VESPA LXV 50 Service Station Manual
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VESPA LXV 50 Service Station Manual

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SERVICE STATION MANUAL
633860 IT- 633861 EN - 633862 FR - 633863 DE -
633864 ES - 633865 PT - 633866 NL - 633867 EL
Vespa LXV 50

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  • Page 1 SERVICE STATION MANUAL 633860 IT- 633861 EN - 633862 FR - 633863 DE - 633864 ES - 633865 PT - 633866 NL - 633867 EL Vespa LXV 50...
  • Page 2 SERVICE STATION MANUAL Vespa LXV 50 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA 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.
  • Page 3 SERVICE STATION MANUAL Vespa LXV 50 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Vespa LXV 50 Characteristics 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 LXV 50 Characteristics Vehicle identification EHICLE IDENTIFICATION Specification Desc./Quantity Engine prefix C381M ÷ 1001 Chassis prefix ZAPC38102 ÷ 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 98 ± 5 kg Overall height 1180 mm Wheelbase 1280 mm...
  • Page 9 Vespa LXV 50 Characteristics Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 9.9 ±0.5 : 1 Carburettor DELL'ORTO PHVA 17.5 Air filter Sponge impregnated with fuel mixture (50% SELENIA air filter oil and 50% unleaded petrol).

  • Page 10: Wheels And Tyres

    Vespa LXV 50 Characteristics Specification Desc./Quantity Front suspension Single arm suspension with swinging arm articulated to the steering tube. Hydraulic double-acting shock absorber and co- axial spring Front suspension stroke 70 mm Trail (suspension rebounded/compressed) 71/68 mm Rear suspension Single hydraulic double-acting shock absorber, helicoidal co- axial spring.

  • Page 11: Front Brake

    Vespa LXV 50 Characteristics elements after checking the steel tab is not de- formed and/or does not guarantee correct tight- ness at its fitting; replace if necessary. N.B. UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI- NIUM COVERS.

  • Page 12: Steering Assembly

    Vespa LXV 50 Characteristics Name Torque in Nm Wheel rim screws 20 ÷ 25 Shock absorber lower bolts (°) 20 ÷ 27 STEERING ASSEMBLY Name Torque in Nm Steering upper ring nut 35 ÷ 40 Steering lower ring nut 8 ÷ 10 Handlebar fixing screw 50 ÷...

  • Page 13: Piston Rings

    Vespa LXV 50 Characteristics Name Initials Cylinder Piston Play on fitting coupling 1st oversize 40.205 - 40.212 40.143 - 40.15 0.055 - 0.069 coupling 1st oversize 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069 coupling 1st oversize 40.219 - 40.226 40.157 - 40.164...
  • Page 14 Vespa LXV 50 Characteristics Name Description Dimensions Initials Quantity Flywheel-side half-shaft 13.75+0.040 clearance E = 0.25 to 0.50 - clearance F = 0.20 to 0.75 Lining between the 40.64 clearance E = 0.25 to shoulders 0.50 - clearance F = 0.20 to 0.75...
  • Page 15 INDEX OF TOPICS TOOL OOLING...
  • Page 16 Vespa LXV 50 Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø 15-mm bearings 001467Y014 Pliers to extract ø 15-mm bearings...
  • Page 17 Vespa LXV 50 Tooling Stores code Description 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater...
  • Page 18 Vespa LXV 50 Tooling Stores code Description 020166Y Pin lock fitting tool 020261Y Starter spring fitting 020265Y Bearing fitting base 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing TOOL - 18...
  • Page 19 Vespa LXV 50 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 19...
  • Page 20 Vespa LXV 50 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020359Y 42x47-mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide TOOL - 20...
  • Page 21 Vespa LXV 50 Tooling Stores code Description 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 001467Y029 Bell for bearings, O.D. 38 mm 020037Y Punch 020036Y Punch TOOL - 21...
  • Page 22 Vespa LXV 50 Tooling Stores code Description 020021Y Front suspension service tool 020038Y Punch 020074Y Support base for checking crankshaft alignment 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring TOOL - 22...
  • Page 23 Vespa LXV 50 Tooling Stores code Description 004499Y002 Bearing extractor screw 004499Y007 Half rings 020171Y Punch for driven pulley roller bearing 020340Y Flywheel and transmission oil seals fitting punch 020360Y Adaptor 52 x 55 mm 020358Y 37x40-mm adaptor 020362Y 12 mm guide...
  • Page 24 Vespa LXV 50 Tooling Stores code Description 020363Y 20 mm guide 020365Y 22 mm guide 020439Y 17 mm guide 020441Y 26 x 28 mm adaptor 020452Y Tube for removing and refitting the driven pulley shaft TOOL - 24...
  • Page 25 Vespa LXV 50 Tooling Stores code Description 020451Y Starting ring gear lock 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 25...

