VESPA LX 2012, S 2012 Service Station Manual

Download

Page 1

SERVICE STATION MANUAL

677662 EN

Vespa LX - S 125 3V ie 150 3V ie (2012)

Page 2

SERVICE STATION

MANUAL

Vespa LX - S 125 3V ie 150 3V ie (2012)

The descriptions and images in this publication are given for illustrative purposes only and are not binding.

While the basic specifications as described and illustrated in this manual remain unchanged, Piaggio Việt Nam 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.

or in part is prohibited."

PIAGGIO VIỆT NAM- After Sales

LOT M - BINH XUYEN INDUSTRIAL ZONE - VINCH PHUC - VIET NAM

CUSTOMER SERVICE CENTRE

Please contact with us following:

Hot line: 1800 5555 85

Email:

customer.service@piaggio.com.vn

Website:

www.piaggio.com.vn

Page 3

SERVICE STATION MANUAL

Vespa LX - S 125 3V ie 150 3V ie

(2012)

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.

Page 4

Page 5

INDEX OF TOPICS

CHARACTERISTICS 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

Page 6

INDEX OF TOPICS

CHARACTERISTICS CHAR

Page 7

This section describes the general specifications of the vehicle.

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 - S 125 3V ie 150 3V ie (2012) Characteristics

CHAR - 7

Page 8

Vehicle identification

THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION.

VEHICLE IDENTIFICATION VESPA LX

Specification Desc./Quantity

Chassis prefix (125) ZAPM68300 - 10000001

Engine prefix (125) M669M 1001

Chassis prefix (150) ZAPM68400 - 10000001

Engine prefix (150) M66AM - 1001

THE FOLLOWING INDICACTIONS REFER TO THE S VERSION.

VEHICLE IDENTIFICATION VESPA S

Specification Desc./Quantity

Chassis prefix (125) ZAPM68301 - 10000001

Engine prefix (125) M669M 1001

Chassis prefix (150) ZAPM68401 - 10000001

Engine prefix (150) M66AM - 1001

Chassis number

The chassis number «A» is stamped near the battery compartment. To read it proceed as follows:

- lift the saddle;

- lift the helmet compartment by removing it.

Engine number

The engine number «B» is stamped near the rear left shock absorber lower support.

Dimensions and mass

THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION.

Characteristics Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 8

Page 9

THE FOLLOWING INDICACTIONS REFER TO THE S VERSION.

Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics

CHAR - 9

Page 10

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Length 1770 mm

Width 705 mm

Maximum height 1150 mm

Wheelbase 1280 mm

Kerb weight 114 kg ± 5 kg

Maximum weight allowed 264 kg

Engine

125 CM³ ENGINE SPECIFICATIONS

Specification Desc./Quantity

Type Single-cylinder, 4-stroke

Engine capacity 124.5 cm³

Bore x stroke 52.0 x 58.6 mm

Max. power 7.2 kW at 7750 rpm

MAX. torque 9.5 Nm at 6000 rpm

Compression ratio 10:1

Idle speed 1750±50 rpm

Valve clearance (cold engine) intake: 0.08 mm exhaust: 0.08 mm

Timing system 3 valves (2 intake, 1 drainage). single overhead camshaft

chain-driven.

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.

Cooling Forced-air circulation cooling.

Fuel system Electronic injection with Ø 26 mm throttle body, single injector.

Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter.

Emissions compliance EURO 3

150 CM³ ENGINE SPECIFICATIONS

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke

Engine capacity 154.8 cm³

Bore x stroke 58.0 x 58.6 mm

Max. power 8.7 kW at 7500 rpm

MAX. torque 12 Nm at 5000 rpm

Compression ratio 10.5: 1

Idle speed 1750±50 rpm

Valve clearance (cold engine) intake: 0.08 mm exhaust: 0.08 mm

Timing system 3 valves (2 intake, 1 drainage). single overhead camshaft

chain-driven.

Lubrication Engine lubrication with lobe pump (inside crankcase), chain-

driven, with double filter: mesh and paper.

Cooling Forced-air circulation cooling.

Fuel system Electronic injection with Ø 26 mm throttle body, single injector.

Fuel Unleaded petrol (95 RON)

Exhaust silencer Absorption-type exhaust muffler with catalytic converter.

Emissions compliance EURO 3

Transmission

TRANSMISSION

Specification

Desc./Quantity

Transmission CVT expandable pulley variator with torque server, V-belt, self-

ventilating dry automatic centrifugal clutch and transmission

housing with forced-circulation air cooling.

Final reduction gear Gear reduction unit in oil bath.

