VESPA PX 125 150 euro 2, PX 125 Euro 3, PX 150 Euro 3 Workshop Manual

WORKSHOP MANUAL

633241

Vespa PX 125 150 Euro 2

WORKSHOP

MANUAL

Vespa PX 125 150 Euro 2

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 sub­agents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the
principles of mechanics and standard procedures required for general vehicle repair. Any relevant changes concerning the vehicle
characteristics or specific repair operations will be divulged in the form of updates to this manual. Satisfactory repair or service
cannot be achieved without the necessary equipment and tools. Refer to the pages of this manual concerning specific tools and
equipment and the special tools catalogue.

N.B.

Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well­ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling
members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.

Vehicle identification

VEHICLE IDENTIFICATION

Specification

Desc./Quantity

Frame prefix (125) VNX2T

Engine prefix (125) VNX1M

Frame prefix (150) VLX1T

Vespa PX 125 150 Euro 2 Characteristics

CHAR - 7

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

Engine

ENGINE

Specification

Desc./Quantity

Engine type 2-stroke with rotary intake timing

Characteristics Vespa PX 125 150 Euro 2

CHAR - 8

Specification Desc./Quantity

No. of cylinders 1
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
Compression ratio (150) 8 : 1

Carburettor Dell'orto SI 20/20 D

Engine idle speed 1900 ± 100 rpm

CO value 3,8 ± 0,5%

Air filter Metallic net soaked in oil-petrol mixture

Starting system Electric starter motor and kick-start

Lubrication Mixture oil

Fuel supply Oil-petrol mixture through carburettor with automatic mixer

(mass flow varying with engine speed) and throttle valve

Clutch Multi-disc.

Cooling Forced air by a centrifugal fan.
Max power output (shaft) 125cc 6 Kw (8 hp) at 5600 rpm
Max power output (shaft) 150cc 6.6 Kw (9 hp) at 5,700 rpm

Max speed (125) 80,7 Km/h
Max speed (150) 82,8 Km/h

Transmission

TRANSMISSION

Specification

Desc./Quantity

Gear-box 4-speed with constantly engaged gears

Capacities

CAPACITIES

Specification

Desc./Quantity

Gear-box ~ 250 cc.

Mixer oil tank ~1.6 litres (including 0.4 l reserve)

Fuel tank ~8 litres (including ~2.1 l reserve)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

1 Ignition type Electronic ignition by capacitive discharge with H.T. coil
2 Spark advance (T.D.C.) 18° ± 1
3 Spark plug CHAMPION RL82C
4 Battery 12V - 9Ah
5 Fuse 7.5 A
6 Generator AC

Frame and suspensions

FRAME AND SUSPENSIONS

Specification

Desc./Quantity

Suspensions Steering column pivoted onto front wheel hub, helicoid spring

suspension and hydraulic shock-absorber (compression and

rebound damping)

Frame Monocoque-type shell obtained from pressed steel

Vespa PX 125 150 Euro 2 Characteristics

CHAR - 9

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

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front tyre 3,50 x 10"
Rear tyre 3,50 x 10"

Rims Pressed steel

Wheels Interchangeable with 2.00"×10" pressed steel rims.
Front tyre pressure 1,3 bar
Rear tyre pressure 1,8 bar

2,3 bar driver and passenger

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU­LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Carburettor

125cc Version

Dell'Orto

CARBURETTOR

Specification

Desc./Quantity

Type SI20/20D

Diffuser diameter 20 mm

Main jet 96/100

Slow running jet 45/100 *

Main air jet 140/100

Throttle valve (type) 6823.09

Emulsifier (code) BE5

Sprayer 280/100

Starter jet 60/100

Air idling screw 1/2 turn

* With idling air hole 140/100

150cc Version

Characteristics Vespa PX 125 150 Euro 2

CHAR - 10

Dell'Orto

CARBURETTOR

Specification Desc./Quantity

Type SI20/20D

Diffuser diameter 20 mm

Main jet 98

Slow running jet 45/160

Main air jet 150

Throttle valve (type) 6823.16.64

Emulsifier (code) BE5

Sprayer 280/100

Starter jet 60/100

Air idling screw 1 3/4

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 ÷ 75

Rim - hub fixing nuts (front-rear) 20 ÷ 27

Shock-absorber - frame fixing nut* 30÷40

Shock-absorber - engine bolt* 13 ÷ 23

Rear wheel axle* 75÷90

FRONT SUSPENSION

Name

Torque in Nm

Shock-absorber mounting plate - steering column fixing nuts 20÷27

Upper shock-absorber fixing nut 30÷40
Lower shock-absorber fixing nut 20÷27

Front wheel axle nut* 60÷100

FRONT BRAKE

Name

Torque in Nm

Reservoir - pipe fitting 8÷12

Pipe - calliper fitting 15÷25

Intermediate pipe fitting 10÷15

Calliper fixing screw* 20÷25

Disc fixing screw* 5÷6
Oil draining screw 10÷12

ENGINE

Name

Torque in Nm

Coils mounting bracket fixing screw 3÷4

Kick-start lever fixing nut 23÷26

Clutch assy. fixing nut 40 ÷ 45

Multi-gear pinion nut 30 ÷ 35

Flywheel fixing nut 60 ÷ 65

Carburettor fixing bolts 16÷20

Clutch cover fixing screws 6÷8

Cylinder head fixing nuts 13÷18

Spark plug 20÷25

Crankcase mating screws 11÷13

Vespa PX 125 150 Euro 2 Characteristics

CHAR - 11

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 ÷ 26

Gear-box trunnion 15 ÷ 18

N.B.

* Safety tightenings

IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE AS­SEMBLY.

NOTICE OF TECHNICAL SERVICING

Tightening torque - riding mirror

This is to inform you that a standard tightening torque has been introduced for the riding mirror fixing
screw: 20 - 25 Nm.

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.

Characteristics Vespa PX 125 150 Euro 2

CHAR - 12

MATING CATEGORIES - 125CC ENGINE

Name Initials Cylinder Piston Play on fitting

Cylinder - piston B 52,505 52,290 0,215
Cylinder - piston C 52,510 52,295 0,215
Cylinder - piston D 52,515 52,300 0,215
Cylinder - piston E 52,520 52,305 0,215
Cylinder - piston F 52,525 52,310 0,215
Cylinder - piston G 52,530 52,315 0,215
Cylinder - piston H 52,535 52,320 0,215

Cylinder - piston (1st

oversize)

C 52,710 52,495 0,215

Cylinder - piston (1st

oversize)

D 52,715 52,500 0,215

Cylinder - piston (1st

oversize)

E 52,720 52,505 0,215

Cylinder - piston (1st

oversize)

F 52,725 52,510 0,215

Cylinder - piston (1st

oversize)

G 52,730 52,515 0,215

Cylinder - piston (2nd

oversize)

C 52,910 52,695 0,215

Cylinder - piston (2nd

oversize)

D 52,915 52,700 0,215

Cylinder - piston (2nd

oversize)

E 52,920 52,705 0,215

Cylinder - piston (2nd

oversize)

F 52,925 52,710 0,215

Cylinder - piston (2nd

oversize)

G 52,930 52,715 0,215

Cylinder - piston (3rd

oversize)

C 53,110 52,895 0,215

Cylinder - piston (3rd

oversize)

D 53,115 52,900 0,215

Cylinder - piston (3rd

oversize)

E 53,120 52,905 0,215

Cylinder - piston (3rd

oversize)

F 53,125 52,910 0,215

Cylinder - piston (3rd

oversize)

G 53,130 52,915 0,215

Vespa PX 125 150 Euro 2 Characteristics

CHAR - 13

MATING CATEGORIES - 150CC ENGINE

Name

Initials Cylinder Piston Play on fitting

Cylinder - piston B 57,795 57,555 0,240
Cylinder - piston C 57,800 57,650 0,240
Cylinder - piston D 57,805 57,565 0,240
Cylinder - piston E 57,810 57,570 0,240
Cylinder - piston F 57,815 57,575 0,240
Cylinder - piston G 57,820 57,580 0,240
Cylinder - piston H 57,825 57,585 0,240