  • Page 26: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 27: Maintenance Chart

    Vespa LXV 50 Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AFTER 1000 KM Action Hub oil - change Oil mixer/throttle linkage - adjustment Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake fluid level - check...
  • Page 28 Vespa LXV 50 Maintenance Action Hub oil level - check Spark plug/electrode gap - replacement Air filter - cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement Brake control levers - greasing Brake pads - check condition and wear...
  • Page 29 Vespa LXV 50 Maintenance 60000 K FTER 150' Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idle speed - adjustment Cylinder cooling system - check/cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement...

  • Page 30: Checking The Spark Advance

    Vespa LXV 50 Maintenance Checking the spark advance -Check to be made at over 4000 rpm with strobo- scopic gun. The advanced ignition measured must be 17° before the TDC. - This value is correct when the reference mark on...
  • Page 31 Vespa LXV 50 Maintenance - Refit the central flap. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO- TOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI- OUSLY DAMAGE THE ENGINE.

  • Page 32: Air Filter

    Vespa LXV 50 Maintenance Replacement -Remove the oil cap «A». - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw on the drainage plug and fill up the hub with oil (about 85 cc) Air filter -Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter.

  • Page 33: Checking The Ignition Timing

    Vespa LXV 50 Maintenance Checking the ignition timing - Adjust the control cables: Mix cable: see procedure indicated in "Mixer tim- ing". Throttle cable: adjust the set screw on the carbu- rettor in such a way that the sheath has no back- lash.

  • Page 34: Level Check

    Vespa LXV 50 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». A certain lowering of the level is caused by wear on the pads.

  • Page 35: Headlight Adjustment

    Vespa LXV 50 Maintenance 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 scooter is perpendicular to the screen;...

  • Page 36: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 37: Poor Performance

    Vespa LXV 50 Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel nozzles or cock clogged or dirty...
  • Page 38 Vespa LXV 50 Troubleshooting Possible Cause Operation spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug and start the vehicle. Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill...

  • Page 39: High Fuel Consumption

    Vespa LXV 50 Troubleshooting High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty. Clean according to the procedure Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and power supply SAS malfunctions SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-...

  • Page 40: Brakes Overheating

    Vespa LXV 50 Troubleshooting Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective piston sliding Check calliper and replace any damaged part. Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum.
  • Page 41 Vespa LXV 50 Troubleshooting Possible Cause Operation lock-nuts, the limit switch rubber buffers and the movement bushings. Suspension oil leakage IL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Service the pumping members and check the sleeves and sealing rings are in good conditions.

  • Page 42: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 43 Vespa LXV 50 Electrical system KEY: 1. Electronic ignition device 2. Spark plug 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 8. Starter motor 9. Starter remote control 10. Starter button 11. STOP button on front brake 12.
  • Page 44 Vespa LXV 50 Electrical system 20. Front headlight assembly with high- and low-beam bulb A. Tail light bulb B. Low-/high-beam light bulb 21. Right turn front indicator lamp 22. Light switch 23. High-beam light flash switch 24. Fuel level warning light control 25.
  • Page 45 Vespa LXV 50 Electrical system Ignition KEY: 1. Electronic ignition device 2. Spark plug 3. Magneto flywheel 6. Key switch ELE SYS - 45...
  • Page 46 Vespa LXV 50 Electrical system Headlights and automatic starter section KEY: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 16. Rear headlight assembly with tail light and stop light bulbs 20. Front headlight assembly with high- and low-beam bulb A.
  • Page 47 Vespa LXV 50 Electrical system F. High-beam warning light G. headlight warning light H. turn indicator warning light 27. Automatic starter 28. Carburettor heater 29. Carburettor heater control device Battery recharge and starting KEY: 3. Magneto flywheel 4. Voltage regulator 5.
  • Page 48 Vespa LXV 50 Electrical system 26. Low oil warning light control Level indicators and enable signals section KEY: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 24. Fuel level warning light control 25. Instrument panel A.

