VESPA PX 125 150 euro 2 Workshop Manual
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VESPA PX 125 150 euro 2 Workshop Manual

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Vespa PX 125 150 Euro 2

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  • Page 1 WORKSHOP MANUAL 633241 Vespa PX 125 150 Euro 2...
  • Page 2 WORKSHOP MANUAL Vespa PX 125 150 Euro 2...
  • Page 3 WORKSHOP MANUAL Vespa PX 125 150 Euro 2 This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio-Gilera dealers and 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.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Vespa PX 125 150 Euro 2 Characteristics Rules Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.
  • Page 8 Vespa PX 125 150 Euro 2 Characteristics Specification Desc./Quantity Engine prefix (150) VLX1M Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Empty weight 104 Kg Wheelbase 1235 mm Max height 1110 mm Max length 1760 mm Handlebars width 700 mm...
  • Page 9 Vespa PX 125 150 Euro 2 Characteristics Specification Desc./Quantity No. of cylinders Bore and stroke (125) 52,2 x 57 mm Bore and stroke (150) 58 x 57 mm Displacement (125) 123,4 Cm3 Displacement (150) 150,599 Cm3 Compression ratio (125) 8 : 1...

  • Page 10: Wheels And Tyres

    Vespa PX 125 150 Euro 2 Characteristics Brakes BRAKES Specification Desc./Quantity Front Ø 220 mm disc hydraulically operated via lever mounted on RHS of handlebars Rear Ø 140 mm drum with expanding shoes mechanically activated via pedal on RHS of footrest...

  • Page 11: Tightening Torques

    Vespa PX 125 150 Euro 2 Characteristics Dell'Orto CARBURETTOR Specification Desc./Quantity Type SI20/20D Diffuser diameter 20 mm Main jet Slow running jet 45/160 Main air jet Throttle valve (type) 6823.16.64 Emulsifier (code) Sprayer 280/100 Starter jet 60/100 Air idling screw...

  • Page 12: Assembly Clearances

    Vespa PX 125 150 Euro 2 Characteristics Name Torque in Nm Wheel axle nut 90÷110 Gear shifter nuts 12÷15 Starter motor screws 10÷12 Fan cover screws 8÷10 Air-box fixing screws 6÷8 Gear fixing nut 30÷35 Mixer fixing screws 6÷8 Head fixing nuts 16 ÷...
  • Page 13 Vespa PX 125 150 Euro 2 Characteristics MATING CATEGORIES - 125CC ENGINE Name Initials Cylinder Piston Play on fitting Cylinder - piston 52,505 52,290 0,215 Cylinder - piston 52,510 52,295 0,215 Cylinder - piston 52,515 52,300 0,215 Cylinder - piston...
  • Page 14 Vespa PX 125 150 Euro 2 Characteristics MATING CATEGORIES - 150CC ENGINE Name Initials Cylinder Piston Play on fitting Cylinder - piston 57,795 57,555 0,240 Cylinder - piston 57,800 57,650 0,240 Cylinder - piston 57,805 57,565 0,240 Cylinder - piston...
  • Page 15 Vespa PX 125 150 Euro 2 Characteristics Name Initials Cylinder Piston Play on fitting Cylinder - piston (3rd 58,420 58,180 0,240 oversize) Piston rings PISTON RINGS - 125CC ENGINE Name Description Dimensions Initials Quantity Piston ring 52,5 0,2 ÷ 0,35...
  • Page 16 Vespa PX 125 150 Euro 2 Characteristics 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 0,15 ÷ 0,46...
  • Page 17 Vespa PX 125 150 Euro 2 Characteristics − The maximum allowable end-play for the connecting rod after use (intended as the longitudinal slide on the big end) is 0.7mm. Gearbox shoulders GEARBOX SHOULDERS Name Description Dimensions Initials Quantity Shoulder 2,05 +0 -0,06 0,15 ÷...
  • Page 18 INDEX OF TOPICS TOOL OOLING...
  • Page 19 Vespa PX 125 150 Euro 2 Tooling TOOLING Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 002850y Oil tank spanner 002973y Fuel tap spanner...
  • Page 20 Vespa PX 125 150 Euro 2 Tooling Stores code Description 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter TOOL - 20...
  • Page 21 Vespa PX 125 150 Euro 2 Tooling Stores code Description 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 001330Y Tool for fitting steering seats TOOL - 21...
  • Page 22 Vespa PX 125 150 Euro 2 Tooling Stores code Description 020021Y Front suspension service tool 020321y Carburettor float removing tool 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020625Y Kit for sampling gas from the exhaust manifold 001467Y021 Extraction pliers for ø...
  • Page 23 Vespa PX 125 150 Euro 2 Tooling Stores code Description 020151Y Air heater 020150Y Air heater support 020057Y Calking tool 020095Y Flywheel retaining tool 008564Y Flywheel extractor 008886Y Crankshaft extractor 004499Y Camshaft bearing extractor TOOL - 23...
  • Page 24 Vespa PX 125 150 Euro 2 Tooling Stores code Description 020265Y Bearing fitting base 060007Y Crankcase bearing spacer 060824Y Inspection probe 008119Y009 Tube to assemble shafts and axles 001729Y Clutch retaining tool 020322Y Clutch removing/fitting tool TOOL - 24...
  • Page 25 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 26: Maintenance Chart

