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VESPA LX 4T USA, Workshop Manual

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VESPA LX 4T USA Workshop Manual Download Page 167

Starter motor

ELECTRICAL START-UP

Code

Action

Duration

1

001020

Starter motor - Replacement

2

005045

Starter motor cable harness - Re-

placement

3

001017

Starter sprocket wheel - Replace-

ment

4

001021

Kick starter - Inspection

5

008008

Starter spring pack - Replacement

6

001084

Starter lever - Replacement

LX 4T USA

Time

TIME - 167

Summary of Contents for LX 4T USA

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

Page 2: ...es to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproduction...

Page 3: ...ections of this manual relating to specific tools along with the specific tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely observe the...

Page 4: ......

Page 5: ...ARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...ar of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and split pins upon refitting After removal clean ...

Page 8: ...n Desc Quantity Chassis prefix ZAPC38300 1001 Engine prefix M383M 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Dry weight 102 5 Width 740 mm Length 1755 mm Wheel base 1290 mm Overall height 1140 mm Characteristics LX 4T USA CHAR 8 ...

Page 9: ... Sponge impregnated with fuel mixture 50 SELENIA air filter oil and 50 unleaded petrol Starting system electric starter kickstarter Lubrication engine lubrication with lobe pump in the crankcase driven by a chain Mesh prefilter and centrifugal on the crankshaft Fuel supply Gravity feed with unleaded petrol with a minimum octane rat ing of 95 with carburettor Max power crankshaft 2 5 KW 3 4 CV at 6...

Page 10: ... plug DENSO U24ESR NB Battery 12V 9Ah Fuse 10A Generator single phase alternating current Frame and suspensions FRAME AND SUSPENSIONS Specification Desc Quantity Type Unitised body made of stamped plate Front suspension Single arm suspension with swinging arm articulated to the steering tube Hydraulic double acting shock absorber and co axial spring Front suspension stroke 70 mm Trail suspension r...

Page 11: ...le mixture screw 1 3 4 Starter jet 40 Starter air nozzle on the body Ø 1 5 Choke needle travel 11 5 mm Tightening Torques STEERING Name Torque in Nm Upper steering ring nut 30 40 Lower steering ring nut 8 10 Handlebar fastening screw 50 55 Nm FRAME ASSEMBLY Name Torque in Nm Engine swinging arm bolt 33 41 Floating arm frame pin 44 52 Shock absorber chassis nut 20 25 Shock absorber engine nut 33 41...

Page 12: ...e cap 25 28 Flywheel nut 40 to 44 N m Stator screws 3 4 Pick up screws 3 4 Oil pump bulkhead screw 4 5 Timing chain oil pump compartment cover screws 4 5 Oil decantation labyrinth sheet screws 7 8 Oil pump crown screw 8 10 Screws fixing oil pump to crankcase 5 6 Oil sump screws 8 10 Nm Inlet manifold screw 7 9 Manifold carburettor clamp screw 1 2 1 5 Screws fixing cables to starter motor 1 5 2 5 S...

Page 13: ...m piston with shir am cylinder D 39 014 39 021 38 970 38 977 0 037 0 051 Cylinder first uprat A1 39 193 39 200 39 154 39 161 0 032 0 046 Cylinder first uprat B1 39 200 39 207 39 161 39 168 0 032 0 046 Piston first uprat C1 39 207 39 214 39 168 39 175 0 032 0 046 Piston first uprat D1 39 214 39 221 39 175 39 182 0 032 0 046 Cylinder second uprat A2 39 393 39 400 39 354 39 361 0 032 0 046 Cylinder s...

Page 14: ... Compression lining 1 greater 39 2 x 1 A 0 05 0 20 Scraper ring lining 1 greater 39 2 x 2 A 0 20 0 70 1 Compression lining 2 greater 39 4 x 1 A 0 08 0 20 2 Compression lining 2 greater 39 4 x 1 A 0 05 0 20 Scraper ring lining 2 greater 39 4 x 2 A 0 20 0 70 1 Scraper ring lining 3 greater 39 6 x 1 A 0 08 0 20 2 Scraper ring lining 3 greates 39 6 x 1 A 0 05 0 20 Scraper ring lining 3 greates 39 6 x ...

Page 15: ...NT A TO BE TAKEN IS A VALUE OF PISTON RE ENTRY IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER THE FURTHER THE PISTON GETS INSIDE THE CYLINDER THE THINNER THE HEAD GASKET TO BE APPLIED SHOULD BE TO RECOVER THE COMPRESSION RATIO AND VICE VERSA Characteristic Shimming system to control the compression ratio CR 11 1 12 9 PISTON PRO...

Page 16: ... CYLINDER THE FURTHER THE PISTON GETS INSIDE THE CYLINDER THE THINNER THE HEAD GASKET TO BE APPLIED SHOULD BE TO RECOVER THE COMPRESSION RATIO AND VICE VERSA Characteristic Shimming system to control the compression ratio CR 11 1 12 9 PISTON PROTRUSION CHECK Name Measure A Thickness shimming_1 0 05 0 25 0 35 shimming_2 0 25 0 40 0 25 Characteristics LX 4T USA CHAR 16 ...

Page 17: ...nthetic oil AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid MONTBLANC MOLYBDENUM GREASE Grease for driven pulley shaft adjusting ring and movable driven pulley housing Grease with molybdenum disulphide AGIP GREASE PV2 Grease for steering bearings bolt seat ings for swinging...

Page 18: ...INDEX OF TOPICS TOOLING TOOL ...

Page 19: ...1467Y029 Bell for bearings O D 38 mm 004499Y Bearing extractor Fitted with 1 Bell 2 Sleeve 3 Screw 6 Ring 27 Half rings 34 Half rings 005095Y Engine support 008119Y009 Tube to assemble shafts and axles 020004Y Punch for removing fifth wheels from headstock LX 4T USA Tooling TOOL 19 ...

Page 20: ...ch for steering tube ring nut 020074Y Tool to align crankshaft 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020171Y Punch for driven pulley roller bearing 020265Y Bearing fitting base Tooling LX 4T USA TOOL 20 ...

Page 21: ...emble piston on cylinder 020291y Valves assembly disassembly tool 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter LX 4T USA Tooling TOOL 21 ...

