WORKSHOP MANUAL
Contents
1. 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 14 Vespa PX 150 USA 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 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 0 40 Shoulder 3rd oversize 2 50 0 0 06 A 0 15 0 40 Shoulder 4th oversize 2 65 0 0 06 A 0 15 0 40 N B 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 TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP GEAR 80W 90 gearbox oil SAE 80W 90 oil complying with API GL4 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 2 stroke engines SAE 5W 40 brake throttle control and mixer odom SL ACEA A3 JASO MA eter AGIP GP 330 Grease brake level throttle tw2. Remove the flywheel retaining tool Extract the flywheel using the special extractor Specific tooling 008564Y Flywheel extractor ENG 54 Vespa PX 150 USA Ze Vespa PX 150 USA 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 lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 Locking torques N m Flywheel fixing nut 60 65 Cylinder assy and timing system Removing the cylinder head Engine Loosen the four nuts and remove the cylinder EN m head Removing the cylinder piston assy After removing the cylinder detach the wrist pin re SN taining rings and hence remove the piston SS JN AMV DE immun ENG 55 Engine Vespa PX 150 USA 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 attention to positioning the
3. 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 amp 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 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 sometim
4. 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 12 Punch b Sharp edged end SUSP 73 Suspensions Vespa PX 150 USA 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 the tool handgrip until the pin and the NADELLA are simultaneously ejected in the direc tion 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 fit ted with part 2 instead of part 1 on the side oppo site the one shown in the figure N B DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED UPON REFITTING IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN NEW SEALING RINGS AND DUST GUARDS Specific tooling 020021Y Fro
5. A 0 N TIME 98 ENGINE SHROUD CRANKCASE BEARINGS Code Action Duration 001117 Crankshaft Replacement 001118 Crankcase bearings Replacement 001099 Oil seal flywheel side Replacement 001100 Clutch side oil seal Replacement Vespa PX 150 USA 3 4 A 0 N 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 TIME 99 Time Vespa PX 150 USA Flywheel cover FAN COVER Code Action Duration 1 001087 Flywheel cover Replacement TIME 100 Vespa PX 150 USA Time Oil pump AUTOMATIC MIXER Code Action Duration 1 001018 Mixer Replacement 2 001028 Oil pump drive shaft Replacement TIME 101 Time Vespa PX 150 USA 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 102 Vespa PX 150 USA Code 001017 Flywheel magneto OT G 1 Code 001067 001004 001058 001059 003052 Time Action Duration Starter motor shaft Replacement FLYWHEEL MAGNETO Action Duration Stator Removal and refit
6. 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 ENG 60 Vespa PX 150 USA Engine 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 in its housing So to be able to easily insert the retaining screw See also Removing the carburettor ENG 61 Engine Fuel supply Removing the carburettor Remove the two fixing screws and the carburetor cover Remove the fasteners 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 ENG 62 Vespa PX 150 USA Engine Vespa PX 150 USA Remove the main and idle jets and blow with compressed alr 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 D c be E O O E eg O c E ENG 63 Engine Check the starter
7. 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 NNN WIN NNN Os NRA ENG 68 Vespa PX 150 USA Engine 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 ENG 69 Engine Vespa PX 150 USA 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 order Specific tooling 001729Y Clutch retaining tool L
8. use the special tool shown in the figure Specific tooling 020004Y Punch for removing fifth wheels from headstock 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 006029 Y Punch for fitting fifth wheel seat on steering tube SUSP 76 Vespa PX 150 USA Suspensions Refitting Grease bearings and housings Tighten to the prescribed torque and rotate the spanner in an anti clockwise direction by 80 90 Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GP 330 Grease brake level throttle twist grip gaer Calcium complex soap grease NLGI 2 ISO L XBCIB2 Locking torques N m Top steering housing 6 7 hence loosen by 80 90 Upper steering ring nut 5 6 Front shock absorber 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 Shock absorber calliper bracket SUSP 77 Suspensions Vespa PX 150 USA Removal Remove the split ring shown in the figure Remove
