Page 1
Step-by-step assembly
1
Parts in this pack
carburettor and rear brake
1) carburetTor body
2) float chamber
3) rear wheel hub
4) fixing screws
5) rear brake backplate
GS 150
2
stage 17
3
4
5
Page 2
Step-by-step assembly
Press the tab on the oat rmly into the slot in the carburettor body so the assembly looks like this.
Align the carburettor with the engine so you can t the large D-shaped lug into hole A and the smaller lug into hole B.
Take the carburettor body and the oat chamber and align them like this, ready to t them together.
3
5
1 2
4
6
A
B
Page 3
Step-by-step assembly
The assembly should now look like this.
Fit the hub over the rear stub axle, with the slots in it facing outwards.
Now take the rear wheel hub.
You will need to apply some pressure to t the lugs all the way into their holes. To avoid damaging the carburettor, press down on the two marked points only and make sure
both lugs go in at the same time.
10
12
7 8
11
13
9
B
Page 4
Step-by-step assembly
The two lugs on the brake backplate are designed to match up with the slots. Fit the part onto the stub axle.
Slide the backplate all the way onto the axle so the lugs go into the hub, the three holes indicated line up with the holes in the swingarm and the back of the plate is ush with
the face of the swingarm.
Push the hub all the way in, until the outer face of the hub is ush with the
swingarm pivot.
17
19
14
15
18
16
Note the position of the two slots.
Page 5
Step-by-step assembly
20
Only loosely tighten the rst screw, then add screws in the other two holes.
Take the three screws provided and use the tip of the screwdriver to t them into the holes.
When the third screw is in place, go round and tighten all three fully. That completes the assembly for this stage.
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25
24
22
21
Page 6
Step-by-step assembly
1
Parts in this pack
ignition coil and rear hub
1) ignition coil/plug lead
2) fixing screw
3) register screw
4) rear axle retainer
5) coil bracket
GS 150
2
stage 18
3
4
5
Page 7
Step-by-step assembly
Bring the parts together, tting the coil into the back of the bracket and lining up the hole indicated.
Take the ignition coil and its bracket and align them like this.
3
1 2
4
Take the screw provided and use it to fasten the two components together.
5 6 7
Page 8
Step-by-step assemblyStep-by-step assembly
Fit the plug cap on the end of the lead into the hole on top of the shroud over the cylinder head.
The assembly should look like this.
The two pins on the back of the coil bracket are different sizes. Fit them into the matching holes in the engine casing.
Align the coil and plug lead with the engine.
10
8
12
11
9
13
Page 9
Step-by-step assembly
It ts into the hole indicated by the red circle. To provide more access, move the gear selector to the furthest notch.
The assembly should now look like this. Take the small register screw provided.
16
14 15
17
Compress the spring to release the selector pawl, then rotate the selector. You may nd it helpful to use a screwdriver to move it as shown in Step 19.
18 19 20
Step-by-step assembly
Page 10
Step-by-step assembly
Carefully insert the plain end into the hole.
Moving the selector provides a little extra clearance above the hole you will be
working on.
The register screw should now look like this, which completes this stage of the assembly.
Push it all the way into the hole.
Holding the register screw with a pair of long-nosed pliers, line it up with the hole.
23
21
25
24
22
26
Page 11
Step-by-step assembly
1
Parts in this pack
rear wheel
1) fixing screws
2) rear wheel inner rim
GS 150
2
stage 19
Page 12
Step-by-step assemblyStep-by-step assembly
Take the rear wheel rim provided in this pack, plus the rear axle retainer provided with Stage 18. Align the parts like this, matching up the four mounting holes.
Fit the parts together.
2
1
Page 13
Step-by-step assembly
The wheel should now look like this. It will be tted under the rear bodywork, which acts as a mudguard.
8 9
Holding the parts together, start inserting the xing screws provided, but do not tighten them fully yet.
3 4
Continue until you have inserted all four screws, then go round and tighten them all fully.
5 6 7
Step-by-step assembly
Page 14
Step-by-step assembly
1
Parts in this pack
rear wheel
1) rear wheel outer rim
2) fixing screws
GS 150
2
stage 20
Page 15
Step-by-step assembly
Take the two halves of the front wheel and align the xing holes as shown in Step 2.
1 2
This shows the two parts tting together correctly. Note that there is a gap between them and the pins do not go all the way into the recesses.
5 6
Fit the parts together, making sure that all the locating pins on the outer rim go into the holes in the inner rim.
3 4
Page 16
Step-by-step assembly
The ve xing screws provided are used to fasten the parts together.
7 8
When all ve screws are in place, go round again and tighten them fully to complete the wheel assembly.
