Vespa GTS300 Super Workshop Manual
Vespa GTS300 Super Workshop Manual
Vespa GTS300 Super Workshop Manual
********
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.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
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 Sections marked with this symbol indicate the correct use of the vehicle
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
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
Vespa GTS Super 300 ie (2008) Characteristics
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
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Characteristics Vespa GTS Super 300 ie (2008)
Vehicle identification
CHAR - 8
Vespa GTS Super 300 ie (2008) Characteristics
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 with lobe pump (inside the crankcase) controlled by a chain and
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
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
CHAR - 9
Characteristics Vespa GTS Super 300 ie (2008)
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 Automatic expandable pulley variator with torque server, V belt,
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
CHAR - 10
Vespa GTS Super 300 ie (2008) Characteristics
To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.
HORN BUTTON
CHAR - 11
Characteristics Vespa GTS Super 300 ie (2008)
LIGHT SWITCH
STARTER BUTTON
KEY SWITCH
FUEL INJECTOR
Type: 3 holes
Conicity of the nozzle: 20°
Resistance at terminals: 13.7 ÷ 15.2 Ohm
CHAR - 12
Vespa GTS Super 300 ie (2008) Characteristics
CHAR - 13
Characteristics Vespa GTS Super 300 ie (2008)
HV COIL
- Resistance of the primary = 0.5 Ohm ± 8%
- Resistance between primary and ground = infin-
ite
- Resistance between primary and HV output = 3.1
KOhm ± 9%
- 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 ÷ 1 Ohm
terminal insulation from ground
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)
CHAR - 14
Vespa GTS Super 300 ie (2008) Characteristics
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
Tightening Torques
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 35 ÷ 40
Steering lower ring nut 12 ÷ 14
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-delivery 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
Engine and vehicle side swinging arm junction bolt 33 ÷ 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
Screw fixing the shock absorber to the shock absorber - calliper 20 ÷ 27
attachment plate
Wheel axle nut 74 ÷ 88
Wheel screw 20 ÷ 25
Screw fixing rear mudguard to steering 5 ÷ 6.5
shock absorber upper clamp 20 ÷ 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- 24 ÷ 27
tachment
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
Brake disc screws 8 ÷ 10
CHAR - 15
Characteristics Vespa GTS Super 300 ie (2008)
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
torque after having done so with the rear wheel axle 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 ÷ 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 the support arm 20 ÷ 25
Lambda probe clamp on exhaust manifold 40 ÷ 50
Exhaust manifold-muffler joint clamp 12 ÷ 13
Manifold - muffler diaphragm tightening clamp 16 ÷ 18
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 4÷6
Oil pump cover screws 7÷9
Screws fixing oil pump to 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 fixing head to cylinder 7±1 + 10±1 + 270°
Head fixing side screws 11 ÷ 12
Starter ground screw 7 ÷ 8.5
Tappet set screw lock nut 6÷8
Inlet manifold screws 11 ÷ 13
Timing chain tensioner slider screw 10 ÷ 14
Starter ground support screw 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 unit nut on driven pulley 45 ÷ 50
CHAR - 16
Vespa GTS Super 300 ie (2008) Characteristics
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 clamping screws 3÷4
Screw fixing freewheel to flywheel 13 ÷ 15
COOLING
Name Torque in Nm
Water pump rotor cover 3÷4
Thermostat cover screws 3÷4
Bleed screw 3
Overhaul data
Assembly clearances
CHAR - 17
Characteristics Vespa GTS Super 300 ie (2008)
CYLINDER - PISTON
Specification Desc./Quantity
Plunger diameter 74.967 +0.014 -0.014 mm
Cylinder diameter 75 +0.038 +0.01 mm
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder-piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064
cylinder-piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064
cylinder-piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064
cylinder-piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064
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.
- Measure the outside diameter of the gudgeon
pin.
Characteristic
Pin outside diameter
16 +0 -0.004 mm
Characteristic
Standard diameter
16 +0.006 +0.001 mm
CHAR - 18
Vespa GTS Super 300 ie (2008) Characteristics
Fitting clearance
Top piston ring - standard coupling clearance
0.015 - 0.06 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance al-
lowed after use 0.07 mm oil scraper ring - stand-
ard coupling clearance 0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm
Characteristic
Maximum allowable run-out:
0.05 mm
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Crankshaft to crankcase axial
clearance
Crankshaft to crankcase axial clearance
CHAR - 19
Characteristics Vespa GTS Super 300 ie (2008)
CHAR - 20
Vespa GTS Super 300 ie (2008) Characteristics
CRANKSHAFT
Specification Desc./Quantity
Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm
CHAR - 21
Characteristics Vespa GTS Super 300 ie (2008)
CHAR - 22
Vespa GTS Super 300 ie (2008) Characteristics
Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm
Characteristic
Standard diameter
16 +0.025 +0.015 mm
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings must
be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- There are three crankcase versions: with BLUE bushings, with YELLOW bushings and with GREEN
bushings.
- There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter
after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
- The main bushings are available in three thickness categories, identified by colour markings, as shown
in the table below.
BUSHINGS
TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING
B BLUE 1.973 ÷ 1.976
C YELLOW 1.976 ÷ 1.979
E GREEN 1.979 ÷ 1.982
CHAR - 23
Characteristics Vespa GTS Super 300 ie (2008)
COUPLINGS
BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING
HALVES CATEGORY
B 2 29.024 ÷ 29.054
C 1 29.024 ÷ 29.054
2 29.018 ÷ 29.048
E 1 29.018 ÷ 29.048
Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2).
Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare
crankshaft has half-shafts of the same category.
CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
N.B.
CRANKCASES FOR REPLACEMENTS ARE SELECTED
WITH CRANKCASE HALVES OF THE SAME CATEGORY
AND ARE FITTED WITH CATEGORY C BUSHINGS (YEL-
LOW)
Characteristic
Crankshaft-bushing maximum clearance ad-
mitted:
0.08 mm
Diameter of crankcase without bushing
CAT. 1: 32.959 ÷ 32.965 mm
CAT. 2: 32.953 ÷ 32.959 mm
Cylinder Head
Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting
Characteristic
Maximum allowable run-out:
0.1 mm
CHAR - 24
Vespa GTS Super 300 ie (2008) Characteristics
- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the bearings of the camshaft and the rocker pins exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant sealing pad exhibits no oxidation.
HEAD BEARINGS
Specification Desc./Quantity
bearing «A» Ø 12.000 - 12.018 mm
bearing «B» Ø 20.000 ÷ 20.021 mm
bearing «C» Ø 37.000 - 37.025 mm
Characteristic
Standard length
40.2 mm
Allowable limit after use:
38.2 mm
CHAR - 25
Characteristics Vespa GTS Super 300 ie (2008)
Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damages, replace the head.
STANDARD DIAMETER
Specification Desc./Quantity
Inlet: 4.987 - 4.972 mm
Outlet: 4.975 - 4.960 mm
CHAR - 26
Vespa GTS Super 300 ie (2008) Characteristics
Characteristic
Limit values admitted:
0.1 mm
Characteristic
Admissible limit:
0.03 mm
Characteristic
Valve guide:
5 +0.012 mm
CHAR - 27
Characteristics Vespa GTS Super 300 ie (2008)
INLET
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm
OUTLET
Specification Desc./Quantity
Standard clearance: 0.025 ÷ 0.052 mm
Admissible limit: 0.09 mm
- Check that there are no signs of wear on the surface of contact with the articulated register terminal.
STANDARD DIAMETER
Specification Desc./Quantity
Cam shaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm
Cam shaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm
CHAR - 28
Vespa GTS Super 300 ie (2008) Characteristics
Specification Desc./Quantity
Cam shaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm
STANDARD HEIGHT
Specification Desc./Quantity
Cam shaft check: Standard height Inlet: 30.285 mm
Cam shaft check: Standard height Outlet: 29.209 mm
CHAR - 29
Characteristics Vespa GTS Super 300 ie (2008)
Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment
plate.
