PIAGGIO Vespa LX 150 4T Euro 3 Service Station Manual
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PIAGGIO Vespa LX 150 4T Euro 3 Service Station Manual

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SERVICE STATION MANUAL
633976
Vespa LX 125 - 150 4T Euro 3

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Summary of Contents for PIAGGIO Vespa LX 150 4T Euro 3

  • Page 1 SERVICE STATION MANUAL 633976 Vespa LX 125 - 150 4T Euro 3...
  • Page 2 Not all versions shown in this publication are available in all Countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 Vespa LX 125 - 150 4T Euro 3 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.

  • Page 5: Index Of Topics

    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 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.

  • Page 9: Dimensions And Mass

    Vespa LX 125 - 150 4T Euro 3 Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix (125) ZAPM44300 ÷ 1001 Engine prefix (125) M444M ÷ 1001 Chassis prefix (150) ZAPM44400 ÷ 1001 Engine prefix (150) M445M ÷ 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity...
  • Page 10 Wheelbase 1280 mm Length 1800 mm Engine ENGINE Specification Desc./Quantity Engine Single-cylinder, 4-stroke Piaggio LEADER Timing system Single overhead camshaft (SOHC) with 2 valves Valve clearance intake 0.10 outlet 0.15 Bore x stroke (125) 57 x 48.6 mm Bore/stroke (150) 62.6 x 48.6 mm...

  • Page 11: Wheels And Tyres

    Vespa LX 125 - 150 4T Euro 3 Characteristics Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Start-up Electrical / Kick starter Spark plug Champion RG6YC- NGK CR7EB Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Chassis Unitised body made of stamped plate. Steering and suspensions Steering tube articulated on the front wheel carrier hub;...

  • Page 12: Carburettor Setting

    Vespa LX 125 - 150 4T Euro 3 Characteristics This system allows more oxygen to be added to the unburned gases before they reach the con- verter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter.

  • Page 13: Tightening Torques

    Vespa LX 125 - 150 4T Euro 3 Characteristics Kehin CARBURETTOR SETTING Specification Desc./Quantity Type CVEK26 Throttle valve diameter Ø 26.5 Diffuser diameter Ø 26.4 Setting stamping 271B Maximum jet Maximum air jet (on the body) MAJ Maximum air jet (on the body) MAJ2 Tapered pin stamping NELA Throttle valve spring...
  • Page 14 Vespa LX 125 - 150 4T Euro 3 Characteristics Name Torque in Nm Head intake manifold screw 11 ÷ 13 TRANSMISSION Name Torque in Nm Drive pulley nut 75 ÷ 83 Transmission cover screw 11 ÷ 13 Driven pulley shaft nut 54 ÷...

  • Page 15: Front Brake

    Vespa LX 125 - 150 4T Euro 3 Characteristics 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 ÷ 25 Brake disc screw 5 ÷...
  • Page 16 Vespa LX 125 - 150 4T Euro 3 Characteristics Name Initials Cylinder Piston Play on fitting Coupling 3rd over- 63.194 ÷ 63.201 63.147 ÷ 63.154 0.040 ÷ 0.054 size Coupling 3rd over- 63.201 ÷ 63.208 63.154 ÷ 63.161 0.040 ÷ 0.054 size COUPLING BETWEEN (R ) PISTON AND (150) CYLINDER...

  • Page 17: Piston Rings

    Vespa LX 125 - 150 4T Euro 3 Characteristics Name Initials Cylinder Piston Play on fitting Coupling 1st over- 57.197 ÷ 57.204 57.144 ÷ 57.151 0.046 ÷ 0.060 size Coupling 1st over- 57.204 ÷ 57.211 57.151 ÷ 57.158 0.046 ÷ 0.060 size Coupling 1st over- 57.211 ÷...
  • Page 18 Vespa LX 125 - 150 4T Euro 3 Characteristics SEALING RINGS (150) Name Description Dimensions Initials Quantity Compression ring 62.6x1 0.15 ÷ 0.30 Oil scraper ring 62.6x1 0.20 ÷ 0.40 Oil scraper ring 62.6x2.5 0.20 ÷ 0.40 Compression ring 62.8x1 0.15 ÷...
  • Page 19 Vespa LX 125 - 150 4T Euro 3 Characteristics Name Description Dimensions Initials Quantity Crankcase Class 1 32.953 ÷ 32.959 Crankcase Class 2 32.959 ÷ 32.965 Crankshaft half- Category B - blue 1.973 ÷ 1.976 bearing Crankshaft half- Category C - yel- 1.976 ÷...
  • Page 20 Vespa LX 125 - 150 4T Euro 3 Characteristics - Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio.
  • Page 21 Vespa LX 125 - 150 4T Euro 3 Characteristics Product Description Specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil AGIP GREASE MU3 Grease for odometer transmis-...
  • Page 22 Vespa LX 125 - 150 4T Euro 3 Characteristics CHAR - 16...

