VESPA LX Series, User Manual

Page 1: ...MANUALE STAZIONE DI SERVIZIO XXXXXX IT XXXXXX EN XXXXXX FR XXXXXX DE XXXXXX ES XXXXXX PT XXXXXX OL XXXXXX EL Vespa LX 125 150 i e ...

Page 2: ...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 2008 PIAGGIO C S p A Pontedera All rights reserved Rep...

Page 3: ...dispone degli impianti e delle attrezzature necessarie ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici 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 sp...

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

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

Page 7: ... 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 spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and sp...

Page 8: ...0001 Engine prefix 125 M444Mto 1001 Chassis prefix 150 ZAPM4440000 to 100001 Engine prefix 150 M445Mto 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Kerb weight 114 5 kg Maximum height 1140 mm Width 740 mm Wheelbase 1280 mm Length 1770 mm Characteristics Vespa LX 125 150 i e CHAR 8 ...

Page 9: ... 9 kW at 8250 rpm Max power 150 7 9 kW at 8000 rpm Max torque 125 9 6 Nm at 6500 rpm Max torque 150 11 8 Nm at 6250 rpm Cooling Forced air circulation Transmission TRANSMISSION Specification Desc Quantity Transmission With automatic expandable pulley variator with torque server V belt automatic clutch gear reduction unit and transmission housing with forced air circulation cooling Final reduction ...

Page 10: ...3 With the remote control powered check that there is continuity between terminals 30 and 87 4 If these conditions are not fulfilled the remote control is damaged and must be replaced To check buttons and switches check that according to their position the continuity of contacts is correct as indicated in the following charts TURN INDICATOR SWITCH HORN BUTTON LIGHT SWITCH Characteristics Vespa LX ...

Page 11: ...the nozzle 20 Resistance at terminals 13 7 to 15 2 Ohm FUEL PUMP UNIT Mechanical type pressure regulator operating at a pressure of 2 5 BAR Pump winding resistance 1 5 Ohm Input current during regular functioning 1 4 1 8 A Vespa LX 125 150 i e Characteristics CHAR 11 ...

Page 12: ...ation threshold 0 3 0 6 bar With the engine off continuity between terminal and ground HV COIL DIV class O v shape _x0000_s3074 Resistance of the primary 0 5 Ohm 8 Resistance between primary and ground infinite Resistance between primary and HV output 3 1 KOhm 9 Presence of battery voltage between pins 22 and 26 of the interface cable harness upon shifting to ON and for 2 sec Characteristics Vespa...

Page 13: ... shock absorber adjustable to four positions at preloading Rear suspension travel 83 mm Brakes BRAKES Specification Desc Quantity Front brake Ø 200 mm disc brake with hydraulic control activated by han dlebar right side lever Rear brake Ø 110 mm drum brake with mechanical control activated by handlebar left side lever Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Front wheel rim Di...

Page 14: ...ening on exhaust manifold 40 to 50 HEAD AND CYLINDER Name Torque in Nm Ignition spark plug 12 to 14 Head cover screws 11 to 13 Nuts fixing head to cylinder 28 to 30 Head fixing screws external 11 to 13 Starter ground screw 7 to 8 5 Flywheel cover screw 1 to 2 Flywheel air duct screw 3 to 4 Pressure reducer counterweight retainer 7 to 8 5 Camshaft sprocket screw 12 to 14 Timing chain tensioner slid...

Page 15: ...hassis pin 44 to 52 Engine swinging arm pin 33 to 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 screw 20 to 25 Shock absorber lower bolts 20 to 27 Apply LOCTITE 242 threadlock FRONT BRAKE Name Torque in Nm Brake fluid pump...

Page 16: ...50 Name Initials Cylinder Piston Play on fitting Coupling A 62 580 to 62 587 62 541 to 62 548 0 032 to 0 046 Coupling B 62 587 to 62 594 62 548 to 62 555 0 032 to 0 046 Coupling C 62 594 to 62 601 62 555 to 62 562 0 032 to 0 046 Coupling D 62 601 to 62 608 62 562 to 62 569 0 032 to 0 046 125 version COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER 125 Name Initials Cylinder Pist...

Page 17: ... to 0 060 Coupling 3rd oversize P3 57 618 to 57 625 57 565 to 57 572 0 046 to 0 060 Piston rings SEALING RINGS 125 Name Description Dimensions Initials Quantity Compression ring 57 x 1 A 0 15 to 0 30 Oil scraper ring 57x1 A 0 10 to 0 30 Oil scraper ring 57x2 5 A 0 10 to 0 35 Compression ring 1st oversize 57 2 x 1 A 0 15 to 0 30 Oil scraper ring 1st oversize 57 2x1 A 0 10 to 0 30 Oil scraper ring 1...

Page 18: ... 51 400 E AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF BEARINGS Name Description Dimensions Initials Quantity Crankshaft Category 1 28 998 to 29 004 Crankshaft Category 2 29 004 to 29 010 Crankcase Category 1 32 953 to 32 959 Crankcase Category 2 32 959 to 32 965 Crankshaft half bearing Category B blue 1 973 to 1 976 Crankshaft half bearing Category C yellow 1 976 to 1 979 Crankshaft hal...

Page 19: ...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 to 0 1 Thickness 0 8 0 05 Value mea...

Page 20: ...smissions brakes throttle control and odometer Oil for 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased adhesiveness AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP GP 330 Grease for ...

Page 21: ...INDEX OF TOPICS TOOLING TOOL ...

Page 22: ...ering seats 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings OD 39 mm 002465Y Pliers for circlips 005095Y Engine support Tooling Vespa LX 125 150 i e TOOL 22 ...

Page 23: ...nch for fitting fifth wheel seat on steer ing tube 008564Y Flywheel extractor 020004Y Punch for removing fifth wheels from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch Vespa LX 125 150 i e Tooling TOOL 23 ...

Page 24: ...55Y 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 020262Y Crankcase splitting plate Tooling Vespa LX 125 150 i e TOOL 24 ...

Page 25: ...y assembly sheath 020306Y Punch for assembling valve seal rings 020325Y Pliers for brake shoe springs 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter Vespa LX 125 150 i e Tooling TOOL 25 ...

Page 26: ...n 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32x35 mm Adaptor 020359Y 42x47 mm Adaptor Tooling Vespa LX 125 150 i e TOOL 26 ...

Page 27: ...Stores code Description 020360Y 52x55 mm Adaptor 020363Y 20 mm guide 020364Y 25 mm guide 020365Y 22 mm guide 020368Y driving pulley lock wrench Vespa LX 125 150 i e Tooling TOOL 27 ...

Page 28: ...Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Tool to extract valve cotters 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor Peak voltage detec tion 020412Y 15 mm guide Tooling Vespa LX 125 150 i e TOOL 28 ...

Page 29: ...e 020423Y Driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel side oil seal 020426Y Piston fitting fork 020456Y Ø 24 mm adaptor 020427Y Piston assembly band Vespa LX 125 150 i e Tooling TOOL 29 ...

Page 30: ... Description 020428Y Piston position check mounting 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020441Y 26 x 28 mm adaptor Tooling Vespa LX 125 150 i e TOOL 30 ...

Page 31: ...7 mm guide 020444Y Tool for fitting removing the driven pulley clutch 020469Y Reprogramming kit for vehicle diagnostic tester 020480Y Petrol pressure check set 020481Y Control unit interface wiring Vespa LX 125 150 i e Tooling TOOL 31 ...

Page 32: ...tores code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission side oil guard punch 020680Y Diagnosis Tool 020641Y EFI Technology software upgrade Tooling Vespa LX 125 150 i e TOOL 32 ...