9. 1 004083 Glove box Replacement 2 006019 Glove box Painting 3 004081 Glove box door Replacement TIME 111 Time Vespa PX 150 USA Mudguard FRONT MUDGUARD Code Action Duration 1 004002 Front mudguard Replacement 2 006003 Mudguard Painting 3 003045 Steering tube Replacement TIME 112 Vespa PX 150 USA Time Fuel tank FUEL LEVEL SENSOR Code Action Duration 1 005010 Fuel tank float Replacement 1 4 TIME 113 Time Code 004005 004007 004110 006024 Vespa 150 USA FUEL TANK Action Duration Fuel tank Replacement Fuel tap Replacement Fuel tank hose Replacement Fuel tank Painting Code 1 004017 TIME 114 OIL TANK Action Duration Oil tank Replacement Vespa PX 150 USA Time Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and refitting TIME 115 Time Steering column bearings TIME 116 Code 003002 004119 003073 004010 STEERING COLUMN BEARINGS Action Steering bearings Replacement Steering support bearing Replace ment Steering play Adjustment Steering lock Replacement Vespa PX 150 USA Duration Vespa PX 150 USA Time 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 0
10. Characteristics 6 7 hence loosen by 80 90 IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE LUBRICATE NUTS BEFORE AS SEMBLY CHAR 11 25 Vespa PX 150 USA Characteristics 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 VUE EE 4 5 ou mmm E MATING CATEGORIES 150CC ENGINE Name Initials Cylinder Piston Play on fitting Cylinder piston B 57 795 57 559 0 240 Cylinder piston C 57 800 57 650 0 240 Cylinder piston D 57 805 57 565 0 240 Cylinder piston E 57 810 57 570 0 240 Cylinder piston F 57 815 57 575 0 240 Cylinder piston G 57 820 57 980 0 240 Cylinder piston H 57 825 57 585 0 240 Cylinder piston 1st C 58 000 57 760 0 240 oversize Cylinder piston 1 st D 58 005 57 765 0 240 oversize Cylinder piston 1 st E 58 010 57 770 0 240 oversize Cylinder piston 1 st F 58 015 57 775 0 240 oversize Cylinder piston 1st G 58 020 57 780 0 240 oversize Cylinder piston 2nd C 58 200 57 960 0 240 oversize Cylinder piston 2nd D 58 205 57 965 0 240 oversize CHAR 12 Vespa PX 150 USA Characteristics Name Initials Cylinder Piston Play on fitting Cylinder piston 2nd E 58 210 57 970 0 240 oversize Cylinder piston 2nd F 58 215 57 975 0 240 oversize Cylinder piston 2nd G 58 220
11. and wear Check Vehicle and brake test road test Cl See regulations in section Idling speed adjustment MAIN 27 Maintenance Vespa PX 150 USA 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 must 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 wf the carburetor All seals should be replaced upon assembly CARBURETOR Specification Desc Quantity Conical needle Float Emulsifier air adjusting screw Emulsifier Main jet Slow running jet Fuel flow adjusting screw Throttle valve adjusting screw Throttle valve Starter jet Choke device Checking the spark advance In order to ensure the correct timing check the stator is oriented so that the I T index see figure coincides with the marking found on the crank case To check the timing use a timing light connect ing 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 rom the P index is aligned 1 with the I T marking stamped on the volute MAIN 28 Vespa
12. 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 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 5b 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 59 Engine Vespa PX 150 USA CONCEPTUAL DIAGRAMS Specification Desc Quantity Fuel tank filler cap Oil tank filler cap Oil level gauge SEPARATE LUBRICATION device box
13. 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 145 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 Tyre condition and wear Check Vehicle and brake test road test AT 21748 MILES Action AT 24855 MILES Action Cl See regulations in section Idling speed adjustement 65 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 130 26 AT 27962 MILES Action AT 31069 MILES Vespa PX 150 USA Maintenance Action Gear box oil level replaceme
14. check the projec tion of the light beam is between 7 10 and 9 10 of the distance measured from the ground to the centre of the headlight Adjust the headlight as necessary via screw 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 Gearbox Oil Check for the of oil inside the gearbox oil capacity 8 82 oz 250 g with the vehicle axis perfectly ver tical the oil level must be at the height of inspection hole A 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 8 82 oz 250 g of fresh oil through hole A so that the level rea ches the reference height Recommended products AGIP GEAR 80W 90 gearbox oil SAE 80W 90 oil complying with API GL4 specifi cations MAIN 30 Vespa PX 150 USA Vespa PX 150 USA Maintenance MAIN 31 INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Vespa PX 150 USA Electrical system d Era Orange Az Sky Blue Bi White Bl Blue Gi Yellow Grey Brown Black Ro Pink Rs Red Ve Green Vi Purple LEGENDA Specification Desc Quantity 1 Rear stop light switch 2 Lig
15. refit ting Clutch cover CLUTCH COVER Code Action Duration 1 001073 Clutch cover Removal and refitting Clutch TIME 135 Time Vespa PX 150 USA 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 136 Vespa PX 150 USA Time 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 TIME 137 A Air filter 29 Battery 38 46 Brake 81 82 84 85 129 Brake fluid C Carburettor 70 28 61 62 64 104 F Fuel 62 90 113 Fuses 45 H Headlight 30 87 Horn Instrument panel 119 Maintenance 7 24 S Shock absorbers 79 Spark plug 29 T Tank 90 113 114 Transmission 9 Tyres 10
