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SERVICE STATION MANUAL Vespa S 50 2T

1. TIME 153 Time Vespa S 50 2T Exhaust pipe inn i C O L o M y MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement TIME 154 Vespa S 50 2T Air cleaner 3 AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting Re placement 001014 Air filter Replacement cleaning 001015 Air filter box Replacement TIME 155 N TIME 156 Code 004001 004023 004149 004159 004012 004059 Vespa 5 50 2T FRAME Action Duration Chassis Replacement Shield rim Replacement Shield central cover Replacement Plates Stickers Replacement Rear side panels Replacement Spark plug inspection flap Replace ment N Vespa S 50 2T Centre stand 3 STAND Code Action 004004 004102 004179 otand Replacement Side stand Replacement Stand buffer Replacement Time L TE ee TE 4 2 Duration TIME 157 Time Vespa S 50 2T Footrests FOOTREST Code Action Duration 1 004178 Footrest Replacement 2 004078 Front rear footrest rubber Replace ment TIME 158 Vespa 5 50 2T Time Rear cover 1 SHIELD BACK PLATE Code Action Duration 1 004065 Front shield rear part Removal and refitting TIME 159 Time Vespa S 50 2T Underseat compartment HELMET
2. b If no faults are detected with these controls re place the regulator If functioning is still not correct even when the regulator has been replaced check the connec tions of the electrical system ELE SYS 54 Vespa S 50 2T Electrical system FAULT 3 B After checking that there are no short circuits in the system towards earthing with the engine off and the regulator connector detached replace the reg ulator because it is certainly inefficient and re place the protection fuse Following the replacement measure the current and the recharging voltage on the battery ends FIG B The values detected must be 1 5 2 and 13 V at 3000 rpm FAULT 4 D a Place the tester that detects alternating voltages between the connection of the yellow cable 8 on TRE the regulator and the black cable 6 FIG D to check that the voltage supplied by the generator at 3000 rpm is within 26 30 V the battery should be disconnected to measure this If faults are de tected replace the stator otherwise proceed to point b b Yellow black cable 1 connected to the regula tor Insert an ammeter between the grey blue ca ble 2 of the stator and the battery and use the tester to check that the current supplied at 3000 rom is approx 1 5 2 Ampere FIG C If the values detected are lower than those speci fied replace the regulator Before carrying out the check
3. light unit Undo the screw indicated and disconnect the connector Footrest Remove the shield back plate Remove the side fairings Remove the central tunnel inspection door From both sides unscrew The fixing screw at the back The fixing screw on the central part CHAS 130 Vespa S 50 2T Chassis The fixing screw at the front Remove the footrest Side fairings Undo the screw A and the smaller screw B Detach the seats on the fairing CHAS 131 Chassis License plate holder Remove the side fairings Working on both sides undo the two screws in dicated Remove the license plate light Air filter Remove the helmet compartment Remove the side fairings Undo the two indicated clamps to the crankcase Undo the two clamps indicated CHAS 132 Vespa S 50 2T Vespa S 50 2T Chassis Fuel tank Adequately support the rear part of the scooter Remove the wheel and the rear mudguard Remove the battery compartment Disconnect the fuel outlet pipe Undo the two fixing screws to the chassis and collect the fuel pipe supporting plate Remove the turn indicators Remove the rear light unit and undo the indicated Screw Unscrew the closing cap Lower the fuel tank and disconnect the bleed pipes and the level indicator connector CHAS 133 Chassis Vespa S 50 2T Remove the
4. 71 Engine Vespa S 50 2T Stationary driven half pulley Standard diame ter 33 965 to 33 985 mm Stationary driven half pulley Minimum diam eter admitted after use 33 96 mm Inspecting the driven sliding half pulley Remove the 2 inner sealing rings and the two O rings Measure the inside diameter of the mobile half pulley bushing Characteristic Mobile driven half pulley Maximum diameter allowed 34 08 mm Check the belt contact surfaces Insert the new oil seal and O rings on the mobile half pulley Fitting the half pulley on the bushing Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Mo lybdenum disulphide ISO L XBCHB2 DIN KF2K 20 Make sure the pins and collar are not worn reassemble the pins and collar Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr of grease This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole This procedure is necessary to prevent the presence of grease beyond the O ring Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Molybdenum disulphide ISO L XBCHB2 DIN KF2K 20 ENG 72 Vespa S 50 2T Engine Refitting the driven half pulley bearing Fit a new ball bearing with the specific tool F
5. SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Characteristic Transmission oil 80 cm Locking torques N m Hub oil drainage cap 5 Air filter Remove the cap of the purifier unscrewing the six 4 clamping screws and removing the filter Cleaning Wash with water and neutral soap a 4 er aa a ET M a x Dry with a clean cloth and short blasts of com pressed air Saturate with a 50 mixture of gasoline and oil Drip dry the filter and then squeeze it between the hands without wringing Let it dry and refit it again CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased ad hesiveness MAIN 33 Maintenance Vespa S 50 2T transmissions Adjust the control cables Mix cable see procedure indicated in Mixer tim ing Throttle cable adjust the set screw on the carbu rettor in such a way that the sheath has no back lash Splitter control cable adjust set screw on the throt tle control to the handlebar in such a way that there is no backlash on the throttle control Adjust all transmissions in such a way that their sheathings show no sign of backlash Mixer Timing Using the transmission set screw on the crank case w
6. SERVICE STATION MANUAL 664787 664795 IT EN FR DE ES PT NL EL Vespa S 50 2T SERVICE STATION MANUAL Vespa S 50 2T 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 amp C S p A Pontedera All rights reserved Reproduction of this publication in whole or in part is prohibited PIAGGIO amp C S p A After Sales V le Rinaldo Piaggio 23 56025 PONTEDERA Pi SERVICE STATION MANUAL Vespa 5 50 2T This service station manual has been drawn up by Piaggio amp 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 changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual Nev
7. Blue Black 8 Magneto flywheel Yellow ELE SYS 61 Electrical system Vespa S 50 2T MAGNETO FLYWHEEL CONNECTOR 1 Pick up Red 2 Voltage regulator Yellow 3 Battery positive Blue 4 Voltage regulator Yellow Blue 5 Ground White 6 Electronic ignition device Green ELECTRONIC IGNITION DEVICE CONNECTOR 2 1 2 Ground Black White 3 Magneto flywheel Green 4 Not connected AUTOMATIC STARTER CONNECTOR 1 Positive from voltage regulator Yellow Black 2 Ground Black OIL LEVEL INDICATOR CONNECTOR E 1 Positive from voltage regulator Orange 2 Oil reserve warning light Orange 3 Positive from voltage regulator Yellow 4 Live Positive White ELE SYS 62 Vespa S 50 2T INSTRUMENT PANEL CONNECTOR A 1 Right turn indicator warning light White Blue 2 Left turn indicator warning light Pink 3 Positive from voltage regulator Yellow Black 4 Ground Black INSTRUMENT PANEL CONNECTOR B 1 Live Positive White 2 Low fuel warning light Yellow Green 3 Oil reserve warning light Orange 4 Fuel level indicator White Green 5 High beam warning light Purple Electrical system ao x 5 ELE SYS 63 INDEX OF TOPICS FROM VEHICLE ENG VE Vespa S 50 2T Engine from vehicle Exhaust assy Removal Remove the 2 fixing nuts from the manifold to the head Unscrew the 2 screws fi
8. Replacement 2 003073 Steering clearance Adjustment 3 004119 Bearing upper steering fifth wheel Replacement TIME 165 Handlebar covers Vespa S 50 2T TIME 166 Code 004018 004019 005014 005038 ODOMETER HANDLEBAR COVER Action Handlebar front section Replace ment Handlebar rear section Replace ment Odometer Replacement Instrument panel warning light bulbs Replacement Duration Vespa S 50 2T Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 1 004066 Driving mirror Replacement 2 002037 Brake or clutch lever Replacement 3 002071 Left hand grip Replacement 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002054 Throttle or splitter transmission com plete Replacement 8 002060 Complete throttle control Replace ment 9 004162 Mirror support and or brake pump fit ting U bolt Replacement 10 002059 Right hand grip Replacement TIME 167 Time Vespa S 50 2T Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chassis con nection Replacement TIME 168 Vespa S 50 2T Time Seat SADDLE Code Action Duration 1 004003 Saddle Replacement TIME 169 Turn signal lights ON TIME 170 Code 005002 005012 005067 005008 005005 005066 005022 005068 TURN INDICATOR LIGHTS Action F
9. preloading Hear suspension travel 83 mm Brakes BRAKES Specification Desc Quantity Front brake 200 mm disc brake with hydraulic control activated by han dlebar right side lever Rear brake 110 mm drum brake with mechanical control activated by the handlebar left side lever Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Wheel rim type Light alloy rims Front rim 11 x 2 50 Rear rim 10 x 3 00 Front tyre Tubeless 110 70 11 45L Rear tyre Tubeless 120 70 10 54L Front tyre pressure with passenger 1 4 bar Rear tyre pressure with passenger 2 0 bar N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES CHAR 10 Vespa S 50 2T Characteristics Secondary air Follow these steps to clean the sponge filters of the secondary air system 1 Remove the snap on plastic cover 1 on the transmission cover using a small screwdriver as a lever on the retaining tongues in order to insert one of the three slots found on that cap 2 Wash the polyurethane sponge with water and soap dry all components with compressed air and refit to place Refit the intake cap respecting the angle reference 3 Undo the two fixing screws 2 on the aluminium cover of the secondary air housing in order to reach the polyurethane sponge inside that hous ing clean as indicated in point 2 and refit all elements after checking th
10. roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m Steering lower ring nut 8 10 Steering upper ring nut 35 40 Front shock absorber ho ENS oe LAS ER OR X KE SUSP 105 Suspensions Vespa S 50 2T Removal Support the scooter adequately Remove the wheel hub Loosen the shock absorber lower clamps and re move the brake calliper shock absorber support Loosen the screws fixing the front brake pipe re tainer clamp and the odometer cable in order to reach the upper clamps Unscrew the upper fixing nuts Remove the front shock absorber SUSP 106 Vespa S 50 2T Suspensions Refitting To refit carry out the removal operations in reverse order observing the prescribed tightening torques Locking torques N m Lower shock absorber clamping screw 20 27 Upper shock absorber fixing nut 20 30 Shock absorber calliper bracket Removal Remove the front wheel hub with the brake disc Remove the front shock absorber lower clamps Remove the bracket locking seeger ring Unscrew the bracket Before refitting the bracket in the wheel axle place the O ring as shown in the photograph so that it is correctly placed after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Locking
11. the specific punch e Fit the snap ring with the concave or radial part on the bearing side N B FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40 mm adaptor Refitting the wheel axle bearing using a thermal gun After lubricating its outer strip insert the bearing with the special adapter with the aid of a hammer 5 Refit the seeger ring and the oil seal using the 42 x 47 mm adapter and the handle Specific tooling 020151Y Air heater 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42x47 mm adaptor Refitting the ub cover Refit the whole wheel axle Refit the intermediate gear paying attention to the two shim washers Apply LOCTITE 510 for surfaces to the hub cov ers and refit the same with driven pulley shaft Refit the 5 screws and tighten them to the speci fied torque N B CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVI OUS GASKETS BEFORE APPLYING A NEW ONE ENG 80 Vespa S 50 2T Vespa 5 50 2T Locking torques N m Rear hub cap screw 12 13 Flywheel cover Cooling hood Remove the four fixings shown in the figure Remove the fan cover Remove the oil piping retention band from the hood Remove the 2 screws shown in the figure A RIE 25 DRY ESA LS Engine ENG 81 Engine Vespa S
