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SERVICE STATION MANUAL

ETX - STX 150

This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of need
or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which
will be prepared to provide any information on the subject and any further communications on updates
and technical changes related to the vehicle.

NOTE

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

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Summary of Contents for ETX 150

Page 1: ...SERVICE STATION MANUAL 2Q000061 ETX STX 150 ...

Page 2: ...are parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication beforehand ...

Page 3: ...nd changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and ...

Page 4: ......

Page 5: ... TOPICS CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS BODYWORK BODYW ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...EL VA POURS AVOIDING ANY CONTACT WITH NAKED FLAMES SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait unt...

Page 8: ...ETTES OR ANY OTHER HEAT SOURCES ENSURE ADE QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR IT OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT TERY TO BE ACTIVATED Maintenance rules GENERAL PRECAUTIONS AND INFORMATION During repair removal and refitting of...

Page 9: ...ased grease on the oil seal rims Reassemble oil seals and bearings with the brand or batch number facing outward visible side ELECTRICAL CONNECTORS The electrical connectors are disconnected as follows the non compliance with this procedure leads to irretrievable damages to the connector and to the wiring If available press the specific safety couplings Hold the two connectors and deactivate them ...

Page 10: ...ON These numbers are necessary for vehicle registration NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW IN PAR TICULAR MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY This number consists of numbers and letters as in the example shown below LBM 10 XXXXXX KEY LBM production plant vehicle type and variant 1 brand 1 Aprilia 2 Derbi 0 design number check digit year of...

Page 11: ...95 Rapporto di compressione 9 2 0 4 1 N giri del motore al regime minimo 1400 100 rpm giri min N giri del motore al regime massimo 11000 100 rpm giri min Carburatore KEIHIN PTG 22 mm con starter manuale Frizione Multidisco in bagno d olio con comando meccanico sul lato sin istro del manubrio Electric Electric starter Air filter Sponge Transmission RAPPORTI DI TRASMISSIONE Specification Desc Quanti...

Page 12: ...V 5W Luce posizione posteriore stop LED Luce indicatori di direzione LED Luce targa 12V 5W Frame and suspensions TELAIO Specification Desc Quantity Telaio Monotrave Angolo inclinazione sterzo STX 150 27 le misure fanno riferimento al telaio nudo SOSPENSIONI Specification Desc Quantity Forcella anteriore ETX 150 Forcella idraulica a steli rovesciati diam 35 mm 1 38 in Forcella anteriore STX 150 For...

Page 13: ...90 90 17 49S Pressione gonfiaggio anteriore ETX 150 2 25 bar 225 kPa 32 63 PSI Pressione gonfiaggio anteriore STX 150 2 50 bar 250 kPa 36 26 PSI Pneumatico posteriore ETX 150 3 50 17 54P Pneumatico posteriore STX 150 110 80 17 57S Pressione gonfiaggio posteriore ETX 150 2 25 bar 225 kPa 32 63 PSI Pressione gonfiaggio posteriore STX 150 2 50 bar 250 kPa 36 26 PSI Supply ALIMENTAZIONE Specification ...

Page 14: ...Front side FRONT WHEEL pos Description Type Quantity Torque Notes 1 Front wheel fixing nut M12x1 25 1 60 5 Nm 44 25 3 69 lb ft STX 150 Characteristics ETX STX 150 CHAR 14 ...

Page 15: ...r fixing screws M8x30 2 18 25 Nm 13 28 18 44 lbf ft 2 Handlebar half lower fixing screws M6x20 2 7 10 Nm 5 16 7 38 lbf ft Central part EXHAUST pos Description Type Quantity Torque Notes 1 Drainage retainer screws M8x30 2 18 25 Nm 13 28 18 44 lbf ft ETX STX 150 Characteristics CHAR 15 ...

Page 16: ...FOOTRESTS pos Description Type Quantity Torque Notes 1 Screws fastening passenger foot pegs M10x55 2 35 40 Nm 25 81 29 50 lbf ft Back side Characteristics ETX STX 150 CHAR 16 ...

Page 17: ...10x40 2 30 40 Nm 22 13 29 50 lb ft Engine HEAD CYLINDER UNIT pos Description Type Quantity Torque Notes 1 Valve cover fixing screws M6x18 4 25 5 Nm 18 44 3 69 lb ft 2 Timing system gear cover fixing screws M6x20 2 10 2 Nm 7 38 1 47 lb ft 2 Head fixing nuts M8 4 30 2 Nm 22 13 1 47 lb ft 4 Head fixing screw M6x110 4 10 2 Nm 7 38 1 47 lb ft ETX STX 150 Characteristics CHAR 17 ...

Page 18: ...ntity Torque Notes 1 Timing system gear fixing screws M6x10 2 10 2 Nm 7 38 1 47 lb ft STARTER MOTOR pos Description Type Quantity Torque Notes 1 Starter motor fixing screws M6x28 2 10 2 Nm 7 38 1 47 lb ft Characteristics ETX STX 150 CHAR 18 ...

Page 19: ...se fixing screws M6 4 10 2 Nm 7 38 1 47 lb ft 4 Freewheel crankcase fixing screws M6x50 2 10 2 Nm 7 38 1 47 lb ft 5 Freewheel crankcase fixing screws M6x20 3 10 2 Nm 7 38 1 47 lb ft 6 Pinion crankcase fixing screw M6 1 10 2 Nm 7 38 1 47 lb ft 7 Pinion crankcase fixing screw M6x30 1 10 2 Nm 7 38 1 47 lb ft 8 Flywheel crankcase fixing screw M6x25 1 10 2 Nm 7 38 1 47 lb ft ETX STX 150 Characteristics...

Page 20: ...pe Quantity Torque Notes 1 Clutch spring plate fixing screws M6x22 5 10 2 Nm 7 38 1 47 lb ft OIL PUMP pos Description Type Quantity Torque Notes 1 Oil pump gear fixing nut M6 1 10 2 Nm 7 38 1 47 lb ft Characteristics ETX STX 150 CHAR 20 ...

Page 21: ...ing ring nut 1 45 5 Nm 33 19 3 69 lb ft 3 Oil filter cover fixing screws M5x12 3 3 5 Nm 2 21 3 69 lbf ft GEAR SELECTOR pos Description Type Quantity Torque Notes 1 Desmodromic shaft fixing screw M6 1 10 2 Nm 7 38 1 47 lb ft ETX STX 150 Characteristics CHAR 21 ...

