VESPA 150 Service Station Manual Download

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- Check the continuity of the cable harness between the control unit connector and valve connector:

Control unit PIN 17 - valve PIN 1 and control unit PIN 9 - valve PIN 1. If there is no continuity, restore

the cable harness.

Short circuit to negative:

- Disconnect the control unit connector and the valve connector.

- Check the valve connector PIN 1 ground insulation (corresponding to control unit connector PIN 17).

If there is no insulation, restore the cable harness.

- With the valve connector disconnected and the control unit connector connected, turn ignition switch

to ON and activate the component using the diagnosis tool.

- Check the voltage (for 10 seconds) at the ends of the valve connector.

- If there is no voltage, check the continuity of the cable harness between control unit PIN 9 and valve

PIN 2 and restore it if necessary.

- If the above tests provided a positive result, the valve should be replaced.

High idling adjustment device voltage P0509

- shorted to positive.

Error cause

Short circuit to positive: excessive voltage to PIN 17 of the control unit connector.

Troubleshooting

Short circuit to positive:

- Disconnect the control unit connector and the valve connector.

- Verify that there is no short to battery positive on valve connector PIN 1 (corresponding to control unit

connector PIN 17); if there is a short circuit, restore the cable harness.

- With the valve connector disconnected and the control unit connector connected, turn ignition switch

to ON and activate the component using the diagnosis tool.

- Check the voltage (for 10 seconds) at the ends of the valve connector.

- If there is no voltage, check the continuity of the cable harness between control unit PIN 9 and valve

PIN 2 and restore it if necessary.

- If the above tests provided a positive result, the valve should be replaced.

Verificare che i tempi di apertura della valvola di controllo del minimo risultino inferiori al valore massimo,

un valore superiore può essere causato da imbrattamenti del sistema di aspirazione.

Characteristic

Tempo massimo apertura valvola controllo del minimo

20000us (20ms)

Vespa Primavera125 - 150 i.e. 3Valvole (2013)

Electrical system

ELE SYS - 113

Summary of Contents for 150

Page 1: ...SERVICE STATION MANUAL 1Q000118 EN Vespa Primavera125 150 i e 3Valvole 2013 ...

Page 2: ...blication beforehand to make any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of each model should be checked at the official PIAGGIO sales network Copyright 2014 Piaggio C S p A All right...

Page 3: ...ore advisable to read the sections of this manual concerning special tools along with the special tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure t...

Page 4: ......

Page 5: ...CTERISTICS CHAR 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 CHASSIS CHAS PRE DELIVERY PRE DE ...

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

Page 7: ... way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets seali...

Page 8: ...812M VEHICLE IDENTIFICATION USA CND Specification Desc Quantity Chassis prefix ZAPM818G Engine prefix M812M Chassis number The chassis number A is stamped near the fuel tank To read it proceed as follows lift the saddle lift the helmet compartment by removing it Engine number The engine number B is stamped near the rear left shock absorber lower support Characteristics Vespa Primavera125 150 i e 3...

Page 9: ... 6 mm Max power 7 9 kW at 7 700 rpm MAX torque 10 4 Nm at 6 000 rpm Idle speed 1 750 100 rpm Valve clearance when cold intake 0 08 mm exhaust 0 08 mm Timing system 3 valves 2 intake 1 drainage single overhead camshaft chain driven Transmission CVT expandable pulley variator with torque server V belt self ventilating dry automatic centrifugal clutch and transmission housing with forced circulation ...

Page 10: ...ooling Final reduction with gear reduction unit in oil bath Lubrication Engine lubrication with lobe pump inside crankcase chain driven with double filter mesh and paper Cooling Forced air circulation cooling Electric Electric starter Ignition Electronic capacitive discharge ignition with variable advance and separate H V coil Ignition advance Three dimensional map managed by control unit Spark pl...

Page 11: ...re pressure 1 6 bar Rear tyre pressure 1 8 bar Tightening Torques FRAME ASSEMBLY Name Torque in Nm Frame swinging arm bolt 44 to 52 32 5 to 38 4 lbf ft Engine swinging arm bolt 40 45 29 5 33 2 lb ft Silent block swinging arm retaining bolts 40 45 29 5 33 2 lb ft Centre stand pin 40 45 29 5 33 2 lb ft STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut 35 to 40 25 8 to 29 5 lbf ft Lower ste...

Page 12: ...ng screws 10 11 7 4 8 1 lb ft FLYWHEEL COVER Name Torque in Nm Pick up screws 3 4 2 2 2 9 lb ft Stator fixing screws 5 6 3 7 4 4 lb ft Loctite 242 Stator cable plates clamping screws 3 4 2 2 2 9 lb ft Fixing clamps of head pump cover by pass pipe 1 3 1 7 0 9 1 2 lb ft Coil fixing screw 11 13 8 1 9 5 lb ft CRANKCASE Name Torque in Nm Calibrated fixing dowel 5 7 3 7 5 2 lb ft Oil filter cover 24 30 ...

Page 13: ...ISSION AND FINAL REDUCTION Name Torque in Nm Transmission cover screws 11 13 8 1 9 5 lb ft Final reduction cover screws 24 27 17 7 20 lb ft Driven pulley fixing nut 53 59 40 43 5 lb ft Hub oil drain screw 15 17 11 12 5 lb ft Freewheel fixing screws 10 11 7 4 8 1 lb ft Driving pulley retainer nut 75 83 55 61 lb ft LUBRICATION Name Torque in Nm Crankcase timing cover screws 11 13 8 1 9 5 lb ft Screw...

Page 14: ...ng cylinder piston A 57 980 to 57 987 57 933 to 57 940 0 040 to 0 054 cylinder piston B 57 987 to 57 994 57 940 to 57 947 0 040 to 0 054 cylinder piston C 57 994 to 58 001 57 947 to 57 954 0 040 to 0 054 cylinder piston D 58 001 to 58 008 58 954 to 58 961 0 040 to 0 054 N B THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PISTON RINGS MUST BE INSTALLED WITH THE WORD ...

Page 15: ...g mm 52x1 0 0 20 to 0 45 Oil scraper rings mm 52x2 0 0 25 to 0 55 ASSEMBLY CLEARANCE OF BANDS SEAL RINGS 150 DENOMINATION DIMENSIONS ASSEMBLY CLEARANCES A 1 compression ring mm 58x0 8 0 20 to 0 35 2 compression ring mm 58x1 0 0 20 to 0 45 Oil scraper rings mm 58x2 0 0 25 to 0 55 Check that the coupling surface with the head is not worn or misshapen Pistons and cylinders are classified according to...

Page 16: ...on side A 18 1 0 0 05 mm D 0 20 0 50 Half shaft flywheel side B 18 1 0 0 05 mm D 0 20 0 50 Connecting rod C 15 0 10 0 15 mm D 0 20 0 50 Spacer tool E 51 4 0 0 05 mm D 0 20 0 50 Crankshaft bearing diameter Measure the bearings on both x y axes Characteristics Vespa Primavera125 150 i e 3Valvole 2013 CHAR 16 ...

Page 17: ...27 004 to 27 010 mm In order to obtain proper bushing lubrication make sure there are both an outstanding lubrication pressure and a good oil flow rate To that end the bushings must be correctly positioned so as not to obstruct the oil supply channels Characteristic A AXIS CYLINDER Vespa Primavera125 150 i e 3Valvole 2013 Characteristics CHAR 17 ...

Page 18: ...ed to 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 photo Characteristic A AXIS CYLINDER BUSHINGS TYPE IDENTIFICATION CRANKSHAFT HALF BEARINGS B BLUE 1 971 to 1 976 C YELLOW 1 974 to 1 979 E GREEN 1 977 to 1 982 Characteristics Vespa Primavera125 150 i e 3Valvole 2013 CHAR...

Page 19: ... using a bore meter at two depths indicated in the figure the diameter of the bushings After measuring the two diameters take the average Characteristic A AXIS CYLINDER The bushings housing hole in the crankcase half is divided into two categories depending on the size Category 1 and Category 2 CRANKCASE DIAMETER WITHOUT BUSHING Specification Desc Quantity CAT 1 30 959 to 30 965 mm CAT 2 30 953 to...

Page 20: ...d Pay attention to the position of the springs and valves so as not to change the original position upon refitting them Using a trued bar and a thickness gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum run out allowed 0 03 mm In case of irregularities replace the head Check the sealing surfaces for the exhaust manifold Check that the camshaft and the rock...

Page 21: ... mm Remove any carbon deposits from the valve seats Check the width of the mark on the valve seat V with Prussian blue Characteristic Standard value 1 1 3 mm If the width of the mark on the valve seat is larger than the prescribed limits true the seats with a 45 milling cutter and then grind Replace the head in case of excessive wear or damage Vespa Primavera125 150 i e 3Valvole 2013 Characteristi...

