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,...
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.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics 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;...
Page 8: Vehicle Identification
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics Vehicle identification THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION. VEHICLE IDENTIFICATION V ESPA Specification Desc./Quantity Chassis prefix (125) ZAPM68300 - 10000001 Engine prefix (125) M669M 1001 Chassis prefix (150)
Page 9 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics THE FOLLOWING INDICACTIONS REFER TO THE S VERSION. CHAR - 9...
Page 10: Engine Specifications
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics EIGHTS 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...
Page 11: Electrical System
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics 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...
Page 12: Tightening Torques
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics 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...
Page 13 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics 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...
Page 14: Assembly Clearances
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics 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...
Page 15 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics - 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 pis- ton.
Page 16 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics - 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 RANKSHAFT Titolo Durata/Valore Testo Breve (<...
Page 17 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics 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;...
Page 18 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics - 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.
Page 19 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics - 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...
Page 20: Cylinder Head
Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics THE CRANKSHAFT is available in two CATEGO- RIES: Characteristic Crankshaft category: CAT. 1 - CAT. 2 CRANKSHAFT CATEGORY IDENTIFICATION: The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
Page 21 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics HEAD BEARINGS Specification Desc./Quantity bearing «A» Ø 10.000 (+0.015) mm bearing «B» Ø 28.000 (+0.007 +0.028) mm bearing «C» Ø 42.000 (+0.009 +0.034) mm Measure the unloaded spring length...
Page 22 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Intake: 4.030 to 4.015 mm Exhaust: 4.975 to 4.960 mm - Calculate the clearance between valve and valve guide.
Page 23 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. INTAKE Specification Desc./Quantity Standard clearance: 0.10 mm Admissible limit: 0.08 mm...
Page 24 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics TANDARD DIAMETER Specification Desc./Quantity Camshaft check: Standard diameter Bearing A Ø: 25.002 to 25.015 mm Camshaft check: Standard diameter Bearing B diameter: 12.002 to 12.013 mm - Measure the outside diameter of the rocking lever pins - Check the rocking lever pins do not show signs of wear or scoring.
Page 25 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics Slot packing system Characteristic Compression ratio (10.5±0.5):1 Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
Page 26 Vespa LX - S 125 3V ie 150 3V ie (2012) Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis- API GL-4 sions. AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116...
Page 27 INDEX OF TOPICS TOOL OOLING...
Page 28 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling ATTREZZATURA SPECIFICA Stores code Description 001330Y Tool for fitting steering seats 001467Y008 Pliers to extract 17 mm ø bearings 001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bearings...
Page 29 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020004Y Punch for removing steering bearings from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch 020038Y Punch TOOL - 29...
Page 30 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge...
Page 31 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020325Y Pliers for brake-shoe springs 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator TOOL - 31...
Page 32 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020334Y Multiple battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35-mm Adaptor 020358Y 37x40-mm Adaptor 020359Y 42 x 47-mm Adaptor 020360Y 52 x 55-mm Adaptor...
Page 33 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020364Y 25-mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Tool to extract valve cotters 020412Y 15-mm guide 020424Y Driven pulley roller casing fitting punch...
Page 34 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020427Y Piston assembly band 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020441Y 26 x 28 mm adaptor 020444Y011 adapter ring 020444Y009 wrench 46 x 55...
Page 35 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020439Y 17-mm guide 020442Y Pulley lock wrench 020444Y Tool for fitting/ removing the driven pulley clutch 020480Y Petrol pressure check kit 020922Y Diagnosis Tool 020933Y...
Page 36 Vespa LX - S 125 3V ie 150 3V ie (2012) Tooling Stores code Description 020938Y Driving pulley lock 020939Y Flywheel retainer 020941Y Crankshaft timing adjustment tool 020942Y Piston protrusion check tool TOOL - 36...
Page 37 INDEX OF TOPICS MAIN AINTENANCE...
Page 38: Maintenance Chart
Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN; R: REPLACE; A: ADJUST; L: LUBRICATE * Check level every 2,500 km ** Replace every 2 years km x 1.000 or (months) maximum...
Page 39 Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance - Disconnect the spark plug H.V. cable cap. - Unscrew the spark plug using the wrench sup- plied. - Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are...
Page 40 Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance Electrode gap 0.7 to 0.8 mm Spark plug NGK CR8EB Locking torques (N*m) Spark plug tightening 10 to 12 Hub oil Check - Park the vehicle on level ground and centre stand.
Page 41: Air Filter
Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance - Prepare an adequately sized container. - Unscrew the oil drainage plug and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil.
Page 42: Engine Oil
Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance - Undo the six screws and remove the air-box cov- - To clean the filtering element proceed as follows: remove the paper filtering element, blast with com- pressed air and then refit it.
Page 43 Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance 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.
Page 44: Engine Oil Filter
Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance 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.
Page 45: Checking The Ignition Timing
Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance 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.
Page 46 Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the level of liquid with the related warning light «A».
Page 47: Headlight Adjustment
Vespa LX - S 125 3V ie 150 3V ie (2012) Maintenance 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...
Page 48 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 49 Vespa LX - S 125 3V ie 150 3V ie (2012) Troubleshooting 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.
Page 50 Vespa LX - S 125 3V ie 150 3V ie (2012) Troubleshooting 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...
Page 51: Noisy Suspension
Vespa LX - S 125 3V ie 150 3V ie (2012) Troubleshooting 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.
Page 52 Vespa LX - S 125 3V ie 150 3V ie (2012) Troubleshooting TROUBL - 52...
Page 53 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 54 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system «LX» VERSION «S» VERSION ELE SYS - 54...
Page 55 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 56 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 57 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 1. Magneto flywheel - Remove the flywheel cov- er, as described in the «Engine» chapter, to reach it. To get access to the connectors, remove the helmet compartment.
Page 58 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 59 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 11 - 38. Remote controls - Remove the front cen- tral cover to reach it. 29 - 24. Pump and fuel lever transmitter - They are fitted on the tank, remove the fuel tank to reach them.
Page 60 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 28. Injection ECU - Remove the helmet compart- ment to reach it. 30. Diagnosis connector - Remove the helmet compartment to reach it. 31 - 32. Engine temperature sensor - fuel injec- tor - Remove the helmet compartment to reach it.
Page 61 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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 bat- tery compartment.
Page 62 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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...
Page 63 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 64 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 11. Connecting branch controls on the driver and the front headlights 12. On connecting branch rear part of the system ELE SYS - 64...
Page 65 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 13. On connecting branch rear part of the system ELE SYS - 65...
Page 66 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system Back side 1. Spark plug cap 2. Connection of pick-up sensor 3. Stator connection 4. Diagnostics connection 5. HV coil ELE SYS - 66...
Page 67 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 68 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 12. Chassis ground point 13. Lambda probe cable connector 14. Lambda probe Conceptual diagrams Ignition «LX» VERSION ELE SYS - 68...
Page 69 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system «S» VERSION ELE SYS - 69...
Page 70 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 71 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 72 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system «S» VERSION ELE SYS - 72...
Page 73 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 74 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system «S» VERSION 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.
Page 75 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system «S» VERSION ELE SYS - 75...
Page 76 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 77 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system «S» VERSION 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.
Page 78 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 35. Immobilizer Aerial Checks and inspections Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys- tem. The immobiliser is an antitheft system which...
Page 79 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system • 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: •...
Page 80 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 81 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system thoroughly inspected: In any case it is advisable to use resistor spark plugs. Diagnostic codes The Immobilizer system is tested each time the ig- nition key is turned from «OFF» to «ON». During...
Page 82 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system • 1-flash code • 2-flash code • 3-flash code Diagnostic code - 1 flash A one-flash code indicates a system where the se- rial line is not present or is not detected. Check the Immobilizer antenna wiring and change it if nec- essary.
Page 83 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 84: Starter Motor
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system WARNING BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK- ING 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..
Page 85: Table Of Contents
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 86: Fuse No
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system Horn control 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.
Page 87: Fuse No
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system Turn signals system check 1. Battery 2. Fuse No. 1 3. Ignition switch contacts 4. Fuse No. 3 5. Turn indicator control device 6. Turn indicator switch 7.
