VESPA LX 4T USA Workshop Manual
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VESPA LX 4T USA Workshop Manual

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WORKSHOP MANUAL
633571
LX 4T USA

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  • Page 1 WORKSHOP MANUAL 633571 LX 4T USA...

  • Page 2: Workshop Manual

    WORKSHOP MANUAL LX 4T USA 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 WORKSHOP MANUAL LX 4T USA 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

    LX 4T USA Characteristics Rules Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

  • Page 8: Vehicle Identification

    LX 4T USA Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPC38300 ÷ 1001 Engine prefix M383M÷1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Dry weight 102 ± 5 Width 740 mm Length 1755 mm Wheel base 1290 mm.
  • Page 9 LX 4T USA Characteristics Engine ENGINE Specification Desc./Quantity Type Single-cylinder, 4-stroke, Piaggio Hi-Per 4 Bore 39 mm Stroke 41,8 mm Cubic capacity 49.93 cm³ Compression ratio 11,5 ÷ 12 : 1 Timing system single overhead camshaft, driven by a chain to the left side.

  • Page 10: Wheels And Tyres

    LX 4T USA Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V belt, automatic clutch, gear reduction unit. Capacities CAPACITY Specification Desc./Quantity Fuel tank (including 2 litre reserve) ~ 8,5 l Rear hub oil 85 cc...

  • Page 11: Frame Assembly

    LX 4T USA Characteristics Specification Desc./Quantity Light alloy rims (Front rim) 2.50" x 11" Light alloy rims (rear rim) 3.00 x 10" N.B. CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

  • Page 12: Front Brake

    LX 4T USA Characteristics FOR INFORMATION ON SAFETY TIGHTENINGS, REFER TO CHAPTER «PRE-CONSIGNMENT CHECKS». FRONT BRAKE Name Torque in Nm Brake fluid pump-hose fitting 8 ÷ 12 Brake fluid pipe-calliper fitting 20 ÷ 25 Screw tightening calliper to the support 20 ÷...
  • Page 13 LX 4T USA Characteristics Cylinder - piston assy. CONNECTION PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Cylinder (with asso pis- 38,993 ÷ 39,000 38,954 ÷ 38,961 0.032 ÷ 0.046 ton/right way) Cylinder (with shiram 38,993 ÷ 39,000 38,949 ÷...

  • Page 14: Piston Rings

    LX 4T USA Characteristics Piston rings UPRATING TABLE Name Description Dimensions Initials Quantity 1° Compression lining 39 x 1 0,08 ÷ 0,20 2° Compression lining 39 x 1 0,05 ÷ 0,20 Scraper ring lining 39 x 2 0,20 ÷ 0,70 1°...
  • Page 15 LX 4T USA Characteristics Crankcase - crankshaft - connecting rod END PLAY BETWEEN DRIVING SHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission side half 14 +0 -0.005 shaft Flywheel side half shaft 16 +0 -0.005 Connecting rod 14.8 +0.05 -0...
  • Page 16 LX 4T USA Characteristics N.B. 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 GETS INSIDE THE CYLINDER, THE THINNER THE HEAD GASKET TO BE APPLIED SHOULD BE (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.
  • Page 17 LX 4T USA Characteristics Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions...
  • Page 18 INDEX OF TOPICS TOOL OOLING...
  • Page 19 LX 4T USA Tooling TOOLING Stores code Description 001467Y008 Pliers to extract 17 mm ø bearings 001467Y029 Bell for bearings, O.D. 38 mm 004499Y Bearing extractor. Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34...
  • Page 20 LX 4T USA Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020074Y Tool to align crankshaft 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y Bearing fitting base...
  • Page 21 LX 4T USA Tooling Stores code Description 020288Y Fork to assemble piston on cylinder 020291y Valves assembly/disassembly tool 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter TOOL - 21...
  • Page 22 LX 4T USA Tooling Stores code Description 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40-mm adaptor TOOL - 22...
  • Page 23 LX 4T USA Tooling Stores code Description 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25-mm guide 020376Y Adaptor handle TOOL - 23...
  • Page 24 LX 4T USA Tooling Stores code Description 020431Y Valve oil seal extractor 020432Y Tool to fit the start-up sector spring 020439Y 17 mm guide 020444Y Test probe removal / fitting tool 020448Y Pin lock fitting tool 020449Y Piston position check support...
  • Page 25 LX 4T USA Tooling Stores code Description 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser TOOL - 25...

