VESPA GTV 250 i.e. 2008 Guide

SERVICE STATION MANUAL
633845
Vespa GTV 250 i.e.

SERVICE STATION
MANUAL
Vespa GTV 250 i.e.
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. - Aftersales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL
Vespa GTV 250 i.e.
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
PRE-DELIVERY PRE DE
TECHNICAL DATA DT
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
TIME TIME

INDEX OF TOPICS
PRE-DELIVERY PRE DE

Carry out the listed tests before delivering the vehicle.
Warning - Handle fuel with care.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
- Fixing screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Lower front shock absorber fitting
Front wheel axle nut
Front wheel screws
Rear wheel screws
Front and rear wheel hub nut
Front and rear brake calliper clamping screws
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
• Main switch
• Lights: high beam lights, low beam lights, tail lights and their warning lights
- Headlight adjustment according to the regulations currently in force
• Brake light operation by using the RH and LF brake lever
• Turn indicators and their warning lights
• Instrument lighting
Vespa GTV 250 i.e. Pre-delivery
PRE DE - 7

• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• electric saddle opening button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO-
TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE
OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
Level check:
- Hydraulic brake system liquid level
- Rear hub oil level
- Engine coolant level
- Engine oil level
Road test
Test ride:
- Cold start
- Instrument operations
- Response to throttle control
- Stability on acceleration and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
Pre-delivery Vespa GTV 250 i.e.
PRE DE - 8

- Abnormal noise
Static test
Static control after the test drive:
• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.
Functional inspection
Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting,
lock check, tyre pressure check, rear-view mirror and any accessory fitting
Vespa GTV 250 i.e. Pre-delivery
PRE DE - 9

INDEX OF TOPICS
TECHNICAL DATA DT

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 cotter 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.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
Vespa GTV 250 i.e. Technical Data
DT - 11

Vehicle identification
Chassis prefix: *ZAPM451020000 ÷ 1001*
Engine prefix: M451M ÷ 1001
Engine Data
ENGINE SPECIFICATIONS
Specification Desc./Quantity
Engine Single-cylinder, four-stroke
Bore x stroke 72 x 60 mm
Engine capacity 244.29 cm³
Compression ratio 10.5 - 11.5 : 1
Idle speed 1700 +/- 100 rpm
Ignition advance (before TDC) variable (integrated into the ignition system)
Spark plug CHAMPION RG 4 PHP
Valve clearance intake: 0.10 mm discharge: 0.15 mm
Maximum power 15.7 kW at 8500 rpm (EC Standard).
Maximum torque 20.1 Nm at 6500 rpm (EC Standard).
Max. speed 120 km/h
Technical Data Vespa GTV 250 i.e.
DT - 12

Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Length 1930 mm
Overall width 770 mm
Maximum height 1170 mm
Saddle height 800 mm
Wheelbase 1370 mm
Maximum admitted weight ~ 340 kg
Kerb weight 146 ± 5 kg
GENERAL SPECIFICATIONS
Specification Desc./Quantity
Electronic ignition inductive, high efficiency integrated with the injection system,
with variable timing and separate HV coil.
Fuel system throttle body diam. 32 mm and single injector
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Cooling Forced fluid circulation, with engine driven pump; 3-way ther-
mostat to pump intake.
Exhaust silencer Absorption-type exhaust muffler with catalytic converter.
Transmission Automaticexpandablepulleyvariatorwithtorqueserver,Vbelt,
automatic centrifugal dry clutch, gear reduction unit and trans-
mission compartment with forced air circulation cooling.
Vespa GTV 250 i.e. Technical Data
DT - 13

Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission With continuously variable expandable pulley transmission
with torque server, V belt, automatic clutch, gear reduction unit
and transmission housing with forced air circulation cooling
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil approx. 1300 cm³ (recommended oil Selenia HI Scooter 4
Tech)
Fuel tank (including a ~ 2 l reserve) ~ 9.2 l
Rear hub 250 cm³ (recommended oil TUTELA MATRIX)
Cooling system fluid approx. 2.100 ÷ 2.150 l PARAFLU 11FE (Diluted)
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
1 Spark plug CHAMPION RG4 PHP
2 Battery 12V - 12 Ah
3 Sealed Battery 14Ah 12V - 14 Ah (maintenance
free).
4 Generator 380W Rated power 380W at
8000 rpm
BULBS
Specification Desc./Quantity
1 Low-/ high-beam light 55/60 - 12V (Quantity 1)
2 Front position light 5W - 12V (Quantity 2)
3 Instrument Panel warning
lights 1.2W - 12V (Quantity 5)
4 Front turn indicator light 5W - 12V (Quantity 4)
5 Rear turn indicator light 10W - 12V (Quantity 2)
6 Rear tail light 5W - 12V (Quantity 1)
7 Stop Light 16W - 12V (Quantity 1)
8 License Plate Light 5W - 12V (Quantity 1)
FUSES
Specification Desc./Quantity
1 No.1 - Vehicle main fuse 30A
2 No. 2 - Live injection ECU 7.5 A
3 No. 3 - Power to injection
load 10A
4 No. 4 - Battery-powered
injection ECU 7,5A
5 No. 5 - Live accessories
and instrument panel 10A
6 No. 6 - Live light remote
control and horn 7.5 A
7 No. 7 - Live Headlight and
Saddle Opening Switch 15 A
8 No. 8 - Battery-powered
Accessories and Instru-
ment panel
10A
Technical Data Vespa GTV 250 i.e.
DT - 14

