEC - 135
Vespa GTS Super 125 i.e.
Injection
Possible Cause
Fuel system
Operation
Intake air temperature indicator
Ignition advance
Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity
Engine knocking
PRESENCE OF KNOCKING (COMBUSTION SHOCKS)
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Parameter reliability
Intake system sealing
TPS reset successful
Fuel system
Selection of the cylinder base gasket thickness
Operation
Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Spark plug
Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Intake sleeve
Filter box
TPS reset successful
Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness
Fuel supply system
The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 136
Vespa GTS Super 125 i.e.
Injection
Removing the butterfly valve
Remove the helmet compartment.
Remove the fuel piping clamping screw indicated
in the figure.
Remove the fast-release fittings from the injector
support.
INJEC - 137
Injection
Remove the injector connector.
Remove the three screws fixing the manifold to the
cylinder head and the clip fixing the throttle body
to the manifold.
Remove the MIU ECU connector.
Remove the clip fixing the throttle body to the air
cleaner bellows.
INJEC - 138
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Remove the gas command fitting as indicated in
the picture
Refitting the butterfly valve
To refit, perform the operations in the reverse order from the removal operations being careful to
position the clip fixing the throttle body to the air
filter bellows at 45° as shown in the photograph.
INJEC - 139
Injection
Pump supply circuit
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
INJEC - 140
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
5. 7.5A fuse No. 2
6. Injection load relay
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan relay
11.Coolant electric pump
When switched to "ON", the fuel pump starts to
rotate for two seconds and then stops. When the
engine starts, in the presence of rpm timing signal
the pump is continuously supplied.
ELECTRICAL DATA
•
Pump winding resistance ~ 1.5 Ohm
•
Input current during regular operation
1.4 - 1.8 A
•
Input current to the closed hydraulic
circuit ~ 2 A (to be checked with appropriate tool for fuel pressure control
choking the circuit on the return pipe)
Check that the injection load 15A fuse No. 3 works properly.
Check that the 7.5A fuse No. 2 for live control unit power works properly.
Check the efficiency of the injection load relay.
Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the relay.
Check the power supply line of the injection load
solenoid energising coil: after switching to "ON",
make sure there is battery voltage, for 2 seconds,
between the Red-White cable and Black-Purple
cable of the solenoid base. If there is not, check
the continuity of the Red-White cable between the
fuse box and the solenoid base and of the Black-
INJEC - 141
Injection
Purple cable between the pin 20 of the control unit
and the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 142
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Check the presence of fixed voltage between the
grey/black cable of the relay base and ground. If
there is none, check the continuity of the grey/
black cable between the fuse box (No. 3 15 A) and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
pump circuit6
Check, on switching to "ON", that there is battery
voltage, for about two seconds, to the Black-Green
cable of the pump connector and ground with
pump connector disconnected. Otherwise, check
the continuity of the Black-Green cable between
the pump connector and the remote control base.
Check the efficiency of the ground line of the fuel
pump by measuring the continuity between the
pump connector black cable, system side, and the
ground.
If, when switching to "ON", the pump continues to
turn after two seconds of activation, check, with the
control unit disconnected and the injection load reINJEC - 143
Injection
Vespa GTS Super 125 i.e.
mote control disconnected, that the Black-Purple
cable (pin 20 on the interface wiring) is insulated
from the ground.
Specific tooling
020331Y Digital multimeter
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJEC - 144
Vespa GTS Super 125 i.e.
Injection
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
5. 7.5A fuse No. 2
INJEC - 145
Vespa GTS Super 125 i.e.
Injection
6. Injection load relay
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan relay
11.Coolant electric pump
When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA
•
Pump winding resistance ~ 1.5 Ohm
•
Input current during regular operation 1.4 - 1.8 A
•
Input current to the closed hydraulic circuit ~ 2 A (to be checked with appropriate tool for
fuel pressure control choking the circuit on the return pipe)
Check that the injection load 15A fuse No. 3 works
properly.
Check that the 7.5A fuse No. 2 for live control unit
power works properly.
Check the efficiency of the injection load relay.
Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the relay.
Check the power supply line of the injection load
relay energising coil: after switching to "ON", make
sure there is battery voltage, for 2 seconds, between the Red-White cable and Black-Purple cable of the relay base. If there is not, check the
continuity of the Red-White cable between the
fuse box and the relay base and of the Black-Pur-
INJEC - 146
Vespa GTS Super 125 i.e.
Injection
ple cable between the pin 22 of the control unit and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
Check the presence of fixed voltage between the
grey/black cable of the relay base and ground. If
there is none, check the continuity of the grey/
black cable between the fuse box (No. 3 15 A) and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 147
Injection
Vespa GTS Super 125 i.e.
Check, on switching to "ON", that there is battery
voltage, for about two seconds, to the Black-Green
cable of the pump connector and ground with
pump connector disconnected. Otherwise, check
the continuity of the Black-Green cable between
the pump connector and the relay base.
Check the efficiency of the ground line of the fuel
pump by measuring the continuity between the
pump connector black cable, system side, and the
ground.
If, when switching to "ON", the pump continues to
turn after two seconds of activation, check, with the
control unit disconnected and the injection load relay disconnected, that the Black-Purple cable (pin
22 on the interface wiring) is insulated from the
ground.
Specific tooling
020331Y Digital multimeter
Circuit leak test
Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
INJEC - 148
Vespa GTS Super 125 i.e.
Injection
Check during regular operation by placing the appropriate tool between the pump and the injector.
With the battery voltage> 12 V check that the fuel
pressure is 2.5 BAR and that the input current is
1.4 to 1.8 A
With the battery voltage > 12 V, check the capacity of the pump flow rate by disconnecting from the
injector the pipe equipped with the pressure gauge of the appropriate tool. Make a graded burette
available with a flowrate of approximately 1 L. Rotate the pump using the active diagnosis of the palm
top computer. Using a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure
stabilise at approx. 2.5 BAR. Check that, in fifteen seconds, the pump has a flowrate of around 110cc.
Specific tooling
020480Y Petrol pressure check kit
Fuel filter check
Disconnect the terminals from the electric pump
Remove the screw shown in the picture
INJEC - 149
Injection
Remove the clip fixing the piping to the filter shown
in the picture
Separate the lower part of the pump mounting as
shown in the picture.
Remove the filter from the pump mounting
INJEC - 150
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Inspecting the injector circuit
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
5. 7.5A fuse No. 2
6. Injection load relay
7. Fuel pump
8. HV coil
INJEC - 151
Injection
9. Fuel injector
10.Electric fan relay
Check the resistance at the injector ends: 14.5 ± 5% Ohm
Check that the injection load 15A fuse No. 3 works
properly.
Check that the 7.5A fuse No. 2 for live control unit
power works properly.
Check the efficiency of the injection load relay.
Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the relay.
Check the power supply line of the injection load
remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and BlackPurple cable of the remote control base. If there is
not, check the continuity of the Red-White cable
between the fuse box under the saddle hinge and
the remote control base and of the Black-Purple
cable between pin 20 of the control unit and the
remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 152
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Check the presence of fixed voltage between the
grey/black cable of the relay base and ground. If
there is none, check the continuity of the grey/
black cable between the fuse box (No. 3 15 A) and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 153
Injection
With the control unit and the injector disconnected,
check the continuity of the Red-Yellow cable between pin 14 of the interface wiring and the injector
connector
Switch to «ON» and check if there is voltage, with
injector disconnected and control unit connected,
between the Black-Green cable of the injector connector and the ground lead
INJEC - 154
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
With injector disconnected and the injector load
relay disconnected, check the continuity of the
Black-Green cable between the injector connector
and relay base.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJEC - 155
Injection
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
5. 7.5A fuse No. 2
INJEC - 156
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
6. Injection load relay
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan relay
Check the resistance at the injector ends: 14.5 ± 5% Ohm
Check that the injection load 15A fuse No. 3 works
properly.
Check that the 7.5A fuse No. 2 for live control unit
power works properly.
Check the efficiency of the injection load relay.
Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the relay.