Characteristics Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 10

Page 11

Capacities

CAPACITIES

Specification Desc./Quantity

Engine oil 1220 cm³ (of which 120 cm³ in the filtering cartridge)

Hub oil 200 cm³

Fuel tank capacity ~ 7 litres ± 0.5 litres

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Electric Electric starter Ignition Electronic inductive discharge ignition, with variable advance

and separate HV coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR8EB

Electrode gap 0.7 to 0.8 mm

Frame and suspensions

FRAME AND SUSPENSION

Specification

Desc./Quantity

Chassis Stamped plate body with welded structural reinforcements.

Front suspension Single arm with helical spring and single double-acting hy-

draulic shock absorber.

Rear suspension Double-acting shock absorber, adjustable to four positions at

preloading.

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

Wheel rim type Light alloy wheel rims. Front wheel rim 11'' x 2.50 Rear wheel rim 10'' x 3.00

Front tyre Tubeless, 110/70 - 11'' 45L

Rear tyre Tubeless, 120/70 - 10'' 54L

Front tyre pressure 1.6 bar

Rear tyre pressure (with passenger) 2.0 bar (2.3 bar)

Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics

CHAR - 11

Page 12

Tightening Torques

CHASSIS ASSEMBLY

Name Torque in Nm

Swinging arm - chassis pin 44 to 52

Engine-swinging arm bolt 40 to 45

Silent block-swinging arm retaining bolts 40 to 45

Centre stand pin 40 to 45

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

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

Brake pump reservoir screw 15 to 20

(°) Apply LOCTITE 242 threadlock

MUFFLER

Name

Torque in Nm

Silencer heat guard fixing screw 4 to 5

Screws fixing silencer to the crankcase 24 ÷ 27

Lambda probe tightening on exhaust manifold 40 to 50

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

REAR SUSPENSION

Name

Torque in Nm

Rear wheel axle 104 ÷ 126

Shock-absorber/chassis nut 20 to 25

Lower shock absorber clamp 40 to 45

FLYWHEEL

Name

Torque in Nm

Flywheel cover screw 11 ÷ 13

Starter sprocket check fixing screw 5 to 6

Starter motor fixing screws 11 to 13

Flywheel fixing nut 100 to 110

Freewheel fixing screws 10 to 11

FLYWHEEL COVER

Name

Torque in Nm

Pick-up screws 3 - 4

Characteristics Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 12

Page 13

Name Torque in Nm

Stator fixing screws 5 to 6 (Loctite 242)

Stator cable plates clamping screws 3 - 4

Fixing clamps of head pump cover by-pass pipe 1.3 to 1.7

Coil fixing screw 11 to 13

CRANKCASE

Name Torque in Nm

Calibrated fixing dowel 5 - 7

Oil filter cover 24 to 30

Engine oil level shaft 1.3 to 1.7

Engine-crankcase coupling screws 11 ÷ 13

Rear brake screw 15 to 17

Oil sensor 12 to 14

Oil filter 5 to 6

Oil drain screw 14.7 to 16.7

Oil pump bulkhead screw 4 to 6

Freewheel fixing screws 10 to 11

Oil pump fixing screw 5 to 6

Oil pump command crown screw 10 to 14

Rotor cover 1 to 1.50

Rotor clamp 3 to 4

HEAD AND CYLINDER

Name

Torque in Nm

Head cover screws 10.8 to 12.7

Cylinder head nut (PRE-TIGHTENING) 6 - 8

Cylinder head nut (TIGHTENING) 9 to 11 (Tighten to the prescribed torque and then proceed with

270.0°±5.0° rotation)

Cylinder stud bolt fitting See section ENGINE/LUBRICATION/STUD BOLT

Throttle body clamp screws 1.3 to 1.7

Tensioner spring retaining screw 5 to 6

Fastener chain tensioner 11 to 13

Thermostat cover screws 3 - 4

Pressure reducer counterweight retainer screw 7 to 8.5

Injection manifold fixing screws 11 to 13

Valve clearance adjustment screw 6 to 9

Spark plug tightening 10 to 12

Timing system sprocket fixing screw 4 to 6

Screws fixing cylinder to crankcase 10.8 to 12.7

Head blow by 3 to 4

TRANSMISSION AND FINAL REDUCTION

Name

Torque in Nm

Transmission cover screws 11 to 13

Final reduction cover screws 24 to 27

Driven pulley fixing nut 53 to 59

Oil drain screw 14.7 to 16.7

Freewheel fixing screws 10 to 11

Driving pulley retainer nut 75 to 83

LUBRICATION

Name

Torque in Nm

Crankcase timing cover screws 11 to 13

Screws fixing oil pump to the crankcase 4 to 6

Pump rod screw 13 - 15

Minimum oil pressure sensor locking 12 to 14 (LOCTITE 5091 Edge closure between metal body and

plastic block)

Overhaul data

Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics

CHAR - 13

Page 14

Assembly clearances

Cylinder - piston assy.