Page 22: ... Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020358Y 37x40 mm adaptor Tooling LX 4T USA TOOL 22 ...

Page 23: ...Stores code Description 020359Y 42x47 mm adaptor 020360Y Adaptor 52 x 55 mm 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25 mm guide 020376Y Adaptor handle LX 4T USA Tooling TOOL 23 ...

Page 24: ...Y Tool to fit the start up sector spring 020439Y 17 mm guide 020444Y Test probe removal fitting tool 020448Y Pin lock fitting tool 020449Y Piston position check support 020450Y Camshaft fitting removal tool 020451Y Drive pulley stop wrench Tooling LX 4T USA TOOL 24 ...

Page 25: ...res code Description 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser LX 4T USA Tooling TOOL 25 ...

Page 26: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 27: ...r Brake fluid level check Electrical system and battery check Tyre inflation and wear Check Vehicle and brake test road test EVERY 12000 OR 24 MONTHS AND AT 60000 KM Action Engine oil replacement Hub oil level check Spark plug electrode gap check replacement Air filter clean Oil filter net filter clean Idle speed adjustment Throttle lever adjustment Variable speed rollers check or replacement Driv...

Page 28: ...Refer to predelivery operations EVERY 36000 Action Engine oil replacement Hub oil level check Spark plug electrode gap check replacement Air filter clean Oil filter net filter clean Idle speed adjustment Throttle lever adjustment Variable speed rollers check or replacement Driving belt replacement Odometer gear greasing Steering adjustment Brake control levers greasing Brake pads check condition a...

Page 29: ...er to rules Check to CO Refer to predelivery operations EVERY 2 YEARS Action Brake fluid change EVERY 3 000 KM 10 Action Engine oil level check top up Carburettor 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 condi tion The throttle valve should move freely in th...

Page 30: ...arks on the casing at the same time read the spark advance value on the strobo scopic gun display The value should be 10 Repeat the above operation with engine running at 5000 6000 revs min spark advance should be 26 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...

Page 31: ...r into the round groove between the threaded metal part and the ceramic part of the inner electrode while turning the spark plug to allow removal of the oil in excess Detach the spark plug cap and then remove the spark plug Carefully examine the spark plug and replace it if the insulator is damaged or chipped With the aid of a feeler gauge measure the spark gap and if necessary adjust by bending o...

Page 32: ...ifications Replacement Remove oil filler cap dipstick A Unscrew the drain plug B shown in the figure and allow the oil to drain out Retighten the drain plug and fill the hub with oil about 100 cc Air filter After removing the lower part of the left hand side cover unscrew the four fixing screws and the two knobs which are exposed by overturning the sad dle and removing the helmet compartment re mo...

Page 33: ...Retighten the drain plug and pour in approximate ly 600 650 cc of oil Check Rest the vehicle with the engine cold on its centre stand on flat ground Ensure the oil level is between the MAX and MIN marks on the dipstick The MAX mark implies a quantity of 850 cc of oil in the engine If the oil level approaches the MIN mark top up with fresh oil without ever exceeding the MAX mark Recommended product...

Page 34: ...S THEN RECHECK THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD IT MUST ALWAYS REMAIN UNDER THE MAX LEVEL N B IF FILLING FOR THE 1ST TIME OR FOR OVERHAUL ADD 850 C C OF ENGINE OIL IN OTHER CASES 650 C C AND FILL UP IF NECESSARY Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the require ments of API SL ACEA A3 JASO MA specifica tions Locking torques N m Engine o...

Page 35: ... the clearance between the valve and the register corresponds with the indicated values Should the valve clearance values intake and drainage respectively be different from the ones indicated below adjust them by loosening the lock nut and operate on the register with a screwdriver as shown in the figure Characteristic Intake with cold engine 0 10 mm Drainage with cold engine 0 15 mm Headlight adj...

Page 36: ...urettor components with the air filter clean and the spark plug in good con ditions 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 2 Shut down the engine only for the time required to carry out operations 3 and 4 3 Remove the RH side fairing and the SAS box cover by loosening the 3 screws shown in the fig ure Interpo...

Page 37: ...20332Y Digital rev counter 494929Y Exhaust fumes analyser 020331Y Digital multimeter SAS filters inspection and cleaning Use the two screws A on the right side panel and remove it Use the three screws B to remove the cover of the secondary air box Move the cover of the box away and remove the sponge filter C Wash the sponge with water and a neutral soap and dry it with a clean rag and shorts blast...

Page 38: ...Maintenance LX 4T USA MAIN 38 ...

Page 39: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 40: ...Replace the head assembly Worn cylinder Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpms too high Check the idling speed and if necessary adjust the C O Clutch fault Check the spring friction mass and the clutch bell Air filter housing not sealed Correctly refit the filter housing and ...

Page 41: ...the proper tank aeration Level in tank too low Restore the correct level in the tank the float must be parallel to the upper cover contact plane that is the throttle valve mem brane cover Engine tends to cut off at idle ENGINE TENDS TO STOP WHEN IDLING Possible Cause Operation Air calibrated holes in carburettor blocked Dismantle wash with solvent and dry with compressed air Defective floating val...

Page 42: ... bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the wheel correctly fitted and the concentricity of the rear drum check the brake disc screws are locked Fluid leakage in hydraulic braking system Elastic fittings piston ...

Page 43: ...Steering hardening Check the tightening of the top and bottom ring nuts If irregu larities in turning the steering continue even after making the above adjustments check the seats on which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering backlash Check the tight...

Page 44: ...Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper Troubleshooting LX 4T USA TROUBL 44 ...

Page 45: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 46: ... 35 35W 8 Front tail light bulb Type All glass Power 12V 5W Quantity 1 9 Right turn indicator warning light 12V 2W 10 Reserve fuel light 12V 1 2W 11 Left turn indicator warning light 12V 2W 12 High beam warning light 12V 1 2W 13 Dashboard light bulbs Type Bayonet Power 12V 1 2W Quantity 3 14 Headlight warning light 12V 1 2W 15 Odometer with warning lights and level indicator 16 Front headlight Ele...

