WORKSHOP MANUAL Vespa PX 125 150 Euro 2

WORKSHOP MANUAL Vespa PX 125 150 Euro 2

WORKSHOP MANUAL

633241

Vespa PX 125 150 Euro 2

WORKSHOP

MANUAL

Vespa PX 125 150 Euro 2

WORKSHOP MANUAL

Vespa PX 125 150 Euro 2

This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio-Gilera dealers and subagents. 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 general vehicle repair. Any relevant changes concerning the vehicle characteristics or specific repair operations will be divulged in the form of updates to this manual. Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer to the pages of this manual concerning specific tools and equipment and the special tools catalogue.

N.B.

Provides key information to make the procedure easier to understand and carry out.

CAUTION

Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING

Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety

Failure to completely observe these instructions will result in serious risk of personal injury.

Safeguarding the environment

Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness

The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

C

HARACTERISTICS

T

OOLING

M

AINTENANCE

E

LECTRICAL SYSTEM

E

NGINE FROM VEHICLE

E

NGINE

S

USPENSIONS

B

RAKING SYSTEM

C

HASSIS

P

RE

-

DELIVERY

T

IME

CHAR

TOOL

MAIN

ELE SYS

ENG VE

ENG

SUSP

BRAK SYS

CHAS

PRE DE

TIME

INDEX OF TOPICS

C

HARACTERISTICS

CHAR

Vespa PX 125 150 Euro 2

Characteristics

Rules

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

Vehicle identification

Specification

Frame prefix (125)

Engine prefix (125)

Frame prefix (150)

VEHICLE IDENTIFICATION

Desc./Quantity

VNX2T

VNX1M

VLX1T

CHAR - 7

Characteristics

Vespa PX 125 150 Euro 2

Specification

Engine prefix (150)

Dimensions and mass

Desc./Quantity

VLX1M

Specification

Empty weight

Wheelbase

Max height

Max length

Handlebars width

WEIGHT AND DIMENSIONS

Desc./Quantity

104 Kg

1235 mm

1110 mm

1760 mm

700 mm

Engine

CHAR - 8

Specification

Engine type

ENGINE

Desc./Quantity

2-stroke with rotary intake timing

Vespa PX 125 150 Euro 2

Characteristics

Specification

No. of cylinders

Bore and stroke (125)

Bore and stroke (150)

Displacement (125)

Displacement (150)

Compression ratio (125)

Compression ratio (150)

Carburettor

Engine idle speed

CO value

Air filter

Starting system

Lubrication

Fuel supply

Clutch

Cooling

Max power output (shaft) 125cc

Max power output (shaft) 150cc

Max speed (125)

Max speed (150)

Transmission

Desc./Quantity

1

52,2 x 57 mm

58 x 57 mm

123,4 Cm3

150,599 Cm3

8 : 1

8 : 1

Dell'orto SI 20/20 D

1900 ± 100 rpm

3,8 ± 0,5%

Metallic net soaked in oil-petrol mixture

Electric starter motor and kick-start

Mixture oil

Oil-petrol mixture through carburettor with automatic mixer

(mass flow varying with engine speed) and throttle valve

Multi-disc.

Forced air by a centrifugal fan.

6 Kw (8 hp) at 5600 rpm

6.6 Kw (9 hp) at 5,700 rpm

80,7 Km/h

82,8 Km/h

Specification

Gear-box

TRANSMISSION

Desc./Quantity

4-speed with constantly engaged gears

Capacities

Specification

Gear-box

Mixer oil tank

Fuel tank

Electrical system

CAPACITIES

Desc./Quantity

~ 250 cc.

~1.6 litres (including 0.4 l reserve)

~8 litres (including ~2.1 l reserve)

3

4

1

2

5

6

ELECTRICAL SYSTEM

Specification

Ignition type

Spark advance (T.D.C.)

Spark plug

Battery

Fuse

Generator

Desc./Quantity

Electronic ignition by capacitive discharge with H.T. coil

18° ± 1

CHAMPION RL82C

12V - 9Ah

7.5 A

AC

Frame and suspensions

Specification

Suspensions

Frame

FRAME AND SUSPENSIONS

Desc./Quantity

Steering column pivoted onto front wheel hub, helicoid spring suspension and hydraulic shock-absorber (compression and rebound damping)

Monocoque-type shell obtained from pressed steel

CHAR - 9

Characteristics

Vespa PX 125 150 Euro 2

Brakes

Specification

Front

Rear

BRAKES

Desc./Quantity

Ø 220 mm disc hydraulically operated via lever mounted on

RHS of handlebars

Ø 140 mm drum with expanding shoes mechanically activated via pedal on RHS of footrest

Wheels and tyres

Specification

Front tyre

Rear tyre

Rims

Wheels

Front tyre pressure

Rear tyre pressure

WHEELS AND TYRES

Desc./Quantity

3,50 x 10"

3,50 x 10"

Pressed steel

Interchangeable with 2.00"×10" pressed steel rims.

1,3 bar

1,8 bar

2,3 bar driver and passenger

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-

LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Carburettor

125cc Version

Dell'Orto

CARBURETTOR

Specification

Type

Diffuser diameter

Main jet

Slow running jet

Main air jet

Throttle valve (type)

Emulsifier (code)

Sprayer

Starter jet

Air idling screw

* With idling air hole 140/100

150cc Version

Desc./Quantity

SI20/20D

20 mm

96/100

45/100 *

140/100

6823.09

BE5

280/100

60/100

1/2 turn

CHAR - 10

Vespa PX 125 150 Euro 2

Characteristics

Dell'Orto

CARBURETTOR

Specification

Type

Diffuser diameter

Main jet

Slow running jet

Main air jet

Throttle valve (type)

Emulsifier (code)

Sprayer

Starter jet

Air idling screw

Tightening Torques

Desc./Quantity

SI20/20D

20 mm

98

45/160

150

6823.16.64

BE5

280/100

60/100

1 3/4

STEERING UNIT

Name

Upper steering ring nut

Top steering housing

Handlebar fixing screw*

FRAME

Name

Engine - frame bolt *

Rim - hub fixing nuts (front-rear)

Shock-absorber - frame fixing nut*

Shock-absorber - engine bolt*

Rear wheel axle*

FRONT SUSPENSION

Name

Shock-absorber mounting plate - steering column fixing nuts

Upper shock-absorber fixing nut

Lower shock-absorber fixing nut

Front wheel axle nut*

FRONT BRAKE

Name

Reservoir - pipe fitting

Pipe - calliper fitting

Intermediate pipe fitting

Calliper fixing screw*

Disc fixing screw*

Oil draining screw

ENGINE

Name

Coils mounting bracket fixing screw

Kick-start lever fixing nut

Clutch assy. fixing nut

Multi-gear pinion nut

Flywheel fixing nut

Carburettor fixing bolts

Clutch cover fixing screws

Cylinder head fixing nuts

Spark plug

Crankcase mating screws

Torque in Nm

5÷6

6÷7 (hence loosen by 80° - 90°)

30÷44

Torque in Nm

61 ÷ 75

20 ÷ 27

30÷40

13 ÷ 23

75÷90

Torque in Nm

20÷27

30÷40

20÷27

60÷100

Torque in Nm

8÷12

15÷25

10÷15

20÷25

5÷6

10÷12

Torque in Nm

3÷4

23÷26

40 ÷ 45

30 ÷ 35

60 ÷ 65

16÷20

6÷8

13÷18

20÷25

11÷13

CHAR - 11

Characteristics

Vespa PX 125 150 Euro 2

Name

Wheel axle nut

Gear shifter nuts

Starter motor screws

Fan cover screws

Air-box fixing screws

Gear fixing nut

Mixer fixing screws

Head fixing nuts

Gear-box trunnion

Torque in Nm

90÷110

12÷15

10÷12

8÷10

6÷8

30÷35

6÷8

16 ÷ 26

15 ÷ 18

N.B.

* Safety tightenings

IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE AS-

SEMBLY.

NOTICE OF TECHNICAL SERVICING

Tightening torque - riding mirror

This is to inform you that a standard tightening torque has been introduced for the riding mirror fixing screw:

20 - 25 Nm.

Overhaul data

Assembly clearances

Cylinder - piston assy.

The cylinder classification must be carried out at 25 mm from the head mating surface on the rod's swinging plane.