Page 33: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 34: ...I I I I I Cylinder ventilation system C C Brake control levers L L L L L L Brake fluid I I I I I I I I I I I Engine oil R R R R R R R R R R R Hub oil R I I I R I I I R I I Headlight aiming adjustment A A A A A Brake pads I I I I I I I I I I I Sliding blocks variable speed 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 test ride I I I I I I I I I I I Odometer gear ...

Page 35: ... bending the side electrode very carefully In case of anomaly as described before replace the spark plug with another of the recommended type Fit the spark plug with the correct inclination and manually screw it all the way down then use the special spanner to tighten it Refit the cover Place the cap fully over the spark plug and tie down the cable to the bracket Carry out refit operations CAUTION...

Page 36: ...re stand Unscrew the oil dipstick cover dry it with a cloth and reinsert it screwing it in thoroughly Remove the dipstick cover and check that the oil level is between MIN and MAX If the level is below the MIN value restore the proper amount of oil in the hub Screw the oil dipstick back and check it is locked Replacement Remove the oil dipstick cover Maintenance Vespa LX 125 150 i e MAIN 36 ...

Page 37: ...y 100cc Locking torques N m Hub oil drainage screw 15 to 17 Nm Air filter Proceed as follows Undo the indicated fixing screws Remove the left side fairing Remove the helmet compartment Undo the six screws and remove the air box cov er Remove the filtering element and clean it with water and shampoo then dry it with a clean cloth and short blasts of compressed air Finally im merse it in a mixture o...

Page 38: ...on sidered normal especially if during the run in period Consumption levels in particular can be influenced by the conditions of use e g oil consumption increases when driving at full throttle Replacement Change oil and replace filter as indicated in the scheduled maintenance table The engine must be emptied by draining off the oil through the drainage plug of the mesh pre filter flywheel side fur...

Page 39: ...ollowing the procedure below Place the vehicle on its centre stand and on flat ground Undo cap dipstick dry it off with a clean cloth and reinsert it screwing down completely Remove the cap dipstick again and check that the level is between the MIN and MAX reference marks top up if necessary The MAX level mark indicates a quantity of around 1100 cc of oil in the engine If the check is carried out ...

Page 40: ... O ring before fitting it Change the engine oil Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the requirements of API SL ACEA A3 JASO MA specifications Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the ON position However this light should switch off once the engine ...

Page 41: ...urn the engine in the opposite direction to the normal direction of rotation using a compass span ner applied to the camshaft drive sprocket hous ing N B TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE Checking the valve clearance To check valve clearance centre the reference marks of the timing system Use a feeler gauge to check that the clearance between the valve and the register corresponds ...

Page 42: ...ING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK 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...

Page 43: ...the screen 2 Turn on the headlight and check that the bor derline of the projected light beam on the screen is not higher than 9 10 or lower than 7 10 of the distance from the ground to the centre of vehicle 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 ...

Page 44: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 45: ... it shows signs of sulphation replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1 10 of the capacity of the battery itself Faulty spark plug Replace the spark plug Incorrect valve sealing or valve adjustment Inspect the head and or restore the correct clearance Starter motor and start up system fault Check starter motor Altered fuel charac...

Page 46: ... 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 deviation of the disc Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Fluid leak...

Page 47: ...adjustments check the seats in which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering clearance Check the tightening of the top ring nut If irregularities continue in turning the steering even after making the above adjust ments check the seats in which the ball...

Page 48: ...Troubleshooting Vespa LX 125 150 i e TROUBL 48 ...

Page 49: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 50: ...2 7 5A 9 Stop light bulb 10 Key switch contacts 11 Headlight remote control 12 Stop buttons 13 Light switch 14 Fuse No 5 7 5A 15 Fuse No 6 7 5A 16 Fuse No 4 10A 17 Front and rear daylight running lights and license plate light 18 Headlight with twin filament bulb 19 Pre installation for anti theft device Electrical system Vespa LX 125 150 i e ELE SYS 50 ...

Page 51: ...8 Injection electronic control unit 29 Fuel system pump 30 Diagnostics socket 31 Engine temperature sensor 32 Fuel injector 33 HV coil 34 Engine speed sensor 35 Lambda probe 36 Horn button 37 Horn 38 Injection load remote control KEY Or Orange Az Sky Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Vespa LX 125 150 i e Electrical system ELE SYS 51 ...

Page 52: ...Components arrangement Electrical system Vespa LX 125 150 i e ELE SYS 52 ...

Page 53: ... To get access to the connectors remove the helmet compartment 2 Voltage regulator Remove the front central cover to reach it 3 Battery Lift the saddle and remove the cover to reach them 4 Start up remote control Remove the battery to reach it Vespa LX 125 150 i e Electrical system ELE SYS 53 ...

Page 54: ... the front central cover to reach them 11 38 Remote controls Remove the front cen tral cover to reach it 29 24 Pump and fuel lever transmitter They are fitted on the tank remove the fuel tank to reach them Electrical system Vespa LX 125 150 i e ELE SYS 54 ...

Page 55: ...ver cap as described in ENGINE chapter 27 Immobilizer aerial Remove the shield back plate to reach it 28 Injection ECU Remove the helmet compart ment to reach it 30 Diagnosis connector Remove the helmet compartment to reach it Vespa LX 125 150 i e Electrical system ELE SYS 55 ...

Page 56: ... to reach it 33 H V coil Remove the helmet compartment and undo the two screws indicated to reach it Ground points On the vehicle there is a chassis ground point marked with letter A on the right side of the bat tery compartment Electrical system Vespa LX 125 150 i e ELE SYS 56 ...

Page 57: ...ther ground point B on the starter motor On the left side of the chassis under the footrest there is the chassis engine ground lead C Electrical system installation Vespa LX 125 150 i e Electrical system ELE SYS 57 ...

Page 58: ...lywheel 3 To HV coil 4 To the rear lighting devices 5 Chassis ground 6 Start up remote control switch 7 Fuel level transmitter 8 Battery 9 Diagnostic socket 10 Generator connector 11 Pick up connector Electrical system Vespa LX 125 150 i e ELE SYS 58 ...

Page 59: ...3 To rear light 4 Rear left turn indicator 5 Fuel pump 6 To the fuel level transmitter 7 Diagnostic socket 8 Generator connector 9 Pick up connector 10 HV coil 11 Lambda sensor 12 Lambda probe connector Vespa LX 125 150 i e Electrical system ELE SYS 59 ...

Page 60: ... 5 Fuel level transmitter 6 Injector 7 Engine temperature sensor 8 Injection ECU 9 Start up motor ground 10 Start up motor positive terminal 11 Diagnostic socket 12 HV coil 13 Generator connector 14 Pick up connector Electrical system Vespa LX 125 150 i e ELE SYS 60 ...

Page 61: ...al diagrams Ignition 3 12V 10Ah Battery 7 20A Fuse 8 7 5A Fuse 10 Key switch contacts 15 Fuse 15A 23 Instrument panel 26 Fuse 10A 27 Immobilizer aerial 28 Injection ECU 30 Diagnosis socket 33 HV coil 38 Injection load remote control Vespa LX 125 150 i e Electrical system ELE SYS 61 ...

Page 62: ...12V 10Ah Battery 4 Start up remote control switch 5 Starter motor 6 Starter button 7 20A Fuse 8 7 5A Fuse 9 Stop light bulb 10 Key switch contacts 12 Stop buttons 15 Fuse 15A 26 Fuse 10A 28 Injection electronic control unit Electrical system Vespa LX 125 150 i e ELE SYS 62 ...

