VESPA LX 150 4T USA Workshop Manual
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VESPA LX 150 4T USA Workshop Manual

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633572
LX 150 4T USA

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  • Page 1 WORKSHOP MANUAL 633572 LX 150 4T USA...
  • Page 2 WORKSHOP MANUAL LX 150 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 150 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 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 150 4T USA 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 LX 150 4T USA Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPM 428 F5 engine prefix M442M÷1001 Dimensions and mass DIMENSIONS AND WEIGHT Specification Desc./Quantity Curbside weight 110 ± 5 kg Maximum height 1140 mm Width 740 mm...
  • Page 9 LX 150 4T USA Characteristics Capacities CAPACITY Specification Desc./Quantity Engine oil 61 in³ (1,000 cm³) Rear hub oil ~ 100 cm³ Fuel tank capacity ~ 8.5 litres (2 l of which is reserve) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Start-up...
  • Page 10 LX 150 4T USA Characteristics Secondary air In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the muf- fler. To favour the catalytic process, an extra amount of oxygen is added via a secondary air system (SAS).

  • Page 11: Tightening Torques

    LX 150 4T USA Characteristics Specification Desc./Quantity Diffuser diameter Ø 26.4 Setting stamping 265A Maximum jet Maximum air jet (on the body) Tapered pin stamping NELA Throttle valve spring 130 ÷ 180 gr. Minimum jet Idle air jet (on the body) Idle mixture adjustment screw initial opening 1 ¾...

  • Page 12: Crankcase And Crankshaft

    LX 150 4T USA Characteristics (°) Apply LOCTITE 243 threadlock CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead (transmission-side half 4 ÷ 6 shaft) screws Oil filter on crankcase fitting 27 ÷ 33 Rear brake cam tightening screw 11 ÷...
  • Page 13 LX 150 4T USA Characteristics Cylinder - piston assy. COUPLING BETWEEN PISTON (A ) AND CYLINDER ERKE Name Initials Cylinder Piston Play on fitting Coupling 62.580 ÷ 62.587 62.533 ÷ 62.540 0.040 ÷ 0.054 Coupling 62.587 ÷ 62.594 62.540 ÷ 62.547 0.040 ÷...
  • Page 14 LX 150 4T USA Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod with PP 18 -0.10 -0.15...
  • Page 15 LX 150 4T USA Characteristics Slot packing system - Temporarily fit the cylinder on the piston, without the base gasket. - Fit a comparator on the specific device - Reset the comparator on an inspection surface with an average preload of 5 mm for example Keeping the reset position, fit the device on the cylinder and lock it with 2 nuts as shown in the figure.
  • Page 16 LX 150 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 17 INDEX OF TOPICS TOOL OOLING...
  • Page 18 LX 150 4T USA Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø 15-mm bearings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor TOOL - 18...
  • Page 19 LX 150 4T USA Tooling Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge...
  • Page 20 LX 150 4T USA Tooling Stores code Description 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cylinder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing...
  • Page 21 LX 150 4T USA Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 21...
  • Page 22 LX 150 4T USA Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide TOOL - 22...
  • Page 23 LX 150 4T USA Tooling Stores code Description 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor - Peak voltage detec- tion TOOL - 23...
  • Page 24 LX 150 4T USA Tooling Stores code Description 020412Y 15 mm guide 020414Y 28-mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork TOOL - 24...
  • Page 25 LX 150 4T USA Tooling Stores code Description 020427Y Piston fitting band 020428Y Piston position check support 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driven pulley...
  • Page 26 LX 150 4T USA Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission-side oil guard punch 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the exhaust manifold TOOL - 26...
  • Page 27 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 28: Maintenance Chart

    LX 150 4T USA Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change EVERY 3000 KM Action Engine oil - level check/ top-up AFTER 1000 KM Action Engine oil - replacement Hub oil - change Oil filter (net filter) - clean...
  • Page 29 LX 150 4T USA Maintenance Action Driving belt - replacement Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check...
  • Page 30 LX 150 4T USA Maintenance AFTER 36000 KM 300' Action Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment...