  • Page 49: Devices And Accessories

    Vespa LXV 50 Electrical system 26. Low oil warning light control Devices and accessories KEY: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 13. Horn button 14. Horn 15. Left turn rear indicator lamp 17.

  • Page 50: Checks And Inspections

    Vespa LXV 50 Electrical system D. fuel gauge E. Instrument panel lighting F. High-beam warning light G. headlight warning light H. turn indicator warning light Checks and inspections All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irreparably damaged.
  • Page 51 Vespa LXV 50 Electrical system ONTINUITY CHECK Specification Desc./Quantity White cable - Engine Continuity White cable - Frame Continuity Voltage regulator check Voltage regulator The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault: 1) Lighting system bulbs burn out.
  • Page 52 Vespa LXV 50 Electrical system FAULT 3: Blown main fuse After checking that there are no short-circuits in the system towards earthing with the engine off and the regulator connector detached, replace the reg- ulator because it is certainly inefficient, and re- place the protection fuse.
  • Page 53 Vespa LXV 50 Electrical system FAULT 5: Turn indicators not working If the turn indicators do not work, do the following: Remove the regulator connector, and insert the ends of the tester between contact 5 (yellow) and the earthing. - Turn the key switch to ON and check that the battery is getting voltage.
  • Page 54 Vespa LXV 50 Electrical system - If there is voltage for terminal number 4, check both the cable harness and the bulb of the oil warning light. Specific tooling 020331Y Digital multimeter Fuses The electrical system is protected by a valve fuse «B»...
  • Page 55 Vespa LXV 50 Electrical system Specification Desc./Quantity Quantity: 4 Sealed battery INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.
  • Page 56 Vespa LXV 50 Electrical system The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are: 1) Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level.
  • Page 57 Vespa LXV 50 Electrical system supply source must be implemented by connect- ing the corresponding poles (+ to+ and - to -). 4) Cleaning the battery The battery should always be kept clean, espe- cially on its top side, and the terminals should be coated with Vaseline.
  • Page 58 Vespa LXV 50 Electrical system 020334Y Multiple battery charger ELE SYS - 58...

  • Page 59: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 60 Vespa LXV 50 Engine from vehicle Removal of the engine from the vehicle Removing the engine from the chassis -Disconnect the battery. -Remove the muffler assembly. - Remove the rear wheel. - Remove the mechanical transmission of the rear brake.
  • Page 61 INDEX OF TOPICS NGINE...

  • Page 62: Automatic Transmission

    Vespa LXV 50 Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.

  • Page 63: Removing The Driven Pulley Shaft Bearing

    Vespa LXV 50 Engine - Remove the seeger ring located on the exterior of the crankshaft. - Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).

  • Page 64: Removing The Driven Pulley

    Vespa LXV 50 Engine Removing the driven pulley - Lock the clutch bell housing with the specific tool. - Remove the nut, the clutch bell housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE PULLEY MOUNTED.
  • Page 65 Vespa LXV 50 Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven...
  • Page 66 Vespa LXV 50 Engine - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION...
  • Page 67 Vespa LXV 50 Engine Stationary driven half-pulley/Standard diame- Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diam- eter admitted after use Ø 33.96 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.
  • Page 68 Vespa LXV 50 Engine Refitting the driven half-pulley bearing - Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit the new roller bearing with the wording visible from the outside.

  • Page 69: Refitting The Driven Pulley

    Vespa LXV 50 Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...

  • Page 70: Removing The Driving Pulley

    Vespa LXV 50 Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley. - Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.
  • Page 71 Vespa LXV 50 Engine 4) Check the integrity of the sliding blocks of the contact plate. - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inside diameter «A». - Measure outside diameter «B» of the pulley slid- ing bushing shown in the figure.
  • Page 72 Vespa LXV 50 Engine ORDER TO AVOID WRONG TIGHTENING AND CONSE- QUENTLY DAMAGING THE CRANKSHAFT KNURLING. Specific tooling 020451Y Starting ring gear lock Locking torques (N*m) Crankshaft pulley nut 18 to 20 + 90° Nm For 25 km/h engine type versions, the limit washer is 5.5 mm thick...
  • Page 73 Vespa LXV 50 Engine Removing the wheel axle bearings - Remove the oil seal and the seeger ring. - Remove the bearing by pushing from the outside towards the inside of the gear compartment, using the appropriate punch. Specific tooling...
  • Page 74 Vespa LXV 50 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents. - Check capacity ( A ) of the transmission gear (wear, deformations, etc.)