    Vespa PX 125 150 Euro 2 Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AT 1000 KM OR 4 MONTHS Action Gear-box oil level - replacement Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment...
  • Page 27 Vespa PX 125 150 Euro 2 Maintenance Action Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean...
  • Page 28 Vespa PX 125 150 Euro 2 Maintenance (*) See regulations in section «Idling speed adjustement» AT 35000 KM Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing...
  • Page 29 Vespa PX 125 150 Euro 2 Maintenance Action Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test (*) See regulations in section «Idling speed adjustement»...

  • Page 30: Checking The Spark Advance

    Vespa PX 125 150 Euro 2 Maintenance Carburettor Disassemble the carburettor 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 component. − The throttle valve must be free to slide inside the mixture chamber;...

  • Page 31: Spark Plug

    Vespa PX 125 150 Euro 2 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...

  • Page 32: Headlight Adjustment

    Vespa PX 125 150 Euro 2 Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...
  • Page 33 Vespa PX 125 150 Euro 2 Maintenance − Ensure the one-way valve packing properly seals the aluminium outlet fitting. − Refit the aluminium outlet onto the SAS box as shown in the picture. − Remove the gas outlet cap, shown in the figure, on the exhaust.
  • Page 34 Vespa PX 125 150 Euro 2 Maintenance SAS filters inspection and cleaning Remove the two screws «A» from the SAS alumi- nium cover. Disengage the metallic hose from the rubber fastener on the cover without detaching the hose from the sleeve. Remove the plate and the plastic cover and hence extract the sponge filter and wash with soap.
  • Page 35 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 36 Vespa PX 125 150 Euro 2 Electrical system Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple...
  • Page 37 Vespa PX 125 150 Euro 2 Electrical system Specification Desc./Quantity Front RHS turn signal light Rear brake stop button Anti-repeating device Fuel level sender Magneto flywheel Electronic ignition device Rear RHS turn signal light Starter motor Taillight Starter relay Rear LHS turn signal light...
  • Page 38 Vespa PX 125 150 Euro 2 Electrical system COMPONENTS ARRANGEMENT Specification Desc./Quantity Key switch Voltage regulator Electronic Control Unit (C.D.I.) with H.T coil Battery 12V - 9Ah Starter motor Magneto flywheel Anti-repeating device Spark plug Remote starter switch Fuse 7.5 A...
  • Page 39 Vespa PX 125 150 Euro 2 Electrical system Headlights and automatic starter section LIGHTS Specification Desc./Quantity Voltage regulator Magneto flywheel Key switch contacts Headlight bulb 12V-35/35W High-beam warning light 12V - 1.2W Light switch Headlight switch Rear side light bulb...
  • Page 40 Vespa PX 125 150 Euro 2 Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING Specification Desc./Quantity Magneto flywheel To services Key switch contacts Voltage regulator Fuse 7.5 A Remote starter switch Starter motor Battery 12V - 9Ah Enable button...
  • Page 41 Vespa PX 125 150 Euro 2 Electrical system Level indicators and enable signals section SAFETY SWITCHES AND LEVEL GAUGES Specification Desc./Quantity Fuel gauge Fuel level sender Reserve fuel light 12V-1,2W Brake light bulbs 12V-10W Stoplight switches Voltage regulator ELE SYS - 41...
  • Page 42 Vespa PX 125 150 Euro 2 Electrical system Turn signal lights SIGNAL LIGHTS AND HORN Specification Desc./Quantity Turn signals master-box Indicators switch Turn signal warning light 12V - 1,2W Turn signal light bulbs 12V - 21W Horn button Horn Voltage regulator...
  • Page 43 Vespa PX 125 150 Euro 2 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 (-)
  • Page 44 Vespa PX 125 150 Euro 2 Electrical system IGNITION CIRCUIT Specification Desc./Quantity WHITE 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.
  • Page 45 Vespa PX 125 150 Euro 2 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...
  • Page 46 Vespa PX 125 150 Euro 2 Electrical system 4) Battery recharge faulty (regulator open-circuit- ed). Interventions FAULT 3 Replace the regulator, as certainly faulty, and the fuse. FAULT 4 a) Attach an ammeter between the voltage regu- lator and the battery, and check that, at 3,000 rpm and with the battery at 13V, the current sup- plied is approximately 1.5 to 2 A.
  • Page 47 Vespa PX 125 150 Euro 2 Electrical system STARTER MOTOR Specification Desc./Quantity Nominal voltage Nominal power 0,15 kW Direction of rotation Clockwise Engine connection Via pinion and gear ring on crankshaft, transmission-side Control Pushbutton Battery 12V - 9Ah Fuses The starter system and horn are protected by a 7.5A fuse, «A», located on the LHS of the battery...
  • Page 48 Vespa PX 125 150 Euro 2 Electrical system ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE. Dry-charge battery COMMISSIONING A NEW DRY-CHARGED BATTERY - Remove the battery air pipe stop cap and each single cell cap.
  • Page 49 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 50 Vespa PX 125 150 Euro 2 Engine from vehicle 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.
  • Page 51 Vespa PX 125 150 Euro 2 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.
  • Page 52 INDEX OF TOPICS NGINE...