  • Page 23: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 24 Vespa LX 125 - 150 4T Euro 3 Tooling APPROPRIATE TOOL Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15-mm bear- ings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor...
  • Page 25 Vespa LX 125 - 150 4T Euro 3 Tooling Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge...
  • Page 26 Vespa LX 125 - 150 4T Euro 3 Tooling Stores code Description 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cyl- inder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol...
  • Page 27 Vespa LX 125 - 150 4T Euro 3 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 5...
  • Page 28 Vespa LX 125 - 150 4T Euro 3 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 - 6...
  • Page 29 Vespa LX 125 - 150 4T Euro 3 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 volt- age detection TOOL - 7...
  • Page 30 Vespa LX 125 - 150 4T Euro 3 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 - 8...
  • Page 31 Vespa LX 125 - 150 4T Euro 3 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 driv- en pulley clutch TOOL - 9...
  • Page 32 Vespa LX 125 - 150 4T Euro 3 Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission-side oil guard punch 020481Y005 EFI Technology interface wiring 020460Y Scooter diagnosis and tester 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 10...
  • Page 33 Vespa LX 125 - 150 4T Euro 3 Tooling Stores code Description 020641Y EFI Technology software up- grade TOOL - 11...
  • Page 34 Vespa LX 125 - 150 4T Euro 3 Tooling TOOL - 12...

  • Page 35: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 36: Maintenance Chart

    Vespa LX 125 - 150 4T Euro 3 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 Idle speed (*) - adjustment Throttle lever - adjustment...
  • Page 37 Vespa LX 125 - 150 4T Euro 3 Maintenance Action Hub oil level - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer cable - greasing...
  • Page 38 Vespa LX 125 - 150 4T Euro 3 Maintenance (*) See instructions in «Idle speed adjustment» section AFTER 30000 KM, 42000 KM, 66000 KM Action Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean...

  • Page 39: Checking The Spark Advance

    Vespa LX 125 - 150 4T Euro 3 Maintenance Action Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement...

  • Page 40: Level Check

    Vespa LX 125 - 150 4T Euro 3 Maintenance Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.

  • Page 41: Headlight Adjustment

    Vespa LX 125 - 150 4T Euro 3 Maintenance FMVSS DOT4 Synthetic fluid Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...
  • Page 42 Vespa LX 125 - 150 4T Euro 3 Maintenance - Remove the screw fixing the SAS valve to the flywheel cover, indicated in the photograph. - Remove the 6 flywheel cover screws indicated in the photograph and remove the flywheel cover. - Remove the filter indicated in the photograph - Check that the gasket is in good conditions - Check the SAS filter housing for dents or defor-...

  • Page 43: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 44: Poor Performance

    Vespa LX 125 - 150 4T Euro 3 Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil.

  • Page 45: Insufficient Lubrication Pressure

    Vespa LX 125 - 150 4T Euro 3 Troubleshooting Possible Cause Operation service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components - Engine flooded.
  • Page 46 Vespa LX 125 - 150 4T Euro 3 Troubleshooting Engine tends to cut-off at full throttle THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE Possible Cause Operation Maximum jet clogged Remove the carburettor, wash with solvent and dry with compressed air Water or condensate in the carburettor tank Remove the tank, wash with solvent and dry with compressed air...

  • Page 47: Brakes Overheating

    Vespa LX 125 - 150 4T Euro 3 Troubleshooting Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Slippage or irregular functioning Check that there is no grease on the masses. Check that the faying surface between the clutch masses and the clutch bell is mainly in the middle and with equivalent specifications on the three masses.
  • Page 48 Vespa LX 125 - 150 4T Euro 3 Troubleshooting Possible Cause Operation thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the negative ter-...

  • Page 49: Noisy Suspension

    Vespa LX 125 - 150 4T Euro 3 Troubleshooting Noisy suspension NOISY SUSPENSION Possible Cause Operation Noisy suspension If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake cal- liper and the disc.
  • Page 50 Vespa LX 125 - 150 4T Euro 3 Troubleshooting TROUBL - 8...

  • Page 51: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 52 Vespa LX 125 - 150 4T Euro 3 Electrical system KEY (With electric pump) 1. Electronic ignition device 2. Immobilizer aerial 3.TPS potentiometer 4. Magneto flywheel - Pick-up 5. Diagnostics socket 6. Ma J2 air valve (150) 7. Voltage regulator 8.
  • Page 53 Vespa LX 125 - 150 4T Euro 3 Electrical system 20. License plate light bulb 21. Rear left turn indicator 22. Rear light assembly 23. Rear right turn indicator 24. Front left turn indicator 25. Headlight A. Twin-filament bulb B. Front position light bulb 26.
  • Page 54 Vespa LX 125 - 150 4T Euro 3 Electrical system KEY (Without electric pump) 1. Electronic ignition device 2. Immobilizer aerial 3.TPS potentiometer 4. Magneto flywheel - Pick-up 5. Diagnostics socket 6. Ma J2 air valve (150) 7. Voltage regulator 8.
  • Page 55 Vespa LX 125 - 150 4T Euro 3 Electrical system 20. License plate light bulb 21. Rear left turn indicator 22. Rear light assembly 23. Rear right turn indicator 24. Front left turn indicator 25. Headlight A. Twin-filament bulb B. Front position light bulb 26.
  • Page 56 Vespa LX 125 - 150 4T Euro 3 Electrical system Ignition LEGENDA (Con pompa elettrica) 1. Dispositivo di accensione elettronica 2. Antenna immobilizer 8. Fusibili principali 9. Batteria 28. Commutatore a chiave 35. Candela 36. Bobina A.T. ELE SYS - 6...
  • Page 57 Vespa LX 125 - 150 4T Euro 3 Electrical system LEGENDA (Senza pompa elettrica) 1. Dispositivo di accensione elettronica 2. Antenna immobilizer 8. Fusibili principali 9. Batteria 28. Commutatore a chiave 34. Candela 35. Bobina A.T. ELE SYS - 7...
  • Page 58 Vespa LX 125 - 150 4T Euro 3 Electrical system Headlights and automatic starter section LEGENDA (Con pompa elettrica) 1. Dispositivo di accensione elettronica 8. Fusibili principali 9. Batteria 12. Fusibili secondari 18. Deviatore luci 20. Lampada illuminazione targa 22. Fanale posteriore completo 25.
  • Page 59 Vespa LX 125 - 150 4T Euro 3 Electrical system E. Spia luci F. Spia pressione olio G. Spia luci abbaglianti H. Led dissuasione e diagnostica 37. Riscaldatore carburatore 38. Starter automatico LEGENDA (Senza pompa elettrica) 1. Dispositivo di accensione elettronica 8.
  • Page 60 Vespa LX 125 - 150 4T Euro 3 Electrical system A. Spia riserva carburante B. Spia lampeggiatore destro C. Spia lampeggiatore sinistro D. Lampade illuminazione strumento E. Spia luci F. Spia pressione olio G. Spia luci abbaglianti H. Led dissuasione e diagnostica 36.
  • Page 61 Vespa LX 125 - 150 4T Euro 3 Electrical system 12. Fusibili secondari 13. Pulsante di avviamento 14. Pulsante stop sul freno posteriore 15. Pulsante stop sul freno anteriore 22. Fanale posteriore completo 28. Commutatore a chiave LEGENDA (Senza pompa elettrica) 1.
  • Page 62 Vespa LX 125 - 150 4T Euro 3 Electrical system 28. Commutatore a chiave Level indicators and enable signals section KEY(With electric pump) 1. Electronic ignition device 2. Immobilizer aerial 3.TPS potentiometer 8. Main fuses 9. Battery 12. Secondary fuses 28.
  • Page 63 Vespa LX 125 - 150 4T Euro 3 Electrical system G. High-beam warning light H. Immobiliser/diagnosis LED 39. External temperature sensor KEY(Without electric pump) 1. Electronic ignition device 2. Immobilizer aerial 3.TPS potentiometer 8. Main fuses 9. Battery 12. Secondary fuses 28.

