2014-2016 Piaggio Vespa GTS300/Super300 Full Service & Repair Manual

MANUALE STAZIONE DI SERVIZIO 1Q0001xx Vespa GTS Super 300 i.e.

MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 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 2014 - 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

MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 i.e. Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE-DELIVERY PRE DE

INDEX OF TOPICS CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are 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. Vespa GTS Super 300 i.e. Characteristics CHAR - 7

Vehicle identification Chassis prefix: ZAPM45100000 ÷ 1001 Engine prefix: M451M ÷ 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 158 ± 5 kg Maximum weight limit 340 kg Maximum height 1170 mm Overall width 755 mm Overall length 2230 mm Wheelbase 1370 mm Characteristics Vespa GTS Super 300 i.e. CHAR - 8

Engine DATA Specification Desc./Quantity Type single-cylinder, four-stroke and four liquid-cooled valves Cubic capacity 278.3 cm³ Stroke 63 mm Bore 75 mm MAX. torque 22 Nm at 6500 rpm Max. Power 16.4 kW at 7500 rpm Timing system single overhead camshaft, chain-driven, on the left-hand side, three-arm rocking levers set up with threaded set screw Compression ratio 10.5 ÷ 11.5 Engine idle speed 1,650 ± 50 rpm Air filter sponge, impregnated with mixture (50% petrol and 50% oil) Starting system electric starter motor with freewheel Lubrication with lobe pump (inside the crankcase) chain-driven and double filter: mesh and paper Fuel system Electronic injection with electric fuel pump valve clearance intake: 0.10 mm - exhaust: 0.15 mm Minimum lubrication pressure (100° C) 0.8 bar Lubrication pressure 3.5 to 4 bar Cooling Forced-circulation coolant system. OIL PUMP Specification Desc./Quantity Type Trochoidal Distance between the rotors Admissible limit clearance: 0.12 mm Axial rotor clearance Limit values admitted: 0.09 mm Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm Levelness 0.1 mm BY-PASS Specification Desc./Quantity Type With piston Plunger diameter Ø 13.9 - 0.039 -0.057 mm By-pass check up: Standard length 54.2 mm Calibration pressure 4.5 bar OIL FILTER Specification Desc./Quantity Type Paper with pressure relief and anti-drain back by-pass valves OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Specification Desc./Quantity Calibration 0.3 - 0.6 bar HEAD LUBRICATION CONTROL JET Specification Desc./Quantity Diameter 1 ± 0.05 mm * * Tightening torque 5÷7 N m COOLING SYSTEM Specification Desc./Quantity Cooling system capacity ~ 2.100 ÷ 2.150 l Recommended fluid AGIP PERMANENT SPEZIAL Sealing pressure Cap calibrated at 0.9 bar Vespa GTS Super 300 i.e. Characteristics CHAR - 9

THERMOSTAT Specification Desc./Quantity Type Wax-type, with deviator Starts opening at 85±2°C ELECTRIC VENTILATION Specification Desc./Quantity Electric ventilation starts at 102°C Electric ventilation stops at 96°C WATER PUMP Specification Desc./Quantity Type Centrifugal Control Coaxial to crankshaft RADIATOR Specification Desc./Quantity Type Made of aluminium in two sections Transmission TRANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley CVT with torque server, V-belt, automatic clutch, gear reduction unit and transmission com- partment with forced air circulation cooling Capacities CAPACITY Specification Desc./Quantity Fuel tank (including a ~ 2 l reserve) ~ 9.2 l Cooling system fluid ~ 2.100 ÷ 2.150 l Engine oil approx. 1300 cc Rear hub 250 cc Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Ignition/advance Electronic, with inductive discharge and variable advance with three-dimensional mapping Spark plug CHAMPION RG 4 PHP Battery 12V-12Ah Fuses One 30A fuse - One 15A fuse - Three 10A fuses - Four 7.5A fuses - One 3A fuse Generator alternating current Characteristics Vespa GTS Super 300 i.e. CHAR - 10

2014-2016 Piaggio Vespa GTS300/Super300 Full Service & Repair Manual

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