  • Page 31: Checking The Spark Advance

    LX 150 4T USA Maintenance Checking the spark advance - To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire. - Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug).
  • Page 32 LX 150 4T USA Maintenance Braking system 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 33: Headlight Adjustment

    LX 150 4T USA Maintenance Top-up Proceed as follows: - Remove the tank cap by loosening the two screws, remove the gasket and top up using only the liquid specified without exceeding the maxi- mum level. CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
  • Page 34 LX 150 4T USA Maintenance ground to the centre of vehicle headlamp and high- er than 7/10; 3. If otherwise, adjust the right headlight with screw «A». N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS.
  • Page 35 LX 150 4T USA Maintenance 3.8±0.7 to 1650±50 RPM SAS filters inspection and cleaning Proceed as follows: - Remove the right-hand side fairing - Remove the screw on the rear part, to the right of the footrest, indicated in the photograph...
  • Page 36 LX 150 4T USA Maintenance - Remove the filter indicated in the photograph - Check that the gasket is in good conditions - Check the SAS filter housing for dents or defor- mations - Clean the SAS filter carefully. Replace the filter if it is damaged or deformed.
  • Page 37 LX 150 4T USA Maintenance Removing system components The components of the Canister system are sup- ported by rubber belts with two metal supports anchored to the chassis under the helmet com- partment: The Canister and safety valve are on the right side of the vehicle;...
  • Page 38 LX 150 4T USA Maintenance Refitting system components • Replace the components inserting the piping properly and fastening them with new metal strips. • Be careful to the direction of installation of the components. The safety valve and the Roll-over valve, if fitted in the reverse direction, affect the operation of the entire anti-evaporation system.
  • Page 39 LX 150 4T USA Maintenance The Canister tubing connections comprise the installation of a safety valve. This is a unidirectional valve that ensures the air flow towards the manifold when the control vacuum is over 200mbar. The engine vacuum at idle causes a weak air flow that can be easily compensated for with the idle adjustment parameters.
  • Page 40 LX 150 4T USA Maintenance The valve must be removed from the vehicle upon inspection. A MITYVAC pump and a length of pipe are needed for the inspection; proceed as follows: • Attach the MITYVAC pump to the lower joint to the safety valve (white).
  • Page 41 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 42: Troubleshooting

    LX 150 4T USA Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
  • Page 43 LX 150 4T USA Troubleshooting Possible Cause Operation Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace if necessary. Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed; replace if necessary...

