VESPA PX 125 150 euro 2 Workshop Manual Download

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WORKSHOP MANUAL

633241

Vespa PX 125 150 Euro 2

Summary of Contents for PX 125 150 euro 2

Page 1: ...WORKSHOP MANUAL 633241 Vespa PX 125 150 Euro 2 ...

Page 2: ...WORKSHOP MANUAL Vespa PX 125 150 Euro 2 ...

Page 3: ... tools Refer to the pages of this manual concerning specific tools and equipment and the special tools 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: ...OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

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

Page 7: ...g dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and split pins upon refitting After removal clean the components using non flammable or low flash point solvents Lubricate all th...

Page 8: ... AND DIMENSIONS Specification Desc Quantity Empty weight 104 Kg Wheelbase 1235 mm Max height 1110 mm Max length 1760 mm Handlebars width 700 mm Engine ENGINE Specification Desc Quantity Engine type 2 stroke with rotary intake timing Characteristics Vespa PX 125 150 Euro 2 CHAR 8 ...

Page 9: ...cc 6 6 Kw 9 hp at 5 700 rpm Max speed 125 80 7 Km h Max speed 150 82 8 Km h Transmission TRANSMISSION Specification Desc Quantity Gear box 4 speed with constantly engaged gears Capacities CAPACITIES Specification Desc Quantity Gear box 250 cc Mixer oil tank 1 6 litres including 0 4 l reserve Fuel tank 8 litres including 2 1 l reserve Electrical system ELECTRICAL SYSTEM Specification Desc Quantity ...

Page 10: ...ont tyre pressure 1 3 bar Rear tyre pressure 1 8 bar 2 3 bar driver and passenger N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE REGU LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES Carburettor 125cc Version Dell Orto CARBURETTOR Specification Desc Quantity Type SI20 20D Diffuser diameter 20 mm Main jet 96 100 Slow running jet 45 100 Main air jet 140 100 Th...

Page 11: ...le 75 90 FRONT SUSPENSION Name Torque in Nm Shock absorber mounting plate steering column fixing nuts 20 27 Upper shock absorber fixing nut 30 40 Lower shock absorber fixing nut 20 27 Front wheel axle nut 60 100 FRONT BRAKE Name Torque in Nm Reservoir pipe fitting 8 12 Pipe calliper fitting 15 25 Intermediate pipe fitting 10 15 Calliper fixing screw 20 25 Disc fixing screw 5 6 Oil draining screw 1...

Page 12: ... ENSURE THE CORRECT TIGHTENING TORQUE LUBRICATE NUTS BEFORE AS SEMBLY NOTICE OF TECHNICAL SERVICING Tightening torque riding mirror This is to inform you that a standard tightening torque has been introduced for the riding mirror fixing screw 20 25 Nm Overhaul data Assembly clearances Cylinder piston assy The cylinder classification must be carried out at 25 mm from the head mating surface on the ...

Page 13: ...2 720 52 505 0 215 Cylinder piston 1st oversize F 52 725 52 510 0 215 Cylinder piston 1st oversize G 52 730 52 515 0 215 Cylinder piston 2nd oversize C 52 910 52 695 0 215 Cylinder piston 2nd oversize D 52 915 52 700 0 215 Cylinder piston 2nd oversize E 52 920 52 705 0 215 Cylinder piston 2nd oversize F 52 925 52 710 0 215 Cylinder piston 2nd oversize G 52 930 52 715 0 215 Cylinder piston 3rd over...

Page 14: ...er piston 1st oversize E 58 010 57 770 0 240 Cylinder piston 1st oversize F 58 015 57 775 0 240 Cylinder piston 1st oversize G 58 020 57 780 0 240 Cylinder piston 2nd oversize C 58 200 57 960 0 240 Cylinder piston 2nd oversize D 58 205 57 965 0 240 Cylinder piston 2nd oversize E 58 210 57 970 0 240 Cylinder piston 2nd oversize F 58 215 57 975 0 240 Cylinder piston 2nd oversize G 58 220 57 980 0 24...

Page 15: ...0 2 0 35 Piston ring 1st over size 52 7 A 0 2 0 35 Piston ring 2nd over size 52 9 A 0 2 0 35 Piston ring 3rd over size 53 1 A 0 2 0 35 PISTON RINGS 150CC ENGINE Name Description Dimensions Initials Quantity Piston ring 57 8 A 0 2 0 4 Piston ring 1st over size 58 A 0 2 0 4 Piston ring 2nd over size 58 2 A 0 2 0 4 Piston ring 3rd over size 58 4 A 0 2 0 4 Vespa PX 125 150 Euro 2 Characteristics CHAR ...

Page 16: ...AFT ON FLYWHEEL SIDE Name Description Dimensions Initials Quantity Connecting Rod B 15 6 0 1 0 2 F 0 05 0 41 Washer 2 G 0 5 0 05 0 03 F 0 05 0 41 Half crankshaft clutch side C 11 1 0 0 05 F 0 05 0 41 Half crankshaft fly wheel side D 11 1 0 0 05 F 0 05 0 41 Spacer tool H 38 95 Connecting rods and roller cages are subdivided into 4 categories indicated by markings on big end and outer cage rim respe...

Page 17: ...AY TO CHECK THE CLEARANCE USE A FEELER GAUGE Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP GEAR 80W 90 gearbox oil SAE 80W 90 oil complying with API GL4 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brake throttle control and mixer odom eter Oil for 2 stroke engines SAE 5W 40 API SL ACEA A3 JASO MA AGIP GP 330 Grease brake level throttl...

Page 18: ...INDEX OF TOPICS TOOLING TOOL ...

Page 19: ...emoving fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 002850y Oil tank spanner 002973y Fuel tap spanner 020320Y Exhaust gases analyser Vespa PX 125 150 Euro 2 Tooling TOOL 19 ...

Page 20: ...ription 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter Tooling Vespa PX 125 150 Euro 2 TOOL 20 ...

Page 21: ...res code Description 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 001330Y Tool for fitting steering seats Vespa PX 125 150 Euro 2 Tooling TOOL 21 ...

Page 22: ...ice tool 020321y Carburettor float removing tool 006029Y Punch for fitting fifth wheel seat on steer ing tube 020625Y Kit for sampling gas from the exhaust manifold 001467Y021 Extraction pliers for ø 11 mm bearings Tooling Vespa PX 125 150 Euro 2 TOOL 22 ...

Page 23: ...0151Y Air heater 020150Y Air heater support 020057Y Calking tool 020095Y Flywheel retaining tool 008564Y Flywheel extractor 008886Y Crankshaft extractor 004499Y Camshaft bearing extractor Vespa PX 125 150 Euro 2 Tooling TOOL 23 ...

Page 24: ...Y Bearing fitting base 060007Y Crankcase bearing spacer 060824Y Inspection probe 008119Y009 Tube to assemble shafts and axles 001729Y Clutch retaining tool 020322Y Clutch removing fitting tool Tooling Vespa PX 125 150 Euro 2 TOOL 24 ...

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

Page 26: ...ar Check Vehicle and brake test road test Secondary air filter external internal Clean AT 10000 KM O 24 MONTHS Action Gear box oil level replacement Spark plug replacement Air filter on carburetor Clean Idle speed adjustment Transmission gas mixer adjust Odometer gear greasing Steering adjustment Brake and clutch lever greasing Brake pads check condition and wear Brake fluid level check Transmissi...

Page 27: ...lean See regulations in section Idling speed adjustement AT 25000 KM Action Gear box oil level check Spark plug replacement Air filter on carburetor Clean Transmission gas mixer adjust Brake and clutch lever greasing Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyres condition and wear Check Vehicle and brake test road test Secondary air filter ex...

Page 28: ...on elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment check Tyres condition and wear Check Vehicle and brake test road test Secondary air filter external internal Clean See regulations in section Idling speed adjustement AT 45000 KM Action Gear box oil level check Spark plug replacement Air filter on carburetor Clean Transmission gas ...

Page 29: ...hicle and brake test road test Secondary air filter external internal Clean AT 60000 KM Action Gear box oil level replacement Spark plug replacement Air filter on carburetor Clean Idle speed adjustment Cylinder cooling system check cleaning Transmission gas mixer adjust Odometer gear greasing Steering adjustment Brake and clutch lever greasing Brake pads check condition and wear Flexible brake lin...

Page 30: ...esc Quantity Conical needle Float Emulsifier air adjusting screw Emulsifier Main jet Slow running jet Fuel flow adjusting screw Throttle valve adjusting screw Throttle valve Starter jet Choke device Checking the spark advance In order to ensure the correct timing check the stator is oriented so that the I T index see figure coincides with the marking found on the crank case To check the timing use...

Page 31: ... washer is in good state Refit the spark plug by screwing it in by hand and tightening it at the prescribed torque using a box spanner Electric characteristic Spark plug CHAMPION RL82C Spark gap 0 5 0 6 mm Locking torques N m Spark plug 25 30 Nm Air filter Remove the engine cowling and the air box cov er by loosening the four fixing screws shown in the figure and the idle adjusting screw hence rel...

Page 32: ... 10 3 If otherwise adjust the right headlight with screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED CO check The test must be carried out after carefully clean ing all carburettor components and air filter and with the spark plug in good ...

Page 33: ...own in the figure Start the engine adjust the idle speed to 1 300 100 rpm and check the CO readings are equal to 4 1 with the idle air adjusting screw opened by 2 turns If the parameters here specified cannot be met try adjusting the idle air adjusting screw Other wise check the choke device Specific tooling 020320Y Exhaust gases analyser 020332Y Digital rev counter 020625Y Kit for sampling gas fr...

Page 34: ... O ring located on the cover Remove the sponge and wash it with soap and water Dry it with compressed air before refitting Gearbox Oil Check for the presence of oil inside the gearbox oil capacity 250 g with the vehicle axis perfectly vertical the oil level must be at the height of in spection hole A To replace the oil drain the box using filler hole B Pour some fresh oil and let the engine run fo...

Page 35: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 36: ...switch 3 Enable button 4 Indicators switch 5 Front headlight 6 Instrument panel lighting bulb 12V 1 2W 7 Turn signal warning light 12V 1 2W 8 Reserve fuel light 12V 1 2W 9 Headlamp warning light 12V 1 2W 10 High beam warning light 12V 1 2W 11 Instrument panel 12 Headlight switch 13 Start up button 14 Horn 15 Stop light switch front brake Electrical system Vespa PX 125 150 Euro 2 ELE SYS 36 ...

Page 37: ...vel sender 20 Magneto flywheel 21 Electronic ignition device 22 Rear RHS turn signal light 23 Starter motor 24 Taillight 25 Starter relay 26 Rear LHS turn signal light 27 Battery 12V 9Ah 28 Fuse box 29 Voltage regulator 30 Turn signals master box Components arrangement Vespa PX 125 150 Euro 2 Electrical system ELE SYS 37 ...

Page 38: ...g device 8 Spark plug 9 Remote starter switch 10 Fuse 7 5 A 11 Horn 12 Turn signals master box 13 Front headlight 14 Front turn signal lights 15 Taillight 16 Rear turn signal lights Conceptual diagrams Ignition IGNITION Specification Desc Quantity 1 Magneto flywheel 2 Key switch contacts 3 Electronic Control Unit C D I with H T coil 4 Spark plug Electrical system Vespa PX 125 150 Euro 2 ELE SYS 38...

Page 39: ...lator 2 Magneto flywheel 3 Key switch contacts 4 Headlight bulb 12V 35 35W 5 High beam warning light 12V 1 2W 6 Light switch 7 Headlight switch 8 Rear side light bulb 12V 5W 9 Front side light bulb 12V 5W 10 Headlamp warning light 12V 1 2W Vespa PX 125 150 Euro 2 Electrical system ELE SYS 39 ...

Page 40: ...n Desc Quantity 1 Magneto flywheel 2 To services 3 Key switch contacts 4 Voltage regulator 5 Fuse 7 5 A 6 Remote starter switch 7 Starter motor 8 Battery 12V 9Ah 9 Enable button 10 Start up button 11 Anti repeating device Electrical system Vespa PX 125 150 Euro 2 ELE SYS 40 ...

Page 41: ...SAFETY SWITCHES AND LEVEL GAUGES Specification Desc Quantity 1 Fuel gauge 2 Fuel level sender 3 Reserve fuel light 12V 1 2W 4 Brake light bulbs 12V 10W 5 Stoplight switches 6 Voltage regulator Vespa PX 125 150 Euro 2 Electrical system ELE SYS 41 ...

Page 42: ...RN Specification Desc Quantity 1 Turn signals master box 2 Indicators switch 3 Turn signal warning light 12V 1 2W 4 Turn signal light bulbs 12V 21W 5 Horn button 6 Horn 7 Voltage regulator Electrical system Vespa PX 125 150 Euro 2 ELE SYS 42 ...

Page 43: ... Ground lead Checks and inspections Ignition circuit All system checks requiring the detachment of ca bles inspections involving ignition system wiring and devices must be carried out with the engine off so to avoid any possible damage to the ECU which would require its replacement It is therefore important to follow the wire colour coding when reattaching the cables see figure Vespa PX 125 150 Eu...

Page 44: ... attributed to a defective CDI device In the event that the ignition system is still mal functioning it will be necessary to check the gen erator and the stator components as follows After an eye inspection of the connections per form measurements on recharge coil and pick up see table using the specified tester If such read ings do not match the stated values proceed by replacing the stator and i...

Page 45: ...of a reg ulator voltage exceeding 15V replace the regula tor as definitely faulty FAULT 2 a Check the correct current supply from the alter nator detach the regulator connector and attach the alternate current tester between the grey blue wire terminal and earth With the tester set onto alternate current check the supplied voltage at 3 000 rpm is between 25 and 30V b If no faults are found replace...

Page 46: ... this measurement must obvi ously be carried out with the battery disconnec ted Specific tooling 020331Y Digital multimeter Starter motor Bench tests to be performed on the electric starter motor 1 No load test the starter motor unloaded must absorb less than 10 A with a voltage supply 11 7 V and must spin at more than 18 000 rpm 2 Load test load the starter motor so that the absorbed current is e...

Page 47: ...ted on the LHS of the battery tray Before replacing a burst fuse it is necessary to find the cause of the failure Never attempt to close the circuit with any material other than the fuse CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE CAUTION MODIFICATIONS OR REPAIRS TO THE EL...

Page 48: ...nding to that capacity Otherwise charge the battery with direct current equal to 1 10 of rated capacity e g for a battery with a 9Ah rated capacity the charging current should be 0 9 1 0A for approximately a 4 6 hour charge Note Batteries that have been stored for a long time may take a longer charging time The battery chargers drw 020333Y and drw 020334Y have an automatic protection which interru...

Page 49: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 50: ...the engine from the vehicle Remove the exhaust assy Remove the rear wheel Detach the rear brake cable Detach the electrical wires Detach the gear shifter cables Remove the throttle and choke cables Detach the oil and petrol hoses Remove the engine frame bolt shown in the fig ure Engine from vehicle Vespa PX 125 150 Euro 2 ENG VE 50 ...

Page 51: ...bed tightening torques CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSI TIVE LEAD FIRST AND THEN THE NEGATIVE LEAD WARNING Wear safety goggles when using hitting tools WARNING Be very careful when handling fuel Locking torques N m Engine frame bolt 61 75 Shock absorber engine bolt 13 23 Vespa PX 125 150 Euro 2 Engine from vehicle ENG VE 51 ...

Page 52: ...INDEX OF TOPICS ENGINE ENG ...

Page 53: ...cooling hood Remove the fixing screws shown and hence de tach the volute and the gear shifter cover Remove the kick start lever after having detach ed the lower fastener Removing the stator Remove the three screws shown in the figure Remove the stator Vespa PX 125 150 Euro 2 Engine ENG 53 ...

Page 54: ...emove the two screws and detach the drive box from the starter motor With the aid of a hacksaw abrade the pinion head ring Using two screwdrivers detach the cap Remove the retaining ring shown by the arrow in the figure and remove the pinion components WARNING THE PACKING ON THE MATING SURFACE MUST AL WAYS BE REPLACED WITH A NEW ONE USING LOC TITE Engine Vespa PX 125 150 Euro 2 ENG 54 ...

Page 55: ... with the air heater refit the drive shaft with all the components previ ously removed Refit the remaining components following the above operations in the reverse order Specific tooling 001467Y Extractor for bearings for holes 001467Y021 Extraction pliers for ø 11 mm bear ings 020151Y Air heater 020150Y Air heater support Position a new cap onto the pinion and round the edges using the special to...

Page 56: ...er detach the drive gear retaining pin and remove the gear Refit the assembly components in the reverse order Removing the flywheel magneto Retain the flywheel using the special tool hence remove the lock nut Specific tooling 020095Y Flywheel retaining tool Remove the flywheel retaining tool Extract the flywheel using the special extractor Specific tooling 008564Y Flywheel extractor Engine Vespa P...

Page 57: ...s and fay ing surface of driven pulley spring only pulley side Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 Locking torques N m Flywheel fixing nut 60 65 Cylinder assy and timing system Removing the cylinder head Loosen the four nuts and remove the cylinder head Removing the cylinder piston assy After removing the cylinder detach the wrist pin re taining rings and hence...

Page 58: ...particular attention to positioning the piston with the arrow marking on the crown pointing toward the exhaust port Locking torques N m Head fixing nuts 16 26 Crankcase crankshaft Splitting the crankcase halves Remove the twelve fasteners and split the two crankcase halves carefully using a plastic or hard rubber mallet CAUTION WITH A RUBBER BAND TIE THE CONNECTING ROD TO THE TWO STUDS ON THE CLUT...

Page 59: ...r inter nal split rings remove the bearing retaining ring shown From the side opposite that shown in the figure and with the aid of a flat head puncher extract the bearing Using the special extractor remove the roller bearing from the crankshaft Specific tooling 004499Y Camshaft bearing extractor Using the special extractor remove the roller bearing from the crankcase Vespa PX 125 150 Euro 2 Engin...

Page 60: ...s already done for the clutch side half crankcase focusing exclusively on the bearing housing Position the bearing using a length of tube push ing directly on the bearing s outer ring Position the crankshaft onto the special support Install the special spacer as shown in the figure and using a length of tube of adequate diameter push the bearing until the inner ring heated up in oil at 120 C comes...

Page 61: ...hrottle opening Important whenever the mixer device has been removed overhauled or refitted there may be no oil inside the ducts To allow the mixer to safely fill these ducts with oil it is suggested that the fuel tank 1 in the figure is first refilled with approx 3 l of mixture containing 2 of SELENIA HI SCOOTER 2T oil Once this first quantitative has been exhausted any further refill must obviou...

Page 62: ...ap Oil tank filler cap Oil level gauge SEPARATE LUBRICATION device box Oil inlet hose Oil outlet hose Oil outlet valve A Inlet phase B Outlet phase Oil pump Remove the carburettor box Remove the mixer drive shaft from its housing Engine Vespa PX 125 150 Euro 2 ENG 62 ...

Page 63: ...en use pli ers for internal split rings to remove the mixer body Refit the components following the removal pro cedure in the reverse order paying attention in positioning the pump body correctly in its housing so to be able to easily insert the retaining screw See also Removing the carburettor Vespa PX 125 150 Euro 2 Engine ENG 63 ...

Page 64: ...crews and the carburet tor cover Remove the fasteners and the air filter After removing the air filter loosen the two 8mm Allen screws and hence remove the carburettor Loosen the fixing screw and remove the carbu rettor body Engine Vespa PX 125 150 Euro 2 ENG 64 ...

Page 65: ...blow with compressed air Loosen the fixing screw and remove the float bowl Remove the starter jet and blow with com pressed air Remove the float pin to release the float and hence the conical needle Vespa PX 125 150 Euro 2 Engine ENG 65 ...

Page 66: ...ING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS Manual Gear Shifter Remove the fasteners and the gear shifter From the side opposite to that shown in the figure and with the aid of a puncher remove the conical pin and extract the gear shifting lever Engine Vespa PX 125 150 Euro 2 ENG 66 ...

Page 67: ...extract the gears Using a plastic mallet remove the shaft Remove the multiple gear shaft lock nut Remove the multiple gear shaft using a mallet from the side opposite to that shown in the figure Do not let the 21 rollers composing the bearing fall onto the ground Vespa PX 125 150 Euro 2 Engine ENG 67 ...

Page 68: ...e opposite to that shown in the figure After removing the retaining washer shown in the figure remove the fastener underneath it hence extract the even tension gear Remove the rivet head and replace any faulty component Refit the components using new rivets Replace the trunnion if worn CAUTION THE TRUNNION BUSHING HAS A LHS THREAD Locking torques N m Gear box trunnion 15 18 Engine Vespa PX 125 150...

Page 69: ...21 rollers using the recommended grease to keep them in place during the reassem bly With the refitting operation concluded tighten the shaft lock nut to the prescribed torque Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Locking torques N m Multi gear pinion nut 30 35 Before proceeding by refitting the...

Page 70: ...g the gear shaft Specific tooling 008119Y009 Tube to assemble shafts and axles See also Splitting the crankcase halves Clutch Remove the 3 fixing screws and the clutch cover With the aid of a screwdriver remove the bal ance screw Engine Vespa PX 125 150 Euro 2 ENG 70 ...

Page 71: ...729Y Clutch retaining tool Remove the mixer drive gear from its housing Using the special tool remove the clutch discs Specific tooling 020322Y Clutch removing fitting tool Check the conditions of all components and the camber of the metal discs A camber smaller than the prescribed one may cause slippage Refit the clutch assembly components inverting the order followed for the disassembly Vespa PX...

Page 72: ...efit the clutch assembly onto the engine and tighten the locknut using the special retainer Refit the remaining components in following the procedures carried out from their removal in the reverse order Specific tooling 001729Y Clutch retaining tool Locking torques N m Clutch assy fixing nut 40 45 Engine Vespa PX 125 150 Euro 2 ENG 72 ...

Page 73: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 74: ... the outer side of the wheel hub and the seal ring remove the bear ing using a length of pipe of adequate diameter and a mallet as shown in the figure Follow the same procedure to remove the roller cage on the opposite side Handlebar Removal Remove the 2 rear view mirrors and their fixing ring nuts Remove the handlebar cover as described in the Bodywork chapter and the speedometer Suspensions Vesp...

Page 75: ...lumn Removal After removing the top housing lean the vehicle on one side and extract the steering column mak ing sure of having removed the brake calliper Specific tooling 020055Y Wrench for steering tube ring nut Overhaul To remove the bearing housings from the frame use the special tool shown in the figure Specific tooling 020004Y Punch for removing fifth wheels from headstock Vespa PX 125 150 E...

Page 76: ...h connect the steering tube to the front wheel holder swinging hub N B BEFORE PROCEEDING WITH THE DESCRIBED SERVICE CHECK THAT THE STEERING TUBE AND THE WHEEL HOLDER HUB ARE IN EXCELLENT CONDITIONS ONLY THEN IS THE SERVICE JUSTIFIABLE MOREOVER REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE WHEN DEFORMED a Ø 12 Punch b Sharp edged end Use a suitable punch with the dimensions indica te...

Page 77: ...nt suspension service tool Connect the swinging hub to the steering tube with the guiding pin Use the tool fitted with part 3 on the stem and part 4 Lubricate the pin with recommended grease and insert it temporarily on the swinging hub move the tool handgrip until part 3 is fully inserted on the steering tube After fitting the pin insert the two spacers slightly hitting them with the mallet N B B...

Page 78: ... THE SEALING RINGS IN MINERAL OIL AND THE NADELLA ROLLER BUSHINGS PREVIOUSLY WASHED IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMI NATE THE ANTIRUST PROTECTION HALF FILLED WITH GREASE Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Use the tool fitted w...

Page 79: ... L XBCHA3 DIN K3K 20 Refitting Grease bearings and housings Tighten to the prescribed torque and rotate the spanner in an anti clockwise direction by 80 90 Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GP 330 Grease brake level throttle twist grip gaer Calcium complex soap grease NLGI 2 ISO L XBCIB2 Locking torques N m Top steering housing 6 7 hence loosen by...

Page 80: ...ove the split ring shown in the figure Remove the two shock absorber fixing screw and the odo speedometer cable holder Extract the bracket from the axle using a rubber mallet Overhaul In the event of grease leaks through the wheel hub the cause may be found in the sealing ring fitted onto the calliper bracket After removing the wheel hub extract the ring shown in the figure and replace it with a n...

Page 81: ...steners at the prescribed torque following a crosswise sequence Locking torques N m Rim hub fixing nuts front rear 20 27 Shock absorbers Removal For the rear shock absorber replacement it is nec essary to remove the engine shock absorber fixing bolt as shown in the figure Remove the gasoline and oil tanks then remove the shock absorber upper fixing in the underseat compartment housing Vespa PX 125...

Page 82: ...Centre stand Detach the return spring from the centre stand re move the 4 fasteners shown in the figure Suspensions Vespa PX 125 150 Euro 2 SUSP 82 ...

Page 83: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 84: ... ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE LUBRICATE NUTS BEFORE AS SEMBLY Locking torques N m Pipe calliper fitting 15 25 Calliper fixing screw 20 25 Front brake disc Removal Remove the rear wheel by loosening the 5 fas teners Remove the wheel hub Loosen the 5 disc fasteners Refitting When refitting correctly position the disc observing the direction of rotation see figure and apply medium th...

Page 85: ...em is not solved check and if neces sary replace the wheel hub Specific tooling 020335Y Magnetic support for dial gauge Front brake pads Removal To facilitate this operation it is suggested that the front wheel is removed remove the plastic cap and apply leverage with a screwdriver Remove the external split ring from the pin the spring and the pads themselves The pads must be replaced if the thick...

Page 86: ...HE PUMP WARNING THE BRAKE FLUID IS HYGROSCOPIC I E IT ABSORBS HUMIDITY FROM THE AIR IF THE HU MIDITY LEVEL IN THE FLUID EXCEEDS A GIVEN VALUE THE BRAKING PERFORMANCES MAY SERIOUSLY DETERIORATE IT IS THEREFORE RECOMMENDED THAT FRESH FLUID IS TAKEN FROM NEW CONTAINERS IN NORMAL CLIMATIC CONDITIONS THE FLUID SHOULD BE RE PLACED EVERY TWO YEARS IF THE BRAKES ARE HIGHLY STRESSED INCREASE THE FREQUENCY ...

Page 87: ...iner Refitting For refitting perform the operation in the reverse order Tighten the pipe to the prescribed torque and bleed the circuit Locking torques N m Reservoir pipe fitting 8 12 Rear drum brake Remove the rear wheel Straighten the splint pin and remove the lock nut Vespa PX 125 150 Euro 2 Braking system BRAK SYS 87 ...

Page 88: ...escribed torque WARNING ALWAYS USE NEW SPLIT PINS FOR REFITTING WARNING FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN OR DER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE Locking torques N m Wheel axle nut 90 110 Rear Brake Pedal After loosening the brake fixing on the rear wheel remove the 3 fasteners indicate in the figure Remove the rubber from the pedal and detach the electrical wiring A...

Page 89: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 90: ...peedometer cable to replace the dashboard assembly Once the handlebar is removed act upon the two lips on the dashboard Headlight assy After removing the handlebar cover remove the 2 fasteners show in the figure and the headlight ad justing screw underneath the handlebar Detach the wirings To replace the bulbs simply release the springs holding back the socket and replace any blown bulb Chassis Ve...

Page 91: ...the lock body and the new master cylinder on the outer lock body are as follows Carefully clean the body from any impurity if the cylinder has been drilled using compressed air Position the body in its housing after fitting the retaining spring E Insert the cylinder assembly with key and tongue F facing downwards halfway inside the lock body ensuring that during this operation they is in the ON po...

Page 92: ...k Should it be necessary to replace the steering lock cylinder when the keys have gone missing pro ceed as follows Cylinder removal in the event that the key switch is in the LOCK position it is necessary to pro ceed by drilling the cylinder with the aid of a Ø8 mm at least 30 mm long this allows to release or destroy the internal retaining device of the drilled cylinder Hence extract the body and...

Page 93: ...h the fuel tap shut to separate the fuel oil tanks Remove the tank filler cap and insert the special tool through the tube Proceed by loosening the nut and the acting upon ring B until releasing the oil tank Specific tooling 020321y Carburettor float removing tool 002850y Oil tank spanner 002973y Fuel tap spanner Remove the tank filler cap and insert the spanner thus loosening nut D hence extract ...

Page 94: ...removing the handlebar and the steering column assembly remove the 3 fasteners shown in the figure Top case Front Remove the 2 fixings shown in the figure and the 2 top fasteners from inside the glove box Remove the glove box assembly Chassis Vespa PX 125 150 Euro 2 CHAS 94 ...

Page 95: ... steering column cover remove the horn and the grid fixings Replace the grid Side Cowlings Lift the seat and act upon either one of the two lever according to which cowling must be re moved RHS or LHS Vespa PX 125 150 Euro 2 Chassis CHAS 95 ...

Page 96: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 97: ...RE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE WARNING BEFORE RECHARGING THE BATTERY REMOVE THE CAPS OF EACH CELL KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED REMOVE THE BATTERY FROM THE SCOOTER DISCONNECTING THE NEGATIVE TERMINAL FIRST CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRS...

Page 98: ...tank Road test Cold start Speedometer check Throttle check Riding stability Front and rear brake efficiency Front and rear shock absorbers Unusual noises Hot engine restart Leakages after trial run Functional inspection Brake lever excursion Throttle excursion and adjustment Homogeneous steering turning Other Tyre pressure All locks Rear view mirrors and accessory fitting Tooling kit owner manual ...

Page 99: ...INDEX OF TOPICS TIME TIME ...

Page 100: ...Engine ENGINE Code Action Duration 1 001001 Engine from the frame removal and refitting 2 003064 Engine oil replacement 3 003057 Engine retainer Tighten nuts Time Vespa PX 125 150 Euro 2 TIME 100 ...

Page 101: ...KCASE BEARINGS Code Action Duration 1 001117 Crankshaft Replacement 2 001118 Crankcase bearings Replacement 3 001099 Oil seal flywheel side Replacement 4 001100 Clutch side oil seal Replacement Vespa PX 125 150 Euro 2 Time TIME 101 ...

Page 102: ...YLINDER ASSY Code Action Duration 1 001002 Cylinder piston Replacement 2 001107 Cylinder Piston Overhaul Cleaning 3 001093 Spark plug Replacement 4 001094 Spark plug cap Replacement Time Vespa PX 125 150 Euro 2 TIME 102 ...

Page 103: ...Flywheel cover FAN COVER Code Action Duration 1 001087 Flywheel cover Replacement Vespa PX 125 150 Euro 2 Time TIME 103 ...

Page 104: ...18 Mixer Replacement 2 001028 Oil pump drive shaft Replacement Starter motor STARTER MOTOR Code Action Duration 1 001020 Starter motor change 2 001039 Starter motor brushes Replacement 3 001038 Starter motor Overhaul Time Vespa PX 125 150 Euro 2 TIME 104 ...

Page 105: ... Starter motor shaft Replacement KICK START LEVER Code Action Duration 1 008008 Kick starter gear spring Replace ment 2 001120 Crankcase bearings Replacements 3 001084 Starter lever Replacement Vespa PX 125 150 Euro 2 Time TIME 105 ...

Page 106: ...YWHEEL MAGNETO Code Action Duration 1 001067 Stator Removal and refitting 2 001004 Stator Overhaul 3 001058 Flywheel Replacement 4 001059 Pick up Replacement 5 003052 Ignition timing Time Vespa PX 125 150 Euro 2 TIME 106 ...

Page 107: ...Carburettor CARBURETTOR Code Action Duration 1 001063 Carburettor Replacement 2 001008 Carburatore Revisione 3 003058 Carburettor Adjustment Vespa PX 125 150 Euro 2 Time TIME 107 ...

Page 108: ...Exhaust pipe EXHAUST PIPE Code Action Duration 1 001009 Exhaust pipe Replacement Time Vespa PX 125 150 Euro 2 TIME 108 ...

Page 109: ...Air cleaner AIR CLEANER Code Action Duration 1 001014 Air filter Replacement 2 001027 Air cleaner frame bellow Replace ment Vespa PX 125 150 Euro 2 Time TIME 109 ...

Page 110: ...Frame FRAME Code Action Duration 1 004001 Frame Replacement 2 006001 Frame Painting 3 004023 Shield rim Replacement Time Vespa PX 125 150 Euro 2 TIME 110 ...

Page 111: ...Centre stand CENTRE STAND Code Action Duration 1 004004 Centre stand Replacement Legshield spoiler Vespa PX 125 150 Euro 2 Time TIME 111 ...

Page 112: ...OLUMN FAIRING Code Action Duration 1 004024 Steering column fairing Replace ment Side fairings SIDE FAIRING LOCKS Code Action Duration 1 004025 Side fairing locks Replacement Time Vespa PX 125 150 Euro 2 TIME 112 ...

Page 113: ...WHEEL SIDE FAIRINGS Code Action Duration 1 006005 Side fairings Painting Footrests Vespa PX 125 150 Euro 2 Time TIME 113 ...

Page 114: ...tion Duration 1 004015 Footrests Replacement Rear cover GLOVE BOX Code Action Duration 1 004083 Glove box Replacement 2 006019 Glove box Painting 3 004081 Glove box door Replacement Time Vespa PX 125 150 Euro 2 TIME 114 ...

Page 115: ...Mudguard FRONT MUDGUARD Code Action Duration 1 004002 Front mudguard Replacement 2 006003 Mudguard Painting 3 003045 Steering tube Replacement Vespa PX 125 150 Euro 2 Time TIME 115 ...

Page 116: ...Fuel tank FUEL LEVEL SENSOR Code Action Duration 1 005010 Fuel tank float Replacement Time Vespa PX 125 150 Euro 2 TIME 116 ...

Page 117: ... 1 004005 Fuel tank Replacement 2 004007 Fuel tap Replacement 3 004110 Fuel tank hose Replacement 4 006024 Fuel tank Painting Tank oil OIL TANK Code Action Duration 1 004017 Oil tank Replacement Vespa PX 125 150 Euro 2 Time TIME 117 ...

Page 118: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and refitting Time Vespa PX 125 150 Euro 2 TIME 118 ...

Page 119: ...arings Replacement 2 004119 Steering support bearing Replace ment 3 003073 Steering play Adjustment 4 004010 Steering lock Replacement Handlebar components HANDLEBAR COMPONENTS AND BRAKE FLUID PUMP Code Action Duration 1 002059 RHS twist grip Replacement Vespa PX 125 150 Euro 2 Time TIME 119 ...

Page 120: ...ment and circuit bleeding 4 002021 Front brake hose Removal and re fitting GEAR SHIFTER TWIST GRIP Code Action Duration 1 005062 Neutral switch Replacement 2 002071 Left hand grip Replacement 3 002037 Brake or clutch lever Replacement 4 001035 Clutch lever Replacement Time Vespa PX 125 150 Euro 2 TIME 120 ...

Page 121: ...Seat SEAT Code Action Duration 1 004003 Saddle Replacement 2 004054 Saddle lock catch Replacement Vespa PX 125 150 Euro 2 Time TIME 121 ...

Page 122: ...Dashboard warning telltale lights Replacement 2 005014 Odometer Replacement 3 006010 Top handlebar cover Painting 4 004066 Rear view mirror Replacement 5 003001 Top handlebar cover Removal and Refitting 6 006011 Lower handlebar cover Painting Time Vespa PX 125 150 Euro 2 TIME 122 ...

Page 123: ...Turn signal lights TAILLIGHT Code Action Duration 1 005066 Rear light bulbs Replacement 2 005005 Taillight change 3 005028 Rear light assembly glass Replace ment Vespa PX 125 150 Euro 2 Time TIME 123 ...

Page 124: ...ion 1 005011 Starter relay Replacement 2 005012 Front turn signal light Replacement 3 005067 Front turn indicator bulb Replace ment 4 005068 Rear turn indicator bulb Replace ment 5 005022 Rear turn signal light Replacement 6 005006 Turn signals switch Replacement 7 005039 Headlight switch Replacement Time Vespa PX 125 150 Euro 2 TIME 124 ...

Page 125: ...note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mistake the codes 002011 movement sen sor replacement and 005089 tone wheel replace ment in the event of noise of the indicated components The grease recommended is TUTE LA MRM 2 soap based lithium grease with Mo lybdenum disulphide In the following points we indicate with an arrow the area to be greased 1 Drive 2 To...

Page 126: ...Electric devices ELECTRICAL DEVICES Code Action Duration 1 005024 Battery fuse Replacement 2 005025 Battery fuse holder Replacement Time Vespa PX 125 150 Euro 2 TIME 126 ...

Page 127: ...BATTERY VOLTAGE REGULATOR Code Action Duration 1 005009 Voltage regulator Replacement 2 005007 Battery Replacement 3 004071 Battery compartment Replacement Vespa PX 125 150 Euro 2 Time TIME 127 ...

Page 128: ...tion Duration 1 005001 Electric circuit Replacement and Refitting ELECTRICAL DEVICES Code Action Duration 1 005013 Electronic blinker Replacement 2 005045 Starter motor wire harness Re placement Time Vespa PX 125 150 Euro 2 TIME 128 ...

Page 129: ...ELECTRICAL DEVICES Code Action Duration 1 005003 Horn Replacement 2 005017 Stop light switch Replacement 3 005069 Left switch Replacement Vespa PX 125 150 Euro 2 Time TIME 129 ...

Page 130: ...CABLES Code Action Duration 1 002008 Choke cable Replacement 2 002056 Gear shifter cable assy Replace ment 3 002051 Odo Speedometer cable assy Re placement 4 002049 Odometer cable Replacement 5 002046 Gear shifter cable Replacement Time Vespa PX 125 150 Euro 2 TIME 130 ...

Page 131: ...placement 2 002063 Throttle cable assy Replacement 3 002053 Rear brake transmission complete replacement 4 003060 Rear brake cable Adjustment 5 003061 Accelerator transmission Adjust ment 6 002045 Clutch cable Replacement Vespa PX 125 150 Euro 2 Time TIME 131 ...

Page 132: ...rs BRAKE CALLIPERS Code Action Duration 1 003070 Front brake pads Wear check 2 002007 Front brake pads Removal and re fitting 3 002039 Front brake calliper Removal and refitting Time Vespa PX 125 150 Euro 2 TIME 132 ...

Page 133: ...Steering column STEERING COLUMN Code Action Duration 1 003010 Front suspension Service Vespa PX 125 150 Euro 2 Time TIME 133 ...

Page 134: ...Front suspension FRONT SHOCK ABSORBER Code Action Duration 1 003011 Front shock absorber Removal and Refitting Time Vespa PX 125 150 Euro 2 TIME 134 ...

Page 135: ...Braking system REAR BRAKE SHOES Code Action Duration 1 002002 Rear brake shoe s Replacement 2 003071 Rear brake shoe s Wear check Vespa PX 125 150 Euro 2 Time TIME 135 ...

Page 136: ...pedal Removal and refitting REAR BRAKE DRUM Code Action Duration 1 002010 Rear brake drum Replacement 2 001016 Rear wheel Replacement 3 004026 Handlebar cover Replacement 4 001071 Rear wheel rim Removal and refit ting Time Vespa PX 125 150 Euro 2 TIME 136 ...

Page 137: ...ration 1 003033 Front wheel hub Replacement 2 002041 Brake disc Replacement 3 003040 Front wheel bearings Replacement SHOE PLATE Code Action Duration 1 002016 Rear brake shoe plate Replace ment Vespa PX 125 150 Euro 2 Time TIME 137 ...

Page 138: ...R BOX Code Action Duration 1 001162 Secondary air housing Replace ment 2 001161 Secondary air filter Replacement Cleaning 3 001165 Secondary air reed Replacement 4 001163 SAS valve Head connection Re placement 5 001164 Secondary air crankcase manifold Replacement Time Vespa PX 125 150 Euro 2 TIME 138 ...

Page 139: ...Clutch cover CLUTCH COVER Code Action Duration 1 001073 Clutch cover Removal and refitting Clutch CLUTCH Code Action Duration 1 001022 Clutch Removal Vespa PX 125 150 Euro 2 Time TIME 139 ...

Page 140: ...GEAR BOX Code Action Duration 1 001119 Gearbox components Replacement 2 001025 Gearbox Overhaul Gear shifter GEAR SHIFTER Code Action Duration 1 001029 Gear shifter Overhaul Time Vespa PX 125 150 Euro 2 TIME 140 ...

Page 141: ...GEAR SHIFTER FASTENERS Code Action Duration 1 001077 Gear shifter components Removal and refitting Vespa PX 125 150 Euro 2 Time TIME 141 ...

Page 142: ...85 87 88 132 Brake fluid C Carburettor 10 30 63 64 66 107 F Fuel 64 93 116 Fuses 47 H Headlight 32 90 Horn I Identification 7 Instrument panel 122 M Maintenance 7 26 S Shock absorbers 81 Spark plug 31 T Tank 93 116 117 Transmission 9 Tyres 10 ...

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VESPA PX 125 150 euro 2, Workshop Manual

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