MANUALE STAZIONE DI SERVIZIO 665229 (IT), 665230 (EN), 665231 (FR), 665232 (DE), 665233 (ES), 665234 (PT), 665235 (NL), 665236 (EL) Vespa LX 50 4valvole
MANUALE STAZIONE DI SERVIZIO Vespa LX 50 4valvole 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.
MANUALE STAZIONE DI SERVIZIO Vespa LX 50 4valvole Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
INDEX OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM CHASSIS PRE-DELIVERY TIME BRAK SYS CHAS PRE DE TIME
INDEX OF TOPICS CHARACTERISTICS CHAR
Characteristics Vespa LX 50 4valvole Rules Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin.
Vespa LX 50 4valvole Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Chassis prefix Engine prefix Desc.
Vespa LX 50 4valvole Characteristics WEIGHT AND DIMENSIONS Specification Dry weight Width Length Wheelbase Maximum height Desc./Quantity 102 ± 5 740 mm 1755 mm 1290 mm 1140 mm Engine ENGINE Specification Type Bore Stroke Cubic capacity MAX Power MAX torque Compression ratio Timing system Desc./Quantity single-cylinder, four-stroke and four-valve, air-cooled engine 39 mm 41.8 mm 49,9 cm³ 3.2 kW at 8250 rpm 3.8 Nm at 7750 rpm 11.5 - 12.
Vespa LX 50 4valvole Characteristics Capacities CAPACITY Specification Engine oil Transmission oil Fuel tank (reserve) Desc./Quantity ~ 850 cm³ 80 cm³ ~ 8.5 l (2 l) Electrical system When the advance check is carried out with a stroboscopic gun, add 10° flywheel keying to the table below. ELECTRICAL COMPONENTS 1 2 3 4 5 Specification Ignition advance Spark plug Battery Fuses Generator Desc./Quantity reference in table NGK ER9EH-N 12V - 9Ah One 15A fuse - Two 7.
Characteristics CHECKING REMOTE CONTROLS «A» OPERATING AS CIRCUIT BREAKERS 1) Check that, given regular conditions, there is no continuity between terminals 30 and 87. 2) Apply 12V voltage to power terminals 85 and 86 of the remote control. 3) With the remote control powered, check that there is continuity between terminals 30 and 87. 4) If these conditions are not fulfilled, the remote control is damaged and must be replaced.
Vespa LX 50 4valvole Characteristics STARTER BUTTON HORN BUTTON STOP BUTTON Resistance between green cable and ground connection: approx.
Vespa LX 50 4valvole Characteristics - Primary resistance: 0.5 ÷ 0.6 Ohm - Resistance between primary and ground connection: infinite - Resistance between primary and HV output: 3 ÷ 3.6 kOhm - Shielded cap: 5000 Ohm - Power: 120 W - resistance between BLUE cable and GROUND CONNECTION: 1 Ohm Frame and suspensions CHASSIS AND SUSPENSIONS Specification Type FRONT SUSPENSION Front suspension stroke Trail (suspension rebounded/compressed) Rear suspension Rear suspension travel: Desc.
Vespa LX 50 4valvole Characteristics Specification Front tyre pressure Rear tyre pressure: Light alloy rims (Front rim) Light alloy rims (rear rim) Desc./Quantity 1.6 bar 2 bar 2.50" x 11" 3.00 x 10" N.B. CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.
Vespa LX 50 4valvole Characteristics N.B. FOR SAFETY LOCKS, SEE THE «PRE-DELIVERY» CHAPTER. FRONT BRAKE Name Brake fluid pump-hose fitting Brake fluid pipe-calliper fitting Screw tightening calliper to support Brake disc screw Oil bleed valve (on the calliper) Handlebar pump Torque in Nm 8 ÷ 12 20 ÷ 25 20 ÷ 25 5 ÷ 6.
Vespa LX 50 4valvole Characteristics Cylinder - piston assy. COUPLING BETWEEN PISTON AND CYLINDER Name Cylinder Cylinder Piston Piston Cylinder 1st oversize Cylinder 1st oversize Piston 1st oversize Piston 1st oversize Cylinder 2nd oversize Cylinder 2nd oversize Piston 2nd oversize Piston 2nd oversize Cylinder 3rd oversize Cylinder 3rd oversize Piston 3rd oversize Piston 3rd oversize Initials A B C D A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3 Cylinder 38.993 ÷ 39.000 39.000 ÷ 39.007 39.007 ÷ 39.014 39.
Characteristics Vespa LX 50 4valvole - Measure the diameter of the bearings on the piston. Characteristic Pin seat diameter 13 +0.005 +0.010 mm - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS. Characteristic Standard clearance 0.005 ÷ 0.014 mm - Carefully clean the seal housings.
Vespa LX 50 4valvole Characteristics - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D). Characteristic Maximum allowable run-out: 0.05 mm Piston rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening, see figure, of the sealing rings using a thickness gauge.
Vespa LX 50 4valvole Characteristics Name 2nd Compression ring Oil scraper ring 1st Compression ring 1st Oversize 2nd Compression ring 1st Oversize Oil scraper ring 1st Oversize 1st Compression ring 2nd Oversize 2nd Compression ring 2nd Oversize Oil scraper ring 2nd Oversize 1st Compression ring 3rd Oversize 2nd Compression ring 3rd Oversize Oil scraper ring 3rd Oversize Description Dimensions 39 x 1 39 x 2 39.2 x 1 Initials A A A Quantity 0.05 ÷ 0.20 0.20 ÷ 0.70 0.08 ÷ 0.20 39.2 x 1 A 0.05 ÷ 0.
Vespa LX 50 4valvole Characteristics Measure the bearings along X and Y axes Characteristic Crankshaft bearing, transmission side 20 -0.012 -0.025 mm Crankshaft bearing, flywheel side 17 +0.007 0 mm - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft.
Characteristics Vespa LX 50 4valvole - Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure. N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETECTED, TRY STRAIGHTENING THE CRANKSHAFT BY INSERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEEDED. IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED, REPLACE THE CRANKSHAFT. Characteristic Off-line maximum admitted - A 0.15 mm Off-line maximum admitted - B 0.
Vespa LX 50 4valvole Characteristics - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn. - It is advisable to replace the head if any failure is found. Characteristic Maximum allowable run-out: 0.1 mm - Insert the valves into the cylinder head.
Vespa LX 50 4valvole Characteristics Measure the unloaded spring length. • Standard length: 31.3 mm • Admissible limit after use: 29.3 - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45° mill and then grind.
Vespa LX 50 4valvole Characteristics - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Inlet drainage Desc./Quantity 3.970 ÷ 3.985 mm 3.960 ÷ 3.975 mm MINIMUM DIAMETER PERMITTED Specification Inlet drainage Desc./Quantity 3.958 mm 3.945 mm - Calculate the clearance between valve and valve guide.