  • Page 64: Pin Connector

    Vespa LX 125 - 150 4T Euro 3 Electrical system G. High-beam warning light H. Immobiliser/diagnosis LED 38. External temperature sensor Instruments and warning lights control board 4-PIN CONNECTOR Specification Desc./Quantity Ground lead Left turn indicator warning light Right turn indicator warning light Not used 5-PIN CONNECTOR Specification...

  • Page 65: Devices And Accessories

    Vespa LX 125 - 150 4T Euro 3 Electrical system Devices and accessories KEY(With electric pump) 1. Electronic ignition device 6. Ma J2 air valve (150) 8. Main fuses 9. Battery 12. Secondary fuses 16. Horn button 17. Horn 19. Turn signal switch 21.
  • Page 66 Vespa LX 125 - 150 4T Euro 3 Electrical system D. Instrument panel lighting bulbs E. Headlight warning light F. Oil pressure warning light G. High-beam warning light H. Immobiliser/diagnosis LED 32.Turn indicators sound alarm wiring 33. Fuel pump 34.Electric pump control device KEY(Without electric pump) 1.

  • Page 67: Checks And Inspections

    Vespa LX 125 - 150 4T Euro 3 Electrical system 26. Front right turn indicator 28. Key switch 31. Odometer with warning lights and fuel gauge A. Low fuel warning light B. Right turn indicator warning light C. Left turn indicator warning light D.
  • Page 68 Vespa LX 125 - 150 4T Euro 3 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 69: Diagnostic Codes

    Vespa LX 125 - 150 4T Euro 3 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.
  • Page 70 Vespa LX 125 - 150 4T Euro 3 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 71: Ignition Circuit

    Vespa LX 125 - 150 4T Euro 3 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 72 Vespa LX 125 - 150 4T Euro 3 Electrical system - HV primary coil check Disconnect the control unit connector and check that the cable between terminal No. 4 (violet) and terminal No. 12 (black) is not interrupted (see fig- ure).
  • Page 73 Vespa LX 125 - 150 4T Euro 3 Electrical system - Pick-Up Disconnect the control unit connector and connect the positive terminal to connector No. 3 and the negative terminal to connector No. 12 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up.

  • Page 74: Stator Check

    Vespa LX 125 - 150 4T Euro 3 Electrical system 020334Y Multiple battery charger 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 ÷...
  • Page 75 Vespa LX 125 - 150 4T Euro 3 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 76 Vespa LX 125 - 150 4T Euro 3 Electrical system Replace the control unit if there is no voltage; oth- erwise, check the wiring connections between the starter and the control unit. Turn signals system check - If the turn indicators do not work, proceed as fol- lows: - Disconnect the electronic control unit connector and check that there is voltage between terminal...
  • Page 77 Vespa LX 125 - 150 4T Euro 3 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 Minimum 6 h Maximum 24 h 3) Constant current battery charge mode...
  • Page 78 Vespa LX 125 - 150 4T Euro 3 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 WARNING - ONCE THE BATTERY HAS BEEN INSTALLED...

  • Page 79: Pump Supply

    Vespa LX 125 - 150 4T Euro 3 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 connecting the corresponding poles (+ to+ and - to -).
  • Page 80 Vespa LX 125 - 150 4T Euro 3 Electrical system ELE SYS - 30...

  • Page 81: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 82 Vespa LX 125 - 150 4T Euro 3 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 83 Vespa LX 125 - 150 4T Euro 3 Engine from vehicle - Remove the throttle control cable from the car- burettor, indicated in the photograph - Remove the fuel supply pipe from the carburettor - Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph - Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indi-...
  • Page 84 Vespa LX 125 - 150 4T Euro 3 Engine from vehicle - Remove the protection sheath indicated in the figure and disconnect the automatic starter, the carburettor heater and the TPS connectors (150 cm³ version only: disconnect the solenoid valve connector from the MAJ2 control).
  • Page 85 INDEX OF TOPICS NGINE...