Cylinder - piston (1st

oversize)

C 58,000 57,760 0,240

Cylinder - piston (1st

oversize)

D 58,005 57,765 0,240

Cylinder - piston (1st

oversize)

E 58,010 57,770 0,240

Cylinder - piston (1st

oversize)

F 58,015 57,775 0,240

Cylinder - piston (1st

oversize)

G 58,020 57,780 0,240

Cylinder - piston (2nd

oversize)

C 58,200 57,960 0,240

Cylinder - piston (2nd

oversize)

D 58,205 57,965 0,240

Cylinder - piston (2nd

oversize)

E 58,210 57,970 0,240

Cylinder - piston (2nd

oversize)

F 58,215 57,975 0,240

Cylinder - piston (2nd

oversize)

G 58,220 57,980 0,240

Cylinder - piston (3rd

oversize)

C 58,400 58,160 0,240

Cylinder - piston (3rd

oversize)

D 58,405 58,165 0,240

Cylinder - piston (3rd

oversize)

E 58,410 58,170 0,240

Cylinder - piston (3rd

oversize)

F 58,415 58,175 0,240

Characteristics Vespa PX 125 150 Euro 2

CHAR - 14

Name Initials Cylinder Piston Play on fitting

Cylinder - piston (3rd

oversize)

G 58,420 58,180 0,240

Piston rings

PISTON RINGS - 125CC ENGINE

Name Description Dimensions Initials Quantity

Piston ring 52,5 A 0,2 ÷ 0,35

Piston ring (1st over-

size)

52,7 A 0,2 ÷ 0,35

Piston ring (2nd over-

size)

52,9 A 0,2 ÷ 0,35

Piston ring (3rd over-

size)

53,1 A 0,2 ÷ 0,35

PISTON RINGS - 150CC ENGINE

Name

Description Dimensions Initials Quantity

Piston ring 57,8 A 0,2 ÷ 0,4

Piston ring (1st over-

size)

58 A 0,2 ÷ 0,4

Piston ring (2nd over-

size)

58,2 A 0,2 ÷ 0,4

Piston ring (3rd over-

size)

58,4 A 0,2 ÷ 0,4

Vespa PX 125 150 Euro 2 Characteristics

CHAR - 15

Crankcase - crankshaft - connecting rod

CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE «E» BETWEEN BIG END

AND HALF CRANKSHAFT ON FLYWHEEL-SIDE

Name

Description Dimensions Initials Quantity

Connecting Rod A= 15,4 +0 -0,05 E 0,15 ÷ 0,46

Washer (2) G= 0,5 +0,05 -0,03 E 0,15 ÷ 0,46

Half-crankshaft clutch-

side

C= 11,1 -0 +0,05 E 0,15 ÷ 0,46

Half-crankshaft fly-

wheel-side

D= 11,1 -0 +0,05 E 0,15 ÷ 0,46

Spacer tool H= 38,95

CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE «F» BETWEEN BIG END

ROLLER CAGE AND HALF CRANKSHAFT ON FLYWHEEL-SIDE

Name

Description Dimensions Initials Quantity

Connecting Rod B= 15,6 -0,1 -0,2 F 0,05 ÷ 0,41

Washer (2) G= 0,5 +0,05 -0,03 F 0,05 ÷ 0,41

Half-crankshaft clutch-

side

C= 11,1 -0 +0,05 F 0,05 ÷ 0,41

Half-crankshaft fly-

wheel-side

D= 11,1 -0 +0,05 F 0,05 ÷ 0,41

Spacer tool H= 38,95

− Connecting rods and roller cages are subdivided into 4 categories (indicated by markings on big end
and outer cage rim, respectively)

− Mate connecting rod with cage of same category; if such assembly results to be excessively noisy,
use a roller cage from next category.

− For the wrist pin, fitted with 0 clearance, the maximum allowable play after use must be 0.02 mm.

Characteristics Vespa PX 125 150 Euro 2

CHAR - 16

− The maximum allowable end-play for the connecting rod after use (intended as the longitudinal slide
on the big end) is 0.7mm.

Gearbox shoulders

GEARBOX SHOULDERS

Name Description Dimensions Initials Quantity

Shoulder 2,05 +0 -0,06 A 0,15 ÷ 0,40

Shoulder (1st oversize) 2,20 +0 -0,06 A 0,15 ÷ 0,40
Shoulder (2nd oversize) 2,35 +0 -0,06 A 0,15 ÷ 0,40
Shoulder (3rd oversize) 2,50 +0 -0,06 A 0,15 ÷ 0,40
Shoulder (4th oversize) 2,65 +0 -0,06 A 0,15 ÷ 0,40

N.B.

IF THE SPECIFIED CLEARANCE «A» CANNOT BE ACHIEVED, REPLACE THE SHOULDER RING
WITH AN OVERSIZED ONE SUCH TO ALLOW OBTAINING THE PRESCRIBED PLAY. TO CHECK
THE CLEARANCE, USE A FEELER GAUGE.

Products

TABLE OF RECOMMENDED PRODUCTS

Product

Description Specifications

AGIP GEAR 80W-90 gearbox oil SAE 80W-90 oil complying with API GL4

specifications

AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions

(brake, throttle control and mixer, odom-

eter)

Oil for 2-stroke engines: SAE 5W-40, API

SL, ACEA A3, JASO MA

AGIP GP 330 Grease (brake level, throttle twistgrip,

gaer)

Calcium complex soap grease NLGI 2;

ISO-L-XBCIB2

AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO

FC, ISO-L-EGD

AGIP GREASE MU3 Grease for odometer transmission gear

case

Soap-based lithium grease with NLGI 3;

ISO-L-XBCHA3, DIN K3K-20

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

Vespa PX 125 150 Euro 2 Characteristics

CHAR - 17

INDEX OF TOPICS

TOOLING TOOL

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 Exhaust gases analyser

Vespa PX 125 150 Euro 2 Tooling

TOOL - 19

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

Tooling Vespa PX 125 150 Euro 2

TOOL - 20

Stores code Description

020333Y Single battery charger

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

001330Y Tool for fitting steering seats

Vespa PX 125 150 Euro 2 Tooling

TOOL - 21

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

Tooling Vespa PX 125 150 Euro 2

TOOL - 22

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

Vespa PX 125 150 Euro 2 Tooling

TOOL - 23

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

Tooling Vespa PX 125 150 Euro 2

TOOL - 24

INDEX OF TOPICS

MAINTENANCE MAIN

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
Brake and clutch lever - greasing
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test

AT 5000 KM OR 12 MONTHS

Action

Gear-box oil level - check
Spark plug - replacement
Air filter on carburetor - Clean
Transmission gas mixer- adjust
Brake and clutch lever - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyres condition and wear - Check
Vehicle and brake test - road test
Secondary air filter (external / internal) - Clean

AT 10000 KM O 24 MONTHS

Action

Gear-box oil level - replacement
Spark plug - replacement
Air filter on carburetor - Clean
Idle speed (*) - adjustment
Transmission gas mixer- adjust
Odometer gear - greasing
Steering - adjustment
Brake and clutch lever - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment check
Tyres condition and wear - Check
Vehicle and brake test - road test

(*) See regulations in section «Idling speed adjustement»

AT 15000 KM OR 36 MONTHS

Action

Gear-box oil level - check
Spark plug - replacement
Air filter on carburetor - Clean
Transmission gas mixer- adjust
Brake and clutch lever - greasing

Maintenance Vespa PX 125 150 Euro 2

MAIN - 26

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

AT 20000 KM

Action

Gear-box oil level - replacement
Spark plug - replacement
Air filter on carburetor - Clean
Idle speed (*) - adjustment
Cylinder cooling system - check/cleaning
Transmission gas mixer- adjust
Odometer gear - greasing
Steering - adjustment
Brake and clutch lever - greasing
Brake pads - check condition and wear
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
Secondary air filter (external / internal) - Clean

(*) See regulations in section «Idling speed adjustement»