Vespa LX 50 4valvole Characteristics Measure the valve guides VALVE GUIDE DIAMETER Specification Valve guide Valve guide Desc./Quantity Standard diameter: 4 + 0.012 mm Maximum admissible diameter: 4 + 0.022 mm - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. INLET Specification Standard clearance Admissible limit Desc./Quantity 0.015 ÷ 0.042 mm 0.06 mm OUTLET Specification Standard clearance Admissible limit Desc./Quantity 0.025 ÷ 0.
Vespa LX 50 4valvole Characteristics - Inspect the cam shaft for signs of abnormal wear on the cams. Characteristic Standard diameter - Bearing A: Ø 12 +0.002 +0.010 mm Standard diameter - Bearing B: Ø 16-0.015 -0.023 mm Minimum diameter allowed - Bearing A: Ø 11.98 mm Minimum diameter allowed - Bearing B: Ø 15.96 mm -Using a gauge, measure the cam height.
Vespa LX 50 4valvole Characteristics Slot packing system Characteristic Compression ratio 11.5 ÷ 12 : 1 PISTON PROTRUSION CHECK Name shimming_1 shimming_2 Measure A 1.7 ÷ 1.95 1.95 ÷ 2.2 Thickness 0.25 0.
INDEX OF TOPICS TOOLING TOOL
Vespa LX 50 4valvole Tooling TOOLS TOOL - 28 Stores code 001467Y008 Description Pliers to extract 17 mm ø bearings 001467Y029 Bell for bearings, O.D. 38 mm 004499Y Bearing extractor.
Vespa LX 50 4valvole Tooling Stores code 020055Y Description Wrench for steering tube ring nut 020074Y 020150Y Tool to align crankshaft Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y Bearing fitting base TOOL - 29
Vespa LX 50 4valvole Tooling TOOL - 30 Stores code 020288Y Description Fork to assemble piston on cylinder 020291Y Valve fitting/ removal tool 020306Y Punch for assembling valve seal rings 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter
Vespa LX 50 4valvole Tooling Stores code 020332Y Description Digital rpm indicator 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 020359Y 37x40-mm Adaptor 42x47-mm Adaptor TOOL - 31
Vespa LX 50 4valvole Tooling TOOL - 32 Stores code 020360Y Description 52x55-mm Adaptor 020362Y 12 mm guide 020363Y 20-mm guide 020364Y 25-mm guide 020376Y Adaptor handle 020431Y Valve oil seal extractor
Vespa LX 50 4valvole Tooling Stores code 020432Y Description Tool to fit the start-up sector spring 020439Y 17-mm guide 020444Y 020448Y Pin fitting/removal tool Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting/removal tool 020451Y 020452Y Driving pulley lock wrench Tube for removing and refitting the driven pulley shaft TOOL - 33
Vespa LX 50 4valvole Tooling TOOL - 34 Stores code 020456Y Description Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 020683Y Valve pressing member
INDEX OF TOPICS MAINTENANCE MAIN
Vespa LX 50 4valvole Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
Vespa LX 50 4valvole Maintenance - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condition. -The throttle valve should move freely in the chamber. Replace valve in case of wear due to excessive clearance. - If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor.
Maintenance Vespa LX 50 4valvole Checking the spark advance The vehicle is fitted with a variable advance electronic device. There are two timing references on the flywheel cover in order to ensure a better precision when detecting the reference on the fan. CAUTION SHOULD THE FLASH INDICATIONS BE UNSTABLE AND THE RPM INDICATION DOES NOT CORRESPOND WITH THE TRUE ENGINE SPEED VARIATION (FOR EXAMPLE, VALUES SHOWN ARE HALVED), INSTALL A 10 ÷ 15 KΩ RESISTIVE CABLE CONNECTED IN SERIES TO AN HV CABLE.
Vespa LX 50 4valvole Maintenance Spark plug Disconnect and remove the spark plug tube. - Examine it carefully and replace it if the insulator is chipped or cracked. - Measure electrode gap with a thickness gauge and, if necessary, adjust the gap by carefully bending the outer electrode forward or away. - Make sure the sealing washer is in good conditions. - Fit the spark plug, screw it manually and lock it to the prescribed torque with a spark plug spanner. Characteristic Electrode gap 0.5 ÷ 0.
Maintenance SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Replacement Remove the oil filler cap/dipstick "A". - Unscrew the oil drainage plug "B" shown in the figure and drain out all the oil.
Vespa LX 50 4valvole Maintenance Replacement Loosen the oil filler plug. - Unscrew the drainage plug from the mesh filter on the flywheel side, and let the oil drain off. - Tighten the drainage plug and refill with ~ 600-650 cm³ of oil. Check Park the vehicle on a level surface and rest it on its stand (cold engine). - Check that the oil level is between the MAX and MIN marks on the dipstick. - The MAX level reference indicates ~ 850 cm³ in the engine.
Maintenance - After this operation, refit the filter and screw the oil cap at the prescribed torque using a new ORing - Refill the engine with oil through the oil filling hole located in the oil sump. - Engine oil capacity: ~ 850 cc. - Lock the cap manually. N.B. Run the engine for a couple of minutes and check the oil level when the engine is cold. The level should always be below the MAX mark N.B.
Vespa LX 50 4valvole Maintenance Checking the valve clearance - Remove the spark plug access cover, undo the 4 fixing screws indicated in the figure and remove the tappet cover. - To check valve clearance, centre the reference marks of the timing system point as described above. - Use a thickness gauge to check valve clearance - If the valve clearance values, inlet and outlet respectively, differ from those indicated below, replace the calibrated pads in order to restore the correct valve clearance.
Maintenance CO check The check may be necessary in the event of irregularities in the engine performances, or when adjusting the engine idle speed. - The test must be carried out only after having carefully cleaned all carburettor components with the air filter clean and the spark plug in good conditions. 1) Warm up the engine by riding the vehicle for about 5-10 minutes, as this is the time required for the choke device to disengage.
Vespa LX 50 4valvole Maintenance 10) Slowly twist the throttle handgrip, bringing the engine up to a speed of 4,000 rpm and then release it; check the idle speed is the same as before, otherwise repeat the operations starting from point (3). Specific tooling 020332Y Digital rpm indicator 494929Y Exhaust fumes analyser 020331Y Digital multimeter SAS filters inspection and cleaning Unscrew the two screws «A» of the right side fairing and remove it.
INDEX OF TOPICS TROUBLESHOOTING TROUBL
Vespa LX 50 4valvole Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Air filter obstructed or dirty.