Page 22: ...ucts chart TABELLA PRODOTTI CONSIGLIATI Product Description Specifications eni i Base 15W 40 Olio motore Utilizzare oli di marca con prestazioni conformi o superiori alle specifiche ACEA A3 B4 04 API Service SL CF MB 229 1 VW 501 01 505 00 AGIP FORK 10W Olio forcella SAE 10W AGIP BRAKE 4 Brake fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 synthetic fluid AGIP GREASE SM2 Lithium gre...

Page 23: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 24: ...SPECIAL TOOLS Stores code Description 020287Y tool for sealing ring fitting 020382Y Valve cotters removal tool 020970Y Flywheel retainer 020971Y Flywheel extractor Special tools ETX STX 150 S TOOLS 24 ...

Page 25: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 26: ...DJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE G CLOSE B RECHARGE 1 Lubricate every 500 km 310 68 mi 2 Check every 3 000 km 3 728 23 mi Replace every 12 000 km 7 456 45 mi 3 Check every 6 000 km 3 728 23 mi Replace every 20 000 km 12 427 42 mi 4 Grease every 2 years or 20 000 Km 12 427 42 mi 5 Charge the battery once a month if the vehicle is unused ROUTINE MAINTENA...

Page 27: ...s stand Insert a Phillips screwdriver in the slot and actuate on the set screw placed in the carburettor TURN IT CLOCKWISE to increase revs TURN IT ANTICLOCKWISE to reduce revs Accelerate and decelerate some times with the throttle grip to check its correct functioning and that the idle speed is stable NOTE TAKE THE VEHICLE TO AN official aprilia Dealer IF RE QUIRED Depression carburettor Disassem...

Page 28: ...g Remove the spark plug regularly clean off carbon scales and replace spark plug if necessary For removal and cleaning Make sure that the ignition switch is set to OFF Remove the tube 1 from the spark plug Clean off any trace of dirt from the spark plug base Using the special box spanner 2 in the tools pouch unlock the spark plug Unscrew and completely remove the spark plug 3 from its seat making ...

Page 29: ... 0 7 0 05 mm 0 028 0 0020 in adjust it if required by carefully bending the earth electrode Make sure the washer is in good con ditions Once the washer is fitted fin ger screw the spark plug to avoid damaging the thread Tighten using the spanner supplied in the tool kit make the spark plug com plete 1 2 a turn to press the washer CAUTION TIGHTEN THE SPARK PLUG CORRECTLY OTHERWISE THE ENGINE MAY OV...

Page 30: ...to oblò d ispezione posizionato sul lato destro veicolo il livello olio MAX livello massimo MIN livello minimo La differenza tra MAX e MIN è di circa 400 cc 24 4 cu in Il livello è corretto se raggiunge approssimativamente il livello MAX Controllare periodicamente il livello olio motore CAUTION NEVER ALLOW THE OIL LEVEL TO DROP BELOW THE MINIMUM LEVEL OR FILL ABOVE THE MAXIMUM LEVEL IF YOU DO NOT ...

Page 31: ...in out com pletely Replace the sealing washer of the drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Screw and tighten the drainage plug 2 Replace the oil filter Fill up to the right engine oil level by adding recommended engine oil Fuel filter Remove the fuel tank Remove the left side fairing Remove the petrol filter 1 Disconnect the pipes 2 Unscrew the cover 3 of th...

Page 32: ...er housing removal Loosen the clamp 1 locking the filter box 2 to the carburettor 3 Disconnect the blow by pipes 4 from the filter box Disconnect the breather pipe 5 Remove the filter box laterally Maintenance ETX STX 150 MAIN 32 ...

Page 33: ...em is very noisy check the clear ance between the valves and the rocking levers The following operation can be carried out also with the engine fitted on the vehicle VALVE CLEARANCE CHECK Remove the screws 1 of both valve covers 2 CAUTION EACH TIME THE COVERS OF THE CYLINDER HEAD VALVE ARE REMOVED THE GASKETS 3 MUST BE CHECKED AND IF NECESSARY REPLACED ETX STX 150 Maintenance MAIN 33 ...

Page 34: ... spark plug 4 Remove the inspection cover 5 Turn the crankshaft until in the inspec tion cover the reference notch 6 is visible corresponding to the upper dead centre of the piston Maintenance ETX STX 150 MAIN 34 ...

Page 35: ...CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED THE TAPPETS WILL BE NOISY OTHERWISE THE VALVES DO NOT CLOSE CORRECTLY WHICH CAN LEAD TO PROB LEMS SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURN OUT ETC Braking system Level check Frequently check the brake fluid tank level through the inspection points on the right side of the handlebar corresponding to the sight glass in the model ETX or the refe...

Page 36: ...EXPOSURE OF THE BRAKE FLUID TO THE AIR THE BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IS IN CONTACT WITH THE AIR LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE REFILL PROCEDURE TO AVOID BRAKE FLUID SPILLING OUT DURING THE PROCEDURE MAINTAIN THE FLUID IN THE TANK PARALLEL TO THE EDGES OF THE TANK HORIZONTAL DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLU...

Page 37: ... PASTIGLIE FRENO CONTROLLARE L EFFICIENZA FRENANTE NEL CASO IN CUI LA CORSA LIBERA DELLA LEVA FRE NO SIA TROPPO LUNGA O IN CASO DI PERDITE PO TREBBE ESSERE NECESSARIO SPURGARE ARIA DAL SISTEMA IN TAL CASO RIVOLGERSI AD UN Concessionario Uffi ciale Aprilia Clutch system Adjusting the lever Adjust the clutch if the motor stops or if the vehicle moves forward with the clutch activated and the gear in...

Page 38: ...Loosen the nut 4 Turn the adjuster 5 until the clearance at the extreme end of the clutch lever is between 10 20 mm 0 39 0 79 in Tighten the nut 4 until the adjuster is locked in place 5 Check the clearance at the extremity of the clutch lever Start the engine Completely activate the clutch and in sert first gear Make sure that the engine does not stop and that the vehicle does not move forward an...

Page 39: ... orizzontale del proiettore circa 9 10 dell altezza totale Per effettuare la regolazione verticale del fas cio luminoso Posizionare il veicolo sul cavalletto centrale Operando dal lato posteriore sinistro del cupolino agire con un cacciavite a croce sull apposita vite AVVITANDO senso orario il fascio luminoso si al za SVITANDO senso antiorario il fascio luminoso si abbassa Con questa vite si regol...

Page 40: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 41: ...tery engine ground cable 1 Right handlebar control 1 Left handlebar control 1 Horn 1 Ignition switch 1 Instrument panel 1 Lights control unit 1 CDI 1 Diode 1 Headlamp 1 Taillight 1 Right front turn indicator 1 Left front turn indicator 1 Rear right turn indicator 1 Rear left turn indicator 1 Front stop switch 1 Clutch switch 1 Rear stop switch 1 Voltage regulator 1 Start up relay 1 Fuel level sens...