Page 47: ...pe Spherical Power 12V 21 5W Quantity 1 27 Battery 12V 9Ah 28 Electronic ignition device 29 Magneto flywheel 30 Starter motor 31 Fuse carrier N 1 fuse to 10 A 32 rear left turn indicator 33 Rear turn indicator bulbs Two 12V 10W spherical 34 Voltage regulator 35 Claxon in c c 36 Resistance 10 Ohm 10W Electrical cables color B White Bl Blu G Yellow Mr Brown N Black Gr Gray Rs Pink R Red Vi Purple V ...

Page 48: ...ction HEADLIGHTS Specification Desc Quantity 1 Magneto flywheel 2 Voltage regulator 3 Light switch 4 Headlight bulb 12V 35 35W 5 High beam warning light 12V 1 2W 6 Rear light bulb 12V 5W 7 Headlight warning light 12V 1 2W 8 Front position light filament 12V 5W 9 Instrument panel light bulbs Type All glass Power 12V 1 2W Quantity 2 10 Dashboard light bulbs 12V 2W Electrical system LX 4T USA ELE SYS...

Page 49: ...1 Voltage regulator 2 Magneto flywheel 3 Automatic starter 4 Battery 12V 9Ah 5 Remote starter switch 6 Starter motor 7 Start up button 8 Brake light filament 12V 21W 9 Front and rear brake light button 10 Key switch 11 Main fuse 10A 12 Resistance 6 8 Ohm 10W LX 4T USA Electrical system ELE SYS 49 ...

Page 50: ...CATORS Specification Desc Quantity 1 Voltage regulator 2 Fuel Level indicator 3 Fuel level sender 4 Reserve fuel light 12V 1 2W 5 Front and rear brake light button 6 Fuse 10 A 7 Battery 12V 9Ah 8 Brake light filament 12V 21W 9 Key switch contacts Electrical system LX 4T USA ELE SYS 50 ...

Page 51: ... Indicators switch 2 Horn button 3 Horn 4 Two 2 turn signal warning light bulbs 12V 2W 5 4 Turn indicator bulbs 12V 10W 6 Voltage regulator 7 Key switch contacts 8 Fuse 10 A 9 Battery 12V 9Ah Instruments and warning lights control board LX 4T USA Electrical system ELE SYS 51 ...

Page 52: ...t and replace the control unit If after replacement the vehicle starts properly the control unit is failing and must be replaced If faulty or failed operation persists conduct the following checks on the generator and on the sta tor components After a visual inspection of the electrical connec tions it is possible to perform measurements on the stator winding and pick up see table using the specif...

Page 53: ... resistance between the brown earth and black earth terminal N B VALUES ARE STATED AT AMBIENT TEMPERATURE A CHECK WITH THE STATOR AT OPERATING TEMPERA TURE LEADS TO VALUES HIGHER THAN THOSE STATED Electric characteristic Stator Brown earth approx 170 Ω Pick Up Stator Black earth 1 Ω Stator Voltage regulator check The malfunctioning of the voltage regulator might cause the following problems depend...

Page 54: ... to the voltage regulator and the operation of the light switch If no voltage is found put the negative terminal to earth if this provides voltage readings check the earth wire on the regulator otherwise replace the regulator as certainly faulty As a last test it is possible to check the output volt age from the stator Detach the regulator connector and interpose the tester between the Gray Blue w...

Page 55: ...switch is turned to ON and with the regulator connector detach ed it is then necessary to check the wirings and systems downstream the key switch are not short circuited with earth Proceed by measuring the resistance between contacts 3 White and 2 Black from the voltage regulator with the connector detached If the reading differs excessively from the figures shown replace the regulator as short ci...

Page 56: ...ltage If the readings do not match the above figures replace the regulator otherwise check wiring and connections Electric characteristic Resistance of voltage regulator 8 MΩ Turn signals system check 4 TURN INDICATORS NOT WORKING If the turn indicators do not work do the following Disconnect the regulator connection and insert the multimeter probes between the white cable 3 and the black one 2 Tu...

Page 57: ... recharge If voltage is below 12 60 V a renewal recharge is required as explained in 2 2 Constant voltage battery charge mode Constant voltage equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for nominal capacity Duration of the charge 10 to 12 h recommended Minimum 6 h Maximum 24 h 3 Constant current battery charge mode Charge current equal to 1 10 of the nominal capacity of the batt...

Page 58: ...d and is subject to quick wear 2 Load status check After restoring the electrolyte level check its den sity using an appropriate densitometer see the figure When the battery is charged you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1 26 to 1 28 at a temperature of no lower than 15 C A density reading of less than 20 Bé indicates that the battery is completely flat...

Page 59: ...MANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY 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 2...

Page 60: ...H CLOSED END NEAR THE POSITIVE TERMINAL WITH THE CORRE SPONDING LONG TUBE WITH OPEN END THAT YOU FIND FITTED TO THE VEHICLE TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Electrical system LX 4T USA ELE SYS 60 ...

Page 61: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 62: ...move the muffler assembly Remove the rear wheel Remove the rear brake mechanical transmission Disconnect the electric terminals Remove the throttle grip transmission Disconnect the tubing petrol vacuum operated cock control Disconnect the swinging arm on the engine side Disconnect the rear shock absorber lower clamping WARNING Be very careful when handling fuel CAUTION When installing the battery ...

Page 63: ...INDEX OF TOPICS ENGINE ENG ...

Page 64: ...THE APPROPRIATE COUPLINGS TO REMOVE THE COVER Kickstart To remove the start up pinion push the starter lever to facilitate extracting the pinion Remove the kick start screw and lever Remove the seeger ring and the washer indicated in the figure Pull out the toothed sector WARNING THE SECTOR KEEPS THE SPRING SET BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS Air duct To remove the intake throat on the...

Page 65: ...ing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside N B WHEN REFITTING ALWAYS REPLACE THE BEARING WITH A NEW ONE CAUTION WHEN REMOVING REFITTING THE BEARING TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE Removing the driven pulley Lock the clutch bell housing with the specific tool Remove the nut the clutch bell housing and the wh...

Page 66: ...he 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 con tact CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW IS TIGHTENED UP TOO FAR Using a 34 mm socket wrench remove the clutch locking nut Loosen the central screw by undoing spring of the driven pulley unit Separate the components Spec...