16. 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 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 45 Electrical system Vespa PX 150 USA 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 corresponding to 31 1 BA with minimum ambient temperature of 59A F 15A C up to the top level indicated on the single block Slightly tilt the battery to remove any air bubbles formed during the filling Place the caps on the filling holes of the single elements without tightening them and let the battery stand During this phase the battery undergoes a ga
17. springs holding back the socket and replace any blown bulb CHAS 87 Chassis Vespa PX 150 USA 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 al lows 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 han dlebar cover CHAS 88 Vespa PX 150 USA Chassis Replace the seat and glove box cylinders To re place these follow the operations
18. 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 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 fix ing SCrews Refitting the rear wheel When refitting the rear wheel tighten all fasteners at the prescribed torque following a crosswise sequence Locking torques N m SUSP 78 Vespa PX 150 USA Suspensions 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 spring from the centre stand re NE move the 4 fasteners shown in the figure SUSP 79 INDEX OF TOPICS Brana SYSTEM BRAK SYS Vespa PX 150 USA Braking system Front brake calliper Removal Detach the brake hose from the calliper using a container to collect the fluid Remove
19. tool Carburettor float removing tool Punch for fitting fifth wheel seat on steer ing tube Kit for sampling gas from the exhaust manifold qa Extraction pliers for 11 mm bearings Vespa PX 150 USA Tooling Stores code Description 020151Y Air heater 020150Y Air heater support A 020057Y Calking tool 020095Y Flywheel retaining tool 008564Y Flywheel extractor 008886Y Crankshaft extractor 004499Y Camshaft bearing extractor TOOL 21 Tooling Stores code 020265Y 060007Y 060824Y 008119Y009 001729Y 020322Y TOOL 22 Vespa PX 150 USA Description Bearing fitting base Crankcase bearing spacer Inspection probe Tube to assemble shafts and axles Clutch retaining tool Clutch removing fitting tool INDEX OF TOPICS Maintenance Vespa PX 150 USA Maintenance chart EVERY 2 YEARS Action Brake fluid change AT 621 37 MILES OR 4 MONTHS GU 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 3106 86 MILES OR 12 MONTHS 65 Action Gear box oil level check Spark plug replacement Air filter on carburetor Clean Transmission gas mixer adjust Brake and clutch lever greasing
20. 01035 Clutch lever Replacement HANDLEBAR COMPONENTS AND BRAKE FLUID PUMP Code Action Duration 1 002059 RHS twist grip Replacement 2 002024 Front brake pump Removal and re fitting 3 002047 Front brake fluid Replacement and circuit bleeding TIME 117 Time Vespa PX 150 USA 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 118 Vespa PX 150 USA Instrument panel O 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 TIME 119 Time Vespa PX 150 USA Turn signal lights HEADLIGHT Code Action Duration 1 005008 Headlight bulbs Replacement 2 005002 Front light Replacement TIME 120 Vespa PX 150 USA Time 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 indic
21. 57 980 0 240 oversize Cylinder piston 3rd C 58 400 58 160 0 240 oversize Cylinder piston 3rd D 58 405 58 165 0 240 oversize Cylinder piston 3rd E 58 410 58 170 0 240 oversize Cylinder piston 3rd F 58 415 58 175 0 240 oversize Cylinder piston 3rd G 58 420 58 180 0 240 oversize Piston rings PISTON RINGS 150CC ENGINE Name Description Dimensions Initials Quantity Piston ring 57 8 A 0 2 0 4 Piston ring 1st over 58 A 0 2 0 4 size Piston ring 2nd over 58 2 A 0 2 0 4 size Piston ring 3rd over 58 4 A 0 2 0 4 size CHAR 13 Characteristics Vespa PX 150 USA 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 C 11 1 0 0 05 E 0 15 0 46 side Half crankshaft fly D 11 1 0 0 05 E 0 15 0 46 wheel side Spacer tool H 38 95 CONNECTING ROD CRANKSHAFT ASSEMBLY CLEARANCE F BETWEEN BIG END ROLLER CAGE AND HALF CRANKSHAFT ON FLYWHEEL SIDE Name Description Dimensions Initials Quantity Connecting Rod B 15 6 0 1 0 2 F 0 05 0 41 Washer 2 G 0 5 0 05 0 03 F 0 05 0 41 Half crankshaft clutch C 11 1 0 0 05 F 0 05 0 41 side Half crankshaft fly D 11 1 0 0 05 F 0 05 0 41 wheel side Spacer tool H 38 95
22. 823 16 64 BES 280 100 60 100 1 3 4 Vespa PX 150 USA Tightening Torques 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 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 N B Safety tightenings Torque in Nm 56 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 90 110 12 15 10 12 8 10 6 8 30 35 6 8 16 26 15 18
23. AS 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 Other Tire pressure All locks Rear view mirrors and accessory fitting Tooling kit owner manual warranty certificate and customer service card CAUTION CHECK THE INFLATING PRESSURES WHEN THE TIRES ARE AT AMBIENT TEMPERATURE CAUTION NOT EXCEED THE RECOMMENDED INFLATING PRESSURES AS THE TIRES MAY BURST Brake lever excursion Throttle excursion and adjustment Homogeneous steering turning PRE DE 95 INDEX OF TOPICS Time TIME Vespa PX 150 USA Engine ENGINE Code Action Duration 001001 Engine from the frame removal and refitting 003064 Engine oil replacement 003057 Engine retainer Tighten nuts Time TIME 97 Time Crankshaft Vespa PX 150 USA
