VESPA LXV 50 Page 16 Service Station Manual Download

Page: 16 / 162

TOOLS

Stores code

Description

001330Y

Tool for fitting steering seats

001467Y006

Pliers to extract 20 mm bearings

001467Y009

Driver for OD 42-mm bearings

001467Y013

Pliers to extract ø 15-mm bearings

001467Y014

Pliers to extract ø 15-mm bearings

001467Y017

Bell for bearings, OD 39 mm

002465Y

Pliers for circlips

Tooling

Vespa LXV 50

TOOL - 16

Summary of Contents for LXV 50

Page 1: ...SERVICE STATION MANUAL 633860 IT 633861 EN 633862 FR 633863 DE 633864 ES 633865 PT 633866 NL 633867 EL Vespa LXV 50 ...

Page 2: ...changes 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 Reprodu...

Page 3: ...the sections 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 observ...

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: ...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 a...

Page 8: ...esc Quantity Engine prefix C381M 1001 Chassis prefix ZAPC38102 1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc Quantity Kerb weight 98 5 kg Overall height 1180 mm Wheelbase 1280 mm Length 1800 mm Width 740 mm Characteristics Vespa LXV 50 CHAR 8 ...

Page 9: ...arburettor Cooling Forced air circulation Transmission TRANSMISSION Specification Desc Quantity Transmission With automatic expandable pulley variator torque server V belt automatic clutch gear reduction unit Capacities CAPACITY Specification Desc Quantity Rear hub oil Quantity approx 85 cc oil mixer tank Plastic capacity 1 2 l Fuel tank capacity 8 5 l 2 l of which is reserve Electrical system ELE...

Page 10: ...nt tyre pressure 1 6 bar Rear tyre pressure 2 bar Light alloy rims Front rim 2 50 x 11 Light alloy rims rear rim 3 00 x 10 N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES Secondary air Follow these steps to clean the sponge filters of the secondary air system 1 Remove the snap on plastic cover 1 on the transmissi...

Page 11: ...gulation reference number 8444 Maximum nozzle 53 Maximum air nozzle on the body Ø 1 5 Tapered pin stamped code A22 Pin position notches from above 1 Diffuser 209 HA Minimum nozzle 32 Minimum air nozzle on the body Free Initial minimum mix screw opening 1 1 2 Starter jet 50 Starter air nozzle on the body Ø 1 5 Stroke of starter pin 11 mm Gasoline inlet hole Ø 1 5 Tightening Torques FRONT BRAKE Name...

Page 12: ...old screws 8 9 Flywheel hood fixing screws 1 2 Cylinder hood fixing screws 3 5 5 Stator clamping screws 3 4 Pick Up clamping screw 4 5 Mixer clamping screws 3 4 Screw fixing brake lever to the journal on the engine 12 13 FRAME ASSEMBLY Name Torque in Nm Swinging arm engine pin 33 41 Swinging arm pin frame 44 52 Shock absorber chassis nut 20 to 25 Nm Swinging arm frame plate 33 41 shock absorber en...

Page 13: ...055 0 069 Coupling 2nd oversize P2 40 426 40 433 40 364 40 371 0 055 0 069 Piston rings SEALING RING Name Description Dimensions Initials Quantity Compression ring 40 A 0 10 to 0 25 Compression ring 1st oversize 40 2 A 0 10 to 0 25 Compression ring 2nd Oversize 40 4 A 0 10 to 0 25 Crankcase crankshaft connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE CRANKSHAFT AND CONNECTING ROD Name Description D...

Page 14: ... MA AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased adhesiveness AGIP CITY TEC 2T Mixer oil synthetic oil for 2 stroke engines JASO FC ISO L EGD 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...

Page 15: ...INDEX OF TOPICS TOOLING TOOL ...

Page 16: ... 001467Y006 Pliers to extract 20 mm bearings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings 001467Y017 Bell for bearings OD 39 mm 002465Y Pliers for circlips Tooling Vespa LXV 50 TOOL 16 ...