CHAR - 12

Vespa PX 125 150 Euro 2

Characteristics

Name

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

C

D

E

F

G

C

D

E

F

G

F

G

MATING CATEGORIES - 125CC ENGINE

Initials

F

G

H

C

B

C

D

E

Cylinder

52,505

52,510

52,515

52,520

52,525

52,530

52,535

52,710

Piston

52,290

52,295

52,300

52,305

52,310

52,315

52,320

52,495

D

E

52,715

52,720

52,500

52,505

53,110

53,115

53,120

53,125

53,130

52,725

52,730

52,910

52,915

52,920

52,925

52,930

52,895

52,900

52,905

52,910

52,915

52,510

52,515

52,695

52,700

52,705

52,710

52,715

Play on fitting

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

0,215

CHAR - 13

Characteristics

Vespa PX 125 150 Euro 2

Name

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (1st oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (2nd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

Cylinder - piston (3rd oversize)

CHAR - 14

C

D

E

F

C

D

E

F

G

F

G

MATING CATEGORIES - 150CC ENGINE

Initials

F

G

H

C

B

C

D

E

Cylinder

57,795

57,800

57,805

57,810

57,815

57,820

57,825

58,000

Piston

57,555

57,650

57,565

57,570

57,575

57,580

57,585

57,760

D

E

58,005

58,010

57,765

57,770

58,015

58,020

58,200

58,205

58,210

58,215

58,220

58,400

58,405

58,410

58,415

57,775

57,780

57,960

57,965

57,970

57,975

57,980

58,160

58,165

58,170

58,175

Play on fitting

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

0,240

Vespa PX 125 150 Euro 2

Name

Cylinder - piston (3rd oversize)

Piston rings

Initials

G

Cylinder

58,420

Piston

58,180

Characteristics

Play on fitting

0,240

Name

Piston ring

Piston ring (1st oversize)

Piston ring (2nd oversize)

Piston ring (3rd oversize)

Name

Piston ring

Piston ring (1st oversize)

Piston ring (2nd oversize)

Piston ring (3rd oversize)

PISTON RINGS - 125CC ENGINE

Description Dimensions

52,5

52,7

Initials

A

A

52,9 A

53,1 A

PISTON RINGS - 150CC ENGINE

Description Dimensions

57,8

58

Initials

A

A

58,2 A

58,4 A

Quantity

0,2 ÷ 0,35

0,2 ÷ 0,35

0,2 ÷ 0,35

0,2 ÷ 0,35

Quantity

0,2 ÷ 0,4

0,2 ÷ 0,4

0,2 ÷ 0,4

0,2 ÷ 0,4

CHAR - 15

Characteristics

Crankcase - crankshaft - connecting rod

Vespa PX 125 150 Euro 2

CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE «E» BETWEEN BIG END

AND HALF CRANKSHAFT ON FLYWHEEL-SIDE

Name

Connecting Rod

Washer (2)

Half-crankshaft clutchside

Half-crankshaft flywheel-side

Spacer tool

Description Dimensions

A= 15,4 +0 -0,05

G= 0,5 +0,05 -0,03

C= 11,1 -0 +0,05

D= 11,1 -0 +0,05

H= 38,95

Initials

E

E

E

E

Quantity

0,15 ÷ 0,46

0,15 ÷ 0,46

0,15 ÷ 0,46

0,15 ÷ 0,46

CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE «F» BETWEEN BIG END

ROLLER CAGE AND HALF CRANKSHAFT ON FLYWHEEL-SIDE

Name

Connecting Rod

Washer (2)

Half-crankshaft clutchside

Half-crankshaft flywheel-side

Spacer tool

Description Dimensions

B= 15,6 -0,1 -0,2

G= 0,5 +0,05 -0,03

C= 11,1 -0 +0,05

D= 11,1 -0 +0,05

H= 38,95

Initials

F

F

F

F

Quantity

0,05 ÷ 0,41

0,05 ÷ 0,41

0,05 ÷ 0,41

0,05 ÷ 0,41

Connecting rods and roller cages are subdivided into

4 categories

(indicated by markings on big end and outer cage rim, respectively)

Mate connecting

rod with cage of same category

; if such assembly results to be excessively noisy, use a roller cage from

next category

.

For the wrist pin, fitted with 0 clearance,

the maximum allowable play after use must be 0.02 mm.

CHAR - 16

Vespa PX 125 150 Euro 2

Characteristics

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

Shoulder

Shoulder (1st oversize)

Shoulder (2nd oversize)

Shoulder (3rd oversize)

Shoulder (4th oversize)

N.B.

Description Dimensions

2,05 +0 -0,06

2,20 +0 -0,06

2,35 +0 -0,06

2,50 +0 -0,06

2,65 +0 -0,06

Initials

A

A

A

A

A

Quantity

0,15 ÷ 0,40

0,15 ÷ 0,40

0,15 ÷ 0,40

0,15 ÷ 0,40

0,15 ÷ 0,40

IF THE SPECIFIED CLEARANCE «A» CANNOT BE ACHIEVED, REPLACE THE SHOULDER RING

WITH AN OVERSIZED ONE SUCH TO ALLOW OBTAINING THE PRESCRIBED PLAY. TO CHECK

THE CLEARANCE, USE A FEELER GAUGE.

Products

Product

AGIP GEAR 80W-90

AGIP CITY HI TEC 4T

AGIP GP 330

AGIP CITY TEC 2T

AGIP GREASE MU3

AGIP BRAKE 4

TABLE OF RECOMMENDED PRODUCTS

Description

gearbox oil

Specifications

SAE 80W-90 oil complying with API GL4 specifications

Oil for 2-stroke engines: SAE 5W-40, API

SL, ACEA A3, JASO MA

Oil to lubricate flexible transmissions

(brake, throttle control and mixer, odometer)

Grease (brake level, throttle twistgrip, gaer)

Mixer oil

Grease for odometer transmission gear case

Brake fluid

Calcium complex soap grease NLGI 2;

ISO-L-XBCIB2 synthetic oil for 2-stroke engines: JASO

FC, ISO-L-EGD

Soap-based lithium grease with NLGI 3;

ISO-L-XBCHA3, DIN K3K-20

FMVSS DOT 4 Synthetic fluid

CHAR - 17

INDEX OF TOPICS

T

OOLING

TOOL

Vespa PX 125 150 Euro 2

Stores code

020004Y

TOOLING

Description

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

Tooling

TOOL - 19

Tooling

Stores code

020325Y

Description

Brake-shoe spring calliper

Vespa PX 125 150 Euro 2

020329Y MityVac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rev counter

TOOL - 20

Vespa PX 125 150 Euro 2

Stores code

020333Y

Description

Single battery charger

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

Tooling

001330Y Tool for fitting steering seats

TOOL - 21

Tooling

Stores code

020021Y

Description

Front suspension service tool

Vespa PX 125 150 Euro 2

TOOL - 22

020321y Carburettor float removing tool

006029Y

020625Y

Punch for fitting fifth wheel seat on steering tube

Kit for sampling gas from the exhaust manifold

001467Y021 Extraction pliers for ø 11 mm bearings

Vespa PX 125 150 Euro 2

Stores code

020151Y

Description

Air heater

020150Y

020057Y

020095Y

008564Y

Air heater support

Calking tool

Flywheel retaining tool

Flywheel extractor

008886Y Crankshaft extractor

004499Y Camshaft bearing extractor

Tooling

TOOL - 23

Tooling

Stores code

020265Y

Description

Bearing fitting base

Vespa PX 125 150 Euro 2

060007Y Crankcase bearing spacer

060824Y Inspection probe

008119Y009 Tube to assemble shafts and axles

001729Y

020322Y

Clutch retaining tool

Clutch removing/fitting tool

TOOL - 24

INDEX OF TOPICS

M

AINTENANCE

MAIN

Maintenance

Vespa PX 125 150 Euro 2

Maintenance chart

Brake fluid - change

AT 1000 KM OR 4 MONTHS

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 and wear - check

Vehicle and brake test - road test

AT 5000 KM OR 12 MONTHS

Action

Gear-box oil level - check

Spark plug - replacement

Air filter on carburetor - Clean

Transmission gas mixer- adjust

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Electrical system and battery - check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

AT 10000 KM O 24 MONTHS

Action

Gear-box oil level - replacement

Spark plug - replacement

Air filter on carburetor - Clean

Idle speed (*) - adjustment

Transmission gas mixer- adjust

Odometer gear - greasing

Steering - adjustment

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Transmission elements - lubrication

Safety locks - check

Suspensions - check

Electrical system and battery - check

Headlight - adjustment check

Tyres condition and wear - Check

Vehicle and brake test - road test

(*) See regulations in section «Idling speed adjustement»

AT 15000 KM OR 36 MONTHS

Action

Gear-box oil level - check

Spark plug - replacement

Air filter on carburetor - Clean

Transmission gas mixer- adjust

Brake and clutch lever - greasing

EVERY 2 YEARS

Action

MAIN - 26

Vespa PX 125 150 Euro 2

Action

Brake pads - check condition and wear

Brake fluid level - check

Electrical system and battery - check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

AT 20000 KM

Action

Gear-box oil level - replacement

Spark plug - replacement

Air filter on carburetor - Clean

Idle speed (*) - adjustment

Cylinder cooling system - check/cleaning

Transmission gas mixer- adjust

Odometer gear - greasing

Steering - adjustment

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Transmission elements - lubrication

Safety locks - check

Suspensions - check

Electrical system and battery - check

Headlight - adjustment check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

(*) See regulations in section «Idling speed adjustement»

AT 25000 KM

Action

Gear-box oil level - check

Spark plug - replacement

Air filter on carburetor - Clean

Transmission gas mixer- adjust

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Electrical system and battery - check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