AT 25000 KM

Action

Gear-box oil level - check
Spark plug - replacement
Air filter on carburetor - Clean
Transmission gas mixer- adjust
Brake and clutch lever - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyres condition and wear - Check
Vehicle and brake test - road test
Secondary air filter (external / internal) - Clean

AT 30000 KM

Action

Gear-box oil level - replacement
Spark plug - replacement
Air filter on carburetor - Clean
Idle speed (*) - adjustment
Transmission gas mixer- adjust
Odometer gear - greasing
Steering - adjustment
Brake and clutch lever - greasing
Brake pads - check condition and wear
Flexible brake lines - Change
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment check
Tyres condition and wear - Check
Vehicle and brake test - road test

Vespa PX 125 150 Euro 2 Maintenance

MAIN - 27

(*) 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
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

AT 40000 KM

Action

Gear-box oil level - replacement
Spark plug - replacement
Air filter on carburetor - Clean
Idle speed (*) - adjustment
Cylinder cooling system - check/cleaning
Transmission gas mixer- adjust
Odometer gear - greasing
Steering - adjustment
Brake and clutch lever - greasing
Brake pads - check condition and wear
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
Secondary air filter (external / internal) - Clean

(*) See regulations in section «Idling speed adjustement»

AT 45000 KM

Action

Gear-box oil level - check
Spark plug - replacement
Air filter on carburetor - Clean
Transmission gas mixer- adjust
Brake and clutch lever - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyres condition and wear - Check
Vehicle and brake test - road test
Secondary air filter (external / internal) - Clean

AT 50000 KM

Action

Gear-box oil level - replacement
Spark plug - replacement
Air filter on carburetor - Clean
Idle speed (*) - adjustment
Transmission gas mixer- adjust
Odometer gear - greasing
Steering - adjustment
Brake and clutch lever - greasing
Brake pads - check condition and wear

Maintenance Vespa PX 125 150 Euro 2

MAIN - 28

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»

AT 55000 KM

Action

Gear-box oil level - check
Spark plug - replacement
Air filter on carburetor - Clean
Transmission gas mixer- adjust
Brake and clutch lever - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyres condition and wear - Check
Vehicle and brake test - road test
Secondary air filter (external / internal) - Clean

AT 60000 KM

Action

Gear-box oil level - replacement
Spark plug - replacement
Air filter on carburetor - Clean
Idle speed (*) - adjustment
Cylinder cooling system - check/cleaning
Transmission gas mixer- adjust
Odometer gear - greasing
Steering - adjustment
Brake and clutch lever - greasing
Brake pads - check condition and wear
Flexible brake lines - Change
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment check
Tyres condition and wear - Check
Vehicle and brake test - road test
Secondary air filter (external / internal) - Clean

(*) See regulations in section «Idling speed adjustement»

Vespa PX 125 150 Euro 2 Maintenance

MAIN - 29

Carburettor

Disassemble the carburettor and clean all compo­nents 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; replace if excessive play is
found.

− If the mixture chamber is excessively worn, such
to prevent the sliding of the throttle valve (although
new), replace the carburettor.

− All seals should be replaced upon reassembly.

CARBURETTOR

Specification

Desc./Quantity

Conical needle

Float

Emulsifier air adjusting screw

Emulsifier

Main jet

Slow-running jet

Fuel flow adjusting screw

Throttle valve adjusting screw

Throttle valve

Starter jet

Choke device

Checking the spark advance

In order to ensure the correct timing, check the
stator is oriented so that the I.T. index (see figure)
coincides with the marking found on the crank­case.

− To check the timing, use a timing light, connect­ing it to the H.T. cable via the clip provided and
then starting the engine.

− The correct spark advance is obtained when,
with the engine running between 2,500 and 3,000
rpm, the «P» index is aligned (±1°) with the I.T.
marking stamped on the volute.

Maintenance Vespa PX 125 150 Euro 2

MAIN - 30

− In the impossibility of obtaining the specified val­ues, or if the engine is found to be running rough,
proceed by replacing defective components.

Specific tooling

020330Y Stroboscopic light to check timing
020332Y Digital rev counter

Spark plug

− Detach the spark plug cap

− Carefully inspect the spark plug and replace it if

the insulator is damaged

− Using a feeler gauge, measure the spark gap,
and adjust it if necessary

− Ensure the sealing washer is in good state

− Refit the spark plug by screwing it in by hand,

and tightening it at the prescribed torque using a
box spanner

Electric characteristic

Spark plug

CHAMPION RL82C

Spark gap

0,5 ÷ 0,6 mm

Locking torques (N*m)

Spark plug 25 - 30 Nm

Air filter

− Remove the engine cowling and the air-box cov­er by loosening the four fixing screws shown in the
figure and the idle adjusting screw; hence release
the filter.

− Clean the filter with 50% fuel-oil mixture, hence
dry it with compressed air.

Recommended products

AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISO­L-EGD

Vespa PX 125 150 Euro 2 Maintenance

MAIN - 31

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;

2. Turn on the headlight and check that the bor­derline of the projected light beam on the screen
is not lower than 9/10 of the distance from the
ground to the centre of vehicle headlamp and high­er than 7/10;

3. If otherwise, adjust the right headlight with screw
«A».

N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINI­MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU­TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.

CO check

The test must be carried out after carefully clean­ing all carburettor components and air filter, and
with the spark plug in good conditions.

− Warm up the engine by riding the vehicle for at
least ten minutes

− Switch off the engine

− Remove the 2 secondary air box screws shown

in the figure

− Place a plastic sheet between the one-way valve
and the aluminium outlet as shown in the figure

Maintenance Vespa PX 125 150 Euro 2

MAIN - 32

− 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.

− Attach the special tool and orientate the connec­tors as shown in the figure.

− Start the engine, adjust the idle speed to 1,300
±100 rpm and check the CO readings are equal to
4±1% with the idle air adjusting screw opened by
2+¾ turns.

− If the parameters here specified cannot be met,
try adjusting the idle air adjusting screw. Other­wise, check the choke device.

Specific tooling

020320Y Exhaust gases analyser
020332Y Digital rev counter
020625Y Kit for sampling gas from the exhaust

manifold

Vespa PX 125 150 Euro 2 Maintenance

MAIN - 33

SAS filters inspection and cleaning

Remove the two screws «A» from the SAS alumi­nium 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. Dry the filter with compressed
air before refitting, having care to place the plate
in the grooving machined onto the plastic and alu­minium covers. Upon reassembly, always replace
the O-ring, located on the cover.

Remove the sponge and wash it with soap and
water. Dry it with compressed air before refitting.

Gearbox Oil

− Check for the presence of oil inside the gearbox
(oil capacity ~250 g); with the vehicle axis perfectly
vertical, the oil level must be at the height of in­spection hole «A».

− To replace the oil, drain the box using filler hole
«B».

− Pour some fresh oil and let the engine run for a
few seconds, hence drain the box again.

− Pour 250 g of fresh oil through hole «A», so that
the level reaches the reference height.

