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Vespa Gtv 250 Ie Service Repair Manual – Download
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Vespa Gtv 250 Ie Service Repair Manual
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Description
Vespa Gtv 250 Ie Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:404
DOWNLOADABLE:YES
FILE TYPE:PDF
VESPA GTV 250 IE SERVICE REPAIR MANUAL – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Vespa Gtv 250 Ie Service Repair Manual
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement.
- Using unsuitable coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.
TABLE OF CONTENTS:
Vespa Gtv 250 Ie Service Repair Manual
Man: Vespa GTV 250 i.e......................................... 5 Cap:Characteristics........................................ 7 Sez:Rules.............................................. 8 Sez:Safety rules....................................... 8 Sez:Maintenance rules.................................. 8 Sez:Vehicle identification............................. 8 Sez:Dimensions and mass................................ 9 Sez:Engine............................................. 11 Sez:Transmission....................................... 11 Sez:Capacities......................................... 11 Sez:Electrical system.................................. 11 Sez:Frame and suspensions.............................. 13 Sez:Brakes............................................. 13 Sez:Wheels and tyres................................... 13 Sez:Tightening Torques................................. 14 Sez:Overhaul data...................................... 16 Sez:Assembly clearances................................ 16 Sez:Cylinder - piston assy............................. 16 Sez:Crankcase - crankshaft - connecting rod............ 17 Sez:Slot packing system................................ 18 Sez:Products........................................... 19 Cap:Tooling................................................ 21 Cap:Maintenance............................................ 35 Sez:Maintenance chart.................................. 36 Sez:Checking the spark advance......................... 38 Sez:Spark plug......................................... 39 Sez:Hub oil............................................ 40 Sez:Check.............................................. 40 Sez:Replacement........................................ 41 Sez:Air filter......................................... 41 Sez:Engine oil......................................... 42 Sez:Replacement........................................ 42 Sez:Check.............................................. 43 Sez:Engine oil filter.................................. 44 Sez:Oil pressure warning light......................... 44 Sez:Checking the ignition timing....................... 44 Sez:Cooling system..................................... 45 Sez:Braking system..................................... 45 Sez:Level check........................................ 46 Sez:Top-up............................................. 46 Sez:Headlight adjustment............................... 47 Cap:Troubleshooting........................................ 49 Sez:Engine............................................. 50 Sez:Excessive oil consumption/Exhaust smoke............ 50 Sez:Insufficient lubrication pressure.................. 50 Sez:Transmission and brakes............................ 50 Sez:Clutch grabbing or performing inadequately......... 50 Sez:Insufficient braking............................... 50 Sez:Brakes overheating................................. 51 Sez:Steering and suspensions........................... 51 Sez:Heavy steering..................................... 51 Sez:Excessive steering play............................ 51 Sez:Noisy suspension................................... 52 Sez:Suspension oil leakage............................. 52 Cap:Electrical system...................................... 0 Sez:Electrical system installation..................... 55 Sez:Front side......................................... 55 Sez:Back side.......................................... 60 Sez:Conceptual diagrams................................ 65 Sez:Ignition........................................... 65 Sez:Battery recharge and starting...................... 66 Sez:Level indicators and enable signals section........ 68 Sez:Devices and accessories............................ 69 Sez:Lights and turn indicators......................... 70 Sez:Checks and inspections............................. 70 Sez:Immobiliser........................................ 71 Sez:Virgin circuit..................................... 74 Sez:Diagnostic codes................................... 75 Sez:Diagnostic code - 1 flash.......................... 76 Sez:Diagnostic code - 2 flashes........................ 76 Sez:Diagnostic code - 3 flashes........................ 77 Sez:Battery recharge circuit........................... 77 Sez:Stator check....................................... 77 Sez:Recharge system voltage check...................... 78 Sez:Turn signals system check.......................... 79 Sez:Fuses.............................................. 79 Sez:Dashboard.......................................... 80 Sez:Sealed battery..................................... 82 Sez:Battery installation............................... 83 Sez:Connectors......................................... 85 Cap:Engine from vehicle.................................... 0 Sez:Exhaust assy. Removal.............................. 88 Sez:Removal of the engine from the vehicle............. 89 Cap:Engine................................................. 95 Sez:Automatic transmission............................. 96 Sez:Transmission cover................................. 96 Sez:Air duct........................................... 96 Sez:Removing the driven pulley shaft bearing........... 97 Sez:Refitting the driven pulley shaft bearing.......... 97 Sez:Baffle roller...................................... 97 Sez:Plastic roller..................................... 97 Sez:Removing the driven pulley......................... 98 Sez:Inspecting the clutch drum......................... 98 Sez:Removing the clutch................................ 