VESPA 125 Primavera Service Station Manual

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Service Station Manual

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SERVICE STATION MANUAL
1Q000118 EN
Vespa Primavera125 - 150 i.e. 3Valvole (2013)
SERVICE STATION
MANUAL
Vespa Primavera125 - 150 i.e. 3Valvole
(2013)
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of each
model should be checked at the official PIAGGIO sales network.
© Copyright 2014 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
Vespa Primavera125 - 150 i.e.
3Valvole (2013)
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles
has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant
changes to vehicle characteristics or to specific repair operations will be communicated by updates to
this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools
are unavailable. It is therefore advisable to read the sections of this manual concerning special tools,
along with the special tool 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
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- 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.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 7
Vehicle identification
VEHICLE IDENTIFICATION 125
Specification Desc./Quantity
Chassis prefix ZAPM81100
Engine prefix M811M
VEHICLE IDENTIFICATION 150
Specification Desc./Quantity
Chassis prefix ZAPM81200
Engine prefix M812M
VEHICLE IDENTIFICATION USA-CND
Specification Desc./Quantity
Chassis prefix ZAPM818G
Engine prefix M812M
Chassis number
The chassis number «A» is stamped near the fuel
tank.
To read it, proceed as follows:
- lift the saddle;
- lift the helmet compartment by removing it.
Engine number
The engine number «B» is stamped near the rear
left shock absorber lower support.
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 8
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Desc./Quantity
Length 1860 mm (73.23 in)
Width 735 mm (28.94 in)
Height 1145 mm (45.08 in)
Wheelbase 1340 mm (52.76 in)
Kerb weight 118 ± 5 kg
Kerb weight versions USA-CND 264 lb.
Maximum weight limit 305 kg
Maximum weight limit versions USA-CND 727 lb.
Engine
125 CM³ ENGINE SPECIFICATIONS
Specification
Desc./Quantity
Type Single-cylinder, 4-stroke
Engine capacity 124 cm³
Bore x stroke 52.0 x 58.6 mm
Max. power 7.9 kW at 7,700 rpm
MAX. torque 10.4 Nm at 6,000 rpm
Idle speed (1,750±100) rpm
Valve clearance (when cold) intake: 0.08 mm exhaust: 0.08 mm
Timing system 3 valves (2 intake, 1 drainage). single overhead camshaft
chain-driven.
Transmission CVT expandable pulley variator with torque server, V-belt, self-
ventilating dry automatic centrifugal clutch and transmission
housing with forced-circulation air cooling.
Final reduction with gear reduction unit in oil bath.
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 9
Specification Desc./Quantity
Cooling Forced-air circulation cooling.
Electric Electric starter
Ignition Electronic capacitive discharge ignition, with variable advance
and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug (125 cm³) NGK CR8EB
Electrode gap 0.7 - 0.8 mm
Fuel system Electronic injection with Ø 26 mm throttle body, single injector
Fuel Unleaded petrol (95 RON)
Exhaust silencer Absorption-type exhaust muffler with catalytic converter.
Emissions compliance EURO 3
150 CM³ ENGINE SPECIFICATIONS
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Engine capacity 155 cm³
Bore x stroke 58.0 x 58.6 mm
MAX. power 9.5 kW at 7,750 rpm
MAX. torque 12.8 Nm at 6,500 rpm
Idle speed (1,750±100) rpm
Valve clearance (when cold) intake: 0.08 mm exhaust: 0.08 mm
Timing system 3 valves (2 intake, 1 drainage). single overhead camshaft
chain-driven.
Transmission CVT expandable pulley variator with torque server, V-belt, self-
ventilating dry automatic centrifugal clutch and transmission
housing with forced-circulation air cooling.
Final reduction with gear reduction unit in oil bath.
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Cooling Forced-air circulation cooling.
Electric Electric starter
Ignition Electronic capacitive discharge ignition, with variable advance
and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug (150 cm³) NGK CR8EB
Electrode gap 0.7 - 0.8 mm
Fuel system Electronic injection with Ø 28 mm throttle body, single injector
Fuel Unleaded petrol (95 RON)
Exhaust silencer Absorption-type exhaust muffler with catalytic converter.
