VESPA GTV 125 Guide

SERVICE STATION MANUAL
664619 IT-664620 EN-664621 FR-664622 DE-664623
ES-664624 PT-664625 OL-664626 EL
Vespa GTV 125

SERVICE STATION
MANUAL
Vespa GTV 125
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 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)

SERVICE STATION MANUAL
Vespa GTV 125
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 changes 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 relating to 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
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 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 refitting.
- 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 vehicle that involve the electrical system, make
suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.
Characteristics Vespa GTV 125
CHAR - 2

Vehicle identification
Chassis prefix: ZAPM313010000 ÷ 1001
Engine prefix: M315M1001
Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Total kerb weight 148 ± 5 kg
Overall width 770 mm
Length 1940 mm
Wheelbase 1395 mm
Height 1180 mm
Saddle height 800 mm
Vespa GTV 125 Characteristics
CHAR - 3

Engine
ENGINE
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 57 mm
Stroke 48.6 mm
Cubic capacity 124 cm³
Compression ratio 12 ± 0.5: 1
Carburettor Keihin CVK 30
Engine idle speed 1650 ± 50 rpm
Air filter sponge,impregnatedwithmixture(50%petroland
50% oil)
Starting system electric starter
Lubrication with lobe pump (inside the crankcase) chain-driv-
en and double filter: mesh and paper
Fuel supply petrol, with vacuum pump and through carburettor
MAX. power 10.5 to 9500 rpm
MAX torque 12 Nm at 8,000 rpm
Characteristics Vespa GTV 125
CHAR - 4

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 ~ 1000 cm³
Fuel tank (including a ~ 2 l reserve) ~ 9.5 l
Rear hub 150 cm³
Cooling system fluid ~ 2.100 ÷ 2.150 l
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
Type of ignition Electronic capacitive discharge ignition, with vari-
able timing and separate HV coil
Variable ignition advance (before TDC) 10° ± 1° at 2000 rpm
Spark plug Champion RG 4 HC
Battery Sealed, 12 V / 10 Ah
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
Vespa GTV 125 Characteristics
CHAR - 5

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
Carburettor
125cc Version
Kehin
CARBURETTOR KEIHIN
Specification Desc./Quantity
Depression carburettor CVEK-30
Body stamping CVEK
CUT-OFF device Not present
Max. jet 98
Minimum jet 38
Max.air jet 150
Minimum air jet 130
Throttle valve spring 100 ÷ 160 g
Minimum mixture set screw initial opening 2 ± ¼
Tapered pin NDVA
Tapered pin notches from top Single-notch pin
Diffuser nozzle Ø 5.0
Characteristics Vespa GTV 125
CHAR - 6

Specification Desc./Quantity
Petrol inlet hole -
Starter air jet Ø 1.5
Starter diffuser nozzle -
Starter jet 42
Diameter of starter pin -
Starter device resistance ~ 20 Ω
Venturi diffuser Ø 29 (47x30.9)
Throttle valve Ø 30.5
Diffuser maximum cone -
N.B.
* THE IDENTIFICATION LETTER MAY VARY WITH EACH CARBURETTOR UPDATE.
Tightening Torques
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 30 ÷ 40
Lower steering ring nut 8 ÷ 10
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 25 - 30
Side stand fixing bolt 40 ÷ 45
FRONT SUSPENSION
Name Torque in Nm
Screw fixing the shock absorber to the shock ab-
sorber - calliper attachment plate 20 ÷ 27
Wheel axle nut 75 ÷ 90
Wheel screw 20 ÷ 25
Screw fixing rear mudguard to steering 5 ÷ 6.5
FRONT BRAKE
Name Torque in Nm
Brake fluid pump - hose fitting 20 ÷ 25
Brake fluid hose-calliper fitting 20 ÷ 25
Screw fixing calliper to the shock absorber - cal-
liper plate attachment 20 ÷ 25
Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium
strength)
Oil bleed screw 12 - 16
Pad fastening pin 19.6 ÷ 24.5
Vespa GTV 125 Characteristics
CHAR - 7