Vespa LX 50 4valvole Troubleshooting Possible Cause Failing automatic starter on the carburettor Wrong ignition advance Incorrect valve sealing or valve adjustment Rpm too low at start-up or engine and start-up system damaged Altered fuel characteristics Carburettor nozzles clogged or dirty Operation Check the electrical wiring and mechanical movement, replace if necessary.
Vespa LX 50 4valvole Troubleshooting High fuel consumption EXCESSIVE FUEL CONSUMPTION Possible Cause Air filter blocked or dirty. Operation Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
Vespa LX 50 4valvole Troubleshooting Electrical system Battery BATTERY Possible Cause Operation The battery is the electrical device in the system that requires The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months.
Vespa LX 50 4valvole Possible Cause Troubleshooting Operation In conclusion, check the tightening torque of the wheel hub, the brake calliper, the shock absorber disk in the attachment to the hub and the steering tube. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Oil leakage from suspension Operation Replace the damper.
INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS
Vespa LX 50 4valvole Electrical system 1. Light remote control 2.
Electrical system 3.Town light bulb 4. Instrument panel lighting bulbs 5. Headlight warning light 6. Filament for rear position light 7. High-beam warning light 8. Headlight bulb 9.Automatic starter 10.NTC temperature sensor 11.Electronic ignition device 12. Turn indicator switch 13. Left turn indicator bulbs 14. Turn indicator warning light 15. Right turn indicator bulbs 16.HV coil 17.Key switch contacts 18.Diagnostics socket 19.Fuse 10A 20.PTC 21.Horn button 22.Horn 23.Stop buttons 24.
Vespa LX 50 4valvole Electrical system Rs = Pink, R = Red, Vi = Purple, V = Green Conceptual diagrams ELE SYS - 55
Electrical system Ignition 11.
Vespa LX 50 4valvole Electrical system 16.HV coil 17.Key switch contacts 19.Fuse 10A 33.Fuse 15A 34.Battery 35.Key switch contacts 38.
Electrical system Headlights and automatic starter section 1.
Vespa LX 50 4valvole Electrical system 2. Light switch 3.Town light bulb 4. Instrument panel lighting bulbs 5. Headlight warning light 6. Filament for rear position light 7. High-beam warning light 8. Headlight bulb 9.Automatic starter 11.Electronic ignition device 20.PTC 27.Voltage regulator 33.Fuse 15A 34.Battery 35.Key switch contacts 36.Fuse 7.5A 37.
Electrical system Battery recharge and starting 23.
Vespa LX 50 4valvole Electrical system 27.Voltage regulator 29.Stop light filament 30.Starter button 31.Starter motor 32.Starter remote control switch 33.Fuse 15A 34.Battery 35.Key switch contacts 36.Fuse 7.5A 37.
Electrical system Level indicators and enable signals section 10.
Vespa LX 50 4valvole Electrical system 11.Electronic ignition device 24.Low fuel warning light 25.Fuel gauge 26.S.I.S. Valve 28.Fuel level transmitter 33.Fuse 15A 34.Battery 35.Key switch contacts 36.Fuse 7.
Electrical system Turn signal lights 12.
Vespa LX 50 4valvole Electrical system 13. Left turn indicator bulbs 14. Turn indicator warning light 15. Right turn indicator bulbs 21.Horn button 22.Horn 27.Voltage regulator 33.Fuse 15A 34.Battery 35.Key switch contacts 36.Fuse 7.5A 37.
Vespa LX 50 4valvole Electrical system Checks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all replace the control unit by another one in operating conditions. Remember that the engine must be off to disconnect and replace the control unit. If after replacement the vehicle starts properly, the control unit is failing and must be replaced.
Vespa LX 50 4valvole Electrical system Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the 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. No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure: - Check the Pick-Up.
Electrical system Vespa LX 50 4valvole If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor. Specific tooling 020409Y Multimeter adaptor - Peak voltage detection Electric characteristic HV coil secondary resistance 3000 ÷ 3600 Ohm - Pick-Up Disconnect the ECU connector and connect the positive terminal to connector No. 3 (green) and the negative terminal to connector No. 4 (black).
Vespa LX 50 4valvole Electrical system Electric characteristic High voltage coil voltage value High voltage coil voltage value: > 100 Volt Stator check - Using a tester, check the resistance between the brown-earth and black-earth terminal. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED. Electric characteristic Stator : Brown-earth approx.
Electrical system properly. Check the cable harness from the light switch to the remote control and whether the switch works properly . If no voltage is detected, try connecting the negative probe directly to earth; if voltage is detected with this operation, check the earth wiring of the regulator; otherwise, replace the regulator because it is failing.
Vespa LX 50 4valvole Electrical system which may cause a short circuit to ground (thus preventing damaging the regulator). Afterwards measure the resistance between contact 3 (Orange) and contact 2 (Black) of the voltage regulator (with connector disconnected) If the value measured is far from that indicated, replace the regulator because it is in short circuit. b) Battery fails to recharge (regulator interrupted).
Electrical system Turn signals system check 4) TURN INDICATORS NOT WORKING If the turn indicators do not work, do the following: - Remove the regulator connector and place the tester probes between the orange cable (3) and the black cable (2). - Turn the key switch to ON and check that the battery is getting voltage. If no voltage is detected, repeat the test now between the orange cable and the ground lead.
Vespa LX 50 4valvole Electrical system Connectors ELECTRONIC STARTER SECTION "A" 1. HV COIL CONTROL 2. KEY SWITCH CONTACTS TO GROUND 3. HV COIL POSITIVE SECTION "B" 1. KEY POSITIVE 2. STARTER POWER SUPPLY 3. PICK UP SIGNAL 4. GROUND 5. SOLENOID VALVE 6. NTC TEMPERATURE SENSOR 7. LIGHT REMOTE CONTROL 8. DIAGNOSIS SOCKET VOLTAGE REGULATOR 1. LIGHTING SYSTEM POWER SUPPLY (alternating) 2. GROUND 3. BATTERY POSITIVE 4. FROM FLYWHEEL (alternating) 5.
INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE
Vespa LX 50 4valvole Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Undo the 2 screws fixing the muffler to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover. Removal of the engine from the vehicle Smontaggio motore dal telaio -Disconnect the battery. -Remove the muffler assembly. - Remove the rear wheel. - Remove the rear brake mechanical transmission.
INDEX OF TOPICS ENGINE ENG
Vespa LX 50 4valvole Engine Automatic transmission Transmission cover - Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehicle, it is necessary to remove the transmission cooling coupling and the air filter housing retainers. N.B. USE A MALLET ON THE APPROPRIATE COUPLINGS TO REMOVE THE COVER. Kickstart -To remove the start up pinion push the starter lever to facilitate extracting the pinion.
Engine Vespa LX 50 4valvole Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing. N.B. IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DIAMETER EXTRACTOR CAN BE USED.
