WORKSHOPMANUAL633376VespaPX150USAWORKSHOPMANUALVespaPX150USAWORKSHOPMANUALVespaPX150USAThis manual has been prepared by Piaggio &C. S.p.A, for use in the workshops ofauthorized Piaggio-Gilera dealers and sub-agents. t is assumed that the personutilizing this manual for servicing or repairing Piaggio vehicles has knowledge of theprinciples of mechanics andstandardprocedures requiredfor general vehiclerepair.Any relevant changes concerning the vehicle characteristics or specific repairoperations will be divulged in the formof updates to this manual. Satisfactory repairor service cannot be achieved without the necessary equipment and tools. Refer tothe pages of this manual concerning specific tools and equipment and the specialtoolscatalogue.N.B. Provideskeyinformationtomaketheprocedureeasier tounderstandandcarryout.CAUTIONReferstospecificprocedurestocarryout for preventingdamagestothevehicle.WARNINGReferstospecificprocedurestocarryout toprevent injuriestotherepairer.PersonaI safetyFailuretocompletelyobservetheseinstructionswill result inseriousriskof personalinjury.Safeguardingtheenvironment Sectionsmarkedwiththissymbol indicatethecorrect useof thevehicletoprevent damagingtheenvironment.VehicIeintactnessTheincompleteor non-observanceof theseregulationsleadstotheriskof seriousdamagetothevehicleandsometimeseventheinvalidityof theguarantee.INDEXOFTOPICSCHARACTERISTICS CHARTOOLING TOOLMAINTENANCE MAINELECTRICALSYSTEM ELESYSENGINEFROMVEHICLE ENGVEENGINE ENGSUSPENSIONS SUSPBRAKINGSYSTEM BRAKSYSCHASSIS CHASPRE-DELIVERY PREDETIME TIMEINDEXOFTOPICSCHARACTERISTICS CHARRuIesSafetyruIes- Shouldit benecessarytokeeptheenginerunningwhileservicing, makesurethat theareaor roomiswell ventilated, andusespecial exhaust fans, if required. Never let theenginerunninginclosedrooms. nfact, exhaust gasesaretoxic.- Thebatteryelectrolytecontainssulphuricacid. Protect your eyes, clothesandskin. Sulphuricacidishighlycorrosive; intheevent of contact withyour eyesor clothes, rinsethoroughlywithwater andconsult adoctor immediately.- Thebatteryproduceshydrogen, agasthat canbehighlyexplosive. Donot smokeandavoidsparksandflameswhenclosetothebattery, especiallyduringrecharge.- Fuel ishighlyflammable, andinsomeconditionsit canbeexplosive. Donot smokeintheworkingarea, andavoidfreeflamesor sparks.- Cleanthebrakepadsinawell ventilatedenvironment, directingthecompressedair jet soastonotintakethedust producedbythewear of thefrictionmaterial. Eventhoughthelatter containsnoas-bestos, dust inhalationisharmful.SafetyruIes- Useoriginal PAGGOsparepartsandlubricantsrecommendedbytheManufacturer. Non-originalor non-conformingsparesmaydamagethevehicle.- Useonlythespecifictoolsdesignedfor thisvehicle.- Alwaysusenewgaskets, sealingringsandsplit pinsuponreassembly.- After removal, cleanthecomponentsusingnon-flammableor lowfire-point solvent. Lubricateallworkingsurfacesbeforereassembly, except for conical couplings.- After reassembly, checkthat all componentshavebeeninstalledproperlyandthat theyareingoodworkingorder.- For removal, overhaul andreassemblyoperationsuseonlytoolsprovidedwithmetricmeasures.Metricbolts, nutsandscrewsarenot interchangeablewithcouplingmemberswithEnglishmeasure-ment. Usingimproper couplingmembersandtoolsmayimpair thevehicle.- Shouldanyinterventionstothevehicleelectricsystemberequired, checkthat theelectrical connec-tions- especiallyearthandbatteryconnections- havebeenimplementedproperly.DimensionsandmassWEIGHTANDDIMENSIONSCharacteristics VespaPX150USACHAR- 2Specification Desc./QuantityEmptyweight 229,28Lb(104Kg)Wheelbase 48,62inch(1235mm)Maxheight 43,70inch(1110mm)Maxlenght 69,29inch(1760mm)Handlebarswidth 27,56inch(700mm)EngineENGINESpecification Desc./QuantityEnginetype 2-strokewithrotaryintaketimingNo. of cylinders 1Alesaggioper corsa(150) 0,19x2,24inch(58x57mm)Cilindrata(150) 919inch3(150,599cm3)VespaPX150USA CharacteristicsCHAR- 3Specification Desc./QuantityCompressionratio(150) 8: 1Carburetor Dell'ortoS 20/20DEngineidle 1900100rpmCOvalue 3,80,5%Air filter Metallicnet soakedinoil-petrol mixtureStartingsystem Electricstarter motor andkick-startLubrication MixtureoilFuel supply Oil-petrol mixturethroughcarburetor withauto-maticmixer (massflowvaryingwithenginespeed) andthrottlevalveClutch Multi-disc.Cooling Byforcedair withcentrifugal fan.Maxpower output (shaft) 150cc 6.6Kw(9hp) at 5,700rpmMaxspeed(150) 82,8Km/hTransmissionTRANSMISSIONSpecification Desc./QuantityGear-box 4-speedwithconstantlyengagedgearsCapacitiesCAPACITIESSpecification Desc./QuantityGear-box ~250cc.Mixer oil tank ~0,42gal, including0,10gal reserve(~1,6l, in-cluding0,4l reserve)Fuel tank ~2,11gal, including~0,55gal reserve(~8l, in-cluding~2,1l reserve)EIectricaI systemELECTRICALSYSTEMSpecification Desc./Quantity1 gnitiontype ElectronicignitionbycapacitivedischargewithH.T. coil2 Sparkadvance(T.D.C.) 18 1Characteristics VespaPX150USACHAR- 4Specification Desc./Quantity3 Sparkplug CHAMPONRL82C4 Battery 12V- 9Ah5 Fuse 7,5A6 Generator ACFrameandsuspensionsFRAMEANDSUSPENSIONSSpecification Desc./QuantitySuspensions Steeringcolumnpivotedontofront wheel hub,helicoidspringsuspensionandhydraulicshock-absorber (compressionandrebounddamping)Frame Monocoque-typeshell obtainedfrompressedsteelBrakesBRAKESSpecification Desc./QuantityFront 220mmdischydraulicallyoperatedvialevermountedonRHSof handlebarsRear 140mmdrumwithexpandingshoesmechanic-allyactivatedviapedal onRHSof footrestWheeIsandtyresWHEELSANDTIRESSpecification Desc./QuantityFront tire 3,50x10"Rear tire 3,50x10"Rims PressedsteelWheels nterchangeablewith2.00"10" pressedsteelrims.Front tirepressure 18,85PS (1,3bar)Rear tirepressure 26,11PS (1,8bar)33,36PS (2,3bar) driver andpassengerN.B.CHECKANDADJUSTTIREPRESSUREWITHTIRESATAMBIENTTEMPERATURE. ADJUSTPRESSUREACCORDINGTOTHEWEIGHTOFTHERIDERANDACCESSORIES.VespaPX150USA CharacteristicsCHAR- 5Carburettor150ccVersionDeII'OrtoCARBURETTORSpecification Desc./QuantityType S20/20DDiffuser diameter 20mmMainjet 98Slowrunningjet 45/160Mainair jet 150Throttlevalve(type) 6823.16.64Emulsifier (code) BE5Sprayer 280/100Starter jet 60/100Air idlingscrew 13/4TighteningTorquesSTEERINGUNITName TorqueinNmUpper steeringringnut 56Topsteeringhousing 67(henceloosenby80 - 90)Handlebar fixingscrew* 3044FRAMEName TorqueinNmEngine- framebolt * 6175Rim- hubfixingnuts(front-rear) 2027Shock-absorber - framefixingnut* 3040Shock-absorber - enginebolt* 1323Rear wheel axle* 7590FRONTSUSPENSIONName TorqueinNmShock-absorber mountingplate- steeringcolumn 2027Characteristics VespaPX150USACHAR- 6Name TorqueinNmfixingnutsUpper shock-absorber fixingnut 3040Lower shock-absorber fixingnut 2027Front wheel axlenut* 60100FRONTBRAKEName TorqueinNmReservoir - pipefitting 812Pipe- calliper fitting 1525ntermediatepipefitting 1015Calliper fixingscrew* 2025Discfixingscrew* 56Oil drainingscrew 1012ENGINEName TorqueinNmCoilsmountingbracket fixingscrew 34Kick-start lever fixingnut 2326Clutchassy. fixingnut 4045Multi-gear pinionnut 3035Flywheel fixingnut 6065Carburettor fixingbolts 1620Clutchcover fixingscrews 68Cylinder headfixingnuts 1318Sparkplug 2025Crankcasematingscrews 1113Wheel axlenut 90110Gear shifter nuts 1215Starter motor screws 1012Fancover screws 810Air-boxfixingscrews 68Gear fixingnut 3035Mixer fixingscrews 68Headfixingnuts 1626Gear-boxtrunnion 1518N.B.VespaPX150USA CharacteristicsCHAR- 7* SafetytighteningsINORDERTOENSURETHECORRECTTIGHTENINGTORQUE, LUBRICATENUTSBEFOREASSEMBLY.OverhauI dataAssembIycIearancesCyIinder - pistonassy.Thecylinder classificationmust becarriedout at 25mmfromtheheadmatingsur-faceontherod'sswingingplane.MATINGCATEGORIES- 150CCENGINEName PIay InitiaIs CyIinder Piston PIayonfittingCylinder - pis-tonvalue B 57,795 57,555 0,240Cylinder - pis-tonvalue C 57,800 57,650 0,240Cylinder - pis-tonvalue D 57,805 57,565 0,240Cylinder - pis-tonvalue E 57,810 57,570 0,240Cylinder - pis-tonvalue F 57,815 57,575 0,240Characteristics VespaPX150USACHAR- 8Name PIay InitiaIs CyIinder Piston PIayonfittingCylinder - pis-tonvalue G 57,820 57,580 0,240Cylinder - pis-tonvalue H 57,825 57,585 0,240Cylinder - pis-ton(1st over-size)value C 58,000 57,760 0,240Cylinder - pis-ton(1st over-size)value D 58,005 57,765 0,240Cylinder - pis-ton(1st over-size)value E 58,010 57,770 0,240Cylinder - pis-ton(1st over-size)value F 58,015 57,775 0,240Cylinder - pis-ton(1st over-size)value G 58,020 57,780 0,240Cylinder - pis-ton(2ndover-size)value C 58,200 57,960 0,240Cylinder - pis-ton(2ndover-size)value D 58,205 57,965 0,240Cylinder - pis-ton(2ndover-size)value E 58,210 57,970 0,240Cylinder - pis-ton(2ndover-size)value F 58,215 57,975 0,240Cylinder - pis-ton(2ndover-size)value G 58,220 57,980 0,240Cylinder - pis-ton(3rdover-size)value C 58,400 58,160 0,240Cylinder - pis-ton(3rdover-size)value D 58,405 58,165 0,240Cylinder - pis-ton(3rdover-size)value