AT 30000 KM

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

Flexible brake lines - Change

Brake fluid level - check

Transmission elements - lubrication

Safety locks - check

Suspensions - check

Electrical system and battery - check

Headlight - adjustment check

Tyres condition and wear - Check

Vehicle and brake test - road test

Maintenance

MAIN - 27

Maintenance

(*) See regulations in section «Idling speed adjustement»

AT 35000 KM

Action

Gear-box oil level - check

Spark plug - replacement

Air filter on carburetor - Clean

Transmission gas mixer- adjust

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Electrical system and battery - check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

AT 40000 KM

Action

Gear-box oil level - replacement

Spark plug - replacement

Air filter on carburetor - Clean

Idle speed (*) - adjustment

Cylinder cooling system - check/cleaning

Transmission gas mixer- adjust

Odometer gear - greasing

Steering - adjustment

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Transmission elements - lubrication

Safety locks - check

Suspensions - check

Electrical system and battery - check

Headlight - adjustment check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

(*) See regulations in section «Idling speed adjustement»

AT 45000 KM

Action

Gear-box oil level - check

Spark plug - replacement

Air filter on carburetor - Clean

Transmission gas mixer- adjust

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Electrical system and battery - check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

AT 50000 KM

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

MAIN - 28

Vespa PX 125 150 Euro 2

Vespa PX 125 150 Euro 2

Brake fluid level - check

Transmission elements - lubrication

Safety locks - check

Suspensions - check

Electrical system and battery - check

Headlight - adjustment check

Tyres condition and wear - Check

Vehicle and brake test - road test

(*) See regulations in section «Idling speed adjustement»

Action

AT 55000 KM

Action

Gear-box oil level - check

Spark plug - replacement

Air filter on carburetor - Clean

Transmission gas mixer- adjust

Brake and clutch lever - greasing

Brake pads - check condition and wear

Brake fluid level - check

Electrical system and battery - check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

AT 60000 KM

Action

Gear-box oil level - replacement

Spark plug - replacement

Air filter on carburetor - Clean

Idle speed (*) - adjustment

Cylinder cooling system - check/cleaning

Transmission gas mixer- adjust

Odometer gear - greasing

Steering - adjustment

Brake and clutch lever - greasing

Brake pads - check condition and wear

Flexible brake lines - Change

Brake fluid level - check

Transmission elements - lubrication

Safety locks - check

Suspensions - check

Electrical system and battery - check

Headlight - adjustment check

Tyres condition and wear - Check

Vehicle and brake test - road test

Secondary air filter (external / internal) - Clean

(*) See regulations in section «Idling speed adjustement»

Maintenance

MAIN - 29

Maintenance

Carburettor

Disassemble the carburettor and clean all components with solvent, hence dry with compressed air all ducts, in order to ensure proper cleaning.

Carefully check the state of each component.

The throttle valve must be free to slide inside the mixture chamber; replace if excessive play is found.

If the mixture chamber is excessively worn, such to prevent the sliding of the throttle valve (although new), replace the carburettor.

All seals should be replaced upon reassembly.

Vespa PX 125 150 Euro 2

CARBURETTOR

Specification

Conical needle

Float

Emulsifier air adjusting screw

Emulsifier

Main jet

Slow-running jet

Fuel flow adjusting screw

Throttle valve adjusting screw

Throttle valve

Starter jet

Choke device

Checking the spark advance

In order to ensure the correct timing, check the stator is oriented so that the I.T. index (see figure) coincides with the marking found on the crankcase.

To check the timing, use a timing light, connecting it to the H.T. cable via the clip provided and then starting the engine.

The correct spark advance is obtained when, with the engine running between 2,500 and 3,000 rpm, the «P» index is aligned (±1°) with the I.T.

marking stamped on the volute.

MAIN - 30

Desc./Quantity

Vespa PX 125 150 Euro 2

In the impossibility of obtaining the specified values, 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 is damaged

Using a feeler gauge, measure the spark gap, and adjust it if necessary

Ensure the sealing washer is in good state

Refit the spark plug by screwing it in by hand, and tightening it at the prescribed torque using a box spanner

Electric characteristic

Spark plug

CHAMPION RL82C

Spark gap

0,5 ÷ 0,6 mm

Locking torques (N*m)

Spark plug

25 - 30 Nm

Air filter

Remove the engine cowling and the air-box cover by loosening the four fixing screws shown in the figure and the idle adjusting screw; hence release the filter.

Clean the filter with 50% fuel-oil mixture, hence dry it with compressed air.

Recommended products

AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISO-

L-EGD

Maintenance

MAIN - 31

Maintenance

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 perpendicular to the screen;

2

. Turn on the headlight and check that the borderline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10;

3

. If otherwise, adjust the right headlight with screw

«

A

».

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINI-

MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-

TORY REGULATIONS IN FORCE IN EVERY COUNTRY

WHERE THE vehicle IS USED.

CO check

The test must be carried out after carefully cleaning all carburettor components and air filter, and with the spark plug in good conditions.

Warm up the engine by riding the vehicle for at least ten minutes

Switch off the engine

Remove the 2 secondary air box screws shown in the figure

Place a plastic sheet between the one-way valve and the aluminium outlet as shown in the figure

Vespa PX 125 150 Euro 2

MAIN - 32

Vespa PX 125 150 Euro 2

Ensure the one-way valve packing properly seals the aluminium outlet fitting.

Refit the aluminium outlet onto the SAS box as shown in the picture.

Remove the gas outlet cap, shown in the figure, on the exhaust.

Attach the special tool and orientate the connectors as shown in the figure.

Start the engine, adjust the idle speed to 1,300

±100 rpm and check the CO readings are equal to

4±1% with the idle air adjusting screw opened by

2+¾ turns.

If the parameters here specified cannot be met, try adjusting the idle air adjusting screw. Otherwise, check the choke device.

Specific tooling

020320Y Exhaust gases analyser

020332Y Digital rev counter

020625Y Kit for sampling gas from the exhaust manifold

Maintenance

MAIN - 33

Maintenance

SAS filters inspection and cleaning

Remove the two screws «

A

» from the SAS aluminium cover. Disengage the metallic hose from the rubber fastener on the cover without detaching the hose from the sleeve. Remove the plate and the plastic cover and hence extract the sponge filter and wash with soap. Dry the filter with compressed air before refitting, having care to place the plate in the grooving machined onto the plastic and aluminium covers. Upon reassembly, always replace the O-ring, located on the cover.

Remove the sponge and wash it with soap and water. Dry it with compressed air before refitting.

Vespa PX 125 150 Euro 2

Gearbox Oil

Check for the presence of oil inside the gearbox

(oil capacity ~250 g); with the vehicle axis perfectly vertical, the oil level must be at the height of inspection hole «

A

».

To replace the oil, drain the box using filler hole

«

B

».

Pour some fresh oil and let the engine run for a few seconds, hence drain the box again.

Pour 250 g of fresh oil through hole «

A

», so that the level reaches the reference height.

Recommended products

AGIP GEAR 80W-90 gearbox oil

SAE 80W-90 oil complying with API GL4 specifications

MAIN - 34

INDEX OF TOPICS

E

LECTRICAL SYSTEM

ELE SYS

Electrical system

Vespa PX 125 150 Euro 2

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

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

ELECTRICAL SYSTEM

Specification

Front LHS turn signal light

Key switch

Enable button

Indicators switch

Front headlight

Instrument panel lighting bulb

Turn signal warning light

Reserve fuel light

Headlamp warning light

High-beam warning light

Instrument panel

Headlight switch

Start up button

Horn

Stop light switch (front brake)

