MANUALE STAZIONE DI SERVIZIO

1Q000844

Vespa sei giorni 300 hpe

 MANUALE
STAZIONE DI
SERVIZIO

Vespa sei giorni 300 hpe

The descriptions and images in this publication are given for illustrative purposes only. While the basic
features as described and illustrated in this manual remain unchanged, Piaggio & C. S.p.A. reserves the
right, at any time and without being required to update this publication beforehand, to make any changes
to components, parts or accessory supplies which it deems necessary to improve the product, or which
are required for manufacturing or commercial reasons.
Not all the versions shown in this publication are available in every country. Availability of the individual
versions must be verified with the official PIAGGIO sales network.
© Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
 MANUALE STAZIONE DI
SERVIZIO
Vespa sei giorni 300 hpe
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa
pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei
principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni
importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno
comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro
completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per
questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il
catalogo degli attrezzi specifici.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS

GENERAL MANDATORY REQUIREMENTS

NORM

PRE-DELIVERY PRE DE

TECHNICAL DATA DT

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS
INDEX OF TOPICS

GENERAL MANDATORY REQUIREMENTS NORM

Vespa sei giorni 300 hpe General mandatory requirements

General information
This section contains general information regarding the vehicle and the use of the manual, as well as
important notes regarding safety.

IMPORTANT WARNINGS AND NOTES

Each symbol has a precise meaning, as illustrated below.

• WARNING: - This symbol indicates risks for the health of the operator and of the nearby
persons if the described procedures are performed incorrectly.
• CAUTION:- This symbol indicates that the component on which works are being performed
may be damaged if the described procedures are performed incorrectly.
• NOTE: - This paragraph provides additional instructions for the ongoing procedure, so that
the operation may be performed in an efficient manner.

REACH REGULATION WARNINGS :

To protect the health and safety of the PROFESSIONAL CLIENT, as provided by the:

• (EC) Regulation No. 1907/2006 (REACh);

• 2000/53/EC (END of LIFE VEHICLES);
• SCIP Database Directive (art.9, par.1 lett.i) of the framework directive regarding waste, as
modified by the Directive 2018/851

The technical personnel operating during the ordinary and special maintenance activities has the obli-
gation to always wear the personal protection equipment:

1. chemical protection gloves if the specific type is not explicitly indicated, or, if required, special
gloves according to the substance used;
2. mask, possibly a chemically active one, if specifically required;
3. protective goggles.

The above indications represent an alternative for the prescriptions of other regulations and of the
legislation in force in the specific countries. Regarding the use of other PPE, governed by the laws
regarding the safety at work, the relevant legislation in force apply.

NORM - 7
General mandatory requirements Vespa sei giorni 300 hpe

GENERAL SAFETY WARNINGS :

1. Always wear protective goggles and proper clothing.

2. Always use a safety support to operate under the vehicle.
3. Check that the ignition switch is always OFF, unless the procedure indicates otherwise.
4. Pull the hand brake (if applicable) before starting working on the vehicle.
5. Start the engine only in well ventilated places, to avoid the risks related to the carbon oxide.
6. Keep a safe distance from the mobile parts during the operation of the engine, especially from
the fans and belts.
7. To avoid burns, avoid contact with the hot metallic parts, such as the radiator, exhaust manifold,
exhaust pipe, catalytic converter and silencer.
8. Do not smoke during maintenance operations.
9. To avoid any injuries, do not wear rings, watches, jewellery and loose clothing before starting to
work on the vehicle.
10.Keep your hands and other objects away from the blades of the radiator's fan (if present)!
11.The cooling fan (if present) is fitted on the radiator and may start any time due to a temperature
increase of the cooling fluid. It is important to check that the cooling fan's starter motor is discon-
nected from the wiring harness before starting the works.

The measurement units used in the manual are imperial UNITS of measurement. (International
system for UNITS). Example: 24.5-34.3 Nm

NORM - 8
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery Vespa sei giorni 300 hpe

Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.

Aesthetic inspection

Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt

Tightening torques inspection

Lock check
Check to make sure that the marking in coloured mark is present on the:
- Safety fasteners
- Fastening screws
Safety fasteners:
- Front shock absorber lower fastener
- Rear shock absorber lower fastener
- Swinging arm pin - Engine
- Front wheel brake calliper
- Rear wheel brake calliper
- Coolant delivery and return pipe ties on the coolant pump cover

Electrical system

• Main switch
• Lights: high beam lights, low beam lights, tail lights and their warning lights
- Headlight adjustment according to the regulations currently in force
• Brake light operation by using the RH and LF brake lever
• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• electric saddle opening button

PRE DE - 10
Vespa sei giorni 300 hpe Pre-delivery

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATELY CHARGING THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS
USED FOR THE FIRST TIME WITH SHORTEN THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO-
TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE
OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
The vehicle is equipped with an OBD (On-Board
Diagnostics) port, compliant with the Euro 5 direc-
tives and which allows the connection between the
vehicle and the diagnostic tool.
N.B.
AT EACH SCHEDULED MAINTENANCE A VERIFICATION
MUST BE PERFORMED WITH THE DIAGNOSTIC TOOL TO
CHECK IF THERE ARE ERRORS AND THE IF THE PARAM-
ETERS ARE CORRECT. ENSURE THAT THE VEHICLE
CALIBRATION IS UP TO DATE AFTER UPDATING THE DI-
AGNOSTIC TOOL.

Levels check
Level check:
- Hydraulic brake system liquid level
- Rear hub oil level
- Engine coolant level
- Engine oil level

Road test
Test ride:
- Cold start
- Instrument operations
- Response to throttle control
- Stability on acceleration and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency

PRE DE - 11
Pre-delivery Vespa sei giorni 300 hpe

- Abnormal noise

Static test

Static control after the test drive:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.

Functional inspection

Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: document checks, chassis and engine number check, tools and equipment (if present), licence
plate fitting, lock check, tyre pressure check, rear-view mirror and any accessory fitting

Specific operations for the vehicle

Install the underbody caps as shown in the figure.

PRE DE - 12
Vespa sei giorni 300 hpe Pre-delivery

PRE DE - 13
INDEX OF TOPICS

TECHNICAL DATA DT
Vespa sei giorni 300 hpe Technical Data

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; 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 carefully to avoid
the risk of inhaling dust produced by worn 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 spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, seal rings and cotter pins when reassembling.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.

DT - 15
Technical Data Vespa sei giorni 300 hpe

Vehicle identification

The identification numbers consist of a prefix

stamped on the chassis and on the engine, fol-
lowed by a number. They must be quoted when
ordering spare parts. We recommend that you
check that the prefix and chassis number stamped
on the vehicle correspond with those in the vehicle
documents.
CAUTION

NOTE THAT ALTERING SERIAL NUMBERS MAY BE PUN-

ISHABLE WITH SEVERE LEGAL PENALTIES (IMPOUND-
ING OF VEHICLE, ETC.).

FRAME IDENTIFICATION NUMBER:

Lift the saddle and remove the helmet compart-
ment. The chassis identification number is stam-
ped on the chassis' rear crossbeam.

ENGINE IDENTIFICATION NUMBER:

The engine identification number is stamped in the
rear part of the engine near the shock absorber
lower support.

DT - 16
Vespa sei giorni 300 hpe Technical Data

Vehicle data

VEHICLE DATA
Specification Desc./Quantity
Frame Stamped plate supporting body.
Front suspension Single arm suspension (cantilever wheel) fitted with a dual-
chamber hydraulic shock absorber with coaxial spring.
Rear suspension Two double-acting shock absorbers, adjustable to four posi-
tions at pre-loading.
Front brake Ø 220 mm hydraulically operated disc brake controlled from RH
handlebar lever; braking assisted by ABS system.
Rear brake Ø 220 mm hydraulically operated disc brake controlled from LH
handlebar lever; braking assisted by ABS system.
Wheel rims type Light alloy.
Front rim 12'' x 3.00
Rear rim 12'' x 3.00
Front tire 120/70 - 12'' 51P Tubeless
Rear tire Tubeless 130/70 - 12'' 62P
Front tire pressure (with passenger) 1.8 bar (-)
Rear tire pressure (with passenger) 2.0 bar (2.2 bar)
Kerb weight 160 kg
Maximum weight limit 340 kg
Battery 12V-10Ah

Engine Data

ENGINE SPECIFICATIONS
Specification Desc./Quantity
Type Single cylinder 4-stroke
Engine capacity 278 cm³
Bore x Stroke 75x63 mm
Compression ratio 11 ± 0.5: 1

DT - 17
Technical Data Vespa sei giorni 300 hpe

Specification Desc./Quantity
Idle engine speed 1,700 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance (cold engine) Intake: 0.10 ± 0.02 mm Exhaust: 0.10 ± 0.02 mm
Maximum power 17.5 kW at 8250 rpm
Maximum torque 26.0 Nm at 5250 rpm
Transmission CVT expandable pulley continuously variable transmission
with torque server, V-belt, self-ventilating dry automatic centri-
fugal clutch and transmission housing with forced-circulation
air cooling.
Final drive reduction gear Gear reduction unit in oil bath.
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Cooling Forced coolant circulation system.
Starting Electric
Ignition Electronic inductive discharge ignition, high efficiency, with
separate HV coil.
Ignition advance α/N three-dimensional map managed by control unit
Spark plug NGK MR7BI-8
Power supply Electronic injection with Ø 32-mm throttle body and electric fuel
pump.
Fuel Unleaded gasoline E10 (95 R.O.N.)
Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con-
verter and lambda probe.
Emissions compliance EURO 5

Capacities

CAPACITY
Specification Desc./Quantity
Engine oil 1.3 l
Transmission oil 250 cm³
Cooling system fluid ~2l
Fuel tank 8.5 ± 0.5 litres

MEASUREMENT UNITS CONVERSION - FROM THE ANGLO-SAXON SYSTEM TO THE INTERNATION-

AL SYSTEM (I.S.).
Specification Desc./Quantity
1 Inch (in) 25.4 Millimetres (mm)
1 Foot (ft) 0.305 Metres (m)
1 Mile (mi) 1.609 Kilometres (km)
1 US gallon (gal US) 3.785 Litres (l)
1 Pound (lb) 0.454 Kilograms (Kg)
1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)
1 Pound per foot (lb ft) 1.356 Newton metres (N m)
1 Mile per hour (mi/h) 1.602 Kilometres per hour (km/h)
1 Pound per square foot (PSI) 0.069 (bar)
1 Fahrenheit (°F) 32+(9/5) Celsius (°C)

Tightening Torques

FRONT SUSPENSION TIGHTENING TORQUES

Name Torque in Nm
Lower lock-nut - Steering tube 11.7 - 13.7 Nm
Upper lock-nut - Steering tube 34.3 - 39.2 Nm
Handlebars - Steering tube 50 - 55 Nm
Front wheel - Front wheel hub 19 - 24 Nm
Throttle control sleeve - Handlebar 3 - 4 Nm
Front shock absorber (lower fastening) - Steering tube 19 - 26 Nm
Front shock absorber (upper fastening) - Steering tube 19 - 24 Nm
Front shock absorber - Shock absorber plate 19 - 29 Nm

DT - 18
Vespa sei giorni 300 hpe Technical Data

Name Torque in Nm
Front wheel hub - Front wheel axle 74 - 88 Nm
ABS sensor - ABS support bracket 4.5 - 5 Nm
Odometer transmission - Front wheel hub 4 - 6 Nm

REAR SUSPENSION TIGHTENING TORQUES

Name Torque in Nm
Swinging arm (engine side) - Engine 67 - 75 Nm
Swinging arm (frame side) - Frame 76 - 83 Nm
Silent block bracket - Frame 42 - 52 Nm
Swinging arm (engine side) - Swinging arm (frame side) 40 - 45 Nm
Rear shock absorber (lower) - Silencer support bracket 40 - 45 Nm
Rear shock absorber (lower) - Shock absorber support bracket 40 - 45 Nm
Shock absorber support bracket - Engine 20 - 25 Nm
Rear shock absorber (upper) - Frame 20 - 25 Nm
Rear wheel hub - Rear wheel axle 104 - 126 Nm
Rear wheel - Rear wheel hub 20 - 25 Nm
Silencer support arm - Engine 20 - 25 Nm
ABS sensor - Silencer support bracket 5 - 6 Nm
Central stand - Engine 40 - 45 Nm
Side stand support bracket - Frame 6 - 10 Nm
Side stand - Side stand support bracket 35 - 40 Nm
Side stand button - Side stand support bracket 5 - 7 Nm
Ground cable - Frame 7.5 - 9.5 Nm
Ground braid - Frame 7.5 - 9.5 Nm
Ground cable - Engine 11 - 13 Nm
Starter motor ground cable - Frame 11 - 12.5 Nm

BRAKE SYSTEM TIGHTENING TORQUES

Name Torque in Nm
Front brake calliper - Front shock absorber support 19 - 24 Nm
Rear brake calliper - Crankcase 20 - 25 Nm
Brake pump - Handlebars 7 - 10 Nm
Front brake pipe coupling - Front brake calliper 19 - 24 Nm
Rear brake pipe coupling - Rear brake calliper 20 - 25 Nm
Front brake pipe - Brake pump 20 - 25 Nm
Brake disc - Wheel hub 8 - 10 Nm
Brake pump pipe - ABS control unit 17 - 20 Nm
Front calliper brake pipe - ABS control unit 17 - 20 Nm
Rear calliper brake pipe - Rear brake pipe coupling 13 - 17 Nm
Rear brake pipe coupling - ABS control unit 17 - 20 Nm

BODYWORK TIGHTENING TORQUES

Name Torque in Nm
Saddle - Frame 8 - 10 Nm
Handle - Frame 8 - 10 Nm
Rear handle cover - Handle 1 - 1.7 Nm
Saddle support cover - Frame 8 - 10 Nm
Rear view mirrors - Handlebars 29 - 31 Nm
Rear handlebar cover - Front handlebar cover 1 - 1.7 Nm
Panel lights - Rear handlebar cover 1 - 1.7 Nm
Headlamp - Headlamp cover 5 - 6 Nm
Front direction indicator - Leg shield 1 - 1.7 Nm
Central frame cover - Footrest 1 - 1.7 Nm
Expansion chamber cover - Leg shield back plate 1 - 1.7 Nm
Leg shield back plate (upper external fastening) - Leg shield 1 - 1.7 Nm
Leg shield back plate (upper internal fastening) - Leg shield 1 - 1.7 Nm
Leg shield back plate (lower internal fastening) - Footrest 1 - 1.7 Nm
Leg shield back plate (lower external fastening) - Footrest 1 - 1.7 Nm
Leg shield back plate (central fastening) - Frame 4.5 - 7 Nm
Rear light assembly - Frame 4.5 - 7 Nm
Rear direction indicator - Frame 1 - 1.7 Nm
Footrest (central fastening) - Frame 4.5 - 7 Nm
Footrest (lateral fastening) - Frame 1 - 1.7 Nm
Footrest (rear fastening) - Frame 4.5 - 7 Nm
Passenger footrest - Frame 17 - 22 Nm

DT - 19
Technical Data Vespa sei giorni 300 hpe

Name Torque in Nm
Lateral cover (front fastening) - Footrest 1 - 1.7 Nm
Lateral cover (rear fastening) - Frame 4.5 - 7 Nm
Spoiler terminal - Footrest 1 - 1.7 Nm
Fuel pipe clamp - Fuel tank 4.5 - 7 Nm
Fuel tank (front fastening) - Frame 8 - 10 Nm
Fuel tank (rear fastening) - Frame 8 - 10 Nm
Fuel tank (upper fastening) - Frame 8 - 10 Nm
Front splash guard (front fastening) - Front mudguard 2 - 4 Nm
Front splash guard (rear fastening) - Front mudguard 2 - 4 Nm
Headlamp cover (central fastening) - Front mudguard 7 - 10 Nm
Headlamp cover (front fastening) - Front mudguard 2 - 4 Nm
Headlamp cover (rear fastening) - Front mudguard 7 - 10 Nm
Front mudguard - Steering tube 5 - 6 Nm
Front mudguard support bracket - Suspension flange 8 - 10 Nm
Front mudguard support bracket - Steering tube 8 - 10 Nm
Suspension flange - Headlight support bracket 8 - 10 Nm
Headlamp retainer bracket - Headlight support bracket 8 - 10 Nm
Steering tube protection (lower fastening) - Steering tube 4 - 7 Nm
Steering tube protection (lower fastening) - Front mudguard 2 - 4 Nm
Front central cover - Frame 1 - 1.7 Nm
Front windshield - Windshield support 4.5 - 7 Nm
battery fastening bracket - Frame 4.5 - 7 Nm

TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 to 13
Clutch unit nut on driven pulley 45 - 50
Driver pulley nut 75 - 83
Transmission cover screws 11 - 13 Nm
Driven pulley shaft nut 54 - 60
Rear hub cover screws 24 to 27

LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 to 17
Oil filter on crankcase fitting 27 - 33
Engine oil drainage plug/ mesh filter 24 to 30
Oil filter 4-6
Oil pump cover screws 7-9
Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 - 14
Oil pump cover plate screws 4-6
Oil sump screws 10 - 14
Minimum oil pressure sensor 12 - 14

CYLINDER HEAD
Name Torque in Nm
Spark plug 12 - 14
Cylinder head cover screws 6-7
Nuts fixing head to cylinder 7±1 + 10±1 + 90° + 90° + 90°
Head fixing side screws 11 - 12
Starter ground screw 7 to 8.5
Tappet adjustment check nut 6-8
Inlet manifold screws 11 to 13
Timing chain tensioner slider screw 10 - 14
Starter counterweight support screw 11 to 15
Timing chain tensioner support screw 11 to 13
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4-6

FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 to 13
Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)

DT - 20
Vespa sei giorni 300 hpe Technical Data

Name Torque in Nm
Flywheel nut 94 - 102
Pick-up fixing screws 3-4
Screw fixing freewheel to flywheel 13 - 15

COOLING
Name Torque in Nm
Water pump rotor cover 3-4
Thermostat cover screws 3-4
Bleeder screw 3

CRANKSHAFT AND CASE

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4-6
shaft) screws
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)

SILENCER
Name Torque in Nm
Silencer heat guard fixing screw 4-5
Screw used to fasten silencer to supporting arm 20 - 25
Lambda probe tightening on exhaust manifold 40 - 50
Manifold/silencer joint tightening torque 12 - 13
Manifold - silencer diaphragm tightening clamp 16 - 18

Overhaul data

Assembly clearances

Cylinder - piston assy.

DT - 21
Technical Data Vespa sei giorni 300 hpe

CYLINDER - PISTON
Specification Desc./Quantity
Plunger diameter 74.967 +0.014 -0.014 mm
Cylinder diameter 75 +0.038 +0.01 mm

COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder - piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064
cylinder - piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064
cylinder - piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064
cylinder - piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Check the pin external diameter.

Characteristic
Pin external diameter
16 +0 -0.004 mm

- Measure the diameter of the bearings on the pis-

ton.

Characteristic
Standard diameter
16 +0.006 +0.001 mm

- Calculate the piston pin coupling clearance.

N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS
Characteristic
Standard clearance:
0.001 - 0.010 mm

DT - 22
Vespa sei giorni 300 hpe Technical Data

- Carefully clean the seal housings.

- Measure the coupling clearance between the
sealing rings and the piston grooves using suitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.

Fitting clearance
1st compression ring - standard coupling
clearance 0.015 - 0.06 mm 1st compression ring -
maximum clearance allowed after use 0.07 mm
2nd compression ring - standard coupling
clearance 0.015 - 0.06 mm 2nd compression ring -
maximum clearance allowed after use 0.07 mm
oil scraper ring - standard coupling clearance
0.015 - 0.06 mm oil scraper ring - maximum clear-
ance allowed after use 0.07 mm
- Check that the head coupling surface is not worn
or misshapen.
- Pistons and cylinders are classified according to
diameter. The coupling is carried out in pairs (M-
M, N-N, O-O, P-P).

Characteristic
Maximum allowable run-out:
0.001 in 0.05 mm

Piston rings

Sealing rings
- Alternately insert the three sealing rings into the
cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpen-
dicularly to the cylinder axis.
- Measure the opening (see figure) of the sealing
rings using a feeler gauge.
- Replace the piston rings if values higher than
those prescribed are measured.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, MAKE
SURE THAT COUPLING CLEARANCE BETWEEN THE
SEAL RINGS AND ITS GROOVES, AND THAT BETWEEN
THE PISTON AND THE CYLINDER ARE AS SPECIFIED. IN

DT - 23
Technical Data Vespa sei giorni 300 hpe

ANY CASE, NEW PISTON SEALING RINGS USED IN COM-

BINATION WITH A USED CYLINDER MAY HAVE DIFFER-
ENT BEDDING CONDITIONS THAN THE STANDARD
ONES.

Characteristic
Top piston ring
Standard opening: 0.15 to 0.30 mm
Middle piston ring
Standard opening: 0.20 - 0.40 mm
scraper ring
Standard opening: 0.20 - 0.40 mm

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Transmissionside half- 16.6 +0-0.05 A D = 0.20 - 0.50
shaft
Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50
Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

DT - 24
Vespa sei giorni 300 hpe Technical Data

CRANKSHAFT
Specification Desc./Quantity
Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm

DT - 25
Technical Data Vespa sei giorni 300 hpe

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity
A= 0.15 mm
B= 0.010 mm
C= 0.010 mm
D= 0.10 mm

DT - 26
Vespa sei giorni 300 hpe Technical Data

Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm

- Using a bore gauge, measure the connecting rod

small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.

Characteristic
Standard diameter
16 +0.025 +0.015 mm

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be
perfectly orthogonal to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- There are three crankcase versions: with BLUE, YELLOW or GREEN bushings.
- There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter
after driving is variable on the basis of a coupling selection.
- There are 2 categories of bushing seats in the crankcase - Cat 1 and Cat 2 - just like those for the
crankshaft.
- The main bushings are subdivided into 3 categories according to thickness; see table below:

BEARINGS
TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING
B BLUE 1.973 - 1.976
C YELLOW 1.976 - 1.979
E GREEN 1.979 - 1.982

COUPLINGS
BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING
HALVES CATEGORY
B 2 29.024 ÷ 29.054

DT - 27
Technical Data Vespa sei giorni 300 hpe

BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING

HALVES CATEGORY
C 1 29.024 ÷ 29.054
2 29.018 ÷ 29.048
E 1 29.018 ÷ 29.048

Combine the crankshaft with two crankwebs category 1 with a crankcase category 1 (or cat. 2 with cat.
2) A spare crankcase cannot be combined with a crankshaft with mixed categories. The spare crank-
shaft has half-shafts of the same category.

CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
N.B.
SPARE CRANKCASES ARE SELECTED WITH CRANK-
CASE HALVES OF THE SAME CATEGORY AND ARE FIT-
TED WITH CATEGORY C (YELLOW) BUSHINGS

Characteristic
Crankshaft-bushing maximum clearance ad-
mitted:
0.08 mm
Diameter of crankcase without bushing
CAT 1: 32.959 - 32.965 mm

CAT 2: 32.953 - 32.959 mm

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting

- Using a trued bar and a feeler gauge, check that

the cylinder head surface is not worn or distorted.

Characteristic
Maximum allowable run-out:
0.1 mm

- In case of faults, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocker pin capacities exhibit no wear.

DT - 28
Vespa sei giorni 300 hpe Technical Data

- Check that the head cover shows no signs of wear.

- Check that the coolant seal plug exhibits no oxidation.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD BEARINGS
Specification Desc./Quantity
bearing «A» Ø 12.000 - 12.018
bearing «B» Ø 20.000 - 20.021
bearing «C» Ø 37.000 - 37.025

Measure the unloaded spring length

Characteristic
Standard length
40.2 mm
Allowable limit after use:
38.2 mm

DT - 29
Technical Data Vespa sei giorni 300 hpe

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".

Characteristic
Standard value:
1 - 1.3 mm
Limit allowed:
1.6 mm

- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTH

Specification Desc./Quantity
Valve check: Standard length Intake: 94.6 mm
Valve check: Standard length Exhaust: 94.4 mm

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

STANDARD DIAMETER
Specification Desc./Quantity
Intake: 4.987 - 4.972 mm
Exhaust: 4.975 - 4.960 mm

DT - 30
Vespa sei giorni 300 hpe Technical Data

MINIMUM DIAMETER PERMITTED

Specification Desc./Quantity
Intake: 4.96 mm
Exhaust: 4.945 mm

- Calculate the clearance between the valve and the valve guide.

- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the
extent of the deformation with a dial gauge.

Characteristic
Limit value admitted:
0.1 mm

- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve
head and rotating it on the «V» shaped support.

Characteristic
Limit allowed:
0.03 mm

Measure the valve guide.

Characteristic
Valve guide:
5 +0.012 mm

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.

DT - 31
Technical Data Vespa sei giorni 300 hpe

INTAKE
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Limit allowed: 0.08 mm

EXHAUST
Specification Desc./Quantity
Standard clearance: 0.025 - 0.052 mm
Limit allowed: 0.09 mm

- Check that there are no signs of wear on the mating surface with the set screw articulated terminal.

- If no anomalies are found during the above

checks, you can use the same valves. To obtain
better sealing performance, grind the valve seats.
Grind the valves gently with a fine-grained lapping
compound. During the grinding, keep the cylinder
head with the valve axes in a horizontal position.
This will prevent the lapping compound residues
from penetrating between the valve stem and the
guide (see figure).
CAUTION
TO AVOID SCORING THE MATING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPING
COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A
SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
- Check that the camshaft bearings exhibit no scores or abnormal wear.
- Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETER
Specification Desc./Quantity
Camshaft check: Standard diameter Bearing A Ø: 36.95 - 36.975 mm
Camshaft check: Standard diameter Bearing B diameter: 19.959 - 19.98 mm

DT - 32
Vespa sei giorni 300 hpe Technical Data

MINIMUM DIAMETER PERMITTED

Specification Desc./Quantity
Camshaft check: Minimum diameter permitted Bearing A Ø: 36.94 mm
Camshaft check: Minimum diameter permitted Bearing B diameter: 19.950 mm

-Using a gauge, measure the cam height.

STANDARD HEIGHT
Specification Desc./Quantity
Camshaft check: Standard height Intake: 30.285 mm
Camshaft check: Standard height Exhaust: 29.209 mm

Check the axial clearance of the camshaft

CAMSHAFT AXIAL CLEARANCE

Specification Desc./Quantity
Camshaft check: Standard axial clearance: 0.11 - 0.41 mm
Camshaft check: Maximum admissible axial clearance: 0.42 mm

- Measure the external diameter of the rocking lever pins

- Check the rocker pins do not show signs of wear or scoring.

DT - 33
Technical Data Vespa sei giorni 300 hpe

- Measure the internal diameter of each rocker

Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment
plate.

DIAMETER OF PINS AND ROCKING LEVERS

Specification Desc./Quantity
Rocking lever inside diameter: Standard diameter Ø 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter Ø 11.977 - 11.985 mm

CLASSIFICATION OF DECOMPRESSION PIN/SCREW KNOB - CAMSHAFT

Decompression pin/screw knob
- Class identification sign: A - B - C
- Stamp of the class identification sign: pin end on
screw knob side

Camshaft
- Class identification sign: A - B - C
- Stamp of the class identification sign: camshaft -
sprocket timing view

CLASS MATCHING
Decompression screw knob Decompression screw knob Decompression screw knob
(pin) - Class A (pin) - Class B (pin) - Class C
Camshaft - Class A A-A NO NO
Camshaft - Class B NO B-B NO
Camshaft - Class C NO NO C-C
Check the combustion chamber's pressure during the ignition so that it ranges between the accepted
values listed below and also check the engine's revolutions.

DT - 34
Vespa sei giorni 300 hpe Technical Data

Perform the check when the battery is loaded, at room temperature and use a pressure gauge to detect
the (relative) pressure during the ignition and the corresponding engine revolutions.