  • Page 75: Flywheel Cover

    Vespa LXV 50 Engine Refitting the wheel axle bearing - Heat the half crankcase on the transmission side using a thermal gun. - After lubricating its outer strip, insert the bearing with the special adapter with the aid of a hammer.

  • Page 76: Cooling Fan

    Vespa LXV 50 Engine Cooling hood - Remove the four fixings shown in the figure. - Remove the fan cover - Remove the oil piping retention band from the hood - Remove the 2 screws shown in the figure Cooling fan - Remove the cooling fan by acting on the three fixings indicated in the figure.

  • Page 77: Removing The Stator

    Vespa LXV 50 Engine Removing the stator - Remove the three stator fixings shown in the photo - Remove the two pick-up fixings shown in the photo - Remove the stator with the wiring Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
  • Page 78 Vespa LXV 50 Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor.

  • Page 79: Removing The Intake Manifold

    Vespa LXV 50 Engine N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC. Locking torques (N*m) Flywheel nut 40 to 44 N.m Refitting the starter motor - Fit a new O-ring on the starter and lubricate it.

  • Page 80: Inspecting The Small End

    Vespa LXV 50 Engine Removing the cylinder - piston assy. Remove the cylinder very carefully Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION REPLACE THE PIN RETENTION SNAP RINGS Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer.

  • Page 81: Inspecting The Piston

    Vespa LXV 50 Engine Inspecting the wrist pin - Check the wrist pin external diameter using a mi- crometer Characteristic Wrist pin: standard diameter 12 +0.005 +0.001 mm Inspecting the piston - Measure the bearings on the piston using a bore meter - Calculate the piston-pin coupling clearance.

  • Page 82: Removing The Piston

    Vespa LXV 50 Engine Inspecting the cylinder - Check that the cylinder does not show seizures. Otherwise, replace it or adjust it respecting the al- lowable increases - Measure the internal diameter of the cylinder with a bore meter, according to the directions given in...
  • Page 83 Vespa LXV 50 Engine - Use new wrist pin snap rings. - Use new cylinder base gasket. - Before refitting carefully clean all the surfaces. - Use oil to be mixed during the fitting of the piston and the cylinder.

  • Page 84: Crankcase - Crankshaft

    Vespa LXV 50 Engine Inspecting the timing system components CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA. Crankcase - crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners. Install the special strip on the half crankcase on...

  • Page 85: Removing The Crankshaft

    Vespa LXV 50 Engine Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length. - Remove the crankshaft from the transmission side half crankcase Specific tooling...
  • Page 86 Vespa LXV 50 Engine Refitting the crankshaft bearings Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track Specific tooling...
  • Page 87 Vespa LXV 50 Engine - Firmly insert the crankshaft until the bearing rea- ches the end-of-stroke stop - Let the temperature of the half crankcase settle at the temperature of the crankshaft. - Again install the special crankcase separation plate NOT installing the crankshaft protection - During the assembly phase keep the central thrust screw loose.

  • Page 88: Crankshaft Oil Seals

    Vespa LXV 50 Engine - Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement - Insert at least three clamping screws and tighten up rapidly - Insert the other 5 screws and tighten them to the specified torque.
  • Page 89 Vespa LXV 50 Engine Refitting - Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter N.B. THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH...

  • Page 90: Fuel Supply

    Vespa LXV 50 Engine Remove the tube passage seal from the crank- case shown in the figure Refitting To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure...
  • Page 91 Vespa LXV 50 Engine OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT- LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUC- TION PULSATION AND THEREBY GUARANTEE A CON- STANT TAP FLOW RATE.

  • Page 92: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 93: Removing The Front Wheel

    Vespa LXV 50 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the five Allen screws that fix the wheel to the hub. N.B. BEFORE REMOVING THE WHEEL HUB, REMOVE THE BRAKE CALLIPER.
  • Page 94 Vespa LXV 50 Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide...

  • Page 95: Refitting The Front Wheel

    Vespa LXV 50 Suspensions Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 Refitting the front wheel - When refitting, tighten the 5 screws to the speci- fied torque Locking torques (N*m) Nut tightening torque 20 to 25 N•m...