Vespa LX 50 4valvole Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the inner diameter of the clutch bell. Characteristic Clutch bell diameter/standard value Ø 107+0.2 +0 mm Clutch bell diameter/max. value allowed after use Ø 107.5 mm Eccentricity measured /max. 0.20 mm Removing the clutch - Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and have the central screw make contact.
Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Vespa LX 50 4valvole Engine Removing the driven half-pulley bearing - Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLIERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING. Specific tooling 001467Y029 Bell for bearings, O.D. 38 mm - Remove the ball bearing retention snap ring. - Expel the ball bearing from the side of the clutch housing by means of the special tool. N.B.
Engine Vespa LX 50 4valvole Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two Orings. - Measure the inside diameter of the mobile halfpulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø 34.08 mm - Check the belt contact surfaces. - Insert the new oil seal and O-rings on the mobile half-pulley. - Fitting the half-pulley on the bushing.
Vespa LX 50 4valvole Engine 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation - Measure the free length of the spring Characteristic Standard length 118 mm Minimum length allowed after use XXXX - Check the thickness of the clutch mass friction material. -The masses must not show traces of lubricants; otherwise, check the driven pulley unit. N.B.
Engine - Reassemble the nut securing the clutch and tighten to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCKET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE NUT IN CONTACT WITH THE CLUTCH Locking torques (N*m) Nut locking clutch unit on pulley 55 ÷ 60 Nm Refitting the driven pulley -Refit the driven pulley assembly, the clutch bell and the nut, using the specific tool.
Vespa LX 50 4valvole 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.
Engine 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting. N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.
Vespa LX 50 4valvole Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the return spring. - Remove the damaged components. - Grease the spring. - Remove the toothed sector and load the spring with an appropriate tool. - Refit the washer, the Seeger and the Kick-start lever.
Engine Removing the hub cover • Remove the transmission cover • Remove the clutch assembly • Discharge the rear hub oil. • Remove the 5 screws indicated in the figure. • Remove the hub cover with driven pulley shaft. See also Refitting the clutch Removing the wheel axle - Remove the intermediate gear and the complete gear wheel axle. - When removing the intermediate gear pay attention to the various shim adjustments. Removing the wheel axle bearings - Remove the oil seal and the Seeger ring.
Vespa LX 50 4valvole Engine Removing the driven pulley shaft bearing - Remove the Seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane. - Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.
Engine Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the specific tool positioned under the press and insert the driven pulley axle. - Refit the oil seal flush with the cover. Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft • Heat the hub cover and insert the bearing with the specific punch. • Fit the snap ring with the concave or radial part on the bearing side. N.B.
Vespa LX 50 4valvole Engine Refitting the ub cover - Refit the whole wheel axle. - Refit the intermediate gear paying attention to the two shim washers. - Apply LOCTITE 510 for surfaces to the hub covers and refit the same with driven pulley shaft. - Refit the 5 screws and tighten them to the specified torque. N.B. CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BEFORE APPLYING A NEW ONE.
Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque. Removing the stator - Remove the 2 Pick-Up screws and the 2 stator fixing screws indicated in the figure. - Remove the stator and its wiring.
Vespa LX 50 4valvole Engine Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque. N.B. THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEMBLY.
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. Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. - Check that the flywheel splines exhibit no loosening.
Vespa LX 50 4valvole Engine Starter gear rim - Check the toothing is level and in good conditions Intermediate gear - Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns adequately. Refitting the flywheel magneto - Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings.
Engine Refitting the starter motor - Install the starter motor in its seating in the crankcase. - Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the prescribed torque. - Tighten the locking screw of the positive cable (red) on the side contact. N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.
Vespa LX 50 4valvole Engine Removing the timing system drive - Temporarily loosen the tensioner central screw and remove it together with the spring. - Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket. N.B.
Engine Removing the cam shaft - Remove the limit screw of the rocking lever pins shown in the figure. - Remove the Seeger ring retaining the camshaft bearing. - Remove pins and rocking levers. - Remove the calibrated pads N.B. MARK THE ASSEMBLY POSITION OF THE ROCKING LEVERS IN ORDER TO AVOID MISPLACING THE INTAKE AND DISCHARGE ENDS. - Remove the entire camshaft with bearing using the specific tool shown in the figure.
Vespa LX 50 4valvole Engine Removing the cylinder head - Remove the cooling covers, the timing control, the camshaft and the rocking levers. - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket. N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS AND ROCKING LEVERS WITHOUT REMOVING THE DRIVING PULLEY UNIT.
Engine Removing the cylinder - piston assy. - Remove the cylinder paying attention to the 2 cylinder centring dowels in the housing. - Remove the cylinder base gasket. To avoid damaging the piston, keep it fixed while removing the cylinder. - Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings. 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. N.B.
Vespa LX 50 4valvole Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. Characteristic Standard diameter: gudgeon pin 13 -0-0.004mm Minimum admissible diameter gudgeon pin 12.990 mm Inspecting the piston - Measure the diameter of the bearings on the piston. Characteristic Pin seat diameter 13 +0.005 +0.010 mm - Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the grooves using suitable sensors, as shown in the diagram.
Engine Vespa LX 50 4valvole Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D). Characteristic Maximum allowable run-out: 0.
Vespa LX 50 4valvole Engine SEAL RINGS Name 1st Compression ring 2nd Compression ring Oil scraper ring 1st Compression ring 1st Oversize 2nd Compression ring 1st Oversize Oil scraper ring 1st Oversize 1st Compression ring 2nd Oversize 2nd Compression ring 2nd Oversize Oil scraper ring 2nd Oversize 1st Compression ring 3rd Oversize 2nd Compression ring 3rd Oversize Oil scraper ring 3rd Oversize Description Dimensions 39 x 1 39 x 1 39 x 2 39.2 x 1 Initials A A A A Quantity 0.08 ÷ 0.20 0.05 ÷ 0.20 0.
Engine - With the opening in the position indicated on the tool, set the lock ring into position in the tool with the punch. - Rest the tool on the piston paying attention that the 90°chamfered side faces upwards as indicated in the figure. - Fit the gudgeon pin stop using the plug. CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING. Refitting the piston rings - Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superimpose.
Vespa LX 50 4valvole Engine Refitting the cylinder - Insert the cylinder base gasket. - Fit the cylinder as shown in the figure. - The piston can be kept out of the housing plane using the appropriate tool. N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
Vespa LX 50 4valvole Engine Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD CHECK Specification Standard diameter (mm) A Standard diameter (mm) B Standard diameter (mm) C 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.
Vespa LX 50 4valvole Engine Inspecting the valve sealings - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45° mill and then grind. - In case of excessive wear or damage, replace the head. - Insert the valves into the cylinder head.
Vespa LX 50 4valvole Engine - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Inlet drainage Desc./Quantity 3.970 ÷ 3.985 mm 3.960 ÷ 3.975 mm MINIMUM DIAMETER PERMITTED Specification Inlet drainage - Calculate the clearance between valve and valve guide. - Check the concentricity of the valve head by arranging a dial gauge at right angle relative to the valve head and rotate it on a "V" shaped abutment.
Vespa LX 50 4valvole Engine Inspecting the valve stem guide clearance Measure the valve guides VALVE GUIDE DIAMETER Specification Valve guide Valve guide Desc./Quantity Standard diameter: 4 + 0.012 mm Maximum admissible diameter: 4 + 0.022 mm - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. INLET Specification Standard clearance Admissible limit Desc./Quantity 0.015 ÷ 0.042 mm 0.
Vespa LX 50 4valvole Engine Refitting the valves - Lubricate the valve guides with graphite grease. - Place the lower caps of the valve spring on the head. - Use the punch to fit the 4 sealing rings one at a time. - Fit the valves, the springs and the upper caps. - Using the appropriate tool, compress the springs and insert the cotters in their seats. Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. Characteristic Standard diameter - Bearing A: Ø 12 +0.002 +0.
Vespa LX 50 4valvole Engine - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones. N.B. A BALL BEARING IS FITTED ON BEARING «A»; CONSEQUENTLY, BEARING «B» IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM Characteristic Standard height - Inlet 24.397 mm Standard height - Outlet 23.996 mm Fitting clearance Maximum admissible axial clearance: 0.
Engine Vespa LX 50 4valvole - Insert the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque. Specific tooling 020450Y Camshaft fitting/removal tool - Fit pins, inlet rocking lever and discharge rocking lever. - Lubricate the 2 rocking levers through the holes. N.B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS ESSENTIAL TO FIT A NEW BEARING. - Screw up the limit screw of the rocking lever pins and tighten it to the prescribed torque.
Vespa LX 50 4valvole Engine Refitting the timing chain - Insert the timing chain pads in their corresponding seatings, the screw and the spacer as indicated in the figure. - Tighten to the prescribed torque and check the tensioner pad moves adequately. - Insert the timing pinion in driving shaft with the chamfered side facing the insertion (towards the main bearing). - Loop the timing chain around the sprocket on the crankshaft.
Engine Vespa LX 50 4valvole Camshaft pulley screw 12 ÷ 14 Head cover screw 8 ÷ 10 Nm - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. - Insert the spring with the central screw and tighten it to the prescribed torque. - Fit the spark plug. Characteristic Electrode gap 0.5 ÷ 0.
Vespa LX 50 4valvole Engine FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD. Locking torques (N*m) Inlet manifold screw 7 ÷ 9 Nm Crankcase - crankshaft - First remove the following units: Driving pulley Driven pulley Final reduction greasing Oil pump Flywheel with stator Cylinder-piston-head unit Starter motor with cables. See also Removing the driving pulley Removal Removing the driven pulley Removing the cylinder - piston assy.
Engine - Check the axial clearance on the connecting rod. Fitting clearance Standard connecting rod axial clearance 0.15 ÷ 0.30 mm Max. connecting rod clearance 0.5 mm - Check the correct radial clearance of the connecting rod by holding the driving shaft with your hands and, with a dial gauge fitted to the rod small end, measuring the clearance, move the connecting rod vertically as shown in the figure. Fitting clearance Connecting rod radial - standard clearance 0.006 ÷ 0.018 mm Connecting rod max.
Vespa LX 50 4valvole Engine Refitting the crankshaft bearings - Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 120° C with a thermal gun (and support). - Fit the punch with guide and adaptor, place the bearing on the punch using grease (to keep it from falling). -Insert the bearing in the crankcase; if needed, use a mallet but do so with extreme care so as not to damage the engine crankcase limit stop.
Engine Vespa LX 50 4valvole Inspecting the crankshaft alignment - Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure. N.B. IF VALUES OTHER THAN THOSE ALLOWED ARE DETECTED, TRY STRAIGHTENING THE CRANKSHAFT BY INSERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEEDED. IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED, REPLACE THE CRANKSHAFT. Characteristic Off-line maximum admitted - A 0.
Vespa LX 50 4valvole Engine - Fit the gasket recommended for surfaces on the half casing on the transmission side after greasing the two faying surfaces carefully. -Insert the flywheel half casing. - Fit the 10 screws and tighten them to the prescribed torque. N.B. WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Engine - Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain. -Remove the oil seal with a tube section of 30 mm in diameter (Ø 32 mm Max). Refitting - Apply engine oil on the oil seal and it seating on the crankcase.
Vespa LX 50 4valvole Engine Removal - Remove the chain compartment cover undoing the 3 fixing screws indicated in the figure. - Take out the cover using the appropriate fusion couplings on the cover with a pair of pliers - Undo the 2 clamping screws in the figure and remove the cover over the pump control crown gear. - Block the rotation of the oil pump control gear with a screwdriver inserted through one of its pump holes.
Engine - Measure distance between rotors (inner rotor/ outer rotor) with a thickness gauge in the position shown in the picture. Characteristic Admissible maximum clearance 1 0.15 mm Measure the distance between the outer rotor and the pump body (see figure). Characteristic Admissible maximum clearance 2 0.20 mm - Check the axial clearance of the rotors using a trued bar as reference as shown in the figure. N.B. MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY.
Vespa LX 50 4valvole Engine - Fit the pulley on the pump, the central screw to the specified torque and the belleville washer. - Check that there is no seizing and/or friction during the pulley rotation. N.B. FIT THE BELLEVILLE WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY. Locking torques (N*m) Central screw 12 ÷ 14 Nm Cover screws 0.7 ÷ 0.
Engine Fuel supply - Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - By means of the MITYVAC pump apply 0.1 bar of suction to the tap. - Make sure that the suction is kept stable and that and that there are no fuel leaks. - Reconnect the suction pipe to the manifold. - Position the fuel pipe with the outlet at the point of the tap.
Vespa LX 50 4valvole Engine N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING. Removing the carburettor - To detach the carburettor from the engine, remove the two clamps anchoring the carburettor to the inlet manifold and the air intake coupling to the filter. - Remove the fuel supply pipe. - Disconnect the starter connection. - Detach the accelerator cable with the sheath that connects the plate and the support. - Remove the carburettor.
Engine - Remove the chamber components following the procedure below. - Undo the 2 screws fixing the intake pump diaphragm cover. - Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring. -Remove the accelerating pump jet together with the ball spring. - Remove the screw indicated in the figure fixing the float pin. - Remove the float and the plunger. -Remove the maximum nozzle. -Remove diffuser.
Vespa LX 50 4valvole Engine -Remove the minimum nozzle. - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT. - Remove the idle flow screw with the O-ring and the spring.
