Vespa et4 125 werkstatthandbuch pdf


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Vespa et4 125 werkstatthandbuch pdf

Manuals Brands VESPA Manuals Scooter ET4 50 Workshop manual VESPA ET4 50 Workshop Manual Scooter. Quick Links. Table of Contents. WORKSHOP MANUAL. Troubleshooting Troubleshooting 34 Engine Poor performance Related Manuals for VESPA ET4 50 Scooter VESPA ET2 50 User Manual 60 pages.

Scooter VESPA Operation And Maintenance Vespa scooter operation and maintenance 32 pages. Summary of Contents for VESPA ET4 50 Page 1 WORKSHOP MANUAL ET4 Page 2 WORKSHOP MANUAL ET4 50 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.

Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Page 7: Safety Rules ET4 50 Characteristics Rules 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. Page 9: Electrical System ET4 50 Characteristics Engine ENGINE Specification Desc. Hydraulic double-acting shock absorber and co- axial spring Front suspension stroke Page Tightening Torques ET4 50 Characteristics Specification Desc. Page 15 ET4 50 Characteristics N. Page 16 INDEX OF TOPICS TOOL OOLING Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34 Half rings Page 18 ET4 50 Tooling Stores code Description Y Wrench for steering tube ring nut Y Tool to align crankshaft Y Air heater support Y Air heater Y Flywheel extractor Y Punch for driven pulley roller bearing Y Bearing fitting base TOOL - Page 20 ET4 50 Tooling Stores code Description Y Digital rev counter Y Single battery charger Y Multiple battery charger Y Magnetic support for dial gauge Y Flywheel and transmission oil seals fitting punch Y 37xmm adaptor TOOL - Page 21 ET4 50 Tooling Stores code Description Y 42xmm adaptor Y Adaptor 52 x 55 mm Y 12 mm guide Y 20 mm guide Y mm guide Y Adaptor handle TOOL - Page Checking The Spark Advance ET4 50 Maintenance Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning.

Page Spark Plug ET4 50 Maintenance RPM LIMITER Specification Desc. Page Engine Oil ET4 50 Maintenance NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER. Engine oil Replacement -Loosen the oil filler plug.

Page 32 ET4 50 Maintenance CO check - This check can be required when engine opera- tion is irregular or while adjusting the slow running. Page 33 ET4 50 Maintenance Y Exhaust fumes analyser Y Digital multimeter MAIN - Let it drip. Wring out without squeezing it and then refit Starter motor faulty. Page 37 ET4 50 Troubleshooting Possible Cause Operation lenia Air Filter Oilthen hand dry without squeezing, allow to drip dry and then reassemble. The starter remains on Check that the starter runs correctly and it is properly powered Loose nozzles Check the maximum and minimum nozzles are adequately Page Noisy Suspension ET4 50 Troubleshooting Battery BATTERY Possible Cause Operation This device requires the most assiduous surveillance and the This device requires the most assiduous surveillance and the most diligent maintenance.

If the vehicle is not used for some time 1 month or more the battery needs to be recharged pe- riodically. TROUBL - Page 40 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Page 43 ET4 50 Electrical system Headlights and automatic starter section LIGHTS Specification Desc.

Page 44 ET4 50 Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING Specification Desc. Page 45 ET4 50 Electrical system Level indicators and enable signals section SAFETY SWITCHES Specification Desc. Page 46 ET4 50 Electrical system Turn signal lights TURN SIGNAL LIGHTS Specification Desc.

Page 47 ET4 50 Electrical system Instruments and warning lights control board WARNING LIGHTS AND GAUGES PANEL Specification Desc. Page 48 ET4 50 Electrical system If faulty or failed operation persists, conduct the following checks on the generator and on the sta- tor components: After a visual inspection of the electrical connec- tions, it is possible to perform measurements on the stator winding and pick-up see tableusing the specific multimeter.

Page 49 ET4 50 Electrical system Voltage regulator check The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault: 1 Bulbs burnt out regulator in short circuit. Page 50 ET4 50 Electrical system As a last test it is possible to check the output volt- age from the stator: -Detach the regulator connector and interpose the tester in AC mode, between the Gray-Blue wire 4 and earth see figure.