Characteristic
Compression ratio
10.5 ÷ 11.5 : 1
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
CHAR - 30
Vespa GTS Super 300 ie (2008) Characteristics
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 GAUGE, EQUIPPED WITH A SUPPORT, ON
A GROUND PLANE
Products
CHAR - 31
INDEX OF TOPICS
TOOLING TOOL
Vespa GTS Super 300 ie (2008) Tooling
ATTREZZATURA SPECIFICA
Stores code Description
001330Y Tool for fitting steering seats
TOOL - 33
Tooling Vespa GTS Super 300 ie (2008)
020036Y Punch
020038Y Punch
TOOL - 34
Vespa GTS Super 300 ie (2008) Tooling
TOOL - 35
Tooling Vespa GTS Super 300 ie (2008)
TOOL - 36
Vespa GTS Super 300 ie (2008) Tooling
020357Y 32 x 35 mm adaptor
020359Y 42x47-mm adaptor
020360Y Adaptor 52 x 55 mm
020363Y 20 mm guide
TOOL - 37
Tooling Vespa GTS Super 300 ie (2008)
020375Y Adaptor 28 x 30 mm
TOOL - 38
Vespa GTS Super 300 ie (2008) Tooling
TOOL - 39
Tooling Vespa GTS Super 300 ie (2008)
020456Y Ø 24 mm adaptor
020477Y Adaptor 37 mm
020483Y 30 mm guide
TOOL - 40
Vespa GTS Super 300 ie (2008) Tooling
TOOL - 41
Tooling Vespa GTS Super 300 ie (2008)
TOOL - 42
Vespa GTS Super 300 ie (2008) Tooling
020115Y Ø 18 punch
TOOL - 43
INDEX OF TOPICS
MAINTENANCE MAIN
Vespa GTS Super 300 ie (2008) Maintenance
Maintenance chart
km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Safety locks I I I I I
Spark plug R R R R R R
Driving belt R R R R
Throttle control A A A A A A A
Air filter C C C C C C
Belt compartment air filter I I I I I I
Oil filter R R R R R R R
Valve clearance A A A
Electrical system and battery I I I I I I I
Brake fluid * I I I I I I I
Coolant * I I I I I I I
Engine oil R I R I R I R I R I R I R
Hub oil R I R I R I R
Brake pads I I I I I I I I I I I I I
Sliding blocks / variable speed rollers R R R R R R
Tyre pressure and wear I I I I I I I
Vehicle road test I I I I I I I
Suspensions I I I I I I
Steering A A A A A A A
MAIN - 45
Maintenance Vespa GTS Super 300 ie (2008)
Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing
020621Y HV cable extraction adaptor
MAIN - 46
Vespa GTS Super 300 ie (2008) Maintenance
Spark plug
Characteristic
Electrode gap
MAIN - 47
Maintenance Vespa GTS Super 300 ie (2008)
0.7-0.8 mm
Electric characteristic
Spark plug
NGK CR8EKB
Hub oil
Check
Replacement
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Rear hub oil
Capacity approximately 250 cc
MAIN - 48
Vespa GTS Super 300 ie (2008) Maintenance
Air filter
Proceed as follows:
1. unscrew the fixing screw «A».
2. unscrew the nut «B» under the body.
3. remove the left side fairing.
4. remove the helmet compartment;
5. unscrew the fixing screws «C» that can be
reached once the helmet compartment has been
removed;
6. Unscrew the screws «D» and remove the air fil-
ter cover.
Remove the filtering element and clean it with wa-
ter and shampoo; then dry it with a clean cloth and
short blasts of compressed air. Finally, immerse it
in a mixture of 50% oil of the recommended type
and 50% petrol. Then gently squeeze the filter el-
ement between your hands, allow it to drip and
then refit it. Oil or water deposits in the filter hous-
ing can be cleaned off by removing the two rubber
caps «E».
CAUTION
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness
MAIN - 49
Maintenance Vespa GTS Super 300 ie (2008)
Engine oil
In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the
thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be con-
sidered normal, especially if during the run-in period. Consumption levels in particular can be influenced
by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Replacement
MAIN - 50
Vespa GTS Super 300 ie (2008) Maintenance
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the require-
ments of API SL, ACEA A3, JASO MA specifica-
tions
Check
This operation must be carried out with the engine cold and following the procedure below:
The MAX level mark indicates a quantity of around 1300 cc of engine oil. If the check is carried out after
the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry
out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
Oil top up
The oil should be topped up after having checked
the level and in any case by adding oil without
ever exceeding the MAX. level.
Restoration of the level from MIN to MAX requires
approximately 200 cc.
The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter
being careful to lubricate the O-ring before fitting it. Change the engine oil.
MAIN - 51
Maintenance Vespa GTS Super 300 ie (2008)
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned
to the «ON» position. However, this light should switch off once the engine has been started.
If the light turns on during braking, at idling speed or while turning a corner, it is necessary to
check the oil level and the lubrication system.
Cooling system
MAIN - 52
Vespa GTS Super 300 ie (2008) Maintenance
Braking system
Level check
The brake fluid tanks for the front and rear brakes
are located on the pumps under the handlebar
cover. Proceed as follows:
- Remove the brake pump cover
- Rest the vehicle on its centre stand with the han-
dlebars perfectly horizontal;
- Check the fluid level through the sight glass as
shown in the figure. A certain lowering of the level
is caused by wear on the pads.
MAIN - 53
Maintenance Vespa GTS Super 300 ie (2008)
Top-up
- Remove the gasket and fill with DOT 4 until the spyglass is completely covered
MAIN - 54
Vespa GTS Super 300 ie (2008) Maintenance
Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the bor-
derline of the projected light beam on the screen
is not lower than 9/10 of the distance from the
ground to the centre of vehicle headlamp and high-
er than 7/10;
3. If otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
MAIN - 55
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Vespa GTS Super 300 ie (2008) Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.
Engine
EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats Replace the head assembly
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil guard Replace the valve oil guard
Worn valve guides Check and replace the head unit if required
Insufficient braking
TROUBL - 57
Troubleshooting Vespa GTS Super 300 ie (2008)
Brakes overheating
BRAKES OVERHEATING
Possible Cause Operation
Defective sliding of pistons Check calliper and replace any damaged part.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace gaskets.
Heavy steering
STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities in turning the steering continue even after making the
above adjustments, check the seats on which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Noisy suspension
NOISY SUSPENSION
Possible Cause Operation
Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorbers; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disk in the
attachment to the hub and the steering tube.