  • Page 44: Excessive Fuel Consumption

    LX 150 4T USA Troubleshooting High fuel consumption EXCESSIVE 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 Loose nozzles Check the maximum and minimum nozzles are adequately...
  • Page 45 LX 150 4T USA Troubleshooting Electrical system Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.
  • Page 46 LX 150 4T USA Troubleshooting Noisy suspension NOISY SUSPENSION Possible Cause Operation Noisy suspension If the front suspension is noisy, check: that the front shock ab- sorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc.
  • Page 47 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 48 LX 150 4T USA Electrical system Legend 1. Rear brake stop button 2. High/low beam selector 3. Turn indicator selector 4. Horn button 5. Immobilizer aerial 6. Electronic ignition 7. Relay 8. Horn 9. Turn indicator bulb 10. Front left indicator.
  • Page 49 LX 150 4T USA Electrical system 13. Heater 14. Automatic choke 15. Pick-up 16. Magneto 17. Starter motor 18. Fuse holder with 2 15A fuses 19. 2 turn indicator bulbs 20. Rear left indicator 21. Rear parking and brake light bulb 22.
  • Page 50 LX 150 4T USA Electrical system Wire colour coding R = Red B = White Bl = Blue N = Black V= Green Rs = Pink Mr = Brown Gr = Grey Az = Light blue G = Yellow Vi = Purple...
  • Page 51 LX 150 4T USA Electrical system Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity electronic control unit Carburettor heater Automatic starter Key switch no. 2 main fuses Battery 12V-9Ah Headlamp relay Light switch Low-beam light bulb...
  • Page 52 LX 150 4T USA Electrical system Battery recharge and starting BATTERY CHARGER AND STARTING Specification Desc./Quantity Magneto flywheel Voltage regulator Pick - up Main fusible Battery 12V-9Ah Starter relay Starter motor Start up button Front and rear brake light button...
  • Page 53 LX 150 4T USA Electrical system Level indicators and enable signals section CONSENSES AND LEVEL INDICATORS Specification Desc./Quantity electronic control unit Battery 12V-9Ah Main fusible Key switch Engine oil pressure sensor Engine oil pressure warning light 12V - 2W Reserve fuel light...
  • Page 54 LX 150 4T USA Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity electronic control unit Indicators switch 4 Turn indicator bulbs 12V-10W Turn signal warning light bulbs 12V - 2W Main fusible Battery 12V-9Ah Horn Fuse 7.5 A...
  • Page 55 LX 150 4T USA Electrical system 4-PIN CONNECTOR Specification Desc./Quantity Ground lead Left turn indicator warning light Right turn indicator warning light Not used 5-PIN CONNECTOR Specification Desc./Quantity Fuel gauge High-beam lamp warning light 12V - 1.2W Engine oil pressure warning light...
  • Page 56 LX 150 4T USA Electrical system Whenever the LED is off and remains so, even when switching it to «ON», it is necessary to check - the battery is charged - 15A main fuse is working correctly. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located behind the front left fuse box flap.
  • Page 57 LX 150 4T USA Electrical system - Alternatively insert all the available black keys and turn each one of them to "ON" for 2 seconds. - Insert the MASTER key again and turn it to "ON" for 2 seconds. The maximum time to change keys is 10 seconds.
  • Page 58 LX 150 4T USA Electrical system 3-FLASH CODE Example with programmed electronic control unit, aerial working properly and unknown transponder code. Ignition disabled-Vehicle immobilised Diagnostic code - 2 flashes When the 2-flash code is detected, carry out the following checks: - Check if the failure continues even after changing key (including the MASTER key).
  • Page 59 LX 150 4T USA Electrical system Example with programmed control unit, trans- ponder, programmed key and working aerial. The ignition is enabled (regular use conditions) Ignition circuit All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged.
  • Page 60 LX 150 4T USA Electrical system - H.T. coil primary circuit inspection Detach the connector from the ECU and check for continuity between terminals 3 (purple) and 8 (black) (see figure). If unacceptable values are found, repeat the in- spection directly from the positive and negative terminals of the H.T.
  • Page 61 LX 150 4T USA Electrical system If unacceptable values are found, replace the Pick- N.B. THE MULTIMETER MUST BE SELECTED TO DETECT CONTINUOUS VOLTAGE. Electric characteristic Pick-Up voltage value Pick-Up voltage value: > 2 Volt - H.V. coil With the control unit and HV coil connected to the...
  • Page 62 LX 150 4T USA Electrical system Stator check Disconnect the connector from the voltage regu- lator and check there is continuity between any yellow cable and the other two cables. Electric characteristic Ohm value: 0.7 ÷ 0.9 Ohm Also check that all yellow cables are insulated from the ground connection.
  • Page 63 LX 150 4T USA Electrical system Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V.
  • Page 64 LX 150 4T USA Electrical system If no tension is found, replace the ECU; otherwise check the wiring between the choke device and the ECU. Turn signals system check - If the turn signal lights are faulty, proceed as fol-...
  • Page 65 LX 150 4T USA Electrical system 2) Constant voltage battery charge mode - Constant voltage charge equal to 14.40 ÷ 14.70V -Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended...
  • Page 66 LX 150 4T USA Electrical system 5) Once the above operations have been per- formed, install the battery on the vehicle ensuring that it is wired up properly. 1 Hold the vertical tube 2 Look at the level 3 The float must be freed...
  • Page 67 LX 150 4T USA Electrical system 4) Battery cleaning The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
  • Page 68 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 69 LX 150 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 70 LX 150 4T USA Engine from vehicle - Disconnect the belt cooling tube and the swinging arm retaining spring shown in the photograph - Disconnect the spark plug tube - Remove the throttle control cable from the car- burettor, indicated in the photograph...
  • Page 71 LX 150 4T USA Engine from vehicle - Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indi- cated in the figure - Remove the protection sheath indicated in the figure and disconnect the automatic starter and...
  • Page 72 INDEX OF TOPICS NGINE...

