VESPA LX 50 Workshop Manual
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VESPA LX 50 Workshop Manual

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WORKSHOP MANUAL
633416
Vespa LX 50

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  • Page 1 WORKSHOP MANUAL 633416 Vespa LX 50...

  • Page 2: Workshop Manual

    WORKSHOP MANUAL Vespa LX 50 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet 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 Vespa LX 50 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.

  • Page 5: Index Of Topics

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

  • Page 7: Safety Rules

    Vespa LX 50 Characteristics Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...

  • Page 8: Vehicle Identification

    Vespa LX 50 Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPC38101 ÷ 1001 Engine prefix C381M ÷ 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Dry weight 96±4 Kg Maximum height 1140 mm Wheelbase 1290 mm Length...
  • Page 9 Vespa LX 50 Characteristics Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 10,3 :1 Carburettor DELL'ORTO PHVA 17.5 CO adjustment 3.5% ± 0.5 Engine idle speed 1800 to 2000 r.p.m.

  • Page 10: Electrical System

    Vespa LX 50 Characteristics Specification Desc./Quantity Fuel supply Gravity feed, with unleaded petrol (with a minimum octane rat- ing of 95) with carburettor. Cooling system forced coolant circulation system Transmission RANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V- belt, automatic clutch, gear reduction unit.

  • Page 11: Wheels And Tyres

    Vespa LX 50 Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front tyre size 110/70"-11" Rear tyre size 120/70-10" Front tyre pressure 1.6 bar Rear tyre pressure: 2 bar Light alloy rims (Front rim) 2.50" x 11" Light alloy rims (rear rim) 3.00 x 10"...

  • Page 12: Front Brake

    Vespa LX 50 Characteristics Carburettor 50cc Version Dell'Orto DELLORTO CARBURETTOR Specification Desc./Quantity Type PHVA 17.5 RD Diffuser diameter Ø 17.5 Regulation reference number 8423 Maximum nozzle: Maximum air nozzle (on the body): Ø 1.5 Tapered pin stamped code: Pin position (notches from above):...

  • Page 13: Frame Assembly

    Vespa LX 50 Characteristics Name Torque in Nm Flywheel fan screws 3 ÷ 4 Half-crank case joint bolts 12 ÷ 13 Bolts holding exhaust pipe to the crankcase 22 ÷ 24 Screws holding the filter box to the crank case 4 ÷...

  • Page 14: Piston Rings

    Vespa LX 50 Characteristics Piston rings SEALING RING Name Description Dimensions Initials Quantity Compression ring 0.10 to 0.25 Compression ring 1st 40.2 0.10 to 0.25 oversize Compression ring 2nd 40.4 0.10 to 0.25 Oversize Crankcase - crankshaft - connecting rod...
  • Page 15 Vespa LX 50 Characteristics Slot packing system This type of engines foresees the use of one size of basic gaskets. Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-...
  • Page 16 INDEX OF TOPICS TOOL OOLING...
  • Page 17 Vespa LX 50 Tooling ATTREZZATURA Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø 15-mm bearings 001467Y014 Pliers to extract ø 15-mm bearings...
  • Page 18 Vespa LX 50 Tooling Stores code Description 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater...
  • Page 19 Vespa LX 50 Tooling Stores code Description 020166Y Pin lock fitting tool 020261Y Starter spring fitting 020265Y Bearing fitting base 020325Y Pliers for brake-shoe springs 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing TOOL - 19...
  • Page 20 Vespa LX 50 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 20...
  • Page 21 Vespa LX 50 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020359Y 42x47-mm Adaptor 020376Y Adaptor handle 020412Y 15-mm guide TOOL - 21...
  • Page 22 Vespa LX 50 Tooling Stores code Description 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser 001467Y029 Bell for bearings, O.D. 38 mm 020037Y Punch 020036Y Punch TOOL - 22...
  • Page 23 Vespa LX 50 Tooling Stores code Description 020021Y Front suspension service tool 020038Y Punch 020074Y Support base for checking crankshaft alignment 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring TOOL - 23...
  • Page 24 Vespa LX 50 Tooling Stores code Description 004499Y002 Bearing extractor screw 004499Y007 Half rings 020171Y Punch for driven pulley roller bearing 020340Y Flywheel and transmission oil seals fitting punch 020360Y 52x55-mm Adaptor 020358Y 37x40-mm Adaptor 020362Y 12 mm guide TOOL - 24...
  • Page 25 Vespa LX 50 Tooling Stores code Description 020363Y 20-mm guide 020365Y 22 mm guide 020439Y 17-mm guide 020441Y 26 x 28 mm adaptor 020452Y Tube for removing and refitting the driven pulley shaft TOOL - 25...
  • Page 26 Vespa LX 50 Tooling Stores code Description 020451Y Starting ring gear lock 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 26...

  • Page 27: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 28: Maintenance Chart

    Vespa LX 50 Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AFTER 1000 KM Action Hub oil - change Oil mixer/throttle linkage - adjustment Odometer gear - greasing Steering - adjustment Brake control levers - greasing Brake fluid level - check...
  • Page 29 Vespa LX 50 Maintenance Action Hub oil level - check Spark plug/electrode gap - replacement Air filter - cleaning Oil mixer/throttle linkage - adjustment Driving belt - replacement Brake control levers - greasing Brake pads - check condition and wear...
  • Page 30 Vespa LX 50 Maintenance (*) See regulations in the «Adjusting the idle speed» section (**) See regulations in the «Secondary air system» section 60000 K FTER 150' Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean...

  • Page 31: Checking The Spark Advance

    Vespa LX 50 Maintenance 1. Automatic starter - 2. Idle air set screw - 3. Idle speed set screw - 4. Throttle valve spring - 5. Throttle valve tapered pin - 6. Throttle valve - 7. Carburettor body - 8. Pin - 9. Min. jet - 10. Float - 11. Max. jet - 12.
  • Page 32 Vespa LX 50 Maintenance - Engage the spark plug with the due inclination and screw it right down by hand, then do it up with the wrench at the prescribed torque; -Put the hood on the sparking plug as far as it will - Refit the central flap.

  • Page 33: Air Filter

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

  • Page 34: Checking The Ignition Timing

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

  • Page 35: Level Check

    Vespa LX 50 Maintenance Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.

  • Page 36: Headlight Adjustment

    Vespa LX 50 Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10-m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...
  • Page 37 Vespa LX 50 Maintenance - If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Oth- erwise, check the automatic choke device Specific tooling 020320Y Exhaust gases analyser 020332Y Digital rpm indicator SAS filters inspection and cleaning Remove the right side fairing by undoing the 2 screws marked «B»...

  • Page 38: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 39: Poor Performance

    Vespa LX 50 Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel nozzles or cock clogged or dirty...
  • Page 40 Vespa LX 50 Troubleshooting Possible Cause Operation to keep the cap in contact with the spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug and start the vehicle. Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill...

  • Page 41: High Fuel Consumption

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

  • Page 42: Brakes Overheating

    Vespa LX 50 Troubleshooting Brakes overheating BRAKES OVERHEATING Possible Cause Operation Defective piston sliding Check calliper and replace any damaged part. Brake disc or drum deformed Using a dial gauge, check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum.
  • Page 43 Vespa LX 50 Troubleshooting Possible Cause Operation lock-nuts, the limit switch rubber buffers and the movement bushings. Suspension oil leakage IL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Service the pumping members and check the sleeves and sealing rings are in good conditions.

  • Page 44: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 45: Electrical Components

    Vespa LX 50 Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Rear brake stop button Light switch Turn indicator switch Horn button Front left turn indicator Voltage regulator Electronic ignition device rear left turn indicator Flywheel magneto Pick - up Starter motor 7.5A...
  • Page 46 Vespa LX 50 Electrical system Specification Desc./Quantity Left turn indicator warning light Oil warning light Dashboard light bulbs Type: Bayonet Power: 12V 1.2W Quantity: 3 High-beam lamp warning light 12V - 1.2W INSTRUMENT PANEL Horn R = Red - B = White - Bl = Blue - N = Black - V = Green - Rs = Pink -Mr = Brown - Gr = Grey - Az = Sky...
  • Page 47 Vespa LX 50 Electrical system Headlights and automatic starter section LIGHTS Specification Desc./Quantity Voltage regulator Magneto flywheel Light switch Rear light bulb 12V - 5W Headlight bulb 12V-35/35W High-beam warning light 12V - 1.2W N°3 instrument lighting bulbs 12V - 1.2W...
  • Page 48 Vespa LX 50 Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING Specification Desc./Quantity Magneto flywheel Voltage regulator Main fuse 7,5A Brake light filament 12V - 21W Front and rear brake light button Start up button Starter motor Remote starter switch...
  • Page 49 Vespa LX 50 Electrical system Level indicators and enable signals section START PERMISSIVE BUTTONS AND LEVEL INDICATORS Specification Desc./Quantity Magneto flywheel Voltage regulator Key switch Main fuse 7,5A Brake light filament 12V - 21W Front and rear brake light button...