TROUBL - 58
Vespa GTS Super 300 ie (2008) Troubleshooting
TROUBL - 59
INDEX OF TOPICS
KEY
1. Pre-installation for anti-theft device
2. Left turn indicator bulbs
3. Right turn indicator bulbs
4. Turn indicator switch
5. Turn indicator control device
6. Instrument panel
7. Oil pressure sensor
8. Fuel level transmitter
9. Immobilizer aerial
10. Injection ECU
11. Diagnostics socket
12. Fuel pump
13. Engine temperature sensor
14. Fuel injector
15. HV coil
16. Engine rpm sensor
17. Lambda probe
18. Horn
19. Horn button
ELE SYS - 61
Electrical system Vespa GTS Super 300 ie (2008)
Key
Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
ELE SYS - 62
Vespa GTS Super 300 ie (2008) Electrical system
Components arrangement
ELE SYS - 63
Electrical system Vespa GTS Super 300 ie (2008)
ELE SYS - 64
Vespa GTS Super 300 ie (2008) Electrical system
ELE SYS - 65
Electrical system Vespa GTS Super 300 ie (2008)
ELE SYS - 66
Vespa GTS Super 300 ie (2008) Electrical system
Ground points
On the vehicle there is a ground point on the chassis marked with the letter "A"
ELE SYS - 67
Electrical system Vespa GTS Super 300 ie (2008)
ELE SYS - 68
Vespa GTS Super 300 ie (2008) Electrical system
Front side
ELE SYS - 69
Electrical system Vespa GTS Super 300 ie (2008)
3. Insert in clamp
4. Fuse box
5. From the wire unit
ELE SYS - 70
Vespa GTS Super 300 ie (2008) Electrical system
ELE SYS - 71
Electrical system Vespa GTS Super 300 ie (2008)
9. Voltage regulator
1. Immobilizer aerial
2. Foldable clamp to hold cables
3. Battery negative terminal
ELE SYS - 72
Vespa GTS Super 300 ie (2008) Electrical system
1. To stop switch
2. To turn indicator switch
3. To light switch
4. To horn button
5. To instrument panel
6. To headlight
7. To position light
8. To starter button
9. To engine stop switch
ELE SYS - 73
Electrical system Vespa GTS Super 300 ie (2008)
Back side
1. To HV coil
2. Foldable clamp
3. Foldable clamps to hold the red sheathing
4. Diagnostic socket
5. Starter remote control
ELE SYS - 74
Vespa GTS Super 300 ie (2008) Electrical system
ELE SYS - 75
Electrical system Vespa GTS Super 300 ie (2008)
1. Fuse box
2. Remote control switch
3. Ground lead clamping to chassis
4. Oil pressure sensor
5. Lambda probe connector
6. Lambda sensor
7. To wire unit
8. To the spark plug
9. HV coil
ELE SYS - 76
Vespa GTS Super 300 ie (2008) Electrical system
1. To flywheel
2. To saddle opening actuator
3. Fuse box
4. Foldable clamp to hold cables
5. Clamp
6. Injector connector
7. To HV coil
8. To front wire unit
9. To rear turn indicators
10.To fuel gauge and fuel tank
ELE SYS - 77
Electrical system Vespa GTS Super 300 ie (2008)
Conceptual diagrams
ELE SYS - 78
Vespa GTS Super 300 ie (2008) Electrical system
Ignition
KEY
6. Instrument panel
9. Immobilizer aerial
10. Injection ECU
15. HV coil
20. Injection load remote control
22. Battery
26. Main fuses
31. Engine stop switch
40. Key switch contacts
ELE SYS - 79
Electrical system Vespa GTS Super 300 ie (2008)
KEY
10. Injection ECU
21. Stop light bulb
22. Battery
23. Start-up remote control
24. Starter motor
25. Starter button
26. Main fuses
27. Voltage regulator
28. Magneto flywheel
39. Stop buttons
40. Key switch contacts
41. Auxiliary fuses
ELE SYS - 80
Vespa GTS Super 300 ie (2008) Electrical system
KEY
6. Instrument panel
7. Oil pressure sensor
8. Fuel level transmitter
9. Immobilizer aerial
10. Injection ECU
13. Engine temperature sensor
14. Fuel injector
16. Engine rpm sensor
17. Lambda probe
20. Injection load remote control
22. Battery
26. Main fuses
31. Engine stop switch
40. Key switch contacts
41. Auxiliary fuses
ELE SYS - 81
Electrical system Vespa GTS Super 300 ie (2008)
KEY
1. Pre-installation for anti-theft device
2. Left turn indicator bulbs
3. Right turn indicator bulbs
6. Instrument panel
10. Injection ECU
12. Fuel pump
18. Horn
19. Horn button
20. Injection load remote control
22. Battery
26. Main fuses
29. Radiator electric fan
30. Remote control for electric fan
33. Saddle opening actuator
34. Saddle opening button
35. Key switch contacts
40. Key switch contacts
ELE SYS - 82
Vespa GTS Super 300 ie (2008) Electrical system
KEY
2. Left turn indicator bulbs
3. Right turn indicator bulbs
4. Turn indicator switch
5. Turn indicator control device
6. Instrument panel
10. Injection ECU
22. Battery
26. Main fuses
32. Light switch
36. Tail lights and license plate light bulbs
37. Headlight with twin-filament light bulb
38. Headlight remote control
40. Key switch contacts
41. Auxiliary fuses
ELE SYS - 83
Electrical system Vespa GTS Super 300 ie (2008)
Immobiliser
ELE SYS - 84
Vespa GTS Super 300 ie (2008) Electrical system
ELE SYS - 85
Electrical system Vespa GTS Super 300 ie (2008)
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
ELE SYS - 86
Vespa GTS Super 300 ie (2008) Electrical system
Virgin circuit
ELE SYS - 87
Electrical system Vespa GTS Super 300 ie (2008)
Characteristic
Shielded cap resistance
~ 5000 Ω.
Diagnostic codes
ELE SYS - 88
Vespa GTS Super 300 ie (2008) Electrical system
5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-
mitted are:
• Code 1 flash
• 2-flash code
• 3-flash code
ELE SYS - 89
Electrical system Vespa GTS Super 300 ie (2008)
Stator check
Stator winding check-up
WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Lift the saddle and remove the helmet compartment.
2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the
photograph.
ELE SYS - 90
Vespa GTS Super 300 ie (2008) Electrical system
3) Measure the resistance between each of the yellow terminals and the other two.
Electric characteristic
Resistance:
0.2 - 1 Ω
Electric characteristic
Voltage ranging between 14.0 and 15.0V at 5000 rpm.
Maximum current output check.
- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.
- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.
- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter.
With an efficient battery a value must be detected: > 20A
ELE SYS - 91
Electrical system Vespa GTS Super 300 ie (2008)
VOLTAGE REGULATOR/RECTIFIER
Specification Desc./Quantity
Type Non-adjustable three-phase transistor
Voltage 14 ÷ 15V at 5000 rpm with lights off
Starter motor
KEY
1. Battery
2. Start-up remote control
3. Fuse No. 1
4. Fuse No. 3
5. Key switch contacts
6. Fuse No. 2
7. Electronic control unit
8. Engine stop switch
9. Stop buttons
10. Fuse No. 8
11. Starter button
12. Starter motor
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1; 2; 3 and 8.
ELE SYS - 92
Vespa GTS Super 300 ie (2008) Electrical system
Horn control
KEY
1. Battery
2. Fuse No. 1
3. Key switch contacts
4. Fuse No. 5
ELE SYS - 93
Electrical system Vespa GTS Super 300 ie (2008)
5. Horn button
6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1 and 5.
2) Check the key switch and horn button contacts.
3) With the key switch set to «ON» and the horn button pressed, check if there is voltage between the
Yellow-Pink cable of the horn device and the ground connection. If there is not, check the cable har-
nesses.
4) Check the horn device ground connection.
KEY
1. Battery
2. Fuse No. 1
3. Key switch contacts
4. Fuse No. 4
5. Turn indicator control device
6. Turn indicator switch
7. Turn indicator bulbs
WARNING
ELE SYS - 94
Vespa GTS Super 300 ie (2008) Electrical system
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check that bulbs operate properly.
2) Check fuses No. 1 and 4.
3) Check key switch contacts.
4) With the key switch set to «ON», check if there is voltage between the Blue-Black cable of the turn
indicators switch and the ground connection. If there is not, check the cable harnesses and the con-
nections of the turn indicator control device.
5) Check the turn indicator switch contacts.
6) With the turn indicator switch pressed to the right, check if there is voltage between the White-Blue
cable of the switch and the ground connection. If there is not, check the cable harnesses.
7) With the turn indicator switch pressed to the left, check if there is voltage between the Pink cable of
the switch and the ground connection. If there is not, check the cable harnesses.
8) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values be-
tween the White-Green cable and the Black cable
of the fuel level transmitter under different condi-
tions.
2) If the transmitter operates correctly but the in-
dication on the instrument panel is not exact,
check that the cable harnesses between them are
not interrupted.
Electric characteristic
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω
ELE SYS - 95
Electrical system Vespa GTS Super 300 ie (2008)
Lights list
KEY
1. Battery
2. Fuse No. 1
3. Fuse No. 6
4. Key switch contacts
5. Fuse No. 5
6. Fuse No. 9
7. Electronic control unit
8. Tail lights and license plate light bulbs
9. Low-/high-beam twin filament bulb
10. Light switch
11. Headlight remote control
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
TAIL LIGHTS AND LICENSE PLATE LIGHT LINE
1) Check that bulbs operate properly.
2) Check fuses No. 1 and 9.
3) Check key switch contacts.
4) Check if there is voltage between the Yellow-Black cable of fuse No. 9 and the ground connection.
If there is not, check the cable harnesses.
ELE SYS - 96
Vespa GTS Super 300 ie (2008) Electrical system
5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
HIGH-BEAM /LOW-BEAM LIGHTS LINE
1) Check that bulbs operate properly.
2) Check fuses No. 1; 5 and 6.
3) Check key switch contacts.
4) Check if there is voltage between the Grey cable of the headlight remote control and the ground
connection. If there is not, check the cable harnesses.
5) With the key switch set to «ON» and the engine running, check if there is voltage between the Yellow-
Red cable of the headlight remote control and the ground connection. If there is not, check the cable
harnesses.