Check the power supply line of the injection load
relay energising coil: after switching to "ON", make
sure there is battery voltage, for 2 seconds, between the Red-White cable and Black-Purple cable of the relay base. If there is not, check the
continuity of the Red-White cable between the
fuse box and the relay base and of the Black-Purple cable between the pin 22 of the control unit and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 157
Injection
Check the presence of fixed voltage between the
grey/black cable of the relay base and ground. If
there is none, check the continuity of the grey/
black cable between the fuse box (No. 3 15 A) and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 158
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
With the control unit and the injector disconnected,
check the continuity of the Red-Yellow cable between pin 34 of the interface wiring and the injector
connector
Switch to «ON» and check if there is voltage, with
injector disconnected and control unit connected,
between the Black-Green cable of the injector connector and the ground lead
INJEC - 159
Injection
With injector disconnected and the injector load
relay disconnected, check the continuity of the
Black-Green cable between the injector connector
and relay base.
Inspecting the injector hydraulics
To carry out the injector check, remove the intake
manifold by removing the three clamping screws
at the head and the clip connecting the control unit
to the manifold.
Install the appropriate tool for checking fuel pressure and position the manifold over a container
graduated by at least 100 cm³. Connect the injector with the cable making up part of the supply for
the injection tester. Connect the clamps of the cable to an auxiliary battery. Activate the fuel pump
with the active diagnosis. Check that, within fifteen
seconds, approximately 40 cm³ of fuel is dispensed with an adjustment pressure of approximately 2.5 BAR.
Specific tooling
020480Y Petrol pressure check kit
INJEC - 160
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Proceed with the injector seal test.
Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute
Tachometer
With wiring disconnected from the control unit and
connected to the system, check that the sensor
resistance between pins 13 - 15 is between 100
and 150 Ohm at an engine temperature of approximately 20°
INJEC - 161
Injection
Vespa GTS Super 125 i.e.
Disconnect the fuel pipe connector. Start up the
engine and wait for it to stop. With the wiring connected to the control unit and system try to start up
the engine and check that the voltage between
pins 13 and 15 is around 2.8 V
With the interface cable harness disconnected
from the control unit, check continuity between pin
13 and the red cable of the engine speed sensor
connector and between pin 15 and the brown cable of the engine speed sensor connector
With the interface wiring and rpm sensor connector disconnected from the control unit, check that
the Red and Brown cables (pin 13 - 15) are isolated from each other and insulated from the ground.
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJEC - 162
Vespa GTS Super 125 i.e.
Injection
With wiring disconnected from the control unit and connected to the system, check that the sensor
resistance between pins 20 - 29 is between 100 and 150 Ohm at an engine temperature of approximately 20°
Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected
to the control unit and system try to start-up the engine and check that the voltage between pins 20 and
29 is around 2.8 V
With the interface wiring disconnected from the control unit, check continuity between pin 29 and the
red cable of the engine speed sensor connector and between pin 20 and the brown cable of the engine
speed sensor connector
With the interface wiring disconnected from the control unit and engine speed sensor connector , check
that the Red and Brown cables (pin 29 - 20) are isolated from each other and insulated from the ground.
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
INJEC - 163
Injection
HT coil
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
INJEC - 164
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
5. 7.5A fuse No. 2
6. Injection load relay
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan relay
11.Coolant electric pump
The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two significant parameters:
- Ignition advance
This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up phase.
The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression
phase.
Specific tooling
020331Y Digital multimeter
Check that the injection load 15A fuse No. 3 works
properly.
Check that the 7.5A fuse No. 2 for live control unit
power works properly.
Check there is voltage between pins 22 and 26 of
the interface wiring for around two seconds when
switching to «ON».
INJEC - 165
Injection
Check the resistance of the primary coil between
pin 22 of the interface wiring and the green black
cable of the injection load solenoid base with the
control unit disconnected and the solenoid disconnected.
Resistance of the primary = 0.5 ± 8% Ohm
Check the efficiency of the injection load relay.
Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the relay.
Check the power supply line of the injection load
solenoid energising coil: after switching to "ON",
make sure there is battery voltage, for 2 seconds,
between the Red-White cable and Black-Purple
cable of the solenoid base. If there is not, check
the continuity of the Red-White cable between the
fuse box and the solenoid base and of the BlackPurple cable between the pin 20 of the control unit
and the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 166
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
INJEC - 167
Injection
Vespa GTS Super 125 i.e.
Check the presence of fixed voltage between the
grey/black cable of the relay base and ground. If
there is none, check the continuity of the grey/
black cable between the fuse box (No. 3 15 A) and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJEC - 168
Vespa GTS Super 125 i.e.
Injection
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
5. 7.5A fuse No. 2
INJEC - 169
Injection
Vespa GTS Super 125 i.e.
6. Injection load relay
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan relay
11.Coolant electric pump
The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two significant parameters:
- Ignition advance
This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up phase.
The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression
phase.
Specific tooling
020331Y Digital multimeter
Check that the injection load 15A fuse No. 3 works
properly.
Check that the 7.5A fuse No. 2 for live control unit
power works properly.
Check there is voltage between pins 1 and 7 of the interface wiring, for around two seconds, when
switching to «ON».
Check the resistance of the primary coil between
pin 1 of the interface wiring and the green black
cable of the injection load relay base with the control unit disconnected and the relay disconnected.
Resistance of the primary = 0.5 ± 8% Ohm
INJEC - 170
Vespa GTS Super 125 i.e.
Injection
Check the efficiency of the injection load relay.
Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the relay.
Check the power supply line of the injection load
relay energising coil: after switching to "ON", make
sure there is battery voltage, for 2 seconds, between the Red-White cable and Black-Purple cable of the relay base. If there is not, check the
continuity of the Red-White cable between the
fuse box and the relay base and of the Black-Purple cable between the pin 22 of the control unit and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 171
Injection
Check the presence of fixed voltage between the
grey/black cable of the relay base and ground. If
there is none, check the continuity of the grey/
black cable between the fuse box (No. 3 15 A) and
the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (RELAYS, CONTROL
UNIT, FUSES ETC.).
INJEC - 172
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Coolant temperature sensor
TEMPERATURE SENSOR
1
2
Specification
Water temperature sensor
engine stop switch
1
Desc./Quantity
With the control unit side connector disconnected
and the coolant temperature sensor connector
connected, check the resistance between pins 9
and 26 in relation to the engine temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the control unit side connector disconnected
and the coolant temperature connector disconnected, check the insulation between the two light
blue/green and pink/yellow cables
INJEC - 173
Vespa GTS Super 125 i.e.
Injection
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
TEMPERATURE SENSOR
1
INJEC - 174
Specification
Water temperature sensor
Desc./Quantity
Vespa GTS Super 125 i.e.
Injection
With the connector on the control unit side disconnected, and the coolant temperature sensor connector connected, check that the resistance values between pins 13 and 7 correspond to the
engine temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the control unit side connector disconnected,
and the coolant temperature connector disconnected, check the insulation between the two light
blue-green and grey-green cables.
Zeroing the throttle
Resetting the throttle valve position signal (TPS reset)
The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.
INJEC - 175
Injection
Connect the diagnostic tester.
Switch to «ON».
Select the functions of the diagnostic tester on
«TPS RESET».
Specific tooling
020922Y Diagnosis Tool
Make sure that the throttle valve with the control is
supporting the stop screw.
Guaranteeing that this position will be kept, send
a confirmation for the TPS reset procedure.
INJEC - 176
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
Reset should be performed in the following cases:
- on first fitting.
- if the injection control unit is replaced.
N.B.
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Given that the TPS resetting is also done when the
control unit is replaced, place the control unit - filter
box bellows at 45° during the refitting operation as
shown in the picture.
Lambda probe
SIGNAL CONTROL
1. Lambda probe
INJEC - 177
Injection
Vespa GTS Super 125 i.e.
Install the electronic control unit interface wiring.
Start the engine and warm up until the electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
and 11 (+)
With the engine running at idle speed, check that
the voltage oscillates between 0V and 1V
With the throttle valve completely open, the voltage is approx. 1V.
During the closing phase, the voltage is approx.
0V.
If the voltage remains constant, the sensor may be
damaged. Remove the sensor and check that
there are no oil or carbon deposits inside it..
SIGNAL CONTROL
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
1. Lambda probe
Install the electronic control unit interface wiring.