  • Page 86: Automatic Transmission

    Vespa LX 125 - 150 4T Euro 3 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 87 Vespa LX 125 - 150 4T Euro 3 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 88: Removing The Driven Pulley Shaft Bearing

    Vespa LX 125 - 150 4T Euro 3 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 DAMAGING THE COVER PAINT.

  • Page 89: Removing The Driven Pulley

    Vespa LX 125 - 150 4T Euro 3 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 90: Removing The Clutch

    Vespa LX 125 - 150 4T Euro 3 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 alignment...
  • Page 91 Vespa LX 125 - 150 4T Euro 3 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 EX- HIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN- OTHER.
  • Page 92 Vespa LX 125 - 150 4T Euro 3 Engine RINGLET OF THE DRIVEN PULLEY UPON RE- MOVING IT. Specific tooling 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.

  • Page 93: Refitting The Driven Pulley

    Vespa LX 125 - 150 4T Euro 3 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 94 Vespa LX 125 - 150 4T Euro 3 Engine Specific tooling 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...
  • Page 95 Vespa LX 125 - 150 4T Euro 3 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 96 Vespa LX 125 - 150 4T Euro 3 Engine Specific tooling 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 97: Removing The Driving Pulley

    Vespa LX 125 - 150 4T Euro 3 Engine ELT SIZE Specification Desc./Quantity Minimum width 21.5 mm Standard width 22.5 ± 0.2 mm 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.
  • Page 98 Vespa LX 125 - 150 4T Euro 3 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 99 Vespa LX 125 - 150 4T Euro 3 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 100 Vespa LX 125 - 150 4T Euro 3 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 101 Vespa LX 125 - 150 4T Euro 3 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 102 Vespa LX 125 - 150 4T Euro 3 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. Refitting the driven pulley shaft bearing - Heat up the parts using the specific heat gun Specific tooling...
  • Page 103 Vespa LX 125 - 150 4T Euro 3 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 104 Vespa LX 125 - 150 4T Euro 3 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 105: Cooling Fan

    Vespa LX 125 - 150 4T Euro 3 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 106 Vespa LX 125 - 150 4T Euro 3 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. N.B.
  • Page 107 Vespa LX 125 - 150 4T Euro 3 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 108 Vespa LX 125 - 150 4T Euro 3 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 109: Removing The Cam Shaft

    Vespa LX 125 - 150 4T Euro 3 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 110: Removing The Valves

    Vespa LX 125 - 150 4T Euro 3 Engine MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. 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 removal tool...

  • Page 111: Inspecting The Small End

    Vespa LX 125 - 150 4T Euro 3 Engine - Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston. N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL. Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer.
  • Page 112 Vespa LX 125 - 150 4T Euro 3 Engine - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASURE- MENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PIS- TON.

  • Page 113: Inspecting The Piston

    Vespa LX 125 - 150 4T Euro 3 Engine - The pistons are oversized due to cylinder rectifi- cation and are subdivided into three categories 1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They are also classified into 4 categories A-A, B-B, C- C, D-D.
  • Page 114 Vespa LX 125 - 150 4T Euro 3 Engine - With the opening in position indicated on the tool, take stop ring in the closed position using the punch. - Fit the wrist pin stop using the plug as shown in the figure N.B.

  • Page 115: Inspecting The Cylinder Head

    Vespa LX 125 - 150 4T Euro 3 Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure. N.B.
  • Page 116 Vespa LX 125 - 150 4T Euro 3 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft drive pulley, the chain assembly and the sprocket wheel are not worn. - If sings of wear are found, replace the parts.
  • Page 117 Vespa LX 125 - 150 4T Euro 3 Engine Characteristic Standard drainage guide diameter 5.012 mm Standard inlet guide diameter 5.012 mm - 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.
  • Page 118 Vespa LX 125 - 150 4T Euro 3 Engine - Check that there are no signs of wear on the contact surface with the articulated register termi- nal. - If the sealing surface on the valves is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.

  • Page 119: Inspecting The Cam Shaft

    Vespa LX 125 - 150 4T Euro 3 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. - Check the length clearance of the springs. Characteristic Valve spring length 33.9 ÷...
  • Page 120 Vespa LX 125 - 150 4T Euro 3 Engine Minimum admitted diameter bearing A Ø: 32.440 mm Minimum admitted diameter bearing B Ø: 19.950 mm Inlet cam height 27.512 mm Outlet cam height 27.212 mm - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft.
  • Page 121 Vespa LX 125 - 150 4T Euro 3 Engine In case of anomalies, replace the damaged com- ponents. Characteristic Minimum diameter permitted Ø 11.970 mm Maximum diameter admitted Ø 12.030 mm Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder.
  • Page 122 Vespa LX 125 - 150 4T Euro 3 Engine - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que. Locking torques (N*m) Locking torque 4 ÷ 6 - 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.
  • Page 123 Vespa LX 125 - 150 4T Euro 3 Engine - Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Locking torque 12 - 14 - Set the tensioner cursor in the rest position.