Desc./Quantity

12V-1,2W

12V - 1,2W

12V-1,2W

12V - 1,2W

12V - 1.2W

ELE SYS - 36

Vespa PX 125 150 Euro 2

24

25

26

27

28

29

30

20

21

22

23

16

17

18

19

Specification

Front RHS turn signal light

Rear brake stop button

Anti-repeating device

Fuel level sender

Magneto flywheel

Electronic ignition device

Rear RHS turn signal light

Starter motor

Taillight

Starter relay

Rear LHS turn signal light

Battery

Fuse box

Voltage regulator

Turn signals master-box

Components arrangement

Desc./Quantity

Electrical system

12V - 9Ah

ELE SYS - 37

Electrical system

Vespa PX 125 150 Euro 2

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

COMPONENTS ARRANGEMENT

Specification

Key switch

Voltage regulator

Electronic Control Unit (C.D.I.) with H.T coil

Battery

Starter motor

Magneto flywheel

Anti-repeating device

Spark plug

Remote starter switch

Fuse

Horn

Turn signals master-box

Front headlight

Front turn signal lights

Taillight

Rear turn signal lights

Desc./Quantity

12V - 9Ah

7.5 A

Conceptual diagrams

Ignition

3

4

1

2

ELE SYS - 38

IGNITION

Specification

Magneto flywheel

Key switch contacts

Electronic Control Unit (C.D.I.) with H.T coil

Spark plug

Desc./Quantity

Vespa PX 125 150 Euro 2

Headlights and automatic starter section

Electrical system

7

8

5

6

3

4

1

2

9

10

Specification

Voltage regulator

Magneto flywheel

Key switch contacts

Headlight bulb

High-beam warning light

Light switch

Headlight switch

Rear side light bulb

Front side light bulb

Headlamp warning light

LIGHTS

Desc./Quantity

12V-35/35W

12V - 1.2W

12V - 5W

12V - 5W

12V - 1,2W

ELE SYS - 39

Electrical system

Battery recharge and starting

Vespa PX 125 150 Euro 2

7

8

5

6

3

4

1

2

9

10

11

BATTERY RECHARGE AND STARTING

Specification

Magneto flywheel

To services

Key switch contacts

Voltage regulator

Fuse

Remote starter switch

Starter motor

Battery

Enable button

Start up button

Anti-repeating device

Desc./Quantity

7.5 A

12V - 9Ah

ELE SYS - 40

Vespa PX 125 150 Euro 2

Level indicators and enable signals section

Electrical system

3

4

1

2

5

6

SAFETY SWITCHES AND LEVEL GAUGES

Specification

Fuel gauge

Fuel level sender

Reserve fuel light

Brake light bulbs

Stoplight switches

Voltage regulator

Desc./Quantity

12V-1,2W

12V-10W

ELE SYS - 41

Electrical system

Turn signal lights

Vespa PX 125 150 Euro 2

5

6

7

3

4

1

2

SIGNAL LIGHTS AND HORN

Specification

Turn signals master-box

Indicators switch

Turn signal warning light

Turn signal light bulbs

Horn button

Horn

Voltage regulator

Desc./Quantity

12V - 1,2W

12V - 21W

ELE SYS - 42

Vespa PX 125 150 Euro 2

Instruments and warning lights control board

Electrical system

5

6

7

3

4

1

2

DASHBOARD LIGHTS AND GAUGES

Specification

+ Battery

Fuel gauge

Low fuel warning light

Turn signals warning light

High-beam warning light

Side-lamps warning light

Ground lead (-)

Desc./Quantity

Checks and inspections

Ignition circuit

All system checks requiring the detachment of cables (inspections involving ignition system wiring and devices) must be carried out with the engine off, so to avoid any possible damage to the ECU, which would require its replacement.

It is therefore important to follow the wire colour coding when reattaching the cables (see figure)

ELE SYS - 43

Electrical system

Vespa PX 125 150 Euro 2

3

4

1

2

Specification

WHITE

RED

GREEN

GREEN

IGNITION CIRCUIT

Stator check

1

2

In the event of a malfunctioning of the ignition system, 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 properly once the new ECU has been fitted, then the cause of the problem is obviously to be attributed to a defective CDI device.

In the event that the ignition system is still malfunctioning, it will be necessary to check the generator and the stator components, as follows:

After an eye inspection of the connections, perform measurements on recharge coil and pick-up

(see table) using the specified tester. If such readings do not match the stated values, proceed by replacing the stator and its components.

Specific tooling

020331Y Digital multimeter

STATOR CHECK

Specification

RED - WHITE wire

GREEN - WHITE wire

Desc./Quantity

Desc./Quantity

90 ÷ 140 ohm

800 ÷ 1100 ohm

ELE SYS - 44

Vespa PX 125 150 Euro 2

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 (regulator open-circuited).

2. Failure of the lighting system and automatic choke device (regulator short-circuited).

Interventions

FAULT 1

At 5,000 rpm with the lights on, check the regulator voltage is between

12.3

V and

14.5

V. At

5,000 rpm

with the lights on, check the regulator voltage is between

13V

and

15V

. In the presence of a regulator voltage exceeding

15V

, replace the regulator as definitely faulty.

FAULT 2

a) Check the correct current supply from the alternator: detach the regulator connector and attach the alternate current tester between the grey-blue wire terminal and earth. With the tester set onto alternate current, check the supplied voltage at

3,000 rpm

is between

25 and 30

V.

b) If no faults are found, replace the voltage regulator.

c) If the system is still malfunctioning after the regulator has been replaced, check the connections of the electrical system.

Direct current section The failure of the regulator's direct current section may cause, depending on the type of failure, the following inconveniences:

3) Blown fuse (regulator short-circuited), resulting in the catastrophic failure of the battery charging system.

Electrical system

ELE SYS - 45

Electrical system

Vespa PX 125 150 Euro 2

4) Battery recharge faulty (regulator open-circuited).

Interventions

FAULT 3

Replace the regulator, as certainly faulty, and the fuse.

FAULT 4

a) Attach an ammeter between the voltage regulator and the battery, and check that, at

3,000 rpm

and with the battery at

13V

, the current supplied is approximately

1.5 to 2

A.

If the measured values are below this limit, then replace the voltage regulator.

b) If replacing the regulator does not solve the problem, check, using the recommended tester, for peaks in the alternate currents between the yellow wire connection and the red wire departing from the positive battery pole. The voltage supplied by the generator must be between

26 and

30V

, at

3,000 rpm

(this measurement must obviously be carried out with the battery disconnected).

Specific tooling

020331Y Digital multimeter

Starter motor

Bench tests to be performed on the electric starter motor

1) No-load test: the starter motor, unloaded, must absorb less than 10 A with a voltage supply > 11.7

V and must spin at more than 18,000 rpm.

2) Load test: load the starter motor so that the absorbed current is equal to 40 A, and the supplied voltage is 10 V. In such conditions, the output torque provided must 0.014 Nm, at a speed of no less than 10,000 rpm.

3) Breakaway test: with the rotor restrained and supplied voltage of 7 V, the absorbed current must not be higher than 100 A and the torque not less than 0.033 Nm.

N.B.

ALL THESE CHARACTERISTICS MUST BE MEASURED WITH CHARGED BATTERY AND AFTER

RUNNING THE MOTOR FOR 30" IN THE CONDITIONS STATED IN 1.

ELE SYS - 46

Vespa PX 125 150 Euro 2

Electrical system

3

4

1

2

5

6

STARTER MOTOR

Specification

Nominal voltage

Nominal power

Direction of rotation

Engine connection

Control

Battery

Desc./Quantity

12V

0,15 kW

Clockwise

Via pinion and gear ring on crankshaft, transmission-side

Pushbutton

12V - 9Ah

Fuses

The starter system and horn are protected by a

7.5A fuse, «

A

», located on the LHS of the battery tray. Before replacing a burst fuse, it is necessary to find the cause of the failure. Never attempt to close the circuit with any material other than the fuse.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE

THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY

TO REPLACE THE FUSE WITH ANY OTHER MATERIAL

(E.G., A PIECE OF ELECTRIC WIRE).

CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS-

TEM, PERFORMED INCORRECTLY OR WITHOUT STRICT

ELE SYS - 47

Electrical system

Vespa PX 125 150 Euro 2

ATTENTION TO THE TECHNICAL SPECIFICATIONS OF

THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING

AND RISK OF FIRE.

Dry-charge battery

COMMISSIONING A NEW DRY-CHARGED BATTERY

- Remove the battery air pipe stop cap and each single cell cap.

- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an ambient temperature not below 15°C, until it reaches the upper level indicated on the block.

- Tilt the battery slightly to remove any air bubbles formed during filling.

- Place the caps on each single cell filling hole without screwing them and leave the battery to rest.

During this stage, the battery is subjected to a gasification phenomenon and temperature increases.

- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).

- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte

Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water;

- Before 24 hours elapse, recharge the battery following these steps:

- Connect the battery charger terminals observing the correct polarity;

- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity;

- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge.

Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge.

- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester.

- If the open-circuit voltage is higher or equal to

12.6V

, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging.

- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle.

- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.

Note:

With the battery charger drw. 020334Y, it is possible to check the battery charge level with the

Check

function. The value indicated on the display must be higher than the value indicated on the chart; otherwise, recharge the battery again in the same way indicated above.

ELE SYS - 48

INDEX OF TOPICS

E

NGINE FROM VEHICLE

ENG VE

Engine from vehicle

Exhaust assy. Removal

Remove the two fasteners, exhaust pipe-manifold and then the bolt fixing the exhaust to the engine.

Vespa PX 125 150 Euro 2

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 and choke cables.

Detach the oil and petrol hoses.

Remove the engine-frame bolt shown in the figure.

ENG VE - 50

Vespa PX 125 150 Euro 2

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 careful when handling fuel.

Locking torques (N*m)

Engine - frame bolt *

61 ÷ 75

Shock-absorber engine bolt*

13 ÷ 23

Engine from vehicle

ENG VE - 51

INDEX OF TOPICS

E

NGINE

ENG

Vespa PX 125 150 Euro 2

Flywheel cover

Cooling hood

Remove the three fixing screws shown in the figure and the cooling hood.

Remove the fixing screws shown and hence detach the volute and the gear shifter cover.

Remove the kick-start lever after having detached the lower fastener.

Removing the stator

Remove the three screws shown in the figure.

Remove the stator.

Engine

ENG - 53

Engine

Refitting the stator

In order to guarantee the correct engine timing pay attention to the position of the stator, as shown in the figure.

Vespa PX 125 150 Euro 2

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, detach the cap.

Remove the retaining ring shown by the arrow in the figure and remove the pinion components.

