VESPA LXV 125 Service Station Manual Download Page 163

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Front brake calliper

Removal

- Remove the front wheel.

- Remove the pad retention pin.

- Using a pin partially remove the brake pad re-

tention pin.

- Remove the screws fixing the brake calliper to

the crankcase then remove the brake calliper com-

plete with pipe.

- Complete the extraction of the pad retention pin,

the spring and the pads.

N.B.

IF BRAKE CALLIPER REPLACEMENT OR SERVICE IS
NEEDED, BEFORE REMOVING THE CALLIPER CLAMPS
TO THE SUPPORT BRACKET, LOOSEN THE OIL JOINT
FITTING.

Overhaul

- Remove the front brake calliper

- Suitably hold the brake calliper in a clamp

- Remove the two calliper coupling screws as

shown in the photo

- Remove the two pistons from the calliper body

with the aid of short blasts of compressed air

through the brake fluid holes

- Remove the dust ring and the O-ring of each half

calliper.

- Remove the O-rings in the half calliper.

N.B.

WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO
SCRATCH THE HALF CALLIPER SEATS

LXV 125

Braking system

BRAK SYS - 163

Summary of Contents for LXV 125

Page 1: ...Service station manual 633852 IT 633853 EN 633854 FR 633855 DE 633856 ES 633857 PT 633858 NL 633859 EL LXV 125 ...

Page 2: ...nges 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 Reproducti...

Page 3: ...to read the sections of this manual relating to special tools along with the special 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 ...

Page 4: ...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 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 6: ...t you do not breathe in the dust produced by the wear 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...

Page 7: ...esc Quantity Engine prefix ZAP M444M Chassis prefix ZAP M443010000 0000 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Kerb weight 114 5 kg Overall height 1180 mm Width 740 mm Wheelbase 1280 mm Length 1800 mm LXV 125 Characteristics CHAR 7 ...

Page 8: ...r reduction unit and transmission housing with forced air circulation cooling Capacities CAPACITY Specification Desc Quantity Engine oil 61 in 1 000 cm Rear hub oil 100 cm Fuel tank capacity 8 5 litres 2 l of which is reserve Electrical system ELECTRICAL SYSTEM Specification Desc Quantity Start up Electric Spark plug Champion RG6YC NGK CR7EB Frame and suspensions FRAME AND SUSPENSIONS Specificatio...

Page 9: ...ping CVK Throttle valve diameter Ø 26 5 Diffuser diameter Ø 26 4 Maximum jet 82 Maximum air jet on the body 85 Tapered pin stamping NELA Throttle valve spring 130 180 gr Minimum jet 35 Idle air jet on the body 150 Idle mixture adjustment screw initial opening 2 Starter jet 42 Starter air jet on the body Ø 1 5 Starter pin travel 10 mm at 24 Starter resistance 20 Ohm at 24 Kehin CARBURETTOR SETTING ...

Page 10: ...lley screw 12 14 Timing chain tensioner slider screw 10 14 Starter ground support screw 11 15 Tensioner screws 11 13 Timing chain tensioner central screw 5 6 Camshaft retention plate screw 5 6 Nut fixing muffler to cylinder head 16 18 Head intake manifold screw 11 13 TRANSMISSION Name Torque in Nm Drive pulley nut 75 83 Transmission cover screw 11 13 Driven pulley shaft nut 54 60 Rear hub cap scre...

Page 11: ...tightening calliper to the support 20 25 Brake disc screw 5 6 5 Oil bleed valve on the calliper 10 12 Handlebar pump 7 10 REAR SUSPENSION Name Torque in Nm Rear wheel axle 104 126 Lower shock absorber clamp 33 41 Shock absorber frame nut 20 25 Overhaul data Assembly clearances Cylinder piston assy COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER Name Initials Cylinder Piston Pla...

Page 12: ... oversize P1 57 218 57 225 57 165 57 172 0 046 0 060 Coupling 2nd oversize M2 57 397 57 404 57 344 57 351 0 046 0 060 Coupling 2nd oversize N2 57 404 57 411 57 351 57 358 0 046 0 060 Coupling 2nd oversize O2 57 411 57 418 57 358 57 365 0 046 0 060 Coupling 2nd oversize P2 57 418 57 425 57 365 57 372 0 046 0 060 Coupling 3rd oversize M3 57 597 57 604 57 544 57 551 0 046 0 060 Coupling 3rd oversize ...

Page 13: ...ion Dimensions Initials Quantity Crankshaft Category 1 28 998 29 004 Crankshaft Class 2 29 004 29 010 Crankcase Category 1 32 953 32 959 Crankcase Category 2 32 959 32 965 Crankshaft half bearing Category B blue 1 973 1 976 Crankshaft half bearing Type C yellow 1 976 1 979 Crankshaft half bearing Category E green 1 979 1 982 Crankshaft category 1 Crankcase category 1 E E Crankshaft category 1 Cran...

Page 14: ...oint of the dial gauge rotation Calculate the difference between the two measurements use the chart below to identify the thickness of the cylinder base gasket to be used for refitting The proper identification of the cylinder base gasket thickness allows maintaining the correct compression ratio Remove the special tool and the cylinder Characteristic Compression ratio 125 10 6 1 SHIMMING SYSTEM S...

Page 15: ...rol and odometer Oil for 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased adhesiveness AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP GP 330 Grease for brake control levers throttle ...

Page 16: ...INDEX OF TOPICS TOOLING TOOL ...

Page 17: ...ription 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor LXV 125 Tooling TOOL 17 ...

Page 18: ...ch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge Tooling LXV 125 TOOL 18 ...

Page 19: ...tting strip 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cylinder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing LXV 125 Tooling TOOL 19 ...

Page 20: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger Tooling LXV 125 TOOL 20 ...

Page 21: ...ores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47 mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25 mm guide LXV 125 Tooling TOOL 21 ...

Page 22: ...Description 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor Peak voltage detec tion Tooling LXV 125 TOOL 22 ...

Page 23: ...tion 020412Y 15 mm guide 020414Y 28 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel side oil seal 020426Y Piston fitting fork LXV 125 Tooling TOOL 23 ...

Page 24: ...ton fitting band 020428Y Piston position check support 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting removing the driven pulley clutch Tooling LXV 125 TOOL 24 ...

Page 25: ...Stores code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission side oil guard punch LXV 125 Tooling TOOL 25 ...

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

Page 27: ...on AFTER 6000 KM 18000 KM 54000 KM 150 Action Engine oil replacement Hub oil level check Spark plug electrode gap check Air filter clean Engine oil change Oil filter net filter clean Valve clearance adjustment Variable speed rollers pads check Driving belt checking Brake pads check condition and wear Brake fluid level check Electrical system and battery check Centre stand lubrication Tyre pressure...

