VESPA LX 150 4T Euro 3, LX 125 4T Euro 3 Service Station Manual

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SERVICE STATION MANUAL

633977 EN

Vespa LX 125 - 150 4T Euro 3

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SERVICE STATION

MANUAL

Vespa LX 125 - 150 4T Euro 3

The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. reserves the right, at any time and without being required to update this publication 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.

in part is prohibited.

Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

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SERVICE STATION MANUAL

Vespa LX 125 - 150 4T Euro 3

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable 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 completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

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INDEX OF TOPICS

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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.

Vespa LX 125 - 150 4T Euro 3 Characteristics

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Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

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

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Specification Desc./Quantity

Maximum height 1140 mm

Width 740 mm

Wheelbase 1280 mm

Length 1800 mm

Engine

ENGINE

Specification Desc./Quantity

ENGINE Single-cylinder, 4-stroke Piaggio LEADER

Timing system Single overhead camshaft (SOHC) with 2 valves

Valve clearance intake 0.10

exhaust 0.15

Bore x stroke (125) 57 x 48.6 mm

Bore/stroke (150) 62.6 x 48.6 mm Engine capacity (125) 124 cm³ Engine capacity (150) 151 cm³

Compression ratio (125/150) 10.6 ± 0.5 to 1

Engine idle speed 1,650±100 rpm

carburettor KEIHIN CVEK26

Ignition Starter / Kick starter

Max. power (125) 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 circulation cooling.

Capacities

CAPACITY

Specification

Desc./Quantity

Engine oil 61 in³ (1,000 cm³)

Rear hub oil ~ 100 cm³

Fuel tank capacity ~ 8.5 litres (2 l of which is reserve)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

Ignition Starter / Kick starter

Spark plug Champion RG6YC- NGK CR7EB

Vespa LX 125 - 150 4T Euro 3 Characteristics

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Frame and suspensions

CHASSIS AND SUSPENSION

Specification Desc./Quantity

Chassis Unitised body made of stamped plate.

Steering and suspension Steering tube articulated on the front wheel carrier hub; heli-

coidal spring suspension and double-acting hydraulic shock

absorber; rear with double-acting shock absorber and coaxial

spring adjustable to 4 positions at preloading.

Brakes

BRAKES

Specification Desc./Quantity

Front brake Disc brake (Ø 200 mm) with hydraulic control (lever on the far

right of the handlebar) and fixed calliper.

Rear brake Ø110 mm drum brake

Wheels and tyres

WHEELS AND TYRES

Specification

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 muffler. To favour the catalytic process, an extra amount of oxygen is added to the exhaust through a secondary air system (SAS). This system allows more oxygen to be added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter.

Characteristics Vespa LX 125 - 150 4T Euro 3

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The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise. To ensure the best functioning of the SAS system clean the filter as indicated in the scheduled maintenance table. The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.

Carburettor

125cc Version

Kehin

CARBURETTOR SETTING

Specification

Desc./Quantity

Type CVEK26

Throttle valve diameter Ø 26.5

Diffuser diameter 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 ½

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

Desc./Quantity

Type CVEK26

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Setting stamping 271B

Maximum jet 80

Maximum air jet (on the body) MAJ 85

Maximum air jet (on the body) MAJ2 80

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Vespa LX 125 - 150 4T Euro 3 Characteristics

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Specification Desc./Quantity

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 1 ¾

Starter nozzle 42

Starter air jet (on the body) Ø 1.5

Starter pin travel 10 mm (at 24°)

Starter resistance 20 Ohm (at 24°)

Tightening Torques

LUBRICATION

Name Torque in Nm

Hub oil drainage cap 15 to 17

Oil filter 4 to 6

Oil pump cover screws 5 to 6

Oil pump screws 5 ÷ 6

Pump control pulley screw 10 to 14

Chain cover screws 4 to 6

Oil sump screws 10 to 14

Minimum oil pressure sensor 12 to 14

Blow-by recovery duct fixing screws 3 - 4

HEAD AND CYLINDER

Name

Torque in Nm

Ignition spark plug 12 to 14

Head cover screws 11 - 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 - 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 manifold screw 11 to 13

(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.

