VESPA LX 125 4T Euro 3, Service Station Manual

Page 1: ...SERVICE STATION MANUAL 633977 EN Vespa LX 125 150 4T Euro 3 ...

Page 2: ...on 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 2013 Piaggio C S p A All rights reser...

Page 3: ...isable 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 compl...

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Page 5: ...CS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...the 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 u...

Page 8: ...ity Chassis prefix 125 ZAPM44300 1001 Engine prefix 125 M444M 1001 Chassis prefix 150 ZAPM44400 1001 Engine prefix 150 M445M 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Kerb weight 114 5 kg Characteristics Vespa LX 125 150 4T Euro 3 CHAR 8 ...

Page 9: ...5 7 65 kW at 8250 rpm Max power 150 8 9 kW at 7 750 rpm Max torque 125 9 6 Nm at 7 250 rpm Max torque 150 11 8 Nm at 6 500 rpm Cooling Forced circulation air cooling Transmission TRANSMISSION Specification Desc Quantity Transmission With continuously variable expandable pulley transmission with torque server V belt automatic clutch gear reduction unit and transmission housing with forced air circu...

Page 10: ...tion Desc Quantity Front wheel rim Die cast aluminium alloy 2 50 x11 Front tyre Tubeless 110 70 11 Rear wheel rim Die cast aluminium alloy 3 00 x 10 Rear tyre Tubeless 120 70 10 Front tyre pressure 1 6 bar Rear tyre pressure 2 bar Rear wheel pressure rider and passenger 2 3 bar Secondary air In order to reduce polluting emissions the vehicle is furnished with a catalytic converter in the muf fler ...

Page 11: ...ter Ø 26 4 Setting stamping 270C Maximum jet 82 Maximum air jet on the body 85 Tapered pin stamping NJHA Throttle valve spring 130 180 gr Minimum jet 42 Idle air jet on the body 150 Idle mixture adjustment screw initial opening 2 Starter nozzle 35 Starter air jet on the body Ø 1 5 Starter pin travel 10 mm at 24 Starter resistance 20 Ohm at 24 150cc Version Kehin CARBURETTOR SETTING Specification D...

Page 12: ... screw 7 to 8 5 Flywheel cover screw 1 to 2 Flywheel air duct screw 3 4 Pressure reducer counterweight retainer 7 8 5 Camshaft pulley screw 12 14 Timing chain tensioner slider screw 10 to 14 Starter counterweight support screw 11 to 15 Tensioner screws 11 to 13 Timing chain tensioner central screw 5 6 Camshaft retention plate screw 5 6 Nut fixing silencer to cylinder head 16 to 18 Head intake mani...

Page 13: ...swinging arm bolt 33 41 Stand bolt 32 to 40 Swinging arm silent block containment bolt 33 to 41 FRONT SUSPENSION Name Torque in Nm Shock absorber upper nut 20 to 30 Front wheel axle nut 75 to 90 Shock absorber upper bracket bolts 20 to 25 Wheel rim screws 20 to 25 Shock absorber lower bolts 20 to 27 FRONT BRAKE Name Torque in Nm Brake fluid pump hose fitting 8 to 12 Brake fluid pipe calliper fitti...

Page 14: ...994 56 940 to 56 947 0 040 0 054 Coupling C 56 994 to 57 001 56 947 to 56 954 0 040 0 054 Coupling D 57 001 to 57 008 56 954 to 56 961 0 040 0 054 Coupling 1st oversize A1 57 180 to 57 187 57 133 to 57 140 0 040 0 054 Coupling 1st oversize B1 57 187 to 57 194 57 140 to 57 147 0 040 0 054 Coupling 1st oversize C1 57 194 to 57 201 57 147 to 57 154 0 040 0 054 Coupling 1st oversize D1 57 201 to 57 20...

Page 15: ...craper ring 2nd oversize 57 4x1 A 0 10 0 30 Oil scraper ring 2nd oversize 57 4x2 5 A 0 10 0 35 Compression ring 3rd oversize 57 6x1 A 0 15 0 30 Oil scraper ring 3rd oversize 57 6x1 A 0 10 0 30 Oil scraper ring 3rd oversize 57 6x2 5 A 0 10 0 35 Maximum clearance after use 1 mm SEALING RINGS 150 Name Description Dimensions Initials Quantity Compression ring 62 6x1 A 0 15 0 30 Oil scraper ring 62 6x1...

Page 16: ...s Initials Quantity Crankshaft Category 1 28 998 29 004 Crankshaft Category 2 29 004 29 010 Crankcase Category 1 32 953 32 959 Crankcase Category 2 32 959 32 965 Crankshaft half bearing Category B blue 1 973 1 976 Crankshaft half bearing Category C yellow 1 976 1 979 Crankshaft half bearing Category E green 1 979 1 982 Crankshaft category 1 Crankcase category 1 E E Crankshaft category 1 Crankcase ...

Page 17: ...wo measurements use the chart below to identify the thickness of the cylinder base gasket to be used for refitting Correctly identify the cylinder base gasket thickness to keep the correct compression ratio Remove the special tool and the cylinder Characteristic Compression ratio 125 150 10 6 0 5 to 1 SHIMMING SYSTEM 125 Specification Desc Quantity Value measured 0 0 1 Thickness 0 8 0 05 Value mea...

Page 18: ...A NC 956 DOT 4 eni i Ride PG 5W 40 Synthetic based lubricant for high per formance four stroke engines JASO MA MA2 API SL ACEA A3 AGIP FILTER OIL Special product for the treatment of foam filters AGIP GREASE MU3 Yellow brown lithium base medium fi bre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 AGIP GP 330 Water repellent stringy calcium spray grease R I D A D R 2 10 b 2 R I Na 2 42 I A T...

Page 19: ...INDEX OF TOPICS TOOLING TOOL ...

Page 20: ...30Y Tool for fitting steering seats 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract ø 15 mm bearings 002465Y Calliper for circlips 005095Y Engine support 008564Y Flywheel extractor Tooling Vespa LX 125 150 4T Euro 3 TOOL 20 ...

Page 21: ...steering bearings from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge Vespa LX 125 150 4T Euro 3 Tooling TOOL 21 ...

Page 22: ...plate 020263Y Driven pulley assembly sheath 020287Y Clamp to fit piston on cylinder 020306Y Punch for assembling valve seal rings 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing Tooling Vespa LX 125 150 4T Euro 3 TOOL 22 ...