12. 15 mm bearings Pliers to extract 15 mm bearings Bell for bearings OD 39 mm Pliers for circlips TOOL 17 Tooling Stores code 006029Y 020004Y 020055Y 020150Y 020151Y 020162Y 020163Y TOOL 18 Vespa S 50 2T Description Punch for fitting fifth wheel seat on steer ing tube Punch for removing fifth wheels from headstock Wrench for steering tube ring nut Air heater support Air heater Flywheel extractor Crankcase splitting plate Vespa S 50 2T Stores code 020166Y 020261Y 020265Y 020325Y 020329Y 020330Y Description Pin lock fitting tool Starter spring fitting Bearing fitting base Brake shoe spring calliper MityVac vacuum operated pump Stroboscopic light to check timing Tooling TOOL 19 Tooling Stores code 020331Y 020332Y 020333Y 020334Y TOOL 20 Description Digital multimeter Digital rev counter Single battery charger Multiple battery charger Vespa S 50 2T Vespa S 50 2T Tooling Stores code Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020359Y 42x47 mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide TOOL 21 Tooling Stores code 020456Y 020565Y 001467Y029 020037Y 020036Y TOOL 22 Description 24 mm adaptor Flywheel lock calliper spanner Bell for bearings O D 38 mm Punch Punch Ve
13. 50 2T Cooling fan Remove the cooling fan by acting onthe three 7 fixings indicated in the figure Removing the stator Remove the three stator fixings shown in the photo Remove the two pick up fixings shown in the photo Remove the stator with the wiring Refitting the stator Refit the stator and flywheel carrying out the removal procedure in reverse tightening the retainers to the specified torque N B THE PICK UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM BLY Locking torques N m Stator clamping screws 3 4 Pick Up clamping screw 4 5 Flywheel and starting ENG 82 Vespa S 50 2T Engine Removing the starter motor Remove the two clamps shown in the figure Removing the flywheel magneto Lock the rotation of the flywheel using the calliper spanner Remove the nut CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS Extract the flywheel with the extractor Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor Inspecting the flywheel components Check the condition of the flywheel and any dis tortions that might cause rubbing on the stator and on the Pick Up Engine Vespa S 50 2T Refitting the flywheel magneto Fit the flywheel being careful to insert the key properly Lock the fl
14. AGIP GREASE MUS Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L DIN K3K 20 Use the tool fitted with part 20 on its stem and part 21 on the tool base as shown in the figure By moving the tool handgrip push the two NA DELLA bushings until their internal bottoms make contact with the pin end Use the tool fitted with parts 3 and 4 to fit the pin and press moving the tool handgrip until wedging the washers on the swinging hub Now remove the two spacers parts 17 and 16 and once the space between the NADELLAs steering tube and swinging hub has been fully filled with grease move the dust guard rings until they are placed in that space By wedging the washers as described above the front suspension unit refitting stage is finished Recommended products AGIP GREASE MUS Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L DIN K3K 20 SUSP 104 Vespa S 50 2T Refitting CAUTION Suspensions USE NEW ROLLER CASINGS PIN SEALING RINGS AND DUST GUARDS FOR REFITTING When fitting the fork lubricate with the steering bearing tracks with the recommended grease Tighten the lower ring nut A and the upper ring nut B to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect
15. COMPARTMENT Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover change 3 00401 1 Central chassis cover Replacement 4 004071 Battery compartment replacement TIME 160 Vespa 5 50 2T Plate holder N LICENSE PLATE HOLDER Code Action Duration 004136 License plate support Replacement 005048 Licence plate holder Replacement 005032 Licence plate light glass Replace ment Time TIME 161 Time Vespa S 50 2T Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement TIME 162 Vespa S 50 2T Fuel tank Code 004168 005010 004112 004005 004007 004109 Tr FUEL TANK Action Duration Fuel tank cap Replacement Tank float Replacement Cock carburettor hose Replace ment Fuel tank Replacement Fuel valve Replacement Fuel tank breather Replacement Time TIME 163 Vespa S 50 2T Time Tank oil Code 1 005018 2 004017 3 004095 4 004091 Rear shock absorber TIME 164 OIL RESERVOIR Action Duration Oil reservoir float Replacement Oil reservoir Replacement reservoir cock Replacement Oil reservoir hose Replacement Vespa S 50 2T Time REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 oteering fifth wheel
16. Pre delivery Vespa S 50 2T Starter CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE WARNING BEFORE RECHARGING THE BATTERY REMOVE THE CAPS OF EACH CELL KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED REMOVE THE BATTERY FROM THE SCOOTER DISCONNECTING THE NEGATIVE TERMINAL FIRST CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE LEAD WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS IT CONTAINS SUL PHURIC ACID AVOID CONTACT WITH EYES SKIN AND CLOTHING IN CASE OF CONTACT WITH EYES OR SKIN RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO EN SURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Level check Hydraulic brake system fluid level Rear hub oi
17. acts on the bearing s inner track Specific tooling 020265Y Bearing fitting base Inspecting the crankshaft alignment With the specific tool shown check that the eccen tricity of the surfaces of diam A B C are within 0 03 mm reading limit on the dial gauge in addition check the eccentricity of diam D for which a maximum reading of 0 02 mm is permitted In the case where eccentricity is not much above prescribed levels straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp with an aluminium bushing as re quired Specific tooling 020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft alignment ENG 91 Engine Refitting the crankshaft Position the transmission side half crankcase on two wooden supports Using a thermal gun heat the bearing seat to about 120 Firmly insert the crankshaft until the bearing rea ches the end of stroke stop Let the temperature of the half crankcase settle at the temperature of the crankshaft Again install the special crankcase separation plate NOT installing the crankshaft protection During the assembly phase keep the central thrust screw loose Take the four clamping screws to the end of the stroke and loosen them again with the same angle e g 90 When the temperature has settled preload the thrust screw of the tool manually until the ball bear ing cleara
18. crankshaft connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Connecting rod 11 750 0 05 A clearance E 0 25 to 0 50 shoulder washer 0 5 0 03 G clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Half shaft transmission 13 75 0 040 clearance E 0 25 to side 0 50 clearance F 0 20 to 0 75 Flywheel side half shaft 13 75 0 040 D clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Lining between the 40 64 H clearance E 0 25 to shoulders 0 50 clearance F 0 20 to 0 75 Cage 11 800 0 35 B clearance F 0 20 to 0 75 SES SR 52 JE Slot packing system This type of engines foresees the use of one size of basic gaskets CHAR 14 Vespa S 50 2T Products Characteristics RECOMMENDED PRODUCTS TABLE Product AGIP ROTRA 80W 90 AGIP CITY HI TEC 4T AGIP FILTER OIL AGIP CITY TEC 2T AGIP BRAKE 4 MONTBLANC MOLYBDENUM GREASE AGIP GREASE PV2 AGIP GREASE SM 2 AGIP GP 330 Description Rear hub oil Oil to lubricate flexible transmissions brake throttle control and mixer odom eter Oil for air filter sponge Mixer oil Brake fluid Grease for driven pulley shaft adjusting ring and movable driven pulley housing Grease for the steering bearings pin seats and swinging arm Grease for odometer transmission gear case Grease for brake control levers throttle stand Specifications SAE 80W 90 Oil t
19. hydraulic braking system Elastic fittings piston seals or brake pump breakdown replace The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in the pump Defective sliding of the cables in their sheathes Lubricate or substitute Brake noise Check the wear of the brake pads and or shoes TROUBL 41 Troubleshooting Vespa S 50 2T Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective sliding of pistons Replace the calliper Brake disc or drum deformed Using a dial gauge check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum Electrical system Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance If the vehicle is not used for some time 1 month or more the battery needs to be recharged periodically The battery runs down completely in the course of 5 6 months If the battery is fitted on a motorcycle be careful not to invert the connections keep ing in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Torque not conforming Check the tig
20. nut 40 44 Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Characteristic Transmission belt Minimum width 17 5 mm ENG 74 Vespa S 50 2T Removing the driving pulley Lock the driving pulley using the appropriate tool Remove the central nut with the related washer then remove the drive and the plastic fan Remove the stationary half pulley Engine Remove the belt washer and remove the mobile half pulley with its bushing being careful that the rollers and contrast plate fitted loosely on it do not come off Specific tooling 020451 Y Starting ring gear lock Mixer gears and belt Remove gear and belt CAUTION PAY PARTICULAR ATTENTION TO NOT TOUCHING OR BENDING THE BELT BECAUSE THIS COULD BREAK SUD DENLY DURING OPERATION CAUTION ON REFITTING MAKE SURE THAT DIRT DOES NOT GET INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN N B REPLACE THE BELT AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE Inspecting the rollers case 1 Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation 2 Check the roller running tracks on the contact pulley there must not be signs of wear and check the condition of the contact surface of the belt on the half pulleys mobile and stationary 3 C
21. sealing rings in the cylinder Using the piston insert the seals perpendicularly to the cylinder axis Measure the opening of the sealing rings using a thickness gauge as shown in the photograph f the values are higher than the values prescri bed in the chart substitute the rings ENG 87 Engine Vespa S 50 2T Removing the piston Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool Push detail 2 into detail 1 until the stop and extract detail 2 Insert detail 3 into detail 1 position the assembly in the snap ring assembly area and push detail 3 all the way in N B REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM THE REMOVAL OPERATIONS Specific tooling 020166Y Pin lock fitting tool Locking torques N m Cylinder head nuts 10 11 Use new wrist pin snap rings Use new cylinder base gasket Before refitting carefully clean all the surfaces Use oil to be mixed during the fitting of the piston and the cylinder CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON THE PISTON WITH THE SPECIFIC TOOL Recommended products AGIP CITY TEC 2T Oil Recommended oil ENG 88 Vespa S 50 2T Engine Inspecting the timing system components CAUTION CHECK THE CORRECT REED UNIT SEAL NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA C
22. the prescribed tor que Locking torques N m Locking torque 137 152 Nm Swing arm SUSP 111 Suspensions Vespa S 50 2T Removal Support the scooter adequately Remove the central tunnel inspection door To remove the upper clamp from the chassis proceed as follows Unscrew the pin and collect the washer Remove the cap from the lower part Collect the lower fixing nut and collect the wash er SUSP 112 Vespa S 50 2T Suspensions Working on both sides remove the cover caps Working on the right side unscrew the side fixing nut to the chassis and collect the washer Working on the left side remove the pin Remove the spoiler terminal from both sides Working on the right side unscrew the fixing nut SUSP 113 Suspensions Vespa S 50 2T Working on the left side release the pin from the spring shown Remove the fixing pin to the engine and collect the spacer Now the swinging arm is free Remove the swinging arm from the vehicle first release it from the engine side and then from the chassis side Overhaul Check that the silent blocks are in good condi tions Otherwise replace the swinging arm SUSP 114 Vespa S 50 2T Suspensions Refitting For rifting respect the locking torques Locking torques N m Swinging arm to engine pin locknut 33 41 Swinging arm to chassis pin locknut 44 52 Swingin