Page 28: ...eplacement Cylinder ventilation system cleaning Odometer gear greasing Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Secondary air filter cleaning Centre stand lubrication Vehicle...

Page 29: ...rake test road test See instructions in Idle speed adjustment section AFTER 72 000 KM 300 Action Engine oil replacement Hub oil change Spark plug replacement Air filter clean Engine oil change Oil filter net filter clean Valve clearance adjustment Idle speed adjustment Throttle lever adjustment Pads and variator rollers replacement Driving belt replacement Odometer gear greasing Steering adjustmen...

Page 30: ... transmission compartment air intake cover shown in the photograph Rotate the driving pulley fan using a screwdriver until the reference marks between the flywheel and flywheel cover coincide as shown in the pho tograph Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the photograph Refit the spark plug Refit the plastic cap on the flywheel...

Page 31: ...ignition advance use the stroboscopic light with induction pincers connected to the spark plug power wire Connect the induction pincers being careful to respect the proper polarity the arrow stamped on the pincers must be pointing at the spark plug Place the light selector in central position 1 spark 1 crankshaft turn as in 2 T engines Start the engine and check that the light works properly and t...

Page 32: ...OLUTION LIMITER Specification Desc Quantity Operation threshold First threshold 9300 50 Second threshold 9800 50 Reactivation threshold First threshold 8850 50 Second threshold 9350 50 Spark elimination First threshold 10 sparks on 15 Second threshold 15 sparks on 15 Braking system Level check Proceed as follows Rest the vehicle on its centre stand with the han dlebars perfectly horizontal Check t...

Page 33: ... BE INEF FICIENT NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDITIONS THE FLUID MUST BE CHANGED EVERY 20 000 KM OR ANYWAY EV ERY TWO YEARS N B SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Headlight adjustment Procee...

Page 34: ...I MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED SAS filters inspection and cleaning Proceed as follows Remove the right hand side fairing Remove the screw on the rear part to the right of the footrest indicated in the photograph Remove the spoiler terminal Remove the screw fixing the SAS valve to the flywheel cover indicated in th...

Page 35: ...ilter housing for dents or defor mations Clean the SAS filter carefully Replace the filter if it is damaged or deformed To refit carry out the removal operations but in re verse order CAUTION WHEN TRAVELLING ON DUSTY ROADS THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER LXV 125 Maintenance MAIN 35...

Page 36: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 37: ... valves Remove the head and the valves grind or replace the valves Valve seat distorted 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 ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpm too high Adjust the idle speed Clutch fault Check the springs clutch masses Starti...

Page 38: ...s area Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level using the recommended oil type Selenia HI Scooter 4 Tech Engine tends to cut off at full throttle THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE Possible Cause Operation Maximum jet clogged Remove the carburettor wash ...

Page 39: ...Insufficient braking INEFFICIENT OR NOISY BRAKING Possible Cause Operation Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or drum wear conditions Front brake disk loose or deformed Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Air bubbles inside the hydraulic braking system Carefu...

Page 40: ...failure With the key switch set to ON jump the contacts 1 Blue Black and 5 Orange on the control unit connector If by operating the turn indicator control the lights are not stead ily on replace the control unit otherwise check the cable harness and the switch Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and ...

Page 41: ...arings are good condition Finally check the locking torque of the wheel axle nut the brake calliper and the disc Check that the swinging arm con necting the engine to the chassis and the rear shock absorber work properly Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Replace the damper LXV 125 Troubleshooting TROUBL 41 ...

Page 42: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 43: ...S 7 Riscaldatore carburatore 8 Starter automatico 9 Commutatore a chiave 10 Regolatore di tensione 11 Fusibili principali 12 Batteria 13 Motorino di avviamento 14 Teleruttore di avviamento 15 Pulsante di avviamento 16 Pulsante di stop sul freno posteriore 17 Fusibili secondari 18 Pulsante di stop sul freno anteriore 19 Commutatore lampeggiatori LXV 125 Electrical system ELE SYS 43 ...

Page 44: ... di direzione anteriore destro 29 Sensore pressione olio 30 Gruppo strumenti A Spia indicatori di direzione B Spia luce abbagliante C Spia riserva carburante D Spia pressione olio E Spia immobilizer 31 Predisposizione spia acustica indicatori di direzione 32 Trasmettitore livello carburante 33 Relé luce anabbagliante 34 Relé luce abbagliante 35 Deviatore luci con sprazzo 36 Pompa carburante 37 Dis...

Page 45: ...iometer 6 Voltage regulator 7 Key switch 8 Engine stop switch 9 Automatic starter 10 Carburettor heater 11 Fuse box 12 Battery 13 Starter motor 14 Starter remote control 15 Starter button 16 Fuel pump 17 Fuse box 18 STOP button on front brake 19 STOP button on rear brake LXV 125 Electrical system ELE SYS 45 ...

Page 46: ...28 Right turn front indicator lamp 29 High beam light remote control 30 Low beam light remote control 31 Fuel level warning light control 32 Low oil warning light control 33 Instrument panel 34 Horn button 35 Horn 36 Turn indicator sound alarm wiring 37 Spark plug 38 High voltage coil 39 external temperature sensor Ar Orange Az Sky Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink ...

Page 47: ...ompa elettrica 1 Dispositivo di accensione elettronica 2 Antenna immobilizer 5 Deviatore arresto motore 9 Commutatore a chiave 11 Fusibili principali 12 Batteria 39 Bobina A T 40 Candela LXV 125 Electrical system ELE SYS 47 ...

Page 48: ...eto flywheel 2 Electronic ignition device 3 Immobilizer aerial 6 Voltage regulator 7 Key switch 8 Engine stop switch 11 Fuse box 12 Battery 37 Spark plug 38 High voltage coil Electrical system LXV 125 ELE SYS 48 ...

Page 49: ...tatore a chiave 11 Fusibili principali 12 Batteria 17 Fusibili secondari 22 Lampada illuminazione targa 24 Lampada luce di stop e di posizione posteriore 27 Proiettore completo A Lampada per luce di posizione B Lampada per luce abbagliante e anabbagliante 30 Gruppo strumenti A Spia indicatori di direzione B Spia luce abbagliante C Spia riserva carburante LXV 125 Electrical system ELE SYS 49 ...

Page 50: ...vice 7 Key switch 9 Automatic starter 10 Carburettor heater 11 Fuse box 12 Battery 17 Fuse box 22 Rear headlight assembly with tail light stop light bulb 23 License plate bulb 25 Light switch 27 Front headlight assembly with high low beam light bulb 29 High beam light remote control 30 Low beam light remote control Electrical system LXV 125 ELE SYS 50 ...

Page 51: ...o motore 9 Commutatore a chiave 10 Regolatore di tensione 11 Fusibili principali 12 Batteria 13 Motorino di avviamento 14 Teleruttore di avviamento 15 Pulsante di avviamento 16 Pulsante di stop sul freno posteriore 17 Fusibili secondari 18 Pulsante di stop sul freno anteriore 24 Lampada luce di stop e di posizione posteriore LXV 125 Electrical system ELE SYS 51 ...

Page 52: ...e stop switch 11 Fuse box 12 Battery 13 Starter motor 14 Starter remote control 15 Starter button 17 Fuse box 18 STOP button on front brake 19 STOP button on rear brake 22 Rear headlight assembly with tail light stop light bulb Electrical system LXV 125 ELE SYS 52 ...

Page 53: ...sterna 5 Deviatore arresto motore 6 T P S 9 Commutatore a chiave 11 Fusibili principali 12 Batteria 17 Fusibili secondari 29 Sensore pressione olio 30 Gruppo strumenti A Spia indicatori di direzione B Spia luce abbagliante C Spia riserva carburante D Spia pressione olio E Spia immobilizer 32 Trasmettitore livello carburante LXV 125 Electrical system ELE SYS 53 ...

Page 54: ...rial 4 Diagnostics socket 5 TPS potentiometer 7 Key switch 11 Fuse box 12 Battery 17 Fuse box 31 Fuel level warning light control 32 Low oil warning light control 33 Instrument panel 39 external temperature sensor Electrical system LXV 125 ELE SYS 54 ...

Page 55: ... secondari 19 Commutatore lampeggiatori 20 Clacson 21 Pulsante clacson 23 Indicatore di direzione posteriore sinistro 25 Indicatore di direzione posteriore destro 26 Indicatore di direzione anteriore sinistro 28 Indicatore di direzione anteriore destro 30 Gruppo strumenti A Spia indicatori di direzione B Spia luce abbagliante C Spia riserva carburante LXV 125 Electrical system ELE SYS 55 ...

Page 56: ... carburante 37 Dispositivo di gestione pompa 1 Chiave 3 Massa pompa 4 Pompa 5 Massa 6 Giri motore KEY 2 Electronic ignition device 7 Key switch 8 Engine stop switch 11 Fuse box 12 Battery 16 Fuel pump 17 Fuse box 20 Turn indicator switch 21 Left turn rear indicator lamp Electrical system LXV 125 ELE SYS 56 ...

Page 57: ...r chiave master con trasponder incorporato chiave rossa con impugnatura grande chiave di servizio con trasponder incorporato chiave nera con impugnatura piccola bobina A T led diagnostico Il led diagnostico svolge anche la funzione di lampeggio deterrente Questa funzione si ottiene ogni volta che il commutatore a chiave viene posizionato in OFF o se l interruttore di arresto di emergenza viene com...

Page 58: ... clean and reprogrammed for the memorisation of the service keys The master and service keys must be used to code the system as follows Insert the Master key turn it to ON and keep this position for two seconds lower and upper limits 1 to 3 seconds Insert the service key and turn it to ON for 2 seconds If you have copies of the key repeat the operation with each key Insert the MASTER key again and...

Page 59: ...permanently The keys can be stored to memory the vehicle can be star ted but with a limitation imposed on the number of revs 2 Previously unused control unit transpond er absent or cannot be used The LED is per manently ON in this condition no operations are possible including starting of the vehicle 3 Programmed control unit the service key in normal condition of use a single 0 7 second flash is ...

Page 60: ...t or is not detected Check the Immobilizer aerial wiring and change it if nec essary Diagnostic code 2 flashes A two flash code shows a system where the con trol unit does not show the transponder signal This might depend on the inefficiency of the immobiliser aerial or the transponder Turn the switch to ON using several keys if the code is repeated even with the Master key check the aerial wiring...

Page 61: ...relevant for the ignition system The Pick Up is connected to the control unit by a single cable therefore the control unit is connected to the Pick Up by the chassis and the engine ground lead To avoid disturbances in the ignition system during start up it is very important that the engine chassis ground connection bonding is efficient No spark plug Once the lack of power to the spark plug has bee...

Page 62: ... characteristic High voltage coil primary resistance value High voltage coil primary resistance value 0 4 0 5 Ohm HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal see figure If non conforming values are measured replace the HV coil To carry out a more complete diagnosis check the peak ...

Page 63: ...ive connector If non conforming values are measured replace the control unit THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK Electric characteristic High voltage coil voltage value High voltage coil voltage value 100 Volt Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel The alternator is directly connected to the voltage regulator...

Page 64: ...RATURE A CHECK WITH THE STATOR AT OPERATING TEMPERA TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED Voltage regulator check With a perfectly charged battery and lights off measure voltage at the battery poles with a high running engine The voltage should not exceed 15 2 Volt In case higher voltages are detected replace the regulator In case of voltage values lower than 14 Volt check the stator ...

Page 65: ...with the key switch set to ON and the en gine emergency cut off switch set to RUN check there is voltage in the battery If there is no voltage check the wiring connections to the key switch and that fuse No 1 works properly If there is voltage check again the ignition control unit connector After disconnecting the starter start up the engine and keep it at idle speed and check there is voltage whe...

Page 66: ...o 12 Black and earth connection If no voltage is detected check the cable harness and the connections otherwise proceed as fol lows Jump terminals No 2 Black Blue and No 9 Sky blue see figure and turn the turn indicator switch alternatively to the left and the right with the key switch in ON and check that the lights turn on If they do replace the control unit because it is faulty If they do not t...

Page 67: ...ITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE BULBS Specification Desc Quantity 1 High low beam light bulb Type Halogen H4 Power 12V 55 60W Quantity 1 2 Fro...

Page 68: ... V a renewal recharge is required as explained in 2 2 Constant voltage battery charge mode Constant voltage charge equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for Nominal capacity Charge time 10 to 12 h recommended Minimum 6 h Maximum 24 h 3 Constant current battery charge mode Charge current equal to 1 10 of the battery rated capacity Charge time Maximum 5 h Dry charge battery W...

Page 69: ...e battery on the vehicle ensuring that it is wired up properly 1 Hold the vertical tube 2 Look at the level 3 The float must be freed WARNING ONCE THE BATTERY HAS BEEN INSTALLED IN THE VE HICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE WITH CLOSED END NEAR THE POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE WITH OPEN END THAT YOU FIND FITTED TO THE VEHICLE TO EN SURE THAT THE GASES THAT FORM CA...

Page 70: ...charging must be carried out with the specific battery charger single or multiple setting the battery charger selector to the type of battery to be recharged Connections to the power supply source must be implemented by connecting the corresponding poles to and to 4 Battery cleaning The battery should always be kept clean especially on its top side and the terminals should be coated with Vaseline ...

Page 71: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 72: ...r Removal of the engine from the vehicle Remove the left and right side fairings Remove the helmet compartment Remove the full muffler assembly Remove the 3 rear brake transmission fixing screws indicated in the photograph Disconnect the rear brake transmission unscrew ing the set screw Disconnect the belt cooling tube and the swinging arm retaining spring shown in the photograph Disconnect the sp...

Page 73: ...emove the fuel supply pipe from the carburettor Remove the fuel valve low pressure pipe from the manifold as shown in the photograph Remove the flywheel wiring connector the earth terminal and the starter motor positive cable indi cated in the figure LXV 125 Engine from vehicle ENG VE 73 ...

Page 74: ...ttor heater and TPS connectors Unscrew the engine pin swinging arm nut on the right hand side of the vehicle and slide off the pin on the left hand side Support the vehicle adequately with a jack and remove the shock absorber lower clamping The engine is now free Engine from vehicle LXV 125 ENG VE 74 ...

Page 75: ...INDEX OF TOPICS ENGINE ENG ...

Page 76: ...em Remove the transmission cover If this operation is performed directly on the vehicle it is necessary to remove the cooling air coupling and the three air filter housing retainers Specific tooling 020423Y driven pulley lock wrench Kickstart Check the following for wear toothed section toothed section shaft cover seat bushing pinion shaft and its seating in the crankcase and the re turn spring Re...

Page 77: ...en the screws to the prescribed torque Remove the start up pinion pushing the starter lever Unscrew the kick starter screw remove the lever Remove the seeger ring and the washer indicated in the figure Pull out the toothed section WARNING THE SECTION KEEPS THE SPRING SET BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS Air duct Unscrew the Torx screws fixing the air manifold bulkhead and remove the bul...

Page 78: ...TO AVOID DAM AGING THE COVER PAINT Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm Refitting the driven pulley shaft bearing Heat up the crankcase inside with the hot air gun Insert the bearing in its housing refit the Seeger ring N B ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING Specific tooling 020151Y Air heater 020376Y Adaptor handle Engine LXV 125 ENG 78 ...

Page 79: ... bell is not worn or damaged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value Ø 134 5 mm Clutch bell standard value Standard value Ø 134 134 2 mm Checking the bell working surface eccentricity Install the bell on a driven pulley shaft using 2 bearings inner diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support...

Page 80: ...d in the tool set to C Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes After wards make the support screw make contact with a minimum force Using the specific wrench inserted 46 mm from the side remove the clutch central locking nut Separate the driven pulley into its components clutch with fan and contrast spring with plastic fittings CAUTION THE TOO...

Page 81: ... 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 3 guide pins and the movable half pulley Removing the driven half pulley bearing Remove the retaining ring using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as shown in the figure Remove the roller bearin...

Page 82: ... bush ing Characteristic Minimum diameter permitted Ø 40 96 mm Standard diameter Ø 40 965 mm Inspecting the driven sliding half pulley Remove the 2 inner sealing rings and the two O rings Measure the inside diameter of the mobile half pulley bushing Characteristic Minimum admissible diameter Ø 41 08 mm Standard diameter Ø 41 035 mm Engine LXV 125 ENG 82 ...

Page 83: ...or 28 x 30 mm 020376Y Adaptor handle 020439Y 17 mm guide Refitting the driven pulley Check that the faying surfaces between the 2 half pulleys and the belt do not show any signs of wear scoring and grease Insert the new oil seals and O rings on the mov able half pulley Assemble the half pulley on the ringlet with the appropriate protection sheath Make sure the pins and collar are not worn re assem...

Page 84: ...teristic Standard length 106 mm Refitting 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 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...

Page 85: ...nto the adapter ring before proceeding to tighten the clutch nut Place the tool in the clamp with the control screw on the horizontal axis Fully preload the spring Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench Loosen the tool clamp and insert the belt accord ing to its direction of rotation Lock the driven pulley again using the specific tool Pr...

Page 86: ...he wear checks foreseen in the scheduled maintenance services at 6 000 km 18 000 km etc check that the rim bottom of the toothing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Check that the driving belt is not damaged Check the width of the belt BELT SIZE Specification Desc Quantity Minimum width ...

Page 87: ... rollers Remove the return rollers plate with the relative guide pads Inspecting the rollers case Check that the internal bushing is not abnormally worn and measure inner diameter N B DO NOT LUBRICATE OR CLEAN THE BUSHING BUSHING ROLLER CONTAINER Specification Desc Quantity Maximum allowable diameter Ø 26 121 mm Standard diameter Ø 26 0 0 021 mm BUSH SLIDE PULLEY Specification Desc Quantity Minimu...

Page 88: ...al lining fixed half pulley external lining drive and nut spread threadlock on the thread and screw the nut to the prescribed torque Avoid the half pulley rotation using a calliper spanner N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT Specific tooling 020368Y driving pulley lock wrench Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking to...

Page 89: ...and the torque wrench tools Replace the plastic cover Specific tooling 020423Y driven pulley lock wrench Locking torques N m Transmission cover screws 11 13 Driven pul ley shaft nut 54 60 End gear Removing the hub cover Empty the rear hub through the oil drainage tap located inside the hub cover Remove the brake shoe and relevant spring Remove the 7 flanged screws as shown in the figure Remove the...

Page 90: ...tor to remove the three 15 mm bearings 2 in the crankcase and 1 in the hub cover Specific tooling 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings Removing the wheel axle bearings Take out the clip on the outside of the gearbox cover Remove the bearing with the adequate tools ad equately supporting the hub cover as shown in the figure Specific tooling 020376Y A...

Page 91: ...river working from inside the bearing and being careful not to damage the housing make it come out of the belt transmission side Remove the seeger ring shown in the figure With the sectional punch remove the driven pulley shaft bearing Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide See also Removing the driven pulley Inspecting the hub shaft Check the three ...

Page 92: ... it with ball bearing in view from the inside of the hub cover using the adequate tools Specific tooling 020376Y Adaptor handle Refit the Seeger ring with the opening facing the bearing as shown in the figure and fit a new oil guard flush with the crankcase Refitting the wheel axle bearing Heat up the parts using the specific heat gun Specific tooling 020151Y Air heater 020150Y Air heater support ...

Page 93: ...5 mm Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the specific heat gun Specific tooling 020150Y Air heater support 020151Y Air heater The three 15 mm bearings must be fitted using the appropriate tools Refitting the hub bearings Insert the cover prepared in the crankcase taking care of inserting the gear of the pul...

Page 94: ...HOUSING Loosen the clamp and remove the carburettor from the manifold Remove the complete manifold acting on the 2 retainers as shown in the figure Remove the 2 self threading screws left and right and the lateral base retaining screw on the crank case base Take off the housings Remove the gasket seal of the housing on the head N B IF THE FLYWHEEL HOUSING IS NOT REMOVED IT IS AL SO NECESSARY TO RE...

Page 95: ... The long spacers should be in a high position CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR Remove the cooling fan by acting on the three fixings indicated in the figure Removing the stator Remove the electric terminal of the minimum oil pressure switch Remove the two Pick Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the fi...

Page 96: ...E REFERENCE PIN AS SHOWN IN THE DETAIL DRAWING Locking torques N m Stator screw 3 4 Flywheel and starting 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 Specific tooling 020565Y Flywheel lock calliper spanner Extract the flywheel with the extrac...

Page 97: ...ick Up Different values result from deformations visible on the Pick Up support N B A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED Locking torques N m Flywheel nut 52 58 Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter on the crankcase locking the two screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRIBED ...

Page 98: ...two fixings shown in the figure Remove the tensioner with its gasket Remove the internal hex screw and the counter weight shown in the figure Remove the camshaft command pulley and its washer Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner pad The chain tensioning pad must be removed from the transmission side As reg...

Page 99: ... INVERSION OF INLET WITH THE OUT LET Removing the cylinder head 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 IN CASE OF NEED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS ROCKING LEVERS AND FIXING BRACKET THE HEAD CAN ALSO BE...

Page 100: ...e the oil seals with the appropriate tool Remove the lower spring supports Specific tooling 020431Y Valve oil seal extractor Removing the cylinder piston assy Remove the chain guide pad Remove the cylinder base gasket CAUTION TO AVOID DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER Remove the two stop rings the wrist pin and the piston Remove the 3 piston rings from the piston N B BE CA...

Page 101: ...up Maximum diameter 15 030 mm Rod small end check up Standard diameter 15 0 015 0 025 mm Inspecting the wrist pin Check the outer diameter of the gudgeon pin Characteristic Standard pin diameter 14 996 15 mm Minimum diameter permitted Ø 14 994 mm Calculate the piston pin coupling clearance N B THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED ...

Page 102: ... D Characteristic Maximum allowable run out 0 05 mm The cylinder rectifying operation should be car ried out with a surfacing that respects the original angle The cylinder surface roughness should be 0 9 micron This is indispensable for a good seating of the sealing rings which in turn minimises oil consump tion and guarantees optimum performance The pistons are oversized due to cylinder rectifi c...

Page 103: ...tall piston and wrist pin onto the connecting rod aligning the piston arrow the arrow facing to wards the exhaust Fit the pin stop ring onto the appropriate tool Specific tooling 020430Y Pin lock fitting tool With the opening in position indicated on the tool take stop ring in the closed position using the punch Fit the wrist pin stop using the plug as shown in the figure N B THE TOOL FOR INSTALLI...

Page 104: ...on ring with the word top or the reference mark facing the crown of the piston Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure Lubricate the components with engine oil N B SO AS TO OBTAIN THE BEST CONFIGURATION THE 2 SEALING RINGS ARE MADE WITH A CONTACT CONICAL CYLINDER SECTION Refitting the cylinder Insert the cylinder base gasket with the thickness det...

Page 105: ...tic Maximum admitted unevenness Head check 0 05 mm STANDARD DIAMETER Specification Desc Quantity Standard diameter A Ø 32 5 32 525 Standard diameter B Ø 20 20 021 Standard diameter C Ø 12 12 018 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 sin...

Page 106: ...e on the valve seats VALVE SEAL SURFACE Specification Desc Quantity Inlet valve seal surface 2 4 2 8 mm Outlet valve seal surface 2 2 2 6 mm 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 heights in the rocker arm push direction Characteristic Standard drainage guide diameter 5 ...

Page 107: ...istic Minimum diameter admitted Inlet 4 96 mm Minimum diameter admitted Outlet 4 95 mm Standard clearance Inlet 0 013 0 040 mm Standard clearance Outlet 0 025 0 052 mm Maximum clearance admitted Inlet 0 062 mm Maximum clearance admitted Outlet 0 072 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 ...

Page 108: ...E VALVE WHEN NO LAPPING COM POUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED Insert the 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 Insp...

Page 109: ...ess the springs and insert the cotters in their seats Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft Inspect the cam shaft for signs of abnormal wear on the cams Characteristic Standard diameter Bearing A Ø 32 5 mm 0 025 0 050 mm Standard diameter Bearing B 20 0 020 0 041 mm Minimum admitted diameter bea...

Page 110: ...yielded Replace any defective or worn components Check there are no signs of scoring or wear on the rocking lever bolt Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate Measure the internal diameter of each rocking lever Check that the elastic washer dedicated to the axle clearance of the rocking levers is not worn In case of anomalies replac...

Page 111: ...l on the crank shaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the tensioner pad by the cylinder head Fit the spacer and the screw fastener Fit the pin the outlet rocking lever the spring washer and the inlet rocking lever Lubricate the 2 rocking levers through the holes at the top Lubricate the 2 bearings and insert the camshaft in ...

Page 112: ...it the end stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft Fit the automatic valve lifter return spring During this operation the spring must be loaded approximately 180 N B GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE Fit the automatic valve lifter retaining dish using the counterweight screw fastener as a refere...

Page 113: ...tting direction use the supplements on the timing side as reference Assemble the screw fixing the housing to the crankcase to the specified torque and the 2 self threading screws joining the half shells Take care that the gasket is well inserted in its housing during the assembly stage Place the spark plug access cap Locking torques N m Locking torque 3 4 Fit the inlet manifold and lock the 2 scre...

Page 114: ...cribed in the transmission chapter Remove the oil sump the by pass the chain compartment cover and the oil pump as in the lu brication chapter Remove the flywheel cover the fan the flywheel and the stator as described in the magneto fly wheel chapter Remove the oil filter and the oil pressure bulb Remove the cylinder piston head unit as descri bed in the cylinder head timing system chapter Remove ...

Page 115: ...of the crankcase halves Remove the two screws and the internal cover shown in the diagram CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS Remove the oil guard on the flywheel side Remove the oil filter fitting shown in the diagram Check the...

Page 116: ...rankshaft does not have any defect the problem must be due to either excessive wear or wrong machining on the crankcase CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING Characteristic Distance between the shoulders 55 67 55 85 mm Check the diameters of both the bearings of the crankshaft in accordance with the axes and surf...

Page 117: ... may not be replaced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the lubrication duct with compressed air Make sure that the 2 caps on the crankpin are properly fitted A wrong installation of a cap can seriously affect the bushing lubrication pressur...