CYLINDER - PISTON (125)

Specification Desc./Quantity

Piston diameter 51.961 (±0.014) mm

Cylinder diameter 52 (+0.008 -0.020) mm

CYLINDER - PISTON (150)

Specification

Desc./Quantity

Piston diameter 57.947 (± 0.014) mm

Cylinder diameter 58 (+0.008 -0.020) mm

COUPLING CATEGORIES (125)

Name

Initials Cylinder Piston Play on fitting

cylinder-piston A 51.980 to 51.987 51.947 to 51.954 0.026 ÷ 0.040 cylinder-piston B 51.987 to 51.994 51.954 to 51.961 0.026 ÷ 0.040 cylinder-piston C 51.994 to 52.001 51.961 to 51.968 0.026 ÷ 0.040 cylinder-piston D 52.001 to 52.008 51.968 ÷ 51.975 0.026 ÷ 0.040

COUPLING CATEGORIES (150)

Name

Initials Cylinder Piston Play on fitting

cylinder-piston A 57.980 to 57.987 57.933 to 57.940 0.040 to 0.054 cylinder-piston B 57.987 to 57.994 57.940 to 57.947 0.040 to 0.054 cylinder-piston C 57.994 to 58.001 57.947 to 57.954 0.040 to 0.054 cylinder-piston D 58.001 to 58.008 58.954 to 58.961 0.040 to 0.054

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

Characteristics Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 14

Page 15

- Measure the outer diameter of the gudgeon pin.

Characteristic

Pin outside diameter

14 (+0 -0.004) mm

- Measure the diameter of the housings on the piston.

Characteristic

Standard diameter

14 (+0.006 +0.001) mm

- Carefully clean the seal housings.

- Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram.

- If the clearance is greater than that indicated in the table, replace the piston.

- Check the clearance upon mounting (A) of the bands:

N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE

OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE.

ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS (125)

DESIGNATION

SIZES ASSEMBLY CLEARANCES (A)

1° compression ring (mm) 52x0.8 0.20 to 0.35 2° compression ring (mm) 52x1.0 0.20 to 0.45 Oil ring segments (mm) 52x2.0 0.25 to 0.55

ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS (150)

DESIGNATION

SIZES ASSEMBLY CLEARANCES (A)

1° compression ring (mm) 58x0.8 0.20 to 0.35 2° compression ring (mm) 58x1.0 0.20 to 0.45 Oil ring segments (mm) 58x2.0 0.25 to 0.55

- Check that the head coupling surface is not worn or misshapen.

Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics

CHAR - 15

Page 16

- Pistons and cylinders are classified according to diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

Crankshaft Axial clearance between

crankshaft and connecting rod

Axial clearance between crankshaft and connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name

Code Sizes Assembly clearance

Half-shaft, transmission side A 18.1 (+0; -0.05) mm D = 0.20 - 0.50 Flywheel-side half shaft B 18.1 (+0; -0.05) mm D = 0.20 - 0.50 Connecting rod C 15 (-0.10; -0.15) mm D = 0.20 - 0.50 Spacer tool E 51.4 (+0; +0.05) mm D = 0.20 - 0.50

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

Characteristics Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 16

Page 17

CRANKSHAFT

Specification

Desc./Quantity

Crankshaft bearings: Standard diameter: Cat. 1 26.998 to 27.004 mm Crankshaft bearings: Standard diameter: Cat. 2 27.004 to 27.010 mm

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.

Characteristic

«A»

AXIS CYLINDER

Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics

CHAR - 17

Page 18

- The main bushings have 2 half-bearings, 1 with and 1 without the lubrication channel.

- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder.

- To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the photo.

Characteristic

«A»

AXIS CYLINDER

BUSHINGS

TYPE

IDENTIFICATION CRANKSHAFT HALF-BEARING

B BLUE 1.971 to 1.976 C YELLOW 1.974 to 1.979 E GREEN 1.977 to 1.982

Characteristics Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 18

Page 19

- The section of the oil feeding channels is also influenced by the driving depth of the bushings.

- Visually check the wear of the bushings: in the coupling ends shown in the photo the bushing usually keeps the original look, check in the rest of the bushing if there is evident removal of material. If this occurs as stated, proceed to replace the crankcase halves.

N.B. SMALL MARKS AND SCRATCHES OF THE SHAFT ROTA-

TION ARE NORMAL SIGNS OF ENGINE USAGE, AND DO NOT AFFECT THE CORRECT FUNCTIONING.

Measurement of crankcase halves - crankshaft coupling clearance.

- The nominal diameters of the bushings, even if of the same coupling category, may differ by hundredths due to the plastic slackening of the material of the crankcase due to the driving load.

- Measure along the axis of the « A» cylinder, using a bore meter at two depths indicated in the figure, the diameter of the bushings.

- After measuring the two diameters, take the average.

Characteristic

«A»

AXIS CYLINDER

- The bushings housing hole in the crankcase half is divided into two categories depending on the size, Category 1 and Category 2.