23. the two fixing screws to the shock absorber calliper support N B SHOULD IT BE NECESSARY TO REPLACE THE CALLIP ER FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER Refitting Vespa S 50 2T To fit follow the removal steps but in reverse order be careful to tighten to the prescribed torques N B ONCE REFITTING IS FINISHED BLEED THE SYSTEM Locking torques N m Screw tightening calliper to the support 20 25 Brake pipe connection 20 to 25 Nem Front brake disc Removal Remove the front wheel Remove the front brake calliper Remove the hub and the disc operating on the wheel axle nut Adequately support the hub with the disc and op erating on the five screws shown in the photo graph remove the brake disc BRAK SYS 118 Vespa S 50 2T Braking system Refitting Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it Tighten the 5 screws to the specified torque Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking torques N m Brake disc screws 8 10 Disc Inspection Remove the front wheel Use a micrometer to check the disc thickness as shown in the photograph Repeat the measurement in at least 6 points on the disk Remove the front brake calliper In order to secure the appropriate too
24. type Engage the spark plug with the due inclination and screw it right down by hand then do it up with the wrench at the prescribed torque Fit the cap on the sparking plug as far as it will go Refit the central flap MAIN 31 Maintenance Vespa S 50 2T CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE EN GINE IS COLD REPLACE THE SPARK PLUG AS INDICA TED IN THE SCHEDULED MAINTENANCE TABLE USING NON COMPLYING IGNITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERI OUSLY DAMAGE THE ENGINE Characteristic Spark plug CHAMPION RN3C Electric characteristic Electrode gap 0 6 to 0 7 mm Locking torques N m Spark plug 25 30 Nm Hub oil Check Do the following to check the correct level Park the vehicle on its centre stand on flat ground Unscrew the oil dipstick A and dry it with a clean cloth then reinsert it screwing it in all the Way Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end Screw up the oil dipstick back in and make sure itis locked properly in place MAIN 32 Vespa S 50 2T Maintenance Replacement Remove the oil filler cap A Unscrew the oil drainage cap B and drain out all the oil J Screw the drainage plug again to the prescribed torque and refill the hub with the recommended oil i Recommended products AGIP ROTRA 80W 90 Rear hub oil
25. using recommended grease Replace Dismantle wash with solvent and dry with compressed air Clean the cock filter Check the cap with filter is fitted to the transmission cover clean the speed variator replace the rollers if worn out REAR WHEEL Possible Cause Idling rpm too high Clutch fault Air filter housing not sealed Starting difficulties Operation Adjust the idle speed Check the spring friction mass and the clutch bell Correctly refit the filter housing and replace it if it is damaged DIFFICULTY STARTING Possible Cause Carburettor nozzles clogged or dirty Faulty fuel cock Starter inefficient Defective spark plug or with incorrect electrode gap Battery flat Engine flooded Operation Dismantle wash with solvent and dry with compressed air Check that at ignition and with throttle untwisted no petrol flows out the delivery pipe otherwise replace the vacuum op erated cock Check electric wiring circuit continuity mechanical sliding and power supply Check and if necessary replace the spark plug and the elec trode gap Check the state of the battery If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1 10 of the capacity of the battery itself Start up keeping the throttle fully open alternating approximate ly five seconds of turning it with five seconds still If however it does not start remove the spark plug the engine over with th
26. 0 Side stand bracket fixing screw 15 20 Overhaul data Assembly clearances Cylinder piston assy COUPLING BETWEEN PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Standard coupling M 40 005 40 012 39 943 39 95 0 055 0 069 Standard coupling N 40 012 40 019 39 95 39 957 0 055 0 069 Standard coupling 40 019 40 026 39 957 39 964 0 055 0 069 Standard coupling P 40 026 40 033 39 964 39 971 0 055 0 069 coupling 1st oversize M1 40 205 40 212 40 143 40 15 0 055 0 069 coupling 1st oversize N1 40 212 40 219 40 15 40 157 0 055 0 069 coupling 1st oversize O1 40 219 40 226 40 157 40 164 0 055 0 069 coupling 1st oversize P1 40 226 40 233 40 164 40 171 0 055 0 069 Coupling 2nd oversize M2 40 405 40 412 40 343 40 35 0 055 0 069 Coupling 2nd oversize N2 40 412 40 419 40 35 40 357 0 055 0 069 Coupling 2nd oversize O2 40 419 40 426 40 357 40 364 0 055 0 069 Coupling 2nd oversize P2 40 426 40 433 40 364 40 371 0 055 0 069 ERAJ d be zz i PILA Pres 1 i T A i F We 2 RD BG Du A YA wu lg vA 7 7 A ig p 2 if Piston rings SEALING RING Name Description Dimensions Initials Quantity Compression ring 40 A 0 10 to 0 25 Compression ring 1st 40 2 A 0 10 to 0 25 oversize Compression ring 2nd 40 4 A 0 10 to 0 25 Oversize CHAR 13 Characteristics Vespa S 50 2T Crankcase
27. 0036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 NLGI 2 ISO L XBCIB2 Steering bearing Removal Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis SUSP 109 Suspensions Vespa S 50 2T N B TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING JUST USE A SCREW DRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE Specific tooling 020004Y Punch for removing fifth wheels from headstock Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing fifth wheels from headstock Refit the fifth wheel fitting and the dust guard on the steering tube until they stop using the specific tool Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube Rear Removing the rear wheel Remove the muffler Remove the cotter pin and remove the cap SUSP 110 Vespa S 50 2T Suspensions Unscrew the nut fixing the wheel axle and collect 1 the washer Refitting the rear wheel To refit follow the removal steps but in reverse order be careful to tighten to
28. 020331Y Digital multimeter Pick UP CHECK FIGURE A Specification Red cable 1 and White cable 2 RECHARGING COIL CHECK FIGURE B Specification Red cable 3 and Green cable 4 CONTINUITY CHECK Specification White cable Engine White cable Frame Desc Quantity 90 140 Ohm Desc Quantity 800 1100 Ohm Desc Quantity Continuity Continuity Electrical system ELE SYS 53 Electrical system Vespa S 50 2T Voltage regulator check Voltage regulator A The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault 1 Lighting system bulbs burn out EEE 2 Lighting system is not working 3 Battery overcharges the main fuse blows 4 Battery not recharging 5 Turn indicators not working 6 Oil and fuel check warning light not working Remedies FAULT 1 Check that the control voltage is between 13V and 14 5V at 5000 rpm with the lights on Check that the control voltage is 16V at 5000 rpm with the lights off Replace the voltage regulator if control voltages are over gt 16V FAULT 2 a Check that voltage to stator is correctly sup plied disconnect the regulator connector and place the tester to detect alternating voltages be tween the connection of the grey blue cable 2 and the black cable 6 to check that the voltage supplied at 3000 rpm is within 25 30 V FIG A If faults are detected replace the stator
29. 2T Devices and accessories E 1 00 KEY 2 Magneto flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 9 Horn button 10 Horn 14 Turn indicator switch 16 Rear left turn indicator 18 Rear right turn indicator 19 Front left turn indicator 21 Front right turn indicator 23 Instrument panel A Turn indicator warning light 25 Heater 26 Heater control device ELE SYS 52 Vespa S 50 2T Checks and inspections All the control operations of the system that entail disconnecting cables to check connections and the devices making up the ignition circuit must be done with the engine off if this is not done the controls might be irreparably damaged Ignition circuit 1 Check the condition of the spark plug clean it A with a metal brush remove deposits apply short blasts of compressed air and if necessary replace it 2 Without removing the stator carry out the fol lowing checks After visually checking the electrical wiring use a specific tester to measure the loading reel the pick up see chart and cable continuity B If checks on the loading boil the pick up and ca ble continuity show irregularities replace the sta tor otherwise replace the control unit Remember that the engine must be off to dis connect any connections in order to replace the central unit Specific tooling
30. 4 h 3 Constant current battery charge mode Charge current equal to 1 10 of the nominal capacity of the battery Duration of the charge 5 h WARNING WHEN THE BATTERY IS REALLY FLAT WELL BELOW 12 6V IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF ELE SYS 58 Vespa S 50 2T Electrical system Dry charge battery WARNING THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS IT CON TAINS SULPHURIC ACID AVOID CONTACT WITH THE EYES THE SKIN AND CLOTHING IF COMING INTO CONTACT WITH EYES OR SKIN WASH ABUNDANTLY WITH WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK MAGNESIUM MILK BATTERED EGG OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION THE BATTERIES PRODUCE EXPLOSIVE GAS KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF REACH OF CHILDREN The battery is an electrical device which requires careful monitoring and diligent maintenance The maintenance rules are 1 Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level Only use d
31. 6 Driving pulley Removal and refitting 2 001086 Driving half pulley replace 3 001011 Driving belt Replacement 4 001177 Variator rollers shoes Replace ment TIME 149 Vespa S 50 2T Transmission cover TIME 150 TRANSMISSION COVER Code Action Duration 001087 Flywheel cover Replacement 001135 Transmission cover bearing Re placement 001096 Transmission crankcase cover Re placement Vespa S 50 2T Time Starter motor ELECTRICAL START UP Code Action Duration 1 001020 Starter motor Replacement 2 005045 Starter motor cable harness Re placement 3 001017 Starter sprocket wheel Replace ment 4 001021 Kick starter Inspection 5 008008 Starter spring pack Replacement 6 001084 Starter lever Replacement TIME 151 Flywheel magneto GO Po TIME 152 Code 001109 001173 001067 001058 001087 MAGNETO FLYWHEEL Action Cooling fan Replacement Rotor Replacement Stator Fitting and Refitting Flywheel Replacement Flywheel cover Replacement Vespa 5 50 2T Duration Vespa S 50 2T Carburettor Code 001008 001063 007020 001081 001082 003058 004177 CARBURETTOR Action Duration Carburettor Inspection Carburettor Replacement Carburettor heating tubing replace ment Automatic choke Replacement Carburettor heating resistor Re placement Carburettor Adjustment Heating hood Replacement Time
32. B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFER ENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Remove the collar with the aid of 2 screwdrivers ENG 70 Vespa S 50 2T Engine Remove the three guide pins and the mobile half pulley Removing the driven half pulley bearing Remove the roller bearing with the special ex tractor inserted from the bottom of the fixed half pulley CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING Specific tooling 001467Y029 Bell for bearings O D 38 mm Remove the ball bearing retention snap ring Expel the ball bearing from the side of the clutch housing by means of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the work surface of the belt If there are replace the half pulley Make sure the bearings do not show signs of un usual wear Measure the external diameter of the pulley bush ing Characteristic ENG
33. E 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 Locking torques N m System bleed calliper fitting 20 25 Nm Brake fluid level check Rest the vehicle on its centre stand on flat ground he brake fluid reservoir has a sight glass A made of transparent material the quantity of liquid contained in the sight glass indicates the level of fluid in the reservoir When the sight glass A is full the level inside the reservoir is above the MIN level when it is par tially full the level has dropped to the MIN level BRAK SYS 122 Vespa S 50 2T Braking system when it is fully empty the level of fluid in the res ervoir is below the MIN level THE LEVEL TENDS TO DROP AS THE BRAKE PADS WORN MINIMUM LEVEL SHOULD NOT BE REACHED IF THE LEVEL IS TOO LOW CHECK AND FIX THE SYSTEM SEALS IF REQUIRED TOP UP THE PUMP TANK IF RE QUIRED CONSIDERING THAT THE MAX LEVEL MUST ONLY BE OBTAINED WITH NEW PADS Under standard climatic conditions replace fluid as indicated in the scheduled maintenance table Front brake pump Removal Remove the front and rear handlebar covers Remove the two screws fixing the brake pump to the handlebar indicated in the photograph Remove the oi
34. G THE BEARING TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE ENG 68 Vespa S 50 2T Engine Removing the driven pulley Lock the clutch bell housing with the specific tool Remove the the clutch bell housing and the whole of the driven pulley assembly THE UNIT ALSO REMOVED WITH THE DRIVE PULLEY MOUNTED Specific tooling 020565Y Flywheel lock calliper spanner Inspecting the clutch drum Check that the clutch bell is not worn or damaged Measure the inner diameter of the clutch bell Characteristic Clutch bell diameter standard value 10740 2 0 mm Clutch bell diameter max value allowed after use 107 5 mm Eccentricity measured max 0 20 mm Removing the clutch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and put the central screw under stress CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR ENG 69 Engine Vespa S 50 2T Using a 34 mm socket wrench remove the clutch locking nut Loosen the central screw thereby undoing the driven pulley unit Separate the components Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass friction material he masses must not show traces of lubricants otherwise check the driven pulley unit seals N
35. IGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANK SHAFT CHAPTER Characteristic Rod small end standard diameter 17 0 011 0 001 Rod small end maximum allowable diameter 17 060 mm Inspecting the wrist pin Check the wrist pin external diameter using a mi crometer Characteristic Wrist pin standard diameter 12 40 005 0 001 mm Inspecting the piston Measure the bearings on the piston using a bore meter Calculate the piston pin coupling clearance Characteristic Wrist pin housing standard diameter 12 40 007 0 012 Wrist pin housing standard clearance 0 002 0 011 mm ENG 86 Vespa S 50 2T Engine Measure the outer diameter of the piston per pendicular to the pin axis Take the measurement in the position shown in the figure To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy Inspecting the cylinder Check that the cylinder does not show seizures Otherwise replace it or adjust it respecting the al lowable increases Measure the internal diameter of the cylinder with a bore meter according to the directions given in the figure Check that the fitting surface with the head is not dented or distorted To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy Inspecting the piston rings Alternatively insert the two
36. LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN A MINIMUM LEVEL SHOULD NOT BE REACHED IF THE LEVEL IS TOO LOW CHECK AND FIX THE SYSTEM SEALS IF REQUIRED TOP UP THE PUMP TANK IF RE QUIRED CONSIDERING THAT THE MAX LEVEL MUST ONLY BE OBTAINED WITH NEW PADS Maintenance Under standard climatic conditions replace fluid as indicated in the scheduled maintenance table Top up Proceed as follows Remove the rear view mirrors Undo the two screws A Undo the screw B and remove the front han dlebar cover MAIN 35 Maintenance Vespa S 50 2T Remove the reservoir cover by looseningthe two fixing screws D and refill with the prescribed brake fluid type only and without exceeding the maximum level CAUTION ONLY USE DOT 4 CLASSIFIED BRAKE FLUID CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES SKIN AND CLOTHING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK CAUTION BRAKE FLUID IS HYGROSCOPIC THAT IS IT ABSORBS MOISTURE FROM THE SURROUNDING AIR IF THE CON TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEFFICIENT NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDITIONS REPLACE FLU ID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE N B SEE THE BRAKING SYSTEM CHAP
37. RMED a 12 Punch b Sharp edged end Use a suitable punch with the dimensions indica ted on the figure hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end Repeat the operation for the second washer using the punch on the side opposite to the one shown in the figure Use the tool fitted with part 1 as shown in the figure and move the tool handgrip until the pin and the NADELLA are simultaneously ejected in the direc tion opposite the tool thrusting force After removing the pin and the first NADELLA the swinging hub gets detached from the steering tube SUSP 102 Vespa S 50 2T Suspensions To remove the second NADELLA use the tool fit ted with part 2 instead of part 1 on the side oppo site the one shown in the figure N B DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED UPON REFITTING IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN NEW SEALING RINGS AND DUST GUARDS Specific tooling 020021Y Front suspension service tool Connect the swinging hub to the steering tube with the guiding pin Use the tool fitted with part 3 on the stem and part 4 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 mn steering tube After fitting the pin insert the two spac
38. TER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid 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 MAIN 36 Vespa 5 50 2T Maintenance 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 SAS filters inspection and cleaning Remove the right side fairing by undoing the 2 screws marked B indicated in the figure Remove the two screws A from the aluminium SAS cover Release the metal tube from the rub ber housing on the cover without extracting the tube from the cover sleeve Remove the tab and plastic cover extract the sponge and wash it in water and soap Dry it with compressed air before refitting it making sure to correctly
39. acement Voltage regulator Replacement Battery Replacement Fuse 1 Replacement Control unit Replacement Spark plug cap Replacement Fuse block 1 Replacement Time TIME 173 Time Vespa S 50 2T Electronic controls Me c ELECTRICAL CONTROLS Code Action Duration 1 005039 Headlight switch Replacement 2 005006 Light switch or turn indicators Re placement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005016 Key switch Replacement 7 004096 Lock series Replacement 8 004010 Anti theft lock Replacement TIME 174 Vespa S 50 2T Transmissions Code 002051 002012 002057 002058 002053 002049 003061 TRANSMISSION Action Duration Odometer transmission assembly Replacement Splitter Replacement Carburettor splitter transmission complete Replacement Mix splitter transmission complete Replacement Rear brake transmission complete Replacement Odometer cable Replacement Accelerator transmission Adjust ment Time TIME 175 Front suspension TIME 176 Code 003045 003010 003035 001064 003044 003011 Vespa S 50 2T FRONT SUSPENSION Action Duration oteering tube Replacement Front suspension Service Shock absorber support and brake calliper Replacement Odometer reel Replacement Shock absorber cover Replace ment Front shock absorber Removal and Refi
40. ainly not functioning properly FAULT 6 Oil reserve check warning light not working FIG H Disconnect the voltage regulator con nector Supply 12V to the terminal marked with number 1 2 3 5 Bl 7 8 5 with a digital tester check that the terminal num ber 4 has a similar output 12V for about 5 sec onds ELE SYS 56 Vespa S 50 2T Electrical system f no voltage is detected for terminal number 4 replace the regulator If there is voltage for terminal number 4 check both the installation and the bulb of the oil warning light Specific tooling 020331 Y Digital multimeter level indicators Check resistance between Pin 4 and the ground connection on the 5 way connector in the instrument panel to check the efficiency of the fuel gauge Electric characteristic Resistance value when the tank is full lt 7 Resistance value when the tank is half full 38 O 40 Resistance value with empty tank and low fuel warning light on 90 O 130 3 0 Lights list BULBS Specification Desc Quantity 1 High low beam light bulb Type Spherical Power 12V 35 35W Quantity 1 2 Front tail light bulb Type All glass Power 12V 5W Quantity 1 3 Front turn indicator bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 LHS 4 Rear turn indicator light bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 LHS 5 Stop and tail light bulb Type Spherical Power 12V 21 5W Quantity 1 6 W
41. al track of the bearing and remove said bearing with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft ENG 78 Vespa S 50 2T Engine Position the special tube on the internal raceway 5 of the bearing and from the shaft toothed side as indicated in the figure Expel the driven pulley shaft with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Inspecting the hub shaft Check the three shafts for wear or distortion of the toothed surfaces the bearing housings and the oil seal housings In case of anomalies replace the damaged com ponents Check capacity A of the transmission gear wear deformations etc Check the pulley shaft seating Superficial wear may indicate irregularities in the crankcase seatings or in the pulley shaft capacities Inspecting the hub cover Check that the fitting surface is not dented or distorted If faults are found replace the hub cover Refitting the driven pulley shaft bearing Support the inner track of the bearing from the outside of the hub cover with the specific tool posi tioned under the press and insert the driven pulley axle Refit the oil seal flush with the cover Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft ENG 79 Engine Heat the hub cover and insert the bearing with
42. ance Vespa S 50 2T AFTER 60 000 KM Action Hub oil change Spark plug replacement Air filter clean ldling speed adjustment Cylinder cooling system check cleaning Oil mixer throttle linkage adjustment Driving belt replacement Variable speed rollers replacement Mixer belt replacement Odometer gear greasing Steering Check Brake control levers greasing Brake pads check condition and wear Brake fluid check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Secondary air filter cleaning Vehicle and brake test road test See the Idle speed adjustment section Carburettor Disassemble the carburettor in its parts wash all of them with solvent dry all body grooves with compressed air to ensure adequate cleaning Check carefully that the parts are in good condi tion The throttle valve should move freely in the chamber Replace valve in case of wear due to excessive clearance f there are wear marks in the chamber causing inadequate tightness or a free valve slide even if itis new replace the carburettor 115 advisable to replace the gaskets at every refit WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS 1 Automatic starter 2 Idle air set screw 3 Idle speed set screw 4 Throttle va
43. andlebar fixing screw ENGINE ASSEMBLY Name Clutch bell nut Clutch lock ring nut Nut locking driving pulley on crankshaft Start up lever screw Flywheel nut Flywheel fan screws Half crank case joint bolts Bolts holding exhaust pipe to the crankcase screws holding the filter box to the crank case Head nuts Starter screws Ignition spark plug Hub oil drainage cap Oil hub level dipstick Rear hub cap screws Transmission cover screws Inlet manifold screws Flywheel hood fixing screws Cylinder hood fixing screws Stator clamping screws Pick Up clamping screw Mixer clamping screws screw fixing brake lever to the journal on the engine Vespa 5 50 2T Desc Quantity 32 Free 1 1 2 50 1 5 11 mm 1 5 Torque in Nm 8 12 20 25 20 25 8 10 20 25 7 10 Torque in Nm 20 30 75 90 20 25 20 25 20 27 Torque in Nm 35 40 8 10 50 55 Torque in Nm 40 44 55 60 40 44 Nm 12 13 40 44 3 4 12 13 22 24 4 5 10 11 12 13 25 30 SESS Manual 12 13 12 13 8 9 1 2 doo eo 3 4 4 5 3 4 12 13 CHAR 12 Vespa S 50 2T FRAME ASSEMBLY Characteristics Name Torque in Nm owinging arm to engine pin locknut 33 41 Swinging arm to chassis pin locknut 44 52 Shock absorber to chassis fixing nut 20 25 Swinging arm plate to chassis screw 33 41 Shock absorber to engine fixing nut 33 41 Rear wheel nut 137 152 Stand screw torque 18 5 to 19 Nm Side stand fixing screw 12 2
44. arning light bulbs turn indicators low beam lights Type glass high beam lights low fuel low oil Power 12V 1 2W Quantity 5 7 Instrument panel lighting bulbs Type All glass Power 12V 1 2W Quantity 3 ELE SYS 57 Electrical system Vespa S 50 2T Fuses The electrical system is protected by a plug fuse B located to the left of the battery compartment N S The ignition system headlight and the rear light T are not fuse protected Before replacing a blown fuse find and solve the problem that caused it to blow Do not replace the fuse with any alternative form of conductor CAUTION IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYS TEM NEVER DISCONNECT THE WIRING WHILE THE EN GINE IS RUNNING DO NOT TIP THE SCOOTER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BAT TERY ELECTROLYTE Electric characteristic Fuse 7 5 Sealed battery INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1 Voltage check Before installing the battery on the vehicle check the open circuit voltage with a normal tester If the voltage exceeds 12 60 V the battery may 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 equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for nominal capacity Duration of the charge 10 to 12 h recommended Minimum 6 h Maximum 2