E 58,410 58,170 0,240VespaPX150USA CharacteristicsCHAR- 9Name PIay InitiaIs CyIinder Piston PIayonfittingCylinder - pis-ton(3rdover-size)value F 58,415 58,175 0,240Cylinder - pis-ton(3rdover-size)value G 58,420 58,180 0,240PistonringsPISTONRINGS- 150CCENGINEName Description Dimensions InitiaIs QuantityPistonring 57,8 A 0,20,4Pistonring(1stoversize)58 A 0,20,4Pistonring(2ndoversize)58,2 A 0,20,4Pistonring(3rdoversize)58,4 A 0,20,4Crankcase- crankshaft - connectingrodCharacteristics VespaPX150USACHAR- 10CONNECTINGROD- CRANKSHAFT. ASSEMBLYCLEARANCEEBETWEENBIGENDANDHALFCRANKSHAFTONFLYWHEEL-SIDEName Description Dimensions InitiaIs QuantityConnectingRod A=15,4+0-0,05 E 0,150,46Washer (2) G=0,5+0,05-0,03 E 0,150,46Half-crankshaftclutch-sideC=11,1-0+0,05 E 0,150,46Half-crankshaft fly-wheel-sideD=11,1-0+0,05 E 0,150,46Spacer tool H=38,95CONNECTINGROD- CRANKSHAFT. ASSEMBLYCLEARANCEFBETWEENBIGENDROLLERCAGEANDHALFCRANKSHAFTONFLYWHEEL-SIDEName Description Dimensions InitiaIs QuantityConnectingRod B=15,6-0,1-0,2 F 0,050,41Washer (2) G=0,5+0,05-0,03 F 0,050,41Half-crankshaftclutch-sideC=11,1-0+0,05 F 0,050,41Half-crankshaft fly-wheel-sideD=11,1-0+0,05 F 0,050,41Spacer tool H=38,95~Connectingrodsandroller cagesaresubdividedinto4categories(indicatedbymarkingsonbigendandouter cagerim, respectively)~Mateconnectingrodwithcageof samecategory; if suchassemblyresultstobeexcessivelyVespaPX150USA CharacteristicsCHAR- 11noisy, usearoller cagefromnext category.~For thewrist pin, fittedwith0clearance, themaximumaIIowabIepIayafter usemust be0.02mm.~Themaximumallowableend-playfor theconnectingrodafter use(intendedasthelongitudinalslideonthebigend) is0.7mm.GearboxshouIdersGEARBOXSHOULDERSName Description Dimensions InitiaIs QuantityShoulder 2,05+0-0,06 A 0,150,40Shoulder (1st over-size)2,20+0-0,06 A 0,150,40Shoulder (2ndoversize)2,35+0-0,06 A 0,150,40Shoulder (3rdoversize)2,50+0-0,06 A 0,150,40Shoulder (4thoversize)2,65+0-0,06 A 0,150,40N.B.IFTHESPECIFIEDCLEARANCEACANNOTBEACHIEVED, REPLACETHESHOULDERRINGWITHANOVERSIZEDONESUCHTOALLOWOBTAININGTHEPRESCRIBEDPLAY. TOCHECKTHECLEAR-ANCE, USEAFEELERGAUGE.ProductsTABLEOFRECOMMENDEDPRODUCTSProduct Description SpecificationsTUTELAZCGEMAX6 GearboxOil SAE80Woil complyingwith, orexceeding, AP GL4specifica-tions.SELENAH Scooter 2Tech Oil for flexibletransmissionlub- Oil for two-strokemotorsCharacteristics VespaPX150USACHAR- 12Product Description Specificationsrication(accelerationcontrol,mixer andkmcounter)SYSTEMTW249AREXONS Grease(brakelevel, throttletwistgrip, gaer)CalciumcomplexsoapgreaseNLG 1-2SELENAH Scooter 2Tech Mixer Oil Syntheticoil that passesAP TC++specificationsJOTA3FS Speedometer transmission LithiumsoapgreaseNLG 33TUTELATOP4 Brakefluid SyntheticfluidSAEJ1703,NHTSA116DOT4, SO4925VespaPX150USA CharacteristicsCHAR- 13Characteristics VespaPX150USACHAR- 14INDEXOFTOPICSTOOLING TOOLTOOLINGStorescode Description020004Y Drift for removingthrust ringsfromsteeringheadtube020055Y Steeringtuberingnut spanner020074Y Crankshaft aligningtool002850y Oil tankspanner002973y Fuel tapspanner020320Y Exhaust gasesanalyserTooling VespaPX150USATOOL- 2Storescode Description020325y Pliersfor brake-shoesprings020329Y PumpMTYVAC020330Y Stroboscopicgunfor two- andfour-strokeengines020331Y Digital multimeter020332Y Digital rpmcounterVespaPX150USA ToolingTOOL- 3Storescode Description020333Y Singlebatterycharger020334Y Multiplebatterycharger020335Y Magneticstandandcomparator001330Y Steeringseat installer, tobefit-tedwithparts: 001330Y009-Forlower seat, 001330Y013-For up-per seatTooling VespaPX150USATOOL- 4Storescode Description020021y Front suspensionoverhaul kit020321y Carburettor float removingtool006029y Drift for fittingthrust ringseatsonsteeringtube020625Y Exhaust gasescollectingkit001467y021 11mmbearingclipVespaPX150USA ToolingTOOL- 5Storescode Description020151Y Air heater "METABOHG1500/2"020150Y Support for air heater "METABOHG1500/2"020057Y Calkingtool020095Y Flywheel retainingtool008564Y Flywheel extractor008886Y Crankshaft extractor004499y BearingextractorTooling VespaPX150USATOOL- 6Storescode Description020265y Bearingfittingstand060007Y Crankcasebearingspacer060824Y nspectionprobe008119y009 Tube(shaft fittingtool)001729Y Clutchretainingtool020322Y Clutchremoving/fittingtoolVespaPX150USA ToolingTOOL- 7Tooling VespaPX150USATOOL- 8INDEXOFTOPICSMAINTENANCE MAINMaintenancechartEVERY2YEARSActionBrakefluid- ChangeAT621,37MILESOR4MONTHS80'ActionGear-boxoil level - replacementThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakefluidlevel - CheckNuts, boltsandfasteners- CheckElectrical systemandbattery- CheckTires-inflationandwear - CheckVehicleandbraketest - RoadtestAT3106,86MILESOR12MONTHS65'ActionGear-boxoil level - checkSparkplug- ReplaceAir filter oncarburetor - CleanThrottlemixer cable- adjustmentBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckElectrical systemandbattery- CheckTiresconditionandwear - CheckVehicleandbraketest - RoadtestAT6213,71MILESOR24MONTHS130'ActionGear-boxoil level - replacementMaintenance VespaPX150USAMAN- 2ActionSparkplug- ReplaceAir filter oncarburetor - Cleandlingspeed(*) - AdjustmentThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckTransmissions- LubricateNuts, boltsandfasteners- CheckSuspensions- CheckElectrical systemandbattery- CheckHeadlight - adjustmentTiresconditionandwear - CheckVehicleandbraketest - Roadtest(*) See regulations in section Idling speed adjustementAT9320,57MILESOR36MONTHS65'ActionGear-boxoil level - checkSparkplug- ReplaceAir filter oncarburetor - CleanThrottlemixer cable- adjustmentBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckElectrical systemandbattery- CheckTiresconditionandwear - CheckVehicleandbraketest - RoadtestAT12427MILES135'ActionGear-boxoil level - replacementVespaPX150USA MaintenanceMAN- 3ActionSparkplug- ReplaceAir filter oncarburetor - Cleandlingspeed(*) - AdjustmentCylinder coolingsystem- Check/CleanThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckTransmissions- LubricateNuts, boltsandfasteners- CheckSuspensions- CheckElectrical systemandbattery- CheckHeadlight - adjustmentTiresconditionandwear - CheckVehicleandbraketest - Roadtest(*) See in section Idling speed adjustmentAT15534MILES65'ActionGear-boxoil level - checkSparkplug- ReplaceAir filter oncarburetor - CleanThrottlemixer cable- adjustmentBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckElectrical systemandbattery- CheckTiresconditionandwear - CheckVehicleandbraketest - RoadtestAT18641MILES160'Maintenance VespaPX150USAMAN- 4ActionGear-boxoil level - replacementSparkplug- ReplaceAir filter oncarburetor - Cleandlingspeed(*) - AdjustmentThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakepads- Checkcondition+wearFlexiblebrakelines- ChangeBrakefluidlevel - CheckTransmissions- LubricateNuts, boltsandfasteners- CheckSuspensions- CheckElectrical systemandbattery- CheckHeadlight - adjustmentTiresconditionandwear - CheckVehicleandbraketest - Roadtest(*) See regulations in section Idling speed adjustmentAT21748MILES65'ActionGear-boxoil level - checkSparkplug- ReplaceAir filter oncarburetor - CleanThrottlemixer cable- adjustmentBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckElectrical systemandbattery- CheckTiresconditionandwear - CheckVehicleandbraketest - RoadtestAT24855MILES145'VespaPX150USA MaintenanceMAN- 5ActionGear-boxoil level - replacementSparkplug- ReplaceAir filter oncarburetor - Cleandlingspeed(*) - AdjustmentCylinder coolingsystem- Check/CleanThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckTransmissions- LubricateNuts, boltsandfasteners- CheckSuspensions- CheckElectrical systemandbattery- CheckHeadlight - adjustmentTiresconditionandwear - CheckVehicleandbraketest - Roadtest(*) See regulations in section Idling speed adjustementAT27962MILES65'ActionGear-boxoil level - checkSparkplug- ReplaceAir filter oncarburetor - CleanThrottlemixer cable- adjustmentBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckElectrical systemandbattery- CheckTiresconditionandwear - CheckVehicleandbraketest - RoadtestAT31069MILES130'Maintenance VespaPX150USAMAN- 6ActionGear-boxoil level - replacementSparkplug- ReplaceAir filter oncarburetor - Cleandlingspeed(*) - AdjustmentThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckTransmissions- LubricateNuts, boltsandfasteners- CheckSuspensions- CheckElectrical systemandbattery- CheckHeadlight - adjustmentTiresconditionandwear - CheckVehicleandbraketest - Roadtest(*) See regulations in section Idling speed adjustmentAT34175MILES65'ActionGear-boxoil level - checkSparkplug- ReplaceAir filter oncarburetor - CleanThrottlemixer cable- adjustmentBrakeandclutchlever - greasingBrakepads- Checkcondition+wearBrakefluidlevel - CheckElectrical systemandbattery- CheckTiresconditionandwear - CheckVehicleandbraketest - RoadtestAT37282MILES205'VespaPX150USA MaintenanceMAN- 7ActionGear-boxoil level - replacementSparkplug- ReplaceAir filter oncarburetor - Cleandlingspeed(*) - AdjustmentCylinder coolingsystem- Check/CleanThrottlemixer cable- adjustmentSpeedometer cable- GreaseSteering- AdjustBrakeandclutchlever - greasingBrakepads- Checkcondition+wearFlexiblebrakelines- ChangeBrakefluidlevel - CheckTransmissions- LubricateNuts, boltsandfasteners- CheckSuspensions- CheckElectrical systemandbattery- CheckHeadlight - adjustmentTiresconditionandwear - CheckVehicleandbraketest - Roadtest(*) See regulations in section Idling speed adjustmentCarburettorDisassemblethecarburetor andcleanall com-ponentswithsolvent, hencedrywithcompressedair all ducts, inorder toensureproper cleaning. Carefullycheckthestateof eachcom-ponent. Thethrottlevalvemust befreetoslideinsidethemixturechamber; replaceifexcessiveplayisfound. f themixturechamber isexcessivelyworn, suchtoprevent theslidingof thethrottlevalve(althoughnew), replaceMaintenance VespaPX150USAMAN- 8thecarburetor. All sealsshouldbereplaceduponre-assembly.CARBURETORSpecification Desc./QuantityConical needleFloatEmulsifier air adjustingscrewEmulsifierMainjetSlow-runningjetFuel flowadjustingscrewThrottlevalveadjustingscrewThrottlevalveStarter jetChokedeviceCheckingthesparkadvancenorder toensurethecorrect timing, checkthestator isorientedsothat the.T. index(seefigure)coincideswiththemarkingfoundonthecrank-case.~Tocheckthetiming, useatiminglight, connect-VespaPX150USA MaintenanceMAN- 9ingit totheH.T. cableviatheclipprovidedandthenstartingtheengine.~Thecorrect sparkadvanceisobtainedwhen,withtheenginerunningbetween2,500and3,000rpm, thePindexisaligned(1) withthe.T.markingstampedonthevolute.~ntheimpossibilityof obtainingthespecifiedvalues, or if theengineisfoundtoberunningrough, proceedbyreplacingdefectivecompon-ents.SpecifictooIing020330YStroboscopicgunfor two- andfour-strokeengines020332YDigitaI rpmcounterSparkpIug~Detachthesparkplugcap~Carefullyinspect thesparkplugandreplaceit iftheinsulator isdamaged~Usingafeeler gauge, measurethesparkgap,andadjust it if necessary~Ensurethesealingwasher isingoodstate~Refit thesparkplugbyscrewingit inbyhand,andtighteningit at theprescribedtorqueusingaboxspannerEIectriccharacteristicSparkpIugCHAMPONRL82CSparkgap0,50,6mmLockingtorques(N*m)SparkpIung25- 30NmMaintenance VespaPX150USAMAN- 10Air fiIter~Removetheenginecowlingandtheair-boxcover bylooseningthefour fixingscrewsshowninthefigureandtheidleadjustingscrew; hencereleasethefilter.~Cleanthefilter with50%fuel-oil mixture, hencedryit withcompressedair.RecommendedproductsSELENIAHI Scooter 2TechMixer OiISyntheticoil that passesAP TC++specificationsHeadIight adjustmentProceedasfollows:Placethevehicle, inridingorder andwiththetyresinflatedtotheprescribedpressure, onflatground, 32,81feet (10m) awayfromahalf-litwhitescreen. Ensurethevehicleaxisisperpen-dicular tothescreen; Turntheheadlight onandchecktheprojectionof thelight beamisbetween7/10and9/10of thedistancemeasuredfromthegroundtothecentreof theheadlight; Adjust theheadlight asnecessary, viascrewA.WARNINGTHEPROCEDUREDESCRIBEDABOVECOMPLIESWITHTHE"EURONORM"CONCERNINGTHEMAX.ANDMIN. HEIGHTOFTHELIGHTBEAMOFAROADVEHICLE. PLEASECHECKWITHTHELOC-ALAUTHORITIESFORWHATREQUIREMENTSMUSTBEFULFILLEDINEVERYSINGLECOUNTRYWHERETHEVEHICLEISTOBEUSED.GearboxOiI Checkfor thepresenceof oil insidethegearbox(oil capacity~8,82ozVespaPX150USA MaintenanceMAN- 11(~250g)); withthevehicleaxisper-fectlyvertical, theoil level must beattheheight of inspectionholeA. Toreplacetheoil, draintheboxusingfiller holeB. Pour somefreshoil andlet theenginerunfor afewseconds, hencedraintheboxagain. Pour 8,82oz(250g) of freshoilthroughholeA, sothat thelevelreachesthereferenceheight.RecommendedproductsTUTELAZCGEMAX6GearboxOiISAE80Woil complyingwith, or exceeding, APGL4specifications.Maintenance VespaPX150USAMAN- 12INDEXOFTOPICSELECTRICALSYSTEM ELESYSAr =Orange, Az=Light blue, Bi =White, BI =Blue, Gi =Yellow, Gr =Grey, Ma=Brown, Ne=Black, Ro=Pink, Rs=Red, Ve=Green, Vi =Purple.LEGENDASpecification Desc./Quantity1 Rear stoplight switch2 Light switchwithflash3 Turnsignal switch4 Hornbutton5 Horn6 2yellowlightsfor turnsignal lights7 Front L.H. turnsignal light8 Heatingcontrol device9 Flywheel magnetoElectrical system VespaPX150USAELESYS- 2Specification Desc./Quantity10 Control deviceignition11 Starter motor12 Fusecarrier (N 1fuseto7,5A)13 Battery14 Rear L.H. turnsignal light15 Directionindicator lights(N 2)16 Rear parkingandstoplight bulbs17 Taillight assembly18 Rear R.H. turnsignal light19 Voltageregulator20 Low-oil warninglight switch21 Starter relay22 Frameearth23 Starter motor wireunit24 Automaticstarter25 Heater26 Chassiswireunit27 Fuel level thermistor28 Front R.H. turnsignal light29 gnitionkey-switch30 Starter button31 Front brakestoplight switch32 Headlight33 Light34 Sidelight bulb35 left turnindicator warninglight 12V-2W36 Headlampwarninglight37 High-beamlampwarninglight38 Licenseplatelight bulb39 Low-fuel warninglight40 Right turnindicator warninglight 12V-2W41 Low-oil warninglight42 Odometer withwarninglightsandlevelgaugesVespaPX150USA Electrical systemELESYS- 3ComponentsarrangementCOMPONENTSARRANGEMENTSpecification Desc./Quantity1 Key-switch2 Voltageregulator3 ElectronicControl Unit (C.D..) withH.Tcoil4 Battery 12V- 9Ah5 Starter motor6 Magnetoflywheel7 Anti-repeatingdevice8 Sparkplug9 Remotestarter switch10 Fuse 7,5A11 HornElectrical system VespaPX150USAELESYS- 4Specification Desc./Quantity12 Turnsignalsmaster-box13 Front headlight14 Front turnsignal lights15 Taillight16 Rear turnsignal lightsConceptuaI diagramsIgnitionIGNITIONSpecification Desc./Quantity1 Magnetoflywheel2 Keyswitchcontacts3 ElectronicControl Unit (C.D..) withH.Tcoil4 SparkplugHeadIightsandautomaticstarter sectionVespaPX150USA Electrical systemELESYS- 5FANALERIASpecification Desc./Quantity1 Voltageregulator2 Magnetoflywheel3 Keyswitchcontacts4 Lampadaproiettore 12V-55/60W5 Highbeamwarninglight bulb 12V-1,2W6 Light switchwithflash7 Light remotecontrol switch8 Rear sidelight bulb 12V- 5W9 nstrument panel lightingbulb 12V-1,2W10 Headlampwarninglight 12V- 1,2W11 Fuse7,5A12 Battery 12V- 9AhBatteryrechargeandstartingElectrical system VespaPX150USAELESYS- 6RICARICABATTERIAEAVVIAMENTOSpecification Desc./Quantity1 Magnetoflywheel2 Control deviceignition3 Keyswitchcontacts4 Voltageregulator5 Fuse 7,5A6 Remotestarter switch7 Starter motor8 Battery 12V- 9Ah9 Enablebutton10 Start upbutton11 Anti-repeatingdevice12 Enginestopswitch13 Enginestopremotecontrol switchLeveI indicatorsandenabIesignaIssectionVespaPX150USA Electrical systemELESYS- 7SAFETYSWITCHESANDLEVELGAUGESSpecification Desc./Quantity1 Fuel level gauge2 Fuel level sendingunit3 Reservefuel light 12V-1,2W4 Brakelight bulbs 12V-10W5 Stoplight switches6 VoltageregulatorTurnsignaI IightsElectrical system VespaPX150USAELESYS- 8SIGNALLIGHTSANDHORNSpecification Desc./Quantity1 Turnsignalsmaster-box2 ndicatorsswitch3 Turnsignal warninglight 12V- 1,2W4 Turnsignal light bulbs 12V- 21W5 Hornbutton6 Horn7 Voltageregulator8 Heater control device9 Fuse7,5A10 Battery 12V- 9AhInstrumentsandwarningIightscontroI boardVespaPX150USA Electrical systemELESYS- 9DASHBOARDLIGHTSANDGAUGESSpecification Desc./Quantity1 +Battery2 Fuel gauge3 Lowfuel warninglight4 Turnsignalswarninglight5 High-beamwarninglight6 Side-lampswarninglight7 Earth(-)ChecksandinspectionsIgnitioncircuitAll systemchecksrequiringthedetachment ofcables(inspectionsinvolvingignitionsystemwir-inganddevices) must becarriedout withtheen-gineoff, sotoavoidanypossibledamagetotheECU, whichwouldrequireitsreplacement.t isthereforeimportant tofollowthewirecolorcodingwhenreattachingthecables(seefigure)Electrical system VespaPX150USAELESYS- 10IGNITIONCIRCUITSpecification Desc./Quantity1 WHTE2 RED3 GREEN4 GREENStator checkntheevent of amalfunctioningof theignitionsystem, withnoevident cause, it will beneces-sarytoreplacetheECU.~Remember that all wirescanonlybedetachedwiththeengineoff.~f theignitionsystemisfoundtobeworkingproperlyoncethenewECUhasbeenfitted, thenthecauseof theproblemisobviouslytobeattrib-utedtoadefectiveCD device.