Page 42: ...onnected and correctly tightened to ensure proper engine and therefore proper vehicle operation CHASSIS Instrument panel connector Start up relay connector Speed sensor connector Lights control unit connector Front headlamp connector Taillight connector Fuel level sensor connector Alternator connector Regulator connector Starter motor eyelet Right handlebar control connector Left handlebar control...

Page 43: ...cable har ness in the various areas are followed meticulously in order to guarantee functionality and reliability Front side TABLE A FRONT HEADLIGHT ASSEMBLY 1 Front lights cable harness connector 2 Front light cable harness 3 Front main cable harness 4 Left front turn indicator connectors 5 Right front turn indicator connectors TABLE A1 FRONT HEADLIGHT ASSEMBLY Fix the front cable harness to the ...

Page 44: ...d sensor connector 4 Speed sensor connector TABLE C LIGHT SWITCH 1 Right light switch cable harness 2 Left light switch cable harness Use a cable grommet 3 and lock the throttle grip cable to the right light switch cable harness Use a cable grommet 4 and lock the clutch cable to the left light switch cable harness Electrical system ETX STX 150 ELE SYS 44 ...

Page 45: ...lizer connector Central part TABLE A MAIN CABLE HARNESS 1 Main cable harness 2 Fuel level sensor connector In the points with the white belt on the main cable harness lock it to the frame with two clamps 3 TABLE A1 MAIN CABLE HARNESS 1 Main cable harness In the points with the white belt on the main cable harness lock it to the frame with two clamps 3 ETX STX 150 Electrical system ELE SYS 45 ...

Page 46: ...e indicated point lock the main ca ble harness to the frame with a clamp 3 TABLE B HORN 1 Horn 2 Horn connectors 3 Horn cable harness Pass the cable harness between the frame and the support plate in the in dicated point TABLE C COIL 1 Coil 2 Connector 3 Eyelet 4 Spark plug cap Pass the spark plug cap cable harness through the cable grommet 5 Electrical system ETX STX 150 ELE SYS 46 ...

Page 47: ...elet 2 Battery positive cable harness 3 Turn indicator diode TABLE F STARTER MOTOR 1 Starter motor 2 Starter motor positive cable harness Clamp the cable harness to the frame in the indicated points TABLE G BATTERY NEGATIVE 1 Battery negative eyelet 2 Battery negative cable harness 3 Main cable harness ETX STX 150 Electrical system ELE SYS 47 ...

Page 48: ...g TABLE I ENGINE SPEED SENSOR GEAR SENSOR 1 Rpm sensor 2 Gear sensor 3 Rpm sensor cable harness 4 Gear sensor cable harness Lock the cable harness of the two sen sors with a clamp to the frame in the indicated points Back side TABLE A REAR LIGHT UNIT Pass the cable harness of the turn in dicators 1 and the licence plate light 2 through the cable grommet 3 Electrical system ETX STX 150 ELE SYS 48 ...

Page 49: ... casing un der the frame in the indicated points and lock the cable harness with a clamp 5 TABLE B REAR STOP SWITCH 1 Rear stop switch 2 Rear stop switch cable harness Fasten the cable harness to the swing arm by a clamp 3 TABLE B1 REAR STOP SWITCH 2 Rear stop switch cable harness 3 Rear stop switch connector Fix the cable harness to the frame with two clamps 4 ETX STX 150 Electrical system ELE SY...

Page 50: ...General wiring diagram Key 1 Speed sensor 2 Lights control unit 3 Right turn signal switch 4 Ignition switch Electrical system ETX STX 150 ELE SYS 50 ...

Page 51: ...egulator 18 Alternator 19 Gear sensor 20 Diode 21 Horn 22 Fuel level sensor 23 Clutch switch 24 Left turn signal switch 25 LH front indicator 26 Front position light 27 Low beam light 28 High beam light 29 RH front indicator 30 Instrument panel 31 Front stop switch Cable colours key Ar orange Az sky blue Bl blue Bi white Gi yellow Gr grey Mabrown Ne black R red Ve green ETX STX 150 Electrical syst...

Page 52: ...Vi purple VeC clear green Electrical system ETX STX 150 ELE SYS 52 ...

Page 53: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 54: ...he tank Remove the side fairings Disconnect the spark plug cap 1 Disconnect the oil vapour recovery pipe 2 from the head Disconnect the clutch cable 3 from the lever Remove the clutch cable locking plate 4 Engine from vehicle ETX STX 150 ENG VE 54 ...

Page 55: ... starter motor power sup ply cable 6 Remove the gear lever linkage 7 Remove the pinion crankcase Disconnect the connectors of the gear sensor and the engine speed sensor remove the clamp 8 and free the two cable harness ETX STX 150 Engine from vehicle ENG VE 55 ...

Page 56: ...ving from the frame Remove the two front pins 10 and re lated cradle nuts Remove the rear pin 11 and related lower nut fixing the engine to the frame Remove the rear pin 12 and related upper nut fixing the engine to the frame Engine from vehicle ETX STX 150 ENG VE 56 ...

Page 57: ... Remove the upper pin 13 and related nut fixing the engine to the frame Remove the engine ETX STX 150 Engine from vehicle ENG VE 57 ...

Page 58: ...INDEX OF TOPICS ENGINE ENG ...

Page 59: ...ES Gearbox Gearbox shafts Disassembling the gearbox After removing the closing screws of the engine crankcase place the en gine from the clutch side and remove the opposite crankcase by lifting it carefully Remove the gasket Remove the forks guide pin 1 Remove the fork 2 ETX STX 150 Engine ENG 59 ...

Page 60: ...K HIGHLIGHTED IN THE IMAGE DURING ASSEMBLY MUST FACE DOWNWARDS UNLIKE THE OTHER TWO FORKS Remove the complete gearbox Removing the primary shaft Remove the main shaft Operate on the main shaft from the out put shaft gear side 1 and remove it Engine ETX STX 150 ENG 60 ...

Page 61: ...Remove the washer 20 2x0 5x27 2 Working from the opposite side re move the washer 15 2x1x25 3 Remove the fixed gear of the second gear 4 Remove the free gear of the fifth gear 5 ETX STX 150 Engine ENG 61 ...

Page 62: ... Remove the washer 6 Remove the circlip 7 Remove the free gear of the fourth gear 8 Remove the circlip 9 Engine ETX STX 150 ENG 62 ...

