Summary of Contents for VESPA GS 150
- Page 1 Step-by-step assembly stage 17 GS 150 Parts in this pack carburettor and rear brake carburetTor body float chamber 3) rear wheel hub 4) fixing screws rear brake backplate...
- Page 2 Step-by-step assembly Take the carburettor body and the float chamber and align them like this, ready to fit them together. Press the tab on the float firmly into the slot in the carburettor body so the assembly looks like this. Align the carburettor with the engine so you can fit the large D-shaped lug into hole A and the smaller lug into hole B.
- Page 3 Step-by-step assembly You will need to apply some pressure to fit 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. The assembly should now look like this.
- Page 4 Step-by-step assembly Push the hub all the way in, until the outer face of the hub is flush with the Note the position of the two slots. swingarm pivot. 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 flush with the face of the swingarm.
- Page 5 Step-by-step assembly Take the three screws provided and use the tip of the screwdriver to fit them into the holes. Only loosely tighten the first screw, then add screws in the other two holes. When the third screw is in place, go round and tighten all three fully. That completes the assembly for this stage.
- Page 6 Step-by-step assembly stage 18 GS 150 Parts in this pack ignition coil and rear hub ignition coil/plug lead fixing screw 3) register screw 4) rear axle retainer coil bracket 72 72...
- Page 7 Step-by-step assembly Take the ignition coil and its bracket and align them like this. Bring the parts together, fitting the coil into the back of the bracket and lining up the hole indicated. Take the screw provided and use it to fasten the two components together. 73 73...
- Page 8 Step-by-step assembly Step-by-step assembly The assembly should look like this. Align the coil and plug lead with the engine. Fit the plug cap on the end of the lead into the hole on top of the shroud over the cylinder head. The two pins on the back of the coil bracket are different sizes.
- Page 9 Step-by-step assembly Step-by-step assembly The assembly should now look like this. Take the small register screw provided. It fits into the hole indicated by the red circle. To provide more access, move the gear selector to the furthest notch. Compress the spring to release the selector pawl, then rotate the selector. You may find it helpful to use a screwdriver to move it as shown in Step 19. 75 75...
- Page 10 Step-by-step assembly Moving the selector provides a little extra clearance above the hole you will be Holding the register screw with a pair of long-nosed pliers, line it up with the hole. working on. Carefully insert the plain end into the hole. Push it all the way into the hole.
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Page 11: Rear Wheel
Step-by-step assembly stage 19 GS 150 Parts in this pack rear wheel fixing screws rear wheel inner rim 77 77... - Page 12 Step-by-step assembly Step-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. 78 78...
- Page 13 Step-by-step assembly Step-by-step assembly Holding the parts together, start inserting the fixing screws provided, but do not tighten them fully yet. Continue until you have inserted all four screws, then go round and tighten them all fully. The wheel should now look like this. It will be fitted under the rear bodywork, which acts as a mudguard. 79 79...
- Page 14 Step-by-step assembly stage 20 GS 150 Parts in this pack rear wheel rear wheel outer rim fixing screws 80 80...
- Page 15 Step-by-step assembly Take the two halves of the front wheel and align the fixing holes as shown in Step 2. Fit the parts together, making sure that all the locating pins on the outer rim go into the holes in the inner rim. This shows the two parts fitting together correctly.
- Page 16 Step-by-step assembly Step-by-step assembly The five fixing screws provided are used to fasten the parts together. Keeping the rims together, start inserting the fixing screws provided, but do not tighten them fully yet. When all five screws are in place, go round again and tighten them fully to complete the wheel assembly. 82 82...
- Page 17 Step-by-step assembly stage 21 GS 150 Parts in this pack rear tyre rear tyre...
- Page 18 Step-by-step assembly Take the tyre and the wheel you just assembled. Angle the tyre to fit 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. As you near the full circle, you may find it helps to use a flat-tipped screwdriver to ease the beads over the rim.
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Page 19: Headlight Assembly
Step-by-step assembly stage 22 GS 150 Parts in this pack headlight assembly headlight glass headlight rim 3) headlight reflector 4) fixing screws... - Page 20 Step-by-step assembly Start by fitting 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. Press the glass into the frame as shown, then take the reflector.
- Page 21 Step-by-step assembly The headlight should look like this. It can be tricky to insert the very small fixing screws in one go, so we suggest you separate the parts, remembering how they fit together, while you start to fit the three screws provided. Start driving the screws into the holes.
- Page 22 Step-by-step assembly Take the reflector and refit it to the lens and rim in the same way as you did during the test-assembly. Keeping the reflector pressed firmly into the rim, so it fits flush all round, screw all three screws firmly into the mounting posts. The complete assembly should look like this.
- Page 23 Step-by-step assembly stage 23 GS 150 Parts in this pack right handlebar and brake handlebar fixing screws switch mounting screws 3) cable stop fixing screw 4) switch brake cable retainer 6) right handlebar, brake lever and cable...