Specification Desc./Quantity
9 No. 9 - Live Stop light and
Starter key 7.5 A
10 No. 10 - Power to tail light
andinstrument panellight-
ing
7.5 A
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 dual-
chamber hydraulic shock absorber with coaxial spring.
Front shock absorber axial travel 86.5 mm
Rear suspension Engine based on swingarm balanced on the chassis by means
of an arm with 2 degrees of freedom. Pair of double action hy-
draulic shock absorbers and coaxial springs with adjustment of
the preload on 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)
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front wheel Alloy wheel rims: 12" x 3.00"
Rear wheel Alloy wheel rims: 12" x 3.00"
Front tyre Tubeless 120/70-12" 51P
Rear tyre Without inner tube: 130/70-12" 62P
TYRE PRESSURE
Specification Desc./Quantity
Front tyre pressure 1.8 bar
Rear tyre pressure 2 bar
Rear tyre pressure - driver and 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
Vespa GTV 250 i.e. Technical Data
DT - 15

Name Torque in Nm
Lower steering ring nut 12 - 14
Handlebar fixing screw 50 - 55
Fixing screws for the handlebar control unit U-bolts 7 - 10
FRAME ASSEMBLY
Name Torque in Nm
Swinging arm pin - engine 64 - 72
swinging arm bolt - body shell 76 to 83
Engine and vehicle side swinging arm junction bolt 33 - 41
Bolt of the Silent block support plate 42 to 52
Central stand bolt 32 - 40
Side stand fixing bolt 35 - 40
FRONT SUSPENSION
Name Torque in Nm
Screwfixingtheshock absorber totheshockabsorber - calliper
attachment plate 20 to 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
FRENO ANTERIORE
Name Torque in Nm
Brake fluid pump-hose joint 20 - 25
Brake fluid pipe-calliper fitting 19 - 24
Screw fixing calliper to the shock absorber - calliper plate at-
tachment 24 to 27
Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium strength)
Oil bleed screw 12 - 16
Pad fastening pin 19.6 - 24.5
Brake pump reservoir screws 1.5 - 2
REAR SUSPENSION
Name Torque in Nm
Retainer for left shock absorber to crankcase support plate 20 - 25
Shock absorber upper fitting 20 - 25
Shock absorber lower fitting 33 ÷ 41
Rear wheel axle 104 ÷ 126
Screw fixing wheel to hub 20 - 25
Screws for silencer - shock absorber support arm on engine 20 - 25 (The two screws must be tightened after having done
so with the rear wheel axle nut at the specified torque. Safety
fasteners: see «Pre-delivery Operations»)
REAR BRAKE
Name Torque in Nm
Brake fluid pump-hose joint 20 - 25
Brake fluid pipe-calliper fitting 20 - 25
Rear disc tightening bolt 11 to 13
Oil bleed screw 12-16
Calliper to engine tightening screw 20 - 25
Brake pump reservoir screws 1.5 - 2
Callipers fitting screw 30 - 33
SILENCER
Name Torque in Nm
Silencer heat guard fixing screw 4 - 5
Screw used to fasten silencer to supporting arm 20 - 25
Lambda probe tightening on exhaust manifold 40 - 50
Manifold/silencer joint tightening torque 12 - 13
Manifold - silencer diaphragm tightening clamp 16 - 18
Technical Data Vespa GTV 250 i.e.
DT - 16

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 to 30
Oil filter 4 - 6
Oil pump cover screws 7 - 9
Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket 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
Cylinder 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 to 8.5
Tappet adjustment check nut 6 - 8
Inlet manifold screws 11 to 13
Timing chain tensioner slider screw 10 - 14
Starter counterweight support screw 11 to 15
Timing chain tensioner support screw 11 to 13
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4 - 6
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 to 13
Clutch unit nut on driven pulley 45 - 50
Driver pulley nut 75 - 83
Transmission cover screws 11 - 13 Nm
Driven pulley shaft nut 54 - 60
Rear hub cover screws 24 to 27
FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 to 13
Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)
Flywheel nut 94 - 102
Pick-up fixing screws 3 - 4
Screw fixing freewheel to flywheel 13 - 15
CRANKSHAFT AND CASE
Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws 4 - 6
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)
COOLING
Name Torque in Nm
Water pump rotor cover 3 - 4
Thermostat cover screws 3 - 4
Bleeder screw 3
Vespa GTV 250 i.e. Technical Data
DT - 17

Overhaul data
Assembly clearances
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 Axial clearance between
crankshaft and connecting rod
Axial clearance between crankshaft and connecting rod
Technical Data Vespa GTV 250 i.e.
DT - 18

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
Name Description Dimensions Initials Quantity
Transmissionside half-
shaft 16.6 +0-0.05 A D = 0.20 - 0.50
Flywheel-side halfshaft 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 to 11.5 : 1
Vespa GTV 250 i.e. Technical Data
DT - 19

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 DIAL GAUGE, EQUIPPED WITH A SUP-
PORT, 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
Technical Data Vespa GTV 250 i.e.
DT - 20