  • Page 73: Automatic Transmission

    LX 150 4T USA Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes.
  • Page 74 LX 150 4T USA Engine AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 - Operating the starter lever, load the spring and introduce the pinion in its seat. - Refit the intake throat with the 3 screws and the Kick-starter cover with the 4 screws.
  • Page 75 LX 150 4T USA Engine Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Use the specific tools to remove the bearing from the crankcase. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM- AGING THE COVER PAINT.

  • Page 76: Removing The Driven Pulley

    LX 150 4T USA Engine 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

  • Page 77: Removing The Clutch

    LX 150 4T USA Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft...
  • Page 78 LX 150 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 79 LX 150 4T USA Engine 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020439Y 17 mm guide Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bush- ing. Characteristic Minimum diameter permitted Ø 40.96 mm Standard diameter Ø...
  • Page 80 LX 150 4T USA Engine Refitting the driven half-pulley bearing - Assemble a new roller case using the specific punch, fit the bearing with the label facing outward and insert it completely up to the punch on the half- pulley.
  • Page 81 LX 150 4T USA Engine 020263Y Sheath for driven pulley fitting Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the unloaded length of the spring of the movable driven half-pulley.
  • Page 82 LX 150 4T USA Engine - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring 11 with the chamfering facing upwards.
  • Page 83 LX 150 4T USA Engine 020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 46x55 Wrench Locking torques (N*m) Nut locking clutch unit on pulley 55 ÷ 60 Nm Refitting the driven pulley - Reassemble the clutch bell and spacer.

  • Page 84: Removing The Driving Pulley

    LX 150 4T USA Engine Removing the driving pulley - Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the Belleville washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer.
  • Page 85 LX 150 4T USA Engine - Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves.
  • Page 86 LX 150 4T USA Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
  • Page 87 LX 150 4T USA Engine Removing the wheel axle Remove the intermediate gear and the complete hub cover. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following.
  • Page 88 LX 150 4T USA Engine With the appropriate tools, remove the oil seal as shown in the figure. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven pulley.
  • Page 89 LX 150 4T USA Engine Inspecting the hub cover - Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the brake camshaft. - If faults are found, replace the hub cover.
  • Page 90 LX 150 4T USA Engine • Assemble the Seeger ring. • Assemble the oil seal flush with the in- ternal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub.
  • Page 91 LX 150 4T USA Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Screw the 7 screws to the specified torque, po- sitioning the support plate of the pipe in the posi- tion shown in the figure.

  • Page 92: Removing The Stator

    LX 150 4T USA Engine mm. Remember that such operation must have performed on a disassembled manifold which must be cleaned afterwards. Cooling fan - Refit the parts in reverse order of the removal operation. - Make sure that there are spacers with the two rear retainers of the housing.
  • Page 93 LX 150 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. - Place the cable harness as shown in the figure.
  • Page 94 LX 150 4T USA Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly.
  • Page 95 LX 150 4T USA Engine Removing the timing system drive - Remove the parts listed below first: transmission cover, belt driving pulley, oil pump pulley cover and pinion separator washer. - Remove the tappet cover. - Remove the central screw fastener and the au- tomatic valve-lifter retaining cover, as shown in the figure.