TRANSMISSION

Name

Torque in Nm

Drive pulley nut 75 - 83

Transmission cover screw 11 to 13

Driven pulley shaft nut 54 - 60

Rear hub cap screw 24 to 27

Clutch unit nut on driven pulley 45 to 50

FLYWHEEL

Name

Torque in Nm

Flywheel fan screws 3 to 4

Stator assembly screws (°) 3 to 4

Flywheel nut 52 - 58

Pick-up screw 3 to 4

(°) Apply LOCTITE 243 threadlock

Characteristics Vespa LX 125 - 150 4T Euro 3

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CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmission-side half

shaft) screws

4 to 6

Oil filter on crankcase fitting 27 - 33

Rear brake cam tightening screw 11 to 13

Engine-crankcase coupling screws 11 ÷ 13

Pre-filter cap 24 to 30

Starter motor fixing screw 11 to 13 Silencer to crankcase fixing screws 24 - 27

Engine oil drainage cap 24 to 30

STEERING ASSEMBLY

Name Torque in Nm

Steering upper ring nut 35 to 40 Steering lower ring nut 12 to 14 Handlebar fixing screw 50 to 55

CHASSIS ASSEMBLY

Name Torque in Nm

Swinging arm - chassis pin 44 to 52

Engine-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 fitting 20 ÷ 25

Screw tightening calliper to support 20 - 25

Brake disc screw 5 to 6.5

Oil bleed valve (on the calliper) 10 to 12

Handlebar pump 7 ÷ 10

REAR SUSPENSION

Name

Torque in Nm

Rear wheel axle 104 ÷ 126

Shock absorber lower clamping 33 to 41

Shock absorber/Chassis nut: 20 ÷ 25

Overhaul data

Assembly clearances

Cylinder - piston assy.

Version 150

Vespa LX 125 - 150 4T Euro 3 Characteristics

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COUPLING BETWEEN (ASSO-WERKE) PISTON AND CYLINDER (150)

Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 - 62.587 62.533 - 62.540 0.040 - 0.054 Coupling B 62.587 - 62.594 62.540 - 62.547 0.040 - 0.054 Coupling C 62.594 - 62.601 62.547 - 62.554 0.040 - 0.054

Coupling D 62.601 - 62.608 62.554 - 62.561 0.040 - 0.054 coupling 1st oversize A1 62.780 - 62.787 62.733 - 62.740 0.040 - 0.054 coupling 1st oversize B1 62.787 - 62.794 62.740 - 62.747 0.040 - 0.054 coupling 1st oversize C1 62.794 - 62.801 62.747 - 62.754 0.040 - 0.054 coupling 1st oversize D1 62.801 - 62.808 62.754 - 62.761 0.040 - 0.054

Coupling 2nd oversize A2 62.980 - 62.987 62.933 - 62.940 0.040 - 0.054 Coupling 2nd oversize B2 62.987 - 62.994 62.940 - 62.947 0.040 - 0.054 Coupling 2nd oversize C2 62.994 - 63.001 62.947 - 62.954 0.040 - 0.054 Coupling 2nd oversize D2 63.001 - 63.008 62.954 - 62.961 0.040 - 0.054

Coupling 3rd oversize A3 63.180 - 63.187 63.133 - 63.140 0.040 - 0.054 Coupling 3rd oversize B3 63.187 - 63.194 63.140 - 63.147 0.040 - 0.054 Coupling 3rd oversize C3 63.194 - 63.201 63.147 - 63.154 0.040 - 0.054 Coupling 3rd oversize D3 63.201 - 63.208 63.154 - 63.161 0.040 - 0.054

COUPLING BETWEEN (RIGHT WAY) PISTON AND CYLINDER (150)

Name Initials Cylinder Piston Play on fitting

Coupling A 62.580 - 62.587 62.541 - 62.548 0.032 - 0.046

Coupling B 62.587 - 62.594 62.548 - 62.555 0.032 - 0.046

Coupling C 62.594 - 62.601 62.555 - 62.562 0.032 - 0.046

Coupling D 62.601 - 62.608 62.562 - 62.569 0.032 - 0.046

Version 125

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER

(125)

Name

Initials Cylinder Piston Play on fitting

Coupling A 56.980 to 56.987 56.933 to 56.940 0.040 - 0.054

Coupling B 56.987 to 56.994 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 57.208 57.154 to 57.161 0.040 - 0.054 Coupling 2nd oversize A2 57.380 to 57.387 57.333 to 57.340 0.040 - 0.054 Coupling 2nd oversize B2 57.387 to 57.394 57.340 to 57.347 0.040 - 0.054 Coupling 2nd oversize C2 57.394 to 57.401 57.347 to 57.354 0.040 - 0.054 Coupling 2nd oversize D2 57.401 to 57.408 57.354 to 57.361 0.040 - 0.054