Emissions compliance EURO 3
Transmission
TRANSMISSION
Specification
Desc./Quantity
Transmission CVT expandable pulley variator with torque server, V-belt, self-
ventilating dry automatic centrifugal clutch and transmission
housing with forced-circulation air cooling.
Final reduction with gear reduction unit in oil bath.
Capacities
CAPACITY
Specification
Desc./Quantity
Engine oil 1340 (of which 120 cm³ in the filtering cartridge) (45.31 US fl
oz (of which 4.06 US fl oz in the filtering cartridge))
Hub oil 270 cm³ (9.13 US fl oz)
Fuel tank capacity 8 ± 0.1 l (2.11 ± 0.03 UK gal)
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 10
Frame and suspensions
FRAME AND SUSPENSION
Specification Desc./Quantity
Chassis Stamped plate body with welded structural reinforcements.
Front suspension Single arm with helical spring and single double-acting hy-
draulic shock absorber.
Rear suspension Double-acting shock absorber, adjustable to four positions at
preloading.
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 200-mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear brake Ø 140-mm drum brake with mechanical control activated by
handlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES
Specification
Desc./Quantity
Wheel rim type Light alloy.
Front wheel rim 11'' x 2.50
Rear wheel rim 11'' x 2.75
Front tyre Tubeless, 110/70 - 11'' 45L
Rear tyre Tubeless, 120/70 - 11'' 56L
Front tyre pressure 1.6 bar
Rear tyre pressure 1.8 bar
Tightening Torques
FRAME ASSEMBLY
Name
Torque in Nm
Frame-swinging arm bolt 44 to 52 (32.5 to 38.4 lbf*ft)
Engine-swinging arm bolt 40 - 45 (29.5 - 33.2 lb*ft)
Silent block-swinging arm retaining bolts 40 - 45 (29.5 - 33.2 lb*ft)
Centre stand pin 40 - 45 (29.5 - 33.2 lb*ft)
STEERING ASSEMBLY
Name
Torque in Nm
Upper steering ring nut 35 to 40 (25.8 to 29.5 lbf*ft)
Lower steering ring nut 12 to 14 (8.9 to 10.3 lbf*ft)
Handlebar fixing screw 50 to 55 (36.9 to 40.6 lbf*ft)
FRONT BRAKE
Name
Torque in Nm
Brake fluid pump-hose joint 8 to 12 (5.9 to 8.9 lbf*ft)
Brake fluid pipe-calliper fitting 20 to 25 (14.8 to 18.4 lbf*ft)
Screw tightening calliper to support 20 to 25 (14.8 to 18.4 lbf*ft)
Brake disc screw (°) 5 to 6.5 (3.7 to 4.8 lbf*ft)
Oil bleed valve (on the calliper) 10 to 12 (7.4 to 8.9 lbf*ft)
Handlebar pump 7 to 10 (5.2 to 7.4 lbf*ft)
Brake pump reservoir screw 15 to 20 (11.1 to 14.8 lbf*ft)
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 11
(°) Apply LOCTITE 242 threadlock
SILENCER
Name Torque in Nm
Silencer heat guard fixing screws 4 to 5 (3.6 to 3.7 lbf*ft)
Screws fixing silencer to the crankcase 24 to 27 (17.7 to 19.9 lbf*ft)
Oxygen sensor tightening on exhaust manifold 40 to 50 (29.5 to 36.9 lbf*ft)
FRONT SUSPENSION
Name Torque in Nm
Shock absorber upper nut 20 to 30 (14.8 to 22.8 lb*ft)
Front wheel axle nut 75 to 90 (55.3 to 66.4 lbf*ft)
Shock absorber upper bracket bolts 20 to 25 (14.8 to 18.4 lb*ft)
Wheel screw 20 to 25 (14.8 to 18.4 lbf*ft)
Shock absorber lower bolts (°) 20 to 27 (14.8 to 19.9 lb*ft)
(°) Apply LOCTITE 242 threadlock
REAR SUSPENSION
Name Torque in Nm
Rear wheel axle 104 to 126 (76.7 to 92.9 lbf*ft)