  • Page 96: Removing The Cylinder Head

    LX 150 4T USA Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pin of the rocking levers from the flywheel side holes.

  • Page 97: Removing The Valves

    LX 150 4T USA Engine Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. Specific tooling 020382Y Valve cotters equipped with part 012...

  • Page 98: Inspecting The Small End

    LX 150 4T USA Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANK-...

  • Page 99: Inspecting The Piston

    LX 150 4T USA Engine - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Measure 36.5 mm from the piston crown's shown in the figure. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.

  • Page 100: Removing The Piston

    LX 150 4T USA Engine STANDARD COUPLING CLEARANCE Name Description Dimensions Initials Quantity Top piston ring 0.025 ÷ 0.070 Middle piston ring 0.015 ÷ 0.060 oil scraper 0.015 ÷ 0.060 MAXIMUM ADMITTED CLEARANCE AFTER USE Name Description Dimensions Initials Quantity Top piston ring 0.080 mm...
  • Page 101 LX 150 4T USA Engine Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.

  • Page 102: Inspecting The Cylinder Head

    LX 150 4T USA Engine 020427Y Piston fitting band Inspecting the cylinder head - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear.
  • Page 103 LX 150 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 104 LX 150 4T USA Engine - If the width of the impression on the valve seat or the diameter of the valve guide exceed the speci- fied limits, replace the cylinder head. - Check width of the impression on the valve seat «V»...
  • Page 105 LX 150 4T USA Engine 79.6 mm - If the checks above give no failures, you can use the same valves. For best sealing results, it is ad- visable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During grinding, keep the cylinder head in a horizontal position.
  • Page 106 LX 150 4T USA Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the lower plates of the valve spring on the head. - Use the punch to fit the 2 sealing rings one at a time.
  • Page 107 LX 150 4T USA Engine - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
  • Page 108 LX 150 4T USA Engine -Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque. Locking torques (N*m) Locking torque 28 ÷ 30 - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
  • Page 109 LX 150 4T USA Engine - Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - While doing so, fit the chain onto the control cam- shaft pulley and keep the reference 2V in corre- spondence with the reference mark on the head.
  • Page 110 LX 150 4T USA Engine Locking torques (N*m) Locking torque 11 ÷ 13 - Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque. Locking torques (N*m) Locking torque 5 - 6 - Adjust the valve clearance.
  • Page 111 LX 150 4T USA Engine - Refit the cylinder head cover, tightening the 4 clamping screws to the prescribed torque. - Refit the fan and the housing. - Reassemble the oil pump control, the chain com- partment cover, the by-pass and the oil sump as described in the lubrication chapter.
  • Page 112 LX 150 4T USA Engine 0.15 ÷ 0.40 mm Splitting the crankcase halves Remove the 11 coupling screws to the crankcase. - Separate the crankcase while keeping the crank- shaft in one of the two halves of the crankcase. Remove the crankshaft.
  • Page 113 LX 150 4T USA Engine - Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
  • Page 114 LX 150 4T USA Engine Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 115 LX 150 4T USA Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean the all surfaces and oil ducts. - On the transmission side crankcase half, take particular care cleaning the housing and oil ducts...
  • Page 116 LX 150 4T USA Engine - Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and di- mensions.
  • Page 117 LX 150 4T USA Engine - The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like those for the crankshaft. 3 - The main bushings are subdivided into 3 thickness categories; see the table below: N.B.
  • Page 118 LX 150 4T USA Engine - Lubricate the main bushings and insert the crank- shaft in the transmission side crankcase half. - Reassemble the two crankcase halves. - Fit the 11 screws and tighten them to the pre- scribed torque.
  • Page 119 LX 150 4T USA Engine Conceptual diagrams ENG - 119...