Start the engine and warm up until the electric fan switches on.
Use an analogue multimeter with a direct voltage scale measuring down to 2 V.
Place the multimeter probes between pins 11 (-) and 12 (+).
INJEC - 178
Vespa GTS Super 125 i.e.
Injection
With the engine running at idle speed, check that
the voltage oscillates between 0V and 1V
With the throttle valve completely open, the voltage is approx. 1V.
During the closing phase, the voltage is approx.
0V.
If the voltage remains constant, the sensor may be
damaged. Remove the sensor and check that
there are no oil or carbon deposits inside it..
INJEC - 179
Injection
Impianto elettroventilatore
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
INJEC - 180
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Injection
4. Key switch contacts
5. 7.5A fuse No. 2
6. Injection load remote control
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan remote control
11.Coolant electric pump
12.Fuse No. 5; 15A
13.Electric fan motor
Check that the 7.5A fuse No. 2 works properly
With the ignition switch set to ON, check if there is
+12 V battery voltage between the RED - WHITE
cable of the electric fan relay and the ground connection.
Check if the RED - WHITE cable between the fuse
box and the electric fan relay base is not interrupted
Using a diagnosis Palmtop, carry out an active diagnosis for the "ELECTRIC FAN". Check if there
is battery voltage at pins 85 - 86 of the electric fan
relay
INJEC - 181
Injection
Vespa GTS Super 125 i.e.
Check if the BLUE - YELLOW cable between the
control unit pin 8 and the electric fan remote control base is not interrupted
Check the 15A Fuse No. 5
Check if there is +12 V voltage between the GREY
cable of the electric fan relay base and the ground
connection.
Check if the GREY cable between the fuse box in
the glove-box compartment and the electric fan
relay base is not interrupted.
Check if the RED cable between the electric fan
relay base and the electric fan motor is not interrupted.
Check that the electric fan motor is earthed.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
INJEC - 182
Vespa GTS Super 125 i.e.
Injection
1. Battery 12V
2. 15A fuse No. 3
3. 30A fuse No. 1
4. Ignition switch contacts
INJEC - 183
Injection
Vespa GTS Super 125 i.e.
5. 7.5A fuse No. 2
6. Injection load relay
7. Fuel pump
8. HV coil
9. Fuel injector
10.Electric fan relay
11.Coolant electric pump
12.Fuse No. 5 of 7.5A
13.Electric fan motor
Check that the 7.5A fuse No. 2 works properly
With the ignition switch set to ON, check if there is
+12 V battery voltage between the RED - WHITE
cable of the electric fan relay and the ground connection.
Check if the RED - WHITE cable between the fuse
box and the electric fan relay base is not interrupted
Using a diagnosis Palmtop, carry out an active diagnosis for the "ELECTRIC FAN". Check if there
is battery voltage at pins 85 - 86 of the electric fan
relay
Check if the blue - yellow cable between the control unit pin 24 and the electric fan relay base is not
interrupted.
INJEC - 184
Vespa GTS Super 125 i.e.
Injection
Check the 7.5A Fuse No. 5
Check if there is +12 V voltage between the GREY
cable of the electric fan relay base and the ground
connection.
Check if the GREY cable between the fuse box in
the glove-box compartment and the electric fan
relay base is not interrupted.
Check if the RED cable between the electric fan
relay base and the electric fan motor is not interrupted.
Check that the electric fan motor is earthed.
INJEC - 185
INDEX OF TOPICS
SUSPENSIONS
SUSP
Vespa GTS Super 125 i.e.
Suspensions
This section is dedicated to operations that can be carried out on the suspensions.
Front
Removing the front wheel
- Remove the 5 fixing screws indicated in the picture.
Locking torques (N*m)
Wheel fixing screw 20 to 25
Front wheel hub overhaul
- Support the vehicle adequately.
- Remove the front wheel.
- Remove the front brake calliper.
- Remove the cotter pin and remove the cap.
- Unscrew the nut fixing the front wheel hub.
SUSP - 187
Suspensions
- Remove the wheel hub.
- Remove the ball bearing check Seeger ring indicated in the picture
Extract the ball bearing using the specific tool
Specific tooling
001467Y014 Calliper 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.
SUSP - 188
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Suspensions
- 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
020359Y 42 x 47-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 Yellow-brown, lithiumbase, medium-fibre multipurpose grease.
ISO L-X-BCHA 3 - DIN 51 825 K3K -20
Refitting the front wheel
- To refit, carry out the removal operations but in reverse order and comply with the specified locking
torque.
Locking torques (N*m)
Wheel fixing screw 20 to 25 Wheel axle nut 74 - 88
SUSP - 189
Suspensions
Steering column
Removal
- Remove the front wheel
- Remove the brake calliper
- Loosen the screw fixing the odometer cable plate
and take out the cable.
- Remove the suspension arm housing by unscrewing the three screws indicated in the photograph.
SUSP - 190
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Suspensions
- Remove the retainer fixing the odometer cable to
the mudguard indicated in the photograph
- Remove the retainer fixing the brake piping to the
front shock absorber upper plate
- Remove the retainer fixing the brake piping to the
suspension arm
- Pre-loosen the 3 nuts fixing the mudguard to the
suspension
SUSP - 191
Suspensions
Vespa GTS Super 125 i.e.
- Remove the rear handlebar cover.
- Remove the screw fixing the handlebar to the
steering tube
- Tilt the handlebar towards the shield back plate
being careful not to scratch the plastic parts
- Remove the steering tube ring nut cover
- Use a specific tool to remove the counter-ring nut,
the spacer washer and the ring nut of the upper
disk of the fifth wheel fitting
- Slide off the steering tube and remove permanently the mudguard from the suspension
Specific tooling
020055Y Wrench for steering tube ring nut
Overhaul
Carry out this operation only if strictly necessary and in any case remove and replace the old part with
a new one.
SUSP - 192
Vespa GTS Super 125 i.e.
Suspensions
- Remove the steering tube
- Use a special tool remove the upper disk of the
fifth wheel fitting seat on the headstock by operating form the lower part of the headstock as indicated in the photograph. Afterwards remove the
lower disk of the fifth wheel operating from the upper part
Specific tooling
020004Y Punch for removing steering bearings
from headstock
- Remove the fifth wheel fitting and the dust gaiter
on the steering bearing as shown in figure, using
the specific tool. Proceed giving a few taps with the
mallet.
Specific tooling
020004Y Punch for removing steering bearings
from headstock
SUSP - 193
Suspensions
- Refit the fifth wheel fitting and the dust gaiter on
the steering bearing until they stop, using the specific tool.
Specific tooling
006029Y Punch for fitting steering bearing seat
on steering tube
- Use the specific tool to fit the fifth wheel fitting on
the headstock as indicated in the figure
Specific tooling
001330Y Tool for fitting steering seats
- Remove the steering tube
- Remove the attachment bracket
- Use the specific tool with the part 1 and operate
the handgrip until removing temporarily the pin and
the Nadella opposite the tool thrusting direction.
- To extract the second Nadella, use the tool with
the part 2, instead of part 1, on opposite side to the
one indicated in the figure.
Specific tooling
020021Y Front suspension service tool
- Fit both dust guard rings «C» on the swinging hub
as shown in the detail drawing «A».
- Connect the swinging hub to the steering tube
with the guiding pin, part 5.
- Use the specific tool fitted with part 3 on the stem
and part 4 on the tool base.
- Lubricate the pin with recommended grease and
insert it temporarily on the swinging hub, move the
tool handgrip until part 3 is fully inserted on the
steering tube.
SUSP - 194
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Suspensions
- Once the pin has been fitted, insert the two
spacers part 17 slightly hitting with a mallet (see
next figure).
CAUTION
USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND
DUST GUARDS FOR REFITTING.
Specific tooling
020021Y Front suspension service tool
Recommended products
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, NATO G 460 symbol
To fit sealing rings, roller casings and wedging
washers proceed as follows
- Lubricate the sealing rings with mineral oil and
half-fill the roller casings with recommended
grease.
- Insert the sealing ring on the pin and the roller
bushing with wedging washers at the same time.
- Remove the specific tool and then the part 5
(guide) partially ejected in the previous assembly
stage; part 4 must be always fitted.