Page 17: ...eel seat on steer ing tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate Vespa LXV 50 Tooling TOOL 17 ...

Page 18: ...66Y Pin lock fitting tool 020261Y Starter spring fitting 020265Y Bearing fitting base 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing Tooling Vespa LXV 50 TOOL 18 ...

Page 19: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger Vespa LXV 50 Tooling TOOL 19 ...

Page 20: ...tores code Description 020335Y Magnetic support for dial gauge 020350Y Electrical system check instrument 020359Y 42x47 mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide Tooling Vespa LXV 50 TOOL 20 ...

Page 21: ...Stores code Description 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner 001467Y029 Bell for bearings O D 38 mm 020037Y Punch 020036Y Punch Vespa LXV 50 Tooling TOOL 21 ...

Page 22: ...escription 020021Y Front suspension service tool 020038Y Punch 020074Y Support base for checking crankshaft alignment 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring Tooling Vespa LXV 50 TOOL 22 ...

Page 23: ... extractor screw 004499Y007 Half rings 020171Y Punch for driven pulley roller bearing 020340Y Flywheel and transmission oil seals fitting punch 020360Y Adaptor 52 x 55 mm 020358Y 37x40 mm adaptor 020362Y 12 mm guide Vespa LXV 50 Tooling TOOL 23 ...

Page 24: ...tores code Description 020363Y 20 mm guide 020365Y 22 mm guide 020439Y 17 mm guide 020441Y 26 x 28 mm adaptor 020452Y Tube for removing and refitting the driven pulley shaft Tooling Vespa LXV 50 TOOL 24 ...

Page 25: ...Stores code Description 020451Y Starting ring gear lock 020444Y Tool for fitting removing the driven pulley clutch Vespa LXV 50 Tooling TOOL 25 ...

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

Page 27: ...ds check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AFTER 10000 KM 50000 KM 95 Action Hub oil change Spark plug electrode gap replacement Air filter clean Idle speed adjustment Oil mixer throttle linkage adjustment Variable speed rollers replacement Odometer gear greasing Driving belt checking Steerin...

Page 28: ...ntrol 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 Vehicle and brake test road test AFTER 30000 KM 130 Action Hub oil change Spark plug electrode gap replacement Air filter clean Idle speed adjustment Oil mixer t...

Page 29: ...ations in the Secondary air system section 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 the chamber Replace valve in case of wear due to excessive clearance If there are wear marks in the chamber ca...

Page 30: ...ht to check timing Spark plug Place the vehicle on its central stand Remove the central cover indicated in the figure by undoing the 2 fixing screws Disconnect spark plug HV wire hood Undo the spark plug using the socket wrench Examine the condition of the spark plug check that the insulating material is whole and measure the distance between the electrodes using a thick ness gauge Adjust the dist...

Page 31: ... Spark plug 25 30 Nm Hub oil Check Do the following to check the correct level 1 Stand the vehicle on the centre stand on flat ground 2 Remove the dipstick A and dry it with a clean cloth Reinsert it screwing it in all the way 3 Remove the stick and check that the oil level is slightly over the second notch starting from the lower end 4 Screw the dipstick back in checking that it is locked in plac...

Page 32: ...l soap Dry with a clean cloth and short blasts of com pressed air Saturate with a 50 mixture of gasoline and oil Drip dry the filter and then squeeze it between the hands without wringing Let it dry and refit it again CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER Recommended products AGIP FILTER OIL Oil for air filter sponge M...

Page 33: ...th the reference mark on the mixer body as shown in the figure While doing this the engine must be fuelled with a 2 oil mixture 0 5 litre minimum if the reservoir is empty CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS RE FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF UNDO THE MIXER PIPE FROM THE CARBURETTOR AN...

Page 34: ...CCIDENTAL CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK CAUTION THE BRAKE FLUID IS HYGROSCOPIC IN OTHER WORDS IT ABSORBS MOISTURE FROM THE SURROUNDING AIR IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEF FICIENT NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CON...

