VESPA PX 150 USA Workshop Manual

WORKSHOP MANUAL

633376

Vespa PX 150 USA

WORKSHOP

MANUAL

Vespa PX 150 USA

WORKSHOP MANUAL

Vespa PX 150 USA

This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio-

Gilera dealers and sub-agents. It is assumed that the person utilizing this manual for servicing or repairing

Piaggio vehicles has knowledge of the principles of mechanics and standard procedures required for

general vehicle repair. 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

- Should it be necessary to keep the engine running while servicing, make sure that the area or room

is well ventilated, and use special exhaust fans, if required. Never let the engine running in closed rooms.

In fact, exhaust gases 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 clothes, rinse thoroughly with water and consult

a doctor immediately.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

and flames when close to the battery, especially during recharge.

- Fuel is highly flammable, and in some conditions it can be explosive. Do not smoke in the working

area, and avoid free flames or sparks.

- Clean the brake pads in a well ventilated environment, directing the compressed air jet so as to not

intake the dust produced by the wear of the friction material. Even though the latter contains no as-

bestos, dust inhalation 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.

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification

Desc./Quantity

Empty weight 229,28 Lb (104 Kg)

Wheelbase 48,62 inch (1235 mm)

Max height 43,70 inch (1110 mm)

Vespa PX 150 USA Characteristics

CHAR - 7

Specification Desc./Quantity

Max lenght 69,29 inch (1760 mm)

Handlebars width 27,56 inch (700 mm)

Engine

ENGINE

Specification

Desc./Quantity

Engine type 2-stroke with rotary intake timing

No. of cylinders 1

Alesaggio per corsa (150) 0,19 x 2,24 inch (58 x 57 mm)

Cilindrata (150) 919 inch3 (150,599 cm3)

Compression ratio (150) 8 : 1

Carburetor 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 carburetor with automatic mixer

(mass flow varying with engine speed) and throttle valve

Characteristics Vespa PX 150 USA

CHAR - 8

Specification Desc./Quantity

Clutch Multi-disc.

Cooling Forced air by a centrifugal fan.

Max power output (shaft) 150cc 6.6 Kw (9 hp) at 5,700 rpm

Max speed (150) 82,8 Km/h

Transmission

TRANSMISSION

Specification Desc./Quantity

Gear-box 4-speed with constantly engaged gears

Capacities

CAPACITIES

Specification Desc./Quantity

Gear-box ~ 250 cc.

Oil tank mixer ~ 1.6 l (including a reserve of 0.4 l)

Fuel tank ~2,11 gal, including ~0,55 gal reserve (~8 l, 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

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

Vespa PX 150 USA Characteristics

CHAR - 9

Wheels and tyres

WHEELS AND TIRES

Specification Desc./Quantity

Front tire 3,50 x 10"

Rear tire 3,50 x 10"

Rims Pressed steel

Wheels Interchangeable with 2.00"×10" pressed steel rims.

Front tire pressure 18,85 PSI (1,3 bar)

Rear tire pressure 26,11 PSI (1,8 bar)

33,36 PSI (2,3 bar) driver and passenger

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-

LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES

Carburettor

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

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

Characteristics Vespa PX 150 USA

CHAR - 10

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

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 AS-

SEMBLY.

Vespa PX 150 USA Characteristics

CHAR - 11

Overhaul data

Assembly clearances

Cylinder - piston assy.

The cylinder classification must be carried out at 25 mm from the head mating surface on the rod's

swinging plane.

MATING CATEGORIES - 150CC ENGINE

Name

Initials 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

Characteristics Vespa PX 150 USA

CHAR - 12

Name Initials Cylinder Piston Play on fitting

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

Cylinder - piston (3rd

oversize)

G 58,420 58,180 0,240

Piston rings

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 150 USA Characteristics

CHAR - 13

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 150 USA

CHAR - 14

− 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 150 USA Characteristics

CHAR - 15

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 150 USA Tooling

TOOL - 17

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 150 USA

TOOL - 18

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 150 USA Tooling

TOOL - 19

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 150 USA

TOOL - 20

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VESPA PX 150 USA Workshop Manual

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