VESPA PX 150 USA Workshop Manual
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VESPA PX 150 USA Workshop Manual

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WORKSHOP MANUAL
633376
Vespa PX 150 USA

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Summary of Contents for VESPA PX 150 USA

  • Page 1 WORKSHOP MANUAL 633376 Vespa PX 150 USA...

  • Page 2: Workshop Manual

    WORKSHOP MANUAL Vespa PX 150 USA...
  • Page 3 WORKSHOP MANUAL Vespa PX 150 USA This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio- Gilera dealers and sub-agents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the principles of mechanics and standard procedures required for general vehicle repair.

  • Page 5: Index Of Topics

    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 150 USA Characteristics Rules Safety rules - Should it be necessary to keep the engine running while servicing, make sure that the area or room is well ventilated, and use special exhaust fans, if required. Never let the engine running in closed rooms.
  • Page 8 Vespa PX 150 USA Characteristics Specification Desc./Quantity Max lenght 69,29 inch (1760 mm) Handlebars width 27,56 inch (700 mm) Engine ENGINE Specification Desc./Quantity Engine type 2-stroke with rotary intake timing No. of cylinders Alesaggio per corsa (150) 0,19 x 2,24 inch (58 x 57 mm)

  • Page 9: Electrical System

    Vespa PX 150 USA Characteristics Specification Desc./Quantity Clutch Multi-disc. Cooling Forced air by a centrifugal fan. Max power output (shaft) 150cc 6.6 Kw (9 hp) at 5,700 rpm Max speed (150) 82,8 Km/h Transmission TRANSMISSION Specification Desc./Quantity Gear-box 4-speed with constantly engaged gears...

  • Page 10: Wheels And Tyres

    Vespa PX 150 USA Characteristics Wheels and tyres WHEELS AND TIRES Specification Desc./Quantity Front tire 3,50 x 10" Rear tire 3,50 x 10" Rims Pressed steel Wheels Interchangeable with 2.00"×10" pressed steel rims. Front tire pressure 18,85 PSI (1,3 bar)

  • Page 11: Steering Unit

    Vespa PX 150 USA Characteristics Tightening Torques STEERING UNIT Name Torque in Nm Upper steering ring nut 5÷6 Top steering housing 6÷7 (hence loosen by 80° - 90°) Handlebar fixing screw* 30÷44 FRAME Name Torque in Nm Engine - frame bolt * 61 ÷...

  • Page 12: Assembly Clearances

    Vespa PX 150 USA Characteristics Overhaul data Assembly clearances Cylinder - piston assy. The cylinder classification must be carried out at 25 mm from the head mating surface on the rod's swinging plane. MATING CATEGORIES - 150CC ENGINE Name Initials...

  • Page 13: Piston Rings

    Vespa PX 150 USA Characteristics Name Initials Cylinder Piston Play on fitting Cylinder - piston (2nd 58,210 57,970 0,240 oversize) Cylinder - piston (2nd 58,215 57,975 0,240 oversize) Cylinder - piston (2nd 58,220 57,980 0,240 oversize) Cylinder - piston (3rd...
  • Page 14 Vespa PX 150 USA 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 15 Vespa PX 150 USA Characteristics − The maximum allowable end-play for the connecting rod after use (intended as the longitudinal slide on the big end) is 0.7mm. Gearbox shoulders GEARBOX SHOULDERS Name Description Dimensions Initials Quantity Shoulder 2,05 +0 -0,06 0,15 ÷...
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 Vespa PX 150 USA 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 020320Y...
  • Page 18 Vespa PX 150 USA 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 - 18...
  • Page 19 Vespa PX 150 USA 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 - 19...
  • Page 20 Vespa PX 150 USA 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 11 mm bearings...
  • Page 21 Vespa PX 150 USA 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 - 21...
  • Page 22 Vespa PX 150 USA 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 - 22...

  • Page 23: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 24: Maintenance Chart

    Vespa PX 150 USA Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AT 621,37 MILES OR 4 MONTHS Action Gear-box oil level - replacement Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing...
  • Page 25 Vespa PX 150 USA Maintenance Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check...
  • Page 26 Vespa PX 150 USA Maintenance Action Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyre condition and wear - Check Vehicle and brake test - road test (*) See regulations in section «Idling speed adjustment»...
  • Page 27 Vespa PX 150 USA Maintenance Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing...

  • Page 28: Checking The Spark Advance

    Vespa PX 150 USA Maintenance Carburettor Disassemble the carburetor and clean all compo- nents with solvent, hence dry with compressed air all ducts, in order to ensure proper cleaning. • Carefully check the state of each com- ponent. • The throttle valve must be free to slide inside the mixture chamber;...

  • Page 29: Spark Plug

    Vespa PX 150 USA Maintenance − In the impossibility of obtaining the specified val- ues, or if the engine is found to be running rough, proceed by replacing defective components. Specific tooling 020330Y Stroboscopic light to check timing 020332Y Digital rev counter Spark plug −...

  • Page 30: Headlight Adjustment

    Vespa PX 150 USA Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle, in riding order and with the tyres inflated to the prescribed pressure, on flat ground, 32,81 feet (10 m) away from a half-lit white screen. Ensure the vehicle axis is perpendicular to the screen;...
  • Page 31 Vespa PX 150 USA Maintenance MAIN - 31...

  • Page 32: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 33 Vespa PX 150 USA 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 34 Vespa PX 150 USA Electrical system Specification Desc./Quantity Voltage regulator Mixer oil warning light control Starter remote control Frame earth Starter motor wire unit Automatic starter Heater Chassis wire unit Fuel level sender front right turn indicator Key switch Starter button...
  • Page 35 Vespa PX 150 USA Electrical system Components arrangement 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 36 Vespa PX 150 USA Electrical system Conceptual diagrams Ignition IGNITION Specification Desc./Quantity Magneto flywheel Key switch contacts Electronic Control Unit (C.D.I.) with H.T coil Spark plug ELE SYS - 36...
  • Page 37 Vespa PX 150 USA Electrical system Headlights and automatic starter section FANALERIA Specification Desc./Quantity Voltage regulator Magneto flywheel Key switch contacts Lampada proiettore 12V-55/60W High-beam warning light 12V - 1.2W Light switch Light remote control switch Rear side light bulb...
  • Page 38 Vespa PX 150 USA Electrical system Battery recharge and starting RICARICA BATTERIA E AVVIAMENTO Specification Desc./Quantity Magneto flywheel Electronic ignition device Key switch contacts Voltage regulator Fuse 7.5 A Remote starter switch Starter motor Battery 12V - 9Ah Enable button...
  • Page 39 Vespa PX 150 USA Electrical system Level indicators and enable signals section SAFETY SWITCHES AND LEVEL GAUGES Specification Desc./Quantity Fuel gauge Fuel level sending unit Reserve fuel light 12V-1,2W Brake light bulbs 12V-10W Stoplight switches Voltage regulator ELE SYS - 39...

  • Page 40: Turn Signal Lights

    Vespa PX 150 USA 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 Key switch contacts...

  • Page 41: Checks And Inspections

    Vespa PX 150 USA Electrical system Instruments and warning lights control board DASHBOARD LIGHTS AND GAUGES Specification Desc./Quantity + Battery Fuel gauge Low fuel warning light Turn signals warning light High-beam warning light Side-lamps warning light Ground lead (-) Checks and inspections...

  • Page 42: Ignition Circuit

    Vespa PX 150 USA 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. − Remember that all wires can only be detached with the engine off.
  • Page 43 Vespa PX 150 USA Electrical system Voltage regulator check Voltage regulator inspection In the event of a suspected failure of the voltage regulator, carry out the following inspections: Alternate current section The failure of the alternate current section of the...

  • Page 44: Starter Motor

    Vespa PX 150 USA 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 45 Vespa PX 150 USA 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 46 Vespa PX 150 USA Electrical system ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE. Dry-charge battery BATTERY START UP WITH DRY CHARGE - Remove the battery ventilation duct closing cap and remove the caps from the single elements.

  • Page 47: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 48 Vespa PX 150 USA 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 49 Vespa PX 150 USA Engine from vehicle − Remove the rear shock-absorber fixing nut and hence the bolt. − For the reassembly, follow the above operations in reverse order, using the prescribed tightening torques. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSI- TIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
  • Page 50 INDEX OF TOPICS NGINE...

  • Page 51: Flywheel Cover

    Vespa PX 150 USA Engine Flywheel cover Cooling hood − Remove the three fixing screws shown in the figure and the cooling hood. − Remove the fixing screws shown and hence de- tach the volute and the gear shifter cover.

  • Page 52: Removing The Starter Motor

    Vespa PX 150 USA 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 53 Vespa PX 150 USA Engine − Using pliers for internal split rings, remove the retaining ring shown. − Lift the assembly by the end of the shaft and re- move the shaft by hitting the housing with a mallet. − The removal of the bearing may be carried out by pushing in the direction shown in the figure.
  • Page 54 Vespa PX 150 USA 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 55: Removing The Cylinder Head

    Vespa PX 150 USA 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 56: Inspecting The Small End

    Vespa PX 150 USA 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. Refitting the cylinder −...