Page 63: ...ear of the third gear 11 Removing the secondary shaft Remove the transmission shaft Working on the transmission shaft from the pinion side and remove the spacer washer 20x1x27 1 Remove the gear of the second gear 2 ETX STX 150 Engine ENG 63 ...

Page 64: ... Remove the gear of the fifth gear 3 Working from the opposite side re move the washer 15 2x1x30 4 Remove the starter gear 5 and the bushing 6 Remove the washer 16 5x0 5x24 7 Engine ETX STX 150 ENG 64 ...

Page 65: ... Remove the gear of the first gear 8 and the bushing 9 Remove the washer 16 5x0 5x24 10 Remove the gear of the third gear 11 Remove the circlip 12 ETX STX 150 Engine ENG 65 ...

Page 66: ...ontaggio desmodromico Working from the outside of the clutch side crankcase remove the fixing screw 1 of the gear selector drum 2 making sure to collect the washer Remove the gear selector drum 2 and the pin 3 inserted in the desmodromic Engine ETX STX 150 ENG 66 ...

Page 67: ...on gears movement and if it is not regular replace the damaged part Checking the desmodromic drum Check the wear of the grooves 1 and of the contact surfaces with the bear ings 2 In case of abnormal wear replace the desmodromic and check the bearings in the crankcase Checking the forks Check the transmission fork cam roller 1 and the gear fork tooth 2 for damage distortion and wear Replace the tra...

Page 68: ...ion forks Gear selector Removing the gear selector Drain the engine oil Remove the clutch cover Remove the complete selector shaft 1 making sure to collect the washer 2 Remove the fixing screw 3 of the complete index lever 4 Remove the complete index lever 4 Engine ETX STX 150 ENG 68 ...

Page 69: ...ex lever 4 Remove the fixing screw 6 and the relative washer 7 of the gear selector drum 8 Remove the gear selector drum 8 GEAR SELECTOR SHAFT REMOVAL Remove the upper circlip 1 locking the gear selector plate ETX STX 150 Engine ENG 69 ...

Page 70: ... Remove the spring 2 Remove the gear selector plate 3 Working from the opposite side re move the circlip 4 Remove the washer 5 Engine ETX STX 150 ENG 70 ...

Page 71: ...es freely If necessary replace the parts Check the gear selector spring for damage and wear If necessary replace the part Check the selector shaft and its teeth for damage and wear If necessary replace the part Check the lever spring for damage and wear If necessary replace the part Generatore Starter motor ETX STX 150 Engine ENG 71 ...

Page 72: ...n the frame Remove the locking nut 1 of the sup ply cable 2 Remove the two fixing screws 3 making sure to collect the rubber spacer washers 4 Remove the starter motor 5 and if necessary replace the sealing gasket 6 Removing the idle gear Remove the three fixing screws 1 of the intermediate gear cover 2 Engine ETX STX 150 ENG 72 ...

Page 73: ...p system check IF THE DUAL FREEWHEEL GEAR TOOTHING IS DEFORMED THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL Check the dual freewheel gear tooth ing 1 and the dual intermediate gear 2 to see if the material is damaged or deformed In case of deformations or non uniform consumption of the gears replace them Generator side ETX STX 150 Engine ENG 73 ...

Page 74: ...g screws M6 4 10 2 Nm 7 38 1 47 lb ft 4 Freewheel crankcase fixing screws M6x50 2 10 2 Nm 7 38 1 47 lb ft 5 Freewheel crankcase fixing screws M6x20 3 10 2 Nm 7 38 1 47 lb ft 6 Pinion crankcase fixing screw M6 1 10 2 Nm 7 38 1 47 lb ft 7 Pinion crankcase fixing screw M6x30 1 10 2 Nm 7 38 1 47 lb ft 8 Flywheel crankcase fixing screw M6x25 1 10 2 Nm 7 38 1 47 lb ft Remove the two fixing screws 1 of t...

Page 75: ...ng screw 3 of the lock ing plate of the alternator wiring Remove the starter motor the intermediate gear cover and the gear itself Remove the 8 fixing screws 4 of the alternator crankcase Remove the alternator crankcase 5 ETX STX 150 Engine ENG 75 ...

Page 76: ...Torque Notes 1 Flywheel fixing screw M10x36 1 55 5 Nm 40 57 3 69 lb ft Place the specific rotor lock tool and fit with the screws with the protrusion as indicated in the figure Specific tooling 020970Y Flywheel retainer Remove the rotor fixing screw Engine ETX STX 150 ENG 76 ...

Page 77: ...o allow the ex traction of the rotor Specific tooling 020971Y Flywheel extractor Remove the rotor Removing the stator Remove the three fixing screws 1 of the stator and the two screws 2 of the pick up Remove the cables 3 from the con nector 4 ETX STX 150 Engine ENG 77 ...

Page 78: ...rank case Remove the stator and the pick up Freewheel removal Remove the three fixing screws 1 of the freewheel to the rotor Remove the freewheel 2 from the ro tor 3 Remove the flange 4 from the free wheel 2 Engine ETX STX 150 ENG 78 ...

Page 79: ...ne ingranaggio ruota libera Remove the freewheel gear 1 by pull ing it from the crankshaft Remove the spacer 2 by pulling it from the crankshaft Clutch side Removing the clutch cover ETX STX 150 Engine ENG 79 ...

Page 80: ...rankcase fixing screws M6x50 2 10 2 Nm 7 38 1 47 lb ft 5 Freewheel crankcase fixing screws M6x20 3 10 2 Nm 7 38 1 47 lb ft 6 Pinion crankcase fixing screw M6 1 10 2 Nm 7 38 1 47 lb ft 7 Pinion crankcase fixing screw M6x30 1 10 2 Nm 7 38 1 47 lb ft 8 Flywheel crankcase fixing screw M6x25 1 10 2 Nm 7 38 1 47 lb ft Remove the clutch cable 1 from the cable guide 2 Remove the 13 fixing screws 3 of the ...

Page 81: ...pin 7 of the spring from the clutch driving shaft 6 Slide off the clutch driving shaft 6 from the clutch cover 4 Check and if necessary replace the oil seal 8 Remove the gasket 9 NOTE ALWAYS REPLACE THE GASKET EACH TIME THE CLUTCH COVER IS REMOVED ETX STX 150 Engine ENG 81 ...

Page 82: ...move the three fixing screws 1 of the oil filter cover Remove the oil filter cover 2 Remove the gasket 3 NOTE ALWAYS REPLACE THE GASKET EACH TIME THE EN GINE OIL FILTER COVER IS REMOVED Remove the cotter pin 4 Engine ETX STX 150 ENG 82 ...

