VESPA GTS 250 I.E. Instruction manual

WORKSHOP MANUAL
633577
Vespa GTS 250 I.E.

WORKSHOP
MANUAL
Vespa GTS 250 I.E.
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all Countries. The availability of single versions
should be checked at the official Piaggio sales network.
"©Copyright2007-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUAL
Vespa GTS 250 I.E.
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-
Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific 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 Sectionsmarked with this symbol indicatethe correct use of thevehicle
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 scooter.
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 open flames or sparks.
- Clean the brake pads in a well ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon reassembly.
- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the scooter that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
Characteristics Vespa GTS 250 I.E.
CHAR - 2

Vehicle identification
Chassis prefix: ZAPM45100000 ÷ 1001
Engine prefix: M451M ÷ 1001
Dimensions and mass
DIMENSIONS AND MASS
Specification Desc./Quantity
Total loadless weight 151 ± 5 kg
Width (to hand grips) 755 mm
Length 1930 mm
Wheel base 1370 mm
Saddle height 800 mm
Vespa GTS 250 I.E. Characteristics
CHAR - 3

Engine
DATA
Specification Desc./Quantity
Type single-cylinder, four-stroke and four liquid-cooled
valves
Timing system single overhead camshaft chain driven on the left-
hand side, three-arm rocking levers set up with
threaded set screw
Bore 72 mm
Stroke 60 mm
Cubic capacity 249.29 mm
Compression ratio 10.5 ÷ 11.5
Idle speed 1650 ± 50 rpm
Air filter sponge,impregnatedwithmixture(50%petroland
50% oil)
Starting system electric starter motor with freewheel
Lubrication with lobe pump (inside the crankcase) chain-driv-
en and double filter: mesh and paper
Fuel supply by electronic injection with electric fuel pump
Max. speed 120 km/h
valve clearance intake: 0.10 mm - discharge: 0.15 mm
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque
server,Vbelt,automaticclutch,gearreductionunit
and transmission housing with forced air circula-
tion cooling
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil approx. 1300 cc (recommended oil Selenia HI
Scooter 4 Tech)
Fuel tank (including a ~ 2 l reserve) ~ 9.2 l
Rear hub 250 cc ( recommended oil TUTELA MATRIX)
Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted)
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
Characteristics Vespa GTS 250 I.E.
CHAR - 4

Specification Desc./Quantity
Fuses 1: 30A - 1: 15A - 3: 10A - 4: 7,5A - 1: 3A
Generator alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification Desc./Quantity
Type Unitised body made of stamped plate
Front suspension Single arm suspension (cantilever wheel) fitted
withadouble-actinghydraulicshockabsorberwith
coaxial spring
Front shock absorber axial travel 86.5 mm
Rear suspension Engine with swinging fork attached 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.
Rear shock absorber axial travel 89.5 mm
Brakes
BRAKES
Specification Desc./Quantity
Front Ø 220 disc brake and floating calliper with Ø 25
mm twin plungers and hydraulic control (lever on
the far right end of the handlebar)
Rear Ø 220 disc brake and calliper with two Ø 30 mm
counteracting plungers and hydraulic control (lev-
er on the far left end of the handlebar)
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front wheels - light alloy rims 3.00x12
Rear wheels - light alloy rims 3.00x12
Front tyres 120/70-12" Tubeless
Rear tyres 130/70-12" Tubeless
TYRE PRESSURE
Specification Desc./Quantity
Front tyre pressure (when cold) 1.8 bar
Rear tyre pressure (when cold) 2 bar
Tyre pressure (when cold) with passenger 2.2 bar
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Vespa GTS 250 I.E. Characteristics
CHAR - 5

Tightening Torques
GRUPPO STERZO
Name Torque in Nm
Upper steering ring nut 35 ÷ 40
Lower steering ring nut 12 - 14
Handlebar fixing screw 45 ÷ 50 (The two screws must be tightened to the
prescribed torque after having done so with the
rear wheel axle nut. Safety locks: see «Pre-deliv-
ery Operations» )
Fixing screws for handlebar control assembly U-
bolts 7 ÷ 10
FRAME ASSEMBLY
Name Torque in Nm
Engine-swinging arm bolt 64 - 72
swinging arm bolt - body shell 76 ÷ 83
Engineand vehicle side swinging arm junction bolt 33 ÷ 41
Bolt of the Silent block support plate 42 ÷ 52
Centre stand bolt 32 ÷ 40
Side stand fixing bolt 35 ÷ 40
SOSPENSIONE ANTERIORE
Name Torque in Nm
Screw fixing the shock absorber to the shock ab-
sorber - calliper attachment plate 20 ÷ 27
Wheel axle nut 74 ÷ 88
Wheel screw 20 ÷ 25
Screw fixing rear mudguard to steering 5 ÷ 6.5
shock absorber upper clamp 20 ÷ 30
FRENO ANTERIORE
Name Torque in Nm
Brake fluid pump - hose fitting 20 ÷ 25
Brake fluid tube- calliper fitting 19 ÷ 24
Vite serraggio pinza alla piastra attacco ammor-
tizzatore - pinza freno 24 ÷ 27
Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium
strength)
Oil bleed screw 12 - 16
Pad fastening pin 19.6 ÷ 24.5
Viti vaschetta pompa freno 1,5 ÷ 2
REAR SUSPENSION
Name Torque in Nm
Retainer for left shock absorber to crankcase sup-
port plate 20 ÷ 25
Shock absorber upper fitting 20 ÷ 25
Shock absorber lower fitting 33 ÷ 41
Rear wheel shaft 104 ÷ 126
Screw fixing wheel to hub 20 ÷ 25
Screws for muffler - shock absorber support arm
on engine 20 ÷ 25 (The two screws must be tightened to the prescribed torque after having done so with the
Characteristics Vespa GTS 250 I.E.
CHAR - 6