Page 22: ... valve stem by resting it on a V shaped support and measuring the ex tent of the deformation using a dial gauge Characteristic Limit value allowed 0 02 mm Check the oscillation of the valve head by ar ranging a dial gauge at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Limit allowed 0 3 mm Measure the valve guides Characteristic Valve guide 4 3 0 1 mm ...

Page 23: ...ding the valve seats Grind the valves gently with fine grained lapping com pound Upon grinding keep the cylinder head in 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 FAYING SURFACE DO NOT ROTATE THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALV...

Page 24: ...of wear or scoring on the rocker pins Check the internal diameter of each rocker arm Check there are no signs of wear on the contact pads with the cam and on the jointed adjustment plate DIAMETER OF PINS AND ROCKING LEVERS Specification Desc Quantity Rocking lever inside diameter Standard diameter C Ø 10 015 to 10 035 mm Rocking lever pin diameter Standard diameter D Ø 10 015 to 10 023 mm Characte...

Page 25: ...inder the thinner the base gasket to be used should be to compensate the compression ratio and vice versa N B DISTANCE A SHOULD BE MEASURED WITH NO GASKET FITTED BETWEEN THE CRANK CASE AND THE CYLINDER AND AFTER RESETTING THE DIAL GAUGE WITH SUPPORT ON A GROUND PLANE ENGINE 125 150 SHIMMING Name Measure A Thickness Shimming 0 0 1 0 8 0 05 Shimming 0 1 0 3 0 6 0 05 Shimming 0 3 0 4 0 4 0 05 Vespa P...

Page 26: ...ase ISO L X BCHA 3 DIN 51 825 K3K 20 AGIP GP 330 Water repellent stringy calcium spray grease R I D A D R 2 10 b 2 R I Na 2 42 I A T A 2 I M D G class 2 UN 1950 Page 9022 EM 25 89 UNIT OF MEASURE CONVERSION ENGLISH SYSTEM TO INTERNATIONAL SYSTEM IS 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 USgal 3 785 Litres l 1 Pou...

Page 27: ...INDEX OF TOPICS TOOLING TOOL ...

Page 28: ... extract 17 mm diameter bear ings 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract 15 mm diameter bear ings 002465Y Calliper for circlips 005095Y Engine support 006029Y Punch for fitting steering bearing seat on steering tube Tooling Vespa Primavera125 150 i e 3Valvole 2013 TOOL 28 ...

Page 29: ...ode Description 020004Y Punch to remove steering bearings from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch 020038Y Punch Vespa Primavera125 150 i e 3Valvole 2013 Tooling TOOL 29 ...

Page 30: ...tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Gauge for oil pressure check 020263Y Sheath for fitting the driven pulley Tooling Vespa Primavera125 150 i e 3Valvole 2013 TOOL 30 ...

Page 31: ...20325Y Pliers for brake shoe springs 020329Y Vacuum pump Mity Vac 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter 020332Y Digital rpm indicator Vespa Primavera125 150 i e 3Valvole 2013 Tooling TOOL 31 ...

Page 32: ...le battery charger 020335Y Dial gauge magnetic support 020357Y 32 x 35 mm adaptor 020358Y 37 x 40 mm adaptor 020359Y 42 x 47 mm adaptor 020360Y 52 x 55 mm adaptor 020363Y 20 mm guide Tooling Vespa Primavera125 150 i e 3Valvole 2013 TOOL 32 ...

Page 33: ... 020375Y 28 x 30 mm adaptor 020376Y Adapter handle 020382Y Valve cotters removal tool 020412Y 15 mm guide 020424Y Punch for fitting driven pulley roller casing 020426Y Piston fitting fork Vespa Primavera125 150 i e 3Valvole 2013 Tooling TOOL 33 ...

Page 34: ...27Y Piston fitting ring 020431Y Valve oil seal extractor 020434Y Fitting for oil pressure check 020441Y 26 x 28 mm adaptor 020444Y011 adapter ring 020444Y009 wrench 46 x 55 Tooling Vespa Primavera125 150 i e 3Valvole 2013 TOOL 34 ...

Page 35: ...Y Pulley lock wrench 020444Y Tool for fitting removing the clutch on the driven pulley 020480Y Fuel pressure check set 020922Y Diagnosis Tool 020933Y Flywheel extractor 020937Y Driven pulley lock Vespa Primavera125 150 i e 3Valvole 2013 Tooling TOOL 35 ...

Page 36: ...ion 020938Y Driving pulley check ring 020939Y Flywheel retainer 020941Y Crankshaft timing adjustment tool 020942Y Piston protrusion check tool 020922Y Diagnosis Tool Tooling Vespa Primavera125 150 i e 3Valvole 2013 TOOL 36 ...

Page 37: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 38: ...I I I I I Engine oil R I R I R I R Hub oil I I I Headlight aiming adjustment A A A Brake pads I I I I I I I Tyre pressure and wear I I I I I I I Vehicle road test I I I I I I I Suspension I I I Steering A A A A Transmission L L L Labour time minutes 80 30 190 30 190 30 190 Versions for market USA CND SCHEDULED MAINTENANCE TABLE I CHECK AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R R...

Page 39: ...spark plug external inspection door by undoing the indicated screw Disconnect the spark plug H V cable cap Unscrew the spark plug using the wrench supplied Check the conditions of the spark plug make sure the insulation is intact that the electrodes are not excessively worn or sooty the conditions of the washer and measure the distance between the electrodes using the appropriate feeler gauge In c...

Page 40: ...ON CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRI BED MAY SERIOUSLY DAMAGE THE ENGINE Characteristic Electrode gap 0 7 to 0 8 mm Spark plug NGK CR8EB Locking torques N m Spark plug tightening 10 to 12 Hub oil Check Check oil level with the vehicle placed on the cen tre stand and on a flat surface Undo the indicated screw and check for oil by in serting a shank plug The level should be just ...

Page 41: ... drain out all the oil Screw in the drainage cap again and fill the hub with the prescribed oil Recommended products AGIP GEAR SAE 80W 90 Lubricant for gearboxes and transmissions API GL 4 Characteristic Hub oil 270 cm Locking torques N m Hub oil drain screw 15 to 17 Vespa Primavera125 150 i e 3Valvole 2013 Maintenance MAIN 41 ...

Page 42: ... air passage sections are not damaged or deformed Check the correct sealing of the coupling between the filter housing and the cover CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE Engine oil In four stroke engines the engine oil is used to lubricate the timing elements the bench bearings and th...

Page 43: ...gs are in good conditions Lubricate them and refit the mesh filter and the oil drainage plug screwing them up to the prescribed torque Refit the new cartridge filter being careful to lubri cate the O ring before fitting it Change the engine oil Since a certain quantity of oil still remains in the circuit oil must be filled from oil dipstick cover Then start up the vehicle leave it running for a fe...

Page 44: ...en stopped so as to get the correct level Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX level Engine oil filter Change oil and replace filter as indicated in the scheduled maintenance table Use new oil of the rec ommended type for topping up and changing purposes Make sure the pre filter and drainage plug O rings ...

Page 45: ... in compression To do this use the appropriate tools Use the holes on the engine crankcase to secure the tool Position the specific tool in the window between the flywheel pick up references as illustrated in the figure The arrows stamped respectively on the valve frame and sprocket must coincide N B IF THE TIMING UNIT IS NOT IN PHASE CHECK THE COR RECT FITTING OF COMPONENTS As a further verificat...

Page 46: ...ance values intake and exhaust respectively are different from the ones indicated below adjust them by loosening the lock nut and operating on the corresponding set screw as shown in the fig ure Characteristic Valve clearance when cold intake 0 08 mm exhaust 0 08 mm Braking system Level check Proceed as follows Rest the vehicle on its centre stand with the han dlebars perfectly horizontal Check th...

Page 47: ... A CERTAIN VALUE BRAKING WILL BE INEFFICIENT NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDITIONS REPLACE FLU ID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE N B SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS Recommended products AGIP BRAKE 4 Brake fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO...

Page 48: ... the external environment The volume of air is limited by the operation of the ventilation valve Roll over 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 ...

Page 49: ... lack of control vacuum therefore any expansion of the fuel tank will not cause pollution of the intake manifold and then cause flooding of the engine To control the valve it is preferable to it alterna tively just access the manifold side pipe Connect the MITY VAC pump on the engine side duct Select the pump command on the vac uum position then slowly apply vac uum up to the valve threshold check...

Page 50: ...vertical axis check that it is possible to intake air without movements of the gauge needle Switch the control of the pump to pres sure and keeping the valve in the ver tical axis check that it is possible to pressurise the valve up to values slightly below 1 45PSI 0 87PSI 10kPa 6kPa 100mbar 60mbar N B The setting pressure is easily recognisable in that when it is reached the valve discharges the ...