  • Page 26: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 27: Maintenance Chart

    LX 4T USA Maintenance Maintenance chart AFTER 1,000 KM OR 4 MONTHS Action Hub oil - change Valve clearance - check Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear...
  • Page 28 LX 4T USA Maintenance 24000 48000 VERY KM OR Action Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Oil filter (net filter) - clean Valve clearance - check...

  • Page 29: Every 2 Years

    LX 4T USA Maintenance Action Valve clearance - check Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving belt - replacement Cylinder ventilation system - check Odometer gear - greasing Steering - adjustment...

  • Page 30: Checking The Spark Advance

    LX 4T USA Maintenance 1. Needle valve - 2. Idle speed adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin - 6. Jet holder - 7. Float - 8. Tank - 9. Starter device - 10. Vacuum valve - 11. Cover - 12. Minimum jet.

  • Page 31: Spark Plug

    LX 4T USA Maintenance Spark plug The central electrode of the above spark plug is treated with silicone oil that acts as an antioxidant agent. If the silicone oil is in excess, crystals tend to form and, by causing hot fire points to preignition phenomena, tend to reduce the spark plug performance.

  • Page 32: Air Filter

    LX 4T USA Maintenance Check - Place the vehicle on the stand on level ground. - Unscrew oil dipstick «A», wipe it with a clean rag, reinsert it and screw it in fully. - Pull out the dipstick and check that the oil level is in the middle (two-notch dipstick) or reaches the middle notch (three-notch dipstick).

  • Page 33: Engine Oil

    LX 4T USA Maintenance -Let the filter cartridge drip and then squeeze it between the hands without wringing. CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER. Engine oil Replacement -Loosen the oil filler plug.

  • Page 34: Engine Oil Filter

    LX 4T USA Maintenance Engine oil filter - Change the oil when the engine is warm. - Place a container under the oil sump and remove the cap for draining the oil. - After draining the oil clean the mesh filter with a specific solvent and then blow it down with com- pressed air.

  • Page 35: Checking The Valve Clearance

    LX 4T USA Maintenance If the reference is opposite the indicator on the head, turn the crankshaft once more as the piston must be at the TDC of the bursting phase. N.B. TIME THE TIMING SYSTEM UNIT AS DESCRIBED IN CHAP-...
  • Page 36 LX 4T USA Maintenance 2. Turn on the headlight and check that the bor- derline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and high- er than 7/10;...
  • Page 37 LX 4T USA Maintenance 6) Start up the engine and, before adjusting the idle speed, ensure the oil temperature is between 70 and 80 °C. 7) Wait for a few minutes to let the temperature stabilise. 8) Without ever activating the throttle and through the idle screw, bring the engine speed to 1,950 ±...
  • Page 38 LX 4T USA Maintenance MAIN - 38...

  • Page 39: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 40: Poor Performance

    LX 4T USA Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter clogged or dirty Disassemble, wash sponge with water and shampoo and im- merse in a mixture of 50% petrol and Selenia Air Filter oil. Let it drip. Wring out without squeezing it and then refit...

  • Page 41: Engine Tends To Cut Out At Full Throttle

    LX 4T USA Troubleshooting Possible Cause Operation Wrong ignition advance Check flywheel keying on the crankshaft, replace control unit if necessary Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance Starting rpm too low. Starter motor faulty.

  • Page 42: Brakes Overheating

    LX 4T USA Troubleshooting Possible Cause Operation lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. The starter remains on Check that the starter runs correctly and it is properly powered Loose nozzles...

