VESPA GTS Super 125 i.e. (2009) User manual

MANUALE STAZIONE DI SERVIZIO
*******
Vespa GTS Super 125 i.e. (2009)

MANUALE
STAZIONE DI
SERVIZIO
Vespa GTS Super 125 i.e. (2009)
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 each
model should be checked at the official Piaggio sales network.
"©Copyright2008-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)

MANUALE STAZIONE DI
SERVIZIO
Vespa GTS Super 125 i.e. (2009)
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 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
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 spare parts 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 measurement. Using unsuitable
coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.
Vespa GTS Super 125 i.e. (2009) 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
Maximum length 1930 mm
Wheelbase 1370 mm
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 8

Engine
DATA
Specification Desc./Quantity
Type single-cylinder, four-stroke and four liquid-cooled valves
Engine capacity 124 cm³
Bore x stroke 57 x 48.6 mm
Max. power 11 kW at 9750 rpm
MAX. torque 12 Nm 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 12 ± 0.5: 1
Engine idle speed 1,750 ± 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 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
Recommended fluid AGIP PERMANENT SPEZIAL
Sealing pressure Cap calibrated at 0.9 bar
THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Vespa GTS Super 125 i.e. (2009) Characteristics
CHAR - 9

Specification Desc./Quantity
Starts opening at 85±2°C
ELECTRIC VENTILATION
Specification Desc./Quantity
Electric ventilation starts at 102°C
Electric ventilation stops at 96°C
RADIATOR
Specification Desc./Quantity
Type Made of aluminium in two sections
WATER PUMP
Specification Desc./Quantity
Type Centrifugal
Control Electric
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque server, V-
belt, automatic clutch, gear reduction unit and transmission
compartment 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 NGK CR8EKB
Battery 12V-12Ah
Fuses 1 30A - 2 15A - 4 7.5A
Generator alternating current
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 10

CHECKING REMOTE CONTROLS «A» OPER-
ATING 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 remote control.
3) With the remote control powered, check that
there is continuity between terminals 30 and 87.
4) If these conditions are not fulfilled, the remote
control 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
Vespa GTS Super 125 i.e. (2009) Characteristics
CHAR - 11

LIGHT SWITCH
STARTER BUTTON
KEY SWITCH
FUEL INJECTOR
Type: 3 holes
Conicity of the nozzle: 20°
Resistance at terminals: 13.7 to 15.2 Ohm
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 12

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
ENGINE SPEED SENSOR
Resistance between pins 13 and 15: 100 to 150
Ohm at approx. 20°
ENGINE TEMPERATURE SENSOR
0° = 5900 Ohm
+10° = 3800 Ohm
+20° = 2500 Ohm
+30° = 1700 Ohm
+80° = 300 Ohm
MINIMUM OIL PRESSURE SENSOR
Normally closed switch
Activation threshold: 0.3 - 0.6 bar
With the engine off: continuity between terminal
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 HV output = 3.1 KOhm ± 9%
Vespa GTS Super 125 i.e. (2009) Characteristics
CHAR - 13

- Presence of battery voltage between pins 22 and
26 of the interface cable harness upon
shifting to ON and for 2 sec.
STATOR
Power: 450 W
Resistance between terminals: 0.2 to 1 Ohm
terminal insulation from ground
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Type Unitised body made of stamped plate
Front suspension Single arm suspension (cantilever wheel) fitted with a double-
acting hydraulic shock absorber with coaxial spring
Front shock absorber axial travel 86.5 mm
Rear suspension 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 adjust-
ment 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 plung-
ers 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 (lever on the far left end of the
handlebar)
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 14

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 BOTH RIDER AND ACCESSORIES
Tightening Torques
STEERING ASSEMBLY
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
torqueafterhavingdonesowith the rear wheelaxle nut. Safety
locks: see «Pre-delivery Operations»)
Fixing screws for the handlebar control unit U-bolts 7 ÷ 10
FRAME ASSEMBLY
Name Torque in Nm
Engine-swinging arm pin 64 ÷ 72
swinging arm bolt - body shell 76 ÷ 83
Engine and vehicle side swinging arm junction bolt 33 to 41
Bolt of the Silent block support plate 42 ÷ 52
Centre stand bolt 32 ÷ 40
Side stand fixing bolt 35 ÷ 40
FRONT SUSPENSION
Name Torque in Nm
Screwfixingthe shockabsorberto theshockabsorber -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 to 30
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 19 ÷ 24
Screw fixing calliper to the shock absorber - calliper plate at-
tachment 24 ÷ 27
Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium strength)
Oil bleed screw 12 - 16
Pad fixing pin 19.6 ÷ 24.5
Brake pump reservoir screws 1.5 ÷ 2
Brake disc screws 8 to 10
Vespa GTS Super 125 i.e. (2009) Characteristics
CHAR - 15