Page 67: ...HIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFER ENT 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 Characteristic Check minimum thickness 1 mm Pin retaining collar Remove the collar with the aid of 2 screwdrivers Remove the three guide pins and the mobile half pulley LX 4T USA Engi...

Page 68: ...means of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the work surface of the belt If there are replace the half pulley Make sure the bearings do not show signs of un usual wear Measure the ...

Page 69: ...r with a curved spout to lubricate the driven pulley unit with around 6 gr of grease This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole This procedure is necessary to prevent the presence of grease beyond the O ring Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLG...

Page 70: ...se check the driven pulley unit N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFER ENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Minimum thickness permitted 1 mm Refitting the clutch Preassemble the driven pulley group wi...

Page 71: ...ocking 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 Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Driven pulley shaft nut 40 to 44 Nm Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Characte...

Page 72: ...ing or deformation 2 Check the roller running tracks on the contact pulley there must not be signs of wear and check the condition of the contact surface of the belt on the half pulleys mobile and stationary 3 Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders 4 Check the integrity of the s...

Page 73: ...efit the components of the assembly roller con tainer assembly with bushing limiting washer sta tionary half pulley cooling fan belt with drive washer and nut With the specific tool tighten the lock nut to 20 Nm and then perform a final 90 locking in order to prevent the rotation of the driving pulley N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT...

Page 74: ...eger and the Kick start lever Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Insert the pinion in its seating by pushing the starter lever Fit the intake throat and tighten the 3 screws Make sure the oil sump presents centring dowels and sealing gaskets Replace the cover tightening the 12 screws to the p...

Page 75: ...xle Remove the intermediate gear and the complete gear wheel axle When removing the intermediate gear pay atten tion to the various shim adjustments 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 020363Y 20 mm guide 020376Y Adaptor handle ...

Page 76: ... figure Expel the driven pulley shaft with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft 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 et...

Page 77: ...ave or radial part on the bearing side N B FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40 mm adaptor 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 ...

Page 78: ... N m Locking torque 11 to 13 Nm Flywheel cover Cooling hood Remove the manifold and the carburettor undo ing the 2 fixing screws on the head Remove the fastening clamp of the secondary air pipe and disconnect it Remove the 4 front coupling screws 1 of them is a knob and the side fixing screw at the crankcase base Remove the 4 side screws Extract the 3 covers Remove the cover sealing gaskets on the...

Page 79: ...efitting 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 LX 4T USA Engine ENG 79 ...

Page 80: ...TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COV ER ASSEMBLY Locking torques N m Pick up screws 3 4 Stator screws 3 4 Flywheel and starting Removing the starter motor Unscrew the screw on the power positive contact and disconnect the cable Unscrew the 2 screws fixing the starter motor to the crankcase and recover the power wiring Engine LX 4T USA ENG 80...

Page 81: ...ecific 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 riveted joints are correctly tightened Check there are no deformations that may cause rubbing on the stator and the Pick Up Check that the stator winding its ferromagnetic support and the pick up ...

Page 82: ...ck up being careful to pass the wiring through the appropriate crankcase couplings Refit the flywheel to the crankshaft being careful to respect the keying then lock rotation with the specific tool and tighten the nut to the prescribed torque 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 Specific tooling 020565Y Flywhe...

Page 83: ...e contact N B REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD TIMING LUBRICATION FLYWHEEL AND TRANSMISSION CHAPTERS Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the rocker arms cover Remove the cooling covers Remove the 4 retainers of the tappet cover Remove the cover and the O ring Remove the 4 screws and then remove the Blow by cover Clean t...

Page 84: ...he central screw and the belleville washer indicated in the figure and lock the cam shaft crown with the specific tool N B TO FACILITATE REMOVING THE HEAD COMPONENTS SET THE CRANKSHAFT TO THE TIMING POINT TDC OF THE COMPRESSION END Specific tooling 020565Y Flywheel lock calliper spanner Remove the camshaft control pulley and the washer below Remove the pinion of the crankshaft timing control To re...

Page 85: ...ATES FROM THE CAMSHAFT IT IS ESSENTIAL TO FIT A NEW BEAR Specific tooling 020450Y Camshaft fitting removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y027 Bearing extractor part Pull out the rocking lever bolt operating on the flywheel hole and remove the rocking levers at the same time N B MA...

Page 86: ...EEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS AND ROCKING LEVERS WITHOUT RE MOVING THE DRIVING PULLEY UNIT REMEMBER TO HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE FITTING Removing the valves Using the specific tool fitted with the element shown in the figure remove the cotters the plates and the spring between the valves Remove the oil seals ...

Page 87: ...ngs N B BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR ING REMOVAL Inspecting the small end Measure the internal diameter of the small end using an internal micrometer N B IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANK SHAFT CHAPTER Characteristic Max diameter admitted check ...

Page 88: ...ng a thickness gauge as shown in the figure If the clearances detected exceed the limits specified in the table the piston and the piston rings should be replaced PISTON Name Description Dimensions Initials Quantity Top piston ring 0 030 0 065 mm 0 080 mm Middle piston ring 0 020 0 055 mm 0 070 mm oil scraper 0 040 0 160 mm 0 20 mm Calculate the piston pin coupling clearance Fitting clearance Pin ...

Page 89: ...minimises oil consump tion and guarantees optimum performance The pistons are oversized due to cylinder rectifi cation and are subdivided into two categories 1st and 2nd with 0 2 0 4mm oversize They are also classified into 4 categories A A B B C C D D Inspecting the piston rings Alternately insert the three sealing rings into the cylinder in the area where it retains its original di ameter Using ...

Page 90: ...g to wards the exhaust Fit the pin stop ring onto the appropriate tool Specific tooling 020448Y Pin lock fitting tool 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...

Page 91: ...fied replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BE TWEEN THE PISTON RINGS AND THE PISTON RING GROOVES AND BETWEEN THE PISTON AND THE CYLINDER IS AS SPECIFIED IN ANY CASE NEW PISTON RINGS USED IN COMBI NATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD SEALING RINGS Name Descripti on Dimensio ns Initials Quantity To...