  • Page 53: Removing The Stator

    Vespa PX 125 150 Euro 2 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.
  • Page 54 Vespa PX 125 150 Euro 2 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.
  • Page 55 Vespa PX 125 150 Euro 2 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 mallet.
  • Page 56 Vespa PX 125 150 Euro 2 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.

  • Page 57: Removing The Cylinder Head

    Vespa PX 125 150 Euro 2 Engine 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-...

  • Page 58: Inspecting The Small End

    Vespa PX 125 150 Euro 2 Engine Inspecting the small end − Always fit a roller cage of the type prescribed in the assembly clearance tables. − The arrow in the figure shows the location of the connecting rod's identification marking.
  • Page 59 Vespa PX 125 150 Euro 2 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.
  • Page 60 Vespa PX 125 150 Euro 2 Engine Refitting the crankshaft bearings − Heat the bearing housing with the air heater positioned onto its support. − After heating the crankcase, position the bearing using a length of tube pushing directly on the bear- ing's outer ring.
  • Page 61 Vespa PX 125 150 Euro 2 Engine Lubrication Conceptual diagrams Automatic fuel mixer The system is fed by oil contained in a separate tank. The vehicle is equipped with two distinct tanks, each with individual hoses, for fuel and lubricant.
  • Page 62 Vespa PX 125 150 Euro 2 Engine CONCEPTUAL DIAGRAMS Specification Desc./Quantity Fuel tank filler cap Oil tank filler cap Oil level gauge SEPARATE LUBRICATION device box Oil inlet hose Oil outlet hose Oil outlet valve Inlet phase Outlet phase Oil pump −...
  • Page 63 Vespa PX 125 150 Euro 2 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.