Recommended products

AGIP GEAR 80W-90 gearbox oil

SAE 80W-90 oil complying with API GL4 specifi­cations

Maintenance Vespa PX 125 150 Euro 2

MAIN - 34

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

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

ELECTRICAL SYSTEM

Specification

Desc./Quantity

1 Front LHS turn signal light
2 Key switch
3 Enable button
4 Indicators switch
5 Front headlight
6 Instrument panel lighting bulb 12V-1,2W
7 Turn signal warning light 12V - 1,2W
8 Reserve fuel light 12V-1,2W
9 Headlamp warning light 12V - 1,2W
10 High-beam warning light 12V - 1.2W
11 Instrument panel
12 Headlight switch
13 Start up button
14 Horn
15 Stop light switch (front brake)

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 36

Specification Desc./Quantity

16 Front RHS turn signal light
17 Rear brake stop button
18 Anti-repeating device
19 Fuel level sender
20 Magneto flywheel
21 Electronic ignition device
22 Rear RHS turn signal light
23 Starter motor
24 Taillight
25 Starter relay
26 Rear LHS turn signal light
27 Battery 12V - 9Ah
28 Fuse box
29 Voltage regulator
30 Turn signals master-box

Components arrangement

Vespa PX 125 150 Euro 2 Electrical system

ELE SYS - 37

COMPONENTS ARRANGEMENT

Specification Desc./Quantity

1 Key switch
2 Voltage regulator
3 Electronic Control Unit (C.D.I.) with H.T coil
4 Battery 12V - 9Ah
5 Starter motor
6 Magneto flywheel
7 Anti-repeating device
8 Spark plug
9 Remote starter switch
10 Fuse 7.5 A
11 Horn
12 Turn signals master-box
13 Front headlight
14 Front turn signal lights
15 Taillight
16 Rear turn signal lights

Conceptual diagrams

Ignition

IGNITION

Specification

Desc./Quantity

1 Magneto flywheel
2 Key switch contacts
3 Electronic Control Unit (C.D.I.) with H.T coil
4 Spark plug

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 38

Headlights and automatic starter section

LIGHTS

Specification

Desc./Quantity

1 Voltage regulator
2 Magneto flywheel
3 Key switch contacts
4 Headlight bulb 12V-35/35W
5 High-beam warning light 12V - 1.2W
6 Light switch
7 Headlight switch
8 Rear side light bulb 12V - 5W
9 Front side light bulb 12V - 5W
10 Headlamp warning light 12V - 1,2W

Vespa PX 125 150 Euro 2 Electrical system

ELE SYS - 39

Battery recharge and starting

BATTERY RECHARGE AND STARTING

Specification

Desc./Quantity

1 Magneto flywheel
2 To services
3 Key switch contacts
4 Voltage regulator
5 Fuse 7.5 A
6 Remote starter switch
7 Starter motor
8 Battery 12V - 9Ah
9 Enable button
10 Start up button
11 Anti-repeating device

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 40

Level indicators and enable signals section

SAFETY SWITCHES AND LEVEL GAUGES

Specification

Desc./Quantity

1 Fuel gauge
2 Fuel level sender
3 Reserve fuel light 12V-1,2W
4 Brake light bulbs 12V-10W
5 Stoplight switches
6 Voltage regulator

Vespa PX 125 150 Euro 2 Electrical system

ELE SYS - 41

Turn signal lights

SIGNAL LIGHTS AND HORN

Specification

Desc./Quantity

1 Turn signals master-box
2 Indicators switch
3 Turn signal warning light 12V - 1,2W
4 Turn signal light bulbs 12V - 21W
5 Horn button
6 Horn
7 Voltage regulator

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 42

Instruments and warning lights control board

DASHBOARD LIGHTS AND GAUGES

Specification

Desc./Quantity

1 + Battery
2 Fuel gauge
3 Low fuel warning light
4 Turn signals warning light
5 High-beam warning light
6 Side-lamps warning light
7 Ground lead (-)

Checks and inspections

Ignition circuit

All system checks requiring the detachment of ca­bles (inspections involving ignition system wiring
and devices) must be carried out with the engine
off, so to avoid any possible damage to the ECU,
which would require its replacement.
It is therefore important to follow the wire colour
coding when reattaching the cables (see figure)

Vespa PX 125 150 Euro 2 Electrical system

ELE SYS - 43

IGNITION CIRCUIT

Specification Desc./Quantity

1 WHITE
2 RED
3 GREEN
4 GREEN

Stator check

In the event of a malfunctioning of the ignition sys­tem, with no evident cause, it will be necessary to
replace the ECU.

− Remember that all wires can only be detached
with the engine off.

− If the ignition system is found to be working prop­erly once the new ECU has been fitted, then the
cause of the problem is obviously to be attributed
to a defective CDI device.

− In the event that the ignition system is still mal­functioning, it will be necessary to check the gen­erator and the stator components, as follows:
After an eye inspection of the connections, per­form measurements on recharge coil and pick-up
(see table) using the specified tester. If such read­ings do not match the stated values, proceed by
replacing the stator and its components.

Specific tooling

020331Y Digital multimeter

STATOR CHECK

Specification

Desc./Quantity

1 RED - WHITE wire 90 ÷ 140 ohm
2 GREEN - WHITE wire 800 ÷ 1100 ohm

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 44

Voltage regulator check

Voltage regulator inspection
In the event of a suspected failure of the voltage
regulator, carry out the following inspections:

Alternate current section

The failure of the alternate current section of the
voltage regulator give rise, depending on the type
of fault, to the following inconveniences:

1. Blown light bulbs (regulator open-circuited).

2. Failure of the lighting system and automatic
choke device (regulator short-circuited).

Interventions
FAULT 1

At 5,000 rpm with the lights on, check the regulator
voltage is between 12.3V and 14.5V. At 5,000
rpm with the lights on, check the regulator voltage
is between 13V and 15V. In the presence of a reg­ulator voltage exceeding 15V, replace the regula­tor as definitely faulty.

FAULT 2

a) Check the correct current supply from the alter­nator: detach the regulator connector and attach
the alternate current tester between the grey-blue
wire terminal and earth. With the tester set onto
alternate current, check the supplied voltage at
3,000 rpm is between 25 and 30V.
b) If no faults are found, replace the voltage regu­lator.
c) If the system is still malfunctioning after the reg­ulator has been replaced, check the connections
of the electrical system.
Direct current section The failure of the regulator's
direct current section may cause, depending on
the type of failure, the following inconveniences:

3) Blown fuse (regulator short-circuited), resulting
in the catastrophic failure of the battery charging
system.

Vespa PX 125 150 Euro 2 Electrical system

ELE SYS - 45

4) Battery recharge faulty (regulator open-circuit­ed).

Interventions
FAULT 3

Replace the regulator, as certainly faulty, and the
fuse.

FAULT 4

a) Attach an ammeter between the voltage regu­lator and the battery, and check that, at 3,000
rpm and with the battery at 13V, the current sup­plied is approximately 1.5 to 2 A.
If the measured values are below this limit, then
replace the voltage regulator.
b) If replacing the regulator does not solve the
problem, check, using the recommended tester,
for peaks in the alternate currents between the
yellow wire connection and the red wire departing
from the positive battery pole. The voltage sup­plied by the generator must be between 26 and
30V, at 3,000 rpm (this measurement must obvi­ously be carried out with the battery disconnec­ted).

Specific tooling

020331Y Digital multimeter

Starter motor

Bench tests to be performed on the electric starter motor

1) No-load test: the starter motor, unloaded, must absorb less than 10 A with a voltage supply > 11.7
V and must spin at more than 18,000 rpm.

2) Load test: load the starter motor so that the absorbed current is equal to 40 A, and the supplied
voltage is 10 V. In such conditions, the output torque provided must 0.014 Nm, at a speed of no less
than 10,000 rpm.

3) Breakaway test: with the rotor restrained and supplied voltage of 7 V, the absorbed current must not
be higher than 100 A and the torque not less than 0.033 Nm.

N.B.

ALL THESE CHARACTERISTICS MUST BE MEASURED WITH CHARGED BATTERY AND AFTER
RUNNING THE MOTOR FOR 30" IN THE CONDITIONS STATED IN 1.

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 46

STARTER MOTOR

Specification

Desc./Quantity

1 Nominal voltage 12V
2 Nominal power 0,15 kW
3 Direction of rotation Clockwise
4 Engine connection Via pinion and gear ring on crankshaft, transmission-side
5 Control Pushbutton
6 Battery 12V - 9Ah

Fuses

The starter system and horn are protected by a

7.5A fuse, «A», located on the LHS of the battery
tray. Before replacing a burst fuse, it is necessary
to find the cause of the failure. Never attempt to
close the circuit with any material other than the
fuse.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE
THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).

CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS­TEM, PERFORMED INCORRECTLY OR WITHOUT STRICT

Vespa PX 125 150 Euro 2 Electrical system

ELE SYS - 47

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.

- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an am­bient temperature not below 15°C, until it reaches the upper level indicated on the block.

- Tilt the battery slightly to remove any air bubbles formed during filling.