Coupling 3rd oversize A3 57.580 to 57.587 57.533 to 57.540 0.040 - 0.054

Coupling 3rd oversize B3 57.587 to 57.594 57.540 to 57.547 0.040 - 0.054

Coupling 3rd oversize C3 57.594 to 57.601 57.547 to 57.554 0.040 - 0.054

Coupling 3rd oversize D3 57.601 to 57.608 57.554 to 57.561 0.040 - 0.054

PISTON TO CAST IRON CYLINDER COUPLING (125)

Name

Initials Cylinder Piston Play on fitting

Coupling M 56.997 - 57.004 56.944 - 56.951 0.046 - 0.060 Coupling N 57.004 - 57.011 56.951 - 56.958 0.046 - 0.060 Coupling O 57.011 - 57.018 56.958 - 56.965 0.046 - 0.060

Coupling P 57.018 - 57.025 56.965 - 56.972 0.046 - 0.060 coupling 1st oversize M1 57.197 - 57.204 57.144 - 57.151 0.046 - 0.060 coupling 1st oversize N1 57.204 - 57.211 57.151 - 57.158 0.046 - 0.060 coupling 1st oversize O1 57.211 - 57.218 57.158 - 57.165 0.046 - 0.060 coupling 1st oversize P1 57.218 - 57.225 57.165 - 57.172 0.046 - 0.060

Coupling 2nd oversize M2 57.397 - 57.404 57.344 - 57.351 0.046 - 0.060 Coupling 2nd oversize N2 57.404 - 57.411 57.351 - 57.358 0.046 - 0.060 Coupling 2nd oversize O2 57.411 - 57.418 57.358 - 57.365 0.046 - 0.060

Characteristics Vespa LX 125 - 150 4T Euro 3

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Name Initials Cylinder Piston Play on fitting

Coupling 2nd oversize P2 57.418 - 57.425 57.365 - 57.372 0.046 - 0.060

Coupling 3rd oversize M3 57.597 - 57.604 57.544 - 57.551 0.046 - 0.060 Coupling 3rd oversize N3 57.604 - 57.611 57.551 - 57.558 0.046 - 0.060 Coupling 3rd oversize O3 57.611 - 57.618 57.558 - 57.565 0.046 - 0.060 Coupling 3rd oversize P3 57.618 - 57.625 57.565 - 57.572 0.046 - 0.060

Piston rings

SEALING RINGS (125)

Name Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 - 0.30

Oil scraper ring 57x1 A 0.10 - 0.30 Oil scraper ring 57x2.5 A 0.10 - 0.35

Compression ring 1st

oversize

57.2 x 1 A 0.15 - 0.30

Oil scraper ring 1st

oversize

57.2x1 A 0.10 - 0.30

Oil scraper ring 1st

oversize

57.2x2.5 A 0.10 - 0.35

Compression ring 2nd

oversize

57.4x1 A 0.15 - 0.30

Oil scraper 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 A 0.20 - 0.40 Oil scraper ring 62.6x2.5 A 0.20 - 0.40

Compression ring 1st

oversize

62.8x1 A 0.15 - 0.30

Oil scraper ring 1st

oversize

62.8x1 A 0.20 - 0.40

Oil scraper ring 1st

oversize

62.8x2.5 A 0.20 - 0.40

Compression ring 2nd

oversize

63.0 x 1 A 0.15 - 0.30

Oil scraper ring 2nd

oversize

63.0 x 1 A 0.20 - 0.40

Oil scraper ring 2nd

oversize

63.0 x 2.5 A 0.20 - 0.40

Compression ring 3rd

oversize

63.2 x 1 A 0.15 - 0.30

Oil scraper ring 3rd

oversize

63.2 x 1 A 0.20 - 0.40

Oil scraper ring 3rd

oversize

63.2 x 2.5 A 0.20 - 0.40

Vespa LX 125 - 150 4T Euro 3 Characteristics

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Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Half-shaft, transmission

side

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half shaft 16.6 +0-0.05 B D = 0.20 - 0.50 Connecting rod with PP 18 -0.10 -0.15 C 0.20 to 0.50

Crank pin width 51.400 E

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

Name

Description Dimensions 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 category 2

C - C

Crankshaft category 2 -

Crankcase category 1

C - C

Crankshaft category 2 -

Crankcase category 2

B - B

Crankshaft/crankcase axial clearance: 0.15 to 0.40

Characteristics Vespa LX 125 - 150 4T Euro 3

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Slot packing system

- Provisionally fit the piston into the cylinder, without any base gasket.