6) Check that the White-Black cable connecting the headlight remote control switch and the control unit
(pin 19) is not interrupted.
7) Check the headlight remote control switch.
8) Check that the Grey-Red cable of the light switch and the headlight remote control switch is not
interrupted.
9) Check the light switch contacts.
10) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
Fuses
ELE SYS - 97
Electrical system Vespa GTS Super 300 ie (2008)
FUSES
Specification Desc./Quantity
1 Fuse No. 1 Capacity: 30 A
Protected circuits: Battery recharge circuit, fuses No.
6-7.
Live: Fuses No. 4 - 5 - 8 - 9
2 Fuse No. 2 Capacity: 7.5 A
Protected circuits: Electric fan remote control, injection
load remote control, immobilizer aerial, ECU.
3 Fuse No. 3 Capacity: 15A
Protected circuits: Injection load (via remote control),
ECU.
4 Fuse No. 4 Capacity: 10 A
Protected circuits: Turn indicators, pre-installation for
anti-theft device, instrument panel.
5 Fuse No. 5 Capacity: 7.5 A
Protected circuits: Horn, headlight remote control.
6 Fuse No. 6 Capacity: 15A
Protected circuits: Electric fan (via remote control),
high-beam and low-beam lights (via remote control).
Live: Saddle opening actuator.
7 Fuse No. 7 Capacity: 10 A
Protected circuits: Pre-installation for anti-theft device,
instrument panel.
8 Fuse No. 8 Capacity: 7.5 A
Protected circuits: Start-up circuit, stop light.
9 Fuse No. 9 Capacity: 7.5 A
Protected circuits: Tail lights, instrument panel lighting.
ELE SYS - 98
Vespa GTS Super 300 ie (2008) Electrical system
Dashboard
A = Digital clock
B = Odometer
C = Speedometer
D = Injection telltale light
E = Engine oil pressure warning light
F = Turn indicators
G = High-beam warning light
H = Headlight warning light
I = Fuel gauge
L = Low fuel warning light
M = Coolant temperature gauge
N = Immobilizer LED
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
ELE SYS - 99
Electrical system Vespa GTS Super 300 ie (2008)
Connectors
DIAGNOSIS CONNECTOR
1. Not connected
2. Ground (Black)
3. Electronic control unit (Purple-White)
PICK-UP CONNECTOR
1. Positive from control unit (Red)
2. Negative from control unit (Brown)
3. Not connected
INJECTOR CONNECTOR
1. Power via remote control (Black-Green)
2. Electronic control unit (Red-Yellow)
HV COIL CONNECTOR
1. Power via remote control (Black-Green)
2. Electronic control unit (Pink-Black)
This section describes the operations to carry out when removing the engine from the scooter.
- Remove the right and left fairings and the spoiler terminals.
ENG VE - 105
Engine from vehicle Vespa GTS Super 300 ie (2008)
CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE-
PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.
ENG VE - 106
Vespa GTS Super 300 ie (2008) Engine from vehicle
ENG VE - 107
Engine from vehicle Vespa GTS Super 300 ie (2008)
ENG VE - 108
Vespa GTS Super 300 ie (2008) Engine from vehicle
ENG VE - 109
Engine from vehicle Vespa GTS Super 300 ie (2008)
ENG VE - 110
Vespa GTS Super 300 ie (2008) Engine from vehicle
ENG VE - 111
INDEX OF TOPICS
ENGINE ENG
Vespa GTS Super 300 ie (2008) Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
Specific tooling
020423Y driven pulley lock wrench
Air duct
Version 250
ENG - 113
Engine Vespa GTS Super 300 ie (2008)
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020412Y 15 mm guide
Specific tooling
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
Baffle roller
ENG - 114
Vespa GTS Super 300 ie (2008) Engine
Plastic roller
ENG - 115
Engine Vespa GTS Super 300 ie (2008)
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
ENG - 116
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020444Y011 adapter ring
020444Y009 46x55 Wrench
020444Y Tool for fitting/ removing the driven
pulley clutch
Characteristic
ENG - 117
Engine Vespa GTS Super 300 ie (2008)
ENG - 118
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
001467Y035 Belle for OD 47-mm bearings
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
Characteristic
Half-pulley minimum diameter
Minimum admissible diameter Ø 40.96 mm
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm
ENG - 119
Engine Vespa GTS Super 300 ie (2008)
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020424Y Driven pulley roller casing fitting
punch
ENG - 120
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
ENG - 121
Engine Vespa GTS Super 300 ie (2008)
Characteristic
Standard length
123 mm
acceptable limit after use:
118 mm
ENG - 122
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 46x55 Wrench
ENG - 123
Engine Vespa GTS Super 300 ie (2008)
Drive-belt
Characteristic
Driving belt - minimum width
19.5 mm
Driving belt - standard width
21.3 ± 0.2 mm
ENG - 124
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020626Y Driving pulley lock wrench
Characteristic
Movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
ENG - 125
Engine Vespa GTS Super 300 ie (2008)
ENG - 126
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020626Y Driving pulley lock wrench
Specific tooling
020423Y driven pulley lock wrench
ENG - 127
Engine Vespa GTS Super 300 ie (2008)
End gear
ENG - 128
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
001467Y013 Pliers to extract ø 15-mm bearings
Specific tooling
020376Y Adaptor handle
020477Y Adaptor 37 mm
020483Y 30 mm guide
020359Y 42x47-mm adaptor
020489Y Hub cover support stud bolt set
ENG - 129
Engine Vespa GTS Super 300 ie (2008)
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide
ENG - 130
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020483Y 30 mm guide
ENG - 131
Engine Vespa GTS Super 300 ie (2008)
Specific tooling
020150Y Air heater support
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
N.B.
TO FIT THE BEARING ON THE COVER, SUPPORT THE COVER WITH THE STUD BOLT SET.
- Refit the driven pulley shaft bearing with a mod-
ular punch as shown in the figure.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020363Y 20 mm guide
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
- Refit the seeger ring with the opening facing the bearing and fit a new oil guard flush with the crankcase
from the pulley side.
ENG - 132
Vespa GTS Super 300 ie (2008) Engine
Flywheel cover
ENG - 133
Engine Vespa GTS Super 300 ie (2008)
ENG - 134
Vespa GTS Super 300 ie (2008) Engine
- Refit the cover over the engine and tighten the screws to the prescribed torque.
- Carry out the steps in the reverse order from the dismantling procedure.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE PRESENT.
Locking torques (N*m)
Flywheel cover screws 11 - 13
ENG - 135
Engine Vespa GTS Super 300 ie (2008)
ENG - 136
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020627Y Flywheel lock wrench
Specific tooling
020467Y Flywheel extractor
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
ENG - 137
Engine Vespa GTS Super 300 ie (2008)
ENG - 138
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020627Y Flywheel lock wrench
Loosen the three screws and remove the air intake manifold.
- When refitting, secure to the specified torque.
ENG - 139
Engine Vespa GTS Super 300 ie (2008)
ENG - 140
Vespa GTS Super 300 ie (2008) Engine
ENG - 141
Engine Vespa GTS Super 300 ie (2008)
ENG - 142
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020382Y011 adapter for valve removal tool
020382Y Valve cotters equipped with part 012
removal tool
020431Y Valve oil seal extractor
ENG - 143
Engine Vespa GTS Super 300 ie (2008)
ENG - 144
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020454Y Pin lock fitting tool
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool.
Specific tooling
020428Y Piston position check support
ENG - 145
Engine Vespa GTS Super 300 ie (2008)
- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-
sion ratio.
- Remove the special tool and the cylinder.
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
See also
Slot packing system
ENG - 146
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020426Y Piston fitting fork
020393Y Piston fitting band
ENG - 147
Engine Vespa GTS Super 300 ie (2008)
ENG - 148
Vespa GTS Super 300 ie (2008) Engine
Specific tooling
020306Y Punch for assembling valve seal
rings
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
ENG - 149
Engine Vespa GTS Super 300 ie (2008)
ENG - 150
Vespa GTS Super 300 ie (2008) Engine
ENG - 151
Engine Vespa GTS Super 300 ie (2008)
ENG - 152
Vespa GTS Super 300 ie (2008) Engine
Crankcase - crankshaft
ENG - 153
Engine Vespa GTS Super 300 ie (2008)
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
CAUTION
KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES
OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.