  • Page 57: Removing The Crankshaft

    Vespa PX 150 USA Engine Removing the crankshaft − Install the special tool as shown and extract the crankshaft. Specific tooling 008886Y Crankshaft extractor Removing the crankshaft bearings − After removing the oil seal, using pliers for inter- nal split rings, remove the bearing retaining ring shown.
  • Page 58 Vespa PX 150 USA 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 59 Vespa PX 150 USA Engine Lubrication Conceptual diagrams Automatic fuel mixer The system is fed by oil contained in a separate tank. The vehicle is equipped with two distinct tanks, each with individual hoses, for fuel and lubricant. The fuel tank must be filled with petrol, no petrol-oil mixture of any kind, while for the lubricant tank Selenia Hi Scooter 2T oil should be used.

  • Page 60: Oil Pump

    Vespa PX 150 USA 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 − Remove the carburettor box.
  • Page 61 Vespa PX 150 USA Engine − Remove the 3 fixing screws and the mixer cover with the lever. − Remove the mixer pumping element. − Remove the mixer fixing screw and then use pli- ers for internal split rings to remove the mixer body.

  • Page 62: Fuel Supply

    Vespa PX 150 USA Engine Fuel supply Removing the carburettor − Remove the two fixing screws and the carburetor cover. − Remove the fasteners and the air filter. − After removing the air filter, loosen the two 8mm Allen screws and hence remove the carburetor.
  • Page 63 Vespa PX 150 USA 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. − Remove the float pin to release the float, and hence the conical needle.
  • Page 64 Vespa PX 150 USA 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 65 Vespa PX 150 USA Engine − Split the two half-crankcases. − Using pliers for external split rings, remove the retaining ring and extract the gears. − Using a plastic mallet, remove the shaft. − Remove the multiple gear shaft lock nut.
  • Page 66 Vespa PX 150 USA 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 67 Vespa PX 150 USA Engine − Refit the trunnion «A» onto the gear shifter shaft «B» and tighten it to the prescribed torque (LHS thread). − Prepare a tool «D» as shown in the figure and insert it into the groove machined on the shaft.
  • Page 68 Vespa PX 150 USA 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 − Remove the 3 fixing screws and the clutch cover.
  • Page 69 Vespa PX 150 USA Engine − Restrain the clutch using the special tool, as shown in the figure, then remove the locknut and the clutch assembly. CAUTION DURING THE OPERATIONS OF REMOVAL, DO NOT LET THE WOODRUFF KEY FALL INSIDE THE ENGINE.
  • Page 70 Vespa PX 150 USA 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 71: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 72: Front Wheel Hub Overhaul

    Vespa PX 150 USA 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 73: Steering Column

    Vespa PX 150 USA 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 Steering column Removal −...
  • Page 74 Vespa PX 150 USA Suspensions Use a suitable punch with the dimensions indica- ted on the figure; hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end. Repeat the operation for the second washer using the punch on the side opposite to the one shown in the figure.
  • Page 75 Vespa PX 150 USA Suspensions Recommended products AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum disul- phide; ISO-L-XBCHB2, DIN KF2K-20 Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time.
  • Page 76 Vespa PX 150 USA Suspensions - Now, remove the two spacers (parts 17 and 16) and, once the space between the NADELLAs - steering tube and swinging hub - has been fully filled with grease, move the dust guard rings until they are placed in that space.

  • Page 77: Front Shock Absorber

    Vespa PX 150 USA Suspensions Refitting − Grease bearings and housings. − Tighten to the prescribed torque and rotate the spanner in an anti-clockwise direction by 80°-90°. Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GP 330 Grease (brake level, throttle twist- grip, gaer) Calcium complex soap grease NLGI 2;...

  • Page 78: Removing The Rear Wheel

    Vespa PX 150 USA Suspensions Removal Remove the split ring shown in the figure. Remove the two shock-absorber fixing screw and the odo/speedometer cable holder. Extract the bracket from the axle using a rubber mallet. Overhaul In the event of grease leaks through the wheel hub, the cause may be found in the sealing ring fitted onto the calliper bracket.

  • Page 79: Shock Absorbers

    Vespa PX 150 USA Suspensions Rim - hub fixing nuts (front-rear) 20 ÷ 27 Shock absorbers Removal For the rear shock-absorber replacement it is nec- essary to remove the engine - shock-absorber fixing bolt as shown in the figure. Remove the gasoline and oil tanks, then remove the shock absorber upper fixing in the underseat compartment housing.