- Assemble a dial gauge on the specific tool

- Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.

- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)

- Calculate the difference between the two 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 measured 0.1 - 0.3

Thickness 0.6 ± 0.05

Value measured 0.3 - 0.4

Thickness 0.4 ± 0.05

SHIMMING SYSTEM (150)

Specification

Desc./Quantity

Value measured 1 - 1.1

Thickness 0.8 ± 0.05

Value measured 1.1 - 1.3

Thickness 0.6 ± 0.05

Vespa LX 125 - 150 4T Euro 3 Characteristics

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Specification Desc./Quantity

Value measured 1.3 - 1.4

Thickness 0.4 ± 0.05

Products

Recommended products

AGIP BRAKE 4 Brake fluid.

Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4

- ISO 4925 - CUNA NC 956 DOT 4

Vespa LX 125 - 150 4T Euro 3 Maintenance

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Headlight adjustment

Proceed as follows:

1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam on the screen is no higher than 9/10 or lower than 7/10 of the distance from the ground to the centre of the vehicle'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 MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

SAS filters inspection and cleaning

Proceed as follows:

- Remove the right-hand side fairing

- Remove the screw on the rear part, to the right of the footrest, indicated in the photograph

- Remove the spoiler terminal

Maintenance Vespa LX 125 - 150 4T Euro 3

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- Remove the screw fixing the SAS valve to the flywheel cover, indicated in the photograph.

- Remove the 6 flywheel cover screws indicated in the photograph and remove the flywheel cover.

- Remove the filter indicated in the photograph

- Check that the gasket is in good conditions

- Check the SAS filter housing for dents or deformations

- Clean the SAS filter carefully. Replace the filter if it is damaged or deformed. To refit, carry out the removal operations but in reverse 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 FILTER

Vespa LX 125 - 150 4T Euro 3 Maintenance

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

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Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Air filter blocked or dirty Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit. Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the

tank, if necessary. Replace the cock as a last resource.

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.

Excessive drive belt wear Check it and replace, if necessary

Lack of compression: parts, cylinder and valves worn Replace the worn parts

Oil level exceeds maximum Check for causes and fill to reach the correct level

Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the movable guide of the driven pulley

with grease.

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valves

Valve seat distorted Replace 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 the battery. If it shows signs of sulphating

replace it and bring the new battery into service charging it for

eight hours at a current of 1/10 of the capacity of the battery

itself

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

Flooded engine Try starting-up with the throttle fully open. If the engine fails to

start, remove the spark plug, dry it and before refitting, make

the engine turn so as to expel the fuel excess taking care to

connect the cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance

Rpm too low at start-up or engine and start-up system dam-

aged

Check the starter motor and the kick-starter unit

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill

Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-

plying a vacuum to the vacuum pipe

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.

Vespa LX 125 - 150 4T Euro 3 Troubleshooting

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Possible Cause Operation

Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed;

replace if necessary

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air

Air filter obstructed or dirty. Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit.

Fuel pump fault Check the pump control device

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKY EXHAUST

Possible Cause Operation

Worn valve guides Check and replace the head unit if required

Worn valve oil guard Replace the valve oil seal

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

By-Pass area.

Oil pump with excessive clearance Perform the dimensional 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 carburettor chamber Remove the tank, wash with solvent and dry with compressed

air

Level in chamber too low Restore the level in the chamber by bending on the float the

thrusting reed of the petrol intake rod so as to have the float

parallel to the chamber level with the carburettor inverted.

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE SPEED

Possible Cause

Operation

Incorrect idle adjustment Adjust using the rpm indicator

Incorrect timing Time the system and check the timing system components

The starter remains on Check: electric wiring, circuit not interrupted, mechanical

movement and power supply; replace if necessary

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

Pressure too low at the end of compression Check the thermal group seals and replace worn components

Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air

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High fuel consumption

EXCESSIVE FUEL CONSUMPTION

Possible Cause Operation

Air filter blocked or dirty Clean according to the procedure

Inefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and

power supply

Loose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittings

Incorrect float level Restore the level in the chamber by bending on the float the

thrusting reed of the petrol intake rod so as to have the float

parallel to the chamber level with the carburettor inverted.

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Slippage or irregular functioning Check that there is no grease on the masses.

Check that the faying surface between the clutch masses and

the clutch housing is mainly in the middle and with equivalent

specifications on the three masses.

Check that the clutch housing is not scored or worn abnormally

Never run the engine without the clutch housing

Insufficient 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 bleed the hydraulic braking system, (there must be

no flexible movement of the brake lever).

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Excessive clearance in the rear brake control cable Adjust the clearance with the appropriate adjuster located on

the back part of the crankcase.

Brakes overheating

BRAKES OVERHEATING

Possible Cause

Operation

Rubber gaskets swollen or stuck Replace gaskets.

Compensation holes on the pump clogged Clean carefully and blast with compressed air

Brake disc slack or distorted 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.

Defective piston sliding Check calliper and replace any damaged part.

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Electrical system

Battery

BATTERY

Possible Cause Operation

Battery The battery is the electrical device in the system that requires

the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery

needs to be recharged periodically. The battery runs down completely in the course of 5 to 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keep-

ing in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM

chapter for the recharging of the batteries.

Turn signal lights malfunction

TURN INDICATORS NOT WORKING

Possible Cause Operation

Electronic ignition device failure With 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 bottom ring nuts. If irregu-

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: if they are recessed or if the balls are squashed, replace

them.

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 bearings rotate: re-

place if they are recessed.

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Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

NOISY SUSPENSION If the front suspension is noisy, check: that the front shock ab-

sorber works properly and the ball bearings are 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.

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 41

KEY (With electric pump)

1. Electronic ignition device

2. Immobilizer aerial

3.TPS potentiometer

4. Magneto flywheel - Pick-up

5. Diagnostics 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

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20. License plate light bulb

21. Rear left turn indicator

22. Rear light assembly

23. Rear right turn indicator

24. Front left turn indicator

25. Headlight

A. Twin-filament bulb B. Front position light bulb

26. Front right turn indicator

27. Remote control headlight

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 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. Carburettor heater

38. Automatic starter

39. External temperature sensor

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KEY (Without electric pump)

1. Electronic ignition device

2. Immobilizer aerial

3.TPS potentiometer

4. Magneto flywheel - Pick-up

5. Diagnostics 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

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20. License plate light bulb

21. Rear left turn indicator

22. Rear light assembly

23. Rear right turn indicator

24. Front left turn indicator

25. Headlight

A. Twin-filament bulb B. Front position light bulb

26. Front right turn indicator

27. Remote control headlight

28. Key switch

29. Fuel level transmitter

30. Engine oil pressure sensor

31. Odometer with warning lights and fuel gauge

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: Orange Az: Light blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Conceptual diagrams

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Ignition

LEGENDA (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.

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LEGENDA (Senza 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.

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Headlights and automatic starter section

LEGENDA (Con pompa elettrica)

1. Dispositivo di 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

A. Spia riserva carburante B. Spia lampeggiatore destro C. Spia lampeggiatore sinistro D. Lampade illuminazione strumento

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E. Spia luci F. Spia pressione olio G. Spia luci abbaglianti H. Led dissuasione e diagnostica

37. Riscaldatore carburatore

38. Starter automatico

LEGENDA (Senza pompa elettrica)

1. Dispositivo di 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

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A. Spia riserva carburante B. Spia lampeggiatore destro C. Spia lampeggiatore sinistro D. Lampade illuminazione strumento E. Spia luci F. Spia pressione olio G. Spia luci abbaglianti 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

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12. Fusibili secondari

13. Pulsante di avviamento

14. Pulsante stop sul freno posteriore

15. Pulsante stop sul freno anteriore

22. Fanale posteriore completo

28. Commutatore a chiave

LEGENDA (Senza 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

12. Fusibili secondari

13. Pulsante di avviamento

14. Pulsante stop sul freno posteriore

15. Pulsante stop sul freno anteriore

22. Fanale posteriore completo

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28. Commutatore a chiave

Level indicators and enable signals section

KEY(With electric pump)

1. Electronic ignition device

2. Immobilizer aerial

3.TPS potentiometer

8. Main fuses

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

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G. High-beam warning light H. Immobiliser/diagnosis LED

39. External temperature sensor

KEY(Without electric pump)

1. Electronic ignition device

2. Immobilizer aerial

3.TPS potentiometer

8. Main fuses

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

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G. High-beam warning light H. Immobiliser/diagnosis LED

38. External temperature sensor

Instruments and warning lights control board

4-PIN CONNECTOR

Specification

Desc./Quantity

1 Ground lead 2 Left turn indicator warning light 3 Right turn 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

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Devices and accessories

KEY(With 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

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

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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

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

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26. Front right turn indicator

28. Key switch

31. Odometer with warning lights and fuel gauge

32. Turn indicators sound alarm wiring

33. Fuel pump

Checks and inspections

Immobiliser

The electric ignition system is fed with direct current and is protected 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 the battery charge. When the ignition key is turned to «ON», the deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON». The duration of the flash depends on the electronic control unit program (see figure).