45. ct ing the corresponding poles to and to 4 Cleaning the battery The battery should always be kept clean espe cially on its top side and the terminals should be coated with Vaseline WARNING Before recharging the battery remove the plugs of each cell Keep the battery away from naked flames or sparks when charging Remove the battery from the vehicle removing the negative clamp first CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED USING A FUSE OF UNSUITABLE RATING MAY SERIOUS LY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE CAUTION DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BATTERY USE DISTIL LED WATER ONLY CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Vespa S 50 2T 1 Remove the short closed tube and the caps then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1 26 corresponding to 30 B at a minimum temperature of 15 until the upper level is reached 2 Leave to rest for at least 2 hours then restore the level with sulphuric acid ELE SYS 60 Vespa S 50 2T Electrical system 3 Within the following 24 hours recharge with the specific batte
46. drive pulley N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSE QUENTLY DAMAGING THE CRANKSHAFT KNURLING Specific tooling 020451Y Starting ring gear lock Locking torques N m Crankshaft pulley nut 18 to 20 90 Nm For 25 km h engine type versions the limit washer is 5 5 mm thick End gear Removing the hub cover Remove the transmission cover O 5 e Remove the clutch assembly AM Discharge the rear hub oil Remove the 5 screws indicated in the figure Eus j See also Refitting the clutch ENG 77 Vespa S 50 2T Removing the wheel axle Remove the intermediate gear and the complete gear wheel axle When removing the intermediate gear pay atten tion to the various shim adjustments Removing the wheel axle bearings Remove the oil seal and the seeger ring Remove the bearing by pushing from the outside towards the inside of the gear compartment using the appropriate punch Specific tooling 020363Y 20 mm guide 020376Y Adaptor handle 020358Y 37x40 mm adaptor Removing the driven pulley shaft bearing Remove the seeger ring inside the cover Remove the oil seal from the outside Remove the centring dowels and position the cover on a plane Position the special tool on the intern
47. e throttle open being careful to keep the cap in contact with the TROUBL 39 Troubleshooting Vespa S 50 2T Possible Cause Operation spark plug and the spark plug grounded but away from its hole Refit a dry spark plug and start the vehicle Altered fuel characteristics Drain off the fuel no longer up to standard then refill Faulty spark plug Remove the encrustation restore the plug gap or replace being sure to use the types of spark plug recommended at all times Bear in mind that many problems engines have derive from the use of the wrong spark plug Intake joint cracked or with a bad seal Replace intake joint and check for correct sealing on the head Purifier carburettor fitting damaged Replace Excessive oil consumption Exhaust smoke EXCESSIVE OIL CONSUMPTION SMOKEY EXHAUST Possible Cause Operation Excess of encrustations in the combustion chamber Remove the encrustations Engine tends to cut off at full throttle ENGINE STOP FULL THROTTLE Possible Cause Operation Maximum nozzle dirty lean mixture Wash the nozzle with solvent and dry with compressed air Dirty carburettor Wash the carburettor with solvent and dry with compressed air Water in the carburettor Empty the tank through the appropriate bleed nipple Air filter dirty Clean or replace Defective floating valve Check the proper sliding of the float and the functioning of the valve Tank breather hole obstructed Restore the proper tank aeration Engine tends to cut o
48. e steel tab is not de formed and or does not guarantee correct tight ness at its fitting replace if necessary N B UPON REFITTING MAKE SURE TO CORRECTLY FIT THE TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI NIUM COVERS CAUTION WHILE CARRYING OUT OPERATION 3 ALWAYS CHECK THE TWO RUBBER COUPLINGS 3 ON ONE END OF THE SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND CONTINUITY IF NECESSARY REPLACE THEM AND USE NEW CLAMPS TO FIX THEM Carburettor 50cc Version Dell Orto DELLORTO CARBURETTOR Specification Desc Quantity Type PHVA 17 5 RD Diffuser diameter 017 5 Regulation reference number 8423 Maximum nozzle 53 Maximum air nozzle on the body 1 5 Tapered pin stamped code A22 Pin position notches from above 1 Diffuser 209 HA CHAR 11 Characteristics Specification Minimum nozzle Minimum air nozzle on the body Initial minimum mix screw opening Starter jet Starter air nozzle on the body Stroke of starter pin Gasoline inlet hole Tightening Torques FRONT BRAKE Name Brake fluid pump hose fitting Brake fluid pipe calliper fitting ocrew tightening calliper to the support Brake disc screws Circuit bleed calliper fitting Handlebar pump FRONT SUSPENSION Name Upper shock absorber fixing nut Front wheel axle nut Shock absorber upper bracket bolts Wheel rim screws Lower shock absorber clamping screw STEERING ASSEMBLY Name oteering upper ring nut Steering lower ring nut H
49. e 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 Vehicle identification Chassis prefix ZAPC38103 Engine prefix C381M Dimensions and mass n X 5 E BE i zm t E TE Ez ILI 5 2 AE e ii CHAR 8 Vespa S 50 2T 1140 Vespa S 50 2T Characteristics WEIGHTS AND DIMENSIONS Specification Kerb weight Maximum weight allowed Maximum height Width Wheelbase Length Engine Specification Type Cubic capacity Bore x stroke Compression ratio Engine idle speed Timing system Valve clearance Max Power MAX torque LUBRICATION Lubrication pressure Minimum lubrication pressure 100 C Fuel supply Cooling Fuel Exhaust muffler Emissions Transmission Specification Transmission Final reduction Capacities CAPACITY Specification Cooling system fluid Tran
50. ers slightly hitting them with the mallet BEFORE PROCEEDING WITH THE DESCRIBED FITTING PLACE THE TWO DUST GUARD RINGS ON THE SWING ING HUB AS SHOWN IN THE FIGURE Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum disul phide ISO L XBCHB2 DIN KF2K 20 Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time Remove the tool and the part 5 guide which has been partially ejected during the previous pin fitting phase and leave part 4 always fitted Replace part 3 with part 16 on the stem By moving the tool handgrip push the wedging washer roller bushing seal ring unit placing part Le 16 until it stops on the swinging hub SUSP 103 Suspensions Vespa 5 50 2T Repeat the above operation using the tool with part 16 and part 22 instead of part 4 always fitted to the stem on the side opposite that indicated in the figure to fit the second wedging washer roller bushing sealing ring unit WARNING BEFORE PROCEEDING WITH THE DESCRIBED PRE FIT TING DIP THE SEALING RINGS IN MINERAL OIL AND THE NADELLA ROLLER BUSHINGS PREVIOUSLY WASHED IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMI NATE THE ANTIRUST PROTECTION HALF FILLED WITH GREASE Specific tooling 020021Y Front suspension service tool Recommended products
51. ertheless 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 gt 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 CHAR O L gt JJ P m 20 o o TOOLING TOOL MAIN gt Z m lt gt Z m TROUBL TROUBLESHOOTING ELE SYS ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENG SUSP BRAK SYS BRAKING SYSTEM CHAS PRE DELIVERY PRE DE I gt Co o TIME TIME INDEX OF TOPICS Characteristics CHAR Vespa S 50 2T Characteristics Rules This section describes general safety rules for any maintenance operations
52. ff at idle ENGINE STOP IDLING Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Starter that stays open Check electric wiring circuit continuity mechanical sliding and power supply Reed valve does not close Check replace the reed pack Wrong idling adjustment Adequately adjust the engine idle speed Spark plug defective or faulty Replace the spark plug with one with the specified degree and check the plug gap Excessive exhaust noise INCREASED NOISINESS Possible Cause Operation Secondary metal air pipe deteriorated Check there are no leaks on the hoses on the crankcase and the housing check that there is a cap with filter and itis correctly fitted to the transmission cover Good condition of the missing secondary air circuit components Check the individual components and the piping check the precision of the fitting Replace the damaged components TROUBL 40 Vespa S 50 2T Troubleshooting High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty Clean according to the procedure Starter inefficient Check electric wiring circuit continuity mechanical sliding and power supply SAS malfunctions SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF FLER Possible Cause Operation Secondary air reed blocking Replace Secondary air filter clogging Clean the filter and the housing Blockage of the secondary air fittin
53. fit the tab in the housing on the two plastic and aluminium covers Every time you disassemble the filter replace the O ring seal located in the cover MAIN 37 INDEX OF TOPICS TROUBLESHOOTING TROUBL Vespa S 50 2T Troubleshooting This section makes it possible to find the solutions to use in troubleshooting For each breakdown a list of the possible causes and respective interventions is given Engine Poor performance PooR PERFORMANCE Possible Cause Fuel nozzles or cock clogged or dirty Excess of encrustations in the combustion chamber Lack of compression wear of the piston rings or cylinder Exhaust pipe clogged due to excessive encrustations Air filter blocked or dirty Starter inefficient stays on Clutch slipping Defective mobile pulley sliding Transmission belt worn Carburettor nozzles clogged Fuel filter on vacuum operated cock blocked Roller wear Presence of oil Dirt Rear wheel spins at idle Operation Dismantle wash with solvent and dry with compressed air Remove the encrustations Check the worn parts and replace them Replace the exhaust pipe and check the carburation and mixer timer Clean according to the procedure Check the mechanical sliding continuity of the circuit the pres ence of power and electrical wiring Check the centrifugal brake shoe assembly and or clutch bell and replace if necessary Check all the parts replace the faulty parts and lubricate only the driven pulley
54. fuel outlet pipe By means of the MITIVAC pump apply 0 1 bar of suction to the tap Make sure that the suction is kept stable and that and that there are no fuel leaks Reconnect the suction pipe to the manifold Position the fuel pipe with the outlet at the point of the tap Turn the engine by using the starter for five sec onds with the carburettor at minimum Take up the fuel by means of a graded burette N B THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE IN THIS CASE THE TENDENCY IS TO OB TAIN A REDUCED FUEL FLOW RATE THE SUCTION OUT LET ON THEMANIFOLD HAS A SECTION INTENTIONALL Y REDUCED FOR THE PURPOSE OF ENHANCING THE SUC TION PULSATION AND THEREBY GUARANTEE A CON STANT TAP FLOW RATE Specific tooling 020329Y MityVac vacuum operated pump Characteristic Minimum flow rate 20 cc ENG 96 INDEX OF TOPICS Suspensions Vespa S 50 2T This section is devoted to operations that can be carried out on the suspension Front Removing the front wheel Support the scooter adequately Loosen the five screws fixing the wheel to the hub Front wheel hub overhaul Support the scooter adequately Remove the front wheel Remove the front calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub SUSP 98 Vespa S 50 2T Suspensions Remove the wheel hub Re
55. g Slide off the pads and replace them once the plungers are down Carry out these operations in reverse order to fit CAUTION BEFORE USING THE BRAKE OPERATE THE LEVER A FEW TIMES Refitting Insert the brake pads Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo Insert the lock on the bolt and then the protection A cover Fill BRAK SYS 121 Braking system Vespa S 50 2T Front Remove the rubber cap from the bleed screw Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered With the right hand brake lever load the system and bring it up to the required pressure Keeping the right hand brake lever pulled loosen the bleed screw to purge the air Then tighten the bleed screw Release the brake lever 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 PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE 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 MAK
56. g arm plate to chassis screw 33 41 Shock absorbers Removal Adequately support the rear part of the scooter Remove the battery cover Undo the indicated upper fixing screw to the frame Unscrew the lower fixing pin to the transmission crankcase SUSP 115 Suspensions Refitting Vespa S 50 2T To fit follow the removal steps but in reverse order be careful to tighten to the prescribed torques Locking torques N m Shock absorber engine pin torque 33 to 41 Shock absorber frame nut torque 20 to 25 Nm Centre stand Replace complete stand Work on the screws shown in the figure When refitting secure to the prescribed torque Locking torques N m Stand screw torque 18 5 to 19 Nm Side stand REMOVAL Uncouple the centre stand return spring Hemove the screw shown in the photograph FITTING To refit carry out the removal operations in re verse order and comply with the specified torque Locking torques N m Side stand fixing bolt 35 40 SUSP 116 A EU 1 1 1 1 1 L JE hi p m rT x ral den da ase de i a a 1 amem 3 T vor m T ES 2 Xu o 4 ho L 2 ae Y INDEX OF TOPICS Brana SYSTEM BRAK SYS Braking system Front brake calliper Removal Remove the front wheel Undo