Page 63: ...use 15A 23 Instrument panel 24 Fuel level transmitter 25 Oil pressure sensor 26 Fuse 10A 27 Immobilizer aerial 28 Injection electronic control unit 31 Engine temperature sensor 32 Fuel injector 34 Engine speed sensor 35 Lambda probe 38 Injection load remote control Vespa LX 125 150 i e Electrical system ELE SYS 63 ...

Page 64: ...Fuse 10A 19 Pre installation for anti theft device 20 Turn indicators bulb 21 Turn indicator switch 22 Turn indicators control device 23 Instrument panel 26 Fuse 10A 28 Injection electronic control unit 29 Fuel pump 37 Horn 38 Injection load remote control Electrical system Vespa LX 125 150 i e ELE SYS 64 ...

Page 65: ...tch 14 Fuse 7 5A 15 Fuse 15A 16 Fuse 10A 17 Front and rear daylight running lights and license plate light 18 Headlight with twin filament bulb 20 Turn indicators bulb 21 Turn indicator switch 22 Turn indicators control device 23 Instrument panel 28 Injection electronic control unit Vespa LX 125 150 i e Electrical system ELE SYS 65 ...

Page 66: ...ith 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 key switch is turned to OFF and it remains active 48 hours so as not to damage the battery charging process When the key switch is turned to ON it interrupts the function of the immobiliser lamp and a start enable lamp comes ON The duration of the...

Page 67: ...ltage check that fuse 3 and its cable are in working order With the key switch set to ON there is battery voltage between terminals 5 26 and terminal 5 chassis ground fixed power sup ply If there is no voltage check the key switch contacts that fuse 2 and its cable are in working order After removing the shield back plate remove the electrical connection from the aerial as shown in the picture Rem...

Page 68: ...stem is not encrypted any key will start the engine but limited to 2000 rpm The keys can only be recognised if the control unit has been programmed properly The data storage procedure for a previously un programmed control unit provides for the recogni tion of the red key master key as the first key to be stored to memory this becomes particularly important because it is the only key that enables ...

Page 69: ...e pro cedure If you do not start again from the begin ning Once the system has been programmed master key transponder decoder and control unit are strictly matched With this link established it is now possible to en code new service keys in the event of losses replacements etc Each new programming deletes the previous one so in order to add or eliminate keys you must re peat the procedure using al...

Page 70: ... cannot be used The LED is per manently ON in this condition no operations are possible including starting of the vehicle 3 Programmed control unit the service key in normal condition of use a single 0 7 second flash is displayed after which the LED remains off steadily The engine can be started 4 Programmed control unit Master key in a 0 7 sec flash is displayed followed by the LED re maining off...

Page 71: ...ck the aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Diagnostic code 3 flashes A three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code is repeated even with the Master key replace ...

Page 72: ... Resistance 0 2 1 Ω 4 Check that there is insulation between the each yellow cable and the ground 5 If values are incorrect replace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing the specific cover 2 Check that the battery does not show signs of losing fluid before checking the output voltage 3 Turn the ignition key to position OFF connect the termin...

Page 73: ...ights and let the battery voltage set to 12V Connect ammeter pliers to the 2 recharge positive poles in output from the regulator Keep the lights on and start the engine bring it to normal speed and read the values on the ammeter With an efficient battery a value must be detected 20A VOLTAGE REGULATOR RECTIFIER Specification Desc Quantity Type Non adjustable three phase transistor Voltage 14 to 15...

Page 74: ...k if there is voltage between the Orange White cable of the start up remote control switch and the ground connec tion If there is not check the cable harnesses 5 Check the start up remote control switch 6 Check that the Red cable between the battery and the start up remote control switch is not interrupted Also check continuity between the latter and the starter motor 7 Check the starter motor gro...

Page 75: ...key switch and horn button contacts 3 With the key switch set to ON and the horn button pressed check if there is voltage between the Grey Black cable of the horn device and the ground connection If there is not check the cable har nesses 4 Check the horn device ground connection Turn signals system check KEY 1 Battery 2 Fuse No 1 3 Key switch contacts 4 Fuse No 3 Vespa LX 125 150 i e Electrical s...

Page 76: ...t check the cable harnesses 7 With the turn indicator switch pressed to the left check if there is voltage between the Pink cable of the switch and the ground connection If there is not check the cable harnesses 8 Check that the cable harnesses of the bulbs and their ground connection are not interrupted level indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNE...

Page 77: ...UITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED LINE FOR DAYLIGHT RUNNING LIGHTS LICENSE PLATE LIGHT AND DASHBOARD LIGHTING BULB 1 Check that bulbs operate properly 2 Check fuses No 1 and 5 3 Check key switch contacts 4 Check if there is voltage between the Yellow Black cable of fuse No 5 and the ground If not check cable harnesses 5 Check that the cable harnesses of ...

Page 78: ...the Grey cable of the light switch and the headlight remote control is not interrupted 9 Check the light switch contacts 10 Check that the cable harnesses of the bulbs and their ground connection are not interrupted Fuses The electrical system is equipped with 1 four protection fuses A that can be reached by removing the shield front cover 2 two fuses B located in the battery compart ment The char...

Page 79: ...light warning light I Fuel gauge L Low fuel warning light M Immobilizer LED Sealed battery If the vehicle is provided with a sealed battery the only maintenance required is checking its charge and recharging when necessary These operations should be carried out before delivering the vehicle and on a six month basis while the vehicle is stored in open circuit Besides upon pre delivery it is therefo...

Page 80: ...ura Key 1 Engine temperature sensor With the connector control unit side disconnected and the coolant temperature sensor connector connected check the resistance between pins 9 and 26 in relation to the engine temperature 20 C 3502 237 ohm 80 C 357 19 ohm With the connector control unit side disconnected and the engine temperature sensor connector dis Electrical system Vespa LX 125 150 i e ELE SYS...

Page 81: ...ink Yellow cables Connectors DIAGNOSIS CONNECTOR 1 Not connected 2 Ground Black 3 Electronic control unit Purple White PICK UP CONNECTOR 1 Positive from control unit Red 2 Negative from control unit Brown 3 Not connected Vespa LX 125 150 i e Electrical system ELE SYS 81 ...

Page 82: ...ine temperature sensor Sky blue Green 10 Not connected 11 Lambda probe positive Sky blue Black 12 Not connected 13 Engine speed sensor positive Red 14 Injector Red Yellow 15 Engine speed sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer warning light Red Green 18 To ground Grey Green 19 Low beam lights automatic ignition White Black 20 Injection load remote control Black Purple 21 Lam...

Page 83: ...lack Green 2 Electronic control unit Red Yellow LAMBDA PROBE CONNECTOR 1 Positive from control unit Sky blue Black 2 Negative from control unit White Green 3 Electronic control unit Green Yellow 4 Power supply via solenoid Black Green VOLTAGE REGULATOR CONNECTOR 1 Battery Red Black 2 Ground Black Vespa LX 125 150 i e Electrical system ELE SYS 83 ...

Page 84: ... Pink White INSTRUMENT PANEL CONNECTOR B 1 Ground Black 2 Engine control telltale light Brown Black 3 Low fuel warning light Yellow Green INSTRUMENT PANEL CONNECTOR C 1 Immobilizer warning light Red Green 2 Battery powered Grey Black 3 Lighting Yellow Black 4 Power permanent supply White HV COIL CONNECTOR 1 Power via remote control Black Green 2 Electronic control unit Pink Black Electrical system...

Page 85: ...ermanent supply White 6 Not connected 7 Not connected 8 Not connected IMMOBILIZER AERIAL CONNECTOR 1 Live supply Red White 2 Ground Black 3 Electronic control unit Orange White FUEL LEVEL TRANSMITTER CONNECTOR 1 Fuel level indicator White Green 2 Ground Black 3 Low fuel warning light Yellow Green Vespa LX 125 150 i e Electrical system ELE SYS 85 ...