Page 35: ...EDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI 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 Remove the right side fairing by undoing the 2 screws marked B indicated in the figure Remove the two screws A from the aluminium SAS cover Release the metal tube from the rub ber...

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

Page 37: ...l Dirt Check the cap with filter is fitted to the transmission cover clean the speed variator replace the rollers if worn out 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 repl...

Page 38: ... Water in the carburettor Empty the tank through the appropriate bleed nipple Air filter dirty Clean or replace Defective floating valve Check the proper sliding of the float and the functioning of the valve Tank breather hole obstructed Restore the proper tank aeration Engine tends to cut off at idle ENGINE STOP IDLING Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and...

Page 39: ...the engine without the clutch bell Check the cap with filter is fitted to the transmission cover Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause Operation Poor braking The rear drum type brake is adjusted by regulating the special adjustment on the wheel bearing in mind that with the control levers in the rest position the wheels must turn freely The braking action should begin when...

Page 40: ...ted to the terminal marked Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts If irregularities continue in turning the steering even after mak ing the above adjustments check the seats in which the ...

Page 41: ...movement bushings Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Service the pumping members and check the sleeves and sealing rings are in good conditions Replace the damaged parts Vespa LXV 50 Troubleshooting TROUBL 41 ...

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

Page 43: ... remote control 10 Starter button 11 STOP button on front brake 12 STOP button on rear brake 13 Horn button 14 Horn 15 Left turn rear indicator lamp 16 Rear headlight assembly with tail light and stop light bulbs 17 Turn indicator switch 18 Right turn rear indicator lamp 19 Left turn front indicator lamp Vespa LXV 50 Electrical system ELE SYS 43 ...

Page 44: ...ght B Fuel level warning light C Oil mix level warning light D fuel gauge E Instrument panel lighting F High beam warning light G headlight warning light H turn indicator warning light 26 Low oil warning light control 27 Automatic starter 28 Carburettor heater 29 Carburettor heater control device Ar Orange Az Sky Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi ...

Page 45: ...Ignition KEY 1 Electronic ignition device 2 Spark plug 3 Magneto flywheel 6 Key switch Vespa LXV 50 Electrical system ELE SYS 45 ...

Page 46: ...t and stop light bulbs 20 Front headlight assembly with high and low beam bulb A Tail light bulb B Low high beam light bulb 22 Light switch 23 High beam light flash switch 25 Instrument panel A turn indicator warning light B Fuel level warning light C Oil mix level warning light D fuel gauge E Instrument panel lighting Electrical system Vespa LXV 50 ELE SYS 46 ...

Page 47: ...r control device Battery recharge and starting KEY 3 Magneto flywheel 4 Voltage regulator 5 Main fuse 6 Key switch 7 Battery 8 Starter motor 9 Starter remote control 10 Starter button 11 STOP button on front brake 12 STOP button on rear brake 16 Rear headlight assembly with tail light and stop light bulbs Vespa LXV 50 Electrical system ELE SYS 47 ...

Page 48: ... 6 Key switch 7 Battery 24 Fuel level warning light control 25 Instrument panel A turn indicator warning light B Fuel level warning light C Oil mix level warning light D fuel gauge E Instrument panel lighting F High beam warning light G headlight warning light H turn indicator warning light Electrical system Vespa LXV 50 ELE SYS 48 ...

Page 49: ...y 13 Horn button 14 Horn 15 Left turn rear indicator lamp 17 Turn indicator switch 18 Right turn rear indicator lamp 19 Left turn front indicator lamp 21 Right turn front indicator lamp 25 Instrument panel A turn indicator warning light B Fuel level warning light C Oil mix level warning light Vespa LXV 50 Electrical system ELE SYS 49 ...