  • Page 124: Crankcase - Crankshaft

    Vespa LX 125 - 150 4T Euro 3 Engine Locking torques (N*m) Locking torque 3 ÷ 4 - Fit the inlet manifold and lock the 2 screws to the specified torque. - Fit the carburettor onto the inlet manifold and lock the clamp N.B.
  • Page 125 Vespa LX 125 - 150 4T Euro 3 Engine - Remove the 2 retainers indicated in the figure and the starter motor. - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with specific tool dial gauge.
  • Page 126 Vespa LX 125 - 150 4T Euro 3 Engine - Remove the oil guard on the flywheel side. - Remove the oil filter fitting shown in the diagram - Check the axial clearance on the connecting rod. Characteristic Standard clearance 0.20 ÷...
  • Page 127 Vespa LX 125 - 150 4T Euro 3 Engine Distance between the shoulders 55.67 ÷ 55.85 mm - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart below.
  • Page 128 Vespa LX 125 - 150 4T Euro 3 Engine N.B. THE MAIN BEARINGS ARE NOT GRINDABLE Specific tooling 020074Y Support base for checking crankshaft alignment Characteristic Off-line maximum admitted A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm Inspecting the crankcase halves - Before proceeding to check the crankcase...
  • Page 129 Vespa LX 125 - 150 4T Euro 3 Engine - On the flywheel side crankcase half, take partic- ular care cleaning the oil ducts for the main bush- ings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the fly- wheel side oil seal.

  • Page 130: Main Bearings

    Vespa LX 125 - 150 4T Euro 3 Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
  • Page 131 Vespa LX 125 - 150 4T Euro 3 Engine Specification Desc./Quantity Green Refitting the crankcase halves - Fit the internal bulkhead by locking the two screws to the prescribed torque. Locking torques (N*m) Locking torque 4 ÷ 6 - Fit the oil filter joint and tighten it to the prescribed torque.
  • Page 132 Vespa LX 125 - 150 4T Euro 3 Engine Locking torque 11 ÷ 13 - Lubricate the flywheel oil seal. - Use the appropriate tool to assemble the oil seal. - Fit a new O-ring on the pre-filter and lubricate it. - Insert the pre-filter on the engine with its corre- sponding cover to the specific torque.
  • Page 133 Vespa LX 125 - 150 4T Euro 3 Engine Conceptual diagrams ENG - 49...

  • Page 134: Oil Pressure Check

    Vespa LX 125 - 150 4T Euro 3 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 is between 0.5 ÷...
  • Page 135 Vespa LX 125 - 150 4T Euro 3 Engine Removal - Remove the transmission cover and the com- plete driving pulley beforehand - 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 136 Vespa LX 125 - 150 4T Euro 3 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 CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING...
  • Page 137 Vespa LX 125 - 150 4T Euro 3 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 CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
  • Page 138 Vespa LX 125 - 150 4T Euro 3 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 139 Vespa LX 125 - 150 4T Euro 3 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. Characteristic Limit values admitted: 0.09 mm...
  • Page 140 Vespa LX 125 - 150 4T Euro 3 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 141: Fuel Supply

    Vespa LX 125 - 150 4T Euro 3 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 142 Vespa LX 125 - 150 4T Euro 3 Engine After having removed the cable harness protec- tion, remove the connector as indicated in the photograph Check the solenoid resistance inside the valve with a multimeter. Electric characteristic Solenoid resistance 35.5 ÷ 40.5 mm at 20°C Apply 12V DC to the connector ends as indicated in the photograph.
  • Page 143 Vespa LX 125 - 150 4T Euro 3 Engine With the multimeter, check if the potentiometer is working correctly by placing the probes on both contactors indicated in the photograph . With throttle valve completely closed, the resist- ance value should be approx. 1.3 kOhm. With throttle valve completely open, the resistance value should be approx.

  • Page 144: Removing The Carburettor

    Vespa LX 125 - 150 4T Euro 3 Engine - Completely empty the gas tank. - Remove the petrol delivery tube and the suction tube. - Loosen the clip and remove the tap. - Clean the tank and the filter of the tap with a spe- cific solvent.
  • Page 145 Vespa LX 125 - 150 4T Euro 3 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 4 fixing screws shown in the figure and the vacuum chamber cover.
  • Page 146 Vespa LX 125 - 150 4T Euro 3 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. - Remove the chamber with the accelerating pump, its control and gasket.
  • Page 147 Vespa LX 125 - 150 4T Euro 3 Engine - 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 148 Vespa LX 125 - 150 4T Euro 3 Engine -Remove diffuser. - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 149 Vespa LX 125 - 150 4T Euro 3 Engine -Remove the minimum nozzle. - Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EM- BEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PRO- GRESSIONS AND INLET NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE...
  • Page 150 Vespa LX 125 - 150 4T Euro 3 Engine - For maximum circuit, check the air adjustment is correct as shown in the figure. - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve.
  • Page 151 Vespa LX 125 - 150 4T Euro 3 Engine - Wash and blow the minimum nozzle properly and reassemble it. - Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the noz- zle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser.
  • Page 152 Vespa LX 125 - 150 4T Euro 3 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the acceleration pump valves fol- lowing this order: INTAKE VALVE (A)
  • Page 153 Vespa LX 125 - 150 4T Euro 3 Engine - Adjust the carburettor by turning the screw twice from the close position. Level check - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
  • Page 154 Vespa LX 125 - 150 4T Euro 3 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 155 Vespa LX 125 - 150 4T Euro 3 Engine - 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 156: Adjusting The Idle

    Vespa LX 125 - 150 4T Euro 3 Engine plate with the machined side contacting the starter, tighten the fixing screws. - Position the starter as shown in the figure. - Assemble the protection casing. N.B. TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIR- CUITS USE A CABLE SECTION WITH A TER- MINAL SUITABLE TO BE CONNECTED TO THE...
  • Page 157 Vespa LX 125 - 150 4T Euro 3 Engine - Using the rpm indicator of the analyser or an in- dependent one (020332y), adjust the idle set screw until 1600 ÷ 1700 rpm is obtained. N.B. THE WASTED SPARK IGNITION SYSTEM OF- FERS REMARKABLE POWER.
  • Page 158 Vespa LX 125 - 150 4T Euro 3 Engine ENG - 74...

  • Page 159: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 160: Removing The Front Wheel

    Vespa LX 125 - 150 4T Euro 3 Suspensions Front suspension 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.
  • Page 161 Vespa LX 125 - 150 4T Euro 3 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 - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the...
  • Page 162 Vespa LX 125 - 150 4T Euro 3 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 Handlebar Removal Remove the handlebar cover before carrying out...

  • Page 163: Steering Column

    Vespa LX 125 - 150 4T Euro 3 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 - Press and remove the wedging washer with the help of a pointed end.
  • Page 164 Vespa LX 125 - 150 4T Euro 3 Suspensions 001330Y Tool for fitting steering seats 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 ° C and +120 °C;...
  • Page 165 Vespa LX 125 - 150 4T Euro 3 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 166 Vespa LX 125 - 150 4T Euro 3 Suspensions - Use the specific tool, fitted with part 1*, and op- erate the handgrip until the pin and the Nadella are simultaneously ejected in the direction opposite the tool thrusting force. - To eject the second Nadella, use the tool fitted with part 2* instead of part 1, on the side opposite the one shown in the figure.

  • Page 167: Front Shock Absorber

    Vespa LX 125 - 150 4T Euro 3 Suspensions When fitting the fork, lubricate with the steering bearing tracks with the recommended grease. Tighten the lower ring nut "A" and the upper ring nut "B" to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm White anhydrous-calcium based protective grease...
  • Page 168 Vespa LX 125 - 150 4T Euro 3 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. Locking torques (N*m) shock absorber lower clamp 20 - 27 Nm shock absorber upper clamp 20 ÷...
  • Page 169 Vespa LX 125 - 150 4T Euro 3 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 to the bracket and tighten at the prescribed torque Locking torques (N*m)
  • Page 170 Vespa LX 125 - 150 4T Euro 3 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 - Assemble a new roller bearing on the shock ab- sorber side and move it until it stops using the...

  • Page 171: Steering Bearing

    Vespa LX 125 - 150 4T Euro 3 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 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 172: Refitting The Rear Wheel

    Vespa LX 125 - 150 4T Euro 3 Suspensions -Remove the wheel acting on the central fixing point. 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.

  • Page 173: Shock Absorbers

    Vespa LX 125 - 150 4T Euro 3 Suspensions Refitting For rifting, respect the locking torques Locking torques (N*m) Part C 33 ÷ 41 Part B 44 ÷ 52 Part A 33 ÷ 41 Shock absorbers SUSP - 15...

  • Page 174: Centre-Stand

    Vespa LX 125 - 150 4T Euro 3 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 175 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 176: Front Brake Calliper

    Vespa LX 125 - 150 4T Euro 3 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 177 Vespa LX 125 - 150 4T Euro 3 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 with the aid of short blasts of compressed air through the brake fluid holes - Remove the dust ring and the O-ring of each half...
  • Page 178 Vespa LX 125 - 150 4T Euro 3 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. - Insert the clip on the pad fixing pin N.B.

  • Page 179: Front Brake Disc

    Vespa LX 125 - 150 4T Euro 3 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- erating on the five screws shown in the photo- graph, remove the brake disc Refitting...

  • Page 180: Disc Inspection

    Vespa LX 125 - 150 4T Euro 3 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 - In order to secure the appropriate tool adequately...
  • Page 181 Vespa LX 125 - 150 4T Euro 3 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 182: Brake Fluid Level Check

    Vespa LX 125 - 150 4T Euro 3 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 183 Vespa LX 125 - 150 4T Euro 3 Braking system - Disconnect the tube, collecting the brake oil in a container. - On refitting, perform the operation in reverse. - Tighten the hydraulic line to the prescribed torque and bleed the system. Locking torques (N*m) Brake fluid pump - hose fitting 16 ÷20 Nm Removal...
  • Page 184 Vespa LX 125 - 150 4T Euro 3 Braking system ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED. 1. Reservoir cap screw 2. Reservoir cap. 3. Diaphragm. 4. Bellows. 5. Sealing ring 6. Piston. 7.

  • Page 185: Rear Drum Brake

    Vespa LX 125 - 150 4T Euro 3 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. 3.
  • Page 186 Vespa LX 125 - 150 4T Euro 3 Braking system BRAK SYS - 12...
  • Page 187 INDEX OF TOPICS CHAS HASSIS...

  • Page 188: Instrument Panel

    Vespa LX 125 - 150 4T Euro 3 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 189 Vespa LX 125 - 150 4T Euro 3 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 190: Air Filter

    Vespa LX 125 - 150 4T Euro 3 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 housing to the engine, indi- cated in the figure.

  • Page 191: Front Mudguard

    - Remove the three mudguard-steering tube clamps indicated in the figure Front central cover - Remove the "PIAGGIO" clip-on badge - Unscrew the screw indicated in the figure - Remove the grille CHAS - 5...
  • Page 192 Vespa LX 125 - 150 4T Euro 3 Chassis CHAS - 6...
  • Page 193 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 194 Vespa LX 125 - 150 4T Euro 3 Pre-delivery Aesthetic inspection Appearance checks: - 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 Front wheel axle nut Wheel hub nut...
  • Page 195 Vespa LX 125 - 150 4T Euro 3 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 THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.

  • Page 196: Static Test

    Vespa LX 125 - 150 4T Euro 3 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 197 INDEX OF TOPICS TIME...
  • Page 198 Vespa LX 125 - 150 4T Euro 3 Time Engine ENGINE Code Action Duration 001001 engine from frame - removal and refitting TIME - 2...
  • Page 199 Vespa LX 125 - 150 4T Euro 3 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replace- ment 001153 Half crankcase gasket - Re- placement 002031 Rear wheel hub bearings - Replacement TIME - 3...
  • Page 200 Vespa LX 125 - 150 4T Euro 3 Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Re- placement TIME - 4...

  • Page 201: Cylinder Assy

    Vespa LX 125 - 150 4T Euro 3 Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder-Piston - Replace- ment 001107 Cylinder / piston - Inspection / cleaning TIME - 5...

  • Page 202: Cylinder Head Assy

    Vespa LX 125 - 150 4T Euro 3 Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001056 Head gasket - change 001126 Head - Replacement TIME - 6...
  • Page 203 Vespa LX 125 - 150 4T Euro 3 Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Re- placement 001049 Valves - Adjustments TIME - 7...

  • Page 204: Cylinder Head Cover

    Vespa LX 125 - 150 4T Euro 3 Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001088 Head cover gasket - Replace- ment 001159 Oil vapour recovery tank - Service 001093 Spark plug - Replacement 001097 Cooling hood - Replacement 001091...

  • Page 205: Chain Tensioner

    Vespa LX 125 - 150 4T Euro 3 Time Chain tensioner CHAIN TIGHTENER Code Action Duration 001129 Chain tensioner - Service and Replacement 001124 By pass lubrication - Re- placement TIME - 9...

  • Page 206: Oil Filter

    Vespa LX 125 - 150 4T Euro 3 Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Re- placement 003064 Engine oil - change 001102 Net oil filter - Replacement / Cleaning TIME - 10...

  • Page 207: Flywheel Cover

    Vespa LX 125 - 150 4T Euro 3 Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replace- ment 001163 Muffler secondary air con- nection - Replacement 001161 Secondary air filter - Replace- ment / Cleaning 001174 SAS valve - Replacement 001164 Crankcase secondary air...

  • Page 208: Driven Pulley

    Vespa LX 125 - 150 4T Euro 3 Time Driven pulley DRIVEN PULLEY Code Action Duration 001155 Clutch bell housing - Re- placement 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement TIME - 12...

  • Page 209: Oil Pump

    Vespa LX 125 - 150 4T Euro 3 Time Oil pump OIL PUMP Code Action Duration 001051 Belt/Timing chain - Change 001125 Chain guide pads - Replace- ment 001042 Oil pump - Service 001112 Oil pump - change 001130 Oil sump - Replacement 001100 Oil seal, clutch side - Re- placement...
  • Page 210 Vespa LX 125 - 150 4T Euro 3 Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 004125 Rear wheel axle - Replace- ment 001156 Gear reduction unit cover - Replacement 003065 Gear box oil - Replacement 001010 Gear reduction unit - Inspec- tion TIME - 14...

  • Page 211: Driving Pulley

    Vespa LX 125 - 150 4T Euro 3 Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Drive pulley - Removal and refitting 001086 Driving half-pulley - Replace- ment 001177 Variator rollers / shoes - Re- placement 001011 Driving belt - Replacement TIME - 15...

  • Page 212: Transmission Cover

    Vespa LX 125 - 150 4T Euro 3 Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cov- er - Replacement 001135 Transmission cover bearing - Replacement 001065 Transmission cover - Remov- al and Refit TIME - 16...

  • Page 213: Starter Motor

    Vespa LX 125 - 150 4T Euro 3 Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Replacement 001017 Starter sprocket wheel - Re- placement 001021 Kick starter - Inspection 008008 Starter spring pack - Re- placement...

  • Page 214: Magneto Flywheel

    Vespa LX 125 - 150 4T Euro 3 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067 Stator - Removal and Refit- ting 001058 Flywheel - Replacement TIME - 18...
  • Page 215 Vespa LX 125 - 150 4T Euro 3 Time Belt cooling duct BELT COOLING PIPE Code Action Duration 001170 Air manifold - replacement 001132 Transmission air inlet pipe - Replacement 001131 Transmission air intake - Re- placement TIME - 19...
  • Page 216 Vespa LX 125 - 150 4T Euro 3 Time Carburettor CARBURETTOR Code Action Duration 001082 Carburettor heating resistor - Replacement 001013 Intake manifold - change 004122 Air cleaner carburettor fitting - Replacement 001081 Automatic choke - Replace- ment 001008 Carburettor - Inspection 001063 Carburettor - Replacement TIME - 20...

  • Page 217: Exhaust Pipe

    Vespa LX 125 - 150 4T Euro 3 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001136 Exhaust emissions - Adjust- ment 001095 Muffler guard - Replacement TIME - 21...