24. 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 6213 71 MILES OR 24 MONTHS 130 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 Tyre condition and wear Check Vehicle and brake test road test Cl See regulations in section Idling speed adjustement AT 9320 57 MILES OR 36 MONTHS 65 MAIN 24 Vespa PX 150 USA 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 139 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 ad
25. PX 150 USA Maintenance 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 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 cov er 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 FG ISO L EGD MAIN 29 Maintenance 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 froma half lit white screen Ensure the vehicle axis is perpendicular to the screen 2 Turn the headlight on and
26. RED GREEN 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 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 mal functioning it will be necessary to check the gen erator and the stator components as follows After an eye inspection of the connections per form measurements on recharge coil and pick up see table using the specified tester If such read ings do not match the stated values proceed by replacing the stator and its components Specific tooling 020331Y Digital multimeter STATOR CHECK Specification Desc Quantity 1 RED WHITE wire 90 140 ohm 2 GREEN WHITE wire 800 1100 ohm ELE SYS 42 Vespa PX 150 USA Electrical system 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 sy
27. 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 82 Vespa PX 150 USA Braking system 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 FL
28. Replacement Vespa PX 150 USA Time 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 TIME 129 Time Vespa PX 150 USA Steering column STEERING COLUMN Code Action Duration 1 003010 Front suspension Service TIME 130 Vespa PX 150 USA Time Front suspension FRONT SHOCK ABSORBER Code Action Duration 1 003011 Front shock absorber Removal and Refitting TIME 131 Time Vespa PX 150 USA 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 132 Vespa PX 150 USA Time Code Action Duration S 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 TIME 133 Time Vespa PX 150 USA SHOE PLATE Code Action Duration 1 002016 Rear brake shoe plate Replace ment 2 003012 Brake shoe plate Removal and Re fitting 1 2 8 4 TIME 134 Vespa PX 150 USA Time 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
29. UID 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 83 Braking system Vespa PX 150 USA 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 BRAK SYS 84 Vespa PX 150 USA 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 Sp
30. Vespa PX 150 USA ELECTRICAL CONNECTIONS Code Action Duration 1 005001 Electric circuit Replacement and Refitting TIME 124 Vespa PX 150 USA Time 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 TIME 125 Time Vespa PX 150 USA ELECTRICAL DEVICES Code Action Duration 1 005013 Electronic blinker Replacement 2 005045 Starter motor wire harness Re placement TIME 126 Vespa PX 150 USA Time 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 Replacement 5 002046 Gear shifter cable Replacement TIME 127 Time Vespa PX 150 USA 2 5 TIME 128 Code 002055 002063 002053 003060 003061 002045 CABLES Action Duration Clutch cable assy Replacement Throttle cable assy Replacement Rear brake transmission complete replacement Rear brake cable Adjustment Accelerator transmission Adjust ment Clutch cable
31. asher 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 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 SUSP 75 Suspensions Vespa PX 150 USA 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 GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L DIN K3K 20 To remove the bearing housings from the frame
32. ator bulb Replace ment D 005022 Rear turn signal light Replacement 6 005006 Turn signals switch Replacement 7 005039 Headlight switch Replacement TIME 121 Time Vespa PX 150 USA Front wheel r Fr Nu Pra a A A ons um em 2 LONE NE P dL e ET _ Ly f 2 A E SE de VAR D gt K Sa a tat e SEL EN ea I T F N E r la Rag i LEN bi LI P ak 3 4 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 PASS 900001 Tone wheel drive greasing 15 1 Never mistake the codes 002011 movement sen sor replacement and 005089 tone wheel replace ST ment in the event of noise of the indicated components The grease recommended is TUTE LA MRM 2 soap based lithium grease with Mo lybdenum disulphide In the following points we indicate with an arrow the area to be greased 1 Drive 2 Tone wheel TIME 122 Vespa PX 150 USA Time Electric devices e ECU CDI Code Action Duration 1 001023 CPU Replacement TIME 123 Time
33. 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 puncher remove the conical pin and extract the gear shifting lever ENG 64 Vespa PX 150 USA Vespa PX 150 USA Engine 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 SN PAN 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 ENG 65 Engine Vespa PX 150 USA 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 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