Page 50: ...d replace it if necessary 2 Without removing the stator carry out the fol lowing checks After visually checking the electrical wiring per form measurements on the loading coil the pickup and the continuity using the appropriate tester If checks on the loading reel pickup and continuity show abnormalities replace the stator otherwise replace the central unit Remember that disconnections due to repl...

Page 51: ...th the lights on Check that the control voltage is 16V at 5000 rpm with the lights off Replace the voltage regulator if control voltages are over 16V FAULT 2 Lighting system not working a Check that voltage to stator is correctly sup plied disconnect the regulator connector and place the tester to detect alternating voltages be tween the connection of the grey blue cable 2 and the black cable 6 to...

Page 52: ...ection of the yellow cable 8 on the regulator and the black ca ble 6 to check that the voltage supplied by the generator at 3000 r 1 is within 26 30 V In case of irregularities replace the stator otherwise pro ceed to point b b Yellow cable 1 connected to the regulator In sert an ammeter between the Red cable 2 of the stator and the battery and check with the tester that the current supplied at 30...

Page 53: ...s jump the contacts 5 yellow and 7 blue black on the con nector set the key switch to ON and turn the turn indicator switch left and right to see when the lights are steadily on as they are powered directly from the battery If even after this operation the turn indicators fail to turn on check the wiring is not damaged and switch works properly If these last two tests have a positive result replac...

Page 54: ...CH IN ORDER TO AVOID DANGEROUS LEAKAGE OF BAT TERY ELECTROLYTE Electric characteristic Fuse Fuse valve 7 5 A BULBS Specification Desc Quantity 1 High low beam light bulb Type Spherical Power 12V 35 35W Quantity 1 2 Front tail light bulb Type All glass Power 12V 5W Quantity 1 3 Front turn indicator bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 LHS 4 Rear turn indicator light bulb Type Spherica...

Page 55: ...AT WELL BELOW 12 6V IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF Dry charge battery WARNING Battery electrolyte is toxic and it may cause serious burns It contains sulphuric acid Avoid contact with eyes skin and clothing In c...

Page 56: ...han 15 C A density reading of less than 20 Bé indicates that the battery is completely flat and it must therefore be recharged After charging the battery check each element electrolyte level and density If the scooter is not used for a given time 1 month or more it will be necessary to periodically recharge the battery The battery runs down completely in the course of three months If it is necessa...

Page 57: ...ort closed tube and the caps then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1 26 corresponding to 30 Bé at a minimum temperature of 15 C until the upper level is reached 2 Leave to rest for at least 2 hours then restore the level with sulphuric acid 3 Within the following 24 hours recharge with the specific battery charger single or multip...

Page 58: ...020334Y Multiple battery charger Electrical system Vespa LXV 50 ELE SYS 58 ...

Page 59: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 60: ...e rear brake Disconnect the electric terminals Remove the throttle grip and mixer transmissions Disconnect the hoses petrol oil vacuum operated cock control WARNING Be very careful when handling fuel CAUTION When installing the battery first attach the positive cable and then the negative cable WARNING Wear safety goggles when using hitting tools Engine from vehicle Vespa LXV 50 ENG VE 60 ...

Page 61: ...INDEX OF TOPICS ENGINE ENG ...

Page 62: ... reverse and tighten the screws to the prescribed torque Locking torques N m Starter lever replacement 12 to 13 Nm Upon refitting apply the recommended grease to the bushing to the spring and along the toothed sector Use the special tool for the charging of the spring as shown in the figure Refit the seeger ring after checking that it is in good condition Specific tooling 020261Y Starter spring fi...

Page 63: ...aring Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing N B IN CASE OF DIFFICULTY A STANDARD 8MM INSIDE DI AMETER EXTRACTOR CAN BE USED Refitting the driven pulley shaft bearing Refit the bearing with the aid of a bushing with the same diameter as the external plate of the beari...

Page 64: ...e clutch bell is not worn or damaged Measure the inner diameter of the clutch bell Characteristic Clutch bell diameter standard value Ø 107 0 2 0 mm Clutch bell diameter max value allowed after use Ø 107 5 mm Eccentricity measured max 0 20 mm Removing the clutch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and put the central sc...

Page 65: ...material The masses must not show traces of lubricants otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EXHIBIT A 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 P...

Page 66: ...e the ball bearing retention snap ring Expel the ball bearing from the side of the clutch housing by means of the special tool N B 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 the...

Page 67: ...ded products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Mo lybdenum disulphide ISO L XBCHB2 DIN KF2K 20 Make sure the pins and collar are not worn reassemble the pins and collar Use a greaser 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 bu...

Page 68: ...r 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring Check that the contrast spring of the driven pulley does not show signs of deformation Measure the free length of the spring Characteristic Standard length 118 mm Minimum length allowed after use XXXX Refitting the clutch Preassemble the driven pulley group with spring sheath and clutch Position the spring wit...

Page 69: ...king 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 Characteri...

Page 70: ...EAK SUD DENLY DURING OPERATION CAUTION ON REFITTING MAKE SURE THAT DIRT DOES NOT GET INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN N B REPLACE THE BELT EVERY 20000 KM Inspecting the rollers case 1 Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation 2 Check the roller running trac...

Page 71: ...ovable driven half pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting N B IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE Refit the components of the assembly roller con tainer assembly with bushing limiting washer sta tionary half pulley cooling fan belt wit...

Page 72: ...5 5 mm thick End gear Removing the hub cover Remove the transmission cover Remove the clutch assembly Discharge the rear hub oil Remove the 5 screws indicated in the figure Remove the hub cover with driven pulley shaft See also Refitting the clutch Removing the wheel axle Remove the intermediate gear and the complete gear wheel axle When removing the intermediate gear pay atten tion to the various...

Page 73: ...he oil seal from the outside Remove the centring dowels and position the cover on a plane Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the f...

Page 74: ...aults are found replace the hub cover Refitting the driven pulley shaft bearing Support the inner track of the bearing from the outside of the hub cover with the specific tool posi tioned under the press and insert the driven pulley axle Refit the oil seal flush with the cover Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Heat the hub cover and insert the bearing...

Page 75: ...le 020363Y 20 mm guide 020359Y 42x47 mm adaptor Refitting the ub cover Refit the whole wheel axle Refit the intermediate gear paying attention to the two shim thicknesses Apply LOCTITE 510 for surfaces to the hub cov ers and refit the same with driven pulley shaft Refit the 5 screws and tighten them to the speci fied torque N B CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF ...

Page 76: ... in the figure Remove the fan cover Remove the oil piping retention band from the hood Remove the 2 screws shown in the figure Cooling fan Remove the cooling fan by acting on the three fixings indicated in the figure Engine Vespa LXV 50 ENG 76 ...

Page 77: ...out the removal procedure in reverse tightening the retainers to the specified torque N B THE PICK UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM BLY Locking torques N m Pick up screws 3 4 Stator screws 3 4 Flywheel and starting Removing the starter motor Remove the two clamps shown in the figure Vespa LXV ...

Page 78: ...r 020162Y Flywheel extractor Inspecting the flywheel components Check the condition of the flywheel and any dis tortions that might cause rubbing on the stator and on the Pick Up Refitting the flywheel magneto Fit the flywheel being careful to insert the key properly Lock the flywheel nut at the prescribed torque Check the Pick Up air gap The air gap may not be modified in the fitting of the Pick ...

Page 79: ...e crankcase locking the two screws to the prescribed torque 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 intake manifold Use an anti tampering TORX spanner to remove the two clamping screws of the intake manifold Removing the cylinder ...

Page 80: ...nd 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 Rod small end standard diameter 17 0 011 0 001 Rod small end maximum allowable diameter 17 060 mm Engine Vespa LXV 5...

Page 81: ...er Calculate the piston pin coupling clearance Characteristic Wrist pin housing standard diameter 12 0 007 0 012 Wrist pin housing standard clearance 0 002 0 011 mm Measure the outer diameter of the piston per pendicular to the pin axis Take the measurement in the position shown in the figure To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy Vespa L...

