VESPA GTS Super 300 ie 2008 User manual

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.
"©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)

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 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 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
suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.
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 withlobepump(insidethecrankcase)controlledbyachainand
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
TRANSMISSION
Specification Desc./Quantity
Transmission Automaticexpandablepulleyvariatorwithtorqueserver,Vbelt,
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