34. ders 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 orto SI 20 20 D Engine idle speed 1900 100 rpm CO value 3 8 0 5 Air filter Metallic net soaked in oil petrol mixture Starting system Electric starter motor and kick start Lubrication Mixture oil Fuel supply Oil petrol mixture through carburetor with automatic mixer mass flow varying with engine speed and throttle valve CHAR 8 Vespa PX 150 USA Specification Clutch Cooling Max power output shaft 150cc Max speed 150 Transmission Specification Gear box Capacities Specification Gear box Oil tank mixer Fuel tank Characteristics Desc Quantity Multi disc Forced air by a centrifugal fan 6 6 Kw 9 hp at 5 700 rom 82 8 Km h TRANSMISSION Desc Quantity 4 speed with constantly engaged gears CAPACITIES Desc Quantity 250100 1 6 I including a reserve of 0 4 72 11 gal including 0 55 gal reserve 8 I including 2 1 reserve Electrical system ELECTRICAL SYSTEM Specification Desc Quantity 1 Ignition type Electronic ignition by capacitive discharge with H T coil 2 Spark advance T D C 18 1 3 Spark plug CHAMPION RL82C 4 Battery 12V 9Ah D Fuse 7 5 6 Generator AC Frame and suspensions FRAME AND SUSPENSIONS Specification Desc Quantity Suspensions Steering column pivoted onto front wheel hub helicoid spring suspension and hydrau
35. 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 new cylinder Bear in mind that for the replacement of the cylinder on the seat lock it is necessary to re move 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 pro ceed as follows Cylinder removal in the event that the key switch is in the LOCK position it is necessary to pro ceed by drilling the cylinder with the aid of a 8 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 89 Chassis Vespa PX 150 USA 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 f
36. ecific tooling 020325Y Brake shoe spring calliper Refit the components following the removal pro cedures 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 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 85 INDEX OF TOPICS Cassis CHAS Vespa PX 150 USA Chassis 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 dashboard Headlight assy After removing the handlebar cover remove the 2 fasteners show in the figure and the headlight ad justing screw underneath the handlebar Detach the wirings To replace the bulbs simply release the
37. es even the invalidity of the guarantee INDEX OF TOPICS CHAR O E JU Z gt 5 2 D o o TOOL MAINTENANCE MAIN ENG VE ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG SUSP BRAK SYS BRAKING SYSTEM CHAS PRE DE PRE DELIVERY TIME TIME I gt d o INDEX OF TOPICS Characteristics CHAR Vespa PX 150 USA Characteristics 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 Sulphuric acid is highly corrosive in the event of contact with your eyes or clothes rinse thoroughly with water and consult a doctor immediately The battery produces hydrogen a gas that can be highly explosive Do not smoke and avoid sparks and flames when close to the battery especially during recharge Fuel is highly flammable and in some conditions it can be explosive Do not smoke in the working area and avoid free flames or sparks Clean the brake pads in a well ventilated environment directing the compressed air jet so as to not intake the dust produced by the wear of the friction material Even though the latter contains no as bestos dust inhalation is har
38. estore if required up to the tol reference using distilled water tighten the caps of the single elements and install it on the vehicle If lower voltages are detected recharge the battery for 4 6 hours more as described above Note With battery charger dwg 020334Y you can check the battery charge level by the function Check The value shown on the display must be higher than that indicated in the table if not recharge as described above ELE SYS 46 INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Engine from vehicle Vespa PX 150 USA 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 and choke cables Detach the oil and petrol hoses Remove the engine frame bolt shown in the fig ure ENG VE 48 Vespa PX 150 USA Engine from vehicle 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
39. evel indicators and enable signals section SAFETY SWITCHES AND LEVEL GAUGES Specification Desc Quantity Fuel gauge Fuel level sending unit Reserve fuel light 12V 1 2W Brake light bulbs 12V 10W Stoplight switches Voltage regulator ELE SYS 39 Electrical system Turn signal lights 0 ISI ELE SYS 40 Vespa PX 150 USA SIGNAL LIGHTS AND HORN Specification Turn signals master box Indicators switch Turn signal warning light Turn signal light bulbs Horn button Horn Voltage regulator Key switch contacts Fuse 7 5A Battery Desc Quantity 12V 1 2W 12V 21W 12V 9Ah Vespa PX 150 USA Electrical system Instruments and warning lights control board DASHBOARD LIGHTS AND GAUGES Specification Desc Quantity Battery Fuel gauge Low fuel warning light Turn signals warning light High beam warning light Side lamps warning light Ground lead Checks and inspections Ignition circuit All system checks requiring the detachment of ca bles inspections involving ignition system wiring and devices must be carried out with the engine off so to avoid any possible damage to the ECU which would require its replacement It is therefore important to follow the wire color coding when reattaching the cables see figure ELE SYS 41 Electrical system Vespa PX 150 USA IGNITION CIRCUIT Specification Desc Quantity WHITE