Page 82: ... seals perpendicularly to the cylinder axis Measure the opening of the sealing rings using a thickness gauge as shown in the photograph If the values are higher than the values prescri bed in the chart substitute the rings Removing the piston Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool Push detail 2 into detail 1 until the stop and extract detail 2 ...

Page 83: ...oil to be mixed during the fitting of the piston and the cylinder CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON THE PISTON WITH THE SPECIFIC TOOL Recommended products AGIP CITY TEC 2T Oil Recommended oil Vespa LXV 50 Engine ENG 83 ...

Page 84: ...MELLA Crankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling 020163Y Crankcase splitting plate Engine Vespa LXV 50 ENG 84 ...

Page 85: ...kcase or the crankshaft indifferently Using the special tool remove any bearings that have been left on the crankshaft N B The half rings must be inserted on the bearings with a few mal let blows Specific tooling 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings Using the specific tool remove any bearings left on the half c...

Page 86: ...the dial gauge in addition check the eccentricity of diam D for which a maximum reading of 0 02 mm is permitted In the case where eccentricity is not much above prescribed levels straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp with an aluminium bushing as re quired Specific tooling 020335Y Magnetic support for dial gauge 020074Y Support base for checking...

Page 87: ...f the stroke and loosen them again with the same angle e g 90 When the temperature has settled preload the thrust screw of the tool manually until the ball bear ing clearance is cancelled out Specific tooling 020163Y Crankcase splitting plate Refitting the crankcase halves Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur face using a suitable solve...

Page 88: ...a position back from the one indicated in the figure Install the special magnetic support with dial gauge at the end of the crankshaft Check the axial clearance of the crankcase If this is not within the maximum limit allowed re peat the crankcase coupling procedure Specific tooling 020335Y Magnetic support for dial gauge Characteristic Axial clearance with warm crankcase 0 10 0 12 mm Axial cleara...

Page 89: ...H THE FITTED WRENCH Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Install a new transmission side oil seal using the special tool with adapter ring The transmission side oil seal is recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump Removal Remove the 2 screws shown in the figure Vespa LXV 50 Engine ENG...

Page 90: ...he 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 engine by using the starter for five sec onds with the carburettor at minimum Take up the fuel b...

Page 91: ...MityVac vacuum operated pump Characteristic Minimum flow rate 20 cc Completely empty the gas tank Remove the petrol delivery tube and the suction tube Loosen the clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent 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 B...

Page 92: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 93: ...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 Vespa LXV 50 Suspensions SUSP 93 ...

Page 94: ...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 Punch...

Page 95: ...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 96: ...art 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 Specific tooling 020021Y Front suspension service tool 001330Y Tool for fitting steering seats Recommended products AGIP GREASE PV2 Grease for control lever...

Page 97: ...refit the second wedging washer roller casing sealing ring unit 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 Fit both dust guard rings C on the swinging hub as shown...

Page 98: ...end Use the specific tool fitted with part 1 and op erate the handgrip until the pin and the Nadella are simultaneously ejected in the direction opposite the tool thrusting force To eject the second Nadella use the tool fitted with part 2 instead of part 1 on the side opposite the one shown in the figure Supplied with the tool Specific tooling 020021Y Front suspension service tool The front suspen...

Page 99: ...nd For the second washer repeat the operation us ing the punch on the side opposite to the one shown in the figure A Ø12 Punch B Sharp edged end Refitting CAUTION USE NEW ROLLER CASINGS PIN SEALING RINGS AND DUST GUARDS FOR REFITTING Vespa LXV 50 Suspensions SUSP 99 ...

Page 100: ...d 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 Vespa LXV 50 SUSP 100 ...

Page 101: ...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 Vespa LXV 50 Suspensions SUSP 101 ...

Page 102: ...sorber 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 R...