Page 92: ...ISTON RINGS ARE MADE OF CONE SHAPED CONTACT SECTION TO THE CYLINDER AS A RESULT IT IS IMPOR TANT TO RESPECT THE FITTING INSTRUCTION TO AS SEMBLY THE RINGS WITH THE T MARK FACING UPWARDS Refitting the cylinder Insert the cylinder base gasket Fit the cylinder as shown in the figure It is possible to maintain the piston out of the crankcase plane using the special tool N B BEFORE FITTING THE CYLINDER...

Page 93: ...nifold and the exhaust manifold are not worn Characteristic Maximum admitted unevenness Head check 0 05 mm HEAD CHECK Specification Desc Quantity Standard diameter mm A Ø 32 015 32 025 mm Standard diameter mm B Ø 16 0 16 018 Standard diameter mm C Ø 11 0 11 018 Inspecting the timing system components Check that the guide shoe and the tensioner shoe are not worn out Ensure that the camshaft drive p...

Page 94: ... valves into the cylinder head Test the 2 valves alternatively The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers Inspecting the valve housings Remove any carbon formation from the valve guides Measure the inside diameter of each valve guide Take the measurement at three different heig...

Page 95: ...tting clearance Standard clearance Intake 0 015 0 042 mm Standard clearance drainage 0 025 0 052 mm Check that there are no signs of wear on the contact surface with the articulated register termi nal If the sealing surface on the valves is wider than the specified limit damaged in one or more points or curved replace the valve with a new one Characteristic Valve standard length Intake 70 1 mm Val...

Page 96: ... OF LAPPING COMPOUND BEING USED Inspecting the springs and half cones Check that the upper spring caps and the cotter halves show no signs of abnormal wear Refitting the valves Lubricate the valve guides with graphite grease Place the lower plates of the valve spring on the head Use the punch to fit the 2 sealing rings one at a time Specific tooling 020306Y Punch for assembling valve seal rings Fi...

Page 97: ...w ones N B A BALL BEARING IS FITTED ON BEARING A CONSE QUENTLY BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE HEAD ALUMINIUM Characteristic Standard height Intake 25 935 mm Standard height Discharge 25 935 mm Fitting clearance Maximum admissible axial clearance 0 5 mm Check there are no signs of scoring or wear on the rocking lever bolt Measure the diameter A Measure the internal diam...

Page 98: ...nuts to the prescribed torque Specific tooling 020450Y Camshaft fitting removal tool Locking torques N m Head cylinder stud bolt nuts 6 7 135 90 Nm first fitting upon refitting tighten again at 6 7 90 90 Nm Loosen the rocking lever registers Fit the pin the intake rocking lever and the dis charge rocking lever Lubricate the 2 rocking levers through the holes N B IF A BEARING SEPARATES FROM THE CAM...

Page 99: ... Insert the timing chain pads in their correspond ing seatings the screw and the spacer as indica ted 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 Locking torques N m Chain tensione...

Page 100: ...N m Camshaft pulley screw 12 14 Head cover screw 8 10 Nm Predisporre il cursore del tenditore nella posizione di riposo Montare il tenditore sul cilindro utilizzando una nuova guarnizione bloccare le 2 viti alla coppia pre scritta Inserire la molla con la vite centrale e bloccarla alla coppia prescritta Montare la candela Characteristic Recommended spark plug NGK CR 9EB CHAMPION RG 4HC Alternative...

Page 101: ...it the carburettor on the inlet manifold and lock the clamp Fit the secondary air pipe and fix it with the ap propriate clamp N B 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...

Page 102: ...URITIES LEAK OUT A CENTRIFUGAL OIL FILTER S LIFE IS THE SAME AS THE ENGINE S AND IS MAINTENANCE FREE Check the axial clearance on the connecting rod Fitting clearance Connecting rod endfloat standard clearance 0 15 0 30 mm Connecting rod endfloat standard clearance 0 5 mm Check the correct radial clearance of the con necting rod by holding the driving shaft with your hands and with a dial gauge fi...

Page 103: ...ing extractor ring 004499Y034 Bearing extractor part 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 ...

Page 104: ...gnment in the 4 points indicated in figure N B IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC TED TRY STRAIGHTENING THE CRANKSHAFT BY IN SERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE DED 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 02 mm Off...

Page 105: ...asing Fit the 10 screws and tighten them to the pre scribed torque N B WHEN FITTING THE HALF CASING AND THE CRANK SHAFT TAKE CARE NO TO DAMAGE THE SHAFT THREA DED TANGS Recommended products Loctite 510 Liquid sealant Gasket Locking torques N m Half casing joint bolts 8 10 Nm Fit a new O Ring on the mesh oil filter and on the filling cap lubricate the rings Insert the filter on the engine and lock ...

Page 106: ...se Refitting Apply engine oil on the oil seal and it seating on the crankcase From the outside and using the specific punch place the oil seal fully down until it reaches the bottom of the seating in the crankcase N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE IN INADEQUATE OIL SEALING Fit a new oil seal on the outer rim with the help of the sp...

Page 107: ... screws in the figure and re move 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 Remove the central screw and the belleville washer Remove the chain with the crown gear Remove the pinion of the crankshaft control Remove the oil pump by undoing the 2 screws indicated in the figure Remove the oil pu...

Page 108: ...r 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 PR...

Page 109: ...escribed torque 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 dur ing 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 9 Nm Oil pump screws 5 6 Removing the oil sump Remove the oil filling cap ...

Page 110: ... clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent Refit the tap making sure that there is an O Ring Turn the tap to the direction it had before it was removed and block the clip N B THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING Disconnect the fuel supply and the suction taking pipe from the carburettor Check that there are no fuel leaks b...

Page 111: ...stic Minimum flow rate 20 cc Removing the carburettor To detach the carburettor from the engine re move 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 Remove the protection...

Page 112: ...THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Remove the 3 fixing screws and the tank with the gasket Remove the tank components following the pro cedure below Undo the 2 screws fixing the intake pump dia phragm 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 Engine...

Page 113: ...pump jet together with the ball spring Remove the screw indicated in the figure fixing the float pin Remove the float and the plunger Remove the maximum nozzle Remove diffuser Remove the minimum nozzle LX 4T USA Engine ENG 113 ...

Page 114: ...UTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PIN SEATING STARTER NOZZLE THROTTLE VALVE CONTROL VALVE SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Refitting the carburettor Before refitting wash the carburettor body accu rately with a degreasing solvent and c...