99 Sez:Inspecting the clutch..............................100 Sez:Pin retaining collar...............................101 Sez:Removing the driven half-pulley bearing............101 Sez:Inspecting the driven fixed half-pulley............102 Sez:Inspecting the driven sliding half-pulley..........102 Sez:Refitting the driven half-pulley bearing...........103 Sez:Refitting the driven pulley........................104 Sez:Inspecting the clutch spring.......................105 Sez:Refitting the clutch...............................105 Sez:Refitting the driven pulley........................106 Sez:Drive-belt.........................................106 Sez:Removing the driving pulley........................107 Sez:Inspecting the rollers case........................108 Sez:Refitting the driving pulley.......................109 Sez:Refitting the transmission cover...................110 Sez:End gear...........................................110 Sez:Removing the hub cover.............................111 Sez:Removing the wheel axle............................111 Sez:Removing the hub bearings..........................111 Sez:Removing the wheel axle bearings...................112 Sez:Removing the driven pulley shaft bearing...........112 Sez:Inspecting the hub shaft...........................113 Sez:Inspecting the hub cover...........................113 Sez:Refitting the wheel axle bearing...................113 Sez:Refitting the hub cover bearings...................114 Sez:Refitting the hub bearings.........................115 Sez:Refitting the ub cover.............................116 Sez:Flywheel cover.....................................116 Sez:Removing the hub cover.............................116 Sez:Removing the stator................................117 Sez:Refitting the stator...............................117 Sez:Refitting the flywheel cover.......................118 Sez:Flywheel and starting..............................118 Sez:Removing the starter motor.........................118 Sez:Removing the flywheel magneto......................119 Sez:Inspecting the flywheel components.................120 Sez:Refitting the free wheel...........................120 Sez:Refitting the flywheel magneto.....................121 Sez:Refitting the starter motor........................122 Sez:Cylinder assy. and timing system...................122 Sez:Removing the intake manifold.......................122 Sez:Removing the rocker-arms cover.....................122 Sez:Removing the timing system drive...................123 Sez:Removing the cam shaft.............................124 Sez:Removing the cylinder head.........................125 Sez:Removing the valves................................126 Sez:Removing the cylinder - piston assy................126 Sez:Inspecting the small end...........................127 Sez:Inspecting the wrist pin...........................127 Sez:Inspecting the piston..............................127 Sez:Inspecting the cylinder............................128 Sez:Inspecting the piston rings........................129 Sez:Removing the piston................................130 Sez:Choosing the gasket................................130 Sez:Refitting the piston rings.........................131 Sez:Refitting the cylinder.............................132 Sez:Inspecting the cylinder head.......................133 Sez:Inspecting the timing system components............133 Sez:Inspecting the valve sealings......................134 Sez:Inspecting the valve housings......................134 Sez:Inspecting the valves..............................134 Sez:Inspecting the springs and half-cones..............137 Sez:Refitting the valves...............................137 Sez:Inspecting the cam shaft...........................138 Sez:Refitting the head and timing system components....139 Sez:Refitting the rocker-arms cover....................142 Sez:Refitting the intake manifold......................142 Sez:Crankcase - crankshaft.............................143 Sez:Splitting the crankcase halves.....................143 Sez:Inspecting the crankshaft alignment................145 Sez:Inspecting the crankcase halves....................146 Sez:Inspecting the crankshaft plain bearings...........147 Sez:Refitting the crankcase halves.....................149 Sez:Studs..............................................151 Sez:Lubrication........................................151 Sez:Conceptual diagrams................................151 Sez:Oil pressure check.................................153 Sez:Crankshaft oil seals...............................154 Sez:Removal............................................154 Sez:Refitting..........................................155 Sez:Oil pump...........................................156 Sez:Removal............................................156 Sez:Inspection.........................................157 Sez:Refitting..........................................158 Sez:Removing the oil sump..............................159 Sez:Inspecting the by-pass valve.......................159 Sez:Refitting the oil sump.............................160 Cap:Injection..............................................161 Sez:Precautions........................................164 Sez:Terminals setup....................................166 Sez:EMS circuit diagram................................167 Sez:Troubleshooting procedure..........................168 Sez:Engine does not start..............................168 Sez:Starting difficulties..............................169 Sez:Engine stops at idle...............................169 Sez:Engine does not rev down...........................170 Sez:Exhaust backfires in deceleration..................170 Sez:Engine revs irregularly............................171 Sez:Poor performance at full throttle..................171 Sez:Engine knocking....................................172 Sez:Fuel supply system.................................172 Sez:Removing the butterfly valve.......................173 Sez:Refitting the butterfly valve......................175 Sez:Pump supply circuit................................175 Sez:Circuit leak test..................................180 Sez:Fuel filter check..................................181 Sez:Inspecting the injector circuit....................182 Sez:Inspecting the injector hydraulics.................187 Sez:Components location................................188 Sez:Tachometer.........................................188 Sez:HT coil............................................190 Sez:Coolant temperature sensor.........................195 Sez:Zeroing the throttle...............................197 Sez:Lambda probe.......................................199 Cap:Suspensions............................................207 Sez:Front..............................................208 Sez:Removing the front wheel...........................208 Sez:Front wheel hub overhaul...........................208 Sez:Refitting the front wheel..........................210 Sez:Steering column....................................210 Sez:Removal............................................210 Sez:Overhaul...........................................213 Sez:Refitting..........................................215 Sez:Front shock absorber...............................216 Sez:Removal............................................216 Sez:Refitting..........................................216 Sez:Shock-absorber - calliper bracket..................216 Sez:Overhaul...........................................217 Sez:Rear...............................................218 Sez:Removing the rear wheel............................218 Sez:Refitting the rear wheel...........................219 Sez:Swing-arm..........................................219 Sez:Removal............................................219 Sez:Overhaul...........................................221 Sez:Refitting..........................................224 Sez:Shock absorbers....................................225 Sez:Removal............................................225 Sez:Refitting..........................................225 Sez:Exhaust bracket....................................226 Sez:Removal............................................226 Sez:Refitting..........................................226 Sez:Centre-stand.......................................226 Sez:Side stand.........................................226 Cap:Braking system......................................... 