N.B.
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,
MAKE SURE THAT THE MEASUREMENTS ARE NOT
MODIFIED BY THE RADIUSES OF FITTINGS WITH THE
CRANKSHAFT BEARINGS.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.
See also
Crankcase - crankshaft - connecting rod
ENG - 154
Vespa GTS Super 300 ie (2008) Engine
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
Characteristic
Lubrication pressure
3.5 ÷ 4 bar
ENG - 155
Engine Vespa GTS Super 300 ie (2008)
ENG - 156
Vespa GTS Super 300 ie (2008) Engine
Studs
ENG - 157
Engine Vespa GTS Super 300 ie (2008)
Recommended products
Loctite 'Quick Set' Strong 270 threadlock
Strong 270 threadlock
Lubrication
Conceptual diagrams
LUBRICATION CIRCUIT
ENG - 158
Vespa GTS Super 300 ie (2008) Engine
ENG - 159
Engine Vespa GTS Super 300 ie (2008)
Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.
ENG - 160
Vespa GTS Super 300 ie (2008) Engine
Removal
Specific tooling
020622Y Transmission-side oil guard punch
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
ENG - 161
Engine Vespa GTS Super 300 ie (2008)
Specific tooling
020622Y Transmission-side oil guard punch
Oil pump
ENG - 162
Vespa GTS Super 300 ie (2008) Engine
Removal
Inspection
ENG - 163
Engine Vespa GTS Super 300 ie (2008)
Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm
Refitting
ENG - 164
Vespa GTS Super 300 ie (2008) Engine
ENG - 165
Engine Vespa GTS Super 300 ie (2008)
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 166
INDEX OF TOPICS
INJECTION INJEC
Injection Vespa GTS Super 300 ie (2008)
INJEC - 168
Vespa GTS Super 300 ie (2008) Injection
COMPONENT TRANSPOSITION
Specification Desc./Quantity
1 Instrument panel
2 Throttle body and electronic injection control unit (MIU)
3 Diagnostics socket connector
4 Fuel pump
5 Water temperature sensor
6 Fuel injector
7 HV coil
8 Engine rpm sensor
9 Lambda sensor
10 Injection load remote control
11 Battery 12V - 12 Ah
12 Electric fan remote control
INJEC - 169
Injection Vespa GTS Super 300 ie (2008)
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector
Specific tooling
020460Y Scooter diagnosis and tester
The MIU injection-ignition system carries out
checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the anti-
theft immobilizer system.
The MIU control unit is connected to a diagnostic
LED on the instrument panel, that also carries out
the deterrent flashing functions.
INJEC - 170
Vespa GTS Super 300 ie (2008) Injection
The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the scooter.
Precautions
1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel feed system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the quick coupler
of a pipe in the fuel supply system, check that there are no naked flames, and do not smoke. Act with
caution to prevent spraying in the eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to
respect this norm will damage the fuel pump.
6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and wiring.
8. When an ignition fault is detected, start the checks from the battery and the injection system con-
nections.
9. Before disconnecting the MIU control unit connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the polarity when fitting the battery.
11. To avoid damage, only disconnect and reconnect the MIU system connectors if required. Before
reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, protect the system connector with
its cap. Failure to do this may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Troubleshooting hints
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
INJEC - 171
Injection Vespa GTS Super 300 ie (2008)
c. Remote controls
d. Connectors
B: Chassis earthing
C: Fuel supply
a. Broken fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap
E: Intake circuit
a. Dirty air filter
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c.Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connections as follows:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 When troubleshooting use a multimeter with an internal resistance over 10 Ohm /V. Instruments that
are not suitable might damage the MIU control unit. Instruments must be used with definitions over 0.1V
and 0.5 W , the precision must be greater than 2%.
INJEC - 172
Vespa GTS Super 300 ie (2008) Injection
Terminals setup
INJEC - 173
Injection Vespa GTS Super 300 ie (2008)
26.Ground lead
1. Battery 12V - 12 Ah
2. Rpm sensor
3. coolant temperature sensor
4. Immobilizer aerial
5. Stop switches
6. Fuse No. 1; 30A
7. Key switch contacts
8. Fuse No. 8; 7.5A
INJEC - 174
Vespa GTS Super 300 ie (2008) Injection
Troubleshooting procedure
INJEC - 175
Injection Vespa GTS Super 300 ie (2008)
Starting difficulties
ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW
Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel feed (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity
INJEC - 176
Vespa GTS Super 300 ie (2008) Injection
INJEC - 177
Injection Vespa GTS Super 300 ie (2008)
Engine knocking
INJEC - 178
Vespa GTS Super 300 ie (2008) Injection
The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 179
Injection Vespa GTS Super 300 ie (2008)
INJEC - 180
Vespa GTS Super 300 ie (2008) Injection
INJEC - 181
Injection Vespa GTS Super 300 ie (2008)
1. Battery 12V
2. Fuse No. 3; 15A
3. Fuse No. 1; 30A
4. Key switch contacts
5. Fuse No. 2; 7.5A
6. Injection load remote control
7. Fuel pump
8. HV coil
INJEC - 182
Vespa GTS Super 300 ie (2008) Injection
9. Fuel injector
10.Electric fan remote control
When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts up, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA
INJEC - 183
Injection Vespa GTS Super 300 ie (2008)
INJEC - 184
Vespa GTS Super 300 ie (2008) Injection
pump circuit 6
INJEC - 185
Injection Vespa GTS Super 300 ie (2008)
Specific tooling
020331Y Digital multimeter
Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Make a graded burette available with a flow
rate of approximately 1 L. Rotate the pump using the active diagnosis of the palm top computer. Using
a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5
BAR. Check that, in fifteen seconds, the pump has a flow rate of around 110 cm³.
Specific tooling
020480Y Petrol pressure check set
INJEC - 186
Vespa GTS Super 300 ie (2008) Injection
INJEC - 187
Injection Vespa GTS Super 300 ie (2008)
1. Battery 12V
2. Fuse No. 3; 15A
3. Fuse No. 1; 30A
4. Key switch contacts
5. Fuse No. 2; 7.5A
6. Injection load remote control
7. Fuel pump
8. HV coil
INJEC - 188
Vespa GTS Super 300 ie (2008) Injection
9. Fuel injector
10.Electric fan remote control
INJEC - 189
Injection Vespa GTS Super 300 ie (2008)
INJEC - 190
Vespa GTS Super 300 ie (2008) Injection
INJEC - 191
Injection Vespa GTS Super 300 ie (2008)
Specific tooling
020480Y Petrol pressure check set
INJEC - 192
Vespa GTS Super 300 ie (2008) Injection
INJEC - 193
Injection Vespa GTS Super 300 ie (2008)
Components location
INJEC - 194
Vespa GTS Super 300 ie (2008) Injection
COMPONENT LAYOUT
Specification Desc./Quantity
1 Instrument panel
2 Throttle body and electronic injection control unit (MIU)
3 Diagnostic socket
4 Fuel pump
5 Water temperature sensor
6 Fuel injector
7 HV coil
8 Flywheel - rpm timing sensor
9 Lambda sensor
10 Injection load remote control
11 Battery 12V - 12 Ah
12 Electric fan remote control
Tachometer
INJEC - 195
Injection Vespa GTS Super 300 ie (2008)
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
INJEC - 196
Vespa GTS Super 300 ie (2008) Injection
HT coil
1. Battery 12V
2. Fuse No. 3; 15A
3. Fuse No. 1; 30A
4. Key switch contacts
5. Fuse No. 2; 7.5A
6. Injection load remote control
7. Fuel pump
8. HV coil
INJEC - 197
Injection Vespa GTS Super 300 ie (2008)
9. Fuel injector
10.Electric fan remote control
The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two important parameters:
- Ignition advance
This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure
With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up.
The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during
compression.