Page 115: ...extremely small and is oriented to the throttle valve Check that the carburettor body has the closing ball for the idle circuit pipe Check that the coupling surfaces the tank and the diaphragm are not dented Check that the depression valve housing pipe is not scratched Check that the throttle valve and the shaft do not show abnormal wear Check that the plunger seat does not show abnormal wear Repl...

Page 116: ... are no fuel infiltrations Replace it in case of anomalies Fit the float together with the pin and rod in its position and lock it with its screw N B INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY Insert the ball in the corresponding accelerating pump Fit the spring Fit the accelerating pump nozzle WARNING WHEN REFITTING PAY SPECIAL ATTENTION TO THE COMPONENTS AS THEY ARE SMALL Check th...

Page 117: ...allel as shown in the figure Blow air in to the tank and then assembly it and its gasket on the carburettor body with the 3 fixing screws N B ALWAYS USE NEW RINGS AND GASKETS FOR REFIT TING WARNING THE SCREW IN THE TANK BOTTOM IS A BLEEDING ONE AND CONSEQUENTLY IT ONLY REQUIRES CLEANING Insert the diaphragm into the throttle valve Insert the tapered pin together with the plastic support and the co...

Page 118: ...d as a function of the ambient temperature Measure the piston projection as shown in the figure and check the corresponding value Ensure the choke is settled to the ambient tem perature Characteristic Projection value 11 5 mm ambient temperature 24 C The choke device must disengage progressively through electric heating Check the choke resistance when this has settled to ambient temperature Charac...

Page 119: ... timing values are dif ferent from the ones prescribed replace the start er Characteristic Battery 12V 9Ah max protrusion 15 mm max time 15 min Fit the starter the support bracket and the pro tection with the screw indicated in the figure Insert rubber pipes for tank ventilation Insert the O Ring the washer the spring and the idle flow screw in their seatings LX 4T USA Engine ENG 119 ...

Page 120: ...clearance and complying timing spark plug should be in optimum conditions air filter clean and sealed and the exhaust system tight Warm up the engine by running it at least 10 mi nutes at a speed as close as possible to the max imum one Connect the vehicle to the exhaust fumes analy ser inserting the probe into a sealed extension pipe placed at the muffler exit end N B THE EXTENSION TUBE IS INDISP...

Page 121: ... CO lean mix If the adjustment of the flow screw causes a rpm increase readjust the revs again and if necessary the flow screw to reach stable values Characteristic CO adjustment 3 2 0 5 When the oil temperature the numbers of revs and the percentage of carbon monoxide are respected the idle carburetion is considered correct Further information can be drawn from the analyser carbon dioxide percent...

Page 122: ...nition failure or incorrect timing or a clogged or unsealed exhaust valve If it is difficult to adjust CO values check accurately That the automatic starter is efficient That the tapered pin housing is efficient Tank level adjustments Engine LX 4T USA ENG 122 ...

Page 123: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 124: ...E WHEEL HUB REMOVE THE BRAKE CALLIPER Front wheel hub overhaul Remove the ball bearing check seeger ring indi cated in the photograph 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 Suspensions LX 4T USA SUSP 124 ...

Page 125: ... 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 cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Punc...

Page 126: ...removing the transmissions and discon necting the electrical terminals remove the termi nal 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 Refitting Carry out the operations in the reverse order to the removal observing the prescribed ti...

Page 127: ...h the pin end 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 Remove the spacers part 17 fill with grease the area between the steering tube and the swinging hub and place the dust guard rings in that place Supplied with the tool N B ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION O...

Page 128: ...ce part 3 with part 16 on the stem Push from the handgrip the wedging washer roller casing seal ring unit placing part 16 until it stops on the swinging hub Repeat the operation described above using the tool fitted with part 16 and part 22 instead of part 4 on the stem on the side opposite the one shown in the figure to refit the second wedging washer roller casing sealing ring unit Supplied with...

Page 129: ...h 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 specific tool fitted with part 1 and op erate the handgrip until the pin and the Nadella are simultaneously ejected in the d...

Page 130: ... opposite to the one shown in the figure A Ø12 Punch B Sharp edged end 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 Suspensions LX 4T USA SUSP 130 ...

Page 131: ...P 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 Locking torques N m Steering lower ring nut 8 10 Steering upper ring nut 35 40 CAUTION USE NEW ROLLER CASINGS PIN SEALING RINGS AND DUST GUARDS FOR REFITTING Front shock absorber LX 4T USA Suspensions S...

Page 132: ... reverse order observing the prescribed tightening torques Locking torques N m shock absorber lower clamp 20 27 shock absorber upper clamp 20 30 Shock absorber calliper bracket Removal Remove the front wheel hub with the brake disc Remove the front shock absorber lower clamps Remove the bracket locking seeger ring Unscrew the bracket Suspensions LX 4T USA SUSP 132 ...

Page 133: ...absorber clamp 20 27 Overhaul The bracket for the shock absorber calliper at tachment has two roller bearings separated one from the other as shown in the photograph Remove the two roller bearings from the bracket with the specific tool operating on the shock ab sorber attachment side as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide...

Page 134: ...itably hold the brake calliper shock absorber attachment bracket Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool Specific tooling 020037Y Punch Refitting Refit the parts in reverse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Spe...

Page 135: ... tooling 020004Y Punch for removing fifth wheels from headstock 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 headstock Refit the fifth wheel fitting and the dust guard on the steering tube until they stop using the specific too...

Page 136: ...e 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 Suspensions LX 4T USA SUSP 136 ...

Page 137: ...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 LX 4T USA Suspensions SUSP 137 ...

Page 138: ...ng 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 Locking torques N m Shock absorber engine pin torque 33 to 41 N m Shock absorber frame nut torque 20 to 25 Nm Suspensions LX 4T USA SUSP 138 ...

Page 139: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 140: ...Calliper tightening screw 20 25 Nm Brake fluid tube calliper 20 25 Nm Overhaul Remove the calliper assembling bolts and take out the internal bodies and components If necessary in order to make it easier to take out the plungers inject shorts blasts of compressed air through the brake fluid pipe Check that the cylinders of the internal and external body of the calliper do not show scratches or sig...