- Place the caps on each single cell filling hole without screwing them and leave the battery to rest.
During this stage, the battery is subjected to a gasification phenomenon and temperature increases.

- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).

- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level
using the same filling electrolyte
Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled
water;

- Before 24 hours elapse, recharge the battery following these steps:

- Connect the battery charger terminals observing the correct polarity;

- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by
selecting the position corresponding to that capacity;

- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with
a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge.
Note: Batteries that have been stored for a long time may take a longer charging time. The battery
chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge
after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the
activation of the safety system and not the end of the charge.

- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a
standard tester.

- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake
or tilt the battery to eliminate any air bubbles formed during recharging.

- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary,
clean battery properly, close each single cell cap tightly and install it on the vehicle.

- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.

Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the
Check function. The value indicated on the display must be higher than the value indicated on the chart;

otherwise, recharge the battery again in the same way indicated above.

Electrical system Vespa PX 125 150 Euro 2

ELE SYS - 48

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

− Remove the two fasteners, exhaust pipe-mani­fold and then the bolt fixing the exhaust to the
engine.

Removal of the engine from the vehicle

− Remove the exhaust assy.

− Remove the rear wheel.

− Detach the rear brake cable.

− Detach the electrical wires.

− Detach the gear shifter cables.

− Remove the throttle and choke cables.

− Detach the oil and petrol hoses.

− Remove the engine-frame bolt shown in the fig-

ure.

Engine from vehicle Vespa PX 125 150 Euro 2

ENG VE - 50

− Remove the rear shock-absorber fixing nut and
hence the bolt.

− For the reassembly, follow the above operations
in reverse order, using the prescribed tightening
torques.

CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSI-

TIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING

Wear safety goggles when using hitting tools.

WARNING
Be very careful when handling fuel.

Locking torques (N*m)

Engine - frame bolt * 61 ÷ 75 Shock-absorber ­engine bolt* 13 ÷ 23

Vespa PX 125 150 Euro 2 Engine from vehicle

ENG VE - 51

INDEX OF TOPICS

ENGINE ENG

Flywheel cover

Cooling hood

− Remove the three fixing screws shown in the
figure and the cooling hood.

− Remove the fixing screws shown and hence de­tach the volute and the gear shifter cover.

− Remove the kick-start lever after having detach­ed the lower fastener.

Removing the stator

− Remove the three screws shown in the figure.

− Remove the stator.

Vespa PX 125 150 Euro 2 Engine

ENG - 53

Refitting the stator

In order to guarantee the correct engine timing pay
attention to the position of the stator, as shown in
the figure.

Flywheel and starting

Removing the starter motor

− Remove the two screws and detach the drive box
from the starter motor.

− With the aid of a hacksaw, abrade the pinion
head ring.

− Using two screwdrivers, detach the cap.

− Remove the retaining ring shown by the arrow in

the figure and remove the pinion components.

WARNING
THE PACKING ON THE MATING SURFACE MUST AL-

WAYS BE REPLACED WITH A NEW ONE, USING «LOC­TITE».

Engine Vespa PX 125 150 Euro 2

ENG - 54

− Using pliers for internal split rings, remove the
retaining ring shown.

− Lift the assembly by the end of the shaft and re­move 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.
This will also result in the removal of the drive gear.

− In the event that the bearing remains on drive
gear, use the special extractor.

− After heating the drive gear with the air heater,
refit the drive shaft with all the components previ­ously removed.

− Refit the remaining components following the
above operations in the reverse order.

Specific tooling

001467Y Extractor for bearings for holes
001467Y021 Extraction pliers for ø 11 mm bear-

ings
020151Y Air heater
020150Y Air heater support

− Position a new cap onto the pinion and round the
edges using the special tool to safely lock the as­sembly in a vice.

− Rotate the assembly by a quarter turn and pro­ceed by rounding the remaining section of the caps
circumference.

Specific tooling

020057Y Calking tool

Vespa PX 125 150 Euro 2 Engine

ENG - 55

− After removing the rear cover, release the brush
clips connected to the magnetic fields.

− Remove the brush plate. Detach the old brushes
and weld a new set of brushes, hence replace the
brush plate.

− After removing the rear cover, detach the drive
gear retaining pin and remove the gear.

− Refit the assembly components in the reverse
order.

Removing the flywheel magneto

− Retain the flywheel using the special tool, hence
remove the lock nut.

Specific tooling

020095Y Flywheel retaining tool

− Remove the flywheel retaining tool.

− Extract the flywheel using the special extractor.

Specific tooling

008564Y Flywheel extractor

Engine Vespa PX 125 150 Euro 2

ENG - 56

Refitting the flywheel magneto

− Refit the components following above opera­tions in the reverse order.

− After refitting the flywheel, apply grease on the
thread.

Recommended products

AGIP GREASE PV2 Grease for steering bear­ings, bolt seatings for swinging arms and fay­ing surface of driven pulley spring (only pulley
side)

Soap-based lithium and zinc oxide grease con­taining NLGI 2; ISO-L-XBCIB2

Locking torques (N*m)

Flywheel fixing nut 60 ÷ 65

Cylinder assy. and timing system

Removing the cylinder head

− Loosen the four nuts and remove the cylinder
head.

Removing the cylinder - piston assy.

After removing the cylinder detach the wrist pin re­taining rings and hence remove the piston.

Vespa PX 125 150 Euro 2 Engine

ENG - 57

Inspecting the small end

− Always fit a roller cage of the type prescribed in
the assembly clearance tables.

− The arrow in the figure shows the location of the
connecting rod's identification marking.

Refitting the cylinder

− Refit the cylinder assembly components following the removal procedure in the reverse order, paying
particular attention to positioning the piston with the arrow marking on the crown pointing toward the
exhaust port.

Locking torques (N*m)

Head fixing nuts 16 ÷ 26

Crankcase - crankshaft

Splitting the crankcase halves

− Remove the twelve fasteners and split the two
crankcase halves carefully using a plastic or hard
rubber mallet.

CAUTION
WITH A RUBBER BAND TIE THE CONNECTING ROD TO

THE TWO STUDS ON THE CLUTCH-SIDE, SO TO AVOID
ANY ACCIDENTAL DAMAGE DURING THIS PHASE AND
THE FOLLOWING ONES.

Engine Vespa PX 125 150 Euro 2

ENG - 58

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 inter­nal split rings, remove the bearing retaining ring
shown.

− From the side opposite that shown in the figure
and with the aid of a flat head puncher, extract the
bearing.

− Using the special extractor, remove the roller
bearing from the crankshaft.

Specific tooling

004499Y Camshaft bearing extractor

− Using the special extractor, remove the roller
bearing from the crankcase.

Vespa PX 125 150 Euro 2 Engine

ENG - 59

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 bear­ing's outer ring.

− Position the bearing's retaining ring, hence pro­ceed by refitting the sealing ring.

Specific tooling

020151Y Air heater
020150Y Air heater support

− Heat up the crankcase, as already done for the
clutch-side half-crankcase, focusing exclusively
on the bearing housing.

− Position the bearing using a length of tube push­ing directly on the bearing's outer ring.

− Position the crankshaft onto the special support.

− Install the special spacer as shown in the figure

and, using a length of tube of adequate diameter,
push the bearing until the inner ring (heated up in
oil at 120°C) comes into contact with the spacer.

− Once the assembly is completed, remove the
spacer.