57. g on the muffler Remove the encrustations from the joint being careful not to let the debris fall into the muffler Transmission and brakes Clutch grabbing or performing inadequately CLUTCH BRAKES Possible Cause Operation Slippage or irregular functioning Check that the masses open and return normally Check that there is no grease on the masses Check that the clutch masses contact surface with the clutch bell is mainly in the middle with characteristics equivalent on the three masses Check that the clutch bell is not scored or worn abnormally Never operate the engine without the clutch bell Check the cap with filter is fitted to the transmission cover Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause Operation Poor braking The rear drum type brake is adjusted by regulating the special adjustment on the wheel bearing in mind that with the control levers in the rest position the wheels must turn freely The braking action should begin when the brake levers are pressed by about a third Check the brake pad wear If itis not possible to remove any problems by simply adjusting the transmissions check the brake pads and front brake disc the brake shoes and the rear drum If you encounter excessive wear or scoring make the necessary replacements Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Fluid leakage in
58. hat exceeds the re quirements of API specifications Oil for 2 stroke engines SAE 5W 40 API SL ACEA A3 JASO MA Mineral oil with specific additives for in creased adhesiveness synthetic oil for 2 stroke engines JASO FC ISO L EGD FMVSS DOT 4 Synthetic fluid Grease with molybdenum disulphide White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Lithium grease with NLGI 2 molybdenum disulphide ISO L XBCHB2 DIN KF2K 20 White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 UNIT OF MEASUREMENT CONVERSION ENGLISH SYSTEM AND INTERNATIONAL SYSTEM IS Specification 1 Inch in 1 Foot ft 1 Mile mi 1 US Gallon US gal 1 Pound Ib 1 Cubic inch in3 1 Foot pound ft Ib 1 Miles per hour mi h 1 Pound per square inch PSI 1 Fahrenheit F Desc Quantity 25 4 Millimetres mm 0 305 Meter m 1 609 Kilometre km 3 785 Litre 1 0 454 Kilogram Kg 16 4 Cubic centimetres cm 1 856 Newton meter Nm 1 602 Kilometres per hour km h 0 069 bar 32 9 5 Celsius C CHAR 15 INDEX OF TOPICS TOOL Vespa S 50 2T Stores code 001330Y 001467Y006 001467Y009 001467Y013 001467Y014 001467Y017 002465Y Tooling TOOLS Description Tool for fitting steering seats Ce lt gt Pliers to extract 20 mm bearings Driver for OD 42 mm bearings Pliers to extract
59. heck that the rollers do not show signs of marked facetting on the sliding surface and that quo ER GEN MM y A ENG 75 Engine Vespa S 50 2T the metallic insert does not come out of the plastic shell borders 4 Check the integrity of the sliding blocks of the contact plate Check that the internal bushing shown in the fig ure is not abnormally worn and measure inside diameter A Measure outside diameter B of the pulley slid ing bushing shown in the figure CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING Characteristic Driving pulley Maximum diameter 20 12 mm Driving pulley Standard diameter 20 021 mm Driving pulley bushing Diameter maximum XXX mm Driving pulley bushing Standard diameter 20 0 020 0 041mm Refitting the driving pulley Manually move the movable driven half pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting N B IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE ENG 76 Vespa S 50 2T Engine Refit the particular components of the assembly roller container assembly with bushing limiting washer stationery half pulley cooling fan belt with drive washer and nut With the specific tool tighten the lock nut to the prescribed torque and then perform a final 90 lock in order to prevent the rotation of the
60. htening of the top and bottom ring nuts If irregularities continue in turning the steering even after mak ing the above adjustments check the seats in which the ball bearings rotate replace if they are recessed Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts If irregularities continue in turning the steering even after mak ing the above adjustments check the seats in which the ball bearings rotate replace if they are recessed Noisy suspension NOISY SUSPENSION Possible Cause Operation NOISY SUSPENSION If the front suspension is noisy check the efficiency of the front shock absorbers the condition of the ball bearings and relevant TROUBL 42 Vespa S 50 2T Troubleshooting Possible Cause Operation lock nuts the limit switch rubber buffers and the movement bushings Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Service the pumping members and check the sleeves and sealing rings are in good conditions Replace the damaged parts TROUBL 43 INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Vespa S 50 2T Electrical system I zd o 00 KEY Electronic ignition device Magneto flywheel Pick up Key switch Voltage regulator 5A Fuse 12V 9Ah Battery Starter motor Start up remo
61. istilled water to restore this level If itis necessary to add water too frequently check the vehicle s electrical system the battery works overcharged and is subject to quick wear 2 Load status check After restoring the electrolyte level check its den sity using an appropriate densitometer see the figure When the battery is charged you should detect a density of 30 to 32 B corresponding to a specific weight of 1 26 to 1 28 at a temperature of no lower than 15 C A density reading of less than 20 B indicates that the battery is completely flat and it must therefore be recharged After charging the battery check each element electrolyte level and density If the scooter is not used for a given time 1 month or more it will be necessary to periodically recharge the battery The battery runs down completely in the course of three months ELE SYS 59 Electrical system If it is necessary to refit the battery in the vehicle be careful not to reverse the connections remem bering that the earth wire black marked must be connected to the negative terminal while the other two red wires marked must be connected to the terminal marked with the positive sign Regular bench charging must be carried out with the specific battery charger single or multiple setting the battery charger selector to the type of battery to be recharged Connections to the power supply source must be implemented by conne
62. it the ball bearing retention snap ring Fit the new roller bearing with the wording visible from the outside CAUTION PROPERLY SUPPORT THE HALF PULLEY TO PREVENT DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller case Inspecting the clutch spring Check that the contrast spring of the driven pulley does not show signs of deformation Measure the free length of the spring Characteristic Standard length 118 mm Minimum length allowed after use XXXX Refitting the clutch Preassemble the driven pulley group with spring sheath and clutch Position the spring with the sheath Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar ENG 73 Engine Vespa S 50 2T 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 NUT IN CONTACT WITH THE CLUTCH Locking torques N m Clutch lock ring nut 55 60 Refitting the driven pulley Refit the driven pulley assembly the clutch bell and the nut using the specific tool Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Clutch bell
63. ith throttle control untwisted adjust the reference mark on the rotating plate so that it is lined up with the reference mark on the mixer body as shown in the figure While doing this the engine must be fuelled with a 2 96 oil mixture 0 5 litre minimum if the reservoir is empty CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS RE FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF UNDO THE MIXER PIPE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREWS SEE THE ARROW IN THE FIGURE UNTIL THE OIL BEGINS TO FLOW OUT TIGHTEN THE SCREWS START UP THE ENGINE AND WAIT FOR OIL TO FLOW OUT OF THE TUBE RECONNECT THE DELIVERY PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH THE RELEVANT METAL CLIP Recommended products AGIP CITY TEC 2T Mixer oil synthetic oil for 2 stroke engines JASO FC ISO L EGD Braking system MAIN 34 Vespa 5 50 2T Level check Rest the vehicle on its centre stand on flat ground The brake fluid reservoir has a sight glass A made of transparent material the quantity of liquid contained in the sight glass indicates the level of fluid in the reservoir When the sight glass A is full the level inside the reservoir is above the MIN level when it is par tially full the level has dropped to the MIN level when it is fully empty the level of fluid in the res ervoir is below the MIN level N B THE
64. l adequately use a metal plate with M8 threaded hole and fix it to one of the two front brake calliper attachment points Place the dial gauge on the disk outer edge Make the wheel hub turn and check the disk de viation Specific tooling 020335Y Magnetic support for dial gauge BRAK SYS 119 Braking system Vespa S 50 2T Characteristic Minimum thickness allowed after use 4 mm Disc thickness at wear limit front 3 5 mm Max deviation allowed 0 1 mm f a value other than that prescribed is detected replace the disc and check again If the problem persists check and replace the wheel hub if required Front brake pads Removal Proceed as follows Remove the front calliper Remove the cotter pin and slide off the pin that locks the two pads Remove the pads being careful with the pad spring clamp Check the thickness of the friction material of the pads Replace the pads if the thickness is below the minimum value he replacement must be made with greater re sidual thickness if the pad has not worn evenly A 0 5 mm thickness difference in the residual friction material is permitted Characteristic Minimum value 1 5 mm See also Front brake calliper BRAK SYS 120 Vespa S 50 2T Braking system Pads must be replaced when the friction material thickness reaches the wear limit To replace remove the protection cover the bolt and the leaf sprin
65. l 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 Abnormal noise PRE DE 138 Vespa S 50 2T Pre delivery Static test otatic control after the test ride Starting when warm Starter operation Minimum hold turning the handlebar Uniform turning of the steering Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the frame and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors and any accessories PRE DE 139 INDEX OF TOPICS Time TIME Vespa S 50 2T Time Engine ENGINE Code Action Duration 1 001001 engine from frame removal fitting TIME 141 Time Vespa S 50 2T Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement TIME 142 Vespa S 50 2T Crankshaft Code 001118 001100 001099 001117 CRANKSHAFT Action Main beari
66. l pipe joint from the pump Remove the connector to the stop light switch 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 BRAK SYS 123 Braking system Vespa S 50 2T CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED 1 Reservoir cap screw Reservoir cap Diaphragm Bellows Sealing ring Piston Gasket Spring D Reservoir Refitting To refit carry out the removal operations but in reverse order observing the specified torques N B USE NEW COPPER GASKETS ON THE JOINTS CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM Locking torques N m Oil pipe joint to the pump 20 25 Brake pump fixing screws to the handle bar 7 10 Nm Pipe brake calliper coupling 20 25 BRAK SYS 124 Vespa S 50 2T Braking system Rear drum brake Once the muffler and the wheel have been re moved follow these steps Remove the shoe spring using the specific pliers Remove the shoes with the help of a lever Refit the new shoes with a few taps with the mal let Attach the sp
67. lve spring 5 Throttle valve tapered pin 6 Throttle valve 7 Carburettor body 8 Pin 9 Min jet 10 Float 11 Max jet 12 Float chamber MAIN 30 Vespa 5 50 2T Maintenance Checking the spark advance Check to be made at over 4000 rpm with strobo scopic gun The advanced ignition measured must 17 before the TDC This value is correct when the reference mark on the flywheel hood is aligned with the reference mark on the cooling fan and the phase shifter on the stroboscopic gun is set on 17 N B IN CASE OF MALFUNCTION CARRY OUT THE CHECKS PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER CAUTION BEFORE CARRYING OUT THE ABOVE CHECKS CHECK THE CORRECT KEYING OF THE FLYWHEEL ON THE CRANKSHAFT Specific tooling 020330Y Stroboscopic light to check timing Spark plug Place the vehicle on its central stand Remove the central cover indicated in the figure by undoing the 2 fixing screws 4 Disconnect the spark plug HV wire 0 6 0 7 mm LL s E i warp rpg 50 F F Undo the spark plug using the socket wrench 4 d Examine the condition of the spark plug check that the insulating material is whole and measure the distance between the electrodes using a thick Peru ness gauge Adjust the distance if necessary by bending the side electrode very carefully In the case of defects replace the spark plug with one of the specified