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In case the LED turns off and remains so even when switching over to «ON», check if:

- the battery is charged

- 15A main fuse is working correctly. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located behind the front left fuse box flap. If the serial LED remains off, proceed to check the control unit supply as follows:

- Disconnect the control unit connector and check if:

- There is battery voltage between terminal 8 (Red/ Blue) and the ground 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 evident loss of power may be felt. Program the system with the MASTER (Brown) and SERVICE (Blue) keys as follows:

- Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds).

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- Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds.

- Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys (blue) can be programmed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Once the control unit has been programmed, the control unit is inseparably matched with the MASTER key transponder. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes 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 warnings. That is, the LED is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-sec flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:

2-FLASH CODE

Example with programmed electronic control unit, no transponder and/or aerial malfunction

Ignition disabled-Vehicle immobilised

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3-FLASH CODE

Example with programmed electronic control unit, aerial working properly and unknown transponder code.

Ignition disabled-Vehicle immobilised

Diagnostic code - 2 flashes

When the 2-flash code is detected, carry out the following checks:

- Check if the failure continues even after changing key (including the MASTER key). If the failure persists with any key, disconnect the aerial connector from the electronic control unit and check the aerial continuity with the multimeter. If it does not work, replace the aerial. If no faults are found, replace the control unit.

CAUTION

BEFORE PROGRAMMING THE NEW ELECTRONIC 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 used, proceed with coding a new service key (Blue).

- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to «ON», only a 0.7-sec flash is detected (see diagram). In this case, the engine can be started.

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Example with programmed control unit, transponder, programmed key and working aerial. The

ignition is enabled (regular use conditions)

Ignition circuit

All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; therefore, the control 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 connector and check that the cable between terminal No. 3 (Green) and terminal No. 12 (Black) is not interrupted. The check includes the Pick-Up and its power line. If a break in the circuit is found, check again the flywheel and the engine earth connectors. If nonconforming values are measured, replace the Pick-Up; otherwise, repair the cable harness.

Electric characteristic

Pick-up resistance value

Pick-up resistance value: 105 ÷ 124 Ohm

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- HV primary coil check

Disconnect the control unit connector and check that the cable between terminal No. 4 (violet) and terminal No. 12 (black) is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If the values are correct, repair the cable harness or reset the connections; otherwise, replace the HV coil

Electric characteristic

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 with the multimeter adaptor.

Electric characteristic

High voltage coil secondary resistance value

High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm

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- Pick-Up

Disconnect the control unit connector and connect the positive terminal to connector No. 3 and the negative terminal to connector No. 12 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up. Replace Pick-Up if non-conforming values are measured.

N.B. THE MULTIMETER MUST BE SELECTED TO DETECT

CONTINUOUS VOLTAGE.

Electric characteristic

Pick-Up voltage value

Pick-Up voltage value: > 2 Volt

- H.V. coil

With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and connect the positive terminal to the ground one and the negative to the coil positive connector. 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, the latter is directly connected to ground and to the battery positive passing through the 15A safety fuse. This system therefore requires no connection to the ignition key. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling

020333Y Single battery charger

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020334Y Multiple battery charger

Stator check

Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic

Ohm value:

0.7 ÷ 0.9 Ohm

Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions 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 values lower than 14 Volt, check the stator and the corresponding cable harness.

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Recharge system voltage check

Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine. In case the generated current value is lower than 8A, repeat the test using a new regulator and/stator alternatively.

Choke Inspection

Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected 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 positive 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 connections to the key switch.

If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed; then check if there is voltage by connecting the multimeter positive probe to terminal 9 (Orange), and the negative one to terminal 11 (White/Black) (see figure).

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Replace the control unit if there is no voltage; otherwise, check the wiring connections between the starter and the control unit.

Turn signals system check

- If the turn indicators do not work, proceed as follows:

- Disconnect the electronic control unit connector and check that there is voltage between terminal 9 (Orange) and the earth connection with the key switch set to "ON".

- Check that the same happens between terminal 9 (Orange) and terminal 12 (Black).

If no voltage is detected, check the cable harness and the connections; otherwise, proceed as follows:

- Jump terminals 2 (Black/Blue) and 9 (Orange), see figure. Turn the turn indicator switch alternately to the left and to the right with the key switch in "ON" and check if the lights turn on. If they 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-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months.

INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

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- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 to 14.70V

- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity

- Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

Dry-charge battery

WARNING

- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about 15 minutes and seek immediate medical attention. In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. 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 specified for batteries with a specific gravity of 1.26, corresponding to 30 Bé at a minimum temperature of 15°C. until the upper level is reached.

2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.

3) - Within the following 24 hours, recharge using the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that these values are stabilised.

4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.

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5) Once the above operations have been performed, install the battery on the vehicle ensuring that it is wired up properly.

1 Hold the vertical tube 2 Look at the level 3 The float must be freed

WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

Battery maintenance

The battery is an electrical device which requires careful monitoring and careful maintenance. The maintenance rules are:

1) Check the level of the electrolyte

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If water topping is required too often, check the vehicle electrical system: the battery works overcharged and is subject to quick wear.

2)Load status check

After topping-up the electrolyte 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 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.

3) Recharging the battery

Remove the battery from the vehicle removing the negative clamp first. Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

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4) Cleaning the battery

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

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 negative probe to pin 3, making sure there is battery voltage as indicated in the table.

PUMP SUPPLY

Specification

Desc./Quantity

Key set to «KEY ON» Supply to the pump for 13 seconds

Engine revs from 0 to 200 rpm Always «OFF»

Engine revs from 200 to 1200 rpm Always «ON»

Engine revs from 1200 to 2000 rpm 0.2 seconds «ON»

9 seconds «OFF»

Engine rpm ] 2000 rpm Always «ON»

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

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Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the head

- Undo the 2 screws fixing the silencer to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.

Removal 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 unscrewing the set screw

- Disconnect the belt cooling tube and the swinging arm retaining spring shown in the photograph

- Disconnect the spark plug tube

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- Remove the throttle control cable from the carburettor, indicated in the photograph

- Remove the 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 cable indicated in the figure

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- Remove the protection sheath indicated in the figure and disconnect the automatic starter, the carburettor heater and the TPS connectors (150 cm³ version only: 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.

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INDEX OF TOPICS

ENGINE ENG

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This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes. Using the clutch housing lock wrench, remove the driven pulley axle locking nut and recover the washer.

- Remove the cap/dipstick from the engine oil filling hole.

- Remove the 10 screws and the ground cable fastened under one of 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 return spring.

- Remove the damaged components.

- Lubricate the spring with the recommended grease.

- Remove the toothed sector and load the spring with an appropriate tool.

- Refit the washer, the seeger ring and the Kickstart lever.

Specific tooling

020432Y Tool to fit the start-up sector spring

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Recommended products

AGIP GREASE MU3 Yellow-brown, lithiumbase, medium-fibre multipurpose grease.

ISO L-X-BCHA 3 - DIN 51 825 K3K -20

- Operating the starter lever, load the spring and introduce the pinion in its seat.

- Refit the intake throat with the 3 screws and the Kick-starter cover with the 4 screws. Tighten 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 bulkhead and remove the bulkhead.

- Remove the 3 screws, then take out the duct as well as the filter.

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Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Use the specific tools to remove the bearing from the crankcase.

CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID 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

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020357Y 32 x 35-mm Adaptor 020412Y 15-mm guide

Removing the driven pulley

- Remove the spacer, the clutch housing and the whole driven pulley unit.

N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING

PULLEY MOUNTED.

Inspecting the clutch drum

- Check that the clutch bell is not 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 check the crankshaft alignment.

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- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity.

- Repeat the measurement in 3 positions (Central, internal, external).

- If faults are found, replace the bell.

Specific tooling

020074Y Support base for checking crankshaft alignment

020335Y Magnetic mounting for dial gauge

Characteristic

clutch housing inspection: Limit eccentricity.

Admissible limit eccentricity: 0.15 mm

Removing the clutch

- Prepare the locking tool for the driven pulley with the pins half-screwed in the tool set to «C».

- Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. Afterwards 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 BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch 020444Y009 wrench 46 x 55

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Inspecting 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 seals.