Page 23: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger Vespa LX 125 150 4T Euro 3 Tooling TOOL 23 ...

Page 24: ...escription 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35 mm Adaptor 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55 mm Adaptor 020363Y 20 mm guide 020364Y 25 mm guide Tooling Vespa LX 125 150 4T Euro 3 TOOL 24 ...

Page 25: ...ription 020368Y driving pulley lock wrench 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020412Y 15 mm guide 020414Y 28 mm guide Vespa LX 125 150 4T Euro 3 Tooling TOOL 25 ...

Page 26: ...ey lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel side oil seal 020426Y Piston fitting fork 020427Y Piston assembly band 020428Y Piston position check mounting Tooling Vespa LX 125 150 4T Euro 3 TOOL 26 ...

Page 27: ...ol 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020444Y Tool for fitting removing the driven pulley clutch 020565Y Flywheel lock calliper spanner 020622Y Transmission side oil seal punch Vespa LX 125 150 4T Euro 3 Tooling TOOL 27 ...

Page 28: ...Stores code Description 020481Y005 EFI Technology interface wiring 020922Y Diagnosis Tool Tooling Vespa LX 125 150 4T Euro 3 TOOL 28 ...

Page 29: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 30: ... oil R I I I R I R I R I I Headlight direction adjustment A A A A A Brake pads I I I I I I I I I I I Sliding shoes CVT rollers I R I R I R I R I R Tyre pressure and wear I I I I I I I I I I I Vehicle road test I I I I I I I I I I I Idle speed A A A A A A Odometer gear L L L L L Suspension I I I I I Steering A A A A A A Transmission L L L L L Operation time 80 150 160 150 175 95 270 95 175 150 160 ...

Page 31: ...CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS CAUTION BRAKE FLUID IS HYGROSCOPIC THAT IS IT ABSORBS MOISTURE FROM THE SURROUNDING AIR IF THE CON TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEFFICIENT NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDI...

Page 32: ... 10 or lower than 7 10 of the distance from the ground to the centre of the ve hicle s headlamp 3 If otherwise adjust the right headlight with screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED SAS filters inspection and cleaning Proceed as...

Page 33: ... in good conditions Check the SAS filter housing for dents or defor mations Clean the SAS filter carefully Replace the filter if it is damaged or deformed To refit carry out the removal operations but in re verse order CAUTION WHEN TRAVELLING ON DUSTY ROADS THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR...

Page 34: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 35: ...ce the head unit Worn cylinder Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings Rear wheel spins at idle REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpm too high Adjust the engine idle speed Clutch fault Check the springs clutch masses Starting difficulties START UP PROBLEMS Possible Cause Operation Flat battery Check the state of...

Page 36: ...mensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level adding the recommended oil type Engine tends to cut off at full throttle THE ENGINE TENDS TO STOP AT MAXIMUM THROTTLE Possible Cause Operation Maximum jet clogged Remove the carburettor wash with solvent and dry with com pressed air Water or condensation in the carburet...

Page 37: ...ufficient braking INEFFICIENT OR NOISY BRAKING Possible Cause Operation Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or drum wear conditions Front brake disk loose or deformed Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Air bubbles inside the hydraulic braking system Carefully...

Page 38: ...th the ignition switch set to ON jump the contacts 1 Blue Black and 5 Orange on the control unit connector If by operating the turn indicators control the lights are not steadily on replace the control unit otherwise check the cable harness and the switch Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and botto...

Page 39: ...e good condition Finally check the locking torque of the wheel axle nut the brake calliper and the disc Check that the swinging arm con necting the engine to the chassis and the rear shock absorber work properly Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper Vespa LX 125 150 4T Euro 3 Troubleshooting TROUBL 39 ...

Page 40: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 41: ...socket 6 Ma J2 air valve 150 7 Voltage regulator 8 Main fuses 9 Battery 10 Starter motor 11 Start up remote control switch 12 Secondary fuses 13 Start up button 14 Stop button on rear brake 15 Stop button on front brake 16 Horn button 17 Horn 18 Light switch 19 Turn signal switch Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 41 ...

Page 42: ...r 31 Odometer with warning lights and fuel gauge A Low fuel warning light B Right turn indicator warning light C Left turn indicator warning light D Instrument panel lighting bulbs E Headlight warning light F Oil pressure warning light G High beam warning light H Immobiliser diagnosis LED 32 Turn indicators sound alarm wiring 33 Fuel pump 34 Electric pump control device 35 Spark plug 36 HV coil 37...

Page 43: ... socket 6 Ma J2 air valve 150 7 Voltage regulator 8 Main fuses 9 Battery 10 Starter motor 11 Start up remote control switch 12 Secondary fuses 13 Start up button 14 Stop button on rear brake 15 Stop button on front brake 16 Horn button 17 Horn 18 Light switch 19 Turn signal switch Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 43 ...

Page 44: ...ow fuel warning light B Right turn indicator warning light C Left turn indicator warning light D Instrument panel lighting bulbs E Headlight warning light F Oil pressure warning light G High beam warning light H Immobiliser diagnosis LED 32 Turn indicators sound alarm wiring 33 Fuel pump 34 Spark plug 35 HV coil 36 Carburettor heater 37 Automatic starter 38 External temperature sensor KEY Ar Orang...

Page 45: ...Con pompa elettrica 1 Dispositivo di accensione elettronica 2 Antenna immobilizer 8 Fusibili principali 9 Batteria 28 Commutatore a chiave 35 Candela 36 Bobina A T Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 45 ...

Page 46: ...pompa elettrica 1 Dispositivo di accensione elettronica 2 Antenna immobilizer 8 Fusibili principali 9 Batteria 28 Commutatore a chiave 34 Candela 35 Bobina A T Electrical system Vespa LX 125 150 4T Euro 3 ELE SYS 46 ...

Page 47: ...lluminazione targa 22 Fanale posteriore completo 25 Proiettore A Lampada biluce B Lampada luce di posizione anteriore 27 Teleruttore proiettore 28 Commutatore a chiave 31 Contakm con spie e strumento indicatore di livello A Spia riserva carburante B Spia lampeggiatore destro C Spia lampeggiatore sinistro D Lampade illuminazione strumento Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 47 ...