DIAMETER OF CRANKCASE WITHOUT BUSHING

Specification

Desc./Quantity

CAT 1 30.959 to 30.965 mm CAT 2 30.953 to 30.959 mm

- Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat.

2). Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare crankshaft has half-shafts of the same category.

- According to the classification of the shaft CAT.1 - CAT.2 combine a complete crankcase pre-fitted with suitable bushings according to the starting shaft.

Recommended products

AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions.

API GL-4

Characteristic

Rear hub oil

~ 200 cm³

Locking torques (N*m)

Hub oil drainage screw 15 to 17

Air filter

- Remove the helmet compartment.

- Disconnect the air intake pipe from the filter box.

- Undo the indicated fixing screws.

- Remove the left side fairing.

Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance

MAIN - 41

Page 42

- Undo the six screws and remove the air-box cover.

- To clean the filtering element proceed as follows: remove the paper filtering element, blast with compressed air and then refit it.

- Make sure the filtering element is in the correct position.

- Check that the air passage sections are not damaged or deformed.

- Check the correct sealing of the coupling between the filter housing and the cover.

N.B.

FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RESULT IN WRONG VACUUM INSIDE THE FILTER HOUSING, WHICH IN TURN MAY PRODUCE VARIATIONS IN CARBURETION.

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

Engine oil

In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered 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; furthermore to facilitate oil drainage, loosen or remove the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it.

Maintenance Vespa LX - S 125 3V ie 150 3V ie (2012)

MAIN - 42

Page 43

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from oil dipstick/cover. Then start up the vehicle, leave it running for a few minutes and switch it off: After about five minutes, check the level and, if necessary, top-up but never exceeding the MAX level reference mark. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

eni i-Ride PG 10W-40 Synthetic-based lubricant for four stroke engines.

JASO MA, MA2 - API SL - ACEA A3

Check

This operation must be carried out with the engine cold and following 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 1220 cc of engine oil. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level.

Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance

MAIN - 43

Page 44

Engine oil top-up

The oil should be topped up after having checked the level and in any case by adding oil without

ever exceeding the MAX. level.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products

eni i-Ride PG 10W-40 Synthetic-based lubricant for four stroke engines.

JASO MA, MA2 - API SL - ACEA A3

Oil pressure warning light

The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

Maintenance Vespa LX - S 125 3V ie 150 3V ie (2012)

MAIN - 44

Page 45

Checking the ignition timing

Position the engine at top dead centre (TDC) in compression. To do this, use the appropriate tools. Use the holes on the engine crankcase to secure the tool. Position the specific tool in the window between the flywheel pick-up references as illustrated in the figure. The arrows stamped respectively on the valve frame and sprocket must coincide.

N.B. IF THE TIMING UNIT IS NOT IN PHASE CHECK THE COR-

RECT FITTING OF COMPONENTS.

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 with the indicated values. When the valve clearance values, intake and exhaust respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operating on the corresponding set screw, as shown in the figure.

Characteristic

Valve clearance (cold engine)

intake: 0.08 mm exhaust: 0.08 mm

Braking system

Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance

MAIN - 45

Page 46

Level check

Proceed as follows:

- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;

- Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the brake pads.

Top-up

Proceed as follows:

- Remove the front handlebar cover.

- Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid specified without exceeding the maximum level.

CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER.

CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO

NOT LET IT COME INTO CONTACT WITH PAINTED PARTS. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS

MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE.

N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO

THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended products

AGIP BRAKE 4 Brake fluid.

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

- ISO 4925 - CUNA NC 956 DOT 4

Maintenance Vespa LX - S 125 3V ie 150 3V ie (2012)

MAIN - 46

Page 47

Locking torques (N*m)

Brake pump reservoir screws 15 to 20

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».

Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance

MAIN - 47

Page 48

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 49

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.

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

Starting difficulties

DIFFICULTY STARTING UP

Possible Cause

Operation

Flat battery Check the state of the battery. If 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 characteristics Drain off the fuel no longer up to standard; then, refill

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.

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause

Operation

Wrong valve adjustment Adjust the valve clearance properly

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

Misshapen/worn valve seats Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

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

fitted properly

Replace the piston cylinder unit or just the piston rings

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

Worn valve oil guard Replace the valve oil seal

Worn valve guides Check and replace the head unit if required

Vespa LX - S 125 3V ie 150 3V ie (2012) Troubleshooting

TROUBL - 49

Page 50

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

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

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.

Electrical system

Troubleshooting Vespa LX - S 125 3V ie 150 3V ie (2012)

TROUBL - 50

Page 51

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.

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.

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

Faulty or broken seals Replace the shock absorber Check the condition of wear of the

steering covers and the adjustments.