Specific tooling

020265Y Bearing fitting base
060007Y Crankcase bearing spacer

Engine Vespa PX 125 150 Euro 2

ENG - 60

Lubrication

Conceptual diagrams

Automatic fuel mixer

The system is fed by oil contained in a separate tank.
The vehicle is equipped with two distinct tanks, each with individual hoses, for fuel and lubricant.
The fuel tank must be filled with petrol, no petrol-oil mixture of any kind, while for the lubricant tank
Selenia Hi Scooter 2T oil should be used. The oil level may be checked through the transparent tube
(see figure, 3) protruding from the tank.
Fuel is fed to the carburettor by gravity; oil is supplied through pump «p» whose stroke is controlled by
the radial position of a shoe, on the inclined plane of the pump, driven by the throttle cable via a lever.
This means that for any given position of the throttle twist-grip the location of the shoe varies, thus
varying the pump stroke hence suggesting that the oil mass flow is a function of both engine speed and
throttle opening.
Important: whenever the mixer device has been removed, overhauled or refitted, there may be no oil
inside the ducts.
To allow the mixer to safely fill these ducts with oil, it is suggested that the fuel tank (1 in the figure) is
first refilled with approx. 3 l of mixture containing 2% of SELENIA HI SCOOTER 2T oil. Once this first
quantitative has been exhausted, any further refill must obviously consist of petrol only. The pump
assembly constitutes, essentially, of a pumping element and its sliding housing, and is driven by a gear
transmission (crankshaft/mixer shaft ratio: 1/85). The pumping element "P" is also provided, on its shaft,
with a flatten surface which, because of the rotation, alternately opens and closes the oil inlet (5) and
outlet (6) ducts, with the latter being equipped with a valve consisting of a sphere and spring. By such
means the pump alternately performs the two phases of oil intake (A in the figure) and supply to the
fuel diffuser (8 in the figure), where the fuel mixture is formed and fed into the engine.

Vespa PX 125 150 Euro 2 Engine

ENG - 61

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

A Inlet phase
B Outlet phase

Oil pump

− Remove the carburettor box.

− Remove the mixer drive shaft from its housing.

Engine Vespa PX 125 150 Euro 2

ENG - 62

− Remove the 3 fixing screws and the mixer cover
with the lever.

− Remove the mixer pumping element.

− Remove the mixer fixing screw and then use pli-

ers for internal split rings to remove the mixer
body.

− Refit the components following the removal pro­cedure in the reverse order, paying attention in
positioning the pump body correctly in its housing,
so to be able to easily insert the retaining screw.

See also

Removing the

carburettor

Vespa PX 125 150 Euro 2 Engine

ENG - 63

Fuel supply

Removing the carburettor

− Remove the two fixing screws and the carburet­tor cover.

− Remove the fasteners and the air filter.

− After removing the air filter, loosen the two 8mm

Allen screws and hence remove the carburettor.

− Loosen the fixing screw and remove the carbu­rettor body.

Engine Vespa PX 125 150 Euro 2

ENG - 64

− 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 com­pressed air.

− Remove the float pin to release the float, and
hence the conical needle.

Vespa PX 125 150 Euro 2 Engine

ENG - 65

− 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.

From the side opposite to that shown in the figure
and with the aid of a puncher, remove the conical
pin and extract the gear shifting lever.

Engine Vespa PX 125 150 Euro 2

ENG - 66

− 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.

− Remove the multiple gear shaft using a mallet

from the side opposite to that shown in the figure.
Do not let the 21 rollers composing the bearing fall
onto the ground.

Vespa PX 125 150 Euro 2 Engine

ENG - 67

− After removing the internal oil seal and the ex­ternal dust cover, remove the bearing retaining
ring through the use of internal split ring pliers.

− Extract the roller bearing using a flat head punch­er from the side opposite to that shown in the
figure.

− After removing the retaining washer shown in the
figure, remove the fastener underneath it, hence
extract the even tension gear.

− Remove the rivet head and replace any faulty
component.

− Refit the components using new rivets.

− Replace the trunnion if worn.

CAUTION
THE TRUNNION BUSHING HAS A LHS THREAD.

Locking torques (N*m)

Gear-box trunnion 15 ÷ 18

Engine Vespa PX 125 150 Euro 2

ENG - 68

− Refit the trunnion «A» onto the gear shifter shaft
«B» and tighten it to the prescribed torque (LHS
thread).

− Prepare a tool «D» as shown in the figure and
insert it into the groove machined on the shaft.

− Align the tool's protrusion «C» with the edge «F»
of the bushing to be rounded.

− Using a hammer and a length of tube (internal
diameter 17.5 mm), round the threaded end of the
bushing on the trunnion.

− Install the multiple gear onto its housing carefully
positioning the 21 rollers, using the recommended
grease to keep them in place during the reassem­bly.

− With the refitting operation concluded, tighten
the shaft lock nut to the prescribed torque.

Recommended products

AGIP GREASE MU3 Grease for odometer
transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L­XBCHA3, DIN K3K-20

Locking torques (N*m)

Multi-gear pinion nut 30 ÷ 35

− Before proceeding by refitting the shifter shaft, it
is necessary to check the axial play of the gear
assembly.

− Install the gears onto the shaft and check the end
play with the special feeler gauge.

Specific tooling

060824Y Inspection probe

Characteristic

Vespa PX 125 150 Euro 2 Engine

ENG - 69

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.

− With the aid of a screwdriver, remove the bal-

ance screw.

Engine Vespa PX 125 150 Euro 2

ENG - 70

− Restrain the clutch using the special tool, as
shown in the figure, then remove the locknut and
the clutch assembly.

CAUTION
DURING THE OPERATIONS OF REMOVAL, DO NOT LET

THE WOODRUFF KEY FALL INSIDE THE ENGINE.

Specific tooling

001729Y Clutch retaining tool

− Remove the mixer drive gear from its housing.

− Using the special tool, remove the clutch discs.

Specific tooling

020322Y Clutch removing/fitting tool

− Check the conditions of all components and the
camber of the metal discs. A camber smaller than
the prescribed one may cause slippage.

− Refit the clutch assembly components inverting
the order followed for the disassembly.

Vespa PX 125 150 Euro 2 Engine

ENG - 71

− Place the mixer drive gear with the rounded edge
facing the crankcase bearing.

− Correctly position the woodruff key inside its
housing.

− Refit the clutch assembly onto the engine and
tighten the locknut using the special retainer.

− Refit the remaining components in following the
procedures carried out from their removal in the
reverse order.

Specific tooling

001729Y Clutch retaining tool

Locking torques (N*m)

Clutch assy. fixing nut 40 ÷ 45

Engine Vespa PX 125 150 Euro 2

ENG - 72

INDEX OF TOPICS

SUSPENSIONS SUSP

Front

Front wheel hub overhaul

After removing the front brake calliper, remove the
plastic cap shown in the figure.
Remove the pin and the locknut.
It is now possible to remove the wheel axle nut.

After removing the split ring on the outer side of
the wheel hub, and the seal ring, remove the bear­ing using a length of pipe of adequate diameter
and a mallet, as shown in the figure. Follow the
same procedure to remove the roller cage on the
opposite side.

Handlebar

Removal

Remove the 2 rear view mirrors and their fixing ring
nuts. Remove the handlebar cover as described in
the «Bodywork» chapter and the speedometer.

Suspensions Vespa PX 125 150 Euro 2

SUSP - 74

Refitting

Upon reassembly, tighten to the prescribed tor­que.

N.B.

* Safety tightenings

IN ORDER TO ENSURE THE CORRECT TIGHTENING TOR­QUE, LUBRICATE NUTS BEFORE ASSEMBLY.

Locking torques (N*m)

Handlebar fixing screw* 30÷44

Steering column

Removal

− After removing the top housing, lean the vehicle
on one side and extract the steering column, mak­ing sure of having removed the brake calliper.

Specific tooling

020055Y Wrench for steering tube ring nut

Overhaul

To remove the bearing housings from the frame
use the special tool shown in the figure.

Specific tooling

020004Y Punch for removing fifth wheels from
headstock

Vespa PX 125 150 Euro 2 Suspensions

SUSP - 75

− Using the special tool remove the bearing and
dust ring housings from the steering column as
shown in the picture.

− Proceed with mallet hits.

Specific tooling

020004Y Punch for removing fifth wheels from
headstock

− Using the special tool, refit the dust ring and the
bearing housing onto the steering column and
push them as far as they go.

Specific tooling

006029Y Punch for fitting fifth wheel seat on
steering tube

Servicing the front suspension-steering assembly,
described below, deals mainly with replacing parts
(pin- NADELLA roller bushings - sealing rings unit
and dust guard) which connect the steering tube
to the front wheel holder swinging hub.