68. move the ball bearing check seeger ring indi cated in the photograph Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract 15 mm bearings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver SUSP 99 Suspensions Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20 mm guide Heat the roller bearing seat with a heat gun Use the specific tool to introduce and push the bearing until it stops with the shielded side facing out Refit the ball bearing check seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020357Y 32 x 35 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 DIN K3K 20 Vespa 5 50 2T m To refit follow the removal steps but in reverse order be careful to tighten to the prescribed torque Locking torques N m Front wheel axle nut 75 90 SUSP 100 Vespa S 50 2T Suspensions Refitting the front wheel When
69. nce is cancelled out Specific tooling 020163Y Crankcase splitting plate ENG 92 Vespa S 50 2T Vespa S 50 2T Engine Refitting the crankcase halves Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur face using a suitable solvent e g trichloroethy lene Heat the flywheel side half crankcase with a ther mal gun Recommended products Loctite 510 Liquid sealant Gasket Keeping the half crankcase on the transmission side insert the flywheel side half crankcase with a clean precise movement Insert at least three clamping screws and tighten rapidly Insert the other 5 screws and tighten them to the Specified torque Locking torques N m Half crank case joint bolts 12 13 Move the crankcase separation plate in a position back from the one indicated in the figure Install the special magnetic support with dial gauge at the end of the crankshaft Check the axial clearance of the crankcase If this is not within the maximum limit allowed re peat the crankcase coupling procedure Specific tooling 020335Y Magnetic support for dial gauge Characteristic Axial clearance with warm crankcase 0 10 0 12 mm Axial clearance with cold crankcase 0 06 to 0 08 mm Limit value with cold crankcase 0 02 0 03 mm ENG 93 Engine Vespa S 50 2T Lubrication Crankshaft oil seals Refitting Install a new flywheel side oil seal o
70. nd wear check Vehicle and brake test road test AFTER 5 000 KM 25 000 KM 35 000 KM AND 55 000 KM 40 Action Hub oil check Spark plug electrode gap replacement Air filter clean Oil mixer throttle linkage adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AFTER 10 000 50 000 KM 95 Action Hub oil change Spark plug replacement Air filter clean ldling speed adjustment Oil mixer throttle linkage adjustment Variable speed rollers replacement Odometer gear greasing Driving belt checking Steering Check Brake control levers greasing Brake pads check condition and wear Brake fluid check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Vehicle and brake test road test See the Idle speed adjustment section MAIN 28 Vespa S 50 2T Maintenance AFTER 15 000 KM AND 45 000 KM Action Hub oil check Spark plug replacement Air filter cleaning Oil mixer throttle linkage adjustment Driving belt replacement Brake control levers greasing Brake pads check condition and wear Brake fluid check Electrical system and battery check Tyre pressure and wear check Seco
71. ndary air filter cleaning Vehicle and brake test road test AFTER 20 000 KM 40 000 Action Hub oil change Spark plug replacement Air filter clean Idling speed adjustment Cylinder cooling system check cleaning Oil mixer throttle linkage adjustment Driving belt checking Variable speed rollers replacement Mixer belt replacement Odometer gear greasing Steering Check Brake control levers greasing Brake pads check condition and wear Brake fluid check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Vehicle and brake test road test See the Idle speed adjustment section AFTER 30 000 KM Action Hub oil change Spark plug replacement Air filter clean Idling speed adjustment Oil mixer throttle linkage adjustment Driving belt replacement Variable speed rollers replacement Odometer gear greasing Steering Check Brake control levers greasing Brake pads check condition and wear Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Secondary air filter cleaning Vehicle and brake test road test See the Idle speed adjustment section MAIN 29 Mainten
72. ngs Replacement Oil seal clutch side Replacement Oil seal flywheel side Replacement Crankshaft Replacement Duration Time TIME 143 Time Vespa S 50 2T Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Inspection clean ing TIME 144 Vespa S 50 2T Cylinder head assy GO Po Code 001097 001093 001126 001013 001178 Action Cooling hood Replacement Spark plug Replacement Head Replacement Intake manifold Replacement Disc pack Replacement Duration Time TIME 145 Driven pulley Vespa S 50 2T 146 Code 001012 001110 001022 001155 DRIVEN PULLEY CLUTCH Action Driven pulley Service Driven pulley Replacement Clutch Replacement Clutch bell housing Replacement Duration Vespa S 50 2T Time Oil pump OIL PUMP Code Action Duration 1 001028 Mix movement gear socket Re placement 2 001019 Mixer belt replacement 3 001018 Mixer Replacement TIME 147 Final gear assy Vespa S 50 2T TIME 148 Code 001010 001156 003065 004125 FINAL REDUCTION GEAR Action Duration Geared reduction unit Service Gear reduction unit cover Replace ment Gear box oil Replacement Rear wheel axle Replacement Vespa S 50 2T Time Driving pulley DRIVING PULLEY Code Action Duration 1 00106
73. nly with the special tool s punch The flywheel side oil seal is recognised by its smaller diameter N B THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Install a new transmission side oil seal using the special tool with adapter ring The transmission side oil seal is recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump Removal Remove the 2 screws shown in the figure ENG 94 Vespa S 50 2T Engine Remove the tube passage seal from the crank case shown in the figure Refitting To refit perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure Fuel supply Completely empty the gas tank Remove the petrol delivery tube and the suction tube Loosen the clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent Refit the tap making sure that there is an O Ring Turn the tap to the direction it had before it was removed and block the clip N B THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING ENG 95 Vespa S 50 2T Disconnect the fuel supply and the suction taking pipe from the carburettor Check that there are no fuel leaks between the two tubes Close the
74. 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 th
75. products AGIP GREASE MUS Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L DIN K3K 20 Remove the seeger ring located on the exterior IS rj X of the crankshaft Dismantle the dog gear from its seat slackening the tension that the toothed sector applies to it by means of the spring to do this it is necessary to rotate the toothed sector slightly see the figure CAUTION Engine Vespa S 50 2T WHILE REMOVING THE TOOTHED SECTOR BE VERY CAREFUL OF THE SPRING TENSION IT COULD CONSTI TUTE A HAZARD FOR THE OPERATOR Remove the screws shown in the figure and re move the engine starting lever For the assembly work in reverse and tighten the screws to the prescribed torque Locking torques N m Starter lever fixing screw 12 13 Removing the driven pulley shaft bearing Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the P driven pulley shaft or a pin of the same diameter to remove the bearing N B IN CASE OF DIFFICULTY A STANDARD 8MM INSIDE DI AMETER EXTRACTOR CAN BE USED Refitting the driven pulley shaft bearing Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside N B WHEN REFITTING ALWAYS REPLACE THE BEARING WITH A NEW ONE CAUTION WHEN REMOVING REFITTIN
76. rankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners x p Me y SR i d ENG 89 Engine Vespa S 50 2T Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length Remove the crankshaft from the transmission side half crankcase Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft bearings The bearings can stay on either the half crankcase or the crankshaft indifferently Using the special tool remove any bearings that have been left on the crankshaft N B The half rings must be inserted on the bearings with a few mal let blows Specific tooling 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings ENG 90 Vespa S 50 2T Engine Using the specific tool remove any bearings left on the half crankcase Specific tooling 001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings Refitting the crankshaft bearings Heat the bearings in an oil bath at around 150 C and fit them on the crankshaft if necessary using a section of tube that
77. refitting tighten the 5 screws to the speci fied torque Locking torques N m Wheel rim screws 20 25 Handlebar Removal Remove the handlebar cover before carrying out this operation After removing the transmissions and discon necting the electrical terminals remove the termi nal fixing the handlebar to the steering Check all components and replace faulty parts N B IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting Carry out the removal operations but in the reverse order observing the prescribed tightening torque Locking torques N m Handlebar fixing screw 50 55 Steering column SUSP 101 Suspensions Vespa 5 50 2T Removal After removing the upper seat lean the vehicle on one side and extract the steering tube completely from the fork Specific tooling 020055Y Wrench for steering tube ring nut Overhaul Servicing the front suspension steering assembly described below deals mainly with replacing parts pin NADELLA roller bushings sealing rings unit and dust guard which connect the steering tube to the front wheel holder swinging hub N B BEFORE PROCEEDING WITH THE DESCRIBED SERVICE CHECK THAT THE STEERING TUBE AND THE WHEEL HOLDER HUB ARE IN EXCELLENT CONDITIONS ONLY THEN IS THE SERVICE JUSTIFIABLE MOREOVER REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE WHEN DEFO
78. ring using the specific spanner CAUTION REPLACE THE SHOES BEFORE THE FRICTION MATERI AL IS FULLY WORN Specific tooling 020325Y Brake shoe spring calliper BRAK SYS 125 INDEX OF TOPICS Cassis CHAS Vespa S 50 2T Chassis Seat Lift the saddle and remove the helmet compart ment A Undo the two screws indicated Rear handlebar cover Remove the front handlebar cover Undo the three screws indicated in figure fixing it to the handlebar the odometer transmission and the electrical connectors CHAS 127 Chassis Instrument panel Remove the rear handlebar cover Undo the three screws indicated fixing the rear handlebar cover Front handlebar cover Proceed as follows Remove the rear view mirrors Undo the two screws A Undo the screw B and remove the front han dlebar cover Disconnect the electrical terminals and remove the turn indicator bulb CHAS 128 Vespa S 50 2T Vespa S 50 2T Chassis Headlight assy Remove the front handlebar cover Undo the four screws indicated fixing the front handlebar cover Knee guard Undo the five screws indicated Remove the rubber strip from both sides and un do the indicated screw Remove the shield back plate bringing it to the rear part of the scooter CHAS 129 Chassis Vespa S 50 2T Taillight assy Undo the two fixing screws and remove the rear
79. ront headlamp Replacement Front turn indicator Replacement Front turn indicator bulb Replace ment Front headlamp bulbs Replacement Taillight Replacement Rear light bulbs Replacement Hear turn indicators Replacement Rear turn indicator bulb Replace ment Vespa S 50 2T Duration Vespa S 50 2T Time Front wheel Qu 5 E 2 p An D 1 yy iF i T A 7 HE T 1 n E p si 4 i 4 it i ng x d il E Be i i p e ri 6 0 1 A L i i l si CY a Er n AP a a FRONT WHEEL Code Action Duration 1 004123 Front wheel Replacement 2 003047 Front tyre replace 3 003037 Front wheel rim Replacement 4 003033 Front wheel hub Replacement 5 002041 Front brake disc Replacement 6 003034 Front wheel hub bearing Replace ment TIME 171 Time Vespa S 50 2T Rear wheel o d Te em 3 I 3 i REAR WHEEL Code Action Duration 1 004126 Rear wheel tyre Replacement 2 001071 Rear wheel rim Removal and Refit ting 3 001016 Rear wheel Replacement TIME 172 Vespa S 50 2T Electric devices Co J O O1 Code 005001 00501 1 005009 005007 005052 001023 001094 005054 ELECTRICAL COMPONENTS Action Duration Electrical system Replacement Start up remote control switch Re pl