~ntheevent that theignitionsystemisstill mal-functioning, it will benecessarytocheckthegen-erator andthestator components, asfollows:After aneyeinspectionof theconnections, per-formmeasurementsonrechargecoil andpick-up(seetable) usingthespecifiedtester. f suchreadingsdonot matchthestatedvalues, proceedbyreplacingthestator anditscomponents.SpecifictooIing020331YDigitaI muItimeterSTATORCHECKSpecification Desc./Quantity1 RED- WHTEwire 90140ohm2 GREEN- WHTEwire 8001100ohmVoItagereguIator checkVespaPX150USA Electrical systemELESYS- 11ntheevent of suspiciousmalfunctioningof thevoltageregulator, proceedwiththefollowingchecks:AIternatecurrent sectionFailureof thealternatecurrent sectionof thevoltageregulator maycause, accordingtothetypeof fault, thefollowinginconveniences:1. Blownlight bulbs(regulator open-circuited).2. Failureof thelightingsystemandautomaticchokedevice(regulator short-circuited).InterventionsFAULT1Replacetheregulator, sincethisisfaulty.FAULT2a) Checkthecorrect current supplyfromtheal-ternator: detachtheregulator connector andat-tachthetester betweenthegrey-bluewirecon-nectionandearth. Withthetester set onalternatecurrent, checkthesuppliedvoltageat 3,000rpmisbetween25and30V.b) f nofaultsarefound, replacethevoltageregu-lator.c) f thesystemisstill malfunctioningafter theregulator hasbeenreplaced, checktheconnec-tionsof theelectrical system.Direct current sectionFailureof theregulator'sdirect current sectionmaycause, dependingonthetypeof failure, thefollowinginconveniences:3. Blownfuse(regulator short-circuited), resultinginthecatastrophicfailureof thebatteryrechar-gingsystem.4. Batteryrechargefaulty(regulator open-cir-cuited).InterventionsElectrical system VespaPX150USAELESYS- 12FAULT3Replacetheregulator, certainlyfaulty, andthefuse.FAULT4a) Attachanammeter betweenthevoltageregu-lator andthebattery, andcheckthat, at 3,000rpmandwiththebatteryat 13V, thecurrent suppliedisapproximately1.5- 2A.f themeasuredvaluesarebelowthislimit, re-placethevoltageregulator.b) f theregulator replacement doesnot solvetheproblem, check, usingthespecifiedtester, forpeaksinthealternatecurrentsbetweentheyel-lowwireconnectionandtheredwiretotheposit-ivebatterypole. Thevoltagesuppliedbythegen-erator must bebetween26and30V, at 3,000rpm(thismeasurement must obviouslybecarriedout withthebatterydisconnected).SpecifictooIing020331YDigitaI muItimeterStarter motorBenchteststobeperformedontheeIectricstarter motor1) No-loadtest: thestarter motor, unloaded, must absorblessthan10Awithavoltagesupply>11.7Vandmust spinat morethan18,000rpm.2) Loadtest: loadthestarter motor sothat theabsorbedcurrent isequal to40A, andthesuppliedvoltageis10V. nsuchconditions, theoutput torqueprovidedmust 0.014Nm, at aspeedof nolessthan10,000rpm.3) Breakawaytest: withtherotor restrainedandsuppliedvoltageof 7V, theabsorbedcurrent mustnot behigher than100Aandthetorquenot lessthan0.033Nm.N.B.ALLTHESECHARACTERISTICSMUSTBEMEASUREDWITHCHARGEDBATTERYANDAFTERRUN-NINGTHEMOTORFOR30"INTHECONDITIONSSTATEDIN1.VespaPX150USA Electrical systemELESYS- 13STARTERMOTORSpecification Desc./Quantity1 Nominal voltage 12V2 Nominal power 0,15kW3 Directionof rotation Clockwise4 Engineconnection Viapinionandgear ringoncrankshaft,transmission-side5 Control Pushbutton6 Battery 12V- 9AhFusesThestarter systemandhornareprotectedbya7.5Afuse, A, locatedontheLHSof thebatterytray. Beforereplacingaburst fuse, it isnecessarytofindthecauseof thefailure. Never attempt toclosethecircuit withanymaterial other thanthefuse.BEFOREREPLACINGTHEBLOWNFUSE, TRYTOELIMINATETHEFAULTTHATHASCAUSEDITTOBLOW. NEVERTRYTOREPLACEAFUSEUSINGElectrical system VespaPX150USAELESYS- 14DIFFERENTMATERIAL(FOREXAMPLEAPIECEOFELECTRICWIRE).MODIFICATIONSORREPAIRSTOTHEELECTRICSYSTEMCARRIEDOUTINCORRECTLYORWITHOUTTAKINGNOTEOFTHESYSTEM'STECH-NICALCHARACTERISTICS, CANCAUSEFUNC-TIONANOMALIESANDFIREHAZARD.Dry-chargebatteryBATTERYSTARTUPWITHDRYCHARGE- Removethebatteryventilationduct closingcapandremovethecapsfromthesingleelements.- Fill thebatterywithelectrolytehavingadensityof 1.270+/-0.01Kg/l (correspondingto31+/-1B)withminimumambient temperatureof 59F(15C), uptothetoplevel indicatedonthesingleblock.- Slightlytilt thebatterytoremoveanyair bubblesformedduringthefilling.- Placethecapsonthefillingholesof thesingleelementswithout tighteningthemandlet thebatterystand. Duringthisphase, thebatteryundergoesagasificationphenomenonandtemperaturerises.- Let it standuntil ambient temperatureisreachedagain(thisphasemayrequireupto60minutes).- Slightlytilt thebatterytofavour theremoval of anyair bubbles, thenrestorethelevelsusingthesameelectrolyte.Note: ThisistheIast timethat eIectroIytecanbeadded. Futuretopupsmust bemadeusingonIydistiIIedwater;- Within24hours, refill asfollows:- Connect thebatterycharger terminalsaccordingtotheright polarity;- Usingthebatterycharger dwg. 020333Yand/or dwg. 020334Y, select thebatterycapacity;- f thebatterycharger isnot available, chargethebatterywithaconstant current of 1/10of theratedcapacity(for examplefor abatterywithratedcapacityof 9Ah, thechargecurrent must be0.9-1.0A),for approx. 4-6hours.Note: Batteriesstoredfor aIongtimecanrequireIonger times. Batterychargersdwg.020333Yanddwg. 020334Yhaveanautomaticprotectionthat stopstherechargeafter 12hourstoprevent overheatingthebattery. Inthiscase, theturningonof the greenIeddoesnotindicatetheendof thechargebut thestart of thesafetysystem.- Let thebatterystandwithopencircuit for approx. 4-6hours, thencheckthevoltageusinganormaltester.- f theopencircuit voltageismoreor equal to 12.6V, thebatterychargeisgood. Slightlytilt thebat-VespaPX150USA Electrical systemELESYS- 15terytoeliminateanyair bubblesformedwhilerecharging.- Checktheelectrolytelevel again, restoreif requireduptothetol referenceusingdistilledwater,tightenthecapsof thesingleelementsandinstall it onthevehicle.- f lower voltagesaredetected, rechargethebatteryfor 4-6hoursmoreasdescribedabove.Note: Withbatterycharger dwg. 020334YyoucancheckthebatterychargeIeveI bythefunc-tionCheck. ThevaIueshownonthedispIaymust behigher thanthat indicatedinthetabIe; ifnot, rechargeasdescribedabove.Electrical system VespaPX150USAELESYS- 16INDEXOFTOPICSENGINEFROMVEHICLE ENGVEExhaust assy. RemovaI~Removethetwofasteners, exhaust pipe-manifoldandthenthebolt fixingtheexhaust totheengine.RemovaI of theenginefromthevehicIe~Removetheexhaust assy.~Removetherear wheel.~Detachtherear brakecable.~Detachtheelectrical wires.~Detachthegear shifter cables.~Removethethrottleandchokecables.~Detachtheoil andpetrol hoses.~Removetheengine-framebolt showninthefig-ure.Enginefromvehicle VespaPX150USAENGVE- 2~Removetherear shock-absorber fixingnut andhencethebolt.~For thereassembly, followtheaboveopera-tionsinreverseorder, usingtheprescribedtight-eningtorques.CAUTIONWHENINSTALLINGTHEBATTERY, FIRSTFIXTHEPOSITIVECABLEANDTHENTHENEGATIVECABLE.WARNINGBEATINGTOOLSSHOULDBEUSEDWEARINGSAFETYGLASSES.WARNINGPAYTHEUTMOSTATTENTIONWHENHANDLINGPETROL.Lockingtorques(N*m)Engine- frameboIt * 6175Shock-absorber -engineboIt* 1323VespaPX150USA EnginefromvehicleENGVE- 3Enginefromvehicle VespaPX150USAENGVE- 4INDEXOFTOPICSENGINE ENGFIywheeI coverCooIinghood~Removethethreefixingscrewsshowninthefigureandthecoolinghood.~Removethefixingscrewsshownandhencede-tachthevoluteandthegear shifter cover.~Removethekick-start lever after havingde-tachedthelower fastener.Removingthestator~Removethethreescrewsshowninthefigure.~Removethestator.Refittingthestatornorder toguaranteethecorrect enginetimingpayattentiontothepositionof thestator, asEngine VespaPX150USAENG- 2showninthefigure.FIywheeI andstartingRemovingthestarter motor~Removethetwoscrewsanddetachthedriveboxfromthestarter motor.~Withtheaidof ahacksaw, abradethepinionheadring.~Usingtwoscrewdrivers, detachthecap.~Removetheretainingringshownbythearrowinthefigureandremovethepinioncomponents.WARNINGTHEPACKINGONTHEMATINGSURFACEMUSTALWAYSBEREPLACEDWITHANEWONE, USINGLOCTITE.VespaPX150USA EngineENG- 3~Usingpliersfor internal split rings, removetheretainingringshown.~Lift theassemblybytheendof theshaft andre-movetheshaft byhittingthehousingwithamal-let.~Theremoval of thebearingmaybecarriedoutbypushinginthedirectionshowninthefigure.Thiswill alsoresult intheremoval of thedrivegear.~ntheevent that thebearingremainsondrivegear, usethespecial extractor.~After heatingthedrivegear withtheair heater,refit thedriveshaft withall thecomponentsprevi-ouslyremoved.~Refit theremainingcomponentsfollowingtheaboveoperationsinthereverseorder.SpecifictooIing001467YBeII001467y02111mmbearingcIip020151YAir heater "METABOHG1500/2"020150YSupport for air heater "METABOHG1500/2"~Positionanewcapontothepinionandroundtheedgesusingthespecial tool tosafelylocktheassemblyinavice.~Rotatetheassemblybyaquarter turnandpro-ceedbyroundingtheremainingsectionof thecapscircumference.SpecifictooIing020057YCaIkingtooIEngine VespaPX150USAENG- 4~After removingtherear cover, releasethebrushclipsconnectedtothemagneticfields.~Removethebrushplate. Detachtheoldbrushesandweldanewset of brushes, hencere-placethebrushplate.~After removingtherear cover, detachthedrivegear retainingpinandremovethegear.~Refit theassemblycomponentsinthereverseorder.RemovingthefIywheeI magneto~Retaintheflywheel usingthespecial tool,henceremovethelocknut.SpecifictooIing020095YFIywheeI retainingtooI~Removetheflywheel retainingtool.~Extract theflywheel usingthespecial extractor.SpecifictooIing008564YFIywheeI extractorVespaPX150USA EngineENG- 5RefittingthefIywheeI magneto~Refit thecomponentsfollowingaboveopera-tionsinthereverseorder.