N.B.
BEFORE PROCEEDING WITH THE DESCRIBED SERVICE,

CHECK THAT THE STEERING TUBE AND THE WHEEL
HOLDER HUB ARE IN EXCELLENT CONDITIONS: ONLY
THEN IS THE SERVICE JUSTIFIABLE.
MOREOVER, REMEMBER THE STEERING TUBE SHOULD
BE REPLACED WITH A NEW ONE WHEN DEFORMED.

a = Ø 12 Punch
b = Sharp-edged end

Use a suitable punch with the dimensions indica­ted on the figure; hit with a mallet until the wedging
washer is crushed and then extract it with the help
of a pointed end.
Repeat the operation for the second washer using
the punch on the side opposite to the one shown
in the figure.
Use the tool fitted with part 1 as shown in the figure
and move the tool handgrip until the pin and the

Suspensions Vespa PX 125 150 Euro 2

SUSP - 76

NADELLA are simultaneously ejected in the direc­tion 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 fit­ted with part 2 instead of part 1, on the side oppo­site the one shown in the figure.

N.B.
DURING THE REMOVAL OPERATIONS DESCRIBED

ABOVE, THE ROLLER BUSHINGS ARE DESTROYED
WHEN THE EXTRACTOR IS USED. UPON REFITTING, IT IS
THEREFORE NECESSARY TO USE NEW BUSHINGS AS
WELL AS A NEW PIN, NEW SEALING RINGS AND DUST
GUARDS.

Specific tooling

020021Y Front suspension service tool

Connect the swinging hub to the steering tube with
the guiding pin.

- Use the tool fitted with part 3 on the stem and part
4 .
Lubricate the pin with recommended grease and
insert it temporarily on the swinging hub, move the
tool handgrip until part 3 is fully inserted on the
steering tube.
After fitting the pin, insert the two spacers, slightly
hitting them with the mallet.

N.B.
BEFORE PROCEEDING WITH THE DESCRIBED FITTING,

PLACE THE TWO DUST GUARD RINGS ON THE SWING­ING HUB AS SHOWN IN THE FIGURE.

Specific tooling

020021Y Front suspension service tool

Recommended products

AGIP GREASE SM 2 Grease for odometer
transmission gear case

Lithium grease with NLGI 2 molybdenum disul­phide; ISO-L-XBCHB2, DIN KF2K-20

Vespa PX 125 150 Euro 2 Suspensions

SUSP - 77

Insert the sealing ring on the pin and the roller
bushing with its wedging washer at the same time.

- Remove the tool and the part 5 (guide), which has
been partially ejected during the previous pin fitting
phase, and leave part 4 always fitted.

- Replace part 3 with part 16 (on the stem).

- By moving the tool handgrip, push the wedging
washer - roller bushing - seal ring unit, placing part
16 until it stops on the swinging hub.

- Repeat the above operation using the tool with
part 16 and part 22, instead of part 4, always fitted
to the stem, on the side opposite that indicated in
the figure to fit the second wedging washer - roller
bushing - sealing ring unit.

WARNING
BEFORE PROCEEDING WITH THE DESCRIBED PRE-FIT-

TING, DIP THE SEALING RINGS IN MINERAL OIL AND THE
"NADELLA" ROLLER BUSHINGS (PREVIOUSLY WASHED
IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMI­NATE THE ANTIRUST PROTECTION), HALF-FILLED WITH
GREASE.

Specific tooling

020021Y Front suspension service tool

Recommended products

AGIP GREASE MU3 Grease for odometer
transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L­XBCHA3, DIN K3K-20

- Use the tool fitted with part 20 on its stem and
part 21 on the tool base as shown in the figure.

- By moving the tool handgrip, push the two NA­DELLA bushings until their internal bottoms make
contact with the pin end.

- Use the tool fitted with parts 3 and 4 to fit the pin,
and press moving the tool handgrip, until wedging
the washers on the swinging hub.

- Now, remove the two spacers (parts 17 and 16)
and, once the space between the NADELLAs ­steering tube and swinging hub - has been fully

Suspensions Vespa PX 125 150 Euro 2

SUSP - 78

filled with grease, move the dust guard rings until
they are placed in that space.

- By wedging the washers as described above, the
front suspension unit refitting stage is finished.

Recommended products

AGIP GREASE MU3 Grease for odometer
transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L­XBCHA3, DIN K3K-20

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 twist­grip, gaer)

Calcium complex soap grease NLGI 2; ISO-L­XBCIB2

Locking torques (N*m)

Top steering housing 6÷7 (hence loosen by 80° -

90°) Upper steering ring nut 5÷6

Front shock absorber

Vespa PX 125 150 Euro 2 Suspensions

SUSP - 79

Removal

Remove the 2 fixings shown in the figure and the
2 fasteners on the shock-absorber support bracket
located on the steering column.
Free the shock-absorber from the support bracket
removing the top fixing.

Shock-absorber - calliper bracket

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.
After removing the wheel hub, extract the ring
shown in the figure and replace it with a new one.

Rear

Suspensions Vespa PX 125 150 Euro 2

SUSP - 80

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 fix­ing screws.

Refitting the rear wheel

− When refitting the rear wheel, tighten all fasteners at the prescribed torque following a crosswise
sequence.

Locking torques (N*m)

Rim - hub fixing nuts (front-rear) 20 ÷ 27

Shock absorbers

Removal

For the rear shock-absorber replacement it is nec­essary 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.

Vespa PX 125 150 Euro 2 Suspensions

SUSP - 81

Centre-stand

Detach the return spring from the centre stand, re­move the 4 fasteners shown in the figure.

Suspensions Vespa PX 125 150 Euro 2

SUSP - 82

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

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.

− Bleed the system.

N.B.

* Safety tightenings

IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE AS­SEMBLY.

Locking torques (N*m)

Pipe - calliper fitting 15÷25 Calliper fixing screw* 20÷25

Front brake disc

Removal

− Remove the rear wheel by loosening the 5 fas­teners.

− Remove the wheel hub.

− Loosen the 5 disc fasteners.

Refitting

− When refitting, correctly position the disc, observing the direction of rotation (see figure) and apply
medium thread-lock.

Braking system Vespa PX 125 150 Euro 2

BRAK SYS - 84

N.B.

* Safety tightenings

IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE AS­SEMBLY.

Recommended products

Loctite 243 Medium strength threadlock

Loctite 243 medium-strength threadlock

Locking torques (N*m)

Disc fixing screw* 5÷6

Disc Inspection

− Remove the wheel and check any possible disc's
out-of-plane. The measured value must be less
than 0.1 mm. If higher, replace the disc and repeat
the check.

− If the problem is not solved check and, if neces­sary, replace the wheel hub.

Specific tooling

020335Y Magnetic support for dial gauge

Front brake pads

Removal

− To facilitate this operation it is suggested that the
front wheel is removed, remove the plastic cap and
apply leverage with a screwdriver.

− Remove the external split ring from the pin, the
spring and the pads themselves.

− The pads must be replaced if the thickness of the
working material is less than 1.5 mm.

Refitting

− When refitting, operate in the opposite way, paying attention in positioning the spring with the arrow
pointing upwards.

Vespa PX 125 150 Euro 2 Braking system

BRAK SYS - 85

Fill

Front

− Once the bleeding valve is shut, top-up the circuit using fresh brake fluid.

− Loosen the bleed screw.

− Connect the special tool's tube to the bleed hole. To bleed the system, constantly refill the reservoir,

while pumping out air with the Mityvac, until all air has been removed from the circuit, i.e. only fluid is
pumped out of the system.

− Tighten the bleed screw.

N.B.

IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG
THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS.

CAUTION

- DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL.

N.B.

DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE
SYSTEM THROUGH THE PUMP.