40. handling fuel Locking torques N m Engine frame bolt 61 75 Shock absorber engine bolt 13 23 ENG VE 49 INDEX OF TOPICS Vespa PX 150 USA Engine 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 LOT Ia A S Remove the kick start lever after having detach ed the lower fastener Removing the stator Remove the three screws shown in the figure Remove the stator ENG 51 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 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 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 52 Vespa PX 150 USA Vespa PX 150 USA Engine 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
41. ht 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 control device 9 Flywheel magneto 10 Electronic ignition device 11 Starter motor 12 Fuse carrier N 1 fuse to 7 5 A 13 Battery 14 rear left turn indicator 15 Direction indicator lights N 2 16 Rear parking and stop light bulbs 17 Rear light assembly 18 rear right turn indicator ELE SYS 33 Electrical system 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 ELE SYS 34 Specification Voltage regulator Mixer oil warning light control Starter remote control Frame earth Starter motor wire unit Automatic starter Heater Chassis wire unit Fuel level sender front right turn indicator Key switch Starter button Front brake stop button Headlight Light Sidelight bulb Left turn indicator warning light Headlamp warning light High beam lamp warning light License plate light bulb Low fuel warning light Right turn indicator warning light Low oil warning light Odometer with warning lights and level indicator Vespa PX 150 USA Desc Quantity 12V 2W 12V 2W Vespa PX 150 USA Components arrangement COMPONENTS ARRANGEMENT Electrical system Specification Desc Quantity Go PO Key switch Voltage regulator Electronic Control Unit C D I with H T coil Battery 12V 9Ah Starter motor Magneto flywhee
42. if worn CAUTION THE TRUNNION BUSHING HAS A LHS THREAD Locking torques N m Gear box trunnion 15 18 ENG 66 Vespa PX 150 USA Engine 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 with the edge F of the bushing to be rounded BIO 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 reassem bly With the refitting operation concluded tighten the shaft lock nut to the prescribed torque Recommended products AGIP GREASE MUS Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L 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 ENG 67 Vespa PX 150 USA Engine Axial play 0 20 0 40 mm Using the special tool proceed by removing the
43. istgrip Calcium complex soap grease NLGI 2 gaer ISO L XBCIB2 AGIP CITY TEC 2T Mixer oil synthetic oil for 2 stroke engines JASO FC ISO L EGD AGIP GREASE MU3 Grease for odometer transmission gear Soap based lithium grease with NLGI case ISO L XBCHA3 DIN K3K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid CHAR 15 INDEX OF TOPICS Toouna TOOL Vespa PX 150 USA Stores code 020004Y 020055Y 020074Y 002850y 002973y 020320Y Tooling TOOLING Description Punch for removing fifth wheels from headstock Wrench for steering tube ring nut Support base for checking crankshaft alignment N d Oil tank spanner Fuel tap spanner Exhaust gases analyser Ai LT FLUX IMFERBED ML IR ALTER TOOL 17 Tooling Stores code 020325Y 020329Y 020330Y 020331 Y 020332Y TOOL 18 Vespa PX 150 USA Description Brake shoe spring calliper MityVac vacuum operated pump Stroboscopic light to check timing Digital multimeter Digital rev counter Vespa PX 150 USA Stores code 020333Y 020334Y 020335Y 001330Y Description Single battery charger Multiple battery charger Magnetic support for dial gauge Tool for fitting steering seats Tooling TOOL 19 Tooling TOOL 20 Stores code 020021Y 020321y 006029Y 020625Y 001467Y021 Vespa PX 150 USA Description Front suspension service
44. justment 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 Tyre condition and wear Check Vehicle and brake test road test See in section Idling speed adjustment AT 15534 MILES 65 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 18641 MILES 160 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 Maintenance MAIN 25 Maintenance Safety locks check Suspensions check Electrical system and battery check Headlight adjustment check Tyre condition and wear Check Vehicle and brake test road test Vespa PX 150 USA Action Cl See regulations in section Idling speed adjustment 65 Gear box oil level
45. l Anti repeating device Spark plug Remote starter switch Fuse 7 5 Horn Turn signals master box Front headlight Front turn signal lights Taillight Rear turn signal lights ELE SYS 35 Electrical system Vespa PX 150 USA Conceptual diagrams Ignition ELE SYS 36 IGNITION Specification Desc Quantity Magneto flywheel Key switch contacts Electronic Control Unit C D l with H T coil Spark plug Vespa PX 150 USA Headlights and automatic starter section 5 Go PO co Specification Voltage regulator Magneto flywheel Key switch contacts Lampada proiettore High beam warning light Light switch Light remote control switch Rear side light bulb Instrument panel lighting bulb Headlamp warning light Fuse 7 5A Battery Electrical system Desc Quantity 12V 55 60W 12V 1 2W 12V SW 12V 1 2W 12V 1 2W 12V 9Ah ELE SYS 37 Electrical system Vespa PX 150 USA Battery recharge and starting Fo va LE RICARICA BATTERIA E AVVIAMENTO Specification Desc Quantity Magneto flywheel Electronic ignition device Key switch contacts Voltage regulator Fuse 75A Remote starter switch Starter motor Battery 12V 9Ah Enable button Start up button Anti repeating device Engine stop switch Engine stop remote control switch BIO OIN 0O0 ELE SYS 38 Vespa PX 150 USA Electrical system L