  • Page 43: Noisy Suspension

    LX 4T USA Troubleshooting Battery BATTERY Possible Cause Operation This device requires the most assiduous surveillance and the This device requires the most assiduous surveillance and the most diligent maintenance. most diligent maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged pe- riodically.
  • Page 44 LX 4T USA Troubleshooting Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper. TROUBL - 44...

  • Page 45: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 46: Electrical Components

    LX 4T USA Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Front left turn indicator Front turn indicator bulbs Front turn indicator bulbs 12V-10W x 2 Horn button Indicators switch Light switch Rear stop switch Headlight bulb 12V-35/35W Front tail light bulb...
  • Page 47 LX 4T USA Electrical system Specification Desc./Quantity Front brake stop button Starter button Key switch front right turn indicator Fuel level transmitter Automatic starter Starter remote control rear right turn indicator Rear light assembly Stop and tail light bulb Type: Spherical...
  • Page 48 LX 4T USA Electrical system IGNITION Specification Desc./Quantity Magneto flywheel Pick - up Key switch contacts Electronic ignition device Fuse 10 A Voltage regulator Battery 12V-9Ah Headlights and automatic starter section HEADLIGHTS Specification Desc./Quantity Magneto flywheel Voltage regulator Light switch...
  • Page 49 LX 4T USA Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP SECTION Specification Desc./Quantity Voltage regulator Magneto flywheel Automatic starter Battery 12V-9Ah Remote starter switch Starter motor Start up button Brake light filament 12V-21W Front and rear brake light button...
  • Page 50 LX 4T USA Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity Voltage regulator Fuel Level indicator Fuel level sender Reserve fuel light 12V-1,2W Front and rear brake light button Fuse 10 A...

  • Page 51: Turn Signal Lights

    LX 4T USA Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Indicators switch Horn button Horn Two (2) turn signal warning light bulbs 12V - 2W 4 Turn indicator bulbs 12V-10W Voltage regulator Key switch contacts Fuse...

  • Page 52: Checks And Inspections

    LX 4T USA Electrical system WARNING LIGHTS AND GAUGES PANEL Specification Desc./Quantity Left turn indicator warning light 12V - 2W High-beam warning light 12V - 1.2W Fuel Level indicator Instrument panel lighting bulb 12V-1,2W Headlight warning light 12V 1.2W Reserve fuel light...

  • Page 53: Ignition Circuit

    LX 4T USA Electrical system STATOR WINDING CHECK Specification Desc./Quantity ~ 1 Ω 1) Black cable and earth Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the con- nections and the devices making up the ignition...
  • Page 54 LX 4T USA Electrical system 3) Battery fails to charge 4) Turn indicators failure The regulator is provided with earth supplied from the electrical equipment, therefore the regulator body does not supply earth to the internal circuits. Check the insulation between each terminal of the regulator and its body, using the specific tester.
  • Page 55 LX 4T USA Electrical system Recharge system voltage check 3) BATTERY DOES NOT RECHARGE The fault in the DC section of the voltage regulator may cause, depending on the type of failure, the following faults: a) Bursting of protection fuse due to exces- sively high voltage (regulator short-circuited) and resulting in the battery not recharging.
  • Page 56 LX 4T USA Electrical system avoid damaging the instrument measuring the cur- rent). Check the voltage at idle is at least 13V (charged battery) and the recharge current is 1.5 - 2A with the lighting system and the choke device exclu- ded, as described in the chapter "CHECKING THE...
  • Page 57 LX 4T USA Electrical system - If the above tests have positive results, jump the contacts 5 (blue/black) and 3 (white) on the con- nector, set the key switch to ON and the turn indicator switch left and right to see when the lights are steadily on (as they are powered directly from the battery).
  • Page 58 LX 4T USA Electrical system In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area when recharging the battery indoors.
  • Page 59 LX 4T USA Electrical system Regular bench charging must be carried out with the specific battery charger, (single) or (multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connect- ing the corresponding poles (+ to+ and - to -).
  • Page 60 LX 4T USA Electrical system - ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE- SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

  • Page 61: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 62 LX 4T USA Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying at- tention to the interference between its supporting bracket and the cooling cover.
  • Page 63 INDEX OF TOPICS NGINE...