0 Sez:Rear brake calliper................................230 Sez:Removal............................................230 Sez:Overhaul...........................................230 Sez:Refitting..........................................231 Sez:Front brake calliper...............................232 Sez:Removal............................................232 Sez:Overhaul...........................................233 Sez:Refitting..........................................234 Sez:Rear brake disc....................................234 Sez:Removal............................................234 Sez:Refitting..........................................235 Sez:Disc Inspection....................................235 Sez:Front brake disc...................................236 Sez:Removal............................................236 Sez:Refitting..........................................236 Sez:Disc Inspection....................................237 Sez:Front brake pads...................................237 Sez:Removal............................................237 Sez:Refitting..........................................238 Sez:Rear brake pads....................................239 Sez:Removal............................................239 Sez:Refitting..........................................240 Sez:Fill...............................................240 Sez:Rear - combined....................................240 Sez:Brake fluid level check............................241 Sez:Front brake pump...................................242 Sez:Removal............................................242 Sez:Overhaul...........................................243 Sez:Refitting..........................................244 Cap:Cooling system......................................... 0 Sez:System bleed.......................................246 Sez:Check..............................................246 Cap:Chassis................................................249 Sez:Seat...............................................250 Sez:Rear rack..........................................252 Sez:Instrument panel...................................253 Sez:Headlight assy.....................................254 Sez:Knee-guard.........................................254 Sez:Taillight assy.....................................256 Sez:Footrest...........................................257 Sez:Side fairings......................................258 Sez:Helmet bay.........................................258 Sez:Fuel tank..........................................258 Sez:Rear central cover.................................259 Sez:Front mudguard.....................................259 Sez:Radiator fan.......................................260 Sez:Front central cover................................261 Cap:Pre-delivery........................................... 0 Sez:Aesthetic inspection...............................264 Sez:Tightening torques inspection......................264 Sez:Electrical system..................................264 Sez:Levels check.......................................265 Sez:Road test..........................................265 Sez:Static test........................................266 Sez:Functional inspection..............................266 Cap:Time...................................................267 Sez:Engine.............................................268 Sez:Crankcase..........................................268 Sez:Crankshaft.........................................268 Sez:Cylinder assy......................................269 Sez:Cylinder head assy.................................270 Sez:Rocker arms support assy...........................271 Sez:Cylinder head cover................................272 Sez:Oil filter.........................................273 Sez:Flywheel cover.....................................273 Sez:Driven pulley......................................274 Sez:Oil pump...........................................275 Sez:Final gear assy....................................275 Sez:Driving pulley.....................................276 Sez:Transmission cover.................................277 Sez:Starter motor......................................278 Sez:Flywheel magneto...................................279 Sez:Butterfly valve....................................280 Sez:Exhaust pipe.......................................281 Sez:Air cleaner........................................282 Sez:Frame..............................................283 Sez:Centre-stand.......................................284 Sez:Footrests..........................................285 Sez:Rear cover.........................................286 Sez:Underseat compartment..............................286 Sez:Plate holder.......................................287 Sez:Mudguard...........................................288 Sez:Fuel tank..........................................289 Sez:Radiator...........................................290 Sez:Rear shock-absorber................................291 Sez:Steering column bearings...........................292 Sez:Handlebar covers...................................293 Sez:Handlebar components...............................294 Sez:Swing-arm..........................................295 Sez:Seat...............................................296 Sez:Instrument panel...................................297 Sez:Rear rack..........................................298 Sez:Locks..............................................299 Sez:Turn signal lights.................................300 Sez:Front wheel........................................302 Sez:Rear wheel.........................................302 Sez:Electric devices...................................303 Sez:Transmissions......................................304 Sez:Front suspension...................................305 Sez:Braking system.....................................306 Sez:Stickers...........................................307
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