Page 88 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 89: Electronic Control Unit
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 90 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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...
Page 91 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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»...
Page 92 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 93 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system A = Digital clock B = Odometer C = Speedometer D = Engine control telltale light E = Engine oil pressure warning light F = Turn indicators...
Page 94: Battery Installation
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 95 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 96 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 97 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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...
Page 98: Starter Button
Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 99 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 100 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system 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.
Page 101 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system IMMOBILIZER ANTENNA CONNECTOR 1. Ignition switched live (Orange-Blue) 2. Ground lead (Black) 3. Electronic control unit (Orange-White) FUEL LEVEL TRANSMITTER CONNECTOR 1. Fuel level indicator (White - Green) 2.
Page 102 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system INSTRUMENT PANEL CONNECTOR «C» 1. Immobilizer warning light (Yellow) 2. Battery power (Red-White) THE FOLLOWING INDICACTIONS REFER TO THE S VERSION. INSTRUMENT PANEL CONNECTOR «A» 1. Right indicator warning light (White-Blue) 2.
Page 103 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system Function Commands engine starting through the injection control unit. Operation / Operating principle The starter button, the brake switches, the starter command relay and the injection control unit between PIN 5 and 10 are involved.
Page 104 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system - Check the continuity of the cable harness between the sensor connector and control unit connector: Control unit PIN 13 - sensor PIN 1 and control unit PIN 15 - sensor PIN 2. Restore the cabling if nec- essary.
Page 105 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system Circuit open or short circuit to negative:interruption of the circuit or null voltage between control unit connector PIN 11 and 12. Troubleshooting Short circuit to positive: - Disconnect the control unit connector and the sensor connector.
Page 106 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system - Verify continuity of the cabling between the sensor connector and the injection relay: sensor PIN 1 - injection relay PIN 3. Restore the cabling if necessary.
Page 107 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system - Perform the check of the injector and control unit connectors. - Verify continuity of the cable harness between the control unit connector and the injector connector (control unit PIN 34 - injector PIN 2).
Page 108 Vespa LX - S 125 3V ie 150 3V ie (2012) Electrical system Short circuit to positive:excessive voltage at PIN 1 of the control unit connector. Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 1 of the control unit connector.
Page 109 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 110 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Remove the Lambda probe from its support and disconnect it.
Page 111 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine from vehicle SUPPORT THE VEHICLE ADEQUATELY. - Disconnect the battery. - Remove the side fairings and footrest left and right terminals. - Remove the helmet compartment. - Remove the full muffler unit.
Page 112 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine from vehicle - Disconnect the fuel hoses and the main cable harness from the injector. - Disconnect the main cable harness from the en- gine temperature sensor. - Disconnect the two magneto flywheel cable har-...
Page 113 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine from vehicle - Disconnect the throttle control cables from the throttle body pulley, acting on the indicated adjust- er screws. - Working on the right side, unscrew and remove...
Page 114 INDEX OF TOPICS NGINE...
Page 115: Automatic Transmission
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Remove the air duct. - Remove the plastic cover that has the vehicle logo on it.
Page 116 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Unscrew the ten screws fixing the engine and re- move the transmission cover. See also Air duct Air duct - Remove the plastic cover. - Unscrew the two screws indicated and remove the duct.
Page 117 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the driven pulley shaft bearing - Remove the Seeger ring. CAUTION PLACE THE COVER ON A SURFACE, REMOVING OR EX- CLUDING THE ALIGNMENT DOWELS. - Support the transmission cover adequately.
Page 118: Removing The Driven Pulley
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Insert the Seeger ring. - Insert the alignment dowels if removed during disassembly. Removing the driven pulley - Undo the clutch fixing screw, recovering the lin- ing.
Page 119: Inspecting The Clutch Drum
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine 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...
Page 120: Removing The Clutch
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the clutch - Prepare the locking tool for the driven pulley with the pins half-screwed in the tool set to «C». - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
Page 121 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine 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.
Page 122 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine 001467Y008 Pliers to extract 17 mm ø bearings 001467Y009 Bell for OD 42-mm bearings Inspecting the driven fixed half-pulley - Measure the outside diameter of the pulley bush- ing.
Page 123: Refitting The Driven Pulley
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - To assemble the new ball bearing insert it com- pletely down in its housing with the specific punch and finally assemble the Seeger ring. Specific tooling 020375Y 28 x 30 mm adaptor...
Page 124 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the clutch spring - Measure the length of the spring when it is re- laxed. Characteristic Standard length: 106 mm Refitting the driven pulley - Reassemble the clutch housing and spacer.
Page 125: Removing The Driving Pulley
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the driving pulley - Using specific tools, lock the driving pulley and loosen the nut. Specific tooling 020938Y Driving pulley lock - Remove the flat washer and the cup washer.
Page 126 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure.
Page 127 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting the driving pulley - Perform the operations in reverse order of disas- sembly. CAUTION INSERT THE ROLLERS WITH THE LARGEST SUPPORT SURFACE ACCORDING TO THE DIRECTION OF ROTA- TION.
Page 128 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Clutch cover retainer screws 10.8 to 12.8 End gear Removing the hub cover - Use a container large enough to recover the final reduction oil. Unscrew the indicated screw and re- cover the aluminium seal.
Page 129 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the wheel axle - Remove the intermediate gear. - Remove the wheel axle. Removing the hub bearings Removing the clutch shaft bearing - Remove the Seeger ring.
Page 130 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the Wheel axle bearing - Remove the bearing using the specific tools . Specific tooling 001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bear-...
Page 131 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the hub shaft - Check the three shafts and the intermediate gear for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings.
Page 132 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting the driven pulley shaft bearing - Use the heat gun to heat the bearing seat. - Using the specific equipment set a new bearing. - Insert a locking seeger.
Page 133 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting the hub cover bearings Fitting the Wheel axle bearing - Use the heat gun to heat the bearing seat. - Plant a new bearing using the equipment, apply...
Page 134 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting the ub cover - Clean the engine crankcase and reduction cover surfaces adequately. - Working in reverse with respect to the disassem- bly, inert the command pinion and the intermediate gear into the hub box.
Page 135 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Cooling hood - Unscrew the five indicated screws and remove the cooling cap. Cooling fan - Remove the front part of the fan, unscrewing the three fixing screws.
Page 136 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the hub cover - Remove the oil dipstick. - Remove the sensor connector. - Unscrew the eleven fixing screws of the flywheel cover. - Remove the cover.
Page 137: Removing The Stator
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the stator - Remove the flywheel cover. - Unscrew the 2 flywheel fixing screws and the four pick-up fixing screws and cable harness retainer screws. - Remove the flywheel and the pick-up complete with cable harness.
Page 138 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Tighten the screws and tighten to the specified torque. CAUTION TO AVOID DAMAGING THE OIL SEAL, USE THE SPECIFIC TOOL PRIOR TO POSITIONING THE FLYWHEEL COVER. Specific tooling...
Page 139 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the flywheel magneto - Undo the screw indicated and remove the plate. - Install the specific tool and unscrew the retainer nut of the flywheel, recovering the washer.
Page 140 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate. - Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.
Page 141 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Cylinder assy. and timing system Removing the intake manifold - The intake manifold is positioned on the head, loosen the clamps and remove the sleeve con- necting to the throttle body.
Page 142 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the rocker-arms cover - Remove the protective cover, undoing the three screws. - Remove the engine temperature sensor. - Undo the screw indicated. - remove the upper part of the cover.
Page 143 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Unscrew the four screws and remove the tappet cover. ENG - 143...
Page 144 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the timing system drive - Before carrying out operations on the timing sys- tem we recommend positioning the engine at TDC in compression. To do this use the specific tools.
Page 145 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Undo the two screws on the timing system gear. - Disengage the timing system gear and remove the camshaft control sprocket. - Remove the cylinder as described in section «Engine/Piston cylinder disassembly»...
Page 146 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Remove the control gear. - Remove the seal OR. - Remove the flat washer. CAUTION REMEMBER TO CORRECTLY POSITION THE SEAL OR IN THE REFITTING PHASE. ENG - 146...