  • Page 96: Steering Column

    Vespa LXV 50 Suspensions Steering column Removal After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork. Specific tooling 020055Y Wrench for steering tube ring nut Overhaul Use the tool fitted with parts 3 and 4, as indicated to fit the pin, and press operating the handgrip, until wedging the washers on the swinging hub.
  • Page 97 Vespa LXV 50 Suspensions - Lubricate the sealing rings with mineral oil and half-fill the roller casings with grease. - Insert the seal ring on the pin and the roller bush- ing with wedging washers at the same time. - Remove the specific tool, then the part 5 (guiding) partially ejected in the previous assembly stage;...
  • Page 98 Vespa LXV 50 Suspensions * Supplied with the tool Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °...
  • Page 99 Vespa LXV 50 Suspensions - Press and remove the wedging washer with the help of a pointed end. - For the second washer, repeat the operation us- ing the punch on the side opposite to the one shown in the figure.

  • Page 100: Front Shock Absorber

    Vespa LXV 50 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 Recommended products AGIP GREASE PV2 Grease for the steering...
  • Page 101 Vespa LXV 50 Suspensions Removal - Remove the steering tube - Remove the shock absorber lower clamps - Remove the shock absorber upper clamps Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
  • Page 102 Vespa LXV 50 Suspensions - Before refitting the bracket in the wheel axle, place the O-ring as shown in the photograph so that it is correctly placed after fitting the bracket. - Refit the washer and the Seeger ring. - Refit the lower screws fixing the shock absorber...

  • Page 103: Steering Bearing

    Vespa LXV 50 Suspensions - Suitably hold the brake calliper - shock absorber attachment bracket - Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm...

  • Page 104: Removing The Rear Wheel

    Vespa LXV 50 Suspensions - Remove the fifth wheel fitting and the dust guard on the steering tube as shown in figure, using the specific tool. Proceed giving a few taps with the mallet. Specific tooling 020004Y Punch for removing fifth wheels from...

  • Page 105: Refitting The Rear Wheel

    Vespa LXV 50 Suspensions Refitting the rear wheel - Fit the wheel, tighten the nut to the prescribed torque. - Refit the cap and the split pin folding it correctly as shown in the figure. Locking torques (N*m) Locking torque 137 ÷...

  • Page 106: Shock Absorbers

    Vespa LXV 50 Suspensions Refitting For rifting, respect the locking torques Locking torques (N*m) Part C Part B Part A 33 ÷ 41 44 ÷ 52 33 ÷ 41 Shock absorbers SUSP - 106...
  • Page 107 Vespa LXV 50 Suspensions Removal - To replace the shock absorber remove the bat- tery access flap to reach and remove the shock absorber/ frame anchoring nut. Then remove the shock absorber/engine anchorage nut. - When refitting, tighten the shock absorber/chas- sis anchoring nut and the shock absorber/engine pin to the prescribed torque.
  • Page 108 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 109: Front Brake Calliper

    Vespa LXV 50 Braking system 1. Tank cover. 2 - Pump body. 3 - Brake lever. 4 - Pump plunger. 5- Oil delivery hose. 6 - Protection cap for air bleed screw. 7- Calliper. 8- Dust guard 9- Piston sealing ring.

  • Page 110: Front Brake Disc

    Vespa LXV 50 Braking system - bed the O-Ring gasket (4) on a calliper body. - Couple the internal body with the external one with assembling bolts. Refitting the pads and purging air (see previous sections). - Place the calliper on the disc and lock it to the support by tightening the bolts.

  • Page 111: Disc Inspection

    Vespa LXV 50 Braking system tightening torque 5 ÷ 6.5 Nm Disc Inspection Specific tooling 020335Y Magnetic support for dial gauge Characteristic Max oscillation allowed 0.1 mm. Front brake pads Removal - Pads must be replaced when the friction material thickness reaches the wear limit.

  • Page 112: Recommended Products

    Vespa LXV 50 Braking system The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw. -When the operation is over, tighten up the oil bleed screw to the prescribed torque. N.B. IF AIR CONTINUES TO COME OUT DURING PURGING, EX-...

  • Page 113: Rear Drum Brake

    Vespa LXV 50 Braking system Rear drum brake Once the muffler and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner. 2. Remove the shoe with the aid of a lever.
  • Page 114 INDEX OF TOPICS CHAS HASSIS...
  • Page 115 Vespa LXV 50 Chassis Seat Remove the saddle opening cable Remove the four screws shown in the figure and the rear seat from the chassis saddle. Unscrew the two screws of saddle fixing hook cov- To remove the cable and the sheath: - Remove the elastic ring and unscrew the cable end from the seat on the saddle fixing hook.