  • Page 64: Automatic Transmission

    LX 4T USA Engine Automatic transmission Transmission cover - Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehi- cle, it is necessary to remove the transmission cooling coupling and the air filter housing retain- ers.

  • Page 65: Removing The Driven Pulley Shaft Bearing

    LX 4T USA Engine Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

  • Page 66: Inspecting The Clutch Drum

    LX 4T USA Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the inner diameter of the clutch bell. Characteristic Clutch bell diameter/standard value Ø 107+0.2 +0 mm Clutch bell diameter/max. value allowed after Ø...
  • Page 67 LX 4T USA 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. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL CONTACT SURFACE AND MUST NOT BE DIFFER- ENT FROM ONE ANOTHER.
  • Page 68 LX 4T USA Engine 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 POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 69 LX 4T USA Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø 34.08 mm - Check the belt contact surfaces.
  • Page 70 LX 4T USA Engine 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation...

  • Page 71: Refitting The Driven Pulley

    LX 4T USA 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 72: Removing The Driving Pulley

    LX 4T USA 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 73: Specific Tooling

    LX 4T USA Engine 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.
  • Page 74 LX 4T USA Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and it seating in the crankcase and the return spring. - Remove the damaged components. - Grease the spring.
  • Page 75 LX 4T USA Engine Removing the hub cover • Remove the transmission cover • Remove the clutch assembly • Discharge the rear hub oil. • Remove the 5 screws indicated in the figure. • Remove the hub cover with driven pulley shaft.
  • Page 76 LX 4T USA Engine Removing the driven pulley shaft bearing - Remove the seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane. - Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.
  • Page 77 LX 4T USA Engine Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the specific tool posi- tioned under the press and insert the driven pulley axle.

  • Page 78: Flywheel Cover

    LX 4T USA Engine Refitting the ub cover - Refit the whole wheel axle. - Refit the intermediate gear paying attention to the two shim thicknesses. - Apply LOCTITE 510 for surfaces to the hub cov- ers and refit the same with driven pulley shaft.

  • Page 79: Cooling Fan

    LX 4T USA Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.

  • Page 80: Removing The Starter Motor

    LX 4T USA Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. N.B. THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COV- ER ASSEMBLY.
  • Page 81 LX 4T USA 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 82: Intermediate Gear

    LX 4T USA Engine Starter gear rim - Check the toothing is level and in good conditions Intermediate gear - Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the bendix opens and returns ade- quately.

  • Page 83: Starter Motor Screws

    LX 4T USA Engine Refitting the starter motor - Install the starter motor in its seating in the crank- case. - Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the pre- scribed torque.
  • Page 84 LX 4T USA Engine Removing the timing system drive - Temporarily loosen the tensioner central screw and remove it together with the spring. - Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket.

  • Page 85: Removing The Cam Shaft

    LX 4T USA Engine Removing the cam shaft - Remove the bearing clamping screw indicated in the figure. - Remove the entire camshaft with bearing using the specific tool shown in the figure. - Take out the camshaft bearing with the aid of the specific tool, being careful to mount a screw on the camshaft in order to protect its thread.

  • Page 86: Removing The Cylinder Head

    LX 4T USA Engine Removing the cylinder head - Remove the cooling covers, the timing control, the camshaft and the rocking levers. - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion.

  • Page 87: Inspecting The Small End

    LX 4T USA Engine Removing the cylinder - piston assy. - Remove the cylinder paying attention to the 2 cylinder centring dowels in the housing. - Remove the cylinder base gasket. To avoid damaging the piston, keep it fixed while removing the cylinder.

  • Page 88: Inspecting The Piston

    LX 4T USA Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. Characteristic Standard diameter gudgeon pin 13 -0-0.004mm Minimum admissible diameter pin 12.990 mm Inspecting the piston - Carefully clean the sealing rings housings with the aid of an old piston ring.
  • Page 89 LX 4T USA Engine - Carry out the measurement at 27 from the piston crown as shown in the figure. Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure.