~After refittingtheflywheel, applygreaseonthethread.RecommendedproductsGreaseZ2Product descriptionGreaseZ2Lockingtorques(N*m)FIywheeI fixingnut 6065CyIinder assy. andtimingsystemRemovingthecyIinder head~Loosenthefour nutsandremovethecylinderhead.RemovingthecyIinder - pistonassy.After removingthecylinder detachthewrist pinretainingringsandhenceremovethepiston.InspectingthesmaII endEngine VespaPX150USAENG- 6~Alwaysfit aroller cageof thetypeprescribedintheassemblyclearancetables.~Thearrowinthefigureshowsthelocationoftheconnectingrod'sidentificationmarking.RefittingthecyIinder~Refit thecylinder assemblycomponentsfollowingtheremoval procedureinthereverseorder, pay-ingparticular attentiontopositioningthepistonwiththearrowmarkingonthecrownpointingtowardtheexhaust port.Lockingtorques(N*m)Headfixingnuts1626Crankcase- crankshaftSpIittingthecrankcasehaIves~Removethetwelvefastenersandsplit thetwocrankcasehalvescarefullyusingaplasticor hardrubber mallet.CAUTIONWITHARUBBERBANDTIETHECONNECTINGRODTOTHETWOSTUDSONTHECLUTCH-SIDE,SOTOAVOIDANYACCIDENTALDAMAGEDUR-INGTHISPHASEANDTHEFOLLOWINGONES.Removingthecrankshaft~nstall thespecial tool asshownandextract thecrankshaft.SpecifictooIing008886YCrankshaft extractorVespaPX150USA EngineENG- 7Removingthecrankshaft bearings~After removingtheoil seal, usingpliersfor in-ternal split rings, removethebearingretainingringshown.~Fromthesideoppositethat showninthefigureandwiththeaidof aflat headpuncher, extractthebearing.~Usingthespecial extractor, removetherollerbearingfromthecrankshaft.SpecifictooIing004499yBearingextractor~Usingthespecial extractor, removetherollerbearingfromthecrankcase.Engine VespaPX150USAENG- 8Refittingthecrankshaft bearings~Heat thebearinghousingwiththeair heater po-sitionedontoitssupport.~After heatingthecrankcase, positionthebear-ingusingalengthof tubepushingdirectlyonthebearing'souter ring.~Positionthebearing'sretainingring, hencepro-ceedbyrefittingthesealingring.SpecifictooIing020151YAir heater "METABOHG1500/2"020150YSupport for air heater "METABOHG1500/2"~Heat upthecrankcase, asalreadydonefor theclutch-sidehalf-crankcase, focusingexclusivelyonthebearinghousing.~Positionthebearingusingalengthof tubepushingdirectlyonthebearing'souter ring.~Positionthecrankshaft ontothespecial sup-port.~nstall thespecial spacer asshowninthefigureand, usingalengthof tubeof adequatediameter,pushthebearinguntil theinner ring(heatedupinoil at 248For 120C) comesintocontact withthespacer.~Oncetheassemblyiscompleted, removethespacer.SpecifictooIing020265yBearingfittingstand060007YCrankcasebearingspacerVespaPX150USA EngineENG- 9LubricationConceptuaI diagramsAutomaticfuel mixerThesystemisfedbyoil containedinaseparatetank.Thevehicleisequippedwithtwodistinct tanks, eachwithindividual hoses, for fuel andlubricant.Thefuel tankmust befilledwithpetrol, nopetrol-oil mixtureof anykind, whilefor thelubricant tankSeleniaHi Scooter 2Toil shouldbeused. Theoil level maybecheckedthroughthetransparent tube(seefigure, 3) protrudingfromthetank.Fuel isfedtothecarburetor bygravity; oil issuppliedthroughpumppwhosestrokeiscontrolledbytheradial positionof ashoe, ontheinclinedplaneof thepump, drivenbythethrottlecableviaalever.Thismeansthat for anygivenpositionof thethrottletwist-gripthelocationof theshoevaries, thusvaryingthepumpstrokehencesuggestingthat theoil massflowisafunctionof bothenginespeedandthrottleopening.Important: whenever themixer devicehasbeenremoved, overhauledor refitted, theremaybenooilinsidetheducts.Toallowthemixer tosafelyfill theseductswithoil, it issuggestedthat thefuel tank(1inthefigure) isEngine VespaPX150USAENG- 10first refilledwithapprox. 3l of mixturecontaining2%of SELENAH SCOOTER2Toil. Oncethisfirstquantitativehasbeenexhausted, anyfurther refill must obviouslyconsist of petrol only. Thepumpassemblyconstitutes, essentially, of apumpingelement anditsslidinghousing, andisdrivenbyagear transmission(crankshaft/mixer shaft ratio: 1/85). Thepumpingelement "P" isalsoprovided, onitsshaft, withaflattensurfacewhich, becauseof therotation, alternatelyopensandclosestheoil in-let (5) andoutlet (6) ducts, withthelatter beingequippedwithavalveconsistingof asphereandspring. Bysuchmeansthepumpalternatelyperformsthetwophasesof oil intake(Ainthefigure)andsupplytothefuel diffuser (8inthefigure), wherethefuel mixtureisformedandfedintotheen-gine.CONCEPTUALDIAGRAMSSpecification Desc./QuantityFuel tankfiller capOil tankfiller capOil level gaugeSEPARATELUBRCATONdeviceboxOil inlet hoseOil outlet hoseOil outlet valveA nlet phaseB Outlet phaseVespaPX150USA EngineENG- 11OiI pump~Removethecarburettor box.~Removethemixer driveshaft fromitshousing.~Removethe3fixingscrewsandthemixer cov-er withthelever.~Removethemixer pumpingelement.~Removethemixer fixingscrewandthenusepliersfor internal split ringstoremovethemixerbody.~Refit thecomponentsfollowingtheremoval pro-Engine VespaPX150USAENG- 12cedureinthereverseorder, payingattentioninpositioningthepumpbodycorrectlyinitshousing,sotobeabletoeasilyinsert theretainingscrew.SeeaIsoRemovingthecarburettorFueI suppIyRemovingthecarburettor~Removethetwofixingscrewsandthecarbur-etor cover.~Removethefastenersandtheair filter.~After removingtheair filter, loosenthetwo8mmAllenscrewsandhenceremovethecarburetor.VespaPX150USA EngineENG- 13~Loosenthefixingscrewandremovethecarbur-etor body.~Removethemainandidlejetsandblowwithcompressedair.~Loosenthefixingscrewandremovethefloatbowl.~Removethestarter jet andblowwithcom-pressedair.Engine VespaPX150USAENG- 14~Removethefloat pintoreleasethefloat, andhencetheconical needle.~Checkthestarter chokevalve; replaceif worn.Refittingthecarburettor~Refit thecomponentsreplacingall seals.WARNINGPETROLISHIGHLYEXPLOSIVE. ALWAYSFITNEWSEALSANDGASKETSTOPREVENTLEAKAGE.VespaPX150USA EngineENG- 15ManuaI Gear ShifterRemovethefastenersandthegear shifter.Fromthesideoppositetothat showninthefigureandwiththeaidof apuncher, removetheconicalpinandextract thegear shiftinglever.~Split thetwohalf-crankcases.~Usingpliersfor external split rings, removetheretainingringandextract thegears.~Usingaplasticmallet, removetheshaft.~Removethemultiplegear shaft locknut.Engine VespaPX150USAENG- 16~Removethemultiplegear shaft usingamalletfromthesideoppositetothat showninthefigure.Donot let the21rollerscomposingthebearingfall ontotheground.~After removingtheinternal oil seal andtheex-ternal dust cover, removethebearingretainingringthroughtheuseof internal split ringpliers.~Extract theroller bearingusingaflat headpuncher fromthesideoppositetothat showninthefigure.~After removingtheretainingwasher showninthefigure, removethefastener underneathit,henceextract theeventensiongear.~Removetherivet headandreplaceanyfaultycomponent.~Refit thecomponentsusingnewrivets.~Replacethetrunnionif worn.CAUTIONTHETRUNNIONBUSHINGHASALHSTHREAD.VespaPX150USA EngineENG- 17Lockingtorques(N*m)Gear-boxtrunnion1518~Refit thetrunnionAontothegear shiftershaft Bandtightenit totheprescribedtorque(LHSthread).~Prepareatool Dasshowninthefigureandinsert it intothegroovemachinedontheshaft.~Alignthetool'sprotrusionCwiththeedgeFof thebushingtoberounded.~Usingahammer andalengthof tube(internaldiameter 17.5mm), roundthethreadedendof thebushingonthetrunnion.~nstall themultiplegear ontoitshousingcare-fullypositioningthe21rollers, usingtherecom-mendedgreasetokeeptheminplaceduringthereassembly.~Withtherefittingoperationconcluded, tightentheshaft locknut totheprescribedtorque.RecommendedproductsJOTA3FSSpeedometer transmissionLithiumsoapgreaseNLG 33Lockingtorques(N*m)MuIti-gear pinionnut 3035Engine VespaPX150USAENG- 18~Beforeproceedingbyrefittingtheshifter shaft, itisnecessarytochecktheaxial playof thegearassembly.~nstall thegearsontotheshaft andchecktheendplaywiththespecial feeler gauge.SpecifictooIing060824YInspectionprobeCharacteristicAxiaI pIay0,200,40mm~Usingthespecial tool, proceedbyremovingthegear shaft.SpecifictooIing008119y009Tube(shaft fittingtooI)SeeaIsoSplittingthecrankcasehalvesCIutch~Removethe3fixingscrewsandtheclutchcov-er.~Withtheaidof ascrewdriver, removethebal-ancescrew.VespaPX150USA EngineENG- 19~Restraintheclutchusingthespecial tool, asshowninthefigure, thenremovethelocknut andtheclutchassembly.CAUTIONDURINGTHEOPERATIONSOFREMOVAL, DONOTLETTHEWOODRUFFKEYFALLINSIDETHEEN-GINE.SpecifictooIing001729YCIutchretainingtooI~Removethemixer drivegear fromitshousing.~Usingthespecial tool, removetheclutchdiscs.SpecifictooIing020322YCIutchremoving/fittingtooI~Checktheconditionsof all componentsandtheEngine VespaPX150USAENG- 20camber of themetal discs. Acamber smaller thantheprescribedonemaycauseslippage.~Refit theclutchassemblycomponentsinvertingtheorder followedfor thedisassembly.~Placethemixer drivegear withtheroundededgefacingthecrankcasebearing.~Correctlypositionthewoodruff keyinsideitshousing.~Refit theclutchassemblyontotheengineandtightenthelocknut usingthespecial retainer.~Refit theremainingcomponentsinfollowingtheprocedurescarriedout fromtheir removal inthereverseorder.SpecifictooIing001729YCIutchretainingtooILockingtorques(N*m)CIutchassy. fixingnut 4045VespaPX150USA EngineENG- 21Engine VespaPX150USAENG- 22INDEXOFTOPICSSUSPENSIONS SUSPFrontFront wheeI huboverhauIAfter removingthefront brakecalliper, removetheplasticcapshowninthefigure.Removethepinandthelocknut.t isnowpossibletoremovethewheel axlenut.After removingthesplit ringontheouter sideofthewheel hub, andtheseal ring, removethebearingusingalengthof pipeof adequatedia-meter andamallet, asshowninthefigure. Followthesameproceduretoremovetheroller cageontheoppositeside.HandIebarRemovaIRemovethe2rear viewmirrorsandtheir fixingringnuts. Removethehandlebar cover asde-scribedintheBodyworkchapter andthespeedometer.RefittingUponreassembly, tightentotheprescribedSuspensions VespaPX150USASUSP- 2torque.N.B.* SafetytighteningsINORDERTOENSURETHECORRECTTIGHT-ENINGTORQUE, LUBRICATENUTSBEFOREASSEMBLY.Lockingtorques(N*m)HandIebar fixingscrew* 3044SteeringcoIumnRemovaI~After removingthetophousing, leanthevehicleononesideandextract thesteeringcolumn,makingsureof havingremovedthebrakecalliper.SpecifictooIing020055YSteeringtuberingnut spannerOverhauIThesteering-front suspensionassemblyoverhauloperation, describedhere, impliesessentiallythesubstitutionof thecomponents(pin-roller bushingassembly, sealingringsanddust covers) linkingthesteeringcolumntothefront swingarmassy.N.B.BEFOREPROCEEDINGWITHTHEOVER-HAULOPERATIONENSURETHESTEERINGCOLUMNANDTHEHUBAREINOPTIMALCONDITIONS: THISISTHEONLYCASEINWHICHTHEOVERHAULOPERATIONMAYBEPERFROMED.NOTETHATIFTHESTEERINGCOLUMNHASBEENDEFORMEDINANYWAYITMUSTBEREPLACEDWITHANEWONE.VespaPX150USA SuspensionsSUSP- 3a=puncher 12b=Sharp-edgedendUseapuncher withthedimensionsindicatedinthefigure; usingamallet, squashtheimpactionwasher andextract it.Repeat thisoperationfromthesideoppositetothat showninthefigure, toremovethesecondwasher.Applythetool withpart 1asshowninthefigureandact uponthehandleuntil thecontemporaryextractionof bothpinandneedlecageisob-tained.Byexpellingthesetwocomponents, theswing-armiscompletelydetachedfromthesteeringcolumn.Toexpel thesecondneedlecage, install part 2ontothespecial tool, insteadof 1, andoperatefromthesideoppositetothat showninthefigure.N.B.THEOPERATIONDESCRIBEDABOVERESULTSINTHEDESTRUCTIONOFTHENEEDLECAGESFOL-LOWINGTHEIREXTRACTION. UPONREFITTINGITISTHEREFORENECESSARYTOUSENEWNEEDLECAGES, ASWELLASNEWPIN, SEALINGRINGSANDDUSTCOVERS.SpecifictooIing020021yFront suspensionoverhauI kitAttachtheswingarmtothesteeringcolumnusingtheguidepin.~Withthetool fittedwithpart 3onitsshaft, andpart 4at itslower end, insert thepin, greasedwiththe(MoIyketepowder) basedgrease, ontotheswing-armandact uponthetool'shandleasfaraspart 3will go.Suspensions VespaPX150USASUSP- 4Oncethepinisfitted, insert thetwospacerswithaidof amallet.N.B.BEFOREPROCEEDINGWITHTHEPROCESSABOVE, FITTHETWODUSTCOVERRINGSONTOTHESWING-ARMASSHOWNINTHEDETAILEDVIEW.SpecifictooIing020021yFront suspensionoverhauI kitRecommendedproductsTUTELAMRM2Greasefor drivenpuIIeybush-ingandmobiIedrivenpuIIeyseatBisulphidesoapgreasewithMolybdenumNLG2nsert thesealingringontothepinandtherollerbushingfittedwiththesecuringwasher.~Removethetool andpart 5(guide), partiallyex-pelledduringthepreviouspinassemblingphase,leavingpart 4inplace.~Replacepart 3withpart 16, againontheshaft.~Actinguponthehandle, pushthesecuringwasher - roller bushing- sealingringassemblyasfar aspart 16will go.~Repeat theaboveoperation, usingthetool fit-tedwithparts16and22insteadof part 4, tofittheassemblyontotheoppositeside.WARNINGBEFORECARRYINGOUTTHEABOVEOPERA-TIONS, ITISNECESSARYTOIMMERSETHESEAL-INGRINGSINMINERALOILANDFILLTHEROLLERBUSHINGSHALFWAYWITHGREASE,AFTERWASHINGTHEMINPUREPETROL.SpecifictooIing020021yFront suspensionoverhauI kitRecommendedproductsJOTA3FSSpeedometer transmissionVespaPX150USA SuspensionsSUSP- 5LithiumsoapgreaseNLG 33~Usethetool fittedwithpart 20ontoitsshaft andpart 21onitslower surface, asshowninthefig-ure.~Actinguponthehandle, pushtheroller bushinginuntil it touchestheedgeof thepin.~Usethetool fittedwithparts3and4, tofit thepin, andtwist thehandleuntil thewasherssecureontheswing-arm.~At thispoint, removethetwospacers(part 17and16) and, after completelyfillingtheregionbetweentheroller bushings, steeringcolumnandswing-armwithgrease, movethedust coversandlocatethemintheabovearea.~Thesecuringoperationfor thewasherscon-cludestheassemblingoperationfor thefront sus-pension.RecommendedproductsJOTA3FSSpeedometer transmissionLithiumsoapgreaseNLG 33Toremovethebearinghousingsfromtheframeusethespecial tool showninthefigure.SpecifictooIing020004YDrift for removingthrust ringsfromsteeringheadtube~Usingthespecial tool removethebearinganddust ringhousingsfromthesteeringcolumnasshowninthepicture.~Proceedwithmallet hits.Suspensions VespaPX150USASUSP- 6SpecifictooIing020004YDrift for removingthrust ringsfromsteeringheadtube~Usingthespecial tool, refit thedust ringandthebearinghousingontothesteeringcolumnandpushthemasfar astheygo.SpecifictooIing006029yDrift for fittingthrust ringseatsonsteeringtubeRefitting~Greasebearingsandhousings.~Tightentotheprescribedtorqueandrotatethespanner inananti-clockwisedirectionby80-90.SpecifictooIing020055YSteeringtuberingnut spannerRecommendedproductsSYSTEMTW249AREXONSGrease(brakeIeveI, throttIetwistgrip, gaer)CalciumcomplexsoapgreaseNLG 1-2Lockingtorques(N*m)Topsteeringhousing67(henceIoosenby80 - 90) Upper steeringringnut 56Front shockabsorberVespaPX150USA SuspensionsSUSP- 7RemovaIRemovethe2fixingsshowninthefigureandthe2fastenersontheshock-absorber support brack-et locatedonthesteeringcolumn.Freetheshock-absorber fromthesupport bracketremovingthetopfixing.Shock-absorber - caIIiper bracketRemovaIRemovethesplit ringshowninthefigure.Removethetwoshock-absorber fixingscrewandtheodo/speedometer cableholder.Extract thebracket fromtheaxleusingarubbermallet.OverhauIntheevent of greaseleaksthroughthewheelhub, thecausemaybefoundinthesealingringfittedontothecalliper bracket.After removingthewheel hub, extract theringshowninthefigureandreplaceit withanewone.RearSuspensions VespaPX150USASUSP- 8Removingtherear wheeI~After removingthesparewheel, removethethreefastenersshowninthefigure.~Removetherear wheel bylooseningthefivefixingscrews.Refittingtherear wheeI~Whenrefittingtherear wheel, tightenall fastenersat theprescribedtorquefollowingacrosswisesequence.Lockingtorques(N*m)Rim- hubfixingnuts(front-rear) 2027ShockabsorbersRemovaIFor therear shock-absorber replacement it isne-cessarytoremovetheengine- shock-absorberfixingbolt asshowninthefigure.Removethegasolineandoil tanks, thenremovetheshockabsorber upper fixingintheunderseatcompartment housing.Centre-standDetachthereturnspringfromthecentrestand,removethe4fastenersshowninthefigure.VespaPX150USA SuspensionsSUSP- 9Suspensions VespaPX150USASUSP- 10INDEXOFTOPICSBRAKINGSYSTEM BRAKSYSFront brakecaIIiperRemovaI~Detachthebrakehosefromthecalliper usingacontainer tocollect thefluid.~Removethefastenersshowninthefigure.Refitting~Whenrefitting, tightenthenutstotheprescribedtorque.~Bleedthesystem.N.B.* SafetytighteningsINORDERTOENSURETHECORRECTTIGHTENINGTORQUE, LUBRICATENUTSBEFOREASSEMBLY.Lockingtorques(N*m)Pipe- caIIiper fitting1525CaIIiper fixingscrew* 2025Front brakediscRemovaI~Removetherear wheel bylooseningthe5fasteners.~Removethewheel hub.~Loosenthe5discfasteners.Brakingsystem VespaPX150USABRAKSYS- 2Refitting~Whenrefitting, correctlypositionthedisc, observingthedirectionof rotation(seefigure) andapplymediumthread-lock.N.B.* SafetytighteningsINORDERTOENSURETHECORRECTTIGHTENINGTORQUE, LUBRICATENUTSBEFOREASSEMBLY.RecommendedproductsLoctite243Thread-BrakeMediumLoctiteThread-Brake243Lockingtorques(N*m)Discfixingscrew* 56DiscInspection~Removethewheel andcheckanypossibledisc'sout-of-plane. Themeasuredvaluemust belessthan0.1mm. f higher, replacethediscandrepeat thecheck.~f theproblemisnot solvedcheckand, if neces-sary, replacethewheel hub.SpecifictooIing020335YMagneticstandandcomparatorFront brakepadsRemovaI~Tofacilitatethisoperationit issuggestedthatthefront wheel isremoved, removetheplasticcapandapplyleveragewithascrewdriver.~Removetheexternal split ringfromthepin, thespringandthepadsthemselves.~Thepadsmust bereplacedif thethicknessoftheworkingmaterial islessthan1.5mm.VespaPX150USA BrakingsystemBRAKSYS- 3Refitting~Whenrefitting, operateintheoppositeway, payingattentioninpositioningthespringwiththearrowpointingupwards.FiIIFront~Oncethebleedingvalveisshut, top-upthecircuit usingfreshbrakefluid.~Loosenthebleedscrew.