  • Page 116: Instrument Panel

    Vespa LXV 50 Chassis Instrument panel - Remove the front grille - Remove the shield back plate - Remove the two fixing screws of the instrument panel. - Remove the odometer cable. - Remove the connector of the electric connections...
  • Page 117 Vespa LXV 50 Chassis Headlight assy. - Remove the four fixing screws from the light sup- port. Knee-guard - Unscrew the 2 screws shown in the figure placed under the front grille. - Remove the 3 screws shown in the figure, placed inside the glove-box;...
  • Page 118 Vespa LXV 50 Chassis Footrest - Operate on the 3 screws shown in the figure once the glove-box and fairing have been removed. Air filter - Remove the helmet compartment. - after removing the side fairing, remove the 2 screws fixing the filter box to the engine, indicated in the figure.

  • Page 119: Front Mudguard

    Vespa LXV 50 Chassis Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard - Remove the three mudguard-steering tube clamps indicated in the figure Front central cover - Remove the "PIAGGIO"...
  • Page 120 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 121 Vespa LXV 50 Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...
  • Page 122 Vespa LXV 50 Pre-delivery 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 BATTERY LIFE. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.

  • Page 123: Static Test

    Vespa LXV 50 Pre-delivery Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 124 INDEX OF TOPICS TIME...
  • Page 125 Vespa LXV 50 Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 engine from frame - removal and re- fitting...
  • Page 126 Vespa LXV 50 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement TIME - 126...
  • Page 127 Vespa LXV 50 Time Crankshaft RANKSHAFT Code Action Duration 001118 Main bearings - Replacement 001100 Oil seal, clutch side - Replacement 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement TIME - 127...

  • Page 128: Cylinder Assy

    Vespa LXV 50 Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 128...

  • Page 129: Cylinder Head Assy

    Vespa LXV 50 Time Cylinder head assy. HEAD Code Action Duration 001097 Cooling hood - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 001013 Intake manifold - Replacement 001178 Disc pack - Replacement TIME - 129...

  • Page 130: Driven Pulley

    Vespa LXV 50 Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 130...

  • Page 131: Oil Pump

    Vespa LXV 50 Time Oil pump OIL PUMP Code Action Duration 001028 Mix movement gear socket - Re- placement 001019 Mixer belt - replacement 001018 Mixer - Replacement TIME - 131...
  • Page 132 Vespa LXV 50 Time Final gear assy. INAL REDUCTION GEAR Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replacement TIME - 132...

  • Page 133: Driving Pulley

    Vespa LXV 50 Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Driving pulley - Removal and refitting 001086 Driving half-pulley - replace 001011 Driving belt - Replacement 001177 Variator rollers / shoes - Replace- ment TIME - 133...

  • Page 134: Transmission Cover

    Vespa LXV 50 Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001135 Transmission cover bearing - Re- placement TIME - 134...

  • Page 135: Starter Motor

    Vespa LXV 50 Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Re- placement 001017 Starter sprocket wheel - Replace- ment 001021 Kick starter - Inspection 008008 Starter spring pack - Replacement...

  • Page 136: Flywheel Magneto

    Vespa LXV 50 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement 001087 Flywheel cover - Replacement TIME - 136...
  • Page 137 Vespa LXV 50 Time Carburettor CARBURETTOR Code Action Duration 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 001081 Automatic choke - Replacement 001082 Carburettor heating resistor - Re- placement 003058 Carburettor - Adjustment...

  • Page 138: Exhaust Pipe

    Vespa LXV 50 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 138...

  • Page 139: Air Cleaner

    Vespa LXV 50 Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Re- placement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 139...
  • Page 140 Vespa LXV 50 Time Frame RAME Code Action Duration 004001 Chassis - Replacement 004023 Shield rim - Replacement 004149 Shield central cover - Replacement 004159 Plates / Stickers - Replacement 004012 Rear side panels - Replacement 004059 Spark plug inspection flap - Replace-...

  • Page 141: Centre-Stand

    Vespa LXV 50 Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 004171 Stand support plate - Replacement TIME - 141...
  • Page 142 Vespa LXV 50 Time Footrests OOTREST Code Action Duration 004078 Front/rear footrest rubber - Replace- ment 004178 Footrest - Replacement TIME - 142...