  • Page 64: Fuel Supply

    Vespa PX 125 150 Euro 2 Engine Fuel supply Removing the carburettor − Remove the two fixing screws and the carburet- tor cover. − Remove the fasteners and the air filter. − After removing the air filter, loosen the two 8mm Allen screws and hence remove the carburettor.
  • Page 65 Vespa PX 125 150 Euro 2 Engine − Remove the main and idle jets and blow with compressed air. − Loosen the fixing screw and remove the float bowl. − Remove the starter jet and blow with com- pressed air.
  • Page 66 Vespa PX 125 150 Euro 2 Engine − Check the starter choke valve; replace if worn. Refitting the carburettor − Refit the components replacing all seals. WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS Manual Gear Shifter Remove the fasteners and the gear shifter.
  • Page 67 Vespa PX 125 150 Euro 2 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.
  • Page 68 Vespa PX 125 150 Euro 2 Engine − 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.
  • Page 69 Vespa PX 125 150 Euro 2 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.
  • Page 70 Vespa PX 125 150 Euro 2 Engine Axial play 0,20 ÷ 0,40 mm − Using the special tool, proceed by removing the gear shaft. Specific tooling 008119Y009 Tube to assemble shafts and axles See also Splitting the crankcase halves Clutch −...
  • Page 71 Vespa PX 125 150 Euro 2 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.
  • Page 72 Vespa PX 125 150 Euro 2 Engine − 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.
  • Page 73 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 74 Vespa PX 125 150 Euro 2 Suspensions Front Front wheel hub overhaul After removing the front brake calliper, remove the plastic cap shown in the figure. Remove the pin and the locknut. It is now possible to remove the wheel axle nut.
  • Page 75 Vespa PX 125 150 Euro 2 Suspensions Refitting Upon reassembly, tighten to the prescribed tor- que. N.B. * Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TOR- QUE, LUBRICATE NUTS BEFORE ASSEMBLY. Locking torques (N*m) Handlebar fixing screw* 30÷44...
  • Page 76 Vespa PX 125 150 Euro 2 Suspensions − Using the special tool remove the bearing and dust ring housings from the steering column as shown in the picture. − Proceed with mallet hits. Specific tooling 020004Y Punch for removing fifth wheels from headstock −...
  • Page 77 Vespa PX 125 150 Euro 2 Suspensions 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.
  • Page 78 Vespa PX 125 150 Euro 2 Suspensions Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time. - Remove the tool and the part 5 (guide), which has been partially ejected during the previous pin fitting phase, and leave part 4 always fitted.

  • Page 79: Front Shock Absorber

    Vespa PX 125 150 Euro 2 Suspensions 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...
  • Page 80 Vespa PX 125 150 Euro 2 Suspensions Removal Remove the 2 fixings shown in the figure and the 2 fasteners on the shock-absorber support bracket located on the steering column. Free the shock-absorber from the support bracket removing the top fixing.

  • Page 81: Removing The Rear Wheel

    Vespa PX 125 150 Euro 2 Suspensions 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 −...
  • Page 82 Vespa PX 125 150 Euro 2 Suspensions Centre-stand Detach the return spring from the centre stand, re- move the 4 fasteners shown in the figure. SUSP - 82...
  • Page 83 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 84: Front Brake Disc

    Vespa PX 125 150 Euro 2 Braking system Front brake calliper Removal − Detach the brake hose from the calliper using a container to collect the fluid. − Remove the fasteners shown in the figure. Refitting − When refitting, tighten the nuts to the prescribed torque.

  • Page 85: Front Brake Pads

    Vespa PX 125 150 Euro 2 Braking system N.B. * Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE AS- SEMBLY. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Disc fixing screw* 5÷6 Disc Inspection −...
  • Page 86 Vespa PX 125 150 Euro 2 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.

  • Page 87: Rear Drum Brake

    Vespa PX 125 150 Euro 2 Braking system 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.
  • Page 88 Vespa PX 125 150 Euro 2 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.
  • Page 89 INDEX OF TOPICS CHAS HASSIS...
  • Page 90 Vespa PX 125 150 Euro 2 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.
  • Page 91 Vespa PX 125 150 Euro 2 Chassis − 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: −...
  • Page 92 Vespa PX 125 150 Euro 2 Chassis Replace the seat and glove-box cylinders. To re- place these follow the operations described for the removal of the cylinder when the ignition key- switch is in the «LOCK» position. If the locks have been left open however, extract the cylinder by pushing lip «F»...
  • Page 93 Vespa PX 125 150 Euro 2 Chassis − Remove the 2 fasteners for each turn signal light. Fuel tank After removing the seat, detach the electrical con- nection of the fuel level sensor. Remove the 2 remaining fixings to free the fuel tank assembly.