Page 86: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 87: ...lambda probe cable from the brack ets on the fan cover Loosen the 2 exhaust fixing screws to the crank case then remove the whole exhaust Remove the lambda probe from the manifold CAUTION SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP ALWAYS RE PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP Vespa LX 125 150 i e Engine from vehicle ENG VE 87 ...

Page 88: ...transmis sion retainer brackets indicated in the picture Disconnect the rear brake transmission by un screwing the adjuster screw Disconnect the belt cooling pipe and the swinging arm retaining spring shown in the picture Disconnect the ground lead 1 from the engine Disconnect the spark plug tube Loosen the clamp indicated in the picture and disconnect the sleeve connecting the air filter to the t...

Page 89: ...e three screws with anti tampering de vice that fasten the intake manifold on the head Detach from the head the manifold with throttle body and commands and collect the gasket 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 ...

Page 90: ...Engine from vehicle Vespa LX 125 150 i e ENG VE 90 ...

Page 91: ...INDEX OF TOPICS ENGINE ENG ...

Page 92: ...ulley axle locking nut and recover the washer Remove the cap dipstick from the engine oil filling hole Remove the ten screws 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 Air duct Unscrew the Torx screws fixing the air...

Page 93: ...ID 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 Vespa LX 125 150 i e Engine ENG 93 ...

Page 94: ...is not worn or damaged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value Ø 134 5 mm Clutch bell 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 check...

Page 95: ...ing 11 with the chamfering facing the inside of the tool 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 wit...

Page 96: ...O PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Simultaneously turn and pull the collar manually to remove it N B USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL TY N B BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O RING SEAL Removing the driven half pulley bearing Remove the retainer rin...

Page 97: ...ixed half pulley Measure the external diameter of the pulley bush ing 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 Vespa ...

Page 98: ...adaptor 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 th...

Page 99: ...limit after use 102 5 mm 4 035 in Refitting the clutch 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 TOO...

Page 100: ... adapter 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 t...

Page 101: ...e sure the driving belt is not damaged and does not show abnormal wear Replace as indicated in the scheduled maintenance table Removing the driving pulley Lock the driving pulley with the specific tool as shown in the figure Disassemble the central nut and the Belleville washer remove the drive and the 2 washers Remove the stationary half pulley and the steel washer Specific tooling 020368Y drivin...

Page 102: ...and measure inner diameter N B DO NOT LUBRICATE OR CLEAN THE BUSHING BUSHING ROLLER CONTAINER 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 diameter permitted Ø 25 950 mm Standard diameter Ø 26 0 020 0 041 mm VARIABLE SPEED ROLLERS Specification Desc Quantity Minimum diameter permitted Ø 18...

Page 103: ...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 Locking torque 75 to 83 Refitting the transmission cover Check that there are 2 centring dowels and that the sealing gasket for the oil sump on the trans mission cover is adequately fitted Rep...

Page 104: ...e 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 and the brake pad lever sliding unscrewing the relevant retaining screw to reach the rear of the cover Take off the hub cover and relevant gaskets Removing the wheel axle Remove the intermediate gear and the complete hub cover Engine V...

Page 105: ...uately supporting the hub cover as shown in the figure Specific tooling 020376Y Adaptor handle 020364Y 25 mm guide With the appropriate tools remove the oil seal as shown in the figure Specific tooling 020376Y Adaptor handle 020359Y 42x47 mm Adaptor Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft from the relevant bearing and oil seal remove driven pul...

Page 106: ...ged com ponents Inspecting the hub cover Check that the fitting surface is not dented or distorted Check the capacity of the bearings and the brake camshaft If faults are found replace the hub cover Refitting the driven pulley shaft bearing Heat up the parts using the specific heat gun Specific tooling 020150Y Air heater mounting 020151Y Air heater Reassemble the driven pulley axle bearing positio...

Page 107: ...20364Y 25 mm guide 020360Y 52x55 mm Adaptor 020376Y Adaptor handle Assemble the Seeger ring Assemble the oil seal flush with the in ternal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub Specific tooling 020376Y Adaptor handle 020360Y 52x55 mm Adaptor Refitting the hub cover bearings For the fitting of the hub box bearings the ...

Page 108: ... the ub cover Fit a new gasket together with the alignment dowels Fit the gearbox cover making sure the breather pipe is in the correct position Tighten the 7 screws to the prescribed torque Locking torques N m Locking torque 24 to 27 Flywheel cover Cooling hood Remove the fan cover cap acting on the 4 fixing screws CAUTION DURING REMOVAL SLIDE THE CABLE GROMMET FROM THE HOUSING ON THE CAP Engine ...

Page 109: ...the lateral left fixing screw on the crank case base Take off the two caps from the thermal group Remove the gasket seal of the housing on the head Cooling fan Remove the fan cover cap Remove the cooling fan by acting on the three fixings indicated in the figure Vespa LX 125 150 i e Engine ENG 109 ...

Page 110: ... Remove the stator and its wiring Refitting the stator Refit the stator and flywheel carrying out the re moval procedure in reverse tightening the retain ers to the specified torque Place the cable harness as shown in the figure N B THE PICK UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REFERENCE PIN AS SHOWN IN THE DETAIL DRAWING Locking torques N m Stator screw 3 to 4 Flywheel and...

Page 111: ... 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 Specific tooling 008564Y Flywheel extractor Inspecting the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pick up control plate Vespa LX 125 150 i e Eng...

Page 112: ... mounting N B A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED Locking torques N m Flywheel nut 52 to 58 Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter on the crankcase and lock the 2 screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD TIMING LUBRICATION FLYWHEEL AND TRANSMISSION CH...

Page 113: ...n 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 command pulley and its washer Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioner slider must be removed from the transmission side As regards the lo...

Page 114: ...VERSION OF INLET WITH THE OUTLET 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 centring 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 R...

Page 115: ...l seals 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 pad 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 CAREFU...

Page 116: ...eck 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 to 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 DIAMETE...

Page 117: ...ic Maximum allowable run out 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 are s...

Page 118: ... and wrist 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 wrist pin snap ring using the plug as shown in the figure N B THE TOOL FOR INSTAL...

Page 119: ...ng with the word 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 determin...

Page 120: ...admitted unevenness Head check 0 05 mm STANDARD DIAMETER Specification Desc Quantity Standard diameter A Ø 32 5 to 32 525 Standard diameter B Ø 20 to 20 021 Standard diameter C Ø 12 to 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 si...

Page 121: ...e seats VALVE SEAL SURFACE Specification Desc Quantity Intake valve seal surface 2 4 to 2 8 mm Exhaust valve seal surface 2 2 to 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 m...

Page 122: ...imum diameter admitted Inlet 4 96 mm Minimum diameter admitted Outlet 4 95 mm Standard clearance Inlet 0 013 to 0 040 mm Standard clearance Outlet 0 025 to 0 052 mm Maximum clearance admitted Inlet 0 062 mm Maximum clearance admitted Outlet 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 tha...

Page 123: ...LVE 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 Inspecti...

Page 124: ...springs 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...

Page 125: ...eplace 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 anomalies replace the dam...

Page 126: ...the 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 outlet rocking lever the spring washer and the inlet rocking lever Lubricate the 2 rocking levers through the holes at the top Lubricate the 2 bearings and insert the camshaft in the c...

Page 127: ...end 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 Tig...

Page 128: ... On the fitting 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 threading 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 Refit the cylinder head cover...