~Connect thespecial tool'stubetothebleedhole. Tobleedthesystem, constantlyrefill thereser-voir, whilepumpingout air withtheMityvac, until all air hasbeenremovedfromthecircuit, i.e. onlyfluidispumpedout of thesystem.~Tightenthebleedscrew.N.B.IFYOUFINDYOUCANNOTELIMINATETHEAIR, EXAMINEALLTHEUNIONSINTHECIRCUIT.IFYOUDON'TFINDANYLEAKS, SEEKTHEFAULTINTHEVARIOUSSEALSONTHEMAS-TERCYLINDERANDBRAKECALLIPERPISTONS.CAUTIONDURINGTHISPROCEDURETHEVEHICLEMUSTBEONTHESTANDONALEVELANDHORIZONTALFLOOR.N.B.DURINGTHEBLEEDPROCEDURE, CHECKTHEFLUIDLEVELINTHEMASTERCYLINDERRESERVOIRFREQUENTLYTOPREVENTTHERISKOFAIRENTERINGTHECIRCUITTHROUGHTHEMASTERCYL-INDER.WARNINGTHEBRAKEFLUIDISHYGROSCOPIC, I.E. ITABSORBSHUMIDITYFROMTHEAIR. IFTHEHUMIDITYLEVELINTHEFLUIDEXCEEDSAGIVENVALUE, THEBRAKINGPERFORMANCESMAYSERIOUSLYDETERIORATE. ITISTHEREFORERECOMMENDEDTHATFRESHFLUIDISTAKENFROMNEWCON-TAINERS. INNORMALCLIMATICCONDITIONS, THEFLUIDSHOULDBEREPLACEDEVERYTWOYEARS. IFTHEBRAKESAREHIGHLYSTRESSED, INCREASETHEFREQUENCYWITHWHICHTHEFLU-IDISREPLACED.CAUTIONDURINGTHEOPERATION, OILMAYLEAKBETWEENTHEBLEEDERSCREWANDTHESEATONTHECALIPER. INTHATCASE, CAREFULLYDRYTHECALIPERANDDEGREASETHEDISC.RecommendedproductsTUTELATOP4BrakefIuidBrakingsystem VespaPX150USABRAKSYS- 4SyntheticfluidSAEJ1703, NHTSA116DOT4, SO4925Withtheoperationconcluded, tightenthebleedscrewtotheprescribedtorque.SpecifictooIing020329YPumpMITYVACLockingtorques(N*m)OiI drainingscrew1012Front brakepumpRemovaI~Loosenthetwofastenersshowninthefigure.~Detachthehose, collectingthefluidinsideacontainer.Refitting~For refitting, performtheoperationinthereverseorder.~Tightenthepipetotheprescribedtorqueandbleedthecircuit.Lockingtorques(N*m)Reservoir - pipefitting812Rear drumbrake~Removetherear wheel.~Straightenthesplint pinandremovethelockVespaPX150USA BrakingsystemBRAKSYS- 5nut.~After removingthehub, proceedasfollows:1. Removetheshoespringusingthespecial pli-ers.2. Removethetworetainersshowninthefigure.3. Removetheshoesusingalever.4. Fit thenewshoeswiththeaidof amallet.5. Attachthereturnspringusingthespecial pli-ers.SpecifictooIing020325yPIiersfor brake-shoesprings~Refit thecomponentsfollowingtheremoval pro-ceduresinthereverseorder, tighteningthewheelnut totheprescribedtorque.WARNINGUSEANEWSPLITPIN.WARNINGBENDOVERTHESPLITPINENDSASSHOWNINORDERTOELIMINATEPLAYBETWEENTHECAPANDWHEELSPINDLE.Lockingtorques(N*m)WheeI axIenut 90110Rear BrakePedaIAfter looseningthebrakefixingontherear wheel,removethe3fastenersindicateinthefigure.Brakingsystem VespaPX150USABRAKSYS- 6Removetherubber fromthepedal anddetachtheelectrical wiring.After thisoperationit ispossibletoremovetheforebrakecableretainer, removingthesplint pinanditspin.t isalsopossibletoreplacethestopswitchbyactinguponitsfixing.VespaPX150USA BrakingsystemBRAKSYS- 7Brakingsystem VespaPX150USABRAKSYS- 8INDEXOFTOPICSCHASSIS CHASSeatRemovethe3fastenersshowninthefigure.Rear handIebar coverAfter removingtherear-viewmirrors, theattach-mentsandtheir seals, removethefour fastenersshowninthefigure, detachtheelectrical wiringandtheodo/speedometer cabletoreplacethedashboardassembly.Oncethehandlebar isremovedact uponthetwolipsonthedashboard.HeadIight assy.After removingthehandlebar cover, removethe2fastenersshowinthefigureandtheheadlight ad-justingscrewunderneaththehandlebar.Detachthewirings. Toreplacethebulbssimplyreleasethespringsholdingbackthesocket andreplaceanyblownbulb.~Removethe2fastenersfor eachturnsignallight.Chassis VespaPX150USACHAS- 2Removingtheignitionkey-switchwhenon*off*Toremovetheignitionkey-switchwhenintheONposition, i.e. steeringlockdisengageandignitionearthed, proceedasfollows:~Removethethreehandlebar fixingscrewsandthehandlebar cover.~nsert asmall screwdriver insidetheholeshowninthefigure(fromunderneaththelockbody) andpushuntil releasingthesecuringtongue; henceextract bodyandmaster cylinder.Therefittingoperationsof thelockbodyandthenewmaster cylinder (ontheouter lockbody) areasfollows:~Carefullycleanthebodyfromanyimpurity(ifthecylinder hasbeendrilled), usingcompressedair.~Positionthebodyinitshousingafter fittingtheretainingspringE.~nsert thecylinder assembly, withkeyandtongueFfacingdownwards, halfwayinsidethelockbody, ensuringthat duringthisoperation,theyisintheONposition(theonlypositionthatallowstheinsertionof thecylinder); at thepointturnthekeyleftwardsandpushasfar asthecyl-inder will go.~ChecktheassemblyviathekeyexcursioninVespaPX150USA ChassisCHAS- 3thethreepositionsandproceedbyrefittingthehandlebar cover.Replacetheseat andglove-boxcylinders. Tore-placethesefollowtheoperationsdescribedfortheremoval of thecylinder whentheignitionkey-switchisintheLOCKposition. f thelockshavebeenleft openhowever, extract thecylinder bypushinglipFshowninthefigureafter havingcarefullycleanedthehousing. Theninsert thenewcylinder. Bear inmindthat for thereplace-ment of thecylinder ontheseat lock, it isneces-sarytoremovethelockassembly, actinguponthethreescrews.Removingtheignitionkey-switchwhenon*Iock*Shouldit benecessarytoreplacethesteeringlockcylinder whenthekeyshavegonemissing,proceedasfollows:CyIinder removaI: intheevent that thekey-switchisintheLOCKposition, it isnecessarytoproceedbydriIIingthecyIinder withtheaidof a8mmat least 30mmlong: thisallowstore-lease(or destroy) theinternal retainingdeviceofthedrilledcylinder. Henceextract thebodyandanyresiduessotobeabletousethebodyfor re-fitting.TaiIIight assy.~Removethe2fixingsshowninthefigureandreplacetheblownbulbs.~Replace, if necessary, thetaillight lens.~Toreplacethetaillight assy., removethelens,detachthewiringandremovethe2fastenersChassis VespaPX150USACHAS- 4fromunderneaththeframe.~Removethe2fastenersfor eachturnsignallight.FueI tankAfter removingtheseat, detachtheelectrical con-nectionof thefuel level sensor. Removethe2re-mainingfixingstofreethefuel tankassembly.Lift bothtanksthusdetachingthehoseswiththefuel tapshut toseparatethefuel-oil tanks. Re-movethetankfiller capandinsert thespecial toolthroughthetube. ProceedbylooseningthenutandtheactinguponringBuntil releasingtheoil tankSpecifictooIing020321YCarburetor fIoat removingtooI002850yOiI tankspanner002973yFueI tapspannerRemovethetankfiller capandinsert thespannerthuslooseningnut D, henceextract thefuelVespaPX150USA ChassisCHAS- 5tap.Front mudguard~Removethe2fixingsfromunderneaththemudguard.~After removingthehandlebar andthesteeringcolumnassembly, removethe3fastenersshowninthefigure.Top-caseFront~Removethe2fixingsshowninthefigureandthe2topfastenersfrominsidetheglove-box.~Removetheglove-boxassembly.Chassis VespaPX150USACHAS- 6Front centraI coverAfter removingthesteeringcolumncover, removethehornandthegridfixings.Replacethegrid.SideCowIingsLift theseat andact uponeither oneof thetwolever, accordingtowhichcowlingmust bere-moved(RHSor LHS).VespaPX150USA ChassisCHAS- 7Chassis VespaPX150USACHAS- 8INDEXOFTOPICSPRE-DELIVERY PREDECarryout thelistedtestsbeforedeliveringthevehicle.WARNINGBEVERYCAREFULWHENHANDLINGFUEL.Aestheticinspection~Paint~Plasticjoints~Damages~DirtTighteningtorquesinspection~All tightentorquessummarizedinpages1- 5.~External coversscrews.EIectricaI system~Fill thebatterywithacid, andchargewithappropriatecharger.~gnitionkey-switch.~Low-beamlight, high-beamlight, warninglights, side-light.~Headlight adjustment.~Taillight.~Stoplight (eventuallyfront andrear lights).~Turnsignal lightsandwarninglights.~Dashboardillumination.~Horn.~Starter button.CAUTIONTOENSUREMAXIMUMPERFORMANCE, THEBATTERYMUSTBECHARGEDBEFOREUSE. INAD-EQUATECHARGINGOFTHEBATTERYBEFOREITISFIRSTUSEDWITHALOWLEVELOFTHEELEC-TROLYTESHORTENSTHELIFEOFTHEBATTERY.WARNINGBEFORERECHARGINGTHEBATTERY, REMOVETHEPLUGSOFEACHELEMENT.KEEPSPARKSANDFREEFLAMESAWAYFROMTHEBATTERYWHILERECHARGING.REMOVETHEBATTERYFROMTHEVEHICLEDISCONNECTINGTHENEGATIVETERMINALFIRST.CAUTIONWHENINSTALLINGTHEBATTERY, FIRSTFIXTHEPOSITIVECABLEANDTHENTHENEGATIVEPre-delivery VespaPX150USAPREDE- 2CABLE.CAUTIONTHEBATTERYELECTROLYTEISDANGEROUSANDMAYCAUSESERIOUSBURNS. ITCONTAINSSUL-PHURICACID. CONTACTWITHEYES, SKINANDCLOTHESSHOULDBEAVOIDED.INTHEEVENTOFCONTACTWITHEYESANDSKIN, RINSETHOROUGHLYWITHWATERFORABOUT15MINUTESANDCONSULTADOCTORIMMEDIATELY.INTHEEVENTOFFLUIDINGESTION, DRINKABUNDANTWATERORMILKIMMEDIATELY.THEN, DRINKMILKOFMAGNESIA, BEATENEGGORVEGETABLEOIL. CONSULTADOCTORIMMEDIATELY.BATTERIESPRODUCEEXPLOSIVEGASES; KEEPAWAYFROMFREEFLAMES, SPARKSORCIGARETTES; IFRECHARGINGTHEBATTERYINACLOSEDENVIRONMENT, ENSUREPROPERVENTILATION.ALWAYSSHIELDYOUREYESWHENWORKINGCLOSETOBATTERIES.KEEPAWAYFROMTHEREACHOFCHILDREN.CAUTIONNEVERUSEFUSESHAVINGACAPACITYGREATERTHANTHERECOMMENDEDVALUE. THEUSEOFAFUSEOFUNSUITABLECAPACITYMAYRESULTINSERIOUSDAMAGESTOTHEWHOLEVEHICLEOREVENCULMINATEINAFIRE.LeveIscheck~Brakefluid.~Gear-box.~Oil tank.Roadtest~Coldstart.~Speedometer check.~Throttlecheck.~Ridingstability.~Front andrear brakeefficiency.~Front andrear shock-absorbers.~Anomalousnoises.~Hot enginerestart.~Leakages(after road-test).FunctionaI inspectionOther~Tirepressure.VespaPX150USA Pre-deliveryPREDE- 3~All locks.