- Replace part 3 with part 16 on the stem.
- Push, from the handgrip, the wedging washer roller casing - sealing ring unit, placing part 16 until
it stops on the swinging hub
- Repeat the operation described above using the
tool fitted with part 16 and part 22* instead of part
4 on the stem, on the side opposite the one shown
in the figure to refit the second wedging washer roller casing - sealing ring unit.
SUSP - 195
Suspensions
Vespa GTS Super 125 i.e.
To position roller casings on the pin (pin end in
contact with the internal bottom of the roller casings) proceed as follows:
- Use the tool with part 20 and 21 fitted to the stem
as indicated in the figure.
- Push the two roller casings with the handgrip until
their bottoms make contact with the pin end.
- Use the specific tool fitted with parts 3 and 4 as
indicated for fitting the spin and push with the
handgrip until the washer is wedged in the swinging hub.
- Remove the spacers, part 17; fill with recommended grease the area between the steering tube
and the swinging hub, and place the dust guard
rings in that place.
Recommended products
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, NATO G 460 symbol
Refitting
To refit, carry out the removal operations but in reverse order; grease the fifth wheel fittings and tighten
at the specified locking torques
Locking torques (N*m)
Handlebar to steering tube 45 ÷ 50 Upper steering ring nut 35 - 40 Lower steering ring nut 12 14
Front shock absorber
SUSP - 196
Vespa GTS Super 125 i.e.
Suspensions
Removal
- Support the vehicle adequately.
- Remove the wheel hub.
- Loosen the shock absorber lower clamps and remove the brake calliper shock absorber mounting.
- Loosen the screws fixing the front brake pipe retainer clamp and the odometer cable in order to
reach the upper clamps.
- Unscrew the upper fixing nuts.
- Remove the front shock absorber.
SUSP - 197
Suspensions
Vespa GTS Super 125 i.e.
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
Locking torques (N*m)
shock absorber lower clamping 20 - 27 shock absorber upper clamp 20 to 30
Shock-absorber - calliper bracket
- Remove the front wheel hub with the brake disc
- Remove the front shock absorber lower clamps
- Remove the bracket locking Seeger ring
- Unscrew the bracket
- Before refitting the bracket in the wheel axle,
place the O-ring as shown in the photograph so
that it is correctly placed after fitting the bracket.
- Refit the washer and the Seeger ring.
- Refit the lower screws fixing the shock absorber
to the bracket and tighten at the prescribed torque
Locking torques (N*m)
Shock absorber lower clamping 20 to 27
SUSP - 198
Vespa GTS Super 125 i.e.
Suspensions
Overhaul
- The bracket for the shock absorber -calliper attachment has two roller bearings separated one
from the other as shown in the photograph
- Remove the two roller bearings from the bracket
with the specific tool operating on the shock absorber attachment side as shown in the photograph
Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020365Y 22 mm guide
- Remove the oil seal on the wheel hub side with
the screwdriver as shown in the photograph
- Suitably hold the brake calliper - shock absorber
attachment bracket
- Fit a new oil seal and move it until it stops using
the specific tool
Specific tooling
020376Y Adaptor handle
020360Y 52 x 55-mm Adaptor
SUSP - 199
Suspensions
- Assemble a new roller bearing on the shock absorber side and move it until it stops using the
specific tool
Specific tooling
020036Y Punch
- Suitably hold the brake calliper - shock absorber
attachment bracket
- Assemble a new roller bearing on the wheel hub
side and move it until it stops using the specific tool
Specific tooling
020037Y Punch
Refitting
- Refit the parts in reverse order of the removal
operation.
CAUTION
BEFORE CARRYING OUT REFITTING OPERATIONS IN
THE AREAS MARKED WITH AN ASTERISK, LUBRICATE
THEM WITH THE RECOMMENDED PRODUCT
Specific tooling
020036Y Punch
020037Y Punch
Recommended products
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, NATO G 460 symbol
Rear
SUSP - 200
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Suspensions
Removing the rear wheel
- Remove the bracket supporting the rear shock
absorber and the muffler;
- Remove the rear wheel by unscrewing the 5
screws indicated in the photograph
Refitting the rear wheel
To refit, carry out the removal operations but in reverse order, observing the prescribed torques.
Locking torques (N*m)
Wheel fixing screws: 20 - 25
Swing-arm
Removal
- Place the vehicle on its centre stand;
- Remove the engine housing
- Remove the swinging arm/engine fitting shown in
the picture
- Move the engine back
- Remove the spring anchoring the swinging arm
to the chassis as shown in the picture
SUSP - 201
Suspensions
- Remove the two screws fixing the buffer support
bracket to the chassis
- Remove the left and right caps located under the
footrest to reach the pin fixing the swinging arm to
the body.
- Remove the pin. Then remove the swinging arm.
SUSP - 202
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Suspensions
- Check the entire swinging arm assembly.
- Check all the centring bushing components and
silent block rubber buffers.
- Replace the work components that cause excessive clearance on the rear suspension.
Overhaul
- Check there is no sticking in the movement of the
connection of the swinging arm on the engine side
to the swinging arm on the chassis side.
- Check the axial clearance between the two
swinging arms using a feeler gauge
Characteristic
Standard clearance
0.40 - 0.60 mm
Allowable limit after use:
1.5 mm
- In order to check the clearance of the swinging
arm on the frame side, prepare a retainer using the
fixing pin of the swinging arm on the frame and two
rings from the special tool 020229Y. Alternatively,
use two washers with 12-mm inside diameter for
pins, minimum 30-mm outside diameter and 4-mm
thick at least.
- Check there is no sticking in the rotation.
- Check the axial clearance of the swinging arm on
the chassis side
Characteristic
Standard clearance
0.40 - 0.60 mm
Allowable limit after use:
1.5 mm
SUSP - 203
Suspensions
- Separate the swinging arm on the engine side
from the vehicle side arm.
- Remove the plastic bushings and the internal
spacer shown in the picture.
- Using a suitable pin remove the roller casings as
shown in the pictures
- Using an appropriate tool plant new roller casings, being careful to position the bearings with the
seal rings facing outwards
Specific tooling
020244Y 15-mm diameter punch
020115Y Ø 18 punch
Characteristic
Length of the swinging arm tube on the engine
side:
L 175.3 + 0.3 0
Length of the internal swinging arm spacer on
the engine side:
L 183 + 0.3 0
Engine side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Chassis side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the frame side:
290 ± 0.1 mm
SUSP - 204
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Suspensions
Length of the swinging arm tube on the chassis side:
283 ± 0.1 mm
- Lubricate roller casings and the plastic bushings
with grease
- Insert the spacers
- Assemble the two arms with the relative bolt in
the position shown in the picture
- Adjust the bolt as shown in the picture
- Position the chassis side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the picture
Recommended products
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, NATO G 460 symbol
- Make sure the silent bloc is not broken. If it is,
replace the coupling.
- Remove the Seeger ring shown in the picture
- Remove the full silent bloc bracket
- Undo the silent bloc ring shown in the picture
SUSP - 205
Suspensions
Vespa GTS Super 125 i.e.
- Hold the full silent bloc bracket in the clamp
- Using the appropriate tool, remove the silent bloc
from the bracket from the side corresponding to
the inside of the vehicle. This is to guarantee the
tool is centred properly on the support
- Install a new silent bloc, making sure it aligns
properly with the reference tooth.
- Fit the silent blocs, making sure the chamfered
part of the silent bloc matches the chamfered part
of the bracket
- Using the appropriate tool, fit the silent bloc as
shown in the picture
Refitting
- To refit, perform the removal operations in reverse.
- Grease the bearings and the rolling parts with the recommended grease.
SUSP - 206
Vespa GTS Super 125 i.e.
Suspensions
-Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.
Locking torques (N*m)
Engine- and vehicle-side swinging arm junction bolt 40 ÷ 45 Swinging arm pin - Engine 64 ÷ 72
Body shell - Swinging arm pin 76 ÷ 83 Screw fixing the silent-block support plate to the body 42
÷ 52
Shock absorbers
Removal
Proceed as follows:
- place the vehicle on its centre stand;
- remove the luggage rack
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the muffler assembly;
- undo the shock absorber spring assembly clamping screw from the support fixed to the engine on
the one side and from that fixed to the muffler on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.