Name Torque in Nm
Brake pump reservoir screws 15 ÷ 20
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
rear wheel axle nut. Safety locks: see «Pre-deliv-
ery Operations» )
REAR BRAKE
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
Brake pump reservoir screws 15 ÷ 20
Calliper coupling screws 30 ÷ 33
MUFFLER
Name Torque in Nm
Muffler heat guard clamping screw 5 - 6
Exhaust fumes inlet screw 13 ÷ 15
Screw for fixing muffler to the support arm 20 ÷ 25
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 8 ÷ 10
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 for head fastening to the cylinder 7± 1 + 180° (2x90°) (Fasten nuts in two crossed
passes)(Beforefittingthenuts,lubricatethemwith
engine oil.)
Head fixing side screws 11 ÷ 13
Characteristics Vespa GTV 125
CHAR - 8

Name Torque in Nm
Starter ground screw 7 ÷ 8.5
M5 side screw locking washers on camshaft 7 ÷ 8.5
Tappet set screw lock nut 6 ÷ 8
Inlet manifold screws 11 ÷ 13
Timing chain tensioner slider screw 10 ÷ 14
M6 central screw locking washers on camshaft 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
Clutch assembly nut on driven pulley 55 ÷ 60
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 fixing screws 5 - 6
Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength
threadlock)
Flywheel nut 52 ÷ 58
Pick-Up clamping screws 3 ÷ 4
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 motor 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
Screws of the water pump rotor driving link 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Overhaul data
Assembly clearances
Vespa GTV 125 Characteristics
CHAR - 9

Cylinder - piston assy.
ENGINE COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059
Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059
Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059
Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059
Cylinder 1st Over-
size A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059
Cylinder 1st Over-
size B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059
Piston 1st Over-
size C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059
Piston 1st Over-
size D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059
Cylinder 2nd Over-
size A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059
Cylinder 2nd Over-
size B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059
Piston 2nd Over-
size C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059
Piston 2nd Over-
size D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059
Cylinder 3rd Over-
size A 3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059
Cylinder 3rd Over-
size B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059
Piston 3rd Over-
size C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059
Piston 3rd Over-
size D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059
Characteristics Vespa GTV 125
CHAR - 10

Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000
car.) Indirizzo Immagine
Crankshaft Crankshaftto crankcase
axial clearance
Crankshaft to crankcase axial clearance
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
Vespa GTV 125 Characteristics
CHAR - 11

Slot packing system
Characteristic
Compression ratio
12 ± 0.5: 1
Measurement "A" to be taken is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the bigger the base gasket to be used (to recover the compression
ratio) and vice versa.
N.B.
DISTANCE "A" MUST BE MEASURED WITHOUT ANY GASKET FITTED BETWEEN CRANKCASE
AND CYLINDER
SHIMMING
Name Measure A Thickness
Shimming 2.2 ÷ 2.4 0.4 ± 0.05
Shimming 2.4 ÷ 2.6 0.6 ± 0.05
Oversizes
Characteristics Vespa GTV 125
CHAR - 12

ENGINE OVERSIZES
Name Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 ÷ 0.30
Oil scraper ring 57 x 1 A 0.10 ÷ 0.30
Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35
Compression ring
1st oversize 57.2 x 1 A 0.15 ÷ 0.30
Oil scraper ring 1st
Oversize 57.2 x 1 A 0.10 ÷ 0.30
Oil scraper ring 1st
Oversize 57.2 x 2.5 A 0.15 ÷ 0.35
Compression ring
2nd Oversize 57.4 x 1 A 0.15 ÷ 0.30
Oil scraper ring
2nd Oversize 57.4 x 1 A 0.10 ÷ 0.30
Oil scraper ring
2nd Oversize 57.4 x 2.5 A 0.15 ÷ 0.35
Compression ring
3rd Oversize 57.6 x 1 A 0.15 ÷ 0.30
Oil scraper ring 3rd
Oversize 57.6 x 1 A
Oil scraper ring 3rd
Oversize 57.6 x 2.5 A 0.15 ÷ 0.35
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 Calcium complex soap-based
grease with NLGI 2; ISO-L-
XBCIB2
Grease (brake control levers,
throttle grip)
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid
SPECIAL AGIP PERMANENT
fluid coolant Monoethylene glycol-based anti- freeze fluid, CUNA NC 956-16
Vespa GTV 125 Characteristics
CHAR - 13

Characteristics Vespa GTV 125
CHAR - 14