46. lic shock absorber compression and rebound damping Frame Monocoque type shell obtained from pressed steel Brakes Specification Front Rear BRAKES Desc Quantity 220 mm disc hydraulically operated via lever mounted on RHS of handlebars 140 mm drum with expanding shoes mechanically activated via pedal on RHS of footrest CHAR 9 Characteristics Wheels and tyres Vespa PX 150 USA 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 x10 pressed steel rims Front tire pressure Rear tire pressure 18 85 PSI 1 3 bar 26 11 PSI 1 8 bar 33 36 PSI 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 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 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 CHAR 10 Desc Quantity 120 20D 20 mm 96 100 45 100 140 100 6823 09 BE5 280 100 60 100 1 2 turn Desc Quantity 5120 20D 20 mm 98 45 160 150 6
47. 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 previ ously removed Refit the remaining components following the above operations in the reverse order Specific tooling 001467Y Extractor for bearings for holes 001467Y021 Extraction pliers for 11 mm bear ings 020151Y Air heater 020150Y Air heater support Position a new cap onto the pinion and round the edges using the special tool to safely lock the as sembly in a vice Rotate the assembly by a quarter turn and pro ceed by rounding the remaining section of the caps circumference Specific tooling 020057Y Calking tool ENG 53 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 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
48. mful 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 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Empty weight 229 28 Lb 104 Kg Wheelbase 48 62 inch 1235 mm Max height 43 70 inch 1110 mm CHAR 7 Characteristics Vespa PX 150 USA Specification Desc Quantity Max lenght 69 29 inch 1760 mm Handlebars width 27 56 inch 700 mm OLLL Engine ENGINE Specification Desc Quantity Engine type 2 stroke with rotary intake timing No of cylin
49. nt 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 Tyre condition and wear Check Vehicle and brake test road test Cl See regulations in section Idling speed adjustment AT 34175 MILES 65 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 37282 MILES 205 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 Tyre condition
50. nt suspension service tool Connect the swinging hub to the steering tube with the guiding pin Use the tool fitted with part 3 on the stem and part 4 Lubricate the pin with recommended grease and insert it temporarily on the swinging hub move the tool handgrip until part 3 is fully inserted on the p steering tube 7 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 SUSP 74 Vespa PX 150 USA Suspensions 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 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 Le 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 w
51. ocking torques N m Clutch assy fixing nut 40 45 ENG 70 INDEX OF TOPICS Suspensions Vespa PX 150 USA 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 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 72 Vespa PX 150 USA Suspensions Refitting Upon reassembly tighten to the prescribed tor que B N B Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TOR QUE LUBRICATE NUTS BEFORE ASSEMBLY AR S 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 mak ing sure of having removed the brake calliper Specific tooling 020055Y Wrench for steering tube ring nut Overhaul Servicing the front suspension steering assembly described below deals mainly with replacing parts pin NADELLA roller bushings
52. p plied 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 sup plied by the generator must be between 26 and 30V at 3 000 rpm this measurement must obvi ously be carried out with the battery disconnec ted Specific tooling 020331Y Digital multimeter Starter motor Bench tests to be performed on the electric starter motor 1 No load test the starter motor unloaded must absorb less than 10 A with a voltage supply gt 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 44 Vespa PX 150 USA Electrical system STARTER MOTOR Specification Desc Quantity 1 Nominal voltage 12V 2 Nominal power 0 15 kW 3 Direction of
53. 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 56 Vespa PX 150 USA Engine 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 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 ENG 57 Engine Vespa PX 150 USA 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
54. ree 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 Carburetor float removing tool 002850y Oil tank spanner 002973 y Fuel tap spanner Remove the tank filler cap and insert the spanner thus loosening nut D hence extract the fuel tap CHAS 90 Vespa PX 150 USA Chassis Front mudguard Remove the 2 fixings from underneath the mud guard After removing the handlebar and the steering V 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 91 Chassis Vespa PX 150 USA 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 CHAS 92 INDEX OF TOPICS Pre delivery Vespa PX 150 USA Carry out the listed tests before delivering the vehicle WARNING BE VERY CAREFUL WHEN HANDLING FUEL Aesthetic inspection Paint Plastic joints Damages Dirt Tigh
