It also describes features, details and devices to assure. We believe that if you follow our suggestions, you will soon get to know your new vehicle and it will serve you. This booklet forms an integral part of the scooter; should the scooter be sold, it must be transferred to the new owner.
Previous Page. Next Page. Page 1 Vespa would like to thank you for choosing one of its products. Please read it carefully before riding the scooter for the first time. It also describes features, details and devices to assure you that you have made the right choice.
Page 2 The instructions given in this manual are intended to provide a clear, simple guide to using your scooter; details are also given of routine maintenance procedures and regular checks that should be carried out on the vehicle at an Authorised PIAGGIO Dealer or Service Centre. The booklet also contains instructions for simple repairs. Page 3 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 dam- aging 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.
Automatic transmission Safe driving Rear rack Engine oil level Engine oil level check Page 6 Warnings Besides hours and minutes, month and day can also be displayed with the «T» button. In order to adjust the above mentioned functions, operate button «U». Releasing the steering wheel Reinsert the key and turn it to «OFF». Page Programming The Immobilizer System Take your scooter to an Authorised Piaggio Service Centre carrying with you the red-handgrip key and all the blue keys in your possession.
The codes of keys not submitted for the new storage procedure are deleted from the memory. Any lost keys will therefore not be enabled to start the engine. Page Accessing The Fuel Tank Final step - red key After pulling out the last blue key, insert the red key again and turn it to "ON" this operation should be performed within 10 seconds of pulling out the previous key.
Leave it in this position for 1 to 3 seconds and return it to the «OFF» position. Proper programming check Insert the red key disabling the transponder i. Page The Saddle Saddles fitted to this scooter are upholstered in Authentic Leather, and are a stylish accessory to emphasise an already exclusive product such as your Vespa. As leather is a natural and vivid material, it tends to get "very opaque" aspect as time goes by, an aspect typical of Authentic Leather.
Page Opening The Saddle In case of forced and prolonged exposure to water, dry the saddle far from any heat source, do not to use alcohol, solvent-based products and pay special care when refuelling. If the saddle gets stained, wipe the area and if necessary wash it with lukewarm water and neutral soap. These numbers must always be indicated on spare parts requests. To read the chassis number, lift the saddle and remove the helmet compartment «C». Page Checks Checks Before using the vehicle, check: 1.
Afterwards remove the retainers fixing the piping to the engine crankcase, indicated in the photograph. Engine from vehicle When refitting the engine to the scooter, carry out the operations in reverse order from that adopted when removing it and respect the tightening torque shown in the Characteristics Chapter.
Check that with valve in abutment against the reg- ister there is a small clearance. Engine This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
Engine - Remove the five screws on two different levels as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely.
Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. Characteristic Max. Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins in position «C» screwed from the tool internal side.
Characteristic Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling Y Bearing housing outside diameter 47 mm - Remove the roller bearing using the modular punch.
Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. Characteristic Standard length mm Acceptable limit after use Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench.
Engine Drive-belt - Check that the driving belt is not damaged. Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half. Engine Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley.
Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. Removing the wheel axle - Remove the wheel axis complete with gear. Engine Removing the hub bearings - Check the state of the bearings being examined wear, clearance and noisiness. If faults are de- tected, do the following. Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above.
Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. Engine Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the special heat gun. Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els. Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder.
Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Engine Removing the starter motor - Remove the two screws indicated in the figure. Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling Y Flywheel lock wrench - Remove the plate indicated in the photo.
Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i. Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring Engine - Loosen the central screw on the tensioner first. Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram.
Removing the valves - Using the appropriate tool fitted with an adapter, remove the cotters, caps, springs and valves. Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. Engine Inspecting the piston - Measure the diameter of the wrist pin seat on the piston. Engine Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure.
Engine scraper ring Standard opening: 0. Engine N. Engine Refitting the piston rings Fitting the sealing rings - Place the oil scraper spring on the piston. Engine Y Piston fitting band Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted.
Maximum allowable run-out: 0. Engine Inspecting the valve sealings - Insert the valves into the cylinder head. Engine Inspecting the valves - Measure the width of the sealing surface on the valve seats and on the valves.
Sealing surface width: After use: Intake and ex- haust: 1. Engine Valve check standard clearance Inlet: 0. Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil.
Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. Engine Diameter Engine - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que. Engine - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque. Engine Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft.
To do this, use a plate and a support with appropriate tool dial gauge. Engine Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure.
Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean the all surfaces and oil ducts. Engine Crankcase Engine half Bushing halves shaft Cat. Engine - Fit the 10 screws and tighten them to the speci- fied torque. Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase.
Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.
Engine ENG - Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. Engine Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
Engine - Orientate the oil guard by inserting the bracket which is part of the appropriate tool - Tighten the threaded bar onto the crankshaft as far as it will go. Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. Engine Measure the distance between the outer rotor and the pump body see figure. Characteristic Axial rotor clearance Limit values admitted: 0.
Engine - Fit the sprocket wheel with a new O-ring. Tighten to the specified torque. Engine Inspecting the by-pass valve - Check the unloaded spring length.
Injection MIU injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the crankshaft teeth and pick-up sensor. Injection - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel.
Failures are detected and restored by the diag- nostic tester. Injection Before reconnecting the quick couplers of the power supply system, check that the terminals are perfectly clean. Troubleshooting hints 1 A fault in the MIU system could most likely be due to the connections and not the components. Injection Specification Desc. Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure.
Injection Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the MIU connector Remove the clip fixing the throttle body to the pu When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied.
INJEC - Injection control unit disconnected and the injection load re- mote control disconnected, that the Black-Purple cable pin 20 on the interface wiring is insulated from the earth. Check during regular functioning by placing the appropriate tool between the pump and the injec- tor.
Injection Fuel filter check Disconnect the terminals from the electric pump Remove the screw shown in the photograph Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Check that the 7. Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check the presence of voltage, Injection With injector disconnected and the injector load remote control disconnected, check the continuity of the Black-Green cable between the injector con- nector and remote control base.
Schema valido dal numero di telaio ZAPM in poi. Injection Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring con- nected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2.
Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected. Injection With the control unit side connector disconnected and coolant temperature sensor connector dis- connected, check the continuity between pin 9 of the interface wiring and the light blue-green cable of the connector and between pin 19 of the inter- face wiring and the grey-green cable of the con- nector.
Injection Connect the diagnostic tester. Turn to "ON". Specific tooling Y Scooter diagnosis and tester Make sure that the throttle valve is supporting the stop screw. Injection Reset should be performed in the following cases: - on first fitting. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pho- tograph.
Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. Suspensions - Remove the retainer fixing the odometer cable to the mudguard indicated in the photograph - Remove the retainer fixing the brake piping to the front shock absorber upper plate - Remove the retainer fixing the brake piping to the Suspensions - Pre-loosen the 3 nuts fixing the mudguard to the suspension - Remove the rear handlebar cover.
Suspensions Overhaul Carry out this operation only if strictly necessary and in any case remove and replace the old part with a new one. Suspensions - Use the specific tool to fit the fifth wheel fitting on the headstock as indicated in the figure Specific tooling Y Tool for fitting steering seats - Remove the steering tube - Remove the attachment bracket That is the motor you have so between those and the GTV manuals, you should be covered. Do I have to get the engine and hub oil from a Vespa dealer?
Would they have it at any motorcycle dealer? I guess I'll will still have to get the oil filter from the Vespa dealer, scooter works or online? Doubt I can get that at an autoparts or motorcycle dealer.
Hiflofiltro HF fit? You need the HF as stated. Ordered the Will keep you posted Post Reply. All Content Copyright by Modern Vespa.
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