Vespa LX - S 125 3V ie 150 3V ie (2012) Troubleshooting

TROUBL - 51

Page 52

Troubleshooting Vespa LX - S 125 3V ie 150 3V ie (2012)

TROUBL - 52

Page 53

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 54

«LX» VERSION

«S» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 54

Page 55

KEY

1. Instrument panel

2. Turn indicator control device

3. Turn indicator switch

4. Left turn indicator bulbs

5. Right turn indicator bulbs

6. Daylight running light bulbs and license plate light

7. Headlight with twin-filament bulb

8. Light switch

9. Headlight relay

10. Stop buttons

11. Fuses No. 3, 4, 6;

12. Light switch

13. Fuse No. 5

14. Fuse No. 2

15. Ignition switch

16. Starter motor

17. Starter remote control switch

18. Fuse No. 1

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 55

Page 56

19. Magneto flywheel

20. Voltage regulator

21. Battery

22. Stop light bulb

23. Injection load relay

24. Horn button

25. Horn

26. Lambda probe

27. Engine speed sensor

28. HV coil

29. Diagnostics socket

30. Injector

31. Engine temperature sensor

32. Fuel pump

33. Side stand switch

34. Electronic control unit

35. Immobilizer Aerial

36. Fuel level transmitter

37. Oil pressure 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

Components arrangement

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 56

Page 57

1. Magneto flywheel - Remove the flywheel cover, as described in the «Engine» chapter, to reach it. To get access to the connectors, remove the helmet compartment.

2. Voltage regulator - Remove the front central cover to reach it.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 57

Page 58

3. Battery - Lift the saddle and remove the cover to reach them.

4. Starter remote control - Remove the battery to reach it.

7 - 8 - 14 - 15 - 16 -26. Fuses - Remove the battery cover and/or the front central cover to reach them.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 58

Page 59

11 - 38. Remote controls - Remove the front central cover to reach it.

29 - 24. Pump and fuel lever transmitter - They are fitted on the tank, remove the fuel tank to reach them.

25. Oil pressure sensor - To access, remove the fan cover cap as described in the ENGINE chapter.

27. Immobilizer aerial- Remove the shield back plate to reach it.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 59

Page 60

28. Injection ECU - Remove the helmet compartment to reach it.

30. Diagnosis connector - Remove the helmet compartment to reach it.

31 - 32. Engine temperature sensor - fuel injector - Remove the helmet compartment to reach it.

33. H.V. coil - Remove the helmet compartment

and undo the two screws indicated to reach it.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 60

Page 61

35. Side stand switch - It is fitted on the side stand.

Ground points

On the vehicle there is a chassis ground point, marked with letter "A", on the right side of the battery compartment.

There is another ground point "B" on the starter motor.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 61

Page 62

On the left side of the chassis, under the footrest, there is the chassis-engine ground lead "C".