~Rear-viewmirrorsandaccessoryfitting.~Toolingkit, owner manual, warrantycertificateandcustomer servicecard.CAUTIONCHECKTHEINFLATINGPRESSURESWHENTHETIRESAREATAMBIENTTEMPERATURE.CAUTIONNOTEXCEEDTHERECOMMENDEDINFLATINGPRESSURESASTHETIRESMAYBURST.~Brakelever excursion.~Throttleexcursionandadjustment.~Homogeneoussteeringturning.Pre-delivery VespaPX150USAPREDE- 4INDEXOFTOPICSTIME TIMEEngineENGINECode Action Duration1 001001 Enginefromtheframe- re-moval andrefitting2 003064 Engineoil - replacement3 003057 Engineattachment - NutstighteningCrankshaftTime VespaPX150USATME- 2WRISTPINPISTONCYLINDERASSYCode Action Duration1 001002 Cylinder/piston- Replace-ment2 001107 Cylinder/Piston- Overhaul/Cleaning3 001093 Sparkplug- Replacement4 001094 Sparkplugcap- Replace-mentVespaPX150USA TimeTME- 3ENGINESHROUD- CRANKCASEBEARINGSCode Action Duration1 001117 Enginedrivingshaft - Re-placement2 001118 Crankcasebearings- Re-placement3 001099 Oil seal, flywheel side- Re-placement4 001100 Clutch-sideoil seal - Re-placementFIywheeI coverTime VespaPX150USATME- 4FANCOVERCode Action Duration1 001087 Flywheel housing- Replace-mentOiI pumpVespaPX150USA TimeTME- 5AUTOMATICMIXERCode Action Duration1 001018 Mixer - Replacement2 001028 Oil pumpdriveshaft - Re-placementStarter motorSTARTERMOTORCode Action Duration1 001020 Startingmotor - Replace-ment2 001039 Starter motor brushes- Re-placement3 001038 Starter motor - Overhaul4 001017 Starter motor shaft - Re-placementTime VespaPX150USATME- 6KICK-STARTLEVERCode Action Duration1 008008 Kick-starter gear spring- Re-placement2 001120 Crankcasebearings- Re-placements3 001084 Startinglever - ReplacementFIywheeI magnetoVespaPX150USA TimeTME- 7FLYWHEEL MAGNETOCode Action Duration1 001067 Stator - Removal andrefitting2 001004 Stator - Overhaul3 001058 Flywheel - Replacement4 001059 Pick-up- Replacement5 003052 gnitiontimingCarburettorTime VespaPX150USATME- 8CARBURETTORCode Action Duration1 001063 Carburettor - Replacement2 001008 Carburatore- Revisione3 003058 Carburettor - AdjustmentExhaust pipeVespaPX150USA TimeTME- 9EXHAUSTPIPECode Action Duration1 001009 Exhaust pipe- ReplacementAir cIeanerTime VespaPX150USATME- 10AIRCLEANERCode Action Duration1 001014 Air filter - Replacement2 001027 Air-cleaner/framebellow-ReplacementFrameFRAMECode Action Duration1 004001 Frame- Replacement2 006001 Frame- Painting3 004023 Front shieldbeading- Re-placementCentre-standVespaPX150USA TimeTME- 11CENTRE-STANDCode Action Duration1 004004 Centre-stand- ReplacementLegshieIdspoiIerSTEERINGCOLUMNFAIRINGTime VespaPX150USATME- 12Code Action Duration1 004024 Steeringcolumnfairing- Re-placementSidefairingsSIDEFAIRINGLOCKSCode Action Duration1 004025 Sidefairinglocks- Replace-mentVespaPX150USA TimeTME- 13WHEELSIDEFAIRINGSCode Action Duration1 006005 Sidefairings- PaintingFootrestsFOOTRESTSTime VespaPX150USATME- 14Code Action Duration1 004015 Footrests- ReplacementRear coverGLOVE-BOXCode Action Duration1 004083 Glove-box- Replacement2 006019 Glove-box- Painting3 004081 Glove-boxdoor - Replace-mentMudguardVespaPX150USA TimeTME- 15FRONTMUDGUARDCode Action Duration1 004002 Front mudguard- Replace-ment2 006003 Front mudguard- Painting3 003045 Steeringcolumn- Replace-mentFueI tankTime VespaPX150USATME- 16FUELLEVELSENSORCode Action Duration1 005010 Fuel tankfloat - Replace-mentVespaPX150USA TimeTME- 17FUELTANKCode Action Duration1 004005 Fuel tank- Replacement2 004007 Fuel tap- Replacement3 004110 Fuel tankhose- Replace-ment4 006024 Fuel tank- PaintingTankoiIOILTANKCode Action Duration1 004017 Oil tank- ReplacementRear shock-absorberTime VespaPX150USATME- 18REARSHOCK-ABSORBERCode Action Duration1 003007 Rear shock-absorber - Re-moval andrefittingSteeringcoIumnbearingsVespaPX150USA TimeTME- 19STEERINGCOLUMNBEARINGSCode Action Duration1 003002 Steeringbearings- Replace-ment2 004119 Steeringsupport bearing-Replacement3 003073 Steeringplay- Adjustment4 004010 Steeringlock- ReplacementHandIebar componentsHANDLEBARCOMPONENTSANDBRAKEFLUIDPUMPTime VespaPX150USATME- 20Code Action Duration1 002059 RHStwist-grip- Replace-ment2 002024 Front brakepump- Removalandrefitting3 002047 Front brakefluid- Replace-ment andcircuit bleeding4 002021 Front brakehose- RemovalandrefittingGEAR-SHIFTERTWIST-GRIPCode Action Duration1 005062 Neutral switch- Replace-ment2 002071 Left knob- Replacement3 002037 Completegascontrol - Re-placement4 001035 Clutchlever - ReplacementSeatVespaPX150USA TimeTME- 21SEATCode Action Duration1 004003 Saddle- Replacement2 004054 Seat lock- ReplacementInstrument paneITime VespaPX150USATME- 22HANDLEBARCOVERSANDDASHBOARDCode Action Duration1 005038 Dashboardwarninglights-Replacement2 005014 Odometer - Replacement3 006010 Tophandlebar cover - Paint-ing4 004066 Rear-viewmirror - Replace-ment5 003001 Tophandlebar cover - Re-moval andRefitting6 006011 Lower handlebar cover -PaintingTurnsignaI IightsVespaPX150USA TimeTME- 23TURNSIGNALLIGHTSCode Action Duration1 005011 Starter relay- Replacement2 005012 Front turnsignal light - Re-placement3 005067 Front directionindicator bulb- Replacement4 005068 Rear directionindicator lamp- Replacement5 005022 Rear turnsignal light- Re-placement6 005006 Turnsignalsswitch- Re-placement7 005039 Headlight switch- Replace-mentTime VespaPX150USATME- 24TAILLIGHTCode Action Duration1 005066 Rear light bulbs- Replace-ment2 005005 Taillight - Replacement3 005028 Rear optical unit glass- Re-placementHEADLIGHTVespaPX150USA TimeTME- 25Code Action Duration1 005008 Headlight bulbs- Replace-ment2 005002 Front number platelamp-ReplacementFront wheeIWHEELCode Action Duration1 004123 Front wheel - Replacement2 003047 Front tyre- Replacement3 003037 Front wheel rim- Removalandrefitting4 006018 Wheel rim- Painting5 003063 Tyrepressure- CheckEIectricdevicesTime VespaPX150USATME- 26ELECTRICALDEVICESCode Action Duration1 005013 Electronicblinker - Replace-ment2 005045 Starter motor wireharness-ReplacementVespaPX150USA TimeTME- 27ELECTRICALCONNECTIONSCode Action Duration1 005001 Electriccircuit - ReplacementandRefittingTime VespaPX150USATME- 28BATTERY- VOLTAGEREGULATORCode Action Duration1 005009 Voltageregulator - Replace-ment2 005007 Battery- Replacement3 004071 Batteryhousing- Replace-mentELECTRICALDEVICESCode Action Duration1 005024 Batteryfuse- Replacement2 005025 Batteryfuseholder - Re-placementVespaPX150USA TimeTME- 29ELECTRICALDEVICESCode Action Duration1 005003 Horn- Replacement2 005017 Stoplight switch- Replace-ment3 005069 LHSswitch- ReplacementTime VespaPX150USATME- 30ECU- CDICode Action Duration1 001023 CPU- ReplacementTransmissionsCABLESVespaPX150USA TimeTME- 31Code Action Duration1 002008 Chokecable- Replacement2 002056 Gear shifter cableassy. - Re-placement3 002051 Odo/Speedometer cableassy. - Replacement4 002049 Odo/Speedometer cable-Replacement5 002046 Gear shifter cable- Replace-mentCABLESCode Action Duration1 002055 Clutchcableassy. - Replace-ment2 002063 Throttlecableassy. - Re-placement3 002053 Rear brakecableassembly-Replacement4 003060 Rear brakecable- Adjust-ment5 003061 Throttlecable- Adjustment6 002045 Clutchcable- ReplacementTime VespaPX150USATME- 32BrakecaIIipersBRAKECALLIPERSCode Action Duration1 003070 Front brakepads- wearcheck2 002007 Front brakepads- Removalandrefitting3 002039 Front brakecalliper - Remov-al andrefittingSteeringcoIumnVespaPX150USA TimeTME- 33STEERINGCOLUMNCode Action Duration1 003010 Front suspension- OverhaulFront suspensionTime VespaPX150USATME- 34FRONTSHOCK-ABSORBERCode Action Duration1 003011 Front shockabsorber - Re-moval andrefittingBrakingsystemREARBRAKEPEDALCode Action Duration1 002014 Brakepedal - Removal andrefittingVespaPX150USA TimeTME- 35FRONTWHEELHUBCode Action Duration1 003033 Front wheel hub- Replace-ment2 002041 Brakedisc- Replacement3 003040 Front wheel bearings- Re-placementSHOEPLATETime VespaPX150USATME- 36Code Action Duration1 002016 Rear brakeshoeplate- Re-placement2 003012 Brakeshoeplate- RemovalandRefittingREARBRAKESHOESCode Action Duration1 002002 Rear brakeshoe(s) - Re-placement2 003071 Rear brakeshoe(s) - WearcheckVespaPX150USA TimeTME- 37REARBRAKEDRUMCode Action Duration1 002010 Rear brakedrum- Replace-ment2 001016 Rear wheel - Replacement3 004026 Handlebar cover - Replace-ment4 001071 Rear wheel rim- RemovalandrefittingCIutchcoverTime VespaPX150USATME- 38CLUTCHCOVERCode Action Duration1 001073 Clutchcover - Removal andrefittingCIutchCLUTCHCode Action Duration1 001022 Clutch- RemovalGear-boxVespaPX150USA TimeTME- 39GEAR-BOXCode Action Duration1 001119 Gearboxcomponents- Re-placement2 001025 Gearbox- OverhaulGear shifterGEARSHIFTERFASTENERSCode Action Duration1 001077 Gear shifter components-Removal andrefittingTime VespaPX150USATME- 40GEARSHIFTERCode Action Duration1 001029 Gear shifter -OverhaulVespaPX150USA TimeTME- 41