55. ring hence ceed 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 push ing directly on the bearing s outer ring Position the crankshaft onto the special support Install the special spacer as shown in the figure and using a length of tube of adequate diameter push the bearing until the inner ring heated up in oil at 248 F or 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 58 Vespa PX 150 USA 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 carburetor 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
56. sification phenomenon and temperature rises Let it stand until ambient temperature is reached again this phase may require up to 60 minutes Slightly tilt the battery to favour the removal of any air bubbles then restore the levels using the same electrolyte Note This is the last time that electrolyte can be added Future top ups must be made using only distilled water Within 24 hours refill as follows Connect the battery charger terminals according to the right polarity Using the battery charger dwg 020333Y and or dwg 020334Y select the battery capacity If the battery charger is not available charge the battery with a constant current of 1 10 of the rated Capacity for example for a battery with rated capacity of 9Ah the charge current must be 0 9 1 0A for approx 4 6 hours Note Batteries stored for a long time can require longer times Battery chargers dwg 020333Y and dwg 020334Y have an automatic protection that stops the recharge after 12 hours to prevent overheating the battery In this case the turning on of the green led does not indicate the end of the charge but the start of the safety system Let the battery stand with open circuit for approx 4 6 hours then check the voltage using a normal tester If the open circuit voltage is more or equal to 12 6V the battery charge is good Slightly tilt the battery to eliminate any air bubbles formed while recharging Check the electrolyte level again r
57. stem 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 3V and 14 5V At 5 000 rpm with the lights on check the regulator voltage is between 13V and 15V In the presence of a reg ulator voltage exceeding 15V replace the regula tor as definitely faulty FAULT 2 a Check the correct current supply from the alter nator detach the regulator connector and attach the alternate current tester between the grey blue wire terminal and earth With the tester set onto alternate current check the supplied voltage at 3 000 rpm is between 25 and 30V b If no faults are found replace the voltage regu lator C If the system is still malfunctioning after the reg ulator 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 ELE SYS 43 Electrical system Vespa PX 150 USA 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 su
58. tening torques inspection All tighten torques summarized 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 94 Vespa PX 150 USA Pre delivery THE BATTERIES PRODUCE EXPLOSIVE G
59. 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 BEFORE AS SEMBLY Locking torques N m Pipe calliper fitting 15 25 Calliper fixing screw 20 25 Front brake disc Removal Remove the rear wheel by loosening the 5 fas teners Remove the wheel hub Loosen the 5 disc fasteners Refitting When refitting correctly position the disc observing the direction of rotation see figure and apply medium thread lock BRAK SYS 81 Braking system Vespa PX 150 USA 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 neces sary replace the wheel hub Specific tooling 020335Y Magnetic support for dial gauge Front brake pads Removal To facilitate this operation it is suggested that the 15 front wheel is removed remove the plastic cap and apply leverage with screwdriver
60. ting Stator Overhaul Flywheel Replacement Pick up Replacement Ignition timing TIME 103 Time Vespa PX 150 USA Carburettor 1 2 3 CARBURETTOR Code Action Duration 1 001063 Carburettor Replacement 2 001008 Carburatore Revisione 3 003058 Carburettor Adjustment TIME 104 Vespa PX 150 USA Time Exhaust pipe EXHAUST PIPE Code Action Duration 1 001009 Exhaust pipe Replacement TIME 105 Time Vespa PX 150 USA Air cleaner AIR CLEANER Code Action Duration 1 001014 Air filter Replacement 2 001027 Air cleaner frame bellow Replace ment TIME 106 Vespa PX 150 USA Frame FRAME Code Action Duration 004001 Frame Replacement 006001 Frame Painting 004023 Shield rim Replacement Time TIME 107 Time Vespa PX 150 USA Centre stand CENTRE STAND Code Action Duration 1 004004 Centre stand Replacement Legshield spoiler TIME 108 Vespa PX 150 USA Time 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 TIME 109 Time Vespa PX 150 USA SIDE FAIRING LOCKS Code Action Duration 1 004025 Side fairing locks Replacement Footrests TIME 110 Vespa PX 150 USA Time FOOTRESTS Code Action Duration 1 004015 Footrests Replacement Rear cover GLOVE BOX Code Action Duration
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