Page 147 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Release the timing chain from the crankshaft - Remove the control gear. See also Removal Removing the cylinder - piston assy. Removing the cam shaft - Undo the camshaft lock screw.
Page 148 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the cylinder head - Gradually loosen the four screws in crossed se- quence and recover the washers. - Undo the two external screws. ENG - 148...
Page 149 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Remove the cylinder head. - Remove the chain guide slider and the gasket. - Remove the gasket. N.B. ON ASSEMBLY PAY CLOSE ATTENTION TO THE TWO DOWELS.
Page 150: Removing The Valves
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the valves - Use the specific tool to remove the cotters, cap and spring. CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS.
Page 151 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Use the specific tool to remove the valve oil seal. Specific tooling 020431Y Valve oil seal extractor - Slide off the valve and remove the lower support.
Page 152 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the wrist pin N.B.
Page 153: Removing The Piston
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the piston - Fit the piston and pin onto the connecting rod, aligning the piston arrow towards the engine di- rection of rotation. CAUTION AT EVERY NEW MOUNTING USE RETAINER RING PINS.
Page 154 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres- sion ratio.
Page 155: Inspecting The Cylinder Head
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure.
Page 156 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
Page 157 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine VALVE CLEARANCE CHECK - Remove the cover. - Position the engine to the TDC in compression - Using a feeler gauge check the valve clearance. CAUTION - USE THE FEELER GAUGE LATERALLY, IN LINE WITH...
Page 158 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Cylinder Head Refitting the valves CAUTION MOUNT THE VALVE SPRINGS WITH THE GREEN COL- OURED COIL FACING UPWARD. - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.
Page 159 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the cam shaft N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Refitting the head and timing system components...
Page 160 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine - Tighten the nuts to an initial pre-torque of 9-11 - Tighten up the nuts by rotating 270.0±5.0° with crossed sequence. - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
Page 161 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Locking torques (N*m) Intake manifold fixing screws 10.8 to 12.8 Crankcase - crankshaft Splitting the crankcase halves - Undo the eight crankcase coupling screws. - Separate the crankcase halves while keeping the crankshaft in one of these two halves.
Page 162 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the crankshaft alignment N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts.
Page 163 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (3.2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 164 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine CAUTION CAREFULLY CHECK THE CLEANING OF THE BY-PASS DUCT. CHECK THAT THE PISTON SLIDES BY HAND, FREELY AND WITHOUT STICKING. CAUTION IT IS ADVISABLE TO INSERT THE CRANKSHAFT IN THE...
Page 165 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Lubrication Conceptual diagrams The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the cartridge filter «E» where there is also a safety valve «D».
Page 166: Oil Pressure Check
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch.
Page 167 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removal - Unscrew the three screws and remove them, complete with the copper gaskets. - Using pliers remove the door by acting on the appendices. - Remove the spacer and the O-ring.
Page 168: Oil Pump
Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting - Insert the components making sure to thoroughly grease the O-ring and the fork oil seal. - Follow the steps in reverse order taking care to tighten to torque.
Page 169 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removal - Remove the oil sump and the by-pass. - Remove the oil shield. - Preventing rotation, unscrew the water pump command screw and collect the washer. - Remove the oil pump command sprocket com- plete with chain.
Page 170 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Inspection - Remove the two screws and remove the oil pump cover. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible.
Page 171 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Refitting - Follow the steps in reverse order to the removal, tightening the screws to the specified torque. - Insert the oil pump. - Insert the control sprocket and the chain.
Page 172 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmis- sion chapter.
Page 173 Vespa LX - S 125 3V ie 150 3V ie (2012) Engine Piston standard diameter 12.861 + 12.843 mm Refitting the oil sump - Refit the by-pass piston in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal.
Page 174 INDEX OF TOPICS INJEC NJECTION...
Page 175 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection OMPONENT LAYOUT Specification Desc./Quantity Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Fuel pump Engine temperature sensor Fuel injector HV coil Engine speed sensor...
Page 176 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection The fuel system pressure is kept constant in relation to ambient pressure. The fuel system circuit consists of: - Fuel pump - Fuel filter - Injector - Pressure regulator The pump, the filter and the regulator are placed inside the fuel tank on a single support.
Page 177 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Failures are detected and restored by the diagnostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine temperature, stop).
Page 178 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection b.Burnt fuse c.Remote control switches d.Connectors B: Chassis ground C: Fuel system a. Faulty fuel pump b.Dirty fuel filter D: Ignition system a. Faulty spark plug b.Faulty coil c.Faulty screened cap...
Page 179 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump.
Page 180 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 8. Not connected 9. Battery power (Red-White) 10. Start-up enabling switch (Purple-White) 11. Lambda probe positive (Green-Blue) 12. Lambda probe negative (Light blue-Black) 13. Water temperature sensor (Sky blue-Green) 14.
Page 181 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection THE FOLLOWING INDICACTIONS REFER TO THE S VERSION. INJEC - 181...
Page 182 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 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.
Page 183 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 35. Immobilizer Aerial Troubleshooting procedure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient, repair according to the indications of the...
Page 184 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Possible Cause Operation HV coil Injector Revolution timing sensor Air temperature Engine temperature Ignition efficiency Spark plug Ignition timing Correctness of the parameters Throttle valve position sensor Stepper...
Page 185 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Possible Cause Operation Throttle body - manifold Air cleaner joint Filter box Fuel system (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing (infiltrations)
Page 186 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Engine knocking PRESENCE OF KNOCKING (COMBUSTION SHOCKS) Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature...
Page 187 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Removing the injector - Remove the helmet compartment. - Remove the connector from the injector. - Remove the quick release of the petrol delivery pipes. INJEC - 187...
Page 188 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection - Undo the fixing screws and slide the injector from the manifold being careful not to damage the seal- ing OR gasket. CAUTION DO NOT DISASSEMBLE THE INJECTOR COMPONENTS.
Page 189 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Removing the butterfly valve - Remove the helmet compartment. - Remove the fuel piping clamping screw indicated in the figure. - Remove the fast-release fitting from the injector.
Page 190 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection - Remove the mounting bracket of the throttle con- trol cables undoing the two fixing screws. - Release the cable ends of the throttle body pul- ley. - Remove the throttle body with air cleaner joint, manifold and injector.
Page 191 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Pump supply circuit 1. Battery 12V- 6 Ah 2. Fuse No. 6 of 10A 3. Fuse No. 1; 20A 4. Ignition switch contacts 5. 7.5A fuse No. 2...
Page 192 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Lambda probe When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied.
Page 193 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Check the presence of fixed voltage between the Red-White cable of the relay base and ground. Otherwise, check the continuity of the Red-White cable between the fuse-box (No. 6, 10 A) and the relay base.
Page 194 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Check during regular operation by placing the ap- propriate tool between the pump and the injector. With the battery voltage > 12 V check that the fuel pressure is 2.5 BAR and that the input current is 1.4 to 1.8 A.
Page 195 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture. Remove the filter from the pump mounting...
Page 196 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Inspecting the injector circuit 1. Battery 12V- 6 Ah 2. Fuse No. 6 of 10A 3. Fuse No. 1; 20A 4. Ignition switch contacts 5. 7.5A fuse No. 2...
Page 197 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Lambda probe Check the resistance at the injector ends: 14.5 ± 5% Ohm Check efficiency of the fuse No. 6 of 10A injection loads, next to the battery.
Page 198 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Check the presence of fixed voltage between the Red-White cable of the relay base and ground. Otherwise, check the continuity of the Red-White cable between the fuse-box (No. 6, 10 A) and the relay base.
Page 199 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Switch to «ON» and check if there is voltage, with injector disconnected and control unit connected, between the Black-Green cable of the injector con- nector and the ground lead...
Page 200 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Specific tooling 020480Y Petrol pressure check kit Proceed with the injector seal test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector.
Page 201 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection HT coil 1. Battery 12V- 6 Ah 2. Fuse No. 6 of 10A 3. Fuse No. 1; 20A 4. Ignition switch contacts 5. 7.5A fuse No. 2 INJEC - 201...