Page 141: ... is tolerated CAUTION RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH Locking torques N m Screw tightening calliper to the support 20 25 Attachment to the calliper 25 30 Nm 1 DUST GUARDS 2 SEALING RINGS 3 PLUNGERS 4 O RING GASKET Front brake disc Removal Should the brake disc be replaced...

Page 142: ...the pads and replace them once the plungers are down Carry out these operations in reverse order to fit CAUTION BEFORE USING THE BRAKE OPERATE THE LEVER A FEW TIMES Front Once the bleed valve is closed fill the system with brake liquid to the maximum level Undo the bleed screw Apply the tube of the special tool to the bleed screws When bleeding it is necessary to fill the oil tank in continuation ...

Page 143: ...IT AB SORBS HUMIDITY FROM THE SURROUNDING AIR IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX CEEDS A GIVEN VALUE BRAKING EFFICIENCY WILL BE REDUCED THEREFORE ALWAYS USE FLUID FROM SEALED CON TAINERS UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS IF THE BRAKES ARE USED INTENSELY AND OR IN HARSH CONDITIONS CHANGE THE FLUID MORE FRE QUENTLY CAUTION WHEN C...

Page 144: ...SOLVENT CONTACT WITH BRAKE FLUID WILL DAMAGE PAINTED SURFACES RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH THE SEALING RINGS MUST BE IMMERSED IN THE OPER ATING LIQUID Refitting Before fitting the parts must be perfectly clean and free of traces of oil diesel fuel grease etc They shoul...

Page 145: ...d follow these steps 1 Remove the shoe spring using the specific span ner 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 Specific tooling 020325Y Brake shoe spring calliper LX 4T USA Braking system BRAK SYS 145 ...

Page 146: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 147: ...ument panel Operate the 4 screws shown in the figure to re place 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 LX 4T USA Chassis CHAS 147 ...

Page 148: ...s 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 LX 4T USA CHAS 148 ...

Page 149: ...love 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 Remove the two clamps indicated in the figure LX 4T USA Chassis CHAS 149 ...

Page 150: ...e 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 clip on badge Unscrew the screw indicated in the figure Remove the grille Chassis LX 4T USA CHAS 150 ...

Page 151: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 152: ...cording to directions Check the following devices Keyswitch Headlight full dipped beam panel indicator lights side lights Headlight adjustment Taillight Brake light front and rear brake Turn signals and relative indicators Speedometer and instrument panel lighting Horn Start button CAUTION TO ENSURE BEST PERFORMANCE BATTERY MUST BE CHARGED BEFORE USE ONLY IF VOLTAGE IS BELOW 12 7V FAILURE TO RECHA...

Page 153: ... ABOUT 15 MINUTES AND SEEK MEDICAL ASSISTANCE IM MEDIATELY IN THE CASE OF INGESTION OF ELECTROLYTE DRINK PLENTY OF WATER OR VEGETABLE OIL AND CALL A DOCTOR IMMEDIATELY Levels check Brake fluid Hub oil Engine oil level Road test Cold start Speedometer check Throttle check Riding stability Front and rear brake efficiency Front and rear shock absorbers Unusual noises Hot engine restart Leakages after...

Page 154: ...CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST WARNING BE VERY CAREFUL WHEN HANDLING FUEL Pre delivery LX 4T USA PRE DE 154 ...

Page 155: ...INDEX OF TOPICS TIME TIME ...

Page 156: ...Engine ENGINE Code Action Duration 1 001001 Engine from frame Removal and re fit 2 003064 Engine oil change Time LX 4T USA TIME 156 ...

Page 157: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase replace Crankshaft LX 4T USA Time TIME 157 ...

Page 158: ...99 Oil seal flywheel side Replacement 3 001100 Oil seal clutch side Replacement 4 001118 Main bearings Replacement Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder Piston Inspection Clean ing Time LX 4T USA TIME 158 ...

Page 159: ...Cylinder head assy HEAD Code Action Duration 1 001056 Head gasket change 2 001045 Valves Replacement 3 001126 Head Replacement LX 4T USA Time TIME 159 ...

Page 160: ...Rocker arms support assy CAMSHAFT SUPPORT Code Action Duration 1 001049 Valve clearance Adjustment 2 001148 Valve rocking levers Replacement 3 001044 Camshaft Replacement Time LX 4T USA TIME 160 ...

Page 161: ...Cylinder head cover HEAD COVER Code Action Duration 1 001093 Spark plug Replacement 2 001088 Head cover gasket change 3 001097 Cooling hood Replacement 4 001089 Head cover change LX 4T USA Time TIME 161 ...

Page 162: ...pulley DRIVEN PULLEY CLUTCH Code Action Duration 1 001110 Driven pulley Replacement 2 001012 Driven pulley Overhaul 3 001022 Clutch Replacement 4 001155 Clutch bell housing Replacement Time LX 4T USA TIME 162 ...

Page 163: ...ain change 2 001112 Oil pump change 3 001042 Oil pump overhaul 4 001121 Chain cover oil seal Replacement 5 001122 Oil pump chain change 6 001125 Chain guide pads change 7 001130 Oil sump change 8 001129 Chain tightener overhaul and re place LX 4T USA Time TIME 163 ...

Page 164: ...DUCTION GEAR ASSEMBLY Code Action Duration 1 004125 Rear wheel axle Replacement 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 001010 Gear reduction unit Inspection Time LX 4T USA TIME 164 ...

Page 165: ...VING PULLEY Code Action Duration 1 001177 Variator rollers shoes Replace ment 2 001086 Driving half pulley replace 3 001066 Driving pulley Removal and refitting 4 001011 rear view belt Replacement LX 4T USA Time TIME 165 ...

Page 166: ... Code Action Duration 1 001096 Transmission crankcase cover re place 2 001132 Transmission air intake pipe Re placement 3 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement Time LX 4T USA TIME 166 ...

Page 167: ...01020 Starter motor Replacement 2 005045 Starter motor cable harness Re placement 3 001017 Starter sprocket wheel Replace ment 4 001021 Kick starter Inspection 5 008008 Starter spring pack Replacement 6 001084 Starter lever Replacement LX 4T USA Time TIME 167 ...