  • Page 94: Front Mudguard

    Vespa PX 125 150 Euro 2 Chassis Front mudguard − Remove the 2 fixings from underneath the mud- guard. − After removing the handlebar and the steering column assembly, remove the 3 fasteners shown in the figure. Top-case Front − Remove the 2 fixings shown in the figure and the 2 top fasteners from inside the glove-box.
  • Page 95 Vespa PX 125 150 Euro 2 Chassis 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).
  • Page 96 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 97 Vespa PX 125 150 Euro 2 Pre-delivery Carry out the listed tests before delivering the vehicle. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. Aesthetic inspection − Paint − Plastic joints − Damages − Dirt Tightening torques inspection − All tighten torques summarised in pages 1 - 5.
  • Page 98 Vespa PX 125 150 Euro 2 Pre-delivery THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY.
  • Page 99 INDEX OF TOPICS TIME...
  • Page 100 Vespa PX 125 150 Euro 2 Time Engine ENGINE Code Action Duration 001001 Engine from the frame - removal and refitting 003064 Engine oil - replacement 003057 Engine retainer - Tighten nuts TIME - 100...
  • Page 101 Vespa PX 125 150 Euro 2 Time Crankshaft 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 TIME - 101...
  • Page 102 Vespa PX 125 150 Euro 2 Time WRIST PIN PISTON CYLINDER ASSY Code Action Duration 001002 Cylinder/piston - Replacement 001107 Cylinder/Piston - Overhaul/Cleaning 001093 Spark plug - Replacement 001094 Spark plug cap - Replacement TIME - 102...
  • Page 103 Vespa PX 125 150 Euro 2 Time Flywheel cover FAN COVER Code Action Duration 001087 Flywheel cover - Replacement TIME - 103...
  • Page 104 Vespa PX 125 150 Euro 2 Time Oil pump AUTOMATIC MIXER Code Action Duration 001018 Mixer - Replacement 001028 Oil pump drive shaft - Replacement Starter motor STARTER MOTOR Code Action Duration 001020 Starter motor - change 001039 Starter motor brushes - Replacement...
  • Page 105 Vespa PX 125 150 Euro 2 Time Code Action Duration 001017 Starter motor shaft - Replacement KICK-START LEVER Code Action Duration 008008 Kick-starter gear spring - Replace- ment 001120 Crankcase bearings - Replacements 001084 Starter lever - Replacement TIME - 105...

  • Page 106: Flywheel Magneto

    Vespa PX 125 150 Euro 2 Time Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 001067 Stator - Removal and refitting 001004 Stator - Overhaul 001058 Flywheel - Replacement 001059 Pick-up - Replacement 003052 Ignition timing TIME - 106...
  • Page 107 Vespa PX 125 150 Euro 2 Time Carburettor CARBURETTOR Code Action Duration 001063 Carburettor - Replacement 001008 Carburatore - Revisione 003058 Carburettor - Adjustment TIME - 107...
  • Page 108 Vespa PX 125 150 Euro 2 Time Exhaust pipe EXHAUST PIPE Code Action Duration 001009 Exhaust pipe - Replacement TIME - 108...