Page 48: ...i accensione elettronica 8 Fusibili principali 9 Batteria 12 Fusibili secondari 18 Deviatore luci 20 Lampada illuminazione targa 22 Fanale posteriore completo 25 Proiettore A Lampada biluce B Lampada luce di posizione anteriore 27 Teleruttore proiettore 28 Commutatore a chiave 31 Contakm con spie e strumento indicatore di livello Electrical system Vespa LX 125 150 4T Euro 3 ELE SYS 48 ...

Page 49: ...i H Led dissuasione e diagnostica 36 Riscaldatore carburatore 37 Starter automatico Battery recharge and starting LEGENDA Con pompa elettrica 1 Dispositivo di accensione elettronica 4 Volano magnete Pick up 7 Regolatore di tensione 8 Fusibili principali 9 Batteria 10 Motorino di avviamento 11 Teleruttore di avviamento Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 49 ...

Page 50: ... elettrica 1 Dispositivo di accensione elettronica 4 Volano magnete Pick up 7 Regolatore di tensione 8 Fusibili principali 9 Batteria 10 Motorino di avviamento 11 Teleruttore di avviamento 12 Fusibili secondari 13 Pulsante di avviamento 14 Pulsante stop sul freno posteriore 15 Pulsante stop sul freno anteriore 22 Fanale posteriore completo Electrical system Vespa LX 125 150 4T Euro 3 ELE SYS 50 ...

Page 51: ...ery 12 Secondary fuses 28 Key switch 29 Fuel level transmitter 30 Engine oil pressure sensor 31 Odometer with warning lights and fuel gauge A Low fuel warning light B Right turn indicator warning light C Left turn indicator warning light D Instrument panel lighting bulbs E Headlight warning light F Oil pressure warning light Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 51 ...

Page 52: ...ses 9 Battery 12 Secondary fuses 28 Key switch 29 Fuel level transmitter 30 Engine oil pressure sensor 31 Odometer with warning lights and fuel gauge A Low fuel warning light B Right turn indicator warning light C Left turn indicator warning light D Instrument panel lighting bulbs E Headlight warning light F Oil pressure warning light Electrical system Vespa LX 125 150 4T Euro 3 ELE SYS 52 ...

Page 53: ...urn indicator warning light 4 Not used 5 PIN CONNECTOR Specification Desc Quantity 1 Fuel gauge 2 High beam warning light 12V 1 2W 3 Engine oil pressure warning light 12V 2W 4 permanent power supply 5 Low fuel warning light 6 Instrument panel lighting and headlamp warning light 2 PIN CONNECTOR Specification Desc Quantity 1 Immobiliser diagnosis LED 2 Immobiliser diagnosis LED Vespa LX 125 150 4T E...

Page 54: ... Horn 19 Turn signal switch 21 Rear left turn indicator 23 Rear right turn indicator 24 Front left turn indicator 26 Front right turn indicator 28 Key switch 31 Odometer with warning lights and fuel gauge A Low fuel warning light B Right turn indicator warning light C Left turn indicator warning light Electrical system Vespa LX 125 150 4T Euro 3 ELE SYS 54 ...

Page 55: ...nd alarm wiring 33 Fuel pump 34 Electric pump control device KEY Without electric pump 1 Electronic ignition device 6 Ma J2 air valve 150 8 Main fuses 9 Battery 12 Secondary fuses 16 Horn button 17 Horn 19 Turn signal switch 21 Rear left turn indicator 23 Rear right turn indicator 24 Front left turn indicator Vespa LX 125 150 4T Euro 3 Electrical system ELE SYS 55 ...

Page 56: ... by an anti theft immobilizer integrated to the control unit The ignition system consists of an electronic control unit immobilizer aerial master and service keys with built in transponder HV coil diagnosis LED The diagnosis LED also works as a blinking light to deter theft This function is activated every time the ignition key is turned to OFF and it remains active 48 hours so as not to affect th...

Page 57: ...lead There is battery voltage between the terminal 8 Red Blue and the terminal 12 Black as shown in the figure there is battery voltage between terminals 9 and 12 with the key switch in ON If no faults are found replace the control unit Virgin circuit If the ignition system has not been programmed the engine can be started but it will run limited to 2000 rpm When trying to accelerate some evi dent...

Page 58: ... etc Each new programming dele tes the previous one If a service key setting is lost it is essential to carefully check the efficiency of the high voltage system Shielded cap resistance 5000 Ω In any case it is advisable to use resistor spark plugs as shown in the figure Diagnostic codes The flash indicating the switching to ON 0 7 sec flash can be followed by a phase of programmed failure warning...

Page 59: ...ONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY Specific tooling 020331Y Digital multimeter Electric characteristic Resistance value 7 9 Ohm Diagnostic code 3 flashes If the 3 flash code is detected check if the failure occurs when the MASTER key in inserted into the ignition key If the failure disappears when the MASTER key is u...

Page 60: ... unit is connected to the Pick Up by the chassis and the engine ground lead To avoid disturbances in the ignition system during start up it is very important that the engine chassis ground connection bonding is efficient No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited follow this procedure Pick Up check Disconnect the control unit co...

Page 61: ...teristic High voltage coil primary resistance value High voltage coil primary resistance value 0 4 0 5 Ohm HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal see figure If non conforming values are measured replace the HV coil To carry out a more complete diagnosis check the peak voltage...

Page 62: ...r If non conforming values are measured replace the control unit THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK Electric characteristic High voltage coil voltage value High voltage coil voltage value 100 Volt Battery recharge circuit The charging circuit consists of three phase alternator and a permanent magneto flywheel The generator is directly connected to the voltage regulator In turn t...

Page 63: ...detected repeat the checks directly to the stator In case of further rep etitions of incorrect values replace the stator or repair the wiring Voltage regulator check With a perfectly charged battery and lights off measure voltage at the battery poles with a high running engine The voltage should not exceed 15 2 Volt In case higher voltages are detected replace the regulator In case of voltage valu...

Page 64: ...supply keep the connector connec ted to the system and check that the two terminals receive battery voltage when the engine is on see figure If no voltage is detected connect the multimeter negative terminal to the ground lead and the pos itive terminal to the automatic starter orange cable with the key switch set to ON check whether there is battery voltage if there is no voltage check the wiring...

Page 65: ...y do replace the control unit because it is faulty If they do not turn on check the control unit turn indicator switch connection cable harness then repeat the test Sealed battery If the vehicle is provided with a sealed battery the only maintenance required is the check of its charge and recharging if necessary These operations should be carried out before delivering the vehicle and on a six mont...

