Vespa GTS 250 I.E. - Workshop Manual

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WORKSHOP MANUAL

633577

Vespa GTS 250 I.E.

Main Page

Index of Topics5
Characteristics7
Maintenance Rules8
Safety Rules8
Dimensions and Mass9
Vehicle Identification9
Capacities10
Electrical System10
Engine10
Transmission10
Brakes11
Frame and Suspensions11
Wheels and Tyres11
Table of Contents12
Tightening Torques12
Assembly Clearances14
Crankcase - Crankshaft - Connecting Rod15
Cylinder - Piston Assy15
Slot Packing System16
Products18
Tooling19
Maintenance33
Maintenance Chart34
Checking the Spark Advance36
Spark Plug37
Hub Oil: Check38
Air Filter39
Replacement39
Engine Oil40
Engine Oil Filter42
Oil Pressure Warning Light42
Checking the Ignition Timing43
Cooling System43
Braking System44
Level Check44
Top-Up44
Headlight Adjustment45
Troubleshooting47
Clutch Grabbing or Performing Inadequately48
Excessive Oil Consumption/Exhaust Smoke48
Insufficient Lubrication Pressure48
Transmission and Brakes48
Brakes Overheating49
Heavy Steering49
Insufficient Braking49
Steering and Suspensions49
Noisy Suspension50
Suspension Oil Leakage50
Electrical System51
Electrical System Installation55
Front Side56
Back Side61
Ignition66
Headlights and Automatic Starter Section67
Lights and Turn Indicators68
Battery Recharge and Starting70
Level Indicators and Enable Signals Section72
Consensuses and Level Indicators73
Devices and Horn74
Turn Signal Lights74
Checks and Inspections76
Immobiliser76
Virgin Circuit79
Diagnostic Codes80
Diagnostic Code - 1 Flash81
Battery Recharge Circuit82
Diagnostic Code - 2 Flashes82
Diagnostic Code - 3 Flashes82
Stator Check82
Recharge System Voltage Check83
Fuses84
Turn Signals System Check84
Dashboard86
Sealed Battery87
Battery Installation88
Connectors90
Engine from Vehicle91
Exhaust Assy. Removal92
Removal of the Engine from the Vehicle93
Engine99
Air Duct100
Automatic Transmission100
Transmission Cover100
Refitting the Driven Pulley Shaft Bearing101
Removing the Driven Pulley Shaft Bearing101
Plastic Roller102
Removing the Driven Pulley102
Inspecting the Clutch Drum103
Inspecting the Clutch104
Removing the Clutch104
Pin Retaining Collar105
Removing the Driven Half-Pulley Bearing105
Inspecting the Driven Fixed Half-Pulley106
Inspecting the Driven Sliding Half-Pulley107
Refitting the Driven Half-Pulley Bearing107
Refitting the Driven Pulley108
Inspecting the Clutch Spring109
Refitting the Clutch109
Drive-Belt111
Removing the Driving Pulley111
Inspecting the Rollers Case112
Refitting the Driving Pulley113
Refitting the Transmission Cover114
Removing the Hub Cover115
Removing the Wheel Axle115
Removing the Hub Bearings116
Removing the Wheel Axle Bearings116
Inspecting the Hub Cover117
Inspecting the Hub Shaft117
Refitting the Wheel Axle Bearing118
Refitting the Hub Cover Bearings119
Refitting the Hub Bearings120
Refitting the Ub Cover120
Removing the Stator121
Refitting the Flywheel Cover122
Refitting the Stator122
Removing the Flywheel Magneto123
Removing the Starter Motor123
Inspecting the Flywheel Components124
Refitting the Free Wheel124
Refitting the Flywheel Magneto125
Cylinder Assy. and Timing System126
Refitting the Starter Motor126
Removing the Intake Manifold126
Removing the Rocker-Arms Cover127
Removing the Timing System Drive127
Removing the Cam Shaft129
Removing the Cylinder Head129
Removing the Cylinder - Piston Assy130
Removing the Valves130
Inspecting the Small End131
Inspecting the Wrist Pin131
Inspecting the Piston132
Inspecting the Cylinder133
Inspecting the Piston Rings133
Choosing the Gasket134
Removing the Piston134
Refitting the Cylinder136
Refitting the Piston Rings136
Inspecting the Cylinder Head137
Inspecting the Timing System Components137
Inspecting the Valve Housings138
Inspecting the Valve Sealings138
Inspecting the Valves139
Inspecting the Springs and Half-Cones141
Refitting the Valves141
Inspecting the Cam Shaft142
Refitting the Head and Timing System Components143
Refitting the Intake Manifold146
Refitting the Rocker-Arms Cover146
Crankcase - Crankshaft147
Splitting the Crankcase Halves147
Inspecting the Crankshaft Alignment149
Inspecting the Crankcase Halves150
Inspecting the Crankshaft Plain Bearings151
Refitting the Crankcase Halves153
Conceptual Diagrams155
Studs155
Oil Pressure Check157
Oil Pump159
Removing the Oil Sump162
Inspecting the By-Pass Valve163
Refitting the Oil Sump163
Injection165
MIU Injection System166
Precautions169
Troubleshooting Hints170
EMS Circuit Diagram171
Terminals Setup171
Engine Does Not Start174
Troubleshooting Procedure174
Engine Stops at Idle175
Starting Difficulties175
Engine Does Not Rev down176
Exhaust Backfires in Deceleration176
Engine Revs Irregularly177
Poor Performance at Full Throttle177
Engine Knocking178
Fuel Supply System178
Removing the Butterfly Valve179
Pump Supply Circuit181
Refitting the Butterfly Valve181
Circuit Leak Test188
Fuel Filter Check189
Inspecting the Injector Circuit190
Inspecting the Injector Hydraulics197
Components Location198
Tachometer199
HT Coil200
Coolant Temperature Sensor207
Zeroing the Throttle208
Lambda Probe210
Signal Check217
Suspensions219
Front Wheel Hub Overhaul220
Removing the Front Wheel220
Refitting the Front Wheel222
Steering Column: Removal222
Overhaul225
Front Shock Absorber228
Lower Steering Ring Nut228
- Shock-Absorber - Calliper Bracket228
- Refitting the Rear Wheel231
- Removing the Rear Wheel231
- Swing-Arm: Removal231
Engine and Vehicle Side Swinging Arm Junction Bolt237
- Shock Absorbers237
- Centre Stand Bolt238
- Exhaust Bracket238
- Side Stand Fixing Bolt239

Vespa GTS 250 I.E. - Workshop Manual

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