  • Page 143: Rear Cover

    Vespa LXV 50 Time Rear cover HIELD BACK PLATE Code Action Duration 004174 Trunk levers - Replacement 004065 Front shield, rear part - Removal and refitting 004081 Glove box door - Replacement 004082 Trunk gasket - Replacement TIME - 143...

  • Page 144: Underseat Compartment

    Vespa LXV 50 Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005046 Battery cover - change 004011 Central chassis cover - Replacement 004071 Battery compartment - replacement TIME - 144...
  • Page 145 Vespa LXV 50 Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate support - Replacement 005048 Licence plate holder - Replacement 005032 Licence plate light glass - Replace- ment TIME - 145...
  • Page 146 Vespa LXV 50 Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 146...
  • Page 147 Vespa LXV 50 Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Replace- ment 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 004109 Fuel tank breather - Replacement...

  • Page 148: Oil Reservoir

    Vespa LXV 50 Time Tank oil OIL RESERVOIR Code Action Duration 005018 Oil reservoir float - Replacement 004017 Oil reservoir - Replacement 004095 Oil reservoir cock - Replacement 004091 Oil reservoir hose - Replacement Rear shock-absorber TIME - 148...

  • Page 149: Rear Shock Absorber

    Vespa LXV 50 Time REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment 004119 Bearing / upper steering fifth wheel -...

  • Page 150: Handlebar Covers

    Vespa LXV 50 Time Handlebar covers ODOMETER - HANDLEBAR COVERS Code Action Duration 004053 Spoiler - Replacement 004018 Handlebar front section - Replace- ment 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement 004019 Handlebar rear section - Replace-...

  • Page 151: Handlebar Components

    Vespa LXV 50 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002024 Front brake pump - Removal and Re-...

  • Page 152: Swinging Arm

    Vespa LXV 50 Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chassis con- nection - Replacement TIME - 152...
  • Page 153 Vespa LXV 50 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004008 Luggage rack - Replacement TIME - 153...

  • Page 154: Turn Signal Lights

    Vespa LXV 50 Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Front headlamp bulbs - Replacement 005005 Taillight - Replacement...

  • Page 155: Front Wheel

    Vespa LXV 50 Time Front wheel FRONT WHEEL Code Action Duration 004123 Front wheel - Replacement 003047 Front tyre - replace 003037 Front wheel rim- Replacement 003033 Front wheel hub- Replacement 002041 Front brake disc - Replacement 003034 Front wheel hub bearing - Replace-...

  • Page 156: Electric Devices

    Vespa LXV 50 Time REAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Removal and Refit- ting 001016 Rear wheel - Replacement 002002 Rear brake pads/shoes - Replace- ment Electric devices LECTRICAL COMPONENTS...

  • Page 157: Electronic Controls

    Vespa LXV 50 Time Electronic controls ELECTRICAL CONTROLS Code Action Duration 005039 Headlight switch - Replacement 005006 Light switch or turn indicators - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement 005016...
  • Page 158 Vespa LXV 50 Time Transmissions RANSMISSION Code Action Duration 002051 Odometer transmission assembly - Replacement 002012 Splitter - Replacement 002057 Carburettor / splitter transmission complete - Replacement 002058 Mix / splitter transmission complete - Replacement 002053 Rear brake transmission complete -...

  • Page 159: Brake Callipers

    Vespa LXV 50 Time Brake callipers CALLIPER Code Action Duration 002021 Front brake hose - Remov. and Re- fitt. 002007 Front brake shoes/pads - Remov. and Refitt 002039 Front brake calliper - Removal and Refitting 002047 Front brake fluid and air bleeding...

  • Page 160: Front Suspension

    Vespa LXV 50 Time Front suspension FRONT SUSPENSION Code Action Duration 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber support and brake calliper - Replacement 001064 Odometer reel - Replacement 003044 Shock absorber cover - Replace-...
  • Page 161 Vespa LXV 50 Time Secondary air box SECONDARY AIR HOUSING Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001163 Muffler secondary air connection -...
  • Page 162 Air filter: 32, 118 Battery: 40, 47, 55 Brake: 109–113, 159 Carburettor: 11, 29, 137 Engine stop: Fuel: 39, 90, 147 Fuses: 54 Headlight: 35, 117 Hub oil: 31 Identification: 8 Instrument panel: 116 Maintenance: 7, 27 Odometer: Saddle: Shock absorbers: 106 Spark plug: 30 Stand: Start-up:...

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