Page 66: ...il Seek immediate medical attention Batteries produce explosive gases keep clear of free flames sparks or cigarettes ventilate the area when recharging the battery indoors Always protect your eyes when working close to batteries Keep out of the reach of children Commissioning dry charged batteries 1 Remove the short closed tube and the plugs then pour sulphuric acid into the cells using the type s...

Page 67: ...lyte level check its density using an appropriate densitometer see figure When the battery is charged you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1 26 to 1 28 at a temperature of no lower than 15 C A density reading of less than 20 Bé indicates that the battery is completely flat and it must therefore be recharged If the vehicle is not used for a given time 1 m...

Page 68: ...UTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Pump electrics check Connect the tester positive probe to pin 4 of the connector of the fuel pump control device and the ne...

Page 69: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 70: ...of the engine from the vehicle Remove the left and right side fairings Remove the helmet compartment Remove the full silencer assembly Remove the 3 rear brake transmission fixing screws indicated in the photograph Disconnect the rear brake transmission unscrew ing the set screw Disconnect the belt cooling tube and the swinging arm retaining spring shown in the photograph Disconnect the spark plug ...

Page 71: ...fuel supply pipe from the carburettor Remove the fuel valve low pressure pipe from the manifold as shown in the photograph Remove the flywheel wiring connector the ground terminal and the starter motor positive ca ble indicated in the figure Vespa LX 125 150 4T Euro 3 Engine from vehicle ENG VE 71 ...

Page 72: ...nly disconnect the solenoid valve connector from the MAJ2 control Unscrew the engine pin swinging arm nut on the right hand side of the vehicle and slide off the pin on the left hand side Support the vehicle adequately with a jack and remove the shock absorber lower clamping The engine is now free Engine from vehicle Vespa LX 125 150 4T Euro 3 ENG VE 72 ...

Page 73: ...INDEX OF TOPICS ENGINE ENG ...

Page 74: ... them Remove the transmission cover If this operation is performed directly on the vehicle it is necessary to remove the cooling air sleeve and the three air filter housing retainers Specific tooling 020423Y Driven pulley lock wrench Kickstart Check the following for wear toothed section toothed section shaft cover seat bushing pinion shaft and its seating in the crankcase and the re turn spring R...

Page 75: ... the screws to the prescribed torque Remove the start up pinion pushing the starter lever Unscrew the kick starter screw remove the lever Remove the seeger ring and the washer indicated in the figure Pull out the toothed section WARNING THE SECTION KEEPS THE SPRING SET BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS Air duct Unscrew the Torx screws fixing the air duct bulk head and remove the bulkhead...

Page 76: ...DAM AGING THE COVER PAINT Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor Refitting the driven pulley shaft bearing Heat up the crankcase inside with the hot air gun Insert the bearing in its housing refit the Seeger ring N B ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING Specific tooling 020151Y Air heater 020376Y Adaptor handle Engine Vespa LX 125 150 4T Euro 3 ENG 7...

Page 77: ...ot worn or damaged Measure the clutch bell inside diameter Characteristic Max value clutch housing Max value Ø 134 5 mm clutch housing standard value Standard value Ø 134 134 2 mm Checking the bell working surface eccentricity Install the bell on a driven pulley shaft using 2 bearings inside diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft unit on the support to che...

Page 78: ... tool set to C Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes After wards make the support screw make contact with a minimum force Using the specific wrench inserted 46 mm from the side remove the clutch central locking nut Separate the driven pulley into its components clutch with fan and contrast spring with plastic fittings CAUTION THE TOOL MUST B...

Page 79: ... IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Remove the collar with the aid of 2 screwdrivers Remove the 3 guide pins and the movable half pulley Removing the driven half pulley bearing Remove the retainer ring using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as shown in the figure Remove the roller bearing using the...

Page 80: ...Characteristic Minimum diameter permitted Ø 40 96 mm Standard diameter Ø 40 965 mm Inspecting the driven sliding half pulley Remove the 2 inner sealing rings and the two O rings Measure the inside diameter of the mobile half pulley bushing Characteristic Minimum admissible diameter Ø 41 08 mm Standard diameter Ø 41 035 mm Engine Vespa LX 125 150 4T Euro 3 ENG 80 ...

Page 81: ...aptor 020376Y Adaptor handle 020439Y 17 mm guide Refitting the driven pulley Check that the faying surfaces between the 2 half pulleys and the belt do not show any signs of wear scoring and grease Insert the new oil seals and O rings on the mov able half pulley Assemble the half pulley on the ringlet with the appropriate protection sheath Make sure the pins and collar are not worn re assemble the ...

Page 82: ...h Check the thickness of the clutch mass friction material The masses must not show traces of lubricants otherwise check the driven pulley unit N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFER ENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING ...

Page 83: ...apter ring before proceeding to tighten the clutch nut Place the tool in the clamp with the control screw on the horizontal axis Fully preload the spring Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench Loosen the tool clamp and insert the belt accord ing to its direction of rotation Lock the driven pulley again using the specific tool Preload the ...

Page 84: ...ar checks foreseen in the scheduled maintenance services at 6000 km 18000 km etc check that the rim bottom of the toothing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Check that the drive belt is not damaged Check the width of the belt BELT SIZE Specification Desc Quantity Minimum width 21 5 mm S...

Page 85: ... Remove the return rollers plate with the relative guide sliders Inspecting the rollers case Check that the internal bushing is not abnormally worn and measure inner diameter N B DO NOT LUBRICATE OR CLEAN THE BUSHING BUSHING ROLLER HOUSING Specification Desc Quantity Maximum allowable diameter Ø 26 121 mm Standard diameter Ø 26 0 0 021 mm BUSH SLIDE PULLEY Specification Desc Quantity Minimum diame...

Page 86: ...ng fixed half pulley external lining drive and nut spread threadlock on the thread and screw the nut to the prescribed torque Avoid the half pulley rotation using a calliper spanner N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT Specific tooling 020368Y driving pulley lock wrench Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Lockin...

Page 87: ...que wrench tools Refit the plastic cover Specific tooling 020423Y Driven pulley lock wrench Locking torques N m Transmission cover screws 11 13 Driven pulley shaft nut 54 60 End gear Removing the hub cover Empty the rear hub through the oil drainage tap located inside the hub cover Remove the brake shoe and relevant spring Remove the 7 flanged screws as shown in the figure Remove the rubber cover ...