  • Page 120: Oil Pressure Check

    LX 150 4T USA Engine Oil pressure check - After removing the cover protections as descri- bed in the "Flywheel" chapter, disconnect the elec- trical connexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...
  • Page 121 LX 150 4T USA Engine Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided. - Screw the threaded bar onto the base of the tool and extract the oil guard.
  • Page 122 LX 150 4T USA Engine - Preassemble the oil seal with the appropriate tool, positioning the screws - Place the sheath over the crankshaft - Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase...
  • Page 123 LX 150 4T USA Engine - Use the nut to move the base of the tool until you can see end of the oil seal driving stroke - Remove all of the tool components following the procedure in reverse order...
  • Page 124 LX 150 4T USA Engine - Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion. - Remove the oil pump acting on the 2 retainers as shown in the figure.
  • Page 125 LX 150 4T USA Engine Measure the distance between the outer rotor and the pump body; see figure. Characteristic Admissible limit clearance: 0.20 mm Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure.
  • Page 126 LX 150 4T USA Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmis- sion chapter. - Drain the oil from the sump as described above.

  • Page 127: Fuel Supply

    LX 150 4T USA Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.

  • Page 128: Removing The Carburettor

    LX 150 4T USA Engine N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR- RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-...
  • Page 129 LX 150 4T USA Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
  • Page 130 LX 150 4T USA Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure.
  • Page 131 LX 150 4T USA Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
  • Page 132 LX 150 4T USA Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 132...
  • Page 133 LX 150 4T USA Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 134 LX 150 4T USA Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
  • Page 135 LX 150 4T USA Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear.
  • Page 136 LX 150 4T USA Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
  • Page 137 LX 150 4T USA Engine - The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position. Level check - Place the carburettor inclined as shown in the figure.
  • Page 138 LX 150 4T USA Engine - Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover. - Tighten the screws. - Wash and blow dry the filter sponge of the am- bient pressure intake.
  • Page 139 LX 150 4T USA Engine - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Inspecting the automatic choke device - Check that the automatic starter piston is not de- formed or rusty.
  • Page 140 LX 150 4T USA Engine With a 12V battery power the automatic starter and check that the piston protrudes as much as possi- ble. - The correct warm up time depends on the ambi- ent temperature. - If protrusion, resistance or timing values are dif-...
  • Page 141 LX 150 4T USA Engine Adjusting the idle - The engine does not require frequent adjustment of the idle, however it is important that this adjust- ment be made in complete compliance with a few rules. - Before adjusting the carburettor make sure that...
  • Page 142 LX 150 4T USA Engine Additional information can be obtained from the analyser: - the percentage of carbon dioxide (CO2), the per- centage of carbon dioxide has a reverse trend compared to the percentage of (CO), values above 12.5% are considered correct. Values out of this range are considered as an indication of a non- airtight condition on the exhaust system.
  • Page 143 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 144: Removing The Front Wheel

    LX 150 4T USA Suspensions Sospensioni anteriore 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.
  • Page 145 LX 150 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 146 LX 150 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 147: Steering Column

    LX 150 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 parts 3 and 4, as indicated to fit the pin, and press operating the handgrip, until wedging the washers on the swinging hub.
  • Page 148 LX 150 4T USA 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.
  • Page 149 LX 150 4T USA 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 150 LX 150 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 151: Front Shock Absorber

    LX 150 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 152 LX 150 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 153 LX 150 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.
  • Page 154 LX 150 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 155: Removing The Rear Wheel

    LX 150 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 156 LX 150 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 157: Shock Absorbers

    LX 150 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 - 157...
  • Page 158 LX 150 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 159 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 160 LX 150 4T USA Braking system Front brake calliper Removal - Remove the front wheel. - Remove the pad retention pin. - Using a pin partially remove the brake pad re- tention pin. - Remove the screws fixing the brake calliper to the crankcase then remove the brake calliper com- plete with pipe.
  • Page 161 LX 150 4T USA Braking system Overhaul - Remove the front brake calliper - Suitably hold the brake calliper in a clamp - Remove the two calliper coupling screws as shown in the photo - Remove the two pistons from the calliper body...
  • Page 162 LX 150 4T USA Braking system Refitting - Insert the brake pads in the calliper. - Insert the pad fixing pin and the retention screw being careful to position the terminals of it pointing towards the bleed screw as shown in the photo.

