Vespa S 125 (2007) manual

SERVICE STATION MANUAL 664779-664786 (IT-EN-FR-DE-ES-PT-NL-EL) Vespa S 125[...]

SERVICE STATION MANUAL Vespa S 125 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to componen[...]

SERVICE STATION MANUAL Vespa S 125 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any signific[...]

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INDEX OF TOPICS C HARACTERISTICS CHAR T OOLING TOOL M AINTENANCE MAIN T ROUBLESHOOTING TROUBL E LECTRICAL SYSTEM ELE SYS E NGINE FROM VEHICLE ENG VE E NGINE ENG S USPENSIONS SUSP B RAKING SYSTEM BRAK SYS C HASSIS CHAS P RE - DELIVERY PRE DE T IME TIME[...]

INDEX OF TOPICS C HARACTERISTICS CHAR[...]

Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - T[...]

Vehicle identification Chassis prefix: ZAPM44302 Engine prefix: M444M Dimensions and mass Characteristics Vespa S 125 CHAR - 8[...]

WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 114 ± 5 kg Maximum weight allowed 300 kg Maximum height 1140 mm Width 740 mm Wheelbase 1280 mm Length 1800 mm Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke Cubic capacity 124 cm³ Bore x stroke 57.0 x 48.6 mm Compression ratio 10.6 ± 0.5 : 1 Engine idle sp[...]

Specification Desc./Quantity Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil. Ignition advance Three-dimensional map managed by control unit Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EB Battery Sealed, 12 V / 10 Ah Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Frame Sta[...]

verter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter. The system is fitted with a control valve that disa- bles operation while decelerating to avoid unwan- ted noise. To ensure the best functioning of the SAS system clean the filter as indicated in the schedu[...]

Name Torque in Nm Chain cover screws 4 ÷ 6 Oil sump screws 10 ÷ 14 Minimum oil pressure sensor 12 ÷ 14 Blow-by recovery duct fixing screws 3 - 4 HEAD AND CYLINDER Name Torque in Nm Ignition spark plug 12 ÷ 14 Head cover screws 11 ÷ 13 Nuts fixing head to cylinder (*) 10 + 90° + 90° [further tighten by 90° with new stud bolts]. Head fixing s[...]

FRAME ASSEMBLY Name Torque in Nm Swinging arm pin - frame 44 ÷ 52 Engine-swinging arm bolt 33 ÷ 41 Stand bolt 32 ÷ 40 Swinging arm silent-block containment bolt 33 ÷ 41 FRONT BRAKE Name Torque in Nm Brake fluid pump-hose fitting 8 ÷ 12 Brake fluid pipe-calliper fitting 20 ÷ 25 Screw tightening calliper to the support 20 ÷ 25 Brake disc screw[...]

Piston rings SEAL RINGS Name Description Dimensions Initials Quantity Compression ring 57 x 1 A 0.15 ÷ 0.30 Oil scraper ring 57x1 A 0.10 ÷ 0.30 Oil scraper ring 57x2.5 A 0.10 ÷ 0.35 Compression ring 1st oversize 57.2 x 1 A 0.15 ÷ 0.30 Oil scraper ring 1st oversize 57.2x1 A 0.10 ÷ 0.30 Oil scraper ring 1st oversize 57.2x2.5 A 0.10 ÷ 0.35 Compr[...]

CRANKSHAFT - CRANKCASE Name Description Dimensions Initials Quantity Crankshaft Category 1 28.998 ÷ 29.004 Crankshaft Class 2 29.004 ÷ 29.010 Crankcase Category 1 32.959 ÷ 32.965 Crankcase Class 2 32.953 ÷ 32.959 Fitting clearances Crankshaft/crankcase axial clearance (H): 0.15 ÷ 0.40 mm (when cold) Vespa S 125 Characteristics CHAR - 15[...]

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, transmission side 16.6 +0-0.05 A D = 0.20 - 0.50 Flywheel-side half-shaft 16.6 +0-0.05 B D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50 Spacer tool 51.4 +0.05 E D = 0.20 - 0.50 Slot packing system - Provisionally fit the [...]

SHIMMING SYSTEM Specification Desc./Quantity Value measured 0 ÷ 0.1 Thickness 0.8 ± 0.05 Value measured 0.1 ÷ 0.3 Thickness 0.6 ± 0.05 Value measured 0.3 - 0.4 Thickness 0.4 ± 0.05 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 spec[...]

INDEX OF TOPICS T OOLING TOOL[...]

APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø 15-mm bearings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor Vespa S 125 Tooling TOOL - 19[...]

Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge Tooling Vespa S 125 TOOL - 20[...]

Stores code Description 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cylinder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing Vespa S 125 Tooling TOOL - 21[...]

Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor Tooling Vespa S 125 TOOL - 22[...]

Stores code Description 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle Vespa S 125 Tooling TOOL - 23[...]

Stores code Description 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor - Peak voltage detec- tion 020412Y 15 mm guide 020414Y 28-mm guide 020423Y driven pulley lock wrench Tooling Vespa S 125 TOOL - 24[...]

Stores code Description 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork 020427Y Piston fitting band 020428Y Piston position check support 020430Y Pin lock fitting tool Vespa S 125 Tooling TOOL - 25[...]

Stores code Description 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driven pulley clutch 020565Y Flywheel lock calliper spanner 020622Y Transmission-side oil guard punch 020481Y005 EFI Technology interface wiring Tooling Vespa S 125 TOOL - 26[...]

Stores code Description 020460Y Scooter diagnosis and tester 020469Y Reprogramming kit for scooter diagnosis tester 020641Y EFI Technology software upgrade Vespa S 125 Tooling TOOL - 27[...]

INDEX OF TOPICS M AINTENANCE MAIN[...]

Maintenance chart EVERY 2 YEARS Action Brake fluid - change EVERY 3,000 KM Action Engine oil - level check/ top-up AFTER 1,000 KM 80' Action Engine oil - replacement Hub oil - change Oil filter (net filter) - clean Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check c[...]

Action Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Centre stand - lubrication Secondar[...]

AFTER 36,000 KM 270' Action Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing St[...]

Checking the spark advance The scooter is fitted with a control unit that manages ignition advance according to engine revs and the opening angle of the carburettor throttle valve. LIMITER ACTIVATION Specification Desc./Quantity Operation threshold First threshold : 9500 ± 50 Second threshold : 9800 ± 50 Reactivation threshold First threshold : 9[...]

THE USE OF SPARK PLUGS OTHER THAN THE INDICA- TED TYPE OR OF SHIELDLESS SPARK PLUG CAPS CAN CAUSE ELECTRICAL SYSTEM FAILURES. Characteristic Spark plug CHAMPION RG 6 YC Alternative spark plug NGK CR7EB Electrode gap 0.7 ÷ 0.8 mm Hub oil Check - Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick « A », dry it with a cl[...]

Replacement - Unscrew the oil filling cap/dipstick « A ». - Remove the rear wheel, place a suitable con- tainer, unscrew the drainage screw « B » and let the oil flow out completely. - Once the oil has been drained off, tighten the filling screw to the prescribed torque. - Fill with the recommended product to the prescribed amount. Recommended [...]

Air filter - Remove the side fairing by undoing the screw « A » and the smaller screw « B ». - Take out the air cleaner cover « D » after undoing the six fixing screws « C », then take out the filtering element. 1. Wash the sponge with water and neutral soap. 2. Dry it with a clean cloth and small blasts of com- pressed air. 3. Impregnate t[...]

In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be con- sidered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle". Replacement Replace oil and filter as[...]

Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified 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 circ[...]

USING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERIOUS DAMAGE. Always check oil level before carrying out top-ups and add oil without exceeding the MAX level . An engine oil check-up and top-up should be carried out as indicated in the scheduled maintenance ta[...]

Fuel filter - Remove the helmet compartment in order to reach the fuel filter. - Disconnect the pipe connecting clamps to re- move the filter. CAUTION THE TANK DOES NOT HAVE A COCK, SO PLACE A SUIT- ABLE CONTAINER TO COLLECT THE FUEL. Checking the ignition timing - Remove the 4 fixing screws and detach the fly- wheel cover from the engine. - Rotate[...]

Checking the valve clearance -To check valve clearance, centre the reference marks of the timing system. - Use a thickness gauge to check that the clear- ance between the valve and the set screw corre- sponds with the indicated values. When the valve clearance values, intake and drainage respective- ly, are different from the ones indicated below, [...]

Top-up Proceed as follows: -Remove the rear-view mirrors. - Undo the two screws « A ». - Undo the screw « B » and remove the front han- dlebar cover. - Remove the reservoir cover « C » by loosening the two fixing screws « D » and refill with the prescribed brake fluid type only and without exceeding the maximum level. CAUTION ONLY USE DOT 4[...]

Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Headlight adjustment Proceed as follows: 1 . Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendi[...]

- Remove the screw fixing the SAS valve to the flywheel cover, indicated in the photograph. - Remove the 6 flywheel cover screws indicated in the photograph and remove the flywheel cover. - Remove the filter indicated in the photograph - Check that the gasket is in good conditions - Check the SAS filter housing for dents or defor- mations - Clean t[...]

INDEX OF TOPICS T ROUBLESHOOTING TROUBL[...]

Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent an[...]

Possible Cause Operation Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air Air filter obstructed or dirty. Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Fuel pump fau[...]

High fuel consumption EXCESSIVE FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Clean according to the procedure Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and power supply Loose nozzles Check the maximum and minimum nozzles are adequately fixed in their fittings Incorrect float level R[...]

Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months. If the b[...]

Possible Cause Operation brake calliper and the disc. Check that the swinging arm con- necting the engine to the chassis and the rear shock absorber work properly. Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper. Vespa S 125 Troubleshooting TROUBL - 49[...]

INDEX OF TOPICS E LECTRICAL SYSTEM ELE SYS[...]

KEY 1. Throttle body position 2. Electronic ignition device 3. Magneto flywheel - Pick-up 4. Diagnostics socket 5. Voltage regulator 6. Main fuses 7. Auxiliary fuses 8. 12V-10Ah Battery 9. Starter motor 10. Start-up remote control switch 11. Starter button 12. Stop button on rear brake 13. Stop button on front brake 14. Light switch 15. Turn indica[...]

20. Rear right turn indicator bulb 21. Front left turn indicator bulb 22. Headlight A. Low-/high-beam twin filament bulb B. Front tail light bulb 23. Front right turn indicator bulb 24. Instrument panel A. Turn indicator warning light B. Headlight warning light C. Instrument panel lighting bulbs D. Fuel gauge E. Low fuel warning light F. Oil warnin[...]

Components arrangement 3. Magneto flywheel - Pick-up: remove the helmet compartment to reach it. - Stator phases resistance values: Electric characteristic Ohm value: 0.7 ÷ 0.9 Ohm Pick-up resistance value 105 ÷ 124 Ohm 1 / 4 / 9 / 31 / 35 - Throttle body position / Diag- nostics socket / Starter motor / Fuel pump / Auto- matic starter: remove th[...]

5 - Voltage regulator: remove the front central cov- er to reach it. - Generated current value, with lights on and en- gine at high revs: Electric characteristic Generated current value > 8A 36 - Temperature sensor remove the front central cover to reach it. - Temperature sensor resistance value: Electric characteristic Resistance value (at 25°[...]

10 - Start-up remote control switch: remove the battery to reach it. 26 - Fuel level transmitter: remove the fuel tank to reach it. - Fuel level transmitter resistance value: Electric characteristic Resistance value when the tank is full < = 7 Ω Resistance value when the tank is half-full 38 Ω ±4 Ω Resistance value when the tank is empty 90 [...]

33 - Spark plug: remove the helmet compartment to reach it. 34 - HV coil: remove the inspection door from the central tunnel to reach it. - HV coil resistance values: Electric characteristic High voltage coil primary resistance value High voltage coil primary resistance value: 0.4 ÷ 0.5 Ohm High voltage coil secondary resistance value High voltage[...]

Ignition KEY 2. Electronic ignition device 3. Magneto flywheel - Pick-up 6. Main fuses 8. 12V-10Ah Battery 30. Key switch 33. Spark plug 34. HV coil Vespa S 125 Electrical system ELE SYS - 57[...]

Headlights and automatic starter section KEY 2. Electronic ignition device 6. Main fuses 7. Auxiliary fuses 8. 12V-10Ah Battery 14. Light switch 16. Light remote control 17. License plate light bulb 19. Tail light and rear stop light bulb 22. Headlight A. Low-/high-beam twin filament bulb B. Front tail light bulb 24. Instrument panel B. Headlight w[...]

37. Carburettor heater Battery recharge and starting KEY 3. Magneto flywheel - Pick-up 5. Voltage regulator 6. Main fuses 7. Auxiliary fuses 8. 12V-10Ah Battery 9. Starter motor 10. Start-up remote control switch 11. Starter button 12. Stop button on rear brake 13. Stop button on front brake 19. Tail light and rear stop light bulb 30. Key switch Ve[...]

Level indicators and enable signals section KEY 1. Throttle body position 2. Electronic ignition device 6. Main fuses 7. Auxiliary fuses 8. 12V-10Ah Battery 24. Instrument panel D. Fuel gauge E. Low fuel warning light F. Oil warning light 26. Fuel level transmitter 27. Engine oil pressure sensor 30. Key switch 36. Temperature sensor Electrical syst[...]

Devices and accessories KEY 2. Electronic ignition device 4. Diagnostics socket 6. Main fuses 7. Auxiliary fuses 8. 12V-10Ah Battery 15. Turn indicator switch 18. Rear left turn indicator bulb 20. Rear right turn indicator bulb 21. Front left turn indicator bulb 23. Front right turn indicator bulb 24. Instrument panel A. Turn indicator warning ligh[...]

32. Fuel electric pump control device Checks and inspections Ignition circuit All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off : if this is not done, the controls might be irretrievably damaged. The battery provides the ba[...]

- there is battery voltage between terminals 9 and 12 with the key switch in «ON». If no faults are found, replace the control unit. No spark plug Once the lack of power to the spark plug has been detected, proceed as follows: - Check the Pick-Up. Disconnect the control unit connector and check that the cable between terminal No. 10 (Green) and t[...]

High voltage coil primary resistance value: 0.4 ÷ 0.5 Ohm - HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the pe[...]

- H.V. coil With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary dur- ing the start-up test with the voltage peak adaptor and connect the positive terminal to the earth one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit. THE POSITIVE TER[...]

Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further rep- etitions of incorrect values replace the stator or repair the wiring. Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the bat[...]

Choke Inspection Refer to the engine section to check the resistance and operating conditions of the component. As re- gards voltage supply, keep the connector connec- ted to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If no voltage is detected, connect the multimeter negative terminal to [...]

If no voltage is detected, check the cable harness and the connections; otherwise, proceed as fol- lows: - Jump terminals 2 (Black/Blue) and 9 (Orange), see figure. Turn the turn indicator switch alternate- ly to the left and to the right with the key switch in "ON" and check if the lights turn on. If they do, replace the control unit bec[...]

- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about 15 minutes and seek immediate medical attention. In the event of accidental ingestion of the fluid, immediately drink large quantities of w[...]

The battery is an electrical device which requires careful monitoring and careful maintenance. The maintenance rules are: 1) Electrolyte level check The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle elect[...]

020334Y Multiple battery charger Pump electrics check If the engine does not work properly, the electric pump control unit may not work properly either. In this case: - Remove the helmet compartment so as to reach the electric fuel pump. - Disconnect the fuel supply connector from the pump. - Check that the fuel supply to the pump is ade- quate acc[...]

Connectors FUEL PUMP CONTROL DEVICE CONNECTOR 1. Live power supply (Orange) 2. Not connected 3. Fuel pump negative (White-Black) 4. Fuel pump positive (Blue-Black) 5. Ground (Black) 6. Engine revs (Purple) VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Blue) 2. Magneto flywheel (Yellow) 3. Not connected 4. Magneto flywheel (Yellow) 5. Ground [...]

STARTER CONNECTOR 1. Live power supply (Orange) 2. Control unit negative (White-Black) MAGNETO FLYWHEEL CONNECTOR 1. Engine oil pressure sensor (Brown) 2. Voltage regulator (Yellow) 3. Pick-up (Green) 4. Voltage regulator (Yellow) 5. Not connected 6. Voltage regulator (Yellow) INSTRUMENT PANEL CONNECTOR "A" 1. Right turn indicator warning[...]

CDI CONTROL UNIT CONNECTOR 1. Not connected 2. Turn indicator switch (Blue-Black) 3. Not connected 4. HV coil (Purple) 5. TPS positive (Red-Green) 6. Not connected 7. Diagnosis connector (Purple-White) 8. Battery powered (Red-Blue) 9. Live power supply (Orange) 10. Pick-up (Green) 11. Automatic starter negative (White-Black) 12. Ground (Black) 13. [...]

INDEX OF TOPICS E NGINE FROM VEHICLE ENG VE[...]

Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying at- tention to the interference between its supporting bracket and the cooling cover. Removal of the engine from the vehicle - Remove the left and right side fairings - Remove [...]

- Remove the throttle control cable from the car- burettor, indicated in the photograph - Remove the fuel supply pipe from the carburettor - Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indi- cated in the figure - Remove the protection sheath indicated in the figure and disconnect the automatic start[...]

- Unscrew the engine pin-swinging arm nut on the right-hand side of the vehicle and slide off the pin on the left hand side - Support the vehicle adequately (with a jack) and remove the shock absorber lower clamping. The engine is now free. Engine from vehicle Vespa S 125 ENG VE - 78[...]

INDEX OF TOPICS E NGINE ENG[...]

This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes. Using the clutch bell lock wrench, remove the driv- en pull[...]

AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 - Operating the starter lever, load the spring and introduce the pinion in its seat. - Refit the intake throat with the 3 screws and the Kick-starter cover with the 4 screws. Tighten the screws to the prescribed torque. - Remo[...]

Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Use the specific tools to remove the bearing from the crankcase. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM- AGING THE COVER PAINT. Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm Refitting the driven pulley shaft bearing - Heat u[...]

020357Y 32 x 35 mm adaptor 020412Y 15 mm guide Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic [...]

- Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic support for dial gauge Characteristic clutch bell inspection: Limit [...]

Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL CONTACT SURFACE AND MUST NOT BE DIFFER- ENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAU[...]

020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020439Y 17 mm guide Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bush- ing. Characteristic Minimum diameter permitted Ø 40.96 mm Standard diameter Ø 40.965 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.[...]

Refitting the driven half-pulley bearing - Assemble a new roller case using the specific punch, fit the bearing with the label facing outward and insert it completely up to the punch on the half- pulley. N.B. REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT. Specific tooling 020424Y[...]

020263Y Sheath for driven pulley fitting Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the unloaded length of the spring of the movable driven half-pulley. Characteristic Standard len[...]

- Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position " C " on the inside. - Introduce the adapter ring 11 with the chamfering facing upwards. - Insert the clutch on the adapter ring. - Lubricate the end of the spring tha[...]

020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 46x55 Wrench Locking torques (N*m) Clutch unit nut on driven pulley 45 ÷ 50 Refitting the driven pulley - Reassemble the clutch bell and spacer. Drive-belt During the wear check foreseen in the scheduled maintenance, check that the rim bottom of the toot[...]

Removing the driving pulley - Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the Belleville washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer. Specific tooling 020368Y driving pulley lock wrench - Remove the belt and slide the movable half-p[...]

VARIABLE SPEED ROLLERS Specification Desc./Quantity Minimum diameter permitted Ø 18.5 mm Standard diameter 19 ± 1 mm - Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves. Refitting the driving pulley - Reassemble t[...]

Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque. - Refit the oil loading cap/bar. - refit the steel washer and the driven pulley nut. - Tighten the nut to [...]

Removing the wheel axle Remove the intermediate gear and the complete hub cover. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover). [...]

With the appropriate tools, remove the oil seal as shown in the figure. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven pulley. - Extract the driven pulley shaft from its bearing. - Re[...]

Inspecting the hub cover - Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the brake camshaft. - If faults are found, replace the hub cover. Refitting the driven pulley shaft bearing - Heat up the parts using the specific heat gun Specific tooling 020150Y Air heater support 020151Y Air heater - Re[...]

• Assemble the Seeger ring. • Assemble the oil seal flush with the in- ternal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub. Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm Refitting the hub cover bearings - For the fitting of the hub box bearings the en[...]

Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Screw the 7 screws to the specified torque, po- sitioning the support plate of the pipe in the posi- tion shown in the figure. Locking torques (N*m) Rear hub cap screw 24 ÷ 27 Flywheel [...]

mm. Remember that such operation must have performed on a disassembled manifold which must be cleaned afterwards. Cooling fan - Refit the parts in reverse order of the removal operation. - Make sure that there are spacers with the two rear retainers of the housing. - The long spacers should be in a high position. CAUTION TAKE CARE TO CORRECTLY POSI[...]

Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. - Place the cable harness as shown in the figure. N.B. THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REFERENCE PIN AS SHOWN IN THE DETAIL DRAWING. Locking torques (N*m) Sta[...]

Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS Specific tooling 020565Y Flywheel lock calliper spanner - Extract the flywheel with the extractor. Specific tooling 008564Y Flywheel extractor[...]

Refitting the starter motor - Fit a new O-ring on the starter and lubricate it. - Fit the starter on the crankcase, locking the two screws to the prescribed torque. N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS. Locking torques (N*m) Starter motor fixing screw 11 ÷ 13 Cyli[...]

- Unscrew the central screw and remove the au- tomatic valve-lifter retaining cover, as shown in the figure. - Remove the return spring of the automatic valve- lifter assembly and the automatic valve-lifter as- sembly and its washer. - Loosen the central screw on the tensioner. - Remove the two screws indicated in the figure. - Remove the tensioner[...]

- Remove the camshaft control pulley with its washer. - Undo the screws indicated in the figure, the spacer and the tensioner pad. - Remove the command sprocket wheel and the timing chain. The chain tensioning pad must be removed from the transmission side. As regards the lower chain guide pad, it may only be removed after the head has been removed[...]

Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic wash- er. N.B. MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INLET WITH THE OUT- LET. [...]

Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool - Remove the oil seals with the appropriate tool. - Remove the lower spring [...]

Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANK- SHAFT" CHAPTER". Characteristic Rod small end check[...]

- Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Measure 36.5 mm from the piston crown's shown in the figure. - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or[...]

Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston. STANDARD COUPLING CLEARANCE Name Description Dimensions Initials Quantity Top piston r[...]

Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston. The tapered side of the middle piston ring should always be facing away from the crown of the pis- ton. - Fit the midd[...]

020427Y Piston fitting band Inspecting the cylinder head - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn. Characteristic Maximum ad[...]

- Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole assembly. Inspecting the valve sealings - Measure the width of the sealing surface on the valve seats. VALVE SEAL SURFACE «A» Specification Desc./Quant[...]

- If the width of the impression on the valve seat or the diameter of the valve guide exceed the speci- fied limits, replace the cylinder head. - Check width of the impression on the valve seat « V » Characteristic Wear limits: Max. 1.6 mm. Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the dia[...]

79.6 mm - If the checks above give no failures, you can use the same valves. For best sealing results, it is ad- visable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During grinding, keep the cylinder head in a horizontal position. This will prevent the lapping compound residues from penetrating between the val[...]

Refitting the valves - Lubricate the valve guides with engine oil. - Place the lower plates of the valve spring on the head. - Use the punch to fit the 2 sealing rings one at a time. Specific tooling 020306Y Punch for assembling valve seal rings - Fit the valves, the springs and the spring retaining caps. Using the appropriate tool with adapter 11,[...]

- Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones. Characteristic Maximum axial clearance admitted 0.42 mm - Check there are no signs of wear on t[...]

Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder. -Screw the nuts and lock them in a crossed se- quence and in 2 or 3 stages to the specific torque. Locking torques (N*m) Nuts fixing head to cylinder (*) 10 + 90° + 90°[...]

- Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que. Locking torques (N*m) Camshaft retention plate screw 5 - 6 - Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - While doing so, fit the c[...]

- Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Camshaft pulley screw 12 ÷ 14 - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws[...]

- Fit the inlet manifold and lock the 2 screws to the specified torque. - Fit the carburettor onto the inlet manifold and lock the clamp N.B. FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD. Locking torques (N*m) Head intake manifold screw 11 ÷ 13 - Refit the cylinder head cover, tightening the 4 clamping screws to the prescribed torque[...]

- Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with specific tool dial gauge. Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Standard clearance 0.15 ÷ 0.40 mm Splitting the crankcase halves Remove the 11[...]

- Check the axial clearance on the connecting rod. Characteristic Standard clearance 0.20 ÷ 0.50 mm - Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram. CAUTION BE CAREFUL NOT TO LET THE MEASUR[...]

Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft. The connecting [...]

D = 0.10 mm Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean the all surfaces and oil ducts. - On the transmission side crankcase half, take particular care cleaning the housing and oil ducts for the following components: the oil pump, the oil by-pass valve, the main bushings and the cooling jet on[...]

- Inspect the mating surfaces on the crankcase halves for scratches or deformation, taking partic- ular with the surfaces that mate with the cylinder and the mating surfaces between the crankcase halves. - Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in the oil pressure and affect the lubricating[...]

Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40 If the engine crankcase needs to be replaced and your crankshaft is Cat.1, order a crankcase prepared to house a Cat.1 crankshaft. If the engine crankcase needs to be replaced and your crankshaft is Cat.2, order a crankcase prepared to house a Cat.2 crankshaft. If the crankshaft needs to be replace[...]

- Lubricate the main bushings and insert the crank- shaft in the transmission side crankcase half. - Reassemble the two crankcase halves. - Fit the 11 screws and tighten them to the pre- scribed torque. N.B. WHEN FITTING THE HALF CASING AND THE CRANK- SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA- DED TANGS. Locking torques (N*m) Engine-crankcase c[...]

Conceptual diagrams Engine Vespa S 125 ENG - 128[...]

Oil pressure check - After removing the fan cover housing as descri- bed in the "Flywheel" chapter, disconnect the elec- trical connection of the minimum oil pressure switch and then remove the switch. - Fit the special tool. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure is between 0.5[...]

Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided. - Screw the threaded bar onto the base of the tool and extract the oil guard. Specific tooling 020622Y Transmission-side oil guard punch Refitting - Prepare the new oil guard, lubrica[...]

- Preassemble the oil seal with the appropriate tool, positioning the screws - Place the sheath over the crankshaft - Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. WHEN THE POSITION IS REACHED, DO NOT RETRACT [...]

- Use the nut to move the base of the tool until you can see end of the oil seal driving stroke - Remove all of the tool components following the procedure in reverse order CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN. Assemble a new oil seal on the [...]

- Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion. - Remove the oil pump acting on the 2 retainers as shown in the figure. - Remove the oil pump seal. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS M[...]

Measure the distance between the outer rotor and the pump body; see figure. Characteristic Admissible limit clearance: 0.20 mm Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure. Characteristic Limit values admitted: 0.09 mm Refitting - Place the circlip retaining the internal rotor. - Tighten the two fixi[...]

- Fit the crankshaft control pinion. - Fit the control chain. - Place the belleville washer and the nut and tight- en them to the prescribed torque. N.B. FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP TURNS FREELY. Locking torques (N*m) Pump control pulley screw 10 ÷ 14 - Fit the pulley cover and tighte[...]

Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defec- tive parts. Characteristic By-pass check up: Standard length 54.2 mm Refitting the oil sump - Refit the[...]

- TPS check With the multimeter, check if the potentiometer is working correctly by placing the probes on both contacts indicated in the photograph . With the throttle fully closed, the resistive value should respect the indicated value. With throttle fully open, the resistive value should respect the indicated value. Electric characteristic Resist[...]

Removing the carburettor - To detach the carburettor from the engine, it is necessary to move the air filter and remove the throttle control transmission, the automatic starter connection, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, the heater, the intake fitting and [...]

- Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY. - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- dle Ve[...]

- Remove the 4 screws indicated in the figure. - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL. N.B. AVOID REMOVING THE PISTON OF THE PUMP AND [...]

-Remove the maximum nozzle. -Remove diffuser. Vespa S 125 Engine ENG - 141[...]

- Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT. -Remove the minimum nozzle. - Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR B[...]

Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure. - For the minimum circuit, make sure the following points are properly cleaned: [...]

- Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear. - Check that the plunger seat does not show abnormal wear. - Replace the carburettor in case of irregularities. - Check that the retur[...]

- Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the [...]

- The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position. Level check - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plu[...]

- Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover. - Tighten the screws. - Wash and blow dry the filter sponge of the am- bient pressure intake. Vespa S 125 Engine ENG - 147[...]

- Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Inspecting the automatic choke device - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support. - Check that t[...]

With a 12V battery power the automatic starter and check that the piston protrudes as much as possi- ble. - The correct warm up time depends on the ambi- ent temperature. - If protrusion, resistance or timing values are dif- ferent from the ones prescribed, replace the start- er. - Assemble the starter to the carburettor being careful to position t[...]

Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow cer- tain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to re- spect the lubrication requirements, valve clear- ance, and complying timing, spark plug should be in optimum conditions, air filte[...]

INDEX OF TOPICS S USPENSIONS SUSP[...]

Front suspension This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Support the scooter adequately. - Loosen the five screws fixing the wheel to the hub. Front wheel hub overhaul - Support the scooter adequately. - Remove the front wheel. - Remove the front calliper. - Remove the cotter[...]

- Remove the wheel hub. - Remove the ball bearing check seeger ring indi- cated in the photograph Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings 001467Y017 Bell for bearings, OD 39 mm - Remove the oil seal on the roller bearing side using a screwdriver. Vespa S 125 Suspensions SUSP -[...]

- Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing out - Refit the ball bearing check seeger ring Specific toolin[...]

Refitting the front wheel - Upon refitting, tighten the five screws to the pre- scribed torque. Locking torques (N*m) Wheel rim screws 20 ÷ 25 Handlebar Removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and discon- necting the electrical terminals, remove the termi- nal fixing the handlebar [...]

Removal After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork. Specific tooling 020055Y Wrench for steering tube ring nut Overhaul Servicing the front suspension-steering assembly, described below, deals mainly with replacing parts (pin- NADELLA roller bushings - sealing rings unit and du[...]

To remove the second NADELLA, use the tool fit- ted with part 2 instead of part 1, on the side oppo- site the one shown in the figure. N.B. DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE, THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED. UPON REFITTING, IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN, NEW SEALING RINGS[...]

- Repeat the above operation using the tool with part 16 and part 22, instead of part 4, always fitted to the stem, on the side opposite that indicated in the figure to fit the second wedging washer - roller bushing - sealing ring unit. WARNING BEFORE PROCEEDING WITH THE DESCRIBED PRE-FIT- TING, DIP THE SEALING RINGS IN MINERAL OIL AND THE "NA[...]

Refitting CAUTION USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING. When fitting the fork, lubricate with the steering bearing tracks with the recommended grease. Tighten the lower ring nut "A" and the upper ring nut "B" to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering [...]

Removal - Support the scooter adequately. - Remove the wheel hub. - Loosen the shock absorber lower clamps and re- move the brake calliper shock absorber support. - Loosen the screws fixing the front brake pipe re- tainer clamp and the odometer cable in order to reach the upper clamps. - Unscrew the upper fixing nuts. - Remove the front shock absor[...]

Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques. Locking torques (N*m) shock absorber lower clamp 20 - 27 shock absorber upper clamp 20 ÷ 30 Shock-absorber - calliper bracket Removal - Remove the front wheel hub with the brake disc - Remove the front shock absorber lower clamps - R[...]

Overhaul - The bracket for the shock absorber -calliper at- tachment has two roller bearings separated one from the other as shown in the photograph - 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 020376Y Adaptor handle 020441Y 2[...]

- Assemble a new roller bearing on the shock ab- sorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch - Suitably 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 [...]

N.B. TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING JUST USE A SCREW- DRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE. Specific tooling 020004Y Punch for removing fifth wheels from headstock - Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure, using the specific tool. Proceed giving a few taps wi[...]

- Unscrew the nut fixing the wheel axle and collect the washer. Refitting the rear wheel - To refit, follow the removal steps but in reverse order; be careful to tighten to the prescribed tor- que. Locking torques (N*m) Locking torque 137 ÷ 152 Nm Swing-arm Vespa S 125 Suspensions SUSP - 165[...]

Removal - Support the scooter adequately. - Remove the central tunnel inspection door. - To remove the upper clamp from the chassis, proceed as follows: - Unscrew the pin and collect the washer. - Remove the cap from the lower part. - Collect the lower fixing nut and collect the wash- er. Suspensions Vespa S 125 SUSP - 166[...]

- 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. - Working on the left side, remove the pin. - Remove the spoiler terminal from both sides. - Working on the right side, unscrew the fixing nut. Vespa S 125 Suspensions SUSP - 167[...]

- Working on the left side, release the pin from the spring shown. - 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 condi- tions. - Otherwi[...]

Refitting - To fit, follow the removal steps but in reverse or- der; be careful to tighten to the prescribed torques. Locking torques (N*m) Part A 33 ÷ 41 Part B 44 ÷ 52 Part C 33 ÷ 41 Shock absorbers Removal - Adequately support the rear part of the scooter. - Remove the battery cover. - Undo the indicated upper fixing screw to the frame. - Uns[...]

Refitting - To fit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torques. Locking torques (N*m) Shock absorber/engine pin torque 33 to 41 N·m Shock absorber/frame nut torque 20 to 25 Nm Centre-stand REMOVAL - Use a jack to support the vehicle properly. - Remove the two return springs from the centre stand.[...]

INDEX OF TOPICS B RAKING SYSTEM BRAK SYS[...]

Front brake calliper Removal - Remove the front wheel. - Undo the two fixing screws to the shock absorber - calliper support. N.B. SHOULD IT BE NECESSARY TO REPLACE THE CALLIP- ER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER. Refitting To fit, follow the removal steps but in reverse order; be careful to tighten to the prescri[...]

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 Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Brake disc screws [...]

Characteristic Minimum thickness allowed after use: 4 mm Disc thickness at wear limit (front) 3.5 mm Max. deviation allowed: 0.1 mm - If a value other than that prescribed is detected, replace the disc and check again. - If the problem persists, check and replace the wheel hub if required. Front brake pads Removal Proceed as follows: - Remove the f[...]

Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the lock on the bolt and then the protection cover Fill Front - Remove the rubber cap from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. [...]

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 BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER TH[...]

Removal - Remove the front and rear handlebar covers - Remove the two screws fixing the brake pump to the handlebar indicated in the photograph - Remove the oil pipe joint from the pump - Remove the connector to the stop light switch Overhaul Proceed as follows: 1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take[...]

Refitting To refit, carry out the removal operations but in reverse order, observing the specified torques. N.B. USE NEW COPPER GASKETS ON THE JOINTS. CAUTION ONCE REFITTING IS FINISHED, BLEED THE SYSTEM. Locking torques (N*m) Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handle bar: 7 ÷ 10 Nm Pipe / brake calliper coupling 2[...]

020325Y Brake-shoe spring calliper Vespa S 125 Braking system BRAK SYS - 179[...]

INDEX OF TOPICS C HASSIS CHAS[...]

Seat - Lift the saddle and remove the helmet compart- ment « A ». - Undo the two screws indicated. Rear handlebar cover - Remove the front handlebar cover. - Undo the three screws indicated in figure fixing it to the handlebar, the odometer transmission and the electrical connectors. Vespa S 125 Chassis CHAS - 181[...]

Instrument panel - Remove the rear handlebar cover. - Undo the three screws indicated fixing the rear handlebar cover. Front handlebar cover Proceed as follows: -Remove the rear-view mirrors. - Undo the two screws « A ». - Undo the screw « B » and remove the front han- dlebar cover. - Disconnect the electrical terminals and remove the turn indi[...]

Headlight assy. - Remove the front handlebar cover. - Undo the four screws indicated fixing the front handlebar cover. Knee-guard - Undo the five screws indicated. - Remove the rubber strip from both sides and un- do the indicated screw. - Remove the shield back plate bringing it to the rear part of the scooter. Vespa S 125 Chassis CHAS - 183[...]

Taillight assy. - Undo the two fixing screws and remove the rear light unit. - Undo the screw indicated and disconnect the connector. Footrest - Remove the shield back plate. - Remove the side fairings. - Remove the central tunnel inspection door. From both sides, unscrew: - The fixing screw at the back. - The fixing screw on the central part. Chas[...]

- The fixing screw at the front. - Remove the footrest. Side fairings - Undo the screw « A » and the smaller screw « B ». - Detach the seats on the fairing. Vespa S 125 Chassis CHAS - 185[...]

License plate holder - Remove the side fairings. - Working on both sides, undo the two screws in- dicated. - Remove the license plate light. Air filter - Remove the helmet compartment. - Remove the side fairings. - Undo the two indicated clamps to the crankcase. - Undo the two clamps indicated. Chassis Vespa S 125 CHAS - 186[...]

Fuel tank - Adequately support the rear part of the scooter. - Remove the wheel and the rear mudguard. - Remove the battery compartment. - Disconnect the fuel outlet pipe. - Undo the two fixing screws to the chassis and collect the fuel pipe supporting plate. - Remove the turn indicators. - Remove the rear light unit and undo the indicated screw. -[...]

- Remove the tank. Front mudguard - 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. Chassis Vespa S 125 CHAS - 188[...]

- Undo the two screws indicated. - Remove the front central cover, sliding it up- wards. Vespa S 125 Chassis CHAS - 189[...]

INDEX OF TOPICS P RE - DELIVERY PRE DE[...]

Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Frame - swinging arm bolt * Swinging arm bolt - Engine Engine arm pin [...]

CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE 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 BATTER[...]

Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspectio[...]

INDEX OF TOPICS T IME TIME[...]

Engine ENGINE Code Action Duration 1 001001 engine from frame - removal and re- fitting Vespa S 125 Time TIME - 195[...]

Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase - Replacement 2 001153 Half crankcase gasket - Replace- ment 3 002031 Rear wheel hub bearings - Replace- ment Time Vespa S 125 TIME - 196[...]

Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft - Replacement 2 001099 Oil seal, flywheel side - Replacement Vespa S 125 Time TIME - 197[...]

Cylinder assy. CYLINDER GROUP Code Action Duration 1 001002 Cylinder-Piston - Replacement 2 001107 Cylinder / piston - Inspection / clean- ing Time Vespa S 125 TIME - 198[...]

Cylinder head assy. HEAD UNIT Code Action Duration 1 001045 Valves - Replacement 2 001056 Head gasket - change 3 001126 Head - Replacement Vespa S 125 Time TIME - 199[...]

Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001044 Camshaft - Replacement 2 001148 Rocking lever valve - Replacement 3 001049 Valves - Adjustments 4 001169 Decompressor - Replacement Time Vespa S 125 TIME - 200[...]

Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover - Replacement 2 001088 Head cover gasket - Replacement 3 001159 Oil vapour recovery tank - Service 4 001093 Spark plug - Replacement 5 001097 Cooling hood - Replacement 6 001091 Head cover sealing ring 7 001074 Oil vapour recovery pipe - Replace- ment Vespa S 125 Time TIME - 20[...]

Chain tensioner CHAIN TIGHTENER Code Action Duration 1 001129 Chain tensioner - Service and Re- placement 2 001124 By pass lubrication - Replacement Time Vespa S 125 TIME - 202[...]

Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter - Replacement 2 001160 Oil pressure sensor - Replacement 3 003064 Engine oil - Change 4 001102 Net oil filter - Replacement / Cleaning Vespa S 125 Time TIME - 203[...]

Flywheel cover FLYWHEEL COVER Code Action Duration 1 001087 Flywheel cover - Replacement Time Vespa S 125 TIME - 204[...]

Driven pulley DRIVEN PULLEY Code Action Duration 1 001155 Clutch bell housing - Replacement 2 001022 Clutch - Replacement 3 001012 Driven pulley - Overhaul 4 001110 Driven pulley - Replacement Vespa S 125 Time TIME - 205[...]

Oil pump OIL PUMP Code Action Duration 1 001051 Belt/Timing chain - Change 2 001125 Chain guide pads - Replacement 3 001042 Oil pump - Service 4 001112 Oil pump - change 5 001130 Oil sump - Replacement 6 001100 Oil seal, clutch side - Replacement 7 001122 Oil pump chain - Replacement Time Vespa S 125 TIME - 206[...]

Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 1 004125 Rear wheel axle - Replacement 2 001156 Gear reduction unit cover - Replace- ment 3 003065 Gear box oil - Replacement 4 001010 Gear reduction unit - Inspection Vespa S 125 Time TIME - 207[...]

Driving pulley DRIVING PULLEY Code Action Duration 1 001066 Drive pulley - Removal and refitting 2 001086 Driving half-pulley - Replacement 3 001177 Variator rollers / shoes - Replace- ment 4 001011 Driving belt - Replacement Time Vespa S 125 TIME - 208[...]

Transmission cover TRANSMISSION COVER Code Action Duration 1 001096 Transmission crankcase cover - Re- placement 2 001135 Transmission cover bearing - Re- placement 3 001065 Transmission cover - Removal and Refit Vespa S 125 Time TIME - 209[...]

Starter motor ELECTRICAL START-UP Code Action Duration 1 001020 Starter motor - Replacement 2 005045 Starter motor cable harness - Re- placement 3 001017 Starter sprocket wheel - Replace- ment 4 001021 Kick starter - Inspection 5 008008 Starter spring pack - Replacement 6 001084 Starter lever - Replacement Time Vespa S 125 TIME - 210[...]

Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001109 Cooling fan - Replacement 2 001173 Rotor - Replacement 3 001067 Stator - Removal and Refitting 4 001058 Flywheel - Replacement Vespa S 125 Time TIME - 211[...]

Belt cooling duct BELT COOLING PIPE Code Action Duration 1 001170 Air manifold - replacement 2 001132 Transmission air inlet pipe - Replace- ment 3 001131 Transmission air intake - Replace- ment Time Vespa S 125 TIME - 212[...]

Carburettor CARBURETTOR Code Action Duration 1 001082 Carburettor heating resistor - Re- placement 2 001013 Intake manifold - change 3 004122 Air cleaner carburettor fitting - Re- placement 4 001081 Automatic choke - Replacement 5 001008 Carburettor - Inspection 6 001063 Carburettor - Replacement Vespa S 125 Time TIME - 213[...]

Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler - Replacement 2 001095 Muffler guard - Replacement Time Vespa S 125 TIME - 214[...]

Air cleaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting - Re- placement 2 001014 Air filter - Replacement/Cleaning 3 001015 Air filter box - Replacement 4 001027 Body / air cleaner union - Replace- ment Vespa S 125 Time TIME - 215[...]

Frame F RAME Code Action Duration 1 004001 Chassis - Replacement 2 004023 Shield rim - Replacement 3 004149 Shield central cover - Replacement 4 004159 Plates / Stickers - Replacement 5 004012 Rear side panels - Replacement 6 004059 Spark plug inspection flap - Replace- ment Time Vespa S 125 TIME - 216[...]

Centre-stand STAND Code Action Duration 1 001053 Stand bolt - Replacement 2 004004 Stand - Replacement 3 004102 Side stand - Replacement 4 004179 Stand buffer - Replacement Vespa S 125 Time TIME - 217[...]

Footrests F OOTREST Code Action Duration 1 004178 Footrest - Replacement 2 004078 Front/rear footrest rubber - Replace- ment Time Vespa S 125 TIME - 218[...]

Rear cover SHIELD BACK PLATE Code Action Duration 1 004065 Front shield, rear part - Removal and refitting Vespa S 125 Time TIME - 219[...]

Underseat compartment HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment - Replacement 2 005046 Battery cover - change 3 004011 Central chassis cover - Replacement 4 004071 Battery compartment - replacement Time Vespa S 125 TIME - 220[...]

Plate holder LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate support - Replacement 2 005048 Licence plate holder - Replacement 3 005032 Licence plate light glass - Replace- ment Vespa S 125 Time TIME - 221[...]

Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard - Replacement 2 004009 Rear mudguard - Replacement Time Vespa S 125 TIME - 222[...]

Fuel tank FUEL TANK Code Action Duration 1 004168 Fuel tank cap - Replacement 2 005010 Tank float - Replacement 3 004112 Cock-carburettor hose - Replace- ment 4 004005 Fuel tank - Replacement 5 004007 Fuel valve - Replacement 6 004109 Fuel tank breather - Replacement Vespa S 125 Time TIME - 223[...]

Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber - Removal and Refitting 2 003085 Suspension strut - Replacement Time Vespa S 125 TIME - 224[...]

Steering column bearings S TEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheel - Replacement 2 003073 Steering clearance - Adjustment 3 004119 Bearing / upper steering fifth wheel - Replacement Vespa S 125 Time TIME - 225[...]

Handlebar covers ODOMETER - HANDLEBAR COVER Code Action Duration 1 004018 Handlebar front section - Replace- ment 2 004019 Handlebar rear section - Replace- ment 3 005014 Odometer - Replacement 4 005038 Instrument panel warning light bulbs - Replacement Time Vespa S 125 TIME - 226[...]

Handlebar components HANDLEBAR COMPONENTS Code Action Duration 1 004066 Driving mirror - Replacement 2 002037 Brake or clutch lever - Replacement 3 002071 Left hand grip - Replacement 4 003001 Handlebar - Removal and refitting 5 005017 Stop switch - Replacement 6 002024 Front brake pump - Removal and Re- fitting 7 003061 Accelerator transmission - [...]

Swing-arm SWINGING ARM Code Action Duration 1 001072 Swinging arm - Engine-chassis con- nection - Replacement Time Vespa S 125 TIME - 228[...]

Seat S ADDLE Code Action Duration 1 004003 Saddle - Replacement Vespa S 125 Time TIME - 229[...]

Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 1 005002 Front headlamp - Replacement 2 005012 Front turn indicator - Replacement 3 005067 Front turn indicator bulb - Replace- ment 4 005008 Front headlamp bulbs - Replacement 5 005005 Taillight - Replacement 6 005066 Rear light bulbs - Replacement 7 005022 Rear turn indicators - Replac[...]

Front wheel FRONT WHEEL Code Action Duration 1 004123 Front wheel - Replacement 2 003047 Front tyre - replace 3 003037 Front wheel rim- Replacement 4 003033 Front wheel hub- Replacement 5 002041 Front brake disc - Replacement 6 003034 Front wheel hub bearing - Replace- ment Vespa S 125 Time TIME - 231[...]

Rear wheel R EAR WHEEL Code Action Duration 1 004126 Rear wheel tyre - Replacement 2 001071 Rear wheel rim - Removal and Refit- ting 3 001016 Rear wheel - Replacement Time Vespa S 125 TIME - 232[...]

Fuel pump FUEL PUMP Code Action Duration 1 004073 Fuel pump - Replacement 2 004089 Tank-pump hose - Replacement 3 004137 Carburettor pump hose - Replace- ment 4 004072 Fuel filter - Replacement Vespa S 125 Time TIME - 233[...]

Electric devices ELECTRICAL COMPONENTS Code Action Duration 1 005001 Electrical system - Replacement 2 005011 Start-up remote control switch - Re- placement 3 005009 Voltage regulator - Replacement 4 005007 Battery - Replacement 5 005052 Fuse (1) - Replacement 6 001023 Control unit - Replacement 7 001094 Spark plug cap - Replacement 8 001069 HV coi[...]

Electronic controls ELECTRICAL CONTROLS Code Action Duration 1 005039 Headlight switch - Replacement 2 005006 Light switch or turn indicators - Re- placement 3 005040 Horn button - Replacement 4 005003 Horn - Replacement 5 005041 Starter button - Replacement 6 005016 Key switch - Replacement 7 004096 Lock series - Replacement 8 004010 Anti-theft lo[...]

Transmissions TRANSMISSIONS Code Action Duration 1 002053 Rear brake transmission complete - Replacement 2 002051 Odometer transmission assembly - Replacement 3 002049 Odometer cable - Replacement Time Vespa S 125 TIME - 236[...]

Front suspension FRONT SUSPENSION Code Action Duration 1 003045 Steering tube - Replacement 2 003010 Front suspension - Service 3 003035 Shock absorber support and brake calliper - Replacement 4 001064 Odometer reel - Replacement 5 003044 Shock absorber cover - Replace- ment 6 003011 Front shock absorber - Removal and Refitting Vespa S 125 Time TIM[...]

Braking system BRAKING SYSTEM Code Action Duration 1 002021 Front brake hose - Remov. and Re- fitt. 2 002007 Front brake shoes/pads - Remov. and Refitt 3 002039 Front brake calliper - Removal and Refitting 4 002047 Front brake fluid and air bleeding system - Replacement 5 002002 Shoes - Rear brake pads - Replace- ment Time Vespa S 125 TIME - 238[...]

Secondary air box SECONDARY AIR SYSTEM Code Action Duration 1 001164 Crankcase secondary air connection - Replacement 2 001161 Secondary air filter - Replacement / Cleaning 3 001174 SAS valve - Replacement 4 001163 Muffler secondary air connection - Replacement Vespa S 125 Time TIME - 239[...]

A Air filter: 35 , 186 B Battery: 48 , 59 , 65 , 68 Brake: 172 , 174 , 176 , 178 Brake fluid: 176 C Carburettor: 11 , 138 , 143 , 213 E Engine oil: 35 F Fuel: 39 , 47 , 136 , 187 , 223 , 233 H Headlight: 42 , 183 Hub oil: 33 I Identification: 8 Instrument panel: 182 M Maintenance: 7 , 29 O Odometer: Oil filter: 38 , 203 S Saddle: Shock absorbers: 1[...]