Vespa PX 150 USA manual

WORKSHOP MANUAL 633376 Vespa PX 150 USA[...]

WORKSHOP MANUAL Vespa PX 150 USA[...]

WORKSHOP MANUAL Vespa PX 150 USA This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio- Gilera dealers and sub-agents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the principles of mechanics and standard procedures required for gen[...]

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INDEX OF TOPICS C HARACTERISTICS CHAR T OOLING TOOL M AINTENANCE MAIN 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 Safety rules - Should it be necessary to keep the engine running while servicing, make sure that the area or room is well ventilated, and use special exhaust fans, if required. Never let the engine running in closed rooms. In fact, exhaust gases are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin.[...]

Specification Desc./Quantity Max lenght 69,29 inch (1760 mm) Handlebars width 27,56 inch (700 mm) Engine ENGINE Specification Desc./Quantity Engine type 2-stroke with rotary intake timing No. of cylinders 1 Alesaggio per corsa (150) 0,19 x 2,24 inch (58 x 57 mm) Cilindrata (150) 919 inch3 (150,599 cm3) Compression ratio (150) 8 : 1 Carburetor Dell&[...]

Specification Desc./Quantity Clutch Multi-disc. Cooling Forced air by a centrifugal fan. Max power output (shaft) 150cc 6.6 Kw (9 hp) at 5,700 rpm 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. Oil t[...]

Wheels and tyres WHEELS AND TIRES Specification Desc./Quantity Front tire 3,50 x 10" Rear tire 3,50 x 10" Rims Pressed steel Wheels Interchangeable with 2.00"×10" pressed steel rims. Front tire pressure 18,85 PSI (1,3 bar) Rear tire pressure 26,11 PSI (1,8 bar) 33,36 PSI (2,3 bar) driver and passenger N.B. CHECK AND ADJUST TYRE[...]

Tightening Torques STEERING UNIT Name Torque in Nm Upper steering ring nut 5÷6 Top steering housing 6÷7 (hence loosen by 80° - 90°) Handlebar fixing screw* 30÷44 FRAME Name Torque in Nm Engine - frame bolt * 61 ÷ 75 Rim - hub fixing nuts (front-rear) 20 ÷ 27 Shock-absorber - frame fixing nut* 30÷40 Shock-absorber - engine bolt* 13 ÷ 23 Rea[...]

Overhaul data Assembly clearances Cylinder - piston assy. The cylinder classification must be carried out at 25 mm from the head mating surface on the rod's swinging plane. MATING CATEGORIES - 150CC ENGINE Name Initials Cylinder Piston Play on fitting Cylinder - piston B 57,795 57,555 0,240 Cylinder - piston C 57,800 57,650 0,240 Cylinder - pi[...]

Name Initials Cylinder Piston Play on fitting 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 0,240 Cylinder - piston (3rd oversize) C 58,400 58,160 0,240 Cylinder - piston (3rd oversize) D 58,405 58,165 0,240 Cylinder - piston (3rd oversi[...]

Crankcase - crankshaft - connecting rod CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE «E» BETWEEN BIG END AND HALF CRANKSHAFT ON FLYWHEEL-SIDE Name Description Dimensions Initials Quantity Connecting Rod A= 15,4 +0 -0,05 E 0,15 ÷ 0,46 Washer (2) G= 0,5 +0,05 -0,03 E 0,15 ÷ 0,46 Half-crankshaft clutch- side C= 11,1 -0 +0,05 E 0,15 ÷ 0,46 Half[...]

− The maximum allowable end-play for the connecting rod after use (intended as the longitudinal slide on the big end) is 0.7mm . Gearbox shoulders GEARBOX SHOULDERS Name Description Dimensions Initials Quantity Shoulder 2,05 +0 -0,06 A 0,15 ÷ 0,40 Shoulder (1st oversize) 2,20 +0 -0,06 A 0,15 ÷ 0,40 Shoulder (2nd oversize) 2,35 +0 -0,06 A 0,15 ?[...]

INDEX OF TOPICS T OOLING TOOL[...]

TOOLING 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 002850y Oil tank spanner 002973y Fuel tap spanner 020320Y Exhaust gases analyser Vespa PX 150 USA Tooling TOOL - 17[...]