12 13
9 1110
Keeping the rims together, start inserting the xing screws provided, but do not tighten them fully yet.
Step-by-step assembly
Page 17
Step-by-step assembly
1
Parts in this pack
rear tyre
1) rear tyre
GS 150
stage 21
Page 18
Step-by-step assembly
Take the tyre and the wheel you just assembled. Angle the tyre to t it over the rim. Trying to exert a constant pressure, ease the tyre walls over the circumference of the rim a little at
a time.
1 2
Repeat the process on the other side of the wheel. Then check that the tyre is evenly seated all round by making sure that the inner circles moulded into the rubber are concentric with the
wheel rim. If they aren’t, you can gently bounce the tyre on a at surface to adjust the position.
5 6
As you near the full circle, you may nd it helps to use a at-tipped screwdriver to ease the beads over the rim. Do this gently to avoid damaging the nish of the wheel.
3 4
Page 19
Step-by-step assembly
1
2
4
3
Parts in this pack
headlight assembly
1) headlight glass
2) headlight rim
3) headlight reflector
4) fixing screws
GS 150
stage 22
Page 20
Step-by-step assembly
Start by tting the headlight glass into the rim. With the curved side facing outwards, match up the two square notches (circled in red) and semicircular notches (circled in blue) with the
locating ribs and mounting posts inside the rim.
1 32
Press the glass into the frame as shown, then take the reector. Match up the notches with the locating ribs in the rim, in the same way you did with the lens.
4 65
Test-t the reector, noting how the three holes in the reector line up with the mounting posts on the rim. They will be used to x the headlight shell in place.
7 8
Page 21
Step-by-step assembly
The headlight should look like this.
9 1110
Start driving the screws into the holes. You only need a couple of turns, so the end of the screw doesn’t protrude through the plastic.
12 1413
Continue until all three screws are retained in the reector.
15 16
It can be tricky to insert the very small xing screws in one go, so we suggest you separate the parts, remembering how
they t together, while you start to t the three screws provided.
Page 22
Step-by-step assembly
Take the reector and ret it to the lens and rim in the same way as you did during the test-assembly.
17 18
The complete assembly should look like this. The peak projecting from the rim will t at the top of the headlight, while the hole in the back is used to t the light inside the reector.
22 23
Keeping the reector pressed rmly into the rim, so it ts ush all round, screw all three screws rmly into the mounting posts.
19 2120
Page 23
Step-by-step assembly
1
2
4
6
53
Parts in this pack
right handlebar and brake
1) handlebar fixing screws
2) switch mounting screws
3) cable stop fixing screw
4) switch
5) brake cable retainer
6) right handlebar,
brake lever and cable
GS 150
stage 23
Page 24
Step-by-step assembly
Take the switch and t it on top of the brake lever clamp, lining up the two xing holes circled in red. Make sure the switch is the right way up, with the black switch lever itself pointing
downwards in the direction shown.
1 32
Take the two smallest silver screws from the pack and use them to x the switch to the clamp.
Make sure that the switch is rmly xed to the clamp.
4
7
6
9
5
8
Page 25
Step-by-step assembly
Take the handlebar assembly and the lower handlebar cover from Pack 1. With the brake lever pointing forwards, t the large hole in the handlebar (circled in red) over the matching
post inside the handlebar cover.
10 1211
Lead the brake cable through the two guide just beyond the end of the handlebar (indicated in red in Step 13) and press the end of the black outer sheath into the large channel that
forms a stop in the further of the two guides. Then take the free end of the brake cable down through the oval hole indicated in Step 15.
The cable should run like this.
13
16
15
18
14
17
Now take the two largest black screws provided and use them to secure the handlebar to the cover.
Page 26
Step-by-step assembly
Tighten the screws rmly through both holes, making sure the handlebar is unable to move.
19 2120
With the at side of the cable retainer facing down, t the hole in the round end over the circular lug next to the cable stop. Then take the remaining screw.
Tighten the screw into the hole to x the cable stop to the handlebar cover, securing the end of the brake cable in place and completing this stage of the assembly.
22
25
24
27
23
26
Take the brake cable retainer provided.
Page 27
Step-by-step assembly
1 2 4
6
5
3
Parts in this pack
left handlebar & controls
GS 150
stage 24
7
1) gear selector spring
2) outer gear selector ratchet
3) inner gear selector ratchet
4) clutch Cable retainer
5) clutch/gear selector lever
and cable
6) Fixing screws
7) left handlebar
Page 28
Step-by-step assembly
Take the spring and slip it over the thin end of the handlebar.