  • Page 80: Braking System

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 81: Front Brake Disc

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

  • Page 82: Front Brake Pads

    Vespa PX 150 USA 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 83 Vespa PX 150 USA Braking system Fill Front − Once the bleeding valve is shut, top-up the circuit using fresh brake fluid. − Loosen the bleed screw. − Connect the special tool's tube to the bleed hole. To bleed the system, constantly refill the reservoir, while pumping out air with the Mityvac, until all air has been removed from the circuit, i.e.

  • Page 84: Rear Drum Brake

    Vespa PX 150 USA 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 85 Vespa PX 150 USA Braking system − After removing the hub, proceed as follows: 1. Remove the shoe spring using the special pliers. 2. Remove the two retainers shown in the figure. 3. Remove the shoes using a lever. 4. Fit the new shoes with the aid of a mallet.
  • Page 86 INDEX OF TOPICS CHAS HASSIS...
  • Page 87 Vespa PX 150 USA Chassis Seat Remove the 3 fasteners shown in the figure. Rear handlebar cover After removing the rear-view mirrors, the attach- ments and their seals, remove the four fasteners shown in the figure, detach the electrical wiring and the odo/speedometer cable to replace the dashboard assembly.
  • Page 88 Vespa PX 150 USA 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 89 Vespa PX 150 USA 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 90: Fuel Tank

    Vespa PX 150 USA 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 91: Front Mudguard

    Vespa PX 150 USA 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 92 Vespa PX 150 USA 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 93 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 94: Electrical System

    Vespa PX 150 USA 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 summarized in pages 1 - 5.

  • Page 95: Functional Inspection

    Vespa PX 150 USA 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 96 INDEX OF TOPICS TIME...
  • Page 97 Vespa PX 150 USA Time Engine ENGINE Code Action Duration 001001 Engine from the frame - removal and refitting 003064 Engine oil - replacement 003057 Engine retainer - Tighten nuts TIME - 97...
  • Page 98 Vespa PX 150 USA 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 - 98...
  • Page 99 Vespa PX 150 USA 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 - 99...

  • Page 100: Fan Cover

    Vespa PX 150 USA Time Flywheel cover FAN COVER Code Action Duration 001087 Flywheel cover - Replacement TIME - 100...
  • Page 101 Vespa PX 150 USA Time Oil pump AUTOMATIC MIXER Code Action Duration 001018 Mixer - Replacement 001028 Oil pump drive shaft - Replacement TIME - 101...

  • Page 102: Kick-Start Lever

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

  • Page 103: Flywheel Magneto

    Vespa PX 150 USA Time Code Action Duration 001017 Starter motor shaft - Replacement Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 001067 Stator - Removal and refitting 001004 Stator - Overhaul 001058 Flywheel - Replacement 001059 Pick-up - Replacement 003052...
  • Page 104 Vespa PX 150 USA Time Carburettor CARBURETTOR Code Action Duration 001063 Carburettor - Replacement 001008 Carburatore - Revisione 003058 Carburettor - Adjustment TIME - 104...

  • Page 105: Exhaust Pipe

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

  • Page 106: Air Cleaner

    Vespa PX 150 USA Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement 001027 Air-cleaner/frame bellow - Replace- ment TIME - 106...
  • Page 107 Vespa PX 150 USA Time Frame FRAME Code Action Duration 004001 Frame - Replacement 006001 Frame - Painting 004023 Shield rim - Replacement TIME - 107...

  • Page 108: Centre-Stand

    Vespa PX 150 USA Time Centre-stand CENTRE-STAND Code Action Duration 004004 Centre-stand - Replacement Legshield spoiler TIME - 108...
  • Page 109 Vespa PX 150 USA Time STEERING COLUMN FAIRING Code Action Duration 004024 Steering column fairing - Replace- ment Side fairings WHEEL SIDE FAIRINGS Code Action Duration 006005 Side fairings - Painting TIME - 109...
  • Page 110 Vespa PX 150 USA Time SIDE FAIRING LOCKS Code Action Duration 004025 Side fairing locks - Replacement Footrests TIME - 110...

  • Page 111: Rear Cover

    Vespa PX 150 USA 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 - 111...

  • Page 112: Front Mudguard

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

  • Page 113: Fuel Level Sensor

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

  • Page 114: Oil Tank

    Vespa PX 150 USA 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 004017 Oil tank - Replacement...

  • Page 115: Rear Shock Absorber

    Vespa PX 150 USA Time Rear shock-absorber REAR SHOCK-ABSORBER Code Action Duration 003007 Rear shock-absorber - Removal and refitting TIME - 115...
  • Page 116 Vespa PX 150 USA 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 TIME - 116...