Page 88: ...emove the three 15 mm bearings 2 in the crankcase and 1 in the hub cover Specific tooling 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract ø 15 mm bear ings Removing the wheel axle bearings Take out the clip on the outside of the hub cover Remove the bearing with the adequate tools ad equately supporting the hub cover as shown in the figure Specific tooling 020376Y Adaptor hand...

Page 89: ...king from inside the bearing and being careful not to damage the housing make it come out of the belt transmission side Remove the Seeger ring shown in the figure With the sectional punch remove the driven pulley shaft bearing Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide See also Removing the driven pulley Inspecting the hub shaft Check the three shafts fo...

Page 90: ...th ball bearing in view from the inside of the hub cover using the adequate tools Specific tooling 020376Y Adaptor handle Refit the Seeger ring with the opening facing the bearing as shown in the figure and fit a new oil seal flush with the crankcase Refitting the wheel axle bearing Heat up the parts using the specific heat gun Specific tooling 020151Y Air heater 020150Y Air heater mounting The wh...

Page 91: ...ting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the specific heat gun Specific tooling 020150Y Air heater mounting 020151Y Air heater The three 15 mm bearings must be fitted using the appropriate tools Refitting the hub bearings Insert the cover prepared in the crankcase taking care of inserting the gear of the pulley shaft...

Page 92: ...NG Loosen the clamp and remove the carburettor from the manifold Remove the complete manifold acting on the 2 retainers as shown in the figure Remove the 2 self tapping screws left and right and the lateral base retaining screw on the crank case base Take off the housings Remove the gasket seal of the housing on the head N B IF THE FLYWHEEL HOUSING IS NOT REMOVED IT IS AL SO NECESSARY TO REMOVE TH...

Page 93: ...g spacers should be in a high position CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR Remove the cooling fan by acting on the three fixings indicated in the figure Removing the stator Remove the electric terminal of the minimum oil pressure switch Remove the two Pick Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure Rem...

Page 94: ... DOWEL AS SHOWN IN THE DETAIL DRAWING Locking torques N m Stator screw 3 4 Flywheel and starting Removing the flywheel magneto Lock the rotation of the flywheel using the calliper spanner Remove the nut CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS Specific tooling 020565Y Flywheel lock calliper spanner Extract the flywheel with the extractor Speci...

Page 95: ...erent values result from deformations visible on the Pick Up mounting N B A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED Locking torques N m Flywheel nut 52 58 Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRIBED IN TH...

Page 96: ...wn in the figure Remove the tensioner with its gasket Remove the internal hex screw and the counter weight shown in the figure Remove the camshaft control pulley with its washer Remove the control sprocket wheel and the tim ing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The tensioner pad must be removed from the transmission side As regards the lower ch...

Page 97: ...ION OF INTAKE WITH THE EXHAUST Removing the cylinder head Remove the spark plug Remove the 2 side fixings shown in the figure Loosen the 4 head cylinder fastening nuts in two or three stages and in criss cross fashion Remove the head the two alignment dowels and the gasket N B IF NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKER PINS AND FIXING BRACKET THE HEAD CAN ALSO BE REMOVED WITHOUT RE...

Page 98: ...ls with the appropriate tool Remove the lower spring supports Specific tooling 020431Y Valve oil seal extractor Removing the cylinder piston assy Remove the chain guide slider Remove the cylinder base gasket CAUTION TO AVOID DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER Remove the two retainer rings the wrist pin and the piston Remove the 3 piston rings from the piston N B BE CAREFUL ...

Page 99: ...heck up Maximum diameter 15 030 mm Connecting rod small end check up Standard diameter 15 0 015 0 025 mm Inspecting the wrist pin Check the outer diameter of the gudgeon pin Characteristic Standard pin diameter 14 996 15 mm Minimum diameter permitted Ø 14 994 mm Calculate the piston pin coupling clearance N B THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS FOR THIS REASON MEASUREMENT OF THE DIAMETER ...

Page 100: ...ximum allowable run out 0 001 over 0 05 mm The cylinder rectifying operation should be car ried out with a surfacing that respects the original angle The cylinder surface roughness should be 0 9 micron This is indispensable for a good seating of the sealing rings which in turn minimises oil consump tion and guarantees optimum performance The pistons are oversized due to cylinder rectifi cation and...

Page 101: ...rist pin onto the connecting rod aligning the piston arrow the arrow facing to wards the exhaust Fit the pin retainer ring onto the appropriate tool Specific tooling 020430Y Pin lock fitting tool With the opening in position indicated on the tool take retainer ring in the closed position using the punch Fit the pin retainer ring using the plug as shown in the figure N B THE TOOL FOR INSTALLING THE...

Page 102: ...ord top or the reference mark facing the crown of the piston Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure Lubricate the components with engine oil N B SO AS TO OBTAIN THE BEST CONFIGURATION THE 2 SEALING RINGS ARE MADE WITH A CONTACT CONICAL CYLINDER SECTION Refitting the cylinder Insert the cylinder base gasket with the thickness determined above Usin...

Page 103: ...itted unevenness Cylinder head check 0 05 mm STANDARD DIAMETER Specification Desc Quantity Standard diameter A Ø 32 5 32 525 Standard diameter B Ø 20 20 021 Standard diameter C Ø 12 12 018 Inspecting the timing system components Check that the guide slider and the tensioner slider are not worn out Ensure that the camshaft drive pulley the chain assembly and the sprocket wheel are not worn If sings...

Page 104: ...e seats VALVE SEAL SURFACE Specification Desc Quantity Intake valve seal surface 2 4 2 8 mm Exhaust valve seal surface 2 2 2 6 mm Inspecting the valve housings Remove any carbon formation from the valve guides Measure the inside diameter of each valve guide Take the measurement at three different heights in the rocker arm push direction Characteristic Standard drainage guide diameter 5 012 mm Stan...

Page 105: ...m diameter admitted Intake 4 96 mm Minimum diameter admitted Exhaust 4 95 mm Standard clearance Intake 0 013 0 040 mm Standard clearance Exhaust 0 025 0 052 mm Maximum clearance admitted Intake 0 062 mm Maximum clearance admitted Exhaust 0 072 mm Check that there are no signs of wear on the contact surface with the articulated register termi nal If the sealing surface on the valves is wider than t...

Page 106: ...E VALVE WHEN NO LAPPING COM POUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED Insert the valves into the cylinder head Test the 2 valves alternatively The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers Insp...