  • Page 109: Air Cleaner

    Vespa PX 125 150 Euro 2 Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement 001027 Air-cleaner/frame bellow - Replace- ment TIME - 109...
  • Page 110 Vespa PX 125 150 Euro 2 Time Frame FRAME Code Action Duration 004001 Frame - Replacement 006001 Frame - Painting 004023 Shield rim - Replacement TIME - 110...
  • Page 111 Vespa PX 125 150 Euro 2 Time Centre-stand CENTRE-STAND Code Action Duration 004004 Centre-stand - Replacement Legshield spoiler TIME - 111...
  • Page 112 Vespa PX 125 150 Euro 2 Time STEERING COLUMN FAIRING Code Action Duration 004024 Steering column fairing - Replace- ment Side fairings SIDE FAIRING LOCKS Code Action Duration 004025 Side fairing locks - Replacement TIME - 112...
  • Page 113 Vespa PX 125 150 Euro 2 Time WHEEL SIDE FAIRINGS Code Action Duration 006005 Side fairings - Painting Footrests TIME - 113...
  • Page 114 Vespa PX 125 150 Euro 2 Time FOOTRESTS Code Action Duration 004015 Footrests - Replacement Rear cover GLOVE-BOX Code Action Duration 004083 Glove box - Replacement 006019 Glove-box - Painting 004081 Glove-box door - Replacement TIME - 114...
  • Page 115 Vespa PX 125 150 Euro 2 Time Mudguard FRONT MUDGUARD Code Action Duration 004002 Front mudguard - Replacement 006003 Mudguard - Painting 003045 Steering tube - Replacement TIME - 115...
  • Page 116 Vespa PX 125 150 Euro 2 Time Fuel tank FUEL LEVEL SENSOR Code Action Duration 005010 Fuel tank float - Replacement TIME - 116...
  • Page 117 Vespa PX 125 150 Euro 2 Time FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 004007 Fuel tap - Replacement 004110 Fuel tank hose - Replacement 006024 Fuel tank - Painting Tank oil OIL TANK Code Action Duration...
  • Page 118 Vespa PX 125 150 Euro 2 Time Rear shock-absorber REAR SHOCK-ABSORBER Code Action Duration 003007 Rear shock-absorber - Removal and refitting TIME - 118...
  • Page 119 Vespa PX 125 150 Euro 2 Time Steering column bearings STEERING COLUMN BEARINGS Code Action Duration 003002 Steering bearings - Replacement 004119 Steering support bearing - Replace- ment 003073 Steering play - Adjustment 004010 Steering lock - Replacement Handlebar components...
  • Page 120 Vespa PX 125 150 Euro 2 Time Code Action Duration 002024 Front brake pump - Removal and re- fitting 002047 Front brake fluid - Replacement and circuit bleeding 002021 Front brake hose - Removal and re- fitting GEAR-SHIFTER TWIST-GRIP Code...
  • Page 121 Vespa PX 125 150 Euro 2 Time Seat SEAT Code Action Duration 004003 Saddle - Replacement 004054 Saddle lock catch - Replacement TIME - 121...

  • Page 122: Instrument Panel

    Vespa PX 125 150 Euro 2 Time Instrument panel HANDLEBAR COVERS AND DASHBOARD Code Action Duration 005038 Dashboard warning/telltale lights - Replacement 005014 Odometer - Replacement 006010 Top handlebar cover - Painting 004066 Rear-view mirror - Replacement 003001 Top handlebar cover - Removal and...

  • Page 123: Turn Signal Lights

    Vespa PX 125 150 Euro 2 Time Turn signal lights TAILLIGHT Code Action Duration 005066 Rear light bulbs - Replacement 005005 Taillight - change 005028 Rear light assembly glass - Replace- ment TIME - 123...
  • Page 124 Vespa PX 125 150 Euro 2 Time HEADLIGHT Code Action Duration 005008 Headlight bulbs - Replacement 005002 Front light - Replacement TURN SIGNAL LIGHTS Code Action Duration 005011 Starter relay - Replacement 005012 Front turn signal light - Replacement 005067...