Page 83: ... Using an aluminium lock place it in the indicated zone and lock the gears Remove the pin 5 and the spring 6 Remove the ring nut 7 Remove the spacer washer 8 ETX STX 150 Engine ENG 83 ...

Page 84: ... Remove the oil filter base 9 Remove the timing chain 10 between crankshaft and oil pump gear Remove the timing system gear 11 Engine ETX STX 150 ENG 84 ...

Page 85: ...s 1 Clutch spring plate fixing screws M6x22 5 10 2 Nm 7 38 1 47 lb ft Remove the engine oil filter to allow the complete removal of the clutch Remove the clutch pressure plate rod 1 and the pin 2 Remove the six fixing screws 3 of the clutch pressure plate 4 ETX STX 150 Engine ENG 85 ...

Page 86: ... Remove the bearing 5 from the clutch pressure plate 4 Remove the six springs 6 Remove the circlip 7 locking the clutch hub 8 Remove the clutch hub 8 Engine ETX STX 150 ENG 86 ...

Page 87: ... Remove the clutch plate pack 9 Remove the thrust plate 10 Remove the spacer washer 11 Remove the clutch housing 12 ETX STX 150 Engine ENG 87 ...

Page 88: ...king the clutch housing Check the clutch housing for damage and wear that may result in clutch irregular operation PRIMARY DRIVEN GEAR CHECK Check the primary driven gear for damage and wear and if necessary replace the primary driven gear and the clutch bell all together Make sure there is not excessive noise during operation if necessary replace the primary drive gear and the clutch bell all tog...

Page 89: ...r operation especially on the discs friction surface and on the sliding channels If necessary replace the hub Head and timing Removing the intake manifold Remove the carburettor Remove the two fixing screws 1 of the manifold 2 Remove the manifold 2 Removing the cylinder head ETX STX 150 Engine ENG 89 ...

Page 90: ...g screws M6x20 2 10 2 Nm 7 38 1 47 lb ft 2 Head fixing nuts M8 4 30 2 Nm 22 13 1 47 lb ft 4 Head fixing screw M6x110 4 10 2 Nm 7 38 1 47 lb ft TIMING SYSTEM pos Description Type Quantity Torque Notes 1 Timing system gear fixing screws M6x10 2 10 2 Nm 7 38 1 47 lb ft Remove the two fixing screws 1 of the timing system gear cover 2 Engine ETX STX 150 ENG 90 ...

Page 91: ...stem gear cover 2 Remove the central screw 3 of the chain tensioner making sure to collect the tensioning spring 4 Remove the two fixing screws 5 of the chain tensioner Remove the chain tensioner 6 ETX STX 150 Engine ENG 91 ...

Page 92: ...ove the two fixing screws 7 of the timing system gear Remove the timing system gear 8 Remove the screw 9 fixing the head to the cylinder Remove the four fixing bolts 10 of the head Engine ETX STX 150 ENG 92 ...

Page 93: ...collect the seal 13 Cylinder head Removing the overhead camshaft Remove the cylinder head and the rockers Warm up the corresponding cylinder head of the camshaft bearing to facili tate the removal Take out the camshaft complete with the bearing ETX STX 150 Engine ENG 93 ...

Page 94: ... of the camshaft Remove the four fixing screws 1 of the rocker valve seats covers Remove the two covers 2 of the rocker valve seats Remove the fixing screws 3 and the locking plate 4 of the rockers shafts Remove the lock shafts 5 of the rockers Engine ETX STX 150 ENG 94 ...

Page 95: ...Removing the valves Remove the head Using the appropriate tool compress the intake valve spring Specific tooling 020382Y Valve cotters removal tool Remove the cotters 1 and then the appropriate tool ETX STX 150 Engine ENG 95 ...

Page 96: ...REVIOUSLY DESCRIBED PROCEDURE ALSO FOR THE REMOVAL OF THE INTAKE VALVE Checking the overhead camshaft CAMSHAFT Characteristic Standard diameter 25 0 03 mm 0 98 0 0012 in Intake cam height 6 075 mm 0 239 in Exhaust cam height 5 704 mm 0 224 in CAMSHAFT GEAR CHECK Engine ETX STX 150 ENG 96 ...

Page 97: ...rockers is not exceedingly worn Check the rocker to valve and rocker to rod contact surfaces Inspecting the valve housings Check that the valve guide does not show any signs of wear and is within the indicated values otherwise replace the component Characteristic Intake guide standard diameter 5 485 5 475 mm 0 2159 0 2155 in Intake guide Wear limit 0 01 0 04 mm 0 00039 0 00157 in Discharge guide s...

Page 98: ...signs of abnormal wear Replace a component when worn Measure the unloaded spring length Characteristic Standard length of spring valve 44 8 39 2 mm 1 76 1 54 in Timing Removing the chain tensioner Remove the central screw 1 of the chain tensioner making sure to collect the tensioning spring 2 Engine ETX STX 150 ENG 98 ...

Page 99: ...val Remove the camshaft timing system gear cover and the gear Remove the chain tensioner Remove the alternator crankcase the complete alternator and the spacer to be able to access the safety plate for the chain Remove the fixing screw 1 of the plate Remove the plate 2 ETX STX 150 Engine ENG 99 ...

Page 100: ...ove the alternator crankcase Remove the fixing screw 1 of the chain pad paying attention to collect the washer 2 Slide off and remove the chain tension er pad 3 from the crankcase Unhook the chain guide pad 4 from the crankcase and remove it Engine ETX STX 150 ENG 100 ...

Page 101: ...hecking the chain Check the timing chain for damage or stiffness while moving If necessary replace the timing chain together with the camshaft gears Check the timing chain guide sliders for damage If necessary replace the parts Checking the sliders Check that the guide slider and the tensioner pad are not excessively worn Replace the sliders when wear is found Cam timing ETX STX 150 Engine ENG 101...

Page 102: ...d on the valves but that there is clear ance otherwise check the crankshaft installation procedure Install the timing system gear paying attention that the notches are aligned with the head level line Check that the timing chain is correctly positioned on the gear on the crank shaft Engine ETX STX 150 ENG 102 ...

Page 103: ...ator cover Remove the inspection cap on the al ternator cover and check that the ref erence notch is present which can be identified by the letter T on the rotor If there is no correspondence between the signs present on the timing system gear and the reference notch on the rotor the timing adjustment procedure must be repeated ETX STX 150 Engine ENG 103 ...

Page 104: ...sembly Removing the cylinder Remove the complete cylinder head gasket the timing chain and the sliders Remove the cylinder Remove the gasket Disassembling the piston Remove the retainer ring 1 Engine ETX STX 150 ENG 104 ...