Page 107: ...ngs and insert the cotters in their seats Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft Inspect the cam shaft for signs of abnormal wear on the cams Characteristic Standard diameter Bearing A Ø 32 5 mm 0 025 0 050 mm Standard diameter Bearing B 20 0 020 0 041 mm Minimum admitted diameter bearing A Ø 32 ...

Page 108: ...lace any defective or worn components Check there are no signs of scoring or wear on the rocking lever bolt Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate Measure the internal diameter of each rocking lever Check that the elastic washer dedicated to the axle clearance of the rocking levers is not worn In case of failure replace the damaged...

Page 109: ...crank shaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the tensioner pad by the cylinder head Fit the spacer and the screw fastener Fit the pin the exhaust rocking lever the spring washer and the intake rocking lever Lubricate the 2 rocking levers through the holes at the top Lubricate the 2 bearings and insert the camshaft in the cyl...

Page 110: ... stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft Fit the automatic valve lifter return spring During this operation the spring must be loaded approximately 180 N B GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE Fit the automatic valve lifter retaining dish using the counterweight screw fastener as a reference Tighte...

Page 111: ...ting direction use the supplements on the timing side as reference Assemble the screw fixing the housing to the crankcase to the specified torque and the 2 self tapping screws joining the half shells Take care that the gasket is well inserted in its housing during the assembly stage Place the spark plug access cap Locking torques N m Locking torque 3 to 4 Fit the intake manifold and lock the 2 scr...

Page 112: ...n the transmission chapter Remove the oil sump the by pass the chain compartment cover and the oil pump as in the lu brication chapter Remove the flywheel cover the fan the flywheel and the stator as described in the magneto fly wheel chapter Remove the oil filter and the oil pressure bulb Remove the cylinder piston head unit as descri bed in the cylinder head timing system chapter Remove the 2 re...

Page 113: ...rankcase halves Remove the two screws and the internal shield shown in the diagram CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS Remove the oil seal on the flywheel side Remove the oil filter fitting shown in the diagram Check the axial clea...

Page 114: ...s not have any defect the problem must be due to either excessive wear or wrong machining on the crankcase CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING Characteristic Distance between the shoulders 55 67 55 85 mm Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in...

Page 115: ...ced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the lubrication duct with compressed air Make sure that the 2 caps on the crankpin are properly fitted A wrong installation of a cap can seriously affect the bushing lubrication pressure N B THE MAIN BE...

Page 116: ...N BUSHINGS AND CONNECTING ROD On the flywheel side crankcase half take partic ular care cleaning the oil ducts for the main bush ings the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the fly wheel side oil seal N B THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET THIS GIVES A LOW PRESSURE HEAD LUBRICATION THIS CHOICE WAS MADE TO REDUCE THE OIL TEMP...

Page 117: ...thrusts caused by combustion and for this reason it is arranged opposite 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 figure The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface...

Page 118: ...G DURING THE DRIVING OPERATION MAIN BEARINGS Specification Desc Quantity B Blue C Yellow E Green Refitting the crankcase halves Fit the internal bulkhead by locking the two screws to the prescribed torque Locking torques N m Locking torque 4 to 6 Fit the oil filter joint and tighten it to the prescribed torque Place a new gasket on one of the crankcase halves preferably on the transmission side to...

Page 119: ...ppropriate tool to assemble the oil seal Fit a new O ring on the pre filter and lubricate it Insert the pre filter on the engine with its corre sponding cover to the specific torque N B REMOVE ANY EXCESS FROM THE CRANKCASE COU PLING GASKET ON THE CYLINDER PLANE TO ENSURE BETTER SEALING PERFORMANCE N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE ...

Page 120: ...Conceptual diagrams Engine Vespa LX 125 150 4T Euro 3 ENG 120 ...

Page 121: ...atm Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the prescribed torque and fit the flywheel cover If the oil pressure is not within the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND...

Page 122: ...e threaded bar onto the base of the tool and extract the oil seal Specific tooling 020622Y Transmission side oil seal punch Refitting Prepare the new oil seal lubricating the sealing lip Warning do not lubricate the surface for keying onto the engine crankcase CAUTION DO NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE Engine Vespa LX 125 150 4T Euro 3 ENG 122 ...

Page 123: ...TION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL SEAL FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH Orientate the oil seal by inserting the bracket which is part of the specific tool Tighten the threaded bar onto the crankshaft as far as it will go Vespa LX 125 150 4T Euro ...

Page 124: ... new oil seal on the flywheel side using the specific tool as shown in the photograph N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE IN INADEQUATE OIL SEAL Specific tooling 020425Y Punch for flywheel side oil seal Oil pump Removal Remove the cover of the pump control pulley us ing the two retainers as shown in the figure Block the rotation of t...

Page 125: ...IRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the circlip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Reassemble the rotors in the pump body keep ing the two reference marks visible Replace the retainer ring Using a feeler gauge check the distance be tween the rotors in the position shown in...

Page 126: ...haft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the assembly Fit the pulley to the pump the central screw to the specified torque and the cup washer Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE CUP WASHER SO THAT ITS OUTER CURVED RIM TOUCHES TH...

Page 127: ...e and the 2 rear brake transmission fixing brackets Remove the spring the by pass piston and the gasket shown in the second image Inspecting the by pass valve Check the unloaded spring length Check that the small piston is not scored Ensure that it slides freely on the crankcase and that it guarantees a good seal If not eliminate any impurities or replace defec tive parts Characteristic By pass ch...

Page 128: ...verse order from which they were removed Tighten the screws to the prescribed torque Refit the driving pulley assembly the drive belt the sprocket wheel and the transmission cover as described in the Transmission chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the connecting rod as sembly Locking torques N m Locking torque 11 to 1...

Page 129: ...ce inside the valve with a multimeter Electric characteristic Solenoid resistance 35 5 40 5 mm at 20 C Apply 12V DC to the connector ends as indicated in the photograph Check that the solenoid valve opens Check that air intake pipe on the carburettor shown in the photograph is not blocked Vespa LX 125 150 4T Euro 3 Engine ENG 129 ...

Page 130: ...table and that and that there are no fuel leaks Reconnect the vacuum pipe to the manifold Position the fuel pipe with the outlet at the point of the tap Turn the engine by using the starter motor for five seconds with the carburettor at minimum Take up the fuel by means of a graded burette N B THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE IN...