Electrical system installation

Front side

1. Fuse boxes

2. Turn indicator control device

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 62

Page 63

3. Voltage regulator

4. Horn

5. Immobilizer antenna

6. Front left turn indicator

7. Front right turn indicator

8. Voltage regulator

9. Connection cables injection load relays and lighting

10. Voltage regulator connection

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 63

Page 64

11. Connecting branch controls on the driver and the front headlights

12. On connecting branch rear part of the system

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 64

Page 65

13. On connecting branch rear part of the system

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 65

Page 66

Back side

1. Spark plug cap

2. Connection of pick-up sensor

3. Stator connection

4. Diagnostics connection

5. HV coil

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 66

Page 67

6. Connections branch of fuel pump and fuel level transmitter

7. Connection electronic control unit

8. Injector connection

9. Engine temperature sensor

10. Connections to the battery poles

11. Starter remote control switch

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 67

Page 68

12. Chassis ground point

13. Lambda probe cable connector

14. Lambda probe

Conceptual diagrams

Ignition

«LX» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 68

Page 69

«S» VERSION

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 69

Page 70

KEY

1. Instrument panel

11. Fuses No. 3, 4, 6;

14. Fuse No. 2

15. Ignition switch

18. Fuse No. 1

21. Battery

23. Injection load relay

28. H.V. coil

34. Electronic control unit

35. Immobilizer Aerial

Battery recharge and starting

«LX» VERSION

«S» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 70

Page 71

KEY

10. Stop buttons

11. Fuses No. 3, 4, 6;

14. Fuse No. 2

15. Ignition switch

16. Starter motor

17. Starter remote control switch

18. Fuse No. 1

19. Magneto flywheel

20. Voltage regulator

21. Battery

22. Stop light bulb

34. Electronic control unit

Level indicators and enable signals section

«LX» VERSION

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 71

Page 72

«S» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 72

Page 73

KEY

1. Instrument panel

11. Fuses No. 3, 4, 6;

14. Fuse No. 2

15. Ignition switch

18. Fuse No. 1

21. Battery

23. Injection load relay

26. Lambda probe

27. Engine speed sensor

30. Injector

31. Engine temperature sensor

33. Side stand switch

34. Electronic control unit

35. Immobilizer Aerial

36. Fuel level transmitter

37. Oil pressure sensor

Devices and accessories

«LX» VERSION

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 73

Page 74

«S» VERSION

KEY

11. Fuses No. 3, 4, 6;

14. Fuse No. 2

15. Ignition switch

18. Fuse No. 1

21. Battery

23. Injection load relay

24. Horn button

25. Horn

32. Fuel pump

34. Electronic control unit

Lights and turn indicators

«LX» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 74

Page 75

«S» VERSION

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 75

Page 76

KEY

1. Instrument panel

2. Turn indicator control device

3. Turn indicator switch

4. Left turn indicator bulbs

5. Right turn indicator bulbs

6. Daylight running light bulbs and license plate light

7. Headlight with twin-filament bulb

8. Light switch

9. Headlight relay

11. Fuses No. 3, 4, 6;

12. Light switch

13. Fuse No. 5

14. Fuse No. 2

15. Ignition switch

18. Fuse No. 1

21. Battery

34. Electronic control unit INJECTION «LX» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 76

Page 77

«S» VERSION

KEY

1. Instrument panel

9. Headlight relay

11. Fuses No. 3, 4, 6;

14. Fuse No. 2

15. Ignition switch

17. Starter remote control switch

18. Fuse No. 1

21. Battery

23. Injection load relay

26. Lambda probe

27. Engine speed sensor

28. H.V. coil

29. Diagnostics socket

30. Injector

31. Engine temperature sensor

32. Fuel pump

33. Side stand switch

34. Electronic control unit

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 77

Page 78

35. Immobilizer Aerial

Checks and inspections

Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means of the coded keys that the control unit recognises. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobilizer system consists of the following components:

- Control unit

- Immobilizer antenna

- 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 switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process. When the ignition switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition switch and/or the instrument panel is not initiated, check if:

•

there is battery voltage

•

that fuse No. 1 and fuse No. 2 are in good conditions.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 78

Page 79

•

there is power to the control unit as specified below:

Remove the connector mounting bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions:

With the key switch set to OFF:

• there is battery voltage between terminals 7-9 and terminal 9-chassis ground (fixed power supply). If there is no voltage check that fuse 2 and its cable are in working order.

With the key switch in the ON position:

• there is battery voltage between terminals 6-7 and terminal 6-chassis ground (fixed power supply). If there is no voltage, check the ignition key contacts, that fuse 6 and its cable are in working order.

After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture.

Remove the protective base from the connector.

With the ignition switch at ON check there is battery voltage between the Orange-Blue and Black cables.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 79

Page 80

Virgin circuit

When the ignition system 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 not programmed control unit provides for the recognition of the Master as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys. The Master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits 1 to 3 seconds).

- Insert the service key and turn it to «ON» for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- 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 can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, the Master key transponder is strictly matched with the control unit. 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; to add or delete a key it is therefore necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 80

Page 81

thoroughly inspected: In any case it is advisable to use resistor spark plugs.

Diagnostic codes

The Immobilizer system is tested each time the ignition key is turned from «OFF» to «ON». During this diagnosis phase a number of control unit statuses can be identified and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the LED remains off permanently, the ignition is enabled. If, however, the LED remains on permanently, it means the ignition is inhibited:

1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs.

2. Previously unused control unit - transponder absent or cannot be used: the LED is on

permanently. In this condition no operations are possible including the start up 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 remaining off for 2 sec and then by short 0.46-sec flashes, the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the LED remains permanently OFF. The engine can be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 81

Page 82

•

1-flash code

•

2-flash code

•

3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer antenna wiring and change it if necessary.

Diagnostic code - 2 flashes

A two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobilizer antenna or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check 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 the control unit. If this is not the case, reprogram the decoder.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 82

Page 83

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery's positive terminal passing through the 20A protective fuse. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.

Stator check

Checking the stator windings

WARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Lift the saddle and remove the helmet compartment.

2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the picture.

3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristic

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 terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

Charging current check

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 83

Page 84

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm. Maximum current output check.

- With engine off and panel set to "ON" turn on the lights 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 15V at 5000 rpm with lights off

Starter motor

KEY

1. Battery

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 84

Page 85

2. Starter relay

3. Fuse No. 1

4. Fuse No. 6

5. Ignition switch contacts

6. Fuse No. 2

7. Electronic control unit

8. Starter motor

9. Stop buttons

10. Fuse No. 3

11. Starter button

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check fuses No. 1, 2, 3 and 6.

2) Check ignition switch contacts.

3) Check the contacts of the stop buttons and the starter button.