WARNING

THE PACKING ON THE MATING SURFACE MUST AL-

WAYS BE REPLACED WITH A NEW ONE, USING «LOC-

TITE».

ENG - 54

Vespa PX 125 150 Euro 2

Using pliers for internal split rings, remove the retaining ring shown.

Lift the assembly by the end of the shaft and remove 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 event that the bearing remains on drive gear, use the special extractor.

After heating the drive gear with the air heater, refit the drive shaft with all the components previously removed.

Refit the remaining components following the above operations in the reverse order.

Specific tooling

001467Y Extractor for bearings for holes

001467Y021 Extraction pliers for ø 11 mm bearings

020151Y Air heater

020150Y Air heater support

Position a new cap onto the pinion and round the edges using the special tool to safely lock the assembly in a vice.

Rotate the assembly by a quarter turn and proceed by rounding the remaining section of the caps circumference.

Specific tooling

020057Y Calking tool

Engine

ENG - 55

Engine

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.

Vespa PX 125 150 Euro 2

After removing the rear cover, detach the drive gear retaining pin and remove the gear.

Refit the assembly components in the reverse order.

Removing the flywheel magneto

Retain the flywheel using the special tool, hence remove the lock nut.

Specific tooling

020095Y Flywheel retaining tool

Remove the flywheel retaining tool.

Extract the flywheel using the special extractor.

Specific tooling

008564Y Flywheel extractor

ENG - 56

Vespa PX 125 150 Euro 2

Refitting the flywheel magneto

Refit the components following above operations in the reverse order.

After refitting the flywheel, apply grease on the thread.

Recommended products

AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faying surface of driven pulley spring (only pulley side)

Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2

Locking torques (N*m)

Flywheel fixing nut

60 ÷ 65

Cylinder assy. and timing system

Removing the cylinder head

Loosen the four nuts and remove the cylinder head.

Removing the cylinder - piston assy.

After removing the cylinder detach the wrist pin retaining rings and hence remove the piston.

Engine

ENG - 57

Engine

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.

Vespa PX 125 150 Euro 2

Refitting the cylinder

Refit the cylinder assembly components following the removal procedure in the reverse order, paying particular attention to positioning the piston with the arrow marking on the crown pointing toward the exhaust port.

Locking torques (N*m)

Head fixing nuts 16 ÷ 26

Crankcase - crankshaft

Splitting the crankcase halves

Remove the twelve fasteners and split the two crankcase halves carefully using a plastic or hard rubber mallet.

CAUTION

WITH A RUBBER BAND TIE THE CONNECTING ROD TO

THE TWO STUDS ON THE CLUTCH-SIDE, SO TO AVOID

ANY ACCIDENTAL DAMAGE DURING THIS PHASE AND

THE FOLLOWING ONES.

ENG - 58

Vespa PX 125 150 Euro 2

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 internal split rings, remove the bearing retaining ring shown.

From the side opposite that shown in the figure and with the aid of a flat head puncher, extract the bearing.

Using the special extractor, remove the roller bearing from the crankshaft.

Specific tooling

004499Y Camshaft bearing extractor

Using the special extractor, remove the roller bearing from the crankcase.

Engine

ENG - 59

Engine

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 bearing's outer ring.

Position the bearing's retaining ring, hence proceed by refitting the sealing ring.

Specific tooling

020151Y Air heater

020150Y Air heater support

Heat up the crankcase, as already done for the clutch-side half-crankcase, focusing exclusively on the bearing housing.

Position the bearing using a length of tube pushing directly on the bearing's outer ring.

Vespa PX 125 150 Euro 2

Position the crankshaft onto the special support.

Install the special spacer as shown in the figure and, using a length of tube of adequate diameter, push the bearing until the inner ring (heated up in oil at 120°C) comes into contact with the spacer.

Once the assembly is completed, remove the spacer.

Specific tooling

020265Y Bearing fitting base

060007Y Crankcase bearing spacer

ENG - 60

Vespa PX 125 150 Euro 2

Engine

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 used. The oil level may be checked through the transparent tube

(see figure, 3) protruding from the tank.

Fuel is fed to the carburettor by gravity; oil is supplied through pump «p» whose stroke is controlled by the radial position of a shoe, on the inclined plane of the pump, driven by the throttle cable via a lever.

This means that for any given position of the throttle twist-grip the location of the shoe varies, thus varying the pump stroke hence suggesting that the oil mass flow is a function of both engine speed and throttle opening.

Important:

whenever the mixer device has been removed, overhauled or refitted, there may be no oil inside the ducts.

To allow the mixer to safely fill these ducts with oil, it is suggested that the fuel tank (1 in the figure) is first refilled with approx. 3 l of mixture containing 2% of SELENIA HI SCOOTER 2T oil. Once this first quantitative has been exhausted, any further refill must obviously consist of petrol only. The pump assembly constitutes, essentially, of a pumping element and its sliding housing, and is driven by a gear transmission (crankshaft/mixer shaft ratio: 1/85). The pumping element "P" is also provided, on its shaft, with a flatten surface which, because of the rotation, alternately opens and closes the oil inlet (5) and outlet (6) ducts, with the latter being equipped with a valve consisting of a sphere and spring. By such means the pump alternately performs the two phases of oil intake (A in the figure) and supply to the fuel diffuser (8 in the figure), where the fuel mixture is formed and fed into the engine.

ENG - 61

Engine

Vespa PX 125 150 Euro 2

CONCEPTUAL DIAGRAMS

Specification

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

B

Desc./Quantity

Inlet phase

Outlet phase

Oil pump

Remove the carburettor box.

Remove the mixer drive shaft from its housing.

ENG - 62

Vespa PX 125 150 Euro 2

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 pliers for internal split rings to remove the mixer body.

Refit the components following the removal procedure in the reverse order, paying attention in positioning the pump body correctly in its housing, so to be able to easily insert the retaining screw.

See also

Removing the

carburettor

Engine

ENG - 63

Engine

Fuel supply

Removing the carburettor

Remove the two fixing screws and the carburettor cover.

Vespa PX 125 150 Euro 2

Remove the fasteners and the air filter.

After removing the air filter, loosen the two 8mm

Allen screws and hence remove the carburettor.

Loosen the fixing screw and remove the carburettor body.

ENG - 64

Vespa PX 125 150 Euro 2

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 compressed air.

Remove the float pin to release the float, and hence the conical needle.

Engine

ENG - 65

Engine

Check the starter choke valve; replace if worn.

Vespa PX 125 150 Euro 2

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 puncher, remove the conical pin and extract the gear shifting lever.

ENG - 66

Vespa PX 125 150 Euro 2

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 composing the bearing fall onto the ground.

Engine

ENG - 67

Engine

After removing the internal oil seal and the external dust cover, remove the bearing retaining ring through the use of internal split ring pliers.

Extract the roller bearing using a flat head puncher from the side opposite to that shown in the figure.

After removing the retaining washer shown in the figure, remove the fastener underneath it, hence extract the even tension gear.

Remove the rivet head and replace any faulty component.

Refit the components using new rivets.

Replace the trunnion if worn.

CAUTION

THE TRUNNION BUSHING HAS A LHS THREAD.

Locking torques (N*m)

Gear-box trunnion

15 ÷ 18

Vespa PX 125 150 Euro 2

ENG - 68

Vespa PX 125 150 Euro 2

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 (internal diameter 17.5 mm), round the threaded end of the bushing on the trunnion.

Install the multiple gear onto its housing carefully positioning the 21 rollers, using the recommended grease to keep them in place during the reassembly.

With the refitting operation concluded, tighten the shaft lock nut to the prescribed torque.

Recommended products

AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

Locking torques (N*m)

Multi-gear pinion nut

30 ÷ 35

Before proceeding by refitting the shifter shaft, it is necessary to check the axial play of the gear assembly.

Install the gears onto the shaft and check the end play with the special feeler gauge.

Specific tooling

060824Y Inspection probe

Characteristic

Engine

ENG - 69

Engine

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

Vespa PX 125 150 Euro 2

See also

Splitting the crankcase halves

Clutch

Remove the 3 fixing screws and the clutch cover.

With the aid of a screwdriver, remove the balance screw.

ENG - 70

Vespa PX 125 150 Euro 2

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 clutch discs.

Specific tooling

020322Y Clutch removing/fitting tool

Check the conditions of all components and the camber of the metal discs. A camber smaller than the prescribed one may cause slippage.

Refit the clutch assembly components inverting the order followed for the disassembly.

Engine

ENG - 71

Engine

Place the mixer drive gear with the rounded edge facing the crankcase bearing.

Vespa PX 125 150 Euro 2

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 order.

Specific tooling

001729Y Clutch retaining tool

Locking torques (N*m)

Clutch assy. fixing nut

40 ÷ 45

ENG - 72

INDEX OF TOPICS

S

USPENSIONS

SUSP

Suspensions

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.

Vespa PX 125 150 Euro 2

After removing the split ring on the outer side of the wheel hub, and the seal ring, remove the bearing using a length of pipe of adequate diameter and a mallet, as shown in the figure. Follow the same procedure to remove the roller cage on the opposite side.

