VESPA PX 125 150 euro 2 Instruction 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 sub-
agents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the
principlesofmechanicsandstandardproceduresrequiredforgeneralvehiclerepair.Anyrelevantchangesconcerningthevehicle
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 Sectionsmarkedwiththis 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 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.
- 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
suretheelectric connectionshavebeen madeproperly,particularlythegroundandbattery 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. REGU-
LATE 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 AS-
SEMBLY.
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
CONNECTINGROD-CRANKSHAFT.ASSEMBLYCLEARANCE«E»BETWEENBIGEND
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
CONNECTINGROD - 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