Page 105: ...he seal surfaces for damages CAUTION IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT REPLACE THE CYLINDER AND THE PISTON Checking the piston Measure the piston skirt diameter 1 with a micrometer 2 10mm 0 39in from the piston lower border Replace the cylinder the piston and the piston ring all together if not com plying with specifications Characteristic Minimum piston diameter 61 0 05 mm 2 40 0 0...

Page 106: ...t the piston ring to the cylinder Level the installed piston ring with the piston crown Measure piston ring port and replace it if not complying with specifications CAUTION IT IS NOT POSSIBLE TO MEASURE THE OIL SCRAPER RING END LIGHT IF THERE IS AN EXCESSIVE CLEAR ANCE REPLACE THE THREE PISTON RINGS PIN Clean off combustion residues from the piston crown and from the area above the top ring Check ...

Page 107: ...ns Characteristic Pin hole diameter on piston 15 002 15 008 mm 0 5906 0 5909 in Installing the cylinder With the special tool tighten the piston rings of the piston and insert it in the cylinder sliding it downwards Specific tooling 020287Y tool for sealing ring fitting Crankcase crankshaft ETX STX 150 Engine ENG 107 ...

Page 108: ... M6x55 1 10 2 Nm 7 38 1 47 lb ft Loctite 270 Splitting the crankcase halves Remove the complete cylinder head timing system and the cylinder Remove the clutch and the timing sys tem gears Remove the alternator Remove the 11 fixing screws 1 of the alternator side crankcase Remove the screw 2 fixing the clutch side crankside Detach the crankcase Engine ETX STX 150 ENG 108 ...

Page 109: ...m the free wheel side crankcase Removing the countershaft Using an aluminium lock place it in the indicated zone and lock the gears Remove the locking ring nut 1 of the timing system gear connected to the countershaft Detach the crankcase Remove the countershaft 2 ETX STX 150 Engine ENG 109 ...

Page 110: ...l pump gear fixing nut M6 1 10 2 Nm 7 38 1 47 lb ft 2 Oil pump fixing ring nut 1 45 5 Nm 33 19 3 69 lb ft 3 Oil filter cover fixing screws M5x12 3 3 5 Nm 2 21 3 69 lbf ft Removing Remove the two fixing screws 1 of the cover plate 2 of the oil pump gear Engine ETX STX 150 ENG 110 ...

Page 111: ... Remove the cover plate 2 Remove the fixing screw 3 of the tim ing system gear Remove the timing system gear 4 Remove the two fixing screws 5 of the oil pump 6 ETX STX 150 Engine ENG 111 ...

Page 112: ... Remove the oil pump shaft 6 Remove the complete oil pump 7 Remove the fixing screw 8 of the oil pump cover Remove the oil pump cover 9 Engine ETX STX 150 ENG 112 ...

Page 113: ...ND THEREFORE NOT VISIBLE Inspection Check the rotors of the oil pump the sliding surfaces of the external rotors in both bodies and the surfaces to check for possible grooves Characteristic Internal rotor thickness 12 98 12 60 mm 0 511 0 496 in External rotor thickness 12 98 12 60 mm 0 511 0 496 in Internal rotor axial clearance 0 1 mm 0 0039 in External rotor axial clearance 0 1 mm 0 0039 in ETX ...

Page 114: ...Engine ETX STX 150 ENG 114 ...

Page 115: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 116: ...ONT WHEEL pos Description Type Quantity Torque Notes 1 Front wheel fixing nut M12x1 25 1 60 5 Nm 44 25 3 69 lb ft Operating from the left side of the mo torcycle remove the fixing nut of the front wheel Suspensions ETX STX 150 SUSP 116 ...

Page 117: ... Remove the pin from the right side of the motorcycle Remove the spacer Remove the odometer from the wheel rim Remove the wheel complete Handlebar ETX 150 ETX STX 150 Suspensions SUSP 117 ...

Page 118: ...fixing screws M8x30 2 18 25 Nm 13 28 18 44 lbf ft 2 Handlebar half lower fixing screws M6x20 2 7 10 Nm 5 16 7 38 lbf ft Removing The following described operations vary according to the identified model ETX 150 Remove the four screws 1 fixing the U bolt Suspensions ETX STX 150 SUSP 118 ...

Page 119: ...e the two fixing screws 1 of the semi handlebar to the steering yoke on the upper part Remove the two fixing screws 2 of the semi handlebar to the steering yoke on the lower part and the equivalent for the left semi handlebar ETX STX 150 Suspensions SUSP 119 ...

Page 120: ...H LEVER AND THE FRONT BRAKE PUMP MUST BE REMOVED Front fork Removing the fork legs The operations to be carried out are different according to the specific model and regarding a single stem of the described motorcycle ETX 150 Remove the lower front mudguard Remove the front wheel Loosen the two fixing screws of the stem 1 Remove the stem 2 Suspensions ETX STX 150 SUSP 120 ...

Page 121: ...ally loosen the cap 3 STX 150 Remove the front mudguard Remove the front wheel Loosen the fixing screw 1 at the upper steering plate of the stem Loosen the screw 2 at the lower steering plate fixing the stem Remove the stem 3 ETX STX 150 Suspensions SUSP 121 ...

Page 122: ...r with at least 0 5 l 0 11 UK gal 0 13 US gal volume completely undo the stem from the fork cap and drain the oil Place the foot of the fork in the vice supplied with specific protection and warm up the indicated area with a heat blower Loosen and remove the screw 4 fix ing the fork foot Suspensions ETX STX 150 SUSP 122 ...

Page 123: ... Remove the fork foot 5 Remove the stem completely 6 from the sleeve Remove the dust gaiter 7 Remove the retainer ring 8 ETX STX 150 Suspensions SUSP 123 ...

Page 124: ... Remove the oil seal 9 Remove the oil seal 9 STX 150 Using the Teflon shoes lock the stem in a vice and remove the cap 1 Remove the preload pipe 2 Suspensions ETX STX 150 SUSP 124 ...

Page 125: ... tainer with at least 0 5 l 0 11 UK gal 0 13 US gal volume and drain the oil Remove the protection 4 from the sleeve Pull off the sleeve from the stem Remove the dust gaiter 5 Remove the retainer ring 6 ETX STX 150 Suspensions SUSP 125 ...

Page 126: ... BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in good conditions Filling oil Place the sleeve in vertical position in a vice with protection shoes Press the stem in the sleeve Place a support under the sleeve to remain it pressed Pour part of the fork oil insid...

Page 127: ... the rear wheel Loosen the chain tension and remove it Remove the rear brake control rod Remove the fixing nut 1 the washer 2 and the chain tensioner pad 3 Remove the pin 4 and the chain ten sioner pad Collect the spacer 6 located between the drum brake and the swingarm ETX STX 150 Suspensions SUSP 127 ...