PRESSURE CHECK IN THE COMBUSTION CHAMBER_DURING IGNITION

Engine speed (RPM) Relative pressure (bar)
MIN 400 4,5
MAX 600 8,0

DT - 35
INDEX OF TOPICS

TOOLING TOOL
Vespa sei giorni 300 hpe Tooling

SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats

001467Y017 Bell for bearings, OD 39 mm

001467Y014 Calliper to extract ø 15-mm bearings

001467Y035 Bearing housing, external ø 47 mm

001467Y013 Calliper to extract ø 15-mm bearings

005095Y Engine support

TOOL - 37
Tooling Vespa sei giorni 300 hpe

Stores code Description

002465Y Calliper for circlips

006029Y Punch for fitting steering bearing on the

steering tube

020004Y Punch for removing steering bearings

from headstock

020021Y Front suspension service tool

020036Y Punch

020038Y Punch

TOOL - 38
Vespa sei giorni 300 hpe Tooling

Stores code Description

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaft

alignment

020115Y punch ø 18

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure gauge

TOOL - 39
Tooling Vespa sei giorni 300 hpe

Stores code Description

020244Y punch ø 15

020262Y Crankcase splitting plate

020271Y Tool for removing-fitting silent bloc

020263Y Driven pulley assembly sheath

020306Y Punch valve seal rings fitting

020329Y Mity-Vac vacuum pump

TOOL - 40
Vespa sei giorni 300 hpe Tooling

Stores code Description

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rpm indicator

020335Y Magnetic mounting for dial gauge

TOOL - 41
Tooling Vespa sei giorni 300 hpe

Stores code Description

020357Y 32 x 35-mm Adaptor

020359S 42 x 47 mm Adaptor

020360S 52 x 55 mm adaptor

020363Y 20-mm guide

020364Y 25-mm guide

020365Y 22 mm guide

TOOL - 42
Vespa sei giorni 300 hpe Tooling

Stores code Description

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle

020382Y Valve cotters equipped with part 012 re-

moval tool

020382Y011 adapter for valve removal tool

020393Y Piston fitting ring

020412Y 15-mm guide

TOOL - 43
Tooling Vespa sei giorni 300 hpe

Stores code Description

020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020426Y Piston fitting fork

020431Y Valve oil seal extractor

020434Y Union for oil pressure measurement

020441S 26 x 28 mm adaptor

TOOL - 44
Vespa sei giorni 300 hpe Tooling

Stores code Description

020444Y Tool for installing/removing clutch on/
from driven pulley

020454Y Tool for fitting the pin snap rings (200 -

250)

020456Y Ø 24 mm adaptor

020467Y Flywheel extractor

020477Y Adapter 37 mm

020480Y Fuel pressure measurement kit

TOOL - 45
Tooling Vespa sei giorni 300 hpe

Stores code Description

020483Y 30-mm guide

020489Y Hub cover support stud bolt kit

020621Y A.T cable pick-up adapter

020622Y Transmission-side oil seal punch

020627Y Flywheel lock tool

020648Y Single battery charger

TOOL - 46
Vespa sei giorni 300 hpe Tooling

Stores code Description

020922Y Diagnosis Tool

021021Y Drive pulley lock

021017Y EOBD E5 diagnostics cable

TOOL - 47
INDEX OF TOPICS

MAINTENANCE MAIN
Vespa sei giorni 300 hpe Maintenance

This section describes the general specifications of the vehicle.

Maintenance chart

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(*): Check the engine oil level and if necessary, top up at 5.000 Km (3.1 miles)

km x 1,000 (mi x 1,000) 1 5 10 20 30 40 50 60 EVERY EVERY

(0.6) (3.1) (6.2) (12.4) (18.6) (24.8) (31) (37.2) 24 12
MONTH MONTH
S S
Safety blocks I I I I I
Spark plug R R R
Centre stand L L L L L L L L
Drive belt R R R R R R
Throttle control I I I I I I I I I
Complete roller housing I I I I I I
Diagnosis by tool I I I I I I I I I
Air filter R R R R R R
CVT Filter I I I I I I
Engine oil filter R R R R R R R R R
Valve clearance A A A A A A
Electrical system and battery I I I I I I I
Braking system I I I I I I I I I
Coolant I I I I I I I I R
Brake Fluid I I I I I I I I R
Engine oil (*) R I R R R R R R R R
Hub oil R I R I R I R I I
Headlight direction adjustment I I I I I I
Brake pads I I I I I I I I
Sliding shoes / CVT rollers R R R R R R
Tire pressure and wear I I I I I I I I I
Vehicle road test I I I I I I I I I
Suspensions I I I I I I I I
Steering A A A A A A A I I
Time required (minutes) 70 10 160 160 160 160 160 200 60 60
N.B.
AT EACH SCHEDULED SERVICE, USE THE DIAGNOSTIC TOOL TO CHECK FOR ERRORS AND
CHECK THAT ALL PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.
CAUTION
AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE
MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 5,000 Km (3,106 mi) OR
5 MONTHS.

MAIN - 49
Maintenance Vespa sei giorni 300 hpe

Recommended products

Piaggio Group recommends the use of prod-

ucts from its Castrol official partner for the
scheduled maintenance of its vehicles.
Only use lubricants and fluids which meet or ex-
ceed the performance characteristics specified.
This also applies when topping up only.

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
Engine oil 5W -40 Synthetic-based lubricant for four-stroke SAE 5W-40; JASO MA, MA2; API SL;
engines. ACEA A3
Transmission oil 80W-90 Lubricant for gearboxes and transmis- SAE 80W-90 API GL-4
sions.
Anti-freeze liquid, ready to use, colour red Ethylene glycol antifreeze liquid with or- ASTM D 3306 - ASTM D 4656 - ASTM D
ganic inhibition additives. Red, ready to 4985 - CUNA NC 956-16
use.
DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
Water repellent spray grease Water repellent pouring calcium spray White, soap base spray grease with NLGI
grease. 2 Calcium complex; ISO-L-XBCIB2

Checking the spark advance

The ignition advance is determined electronically

on the basis of parameters known by the control
unit. For this reason it is not possible to interpret
the reference values based on the engine rpm.
The ignition advance value is detectable at any
time using the diagnostic tool. It is possible to
check whether the ignition advance determined by
the injection system matches the value actually
activated on the engine, by means of the strobo-
scopic light.
Proceed as follows:
- Remove the spark plug.
- Remove the plastic cap from the flywheel cover.

MAIN - 50
Vespa sei giorni 300 hpe Maintenance

- Remove the transmission compartment air intake

cover.

- Rotate the drive pulley fan until the reference

marks on the flywheel and the flywheel cover are
aligned.

- Reposition the reference mark on the transmis-

sion side between the fan and the transmission
cover.
- Refit the spark plug.
- Refit the plastic cap on the flywheel cover.

- Adjust the spark gap so that it is in the contact

position (no notches visible).

MAIN - 51
Maintenance Vespa sei giorni 300 hpe

- Install the spark gap on the engine between the

spark plug and the spark plug hood.

- Connect the induction clamp on the spark gap

cable respecting the proper polarity (the arrow on
the clamp must be pointing at the spark plug).
- Connect the diagnostic tool, start the engine and
select «parameters» from the menu.
- Set the stroboscopic light control to the traditional
four-stroke engine position (1 spark, 2 revs).

- Check that the measured rpm and ignition ad-

vance values match those indicated by the diag-
nostic tool.

If the values do not match, check:

- the distribution timing.
- the engine speed sensor.
- the injection control unit.

MAIN - 52
Vespa sei giorni 300 hpe Maintenance

Spark plug

Proceed as follows:
Lift the saddle and remove the helmet compart-
ment.

Disconnect the spark-plug cap, detaching the H.V.

cable from the safety bracket by rotating it clock-
wise.

Undo the spark plug using the specific spark plug

spanner.

Remove the spark plug.

When refitting, place the spark plug into the hole at the required angle and finger tighten it as far as it
will go.Use the wrench only to tighten it.
Insert the cap on the spark-plug, securing it to the safety bracket.
CAUTION

THE SPARK PLUGS MUST BE DISMANTLED WHEN THE ENGINE IS COLD. SPARK PLUG MAIN-
TENANCE IS DESCRIBED IN THE SCHEDULED MAINTENANCE TABLE. THE USE OF NON-
CONFORMING ELECTRONIC CONTROL UNITS AND ELECTRONIC IGNITIONS AND SPARK
PLUGS OTHER THAN THOSE RECOMMENDED MAY SERIOUSLY DAMAGE THE ENGINE..
N.B.
USING SPARK PLUGS OTHER THAN THE INDICATED TYPE OR SHIELD-LESS SPARK PLUG
CAPS CAN CAUSE ELECTRICAL SYSTEM FAILURES.

MAIN - 53
Maintenance Vespa sei giorni 300 hpe

Hub oil

Check

- Rest the vehicle on its centre stand on level

ground.
- Unscrew the oil dipstick, dry it with a clean cloth
and reinsert it, screwing it fully into place.

- Unscrew the dipstick and check that the oil level

corresponds to the «MAX» mark as indicated in
figure; if the level is below this mark, top-up the hub
oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.

Replacement

Rest the vehicle on its centre stand on level

ground.
- Unscrew the hub oil dipstick.

MAIN - 54
Vespa sei giorni 300 hpe Maintenance

- Unscrew the drainage screw and drain all the oil

into a suitable container.
- Tighten the drainage screw, applying the pre-de-
fined torque, and refill the hub using the recom-
mended product.

Air filter

Proceed as follows:
- Remove the left side fairing.

- Lift the saddle and remove the helmet compart-

ment.

- Unscrew the knobs, which are accessible after

removing the helmet compartment.

MAIN - 55
Maintenance Vespa sei giorni 300 hpe

- Unscrew the air filter cover fastening screws.

- Remove the cover from the air filter.

- Replace the filter element.

CAUTION

REPLACE THE AIR FILTER IN ACCORDANCE WITH THE

INSTRUCTIONS PROVIDED IN THE SCHEDULED MAINTE-
NANCE TABLE. IN THE EVENT OF HEAVY DUTY USAGE,
THE MAINTENANCE OPERATIONS MUST BE CARRIED
OUT MORE FREQUENTLY ON THE VEHICLE, IN ORDER
TO AVOID DAMAGING THE ENGINE.

WARNING

ALWAYS USE NEW GASKETS / O -RINGS; WHENEVER

NEEDED, REMOVE THE AIR FILTER CASE OR REPLACE
THE FILTER ELEMENT. FAILURE TO COMPLY WITH THIS
NOTE MAY CAUSE SEALING PROBLEMS AT THE FILTER
ELEMENT AND THEREFORE MAY DAMAGE AND WEAR
THE ENGINE.

Engine oil

In four-stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and
the head-engine block-piston assembly. An insufficient quantity of oil can cause serious damage
to the engine.

MAIN - 56
Vespa sei giorni 300 hpe Maintenance

In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should
be considered normal, especially if during the run-in period. Consumption levels in particular can be
influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change the engine oil and replace the filter in ac-

cordance with the instructions provided in the
scheduled maintenance table.
- Unscrew the dipstick so that the oil drains from
the engine more efficiently.

- Unscrew the engine oil drainage cap «A» and

remove the mesh filter, allow the oil to drain into a
suitable container.
- Unscrew the engine oil filter «B».

- Check the condition of the o-rings on the drain-

age cap and the mesh filter.
- Lubricate the o-rings, insert the mesh filter in its
housing and tighten the drainage cap, applying the
pre-defined torque.

MAIN - 57
Maintenance Vespa sei giorni 300 hpe

- Lubricate the engine oil filter o-ring and secure it

in its housing, applying the pre-defined tightening
torque.

- Restore the engine oil level using the recommen-

ded product.
Start the engine, leave it running for a few minutes
and switch it off again. Check the level again after
approximately five minutes and top up if necessa-
ry. Do not exceed the MAX level mark.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
WARNING
USED OIL CONTAINS ENVIRONMENTALLY HARMFUL
SUBSTANCES

Check

This check must be carried out when the engine is

cold, if necessary, wait for 10 minutes after switch-
ing the engine off.
- Rest the vehicle on its centre stand on level
ground.
- Unscrew the oil dipstick, dry it with a clean cloth
and reinsert it, screwing it fully into place.

- Unscrew the dipstick and check that the oil level

is between the «MIN» and «MAX» marks indicated
in figure; if the level is below the «MIN» mark, top-
up the engine oil, taking care never to exceed
the «MAX» level mark.
-Screw up the oil dipstick again and make sure it
is locked properly into place.

MAIN - 58
Vespa sei giorni 300 hpe Maintenance

Engine oil filter

The engine oil filter must be changed in accord-

ance with the instructions provided in the sched-
uled maintenance table. Lubricate the o-ring
before replacing the oil filter.

Oil pressure warning light

The vehicle is equipped with a tell-tale light on the

instrument cluster that lights up when the key is
turned to the «ON» position. However, this light
should come off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication sys-
tem.

Checking the ignition timing

Proceed as follows:
- Lift the saddle and remove the helmet compart-
ment.

MAIN - 59
Maintenance Vespa sei giorni 300 hpe

- Unscrew the inspection cap on the flywheel side

cover.

- Loosen the ignition spark plug and align the ref-

erence marks on the flywheel and the crankcase
by rotating the crankshaft.

- Remove the big end cover.

Make sure that the 4V reference point on the cam-
shaft control crown gear is aligned with the refer-
ence mark on the big end. If the reference is
positioned diametrically opposite the reference
mark on the big end, perform a complete rotation
of the crankshaft.

Checking the valve clearance

Checking the valve clearance should be carried

out according to the scheduled maintenance table.
Place the vehicle on the centre stand above a suit-
able lift so that the front wheel can be locked.
Disconnect the battery cables.
Remove the helmet compartment.
Remove the side fairings and the footrest termi-
nals.
Remove the silencer.
Lift the rear of the body using a suitable device.

MAIN - 60
Vespa sei giorni 300 hpe Maintenance

Remove the screws fixing the filter box to the en-

gine.

Acting on the device, lift the body shell of the ve-

hicle
Raise the stand from the floor and then lower the
vehicle until the rear wheel touches the supporting
surface.
Unscrew and remove the right shock absorber
lower fixing nut.

Lift the filter box.

Unscrew and remove the lower fixing bolt of the
left shock absorber.

Disconnect the spark plug tube.

MAIN - 61
Maintenance Vespa sei giorni 300 hpe

Disconnect the throttle control transmissions

Unscrew the fuel pipe clamp fixing nut.

Unscrew and remove the transmission cover's fas-

tening screws.

Remove the transmission cover.

MAIN - 62
Vespa sei giorni 300 hpe Maintenance

Using the lifting device, lift the body of the vehicle,

the engine rotates slightly between the rear wheel
and the swingarm.
The big end raises making the tapper cover ac-
cessible.
Undo and remove the screws that secure the tap-
pet cover.
Remove the tappet cover.

Act on the crankshaft to move the piston to the up-

per dead centre.

Verify the alignment of the reference on the big

end with the one on the camshaft sprocket.

Using a feeler gauge, check the clearance be-

tween the adjuster and the valve.

Characteristic
Valve clearance (cold engine)
Intake: 0.10 ± 0.02 mm Exhaust: 0.10 ± 0.02 mm

MAIN - 63
Maintenance Vespa sei giorni 300 hpe

If an incorrect value is found, adjust it back to the

prescribed value.

Fit the tappet cover.

Insert and tighten the fastening screws at the rec-
ommended torque.

Locking torques (N*m)

Tappet cover screws 6 - 7 Nm

Position the transmission cover.

Insert and tighten the fixing screws of the trans-

mission cover to the prescribed torque.

Locking torques (N*m)

Transmission cover screws 11 - 13 Nm

MAIN - 64
Vespa sei giorni 300 hpe Maintenance

Acting on the lifting device, lower the vehicle body

to align the lower coupling of the shock absorber
with the corresponding coupling on the engine.
Insert and fasten the fixing bolt at the prescribed
torque .

Locking torques (N*m)

Rear shock absorber - Engine 40 - 45 Nm

Insert the lower fixing bolt of the right shock ab-

sorber and tighten to the specified torque.

Locking torques (N*m)

Rear shock absorber - Silencer support brack-
et 40 - 45 Nm

Insert and tighten the fuel pipe clamp fixing nut.

Insert the throttle control cable in the support

bracket.

MAIN - 65
Maintenance Vespa sei giorni 300 hpe

Insert the spark plug tube

Position the air filter box.

Insert and tighten the screws fixing the filter box to
the engine.

Using the lifting device, place the vehicle back on

the centre stand.
Disconnect the lifting equipment .
Insert the helmet compartment.
fit the silencer.
Assemble the side fairings and the footrest termi-
nals.
Connect the battery cables.

Cooling system

Level check

check the fluid when the engine is cold, according

to the scheduled maintenance table, in the way
shown below:
- Position the vehicle on the central stand.
- Unscrew the expansion chamber cover fastening
screw.

MAIN - 66
Vespa sei giorni 300 hpe Maintenance

- Check that the coolant level is between the

"MIN" and "MAX" indications on the tank.

Top-up

If necessary, top the cooling system up, with the engine cold, if you find the liquid is too close to the
minimum level. If it becomes necessary to top-up the coolant level at frequent intervals, or you find that
the expansion chamber is completely dry, check the cooling system to find the cause of the problem.
Replace the coolant, using the recommended product, in accordance with the instructions provided in
the scheduled maintenance table. For instructions on how to drain the system, refer to the dedicated
section of the chapter covering the «Cooling System».
WARNING

TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW THE EXPANSION TANK COVER WHILE
THE ENGINE IS STILL HOT.
WARNING

TO PREVENT AVOID HARMFUL FLUID LEAKAGE WHILE RIDING, ENSURE THAT THE LEVEL
NEVER EXCEEDS THE MAXIMUM VALUE.
TO ENSURE CORRECT ENGINE OPERATION, KEEP THE RADIATOR GRILLE CLEAN.

Braking system

Level check

Rest the vehicle on its centre stand and with the

handlebars perfectly horizontal.
Check the liquid level through the relative inspec-
tion sight glass.
If the sight glass is full, the brake fluid level is cor-
rect. If the brake fluid is near the «MIN» reference,
top-up

MAIN - 67
Maintenance Vespa sei giorni 300 hpe

Headlight adjustment

Proceed as follows:
1. Position the vehicle in running order and with
the tyres inflated to the prescribed pressure, onto
a flat surface 10 m away from a half-lit white
screen; ensure that the longitudinal axis of the ve-
hicle is perpendicular to the screen;
2. Turn on the headlight and check that the boun-
dary of the light beam projected onto the screen is
not higher than 9/10 or lower than 7/10 of the dis-
tance between the centre of the headlight and the
ground;
3. If this is not the case, adjust the headlight by
turning the screw.
N.B.
THE PROCEDURE DESCRIBED IS THAT ESTABLISHED
BY EUROPEAN STANDARDS FOR THE MAXIMUM AND
MINIMUM HEIGHT OF THE LIGHT BEAM. REFER TO THE
STATUTORY REGULATIONS IN FORCE IN EVERY COUN-
TRY WHERE THE VEHICLE IS USED.

Anti-evaporation system

The vehicle is equipped with the "Canister", main component of the system for the control of evaporative
emissions, compliant with the current standards.

A. Fuel pump
B. Fuel tank
C. Two-way fuel vapour ventilation valve
D.Canister
E.Air purge pipe into atmosphere
F.One-way electronic fuel vapour purge control
valve (controlled by ECU)
G. Vacuum fitting
H. Throttle body
I. Air induction fitting
L. Injector

MAIN - 68
Vespa sei giorni 300 hpe Maintenance

The evaporative emissions control system is located on the rear left hand side of the vehicle.
Key:
1 Canister
2 Bleeder pipe
3 Pipe for connecting the canister to the inlet fitting
4 Canister valve
5 Pipe for connecting the fuel tank to the canister

MAIN - 69
Maintenance Vespa sei giorni 300 hpe

Key:
6 Breather valve

Removing system components

Remove the helmet compartment to gain access to the components of the evaporative emissions con-
trol system.

MAIN - 70
Vespa sei giorni 300 hpe Maintenance

After having removed the clamps, unscrew the

fastening screw to release the system and bring
the components inside the engine compartment.

Refitting system components

Upon reassembling the components, use caution
when connecting the pipes to the canister.

1. canister - insertion coupling connection pipe.

2. tank - canister connection pipe.
3. Bleeder pipe.

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Maintenance Vespa sei giorni 300 hpe

Refit the components by properly inserting the pipes and securing them with new metal clamps.
CAUTION

TAKE CARE TO ENSURE THE PROPER DIRECTION OF THE COMPONENTS' INSTALLATION: IF

INSTALLED IN REVERSE, THEY COULD COMPROMISE THE FUNCTIONALITY OF THE ENTIRE
EVAPORATING SYSTEM.
After having installed the components, secure the pipes with new ties.

MAIN - 72
Vespa sei giorni 300 hpe Maintenance

Upon refitting the canister valve, observe the di-

rection of the arrow toward the engine.

Refit the canister support bracket on the chassis

and tighten the fastening screws.

Locking torques (N*m)

Canister - Frame support bracket 12.0 ± 1.0 Nm

MAIN - 73
Maintenance Vespa sei giorni 300 hpe

Make sure that the orientation of the breather valve

is correct.
If you detect different pressures, replace the valve.

Characteristic
Discharge pressure
80/100 mbar
Intake pressure
≤ 20 mbar

Canister inspection

The canister is essential to treat the hydrocarbons present in the volume of gas that escapes from the
tank when there is an increase in internal pressure (tank heating induced by the cooling radiator, by the
motor or by the external environment).
Although the amount of hydrocarbons coming from the tank is small enough to avoid the saturation of
the canister, it is necessary to regenerate the activated carbon by means of a reversed flow of ambient
air sucked by the engine.
These vacuums of pollution and carbon regeneration take place at each cycle of use of the vehicle.

To control the canister, it is necessary to proceed

with its removal while keeping the 2 pipes connec-
ted.

• Shake the Canister and make sure

there is no noise.
• Using a compressed air gun, blow al-
ternately in 3 ducts and make sure that
pressure does not build inside the can-
ister.
• Check that the air flow is kept free and
that no carbon residues escape out of
any pipe.

If you detect noise, clogging or loss of carbon, re-

place the canister.

MAIN - 74
INDEX OF TOPICS

TROUBLESHOOTING TROUBL
Troubleshooting Vespa sei giorni 300 hpe

This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

LOW LUBRICATION PRESSURE

Possible Cause Operation
By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation
Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass contact surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch housing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation
Inefficient braking system Check the pad wear (1.5 MIN). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and replace brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

TROUBL - 76
Vespa sei giorni 300 hpe Troubleshooting

Possible Cause Operation

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle

Brakes overheating

BRAKES OVERHEATING
Possible Cause Operation
Defective plunger sliding Check calliper and replace any damaged part.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air.
Swollen or glued rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation
Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.

Noisy suspension

NOISY SUSPENSION
Possible Cause Operation
Faults in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorbers; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disc in the
attachment to the hub and the steering tube.

TROUBL - 77
Troubleshooting Vespa sei giorni 300 hpe

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation
Faulty or broken seals Replace the shock absorber. Check the condition of wear of
the steering covers and the adjustments.

TROUBL - 78
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system Vespa sei giorni 300 hpe

Components arrangement

ELE SYS - 80
Vespa sei giorni 300 hpe Electrical system

1. ABS control unit: Remove the leg shield back

plate to reach it.

2. Immobilizer antenna: Remove the leg shield

back plate to reach it.

3. Electronic injection control unit: To access re-

move the helmet compartment.

4. Diagnostics connector: To access remove the

helmet compartment.

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Electrical system Vespa sei giorni 300 hpe

5. H.V. coil: Located above the transmission cover,

remove the battery to gain access to it.

6. relays: Remove the central front cover to reach

them.

7. Horn: Remove the central front cover to reach

them.

8. Starter relay: To access remove the helmet

compartment.

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Vespa sei giorni 300 hpe Electrical system

9. Fuses: Open the top box to reach them

10. Voltage regulator: to access remove the bat-

tery.

11. Magneto flywheel connector: remove the foot-

rest to reach it.

12. Pick-up connector: remove the footrest to

reach it.

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Electrical system Vespa sei giorni 300 hpe

13. Roll-over sensor: Remove the footrest to reach

it.

14. Ignition switch contacts: Remove the leg shield

back plate to reach it.

15. fuel level sensor: To access remove the helmet

compartment.

16. Coolant temperature sensor: To access re-

move the helmet compartment.

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Vespa sei giorni 300 hpe Electrical system

17. Direction indicator device: Remove the leg

shield back plate to reach it.

18. front phonic wheel sensor connector: Remove

the leg shield back plate to reach it.

19. Front left turn signal and daylight running light

connector: Remove the leg shield back plate to
reach it.

20. Front right turn signal and daylight running light

connector: Remove the leg shield back plate to
reach it.

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Electrical system Vespa sei giorni 300 hpe

21. Fuel pump: To access remove the helmet com-

partment.

22. rear phonic wheel sensor connector: To ac-

cess remove the helmet compartment.

23. Injector: To access remove the helmet com-

partment.

24. Bike finder device: Remove the leg shield back

plate to reach it.

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Vespa sei giorni 300 hpe Electrical system

25. Accessories connector: Remove the central

front cover to reach them.

26. Right hand handlebar device connector

27. Warning light unit connector
28. Left hand handlebar device connector
Remove the leg shield back plate to reach it.

Instrument panel

A = Speedometer
B = Odometer
C = Engine temperature warning light

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Electrical system Vespa sei giorni 300 hpe

D = ABS warning light

E = Immobilizer indicator light
F = Turn indicator warning light
F = Engine control warning light
H = Clock function set-up button
I = Clock function selector button
L = Clock
M = Low engine oil pressure warning lamp
N = Reserve fuel tank warning light
O = Fuel gauge
P = Low beam headlight warning light
Q = High beam headlight warning light

Ground points

There are two ground connections on the vehicle:

The engine ground, indicated with the letter "A".
The chassis ground, indicated with the letter "B".
Located in the rear left of the vehicle, to access
them remove the helmet compartment.

Checks and inspections

Immobiliser

The electronic ignition system is controlled by the injection electronic control unit with the integrated
Immobilizer system. The immobilizer is an anti-theft system which allows the vehicle to work only if it
is activated by means of the coded keys that the control unit recognises. The code is stored in a trans-
ponder installed in the body of the key. This allows the driver clear operation without having to do
anything other than just turning the key.
The Immobilizer system consists of the following components: - injection electronic control unit. - im-
mobilizer antenna - master key with built-in transponder - reserve key - diagnostic led on the instrument
panel
The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the
ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF"
position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition

ELE SYS - 88
Vespa sei giorni 300 hpe Electrical system

switch is turned to "ON", it interrupts the function of the Immobilizer lamp and a start enable lamp comes
"ON". The length of time the lamp remains for depends on the control unit settings.
The diagnostic LED is normally mounted on the instrument panel and receives its power supply directly
from the battery. It is controlled by the injection electronic control unit via a negative signal. If the LED
is extinguished, irrespective of the position of the ignition switch and/or the instrument panel does not
initialise, check: - that the emergency stop button functions correctly; - the connection line used to
manage the diagnostic LED, between the injection electronic control unit and the instrument panel; -
the connection line between the injection electronic control unit and the emergency stop switch.

NOTE: CONSULT THE SPECIFIC ELECTRICAL CIRCUIT DIAGRAM FOR THE VEHICLE WHEN
CARRYING OUT THE FOLLOWING OPERATIONS
Emergency stop button check
1. Disconnect the emergency stop button electrical connector and carry out a continuity check on the
connection lines to the injection electronic control unit; 2. Carry out a continuity check on the connection
line between emergency stop button and ground. 3. Using a multimeter, check that the emergency stop
button functions correctly; connect the terminals of the multimeter between the two pins on the switch
that are connected to ground and the injection electronic control unit. Press the button and check that
it functions correctly.
Electronic injection control unit check
1. Disconnect the connector from the injection electronic control unit. 2. Make sure that the connection
line between the injection electronic control unit and the instrument panel (diagnostic LED management
line) is not shorted to the battery. 3. Carry out a continuity test on the connection line between the
injection electronic control unit and the instrument pane (diagnostic LED management line).
If no faults are found, replace the injection electronic control unit.
Instrument panel check
1. Disconnect the instrument panel electrical connector. 2. Make sure that the connection line between
the injection electronic control unit and the instrument panel (diagnostic LED management line) is not
shorted to the battery. 3. Carry out a continuity test on the connection line between the engine electronic
control unit and the instrument pane (diagnostic LED management line).
If no other faults are found, replace the instrument panel.

After removing the leg shield back plate, remove

the electrical connection from the antenna as
shown in the picture.

ELE SYS - 89
Electrical system Vespa sei giorni 300 hpe

Remove the protective base from the connector.

With the ignition switch at «ON» check if there is

battery voltage between the Red-White and Black
cables.

Virgin circuit

When the ignition system is not encoded, any key can operate the engine limited to 2,000 rpm. The
keys can only be recognised if the control unit has been programmed properly.
The memorisation procedure of a new control unit provides for the recognition of the MASTER as the
first key to be saved: this becomes particularly important because it is the only key that enables
the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.

The Master and service keys must be used to code

the system as follows:
- Insert the Master key «A», switch to «ON» and
maintain this position for 2 seconds (limit values 1
- 3 seconds).
- Insert the service key «B» and switch to «ON»
for 2 seconds.
If you have duplicate copies of the service key, re-
peat the operation for each key.
- Insert the Master key again and turn it to «ON »
for 2 seconds.

The maximum time to change keys is 10 seconds.

A maximum of 3 service keys can be programmed at one time.
The times and the procedure must be followed exactly, otherwise repeat from the beginning.

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Vespa sei giorni 300 hpe Electrical system

Once the system has been programmed, master key transponder, decoder and control unit are
strictly matched.
With this link established, it is now possible to encode new service keys, in the event of losses, re-
placements, etc.
Each new programming deletes the previous one so, in order to add or eliminate keys, you must
repeat the procedure using all the keys you intend to keep using.

If a service key becomes uncoded, the efficiency

of the high voltage circuit shielding must be thor-
oughly inspected. In any case it is advisable to use
resistive spark plugs.

Characteristic
Shielded cap resistance
~ 5,000 Ω

Diagnostic codes

The Immobilizer system is tested each time the

Ignition switch is turned from «OFF» to «ON».
During this diagnosis phase a number of control
unit statuses can be identified and various light
codes displayed. Regardless of the code transmit-
ted, if at the end of the diagnosis the LED remains
off permanently, the ignition is enabled. If, howev-
er, the LED remains on permanently, it means the
ignition is inhibited:
1. Previously unused control unit - key inser-
ted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be star-
ted but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transpond-
er absent or cannot be used: the LED is on
permanently. In this condition no operations are
possible including the start up of the vehicle.

ELE SYS - 91
Electrical system Vespa sei giorni 300 hpe

3. Programmed control unit - the service key in

(normal condition of use): a single 0.7-second
flash is displayed, after which the LED remains off
steadily. The engine can be started.
4. Programmed control unit - Master key in: a
0.7-sec flash is displayed followed by the LED re-
maining off for 2 sec and then by short 0.46-sec
flashes, the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
LED remains permanently OFF. The engine can
be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-
mitted are:

• 1-flash code
• 2-flash code
• 3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the
Immobilizer antenna wiring and change it if nec-
essary.

ELE SYS - 92
Vespa sei giorni 300 hpe Electrical system

Diagnostic code - 2 flashes

A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This
might depend on the inefficiency of the Immobilizer
antenna or the transponder.
Turn the switch to ON using several keys: if the
code is repeated even with the Master key, check
the antenna wiring and change it if necessary. If
this is not the case, replace the defective key and/
or reprogram the control unit. Replace the control
unit if the problem continues.

Diagnostic code - 3 flashes

A three-flash code indicates a system where the

control unit does not recognise the key. Turn the
switch to ON using several keys: if the error code
is repeated even with the Master key, replace the
control unit. If this is not the case, reprogram the
decoder.

Lights list

This section lists the bulb types required for the

vehicle's equipment.

BULBS
Specification Desc./Quantity
1 High beam/low beam bulb (for right-hand riding) Type: Halogen (H4)
Power: 12V - 55W/60W
Quantity: 1
2 High beam/low beam bulb (for left-hand riding) Type: Halogen (S2)
Power: 12V - 35W/35W
Quantity: 1

ELE SYS - 93
Electrical system Vespa sei giorni 300 hpe

Specification Desc./Quantity
3 Front side light bulb (front headlamp) Type: All glass
Power: 12V - 5W
Quantity: 1
4 Front side light bulb lamp (front shield) Type: LED
Power: -
Quantity: 2
5 Front and rear turn indicator bulbs Type: All glass
Power: 12V - 6W
Quantity: 4
6 Rear tail light bulb Type: LED
Quantity: 2
7 Stop light bulb Type: LED
Quantity: 1
8 Licence plate light bulb Type: LED
Quantity: 2

Fuses

The electrical system is equipped with:

1. one fuse «A», located in the battery compart-
ment;

2. six protection fuses «B» located in the glove

compartment to the left;

3. one fuse «C» located under the seat, accessible

by extracting the helmet compartment.
The tables show the position and characteristics
of the fuses on the vehicle.
CAUTION

BEFORE REPLACING THE BLOWN FUSE, TRY TO ELIMI-

NATE THE FAULT THAT HAS CAUSED IT TO BLOW. NEV-
ER TRY TO REPLACE A FUSE USING DIFFERENT MATE-
RIAL (FOR EXAMPLE A PIECE OF ELECTRIC WIRE).
CAUTION

ELE SYS - 94
Vespa sei giorni 300 hpe Electrical system

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS-

TEM, PERFORMED INCORRECTLY OR WITHOUT STRICT
ATTENTION TO THE TECHNICAL SPECIFICATIONS OF
THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK
OF FIRE.

Fuse «A».

FUSE «A»
Specification Desc./Quantity
1 Fuse no. 1 Capacity: 30 A
Protected circuits: battery recharge, fuses No. 2-3-4.
Protected circuits (key-on power): Fuses No. 5-6-7.

Fuse «B».

FUSE «B»
Specification Desc./Quantity
1 Fuse no. 2 Capacity: 10 A
Protected circuits: engine control unit, injection loads
relay (contacts), lambda probe heater, canister solenoid
valve, electric fan relay (coil).
2 Fuse no. 3 Capacity: 15 A
Protected circuits: electric fan (via relay), fuse No. 8,
instrument cluster, headlamp (via relay), accessories
provision.
Protected circuits (key-on power): electrical saddle
opening.
3 Fuse no. 4 Capacity: 25 A
Protected circuits: ABS ECU.
4 Fuse no. 5 Capacity: 7.5 A
Protected circuits (key-on power): ABS control unit,
engine control unit, immobilizer aerial, tilting sensor, ig-
nition button, injection load relay.
5 Fuse no. 6 Capacity: 7.5 A
Protected circuits (key-on power): key-on power for
horn, light selector switch, horn, brake lights, flasher unit.
6 Fuse no. 7 Capacity: 7.5 A

ELE SYS - 95
Electrical system Vespa sei giorni 300 hpe

Specification Desc./Quantity
Protected circuits (key-on power): daylight running
lights, license plate light, OBD port, USB port, pre-wiring
for accessories,instrument panel.

Fuse «C».

FUSE «C»
Specification Desc./Quantity
1 Fuse no. 8 Capacity: 5 A
Protected circuits: OBD port.

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 - 14.70V
- Initial charge voltage equal to 0.3 - 0.5 for Nominal capacity
- Charge time:
10 - 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h

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Vespa sei giorni 300 hpe Electrical system

Battery installation
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY
COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR
APPROX. 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.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.

2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.

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Electrical system Vespa sei giorni 300 hpe

Note: If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Only once the container is completely empty, gently remove the container
itself from the battery. Leave the battery to rest, without sealing the six cells, for at least 1 hour before
charging.

6) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry charge battery MF like the completely loa-
ded YTX, must have a zero load voltage between
12.8 - 13.15 V Bring the battery to full charge, us-
ing the 020648Y battery charger:
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

ELE SYS - 98
Vespa sei giorni 300 hpe Electrical system

e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.

f - Check the ignition of the green LED indicated

with a red arrow in figure.

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i

i - The battery is now properly activated, disconnect the battery charger from the power supply and
unplug the terminals from the battery.
7) Battery closing.
Insert the airtight cover strips into the filling holes.
Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery.

ELE SYS - 99
Electrical system Vespa sei giorni 300 hpe

Note: To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Assembly procedure of the battery on the vehicle.

Connectors

ROLL-OVER SENSOR CONNECTOR

1. Not connected
2. GrVe - Ground reference from injection elec-
tronic control unit
3. RsBi - Ignition switch controlled power supply
4. GrNe - Signal output for injection electronic con-
trol unit

OIL PRESSURE PICK-UP/SENSOR CONNEC-

TOR
1. Rs - Signal (+) from injection electronic control
unit
2. Ma - Signal (-) from injection electronic control
unit
3. RoBi - Engine oil pressure indicator command
signal

RIGHT HAND HANDLEBAR DEVICE CONNEC-

TOR
1. Bi - Ignition key-controlled power supply (right
hand STOP button)
2. BiNe - Starter relay coil and STOP light com-
mand signal (+) output
3. MaRs - Engine start signal output (+) for injec-
tion electronic control unit
4. RsBi - Ignition controlled power supply
5. GrVe - Ground reference from injection elec-
tronic control unit
6. VeNe - Engine stop signal output (-) for injection
electronic control unit

ELE SYS - 100

Vespa sei giorni 300 hpe Electrical system

LEFT HAND HANDLEBAR DEVICE CONNEC-

TOR
1. BiNe - Starter relay coil and STOP light com-
mand signal (+) output
2. Bi - Ignition key-controlled power supply (left
hand STOP button)
3. Bi - Ignition key-controlled power supply (horn
function)
4. GiRo - Horn command signal (+) output
5. Ro - Left hand direction indicator lights signal
(+) output
6. BLNe - Signal input from flasher
7. BiBL - Right hand direction indicator lights signal
(+) output
8. GiNe - High-beam headlights relay coil com-
mand signal (+) output
9. Bi - Ignition key-controlled power supply (high-
beam low-beam headlights function)
10. MaBi - Low-beam headlights relay coil com-
mand signal (+) output

IGNITION SWITCH CONNECTOR

1. Gr - Battery power supply input
2. Not connected
3. BLNe - Ignition switched power feed output for
saddle release button
4. Ar - Ignition key-controlled power supply output
5. RsNe - Battery power supply input

LOW-BEAM HEAD LIGHTS RELAY CONNEC-

TOR
30. Gr - Battery power supply
85. Ne - Ground
86. MaBi - Signal (+) input from external lights
switch
87. Ma - Low-beam headlights ON command sig-
nal (+) output

ELE SYS - 101

Electrical system Vespa sei giorni 300 hpe

HIGH-BEAM HEAD LIGHTS RELAY CONNEC-

TOR
30. Gr - Battery power supply
85. Ne - Ground
86. GiNe - Signal (+) input from external lights
switch
87. Vi - High-beam headlights ON command signal
(+) output

FRONT RIGHT DIRECTION INDICATOR LIGHT

CONNECTOR
1. BiBL - Signal (+) input from direction indicator
switch
2. GiNe - Ignition key-controlled power supply
(parking lights)
3. Ne - Ground

FRONT LEFT DIRECTION INDICATOR CON-

NECTOR
1. Ro - Signal (+) input from direction indicator
switch
2. GiNe - Ignition key-controlled power supply
(parking lights)
3. Ne - Ground

VOLTAGE REGULATOR CONNECTOR

1. RsNe - Battery power supply
2. Ne - Ground

ELE SYS - 102

Vespa sei giorni 300 hpe Electrical system

ELECTRIC FAN CONNECTOR

1. Ne - Ground
2. Rs - Signal input (+) from electric fan relay

IMMOBILIZER ANTENNA CONNECTOR

1. RsBi - Ignition controlled power supply
2. Ne - Ground
3. ArBi - Signal output for injection electronic con-
trol unit (start enable)

HORN CONNECTOR
1. Ne - Ground
2. GiRo - Signal (+) input from horn button

SADDLE OPENING BUTTON CONNECTOR

1. BLNe - Ignition controlled power supply
2. BL - Saddle opening motor actuator command
signal (+) output

ELE SYS - 103

Electrical system Vespa sei giorni 300 hpe

FUSE BOX CONNECTOR

1. BiNe - Battery power supply output (injection
control unit, injection loads relay)
2. Gr - Battery power supply output (electric fan
relay, low-beam headlights relay, high-beam
headlights relay, accessories pre-installation con-
nector, ignition switch, immobilizer indicator man-
agement instrument panel, OBD socket)
3. GrRs - Battery power supply output (ABS control
unit)
4. RsBi - Ignition key-controlled power supply out-
put (ABS control unit, immobilizer antenna, injec-
tion loads relay coil, engine start button, injection
electronic control unit, tilt sensor)
5. Bi - Ignition key-controlled power supply output
(external lights switch, horn button, left and right
hand STOP buttons, USB port, blinker, accesso-
ries pre-installation connector)
6. GiNe - Ignition key-controlled power supply out-
put (taillight, front light assemblies, instrument
panel, indicators assembly, OBD socket)
7. RsNe - Battery power supply input
8. RsNe - Battery power supply input
9. RsNe - Battery power supply input
10. Ar - Ignition key-controlled power supply
11. Ar - Ignition key-controlled power supply
12. Ar - Ignition key-controlled power supply

WIRING FOR ACCESSORIES - CONNECTOR

1. Ne - Ground
2. BiVe - Fuel gauge
3. RoRs - CAN H line
4. RoBi - CAN L line
5. ArNe - ISO K line
6. Not connected
7. Gr - Battery power supply
8. Bi - Ignition controlled power supply
9. Not connected

ELE SYS - 104

Vespa sei giorni 300 hpe Electrical system

10. Ro - Signal input from saddle opening button

11. Ro - Left hand direction indicators
12. BiBL - Right hand direction indicators
13. Vi - High beam lights
14. Az - Vehicle speed

HEADLIGHT CONNECTOR
1. Not connected
2. Ma - High-beam headlights ON command signal
(+) input
3. Vi - Low-beam headlights ON command signal
(+) input
4. Ne - Ground

BATTERY CONNECTOR
1. Rs - Power supply output (main fuse 30A, starter
motor relay contact)
2. Ne - Ground

HV COIL CONNECTOR.
1. RoNe - Signal (-) input from injection electronic
control unit
2. NeVe - Power supply input from injection loads
relay

LAMBDA PROBE CONNECTOR

1. Signal (+) for injection electronic control unit
2. Signal (-) for injection electronic control unit
3. NeVe - Power supply input from injection loads
relay (lambda probe heater)
4. AzRs - Ground reference from injection elec-
tronic control unit (lambda probe heater)

ELE SYS - 105

Electrical system Vespa sei giorni 300 hpe

ENGINE/CHASSIS GROUND CONNECTOR

- Ne - Chassis/engine ground

REAR LEFT DIRECTION INDICATOR LIGHT

CONNECTOR
1. Ne - Ground
2. Ro - Signal (+) input from direction indicator
switch

REAR RIGHT DIRECTION INDICATOR LIGHT

CONNECTOR
1. Ne - Ground
2. BiBL - Signal (+) input from direction indicator
switch

TAILLIGHT CONNECTOR
1. GiNe - Ignition key-controlled power supply
(parking lights)
2. Ne - Ground
3. BiNe - STOP light activation signal (+) input

ELE SYS - 106

Vespa sei giorni 300 hpe Electrical system

INJECTOR CONNECTOR
1. NeVe - Power supply input from injection loads
relay
2. RsGi - Signal (-) input from injection electronic
control unit

COOLANT TEMPERATURE SENSOR CON-

NECTOR
1. GrVe - Ground reference from injection elec-
tronic control unit
2. Not connected
3. AzVe - Signal output for injection electronic con-
trol unit
4. Not connected

ABS CONTROL UNIT CONNECTOR

1. Not connected
2. RoRs - CAN H
3. BLVe - ABS indicator command signal (-) output
4. RsBi - Ignition controlled power supply
5. ArNe - ISO_K
6. MaRs - Signal from rear ABS sensor
7. Not connected
8. AzRs - Signal from front ABS sensor
9. Not connected
10. Ne - Ground
11. RoBi - CAN L
12. Not connected
13. Az - Vehicle speed signal output
14. Ne - Ground PCC_2
15. MaNe - Ground reference for rear ABS sensor
16. Ne - Ground_PCC1
17. AzNe - Ground reference for front ABS sensor
18. GrRs - Battery power supply

ELE SYS - 107

Electrical system Vespa sei giorni 300 hpe

FRONT ABS SENSOR CONNECTOR

1. AzNe - Ground reference from ABS control unit
2. AzRs - Signal for ABS control unit

REAR ABS SENSOR CONNECTOR

1. MaNe - Ground reference from ABS control unit
2. MaRs - Signal for ABS control unit

USB PORT CONNECTOR

1. Bi - Ignition controlled power supply
2. Ne - Ground

SADDLE ACTUATOR CONNECTOR

1. Ne - Ground
2. BL - Signal (+) input from saddle opening button

ELE SYS - 108

Vespa sei giorni 300 hpe Electrical system

INJECTION LOAD RELAY CONNECTOR

30. BiNe - Battery power supply input
85. NeVi - Signal (-) input from injection electronic
control unit (coil command)
86. RsBi - Ignition key-controlled power supply
87. NeVe - Power supply output for injection loads

MAIN FUSE CONNECTOR

1. Rs - Battery power supply input
2. RsNe - Protected battery power feed output

OBD SOCKET CONNECTOR

1. GiNe - Ignition controlled power supply
2. RoRs - CAN H
3. Ne - Ground
4. RsGi - Battery power supply
5. RoBi - CAN L
6. ArNe - K Line

OBD SOCKET FUSE CONNECTOR

1. RsGi - Power supply output for OBD socket
2. Gr - Battery power supply

ELE SYS - 109

Electrical system Vespa sei giorni 300 hpe

FUEL PUMP CONNECTOR

1. Ne - Ground
2. NeVe - Power supply input from injection loads
relay

STARTER RELAY CONNECTOR

30. Rs - Battery power supply
87. Power supply output for starter motor

FUEL LEVEL TRANSMITTER CONNECTOR

1. BiVe - Signal output for instrument panel and
accessories pre-installation connector
2. Ne - Ground
3. GiVe - Power supply input from instrument panel
(reserve indicator management)

STAND SENSOR CONNECTOR

1. MaRs - Signal (-) for injection electronic control
unit
2. GrVe - Ground reference from injection elec-
tronic control unit

ELE SYS - 110

Vespa sei giorni 300 hpe Electrical system

INJECTION ECU CONNECTOR

1. RoNe - Coil command signal output (-)
2. Not connected
3. Not connected
4. VeNe - Engine stop switch signal input
5. MaRs - Ignition button signal input
6. RsBi - Ignition controlled power supply
7. Ne - Power ground
8. Not connected
9. BiNe - Battery power supply
10. ArBL - Starter relay coil command signal (-)
output
11. AzNe- Lambda probe (+)
12. BiVe - Lambda probe (-)
13. AzVe - Engine temperature sensor signal input
14. ArBi - Immobilizer (start enable) signal input
15. GrVe - Ground reference for sensors
16. Not connected
17. RsVe - Immobilizer indicator on command sig-
nal (-) output
18. GrNe - Signal input from tilt sensor
19. MaRs - Stand button signal (-) input
20. Ma - Pick-up (-)
21. Not connected
22. NeVi - Injection loads relay coil command sig-
nal (-) output
23. Ne - Power ground
24. BLGi - Engine electric fan relay coil command
signal (-) output
25. MaNe - Injection indicator command signal (-)
command
26. RoRs - CAN H
27. RoBi - CAN L
28. Not connected
29. Rs - Pick-up (+)
30. Not connected
31. AzRs - Ground reference for lambda probe
heater

ELE SYS - 111

Electrical system Vespa sei giorni 300 hpe

32. BiRs - Canister valve

33. VeGi - Coolant temperature indicator com-
mand signal (-) output
34. RsGi - Injector power supply

BLINKER CONNECTOR
L. BLNe - Signal output for blinkers switch
B. Bi - Ignition controlled power supply

INSTRUMENT PANEL CONNECTOR

1. GiNe - Ignition key-controlled power supply for
fuel level indicator
2. BiVe - Fuel level indicator command signal input
from fuel level sender
3. GiVe - Fuel reserve indicator command signal
input from fuel level sender
4. RoBi - Oil indicator command signal input from
engine oil pressure sensor
5. Vi - High-beam headlights indicator command
signal input from high-beam headlights relay
6. GiNe - Ignition key-controlled power supply for
instrument panel lighting and parking lights indi-
cator
7. Ne - Ground

ELECTRIC FAN RELAY CONNECTOR

30. Gr - Battery power supply
85. BLGi - Coil command signal (-) input from in-
jection electronic control unit
86. NeVe - Coil power supply input from injection
loads relay
87. Rs - Power supply output for electric fan motor

ELE SYS - 112

Vespa sei giorni 300 hpe Electrical system

INDICATOR LIGHTS UNIT CONNECTOR

1. Ro - Left hand direction indicators warning light
signal (+) input from direction indicators switch
2. BiBL - Right hand direction indicators warning
light signal (+) input from direction indicators
switch
3. GiNe - Ignition key-controlled power supply for
water temperature indicator
4. VeGi - Water temperature indicator command
signal (-) input from injection electronic control unit
5. MaNe - MIL indicator command signal (-) input
from injection electronic control unit
6. BLVe - ABS indicator command signal (-) input
from ABS control unit
7. Ne - Ground for clock lighting
8. GiNe - Ignition key-controlled power supply for
clock lighting
9. RsVe - Immobilizer indicator command signal (-)
input from injection electronic control unit
10. Gr - Battery power supply for Immobilizer indi-
cator
11. Not connected
12. Not connected

Canister Valve
1. (Red/White) Signal output for MIUG4 control
unit
2. (Black/Green) - Reference ground

Diagnostic instrument

APPLY LOCTITE FORTE 263 ON THE SCREW FIXING THE PISTON COOLING NOZZLE.

ERROR CODES
PCODE Description
P0108 Pressure sensor - SC to Vbatt
P0107 Pressure sensor - SC to Gnd
P0132 Lambda probe - SC to Vbatt

ELE SYS - 113

Electrical system Vespa sei giorni 300 hpe

PCODE Description
P0130 Lambda probe - SC to Gnd
P0133 Lambda probe - Signal not plausible
P0134 Lambda probe - OC
P0118 Engine temperature sensor - SC to Vbatt
P0117 Engine temperature sensor - SC to Gnd
P0113 Air temperature sensor - SC to Vbatt
P0112 Air temperature sensor - SC to Gnd
P0563 Battery voltage - SC to Vbatt
P0562 Battery voltage - SC to Gnd
P0336 Engine revolution sensor (operational) - Implausible signal
P0262 Injector - SC to Vbatt
P0261 Injector - SC to Gnd
P0201 Injector - OC
P2301 Coil - SC to Vbatt
P2300 Coil - SC to Gnd
P0232 Fuel pump relay - SC to Vbatt
P0231 Fuel pump relay - SC to Gnd
P1652 MIL warning lamp - SC to Vbatt
P1651 MIL warning lamp - SC to Gnd
P0650 MIL warning lamp - OC
P1964 ASR warning lamp (anti-slip control) - SC to Vbatt
P1965 ASR warning lamp (anti-slip control) - SC to Gnd
P1965 ASR warning lamp (anti-slip control) - OC
P0692 Cooling fan relay - SC to Vbatt
P0691 Cooling fan relay - SC to Gnd
P0480 Cooling fan relay - OC
P0032 Lambda probe heater - SC to Vbatt
P0031 Lambda probe heater - SC to Gnd
P0030 Lambda probe heater - OC
P0606 ECU microprocessor - signal not plausible
P0123 Throttle valve position sensor - SC to Vbatt
P0120 Throttle valve position sensor - SC to Gnd
P1800 Rear wheel radius acquisition - signal not plausible
U0001 Bus off on CAN - SC to Gnd
U0002 NCM node absent - signal not plausible
U0121 CAN line diagnosis (ABS node) - OC
U1121 CAN line diagnosis (ABS node) - signal not plausible
P130A Headlights relay - SC to Vbatt
P130B Headlights relay - SC to Gnd
P130C Headlights relay - OC
P0509 Stepper motor control - SC to Vbatt
P0508 Stepper motor control - SC to Gnd
P0505 Stepper motor control - OC
P0511 Stepper motor control - Implausible signal
U1185 Immobilizer error - SC to Gnd
U0185 Immobilizer error - OC
U0486 Immobilizer error - signal not plausible
P0512 Starter button - signal not plausible
P0217 Engine overtemperature state - signal not plausible
P0604 ECU RAM test - signal not plausible
P0601 ECU EEPROM test - signal not plausible
P0459 Canister purge valve - SC to Vbatt
P0458 Canister purge valve - OC or SC to Gnd
P1308 Wheel radius not acquired - signal not plausible
P0301 Misfire - signal not plausible
P0301 Misfire - OC
P0171 Lean air/fuel mixture - signal not plausible
P0172 Rich air/fuel mixture - signal not plausible
P0114 Air temperature sensor - OC
P0111 Air temperature sensor - signal not plausible
P0119 Engine temperature sensor - OC
P0116 Engine temperature sensor - signal not plausible
P1206 Pressure sensor - OC
P1106 Pressure sensor - signal not plausible
P1761 Electric tip-over sensor - SC to Vbatt
P1762 Electric tip-over sensor - SC to Gnd

ELE SYS - 114

Vespa sei giorni 300 hpe Electrical system

PCODE Description
P1101 Throttle valve position sensor - signal not plausible
P1108 Manifold pressure too low - signal not plausible
P1607 Data buffer - signal not plausible

ELE SYS - 115

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Vespa sei giorni 300 hpe Engine from vehicle

Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.

Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.

FRAME ASSEMBLY
Name Torque in Nm
Swinging arm pin - engine 64 - 72
swinging arm bolt - body shell 76 to 83
Engine and vehicle side swinging arm junction bolt 33 - 41
Bolt of the Silent block support plate 42 to 52
Central stand bolt 32 - 40
Side stand fixing bolt 35 - 40

REAR SUSPENSION
Name Torque in Nm
Retainer for left shock absorber to crankcase support plate 20 - 25
Shock absorber lower fitting 40 - 45
Shock absorber upper fitting 20 - 25
Rear wheel axle 104 ÷ 126
Screw fixing wheel to hub 20 - 25
Screws for silencer - shock absorber support arm on engine 20 - 25 (The two screws must be tightened after having done
so with the rear wheel axle nut at the specified torque. Safety
fasteners: see «Pre-delivery Operations»)
Engine- and vehicle-side swinging arm junction bolt 40 - 45

SILENCER
Name Torque in Nm
Silencer heat guard fixing screw 4-5
Screw used to fasten silencer to supporting arm 20 - 25
Lambda probe tightening on exhaust manifold 40 - 50
Manifold/silencer joint tightening torque 12 - 13
Manifold - silencer diaphragm tightening clamp 16 - 18

Exhaust assy. Removal

- Remove the left and right fairing and spoiler terminals.

- Remove the Lambda probe from its support and

disconnect it.

ENG VE - 117
Engine from vehicle Vespa sei giorni 300 hpe

Remove the lambda probe cable retainer clamp

from the coolant pipe shown in the photo

- Undo the two exhaust manifold fixings on the

head. To unscrew the nuts that fix the silencer
flange to the head properly, use a jointed wrench
that allows, according to the travel direction, to get
also at the right nut. That is difficult to do with a
traditional straight wrench.

- Undo the three screws that fix the muffler to the

support arm.
- Remove the complete silencer.

- Remove the lambda probe from the manifold.

CAUTION
WARNING

SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS REPLACE THE
GRAPHITE GASKET BETWEEN THE PRIMARY PIPE AND SILENCER.

ENG VE - 118
Vespa sei giorni 300 hpe Engine from vehicle

Removal of the engine from the vehicle

CAUTION

SUPPORT THE VEHICLE ADEQUATELY.

- Disconnect the battery.
- Remove the helmet compartment.
- Remove the side fairings and the spoiler termi-
nals.
- Remove the rear brake calliper.
- Remove the air cleaner from the housing by un-
screwing the three screws indicated in the photo-
graph.
CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE

ENGINE IS COLD.

- Remove the clamp from the blow-by pipe and

take the pipe out; remove the retainer clamp.
- Remove the clamp indicated in the photograph
and disconnect the sleeve connecting it to the
throttle body.

- Get a + 2.5 l container to collect the coolant.

ENG VE - 119
Engine from vehicle Vespa sei giorni 300 hpe

- Remove the coolant inlet pipe to the motor as

indicated in the photograph.

- Disconnect the fuel pipe from the injector and re-

move the screw locking the retainer clamp.
- Disconnect the injector wiring and the throttle
body control unit wiring.

- Disconnect the cable harnesses from the two

clamps indicated.

- Remove the coolant outlet pipe from the engine

as indicated.

ENG VE - 120
Vespa sei giorni 300 hpe Engine from vehicle

- Remove the spark plug cap.

- Remove the coolant temperature sensor con-
nector indicated in the picture.

- Remove the throttle control cables from the throt-

tle body by undoing the nuts indicated in the pho-
tograph.

- Loosen the clamp indicated in the photograph

and remove the throttle body.

- Remove the clamp retaining the starter motor

from the sleeve.

ENG VE - 121
Engine from vehicle Vespa sei giorni 300 hpe

- Remove the positive and negative wiring from the

starter motor as shown in the picture.

- Disconnect the connectors from the flywheel wir-

ing as shown in the photo.
- Release the cables from the retainer clamps.

- Remove the four retainers of the rear brake pipes

from the crankcase.
- Remove the rear shock absorbers.

ENG VE - 122
Vespa sei giorni 300 hpe Engine from vehicle

- Remove the engine-swinging arm fixing pin by

undoing the nut and operating on the head of the
pin as shown in the photograph.
- The engine is now free.

Upon refitting the engine to the vehicle, carry out

the removal operations but in reverse order, and
respect the tightening torques shown in the «Spec-
ifications» Chapter.
- Check that there is a small clearance when the
valve is in abutment against the set screw.
- Check the engine oil level and if necessary, top
it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct
functioning.
- Pay particular attention to the sleeve, be careful
to position the throttle body reference marks as in-
dicated in the photograph.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE
THROTTLE CONTROL TRANSMISSION PROPERLY.

ENG VE - 123
INDEX OF TOPICS

ENGINE ENG
Vespa sei giorni 300 hpe Engine

This section describes the operations to be carried out on the engine and the tools to be used.

SILENCER
Name Torque in Nm
Silencer heat guard fixing screw 4-5
Screw used to fasten silencer to supporting arm 20 - 25
Lambda probe tightening on exhaust manifold 40 - 50
Manifold/silencer joint tightening torque 12 - 13
Manifold - silencer diaphragm tightening clamp 16 - 18

LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 to 17
Oil filter on crankcase fitting 27 - 33
Engine oil drainage plug/ mesh filter 24 to 30
Oil filter 4-6
Oil pump cover screws 7-9
Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 - 14
Oil pump cover plate screws 4-6
Oil sump screws 10 - 14
Minimum oil pressure sensor 12 - 14

CYLINDER HEAD
Name Torque in Nm
Spark plug 12 - 14
Cylinder head cover screws 6-7
Nuts fixing head to cylinder 7±1 + 10±1 + 90° + 90° + 90°
Head fixing side screws 11 - 12
Starter ground screw 7 to 8.5
Tappet adjustment check nut 6-8
Inlet manifold screws 11 to 13
Timing chain tensioner slider screw 10 - 14
Starter counterweight support screw 11 to 15
Timing chain tensioner support screw 11 to 13
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4-6

TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 to 13
Clutch unit nut on driven pulley 45 - 50
Driver pulley nut 75 - 83
Transmission cover screws 11 - 13 Nm
Driven pulley shaft nut 54 - 60
Rear hub cover screws 24 to 27

FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 to 13
Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)
Flywheel nut 94 - 102
Pick-up fixing screws 3-4
Screw fixing freewheel to flywheel 13 - 15

CRANKSHAFT AND CASE

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4-6
shaft) screws
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)

ENG - 125
Engine Vespa sei giorni 300 hpe

This section describes the operations to be carried out on the engine and the tools to be used.

SILENCER
Name Torque in Nm
Silencer heat guard fixing screw 4-5
Screw used to fasten silencer to supporting arm 20 - 25
Lambda probe tightening on exhaust manifold 40 - 50
Manifold/silencer joint tightening torque 12 - 13
Manifold - silencer diaphragm tightening clamp 16 - 18

LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 to 17
Oil filter on crankcase fitting 27 - 33
Engine oil drainage plug/ mesh filter 24 to 30
Oil filter 4-6
Oil pump cover screws 7-9
Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 - 14
Oil pump cover plate screws 4-6
Oil sump screws 10 - 14
Minimum oil pressure sensor 12 - 14

CYLINDER HEAD
Name Torque in Nm
Spark plug 12 - 14
Cylinder head cover screws 6-7
Nuts fixing head to cylinder 7±1 + 10±1 + 90° + 90° + 90°
Head fixing side screws 11 - 12
Starter ground screw 7 to 8.5
Tappet adjustment check nut 6-8
Inlet manifold screws 11 to 13
Timing chain tensioner slider screw 10 - 14
Starter counterweight support screw 11 to 15
Timing chain tensioner support screw 11 to 13
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4-6

TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 to 13
Clutch unit nut on driven pulley 45 - 50
Driver pulley nut 75 - 83
Transmission cover screws 11 - 13 Nm
Driven pulley shaft nut 54 - 60
Rear hub cover screws 24 to 27

FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 to 13
Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)
Flywheel nut 94 - 102
Pick-up fixing screws 3-4
Screw fixing freewheel to flywheel 13 - 15

CRANKSHAFT AND CASE

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4-6
shaft) screws
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13

ENG - 126
Vespa sei giorni 300 hpe Engine

Name Torque in Nm
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)

Automatic transmission

Transmission cover

To remove the transmission cover, proceed as fol-

lows:
- Block clutch housing rotation using the appropri-
ate tool.

Specific tooling
020423Y Driven pulley lock wrench

- Unscrew the fixing nut.

- Remove the nut and the washer.

ENG - 127
Engine Vespa sei giorni 300 hpe

- Unscrew and remove the transmission cover's

fixing screws.

- Remove the transmission cover.

Removing the driven pulley shaft bearing

To remove the driven pulley shaft support bearing,

proceed as follows:
- Remove the Seeger ring inside the transmission
cover.

- Remove the bearing using the specific tool.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020412Y 15-mm guide

ENG - 128
Vespa sei giorni 300 hpe Engine

Refitting the driven pulley shaft bearing

- Heat the transmission cover from the inside.

- Insert a new bearing using the specific tool.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020412Y 15-mm guide

- Fit the Seeger ring.

Removing the driven pulley

- Remove the clutch housing and the driven pulley

assembly.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.

Baffle roller

ENG - 129
Engine Vespa sei giorni 300 hpe

Plastic roller

- Check that the roller does not show signs of wear

and that it turns freely.
- Remove the special clamping screws as indica-
ted in the picture

- Check the outer diameter of the roller does not

have defects that could jeopardise belt functioning
- For refitting, place the roller with the belt contain-
ment edge on the engine crankcase side
- Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Inspecting the clutch drum

- Make sure that the clutch housing is not worn or

damaged.
- Measure the clutch housing inside diameter.

Characteristic
Clutch housing max. value
Max. value: Ø 134.5 mm
clutch housing standard value
Standard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft unit on the support to check
the crankshaft alignment.

ENG - 130
Vespa sei giorni 300 hpe Engine

- Using a dial gauge and the magnetic base, meas-

ure the bell eccentricity.
- Repeat the measurement at 3 positions (Central,
internal, external).
- In case of faults, replace the bell.

Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic mounting for dial gauge

Characteristic
clutch housing check: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm

Removing the clutch

To remove the driven pulley unit, proceed as fol-

lows:
- Fit the specific driven pulley spring compressor
tool, fixing it firmly in a vice.

Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley

- Insert the long pins in the "F" position, screwed

from the external side of the tool.

ENG - 131
Engine Vespa sei giorni 300 hpe

- Fit the adapter ring on the clutch.

Specific tooling
020444Y008 adapter ring

- Fit the driven pulley assembly on the tool together

with the adapter ring.

- Tightening the screw mechanism of the tool,

compress the return spring.

- Using the specific 46x55 wrench, unscrew the

clutch fixing hexagonal fixing ring.

Specific tooling
020444Y009 wrench 46 x 55

ENG - 132
Vespa sei giorni 300 hpe Engine

- Remove the hexagonal ring nut.

- Loosen the screw mechanism of the tool and
separate the driven pulley components

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.
- The masses must exhibit no traces of lubricants;
in that case, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FACING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID
VARIATION IN THE RETURN SPRING LOAD.

Characteristic
Check minimum thickness
1 mm

Pin retaining collar

- Simultaneously turn and pull the collar manually

to remove it.
N.B.
USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL-
TY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO
FAR TO AVOID DAMAGE THAT COULD COMPROMISE
THE O-RING SEAL.

ENG - 133
Engine Vespa sei giorni 300 hpe

- Remove the 4 torque server pins and pull the

pulley halves apart.

Inspecting the driven fixed half-pulley

- Measure the outside diameter of the pulley bush-

ing.
- Check the contact surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.

Characteristic
Half-pulley minimum diameter
Minimum admissible diameter: Ø 40.96 mm
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm

ENG - 134
Vespa sei giorni 300 hpe Engine

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.
- Remove the retainer ring using two flat blade
screwdrivers.
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.

- Support the pulley properly using the bell as

shown in the figure.

Specific tooling
001467Y035 Bearing housing, external ø 47
mm

- Remove the roller bearing using the modular punch.

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20-mm guide

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings

- Measure the movable half-pulley bushing inside
diameter.
- Check the contact surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.

ENG - 135
Engine Vespa sei giorni 300 hpe

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Desc./Quantity
Wear limit 0.3 mm
standard diameter Ø 41.000 - 41.035 mm
maximum allowable diameter Ø 41.08 mm

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the

threaded side using a wooden surface.
- Fit a new roller bearing as shown in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
Fit the retainer ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE SHIELDING

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020424Y Driven pulley roller casing fitting
punch

ENG - 136
Vespa sei giorni 300 hpe Engine

Refitting the driven pulley

- Insert the new oil seals and O-rings on the mov-

able half-pulley.
- Lightly grease the O-rings «A» shown in the fig-
ure.
- Fit the half-pulley over the bushing using the spe-
cific tool.
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 grams of
grease. Apply grease through one of the holes in
the bushing until it comes out through the hole on
the opposite side. This operation is necessary to
avoid the presence of grease beyond the O-rings.
N.B.
THE TORQUE SERVER CAN BE GREASED WHETHER
WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-
PLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling
020263Y Driven pulley assembly sheath

Recommended products
Molybdenum disulphide grease Lithium
grease with molybdenum disulphide
Grey black grease.

Inspecting the clutch spring

- Measure the length of the spring when it is re-

laxed.

Characteristic
Standard length
123 mm
Acceptable limit after use:
118 mm

ENG - 137
Engine Vespa sei giorni 300 hpe

Refitting the clutch

To fit the clutch unit to the driven pulley, proceed

as follows:
- Place the specific tool in the vice with the control
screw on the vertical axis.

Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley

- Prepare the tool, with the long pins inserted in the

"F" position, screwed from the external side.

- Put the adapter ring on the tool.

Specific tooling
020444Y008 adapter ring

- Insert the clutch on the adapter ring.

ENG - 138
Vespa sei giorni 300 hpe Engine

- Lubricate the end of the spring that abuts against

the torque server closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.

- Insert the drive belt into the pulley unit according

to their direction of rotation.

- Insert the pulley unit with the belt into the tool.

- Make sure that the clutch is fully inserted in the

adapter ring.
- Slightly pre-load the spring.

ENG - 139
Engine Vespa sei giorni 300 hpe

- Place the tool in the clamp with the control screw

on the horizontal axis.
- Fully pre-load the spring.
- Insert the hexagonal nut and tighten it to the pre-
scribed torque using the specific 46x55 wrench.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED CONTACTING THE CLUTCH.
N.B.
DURING THE SPRING PRE-LOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.

Specific tooling
020444Y009 wrench 46 x 55

Locking torques (N*m)

Centrifugal clutch - Driven pulley 48.0 ± 2.0 Nm
- Pre-load the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.

Refitting the driven pulley

- Refit the clutch bell.

ENG - 140
Vespa sei giorni 300 hpe Engine

Drive-belt

- Check that the drive belt is not damaged.

- Check belt for correct width.

Characteristic
Drive belt - minimum width
21,0 mm

During the wear checks foreseen in the scheduled

maintenance services, check that the rim bottom
of the toothing does not show signs of incisions or
cracking (see figure): The rim bottom of the tooth
must not have incisions or cracking; if it does,
change the belt.

Removing the driving pulley

To remove the drive pulley, proceed as follows:

- Turn the crankshaft until the cavities of the pulley
are on a vertical axis.

- Block the drive pulley using a specific tool.

Specific tooling
021021Y Drive pulley lock

ENG - 141
Engine Vespa sei giorni 300 hpe

- Unscrew the pulley fixing nut.

- Unscrew the screws and remove the tool.

- Remove the nut, the spring washer and the flat

washer.

- Remove the stationary drive pulley half

ENG - 142
Vespa sei giorni 300 hpe Engine

- Remove the entire roller housing.

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the sliding shoes for the variator back-
plate are not worn.
- Check the wear of the roller housings and of the
belt facing surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic
Maximum allowable clearance of the mobile
half-pulley bushing - sliding bushing
0.15 mm
Roller: Standard Diameter
Diameter 20.5 - 20.7 mm
Roller: Minimum diameter permitted
Ø 20 mm

ENG - 143
Engine Vespa sei giorni 300 hpe

Refitting the driving pulley

To fit the drive pulley, proceed as follows:

- Insert the entire roller housing.

- Insert the stationary drive pulley half

ENG - 144
Vespa sei giorni 300 hpe Engine

- Insert the flat washer, the spring washer and the

nut.
- Pay specific attention to the orientation of the
spring washer.

- Fit the specific tool.

Specific tooling
021021Y Drive pulley lock

- Tighten the fixing nut to the specified torque.

Locking torques (N*m)

Stationary drive pulley - Crankshaft 79.0 ± 4.0 Nm

- Remove the special tool.

Specific tooling
021021Y Drive pulley lock

ENG - 145
Engine Vespa sei giorni 300 hpe

Refitting the transmission cover

- Make sure the alignment dowels are present.

- Put the transmission cover.

- Insert and tighten the fixing screws of the trans-

mission cover to the prescribed torque.

- Put the washer and the fixing nut.

- Block clutch housing rotation using the appropri-

ate tool.

Specific tooling
020423Y Driven pulley lock wrench

ENG - 146
Vespa sei giorni 300 hpe Engine

- Tighten the fixing nut to the specified torque.

End gear

Removing the hub cover

- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the
figure.
- Remove the hub cover and its gasket.

Removing the wheel axle

- Remove the wheel axis complete with gear.

- Remove the intermediate gear.

ENG - 147
Engine Vespa sei giorni 300 hpe

Removing the hub bearings

- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-
tected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover)

Specific tooling
001467Y013 Calliper to extract ø 15-mm bear-
ings

Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover.

- Support the hub cover and expel the bearing.
By means of the appropriate tools, remove the oil
seal as in the figure.

Specific tooling
020376Y Adaptor handle
020477Y Adapter 37 mm
020483Y 30-mm guide
020359S 42 x 47 mm Adaptor
020489Y Hub cover support stud bolt kit

ENG - 148
Vespa sei giorni 300 hpe Engine

Removing the driven pulley shaft bearing

- As you need to remove the driven pulley shaft, its

bearing and oil seal, remove the transmission cov-
er as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil seal using a screwdriver, working
from inside the bearing and being careful not to
damage the housing, make it come out of the belt
transmission side.
- Remove the Seeger ring shown in the figure
- Remove the driven pulley shaft bearing using the
modular punch.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20-mm guide

Inspecting the hub shaft

- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- If faults are found, replace the damaged compo-
nents.

ENG - 149
Engine Vespa sei giorni 300 hpe

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of faults, replace the damaged components.

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat
gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
- Fit the Seeger ring.
- Fit the oil seal with seal lip towards the inside of
the hub and place it flush with the internal surface
by means of the appropriate tool used from the 52-
mm side.
The 52-mm side of the adapter must be turned to-
wards the bearing.

Specific tooling
020376Y Adaptor handle
020360S 52 x 55 mm adaptor
020483Y 30-mm guide

ENG - 150
Vespa sei giorni 300 hpe Engine

Refitting the hub cover bearings

In order to fit the hub box bearings, the engine

crankcase and the cover must be heated with the
special heat gun.
- The three 15-mm bearings must be fitted using
the appropriate tools:
- The 42 mm side of the adapter must be turned
towards the bearing.

Specific tooling
020150Y Air heater mounting
020151Y Air heater
020376Y Adaptor handle
020359S 42 x 47 mm Adaptor
020412Y 15-mm guide

N.B.
TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUD
BOLT KIT.
- Refit the driven pulley shaft bearing with a mod-
ular punch as shown in the figure.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.

Specific tooling
020376Y Adaptor handle
020359S 42 x 47 mm Adaptor
020363Y 20-mm guide
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
- Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase
from the pulley side.

ENG - 151
Engine Vespa sei giorni 300 hpe

Refitting the hub bearings

- Assemble the 3 shafts in the engine crankcase

as shown in the figure.

Refitting the ub cover

- Fit a new gasket together with the alignment

dowels.
- Seal the gasket of the breather pipe using black
silicone sealant.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Position the shorter screw that can also be rec-
ognised from the different colour as shown in the
figure.
- Fix the breather tube support by means of the
lower screw.
- Fit the remaining screws and tighten the seven
screws to the prescribed torque.

Flywheel cover

ENG - 152
Vespa sei giorni 300 hpe Engine

Removing the hub cover

To remove the flywheel cover, proceed as follows:

- Remove the clip fixing the sleeve to the cylinder.

- Remove the fixing screws of the flywheel cover.

- Remove the flywheel cover.

- Remove the keying spring of the water pump

shaft.

ENG - 153
Engine Vespa sei giorni 300 hpe

- remove the cover gasket.

Removing the stator

- Remove the two pick-up screws and the screw

holding the wiring support and the three stator
clamping screws shown in the figure.
- Remove the stator and its cable harness.

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.

Locking torques (N*m)

Stator assembly screws (°) 3 - 4

ENG - 154
Vespa sei giorni 300 hpe Engine

Refitting the flywheel cover

- Position the spline clip on the crankshaft and ori-

ent the end as shown in the figure.

- Orient the water pump shaft with reference to the

transmission gear seat as shown in the picture.

- Refit the cover over the engine and tighten the screws to the prescribed torque.
- Carry out the removal steps but in the reverse order.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE PRESENT.
Locking torques (N*m)
Flywheel cover screws 11 - 13

Flywheel and starting

Removing the starter motor

- Disconnect the positive connector for electrical

system connection to the starter motor.

ENG - 155
Engine Vespa sei giorni 300 hpe

- Unscrew the starter motor's fixing screws.

- Remove the screws and the negative connector.

- Remove the starter motor.

Removing the flywheel magneto

- Remove the water pump shaft and crankshaft

spline clip

ENG - 156
Vespa sei giorni 300 hpe Engine

- Line up the two holes in the flywheel as shown in

the picture

- Screw in the guide bushing that is part of the

special flywheel stop tool on the flywheel as shown
in the picture

- Insert the special flywheel stop tool on the fly-

wheel as shown in the picture

Specific tooling
020627Y Flywheel lock tool

- Remove the flywheel nut with its washer

- Do up the flywheel nut by three or four threads
so that the flywheel does not fall accidentally on
extraction
- Screw the extractor onto the flywheel and extract
it as shown in the picture

Specific tooling
020467Y Flywheel extractor

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate.

ENG - 157
Engine Vespa sei giorni 300 hpe

Refitting the free wheel

- Make sure the freewheel contact surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.

Recommended products
Loctite 243 Medium strength thread-locking sealant.
Blue

- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Locking torques (N*m)

Screw fixing freewheel to flywheel 13 - 15

- Oil the free wheel "rollers".

Refitting the flywheel magneto

- Insert the free wheel on the flywheel as shown in

the picture
- Then refit the flywheel with free wheel and trans-
mission gear

ENG - 158
Vespa sei giorni 300 hpe Engine

- Using the special flywheel lock wrench, tighten

up the flywheel fixing nut to the prescribed torque
- Refit the retention plate

Specific tooling
020627Y Flywheel lock tool

Locking torques (N*m)

Flywheel nut 94 - 102

Refitting the starter motor

- Insert the starter motor in its seat.

- Insert the fixing screws and the negative con-

nector.

- Tighten the starter motor fixing screws to the rec-

ommended torque.

Locking torques (N*m)

Starter motor - Crankcase 12,0 ± 1,0

ENG - 159
Engine Vespa sei giorni 300 hpe

- Connect the positive connector for electrical sys-

tem connection to the starter motor.

Cylinder assy. and timing system

Removing the intake manifold

- Remove the throttle body and the injector.

- Unscrew the manifold fastening screws.

- Remove the fixing screws.

- Remove the manifold.

ENG - 160
Vespa sei giorni 300 hpe Engine

- Remove the gasket.

Removing the rocker-arms cover

- Remove the 5 screws indicated in the figure

Removing the timing system drive

First remove the parts listed below:

• Transmission cover
• Driving pulley
• Oil sump
• Oil pump pulley cover
• O-ring from the crankshaft and the pin-
ion separating washer

- Remove the tappet cover.

- Undo the central screw.

ENG - 161
Engine Vespa sei giorni 300 hpe

- Remove the central screw and the washer.

- Unscrew and remove the screw fastening the

counterweight.

- Remove the spring and the counterweight.

Remove the decompression counterweight.

ENG - 162
Vespa sei giorni 300 hpe Engine

- Remove the distribution system's screw plug.

- Using a small screwdriver, loosen the chain ten-

sioner by turning anticlockwise.

- Remove the timing system sprocket.

- Remove the control sprocket wheel and the tim-

ing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner slider.
The tensioner pad must be removed from the
transmission side. As regards the lower chain
guide slider, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED

ENG - 163
Engine Vespa sei giorni 300 hpe

Removing the cam shaft

To remove the camshaft proceed as follows:

- Remove the tappet cover.
- Remove the timing system sprocket.
- Unscrew and remove the fixing screws of the
camshaft retaining bracket.

- Remove the camshaft retaining plate.

- Remove the camshaft.

- Remove the rocker pins.

ENG - 164
Vespa sei giorni 300 hpe Engine

- Remove the rockers.

Removing the cylinder head

- Remove the tappet cover.

- Remove the timing system components.
- Remove the spark plug.

- Unscrew and remove the fixing screws on the

timing system side.

- Operating in crossed sequence and in several

stages, loosen the fixing nuts of the head.

ENG - 165
Engine Vespa sei giorni 300 hpe

- Remove the cylinder head.

Removing the valves

- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOG-
NISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling
020382Y011 adapter for valve removal tool
020382Y Valve cotters equipped with part 012
removal tool
020431Y Valve oil seal extractor

Removing the cylinder - piston assy.

To remove the cylinder and the piston, proceed as

follows:
- Remove the cylinder head.

ENG - 166
Vespa sei giorni 300 hpe Engine

- Remove the chain tensioner sliding shoe.

- Remove the alignment dowels and the O-Rings.

- Remove the clamp and disconnect the sleeve of

the cooling system.

- Pull out the cylinder.

CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.

ENG - 167
Engine Vespa sei giorni 300 hpe

- Remove the piston.

Inspecting the small end

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Inspecting the wrist pin

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder - piston assy.

Inspecting the piston

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder - piston assy.

Inspecting the cylinder

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder - piston assy.

Inspecting the piston rings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.

ENG - 168
Vespa sei giorni 300 hpe Engine

See also
Piston rings

Removing the piston

- Fit the piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.
- Fit the pin retainer ring onto the appropriate tool
- With opening in the position indicated on the tool
S = left
D= right
- Place the wrist pin retainer ring into position using
a punch.
- Fit the pin retainer ring using the plug as shown
in the figure.
N.B.
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST
BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-
ING.

Specific tooling
020454Y Tool for fitting the pin snap rings

Refitting the piston rings

- Place the scraper ring spring on the piston.

- Install the scraper ring keeping the opening op-
posed to the spring junction and with the writing
"top" facing the piston crown. The chamfered side
of the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
crown.
- Install the first compression ring in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the in-
stallation of the linings.

ENG - 169
Engine Vespa sei giorni 300 hpe

N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.

- Misalign the lining openings at 120° as shown in the figure.

- Lubricate the components with engine oil.
- The engine uses the first compression lining with an L section.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness

determined above.
- Using the fork support and the piston ring retain-
ing band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.

Specific tooling
020426Y Piston fitting fork
020393Y Piston fitting ring

Inspecting the cylinder head

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the timing system components

- check that the fixed chain tensioner sliding shoe

and the mobile chain tensioner sliding shoe are not
excessively worn.
- Check that the pinion, the chain and the timing
system sprocket are not excessively worn.
- If they are, replace them.

ENG - 170
Vespa sei giorni 300 hpe Engine

- check the correct operation of the tensioner; once

opened, press to check that the plunger does not
return.

Inspecting the valve sealings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the valves

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the springs and half-cones

- Check that the upper and lower supporting spring

washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.

- Measure the unloaded spring length.

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

ENG - 171
Engine Vespa sei giorni 300 hpe

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seal
rings.
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE
VALVE SPRINGS WITH THE REFERENCE COLOUR ON
COTTER SIDE (TURNS WITH GREATER PITCH).

Specific tooling
020306Y Punch valve seal rings fitting
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool

Inspecting the cam shaft

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Refitting the head and timing system components

- Fit the control pinion and the timing chain on the

crankshaft.
- Insert the mobile chain tensioner sliding shoe.
- Insert the fastening screw and tighten to the
specified torque.

Locking torques (N*m)

Mobile chain tensioner sliding shoe - Crank-
case 12.0 ± 1.0 Nm

ENG - 172
Vespa sei giorni 300 hpe Engine

- Lubricate the O-rings and insert them on the stud

bolts

- Insert the fixed chain tensioner sliding shoe.

- Insert the two alignment dowels between the

head and the cylinder.

- Insert the head gasket.

ENG - 173
Engine Vespa sei giorni 300 hpe

- Insert the head.

N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

- Lubricate the stud bolt threading.

- Fit the head fixing nuts.
- Following the order shown in the figure, tighten
the head fixing nuts to the prescribed torque.

Locking torques (N*m)

Head - Cylinder (pre-stage) 7.0 ± 1.0 Nm Head -
cylinder 10.0 ± 1.0 Nm Head - Cylinder (Angle ro-
tation) 270°

- Insert the screws on the timing system chain side

and tighten them to specified torque.

Locking torques (N*m)

Head - Crankcase 12.0 ± 1.0 Nm

- Lubricate the two housings and insert the cam-

shaft in its seat with the cam teeth opposing the
rockers.

ENG - 174
Vespa sei giorni 300 hpe Engine

- Insert the camshaft retaining plate.

- Insert and tighten the camshaft retaining plate

fixing screws, applying the recommended torque.

Locking torques (N*m)

Camshaft retaining plate - Head 5.0 ± 1.0 Nm

- Bring the piston to the TDC by aligning the refer-

ence marks on the flywheel and the flywheel cover.

- Fit the timing system sprocket.

ENG - 175
Engine Vespa sei giorni 300 hpe

- Align the reference marks on the sprocket and

head, without moving the timing chain.

- Insert the decompression counterweight.

- Fit the counterweight.

- Pre-load the spring and insert it in its seat.

ENG - 176
Vespa sei giorni 300 hpe Engine

- Insert the screw fastening the counterweight and

tighten to the specified torque.

Locking torques (N*m)

Decompression counterweight - Camshaft 8.0 ±
1.0 Nm

- Fit the washer.

- Insert the fixing screw and tighten to the specified
torque.

Locking torques (N*m)

Compression release weight - Camshaft 13.0 ±
2.0 Nm

Refitting the rocker-arms cover

- Fit the tappet cover paying particular attention to

the correct positioning of the gasket.

- Insert and tighten the fixing screws, applying the

recommended torque.

Locking torques (N*m)

Tappet cover - Head 6.5 ± 1.0 Nm

ENG - 177
Engine Vespa sei giorni 300 hpe

Refitting the intake manifold

- Fit a new gasket.

- Put the manifold.

- Insert the fastening screws

- Tighten the manifold fixing screws to the prescri-

bed torque.
- Refit the throttle body and the injector.

Locking torques (N*m)

Intake manifold - Head 12.0 ± 1.0 Nm

Crankcase - crankshaft

ENG - 178
Vespa sei giorni 300 hpe Engine

Splitting the crankcase halves

- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do
this, use a plate and a support with appropriate tool
dial gauge.
- Upper clearances are an indication of wear on
the surfaces of the crankshaft casing support.
- Remove the 10 crankshaft coupling screws.
- Separate the crankcase while keeping the crank-
shaft in one of the two halves of the crankcase.
- Remove the crankshaft.
- Remove the half crankcase coupling gasket.
- Remove the two screws and the internal shield
shown in the diagram.
- Remove the oil seal on the flywheel side.
- Remove the oil filter fitting shown in the diagram.
- Check the axial clearance on the connecting rod.
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crank-
shaft between these surfaces, as shown in the
diagram.
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
- Check the diameters of both the bearings of the
crankshaft in accordance with the axes and surfa-
ces shown in the figure. The half-shafts are clas-
sified in two categories Cat. 1 and Cat. 2 as shown
the chart below.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-

ENG - 179
Engine Vespa sei giorni 300 hpe

INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN

DAMAGE THE MAIN BUSHINGS.
CAUTION

KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES

OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.
N.B.
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,
MAKE SURE THAT THE MEASUREMENTS ARE NOT
MODIFIED BY THE RADIUSES OF FITTINGS WITH THE
CRANKSHAFT BEARINGS.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.

See also
Crankcase - crankshaft - connecting rod

Inspecting the crankshaft alignment

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the piston, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.

ENG - 180
Vespa sei giorni 300 hpe Engine

- Inspect the coupling surfaces on the crankcase

halves for scratches or deformation, taking partic-
ular care with the cylinder/crankcase surfaces and
the crankcase halves surfaces.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bushings and
connecting rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET;: THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.

Characteristic
Lubrication pressure
3.5 - 4 bar

ENG - 181
Engine Vespa sei giorni 300 hpe

- The solid half-bearing is intended to stand the

thrusts caused by combustion, and for this reason
it is arranged opposite the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
shown in the figure.
- The oil feeding channel section is also affected
by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Refitting the crankcase halves

- Fit the internal shield by locking the two screws

to the prescribed torque.
- Fit the oil filter fitting and tighten it to the prescri-
bed torque
- Position the oil pre-filter element as shown in the
picture.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, to-
gether with the alignment dowels.
- Lubricate the main bushings and insert the crank-
shaft in the transmission side crankcase half.
- Reassemble both crankcase halves.
- Fit the 10 screws and tighten them to the speci-
fied torque.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the filter on the engine with the relative cap.
Tighten to the prescribed torque.

Locking torques (N*m)

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 - 6 Engine-crank-
case coupling screws 11 ÷ 13 Oil filter on
crankcase fitting 27 - 33 Engine oil drainage
plug/ mesh filter 24 to 30

ENG - 182
Vespa sei giorni 300 hpe Engine

Studs

Check that the stud bolts have not worked loose

from their seat in the crankcase.
Check the depth of stud bolt driving with a gauge,
as indicated in the picture. If it varies significantly
from the driving depth indicated, it means that the
stud bolt has yielded.
In this case, replace it.

ENG - 183
Engine Vespa sei giorni 300 hpe

By working on two fitted cylinder head fixing nuts,

nut and lock nut, as shown in the picture, remove
the stud bolt from its seat.
Clean the threaded seat on the carter thoroughly.
Refit a new stud bolt and apply the special product
on the threading crankcase side.
Tighten up to the depth of the driving indicated.

Recommended products
Loctite 270 High resistant threadlock.
green

Lubrication

Conceptual diagrams

LUBRICATION CIRCUIT

ENG - 184
Vespa sei giorni 300 hpe Engine

Oil pressure check

- Remove the electrical minimum oil pressure

switch connection and remove the switch.
- Check that the oil pressure reading is between
0.5 and 1.2 atm with the engine idling at 1650 rpm
and the oil at the required temperature (wait for at
least one electric ventilation).
- Check that the oil pressure is between 3.2 and
4.2 atm with the engine running at 6,000 rpm and
the oil at the required temperature.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the flywheel cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER
CONDITION.

Characteristic
Oil pressure
Minimum pressure admitted at 6,000 rpm: 3.2 atm.

Locking torques (N*m)

Minimum oil pressure sensor 12 ÷ 14

Crankshaft oil seals

ENG - 185
Engine Vespa sei giorni 300 hpe

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided

Specific tooling
020622Y Transmission-side oil seal punch

- Screw the threaded bar onto the base of the tool

and extract the oil seal.

Specific tooling
020622Y Transmission-side oil seal punch

Refitting

- Always use a new oil seal upon refitting

- Prepare the new oil seal by lubricating the sealing
lip
- Pre-assemble the oil seal with the appropriate
tool by positioning the screws.
- Insert the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase
- Insert the adaptor bushing of the tool in the hole
on the crankcase.

ENG - 186
Vespa sei giorni 300 hpe Engine

- Orientate the oil seal by inserting the bracket

which is part of the appropriate tool
- Tighten the threaded bar onto the crankshaft as
far as it will go
- Use the nut to move the base of the tool until you
can see the end of the oil seal driving stroke
- Remove all the tool components following the
procedure but in reverse order.
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ONTO THE
ENGINE CRANKCASE
CAUTION
ORIENT THE OIL SEAL BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
SEAL. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL SEAL
SHEATH
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN

Specific tooling
020622Y Transmission-side oil seal punch

Oil pump

ENG - 187
Engine Vespa sei giorni 300 hpe

Removal

- Undo the two clamping screws in the figure and

remove the cover over the pump control sprocket.

- Block the rotation of the oil pump driving pulley

by inserting a screwdriver through one of its holes
- Remove the central screw with cup washer, as
shown in the diagram.
- Remove the chain with the sprocket.
- Remove the control sprocket wheel and its O-
ring.
- Remove the oil pump by undoing the two screws
in the figure.
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED

Inspection

- Remove the two screws and the oil pump cover.

- Remove the cir-clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible. Replace the
retainer ring.
- Check the clearance between the rotors in the
position shown in the diagram using a feeler gauge

ENG - 188
Vespa sei giorni 300 hpe Engine

Measure the distance between the outer rotor and

the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.

Characteristic
Axial rotor clearance
Limit value admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm

Refitting

- Check there are no signs of wear on the oil pump

shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the unit.
- Fit the pump cover in the position that permits the
crankcase clamping screws to be aligned.
- Make sure the gasket is positioned properly and
refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
screws to the prescribed torque.

ENG - 189
Engine Vespa sei giorni 300 hpe

- Fit the sprocket wheel with a new O-ring.

- Fit the chain.
- Fit the central screw and the cup washer. Tighten
to the prescribed torque.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM
TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP
TURNS FREELY.

Locking torques (N*m)

Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 - 14 Oil
pump cover screws 0.7 - 0.9

Removing the oil sump

To remove the oil sump, proceed as follows:

- Drain all the engine oil.
- Remove the transmission cover.
- Unscrew and remove the fixing screws.

- Remove the oil sump.

ENG - 190
Vespa sei giorni 300 hpe Engine

- Remove the valve spring.

- Remove the valve piston.

- Remove the oil sump gasket.

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defec-
tive parts.

Characteristic
By-pass check up:Standard length
54.2 mm

ENG - 191
Engine Vespa sei giorni 300 hpe

Refitting the oil sump

- Fit a new oil sump gasket.

- Insert the valve piston.

- Insert the valve spring.

- Insert the alignment dowels.

- Insert the oil sump taking care to insert the spring
into the appendage in the sump.

ENG - 192
Vespa sei giorni 300 hpe Engine

- Insert and tighten the fixing screws, applying the

recommended torque.
- Refit the transmission cover.

Locking torques (N*m)

Oil sump - Crankcase 12.0 ± 1.0 Nm

ENG - 193
INDEX OF TOPICS

INJECTION INJEC
Vespa sei giorni 300 hpe Injection

MIU injection system

This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Mixture and ignition are managed on the basis of engine revs and throttle valve opening. Further cor-
rections are made according to the following parameters:
- Coolant temperature
- Intake air temperature
- Lambda probe
The system implements cold engine idle fuel/air mixture correction with a stepper motor on a by-pass
circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time,
thereby ensuring the idle steadiness and the proper mixture.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel system pressure is kept constant in relation to ambient pressure.
The fuel system circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by a pipe with fast-release fittings. The pressure regulator is located at the
beginning of the circuit.
The fuel pump is controlled by the MIU control unit; this ensures safety of the vehicle.
The ignition circuit consists of:
- H.V. coil
- H.V. cable.
- Shielded cap
- MIU control unit
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump

INJEC - 195
Injection Vespa sei giorni 300 hpe

- H.V. coil
- Injector

The control unit is fitted with a self-diagnosis system connected to a warning light on the instrument
panel.

Failures are detected and restored by the diagnostic tester.

In any case, when the fault is no longer present, data storage is automatically wiped clean after 16
cycles of use (cold starting, running at regular engine temperature, stop).
The diagnostic tester is also required to adjust the idle mixture.

Specific tooling
020922Y Diagnosis Tool

The MIU injection-ignition system carries out checks on the rpm indicator and the electric fan for radiator
cooling.
The MIU control unit has a decoder for the anti-theft immobilizer system.
The MIU control unit is connected to a diagnostic LED on the instrument panel, that also carries out the
deterrent flashing functions.

The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the vehicle.

Precautions

1. Before repairing any part of the injection system, check if any faults have been stored. Do not dis-
connect the battery before checking for faults.
2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the fast-release
fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
avoid spraying fuel to your eyes.
3. When repairing electric components, the battery must always be disconnected unless it is strictly
necessary for the battery to be connected.
4. When functional checks are performed, make sure that the battery voltage exceeds 12V.
5. Before attempting to start the vehicle, ensure that there are at least two litres of fuel in the tank.
Failure to respect this norm will damage the fuel pump.
6. If a long period is envisaged with the vehicle not in use, fill the tank to at least the halfway mark. This
will ensure the pump will be covered by fuel.
7. When washing the vehicle, do not spray excessive water on electric components and wiring har-
nesses.
8. In the event of ignition problems, begin troubleshooting from the battery and the injection system
connections.
9. Before disconnecting the MIU control unit connector, perform the following steps in the order shown:
- Set the switch to «OFF»

INJEC - 196
Vespa sei giorni 300 hpe Injection

- Disconnect the battery

Failure to respect this norm may damage the control unit.
10. Do not invert the poles when fitting the battery.
11. In order to not cause damage, disconnect and reconnect the connectors of the MIU system only
after proven necessary. Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, remember to protect the system
connector with its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Troubleshooting tips
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Power supply
a. Battery voltage
b. Blown fuse
c. Relays
d. Connectors
B: Frame ground connection
C: Fuel system
a. Faulty fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Faulty coil
c. Faulty shielded cap
E: Intake circuit
a. Air filter dirty
b. b. Dirty by-pass circuit
c. Faulty stepper motor
F: Others
a. Wrong timing system
b. Wrong idle mixture
c. Incorrect reset of the throttle valve position sensor
2 MIU system failure may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connectors taking into consideration the following point:

INJEC - 197
Injection Vespa sei giorni 300 hpe

A check that the terminals are not bent.

B check that the connectors have been properly connected.
C - Check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 For troubleshooting, use a multimeter with an internal resistance of more than 10 KW/V. Unsuitable
instruments can damage the MIU ECU. The instruments to be preferred have a definition over 0.1V and
0.5W and an accuracy over 2%.

Terminals setup

MIUG4 control unit

1. (Pink/Black) H.V. coil signal output (-)
2. Not connected
3. (Blue/Brown) ASR warning light command signal output
4. (Green/Black) Signal input (-) from engine stop button
5. (Brown/Red) Signal input (+) from the start button
6. (Red/White) Key-on power input (from fuse F4)
7. (Black) Power ground
8. Not connected
9. (White/Black) Battery power input (from fuse F1)
10. (Orange/Blue) Starter relay coil command signal output (-)
11. (Light blue/Black) Lambda probe (+)
12. (White/Green) Lambda probe (-)
13. (Light blue/Green) Engine temperature sensor signal input
14. (Orange/White) "ENABLE" signal input from the immobilizer antenna
15. (Grey/Green) Sensor ground reference
16. Not connected
17. (Red/Green) Immobilizer warning light control signal output (-)
18. (Grey/Black) Tilting sensor signal input
19. (Brown/Red) Signal input (-) from the stand button
20. (Brown) Pickup (-)

INJEC - 198
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21. (Light blue/White) Signal input (-) from the ASR button
22. (Black/Purple) Injection loads coil command signal output (-)
23. (Black) Power ground
24. (Blue/Yellow) Electric fan relay coil command signal output (-)
25. (Brown/Black) MIL warning light control signal output (-)
26. (Pink/Red) CAN H line
27. (Pink/White) CAN L Line
28. Not connected
29. (Red) Pickup (+)
30. Not connected
31. (Light blue/red) Ground reference for lambda probe heater
32. Not connected
33. (Purple/White) Lights relay coil command signal output (-)
34. (Red/Yellow) Injector command signal output (-)

EMS circuit diagram

1. Battery 12V - 12 Ah
2. Starter relay
3. Starter motor
4. Starter button

INJEC - 199
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5. Voltage regulator
6. Magneto flywheel
7. Fuse No.1 - 30A
8. Fuse No. 5 - 7.5A
9. Fuse No. 2 - 15A
10. Fuse No. 6 - 7.5A
11. Fuse No. 3 - 15A
12. Fuse No. 4 - 7.5A
14. Ignition switch contacts
15. Engine stop switch
16. 2 stop buttons
17. Brake lamp 12v-16w
18. Injection load relay
19. Electric fan relay
20. Radiator electric fan
23. Lambda probe
24. Engine speed sensor
25. H.V. coil
26. Fuel injector
27. Engine temperature sensor
28. Fuel pump
29. Diagnosis socket
30. Electronic injection control unit
31. Immobilizer antenna
34. Instrument panel
36. Headlight relay

Troubleshooting procedure

Engine does not start

ENGINE DOES NOT START EVEN IF PULLED

Possible Cause Operation
Immobilizer enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Faults detected by self-diagnosis Pump relay
H.V. coil.
Injector
Engine speed timing sensor
Fuel system Fuel in the tank
Fuel pump activation
Fuel pressure (low)

INJEC - 200
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Possible Cause Operation

Injector flow (low)
Power to spark plug Shielded spark plug cap H.V. coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing adjustment - injection start
Intake air temperature
End of compression pressure End of compression pressure

Starting difficulties

ENGINE STARTER PROBLEMS

Possible Cause Operation
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Starter speed Starter motor and relay
Battery
Ground connections
End of compression pressure End of compression pressure
Power to spark plug Spark plug
Shielded cap
H.V. coil.
Engine speed timing sensor
Ignition advance
Fuel system Fuel pressure (low)
Injector flow (low)
Injector sealing (poor)
Correctness of the parameters Coolant temperature
Intake air temperature Stepper throttle valve position (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter ef-
ficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW

Possible Cause Operation
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter housing
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector flow

INJEC - 201
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Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

Possible Cause Operation
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter housing
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector flow

Exhaust backfires in deceleration

EXHAUST BACKFIRING WHEN DECELERATING

Possible Cause Operation
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Lambda probe
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter housing
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector flow
Exhaust system sealing (infiltrations) Manifold - head
Manifold - silencer
silencer welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

Possible Cause Operation
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing Intake sleeve
Filter housing

INJEC - 202
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Possible Cause Operation

Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature signal
Ignition advance
TPS reset successful TPS reset successful
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Lambda probe

Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICK-UP
Possible Cause Operation
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Lambda probe
Power to spark plug Spark plug
Shielded cap
H.V. cable
H.V. coil
Intake system Air filter
Filter box (sealing)
Intake sleeve (sealing)
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature signal
Ignition advance
Fuel system Fuel level in the tank
Fuel pressure
Fuel filter
Injector flow

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

Possible Cause Operation
Faults detected by self-diagnosis Pump relay
H.V. coil
Injector
Engine speed timing sensor
Air temperature
Coolant temperature
Lambda probe
Ignition efficiency Spark plug
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature signal
Ignition advance
Intake system sealing Intake sleeve
Filter housing
TPS reset successful TPS reset successful
Fuel system Fuel pressure

INJEC - 203
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Possible Cause Operation

Fuel filter
Injector flow
Fuel quality
Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel system circuit includes the electric pump,
the filter, the pressure regulator, the electro-injec-
tor and the fuel delivery pipes.
The electrical pump is located in the tank from
which the fuel is pumped and sent to the injector
through the filter.
The pressure is controlled by the pressure regu-
lator situated in the pump assembly in the tank.

Key:
1. Fuel pump ring nut
2. Fuel pump
3. Fuel pump gasket
4. Complete vent pipe
5. Fuel tank
6. Fuel tank cap
7. Fuel delivery pipe

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8. Fuel gauge

REMOVING THE COMPLETE FUEL PUMP

Remove the fuel tank.
CAUTION

FUEL IS HIGHLY FLAMMABLE. DO NOT SMOKE AND

KEEP ALL NAKED FLAME AND SOURCES OF SPARKING
OUT OF THE AREA: FIRE HAZARD. DO NOT INHALE THE
FUEL SMOKE. DO NOT ALLOW FUEL TO COME INTO
CONTACT WITH PLASTIC COMPONENTS OR THE BODY-
WORK OF THE VEHICLE.

Unscrew and remove the fastener ring of the fuel

pump, rotating it counter-clockwise.

Remove the fuel pump fastening ring.

Mark the correct orientation of the fuel pump rela-

tive to its seat on the tank with a marker pen.

INJEC - 205
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NOTE:
Apply the marking on the fuel pump and the rela-
tive seat as shown in the figure.

Lift the fuel pump and rock it back and forth and
side to side to disengage it from the gasket.

Disengage the sealing gasket from the tank and

extract the complete fuel pump assembly.

FITTING THE COMPLETE FUEL PUMP

Fit the new sealing gasket on the body of the fuel
pump.

INJEC - 206
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Slide the gasket and position it temporarily in its

housing on the upper part of the fuel pump.

Apply the assembly marking to new fuel pump as

shown in the figure.

Place the complete fuel pump inside the tank.

NOTE:
Ensure that the fuel pump is oriented correctly by
aligning the markings made previously on the
pump and the respective housing

INJEC - 207
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Fit the gasket, pushing downwards to ensure that

it is flush with the surface of the tank.

Push the fuel pump downwards to bring it against

the gasket.

Fit the fastener ring of the fuel pump.

Tighten the fastener ring of the fuel pump firmly,

turning clockwise.
Refit the fuel tank on the vehicle.
WARNING

MAKE SURE THAT THE FASTENER RING IS TIGHTENED

COMPLETELY.

INJEC - 208
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REMOVING THE COMPLETE FUEL LEVEL

SENSOR
Unscrew the fuel level sensor, turning anticlock-
wise; use the specific tool included with the vehicle
if necessary.

Specific tooling
020442Y Pulley lock wrench

Remove the fuel level sensor from the fuel tank.

CAUTION

FUEL IS HIGHLY FLAMMABLE. DO NOT SMOKE AND

KEEP ALL NAKED FLAME AND SOURCES OF SPARKING
OUT OF THE AREA: FIRE HAZARD. DO NOT INHALE THE
FUEL SMOKE. DO NOT ALLOW FUEL TO COME INTO
CONTACT WITH PLASTIC COMPONENTS OR THE BODY-
WORK OF THE VEHICLE.

FITTING THE COMPLETE FUEL LEVEL SEN-

SOR
Fit the fuel level sensor, complete with sealing
gasket inside the tank.

Tighten the fuel level sensor, turning clockwise;

use the specific tool included with the vehicle if
necessary.
Refit the fuel tank on the vehicle.

Specific tooling
020442Y Pulley lock wrench

INJEC - 209
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Removing the butterfly valve

To remove the throttle body, proceed as follows:

- Unscrew and remove the fuel pipe clamp fasten-
ing screw.

- Disconnect the injector connector.

- Disconnect the engine temperature sensor con-

nector.

- Loosen the clamps of the intake manifold and of

the filter box connection sleeve.

INJEC - 210
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- Disconnect the connector of the control unit.

-Loosen the fixing nuts of the throttle control trans-

missions.

- Disconnect the throttle control cables.

- Remove the throttle body.

INJEC - 211
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Refitting the butterfly valve

- put the throttle body.

- Connect the throttle control cables.

-Tighten the fixing nuts of the throttle control trans-

missions.

- Put the throttle body in the intake manifold and in

the connection pipe to the filter box.
- Tighten the clamps.

INJEC - 212
Vespa sei giorni 300 hpe Injection

- Connect the control unit connector.

- Connect the engine temperature sensor connec-

tor.

- Connect the injector connector.

- Insert and tighten the screw that fastens the fuel

pipe clamp.

INJEC - 213
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Pump supply circuit

1. Battery 12V
2. Fuse no.7 - 10A
3. Fuse no.1 - 30A
4. Fuse No. 5; 15A
5. Ignition switch
6. Fuse no.2 - 7.5A
7. Fuse no.4 - 7.5A
8. Injection load relay
9. Fuel pump
10.Electronic injection control unit
11.Instrument panel
12.Fuel level indicator

When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA

• Pump winding resistance ~ 1.5 Ohm

• Input current during regular operation 1.4 - 1.8 A
• Input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel
pressure control, choking the circuit on the return pipe)

INJEC - 214
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1. Disconnect the fuel pump electrical connec-

tor.
2. Turn the ignition switch to «ON».
3. Check that there is a voltage present be-
tween pin 2 and ground on the fuel pump
connector for approximately 2 seconds.
4. Carry out a continuity check on the connec-
tion line between pin 2 on the fuel pump
connector and pin 87 on the injection loads
relay.
5. Carry out a continuity check on the connec-
tion line between pin 1 on the fuel pump
connector and ground

Circuit leak test

Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.

Check during regular operation by placing the ap-

propriate tool between the pump and the injector.
With the battery voltage> 12 V check that the fuel
pressure is 3.0 BAR and that the input current is
1.4 to 1.8 A

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Prepare a graded burette with flow rate of
approximately 1 L. Rotate the pump using the active diagnosis of the palm top computer. Using a pair
of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 3.0 BAR.
Check that within 15 seconds the pump has a flow rate of approx. 120 cm³.

Specific tooling
020480Y Fuel pressure measurement kit

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Fuel filter check

Disconnect the terminals of the electrical pump

Remove the screw shown in the picture

Remove the clamp fixing the piping to the filter

shown in the photograph

Separate the lower part of the pump mounting as

shown in the picture.

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Remove the filter from the pump mounting

Inspecting the injector circuit

1. Battery
2. Fuse n° 7 -10A
3. Fuse no.1 - 30A
4. Ignition switch
5. Fuse no.4 - 7.5A
6. Injection load relay
7. Electronic injection control unit
8. Injector
Checking the resistance at the injector ends: 14.5 ± 5% Ohm
With the control unit and the injector disconnected, check for continuity between pin 34 on the control
unit connector and pin 2 on the injector connector.

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Switch to «ON» and check that, with the injector

disconnected and the control unit connected, there
is a voltage present between pin 1 on the injector
connector and ground.

Inspecting the injector hydraulics

To check the injector, proceed as follows:

- Unscrew and remove the screws that fasten the
injector to the intake manifold.

- Remove the injector from the intake manifold.

- Install the specific tool to check the fuel pressure

and put the manifold on a graduated container of
at least 100 cm³.
- Connect the injector with the supplied cable for
the injection tester.
- Connect the cable terminals to an auxiliary bat-
tery and activate the fuel pump with the diagnos-
tics active.

Specific tooling
020480Y Fuel pressure measurement kit

INJEC - 218
Vespa sei giorni 300 hpe Injection

- Check that within 15 approx. 44 cm³ of fuel is de-

livered with an adjustment pressure of approx. 3
BAR.

Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute

HT coil

1. Battery
2. Fuse n° 7 -10A

INJEC - 219
Injection Vespa sei giorni 300 hpe

3. Fuse no.1 - 30A

4. Ignition switch
5. Fuse no.4 - 7.5A
6. Injection load relay
7. Electronic injection control unit
8. H.V. coil

The system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two significant parameters:
- Ignition advance
This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up phase.
The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression
phase.

Specific tooling
020331Y Digital multimeter

With the control unit and the coil disconnected, check for continuity between pin 1 on the control unit
connector and pin 2 on the coil connector.

Switch to «ON» and check that, with the coil dis-

connected and the control unit connected, there is
a voltage present between pin 1 on the coil con-
nector and ground.

Zeroing the throttle

Resetting the throttle valve position signal (T.P.S reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.

INJEC - 220
Vespa sei giorni 300 hpe Injection

The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.

Connect the diagnostic tester.

Switch to «ON».
Select the functions of the diagnostic tester on «TPS RESET».

Specific tooling
020922Y Diagnosis Tool

Make sure that the throttle valve with the control is

supporting the stop screw.

Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.

Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
N.B.
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Given that the TPS resetting is also done when the
control unit is replaced, place the control unit - filter
box bellows at 45° during the refitting operation as
shown in the picture.

INJEC - 221
Injection Vespa sei giorni 300 hpe

INJEC - 222
INDEX OF TOPICS

SUSPENSIONS SUSP
Suspensions Vespa sei giorni 300 hpe

Front

FRONT SUSPENSION TIGHTENING TORQUES

Name Torque in Nm
Lower lock-nut - Steering tube 11.7 - 13.7 Nm
Upper lock-nut - Steering tube 34.3 - 39.2 Nm
Handlebars - Steering tube 50 - 55 Nm
Front wheel - Front wheel hub 19 - 24 Nm
Throttle control sleeve - Handlebar 3 - 4 Nm
Front shock absorber (lower fastening) - Steering tube 19 - 26 Nm
Front shock absorber (upper fastening) - Steering tube 19 - 24 Nm
Front shock absorber - Shock absorber plate 19 - 29 Nm
Front wheel hub - Front wheel axle 74 - 88 Nm
ABS sensor - ABS support bracket 4.5 - 5 Nm
Odometer transmission - Front wheel hub 4 - 6 Nm

STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 35 - 40
Lower steering ring nut 12 - 14
Handlebar fixing screw 50 - 55
Fixing screws for the handlebar control unit U-bolts 7 - 10

FRONT SUSPENSION
Name Torque in Nm
Screw fixing the shock absorber to the shock absorber - calliper 20 to 27
attachment plate
Wheel axle nut 74 - 88
Wheel screw 20 - 25
Screw fixing rear mudguard to steering 5 - 6.5
shock absorber upper clamp 20 to 30

Removing the front wheel

Rest the vehicle on its centre stand.

Suitably secure the rear part of the vehicle by rais-
ing the front slightly.
Loosen the screws fixing the wheel rim to the hub.

SUSP - 224
Vespa sei giorni 300 hpe Suspensions

Remove the front wheel.

Front wheel hub overhaul

REMOVING THE FRONT WHEEL HUB

Rest the vehicle on its centre stand.
Suitably secure the rear part of the vehicle by rais-
ing the front slightly.
Remove the front wheel.
Remove the front brake calliper.
Remove the safety cotter pin bending the flaps.

Remove the safety cap.

Unscrew the nut fixing the front wheel hub to the

wheel axis.

SUSP - 225
Suspensions Vespa sei giorni 300 hpe

Remove the nut.

Remove the front wheel hub from its seat.

FRONT WHEEL HUB SERVICE

Remove the oil seal on the brake disc side using
a flat-head screwdriver.

Turn the hub on the wheel side.

Using the relative clamps, remove the Seeger ring.

SUSP - 226
Vespa sei giorni 300 hpe Suspensions

Engage the specific tool on the inner ring of the

bearing on the wheel side.

Specific tooling
001467Y Extractor for bearings for holes

Remove the bearing using the specific tool.

Specific tooling
001467Y Extractor for bearings for holes
001467Y017 Bell Ø 35

Remove the bearing and the specific tool.

Remove the roller bearing using the specific tool.

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20-mm guide

SUSP - 227
Suspensions Vespa sei giorni 300 hpe

Check the seat of the bearing.

Heat the bearing's seat on the hub using the spe-
cific tool.

Specific tooling
020151Y Air heater

Using the specific tool, place the new ball bearing

in its seat with the shielding facing up.

Specific tooling
020376Y Adaptor handle
020357Y 32 x 35-mm Adaptor
020412Y 15-mm guide

Put the bearing all the way into its seat.

Put in the Seeger ring.

SUSP - 228
Vespa sei giorni 300 hpe Suspensions

Turn the hub on the opposite side.

Using the specific tool, insert the roller bearing all
the way in.
Apply the recommended product in the chamber
between the ball bearing and the roller bearing.

Specific tooling
020038Y Punch

Recommended products
Lubricant grease Lithium and medium fibre
yellow brown coloured grease suitable for var-
ious uses.
ISO L-X-BCHA 3 - DIN 51 825 K3K -20

Using the specific tool, put a new oil seal in its seat.

Specific tooling
020376Y Adaptor handle
020357Y 32 x 35-mm Adaptor
020412Y 15-mm guide

Put the oil seal all the way into its seat.

FITTING THE FRONT WHEEL HUB

Place the wheel hub on the front wheel axle.

SUSP - 229
Suspensions Vespa sei giorni 300 hpe

Screw on the fixing nut on the wheel axle.

Tighten the fixing nut on the wheel axle to the pre-

scribed torque.

Put on the safety cap so that the hole for the cotter
pin is visible.

Insert the safety cotter pin and fold the flaps out-
wards.
Refit the front brake calliper.
Fit the front wheel.

SUSP - 230
Vespa sei giorni 300 hpe Suspensions

Refitting the front wheel

Put back the front wheel on the wheel hub.

Tighten to the recommended torque the screws

fixing the front wheel to the hub.

Handlebar

Removal

Remove the rear-view mirrors.

Remove the windscreen.
Remove the front centre cover.
Remove the rear handlebar cover.
Remove the leg shield back plate.
Disconnect the stop light switch connectors from
both brake pumps.

SUSP - 231
Suspensions Vespa sei giorni 300 hpe

Remove the brake pumps as described in this

manual, in the section "braking system > front/
rear pump > removal".

Suitably protect the couplings and secure them so

they are tilted upward to keep air from entering.

Unscrew the screws used to fasten the expansion

chamber and move it away from its housing with-
out disconnecting the pipes.

Detach the electrical wiring harness retaining

clamp.

SUSP - 232
Vespa sei giorni 300 hpe Suspensions

Disconnect the indicated connectors from the left

and right hand handlebar electrical devices.

Unscrew the screws used to fasten the right hand

electrical device.

Detach the throttle gas control closure transmis-

sion from the sleeve cam.

Rotate the cable by 90° and slide it out of the elec-

trical device.
Slide the right hand device off the handlebar.

SUSP - 233
Suspensions Vespa sei giorni 300 hpe

Unscrew the screws used to fasten the front device

retaining U-bolt.

Detach the throttle gas control aperture cable from

the sleeve cam.

Unscrew the screw used to fasten the gas com-

mand cable retaining plate.

Slide the gas command cable from the device.

SUSP - 234
Vespa sei giorni 300 hpe Suspensions

Unscrew the screws used to fasten the left hand

electrical device and slide it off the handlebar.

Unscrew the terminal screws from both ends of the

handlebar and remove it.

Slide the gas command sleeve out.

Remove the left hand knob using a jet of com-

pressed air.

SUSP - 235
Suspensions Vespa sei giorni 300 hpe

Unscrew the screws used to fasten the front han-

dlebar cover to the handlebar frame.

Unscrew the screw used to fasten the handlebar

to the steering tube.

Make a note of the layout of the brake pipes, the

gas command transmission cables and the vari-
ous wiring harnesses, in order to ensure they are
positioned correctly during reassembly.
Remove the handlebars

Refitting

Reposition the brake pipes, the gas command

transmission cables and the various wiring har-
nesses correctly inside the handlebar.
Reposition the handlebars on the steering tube.

SUSP - 236
Vespa sei giorni 300 hpe Suspensions

The screw used to fasten the handlebar to the

steering tube, applying the recommended torque.

Tighten the screws used to fasten the front han-

dlebar cover to the handlebar.

Using a jet of compressed air, reposition the right

hand knob on the handlebar.

Insert the throttle sleeve on the handlebar.

SUSP - 237
Suspensions Vespa sei giorni 300 hpe

Working on both sides of the handlebars, tighten

the screws used to fasten the handlebar terminals,
applying the recommended torque.

Reposition the gas command throttle aperture

transmission on the right hand handlebar support
and tighten the fastening screw.

Reposition the transmission on the gas command

sleeve cam.

Tighten the screws used to fasten the U-bolt to the

right hand support, applying the recommended
torque.

SUSP - 238
Vespa sei giorni 300 hpe Suspensions

Insert the gas command closure transmission on

the right hand electrical device and rotate it by 90°.

Reposition the transmission on the gas command

sleeve cam.

Reposition the device wiring harness and the gas

command transmission cables correctly.
Tighten the screws used to fasten the right hand
electrical device to the handlebar, applying the
recommended torque.

Reposition the device wiring harness correctly.

Tighten the screws used to fasten the left hand
electrical device to the handlebar, applying the
recommended torque.

SUSP - 239
Suspensions Vespa sei giorni 300 hpe

Reposition the device wiring harnesses inside the

clamps and connect the connectors.

Reposition the expansion chamber and tighten the

fastening screws, applying the recommended tor-
que.

Fit the brake pumps as described in this manual,

in the section "braking system > front/rear pump
> fitting".

Connect the stop light switch connectors on both

brake pumps.
Reassemble the leg shield back plate.
Refit the rear handlebar cover.
Refit the windscreen.
Refit the rear-view mirrors.

Steering column

SUSP - 240
Vespa sei giorni 300 hpe Suspensions

Removal

Adequately support the front part of the vehicle.

Remove the windscreen.
Remove the front centre cover.
Remove the rear handlebar cover.
Remove the front wheel.
Unscrew the front suspension cover external fas-
tening screws.

Unscrew the front suspension cover inner fasten-

ing screws, and remove the cover.

Free the brake pipe from the respective clamps

mounted on the steering tube.

Unscrew the screw used to fasten the odometer

transmission cables and able sensor cable retain-
ing clamps.

SUSP - 241
Suspensions Vespa sei giorni 300 hpe

Unscrew the screw used to fasten the ABS sensor

to the support.

Unscrew the screw used to fasten the odometer

transmission to the wheel hub.

Remove the front brake calliper as described in

this manual, in the section "braking system >
front brake calliper > removal".
Protect the coupling.

Remove the front shock absorber as described in

this manual, in the section "suspensions > front
> front shock absorber > removal".

SUSP - 242
Vespa sei giorni 300 hpe Suspensions

Open the front top-box and remove the lid from the
fusebox.

Unscrew the screws used to fasten the top-box lid.

Using a flat-head screwdriver, release the retain-

ing lever and detach the lid.

Remove the fusebox from the lid.

SUSP - 243
Suspensions Vespa sei giorni 300 hpe

Disconnect the USB port connector.

Disconnect the front light assembly connector.

Disconnect the left hand brake pump from the han-

dlebar and unscrew the screw used to fasten the
steering tube to the handlebar.
Tilt the handlebar forwards.

Reposition the protective collar.

SUSP - 244
Vespa sei giorni 300 hpe Suspensions

Unscrew the upper ring nut, using the special tool.

Specific tooling
020055Y Wrench for steering tube ring nut

Remove the washer.

Unscrew the lower ring nut, using the special tool.

Remove the ball cage from the upper steering
bearing.

Specific tooling
020055Y Wrench for steering tube ring nut

Remove the steering tube from below.

Carefully slide out the brake pipes, the odometer
transmission and the phonic wheel and front head-
lamp wiring harnesses.

Overhaul

Servicing the front suspension-steering assembly, described below, deals mainly with replacing parts
(pin- NADELLA roller bushings - sealing rings unit and dust gaiter) which connect the steering tube to
the front wheel holder swinging hub.

SUSP - 245
Suspensions Vespa sei giorni 300 hpe

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 SERV-
ICE JUSTIFIABLE.
MOREOVER, REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE
WHEN DEFORMED.
a = Ø 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 hand-grip 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.
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
GAITER.

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 hand-grip until part 3 is fully inserted on the
steering tube.

SUSP - 246
Vespa sei giorni 300 hpe Suspensions

After fitting the pin, insert the two spacers, slightly

hitting them with the mallet.
N.B.
BEFORE PROCEEDING WITH THE DESCRIBED FITTING,
PLACE THE TWO DUST GAITER RINGS ON THE SWING-
ING HUB AS SHOWN IN THE FIGURE.

Specific tooling
020021Y Front suspension service tool

Recommended products
Molybdenum disulphide grease Lithium
grease with molybdenum disulphide.
Grey black grease

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 hand-grip, push the wedging
washer - roller bushing - seal ring unit, placing part
16 until it stops on the swinging hub.
- 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 ANTI-RUST PROTECTION), HALF-FILLED WITH
GREASE.

Specific tooling
020021Y Front suspension service tool

Recommended products
Multi-purpose grease "Multi-purpose" lithium
and medium fibre-based yellow brown grease
suitable for various uses.
ISO L-X-BCHA 3 - DIN 51 825 K3K -20

SUSP - 247
Suspensions Vespa sei giorni 300 hpe

- 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 hand-grip, 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 hand-grip, 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 gaiter 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
Multi-purpose grease "Multi-purpose" lithium
and medium fibre-based yellow brown grease
suitable for various uses.
ISO L-X-BCHA 3 - DIN 51 825 K3K -20

Refitting

Reposition the brake pipes, the odometer trans-

mission and the phonic wheel and front headlamp
wiring harnesses correctly.
Insert the steering tube, complete with the lower
steering bearing ball cage.

SUSP - 248
Vespa sei giorni 300 hpe Suspensions

Reposition the upper steering bearing ball cage,

using the recommended product.
Using the specific tool, tighten the lower ring nut,
applying the recommended torque.

Specific tooling
020055Y Wrench for steering tube ring nut

Recommended products
Calcium based grease Calcium grease
Smooth-textured appearance; Ivory coloured
Specification TL 9150 066, symbol NATO G 460

Insert the washer.

Using the specific tool, tighten the upper ring nut,

applying the recommended torque.

Specific tooling
020055Y Wrench for steering tube ring nut

Reposition the protective collar.

SUSP - 249
Suspensions Vespa sei giorni 300 hpe

The screw used to fasten the handlebar to the

steering tube, applying the recommended torque.

Connect the front headlamp connector.

Connect the USB port connector.

Reposition the fusebox in its housing.

SUSP - 250
Vespa sei giorni 300 hpe Suspensions

Tighten the screws used to fasten the top-box lid.

Replace the lid on the fusebox.

Refit the front shock absorber as described in this

manual, in the section "suspensions > front >
front shock absorber > fitting".

Refit the front brake calliper as described in this

manual, in the section "braking system > front
brake calliper > fitting".

Grease the odometer movement pick-up sprocket

using the recommended product, and reposition it
in its housing.

Recommended products
Calcium based grease Calcium grease
Smooth-textured appearance; Ivory coloured
Specification TL 9150 066, symbol NATO G 460

SUSP - 251
Suspensions Vespa sei giorni 300 hpe

Insert the odometer transmission in its housing

and tighten the fastening screw.

Reposition the ABS sensor in its housing and tight-

en the fastening screw.
Measure the distance "Y" between the ABS sensor
and the phonic wheel.
If the distance "Y" is:
- < 0.1 mm, insert 2 calibrated washers
- 0.1 mm < Y < 0.8 mm, insert 1 calibrated washer
- 0.8 mm < Y < 1.7 mm, do not insert any calibrated
washers

Reposition the ABS sensor siring harness and the

brake pipe, and tighten the retaining clamp on the
front mudguard.

fasten the brake piping to the steering tube.

SUSP - 252
Vespa sei giorni 300 hpe Suspensions

Tighten the internal fastening screws on the front

suspension cover.

Tighten the external fastening screw on the front

suspension cover.
Fit the front wheel.
Refit the rear handlebar cover.
Refit the front centre cover.
Refit the windscreen.

Front shock absorber

Removal

Rest the vehicle on its centre stand.

Remove the front wheel.
Unscrew the inside screws fixing the cover of the
steering tube to the front mudguard.

Unscrew the outside screw fixing the steering tube

cover and remove it.

SUSP - 253
Suspensions Vespa sei giorni 300 hpe

Unscrew the lower screws fixing the shock ab-

sorber to the support.

Unscrew the upper screws fixing the shock ab-

sorber to the steering tube.

Remove the shock absorber.

Refitting

Reposition the shock absorber in its seat.

SUSP - 254
Vespa sei giorni 300 hpe Suspensions

Tighten the upper screws fixing the shock absorb-

er to steering tube with the prescribed torque.

Tighten the lower screws fixing the shock absorber

to the support with the prescribed torque.

Reposition the cover of the steering tube and tight-

en the outside screw to the prescribed torque.

Tighten the inside screws of the cover of the steer-

ing tube to the front mudguard with the prescribed
torque.

Shock-absorber - calliper bracket

SUSP - 255
Suspensions Vespa sei giorni 300 hpe

Removal

Rest the vehicle on its centre stand.

Remove the front wheel.
Remove the front brake calliper.
Remove the speed sensor.
Remove the front wheel hub.
Remove the front shock absorber.
Remove the Seeger ring

Remove the special washer.

Remove the brake calliper-shock absorber sup-

port.

Recuperate the adjustment washer and the O-

ring.

SUSP - 256
Vespa sei giorni 300 hpe Suspensions

Overhaul

Using a flat-head screwdriver, remove the hub

side dust gaiter.

Using a flat-head screwdriver, remove the dust

gaiter on the shock absorber side.

Using the specific tool, remove the roller cages.

Specific tooling
020365Y 22 mm guide
020376Y Adaptor handle
020441S 26 x 28 mm adaptor

After checking the roller cage seat on the support,

use the specific tool to install a new roller cage on
the wheel hub side.

Specific tooling
020037Y Punch

SUSP - 257
Suspensions Vespa sei giorni 300 hpe

Using the specific tool, install a roller cage on the

front shock absorber side.

Specific tooling
020036Y Punch

Using the specific tool, install a dust gaiter on the

shock absorber side.

Specific tooling
020365Y 22 mm guide
020376Y Adaptor handle
020441S 26 x 28 mm adaptor

Using the specific tool, install a new dust gaiter on

the wheel hub side.

Specific tooling
020360S 52 x 55 mm adaptor
020376Y Adaptor handle

Refitting

Insert a new adjustment washer and a new O-ring.

SUSP - 258
Vespa sei giorni 300 hpe Suspensions

Insert the brake calliper-shock absorber on the

wheel axle after greasing the seats of the roller
cages with the recommended product.

Recommended products
Calcium based grease Calcium grease
Smooth-textured appearance; Ivory coloured
Specification TL 9150 066, symbol NATO G 460

Insert the special washer on the front wheel axle

and make sure it is fully into its seat.

insert the locking Seeger ring of the support.

Refit the front shock absorber.
Refit the front wheel hub.
Refit the speed sensor.
Refit the front brake calliper.
Fit the front wheel.

Check the "Y" distance between the speed sensor

and the tone wheel:
If the "Y" distance is less than 0.7 mm, add an ap-
propriate calibrated washer.
If the "Y" distance is greater than 1.9 mm, remove
a calibrated washer.

Steering bearing

SUSP - 259
Suspensions Vespa sei giorni 300 hpe

Removal

Remove the lower ball cage from the steering tube.

Remove the lower plate of the steering bearing

from the steering tube.

Using the specific tool, remove the track of the

lower steering bearing on the steering headstock.

Specific tooling
020004Y Punch for removing steering bearings
from headstock

Using the specific tool, remove the track of the up-

per steering bearing on the steering headstock.

Specific tooling
020004Y Punch for removing steering bearings
from headstock

SUSP - 260
Vespa sei giorni 300 hpe Suspensions

Refitting

Insert the specific tool and the upper track of the

lower steering bearing into the steering headstock.

Specific tooling
001330Y Tool for fitting steering seats

Insert the lower plate of the upper steering bearing

into the specific tool and tighten the nut.

Make sure the tracks go all the way onto the steer-
ing headstock.

SUSP - 261
Suspensions Vespa sei giorni 300 hpe

Using the specific tool, refit the lower plate of the

steering tube bearing.

Specific tooling
020459Y Punch for fitting the bearing on the
steering tube

Grease the track of the seat of the steering bearing

with the recommended product.
Reposition the ball cage and refit the steering tube
onto the headstock.

Recommended products
Calcium based grease Calcium grease
Smooth-textured appearance; Ivory coloured
Specification TL 9150 066, symbol NATO G 460

Rear

REAR SUSPENSION TIGHTENING TORQUES

Name Torque in Nm
Swinging arm (engine side) - Engine 67 - 75 Nm
Swinging arm (frame side) - Frame 76 - 83 Nm
Silent block bracket - Frame 42 - 52 Nm
Swinging arm (engine side) - Swinging arm (frame side) 40 - 45 Nm
Rear shock absorber (lower) - Silencer support bracket 40 - 45 Nm
Rear shock absorber (lower) - Shock absorber support bracket 40 - 45 Nm
Shock absorber support bracket - Engine 20 - 25 Nm
Rear shock absorber (upper) - Frame 20 - 25 Nm
Rear wheel hub - Rear wheel axle 104 - 126 Nm
Rear wheel - Rear wheel hub 20 - 25 Nm
Silencer support arm - Engine 20 - 25 Nm
ABS sensor - Silencer support bracket 5 - 6 Nm
Central stand - Engine 40 - 45 Nm
Side stand support bracket - Frame 6 - 10 Nm
Side stand - Side stand support bracket 35 - 40 Nm
Side stand button - Side stand support bracket 5 - 7 Nm
Ground cable - Frame 7.5 - 9.5 Nm
Ground braid - Frame 7.5 - 9.5 Nm
Ground cable - Engine 11 - 13 Nm
Starter motor ground cable - Frame 11 - 12.5 Nm

REAR SUSPENSION
Name Torque in Nm
Retainer for left shock absorber to crankcase support plate 20 - 25
Shock absorber lower fitting 40 - 45
Shock absorber upper fitting 20 - 25
Rear wheel axle 104 ÷ 126
Screw fixing wheel to hub 20 - 25

SUSP - 262
Vespa sei giorni 300 hpe Suspensions

Name Torque in Nm
Screws for silencer - shock absorber support arm on engine 20 - 25 (The two screws must be tightened after having done
so with the rear wheel axle nut at the specified torque. Safety
fasteners: see «Pre-delivery Operations»)
Engine- and vehicle-side swinging arm junction bolt 40 - 45

Removing the rear wheel

Remove the complete silencer.

Remove the silencer mounting bracket.
Remove the screws fixing the rear wheel to the
wheel hub.

Remove the rear wheel.

Refitting the rear wheel

Refit the rear wheel on the wheel hub.

SUSP - 263
Suspensions Vespa sei giorni 300 hpe

Tighten the screws fixing the rear wheel to the

wheel hub to the specified torque.
Refit the silencer support bracket.
Refit the silencer.

Swing-arm

Removal

- Place the vehicle on its centre stand;

- Remove the engine housing
- Remove the swinging arm/engine fitting shown in
the picture
- Move the engine back

- Remove the spring anchoring the swinging arm

to the chassis as shown in the picture

- Remove the two screws fixing the buffer support

bracket to the chassis

SUSP - 264
Vespa sei giorni 300 hpe Suspensions

- Remove the left and right caps located under the

footrest to reach the pin fixing the swinging arm to
the body.
- Remove the pin. Then remove the swinging arm

- Check the entire swinging arm assembly.

- Check all the centring bushing components and
silent block rubber buffers.
- Replace the work components that cause exces-
sive clearance on the rear suspension.

SUSP - 265
Suspensions Vespa sei giorni 300 hpe

Overhaul

- Check there is no sticking in the movement of the

connection of the swinging arm on the engine side
to the swinging arm on the chassis side.
- Check the axial clearance between the two
swinging arms using a feeler gauge

Characteristic
Standard clearance
0.40 - 0.60 mm
Allowable limit after use:
1.5 mm

- In order to check the clearance of the swinging

arm on the frame side, prepare a retainer using the
fixing pin of the swinging arm on the frame and two
rings from the special tool 020229Y. Alternatively,
use two washers with 12-mm inside diameter for
pins, minimum 30-mm outside diameter and 4-mm
thick at least.

- Check there is no sticking in the rotation.

- Check the axial clearance of the swinging arm on
the chassis side

Characteristic
Standard clearance
0.40 - 0.60 mm
Allowable limit after use:
1.5 mm

- Separate the swinging arm on the engine side

from the vehicle side arm.
- Remove the plastic bushings and the internal
spacer shown in the picture

SUSP - 266
Vespa sei giorni 300 hpe Suspensions

- Using a suitable pin remove the roller casings as

shown in the pictures

- Using an appropriate tool plant new roller cas-

ings, being careful to position the bearings with the
seal rings facing outwards

Specific tooling
020244Y punch ø 15
020115Y punch ø 18

Characteristic
Length of the swinging arm tube on the engine
side:
L 175.3 + 0.3 0
Length of the internal swinging arm spacer on
the engine side:
L 183 + 0.3 0
Engine side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Chassis side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the chassis side:
290 ± 0.1 mm
Length of the swinging arm tube on the chas-
sis side:
283 ± 0.1 mm

SUSP - 267
Suspensions Vespa sei giorni 300 hpe

- Lubricate roller casings and the plastic bushings

with grease
- Insert the spacers
- Assemble the two arms with the relative bolt in
the position shown in the picture
- Adjust the bolt as shown in the picture
- Position the chassis side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the picture

Recommended products
Calcium based grease Calcium grease
Ivory coloured calcium grease; TL 9150 066;
NATO G 460

- Make sure the silent bloc is not broken. If it is,

replace the coupling
- Remove the Seeger ring shown in the picture

- Remove the full silent bloc bracket

- Undo the silent bloc ring shown in the picture

SUSP - 268
Vespa sei giorni 300 hpe Suspensions

- Hold the full silent bloc bracket in the clamp

- Using the appropriate tool, remove the silent bloc
from the bracket from the side corresponding to
the inside of the vehicle. This is to guarantee the
tool is centred properly on the support

- Install a new silent bloc, making sure it aligns

properly with the reference tooth.
- Fit the silent blocs, making sure the chamfered
part of the silent bloc matches the chamfered part
of the bracket

- Using the appropriate tool, fit the silent bloc as

shown in the picture

Refitting

- To refit, perform the removal operations in reverse.

- Grease the bearings and the rolling parts with the recommended grease.

SUSP - 269
Suspensions Vespa sei giorni 300 hpe

- Complete the fitting procedure by tightening the bolts, applying the recommended torque values.

Shock absorbers

Removal

Proceed as follows:
- set the vehicle on its centre stand and support it
adequately.
- Remove the luggage rack.
- Remove the silencer.
- Unscrew and remove the right shock absorber
lower fixing nut.

- Unscrew and remove the left shock absorber

lower fixing screw.

- Support the shock absorbers and unscrew its top

fixing nuts.

SUSP - 270
Vespa sei giorni 300 hpe Suspensions

Refitting

For fitting, proceed as follows:

- Insert the top attachment of the rear shock ab-
sorbers into the seat in the chassis.
- Tighten the nuts to the specified torque.

- Insert the lower fixing bolt of the left shock ab-

sorber.
- Tighten the bolt to the specified torque.

- Insert the lower fixing bolt of the right shock ab-

sorber and tighten to the specified torque.
- Fit the silencer.
- Fit the luggage rack.

Exhaust bracket

Removal

To remove the silencer support bracket, proceed as follows:

- set the vehicle on its centre stand and support it adequately.
- remove the silencer.

SUSP - 271
Suspensions Vespa sei giorni 300 hpe

- Unscrew and remove the screw fixing the rear

ABS sensor and the screws of the retention
clamps of the relative cable.

- Remove the split pin.

- Remove the cap.

- Unscrew and remove the rear wheel nut.

SUSP - 272
Vespa sei giorni 300 hpe Suspensions

- Remove the spacer.

- Unscrew and remove the right shock absorber

nut.

- Unscrew and remove the screws fixing the brack-

et to the engine.

- The silencer support bracket is now free and it can be disconnected from the engine.

Refitting

using the recommended product, lubricate the

contact surfaces between the wheel axle and the
bearing on the bracket, as indicated in figure. Take
care not to apply the grease to the threaded
portion of the wheel axle.

SUSP - 273
Suspensions Vespa sei giorni 300 hpe

To fit the silencer support bracket, proceed as fol-

lows:
- Place the bracket on the engine inserting it onto
the wheel pin.
- Insert the spacer.

- Insert the rear wheel nut and tighten to the speci-

fied torque.

- Insert the cap nut.

- Insert the cotter pin and bend its ends outwards.

SUSP - 274
Vespa sei giorni 300 hpe Suspensions

- Insert and tighten the screws fixing the bracket to

the engine carter to the specified torque.

- Insert the lower fixing bolt of the right shock ab-

sorber and tighten to the specified torque.

- Insert the rear wheel ABS sensor in its seat and

tighten the fixing screws.

After assembling the sensor in its seat, measure

the distance "Y" between the sensor and the tone
wheel with a feeler gauge.
If the "Y" measurement is less than 0.4 mm, as-
semble a calibrated washer between the sensor
and the silencer support bracket.

- Fit the silencer.

SUSP - 275
Suspensions Vespa sei giorni 300 hpe

Centre-stand

REMOVAL
- Support the vehicle adequately.
- Remove the two return springs from the centre
stand.
- Undo the nut shown in the figure.
- Remove the pin from the right side.
- Remove the centre stand.
FITTING
- On refitting tighten the nut to the specified torque.

Side stand

REMOVAL
- Uncouple the centre stand return spring;
Remove the screw shown in the photograph
FITTING
To refit, carry out the removal operations in re-
verse order and comply with the specified torque.

SUSP - 276
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Braking system Vespa sei giorni 300 hpe

This section is dedicated to the description of the brake system components.

FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose joint 20 - 25
Brake fluid pipe-calliper fitting 19 - 24
Screw fixing calliper to the shock absorber - calliper plate at- 24 to 27
tachment
Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium strength)
Oil bleed screw 12 - 16
Pad fastening pin 19.6 - 24.5
Brake pump reservoir screws 1.5 - 2
Brake disc screws 8 to 10

REAR BRAKE
Name Torque in Nm
Brake fluid pump-hose joint 20 - 25
Brake fluid pipe-calliper fitting 20 - 25
Rear disc tightening bolt 11 to 13
Oil bleed screw 12-16
Calliper to engine tightening screw 20 - 25
Brake pump reservoir screws 1.5 - 2
Callipers fitting screw 30 - 33 Nm

ABS

BRAK SYS - 278

Vespa sei giorni 300 hpe Braking system

Key:

1. Recirculation pumps
2. Front brake circuit inlet solenoid valve
3. Front brake circuit outlet solenoid valve
4. Front brake circuit low pressure accumulator
5. Front Calliper (PA Pump)
6. Front Brake (PFA)
7. Front Brake Tank
8. Front brake control lever
9. Rear brake circuit inlet solenoid valve
10.Rear brake circuit outlet solenoid valve
11.Rear brake circuit low pressure accumulator
12.Rear Calliper (PP)
13.Rear Brake Pump (PFP)

BRAK SYS - 279

Braking system Vespa sei giorni 300 hpe

14.Rear Brake Tank

15.Rear brake lever

OPERATION OF THE ABS

General considerations

• The front circuit is the same as the rear one.

• The ABS intake valve (2 - 9) is normally open and is closed only when the system intervenes
to prevent locking.
• The exhaust valve (10 - 3) is normally closed and is only opened when the system intervenes
to prevent locking.
• With the system in stand-by mode, the ABS processor controls the wheel speed instant by
instant to assess any slippage of the wheels.
• While in stand-by, the system does not intervene in any way on the braking of the rider, the
braking system is identical to the one without ABS.
• ABS Cycle phases (the following operations refer to the front circuit but they are also valid
for the rear):

A - Start braking: the rider starts braking as he would usually do.

B - Pressure reduction: coincides with the recognition of the dangerous situation (wheel slippage
exceeds the threshold): The system closes the intake valve (2 - 9) and temporarily opens the exhaust
valve (10 - 3). In this phase, the rider cannot increase the pressure of the callipers (12 - 5) and the
system reduces the pressure in the callipers. The excess fluid temporarily fills the front tank (14 - 7)
until the ABS pump (1) self-operates by driving the fluid in the direction of brake pump (6 - 13).
C - Maintaining pressure: the pressure in the callipers (12 - 5) remains low until the full restoration of
speed / grip of the wheel. The system returns the fluid removed from the calliper (12 - 5) to the system
section between the brake pump (6 - 13) and the ABS intake valve (2 - 9).
D - Pressure restoration: through the temporary openings of the intake valve (2 - 9), pressure from
the callipers (12 - 5) is increased until the maximum deceleration has been reached, the system then
re-assigns braking control to the rider.
E - In the event that the wheel does not regain full grip, the system continues to operate as before until
it is restored or until the vehicle stops. An error may be generated, however, if the pressure reduction
stage persists for longer than a predetermined limit.

Modulator

REMOVAL
CAUTION

IT IS EXTREMELY IMPORTANT TO CAREFULLY FOLLOW THE REMOVAL AND REASSEMBLY

PROCEDURES DESCRIBED BELOW. THESE PROCEDURES MAKE IT POSSIBLE TO AVOID AIR

BRAK SYS - 280

Vespa sei giorni 300 hpe Braking system

FROM ENTERING THE BRAKING CIRCUIT AND ESPECIALLY IN THE ABS MODULATOR WHILE
REPLACING THE COMPONENTS.
Support the vehicle adequately.
Remove the leg shield back plate.
Remove the front centre cover.
Remove the wheels.
Unscrew the screws on the rear brake hose fas-
tening clamps.

Unscrew and remove the front brake calliper fixing

screws and remove it from the support.

With new pads or pads in a good condition, oper-

ate the brake pump repeatedly to bring the pads in
contact with each other.

Refill the front brake pump tank and fit the cap.

BRAK SYS - 281

Braking system Vespa sei giorni 300 hpe

Operate the brake lever just beyond the point of

closing communication with the tank.
Block the position of the lever by fastening it.

Undo the fixing screws of the rear brake calliper to

the engine.

With new pads or pads in a good condition, oper-

ate the brake pump repeatedly to bring the pads in
contact with each other.

Refill the rear brake pump tank and fit the cap.

BRAK SYS - 282

Vespa sei giorni 300 hpe Braking system

Operate the brake lever just beyond the point of

closing communication with the tank.
Block the position of the lever by fastening it.

Unscrew the fixing nuts and remove the turn indi-

cators device including bracket.

Disconnect the front tone wheel sensor connector.

Open the hydraulic hoses fastening clamp.

BRAK SYS - 283

Braking system Vespa sei giorni 300 hpe

Disconnect the modulator connector.

Unscrew the connectors fastening the circuit pipes

entering and exiting the modulator.
N.B.
PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING
THE REMOVAL OF THE PIPING FROM THE MODULATOR.
USE A SMALL CONTAINER AND A CLOTH.

Through the front opening of the shield, unscrew

and remove the modulator fixing screw to the side
support bracket.

Undo and remove the fastening nuts of the mod-

ulator lower support bracket

BRAK SYS - 284

Vespa sei giorni 300 hpe Braking system

Remove the modulator complete with lower sup-

port bracket.

Separate the ABS modulator from the lower sup-

port bracket by unscrewing the fastening screws.

FITTING
Install the new modulator on the support bracket,
tightening the fastening screws to the specified
torque.

Insert the ABS modulator complete with bracket in

its seat.

BRAK SYS - 285

Braking system Vespa sei giorni 300 hpe

Through the front opening of the shield, insert and

tighten the modulator fixing screw at the prescri-
bed torque to the side support bracket.

Unscrew the seal plug on the RW outlet of the

modulator.
N.B.
PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING
THE REMOVAL OF THE PIPING FROM THE MODULATOR.
USE A SMALL CONTAINER AND A CLOTH.

Connect the pipe supplying the rear calliper to the

RW outlet on the modulator.
Screw in the connector all the way and then loosen
it half a turn.

Slowly move away the rear calliper pads.

BRAK SYS - 286

Vespa sei giorni 300 hpe Braking system

Until the brake fluid exits the slow connector.

Block the connector on the modulator while the
fluid is exiting.
CAUTION

THE CONNECTOR MUST BE TIGHTENED BEFORE RE-

MOVING THE THRUST FROM THE PADS. OTHERWISE,
AIR ENTERS THE PIPE.

Unscrew the seal plug on the RC inlet of the mod-

ulator.
N.B.
PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING
THE REMOVAL OF THE PIPING FROM THE MODULATOR.
USE A SMALL CONTAINER AND A CLOTH.

Move the rear calliper pads further away until the

brake fluid exits from the seat of the RC inlet.

Connect the rear brake master cylinder delivery

pipe to the RC outlet on the modulator.
Screw in the connector all the way and then loosen
it half a turn.

BRAK SYS - 287

Braking system Vespa sei giorni 300 hpe

Pull the rear brake lever until brake fluid and air
slowly exit the RC connector.
Block the connector while the brake fluid is exiting.
CAUTION

THE CONNECTOR MUST BE TIGHTENED BEFORE RE-

LEASING THE BRAKE PUMP LEVER. OTHERWISE THE
PUMP INTAKES AIR IN THE PIPE.

Free the rear brake pump lever.

Check and if necessary top up the level of the

brake fluid in the brake pump tank.
Close the tank cap.

Refit the rear brake calliper on the disc, tightening

the screws to the specified torque.
Actuate the brake pump lever, recovering the dis-
tance of the pads.
Check the system's efficiency.
If the work was performed properly, the brake must
be efficient.

BRAK SYS - 288

Vespa sei giorni 300 hpe Braking system

Proceed in the same manner to connect the front

brake pipes.
Unscrew the seal plug on the FW outlet of the
modulator.
N.B.
PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING
THE REMOVAL OF THE PIPING FROM THE MODULATOR.
USE A SMALL CONTAINER AND A CLOTH.

- Connect the pipe supplying the front calliper to

the FW outlet on the modulator.
Screw in the connector all the way and then loosen
it half a turn.

Slowly move away the front calliper pads.

Until the brake fluid exits the slow connector.

Block the connector on the modulator while the
fluid is exiting.
CAUTION

THE CONNECTOR MUST BE TIGHTENED BEFORE RE-

MOVING THE THRUST FROM THE PADS. OTHERWISE,
AIR ENTERS THE PIPE.

BRAK SYS - 289

Braking system Vespa sei giorni 300 hpe

Unscrew the seal plug on the FC inlet of the mod-

ulator.
N.B.
PAY ATTENTION TO THE LOSS OF BRAKE FLUID DURING
THE REMOVAL OF THE PIPING FROM THE MODULATOR.
USE A SMALL CONTAINER AND A CLOTH.

Move the front calliper pads further away until the

brake fluid exits from the seat of the FC inlet.

Connect the front brake master cylinder delivery

pipe to the FC outlet on the modulator.
Screw in the connector all the way and then loosen
it half a turn.

Pull the front brake lever until brake fluid and air
slowly exit the FC connector.
Block the connector while the brake fluid is exiting.
CAUTION

THE CONNECTOR MUST BE TIGHTENED BEFORE RE-

LEASING THE BRAKE PUMP LEVER. OTHERWISE THE
PUMP INTAKES AIR IN THE PIPE.

BRAK SYS - 290

Vespa sei giorni 300 hpe Braking system

Free the front brake pump lever.

Check and if necessary top up the level of the

brake fluid in the brake pump tank.
Close the tank cap.

Refit the front brake calliper on the disc, tightening

the screws to the specified torque.
Actuate the brake pump lever, recovering the dis-
tance of the pads.
Check the system's efficiency.
If the work was performed properly, the brake must
be efficient.

Block the hydraulic hoses with the appropriate

clamp

BRAK SYS - 291

Braking system Vespa sei giorni 300 hpe

Connect the connector to the modulator until the

click of the stop tooth is heard.

Connect the front tone wheel sensor connector.

Connect the direction indicator device connector

Position the direction indicator device complete

with bracket in its seat
Insert and tighten the bracket fixing nuts.

BRAK SYS - 292

Vespa sei giorni 300 hpe Braking system

Insert and tighten the screws of the rear brake pipe

fastening clamps.
Assemble the wheels.
Assemble the front centre cover.
Assemble the leg shield back plate.

Rear brake calliper

Removal

Remove the silencer.

Remove the silencer supporting arm.
Remove the rear wheel.
Unscrew the screws on the rear brake hose fas-
tening clamps.

Operate the brake lever just beyond the point of

closing communication with the tank.
Block the position of the lever by fastening it.

Previously loosen the screw fastening the pipe

connector to the calliper.

BRAK SYS - 293

Braking system Vespa sei giorni 300 hpe

Undo the fixing screws of the rear brake calliper to

the engine.

Extract the calliper from the disc and turn it so that

the end part of the pipe is tilted upwards.
Maintaining this position, remove the calliper by
acting on the connector with the relative copper
washers.
WARNING
KEEP THE END OF THE PIPE TILTED UPWARD.

Suitably protect the connector and secure it so it

is tilted upward to keep air from entering.
Immediately proceed with installing the new brake
calliper.
CAUTION

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS

MOISTURE FROM THE AIR. IT IS IMPORTANT TO COM-
PLETE THESE OPERATIONS AS QUICKLY AS POSSIBLE
TO AVOID THE DEGRADATION OF THE CHARACTERIS-
TICS OF THE FLUID.

Refitting

Keeping the end of the pipe upwards, connect the

new calliper using the connector and the new cop-
per washers.
Keeping the calliper aligned with the vehicle, tem-
porarily block the connector to maintain a seal.

BRAK SYS - 294

Vespa sei giorni 300 hpe Braking system

Fasten or maintain the calliper in the up position

and free the pump lever.
WARNING
TO RELEASE THE BRAKE LEVER, CUT THE WIRE OF THE
FASTENING IN ORDER TO OPEN THE COMMUNICATION
WITH THE TANK. AVOID ANY ADDITIONAL OPERATION
OF THE BRAKE LEVER.

Keeping the calliper up, connect the drain pipe and

open the bleed valve connector.
Allow the air to flow out until only brake fluid exits.
CAUTION
THIS BLEEDING PHASE MUST TAKE PLACE BY MEANS
OF GRAVITY. DO NOT ACTIVATE THE PUMP LEVER.

Check and if necessary top up the tank level.

Lower the calliper to the position shown in the pho-

to and open the bleed valve connector again.
Let the air flow out and close the bleed valve con-
nector when the level of the brake fluid in the drain
pipe has risen at least 10 cm without the outflow
of air.

BRAK SYS - 295

Braking system Vespa sei giorni 300 hpe

Install the brake calliper on the disc and tighten the

fastening screws on the engine to the specified
torque.

Loosen the connector fastening the pipe as little

as possible to settle the pipe in the neutral position.
Finally block the connector to the specified torque.

Refill the level of the brake fluid and close the tank
cover.

Fix the rear brake pipe fastening clamps with the

appropriate screws.
Fit the rear wheel.
Assemble the silencer supporting arm.
fit the silencer.

Check the system's efficiency.

If the work was performed properly, the brake must be efficient.

Front brake calliper

BRAK SYS - 296

Vespa sei giorni 300 hpe Braking system

Removal

Remove the front wheel.

Operate the brake lever just beyond the point of
closing communication with the tank.
Block the position of the lever by fastening it.

Previously loosen the screw fastening the pipe

connector to the calliper.

Disconnect the front wheel sensor cable retaining

clamps.

Unscrew and remove the front brake calliper fixing

screws and remove it from the support.

BRAK SYS - 297

Braking system Vespa sei giorni 300 hpe

Lift the calliper so that the end part of the pipe is

tilted upwards.
Maintaining this position, remove the calliper by
acting on the connector with the relative copper
washers.

Refitting

Without lowering the pipe, connect the new calliper

using the connector and the new copper washers.
Keeping the calliper aligned with the vehicle, tem-
porarily block the connector to maintain a seal.

Fasten or maintain the calliper in the up position

and free the pump lever.
WARNING
TO RELEASE THE BRAKE LEVER, CUT THE WIRE OF THE
FASTENING IN ORDER TO OPEN THE COMMUNICATION
WITH THE TANK. AVOID ANY ADDITIONAL OPERATION
OF THE BRAKE LEVER.

Keeping the calliper up, connect the drain pipe and

open the bleed valve connector.
Allow the air to flow out until only brake fluid exits.
CAUTION
THIS BLEEDING PHASE MUST TAKE PLACE BY MEANS
OF GRAVITY. DO NOT ACTIVATE THE PUMP LEVER.

BRAK SYS - 298

Vespa sei giorni 300 hpe Braking system

Check and if necessary top up the tank level.

Lower the calliper in the driving direction and

slightly inclined to the right so the bleed screw is
in the highest point of the calliper.
Reopen the bleed valve connector and let the air
flow out.
- Close the bleed valve connector when the level
of the brake fluid in the drain pipe has risen at least
10 cm without the outflow of air.

Separate the pads, if necessary, and install the

brake calliper on the disc
Fasten the screws fastening the support to the
specified torque.

Loosen the connector fastening the pipe as little

as possible to settle the pipe in the neutral position.
Finally block the connector to the specified torque.
WARNING
KEEP THE PIPE IN POSITION WHEN TIGHTENING THE
CONNECTOR.

Refill the level of the brake fluid and close the tank cover.

Rear brake disc

BRAK SYS - 299

Braking system Vespa sei giorni 300 hpe

Removal

Remove the rear brake calliper.

Remove the tapered spacer.

Remove the rear wheel hub with the brake disc.

Unscrew and remove the screws fastening the

brake disc to the rear wheel hub.
Remove the disc.

Refitting

Position the brake disc on the rear wheel hub.

Insert and tighten the fastening screws at the rec-
ommended torque.

BRAK SYS - 300

Vespa sei giorni 300 hpe Braking system

Insert the rear wheel hub with the brake disc on

the wheel axle.

Insert the tapered spacer.

Assemble the brake calliper.
Fit the rear wheel.
Assemble the silencer supporting arm.
fit the silencer.

Disc Inspection

Remove the front wheel.

Check the thickness of the disc with an appropriate
measuring instrument.

Characteristic
Standard thickness of rear disc
3.90 - 4.20 mm

- Repeat the measurement in at least 6 points on the disk.

- Check that the brake disc unit rotates smoothly using a special tool attached to the brake calliper
support as shown in the photo.

- In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it
to one of the two rear brake calliper attachment points
- Fix the flange to the wheel axle using the original nut and spacer and an Æ 17mm bearing
N.B.
FOR A CORRECT READING, MAKE THE DRIVEN PULLEY AXLE ROTATE IN ORDER TO ROTATE
THE DISC.
Specific tooling
020335Y Magnetic mounting for dial gauge
Characteristic

BRAK SYS - 301

Braking system Vespa sei giorni 300 hpe

Max. deviation allowed:

0.1 mm

- If incorrect values are measured, replace the

disc. If the anomaly persists, replace the hub.

Front brake disc

Removal

Remove the front wheel.

Remove the front brake calliper.
Remove the front wheel hub with the disc.

Unscrew the screws fastening the brake disc and

the phonic wheel to the hub and remove them.

BRAK SYS - 302

Vespa sei giorni 300 hpe Braking system

Refitting

Fit the brake disc and tone wheel on the hub.

Insert and tighten the fastening screws at the rec-
ommended torque.

Insert the front wheel hub with the brake disc on

the wheel axle.

Disc Inspection

Remove the front wheel.

Check the thickness of the disc with an appropriate
measuring instrument.

Characteristic
Standard thickness of rear disc
3.90 - 4.20 mm

- Repeat the measurement in at least 6 points on the disk.

- Check that the brake disc unit rotates smoothly using a special tool attached to the brake calliper
support as shown in the photo.

- In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it
to one of the two rear brake calliper attachment points
- Fix the flange to the wheel axle using the original nut and spacer and an Æ 17mm bearing
N.B.
FOR A CORRECT READING, MAKE THE DRIVEN PULLEY AXLE ROTATE IN ORDER TO ROTATE
THE DISC.
Specific tooling

BRAK SYS - 303

Braking system Vespa sei giorni 300 hpe

020335Y Magnetic mounting for dial gauge

Characteristic
Max. deviation allowed:
0.1 mm

- If incorrect values are measured, replace the

disc. If the anomaly persists, replace the hub.

Front brake pads

Removal

Rest the vehicle on its centre stand.

Suitably secure the rear part of the vehicle by rais-
ing the front slightly.
Remove the front wheel.
Loosen, without removing, the screws fixing the
front brake pads.

Disconnect the wiring of the tone wheel sensor

from the clamp, unscrew the screws fixing the front
brake calliper to the support bracket and remove
it.

BRAK SYS - 304

Vespa sei giorni 300 hpe Braking system

Completely unscrew the screws and remove them,

keeping the brake pads in position.

Remove the brake pads.

CAUTION

BE EXTREMELY CAREFUL NOT TO PULL THE BRAKE

LEVER AFTER REMOVING THE PADS. THIS OPERATION
COULD CAUSE THE CYLINDERS TO EXIT THE BRAKE
CALLIPER AS WELL AS THE BRAKE FLUID TO ESCAPE.

- Check the thickness of the wear material and, if

below the minimum value, replace the pads.

Characteristic
Friction material minimum permissible thick-
ness
1.5 mm

- Also check that the wear of the friction material

is uniform and make sure it does not exceed the
indicated tolerance. Otherwise, replace the pads.

Characteristic
Maximum permissible thickness tolerance for
wear material
0.5 mm

BRAK SYS - 305

Braking system Vespa sei giorni 300 hpe

Refitting

Put the new brake pads inside the clamp.

Screw in the fastening screws of the brake pads

on the clamp.

Put the brake calliper on the support bracket and

tighten the fixing screws to the specified torque.
Put the wiring harness of the tone wheel sensor in
its clamp.

Tighten the fixing screws of the brake pads to the

clamp at the specified torque.
Fit the front wheel.

Rear brake pads

BRAK SYS - 306

Vespa sei giorni 300 hpe Braking system

Removal

Rest the vehicle on its centre stand.

Remove the complete silencer.
Remove the silencer support bracket.
Remove the rear wheel.
Unscrew the screws fixing the rear brake calliper
to the engine and remove it.

Remove the stop spring from the fastening pin of

the brake pads.

Extract the fastening pin of the brake pads.

Remove the compression spring.

BRAK SYS - 307

Braking system Vespa sei giorni 300 hpe

Take the brake pads out of the rear brake calliper.

CAUTION

BE EXTREMELY CAREFUL NOT TO PULL THE BRAKE

LEVER AFTER REMOVING THE PADS. THIS OPERATION
COULD CAUSE THE CYLINDERS TO EXIT THE BRAKE
CALLIPER AS WELL AS THE BRAKE FLUID TO ESCAPE.

- Check the thickness of the wear material and, if

below the minimum value, replace the pads.

Characteristic
Friction material minimum permissible thick-
ness
1.5 mm

- Also check that the wear of the friction material

is uniform and make sure it does not exceed the
indicated tolerance. Otherwise, replace the pads.

Characteristic
Maximum permissible thickness tolerance for
wear material
0.5 mm

Refitting

Put the new brake pads inside the clamp.

BRAK SYS - 308

Vespa sei giorni 300 hpe Braking system

Put the compression spring back inside the brake

calliper.

Insert the fastening pin of the brake pads.

Insert the stop spring on the fastening pin of the

brake pads.

Put back the brake calliper in it seat and tighten

the fixing screws to the specified torque.
Refit the rear wheel.
Refit the silencer support bracket.
Refit the complete silencer.

Fill

BRAK SYS - 309

Braking system Vespa sei giorni 300 hpe

Rear - combined

For this procedure, see section «Misc. documents».

Front

For this procedure, see section «Misc. documents».

Brake fluid level check

Rest the vehicle on its centre stand and with the

handlebars perfectly horizontal.
Check the liquid level through the relative inspec-
tion sight glass.
If the sight glass is full, the brake fluid level is cor-
rect. If the brake fluid is near the «MIN» reference,
top-up

Front brake pump

Removal

Remove the front wheel.

Disconnect the stop light switch connectors.

Disconnect the front wheel sensor cable retaining

clamps.

BRAK SYS - 310

Vespa sei giorni 300 hpe Braking system

Unscrew and remove the front brake calliper fixing

screws and remove it from the support.

With new pads or pads in a good condition, oper-

ate the brake pump repeatedly to bring the pads in
contact with each other.

Previously loosen the brake pump connector.

Unscrew the screws of the U-bolt fastening the

pump.

BRAK SYS - 311

Braking system Vespa sei giorni 300 hpe

Position the pump as shown in the photo and re-

move the connector with the copper washers.

Suitably protect the connector and secure it so it

is tilted upward to keep air from entering.

Immediately proceed with installing the new brake pump.

CAUTION

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE AIR. IT IS IM-
PORTANT TO COMPLETE THESE OPERATIONS AS QUICKLY AS POSSIBLE TO AVOID THE
DEGRADATION OF THE CHARACTERISTICS OF THE FLUID.

Refitting

Install the new pump on the handlebars, paying

attention to the correct position of the U-bolt.
Block the screws temporarily.

BRAK SYS - 312

Vespa sei giorni 300 hpe Braking system

Remove the tank cover and tighten the pipe fas-

tening connector to the specified torque using new
copper washers.

Position the handlebars so that the pump tank is

levelled horizontally.
Top up with DOT4 brake fluid to the maximum lev-
el.

Recommended products
DOT 4 brake fluid Synthetic brake fluid.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC
956 DOT4

Operate the brake pump lever repeatedly, making

the air bubble in the tank.
CAUTION
PERFORM THE OPERATION WITH THE HANDLEBARS
TURNED IN THE MAXIMUM POSITION AWAY FROM THE
BRAKE PUMP.

When the air finished bubbling in the tank, move

the pads away in order to send the brake fluid to
the pump.
During this operation, there will be a backflow of
air in the tank.
Operate the pump lever until the pads are in con-
tact with each other and repeat the procedure until
the air stops exiting.

BRAK SYS - 313

Braking system Vespa sei giorni 300 hpe

Refit the calliper on the support and tighten the

screws to the specified torque.

Restore the working distance of the pads and top

up the brake fluid level to the maximum.

Close the pump cover and remove the screws with

the U-bolt fastened to the handlebars.

Lift the pump so it is upright and repeatedly oper-

ate the control lever.
This operation is required so the residual air con-
tained in the pump cylinder will exit.
For an optimal result, slightly vary the position of
the pump each time the lever is operated.

BRAK SYS - 314

Vespa sei giorni 300 hpe Braking system

Install the pump on the handlebars, paying atten-

tion to the correct orientation of the U-bolt.
Gradually tighten the fastening screws to the
specified torque.

Connect the stop light switch connector.

Rear brake pump - combined

Removal

Remove the rear wheel.

Disconnect the stop light switch cables.

Unscrew the screw on the clamp fastening the rear

brake hose to the engine.

BRAK SYS - 315

Braking system Vespa sei giorni 300 hpe

Undo the fixing screws of the rear brake calliper to

the engine.

With new pads or pads in a good condition, oper-

ate the brake pump repeatedly to bring the pads in
contact with each other.

Previously loosen the brake pump connector.

Unscrew the screws of the U-bolt fastening the

pump.

BRAK SYS - 316

Vespa sei giorni 300 hpe Braking system

Disconnect the pump from the handlebar, position

it as shown in the photo and remove the connector
with the copper washers.

Suitably protect the connector and secure it so it

is tilted upward to keep air from entering.

Immediately proceed with installing the new brake pump.

CAUTION

BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE AIR. IT IS IM-
PORTANT TO COMPLETE THESE OPERATIONS AS QUICKLY AS POSSIBLE TO AVOID THE
DEGRADATION OF THE CHARACTERISTICS OF THE FLUID.

Refitting

Install the new pump on the handlebars, paying

attention to the correct position of the U-bolt.
Block the screws temporarily.

BRAK SYS - 317

Braking system Vespa sei giorni 300 hpe

Remove the tank cover and tighten the pipe fas-

tening connector to the specified torque using new
copper washers.

Position the handlebars so that the pump tank is

levelled horizontally.
Top up with DOT4 brake fluid to the maximum lev-
el.

Recommended products
DOT 4 brake fluid Synthetic brake fluid.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC
956 DOT4

Operate the brake pump lever repeatedly, making

the air bubble in the tank.
CAUTION
PERFORM THE OPERATION WITH THE HANDLEBARS
TURNED IN THE MAXIMUM POSITION AWAY FROM THE
BRAKE PUMP.

When the air finished bubbling in the tank, move

the pads away in order to send the brake fluid to
the pump.
During this operation, there will be a backflow of
air in the tank.
Operate the pump until the pads are in contact with
each other and repeat the procedure until the air
stops exiting.

BRAK SYS - 318

Vespa sei giorni 300 hpe Braking system

Refit the calliper on the engine and tighten the

screws to the specified torque.

Restore the working distance of the pads and top

up the brake fluid level to the maximum.

Close the pump cover and remove the screws with

the U-bolt fastened to the handlebars.

Lift the pump so it is upright and repeatedly oper-

ate the control lever.
This operation is required so the residual air con-
tained in the pump cylinder will exit.
For an optimal result, slightly vary the position of
the pump each time the lever is operated.

BRAK SYS - 319

Braking system Vespa sei giorni 300 hpe

Install the pump on the handlebars, paying atten-

tion to the correct orientation of the U-bolt.
Tighten the fastening screws to the prescribed tor-
que.

Connect the stop light switch connectors.

BRAK SYS - 320

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

Cooling system Vespa sei giorni 300 hpe

COOLING
Name Torque in Nm
Water pump rotor cover 3-4
Thermostat cover screws 3-4
Bleeder screw 3

Circuit diagram

COOL SYS - 322

Vespa sei giorni 300 hpe Cooling system

COOL SYS - 323

Cooling system Vespa sei giorni 300 hpe

System bleed
WARNING
NEVER UNSCREW THE EXPANSION TANK CAP BEFORE THE COOLING SYSTEM HAS
COOLED.
Remove the expansion tank cover at the top right
on the shield.
Fill the cooling system until reaching the "MAX"
level of the expansion tank.

Recommended products
Anti-freeze liquid, ready to use, colour red Eth-
ylene glycol antifreeze liquid with organic in-
hibition additives. Red, ready to use.
ASTM D 3306 - ASTM D 4656 - ASTM D 4985 -
CUNA NC 956-16

COOL SYS - 324

Vespa sei giorni 300 hpe Cooling system

- Loosen the bleed screw on the big end.

- Add more coolant in the expansion tank until the
coolant overflows from the bleeder hole.
- Tighten the bleed screw.

- Loosen the bleed screw situated at the top of the

thermostat cover .
- Add more coolant in the expansion tank until the
coolant overflows from the bleeder hole.
- Tighten the bleed screw.

Restore the "MAX" level of the expansion tank

Tighten with force the expansion tank cap.

WARNING
NEVER UNSCREW THE EXPANSION TANK CAP BEFORE
THE COOLING SYSTEM HAS COOLED.

Start the engine at idle speed.

CAUTION

NEVER UNSCREW THE COOLING SYSTEM BLEED SCREW WITH THE ENGINE RUNNING OR
HOT.

COOL SYS - 325

Cooling system Vespa sei giorni 300 hpe

With the engine idling, place a hand close to the

water outlet hose from the engine.

The opening of the thermostat is confirmed as soon as a sudden rise in the temperature of the circulating
liquid in the hose is detected.

With the thermostat open, slowly rotate the accel-

erator handle.
Take the engine to medium revs and maintain it for
about 10 seconds.

Return the engine to idle and wait for the electric fan to start.
Wait for the electric fan to stop and turn off the engine.
CAUTION

NEVER UNSCREW THE COOLING SYSTEM BLEED SCREW WITH THE ENGINE RUNNING OR
HOT.
WARNING
NEVER UNSCREW THE EXPANSION TANK CAP BEFORE THE COOLING SYSTEM HAS
COOLED.
Wait for the complete cooling of the system and
restore the "MAX" level of the coolant

Thermostat

COOL SYS - 326

Vespa sei giorni 300 hpe Cooling system

Removal

To remove the thermostat, proceed as follows:

- Remove the helmet compartment.
- Place a + 2.0 l container under the vehicle to col-
lect the coolant.
- Unscrew and remove the cover fastening screws

- Lift and remove the thermostat cover.

Check

1) Visually inspect that the thermostat is not dam-

aged.
2) Fill a metal container with approx. 1 litre of wa-
ter.
Immerse the thermostat, and keep it in the centre
of the container.
Immerse the multimeter temperature probe, and
keep it close to the thermostat.
Heat up the container using the thermal gun.
Check the temperature at which the thermostat
starts to open:
Heat up until the thermostat is completely open
3) Replace the thermostat if it is not working prop-
erly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.

Specific tooling

COOL SYS - 327

Cooling system Vespa sei giorni 300 hpe

020331Y Digital multimeter

020151Y Air heater

THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening at 85±2°C

Refitting

- Insert the thermostat in the head.

- Position the cover.

- Insert the cover fixing screws and tighten them to

the specified torque.
- Fill the system and bleed it.

Locking torques (N*m)

Thermostat cover screws 3 - 4

COOL SYS - 328

INDEX OF TOPICS

CHASSIS CHAS
Chassis Vespa sei giorni 300 hpe

This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.

BODYWORK TIGHTENING TORQUES

Name Torque in Nm
Saddle - Frame 8 - 10 Nm
Handle - Frame 8 - 10 Nm
Rear handle cover - Handle 1 - 1.7 Nm
Saddle support cover - Frame 8 - 10 Nm
Rear view mirrors - Handlebars 29 - 31 Nm
Rear handlebar cover - Front handlebar cover 1 - 1.7 Nm
Panel lights - Rear handlebar cover 1 - 1.7 Nm
Headlamp - Headlamp cover 5 - 6 Nm
Front direction indicator - Leg shield 1 - 1.7 Nm
Central frame cover - Footrest 1 - 1.7 Nm
Expansion chamber cover - Leg shield back plate 1 - 1.7 Nm
Leg shield back plate (upper external fastening) - Leg shield 1 - 1.7 Nm
Leg shield back plate (upper internal fastening) - Leg shield 1 - 1.7 Nm
Leg shield back plate (lower internal fastening) - Footrest 1 - 1.7 Nm
Leg shield back plate (lower external fastening) - Footrest 1 - 1.7 Nm
Leg shield back plate (central fastening) - Frame 4.5 - 7 Nm
Rear light assembly - Frame 4.5 - 7 Nm
Rear direction indicator - Frame 1 - 1.7 Nm
Footrest (central fastening) - Frame 4.5 - 7 Nm
Footrest (lateral fastening) - Frame 1 - 1.7 Nm
Footrest (rear fastening) - Frame 4.5 - 7 Nm
Passenger footrest - Frame 17 - 22 Nm
Lateral cover (front fastening) - Footrest 1 - 1.7 Nm
Lateral cover (rear fastening) - Frame 4.5 - 7 Nm
Spoiler terminal - Footrest 1 - 1.7 Nm
Fuel pipe clamp - Fuel tank 4.5 - 7 Nm
Fuel tank (front fastening) - Frame 8 - 10 Nm
Fuel tank (rear fastening) - Frame 8 - 10 Nm
Fuel tank (upper fastening) - Frame 8 - 10 Nm
Front splash guard (front fastening) - Front mudguard 2 - 4 Nm
Front splash guard (rear fastening) - Front mudguard 2 - 4 Nm
Headlamp cover (central fastening) - Front mudguard 7 - 10 Nm
Headlamp cover (front fastening) - Front mudguard 2 - 4 Nm
Headlamp cover (rear fastening) - Front mudguard 7 - 10 Nm
Front mudguard - Steering tube 5 - 6 Nm
Front mudguard support bracket - Suspension flange 8 - 10 Nm
Front mudguard support bracket - Steering tube 8 - 10 Nm
Suspension flange - Headlight support bracket 8 - 10 Nm
Headlamp retainer bracket - Headlight support bracket 8 - 10 Nm
Steering tube protection (lower fastening) - Steering tube 4 - 7 Nm
Steering tube protection (lower fastening) - Front mudguard 2 - 4 Nm
Front central cover - Frame 1 - 1.7 Nm
Front windshield - Windshield support 4.5 - 7 Nm
battery fastening bracket - Frame 4.5 - 7 Nm

CHAS - 330
Vespa sei giorni 300 hpe Chassis

Seat

REMOVAL
Remove the helmet compartment.
Support the saddle, undo and remove the saddle
fixing screws.
Remove the saddle.

FITTING
Position the saddle
Support the saddle, insert and tighten the saddle
fixing screws.
Insert the helmet compartment.

SADDLE OPENING DEVICE REMOVAL

Remove the helmet compartment.

Remove the plastic cover above the luggage rack.

CHAS - 331
Chassis Vespa sei giorni 300 hpe

Free the electrical wiring from the retaining ties.

Disconnect the cable from the saddle's lock.

Unscrew and remove the fastening nuts from the

saddle opening device's bracket.

Move the saddle opening device complete with the

bracket downward and disconnect the electrical
connector.

CHAS - 332
Vespa sei giorni 300 hpe Chassis

Unscrew and remove the bolts fastening the de-

vice to the bracket.

Disconnect the device from the spring.

SADDLE OPENING DEVICE ASSEMBLY

Connect the device to the spring.

Insert and tighten the bolts for fastening the device

to the bracket.

CHAS - 333
Chassis Vespa sei giorni 300 hpe

Connect the device's electrical connector and in-

sert the saddle opening device complete with the
bracket into its lodging.

Connect the cable to the saddle's lock.

apply and tighten the nuts for fastening the saddle

opening device's bracket.

Insert the electrical wiring into the retaining ties.

CHAS - 334
Vespa sei giorni 300 hpe Chassis

Mount the plastic cover above the luggage rack.

Insert the helmet compartment.

Rear rack

REMOVAL
Remove the helmet compartment.
Undo and remove the fixing screws of the luggage
rack and the plastic cover.

Remove the fuel tank cap.

Remove the plastic cover.

CHAS - 335
Chassis Vespa sei giorni 300 hpe

Unscrew and remove the fixing screw of the lug-

gage rack screws cover.
Remove the cover of the rear screws of the lug-
gage rack.

Unscrew and remove the rear fixing screws of the

luggage rack.
Remove the luggage rack.

FITTING
Position the luggage rack.
Insert and tighten the rear fixing screws of the lug-
gage rack.

Position the cover of the rear screws of the lug-

gage rack.
Insert and tighten the fixing screw of the luggage
rack screws cover.

CHAS - 336
Vespa sei giorni 300 hpe Chassis

Position the plastic cover.

Screw on the fuel tank cap.

Insert and tighten the fastening screws for the lug-

gage rack and the plastic cover.
Insert the helmet compartment.

Driving mirrors

REMOVAL
Rest the vehicle on its centre stand.
Move the protection rubber.

CHAS - 337
Chassis Vespa sei giorni 300 hpe

Unscrew the fixing counter nut and unscrew the

mirror using the rod.

FITTING
Screw the mirror into its seat using the rod.
Tighten the fixing counter nut to the specified tor-
que.

Put back protection rubber.

Rear handlebar cover

REMOVING THE REAR HANDLEBAR COVER:

Remove the windscreen.
Remove the front centre cover.
Unscrew the rear cover fastening screws.

CHAS - 338
Vespa sei giorni 300 hpe Chassis

Lift the rear cover and disconnect the cable from

the odometer.

Disconnect the instrument assembly connector.

Unscrew the panel lights assembly fastening

screws and remove the complete instrument panel
cover.

ASSEMBLING THE REAR HANDLEBAR COV-

ER:
Place the complete instrument panel cover in po-
sition and tighten the panel lights assembly fas-
tening screws.

CHAS - 339
Chassis Vespa sei giorni 300 hpe

Connect the connector of the instrument unit.

Connect the odometer transmission cable to the

instrument unit, checking that the clamps are fas-
tened correctly.

Tighten the bottom screws fastening the rear cover

to the front cover, applying the pre-defined torque.
Refit the front centre cover.
Refit the windscreen.

Instrument panel

REMOVING THE INSTRUMENT PANEL:

Remove the rear handlebar cover.
Press the locking lever gently and remove the in-
strument panel from the cover.

CHAS - 340
Vespa sei giorni 300 hpe Chassis

Rotate the instrument panel lighting lamp holder

anticlockwise and extract it.

Remove the instrument panel sealing gasket.

ASSEMBLING THE INSTRUMENT PANEL:

Reposition the instrument panel in its housing.
Refit the rear handlebar cover.

REMOVING THE PANEL LIGHTS ASSEMBLY:

Remove the rear handlebar cover.
Remove the leg shield back plate.
Unscrew the screws used to fasten the expansion
chamber and move it away from the vehicle body.

CHAS - 341
Chassis Vespa sei giorni 300 hpe

Release the cable retaining clamp.

Free the corresponding wiring harness and dis-

connect the panel lights assembly connector.

Extract the wiring harness from the handlebar and

remove the panel lights assembly.

ASSEMBLING THE PANEL LIGHTS ASSEM-

BLY:
Insert the panel lights assembly wiring harness in
its housing and connect the connector.
Close the cable retaining clamp so that it secures
the panel lights assembly and right and left elec-
trical device wiring harnesses in position.

CHAS - 342
Vespa sei giorni 300 hpe Chassis

Reposition the expansion chamber in its housing

and tighten the fastening screws, applying the pre-
defined torque.
Refit the rear handlebar cover.
Reassemble the leg shield back plate.

Front handlebar cover

REMOVING THE FRONT HANDLEBAR COVER:

Remove the windscreen.
Remove the front centre cover.
Remove the rear handlebar cover.
Remove the handlebars
Unscrew the screws used to fasten the odometer
transmission cable retaining clamp.

Slide the front handlebar cover off.

ASSEMBLING THE FRONT HANDLEBAR COV-

ER:
Reposition the front handlebar cover in its housing.

CHAS - 343
Chassis Vespa sei giorni 300 hpe

Tighten the screws used to fasten the odometer

transmission cable retaining clamp.
Refit the handlebars.
Refit the rear handlebar cover.
Refit the front centre cover.
Refit the windscreen.

Headlight assy.

REMOVING THE FRONT LIGHT ASSEMBLY

Unscrew the fastening nut and slide the front head-
lamp assembly out.

Undo the screws used to fasten the headlamp as-

sembly support bracket.

Disconnect the high/low beam headlight connec-

tors.

CHAS - 344
Vespa sei giorni 300 hpe Chassis

Remove the rubber protection, and rotate the high/

low beam headlight lamp fastening lock-nut anti-
clockwise.

Remove the high/low beam headlights lamp.

To replace the side light lamp, extract the lamp-

holder.

REMOVING THE FRONT DIRECTION INDICA-

TORS:
To replace the lamps in the front indicators, un-
screw the fastening screws and extract the lamp-
holder.

CHAS - 345
Chassis Vespa sei giorni 300 hpe

Rotate the lamp-holder anticlockwise and extract

the lamp.

FOR EUROPEAN VERSION:

Integrated in the front turn indicators are the daylight running lights of «LED» type. In the event of a
fault, replace the complete direction indicator unit.

Frame central cover

Rest the vehicle on its centre stand.

Unscrew the screws fixing the middle cover to the
footrest and remove it.
When refitting, tighten the fixing screws to the
specified torque.

Knee-guard

REMOVAL
Remove the handlebar covers.
Remove the front centre cover.
Remove the expansion tank cover and the left side
cover by unscrewing the fixing screws.

CHAS - 346
Vespa sei giorni 300 hpe Chassis

Undo and remove the screws under the expansion

tank cover and under the left side cover.

Unscrew and remove the screws on the shield.

Unscrew and remove the screws near the footrest.

Unscrew and remove the central screw inside the

glove box.

CHAS - 347
Chassis Vespa sei giorni 300 hpe

Detach the leg shield back plate from the body.

Disconnect the connector for the USB port and the
connector for the saddle opening button.
Disconnect the fuse terminal block from the leg
shield back plate.
disconnect the emergency saddle opening trans-
mission.
The leg shield back plate is now free and can be
removed.

FITTING
Position the leg shield back plate on the body.
Connect the emergency saddle opening transmis-
sion.
Insert the fuse terminal block into its lodging inside
the leg shield back plate.
Connect the connector for the USB port and the
connector for the saddle opening button.

Insert and tighten the central screw inside the

glove box.

Insert and tighten the screws under the expansion

tank cover and under the left side cover.

CHAS - 348
Vespa sei giorni 300 hpe Chassis

insert and tighten the screws near the footrest.

insert and tighten the screws on the shield.

Assemble the expansion tank cover and the left

side cover.
Insert and tighten the fixing screws.
Assemble the front centre cover.
Fit the handlebar covers.

Taillight assy.

REMOVAL
To remove the rear light assembly, unscrew and
remove the fastening screw.

CHAS - 349
Chassis Vespa sei giorni 300 hpe

Disconnect the connector.

FITTING
Support the light assembly and connect the con-
nector.

Insert the light assembly into its lodging.

Insert and tighten the fastening screw.

REMOVAL
To remove the rear turn signal device, unscrew
and remove the fastening screw.

CHAS - 350
Vespa sei giorni 300 hpe Chassis

Remove the turn signal device, support it, and dis-

connect the connector.

FITTING
Connect the connector and insert the turn signal
device into its lodging.

Insert and tighten the fastening screw.

Footrest

REMOVAL
Remove the leg shield back plate.
Remove the battery compartment cover and the
battery.
Remove the side fairings
Remove the centre screw under the battery com-
partment cover.

CHAS - 351
Chassis Vespa sei giorni 300 hpe

Unscrew and remove the fixing screws of the pas-

senger footrests.
Remove the footrests.

Remove the left and right footrest fixing screw.

Remove the left and right lower cover fixing

screws.
Remove the lower covers.

Remove the non-slip rubber strips of the footrest.

CHAS - 352
Vespa sei giorni 300 hpe Chassis

Remove the screws positioned under the non-slip

rubber strip.
Remove the footrest

FITTING
position the footrest on the frame.
Insert and tighten the screws positioned under the
non-slip rubber strip.

Insert the central screw.

Insert and tighten the left and right footrest fixing

screw.

CHAS - 353
Chassis Vespa sei giorni 300 hpe

assemble the lower covers.

Insert and tighten the left and right lower cover fix-
ing screws.

Assemble the passenger footrests

Insert and tighten the footrest fixing screws.

Insert the non-slip rubber strips on the footrest.

Assemble the side fairings
Assemble the battery compartment cover and the
battery.
Assemble the leg shield back plate.

Helmet bay

Rest the vehicle on its centre stand.

Lift the saddle and remove the helmet compart-
ment by lifting it up.

CHAS - 354
Vespa sei giorni 300 hpe Chassis

Fuel tank

REMOVAL
Support the vehicle adequately.
insert a suitable lifting device beneath the body.
Remove the helmet compartment.
Remove the side fairings.
remove the silencer.

Secure the rear of the vehicle with a suitable hoist.

Remove the plastic cover above the luggage rack.

Remove the rear light assembly and the right rear
turn signal device.

Disconnect the rear shock absorbers' lower at-

tachments.

Using the hoist, lift the vehicle to increase the space between the body and the engine.
CAUTION
MAKE SURE THAT THE ELECTRIC CABLES AND PIPES ARE NOT SUBJECTED TO EXCESSIVE
TENSION WHEN USING THE HOIST.

CHAS - 355
Chassis Vespa sei giorni 300 hpe

Undo and remove the fixing screw of the fuel de-

livery hose to the injector

Disconnect the fuel pipe fitting.

Unscrew and remove the fuel pipe clamp fastening

nut.

Remove the clamp and disconnect the pipe at the

mouth of the tank.

CHAS - 356
Vespa sei giorni 300 hpe Chassis

Unscrew and remove the tank's front fastening

screw.

Unscrew and remove the rear fastening screw un-

derneath the rear light assembly's chrome-plated
frame.

Support the tank.

unscrew and remove the tank fastening screw
near the right rear shock absorber's attachment.
remove the tank by disconnecting the connectors
for the fuel pump and the fuel level indicator.

FITTING
Connect the connectors for the fuel pump and the
fuel level indicator, and insert the tank into its lodg-
ing.
Insert and tighten the tank fastening screw near
the right rear shock absorber's attachment.

CHAS - 357
Chassis Vespa sei giorni 300 hpe

Insert and tighten the tank's rear fastening screw

near the rear light assembly's lodging.

Insert and tighten the tank's front fastening screw.

Position the fuel pipe clamp.

Insert and tighten the fixing nut

Connect the fuel pipe fitting.

CHAS - 358
Vespa sei giorni 300 hpe Chassis

Insert and tighten the clamp fixing screw of the fuel

delivery hose to the injector

Using the hoist, lower the vehicle's body so that

the rear shock absorbers' attachments are
aligned.
Connect the rear shock absorbers.

Lower the vehicle using the hoist.

Remove the lifting device from underneath the body.
fit the silencer.
Mount the rear light assembly and the right rear turn signal device.
connect the pipe at the mouth of the fuel tank and secure it with a new metallic clamp.
Mount the plastic cover on the luggage rack
Mount the side fairings.
Insert the helmet compartment.

Front mudguard

REMOVING THE FRONT MUDGUARD

Remove the windscreen.
Remove the front centre cover.
Remove the rear handlebar cover.
Remove the light assembly.
Remove the front wheel.
Remove the front shock absorber.
Remove the steering tube
Unscrew the front splash guard fastening screw.

CHAS - 359
Chassis Vespa sei giorni 300 hpe

Unscrew the front splash guard fastening screws.

Remove the front splash guard

Unscrew the central headlamp cover fastening

screws.

Unscrew the front headlamp cover fastening bolts.

CHAS - 360
Vespa sei giorni 300 hpe Chassis

Unscrew the rear headlamp cover fastening

screw.

Remove the headlamp cover.

Unscrew the front headlamp support bracket fas-

tening nut and remove it.

Unscrew the front headlamp support bracket re-

taining bracket fastening nut and remove it.

CHAS - 361
Chassis Vespa sei giorni 300 hpe

Unscrew the bolts that fasten the front mudguard

to the steering tube.

Slide the front mudguard off the steering tube.

Unscrew the screw used to fasten the support

bracket to the suspension flange.

Remove the complete headlight support bracket.

CHAS - 362
Vespa sei giorni 300 hpe Chassis

Unscrew the retaining bracket fastening screws

and remove it.

Unscrew the screws used to fasten the flange sus-

pension to the support bracket.

Undo the screws used to fasten the support brack-

et to the steering tube.

ASSEMBLING THE FRONT MUDGUARD

Insert the screws used to fasten the support brack-
et to the steering tube, without tightening them.

CHAS - 363
Chassis Vespa sei giorni 300 hpe

Tighten the screws used to fasten the retaining

bracket to the flange.

Fasten the complete flange to the headlight sup-

port bracket.

Tighten the screw used to fasten the bracket to the

headlight support.

Apply the final tightening torque to the screws used

to fasten the support bracket to the steering tube.

CHAS - 364
Vespa sei giorni 300 hpe Chassis

Insert the front mudguard in its housing.

Insert and tighten the bolts used to fasten the mud-

guard to the headlight support bracket.

Tighten the nut used to fasten the headlamp re-

taining bracket to the cover.

Insert the headlamp support bracket in its housing

and tighten the nut used to fasten it to the retaining
bracket.

CHAS - 365
Chassis Vespa sei giorni 300 hpe

Insert the headlamp cover in its housing and tight-

en the rear fastening screw.

Tighten the front headlamp cover fastening bolts.

Tighten the central headlamp cover fastening

screws.

Insert the front splash guard in its housing.

CHAS - 366
Vespa sei giorni 300 hpe Chassis

Insert the screws used to fasten the front splash

guard to the headlight support bracket.

Tighten the front splash guard central fastening

screw.
Refit the steering tube
Refit the front shock absorber.
Fit the front wheel.
Refit the light assembly.
Refit the rear handlebar cover.
Refit the front centre cover.
Refit the windscreen.

Radiator fan

REMOVAL
- In order to carry out any operation on the radiator
unit, flow out the coolant in the coolant delivery
pipe in the pump.

Remove the leg shield back plate.

Remove the cooling hoses plastic retaining
clamps.

CHAS - 367
Chassis Vespa sei giorni 300 hpe

Unscrew and remove the nuts and screw fastening

the right radiator.

Disconnect the electric fan connector.

Unscrew and remove the electric fan fixing screws

to the left radiator.

Remove the electric fan.

CHAS - 368
Vespa sei giorni 300 hpe Chassis

Remove the hose from its seat.

Unscrew and remove the nuts and screw fastening
the left radiator.
Remove the clamps of the connection hoses to the
right and left radiators.
Remove the radiators.

FITTING
Position the radiators in their seats.
Insert the fluid inlet and outlet hoses to the radia-
tors.
Fasten the connection hoses to the right and left
radiators with new clamps.
Insert the hose in its seat.

Position the electric fan in its housing on the left

radiator.

Connect the electric fan connector.

CHAS - 369
Chassis Vespa sei giorni 300 hpe

Insert and tighten the electric fan fixing screws to

the left radiator.

Insert and tighten the nuts and screw fastening the

right radiator.

Insert the new cooling hoses plastic retaining

clamps.
Reassemble the leg shield back plate.

Fasten the fluid inlet hose to the pump.

Fill the system.

CHAS - 370
Vespa sei giorni 300 hpe Chassis

Front central cover

REMOVAL
Rest the vehicle on its centre stand.
Using a flat-head screwdriver, remove the clip-on
badge.

Unscrew the screw fixing the central cover to the

frame.

Slide the central cover upwards to disengage the

latches and remove it.

FITTING
Place the central cover in its seat.
Make sure to engage the latches correctly, push-
ing the cover downwards

CHAS - 371
Chassis Vespa sei giorni 300 hpe

Tighten the screw fixing the central cover to the

chassis at the specified torque.
Put back the clip-on badge.

Flyscreen

REMOVING THE WINDSHIELD:

Unscrew the screws used to fasten the windshield
to its support on both sides. Remove the chrome-
plated washer.

Remove the windscreen.

Remove the rubber support, complete with bush-

ing, from both sides.

CHAS - 372
Vespa sei giorni 300 hpe Chassis

ASSEMBLING THE WINDSHIELD:

Pre-assemble the windshield with the fastening
bushings and position it on the support brackets.

Tighten the screws used to fasten the windshield

to the brackets, applying the pre-defined tighten-
ing torque.

Battery

REMOVAL
Rest the vehicle on its centre stand.
Remove the chassis central cover.
Unscrew the fixing screws of the battery bracket.

Remove the battery bracket.

CHAS - 373
Chassis Vespa sei giorni 300 hpe

Unscrew the fixing screw of the negative pole «-»

and disconnect it.

Unscrew the fixing screw of the positive pole «+»

and disconnect it.
CAUTION

IT IS EXTREMELY IMPORTANT TO OBSERVE THE INDI-

CATED DISCONNECTION SEQUENCE OF THE CABLES
TO AVOID SHORT-CIRCUITS.

Remove the battery from its housing.

FITTING
Check the state of the battery charge.
Follow the instructions in this manual.
Insert the new battery in its seat as shown in the
figure.

CHAS - 374
Vespa sei giorni 300 hpe Chassis

Screw in the fixing screw of the positive pole «+»

to the battery.

Screw in the fixing screw of the negative pole «-»

to the battery.
CAUTION

IT IS IMPORTANT TO OBSERVE THE INDICATED CON-

NECTION SEQUENCE OF THE CABLES TO THE BATTERY
TO AVOID SHORT-CIRCUITS. FIRST CONNECT THE POS-
ITIVE CABLE «+» AND THEN THE NEGATIVE CABLE«-».
CAUTION

DO NOT REVERSE THE POLARITY: RISK OF SHORT CIR-

CUIT AND DAMAGE TO THE ELECTRICAL SYSTEM.
WARNING

USED BATTERIES ARE HARMFUL TO THE ENVIRON-

MENT. COLLECTION AND DISPOSAL SHOULD BE CAR-
RIED OUT IN COMPLIANCE WITH REGULATIONS IN
FORCE.

Put back the battery bracket and tighten the fixing

screws to the specified torque.
Put back the chassis central cover.

CHAS - 375
A
ABS: 278
Air filter: 55

B
Battery: 96, 97, 373
Brake: 293, 296, 299, 302, 304, 306, 310, 315
Brake fluid: 310
Bulbs:

C
Checks: 88

E
Engine oil: 56

F
Fuel: 204, 216, 355
Fuses: 94

H
Headlight: 68, 344
Hub oil: 54

I
Identification: 16
Instrument panel: 87, 340

M
Maintenance: 15, 49
Mirrors: 337

O
Oil filter: 59

R
Recommended products: 50

S
Shock absorbers: 270
Spark plug: 53
Stand: 276
Suspension: 77, 78
T
Tank: 355
Technical Data: 15
Transmission: 76, 127, 146

V
Vehicle: 12, 16, 17, 117, 119