  • Page 163: Front Brake Disc

    LX 150 4T USA Braking system Front brake disc Removal - Remove the front wheel - Remove the front brake calliper - Remove the hub and the disc operating on the wheel axle nut - Adequately support the hub with the disc and op-...

  • Page 164: Front Brake Pads

    LX 150 4T USA Braking system Disc Inspection - Remove the front wheel - Use a micrometer to check the disc thickness as shown in the photograph - Repeat the measurement in at least 6 points on the disk - Remove the front brake calliper...
  • Page 165 LX 150 4T USA Braking system 0.5 mm thickness difference in the residual friction material is permitted Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo.
  • Page 166 LX 150 4T USA Braking system Front - Remove the rubber cap from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. - With the right-hand brake lever, load the system and bring it up to the required pressure.
  • Page 167 LX 150 4T USA Braking system Front brake pump -After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure). - Disconnect the tube, collecting the brake oil in a container. - On refitting, perform the operation in reverse.
  • Page 168 LX 150 4T USA Braking system - The plunger shows no sign of damage or abnormal wear; - The plunger return spring is in good condition. CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.

  • Page 169: Rear Drum Brake

    LX 150 4T USA 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 170 INDEX OF TOPICS CHAS HASSIS...

  • Page 171: Instrument Panel

    LX 150 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 172 LX 150 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.

  • Page 173: Air Filter

    LX 150 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 174: Front Mudguard

    LX 150 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 175 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 176 LX 150 4T USA 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 177 LX 150 4T USA 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 178 LX 150 4T USA 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 179 INDEX OF TOPICS TIME...
  • Page 180 LX 150 4T USA Time Engine ENGINE Code Action Duration 001001 engine from frame - removal and re- fitting TIME - 180...
  • Page 181 LX 150 4T USA Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement 001153 Half crankcase gasket - Replace- ment 002031 Rear wheel hub bearings - Replace- ment TIME - 181...
  • Page 182 LX 150 4T USA Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement TIME - 182...
  • Page 183 LX 150 4T USA Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 183...
  • Page 184 LX 150 4T USA Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001056 Head gasket - change 001126 Head - Replacement TIME - 184...
  • Page 185 LX 150 4T USA Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Replacement 001049 Valves - Adjustments TIME - 185...

  • Page 186: Cylinder Head Cover

    LX 150 4T USA Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001159 Oil vapour recovery tank - Service 001093 Spark plug - Replacement 001097 Cooling hood - Replacement...
  • Page 187 LX 150 4T USA Time Chain tensioner CHAIN TIGHTENER Code Action Duration 001129 Chain tensioner - Service and Re- placement 001124 By pass lubrication - Replacement TIME - 187...
  • Page 188 LX 150 4T USA Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Replacement 003064 Engine oil - Change 001102 Net oil filter - Replacement / Cleaning TIME - 188...
  • Page 189 LX 150 4T USA Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001163 Muffler secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001174 SAS valve - Replacement 001164 Crankcase secondary air connection...

  • Page 190: Driven Pulley

    LX 150 4T USA Time Driven pulley DRIVEN PULLEY Code Action Duration 001155 Clutch bell housing - Replacement 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement TIME - 190...
  • Page 191 LX 150 4T USA Time Oil pump OIL PUMP Code Action Duration 001051 Belt/Timing chain - Change 001125 Chain guide pads - Replacement 001042 Oil pump - Service 001112 Oil pump - change 001130 Oil sump - Replacement 001100 Oil seal, clutch side - Replacement...
  • Page 192 LX 150 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 193 LX 150 4T USA Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Drive pulley - Removal and refitting 001086 Driving half-pulley - Replacement 001177 Variator rollers / shoes - Replace- ment 001011 Driving belt - Replacement TIME - 193...
  • Page 194 LX 150 4T USA Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001135 Transmission cover bearing - Re- placement 001065 Transmission cover - Removal and Refit TIME - 194...