REAR SUSPENSION
Name Torque in Nm
Retainer for left shock absorber to crankcase support plate 20 ÷ 25
Shock absorber lower fitting 40 ÷ 45
Shock absorber upper fitting 20 ÷ 25
Rear wheel axle 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
torqueafter having done sowith the rear wheelaxle nut. Safety
locks: see «Pre-delivery Operations»)
Engine- and vehicle-side swinging arm junction bolt 40 ÷ 45
REAR BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 20 to 25
Rear disc tightening bolt 11 ÷ 13
Oil bleed screw 12÷16
Calliper to engine tightening screw 20 ÷ 25
Brake pump reservoir screws 1.5 ÷ 2
Calliper coupling screw 30 ÷ 33
MUFFLER
Name Torque in Nm
Muffler heat guard fixing screw 4 ÷ 5
Screw for fixing muffler to mounting arm 20 ÷ 25
Lambda probe tightening on exhaust manifold 40 to 50
Exhaust manifold-muffler joint tightening 12÷13
Manifold - muffler diaphragm tightening clamp 16 to 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 to 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 command 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 to 14
Head cover screws 6 ÷ 7
Nuts fixing head to cylinder 7±1 + 10±1 + 270°
Head fixing side screws 11 ÷ 12
Starter ground screw 7 ÷ 8.5
Tappet adjustment check nut 6 ÷ 8
Intake manifold screws 11 to 13
Timing chain tensioner slider screw 10 ÷ 14
Start up counterweight support screw 11 to 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5 ÷ 6
Camshaft retention plate screw 4 ÷ 6
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 ÷ 13
Clutch unit nut on driven pulley 45 to 50
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 16

Name Torque in Nm
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
Pick-up fixing screws 3 ÷ 4
Screw fixing freewheel to flywheel 13 ÷ 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmission-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 to 4
Thermostat cover screws 3 to 4
Bleed screw 3
Overhaul data
Assembly clearances
Cylinder - piston assy.
- Calculate the coupling clearance between pin
and connecting rod end.
Characteristic
Standard diameter:
Ø 14.996 ÷ 15.0 mm
Standard clearance:
0.015 ÷ 0.029 mm
Vespa GTS Super 125 i.e. (2009) Characteristics
CHAR - 17

- Measure the diameter of the bearings on the pis-
ton.
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.
-Checkthattheheadmatchingsurfaceexhibits no
deformations or wear.
Characteristic
Maximum allowable run-out:
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).
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 18

*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.
Vespa GTS Super 125 i.e. (2009) Characteristics
CHAR - 19

ENGINE COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder A 56.997 to 57.004 56.945 ÷ 56.952 0.045 - 0.059
Cylinder B 57.004 to 57.011 56.952 ÷ 56.959 0.045 - 0.059
Piston C 57.011 to 57.018 56.959 ÷ 56.966 0.045 - 0.059
Piston D 57.018 to 57.025 56.966 ÷ 56.973 0.045 - 0.059
Cylinder 1st Oversize A1 57.197 to 57.204 57.145 ÷ 57.152 0.045 - 0.059
Cylinder 1st Oversize B 1 57.204 to 57.211 57.152 ÷ 57.159 0.045 - 0.059
Piston 1st Oversize C 1 57.211 to 57.218 57.159 ÷ 57.166 0.045 - 0.059
Piston 1st Oversize D 1 57.218 to 57.225 57.166 ÷ 57.173 0.045 - 0.059
Cylinder 2nd Oversize A2 57.397 to 57.404 57.345 ÷ 57.352 0.045 - 0.059
Cylinder 2nd Oversize B 2 57.404 to 57.411 57.352 ÷ 57.359 0.045 - 0.059
Piston 2nd Oversize C 2 57.411 to 57.418 57.359 ÷ 57.366 0.045 - 0.059
Piston 2nd Oversize D 2 57.418 to 57.425 57.366 ÷ 57.373 0.045 - 0.059
Cylinder 3rd Oversize A 3 57.597 to 57.604 57.545 ÷ 57.552 0.045 - 0.059
Cylinder 3rd Oversize B 3 57.604 to 57.611 57.552 ÷ 57.559 0.045 - 0.059
Piston 3rd Oversize C 3 57.611 to 57.618 57.559 ÷ 57.566 0.045 - 0.059
Piston 3rd Oversize D 3 57.618 to 57.625 57.566 ÷ 57.573 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.
Characteristics Vespa GTS Super 125 i.e. (2009)
CHAR - 20