Shock absorber - chassis nut 20 to 25 (14.8 to 18.4 lbf*ft)
Lower shock absorber clamp 40 - 45 (29.5 - 33.2 lb*ft)
FLYWHEEL
Name
Torque in Nm
Flywheel cover screw 11 - 13 (8.1 - 9.5 lb*ft)
Starter sprocket check fixing screw 5 - 6 (3.7 - 4.4 lb*ft)
Starter motor screws 11 - 13 (8.1 - 9.5 lb*ft)
Flywheel fixing nut 100 - 110 (73.7 - 81 lb*ft)
Freewheel fixing screws 10 - 11 (7.4 - 8.1 lb*ft)
FLYWHEEL COVER
Name
Torque in Nm
Pick-up screws 3 - 4 (2.2 - 2.9 lb*ft)
Stator fixing screws 5 - 6 (3.7 - 4.4 lb*ft) (Loctite 242)
Stator cable plates clamping screws 3 - 4 (2.2 - 2.9 lb*ft)
Fixing clamps of head pump cover by-pass pipe 1.3 - 1.7 (0.9 - 1.2 lb*ft)
Coil fixing screw 11 - 13 (8.1 - 9.5 lb*ft)
CRANKCASE
Name
Torque in Nm
Calibrated fixing dowel 5 - 7 (3.7 - 5.2 lb*ft)
Oil filter cover 24 - 30 (17.7 - 22 lb*ft)
Engine oil level shaft 1.3 - 1.7 (0.9 - 1.2 lb*ft)
Engine crankcase coupling screws 11 - 13 (8.1 - 9.5 lb*ft)
Rear brake screw 15 - 17 (11 - 12.5 lb*ft)
Oil sensor 12 - 14 (8.8 - 10.3 lb*ft)
Oil filter 5 - 6 (3.7 - 4.4 lb*ft)
Oil drain screw 14.7 - 16.7 (10.8 - 12.3 lb*ft)
Oil pump bulkhead screw 4 - 6 (2.9 - 4.4 lb*ft)
Freewheel fixing screws 10 - 11 (7.4 - 8.1 lb*ft)
Oil pump fixing screw 5 - 6 (3.7 - 4.4 lb*ft)
oil pump driving crown gear screw 10 - 14 (7.4 - 10.3 lb*ft)
Rotor cover 1 - 1.50 (0.7 - 1.1 lb*ft)
Rotor clamp 3 - 4 (2.2 - 2.9 lb*ft)
HEAD AND CYLINDER
Name
Torque in Nm
Head cover screws 10.8 - 12.7 (7.9 - 9.4 lb*ft)
Cylinder head nut (PRE-TIGHTENING) 6 - 8 (4.4 - 5.9 lb*ft)
Cylinder head nut (TIGHTENING) 9 - 11 (6.6 - 8.1 lb*ft) (Tighten to the specified torque then rotate
270.0°±5.0°)
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 12
Name Torque in Nm
Cylinder stud bolt fitting See section ENGINE/LUBRICATION/STUD BOLT
Throttle body clamp screws 1.3 - 1.7 (0.9 - 1.2 lb*ft)
Tensioner spring retaining screw 5 - 6 (3.7 - 4.4 lb*ft)
Fastener chain tensioner 11 - 13 (8.1 - 9.5 lb*ft)
Thermostat cover screws 3 - 4 (2.2 - 2.9 lb*ft)
Pressure reducer counterweight retainer screw 7 - 8.5 (5.2 - 6.2 lb*ft)
Injection manifold fixing screws 11 - 13 (8.1 - 9.5 lb*ft)
Valve clearance adjustment screw 6 - 9 (4.4 - 6.6 lb*ft)
Spark plug tightening 10 - 12 (7.4 - 8.8 lb*ft)
Timing system sprocket fixing screw 4 - 6 (2.9 - 4.4 lb*ft)
Screws fixing cylinder to crankcase 10.8 - 12.7 (7.9 - 9.4 lb*ft)
Head blow by 3 - 4 (2.2 - 2.9 lb*ft)
TRANSMISSION AND FINAL REDUCTION
Name Torque in Nm
Transmission cover screws 11 - 13 (8.1 - 9.5 lb*ft)
Final reduction cover screws 24 - 27 (17.7 - 20 lb*ft)
Driven pulley fixing nut 53 - 59 (40 - 43.5 lb*ft)
Hub oil drain screw 15 - 17 (11 - 12.5 lb*ft)
Freewheel fixing screws 10 - 11 (7.4 - 8.1 lb*ft)
Driving pulley retainer nut 75 - 83 (55 - 61 lb*ft)
LUBRICATION
Name Torque in Nm
Crankcase timing cover screws 11 - 13 (8.1 - 9.5 lb*ft)
Screws fixing oil pump to crankcase 4 - 6 (2.9 - 4.4 lb*ft)
Pump rod screw 13 - 15 (9.5 - 11 lb*ft)
Minimum oil pressure sensor locking 12 - 14 (8.8 - 10.5 lb*ft) (LOCTITE 5091 Edge closure between
metal body and plastic block)
Overhaul data
Assembly clearances
Cylinder - piston assy.
CYLINDER - PISTON (125)
Specification
Desc./Quantity
Piston diameter 51.961 (±0.014) mm
Cylinder diameter 52 (+0.008 -0.020) mm
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 13
CYLINDER - PISTON (150)
Specification Desc./Quantity
Piston diameter 57.947 (± 0.014) mm
Cylinder diameter 58 (+0.008 -0.020) mm
COUPLING CATEGORIES (125)
Name Initials Cylinder Piston Play on fitting
cylinder - piston A 51.980 - 51.987 51.947 - 51.954 0.026 - 0.040
cylinder - piston B 51.987 - 51.994 51.954 - 51.961 0.026 - 0.040
cylinder - piston C 51.994 - 52.001 51.961 - 51.968 0.026 - 0.040
cylinder - piston D 52.001 - 52.008 51.968 - 51.975 0.026 - 0.040
COUPLING CATEGORIES (150)
Name Initials Cylinder Piston Play on fitting
cylinder - piston A 57.980 to 57.987 57.933 to 57.940 0.040 to 0.054
cylinder - piston B 57.987 to 57.994 57.940 to 57.947 0.040 to 0.054
cylinder - piston C 57.994 to 58.001 57.947 to 57.954 0.040 to 0.054
cylinder - piston D 58.001 to 58.008 58.954 to 58.961 0.040 to 0.054
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Check the pin outside diameter
Characteristic
Pin outside diameter
14 (+0 -0.004) mm
- Measure the diameter of the housings on the pis-
ton.
Characteristic
Standard diameter
14 (+0.006 +0.001) mm
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 14
- Carefully clean the sealing rings housings.
- Measure the sealing rings - pistons coupling
clearance using suitable sensors, as shown in the
diagram
- If clearances measured exceed the limits speci-
fied in the table below, the piston should be re-
placed by a new one.
- Check the clearance upon mounting (A) of the
bands:
N.B.
MEASURE CLEARANCE BY INSERTING THE BLADE OF
THE FEELER GAUGE FROM THE 2nd SEALING RING
SIDE.
ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS (125)
DENOMINATION DIMENSIONS ASSEMBLY CLEARANCES (A)
1° compression ring (mm) 52x0.8 0.20 to 0.35
2° compression ring (mm) 52x1.0 0.20 to 0.45
Oil scraper rings (mm) 52x2.0 0.25 to 0.55
ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS (150)
DENOMINATION
DIMENSIONS ASSEMBLY CLEARANCES (A)
1° compression ring (mm) 58x0.8 0.20 to 0.35
2° compression ring (mm) 58x1.0 0.20 to 0.45
Oil scraper rings (mm) 58x2.0 0.25 to 0.55
- Check that the coupling surface with the head is not worn or misshapen.
- Pistons and cylinders are classified according to diameter. The coupling is carried out in pairs (A-A,
B-B, C-C, D-D).
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo
Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Axial clearance between
crankshaft and connecting rod
Axial clearance between crankshaft and connecting rod
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 15
CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE
Name
Abbreviation Sizes fitting clearance
Half shaft, transmission side A 18.1 (+0; -0.05) mm D = 0.20 - 0.50
Half shaft, flywheel side B 18.1 (+0; -0.05) mm D = 0.20 - 0.50
Connecting rod C 15 (-0.10; -0.15) mm D = 0.20 - 0.50
Spacer tool E 51.4 (+0; +0.05) mm D = 0.20 - 0.50
Crankshaft bearing diameter.