  • Page 195: Starter Motor

    LX 150 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 196: Flywheel Magneto

    LX 150 4T USA Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067 Stator - Removal and Refitting 001058 Flywheel - Replacement TIME - 196...
  • Page 197 LX 150 4T USA Time Belt cooling duct BELT COOLING PIPE Code Action Duration 001170 Air manifold - replacement 001132 Transmission air inlet pipe - Replace- ment 001131 Transmission air intake - Replace- ment TIME - 197...
  • Page 198 LX 150 4T USA Time Carburettor CARBURETTOR Code Action Duration 001082 Carburettor heating resistor - Re- placement 001013 Intake manifold - change 004122 Air cleaner carburettor fitting - Re- placement 001081 Automatic choke - Replacement 001008 Carburettor - Inspection 001063...
  • Page 199 LX 150 4T USA Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001136 Exhaust emissions - Adjustment 001095 Muffler guard - Replacement TIME - 199...

  • Page 200: Air Cleaner

    LX 150 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 - 200...
  • Page 201 LX 150 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 202 LX 150 4T USA Time Centre-stand STAND Code Action Duration 001053 Stand bolt - Replacement 004004 Stand - Replacement TIME - 202...
  • Page 203 LX 150 4T USA Time Footrests OOTREST Code Action Duration 004178 Footrest - Replacement 004078 Front/rear footrest rubber - Replace- ment TIME - 203...
  • Page 204 LX 150 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 - 204...
  • Page 205 LX 150 4T USA Time Underseat compartment UNDERSEAT COMPARTMENT Code Action Duration 005046 Battery cover - Replacement 004016 Helmet compartment - Removal and Refitting 001027 Body / air cleaner union - Replace- ment TIME - 205...

  • Page 206: Helmet Compartment

    LX 150 4T USA Time HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005046 Battery cover - change 004011 Central chassis cover - Replacement 004071 Battery compartment - replacement TIME - 206...
  • Page 207 LX 150 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 - 207...
  • Page 208 LX 150 4T USA Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 208...
  • Page 209 LX 150 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...
  • Page 210 LX 150 4T USA Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 210...
  • Page 211 LX 150 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 - 211...

  • Page 212: Handlebar Covers

    LX 150 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...
  • Page 213 LX 150 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 - Removal and refitting 005017 Stop switch - Replacement...
  • Page 214 LX 150 4T USA Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chassis con- nection - Replacement TIME - 214...
  • Page 215 LX 150 4T USA Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004131 Luggage rack support - Replacement TIME - 215...

  • Page 216: Turn Signal Lights

    LX 150 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...

  • Page 217: Front Wheel

    LX 150 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 218 LX 150 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 219 LX 150 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...
  • Page 220 LX 150 4T USA Time Transmissions TRANSMISSIONS Code Action Duration 002053 Rear brake transmission complete - Replacement 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement TIME - 220...
  • Page 221 LX 150 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 222 LX 150 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 223 LX 150 4T USA Time Secondary air box SECONDARY AIR SYSTEM Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001174 SAS valve - Replacement 001163 Muffler secondary air connection -...
  • Page 224 Air filter: 173 Battery: 45, 52, 61, 64, 65 Brake: 160, 163, 164, 166, 167, 169 Brake fluid: 166 Carburettor: 10, 128, 134, 198 Fuel: 44, 127, 209 Headlight: 33, 172 Horn: Identification: 8 Instrument panel: 171 Maintenance: 7, 28 Oil filter: 188 Saddle: Shock absorbers: 157...

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