  • Page 90: Sealing Rings

    LX 4T USA Engine SEALING RINGS Name Description Dimensions Initials Quantity Top piston ring 0.08 ÷ 0.20 mm 0.35 mm Middle piston ring 0.05 ÷ 0.20 mm 0.30 mm oil scraper 0.20 ÷ 0.70 mm 0.80 mm Removing the piston...
  • Page 91 LX 4T USA Engine Refitting the piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpen- dicularly to the cylinder axis.
  • Page 92 LX 4T USA Engine - Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superim- pose. Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned.

  • Page 93: Inspecting The Cylinder Head

    LX 4T USA Engine Head lock-nuts (cylinder stud replacement only) 6÷7 N*m + 135° + 90° The 45° reduction in rotation is necessary to prevent the excessive straining of the studs. Inspecting the cylinder head - Using a trued bar check that the cylinder head surface is not worn or distorted.
  • Page 94 LX 4T USA Engine - Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole assembly.
  • Page 95 LX 4T USA Engine 5 +0+0.012mm Intake guide: Wear limit 5.022 mm - If the width of the impression on the valve seat or the diameter of the valve guide exceed the specified limits, replace the cylinder head. - Check width of the impression on the valve seat «V»...
  • Page 96 LX 4T USA Engine grinding, keep the cylinder head in a horizontal position. This will prevent the lapping compound resi- dues from penetrating between the valve stem/guide coupling. CAUTION TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT.

  • Page 97: Inspecting The Cam Shaft

    LX 4T USA Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. Characteristic Standard diameter - Bearing A: Ø 12 +0.002 +0.010 Standard diameter - Bearing B: Ø 16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: Ø...
  • Page 98 LX 4T USA Engine Minimum admissible diameter Ø 10.970 mm Maximum diameter allowed: Ø 11.030 mm Refitting the head and timing system components - Fix the head on a workbench. - Screw the tool to fit the camshaft fully down on the bearing's inner track.
  • Page 99 LX 4T USA Engine - Finish the head tightening following the proce- dure below: screw the four head nuts to an initial torque at two crossed passes. Afterwards tighten the nuts with 2 turns of 90° each to be done at two crossed passes.

  • Page 100: Camshaft Pulley Screw

    LX 4T USA Engine - Bring the screw closer but without reaching its final locking point. - Push the tensioner pad lightly so as to check the correct timing. - Use the specific tool to lock the camshaft crown gear and tighten the screw.

  • Page 101: Crankcase - Crankshaft

    LX 4T USA Engine Refitting the rocker-arms cover - Carry out the removal procedure but in reverse order and tighten the four fixing screws to the specified torque. N.B. FIT A NEW O-RING ON THE TAPPET COVER. Locking torques (N*m) Timing chain tensioner screws 8 ÷...
  • Page 102 LX 4T USA Engine Splitting the crankcase halves - Remove the ten crankshaft coupling screws. -Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side. - Remove the crankshaft. CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC- CIDENTALLY FALL.
  • Page 103 LX 4T USA Engine - Check that the half shaft surfaces are not scored and with the aid of a gauge check the driving shaft width as indicated in the figure. Characteristic Standard measure 45 mm Removing the crankshaft bearings - Remove the flywheel bearing fitted on the driving shaft using the specific tool.
  • Page 104 LX 4T USA Engine - Heat a new main bearing in an oil bath at 120°. - Place the driving shaft on the support base and insert the bearing with the aid of an adequate piece of tube if necessary.

  • Page 105: Crankshaft Oil Seals

    LX 4T USA Engine Refitting the crankcase halves -Be careful to place the two centring dowels pref- erably on the flywheel side half casing. -Insert the crankshaft on the half casing on the transmission side. - Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully.
  • Page 106 LX 4T USA Engine Removal - Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain.