Stores code Description 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 150 USA TOOL - 18[...]

Stores code Description 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 001330Y Tool for fitting steering seats Vespa PX 150 USA Tooling TOOL - 19[...]

Stores code Description 020021Y Front suspension service 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 150 USA TOOL - 20[...]

Stores code Description 020151Y 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 150 USA Tooling TOOL - 21[...]

Stores code Description 020265Y 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 150 USA TOOL - 22[...]

INDEX OF TOPICS M AINTENANCE MAIN[...]

Maintenance chart EVERY 2 YEARS Action Brake fluid - change AT 621,37 MILES OR 4 MONTHS 80' Action Gear-box oil level - replacement Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure an[...]

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 Tyre condition and wear - Check Vehicle and brake test - road test AT 12427 MILES 135'[...]

Action Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyre condition and wear - Check Vehicle and brake test - road test (*) See regulations in section «Idling speed adjustment» AT 21748 MILES 65' Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor -[...]

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 Transmission elements - lubrication Safety locks[...]

Carburettor Disassemble the carburetor and clean all compo- nents with solvent, hence dry with compressed air all ducts, in order to ensure proper cleaning. • Carefully check the state of each com- ponent. • The throttle valve must be free to slide inside the mixture chamber; replace if excessive play is found. • If the mixture chamber is exc[...]

− In the impossibility of obtaining the specified val- ues, or if the engine is found to be running rough, proceed by replacing defective components. Specific tooling 020330Y Stroboscopic light to check timing 020332Y Digital rev counter Spark plug − Detach the spark plug cap − Carefully inspect the spark plug and replace it if the insulator [...]

Headlight adjustment Proceed as follows: 1. Place the vehicle, in riding order and with the tyres inflated to the prescribed pressure, on flat ground, 32,81 feet (10 m) away from a half-lit white screen. Ensure the vehicle axis is perpendicular to the screen; 2. Turn the headlight on and check the projec- tion of the light beam is between 7/10 and [...]

Vespa PX 150 USA Maintenance MAIN - 31[...]

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

Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple LEGENDA Specification Desc./Quantity 1 Rear stop light switch 2 Light switch 3 Turn indicator switch 4 Horn button 5 Horn 6 2 yellow lights for turn signal lights 7 Front left turn indicator 8 Heater contro[...]

Specification Desc./Quantity 19 Voltage regulator 20 Mixer oil warning light control 21 Starter remote control 22 Frame earth 23 Starter motor wire unit 24 Automatic starter 25 Heater 26 Chassis wire unit 27 Fuel level sender 28 front right turn indicator 29 Key switch 30 Starter button 31 Front brake stop button 32 Headlight 33 Light 34 Sidelight [...]

Components arrangement COMPONENTS ARRANGEMENT Specification Desc./Quantity 1 Key switch 2 Voltage regulator 3 Electronic Control Unit (C.D.I.) with H.T coil 4 Battery 12V - 9Ah 5 Starter motor 6 Magneto flywheel 7 Anti-repeating 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 [...]

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 150 USA ELE SYS - 36[...]

Headlights and automatic starter section FANALERIA Specification Desc./Quantity 1 Voltage regulator 2 Magneto flywheel 3 Key switch contacts 4 Lampada proiettore 12V-55/60W 5 High-beam warning light 12V - 1.2W 6 Light switch 7 Light remote control switch 8 Rear side light bulb 12V - 5W 9 Instrument panel lighting bulb 12V-1,2W 10 Headlamp warning l[...]

Battery recharge and starting RICARICA BATTERIA E AVVIAMENTO Specification Desc./Quantity 1 Magneto flywheel 2 Electronic ignition device 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 12 Engine stop switch 13 Engine stop [...]

Level indicators and enable signals section SAFETY SWITCHES AND LEVEL GAUGES Specification Desc./Quantity 1 Fuel gauge 2 Fuel level sending unit 3 Reserve fuel light 12V-1,2W 4 Brake light bulbs 12V-10W 5 Stoplight switches 6 Voltage regulator Vespa PX 150 USA Electrical system ELE SYS - 39[...]