Handlebar

Removal

Remove the 2 rear view mirrors and their fixing ring nuts. Remove the handlebar cover as described in the «Bodywork» chapter and the speedometer.

SUSP - 74

Vespa PX 125 150 Euro 2

Refitting

Upon reassembly, tighten to the prescribed torque.

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, making sure of having removed the brake calliper.

Specific tooling

020055Y Wrench for steering tube ring nut

Overhaul

To remove the bearing housings from the frame use the special tool shown in the figure.

Specific tooling

020004Y Punch for removing fifth wheels from headstock

Suspensions

SUSP - 75

Suspensions

Using the special tool remove the bearing and dust ring housings from the steering column as shown in the picture.

Proceed with mallet hits.

Specific tooling

020004Y Punch for removing fifth wheels from headstock

Using the special tool, refit the dust ring and the bearing housing onto the steering column and push them as far as they go.

Specific tooling

006029Y Punch for fitting fifth wheel seat on steering tube

Servicing the front suspension-steering assembly, described below, deals mainly with replacing parts

(pin- NADELLA roller bushings - sealing rings unit and dust guard) which connect the steering tube to the front wheel holder swinging hub.

N.B.

BEFORE PROCEEDING WITH THE DESCRIBED SERVICE,

CHECK THAT THE STEERING TUBE AND THE WHEEL

HOLDER HUB ARE IN EXCELLENT CONDITIONS: ONLY

THEN IS THE SERVICE JUSTIFIABLE.

MOREOVER, REMEMBER THE STEERING TUBE SHOULD

BE REPLACED WITH A NEW ONE WHEN DEFORMED.

a = Ø 12 Punch b = Sharp-edged end

Use a suitable punch with the dimensions indicated 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 the tool handgrip until the pin and the

SUSP - 76

Vespa PX 125 150 Euro 2

Vespa PX 125 150 Euro 2

NADELLA are simultaneously ejected in the direction opposite the tool thrusting force.

After removing the pin and the first NADELLA, the swinging hub gets detached from the steering tube.

To remove the second NADELLA, use the tool fitted with part 2 instead of part 1, on the side opposite 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 AND DUST

GUARDS.

Specific tooling

020021Y Front suspension service tool

Connect the swinging hub to the steering tube with the guiding pin.

- Use the tool fitted with part 3 on the stem and part

4 .

Lubricate the pin with recommended grease and insert it temporarily on the swinging hub, move the tool handgrip until part 3 is fully inserted on the steering tube.

After fitting the pin, insert the two spacers, slightly hitting them with the mallet.

N.B.

BEFORE PROCEEDING WITH THE DESCRIBED FITTING,

PLACE THE TWO DUST GUARD RINGS ON THE SWING-

ING HUB AS SHOWN IN THE FIGURE.

Specific tooling

020021Y Front suspension service tool

Recommended products

AGIP GREASE SM 2 Grease for odometer transmission gear case

Lithium grease with NLGI 2 molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Suspensions

SUSP - 77

Suspensions

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 previous pin fitting phase, and leave part 4 always fitted.

- Replace part 3 with part 16 (on the stem).

- By moving the tool handgrip, push the wedging washer - roller bushing - seal ring unit, placing part

16 until it stops on the swinging hub.

- 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

"NADELLA" ROLLER BUSHINGS (PREVIOUSLY WASHED

IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMI-

NATE THE ANTIRUST PROTECTION), HALF-FILLED WITH

GREASE.

Specific tooling

020021Y Front suspension service tool

Recommended products

AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

- Use the tool fitted with part 20 on its stem and part 21 on the tool base as shown in the figure.

- By moving the tool handgrip, push the two NA-

DELLA bushings until their internal bottoms make contact with the pin end.

- Use the tool fitted with parts 3 and 4 to fit the pin, and press moving the tool handgrip, until wedging the washers on the swinging hub.

- Now, remove the two spacers (parts 17 and 16) and, once the space between the NADELLAs steering tube and swinging hub - has been fully

SUSP - 78

Vespa PX 125 150 Euro 2

Vespa PX 125 150 Euro 2

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 GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

Refitting

Grease bearings and housings.

Tighten to the prescribed torque and rotate the spanner in an anti-clockwise direction by 80°-90°.

Specific tooling

020055Y Wrench for steering tube ring nut

Recommended products

AGIP GP 330 Grease (brake level, throttle twistgrip, gaer)

Calcium complex soap grease NLGI 2; ISO-L-

XBCIB2

Locking torques (N*m)

Top steering housing

6÷7 (hence loosen by 80° -

90°)

Upper steering ring nut

5÷6

Front shock absorber

Suspensions

SUSP - 79

Suspensions

Removal

Remove the 2 fixings shown in the figure and the

2 fasteners on the shock-absorber support bracket located on the steering column.

Free the shock-absorber from the support bracket removing the top fixing.

Vespa PX 125 150 Euro 2

Shock-absorber - calliper bracket

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 wheel hub, extract the ring shown in the figure and replace it with a new one.

Rear

SUSP - 80

Vespa PX 125 150 Euro 2

Removing the rear wheel

After removing the spare wheel, remove the three fasteners shown in the figure.

Remove the rear wheel by loosening the five fixing screws.

Suspensions

Refitting the rear wheel

When refitting the rear wheel, tighten all fasteners at the prescribed torque following a crosswise sequence.

Locking torques (N*m)

Rim - hub fixing nuts (front-rear) 20 ÷ 27

Shock absorbers

Removal

For the rear shock-absorber replacement it is necessary 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.

SUSP - 81

Suspensions

Centre-stand

Detach the return spring from the centre stand, remove the 4 fasteners shown in the figure.

Vespa PX 125 150 Euro 2

SUSP - 82

INDEX OF TOPICS

B

RAKING SYSTEM

BRAK SYS

Braking system

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.

Vespa PX 125 150 Euro 2

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 BEFORE AS-

SEMBLY.

Locking torques (N*m)

Pipe - calliper fitting 15÷25 Calliper fixing screw* 20÷25

Front brake disc

Removal

Remove the rear wheel by loosening the 5 fasteners.

Remove the wheel hub.

Loosen the 5 disc fasteners.

Refitting

When refitting, correctly position the disc, observing the direction of rotation (see figure) and apply medium thread-lock.

BRAK SYS - 84

Vespa PX 125 150 Euro 2

Braking system

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 measured value must be less than 0.1 mm. If higher, replace the disc and repeat the check.

If the problem is not solved check and, if necessary, replace the wheel hub.

Specific tooling

020335Y Magnetic support for dial gauge

Front brake pads

Removal

To facilitate this operation it is suggested that the front wheel is removed, remove the plastic cap and apply leverage with a screwdriver.

Remove the external split ring from the pin, the spring and the pads themselves.

The pads must be replaced if the thickness of the working material is less than 1.5 mm.

Refitting

When refitting, operate in the opposite way, paying attention in positioning the spring with the arrow pointing upwards.

BRAK SYS - 85

Braking system

Vespa PX 125 150 Euro 2

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 out of the system.

Tighten the bleed screw.

N.B.

IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS:

IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG

THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS.

CAUTION

- DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL.

N.B.

DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE

SYSTEM THROUGH THE PUMP.

WARNING

THE BRAKE FLUID IS HYGROSCOPIC, I.E. IT ABSORBS HUMIDITY FROM THE AIR. IF THE HU-

MIDITY LEVEL IN THE FLUID EXCEEDS A GIVEN VALUE, THE BRAKING PERFORMANCES MAY

SERIOUSLY DETERIORATE. IT IS THEREFORE RECOMMENDED THAT FRESH FLUID IS TAKEN

FROM NEW CONTAINERS. IN NORMAL CLIMATIC CONDITIONS, THE FLUID SHOULD BE RE-

PLACED EVERY TWO YEARS. IF THE BRAKES ARE HIGHLY STRESSED, INCREASE THE

FREQUENCY WITH WHICH THE FLUID IS REPLACED.

CAUTION

WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE

BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-

GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

With the operation concluded, tighten the bleed screw to the prescribed torque.

Specific tooling

020329Y MityVac vacuum-operated pump

Locking torques (N*m)

Oil draining screw

10÷12

BRAK SYS - 86

Vespa PX 125 150 Euro 2

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

Remove the rear wheel.

Straighten the splint pin and remove the lock nut.

Braking system

BRAK SYS - 87

Braking system

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 components following the removal procedures in the reverse order, tightening the wheel nut to the prescribed torque.

WARNING

-ALWAYS USE NEW SPLIT PINS FOR REFITTING.

WARNING

- FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN OR-

DER TO AVOID BACKSLASH BETWEEN THE CAP AND

THE WHEEL AXLE.

Locking torques (N*m)

Wheel axle nut

90÷110

Rear Brake Pedal

After loosening the brake fixing on the rear wheel, remove the 3 fasteners indicate in the figure.

Remove the rubber from the pedal and detach the electrical wiring.

Vespa PX 125 150 Euro 2

After this operation it is possible to remove the fore brake cable retainer, removing the splint pin and its pin.