  • Page 125: Front Wheel

    Vespa PX 125 150 Euro 2 Time Front wheel WHEEL Code Action Duration 004123 Front wheel - Replacement 003047 Front tyre - replace 003037 Front wheel rim - Removal and Re- fitting 006018 Wheel rim - Paintwork 003063 Tyre pressure - Check...
  • Page 126 Vespa PX 125 150 Euro 2 Time Electric devices ELECTRICAL DEVICES Code Action Duration 005024 Battery fuse - Replacement 005025 Battery fuse holder - Replacement TIME - 126...
  • Page 127 Vespa PX 125 150 Euro 2 Time BATTERY - VOLTAGE REGULATOR Code Action Duration 005009 Voltage regulator - Replacement 005007 Battery - Replacement 004071 Battery compartment - Replacement TIME - 127...
  • Page 128 Vespa PX 125 150 Euro 2 Time ELECTRICAL CONNECTIONS Code Action Duration 005001 Electric circuit - Replacement and Refitting ELECTRICAL DEVICES Code Action Duration 005013 Electronic blinker - Replacement 005045 Starter motor wire harness - Re- placement TIME - 128...
  • Page 129 Vespa PX 125 150 Euro 2 Time ELECTRICAL DEVICES Code Action Duration 005003 Horn - Replacement 005017 Stop light switch - Replacement 005069 Left switch - Replacement TIME - 129...
  • Page 130 Vespa PX 125 150 Euro 2 Time ECU - CDI Code Action Duration 001023 CPU - Replacement Transmissions CABLES Code Action Duration 002008 Choke cable - Replacement 002056 Gear shifter cable assy. - Replace- ment 002051 Odo/Speedometer cable assy. - Re-...
  • Page 131 Vespa PX 125 150 Euro 2 Time CABLES Code Action Duration 002055 Clutch cable assy. - Replacement 002063 Throttle cable assy. - Replacement 002053 Rear brake transmission complete - replacement 003060 Rear brake cable - Adjustment 003061 Accelerator transmission - Adjust-...

  • Page 132: Brake Callipers

    Vespa PX 125 150 Euro 2 Time Brake callipers BRAKE CALLIPERS Code Action Duration 003070 Front brake pads - Wear check 002007 Front brake pads - Removal and re- fitting 002039 Front brake calliper - Removal and refitting TIME - 132...
  • Page 133 Vespa PX 125 150 Euro 2 Time Steering column STEERING COLUMN Code Action Duration 003010 Front suspension - Service TIME - 133...
  • Page 134 Vespa PX 125 150 Euro 2 Time Front suspension FRONT SHOCK-ABSORBER Code Action Duration 003011 Front shock absorber - Removal and Refitting TIME - 134...

  • Page 135: Braking System

    Vespa PX 125 150 Euro 2 Time Braking system REAR BRAKE SHOES Code Action Duration 002002 Rear brake shoe(s) - Replacement 003071 Rear brake shoe(s) - Wear check TIME - 135...
  • Page 136 Vespa PX 125 150 Euro 2 Time REAR BRAKE PEDAL Code Action Duration 002014 Brake pedal - Removal and refitting REAR BRAKE DRUM Code Action Duration 002010 Rear brake drum - Replacement 001016 Rear wheel - Replacement 004026 Handlebar cover - Replacement...
  • Page 137 Vespa PX 125 150 Euro 2 Time FRONT WHEEL HUB Code Action Duration 003033 Front wheel hub- Replacement 002041 Brake disc - Replacement 003040 Front wheel bearings - Replacement SHOE PLATE Code Action Duration 002016 Rear brake shoe plate - Replace-...
  • Page 138 Vespa PX 125 150 Euro 2 Time Code Action Duration 003012 Brake shoe plate - Removal and Re- fitting Secondary air box SECONDARY AIR BOX Code Action Duration 001162 Secondary air housing - Replace- ment 001161 Secondary air filter - Replacement /...
  • Page 139 Vespa PX 125 150 Euro 2 Time Clutch cover CLUTCH COVER Code Action Duration 001073 Clutch cover - Removal and refitting Clutch CLUTCH Code Action Duration 001022 Clutch - Removal TIME - 139...
  • Page 140 Vespa PX 125 150 Euro 2 Time Gear-box GEAR-BOX Code Action Duration 001119 Gearbox components - Replacement 001025 Gearbox - Overhaul Gear shifter GEAR SHIFTER Code Action Duration 001029 Gear shifter - Overhaul TIME - 140...
  • Page 141 Vespa PX 125 150 Euro 2 Time GEAR SHIFTER FASTENERS Code Action Duration 001077 Gear shifter components - Removal and refitting TIME - 141...
  • Page 142 Air filter: 31 Battery: 40, 48 Brake: 84, 85, 87, 88, 132 Brake fluid: Carburettor: 10, 30, 63, 64, 66, 107 Fuel: 64, 93, 116 Fuses: 47 Headlight: 32, 90 Horn: Identification: 7 Instrument panel: 122 Maintenance: 7, 26 Shock absorbers: 81 Spark plug: 31 Tank: 93, 116, 117 Transmission: 9...

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