Specific tooling
020331Y Digital multimeter
INJEC - 198
Vespa GTS Super 300 ie (2008) Injection
INJEC - 199
Injection Vespa GTS Super 300 ie (2008)
INJEC - 200
Vespa GTS Super 300 ie (2008) Injection
INJEC - 201
Injection Vespa GTS Super 300 ie (2008)
TEMPERATURE SENSOR 1
Specification Desc./Quantity
1 Water temperature sensor
2 Engine stop switch
INJEC - 202
Vespa GTS Super 300 ie (2008) Injection
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
INJEC - 203
Injection Vespa GTS Super 300 ie (2008)
Specific tooling
020460Y Scooter diagnosis and tester
INJEC - 204
Vespa GTS Super 300 ie (2008) Injection
Lambda probe
SIGNAL CONTROL
1. Lambda probe
INJEC - 205
Injection Vespa GTS Super 300 ie (2008)
INJEC - 206
Vespa GTS Super 300 ie (2008) Injection
Impianto elettroventilatore
1. Battery 12V
2. Fuse No. 3; 15A
3. Fuse No. 1; 30A
4. Key switch contacts
5. Fuse No. 2; 7.5A
6. Injection load remote control
7. Fuel pump
INJEC - 207
Injection Vespa GTS Super 300 ie (2008)
8. HV coil
9. Fuel injector
10.Electric fan remote control
11.Fuse No. 6; 15A
12.Electric fan motor
INJEC - 208
Vespa GTS Super 300 ie (2008) Injection
INJEC - 209
INDEX OF TOPICS
SUSPENSIONS SUSP
Vespa GTS Super 300 ie (2008) Suspensions
This section is devoted to operations that can be carried out on the suspension.
Front
SUSP - 211
Suspensions Vespa GTS Super 300 ie (2008)
Specific tooling
001467Y014 Pliers to extract ø 15-mm bearings
001467Y017 Bell for bearings, OD 39 mm
SUSP - 212
Vespa GTS Super 300 ie (2008) Suspensions
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
- Use the specific tool to fit and push the roller cas-
ing until it stops
- Refit the oil seal on the roller bearing side
- Lubricate the area between the roller bearing and
the ball bearing
Specific tooling
020038Y Punch
Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case
Soap-based lithium grease with NLGI 3; ISO-L-
XBCHA3, DIN K3K-20
- To refit, carry out the removal operations but in reverse order and comply with the specified locking
torque.
SUSP - 213
Suspensions Vespa GTS Super 300 ie (2008)
Steering column
Removal
SUSP - 214
Vespa GTS Super 300 ie (2008) Suspensions
SUSP - 215
Suspensions Vespa GTS Super 300 ie (2008)
Specific tooling
020055Y Wrench for steering tube ring nut
Overhaul
Carry out this operation only if strictly necessary and in any case remove and replace the old part with
a new one.
SUSP - 216
Vespa GTS Super 300 ie (2008) Suspensions
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
SUSP - 217
Suspensions Vespa GTS Super 300 ie (2008)
Specific tooling
006029Y Punch for fitting fifth wheel seat on
steering tube
Specific tooling
001330Y Tool for fitting steering seats
Specific tooling
020021Y Front suspension service tool
- Fit both dust guard rings «C» on the swinging hub
as shown in the detail drawing «A».
- Connect the swinging hub to the steering tube
with the guiding pin, part 5.
- Use the specific tool fitted with part 3 on the stem
and part 4 on the tool base.
- Lubricate the pin with recommended grease and
insert it temporarily on the swinging hub, move the
tool handgrip until part 3 is fully inserted on the
steering tube.
SUSP - 218
Vespa GTS Super 300 ie (2008) Suspensions
Specific tooling
020021Y Front suspension service tool
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2 of the swinging arm
SUSP - 219
Suspensions Vespa GTS Super 300 ie (2008)
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2 of the swinging arm
Refitting
To refit, carry out the removal operations but in reverse order; grease the fifth wheel fittings and tighten
at the specified locking torques
SUSP - 220
Vespa GTS Super 300 ie (2008) Suspensions
Removal
SUSP - 221
Suspensions Vespa GTS Super 300 ie (2008)
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
SUSP - 222
Vespa GTS Super 300 ie (2008) Suspensions
Overhaul
Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020365Y 22 mm guide
- Remove the oil seal on the wheel hub side with
the screwdriver as shown in the photograph
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
SUSP - 223
Suspensions Vespa GTS Super 300 ie (2008)
Specific tooling
020036Y Punch
Specific tooling
020037Y Punch
Refitting
Specific tooling
020036Y Punch
020037Y Punch
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2 of the swinging arm
Rear
SUSP - 224
Vespa GTS Super 300 ie (2008) Suspensions
To refit, carry out the removal operations but in reverse order, observing the prescribed torques.
Swing-arm
Removal
SUSP - 225
Suspensions Vespa GTS Super 300 ie (2008)
SUSP - 226
Vespa GTS Super 300 ie (2008) Suspensions
Overhaul
Characteristic
Standard clearance
0.40 ÷ 0.60 mm
Allowable limit after use:
1.5 mm
Characteristic
Standard clearance
0.40 ÷ 0.60 mm
Allowable limit after use:
1.5 mm
SUSP - 227
Suspensions Vespa GTS Super 300 ie (2008)
Specific tooling
020244Y 15 mm diameter punch
020115Y Ø 18 punch
Characteristic
Length of the swinging arm tube on the engine
side:
L 175.3 + 0.3 0
Length of the internal swinging arm spacer on
the engine side:
L 183 + 0.3 0
Engine side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Frame-side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the frame side:
290 ± 0.1 mm
SUSP - 228
Vespa GTS Super 300 ie (2008) Suspensions
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2 of the swinging arm
SUSP - 229
Suspensions Vespa GTS Super 300 ie (2008)
Refitting
SUSP - 230
Vespa GTS Super 300 ie (2008) Suspensions
-Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.
Shock absorbers
Removal
Proceed as follows:
- place the scooter on its centre stand;
- remove the luggage rack
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the muffler assembly;
- undo the shock absorber spring assembly clamp-
ing screw from the support fixed to the engine on
the one side and from that fixed to the muffler on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.
Refitting
To refit, carry out the above removal operations in reverse order, observing the prescribed torques.
SUSP - 231
Suspensions Vespa GTS Super 300 ie (2008)
Exhaust bracket
Removal
Refitting
- The refitting procedure is in the reverse order of the removal operation being careful to respect the
torques indicated and the spacer assembly layout as shown in the photo.
Centre-stand
REMOVAL
- Use a jack to support the vehicle properly.
- Remove the two return springs from the centre
stand.
- Undo the nut shown in the figure.
- Remove the bolt from the right side.
- Remove the centre stand.
FITTING
- On refitting tighten the nut to the specified torque.
SUSP - 232
Vespa GTS Super 300 ie (2008) Suspensions
Side stand
REMOVAL
- Uncouple the centre stand return spring;
Remove the screw shown in the photograph
FITTING
To refit, carry out the removal operations in re-
verse order and comply with the specified torque.
SUSP - 233
INDEX OF TOPICS
Removal
Overhaul
Refitting
- Follow the removal steps but in reverse order and tighten to the prescribed torque.
Removal
Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of com-
pressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
Refitting
Removal
Refitting
- To reassemble the brake disc on the hub, carry out the removal operations in the reverse order ar-
ranging the brake disc on the hub on the side opposite the wheel keying
- Follow the direction of rotation shown by the arrow and tighten to the prescribed torque.
- Fit the hub unit
- disc in the wheel axle
Disc Inspection
Characteristic
Standard thickness:
3.5 mm
- In order to be able to anchor the appropriate tool properly use a metal plate with M8 threaded hole
and fix it to one of the two rear brake calliper attachment points.
- Suitably fix the flange to the wheel axle with the original nut and spacer and a Æ 17 mm bearing.
N.B.
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN
IN ORDER TO ROTATE THE DISC.
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Max. deviation allowed:
0.1 mm
Removal
Refitting
Disc Inspection
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Standard thickness:
3.5 mm
Max. deviation allowed:
0.1 mm
Removal
Refitting
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Removal
Refitting
N.B.
FAILURE TO RESPECT THE PAD POSITIONING REQUIREMENTS WITH RESPECT TO THE DI-
RECTION OF ROTATION COULD COMPROMISE PROPER BRAKE FUNCTIONING AND NOISE-
LESSNESS.