Measure the bearings on both x-y axes.
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 16
CRANKSHAFT
Specification
Desc./Quantity
Camshaft bearings: Standard diameter: Cat. 1 26.998 to 27.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 27.004 to 27.010 mm
- In order to obtain proper bushing lubrication, make sure there are both an outstanding lubrication
pressure and a good oil flow rate. To that end, the bushings must be correctly positioned so as not to
obstruct the oil supply channels.
Characteristic
«A»
AXIS CYLINDER
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 17
- The main bushings have 2 half-bearings, 1 with
and 1 without the lubrication channel.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason,
it is arranged opposed to the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
shown in the photo.
Characteristic
«A»
AXIS CYLINDER
BUSHINGS
TYPE
IDENTIFICATION CRANKSHAFT HALF-BEARINGS
B BLUE 1.971 to 1.976
C YELLOW 1.974 to 1.979
E GREEN 1.977 to 1.982
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 18
- The section of the oil feeding channels is also
influenced by the driving depth of the bushings.
- Visually check the wear of the bushings: in the
coupling ends shown in the photo the bushing usu-
ally keeps the original look, check in the rest of the
bushing if there is evident removal of material. If
this occurs as stated, proceed to replace the
crankcase halves.
N.B.
SMALL MARKS AND SCRATCHES OF THE SHAFT ROTA-
TION ARE NORMAL SIGNS OF ENGINE USAGE, AND DO
NOT AFFECT THE CORRECT FUNCTIONING.
Measurement of crankcase halves - crankshaft coupling clearance.
- The nominal diameters of the bushings, even if of the same coupling category, may differ by hun-
dredths due to the plastic slackening of the material of the crankcase due to the driving load.
- Measure along the axis of the « A» cylinder, using a bore meter at two depths indicated in the figure,
the diameter of the bushings.
- After measuring the two diameters, take the average.
Characteristic
«A»
AXIS CYLINDER
- The bushings housing hole in the crankcase half is divided into two categories depending on the size,
Category 1 and Category 2.
CRANKCASE DIAMETER WITHOUT BUSHING
Specification
Desc./Quantity
CAT 1 30.959 to 30.965 mm
CAT 2 30.953 to 30.959 mm
- Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat.
2). Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The
spare crankshaft has half-shafts of the same category.
- According to the classification of the shaft CAT.1 - CAT.2 combine a complete crankcase pre-fitted
with suitable bushings according to the starting shaft.
CATEGORIES
CRANKCASE HALVES
ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
Vespa Primavera125 - 150 i.e. 3Valvole (2013) Characteristics
CHAR - 19
THE CRANKSHAFT is available in two CATEGO-
RIES:
Characteristic
Crankshaft category:
CAT. 1 - CAT. 2
CRANKSHAFT CATEGORY IDENTIFICATION:
The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the
package with a drawing number plus FC1/FC2 or (001/002).
If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both
crankcase halves, combining the two components (Shaft and Crankcase) featuring the same category.
Cylinder Head
Clean all the coupling surfaces thoroughly before servicing the head. Pay attention to the position of
the springs and valves so as not to change the original position upon refitting them
- Using a trued bar and a thickness gauge, check that the cylinder head surface is not worn or distorted.
Characteristic
Maximum run-out allowed:
0.03 mm
- In case of irregularities, replace the head.
- Check the sealing surfaces for the exhaust manifold.
- Check that the camshaft and the rocker pin bearings show no signs of wear.
- Check that the head cover show no signs of wear.
- Check that there is no cooling liquid leakage from the seals.
- Fit the valves into the cylinder head.
- Alternatively test the intake and exhaust valves.
- The test should be carried out by filling the mani-
fold with fuel and checking that the head does not
ooze through the valves when they are just press-
ed by the fingers.
Characteristics Vespa Primavera125 - 150 i.e. 3Valvole (2013)
CHAR - 20
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VESPA 125 Primavera Service Station Manual

Type
Service Station Manual
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