Engine Vespa LX 50 4valvole Refitting the carburettor - Before refitting, wash the carburettor body accurately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - 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. - For the starter circuit, blow the connection pipe properly with the jet.
Vespa LX 50 4valvole Engine - Wash and blow the minimum nozzle properly and reassemble it. - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindric part directed to the diffuser. - Fit the diffuser. -Assemble the maximum nozzle. - Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock absorber pin and the return clamp.
Engine - Check the diaphragm is in good conditions and remove the remaining components of the accelerating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring. N.B. REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UNDULATIONS, CRACKS OR HARDENING. - Fit the accelerating pump diaphragm cover and tighten the 2 fixing screws making sure the spring below is correctly positioned.
Vespa LX 50 4valvole Engine - Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve. N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH FACING THE INNER SIDE OF THE MEMBRANE TO BE ABLE TO FIT THE LOWER END OF THE THROTTLE VALVE SPRING. - Fit the vacuum chamber cover with the 2 fixing screws paying special attention to the spring.
Engine - The starter should disconnect progressively by means of electric heating. - Check the starter resistance when adjusted to the ambient temperature. Characteristic ambient temperature 24° C Electric characteristic Automatic starter resistance 20 Ω ± 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible. - The correct warm up time depends on the ambient temperature.
Vespa LX 50 4valvole Engine - Insert rubber pipes for chamber ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seatings. - Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter. - Reconnect the fuel supply pipe and tighten the 2 clamping screw fixing the carburettor to the inlet manifold and the air inlet coupling to the filter.
Engine - Using the rpm indicator in the analyser or a separate one, adjust the idle screw. N.B. THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED.
INDEX OF TOPICS SUSPENSIONS SUSP
Suspensions Front Removing the front wheel - Remove the five Allen screws that fix the wheel to the hub. N.B. BEFORE REMOVING THE WHEEL HUB, REMOVE THE BRAKE CALLIPER.
Vespa LX 50 4valvole Suspensions Front wheel hub overhaul - Remove the ball bearing check Seeger ring indicated in the picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings 001467Y017 Bell for bearings, OD 39 mm - Remove the oil seal on the roller bearing side using a screwdriver.
Suspensions - Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing out - Refit the ball bearing check Seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020412Y 15-mm guide - Use the specific tool to fit and push the roller casing until it stops - Refit the oil seal on the roller bearing side - Lubricate the area between the roller bearing and the ball bearing Speci
Vespa LX 50 4valvole Suspensions Removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and disconnecting the electrical terminals, remove the terminal fixing the handlebar to the steering. - Check all components and replace faulty parts. N.B. IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING, TILT THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS.
Suspensions Vespa LX 50 4valvole 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. - Press and remove the wedging washer with the help of a pointed end. - For the second washer, repeat the operation using the punch on the side opposite to the one shown in the figure.
Vespa LX 50 4valvole 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. - Insert the previously greased pin on the swinging hub and with the tool handgrip, move part 3 until it stops on the steering tube.
Suspensions * Supplied with the tool Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 ° C and +120 °C; NLGI 2; ISO-L-XBCIB2 Use the tool fitted with parts 3 and 4, as indicated to fit the pin, and press operating the handgrip, until wedging the washers on the swinging hub.
Vespa LX 50 4valvole Suspensions Refitting When fitting the fork, lubricate with the steering bearing tracks with the recommended grease. Tighten the lower ring nut "A" and the upper ring nut "B" to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2.
Suspensions Vespa LX 50 4valvole 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.
Vespa LX 50 4valvole 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.
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 absorber side and move it until it stops using the specific tool Specific tooling 020036Y Punch - Suitably hold the brake calliper - shock absorber attachment bracket - Assemble a new roller bearing on the wheel hub side and move it until it s
Vespa LX 50 4valvole Suspensions White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 ° C and +120 °C; NLGI 2; ISO-L-XBCIB2 Steering bearing Removal - Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis. N.B. TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING JUST USE A SCREWDRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE.
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 ÷ 152 Nm Swing-arm Removal Remove the swinging arm acting on the three clamps shown in the figure.
Vespa LX 50 4valvole 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 - 149
Suspensions Removal - To replace the shock absorber remove the battery 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/chassis anchoring nut and the shock absorber/engine pin to the prescribed torque.
INDEX OF TOPICS BRAKING SYSTEM BRAK SYS
Braking system Vespa LX 50 4valvole 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. 10- Piston. 11 - Brake pad. 12 - Brake disc. Front brake calliper Removal - Detach the oil brake hose from calliper, pouring the fluid inside a container. - Remove the mountings indicated in the figure. - When refitting, tighten the nuts to the prescribed torque. - Bleed the system.
Vespa LX 50 4valvole 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. - Lock the pipe joint to the calliper to the prescribed torque. Upon fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc..
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. - To replace: remove the protection cover, the bolt and the leaf spring. Slide off the pads and replace them once the plungers are down. Carry out these operations in reverse order to fit.
Vespa LX 50 4valvole Braking system on the bleed screws until no more air comes out of the 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, EXAMINE ALL THE FITTINGS: IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS.
Braking system Removal - Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and actuate the brake lever until no more fluid flows out. -Remove the oil pump from the handlebar; remove the brake lever and then remove the wheel cylinder. 1 - Tank cap screw. 2. Tank cover. 3. Diaphragm. 4. Bellows. 5. Sealing ring. 6. Piston. 7. Gasket. 8 - Spring CAUTION - THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAKING EFFICIENCY.
Vespa LX 50 4valvole Braking system 5. Sealing ring. 6. Piston. 7. Gasket. 8. Spring. Rear drum brake Once the muffler and the wheel have been removed, follow these steps: 1.Remove the shoe spring using the specific spanner. 2. Remove the shoe with the aid of a lever. 3. Refit the new shoes giving a few taps with the mallet. 4. Attach the spring using the specific pliers.
INDEX OF TOPICS CHASSIS CHAS
Vespa LX 50 4valvole Chassis Seat - Lift the saddle and remove the helmet compartment «A». - Undo the two screws indicated. Rear handlebar cover Undo the screws as shown in the figure and remove the handlebar rear section.
Chassis Instrument panel Operate the 4 screws shown in the figure to replace the instrument panel. Front handlebar cover • Remove the 2 screws in the rear handlebar cover and the screw under the headlamp. • Pull up and detach the front handlebar cover, disconnect the headlight assembly connections.
Vespa LX 50 4valvole 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; they can be reached after opening the glove-box door.
Chassis Taillight assy. - Undo the two fixing screws and remove the rear light unit. - Undo the screw indicated and disconnect the connector. Footrest - Operate on the 3 screws shown in the figure once the glove-box and fairing have been removed.