Page 131: ...and block the clip N B THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING Removing the carburettor To detach the carburettor from the engine it is necessary to move the air filter and remove the throttle control transmission the automatic starter connection the clamps anchoring the carburettor to the filter housing and to the intake manifold the air delivery pipe to the diaphragm the...

Page 132: ...ure Remove the 2 screws and the starter support with the gasket Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Engine Vespa LX 125 150 4T Euro 3 ENG 132 ...

Page 133: ...m Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Remove the 4 screws indicated in the figure Remove the chamber with the accelerating pump its control and gasket Vespa LX 125 150 4T Euro 3 Engine ENG 133 ...

Page 134: ...E MADE UP OF NOZZLES SPRING AND BALL N B AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle Remove the maximum nozzle Engine Vespa LX 125 150 4T Euro 3 ENG 134 ...

Page 135: ...e sprayer N B WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS IF THE SPRAY ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT Vespa LX 125 150 4T Euro 3 Engine ENG 135 ...

Page 136: ...NS AND INTAKE NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNEC TION SCREWS THE FIXING SCREWS ARE CAULKED AF TER FITTING AND THEIR REMOVAL DAMAGES THE SHAFT Refitting the carburettor Before refitting wash the carburettor body accu rately with petrol and compressed air Pay special attention to the fuel supply pipe and the plunger seat Engine Vespa...

Page 137: ...TED TO THE THROTTLE VALVE NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY ING Check that there are 5 closing ball joints for the operating pipes on the carburettor body Check that the coupling surfaces the chamber and the diaphragm are not dented Check that the depression valve housing pipe is not scratched Check that the throttle valve and the shaft do not show abnormal wear Check that t...

Page 138: ...nserted and lock it Assemble the maximum nozzle Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock ab sorber pin and the return clamp Replace the rod if worn out Check that the float is not worn on the pin housing or on the contact plate with the plunger and that there are no fuel infiltration Replace it in case of failures Introduce the float with the rod ...

Page 139: ...t of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is free to rotate in its own seat N B MAKE SURE THE TANK GASKET IS CORRECTLY INTRO DUCED N B AVOID DEFORMING THE ACCELERATION PUMP CON TROL ROCKER Wash and blow the flow screw properly Check that screw is not deformed and or rusty Assemble the spri...

Page 140: ...the vacuum valve does not show wear Check that the depression valve does not show threads on the external surfaces Check that the vacuum intake hole is not clogged Check that the diaphragm is not damaged or has hardened otherwise replacement the whole valve Insert the tapered pin into the vacuum valve housing Reassemble the vacuum valve on the carburettor body taking care that the tapered pin is i...

Page 141: ... of the vacuum chamber being careful to correctly insert the spring in its place on the cover Tighten the screws Wash and blow dry the filter sponge of the am bient pressure intake Reassemble the filter with its clamp Vespa LX 125 150 4T Euro 3 Engine ENG 141 ...

Page 142: ...n in the figure and check its corresponding value Make sure that the starter is adjusted for the am bient temperature The starter should disconnect progressively by means of electric heating Check the starter resistance when adjusted to the ambient temperature With a 12V battery power the automatic starter and check that the piston protrudes as much as possi ble The correct warm up time depends on...

Page 143: ...re frequent idle speed adjustments but it is essential to strictly follow cer tain rules when adjusting the idle speed Before adjusting the carburettor make sure to re spect the lubrication requirements valve clear ance and complying timing spark plug should be in optimum conditions air filter clean and sealed and the exhaust system tight Warm up the engine by running it at least 5 mi nutes at app...

Page 144: ...w until 1600 1700 rpm is obtained N B THE WASTED SPARK IGNITION SYSTEM OFFERS RE MARKABLE POWER READINGS MAY NOT BE ACCU RATE IF INADEQUATE RPM INDICATORS ARE USED CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 8000 Engine Vespa LX 125 150 4T Euro 3 ENG 144 ...

Page 145: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 146: ...e wheel to the hub N B BEFORE REMOVING THE WHEEL HUB REMOVE THE BRAKE CALLIPER Front wheel hub overhaul Remove the ball bearing check Seeger ring indi cated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract ø 15 mm bear ings 001467Y017 Bell for bearings OD 39 mm Suspensions Vespa LX 125 150 4T Euro 3 SUSP 146 ...

Page 147: ...ng out Refit the ball bearing check Seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020357Y 32 x 35 mm Adaptor 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punch Recommended products AGIP GREA...

Page 148: ...he electrical terminals remove the termi nal fixing the handlebar to the steering Check all components and replace faulty parts N B IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting Carry out the removal operations but in the reverse order observing the prescribed tightening torque Locking torques N m Handlebar lock...

Page 149: ...arp edged end Use the tool fitted with parts 3 and 4 as indicated to fit the pin and press operating the handgrip until wedging the washers on the swinging hub Remove the spacers part 17 fill with grease the area between the steering tube and the swinging hub and place the dust guard rings in that place Supplied with the tool N B ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION O...

Page 150: ...sing the tool fitted with part 16 and part 22 instead of part 4 on the stem on the side opposite the one shown in the figure to refit the second wedging washer roller casing sealing ring unit Supplied with the tool Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 NATO G 460 s...

Page 151: ... 1 and op erate the handgrip until the pin and the Nadella are simultaneously ejected in the direction opposite the tool thrusting force To eject the second Nadella use the tool fitted with part 2 instead of part 1 on the side opposite the one shown in the figure Supplied with the tool Specific tooling 020021Y Front suspension service tool The front suspension service operation is useful to replac...

Page 152: ...e upper ring nut B to the specified torque Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Locking torques N m Steering lower ring nut 8 10 Steering upper ring nut 35 to 40 Front shock absorber Suspensions Vespa LX 125 150 4T Euro 3 SUSP 152 ...

Page 153: ...der observing the prescribed tightening torques Locking torques N m shock absorber lower clamping 20 27 shock absorber upper clamp 20 to 30 Shock absorber calliper bracket Removal Remove the front wheel hub with the brake disc Remove the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Vespa LX 125 150 4T Euro 3 Suspensions SUSP 153 ...

Page 154: ...mping 20 to 27 Overhaul The bracket for the shock absorber calliper at tachment has two roller bearings separated one from the other as shown in the photograph Remove the two roller bearings from the bracket with the specific tool operating on the shock ab sorber attachment side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remov...

Page 155: ...alliper shock absorber attachment bracket Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y P...