Page 51: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 52: ...signs of sulphation replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1 10 of the capacity of the battery itself Faulty spark plug Replace the spark plug Incorrect valve sealing or valve adjustment Inspect the head and or restore the correct clearance Starter motor and start up system fault Check starter motor Altered fuel characteristics ...

Page 53: ... brake pads or shoes and check for brake disk or drum wear conditions Front brake disk loose or deformed 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 Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Fluid leakage in h...

Page 54: ...s 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 Excessive steering clearance Check the tightening of the top ring nut If irregularities continue in turning the steering even after making the above adjust ments check the seats in which the ball bearings ...

Page 55: ...Vespa Primavera125 150 i e 3Valvole 2013 Troubleshooting TROUBL 55 ...

Page 56: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 57: ...eel 9 Speed sensor 10 Instrument panel 11 MODE button 12 Turn indicator control 13 Pre installation for anti theft device 14 Turn indicator switch 15 Left turn indicator bulbs 16 Turn indicators warning lights 17 Right turn indicator bulbs 18 Stop light 19 Stop buttons Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 57 ...

Page 58: ...ngine stop switch 36 Immobilizer LED 37 Left front daylight running light 38 Right front daylight running light 39 Rear daylight running light 40 License plate light 41 Injector 42 Idle valve 43 Engine speed sensor 44 Engine temperature sensor 45 Lambda probe 46 Fuel pump 47 H V coil 48 Injection warning light 49 Throttle body position 50 Diagnostics socket 51 Immobilizer antenna 52 Injection ECU ...

Page 59: ...wn Ne Black Rs Red Ro Pink Ve Green Vi Violet Gr Grey Components arrangement 1 RIGHT HAND STOP SWITCH Remove the upper handlebar cover to reach it Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 59 ...

Page 60: ...the front case to reach it 4 TURN INDICATORS INTERMITTENCE 5 HORN 6 VOLTAGE REGULATOR Remove the leg shield back plate to reach it 7 INJECTION ECU 8 HEADLIGHT SOLENOID Remove the leg shield back plate to reach it Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 60 ...

Page 61: ...TOR To reach it remove the helmet compartment 12 FRONT RIGHT TURN INDICATOR Remove the leg shield back plate to reach it 13 LEFT HAND STOP SWITCH Remove the upper handlebar cover to reach it Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 61 ...

Page 62: ... it 15 INJECTOR To reach it remove the helmet compartment 16 ENGINE TEMPERATURE SENSOR To reach it remove the helmet compartment 17 IDLE SPEED ADJUSTMENT DEVICE To reach it remove the helmet compartment Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 62 ...

Page 63: ...each it remove the helmet compartment 20 HORN SWITCH 21 TURN INDICATOR SWITCH 22 HIGH LOW BEAM LIGHTS SWITCH Remove the upper handlebar cover to reach it 23 INSTRUMENT PANEL Remove the upper handlebar cover to reach it Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 63 ...

Page 64: ...5 IGNITION SWITCH 26 IMMOBILIZER AERIAL Remove the leg shield back plate to reach it 27 STARTER RELAY Remove the footrests to reach it 28 BATTERY 29 MAIN FUSE Remove the battery cover to reach it Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 64 ...

Page 65: ...ear headlight assembly to reach it 31 REAR LEFT TURN INDICATOR 32 LICENSE PLATE LIGHT Remove the license plate cover to reach it 33 REAR RIGHT TURN INDICATOR Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 65 ...

Page 66: ...ttery cover to reach it 36 PRE INSTALLATION FOR ANTI THEFT DE VICE Remove the footrests to reach it Ground points On the vehicle there is a ground point on the chas sis marked with the letter A remove the footrest to access it Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 66 ...

Page 67: ...e starter motor On the left side of the chassis under the footrest there is the chassis engine ground lead C Electrical system installation Front side 1 Left stop button Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 67 ...

Page 68: ...Instrument panel connector 5 Right control lock 6 Right stop button 7 Left electrical controls connector 8 Ignition switch 9 Voltage regulator 10 Turn indicator control device Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 68 ...

Page 69: ... regulator connector 12 Front left turn indicator connector 13 Horn connections 14 Saddle opening switch connector 15 To speed sensor on wheel Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 69 ...

Page 70: ...16 Headlight relay base 17 Front right turn indicator connector 18 Secondary fuses 19 Speed sensor connector Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 70 ...

Page 71: ...20 Right electrical controls connector 21 Injection ECU 22 Immobilizer aerial 23 Headlight relay Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 71 ...

Page 72: ...tery pole 26 Diagnostics socket 27 Positive battery pole 28 Main fuse 29 To rear cable harness 30 Pre installation for anti theft device 31 Saddle opening actuator connector Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 72 ...

Page 73: ...32 Starter relay 33 Roll over sensor connector 34 Roll over sensor Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 73 ...

Page 74: ...en sensor connector 4 Magneto flywheel connector 5 Starter motor positive 6 Starter motor negative 7 Throttle body position sensor connector 8 Idle valve connector 9 H V coil connections Conceptual diagrams Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 74 ...

Page 75: ...Ignition switch 6 Secondary fuses 41 Injector 43 Engine speed sensor 44 Engine temperature sensor 45 Lambda probe 47 H V coil 49 Throttle body position 52 Injection ECU Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 75 ...

Page 76: ...rter motor 4 Main fuse 5 Ignition switch 6 Secondary fuses 7 Voltage regulator 8 Magneto flywheel 18 Stop light 19 Stop buttons 20 Starter button 21 Starter relay coil 35 engine stop switch 52 Injection ECU Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 76 ...

Page 77: ...10 Instrument panel 29 Engine oil pressure warning light 30 Engine oil pressure sensor 31 Fuel level transmitter 32 Fuel gauge 33 Low fuel warning light 34 Roll over sensor 35 engine stop switch 36 Immobilizer LED 51 Immobilizer antenna 52 Injection ECU Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 77 ...

Page 78: ...Main fuse 5 Ignition switch 6 Secondary fuses 10 Instrument panel 11 MODE button 13 Pre installation for anti theft device 26 Saddle opening actuator 27 Horn button 28 Horn Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 78 ...

Page 79: ...Lights and turn indicators Versions for market USA CND Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 79 ...

Page 80: ...tor bulbs 16 Turn indicators warning lights 17 Right turn indicator bulbs 18 Stop light 19 Stop buttons 22 High beam warning light 23 Light switch 24 Headlight relay 25 Headlight 37 Left front daylight running light 38 Right front daylight running light 39 Rear daylight running light Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 80 ...

Page 81: ...y fuses 21 Starter relay coil 34 Roll over sensor 35 engine stop switch 36 Immobilizer LED 41 Injector 42 Idle valve 43 Engine speed sensor 44 Engine temperature sensor 45 Lambda probe 46 Fuel pump 47 HV coil 48 Injection warning light Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 81 ...

Page 82: ...components Control unit Immobilizer antenna master and service keys with built in transponder HV coil diagnosis LED The diagnosis led also works as a blinking light to deter theft This function is activated every time the ignition switch is turned to OFF and it remains active 48 hours so as not to damage the battery charging process When the ignition switch is turned to ON it interrupts the functi...

Page 83: ...key and turn it to ON for 2 seconds If you have copies of the key repeat the operation with 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 7 service keys can be programmed at one time It is essential to adhere to the times and the pro cedure If you do not start again from the begin ning Once the system has been progra...

Page 84: ...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 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...

Page 85: ...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 un...

Page 86: ...NG BEFORE CARRYING OUT THE CHECK MAKE SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Place the vehicle on its centre stand 2 With the battery correctly connected to the circuit place the multimeter leads between the battery terminals 3 Start the engine ensure that the lights are all out increase the engine speed and at the same time measure the voltage Electric characteristic Voltage ranging be...

Page 87: ...motor 1 Battery 2 Fuse No 1 3 Starter relay 4 Starter motor 5 Ignition switch 6 Fuse no 2 7 Stop buttons 8 Starter button 9 CDI control unit Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 87 ...

Page 88: ...Horn control 1 Battery 2 Fuse No 1 3 Ignition switch 4 Fuse no 2 5 Horn button 6 Horn Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 88 ...

Page 89: ...tch 4 Fuse no 2 5 Turn indicator device 6 Turn indicator switch 7 Turn indicators level indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 89 ...

Page 90: ...tter operates correctly but the in dication on the instrument panel is not exact check that the cable harnesses between them are not interrupted Electric characteristic Resistance value with full tank 7 Ω Resistance value with empty tank 90 13 3 Ω Lights list 1 Battery 2 Fuse No 1 3 Fuse no 2 4 Ignition switch 5 Fuse No 5 Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 90 ...

Page 91: ...1 2 Front side light bulb Type LED Quantity 2 3 Stop light bulb Type LED Quantity 1 4 Rear tail light bulb Type Incandescent Power 12V 10W Quantity 1 5 License plate light bulb Type Incandescent Power 12V 5W Quantity 1 6 Front turn indicator light bulb Type Halogen BAZ9s base Amber Power 12V 6W Quantity 1 RHS 1 LHS 7 Rear turn indicator light bulb Type Halogen BAZ9s base Amber Power 12V 6W Quantit...

Page 92: ...ing light 12 License plate light 13 Rear daylight running light 14 Instrument panel lighting BULBS Specification Desc Quantity 1 High low beam light bulb Type Halogen HS1 Power 12V 60 55W Quantity 1 2 Front daylight running light bulbs Type LED Quantity 2 3 Turn indicator light bulbs Type Incandescent amber Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 92 ...

Page 93: ...ndary fuses positioned as MAIN FUSE HOLDER A battery compartment Access to main fuse A Remove the battery compartment cover as de scribed in Battery paragraph Open the fuse holder SECONDARY FUSES B inside the front case Access to the secondary fuses B Open the front case Open the fuse holders CAUTION BEFORE REPLACING THE FUSE IT IS NECESSARY TO FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW DO ...

Page 94: ...USE CHART Specification Desc Quantity Fuse No 1 Capacity 20 A Protected circuits battery recharge circuit fuses No 2 and 3 live fuses No 4 and 5 Fuse No 2 Capacity 5 A Protected circuits ignition switched live instrument panel in dicators antitheft device pre installation stop lights starter circuit headlight relay horn daylight running lights Fuse No 3 Capacity 5 A Protected circuits ignition swi...

Page 95: ... indicator warning light E Low fuel warning light F Digital display G Low engine oil pressure warning light H High beam headlight warning light I Fuel gauge with petrol symbol L Total or partial odometer M Clock Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 95 ...

Page 96: ...Initial charge voltage equal to 0 3 to 0 5 for Nominal capacity Charge time 10 to 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 Battery installation VRLA battery valve regulated lead acid battery Maintenance Free MF WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURN...

Page 97: ... 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 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 b...

Page 98: ...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 no load voltage between 12 8 13 15 V Bring the battery to full charge us ing the 020648Y battery charger a selec...

Page 99: ...isconnect 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 completely activated disconnect the battery charger from the fuel supply grid disconnect the clamps from the battery and proceed to fitting...

Page 100: ...lator c2 Rs Pickup FUEL PUMP CONNECTOR 1 Power from relay Black Green 2 Not connected 3 Not connected 4 Negative from control unit Green 5 Not connected INJECTION ECU 1 Ve fuel pump 2 MaBi injection warning light 3 AzRs lambda probe heater 4 Gi immobilizer LED 5 RsBi battery 6 RsGi injector ground 7 GrVe Sensor ground 8 RoNe H V coil 9 NeVe loads 10 ArNe K Line Electrical system Vespa Primavera125...

Page 101: ...ATURE SENSOR CONNEC TOR 1 Electronic control unit Sky blue Green 2 Ground lead Grey Green INJECTOR CONNECTOR 1 Power from relay Black Green 2 Electronic control unit Red Yellow LAMBDA PROBE CONNECTOR 1 Heater supply from ECU Black Green 2 Heater ECU negative Light blue Red 3 Lambda signal positive Green Blue 4 Lambda signal negative Grey Green Vespa Primavera125 150 i e 3Valvole 2013 Electrical sy...

Page 102: ...ight Purple 6 Ground lead Black 7 Not connected 8 Speed sensor negative Black Green 9 Not connected 10 Not connected 11 Not connected 12 Fuel level indicator White Green 13 Not connected 14 Speed sensor signal Sky blue 15 Not connected 16 Injection warning light Brown White 17 Ground lead Black 18 Immobilizer LED Yellow 19 Live power supply and instrument panel light ing Yellow Black 20 Battery po...

Page 103: ...Grey Red 5 Key powered Yellow Black 6 Not connected 7 Not connected 8 Not connected FUEL LEVEL TRANSMITTER CONNECTOR 1 Fuel level indicator White Green 2 Ground lead Black SENSORE RIBALTAMENTO Pinout 1 Non collegato 2 Massa da centralina Grigio Verde 3 Alimentazione sotto chiave Bianco 4 Segnale consenso Arancio Blu Vespa Primavera125 150 i e 3Valvole 2013 Electrical system ELE SYS 103 ...

Page 104: ...cui rileva un inclinazione del veicolo superiore a 60 ad esempio in seguito a scivolate o cadute Schema di principio Legenda 1 Batteria 2 Fusibile n 1 3 Contatti del commutatore a chiave 4 Fusibile n 3 5 Sensore ribaltamento 6 Interruttore arresto motore 7 Centralina iniezione Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 104 ...

Page 105: ... the minimum threshold Troubleshooting Check the battery the voltage regulator the correct function of the alternator flywheel and the relative connectors IMMOBILIZER AERIAL Function Detects the transponder code in the key and sends it to the engine control unit ERRORS Immobilizer P0513 unknown transponder Error cause The key has the working transponder but it is not within the recognised ones Tro...

Page 106: ... open circuit Error cause Open circuit circuit interruption Troubleshooting Open circuit Carry out the check procedure of the coil and control unit connectors Check the ground and battery powered insulation of coil PIN 1 Verify continuity of the cabling between the coil and control unit Coil PIN 1 control unit PIN 8 If there is no continuity restore the cable harness Check the ground connection of...

Page 107: ... there is intermittent voltage 4 ms every second for 5 seconds at the ends of the injector connector If there is no voltage check the continuity of the cable harness between control unit PIN 9 and injector PIN 1 and restore it if necessary If the above tests provided a positive result the injector should be replaced High injector voltage P0262 shorted to positive Error cause Short circuit to posit...

Page 108: ...it connector and pump connector Control unit PIN 1 pump PIN 2 and control unit PIN 9 pump PIN 5 If there is no continuity restore the cable harness Short circuit to negative Disconnect the control unit connector and the pump connector Check the pump connector PIN 2 ground insulation corresponding to control unit connector PIN 1 If there is no insulation restore the cable harness High fuel pump vol...

Page 109: ...ore the cabling High engine temperature sensor P0118 open circuit or shorted to positive Error cause Open circuit or short circuit to positive interruption of the circuit or excessive voltage at PIN 16 of the control unit connector Troubleshooting Open circuit Disconnect control unit and sensor connectors and carry out the check procedure Check the continuity of the cable harness between the senso...

Page 110: ...ontrol unit connector Sensor PIN 1 control unit PIN 7 sensor PIN 2 control unit PIN 18 and sensor PIN 3 control unit PIN 14 If necessary restore the cable harness Short circuit to negative Disconnect the sensor connector Check the ground insulation of the three PIN of the sensor connector If there is no ground insulation restore the cabling High sensor voltage input P0123 shorted to positive Error...

Page 111: ...nector Troubleshooting Short circuit to negative Disconnect the connector of the probe and the control unit connector and carry out the check proce dure Check the sensor connector PIN 3 from ground insulation If there is no insulation restore the cable harness High Lambda probe voltage P0132 shorted to positive Error cause Short circuit to positive excessive voltage to PIN 13 of the control unit c...

Page 112: ...probe voltage P0032 shorted to positive Error cause Short circuit to positive excessive voltage to PIN 3 of the control unit connector Troubleshooting Short circuit to positive Disconnect the control unit connector and the heater connector and perform the check procedure Verify that there is no short to battery positive on sensor connector PIN 2 corresponding to control unit connector PIN 3 if the...

Page 113: ...Error cause Short circuit to positive excessive voltage to PIN 17 of the control unit connector Troubleshooting Short circuit to positive Disconnect the control unit connector and the valve connector Verify that there is no short to battery positive on valve connector PIN 1 corresponding to control unit connector PIN 17 if there is a short circuit restore the cable harness With the valve connector...

Page 114: ... and of the control unit and perform the check procedure Check the instrument panel PIN 16 from ground insulation If there is no ground insulation restore the cabling High MIL warning light voltage P1652 shorted to positive Error cause Short circuit to positive excessive voltage at PIN 2 of the control unit connector Troubleshooting Short circuit to positive Disconnect the instrument panel connect...

Page 115: ...o positive Error cause Open circuit or short circuit to positive interruption of the circuit or excessive voltage at PIN 11 of the control unit connector Troubleshooting Open circuit Disconnect the connector of the control unit Remove the headlight relay from its base and ensure its correct functioning Perform the check procedure of the control unit and relay base connector Check continuity of the...

Page 116: ...e presence of voltage in the battery on the relay base connector PIN 85 otherwise check the related cable harnesses the ignition switch contacts and fuses no 2 and 3 Check the ground connection of relay base PIN 87A Check the continuity between relay base PIN 87 and lights switch connector Electrical system Vespa Primavera125 150 i e 3Valvole 2013 ELE SYS 116 ...

Page 117: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 118: ...ing nuts from the manifold to the head Remove the Lambda probe from its support and disconnect it Release the lambda probe cable from the bracket on the fan cover CAUTION FREE THE CABLES OF THE OXYGEN SENSOR BEFORE REMOVING THE SILENCER PUTTING THIS CABLE HARNESS UNDER AN EXCESSIVE VOLTAGE MAY DAMAGE IT Loosen the 2 exhaust fixing screws to the crank case then remove the whole exhaust Engine from ...

Page 119: ...et compartment Remove the full silencer unit Free the sheath on the 2 rear brake transmission securing brackets indicated in the photo Disconnect the rear brake transmission by un screwing the adjuster screw Disconnect the belt cooling pipe indicated in the picture Disconnect the ground lead from the engine Vespa Primavera125 150 i e 3Valvole 2013 Engine from vehicle ENG VE 119 ...

Page 120: ...filter box Remove the ground lead and the positive cable from the starter motor shown in the figure Disconnect the fuel hoses and the main cable harness from the injector Engine from vehicle Vespa Primavera125 150 i e 3Valvole 2013 ENG VE 120 ...

Page 121: ...ture sensor Remove the connector from the idle speed ad justment device Remove the connectors of the H V coil Remove the throttle position sensor connector Disconnect the flywheel connector Vespa Primavera125 150 i e 3Valvole 2013 Engine from vehicle ENG VE 121 ...

Page 122: ...t which holds the coupling bolt swinging arm engine Working on the left side remove the bolt be careful to collect the spacer Support the vehicle adequately with a jack and remove the shock absorber lower clamping Engine from vehicle Vespa Primavera125 150 i e 3Valvole 2013 ENG VE 122 ...

Page 123: ...INDEX OF TOPICS ENGINE ENG ...

Page 124: ...ed out on the engine and the tools required Automatic transmission Transmission cover Remove the air duct Remove the plastic cover that has the vehicle logo on it Insert the specific tools rotate the engine until the driven pulley stops and remove the nut recovering the washer Specific tooling 020937Y Driven pulley lock Unscrew the ten screws fixing the engine and re move the transmission cover Se...

Page 125: ...emove the Seeger ring CAUTION PLACE THE COVER ON A SURFACE REMOVING OR EX CLUDING THE ALIGNMENT DOWELS Support the transmission cover adequately Using appropriate tools remove the bearing Specific tooling 020376Y Adapter handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 125 ...

Page 126: ...bearing during operation on the vertical axis Specific tooling 020151Y Air heater 020376Y Adapter handle 020358Y 37 x 40 mm adaptor 020412Y 15 mm guide Insert the Seeger ring Insert the alignment dowels if removed during disassembly Removing the driven pulley Undo the clutch fixing screw recovering the lin ing Remove the clutch drum Remove the driven pulley Engine Vespa Primavera125 150 i e 3Valvo...

Page 127: ...34 5 mm clutch housing standard value Standard value Ø 134 to 134 2 mm Checking the bell working surface eccentricity Fit the bell on a driven pulley shaft with 2 bearings inside diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support to check the crankshaft alignment Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 127 ...

Page 128: ...ible limit eccentricity 0 15 mm Removing the clutch Prepare the locking tool for the driven pulley with the pins half screwed in the tool set to C Introduce the adapter ring 11 with the chamfering facing the inside of the tool Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes After wards make the support screw make contact with a minimum force Using the...

Page 129: ... wrench 46 x 55 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 FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEAR ING CAUTION DO NOT USE TOOLS TO OPEN THE MASSES TO AV...

Page 130: ...earing Remove the retainer ring using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as shown in the figure Remove the bearing and the rollers with the spe cific extractor N B REST THE HALF PULLEY ON A WOODEN SURFACE TO AVOID DAMAGING ITS THREADED BUSHING ALSO DO THIS UPON REMOVAL Specific tooling 001467Y008 Calliper to extract 17 mm diame ter bearings 001467Y009 Bel...

Page 131: ...ompletely up to the punch stop on the half pulley N B REST THE HALF PULLEY ON A WOODEN SURFACE TO AVOID DAMAGING ITS THREADED BUSHING ALSO DO THIS UPON REMOVAL Specific tooling 020424Y Punch for fitting driven pulley roller casing To assemble the new ball bearing insert it fully down in its seat with the specific punch and finally fit the seeger ring Specific tooling 020375Y 28 x 30 mm adaptor 020...

Page 132: ...ley unit with approximately 6 g of grease Apply the grease through one of the holes in the bushing until grease comes out through the hole on the opposite side This procedure is necessary to prevent the presence of grease beyond the O rings Specific tooling 020263Y Sheath for fitting the driven pulley Recommended products AGIP GREASE SM 2 Gray black smooth tex tured lithium grease containing molyb...

Page 133: ...is not damaged and does not show signs of abnormal wear Replace according to the scheduled maintenance table Removing the driving pulley Using specific tools lock the driving pulley and loosen the nut Specific tooling 020938Y Driving pulley check ring Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 133 ...

Page 134: ...g 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 guide shoes for the variator back plate are not worn Check the wear of the roller housings and of the belt faying surfaces on both pulley halves Engine Vespa Primavera125 150 i e 3Valvole 2013 ...

Page 135: ...imit ø 18 4 mm Refitting the driving pulley Perform the operations in reverse order of disas sembly CAUTION INSERT THE ROLLERS WITH THE LARGEST SUPPORT SURFACE ACCORDING TO THE DIRECTION OF ROTA TION Tighten the torque using the specific tool to lock the pulley CAUTION DURING THE INSTALLATION PAY SPECIAL ATTENTION TO THE ASSEMBLY OF THE BELLEVILLE SPRING AS SHOWN IN FIGURE Specific tooling 020938Y...

Page 136: ... gear Removing the hub cover Use a container large enough to recover the final reduction oil Unscrew the indicated screw and re cover the aluminium seal Unscrew the oil filler screw in order to facilitate bleeding Recommended products AGIP GEAR SAE 80W 90 Lubricant for gear boxes and transmissions API GL 4 Characteristic Hub oil 200 cm Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 136 ...

Page 137: ...ixing screws Remove the final reduction cap complete with the wheel axle being careful not to drop the inter mediate gear Removing the wheel axle Remove the intermediate gear Remove the wheel axle Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 137 ...

Page 138: ...e 020359Y 42 x 47 mm adaptor Removing the intermediate gear bearing Remove the bearing using the specific tools Specific tooling 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract 15 mm diame ter bearings Removing the wheel axle bearing Remove the bearing using the specific tools Specific tooling 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract 15 mm diame ter...

Page 139: ...the intermediate gear bearing Remove the bearing using the specific tools Specific tooling 001467Y013 Calliper to extract 15 mm diame ter bearings 001467Y009 Bell for OD 42 mm bearings Inspecting the hub shaft Check the three shafts and the intermediate gear for wear or distortion of the toothed surfaces the bearing housings and the oil seal housings If faults are found replace the damaged parts C...

Page 140: ...ngs In case of faults replace the damaged parts Refitting the driven pulley shaft bearing Use the heat gun to heat the bearing seat Set a new bearing using the specific equipment Insert a locking seeger Specific tooling 020151Y Air heater 020376Y Adapter handle 020360Y 52 x 55 mm adaptor 020363Y 20 mm guide Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 140 ...

Page 141: ...new bearing using the specific equipment Specific tooling 020151Y Air heater 020376Y Adapter handle 020359Y 42 x 47 mm Adaptor For main bear ings and wheel axle 020412Y 15 mm guide Refitting the hub cover bearings Fitting the wheel axle bearing Use the heat gun to heat the bearing seat Plant a new bearing using the equipment apply grease on the adapter and guide in order to main tain the position ...

Page 142: ... guide Refitting the hub bearings Insert the gears in the cover in order to prevent abnormal movements during insertion into the en gine Insert the wheel axis Refitting the ub cover Clean the engine crankcase and reduction cover surfaces adequately Working in reverse with respect to the disassem bly inert the command pinion and the intermediate gear into the hub box Pay attention to the correct po...

Page 143: ... screw 15 to 17 Restore the level of oil inside duction unit with the recommended product acting on the filler screw until touching Tighten to the specified torque Recommended products AGIP GEAR SAE 80W 90 Lubricant for gear boxes and transmissions API GL 4 Characteristic Hub oil 200 cm Locking torques N m Oil relief screw 15 to 17 Flywheel cover Cooling hood Unscrew the five indicated screws and ...

Page 144: ...ol unscrew the cooling fan fixing screw Remove the fan Recover the wrench Specific tooling 020442Y Pulley lock wrench Removing the hub cover Remove the oil dipstick Remove the sensor connector Unscrew the eleven fixing screws of the flywheel cover Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 144 ...

Page 145: ...s Removing the stator Remove the flywheel cover Unscrew the 2 flywheel fixing screws and the four pick up fixing screws and cable harness retainer screws Remove the flywheel and the pick up complete with cable harness Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 145 ...

Page 146: ...itting the flywheel cover Fit the gasket and be careful with the two align ment dowels Tighten the screws and tighten to the specified torque CAUTION TO AVOID DAMAGING THE OIL SEAL USE THE SPECIFIC TOOL PRIOR TO POSITIONING THE FLYWHEEL COVER Specific tooling 020940Y Flywheel cover oil seal gasket FLYWHEEL COVER SCREWS POSITION DIMENSIONS TORQUE Nm A M6x90 11 13 B M6x35 11 13 C M6x30 11 13 Flywhee...

Page 147: ...er motor Removing the flywheel magneto Undo the screw indicated and remove the plate Install the specific tool and unscrew the retainer nut of the flywheel recovering the washer Specific tooling 020939Y Flywheel retainer Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 147 ...

Page 148: ... Inspecting the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate Refitting the flywheel magneto Perform the procedure in reverse order of disassembly taking care to tighten to specified torque Locking torques N m Flywheel fixing nut 100 to...

Page 149: ...rter motor and lubricate it Fit the starter motor on the crankcase and lock the two screws to the prescribed torque Locking torques N m Starter motor screws 10 8 to 12 8 Cylinder assy and timing system Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 149 ...

Page 150: ... head loosen the clamps and remove the sleeve con necting to the throttle body Undo the three manifold fixing screws and re move it Removing the rocker arms cover Remove the protective cover undoing the three screws Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 150 ...

Page 151: ...emove the engine temperature sensor Undo the screw indicated remove the upper part of the cover Unscrew the four screws and remove the tappet cover Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 151 ...

Page 152: ...Use the holes on the engine crankcase to secure the tool Position the specific tool in the window between the flywheel pick up references as illustrated in the figure Specific tooling 020941Y Crankshaft timing adjustment tool First loosen the tensioner and unscrew the fixing screws Remove the tensioner complete with gasket Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 152 ...

Page 153: ...isassembly After removing the head the camshaft control com ponents can be removed Remove the inspection cover as described in sec Lubrication Main bushing oil seals removal Remove the oil pump command as described in section Lubrication Oil pump Disassembly Undo the chain tensioner pad fixing screw re move the bushing and the slider Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 153 ...

Page 154: ... Remove the chain tensioner pad Remove the control gear Remove the seal OR Remove the flat washer Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 154 ...

Page 155: ...timing chain from the crankshaft Remove the control gear See also Removal Removing the cylinder piston assy Removing the cam shaft Undo the camshaft lock screw Remove the lock Remove the two pins and the rockers Remove the camshaft Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 155 ...

Page 156: ...Removing the cylinder head Gradually loosen the four screws in crossed se quence and recover the washers Undo the two external screws Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 156 ...

Page 157: ... Remove the cylinder head Remove the chain guide slider and the gasket Remove the gasket Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 157 ...

Page 158: ... the cotters cap and spring CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS CAUTION DURING ASSEMBLY POSITION THE VALVE SPRINGS WITH THE GREEN COLOURED COIL FACING UPWARD Specific tooling 020382Y Valve fitting removal tool Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 158 ...

Page 159: ...on to the cyl inder crankcase alignment dowels CAUTION TO AVOID DAMAGING THE PISTON KEEP IT FIRM WHILE REMOVING THE CYLINDER N B IN ORDER NOT TO DAMAGE THE BASE GASKET WITH THE PISTON LOCK FORK 020426Y DURING THE MOUNT ING PHASE IT IS RECOMMENDED TO INSERT THE ALIGNMENT DOWELS OF THE CYLINDER CRANKCASE UNDER THE CYLINDER DURING THE ASSEMBLY Remove the base gasket Vespa Primavera125 150 i e 3Valvol...

Page 160: ...HAP 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 piston rings N B Engine Vespa Primavera125 150 i e 3Valvole...

Page 161: ...cylinder without any base gasket Assemble a dial gauge on the specific tool Specific tooling 020942Y Piston protrusion check tool With a contrasting surface reset the dial gauge with a preloading of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Fit the tool on the cylinder without changing the dial gauge position Lock the tool with the original head fixin...

Page 162: ... catego ries A B C and D and must be fitted so that the reference arrow faces the exhaust duct The letter is found at the centre of the piston Fit the sealing rings with the word TOP or the identification letter facing upwards In any case the step must be facing opposite the piston crown Sealing rings are manufactured with a cylinder contact conical cross section and piston gaps must be offset by ...

Page 163: ...ICATION DUCT AND LUBRICATE THE CYLINDER LINER Specific tooling 020426Y Piston fitting fork 020427Y Piston fitting ring Recommended products eni i Ride PG 5W 40 Synthetic based lubricant for high performance four stroke engines JASO MA MA2 API SL ACEA A3 Inspecting the cylinder head N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Vespa Prima...

Page 164: ...ve the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If signs of wear are found replace the whole as sembly 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 COUPLI...

Page 165: ... THAT MAY AFFECT THE MEAS UREMENTS Characteristic Valve clearance when cold intake 0 08 mm exhaust 0 08 mm 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 N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Vespa Pr...

Page 166: ... three valve seal rings alternately 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 KHÔNG ĐƯỢC THAY ĐỔI VỊ TRÍ VAN ĐÃ LẮP TẠI CHỖ KHỚP MÚT VAN CÓ MÀU QUY CHIẾU BÊN CHỐT HÃM XOAY VỚI BƯỚC LỚN HƠN Specific tooling 020382Y Valve fitting removal tool 020431Y Valve oil seal extractor Engine Vespa Primavera125...

Page 167: ...ad Refitting the head and timing system components Position the crankshaft to the TDC in compres sion Insert the head gasket and check the correct operation of the alignment dowels Insert the chain guide slider Insert the head Lubricate the stud bolt threads with engine oil Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 167 ...

Page 168: ...N ALWAYS USE A NEW HEAD GASKET UPON REFITTING Locking torques N m Cylinder head nut TIGHTENING 9 to 11 Tighten to the prescribed torque and then proceed with 270 0 5 0 rotation Screws fixing cylinder to crankcase 10 8 to 12 7 Refitting the rocker arms cover Remove the cylinder head cover and tighten the four clamping screws to the prescribed torque Pay attention to the integrity of rubber gaskets ...

Page 169: ...HE CRANKSHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS CAUTION GIỮ TRỤC KHUỶU NẰM Ở MỘT TRONG HAI NỬA CỦA VÁCH MÁY TRONG KHI TÁCH RỜI VÁCH MÁY NẾU THAO TÁC KHÔNG TỐT TRỤC KHUỶU CÓ THỂ RƠI Remove the gasket and be careful with the align ment dowels Inspecting the crankshaft components N B TO MEASURE W...

Page 170: ...the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase coupling gasket between 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...

Page 171: ...ial 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 Coupling chart N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Refitting the crankcase halves Follow the removal steps but in reverse order be careful to ...

Page 172: ...e Using specific tools to support the dial gauge verify that the fitting clearance is within the limits Higher clearances are signs of wear of the crankshaft crankcase supporting surfaces Characteristic Crankshaft crankcase axial clearance 0 2 to 0 5 mm Studs Using two nuts fitted as nut and lock nut type remove and then drive from the seat Proceed with a thorough cleaning of the threaded seat on ...

Page 173: ...e main bearings are lubricated and the big end with high pressure the piston pin and connecting rod small end via spray H Subsequently the oil arrives at the timing system where it lubricates the camshaft A and from this valves and rockers The oil passes through the timing chain duct and returns to the sump B by gravity In the system there is a minimal oil pressure sensor I and a spray that serves...

Page 174: ...n the engine once the measurement is complete Refit the oil pressure switch and washer tightening it to the prescribed torque and fit the flywheel cover If oil pressure reading are not within the specified limits check in the following order the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THIS CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FI...

Page 175: ...ew the three screws and remove them complete with the copper gaskets Using pliers remove the door by acting on the appendices Remove the spacer and the O ring Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 175 ...

Page 176: ... reverse order taking care to tighten to torque WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE WE RECOM MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH Locking torques N m Crankcase timing cover screws 11 13 Oil pump Engine Vespa Primavera125 150 i e 3Valvole 2013 ENG 176 ...

Page 177: ...he oil shield Preventing rotation unscrew the water pump command screw and collect the washer Remove the oil pump command sprocket com plete with chain Unscrew the two screws and remove the oil pump Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 177 ...

Page 178: ...e rotors in the position shown in the figure Check the distance between the outer rotor and 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 values 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 clearanc...

Page 179: ...BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY MAKE SURE THAT THE PUMP TURNS FREELY Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Screws fixing oil pump to crankcase 5 6 Preventing rotation tighten the water pump com mand screw complete with washer Vespa Primavera125 150 i e 3Valvole 2013 Engine ENG 179 ...

Page 180: ...e figure with the two rear brake transmission retainer brackets Remove the washers the spring and the by pass piston 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 Standard length 52 4 mm...

Page 181: ...ssion mounting brack ets and the screws in the reverse order from which they were removed Tighten the screws to the prescribed torque Refit the driving pulley assembly the drive belt the sprocket wheel and the transmission cover as described in the Transmission chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the connecting rod as ...

Page 182: ...INDEX OF TOPICS INJECTION INJEC ...

Page 183: ...m 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 petrol pump is controlled by th...

Page 184: ...carburetion Specific tooling 020922Y Diagnosis Tool The injection control unit has a decoder for the an ti theft immobilizer system The injection control unit is connected to a diag nostic LED on the instrument panel that also car ries out the deterrent flashing functions Precautions Troubleshooting tips 1 An injection system failure is more likely to be due to the connections than to the componen...

Page 185: ...e fault occurs again 4 For troubleshooting use a multimeter with an internal resistance of more than 10 K W V Improper instruments may damage the injection control unit The instruments to be preferred have a definition over 0 1V and 0 5 W and an accuracy over 2 1 Before repairing any part of the injection system check if any faults have been stored Do not dis connect the battery before checking fo...

Page 186: ...y if required 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 inje...

Page 187: ...y EMS circuit diagram KEY 1 Battery 4 Main fuse 5 Ignition switch 6 Secondary fuses 21 Starter relay coil 34 Roll over sensor 35 engine stop switch 36 Immobilizer LED 41 Injector 42 Idle valve 43 Engine speed sensor 44 Engine temperature sensor Vespa Primavera125 150 i e 3Valvole 2013 Injection INJEC 187 ...

Page 188: ...g Shielded cap HV Coil secondary insulation Parameter reliability Engine 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 HV coil Injector Engine speed timing sensor Air temperature Engine temper...

Page 189: ...ce Intake system seal seepage Intake manifold head Throttle body manifold Air cleaner joint Filter housing Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector flow 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 HV coil Injector Engine speed timing sensor Air temperatu...

Page 190: ...RMANCE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Idle speed adjustment device Intake system seal Air cleaner joint Filter housing Correctness of the parameters Throttle valve position sensor Idle speed adjustment device Engine temperature sensor Intake air temperature sensor Ignition system Spark plug wear check TPS reset succes...

Page 191: ...g Parameter reliability Throttle valve position signal Engine temperature signal Intake air temperature signal Ignition advance Intake system seal Air cleaner joint Filter housing TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector flow Fuel quality Selecting the thickness for the cylinder base gasket Selecting the thickness for the cylinder base gasket Fuel su...

Page 192: ...ng the injector Remove the helmet compartment Disconnect the connector from the injector Disconnect the quick release of the petrol deliv ery pipes Injection Vespa Primavera125 150 i e 3Valvole 2013 INJEC 192 ...

Page 193: ...t CAUTION DO NOT DISASSEMBLE THE INJECTOR COMPONENTS Refitting the injector For refitting perform the removal operations in re verse order and lubricate the sealing OR gasket with grease for internal application before fitting the injector on the manifold Vespa Primavera125 150 i e 3Valvole 2013 Injection INJEC 193 ...

Page 194: ...y can cause seri ous malfunction it must be observed that the pin of the spring is placed inside the recess in the in jector body as shown in figure Removing the butterfly valve Remove the throttle grip cables Remove the indicated screw Remove the clamp indicated in the photograph Injection Vespa Primavera125 150 i e 3Valvole 2013 INJEC 194 ...

Page 195: ...ucts Cleaner for throttle bodies Spray cleaner for throttle bodies Detergent for throttle bodies Refitting the butterfly valve To refit follow the operations but in reverse order every time the throttle position sensor is discon nected it is necessary to calibrate the self adjusting parameters Do not tamper with the stop screws under the throttle body CAUTION DO NOT TAMPER WITH THE STOP SCREWS UND...

Page 196: ...cific 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 2 5 BAR and that the input current is 1 4 to 1 8 A Injection Vespa Primavera125 150 i e 3Valvole 2013 INJEC 196 ...

Page 197: ...sing a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at approx 2 5 bar Check that within 15 seconds the pump has a flow rate of approx 110 cm Specific tooling 020480Y Fuel pressure check set Fuel filter check After removing from the tank disconnect the elec tric pump terminals Remove the screw indicated in the photograph Remove the clamp fixing the piping t...

Page 198: ... part of the pump support as shown in the photograph Remove the filter from the pump support Inspecting the injector circuit 1 Battery 2 Fuse No 1 3 Fuse no 4 Injection Vespa Primavera125 150 i e 3Valvole 2013 INJEC 198 ...

Page 199: ... bracket on the throttle body and from the clamp fixing it to the wiring Install the appropriate tool for checking fuel pres sure and position the manifold over a container graduated by at least 100 cm Connect the injec tor with the cable making up part of the supply for the injection tester Connect the clamps of the ca ble to an auxiliary battery Activate the fuel pump with the active diagnosis C...

Page 200: ...rom the injector Slight oozing is normal Value limit 1 drop per minute HT coil 1 Battery 2 Fuse No 1 3 Fuse no 4 4 Ignition switch 5 Fuse no 3 6 CDI control unit 7 Coil The combined ignition injection system is a high efficiency induction system The control unit manages two significant parameters Ignition advance Injection Vespa Primavera125 150 i e 3Valvole 2013 INJEC 200 ...

Page 201: ...egulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the related device and the variation of the ignition advance 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 assu...

Page 202: ... all steering positions and confirm the position at the diagnostics instrument Keep the throttle in a completely open position and confirm the position at the diagnostics instrument CAUTION DO NOT TAMPER WITH THE STOP SCREWS UNDER THE THROTTLE BODY AS THE IDLE SPEED IS ADJUSTED IN THE FACTORY Injection Vespa Primavera125 150 i e 3Valvole 2013 INJEC 202 ...

Page 203: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 204: ...to operations that can be carried out on the suspensions Front Removing the front wheel Support the vehicle adequately Loosen the five screws fixing the wheel to the hub Front wheel hub overhaul Support the vehicle adequately Remove the front wheel Remove the front brake calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub Remove the wheel hub Suspensions Ve...

Page 205: ...4 Calliper to extract 15 mm diame ter bearings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Remove the roller bearing using the specific tool Specific tooling 020376Y Adapter handle 020456Y Ø24 mm adaptor 020363Y 20 mm guide Vespa Primavera125 150 i e 3Valvole 2013 Suspensions SUSP 205 ...

Page 206: ...ler bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch Recommended products AGIP GREASE MU3 Yellow brown lithium base medium fibre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 To refit follow the removal steps but in reverse order be careful to tighten to the prescribed torque Locking torques N m Front wheel axle nut 75 to 90 Refi...

Page 207: ...FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS WARNING DO NOT LEAVE THE REMOVED INSTRUMENT DANGLING OR UPSIDE DOWN AS THIS COULD DAMAGE IT IRREP ARABLY FAILURE TO OBSERVE THIS INSTRUCTION CAUSES THE LOSS OF CALIBRATION OF THE INSTRU MENT PANEL WHICH ALTHOUGH OPERATIONAL INDI CATES INCORRECT VALUES Refitting Carry out the removal operations but in the reverse order observing the prescribed tighteni...

Page 208: ...E 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 ...

Page 209: ...ted on the steering tube 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 AGIP GREASE SM 2 Gray black smooth tex tured lithium grease containing molybdenum disulphid...

Page 210: ...stem and part 21 on the tool base as shown in the figure By moving the tool handgrip push the two NA DELLA bushings until their internal bottoms make contact with the pin end Use the tool fitted with parts 3 and 4 to fit the pin and press moving the tool handgrip until wedging the washers on the swinging hub Now remove the two spacers parts 17 and 16 and once the space between the NADELLAs steerin...

Page 211: ...er ring nut B to the specified torque Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Locking torques N m Lower steering ring nut 8 10 Upper steering ring nut 35 40 Front shock absorber Vespa Primavera125 150 i e 3Valvole 2013 Suspensions SUSP 211 ...

Page 212: ...e the wheel hub Remove the seeger indicated in the photograph Unscrew and remove the shock absorber lower retainer Remove the brake calliper shock absorber sup port Remove the two upper fixing screws Remove the front shock absorber Refitting To refit carry out the removal operations in reverse order observing the prescribed tightening torques Suspensions Vespa Primavera125 150 i e 3Valvole 2013 SU...

Page 213: ...ber calliper bracket Removal Unscrew the fixing screw of the shock absorber cover and remove the plastic by unscrewing it downwards Remove the swinging hub cover by disengaging the fittings Undo the indicated screw and remove the speed sensor Vespa Primavera125 150 i e 3Valvole 2013 Suspensions SUSP 213 ...

Page 214: ...aced after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Locking torques N m Lower shock absorber clamp 20 to 27 Overhaul Remove the two roller bearings from the bracket with the specific tool operating on the shock ab sorber attachment side as shown in the photo graph Specific tooling 0...

Page 215: ...tably hold the brake calliper shock absorber attachment bracket Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Spec...

Page 216: ...ues N m Speed sensor fastener screw 8 10 SPEED SENSOR MOUNTING Distance mm Calibration thickness number Y 4 7 5 1 Y 4 4 4 6 2 Y 4 3 4 1 3 Y 4 3 8 4 Y 3 7 3 5 5 Y 3 4 3 2 6 Steering bearing Removal Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis N B TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING...

Page 217: ...rom headstock Refit the fifth wheel fitting and the dust gaiter on the steering bearing until they stop using the spe cific tool Specific tooling 006029Y Punch for fitting steering bearing seat on steering tube Rear Removing the rear wheel Remove the silencer Remove the cotter pin and remove the cap Unscrew the nut fixing the wheel axle and collect the washer Vespa Primavera125 150 i e 3Valvole 20...

Page 218: ...escribed tor que Locking torques N m Locking torque 137 to 152 Nm Swing arm Removal Support the vehicle adequately Working on both sides remove the cover caps Working on the right side unscrew the side fixing nut to the chassis and collect the washer Suspensions Vespa Primavera125 150 i e 3Valvole 2013 SUSP 218 ...

Page 219: ...l from both sides Working on the right side unscrew the fixing nut Remove the fixing pin to the engine and collect the spacer Now the swinging arm is free Remove the swinging arm from the vehicle first release it from the engine side and then from the chassis side Overhaul Check that the silent blocks are in good conditions Vespa Primavera125 150 i e 3Valvole 2013 Suspensions SUSP 219 ...

Page 220: ...ng arm chassis pin 44 to 52 Engine swinging arm pin 40 to 45 Shock absorbers Removal Remove the helmet compartment Remove the four indicated screws then undo the fuel tank cap to remove the plastic cover Adequately support the rear part of the vehicle Undo the indicated upper fixing screw to the chassis Unscrew the lower fixing pin to the transmission crankcase Suspensions Vespa Primavera125 150 i...

Page 221: ...to 45 Centre stand REMOVAL Use a jack to support the vehicle properly Remove the two return springs from the centre stand Undo the fixing nut on the left hand side of the engine Remove the pin from the right side Remove the centre stand FITTING On refitting tighten the nut to the specified torque Locking torques N m Centre stand pin 40 to 45 Vespa Primavera125 150 i e 3Valvole 2013 Suspensions SUS...

Page 222: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 223: ...SHOULD IT BE NECESSARY TO REPLACE THE CALLIP ER FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER Refitting To fit the calliper follow the above operations but in reverse order Locking torques N m Screw tightening calliper to support 20 25 If the calliper was replaced bleed the system CAUTION ALWAYS USE NEW COPPER WASHERS CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM Locking...

Page 224: ...e five screws shown in the photo graph remove the brake disc Refitting Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it Tighten the 5 screws to the specified torque Locking torques N m Brake disc screws 6 0 5 1 Nm Braking system Vespa Primavera125 150 i e 3Valvole 2013 BRAK SYS 224 ...

Page 225: ...ne of the two front brake calliper attachment points Place the dial gauge on the disk outer edge Make the wheel hub turn and check the disk de viation Specific tooling 020335Y Dial gauge magnetic support Characteristic Standard thickness 4 0 2 0 2 mm Max deviation allowed 0 1 mm Front brake pads Removal Remove the brake calliper Undo the indicated screws and remove the brake pads Refitting Follow ...

Page 226: ...voir If necessary bleeding can be done using a special vacuum pump N B DURING THE BLEEDING OPERATIONS FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE...

Page 227: ...IN level N B THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN A MINIMUM LEVEL SHOULD NOT BE REACHED IF THE LEVEL IS TOO LOW CHECK AND FIX THE SYSTEM SEALS IF REQUIRED TOP UP THE PUMP RESERVOIR IF REQUIRED CONSIDERING THAT THE MAX LEVEL MUST ONLY BE OBTAINED WITH NEW PADS Under standard climatic conditions replace fluid as indicated in the scheduled maintenance table Front brake pump Removal Remo...

Page 228: ...ar drum brake Once the silencer and the wheel have been re moved follow these steps 1 Remove the shoe springs using the specific spanner 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mallet 4 Attach the springs using the specific pliers Specific tooling 020325Y Pliers for brake shoe springs Braking system Vespa Primavera125 150 i e 3Valvole 2013 BRAK SY...

Page 229: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 230: ...NIT OF MEASUREMENT EXPRESSED IN TERMS OF THE ANGLO SAXON SYSTEM SEE THE CHARACTERISTICS CHAPTER Seat Open the saddle Remove the helmet compartment Remove the four screws indicated Rear rack Remove the screw and then the indicated cover Remove the two screws indicated Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 230 ...

Page 231: ...nk cap to remove the plastic cover Rear handlebar cover Remove the upper handlebar cover Working on both sides undo the screw to remove the indicated plastic On both sides undo the two indicated screws to remove the control lock Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 231 ...

Page 232: ...move the upper handlebar cover Remove the four indicated screws fixing the in strument panel to the handlebar cover Front handlebar cover Remove the rear view mirrors Unscrew the indicated screw on both sides and the remove the headlight frame Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 232 ...

Page 233: ...nnect the indicated connector and remove the handlebar cover complete with instrument panel Headlight assy Remove the upper handlebar cover Disconnect the connector of the light assembly and remove the four indicated screws Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 233 ...

Page 234: ...emove the indicated screw Remove the bulb cover and take off the bulb Disconnect the connector Undo the indicated nut and remove the turn indi cator from the rear handlebar cover Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 234 ...

Page 235: ...d screws On both sides remove the rubber cap of the turn indicator cover and the indicated underlying screw By disengaging the fittings remove the leg shield back plate towards the rear part of the vehicle Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 235 ...

Page 236: ...e opening lever transmis sion and remove it from the leg shield back plate Taillight assy Operating from the left side of the vehicle undo the indicated toggle screw Remove the light assembly by disengaging the fittings and disconnecting the two connectors Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 236 ...

Page 237: ...bulb Remove the indicated nut disconnect the con nector and remove the turn indicator from the li cense plate holder License plate light Remove the licence plate light cover by unscrew ing the two indicated screws and disconnect the bulb holder Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 237 ...

Page 238: ...screws indicated On both sides of the vehicle unscrew the indica ted screw then remove the plastic and the under lying screw Working on both sides by disengaging the fittings remove the outermost rubber cover and then the underlying screw Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 238 ...

Page 239: ...ld frame By disengaging the fittings remove the footrest by extracting it upwards Remove the indicated plastic on both sides License plate holder Remove the indicated screw on both sides of the license plate holder Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 239 ...

Page 240: ...ndicated screws and disconnect the bulb holder Remove the two screws indicated Air filter Remove the helmet compartment Disconnect the air socket duct Remove the two indicated fixing screws at the crankcase Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 240 ...

Page 241: ...the rear wheel Undo the screw indicated Remove the two screws indicated Fuel tank Remove the helmet compartment Remove the four indicated screws then undo the fuel tank cap to remove the plastic cover Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 241 ...

Page 242: ...ear light unit and undo the indicated underlying screw Remove the fuel piping fixing screw indicated Remove the indicated screw Remove the clamp and slide off the indicated piping Chassis Vespa Primavera125 150 i e 3Valvole 2013 CHAS 242 ...

Page 243: ...d First remove the steering tube and uncouple the front brake pipes from the calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Vespa Primavera125 150 i e 3Valvole 2013 Chassis CHAS 243 ...

Page 244: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 245: ...ssis pin Engine swinging arm pin Engine arm pin Chassis arm Handlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system Battery Main switch Headlamps high beam lights low beam lights tail lights and their warning lights Headlight adjustment according to regulations in force Rear light brake light and license plate light Front and rear stop light switches ...

Page 246: ...PPROX 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 GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHILDREN C...

Page 247: ...SURES AS TYRES MAY BURST Functional inspection Functional Checks Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Proper general functioning and no abnormal noise check Others Check documentation Chassis and engine numbers check Tool kit License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possib...

Page 248: ...id 227 Bulbs C Checks 82 E Engine oil 42 F Fuel 191 197 241 Fuses 93 H Headlight 47 233 Horn 88 Hub oil 40 I Identification 8 Instrument panel 232 M Maintenance 7 38 O Oil filter 44 R Recommended products S Shock absorbers 220 Spark plug 39 Start up Suspension 54 T Tank 241 ...

Page 249: ...Transmission 10 53 124 136 Turn indicators 79 Tyres 11 V Vehicle 8 118 119 ...

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VESPA 150, Service Station Manual

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