Fill
Rear - combined
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
- Use the appropriate spyglass on the pump to check the level of the brake fluid, as shown in the
photograph
Removal
Overhaul
Proceed as follows:
1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take out the dia-
phragm (3);
2) remove the cap (4) and take out the internal parts in order;
3) Check that:
- The body of the pump shows no signs of internal damage or corrosion;
- The plunger shows no sign of damage or abnormal wear;
- The plunger return spring is in good condition.
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.
3. Diaphragm.
4. Bellows.
5. Sealing ring
6. Piston.
7. Gasket.
8. Spring.
9. Reservoir
Refitting
To refit, carry out the removal operations but in reverse order, observing the specified torques.
Circuit diagram
System bleed
Thermostat
Removal
Check
Specific tooling
020331Y Digital multimeter
020151Y Air heater
THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening 85±2°C
Refitting
- Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque.
CHASSIS CHAS
Chassis Vespa GTS Super 300 ie (2008)
This section è is devoted to the operations that can be carried out on the vehicle's bodywork.
Seat
CHAS - 256
Vespa GTS Super 300 ie (2008) Chassis
Rear rack
CHAS - 257
Chassis Vespa GTS Super 300 ie (2008)
Instrument panel
CHAS - 258
Vespa GTS Super 300 ie (2008) Chassis
Headlight assy.
CHAS - 259
Chassis Vespa GTS Super 300 ie (2008)
Knee-guard
CHAS - 260
Vespa GTS Super 300 ie (2008) Chassis
Taillight assy.
CHAS - 261
Chassis Vespa GTS Super 300 ie (2008)
Footrest
CHAS - 262
Vespa GTS Super 300 ie (2008) Chassis
Side fairings
Helmet bay
Fuel tank
CHAS - 263
Chassis Vespa GTS Super 300 ie (2008)
- Remove the screw indicated in the figure that fixes the tank to the body after removing the rear head-
light assembly
CHAS - 264
Vespa GTS Super 300 ie (2008) Chassis
Front mudguard
Radiator fan
CHAS - 265
Chassis Vespa GTS Super 300 ie (2008)
To refit, perform the removal operations but in reverse order being careful when positioning the news
clips for the fluid hoses and when filling the cooling system.
CHAS - 266
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery Vespa GTS Super 300 ie (2008)
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Electrical system
• Main switch
• Lights: high beams, low beams, side/taillights (front and rear) and relevant warning lights
- Regulating the headlights according to the regulations currently in force
• Front and rear stop light buttons and relative light •Turn indicators and relative telltales
• Instrument lighting
• instruments: fuel and temperature indicator
PRE DE - 268
Vespa GTS Super 300 ie (2008) Pre-delivery
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 the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
PRE DE - 269
Pre-delivery Vespa GTS Super 300 ie (2008)
- Abnormal noise
Static test
Functional inspection
PRE DE - 270
INDEX OF TOPICS
TIME TIME
Time Vespa GTS Super 300 ie (2008)
Engine
ENGINE
Code Action Duration
1 001001 Engine from frame - Removal and re-
fit.
2 003064 Engine oil - Change
Crankcase
CRANKCASE
Code Action Duration
1 001153 Crankcase halves gasket - Replace-
ment
2 001133 Engine crankcase- Replacement
TIME - 272
Vespa GTS Super 300 ie (2008) Time
Crankshaft
CRANKSHAFT
Code Action Duration
1 001117 Crankshaft - Replacement
TIME - 273
Time Vespa GTS Super 300 ie (2008)
Cylinder assy.
CYLINDER- PISTON
Code Action Duration
1 001002 Cylinder-Piston - Replacement
2 001154 Pin-ring-piston assembly - Service
3 001129 Chain tightener - Overhaul and re-
placement
TIME - 274
Vespa GTS Super 300 ie (2008) Time
VALVE HEAD
Code Action Duration
1 001126 Head - Replacement
2 001045 Valves - Replacement
3 001049 Valves - Adjustment
4 001056 Head gasket - Replacement
5 001083 Thermistor - Replacement
6 001057 Thermostat - Replacement
TIME - 275
Time Vespa GTS Super 300 ie (2008)
CAMSHAFT
Code Action Duration
1 001148 Rocking lever valve - Replacement
2 001044 Camshaft - Replacement
TIME - 276
Vespa GTS Super 300 ie (2008) Time
HEAD COVER
Code Action Duration
1 001093 Spark plug - Replacement
2 001089 Head cover - Replacement
3 001088 Head cover gasket - Replacement
4 001074 Oil vapour recovery pipe - Replace-
ment
Oil filter
OIL FILTER
Code Action Duration
1 001123 Oil filter -Replacement
2 001160 Oil pressure sensor - Replacement
3 001102 Net oil filter - Replacement / Cleaning
TIME - 277
Time Vespa GTS Super 300 ie (2008)
Flywheel cover
FLYWHEEL COVER
Code Action Duration
1 001087 Flywheel cover - Replacement
2 001150 Flywheel cover gasket - Replace-
ment
3 007007 Water pump rotor - Replacement
4 007017 Water pump cover - Replacement
5 007003 Coolant delivery and return pipe - Re-
placement
Driven pulley
TIME - 278
Vespa GTS Super 300 ie (2008) Time
DRIVEN PULLEY
Code Action Duration
1 001022 Clutch - Replacement
2 001012 Driven pulley - Service
3 001110 Driven pulley - Replacement
4 001155 Clutch bell - Replacement
Oil pump
OIL PUMP
Code Action Duration
1 001125 Chain guide pads - Replacement
2 001051 Belt/Timing chain - Change
3 001042 Oil pump - Service
4 001112 Oil pump - change
5 001122 Oil pump chain - Replacement
6 001130 Oil sump - Replacement
7 001172 Chain cover flap - change
8 001124 Lubrication by-pass - Replacement
TIME - 279
Time Vespa GTS Super 300 ie (2008)
FINAL REDUCTION
Code Action Duration
1 001010 Reduction gear - Replacement
2 003065 Gear box oil - Replacement
3 001156 Geared reduction unit cover - Re-
placement
4 004125 Rear wheel axle - Replacement
TIME - 280
Vespa GTS Super 300 ie (2008) Time
Driving pulley
DRIVING PULLEY
Code Action Duration
1 001086 Driving half-pulley - Replacement
2 001011 Driving belt - Replacement
3 001066 Driving pulley - Removal and refitting
4 001177 Variator rollers / shoes - Replace-
ment
5 001141 Belt anti-flapping roller - Replace-
ment
TIME - 281
Time Vespa GTS Super 300 ie (2008)
Transmission cover
TRANSMISSION COVER
Code Action Duration
1 001135 Transmission cover bearing - Re-
placement
2 001096 Transmission crankcase cover - Re-
placement
3 001131 Transmission air intake - Replace-
ment
4 001065 Transmission cover - Replacement
TIME - 282
Vespa GTS Super 300 ie (2008) Time
Starter motor
ELECTRICAL START-UP
Code Action Duration
1 001020 Starter motor - Replacement
2 001104 Start-up freewheel - Replacement
3 001151 Start-up driven gearing - Replace-
ment
4 001017 Start-up pinion - Replacement
TIME - 283
Time Vespa GTS Super 300 ie (2008)
Flywheel magneto
MAGNETO FLYWHEEL
Code Action Duration
1 001067 Stator - Removal and Refitting
2 001173 Rotor - Replacement
3 001058 Complete flywheel - Replacement
TIME - 284
Vespa GTS Super 300 ie (2008) Time
Butterfly valve
THROTTLE BODY
Code Action Duration
1 001166 Throttle body - Replacement
2 001047 Injector - Replacement
3 001013 Intake manifold - Replacement
TIME - 285
Time Vespa GTS Super 300 ie (2008)
Exhaust pipe
MUFFLER
Code Action Duration
1 001009 Muffler - Replacement
2 001095 Muffler guard - Replacement
3 005138 Lambda probe - Replacement
TIME - 286
Vespa GTS Super 300 ie (2008) Time
Air cleaner
AIR CLEANER