Page 128: ...absorbers REAR SHOCK ABSORBERS pos Description Type Quantity Torque Notes 1 Upper shock absorber fixing nut M10x1 25 2 35 45 Nm 25 81 33 19 lb ft 2 Shock absorber lower fixing screws M10x40 2 30 40 Nm 22 13 29 50 lb ft Suspensions ETX STX 150 SUSP 128 ...

Page 129: ...er fixing screw 3 of the shock absorber and the washer 4 Lift the lower part of the shock absorber and remove it from the upper pin Remove the complete shock absorber 5 NOTE TO REMOVE THE RIGHT REAR SUSPENSION CARRY OUT THE SAME PREVIOUSLY DESCRIBED OPERATIONS ETX STX 150 Suspensions SUSP 129 ...

Page 130: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 131: ...he two front brake calliper fix ing screws Remove the front brake calliper To completely remove the front brake calliper the circuit must be emptied by removing the joint fixing screw Rear brake disc ETX STX 150 Braking system BRAK SYS 131 ...

Page 132: ... Remove the rear wheel Level the safety plate tab Remove the four screws that fix the rear disc Remove the two safety plates Remove the rear brake disc Front brake disc Braking system ETX STX 150 BRAK SYS 132 ...

Page 133: ...Remove the front wheel Level the safety plate tab Remove the four screws that fix the front disc Remove the two safety plates Remove the front brake disc Front brake pads ETX STX 150 Braking system BRAK SYS 133 ...

Page 134: ...Remove the two screws fixing 2 the brake calliper and take it off Complete the removal of the pins 1 Remove the pads 3 If the friction material thickness is reduced to a value of about 1 5 mm 0 06 in replace the brake calliper pads Braking system ETX STX 150 BRAK SYS 134 ...

Page 135: ...ESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESER VOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con tainer to collect the fluid Remove the front brake fluid reservoir cap Quickly press and release the front brake ...

Page 136: ...r until the correct brake fluid level is obtained Refit and block the front brake oil reservoir cap Refit the rubber protection cover Rear drum brake Rimozione Remove the drum brake control rod Remove the complete rear wheel Extract the complete drum brake from the wheel rim Remove the nut 1 and the fixing screw 2 of the brake lever paying at tention to collect the washers Remove the brake lever 3...

Page 137: ... 4 and the gasket 5 of the pin Remove the brake linings 6 by un hooking the springs Remove the pin 7 by unhooking it from the internal part of the cover Remove the brake linings 6 by un hooking the springs ETX STX 150 Braking system BRAK SYS 137 ...

Page 138: ... it from the internal part of the cover Controllo Remove the brake linings and check that the friction material has a thickness of at least 1 5 mm 0 06 in otherwise replace the worn components Braking system ETX STX 150 BRAK SYS 138 ...

Page 139: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS ...

Page 140: ...the adjuster is locked in place 3 Check the clearance at the extremity of the clutch lever Reposition the protective casing 1 If the adjuster 3 is completely screwed in completely unscrewed and or it is not possible to obtain the correct clearance Slide the protective casing 1 out Completely screw in the nut 2 on the adjuster 3 Completely tighten the adjuster 3 Operating from the right vehicle sid...

Page 141: ...stop and that the vehicle does not move forward and that the friction does not slide during acceleration or during driving WARNING CHECK THAT THE CLUTCH LEVER CABLE IS INTACT IT SHOULD NOT BE CRACKED OR CRUSHED AND THE CASING SHOULD NOT BE WORN ANYWHERE ETX STX 150 Clutch system CLU SYS 141 ...

Page 142: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 143: ...la CAUTION BEFORE LOWERING AND LOCKING THE SADDLE CHECK THAT THE KEY HAS NOT BEEN LEFT IN THE GLOVEBOX TOOL KIT COMPARTMENT Engine guard Operating from the left side of the mo torcycle remove the two screws fixing the engine guard Operating from the right side of the mo torcycle remove the two screws fixing the engine guard ETX STX 150 Bodywork BODYW 143 ...

Page 144: ... to remove the fixing screws To remove the support bracket of the engine guard from the right side it is necessary to remove the fixing screws To remove the support bracket of the engine guard from the right side it is necessary to remove the fixing screws Driving mirrors REMOVAL Bodywork ETX STX 150 BODYW 144 ...

Page 145: ...ARE DO NOT SCRATCH OR SPOIL THEM Remove the rear view mirror 4 CAUTION REPEAT THE PROCEDURE TO REMOVE THE OTHER MIRROR AFTER REFITTING ADJUST THE REAR VIEW MIRRORS CORRECTLY AND TIGHTEN THE NUTS IN ORDER TO ENSURE STABILITY After refitting Adjust the rear view mirror angle correctly Headlight assy WINDSHIELD REMOVAL Remove the four screws 1 fixing the top fairing ETX STX 150 Bodywork BODYW 145 ...

Page 146: ...the top fairing and the dashboard DASHBOARD REMOVAL Remove the two upper fixing screws 1 of the dashboard Remove the lower fixing screw 2 of the dashboard Turn forward and lift the dashboard to take the frame off the reference fittings in the lower steering yoke Bodywork ETX STX 150 BODYW 146 ...

Page 147: ...sembly wiring Remove the two screws 6 fixing the front light assembly to the frame Disconnect the low high beam light connectors 7 the speedometer con nector 8 the turn indicator connec tors 9 the instrument panel connec tor 10 Remove the front light assembly and the frame with the instrument panel REMOVING THE INSTRUMENT PANEL ETX STX 150 Bodywork BODYW 147 ...

Page 148: ...frame paying attention to collect the washers 2 Remove the bushings 3 and rubber 4 To remove the instrument panel sup port 5 from the frame remove the two fixing screws 6 LEGSHIELD REMOVAL Remove the four fixing screws 1 of the legshield Bodywork ETX STX 150 BODYW 148 ...

Page 149: ...hield Remove the front shield Remove the four screws 3 to divide the central part from the lateral parts of the legshield HEADLIGHT ASSEMBLY BULB REPLACEMENT DAYLIGHT RUNNING LIGHT Remove the bulb holder 1 of the day light running light ETX STX 150 Bodywork BODYW 149 ...

Page 150: ...om the bulb holder 1 and replace it with one of the same type LOW BEAM LIGHT Remove the rubber protection cover 1 Disconnect the connector 2 Turn the bulb holder 3 anticlockwise and remove it Bodywork ETX STX 150 BODYW 150 ...