1
6
2
7
Slide the spring onto the handlebar until it stops against the thicker portion, then take the inner gear selector ratchet. Slip this over the thin end of the handlebar, with the toothed
side facing outwards.
Slide the inner gear selector ratchet onto the handlebar until it stops against the spring, then take the outer gear selector ratchet, which has two lugs on one end.
3 54
Page 29
Step-by-step assembly
Slip the outer gear selector ratchet over the thin end of the handlebar, with the toothed side facing inwards. Slide it all the way along until the two sets of teeth mesh together.
8 109
Slide the lever along the handlebar until it reaches the outer gear selector ratchet. Rotate the parts so you can engage the lugs on the ratchet with the notches in the end of the lever
clamp as shown in Step 14.
Now take the clutch/gear selector lever and t it over the end of the handlebar, keeping the cable out of the way
.
13 14
11 12
Page 30
Step-by-step assembly
Carefully holding the assembly together, t the end of the handlebar onto the post in the lower handlebar cover as shown in close-up in Step 18.
15 1716
Lead the clutch cable through the guides moulded into the handlebar cover and press the end of the black outer sheath into the stop as indicated in Step 19.
Take the two xing screws provided and use them to x the end of the handlebar to the handlebar cover.
18 19
20 21
Page 31
Step-by-step assembly
Screw the handlebar securely in place.
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27
23
28
After xing the handlebar to the handlebar cover, lead the cable down through the same hole where you placed the brake cable in the previous stage.
Both cables should run in a smooth curve.
24 2625
Page 32
Step-by-step assembly
Take the cable retainer, and with the at side facing down, t the large round hole over the circular lug next to the cable stop.
29 3130
Screw the cable retainer in place with the remaining screw.
That completes this stage. The illustration on the right shows how the assembly appears when the handlebars are in place on the model.
32 33
34 35
Page 33
Step-by-step assembly
1
2
4
6
5
3
parts in this pack
twistgrips
The screw covers (7) are not used until later, so be careful not to lose them.
stage 25
7
1) throttle twistgrip rubber
2) gearchange twistgrip rubber
3) throttle twistgrip
4) gearchange twistgrip
5) throttle twistgip return spring
6) twistgrip end caps
7) screw covers
8) twistgrip retaining screws
8
Page 34
Step-by-step assembly
Identify the shorter of the two twistgrips, which controls the gearchange. One end has two notches that engage with the circled lugs inside the clutch lever clamp. Fit this end over the end
of the lefthand bar.
Press the twistgrip into place so it locks into the clutch lever clamp. Then take one of the large retaining screws provided and screw it into the end of the handlebar.
Tighten the screw to secure the twistgrip but do not overtighten it. It must be free to rotate on the handlebar. Then take the gearchange twistgrip rubber, which is the shorter of the
two grips supplied.
4
7
1
6
9
3
5
8
2
Page 35
Step-by-step assembly
There is a attened rib on the inside of the twistgrip rubber, which must match up with the attened side of the twistgrip in order for it to slide on. This ensures the correct alignment of
the Piaggio logo on the top of the rubber and prevents the rubber from twisting around the grip. Push the rubber all the way up to the handlebar clamp.
Take either of the end caps, which are identical, and push it into the open end of the rubber. Push it all the way in so it snaps into place.
Slip the remaining twistgrip onto the other handlebar, making sure that the large notch at one end is underneath the outer end of the bar as indicated in Step 18.
13
16
10
15
18
12
14
17
11
Page 36
Step-by-step assembly
For clarity, this sequence shows the next step without the twistgrip in place. You need to t the twistgrip return spring over the handlebar and hook the end of the wire that turns inwards
into the small hole at the end of the slot indicated in Step 19. Step 21 shows the spring correctly located.
With the slot in the handlebar exposed by the notch in the twistgrip, follow the sequence above to t the spring over the handlebar and hook the inner end in place. Note the free end
of the spring arrowed in red. This will need to t into the slot arrowed in blue, which is done in Step 26.
Take the remaining large retaining screw and screw it into the end of the handlebar. Tighten the screw to secure the twistgrip, but do not overtighten it.
22
24
19
23
26
21
25
20
Page 37
Step-by-step assembly
Fully tighten the screw, ensuring that the twistgrip is free to rotate on the handlebar, under the control of the return spring, which should bring it back to the start position. Fit the
second twistgrip rubber, which also has a rib to ensure it can only be tted in one position.
Slide the rubber all the way onto the twistgrip, then take the end cap.
Press the cap into the end of the twistgrip until it snaps into place. That completes the assembly
, which now has two working twistgrips and levers.
30
33
27
32
34
29
31
28
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