  • Page 107: Timing Chain/Oil Pump Compartment Cover Screws

    LX 4T USA Engine 020376Y Adaptor handle 020358Y 37x40-mm adaptor Locking torques (N*m) Timing chain/oil pump compartment cover screws 4 ÷ 5 Nm Oil pump Removal - Remove the chain compartment cover undoing the 3 fixing screws indicated in the figure.
  • Page 108 LX 4T USA Engine Inspection - Remove the two screws and the oil pump cover. - Remove the clip retaining the innermost rotor. - Remove and wash the rotors thoroughly with a degreasing solvent and compressed air. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible Replace the clip.
  • Page 109 LX 4T USA Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the assembly.

  • Page 110: Fuel Supply

    LX 4T USA Engine Refitting the oil sump - Clean and grease the faying surfaces. - Apply LOCTITE 510 on the sump surface and tighten the 6 fixing screws to the specified torque. - Refit the driving pulley assembly, the belt, the pinion and the transmission cover.

  • Page 111: Removing The Carburettor

    LX 4T USA Engine - Turn the engine by using the starter for five sec- onds with the carburettor at minimum. - Take up the fuel by means of a graded burette. N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR- RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE..
  • Page 112 LX 4T USA Engine - Remove the 2 fixing screws indicated in the fig- ure, the vacuum chamber cover and the spring. - Remove the vacuum valve together with the di- aphragm; the pin, the spring and its plastic guide.
  • Page 113 LX 4T USA Engine -Remove the accelerating pump jet together with the ball spring. - Remove the screw indicated in the figure fixing the float pin. - Remove the float and the plunger. -Remove the maximum nozzle. -Remove diffuser. -Remove the minimum nozzle.
  • Page 114 LX 4T USA Engine - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 115 LX 4T USA Engine - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by the flow screw, progression holes near the throttle valve. - For the starter circuit, blow the connection pipe properly with the jet.
  • Page 116 LX 4T USA Engine - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindric part directed to the diffuser. - Fit the diffuser.

  • Page 117: Level Check

    LX 4T USA Engine - Fit the accelerating pump diaphragm cover and tighten the 2 fixing screws making sure the spring below is correctly positioned. - Fit the rubber bellows protecting the pin in the upper part of the accelerating pump.
  • Page 118 LX 4T USA Engine - Fit the vacuum chamber cover with the 2 fixing screws paying special attention to the spring. Inspecting the automatic choke device - Ensure the automatic choke piston is not scratch- ed or oxidised. - Ensure the piston is free to slide within its hous- ing.
  • Page 119 LX 4T USA Engine - Use battery to power the automatic starter and check that piston protrudes as much as possible. - The correct warm up time depends on the ambi- ent temperature. - If protrusion, resistance or timing values are dif-...

  • Page 120: Adjusting The Idle

    LX 4T USA Engine - Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter. - Reconnect the fuel supply pipe and tighten the 2 clamping screw fixing the carburettor to the inlet manifold and the air inlet coupling to the filter.
  • Page 121 LX 4T USA Engine - Connect the tester thermometer to the sump, us- ing a cover with oil expressly prepared for probes. - Start the engine and before adjusting the idle speed, make sure that the oil temperature is be- tween 70÷80 °C.
  • Page 122 LX 4T USA Engine loss of engine blows as the mixture is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. If it is difficult to adjust CO values, check accurately: - That the automatic starter is efficient.

  • Page 123: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 124: Removing The Front Wheel

    LX 4T USA Suspensions 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. Front wheel hub overhaul - Remove the ball bearing check seeger ring indi-...
  • Page 125 LX 4T USA 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 126: Refitting The Front Wheel

    LX 4T USA 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 127: Steering Column

    LX 4T USA 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 part 20* and part 21* on its stem as shown in the figure.
  • Page 128 LX 4T USA Suspensions AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 ° C and +120 °C; NLGI 2; ISO-L-XBCIB2 - Lubricate the sealing rings with mineral oil and half-fill the roller casings with grease.
  • Page 129 LX 4T USA Suspensions - Fit both dust guard rings «C» on the swinging hub as shown in the detail drawing «A». - Connect the swinging hub to the steering tube with the guide pin, part 5*. - Use the specific tool fitted with part 3* on its stem and with part 4 at the bottom of the tool.
  • Page 130 LX 4T USA 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 131: Front Shock Absorber