Page 51 ET4 50 Electrical system Proceed by measuring the resistance between contacts 3 White and 2 Black from the voltage regulator with the connector detached. If the reading differs excessively from the figures shown, replace the regulator as short-circuited. Page 54 ET4 50 Electrical system 2 Load status check After restoring the electrolyte level, check its density using an appropriate densitometer see the figure.

Page 56 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Page 57 ET4 50 Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying at- tention to the interference between its supporting bracket and the cooling cover. Page 58 INDEX OF TOPICS NGINE Page Automatic Transmission ET4 50 Engine Automatic transmission Transmission cover - Remove the 12 fixing screws.

If this operation is carried out directly on the vehi- cle, it is necessary to remove the transmission cooling coupling and the air filter housing retain- ers. Page Removing The Driven Pulley ET4 50 Engine Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

Page Inspecting The Clutch Drum ET4 50 Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. Page 62 ET4 50 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL CONTACT SURFACE AND MUST NOT BE DIFFER- ENT FROM ONE ANOTHER.

Page 63 ET4 50 Engine Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. Page 64 ET4 50 Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. Page Refitting The Driven Pulley ET4 50 Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER.

CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE Page Removing The Driving Pulley ET4 50 Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. Page 68 ET4 50 Engine Page 69 ET4 50 Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and it seating in the crankcase and the return spring.

Page 70 ET4 50 Engine Removing the hub cover - Drain the rear hub oil - Remove driven pulley - Remove the rear brake shoes - Remove the 5 screws fixing the cover to the crankcase - Remove the cover with the wheel axle and pull it Page 71 ET4 50 Engine Removing the driven pulley shaft bearing - Remove the seeger ring - Heat the engine crankcase but do not direct the hot air towards the bearing - Extract the driven pulley shaft together with the bearing with a few mallet blows Page 72 ET4 50 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings.

Page 73 ET4 50 Engine Y 20 mm guide Y 42xmm adaptor Refitting the hub bearings - Remove the wheel axle on the cover and pay at- tention not to damage the sealing lip of the oil seal - Apply a thin layer of grease on the two shim Page Removing The Stator ET4 50 Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.

Page 76 ET4 50 Engine Removing the starter motor - Unscrew the screw on the power positive contact and disconnect the cable - Unscrew the 2 screws fixing the starter motor to the crankcase and recover the power wiring. Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. Page 77 ET4 50 Engine Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. Page 78 ET4 50 Engine Refitting the flywheel magneto - Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings.

Page 79 ET4 50 Engine Removing the timing system drive - Temporarily loosen the tensioner central screw and remove it together with the spring. Page 80 ET4 50 Engine Removing the cam shaft - Remove the bearing clamping screw indicated in the figure. Page Removing The Cylinder Head ET4 50 Engine Removing the cylinder head - Remove the cooling covers, the timing control, the camshaft and the rocking levers.

Page Inspecting The Small End ET4 50 Engine Removing the cylinder - piston assy. To avoid damaging the piston, keep it fixed while removing the cylinder. Page Inspecting The Piston ET4 50 Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin.

Characteristic Standard diameter gudgeon pin 13 Page 84 ET4 50 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. Page Removing The Piston ET4 50 Engine N. BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED.

Page 86 ET4 50 Engine Choosing the gasket This engine is manufactured with two different head gasket solutions: - Fibre gasket drw. In order to guarantee an adequate compression ratio, the gaskets match cylinders with different heights: - Fibre gaskets with cylinder Page 87 ET4 50 Engine N.

Page 88 ET4 50 Engine Refitting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpen- dicularly to the cylinder axis. Page 89 ET4 50 Engine - Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superim- pose. Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned.

Page 91 ET4 50 Engine - Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. Inspecting the valve sealings - Measure the width of the sealing surface on the valve seats. Page 93 ET4 50 Engine grinding, keep the cylinder head in a horizontal position.

CAUTION TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. Page 94 ET4 50 Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams.

Manuals Brands VESPA Manuals Scooter Granturismo GT Workshop manual VESPA GT Workshop Manual. Quick Links. Table of Contents. WORKSHOP MANUAL. Related Manuals for VESPA GT Scooter VESPA GT Workshop Manual pages. Scooter VESPA GTV Service Station Manual it en fr de es pt ol el pages. Summary of Contents for VESPA GT Page 1 WORKSHOP MANUAL Vespa GT Page 2 WORKSHOP MANUAL Vespa GT 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.

Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Page 6: Safety Rules Vespa GT Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary; Page 8 Vespa GT Characteristics Engine DATA Specification Desc. Page Wheels And Tyres Vespa GT Characteristics Brakes BRAKES Specification Desc. Page 11 Vespa GT Characteristics Specification Desc. Page Tightening Torques Vespa GT Characteristics Specification Desc. Page 15 Vespa GT Characteristics Cylinder - piston assy.

Page 19 Vespa GT Characteristics Oversizes ENGINE OVERSIZE Name Description Dimensions Initials Quantity Compression ring 57 x 1 0. Page 21 INDEX OF TOPICS TOOL OOLING Page 23 Vespa GT Tooling Stores code Description Y Flywheel extractor Y Punch for removing fifth wheels from headstock Y Front suspension service tool Y Punch Y Punch TOOL - Page 24 Vespa GT Tooling Stores code Description Y Punch Y Wrench for steering tube ring nut Y Support base for checking crankshaft alignment Y Air heater support Y Air heater Y Oil pressure gauge Y Crankcase splitting strip TOOL - Page 25 Vespa GT Tooling Stores code Description Y Sheath for driven pulley fitting Y Clamp to assemble piston on cylinder Y Punch for assembling valve seal rings Y Immobilizer check tester Y MityVac vacuum-operated pump Y Stroboscopic light to check timing Page 26 Vespa GT Tooling Stores code Description Y Digital multimeter Y Digital rev counter Y Single battery charger Y Multiple battery charger TOOL - Page 27 Vespa GT Tooling Stores code Description Y Magnetic support for dial gauge Y 32 x 35 mm adaptor Y 42xmm adaptor Y Adaptor 52 x 55 mm Y 20 mm guide Y mm guide TOOL - Page 28 Vespa GT Tooling Stores code Description Y 22 mm guide Y driving pulley lock wrench Y Adaptor 28 x 30 mm Y Adaptor handle Y Valve cotters equipped with part re- moval tool Y adapter for valve removal tool Page 29 Vespa GT Tooling Stores code Description Y Piston fitting band Y Multimeter adaptor - Peak voltage detec- tion Y 15 mm guide Y mm guide Y driven pulley lock wrench TOOL - Page 30 Vespa GT Tooling Stores code Description Y Driven pulley roller casing fitting punch Y Punch for flywheel-side oil seal Y Piston fitting fork Y Pin lock fitting tool Y Valve oil seal extractor Y Oil pressure control fitting TOOL - Page 33 Vespa GT Tooling Stores code Description Y Flywheel lock calliper spanner Y Exhaust fumes analyser TOOL - Page Checking The Spark Advance Vespa GT Maintenance 2.

Gas valve spring 3. Tapered pin support 4. Tapered pin spring 5. Tapered pin 6. Throttle valve diaphragm 7. Automatic starter 8. Idle speed adjustment screw 9. Accelerating pump rocking lever Idle mixture adjustment screw Float pin Page 41 Vespa GT Maintenance - Operating on the flash corrector displacement of the bulb, make the reference on the flywheel cover coincide with level on the water pump drive.

Read the advance degrees indicated by the stroboscop- ic light. Page 42 Vespa GT Maintenance VERSION Specification Desc. Page Spark Plug Vespa GT Maintenance Spark plug - Rest the vehicle on the central stand. Page 44 Vespa GT Maintenance - Adjust the distance, if required, by bending the side electrode carefully. In case of irregularity, re- place the spark plug with one of the recommended type.

Recommended products Page 46 Vespa GT Maintenance AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness - Remove the left side panel. Page Engine Oil Vespa GT Maintenance 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. Page 48 Vespa GT Maintenance Lubricate them and refit the gauze filter and oil drainage tap, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubri- cate the O-ring before fitting it. Change the engine oil.

Page Checking The Ignition Timing Vespa GT Maintenance 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. The restoration level between the MIN and MAX levels implies a quantity of oil of approx.

Page Cooling System Vespa GT Maintenance Cooling system Introduction of the engine coolant. The fluid level inspection should be carried out ev- ery 6, km when the motor is cold, following the methods indicated below: Place the scooter on its centre stand and on flat ground. Page 51 Vespa GT Maintenance Top-up - Position the vehicle on a flat surface and on the centre stand - Remove the brake pump cover as indicated in the photo Check the brake fluid level through the sight glass on the pump as shown in the photograph Page Headlight Adjustment Vespa GT Maintenance For refitting purposes carry out the operations in the reverse order from the removal operation and respect the tightening torque of the tank cover screws.

CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. Page 53 Vespa GT Maintenance CO check Remove the side, then remove the transmission side cooling air inlet so as to easily reach the flow adjustment screw - Remove the gas cap on the exhaust pipe. The differences are the following: instead of entering through the muffler as for 2T engine, the secondary air enters directly in the dis- charge pipe on the head.

Page 56 Vespa GT Maintenance The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved re- action of the catalytic converter. Page 57 Vespa GT Maintenance - Remove the 2 fixing screws, the gasket and the pipe connecting the SAS valve to the head.

Then remove the pipe. Page 58 Vespa GT Maintenance - Remove the pump support bracket and fuel filter. Page 59 Vespa GT Maintenance - Check that the SAS valve plastic support is not dented or distorted - Check that the gasket is in good conditions - Carefully clean the inside and outside filters. Re- place them if damaged or abnormally distorted.

Page Rear Wheel Spins At Idle Vespa GT 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. Page 62 Vespa GT Troubleshooting Possible Cause Operation lenia Air Filter Oilthen hand dry without squeezing, allow to drip dry and then reassemble. Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components The carburettor is dirty; Page 63 Vespa GT Troubleshooting Engine tends to cut-off at idle THE ENGINE TENDS TO STOP AT IDLE Possible Cause Operation Air calibrated holes in carburettor blocked Dismantle, wash with solvent and dry with compressed air Defective floating valve Check the proper sliding of the float and the functioning of the Check that the brake discs are not worn, scored or warped.

Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; Page Noisy Suspension Vespa GT Troubleshooting 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.

Page 66 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Page 68 Vespa GT Electrical system Specification Desc. Page 69 Vespa GT Electrical system IGNITION Specification Desc. ZAPM, a protective cap has been introduced for the H. Page 70 Vespa GT Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP Specification Desc.

Page 72 Vespa GT Electrical system Immobiliser The electronic ignition system is realised with di- rect current power supply and is equipped with immobilizer antitheft device built in the control unit. The ignition system is made up of: - control unit Page 73 Vespa GT Electrical system If no faults are found, replace the control unit; oth- erwise, check the wiring and the following compo- nents: - Engine stop remote control switch; - Emergency stop switch; - Side stand switch; - Key switch contacts.

Page 74 Vespa GT Electrical system high voltage system shielding: In any case it is ad- visable to use resistive spark plugs. Diagnostic codes The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings. If non-conforming values are measured, replace the Pick-Up; Page 78 Vespa GT Electrical system The three- phase generator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.

For this reason, it is very important that the idle speed is adjusted as prescribed. Page 79 Vespa GT Electrical system - With a tester, check the circuit between connec- tions and is not interrupted. Stage indicative resistance: 0. Page 80 Vespa GT Electrical system Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V.

Page 81 Vespa GT Electrical system check the wiring between starter and control unit, or finally, as last option replace the starter. Turn signals system check - If the turn indicators do not work, proceed as follows: -Disconnect the control unit connector and check that there is battery voltage between terminal No.

Page 82 Vespa GT Electrical system Fuses The electrical system is equipped with: 1.