Page 118: ...ONNECTING ROD LUBRICATION PRESSURE On the flywheel side crankcase half take partic ular care cleaning the oil ducts for the main bush ings the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the fly wheel side oil seal N B THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET THIS GIVES A LOW PRESSURE HEAD LUBRICATION THIS CHOICE WAS MADE TO REDUCE THE OIL...

Page 119: ...tand the thrusts caused by combustion and for this reason it is arranged opposed the cylinder To prevent shutters in the oil feeding channels the matching surface of the two half bearings must be perfectly orthogonal to the cylinder axis as shown in the figure The oil supply channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting ...

Page 120: ...O ALLOW BENDING DURING THE DRIVING OPERATION MAIN BEARINGS Specification Desc Quantity B Blue C Yellow E Green Refitting the crankcase halves Fit the internal bulkhead by locking the two screws to the prescribed torque Locking torques N m Locking torque 4 6 Fit the oil filter joint and tighten it to the prescribed torque Place a new gasket on one of the crankcase halves preferably on the transmiss...

Page 121: ... Use the appropriate tool to assemble the oil seal Fit a new O ring on the pre filter and lubricate it Insert the pre filter on the engine with its corre sponding cover to the specific torque N B REMOVE ANY EXCESS FROM THE CRANKCASE COU PLING GASKET ON THE CYLINDER PLANE TO ENSURE BETTER SEALING PERFORMANCE N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CON...

Page 122: ...Conceptual diagrams Engine LXV 125 ENG 122 ...

Page 123: ...ween 3 2 4 2 atm Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the prescribed torque and fit the fan cover If the oil pressure is outside the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVE...

Page 124: ...ew the threaded bar onto the base of the tool and extract the oil guard Specific tooling 020622Y Transmission side oil guard punch Refitting Prepare the new oil guard lubricating the sealing lip Warning do not lubricate the surface for keying onto the engine crankcase CAUTION DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE Engine LXV 125 ENG 124 ...

Page 125: ...ase CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL GUARD FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL GUARD SHEATH Orientate the oil guard by inserting the bracket which is part of the specific tool Tighten the threaded bar onto the crankshaft as far as it will go LXV 125 Engine...

Page 126: ...semble a new oil seal on the flywheel side using the specific tool as shown in the photograph N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE IN INADEQUATE OIL SEALING Specific tooling 020425Y Punch for flywheel side oil seal Oil pump Removal Remove the cover of the pump control pulley us ing the two retainers as shown in the figure Block the ro...

Page 127: ...THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the clip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Reassemble the rotors in the pump body keep ing the two reference marks visible Replace the clip Using a thickness gauge check the distance be tween the rotors in the position...

Page 128: ...pump shaft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the assembly Fit the pulley to the pump the central screw to the specified torque and the belleville washer Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE BELLEVILLE WASHER SO THAT ITS OUTER C...

Page 129: ... the figure and the 2 rear brake transmission fixing brackets Remove the spring the by pass piston and the gasket shown in the second image Inspecting the by pass valve Check the unloaded spring length Check that the small piston is not scored Ensure that it slides freely on the crankcase and that it guarantees a good seal If not eliminate any impurities or replace defec tive parts Characteristic ...

Page 130: ...cover as de scribed in the Transmissions chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the crankshaft and con necting rod Locking torques N m Locking torque 11 13 SAS valve Inspecting the one way valve Remove the SAS valve Provisionally assemble the rubber coupling of the SAS valve outlet to ensure tightness Connect the MITYVAC ...

Page 131: ...his value is kept all the time If a worn seal is detected replace it With a T bypass and flexible rubber hoses make a parallel connection between the rubber coupling and the vacuum intake of the CUT OFF valve Connect the bypass to the MITYVAC pump Set the pump set to the low pressure mode VACUUM Using a pair of long flat pliers choke the rubber hose next to the valve Operate the pump until vacuum ...

Page 132: ...ply 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 MITIVAC 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 Turn the...

Page 133: ... 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 Removing the carburettor To detach the carburettor from the engine it is necessary to move the air filter and remove the throttle control transmission the automatic starter connectio...

Page 134: ...n the figure Remove the 2 screws and the starter support with the gasket Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Engine LXV 125 ENG 134 ...

Page 135: ... di aphragm Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Remove the 4 screws indicated in the figure Remove the chamber with the accelerating pump its control and gasket LXV 125 Engine ENG 135 ...

Page 136: ...ALVES ARE MADE UP OF NOZZLES SPRING AND BALL N B AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle Remove the maximum nozzle Engine LXV 125 ENG 136 ...

Page 137: ...Remove the sprayer N B WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS IF THE SPRAY ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT LXV 125 Engine ENG 137 ...

Page 138: ...ROGRESSIONS AND INLET NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNEC TION SCREWS THE FIXING SCREWS ARE CAULKED AF TER ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Refitting the carburettor Before refitting wash the carburettor body accu rately with petrol and compressed air Pay special attention to the fuel supply pipe and the plunger seat Eng...

Page 139: ...D IS ORIENTED TO THE THROTTLE VALVE NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY ING Check that there are 5 closing ball joints for the operating pipes on the carburettor body 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...

Page 140: ...quately inserted and lock it Assemble the maximum nozzle Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock ab sorber pin and the return clamp Replace the rod if worn out Check that the float is not worn on the pin housing or on the contact plate with the plunger and that there are no fuel infiltration Replace it in case of anomalies Introduce the float wit...

Page 141: ... amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is free to rotate in its own seat N B MAKE SURE THE TANK GASKET IS CORRECTLY INTRO DUCED N B AVOID DEFORMING THE ACCELERATION PUMP CON TROL ROCKING LEVER Wash and blow the flow screw properly Check that screw is not deformed and or rusty Asse...

Page 142: ...d pin of the vacuum valve does not show wear Check that the depression valve does not show threads on the external surfaces Check that the vacuum intake hole is not clogged Check that the diaphragm is not damaged or has hardened otherwise replacement the whole valve Insert the tapered pin into the vacuum valve housing Reassemble the vacuum valve on the carburettor body taking care that the tapered...

Page 143: ...ston is not de formed or rusty Check that the piston slides freely from the seat to the support Check that the piston sealing gasket is not de formed The starter must be more or less functional de pending on the ambient temperature Measure the protrusion of the piston as shown in the figure and check its corresponding value Make sure that the starter is adjusted for the am bient temperature The st...

Page 144: ...n the O Ring correctly insert the plate with the machined side contacting the starter tighten the fixing screws Position the starter as shown in the figure Assemble the protection casing N B TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNEC TED TO THE STARTER Characteristic Check the automatic starter Kehin Protru...

Page 145: ...st 5 mi nutes at approximately 50 kph Connect a millimetre thermometer 020331y on the sump using a cover with oil expressly pre pared for probes Start the engine and before adjusting the idle speed make sure that the oil temperature is be tween 70 80 C Using the rpm indicator of the analyser or an in dependent one 020332y adjust the idle set screw until 1600 1700 rpm is obtained N B THE WASTED SPA...