Page 129: ...apter 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 retainers indicated in the figure and the starter motor Before opening the crankcase it is advisable to check the axial clearance o...

Page 130: ...ase halves Remove the two screws and the internal cover 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 clearance ...

Page 131: ...oes 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 to 55 85 mm Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces sho...

Page 132: ...placed 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...

Page 133: ...MAIN 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 T...

Page 134: ...e thrusts caused by combustion and for this reason it is arranged opposed 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 surfac...

Page 135: ...DING 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...

Page 136: ... appropriate 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 QUENC...

Page 137: ...Conceptual diagrams Vespa LX 125 150 i e Engine ENG 137 ...

Page 138: ...priate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the prescribed torque and fit the fan 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 WITH AN OIL FILTER IN PR...

Page 139: ... the threaded bar onto the base of the tool and extract the oil seal Specific tooling 020622Y Transmission side oil guard 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 Vespa LX 125 150 i e Engine ENG 139 ...

Page 140: ...CAUTION 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 Engine Vespa LX 125 15...

Page 141: ... a 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 SEALING 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...

Page 142: ...NITIAL DIRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the clip 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 sho...

Page 143: ... 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 belleville washer Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE BELLEVILLE WASHER SO THAT ITS OUTER CURVED RIM ...

Page 144: ...gure 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...

Page 145: ...rack ets and the screws in the reverse 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 Transmissions chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the crankshaft and con necting rod Lo...

Page 146: ...INDEX OF TOPICS INJECTION INJEC ...

Page 147: ...Engine speed sensor 9 Lambda probe 10 Injection load remote control 11 Battery 12V10Ah MIU injection system This vehicle is fitted with an integrated injection and ignition system Injection is indirect in the manifold through an electro injector The injection and ignition are timed on the four stroke cycle by means of a tone wheel keyed on to the crankshaft 24 2 teeth and pick up sensor Vespa LX 1...

Page 148: ...e pump the filter and the regulator are placed inside the fuel tank on a single support The injector is connected by a pipe with fast release fittings The pressure regulator is located at the beginning of the circuit The fuel pump is controlled by the MIU control unit this ensures the scooter safety The ignition circuit consists of HV coil HV cable Shielded cap MIU control unit Spark plug The MIU ...

Page 149: ...the idle mixture Specific tooling 020680Y Diagnosis Tool The MIU control unit has a decoder for the anti theft immobilizer system The MIU control unit is connected to a diagnostic LED on the instrument panel that also carries out the deterrent flashing functions Precautions Troubleshooting hints 1 A MIU failure is more likely to be due to the connections than to the components Before troubleshooti...

Page 150: ...m V Instruments that are not suitable might damage the MIU control unit Instruments must be used with definitions over 0 1V and 0 5 W the precision must be greater than 2 1 Before fixing any part of the injection system check to see if there are any registered faults Do not disconnect the battery before checking for faults 2 The fuel feed system is pressurised at 250 kPa 2 5 BAR Before disconnecti...

Page 151: ...s only if re quired Before reconnecting check that the connectors are dry 12 When carrying out electric inspections do not force the tester probes into the connectors Do not take measurements not specifically foreseen by the manual 13 At the end of every check performed with the diagnostic tester remember to protect the system connector with its cap Failure to observe this precaution may damage th...

Page 152: ...ine speed sensor 16 Diagnostics output 17 Immobilizer LED 18 Pin short circuited with pin 26 19 low beam automatic ignition 20 injection load remote control 21 Lambda probe 22 HV coil 23 incomplete 24 Start up enabling 25 incomplete 26 Ground lead EMS circuit diagram 1 12V 10Ah Battery Injection Vespa LX 125 150 i e INJEC 152 ...

Page 153: ...gine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to the indications of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Fuel system Fuel in the tank Fuel pump activation Fuel pressure low Injector capacity low...

Page 154: ...ngine stops at idle ENGINE DOES NOT IDLE IDLING IS UNSTABLE IDLING TOO LOW Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Ignition efficiency Spark plug Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Engine temperature sensor Intake air temperatu...

Page 155: ...arameters Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake system sealing infiltrations Intake manifold head Throttle body manifold Air cleaner joint Filter box Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold muffler Muffler welding Engine revs irregu...

Page 156: ...ke air temperature indicator Ignition advance Fuel system Fuel level in the tank Fuel pressure Fuel filter Injector capacity Engine knocking PRESENCE OF KNOCKING COMBUSTION SHOCKS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Lambda probe Ignition efficiency Spark plug Parameter rel...

Page 157: ...s located in the tank from which the fuel is pumped and sent to the injector through the filter The pressure is controlled by the pressure regulator situated in the pump assembly in the tank Removing the injector Remove the helmet compartment Remove the connector from the injector Remove the quick release of the petrol delivery pipes Vespa LX 125 150 i e Injection INJEC 157 ...

Page 158: ...g OR gasket CAUTION DO NOT DISASSEMBLE THE INJECTOR COMPONENTS Refitting the injector For refitting perform the removal operations in re verse order and lubricate the sealing OR gasket with grease for internal application before fitting the injector on the manifold Injection Vespa LX 125 150 i e INJEC 158 ...

Page 159: ...ease fitting from the injector Remove the injector connector Remove the three screws with anti tampering device fixing the manifold to the head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector Remove the fastening clamp of the air cleaner joint to the air filter body Vespa LX 125 150 i e Injection INJEC 159 ...

Page 160: ...aner joint manifold and injector Refitting the butterfly valve For refitting perform the steps in the reverse di rection to disassembly taking care to orientate the air cleaner joint by inserting it in the reference tooth on the throttle body as shown in the picture To adjust the throttle control cables act on the specific adjuster screws Injection Vespa LX 125 150 i e INJEC 160 ...

Page 161: ...Pump supply circuit 1 12V 10Ah Battery 2 Fuse No 6 15A 3 Fuse No 1 20A 4 Key switch contacts 5 7 5A fuse No 2 Vespa LX 125 150 i e Injection INJEC 161 ...

Page 162: ...ly supplied ELECTRICAL DATA Pump winding resistance 1 5 Ohm Input current during normal functioning 1 4 to 1 8 A input current to the closed hydraulic circuit 2 A to be checked with specific tool for fuel pressure Check efficiency of the fuse No 6 of 15A injection loads next to the battery Check efficiency of fuse No 2 of 7 5A a 7 5A live control unit power supply after removing the cen tral cover...

Page 163: ...e injection load remote control energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control ba...

Page 164: ...Injection Vespa LX 125 150 i e INJEC 164 ...

Page 165: ...e is battery voltage for about two seconds to the Black Green cable of the pump connector and ground with pump connector disconnected Otherwise check the continuity of the Black Green cable between the pump connector and the remote control base Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable system side and the ground If w...

Page 166: ...1 4 to 1 8 A With the battery voltage 12 V check the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool Make a graded burette available with a flow rate of approximately 1 L Rotate the pump using the active diagnosis of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilis...

Page 167: ...e picture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture Remove the filter from the pump mounting Vespa LX 125 150 i e Injection INJEC 167 ...

Page 168: ...Inspecting the injector circuit 1 12V 10Ah Battery 2 Fuse No 6 15A 3 Fuse No 1 20A 4 Key switch contacts 5 7 5A fuse No 2 Injection Vespa LX 125 150 i e INJEC 168 ...

Page 169: ...ck the resistance at the injector ends 14 5 5 Ohm Check efficiency of the fuse No 6 of 15A injection loads next to the battery Check efficiency of fuse No 2 of 7 5A a 7 5A live control unit power supply after removing the cen tral cover of the shield Vespa LX 125 150 i e Injection INJEC 169 ...