4) Check with the ignition switch «ON», brake engaged and start button pressed, the presence of voltage between the White-Black cable of the starter relay and ground, otherwise check the cable harness.

5) Check the starter relay.

6) Check that the Red cable between the battery and the starter relay is not interrupted. Also check continuity between the latter and the starter motor.

7) Check the starter motor ground connection.

8) Check the continuity of the Purple-White cable between the starter relay and control unit (pin 10).

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 85

Page 86

Horn control

KEY

1. Battery

2. Fuse No. 1

3. Ignition switch contacts

4. Fuse No. 3

5. Horn button

6. Horn

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check fuses No. 1 and 3.

2) Check the ignition switch and horn button contacts.

3) With the ignition 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 harnesses.

4) Check the horn device ground connection.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 86

Page 87

Turn signals system check

KEY

1. Battery

2. Fuse No. 1

3. Ignition switch contacts

4. Fuse No. 3

5. Turn indicator control device

6. Turn indicator switch

7. Turn indicator bulbs (12V - 10W)

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check that bulbs operate properly.

2) Check fuses No. 1 and 3.

3) Check ignition switch contacts.

4) With the ignition key set to «ON», check if there is voltage between the Blue-Black cable of the turn indicators switch and the ground connection. If there is not, check the cable harnesses and the connections of the turn indicator control device.

5) Check the turn indicator switch contacts.

6) With the turn indicator switch pressed to the right, check if there is voltage between the White-Blue cable of the switch and the ground connection. If there is not, 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.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 87

Page 88

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 CONNECTORS DISCONNECTED.

If faults are detected:

1) With a multimeter, check resistance values between the White-Green cable and the Black cable of the fuel level transmitter under different conditions.

2) If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted.

Electric characteristic

Resistance value when the tank is full

<= 7 Ω

Resistance value when the tank is empty

90 +13/-3 Ω

Lights list

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 88

Page 89

KEY

1. Battery

2. Fuse No. 1

3. Fuse No. 4

4. Ignition key contacts

5. Headlight relay

6. Fuse No. 5

7. Electronic control unit

8. Daylight running light bulbs, license plate light

9. High/low beam two-light bulb

10. Light switch

11. Light switch

WARNING

ALL CONTINUITY 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 the ignition switch and light switch contacts.

4) With the key switch set to «ON» check if there is voltage between the Grey-White cable of the fuse No 5 and the ground connection. If there is not, check cable harnesses.

5) Check cable harness continuity between the fuse No 5 and the light switch (Grey-White cable).

6) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.

HIGH BEAM/LOW BEAM LIGHTS LINE

1) Check that bulbs operate properly.

2) Check fuses No. 1 and 4.

3) Check ignition switch contacts.

4) Check if there is voltage between the Grey-Red cable of the headlight remote control and the ground connection. If there is not, check cable harnesses.

5) With the key switch set to «ON», light switch in position 2 and the engine running, check if there is voltage between the Grey cable of the headlight remote control and the ground connection. If there is not, check cable harnesses.

6) Check that the White-Black cable connecting the headlight solenoid and the control unit (pin 33) is not interrupted.

7) Check the headlight remote control switch.

8) Check that the continuity between the Grey cable of the light switch and the headlight remote control is not interrupted.

9) Check the light switch contacts.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 89

Page 90

10) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.

THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION.

BULBS

Specification Desc./Quantity

1 High/low beam light bulb Type: Halogen (HS1)

Power: 12V - 35/35W

Quantity: 1

2 Front daylight running light bulbs Type: Incandescent

Power:12V - 5W

Quantity: 1

3 Stop light/rear daylight running light bulb Type: Incandescent

Power:12V-5W/18W

Quantity: 1

4 License plate bulb Type: Incandescent

Power: 12V - 5W

Quantity: 1

5 Front turn indicator light bulb Type: Incandescent, BAU 15S, Amber

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

6 Rear turn indicator light bulb Type: Incandescent, BAU 15S, Amber

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

7 Instrument panel bulb Type: Incandescent

Power: 12V - 2W

Quantity: 3

THE FOLLOWING INDICACTIONS REFER TO THE S VERSION.

BULBS

Specification

Desc./Quantity

1 High/low beam light bulb Type: Halogen (H4)

Power: 12V - 55/60W

Quantity: 1

2 Front daylight running light bulbs Type: Incandescent

Power:12V - 5W

Quantity: 1

3 Stop light/rear daylight running light bulb Type: Incandescent

Power:12V-5W/18W

Quantity: 1

4 License plate bulb Type: Incandescent

Power: 12V - 5W

Quantity: 1

5 Front turn indicator light bulb Type: Incandescent, BAU 15S, Amber

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

6 Rear turn indicator light bulb Type: Incandescent, BAU 15S, Amber

Power: 12V - 10W

Quantity: 1 RHS + 1 LHS

7 Instrument panel bulb Type: Incandescent

Power: 12V - 1.2W

Quantity: 2

Power: 12V - 2W

Quantity: 1

8 High-beam warning light bulbs, turn indicator, fuel re-

serve, engine check, oil pressure

Type: Incandescent

Power: 12V - 1.2W

Quantity: 6

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 90

Page 91

Fuses

The electrical system is protected by main and secondary fuses:

1. two main fuses inserted in the fuse holder «A» positioned in the battery compartment.