N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-

TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT

A VARIATION 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 halfpulley.

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 specific extractor.

N.B. REST THE HALF-PULLEY ON A WOOD SURFACE TO

AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.

Specific tooling

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020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide

Inspecting the driven fixed half-pulley

- Measure the outside diameter of the pulley bushing.

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 Orings.

- Measure the inside diameter of the mobile halfpulley bushing.

Characteristic

Minimum admissible diameter:

Ø 41.08 mm

Standard diameter

Ø 41.035 mm

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Refitting the driven half-pulley bearing

- Assemble a new roller bearing using the specific punch, fit the bearing with the label facing outward and insert it completely up to the punch on the halfpulley.

N.B. REST THE HALF-PULLEY ON A WOOD SURFACE TO

AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.

Specific tooling

020424Y Driven pulley roller casing fitting punch

- To assemble the new ball bearing insert it completely down in its housing with the specific punch and finally assemble the Seeger ring.

Specific tooling

020375Y 28 x 30 mm 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 movable half-pulley.

- Assemble the half-pulley on the ringlet with the appropriate protection sheath.

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

Specific tooling

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020263Y Driven pulley assembly sheath

Recommended products

AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide.

Inspecting the clutch spring

- Measure the length of the spring when it is relaxed.

Characteristic

Standard length:

106 mm

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 DIFFERENT 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 LOAD.

Characteristic

Minimum thickness permitted:

1 mm

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- Support the driven pulley spring compressor specific tool with the control screw in vertical axis.

- Arrange the tool with the medium length pins screwed in position "C" on the inside.

- Introduce the adapter ring No. 11 with the chamfering facing upwards.

- Insert the clutch on the adapter ring.

- Lubricate the end of the spring that abuts against the torque server closing collar.

- Insert the spring with its plastic holder in contact with the clutch.

- Insert the drive belt into the pulley unit according to their direction of rotation.

- Insert the pulley unit with the belt into the tool.

- Slightly preload the spring.

- Make sure that the clutch is perfectly inserted into the 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 according to its direction of rotation.

- Lock the driven pulley again using the specific tool.

- Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position.

- Remove the driven pulley /belt unit from the tool.

N.B. DURING THE SPRING PRELOADING PHASE, BE CARE-

FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING.

N.B. FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-

METRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.

Specific tooling

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020444Y Tool for fitting/ removing the driven pulley clutch

020444Y011 adapter ring 020444Y009 wrench 46 x 55

Locking torques (N*m)

Nut locking clutch unit on pulley 55 - 60 Nm

Refitting the driven pulley

- Reassemble the clutch housing and spacer.

Drive-belt

During the wear 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 Standard width 22.5 ± 0.2 mm

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Removing the driving pulley

- Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the cup washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer.

Specific tooling

020368Y driving pulley lock wrench

- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling free assembled rollers.

- 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 diameter permitted Ø 25.950 mm

Standard diameter Ø 26-0.020 -0.041 mm

CVT ROLLERS

Specification

Desc./Quantity

Minimum diameter permitted Ø 18.5 mm

Standard diameter Ø 26±0.1 mm

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- Check the guide shoes for the variator back-plate are not worn.

- Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves.

Refitting the driving pulley

- Reassemble the parts of the unit (internal lining, 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)

Locking torque 75 to 83

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Refitting the transmission cover

- Check that there are 2 alignment dowels and that the sealing gasket for the oil sump on the transmission cover is adequately fitted.

- Replace the cover and tighten the 10 screws to the specified torque.

- Refit the oil loading cap/bar.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the prescribed torque using the lock wrench and the torque 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 and the brake shoes lever sliding unscrewing the relevant retaining screw to reach the rear of the cover

- Take off the hub cover and relevant gaskets

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Removing the wheel axle

Remove the intermediate gear and the complete hub cover.

Removing the hub bearings

- Check the state of the bearings being examined (wear, clearance and noisiness). If faults are detected, do the following.

- Use the specific bearing extractor to remove 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 adequately supporting the hub cover, as shown in the figure.

Specific tooling

020376Y Adaptor handle 020364Y 25-mm guide

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With the appropriate tools, remove the oil seal as shown in the figure.

Specific tooling

020376Y Adaptor handle 020359Y 42 x 47-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 pulley.

- Extract the driven pulley shaft from its bearing.

- Remove the oil seal using a screwdriver, working 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

VESPA LX 150 4T Euro 3, LX 125 4T Euro 3 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual