VESPA GTS SUPER 300 I.E. Scooter Shop Manual 2008-2012

MANUALE STAZIONE DI SERVIZIO ******** Vespa GTS Super 300 ie (2008)

MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 ie (2008) The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - After-Sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

MANUALE STAZIONE DI SERVIZIO Vespa GTS Super 300 ie (2008) This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant change to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue. N.B. Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

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

INDEX OF TOPICS CHARACTERISTICS CHAR

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. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections. Vespa GTS Super 300 ie (2008) 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 allowed 340 kg Maximum height 1170 mm Overall width 755 mm Overall length 2230 mm Wheelbase 1370 mm Characteristics Vespa GTS Super 300 ie (2008) 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, 3- arm rocking levers set up with set screw Compression ratio 10.5 ÷ 11.5 Engine idle speed 1650 ± 50 rpm Air filter sponge, impregnated with mixture (50% petrol and 50% oil) Starting system electric starter motor with freewheel Lubrication with lobe pump (inside the crankcase) controlled by a chain and double filter: mesh and paper Fuel supply Electronic injection with electric fuel pump valve clearance intake: 0.10 mm - discharge: 0.15 mm Minimum lubrication pressure (100° C) 0.8 bar Lubrication pressure 3.5 ÷ 4 bar Cooling Forced liquid circulation cooling. 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 Prescribed fluid AGIP PERMANENT SPEZIAL Sealing pressure Cap calibrated at 0.9 bar Vespa GTS Super 300 ie (2008) Characteristics CHAR - 9

THERMOSTAT Specification Desc./Quantity Type Wax-type, with deviator Starts opening 85±2°C ELECTRIC VENTILATION Specification Desc./Quantity Electric ventilation starts at 102°C Electric ventilation stops at 96°C WATER PUMP Specification Desc./Quantity Type Centrifugal Control Coaxial to crankshaft RADIATOR Specification Desc./Quantity Type Made of aluminium in two sections Transmission T RANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing 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 ie (2008) CHAR - 10

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VESPA GTS SUPER 300 I.E. Scooter Shop Manual 2008-2012

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