Turn signal lights SIGNAL LIGHTS AND HORN 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 8 Key switch contacts 9 Fuse 7,5A 10 Battery 12V - 9Ah Electrical system Vespa PX 150 USA ELE SYS - 40[...]

Instruments and warning lights control board DASHBOARD LIGHTS AND GAUGES Specification Desc./Quantity 1 + Battery 2 Fuel gauge 3 Low fuel warning light 4 Turn signals warning light 5 High-beam warning light 6 Side-lamps warning light 7 Ground lead (-) Checks and inspections Ignition circuit All system checks requiring the detachment of ca- bles (in[...]

IGNITION CIRCUIT Specification Desc./Quantity 1 WHITE 2 RED 3 GREEN 4 GREEN Stator check In the event of a malfunctioning of the ignition sys- tem, with no evident cause, it will be necessary to replace the ECU. − Remember that all wires can only be detached with the engine off. − If the ignition system is found to be working prop- erly once th[...]

Voltage regulator check Voltage regulator inspection In the event of a suspected failure of the voltage regulator, carry out the following inspections: Alternate current section The failure of the alternate current section of the voltage regulator give rise, depending on the type of fault, to the following inconveniences: 1. Blown light bulbs (regu[...]

4) Battery recharge faulty (regulator open-circuit- ed). Interventions FAULT 3 Replace the regulator, as certainly faulty, and the fuse. FAULT 4 a) Attach an ammeter between the voltage regu- lator and the battery, and check that, at 3,000 rpm and with the battery at 13V , the current sup- plied is approximately 1.5 to 2 A. If the measured values a[...]

STARTER MOTOR Specification Desc./Quantity 1 Nominal voltage 12V 2 Nominal power 0,15 kW 3 Direction of rotation Clockwise 4 Engine connection Via pinion and gear ring on crankshaft, transmission-side 5 Control Pushbutton 6 Battery 12V - 9Ah Fuses The starter system and horn are protected by a 7.5A fuse, « A », located on the LHS of the battery t[...]

ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE. Dry-charge battery BATTERY START UP WITH DRY CHARGE - Remove the battery ventilation duct closing cap and remove the caps from the single elements. - Fill the battery with electrolyte having a density of 1.270+/-0.01 Kg/l (corresponding to 31+[...]

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

Exhaust assy. Removal − Remove the two fasteners, exhaust pipe-mani- fold and then the bolt fixing the exhaust to the engine. Removal of 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 a[...]

− Remove the rear shock-absorber fixing nut and hence the bolt. − For the reassembly, follow the above operations in reverse order, using the prescribed 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 caref[...]

INDEX OF TOPICS E NGINE ENG[...]

Flywheel cover Cooling hood − Remove the three fixing screws shown in the figure and the 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. − Rem[...]

Refitting the stator In order to guarantee the correct engine timing pay attention to the position of the stator, as shown in the figure. Flywheel and starting Removing the starter motor − Remove 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, [...]

− Using pliers for internal split rings, remove the retaining ring shown. − Lift the assembly by the end of the shaft and re- move the shaft by hitting the housing with a mallet. − The removal of the bearing may be carried out by pushing in the direction shown in the figure. This will also result in the removal of the drive gear. − In the e[...]

− After removing the rear cover, release the brush clips connected to the magnetic fields. − Remove the brush plate. Detach the old brushes and weld a new set of brushes, hence replace the brush plate. − After removing the rear cover, detach the drive gear retaining pin and remove the gear. − Refit the assembly components in the reverse ord[...]

Refitting the flywheel magneto − Refit the components following above opera- tions in the reverse order. − After refitting the flywheel, apply grease on the thread. Recommended products AGIP GREASE PV2 Grease for steering bear- ings, bolt seatings for swinging arms and fay- ing surface of driven pulley spring (only pulley side) Soap-based lithi[...]

Inspecting the small end − Always fit a roller cage of the type prescribed in the assembly clearance tables. − The arrow in the figure shows the location of the connecting rod's identification marking. Refitting the cylinder − Refit the cylinder assembly components following the removal procedure in the reverse order, paying particular a[...]