    LX 4T USA Suspensions Refitting 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 132 LX 4T USA 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 133 LX 4T USA 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 134 LX 4T USA 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 135: Steering Bearing

    LX 4T USA Suspensions White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 ° C and +120 °C; NLGI 2; ISO-L-XBCIB2 Steering bearing Removal - Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis.

  • Page 136: Refitting The Rear Wheel

    LX 4T USA 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 137: Shock Absorbers

    LX 4T USA 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 - 137...
  • Page 138 LX 4T USA 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 139 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 140: Front Brake Calliper

    LX 4T USA 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 141: Front Brake Disc

    LX 4T USA 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 142: Disc Inspection

    LX 4T USA 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 143: Recommended Products

    LX 4T USA 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 144 LX 4T USA Braking system Removal - Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac- tuate the brake lever until no more fluid flows out. -Remove the oil pump from the handlebar; remove the brake lever and then remove the wheel cylin- der.

  • Page 145: Rear Drum Brake

    LX 4T USA Braking system 5. Sealing ring. 6. Piston. 7. Gasket. 8. Spring. 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 146 INDEX OF TOPICS CHAS HASSIS...

  • Page 147: Instrument Panel

    LX 4T USA Chassis Rear handlebar cover Undo the screws as shown in the figure and re- move the handlebar rear section. Instrument panel Operate the 4 screws shown in the figure to re- place the instrument panel. Front handlebar cover •...
  • Page 148 LX 4T USA Chassis Headlight assy. After removing the front handlebar cover, operate the 4 screws shown in the figure and remove the headlight. 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 149 LX 4T USA 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 150: Front Mudguard

    LX 4T USA 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 151 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 152: Safety Locks

    LX 4T USA Pre-delivery Aesthetic inspection - Paintwork - Joins between plastic fairings - Damage - Cleanness Tightening torques inspection Fastenings check - All tightening torques - External fairing screws SAFETY LOCKS Name Torque in Nm Handlebar tightening 40 ÷ 50 Lower steering ring nut 8 ÷...
  • Page 153 LX 4T USA Pre-delivery WARNING KEEP THE BATTERY WELL CLEAR OF NAKED FLAMES AND SPARKS DURING CHARGING. REMOVE THE BATTERY FROM THE VEHICLE BY DISCONNECTING THE NEGATIVE LEAD FIRST. PROTECT THE EYES WHEN WORKING WITH BATTERIES OR IN THEIR IMMEDIATE VICINITY.
  • Page 154 LX 4T USA Pre-delivery CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. PRE DE - 154...
  • Page 155 INDEX OF TOPICS TIME...
  • Page 156 LX 4T USA Time Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit. 003064 Engine oil - change TIME - 156...
  • Page 157 LX 4T USA Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - replace Crankshaft TIME - 157...

  • Page 158: Cylinder Assy

    LX 4T USA Time CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement 001100 Oil seal, clutch side - Replacement 001118 Main bearings - Replacement Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder Piston - Replacement...

  • Page 159: Cylinder Head Assy

    LX 4T USA Time Cylinder head assy. HEAD Code Action Duration 001056 Head gasket - change 001045 Valves - Replacement 001126 Head - Replacement TIME - 159...
  • Page 160 LX 4T USA Time Rocker arms support assy. CAMSHAFT SUPPORT Code Action Duration 001049 Valve clearance - Adjustment 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 160...

  • Page 161: Cylinder Head Cover

    LX 4T USA Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001088 Head cover gasket - change 001097 Cooling hood - Replacement 001089 Head cover - change TIME - 161...

  • Page 162: Driven Pulley

    LX 4T USA Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001110 Driven pulley- Replacement 001012 Driven pulley - Overhaul 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 162...