Page 156: ...Remove the fifth wheel fitting and the dust gaiter on the steering bearing as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing steering bearings from headstock Refit the fifth wheel fitting and the dust gaiter on the steering bearing until they stop using the spe cific tool Specific tooling 006029Y Punch for fitting steer...

Page 157: ...ed torque Refit the cap and the cotter pin folding it correctly as shown in the figure Locking torques N m Locking torque 137 to 152 Nm Swing arm Removal Remove the swinging arm acting on the three clamps shown in the figure Vespa LX 125 150 4T Euro 3 Suspensions SUSP 157 ...

Page 158: ...Refitting For rifting respect the locking torques Locking torques N m Part C 33 to 41 Part B 44 to 52 Part A 33 to 41 Shock absorbers Suspensions Vespa LX 125 150 4T Euro 3 SUSP 158 ...

Page 159: ... absorber chas sis anchoring nut and the shock absorber engine pin to the prescribed torque Locking torques N m Shock absorber engine pin torque 33 to 41 N m Shock absorber chassis nut torque 20 25 Nm Centre stand Replace complete stand Undo the screw marked in the figure When refitting secure to the prescribed torque Locking torques N m Centre stand screw 32 to 40 Vespa LX 125 150 4T Euro 3 Suspe...

Page 160: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 161: ...rews fixing the brake calliper to the crankcase then remove the brake calliper com plete with pipe Complete the extraction of the pad retention pin the spring and the pads N B IF BRAKE CALLIPER REPLACEMENT OR SERVICE IS NEEDED BEFORE REMOVING THE CALLIPER CLAMPS TO THE SUPPORT BRACKET LOOSEN THE OIL JOINT FITTING Vespa LX 125 150 4T Euro 3 Braking system BRAK SYS 161 ...

Page 162: ... the seal rings in the half calliper N B WHEN REMOVING THE O RINGS BE CAREFUL NOT TO SCRATCH THE HALF CALLIPER SEATS Check there are no scorings on the pistons and their seats otherwise replace them Wash and blow all the components carefully Fit the seal rings and new dust guards Refit the pistons in their seats being careful to lubricate with brake fluid Re couple the half callipers and lock the ...

Page 163: ...OTA TION COULD COMPROMISE PROPER BRAKE FUNCTION ING AND NOISELESSNESS Keep the brake pads in contact with the pistons and insert the calliper in the brake disc Fix the calliper to the fork with the two screws with elastic washer at the prescribed torque Fix the brake pipe joint to the calliper and tighten at the prescribed torque Purge the circuit and refit the front wheel Locking torques N m Brak...

Page 164: ...op erating on the five screws shown in the photo graph remove the brake disc Refitting Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it Tighten the 5 screws to the specified torque Locking torques N m Brake disc screws 6 0 5 1 Nm Braking system Vespa LX 125 150 4T Euro 3 BRAK SYS 164 ...

Page 165: ...turn and check the disk de viation Specific tooling 020335Y Magnetic mounting for dial gauge Characteristic Standard thickness 4 0 2 0 2 mm Max deviation allowed 0 1 mm Front brake pads Removal Remove the front wheel Remove the brake calliper Remove protection cover the bolt and the leaf spring Remove the brake pads Check that there are no faults or warping If there are replace them Check that the...

Page 166: ...nds towards the bleed screw as in the photo Insert the lock on the bolt and then the protection cover Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque CAUTION BEFORE USING THE BRAKE OPERATE THE LEVER A FEW TIMES Locking torques N m Rear brake calliper tightening screw 20 to 25 Nm Fill Braking system Vespa LX 125 150 4T Euro 3 BRAK SYS 166 ...

Page 167: ...REVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER...

Page 168: ... Nm Removal Remove the front and rear handlebar covers Remove the two screws fixing the brake pump to the handlebar indicated in the photograph Remove the oil pipe joint from the pump Remove the connector to the stop light switch Overhaul Proceed as follows 1 Remove the brake lever by loosening the retaining screw open the cover 2 and take out the dia phragm 3 2 remove the cap 4 and take out the i...

Page 169: ...ICED 1 Reservoir cap screw 2 Reservoir cap 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8 Spring 9 Tank Refitting To refit carry out the removal operations but in reverse order observing the specified torques Locking torques N m Oil pipe joint to the pump 20 25 Brake pump fixing screws to the handlebar 7 to 10 Nm Vespa LX 125 150 4T Euro 3 Braking system BRAK SYS 169 ...

Page 170: ...the shoe spring using the specific span ner 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mallet 4 Attach the spring using the specific pliers Specific tooling 020325Y Pliers for brake shoe springs Braking system Vespa LX 125 150 4T Euro 3 BRAK SYS 170 ...

Page 171: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 172: ...el Operate the 4 screws shown in the figure to re place the instrument panel Front handlebar cover Remove the 2 screws in the rear handlebar cover and the screw under the headlamp Pull up and detach the front handlebar cover disconnect the headlight assembly connections Chassis Vespa LX 125 150 4T Euro 3 CHAS 172 ...

Page 173: ...in the figure and remove the headlight Knee guard Unscrew the 2 screws shown in the figure placed under the front grille Remove the 3 screws shown in the figure placed inside the glove box they can be reached after opening the glove box door Vespa LX 125 150 4T Euro 3 Chassis CHAS 173 ...

Page 174: ...ave been removed Air filter Remove the helmet compartment after removing the side fairing remove the 2 screws fixing the filter housing to the engine indi cated in the figure Remove the two clamps indicated in the figure Remove the MAJ2 hoses Chassis Vespa LX 125 150 4T Euro 3 CHAS 174 ...

Page 175: ...rom the calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Vespa LX 125 150 4T Euro 3 Chassis CHAS 175 ...

Page 176: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 177: ...s arm Handlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam lights low beam lights tail and parking lights and their warning lights Adjusting the headlights according to the regulations currently in force Rear light parking light stop light Front and rear stop light switches Turn indicators and their warning lights In...

Page 178: ...ND SEEK IMMEDIATE MEDICAL ATTENTION IF IT ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT O...

Page 179: ...ED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the chassis and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors and any acce...

Page 180: ...d 167 C Carburettor 11 131 136 Checks 56 F Fuel 37 128 H Headlight 32 173 I Identification 8 Instrument panel 172 M Maintenance 7 30 R Recommended products S Shock absorbers 158 Spark plug 60 Start up Suspension 39 T Transmission 9 37 74 87 96 Turn indicators Tyres 10 V Vehicle 8 70 ...