Page 146: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 147: ...t fix the wheel to the hub N B BEFORE REMOVING THE 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 LXV 125 Suspensions SUSP 147 ...

Page 148: ... stops with the shielded side facing out Refit the ball bearing check seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020357Y 32 x 35 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 Pu...

Page 149: ...r 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 ...

Page 150: ... the one shown in the figure A Ø12 Punch B Sharp edged end Lubricate the sealing rings with mineral oil and half fill the roller casings with grease Insert the seal ring on the pin and the roller bush ing with wedging washers at the same time Remove the specific tool then the part 5 guiding partially ejected in the previous assembly stage leave part 4 always fitted Replace part 3 with part 16 on t...

Page 151: ...l 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 OF AN ADEQUATE DIAME TER S...

Page 152: ...tube After fitting the pin insert the two spacers part 17 slightly hitting with the mallet 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 part...

Page 153: ...posite the one shown in the figure Supplied with the tool Specific tooling 020021Y Front suspension service tool 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 Refitting CAUTION USE NEW ROLLER CASINGS PIN SEA...

Page 154: ...ied 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 Locking torques N m Steering lower ring nut 8 10 Steering upper ring nut 35 40 Front shock absorber Suspensions LXV 125 SUSP 154 ...

Page 155: ...n 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 LXV 125 Suspensions SUSP 155 ...

Page 156: ... 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 guid...

Page 157: ...uitably 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 Sp...

Page 158: ...c 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 to...

Page 159: ...he 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 LXV 125 Suspensions SUSP 159 ...

Page 160: ...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 Suspensions LXV 125 SUSP 160 ...

Page 161: ... 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 Centre stand Replace complete stand Undo the screw marked in the figure When refitting secure to the prescribed torque Locking torques N m Centre stand screw 32 40 LXV 125 Suspensions SUSP...

Page 162: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 163: ...EDED BEFORE REMOVING THE CALLIPER CLAMPS TO THE SUPPORT BRACKET LOOSEN THE OIL JOINT FITTING Overhaul Remove the front brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupling screws as shown in the photo Remove the two pistons from the calliper body with the aid of short blasts of compressed air through the brake fluid holes Remove the dust ring and the O ring o...

Page 164: ...specified torque Locking torques N m Calliper coupling screw 22 27 Refitting Insert the brake pads in the calliper Insert the pad fixing pin and the retention screw being careful to position the terminals of it pointing towards the bleed screw as shown in the photo Insert the clip on the pad fixing pin N B FAILURE TO RESPECT THE PAD POSITIONING REQUIRE MENTS WITH RESPECT TO THE DIRECTION OF ROTA T...

Page 165: ...e two screws with elastic washer at the prescribed torque Fix the brake pipe joint to the calliper and tighten at the prescribed torque Purge the circuit and refit the front wheel Locking torques N m Brake calliper support clamping 20 25 Nm Brake pipe connection 20 to 25 N m Front brake disc LXV 125 Braking system BRAK SYS 165 ...

Page 166: ... op erating on the five screws shown in the photo graph remove the brake disc Refitting Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it Tighten the 5 screws to the specified torque Locking torques N m Brake disc screws 6 0 5 1 Nm Braking system LXV 125 BRAK SYS 166 ...

Page 167: ...he wheel hub turn and check the disk de viation Specific tooling 020335Y Magnetic support for dial gauge Characteristic Standard thickness 4 0 2 0 2 mm Max deviation allowed 0 1 mm Front brake pads Removal Remove the front wheel Remove the brake calliper Remove protection cover the bolt and the leaf spring Remove the pads Check that there are no flaws or warping If there are replace them Check the...

Page 168: ... the ends towards the bleed screw as in the photo Insert the lock on the bolt and then the protection cover Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque CAUTION BEFORE USING THE BRAKE OPERATE THE LEVER A FEW TIMES Locking torques N m Rear brake calliper tightening screw 20 25 Nm Fill Braking system LXV 125 BRAK SYS 168 ...

Page 169: ...K THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO COMPLY WITH THIS NORM...

Page 170: ...etaining screw open the cover 2 and take out the dia phragm 3 2 remove the cap 4 and take out the internal parts in order 3 Check that The body of the pump shows no signs of internal damage or corrosion The plunger shows no sign of damage or abnormal wear The plunger return spring is in good condition CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED 1 Reservoir ca...

Page 171: ...rake pump fixing screws to the handle bar 7 10 Nm Rear drum brake Once the muffler and the wheel have been re moved follow these steps 1 Remove the shoe spring using the specific span ner 2 Remove the shoe with the aid of a lever 3 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 LXV 125 Braking ...

Page 172: ...Braking system LXV 125 BRAK SYS 172 ...

Page 173: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 174: ...rom the chassis saddle Unscrew the two screws of saddle fixing hook cov er To remove the cable and the sheath Remove the elastic ring and unscrew the cable end from the seat on the saddle fixing hook Remove the other end of the cable from the fixing seat on the locking block Chassis LXV 125 CHAS 174 ...

Page 175: ...ove the odometer cable Remove the connector of the electric connections from the instrument panel Instrument panel lower shell Remove the instrument panel Remove the handlebar Remove the two screws indicated in the figure Remove the screw indicated in the figure placed under the handlebar light fitting LXV 125 Chassis CHAS 175 ...

Page 176: ... sup port Knee guard Remove the front grille 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 LXV 125 CHAS 176 ...

Page 177: ...glove box and fairing have been removed Air filter Remove the helmet compartment after removing the side fairing remove the 2 screws fixing the filter box to the engine indicated in the figure Remove the two clamps indicated in the figure LXV 125 Chassis CHAS 177 ...

Page 178: ...nd the cable from the odometer Remove the steering tube Remove the three mudguards 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 LXV 125 CHAS 178 ...

Page 179: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 180: ... Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam lights low beam lights tail and parking lights and their warning lights Adjusting the headlights according to the regulations currently in force Rear light parking light stop light Front and rear stop light switches Turn indicators and their warning ligh...

Page 181: ...NUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO EN SURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE ...

Page 182: ...NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the frame and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors an...

Page 183: ...INDEX OF TOPICS TIME TIME ...

Page 184: ...Engine ENGINE Code Action Duration 1 001001 engine from frame removal and re fitting Time LXV 125 TIME 184 ...

Page 185: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement 2 001153 Half crankcase gasket Replace ment 3 002031 Rear wheel hub bearings Replace ment LXV 125 Time TIME 185 ...

Page 186: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001099 Oil seal flywheel side Replacement Time LXV 125 TIME 186 ...