  • Page 50: Turn Signal Lights

    Vespa LX 50 Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Battery 12V - 4Ah Main fuse 7,5A Key switch Magneto flywheel Voltage regulator Horn button Horn Indicators switch Two (2) turn signal warning light bulbs 12V - 2W...

  • Page 51: Ignition Circuit

    Vespa LX 50 Electrical system Ignition circuit 1) Check the state of the spark plug (clean it with a metallic brush, remove all incrustations, blow it with compressed air, and replace it if necessary). 2) Without removing the stator, perform the checks...
  • Page 52 Vespa LX 50 Electrical system 6) Failure of the oil and petrol check lamp. Operations FAULT 1: Make sure that at 5000 rpm with the lights on that the regulation voltage is between 13V and 14.5V. Make sure that at 5000 rpm with the lights off the regulation voltage is ï£...
  • Page 53 Vespa LX 50 Electrical system FAULT 4 a) By positioning tester 020331Y between the yel- low wire terminal (8) on the regulator and the black wire (6) (FIG. D), check the generator output volt- age is within 26 and 30 V at 3,000 rpm (this meas- urement must be carried out with the battery detached).
  • Page 54 Vespa LX 50 Electrical system (FIG. G) If the above tests have positive results, jump the contacts 5 (yellow/red) and 7 (blue/black) on the connector, set the key switch to ON and shift the turn indicator switch to the right and left to see when the lights are steadily on (as they are powered directly from the battery).
  • Page 55 Vespa LX 50 Electrical system Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal capacity of the battery -Duration of the charge: 5 h WARNING -WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
  • Page 56 Vespa LX 50 Electrical system A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. After charging the battery, check each element electrolyte level and density. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery.
  • Page 57 Vespa LX 50 Electrical system Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger 1)- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries, with a specific gravity of 1.26, corresponding to 30° Bé, at a minimum temperature of 15°C until the upper level is reached.

  • Page 58: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 59 Vespa LX 50 Engine from vehicle Removal of the engine from the vehicle Removing the engine from the frame -Disconnect the battery. -Remove the muffler assembly. - Remove the rear wheel. - Remove the mechanical transmission of the rear brake.
  • Page 60 INDEX OF TOPICS NGINE...

  • Page 61: Automatic Transmission

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

  • Page 62: Removing The Driven Pulley Shaft Bearing

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

  • Page 63: Removing The Driven Pulley

    Vespa LX 50 Engine Removing the driven pulley - Lock the clutch bell housing with the specific tool. - Remove the nut, the clutch bell housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.
  • Page 64 Vespa LX 50 Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven...
  • Page 65 Vespa LX 50 Engine - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION...
  • Page 66 Vespa LX 50 Engine Stationary driven half-pulley/Standard diame- Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diam- eter admitted after use Ø 33.96 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.
  • Page 67 Vespa LX 50 Engine Refitting the driven half-pulley bearing - Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit the new roller bearing with the wording visible from the outside.

  • Page 68: Refitting The Driven Pulley

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

  • Page 69: Removing The Driving Pulley

    Vespa LX 50 Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley. - Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.
  • Page 70 Vespa LX 50 Engine 4) Check the integrity of the sliding blocks of the contact plate. - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inside diameter «A». - Measure outside diameter «B» of the pulley slid- ing bushing shown in the figure.
  • Page 71 Vespa LX 50 Engine ORDER TO AVOID WRONG TIGHTENING AND CONSE- QUENTLY DAMAGING THE CRANKSHAFT KNURLING. Specific tooling 020451Y Starting ring gear lock Locking torques (N*m) Crankshaft pulley nut 18 to 20 + 90° Nm For 25 km/h engine type versions, the limit washer is 5.5 mm thick...

  • Page 72: Specific Tooling

    Vespa LX 50 Engine Removing the wheel axle bearings - Remove the oil seal and the Seeger ring. - Remove the bearing by pushing from the outside towards the inside of the gear compartment, using the appropriate punch. Specific tooling...
  • Page 73 Vespa LX 50 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents. - Check capacity ( A ) of the transmission gear (wear, deformations, etc.)

  • Page 74: Flywheel Cover

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

  • Page 75: Cooling Fan

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

  • Page 76: Removing The Stator

    Vespa LX 50 Engine Removing the stator - Remove the three stator fixings shown in the photo - Remove the two pick-up fixings shown in the photo - Remove the stator with the wiring Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
  • Page 77 Vespa LX 50 Engine Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor.

  • Page 78: Removing The Intake Manifold

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

  • Page 79: Inspecting The Small End

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

  • Page 80: Inspecting The Piston

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

  • Page 81: Removing The Piston

    Vespa LX 50 Engine Inspecting the cylinder - Check that the cylinder does not show seizures. Otherwise, replace it or adjust it respecting the al- lowable increases - Measure the internal diameter of the cylinder with a bore meter, according to the directions given in...
  • Page 82 Vespa LX 50 Engine - Use new wrist pin snap rings. - Use new cylinder base gasket. - Before refitting carefully clean all the surfaces. - Use oil to be mixed during the fitting of the piston and the cylinder.

  • Page 83: Crankcase - Crankshaft

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

  • Page 84: Removing The Crankshaft

    Vespa LX 50 Engine Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length. - Remove the crankshaft from the transmission side half crankcase Specific tooling...

  • Page 85: Specific Tooling

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

  • Page 87: Crankshaft Oil Seals

    Vespa LX 50 Engine - Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement - Insert at least three clamping screws and tighten up rapidly - Insert the other 5 screws and tighten them to the specified torque.

  • Page 88: Oil Pump

    Vespa LX 50 Engine Refitting - Install a new flywheel-side oil seal only with the special tool's punch The flywheel-side oil seal is recognised by its smaller diameter N.B. THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE WITH THE FITTED WRENCH...

  • Page 89: Fuel Supply

    Vespa LX 50 Engine Remove the tube passage seal from the crank- case shown in the figure Refitting To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure...
  • Page 90 Vespa LX 50 Engine OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB- TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT- LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUC- TION PULSATION AND THEREBY GUARANTEE A CON- STANT TAP FLOW RATE.

  • Page 91: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 92: Removing The Front Wheel

    Vespa LX 50 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the five Allen screws that fix the wheel to the hub. N.B. BEFORE REMOVING THE WHEEL HUB, REMOVE THE BRAKE CALLIPER.
  • Page 93 Vespa LX 50 Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide - Heat the roller bearing seat with a heat gun...

  • Page 94: Refitting The Front Wheel

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

  • Page 95: Steering Column

    Vespa LX 50 Suspensions Steering column Removal After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork. Specific tooling 020055Y Wrench for steering tube ring nut Overhaul -The front suspension service operation is useful to replace the connecting parts between the steering tube and the swinging hub of the front wheel holder, provided that the steering tube and the wheel holder hub are in excellent conditions.
  • Page 96 Vespa LX 50 Suspensions Specific tooling 020021Y Front suspension service tool - Use the tool fitted with part 20* and part 21* on its stem as shown in the figure. - Push the two roller casings with the handgrip until their bottoms make contact with the pin end.
  • Page 97 Vespa LX 50 Suspensions - Lubricate the sealing rings with mineral oil and half-fill the roller casings with grease. - Insert the sealing ring on the pin and the roller bushing with wedging washers at the same time. - Remove the specific tool, then the part 5 (guiding) partially ejected in the previous assembly stage;...
  • Page 98 Vespa LX 50 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; NLGI 2; ISO-L-XBCIB2...

  • Page 99: Front Shock Absorber

    Vespa LX 50 Suspensions When fitting the fork, lubricate with the steering bearing tracks with the recommended grease. Tighten the lower ring nut "A" and the upper ring nut "B" to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering...
  • Page 100 Vespa LX 50 Suspensions Removal - Remove the steering tube - Remove the shock absorber lower clamps - Remove the shock absorber upper clamps Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
  • Page 101 Vespa LX 50 Suspensions - Before refitting the bracket in the wheel axle, place the O-ring as shown in the photograph so that it is correctly placed after fitting the bracket. - Refit the washer and the Seeger ring. - Refit the lower screws fixing the shock absorber...

  • Page 102: Steering Bearing

    Vespa LX 50 Suspensions - Suitably hold the brake calliper - shock absorber attachment bracket - Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y 52x55-mm Adaptor - Assemble a new roller bearing on the shock ab-...

  • Page 103: Removing The Rear Wheel

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

  • Page 104: Refitting The Rear Wheel

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

  • Page 105: Shock Absorbers

    Vespa LX 50 Suspensions Refitting For rifting, respect the locking torques Locking torques (N*m) Part C Part B Part A 33 ÷ 41 44 ÷ 52 33 ÷ 41 Shock absorbers SUSP - 105...
  • Page 106 Vespa LX 50 Suspensions Removal - To replace the shock absorber remove the bat- tery access flap to reach and remove the shock absorber/ frame anchoring nut. Then remove the shock absorber/engine anchorage nut. - When refitting, tighten the shock absorber/chas- sis anchoring nut and the shock absorber/engine pin to the prescribed torque.
  • Page 107 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 108: Front Brake Calliper

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

  • Page 109: Front Brake Disc

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

  • Page 110: Disc Inspection

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

  • Page 111: Recommended Products

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

  • Page 112: Rear Drum Brake

    Vespa LX 50 Braking system Rear drum brake Once the muffler and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner. 2. Remove the shoe with the aid of a lever.
  • Page 113 INDEX OF TOPICS CHAS HASSIS...

  • Page 114: Instrument Panel

    Vespa LX 50 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 115 Vespa LX 50 Chassis Headlight assy. After removing the front handlebar cover, operate the 4 screws shown in the figure and remove the headlight. Knee-guard - Unscrew the 2 screws shown in the figure placed under the front grille. - Remove the 3 screws shown in the figure, placed inside the glove-box;...
  • Page 116 Vespa LX 50 Chassis Footrest - Operate on the 3 screws shown in the figure once the glove-box and fairing have been removed. Air filter - Remove the helmet compartment. - after removing the side fairing, remove the 2 screws fixing the filter box to the engine, indicated in the figure.

  • Page 117: Front Mudguard

    Vespa LX 50 Chassis Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to re- move the front mudguard - Remove the three mudguard-steering tube clamps indicated in the figure Front central cover - Remove the "PIAGGIO"...
  • Page 118 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 119 Vespa LX 50 Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...

  • Page 120: Static Test

    Vespa LX 50 Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.

  • Page 121: Functional Inspection

    Vespa LX 50 Pre-delivery - 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. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
  • Page 122 INDEX OF TOPICS TIME...
  • Page 123 Vespa LX 50 Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 engine from frame - removal and re- fitting...
  • Page 124 Vespa LX 50 Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement TIME - 124...
  • Page 125 Vespa LX 50 Time Crankshaft RANKSHAFT Code Action Duration 001118 Main bearings - Replacement 001100 Clutch-side oil seal - Replacement 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement TIME - 125...

  • Page 126: Cylinder Assy

    Vespa LX 50 Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder / piston - Inspection / clean- TIME - 126...

  • Page 127: Cylinder Head Assy

    Vespa LX 50 Time Cylinder head assy. HEAD Code Action Duration 001097 Cooling hood - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 001013 Intake manifold - Replacement 001178 Disc pack - Replacement TIME - 127...

  • Page 128: Driven Pulley

    Vespa LX 50 Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 128...

  • Page 129: Oil Pump

    Vespa LX 50 Time Oil pump OIL PUMP Code Action Duration 001028 Mix movement gear socket - Re- placement 001019 Mixer belt - replacement 001018 Mixer - Replacement TIME - 129...
  • Page 130 Vespa LX 50 Time Final gear assy. INAL REDUCTION GEAR Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replacement TIME - 130...

  • Page 131: Driving Pulley

    Vespa LX 50 Time Driving pulley DRIVING PULLEY Code Action Duration 001066 Driving pulley - Removal and refitting 001086 Driving half-pulley - replace 001011 Driving belt - Replacement 001177 Variator rollers / shoes - Replace- ment TIME - 131...

  • Page 132: Transmission Cover

    Vespa LX 50 Time Transmission cover TRANSMISSION COVER Code Action Duration 001087 Flywheel cover - Replacement 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement TIME - 132...

  • Page 133: Starter Motor

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

  • Page 134: Flywheel Magneto

    Vespa LX 50 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001109 Cooling fan - Replacement 001173 Rotor - Replacement 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement 001087 Flywheel cover - Replacement TIME - 134...
  • Page 135 Vespa LX 50 Time Carburettor CARBURETTOR Code Action Duration 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 001081 Automatic choke - Replacement 001082 Carburettor heating resistor - Re- placement 003058 Carburettor - Adjustment...

  • Page 136: Exhaust Pipe

    Vespa LX 50 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 136...

  • Page 137: Air Cleaner

    Vespa LX 50 Time Air cleaner AIR CLEANER Code Action Duration 004122 Air cleaner carburettor fitting - Re- placement 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement TIME - 137...
  • Page 138 Vespa LX 50 Time Frame RAME Code Action Duration 004001 Frame - 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 139: Centre-Stand

    Vespa LX 50 Time Centre-stand TAND Code Action Duration 004004 Stand - Replacement 004171 Stand support plate - Replacement TIME - 139...
  • Page 140 Vespa LX 50 Time Footrests OOTREST Code Action Duration 004178 Footrest - Replacement 004078 Front/rear footrest rubber - Replace- ment TIME - 140...

  • Page 141: Rear Cover

    Vespa LX 50 Time Rear cover HIELD BACK PLATE Code Action Duration 004174 Trunk levers - Replacement 004065 Legshield, rear part - Removal and refitting 004081 Glove box door - Replacement 004082 Top box gasket - Replacement TIME - 141...

  • Page 142: Underseat Compartment

    Vespa LX 50 Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 005046 Battery cover - change 004011 Central frame cover - Replacement 004071 Battery compartment - replacement TIME - 142...
  • Page 143 Vespa LX 50 Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder support - Re- placement 005048 Licence plate holder - Replacement 005032 number plate light glass - Replace- ment TIME - 143...
  • Page 144 Vespa LX 50 Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 144...

  • Page 145: Fuel Tank

    Vespa LX 50 Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Replace- ment 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 004109 Fuel tank breather - change...

  • Page 146: Oil Reservoir

    Vespa LX 50 Time Tank oil OIL RESERVOIR Code Action Duration 005018 Oil reservoir float - Replacement 004017 Oil reservoir - Replacement 004095 Oil reservoir cock - Replacement 004091 Oil reservoir hose - Replacement Rear shock-absorber TIME - 146...

  • Page 147: Rear Shock Absorber

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

  • Page 148: Handlebar Covers

    Vespa LX 50 Time Handlebar covers TAVOLA COPRIMANUBRIO Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar covers - Replace- ment 005078 Odometer glass - Replacement 005014 Instrument panel - Replacement TIME - 148...

  • Page 149: Handlebar Components

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

  • Page 150: Swinging Arm

    Vespa LX 50 Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-frame connection swinging arm - Replacement TIME - 150...
  • Page 151 Vespa LX 50 Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004131 Luggage rack support - Replacement TIME - 151...
  • Page 152 Vespa LX 50 Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - change 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Headlight bulbs - Replacement 005005 Taillight - change...

  • Page 153: Front Wheel

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

  • Page 154: Electric Devices

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

  • Page 155: Electronic Controls

    Vespa LX 50 Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement 005016...
  • Page 156 Vespa LX 50 Time Transmissions RANSMISSION Code Action Duration 002051 Odometer transmission assembly - Replacement 002012 Splitter - Replacement 002057 Carburettor / splitter transmission complete - Replacement 002058 Mix / splitter transmission complete - Replacement 002053 Rear brake transmission complete -...

  • Page 157: Brake Callipers

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

  • Page 158: Front Suspension

    Vespa LX 50 Time Front suspension FRONT SUSPENSION Code Action Duration 003045 Steering tube - Replacement 003010 Front suspension - Service 003035 Shock absorber support and brake calliper - Replacement 001064 Odometer reel - Replacement 003044 Shock absorber cover - Replace-...
  • Page 159 Vespa LX 50 Time Secondary air box SECONDARY AIR HOUSING Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001163 Muffler secondary air connection -...
  • Page 160 Air filter: 33, 116 Battery: 42, 48, 54, 55 Brake: 108–112, 157 Carburettor: 12, 30, 135 Engine stop: Fuel: 41, 89, 145 Headlight: 36, 115 Horn: Hub oil: 32 Identification: 8 Instrument panel: 114 Maintenance: 7, 28 Saddle: Shock absorbers: 105 Spark plug: 31 Stand: Start-up:...

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