Refitting
To refit, carry out the above removal operations in reverse order, observing the prescribed torques.
Locking torques (N*m)
SUSP - 207
Suspensions
Vespa GTS Super 125 i.e.
Shock absorber lower fitting 40 ÷ 45 Upper shock absorber fixing screws 20 ÷ 25 Nm
Exhaust bracket
Removal
Remove the full muffler unit.
- Remove the two fixing screws of the bracket to
the engine crankcase
- Remove the split pin, the cover and the fixing nut
of the rear wheel axle and its spacer
- Remove the shock absorber lower clamp
Refitting
- The refitting procedure is in the reverse order of the removal operation being careful to respect the
torques indicated and the spacer assembly layout as shown in the photo.
Locking torques (N*m)
Bracket fixing screws to the engine crankcase: 20 ÷ 25 Shock absorber lower fitting 40 ÷ 45
Wheel axle clamping 104 ÷ 126
Centre-stand
REMOVAL
- Use a jack to support the vehicle properly.
- Remove the two return springs from the centre
stand.
- Undo the nut shown in the figure.
- Remove the pin from the right side.
- Remove the centre stand.
FITTING
- On refitting tighten the nut to the specified torque.
Locking torques (N*m)
Centre stand bolt 32 to 40
SUSP - 208
Vespa GTS Super 125 i.e.
Suspensions
Side stand
REMOVAL
- Uncouple the centre stand return spring;
Remove the screw shown in the photograph
FITTING
To refit, carry out the removal operations in reverse order and comply with the specified torque.
Locking torques (N*m)
Side stand fixing bolt 35 to 40
SUSP - 209
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Vespa GTS Super 125 i.e.
Braking system
This section è is dedicated to the description of the brake system components.
Rear brake calliper
Removal
- Remove the rear wheel.
- Remove the pad retention pin snap ring.
- Using a pin partially remove the brake pad retention pin.
- Remove the screws fixing the brake calliper to
the crankcase then remove the brake calliper complete with pipe.
- Complete the extraction of the pad retention pin,
the spring and the pads.
N.B.
IF IT IS NECESSARY TO REPLACE OR SERVICE THE
BRAKE CALLIPER, BEFORE REMOVING THE FITTINGS
FIXING THE CALLIPER TO THE SUPPORT BRACKET,
FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING
EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAMINED.
Overhaul
- Remove the rear brake calliper.
- Suitably hold the brake calliper in a clamp
- Remove the two calliper coupling screws as
shown in the photo
- Remove the two pistons from the calliper body
with the aid of short blasts of compressed air
through the brake fluid holes
- Remove the dust ring and the O-ring of each half
calliper.
- Remove the O-rings in the half calliper.
N.B.
WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO
SCRATCH THE HALF CALLIPER SEATS
BRAK SYS - 211
Braking system
Vespa GTS Super 125 i.e.
- Check that the pistons and their seats show no
scratches.
- Wash and blow all the components carefully
- Fit the O-rings and new dust guards
- Refit the pistons in their seats being careful to
lubricate with brake fluid
- Re-couple the half callipers and lock the two
screws at the specified torque
Locking torques (N*m)
Calliper coupling screw 30 ÷ 33 Nm
Refitting
- Follow the removal steps but in reverse order and tighten to the prescribed torque.
Locking torques (N*m)
Calliper fixing screw 24 ÷ 27
If the calliper is replaced:
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Screw fixing the oil connection to the calliper 19 ÷ 24
BRAK SYS - 212
Vespa GTS Super 125 i.e.
Braking system
Front brake calliper
Removal
- Remove the front wheel
- Pre-loosen the two fixing pins of the brake pads
- Remove the two front brake calliper devices fastening them to the support as shown in the photograph.
N.B.
WHEN A PROCEDURE IS PLANNED INCLUDING THE
SERVICE OR REPLACEMENT OF THE CALLIPER, FIRST
LOOSEN THE FITTING CONNECTING THE PIPE TO THE
BRAKE CALLIPER
Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of compressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
BRAK SYS - 213
Braking system
- that the cylinder and the floating body of the calliper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
CAUTION
ALL THE INTERNAL COMPONENTS MUST BE REPLACED
EVERY TIME THE CALLIPER IS SERVICED.
The brake pad check spring
1. pad fixing screws
2. reaction plate fixing screws
3. reaction plate
4. fixed plate
5. floating body
6. piston
7. piston sealing rings
8. guide protection rubbers
9. brake pad check spring
10. pads
Refitting
Insert the following on the front brake body:
-The sealing rings and the pistons (1).
-Refit the plate (2).
- Arrange the pad holding clamp (3).
-Refit the pads and bleed air.
-Place the calliper on the disk and lock it to the
support by tightening the bolts at the prescribed
torque.
-Lock the pipe joint to the calliper at the prescribed
torque.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Screws fixing the front calliper to the support: 24 ÷ 27 Screw fixing the oil connection to
the calliper 19 ÷ 24
BRAK SYS - 214
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Braking system
Rear brake disc
Removal
- Remove the rear brake calliper.
- Remove the brake disc and the hub from the
wheel axle
- To remove the brake disc from the hub, hold the
unit firmly with a vice and operate on the 5 fixing
screws indicated in the photograph
Refitting
- To reassemble the brake disc on the hub, carry out the removal operations in the reverse order arranging the brake disc on the hub on the side opposite the wheel keying
- Follow the direction of rotation shown by the arrow and tighten to the prescribed torque.
- Fit the hub unit
- disc in the wheel axle
Locking torques (N*m)
Disk to the hub 11 ÷ 13
Disc Inspection
- Remove the rear brake calliper.
- Check the disc thickness with a micrometer
Characteristic
Standard thickness:
3.5 mm
- Repeat the measurement at no fewer than six points on the disc.
- Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed
onto the brake calliper as shown in the photo.
- In order to be able to anchor the appropriate tool properly use a metal plate with M8 threaded hole
and fix it to one of the two rear brake calliper attachment points.
- Suitably fix the flange to the wheel axle with the original nut and spacer and a Æ 17 mm bearing.
BRAK SYS - 215
Braking system
Vespa GTS Super 125 i.e.
N.B.
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN
IN ORDER TO ROTATE THE DISC.
Specific tooling
020335Y Magnetic mounting for dial gauge
Characteristic
Max. deviation allowed:
0.1 mm
- If you detect incorrect values, replace the disc. If
the anomaly persists, replace the hub.
Front brake disc
Removal
- Remove the front wheel
- Remove the front brake calliper
- Remove the hub and the disc operating on the
wheel axle nut
- Hold the hub and the disc firmly and remove the
brake disc undoing the six screws indicated in the
photograph
BRAK SYS - 216
Vespa GTS Super 125 i.e.
Braking system
Refitting
- Carry out the operations in the reverse order from
the removal being careful to respect the direction
of disc rotation shown by the arrow printed on it
- Tighten the six screws to the specified torque.
Locking torques (N*m)
Brake disc screws 8 ÷ 10
Disc Inspection
- Remove the front wheel
- Use a micrometer to check the disc thickness as
shown in the photograph
- Repeat the measurement in at least 6 points on
the disk
- Remove the front brake calliper
- In order to secure the appropriate tool adequately
use a metal plate with M8 threaded hole and fix it
to one of the two front brake calliper attachment
points
- Place the dial gauge on the disk outer edge
- Make the wheel hub turn and check the disk deviation
Specific tooling
020335Y Magnetic mounting for dial gauge
Characteristic
Standard thickness:
3.5 mm
Max. deviation allowed:
0.1 mm
Front brake pads
BRAK SYS - 217
Braking system
Removal
- Remove the front wheel
- Pre-loosen the two fixing pins of the brake pads
- Remove the brake calliper
- Remove permanently the two pad fixing screws
- Check that there are no flaws or warping. If there
is, replace it.
- Check the thickness of the friction material is
more than 1.5 mm. If it is not, replace it
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
BRAK SYS - 218
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Braking system
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock
Locking torques (N*m)
Screw tightening calliper to support 24 to 27 Pad fastening pin 19.6 to 24.5
Rear brake pads
Removal
- Remove the rear brake calliper.