  • Page 117: Handlebar Components

    Vespa PX 150 USA Time Handlebar components GEAR-SHIFTER TWIST-GRIP Code Action Duration 005062 Neutral switch - Replacement 002071 Left hand grip - Replacement 002037 Brake or clutch lever - Replacement 001035 Clutch lever - Replacement HANDLEBAR COMPONENTS AND BRAKE FLUID PUMP...
  • Page 118 Vespa PX 150 USA Time Code Action Duration 002021 Front brake hose - Removal and re- fitting Seat SEAT Code Action Duration 004003 Saddle - Replacement 004054 Saddle lock catch - Replacement TIME - 118...

  • Page 119: Instrument Panel

    Vespa PX 150 USA 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 120: Turn Signal Lights

    Vespa PX 150 USA Time Turn signal lights HEADLIGHT Code Action Duration 005008 Headlight bulbs - Replacement 005002 Front light - Replacement TIME - 120...
  • Page 121 Vespa PX 150 USA Time TAILLIGHT Code Action Duration 005066 Rear light bulbs - Replacement 005005 Taillight - change 005028 Rear light assembly glass - Replace- ment TURN SIGNAL LIGHTS Code Action Duration 005011 Starter relay - Replacement 005012 Front turn signal light - Replacement...

  • Page 122: Front Wheel

    Vespa PX 150 USA 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 123: Electric Devices

    Vespa PX 150 USA Time Electric devices ECU - CDI Code Action Duration 001023 CPU - Replacement TIME - 123...
  • Page 124 Vespa PX 150 USA Time ELECTRICAL CONNECTIONS Code Action Duration 005001 Electric circuit - Replacement and Refitting TIME - 124...

  • Page 125: Electrical Devices

    Vespa PX 150 USA Time BATTERY - VOLTAGE REGULATOR Code Action Duration 005009 Voltage regulator - Replacement 005007 Battery - Replacement 004071 Battery compartment - Replacement ELECTRICAL DEVICES Code Action Duration 005024 Battery fuse - Replacement 005025 Battery fuse holder - Replacement...
  • Page 126 Vespa PX 150 USA Time ELECTRICAL DEVICES Code Action Duration 005013 Electronic blinker - Replacement 005045 Starter motor wire harness - Re- placement TIME - 126...
  • Page 127 Vespa PX 150 USA Time ELECTRICAL DEVICES Code Action Duration 005003 Horn - Replacement 005017 Stop light switch - Replacement 005069 Left switch - Replacement Transmissions CABLES Code Action Duration 002008 Choke cable - Replacement 002056 Gear shifter cable assy. - Replace-...
  • Page 128 Vespa PX 150 USA 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- ment...

  • Page 129: Brake Callipers

    Vespa PX 150 USA 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 - 129...

  • Page 130: Steering Column

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

  • Page 131: Front Suspension

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

  • Page 132: Rear Brake Pedal

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

  • Page 133: Rear Brake Shoes

    Vespa PX 150 USA Time Code Action Duration 003040 Front wheel bearings - Replacement REAR BRAKE SHOES Code Action Duration 002002 Rear brake shoe(s) - Replacement 003071 Rear brake shoe(s) - Wear check TIME - 133...
  • Page 134 Vespa PX 150 USA Time SHOE PLATE Code Action Duration 002016 Rear brake shoe plate - Replace- ment 003012 Brake shoe plate - Removal and Re- fitting TIME - 134...

  • Page 135: Rear Brake Drum

    Vespa PX 150 USA Time REAR BRAKE DRUM Code Action Duration 002010 Rear brake drum - Replacement 001016 Rear wheel - Replacement 004026 Handlebar cover - Replacement 001071 Rear wheel rim - Removal and refit- ting Clutch cover CLUTCH COVER...
  • Page 136 Vespa PX 150 USA Time CLUTCH Code Action Duration 001022 Clutch - Removal Gear-box GEAR-BOX Code Action Duration 001119 Gearbox components - Replacement 001025 Gearbox - Overhaul TIME - 136...
  • Page 137 Vespa PX 150 USA Time Gear shifter GEAR SHIFTER Code Action Duration 001029 Gear shifter - Overhaul GEAR SHIFTER FASTENERS Code Action Duration 001077 Gear shifter components - Removal and refitting TIME - 137...
  • Page 138 Air filter: 29 Battery: 38, 46 Brake: 81, 82, 84, 85, 129 Brake fluid: Carburettor: 10, 28, 61, 62, 64, 104 Fuel: 62, 90, 113 Fuses: 45 Headlight: 30, 87 Horn: Instrument panel: 119 Maintenance: 7, 24 Shock absorbers: 79 Spark plug: 29 Tank: 90, 113, 114 Transmission: 9...

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