Vespa LX 50 4valvole Chassis Side fairings - Undo the screw «A» and the smaller screw «B». - Detach the seats on the fairing. License plate holder - Remove the side fairings. - Working on both sides, undo the two screws indicated. - Remove the license plate light.
Chassis Air filter - Remove the helmet compartment. - Remove the side fairings. - Undo the two indicated clamps to the crankcase. - Undo the two clamps indicated. Helmet bay - Lift the saddle and remove the helmet compartment «A».
Vespa LX 50 4valvole Chassis Fuel tank CHAS - 165
Chassis - Adequately support the rear part of the scooter. - Remove the wheel and the rear mudguard. - Remove the battery compartment. - Disconnect the fuel outlet pipe. - Undo the two fixing screws to the chassis and collect the fuel pipe supporting plate.
Vespa LX 50 4valvole Chassis - Remove the turn indicators. - Remove the rear light unit and undo the indicated screw. - Unscrew the closing cap. - Lower the fuel tank and disconnect the bleed pipes and the level indicator connector. - Remove the tank.
Chassis Front mudguard - First remove the steering tube and uncouple the front brake pipes from the calliper in order to remove the front mudguard - Remove the three mudguard-steering tube clamps indicated in the figure Front central cover - Remove the "Piaggio" clip-on badge. - Svitare la vite indicata. - Remove the front central cover, sliding it upwards.
INDEX OF TOPICS PRE-DELIVERY PRE DE
Vespa LX 50 4valvole Pre-delivery Aesthetic inspection - Paintwork - Fitting plastics parts - Damage - Dirt Tightening torques inspection Lock check - All tightening torques - External screw of covers SAFETY LOCKS Name Handlebar locking Steering lower ring nut Upper steering ring nut Front wheel axle nut Rear wheel nut Rear shock absorber nut-engine Shock absorber - chassis nut Engine-swinging arm bolt Frame-swinging arm bolt Torque in Nm 40 ÷ 50 8 ÷ 10 30 ÷ 40 75 ÷ 90 137 ÷ 152 33 to 41 N·m 20 ÷ 25 33
Vespa LX 50 4valvole Pre-delivery NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE. WARNING KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL FIRST. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN.
Pre-delivery Vespa LX 50 4valvole CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. WARNING BE VERY CAREFUL WHEN HANDLING FUEL.
INDEX OF TOPICS TIME TIME
Vespa LX 50 4valvole Time Engine ENGINE 1 Code 001001 2 003064 TIME - 174 Action Engine from frame - Removal and refit.
Vespa LX 50 4valvole Time Crankcase CRANKCASE 1 Code 001133 Action Engine crankcase - Replacement Duration Crankshaft TIME - 175
Vespa LX 50 4valvole Time CRANKSHAFT 1 2 3 4 Code 001117 001099 001100 001118 Action Crankshaft - Replacement Oil seal, flywheel side - Replacement Oil seal, clutch side - Replacement Main bearings - Replacement Duration Cylinder assy.
Vespa LX 50 4valvole Time Cylinder head assy.
Vespa LX 50 4valvole Time Rocker arms support assy.
Vespa LX 50 4valvole Time Cylinder head cover HEAD COVER 1 2 3 4 Code 001093 001088 001097 001089 Action Spark plug - Replacement Head cover gasket - Replacement Cooling hood - Replacement Head cover - Replacement Duration TIME - 179
Vespa LX 50 4valvole Time Driven pulley DRIVEN PULLEY - CLUTCH 1 2 3 4 TIME - 180 Code 001110 001012 001022 001155 Action Driven pulley - Replacement Driven pulley - Overhaul Clutch - Replacement Clutch bell housing - Replacement Duration
Vespa LX 50 4valvole Time Oil pump OIL PUMP 1 2 3 4 5 6 7 8 Code 001051 001112 001042 001121 001122 001125 001130 001129 Action Belt/Timing chain - Change Oil pump - change Oil pump - Service Chain cover oil seal - Replacement Oil pump chain - Replacement Chain guide pads - Replacement Oil sump - Replacement Chain tightener - Overhaul and replacement Duration TIME - 181
Vespa LX 50 4valvole Time Final gear assy.
Vespa LX 50 4valvole Time Driving pulley REAR-VIEW 1 Code 001177 2 3 4 001086 001066 001011 PULLEY Action Variator rollers / shoes - Replacement rear-view half-pulley - Replacement Driving pulley - Removal and refitting Driving belt - Replacement Duration TIME - 183
Vespa LX 50 4valvole Time Transmission cover TRANSMISSION COVER 1 Code 001096 2 001132 3 001131 4 001135 TIME - 184 Action Transmission crankcase cover - replace Transmission air inlet pipe - Replacement Transmission air intake - Replacement Transmission cover bearing - Replacement Duration
Vespa LX 50 4valvole Time Starter motor ELECTRICAL START-UP 1 2 Code 001020 005045 3 001017 4 5 6 001021 008008 001084 Action Starter motor - Replacement Starter motor cable harness - Replacement Starter sprocket wheel - Replacement Kick starter - Inspection Starter spring pack - Replacement Starter lever - Replacement Duration TIME - 185
Vespa LX 50 4valvole Time Flywheel magneto MAGNETO FLYWHEEL 1 2 3 4 5 6 TIME - 186 Code 001067 001173 001102 001109 001087 001058 Action Stator - Fitting and Refitting Rotor - Replacement Net oil filter - Replacement / Cleaning Cooling fan - Replacement Flywheel cover - Replacement Flywheel - Replacement Duration
Vespa LX 50 4valvole Time Carburettor CARBURETTOR 1 2 3 4 5 Code 001063 001008 003058 001081 001082 6 001013 Action Carburettor - Replacement Carburettor - Inspection Carburettor - Adjustment Automatic choke - Replacement Carburettor heating resistor - Replacement Intake manifold - change Duration TIME - 187
Vespa LX 50 4valvole Time Exhaust pipe MUFFLER 1 2 3 TIME - 188 Code 001009 001095 001136 Action Muffler - Replacement Muffler guard - Replacement Exhaust emissions - Adjustment Duration
Vespa LX 50 4valvole Time Air cleaner AIR CLEANER 1 Code 004122 2 3 001014 001015 Action Air cleaner carburettor fitting - Replacement Air filter - Replacement / cleaning Air filter box - Replacement Duration TIME - 189
Vespa LX 50 4valvole Time Frame FRAME 1 2 3 4 5 6 TIME - 190 Code 004001 004023 004149 004159 004012 004059 Action Frame - Replacement Shield rim - Replacement Shield central cover - Replacement Plates / Stickers - Replacement Rear side panels - Replacement Spark plug inspection flap - Replacement Duration