  • Page 163: Oil Pump

    LX 4T USA Time Oil pump OIL PUMP Code Action Duration 001051 Belt/Timing chain - change 001112 Oil pump - change 001042 Oil pump - overhaul 001121 Chain cover oil seal - Replacement 001122 Oil pump chain - change 001125...
  • Page 164 LX 4T USA Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 004125 Rear wheel axle - Replacement 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 001010 Gear reduction unit - Inspection...

  • Page 165: Driving Pulley

    LX 4T USA Time Driving pulley DRIVING PULLEY Code Action Duration 001177 Variator rollers / shoes - Replace- ment 001086 Driving half-pulley - replace 001066 Driving pulley - Removal and refitting 001011 rear-view belt - Replacement TIME - 165...

  • Page 166: Transmission Cover

    LX 4T USA Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - re- place 001132 Transmission air intake pipe - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement...

  • Page 167: Starter Motor

    LX 4T USA 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 168: Flywheel Magneto

    LX 4T USA Time Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 001067 Stator - Fitting and Refitting 001173 Rotor - Replacement 001102 Net oil filter - change / Cleaning 001109 Cooling fan - Replacement 001087 Flywheel cover - Replacement 001058...
  • Page 169 LX 4T USA Time Carburettor CARBURETTOR Code Action Duration 001063 Carburettor - Replacement 001008 Carburettor - Inspection 003058 Carburettor - Adjustment 001081 Automatic choke - Replacement 001082 Carburettor heating resistor - Re- placement 001013 Intake manifold - Replacement TIME - 169...

  • Page 170: Exhaust Pipe

    LX 4T USA Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 170...

  • Page 171: Air Cleaner

    LX 4T USA 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 - 171...
  • Page 172 LX 4T USA 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 173: Centre-Stand

    LX 4T USA Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 004171 Stand support plate - Replacement TIME - 173...
  • Page 174 LX 4T USA Time Footrests OOTREST Code Action Duration 004178 Footrest - Replacement 004078 Front/rear footrest rubber - Replace- ment TIME - 174...

  • Page 175: Rear Cover

    LX 4T USA 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 - 175...

  • Page 176: Underseat Compartment

    LX 4T USA 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 - 176...
  • Page 177 LX 4T USA 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 - 177...
  • Page 178 LX 4T USA Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 178...
  • Page 179 LX 4T USA 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 180: Rear Shock Absorber

    LX 4T USA Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 180...
  • Page 181 LX 4T USA Time Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment 004119 Bearing / upper steering fifth wheel - Replacement TIME - 181...

  • Page 182: Handlebar Covers

    LX 4T USA Time Handlebar covers SPEEDOMETER - HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement 005078...

  • Page 183: Handlebar Components

    LX 4T USA 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 184: Swinging Arm

    LX 4T USA Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chassis con- nection - Replacement TIME - 184...
  • Page 185 LX 4T USA Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004131 Luggage rack support - Replacement TIME - 185...

  • Page 186: Turn Signal Lights

    LX 4T USA 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 187: Front Wheel

    LX 4T USA 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 188: Electric Devices

    LX 4T USA 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 ELECTRICAL COMPONENTS...

  • Page 189: Electronic Controls

    LX 4T USA 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 190 LX 4T USA Time Transmissions TRANSMISSIONS Code Action Duration 002053 Rear brake transmission complete - Replacement 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement TIME - 190...

  • Page 191: Front Suspension

    LX 4T USA 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 192: Braking System

    LX 4T USA Time Braking system BRAKING SYSTEM 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 193 LX 4T USA 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 194 Air filter: 32, 149 Battery: 43, 49, 57 Brake: 140–143, 145 Carburettor: 11, 29, 111, 114, 169 Engine oil: 33 Fuel: 41, 110, 179 Headlight: 35, 148 Horn: Hub oil: 31 Identification: 8 Instrument panel: 147 Maintenance: 7, 27 Oil filter: 34 Saddle: Shock absorbers: 137 Spark plug: 31...

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