It is also possible to replace the stop switch by acting upon its fixing.

BRAK SYS - 88

INDEX OF TOPICS

C

HASSIS

CHAS

Chassis

Seat

Remove the 3 fasteners shown in the figure.

Vespa PX 125 150 Euro 2

Rear handlebar cover

After removing the rear-view mirrors, the attachments 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 dashboard.

Headlight assy.

After removing the handlebar cover, remove the 2 fasteners show in the figure and the headlight adjusting screw underneath the handlebar.

Detach the wirings. To replace the bulbs simply release the springs holding back the socket and replace any blown bulb.

CHAS - 90

Vespa PX 125 150 Euro 2

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 hole shown in the figure (from underneath the lock body) and push until releasing the securing tongue; hence extract body and master cylinder.

The refitting operations of the lock body and the new master cylinder (on the outer lock body) are as follows:

Carefully clean the body from any impurity (if the cylinder has been drilled), using compressed air.

Position the body in its housing after fitting the retaining spring «E».

Insert the cylinder assembly, with key and tongue «F» facing downwards, halfway inside the lock body, ensuring that during this operation, they is in the «ON» position (the only position that allows the insertion of the cylinder); at the point turn the key leftwards and push as far as the cylinder will go.

Check the assembly via the key excursion in the three positions and proceed by refitting the handlebar cover.

Chassis

CHAS - 91

Chassis

Vespa PX 125 150 Euro 2

Replace the seat and glove-box cylinders. To replace these follow the operations described for the removal of the cylinder when the ignition keyswitch 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 new cylinder. Bear in mind that for the replacement of the cylinder on the seat lock, it is necessary to remove the lock assembly, acting upon the three screws.

Removing the ignition key-switch when on *lock*

Should it be necessary to replace the steering lock cylinder when the keys have gone missing, proceed as follows:

Cylinder removal:

in the event that the key-switch is in the «LOCK» position, it is necessary to

proceed by drilling the cylinder

with the aid of a Ø8 mm at least 30 mm long: this allows to release (or destroy) the internal retaining device of the drilled cylinder. Hence extract the body and any residues so to be able to use the body for refitting.

Taillight assy.

Remove the 2 fixings shown in the figure and replace the blown bulbs.

Replace, if necessary, the taillight lens.

To replace the taillight assy., remove the lens, detach the wiring and remove the 2 fasteners from underneath the frame.

CHAS - 92

Vespa PX 125 150 Euro 2

Remove the 2 fasteners for each turn signal light.

Fuel tank

After removing the seat, detach the electrical connection 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 the special tool through the tube. Proceed by loosening the nut and the acting upon ring «B» until releasing the oil tank.

Specific tooling

020321y Carburettor float removing tool

002850y Oil tank spanner

002973y Fuel tap spanner

Remove the tank filler cap and insert the spanner thus loosening nut «D», hence extract the fuel tap.

Chassis

CHAS - 93

Chassis

Front mudguard

Remove the 2 fixings from underneath the mudguard.

Vespa PX 125 150 Euro 2

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.

CHAS - 94

Vespa PX 125 150 Euro 2

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 removed (RHS or LHS).

Chassis

CHAS - 95

INDEX OF TOPICS

P

RE

-

DELIVERY

PRE DE

Vespa PX 125 150 Euro 2

Pre-delivery

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 summarised in pages 1 - 5.

External covers screws.

Electrical system

Fill the battery with acid, and charge with appropriate charger.

Ignition key-switch.

Low-beam light, high-beam light, warning lights, side-light.

Headlight adjustment.

Taillight.

Stop light (eventually front and rear lights).

Turn signal lights and warning lights.

Dashboard illumination.

Horn.

Starter button.

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 BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL

FIRST.

CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-

ATIVE LEAD.

- BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-

PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.

IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15

MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.

IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE

OIL. SEEK IMMEDIATE MEDICAL ATTENTION.

PRE DE - 97

Pre-delivery

Vespa PX 125 150 Euro 2

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 RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE

A FIRE.

Levels check

Brake fluid.

Gear-box.

Oil tank.

Road test

Cold start.

Speedometer check.

Throttle check.

Riding stability.

Front and rear brake efficiency.

Front and rear shock-absorbers.

Unusual noises.

Hot engine restart.

Leakages (after trial run).

Functional inspection

Brake lever excursion.

Throttle excursion and adjustment.

Homogeneous steering turning.

Other

Tyre pressure.

All locks.

Rear-view mirrors and accessory fitting.

Tooling kit, owner manual, warranty certificate and customer service card.

CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

PRE DE - 98

INDEX OF TOPICS

T

IME

TIME

Time

Engine

Vespa PX 125 150 Euro 2

1

2

3

Code

001001

003064

003057

ENGINE

Action

Engine from the frame - removal and refitting

Engine oil - replacement

Engine retainer - Tighten nuts

Duration

TIME - 100

Vespa PX 125 150 Euro 2

Crankshaft

Time

3

4

1

2

ENGINE SHROUD - CRANKCASE BEARINGS

Code

001117

001118

001099

001100

Action

Crankshaft - Replacement

Crankcase bearings - Replacement

Oil seal, flywheel side - Replacement

Clutch-side oil seal - Replacement

Duration

TIME - 101

Time

Vespa PX 125 150 Euro 2

3

4

1

2

Code

001002

001107

001093

001094

WRIST PIN PISTON CYLINDER ASSY

Action

Cylinder/piston - Replacement

Cylinder/Piston - Overhaul/Cleaning

Spark plug - Replacement

Spark plug cap - Replacement

Duration

TIME - 102

Vespa PX 125 150 Euro 2

Flywheel cover

Time

1

Code

001087

FAN COVER

Action

Flywheel cover - Replacement

Duration

TIME - 103

Time

Oil pump

Vespa PX 125 150 Euro 2

1

2

Starter motor

Code

001018

001028

AUTOMATIC MIXER

Action

Mixer - Replacement

Oil pump drive shaft - Replacement

Duration

1

2

3

TIME - 104

Code

001020

001039

001038

STARTER MOTOR

Action

Starter motor - change

Starter motor brushes - Replacement

Starter motor - Overhaul

Duration

Vespa PX 125 150 Euro 2

4

Code

001017

Action

Starter motor shaft - Replacement

Duration

Time

1

2

3

Code

008008

001120

001084

KICK-START LEVER

Action

Kick-starter gear spring - Replacement

Crankcase bearings - Replacements

Starter lever - Replacement

Duration

TIME - 105

Time

Flywheel magneto

Vespa PX 125 150 Euro 2

3

4

1

2

5

Code

001067

001004

001058

001059

003052

FLYWHEEL MAGNETO

Action

Stator - Removal and refitting

Stator - Overhaul

Flywheel - Replacement

Pick-up - Replacement

Ignition timing

Duration

TIME - 106

Vespa PX 125 150 Euro 2

Carburettor

Time

1

2

3

Code

001063

001008

003058

CARBURETTOR

Action

Carburettor - Replacement

Carburatore - Revisione

Carburettor - Adjustment

Duration

TIME - 107

Time

Exhaust pipe

Vespa PX 125 150 Euro 2

1

Code

001009

EXHAUST PIPE

Action

Exhaust pipe - Replacement

Duration

TIME - 108

Vespa PX 125 150 Euro 2

Air cleaner

Time

1

2

Code

001014

001027

AIR CLEANER

Action

Air filter - Replacement

Air-cleaner/frame bellow - Replacement

Duration

TIME - 109

Time

Frame

Vespa PX 125 150 Euro 2

1

2

3

Code

004001

006001

004023

FRAME

Action

Frame - Replacement

Frame - Painting

Shield rim - Replacement

Duration

TIME - 110

Vespa PX 125 150 Euro 2

Centre-stand

Time

1

Legshield spoiler

Code

004004

CENTRE-STAND

Action

Centre-stand - Replacement

Duration

TIME - 111

Time

Vespa PX 125 150 Euro 2

1

Side fairings

Code

004024

STEERING COLUMN FAIRING

Action

Steering column fairing - Replacement

Duration

1

Code

004025

SIDE FAIRING LOCKS

Action

Side fairing locks - Replacement

Duration

TIME - 112

Vespa PX 125 150 Euro 2

Time

1

Footrests

Code

006005

WHEEL SIDE FAIRINGS

Action

Side fairings - Painting

Duration

TIME - 113

Time

1

Rear cover

Code

004015

FOOTRESTS

Action

Footrests - Replacement

Vespa PX 125 150 Euro 2

Duration

1

2

3

Code

004083

006019

004081

GLOVE-BOX

Action

Glove box - Replacement

Glove-box - Painting

Glove-box door - Replacement

Duration

TIME - 114

Vespa PX 125 150 Euro 2

Mudguard

Time

1

2

3

Code

004002

006003

003045

FRONT MUDGUARD

Action

Front mudguard - Replacement

Mudguard - Painting

Steering tube - Replacement

Duration

TIME - 115

Time

Fuel tank

Vespa PX 125 150 Euro 2

1

Code

005010

FUEL LEVEL SENSOR

Action

Fuel tank float - Replacement

Duration

TIME - 116

Vespa PX 125 150 Euro 2

3

4

1

2

Tank oil

Code

004005

004007

004110

006024

FUEL TANK

Action

Fuel tank - Replacement

Fuel tap - Replacement

Fuel tank hose - Replacement

Fuel tank - Painting

Duration

Time

1

Code

004017

OIL TANK

Action

Oil tank - Replacement

Duration

TIME - 117

Time

Rear shock-absorber

Vespa PX 125 150 Euro 2

1

Code

003007

REAR SHOCK-ABSORBER

Action

Rear shock-absorber - Removal and refitting

Duration

TIME - 118

Vespa PX 125 150 Euro 2

Steering column bearings

Time

3

4

1

2

Code

003002

004119

003073

004010

STEERING COLUMN BEARINGS

Action

Steering bearings - Replacement

Steering support bearing - Replacement

Steering play - Adjustment

Steering lock - Replacement

Handlebar components

Duration

1

HANDLEBAR COMPONENTS AND BRAKE FLUID PUMP

Code

002059

Action

RHS twist-grip - Replacement

Duration

TIME - 119

Time

2

3

4

Code

002024

002047

002021

Vespa PX 125 150 Euro 2

Duration Action

Front brake pump - Removal and refitting

Front brake fluid - Replacement and circuit bleeding

Front brake hose - Removal and refitting

3

4

1

2

Code

005062

002071

002037

001035

GEAR-SHIFTER TWIST-GRIP

Action

Neutral switch - Replacement

Left hand grip - Replacement

Brake or clutch lever - Replacement

Clutch lever - Replacement

Duration

TIME - 120

Vespa PX 125 150 Euro 2

Seat

Time

1

2

Code

004003

004054

SEAT

Action

Saddle - Replacement

Saddle lock catch - Replacement

Duration

TIME - 121

Time

Instrument panel

Vespa PX 125 150 Euro 2

1

4

5

2

3

6

HANDLEBAR COVERS AND DASHBOARD

Code

005038

005014

006010

004066

003001

006011

Action

Dashboard warning/telltale lights -

Replacement

Odometer - Replacement

Top handlebar cover - Painting

Rear-view mirror - Replacement

Top handlebar cover - Removal and

Refitting

Lower handlebar cover - Painting

Duration

TIME - 122

Vespa PX 125 150 Euro 2

Turn signal lights

Time

1

2

3

Code

005066

005005

005028

TAILLIGHT

Action

Rear light bulbs - Replacement

Taillight - change

Rear light assembly glass - Replacement

Duration

TIME - 123

Time

1

2

Code

005008

005002

Vespa PX 125 150 Euro 2

HEADLIGHT

Action

Headlight bulbs - Replacement

Front light - Replacement

Duration

4

5

6

7

1

2

3

Code

005011

005012

005067

005068

005022

005006

005039

TURN SIGNAL LIGHTS

Action

Starter relay - Replacement

Front turn signal light - Replacement

Front turn indicator bulb - Replacement

Rear turn indicator bulb - Replacement

Rear turn signal light- Replacement

Turn signals switch - Replacement

Headlight switch - Replacement

Duration

TIME - 124

Vespa PX 125 150 Euro 2

Front wheel

Time

1

2

3

Code

004123

003047

003037

4

5

006018

003063

Grease tone wheel or drive

Please take note that the code has been intro-

WHEEL

Action

Front wheel - Replacement

Front tyre - replace

Front wheel rim - Removal and Refitting

Wheel rim - Paintwork

Tyre pressure - Check duced:

900001 - Tone wheel / drive greasing - 15'.

Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components. The grease recommended is TUTE-

LA MRM 2 (soap-based lithium grease with Molybdenum disulphide).

In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel)

Duration

TIME - 125

Time

Electric devices

Vespa PX 125 150 Euro 2

1

2

Code

005024

005025

ELECTRICAL DEVICES

Action

Battery fuse - Replacement

Battery fuse holder - Replacement

Duration

TIME - 126

Vespa PX 125 150 Euro 2

Time

1

2

3

Code

005009

005007

004071

BATTERY - VOLTAGE REGULATOR

Action

Voltage regulator - Replacement

Battery - Replacement

Battery compartment - Replacement

Duration

TIME - 127

Time

1

Vespa PX 125 150 Euro 2

Code

005001

ELECTRICAL CONNECTIONS

Action

Electric circuit - Replacement and

Refitting

Duration

1

2

Code

005013

005045

ELECTRICAL DEVICES

Action

Electronic blinker - Replacement

Starter motor wire harness - Replacement

Duration

TIME - 128

Vespa PX 125 150 Euro 2

Time

1

2

3

Code

005003

005017

005069

ELECTRICAL DEVICES

Action

Horn - Replacement

Stop light switch - Replacement

Left switch - Replacement

Duration

TIME - 129

Time

1

Transmissions

Code

001023

ECU - CDI

Action

CPU - Replacement

Vespa PX 125 150 Euro 2

Duration

1

2

3

4

5

Code

002008

002056

002051

002049

002046

CABLES

Action

Choke cable - Replacement

Gear shifter cable assy. - Replacement

Odo/Speedometer cable assy. - Replacement

Odometer cable - Replacement

Gear shifter cable - Replacement

Duration

TIME - 130

Vespa PX 125 150 Euro 2

Time

1

2

3

4

5

6

Code

002055

002063

002053

003060

003061

002045

CABLES

Action

Clutch cable assy. - Replacement

Throttle cable assy. - Replacement

Rear brake transmission complete replacement

Rear brake cable - Adjustment

Accelerator transmission - Adjustment

Clutch cable - Replacement

Duration

TIME - 131

Time

Brake callipers

Vespa PX 125 150 Euro 2

1

2

3

Code

003070

002007

002039

BRAKE CALLIPERS

Action

Front brake pads - Wear check

Front brake pads - Removal and refitting

Front brake calliper - Removal and refitting

Duration

TIME - 132

Vespa PX 125 150 Euro 2

Steering column

Time

1

Code

003010

STEERING COLUMN

Action

Front suspension - Service

Duration

TIME - 133

Time

Front suspension

Vespa PX 125 150 Euro 2

1

Code

003011

FRONT SHOCK-ABSORBER

Action

Front shock absorber - Removal and

Refitting

Duration

TIME - 134

Vespa PX 125 150 Euro 2

Braking system

Time

1

2

Code

002002

003071

REAR BRAKE SHOES

Action

Rear brake shoe(s) - Replacement

Rear brake shoe(s) - Wear check

Duration

TIME - 135

Time

1

Vespa PX 125 150 Euro 2

Code

002014

REAR BRAKE PEDAL

Action

Brake pedal - Removal and refitting

Duration

3

4

1

2

Code

002010

001016

004026

001071

REAR BRAKE DRUM

Action

Rear brake drum - Replacement

Rear wheel - Replacement

Handlebar cover - Replacement

Rear wheel rim - Removal and refitting

Duration

TIME - 136

Vespa PX 125 150 Euro 2

Time

1

2

3

Code

003033

002041

003040

FRONT WHEEL HUB

Action

Front wheel hub- Replacement

Brake disc - Replacement

Front wheel bearings - Replacement

Duration

1

Code

002016

SHOE PLATE

Action

Rear brake shoe plate - Replacement

Duration

TIME - 137

Time

2

Code

003012

Secondary air box

Vespa PX 125 150 Euro 2

Duration Action

Brake shoe plate - Removal and Refitting

1

2

3

4

5

Code

001162

001161

001165

001163

001164

SECONDARY AIR BOX

Action

Secondary air housing - Replacement

Secondary air filter - Replacement /

Cleaning

Secondary air reed - Replacement

SAS valve / Head connection - Replacement

Secondary air-crankcase manifold -

Replacement

Duration

TIME - 138

Vespa PX 125 150 Euro 2

Clutch cover

Time

1

Clutch

Code

001073

CLUTCH COVER

Action

Clutch cover - Removal and refitting

Duration

1

Code

001022

CLUTCH

Action

Clutch - Removal

Duration

TIME - 139

Time

Gear-box

Vespa PX 125 150 Euro 2

1

2

Gear shifter

1

Code

001119

001025

GEAR-BOX

Action

Gearbox components - Replacement

Gearbox - Overhaul

Code

001029

GEAR SHIFTER

Action

Gear shifter -

Overhaul

Duration

Duration

TIME - 140

Vespa PX 125 150 Euro 2

Time

1

Code

001077

GEAR SHIFTER FASTENERS

Action

Gear shifter components - Removal and refitting

Duration

TIME - 141

A

Air filter:

31

B

Battery:

40

,

48

Brake:

84

,

85

,

87

,

88

,

132

Brake fluid:

C

Carburettor:

10

,

30

,

63

,

64

,

66

,

107

F

Fuel:

64

,

93

,

116

Fuses:

47

H

Headlight:

32

,

90

Horn:

I

Identification:

7

Instrument panel:

122

M

Maintenance:

7

,

26

S

Shock absorbers:

81

Spark plug:

31

T

Tank:

93

,

116

,

117

Transmission:

9

Tyres:

10

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