Name Torque in Nm
rear wheel axle nut. Safety locks: see «Pre-deliv-
ery Operations» )
FRENO POSTERIORE
Name Torque in Nm
Brake fluid pump - hose fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 20 ÷ 25
Rear disc tightening bolt 11 ÷ 13
Oil bleed screw 12÷16
Calliper to engine tightening screw 20 ÷ 25
Viti vaschetta pompa freno 1,5 ÷ 2
Vite accoppiamento pinza 30 ÷ 33 Nm
MUFFLER
Name Torque in Nm
Muffler heat guard fixing screw 4 ÷ 5
Screw for fixing muffler to the support arm 20 ÷ 25
Lambda probe clamp on exhaust manifold 40 ÷ 50
Exhaust manifold-muffler joint clamp 12 ÷ 13
Manifold - muffler diaphragm tightening clamp 16 ÷ 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 ÷ 17
Oil filter on crankcase fitting 27 ÷ 33
Engine oil drainage plug/mesh filter 24 ÷ 30
Oil filter 4 ÷ 6
Oil pump cover screws 7 ÷ 9
Screws fixing oil pump to the crankcase 5 - 6
Oil pump control crown screw 10 ÷ 14
Oil pump cover plate screws 4 ÷ 6
Oil sump screws 10 ÷ 14
Minimum oil pressure sensor 12 ÷ 14
CYLINDER HEAD
Name Torque in Nm
Spark plug 12 ÷ 14
Head cover screws 6 ÷ 7
Nuts fixing head to cylinder 7±1 + 10±1 + 270°
Head fixing side screws 11 ÷ 12 Nm
Starter ground screw 7 ÷ 8.5
Tappet set screw lock nut 6 ÷ 8
Inlet manifold screws 11 ÷ 13
Timing chain tensioner slider screw 10 ÷ 14
Start-up counterweight support screw 11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5 - 6
Camshaft retention plate screw 4 ÷ 6
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 ÷ 13
Vespa GTS 250 I.E. Characteristics
CHAR - 7

Name Torque in Nm
Clutch unit nut on driven pulley 45 ÷ 50
Drive pulley nut 75 ÷ 83
Transmission cover screws 11 ÷ 13
Driven pulley shaft nut 54 ÷ 60
Rear hub cap screws 24 ÷ 27
FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 ÷ 13
Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength
threadlock)
Flywheel nut 94 - 102 Nm
Pick-Up clamping screws 3 ÷ 4
Screw fixing freewheel to flywheel 13 - 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 ÷ 6
Engine-crankcase coupling screws 11 ÷ 13
Starter screws 11 ÷ 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength
threadlock)
COOLING
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Bleed screw: 3
Overhaul data
Assembly clearances
Characteristics Vespa GTS 250 I.E.
CHAR - 8

Cylinder - piston assy.
ENGINE COUPLING CATEGORY
Name Initials Cylinder Piston Play on fitting
Cylinder M 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064
Cylinder N 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064
Piston O 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064
Piston P 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 - 0.064
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000
car.) Indirizzo Immagine
Crankshaft Crankshaftto crankcase
axial clearance
Crankshaft to crankcase axial clearance
Vespa GTS 250 I.E. Characteristics
CHAR - 9

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
Name Description Dimensions Initials Quantity
Half-shaft, trans-
mission side 16.6 +0-0.05 A D = 0.20 - 0.50
Flywheel side half-
shaft 16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50
Spacer tool 51.4 +0.05 E D = 0.20 - 0.50
Slot packing system
Characteristic
Compression ratio
10.5 ÷ 11.5 : 1
Characteristics Vespa GTS 250 I.E.
CHAR - 10

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed
by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls
inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice
versa.
N.B.
MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON
A GROUND PLANE
ENGINE 250 SHIMMING
Name Measure A Thickness
shimming 3.70 - 3.60 0.4 ± 0.05
shimming 3.60 - 3.40 0.6 ± 0.05
shimming 3.40 - 3.30 0.8 ± 0.05
Vespa GTS 250 I.E. Characteristics
CHAR - 11

Products
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE80W/90Oilthatexceedsthe
requirements of API GL3 specifi-
cations
AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-
sions (throttle control) Oil for 4-stroke engines
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives
for increased adhesiveness
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-
based spray grease with NLGI 2;
ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
SPECIAL AGIP PERMANENT
fluid coolant Monoethylene glycol-based anti- freeze fluid, CUNA NC 956-16
Characteristics Vespa GTS 250 I.E.
CHAR - 12

INDEX OF TOPICS
TOOLING TOOL

APPROPRIATE TOOL
Stores code Description
001330Y Tool for fitting steering seats
001467Y017 Bell for bearings, outside Ø 39
mm
001467Y014 Extraction pliers for ø 15 mm
bearings
005095Y Engine support
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seat
on steering tube
020004Y Punch for removing fifth wheels
from the headstock
Tooling Vespa GTS 250 I.E.
TOOL - 2