Page 187: ...Cylinder assy CYLINDER GROUP Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Inspection clean ing LXV 125 Time TIME 187 ...

Page 188: ...Cylinder head assy HEAD UNIT Code Action Duration 1 001045 Valves Replacement 2 001056 Head gasket change 3 001126 Head Replacement Time LXV 125 TIME 188 ...

Page 189: ...Rocker arms support assy ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001044 Camshaft Replacement 2 001148 Rocking lever valve Replacement 3 001049 Valves Adjustments LXV 125 Time TIME 189 ...

Page 190: ... cover Replacement 2 001088 Head cover gasket Replacement 3 001159 Oil vapour recovery tank Service 4 001093 Spark plug Replacement 5 001097 Cooling hood Replacement 6 001091 Head cover sealing ring 7 001074 Oil vapour recovery pipe Replace ment Time LXV 125 TIME 190 ...

Page 191: ...Chain tensioner CHAIN TIGHTENER Code Action Duration 1 001129 Chain tensioner Service and Re placement 2 001124 By pass lubrication Replacement LXV 125 Time TIME 191 ...

Page 192: ...filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor Replacement 3 003064 Engine oil Change 4 001102 Net oil filter Replacement Cleaning Time LXV 125 TIME 192 ...

Page 193: ...n 1 001087 Flywheel cover Replacement 2 001163 Muffler secondary air connection Replacement 3 001161 Secondary air filter Replacement Cleaning 4 001174 SAS valve Replacement 5 001164 Crankcase secondary air connection Replacement LXV 125 Time TIME 193 ...

Page 194: ...iven pulley DRIVEN PULLEY Code Action Duration 1 001155 Clutch bell housing Replacement 2 001022 Clutch Replacement 3 001012 Driven pulley Overhaul 4 001110 Driven pulley Replacement Time LXV 125 TIME 194 ...

Page 195: ...51 Belt Timing chain Change 2 001125 Chain guide pads Replacement 3 001042 Oil pump Service 4 001112 Oil pump change 5 001130 Oil sump Replacement 6 001100 Oil seal clutch side Replacement 7 001122 Oil pump chain Replacement LXV 125 Time TIME 195 ...

Page 196: ...EDUCTION 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 LXV 125 TIME 196 ...

Page 197: ...IVING PULLEY Code Action Duration 1 001066 Drive pulley Removal and refitting 2 001086 Driving half pulley Replacement 3 001177 Variator rollers shoes Replace ment 4 001011 Driving belt Replacement LXV 125 Time TIME 197 ...

Page 198: ... cover TRANSMISSION COVER Code Action Duration 1 001096 Transmission crankcase cover Re placement 2 001135 Transmission cover bearing Re placement 3 001065 Transmission cover Removal and Refit Time LXV 125 TIME 198 ...

Page 199: ...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 LXV 125 Time TIME 199 ...

Page 200: ...lywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001109 Cooling fan Replacement 2 001173 Rotor Replacement 3 001067 Stator Removal and Refitting 4 001058 Flywheel Replacement Time LXV 125 TIME 200 ...

Page 201: ...t cooling duct BELT COOLING PIPE Code Action Duration 1 001170 Air manifold replacement 2 001132 Transmission air inlet pipe Replace ment 3 001131 Transmission air intake Replace ment LXV 125 Time TIME 201 ...

Page 202: ...2 Carburettor heating resistor Re placement 2 001013 Intake manifold change 3 004122 Air cleaner carburettor fitting Re placement 4 001081 Automatic choke Replacement 5 001008 Carburettor Inspection 6 001063 Carburettor Replacement Time LXV 125 TIME 202 ...

Page 203: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement LXV 125 Time TIME 203 ...

Page 204: ...NER Code Action Duration 1 004122 Air cleaner carburettor fitting Re placement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement 4 001027 Body air cleaner union Replace ment Time LXV 125 TIME 204 ...

Page 205: ...1 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 LXV 125 Time TIME 205 ...

Page 206: ...Centre stand STAND Code Action Duration 1 001053 Stand bolt Replacement 2 004004 Stand Replacement Time LXV 125 TIME 206 ...

Page 207: ...Footrests FOOTREST Code Action Duration 1 004078 Front rear footrest rubber Replace ment 2 004178 Footrest Replacement LXV 125 Time TIME 207 ...

Page 208: ...ELD 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 Time LXV 125 TIME 208 ...

Page 209: ...ent 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 LXV 125 Time TIME 209 ...

Page 210: ...e 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 Time LXV 125 TIME 210 ...

Page 211: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement LXV 125 Time TIME 211 ...

Page 212: ...ion 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 Time LXV 125 TIME 212 ...

Page 213: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and Refitting LXV 125 Time TIME 213 ...

Page 214: ...umn 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 Time LXV 125 TIME 214 ...

Page 215: ...e Action Duration 1 004053 Spoiler Replacement 2 004018 Handlebar front section Replace ment 3 005014 Odometer Replacement 4 005038 Instrument panel warning light bulbs Replacement 5 004019 Handlebar rear section Replace ment LXV 125 Time TIME 215 ...

Page 216: ...andlebar Removal and refitting 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 003061 Accelerator transmission Adjust ment 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 11 002063 Throttle control transmission Re placement Time LXV 125 TIME 216 ...

Page 217: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chassis con nection Replacement LXV 125 Time TIME 217 ...

Page 218: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004008 Luggage rack Replacement Time LXV 125 TIME 218 ...

Page 219: ...12 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 LXV 125 Time TIME 219 ...

Page 220: ...004123 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 Time LXV 125 TIME 220 ...

Page 221: ...ric 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 9 005114 Electrical system Service LXV 125 Time TIME 221 ...

Page 222: ... Light switch or turn indicators Re placement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005077 Emergency stop switch Replace ment 7 005016 Key switch Replacement 8 004096 Lock series Replacement 9 004010 Anti theft lock Replacement Time LXV 125 TIME 222 ...

Page 223: ...missions TRANSMISSIONS Code Action Duration 1 002053 Rear brake transmission complete Replacement 2 002051 Odometer transmission assembly Replacement 3 002049 Odometer cable Replacement LXV 125 Time TIME 223 ...

Page 224: ...teering 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 6 003038 Front wheel axle Removal and Re fit Time LXV 125 TIME 224 ...

Page 225: ...ront 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 LXV 125 Time TIME 225 ...

Page 226: ...uid 169 C Carburettor 9 133 138 202 F Fuel 39 132 212 Fuses 67 H Headlight 33 176 I Identification 7 Instrument panel 175 M Maintenance 6 27 O Odometer Oil filter 192 S Saddle Shock absorbers 160 Spark plug 61 Stand Start up T Tank 212 Transmission 8 39 76 89 98 198 Tyres 9 ...

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