Page 170: ...e injection load remote control energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control ba...

Page 171: ...Vespa LX 125 150 i e Injection INJEC 171 ...

Page 172: ...en the fuse box No 6 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC With the control unit and the injector disconnected check the continuity of the Red Yellow cable be tween pin 14 of the interface wiring and the injector connector Injection Vespa LX 125 150 i e INJEC 172 ...

Page 173: ...anti tampering device fixing the head and loosening the clamp connecting the throttle body to the mani fold Release the injector fuel delivery pipe from the bracket on the throttle body Install the appropriate tool for checking fuel pres sure and position the manifold over a container graduated by at least 100 cm Connect the injec tor with the cable making up part of the supply for the injection t...

Page 174: ...ctor seal test Dry the injector outlet with a blast of compressed air Activate the fuel pump Wait for one minute making sure there are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute Tachometer Injection Vespa LX 125 150 i e INJEC 174 ...

Page 175: ...ge between pins 13 and 15 is around 2 8 V With the interface cable harness disconnected from the control unit check continuity between pin 13 and the red cable of the engine speed sensor connector and between pin 15 and the brown ca ble of the engine speed sensor connector With the interface wiring and rpm sensor connec tor disconnected from the control unit check that the Red and Brown cables pin...

Page 176: ...HT coil 1 12V 10Ah Battery 2 Fuse No 6 15A 3 Fuse No 1 20A 4 Key switch contacts 5 7 5A fuse No 2 Injection Vespa LX 125 150 i e INJEC 176 ...

Page 177: ...ure and environmental pressure With the engine at idle the ignition advance is optimised to stabilise the speed at 1450 50 rpm Magnetisation time The coil magnetisation time is controlled by the control unit The ignition power is increased during the engine start up phase The injection system recognises the 4 stroke cycle and therefore ignition is only controlled during compression Specific toolin...

Page 178: ... for around two seconds when switching to ON Check the resistance of primary coil between pin 22 of the interface wiring and the Black Green ca ble of the injection load remote control base that can be reached by removing the shield central cover with the control unit disconnected and the remote control disconnected Resistance of the primary 0 5 8 Ohm Injection Vespa LX 125 150 i e INJEC 178 ...

Page 179: ... energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE...

Page 180: ...base and ground If there is not check the continuity of the Grey Black cable between the fuse box No 6 15 A and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection Vespa LX 125 150 i e INJEC 180 ...

Page 181: ...ed valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor can also assume various fitting positions For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another To obtain the optimum fuel mixture especially at small openings of the throttle valve it is essential to match t...

Page 182: ...ng the stop screw Guaranteeing that this position will be kept send a confirmation for the TPS reset procedure Reset should be performed in the following cases on first fitting if the injection control unit is replaced N B Injection Vespa LX 125 150 i e INJEC 182 ...

Page 183: ...R FLOW DIFFERENTLY FROM THAT OF PRE CALIBRATION Lambda probe SIGNAL CONTROL 1 Lambda probe Install the electronic control unit interface wiring Start the engine and let it warm up Use an analogue multimeter with a direct voltage scale measuring down to 2 V Place the tips of the multimeter between pins 4 and 11 Vespa LX 125 150 i e Injection INJEC 183 ...

Page 184: ...ith the throttle valve completely open the volt age is approx 1V During the closing phase the voltage is approx 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits inside it Injection Vespa LX 125 150 i e INJEC 184 ...

Page 185: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 186: ...wheel Support the vehicle adequately Loosen the five screws fixing the wheel to the hub Front wheel hub overhaul Support the vehicle adequately Remove the front wheel Remove the front brake calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub Suspensions Vespa LX 125 150 i e SUSP 186 ...

Page 187: ...d in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Vespa LX 125 150 i e Suspensions SUSP 187 ...

Page 188: ...7Y 32x35 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 GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 To...

Page 189: ...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 190: ...THEN IS THE SERVICE JUSTIFIABLE MOREOVER REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE WHEN DEFORMED a Ø 12 Punch b Sharp edged end Use a suitable punch with the dimensions indica ted on the figure hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end Repeat the operation for the second washer using the punch on the side opposite to...

Page 191: ...steering tube After fitting the pin insert the two spacers slightly hitting them with the mallet N B BEFORE PROCEEDING WITH THE DESCRIBED FITTING PLACE THE TWO DUST GUARD RINGS ON THE SWING ING HUB AS SHOWN IN THE FIGURE Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum disul...

Page 192: ...HA3 DIN K3K 20 Use the tool fitted with part 20 on its stem and part 21 on the tool base as shown in the figure By moving the tool handgrip push the two NA DELLA bushings until their internal bottoms make contact with the pin end Use the tool fitted with parts 3 and 4 to fit the pin and press moving the tool handgrip until wedging the washers on the swinging hub Now remove the two spacers parts 17...

Page 193: ... the upper ring nut B to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m Lower steering ring nut 8 to 10 Upper steering ring nut 35 to 40 Front shock absorber Vespa LX 125 150 i e Suspe...

Page 194: ...wer clamps and re move the brake calliper shock absorber mounting Loosen the screws fixing the front brake pipe re tainer clamp and the odometer cable in order to reach the upper clamps Unscrew the upper fixing nuts Remove the front shock absorber Suspensions Vespa LX 125 150 i e SUSP 194 ...

Page 195: ...c Remove the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Before refitting the bracket in the wheel axle place the O ring as shown in the photograph so that it is correctly placed after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Locking ...

Page 196: ...ent side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph Suitably hold the brake calliper shock absorber attachment bracket Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y 5...

Page 197: ...l operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Steering be...

Page 198: ...as shown in figure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing fifth wheels from headstock Refit the fifth wheel fitting and the dust guard on the steering tube until they stop using the specific tool Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube Rear Removing the rear wheel Remove the muffler Remove t...

Page 199: ...ollect the washer Refitting the rear wheel To refit follow the removal steps but in reverse order be careful to tighten to the prescribed tor que Locking torques N m Locking torque 137 to 152 Nm Swing arm Vespa LX 125 150 i e Suspensions SUSP 199 ...

Page 200: ...oor To remove the upper clamp from the chassis proceed as follows Unscrew the pin and collect the washer Remove the cap from the lower part Collect the lower fixing nut and collect the wash er Working on both sides remove the cover caps Suspensions Vespa LX 125 150 i e SUSP 200 ...

Page 201: ...assis and collect the washer Working on the left side remove the pin Remove the spoiler terminal from both sides Working on the right side unscrew the fixing nut Working on the left side release the pin from the spring shown Vespa LX 125 150 i e Suspensions SUSP 201 ...

Page 202: ...swinging arm is free Remove the swinging arm from the vehicle first release it from the engine side and then from the chassis side Overhaul Check that the silent blocks are in good condi tions Otherwise replace the swinging arm Suspensions Vespa LX 125 150 i e SUSP 202 ...

Page 203: ... Locking torques N m Part A 33 to 41 Part B 44 to 52 Part C 33 to 41 Shock absorbers Removal Adequately support the rear part of the vehicle Remove the battery Undo the indicated upper fixing screw to the chassis Unscrew the lower fixing pin to the transmission crankcase Vespa LX 125 150 i e Suspensions SUSP 203 ...

Page 204: ...r chassis nut torque 20 to 25 Nm Centre stand REMOVAL Use a jack to support the vehicle properly Remove the two return springs from the centre stand Undo the nut shown in the figure Remove the pin from the right side Remove the centre stand FITTING On refitting tighten the nut to the specified torque Locking torques N m Centre stand screw 32 to 40 Suspensions Vespa LX 125 150 i e SUSP 204 ...

Page 205: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 206: ...LLIPER REPLACEMENT IS NEEDED BE FORE REMOVING THE CALLIPER CLAMPS TO THE MOUNTING BRACKET LOOSEN THE OIL JOINT FITTING Refitting Insert the brake pads in the calliper Insert the pad fixing pin and the retention screw being careful to position the terminals of it pointing towards the bleed screw as shown in the photo Insert the clip on the pad fixing pin N B FAILURE TO RESPECT THE PAD POSITIONING R...

Page 207: ...ith spring washer to the prescribed torque If it is disconnected fasten the brake pipe joint to the calliper and tighten to the prescribed torque Purge the circuit and refit the front wheel Locking torques N m Brake calliper mounting clamping 20 to 25 Nm Brake pipe connection 20 to 25 N m Front brake disc Vespa LX 125 150 i e Braking system BRAK SYS 207 ...

Page 208: ...ting 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 i e BRAK SYS 208 ...

Page 209: ...el hub 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 pin and the spring Remove the brake pads Check that there are no faults or warping If there are replace them Check the thi...

Page 210: ... the ends towards the bleed screw as in the photo Insert the lock on the bolt and then the protection cover Fix the 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 i e BRAK SYS 210 ...

Page 211: ...ING 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 THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM Specific toolin...

Page 212: ...ditions replace fluid as indicated in the scheduled maintenance table Front brake pump 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 from the stop lights switch Refitting To refit carry out the removal operations but in reverse order observing t...

Page 213: ...e the shoe springs using the specific spanner 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 springs using the specific pliers Specific tooling 020325Y Pliers for brake shoe springs Vespa LX 125 150 i e Braking system BRAK SYS 213 ...

Page 214: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 215: ...three screws indicated in figure fixing it to the handlebar the odometer transmission and the electrical connectors Instrument panel Remove the rear handlebar cover Undo the four screws indicated fixing the rear handlebar cover Vespa LX 125 150 i e Chassis CHAS 215 ...

Page 216: ...d Undo the screw under the headlamp Laterally release the handlebar cover end Disconnect the electrical terminals and remove the front handlebar cover Headlight assy Remove the front handlebar cover Undo the four screws indicated fixing the front handlebar cover Chassis Vespa LX 125 150 i e CHAS 216 ...

Page 217: ...ews shown in the figure placed under the front central cover Remove the 3 screws shown in the figure placed inside the glove box they can be reached opening the glove box door Remove the shield back plate by pulling it up wards Taillight assy Undo the two fixing screws and remove the rear light unit Vespa LX 125 150 i e Chassis CHAS 217 ...

Page 218: ...trest Remove the shield back plate Remove the side fairings Remove the central tunnel inspection door From both sides unscrew The fixing screw at the back The fixing screw on the central part The fixing screw at the front Chassis Vespa LX 125 150 i e CHAS 218 ...

Page 219: ...fairings Undo the upper screw and the smallest lower screw Detach the seats on the fairing License plate holder Remove the side fairings Working on both sides undo the two screws in dicated Vespa LX 125 150 i e Chassis CHAS 219 ...

Page 220: ... indicated clamps to the crankcase Undo the two clamps indicated Front mudguard First remove the steering tube and uncouple the front brake pipes from the calliper in order to re move the front mudguard Remove the three mudguard steering tube clamps indicated in the figure Chassis Vespa LX 125 150 i e CHAS 220 ...

Page 221: ...Front central cover Remove the PIAGGIO clip on badge Unscrew the screw indicated in the figure Remove the grille Vespa LX 125 150 i e Chassis CHAS 221 ...

Page 222: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 223: ...ging arm pin Engine arm pin Chassis 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 indi...

Page 224: ...DICAL 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 OF THE REACH OF CHILD...

Page 225: ...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 Proper general functioning and no abnormal noise check Others Check documentation Check the chassis and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirror...

Page 226: ...INDEX OF TOPICS TIME TIME ...

Page 227: ...Engine ENGINE Code Action Duration 1 001001 Engine from chassis Removal and refit Vespa LX 125 150 i e Time TIME 227 ...

Page 228: ...ankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement 2 001153 Crankcase halves gasket Replace ment 3 002031 Rear wheel hub bearings Replace ment Time Vespa LX 125 150 i e TIME 228 ...

Page 229: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001099 Flywheel side oil seal Replacement Vespa LX 125 150 i e Time TIME 229 ...

Page 230: ...Cylinder assy CYLINDER ASSEMBLY Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Inspection clean ing Time Vespa LX 125 150 i e TIME 230 ...

Page 231: ...Cylinder head assy HEAD ASSEMBLY Code Action Duration 1 001045 Valves Replacement 2 001056 Head gasket change 3 001126 Head Replacement Vespa LX 125 150 i e Time TIME 231 ...

Page 232: ...Rocker arms support assy ROCKERS MOUNTING UNIT Code Action Duration 1 001044 Camshaft Replacement 2 001148 Rockers valves Replacement 3 001049 Valves adjust Time Vespa LX 125 150 i e TIME 232 ...

Page 233: ...Replacement 2 001088 Head cover gasket Replacement 3 001159 Oil vapour recovery tank Service 4 001093 Spark plug Replacement 5 001097 Cooling hood Replacement 6 001091 Head cover sealing ring 7 001074 Oil vapour recovery pipe Replace ment Vespa LX 125 150 i e Time TIME 233 ...

Page 234: ...Chain tensioner CHAIN TIGHTENER Code Action Duration 1 001129 Chain tensioner Service and Re placement 2 001124 By pass lubrication Replacement Time Vespa LX 125 150 i e TIME 234 ...

Page 235: ...ilter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor change 3 003064 Engine oil change 4 001102 Net oil filter change Cleaning Vespa LX 125 150 i e Time TIME 235 ...

Page 236: ...087 Flywheel cover Replacement 2 001163 Muffler secondary air connection Replacement 3 001161 Secondary air filter Replacement Cleaning 4 001174 SAS valve Replacement 5 001164 Crankcase secondary air connection Replacement Time Vespa LX 125 150 i e TIME 236 ...

Page 237: ...n pulley DRIVEN PULLEY Code Action Duration 1 001155 Clutch bell Replacement 2 001022 Clutch Replacement 3 001012 Driven pulley overhaul 4 001110 Driven pulley Replacement Vespa LX 125 150 i e Time TIME 237 ...

Page 238: ...elt Timing chain Change 2 001125 Chain guide pads Replacement 3 001042 Oil pump overhaul 4 001112 Oil pump change 5 001130 Oil sump change 6 001100 Clutch side oil seal Replacement 7 001122 Oil pump chain Replacement Time Vespa LX 125 150 i e TIME 238 ...

Page 239: ...DUCTION GEAR Code Action Duration 1 004125 Rear wheel axle Replacement 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 001010 Geared reduction unit Service Vespa LX 125 150 i e Time TIME 239 ...

Page 240: ...LLEY Code Action Duration 1 001066 Driving pulley Removal and refitting 2 001086 Driving half pulley Replacement 3 001177 Variator rollers shoes Replace ment 4 001011 Driving belt Replacement Time Vespa LX 125 150 i e TIME 240 ...

Page 241: ...TRANSMISSION COVER Code Action Duration 1 001096 Transmission crankcase cover Re placement 2 001135 Transmission cover bearing Re placement 3 001065 Transmission cover Removal and Refit Vespa LX 125 150 i e Time TIME 241 ...

Page 242: ...1020 Starter motor Replacement 2 005045 Starter motor cable harness Re placement 3 001017 Start up pinion Replacement 4 001021 Kick starter Inspection 5 008008 Starter spring pack Replacement 6 001084 Starter lever Replacement Time Vespa LX 125 150 i e TIME 242 ...