80. ry charger single or multiple at a density of about 1 10 of the battery nominal capacity and until the acid density is about 1 27 corre sponding to 31 B and these values are stabilised 4 Once the charge is over level the acid by adding distilled water Close and clean carefully 5 Once the above operations have been performed install the battery in the vehicle ensuring the connections between the wiring and the battery terminals are correct WARNING ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE WITH CLOSED END NEAR THE POSITIVE TERMINAL WITH THE CORRE SPONDING LONG TUBE WITH OPEN END THAT YOU FIND FITTED TO THE VEHICLE TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Connectors HEATER CONTROL DEVICE CONNECTOR 1 Positive from voltage regulator Yellow 2 Ground Black 3 Heater Sky Blue 4 Heater Orange Black 5 Not connected 6 Positive from the voltage regulator Yellow Black VOLTAGE REGULATOR CONNECTOR 1 Lights power instrument panel lighting heater 8 control device and automatic starter Yellow Black 2 Magneto flywheel Grey Blue 3 Not connected 4 Oil reserve indicator power Orange 5 Oil reserve indicator power start up circuit and heater control device Yellow Red 6 Ground Black T Turn indicator switch power
81. s on the regulator and the corresponding system it is always good practice to check that there is continuity between the black cable and the earthing ELE SYS 55 Electrical system Vespa S 50 2T FAULT 5 FIG E If the turn indicators do not work proceed as follows Remove the regulator connector and insert the TT 123343567 8 tester probes between the contact 5 yellow red and the ground lead Turn the key switch to ON and check that the battery is getting voltage If no voltage is detected check the wiring and the contacts on the key switch and on the battery FIG F Repeat the procedure now placing the F tester probes between contacts 5 yellow red and 6 black and check the presence of the battery voltage with the key switch set to ON If there is no TT ea voltage check the regulator ground wiring FIG If the above tests have positive results G jump the contacts 5 yellow red and 7 blue black on the connector set the key switch to ON and a am UP P P P ua on shift the turn indicator switch to the right and left to see when the lights are steadily on as they are LES powered directly from the battery If even after this operation the turn indicators fail to turn on check that the wiring is not damaged and the switch works properly If these last two tests have a pos itive result replace the regulator because it is cer t
82. smission oil Fuel tank reserve Mixer oil reservoir reserve Electrical system ELECTRICAL SYSTEM Specification Start up ENGINE Desc Quantity 96 4kg 290 kg 1 140 mm 740 mm 1 290 mm 1 755 mm Desc Quantity single cylinder two stroke 49 cm 40 X 39 3 mm 9 9 0 5 1 1 800 100 rom 3 2 kW at 7 500 rom 4 4 Nm at 6 500 rom Engine lubrication carried out by fuel mixture oil Carburettor DELL ORTO PHVA 17 5 RD Forced air circulation cooling Unleaded petrol 95 RON absorption type exhaust muffler with catalytic converter TRANSMISSION EURO 2 Desc Quantity Automatic expandable pulley variator with torque server V belt automatic centrifugal dry clutch Gear reduction unit in oil bath Desc Quantity 80 cm3 8 51 21 1 51 0 5 1 Desc Quantity Electrical and kick start CHAR 9 Characteristics Vespa S 50 2T Specification Desc Quantity Ignition Capacitive discharge ignition with variable advance and sep arate HV coil Ignition advance 17 at 4 000 rpm Spark plug CHAMPION RN3C Alternative spark plug E Battery 12V 9 Ah Generator Frame and suspensions FRAME AND SUSPENSIONS Specification Desc Quantity Frame otamped plate body with welded structural reinforcements FRONT SUSPENSION Single arm with helicoidal spring and single double acting hy draulic shock absorber Front suspension travel 70 3 mm Hear suspension Double acting shock absorber adjustable to four positions at
83. spa S 50 2T Vespa 5 50 2T Stores code 020021Y 020038Y 020074Y 004499Y001 004499Y006 Description Front suspension service tool Punch Support base for checking crankshaft alignment Bearing extractor bell Bearing extractor ring Tooling TOOL 23 Tooling Stores code 004499Y002 004499Y007 020171Y 020340Y 020360Y 020358Y 020362Y TOOL 24 Vespa S 50 2T Description Bearing extractor screw Half rings Punch for driven pulley roller bearing Flywheel and transmission oil seals fitting punch Adaptor 52 x 55 mm 37x40 mm adaptor 12 mm guide Vespa 5 50 2T Stores code 020363Y 020365Y 020439Y 020441Y 020452Y Description 20 mm guide 22 mm guide 17 mm guide 26 x 28 mm adaptor Tube for removing and refitting the driven pulley shaft Tooling TOOL 25 Tooling TOOL 26 Stores code 020451Y 020444Y Vespa S 50 2T Description Starting ring gear lock Tool for fitting removing the driven pulley clutch INDEX OF TOPICS Maintenance Vespa 5 50 2T Maintenance chart EVERY 2 YEARS Action Brake fluid change AFTER 1 000 KM 50 Action Hub oil change Oil mixer throttle linkage adjustment Odometer gear greasing Steering Check Brake control levers greasing Brake fluid level check Safety locks check Electrical system and battery check Tyre pressure a
84. tank Front mudguard First remove the steering tube and uncouple the front brake pipes from the calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Front central cover Remove the Piaggio clip on badge CHAS 134 Vespa S 50 2T Chassis Undo the two screws indicated Remove the front central cover sliding it up wards CHAS 135 INDEX OF TOPICS Vespa S 50 2T Aesthetic inspection Appearance check Paintwork Fitting of plastics Scratches Dirt Tightening torques inspection Lock check Safety locks Fixing screws Safety locks Rear shock absorber upper retainer Rear shock absorber lower retainer Front rear wheel screws Front wheel axle nut Rear wheel axle nut Swinging arm Chassis bolt Swinging arm Engine bolt Engine arm Frame arm bolt Handlebar lock nut Steering lower ring nut Steering upper ring nut Electrical system Electrical System Main switch Headlamps high beam lights low beam lights tail lights and their warning lights Adjusting the headlights according to the regulations currently in force Rear lights and stop light Front and rear stop light switches Turn indicators and their warning lights Instrument lighting Instrument panel fuel gauge Instrument panel warning lights Horn Pre delivery PRE DE 137
85. te control switch ON O C FP Horn button Horn L ES Starter button N Stop button on rear brake Stop button on front brake I Turn indicator switch Light switch o Rear left turn indicator N Rear light Rear right turn indicator Front left turn indicator ELE SYS 45 Electrical system Vespa 5 50 2T 20 Front light A Tail light bulb B High low beam light bulb 21 Front right turn indicator 22 Fuel level transmitter 23 Instrument panel A Turn indicator warning light B Headlight warning light C Instrument panel lighting bulbs D Fuel gauge E Low fuel warning light F Oil warning light G High beam warning light 24 Automatic starter 25 Heater 26 Heater control device 27 0il reserve warning light 28 Spark plug R Red B White BI Blue N Black V Green Rs Pink Mr Brown Gr Grey Az Sky Blue Yellow Vi Purple A Orange ELE SYS 46 Vespa S 50 2T Electrical system Components arrangement 200405 1 2 5 6 7 8 24 25 28 Electronic ignition device Magneto flywheel Pick Up 7 5A Fuse 12V 9Ah Battery Starter motor Start up remote control Automatic starter Heater Spark plug 3 4 10 26 Key switch Voltage regulator Horn Heater control device ELE SYS 47 Electrical system Vespa S 50 2T Concep
86. torques N m Lower shock absorber clamping screw 20 27 SUSP 107 Suspensions Vespa S 50 2T Overhaul The bracket for the shock absorber calliper at tachment has two roller bearings separated one from the other as shown in the photograph Remove the two roller bearings from the bracket with the specific tool operating on the shock ab sorber attachment side as shown in the photo graph 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 Suitably hold the brake calliper shock absorber attachment bracket Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm SUSP 108 Vespa S 50 2T Suspensions Assemble a new roller bearing on the shock ab sorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch Suitably hold the brake calliper shock absorber attachment bracket Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 02
87. tting Vespa S 50 2T Time Braking system BRAKING SYSTEM Code Action Duration 1 002021 Front brake hose Remov and Re fitt 2 002007 Front brake shoes pads Remov and Refitt 3 002039 Front brake calliper Removal and Refitting 4 002047 Front brake fluid and air bleeding system Replacement 5 002002 Shoes Rear brake pads Replace ment TIME 177 Secondary air box Vespa S 50 2T TIME 178 Code 001164 001161 001162 001163 001165 SECONDARY AIR HOUSING Action Duration Crankcase secondary air connection Replacement Secondary air filter Replacement Cleaning Secondary air housing Replace ment Muffler secondary air connection Replacement Secondary air reed Replacement Air filter 33 132 Battery 42 50 58 59 Brake 118 120 122 123 125 Brake fluid 122 C Carburettor 11 30 153 E Engine stop Fuel 41 95 133 163 Fuses 58 H Headlight 36 129 Hub oil 32 Identification 8 Instrument panel 128 Maintenance 7 28 O Odometer S Saddle Shock absorbers 115 Spark plug 37 Stand 116 Start up T Tank 133 163 164 Transmission 9 41 67 150 Tyres 10
88. tual diagrams Ignition I 1 i per 1 F rest E E fq i o ELE SYS 48 Vespa S 50 2T KEY 1 Electronic ignition device 2 Magneto flywheel Pick up 3 Key switch 5 7 5A Fuse 6 12V 9Ah Battery 28 Spark plug Headlights and automatic starter section Electrical system KEY 2 Magneto flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 15 Light switch 17 Rear light 20 Front light A Tail light bulb B High low beam light bulb ELE SYS 49 Electrical system 23 Instrument panel B Headlight warning light C Instrument panel lighting bulbs G High beam warning light 24 Automatic starter Battery recharge and starting Vespa S 502T KEY 2 Magneto flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 7 Starter motor 8 Start up remote control switch 11 Starter button 12 Stop button on rear brake 13 Stop button on front brake 17 Rear light ELE SYS 50 Vespa 5 50 2T Electrical system Level indicators and enable signals section KEY 2 Magneto flywheel Pick up 3 Key switch 4 Voltage regulator 5 7 5A Fuse 6 12V 9Ah Battery 22 Fuel level transmitter 23 Instrument panel D Fuel gauge E Low fuel warning light F Oil warning light 27 0il reserve warning light ELE SYS 51 Electrical system Vespa 5 50
89. xing the muffler to the housing then remove the whole muffler paying at tention to the interference between its supporting bracket and the cooling cover Removal of the engine from the vehicle Support the scooter adequately Disconnect the battery Remove the muffler assembly Remove the rear wheel Remove the rear brake mechanical transmission Disconnect the electric terminals Remove the throttle grip and mixer transmissions Disconnect the hoses petrol oil Remove the engine side swinging arm and remove the entire engine WARNING Be very careful when handling fuel CAUTION When installing the battery first attach the positive cable and then the negative cable WARNING Wear safety goggles when using hitting tools ENG VE 65 INDEX OF TOPICS Vespa S 50 2T Engine Automatic transmission Transmission cover Loosen the 15 screws and remove the transmis sion cover with the aid of a mallet N B 2 THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT ES FIT BETWEEN THE SHAFT OF THE DRIVEN HALF PULLEY AND THE BEARING HOUSED ON THE CRANKCASE Kickstart Upon refitting apply the recommended grease to the bushing to the spring and along the toothed sector Use the special tool for the charging of the spring as shown in the figure Refit the seeger ring after checking that it is in good condition Specific tooling 020261Y Starter spring fitting Recommended
90. ywheel nut at the prescribed torque Check the Pick Up air gap The air gap may not be modified in the fitting of the Pick Up Other values derive from deformations visible on the Pick Up support VARIATION OF THE AIR DISTANCE LEAD VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING KNOCKING ETC Locking torques N m Flywheel nut 40 44 Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter on the crankcase locking the two screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD TIMING LUBRICATION FLYWHEEL AND TRANSMISSION CHAPTERS Locking torques N m Starter screws 12 13 Cylinder assy and timing system Removing the intake manifold Use an anti tampering TORX spanner to remove the two clamping screws of the intake manifold ENG 84 Vespa S 50 2T Engine Removing the cylinder head Remove the 4 screws shown in the figure Removing the cylinder piston assy Remove the cylinder very carefully Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN RETENTION SNAP RINGS ENG 85 Engine Vespa S 50 2T Inspecting the small end Measure the internal diameter of the small end using an internal micrometer IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS S

SERVICE STATION MANUAL Vespa S 50 2T

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