- Remove the snap ring, slide off the pad retention
pin and the clip.
- Remove the brake pads and check there are no
faults or warping. Otherwise, replace them.
- Check the thickness of the friction material is
more than 1.5 mm. If it is not, replace it
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted
BRAK SYS - 219
Braking system
Vespa GTS Super 125 i.e.
Refitting
- Insert the brake pads
- Insert the fixing pin being careful to position the
clip with the ends towards the bleed screw as in
the photo.
- Insert the lock on the bolt and then the protection
cover
N.B.
FAILURE TO RESPECT THE PAD POSITIONING REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COULD COMPROMISE PROPER BRAKE FUNCTIONING AND NOISELESSNESS.
Fill
Rear - combined
- Remove the rubber cap from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the left-had brake lever, load the system and
bring it up to the required pressure.
- Keeping the left-hand brake lever pulled, loosen
the bleed screw to permit the air in the system to
escape. Then tighten the bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
BRAK SYS - 220
Vespa GTS Super 125 i.e.
Braking system
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Locking torques (N*m)
System bleed calliper fitting: 12 to 16 Nm
Brake fluid level check
- Position the vehicle on a flat surface and on the
centre stand
- Remove the brake pump cover as indicated in the
photo
- Use the appropriate spyglass on the pump to check the level of the brake fluid, as shown in the
photograph
- If the level is below the minimum, fill up by acting
on the two screws shown in the figure.
- Remove the gasket and fill with recommended
brake fluid until the spyglass is completely covered.
CAUTION
BRAK SYS - 221
Braking system
Vespa GTS Super 125 i.e.
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR
EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE.
THEREFORE, WHEN TOPPING UP, AVOID LETTING IT
COME INTO CONTACT WITH THE PAINTED PARTS OF
THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE
SURROUNDING AIR. IF MOISTURE CONTAINED IN THE
BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL
RESULT IN INEFFICIENT BRAKING.
CAUTION
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS
MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL
OF HUMIDITY IN THE BRAKE FLUID EXCEEDS A GIVEN
VALUE, BRAKING EFFICIENCY WILL BE REDUCED.
Never use brake liquid in open or partially used containers.
Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance table.
For refitting purposes carry out the removal operations but in reverse order and respect the tightening
torques of the tank cover screws.
Locking torques (N*m)
Brake pump reservoir screws 1.5 ÷ 2
Front brake pump
Removal
- Remove the rear handlebar cover.
- Remove the two screws fixing the brake pump to
the handlebar indicated in the photograph
- Remove the oil pipe joint from the pump
- Remove the connector to the stop light switch
BRAK SYS - 222
Vespa GTS Super 125 i.e.
Braking system
Overhaul
Proceed as follows:
1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take out the diaphragm (3);
2) remove the cap (4) and take out the internal parts in order;
3) Check that:
- The pump body shows no signs of internal damage or corrosion;
- The plunger shows no sign of damage or abnormal wear;
- The piston return spring is in good condition.
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.
1. Reservoir cap screw
2. Reservoir cap.
3. Diaphragm.
4. Bellows.
5. Sealing ring
6. Piston.
7. Gasket.
8. Spring.
9. Tank
BRAK SYS - 223
Braking system
Vespa GTS Super 125 i.e.
Refitting
To refit, carry out the removal operations but in reverse order, observing the specified torques.
Locking torques (N*m)
Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handlebar: 7 to 10 Nm
BRAK SYS - 224
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Cooling system
Circuit diagram
1. Coolant electric pump
2. Three-way thermostat
3. Electric fan
COOL SYS - 226
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Cooling system
4. Expansion tank
5. Radiator
6. coolant temperature sensor
COOL SYS - 227
INDEX OF TOPICS
CHASSIS
CHAS
Vespa GTS Super 125 i.e.
Chassis
This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.
Seat
- Remove the helmet compartment
- Remove the two screws shown in the photograph
- Remove the saddle
- Remove the helmet compartment
- Remove the 2 nuts indicated in the photograph
- Free the electric cables form the retaining clamps
indicated in the photograph
- Remove the saddle opening transmission cable
- Remove the saddle manual opening transmission cable.
CHAS - 229
Chassis
- Remove the electric connector from the saddle
opening actuator
- Remove the two screws shown in the photograph
- Remove the clip from the transmission
- Remove the actuator from the supporting bracket
Rear rack
- Remove the helmet compartment
- Remove the 4 screws indicated in the figure
- Remove the two screws, indicated in the figure,
that fix the luggage rack to the body
CHAS - 230
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Chassis
Rear handlebar cover
- Remove the front handlebar cover
- Undo the 5 screws indicated in the photograph
-Disconnect the odometer cable
-After disconnecting the wiring remove the rear
handlebar.
Instrument panel
- Remove the rear handlebar cover;
- Remove the four screws indicated in the figure
- Remove the instrument panel.
Front handlebar cover
- Remove the rear-view mirrors.
- Remove the front central cover.
- Remove the front screw indicated in the figure.
CHAS - 231
Chassis
-Undo the 2 screws indicated in the figure;
- Remove the front handlebar cover
- Disconnect the front headlamp connectors
Headlight assy.
- Remove the front handlebar cover.
- Undo the four screws indicated.
- Operate the screw indicated in the figure to remove the front turn indicator
CHAS - 232
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Chassis
Knee-guard
- Remove the rear handlebar cover.
- Remove the two screws indicated in the photograph and located on the shield under the grille
- Remove the expansion tank cover and then its
cap
- Remove the central screw inside the glove-box,
indicated in the photograph
- Remove the two screws indicated in the photograph and located below the expansion tank cover
and the left cover respectively
- Remove the shield back plate lower screws, to
the right and left side of the shield back plate, as
indicated in the photograph
CHAS - 233
Chassis
- Remove the electric saddle opening switch, the
fuse box and the manual saddle opening cable as
shown in the photograph
Taillight assy.
- Operate the screw indicated in the figure to remove the rear turn indicator
Remove screw «A» to remove the rear headlight
assembly.
Access to taillight bulbs, stop light bulb and license
plate bulb.
To reassemble, repeat the operation but in reverse
order.
N.B.
IF MISTING IS NOTICED ON THE INSIDE OF THE HEADLAMP GLASS, THIS DOES NOT INDICATE A FAULT AND
IS ATTRIBUTABLE TO HUMIDITY AND/OR TO LOW TEMPERATURES.
THE PHENOMENON SHOULD QUICKLY DISAPPEAR
WHEN THE LIGHT IS SWITCHED ON.
THE PRESENCE OF DROPS OF WATER, ON THE OTHER
HAND, COULD INDICATE THAT WATER IS INFILTRATING.
CONTACT THE AFTER-SALES SERVICE NETWORK.
CHAS - 234
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Chassis
Footrest
- Remove the shield back plate
- Remove the battery compartment cover
- Remove the side fairings
- Remove the central screw located under the battery compartment cover as indicated in the figure
- Remove the passenger footrests undoing the two
screws indicated in the figure
- Remove the right and left screws fixing the footrest indicated in the figure
- Remove the right and left lower covers as shown
in the figure
CHAS - 235
Chassis
- Remove the screws under the non-slip rubber
mat of the footrest as indicated in the photograph
Side fairings
Unscrew the fixing screw "A"
Unscrew the nut "B" under the body.
Helmet bay
- Lift the saddle and remove the helmet compartment
Fuel tank
- Remove the helmet compartment
- Remove the side fairings
- Remove the luggage rack
- Remove the shock absorber upper clamps
- Remove the two screws, indicated in the figure,
that fix the tank to the body
CHAS - 236
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Chassis
- Remove the screw indicated in the figure that fixes the tank to the body after removing the rear headlight assembly
- Remove the two turn indicators
- Use a jack to lift the body so that there is enough
space between the vehicle rear side and the engine to slide off the tank
To refit, perform the steps in the reverse direction
to disassembly
Rear central cover
- Remove the four screws indicated in the figure
CHAS - 237
Chassis
Front mudguard
- First remove the steering tube and uncouple the
front brake pipes from the calliper in order to remove the front mudguard
- Remove the three mudguard-steering tube
clamps indicated in the figure
Radiator fan
- In order to carry out any operation on the radiator
unit, flow out the coolant in the coolant delivery
pipe in the pump, indicated in the photograph.