Page 202 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection 6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Lambda probe The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
Page 203 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Check efficiency of the injection load relay, that can be reached by removing the central cover of the shield: check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85;...
Page 204 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Zeroing the throttle Resetting the throttle valve position signal (TPS reset) The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated. Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre-set reference conditions.
Page 205 Vespa LX - S 125 3V ie 150 3V ie (2012) Injection Make sure that the throttle valve with the control is supporting the stop screw. Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
Page 206 INDEX OF TOPICS SUSP USPENSIONS...
Page 207: Removing The Front Wheel
Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Sospensioni anteriore This section is dedicated to operations that can be carried out on the suspensions. Front Removing the front wheel - Support the vehicle adequately. - Loosen the five screws fixing the wheel to the hub.
Page 208 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions - Remove the wheel hub. - Remove the ball bearing check Seeger ring indi- cated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract ø...
Page 209 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide - Heat the roller bearing seat with a heat gun...
Page 210 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Refitting the front wheel - Upon refitting, tighten the five screws to the pre- scribed torque. Locking torques (N*m) Wheel rim screws 20 to 25 Handlebar Removal Remove the handlebar cover before carrying out this operation,.
Page 211: Steering Column
Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Refitting Carry out the removal operations but in the reverse order, observing the prescribed tightening torque. Locking torques (N*m) Handlebar lock nut 45 to 50 Steering column Removal...
Page 212 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Use a suitable punch with the dimensions indica- ted on the figure; hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end.
Page 213 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Recommended products AGIP GREASE SM 2 Gray black smooth-tex- tured lithium grease, containing molybdenum disulphide. Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time.
Page 214 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions - Now, remove the two spacers (parts 17 and 16) and, once the space between the NADELLAs - steering tube and swinging hub - has been fully filled with grease, move the dust gaiter rings until they are placed in that space.
Page 215: Front Shock Absorber
Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions When fitting the fork, lubricate with the steering bearing tracks with the recommended grease. Tighten the lower ring nut "A" and the upper ring nut "B" to the specified torque...
Page 216 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Removal - Support the vehicle adequately. - Remove the wheel hub. - Loosen the shock absorber lower clamps and re- move the brake calliper shock absorber mounting. - Loosen the screws fixing the front brake pipe re- tainer clamp and the odometer cable in order to reach the upper clamps.
Page 217 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques. Locking torques (N*m) shock absorber lower clamping 20 - 27 shock absorber upper clamp 20 to 30...
Page 218 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Overhaul - The bracket for the shock absorber -calliper at- tachment has two roller bearings separated one from the other as shown in the photograph - Remove the two roller bearings from the bracket...
Page 219 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions - Assemble a new roller bearing on the shock ab- sorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch - Suitably hold the brake calliper - shock absorber...
Page 220: Removing The Rear Wheel
Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING JUST USE A SCREW- DRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE. Specific tooling 020004Y Punch for removing steering bearings from headstock...
Page 221 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions - Unscrew the nut fixing the wheel axle and collect the washer. Refitting the rear wheel - To refit, follow the removal steps but in reverse order; be careful to tighten to the prescribed tor- que.
Page 222 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Removal - Support the vehicle adequately. - Remove the central tunnel inspection door. - To remove the upper clamp from the chassis, proceed as follows: - Unscrew the pin and collect the washer.
Page 223 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions - Working on the left side, remove the pin. - Remove the spoiler terminal from both sides. - Working on the right side, unscrew the fixing nut. - Working on the left side, release the pin from the spring shown.
Page 224: Shock Absorbers
Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Overhaul - Check that the silent-blocks are in good condi- tions. - Otherwise, replace the swinging arm. Refitting - To fit, follow the removal steps but in reverse or- der;...
Page 225 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions Removal - Adequately support the rear part of the vehicle. - Remove the battery. - Undo the indicated upper fixing screw to the chassis. - Unscrew the lower fixing pin to the transmission crankcase.
Page 226 Vespa LX - S 125 3V ie 150 3V ie (2012) Suspensions SUSP - 226...
Page 227 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 228 Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system Front brake calliper Removal - Remove the front wheel. - Remove the two screws fixing the brake calliper to the mounting bracket, then remove the brake calliper with the pipe from the disc.
Page 229: Front Brake Disc
Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the mounting bracket with the...
Page 230 Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system Removal - Remove the front wheel - Remove the front brake calliper - Remove the hub and the disc operating on the wheel axle nut - Adequately support the hub with the disc and op-...
Page 231: Front Brake Pads
Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system Disc Inspection - Remove the front wheel - Use a micrometer to check the disc thickness as shown in the photograph - Repeat the measurement in at least 6 points on...
Page 232 Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system evenly. A 0.5 mm thickness difference in the re- sidual friction material is permitted Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo.
Page 233 Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system Front - Remove the rubber cap from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered.
Page 234 Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system when it is fully empty, the level of fluid in the res- ervoir is below the MIN level. N.B. THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED.
Page 235: Rear Drum Brake
Vespa LX - S 125 3V ie 150 3V ie (2012) Braking system Rear drum brake Once the silencer and the wheel have been re- moved, follow these steps: 1.Remove the shoe springs using the specific spanner. 2. Remove the shoe with the aid of a lever.
Page 236 INDEX OF TOPICS CHAS HASSIS...
Page 237: Instrument Panel
Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis Rear handlebar cover THE FOLLOWING INDICACTIONS REFER TO THE S VERSION. - Remove the front handlebar cover. - Undo the three screws indicated in figure fixing it to the handlebar, the odometer transmission and the electrical connectors.
Page 238 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis - Remove the rear handlebar cover. - Undo the three screws indicated fixing the rear handlebar cover. THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION. - Remove the rear handlebar cover.
Page 239 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis - Undo the screw «B» and remove the front han- dlebar cover. - Disconnect the electric terminal of the low/high beam headlight bulb and remove the turn indicator bulb.
Page 240 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis Headlight assy. THE FOLLOWING INDICACTIONS REFER TO THE S VERSION. - Remove the front handlebar cover. - Undo the four screws indicated fixing the front handlebar cover. THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION.
Page 241 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis - Remove the rubber strip from both sides and un- do the indicated screw. - Remove the leg shield back plate bringing it to the rear part of the vehicle.
Page 242 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis Taillight assy. - Undo the two fixing screws and remove the rear light unit. - Undo the screw indicated and disconnect the connector. Footrest - Remove the leg shield back plate.
Page 243 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis - The fixing screw at the front. - Remove the footrest. Side fairings - Undo the upper screw and the smallest lower screw. - Detach the seats on the fairing.
Page 244 Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis License plate holder - Remove the side fairings. - Working on both sides, undo the two screws in- dicated. - Remove the license plate light. Air filter - Remove the helmet compartment.
Page 245: Front Mudguard
Vespa LX - S 125 3V ie 150 3V ie (2012) Chassis - Undo the two clamps indicated. Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard...
Page 246 INDEX OF TOPICS PRE DE DELIVERY...
Page 247 Vespa LX - S 125 3V ie 150 3V ie (2012) Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety fasteners - Fixing screws Safety fasteners: •...
Page 248 Vespa LX - S 125 3V ie 150 3V ie (2012) Pre-delivery - Instrument panel warning lights - Horn - Starter CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Page 249 Vespa LX - S 125 3V ie 150 3V ie (2012) Pre-delivery - Abnormal noise Static test Static control after the test ride: - Restarting when warmed up - Minimum hold (turning the handlebar) - Uniform turning of the steering...
Page 250 Air filter: 41, 244 Battery: 51, 70, 83, 93, 94 Brake: 228, 229, 231, 233–235 Brake fluid: 233 Bulbs: Checks: 78 Engine oil: 42 Fuel: 186, 194 Fuses: 91 Headlight: 47, 240 Horn: 86 Hub oil: 40 Identification: 8 Instrument panel: 237 Maintenance: 7, 38 Oil filter: 44 Recommended products:...
Page 251 Tyres: 11 Vehicle: 8, 110...

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