Removing the crankshaft − Install the special tool as shown and extract the crankshaft. Specific tooling 008886Y Crankshaft extractor Removing the crankshaft bearings − After removing the oil seal, using pliers for inter- nal split rings, remove the bearing retaining ring shown. − From the side opposite that shown in the figure and with the a[...]

Refitting the crankshaft bearings − Heat the bearing housing with the air heater positioned onto its support. − After heating the crankcase, position the bearing using a length of tube pushing directly on the bear- ing's outer ring. − Position the bearing's retaining ring, hence pro- ceed by refitting the sealing ring. Specific tool[...]

Lubrication Conceptual diagrams Automatic fuel mixer The system is fed by oil contained in a separate tank. The vehicle is equipped with two distinct tanks, each with individual hoses, for fuel and lubricant. The fuel tank must be filled with petrol, no petrol-oil mixture of any kind, while for the lubricant tank Selenia Hi Scooter 2T oil should be[...]

CONCEPTUAL DIAGRAMS Specification Desc./Quantity Fuel tank filler cap 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 150 USA ENG - 60[...]

− Remove the 3 fixing screws and the mixer cover with the lever. − Remove the mixer pumping element. − Remove the mixer fixing screw and then 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 i[...]

Fuel supply Removing the carburettor − Remove the two fixing screws and the carburetor cover. − Remove the fasteners and the air filter. − After removing the air filter, loosen the two 8mm Allen screws and hence remove the carburetor. − Loosen the fixing screw and remove the carbu- retor body. Engine Vespa PX 150 USA ENG - 62[...]

− Remove the main and idle jets and 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 150 USA Engine ENG - 63[...]

− Check the starter choke valve; replace if worn. Refitting the carburettor − Refit the components replacing all seals. WARNING 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 punche[...]

− Split the two half-crankcases. − Using pliers for external split rings, remove the retaining ring and 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 comp[...]

− After removing the internal oil seal and the ex- ternal dust cover, remove the bearing retaining ring through the use of internal split ring pliers. − Extract the roller bearing using a flat head punch- er from the side opposite to that shown in the figure. − After removing the retaining washer shown in the figure, remove the fastener under[...]

− Refit the trunnion «A» onto the gear shifter shaft «B» and tighten it to the prescribed torque (LHS thread). − Prepare a tool «D» as shown in the figure and insert it into the groove machined on the shaft. − Align the tool's protrusion «C» with the edge «F» of the bushing to be rounded. − Using a hammer and a length of tube[...]

Axial play 0,20 ÷ 0,40 mm − Using the special tool, proceed by removing 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 150 USA ENG - 68[...]

− Restrain the clutch using the special tool, as shown in the figure, then remove the locknut and the clutch assembly. CAUTION DURING THE OPERATIONS OF REMOVAL, DO NOT LET THE WOODRUFF KEY FALL INSIDE THE ENGINE. Specific tooling 001729Y Clutch retaining tool − Remove the mixer drive gear from its housing. − Using the special tool, remove the[...]

− Place the mixer drive gear with the rounded edge facing the crankcase bearing. − Correctly position the woodruff key inside its housing. − Refit 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 [...]

INDEX OF TOPICS S USPENSIONS SUSP[...]

Front Front wheel hub overhaul After removing the front brake calliper, remove the plastic cap shown in the figure. Remove the pin and the locknut. It is now possible to remove the wheel axle nut. After removing the split ring on the outer side of the wheel hub, and the seal ring, remove the bear- ing using a length of pipe of adequate diameter and[...]

Refitting Upon reassembly, tighten to the prescribed tor- que. N.B. * Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TOR- QUE, LUBRICATE NUTS BEFORE ASSEMBLY. Locking torques (N*m) Handlebar fixing screw* 30÷44 Steering column Removal − After removing the top housing, lean the vehicle on one side and extract the steering column, ma[...]

Use a suitable punch with the dimensions indica- ted on the figure; hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end. Repeat the operation for the second washer using the punch on the side opposite to the one shown in the figure. Use the tool fitted with part 1 as shown in the figure and move [...]

Recommended products AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum disul- phide; ISO-L-XBCHB2, DIN KF2K-20 Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time. - Remove the tool and the part 5 (guide), which has been partially ejected during the previ[...]

- Now, remove the two spacers (parts 17 and 16) and, once the space between the NADELLAs - steering tube and swinging hub - has been fully filled with grease, move the dust guard rings until they are placed in that space. - By wedging the washers as described above, the front suspension unit refitting stage is finished. Recommended products AGIP GR[...]

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 to[...]

Removal Remove 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 whee[...]

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. Centre-stand Detach the return sp[...]

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

Front brake calliper Removal − Detach the brake hose from the calliper using a container to collect the fluid. − Remove the fasteners shown in the figure. Refitting − When refitting, tighten the nuts to the prescribed torque. − Bleed the system. N.B. * Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFOR[...]

N.B. * Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE AS- SEMBLY. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Disc fixing screw* 5÷6 Disc Inspection − Remove the wheel and check any possible disc's out-of-plane. The measu[...]

Fill Front − Once the bleeding valve is shut, top-up the circuit using fresh brake fluid. − Loosen the bleed screw. − Connect the special tool's tube to the bleed hole. To bleed the system, constantly refill the reservoir, while pumping out air with the Mityvac, until all air has been removed from the circuit, i.e. only fluid is pumped o[...]

Front brake pump Removal − Loosen the two fasteners shown in the figure. − Detach the hose, collecting the fluid inside a container. 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 ?[...]

− After removing the hub, proceed as follows: 1. Remove the shoe spring using the special pliers. 2. Remove the two retainers shown in the figure. 3. Remove the shoes using a lever. 4. Fit the new shoes with the aid of a mallet. 5. Attach the return spring using the special pliers. Specific tooling 020325Y Brake-shoe spring calliper − Refit the[...]

INDEX OF TOPICS C HASSIS CHAS[...]

Seat Remove the 3 fasteners shown in the figure. Rear handlebar cover After removing the rear-view mirrors, the attach- ments and their seals, remove the four fasteners shown in the figure, detach the electrical wiring and the odo/speedometer cable to replace the dashboard assembly. Once the handlebar is removed act upon the two lips on the dashboa[...]

− Remove the 2 fasteners for each turn signal light. Removing the ignition key-switch when on *off* To remove the ignition key-switch when in the «ON» position, i.e. steering lock disengage and ignition earthed, proceed as follows: − Remove the three handlebar fixing screws and the handlebar cover. − Insert a small screwdriver inside the ho[...]

Replace the seat and glove-box cylinders. To re- place these follow the operations described for the removal of the cylinder when the ignition key- switch is in the «LOCK» position. If the locks have been left open however, extract the cylinder by pushing lip «F» shown in the figure after having carefully cleaned the housing. Then insert the ne[...]

− Remove the 2 fasteners for each turn signal light. Fuel tank After removing the seat, detach the electrical con- nection of the fuel level sensor. Remove the 2 remaining fixings to free the fuel tank assembly. Lift both tanks thus detaching the hoses with the fuel tap shut to separate the fuel-oil tanks. Remove the tank filler cap and insert th[...]

Front mudguard − Remove the 2 fixings from underneath the mud- guard. − After 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. Vespa PX 150 USA Chas[...]

Front central cover After removing the 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). Chassis Vespa PX 150 USA CHAS - 92[...]

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

Carry out the listed tests before delivering the vehicle. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. Aesthetic inspection − Paint − Plastic joints − Damages − Dirt Tightening torques inspection − All tighten torques summarized in pages 1 - 5. − External covers screws. Electrical system − Fill the battery with acid, and charge with ap[...]

THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RA[...]

INDEX OF TOPICS T IME TIME[...]

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 Vespa PX 150 USA Time TIME - 97[...]

Crankshaft ENGINE SHROUD - CRANKCASE 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 Time Vespa PX 150 USA TIME - 98[...]

WRIST PIN PISTON CYLINDER 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 Vespa PX 150 USA Time TIME - 99[...]

Flywheel cover FAN COVER Code Action Duration 1 001087 Flywheel cover - Replacement Time Vespa PX 150 USA TIME - 100[...]

Oil pump AUTOMATIC MIXER Code Action Duration 1 001018 Mixer - Replacement 2 001028 Oil pump drive shaft - Replacement Vespa PX 150 USA Time TIME - 101[...]