- Remove the shield back plate;
- Remove the coolant feed and return hoses from
the right radiator;
- Unscrew the 4 screws fixing the radiator to the
body;
- Detach the radiator
- Detach the pipe from the plastic duct by removing
the plastic clip shown in the photograph. Then remove the duct.
CHAS - 238
Vespa GTS Super 125 i.e.
Vespa GTS Super 125 i.e.
Chassis
- The same procedure also applies to the left radiator for which it is necessary to remove the electric fan first by undoing the three screws indicated
in the photograph and afterwards disconnect the
connector.
To refit, perform the removal operations but in reverse order being careful when positioning the news
clips for the fluid hoses and when filling the cooling system.
Front central cover
- Remove the "PIAGGIO" clip-on badge
- Unscrew the screw indicated in the figure
- Remove the grille
CHAS - 239
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Vespa GTS Super 125 i.e.
Pre-delivery
Carry out the listed tests before delivering the vehicle.
Warning - Handle fuel with care.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
- Fixing screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Lower front shock absorber fitting
Front wheel axle nut
Front wheel screws
Rear wheel screws
Front and rear wheel hub nut
Front and rear brake calliper clamping screws
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
• Main switch
• Lights: high-beam lights, low-beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force
• Front and rear stop light buttons and relative light •Turn indicators and relative telltales
• Instrument lighting
• instruments: fuel and temperature indicator
PRE DE - 241
Pre-delivery
Vespa GTS Super 125 i.e.
•Instrument panel lights
• Horn
• Electrical start up
• Engine stopping with emergency stop switch
• electric saddle opening button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic brake system liquid level.
- Rear hub oil level
- Engine coolant level
- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
PRE DE - 242
Vespa GTS Super 125 i.e.
Pre-delivery
- Abnormal noise
Static test
Static control after the test ride:
• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting,
lock check, tyre pressure check, rear-view mirror and any accessory fitting
PRE DE - 243
INDEX OF TOPICS
TIME
TIME
Vespa GTS Super 125 i.e.
Time
This section is dedicated to the time necessary to carry out repairs.
For each operation, the description, code and time envisages are specified.
Engine
ENGINE
1
Code
001001
2
003064
Action
Engine from chassis - Removal and
refit.
Engine oil - change
Duration
Crankcase
CRANKCASE
1
Code
001153
2
001133
Action
Crankcase halves gasket - Replacement
Engine crankcase - Replacement
Duration
TIME - 245
Vespa GTS Super 125 i.e.
Time
Crankshaft
CRANKSHAFT
1
TIME - 246
Code
001117
Action
Crankshaft - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Cylinder assy.
CYLINDER - PISTON
1
2
3
Code
001002
001154
001129
Action
Cylinder / Piston - Replacement
Pistonsrings-pin assembly - Service
Chain tensioner - Service and Replacement
Duration
TIME - 247
Vespa GTS Super 125 i.e.
Time
Cylinder head assy.
VALVE HEAD
1
2
3
4
5
6
TIME - 248
Code
001126
001045
001049
001056
001083
001057
Action
Head - Replacement
Valves - Replacement
Valves - adjust
Head gasket - change
Thermistor - Replacement
Thermostat - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Rocker arms support assy.
CAMSHAFT
1
2
Code
001148
001044
Action
Rockers valves - Replacement
Camshaft - Replacement
Duration
Cylinder head cover
TIME - 249
Vespa GTS Super 125 i.e.
Time
HEAD COVER
1
2
3
4
Code
001093
001089
001088
001074
Action
Spark plug - Replacement
Head cover - Replacement
Head cover gasket - Replacement
Oil vapour recovery pipe - Replacement
Duration
Oil filter
OIL FILTER
1
2
3
TIME - 250
Code
001123
001160
001102
Action
Oil filter -Replacement
Oil pressure sensor - change
Net oil filter - change / Cleaning
Duration
Vespa GTS Super 125 i.e.
Time
Flywheel cover
FLYWHEEL COVER
1
2
3
4
5
Code
001087
001150
007007
007017
007003
Action
Flywheel cover - Replacement
Flywheel cover gasket - change
Water pump rotor - Replacement
Water pump cover - Replacement
Coolant delivery and return pipe change
Duration
Driven pulley
TIME - 251
Vespa GTS Super 125 i.e.
Time
DRIVEN PULLEY
1
2
3
4
Code
001022
001012
001110
001155
Action
Clutch - Replacement
Driven pulley - overhaul
Driven pulley- Replacement
Clutch housing - Replacement
Duration
Oil pump
OIL PUMP
1
2
3
4
5
6
7
8
TIME - 252
Code
001125
001051
001042
001112
001122
001130
001172
001124
Action
Chain guide pads - Replacement
Belt/Timing chain - Change
Oil pump - overhaul
Oil pump - change
Oil pump chain - Replacement
Oil sump - change
Chain cover flap - change
Lubrication by pass - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Final gear assy.
FINAL REDUCTION GEAR
1
2
3
4
Code
001010
003065
001156
004125
Action
Reduction gear - Replacement
Gear box oil - Replacement
Reduction gear cover - Replacement
Rear wheel axle - Replacement
Duration
TIME - 253
Vespa GTS Super 125 i.e.
Time
Driving pulley
DRIVING PULLEY
1
2
3
4
5
TIME - 254
Code
001086
001011
001066
001177
001141
Action
Driving half-pulley - Replacement
Drive belt - Replacement
Driving pulley - Removal and refitting
CVT rollers / sliders - Replacement
Belt anti-flapping roller - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Transmission cover
TRANSMISSION COVER
1
Code
001135
2
001096
3
001131
4
001065
Action
Transmission cover bearing - Replacement
Transmission crankcase cover - Replacement
Transmission air intake - Replacement
Transmission cover - Replacement
Duration
TIME - 255
Vespa GTS Super 125 i.e.
Time
Starter motor
ELECTRICAL START-UP
1
2
3
4
TIME - 256
Code
001020
001104
001151
001017
Action
Starter motor - Replacement
Start-up freewheel - Replacement
Starter driven gearing - Replacement
Start-up pinion - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Flywheel magneto
MAGNETO FLYWHEEL
1
2
3
Code
001067
001173
001058
Action
Stator - Removal and Refitting
Rotor - Replacement
Complete flywheel - change
Duration
TIME - 257
Vespa GTS Super 125 i.e.
Time
Butterfly valve
THROTTLE BODY
1
2
3
TIME - 258
Code
001166
001047
001013
Action
Throttle body - Replacement
Injector - Replacement
Intake manifold - change
Duration
Vespa GTS Super 125 i.e.
Time
Exhaust pipe
MUFFLER
1
2
3
Code
001009
001095
005138
Action
Silencer - Replacement
Silencer heatshield - Replacement
Lambda probe - Replacement
Duration
TIME - 259
Vespa GTS Super 125 i.e.
Time
Air cleaner
AIR CLEANER
1
2
3
Code
001015
001014
004122
4
001027
TIME - 260
Action
Air filter box - Replacement
Air filter - Replacement / cleaning
Air cleaner/ carburettor union - Replacement
Body / air cleaner union - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Frame
CHASSIS
1
2
3
4
5
6
7
Code
004001
004085
004149
004053
004015
004023
004159
Action
Chassis - Replacement
Fairing (1) - Replacement
Shield central cover - Replacement
Spoiler - Replacement
Footrest - Removal and Refitting
Shield rim - Replacement
Plates / Stickers - Replacement
Duration
TIME - 261
Vespa GTS Super 125 i.e.
Time
Centre-stand
STAND
1
2
Footrests
TIME - 262
Code
004102
004004
Action
Side stand - Replacement
Stand - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
MATS AND COVERS
1
2
3
Code
004079
004071
004078
4
005046
Action
Footrest - replacement
Battery compartment - replacement
Front/rear footrest rubber - Replacement
Battery cover - change
Duration
Rear cover
REAR SHIELD
1
2
Code
004083
004081
Action
Glove box - Replacement
Top box lid - Replacement
Duration
TIME - 263
Vespa GTS Super 125 i.e.