2. four secondary fuses inserted in the fuse holder «B» accessible by removing the front cover of the shield. The tables show the position and characteristics of the fuses on the vehicle.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK OF FIRE.

MAIN FUSES

Specification

Desc./Quantity

Fuse No. 1 Capacity: 20 A

Protected circuits: General, recharge circuit

Fuse No. 6 Capacity: 10 A

Protected circuits: Injection loads relay, MIU ECU, instrument

panel.

SECONDARY FUSES

Specification

Desc./Quantity

Fuse No. 2 Capacity: 7.5 A

Protected circuits: Injection loads relay, MIU ECU, immobil-

izer aerial.

Fuse No. 3 Capacity: 7.5 A

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 91

Page 92

Specification Desc./Quantity

Protected circuits: starter circuit, turn indicator control device,

stop button, horn, instrument panel.

Fuse No. 4 Capacity: 10 A

Protected circuits: Lowbeam/highbeam light switch via relay

Fuse No. 5 Capacity: 7.5 A

Protected circuits: light switch, headlight relay power, instru-

ment panel.

Dashboard

«LX» VERSION

«S» VERSION

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 92

Page 93

A = Digital clock B = Odometer C = Speedometer D = Engine control telltale light E = Engine oil pressure warning light F = Turn indicators G = High beam warning light H = Headlight 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 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

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 93

Page 94

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.

- 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

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN

1) Battery preparation

Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 94

Page 95

2) Electrolyte preparation.

Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphuric acid.

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery.

5) Take out the container.

Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point.

6) Battery closing.

Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 95

Page 96

7) Recharging the new battery

With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged.

If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle.

The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between

12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 96

Page 97

f - Check the ignition of the green LED indicated with a red arrow in figure.

g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place

h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 97

Page 98

Connectors

DIAGNOSTICS CONNECTOR

1. Not connected

2. Ground lead (Black)

3. Electronic control unit (Orange-Black)

PICKUP CONNECTOR

1. Control unit positive (Red)

2. Negative from control unit (Brown)

3. Oil pressure sensor (White-Pink)

FUEL PUMP CONNECTOR

1. Not connected

2. Ground lead (Black)

3. Not connected

4. Not connected

5.Power from relay (Black - Green)

ELECTRONIC CONTROL UNIT CONNECTOR

1. H.V. COIL (Pink-Black)

2. Not connected

3. Not connected

4. Ground (Orange)

5. Starter button (Purple)

6. Ignition switched live (Orange-Blue)

7. Ground No. 1 (Black)

8. Not connected

9. Battery power (Red-White)

10. Start-up enabling switch (Purple-White)

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 98

Page 99

11. Lambda probe positive (Green-Blue)

12. Lambda probe negative (Light blue-Black)

13. Water temperature sensor (Sky blue-Green)

14. Immobilizer aerial (Orange-White)

15. Ground sensors (Grey-Green)

16. Serial line K (Orange-Black)

17. Immobilizer (Yellow)

18. Not connected

19. Side stand (Brown - Red)

20. Speed sensor negative (Brown)

21. Not connected

22. Injection load relay (Black-Purple)

23. Ground No. 2 (Black)

24. Not connected

25. Injection warning light (Brown-White)

26. Not connected

27. Not connected

28. Not connected

29. Engine speed sensor positive (Red)

30. Not connected

31. Lambda probe heater (Light blue-Red)

32. Not connected

33. Low beam lights automatic ignition enabling

(White-Black)

34. Fuel injector (Red-Yellow) ENGINE TEMPERATURE SENSOR CONNEC-

TOR

1. Electronic control unit (Sky blue - Green)

2. Ground lead (Grey-Green)

Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system

ELE SYS - 99

Page 100

INJECTOR CONNECTOR

1. Power from relay (Black - Green)

2. Electronic control unit (Red - Yellow)

LAMBDA PROBE CONNECTOR

1. Power heater from solenoid (Black - Green)

2. Heater negative from control unit (Light blue-

Red)

3. Control unit positive (Green-Blue)

4. Negative from control unit (Light blue-Black)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red-Black)

2. Ground lead (Black)

H.V. COIL CONNECTOR

1. Power from relay (Black - Green)

2. Electronic control unit (Pink - Black)

Electrical system Vespa LX - S 125 3V ie 150 3V ie (2012)

ELE SYS - 100

VESPA LX 2012, S 2012 Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual