GT / GTS Headset Cover Removal
This article shows the steps necessary to remove the headset cover
on a GT or GTS.

Tools Required
Allen wrench, 2.5mm
Open-ended wrench, 17mm (or adjustable crescent wrench)
Screwdriver, Philips & Flathead

Step 1:
Remove Reservoir Covers
Using the 2.5mm allen (aka hex) wrench,
remove the screws to the brake fluid reservoir covers.

Step 2:
Remove Mirrors
Slide the reservoir covers up the mirror stem and
hold them out of the way. Using the 17mm wrench
(or adjustable crescent wrench, shown) loosen the mirrors.

Step 4:
Spin the mirrors out of their sockets and set them aside.

Step 5:
Remove Horn Cover
Using a flat screwdriver and a soft cloth,
insert the screwdriver into the slot on the side of the Piaggio badge
and gently push the handle of the screwdriver toward the legshield.
Do not twist the screwdriver.

Step 6:
Unscrew the Philips-head screw that's behind the Piaggio badge.

 

Step 7:
Remove Headset Cover Screws
Remove the small screws (one each side) from below
the outer edge of the headset, just below the brake levers
on either side of the headset.

Step 8:
Remove the single screw from just below the headlight. Note that there are two screws here, but we are only interested in one of them. The lower screw holds the front of the headset cover in place, and should be black. The upper screw (which adjusts the headlight and should not be removed) is brass colored and is angled slightly. Warning: Do not drop this screw, or it will fall down between the glove box and the legshield and then probably down below the floorboards. In other words, you'll never see the screw again.

Step 9:
Remove Front of Headset Cover
Grasp the front of the headset cover from below and carefully lift upwards to disconnect the internal tabs that hold the two halves of the headset together. You should see the top edge between the two halves separate from each other. Carefully move the front headset cover toward you, being careful not to snag the tabs on the brake reservoirs or anything else in the headset. This operation will require some careful flexing of the headset cover in order to clear all the various parts.

Step10:
Disconnect the headlight connector from the back of the headlight.

Disconnect the pilot light connector.

Step 11:
Unscrew the 4 screws that hold the headlight on.
And take the headlight unit out.

 

Step 12:
Tape visor on headlight unit.
It helps hold it in place while reinstalling the headlight
back in the headset all at the same time.

Note: tape does not hold the visor in place,
it is just much easier to fit back together this way.
It is press fit in, so it will not come off at any speed to ride.

Step 13:
Reassemble and enjoy

Thanks to Jess at ModernVespa for the pictures and info