2. VESPA
  3. GS 150
GS 150

VESPA GS 150 Step-By-Step Assembly

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  • How do I assemble the carburetor and rear brake?
    How do I fit the ignition coil and plug lead?
    How do I assemble the rear wheel?
    How do I assemble the front wheel?
    How do I assemble the headlight?
    How do I assemble the right handlebar and brake?
    How do I assemble the left handlebar and controls?
6767
Step-by-step assembly
1
Parts in this pack
carburettor and rear brake
1) carburetTor body
2) float chamber
3) rear wheel hub
4) fixing screws
5) rear brake backplate
GS 150
2
stage 17
3
4
5
68
Step-by-step assembly
Press the tab on the oat rmly into the slot in the carburettor body so the assembly looks like this.
Align the carburettor with the engine so you can t the large D-shaped lug into hole A and the smaller lug into hole B.
Take the carburettor body and the oat chamber and align them like this, ready to t them together.
3
5
1 2
4
6
A
B
69
Step-by-step assembly
The assembly should now look like this.
Fit the hub over the rear stub axle, with the slots in it facing outwards.
Now take the rear wheel hub.
You will need to apply some pressure to t the lugs all the way into their holes. To avoid damaging the carburettor, press down on the two marked points only and make sure
both lugs go in at the same time.
10
12
7 8
11
13
9
B
70
Step-by-step assembly
The two lugs on the brake backplate are designed to match up with the slots. Fit the part onto the stub axle.
Slide the backplate all the way onto the axle so the lugs go into the hub, the three holes indicated line up with the holes in the swingarm and the back of the plate is ush with
the face of the swingarm.
Push the hub all the way in, until the outer face of the hub is ush with the
swingarm pivot.
17
19
14
15
18
16
Note the position of the two slots.
71
Step-by-step assembly
20
Only loosely tighten the rst screw, then add screws in the other two holes.
Take the three screws provided and use the tip of the screwdriver to t them into the holes.
When the third screw is in place, go round and tighten all three fully. That completes the assembly for this stage.
23
25
24
22
21
7272
Step-by-step assembly
1
Parts in this pack
ignition coil and rear hub
1) ignition coil/plug lead
2) fixing screw
3) register screw
4) rear axle retainer
5) coil bracket
GS 150
2
stage 18
3
4
5
7373
Step-by-step assembly
Bring the parts together, tting the coil into the back of the bracket and lining up the hole indicated.
Take the ignition coil and its bracket and align them like this.
3
1 2
4
Take the screw provided and use it to fasten the two components together.
5 6 7
7474
Step-by-step assemblyStep-by-step assembly
Fit the plug cap on the end of the lead into the hole on top of the shroud over the cylinder head.
The assembly should look like this.
The two pins on the back of the coil bracket are different sizes. Fit them into the matching holes in the engine casing.
Align the coil and plug lead with the engine.
10
8
12
11
9
13
7575
Step-by-step assembly
It ts into the hole indicated by the red circle. To provide more access, move the gear selector to the furthest notch.
The assembly should now look like this. Take the small register screw provided.
16
14 15
17
Compress the spring to release the selector pawl, then rotate the selector. You may nd it helpful to use a screwdriver to move it as shown in Step 19.
18 19 20
Step-by-step assembly
7676
Step-by-step assembly
Carefully insert the plain end into the hole.
Moving the selector provides a little extra clearance above the hole you will be
working on.
The register screw should now look like this, which completes this stage of the assembly.
Push it all the way into the hole.
Holding the register screw with a pair of long-nosed pliers, line it up with the hole.
23
21
25
24
22
26
7777
Step-by-step assembly
1
Parts in this pack
rear wheel
1) fixing screws
2) rear wheel inner rim
GS 150
2
stage 19
7878
Step-by-step assemblyStep-by-step assembly
Take the rear wheel rim provided in this pack, plus the rear axle retainer provided with Stage 18. Align the parts like this, matching up the four mounting holes.
Fit the parts together.
2
1
7979
Step-by-step assembly
The wheel should now look like this. It will be tted under the rear bodywork, which acts as a mudguard.
8 9
Holding the parts together, start inserting the xing screws provided, but do not tighten them fully yet.
3 4
Continue until you have inserted all four screws, then go round and tighten them all fully.
5 6 7
Step-by-step assembly
8080
Step-by-step assembly
1
Parts in this pack
rear wheel
1) rear wheel outer rim
2) fixing screws
GS 150
2
stage 20
8181
Step-by-step assembly
Take the two halves of the front wheel and align the xing holes as shown in Step 2.
1 2
This shows the two parts tting together correctly. Note that there is a gap between them and the pins do not go all the way into the recesses.
5 6
Fit the parts together, making sure that all the locating pins on the outer rim go into the holes in the inner rim.
3 4
8282
Step-by-step assembly
The ve xing screws provided are used to fasten the parts together.
7 8
When all ve screws are in place, go round again and tighten them fully to complete the wheel assembly.
12 13
9 1110
Keeping the rims together, start inserting the xing screws provided, but do not tighten them fully yet.
Step-by-step assembly
8383
Step-by-step assembly
1
Parts in this pack
rear tyre
1) rear tyre
GS 150
stage 21
8484
Step-by-step assembly
Take the tyre and the wheel you just assembled. Angle the tyre to t it over the rim. Trying to exert a constant pressure, ease the tyre walls over the circumference of the rim a little at
a time.
1 2
Repeat the process on the other side of the wheel. Then check that the tyre is evenly seated all round by making sure that the inner circles moulded into the rubber are concentric with the
wheel rim. If they aren’t, you can gently bounce the tyre on a at surface to adjust the position.
5 6
As you near the full circle, you may nd it helps to use a at-tipped screwdriver to ease the beads over the rim. Do this gently to avoid damaging the nish of the wheel.
3 4
8585
Step-by-step assembly
1
2
4
3
Parts in this pack
headlight assembly
1) headlight glass
2) headlight rim
3) headlight reflector
4) fixing screws
GS 150
stage 22
8686
Step-by-step assembly
Start by tting the headlight glass into the rim. With the curved side facing outwards, match up the two square notches (circled in red) and semicircular notches (circled in blue) with the
locating ribs and mounting posts inside the rim.
1 32
Press the glass into the frame as shown, then take the reector. Match up the notches with the locating ribs in the rim, in the same way you did with the lens.
4 65
Test-t the reector, noting how the three holes in the reector line up with the mounting posts on the rim. They will be used to x the headlight shell in place.
7 8
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