Page 243: ... magneto MAGNETO FLYWHEEL Code Action Duration 1 001109 Cooling fan Replacement 2 001173 Rotor Replacement 3 001067 Stator Removal and Refitting 4 001058 Flywheel Replacement Vespa LX 125 150 i e Time TIME 243 ...

Page 244: ...ling duct BELT COOLING PIPE Code Action Duration 1 001170 Air duct replacement 2 001132 Transmission air intake pipe Re placement 3 001131 Transmission air intake Replace ment Time Vespa LX 125 150 i e TIME 244 ...

Page 245: ...urettor heating resistor Re placement 2 001013 Intake manifold change 3 004122 Air cleaner carburettor fitting Re placement 4 001081 Automatic choke Replacement 5 001008 Carburettor Inspection 6 001063 Carburettor Replacement Vespa LX 125 150 i e Time TIME 245 ...

Page 246: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001136 Exhaust emissions Adjustment 3 001095 Muffler guard Replacement Time Vespa LX 125 150 i e TIME 246 ...

Page 247: ...cleaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting Re placement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement Vespa LX 125 150 i e Time TIME 247 ...

Page 248: ...ssis Replacement 2 004023 Shield rim Replacement 3 004149 Shield central cover Replacement 4 004159 Plates Stickers Replacement 5 004012 Rear side panels Replacement 6 004059 Spark plug inspection flap Replace ment Time Vespa LX 125 150 i e TIME 248 ...

Page 249: ...Centre stand STAND Code Action Duration 1 001053 Stand bolt Replacement 2 004004 Stand Replacement Vespa LX 125 150 i e Time TIME 249 ...

Page 250: ...Footrests FOOTREST Code Action Duration 1 004178 Footrest Replacement 2 004078 Front rear footrest rubber Replace ment Time Vespa LX 125 150 i e TIME 250 ...

Page 251: ...BACK PLATE Code Action Duration 1 004174 Trunk levers Replacement 2 004065 Legshield rear part Removal and refitting 3 004081 Top box lid Replacement 4 004082 Top box gasket Replacement Vespa LX 125 150 i e Time TIME 251 ...

Page 252: ...compartment HELMET COMPARTMENT Code Action Duration 1 005046 Battery cover change 2 004016 Helmet compartment Removal and Refitting 3 001027 Body air cleaner union Replace ment Time Vespa LX 125 150 i e TIME 252 ...

Page 253: ...TMENT Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover change 3 004011 Central chassis cover Replacement 4 004071 Battery compartment replacement Vespa LX 125 150 i e Time TIME 253 ...

Page 254: ...ICENSE PLATE HOLDER Code Action Duration 1 004136 License plate holder mounting Re placement 2 005048 number plate holder Replacement 3 005032 number plate light glass Replace ment Time Vespa LX 125 150 i e TIME 254 ...

Page 255: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard change 2 004009 Rear mudguard Replacement Vespa LX 125 150 i e Time TIME 255 ...

Page 256: ...1 004168 Fuel tank cap Replacement 2 005010 Tank float Replacement 3 004112 Cock carburettor hose Replace ment 4 004005 Fuel tank Replacement 5 004007 Fuel valve Replacement 6 004109 Fuel tank breather change Time Vespa LX 125 150 i e TIME 256 ...

Page 257: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Vespa LX 125 150 i e Time TIME 257 ...

Page 258: ...rings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheels Replacement 2 003073 Steering clearance Adjustment 3 004119 Bearing upper steering fifth wheel Replacement Time Vespa LX 125 150 i e TIME 258 ...

Page 259: ...uration 1 004018 Handlebar front section Replace ment 2 004019 Handlebar rear section Replace ment 3 005014 Odometer Replacement 4 005038 Instrument panel warning light bulbs Replacement 5 005078 Odometer glass Replacement Vespa LX 125 150 i e Time TIME 259 ...

Page 260: ...ebar Removal and refitting 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 003061 Accelerator transmission adjust 8 002060 Complete throttle control Replace ment 9 004162 Mirror mounting and or brake pump fitting U bolt Replacement 10 002059 Right hand grip Replacement 11 002063 Throttle control transmission Re placement Time Vespa LX 125 150 i e TIME 260 ...

Page 261: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine chassis connection swinging arm Replacement Vespa LX 125 150 i e Time TIME 261 ...

Page 262: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004131 Luggage rack mounting Replace ment Time Vespa LX 125 150 i e TIME 262 ...

Page 263: ...t turn indicator Replacement 3 005067 Front turn indicator bulb Replace ment 4 005008 Headlight bulbs Replacement 5 005005 Taillight change 6 005066 Rear light bulbs Replacement 7 005022 Rear turning indicators Replace ment 8 005068 Rear turning indicator bulb Re placement Vespa LX 125 150 i e Time TIME 263 ...

Page 264: ...ont wheel Replacement 2 003047 Front tyre Replacement 3 003037 Front wheel rim Replacement 4 003033 Front wheel hub Replacement 5 002041 Front brake disc Replacement 6 003034 Front wheel hub bearing Replace ment Rear wheel Time Vespa LX 125 150 i e TIME 264 ...

Page 265: ...Repl Electric devices ELECTRICAL COMPONENTS Code Action Duration 1 005001 Electrical system Replacement 2 005011 Start up remote control switch Re placement 3 005009 Voltage regulator Replacement 4 005007 Battery change 5 005052 Fuse 1 Replacement 6 001023 Control unit Replacement 7 001094 Spark plug cap Replacement 8 001069 HV coil Replacement Vespa LX 125 150 i e Time TIME 265 ...

Page 266: ...ent 2 005006 Light or turning indicator switch Re placement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005016 Key switch Replacement 7 004096 Lock series Replacement 8 004010 Anti theft lock Replacement Time Vespa LX 125 150 i e TIME 266 ...

Page 267: ...s TRANSMISSIONS Code Action Duration 1 002053 Rear brake transmission complete Replacement 2 002051 Odometer transmission assembly Replacement 3 002049 Odometer cable Replacement Vespa LX 125 150 i e Time TIME 267 ...

Page 268: ...ion 1 003045 Steering tube Replacement 2 003010 Front suspension Service 3 003035 Shock absorber mounting and brake calliper Replacement 4 001064 Odometer sprocket Replacement 5 003044 Shock absorber cover Replace ment Time Vespa LX 125 150 i e TIME 268 ...

Page 269: ...rake hose Remov and Re fitt 2 002007 Front brake shoes pads Remov and Refitt 3 002039 Front brake calliper Removal and Refitting 4 002047 Front brake fluid and air bleed sys tem Replacement 5 002002 Shoes Rear brake pads Replace ment Vespa LX 125 150 i e Time TIME 269 ...

Page 270: ...e Action Duration 1 001164 Crankcase secondary air connection Replacement 2 001161 Secondary air filter Replacement Cleaning 3 001174 SAS valve Replacement 4 001163 Muffler secondary air connection Replacement Time Vespa LX 125 150 i e TIME 270 ...

Page 271: ...r 245 Checks 66 E Electric 265 Engine oil 38 F Fuel 157 166 256 Fuses 78 H Headlight 43 216 Horn 74 Hub oil 36 I Identification 8 Instrument panel 215 M Maintenance 7 34 O Odometer Oil filter 40 235 R Recommended products S Saddle Shock absorbers 203 Spark plug 34 Stand Start up Suspension 47 268 ...

Page 272: ...T Tank 256 Transmission 9 46 92 103 113 241 Turn indicators 65 Tyres 13 V Vehicle 8 87 88 ...