Vespa LX 50 4valvole Time Centre-stand STAND 1 2 Code 004004 004171 Action Stand - Replacement Stand support plate - Replacement Duration TIME - 191
Vespa LX 50 4valvole Time Footrests FOOTREST 1 2 TIME - 192 Code 004178 004078 Action Footrest - Replacement Front/rear footrest rubber - Replacement Duration
Vespa LX 50 4valvole Time Rear cover SHIELD BACK PLATE 1 2 Code 004174 004065 3 4 004081 004082 Action Trunk levers - Replacement Legshield, rear part - Removal and refitting Glove box door - Replacement Top box gasket - Replacement Duration TIME - 193
Vespa LX 50 4valvole Time Underseat compartment HELMET COMPARTMENT 1 2 3 4 TIME - 194 Code 004016 005046 004011 004071 Action Helmet compartment - Replacement Battery cover - change Central frame cover - Replacement Battery compartment - replacement Duration
Vespa LX 50 4valvole Time Plate holder LICENSE PLATE HOLDER 1 Code 004136 2 3 005048 005032 Action License plate holder support - Replacement Licence plate holder - Replacement number plate light glass - Replacement Duration TIME - 195
Vespa LX 50 4valvole Time Mudguard MUDGUARDS 1 2 TIME - 196 Code 004002 004009 Action Front mudguard - Replacement Rear mudguard - Replacement Duration
Vespa LX 50 4valvole Time Fuel tank FUEL TANK 1 2 3 Code 004168 005010 004112 4 5 6 004005 004007 004109 Action Fuel tank cap - Replacement Tank float - Replacement Cock-carburettor hose - Replacement Fuel tank - Replacement Fuel valve - Replacement Fuel tank breather - change Duration TIME - 197
Vespa LX 50 4valvole Time Rear shock-absorber REAR SHOCK ABSORBER 1 TIME - 198 Code 003007 Action Rear shock absorber - Removal and Refitting Duration
Vespa LX 50 4valvole Time Steering column bearings STEERING FIFTH WHEELS 1 2 3 Code 003002 003073 004119 Action Steering fifth wheels - Replacement Steering clearance - Adjustment Bearing / upper steering fifth wheel Replacement Duration TIME - 199
Vespa LX 50 4valvole Time Handlebar covers ODOMETER - HANDLEBAR COVERS 1 Code 004018 2 004019 3 4 005014 005038 5 005078 TIME - 200 Action Handlebar front section - Replacement Handlebar rear section - Replacement Odometer - Replacement Instrument panel warning light bulbs - Replacement Odometer glass - Replacement Duration
Vespa LX 50 4valvole Time Handlebar components HANDLEBAR COMPONENTS 1 2 3 4 5 6 Code 004066 002037 002071 003001 005017 002024 7 002063 8 002060 9 004162 10 002059 Action Driving mirror - Replacement Brake or clutch lever - Replacement Left hand grip - Replacement Handlebar - Replacement Stop switch - Replacement Front brake pump - Removal and Refitting Throttle control transmission - Replacement Complete throttle control - Replacement Mirror support and/or brake pump fitting U-bolt - Replacem
Vespa LX 50 4valvole Time Swing-arm SWINGING ARM 1 TIME - 202 Code 001072 Action Engine-frame connection swinging arm - Replacement Duration
Vespa LX 50 4valvole Time Seat SADDLE 1 2 Code 004003 004131 Action Saddle - Replacement Luggage rack support - Replacement Duration TIME - 203
Vespa LX 50 4valvole Time Turn signal lights TURN INDICATOR LIGHTS 1 2 3 Code 005002 005012 005067 4 5 6 7 005008 005005 005066 005022 8 005068 TIME - 204 Action Front headlamp - change Front turn indicator - Replacement Front turn indicator bulb - Replacement Headlight bulbs - Replacement Taillight - change Rear light bulbs - Replacement Rear turning indicators - Replacement Rear turning indicator bulb - Replacement Duration
Vespa LX 50 4valvole Time Front wheel FRONT WHEEL 1 2 3 4 5 6 Code 004123 003047 003037 003033 002041 003034 Action Front wheel - Replacement Front tyre - Replacement Front wheel rim - Replacement Front wheel hub- Replacement Front brake disc - Replacement Front wheel hub bearing - Replacement Duration Rear wheel TIME - 205
Vespa LX 50 4valvole Time REAR WHEEL 1 2 Code 004126 001071 3 4 001016 002002 Action Rear wheel tyre - Replacement Rear wheel rim - Removal and Refitting Rear wheel - Replacement Rear brake pads/shoes - Repl.
Vespa LX 50 4valvole Time Electronic controls ELECTRIC CONTROLS 1 2 Code 005039 005006 3 4 5 6 7 8 005040 005003 005041 005016 004096 004010 Action Lights switch - Replacement Light or turning indicator switch - Replacement Horn button - Replacement Horn - Replacement Starter button - Replacement Key switch - Replacement Lock series - Replacement Anti-theft lock - Replacement Duration TIME - 207
Vespa LX 50 4valvole Time Transmissions TRANSMISSIONS 1 Code 002053 2 002051 3 002049 TIME - 208 Action Rear brake transmission complete Replacement Odometer transmission assembly Replacement Odometer cable - Replacement Duration
Vespa LX 50 4valvole Time Front suspension FRONT SUSPENSION 1 2 3 Code 003045 003010 003035 4 5 001064 003044 Action Steering tube - Replacement Front suspension - Service Shock absorber support and brake calliper - Replacement Odometer reel - Replacement Shock absorber cover - Replacement Duration TIME - 209
Vespa LX 50 4valvole Time Braking system BRAKING SYSTEM 1 Code 002021 2 002007 3 002039 4 002047 5 002002 TIME - 210 Action Front brake hose - Remov. and Refitt. Front brake shoes/pads - Remov.
Vespa LX 50 4valvole Time Secondary air box SECONDARY AIR HOUSING 1 Code 001164 2 001161 3 001162 4 001163 5 001165 Action Crankcase secondary air connection - Replacement Secondary air filter - Replacement / Cleaning Secondary air housing - Replacement Muffler secondary air connection Replacement Secondary air reed - Replacement Duration TIME - 211
A Air filter: 40, 164 B Battery: 50, 60 Brake: 152–155, 157 C Carburettor: 13, 36, 125, 128, 187 E Engine oil: 40 Engine stop: F Fuel: 49, 124, 165, 197 H Headlight: 43, 161 Hub oil: 39 I Identification: 7 Instrument panel: 160 M Maintenance: 6, 36 O Odometer: Oil filter: 41 S Saddle: Shock absorbers: 149 Spark plug: 39, 67 Stand: Start-up: T Tank: 165, 197 Transmission: 8, 49, 77, 87, 184 Tyres: 12