Page 103: ...per 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 Steering bearing Removal Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat of the lower bearing fitted on the chassis N B TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING...

Page 104: ...ifth wheel fitting and the dust guard on the steering tube until they stop using the specific tool Specific tooling 006029Y Punch for fitting fifth wheel seat on steering tube Rear Removing the rear wheel Use a screwdriver as a lever between the drum and the cover Straighten the split pin and remove the cap Remove the wheel acting on the central fixing point WARNING ALWAYS USE NEW SPLIT PINS FOR R...

Page 105: ... prescribed torque Refit the cap and the split pin folding it correctly as shown in the figure Locking torques N m Locking torque 137 152 Nm Swing arm Removal Remove the swinging arm acting on the three clamps shown in the figure Vespa LXV 50 Suspensions SUSP 105 ...

Page 106: ...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 Vespa LXV 50 SUSP 106 ...

Page 107: ...g 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 Vespa LXV 50 Suspensions SUSP 107 ...

Page 108: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 109: ...alliper 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 sign...

Page 110: ...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 111: ...e 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 wh...

Page 112: ... 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 CAR...

Page 113: ... 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 Vespa LXV 50 Braking system BRAK SYS 113 ...

Page 114: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 115: ...m 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 Vespa LXV 50 Chassis CHAS 115 ...

Page 116: ... 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 Chassis Vespa LXV 50 CHAS 116 ...

Page 117: ...the light sup port 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 Vespa LXV 50 Chassis CHAS 117 ...

Page 118: ...ove 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 Chassis Vespa LXV 50 CHAS 118 ...

Page 119: ...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 Vespa LXV 50 Chassis CHAS 119 ...

Page 120: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 121: ...rame 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 lights...

Page 122: ...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 REACH ...

Page 123: ...ER 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 and a...

Page 124: ...INDEX OF TOPICS TIME TIME ...

Page 125: ...evoted to the time necessary to carry out repairs The description and code for each operation is in dicated Engine ENGINE Code Action Duration 1 001001 engine from frame removal and re fitting Vespa LXV 50 Time TIME 125 ...

Page 126: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Time Vespa LXV 50 TIME 126 ...

Page 127: ... CRANKSHAFT Code Action Duration 1 001118 Main bearings Replacement 2 001100 Oil seal clutch side Replacement 3 001099 Oil seal flywheel side Replacement 4 001117 Crankshaft Replacement Vespa LXV 50 Time TIME 127 ...

Page 128: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Inspection clean ing Time Vespa LXV 50 TIME 128 ...

Page 129: ...ssy HEAD Code Action Duration 1 001097 Cooling hood Replacement 2 001093 Spark plug Replacement 3 001126 Head Replacement 4 001013 Intake manifold Replacement 5 001178 Disc pack Replacement Vespa LXV 50 Time TIME 129 ...

Page 130: ...ulley DRIVEN PULLEY CLUTCH Code Action Duration 1 001012 Driven pulley Service 2 001110 Driven pulley Replacement 3 001022 Clutch Replacement 4 001155 Clutch bell housing Replacement Time Vespa LXV 50 TIME 130 ...

Page 131: ...Oil pump OIL PUMP Code Action Duration 1 001028 Mix movement gear socket Re placement 2 001019 Mixer belt replacement 3 001018 Mixer Replacement Vespa LXV 50 Time TIME 131 ...

Page 132: ...L REDUCTION GEAR Code Action Duration 1 001010 Geared reduction unit Service 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement Time Vespa LXV 50 TIME 132 ...

Page 133: ...ING PULLEY Code Action Duration 1 001066 Driving pulley Removal and refitting 2 001086 Driving half pulley replace 3 001011 Driving belt Replacement 4 001177 Variator rollers shoes Replace ment Vespa LXV 50 Time TIME 133 ...

Page 134: ...Transmission cover TRANSMISSION COVER Code Action Duration 1 001096 Transmission crankcase cover Re placement 2 001135 Transmission cover bearing Re placement Time Vespa LXV 50 TIME 134 ...