Page 168: ...ction Duration 1 001067 Stator Fitting and Refitting 2 001173 Rotor Replacement 3 001102 Net oil filter change Cleaning 4 001109 Cooling fan Replacement 5 001087 Flywheel cover Replacement 6 001058 Flywheel Replacement Time LX 4T USA TIME 168 ...

Page 169: ... 1 001063 Carburettor Replacement 2 001008 Carburettor Inspection 3 003058 Carburettor Adjustment 4 001081 Automatic choke Replacement 5 001082 Carburettor heating resistor Re placement 6 001013 Intake manifold Replacement LX 4T USA Time TIME 169 ...

Page 170: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001136 Exhaust emissions Adjustment Time LX 4T USA TIME 170 ...

Page 171: ...Air cleaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting Re placement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement LX 4T USA Time TIME 171 ...

Page 172: ... Chassis Replacement 2 004023 Shield rim Replacement 3 004149 Shield central cover Replacement 4 004159 Plates Stickers Replacement 5 004012 Rear side panels Replacement 6 004059 Spark plug inspection flap Replace ment Time LX 4T USA TIME 172 ...

Page 173: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004171 Stand support plate Replacement LX 4T USA Time TIME 173 ...

Page 174: ...Footrests FOOTREST Code Action Duration 1 004178 Footrest Replacement 2 004078 Front rear footrest rubber Replace ment Time LX 4T USA TIME 174 ...

Page 175: ...LD BACK PLATE Code Action Duration 1 004174 Trunk levers Replacement 2 004065 Front shield rear part Removal and refitting 3 004081 Glove box door Replacement 4 004082 Trunk gasket Replacement LX 4T USA Time TIME 175 ...

Page 176: ...nt HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Replacement 2 005046 Battery cover change 3 004011 Central chassis cover Replacement 4 004071 Battery compartment replacement Time LX 4T USA TIME 176 ...

Page 177: ... holder LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate support Replacement 2 005048 Licence plate holder Replacement 3 005032 Licence plate light glass Replace ment LX 4T USA Time TIME 177 ...

Page 178: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement Time LX 4T USA TIME 178 ...

Page 179: ...on 1 004168 Fuel tank cap Replacement 2 005010 Tank float Replacement 3 004112 Cock carburettor hose Replace ment 4 004005 Fuel tank Replacement 5 004007 Fuel valve Replacement 6 004109 Fuel tank breather Replacement LX 4T USA Time TIME 179 ...

Page 180: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting Time LX 4T USA TIME 180 ...

Page 181: ...mn bearings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheel Replacement 2 003073 Steering clearance Adjustment 3 004119 Bearing upper steering fifth wheel Replacement LX 4T USA Time TIME 181 ...

Page 182: ...ction Duration 1 004018 Handlebar front section Replace ment 2 004019 Handlebar rear section Replace ment 3 005014 Odometer Replacement 4 005038 Instrument panel warning light bulbs Replacement 5 005078 Odometer glass Replacement Time LX 4T USA TIME 182 ...

Page 183: ... grip Replacement 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002063 Throttle control transmission Re placement 8 002060 Complete throttle control Replace ment 9 004162 Mirror support and or brake pump fit ting U bolt Replacement 10 002059 Right hand grip Replacement LX 4T USA Time TIME 183 ...

Page 184: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chassis con nection Replacement Time LX 4T USA TIME 184 ...

Page 185: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004131 Luggage rack support Replacement LX 4T USA Time TIME 185 ...

Page 186: ...2 Front turn indicator Replacement 3 005067 Front turn indicator bulb Replace ment 4 005008 Front headlamp bulbs Replacement 5 005005 Taillight Replacement 6 005066 Rear light bulbs Replacement 7 005022 Rear turn indicators Replacement 8 005068 Rear turn indicator bulb Replace ment Time LX 4T USA TIME 186 ...

Page 187: ...04123 Front wheel Replacement 2 003047 Front tyre replace 3 003037 Front wheel rim Replacement 4 003033 Front wheel hub Replacement 5 002041 Front brake disc Replacement 6 003034 Front wheel hub bearing Replace ment Rear wheel LX 4T USA Time TIME 187 ...

Page 188: ...eplace ment Electric devices ELECTRICAL COMPONENTS Code Action Duration 1 005001 Electrical system Replacement 2 005011 Start up remote control switch Re placement 3 005009 Voltage regulator Replacement 4 005007 Battery Replacement 5 005052 Fuse 1 Replacement 6 001023 Control unit Replacement 7 001094 Spark plug cap Replacement 8 001069 HV coil Replacement Time LX 4T USA TIME 188 ...

Page 189: ... Replacement 2 005006 Light switch or turn indicators Re placement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005016 Key switch Replacement 7 004096 Lock series Replacement 8 004010 Anti theft lock Replacement LX 4T USA Time TIME 189 ...

Page 190: ...issions TRANSMISSIONS Code Action Duration 1 002053 Rear brake transmission complete Replacement 2 002051 Odometer transmission assembly Replacement 3 002049 Odometer cable Replacement Time LX 4T USA TIME 190 ...

Page 191: ...on Duration 1 003045 Steering tube Replacement 2 003010 Front suspension Service 3 003035 Shock absorber support and brake calliper Replacement 4 001064 Odometer reel Replacement 5 003044 Shock absorber cover Replace ment LX 4T USA Time TIME 191 ...

Page 192: ...ont brake hose Remov and Re fitt 2 002007 Front brake shoes pads Remov and Refitt 3 002039 Front brake calliper Removal and Refitting 4 002047 Front brake fluid and air bleeding system Replacement 5 002002 Shoes Rear brake pads Replace ment Time LX 4T USA TIME 192 ...

Page 193: ...01164 Crankcase secondary air connection Replacement 2 001161 Secondary air filter Replacement Cleaning 3 001162 Secondary air housing Replace ment 4 001163 Muffler secondary air connection Replacement 5 001165 Secondary air reed Replacement LX 4T USA Time TIME 193 ...

Page 194: ...111 114 169 E Engine oil 33 F Fuel 41 110 179 H Headlight 35 148 Horn Hub oil 31 I Identification 8 Instrument panel 147 M Maintenance 7 27 O Oil filter 34 S Saddle Shock absorbers 137 Spark plug 31 Stand Start up T Tank 179 Transmission 10 42 64 74 166 Turn indicators Tyres 10 ...

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