Code Action Duration
1 001015 Air filter box - Replacement
2 001014 Air filter - Replacement / cleaning
3 004122 Air cleaner/ carburettor union - Re-
placement
4 001027 Body / air cleaner union - Replace-
ment
TIME - 287
Time Vespa GTS Super 300 ie (2008)
Frame
CHASSIS
Code Action Duration
1 004001 Chassis - Replacement
2 004085 Fairing (1) - Replacement
3 004149 Shield central cover - Replacement
4 004053 Spoiler - Replacement
5 004015 Footrest - Removal and Refitting
6 004023 Shield rim - Replacement
7 004159 Plates / Stickers - Replacement
TIME - 288
Vespa GTS Super 300 ie (2008) Time
Centre-stand
STAND
Code Action Duration
1 004102 Side stand - Replacement
2 004004 Stand - Replacement
Footrests
TIME - 289
Time Vespa GTS Super 300 ie (2008)
Rear cover
REAR SHIELD
Code Action Duration
1 004083 Glove box - Replacement
2 004081 Glove box door - Replacement
TIME - 290
Vespa GTS Super 300 ie (2008) Time
Underseat compartment
HELMET COMPARTMENT
Code Action Duration
1 004016 Helmet compartment - Removal and
Refitting
2 004011 Central chassis cover - Replacement
TIME - 291
Time Vespa GTS Super 300 ie (2008)
Plate holder
Mudguard
TIME - 292
Vespa GTS Super 300 ie (2008) Time
MUDGUARDS
Code Action Duration
1 004002 Front mudguard - Replacement
2 004009 Rear mudguard - Replacement
3 003044 Shock absorber cover - Replace-
ment
Fuel tank
FUEL TANK
Code Action Duration
1 004005 Fuel tank - Replacement
2 005010 Tank float - Replacement
3 004109 Fuel tank breather - Replacement
4 004073 Fuel pump - Replacement
5 004137 Injector pump pipe - Replacement
TIME - 293
Time Vespa GTS Super 300 ie (2008)
Radiator
RADIATOR
Code Action Duration
1 007002 Water cooling radiator - Replace-
ment
2 007016 Fan complete with support - Re-
placement
3 007001 Expansion tank - Replacement
4 001052 Coolant and air bleed - Replacement
5 007013 Expansion tank / radiator connecting
hose - Replacement
6 007003 Delivery line and coolant return - Re-
placement
7 001170 Air deflector - Replacement
TIME - 294
Vespa GTS Super 300 ie (2008) Time
Rear shock-absorber
TIME - 295
Time Vespa GTS Super 300 ie (2008)
TIME - 296
Vespa GTS Super 300 ie (2008) Time
Handlebar covers
HANDLEBAR COVERS
Code Action Duration
1 004018 Front handlebar covers - Replace-
ment
2 004019 Rear handlebar cover - Replacement
Handlebar components
TIME - 297
Time Vespa GTS Super 300 ie (2008)
HANDLEBAR COMPONENTS
Code Action Duration
1 003001 Handlebar - Removal and refitting
2 002067 Rear brake pump - Replacement
3 002024 Front brake pump - Removal and re-
fitting
4 005017 Stop switch - Replacement
5 002059 Right-hand knob - Replacement
6 002071 Left hand grip - Replacement
7 003059 Counterweight - Replacement
8 002060 Throttle grip - Replacement
9 002063 Throttle control transmission - Re-
placement
10 003061 Accelerator transmission - Adjust-
ment
11 002037 Brake or clutch lever - Replacement
Swing-arm
SWINGING ARM
Code Action Duration
1 001072 Swinging arm - Engine-chassis con-
nection - Replacement
2 004058 Silent block - Replacement
TIME - 298
Vespa GTS Super 300 ie (2008) Time
Seat
SADDLE
Code Action Duration
1 004003 Saddle - Replacement
2 004144 Saddle cover - Replacement
Instrument panel
TIME - 299
Time Vespa GTS Super 300 ie (2008)
INSTRUMENT PANEL
Code Action Duration
1 004066 Driving mirror - Replacement
2 005014 Odometer - Replacement
3 005041 Starter button - Replacement
4 005077 Emergency stop switch - Replace-
ment
5 005006 Light switch or turn indicators - Re-
placement
6 005040 Horn button - Replacement
7 005121 Saddle opening button - Replace-
ment
8 005039 Headlight switch - Replacement
9 005078 Odometer glass - Replacement
10 005038 Instrument panel warning light bulbs
- Replacement
11 005076 Clock / Cell - Replacement
Rear rack
LUGGAGE RACK
Code Action Duration
1 004008 Luggage rack - Replacement
TIME - 300
Vespa GTS Super 300 ie (2008) Time
Locks
LOCKS
Code Action Duration
1 002083 Saddle opening transmission - Re-
placement
2 002092 Transmission splitter/ hook transmis-
sion - Replacement
3 004158 Saddle opening splitter - Replace-
ment
4 005072 Immobilizer aerial - Replacement
5 005099 Electric saddle opening device - Re-
placement
6 004054 Saddle lock catch - Replacement
7 004010 Anti-theft lock - Replacement
8 005016 Key switch - Replacement
TIME - 301
Time Vespa GTS Super 300 ie (2008)
TIME - 302
Vespa GTS Super 300 ie (2008) Time
Front wheel
FRONT WHEEL
Code Action Duration
1 003047 Front tyre - replace
2 003037 Front wheel rim- Replacement
3 004123 Front wheel - Replacement
4 003033 Front wheel hub- Replacement
5 002041 Brake disc - Replacement
TIME - 303
Time Vespa GTS Super 300 ie (2008)
Rear wheel
REAR WHEEL
Code Action Duration
1 004126 Rear wheel tyre - Replacement
2 001071 Front wheel rim - Removal and refit-
ting
3 001016 Rear wheel - Replacement
4 002028 Rear wheel hub - Replacement
5 002070 Rear brake disc - Replacement
TIME - 304
Vespa GTS Super 300 ie (2008) Time
Electric devices
ELECTRICAL DEVICES
Code Action Duration
1 001094 Spark plug cap - Replacement
2 001069 HV coil - Replacement
3 005003 Horn - Replacement
4 005009 Voltage regulator - Replacement
5 005052 Fuse (1) - Replacement
6 005007 Battery - Replacement
7 005120 Control unit power supply remote
control - Replacement
8 005035 Headlight remote control - Replace-
ment
9 005117 Electric fan remote control - Replace-
ment
10 005011 Start-up remote control switch - Re-
placement
11 005054 Fuse block (1) - Replacement
12 005001 Electrical system - Removal and re-
fitting
TIME - 305
Time Vespa GTS Super 300 ie (2008)
Transmissions
TRANSMISSIONS
Code Action Duration
1 002051 Odometer transmission assembly -
Replacement
TIME - 306
Vespa GTS Super 300 ie (2008) Time
Front suspension
FRONT SUSPENSION
Code Action Duration
1 003011 Front shock absorber - Removal and
Refitting
2 003045 Steering tube - Replacement
3 003010 Front suspension - Service
4 003035 Shock absorber support and brake
calliper - Replacement
5 003034 Front wheel hub bearing - Replace-
ment
6 001064 Odometer reel - Replacement
TIME - 307
Time Vespa GTS Super 300 ie (2008)
Braking system
BRAKE SYSTEM
Code Action Duration
1 002039 Front brake calliper - Replacement
2 002007 Front brake pads - Replacement
3 002021 Front brake piping - Replacement
4 002047 Front brake fluid and air bleeding
system - Replacement
5 002020 Rear brake disc piping - Replace-
ment
6 002080 Rear brake oil bleeding system - Re-
placement
7 002002 Rear brake pads - Replacement
8 002048 Rear brake calliper - Replacement
TIME - 308
Vespa GTS Super 300 ie (2008) Time
Stickers
TRANSFERS
Code Action Duration
1 004159 Plates / Stickers - Replacement
TIME - 309
A
Air filter: 49
B
Battery: 80, 90, 99
Brake: 235, 237, 239–241, 243, 245, 246
Brake fluid: 245
C
Coolant: 202
E
Engine oil: 50
F
Fuel: 179, 186, 263, 293
Fuses: 97
H
Headlight: 55, 259
Horn: 93
Hub oil: 48
I
Identification: 8
Instrument panel: 258, 299
L
Light switch:
Luggage rack:
M
Maintenance: 7, 45
O
Oil filter: 51, 277
S
Saddle:
Shock absorbers: 231
Spark plug: 47
Stand: 233
Start-up:
T
Tank: 263, 293
Transmission: 10, 57, 113, 127, 282
Turn indicators: 83
Tyre pressure:
Tyres: 15