Page 135: ...1020 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 Vespa LXV 50 Time TIME 135 ...

Page 136: ...TO FLYWHEEL Code Action Duration 1 001109 Cooling fan Replacement 2 001173 Rotor Replacement 3 001067 Stator Fitting and Refitting 4 001058 Flywheel Replacement 5 001087 Flywheel cover Replacement Time Vespa LXV 50 TIME 136 ...

Page 137: ...pection 2 001063 Carburettor Replacement 3 007020 Carburettor heating tubing replace ment 4 001081 Automatic choke Replacement 5 001082 Carburettor heating resistor Re placement 6 003058 Carburettor Adjustment 7 004177 Heating hood Replacement Vespa LXV 50 Time TIME 137 ...

Page 138: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement Time Vespa LXV 50 TIME 138 ...

Page 139: ...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 Vespa LXV 50 Time TIME 139 ...

Page 140: ...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 Vespa LXV 50 TIME 140 ...

Page 141: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004171 Stand support plate Replacement Vespa LXV 50 Time TIME 141 ...

Page 142: ...Footrests FOOTREST Code Action Duration 1 004078 Front rear footrest rubber Replace ment 2 004178 Footrest Replacement Time Vespa LXV 50 TIME 142 ...

Page 143: ...D 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 Vespa LXV 50 Time TIME 143 ...

Page 144: ...t 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 Vespa LXV 50 TIME 144 ...

Page 145: ...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 Vespa LXV 50 Time TIME 145 ...

Page 146: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement Time Vespa LXV 50 TIME 146 ...

Page 147: ... 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 Vespa LXV 50 Time TIME 147 ...

Page 148: ... Code Action Duration 1 005018 Oil reservoir float Replacement 2 004017 Oil reservoir Replacement 3 004095 Oil reservoir cock Replacement 4 004091 Oil reservoir hose Replacement Rear shock absorber Time Vespa LXV 50 TIME 148 ...

Page 149: ...absorber Removal and Refitting Steering column 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 Vespa LXV 50 Time TIME 149 ...

Page 150: ...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 Time Vespa LXV 50 TIME 150 ...

Page 151: ...placement 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002054 Throttle or splitter transmission com plete Replacement 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 Vespa LXV 50 Time TIME 151 ...

Page 152: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chassis con nection Replacement Time Vespa LXV 50 TIME 152 ...

Page 153: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004008 Luggage rack Replacement Vespa LXV 50 Time TIME 153 ...

Page 154: ... 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 Vespa LXV 50 TIME 154 ...

Page 155: ...123 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 Vespa LXV 50 Time TIME 155 ...

Page 156: ...ce 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 005054 Fuse block 1 Replacement Time Vespa LXV 50 TIME 156 ...

Page 157: ...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 Vespa LXV 50 Time TIME 157 ...

Page 158: ...012 Splitter Replacement 3 002057 Carburettor splitter transmission complete Replacement 4 002058 Mix splitter transmission complete Replacement 5 002053 Rear brake transmission complete Replacement 6 002049 Odometer cable Replacement 7 003061 Accelerator transmission Adjust ment Time Vespa LXV 50 TIME 158 ...

Page 159: ...ration 1 002021 Front 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 Vespa LXV 50 Time TIME 159 ...

Page 160: ...ering 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 Vespa LXV 50 TIME 160 ...

Page 161: ...1164 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 Vespa LXV 50 Time TIME 161 ...

Page 162: ...urettor 11 29 137 E Engine stop F Fuel 39 90 147 Fuses 54 H Headlight 35 117 Hub oil 31 I Identification 8 Instrument panel 116 M Maintenance 7 27 O Odometer S Saddle Shock absorbers 106 Spark plug 30 Stand Start up T Tank 147 148 Transmission 9 39 62 134 Tyres 10 ...

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VESPA LXV 50, Service Station Manual

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