Time
Underseat compartment
HELMET COMPARTMENT
1
Code
004016
2
004011
TIME - 264
Action
Helmet compartment - Removal and
Refitting
Central chassis cover - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Plate holder
LICENSE PLATE HOLDER
1
Code
004136
2
005048
Action
License plate holder mounting - Replacement
number plate holder - Replacement
Duration
Mudguard
TIME - 265
Vespa GTS Super 125 i.e.
Time
MUDGUARDS
1
2
3
Code
004002
004009
003044
Action
Front mudguard - change
Rear mudguard - Replacement
Shock absorber cover - Replacement
Duration
Fuel tank
FUEL TANK
1
2
3
4
5
TIME - 266
Code
004005
005010
004109
004073
004137
Action
Fuel tank - Replacement
Tank float - Replacement
Fuel tank breather - change
Fuel pump - Replacement
Injector pump pipe - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Radiator
RADIATOR
1
Code
007002
2
007016
3
4
5
007001
001052
007013
6
007003
7
001170
Action
Water cooling radiator - Replacement
Fan complete with support - Replacement
Expansion tank - Replacement
Coolant and air bleed - Replacement
Expansion tank / radiator connecting
hose - Replacement
Delivery line and coolant return - Replacement
Air deflector - Replacement
Duration
TIME - 267
Vespa GTS Super 125 i.e.
Time
Rear shock-absorber
REAR SHOCK ABSORBERS
1
Code
003007
2
003077
TIME - 268
Action
Rear shock absorber - Removal and
Refitting
silencer/rear shock absorber support
arm - Service
Duration
Vespa GTS Super 125 i.e.
Time
Steering column bearings
STEERING FIFTH WHEELS
1
2
Code
003002
003073
Action
Steering bearing - Replacement
Steering clearance - Adjustment
Duration
TIME - 269
Vespa GTS Super 125 i.e.
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004018
2
004019
TIME - 270
Action
Front handlebar covers - Replacement
Rear handlebar covers - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Handlebar components
HANDLEBAR COMPONENTS
1
2
3
Code
003001
002067
002024
4
5
6
7
8
9
005017
002059
002071
003059
002060
002063
10
11
003061
002037
Action
Handlebar - Removal and refitting
Rear brake pump - Replacement
Front brake pump - Removal and refitting
Stop switch - Replacement
Right-hand knob - Replacement
Left hand grip - Replacement
Counterweight - Replacement
Throttle grip - Replacement
Throttle control transmission - Replacement
Accelerator transmission - adjust
Brake or clutch lever - Replacement
Duration
TIME - 271
Vespa GTS Super 125 i.e.
Time
Swing-arm
SWINGING ARM
1
Code
001072
2
004058
TIME - 272
Action
Engine-chassis connection swinging
arm - Replacement
Silent block - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Seat
SADDLE
1
2
Code
004003
004144
Action
Saddle - Replacement
Saddle cover - Replacement
Duration
Instrument panel
TIME - 273
Vespa GTS Super 125 i.e.
Time
INSTRUMENT PANEL
1
2
3
4
Code
004066
005014
005041
005077
5
005006
6
7
005040
005121
8
9
10
005039
005078
005038
11
005076
Action
Driving mirror - Replacement
Odometer - Replacement
Starter button - Replacement
Emergency stop switch - Replacement
Light or turning indicator switch - Replacement
Horn button - Replacement
Saddle opening button - Replacement
Lights switch - Replacement
Odometer glass - Replacement
Instrument panel warning light bulbs
- Replacement
Clock / Cell - Replacement
Duration
Rear rack
LUGGAGE RACK
1
TIME - 274
Code
004008
Action
Luggage rack - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Locks
LOCKS
1
Code
002083
2
002092
3
004158
4
5
005072
005099
6
7
8
004054
004010
005016
Action
Saddle opening transmission - Replacement
Transmission splitter/ hook transmission - Replacement
Saddle opening splitter - Replacement
Immobilizer aerial - Replacement
Electric saddle opening device - Replacement
Saddle lock catch - Replacement
Anti-theft lock - Replacement
Key switch - Replacement
Duration
TIME - 275
Vespa GTS Super 125 i.e.
Time
Turn signal lights
INDICATORS AND LIGHTS
1
2
Code
005002
005067
3
005031
4
5
6
7
8
9
005139
005008
005012
005090
005140
005022
10
005068
11
12
005066
005028
TIME - 276
Action
Front headlamp - Replacement
Front turn indicator bulb - Replacement
number plate light bulb - Replacement
Tail light bulb - Replacement
Headlight bulbs - Replacement
Front turn indicator - Replacement
Stop light bulb - Replacement
Front light - Replacement
Rear turning indicators - Replacement
Rear turning indicator bulb - Replacement
Rear light bulbs - Replacement
Rear light assembly glass - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Front wheel
FRONT WHEEL
1
2
3
4
5
Code
003047
003037
004123
003033
002041
Action
Front tyre - Replacement
Front wheel rim - Replacement
Front wheel - Replacement
Front wheel hub- Replacement
Brake disc - Replacement
Duration
TIME - 277
Vespa GTS Super 125 i.e.
Time
Rear wheel
REAR WHEEL
1
2
Code
004126
001071
3
4
5
001016
002028
002070
TIME - 278
Action
Rear wheel tyre - Replacement
Front wheel rim - Removal and Refitting
Rear wheel - Replacement
Rear wheel hub - Replacement
Rear brake disc - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Electric devices
ELECTRIC DEVICES
1
2
3
4
5
6
7
Code
001094
001069
005003
005009
005052
005007
005120
8
9
005035
005117
10
11
12
005011
005054
005001
Action
Spark plug cap - Replacement
HV coil - Replacement
Horn - Replacement
Voltage regulator - Replacement
Fuse (1) - Replacement
Battery - change
Control unit power supply remote
control - Replacement
Headlight solenoid - Replacement
Electric fan remote control - Replacement
Starter relay - Replacement
Fuse block (1) - Replacement
Electrical system - Removal and refitting
Duration
TIME - 279
Vespa GTS Super 125 i.e.
Time
Transmissions
TRANSMISSIONS
1
TIME - 280
Code
002051
Action
Odometer transmission assembly Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Front suspension
FRONT SUSPENSION
1
Code
003011
2
003045
3
4
003010
003035
5
003034
6
001064
Action
Front shock absorber - Removal and
Refitting
Steering tube/Fork tube - Replacement
Front suspension - Service
Shock absorber mounting and brake
calliper - Replacement
Front wheel hub bearing - Replacement
Odometer sprocket - Replacement
Duration
TIME - 281
Vespa GTS Super 125 i.e.
Time
Braking system
BRAKING SYSTEM
1
2
3
4
Code
002039
002007
002021
002047
5
002020
6
002080
7
8
002002
002048
TIME - 282
Action
Front brake calliper - Replacement
Front brake pads - Replacement
Front brake piping - Replacement
Front brake fluid and air bleed system - Replacement
Rear brake disc piping - Replacement
Rear brake oil bleed system Change
Rear brake pads - Replacement
Rear brake calliper - Replacement
Duration
Vespa GTS Super 125 i.e.
Time
Stickers
TRANSFERS
1
Code
004159
Action
Plates / Stickers - Replacement
Duration
TIME - 283
A
Air filter: 46
B
Battery: 66, 82, 94, 95
Brake: 211, 213, 215–217, 219, 221, 222
Brake fluid: 221
C
Checks: 73
Coolant: 173
E
Electric: 279
Engine oil: 47
F
Fuel: 136, 149, 236, 266
Fuses: 92
H
Headlight: 52, 232
Horn: 87
Hub oil: 45
I
Identification: 8
Instrument panel: 231, 273
L
Luggage rack:
M
Maintenance: 7, 44
O
Oil filter: 49, 250
R
Recommended products:
S
Saddle:
Shock absorbers: 207
Spark plug: 44
Stand: 209
Start-up:
Suspension: 55, 56, 281
Switch:
T
Tank: 236, 266
Transmission: 10, 54, 255
Turn indicators: 72
Tyre pressure:
Tyres: 15
V
Vehicle: 8, 115, 116
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