WARNING

THE BRAKE FLUID IS HYGROSCOPIC, I.E. IT ABSORBS HUMIDITY FROM THE AIR. IF THE HU­MIDITY LEVEL IN THE FLUID EXCEEDS A GIVEN VALUE, THE BRAKING PERFORMANCES MAY
SERIOUSLY DETERIORATE. IT IS THEREFORE RECOMMENDED THAT FRESH FLUID IS TAKEN
FROM NEW CONTAINERS. IN NORMAL CLIMATIC CONDITIONS, THE FLUID SHOULD BE RE­PLACED EVERY TWO YEARS. IF THE BRAKES ARE HIGHLY STRESSED, INCREASE THE
FREQUENCY WITH WHICH THE FLUID IS REPLACED.

CAUTION

WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE­GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

With the operation concluded, tighten the bleed
screw to the prescribed torque.

Specific tooling

020329Y MityVac vacuum-operated pump

Locking torques (N*m)

Oil draining screw 10÷12

Braking system Vespa PX 125 150 Euro 2

BRAK SYS - 86

Front brake pump

Removal

− Loosen the two fasteners shown in the figure.

− Detach the hose, collecting the fluid inside a

container.

Refitting

− For refitting, perform the operation in the reverse order.

− Tighten the pipe to the prescribed torque and bleed the circuit.

Locking torques (N*m)

Reservoir - pipe fitting 8÷12

Rear drum brake

− Remove the rear wheel.

− Straighten the splint pin and remove the lock nut.

Vespa PX 125 150 Euro 2 Braking system

BRAK SYS - 87

− After removing the hub, proceed as follows:

1. Remove the shoe spring using the special pliers.

2. Remove the two retainers shown in the figure.

3. Remove the shoes using a lever.

4. Fit the new shoes with the aid of a mallet.

5. Attach the return spring using the special pliers.

Specific tooling

020325Y Brake-shoe spring calliper

− Refit the components following the removal pro­cedures in the reverse order, tightening the wheel
nut to the prescribed torque.

WARNING

-ALWAYS USE NEW SPLIT PINS FOR REFITTING.
WARNING

- FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN OR­DER TO AVOID BACKSLASH BETWEEN THE CAP AND
THE WHEEL AXLE.

Locking torques (N*m)

Wheel axle nut 90÷110

Rear Brake Pedal

After loosening the brake fixing on the rear wheel,
remove the 3 fasteners indicate in the figure.
Remove the rubber from the pedal and detach the
electrical wiring.

After this operation it is possible to remove the fore
brake cable retainer, removing the splint pin and
its pin.
It is also possible to replace the stop switch by
acting upon its fixing.

Braking system Vespa PX 125 150 Euro 2

BRAK SYS - 88

INDEX OF TOPICS

CHASSIS CHAS

Seat

Remove the 3 fasteners shown in the figure.

Rear handlebar cover

After removing the rear-view mirrors, the attach­ments and their seals, remove the four fasteners
shown in the figure, detach the electrical wiring
and the odo/speedometer cable to replace the
dashboard assembly.
Once the handlebar is removed act upon the two
lips on the dashboard.

Headlight assy.

After removing the handlebar cover, remove the 2
fasteners show in the figure and the headlight ad­justing screw underneath the handlebar.
Detach the wirings. To replace the bulbs simply
release the springs holding back the socket and
replace any blown bulb.

Chassis Vespa PX 125 150 Euro 2

CHAS - 90

− Remove the 2 fasteners for each turn signal light.

Removing the ignition key-switch when on *off*

To remove the ignition key-switch when in the
«ON» position, i.e. steering lock disengage and
ignition earthed, proceed as follows:

− Remove the three handlebar fixing screws and
the handlebar cover.

− Insert a small screwdriver inside the hole shown
in the figure (from underneath the lock body) and
push until releasing the securing tongue; hence
extract body and master cylinder.
The refitting operations of the lock body and the
new master cylinder (on the outer lock body) are
as follows:

− Carefully clean the body from any impurity (if the
cylinder has been drilled), using compressed air.

− Position the body in its housing after fitting the
retaining spring «E».

− Insert the cylinder assembly, with key and
tongue «F» facing downwards, halfway inside the
lock body, ensuring that during this operation, they
is in the «ON» position (the only position that al­lows the insertion of the cylinder); at the point turn
the key leftwards and push as far as the cylinder
will go.

− Check the assembly via the key excursion in the
three positions and proceed by refitting the han­dlebar cover.

Vespa PX 125 150 Euro 2 Chassis

CHAS - 91

Replace the seat and glove-box cylinders. To re­place these follow the operations described for the
removal of the cylinder when the ignition key­switch is in the «LOCK» position. If the locks have
been left open however, extract the cylinder by
pushing lip «F» shown in the figure after having
carefully cleaned the housing. Then insert the new
cylinder. Bear in mind that for the replacement of
the cylinder on the seat lock, it is necessary to re­move the lock assembly, acting upon the three
screws.

Removing the ignition key-switch when on *lock*

Should it be necessary to replace the steering lock
cylinder when the keys have gone missing, pro­ceed as follows:
Cylinder removal: in the event that the key-switch
is in the «LOCK» position, it is necessary to pro-
ceed by drilling the cylinder with the aid of a Ø8
mm at least 30 mm long: this allows to release (or
destroy) the internal retaining device of the drilled
cylinder. Hence extract the body and any residues
so to be able to use the body for refitting.

Taillight assy.

− Remove the 2 fixings shown in the figure and
replace the blown bulbs.

− Replace, if necessary, the taillight lens.

− To replace the taillight assy., remove the lens,

detach the wiring and remove the 2 fasteners from
underneath the frame.

Chassis Vespa PX 125 150 Euro 2

CHAS - 92

− Remove the 2 fasteners for each turn signal light.

Fuel tank

After removing the seat, detach the electrical con­nection of the fuel level sensor. Remove the 2
remaining fixings to free the fuel tank assembly.
Lift both tanks thus detaching the hoses with the
fuel tap shut to separate the fuel-oil tanks. Remove
the tank filler cap and insert the special tool
through the tube. Proceed by loosening the nut
and the acting upon ring «B» until releasing the oil
tank.

Specific tooling

020321y Carburettor float removing tool
002850y Oil tank spanner
002973y Fuel tap spanner

Remove the tank filler cap and insert the spanner
thus loosening nut «D», hence extract the fuel tap.

Vespa PX 125 150 Euro 2 Chassis

CHAS - 93

Front mudguard

− Remove the 2 fixings from underneath the mud­guard.

− 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.

− Remove the glove-box assembly.

Chassis Vespa PX 125 150 Euro 2

CHAS - 94

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 re­moved (RHS or LHS).

Vespa PX 125 150 Euro 2 Chassis

CHAS - 95

INDEX OF TOPICS

P

RE-DELIVERY PRE DE

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.

− External covers screws.

Electrical system

− Fill the battery with acid, and charge with appropriate charger.

− Ignition key-switch.

− Low-beam light, high-beam light, warning lights, side-light.

− Headlight adjustment.

− Taillight.

− Stop light (eventually front and rear lights).

− Turn signal lights and warning lights.

− Dashboard illumination.

− Horn.

− Starter button.

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.

CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG­ATIVE LEAD.

- BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL­PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.

Vespa PX 125 150 Euro 2 Pre-delivery

PRE DE - 97

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. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.

Levels check

− Brake fluid.

− Gear-box.

− Oil tank.

Road test

− Cold start.

− Speedometer check.

− Throttle check.

− Riding stability.

− Front and rear brake efficiency.

− Front and rear shock-absorbers.

− Unusual noises.

− Hot engine restart.

− Leakages (after trial run).

Functional inspection

− Brake lever excursion.

− Throttle excursion and adjustment.

− Homogeneous steering turning.

Other

− Tyre pressure.

− All locks.

− Rear-view mirrors and accessory fitting.

− Tooling kit, owner manual, warranty certificate and customer service card.

CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Pre-delivery Vespa PX 125 150 Euro 2

PRE DE - 98

INDEX OF TOPICS

TIME TIME

Engine

ENGINE

Code

Action Duration

1 001001 Engine from the frame - removal and

refitting
2 003064 Engine oil - replacement
3 003057 Engine retainer - Tighten nuts

Time Vespa PX 125 150 Euro 2

TIME - 100