- Page 24 Step-by-step assembly Take the switch and fit it on top of the brake lever clamp, lining up the two fixing holes circled in red. Make sure the switch is the right way up, with the black switch lever itself pointing downwards in the direction shown.
- Page 25 Step-by-step assembly Take the handlebar assembly and the lower handlebar cover from Pack 1. With the brake lever pointing forwards, fit the large hole in the handlebar (circled in red) over the matching post inside the handlebar cover. Lead the brake cable through the two guide just beyond the end of the handlebar (indicated in red in Step 13) and press the end of the black outer sheath into the large channel that forms a stop in the further of the two guides.
- Page 26 Step-by-step assembly Tighten the screws firmly through both holes, making sure the handlebar is unable to move. Take the brake cable retainer provided. With the flat side of the cable retainer facing down, fit the hole in the round end over the circular lug next to the cable stop. Then take the remaining screw. Tighten the screw into the hole to fix the cable stop to the handlebar cover, securing the end of the brake cable in place and completing this stage of the assembly.
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Page 27: Left Handlebar & Controls
Step-by-step assembly stage 24 GS 150 Parts in this pack left handlebar & controls gear selector spring outer gear selector ratchet 3) inner gear selector ratchet 4) clutch Cable retainer clutch/gear selector lever and cable 6) Fixing screws left handlebar... - Page 28 Step-by-step assembly Take the spring and slip it over the thin end of the handlebar. Slide the spring onto the handlebar until it stops against the thicker portion, then take the inner gear selector ratchet. Slip this over the thin end of the handlebar, with the toothed side facing outwards.
- Page 29 Step-by-step assembly Slip the outer gear selector ratchet over the thin end of the handlebar, with the toothed side facing inwards. Slide it all the way along until the two sets of teeth mesh together. Now take the clutch/gear selector lever and fit it over the end of the handlebar, keeping the cable out of the way. Slide the lever along the handlebar until it reaches the outer gear selector ratchet.
- Page 30 Step-by-step assembly Carefully holding the assembly together, fit the end of the handlebar onto the post in the lower handlebar cover as shown in close-up in Step 18. Lead the clutch cable through the guides moulded into the handlebar cover and press the end of the black outer sheath into the stop as indicated in Step 19. Take the two fixing screws provided and use them to fix the end of the handlebar to the handlebar cover.
- Page 31 Step-by-step assembly Screw the handlebar securely in place. After fixing the handlebar to the handlebar cover, lead the cable down through the same hole where you placed the brake cable in the previous stage. Both cables should run in a smooth curve. 97 97...
- Page 32 Step-by-step assembly Take the cable retainer, and with the flat side facing down, fit the large round hole over the circular lug next to the cable stop. Screw the cable retainer in place with the remaining screw. That completes this stage. The illustration on the right shows how the assembly appears when the handlebars are in place on the model. 98 98...
- Page 33 Step-by-step assembly stage 25 parts in this pack twistgrips throttle twistgrip rubber gearchange twistgrip rubber 3) throttle twistgrip 4) gearchange twistgrip throttle twistgip return spring 6) twistgrip end caps screw covers 8) twistgrip retaining screws The screw covers (7) are not used until later, so be careful not to lose them.
- Page 34 Step-by-step assembly Identify the shorter of the two twistgrips, which controls the gearchange. One end has two notches that engage with the circled lugs inside the clutch lever clamp. Fit this end over the end of the lefthand bar. Press the twistgrip into place so it locks into the clutch lever clamp. Then take one of the large retaining screws provided and screw it into the end of the handlebar. Tighten the screw to secure the twistgrip but do not overtighten it.
- Page 35 Step-by-step assembly There is a flattened rib on the inside of the twistgrip rubber, which must match up with the flattened side of the twistgrip in order for it to slide on. This ensures the correct alignment of the Piaggio logo on the top of the rubber and prevents the rubber from twisting around the grip. Push the rubber all the way up to the handlebar clamp. Take either of the end caps, which are identical, and push it into the open end of the rubber.
- Page 36 Step-by-step assembly For clarity, this sequence shows the next step without the twistgrip in place. You need to fit the twistgrip return spring over the handlebar and hook the end of the wire that turns inwards into the small hole at the end of the slot indicated in Step 19. Step 21 shows the spring correctly located. With the slot in the handlebar exposed by the notch in the twistgrip, follow the sequence above to fit the spring over the handlebar and hook the inner end in place.
- Page 37 Step-by-step assembly Fully tighten the screw, ensuring that the twistgrip is free to rotate on the handlebar, under the control of the return spring, which should bring it back to the start position. Fit the second twistgrip rubber, which also has a rib to ensure it can only be fitted in one position. Slide the rubber all the way onto the twistgrip, then take the end cap.
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