  • Page 218: Air Cleaner

    Vespa LX 125 - 150 4T Euro 3 Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Replacement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 22...
  • Page 219 Vespa LX 125 - 150 4T Euro 3 Time Frame RAME Code Action Duration 004001 Chassis - Replacement 004023 Shield rim - Replacement 004149 Shield central cover - Re- placement 004159 Plates / Stickers - Replace- ment 004012 Rear side panels - Replace- ment 004059 Spark plug inspection flap -...
  • Page 220 Vespa LX 125 - 150 4T Euro 3 Time Centre-stand STAND Code Action Duration 001053 Stand bolt - Replacement 004004 Stand - Replacement TIME - 24...
  • Page 221 Vespa LX 125 - 150 4T Euro 3 Time Footrests OOTREST Code Action Duration 004178 Footrest - Replacement 004078 Front/rear footrest rubber - Replacement TIME - 25...

  • Page 222: Rear Cover

    Vespa LX 125 - 150 4T Euro 3 Time Rear cover HIELD BACK PLATE Code Action Duration 004174 Trunk levers - Replacement 004065 Front shield, rear part - Re- moval and refitting 004081 Glove box door - Replace- ment 004082 Trunk gasket - Replacement TIME - 26...

  • Page 223: Underseat Compartment

    Vespa LX 125 - 150 4T Euro 3 Time Underseat compartment UNDERSEAT COMPARTMENT Code Action Duration 005046 Battery cover - change 004016 Helmet compartment - Re- moval and Refitting 001027 Body / air cleaner union - Re- placement TIME - 27...

  • Page 224: Helmet Compartment

    Vespa LX 125 - 150 4T Euro 3 Time HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Re- placement 005046 Battery cover - change 004011 Central chassis cover - Re- placement 004071 Battery compartment - re- placement TIME - 28...
  • Page 225 Vespa LX 125 - 150 4T Euro 3 Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate support - Re- placement 005048 Licence plate holder - Re- placement 005032 Transparent licence plate cover - replace TIME - 29...
  • Page 226 Vespa LX 125 - 150 4T Euro 3 Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replace- ment 004009 Rear mudguard - Replace- ment TIME - 30...

  • Page 227: Fuel Tank

    Vespa LX 125 - 150 4T Euro 3 Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Re- placement 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 004109 Fuel tank breather - Replace- ment...
  • Page 228 Vespa LX 125 - 150 4T Euro 3 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Re- moval and Refitting TIME - 32...
  • Page 229 Vespa LX 125 - 150 4T Euro 3 Time Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Re- placement 003073 Steering clearance - Adjust- ment 004119 Bearing / upper steering fifth wheel - Replacement TIME - 33...

  • Page 230: Handlebar Covers

    Vespa LX 125 - 150 4T Euro 3 Time Handlebar covers SPEEDOMETER - HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Re- placement 004019 Handlebar rear section - Re- placement 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement 005078 Odometer glass - Replace-...

  • Page 231: Handlebar Components

    Vespa LX 125 - 150 4T Euro 3 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 002037 Brake or clutch lever - Re- placement 002071 Left hand grip - Replacement 003001 Handlebar - Removal and re- fitting 005017 Stop switch - Replacement...

  • Page 232: Swinging Arm

    Vespa LX 125 - 150 4T Euro 3 Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chas- sis connection - Replacement TIME - 36...
  • Page 233 Vespa LX 125 - 150 4T Euro 3 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004131 Luggage rack support - Re- placement TIME - 37...

  • Page 234: Turn Signal Lights

    Vespa LX 125 - 150 4T Euro 3 Time Turn signal lights INDICATORS AND LIGHTS Code Action Duration 005002 Front headlamp - change 005012 Front turn indicator - Re- placement 005067 Front turn indicator bulb - Re- placement 005008 Front headlamp bulbs - Re- placement 005005 Taillight - Replacement...

  • Page 235: Front Wheel

    Vespa LX 125 - 150 4T Euro 3 Time Front wheel FRONT WHEEL Code Action Duration 004123 Front wheel - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim- Replace- ment 003033 Front wheel hub- Replace- ment 002041 Front brake disc - Replace- ment 003034 Front wheel hub bearing - Re-...

  • Page 236: Rear Wheel

    Vespa LX 125 - 150 4T Euro 3 Time Rear wheel REAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replace- ment 001071 Rear wheel rim - Removal and Refitting 001016 Rear wheel - Replacement 002002 Rear brake pads/shoes - Re- placement Electric devices TIME - 40...

  • Page 237: Electronic Controls

    Vespa LX 125 - 150 4T Euro 3 Time ELECTRICAL COMPONENTS Code Action Duration 005001 Electrical system - Replace- ment 005011 Start-up remote control switch - Replacement 005009 Voltage regulator - replace 005007 Battery - Replacement 005052 Fuse (1) - Replacement 001023 Control unit - Replacement 001094...
  • Page 238 Vespa LX 125 - 150 4T Euro 3 Time Transmissions TRANSMISSIONS Code Action Duration 002053 Rear brake transmission complete - Replacement 002051 Odometer transmission as- sembly - Replacement 002049 Odometer cable - Replace- ment TIME - 42...

  • Page 239: Front Suspension

    Vespa LX 125 - 150 4T Euro 3 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 - Replace- ment 003044 Shock absorber cover - Re-...

  • Page 240: Braking System

    Vespa LX 125 - 150 4T Euro 3 Time Braking system BRAKING SYSTEM Code Action Duration 002021 Front brake hose - Remov. and Refitt. 002007 Front brake shoes/pads - Re- mov. and Refitt 002039 Front brake calliper - Remov- al and Refitting 002047 Front brake fluid and air bleeding system - Replace-...
  • Page 241 Vespa LX 125 - 150 4T Euro 3 Time Secondary air box SECONDARY AIR SYSTEM Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replace- ment / Cleaning 001174 SAS valve - Replacement 001163 Muffler secondary air con- nection - Replacement TIME - 45...

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