Page 151: ... Remove the bulb 4 HIGH BEAM LIGHT Remove the rubber protection cover 1 Disconnect the connector 2 Turn the bulb holder 3 anticlockwise and remove it ETX STX 150 Bodywork BODYW 151 ...

Page 152: ... Remove the bulb 4 Horn REMOVAL Disconnect the connectors 1 Remove the fixing nut 2 Remove the horn 3 Bodywork ETX STX 150 BODYW 152 ...

Page 153: ...t 1 the Seeger ring 2 and the washer 3 Remove the turn indicator and the wir ing NOTE CARRY OUT THE SAME REMOVAL OPERATION FOR THE TURN INDICATOR ON THE OPPOSITE SIDE REAR TURN INDICATORS REMOVAL Remove the complete license plate holder Remove the nut 1 the Seeger ring 2 the washer 3 and remove the turn indicator NOTE CARRY OUT THE SAME REMOVAL OPERATION FOR THE TURN INDICATOR ON THE OPPOSITE SIDE...

Page 154: ...REMOVAL Remove the tail fairing and unhook the hood of the saddle opening cable 1 from the plate 2 Turn the cable 3 and unhook it from the lock block 4 Remove the fork spring 5 Remove the plate 2 from the lock block Bodywork ETX STX 150 BODYW 154 ...

Page 155: ...t the washer 5 LOCK ON FRAME REMOVAL Remove the two fixing screws 1 of the lock supporting plate 2 Remove the lock supporting plate 2 Remove the two screws 3 fixing the lock supporting plate 2 to the lock 4 ETX STX 150 Bodywork BODYW 155 ...

Page 156: ...ing plate 2 Protezione staffa pedane FOOTREST BRACKET PROTECTION REMOV AL Remove the passenger footrest Remove the fixing screw 1 Remove the footrest bracket protection 2 Side body panels Remove the Allen screw 1 Bodywork ETX STX 150 BODYW 156 ...

Page 157: ...nse plate holder PLATE HOLDER REMOVAL Remove the clamp 1 fixing the con nectors of the rear light unit taillight turn indicators licence plate light and free the wiring Remove the three fixing screws 2 of the license plate holder support frame 3 Remove the two fixing screws 4 of the licence plate holder 5 ETX STX 150 Bodywork BODYW 157 ...

Page 158: ...ht connector 8 Remove the license plate holder com plete with the licence plate support Remove the two fixing screws 9 of the licence plate bracket Remove the licence plate bracket and take off the licence plate holder 5 from the licence plate holder support frame 3 Bodywork ETX STX 150 BODYW 158 ...

Page 159: ...four fixing screws 1 of the license plate light support 2 Remove the license plate light support 2 Remove the screw 3 of the external bulb holder fixing the licence plate light support Remove the external bulb holder 4 ETX STX 150 Bodywork BODYW 159 ...

Page 160: ...lb holder 4 Remove the bulb 6 from the bulb sup port 5 and replace it with one of the same type Remove the two screws 7 of the bulb support 5 to remove it Remove the transparent Plexiglas 8 from the bulb support cover 9 Bodywork ETX STX 150 BODYW 160 ...

Page 161: ... saddle Remove the side fairings Remove the two screws 1 fixing the tank to the frame Remove the spacer rubber rings 2 Disconnect the carburettor pipe 3 from the cock Disconnect the fuel pump connector 4 ETX STX 150 Bodywork BODYW 161 ...

Page 162: ... 6 paying atten tion not to damage the breather pipe from the left side of the motorcycle TANK FAIRING REMOVAL Remove the two screws 1 fixing the bracket 2 to the tank and to the side fairing Remove the bracket 2 and the side fairing completely Bodywork ETX STX 150 BODYW 162 ...

Page 163: ...EMOVAL Operating from the right side of the mo torcycle remove the screw fixing the wheelhouse to the frame Remove the wheelhouse by sliding it backwards Front mudguard FRONT MUDGUARD REMOVAL ETX Operating from the bottom remove the four screws fixing the front mudguard to the lower steering plate ETX STX 150 Bodywork BODYW 163 ...

Page 164: ...eft side of the mo torcycle remove the three screws 1 CARRY OUT THE REMOVAL OF THE SCREWS ALSO FROM THE OPPOSITE SIDE OF THE MO TORCYCLE Remove the lower mudguard STX Operating from the left side of the mo torcycle remove the two front screws 1 Bodywork ETX STX 150 BODYW 164 ...

Page 165: ...ANDLES REMOVAL Operating from the left side of the motorcycle remove the two screws 1 fixing the grab handle 2 Remove the T bushings 3 and spacers 4 Battery BATTERY REMOVAL Make sure that the ignition switch is set to OFF Remove the right hand side fairing Unhook the fixing rings of the lock belt 1 of the battery 2 from the frame ETX STX 150 Bodywork BODYW 165 ...

Page 166: ...he screw 6 of the negative terminal Hold the battery firmly and remove it from its seat Put the battery away on a level surface in a cool and dry place PAY MAXIMUM ATTENTION AND PREVENT ALL CON TACT BETWEEN THE BATTERY POLES AND ANY METAL OBJECT TO PREVENT THE RISK OF SHORT CIRCUITS Tail guard TAIL FAIRING REMOVAL Remove the rear grab handles Remove the fixing screws 1 of the rear light assembly c...

Page 167: ...e the four lower screws 4 fix ing the tail fairing to the wheelhouse Remove the licence plate holder by disconnecting the turn indicator con nectors licence plate light and the rear light assembly Disconnect the cable of the lock for saddle opening ETX STX 150 Bodywork BODYW 167 ...

Page 168: ...embly Remove the two screws 5 fixing the rear light assembly to the tail fairing Remove the rear light assembly from the tail fairing Remove the central fixing screw that connects the two parts of the tail fairing and remove it Bodywork ETX STX 150 BODYW 168 ...

Page 169: ...ioner 98 101 Clutch 37 79 85 88 89 140 Countershaft 109 Crankcase 107 108 Crankshaft 107 109 Cylinder 89 93 104 105 107 D Desmodromic drum 67 Drive chain 12 E Electrical system 12 41 Engine oil 29 Exhaust F Fork 120 122 Forks 67 Front wheel 116 Fuel 31 161 H Handlebar 117 Headlight 38 145 Horn 152 I Identification 10 L License plate holder 157 ...

Page 170: ...ors 144 Mudguard 163 P Primary shaft 60 R Rear wheel 127 Recommended products 22 S Secondary shaft 63 Shock absorbers 128 Spark plug 28 Start up 73 Starter motor 71 72 T Tank 161 Transmission 11 Turn indicators 153 Tyres 13 W Wiring diagram 50 ...

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