Starter motor KICK-START LEVER Code Action Duration 1 008008 Kick-starter gear spring - Replace- ment 2 001120 Crankcase bearings - Replacements 3 001084 Starter lever - Replacement STARTER MOTOR Code Action Duration 1 001020 Starter motor - change 2 001039 Starter motor brushes - Replacement 3 001038 Starter motor - Overhaul Time Vespa PX 150 USA [...]

Code Action Duration 4 001017 Starter motor shaft - Replacement Flywheel magneto FLYWHEEL 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 Vespa PX 150 USA Time TIME - 103[...]

Carburettor CARBURETTOR Code Action Duration 1 001063 Carburettor - Replacement 2 001008 Carburatore - Revisione 3 003058 Carburettor - Adjustment Time Vespa PX 150 USA TIME - 104[...]

Exhaust pipe EXHAUST PIPE Code Action Duration 1 001009 Exhaust pipe - Replacement Vespa PX 150 USA Time TIME - 105[...]

Air cleaner AIR CLEANER Code Action Duration 1 001014 Air filter - Replacement 2 001027 Air-cleaner/frame bellow - Replace- ment Time Vespa PX 150 USA TIME - 106[...]

Frame FRAME Code Action Duration 1 004001 Frame - Replacement 2 006001 Frame - Painting 3 004023 Shield rim - Replacement Vespa PX 150 USA Time TIME - 107[...]

Centre-stand CENTRE-STAND Code Action Duration 1 004004 Centre-stand - Replacement Legshield spoiler Time Vespa PX 150 USA TIME - 108[...]

STEERING COLUMN FAIRING Code Action Duration 1 004024 Steering column fairing - Replace- ment Side fairings WHEEL SIDE FAIRINGS Code Action Duration 1 006005 Side fairings - Painting Vespa PX 150 USA Time TIME - 109[...]

SIDE FAIRING LOCKS Code Action Duration 1 004025 Side fairing locks - Replacement Footrests Time Vespa PX 150 USA TIME - 110[...]

FOOTRESTS Code Action 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 Vespa PX 150 USA Time TIME - 111[...]

Mudguard FRONT MUDGUARD Code Action Duration 1 004002 Front mudguard - Replacement 2 006003 Mudguard - Painting 3 003045 Steering tube - Replacement Time Vespa PX 150 USA TIME - 112[...]

Fuel tank FUEL LEVEL SENSOR Code Action Duration 1 005010 Fuel tank float - Replacement Vespa PX 150 USA Time TIME - 113[...]

FUEL TANK Code Action Duration 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 Time Vespa PX 150 USA TIME - 114[...]

Rear shock-absorber REAR SHOCK-ABSORBER Code Action Duration 1 003007 Rear shock-absorber - Removal and refitting Vespa PX 150 USA Time TIME - 115[...]

Steering column bearings STEERING COLUMN BEARINGS Code Action Duration 1 003002 Steering bearings - Replacement 2 004119 Steering support bearing - Replace- ment 3 003073 Steering play - Adjustment 4 004010 Steering lock - Replacement Time Vespa PX 150 USA TIME - 116[...]

Handlebar components 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 HANDLEBAR COMPONENTS AND BRAKE FLUID PUMP Code Action Duration 1 002059 RHS twist-grip - Replacement 2 002024 Front brake pump [...]

Code Action Duration 4 002021 Front brake hose - Removal and re- fitting Seat SEAT Code Action Duration 1 004003 Saddle - Replacement 2 004054 Saddle lock catch - Replacement Time Vespa PX 150 USA TIME - 118[...]

Instrument panel HANDLEBAR COVERS AND DASHBOARD Code Action Duration 1 005038 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 Vespa PX 150 USA [...]

Turn signal lights HEADLIGHT Code Action Duration 1 005008 Headlight bulbs - Replacement 2 005002 Front light - Replacement Time Vespa PX 150 USA TIME - 120[...]

TAILLIGHT Code Action Duration 1 005066 Rear light bulbs - Replacement 2 005005 Taillight - change 3 005028 Rear light assembly glass - Replace- ment TURN SIGNAL LIGHTS Code Action Duration 1 005011 Starter relay - Replacement 2 005012 Front turn signal light - Replacement 3 005067 Front turn indicator bulb - Replace- ment 4 005068 Rear turn indica[...]

Front wheel WHEEL Code Action Duration 1 004123 Front wheel - Replacement 2 003047 Front tyre - replace 3 003037 Front wheel rim - Removal and Re- fitting 4 006018 Wheel rim - Paintwork 5 003063 Tyre pressure - Check Grease tone wheel or drive Please take note that the code has been intro- duced: 900001 - Tone wheel / drive greasing - 15'. Nev[...]

Electric devices ECU - CDI Code Action Duration 1 001023 CPU - Replacement Vespa PX 150 USA Time TIME - 123[...]

ELECTRICAL CONNECTIONS Code Action Duration 1 005001 Electric circuit - Replacement and Refitting Time Vespa PX 150 USA TIME - 124[...]

BATTERY - VOLTAGE REGULATOR Code Action Duration 1 005009 Voltage regulator - Replacement 2 005007 Battery - Replacement 3 004071 Battery compartment - Replacement ELECTRICAL DEVICES Code Action Duration 1 005024 Battery fuse - Replacement 2 005025 Battery fuse holder - Replacement Vespa PX 150 USA Time TIME - 125[...]

ELECTRICAL DEVICES Code Action Duration 1 005013 Electronic blinker - Replacement 2 005045 Starter motor wire harness - Re- placement Time Vespa PX 150 USA TIME - 126[...]

ELECTRICAL DEVICES Code Action Duration 1 005003 Horn - Replacement 2 005017 Stop light switch - Replacement 3 005069 Left switch - Replacement Transmissions 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 - [...]

CABLES Code Action Duration 1 002055 Clutch cable assy. - Replacement 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 Time Vespa PX 150 USA TIME - 128[...]

Brake callipers 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 Vespa PX 150 USA Time TIME - 129[...]

Steering column STEERING COLUMN Code Action Duration 1 003010 Front suspension - Service Time Vespa PX 150 USA TIME - 130[...]

Front suspension FRONT SHOCK-ABSORBER Code Action Duration 1 003011 Front shock absorber - Removal and Refitting Vespa PX 150 USA Time TIME - 131[...]

Braking system REAR BRAKE PEDAL Code Action Duration 1 002014 Brake pedal - Removal and refitting FRONT WHEEL HUB Code Action Duration 1 003033 Front wheel hub- Replacement 2 002041 Brake disc - Replacement Time Vespa PX 150 USA TIME - 132[...]

Code Action Duration 3 003040 Front wheel bearings - Replacement REAR BRAKE SHOES Code Action Duration 1 002002 Rear brake shoe(s) - Replacement 2 003071 Rear brake shoe(s) - Wear check Vespa PX 150 USA Time TIME - 133[...]

SHOE PLATE Code Action Duration 1 002016 Rear brake shoe plate - Replace- ment 2 003012 Brake shoe plate - Removal and Re- fitting Time Vespa PX 150 USA TIME - 134[...]

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 Clutch cover CLUTCH COVER Code Action Duration 1 001073 Clutch cover - Removal and refitting Clutch Vespa PX 150 USA Time TIME - 135[...]

CLUTCH Code Action Duration 1 001022 Clutch - Removal Gear-box GEAR-BOX Code Action Duration 1 001119 Gearbox components - Replacement 2 001025 Gearbox - Overhaul Time Vespa PX 150 USA TIME - 136[...]

Gear shifter GEAR SHIFTER Code Action Duration 1 001029 Gear shifter - Overhaul GEAR SHIFTER FASTENERS Code Action Duration 1 001077 Gear shifter components - Removal and refitting Vespa PX 150 USA Time TIME - 137[...]

A Air filter: 29 B Battery: 38 , 46 Brake: 81 , 82 , 84 , 85 , 129 Brake fluid: C Carburettor: 10 , 28 , 61 , 62 , 64 , 104 F Fuel: 62 , 90 , 113 Fuses: 45 H Headlight: 30 , 87 Horn: I Instrument panel: 119 M Maintenance: 7 , 24 S Shock absorbers: 79 Spark plug: 29 T Tank: 90 , 113 , 114 Transmission: 9 Tyres: 10[...]